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ICCA 全球調和 製程安全指標
提報指引 2016 年
6 月
責任照顧領導群
The Responsible Carereg Leadership Group
Traditional Chinese version translated by Taiwan Responsible Care Association
1
目錄
前言 2
背景 5
執行摘要 5
RCLG 各協會應向 RCLG 提報的數據 7
ICCA 製程安全事件判定標準流程圖 8
須提報製程安全事件之重要標準 9
製程安全事件判定準則 10
表 1 ndash GHS 分類表 14
表 2 ndash API RP 754 Tier II 分類表 15
附錄 A ndash 嚴重程度表鼓勵所有協會均採用嚴重程度加權制度 17
附錄 B ndash 常見問題集 19
Appendix C ndash List of RCLG Taskforce Members 25
附錄 D ndash 詳細活動時程表 26
附錄 E ndash 選擇性 Excel 追蹤表 27
後語 28
2016 年 6 月 15 日
Dear Members of the Taiwan Responsible Care Association We would like to express our deep appreciation for the work of ICCA and the Responsible Care Leadership Group in developing this valuable guidance which we are delighted to bring under the umbrella of the Taiwan Responsible Care Association Process safety reporting is at the very heart of Responsible Care It has been a proven practice in the chemical industry for decades We strive continuously to improve our management procedures to reduce the occurrence of chemical incidents and measuring is absolutely crucial to that process ndash for you cannot improve what you do not measure Reporting enables companies and associations to share best practices and improve their performance while reducing their environmental footprint Learning from incidents has been key to improving process safety to todayrsquos low levels and we aim to bring them down further still Although the industry has long been tracking and reporting process safety performance at a regional level this proposal for process safety event reporting will for the first time enable broad-based and global reporting of process safety performance right across the chemical and petrochemical industries We invite all members of the Taiwan Responsible Care Association to implement this guidance by 2020 and are committed to helping them do so The national chemical industry associations play a vital role in promoting best practice and we look to them to roll out the guidance to their member companies It is our sincere hope that these guidelines will contribute to enhancing process and plant safety throughout Taiwan For your reference the original and globally applicable guidance
ICCA Process Safety
Guidance_Finaldoc
Patrick Vandenhoeke Head of Responsible Care Leadership Group
3
敬愛的 TRCA 會員
對於 ICCA (International Council of Chemical Associations 國際化學工業協會) 和責任照顧領
導群在制定這一項寶貴指引時的付出我們表達最深的感謝 我們很高興能夠為 TRCA帶來
這一項可作為保護傘的寶貴指引
製程安全是責任照顧制度的核心也是化學工業數十年來成熟的實踐我們不斷努力改善
管理程序以減少化學事故的發生量測對於製程安全管理是絕對至關重要的一環因為我
們無從改進沒有進行過量測的項目提報(製程安全指標)使得公司與協會得以分享最佳典
範在提高績效表現的同時減少環境足跡從事件中學習是改善製程安全達到低事件率的
關鍵我們的目標是再進一步降低製程安全事件率
儘管化工業長期以來一直在各地區追蹤與提報製程安全績效但此次製程安全事件提報的
建議將首度啟用更廣泛的基礎在全球提報製程安全績效提報部門將包括化學工業與石
化工業
我們邀請 TRCA 的所有會員在 2020 年前一同來推行這項提報指引我們也將致力於協助各
位達標國家化學工業協會在推廣最佳實務方面扮演重要角色我們期待他們向所屬會員
公司推動本指引
我們誠摯地希望這些指導方針將有助於台灣提升製程和工廠的安全
謹提供全球適用的指引原始檔案如下請參考
Patrick Vandenhoeke
責任照顧領導群主席
GUIDANCE FOR REPORTING ON THE ICCA GLOBALLY HARMONIZED PROCESS SAFETY METRICJune2016The Responsible Carereg Leadership Group
ContentsBackground2Executive Summary2Data to be reported by RCLG Associations to RCLG4Overview of ICCA Process Safety Event Criteria as a Flow Chart5Key Criteria for Reporting Process Safety Events to RCLG6Detailed Guidelines on Identifying a Process Safety Event7Table 1 ndash GHS Classification Table11Table 2 ndash API RP 754 Tier II Classification Table12Appendix A ndash Severity Table Using A Severity Weighting System is Encouraged for All Associations14Appendix B ndash Frequently Asked Questions16Appendix C ndash List of RCLG Taskforce Members22Appendix D ndash Detailed Schedule of Events23Appendix E ndash Optional Excel Reporting Form24
FIANL DRAFT
June 15 2016
The Responsible Carereg initiative began in 1985 and as the chemical industryrsquos commitment to continuous performance improvements Process Safety has been a pillar of Responsible Care since its inception and many regional approaches to tracking and reporting process safety performance have developed over the 30 years of Responsible Care implementation yet no globally harmonized system had been put into place In 2012 in the wake of several high profile process safety events the International Council of Chemical Associations (ICCA) Board of Directors directed the Responsible Care Leadership Group (RCLG) to develop a recommendation for a globally harmonized process safety performance reporting by no later than 2015
Throughout 2013 and 2014 a Taskforce comprised of multinational companies and RCLG associations chaired by Dr Peter Schmelzer Head of Health Safety and Environmental Protection Bayer HealthCare AG worked to develop a globally harmonized ICCA approach to process safety performance reporting A list of Taskforce members can be found in Appendix C During the same timeframe the American Petroleum Institute (API) also initiated a process to update its Recommend Practice 754 (RP-754) ndash Leading and Lagging Process Safety Metric Standard RP-754 is broadly used in the refining and petrochemical sector and in the Americas region to track process safety performance To optimize global adoption of a unified standard the RCLG Taskforce strived to achieve full harmonization of its recommendation with the revised API RP 754 metric expected to be finalized in the first quarter 2016
Executive SummaryAfter more than 2 years of discussion research debate and feasibility assessment the Process Safety Harmonization Taskforce recommends that ICCA adopt a process safety event rate metric The adoption of this metric would require each RCLG association to collect the number of process safety events experienced by their members on an annual basis as well as total number of worker hours (employees and contractors) experienced by their members each year The process safety event rate is the ratio of events to hours The Taskforce also recommends that reporting of these data points to the RCLG be phased in over the next 3 years allowing regions with the desire and ability to report immediately to do so while also allowing additional time to companies and organizations that are developing the ability to track these data for the first time
The criteria that determine whether a process-related event qualifies as a process safety event are based on a loss of primary containment of a chemical or a release of energy triggering thresholds any one of four impact areas 1) safetyhuman health consequences 2) direct cost due to damage from incident 3) community impact and 4) chemical release quantity (see the flow chart showing reporting triggers) These four impact areas in the recommended ICCA process safety event definition are identical to the impact areas in the RP-754 Tier II incident standard The thresholds for reporting are also identical in all areas with the exception of the chemical release quantity thresholds To address this difference the ICCA process safety event definition will allow companies the use of either the GHS-based reporting thresholds developed by ICCA for the chemical release criteria or the UN Dangerous Goods (UNDG)-based reporting thresholds used in the RP-754 standard for Tier II incidents The Taskforce believes that the two systems though different are comparably robust in the universe of chemicals covered and the severity of incidents captured by reporting While there will be relatively little difference in the numbers of events captured and reported using the two different threshold approaches there may be differences that would be most clearly seen at the company level based on raw material and product use hence the Taskforce cautions companies not to compare their results with companies that use a different chemical release threshold approach Regardless under the RCLG proposal companies can choose the chemical release thresholds by which they report in to their national and regional associations If associations are interested in translating results based on one reporting approach to another the RCLG will provide a translation table However given the complexity of this exercise and the need to access raw incident data the Taskforce does not believe that this adds value and recommends against it
The Taskforce believes that this proposal for process safety event reporting will enable broad-based global reporting of process safety performance across the chemical and petrochemical industries It will provide a roadmap for regions associations and companies that are currently not tracking process safety performance to recognize the benefits that tracking and reporting will bring For regions associations and companies that are already experienced in gathering process safety data this recommendation allows for broader global alignment and focus on continuous improvement in process safety performance The systems that are built to improve process safety performance are informed by robust process safety event data and this is the major objective of this initiative
Data to be reported by RCLG Associations to RCLGOn an annual basis RCLG Associations will be asked to report two data points into ICCA using the RCLG KPI Reporting Website on the schedule provided below
1Total Member Company Worker Hours for Association (employee and contractor)
2Total Number of Process Safety Events
ICCA will use the above two data points to report process safety performance in the form of Process Safety Event Rate (PSER) normalized per 100 employees where an employee works 2000 hours a year
(Total Events Total Hours) x 200000 = PSER
Recommended Reporting Schedule
The Taskforce recommends a phased-in approach for reporting process safety event rate Such a schedule will allow more experienced companies and associations to report in the next several years while allowing other companies and associations to begin reporting by 2019 RCLG Associations would be asked to report the two process safety event rate data points annually to the ICCA through the RCLG KPI metrics reporting system If you do not know your associationrsquos username and password please contact the RCLG
The proposed schedule for process safety event rate reporting by RCLG associations is as follows
April 2015RCLG considers Taskforce proposal
June 2015ICCA Board of Directors considers RCLG final recommendation
July 2015RCLG releases the first detailed reporting guidance document for associations and member companies
Feb 2016 RCLG Reporting RCLG initiates process safety reporting pilot program through association volunteers with updated an enhanced guidance document RCLG rolls out final guidance document in June 2016
2017RCLG Associations begin collecting data from its membership
2018-2019 RCLG Reporting Optional process safety data reporting by RCLG Associations
2020 ReportingRCLG includes process safety as a mandatory metric in the KPI reporting program
See Appendix D ndash Detailed Schedule of Events
Overview of ICCA Process Safety Event Criteria as a Flow ChartNO Does not meet the criteria for a Process Safety Event
Start
NO
NO
NO
Was a chemical substance or a chemical process directly involved
YES
YES
Release of material fire explosion or implosion fromat a chemical process unit
Incident in production distribution storage utilities pilot plants within a companyrsquos facility
YES
NO
Officially declared shelter in place or evacuation
Or Precautionary off site shelter in place or evacuation
Substance Release Thresholds met
Recordable injury
Or
hospital admission of people on or off site
Damage ge $2500direct costto company
NO
NO
NO
ICCA or API 754 Tier II chemical release thresholds exceeded
YES
YES
YES
Yes Reportable as a Process Safety Event
YES
Key Criteria for Reporting Process Safety Events to RCLGTotal Worker Hours
RCLG Associations should report the total number of employee hours worked for each member company in their association and the total number of contractor hours worked for each member company as a combined single number For the purposes of this guidance document each association should refer to their local and regional definitions for employee and contractor The goal for reporting total hours is to include all individuals who are involved with chemical manufacturing except where those individuals are tasked with major construction projects such as large scale investments with specific one-time project organizations created for design engineering and construction of new or significant expansion to existing process facilities When reporting total worker hours companies should report the same hours used for reporting personnel hours This way companies can have the same data set for occupational and process safety Personnel hours should include those hours from all chemical manufacturing operations not just from facilities where a process safety incident occurred
Process Safety Event
For the purposes of this ICCA Reporting a process safety event has occurred when
A When a chemical substance or a chemical process is directly involved AND
B The incident occurred in production distribution storage utility pilot plant within the site boundaries of companyrsquos facility AND
C There was a release of material or energy (eg fire explosion implosion) from a process unit AND
D One or more of the following Reporting Thresholds have been met
1 Safety Injury
middot Injury resulting in a Recordable Lost Time Accident or Fatality or Hospital admission of anyone on or off site OR
2 Direct Damage Cost
middot A fire explosion or clean up necessary to avoidremediate environmental damage resulting in a direct cost equal to or greater than $2500 USDs OR
3 Shelter in Place Evacuation
middot An officially declared shelter in place (on or off site) OR
middot An officially declared evacuation (on or off site) OR
middot A precautionary off site shelter in place or evacuation OR
4 Threshold Release
middot The material released meets one of the GHS thresholds in Table 1 (measured in amount released during one hour)
As an alternative companies can choose to use the release thresholds contained in the API RP-754 standard ndash Table 2 Note ndash Individuals who would like to view the API RP-754 Standard may purchase and download that standard at - Detailed Guidelines on Identifying a Process Safety Event A Chemical InvolvementWhen a chemical substance or chemical process is directly involved
A chemical or chemical process must have been directly involved in the event or incident For this purpose the term process is used broadly to include the equipment and technology needed for petrochemical production including reactors tanks piping boilers cooling towers refrigeration systems etc An incident with no direct chemical or process involvement eg an office building fire even if the office building is on a plant site is not reportable
B LocationThe incident occurred in production distribution storage utility pilot plant within the site boundaries of companyrsquos facility
The incident occurs in production distribution storage (including active storage areas such as warehouses ndash see FAQ section) utilities or pilot plants of a facility reporting metrics under these definitions This includes tank farms ancillary support areas (eg boiler houses and waste water treatment plants) and distribution piping under control of the site All reportable incidents occurring at a location will be reported by the company that is responsible for operating that location This applies to incidents that may occur in contractor work areas as well as other incidents At tolling operations and multi-party sites the company that operates the unit where the incident initiated should record the incident and count it in their reporting
C Release of MaterialThere was a release of material or energy (eg fire explosion implosion) from a process unit
Release of Material ndash an unplanned or uncontrolled release of any material including non-toxic and non-flammable materials (eg steam hot water nitrogen compressed CO2 or compressed air) from a process that results in consequences that exceed one or more of the 4 Reporting Thresholds listed in this document
A release to a flare or scrubber is still considered to be within the primary containment as long as the mitigation system (eg scrubber flare) is operated under normal conditions without any release above the thresholds defined for normal operation A release to a secondary containment (eg waste water treatment or dike) will qualify as a process safety event because the substance is leaving the primary process system
D ThresholdsOne or more of the following Reporting Thresholds must be met for reportable process safety events
1 Safety Injury
Injury resulting in a Recordable Lost Time Accident or Fatality or Hospital admission of anyone on or off site Recordable injuries are work-related injuries that results in any of the following death days away from work restricted work or transfer to another job medical treatment beyond first aid loss of consciousness or a significant injury diagnosed by a physician or other licensed health professional
Lost time injuries and fatalities that occur as a result of process related loss of primary containment fire or explosion are those that fit into one of the following categories
middot Employee (Lost time andor Fatality)
middot Contractor and Subcontractor (Lost time andor Fatality)
middot Third Party (Injuryillness resulting in Hospital Admission or Fatality)
Hospital Admission ndash formal acceptance by a hospital or other inpatient health care facility of a patient who is to be provided with room board and medical service in an area of the hospital or facility where patients generally reside at least overnight Treatment in the hospital emergency room or an overnight stay in the emergency room would not by itself qualify as a ldquohospital admissionrdquo
Examples of injury or fatality cases that would be reportable include a burn injury resulting from steam released during cleaning a physical injury from a cap blown off by pressure during a pressure test or a chemical burn from a spill while taking a sample Examples of injuries or fatality cases that would not be reportable include a fall from an elevated work station while performing maintenance a burn from a fire in a laboratory or office building or injuries from an excavation cave-in None of these cases are directly due to the release of energy or material from the process
2 Direct Damage CostA fire explosion or clean up necessary to avoidremediate environmental damage resulting in a direct cost equal to or greater than $2500 USDs
Costs to be considered for this threshold should be those costs directly attributed to the fire andor explosion such as the replacement value of equipment lost structures lost cost of repairs environmental cleanup (on and off site) emergency response andor fines Direct cost does not include indirect costs such as business opportunity losses loss of profits due to equipment outages cost of obtaining or operating temporary facilities or cost of obtaining replacement products to meet customer demand (product losses)
3 Shelter in Place Evacuation
An officially declared shelter in place or evacuation either on or off site OR a precautionary shelter in place or evacuation off site
For the purposes of this reporting an officially declared shelter in place or evacuation on or off site OR a precautionary shelter in place or evacuation is declared off site would trigger this threshold
Officially Declared ndash A declaration by a recognized community official (eg fire police civil defense emergency management) or delegate (eg Company official) authorized to order the community action (eg shelter-in-place evacuation)
Precautionary Declaration - A precautionary public response is a measure taken from an abundance of caution and issued by a recognized community official or delegate whom has reasonably determined that such an evacuation or shelter in place was necessary to protect the public health and safety
Shelter in Place ndash is the use of a structure and its indoor atmosphere to temporarily separate individuals from a hazardous outdoor atmosphere
Evacuation ndash the act or process of removing persons from a place for reasons of safety or protection
4 Threshold ReleaseAn acute release that exceeds one of the GHS thresholds in Table 1 or in the API 754 standard for Tier II process safety release thresholds in Table 2 (measured in amount released during one hour)
As mentioned in the Executive Summary the ICCA process safety event definition allows use of either GHS-based reporting thresholds developed by ICCA for the chemical release criteria or the UN Dangerous Goods (UNDG)-based reporting thresholds used in the RP-754 standard for Tier II incidents The GHS thresholds are listed in Table 1 It is intended for companies to decide which table to use and to allow companies the option to use one system globally
Acute Release ndash A release of flammable combustible or toxic chemicals from the primary containment (ie vessel or pipe) greater than the chemical release threshold quantities is described for GHS Classification Table 1 and in the API 754 standard for Tier II process safety release thresholds in Table 2
Pressure Relief Device Acute Releases defined above include releases to a properly designed and operating pressure relief device if a quantity is released greater than or equal to the threshold quantities in Table 1 OR in the API 754 standard for Tier II process safety release thresholds Table 2 that results in one or more of the following four consequences
1 Rainout
2 Discharge to a potentially unsafe location
3 A n on-site shelter-in-place or on-site evacuation excluding precautionary on-site shelter-Ain-place or on-site evacuation
4 Public protective measures (eg road closure) including precautionary public protective measures
Releases to a properly designed and operating pressure relief device (such as a flare scrubber etc) do not have to be reported if they do not meet one of the four criteria above
Individuals who would like to view the API RP-754 Standard may download that standard at -
httpwwwapiorgenvironment-health-and-safetyprocess-safetyprocess-safety-standardsstandard-rp-7541 Hour Rule
For the purpose of the reporting under this metric release thresholds are established for materials over a one-hour time frame If the release amount of a material reaches or exceeds the reporting threshold in a 1-hour time period or less it is reportable Typically acute releases occur in 1-hour or less If the duration of the release cannot be determined the duration should be assumed to be 1 hour
Primary Containment ndash A tank vessel pipe rail car or equipment intended to serve as the primary container or used for the transfer of the material Primary containers may be designed with secondary containment systems to contain and control the release Secondary containment systems include but are not limited to tank dikes curbing around process equipment drainage collection systems into segregated oily drain systems the outer wall of double walled tanks etc
Severity Table Severity weighting can provide additional useful information about process safety events that may help drive performance improvement Appendix A is the RCLG methodology for calculating a severity weight for process safety events Using Appendix A a severity weight for each process safety event may be calculated by summing the points associated with each consequence category The ICCA strongly encourages the use of a severity weighting system as the use of such a system increases the ability to communicate performance and is an easier way for our stakeholders to understand process safety events Also the severity weight will not be comparable among other process safety metric reporting formats
Table 2 ndash API RP 754 Tier II Classification Table
2
Appendix A ndash Severity Table Using A Severity Weighting System is Encouraged for All AssociationsSeverity Table (Appendix A) Details
Appendix A above is designed to be used with the GHS Classification System ONLY (Table 1) If your company is using the API RP 754 Tier II Process Safety Metric Threshold Table Table 2 in this document please use the API RP 754 Process Safety Severity Table It is important to state that the severity table in the API RP 754 Standard is for Tier 1 incidents only Comparing the relative severity of events using different tables will not be statistically valid
Acute Environmental Cost - Cost of short-term cleanup and material disposal associated with a PSE with off-site environmental impact Companies may choose to assign severity to costs associated with off-site environmental impacts in a separate category
Rate Adjusted Metrics
Utilizing the severity table described above there are a variety of rate-based metrics which can be generated These include
Process Safety Total Incident Rate (PSTIR) Total event incidents x 200000___
Total Worker Hours
Process Safety Incident Severity Rate (PSESR) (ie severity-weighted Process Safety incident rate formula)
Total severity score for all events incidents x 200000___
PSESR = Total Worker Hours
In determining this rate 1 point is assigned for each Level 4 incident attribute 3 points for each Level 3 attribute 9 points for each Level 2 attributes and 27 points for each Level 1 attributes Theoretically a process safety event could be assigned a minimum of 1 point (ie the incident meets the attributes of a Level 4 incident in only one category) or a maximum of 135 points (ie the incident meets the attributes of a Level 1 incident in each of the five categories)
PS Level ldquoXrdquo incident rate Total Severity Level ldquoXrdquo PS incidents x 200000
Total employee contractor amp subcontractor work hours
Where X can be the total count of Severity Level 4 3 2 or 1 incidents The severity level of an incident is the maximum severity rating of the five consequence categories
Normalization ndash In some associations and member companies process safety events are normalized on a lsquoper 100rsquo employee basis given that a one worker averages 2000 per year So to normalize on a lsquoper 100rsquo employee basis events are multiplied by 200000 worker hours In other associations and member companies events are normalized on a lsquoper 500rsquo employee basis and events are multiplied by 1000000 worker hours Associations and members should discuss this option and come to a conclusion together The above formulas are set at a lsquoper 100rsquo employee rate
15
(K = 1000 MM = 1000000) (For Environmental Impact companies and associations should agree on input criteria where definitions arenrsquot readily available)
Appendix B ndash Frequently Asked QuestionsApplicability
It is recommended that companies record and report Process Safety Events occurring at Company-owned or operated facilities except as noted below
1 PSEs that originated off Company property
2 Marine transport vessel incidents except when the vessel is connected to the facility for the purposes of crude or product transfer
3 Truck andor rail incidents except when the truck or rail car is connected to the facility for the purposes of crude or product transfer
4 Routine emissions that are allowable under permit or regulation
5 Underground contamination that had no process safety consequences Note The exclusion does not apply if the release resulted in an aboveground reportable PSE such as release of toxic vapors or pooling of flammable liquids
6 Office building incidents (eg office heating equipment explosions fires spills releases personnel injury or illness etc)
7 Personnel safety sliptripfall incidents that are not directly associated with evacuating from or responding to a loss of containment incident
8 Loss of Primary Containment (LOPC) incidents from ancillary equipment not connected to the process (eg small sample containers)
9 Planned and controlled drainage of material to collection or drain system designed for such service (Note Exclusion does not apply to an unintended and uncontrolled release of material from primary containment that flows to a collection or drain system)
10 Mechanical work being conducted outside of process units or in maintenance shops
Interpretations and Examples ndash Based on GHS Table 1
The following interpretations and examples have been prepared to help clarify areas of potential uncertainty in the evaluation of reportable Process Safety Incidents (PSE)
COMPANY PREMISES
1 A third-party truck loading a flammable product on Company Premises experiences a leak and subsequent fire and property loss damages of $7000 (direct costs) Although the truck is Operated-by-Others it is connected to the process The incident would be a reportable PSE if property losses in direct costs were equal to or greater than $2500 or some other PSE threshold was met or exceeded (eg a fatality)
2 Similar example as 1 The truck loaded with flammable product overturns in route out of the plant resulting in a fire and loss of the truck This would not be reported as a PSE since the truck is no longer connected to the plant
LOSS OF CONTAINMENT
3 A faulty tank gauge results in the overfilling of a product tank containing ldquoflammable liquidsrdquo Approximately 700 kg of liquid overflows into the tanks diked area This incident is a reportable PSE since it is an acute spill greater than 100 kgs regardless of secondary containment
4 A maintenance contractor opens a process valve and gets sprayed with sulfuric acid resulting in a severe burn and lost time injury This would be a reportable PSE It is an unintended event involving a material and a loss of containment For fatalities and days away from work injuries and illnesses there is no release threshold amount
5 An operator opens a quality control sample point to collect a routine sample of product and receives a bad hand laceration requiring stitches due to a broken glass bottle and misses the next day of work This is not a reportable PSE because it is not related to a loss of containment
ACUTE RELEASES
6 While troubleshooting a higher-than-expected natural gas flow rate operating personnel find a safety valve on the natural gas line that did not reseat properly and was relieving to the atmospheric vent stack through a knock-out drum Upon further investigation it is determined that a total of 100000 kg of natural gas was relieved at a steady rate over a 6 month period This is not a reportable PSE as the release rate (~10 kg per hour) is not ldquoacuterdquo (ie does not exceed the 100 kg TQ for flammable vapors per 1 hour time period)
FLARES amp EMISSION CONTROL DEVICES (eg scrubbers)
7 If a chemical is routed to a flare or emission control device (eg scrubber) it would not be classified as a PSE as long as that flare or control device operates as designed
8 If a scrubber is overwhelmed by a flowrate greater than the design of the scrubber system and discharges a chemical in excess of the reporting threshold it would be reported as a PSE as noted about in this document
As a note an upset emission from a permitted or regulated source ndash including pressure relieve devices - of a quantity greater than or equal to the threshold quantities in Table 1 or 2 in any one-hour period that results in one or more of the following four consequences
middot rainout
middot discharge to a potentially unsafe location
middot an on-site shelter-in-place or on-site evacuation excluding precautionary on-site shelter-in-place or on-site evacuation
middot public protective measures (eg road closure) including precautionary public protective measures
Should be reported as a PSE
SAFETY RELIEF DEVICE SYSTEM
9 There is a unit upset and the relief valve opens to an atmospheric vent which has been designed resulting in a gas release to the atmosphere with no adverse consequences This would not be a reportable PSE since vapors and gases released to atmosphere from safety valves high-pressure rupture disks and similar safety devices that are properly designed for that event per API Standard 521 or equivalent are excluded as long as the release did not result in (1) a liquid carryover that created a reportable PSE related to the liquid (eg lost time incident fatality a fire or explosion that caused $2500 or more of direct cost liquid release or toxic aerosol release at or above threshold amounts etc) or (2) activation of a shelter-in-place response on or off-site or (3) public protective measures be taken
10 There is a unit upset and the relief valve fails to open resulting in overpressure of the equipment and an acute release of flammable gas from a leaking flange The amount released is above the 100 kg (within 1 hour) threshold This is a reportable PSE Releases from flanges are not excluded from PSE reporting
DAYS AWAY FROM WORK INCIDENTS
11 An operator is walking then slips and falls to the floor and suffers a lost time injury The slipfall is due to weather conditions chronic oily floors and slippery shoes This is not a reportable PSE Personnel safety sliptripfall incidents that are not directly associated with evacuating from or responding to a loss of containment incident are specifically excluded from PSE reporting
12 Same as above except that the operator slipped and fell while responding to a small flammable liquid spill (eg less than 10 kg in 1 hour) This would be PSE reportable since the operator was responding to a loss of containment incident A PSE is reportable if the loss of primary containment occurs on Company Premises and results in a lost time incident or fatality For fatalities and lost time incidents there is no release threshold amount
13 Same as above except that the operator slipped and fell several hours after the incident had concluded This would not be PSE reportable The terms evacuating from and responding to in the reporting exclusion mean that the loss of containment and associated emergency response activities are on-going Slipstripfalls after the event have concluded (such as after-the-fact clean-up and remediation) are excluded from PSE reporting
14 A scaffold builder suffers a lost time injury after falling from a scaffold ladder while evacuating from a loss of containment incident on nearby equipment This is a reportable PSE
15 An operator walks past an improperly designed steam trap The steam trap releases and the operators ankle is burned by the steam resulting in a lost time injury This is a reportable PSE because even though the loss of containment was steam (vs hydrocarbon or chemical) the physical state of the material was such that it caused a lost time injury
16 An enclosure has been intentionally purged with nitrogen A contractor bypasses safety controls enters the enclosure and dies This is a reportable fatality but not a reportable PSE since there was no unplanned or uncontrolled loss of primary containment
17 Same as above except that nitrogen inadvertently leaked into the enclosure This would be a reportable PSE (and fatality) since there was a fatality associated with an unplanned loss of primary containment
18 An operator responding to an H2S alarm collapses and has a injury If the alarm was triggered by an actual unplanned or uncontrolled H2S LOPC the event would be a reportable PSE If the alarm was a false alarm the event would not be a reportable PSE because there was no actual release
PIPELINES
19 A pipeline leaks and releases 2000 lbs (900 kgs) of flammable vapor above ground within 1 hour However the release occurred in a remote location within the site The release is PSE reportable since remoteness is not a consideration
FIRES or ENERGY RELEASES NOT ASSOCIATED WITH CHEMICAL RELEASE
As a general rule a fire or energy release is reported as a PSE only if caused by chemical release or results in a chemical release in excess of the reporting quantities Examples include
20 An electrical fire impacts the operation of the process resulting in the release of 400 kg of toluene This event would be reported as a PSE since if the chemical release exceeds the 100 kg reporting threshold for toluene
21 An electrical fire loss of electricity or any other loss of utility occurs which may cause a plant shutdown and possibly incidental equipment damage greater than $2500 (eg damage to reactors or equipment due to inadequate shutdown) but does not create a chemical release greater than the threshold quantity or cause a fatality or serious injury This event would not be reported as a PSE since the equipment damage was not caused by a chemical process fireexplosion and there was not a chemical release greater than the threshold quantity
MARINE TRANSPORT VESSELS
22 A company operated Marine Transport Vessel has an onboard acute spill of combustible material greater than 100 kg The event is not PSE reportable since Marine Transport Vessel incidents are specifically excluded except when the vessel is connected to the refinery petrochemical or chemical manufacturing facility for the purposes of crude or product transfer
23 A third-party barge is being pushed by a tug and hits the company dock A barge compartment is breached and releases 1000 kg of diesel to the water The event is not a reportable PSE since the marine vessel was not berthed at the dock and actively involved in crude or product transfer operations
TRUCK AND RAIL
24 A company railcar derails and spills more than 1000 kg of gasoline while in transit The incident is not PSE reportable since rail incidents off company property are specifically excluded
25 A third-party trucktrailer overturns while in the Company Premises resulting in an acute spill of gasoline greater than 1000 kg The incident is not reported as a PSE reportable if the truck is no longer connected to the loadingunloading facilities However it is recommended that companies also have transportation incident metrics which would capture this event
26 A contract truck hauler is unloading caustic and the hose separates and generates an airborne aerosol andor liquid caustic spill of 2500 kg The event is a reportable PSE since the caustic TQ of 100 kg was exceeded and the truck was still connected to the loadingunloading facility immediately prior to the incident
OFFICE BUILDING
27 There is a boiler fire at the Main Office complex and direct cost damages totaled $75000 The incident is not PSE reportable since Office Building incidents are specifically excluded
MAN-MACHINE INTERFACE INCIDENTS
28 An operations technician is injured while working around the finishing equipment in a polymers plant The injury is caused by the mechanical man-machine interface with the equipment This would not be a reportable Process Safety Event because there was no loss of containment of hazardous material
MIXTURES
29 If a mixture by itself has a GHS classification you use that classification to determine the threshold If the mixture itself does not have a GHS-classification we go back to the individual components of the mixture and based on kg released per threshold group calculate a lsquoweightedrsquo contribution to the thresholds Example a release of 100 kg of a mixture in a one hour period that consists of 05 kg of a substance classified as acute toxic H300 45 kg of substance classified with H301 and 40 kg of a substance with another H-number and the remaining 55 kg of water with no GHS classification would be calculated as 051 + 4510 + 40100 = 05 + 045 + 04 = 135 is exceeding 1 and would be counted as a reportable process safety incident even though none of the individual hazardous components exceeded the threshold for the individual substance
DIRECT DAMAGE COSTS
30 Direct damage costs are considered for this threshold should be those costs directly attributed to the fire andor explosion such as the replacement value of equipment lost structures lost cost of repairs environmental cleanup emergency response andor fines Direct cost does not include indirect costs such as business opportunity losses loss of profits due to equipment outages cost of obtaining or operating temporary facilities or cost of obtaining replacement products to meet customer demand (product losses)
31 As an example a leak of flammable gas occurred in a vent line connected to a gas treatment system At the same time a failure in the process allowed air to enter in the same vent line An explosion occurred and the over pressure damaged the vent line and associated upstream equipment including a seal pot Nobody was hurt The cost for repair was about $12000 This is a PSE considering the cost to repair the equipment due to the explosion and fire
32 As an example after a PSE event a company releases 50 kg of a very special GHS Category 5 product which causes $2000 of damage to equipment The product released was a very special blend of materials and the company incurs over $50000 in materials associated with the product loss This event is not reportable as PSE since the reportable threshold for GHS Category 5 releases is 100 kgs and product losses do not count as Direct Damage Costs
NATURAL DISASTERS
33 Natural disasters can present substantial risks to chemical process operations and damage to plant equipment which may result in a loss of containment of hazardous substances Where the potential for one or more types of natural disasters is deemed relevant to plant operations process safety and operational systems shall address the applicable risk in terms of hazards and consequence analysis plant design operating procedures for loss of utilities and process shutdown and emergency planning and response
Types of natural disasters includes hurricanes and typhoons (including associated storm surge) floods tornadoes earthquakes derechos (straight line wind storms) wildfires volcanic eruptions tsunamis and avalanches
If your facility experiences a natural disaster that triggers one or more of the thresholds it should be reported as a process safety event
PRECAUTIONARY PUBLIC RESPONSE
34 A precautionary public response is a measure taken from an abundance of caution For example a company may require all workers to shelter-in-place in response to an LOPC independent of or prior to any assessment (eg wind direction distance from the LOPC etc) of the potential hazard to those worker For example a recognized community official (eg fire police civil defense emergency management) may order a community shelter-in-place evacuation or public protective measure (eg road closure) in the absence of information from a company experiencing a process safety event or lsquojust in casersquo the wind direction changes or due to the sensitive nature of the potentially affected population (eg school children the elderly)
ACTIVE WAREHOUSE
35 An active warehouse is an on-site warehouse that stores raw materials intermediates or finished products used or produced by a process From a process perspective an active warehouse is equivalent to a bulk storage tank Rather than being stored in a single large container the raw materials intermediates or finished products are stored in smaller containers (eg totes barrels pails etc)
Appendix C ndash List of RCLG Taskforce Members Luiz Shizuo Harayashiki19
Appendix D ndash Detailed Schedule of Events Appendix E ndash Optional Excel Reporting FormWhen member companies begin tracking process safety events a single form should be utilized for all member companies to make data analysis easier and to allow all members to work from the same tracking sheet The RCLG has developed an optional tracking sheet that members and associations can start with when developing their own tracking sheet
DOWNLOAD TRACKING SHEET HERE
This document consists of a contact page the survey itself and a lsquodo not editrsquo page where the drop down menu answer are stored
INTERNATIONAL
COUNCIL OF
CHEMICAL
ASSOCIATIONS
ICCA Process Safety
Event Tracking Sheetxlsx
GUIDANCE FOR REPORTING ON THE ICCA GLOBALLY HARMONIZED PROCESS SAFETY METRICJune2016The Responsible Carereg Leadership Group
ContentsBackground2Executive Summary2Data to be reported by RCLG Associations to RCLG4Overview of ICCA Process Safety Event Criteria as a Flow Chart5Key Criteria for Reporting Process Safety Events to RCLG6Detailed Guidelines on Identifying a Process Safety Event7Table 1 ndash GHS Classification Table11Table 2 ndash API RP 754 Tier II Classification Table12Appendix A ndash Severity Table Using A Severity Weighting System is Encouraged for All Associations14Appendix B ndash Frequently Asked Questions16Appendix C ndash List of RCLG Taskforce Members22Appendix D ndash Detailed Schedule of Events23Appendix E ndash Optional Excel Reporting Form24
FIANL DRAFT
June 15 2016
The Responsible Carereg initiative began in 1985 and as the chemical industryrsquos commitment to continuous performance improvements Process Safety has been a pillar of Responsible Care since its inception and many regional approaches to tracking and reporting process safety performance have developed over the 30 years of Responsible Care implementation yet no globally harmonized system had been put into place In 2012 in the wake of several high profile process safety events the International Council of Chemical Associations (ICCA) Board of Directors directed the Responsible Care Leadership Group (RCLG) to develop a recommendation for a globally harmonized process safety performance reporting by no later than 2015
Throughout 2013 and 2014 a Taskforce comprised of multinational companies and RCLG associations chaired by Dr Peter Schmelzer Head of Health Safety and Environmental Protection Bayer HealthCare AG worked to develop a globally harmonized ICCA approach to process safety performance reporting A list of Taskforce members can be found in Appendix C During the same timeframe the American Petroleum Institute (API) also initiated a process to update its Recommend Practice 754 (RP-754) ndash Leading and Lagging Process Safety Metric Standard RP-754 is broadly used in the refining and petrochemical sector and in the Americas region to track process safety performance To optimize global adoption of a unified standard the RCLG Taskforce strived to achieve full harmonization of its recommendation with the revised API RP 754 metric expected to be finalized in the first quarter 2016
After more than 2 years of discussion research debate and feasibility assessment the Process Safety Harmonization Taskforce recommends that ICCA adopt a process safety event rate metric The adoption of this metric would require each RCLG association to collect the number of process safety events experienced by their members on an annual basis as well as total number of worker hours (employees and contractors) experienced by their members each year The process safety event rate is the ratio of events to hours The Taskforce also recommends that reporting of these data points to the RCLG be phased in over the next 3 years allowing regions with the desire and ability to report immediately to do so while also allowing additional time to companies and organizations that are developing the ability to track these data for the first time
The criteria that determine whether a process-related event qualifies as a process safety event are based on a loss of primary containment of a chemical or a release of energy triggering thresholds any one of four impact areas 1) safetyhuman health consequences 2) direct cost due to damage from incident 3) community impact and 4) chemical release quantity (see the flow chart showing reporting triggers) These four impact areas in the recommended ICCA process safety event definition are identical to the impact areas in the RP-754 Tier II incident standard The thresholds for reporting are also identical in all areas with the exception of the chemical release quantity thresholds To address this difference the ICCA process safety event definition will allow companies the use of either the GHS-based reporting thresholds developed by ICCA for the chemical release criteria or the UN Dangerous Goods (UNDG)-based reporting thresholds used in the RP-754 standard for Tier II incidents The Taskforce believes that the two systems though different are comparably robust in the universe of chemicals covered and the severity of incidents captured by reporting While there will be relatively little difference in the numbers of events captured and reported using the two different threshold approaches there may be differences that would be most clearly seen at the company level based on raw material and product use hence the Taskforce cautions companies not to compare their results with companies that use a different chemical release threshold approach Regardless under the RCLG proposal companies can choose the chemical release thresholds by which they report in to their national and regional associations If associations are interested in translating results based on one reporting approach to another the RCLG will provide a translation table However given the complexity of this exercise and the need to access raw incident data the Taskforce does not believe that this adds value and recommends against it
The Taskforce believes that this proposal for process safety event reporting will enable broad-based global reporting of process safety performance across the chemical and petrochemical industries It will provide a roadmap for regions associations and companies that are currently not tracking process safety performance to recognize the benefits that tracking and reporting will bring For regions associations and companies that are already experienced in gathering process safety data this recommendation allows for broader global alignment and focus on continuous improvement in process safety performance The systems that are built to improve process safety performance are informed by robust process safety event data and this is the major objective of this initiative
On an annual basis RCLG Associations will be asked to report two data points into ICCA using the RCLG KPI Reporting Website on the schedule provided below
1Total Member Company Worker Hours for Association (employee and contractor)
2Total Number of Process Safety Events
ICCA will use the above two data points to report process safety performance in the form of Process Safety Event Rate (PSER) normalized per 100 employees where an employee works 2000 hours a year
(Total Events Total Hours) x 200000 = PSER
Recommended Reporting Schedule
The Taskforce recommends a phased-in approach for reporting process safety event rate Such a schedule will allow more experienced companies and associations to report in the next several years while allowing other companies and associations to begin reporting by 2019 RCLG Associations would be asked to report the two process safety event rate data points annually to the ICCA through the RCLG KPI metrics reporting system If you do not know your associationrsquos username and password please contact the RCLG
The proposed schedule for process safety event rate reporting by RCLG associations is as follows
April 2015RCLG considers Taskforce proposal
June 2015ICCA Board of Directors considers RCLG final recommendation
July 2015RCLG releases the first detailed reporting guidance document for associations and member companies
Feb 2016 RCLG Reporting RCLG initiates process safety reporting pilot program through association volunteers with updated an enhanced guidance document RCLG rolls out final guidance document in June 2016
2017RCLG Associations begin collecting data from its membership
2018-2019 RCLG Reporting Optional process safety data reporting by RCLG Associations
2020 ReportingRCLG includes process safety as a mandatory metric in the KPI reporting program
See Appendix D ndash Detailed Schedule of Events
NO Does not meet the criteria for a Process Safety Event
Start
NO
NO
NO
Was a chemical substance or a chemical process directly involved
YES
YES
Release of material fire explosion or implosion fromat a chemical process unit
Incident in production distribution storage utilities pilot plants within a companyrsquos facility
YES
NO
Officially declared shelter in place or evacuation
Or Precautionary off site shelter in place or evacuation
Substance Release Thresholds met
Recordable injury
Or
hospital admission of people on or off site
Damage ge $2500direct costto company
NO
NO
NO
ICCA or API 754 Tier II chemical release thresholds exceeded
YES
YES
YES
Yes Reportable as a Process Safety Event
YES
Total Worker Hours
RCLG Associations should report the total number of employee hours worked for each member company in their association and the total number of contractor hours worked for each member company as a combined single number For the purposes of this guidance document each association should refer to their local and regional definitions for employee and contractor The goal for reporting total hours is to include all individuals who are involved with chemical manufacturing except where those individuals are tasked with major construction projects such as large scale investments with specific one-time project organizations created for design engineering and construction of new or significant expansion to existing process facilities When reporting total worker hours companies should report the same hours used for reporting personnel hours This way companies can have the same data set for occupational and process safety Personnel hours should include those hours from all chemical manufacturing operations not just from facilities where a process safety incident occurred
Process Safety Event
For the purposes of this ICCA Reporting a process safety event has occurred when
A When a chemical substance or a chemical process is directly involved AND
B The incident occurred in production distribution storage utility pilot plant within the site boundaries of companyrsquos facility AND
C There was a release of material or energy (eg fire explosion implosion) from a process unit AND
D One or more of the following Reporting Thresholds have been met
1 Safety Injury
middot Injury resulting in a Recordable Lost Time Accident or Fatality or Hospital admission of anyone on or off site OR
2 Direct Damage Cost
middot A fire explosion or clean up necessary to avoidremediate environmental damage resulting in a direct cost equal to or greater than $2500 USDs OR
3 Shelter in Place Evacuation
middot An officially declared shelter in place (on or off site) OR
middot An officially declared evacuation (on or off site) OR
middot A precautionary off site shelter in place or evacuation OR
4 Threshold Release
middot The material released meets one of the GHS thresholds in Table 1 (measured in amount released during one hour)
When a chemical substance or chemical process is directly involved
A chemical or chemical process must have been directly involved in the event or incident For this purpose the term process is used broadly to include the equipment and technology needed for petrochemical production including reactors tanks piping boilers cooling towers refrigeration systems etc An incident with no direct chemical or process involvement eg an office building fire even if the office building is on a plant site is not reportable
B LocationThe incident occurred in production distribution storage utility pilot plant within the site boundaries of companyrsquos facility
