Process Safety at BASF

BASF Process Safety Concept Topics

•Why Process Safety? •Process Safety Overview •Process Safety Management -Planning & Construction -Facility Operations •Risk Management •Process Safety Programs

What is Process Safety?

•Fire •Explosion •Chemical release Interdisciplinary approach to prevention.

Process Safety at BASF SE, Ludwigshafen

BASF SE organizes its activities under the "Responsible Care" initiative, demonstrating an independent industrial approach. Process safety as a high priority has been embedded in BASF's genes since the 1921 Ludwigshafen Oppau explosion.

Process safety optimization is continuous work;

•Safety holds a priority above production targets, •Synergy between safety and production closes all gaps. Process safety deficiencies have been the primary cause of major accidents in history. Oppau 1921, BASF: 1,000 t ammonium nitrate explosion. Result of incomplete understanding of product properties and process changes; effects extending beyond the facility, destruction radius of 1 km, and 560 fatalities. Bhopal 1984, UC: Methyl isocyanate release. 30 tons of MIC released (highly toxic gas). Operator error, poor facility conditions, and management failure resulting in effects extending beyond the facility, destruction radius of 1 km, 2,500 fatalities, 300,000 injured.

Ammonium Nitrate Explosion, AZF Toulouse, 21 September 2001

Accidents Over the Last 10 Years

Toulouse 2001, AZF: Ammonium nitrate explosion. 300 t of ammonium nitrate exploded. Incomplete understanding of product properties, effects extending beyond the facility, destruction radius of 0.5 km, 30 fatalities, similar to the 1921 BASF accident. US, Texas City 2005, BP: Refinery explosion. Ignition following liquid leak with subsequent explosion, startup, change management, safety management system, 16 fatalities, USD 2 million in damage. Process Safety Development at BASF SE, Ludwigshafen Process Safety has shown serious progress since its inception. 1840: Approximately 1% annual worker loss from accidents. 1950/60: Fatal accidents at large facilities were considered 'normal'. 1970-2000: Fatalities rare in Western countries. Significant improvement in the number of major accidents. Last 10 years: Major accidents occur rarely. Awareness and information dissemination increased. Accidents now result in financial losses.

Developments from Industrial Trends More Reliable Equipment

• Production materials, advanced sealing technology use, • Mechanical equipment design; intelligent equipment.

Automation, Strict Process Control

• Control systems, sensors provide strict process control.

Systematic Hazard Analysis Methods (HAZOP, FMEA)

• Started being used from the early 1990s.

Management Focus

• Priority given to safety and its importance in company image, • Industrial approaches internalized beyond compliance.

Regulation

Facility inspection programs; objectives replaced with strict rules.

Process Safety Concept at BASF

Safe operation of a chemical facility is affected by various factors: • A facility safety concept, • Safe facility design and construction in compliance with specifications, • An effective maintenance program, • Safe operation by qualified personnel. A weak point in any of these factors can lead to a major accident.

Keys to Success in Process Safety Strong process safety culture,

• Open communication and sharing of concerns or successes, • Must be supported by procedures and actions at all levels.

Strong process safety management programs, Consistent and appropriate operation under all facility conditions,

• Well-trained operation and support personnel, • Approved operating procedures, • Compliance with standards.

Strong process safety knowledge at all levels,

• From management level to all operation and support personnel, • Process safety training.

Four Key Elements of Process Safety Management

1- Hazard Identification: You can only control hazards you have identified. • Safety analysis step program (Steps 0, 1, 2, 3, 4)

2- Elimination or Reduction of Hazards Through Design

• Intensification: Use of smaller quantities. • Substitution: Use of less hazardous materials. • Attenuation: Creation of less hazardous conditions. • Impact limitation: Design to minimize release effects. • Simplification: Design to reduce the probability of operator error.

3- Management of Residual Hazards

• Acceptable maximum risk management consistent with BASF risk matrix. • Risk control measures, additional layers of protection.

4- Documentation & Communication of Facility Safety Concept

• Organizations have no memory (Trevor Kletz). • Facility safety concept = documentation of identified hazards, associated risks, control measures taken. • Regular communication of the facility safety concept with operation and maintenance teams. • Training, periodic review and updating of operating procedures, sharing of lessons learned from accidents.

BASF Concept for Safe Distances

• Minimum distances of facilities to crowded areas, buildings with worker presence (control rooms, laboratories, workshops and offices), neighboring facilities and fire sources are determined by BASF SE regulations or special decisions, • Objective: prevent interaction between facilities (domino effect).

Safety Reviews Are a Team Effort

Same Hazard Potential, Different Risk

• In both cases hazard potentials are the same, • Risk level differs with protective measures.

Semi-Quantitative Risk Assessment – BASF Risk Matrix

Classification of Safety Measures

Developments Related to Culture and Competency Top management commitment creates better safety culture, achieving better progress, Employee competency is the most important factor for high quality in operations:

•Process design for inherent safety, •Design of instrumental safety systems, •Hazard analysis/safety review, •Change management, •Substance safety property measurements, •Incident (accident) analysis, data evaluation, •Development of company regulations and rules.

Challenges for Process Safety Improvements Ensuring consistency within the organization,

•Regional cultures; variations between facilities and departments, •Being open to learning from variable errors from different countries, companies and even different facilities within the same company, •Acquired facilities (various company acquisitions).

Improving safety at older facilities, change management, Developing and maintaining employee competency

•Demographics, •Acquisitions, •Organizational changes, •Reorganization of production, maintenance and specialist work from a productivity-centered perspective. Ömür Vural Taşdemir Process Safety Specialist, EUU/OBT BASF