The incident occurs in production distribution storage (including active storage areas such as warehouses ndash see FAQ section) utilities or pilot plants of a facility reporting metrics under these definitions This includes tank farms ancillary support areas (eg boiler houses and waste water treatment plants) and distribution piping under control of the site All reportable incidents occurring at a location will be reported by the company that is responsible for operating that location This applies to incidents that may occur in contractor work areas as well as other incidents At tolling operations and multi-party sites the company that operates the unit where the incident initiated should record the incident and count it in their reporting
C Release of MaterialThere was a release of material or energy (eg fire explosion implosion) from a process unit
Release of Material ndash an unplanned or uncontrolled release of any material including non-toxic and non-flammable materials (eg steam hot water nitrogen compressed CO2 or compressed air) from a process that results in consequences that exceed one or more of the 4 Reporting Thresholds listed in this document
A release to a flare or scrubber is still considered to be within the primary containment as long as the mitigation system (eg scrubber flare) is operated under normal conditions without any release above the thresholds defined for normal operation A release to a secondary containment (eg waste water treatment or dike) will qualify as a process safety event because the substance is leaving the primary process system
D ThresholdsOne or more of the following Reporting Thresholds must be met for reportable process safety events
1 Safety Injury
Injury resulting in a Recordable Lost Time Accident or Fatality or Hospital admission of anyone on or off site Recordable injuries are work-related injuries that results in any of the following death days away from work restricted work or transfer to another job medical treatment beyond first aid loss of consciousness or a significant injury diagnosed by a physician or other licensed health professional
Lost time injuries and fatalities that occur as a result of process related loss of primary containment fire or explosion are those that fit into one of the following categories
middot Employee (Lost time andor Fatality)
middot Contractor and Subcontractor (Lost time andor Fatality)
middot Third Party (Injuryillness resulting in Hospital Admission or Fatality)
Hospital Admission ndash formal acceptance by a hospital or other inpatient health care facility of a patient who is to be provided with room board and medical service in an area of the hospital or facility where patients generally reside at least overnight Treatment in the hospital emergency room or an overnight stay in the emergency room would not by itself qualify as a ldquohospital admissionrdquo
Examples of injury or fatality cases that would be reportable include a burn injury resulting from steam released during cleaning a physical injury from a cap blown off by pressure during a pressure test or a chemical burn from a spill while taking a sample Examples of injuries or fatality cases that would not be reportable include a fall from an elevated work station while performing maintenance a burn from a fire in a laboratory or office building or injuries from an excavation cave-in None of these cases are directly due to the release of energy or material from the process
2 Direct Damage CostA fire explosion or clean up necessary to avoidremediate environmental damage resulting in a direct cost equal to or greater than $2500 USDs
Costs to be considered for this threshold should be those costs directly attributed to the fire andor explosion such as the replacement value of equipment lost structures lost cost of repairs environmental cleanup (on and off site) emergency response andor fines Direct cost does not include indirect costs such as business opportunity losses loss of profits due to equipment outages cost of obtaining or operating temporary facilities or cost of obtaining replacement products to meet customer demand (product losses)
3 Shelter in Place Evacuation
An officially declared shelter in place or evacuation either on or off site OR a precautionary shelter in place or evacuation off site
For the purposes of this reporting an officially declared shelter in place or evacuation on or off site OR a precautionary shelter in place or evacuation is declared off site would trigger this threshold
Officially Declared ndash A declaration by a recognized community official (eg fire police civil defense emergency management) or delegate (eg Company official) authorized to order the community action (eg shelter-in-place evacuation)
Precautionary Declaration - A precautionary public response is a measure taken from an abundance of caution and issued by a recognized community official or delegate whom has reasonably determined that such an evacuation or shelter in place was necessary to protect the public health and safety
Shelter in Place ndash is the use of a structure and its indoor atmosphere to temporarily separate individuals from a hazardous outdoor atmosphere
Evacuation ndash the act or process of removing persons from a place for reasons of safety or protection
4 Threshold ReleaseAn acute release that exceeds one of the GHS thresholds in Table 1 or in the API 754 standard for Tier II process safety release thresholds in Table 2 (measured in amount released during one hour)
As mentioned in the Executive Summary the ICCA process safety event definition allows use of either GHS-based reporting thresholds developed by ICCA for the chemical release criteria or the UN Dangerous Goods (UNDG)-based reporting thresholds used in the RP-754 standard for Tier II incidents The GHS thresholds are listed in Table 1 It is intended for companies to decide which table to use and to allow companies the option to use one system globally
Acute Release ndash A release of flammable combustible or toxic chemicals from the primary containment (ie vessel or pipe) greater than the chemical release threshold quantities is described for GHS Classification Table 1 and in the API 754 standard for Tier II process safety release thresholds in Table 2
Pressure Relief Device Acute Releases defined above include releases to a properly designed and operating pressure relief device if a quantity is released greater than or equal to the threshold quantities in Table 1 OR in the API 754 standard for Tier II process safety release thresholds Table 2 that results in one or more of the following four consequences
1 Rainout
2 Discharge to a potentially unsafe location
3 A n on-site shelter-in-place or on-site evacuation excluding precautionary on-site shelter-Ain-place or on-site evacuation
4 Public protective measures (eg road closure) including precautionary public protective measures
Releases to a properly designed and operating pressure relief device (such as a flare scrubber etc) do not have to be reported if they do not meet one of the four criteria above
Individuals who would like to view the API RP-754 Standard may download that standard at -
httpwwwapiorgenvironment-health-and-safetyprocess-safetyprocess-safety-standardsstandard-rp-7541 Hour Rule
For the purpose of the reporting under this metric release thresholds are established for materials over a one-hour time frame If the release amount of a material reaches or exceeds the reporting threshold in a 1-hour time period or less it is reportable Typically acute releases occur in 1-hour or less If the duration of the release cannot be determined the duration should be assumed to be 1 hour
Primary Containment ndash A tank vessel pipe rail car or equipment intended to serve as the primary container or used for the transfer of the material Primary containers may be designed with secondary containment systems to contain and control the release Secondary containment systems include but are not limited to tank dikes curbing around process equipment drainage collection systems into segregated oily drain systems the outer wall of double walled tanks etc
Severity Table Severity weighting can provide additional useful information about process safety events that may help drive performance improvement Appendix A is the RCLG methodology for calculating a severity weight for process safety events Using Appendix A a severity weight for each process safety event may be calculated by summing the points associated with each consequence category The ICCA strongly encourages the use of a severity weighting system as the use of such a system increases the ability to communicate performance and is an easier way for our stakeholders to understand process safety events Also the severity weight will not be comparable among other process safety metric reporting formats
Table 1 ndash GHS Classification TableTable 2 ndash API RP 754 Tier II Classification Table
2
Appendix A ndash Severity Table Using A Severity Weighting System is Encouraged for All AssociationsSeverity Table (Appendix A) Details
Appendix A above is designed to be used with the GHS Classification System ONLY (Table 1) If your company is using the API RP 754 Tier II Process Safety Metric Threshold Table Table 2 in this document please use the API RP 754 Process Safety Severity Table It is important to state that the severity table in the API RP 754 Standard is for Tier 1 incidents only Comparing the relative severity of events using different tables will not be statistically valid
Acute Environmental Cost - Cost of short-term cleanup and material disposal associated with a PSE with off-site environmental impact Companies may choose to assign severity to costs associated with off-site environmental impacts in a separate category
Rate Adjusted Metrics
Utilizing the severity table described above there are a variety of rate-based metrics which can be generated These include
Process Safety Total Incident Rate (PSTIR) Total event incidents x 200000___
Total Worker Hours
Process Safety Incident Severity Rate (PSESR) (ie severity-weighted Process Safety incident rate formula)
Total severity score for all events incidents x 200000___
PSESR = Total Worker Hours
In determining this rate 1 point is assigned for each Level 4 incident attribute 3 points for each Level 3 attribute 9 points for each Level 2 attributes and 27 points for each Level 1 attributes Theoretically a process safety event could be assigned a minimum of 1 point (ie the incident meets the attributes of a Level 4 incident in only one category) or a maximum of 135 points (ie the incident meets the attributes of a Level 1 incident in each of the five categories)
PS Level ldquoXrdquo incident rate Total Severity Level ldquoXrdquo PS incidents x 200000
Total employee contractor amp subcontractor work hours
Where X can be the total count of Severity Level 4 3 2 or 1 incidents The severity level of an incident is the maximum severity rating of the five consequence categories
Normalization ndash In some associations and member companies process safety events are normalized on a lsquoper 100rsquo employee basis given that a one worker averages 2000 per year So to normalize on a lsquoper 100rsquo employee basis events are multiplied by 200000 worker hours In other associations and member companies events are normalized on a lsquoper 500rsquo employee basis and events are multiplied by 1000000 worker hours Associations and members should discuss this option and come to a conclusion together The above formulas are set at a lsquoper 100rsquo employee rate
15
(K = 1000 MM = 1000000) (For Environmental Impact companies and associations should agree on input criteria where definitions arenrsquot readily available)
Appendix B ndash Frequently Asked QuestionsApplicability
It is recommended that companies record and report Process Safety Events occurring at Company-owned or operated facilities except as noted below
1 PSEs that originated off Company property
2 Marine transport vessel incidents except when the vessel is connected to the facility for the purposes of crude or product transfer
3 Truck andor rail incidents except when the truck or rail car is connected to the facility for the purposes of crude or product transfer
4 Routine emissions that are allowable under permit or regulation
5 Underground contamination that had no process safety consequences Note The exclusion does not apply if the release resulted in an aboveground reportable PSE such as release of toxic vapors or pooling of flammable liquids
6 Office building incidents (eg office heating equipment explosions fires spills releases personnel injury or illness etc)
7 Personnel safety sliptripfall incidents that are not directly associated with evacuating from or responding to a loss of containment incident
8 Loss of Primary Containment (LOPC) incidents from ancillary equipment not connected to the process (eg small sample containers)
9 Planned and controlled drainage of material to collection or drain system designed for such service (Note Exclusion does not apply to an unintended and uncontrolled release of material from primary containment that flows to a collection or drain system)
10 Mechanical work being conducted outside of process units or in maintenance shops
Interpretations and Examples ndash Based on GHS Table 1
The following interpretations and examples have been prepared to help clarify areas of potential uncertainty in the evaluation of reportable Process Safety Incidents (PSE)
COMPANY PREMISES
1 A third-party truck loading a flammable product on Company Premises experiences a leak and subsequent fire and property loss damages of $7000 (direct costs) Although the truck is Operated-by-Others it is connected to the process The incident would be a reportable PSE if property losses in direct costs were equal to or greater than $2500 or some other PSE threshold was met or exceeded (eg a fatality)
2 Similar example as 1 The truck loaded with flammable product overturns in route out of the plant resulting in a fire and loss of the truck This would not be reported as a PSE since the truck is no longer connected to the plant
LOSS OF CONTAINMENT
3 A faulty tank gauge results in the overfilling of a product tank containing ldquoflammable liquidsrdquo Approximately 700 kg of liquid overflows into the tanks diked area This incident is a reportable PSE since it is an acute spill greater than 100 kgs regardless of secondary containment
4 A maintenance contractor opens a process valve and gets sprayed with sulfuric acid resulting in a severe burn and lost time injury This would be a reportable PSE It is an unintended event involving a material and a loss of containment For fatalities and days away from work injuries and illnesses there is no release threshold amount
5 An operator opens a quality control sample point to collect a routine sample of product and receives a bad hand laceration requiring stitches due to a broken glass bottle and misses the next day of work This is not a reportable PSE because it is not related to a loss of containment
ACUTE RELEASES
6 While troubleshooting a higher-than-expected natural gas flow rate operating personnel find a safety valve on the natural gas line that did not reseat properly and was relieving to the atmospheric vent stack through a knock-out drum Upon further investigation it is determined that a total of 100000 kg of natural gas was relieved at a steady rate over a 6 month period This is not a reportable PSE as the release rate (~10 kg per hour) is not ldquoacuterdquo (ie does not exceed the 100 kg TQ for flammable vapors per 1 hour time period)
FLARES amp EMISSION CONTROL DEVICES (eg scrubbers)
7 If a chemical is routed to a flare or emission control device (eg scrubber) it would not be classified as a PSE as long as that flare or control device operates as designed
8 If a scrubber is overwhelmed by a flowrate greater than the design of the scrubber system and discharges a chemical in excess of the reporting threshold it would be reported as a PSE as noted about in this document
As a note an upset emission from a permitted or regulated source ndash including pressure relieve devices - of a quantity greater than or equal to the threshold quantities in Table 1 or 2 in any one-hour period that results in one or more of the following four consequences
middot rainout
middot discharge to a potentially unsafe location
middot an on-site shelter-in-place or on-site evacuation excluding precautionary on-site shelter-in-place or on-site evacuation
middot public protective measures (eg road closure) including precautionary public protective measures
Should be reported as a PSE
SAFETY RELIEF DEVICE SYSTEM
9 There is a unit upset and the relief valve opens to an atmospheric vent which has been designed resulting in a gas release to the atmosphere with no adverse consequences This would not be a reportable PSE since vapors and gases released to atmosphere from safety valves high-pressure rupture disks and similar safety devices that are properly designed for that event per API Standard 521 or equivalent are excluded as long as the release did not result in (1) a liquid carryover that created a reportable PSE related to the liquid (eg lost time incident fatality a fire or explosion that caused $2500 or more of direct cost liquid release or toxic aerosol release at or above threshold amounts etc) or (2) activation of a shelter-in-place response on or off-site or (3) public protective measures be taken
10 There is a unit upset and the relief valve fails to open resulting in overpressure of the equipment and an acute release of flammable gas from a leaking flange The amount released is above the 100 kg (within 1 hour) threshold This is a reportable PSE Releases from flanges are not excluded from PSE reporting
DAYS AWAY FROM WORK INCIDENTS
11 An operator is walking then slips and falls to the floor and suffers a lost time injury The slipfall is due to weather conditions chronic oily floors and slippery shoes This is not a reportable PSE Personnel safety sliptripfall incidents that are not directly associated with evacuating from or responding to a loss of containment incident are specifically excluded from PSE reporting
12 Same as above except that the operator slipped and fell while responding to a small flammable liquid spill (eg less than 10 kg in 1 hour) This would be PSE reportable since the operator was responding to a loss of containment incident A PSE is reportable if the loss of primary containment occurs on Company Premises and results in a lost time incident or fatality For fatalities and lost time incidents there is no release threshold amount
13 Same as above except that the operator slipped and fell several hours after the incident had concluded This would not be PSE reportable The terms evacuating from and responding to in the reporting exclusion mean that the loss of containment and associated emergency response activities are on-going Slipstripfalls after the event have concluded (such as after-the-fact clean-up and remediation) are excluded from PSE reporting
14 A scaffold builder suffers a lost time injury after falling from a scaffold ladder while evacuating from a loss of containment incident on nearby equipment This is a reportable PSE
15 An operator walks past an improperly designed steam trap The steam trap releases and the operators ankle is burned by the steam resulting in a lost time injury This is a reportable PSE because even though the loss of containment was steam (vs hydrocarbon or chemical) the physical state of the material was such that it caused a lost time injury
16 An enclosure has been intentionally purged with nitrogen A contractor bypasses safety controls enters the enclosure and dies This is a reportable fatality but not a reportable PSE since there was no unplanned or uncontrolled loss of primary containment
17 Same as above except that nitrogen inadvertently leaked into the enclosure This would be a reportable PSE (and fatality) since there was a fatality associated with an unplanned loss of primary containment
18 An operator responding to an H2S alarm collapses and has a injury If the alarm was triggered by an actual unplanned or uncontrolled H2S LOPC the event would be a reportable PSE If the alarm was a false alarm the event would not be a reportable PSE because there was no actual release
PIPELINES
19 A pipeline leaks and releases 2000 lbs (900 kgs) of flammable vapor above ground within 1 hour However the release occurred in a remote location within the site The release is PSE reportable since remoteness is not a consideration
FIRES or ENERGY RELEASES NOT ASSOCIATED WITH CHEMICAL RELEASE
As a general rule a fire or energy release is reported as a PSE only if caused by chemical release or results in a chemical release in excess of the reporting quantities Examples include
20 An electrical fire impacts the operation of the process resulting in the release of 400 kg of toluene This event would be reported as a PSE since if the chemical release exceeds the 100 kg reporting threshold for toluene
21 An electrical fire loss of electricity or any other loss of utility occurs which may cause a plant shutdown and possibly incidental equipment damage greater than $2500 (eg damage to reactors or equipment due to inadequate shutdown) but does not create a chemical release greater than the threshold quantity or cause a fatality or serious injury This event would not be reported as a PSE since the equipment damage was not caused by a chemical process fireexplosion and there was not a chemical release greater than the threshold quantity
MARINE TRANSPORT VESSELS
22 A company operated Marine Transport Vessel has an onboard acute spill of combustible material greater than 100 kg The event is not PSE reportable since Marine Transport Vessel incidents are specifically excluded except when the vessel is connected to the refinery petrochemical or chemical manufacturing facility for the purposes of crude or product transfer
23 A third-party barge is being pushed by a tug and hits the company dock A barge compartment is breached and releases 1000 kg of diesel to the water The event is not a reportable PSE since the marine vessel was not berthed at the dock and actively involved in crude or product transfer operations
TRUCK AND RAIL
24 A company railcar derails and spills more than 1000 kg of gasoline while in transit The incident is not PSE reportable since rail incidents off company property are specifically excluded
25 A third-party trucktrailer overturns while in the Company Premises resulting in an acute spill of gasoline greater than 1000 kg The incident is not reported as a PSE reportable if the truck is no longer connected to the loadingunloading facilities However it is recommended that companies also have transportation incident metrics which would capture this event
26 A contract truck hauler is unloading caustic and the hose separates and generates an airborne aerosol andor liquid caustic spill of 2500 kg The event is a reportable PSE since the caustic TQ of 100 kg was exceeded and the truck was still connected to the loadingunloading facility immediately prior to the incident
OFFICE BUILDING
27 There is a boiler fire at the Main Office complex and direct cost damages totaled $75000 The incident is not PSE reportable since Office Building incidents are specifically excluded
MAN-MACHINE INTERFACE INCIDENTS
28 An operations technician is injured while working around the finishing equipment in a polymers plant The injury is caused by the mechanical man-machine interface with the equipment This would not be a reportable Process Safety Event because there was no loss of containment of hazardous material
MIXTURES
29 If a mixture by itself has a GHS classification you use that classification to determine the threshold If the mixture itself does not have a GHS-classification we go back to the individual components of the mixture and based on kg released per threshold group calculate a lsquoweightedrsquo contribution to the thresholds Example a release of 100 kg of a mixture in a one hour period that consists of 05 kg of a substance classified as acute toxic H300 45 kg of substance classified with H301 and 40 kg of a substance with another H-number and the remaining 55 kg of water with no GHS classification would be calculated as 051 + 4510 + 40100 = 05 + 045 + 04 = 135 is exceeding 1 and would be counted as a reportable process safety incident even though none of the individual hazardous components exceeded the threshold for the individual substance
DIRECT DAMAGE COSTS
30 Direct damage costs are considered for this threshold should be those costs directly attributed to the fire andor explosion such as the replacement value of equipment lost structures lost cost of repairs environmental cleanup emergency response andor fines Direct cost does not include indirect costs such as business opportunity losses loss of profits due to equipment outages cost of obtaining or operating temporary facilities or cost of obtaining replacement products to meet customer demand (product losses)
31 As an example a leak of flammable gas occurred in a vent line connected to a gas treatment system At the same time a failure in the process allowed air to enter in the same vent line An explosion occurred and the over pressure damaged the vent line and associated upstream equipment including a seal pot Nobody was hurt The cost for repair was about $12000 This is a PSE considering the cost to repair the equipment due to the explosion and fire
32 As an example after a PSE event a company releases 50 kg of a very special GHS Category 5 product which causes $2000 of damage to equipment The product released was a very special blend of materials and the company incurs over $50000 in materials associated with the product loss This event is not reportable as PSE since the reportable threshold for GHS Category 5 releases is 100 kgs and product losses do not count as Direct Damage Costs
NATURAL DISASTERS
33 Natural disasters can present substantial risks to chemical process operations and damage to plant equipment which may result in a loss of containment of hazardous substances Where the potential for one or more types of natural disasters is deemed relevant to plant operations process safety and operational systems shall address the applicable risk in terms of hazards and consequence analysis plant design operating procedures for loss of utilities and process shutdown and emergency planning and response
Types of natural disasters includes hurricanes and typhoons (including associated storm surge) floods tornadoes earthquakes derechos (straight line wind storms) wildfires volcanic eruptions tsunamis and avalanches
If your facility experiences a natural disaster that triggers one or more of the thresholds it should be reported as a process safety event
PRECAUTIONARY PUBLIC RESPONSE
34 A precautionary public response is a measure taken from an abundance of caution For example a company may require all workers to shelter-in-place in response to an LOPC independent of or prior to any assessment (eg wind direction distance from the LOPC etc) of the potential hazard to those worker For example a recognized community official (eg fire police civil defense emergency management) may order a community shelter-in-place evacuation or public protective measure (eg road closure) in the absence of information from a company experiencing a process safety event or lsquojust in casersquo the wind direction changes or due to the sensitive nature of the potentially affected population (eg school children the elderly)
ACTIVE WAREHOUSE
35 An active warehouse is an on-site warehouse that stores raw materials intermediates or finished products used or produced by a process From a process perspective an active warehouse is equivalent to a bulk storage tank Rather than being stored in a single large container the raw materials intermediates or finished products are stored in smaller containers (eg totes barrels pails etc)
Appendix C ndash List of RCLG Taskforce Members Luiz Shizuo Harayashiki19
Appendix D ndash Detailed Schedule of Events Appendix E ndash Optional Excel Reporting FormWhen member companies begin tracking process safety events a single form should be utilized for all member companies to make data analysis easier and to allow all members to work from the same tracking sheet The RCLG has developed an optional tracking sheet that members and associations can start with when developing their own tracking sheet
DOWNLOAD TRACKING SHEET HERE
This document consists of a contact page the survey itself and a lsquodo not editrsquo page where the drop down menu answer are stored
INTERNATIONAL
COUNCIL OF
CHEMICAL
ASSOCIATIONS
ICCA Process Safety
Event Tracking Sheetxlsx
4
敬愛的 TRCA 會員您好
謹代表 TRCA 藉此機會對 ICCA (International Council of Chemical Associations 國際化學業
協會)以及 RCLG (Responsible Care Leadership Group 責任照顧領導群)過去幾年來致於調
和製程安全指標所付出的與貢獻致上深深的謝忱
製程安全管理是化學業為關鍵重要的作製程安全指標的提報則是驗證製程安全
管理的核程過去數年來國際與國內化學業致於持續不斷的改進相關績效指
標的表現我們相信減少製程安全事件的發與是否進量測有絕對的關係因為我們無
從改進沒有進過量測的項因此藉由製程安全事件的提報將有效的協助會員公司
與國家協會分享 佳實務經驗並在這個過程中協助會員公司改善製程安全績效表現進
減少環境跡從事故事件中學習是改進製程安全管理的關鍵我們誠摯地希望藉由
製程安全指標提報能降低製程安全事件的發
TRCA 2015 年起籌組 Near Miss 試組並於當年起開始提報製程安全虛驚事件數
以做為未來全提報製程安全事件率的準備感謝試組台灣永光化學業(股)公司
台灣中油(股)公司國喬油化學(股)公司台灣科思創(股)公司奇美實業(股)公司台
橡(股)公司春油化學(股)公司春造樹脂廠(股)公司連化學業(股)公司
李榮化學業(股)公司以及台灣志氯化學(股)公司率先的努配合試為 2020 年全
提報製程安全事件指標提供了難能可貴的經驗
TRCA 為達成 ICCA 擬定 2020 年全提報的標訂於 2019 年開始試提報 2018 年數據
2018 年將陸續展開相關說明與教育訓練研討會議我們相信推 ICCA 全球調和製程安全
指標提報將能更有助於加強與改善台灣化業製程安全管理績效
讓我們起為化業更安全與環保的永續未來努吧
TRCA 責任照顧推委員會主席 Chairman Responsible Care Implementation Committee台灣志氯化學(股)公司總經理 President Taiwan Chlorine Industries Ltd
嚴堅正 Art Yen
5
背景
責任照顧倡議(Responsible Carereg initiative)發起於 1985年其目的在於展現化學工業界持續
改善績效的承諾自從責任照顧倡議開始實施以來製程安全(Process Safety)一直是責任
照顧倡議的核心基礎之一實施責任照顧 30 多年來許多地區已發展出追蹤及提報製程
安全績效的方法然而一直未能建立一套全球調和的提報系統由於一些重大製程安全
事件仍不斷發生在 2012 年國際化學工業協會(ICCA)董事會便責成責任照顧領導群
(RCLG)在 2015 年以前擬定一套全球調和的製程安全績效提報機制
2013-14 年間一個由跨國公司和 RCLG 各協會組成的專案小組正式成立該專案小組由
拜耳醫療保健公司(Bayer HealthCare AG)的衛生安全及環保總監 Peter Schmelzer 博士擔任
召集人其任務即是研擬一套全球調和的 ICCA 製程安全績效提報機制專案小組成員表
詳見附錄 C在此期間美國石油學會(API)也著手開始進行其 API RP 754 ndash領先及落後製程
安全指標標準(Leading and Lagging Process Safety Metric Standard)之修訂RP-754 被廣泛應
用於美洲地區的煉油及石化產業以追蹤製程安全績效為了推動全球採行統一的標準
RCLG 專案小組致力於將其所提出之建議案與預訂於 2016 年第一季完成修訂之 API RP 754
達到完全調和
執行摘要
經過兩年多的討論研究辯論及可行性評估製程安全調和化專案小組(PSHT)建議 ICCA
採行一套製程安全事件發生率指標採行這套指標需要 RCLG 各協會蒐集會員公司在一年
內所發生之製程安全事件次數和工作總時數(包括員工和承攬商)製程安全事件發生率即
事件數除以工作時數的比率專案小組建議向 RCLG 提報這些數據的要求將在未來三年
內分階段實施同意已具有意願和能力提報的地區立即開始提報數據同時也給予正在發
展追蹤數據能力以進行首次提報的公司和機構若干緩衝時間
判定製程相關事件是否符合製程安全事件定義的標準係以化學物質的一次阻絕設施失效
或能量釋放以致引起下列任何一個影響考量面的門檻為根據1) 安全人員健康後果2)
事故造成損失之直接成本3) 社區影響4) 化學物質洩漏量(請參見提報判定流程圖所
示)ICCA 所建議之製程安全事件定義的四個影響考量面與 RP-754Tier II 事故標準的影
響考量面是完全一樣的除了化學物質洩漏量提報門檻有所差異外其他三個影響考量面
6
的提報門檻也是一樣的為因應此一差異針對化學物質外洩量提報門檻ICCA 製程安
全事件定義將容許會員公司採用 ICCA 依據化學品全球調和制度(GHS)健康危害分級為基礎
所發展的提報標準或依據聯合國危險物品(UNDG)分類為基礎所定義之 RP-754 二級製程
安全事件(Tier II) 之提報標準專案小組相信這兩套制度之提報標準雖然有所差異但
從其所涵蓋之化學物質領域和提報事故嚴重程度看來兩者皆相當健全雖然採用這兩種
不同提報門檻所收集和提報的事件數差異相對不大但在公司方面從原料及產品使用的角
度看來兩者可能會有非常明顯的不同因此專案小組提醒會員公司勿將自己公司的
結果與採用不同化學物質洩漏量提報門檻的公司做比較無論如何根據 RCLG 的提議
會員公司可選擇化學物質洩漏門檻以向國家及地區協會進行提報如果各協會有興趣轉
換兩種不同提報方式的結果RCLG 可提供轉換表但由於轉換運算非常複雜且須取得
原始事故數據專案小組相信相互轉換的附加價值不大因此不建議協會採取此一做法
專案小組相信這項製程安全事件提報建議案可廣泛運用在化學及石化產業實施製程安
全績效提報這項提報制度將為目前尚未追蹤製程安全績效的地區協會和會員公司提
供一個指引讓他們可以體認追蹤及提報製程安全績效可以帶來的益處至於已在蒐集製
程安全數據的地區協會和會員公司此建議案將有助於他們更廣泛地與全球接軌並將
重點放在持續改善製程安全績效這些改善製程安全績效的制度仰賴的是可靠的製程安
全事件數據改善製程安全績效正是責任照顧倡議的主要目的
7
RCLG 各協會應向 RCLG 提報的數據
RCLG 各協會每年必須依照下文提供的時程透過 RCLG 關鍵績效指標(KPI)提報網站向
ICCA 提報兩個數據
1 協會所屬會員公司的總工作時數(包括員工和承攬商)
2 製程安全事件總數
ICCA 將利用上述兩個數據以製程安全事件發生率(PSER)的形式報告製程安全績效PSER
計算之常態化是以每 100 位員工每位員工一年工作 2000 小時為基準
(總事件數 總工作時數) x 200000 = PSER
建議之提報時程
針對提報製程安全事件發生率專案小組建議一種分階段導入的方法此一時程可讓更多
已具經驗的協會及公司立即實施提報同時容許其他協會及公司從 2019 年起開始提報
RCLG 各協會必須透過 RCLG KPI 指標提報系統(httpkpiresponsiblecareeu)每年向 ICCA
提報兩個製程安全事件發生率數據如果你不知道你所屬協會的使用者名稱和密碼請聯
絡 RCLG
建議 RCLG 協會提報製程安全事件發生率的時程如下
2015 年 4 月 RCLG 考量專案小組建議案
2015 年 6 月 ICCA 理事會考量 RCLG 的最終建議
2015 年 7 月 RCLG 頒布首份詳細的提報指引供協會及會員公司遵
循
2016 年 2 月 RCLG 提報 RCLG 更新及強化提報指引並針對自願參加的協會
開始實施製程安全試行提報計畫RCLG 於 2016 年 6 月
頒布最終指引
2017 年 RCLG 各協會開始向會員公司蒐集數據
2018-2019 年 RCLG 提報 RCLG 各協會可選擇地開始提報製程安全數據
2020 年提報 RCLG 於 KPI 提報計畫中將製程安全納入為一項強制性
指標
參見附錄 D ndash 詳細活動時程
8
ICCA 製程安全事件判定標準流程圖
事故是否發生在廠內之
生產配銷儲存公
用或試驗工廠
是 是
是
否
否 是否造成須通報工傷
或
廠內廠外人員住院治
療
損壞是否對
公司造成
ge $2500 美
元的直接成
本損失
官方是否宣告就地
避難或疏散或廠
外預防性就地避難
或疏散
否
是
否
是屬於須通報製程安全事件
是
否
是
是
開始
否不符合製程安全事件認定
標準
是否超過 ICCA 或 API
754 Tier II 化學物質洩
漏恕限值
否 發生化學物質外洩火
災或爆炸是否起因於
或發生在化學製程單元
是否直接涉及某種化學物
質或化學製程
否
9
須提報製程安全事件之重要標準
總工作時數
RCLG 各協會應以加總的單一數字提報其所屬會員公司的員工和承攬商總工作時數為達
成本指引之目的各協會應參考其本地和地區對員工及承攬商之定義提報總時數之目標
應納入涉及化學製造之所有個人然而參與主要興建工程專案之人員則不納入計算譬
如為新建或擴建既有製程設施之設計工程和施工而成立之一次性專案組織的大規模投資
案會員公司提報總工作時數時應與人事部門統計之員工工時一致如此各公司便能
取得相同的職業與製程安全數據員工工時應包括所有化學製造作業的工時而非僅計算
發生製程安全事故之廠區的工時
製程安全事件
為執行 ICCA 提報目的製程安全事件之定義條件如下(必須同時符合 ABCD 四個條
件)
A 直接涉及某種化學物質或化學製程且
B 事故發生在廠內之生產配銷儲存公用或試驗工廠且
C 製程單元發生物質洩漏或能量釋放(如火災爆炸和內爆)且
D 已達到以下提報門檻之一
1 安全 工傷
導致記錄性的傷害(OSHA)損失工時或死亡或廠內外任何人員因此
而須住院治療或
2 直接損失成本
火災爆炸或為避免補救環境損害之必要清理作業導致$2500 美元
以上的直接成本支出或
3 就地避難 疏散
官方宣告就地避難(廠內或廠外)或
官方宣告疏散(廠內或廠外)或
廠外預防性就地避難或疏散或
4 洩漏恕限值
物質洩漏程度已達表 1 所列之任一 GHS 恕限值(洩漏量以單位小時計
量)
此外各公司亦可選擇採用 API RP-754 標準中所列之洩漏恕限值(表 2)請注意如欲查
看 API RP-754 標準可登入以下網站購買及下載httpwwwapiorgoil-and-natural-
gashealth-and-safetyprocess-safetyprocess-safety-standards
10
製程安全事件判定準則
A 涉及化學品
直接涉及某種化學物質或化學製程
製程安全事件或事故必須直接涉及化學物質或化學製程就此而言ldquo製程rdquo一詞泛指包含
石化生產所需要之設備和技術包括反應器儲槽管線鍋爐冷卻水塔和冷凍系
統helliphellip等未直接涉及化學物質或製程的事件無須提報譬如辦公大樓起火(即使該辦公大
樓位在廠區內亦然)
B 地點
事故發生在廠內之生產配銷儲存公用或試驗工廠
發生在廠內之生產配銷儲存(包括活動儲存區如倉庫 ndash 參見ldquo常見問題集rdquo)公用及
試驗工廠凡符合提報指標及定義的事故包括在廠區管理下之槽罐區輔助支援區(如
鍋爐室和廢水處理廠)和配銷管線所有須提報之事件應由負責該事故地點運作的公司
負提報之責此一規定亦適用於發生在承攬商作業區域內的事故在代工作業和多方共同
作業廠區負責運作該發生事故單位的公司應記錄事故始末並將之納入其提報中
C 物質洩漏
製程單元發生物質外洩或能量釋放(如火災爆炸和內爆)
物質外洩 ndash 製程任何物質發生非預期或無法控制的洩漏或釋放包括非毒性及不可燃物質
(如蒸汽熱水氮氣壓縮二氧化碳或壓縮空氣)且達到本文件所列四類提報門檻之一
項或以上之後果
在防治系統(如洗滌塔或廢氣燃燒塔)正常運作狀況下只要沒有任何洩漏或排放量超過
法定許可值即使排放到廢氣燃燒塔或滌氣塔仍被視為處於一次阻絕設施內然若排
放到二次阻絕設施(如廢水處理或防溢堤)將被視為製程安全事件因為物質已離開主要製
程系統
11
D 提報門檻
須提報製程安全事件必須達到以下提報門檻之一
1 安全 工傷
導致記錄性傷害(OSHA)損失工時或死亡或廠內外任何人員因此而須住院治療
記錄性傷害是指與工作有關所造成的傷害導致死亡暫時全失能工作受限制或需調整職
務較輕傷害嚴重之醫療處理失去意識或經醫師或其他合格醫療專業人員診斷為重大
傷害
損失工時傷害和死亡是指因製程相關的一次阻絕設施失效火災或爆炸導致以下任何一種
結果
員工(損失工時或死亡)
承攬商及再承攬商 (損失工時或死亡)
第三方(如來賓訪客快遞員)(受傷疾病導致住院治療或死亡)
住院治療是指醫院或其他具有住院病患保健設施的醫療單位正式接受病患住院提供病患
食宿及醫療護理且病患接受治療至少留置至隔日僅在醫院急診室治療或過夜處理不屬
於ldquo住院治療rdquo的定義範圍
須提報之工傷或死亡事件例如在清理作業期間因蒸汽洩漏造成人員燒燙傷壓力測試期間
帽蓋因受壓脫落造成人員身體傷害或取樣作業時因物質外濺造成人員化學灼傷無須提
報之工傷或死亡事件例如在執行維修作業時從高處的工作台墜落實驗室或辦公大樓火災
造成人員燒燙傷或挖掘工程塌陷造成人員傷害這些案例均與因製程造成的能量釋放或
物質洩漏無直接關聯
2 直接損失成本
火災爆炸或為避免補救環境損害之必要清理作業導致$2500美元以上的直接成本支出
此提報門檻所考慮的成本應為可直接歸因於火災或爆炸的成本譬如設備及結構損壞的重
置成本修理成本環境清理(廠內及廠外)支出緊急應變和罰款直接成本不包括間接
成本譬如業務機會損失設備停機造成之利潤損失取得或運轉臨時設施之成本或為
滿足顧客需求取得替代產品的成本(產品損失)
12
3 就地避難 疏散
官方宣告就地避難或疏散(廠內或廠外)或廠外預防性就地避難或疏散
就提報目的而言官方宣告就地避難或疏散(廠內或廠外)或廠外預防性就地避難或疏散
即達到此提報門檻
官方宣告 ndash 由地方權責機關(如消防警察民防緊急應變管理部門)或經授權的代表(如
派駐公司官員)下達的社區行動(如就地避難或疏散)宣告
預防性宣告 ndash 預防性公眾應變是基於謹慎的態度所採取的一種措施權責地方主管機關或經
授權的代表經合理判斷認定為維護公眾健康及安全發布必須採取就地避難或疏散之預
防性措施
就地避難 ndash 利用結構體及其內部空氣以暫時讓人員與室外危害性氣體隔離
疏散 ndash 基於安全或防護理由讓人員離開某處所的行動或過程
4 洩漏恕限值
超過表 1 中所列 GHS 恕限值或表 2 中所列 API 754 標準 Tier II 製程安全洩漏恕限值之一的
急性洩漏事件(洩漏量以單位小時計量)
如ldquo執行摘要rdquo所述ICCA 製程安全事件之定義容許採用 ICCA 依據化學品全球調和制度
(GHS)健康危害分級為基礎所發展的提報標準或依據聯合國危險物品(UNDG)分類為基礎
所定義之 RP-754 二級製程安全事件(Tier II) 之提報標準GHS 恕限值詳見表 1各會員公司
可自行決定選擇哪一個表中的提報恕限值並在全球採用單一制度
ldquo急性rdquo洩漏 ndash易燃性可燃性或毒性化學物質從一次阻絕設施(如容器或管線)洩漏其
任一單位小時之洩漏量超過化學物質洩漏恕限量分述於表 1 中的 GHS 分類和表 2 中的
API 754 標準 Tier II 製程安全洩漏恕限值
洩壓裝置前述所定義之ldquo急性rdquo洩漏包括洩漏或排放至妥善設計且運作中的洩壓裝置若
洩漏或排放量達到表 1 中所列 GHS 恕限值或表 2 中所列 API 754 標準 Tier II 製程安全洩漏
恕限值且導致下列四種後果之任一項或以上之後果
1 二相排放或夾帶液體的排放液滴沉降至地面造成污染
2 排放至具潛在危險性的地點
3 廠內就地避難或疏散不包括預防性廠內就地避難或疏散
4 啟動公眾保護措施(如道路封閉)包括預防性公眾保護措施
13
洩漏或排放至妥善設計且運作中的洩壓裝置(如廢氣燃燒塔洗滌塔等)若其情況未達前
述四項標準中任何一項則不必提報
欲查看 API RP-754 標準可登入以下網站下載此標準httpwwwapiorgenvironment-
health-and-safetyprocess-safetyprocess-safety-standardsstandard-rp-754
一小時法則
為便於衡量此項指標提報與否洩漏恕限值是以物質在任一小時內之洩漏量為標準若任
一小時或更短時間內物質洩漏量達到或超過須提報恕限值該事故便屬於須提報的製程安
全事件急性洩漏事故通常不會超過一小時若無法確定洩漏持續時間則應假設其為一
小時
一次阻絕設施ndash 用來作為主要容器或用於運送或輸送物質之槽罐船隻管線軌道車
或設備主要容器在設計上可能包含二次阻絕設施系統以抑制及控制洩漏二次阻絕設
施系統包括(但不限於)儲槽防溢堤製程設備周遭的圍堵設施油水分離的排水收集系統
雙層儲槽的外壁等
嚴重程度表 ndash 嚴重程度加權可額外提供有關製程安全事件的有用資訊有助於帶動改善績
效附錄 A 為 RCLG 建議之製程安全事件嚴重程度加權計算方法根據附錄 A 的方法便
可藉由加總與各個後果類別關聯的分數計算出各製程安全事件的嚴重程度加權值ICCA
強烈建議採用嚴重程度加權制度因為此制度有助於提升溝通績效的能力也比較容易讓
利害關係人了解製程安全事件並且此嚴重程度加權值與其他製程安全績效指標提報方
式是不具相互比較性的
14
表 1 ndash GHS 分類表
物理性危害(GHS 2x)
洩漏恕限值(1 小時內)
STOTSpecific target organ toxicity(特定標的器官系統毒性物質)
15
表 2 ndash API RP 754 Tier II 分類表
洩漏恕限類別
物質危害性分類 acdef 恕限值
(戶外洩漏) 恕限值
(戶內b洩漏)
T2-1 TIH A 區物質 ge 05 kg (11 lb) ge 025 kg (055
lb)
T2-2 TIH B 區物質 ge 25 kg (55 lb) ge 125 kg (275
lb)
T2-3 TIH C 區物質 ge 10 kg (22 lb) ge 5 kg (11 lb)
T2-4 TIH D 區物質 ge 20 kg (44 lb) ge 10 kg (22 lb)
T2-5
易燃氣體 或 正常沸點 ≦ 35 (95 degF)閃火點lt23 (73 degF)的液體 或 其他包裝組別 I 類的物質 (酸鹼除外)
ge 50 kg (110 lb) ge 25 kg (55 lb)
T2-6
正常沸點 gt 35 degC (95 degF)閃火點 lt 23 degC (73degF)的液體 或 其他包裝組別 II 類的物質 (酸鹼除外)
ge 100 kg (220 lb) 或
ge 07 bbl
ge 50 kg (110 lb) 或
ge 035 bbl
T2-7
閃火點 gt 23 degC (73 degF)和 lt 60 degC (140 degF)的液體 或 閃火點 gt 60 degC (140 degF)的液體在閃火點或高於閃火點的溫度下洩漏 或 強酸鹼 (定義參見 RP 754 文件草案) 或 UNDG第2類第22部分 (不可燃無毒氣體)空氣除外 或 其他包裝組別 III 類的物質
ge 200 kg (440 lb) 或
ge 14 bbl
ge 100 kg (220 lb) 或
ge 07 bbl
T2-8
閃火點 gt 60 degC (140 degF) 和 lt 93 degC (200 degF)的液體在低於閃火點的溫度下洩漏 或 中度酸鹼
ge 1000 kg
(2200 lb) 或
ge 7 bbl
ge 500 kg
(1100 lb) 或
ge 35 bbl
TIH吸入性毒性危害物(Toxic Inhalation Hazard)
16
一般認為以公斤和磅或以磅和桶為單位的恕限值不盡等同各公司應該選用其中一組計量單位並在
所有紀錄文件中一體適用
在判定一種物質之洩漏恕限類別時首先應從物質之含吸入性毒性(TIH Zone)可燃性(閃火點和沸點)
或腐蝕性(強酸或鹼 vs中度酸或鹼)等特性來判別只有當物質的危險度無法利用上述簡單的特性來判別
時(如遇水反應劇烈)才採用UNDGL包裝組別
a 許多物質具有一種以上危險性正確的危險區(Hazard Zone)或包裝組別(Packing Group)歸屬應遵循DOT
49 CFR 1732a [14]或聯合國危險物品運輸建議書(UNRTDG)第2部分[12]的規定參見附錄F
b 具有四面完整牆(從地板到天花板)地板和屋頂的結構物
c 對於未列於UNDG的溶液無水成分將用TIH區或包裝組別分類溶液之恕限值將根據乾基重量之恕限
值反算
d 對於未知UNDG分類的混合物可計算每種成分在恕限值洩漏中的分量如果各種成分之分量的總和
等於或大於100即表示混合物超過門檻值若混合物有明顯且獨立的毒性及可燃性結果則可分
別計算毒性及可燃性危險度參見附錄EPSE實例amp問題 49ndash53
e 閃火點 gt 60 degC (140 degF) 和 lt 93 degC (200 degF)的液體在低於閃火點的溫度下洩漏無論洩漏量多寡其
一次阻絕設施失效(LOPC)均不屬於Tier 1製程安全事件(PSE)
f 中度酸鹼的一次阻絕設施失效無論洩漏量多寡均不屬於Tier 1製程安全事件
17 (K = 1000 MM = 1000000) (在環境影響類別方面若缺乏既有定義協會和會員公司應議定輸入標準)
附錄 A ndash 嚴重程度表鼓勵所有協會均採用嚴重程度加權制度
事件事故類別
嚴重程度等級
安全人體健康 火災或爆炸導致直接
成本 任 1 小時內物質洩
漏量 社區影響 環境影響[廠外]
4 級
1 分
對員工承攬商或再承攬商造成較輕傷害嚴重之傷害 (符合本地法規)
造成以下直接損失成本
美金$25 K ~ $25 K
洩漏量介於
1x le TQ lt 40x
官方宣告就地避難或疏散 (廠內或廠外) 預防性廠外就地避難或疏散
le 3 小時
重大環境整治成本
$25 K ~ $25 K
3 級
3 分
對員工承攬商或再承攬商造成之需要多日缺勤的傷害
對第三方造成之需要初步急救以外治療的傷害 (符合本地法規)
造成以下直接損失成本
$25 K ~ $250 K
洩漏量介於
40x le TQ lt 160x
官方宣告就地避難或疏散 (廠內或廠外)
預防性廠外就地避難或疏散
3 ~ 12 小時
重大環境整治成本
$25 K ~ $250 K
2 級
9 分
對員工承攬商或再承攬商造成 1 人死亡
對第三方造成 1 人住院治療
(符合本地法規)
造成以下直接損失成本
$250 K ~ $25 MM
洩漏量介於
160x le TQ lt 640x
官方宣告就地避難或疏散 (廠內或廠外)
預防性廠外就地避難或疏散
12 ~ 24 小時
重大環境整治成本
$250 K ~ $25 MM
1 級
27 分
對員工承攬商或再承攬商造成多人死亡
對第三方造成多人住院治療
對第三方造成 1 人死亡 (符合本地法規)
造成以下直接損失成本
ge $25 MM
洩漏量
ge 640x TQ
官方宣告就地避難或疏散 (廠內或廠外)
預防性廠外就地避難或疏散
ge 24 小時
重大環境整治成本
ge $25 MM
18 (K = 1000 MM = 1000000) (在環境影響類別方面若缺乏既有定義協會和會員公司應議定輸入標準)
嚴重程度表(附錄 A)細節說明
附錄 A 之設計目的僅適用於採用 GHS 分類制度(表 1)者如果你的公司係採用 API RP 754Tier II 製程安全指標提報恕限值表(表 2)請使用
API RP 754 製程安全嚴重程度表必須提醒的是依 API RP 754 的標準其嚴重程度表僅適用於一級(Tier I)事故去比較採用不同的嚴重度
表所評估出來的相對嚴重度並無統計上的意義
急性的環境成本 ndash 因製程安全事件造成廠外環境影響所導致之短期清理及物質處置的成本各會員公司可選擇將廠外環境影響相關成本另
外區分一個嚴重程度類別
比率調整指標
利用上述嚴重程度表可產生一系列以事件率為基礎的指標包括
製程安全總事件率 (PSTIR) 總事件次數 x 200000
總工作時數
製程安全事件嚴重程度率(PSESR) (即製程安全事件嚴重程度加權計算公式)
PSESR = 所有事件之總嚴重程度分數總合 x 200000
總工作時數
在計算此一比率時各 4 級事件被分配 1 分各 3 級事件被分配 3 分各 2 級事件被分配 9 分各 1 級事件被分配 27 分理論上每個
製程安全事件至少可分配到 1 分(亦即事件僅在一個類別符合第 4 級事件屬性)至多可分配到 135 分(亦即事件在所有五個類別中均符
合第 1 級事件屬性)
ldquoXrdquo級別製程安全事件率 嚴重度級別ldquoXrdquo之製程安全事件總數 x 200000
員工承攬商amp再承攬商總工作時數
X可以是嚴重度級別 432 或 1 級製程安全事件之總數事件之嚴重度等級是選用五類後果類別中之最嚴重等級
標準化 ndash 在某些協會和會員公司中製程安全事件是採 lsquo每 100 名rsquo員工每名員工每年平均工作時數為 2000 小時為基礎予以標準化因
此在lsquo每 100rsquo名rsquo員工的標準基礎上事件被乘以 200000 工作時數也有些其他協會和會員公司將標準化基礎設定為lsquo每 500 名rsquo員工
因此事件被乘以 1000000 工作時數協會和會員公司應就標準化基礎進行討論共同做成選項結論上述的公式設定為lsquo每 100 名rsquo員工
基礎
19
附錄 B ndash 常見問題集
適用性
我們建議會員公司記錄和提報在其所擁有或運作的工廠內發生的製程安全事件惟以下情況不須提報製
程安全事件
1 源自於公司廠區以外的製程安全事件
2 海上運輸船事故惟船隻為了輸送半成品或產品之目的已經與公司的設施相連接時發生的
事故仍須提報
3 卡車或軌道車事故惟卡車或軌道車為了輸送半成品或產品之目的已經與公司的設施相連
接時發生的事故仍須提報
4 許可證或法規容許之例行排放
5 不會造成製程安全危害的地下污染請注意若洩漏至地下導致地上發生須提報製程安全事
件如釋放出毒性蒸汽或致使易燃液體蓄積成池則不適用本排除條件
6 辦公建築事故(如辦公室暖氣設備爆炸火災外溢洩漏人員受傷或疾病等)
7 與疏散或一次阻絕設施失效無直接關聯之人員安全ldquo滑倒絆倒跌倒rdquo事故
8 沒有與製程相連接之輔助設備的一次阻絕設施(如小樣品瓶)失效事故
9 計劃中和在控制下的物質排放至設計用來收集或排放系統中(請注意物質從一次阻絕設施
在非計劃或非受控制情況下排放至收集或排放系統中則不適用本排除條件)
10 在製程區域外部或保養廠內執行之機械作業
說明與實例 ndash 以 GHS 表 1 為基礎
以下說明和實例有助於在評估須提報製程安全事件(PSE)時釐清可能存在的不確定部分
公司廠區
1 一輛第三方的卡車在公司廠區內卸載易燃產品時發生洩漏進而引起火災造成公司財物損失
$7000 美元(直接成本)雖然該卡車是ldquo由他人操作rdquo但其作業與製程相連接若公司的直接成
本財物損失達到或超過$2500 美元或已達到或超過其他 PSE 提報門檻(如1 人死亡)此事故即
屬於須提報的製程安全事件
2 與前例1 類似的例子載著易燃產品的卡車在廠外運輸途中翻覆引發火災並造成卡車毀損
該事故不屬於須提報的製程安全事件因為當時卡車並未與製程相連接
20
阻絕設施失效
3 儲槽液位計故障造成裝有ldquo易燃液體rdquo產品的儲槽外溢約 700 公斤的液體流入儲槽的防溢堤內
此事故屬於須提報的製程安全事件因為其ldquo急性rdquo洩漏量超過 100 公斤即使是阻絕在二次阻絕
設施防溢堤中亦然
4 一名從事維修工作的承攬商在開啟一個製程阻閥時被噴起的硫酸濺到造成嚴重灼傷和損失工
時的工傷此事故屬於須提報的製程安全事件因為它是涉及物質和一次阻絕設施失效的意外事
件對於因洩漏造成死亡和損工的工傷或疾病事故沒有洩漏恕限值
5 一名作業員開啟品管取樣點進行日常取樣作業時手部被一個破碎的玻璃瓶嚴重割破需要進行
縫合治療縫針造成第二天無法上班該事故不屬於須提報的製程安全事件因為它與一次阻絕
設施失效無關
ldquo急性rdquo洩漏
6 一名作業員在進行天然氣流量高於預期值之異常排除時發現天然氣管線上的一個安全閥門未適
當歸位因此天然氣經由氣液分離桶排放至排氣煙囪經進一步檢查作業員判斷在過去 6 個
月間總共有 100000 公斤天然氣以穩定的速率排放至大氣該事故不屬於須提報的製程安全事
件因為其洩漏速率(每小時約 10 公斤)不算ldquo急性rdquo洩漏(未超過易燃蒸汽每小時 100 公斤的恕限
值)
廢氣燃燒塔amp排放控制裝置 (如洗滌塔)
7 若化學物質被導引至廢氣燃燒塔或排放控制裝置(如洗滌塔)只要該廢氣燃燒塔或控制裝置運作在
正常設計範圍內便不屬於須提報的製程安全事件
8 若廢氣流速超過洗滌塔的設計負荷以致未經吸收的化學物質排出超過恕限值該事故屬於須提報
的製程安全事件(如本文註釋所述)
註釋自取得許可或妥善管理的裝置-包括釋壓裝置發生不預期的排放若 1 小時內洩漏量達到或
超過表 1 或表 2 所列的洩漏恕限值且導致下列四種後果之任一項或以上之後果該事故便屬於
須提報的製程安全事件
o 二相排放或夾帶液體的排放液滴沉降至地面造成污染
o 排放至具潛在危險性的地點)
o 廠內就地避難或疏散不包括預防性廠內就地避難或疏散
o 啟動公眾保護措施(如道路封閉)包括預防性公眾保護措施
21
安全洩壓裝置 系統
9 製程單元發生異常安全閥開啟將洩漏物質釋放到排氣口此釋壓排放裝置是依相關要求設計
的且氣體釋到大氣中並未造成不良後果這不是一個須提報的製程安全事件因為安全閥高
壓破裂盤以及類似的安全裝置是依據 API 521 或者同等的標準設計的且此排放並未造成 (1)
夾帶液體並導致須提報的製程安全事件的後果(譬如損失工時意外死亡火災或爆炸造成$2500
美元或以上的直接成本損失液體或毒性氣體洩漏量達到或超過恕限值(2) 啟動廠內或廠外就地
避難應變或(3)啟動公眾保護措施
10 製程單元發生異常安全閥並未開啟造成設備超壓易燃性氣體從一個法蘭處ldquo急性rdquo漏出來
洩露量超過 100 公斤(一小時內)的恕限值該事故屬於須提報的製程安全事件因為從法蘭處外
漏屬於製程安全事件應提報事項
損工事故
11 一名作業員走路時不慎滑倒造成損失工時之工傷滑倒原因為天氣狀況rdquo長期rdquo油垢的地面和
易滑鞋具該事故不屬於須提報的製程安全事件因為人員安全ldquo滑倒絆倒跌倒rdquo事故若非與
一次阻絕設施失效直接關聯的疏散或應變造成則不屬於須提報的製程安全事件
12 與前例相同的事件惟這次作業員跌倒是因為少量易燃液體外漏(如 1 小時內少於 10 公斤)在採取
相關應變措施時發生該事故屬於須提報的製程安全事件因為作業員係為了應變一次阻絕設施
失效的事故而跌倒若一次阻絕設施失效發生在公司廠區且造成失時工傷或死亡後果該事故
便屬於須提報的製程安全事件對於因洩漏造成死亡和損失工時之工傷事故沒有洩漏量門檻
13 與前例相同的事件惟這次作業員跌倒是在事件結束數小時之後該事故不屬於須提報的製程安
全事件在提報要件中所用的ldquo疏散rdquo和ldquo應變rdquo等術語指的是一次阻絕設施失效和相關緊急應變
活動正在持續中事件結束後滑倒絆倒跌倒(如ldquo事後rdquo清理和補救)不屬於須提報製程安全事件
14 工人在因附近設備一次阻絕設施失效在疏散過程中一名鷹架搭建工人從鷹架梯上跌落造成損
失工時之工傷該事故屬於須提報的製程安全事件
15 一名作業員行經一個設計不良的蒸汽卻水器時被外洩的蒸汽燙傷腳踝造成損失工時之工傷
該事故屬於須提報的製程安全事件因為雖然一次阻絕設施失效洩漏出的是蒸汽(而非碳氫化合物
或化學物質)但損失工時之工傷是由於洩漏物質的物理狀態所導致的
16 一個密閉空間依照計畫以氮氣吹清一名承攬商繞過安全管制進入該密閉空間因而死亡該事
故屬於須提報的死亡事件但不屬於須提報的製程安全事件因為其中不涉及非計劃或失控的一
次阻絕設施失效
17 情況同上惟這次氮氣是非刻意洩漏進入該局限空間該事故屬於須提報的製程安全事件(同時也
是一起死亡事件)因為該名承攬商的死亡與非計劃的一次阻絕設施失效有關
22
18 一名作業員因硫化氫(H2S)警報在進行應變處理時昏倒若警報確實是因非計劃或失控的 H2S 一次
阻絕設施失效的外洩事件該事故便屬於須提報的製程安全事件若警報是一個假警報則該事
故便不屬於須提報的製程安全事件因為沒有真正的化學品洩漏發生
管線
19 一條管線破漏1 小時內洩漏 2000 磅(900 公斤)易燃蒸氣到地面但洩漏位置在廠區內很偏僻的
地點該事故仍屬於須提報的製程安全事件因為ldquo偏僻rdquo不是提報與否的考量因素
與化學物質外洩無關之火災或能量釋放事故
一般通則而言唯有當火災或能量釋放事故是因化學物質洩漏所造成或其發生導致化學物質洩漏
超過提報恕限值這些事故才屬於須提報的製程安全事件實例包括
20 一場電氣火災影響製程操作導致甲苯洩漏 400 公斤該事故屬於須提報的製程安全事件因為
化學物質洩漏已超過甲苯的 100 公斤提報恕限值
21 發生電氣火災停電或任何公用資源供應中斷可能造成工廠停工及可能引起設備損失超過
$2500 美元(如因非正常停工導致反應器或設備損壞)但並未造成超過恕限值的化學物質洩漏
亦未造成死亡或嚴重工傷該事故不屬於須提報的製程安全事件因為設備損壞並非化學製程火
災爆炸造成且化學物質洩漏並未超過恕限值
海上運輸船
22 一艘由公司營運的海上運輸船在船上發生ldquo急性rdquo易燃物質外洩洩漏量超過 100 公斤該事故不
屬於須提報的製程安全事件因為除非海上運輸船是為了輸送半成品或產品而與煉油石化或化
學製造廠的設施相連接否則其洩漏事故便不被視為製程安全事件
23 一艘第三方駁船由一艘拖船推向碼頭結果撞上公司的碼頭駁船的一個船艙破裂且造成
1000 公斤柴油洩漏到海中該事故不屬於須提報的製程安全事件因為駁船當時並非停泊在碼
頭內且其作業並非在進行半成品或產品之輸送
卡車與軌道車
24 一輛公司的軌道車在運輸途中出軌造成超過 1000 公斤汽油洩漏該事故不屬於須提報的製程
安全事件因為在公司廠區外發生的軌道車事故不被視為與製程安全有關
23
25 一輛第三方卡車拖車在公司廠區內翻覆造成ldquo急性rdquo汽油洩漏超過 1000 公斤這事故不屬於須
提報的製程安全事件因為卡車拖車當時已不再與裝卸設備連接然而我們建議會員公司另
行訂定運輸安全事故指標將這類事故記錄下來
26 一位合約卡車作業者正在卸載液鹼時發生軟管脫落造成空氣中氣霧和或液鹼液洩漏 2500 公
斤該事故屬於須提報的製程安全事件因為洩漏量已超過液鹼的 100 公斤恕限值且事故發生
前卡車仍與裝卸設備相連接著
辦公建築
27 綜合辦公大樓發生鍋爐火災造成總計$75000 美元的直接成本損失該事故不屬於須提報的製
程安全事件因為辦公大樓事故不被視為與製程安全有關
人機介面事故
28 一名操作技術員在聚合物工廠的終端設備旁作業時受傷這傷害是因機械的人機介面的設備而
造成該事故不屬於須提報的製程安全事件因為技術員受傷並非因危險物質一次阻絕設施失效
而造成的
混合物
29 若混合物本身有 GHS 分類可利用其分類確定恕限值若混合物本身沒有 GHS 分類則可計算混
合物中每個單一組成分之洩漏量(公斤)相對於個別成分恕限值之比值作為其對混合物恕限值之
lsquo加權rsquo貢獻譬如若混合物在 1小時內的洩漏量為 100公斤其中包含 05公斤分類為劇毒 H300
的物質45 公斤分類為 H301 的物質40 公斤另一種分類為 H 開頭的物質其餘 55 公斤則為沒
有 GHS 分類的水分此混合物之計算式為051 + 4510 + 40100 = 05 + 045 + 04 = 135超過
1因此該事故被視為須提報的製程安全事件雖然混合物個別成分之洩漏量均未超過各該物質
本身的恕限值
直接損失成本
30 此一門檻所考慮的成本應為可直接歸因於火災或爆炸的成本譬如設備及結構損壞的重置成本
修理成本環境清理支出緊急應變和罰款直接成本不包括間接成本譬如業務機會損失設
備停機造成之利潤損失取得或運轉臨時設施之成本或為滿足顧客需求取得替代產品的成本
(產品損失)
24
31 範例連接到氣體處理系統的排放管發生易燃氣體外漏同時製程出現問題導致空氣進入同
一條排放管結果發生爆炸過高的壓力損壞了排放管及其相關上游設備包括一個密封罐並
未造成人員受傷修理成本約$12000 美元該事故屬於須提報的製程安全事件因為爆炸及火
災導致設備修理成本超過門檻
32 範例一次製程安全事件後公司又發生一種非常特殊的 GHS 第 5 類產品洩漏 50 公斤造成
$2000 美元的設備損失洩漏的產品是一種非常特別的混合物公司須負擔超過$50000 美元因
產品耗損而產生之材料成本該事故不屬於須提報的製程安全事件因為 GHS 第 5 類產品洩漏的
提報門檻為 100 公斤且產品耗損不被計入直接損失成本
天然災害
33 天然災害可能對化學製程作業構成重大風險且對製程設備造成損壞導致危害物質一次阻絕設
施失效當一種或多種天然災害被認為可能對工廠作業造成影響時製程安全和作業系統應從危
害及後果分析工廠機器設備設計公用設施失效及製程停工之操作程序緊急應變計畫及應變
措施等方面界定潛在風險進行防範
天然災害類型包括颶風及颱風(包括伴隨而來的風暴潮)水災龍捲風地震超強對流風暴(直
線風暴)野火火山爆發海嘯和山崩
若公司廠房設施遭遇天然災害且其後果觸發一種或以上提報門檻該事故便屬於須提報製程安
全事件
預防性公眾應變
34 預防性公眾應變是基於謹慎的態度所採取的一種措施譬如當發生一次阻絕設施失效時公司
可能在尚未進行任何評估(如方向與洩漏點的距離等等)前便要求全體工人就地避難又
如地方權責官員(如消防警察民防緊急應變管理部門)在獲報一家公司發生製程安全事件
後為防lsquo萬一rsquo風向改變或基於可能受到波及的人口敏感族群(如學童或老年人)可能在尚未接
獲明確資訊前便下令社區就地避難或疏散或採取公眾保護措施(如道路封閉)
製程附屬倉庫
35 製程附屬倉庫指的是位於廠內用於儲存將投入於生產製程或產自於製程之原料半成品或成品的
倉庫從製程的觀點看來製程附屬倉庫相當於一個大型儲槽但這些原料半成品或成品並不
是儲存在一的大型容器中而是裝在較小的容器裡(如太空包大桶桶罐等)
25
Appendix C ndash List of RCLG Taskforce Members
Name Affiliation
Peter Schmelzer Bayer CEFIC - Chairman
Americo Diniz Carvalho Neto Braskem
Bradford Johnson American Chemistry Council
David Cummings DuPont
Debra Phillips American Chemistry Council
Hans Schwarz BASF
Kathryn Walton Plastics and Chemicals Industries Association
Kazuyuki Akita Japanese Chemical Industry Association
Kelly Keim ExxonMobil Chemical Company API Representative
Kenan Stevick Dow
Kiyokazu Murata Japanese Chemical Industry Association
Larry Bowler SABIC
Lorna Young Chemical Industry Association of Canada
Louisa Nara Center for Chemical Process Safety
Luiz Shizuo Harayashiki Associaccedilatildeo Brasileira da Induacutestria Quiacutemica
Masatoshi Kumamoto Japanese Chemical Industry Association
Milton Lacerda Petrobras
Phil Scott Chemical Industries Association
Piet Knijff DSM European Process Safety Centre
Scott Donaldson and Eamon Chandler
Shell
Scott Wallace Olin Corporation
Shakeel Kadri Air Products and Chemicals Inc
26
附錄 D ndash 詳細活動時程表
2016 年 2017 年 2018 年 2019 年 2020 年
2 ndash 4 月
RCLG PS 先導計畫
5 月 ndash
針對準則進行調整釐清
6 月 向 RCLG 和 ICCA 董事會報
告先導計畫執行結果
7 ndash 12 月 RCLG 協會考量準
則並為其會員公司發展提報機制
如有需要RCLG可向 ICCA 申請能
力建立基金為會員公司舉辦製程安
全研習會
1 ndash 12 月
RCLG 協會開始向其會員公司蒐集製程安全數據
1 ndash 12 月
如有需要RCLG 各協會運用 RCLG 的基金及專
家舉辦製程安全及績效提報研習會
1 ndash 2 月
擁有數據的協會開始向RCLG 提報製程安全事件
(2017 年數據)
4 月 RCLG 檢討第一個提報循
環的結果挑戰及原始數據(內部)
6 月 RCLG 向 ICCA 董事會呈報
原始數據
7 ndash 12 月 必要時更新及調整準
則
如有需要RCLG 各協會運用 RCLG 的基金及專
家舉辦製程安全及績效提報研習會
1 ndash 2 月
擁有數據的協會開始向RCLG 提報製程安全事件
(2018 年數據)
4 月 RCLG 檢討第二個提報循
環的結果挑戰及原始數據(內部)
6 月 RCLG 向 ICCA 董事會呈報
原始數據
7 ndash 12 月 必要時更新及調整準
則
如有需要RCLG 協會運用 RCLG 的基金及專家
舉辦製程安全及績效提報研習會
1 ndash 2 月
所有協會開始向 RCLG 提報製程安全事件
製程安全事件提報成為
RCLG KPI 衡量指標建議基本集的一部分(2019 年數
據)
4 月 RCLG 檢討第二個提報循
環的結果挑戰及原始數據(內部考量外部提
報)
6 月 RCLG 向 ICCA 董事會呈報
原始數據
27
附錄 E ndash 選擇性 Excel 追蹤表
當會員公司開始追蹤製程安全事件時所有會員公司應採用單一表格以簡化數據分析同時讓所有公司均使用相同的追蹤表RCLG 設
計了一份選擇性追蹤表可供會員公司和協會先行利用之後他們可設計自己的追蹤表
在這裡下載追蹤表
ICCA Process Safety Event Tracking Sheetxlsx
本文件包含三個分頁分別是ldquo聯絡資料rdquoldquo調查表rdquo和儲存下拉式選單選項的ldquo請勿編輯rdquo分頁
備註
附錄 E 追蹤表僅供參考TRCA 將另行提供台灣版表格供會員公司提報
28
後語
台灣化學工業責任照顧協會(Taiwan Responsible Care Association TRCA)成立於 1998 年在台灣推行責任照顧制度已達 20 週年製造商成員
包括台灣主要上市上櫃化工公司會員公司化學品生產製造量約佔全國 80 2016 年台灣化工業的 Chemical Sales 仍站在全球第八名的位
置額度為 630 億歐元化工業總產值達到 34 兆新台幣提供國內 416 萬人工作機會
TRCA 扮演國內廠商與國際制度接軌的角色也是國內化工業與政府機關及利益相關者溝通的橋樑與管道TRCA 會員結構依業務性質分析
涵蓋石化生產化學品製造氣體生產倉儲運輸業化學品貿易業以及工程研發設計等公司TRCA 透過供應鏈及價值鏈推行責任
照顧制度組成毒性化學物質聯防組織協助法規溝通與研析會員名冊請參考 httpwwwtrcaorgtwtrcanwork2aspx
TRCA 於 2010 年成為 ICCA (International Council of Chemical Associations 國際化學工業協會)觀察員ICCA 成立於 1989 年是全球化工製造
業的聯合會也是化學工業與 UNEP OPCW 及 OECD 的交流窗口ICCA 與其會員協會及成員公司致力於邁向永續的未來確保人類健康與
環境安全與保護全球化工業擁有超過 4兆美元的價值影響所有經濟部門ICCA 的會員幾乎在全球每個國家都有商業活動在全球六大
洲推動創新並提供超過 2000 萬個工作機會
台灣化工業在全球占有重要的一席之地在國內產業鏈也位居關鍵位置無論對國內或國際都有身為地球村一員應盡之責我們期許藉由
製程安全指標提報能更進一步提升自我在工安衛生環保與永續發展等面向的績效表現
台灣化學工業責任照顧協會
10452 台北市中山區撫順街 8 號 7 樓
電話02-2585-0552
httpwwwtrcaorgtw
None | |
$2500 to $25000 | |
$25000 to $250000 | |
$250000 to $25000000 | |
More than $25000000 | |
Yes - Using GHS TABLE | |
Yes - Using API RP 754 TABLE | |
NO | |
NA | |
1x le TQ lt 40x | |
40x le TQ lt 160x | |
160x le TQ lt 640x | |
ge 640x TQ | |
Yes le 3 hours | |
Yes 3 hours ge 12 hours | |
Yes 12 hours ge 24 hours | |
Yes ge 24 hours | |
No | |
Small-scale | |
Medium-scale | |
Large-scale | |
No | |
Yes | |
No | |
middot Injury requiring treatment beyond first aid to an employee contractor or subcontractor | |
middot Days Away From Work injury to an employee contractor or subcontractor or middot Injury requiring treatment beyond first aid to a third party | |
middot A fatality of an employee contractor or subcontractor or middot A hospital admission of a third party | |
middot Multiple fatalities of employees contractors or subcontractors or middot multiple hospital admission of third parties or middot A fatality of a third party | |
NA | |
1x le TQ lt 3x | |
3x le TQ lt 9x | |
9x le TQ lt 27x | |
ge 27x TQ |
ICCA Process Safety Pilot Reporting ProgramFebruary 8 2016 | 1 | 2 | 3 | 4 | 5 | 6 | 7 | 8 | 9 | 10 | 12 | 13 | 14 | 15 | |||||||||||||||||||||||
SAFETY Details(Meeting Local Regulations) | Direct Cost from Fire or Explosion | Community Impact | Environmental Impact | Material Released(Measured using the 1 Hour Rule) | |||||||||||||||||||||||||||||||||
Company Association Details | |||||||||||||||||||||||||||||||||||||
GHS | API - RP 754 | ||||||||||||||||||||||||||||||||||||
Company or Assocation Name | Headquarter Association | Location of Event Ex - City State amp Country | Date and Time of Event | Safety InjuryDid the Event result in a Recordable Lost Time Accident or Fatality or Hospital admission of anyone on or off siteUse Drop Down Menu | Safety InjuryIf yes please insert the total number of injuries | Safety InjuryFor puropses of utilizing the Severity Table please indicate the level of severity by chosing the MOST SEVERE classification that describes your incidentUse Drop Down Menu | Safety InjuryDid the incident involve Fatalities If so how many total fatalities If none enter Zero | Safety InjuryPlease Report Total Employee Hours for Calendar Year 2015 | Safety InjuryPlease Report Total Contractor Hours for Calendar Year 2015 | Direct Cost Did the Event result in Direct Damage CostUse Drop Down Menu | Direct Cost If so how muchAmount is in US DollarsUse Drop Down Menu | Community ImpactDid the event result inbull Officially declared shelter-in-place or officially declared evacuation (on or off site)ORbull Precautionary off site shelter in place or evacuation Use Drop Down Menu | Environmental ImpactDid the event result inAcute Environmental Remediation CostIf so indicate the amount in US DollarsUse Drop Down Menu | Material ReleasedDid the Event result in an Acute Release of material beyond one of the two threshold tablesIf so indicate which Threshold Table you used to make this determinationUse Drop Down Menu | Material ReleasedIf so indicate the amount released USING GHS CLASSIFICATION TABLEUse Drop Down Menu | Material ReleasedIf so indicate the amount released USING THE THRESHOLD TABLE FROM API RP-754Use Drop Down Menu | Material ReleasedIf available please indicate the material released | ||||||||||||||||||||
1 | ABC Chemical Company | American Chemistry Council | Washington DC - USA | January 4 2016 | Yes | 2 | middot Days Away From Work injury to an employee contractor or subcontractor or middot Injury requiring treatment beyond first aid to a third party | 0 | 5525000 | 1500250 | No | $2500 to $25000 | Yes le 3 hours | $2500 to $25000 | Yes - Using GHS TABLE | 40x le TQ lt 160x | NA | Chlorine | |||||||||||||||||||
2 | XYZ Chemical Company | American Chemistry Council | Washington DC - USA | 5-Jan-16 | Yes | 1 | middot Injury requiring treatment beyond first aid to an employee contractor or subcontractor | 0 | 5525000 | 1500250 | Yes | $2500 to $25000 | No | $2500 to $25000 | Yes - Using API RP 754 TABLE | NA | 3x le TQ lt 9x | Benzene | |||||||||||||||||||
3 | |||||||||||||||||||||||||||||||||||||
4 | |||||||||||||||||||||||||||||||||||||
5 | |||||||||||||||||||||||||||||||||||||
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8 | |||||||||||||||||||||||||||||||||||||
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11 | |||||||||||||||||||||||||||||||||||||
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14 | |||||||||||||||||||||||||||||||||||||
15 | |||||||||||||||||||||||||||||||||||||
16 | |||||||||||||||||||||||||||||||||||||
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18 | |||||||||||||||||||||||||||||||||||||
19 | |||||||||||||||||||||||||||||||||||||
20 | |||||||||||||||||||||||||||||||||||||
21 | |||||||||||||||||||||||||||||||||||||
22 | |||||||||||||||||||||||||||||||||||||
23 | |||||||||||||||||||||||||||||||||||||
24 | |||||||||||||||||||||||||||||||||||||
25 | |||||||||||||||||||||||||||||||||||||
Zero or None | Yes - Duration Unknown | ||||||||||||||||||||||||||||||||||||
Processes | Mode of Operation | Type of material released | Status of Operation | ||||
REFINING | Start-up | Flammable | Open | ||||
Alkylation HF | Planned shutdown | Combustible | Closed | ||||
Alkylation sulfuric | Emergency shutdown | Toxic | |||||
BitumenResidAsphalt | Normal | Corrosive | Tier 1 Acute Releases | ||||
Calcining | Upset | Utilities | No Release | ||||
Coking | Turnaround | Other | Category 1 | ||||
Crude | Routine maintenance | Category 2 | |||||
Desulfurization | Temporary | Evacuation | Category 3 | ||||
FCC | Other | Yes | Category 4 | ||||
Gas Treating | No | Category 5 | |||||
Hydrogen | Point of Release | Category 6 | |||||
Hydrotreating | Pump | Fire | Category 7 | ||||
Hydrocracking | Compressor | Yes | Multiple Categories | ||||
Isom | BlowerFan | No | |||||
MarineJetty | Pressure Vessel | lt $2500 | |||||
Reforming | FilterCoalescer | ||||||
Sulfur recovery | Furnace | PRDs | |||||
Vapor recoverylight ends | Boiler | Directly to Atmosphere | |||||
Wastewater | Heat exchanger | via Downstream Destructive Device | |||||
REFINING amp PETROCHEMICAL | Cooling Tower | No | |||||
Tank FarmStorage FacilityOffsite | Piping system | Yes | |||||
UtilitiesSteam PlantCogeneration | Reactor | No | |||||
Other | Atmospheric tank | ||||||
PETROCHEMICAL | FlareRelief System | Acute release above thresholds | |||||
CO H2 | Other | Yes | |||||
LNG | No | ||||||
Methane | Events | ||||||
Methanol | No Tier 1 Events | Indoor Outdoor | |||||
Methyl Mercaptan | No Tier 2 Events | No Release | |||||
Formaldehyde | No Tier 1 or Tier 2 Events | Indoor | |||||
Formaldehyde derivatives | NA | Outdoor | |||||
Acetic Acid | |||||||
Acetic Acid derivatives | Event Type | ||||||
Ethane | Injury | ||||||
Ethylene | Fire | ||||||
Ethanol | Explosion | ||||||
Ethylene oxide | PRD Discharge | ||||||
Ethylene derivatives | Acute Release | ||||||
Polyethylene | |||||||
Ethylene dichloride | General | ||||||
Ethylene dichloride derivatives | Yes | ||||||
Ethyl benzene | No | ||||||
Ethyl benzene derivatives | |||||||
Polystyrene | |||||||
Styrene-Butadiene | |||||||
Propane | |||||||
Propylene | |||||||
Polypropylene | |||||||
Isopropanol | |||||||
Propylene oxide | |||||||
Propylene oxide derivatives | |||||||
Butane | |||||||
Isobutane | |||||||
Isobutene | |||||||
Butadiene | |||||||
MTBE | |||||||
ETBE | |||||||
Pentane | |||||||
Hexane | |||||||
Cyclohexane | |||||||
Hexanol | |||||||
Aromatics Derivatives | |||||||
Benzene | |||||||
Toluene | |||||||
Xylene | |||||||
Para Xylene | |||||||
Amines Derivatives | |||||||
TDA MDA IPDA etc | |||||||
Isocyanates | |||||||
Specialty Chemicals | |||||||
LoadingUnloading | |||||||
Pilot Plant |
Instructions | ||||||||||||||
Step 1 | Complete the Contact Tab with your contact information and company information | |||||||||||||
Be sure to note the region of your reporting (IE North America France Japan etc) | ||||||||||||||
Survey on Process Safety Events | ||||||||||||||
Step 2 | Complete the survey one line per Process Safety Event for your companyregion | |||||||||||||
ALL REPORTED DATA SHOULD BE FROM CALENDAR YEAR 2017 | ||||||||||||||
Step 3 | Return completed survey to | |||||||||||||
Company Name | ||||||||||||||
Contact Person | All Surveys Due by xxx date | |||||||||||||
Address | ||||||||||||||
Fax | ||||||||||||||
Telephone | ||||||||||||||
Region | ||||||||||||||
None | |
$2500 to $25000 | |
$25000 to $250000 | |
$250000 to $25000000 | |
More than $25000000 | |
Yes - Using GHS TABLE | |
Yes - Using API RP 754 TABLE | |
NO | |
NA | |
1x le TQ lt 40x | |
40x le TQ lt 160x | |
160x le TQ lt 640x | |
ge 640x TQ | |
Yes le 3 hours | |
Yes 3 hours ge 12 hours | |
Yes 12 hours ge 24 hours | |
Yes ge 24 hours | |
No | |
Small-scale | |
Medium-scale | |
Large-scale | |
No | |
Yes | |
No | |
middot Injury requiring treatment beyond first aid to an employee contractor or subcontractor | |
middot Days Away From Work injury to an employee contractor or subcontractor or middot Injury requiring treatment beyond first aid to a third party | |
middot A fatality of an employee contractor or subcontractor or middot A hospital admission of a third party | |
middot Multiple fatalities of employees contractors or subcontractors or middot multiple hospital admission of third parties or middot A fatality of a third party | |
NA | |
1x le TQ lt 3x | |
3x le TQ lt 9x | |
9x le TQ lt 27x | |
ge 27x TQ |
ICCA Process Safety Pilot Reporting ProgramFebruary 8 2016 | 1 | 2 | 3 | 4 | 5 | 6 | 7 | 8 | 9 | 10 | 12 | 13 | 14 | 15 | |||||||||||||||||||||||
SAFETY Details(Meeting Local Regulations) | Direct Cost from Fire or Explosion | Community Impact | Environmental Impact | Material Released(Measured using the 1 Hour Rule) | |||||||||||||||||||||||||||||||||
Company Association Details | |||||||||||||||||||||||||||||||||||||
GHS | API - RP 754 | ||||||||||||||||||||||||||||||||||||
Company or Assocation Name | Headquarter Association | Location of Event Ex - City State amp Country | Date and Time of Event | Safety InjuryDid the Event result in a Recordable Lost Time Accident or Fatality or Hospital admission of anyone on or off siteUse Drop Down Menu | Safety InjuryIf yes please insert the total number of injuries | Safety InjuryFor puropses of utilizing the Severity Table please indicate the level of severity by chosing the MOST SEVERE classification that describes your incidentUse Drop Down Menu | Safety InjuryDid the incident involve Fatalities If so how many total fatalities If none enter Zero | Safety InjuryPlease Report Total Employee Hours for Calendar Year 2015 | Safety InjuryPlease Report Total Contractor Hours for Calendar Year 2015 | Direct Cost Did the Event result in Direct Damage CostUse Drop Down Menu | Direct Cost If so how muchAmount is in US DollarsUse Drop Down Menu | Community ImpactDid the event result inbull Officially declared shelter-in-place or officially declared evacuation (on or off site)ORbull Precautionary off site shelter in place or evacuation Use Drop Down Menu | Environmental ImpactDid the event result inAcute Environmental Remediation CostIf so indicate the amount in US DollarsUse Drop Down Menu | Material ReleasedDid the Event result in an Acute Release of material beyond one of the two threshold tablesIf so indicate which Threshold Table you used to make this determinationUse Drop Down Menu | Material ReleasedIf so indicate the amount released USING GHS CLASSIFICATION TABLEUse Drop Down Menu | Material ReleasedIf so indicate the amount released USING THE THRESHOLD TABLE FROM API RP-754Use Drop Down Menu | Material ReleasedIf available please indicate the material released | ||||||||||||||||||||
1 | ABC Chemical Company | American Chemistry Council | Washington DC - USA | January 4 2016 | Yes | 2 | middot Days Away From Work injury to an employee contractor or subcontractor or middot Injury requiring treatment beyond first aid to a third party | 0 | 5525000 | 1500250 | No | $2500 to $25000 | Yes le 3 hours | $2500 to $25000 | Yes - Using GHS TABLE | 40x le TQ lt 160x | NA | Chlorine | |||||||||||||||||||
2 | XYZ Chemical Company | American Chemistry Council | Washington DC - USA | 5-Jan-16 | Yes | 1 | middot Injury requiring treatment beyond first aid to an employee contractor or subcontractor | 0 | 5525000 | 1500250 | Yes | $2500 to $25000 | No | $2500 to $25000 | Yes - Using API RP 754 TABLE | NA | 3x le TQ lt 9x | Benzene | |||||||||||||||||||
3 | |||||||||||||||||||||||||||||||||||||
4 | |||||||||||||||||||||||||||||||||||||
5 | |||||||||||||||||||||||||||||||||||||
6 | |||||||||||||||||||||||||||||||||||||
7 | |||||||||||||||||||||||||||||||||||||
8 | |||||||||||||||||||||||||||||||||||||
9 | |||||||||||||||||||||||||||||||||||||
10 | |||||||||||||||||||||||||||||||||||||
11 | |||||||||||||||||||||||||||||||||||||
12 | |||||||||||||||||||||||||||||||||||||
13 | |||||||||||||||||||||||||||||||||||||
14 | |||||||||||||||||||||||||||||||||||||
15 | |||||||||||||||||||||||||||||||||||||
16 | |||||||||||||||||||||||||||||||||||||
17 | |||||||||||||||||||||||||||||||||||||
18 | |||||||||||||||||||||||||||||||||||||
19 | |||||||||||||||||||||||||||||||||||||
20 | |||||||||||||||||||||||||||||||||||||
21 | |||||||||||||||||||||||||||||||||||||
22 | |||||||||||||||||||||||||||||||||||||
23 | |||||||||||||||||||||||||||||||||||||
24 | |||||||||||||||||||||||||||||||||||||
25 | |||||||||||||||||||||||||||||||||||||
Zero or None | Yes - Duration Unknown | ||||||||||||||||||||||||||||||||||||
Processes | Mode of Operation | Type of material released | Status of Operation | ||||
REFINING | Start-up | Flammable | Open | ||||
Alkylation HF | Planned shutdown | Combustible | Closed | ||||
Alkylation sulfuric | Emergency shutdown | Toxic | |||||
BitumenResidAsphalt | Normal | Corrosive | Tier 1 Acute Releases | ||||
Calcining | Upset | Utilities | No Release | ||||
Coking | Turnaround | Other | Category 1 | ||||
Crude | Routine maintenance | Category 2 | |||||
Desulfurization | Temporary | Evacuation | Category 3 | ||||
FCC | Other | Yes | Category 4 | ||||
Gas Treating | No | Category 5 | |||||
Hydrogen | Point of Release | Category 6 | |||||
Hydrotreating | Pump | Fire | Category 7 | ||||
Hydrocracking | Compressor | Yes | Multiple Categories | ||||
Isom | BlowerFan | No | |||||
MarineJetty | Pressure Vessel | lt $2500 | |||||
Reforming | FilterCoalescer | ||||||
Sulfur recovery | Furnace | PRDs | |||||
Vapor recoverylight ends | Boiler | Directly to Atmosphere | |||||
Wastewater | Heat exchanger | via Downstream Destructive Device | |||||
REFINING amp PETROCHEMICAL | Cooling Tower | No | |||||
Tank FarmStorage FacilityOffsite | Piping system | Yes | |||||
UtilitiesSteam PlantCogeneration | Reactor | No | |||||
Other | Atmospheric tank | ||||||
PETROCHEMICAL | FlareRelief System | Acute release above thresholds | |||||
CO H2 | Other | Yes | |||||
LNG | No | ||||||
Methane | Events | ||||||
Methanol | No Tier 1 Events | Indoor Outdoor | |||||
Methyl Mercaptan | No Tier 2 Events | No Release | |||||
Formaldehyde | No Tier 1 or Tier 2 Events | Indoor | |||||
Formaldehyde derivatives | NA | Outdoor | |||||
Acetic Acid | |||||||
Acetic Acid derivatives | Event Type | ||||||
Ethane | Injury | ||||||
Ethylene | Fire | ||||||
Ethanol | Explosion | ||||||
Ethylene oxide | PRD Discharge | ||||||
Ethylene derivatives | Acute Release | ||||||
Polyethylene | |||||||
Ethylene dichloride | General | ||||||
Ethylene dichloride derivatives | Yes | ||||||
Ethyl benzene | No | ||||||
Ethyl benzene derivatives | |||||||
Polystyrene | |||||||
Styrene-Butadiene | |||||||
Propane | |||||||
Propylene | |||||||
Polypropylene | |||||||
Isopropanol | |||||||
Propylene oxide | |||||||
Propylene oxide derivatives | |||||||
Butane | |||||||
Isobutane | |||||||
Isobutene | |||||||
Butadiene | |||||||
MTBE | |||||||
ETBE | |||||||
Pentane | |||||||
Hexane | |||||||
Cyclohexane | |||||||
Hexanol | |||||||
Aromatics Derivatives | |||||||
Benzene | |||||||
Toluene | |||||||
Xylene | |||||||
Para Xylene | |||||||
Amines Derivatives | |||||||
TDA MDA IPDA etc | |||||||
Isocyanates | |||||||
Specialty Chemicals | |||||||
LoadingUnloading | |||||||
Pilot Plant |
Instructions | ||||||||||||||
Step 1 | Complete the Contact Tab with your contact information and company information | |||||||||||||
Be sure to note the region of your reporting (IE North America France Japan etc) | ||||||||||||||
Survey on Process Safety Events | ||||||||||||||
Step 2 | Complete the survey one line per Process Safety Event for your companyregion | |||||||||||||
ALL REPORTED DATA SHOULD BE FROM CALENDAR YEAR 2017 | ||||||||||||||
Step 3 | Return completed survey to | |||||||||||||
Company Name | ||||||||||||||
Contact Person | All Surveys Due by xxx date | |||||||||||||
Address | ||||||||||||||
Fax | ||||||||||||||
Telephone | ||||||||||||||
Region | ||||||||||||||
None | |
$2500 to $25000 | |
$25000 to $250000 | |
$250000 to $25000000 | |
More than $25000000 | |
Yes - Using GHS TABLE | |
Yes - Using API RP 754 TABLE | |
NO | |
NA | |
1x le TQ lt 40x | |
40x le TQ lt 160x | |
160x le TQ lt 640x | |
ge 640x TQ | |
Yes le 3 hours | |
Yes 3 hours ge 12 hours | |
Yes 12 hours ge 24 hours | |
Yes ge 24 hours | |
No | |
Small-scale | |
Medium-scale | |
Large-scale | |
No | |
Yes | |
No | |
middot Injury requiring treatment beyond first aid to an employee contractor or subcontractor | |
middot Days Away From Work injury to an employee contractor or subcontractor or middot Injury requiring treatment beyond first aid to a third party | |
middot A fatality of an employee contractor or subcontractor or middot A hospital admission of a third party | |
middot Multiple fatalities of employees contractors or subcontractors or middot multiple hospital admission of third parties or middot A fatality of a third party | |
NA | |
1x le TQ lt 3x | |
3x le TQ lt 9x | |
9x le TQ lt 27x | |
ge 27x TQ |
ICCA Process Safety Pilot Reporting ProgramFebruary 8 2016 | 1 | 2 | 3 | 4 | 5 | 6 | 7 | 8 | 9 | 10 | 12 | 13 | 14 | 15 | |||||||||||||||||||||||
SAFETY Details(Meeting Local Regulations) | Direct Cost from Fire or Explosion | Community Impact | Environmental Impact | Material Released(Measured using the 1 Hour Rule) | |||||||||||||||||||||||||||||||||
Company Association Details | |||||||||||||||||||||||||||||||||||||
GHS | API - RP 754 | ||||||||||||||||||||||||||||||||||||
Company or Assocation Name | Headquarter Association | Location of Event Ex - City State amp Country | Date and Time of Event | Safety InjuryDid the Event result in a Recordable Lost Time Accident or Fatality or Hospital admission of anyone on or off siteUse Drop Down Menu | Safety InjuryIf yes please insert the total number of injuries | Safety InjuryFor puropses of utilizing the Severity Table please indicate the level of severity by chosing the MOST SEVERE classification that describes your incidentUse Drop Down Menu | Safety InjuryDid the incident involve Fatalities If so how many total fatalities If none enter Zero | Safety InjuryPlease Report Total Employee Hours for Calendar Year 2015 | Safety InjuryPlease Report Total Contractor Hours for Calendar Year 2015 | Direct Cost Did the Event result in Direct Damage CostUse Drop Down Menu | Direct Cost If so how muchAmount is in US DollarsUse Drop Down Menu | Community ImpactDid the event result inbull Officially declared shelter-in-place or officially declared evacuation (on or off site)ORbull Precautionary off site shelter in place or evacuation Use Drop Down Menu | Environmental ImpactDid the event result inAcute Environmental Remediation CostIf so indicate the amount in US DollarsUse Drop Down Menu | Material ReleasedDid the Event result in an Acute Release of material beyond one of the two threshold tablesIf so indicate which Threshold Table you used to make this determinationUse Drop Down Menu | Material ReleasedIf so indicate the amount released USING GHS CLASSIFICATION TABLEUse Drop Down Menu | Material ReleasedIf so indicate the amount released USING THE THRESHOLD TABLE FROM API RP-754Use Drop Down Menu | Material ReleasedIf available please indicate the material released | ||||||||||||||||||||
1 | ABC Chemical Company | American Chemistry Council | Washington DC - USA | January 4 2016 | Yes | 2 | middot Days Away From Work injury to an employee contractor or subcontractor or middot Injury requiring treatment beyond first aid to a third party | 0 | 5525000 | 1500250 | No | $2500 to $25000 | Yes le 3 hours | $2500 to $25000 | Yes - Using GHS TABLE | 40x le TQ lt 160x | NA | Chlorine | |||||||||||||||||||
2 | XYZ Chemical Company | American Chemistry Council | Washington DC - USA | 5-Jan-16 | Yes | 1 | middot Injury requiring treatment beyond first aid to an employee contractor or subcontractor | 0 | 5525000 | 1500250 | Yes | $2500 to $25000 | No | $2500 to $25000 | Yes - Using API RP 754 TABLE | NA | 3x le TQ lt 9x | Benzene | |||||||||||||||||||
3 | |||||||||||||||||||||||||||||||||||||
4 | |||||||||||||||||||||||||||||||||||||
5 | |||||||||||||||||||||||||||||||||||||
6 | |||||||||||||||||||||||||||||||||||||
7 | |||||||||||||||||||||||||||||||||||||
8 | |||||||||||||||||||||||||||||||||||||
9 | |||||||||||||||||||||||||||||||||||||
10 | |||||||||||||||||||||||||||||||||||||
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Zero or None | Yes - Duration Unknown | ||||||||||||||||||||||||||||||||||||
Processes | Mode of Operation | Type of material released | Status of Operation | ||||
REFINING | Start-up | Flammable | Open | ||||
Alkylation HF | Planned shutdown | Combustible | Closed | ||||
Alkylation sulfuric | Emergency shutdown | Toxic | |||||
BitumenResidAsphalt | Normal | Corrosive | Tier 1 Acute Releases | ||||
Calcining | Upset | Utilities | No Release | ||||
Coking | Turnaround | Other | Category 1 | ||||
Crude | Routine maintenance | Category 2 | |||||
Desulfurization | Temporary | Evacuation | Category 3 | ||||
FCC | Other | Yes | Category 4 | ||||
Gas Treating | No | Category 5 | |||||
Hydrogen | Point of Release | Category 6 | |||||
Hydrotreating | Pump | Fire | Category 7 | ||||
Hydrocracking | Compressor | Yes | Multiple Categories | ||||
Isom | BlowerFan | No | |||||
MarineJetty | Pressure Vessel | lt $2500 | |||||
Reforming | FilterCoalescer | ||||||
Sulfur recovery | Furnace | PRDs | |||||
Vapor recoverylight ends | Boiler | Directly to Atmosphere | |||||
Wastewater | Heat exchanger | via Downstream Destructive Device | |||||
REFINING amp PETROCHEMICAL | Cooling Tower | No | |||||
Tank FarmStorage FacilityOffsite | Piping system | Yes | |||||
UtilitiesSteam PlantCogeneration | Reactor | No | |||||
Other | Atmospheric tank | ||||||
PETROCHEMICAL | FlareRelief System | Acute release above thresholds | |||||
CO H2 | Other | Yes | |||||
LNG | No | ||||||
Methane | Events | ||||||
Methanol | No Tier 1 Events | Indoor Outdoor | |||||
Methyl Mercaptan | No Tier 2 Events | No Release | |||||
Formaldehyde | No Tier 1 or Tier 2 Events | Indoor | |||||
Formaldehyde derivatives | NA | Outdoor | |||||
Acetic Acid | |||||||
Acetic Acid derivatives | Event Type | ||||||
Ethane | Injury | ||||||
Ethylene | Fire | ||||||
Ethanol | Explosion | ||||||
Ethylene oxide | PRD Discharge | ||||||
Ethylene derivatives | Acute Release | ||||||
Polyethylene | |||||||
Ethylene dichloride | General | ||||||
Ethylene dichloride derivatives | Yes | ||||||
Ethyl benzene | No | ||||||
Ethyl benzene derivatives | |||||||
Polystyrene | |||||||
Styrene-Butadiene | |||||||
Propane | |||||||
Propylene | |||||||
Polypropylene | |||||||
Isopropanol | |||||||
Propylene oxide | |||||||
Propylene oxide derivatives | |||||||
Butane | |||||||
Isobutane | |||||||
Isobutene | |||||||
Butadiene | |||||||
MTBE | |||||||
ETBE | |||||||
Pentane | |||||||
Hexane | |||||||
Cyclohexane | |||||||
Hexanol | |||||||
Aromatics Derivatives | |||||||
Benzene | |||||||
Toluene | |||||||
Xylene | |||||||
Para Xylene | |||||||
Amines Derivatives | |||||||
TDA MDA IPDA etc | |||||||
Isocyanates | |||||||
Specialty Chemicals | |||||||
LoadingUnloading | |||||||
Pilot Plant |
Instructions | ||||||||||||||
Step 1 | Complete the Contact Tab with your contact information and company information | |||||||||||||
Be sure to note the region of your reporting (IE North America France Japan etc) | ||||||||||||||
Survey on Process Safety Events | ||||||||||||||
Step 2 | Complete the survey one line per Process Safety Event for your companyregion | |||||||||||||
ALL REPORTED DATA SHOULD BE FROM CALENDAR YEAR 2017 | ||||||||||||||
Step 3 | Return completed survey to | |||||||||||||
Company Name | ||||||||||||||
Contact Person | All Surveys Due by xxx date | |||||||||||||
Address | ||||||||||||||
Fax | ||||||||||||||
Telephone | ||||||||||||||
Region | ||||||||||||||
2016 | 2017 | 2018 | 2019 | 2020 | |||||
Feb - April RCLG PS Pilot Program May ndash Adjustmentsclarification to guidance document June Report outcomes of pilot program to RCLG and ICCA Board July - December middot RCLG associations consider guidance and develop reporting methodology for their memberships middot RCLG associations can request ICCA capacity building funds for PS reporting workshops for members if needed | Jan - Dec RCLG Association membership begin collecting PS data from their members Jan ndash Dec Associations hold workshops on Process Safety and performance reporting utilizing RCLG funds and experts if needed | Jan ndash Feb Reporting of process safety incidents to RCLG begins for associations with data (2017 data) April RCLG reviews outcomes challenges and raw data from the first reporting cycle (internally) June RCLG share draft data with ICCA Board July - December Update and adjust guidance as necessary Associations hold workshops on Process Safety and performance reporting utilizing RCLG funds and experts if needed | Jan ndash Feb Reporting of process safety incidents to RCLG begins for associations with data (2018 data) April RCLG reviews outcomes challenges and raw data from the second reporting cycle (internally) June RCLG share draft data with ICCA Board July - December Update and adjust guidance as necessary Associations hold workshops on Process Safety and performance reporting utilizing RCLG funds and experts if needed | Jan ndash Feb Reporting of process safety incidents to RCLG begins for all associations Process Safety incident reporting becomes part of the recommend base set of RCLG KPI metrics (2019 data) April RCLG reviews outcomes challenges and raw data from the second reporting cycle (internally consider external reporting) June RCLG share draft data with ICCA Board |
Name | Affiliation | ||
Peter Schmelzer | Bayer CEFIC - Chairman | ||
Americo Diniz Carvalho Neto | Braskem | ||
Bradford Johnson | American Chemistry Council | ||
David Cummings | DuPont | ||
Debra Phillips | American Chemistry Council | ||
Hans Schwarz | BASF | ||
Kathryn Walton | Plastics and Chemicals Industries Association | ||
Kazuyuki Akita | Japanese Chemical Industry Association | ||
Kelly Keim | ExxonMobil Chemical Company API Representative | ||
Kenan Stevick | Dow | ||
Kiyokazu Murata | Japanese Chemical Industry Association | ||
Larry Bowler | SABIC | ||
Lorna Young | Chemical Industry Association of Canada | ||
Louisa Nara | Center for Chemical Process Safety | ||
Associaccedilatildeo Brasileira da Induacutestria Quiacutemica | |||
Masatoshi Kumamoto | Japanese Chemical Industry Association | ||
Milton Lacerda | Petrobras | ||
Phil Scott | Chemical Industries Association | ||
Piet Knijff | DSM European Process Safety Centre | ||
Scott Donaldson and Eamon Chandler | Shell | ||
Scott Wallace | Olin Corporation | ||
Shakeel Kadri | Air Products and Chemicals Inc |
Event Incident Categories | |||||||||||
Severity Level | SafetyHuman Health | Direct Cost from Fire or Explosion | Material ReleaseWithin 1-Hr Period | Community Impact | Environmental Impact [off-site] | ||||||
Level 4 1 point | middot Injury requiring treatment beyond first aid to an employee contractor or subcontractor (Meets local regulations) | middot Resulting in Direct Damage Cost of $25 K le up to $25 K | middot Release volume between 1x le TQ lt 40x | middot Officially declared shelter-in-place or officially declared evacuation (on or off site) middot Precautionary off site shelter in place or evacuation le 3 hours | middot Acute Environmental Remediation Cost $25 K le up to $25 K | ||||||
Level 3 3 points | middot Days Away From Work injury to an employee contractor or subcontractor or middot Injury requiring treatment beyond first aid to a third party (Meets local regulations) | middot Resulting in Direct Damage Cost of $25 K le up to $250 K | middot Release volume between 40x le TQ lt 160x | middot Officially declared shelter-in-place or officially declared evacuation (on or off site) middot Precautionary off site shelter in place or evacuation 3 hours ge up to 12 hours | middot Acute Environmental Remediation Cost $25 K le up to $250 K | ||||||
Level 2 9 points | middot A fatality of an employee contractor or subcontractor or middot A hospital admission of a third party (Meets local regulations) | middot Resulting in Direct Damage Cost of $250 K le up to $25 MM | middot Release volume between 160x le TQ lt 640x | middot Officially declared shelter-in-place or officially declared evacuation (on or off site) middot Precautionary off site shelter in place or evacuation 12 hours ge up to 24 hours | middot Acute Environmental Remediation Cost $250 K le up to $25 MM | ||||||
Level 1 27 points | middot Multiple fatalities of employees contractors or subcontractors or middot multiple hospital admission of third parties or middot A fatality of a third party (Meets local regulations) | middot Resulting in Direct Damage Costs of ge $25 MM | middot Release volume ge 640x TQ | middot Officially declared shelter-in-place or officially declared evacuation (on or off site) middot Precautionary off site shelter in place or evacuation ge 24 hours | middot Acute Environmental Remediation Cost ge $25 MM |
It is recognized that threshold quantities given in kg and lb or in lb and bbl are not exactly equivalent Companies should select one of the pair and use it consistently for all recordkeeping activities | |
In determining the Threshold Release Category for a material one should first use the toxic (TIH Zone) or flammability (Flash Point and Boiling Point) or corrosiveness (Strong Acid or Base vs Moderate Acid or Base) characteristics Only when the hazard of the material is not expressed by those simple characteristics (eg reacts violently with water) is the UNDGL Packing Group used a Many materials exhibit more than one hazard Correct placement in Hazard Zone or Packing Group shall follow the rules of DOT 49 CFR 1732a [14] or UN Recommendations on the Transportation of Dangerous Goods Section 2 [12] See Annex F b A structure composed of four complete (floor to ceiling) walls floor and roof c For solutions not listed on the UNDG the anhydrous component shall determine the TIH zone or Packing Group classification The threshold quantity of the solution shall be back calculated based on the threshold quantity of the dry component weight d For mixtures where the UNDG classification is unknown the fraction of threshold quantity release for each component may be calculated If the sum of the fractions is equal to or greater than 100 the mixture exceeds the threshold quantity Where there are clear and independent toxic and flammable consequences associated with the mixture the toxic and flammable hazards are calculated independently See Annex E PSE Examples amp Questions 49 - 53 e A LOPC of Liquids with Flash Point gt 60 degC (140 degF) and 93 degC (200 degF) released at a temperature below Flash Point cannot be Tier 1 PSE based upon quantity released no matter the volume f A LOPC of a moderate acidbase cannot be Tier 1 PSE based upon quantity released no matter the volume |
Threshold Release Category | Material Hazard Classification acdef | Threshold Quantity (outdoor release) | Threshold Quantity (indoorb release) | ||||
T2-1 | TIH Zone A Materials | ge 05 kg (11 lb) | ge 025 kg (055 lb) | ||||
T2-2 | TIH Zone B Materials | ge 25 kg (55 lb) | ge 125 kg (275 lb) | ||||
T2-3 | TIH Zone C Materials | ge 10 kg (22 lb) | ge 5 kg (11 lb) | ||||
T2-4 | TIH Zone D Materials | ge 20 kg (44 lb) | ge 10 kg (22 lb) | ||||
T2-5 | Flammable Gases OR Liquids with Normal Boiling Point 35 degC (95 degF) and Flash Point 23 degC (73 degF) OR Other Packing Group I Materials (excluding acidsbases) | ge 50 kg (110 lb) | ge 25 kg (55 lb) | ||||
T2-6 | Liquids with Normal Boiling Point 35 degC (95 degF) and Flash Point 23 degC (73degF) OR Other Packing Group II Materials (excluding acidsbases) | ge 100 kg (220 lb)orge 07 bbl | ge 50 kg (110 lb)orge 035 bbl | ||||
T2-7 | Liquids with Flash Point 23 degC (73 degF) and 60 degC (140 degF) OR Liquids with Flash Point 60 degC (140 degF) released at a temperature at or above Flash Point OR strong acidsbases (see definition Refer to draft RP 754 document) OR UNDG Class 2 Division 22 (non-flammable non-toxic gases) excluding air OR Other Packing Group III Materials | ge 200 kg (440 lb)orge 14 bbl | ge 100 kg (220 lb)orge 07 bbl | ||||
T2-8 | Liquids with Flash Point 60 degC (140 degF) and 93 degC (200 degF) released at a temperature below Flash Point OR Moderate acidsbases | ge 1000 kg (2200 lb)orge 7 bbl | ge 500 kg (1100 lb)orge 35 bbl |
None | |
$2500 to $25000 | |
$25000 to $250000 | |
$250000 to $25000000 | |
More than $25000000 | |
Yes - Using GHS TABLE | |
Yes - Using API RP 754 TABLE | |
NO | |
NA | |
1x le TQ lt 40x | |
40x le TQ lt 160x | |
160x le TQ lt 640x | |
ge 640x TQ | |
Yes le 3 hours | |
Yes 3 hours ge 12 hours | |
Yes 12 hours ge 24 hours | |
Yes ge 24 hours | |
No | |
Small-scale | |
Medium-scale | |
Large-scale | |
No | |
Yes | |
No | |
middot Injury requiring treatment beyond first aid to an employee contractor or subcontractor | |
middot Days Away From Work injury to an employee contractor or subcontractor or middot Injury requiring treatment beyond first aid to a third party | |
middot A fatality of an employee contractor or subcontractor or middot A hospital admission of a third party | |
middot Multiple fatalities of employees contractors or subcontractors or middot multiple hospital admission of third parties or middot A fatality of a third party | |
NA | |
1x le TQ lt 3x | |
3x le TQ lt 9x | |
9x le TQ lt 27x | |
ge 27x TQ |
ICCA Process Safety Pilot Reporting ProgramFebruary 8 2016 | 1 | 2 | 3 | 4 | 5 | 6 | 7 | 8 | 9 | 10 | 12 | 13 | 14 | 15 | |||||||||||||||||||||||
SAFETY Details(Meeting Local Regulations) | Direct Cost from Fire or Explosion | Community Impact | Environmental Impact | Material Released(Measured using the 1 Hour Rule) | |||||||||||||||||||||||||||||||||
Company Association Details | |||||||||||||||||||||||||||||||||||||
GHS | API - RP 754 | ||||||||||||||||||||||||||||||||||||
Company or Assocation Name | Headquarter Association | Location of Event Ex - City State amp Country | Date and Time of Event | Safety InjuryDid the Event result in a Recordable Lost Time Accident or Fatality or Hospital admission of anyone on or off siteUse Drop Down Menu | Safety InjuryIf yes please insert the total number of injuries | Safety InjuryFor puropses of utilizing the Severity Table please indicate the level of severity by chosing the MOST SEVERE classification that describes your incidentUse Drop Down Menu | Safety InjuryDid the incident involve Fatalities If so how many total fatalities If none enter Zero | Safety InjuryPlease Report Total Employee Hours for Calendar Year 2015 | Safety InjuryPlease Report Total Contractor Hours for Calendar Year 2015 | Direct Cost Did the Event result in Direct Damage CostUse Drop Down Menu | Direct Cost If so how muchAmount is in US DollarsUse Drop Down Menu | Community ImpactDid the event result inbull Officially declared shelter-in-place or officially declared evacuation (on or off site)ORbull Precautionary off site shelter in place or evacuation Use Drop Down Menu | Environmental ImpactDid the event result inAcute Environmental Remediation CostIf so indicate the amount in US DollarsUse Drop Down Menu | Material ReleasedDid the Event result in an Acute Release of material beyond one of the two threshold tablesIf so indicate which Threshold Table you used to make this determinationUse Drop Down Menu | Material ReleasedIf so indicate the amount released USING GHS CLASSIFICATION TABLEUse Drop Down Menu | Material ReleasedIf so indicate the amount released USING THE THRESHOLD TABLE FROM API RP-754Use Drop Down Menu | Material ReleasedIf available please indicate the material released | ||||||||||||||||||||
1 | ABC Chemical Company | American Chemistry Council | Washington DC - USA | January 4 2016 | Yes | 2 | middot Days Away From Work injury to an employee contractor or subcontractor or middot Injury requiring treatment beyond first aid to a third party | 0 | 5525000 | 1500250 | No | $2500 to $25000 | Yes le 3 hours | $2500 to $25000 | Yes - Using GHS TABLE | 40x le TQ lt 160x | NA | Chlorine | |||||||||||||||||||
2 | XYZ Chemical Company | American Chemistry Council | Washington DC - USA | 5-Jan-16 | Yes | 1 | middot Injury requiring treatment beyond first aid to an employee contractor or subcontractor | 0 | 5525000 | 1500250 | Yes | $2500 to $25000 | No | $2500 to $25000 | Yes - Using API RP 754 TABLE | NA | 3x le TQ lt 9x | Benzene | |||||||||||||||||||
3 | |||||||||||||||||||||||||||||||||||||
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25 | |||||||||||||||||||||||||||||||||||||
Zero or None | Yes - Duration Unknown | ||||||||||||||||||||||||||||||||||||
Processes | Mode of Operation | Type of material released | Status of Operation | ||||
REFINING | Start-up | Flammable | Open | ||||
Alkylation HF | Planned shutdown | Combustible | Closed | ||||
Alkylation sulfuric | Emergency shutdown | Toxic | |||||
BitumenResidAsphalt | Normal | Corrosive | Tier 1 Acute Releases | ||||
Calcining | Upset | Utilities | No Release | ||||
Coking | Turnaround | Other | Category 1 | ||||
Crude | Routine maintenance | Category 2 | |||||
Desulfurization | Temporary | Evacuation | Category 3 | ||||
FCC | Other | Yes | Category 4 | ||||
Gas Treating | No | Category 5 | |||||
Hydrogen | Point of Release | Category 6 | |||||
Hydrotreating | Pump | Fire | Category 7 | ||||
Hydrocracking | Compressor | Yes | Multiple Categories | ||||
Isom | BlowerFan | No | |||||
MarineJetty | Pressure Vessel | lt $2500 | |||||
Reforming | FilterCoalescer | ||||||
Sulfur recovery | Furnace | PRDs | |||||
Vapor recoverylight ends | Boiler | Directly to Atmosphere | |||||
Wastewater | Heat exchanger | via Downstream Destructive Device | |||||
REFINING amp PETROCHEMICAL | Cooling Tower | No | |||||
Tank FarmStorage FacilityOffsite | Piping system | Yes | |||||
UtilitiesSteam PlantCogeneration | Reactor | No | |||||
Other | Atmospheric tank | ||||||
PETROCHEMICAL | FlareRelief System | Acute release above thresholds | |||||
CO H2 | Other | Yes | |||||
LNG | No | ||||||
Methane | Events | ||||||
Methanol | No Tier 1 Events | Indoor Outdoor | |||||
Methyl Mercaptan | No Tier 2 Events | No Release | |||||
Formaldehyde | No Tier 1 or Tier 2 Events | Indoor | |||||
Formaldehyde derivatives | NA | Outdoor | |||||
Acetic Acid | |||||||
Acetic Acid derivatives | Event Type | ||||||
Ethane | Injury | ||||||
Ethylene | Fire | ||||||
Ethanol | Explosion | ||||||
Ethylene oxide | PRD Discharge | ||||||
Ethylene derivatives | Acute Release | ||||||
Polyethylene | |||||||
Ethylene dichloride | General | ||||||
Ethylene dichloride derivatives | Yes | ||||||
Ethyl benzene | No | ||||||
Ethyl benzene derivatives | |||||||
Polystyrene | |||||||
Styrene-Butadiene | |||||||
Propane | |||||||
Propylene | |||||||
Polypropylene | |||||||
Isopropanol | |||||||
Propylene oxide | |||||||
Propylene oxide derivatives | |||||||
Butane | |||||||
Isobutane | |||||||
Isobutene | |||||||
Butadiene | |||||||
MTBE | |||||||
ETBE | |||||||
Pentane | |||||||
Hexane | |||||||
Cyclohexane | |||||||
Hexanol | |||||||
Aromatics Derivatives | |||||||
Benzene | |||||||
Toluene | |||||||
Xylene | |||||||
Para Xylene | |||||||
Amines Derivatives | |||||||
TDA MDA IPDA etc | |||||||
Isocyanates | |||||||
Specialty Chemicals | |||||||
LoadingUnloading | |||||||
Pilot Plant |
Instructions | ||||||||||||||
Step 1 | Complete the Contact Tab with your contact information and company information | |||||||||||||
Be sure to note the region of your reporting (IE North America France Japan etc) | ||||||||||||||
Survey on Process Safety Events | ||||||||||||||
Step 2 | Complete the survey one line per Process Safety Event for your companyregion | |||||||||||||
ALL REPORTED DATA SHOULD BE FROM CALENDAR YEAR 2017 | ||||||||||||||
Step 3 | Return completed survey to | |||||||||||||
Company Name | ||||||||||||||
Contact Person | All Surveys Due by xxx date | |||||||||||||
Address | ||||||||||||||
Fax | ||||||||||||||
Telephone | ||||||||||||||
Region | ||||||||||||||
2016 | 2017 | 2018 | 2019 | 2020 | |||||
Feb - April RCLG PS Pilot Program May ndash Adjustmentsclarification to guidance document June Report outcomes of pilot program to RCLG and ICCA Board July - December middot RCLG associations consider guidance and develop reporting methodology for their memberships middot RCLG associations can request ICCA capacity building funds for PS reporting workshops for members if needed | Jan - Dec RCLG Association membership begin collecting PS data from their members Jan ndash Dec Associations hold workshops on Process Safety and performance reporting utilizing RCLG funds and experts if needed | Jan ndash Feb Reporting of process safety incidents to RCLG begins for associations with data (2017 data) April RCLG reviews outcomes challenges and raw data from the first reporting cycle (internally) June RCLG share draft data with ICCA Board July - December Update and adjust guidance as necessary Associations hold workshops on Process Safety and performance reporting utilizing RCLG funds and experts if needed | Jan ndash Feb Reporting of process safety incidents to RCLG begins for associations with data (2018 data) April RCLG reviews outcomes challenges and raw data from the second reporting cycle (internally) June RCLG share draft data with ICCA Board July - December Update and adjust guidance as necessary Associations hold workshops on Process Safety and performance reporting utilizing RCLG funds and experts if needed | Jan ndash Feb Reporting of process safety incidents to RCLG begins for all associations Process Safety incident reporting becomes part of the recommend base set of RCLG KPI metrics (2019 data) April RCLG reviews outcomes challenges and raw data from the second reporting cycle (internally consider external reporting) June RCLG share draft data with ICCA Board |
Name | Affiliation | ||
Peter Schmelzer | Bayer CEFIC - Chairman | ||
Americo Diniz Carvalho Neto | Braskem | ||
Bradford Johnson | American Chemistry Council | ||
David Cummings | DuPont | ||
Debra Phillips | American Chemistry Council | ||
Hans Schwarz | BASF | ||
Kathryn Walton | Plastics and Chemicals Industries Association | ||
Kazuyuki Akita | Japanese Chemical Industry Association | ||
Kelly Keim | ExxonMobil Chemical Company API Representative | ||
Kenan Stevick | Dow | ||
Kiyokazu Murata | Japanese Chemical Industry Association | ||
Larry Bowler | SABIC | ||
Lorna Young | Chemical Industry Association of Canada | ||
Louisa Nara | Center for Chemical Process Safety | ||
Associaccedilatildeo Brasileira da Induacutestria Quiacutemica | |||
Masatoshi Kumamoto | Japanese Chemical Industry Association | ||
Milton Lacerda | Petrobras | ||
Phil Scott | Chemical Industries Association | ||
Piet Knijff | DSM European Process Safety Centre | ||
Scott Donaldson and Eamon Chandler | Shell | ||
Scott Wallace | Olin Corporation | ||
Shakeel Kadri | Air Products and Chemicals Inc |
Event Incident Categories | |||||||||||
Severity Level | SafetyHuman Health | Direct Cost from Fire or Explosion | Material ReleaseWithin 1-Hr Period | Community Impact | Environmental Impact [off-site] | ||||||
Level 4 1 point | middot Injury requiring treatment beyond first aid to an employee contractor or subcontractor (Meets local regulations) | middot Resulting in Direct Damage Cost of $25 K le up to $25 K | middot Release volume between 1x le TQ lt 40x | middot Officially declared shelter-in-place or officially declared evacuation (on or off site) middot Precautionary off site shelter in place or evacuation le 3 hours | middot Acute Environmental Remediation Cost $25 K le up to $25 K | ||||||
Level 3 3 points | middot Days Away From Work injury to an employee contractor or subcontractor or middot Injury requiring treatment beyond first aid to a third party (Meets local regulations) | middot Resulting in Direct Damage Cost of $25 K le up to $250 K | middot Release volume between 40x le TQ lt 160x | middot Officially declared shelter-in-place or officially declared evacuation (on or off site) middot Precautionary off site shelter in place or evacuation 3 hours ge up to 12 hours | middot Acute Environmental Remediation Cost $25 K le up to $250 K | ||||||
Level 2 9 points | middot A fatality of an employee contractor or subcontractor or middot A hospital admission of a third party (Meets local regulations) | middot Resulting in Direct Damage Cost of $250 K le up to $25 MM | middot Release volume between 160x le TQ lt 640x | middot Officially declared shelter-in-place or officially declared evacuation (on or off site) middot Precautionary off site shelter in place or evacuation 12 hours ge up to 24 hours | middot Acute Environmental Remediation Cost $250 K le up to $25 MM | ||||||
Level 1 27 points | middot Multiple fatalities of employees contractors or subcontractors or middot multiple hospital admission of third parties or middot A fatality of a third party (Meets local regulations) | middot Resulting in Direct Damage Costs of ge $25 MM | middot Release volume ge 640x TQ | middot Officially declared shelter-in-place or officially declared evacuation (on or off site) middot Precautionary off site shelter in place or evacuation ge 24 hours | middot Acute Environmental Remediation Cost ge $25 MM |
It is recognized that threshold quantities given in kg and lb or in lb and bbl are not exactly equivalent Companies should select one of the pair and use it consistently for all recordkeeping activities | |
In determining the Threshold Release Category for a material one should first use the toxic (TIH Zone) or flammability (Flash Point and Boiling Point) or corrosiveness (Strong Acid or Base vs Moderate Acid or Base) characteristics Only when the hazard of the material is not expressed by those simple characteristics (eg reacts violently with water) is the UNDGL Packing Group used a Many materials exhibit more than one hazard Correct placement in Hazard Zone or Packing Group shall follow the rules of DOT 49 CFR 1732a [14] or UN Recommendations on the Transportation of Dangerous Goods Section 2 [12] See Annex F b A structure composed of four complete (floor to ceiling) walls floor and roof c For solutions not listed on the UNDG the anhydrous component shall determine the TIH zone or Packing Group classification The threshold quantity of the solution shall be back calculated based on the threshold quantity of the dry component weight d For mixtures where the UNDG classification is unknown the fraction of threshold quantity release for each component may be calculated If the sum of the fractions is equal to or greater than 100 the mixture exceeds the threshold quantity Where there are clear and independent toxic and flammable consequences associated with the mixture the toxic and flammable hazards are calculated independently See Annex E PSE Examples amp Questions 49 - 53 e A LOPC of Liquids with Flash Point gt 60 degC (140 degF) and 93 degC (200 degF) released at a temperature below Flash Point cannot be Tier 1 PSE based upon quantity released no matter the volume f A LOPC of a moderate acidbase cannot be Tier 1 PSE based upon quantity released no matter the volume |
Threshold Release Category | Material Hazard Classification acdef | Threshold Quantity (outdoor release) | Threshold Quantity (indoorb release) | ||||
T2-1 | TIH Zone A Materials | ge 05 kg (11 lb) | ge 025 kg (055 lb) | ||||
T2-2 | TIH Zone B Materials | ge 25 kg (55 lb) | ge 125 kg (275 lb) | ||||
T2-3 | TIH Zone C Materials | ge 10 kg (22 lb) | ge 5 kg (11 lb) | ||||
T2-4 | TIH Zone D Materials | ge 20 kg (44 lb) | ge 10 kg (22 lb) | ||||
T2-5 | Flammable Gases OR Liquids with Normal Boiling Point 35 degC (95 degF) and Flash Point 23 degC (73 degF) OR Other Packing Group I Materials (excluding acidsbases) | ge 50 kg (110 lb) | ge 25 kg (55 lb) | ||||
T2-6 | Liquids with Normal Boiling Point 35 degC (95 degF) and Flash Point 23 degC (73degF) OR Other Packing Group II Materials (excluding acidsbases) | ge 100 kg (220 lb)orge 07 bbl | ge 50 kg (110 lb)orge 035 bbl | ||||
T2-7 | Liquids with Flash Point 23 degC (73 degF) and 60 degC (140 degF) OR Liquids with Flash Point 60 degC (140 degF) released at a temperature at or above Flash Point OR strong acidsbases (see definition Refer to draft RP 754 document) OR UNDG Class 2 Division 22 (non-flammable non-toxic gases) excluding air OR Other Packing Group III Materials | ge 200 kg (440 lb)orge 14 bbl | ge 100 kg (220 lb)orge 07 bbl | ||||
T2-8 | Liquids with Flash Point 60 degC (140 degF) and 93 degC (200 degF) released at a temperature below Flash Point OR Moderate acidsbases | ge 1000 kg (2200 lb)orge 7 bbl | ge 500 kg (1100 lb)orge 35 bbl |
1
目錄
前言 2
背景 5
執行摘要 5
RCLG 各協會應向 RCLG 提報的數據 7
ICCA 製程安全事件判定標準流程圖 8
須提報製程安全事件之重要標準 9
製程安全事件判定準則 10
表 1 ndash GHS 分類表 14
表 2 ndash API RP 754 Tier II 分類表 15
附錄 A ndash 嚴重程度表鼓勵所有協會均採用嚴重程度加權制度 17
附錄 B ndash 常見問題集 19
Appendix C ndash List of RCLG Taskforce Members 25
附錄 D ndash 詳細活動時程表 26
附錄 E ndash 選擇性 Excel 追蹤表 27
後語 28
2016 年 6 月 15 日
Dear Members of the Taiwan Responsible Care Association We would like to express our deep appreciation for the work of ICCA and the Responsible Care Leadership Group in developing this valuable guidance which we are delighted to bring under the umbrella of the Taiwan Responsible Care Association Process safety reporting is at the very heart of Responsible Care It has been a proven practice in the chemical industry for decades We strive continuously to improve our management procedures to reduce the occurrence of chemical incidents and measuring is absolutely crucial to that process ndash for you cannot improve what you do not measure Reporting enables companies and associations to share best practices and improve their performance while reducing their environmental footprint Learning from incidents has been key to improving process safety to todayrsquos low levels and we aim to bring them down further still Although the industry has long been tracking and reporting process safety performance at a regional level this proposal for process safety event reporting will for the first time enable broad-based and global reporting of process safety performance right across the chemical and petrochemical industries We invite all members of the Taiwan Responsible Care Association to implement this guidance by 2020 and are committed to helping them do so The national chemical industry associations play a vital role in promoting best practice and we look to them to roll out the guidance to their member companies It is our sincere hope that these guidelines will contribute to enhancing process and plant safety throughout Taiwan For your reference the original and globally applicable guidance
ICCA Process Safety
Guidance_Finaldoc
Patrick Vandenhoeke Head of Responsible Care Leadership Group
3
敬愛的 TRCA 會員
對於 ICCA (International Council of Chemical Associations 國際化學工業協會) 和責任照顧領
導群在制定這一項寶貴指引時的付出我們表達最深的感謝 我們很高興能夠為 TRCA帶來
這一項可作為保護傘的寶貴指引
製程安全是責任照顧制度的核心也是化學工業數十年來成熟的實踐我們不斷努力改善
管理程序以減少化學事故的發生量測對於製程安全管理是絕對至關重要的一環因為我
們無從改進沒有進行過量測的項目提報(製程安全指標)使得公司與協會得以分享最佳典
範在提高績效表現的同時減少環境足跡從事件中學習是改善製程安全達到低事件率的
關鍵我們的目標是再進一步降低製程安全事件率
儘管化工業長期以來一直在各地區追蹤與提報製程安全績效但此次製程安全事件提報的
建議將首度啟用更廣泛的基礎在全球提報製程安全績效提報部門將包括化學工業與石
化工業
我們邀請 TRCA 的所有會員在 2020 年前一同來推行這項提報指引我們也將致力於協助各
位達標國家化學工業協會在推廣最佳實務方面扮演重要角色我們期待他們向所屬會員
公司推動本指引
我們誠摯地希望這些指導方針將有助於台灣提升製程和工廠的安全
謹提供全球適用的指引原始檔案如下請參考
Patrick Vandenhoeke
責任照顧領導群主席
GUIDANCE FOR REPORTING ON THE ICCA GLOBALLY HARMONIZED PROCESS SAFETY METRICJune2016The Responsible Carereg Leadership Group
ContentsBackground2Executive Summary2Data to be reported by RCLG Associations to RCLG4Overview of ICCA Process Safety Event Criteria as a Flow Chart5Key Criteria for Reporting Process Safety Events to RCLG6Detailed Guidelines on Identifying a Process Safety Event7Table 1 ndash GHS Classification Table11Table 2 ndash API RP 754 Tier II Classification Table12Appendix A ndash Severity Table Using A Severity Weighting System is Encouraged for All Associations14Appendix B ndash Frequently Asked Questions16Appendix C ndash List of RCLG Taskforce Members22Appendix D ndash Detailed Schedule of Events23Appendix E ndash Optional Excel Reporting Form24
FIANL DRAFT
June 15 2016
The Responsible Carereg initiative began in 1985 and as the chemical industryrsquos commitment to continuous performance improvements Process Safety has been a pillar of Responsible Care since its inception and many regional approaches to tracking and reporting process safety performance have developed over the 30 years of Responsible Care implementation yet no globally harmonized system had been put into place In 2012 in the wake of several high profile process safety events the International Council of Chemical Associations (ICCA) Board of Directors directed the Responsible Care Leadership Group (RCLG) to develop a recommendation for a globally harmonized process safety performance reporting by no later than 2015
Throughout 2013 and 2014 a Taskforce comprised of multinational companies and RCLG associations chaired by Dr Peter Schmelzer Head of Health Safety and Environmental Protection Bayer HealthCare AG worked to develop a globally harmonized ICCA approach to process safety performance reporting A list of Taskforce members can be found in Appendix C During the same timeframe the American Petroleum Institute (API) also initiated a process to update its Recommend Practice 754 (RP-754) ndash Leading and Lagging Process Safety Metric Standard RP-754 is broadly used in the refining and petrochemical sector and in the Americas region to track process safety performance To optimize global adoption of a unified standard the RCLG Taskforce strived to achieve full harmonization of its recommendation with the revised API RP 754 metric expected to be finalized in the first quarter 2016
Executive SummaryAfter more than 2 years of discussion research debate and feasibility assessment the Process Safety Harmonization Taskforce recommends that ICCA adopt a process safety event rate metric The adoption of this metric would require each RCLG association to collect the number of process safety events experienced by their members on an annual basis as well as total number of worker hours (employees and contractors) experienced by their members each year The process safety event rate is the ratio of events to hours The Taskforce also recommends that reporting of these data points to the RCLG be phased in over the next 3 years allowing regions with the desire and ability to report immediately to do so while also allowing additional time to companies and organizations that are developing the ability to track these data for the first time
The criteria that determine whether a process-related event qualifies as a process safety event are based on a loss of primary containment of a chemical or a release of energy triggering thresholds any one of four impact areas 1) safetyhuman health consequences 2) direct cost due to damage from incident 3) community impact and 4) chemical release quantity (see the flow chart showing reporting triggers) These four impact areas in the recommended ICCA process safety event definition are identical to the impact areas in the RP-754 Tier II incident standard The thresholds for reporting are also identical in all areas with the exception of the chemical release quantity thresholds To address this difference the ICCA process safety event definition will allow companies the use of either the GHS-based reporting thresholds developed by ICCA for the chemical release criteria or the UN Dangerous Goods (UNDG)-based reporting thresholds used in the RP-754 standard for Tier II incidents The Taskforce believes that the two systems though different are comparably robust in the universe of chemicals covered and the severity of incidents captured by reporting While there will be relatively little difference in the numbers of events captured and reported using the two different threshold approaches there may be differences that would be most clearly seen at the company level based on raw material and product use hence the Taskforce cautions companies not to compare their results with companies that use a different chemical release threshold approach Regardless under the RCLG proposal companies can choose the chemical release thresholds by which they report in to their national and regional associations If associations are interested in translating results based on one reporting approach to another the RCLG will provide a translation table However given the complexity of this exercise and the need to access raw incident data the Taskforce does not believe that this adds value and recommends against it
The Taskforce believes that this proposal for process safety event reporting will enable broad-based global reporting of process safety performance across the chemical and petrochemical industries It will provide a roadmap for regions associations and companies that are currently not tracking process safety performance to recognize the benefits that tracking and reporting will bring For regions associations and companies that are already experienced in gathering process safety data this recommendation allows for broader global alignment and focus on continuous improvement in process safety performance The systems that are built to improve process safety performance are informed by robust process safety event data and this is the major objective of this initiative
Data to be reported by RCLG Associations to RCLGOn an annual basis RCLG Associations will be asked to report two data points into ICCA using the RCLG KPI Reporting Website on the schedule provided below
1Total Member Company Worker Hours for Association (employee and contractor)
2Total Number of Process Safety Events
ICCA will use the above two data points to report process safety performance in the form of Process Safety Event Rate (PSER) normalized per 100 employees where an employee works 2000 hours a year
(Total Events Total Hours) x 200000 = PSER
Recommended Reporting Schedule
The Taskforce recommends a phased-in approach for reporting process safety event rate Such a schedule will allow more experienced companies and associations to report in the next several years while allowing other companies and associations to begin reporting by 2019 RCLG Associations would be asked to report the two process safety event rate data points annually to the ICCA through the RCLG KPI metrics reporting system If you do not know your associationrsquos username and password please contact the RCLG
The proposed schedule for process safety event rate reporting by RCLG associations is as follows
April 2015RCLG considers Taskforce proposal
June 2015ICCA Board of Directors considers RCLG final recommendation
July 2015RCLG releases the first detailed reporting guidance document for associations and member companies
Feb 2016 RCLG Reporting RCLG initiates process safety reporting pilot program through association volunteers with updated an enhanced guidance document RCLG rolls out final guidance document in June 2016
2017RCLG Associations begin collecting data from its membership
2018-2019 RCLG Reporting Optional process safety data reporting by RCLG Associations
2020 ReportingRCLG includes process safety as a mandatory metric in the KPI reporting program
See Appendix D ndash Detailed Schedule of Events
Overview of ICCA Process Safety Event Criteria as a Flow ChartNO Does not meet the criteria for a Process Safety Event
Start
NO
NO
NO
Was a chemical substance or a chemical process directly involved
YES
YES
Release of material fire explosion or implosion fromat a chemical process unit
Incident in production distribution storage utilities pilot plants within a companyrsquos facility
YES
NO
Officially declared shelter in place or evacuation
Or Precautionary off site shelter in place or evacuation
Substance Release Thresholds met
Recordable injury
Or
hospital admission of people on or off site
Damage ge $2500direct costto company
NO
NO
NO
ICCA or API 754 Tier II chemical release thresholds exceeded
YES
YES
YES
Yes Reportable as a Process Safety Event
YES
Key Criteria for Reporting Process Safety Events to RCLGTotal Worker Hours
RCLG Associations should report the total number of employee hours worked for each member company in their association and the total number of contractor hours worked for each member company as a combined single number For the purposes of this guidance document each association should refer to their local and regional definitions for employee and contractor The goal for reporting total hours is to include all individuals who are involved with chemical manufacturing except where those individuals are tasked with major construction projects such as large scale investments with specific one-time project organizations created for design engineering and construction of new or significant expansion to existing process facilities When reporting total worker hours companies should report the same hours used for reporting personnel hours This way companies can have the same data set for occupational and process safety Personnel hours should include those hours from all chemical manufacturing operations not just from facilities where a process safety incident occurred
Process Safety Event
For the purposes of this ICCA Reporting a process safety event has occurred when
A When a chemical substance or a chemical process is directly involved AND
B The incident occurred in production distribution storage utility pilot plant within the site boundaries of companyrsquos facility AND
C There was a release of material or energy (eg fire explosion implosion) from a process unit AND
D One or more of the following Reporting Thresholds have been met
1 Safety Injury
middot Injury resulting in a Recordable Lost Time Accident or Fatality or Hospital admission of anyone on or off site OR
2 Direct Damage Cost
middot A fire explosion or clean up necessary to avoidremediate environmental damage resulting in a direct cost equal to or greater than $2500 USDs OR
3 Shelter in Place Evacuation
middot An officially declared shelter in place (on or off site) OR
middot An officially declared evacuation (on or off site) OR
middot A precautionary off site shelter in place or evacuation OR
4 Threshold Release
middot The material released meets one of the GHS thresholds in Table 1 (measured in amount released during one hour)
As an alternative companies can choose to use the release thresholds contained in the API RP-754 standard ndash Table 2 Note ndash Individuals who would like to view the API RP-754 Standard may purchase and download that standard at - Detailed Guidelines on Identifying a Process Safety Event A Chemical InvolvementWhen a chemical substance or chemical process is directly involved
A chemical or chemical process must have been directly involved in the event or incident For this purpose the term process is used broadly to include the equipment and technology needed for petrochemical production including reactors tanks piping boilers cooling towers refrigeration systems etc An incident with no direct chemical or process involvement eg an office building fire even if the office building is on a plant site is not reportable
B LocationThe incident occurred in production distribution storage utility pilot plant within the site boundaries of companyrsquos facility
The incident occurs in production distribution storage (including active storage areas such as warehouses ndash see FAQ section) utilities or pilot plants of a facility reporting metrics under these definitions This includes tank farms ancillary support areas (eg boiler houses and waste water treatment plants) and distribution piping under control of the site All reportable incidents occurring at a location will be reported by the company that is responsible for operating that location This applies to incidents that may occur in contractor work areas as well as other incidents At tolling operations and multi-party sites the company that operates the unit where the incident initiated should record the incident and count it in their reporting
C Release of MaterialThere was a release of material or energy (eg fire explosion implosion) from a process unit
Release of Material ndash an unplanned or uncontrolled release of any material including non-toxic and non-flammable materials (eg steam hot water nitrogen compressed CO2 or compressed air) from a process that results in consequences that exceed one or more of the 4 Reporting Thresholds listed in this document
A release to a flare or scrubber is still considered to be within the primary containment as long as the mitigation system (eg scrubber flare) is operated under normal conditions without any release above the thresholds defined for normal operation A release to a secondary containment (eg waste water treatment or dike) will qualify as a process safety event because the substance is leaving the primary process system
D ThresholdsOne or more of the following Reporting Thresholds must be met for reportable process safety events
1 Safety Injury
Injury resulting in a Recordable Lost Time Accident or Fatality or Hospital admission of anyone on or off site Recordable injuries are work-related injuries that results in any of the following death days away from work restricted work or transfer to another job medical treatment beyond first aid loss of consciousness or a significant injury diagnosed by a physician or other licensed health professional
Lost time injuries and fatalities that occur as a result of process related loss of primary containment fire or explosion are those that fit into one of the following categories
middot Employee (Lost time andor Fatality)
middot Contractor and Subcontractor (Lost time andor Fatality)
middot Third Party (Injuryillness resulting in Hospital Admission or Fatality)
Hospital Admission ndash formal acceptance by a hospital or other inpatient health care facility of a patient who is to be provided with room board and medical service in an area of the hospital or facility where patients generally reside at least overnight Treatment in the hospital emergency room or an overnight stay in the emergency room would not by itself qualify as a ldquohospital admissionrdquo
Examples of injury or fatality cases that would be reportable include a burn injury resulting from steam released during cleaning a physical injury from a cap blown off by pressure during a pressure test or a chemical burn from a spill while taking a sample Examples of injuries or fatality cases that would not be reportable include a fall from an elevated work station while performing maintenance a burn from a fire in a laboratory or office building or injuries from an excavation cave-in None of these cases are directly due to the release of energy or material from the process
2 Direct Damage CostA fire explosion or clean up necessary to avoidremediate environmental damage resulting in a direct cost equal to or greater than $2500 USDs
Costs to be considered for this threshold should be those costs directly attributed to the fire andor explosion such as the replacement value of equipment lost structures lost cost of repairs environmental cleanup (on and off site) emergency response andor fines Direct cost does not include indirect costs such as business opportunity losses loss of profits due to equipment outages cost of obtaining or operating temporary facilities or cost of obtaining replacement products to meet customer demand (product losses)
3 Shelter in Place Evacuation
An officially declared shelter in place or evacuation either on or off site OR a precautionary shelter in place or evacuation off site
For the purposes of this reporting an officially declared shelter in place or evacuation on or off site OR a precautionary shelter in place or evacuation is declared off site would trigger this threshold
Officially Declared ndash A declaration by a recognized community official (eg fire police civil defense emergency management) or delegate (eg Company official) authorized to order the community action (eg shelter-in-place evacuation)
Precautionary Declaration - A precautionary public response is a measure taken from an abundance of caution and issued by a recognized community official or delegate whom has reasonably determined that such an evacuation or shelter in place was necessary to protect the public health and safety
Shelter in Place ndash is the use of a structure and its indoor atmosphere to temporarily separate individuals from a hazardous outdoor atmosphere
Evacuation ndash the act or process of removing persons from a place for reasons of safety or protection
4 Threshold ReleaseAn acute release that exceeds one of the GHS thresholds in Table 1 or in the API 754 standard for Tier II process safety release thresholds in Table 2 (measured in amount released during one hour)
As mentioned in the Executive Summary the ICCA process safety event definition allows use of either GHS-based reporting thresholds developed by ICCA for the chemical release criteria or the UN Dangerous Goods (UNDG)-based reporting thresholds used in the RP-754 standard for Tier II incidents The GHS thresholds are listed in Table 1 It is intended for companies to decide which table to use and to allow companies the option to use one system globally
Acute Release ndash A release of flammable combustible or toxic chemicals from the primary containment (ie vessel or pipe) greater than the chemical release threshold quantities is described for GHS Classification Table 1 and in the API 754 standard for Tier II process safety release thresholds in Table 2
Pressure Relief Device Acute Releases defined above include releases to a properly designed and operating pressure relief device if a quantity is released greater than or equal to the threshold quantities in Table 1 OR in the API 754 standard for Tier II process safety release thresholds Table 2 that results in one or more of the following four consequences
1 Rainout
2 Discharge to a potentially unsafe location
3 A n on-site shelter-in-place or on-site evacuation excluding precautionary on-site shelter-Ain-place or on-site evacuation
4 Public protective measures (eg road closure) including precautionary public protective measures
Releases to a properly designed and operating pressure relief device (such as a flare scrubber etc) do not have to be reported if they do not meet one of the four criteria above
Individuals who would like to view the API RP-754 Standard may download that standard at -
httpwwwapiorgenvironment-health-and-safetyprocess-safetyprocess-safety-standardsstandard-rp-7541 Hour Rule
For the purpose of the reporting under this metric release thresholds are established for materials over a one-hour time frame If the release amount of a material reaches or exceeds the reporting threshold in a 1-hour time period or less it is reportable Typically acute releases occur in 1-hour or less If the duration of the release cannot be determined the duration should be assumed to be 1 hour
Primary Containment ndash A tank vessel pipe rail car or equipment intended to serve as the primary container or used for the transfer of the material Primary containers may be designed with secondary containment systems to contain and control the release Secondary containment systems include but are not limited to tank dikes curbing around process equipment drainage collection systems into segregated oily drain systems the outer wall of double walled tanks etc
Severity Table Severity weighting can provide additional useful information about process safety events that may help drive performance improvement Appendix A is the RCLG methodology for calculating a severity weight for process safety events Using Appendix A a severity weight for each process safety event may be calculated by summing the points associated with each consequence category The ICCA strongly encourages the use of a severity weighting system as the use of such a system increases the ability to communicate performance and is an easier way for our stakeholders to understand process safety events Also the severity weight will not be comparable among other process safety metric reporting formats
Table 2 ndash API RP 754 Tier II Classification Table
2
Appendix A ndash Severity Table Using A Severity Weighting System is Encouraged for All AssociationsSeverity Table (Appendix A) Details
Appendix A above is designed to be used with the GHS Classification System ONLY (Table 1) If your company is using the API RP 754 Tier II Process Safety Metric Threshold Table Table 2 in this document please use the API RP 754 Process Safety Severity Table It is important to state that the severity table in the API RP 754 Standard is for Tier 1 incidents only Comparing the relative severity of events using different tables will not be statistically valid
Acute Environmental Cost - Cost of short-term cleanup and material disposal associated with a PSE with off-site environmental impact Companies may choose to assign severity to costs associated with off-site environmental impacts in a separate category
Rate Adjusted Metrics
Utilizing the severity table described above there are a variety of rate-based metrics which can be generated These include
Process Safety Total Incident Rate (PSTIR) Total event incidents x 200000___
Total Worker Hours
Process Safety Incident Severity Rate (PSESR) (ie severity-weighted Process Safety incident rate formula)
Total severity score for all events incidents x 200000___
PSESR = Total Worker Hours
In determining this rate 1 point is assigned for each Level 4 incident attribute 3 points for each Level 3 attribute 9 points for each Level 2 attributes and 27 points for each Level 1 attributes Theoretically a process safety event could be assigned a minimum of 1 point (ie the incident meets the attributes of a Level 4 incident in only one category) or a maximum of 135 points (ie the incident meets the attributes of a Level 1 incident in each of the five categories)
PS Level ldquoXrdquo incident rate Total Severity Level ldquoXrdquo PS incidents x 200000
Total employee contractor amp subcontractor work hours
Where X can be the total count of Severity Level 4 3 2 or 1 incidents The severity level of an incident is the maximum severity rating of the five consequence categories
Normalization ndash In some associations and member companies process safety events are normalized on a lsquoper 100rsquo employee basis given that a one worker averages 2000 per year So to normalize on a lsquoper 100rsquo employee basis events are multiplied by 200000 worker hours In other associations and member companies events are normalized on a lsquoper 500rsquo employee basis and events are multiplied by 1000000 worker hours Associations and members should discuss this option and come to a conclusion together The above formulas are set at a lsquoper 100rsquo employee rate
15
(K = 1000 MM = 1000000) (For Environmental Impact companies and associations should agree on input criteria where definitions arenrsquot readily available)
Appendix B ndash Frequently Asked QuestionsApplicability
It is recommended that companies record and report Process Safety Events occurring at Company-owned or operated facilities except as noted below
1 PSEs that originated off Company property
2 Marine transport vessel incidents except when the vessel is connected to the facility for the purposes of crude or product transfer
3 Truck andor rail incidents except when the truck or rail car is connected to the facility for the purposes of crude or product transfer
4 Routine emissions that are allowable under permit or regulation
5 Underground contamination that had no process safety consequences Note The exclusion does not apply if the release resulted in an aboveground reportable PSE such as release of toxic vapors or pooling of flammable liquids
6 Office building incidents (eg office heating equipment explosions fires spills releases personnel injury or illness etc)
7 Personnel safety sliptripfall incidents that are not directly associated with evacuating from or responding to a loss of containment incident
8 Loss of Primary Containment (LOPC) incidents from ancillary equipment not connected to the process (eg small sample containers)
9 Planned and controlled drainage of material to collection or drain system designed for such service (Note Exclusion does not apply to an unintended and uncontrolled release of material from primary containment that flows to a collection or drain system)
10 Mechanical work being conducted outside of process units or in maintenance shops
Interpretations and Examples ndash Based on GHS Table 1
The following interpretations and examples have been prepared to help clarify areas of potential uncertainty in the evaluation of reportable Process Safety Incidents (PSE)
COMPANY PREMISES
1 A third-party truck loading a flammable product on Company Premises experiences a leak and subsequent fire and property loss damages of $7000 (direct costs) Although the truck is Operated-by-Others it is connected to the process The incident would be a reportable PSE if property losses in direct costs were equal to or greater than $2500 or some other PSE threshold was met or exceeded (eg a fatality)
2 Similar example as 1 The truck loaded with flammable product overturns in route out of the plant resulting in a fire and loss of the truck This would not be reported as a PSE since the truck is no longer connected to the plant
LOSS OF CONTAINMENT
3 A faulty tank gauge results in the overfilling of a product tank containing ldquoflammable liquidsrdquo Approximately 700 kg of liquid overflows into the tanks diked area This incident is a reportable PSE since it is an acute spill greater than 100 kgs regardless of secondary containment
4 A maintenance contractor opens a process valve and gets sprayed with sulfuric acid resulting in a severe burn and lost time injury This would be a reportable PSE It is an unintended event involving a material and a loss of containment For fatalities and days away from work injuries and illnesses there is no release threshold amount
5 An operator opens a quality control sample point to collect a routine sample of product and receives a bad hand laceration requiring stitches due to a broken glass bottle and misses the next day of work This is not a reportable PSE because it is not related to a loss of containment
ACUTE RELEASES
6 While troubleshooting a higher-than-expected natural gas flow rate operating personnel find a safety valve on the natural gas line that did not reseat properly and was relieving to the atmospheric vent stack through a knock-out drum Upon further investigation it is determined that a total of 100000 kg of natural gas was relieved at a steady rate over a 6 month period This is not a reportable PSE as the release rate (~10 kg per hour) is not ldquoacuterdquo (ie does not exceed the 100 kg TQ for flammable vapors per 1 hour time period)
FLARES amp EMISSION CONTROL DEVICES (eg scrubbers)
7 If a chemical is routed to a flare or emission control device (eg scrubber) it would not be classified as a PSE as long as that flare or control device operates as designed
8 If a scrubber is overwhelmed by a flowrate greater than the design of the scrubber system and discharges a chemical in excess of the reporting threshold it would be reported as a PSE as noted about in this document
As a note an upset emission from a permitted or regulated source ndash including pressure relieve devices - of a quantity greater than or equal to the threshold quantities in Table 1 or 2 in any one-hour period that results in one or more of the following four consequences
middot rainout
middot discharge to a potentially unsafe location
middot an on-site shelter-in-place or on-site evacuation excluding precautionary on-site shelter-in-place or on-site evacuation
middot public protective measures (eg road closure) including precautionary public protective measures
Should be reported as a PSE
SAFETY RELIEF DEVICE SYSTEM
9 There is a unit upset and the relief valve opens to an atmospheric vent which has been designed resulting in a gas release to the atmosphere with no adverse consequences This would not be a reportable PSE since vapors and gases released to atmosphere from safety valves high-pressure rupture disks and similar safety devices that are properly designed for that event per API Standard 521 or equivalent are excluded as long as the release did not result in (1) a liquid carryover that created a reportable PSE related to the liquid (eg lost time incident fatality a fire or explosion that caused $2500 or more of direct cost liquid release or toxic aerosol release at or above threshold amounts etc) or (2) activation of a shelter-in-place response on or off-site or (3) public protective measures be taken
10 There is a unit upset and the relief valve fails to open resulting in overpressure of the equipment and an acute release of flammable gas from a leaking flange The amount released is above the 100 kg (within 1 hour) threshold This is a reportable PSE Releases from flanges are not excluded from PSE reporting
DAYS AWAY FROM WORK INCIDENTS
11 An operator is walking then slips and falls to the floor and suffers a lost time injury The slipfall is due to weather conditions chronic oily floors and slippery shoes This is not a reportable PSE Personnel safety sliptripfall incidents that are not directly associated with evacuating from or responding to a loss of containment incident are specifically excluded from PSE reporting
12 Same as above except that the operator slipped and fell while responding to a small flammable liquid spill (eg less than 10 kg in 1 hour) This would be PSE reportable since the operator was responding to a loss of containment incident A PSE is reportable if the loss of primary containment occurs on Company Premises and results in a lost time incident or fatality For fatalities and lost time incidents there is no release threshold amount
13 Same as above except that the operator slipped and fell several hours after the incident had concluded This would not be PSE reportable The terms evacuating from and responding to in the reporting exclusion mean that the loss of containment and associated emergency response activities are on-going Slipstripfalls after the event have concluded (such as after-the-fact clean-up and remediation) are excluded from PSE reporting
14 A scaffold builder suffers a lost time injury after falling from a scaffold ladder while evacuating from a loss of containment incident on nearby equipment This is a reportable PSE
15 An operator walks past an improperly designed steam trap The steam trap releases and the operators ankle is burned by the steam resulting in a lost time injury This is a reportable PSE because even though the loss of containment was steam (vs hydrocarbon or chemical) the physical state of the material was such that it caused a lost time injury
16 An enclosure has been intentionally purged with nitrogen A contractor bypasses safety controls enters the enclosure and dies This is a reportable fatality but not a reportable PSE since there was no unplanned or uncontrolled loss of primary containment
17 Same as above except that nitrogen inadvertently leaked into the enclosure This would be a reportable PSE (and fatality) since there was a fatality associated with an unplanned loss of primary containment
18 An operator responding to an H2S alarm collapses and has a injury If the alarm was triggered by an actual unplanned or uncontrolled H2S LOPC the event would be a reportable PSE If the alarm was a false alarm the event would not be a reportable PSE because there was no actual release
PIPELINES
19 A pipeline leaks and releases 2000 lbs (900 kgs) of flammable vapor above ground within 1 hour However the release occurred in a remote location within the site The release is PSE reportable since remoteness is not a consideration
FIRES or ENERGY RELEASES NOT ASSOCIATED WITH CHEMICAL RELEASE
As a general rule a fire or energy release is reported as a PSE only if caused by chemical release or results in a chemical release in excess of the reporting quantities Examples include
20 An electrical fire impacts the operation of the process resulting in the release of 400 kg of toluene This event would be reported as a PSE since if the chemical release exceeds the 100 kg reporting threshold for toluene
21 An electrical fire loss of electricity or any other loss of utility occurs which may cause a plant shutdown and possibly incidental equipment damage greater than $2500 (eg damage to reactors or equipment due to inadequate shutdown) but does not create a chemical release greater than the threshold quantity or cause a fatality or serious injury This event would not be reported as a PSE since the equipment damage was not caused by a chemical process fireexplosion and there was not a chemical release greater than the threshold quantity
MARINE TRANSPORT VESSELS
22 A company operated Marine Transport Vessel has an onboard acute spill of combustible material greater than 100 kg The event is not PSE reportable since Marine Transport Vessel incidents are specifically excluded except when the vessel is connected to the refinery petrochemical or chemical manufacturing facility for the purposes of crude or product transfer
23 A third-party barge is being pushed by a tug and hits the company dock A barge compartment is breached and releases 1000 kg of diesel to the water The event is not a reportable PSE since the marine vessel was not berthed at the dock and actively involved in crude or product transfer operations
TRUCK AND RAIL
24 A company railcar derails and spills more than 1000 kg of gasoline while in transit The incident is not PSE reportable since rail incidents off company property are specifically excluded
25 A third-party trucktrailer overturns while in the Company Premises resulting in an acute spill of gasoline greater than 1000 kg The incident is not reported as a PSE reportable if the truck is no longer connected to the loadingunloading facilities However it is recommended that companies also have transportation incident metrics which would capture this event
26 A contract truck hauler is unloading caustic and the hose separates and generates an airborne aerosol andor liquid caustic spill of 2500 kg The event is a reportable PSE since the caustic TQ of 100 kg was exceeded and the truck was still connected to the loadingunloading facility immediately prior to the incident
OFFICE BUILDING
27 There is a boiler fire at the Main Office complex and direct cost damages totaled $75000 The incident is not PSE reportable since Office Building incidents are specifically excluded
MAN-MACHINE INTERFACE INCIDENTS
28 An operations technician is injured while working around the finishing equipment in a polymers plant The injury is caused by the mechanical man-machine interface with the equipment This would not be a reportable Process Safety Event because there was no loss of containment of hazardous material
MIXTURES
29 If a mixture by itself has a GHS classification you use that classification to determine the threshold If the mixture itself does not have a GHS-classification we go back to the individual components of the mixture and based on kg released per threshold group calculate a lsquoweightedrsquo contribution to the thresholds Example a release of 100 kg of a mixture in a one hour period that consists of 05 kg of a substance classified as acute toxic H300 45 kg of substance classified with H301 and 40 kg of a substance with another H-number and the remaining 55 kg of water with no GHS classification would be calculated as 051 + 4510 + 40100 = 05 + 045 + 04 = 135 is exceeding 1 and would be counted as a reportable process safety incident even though none of the individual hazardous components exceeded the threshold for the individual substance
DIRECT DAMAGE COSTS
30 Direct damage costs are considered for this threshold should be those costs directly attributed to the fire andor explosion such as the replacement value of equipment lost structures lost cost of repairs environmental cleanup emergency response andor fines Direct cost does not include indirect costs such as business opportunity losses loss of profits due to equipment outages cost of obtaining or operating temporary facilities or cost of obtaining replacement products to meet customer demand (product losses)
31 As an example a leak of flammable gas occurred in a vent line connected to a gas treatment system At the same time a failure in the process allowed air to enter in the same vent line An explosion occurred and the over pressure damaged the vent line and associated upstream equipment including a seal pot Nobody was hurt The cost for repair was about $12000 This is a PSE considering the cost to repair the equipment due to the explosion and fire
32 As an example after a PSE event a company releases 50 kg of a very special GHS Category 5 product which causes $2000 of damage to equipment The product released was a very special blend of materials and the company incurs over $50000 in materials associated with the product loss This event is not reportable as PSE since the reportable threshold for GHS Category 5 releases is 100 kgs and product losses do not count as Direct Damage Costs
NATURAL DISASTERS
33 Natural disasters can present substantial risks to chemical process operations and damage to plant equipment which may result in a loss of containment of hazardous substances Where the potential for one or more types of natural disasters is deemed relevant to plant operations process safety and operational systems shall address the applicable risk in terms of hazards and consequence analysis plant design operating procedures for loss of utilities and process shutdown and emergency planning and response
Types of natural disasters includes hurricanes and typhoons (including associated storm surge) floods tornadoes earthquakes derechos (straight line wind storms) wildfires volcanic eruptions tsunamis and avalanches
If your facility experiences a natural disaster that triggers one or more of the thresholds it should be reported as a process safety event
PRECAUTIONARY PUBLIC RESPONSE
34 A precautionary public response is a measure taken from an abundance of caution For example a company may require all workers to shelter-in-place in response to an LOPC independent of or prior to any assessment (eg wind direction distance from the LOPC etc) of the potential hazard to those worker For example a recognized community official (eg fire police civil defense emergency management) may order a community shelter-in-place evacuation or public protective measure (eg road closure) in the absence of information from a company experiencing a process safety event or lsquojust in casersquo the wind direction changes or due to the sensitive nature of the potentially affected population (eg school children the elderly)
ACTIVE WAREHOUSE
35 An active warehouse is an on-site warehouse that stores raw materials intermediates or finished products used or produced by a process From a process perspective an active warehouse is equivalent to a bulk storage tank Rather than being stored in a single large container the raw materials intermediates or finished products are stored in smaller containers (eg totes barrels pails etc)
Appendix C ndash List of RCLG Taskforce Members Luiz Shizuo Harayashiki19
Appendix D ndash Detailed Schedule of Events Appendix E ndash Optional Excel Reporting FormWhen member companies begin tracking process safety events a single form should be utilized for all member companies to make data analysis easier and to allow all members to work from the same tracking sheet The RCLG has developed an optional tracking sheet that members and associations can start with when developing their own tracking sheet
DOWNLOAD TRACKING SHEET HERE
This document consists of a contact page the survey itself and a lsquodo not editrsquo page where the drop down menu answer are stored
INTERNATIONAL
COUNCIL OF
CHEMICAL
ASSOCIATIONS
ICCA Process Safety
Event Tracking Sheetxlsx
GUIDANCE FOR REPORTING ON THE ICCA GLOBALLY HARMONIZED PROCESS SAFETY METRICJune2016The Responsible Carereg Leadership Group
ContentsBackground2Executive Summary2Data to be reported by RCLG Associations to RCLG4Overview of ICCA Process Safety Event Criteria as a Flow Chart5Key Criteria for Reporting Process Safety Events to RCLG6Detailed Guidelines on Identifying a Process Safety Event7Table 1 ndash GHS Classification Table11Table 2 ndash API RP 754 Tier II Classification Table12Appendix A ndash Severity Table Using A Severity Weighting System is Encouraged for All Associations14Appendix B ndash Frequently Asked Questions16Appendix C ndash List of RCLG Taskforce Members22Appendix D ndash Detailed Schedule of Events23Appendix E ndash Optional Excel Reporting Form24
FIANL DRAFT
June 15 2016
The Responsible Carereg initiative began in 1985 and as the chemical industryrsquos commitment to continuous performance improvements Process Safety has been a pillar of Responsible Care since its inception and many regional approaches to tracking and reporting process safety performance have developed over the 30 years of Responsible Care implementation yet no globally harmonized system had been put into place In 2012 in the wake of several high profile process safety events the International Council of Chemical Associations (ICCA) Board of Directors directed the Responsible Care Leadership Group (RCLG) to develop a recommendation for a globally harmonized process safety performance reporting by no later than 2015
Throughout 2013 and 2014 a Taskforce comprised of multinational companies and RCLG associations chaired by Dr Peter Schmelzer Head of Health Safety and Environmental Protection Bayer HealthCare AG worked to develop a globally harmonized ICCA approach to process safety performance reporting A list of Taskforce members can be found in Appendix C During the same timeframe the American Petroleum Institute (API) also initiated a process to update its Recommend Practice 754 (RP-754) ndash Leading and Lagging Process Safety Metric Standard RP-754 is broadly used in the refining and petrochemical sector and in the Americas region to track process safety performance To optimize global adoption of a unified standard the RCLG Taskforce strived to achieve full harmonization of its recommendation with the revised API RP 754 metric expected to be finalized in the first quarter 2016
After more than 2 years of discussion research debate and feasibility assessment the Process Safety Harmonization Taskforce recommends that ICCA adopt a process safety event rate metric The adoption of this metric would require each RCLG association to collect the number of process safety events experienced by their members on an annual basis as well as total number of worker hours (employees and contractors) experienced by their members each year The process safety event rate is the ratio of events to hours The Taskforce also recommends that reporting of these data points to the RCLG be phased in over the next 3 years allowing regions with the desire and ability to report immediately to do so while also allowing additional time to companies and organizations that are developing the ability to track these data for the first time
The criteria that determine whether a process-related event qualifies as a process safety event are based on a loss of primary containment of a chemical or a release of energy triggering thresholds any one of four impact areas 1) safetyhuman health consequences 2) direct cost due to damage from incident 3) community impact and 4) chemical release quantity (see the flow chart showing reporting triggers) These four impact areas in the recommended ICCA process safety event definition are identical to the impact areas in the RP-754 Tier II incident standard The thresholds for reporting are also identical in all areas with the exception of the chemical release quantity thresholds To address this difference the ICCA process safety event definition will allow companies the use of either the GHS-based reporting thresholds developed by ICCA for the chemical release criteria or the UN Dangerous Goods (UNDG)-based reporting thresholds used in the RP-754 standard for Tier II incidents The Taskforce believes that the two systems though different are comparably robust in the universe of chemicals covered and the severity of incidents captured by reporting While there will be relatively little difference in the numbers of events captured and reported using the two different threshold approaches there may be differences that would be most clearly seen at the company level based on raw material and product use hence the Taskforce cautions companies not to compare their results with companies that use a different chemical release threshold approach Regardless under the RCLG proposal companies can choose the chemical release thresholds by which they report in to their national and regional associations If associations are interested in translating results based on one reporting approach to another the RCLG will provide a translation table However given the complexity of this exercise and the need to access raw incident data the Taskforce does not believe that this adds value and recommends against it
The Taskforce believes that this proposal for process safety event reporting will enable broad-based global reporting of process safety performance across the chemical and petrochemical industries It will provide a roadmap for regions associations and companies that are currently not tracking process safety performance to recognize the benefits that tracking and reporting will bring For regions associations and companies that are already experienced in gathering process safety data this recommendation allows for broader global alignment and focus on continuous improvement in process safety performance The systems that are built to improve process safety performance are informed by robust process safety event data and this is the major objective of this initiative
On an annual basis RCLG Associations will be asked to report two data points into ICCA using the RCLG KPI Reporting Website on the schedule provided below
1Total Member Company Worker Hours for Association (employee and contractor)
2Total Number of Process Safety Events
ICCA will use the above two data points to report process safety performance in the form of Process Safety Event Rate (PSER) normalized per 100 employees where an employee works 2000 hours a year
(Total Events Total Hours) x 200000 = PSER
Recommended Reporting Schedule
The Taskforce recommends a phased-in approach for reporting process safety event rate Such a schedule will allow more experienced companies and associations to report in the next several years while allowing other companies and associations to begin reporting by 2019 RCLG Associations would be asked to report the two process safety event rate data points annually to the ICCA through the RCLG KPI metrics reporting system If you do not know your associationrsquos username and password please contact the RCLG
The proposed schedule for process safety event rate reporting by RCLG associations is as follows
April 2015RCLG considers Taskforce proposal
June 2015ICCA Board of Directors considers RCLG final recommendation
July 2015RCLG releases the first detailed reporting guidance document for associations and member companies
Feb 2016 RCLG Reporting RCLG initiates process safety reporting pilot program through association volunteers with updated an enhanced guidance document RCLG rolls out final guidance document in June 2016
2017RCLG Associations begin collecting data from its membership
2018-2019 RCLG Reporting Optional process safety data reporting by RCLG Associations
2020 ReportingRCLG includes process safety as a mandatory metric in the KPI reporting program
See Appendix D ndash Detailed Schedule of Events
NO Does not meet the criteria for a Process Safety Event
Start
NO
NO
NO
Was a chemical substance or a chemical process directly involved
YES
YES
Release of material fire explosion or implosion fromat a chemical process unit
Incident in production distribution storage utilities pilot plants within a companyrsquos facility
YES
NO
Officially declared shelter in place or evacuation
Or Precautionary off site shelter in place or evacuation
Substance Release Thresholds met
Recordable injury
Or
hospital admission of people on or off site
Damage ge $2500direct costto company
NO
NO
NO
ICCA or API 754 Tier II chemical release thresholds exceeded
YES
YES
YES
Yes Reportable as a Process Safety Event
YES
Total Worker Hours
RCLG Associations should report the total number of employee hours worked for each member company in their association and the total number of contractor hours worked for each member company as a combined single number For the purposes of this guidance document each association should refer to their local and regional definitions for employee and contractor The goal for reporting total hours is to include all individuals who are involved with chemical manufacturing except where those individuals are tasked with major construction projects such as large scale investments with specific one-time project organizations created for design engineering and construction of new or significant expansion to existing process facilities When reporting total worker hours companies should report the same hours used for reporting personnel hours This way companies can have the same data set for occupational and process safety Personnel hours should include those hours from all chemical manufacturing operations not just from facilities where a process safety incident occurred
Process Safety Event
For the purposes of this ICCA Reporting a process safety event has occurred when
A When a chemical substance or a chemical process is directly involved AND
B The incident occurred in production distribution storage utility pilot plant within the site boundaries of companyrsquos facility AND
C There was a release of material or energy (eg fire explosion implosion) from a process unit AND
D One or more of the following Reporting Thresholds have been met
1 Safety Injury
middot Injury resulting in a Recordable Lost Time Accident or Fatality or Hospital admission of anyone on or off site OR
2 Direct Damage Cost
middot A fire explosion or clean up necessary to avoidremediate environmental damage resulting in a direct cost equal to or greater than $2500 USDs OR
3 Shelter in Place Evacuation
middot An officially declared shelter in place (on or off site) OR
middot An officially declared evacuation (on or off site) OR
middot A precautionary off site shelter in place or evacuation OR
4 Threshold Release
middot The material released meets one of the GHS thresholds in Table 1 (measured in amount released during one hour)
When a chemical substance or chemical process is directly involved
A chemical or chemical process must have been directly involved in the event or incident For this purpose the term process is used broadly to include the equipment and technology needed for petrochemical production including reactors tanks piping boilers cooling towers refrigeration systems etc An incident with no direct chemical or process involvement eg an office building fire even if the office building is on a plant site is not reportable
B LocationThe incident occurred in production distribution storage utility pilot plant within the site boundaries of companyrsquos facility
The incident occurs in production distribution storage (including active storage areas such as warehouses ndash see FAQ section) utilities or pilot plants of a facility reporting metrics under these definitions This includes tank farms ancillary support areas (eg boiler houses and waste water treatment plants) and distribution piping under control of the site All reportable incidents occurring at a location will be reported by the company that is responsible for operating that location This applies to incidents that may occur in contractor work areas as well as other incidents At tolling operations and multi-party sites the company that operates the unit where the incident initiated should record the incident and count it in their reporting
C Release of MaterialThere was a release of material or energy (eg fire explosion implosion) from a process unit
Release of Material ndash an unplanned or uncontrolled release of any material including non-toxic and non-flammable materials (eg steam hot water nitrogen compressed CO2 or compressed air) from a process that results in consequences that exceed one or more of the 4 Reporting Thresholds listed in this document
A release to a flare or scrubber is still considered to be within the primary containment as long as the mitigation system (eg scrubber flare) is operated under normal conditions without any release above the thresholds defined for normal operation A release to a secondary containment (eg waste water treatment or dike) will qualify as a process safety event because the substance is leaving the primary process system
D ThresholdsOne or more of the following Reporting Thresholds must be met for reportable process safety events
1 Safety Injury
Injury resulting in a Recordable Lost Time Accident or Fatality or Hospital admission of anyone on or off site Recordable injuries are work-related injuries that results in any of the following death days away from work restricted work or transfer to another job medical treatment beyond first aid loss of consciousness or a significant injury diagnosed by a physician or other licensed health professional
Lost time injuries and fatalities that occur as a result of process related loss of primary containment fire or explosion are those that fit into one of the following categories
middot Employee (Lost time andor Fatality)
middot Contractor and Subcontractor (Lost time andor Fatality)
middot Third Party (Injuryillness resulting in Hospital Admission or Fatality)
Hospital Admission ndash formal acceptance by a hospital or other inpatient health care facility of a patient who is to be provided with room board and medical service in an area of the hospital or facility where patients generally reside at least overnight Treatment in the hospital emergency room or an overnight stay in the emergency room would not by itself qualify as a ldquohospital admissionrdquo
Examples of injury or fatality cases that would be reportable include a burn injury resulting from steam released during cleaning a physical injury from a cap blown off by pressure during a pressure test or a chemical burn from a spill while taking a sample Examples of injuries or fatality cases that would not be reportable include a fall from an elevated work station while performing maintenance a burn from a fire in a laboratory or office building or injuries from an excavation cave-in None of these cases are directly due to the release of energy or material from the process
2 Direct Damage CostA fire explosion or clean up necessary to avoidremediate environmental damage resulting in a direct cost equal to or greater than $2500 USDs
Costs to be considered for this threshold should be those costs directly attributed to the fire andor explosion such as the replacement value of equipment lost structures lost cost of repairs environmental cleanup (on and off site) emergency response andor fines Direct cost does not include indirect costs such as business opportunity losses loss of profits due to equipment outages cost of obtaining or operating temporary facilities or cost of obtaining replacement products to meet customer demand (product losses)
3 Shelter in Place Evacuation
An officially declared shelter in place or evacuation either on or off site OR a precautionary shelter in place or evacuation off site
For the purposes of this reporting an officially declared shelter in place or evacuation on or off site OR a precautionary shelter in place or evacuation is declared off site would trigger this threshold
Officially Declared ndash A declaration by a recognized community official (eg fire police civil defense emergency management) or delegate (eg Company official) authorized to order the community action (eg shelter-in-place evacuation)
Precautionary Declaration - A precautionary public response is a measure taken from an abundance of caution and issued by a recognized community official or delegate whom has reasonably determined that such an evacuation or shelter in place was necessary to protect the public health and safety
Shelter in Place ndash is the use of a structure and its indoor atmosphere to temporarily separate individuals from a hazardous outdoor atmosphere
Evacuation ndash the act or process of removing persons from a place for reasons of safety or protection
4 Threshold ReleaseAn acute release that exceeds one of the GHS thresholds in Table 1 or in the API 754 standard for Tier II process safety release thresholds in Table 2 (measured in amount released during one hour)
As mentioned in the Executive Summary the ICCA process safety event definition allows use of either GHS-based reporting thresholds developed by ICCA for the chemical release criteria or the UN Dangerous Goods (UNDG)-based reporting thresholds used in the RP-754 standard for Tier II incidents The GHS thresholds are listed in Table 1 It is intended for companies to decide which table to use and to allow companies the option to use one system globally
Acute Release ndash A release of flammable combustible or toxic chemicals from the primary containment (ie vessel or pipe) greater than the chemical release threshold quantities is described for GHS Classification Table 1 and in the API 754 standard for Tier II process safety release thresholds in Table 2
Pressure Relief Device Acute Releases defined above include releases to a properly designed and operating pressure relief device if a quantity is released greater than or equal to the threshold quantities in Table 1 OR in the API 754 standard for Tier II process safety release thresholds Table 2 that results in one or more of the following four consequences
1 Rainout
2 Discharge to a potentially unsafe location
3 A n on-site shelter-in-place or on-site evacuation excluding precautionary on-site shelter-Ain-place or on-site evacuation
4 Public protective measures (eg road closure) including precautionary public protective measures
Releases to a properly designed and operating pressure relief device (such as a flare scrubber etc) do not have to be reported if they do not meet one of the four criteria above
Individuals who would like to view the API RP-754 Standard may download that standard at -
httpwwwapiorgenvironment-health-and-safetyprocess-safetyprocess-safety-standardsstandard-rp-7541 Hour Rule
For the purpose of the reporting under this metric release thresholds are established for materials over a one-hour time frame If the release amount of a material reaches or exceeds the reporting threshold in a 1-hour time period or less it is reportable Typically acute releases occur in 1-hour or less If the duration of the release cannot be determined the duration should be assumed to be 1 hour
Primary Containment ndash A tank vessel pipe rail car or equipment intended to serve as the primary container or used for the transfer of the material Primary containers may be designed with secondary containment systems to contain and control the release Secondary containment systems include but are not limited to tank dikes curbing around process equipment drainage collection systems into segregated oily drain systems the outer wall of double walled tanks etc
Severity Table Severity weighting can provide additional useful information about process safety events that may help drive performance improvement Appendix A is the RCLG methodology for calculating a severity weight for process safety events Using Appendix A a severity weight for each process safety event may be calculated by summing the points associated with each consequence category The ICCA strongly encourages the use of a severity weighting system as the use of such a system increases the ability to communicate performance and is an easier way for our stakeholders to understand process safety events Also the severity weight will not be comparable among other process safety metric reporting formats
Table 1 ndash GHS Classification TableTable 2 ndash API RP 754 Tier II Classification Table
2
Appendix A ndash Severity Table Using A Severity Weighting System is Encouraged for All AssociationsSeverity Table (Appendix A) Details
Appendix A above is designed to be used with the GHS Classification System ONLY (Table 1) If your company is using the API RP 754 Tier II Process Safety Metric Threshold Table Table 2 in this document please use the API RP 754 Process Safety Severity Table It is important to state that the severity table in the API RP 754 Standard is for Tier 1 incidents only Comparing the relative severity of events using different tables will not be statistically valid
Acute Environmental Cost - Cost of short-term cleanup and material disposal associated with a PSE with off-site environmental impact Companies may choose to assign severity to costs associated with off-site environmental impacts in a separate category
Rate Adjusted Metrics
Utilizing the severity table described above there are a variety of rate-based metrics which can be generated These include
Process Safety Total Incident Rate (PSTIR) Total event incidents x 200000___
Total Worker Hours
Process Safety Incident Severity Rate (PSESR) (ie severity-weighted Process Safety incident rate formula)
Total severity score for all events incidents x 200000___
PSESR = Total Worker Hours
In determining this rate 1 point is assigned for each Level 4 incident attribute 3 points for each Level 3 attribute 9 points for each Level 2 attributes and 27 points for each Level 1 attributes Theoretically a process safety event could be assigned a minimum of 1 point (ie the incident meets the attributes of a Level 4 incident in only one category) or a maximum of 135 points (ie the incident meets the attributes of a Level 1 incident in each of the five categories)
PS Level ldquoXrdquo incident rate Total Severity Level ldquoXrdquo PS incidents x 200000
Total employee contractor amp subcontractor work hours
Where X can be the total count of Severity Level 4 3 2 or 1 incidents The severity level of an incident is the maximum severity rating of the five consequence categories
Normalization ndash In some associations and member companies process safety events are normalized on a lsquoper 100rsquo employee basis given that a one worker averages 2000 per year So to normalize on a lsquoper 100rsquo employee basis events are multiplied by 200000 worker hours In other associations and member companies events are normalized on a lsquoper 500rsquo employee basis and events are multiplied by 1000000 worker hours Associations and members should discuss this option and come to a conclusion together The above formulas are set at a lsquoper 100rsquo employee rate
15
(K = 1000 MM = 1000000) (For Environmental Impact companies and associations should agree on input criteria where definitions arenrsquot readily available)
Appendix B ndash Frequently Asked QuestionsApplicability
It is recommended that companies record and report Process Safety Events occurring at Company-owned or operated facilities except as noted below
1 PSEs that originated off Company property
2 Marine transport vessel incidents except when the vessel is connected to the facility for the purposes of crude or product transfer
3 Truck andor rail incidents except when the truck or rail car is connected to the facility for the purposes of crude or product transfer
4 Routine emissions that are allowable under permit or regulation
5 Underground contamination that had no process safety consequences Note The exclusion does not apply if the release resulted in an aboveground reportable PSE such as release of toxic vapors or pooling of flammable liquids
6 Office building incidents (eg office heating equipment explosions fires spills releases personnel injury or illness etc)
7 Personnel safety sliptripfall incidents that are not directly associated with evacuating from or responding to a loss of containment incident
8 Loss of Primary Containment (LOPC) incidents from ancillary equipment not connected to the process (eg small sample containers)
9 Planned and controlled drainage of material to collection or drain system designed for such service (Note Exclusion does not apply to an unintended and uncontrolled release of material from primary containment that flows to a collection or drain system)
10 Mechanical work being conducted outside of process units or in maintenance shops
Interpretations and Examples ndash Based on GHS Table 1
The following interpretations and examples have been prepared to help clarify areas of potential uncertainty in the evaluation of reportable Process Safety Incidents (PSE)
COMPANY PREMISES
1 A third-party truck loading a flammable product on Company Premises experiences a leak and subsequent fire and property loss damages of $7000 (direct costs) Although the truck is Operated-by-Others it is connected to the process The incident would be a reportable PSE if property losses in direct costs were equal to or greater than $2500 or some other PSE threshold was met or exceeded (eg a fatality)
2 Similar example as 1 The truck loaded with flammable product overturns in route out of the plant resulting in a fire and loss of the truck This would not be reported as a PSE since the truck is no longer connected to the plant
LOSS OF CONTAINMENT
3 A faulty tank gauge results in the overfilling of a product tank containing ldquoflammable liquidsrdquo Approximately 700 kg of liquid overflows into the tanks diked area This incident is a reportable PSE since it is an acute spill greater than 100 kgs regardless of secondary containment
4 A maintenance contractor opens a process valve and gets sprayed with sulfuric acid resulting in a severe burn and lost time injury This would be a reportable PSE It is an unintended event involving a material and a loss of containment For fatalities and days away from work injuries and illnesses there is no release threshold amount
5 An operator opens a quality control sample point to collect a routine sample of product and receives a bad hand laceration requiring stitches due to a broken glass bottle and misses the next day of work This is not a reportable PSE because it is not related to a loss of containment
ACUTE RELEASES
6 While troubleshooting a higher-than-expected natural gas flow rate operating personnel find a safety valve on the natural gas line that did not reseat properly and was relieving to the atmospheric vent stack through a knock-out drum Upon further investigation it is determined that a total of 100000 kg of natural gas was relieved at a steady rate over a 6 month period This is not a reportable PSE as the release rate (~10 kg per hour) is not ldquoacuterdquo (ie does not exceed the 100 kg TQ for flammable vapors per 1 hour time period)
FLARES amp EMISSION CONTROL DEVICES (eg scrubbers)
7 If a chemical is routed to a flare or emission control device (eg scrubber) it would not be classified as a PSE as long as that flare or control device operates as designed
8 If a scrubber is overwhelmed by a flowrate greater than the design of the scrubber system and discharges a chemical in excess of the reporting threshold it would be reported as a PSE as noted about in this document
As a note an upset emission from a permitted or regulated source ndash including pressure relieve devices - of a quantity greater than or equal to the threshold quantities in Table 1 or 2 in any one-hour period that results in one or more of the following four consequences
middot rainout
middot discharge to a potentially unsafe location
middot an on-site shelter-in-place or on-site evacuation excluding precautionary on-site shelter-in-place or on-site evacuation
middot public protective measures (eg road closure) including precautionary public protective measures
Should be reported as a PSE
SAFETY RELIEF DEVICE SYSTEM
9 There is a unit upset and the relief valve opens to an atmospheric vent which has been designed resulting in a gas release to the atmosphere with no adverse consequences This would not be a reportable PSE since vapors and gases released to atmosphere from safety valves high-pressure rupture disks and similar safety devices that are properly designed for that event per API Standard 521 or equivalent are excluded as long as the release did not result in (1) a liquid carryover that created a reportable PSE related to the liquid (eg lost time incident fatality a fire or explosion that caused $2500 or more of direct cost liquid release or toxic aerosol release at or above threshold amounts etc) or (2) activation of a shelter-in-place response on or off-site or (3) public protective measures be taken
10 There is a unit upset and the relief valve fails to open resulting in overpressure of the equipment and an acute release of flammable gas from a leaking flange The amount released is above the 100 kg (within 1 hour) threshold This is a reportable PSE Releases from flanges are not excluded from PSE reporting
DAYS AWAY FROM WORK INCIDENTS
11 An operator is walking then slips and falls to the floor and suffers a lost time injury The slipfall is due to weather conditions chronic oily floors and slippery shoes This is not a reportable PSE Personnel safety sliptripfall incidents that are not directly associated with evacuating from or responding to a loss of containment incident are specifically excluded from PSE reporting
12 Same as above except that the operator slipped and fell while responding to a small flammable liquid spill (eg less than 10 kg in 1 hour) This would be PSE reportable since the operator was responding to a loss of containment incident A PSE is reportable if the loss of primary containment occurs on Company Premises and results in a lost time incident or fatality For fatalities and lost time incidents there is no release threshold amount
13 Same as above except that the operator slipped and fell several hours after the incident had concluded This would not be PSE reportable The terms evacuating from and responding to in the reporting exclusion mean that the loss of containment and associated emergency response activities are on-going Slipstripfalls after the event have concluded (such as after-the-fact clean-up and remediation) are excluded from PSE reporting
14 A scaffold builder suffers a lost time injury after falling from a scaffold ladder while evacuating from a loss of containment incident on nearby equipment This is a reportable PSE
15 An operator walks past an improperly designed steam trap The steam trap releases and the operators ankle is burned by the steam resulting in a lost time injury This is a reportable PSE because even though the loss of containment was steam (vs hydrocarbon or chemical) the physical state of the material was such that it caused a lost time injury
16 An enclosure has been intentionally purged with nitrogen A contractor bypasses safety controls enters the enclosure and dies This is a reportable fatality but not a reportable PSE since there was no unplanned or uncontrolled loss of primary containment
17 Same as above except that nitrogen inadvertently leaked into the enclosure This would be a reportable PSE (and fatality) since there was a fatality associated with an unplanned loss of primary containment
18 An operator responding to an H2S alarm collapses and has a injury If the alarm was triggered by an actual unplanned or uncontrolled H2S LOPC the event would be a reportable PSE If the alarm was a false alarm the event would not be a reportable PSE because there was no actual release
PIPELINES
19 A pipeline leaks and releases 2000 lbs (900 kgs) of flammable vapor above ground within 1 hour However the release occurred in a remote location within the site The release is PSE reportable since remoteness is not a consideration
FIRES or ENERGY RELEASES NOT ASSOCIATED WITH CHEMICAL RELEASE
As a general rule a fire or energy release is reported as a PSE only if caused by chemical release or results in a chemical release in excess of the reporting quantities Examples include
20 An electrical fire impacts the operation of the process resulting in the release of 400 kg of toluene This event would be reported as a PSE since if the chemical release exceeds the 100 kg reporting threshold for toluene
21 An electrical fire loss of electricity or any other loss of utility occurs which may cause a plant shutdown and possibly incidental equipment damage greater than $2500 (eg damage to reactors or equipment due to inadequate shutdown) but does not create a chemical release greater than the threshold quantity or cause a fatality or serious injury This event would not be reported as a PSE since the equipment damage was not caused by a chemical process fireexplosion and there was not a chemical release greater than the threshold quantity
MARINE TRANSPORT VESSELS
22 A company operated Marine Transport Vessel has an onboard acute spill of combustible material greater than 100 kg The event is not PSE reportable since Marine Transport Vessel incidents are specifically excluded except when the vessel is connected to the refinery petrochemical or chemical manufacturing facility for the purposes of crude or product transfer
23 A third-party barge is being pushed by a tug and hits the company dock A barge compartment is breached and releases 1000 kg of diesel to the water The event is not a reportable PSE since the marine vessel was not berthed at the dock and actively involved in crude or product transfer operations
TRUCK AND RAIL
24 A company railcar derails and spills more than 1000 kg of gasoline while in transit The incident is not PSE reportable since rail incidents off company property are specifically excluded
25 A third-party trucktrailer overturns while in the Company Premises resulting in an acute spill of gasoline greater than 1000 kg The incident is not reported as a PSE reportable if the truck is no longer connected to the loadingunloading facilities However it is recommended that companies also have transportation incident metrics which would capture this event
26 A contract truck hauler is unloading caustic and the hose separates and generates an airborne aerosol andor liquid caustic spill of 2500 kg The event is a reportable PSE since the caustic TQ of 100 kg was exceeded and the truck was still connected to the loadingunloading facility immediately prior to the incident
OFFICE BUILDING
27 There is a boiler fire at the Main Office complex and direct cost damages totaled $75000 The incident is not PSE reportable since Office Building incidents are specifically excluded
MAN-MACHINE INTERFACE INCIDENTS
28 An operations technician is injured while working around the finishing equipment in a polymers plant The injury is caused by the mechanical man-machine interface with the equipment This would not be a reportable Process Safety Event because there was no loss of containment of hazardous material
MIXTURES
29 If a mixture by itself has a GHS classification you use that classification to determine the threshold If the mixture itself does not have a GHS-classification we go back to the individual components of the mixture and based on kg released per threshold group calculate a lsquoweightedrsquo contribution to the thresholds Example a release of 100 kg of a mixture in a one hour period that consists of 05 kg of a substance classified as acute toxic H300 45 kg of substance classified with H301 and 40 kg of a substance with another H-number and the remaining 55 kg of water with no GHS classification would be calculated as 051 + 4510 + 40100 = 05 + 045 + 04 = 135 is exceeding 1 and would be counted as a reportable process safety incident even though none of the individual hazardous components exceeded the threshold for the individual substance
DIRECT DAMAGE COSTS
30 Direct damage costs are considered for this threshold should be those costs directly attributed to the fire andor explosion such as the replacement value of equipment lost structures lost cost of repairs environmental cleanup emergency response andor fines Direct cost does not include indirect costs such as business opportunity losses loss of profits due to equipment outages cost of obtaining or operating temporary facilities or cost of obtaining replacement products to meet customer demand (product losses)
31 As an example a leak of flammable gas occurred in a vent line connected to a gas treatment system At the same time a failure in the process allowed air to enter in the same vent line An explosion occurred and the over pressure damaged the vent line and associated upstream equipment including a seal pot Nobody was hurt The cost for repair was about $12000 This is a PSE considering the cost to repair the equipment due to the explosion and fire
32 As an example after a PSE event a company releases 50 kg of a very special GHS Category 5 product which causes $2000 of damage to equipment The product released was a very special blend of materials and the company incurs over $50000 in materials associated with the product loss This event is not reportable as PSE since the reportable threshold for GHS Category 5 releases is 100 kgs and product losses do not count as Direct Damage Costs
NATURAL DISASTERS
33 Natural disasters can present substantial risks to chemical process operations and damage to plant equipment which may result in a loss of containment of hazardous substances Where the potential for one or more types of natural disasters is deemed relevant to plant operations process safety and operational systems shall address the applicable risk in terms of hazards and consequence analysis plant design operating procedures for loss of utilities and process shutdown and emergency planning and response
Types of natural disasters includes hurricanes and typhoons (including associated storm surge) floods tornadoes earthquakes derechos (straight line wind storms) wildfires volcanic eruptions tsunamis and avalanches
If your facility experiences a natural disaster that triggers one or more of the thresholds it should be reported as a process safety event
PRECAUTIONARY PUBLIC RESPONSE
34 A precautionary public response is a measure taken from an abundance of caution For example a company may require all workers to shelter-in-place in response to an LOPC independent of or prior to any assessment (eg wind direction distance from the LOPC etc) of the potential hazard to those worker For example a recognized community official (eg fire police civil defense emergency management) may order a community shelter-in-place evacuation or public protective measure (eg road closure) in the absence of information from a company experiencing a process safety event or lsquojust in casersquo the wind direction changes or due to the sensitive nature of the potentially affected population (eg school children the elderly)
ACTIVE WAREHOUSE
35 An active warehouse is an on-site warehouse that stores raw materials intermediates or finished products used or produced by a process From a process perspective an active warehouse is equivalent to a bulk storage tank Rather than being stored in a single large container the raw materials intermediates or finished products are stored in smaller containers (eg totes barrels pails etc)
Appendix C ndash List of RCLG Taskforce Members Luiz Shizuo Harayashiki19
Appendix D ndash Detailed Schedule of Events Appendix E ndash Optional Excel Reporting FormWhen member companies begin tracking process safety events a single form should be utilized for all member companies to make data analysis easier and to allow all members to work from the same tracking sheet The RCLG has developed an optional tracking sheet that members and associations can start with when developing their own tracking sheet
DOWNLOAD TRACKING SHEET HERE
This document consists of a contact page the survey itself and a lsquodo not editrsquo page where the drop down menu answer are stored
INTERNATIONAL
COUNCIL OF
CHEMICAL
ASSOCIATIONS
ICCA Process Safety
Event Tracking Sheetxlsx
4
敬愛的 TRCA 會員您好
謹代表 TRCA 藉此機會對 ICCA (International Council of Chemical Associations 國際化學業
協會)以及 RCLG (Responsible Care Leadership Group 責任照顧領導群)過去幾年來致於調
和製程安全指標所付出的與貢獻致上深深的謝忱
製程安全管理是化學業為關鍵重要的作製程安全指標的提報則是驗證製程安全
管理的核程過去數年來國際與國內化學業致於持續不斷的改進相關績效指
標的表現我們相信減少製程安全事件的發與是否進量測有絕對的關係因為我們無
從改進沒有進過量測的項因此藉由製程安全事件的提報將有效的協助會員公司
與國家協會分享 佳實務經驗並在這個過程中協助會員公司改善製程安全績效表現進
減少環境跡從事故事件中學習是改進製程安全管理的關鍵我們誠摯地希望藉由
製程安全指標提報能降低製程安全事件的發
TRCA 2015 年起籌組 Near Miss 試組並於當年起開始提報製程安全虛驚事件數
以做為未來全提報製程安全事件率的準備感謝試組台灣永光化學業(股)公司
台灣中油(股)公司國喬油化學(股)公司台灣科思創(股)公司奇美實業(股)公司台
橡(股)公司春油化學(股)公司春造樹脂廠(股)公司連化學業(股)公司
李榮化學業(股)公司以及台灣志氯化學(股)公司率先的努配合試為 2020 年全
提報製程安全事件指標提供了難能可貴的經驗
TRCA 為達成 ICCA 擬定 2020 年全提報的標訂於 2019 年開始試提報 2018 年數據
2018 年將陸續展開相關說明與教育訓練研討會議我們相信推 ICCA 全球調和製程安全
指標提報將能更有助於加強與改善台灣化業製程安全管理績效
讓我們起為化業更安全與環保的永續未來努吧
TRCA 責任照顧推委員會主席 Chairman Responsible Care Implementation Committee台灣志氯化學(股)公司總經理 President Taiwan Chlorine Industries Ltd
嚴堅正 Art Yen
5
背景
責任照顧倡議(Responsible Carereg initiative)發起於 1985年其目的在於展現化學工業界持續
改善績效的承諾自從責任照顧倡議開始實施以來製程安全(Process Safety)一直是責任
照顧倡議的核心基礎之一實施責任照顧 30 多年來許多地區已發展出追蹤及提報製程
安全績效的方法然而一直未能建立一套全球調和的提報系統由於一些重大製程安全
事件仍不斷發生在 2012 年國際化學工業協會(ICCA)董事會便責成責任照顧領導群
(RCLG)在 2015 年以前擬定一套全球調和的製程安全績效提報機制
2013-14 年間一個由跨國公司和 RCLG 各協會組成的專案小組正式成立該專案小組由
拜耳醫療保健公司(Bayer HealthCare AG)的衛生安全及環保總監 Peter Schmelzer 博士擔任
召集人其任務即是研擬一套全球調和的 ICCA 製程安全績效提報機制專案小組成員表
詳見附錄 C在此期間美國石油學會(API)也著手開始進行其 API RP 754 ndash領先及落後製程
安全指標標準(Leading and Lagging Process Safety Metric Standard)之修訂RP-754 被廣泛應
用於美洲地區的煉油及石化產業以追蹤製程安全績效為了推動全球採行統一的標準
RCLG 專案小組致力於將其所提出之建議案與預訂於 2016 年第一季完成修訂之 API RP 754
達到完全調和
執行摘要
經過兩年多的討論研究辯論及可行性評估製程安全調和化專案小組(PSHT)建議 ICCA
採行一套製程安全事件發生率指標採行這套指標需要 RCLG 各協會蒐集會員公司在一年
內所發生之製程安全事件次數和工作總時數(包括員工和承攬商)製程安全事件發生率即
事件數除以工作時數的比率專案小組建議向 RCLG 提報這些數據的要求將在未來三年
內分階段實施同意已具有意願和能力提報的地區立即開始提報數據同時也給予正在發
展追蹤數據能力以進行首次提報的公司和機構若干緩衝時間
判定製程相關事件是否符合製程安全事件定義的標準係以化學物質的一次阻絕設施失效
或能量釋放以致引起下列任何一個影響考量面的門檻為根據1) 安全人員健康後果2)
事故造成損失之直接成本3) 社區影響4) 化學物質洩漏量(請參見提報判定流程圖所
示)ICCA 所建議之製程安全事件定義的四個影響考量面與 RP-754Tier II 事故標準的影
響考量面是完全一樣的除了化學物質洩漏量提報門檻有所差異外其他三個影響考量面
6
的提報門檻也是一樣的為因應此一差異針對化學物質外洩量提報門檻ICCA 製程安
全事件定義將容許會員公司採用 ICCA 依據化學品全球調和制度(GHS)健康危害分級為基礎
所發展的提報標準或依據聯合國危險物品(UNDG)分類為基礎所定義之 RP-754 二級製程
安全事件(Tier II) 之提報標準專案小組相信這兩套制度之提報標準雖然有所差異但
從其所涵蓋之化學物質領域和提報事故嚴重程度看來兩者皆相當健全雖然採用這兩種
不同提報門檻所收集和提報的事件數差異相對不大但在公司方面從原料及產品使用的角
度看來兩者可能會有非常明顯的不同因此專案小組提醒會員公司勿將自己公司的
結果與採用不同化學物質洩漏量提報門檻的公司做比較無論如何根據 RCLG 的提議
會員公司可選擇化學物質洩漏門檻以向國家及地區協會進行提報如果各協會有興趣轉
換兩種不同提報方式的結果RCLG 可提供轉換表但由於轉換運算非常複雜且須取得
原始事故數據專案小組相信相互轉換的附加價值不大因此不建議協會採取此一做法
專案小組相信這項製程安全事件提報建議案可廣泛運用在化學及石化產業實施製程安
全績效提報這項提報制度將為目前尚未追蹤製程安全績效的地區協會和會員公司提
供一個指引讓他們可以體認追蹤及提報製程安全績效可以帶來的益處至於已在蒐集製
程安全數據的地區協會和會員公司此建議案將有助於他們更廣泛地與全球接軌並將
重點放在持續改善製程安全績效這些改善製程安全績效的制度仰賴的是可靠的製程安
全事件數據改善製程安全績效正是責任照顧倡議的主要目的
7
RCLG 各協會應向 RCLG 提報的數據
RCLG 各協會每年必須依照下文提供的時程透過 RCLG 關鍵績效指標(KPI)提報網站向
ICCA 提報兩個數據
1 協會所屬會員公司的總工作時數(包括員工和承攬商)
2 製程安全事件總數
ICCA 將利用上述兩個數據以製程安全事件發生率(PSER)的形式報告製程安全績效PSER
計算之常態化是以每 100 位員工每位員工一年工作 2000 小時為基準
(總事件數 總工作時數) x 200000 = PSER
建議之提報時程
針對提報製程安全事件發生率專案小組建議一種分階段導入的方法此一時程可讓更多
已具經驗的協會及公司立即實施提報同時容許其他協會及公司從 2019 年起開始提報
RCLG 各協會必須透過 RCLG KPI 指標提報系統(httpkpiresponsiblecareeu)每年向 ICCA
提報兩個製程安全事件發生率數據如果你不知道你所屬協會的使用者名稱和密碼請聯
絡 RCLG
建議 RCLG 協會提報製程安全事件發生率的時程如下
2015 年 4 月 RCLG 考量專案小組建議案
2015 年 6 月 ICCA 理事會考量 RCLG 的最終建議
2015 年 7 月 RCLG 頒布首份詳細的提報指引供協會及會員公司遵
循
2016 年 2 月 RCLG 提報 RCLG 更新及強化提報指引並針對自願參加的協會
開始實施製程安全試行提報計畫RCLG 於 2016 年 6 月
頒布最終指引
2017 年 RCLG 各協會開始向會員公司蒐集數據
2018-2019 年 RCLG 提報 RCLG 各協會可選擇地開始提報製程安全數據
2020 年提報 RCLG 於 KPI 提報計畫中將製程安全納入為一項強制性
指標
參見附錄 D ndash 詳細活動時程
8
ICCA 製程安全事件判定標準流程圖
事故是否發生在廠內之
生產配銷儲存公
用或試驗工廠
是 是
是
否
否 是否造成須通報工傷
或
廠內廠外人員住院治
療
損壞是否對
公司造成
ge $2500 美
元的直接成
本損失
官方是否宣告就地
避難或疏散或廠
外預防性就地避難
或疏散
否
是
否
是屬於須通報製程安全事件
是
否
是
是
開始
否不符合製程安全事件認定
標準
是否超過 ICCA 或 API
754 Tier II 化學物質洩
漏恕限值
否 發生化學物質外洩火
災或爆炸是否起因於
或發生在化學製程單元
是否直接涉及某種化學物
質或化學製程
否
9
須提報製程安全事件之重要標準
總工作時數
RCLG 各協會應以加總的單一數字提報其所屬會員公司的員工和承攬商總工作時數為達
成本指引之目的各協會應參考其本地和地區對員工及承攬商之定義提報總時數之目標
應納入涉及化學製造之所有個人然而參與主要興建工程專案之人員則不納入計算譬
如為新建或擴建既有製程設施之設計工程和施工而成立之一次性專案組織的大規模投資
案會員公司提報總工作時數時應與人事部門統計之員工工時一致如此各公司便能
取得相同的職業與製程安全數據員工工時應包括所有化學製造作業的工時而非僅計算
發生製程安全事故之廠區的工時
製程安全事件
為執行 ICCA 提報目的製程安全事件之定義條件如下(必須同時符合 ABCD 四個條
件)
A 直接涉及某種化學物質或化學製程且
B 事故發生在廠內之生產配銷儲存公用或試驗工廠且
C 製程單元發生物質洩漏或能量釋放(如火災爆炸和內爆)且
D 已達到以下提報門檻之一
1 安全 工傷
導致記錄性的傷害(OSHA)損失工時或死亡或廠內外任何人員因此
而須住院治療或
2 直接損失成本
火災爆炸或為避免補救環境損害之必要清理作業導致$2500 美元
以上的直接成本支出或
3 就地避難 疏散
官方宣告就地避難(廠內或廠外)或
官方宣告疏散(廠內或廠外)或
廠外預防性就地避難或疏散或
4 洩漏恕限值
物質洩漏程度已達表 1 所列之任一 GHS 恕限值(洩漏量以單位小時計
量)
此外各公司亦可選擇採用 API RP-754 標準中所列之洩漏恕限值(表 2)請注意如欲查
看 API RP-754 標準可登入以下網站購買及下載httpwwwapiorgoil-and-natural-
gashealth-and-safetyprocess-safetyprocess-safety-standards
10
製程安全事件判定準則
A 涉及化學品
直接涉及某種化學物質或化學製程
製程安全事件或事故必須直接涉及化學物質或化學製程就此而言ldquo製程rdquo一詞泛指包含
石化生產所需要之設備和技術包括反應器儲槽管線鍋爐冷卻水塔和冷凍系
統helliphellip等未直接涉及化學物質或製程的事件無須提報譬如辦公大樓起火(即使該辦公大
樓位在廠區內亦然)
B 地點
事故發生在廠內之生產配銷儲存公用或試驗工廠
發生在廠內之生產配銷儲存(包括活動儲存區如倉庫 ndash 參見ldquo常見問題集rdquo)公用及
試驗工廠凡符合提報指標及定義的事故包括在廠區管理下之槽罐區輔助支援區(如
鍋爐室和廢水處理廠)和配銷管線所有須提報之事件應由負責該事故地點運作的公司
負提報之責此一規定亦適用於發生在承攬商作業區域內的事故在代工作業和多方共同
作業廠區負責運作該發生事故單位的公司應記錄事故始末並將之納入其提報中
C 物質洩漏
製程單元發生物質外洩或能量釋放(如火災爆炸和內爆)
物質外洩 ndash 製程任何物質發生非預期或無法控制的洩漏或釋放包括非毒性及不可燃物質
(如蒸汽熱水氮氣壓縮二氧化碳或壓縮空氣)且達到本文件所列四類提報門檻之一
項或以上之後果
在防治系統(如洗滌塔或廢氣燃燒塔)正常運作狀況下只要沒有任何洩漏或排放量超過
法定許可值即使排放到廢氣燃燒塔或滌氣塔仍被視為處於一次阻絕設施內然若排
放到二次阻絕設施(如廢水處理或防溢堤)將被視為製程安全事件因為物質已離開主要製
程系統
11
D 提報門檻
須提報製程安全事件必須達到以下提報門檻之一
1 安全 工傷
導致記錄性傷害(OSHA)損失工時或死亡或廠內外任何人員因此而須住院治療
記錄性傷害是指與工作有關所造成的傷害導致死亡暫時全失能工作受限制或需調整職
務較輕傷害嚴重之醫療處理失去意識或經醫師或其他合格醫療專業人員診斷為重大
傷害
損失工時傷害和死亡是指因製程相關的一次阻絕設施失效火災或爆炸導致以下任何一種
結果
員工(損失工時或死亡)
承攬商及再承攬商 (損失工時或死亡)
第三方(如來賓訪客快遞員)(受傷疾病導致住院治療或死亡)
住院治療是指醫院或其他具有住院病患保健設施的醫療單位正式接受病患住院提供病患
食宿及醫療護理且病患接受治療至少留置至隔日僅在醫院急診室治療或過夜處理不屬
於ldquo住院治療rdquo的定義範圍
須提報之工傷或死亡事件例如在清理作業期間因蒸汽洩漏造成人員燒燙傷壓力測試期間
帽蓋因受壓脫落造成人員身體傷害或取樣作業時因物質外濺造成人員化學灼傷無須提
報之工傷或死亡事件例如在執行維修作業時從高處的工作台墜落實驗室或辦公大樓火災
造成人員燒燙傷或挖掘工程塌陷造成人員傷害這些案例均與因製程造成的能量釋放或
物質洩漏無直接關聯
2 直接損失成本
火災爆炸或為避免補救環境損害之必要清理作業導致$2500美元以上的直接成本支出
此提報門檻所考慮的成本應為可直接歸因於火災或爆炸的成本譬如設備及結構損壞的重
置成本修理成本環境清理(廠內及廠外)支出緊急應變和罰款直接成本不包括間接
成本譬如業務機會損失設備停機造成之利潤損失取得或運轉臨時設施之成本或為
滿足顧客需求取得替代產品的成本(產品損失)
12
3 就地避難 疏散
官方宣告就地避難或疏散(廠內或廠外)或廠外預防性就地避難或疏散
就提報目的而言官方宣告就地避難或疏散(廠內或廠外)或廠外預防性就地避難或疏散
即達到此提報門檻
官方宣告 ndash 由地方權責機關(如消防警察民防緊急應變管理部門)或經授權的代表(如
派駐公司官員)下達的社區行動(如就地避難或疏散)宣告
預防性宣告 ndash 預防性公眾應變是基於謹慎的態度所採取的一種措施權責地方主管機關或經
授權的代表經合理判斷認定為維護公眾健康及安全發布必須採取就地避難或疏散之預
防性措施
就地避難 ndash 利用結構體及其內部空氣以暫時讓人員與室外危害性氣體隔離
疏散 ndash 基於安全或防護理由讓人員離開某處所的行動或過程
4 洩漏恕限值
超過表 1 中所列 GHS 恕限值或表 2 中所列 API 754 標準 Tier II 製程安全洩漏恕限值之一的
急性洩漏事件(洩漏量以單位小時計量)
如ldquo執行摘要rdquo所述ICCA 製程安全事件之定義容許採用 ICCA 依據化學品全球調和制度
(GHS)健康危害分級為基礎所發展的提報標準或依據聯合國危險物品(UNDG)分類為基礎
所定義之 RP-754 二級製程安全事件(Tier II) 之提報標準GHS 恕限值詳見表 1各會員公司
可自行決定選擇哪一個表中的提報恕限值並在全球採用單一制度
ldquo急性rdquo洩漏 ndash易燃性可燃性或毒性化學物質從一次阻絕設施(如容器或管線)洩漏其
任一單位小時之洩漏量超過化學物質洩漏恕限量分述於表 1 中的 GHS 分類和表 2 中的
API 754 標準 Tier II 製程安全洩漏恕限值
洩壓裝置前述所定義之ldquo急性rdquo洩漏包括洩漏或排放至妥善設計且運作中的洩壓裝置若
洩漏或排放量達到表 1 中所列 GHS 恕限值或表 2 中所列 API 754 標準 Tier II 製程安全洩漏
恕限值且導致下列四種後果之任一項或以上之後果
1 二相排放或夾帶液體的排放液滴沉降至地面造成污染
2 排放至具潛在危險性的地點
3 廠內就地避難或疏散不包括預防性廠內就地避難或疏散
4 啟動公眾保護措施(如道路封閉)包括預防性公眾保護措施
13
洩漏或排放至妥善設計且運作中的洩壓裝置(如廢氣燃燒塔洗滌塔等)若其情況未達前
述四項標準中任何一項則不必提報
欲查看 API RP-754 標準可登入以下網站下載此標準httpwwwapiorgenvironment-
health-and-safetyprocess-safetyprocess-safety-standardsstandard-rp-754
一小時法則
為便於衡量此項指標提報與否洩漏恕限值是以物質在任一小時內之洩漏量為標準若任
一小時或更短時間內物質洩漏量達到或超過須提報恕限值該事故便屬於須提報的製程安
全事件急性洩漏事故通常不會超過一小時若無法確定洩漏持續時間則應假設其為一
小時
一次阻絕設施ndash 用來作為主要容器或用於運送或輸送物質之槽罐船隻管線軌道車
或設備主要容器在設計上可能包含二次阻絕設施系統以抑制及控制洩漏二次阻絕設
施系統包括(但不限於)儲槽防溢堤製程設備周遭的圍堵設施油水分離的排水收集系統
雙層儲槽的外壁等
嚴重程度表 ndash 嚴重程度加權可額外提供有關製程安全事件的有用資訊有助於帶動改善績
效附錄 A 為 RCLG 建議之製程安全事件嚴重程度加權計算方法根據附錄 A 的方法便
可藉由加總與各個後果類別關聯的分數計算出各製程安全事件的嚴重程度加權值ICCA
強烈建議採用嚴重程度加權制度因為此制度有助於提升溝通績效的能力也比較容易讓
利害關係人了解製程安全事件並且此嚴重程度加權值與其他製程安全績效指標提報方
式是不具相互比較性的
14
表 1 ndash GHS 分類表
物理性危害(GHS 2x)
洩漏恕限值(1 小時內)
STOTSpecific target organ toxicity(特定標的器官系統毒性物質)
15
表 2 ndash API RP 754 Tier II 分類表
洩漏恕限類別
物質危害性分類 acdef 恕限值
(戶外洩漏) 恕限值
(戶內b洩漏)
T2-1 TIH A 區物質 ge 05 kg (11 lb) ge 025 kg (055
lb)
T2-2 TIH B 區物質 ge 25 kg (55 lb) ge 125 kg (275
lb)
T2-3 TIH C 區物質 ge 10 kg (22 lb) ge 5 kg (11 lb)
T2-4 TIH D 區物質 ge 20 kg (44 lb) ge 10 kg (22 lb)
T2-5
易燃氣體 或 正常沸點 ≦ 35 (95 degF)閃火點lt23 (73 degF)的液體 或 其他包裝組別 I 類的物質 (酸鹼除外)
ge 50 kg (110 lb) ge 25 kg (55 lb)
T2-6
正常沸點 gt 35 degC (95 degF)閃火點 lt 23 degC (73degF)的液體 或 其他包裝組別 II 類的物質 (酸鹼除外)
ge 100 kg (220 lb) 或
ge 07 bbl
ge 50 kg (110 lb) 或
ge 035 bbl
T2-7
閃火點 gt 23 degC (73 degF)和 lt 60 degC (140 degF)的液體 或 閃火點 gt 60 degC (140 degF)的液體在閃火點或高於閃火點的溫度下洩漏 或 強酸鹼 (定義參見 RP 754 文件草案) 或 UNDG第2類第22部分 (不可燃無毒氣體)空氣除外 或 其他包裝組別 III 類的物質
ge 200 kg (440 lb) 或
ge 14 bbl
ge 100 kg (220 lb) 或
ge 07 bbl
T2-8
閃火點 gt 60 degC (140 degF) 和 lt 93 degC (200 degF)的液體在低於閃火點的溫度下洩漏 或 中度酸鹼
ge 1000 kg
(2200 lb) 或
ge 7 bbl
ge 500 kg
(1100 lb) 或
ge 35 bbl
TIH吸入性毒性危害物(Toxic Inhalation Hazard)
16
一般認為以公斤和磅或以磅和桶為單位的恕限值不盡等同各公司應該選用其中一組計量單位並在
所有紀錄文件中一體適用
在判定一種物質之洩漏恕限類別時首先應從物質之含吸入性毒性(TIH Zone)可燃性(閃火點和沸點)
或腐蝕性(強酸或鹼 vs中度酸或鹼)等特性來判別只有當物質的危險度無法利用上述簡單的特性來判別
時(如遇水反應劇烈)才採用UNDGL包裝組別
a 許多物質具有一種以上危險性正確的危險區(Hazard Zone)或包裝組別(Packing Group)歸屬應遵循DOT
49 CFR 1732a [14]或聯合國危險物品運輸建議書(UNRTDG)第2部分[12]的規定參見附錄F
b 具有四面完整牆(從地板到天花板)地板和屋頂的結構物
c 對於未列於UNDG的溶液無水成分將用TIH區或包裝組別分類溶液之恕限值將根據乾基重量之恕限
值反算
d 對於未知UNDG分類的混合物可計算每種成分在恕限值洩漏中的分量如果各種成分之分量的總和
等於或大於100即表示混合物超過門檻值若混合物有明顯且獨立的毒性及可燃性結果則可分
別計算毒性及可燃性危險度參見附錄EPSE實例amp問題 49ndash53
e 閃火點 gt 60 degC (140 degF) 和 lt 93 degC (200 degF)的液體在低於閃火點的溫度下洩漏無論洩漏量多寡其
一次阻絕設施失效(LOPC)均不屬於Tier 1製程安全事件(PSE)
f 中度酸鹼的一次阻絕設施失效無論洩漏量多寡均不屬於Tier 1製程安全事件
17 (K = 1000 MM = 1000000) (在環境影響類別方面若缺乏既有定義協會和會員公司應議定輸入標準)
附錄 A ndash 嚴重程度表鼓勵所有協會均採用嚴重程度加權制度
事件事故類別
嚴重程度等級
安全人體健康 火災或爆炸導致直接
成本 任 1 小時內物質洩
漏量 社區影響 環境影響[廠外]
4 級
1 分
對員工承攬商或再承攬商造成較輕傷害嚴重之傷害 (符合本地法規)
造成以下直接損失成本
美金$25 K ~ $25 K
洩漏量介於
1x le TQ lt 40x
官方宣告就地避難或疏散 (廠內或廠外) 預防性廠外就地避難或疏散
le 3 小時
重大環境整治成本
$25 K ~ $25 K
3 級
3 分
對員工承攬商或再承攬商造成之需要多日缺勤的傷害
對第三方造成之需要初步急救以外治療的傷害 (符合本地法規)
造成以下直接損失成本
$25 K ~ $250 K
洩漏量介於
40x le TQ lt 160x
官方宣告就地避難或疏散 (廠內或廠外)
預防性廠外就地避難或疏散
3 ~ 12 小時
重大環境整治成本
$25 K ~ $250 K
2 級
9 分
對員工承攬商或再承攬商造成 1 人死亡
對第三方造成 1 人住院治療
(符合本地法規)
造成以下直接損失成本
$250 K ~ $25 MM
洩漏量介於
160x le TQ lt 640x
官方宣告就地避難或疏散 (廠內或廠外)
預防性廠外就地避難或疏散
12 ~ 24 小時
重大環境整治成本
$250 K ~ $25 MM
1 級
27 分
對員工承攬商或再承攬商造成多人死亡
對第三方造成多人住院治療
對第三方造成 1 人死亡 (符合本地法規)
造成以下直接損失成本
ge $25 MM
洩漏量
ge 640x TQ
官方宣告就地避難或疏散 (廠內或廠外)
預防性廠外就地避難或疏散
ge 24 小時
重大環境整治成本
ge $25 MM
18 (K = 1000 MM = 1000000) (在環境影響類別方面若缺乏既有定義協會和會員公司應議定輸入標準)
嚴重程度表(附錄 A)細節說明
附錄 A 之設計目的僅適用於採用 GHS 分類制度(表 1)者如果你的公司係採用 API RP 754Tier II 製程安全指標提報恕限值表(表 2)請使用
API RP 754 製程安全嚴重程度表必須提醒的是依 API RP 754 的標準其嚴重程度表僅適用於一級(Tier I)事故去比較採用不同的嚴重度
表所評估出來的相對嚴重度並無統計上的意義
急性的環境成本 ndash 因製程安全事件造成廠外環境影響所導致之短期清理及物質處置的成本各會員公司可選擇將廠外環境影響相關成本另
外區分一個嚴重程度類別
比率調整指標
利用上述嚴重程度表可產生一系列以事件率為基礎的指標包括
製程安全總事件率 (PSTIR) 總事件次數 x 200000
總工作時數
製程安全事件嚴重程度率(PSESR) (即製程安全事件嚴重程度加權計算公式)
PSESR = 所有事件之總嚴重程度分數總合 x 200000
總工作時數
在計算此一比率時各 4 級事件被分配 1 分各 3 級事件被分配 3 分各 2 級事件被分配 9 分各 1 級事件被分配 27 分理論上每個
製程安全事件至少可分配到 1 分(亦即事件僅在一個類別符合第 4 級事件屬性)至多可分配到 135 分(亦即事件在所有五個類別中均符
合第 1 級事件屬性)
ldquoXrdquo級別製程安全事件率 嚴重度級別ldquoXrdquo之製程安全事件總數 x 200000
員工承攬商amp再承攬商總工作時數
X可以是嚴重度級別 432 或 1 級製程安全事件之總數事件之嚴重度等級是選用五類後果類別中之最嚴重等級
標準化 ndash 在某些協會和會員公司中製程安全事件是採 lsquo每 100 名rsquo員工每名員工每年平均工作時數為 2000 小時為基礎予以標準化因
此在lsquo每 100rsquo名rsquo員工的標準基礎上事件被乘以 200000 工作時數也有些其他協會和會員公司將標準化基礎設定為lsquo每 500 名rsquo員工
因此事件被乘以 1000000 工作時數協會和會員公司應就標準化基礎進行討論共同做成選項結論上述的公式設定為lsquo每 100 名rsquo員工
基礎
19
附錄 B ndash 常見問題集
適用性
我們建議會員公司記錄和提報在其所擁有或運作的工廠內發生的製程安全事件惟以下情況不須提報製
程安全事件
1 源自於公司廠區以外的製程安全事件
2 海上運輸船事故惟船隻為了輸送半成品或產品之目的已經與公司的設施相連接時發生的
事故仍須提報
3 卡車或軌道車事故惟卡車或軌道車為了輸送半成品或產品之目的已經與公司的設施相連
接時發生的事故仍須提報
4 許可證或法規容許之例行排放
5 不會造成製程安全危害的地下污染請注意若洩漏至地下導致地上發生須提報製程安全事
件如釋放出毒性蒸汽或致使易燃液體蓄積成池則不適用本排除條件
6 辦公建築事故(如辦公室暖氣設備爆炸火災外溢洩漏人員受傷或疾病等)
7 與疏散或一次阻絕設施失效無直接關聯之人員安全ldquo滑倒絆倒跌倒rdquo事故
8 沒有與製程相連接之輔助設備的一次阻絕設施(如小樣品瓶)失效事故
9 計劃中和在控制下的物質排放至設計用來收集或排放系統中(請注意物質從一次阻絕設施
在非計劃或非受控制情況下排放至收集或排放系統中則不適用本排除條件)
10 在製程區域外部或保養廠內執行之機械作業
說明與實例 ndash 以 GHS 表 1 為基礎
以下說明和實例有助於在評估須提報製程安全事件(PSE)時釐清可能存在的不確定部分
公司廠區
1 一輛第三方的卡車在公司廠區內卸載易燃產品時發生洩漏進而引起火災造成公司財物損失
$7000 美元(直接成本)雖然該卡車是ldquo由他人操作rdquo但其作業與製程相連接若公司的直接成
本財物損失達到或超過$2500 美元或已達到或超過其他 PSE 提報門檻(如1 人死亡)此事故即
屬於須提報的製程安全事件
2 與前例1 類似的例子載著易燃產品的卡車在廠外運輸途中翻覆引發火災並造成卡車毀損
該事故不屬於須提報的製程安全事件因為當時卡車並未與製程相連接
20
阻絕設施失效
3 儲槽液位計故障造成裝有ldquo易燃液體rdquo產品的儲槽外溢約 700 公斤的液體流入儲槽的防溢堤內
此事故屬於須提報的製程安全事件因為其ldquo急性rdquo洩漏量超過 100 公斤即使是阻絕在二次阻絕
設施防溢堤中亦然
4 一名從事維修工作的承攬商在開啟一個製程阻閥時被噴起的硫酸濺到造成嚴重灼傷和損失工
時的工傷此事故屬於須提報的製程安全事件因為它是涉及物質和一次阻絕設施失效的意外事
件對於因洩漏造成死亡和損工的工傷或疾病事故沒有洩漏恕限值
5 一名作業員開啟品管取樣點進行日常取樣作業時手部被一個破碎的玻璃瓶嚴重割破需要進行
縫合治療縫針造成第二天無法上班該事故不屬於須提報的製程安全事件因為它與一次阻絕
設施失效無關
ldquo急性rdquo洩漏
6 一名作業員在進行天然氣流量高於預期值之異常排除時發現天然氣管線上的一個安全閥門未適
當歸位因此天然氣經由氣液分離桶排放至排氣煙囪經進一步檢查作業員判斷在過去 6 個
月間總共有 100000 公斤天然氣以穩定的速率排放至大氣該事故不屬於須提報的製程安全事
件因為其洩漏速率(每小時約 10 公斤)不算ldquo急性rdquo洩漏(未超過易燃蒸汽每小時 100 公斤的恕限
值)
廢氣燃燒塔amp排放控制裝置 (如洗滌塔)
7 若化學物質被導引至廢氣燃燒塔或排放控制裝置(如洗滌塔)只要該廢氣燃燒塔或控制裝置運作在
正常設計範圍內便不屬於須提報的製程安全事件
8 若廢氣流速超過洗滌塔的設計負荷以致未經吸收的化學物質排出超過恕限值該事故屬於須提報
的製程安全事件(如本文註釋所述)
註釋自取得許可或妥善管理的裝置-包括釋壓裝置發生不預期的排放若 1 小時內洩漏量達到或
超過表 1 或表 2 所列的洩漏恕限值且導致下列四種後果之任一項或以上之後果該事故便屬於
須提報的製程安全事件
o 二相排放或夾帶液體的排放液滴沉降至地面造成污染
o 排放至具潛在危險性的地點)
o 廠內就地避難或疏散不包括預防性廠內就地避難或疏散
o 啟動公眾保護措施(如道路封閉)包括預防性公眾保護措施
21
安全洩壓裝置 系統
9 製程單元發生異常安全閥開啟將洩漏物質釋放到排氣口此釋壓排放裝置是依相關要求設計
的且氣體釋到大氣中並未造成不良後果這不是一個須提報的製程安全事件因為安全閥高
壓破裂盤以及類似的安全裝置是依據 API 521 或者同等的標準設計的且此排放並未造成 (1)
夾帶液體並導致須提報的製程安全事件的後果(譬如損失工時意外死亡火災或爆炸造成$2500
美元或以上的直接成本損失液體或毒性氣體洩漏量達到或超過恕限值(2) 啟動廠內或廠外就地
避難應變或(3)啟動公眾保護措施
10 製程單元發生異常安全閥並未開啟造成設備超壓易燃性氣體從一個法蘭處ldquo急性rdquo漏出來
洩露量超過 100 公斤(一小時內)的恕限值該事故屬於須提報的製程安全事件因為從法蘭處外
漏屬於製程安全事件應提報事項
損工事故
11 一名作業員走路時不慎滑倒造成損失工時之工傷滑倒原因為天氣狀況rdquo長期rdquo油垢的地面和
易滑鞋具該事故不屬於須提報的製程安全事件因為人員安全ldquo滑倒絆倒跌倒rdquo事故若非與
一次阻絕設施失效直接關聯的疏散或應變造成則不屬於須提報的製程安全事件
12 與前例相同的事件惟這次作業員跌倒是因為少量易燃液體外漏(如 1 小時內少於 10 公斤)在採取
相關應變措施時發生該事故屬於須提報的製程安全事件因為作業員係為了應變一次阻絕設施
失效的事故而跌倒若一次阻絕設施失效發生在公司廠區且造成失時工傷或死亡後果該事故
便屬於須提報的製程安全事件對於因洩漏造成死亡和損失工時之工傷事故沒有洩漏量門檻
13 與前例相同的事件惟這次作業員跌倒是在事件結束數小時之後該事故不屬於須提報的製程安
全事件在提報要件中所用的ldquo疏散rdquo和ldquo應變rdquo等術語指的是一次阻絕設施失效和相關緊急應變
活動正在持續中事件結束後滑倒絆倒跌倒(如ldquo事後rdquo清理和補救)不屬於須提報製程安全事件
14 工人在因附近設備一次阻絕設施失效在疏散過程中一名鷹架搭建工人從鷹架梯上跌落造成損
失工時之工傷該事故屬於須提報的製程安全事件
15 一名作業員行經一個設計不良的蒸汽卻水器時被外洩的蒸汽燙傷腳踝造成損失工時之工傷
該事故屬於須提報的製程安全事件因為雖然一次阻絕設施失效洩漏出的是蒸汽(而非碳氫化合物
或化學物質)但損失工時之工傷是由於洩漏物質的物理狀態所導致的
16 一個密閉空間依照計畫以氮氣吹清一名承攬商繞過安全管制進入該密閉空間因而死亡該事
故屬於須提報的死亡事件但不屬於須提報的製程安全事件因為其中不涉及非計劃或失控的一
次阻絕設施失效
17 情況同上惟這次氮氣是非刻意洩漏進入該局限空間該事故屬於須提報的製程安全事件(同時也
是一起死亡事件)因為該名承攬商的死亡與非計劃的一次阻絕設施失效有關
22
18 一名作業員因硫化氫(H2S)警報在進行應變處理時昏倒若警報確實是因非計劃或失控的 H2S 一次
阻絕設施失效的外洩事件該事故便屬於須提報的製程安全事件若警報是一個假警報則該事
故便不屬於須提報的製程安全事件因為沒有真正的化學品洩漏發生
管線
19 一條管線破漏1 小時內洩漏 2000 磅(900 公斤)易燃蒸氣到地面但洩漏位置在廠區內很偏僻的
地點該事故仍屬於須提報的製程安全事件因為ldquo偏僻rdquo不是提報與否的考量因素
與化學物質外洩無關之火災或能量釋放事故
一般通則而言唯有當火災或能量釋放事故是因化學物質洩漏所造成或其發生導致化學物質洩漏
超過提報恕限值這些事故才屬於須提報的製程安全事件實例包括
20 一場電氣火災影響製程操作導致甲苯洩漏 400 公斤該事故屬於須提報的製程安全事件因為
化學物質洩漏已超過甲苯的 100 公斤提報恕限值
21 發生電氣火災停電或任何公用資源供應中斷可能造成工廠停工及可能引起設備損失超過
$2500 美元(如因非正常停工導致反應器或設備損壞)但並未造成超過恕限值的化學物質洩漏
亦未造成死亡或嚴重工傷該事故不屬於須提報的製程安全事件因為設備損壞並非化學製程火
災爆炸造成且化學物質洩漏並未超過恕限值
海上運輸船
22 一艘由公司營運的海上運輸船在船上發生ldquo急性rdquo易燃物質外洩洩漏量超過 100 公斤該事故不
屬於須提報的製程安全事件因為除非海上運輸船是為了輸送半成品或產品而與煉油石化或化
學製造廠的設施相連接否則其洩漏事故便不被視為製程安全事件
23 一艘第三方駁船由一艘拖船推向碼頭結果撞上公司的碼頭駁船的一個船艙破裂且造成
1000 公斤柴油洩漏到海中該事故不屬於須提報的製程安全事件因為駁船當時並非停泊在碼
頭內且其作業並非在進行半成品或產品之輸送
卡車與軌道車
24 一輛公司的軌道車在運輸途中出軌造成超過 1000 公斤汽油洩漏該事故不屬於須提報的製程
安全事件因為在公司廠區外發生的軌道車事故不被視為與製程安全有關
23
25 一輛第三方卡車拖車在公司廠區內翻覆造成ldquo急性rdquo汽油洩漏超過 1000 公斤這事故不屬於須
提報的製程安全事件因為卡車拖車當時已不再與裝卸設備連接然而我們建議會員公司另
行訂定運輸安全事故指標將這類事故記錄下來
26 一位合約卡車作業者正在卸載液鹼時發生軟管脫落造成空氣中氣霧和或液鹼液洩漏 2500 公
斤該事故屬於須提報的製程安全事件因為洩漏量已超過液鹼的 100 公斤恕限值且事故發生
前卡車仍與裝卸設備相連接著
辦公建築
27 綜合辦公大樓發生鍋爐火災造成總計$75000 美元的直接成本損失該事故不屬於須提報的製
程安全事件因為辦公大樓事故不被視為與製程安全有關
人機介面事故
28 一名操作技術員在聚合物工廠的終端設備旁作業時受傷這傷害是因機械的人機介面的設備而
造成該事故不屬於須提報的製程安全事件因為技術員受傷並非因危險物質一次阻絕設施失效
而造成的
混合物
29 若混合物本身有 GHS 分類可利用其分類確定恕限值若混合物本身沒有 GHS 分類則可計算混
合物中每個單一組成分之洩漏量(公斤)相對於個別成分恕限值之比值作為其對混合物恕限值之
lsquo加權rsquo貢獻譬如若混合物在 1小時內的洩漏量為 100公斤其中包含 05公斤分類為劇毒 H300
的物質45 公斤分類為 H301 的物質40 公斤另一種分類為 H 開頭的物質其餘 55 公斤則為沒
有 GHS 分類的水分此混合物之計算式為051 + 4510 + 40100 = 05 + 045 + 04 = 135超過
1因此該事故被視為須提報的製程安全事件雖然混合物個別成分之洩漏量均未超過各該物質
本身的恕限值
直接損失成本
30 此一門檻所考慮的成本應為可直接歸因於火災或爆炸的成本譬如設備及結構損壞的重置成本
修理成本環境清理支出緊急應變和罰款直接成本不包括間接成本譬如業務機會損失設
備停機造成之利潤損失取得或運轉臨時設施之成本或為滿足顧客需求取得替代產品的成本
(產品損失)
24
31 範例連接到氣體處理系統的排放管發生易燃氣體外漏同時製程出現問題導致空氣進入同
一條排放管結果發生爆炸過高的壓力損壞了排放管及其相關上游設備包括一個密封罐並
未造成人員受傷修理成本約$12000 美元該事故屬於須提報的製程安全事件因為爆炸及火
災導致設備修理成本超過門檻
32 範例一次製程安全事件後公司又發生一種非常特殊的 GHS 第 5 類產品洩漏 50 公斤造成
$2000 美元的設備損失洩漏的產品是一種非常特別的混合物公司須負擔超過$50000 美元因
產品耗損而產生之材料成本該事故不屬於須提報的製程安全事件因為 GHS 第 5 類產品洩漏的
提報門檻為 100 公斤且產品耗損不被計入直接損失成本
天然災害
33 天然災害可能對化學製程作業構成重大風險且對製程設備造成損壞導致危害物質一次阻絕設
施失效當一種或多種天然災害被認為可能對工廠作業造成影響時製程安全和作業系統應從危
害及後果分析工廠機器設備設計公用設施失效及製程停工之操作程序緊急應變計畫及應變
措施等方面界定潛在風險進行防範
天然災害類型包括颶風及颱風(包括伴隨而來的風暴潮)水災龍捲風地震超強對流風暴(直
線風暴)野火火山爆發海嘯和山崩
若公司廠房設施遭遇天然災害且其後果觸發一種或以上提報門檻該事故便屬於須提報製程安
全事件
預防性公眾應變
34 預防性公眾應變是基於謹慎的態度所採取的一種措施譬如當發生一次阻絕設施失效時公司
可能在尚未進行任何評估(如方向與洩漏點的距離等等)前便要求全體工人就地避難又
如地方權責官員(如消防警察民防緊急應變管理部門)在獲報一家公司發生製程安全事件
後為防lsquo萬一rsquo風向改變或基於可能受到波及的人口敏感族群(如學童或老年人)可能在尚未接
獲明確資訊前便下令社區就地避難或疏散或採取公眾保護措施(如道路封閉)
製程附屬倉庫
35 製程附屬倉庫指的是位於廠內用於儲存將投入於生產製程或產自於製程之原料半成品或成品的
倉庫從製程的觀點看來製程附屬倉庫相當於一個大型儲槽但這些原料半成品或成品並不
是儲存在一的大型容器中而是裝在較小的容器裡(如太空包大桶桶罐等)
25
Appendix C ndash List of RCLG Taskforce Members
Name Affiliation
Peter Schmelzer Bayer CEFIC - Chairman
Americo Diniz Carvalho Neto Braskem
Bradford Johnson American Chemistry Council
David Cummings DuPont
Debra Phillips American Chemistry Council
Hans Schwarz BASF
Kathryn Walton Plastics and Chemicals Industries Association
Kazuyuki Akita Japanese Chemical Industry Association
Kelly Keim ExxonMobil Chemical Company API Representative
Kenan Stevick Dow
Kiyokazu Murata Japanese Chemical Industry Association
Larry Bowler SABIC
Lorna Young Chemical Industry Association of Canada
Louisa Nara Center for Chemical Process Safety
Luiz Shizuo Harayashiki Associaccedilatildeo Brasileira da Induacutestria Quiacutemica
Masatoshi Kumamoto Japanese Chemical Industry Association
Milton Lacerda Petrobras
Phil Scott Chemical Industries Association
Piet Knijff DSM European Process Safety Centre
Scott Donaldson and Eamon Chandler
Shell
Scott Wallace Olin Corporation
Shakeel Kadri Air Products and Chemicals Inc
26
附錄 D ndash 詳細活動時程表
2016 年 2017 年 2018 年 2019 年 2020 年
2 ndash 4 月
RCLG PS 先導計畫
5 月 ndash
針對準則進行調整釐清
6 月 向 RCLG 和 ICCA 董事會報
告先導計畫執行結果
7 ndash 12 月 RCLG 協會考量準
則並為其會員公司發展提報機制
如有需要RCLG可向 ICCA 申請能
力建立基金為會員公司舉辦製程安
全研習會
1 ndash 12 月
RCLG 協會開始向其會員公司蒐集製程安全數據
1 ndash 12 月
如有需要RCLG 各協會運用 RCLG 的基金及專
家舉辦製程安全及績效提報研習會
1 ndash 2 月
擁有數據的協會開始向RCLG 提報製程安全事件
(2017 年數據)
4 月 RCLG 檢討第一個提報循
環的結果挑戰及原始數據(內部)
6 月 RCLG 向 ICCA 董事會呈報
原始數據
7 ndash 12 月 必要時更新及調整準
則
如有需要RCLG 各協會運用 RCLG 的基金及專
家舉辦製程安全及績效提報研習會
1 ndash 2 月
擁有數據的協會開始向RCLG 提報製程安全事件
(2018 年數據)
4 月 RCLG 檢討第二個提報循
環的結果挑戰及原始數據(內部)
6 月 RCLG 向 ICCA 董事會呈報
原始數據
7 ndash 12 月 必要時更新及調整準
則
如有需要RCLG 協會運用 RCLG 的基金及專家
舉辦製程安全及績效提報研習會
1 ndash 2 月
所有協會開始向 RCLG 提報製程安全事件
製程安全事件提報成為
RCLG KPI 衡量指標建議基本集的一部分(2019 年數
據)
4 月 RCLG 檢討第二個提報循
環的結果挑戰及原始數據(內部考量外部提
報)
6 月 RCLG 向 ICCA 董事會呈報
原始數據
27
附錄 E ndash 選擇性 Excel 追蹤表
當會員公司開始追蹤製程安全事件時所有會員公司應採用單一表格以簡化數據分析同時讓所有公司均使用相同的追蹤表RCLG 設
計了一份選擇性追蹤表可供會員公司和協會先行利用之後他們可設計自己的追蹤表
在這裡下載追蹤表
ICCA Process Safety Event Tracking Sheetxlsx
本文件包含三個分頁分別是ldquo聯絡資料rdquoldquo調查表rdquo和儲存下拉式選單選項的ldquo請勿編輯rdquo分頁
備註
附錄 E 追蹤表僅供參考TRCA 將另行提供台灣版表格供會員公司提報
28
後語
台灣化學工業責任照顧協會(Taiwan Responsible Care Association TRCA)成立於 1998 年在台灣推行責任照顧制度已達 20 週年製造商成員
包括台灣主要上市上櫃化工公司會員公司化學品生產製造量約佔全國 80 2016 年台灣化工業的 Chemical Sales 仍站在全球第八名的位
置額度為 630 億歐元化工業總產值達到 34 兆新台幣提供國內 416 萬人工作機會
TRCA 扮演國內廠商與國際制度接軌的角色也是國內化工業與政府機關及利益相關者溝通的橋樑與管道TRCA 會員結構依業務性質分析
涵蓋石化生產化學品製造氣體生產倉儲運輸業化學品貿易業以及工程研發設計等公司TRCA 透過供應鏈及價值鏈推行責任
照顧制度組成毒性化學物質聯防組織協助法規溝通與研析會員名冊請參考 httpwwwtrcaorgtwtrcanwork2aspx
TRCA 於 2010 年成為 ICCA (International Council of Chemical Associations 國際化學工業協會)觀察員ICCA 成立於 1989 年是全球化工製造
業的聯合會也是化學工業與 UNEP OPCW 及 OECD 的交流窗口ICCA 與其會員協會及成員公司致力於邁向永續的未來確保人類健康與
環境安全與保護全球化工業擁有超過 4兆美元的價值影響所有經濟部門ICCA 的會員幾乎在全球每個國家都有商業活動在全球六大
洲推動創新並提供超過 2000 萬個工作機會
台灣化工業在全球占有重要的一席之地在國內產業鏈也位居關鍵位置無論對國內或國際都有身為地球村一員應盡之責我們期許藉由
製程安全指標提報能更進一步提升自我在工安衛生環保與永續發展等面向的績效表現
台灣化學工業責任照顧協會
10452 台北市中山區撫順街 8 號 7 樓
電話02-2585-0552
httpwwwtrcaorgtw
None | |
$2500 to $25000 | |
$25000 to $250000 | |
$250000 to $25000000 | |
More than $25000000 | |
Yes - Using GHS TABLE | |
Yes - Using API RP 754 TABLE | |
NO | |
NA | |
1x le TQ lt 40x | |
40x le TQ lt 160x | |
160x le TQ lt 640x | |
ge 640x TQ | |
Yes le 3 hours | |
Yes 3 hours ge 12 hours | |
Yes 12 hours ge 24 hours | |
Yes ge 24 hours | |
No | |
Small-scale | |
Medium-scale | |
Large-scale | |
No | |
Yes | |
No | |
middot Injury requiring treatment beyond first aid to an employee contractor or subcontractor | |
middot Days Away From Work injury to an employee contractor or subcontractor or middot Injury requiring treatment beyond first aid to a third party | |
middot A fatality of an employee contractor or subcontractor or middot A hospital admission of a third party | |
middot Multiple fatalities of employees contractors or subcontractors or middot multiple hospital admission of third parties or middot A fatality of a third party | |
NA | |
1x le TQ lt 3x | |
3x le TQ lt 9x | |
9x le TQ lt 27x | |
ge 27x TQ |
ICCA Process Safety Pilot Reporting ProgramFebruary 8 2016 | 1 | 2 | 3 | 4 | 5 | 6 | 7 | 8 | 9 | 10 | 12 | 13 | 14 | 15 | |||||||||||||||||||||||
SAFETY Details(Meeting Local Regulations) | Direct Cost from Fire or Explosion | Community Impact | Environmental Impact | Material Released(Measured using the 1 Hour Rule) | |||||||||||||||||||||||||||||||||
Company Association Details | |||||||||||||||||||||||||||||||||||||
GHS | API - RP 754 | ||||||||||||||||||||||||||||||||||||
Company or Assocation Name | Headquarter Association | Location of Event Ex - City State amp Country | Date and Time of Event | Safety InjuryDid the Event result in a Recordable Lost Time Accident or Fatality or Hospital admission of anyone on or off siteUse Drop Down Menu | Safety InjuryIf yes please insert the total number of injuries | Safety InjuryFor puropses of utilizing the Severity Table please indicate the level of severity by chosing the MOST SEVERE classification that describes your incidentUse Drop Down Menu | Safety InjuryDid the incident involve Fatalities If so how many total fatalities If none enter Zero | Safety InjuryPlease Report Total Employee Hours for Calendar Year 2015 | Safety InjuryPlease Report Total Contractor Hours for Calendar Year 2015 | Direct Cost Did the Event result in Direct Damage CostUse Drop Down Menu | Direct Cost If so how muchAmount is in US DollarsUse Drop Down Menu | Community ImpactDid the event result inbull Officially declared shelter-in-place or officially declared evacuation (on or off site)ORbull Precautionary off site shelter in place or evacuation Use Drop Down Menu | Environmental ImpactDid the event result inAcute Environmental Remediation CostIf so indicate the amount in US DollarsUse Drop Down Menu | Material ReleasedDid the Event result in an Acute Release of material beyond one of the two threshold tablesIf so indicate which Threshold Table you used to make this determinationUse Drop Down Menu | Material ReleasedIf so indicate the amount released USING GHS CLASSIFICATION TABLEUse Drop Down Menu | Material ReleasedIf so indicate the amount released USING THE THRESHOLD TABLE FROM API RP-754Use Drop Down Menu | Material ReleasedIf available please indicate the material released | ||||||||||||||||||||
1 | ABC Chemical Company | American Chemistry Council | Washington DC - USA | January 4 2016 | Yes | 2 | middot Days Away From Work injury to an employee contractor or subcontractor or middot Injury requiring treatment beyond first aid to a third party | 0 | 5525000 | 1500250 | No | $2500 to $25000 | Yes le 3 hours | $2500 to $25000 | Yes - Using GHS TABLE | 40x le TQ lt 160x | NA | Chlorine | |||||||||||||||||||
2 | XYZ Chemical Company | American Chemistry Council | Washington DC - USA | 5-Jan-16 | Yes | 1 | middot Injury requiring treatment beyond first aid to an employee contractor or subcontractor | 0 | 5525000 | 1500250 | Yes | $2500 to $25000 | No | $2500 to $25000 | Yes - Using API RP 754 TABLE | NA | 3x le TQ lt 9x | Benzene | |||||||||||||||||||
3 | |||||||||||||||||||||||||||||||||||||
4 | |||||||||||||||||||||||||||||||||||||
5 | |||||||||||||||||||||||||||||||||||||
6 | |||||||||||||||||||||||||||||||||||||
7 | |||||||||||||||||||||||||||||||||||||
8 | |||||||||||||||||||||||||||||||||||||
9 | |||||||||||||||||||||||||||||||||||||
10 | |||||||||||||||||||||||||||||||||||||
11 | |||||||||||||||||||||||||||||||||||||
12 | |||||||||||||||||||||||||||||||||||||
13 | |||||||||||||||||||||||||||||||||||||
14 | |||||||||||||||||||||||||||||||||||||
15 | |||||||||||||||||||||||||||||||||||||
16 | |||||||||||||||||||||||||||||||||||||
17 | |||||||||||||||||||||||||||||||||||||
18 | |||||||||||||||||||||||||||||||||||||
19 | |||||||||||||||||||||||||||||||||||||
20 | |||||||||||||||||||||||||||||||||||||
21 | |||||||||||||||||||||||||||||||||||||
22 | |||||||||||||||||||||||||||||||||||||
23 | |||||||||||||||||||||||||||||||||||||
24 | |||||||||||||||||||||||||||||||||||||
25 | |||||||||||||||||||||||||||||||||||||
Zero or None | Yes - Duration Unknown | ||||||||||||||||||||||||||||||||||||
Processes | Mode of Operation | Type of material released | Status of Operation | ||||
REFINING | Start-up | Flammable | Open | ||||
Alkylation HF | Planned shutdown | Combustible | Closed | ||||
Alkylation sulfuric | Emergency shutdown | Toxic | |||||
BitumenResidAsphalt | Normal | Corrosive | Tier 1 Acute Releases | ||||
Calcining | Upset | Utilities | No Release | ||||
Coking | Turnaround | Other | Category 1 | ||||
Crude | Routine maintenance | Category 2 | |||||
Desulfurization | Temporary | Evacuation | Category 3 | ||||
FCC | Other | Yes | Category 4 | ||||
Gas Treating | No | Category 5 | |||||
Hydrogen | Point of Release | Category 6 | |||||
Hydrotreating | Pump | Fire | Category 7 | ||||
Hydrocracking | Compressor | Yes | Multiple Categories | ||||
Isom | BlowerFan | No | |||||
MarineJetty | Pressure Vessel | lt $2500 | |||||
Reforming | FilterCoalescer | ||||||
Sulfur recovery | Furnace | PRDs | |||||
Vapor recoverylight ends | Boiler | Directly to Atmosphere | |||||
Wastewater | Heat exchanger | via Downstream Destructive Device | |||||
REFINING amp PETROCHEMICAL | Cooling Tower | No | |||||
Tank FarmStorage FacilityOffsite | Piping system | Yes | |||||
UtilitiesSteam PlantCogeneration | Reactor | No | |||||
Other | Atmospheric tank | ||||||
PETROCHEMICAL | FlareRelief System | Acute release above thresholds | |||||
CO H2 | Other | Yes | |||||
LNG | No | ||||||
Methane | Events | ||||||
Methanol | No Tier 1 Events | Indoor Outdoor | |||||
Methyl Mercaptan | No Tier 2 Events | No Release | |||||
Formaldehyde | No Tier 1 or Tier 2 Events | Indoor | |||||
Formaldehyde derivatives | NA | Outdoor | |||||
Acetic Acid | |||||||
Acetic Acid derivatives | Event Type | ||||||
Ethane | Injury | ||||||
Ethylene | Fire | ||||||
Ethanol | Explosion | ||||||
Ethylene oxide | PRD Discharge | ||||||
Ethylene derivatives | Acute Release | ||||||
Polyethylene | |||||||
Ethylene dichloride | General | ||||||
Ethylene dichloride derivatives | Yes | ||||||
Ethyl benzene | No | ||||||
Ethyl benzene derivatives | |||||||
Polystyrene | |||||||
Styrene-Butadiene | |||||||
Propane | |||||||
Propylene | |||||||
Polypropylene | |||||||
Isopropanol | |||||||
Propylene oxide | |||||||
Propylene oxide derivatives | |||||||
Butane | |||||||
Isobutane | |||||||
Isobutene | |||||||
Butadiene | |||||||
MTBE | |||||||
ETBE | |||||||
Pentane | |||||||
Hexane | |||||||
Cyclohexane | |||||||
Hexanol | |||||||
Aromatics Derivatives | |||||||
Benzene | |||||||
Toluene | |||||||
Xylene | |||||||
Para Xylene | |||||||
Amines Derivatives | |||||||
TDA MDA IPDA etc | |||||||
Isocyanates | |||||||
Specialty Chemicals | |||||||
LoadingUnloading | |||||||
Pilot Plant |
Instructions | ||||||||||||||
Step 1 | Complete the Contact Tab with your contact information and company information | |||||||||||||
Be sure to note the region of your reporting (IE North America France Japan etc) | ||||||||||||||
Survey on Process Safety Events | ||||||||||||||
Step 2 | Complete the survey one line per Process Safety Event for your companyregion | |||||||||||||
ALL REPORTED DATA SHOULD BE FROM CALENDAR YEAR 2017 | ||||||||||||||
Step 3 | Return completed survey to | |||||||||||||
Company Name | ||||||||||||||
Contact Person | All Surveys Due by xxx date | |||||||||||||
Address | ||||||||||||||
Fax | ||||||||||||||
Telephone | ||||||||||||||
Region | ||||||||||||||
None | |
$2500 to $25000 | |
$25000 to $250000 | |
$250000 to $25000000 | |
More than $25000000 | |
Yes - Using GHS TABLE | |
Yes - Using API RP 754 TABLE | |
NO | |
NA | |
1x le TQ lt 40x | |
40x le TQ lt 160x | |
160x le TQ lt 640x | |
ge 640x TQ | |
Yes le 3 hours | |
Yes 3 hours ge 12 hours | |
Yes 12 hours ge 24 hours | |
Yes ge 24 hours | |
No | |
Small-scale | |
Medium-scale | |
Large-scale | |
No | |
Yes | |
No | |
middot Injury requiring treatment beyond first aid to an employee contractor or subcontractor | |
middot Days Away From Work injury to an employee contractor or subcontractor or middot Injury requiring treatment beyond first aid to a third party | |
middot A fatality of an employee contractor or subcontractor or middot A hospital admission of a third party | |
middot Multiple fatalities of employees contractors or subcontractors or middot multiple hospital admission of third parties or middot A fatality of a third party | |
NA | |
1x le TQ lt 3x | |
3x le TQ lt 9x | |
9x le TQ lt 27x | |
ge 27x TQ |
ICCA Process Safety Pilot Reporting ProgramFebruary 8 2016 | 1 | 2 | 3 | 4 | 5 | 6 | 7 | 8 | 9 | 10 | 12 | 13 | 14 | 15 | |||||||||||||||||||||||
SAFETY Details(Meeting Local Regulations) | Direct Cost from Fire or Explosion | Community Impact | Environmental Impact | Material Released(Measured using the 1 Hour Rule) | |||||||||||||||||||||||||||||||||
Company Association Details | |||||||||||||||||||||||||||||||||||||
GHS | API - RP 754 | ||||||||||||||||||||||||||||||||||||
Company or Assocation Name | Headquarter Association | Location of Event Ex - City State amp Country | Date and Time of Event | Safety InjuryDid the Event result in a Recordable Lost Time Accident or Fatality or Hospital admission of anyone on or off siteUse Drop Down Menu | Safety InjuryIf yes please insert the total number of injuries | Safety InjuryFor puropses of utilizing the Severity Table please indicate the level of severity by chosing the MOST SEVERE classification that describes your incidentUse Drop Down Menu | Safety InjuryDid the incident involve Fatalities If so how many total fatalities If none enter Zero | Safety InjuryPlease Report Total Employee Hours for Calendar Year 2015 | Safety InjuryPlease Report Total Contractor Hours for Calendar Year 2015 | Direct Cost Did the Event result in Direct Damage CostUse Drop Down Menu | Direct Cost If so how muchAmount is in US DollarsUse Drop Down Menu | Community ImpactDid the event result inbull Officially declared shelter-in-place or officially declared evacuation (on or off site)ORbull Precautionary off site shelter in place or evacuation Use Drop Down Menu | Environmental ImpactDid the event result inAcute Environmental Remediation CostIf so indicate the amount in US DollarsUse Drop Down Menu | Material ReleasedDid the Event result in an Acute Release of material beyond one of the two threshold tablesIf so indicate which Threshold Table you used to make this determinationUse Drop Down Menu | Material ReleasedIf so indicate the amount released USING GHS CLASSIFICATION TABLEUse Drop Down Menu | Material ReleasedIf so indicate the amount released USING THE THRESHOLD TABLE FROM API RP-754Use Drop Down Menu | Material ReleasedIf available please indicate the material released | ||||||||||||||||||||
1 | ABC Chemical Company | American Chemistry Council | Washington DC - USA | January 4 2016 | Yes | 2 | middot Days Away From Work injury to an employee contractor or subcontractor or middot Injury requiring treatment beyond first aid to a third party | 0 | 5525000 | 1500250 | No | $2500 to $25000 | Yes le 3 hours | $2500 to $25000 | Yes - Using GHS TABLE | 40x le TQ lt 160x | NA | Chlorine | |||||||||||||||||||
2 | XYZ Chemical Company | American Chemistry Council | Washington DC - USA | 5-Jan-16 | Yes | 1 | middot Injury requiring treatment beyond first aid to an employee contractor or subcontractor | 0 | 5525000 | 1500250 | Yes | $2500 to $25000 | No | $2500 to $25000 | Yes - Using API RP 754 TABLE | NA | 3x le TQ lt 9x | Benzene | |||||||||||||||||||
3 | |||||||||||||||||||||||||||||||||||||
4 | |||||||||||||||||||||||||||||||||||||
5 | |||||||||||||||||||||||||||||||||||||
6 | |||||||||||||||||||||||||||||||||||||
7 | |||||||||||||||||||||||||||||||||||||
8 | |||||||||||||||||||||||||||||||||||||
9 | |||||||||||||||||||||||||||||||||||||
10 | |||||||||||||||||||||||||||||||||||||
11 | |||||||||||||||||||||||||||||||||||||
12 | |||||||||||||||||||||||||||||||||||||
13 | |||||||||||||||||||||||||||||||||||||
14 | |||||||||||||||||||||||||||||||||||||
15 | |||||||||||||||||||||||||||||||||||||
16 | |||||||||||||||||||||||||||||||||||||
17 | |||||||||||||||||||||||||||||||||||||
18 | |||||||||||||||||||||||||||||||||||||
19 | |||||||||||||||||||||||||||||||||||||
20 | |||||||||||||||||||||||||||||||||||||
21 | |||||||||||||||||||||||||||||||||||||
22 | |||||||||||||||||||||||||||||||||||||
23 | |||||||||||||||||||||||||||||||||||||
24 | |||||||||||||||||||||||||||||||||||||
25 | |||||||||||||||||||||||||||||||||||||
Zero or None | Yes - Duration Unknown | ||||||||||||||||||||||||||||||||||||
Processes | Mode of Operation | Type of material released | Status of Operation | ||||
REFINING | Start-up | Flammable | Open | ||||
Alkylation HF | Planned shutdown | Combustible | Closed | ||||
Alkylation sulfuric | Emergency shutdown | Toxic | |||||
BitumenResidAsphalt | Normal | Corrosive | Tier 1 Acute Releases | ||||
Calcining | Upset | Utilities | No Release | ||||
Coking | Turnaround | Other | Category 1 | ||||
Crude | Routine maintenance | Category 2 | |||||
Desulfurization | Temporary | Evacuation | Category 3 | ||||
FCC | Other | Yes | Category 4 | ||||
Gas Treating | No | Category 5 | |||||
Hydrogen | Point of Release | Category 6 | |||||
Hydrotreating | Pump | Fire | Category 7 | ||||
Hydrocracking | Compressor | Yes | Multiple Categories | ||||
Isom | BlowerFan | No | |||||
MarineJetty | Pressure Vessel | lt $2500 | |||||
Reforming | FilterCoalescer | ||||||
Sulfur recovery | Furnace | PRDs | |||||
Vapor recoverylight ends | Boiler | Directly to Atmosphere | |||||
Wastewater | Heat exchanger | via Downstream Destructive Device | |||||
REFINING amp PETROCHEMICAL | Cooling Tower | No | |||||
Tank FarmStorage FacilityOffsite | Piping system | Yes | |||||
UtilitiesSteam PlantCogeneration | Reactor | No | |||||
Other | Atmospheric tank | ||||||
PETROCHEMICAL | FlareRelief System | Acute release above thresholds | |||||
CO H2 | Other | Yes | |||||
LNG | No | ||||||
Methane | Events | ||||||
Methanol | No Tier 1 Events | Indoor Outdoor | |||||
Methyl Mercaptan | No Tier 2 Events | No Release | |||||
Formaldehyde | No Tier 1 or Tier 2 Events | Indoor | |||||
Formaldehyde derivatives | NA | Outdoor | |||||
Acetic Acid | |||||||
Acetic Acid derivatives | Event Type | ||||||
Ethane | Injury | ||||||
Ethylene | Fire | ||||||
Ethanol | Explosion | ||||||
Ethylene oxide | PRD Discharge | ||||||
Ethylene derivatives | Acute Release | ||||||
Polyethylene | |||||||
Ethylene dichloride | General | ||||||
Ethylene dichloride derivatives | Yes | ||||||
Ethyl benzene | No | ||||||
Ethyl benzene derivatives | |||||||
Polystyrene | |||||||
Styrene-Butadiene | |||||||
Propane | |||||||
Propylene | |||||||
Polypropylene | |||||||
Isopropanol | |||||||
Propylene oxide | |||||||
Propylene oxide derivatives | |||||||
Butane | |||||||
Isobutane | |||||||
Isobutene | |||||||
Butadiene | |||||||
MTBE | |||||||
ETBE | |||||||
Pentane | |||||||
Hexane | |||||||
Cyclohexane | |||||||
Hexanol | |||||||
Aromatics Derivatives | |||||||
Benzene | |||||||
Toluene | |||||||
Xylene | |||||||
Para Xylene | |||||||
Amines Derivatives | |||||||
TDA MDA IPDA etc | |||||||
Isocyanates | |||||||
Specialty Chemicals | |||||||
LoadingUnloading | |||||||
Pilot Plant |
Instructions | ||||||||||||||
Step 1 | Complete the Contact Tab with your contact information and company information | |||||||||||||
Be sure to note the region of your reporting (IE North America France Japan etc) | ||||||||||||||
Survey on Process Safety Events | ||||||||||||||
Step 2 | Complete the survey one line per Process Safety Event for your companyregion | |||||||||||||
ALL REPORTED DATA SHOULD BE FROM CALENDAR YEAR 2017 | ||||||||||||||
Step 3 | Return completed survey to | |||||||||||||
Company Name | ||||||||||||||
Contact Person | All Surveys Due by xxx date | |||||||||||||
Address | ||||||||||||||
Fax | ||||||||||||||
Telephone | ||||||||||||||
Region | ||||||||||||||
None | |
$2500 to $25000 | |
$25000 to $250000 | |
$250000 to $25000000 | |
More than $25000000 | |
Yes - Using GHS TABLE | |
Yes - Using API RP 754 TABLE | |
NO | |
NA | |
1x le TQ lt 40x | |
40x le TQ lt 160x | |
160x le TQ lt 640x | |
ge 640x TQ | |
Yes le 3 hours | |
Yes 3 hours ge 12 hours | |
Yes 12 hours ge 24 hours | |
Yes ge 24 hours | |
No | |
Small-scale | |
Medium-scale | |
Large-scale | |
No | |
Yes | |
No | |
middot Injury requiring treatment beyond first aid to an employee contractor or subcontractor | |
middot Days Away From Work injury to an employee contractor or subcontractor or middot Injury requiring treatment beyond first aid to a third party | |
middot A fatality of an employee contractor or subcontractor or middot A hospital admission of a third party | |
middot Multiple fatalities of employees contractors or subcontractors or middot multiple hospital admission of third parties or middot A fatality of a third party | |
NA | |
1x le TQ lt 3x | |
3x le TQ lt 9x | |
9x le TQ lt 27x | |
ge 27x TQ |
ICCA Process Safety Pilot Reporting ProgramFebruary 8 2016 | 1 | 2 | 3 | 4 | 5 | 6 | 7 | 8 | 9 | 10 | 12 | 13 | 14 | 15 | |||||||||||||||||||||||
SAFETY Details(Meeting Local Regulations) | Direct Cost from Fire or Explosion | Community Impact | Environmental Impact | Material Released(Measured using the 1 Hour Rule) | |||||||||||||||||||||||||||||||||
Company Association Details | |||||||||||||||||||||||||||||||||||||
GHS | API - RP 754 | ||||||||||||||||||||||||||||||||||||
Company or Assocation Name | Headquarter Association | Location of Event Ex - City State amp Country | Date and Time of Event | Safety InjuryDid the Event result in a Recordable Lost Time Accident or Fatality or Hospital admission of anyone on or off siteUse Drop Down Menu | Safety InjuryIf yes please insert the total number of injuries | Safety InjuryFor puropses of utilizing the Severity Table please indicate the level of severity by chosing the MOST SEVERE classification that describes your incidentUse Drop Down Menu | Safety InjuryDid the incident involve Fatalities If so how many total fatalities If none enter Zero | Safety InjuryPlease Report Total Employee Hours for Calendar Year 2015 | Safety InjuryPlease Report Total Contractor Hours for Calendar Year 2015 | Direct Cost Did the Event result in Direct Damage CostUse Drop Down Menu | Direct Cost If so how muchAmount is in US DollarsUse Drop Down Menu | Community ImpactDid the event result inbull Officially declared shelter-in-place or officially declared evacuation (on or off site)ORbull Precautionary off site shelter in place or evacuation Use Drop Down Menu | Environmental ImpactDid the event result inAcute Environmental Remediation CostIf so indicate the amount in US DollarsUse Drop Down Menu | Material ReleasedDid the Event result in an Acute Release of material beyond one of the two threshold tablesIf so indicate which Threshold Table you used to make this determinationUse Drop Down Menu | Material ReleasedIf so indicate the amount released USING GHS CLASSIFICATION TABLEUse Drop Down Menu | Material ReleasedIf so indicate the amount released USING THE THRESHOLD TABLE FROM API RP-754Use Drop Down Menu | Material ReleasedIf available please indicate the material released | ||||||||||||||||||||
1 | ABC Chemical Company | American Chemistry Council | Washington DC - USA | January 4 2016 | Yes | 2 | middot Days Away From Work injury to an employee contractor or subcontractor or middot Injury requiring treatment beyond first aid to a third party | 0 | 5525000 | 1500250 | No | $2500 to $25000 | Yes le 3 hours | $2500 to $25000 | Yes - Using GHS TABLE | 40x le TQ lt 160x | NA | Chlorine | |||||||||||||||||||
2 | XYZ Chemical Company | American Chemistry Council | Washington DC - USA | 5-Jan-16 | Yes | 1 | middot Injury requiring treatment beyond first aid to an employee contractor or subcontractor | 0 | 5525000 | 1500250 | Yes | $2500 to $25000 | No | $2500 to $25000 | Yes - Using API RP 754 TABLE | NA | 3x le TQ lt 9x | Benzene | |||||||||||||||||||
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Zero or None | Yes - Duration Unknown | ||||||||||||||||||||||||||||||||||||
Processes | Mode of Operation | Type of material released | Status of Operation | ||||
REFINING | Start-up | Flammable | Open | ||||
Alkylation HF | Planned shutdown | Combustible | Closed | ||||
Alkylation sulfuric | Emergency shutdown | Toxic | |||||
BitumenResidAsphalt | Normal | Corrosive | Tier 1 Acute Releases | ||||
Calcining | Upset | Utilities | No Release | ||||
Coking | Turnaround | Other | Category 1 | ||||
Crude | Routine maintenance | Category 2 | |||||
Desulfurization | Temporary | Evacuation | Category 3 | ||||
FCC | Other | Yes | Category 4 | ||||
Gas Treating | No | Category 5 | |||||
Hydrogen | Point of Release | Category 6 | |||||
Hydrotreating | Pump | Fire | Category 7 | ||||
Hydrocracking | Compressor | Yes | Multiple Categories | ||||
Isom | BlowerFan | No | |||||
MarineJetty | Pressure Vessel | lt $2500 | |||||
Reforming | FilterCoalescer | ||||||
Sulfur recovery | Furnace | PRDs | |||||
Vapor recoverylight ends | Boiler | Directly to Atmosphere | |||||
Wastewater | Heat exchanger | via Downstream Destructive Device | |||||
REFINING amp PETROCHEMICAL | Cooling Tower | No | |||||
Tank FarmStorage FacilityOffsite | Piping system | Yes | |||||
UtilitiesSteam PlantCogeneration | Reactor | No | |||||
Other | Atmospheric tank | ||||||
PETROCHEMICAL | FlareRelief System | Acute release above thresholds | |||||
CO H2 | Other | Yes | |||||
LNG | No | ||||||
Methane | Events | ||||||
Methanol | No Tier 1 Events | Indoor Outdoor | |||||
Methyl Mercaptan | No Tier 2 Events | No Release | |||||
Formaldehyde | No Tier 1 or Tier 2 Events | Indoor | |||||
Formaldehyde derivatives | NA | Outdoor | |||||
Acetic Acid | |||||||
Acetic Acid derivatives | Event Type | ||||||
Ethane | Injury | ||||||
Ethylene | Fire | ||||||
Ethanol | Explosion | ||||||
Ethylene oxide | PRD Discharge | ||||||
Ethylene derivatives | Acute Release | ||||||
Polyethylene | |||||||
Ethylene dichloride | General | ||||||
Ethylene dichloride derivatives | Yes | ||||||
Ethyl benzene | No | ||||||
Ethyl benzene derivatives | |||||||
Polystyrene | |||||||
Styrene-Butadiene | |||||||
Propane | |||||||
Propylene | |||||||
Polypropylene | |||||||
Isopropanol | |||||||
Propylene oxide | |||||||
Propylene oxide derivatives | |||||||
Butane | |||||||
Isobutane | |||||||
Isobutene | |||||||
Butadiene | |||||||
MTBE | |||||||
ETBE | |||||||
Pentane | |||||||
Hexane | |||||||
Cyclohexane | |||||||
Hexanol | |||||||
Aromatics Derivatives | |||||||
Benzene | |||||||
Toluene | |||||||
Xylene | |||||||
Para Xylene | |||||||
Amines Derivatives | |||||||
TDA MDA IPDA etc | |||||||
Isocyanates | |||||||
Specialty Chemicals | |||||||
LoadingUnloading | |||||||
Pilot Plant |
Instructions | ||||||||||||||
Step 1 | Complete the Contact Tab with your contact information and company information | |||||||||||||
Be sure to note the region of your reporting (IE North America France Japan etc) | ||||||||||||||
Survey on Process Safety Events | ||||||||||||||
Step 2 | Complete the survey one line per Process Safety Event for your companyregion | |||||||||||||
ALL REPORTED DATA SHOULD BE FROM CALENDAR YEAR 2017 | ||||||||||||||
Step 3 | Return completed survey to | |||||||||||||
Company Name | ||||||||||||||
Contact Person | All Surveys Due by xxx date | |||||||||||||
Address | ||||||||||||||
Fax | ||||||||||||||
Telephone | ||||||||||||||
Region | ||||||||||||||
2016 | 2017 | 2018 | 2019 | 2020 | |||||
Feb - April RCLG PS Pilot Program May ndash Adjustmentsclarification to guidance document June Report outcomes of pilot program to RCLG and ICCA Board July - December middot RCLG associations consider guidance and develop reporting methodology for their memberships middot RCLG associations can request ICCA capacity building funds for PS reporting workshops for members if needed | Jan - Dec RCLG Association membership begin collecting PS data from their members Jan ndash Dec Associations hold workshops on Process Safety and performance reporting utilizing RCLG funds and experts if needed | Jan ndash Feb Reporting of process safety incidents to RCLG begins for associations with data (2017 data) April RCLG reviews outcomes challenges and raw data from the first reporting cycle (internally) June RCLG share draft data with ICCA Board July - December Update and adjust guidance as necessary Associations hold workshops on Process Safety and performance reporting utilizing RCLG funds and experts if needed | Jan ndash Feb Reporting of process safety incidents to RCLG begins for associations with data (2018 data) April RCLG reviews outcomes challenges and raw data from the second reporting cycle (internally) June RCLG share draft data with ICCA Board July - December Update and adjust guidance as necessary Associations hold workshops on Process Safety and performance reporting utilizing RCLG funds and experts if needed | Jan ndash Feb Reporting of process safety incidents to RCLG begins for all associations Process Safety incident reporting becomes part of the recommend base set of RCLG KPI metrics (2019 data) April RCLG reviews outcomes challenges and raw data from the second reporting cycle (internally consider external reporting) June RCLG share draft data with ICCA Board |
Name | Affiliation | ||
Peter Schmelzer | Bayer CEFIC - Chairman | ||
Americo Diniz Carvalho Neto | Braskem | ||
Bradford Johnson | American Chemistry Council | ||
David Cummings | DuPont | ||
Debra Phillips | American Chemistry Council | ||
Hans Schwarz | BASF | ||
Kathryn Walton | Plastics and Chemicals Industries Association | ||
Kazuyuki Akita | Japanese Chemical Industry Association | ||
Kelly Keim | ExxonMobil Chemical Company API Representative | ||
Kenan Stevick | Dow | ||
Kiyokazu Murata | Japanese Chemical Industry Association | ||
Larry Bowler | SABIC | ||
Lorna Young | Chemical Industry Association of Canada | ||
Louisa Nara | Center for Chemical Process Safety | ||
Associaccedilatildeo Brasileira da Induacutestria Quiacutemica | |||
Masatoshi Kumamoto | Japanese Chemical Industry Association | ||
Milton Lacerda | Petrobras | ||
Phil Scott | Chemical Industries Association | ||
Piet Knijff | DSM European Process Safety Centre | ||
Scott Donaldson and Eamon Chandler | Shell | ||
Scott Wallace | Olin Corporation | ||
Shakeel Kadri | Air Products and Chemicals Inc |
Event Incident Categories | |||||||||||
Severity Level | SafetyHuman Health | Direct Cost from Fire or Explosion | Material ReleaseWithin 1-Hr Period | Community Impact | Environmental Impact [off-site] | ||||||
Level 4 1 point | middot Injury requiring treatment beyond first aid to an employee contractor or subcontractor (Meets local regulations) | middot Resulting in Direct Damage Cost of $25 K le up to $25 K | middot Release volume between 1x le TQ lt 40x | middot Officially declared shelter-in-place or officially declared evacuation (on or off site) middot Precautionary off site shelter in place or evacuation le 3 hours | middot Acute Environmental Remediation Cost $25 K le up to $25 K | ||||||
Level 3 3 points | middot Days Away From Work injury to an employee contractor or subcontractor or middot Injury requiring treatment beyond first aid to a third party (Meets local regulations) | middot Resulting in Direct Damage Cost of $25 K le up to $250 K | middot Release volume between 40x le TQ lt 160x | middot Officially declared shelter-in-place or officially declared evacuation (on or off site) middot Precautionary off site shelter in place or evacuation 3 hours ge up to 12 hours | middot Acute Environmental Remediation Cost $25 K le up to $250 K | ||||||
Level 2 9 points | middot A fatality of an employee contractor or subcontractor or middot A hospital admission of a third party (Meets local regulations) | middot Resulting in Direct Damage Cost of $250 K le up to $25 MM | middot Release volume between 160x le TQ lt 640x | middot Officially declared shelter-in-place or officially declared evacuation (on or off site) middot Precautionary off site shelter in place or evacuation 12 hours ge up to 24 hours | middot Acute Environmental Remediation Cost $250 K le up to $25 MM | ||||||
Level 1 27 points | middot Multiple fatalities of employees contractors or subcontractors or middot multiple hospital admission of third parties or middot A fatality of a third party (Meets local regulations) | middot Resulting in Direct Damage Costs of ge $25 MM | middot Release volume ge 640x TQ | middot Officially declared shelter-in-place or officially declared evacuation (on or off site) middot Precautionary off site shelter in place or evacuation ge 24 hours | middot Acute Environmental Remediation Cost ge $25 MM |
It is recognized that threshold quantities given in kg and lb or in lb and bbl are not exactly equivalent Companies should select one of the pair and use it consistently for all recordkeeping activities | |
In determining the Threshold Release Category for a material one should first use the toxic (TIH Zone) or flammability (Flash Point and Boiling Point) or corrosiveness (Strong Acid or Base vs Moderate Acid or Base) characteristics Only when the hazard of the material is not expressed by those simple characteristics (eg reacts violently with water) is the UNDGL Packing Group used a Many materials exhibit more than one hazard Correct placement in Hazard Zone or Packing Group shall follow the rules of DOT 49 CFR 1732a [14] or UN Recommendations on the Transportation of Dangerous Goods Section 2 [12] See Annex F b A structure composed of four complete (floor to ceiling) walls floor and roof c For solutions not listed on the UNDG the anhydrous component shall determine the TIH zone or Packing Group classification The threshold quantity of the solution shall be back calculated based on the threshold quantity of the dry component weight d For mixtures where the UNDG classification is unknown the fraction of threshold quantity release for each component may be calculated If the sum of the fractions is equal to or greater than 100 the mixture exceeds the threshold quantity Where there are clear and independent toxic and flammable consequences associated with the mixture the toxic and flammable hazards are calculated independently See Annex E PSE Examples amp Questions 49 - 53 e A LOPC of Liquids with Flash Point gt 60 degC (140 degF) and 93 degC (200 degF) released at a temperature below Flash Point cannot be Tier 1 PSE based upon quantity released no matter the volume f A LOPC of a moderate acidbase cannot be Tier 1 PSE based upon quantity released no matter the volume |
Threshold Release Category | Material Hazard Classification acdef | Threshold Quantity (outdoor release) | Threshold Quantity (indoorb release) | ||||
T2-1 | TIH Zone A Materials | ge 05 kg (11 lb) | ge 025 kg (055 lb) | ||||
T2-2 | TIH Zone B Materials | ge 25 kg (55 lb) | ge 125 kg (275 lb) | ||||
T2-3 | TIH Zone C Materials | ge 10 kg (22 lb) | ge 5 kg (11 lb) | ||||
T2-4 | TIH Zone D Materials | ge 20 kg (44 lb) | ge 10 kg (22 lb) | ||||
T2-5 | Flammable Gases OR Liquids with Normal Boiling Point 35 degC (95 degF) and Flash Point 23 degC (73 degF) OR Other Packing Group I Materials (excluding acidsbases) | ge 50 kg (110 lb) | ge 25 kg (55 lb) | ||||
T2-6 | Liquids with Normal Boiling Point 35 degC (95 degF) and Flash Point 23 degC (73degF) OR Other Packing Group II Materials (excluding acidsbases) | ge 100 kg (220 lb)orge 07 bbl | ge 50 kg (110 lb)orge 035 bbl | ||||
T2-7 | Liquids with Flash Point 23 degC (73 degF) and 60 degC (140 degF) OR Liquids with Flash Point 60 degC (140 degF) released at a temperature at or above Flash Point OR strong acidsbases (see definition Refer to draft RP 754 document) OR UNDG Class 2 Division 22 (non-flammable non-toxic gases) excluding air OR Other Packing Group III Materials | ge 200 kg (440 lb)orge 14 bbl | ge 100 kg (220 lb)orge 07 bbl | ||||
T2-8 | Liquids with Flash Point 60 degC (140 degF) and 93 degC (200 degF) released at a temperature below Flash Point OR Moderate acidsbases | ge 1000 kg (2200 lb)orge 7 bbl | ge 500 kg (1100 lb)orge 35 bbl |
None | |
$2500 to $25000 | |
$25000 to $250000 | |
$250000 to $25000000 | |
More than $25000000 | |
Yes - Using GHS TABLE | |
Yes - Using API RP 754 TABLE | |
NO | |
NA | |
1x le TQ lt 40x | |
40x le TQ lt 160x | |
160x le TQ lt 640x | |
ge 640x TQ | |
Yes le 3 hours | |
Yes 3 hours ge 12 hours | |
Yes 12 hours ge 24 hours | |
Yes ge 24 hours | |
No | |
Small-scale | |
Medium-scale | |
Large-scale | |
No | |
Yes | |
No | |
middot Injury requiring treatment beyond first aid to an employee contractor or subcontractor | |
middot Days Away From Work injury to an employee contractor or subcontractor or middot Injury requiring treatment beyond first aid to a third party | |
middot A fatality of an employee contractor or subcontractor or middot A hospital admission of a third party | |
middot Multiple fatalities of employees contractors or subcontractors or middot multiple hospital admission of third parties or middot A fatality of a third party | |
NA | |
1x le TQ lt 3x | |
3x le TQ lt 9x | |
9x le TQ lt 27x | |
ge 27x TQ |
ICCA Process Safety Pilot Reporting ProgramFebruary 8 2016 | 1 | 2 | 3 | 4 | 5 | 6 | 7 | 8 | 9 | 10 | 12 | 13 | 14 | 15 | |||||||||||||||||||||||
SAFETY Details(Meeting Local Regulations) | Direct Cost from Fire or Explosion | Community Impact | Environmental Impact | Material Released(Measured using the 1 Hour Rule) | |||||||||||||||||||||||||||||||||
Company Association Details | |||||||||||||||||||||||||||||||||||||
GHS | API - RP 754 | ||||||||||||||||||||||||||||||||||||
Company or Assocation Name | Headquarter Association | Location of Event Ex - City State amp Country | Date and Time of Event | Safety InjuryDid the Event result in a Recordable Lost Time Accident or Fatality or Hospital admission of anyone on or off siteUse Drop Down Menu | Safety InjuryIf yes please insert the total number of injuries | Safety InjuryFor puropses of utilizing the Severity Table please indicate the level of severity by chosing the MOST SEVERE classification that describes your incidentUse Drop Down Menu | Safety InjuryDid the incident involve Fatalities If so how many total fatalities If none enter Zero | Safety InjuryPlease Report Total Employee Hours for Calendar Year 2015 | Safety InjuryPlease Report Total Contractor Hours for Calendar Year 2015 | Direct Cost Did the Event result in Direct Damage CostUse Drop Down Menu | Direct Cost If so how muchAmount is in US DollarsUse Drop Down Menu | Community ImpactDid the event result inbull Officially declared shelter-in-place or officially declared evacuation (on or off site)ORbull Precautionary off site shelter in place or evacuation Use Drop Down Menu | Environmental ImpactDid the event result inAcute Environmental Remediation CostIf so indicate the amount in US DollarsUse Drop Down Menu | Material ReleasedDid the Event result in an Acute Release of material beyond one of the two threshold tablesIf so indicate which Threshold Table you used to make this determinationUse Drop Down Menu | Material ReleasedIf so indicate the amount released USING GHS CLASSIFICATION TABLEUse Drop Down Menu | Material ReleasedIf so indicate the amount released USING THE THRESHOLD TABLE FROM API RP-754Use Drop Down Menu | Material ReleasedIf available please indicate the material released | ||||||||||||||||||||
1 | ABC Chemical Company | American Chemistry Council | Washington DC - USA | January 4 2016 | Yes | 2 | middot Days Away From Work injury to an employee contractor or subcontractor or middot Injury requiring treatment beyond first aid to a third party | 0 | 5525000 | 1500250 | No | $2500 to $25000 | Yes le 3 hours | $2500 to $25000 | Yes - Using GHS TABLE | 40x le TQ lt 160x | NA | Chlorine | |||||||||||||||||||
2 | XYZ Chemical Company | American Chemistry Council | Washington DC - USA | 5-Jan-16 | Yes | 1 | middot Injury requiring treatment beyond first aid to an employee contractor or subcontractor | 0 | 5525000 | 1500250 | Yes | $2500 to $25000 | No | $2500 to $25000 | Yes - Using API RP 754 TABLE | NA | 3x le TQ lt 9x | Benzene | |||||||||||||||||||
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Zero or None | Yes - Duration Unknown | ||||||||||||||||||||||||||||||||||||
Processes | Mode of Operation | Type of material released | Status of Operation | ||||
REFINING | Start-up | Flammable | Open | ||||
Alkylation HF | Planned shutdown | Combustible | Closed | ||||
Alkylation sulfuric | Emergency shutdown | Toxic | |||||
BitumenResidAsphalt | Normal | Corrosive | Tier 1 Acute Releases | ||||
Calcining | Upset | Utilities | No Release | ||||
Coking | Turnaround | Other | Category 1 | ||||
Crude | Routine maintenance | Category 2 | |||||
Desulfurization | Temporary | Evacuation | Category 3 | ||||
FCC | Other | Yes | Category 4 | ||||
Gas Treating | No | Category 5 | |||||
Hydrogen | Point of Release | Category 6 | |||||
Hydrotreating | Pump | Fire | Category 7 | ||||
Hydrocracking | Compressor | Yes | Multiple Categories | ||||
Isom | BlowerFan | No | |||||
MarineJetty | Pressure Vessel | lt $2500 | |||||
Reforming | FilterCoalescer | ||||||
Sulfur recovery | Furnace | PRDs | |||||
Vapor recoverylight ends | Boiler | Directly to Atmosphere | |||||
Wastewater | Heat exchanger | via Downstream Destructive Device | |||||
REFINING amp PETROCHEMICAL | Cooling Tower | No | |||||
Tank FarmStorage FacilityOffsite | Piping system | Yes | |||||
UtilitiesSteam PlantCogeneration | Reactor | No | |||||
Other | Atmospheric tank | ||||||
PETROCHEMICAL | FlareRelief System | Acute release above thresholds | |||||
CO H2 | Other | Yes | |||||
LNG | No | ||||||
Methane | Events | ||||||
Methanol | No Tier 1 Events | Indoor Outdoor | |||||
Methyl Mercaptan | No Tier 2 Events | No Release | |||||
Formaldehyde | No Tier 1 or Tier 2 Events | Indoor | |||||
Formaldehyde derivatives | NA | Outdoor | |||||
Acetic Acid | |||||||
Acetic Acid derivatives | Event Type | ||||||
Ethane | Injury | ||||||
Ethylene | Fire | ||||||
Ethanol | Explosion | ||||||
Ethylene oxide | PRD Discharge | ||||||
Ethylene derivatives | Acute Release | ||||||
Polyethylene | |||||||
Ethylene dichloride | General | ||||||
Ethylene dichloride derivatives | Yes | ||||||
Ethyl benzene | No | ||||||
Ethyl benzene derivatives | |||||||
Polystyrene | |||||||
Styrene-Butadiene | |||||||
Propane | |||||||
Propylene | |||||||
Polypropylene | |||||||
Isopropanol | |||||||
Propylene oxide | |||||||
Propylene oxide derivatives | |||||||
Butane | |||||||
Isobutane | |||||||
Isobutene | |||||||
Butadiene | |||||||
MTBE | |||||||
ETBE | |||||||
Pentane | |||||||
Hexane | |||||||
Cyclohexane | |||||||
Hexanol | |||||||
Aromatics Derivatives | |||||||
Benzene | |||||||
Toluene | |||||||
Xylene | |||||||
Para Xylene | |||||||
Amines Derivatives | |||||||
TDA MDA IPDA etc | |||||||
Isocyanates | |||||||
Specialty Chemicals | |||||||
LoadingUnloading | |||||||
Pilot Plant |
Instructions | ||||||||||||||
Step 1 | Complete the Contact Tab with your contact information and company information | |||||||||||||
Be sure to note the region of your reporting (IE North America France Japan etc) | ||||||||||||||
Survey on Process Safety Events | ||||||||||||||
Step 2 | Complete the survey one line per Process Safety Event for your companyregion | |||||||||||||
ALL REPORTED DATA SHOULD BE FROM CALENDAR YEAR 2017 | ||||||||||||||
Step 3 | Return completed survey to | |||||||||||||
Company Name | ||||||||||||||
Contact Person | All Surveys Due by xxx date | |||||||||||||
Address | ||||||||||||||
Fax | ||||||||||||||
Telephone | ||||||||||||||
Region | ||||||||||||||
2016 | 2017 | 2018 | 2019 | 2020 | |||||
Feb - April RCLG PS Pilot Program May ndash Adjustmentsclarification to guidance document June Report outcomes of pilot program to RCLG and ICCA Board July - December middot RCLG associations consider guidance and develop reporting methodology for their memberships middot RCLG associations can request ICCA capacity building funds for PS reporting workshops for members if needed | Jan - Dec RCLG Association membership begin collecting PS data from their members Jan ndash Dec Associations hold workshops on Process Safety and performance reporting utilizing RCLG funds and experts if needed | Jan ndash Feb Reporting of process safety incidents to RCLG begins for associations with data (2017 data) April RCLG reviews outcomes challenges and raw data from the first reporting cycle (internally) June RCLG share draft data with ICCA Board July - December Update and adjust guidance as necessary Associations hold workshops on Process Safety and performance reporting utilizing RCLG funds and experts if needed | Jan ndash Feb Reporting of process safety incidents to RCLG begins for associations with data (2018 data) April RCLG reviews outcomes challenges and raw data from the second reporting cycle (internally) June RCLG share draft data with ICCA Board July - December Update and adjust guidance as necessary Associations hold workshops on Process Safety and performance reporting utilizing RCLG funds and experts if needed | Jan ndash Feb Reporting of process safety incidents to RCLG begins for all associations Process Safety incident reporting becomes part of the recommend base set of RCLG KPI metrics (2019 data) April RCLG reviews outcomes challenges and raw data from the second reporting cycle (internally consider external reporting) June RCLG share draft data with ICCA Board |
Name | Affiliation | ||
Peter Schmelzer | Bayer CEFIC - Chairman | ||
Americo Diniz Carvalho Neto | Braskem | ||
Bradford Johnson | American Chemistry Council | ||
David Cummings | DuPont | ||
Debra Phillips | American Chemistry Council | ||
Hans Schwarz | BASF | ||
Kathryn Walton | Plastics and Chemicals Industries Association | ||
Kazuyuki Akita | Japanese Chemical Industry Association | ||
Kelly Keim | ExxonMobil Chemical Company API Representative | ||
Kenan Stevick | Dow | ||
Kiyokazu Murata | Japanese Chemical Industry Association | ||
Larry Bowler | SABIC | ||
Lorna Young | Chemical Industry Association of Canada | ||
Louisa Nara | Center for Chemical Process Safety | ||
Associaccedilatildeo Brasileira da Induacutestria Quiacutemica | |||
Masatoshi Kumamoto | Japanese Chemical Industry Association | ||
Milton Lacerda | Petrobras | ||
Phil Scott | Chemical Industries Association | ||
Piet Knijff | DSM European Process Safety Centre | ||
Scott Donaldson and Eamon Chandler | Shell | ||
Scott Wallace | Olin Corporation | ||
Shakeel Kadri | Air Products and Chemicals Inc |
Event Incident Categories | |||||||||||
Severity Level | SafetyHuman Health | Direct Cost from Fire or Explosion | Material ReleaseWithin 1-Hr Period | Community Impact | Environmental Impact [off-site] | ||||||
Level 4 1 point | middot Injury requiring treatment beyond first aid to an employee contractor or subcontractor (Meets local regulations) | middot Resulting in Direct Damage Cost of $25 K le up to $25 K | middot Release volume between 1x le TQ lt 40x | middot Officially declared shelter-in-place or officially declared evacuation (on or off site) middot Precautionary off site shelter in place or evacuation le 3 hours | middot Acute Environmental Remediation Cost $25 K le up to $25 K | ||||||
Level 3 3 points | middot Days Away From Work injury to an employee contractor or subcontractor or middot Injury requiring treatment beyond first aid to a third party (Meets local regulations) | middot Resulting in Direct Damage Cost of $25 K le up to $250 K | middot Release volume between 40x le TQ lt 160x | middot Officially declared shelter-in-place or officially declared evacuation (on or off site) middot Precautionary off site shelter in place or evacuation 3 hours ge up to 12 hours | middot Acute Environmental Remediation Cost $25 K le up to $250 K | ||||||
Level 2 9 points | middot A fatality of an employee contractor or subcontractor or middot A hospital admission of a third party (Meets local regulations) | middot Resulting in Direct Damage Cost of $250 K le up to $25 MM | middot Release volume between 160x le TQ lt 640x | middot Officially declared shelter-in-place or officially declared evacuation (on or off site) middot Precautionary off site shelter in place or evacuation 12 hours ge up to 24 hours | middot Acute Environmental Remediation Cost $250 K le up to $25 MM | ||||||
Level 1 27 points | middot Multiple fatalities of employees contractors or subcontractors or middot multiple hospital admission of third parties or middot A fatality of a third party (Meets local regulations) | middot Resulting in Direct Damage Costs of ge $25 MM | middot Release volume ge 640x TQ | middot Officially declared shelter-in-place or officially declared evacuation (on or off site) middot Precautionary off site shelter in place or evacuation ge 24 hours | middot Acute Environmental Remediation Cost ge $25 MM |
It is recognized that threshold quantities given in kg and lb or in lb and bbl are not exactly equivalent Companies should select one of the pair and use it consistently for all recordkeeping activities | |
In determining the Threshold Release Category for a material one should first use the toxic (TIH Zone) or flammability (Flash Point and Boiling Point) or corrosiveness (Strong Acid or Base vs Moderate Acid or Base) characteristics Only when the hazard of the material is not expressed by those simple characteristics (eg reacts violently with water) is the UNDGL Packing Group used a Many materials exhibit more than one hazard Correct placement in Hazard Zone or Packing Group shall follow the rules of DOT 49 CFR 1732a [14] or UN Recommendations on the Transportation of Dangerous Goods Section 2 [12] See Annex F b A structure composed of four complete (floor to ceiling) walls floor and roof c For solutions not listed on the UNDG the anhydrous component shall determine the TIH zone or Packing Group classification The threshold quantity of the solution shall be back calculated based on the threshold quantity of the dry component weight d For mixtures where the UNDG classification is unknown the fraction of threshold quantity release for each component may be calculated If the sum of the fractions is equal to or greater than 100 the mixture exceeds the threshold quantity Where there are clear and independent toxic and flammable consequences associated with the mixture the toxic and flammable hazards are calculated independently See Annex E PSE Examples amp Questions 49 - 53 e A LOPC of Liquids with Flash Point gt 60 degC (140 degF) and 93 degC (200 degF) released at a temperature below Flash Point cannot be Tier 1 PSE based upon quantity released no matter the volume f A LOPC of a moderate acidbase cannot be Tier 1 PSE based upon quantity released no matter the volume |
Threshold Release Category | Material Hazard Classification acdef | Threshold Quantity (outdoor release) | Threshold Quantity (indoorb release) | ||||
T2-1 | TIH Zone A Materials | ge 05 kg (11 lb) | ge 025 kg (055 lb) | ||||
T2-2 | TIH Zone B Materials | ge 25 kg (55 lb) | ge 125 kg (275 lb) | ||||
T2-3 | TIH Zone C Materials | ge 10 kg (22 lb) | ge 5 kg (11 lb) | ||||
T2-4 | TIH Zone D Materials | ge 20 kg (44 lb) | ge 10 kg (22 lb) | ||||
T2-5 | Flammable Gases OR Liquids with Normal Boiling Point 35 degC (95 degF) and Flash Point 23 degC (73 degF) OR Other Packing Group I Materials (excluding acidsbases) | ge 50 kg (110 lb) | ge 25 kg (55 lb) | ||||
T2-6 | Liquids with Normal Boiling Point 35 degC (95 degF) and Flash Point 23 degC (73degF) OR Other Packing Group II Materials (excluding acidsbases) | ge 100 kg (220 lb)orge 07 bbl | ge 50 kg (110 lb)orge 035 bbl | ||||
T2-7 | Liquids with Flash Point 23 degC (73 degF) and 60 degC (140 degF) OR Liquids with Flash Point 60 degC (140 degF) released at a temperature at or above Flash Point OR strong acidsbases (see definition Refer to draft RP 754 document) OR UNDG Class 2 Division 22 (non-flammable non-toxic gases) excluding air OR Other Packing Group III Materials | ge 200 kg (440 lb)orge 14 bbl | ge 100 kg (220 lb)orge 07 bbl | ||||
T2-8 | Liquids with Flash Point 60 degC (140 degF) and 93 degC (200 degF) released at a temperature below Flash Point OR Moderate acidsbases | ge 1000 kg (2200 lb)orge 7 bbl | ge 500 kg (1100 lb)orge 35 bbl |
Dear Members of the Taiwan Responsible Care Association We would like to express our deep appreciation for the work of ICCA and the Responsible Care Leadership Group in developing this valuable guidance which we are delighted to bring under the umbrella of the Taiwan Responsible Care Association Process safety reporting is at the very heart of Responsible Care It has been a proven practice in the chemical industry for decades We strive continuously to improve our management procedures to reduce the occurrence of chemical incidents and measuring is absolutely crucial to that process ndash for you cannot improve what you do not measure Reporting enables companies and associations to share best practices and improve their performance while reducing their environmental footprint Learning from incidents has been key to improving process safety to todayrsquos low levels and we aim to bring them down further still Although the industry has long been tracking and reporting process safety performance at a regional level this proposal for process safety event reporting will for the first time enable broad-based and global reporting of process safety performance right across the chemical and petrochemical industries We invite all members of the Taiwan Responsible Care Association to implement this guidance by 2020 and are committed to helping them do so The national chemical industry associations play a vital role in promoting best practice and we look to them to roll out the guidance to their member companies It is our sincere hope that these guidelines will contribute to enhancing process and plant safety throughout Taiwan For your reference the original and globally applicable guidance
ICCA Process Safety
Guidance_Finaldoc
Patrick Vandenhoeke Head of Responsible Care Leadership Group
3
敬愛的 TRCA 會員
對於 ICCA (International Council of Chemical Associations 國際化學工業協會) 和責任照顧領
導群在制定這一項寶貴指引時的付出我們表達最深的感謝 我們很高興能夠為 TRCA帶來
這一項可作為保護傘的寶貴指引
製程安全是責任照顧制度的核心也是化學工業數十年來成熟的實踐我們不斷努力改善
管理程序以減少化學事故的發生量測對於製程安全管理是絕對至關重要的一環因為我
們無從改進沒有進行過量測的項目提報(製程安全指標)使得公司與協會得以分享最佳典
範在提高績效表現的同時減少環境足跡從事件中學習是改善製程安全達到低事件率的
關鍵我們的目標是再進一步降低製程安全事件率
儘管化工業長期以來一直在各地區追蹤與提報製程安全績效但此次製程安全事件提報的
建議將首度啟用更廣泛的基礎在全球提報製程安全績效提報部門將包括化學工業與石
化工業
我們邀請 TRCA 的所有會員在 2020 年前一同來推行這項提報指引我們也將致力於協助各
位達標國家化學工業協會在推廣最佳實務方面扮演重要角色我們期待他們向所屬會員
公司推動本指引
我們誠摯地希望這些指導方針將有助於台灣提升製程和工廠的安全
謹提供全球適用的指引原始檔案如下請參考
Patrick Vandenhoeke
責任照顧領導群主席
GUIDANCE FOR REPORTING ON THE ICCA GLOBALLY HARMONIZED PROCESS SAFETY METRICJune2016The Responsible Carereg Leadership Group
ContentsBackground2Executive Summary2Data to be reported by RCLG Associations to RCLG4Overview of ICCA Process Safety Event Criteria as a Flow Chart5Key Criteria for Reporting Process Safety Events to RCLG6Detailed Guidelines on Identifying a Process Safety Event7Table 1 ndash GHS Classification Table11Table 2 ndash API RP 754 Tier II Classification Table12Appendix A ndash Severity Table Using A Severity Weighting System is Encouraged for All Associations14Appendix B ndash Frequently Asked Questions16Appendix C ndash List of RCLG Taskforce Members22Appendix D ndash Detailed Schedule of Events23Appendix E ndash Optional Excel Reporting Form24
FIANL DRAFT
June 15 2016
The Responsible Carereg initiative began in 1985 and as the chemical industryrsquos commitment to continuous performance improvements Process Safety has been a pillar of Responsible Care since its inception and many regional approaches to tracking and reporting process safety performance have developed over the 30 years of Responsible Care implementation yet no globally harmonized system had been put into place In 2012 in the wake of several high profile process safety events the International Council of Chemical Associations (ICCA) Board of Directors directed the Responsible Care Leadership Group (RCLG) to develop a recommendation for a globally harmonized process safety performance reporting by no later than 2015
Throughout 2013 and 2014 a Taskforce comprised of multinational companies and RCLG associations chaired by Dr Peter Schmelzer Head of Health Safety and Environmental Protection Bayer HealthCare AG worked to develop a globally harmonized ICCA approach to process safety performance reporting A list of Taskforce members can be found in Appendix C During the same timeframe the American Petroleum Institute (API) also initiated a process to update its Recommend Practice 754 (RP-754) ndash Leading and Lagging Process Safety Metric Standard RP-754 is broadly used in the refining and petrochemical sector and in the Americas region to track process safety performance To optimize global adoption of a unified standard the RCLG Taskforce strived to achieve full harmonization of its recommendation with the revised API RP 754 metric expected to be finalized in the first quarter 2016
Executive SummaryAfter more than 2 years of discussion research debate and feasibility assessment the Process Safety Harmonization Taskforce recommends that ICCA adopt a process safety event rate metric The adoption of this metric would require each RCLG association to collect the number of process safety events experienced by their members on an annual basis as well as total number of worker hours (employees and contractors) experienced by their members each year The process safety event rate is the ratio of events to hours The Taskforce also recommends that reporting of these data points to the RCLG be phased in over the next 3 years allowing regions with the desire and ability to report immediately to do so while also allowing additional time to companies and organizations that are developing the ability to track these data for the first time
The criteria that determine whether a process-related event qualifies as a process safety event are based on a loss of primary containment of a chemical or a release of energy triggering thresholds any one of four impact areas 1) safetyhuman health consequences 2) direct cost due to damage from incident 3) community impact and 4) chemical release quantity (see the flow chart showing reporting triggers) These four impact areas in the recommended ICCA process safety event definition are identical to the impact areas in the RP-754 Tier II incident standard The thresholds for reporting are also identical in all areas with the exception of the chemical release quantity thresholds To address this difference the ICCA process safety event definition will allow companies the use of either the GHS-based reporting thresholds developed by ICCA for the chemical release criteria or the UN Dangerous Goods (UNDG)-based reporting thresholds used in the RP-754 standard for Tier II incidents The Taskforce believes that the two systems though different are comparably robust in the universe of chemicals covered and the severity of incidents captured by reporting While there will be relatively little difference in the numbers of events captured and reported using the two different threshold approaches there may be differences that would be most clearly seen at the company level based on raw material and product use hence the Taskforce cautions companies not to compare their results with companies that use a different chemical release threshold approach Regardless under the RCLG proposal companies can choose the chemical release thresholds by which they report in to their national and regional associations If associations are interested in translating results based on one reporting approach to another the RCLG will provide a translation table However given the complexity of this exercise and the need to access raw incident data the Taskforce does not believe that this adds value and recommends against it
The Taskforce believes that this proposal for process safety event reporting will enable broad-based global reporting of process safety performance across the chemical and petrochemical industries It will provide a roadmap for regions associations and companies that are currently not tracking process safety performance to recognize the benefits that tracking and reporting will bring For regions associations and companies that are already experienced in gathering process safety data this recommendation allows for broader global alignment and focus on continuous improvement in process safety performance The systems that are built to improve process safety performance are informed by robust process safety event data and this is the major objective of this initiative
Data to be reported by RCLG Associations to RCLGOn an annual basis RCLG Associations will be asked to report two data points into ICCA using the RCLG KPI Reporting Website on the schedule provided below
1Total Member Company Worker Hours for Association (employee and contractor)
2Total Number of Process Safety Events
ICCA will use the above two data points to report process safety performance in the form of Process Safety Event Rate (PSER) normalized per 100 employees where an employee works 2000 hours a year
(Total Events Total Hours) x 200000 = PSER
Recommended Reporting Schedule
The Taskforce recommends a phased-in approach for reporting process safety event rate Such a schedule will allow more experienced companies and associations to report in the next several years while allowing other companies and associations to begin reporting by 2019 RCLG Associations would be asked to report the two process safety event rate data points annually to the ICCA through the RCLG KPI metrics reporting system If you do not know your associationrsquos username and password please contact the RCLG
The proposed schedule for process safety event rate reporting by RCLG associations is as follows
April 2015RCLG considers Taskforce proposal
June 2015ICCA Board of Directors considers RCLG final recommendation
July 2015RCLG releases the first detailed reporting guidance document for associations and member companies
Feb 2016 RCLG Reporting RCLG initiates process safety reporting pilot program through association volunteers with updated an enhanced guidance document RCLG rolls out final guidance document in June 2016
2017RCLG Associations begin collecting data from its membership
2018-2019 RCLG Reporting Optional process safety data reporting by RCLG Associations
2020 ReportingRCLG includes process safety as a mandatory metric in the KPI reporting program
See Appendix D ndash Detailed Schedule of Events
Overview of ICCA Process Safety Event Criteria as a Flow ChartNO Does not meet the criteria for a Process Safety Event
Start
NO
NO
NO
Was a chemical substance or a chemical process directly involved
YES
YES
Release of material fire explosion or implosion fromat a chemical process unit
Incident in production distribution storage utilities pilot plants within a companyrsquos facility
YES
NO
Officially declared shelter in place or evacuation
Or Precautionary off site shelter in place or evacuation
Substance Release Thresholds met
Recordable injury
Or
hospital admission of people on or off site
Damage ge $2500direct costto company
NO
NO
NO
ICCA or API 754 Tier II chemical release thresholds exceeded
YES
YES
YES
Yes Reportable as a Process Safety Event
YES
Key Criteria for Reporting Process Safety Events to RCLGTotal Worker Hours
RCLG Associations should report the total number of employee hours worked for each member company in their association and the total number of contractor hours worked for each member company as a combined single number For the purposes of this guidance document each association should refer to their local and regional definitions for employee and contractor The goal for reporting total hours is to include all individuals who are involved with chemical manufacturing except where those individuals are tasked with major construction projects such as large scale investments with specific one-time project organizations created for design engineering and construction of new or significant expansion to existing process facilities When reporting total worker hours companies should report the same hours used for reporting personnel hours This way companies can have the same data set for occupational and process safety Personnel hours should include those hours from all chemical manufacturing operations not just from facilities where a process safety incident occurred
Process Safety Event
For the purposes of this ICCA Reporting a process safety event has occurred when
A When a chemical substance or a chemical process is directly involved AND
B The incident occurred in production distribution storage utility pilot plant within the site boundaries of companyrsquos facility AND
C There was a release of material or energy (eg fire explosion implosion) from a process unit AND
D One or more of the following Reporting Thresholds have been met
1 Safety Injury
middot Injury resulting in a Recordable Lost Time Accident or Fatality or Hospital admission of anyone on or off site OR
2 Direct Damage Cost
middot A fire explosion or clean up necessary to avoidremediate environmental damage resulting in a direct cost equal to or greater than $2500 USDs OR
3 Shelter in Place Evacuation
middot An officially declared shelter in place (on or off site) OR
middot An officially declared evacuation (on or off site) OR
middot A precautionary off site shelter in place or evacuation OR
4 Threshold Release
middot The material released meets one of the GHS thresholds in Table 1 (measured in amount released during one hour)
As an alternative companies can choose to use the release thresholds contained in the API RP-754 standard ndash Table 2 Note ndash Individuals who would like to view the API RP-754 Standard may purchase and download that standard at - Detailed Guidelines on Identifying a Process Safety Event A Chemical InvolvementWhen a chemical substance or chemical process is directly involved
A chemical or chemical process must have been directly involved in the event or incident For this purpose the term process is used broadly to include the equipment and technology needed for petrochemical production including reactors tanks piping boilers cooling towers refrigeration systems etc An incident with no direct chemical or process involvement eg an office building fire even if the office building is on a plant site is not reportable
B LocationThe incident occurred in production distribution storage utility pilot plant within the site boundaries of companyrsquos facility
The incident occurs in production distribution storage (including active storage areas such as warehouses ndash see FAQ section) utilities or pilot plants of a facility reporting metrics under these definitions This includes tank farms ancillary support areas (eg boiler houses and waste water treatment plants) and distribution piping under control of the site All reportable incidents occurring at a location will be reported by the company that is responsible for operating that location This applies to incidents that may occur in contractor work areas as well as other incidents At tolling operations and multi-party sites the company that operates the unit where the incident initiated should record the incident and count it in their reporting
C Release of MaterialThere was a release of material or energy (eg fire explosion implosion) from a process unit
Release of Material ndash an unplanned or uncontrolled release of any material including non-toxic and non-flammable materials (eg steam hot water nitrogen compressed CO2 or compressed air) from a process that results in consequences that exceed one or more of the 4 Reporting Thresholds listed in this document
A release to a flare or scrubber is still considered to be within the primary containment as long as the mitigation system (eg scrubber flare) is operated under normal conditions without any release above the thresholds defined for normal operation A release to a secondary containment (eg waste water treatment or dike) will qualify as a process safety event because the substance is leaving the primary process system
D ThresholdsOne or more of the following Reporting Thresholds must be met for reportable process safety events
1 Safety Injury
Injury resulting in a Recordable Lost Time Accident or Fatality or Hospital admission of anyone on or off site Recordable injuries are work-related injuries that results in any of the following death days away from work restricted work or transfer to another job medical treatment beyond first aid loss of consciousness or a significant injury diagnosed by a physician or other licensed health professional
Lost time injuries and fatalities that occur as a result of process related loss of primary containment fire or explosion are those that fit into one of the following categories
middot Employee (Lost time andor Fatality)
middot Contractor and Subcontractor (Lost time andor Fatality)
middot Third Party (Injuryillness resulting in Hospital Admission or Fatality)
Hospital Admission ndash formal acceptance by a hospital or other inpatient health care facility of a patient who is to be provided with room board and medical service in an area of the hospital or facility where patients generally reside at least overnight Treatment in the hospital emergency room or an overnight stay in the emergency room would not by itself qualify as a ldquohospital admissionrdquo
Examples of injury or fatality cases that would be reportable include a burn injury resulting from steam released during cleaning a physical injury from a cap blown off by pressure during a pressure test or a chemical burn from a spill while taking a sample Examples of injuries or fatality cases that would not be reportable include a fall from an elevated work station while performing maintenance a burn from a fire in a laboratory or office building or injuries from an excavation cave-in None of these cases are directly due to the release of energy or material from the process
2 Direct Damage CostA fire explosion or clean up necessary to avoidremediate environmental damage resulting in a direct cost equal to or greater than $2500 USDs
Costs to be considered for this threshold should be those costs directly attributed to the fire andor explosion such as the replacement value of equipment lost structures lost cost of repairs environmental cleanup (on and off site) emergency response andor fines Direct cost does not include indirect costs such as business opportunity losses loss of profits due to equipment outages cost of obtaining or operating temporary facilities or cost of obtaining replacement products to meet customer demand (product losses)
3 Shelter in Place Evacuation
An officially declared shelter in place or evacuation either on or off site OR a precautionary shelter in place or evacuation off site
For the purposes of this reporting an officially declared shelter in place or evacuation on or off site OR a precautionary shelter in place or evacuation is declared off site would trigger this threshold
Officially Declared ndash A declaration by a recognized community official (eg fire police civil defense emergency management) or delegate (eg Company official) authorized to order the community action (eg shelter-in-place evacuation)
Precautionary Declaration - A precautionary public response is a measure taken from an abundance of caution and issued by a recognized community official or delegate whom has reasonably determined that such an evacuation or shelter in place was necessary to protect the public health and safety
Shelter in Place ndash is the use of a structure and its indoor atmosphere to temporarily separate individuals from a hazardous outdoor atmosphere
Evacuation ndash the act or process of removing persons from a place for reasons of safety or protection
4 Threshold ReleaseAn acute release that exceeds one of the GHS thresholds in Table 1 or in the API 754 standard for Tier II process safety release thresholds in Table 2 (measured in amount released during one hour)
As mentioned in the Executive Summary the ICCA process safety event definition allows use of either GHS-based reporting thresholds developed by ICCA for the chemical release criteria or the UN Dangerous Goods (UNDG)-based reporting thresholds used in the RP-754 standard for Tier II incidents The GHS thresholds are listed in Table 1 It is intended for companies to decide which table to use and to allow companies the option to use one system globally
Acute Release ndash A release of flammable combustible or toxic chemicals from the primary containment (ie vessel or pipe) greater than the chemical release threshold quantities is described for GHS Classification Table 1 and in the API 754 standard for Tier II process safety release thresholds in Table 2
Pressure Relief Device Acute Releases defined above include releases to a properly designed and operating pressure relief device if a quantity is released greater than or equal to the threshold quantities in Table 1 OR in the API 754 standard for Tier II process safety release thresholds Table 2 that results in one or more of the following four consequences
1 Rainout
2 Discharge to a potentially unsafe location
3 A n on-site shelter-in-place or on-site evacuation excluding precautionary on-site shelter-Ain-place or on-site evacuation
4 Public protective measures (eg road closure) including precautionary public protective measures
Releases to a properly designed and operating pressure relief device (such as a flare scrubber etc) do not have to be reported if they do not meet one of the four criteria above
Individuals who would like to view the API RP-754 Standard may download that standard at -
httpwwwapiorgenvironment-health-and-safetyprocess-safetyprocess-safety-standardsstandard-rp-7541 Hour Rule
For the purpose of the reporting under this metric release thresholds are established for materials over a one-hour time frame If the release amount of a material reaches or exceeds the reporting threshold in a 1-hour time period or less it is reportable Typically acute releases occur in 1-hour or less If the duration of the release cannot be determined the duration should be assumed to be 1 hour
Primary Containment ndash A tank vessel pipe rail car or equipment intended to serve as the primary container or used for the transfer of the material Primary containers may be designed with secondary containment systems to contain and control the release Secondary containment systems include but are not limited to tank dikes curbing around process equipment drainage collection systems into segregated oily drain systems the outer wall of double walled tanks etc
Severity Table Severity weighting can provide additional useful information about process safety events that may help drive performance improvement Appendix A is the RCLG methodology for calculating a severity weight for process safety events Using Appendix A a severity weight for each process safety event may be calculated by summing the points associated with each consequence category The ICCA strongly encourages the use of a severity weighting system as the use of such a system increases the ability to communicate performance and is an easier way for our stakeholders to understand process safety events Also the severity weight will not be comparable among other process safety metric reporting formats
Table 2 ndash API RP 754 Tier II Classification Table
2
Appendix A ndash Severity Table Using A Severity Weighting System is Encouraged for All AssociationsSeverity Table (Appendix A) Details
Appendix A above is designed to be used with the GHS Classification System ONLY (Table 1) If your company is using the API RP 754 Tier II Process Safety Metric Threshold Table Table 2 in this document please use the API RP 754 Process Safety Severity Table It is important to state that the severity table in the API RP 754 Standard is for Tier 1 incidents only Comparing the relative severity of events using different tables will not be statistically valid
Acute Environmental Cost - Cost of short-term cleanup and material disposal associated with a PSE with off-site environmental impact Companies may choose to assign severity to costs associated with off-site environmental impacts in a separate category
Rate Adjusted Metrics
Utilizing the severity table described above there are a variety of rate-based metrics which can be generated These include
Process Safety Total Incident Rate (PSTIR) Total event incidents x 200000___
Total Worker Hours
Process Safety Incident Severity Rate (PSESR) (ie severity-weighted Process Safety incident rate formula)
Total severity score for all events incidents x 200000___
PSESR = Total Worker Hours
In determining this rate 1 point is assigned for each Level 4 incident attribute 3 points for each Level 3 attribute 9 points for each Level 2 attributes and 27 points for each Level 1 attributes Theoretically a process safety event could be assigned a minimum of 1 point (ie the incident meets the attributes of a Level 4 incident in only one category) or a maximum of 135 points (ie the incident meets the attributes of a Level 1 incident in each of the five categories)
PS Level ldquoXrdquo incident rate Total Severity Level ldquoXrdquo PS incidents x 200000
Total employee contractor amp subcontractor work hours
Where X can be the total count of Severity Level 4 3 2 or 1 incidents The severity level of an incident is the maximum severity rating of the five consequence categories
Normalization ndash In some associations and member companies process safety events are normalized on a lsquoper 100rsquo employee basis given that a one worker averages 2000 per year So to normalize on a lsquoper 100rsquo employee basis events are multiplied by 200000 worker hours In other associations and member companies events are normalized on a lsquoper 500rsquo employee basis and events are multiplied by 1000000 worker hours Associations and members should discuss this option and come to a conclusion together The above formulas are set at a lsquoper 100rsquo employee rate
15
(K = 1000 MM = 1000000) (For Environmental Impact companies and associations should agree on input criteria where definitions arenrsquot readily available)
Appendix B ndash Frequently Asked QuestionsApplicability
It is recommended that companies record and report Process Safety Events occurring at Company-owned or operated facilities except as noted below
1 PSEs that originated off Company property
2 Marine transport vessel incidents except when the vessel is connected to the facility for the purposes of crude or product transfer
3 Truck andor rail incidents except when the truck or rail car is connected to the facility for the purposes of crude or product transfer
4 Routine emissions that are allowable under permit or regulation
5 Underground contamination that had no process safety consequences Note The exclusion does not apply if the release resulted in an aboveground reportable PSE such as release of toxic vapors or pooling of flammable liquids
6 Office building incidents (eg office heating equipment explosions fires spills releases personnel injury or illness etc)
7 Personnel safety sliptripfall incidents that are not directly associated with evacuating from or responding to a loss of containment incident
8 Loss of Primary Containment (LOPC) incidents from ancillary equipment not connected to the process (eg small sample containers)
9 Planned and controlled drainage of material to collection or drain system designed for such service (Note Exclusion does not apply to an unintended and uncontrolled release of material from primary containment that flows to a collection or drain system)
10 Mechanical work being conducted outside of process units or in maintenance shops
Interpretations and Examples ndash Based on GHS Table 1
The following interpretations and examples have been prepared to help clarify areas of potential uncertainty in the evaluation of reportable Process Safety Incidents (PSE)
COMPANY PREMISES
1 A third-party truck loading a flammable product on Company Premises experiences a leak and subsequent fire and property loss damages of $7000 (direct costs) Although the truck is Operated-by-Others it is connected to the process The incident would be a reportable PSE if property losses in direct costs were equal to or greater than $2500 or some other PSE threshold was met or exceeded (eg a fatality)
2 Similar example as 1 The truck loaded with flammable product overturns in route out of the plant resulting in a fire and loss of the truck This would not be reported as a PSE since the truck is no longer connected to the plant
LOSS OF CONTAINMENT
3 A faulty tank gauge results in the overfilling of a product tank containing ldquoflammable liquidsrdquo Approximately 700 kg of liquid overflows into the tanks diked area This incident is a reportable PSE since it is an acute spill greater than 100 kgs regardless of secondary containment
4 A maintenance contractor opens a process valve and gets sprayed with sulfuric acid resulting in a severe burn and lost time injury This would be a reportable PSE It is an unintended event involving a material and a loss of containment For fatalities and days away from work injuries and illnesses there is no release threshold amount
5 An operator opens a quality control sample point to collect a routine sample of product and receives a bad hand laceration requiring stitches due to a broken glass bottle and misses the next day of work This is not a reportable PSE because it is not related to a loss of containment
ACUTE RELEASES
6 While troubleshooting a higher-than-expected natural gas flow rate operating personnel find a safety valve on the natural gas line that did not reseat properly and was relieving to the atmospheric vent stack through a knock-out drum Upon further investigation it is determined that a total of 100000 kg of natural gas was relieved at a steady rate over a 6 month period This is not a reportable PSE as the release rate (~10 kg per hour) is not ldquoacuterdquo (ie does not exceed the 100 kg TQ for flammable vapors per 1 hour time period)
FLARES amp EMISSION CONTROL DEVICES (eg scrubbers)
7 If a chemical is routed to a flare or emission control device (eg scrubber) it would not be classified as a PSE as long as that flare or control device operates as designed
8 If a scrubber is overwhelmed by a flowrate greater than the design of the scrubber system and discharges a chemical in excess of the reporting threshold it would be reported as a PSE as noted about in this document
As a note an upset emission from a permitted or regulated source ndash including pressure relieve devices - of a quantity greater than or equal to the threshold quantities in Table 1 or 2 in any one-hour period that results in one or more of the following four consequences
middot rainout
middot discharge to a potentially unsafe location
middot an on-site shelter-in-place or on-site evacuation excluding precautionary on-site shelter-in-place or on-site evacuation
middot public protective measures (eg road closure) including precautionary public protective measures
Should be reported as a PSE
SAFETY RELIEF DEVICE SYSTEM
9 There is a unit upset and the relief valve opens to an atmospheric vent which has been designed resulting in a gas release to the atmosphere with no adverse consequences This would not be a reportable PSE since vapors and gases released to atmosphere from safety valves high-pressure rupture disks and similar safety devices that are properly designed for that event per API Standard 521 or equivalent are excluded as long as the release did not result in (1) a liquid carryover that created a reportable PSE related to the liquid (eg lost time incident fatality a fire or explosion that caused $2500 or more of direct cost liquid release or toxic aerosol release at or above threshold amounts etc) or (2) activation of a shelter-in-place response on or off-site or (3) public protective measures be taken
10 There is a unit upset and the relief valve fails to open resulting in overpressure of the equipment and an acute release of flammable gas from a leaking flange The amount released is above the 100 kg (within 1 hour) threshold This is a reportable PSE Releases from flanges are not excluded from PSE reporting
DAYS AWAY FROM WORK INCIDENTS
11 An operator is walking then slips and falls to the floor and suffers a lost time injury The slipfall is due to weather conditions chronic oily floors and slippery shoes This is not a reportable PSE Personnel safety sliptripfall incidents that are not directly associated with evacuating from or responding to a loss of containment incident are specifically excluded from PSE reporting
12 Same as above except that the operator slipped and fell while responding to a small flammable liquid spill (eg less than 10 kg in 1 hour) This would be PSE reportable since the operator was responding to a loss of containment incident A PSE is reportable if the loss of primary containment occurs on Company Premises and results in a lost time incident or fatality For fatalities and lost time incidents there is no release threshold amount
13 Same as above except that the operator slipped and fell several hours after the incident had concluded This would not be PSE reportable The terms evacuating from and responding to in the reporting exclusion mean that the loss of containment and associated emergency response activities are on-going Slipstripfalls after the event have concluded (such as after-the-fact clean-up and remediation) are excluded from PSE reporting
14 A scaffold builder suffers a lost time injury after falling from a scaffold ladder while evacuating from a loss of containment incident on nearby equipment This is a reportable PSE
15 An operator walks past an improperly designed steam trap The steam trap releases and the operators ankle is burned by the steam resulting in a lost time injury This is a reportable PSE because even though the loss of containment was steam (vs hydrocarbon or chemical) the physical state of the material was such that it caused a lost time injury
16 An enclosure has been intentionally purged with nitrogen A contractor bypasses safety controls enters the enclosure and dies This is a reportable fatality but not a reportable PSE since there was no unplanned or uncontrolled loss of primary containment
17 Same as above except that nitrogen inadvertently leaked into the enclosure This would be a reportable PSE (and fatality) since there was a fatality associated with an unplanned loss of primary containment
18 An operator responding to an H2S alarm collapses and has a injury If the alarm was triggered by an actual unplanned or uncontrolled H2S LOPC the event would be a reportable PSE If the alarm was a false alarm the event would not be a reportable PSE because there was no actual release
PIPELINES
19 A pipeline leaks and releases 2000 lbs (900 kgs) of flammable vapor above ground within 1 hour However the release occurred in a remote location within the site The release is PSE reportable since remoteness is not a consideration
FIRES or ENERGY RELEASES NOT ASSOCIATED WITH CHEMICAL RELEASE
As a general rule a fire or energy release is reported as a PSE only if caused by chemical release or results in a chemical release in excess of the reporting quantities Examples include
20 An electrical fire impacts the operation of the process resulting in the release of 400 kg of toluene This event would be reported as a PSE since if the chemical release exceeds the 100 kg reporting threshold for toluene
21 An electrical fire loss of electricity or any other loss of utility occurs which may cause a plant shutdown and possibly incidental equipment damage greater than $2500 (eg damage to reactors or equipment due to inadequate shutdown) but does not create a chemical release greater than the threshold quantity or cause a fatality or serious injury This event would not be reported as a PSE since the equipment damage was not caused by a chemical process fireexplosion and there was not a chemical release greater than the threshold quantity
MARINE TRANSPORT VESSELS
22 A company operated Marine Transport Vessel has an onboard acute spill of combustible material greater than 100 kg The event is not PSE reportable since Marine Transport Vessel incidents are specifically excluded except when the vessel is connected to the refinery petrochemical or chemical manufacturing facility for the purposes of crude or product transfer
23 A third-party barge is being pushed by a tug and hits the company dock A barge compartment is breached and releases 1000 kg of diesel to the water The event is not a reportable PSE since the marine vessel was not berthed at the dock and actively involved in crude or product transfer operations
TRUCK AND RAIL
24 A company railcar derails and spills more than 1000 kg of gasoline while in transit The incident is not PSE reportable since rail incidents off company property are specifically excluded
25 A third-party trucktrailer overturns while in the Company Premises resulting in an acute spill of gasoline greater than 1000 kg The incident is not reported as a PSE reportable if the truck is no longer connected to the loadingunloading facilities However it is recommended that companies also have transportation incident metrics which would capture this event
26 A contract truck hauler is unloading caustic and the hose separates and generates an airborne aerosol andor liquid caustic spill of 2500 kg The event is a reportable PSE since the caustic TQ of 100 kg was exceeded and the truck was still connected to the loadingunloading facility immediately prior to the incident
OFFICE BUILDING
27 There is a boiler fire at the Main Office complex and direct cost damages totaled $75000 The incident is not PSE reportable since Office Building incidents are specifically excluded
MAN-MACHINE INTERFACE INCIDENTS
28 An operations technician is injured while working around the finishing equipment in a polymers plant The injury is caused by the mechanical man-machine interface with the equipment This would not be a reportable Process Safety Event because there was no loss of containment of hazardous material
MIXTURES
29 If a mixture by itself has a GHS classification you use that classification to determine the threshold If the mixture itself does not have a GHS-classification we go back to the individual components of the mixture and based on kg released per threshold group calculate a lsquoweightedrsquo contribution to the thresholds Example a release of 100 kg of a mixture in a one hour period that consists of 05 kg of a substance classified as acute toxic H300 45 kg of substance classified with H301 and 40 kg of a substance with another H-number and the remaining 55 kg of water with no GHS classification would be calculated as 051 + 4510 + 40100 = 05 + 045 + 04 = 135 is exceeding 1 and would be counted as a reportable process safety incident even though none of the individual hazardous components exceeded the threshold for the individual substance
DIRECT DAMAGE COSTS
30 Direct damage costs are considered for this threshold should be those costs directly attributed to the fire andor explosion such as the replacement value of equipment lost structures lost cost of repairs environmental cleanup emergency response andor fines Direct cost does not include indirect costs such as business opportunity losses loss of profits due to equipment outages cost of obtaining or operating temporary facilities or cost of obtaining replacement products to meet customer demand (product losses)
31 As an example a leak of flammable gas occurred in a vent line connected to a gas treatment system At the same time a failure in the process allowed air to enter in the same vent line An explosion occurred and the over pressure damaged the vent line and associated upstream equipment including a seal pot Nobody was hurt The cost for repair was about $12000 This is a PSE considering the cost to repair the equipment due to the explosion and fire
32 As an example after a PSE event a company releases 50 kg of a very special GHS Category 5 product which causes $2000 of damage to equipment The product released was a very special blend of materials and the company incurs over $50000 in materials associated with the product loss This event is not reportable as PSE since the reportable threshold for GHS Category 5 releases is 100 kgs and product losses do not count as Direct Damage Costs
NATURAL DISASTERS
33 Natural disasters can present substantial risks to chemical process operations and damage to plant equipment which may result in a loss of containment of hazardous substances Where the potential for one or more types of natural disasters is deemed relevant to plant operations process safety and operational systems shall address the applicable risk in terms of hazards and consequence analysis plant design operating procedures for loss of utilities and process shutdown and emergency planning and response
Types of natural disasters includes hurricanes and typhoons (including associated storm surge) floods tornadoes earthquakes derechos (straight line wind storms) wildfires volcanic eruptions tsunamis and avalanches
If your facility experiences a natural disaster that triggers one or more of the thresholds it should be reported as a process safety event
PRECAUTIONARY PUBLIC RESPONSE
34 A precautionary public response is a measure taken from an abundance of caution For example a company may require all workers to shelter-in-place in response to an LOPC independent of or prior to any assessment (eg wind direction distance from the LOPC etc) of the potential hazard to those worker For example a recognized community official (eg fire police civil defense emergency management) may order a community shelter-in-place evacuation or public protective measure (eg road closure) in the absence of information from a company experiencing a process safety event or lsquojust in casersquo the wind direction changes or due to the sensitive nature of the potentially affected population (eg school children the elderly)
ACTIVE WAREHOUSE
35 An active warehouse is an on-site warehouse that stores raw materials intermediates or finished products used or produced by a process From a process perspective an active warehouse is equivalent to a bulk storage tank Rather than being stored in a single large container the raw materials intermediates or finished products are stored in smaller containers (eg totes barrels pails etc)
Appendix C ndash List of RCLG Taskforce Members Luiz Shizuo Harayashiki19
Appendix D ndash Detailed Schedule of Events Appendix E ndash Optional Excel Reporting FormWhen member companies begin tracking process safety events a single form should be utilized for all member companies to make data analysis easier and to allow all members to work from the same tracking sheet The RCLG has developed an optional tracking sheet that members and associations can start with when developing their own tracking sheet
DOWNLOAD TRACKING SHEET HERE
This document consists of a contact page the survey itself and a lsquodo not editrsquo page where the drop down menu answer are stored
INTERNATIONAL
COUNCIL OF
CHEMICAL
ASSOCIATIONS
ICCA Process Safety
Event Tracking Sheetxlsx
GUIDANCE FOR REPORTING ON THE ICCA GLOBALLY HARMONIZED PROCESS SAFETY METRICJune2016The Responsible Carereg Leadership Group
ContentsBackground2Executive Summary2Data to be reported by RCLG Associations to RCLG4Overview of ICCA Process Safety Event Criteria as a Flow Chart5Key Criteria for Reporting Process Safety Events to RCLG6Detailed Guidelines on Identifying a Process Safety Event7Table 1 ndash GHS Classification Table11Table 2 ndash API RP 754 Tier II Classification Table12Appendix A ndash Severity Table Using A Severity Weighting System is Encouraged for All Associations14Appendix B ndash Frequently Asked Questions16Appendix C ndash List of RCLG Taskforce Members22Appendix D ndash Detailed Schedule of Events23Appendix E ndash Optional Excel Reporting Form24
FIANL DRAFT
June 15 2016
The Responsible Carereg initiative began in 1985 and as the chemical industryrsquos commitment to continuous performance improvements Process Safety has been a pillar of Responsible Care since its inception and many regional approaches to tracking and reporting process safety performance have developed over the 30 years of Responsible Care implementation yet no globally harmonized system had been put into place In 2012 in the wake of several high profile process safety events the International Council of Chemical Associations (ICCA) Board of Directors directed the Responsible Care Leadership Group (RCLG) to develop a recommendation for a globally harmonized process safety performance reporting by no later than 2015
Throughout 2013 and 2014 a Taskforce comprised of multinational companies and RCLG associations chaired by Dr Peter Schmelzer Head of Health Safety and Environmental Protection Bayer HealthCare AG worked to develop a globally harmonized ICCA approach to process safety performance reporting A list of Taskforce members can be found in Appendix C During the same timeframe the American Petroleum Institute (API) also initiated a process to update its Recommend Practice 754 (RP-754) ndash Leading and Lagging Process Safety Metric Standard RP-754 is broadly used in the refining and petrochemical sector and in the Americas region to track process safety performance To optimize global adoption of a unified standard the RCLG Taskforce strived to achieve full harmonization of its recommendation with the revised API RP 754 metric expected to be finalized in the first quarter 2016
After more than 2 years of discussion research debate and feasibility assessment the Process Safety Harmonization Taskforce recommends that ICCA adopt a process safety event rate metric The adoption of this metric would require each RCLG association to collect the number of process safety events experienced by their members on an annual basis as well as total number of worker hours (employees and contractors) experienced by their members each year The process safety event rate is the ratio of events to hours The Taskforce also recommends that reporting of these data points to the RCLG be phased in over the next 3 years allowing regions with the desire and ability to report immediately to do so while also allowing additional time to companies and organizations that are developing the ability to track these data for the first time
The criteria that determine whether a process-related event qualifies as a process safety event are based on a loss of primary containment of a chemical or a release of energy triggering thresholds any one of four impact areas 1) safetyhuman health consequences 2) direct cost due to damage from incident 3) community impact and 4) chemical release quantity (see the flow chart showing reporting triggers) These four impact areas in the recommended ICCA process safety event definition are identical to the impact areas in the RP-754 Tier II incident standard The thresholds for reporting are also identical in all areas with the exception of the chemical release quantity thresholds To address this difference the ICCA process safety event definition will allow companies the use of either the GHS-based reporting thresholds developed by ICCA for the chemical release criteria or the UN Dangerous Goods (UNDG)-based reporting thresholds used in the RP-754 standard for Tier II incidents The Taskforce believes that the two systems though different are comparably robust in the universe of chemicals covered and the severity of incidents captured by reporting While there will be relatively little difference in the numbers of events captured and reported using the two different threshold approaches there may be differences that would be most clearly seen at the company level based on raw material and product use hence the Taskforce cautions companies not to compare their results with companies that use a different chemical release threshold approach Regardless under the RCLG proposal companies can choose the chemical release thresholds by which they report in to their national and regional associations If associations are interested in translating results based on one reporting approach to another the RCLG will provide a translation table However given the complexity of this exercise and the need to access raw incident data the Taskforce does not believe that this adds value and recommends against it
The Taskforce believes that this proposal for process safety event reporting will enable broad-based global reporting of process safety performance across the chemical and petrochemical industries It will provide a roadmap for regions associations and companies that are currently not tracking process safety performance to recognize the benefits that tracking and reporting will bring For regions associations and companies that are already experienced in gathering process safety data this recommendation allows for broader global alignment and focus on continuous improvement in process safety performance The systems that are built to improve process safety performance are informed by robust process safety event data and this is the major objective of this initiative
On an annual basis RCLG Associations will be asked to report two data points into ICCA using the RCLG KPI Reporting Website on the schedule provided below
1Total Member Company Worker Hours for Association (employee and contractor)
2Total Number of Process Safety Events
ICCA will use the above two data points to report process safety performance in the form of Process Safety Event Rate (PSER) normalized per 100 employees where an employee works 2000 hours a year
(Total Events Total Hours) x 200000 = PSER
Recommended Reporting Schedule
The Taskforce recommends a phased-in approach for reporting process safety event rate Such a schedule will allow more experienced companies and associations to report in the next several years while allowing other companies and associations to begin reporting by 2019 RCLG Associations would be asked to report the two process safety event rate data points annually to the ICCA through the RCLG KPI metrics reporting system If you do not know your associationrsquos username and password please contact the RCLG
The proposed schedule for process safety event rate reporting by RCLG associations is as follows
April 2015RCLG considers Taskforce proposal
June 2015ICCA Board of Directors considers RCLG final recommendation
July 2015RCLG releases the first detailed reporting guidance document for associations and member companies
Feb 2016 RCLG Reporting RCLG initiates process safety reporting pilot program through association volunteers with updated an enhanced guidance document RCLG rolls out final guidance document in June 2016
2017RCLG Associations begin collecting data from its membership
2018-2019 RCLG Reporting Optional process safety data reporting by RCLG Associations
2020 ReportingRCLG includes process safety as a mandatory metric in the KPI reporting program
See Appendix D ndash Detailed Schedule of Events
NO Does not meet the criteria for a Process Safety Event
Start
NO
NO
NO
Was a chemical substance or a chemical process directly involved
YES
YES
Release of material fire explosion or implosion fromat a chemical process unit
Incident in production distribution storage utilities pilot plants within a companyrsquos facility
YES
NO
Officially declared shelter in place or evacuation
Or Precautionary off site shelter in place or evacuation
Substance Release Thresholds met
Recordable injury
Or
hospital admission of people on or off site
Damage ge $2500direct costto company
NO
NO
NO
ICCA or API 754 Tier II chemical release thresholds exceeded
YES
YES
YES
Yes Reportable as a Process Safety Event
YES
Total Worker Hours
RCLG Associations should report the total number of employee hours worked for each member company in their association and the total number of contractor hours worked for each member company as a combined single number For the purposes of this guidance document each association should refer to their local and regional definitions for employee and contractor The goal for reporting total hours is to include all individuals who are involved with chemical manufacturing except where those individuals are tasked with major construction projects such as large scale investments with specific one-time project organizations created for design engineering and construction of new or significant expansion to existing process facilities When reporting total worker hours companies should report the same hours used for reporting personnel hours This way companies can have the same data set for occupational and process safety Personnel hours should include those hours from all chemical manufacturing operations not just from facilities where a process safety incident occurred
Process Safety Event
For the purposes of this ICCA Reporting a process safety event has occurred when
A When a chemical substance or a chemical process is directly involved AND
B The incident occurred in production distribution storage utility pilot plant within the site boundaries of companyrsquos facility AND
C There was a release of material or energy (eg fire explosion implosion) from a process unit AND
D One or more of the following Reporting Thresholds have been met
1 Safety Injury
middot Injury resulting in a Recordable Lost Time Accident or Fatality or Hospital admission of anyone on or off site OR
2 Direct Damage Cost
middot A fire explosion or clean up necessary to avoidremediate environmental damage resulting in a direct cost equal to or greater than $2500 USDs OR
3 Shelter in Place Evacuation
middot An officially declared shelter in place (on or off site) OR
middot An officially declared evacuation (on or off site) OR
middot A precautionary off site shelter in place or evacuation OR
4 Threshold Release
middot The material released meets one of the GHS thresholds in Table 1 (measured in amount released during one hour)
When a chemical substance or chemical process is directly involved
A chemical or chemical process must have been directly involved in the event or incident For this purpose the term process is used broadly to include the equipment and technology needed for petrochemical production including reactors tanks piping boilers cooling towers refrigeration systems etc An incident with no direct chemical or process involvement eg an office building fire even if the office building is on a plant site is not reportable
B LocationThe incident occurred in production distribution storage utility pilot plant within the site boundaries of companyrsquos facility
The incident occurs in production distribution storage (including active storage areas such as warehouses ndash see FAQ section) utilities or pilot plants of a facility reporting metrics under these definitions This includes tank farms ancillary support areas (eg boiler houses and waste water treatment plants) and distribution piping under control of the site All reportable incidents occurring at a location will be reported by the company that is responsible for operating that location This applies to incidents that may occur in contractor work areas as well as other incidents At tolling operations and multi-party sites the company that operates the unit where the incident initiated should record the incident and count it in their reporting
C Release of MaterialThere was a release of material or energy (eg fire explosion implosion) from a process unit
Release of Material ndash an unplanned or uncontrolled release of any material including non-toxic and non-flammable materials (eg steam hot water nitrogen compressed CO2 or compressed air) from a process that results in consequences that exceed one or more of the 4 Reporting Thresholds listed in this document
A release to a flare or scrubber is still considered to be within the primary containment as long as the mitigation system (eg scrubber flare) is operated under normal conditions without any release above the thresholds defined for normal operation A release to a secondary containment (eg waste water treatment or dike) will qualify as a process safety event because the substance is leaving the primary process system
D ThresholdsOne or more of the following Reporting Thresholds must be met for reportable process safety events
1 Safety Injury
Injury resulting in a Recordable Lost Time Accident or Fatality or Hospital admission of anyone on or off site Recordable injuries are work-related injuries that results in any of the following death days away from work restricted work or transfer to another job medical treatment beyond first aid loss of consciousness or a significant injury diagnosed by a physician or other licensed health professional
Lost time injuries and fatalities that occur as a result of process related loss of primary containment fire or explosion are those that fit into one of the following categories
middot Employee (Lost time andor Fatality)
middot Contractor and Subcontractor (Lost time andor Fatality)
middot Third Party (Injuryillness resulting in Hospital Admission or Fatality)
Hospital Admission ndash formal acceptance by a hospital or other inpatient health care facility of a patient who is to be provided with room board and medical service in an area of the hospital or facility where patients generally reside at least overnight Treatment in the hospital emergency room or an overnight stay in the emergency room would not by itself qualify as a ldquohospital admissionrdquo
Examples of injury or fatality cases that would be reportable include a burn injury resulting from steam released during cleaning a physical injury from a cap blown off by pressure during a pressure test or a chemical burn from a spill while taking a sample Examples of injuries or fatality cases that would not be reportable include a fall from an elevated work station while performing maintenance a burn from a fire in a laboratory or office building or injuries from an excavation cave-in None of these cases are directly due to the release of energy or material from the process
2 Direct Damage CostA fire explosion or clean up necessary to avoidremediate environmental damage resulting in a direct cost equal to or greater than $2500 USDs
Costs to be considered for this threshold should be those costs directly attributed to the fire andor explosion such as the replacement value of equipment lost structures lost cost of repairs environmental cleanup (on and off site) emergency response andor fines Direct cost does not include indirect costs such as business opportunity losses loss of profits due to equipment outages cost of obtaining or operating temporary facilities or cost of obtaining replacement products to meet customer demand (product losses)
3 Shelter in Place Evacuation
An officially declared shelter in place or evacuation either on or off site OR a precautionary shelter in place or evacuation off site
For the purposes of this reporting an officially declared shelter in place or evacuation on or off site OR a precautionary shelter in place or evacuation is declared off site would trigger this threshold
Officially Declared ndash A declaration by a recognized community official (eg fire police civil defense emergency management) or delegate (eg Company official) authorized to order the community action (eg shelter-in-place evacuation)
Precautionary Declaration - A precautionary public response is a measure taken from an abundance of caution and issued by a recognized community official or delegate whom has reasonably determined that such an evacuation or shelter in place was necessary to protect the public health and safety
Shelter in Place ndash is the use of a structure and its indoor atmosphere to temporarily separate individuals from a hazardous outdoor atmosphere
Evacuation ndash the act or process of removing persons from a place for reasons of safety or protection
4 Threshold ReleaseAn acute release that exceeds one of the GHS thresholds in Table 1 or in the API 754 standard for Tier II process safety release thresholds in Table 2 (measured in amount released during one hour)
As mentioned in the Executive Summary the ICCA process safety event definition allows use of either GHS-based reporting thresholds developed by ICCA for the chemical release criteria or the UN Dangerous Goods (UNDG)-based reporting thresholds used in the RP-754 standard for Tier II incidents The GHS thresholds are listed in Table 1 It is intended for companies to decide which table to use and to allow companies the option to use one system globally
Acute Release ndash A release of flammable combustible or toxic chemicals from the primary containment (ie vessel or pipe) greater than the chemical release threshold quantities is described for GHS Classification Table 1 and in the API 754 standard for Tier II process safety release thresholds in Table 2
Pressure Relief Device Acute Releases defined above include releases to a properly designed and operating pressure relief device if a quantity is released greater than or equal to the threshold quantities in Table 1 OR in the API 754 standard for Tier II process safety release thresholds Table 2 that results in one or more of the following four consequences
1 Rainout
2 Discharge to a potentially unsafe location
3 A n on-site shelter-in-place or on-site evacuation excluding precautionary on-site shelter-Ain-place or on-site evacuation
4 Public protective measures (eg road closure) including precautionary public protective measures
Releases to a properly designed and operating pressure relief device (such as a flare scrubber etc) do not have to be reported if they do not meet one of the four criteria above
Individuals who would like to view the API RP-754 Standard may download that standard at -
httpwwwapiorgenvironment-health-and-safetyprocess-safetyprocess-safety-standardsstandard-rp-7541 Hour Rule
For the purpose of the reporting under this metric release thresholds are established for materials over a one-hour time frame If the release amount of a material reaches or exceeds the reporting threshold in a 1-hour time period or less it is reportable Typically acute releases occur in 1-hour or less If the duration of the release cannot be determined the duration should be assumed to be 1 hour
Primary Containment ndash A tank vessel pipe rail car or equipment intended to serve as the primary container or used for the transfer of the material Primary containers may be designed with secondary containment systems to contain and control the release Secondary containment systems include but are not limited to tank dikes curbing around process equipment drainage collection systems into segregated oily drain systems the outer wall of double walled tanks etc
Severity Table Severity weighting can provide additional useful information about process safety events that may help drive performance improvement Appendix A is the RCLG methodology for calculating a severity weight for process safety events Using Appendix A a severity weight for each process safety event may be calculated by summing the points associated with each consequence category The ICCA strongly encourages the use of a severity weighting system as the use of such a system increases the ability to communicate performance and is an easier way for our stakeholders to understand process safety events Also the severity weight will not be comparable among other process safety metric reporting formats
Table 1 ndash GHS Classification TableTable 2 ndash API RP 754 Tier II Classification Table
2
Appendix A ndash Severity Table Using A Severity Weighting System is Encouraged for All AssociationsSeverity Table (Appendix A) Details
Appendix A above is designed to be used with the GHS Classification System ONLY (Table 1) If your company is using the API RP 754 Tier II Process Safety Metric Threshold Table Table 2 in this document please use the API RP 754 Process Safety Severity Table It is important to state that the severity table in the API RP 754 Standard is for Tier 1 incidents only Comparing the relative severity of events using different tables will not be statistically valid
Acute Environmental Cost - Cost of short-term cleanup and material disposal associated with a PSE with off-site environmental impact Companies may choose to assign severity to costs associated with off-site environmental impacts in a separate category
Rate Adjusted Metrics
Utilizing the severity table described above there are a variety of rate-based metrics which can be generated These include
Process Safety Total Incident Rate (PSTIR) Total event incidents x 200000___
Total Worker Hours
Process Safety Incident Severity Rate (PSESR) (ie severity-weighted Process Safety incident rate formula)
Total severity score for all events incidents x 200000___
PSESR = Total Worker Hours
In determining this rate 1 point is assigned for each Level 4 incident attribute 3 points for each Level 3 attribute 9 points for each Level 2 attributes and 27 points for each Level 1 attributes Theoretically a process safety event could be assigned a minimum of 1 point (ie the incident meets the attributes of a Level 4 incident in only one category) or a maximum of 135 points (ie the incident meets the attributes of a Level 1 incident in each of the five categories)
PS Level ldquoXrdquo incident rate Total Severity Level ldquoXrdquo PS incidents x 200000
Total employee contractor amp subcontractor work hours
Where X can be the total count of Severity Level 4 3 2 or 1 incidents The severity level of an incident is the maximum severity rating of the five consequence categories
Normalization ndash In some associations and member companies process safety events are normalized on a lsquoper 100rsquo employee basis given that a one worker averages 2000 per year So to normalize on a lsquoper 100rsquo employee basis events are multiplied by 200000 worker hours In other associations and member companies events are normalized on a lsquoper 500rsquo employee basis and events are multiplied by 1000000 worker hours Associations and members should discuss this option and come to a conclusion together The above formulas are set at a lsquoper 100rsquo employee rate
15
(K = 1000 MM = 1000000) (For Environmental Impact companies and associations should agree on input criteria where definitions arenrsquot readily available)
Appendix B ndash Frequently Asked QuestionsApplicability
It is recommended that companies record and report Process Safety Events occurring at Company-owned or operated facilities except as noted below
1 PSEs that originated off Company property
2 Marine transport vessel incidents except when the vessel is connected to the facility for the purposes of crude or product transfer
3 Truck andor rail incidents except when the truck or rail car is connected to the facility for the purposes of crude or product transfer
4 Routine emissions that are allowable under permit or regulation
5 Underground contamination that had no process safety consequences Note The exclusion does not apply if the release resulted in an aboveground reportable PSE such as release of toxic vapors or pooling of flammable liquids
6 Office building incidents (eg office heating equipment explosions fires spills releases personnel injury or illness etc)
7 Personnel safety sliptripfall incidents that are not directly associated with evacuating from or responding to a loss of containment incident
8 Loss of Primary Containment (LOPC) incidents from ancillary equipment not connected to the process (eg small sample containers)
9 Planned and controlled drainage of material to collection or drain system designed for such service (Note Exclusion does not apply to an unintended and uncontrolled release of material from primary containment that flows to a collection or drain system)
10 Mechanical work being conducted outside of process units or in maintenance shops
Interpretations and Examples ndash Based on GHS Table 1
The following interpretations and examples have been prepared to help clarify areas of potential uncertainty in the evaluation of reportable Process Safety Incidents (PSE)
COMPANY PREMISES
1 A third-party truck loading a flammable product on Company Premises experiences a leak and subsequent fire and property loss damages of $7000 (direct costs) Although the truck is Operated-by-Others it is connected to the process The incident would be a reportable PSE if property losses in direct costs were equal to or greater than $2500 or some other PSE threshold was met or exceeded (eg a fatality)
2 Similar example as 1 The truck loaded with flammable product overturns in route out of the plant resulting in a fire and loss of the truck This would not be reported as a PSE since the truck is no longer connected to the plant
LOSS OF CONTAINMENT
3 A faulty tank gauge results in the overfilling of a product tank containing ldquoflammable liquidsrdquo Approximately 700 kg of liquid overflows into the tanks diked area This incident is a reportable PSE since it is an acute spill greater than 100 kgs regardless of secondary containment
4 A maintenance contractor opens a process valve and gets sprayed with sulfuric acid resulting in a severe burn and lost time injury This would be a reportable PSE It is an unintended event involving a material and a loss of containment For fatalities and days away from work injuries and illnesses there is no release threshold amount
5 An operator opens a quality control sample point to collect a routine sample of product and receives a bad hand laceration requiring stitches due to a broken glass bottle and misses the next day of work This is not a reportable PSE because it is not related to a loss of containment
ACUTE RELEASES
6 While troubleshooting a higher-than-expected natural gas flow rate operating personnel find a safety valve on the natural gas line that did not reseat properly and was relieving to the atmospheric vent stack through a knock-out drum Upon further investigation it is determined that a total of 100000 kg of natural gas was relieved at a steady rate over a 6 month period This is not a reportable PSE as the release rate (~10 kg per hour) is not ldquoacuterdquo (ie does not exceed the 100 kg TQ for flammable vapors per 1 hour time period)
FLARES amp EMISSION CONTROL DEVICES (eg scrubbers)
7 If a chemical is routed to a flare or emission control device (eg scrubber) it would not be classified as a PSE as long as that flare or control device operates as designed
8 If a scrubber is overwhelmed by a flowrate greater than the design of the scrubber system and discharges a chemical in excess of the reporting threshold it would be reported as a PSE as noted about in this document
As a note an upset emission from a permitted or regulated source ndash including pressure relieve devices - of a quantity greater than or equal to the threshold quantities in Table 1 or 2 in any one-hour period that results in one or more of the following four consequences
middot rainout
middot discharge to a potentially unsafe location
middot an on-site shelter-in-place or on-site evacuation excluding precautionary on-site shelter-in-place or on-site evacuation
middot public protective measures (eg road closure) including precautionary public protective measures
Should be reported as a PSE
SAFETY RELIEF DEVICE SYSTEM
9 There is a unit upset and the relief valve opens to an atmospheric vent which has been designed resulting in a gas release to the atmosphere with no adverse consequences This would not be a reportable PSE since vapors and gases released to atmosphere from safety valves high-pressure rupture disks and similar safety devices that are properly designed for that event per API Standard 521 or equivalent are excluded as long as the release did not result in (1) a liquid carryover that created a reportable PSE related to the liquid (eg lost time incident fatality a fire or explosion that caused $2500 or more of direct cost liquid release or toxic aerosol release at or above threshold amounts etc) or (2) activation of a shelter-in-place response on or off-site or (3) public protective measures be taken
10 There is a unit upset and the relief valve fails to open resulting in overpressure of the equipment and an acute release of flammable gas from a leaking flange The amount released is above the 100 kg (within 1 hour) threshold This is a reportable PSE Releases from flanges are not excluded from PSE reporting
DAYS AWAY FROM WORK INCIDENTS
11 An operator is walking then slips and falls to the floor and suffers a lost time injury The slipfall is due to weather conditions chronic oily floors and slippery shoes This is not a reportable PSE Personnel safety sliptripfall incidents that are not directly associated with evacuating from or responding to a loss of containment incident are specifically excluded from PSE reporting
12 Same as above except that the operator slipped and fell while responding to a small flammable liquid spill (eg less than 10 kg in 1 hour) This would be PSE reportable since the operator was responding to a loss of containment incident A PSE is reportable if the loss of primary containment occurs on Company Premises and results in a lost time incident or fatality For fatalities and lost time incidents there is no release threshold amount
13 Same as above except that the operator slipped and fell several hours after the incident had concluded This would not be PSE reportable The terms evacuating from and responding to in the reporting exclusion mean that the loss of containment and associated emergency response activities are on-going Slipstripfalls after the event have concluded (such as after-the-fact clean-up and remediation) are excluded from PSE reporting
14 A scaffold builder suffers a lost time injury after falling from a scaffold ladder while evacuating from a loss of containment incident on nearby equipment This is a reportable PSE
15 An operator walks past an improperly designed steam trap The steam trap releases and the operators ankle is burned by the steam resulting in a lost time injury This is a reportable PSE because even though the loss of containment was steam (vs hydrocarbon or chemical) the physical state of the material was such that it caused a lost time injury
16 An enclosure has been intentionally purged with nitrogen A contractor bypasses safety controls enters the enclosure and dies This is a reportable fatality but not a reportable PSE since there was no unplanned or uncontrolled loss of primary containment
17 Same as above except that nitrogen inadvertently leaked into the enclosure This would be a reportable PSE (and fatality) since there was a fatality associated with an unplanned loss of primary containment
18 An operator responding to an H2S alarm collapses and has a injury If the alarm was triggered by an actual unplanned or uncontrolled H2S LOPC the event would be a reportable PSE If the alarm was a false alarm the event would not be a reportable PSE because there was no actual release
PIPELINES
19 A pipeline leaks and releases 2000 lbs (900 kgs) of flammable vapor above ground within 1 hour However the release occurred in a remote location within the site The release is PSE reportable since remoteness is not a consideration
FIRES or ENERGY RELEASES NOT ASSOCIATED WITH CHEMICAL RELEASE
As a general rule a fire or energy release is reported as a PSE only if caused by chemical release or results in a chemical release in excess of the reporting quantities Examples include
20 An electrical fire impacts the operation of the process resulting in the release of 400 kg of toluene This event would be reported as a PSE since if the chemical release exceeds the 100 kg reporting threshold for toluene
21 An electrical fire loss of electricity or any other loss of utility occurs which may cause a plant shutdown and possibly incidental equipment damage greater than $2500 (eg damage to reactors or equipment due to inadequate shutdown) but does not create a chemical release greater than the threshold quantity or cause a fatality or serious injury This event would not be reported as a PSE since the equipment damage was not caused by a chemical process fireexplosion and there was not a chemical release greater than the threshold quantity
MARINE TRANSPORT VESSELS
22 A company operated Marine Transport Vessel has an onboard acute spill of combustible material greater than 100 kg The event is not PSE reportable since Marine Transport Vessel incidents are specifically excluded except when the vessel is connected to the refinery petrochemical or chemical manufacturing facility for the purposes of crude or product transfer
23 A third-party barge is being pushed by a tug and hits the company dock A barge compartment is breached and releases 1000 kg of diesel to the water The event is not a reportable PSE since the marine vessel was not berthed at the dock and actively involved in crude or product transfer operations
TRUCK AND RAIL
24 A company railcar derails and spills more than 1000 kg of gasoline while in transit The incident is not PSE reportable since rail incidents off company property are specifically excluded
25 A third-party trucktrailer overturns while in the Company Premises resulting in an acute spill of gasoline greater than 1000 kg The incident is not reported as a PSE reportable if the truck is no longer connected to the loadingunloading facilities However it is recommended that companies also have transportation incident metrics which would capture this event
26 A contract truck hauler is unloading caustic and the hose separates and generates an airborne aerosol andor liquid caustic spill of 2500 kg The event is a reportable PSE since the caustic TQ of 100 kg was exceeded and the truck was still connected to the loadingunloading facility immediately prior to the incident
OFFICE BUILDING
27 There is a boiler fire at the Main Office complex and direct cost damages totaled $75000 The incident is not PSE reportable since Office Building incidents are specifically excluded
MAN-MACHINE INTERFACE INCIDENTS
28 An operations technician is injured while working around the finishing equipment in a polymers plant The injury is caused by the mechanical man-machine interface with the equipment This would not be a reportable Process Safety Event because there was no loss of containment of hazardous material
MIXTURES
29 If a mixture by itself has a GHS classification you use that classification to determine the threshold If the mixture itself does not have a GHS-classification we go back to the individual components of the mixture and based on kg released per threshold group calculate a lsquoweightedrsquo contribution to the thresholds Example a release of 100 kg of a mixture in a one hour period that consists of 05 kg of a substance classified as acute toxic H300 45 kg of substance classified with H301 and 40 kg of a substance with another H-number and the remaining 55 kg of water with no GHS classification would be calculated as 051 + 4510 + 40100 = 05 + 045 + 04 = 135 is exceeding 1 and would be counted as a reportable process safety incident even though none of the individual hazardous components exceeded the threshold for the individual substance
DIRECT DAMAGE COSTS
30 Direct damage costs are considered for this threshold should be those costs directly attributed to the fire andor explosion such as the replacement value of equipment lost structures lost cost of repairs environmental cleanup emergency response andor fines Direct cost does not include indirect costs such as business opportunity losses loss of profits due to equipment outages cost of obtaining or operating temporary facilities or cost of obtaining replacement products to meet customer demand (product losses)
31 As an example a leak of flammable gas occurred in a vent line connected to a gas treatment system At the same time a failure in the process allowed air to enter in the same vent line An explosion occurred and the over pressure damaged the vent line and associated upstream equipment including a seal pot Nobody was hurt The cost for repair was about $12000 This is a PSE considering the cost to repair the equipment due to the explosion and fire
32 As an example after a PSE event a company releases 50 kg of a very special GHS Category 5 product which causes $2000 of damage to equipment The product released was a very special blend of materials and the company incurs over $50000 in materials associated with the product loss This event is not reportable as PSE since the reportable threshold for GHS Category 5 releases is 100 kgs and product losses do not count as Direct Damage Costs
NATURAL DISASTERS
33 Natural disasters can present substantial risks to chemical process operations and damage to plant equipment which may result in a loss of containment of hazardous substances Where the potential for one or more types of natural disasters is deemed relevant to plant operations process safety and operational systems shall address the applicable risk in terms of hazards and consequence analysis plant design operating procedures for loss of utilities and process shutdown and emergency planning and response
Types of natural disasters includes hurricanes and typhoons (including associated storm surge) floods tornadoes earthquakes derechos (straight line wind storms) wildfires volcanic eruptions tsunamis and avalanches
If your facility experiences a natural disaster that triggers one or more of the thresholds it should be reported as a process safety event
PRECAUTIONARY PUBLIC RESPONSE
34 A precautionary public response is a measure taken from an abundance of caution For example a company may require all workers to shelter-in-place in response to an LOPC independent of or prior to any assessment (eg wind direction distance from the LOPC etc) of the potential hazard to those worker For example a recognized community official (eg fire police civil defense emergency management) may order a community shelter-in-place evacuation or public protective measure (eg road closure) in the absence of information from a company experiencing a process safety event or lsquojust in casersquo the wind direction changes or due to the sensitive nature of the potentially affected population (eg school children the elderly)
ACTIVE WAREHOUSE
35 An active warehouse is an on-site warehouse that stores raw materials intermediates or finished products used or produced by a process From a process perspective an active warehouse is equivalent to a bulk storage tank Rather than being stored in a single large container the raw materials intermediates or finished products are stored in smaller containers (eg totes barrels pails etc)
Appendix C ndash List of RCLG Taskforce Members Luiz Shizuo Harayashiki19
Appendix D ndash Detailed Schedule of Events Appendix E ndash Optional Excel Reporting FormWhen member companies begin tracking process safety events a single form should be utilized for all member companies to make data analysis easier and to allow all members to work from the same tracking sheet The RCLG has developed an optional tracking sheet that members and associations can start with when developing their own tracking sheet
DOWNLOAD TRACKING SHEET HERE
This document consists of a contact page the survey itself and a lsquodo not editrsquo page where the drop down menu answer are stored
INTERNATIONAL
COUNCIL OF
CHEMICAL
ASSOCIATIONS
ICCA Process Safety
Event Tracking Sheetxlsx
4
敬愛的 TRCA 會員您好
謹代表 TRCA 藉此機會對 ICCA (International Council of Chemical Associations 國際化學業
協會)以及 RCLG (Responsible Care Leadership Group 責任照顧領導群)過去幾年來致於調
和製程安全指標所付出的與貢獻致上深深的謝忱
製程安全管理是化學業為關鍵重要的作製程安全指標的提報則是驗證製程安全
管理的核程過去數年來國際與國內化學業致於持續不斷的改進相關績效指
標的表現我們相信減少製程安全事件的發與是否進量測有絕對的關係因為我們無
從改進沒有進過量測的項因此藉由製程安全事件的提報將有效的協助會員公司
與國家協會分享 佳實務經驗並在這個過程中協助會員公司改善製程安全績效表現進
減少環境跡從事故事件中學習是改進製程安全管理的關鍵我們誠摯地希望藉由
製程安全指標提報能降低製程安全事件的發
TRCA 2015 年起籌組 Near Miss 試組並於當年起開始提報製程安全虛驚事件數
以做為未來全提報製程安全事件率的準備感謝試組台灣永光化學業(股)公司
台灣中油(股)公司國喬油化學(股)公司台灣科思創(股)公司奇美實業(股)公司台
橡(股)公司春油化學(股)公司春造樹脂廠(股)公司連化學業(股)公司
李榮化學業(股)公司以及台灣志氯化學(股)公司率先的努配合試為 2020 年全
提報製程安全事件指標提供了難能可貴的經驗
TRCA 為達成 ICCA 擬定 2020 年全提報的標訂於 2019 年開始試提報 2018 年數據
2018 年將陸續展開相關說明與教育訓練研討會議我們相信推 ICCA 全球調和製程安全
指標提報將能更有助於加強與改善台灣化業製程安全管理績效
讓我們起為化業更安全與環保的永續未來努吧
TRCA 責任照顧推委員會主席 Chairman Responsible Care Implementation Committee台灣志氯化學(股)公司總經理 President Taiwan Chlorine Industries Ltd
嚴堅正 Art Yen
5
背景
責任照顧倡議(Responsible Carereg initiative)發起於 1985年其目的在於展現化學工業界持續
改善績效的承諾自從責任照顧倡議開始實施以來製程安全(Process Safety)一直是責任
照顧倡議的核心基礎之一實施責任照顧 30 多年來許多地區已發展出追蹤及提報製程
安全績效的方法然而一直未能建立一套全球調和的提報系統由於一些重大製程安全
事件仍不斷發生在 2012 年國際化學工業協會(ICCA)董事會便責成責任照顧領導群
(RCLG)在 2015 年以前擬定一套全球調和的製程安全績效提報機制
2013-14 年間一個由跨國公司和 RCLG 各協會組成的專案小組正式成立該專案小組由
拜耳醫療保健公司(Bayer HealthCare AG)的衛生安全及環保總監 Peter Schmelzer 博士擔任
召集人其任務即是研擬一套全球調和的 ICCA 製程安全績效提報機制專案小組成員表
詳見附錄 C在此期間美國石油學會(API)也著手開始進行其 API RP 754 ndash領先及落後製程
安全指標標準(Leading and Lagging Process Safety Metric Standard)之修訂RP-754 被廣泛應
用於美洲地區的煉油及石化產業以追蹤製程安全績效為了推動全球採行統一的標準
RCLG 專案小組致力於將其所提出之建議案與預訂於 2016 年第一季完成修訂之 API RP 754
達到完全調和
執行摘要
經過兩年多的討論研究辯論及可行性評估製程安全調和化專案小組(PSHT)建議 ICCA
採行一套製程安全事件發生率指標採行這套指標需要 RCLG 各協會蒐集會員公司在一年
內所發生之製程安全事件次數和工作總時數(包括員工和承攬商)製程安全事件發生率即
事件數除以工作時數的比率專案小組建議向 RCLG 提報這些數據的要求將在未來三年
內分階段實施同意已具有意願和能力提報的地區立即開始提報數據同時也給予正在發
展追蹤數據能力以進行首次提報的公司和機構若干緩衝時間
判定製程相關事件是否符合製程安全事件定義的標準係以化學物質的一次阻絕設施失效
或能量釋放以致引起下列任何一個影響考量面的門檻為根據1) 安全人員健康後果2)
事故造成損失之直接成本3) 社區影響4) 化學物質洩漏量(請參見提報判定流程圖所
示)ICCA 所建議之製程安全事件定義的四個影響考量面與 RP-754Tier II 事故標準的影
響考量面是完全一樣的除了化學物質洩漏量提報門檻有所差異外其他三個影響考量面
6
的提報門檻也是一樣的為因應此一差異針對化學物質外洩量提報門檻ICCA 製程安
全事件定義將容許會員公司採用 ICCA 依據化學品全球調和制度(GHS)健康危害分級為基礎
所發展的提報標準或依據聯合國危險物品(UNDG)分類為基礎所定義之 RP-754 二級製程
安全事件(Tier II) 之提報標準專案小組相信這兩套制度之提報標準雖然有所差異但
從其所涵蓋之化學物質領域和提報事故嚴重程度看來兩者皆相當健全雖然採用這兩種
不同提報門檻所收集和提報的事件數差異相對不大但在公司方面從原料及產品使用的角
度看來兩者可能會有非常明顯的不同因此專案小組提醒會員公司勿將自己公司的
結果與採用不同化學物質洩漏量提報門檻的公司做比較無論如何根據 RCLG 的提議
會員公司可選擇化學物質洩漏門檻以向國家及地區協會進行提報如果各協會有興趣轉
換兩種不同提報方式的結果RCLG 可提供轉換表但由於轉換運算非常複雜且須取得
原始事故數據專案小組相信相互轉換的附加價值不大因此不建議協會採取此一做法
專案小組相信這項製程安全事件提報建議案可廣泛運用在化學及石化產業實施製程安
全績效提報這項提報制度將為目前尚未追蹤製程安全績效的地區協會和會員公司提
供一個指引讓他們可以體認追蹤及提報製程安全績效可以帶來的益處至於已在蒐集製
程安全數據的地區協會和會員公司此建議案將有助於他們更廣泛地與全球接軌並將
重點放在持續改善製程安全績效這些改善製程安全績效的制度仰賴的是可靠的製程安
全事件數據改善製程安全績效正是責任照顧倡議的主要目的
7
RCLG 各協會應向 RCLG 提報的數據
RCLG 各協會每年必須依照下文提供的時程透過 RCLG 關鍵績效指標(KPI)提報網站向
ICCA 提報兩個數據
1 協會所屬會員公司的總工作時數(包括員工和承攬商)
2 製程安全事件總數
ICCA 將利用上述兩個數據以製程安全事件發生率(PSER)的形式報告製程安全績效PSER
計算之常態化是以每 100 位員工每位員工一年工作 2000 小時為基準
(總事件數 總工作時數) x 200000 = PSER
建議之提報時程
針對提報製程安全事件發生率專案小組建議一種分階段導入的方法此一時程可讓更多
已具經驗的協會及公司立即實施提報同時容許其他協會及公司從 2019 年起開始提報
RCLG 各協會必須透過 RCLG KPI 指標提報系統(httpkpiresponsiblecareeu)每年向 ICCA
提報兩個製程安全事件發生率數據如果你不知道你所屬協會的使用者名稱和密碼請聯
絡 RCLG
建議 RCLG 協會提報製程安全事件發生率的時程如下
2015 年 4 月 RCLG 考量專案小組建議案
2015 年 6 月 ICCA 理事會考量 RCLG 的最終建議
2015 年 7 月 RCLG 頒布首份詳細的提報指引供協會及會員公司遵
循
2016 年 2 月 RCLG 提報 RCLG 更新及強化提報指引並針對自願參加的協會
開始實施製程安全試行提報計畫RCLG 於 2016 年 6 月
頒布最終指引
2017 年 RCLG 各協會開始向會員公司蒐集數據
2018-2019 年 RCLG 提報 RCLG 各協會可選擇地開始提報製程安全數據
2020 年提報 RCLG 於 KPI 提報計畫中將製程安全納入為一項強制性
指標
參見附錄 D ndash 詳細活動時程
8
ICCA 製程安全事件判定標準流程圖
事故是否發生在廠內之
生產配銷儲存公
用或試驗工廠
是 是
是
否
否 是否造成須通報工傷
或
廠內廠外人員住院治
療
損壞是否對
公司造成
ge $2500 美
元的直接成
本損失
官方是否宣告就地
避難或疏散或廠
外預防性就地避難
或疏散
否
是
否
是屬於須通報製程安全事件
是
否
是
是
開始
否不符合製程安全事件認定
標準
是否超過 ICCA 或 API
754 Tier II 化學物質洩
漏恕限值
否 發生化學物質外洩火
災或爆炸是否起因於
或發生在化學製程單元
是否直接涉及某種化學物
質或化學製程
否
9
須提報製程安全事件之重要標準
總工作時數
RCLG 各協會應以加總的單一數字提報其所屬會員公司的員工和承攬商總工作時數為達
成本指引之目的各協會應參考其本地和地區對員工及承攬商之定義提報總時數之目標
應納入涉及化學製造之所有個人然而參與主要興建工程專案之人員則不納入計算譬
如為新建或擴建既有製程設施之設計工程和施工而成立之一次性專案組織的大規模投資
案會員公司提報總工作時數時應與人事部門統計之員工工時一致如此各公司便能
取得相同的職業與製程安全數據員工工時應包括所有化學製造作業的工時而非僅計算
發生製程安全事故之廠區的工時
製程安全事件
為執行 ICCA 提報目的製程安全事件之定義條件如下(必須同時符合 ABCD 四個條
件)
A 直接涉及某種化學物質或化學製程且
B 事故發生在廠內之生產配銷儲存公用或試驗工廠且
C 製程單元發生物質洩漏或能量釋放(如火災爆炸和內爆)且
D 已達到以下提報門檻之一
1 安全 工傷
導致記錄性的傷害(OSHA)損失工時或死亡或廠內外任何人員因此
而須住院治療或
2 直接損失成本
火災爆炸或為避免補救環境損害之必要清理作業導致$2500 美元
以上的直接成本支出或
3 就地避難 疏散
官方宣告就地避難(廠內或廠外)或
官方宣告疏散(廠內或廠外)或
廠外預防性就地避難或疏散或
4 洩漏恕限值
物質洩漏程度已達表 1 所列之任一 GHS 恕限值(洩漏量以單位小時計
量)
此外各公司亦可選擇採用 API RP-754 標準中所列之洩漏恕限值(表 2)請注意如欲查
看 API RP-754 標準可登入以下網站購買及下載httpwwwapiorgoil-and-natural-
gashealth-and-safetyprocess-safetyprocess-safety-standards
10
製程安全事件判定準則
A 涉及化學品
直接涉及某種化學物質或化學製程
製程安全事件或事故必須直接涉及化學物質或化學製程就此而言ldquo製程rdquo一詞泛指包含
石化生產所需要之設備和技術包括反應器儲槽管線鍋爐冷卻水塔和冷凍系
統helliphellip等未直接涉及化學物質或製程的事件無須提報譬如辦公大樓起火(即使該辦公大
樓位在廠區內亦然)
B 地點
事故發生在廠內之生產配銷儲存公用或試驗工廠
發生在廠內之生產配銷儲存(包括活動儲存區如倉庫 ndash 參見ldquo常見問題集rdquo)公用及
試驗工廠凡符合提報指標及定義的事故包括在廠區管理下之槽罐區輔助支援區(如
鍋爐室和廢水處理廠)和配銷管線所有須提報之事件應由負責該事故地點運作的公司
負提報之責此一規定亦適用於發生在承攬商作業區域內的事故在代工作業和多方共同
作業廠區負責運作該發生事故單位的公司應記錄事故始末並將之納入其提報中
C 物質洩漏
製程單元發生物質外洩或能量釋放(如火災爆炸和內爆)
物質外洩 ndash 製程任何物質發生非預期或無法控制的洩漏或釋放包括非毒性及不可燃物質
(如蒸汽熱水氮氣壓縮二氧化碳或壓縮空氣)且達到本文件所列四類提報門檻之一
項或以上之後果
在防治系統(如洗滌塔或廢氣燃燒塔)正常運作狀況下只要沒有任何洩漏或排放量超過
法定許可值即使排放到廢氣燃燒塔或滌氣塔仍被視為處於一次阻絕設施內然若排
放到二次阻絕設施(如廢水處理或防溢堤)將被視為製程安全事件因為物質已離開主要製
程系統
11
D 提報門檻
須提報製程安全事件必須達到以下提報門檻之一
1 安全 工傷
導致記錄性傷害(OSHA)損失工時或死亡或廠內外任何人員因此而須住院治療
記錄性傷害是指與工作有關所造成的傷害導致死亡暫時全失能工作受限制或需調整職
務較輕傷害嚴重之醫療處理失去意識或經醫師或其他合格醫療專業人員診斷為重大
傷害
損失工時傷害和死亡是指因製程相關的一次阻絕設施失效火災或爆炸導致以下任何一種
結果
員工(損失工時或死亡)
承攬商及再承攬商 (損失工時或死亡)
第三方(如來賓訪客快遞員)(受傷疾病導致住院治療或死亡)
住院治療是指醫院或其他具有住院病患保健設施的醫療單位正式接受病患住院提供病患
食宿及醫療護理且病患接受治療至少留置至隔日僅在醫院急診室治療或過夜處理不屬
於ldquo住院治療rdquo的定義範圍
須提報之工傷或死亡事件例如在清理作業期間因蒸汽洩漏造成人員燒燙傷壓力測試期間
帽蓋因受壓脫落造成人員身體傷害或取樣作業時因物質外濺造成人員化學灼傷無須提
報之工傷或死亡事件例如在執行維修作業時從高處的工作台墜落實驗室或辦公大樓火災
造成人員燒燙傷或挖掘工程塌陷造成人員傷害這些案例均與因製程造成的能量釋放或
物質洩漏無直接關聯
2 直接損失成本
火災爆炸或為避免補救環境損害之必要清理作業導致$2500美元以上的直接成本支出
此提報門檻所考慮的成本應為可直接歸因於火災或爆炸的成本譬如設備及結構損壞的重
置成本修理成本環境清理(廠內及廠外)支出緊急應變和罰款直接成本不包括間接
成本譬如業務機會損失設備停機造成之利潤損失取得或運轉臨時設施之成本或為
滿足顧客需求取得替代產品的成本(產品損失)
12
3 就地避難 疏散
官方宣告就地避難或疏散(廠內或廠外)或廠外預防性就地避難或疏散
就提報目的而言官方宣告就地避難或疏散(廠內或廠外)或廠外預防性就地避難或疏散
即達到此提報門檻
官方宣告 ndash 由地方權責機關(如消防警察民防緊急應變管理部門)或經授權的代表(如
派駐公司官員)下達的社區行動(如就地避難或疏散)宣告
預防性宣告 ndash 預防性公眾應變是基於謹慎的態度所採取的一種措施權責地方主管機關或經
授權的代表經合理判斷認定為維護公眾健康及安全發布必須採取就地避難或疏散之預
防性措施
就地避難 ndash 利用結構體及其內部空氣以暫時讓人員與室外危害性氣體隔離
疏散 ndash 基於安全或防護理由讓人員離開某處所的行動或過程
4 洩漏恕限值
超過表 1 中所列 GHS 恕限值或表 2 中所列 API 754 標準 Tier II 製程安全洩漏恕限值之一的
急性洩漏事件(洩漏量以單位小時計量)
如ldquo執行摘要rdquo所述ICCA 製程安全事件之定義容許採用 ICCA 依據化學品全球調和制度
(GHS)健康危害分級為基礎所發展的提報標準或依據聯合國危險物品(UNDG)分類為基礎
所定義之 RP-754 二級製程安全事件(Tier II) 之提報標準GHS 恕限值詳見表 1各會員公司
可自行決定選擇哪一個表中的提報恕限值並在全球採用單一制度
ldquo急性rdquo洩漏 ndash易燃性可燃性或毒性化學物質從一次阻絕設施(如容器或管線)洩漏其
任一單位小時之洩漏量超過化學物質洩漏恕限量分述於表 1 中的 GHS 分類和表 2 中的
API 754 標準 Tier II 製程安全洩漏恕限值
洩壓裝置前述所定義之ldquo急性rdquo洩漏包括洩漏或排放至妥善設計且運作中的洩壓裝置若
洩漏或排放量達到表 1 中所列 GHS 恕限值或表 2 中所列 API 754 標準 Tier II 製程安全洩漏
恕限值且導致下列四種後果之任一項或以上之後果
1 二相排放或夾帶液體的排放液滴沉降至地面造成污染
2 排放至具潛在危險性的地點
3 廠內就地避難或疏散不包括預防性廠內就地避難或疏散
4 啟動公眾保護措施(如道路封閉)包括預防性公眾保護措施
13
洩漏或排放至妥善設計且運作中的洩壓裝置(如廢氣燃燒塔洗滌塔等)若其情況未達前
述四項標準中任何一項則不必提報
欲查看 API RP-754 標準可登入以下網站下載此標準httpwwwapiorgenvironment-
health-and-safetyprocess-safetyprocess-safety-standardsstandard-rp-754
一小時法則
為便於衡量此項指標提報與否洩漏恕限值是以物質在任一小時內之洩漏量為標準若任
一小時或更短時間內物質洩漏量達到或超過須提報恕限值該事故便屬於須提報的製程安
全事件急性洩漏事故通常不會超過一小時若無法確定洩漏持續時間則應假設其為一
小時
一次阻絕設施ndash 用來作為主要容器或用於運送或輸送物質之槽罐船隻管線軌道車
或設備主要容器在設計上可能包含二次阻絕設施系統以抑制及控制洩漏二次阻絕設
施系統包括(但不限於)儲槽防溢堤製程設備周遭的圍堵設施油水分離的排水收集系統
雙層儲槽的外壁等
嚴重程度表 ndash 嚴重程度加權可額外提供有關製程安全事件的有用資訊有助於帶動改善績
效附錄 A 為 RCLG 建議之製程安全事件嚴重程度加權計算方法根據附錄 A 的方法便
可藉由加總與各個後果類別關聯的分數計算出各製程安全事件的嚴重程度加權值ICCA
強烈建議採用嚴重程度加權制度因為此制度有助於提升溝通績效的能力也比較容易讓
利害關係人了解製程安全事件並且此嚴重程度加權值與其他製程安全績效指標提報方
式是不具相互比較性的
14
表 1 ndash GHS 分類表
物理性危害(GHS 2x)
洩漏恕限值(1 小時內)
STOTSpecific target organ toxicity(特定標的器官系統毒性物質)
15
表 2 ndash API RP 754 Tier II 分類表
洩漏恕限類別
物質危害性分類 acdef 恕限值
(戶外洩漏) 恕限值
(戶內b洩漏)
T2-1 TIH A 區物質 ge 05 kg (11 lb) ge 025 kg (055
lb)
T2-2 TIH B 區物質 ge 25 kg (55 lb) ge 125 kg (275
lb)
T2-3 TIH C 區物質 ge 10 kg (22 lb) ge 5 kg (11 lb)
T2-4 TIH D 區物質 ge 20 kg (44 lb) ge 10 kg (22 lb)
T2-5
易燃氣體 或 正常沸點 ≦ 35 (95 degF)閃火點lt23 (73 degF)的液體 或 其他包裝組別 I 類的物質 (酸鹼除外)
ge 50 kg (110 lb) ge 25 kg (55 lb)
T2-6
正常沸點 gt 35 degC (95 degF)閃火點 lt 23 degC (73degF)的液體 或 其他包裝組別 II 類的物質 (酸鹼除外)
ge 100 kg (220 lb) 或
ge 07 bbl
ge 50 kg (110 lb) 或
ge 035 bbl
T2-7
閃火點 gt 23 degC (73 degF)和 lt 60 degC (140 degF)的液體 或 閃火點 gt 60 degC (140 degF)的液體在閃火點或高於閃火點的溫度下洩漏 或 強酸鹼 (定義參見 RP 754 文件草案) 或 UNDG第2類第22部分 (不可燃無毒氣體)空氣除外 或 其他包裝組別 III 類的物質
ge 200 kg (440 lb) 或
ge 14 bbl
ge 100 kg (220 lb) 或
ge 07 bbl
T2-8
閃火點 gt 60 degC (140 degF) 和 lt 93 degC (200 degF)的液體在低於閃火點的溫度下洩漏 或 中度酸鹼
ge 1000 kg
(2200 lb) 或
ge 7 bbl
ge 500 kg
(1100 lb) 或
ge 35 bbl
TIH吸入性毒性危害物(Toxic Inhalation Hazard)
16
一般認為以公斤和磅或以磅和桶為單位的恕限值不盡等同各公司應該選用其中一組計量單位並在
所有紀錄文件中一體適用
在判定一種物質之洩漏恕限類別時首先應從物質之含吸入性毒性(TIH Zone)可燃性(閃火點和沸點)
或腐蝕性(強酸或鹼 vs中度酸或鹼)等特性來判別只有當物質的危險度無法利用上述簡單的特性來判別
時(如遇水反應劇烈)才採用UNDGL包裝組別
a 許多物質具有一種以上危險性正確的危險區(Hazard Zone)或包裝組別(Packing Group)歸屬應遵循DOT
49 CFR 1732a [14]或聯合國危險物品運輸建議書(UNRTDG)第2部分[12]的規定參見附錄F
b 具有四面完整牆(從地板到天花板)地板和屋頂的結構物
c 對於未列於UNDG的溶液無水成分將用TIH區或包裝組別分類溶液之恕限值將根據乾基重量之恕限
值反算
d 對於未知UNDG分類的混合物可計算每種成分在恕限值洩漏中的分量如果各種成分之分量的總和
等於或大於100即表示混合物超過門檻值若混合物有明顯且獨立的毒性及可燃性結果則可分
別計算毒性及可燃性危險度參見附錄EPSE實例amp問題 49ndash53
e 閃火點 gt 60 degC (140 degF) 和 lt 93 degC (200 degF)的液體在低於閃火點的溫度下洩漏無論洩漏量多寡其
一次阻絕設施失效(LOPC)均不屬於Tier 1製程安全事件(PSE)
f 中度酸鹼的一次阻絕設施失效無論洩漏量多寡均不屬於Tier 1製程安全事件
17 (K = 1000 MM = 1000000) (在環境影響類別方面若缺乏既有定義協會和會員公司應議定輸入標準)
附錄 A ndash 嚴重程度表鼓勵所有協會均採用嚴重程度加權制度
事件事故類別
嚴重程度等級
安全人體健康 火災或爆炸導致直接
成本 任 1 小時內物質洩
漏量 社區影響 環境影響[廠外]
4 級
1 分
對員工承攬商或再承攬商造成較輕傷害嚴重之傷害 (符合本地法規)
造成以下直接損失成本
美金$25 K ~ $25 K
洩漏量介於
1x le TQ lt 40x
官方宣告就地避難或疏散 (廠內或廠外) 預防性廠外就地避難或疏散
le 3 小時
重大環境整治成本
$25 K ~ $25 K
3 級
3 分
對員工承攬商或再承攬商造成之需要多日缺勤的傷害
對第三方造成之需要初步急救以外治療的傷害 (符合本地法規)
造成以下直接損失成本
$25 K ~ $250 K
洩漏量介於
40x le TQ lt 160x
官方宣告就地避難或疏散 (廠內或廠外)
預防性廠外就地避難或疏散
3 ~ 12 小時
重大環境整治成本
$25 K ~ $250 K
2 級
9 分
對員工承攬商或再承攬商造成 1 人死亡
對第三方造成 1 人住院治療
(符合本地法規)
造成以下直接損失成本
$250 K ~ $25 MM
洩漏量介於
160x le TQ lt 640x
官方宣告就地避難或疏散 (廠內或廠外)
預防性廠外就地避難或疏散
12 ~ 24 小時
重大環境整治成本
$250 K ~ $25 MM
1 級
27 分
對員工承攬商或再承攬商造成多人死亡
對第三方造成多人住院治療
對第三方造成 1 人死亡 (符合本地法規)
造成以下直接損失成本
ge $25 MM
洩漏量
ge 640x TQ
官方宣告就地避難或疏散 (廠內或廠外)
預防性廠外就地避難或疏散
ge 24 小時
重大環境整治成本
ge $25 MM
18 (K = 1000 MM = 1000000) (在環境影響類別方面若缺乏既有定義協會和會員公司應議定輸入標準)
嚴重程度表(附錄 A)細節說明
附錄 A 之設計目的僅適用於採用 GHS 分類制度(表 1)者如果你的公司係採用 API RP 754Tier II 製程安全指標提報恕限值表(表 2)請使用
API RP 754 製程安全嚴重程度表必須提醒的是依 API RP 754 的標準其嚴重程度表僅適用於一級(Tier I)事故去比較採用不同的嚴重度
表所評估出來的相對嚴重度並無統計上的意義
急性的環境成本 ndash 因製程安全事件造成廠外環境影響所導致之短期清理及物質處置的成本各會員公司可選擇將廠外環境影響相關成本另
外區分一個嚴重程度類別
比率調整指標
利用上述嚴重程度表可產生一系列以事件率為基礎的指標包括
製程安全總事件率 (PSTIR) 總事件次數 x 200000
總工作時數
製程安全事件嚴重程度率(PSESR) (即製程安全事件嚴重程度加權計算公式)
PSESR = 所有事件之總嚴重程度分數總合 x 200000
總工作時數
在計算此一比率時各 4 級事件被分配 1 分各 3 級事件被分配 3 分各 2 級事件被分配 9 分各 1 級事件被分配 27 分理論上每個
製程安全事件至少可分配到 1 分(亦即事件僅在一個類別符合第 4 級事件屬性)至多可分配到 135 分(亦即事件在所有五個類別中均符
合第 1 級事件屬性)
ldquoXrdquo級別製程安全事件率 嚴重度級別ldquoXrdquo之製程安全事件總數 x 200000
員工承攬商amp再承攬商總工作時數
X可以是嚴重度級別 432 或 1 級製程安全事件之總數事件之嚴重度等級是選用五類後果類別中之最嚴重等級
標準化 ndash 在某些協會和會員公司中製程安全事件是採 lsquo每 100 名rsquo員工每名員工每年平均工作時數為 2000 小時為基礎予以標準化因
此在lsquo每 100rsquo名rsquo員工的標準基礎上事件被乘以 200000 工作時數也有些其他協會和會員公司將標準化基礎設定為lsquo每 500 名rsquo員工
因此事件被乘以 1000000 工作時數協會和會員公司應就標準化基礎進行討論共同做成選項結論上述的公式設定為lsquo每 100 名rsquo員工
基礎
19
附錄 B ndash 常見問題集
適用性
我們建議會員公司記錄和提報在其所擁有或運作的工廠內發生的製程安全事件惟以下情況不須提報製
程安全事件
1 源自於公司廠區以外的製程安全事件
2 海上運輸船事故惟船隻為了輸送半成品或產品之目的已經與公司的設施相連接時發生的
事故仍須提報
3 卡車或軌道車事故惟卡車或軌道車為了輸送半成品或產品之目的已經與公司的設施相連
接時發生的事故仍須提報
4 許可證或法規容許之例行排放
5 不會造成製程安全危害的地下污染請注意若洩漏至地下導致地上發生須提報製程安全事
件如釋放出毒性蒸汽或致使易燃液體蓄積成池則不適用本排除條件
6 辦公建築事故(如辦公室暖氣設備爆炸火災外溢洩漏人員受傷或疾病等)
7 與疏散或一次阻絕設施失效無直接關聯之人員安全ldquo滑倒絆倒跌倒rdquo事故
8 沒有與製程相連接之輔助設備的一次阻絕設施(如小樣品瓶)失效事故
9 計劃中和在控制下的物質排放至設計用來收集或排放系統中(請注意物質從一次阻絕設施
在非計劃或非受控制情況下排放至收集或排放系統中則不適用本排除條件)
10 在製程區域外部或保養廠內執行之機械作業
說明與實例 ndash 以 GHS 表 1 為基礎
以下說明和實例有助於在評估須提報製程安全事件(PSE)時釐清可能存在的不確定部分
公司廠區
1 一輛第三方的卡車在公司廠區內卸載易燃產品時發生洩漏進而引起火災造成公司財物損失
$7000 美元(直接成本)雖然該卡車是ldquo由他人操作rdquo但其作業與製程相連接若公司的直接成
本財物損失達到或超過$2500 美元或已達到或超過其他 PSE 提報門檻(如1 人死亡)此事故即
屬於須提報的製程安全事件
2 與前例1 類似的例子載著易燃產品的卡車在廠外運輸途中翻覆引發火災並造成卡車毀損
該事故不屬於須提報的製程安全事件因為當時卡車並未與製程相連接
20
阻絕設施失效
3 儲槽液位計故障造成裝有ldquo易燃液體rdquo產品的儲槽外溢約 700 公斤的液體流入儲槽的防溢堤內
此事故屬於須提報的製程安全事件因為其ldquo急性rdquo洩漏量超過 100 公斤即使是阻絕在二次阻絕
設施防溢堤中亦然
4 一名從事維修工作的承攬商在開啟一個製程阻閥時被噴起的硫酸濺到造成嚴重灼傷和損失工
時的工傷此事故屬於須提報的製程安全事件因為它是涉及物質和一次阻絕設施失效的意外事
件對於因洩漏造成死亡和損工的工傷或疾病事故沒有洩漏恕限值
5 一名作業員開啟品管取樣點進行日常取樣作業時手部被一個破碎的玻璃瓶嚴重割破需要進行
縫合治療縫針造成第二天無法上班該事故不屬於須提報的製程安全事件因為它與一次阻絕
設施失效無關
ldquo急性rdquo洩漏
6 一名作業員在進行天然氣流量高於預期值之異常排除時發現天然氣管線上的一個安全閥門未適
當歸位因此天然氣經由氣液分離桶排放至排氣煙囪經進一步檢查作業員判斷在過去 6 個
月間總共有 100000 公斤天然氣以穩定的速率排放至大氣該事故不屬於須提報的製程安全事
件因為其洩漏速率(每小時約 10 公斤)不算ldquo急性rdquo洩漏(未超過易燃蒸汽每小時 100 公斤的恕限
值)
廢氣燃燒塔amp排放控制裝置 (如洗滌塔)
7 若化學物質被導引至廢氣燃燒塔或排放控制裝置(如洗滌塔)只要該廢氣燃燒塔或控制裝置運作在
正常設計範圍內便不屬於須提報的製程安全事件
8 若廢氣流速超過洗滌塔的設計負荷以致未經吸收的化學物質排出超過恕限值該事故屬於須提報
的製程安全事件(如本文註釋所述)
註釋自取得許可或妥善管理的裝置-包括釋壓裝置發生不預期的排放若 1 小時內洩漏量達到或
超過表 1 或表 2 所列的洩漏恕限值且導致下列四種後果之任一項或以上之後果該事故便屬於
須提報的製程安全事件
o 二相排放或夾帶液體的排放液滴沉降至地面造成污染
o 排放至具潛在危險性的地點)
o 廠內就地避難或疏散不包括預防性廠內就地避難或疏散
o 啟動公眾保護措施(如道路封閉)包括預防性公眾保護措施
21
安全洩壓裝置 系統
9 製程單元發生異常安全閥開啟將洩漏物質釋放到排氣口此釋壓排放裝置是依相關要求設計
的且氣體釋到大氣中並未造成不良後果這不是一個須提報的製程安全事件因為安全閥高
壓破裂盤以及類似的安全裝置是依據 API 521 或者同等的標準設計的且此排放並未造成 (1)
夾帶液體並導致須提報的製程安全事件的後果(譬如損失工時意外死亡火災或爆炸造成$2500
美元或以上的直接成本損失液體或毒性氣體洩漏量達到或超過恕限值(2) 啟動廠內或廠外就地
避難應變或(3)啟動公眾保護措施
10 製程單元發生異常安全閥並未開啟造成設備超壓易燃性氣體從一個法蘭處ldquo急性rdquo漏出來
洩露量超過 100 公斤(一小時內)的恕限值該事故屬於須提報的製程安全事件因為從法蘭處外
漏屬於製程安全事件應提報事項
損工事故
11 一名作業員走路時不慎滑倒造成損失工時之工傷滑倒原因為天氣狀況rdquo長期rdquo油垢的地面和
易滑鞋具該事故不屬於須提報的製程安全事件因為人員安全ldquo滑倒絆倒跌倒rdquo事故若非與
一次阻絕設施失效直接關聯的疏散或應變造成則不屬於須提報的製程安全事件
12 與前例相同的事件惟這次作業員跌倒是因為少量易燃液體外漏(如 1 小時內少於 10 公斤)在採取
相關應變措施時發生該事故屬於須提報的製程安全事件因為作業員係為了應變一次阻絕設施
失效的事故而跌倒若一次阻絕設施失效發生在公司廠區且造成失時工傷或死亡後果該事故
便屬於須提報的製程安全事件對於因洩漏造成死亡和損失工時之工傷事故沒有洩漏量門檻
13 與前例相同的事件惟這次作業員跌倒是在事件結束數小時之後該事故不屬於須提報的製程安
全事件在提報要件中所用的ldquo疏散rdquo和ldquo應變rdquo等術語指的是一次阻絕設施失效和相關緊急應變
活動正在持續中事件結束後滑倒絆倒跌倒(如ldquo事後rdquo清理和補救)不屬於須提報製程安全事件
14 工人在因附近設備一次阻絕設施失效在疏散過程中一名鷹架搭建工人從鷹架梯上跌落造成損
失工時之工傷該事故屬於須提報的製程安全事件
15 一名作業員行經一個設計不良的蒸汽卻水器時被外洩的蒸汽燙傷腳踝造成損失工時之工傷
該事故屬於須提報的製程安全事件因為雖然一次阻絕設施失效洩漏出的是蒸汽(而非碳氫化合物
或化學物質)但損失工時之工傷是由於洩漏物質的物理狀態所導致的
16 一個密閉空間依照計畫以氮氣吹清一名承攬商繞過安全管制進入該密閉空間因而死亡該事
故屬於須提報的死亡事件但不屬於須提報的製程安全事件因為其中不涉及非計劃或失控的一
次阻絕設施失效
17 情況同上惟這次氮氣是非刻意洩漏進入該局限空間該事故屬於須提報的製程安全事件(同時也
是一起死亡事件)因為該名承攬商的死亡與非計劃的一次阻絕設施失效有關
22
18 一名作業員因硫化氫(H2S)警報在進行應變處理時昏倒若警報確實是因非計劃或失控的 H2S 一次
阻絕設施失效的外洩事件該事故便屬於須提報的製程安全事件若警報是一個假警報則該事
故便不屬於須提報的製程安全事件因為沒有真正的化學品洩漏發生
管線
19 一條管線破漏1 小時內洩漏 2000 磅(900 公斤)易燃蒸氣到地面但洩漏位置在廠區內很偏僻的
地點該事故仍屬於須提報的製程安全事件因為ldquo偏僻rdquo不是提報與否的考量因素
與化學物質外洩無關之火災或能量釋放事故
一般通則而言唯有當火災或能量釋放事故是因化學物質洩漏所造成或其發生導致化學物質洩漏
超過提報恕限值這些事故才屬於須提報的製程安全事件實例包括
20 一場電氣火災影響製程操作導致甲苯洩漏 400 公斤該事故屬於須提報的製程安全事件因為
化學物質洩漏已超過甲苯的 100 公斤提報恕限值
21 發生電氣火災停電或任何公用資源供應中斷可能造成工廠停工及可能引起設備損失超過
$2500 美元(如因非正常停工導致反應器或設備損壞)但並未造成超過恕限值的化學物質洩漏
亦未造成死亡或嚴重工傷該事故不屬於須提報的製程安全事件因為設備損壞並非化學製程火
災爆炸造成且化學物質洩漏並未超過恕限值
海上運輸船
22 一艘由公司營運的海上運輸船在船上發生ldquo急性rdquo易燃物質外洩洩漏量超過 100 公斤該事故不
屬於須提報的製程安全事件因為除非海上運輸船是為了輸送半成品或產品而與煉油石化或化
學製造廠的設施相連接否則其洩漏事故便不被視為製程安全事件
23 一艘第三方駁船由一艘拖船推向碼頭結果撞上公司的碼頭駁船的一個船艙破裂且造成
1000 公斤柴油洩漏到海中該事故不屬於須提報的製程安全事件因為駁船當時並非停泊在碼
頭內且其作業並非在進行半成品或產品之輸送
卡車與軌道車
24 一輛公司的軌道車在運輸途中出軌造成超過 1000 公斤汽油洩漏該事故不屬於須提報的製程
安全事件因為在公司廠區外發生的軌道車事故不被視為與製程安全有關
23
25 一輛第三方卡車拖車在公司廠區內翻覆造成ldquo急性rdquo汽油洩漏超過 1000 公斤這事故不屬於須
提報的製程安全事件因為卡車拖車當時已不再與裝卸設備連接然而我們建議會員公司另
行訂定運輸安全事故指標將這類事故記錄下來
26 一位合約卡車作業者正在卸載液鹼時發生軟管脫落造成空氣中氣霧和或液鹼液洩漏 2500 公
斤該事故屬於須提報的製程安全事件因為洩漏量已超過液鹼的 100 公斤恕限值且事故發生
前卡車仍與裝卸設備相連接著
辦公建築
27 綜合辦公大樓發生鍋爐火災造成總計$75000 美元的直接成本損失該事故不屬於須提報的製
程安全事件因為辦公大樓事故不被視為與製程安全有關
人機介面事故
28 一名操作技術員在聚合物工廠的終端設備旁作業時受傷這傷害是因機械的人機介面的設備而
造成該事故不屬於須提報的製程安全事件因為技術員受傷並非因危險物質一次阻絕設施失效
而造成的
混合物
29 若混合物本身有 GHS 分類可利用其分類確定恕限值若混合物本身沒有 GHS 分類則可計算混
合物中每個單一組成分之洩漏量(公斤)相對於個別成分恕限值之比值作為其對混合物恕限值之
lsquo加權rsquo貢獻譬如若混合物在 1小時內的洩漏量為 100公斤其中包含 05公斤分類為劇毒 H300
的物質45 公斤分類為 H301 的物質40 公斤另一種分類為 H 開頭的物質其餘 55 公斤則為沒
有 GHS 分類的水分此混合物之計算式為051 + 4510 + 40100 = 05 + 045 + 04 = 135超過
1因此該事故被視為須提報的製程安全事件雖然混合物個別成分之洩漏量均未超過各該物質
本身的恕限值
直接損失成本
30 此一門檻所考慮的成本應為可直接歸因於火災或爆炸的成本譬如設備及結構損壞的重置成本
修理成本環境清理支出緊急應變和罰款直接成本不包括間接成本譬如業務機會損失設
備停機造成之利潤損失取得或運轉臨時設施之成本或為滿足顧客需求取得替代產品的成本
(產品損失)
24
31 範例連接到氣體處理系統的排放管發生易燃氣體外漏同時製程出現問題導致空氣進入同
一條排放管結果發生爆炸過高的壓力損壞了排放管及其相關上游設備包括一個密封罐並
未造成人員受傷修理成本約$12000 美元該事故屬於須提報的製程安全事件因為爆炸及火
災導致設備修理成本超過門檻
32 範例一次製程安全事件後公司又發生一種非常特殊的 GHS 第 5 類產品洩漏 50 公斤造成
$2000 美元的設備損失洩漏的產品是一種非常特別的混合物公司須負擔超過$50000 美元因
產品耗損而產生之材料成本該事故不屬於須提報的製程安全事件因為 GHS 第 5 類產品洩漏的
提報門檻為 100 公斤且產品耗損不被計入直接損失成本
天然災害
33 天然災害可能對化學製程作業構成重大風險且對製程設備造成損壞導致危害物質一次阻絕設
施失效當一種或多種天然災害被認為可能對工廠作業造成影響時製程安全和作業系統應從危
害及後果分析工廠機器設備設計公用設施失效及製程停工之操作程序緊急應變計畫及應變
措施等方面界定潛在風險進行防範
天然災害類型包括颶風及颱風(包括伴隨而來的風暴潮)水災龍捲風地震超強對流風暴(直
線風暴)野火火山爆發海嘯和山崩
若公司廠房設施遭遇天然災害且其後果觸發一種或以上提報門檻該事故便屬於須提報製程安
全事件
預防性公眾應變
34 預防性公眾應變是基於謹慎的態度所採取的一種措施譬如當發生一次阻絕設施失效時公司
可能在尚未進行任何評估(如方向與洩漏點的距離等等)前便要求全體工人就地避難又
如地方權責官員(如消防警察民防緊急應變管理部門)在獲報一家公司發生製程安全事件
後為防lsquo萬一rsquo風向改變或基於可能受到波及的人口敏感族群(如學童或老年人)可能在尚未接
獲明確資訊前便下令社區就地避難或疏散或採取公眾保護措施(如道路封閉)
製程附屬倉庫
35 製程附屬倉庫指的是位於廠內用於儲存將投入於生產製程或產自於製程之原料半成品或成品的
倉庫從製程的觀點看來製程附屬倉庫相當於一個大型儲槽但這些原料半成品或成品並不
是儲存在一的大型容器中而是裝在較小的容器裡(如太空包大桶桶罐等)
25
Appendix C ndash List of RCLG Taskforce Members
Name Affiliation
Peter Schmelzer Bayer CEFIC - Chairman
Americo Diniz Carvalho Neto Braskem
Bradford Johnson American Chemistry Council
David Cummings DuPont
Debra Phillips American Chemistry Council
Hans Schwarz BASF
Kathryn Walton Plastics and Chemicals Industries Association
Kazuyuki Akita Japanese Chemical Industry Association
Kelly Keim ExxonMobil Chemical Company API Representative
Kenan Stevick Dow
Kiyokazu Murata Japanese Chemical Industry Association
Larry Bowler SABIC
Lorna Young Chemical Industry Association of Canada
Louisa Nara Center for Chemical Process Safety
Luiz Shizuo Harayashiki Associaccedilatildeo Brasileira da Induacutestria Quiacutemica
Masatoshi Kumamoto Japanese Chemical Industry Association
Milton Lacerda Petrobras
Phil Scott Chemical Industries Association
Piet Knijff DSM European Process Safety Centre
Scott Donaldson and Eamon Chandler
Shell
Scott Wallace Olin Corporation
Shakeel Kadri Air Products and Chemicals Inc
26
附錄 D ndash 詳細活動時程表
2016 年 2017 年 2018 年 2019 年 2020 年
2 ndash 4 月
RCLG PS 先導計畫
5 月 ndash
針對準則進行調整釐清
6 月 向 RCLG 和 ICCA 董事會報
告先導計畫執行結果
7 ndash 12 月 RCLG 協會考量準
則並為其會員公司發展提報機制
如有需要RCLG可向 ICCA 申請能
力建立基金為會員公司舉辦製程安
全研習會
1 ndash 12 月
RCLG 協會開始向其會員公司蒐集製程安全數據
1 ndash 12 月
如有需要RCLG 各協會運用 RCLG 的基金及專
家舉辦製程安全及績效提報研習會
1 ndash 2 月
擁有數據的協會開始向RCLG 提報製程安全事件
(2017 年數據)
4 月 RCLG 檢討第一個提報循
環的結果挑戰及原始數據(內部)
6 月 RCLG 向 ICCA 董事會呈報
原始數據
7 ndash 12 月 必要時更新及調整準
則
如有需要RCLG 各協會運用 RCLG 的基金及專
家舉辦製程安全及績效提報研習會
1 ndash 2 月
擁有數據的協會開始向RCLG 提報製程安全事件
(2018 年數據)
4 月 RCLG 檢討第二個提報循
環的結果挑戰及原始數據(內部)
6 月 RCLG 向 ICCA 董事會呈報
原始數據
7 ndash 12 月 必要時更新及調整準
則
如有需要RCLG 協會運用 RCLG 的基金及專家
舉辦製程安全及績效提報研習會
1 ndash 2 月
所有協會開始向 RCLG 提報製程安全事件
製程安全事件提報成為
RCLG KPI 衡量指標建議基本集的一部分(2019 年數
據)
4 月 RCLG 檢討第二個提報循
環的結果挑戰及原始數據(內部考量外部提
報)
6 月 RCLG 向 ICCA 董事會呈報
原始數據
27
附錄 E ndash 選擇性 Excel 追蹤表
當會員公司開始追蹤製程安全事件時所有會員公司應採用單一表格以簡化數據分析同時讓所有公司均使用相同的追蹤表RCLG 設
計了一份選擇性追蹤表可供會員公司和協會先行利用之後他們可設計自己的追蹤表
在這裡下載追蹤表
ICCA Process Safety Event Tracking Sheetxlsx
本文件包含三個分頁分別是ldquo聯絡資料rdquoldquo調查表rdquo和儲存下拉式選單選項的ldquo請勿編輯rdquo分頁
備註
附錄 E 追蹤表僅供參考TRCA 將另行提供台灣版表格供會員公司提報
28
後語
台灣化學工業責任照顧協會(Taiwan Responsible Care Association TRCA)成立於 1998 年在台灣推行責任照顧制度已達 20 週年製造商成員
包括台灣主要上市上櫃化工公司會員公司化學品生產製造量約佔全國 80 2016 年台灣化工業的 Chemical Sales 仍站在全球第八名的位
置額度為 630 億歐元化工業總產值達到 34 兆新台幣提供國內 416 萬人工作機會
TRCA 扮演國內廠商與國際制度接軌的角色也是國內化工業與政府機關及利益相關者溝通的橋樑與管道TRCA 會員結構依業務性質分析
涵蓋石化生產化學品製造氣體生產倉儲運輸業化學品貿易業以及工程研發設計等公司TRCA 透過供應鏈及價值鏈推行責任
照顧制度組成毒性化學物質聯防組織協助法規溝通與研析會員名冊請參考 httpwwwtrcaorgtwtrcanwork2aspx
TRCA 於 2010 年成為 ICCA (International Council of Chemical Associations 國際化學工業協會)觀察員ICCA 成立於 1989 年是全球化工製造
業的聯合會也是化學工業與 UNEP OPCW 及 OECD 的交流窗口ICCA 與其會員協會及成員公司致力於邁向永續的未來確保人類健康與
環境安全與保護全球化工業擁有超過 4兆美元的價值影響所有經濟部門ICCA 的會員幾乎在全球每個國家都有商業活動在全球六大
洲推動創新並提供超過 2000 萬個工作機會
台灣化工業在全球占有重要的一席之地在國內產業鏈也位居關鍵位置無論對國內或國際都有身為地球村一員應盡之責我們期許藉由
製程安全指標提報能更進一步提升自我在工安衛生環保與永續發展等面向的績效表現
台灣化學工業責任照顧協會
10452 台北市中山區撫順街 8 號 7 樓
電話02-2585-0552
httpwwwtrcaorgtw
None | |
$2500 to $25000 | |
$25000 to $250000 | |
$250000 to $25000000 | |
More than $25000000 | |
Yes - Using GHS TABLE | |
Yes - Using API RP 754 TABLE | |
NO | |
NA | |
1x le TQ lt 40x | |
40x le TQ lt 160x | |
160x le TQ lt 640x | |
ge 640x TQ | |
Yes le 3 hours | |
Yes 3 hours ge 12 hours | |
Yes 12 hours ge 24 hours | |
Yes ge 24 hours | |
No | |
Small-scale | |
Medium-scale | |
Large-scale | |
No | |
Yes | |
No | |
middot Injury requiring treatment beyond first aid to an employee contractor or subcontractor | |
middot Days Away From Work injury to an employee contractor or subcontractor or middot Injury requiring treatment beyond first aid to a third party | |
middot A fatality of an employee contractor or subcontractor or middot A hospital admission of a third party | |
middot Multiple fatalities of employees contractors or subcontractors or middot multiple hospital admission of third parties or middot A fatality of a third party | |
NA | |
1x le TQ lt 3x | |
3x le TQ lt 9x | |
9x le TQ lt 27x | |
ge 27x TQ |
ICCA Process Safety Pilot Reporting ProgramFebruary 8 2016 | 1 | 2 | 3 | 4 | 5 | 6 | 7 | 8 | 9 | 10 | 12 | 13 | 14 | 15 | |||||||||||||||||||||||
SAFETY Details(Meeting Local Regulations) | Direct Cost from Fire or Explosion | Community Impact | Environmental Impact | Material Released(Measured using the 1 Hour Rule) | |||||||||||||||||||||||||||||||||
Company Association Details | |||||||||||||||||||||||||||||||||||||
GHS | API - RP 754 | ||||||||||||||||||||||||||||||||||||
Company or Assocation Name | Headquarter Association | Location of Event Ex - City State amp Country | Date and Time of Event | Safety InjuryDid the Event result in a Recordable Lost Time Accident or Fatality or Hospital admission of anyone on or off siteUse Drop Down Menu | Safety InjuryIf yes please insert the total number of injuries | Safety InjuryFor puropses of utilizing the Severity Table please indicate the level of severity by chosing the MOST SEVERE classification that describes your incidentUse Drop Down Menu | Safety InjuryDid the incident involve Fatalities If so how many total fatalities If none enter Zero | Safety InjuryPlease Report Total Employee Hours for Calendar Year 2015 | Safety InjuryPlease Report Total Contractor Hours for Calendar Year 2015 | Direct Cost Did the Event result in Direct Damage CostUse Drop Down Menu | Direct Cost If so how muchAmount is in US DollarsUse Drop Down Menu | Community ImpactDid the event result inbull Officially declared shelter-in-place or officially declared evacuation (on or off site)ORbull Precautionary off site shelter in place or evacuation Use Drop Down Menu | Environmental ImpactDid the event result inAcute Environmental Remediation CostIf so indicate the amount in US DollarsUse Drop Down Menu | Material ReleasedDid the Event result in an Acute Release of material beyond one of the two threshold tablesIf so indicate which Threshold Table you used to make this determinationUse Drop Down Menu | Material ReleasedIf so indicate the amount released USING GHS CLASSIFICATION TABLEUse Drop Down Menu | Material ReleasedIf so indicate the amount released USING THE THRESHOLD TABLE FROM API RP-754Use Drop Down Menu | Material ReleasedIf available please indicate the material released | ||||||||||||||||||||
1 | ABC Chemical Company | American Chemistry Council | Washington DC - USA | January 4 2016 | Yes | 2 | middot Days Away From Work injury to an employee contractor or subcontractor or middot Injury requiring treatment beyond first aid to a third party | 0 | 5525000 | 1500250 | No | $2500 to $25000 | Yes le 3 hours | $2500 to $25000 | Yes - Using GHS TABLE | 40x le TQ lt 160x | NA | Chlorine | |||||||||||||||||||
2 | XYZ Chemical Company | American Chemistry Council | Washington DC - USA | 5-Jan-16 | Yes | 1 | middot Injury requiring treatment beyond first aid to an employee contractor or subcontractor | 0 | 5525000 | 1500250 | Yes | $2500 to $25000 | No | $2500 to $25000 | Yes - Using API RP 754 TABLE | NA | 3x le TQ lt 9x | Benzene | |||||||||||||||||||
3 | |||||||||||||||||||||||||||||||||||||
4 | |||||||||||||||||||||||||||||||||||||
5 | |||||||||||||||||||||||||||||||||||||
6 | |||||||||||||||||||||||||||||||||||||
7 | |||||||||||||||||||||||||||||||||||||
8 | |||||||||||||||||||||||||||||||||||||
9 | |||||||||||||||||||||||||||||||||||||
10 | |||||||||||||||||||||||||||||||||||||
11 | |||||||||||||||||||||||||||||||||||||
12 | |||||||||||||||||||||||||||||||||||||
13 | |||||||||||||||||||||||||||||||||||||
14 | |||||||||||||||||||||||||||||||||||||
15 | |||||||||||||||||||||||||||||||||||||
16 | |||||||||||||||||||||||||||||||||||||
17 | |||||||||||||||||||||||||||||||||||||
18 | |||||||||||||||||||||||||||||||||||||
19 | |||||||||||||||||||||||||||||||||||||
20 | |||||||||||||||||||||||||||||||||||||
21 | |||||||||||||||||||||||||||||||||||||
22 | |||||||||||||||||||||||||||||||||||||
23 | |||||||||||||||||||||||||||||||||||||
24 | |||||||||||||||||||||||||||||||||||||
25 | |||||||||||||||||||||||||||||||||||||
Zero or None | Yes - Duration Unknown | ||||||||||||||||||||||||||||||||||||
Processes | Mode of Operation | Type of material released | Status of Operation | ||||
REFINING | Start-up | Flammable | Open | ||||
Alkylation HF | Planned shutdown | Combustible | Closed | ||||
Alkylation sulfuric | Emergency shutdown | Toxic | |||||
BitumenResidAsphalt | Normal | Corrosive | Tier 1 Acute Releases | ||||
Calcining | Upset | Utilities | No Release | ||||
Coking | Turnaround | Other | Category 1 | ||||
Crude | Routine maintenance | Category 2 | |||||
Desulfurization | Temporary | Evacuation | Category 3 | ||||
FCC | Other | Yes | Category 4 | ||||
Gas Treating | No | Category 5 | |||||
Hydrogen | Point of Release | Category 6 | |||||
Hydrotreating | Pump | Fire | Category 7 | ||||
Hydrocracking | Compressor | Yes | Multiple Categories | ||||
Isom | BlowerFan | No | |||||
MarineJetty | Pressure Vessel | lt $2500 | |||||
Reforming | FilterCoalescer | ||||||
Sulfur recovery | Furnace | PRDs | |||||
Vapor recoverylight ends | Boiler | Directly to Atmosphere | |||||
Wastewater | Heat exchanger | via Downstream Destructive Device | |||||
REFINING amp PETROCHEMICAL | Cooling Tower | No | |||||
Tank FarmStorage FacilityOffsite | Piping system | Yes | |||||
UtilitiesSteam PlantCogeneration | Reactor | No | |||||
Other | Atmospheric tank | ||||||
PETROCHEMICAL | FlareRelief System | Acute release above thresholds | |||||
CO H2 | Other | Yes | |||||
LNG | No | ||||||
Methane | Events | ||||||
Methanol | No Tier 1 Events | Indoor Outdoor | |||||
Methyl Mercaptan | No Tier 2 Events | No Release | |||||
Formaldehyde | No Tier 1 or Tier 2 Events | Indoor | |||||
Formaldehyde derivatives | NA | Outdoor | |||||
Acetic Acid | |||||||
Acetic Acid derivatives | Event Type | ||||||
Ethane | Injury | ||||||
Ethylene | Fire | ||||||
Ethanol | Explosion | ||||||
Ethylene oxide | PRD Discharge | ||||||
Ethylene derivatives | Acute Release | ||||||
Polyethylene | |||||||
Ethylene dichloride | General | ||||||
Ethylene dichloride derivatives | Yes | ||||||
Ethyl benzene | No | ||||||
Ethyl benzene derivatives | |||||||
Polystyrene | |||||||
Styrene-Butadiene | |||||||
Propane | |||||||
Propylene | |||||||
Polypropylene | |||||||
Isopropanol | |||||||
Propylene oxide | |||||||
Propylene oxide derivatives | |||||||
Butane | |||||||
Isobutane | |||||||
Isobutene | |||||||
Butadiene | |||||||
MTBE | |||||||
ETBE | |||||||
Pentane | |||||||
Hexane | |||||||
Cyclohexane | |||||||
Hexanol | |||||||
Aromatics Derivatives | |||||||
Benzene | |||||||
Toluene | |||||||
Xylene | |||||||
Para Xylene | |||||||
Amines Derivatives | |||||||
TDA MDA IPDA etc | |||||||
Isocyanates | |||||||
Specialty Chemicals | |||||||
LoadingUnloading | |||||||
Pilot Plant |
Instructions | ||||||||||||||
Step 1 | Complete the Contact Tab with your contact information and company information | |||||||||||||
Be sure to note the region of your reporting (IE North America France Japan etc) | ||||||||||||||
Survey on Process Safety Events | ||||||||||||||
Step 2 | Complete the survey one line per Process Safety Event for your companyregion | |||||||||||||
ALL REPORTED DATA SHOULD BE FROM CALENDAR YEAR 2017 | ||||||||||||||
Step 3 | Return completed survey to | |||||||||||||
Company Name | ||||||||||||||
Contact Person | All Surveys Due by xxx date | |||||||||||||
Address | ||||||||||||||
Fax | ||||||||||||||
Telephone | ||||||||||||||
Region | ||||||||||||||
None | |
$2500 to $25000 | |
$25000 to $250000 | |
$250000 to $25000000 | |
More than $25000000 | |
Yes - Using GHS TABLE | |
Yes - Using API RP 754 TABLE | |
NO | |
NA | |
1x le TQ lt 40x | |
40x le TQ lt 160x | |
160x le TQ lt 640x | |
ge 640x TQ | |
Yes le 3 hours | |
Yes 3 hours ge 12 hours | |
Yes 12 hours ge 24 hours | |
Yes ge 24 hours | |
No | |
Small-scale | |
Medium-scale | |
Large-scale | |
No | |
Yes | |
No | |
middot Injury requiring treatment beyond first aid to an employee contractor or subcontractor | |
middot Days Away From Work injury to an employee contractor or subcontractor or middot Injury requiring treatment beyond first aid to a third party | |
middot A fatality of an employee contractor or subcontractor or middot A hospital admission of a third party | |
middot Multiple fatalities of employees contractors or subcontractors or middot multiple hospital admission of third parties or middot A fatality of a third party | |
NA | |
1x le TQ lt 3x | |
3x le TQ lt 9x | |
9x le TQ lt 27x | |
ge 27x TQ |
ICCA Process Safety Pilot Reporting ProgramFebruary 8 2016 | 1 | 2 | 3 | 4 | 5 | 6 | 7 | 8 | 9 | 10 | 12 | 13 | 14 | 15 | |||||||||||||||||||||||
SAFETY Details(Meeting Local Regulations) | Direct Cost from Fire or Explosion | Community Impact | Environmental Impact | Material Released(Measured using the 1 Hour Rule) | |||||||||||||||||||||||||||||||||
Company Association Details | |||||||||||||||||||||||||||||||||||||
GHS | API - RP 754 | ||||||||||||||||||||||||||||||||||||
Company or Assocation Name | Headquarter Association | Location of Event Ex - City State amp Country | Date and Time of Event | Safety InjuryDid the Event result in a Recordable Lost Time Accident or Fatality or Hospital admission of anyone on or off siteUse Drop Down Menu | Safety InjuryIf yes please insert the total number of injuries | Safety InjuryFor puropses of utilizing the Severity Table please indicate the level of severity by chosing the MOST SEVERE classification that describes your incidentUse Drop Down Menu | Safety InjuryDid the incident involve Fatalities If so how many total fatalities If none enter Zero | Safety InjuryPlease Report Total Employee Hours for Calendar Year 2015 | Safety InjuryPlease Report Total Contractor Hours for Calendar Year 2015 | Direct Cost Did the Event result in Direct Damage CostUse Drop Down Menu | Direct Cost If so how muchAmount is in US DollarsUse Drop Down Menu | Community ImpactDid the event result inbull Officially declared shelter-in-place or officially declared evacuation (on or off site)ORbull Precautionary off site shelter in place or evacuation Use Drop Down Menu | Environmental ImpactDid the event result inAcute Environmental Remediation CostIf so indicate the amount in US DollarsUse Drop Down Menu | Material ReleasedDid the Event result in an Acute Release of material beyond one of the two threshold tablesIf so indicate which Threshold Table you used to make this determinationUse Drop Down Menu | Material ReleasedIf so indicate the amount released USING GHS CLASSIFICATION TABLEUse Drop Down Menu | Material ReleasedIf so indicate the amount released USING THE THRESHOLD TABLE FROM API RP-754Use Drop Down Menu | Material ReleasedIf available please indicate the material released | ||||||||||||||||||||
1 | ABC Chemical Company | American Chemistry Council | Washington DC - USA | January 4 2016 | Yes | 2 | middot Days Away From Work injury to an employee contractor or subcontractor or middot Injury requiring treatment beyond first aid to a third party | 0 | 5525000 | 1500250 | No | $2500 to $25000 | Yes le 3 hours | $2500 to $25000 | Yes - Using GHS TABLE | 40x le TQ lt 160x | NA | Chlorine | |||||||||||||||||||
2 | XYZ Chemical Company | American Chemistry Council | Washington DC - USA | 5-Jan-16 | Yes | 1 | middot Injury requiring treatment beyond first aid to an employee contractor or subcontractor | 0 | 5525000 | 1500250 | Yes | $2500 to $25000 | No | $2500 to $25000 | Yes - Using API RP 754 TABLE | NA | 3x le TQ lt 9x | Benzene | |||||||||||||||||||
3 | |||||||||||||||||||||||||||||||||||||
4 | |||||||||||||||||||||||||||||||||||||
5 | |||||||||||||||||||||||||||||||||||||
6 | |||||||||||||||||||||||||||||||||||||
7 | |||||||||||||||||||||||||||||||||||||
8 | |||||||||||||||||||||||||||||||||||||
9 | |||||||||||||||||||||||||||||||||||||
10 | |||||||||||||||||||||||||||||||||||||
11 | |||||||||||||||||||||||||||||||||||||
12 | |||||||||||||||||||||||||||||||||||||
13 | |||||||||||||||||||||||||||||||||||||
14 | |||||||||||||||||||||||||||||||||||||
15 | |||||||||||||||||||||||||||||||||||||
16 | |||||||||||||||||||||||||||||||||||||
17 | |||||||||||||||||||||||||||||||||||||
18 | |||||||||||||||||||||||||||||||||||||
19 | |||||||||||||||||||||||||||||||||||||
20 | |||||||||||||||||||||||||||||||||||||
21 | |||||||||||||||||||||||||||||||||||||
22 | |||||||||||||||||||||||||||||||||||||
23 | |||||||||||||||||||||||||||||||||||||
24 | |||||||||||||||||||||||||||||||||||||
25 | |||||||||||||||||||||||||||||||||||||
Zero or None | Yes - Duration Unknown | ||||||||||||||||||||||||||||||||||||
Processes | Mode of Operation | Type of material released | Status of Operation | ||||
REFINING | Start-up | Flammable | Open | ||||
Alkylation HF | Planned shutdown | Combustible | Closed | ||||
Alkylation sulfuric | Emergency shutdown | Toxic | |||||
BitumenResidAsphalt | Normal | Corrosive | Tier 1 Acute Releases | ||||
Calcining | Upset | Utilities | No Release | ||||
Coking | Turnaround | Other | Category 1 | ||||
Crude | Routine maintenance | Category 2 | |||||
Desulfurization | Temporary | Evacuation | Category 3 | ||||
FCC | Other | Yes | Category 4 | ||||
Gas Treating | No | Category 5 | |||||
Hydrogen | Point of Release | Category 6 | |||||
Hydrotreating | Pump | Fire | Category 7 | ||||
Hydrocracking | Compressor | Yes | Multiple Categories | ||||
Isom | BlowerFan | No | |||||
MarineJetty | Pressure Vessel | lt $2500 | |||||
Reforming | FilterCoalescer | ||||||
Sulfur recovery | Furnace | PRDs | |||||
Vapor recoverylight ends | Boiler | Directly to Atmosphere | |||||
Wastewater | Heat exchanger | via Downstream Destructive Device | |||||
REFINING amp PETROCHEMICAL | Cooling Tower | No | |||||
Tank FarmStorage FacilityOffsite | Piping system | Yes | |||||
UtilitiesSteam PlantCogeneration | Reactor | No | |||||
Other | Atmospheric tank | ||||||
PETROCHEMICAL | FlareRelief System | Acute release above thresholds | |||||
CO H2 | Other | Yes | |||||
LNG | No | ||||||
Methane | Events | ||||||
Methanol | No Tier 1 Events | Indoor Outdoor | |||||
Methyl Mercaptan | No Tier 2 Events | No Release | |||||
Formaldehyde | No Tier 1 or Tier 2 Events | Indoor | |||||
Formaldehyde derivatives | NA | Outdoor | |||||
Acetic Acid | |||||||
Acetic Acid derivatives | Event Type | ||||||
Ethane | Injury | ||||||
Ethylene | Fire | ||||||
Ethanol | Explosion | ||||||
Ethylene oxide | PRD Discharge | ||||||
Ethylene derivatives | Acute Release | ||||||
Polyethylene | |||||||
Ethylene dichloride | General | ||||||
Ethylene dichloride derivatives | Yes | ||||||
Ethyl benzene | No | ||||||
Ethyl benzene derivatives | |||||||
Polystyrene | |||||||
Styrene-Butadiene | |||||||
Propane | |||||||
Propylene | |||||||
Polypropylene | |||||||
Isopropanol | |||||||
Propylene oxide | |||||||
Propylene oxide derivatives | |||||||
Butane | |||||||
Isobutane | |||||||
Isobutene | |||||||
Butadiene | |||||||
MTBE | |||||||
ETBE | |||||||
Pentane | |||||||
Hexane | |||||||
Cyclohexane | |||||||
Hexanol | |||||||
Aromatics Derivatives | |||||||
Benzene | |||||||
Toluene | |||||||
Xylene | |||||||
Para Xylene | |||||||
Amines Derivatives | |||||||
TDA MDA IPDA etc | |||||||
Isocyanates | |||||||
Specialty Chemicals | |||||||
LoadingUnloading | |||||||
Pilot Plant |
Instructions | ||||||||||||||
Step 1 | Complete the Contact Tab with your contact information and company information | |||||||||||||
Be sure to note the region of your reporting (IE North America France Japan etc) | ||||||||||||||
Survey on Process Safety Events | ||||||||||||||
Step 2 | Complete the survey one line per Process Safety Event for your companyregion | |||||||||||||
ALL REPORTED DATA SHOULD BE FROM CALENDAR YEAR 2017 | ||||||||||||||
Step 3 | Return completed survey to | |||||||||||||
Company Name | ||||||||||||||
Contact Person | All Surveys Due by xxx date | |||||||||||||
Address | ||||||||||||||
Fax | ||||||||||||||
Telephone | ||||||||||||||
Region | ||||||||||||||
None | |
$2500 to $25000 | |
$25000 to $250000 | |
$250000 to $25000000 | |
More than $25000000 | |
Yes - Using GHS TABLE | |
Yes - Using API RP 754 TABLE | |
NO | |
NA | |
1x le TQ lt 40x | |
40x le TQ lt 160x | |
160x le TQ lt 640x | |
ge 640x TQ | |
Yes le 3 hours | |
Yes 3 hours ge 12 hours | |
Yes 12 hours ge 24 hours | |
Yes ge 24 hours | |
No | |
Small-scale | |
Medium-scale | |
Large-scale | |
No | |
Yes | |
No | |
middot Injury requiring treatment beyond first aid to an employee contractor or subcontractor | |
middot Days Away From Work injury to an employee contractor or subcontractor or middot Injury requiring treatment beyond first aid to a third party | |
middot A fatality of an employee contractor or subcontractor or middot A hospital admission of a third party | |
middot Multiple fatalities of employees contractors or subcontractors or middot multiple hospital admission of third parties or middot A fatality of a third party | |
NA | |
1x le TQ lt 3x | |
3x le TQ lt 9x | |
9x le TQ lt 27x | |
ge 27x TQ |
ICCA Process Safety Pilot Reporting ProgramFebruary 8 2016 | 1 | 2 | 3 | 4 | 5 | 6 | 7 | 8 | 9 | 10 | 12 | 13 | 14 | 15 | |||||||||||||||||||||||
SAFETY Details(Meeting Local Regulations) | Direct Cost from Fire or Explosion | Community Impact | Environmental Impact | Material Released(Measured using the 1 Hour Rule) | |||||||||||||||||||||||||||||||||
Company Association Details | |||||||||||||||||||||||||||||||||||||
GHS | API - RP 754 | ||||||||||||||||||||||||||||||||||||
Company or Assocation Name | Headquarter Association | Location of Event Ex - City State amp Country | Date and Time of Event | Safety InjuryDid the Event result in a Recordable Lost Time Accident or Fatality or Hospital admission of anyone on or off siteUse Drop Down Menu | Safety InjuryIf yes please insert the total number of injuries | Safety InjuryFor puropses of utilizing the Severity Table please indicate the level of severity by chosing the MOST SEVERE classification that describes your incidentUse Drop Down Menu | Safety InjuryDid the incident involve Fatalities If so how many total fatalities If none enter Zero | Safety InjuryPlease Report Total Employee Hours for Calendar Year 2015 | Safety InjuryPlease Report Total Contractor Hours for Calendar Year 2015 | Direct Cost Did the Event result in Direct Damage CostUse Drop Down Menu | Direct Cost If so how muchAmount is in US DollarsUse Drop Down Menu | Community ImpactDid the event result inbull Officially declared shelter-in-place or officially declared evacuation (on or off site)ORbull Precautionary off site shelter in place or evacuation Use Drop Down Menu | Environmental ImpactDid the event result inAcute Environmental Remediation CostIf so indicate the amount in US DollarsUse Drop Down Menu | Material ReleasedDid the Event result in an Acute Release of material beyond one of the two threshold tablesIf so indicate which Threshold Table you used to make this determinationUse Drop Down Menu | Material ReleasedIf so indicate the amount released USING GHS CLASSIFICATION TABLEUse Drop Down Menu | Material ReleasedIf so indicate the amount released USING THE THRESHOLD TABLE FROM API RP-754Use Drop Down Menu | Material ReleasedIf available please indicate the material released | ||||||||||||||||||||
1 | ABC Chemical Company | American Chemistry Council | Washington DC - USA | January 4 2016 | Yes | 2 | middot Days Away From Work injury to an employee contractor or subcontractor or middot Injury requiring treatment beyond first aid to a third party | 0 | 5525000 | 1500250 | No | $2500 to $25000 | Yes le 3 hours | $2500 to $25000 | Yes - Using GHS TABLE | 40x le TQ lt 160x | NA | Chlorine | |||||||||||||||||||
2 | XYZ Chemical Company | American Chemistry Council | Washington DC - USA | 5-Jan-16 | Yes | 1 | middot Injury requiring treatment beyond first aid to an employee contractor or subcontractor | 0 | 5525000 | 1500250 | Yes | $2500 to $25000 | No | $2500 to $25000 | Yes - Using API RP 754 TABLE | NA | 3x le TQ lt 9x | Benzene | |||||||||||||||||||
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Zero or None | Yes - Duration Unknown | ||||||||||||||||||||||||||||||||||||
Processes | Mode of Operation | Type of material released | Status of Operation | ||||
REFINING | Start-up | Flammable | Open | ||||
Alkylation HF | Planned shutdown | Combustible | Closed | ||||
Alkylation sulfuric | Emergency shutdown | Toxic | |||||
BitumenResidAsphalt | Normal | Corrosive | Tier 1 Acute Releases | ||||
Calcining | Upset | Utilities | No Release | ||||
Coking | Turnaround | Other | Category 1 | ||||
Crude | Routine maintenance | Category 2 | |||||
Desulfurization | Temporary | Evacuation | Category 3 | ||||
FCC | Other | Yes | Category 4 | ||||
Gas Treating | No | Category 5 | |||||
Hydrogen | Point of Release | Category 6 | |||||
Hydrotreating | Pump | Fire | Category 7 | ||||
Hydrocracking | Compressor | Yes | Multiple Categories | ||||
Isom | BlowerFan | No | |||||
MarineJetty | Pressure Vessel | lt $2500 | |||||
Reforming | FilterCoalescer | ||||||
Sulfur recovery | Furnace | PRDs | |||||
Vapor recoverylight ends | Boiler | Directly to Atmosphere | |||||
Wastewater | Heat exchanger | via Downstream Destructive Device | |||||
REFINING amp PETROCHEMICAL | Cooling Tower | No | |||||
Tank FarmStorage FacilityOffsite | Piping system | Yes | |||||
UtilitiesSteam PlantCogeneration | Reactor | No | |||||
Other | Atmospheric tank | ||||||
PETROCHEMICAL | FlareRelief System | Acute release above thresholds | |||||
CO H2 | Other | Yes | |||||
LNG | No | ||||||
Methane | Events | ||||||
Methanol | No Tier 1 Events | Indoor Outdoor | |||||
Methyl Mercaptan | No Tier 2 Events | No Release | |||||
Formaldehyde | No Tier 1 or Tier 2 Events | Indoor | |||||
Formaldehyde derivatives | NA | Outdoor | |||||
Acetic Acid | |||||||
Acetic Acid derivatives | Event Type | ||||||
Ethane | Injury | ||||||
Ethylene | Fire | ||||||
Ethanol | Explosion | ||||||
Ethylene oxide | PRD Discharge | ||||||
Ethylene derivatives | Acute Release | ||||||
Polyethylene | |||||||
Ethylene dichloride | General | ||||||
Ethylene dichloride derivatives | Yes | ||||||
Ethyl benzene | No | ||||||
Ethyl benzene derivatives | |||||||
Polystyrene | |||||||
Styrene-Butadiene | |||||||
Propane | |||||||
Propylene | |||||||
Polypropylene | |||||||
Isopropanol | |||||||
Propylene oxide | |||||||
Propylene oxide derivatives | |||||||
Butane | |||||||
Isobutane | |||||||
Isobutene | |||||||
Butadiene | |||||||
MTBE | |||||||
ETBE | |||||||
Pentane | |||||||
Hexane | |||||||
Cyclohexane | |||||||
Hexanol | |||||||
Aromatics Derivatives | |||||||
Benzene | |||||||
Toluene | |||||||
Xylene | |||||||
Para Xylene | |||||||
Amines Derivatives | |||||||
TDA MDA IPDA etc | |||||||
Isocyanates | |||||||
Specialty Chemicals | |||||||
LoadingUnloading | |||||||
Pilot Plant |
Instructions | ||||||||||||||
Step 1 | Complete the Contact Tab with your contact information and company information | |||||||||||||
Be sure to note the region of your reporting (IE North America France Japan etc) | ||||||||||||||
Survey on Process Safety Events | ||||||||||||||
Step 2 | Complete the survey one line per Process Safety Event for your companyregion | |||||||||||||
ALL REPORTED DATA SHOULD BE FROM CALENDAR YEAR 2017 | ||||||||||||||
Step 3 | Return completed survey to | |||||||||||||
Company Name | ||||||||||||||
Contact Person | All Surveys Due by xxx date | |||||||||||||
Address | ||||||||||||||
Fax | ||||||||||||||
Telephone | ||||||||||||||
Region | ||||||||||||||
2016 | 2017 | 2018 | 2019 | 2020 | |||||
Feb - April RCLG PS Pilot Program May ndash Adjustmentsclarification to guidance document June Report outcomes of pilot program to RCLG and ICCA Board July - December middot RCLG associations consider guidance and develop reporting methodology for their memberships middot RCLG associations can request ICCA capacity building funds for PS reporting workshops for members if needed | Jan - Dec RCLG Association membership begin collecting PS data from their members Jan ndash Dec Associations hold workshops on Process Safety and performance reporting utilizing RCLG funds and experts if needed | Jan ndash Feb Reporting of process safety incidents to RCLG begins for associations with data (2017 data) April RCLG reviews outcomes challenges and raw data from the first reporting cycle (internally) June RCLG share draft data with ICCA Board July - December Update and adjust guidance as necessary Associations hold workshops on Process Safety and performance reporting utilizing RCLG funds and experts if needed | Jan ndash Feb Reporting of process safety incidents to RCLG begins for associations with data (2018 data) April RCLG reviews outcomes challenges and raw data from the second reporting cycle (internally) June RCLG share draft data with ICCA Board July - December Update and adjust guidance as necessary Associations hold workshops on Process Safety and performance reporting utilizing RCLG funds and experts if needed | Jan ndash Feb Reporting of process safety incidents to RCLG begins for all associations Process Safety incident reporting becomes part of the recommend base set of RCLG KPI metrics (2019 data) April RCLG reviews outcomes challenges and raw data from the second reporting cycle (internally consider external reporting) June RCLG share draft data with ICCA Board |
Name | Affiliation | ||
Peter Schmelzer | Bayer CEFIC - Chairman | ||
Americo Diniz Carvalho Neto | Braskem | ||
Bradford Johnson | American Chemistry Council | ||
David Cummings | DuPont | ||
Debra Phillips | American Chemistry Council | ||
Hans Schwarz | BASF | ||
Kathryn Walton | Plastics and Chemicals Industries Association | ||
Kazuyuki Akita | Japanese Chemical Industry Association | ||
Kelly Keim | ExxonMobil Chemical Company API Representative | ||
Kenan Stevick | Dow | ||
Kiyokazu Murata | Japanese Chemical Industry Association | ||
Larry Bowler | SABIC | ||
Lorna Young | Chemical Industry Association of Canada | ||
Louisa Nara | Center for Chemical Process Safety | ||
Associaccedilatildeo Brasileira da Induacutestria Quiacutemica | |||
Masatoshi Kumamoto | Japanese Chemical Industry Association | ||
Milton Lacerda | Petrobras | ||
Phil Scott | Chemical Industries Association | ||
Piet Knijff | DSM European Process Safety Centre | ||
Scott Donaldson and Eamon Chandler | Shell | ||
Scott Wallace | Olin Corporation | ||
Shakeel Kadri | Air Products and Chemicals Inc |
Event Incident Categories | |||||||||||
Severity Level | SafetyHuman Health | Direct Cost from Fire or Explosion | Material ReleaseWithin 1-Hr Period | Community Impact | Environmental Impact [off-site] | ||||||
Level 4 1 point | middot Injury requiring treatment beyond first aid to an employee contractor or subcontractor (Meets local regulations) | middot Resulting in Direct Damage Cost of $25 K le up to $25 K | middot Release volume between 1x le TQ lt 40x | middot Officially declared shelter-in-place or officially declared evacuation (on or off site) middot Precautionary off site shelter in place or evacuation le 3 hours | middot Acute Environmental Remediation Cost $25 K le up to $25 K | ||||||
Level 3 3 points | middot Days Away From Work injury to an employee contractor or subcontractor or middot Injury requiring treatment beyond first aid to a third party (Meets local regulations) | middot Resulting in Direct Damage Cost of $25 K le up to $250 K | middot Release volume between 40x le TQ lt 160x | middot Officially declared shelter-in-place or officially declared evacuation (on or off site) middot Precautionary off site shelter in place or evacuation 3 hours ge up to 12 hours | middot Acute Environmental Remediation Cost $25 K le up to $250 K | ||||||
Level 2 9 points | middot A fatality of an employee contractor or subcontractor or middot A hospital admission of a third party (Meets local regulations) | middot Resulting in Direct Damage Cost of $250 K le up to $25 MM | middot Release volume between 160x le TQ lt 640x | middot Officially declared shelter-in-place or officially declared evacuation (on or off site) middot Precautionary off site shelter in place or evacuation 12 hours ge up to 24 hours | middot Acute Environmental Remediation Cost $250 K le up to $25 MM | ||||||
Level 1 27 points | middot Multiple fatalities of employees contractors or subcontractors or middot multiple hospital admission of third parties or middot A fatality of a third party (Meets local regulations) | middot Resulting in Direct Damage Costs of ge $25 MM | middot Release volume ge 640x TQ | middot Officially declared shelter-in-place or officially declared evacuation (on or off site) middot Precautionary off site shelter in place or evacuation ge 24 hours | middot Acute Environmental Remediation Cost ge $25 MM |
It is recognized that threshold quantities given in kg and lb or in lb and bbl are not exactly equivalent Companies should select one of the pair and use it consistently for all recordkeeping activities | |
In determining the Threshold Release Category for a material one should first use the toxic (TIH Zone) or flammability (Flash Point and Boiling Point) or corrosiveness (Strong Acid or Base vs Moderate Acid or Base) characteristics Only when the hazard of the material is not expressed by those simple characteristics (eg reacts violently with water) is the UNDGL Packing Group used a Many materials exhibit more than one hazard Correct placement in Hazard Zone or Packing Group shall follow the rules of DOT 49 CFR 1732a [14] or UN Recommendations on the Transportation of Dangerous Goods Section 2 [12] See Annex F b A structure composed of four complete (floor to ceiling) walls floor and roof c For solutions not listed on the UNDG the anhydrous component shall determine the TIH zone or Packing Group classification The threshold quantity of the solution shall be back calculated based on the threshold quantity of the dry component weight d For mixtures where the UNDG classification is unknown the fraction of threshold quantity release for each component may be calculated If the sum of the fractions is equal to or greater than 100 the mixture exceeds the threshold quantity Where there are clear and independent toxic and flammable consequences associated with the mixture the toxic and flammable hazards are calculated independently See Annex E PSE Examples amp Questions 49 - 53 e A LOPC of Liquids with Flash Point gt 60 degC (140 degF) and 93 degC (200 degF) released at a temperature below Flash Point cannot be Tier 1 PSE based upon quantity released no matter the volume f A LOPC of a moderate acidbase cannot be Tier 1 PSE based upon quantity released no matter the volume |
Threshold Release Category | Material Hazard Classification acdef | Threshold Quantity (outdoor release) | Threshold Quantity (indoorb release) | ||||
T2-1 | TIH Zone A Materials | ge 05 kg (11 lb) | ge 025 kg (055 lb) | ||||
T2-2 | TIH Zone B Materials | ge 25 kg (55 lb) | ge 125 kg (275 lb) | ||||
T2-3 | TIH Zone C Materials | ge 10 kg (22 lb) | ge 5 kg (11 lb) | ||||
T2-4 | TIH Zone D Materials | ge 20 kg (44 lb) | ge 10 kg (22 lb) | ||||
T2-5 | Flammable Gases OR Liquids with Normal Boiling Point 35 degC (95 degF) and Flash Point 23 degC (73 degF) OR Other Packing Group I Materials (excluding acidsbases) | ge 50 kg (110 lb) | ge 25 kg (55 lb) | ||||
T2-6 | Liquids with Normal Boiling Point 35 degC (95 degF) and Flash Point 23 degC (73degF) OR Other Packing Group II Materials (excluding acidsbases) | ge 100 kg (220 lb)orge 07 bbl | ge 50 kg (110 lb)orge 035 bbl | ||||
T2-7 | Liquids with Flash Point 23 degC (73 degF) and 60 degC (140 degF) OR Liquids with Flash Point 60 degC (140 degF) released at a temperature at or above Flash Point OR strong acidsbases (see definition Refer to draft RP 754 document) OR UNDG Class 2 Division 22 (non-flammable non-toxic gases) excluding air OR Other Packing Group III Materials | ge 200 kg (440 lb)orge 14 bbl | ge 100 kg (220 lb)orge 07 bbl | ||||
T2-8 | Liquids with Flash Point 60 degC (140 degF) and 93 degC (200 degF) released at a temperature below Flash Point OR Moderate acidsbases | ge 1000 kg (2200 lb)orge 7 bbl | ge 500 kg (1100 lb)orge 35 bbl |
None | |
$2500 to $25000 | |
$25000 to $250000 | |
$250000 to $25000000 | |
More than $25000000 | |
Yes - Using GHS TABLE | |
Yes - Using API RP 754 TABLE | |
NO | |
NA | |
1x le TQ lt 40x | |
40x le TQ lt 160x | |
160x le TQ lt 640x | |
ge 640x TQ | |
Yes le 3 hours | |
Yes 3 hours ge 12 hours | |
Yes 12 hours ge 24 hours | |
Yes ge 24 hours | |
No | |
Small-scale | |
Medium-scale | |
Large-scale | |
No | |
Yes | |
No | |
middot Injury requiring treatment beyond first aid to an employee contractor or subcontractor | |
middot Days Away From Work injury to an employee contractor or subcontractor or middot Injury requiring treatment beyond first aid to a third party | |
middot A fatality of an employee contractor or subcontractor or middot A hospital admission of a third party | |
middot Multiple fatalities of employees contractors or subcontractors or middot multiple hospital admission of third parties or middot A fatality of a third party | |
NA | |
1x le TQ lt 3x | |
3x le TQ lt 9x | |
9x le TQ lt 27x | |
ge 27x TQ |
ICCA Process Safety Pilot Reporting ProgramFebruary 8 2016 | 1 | 2 | 3 | 4 | 5 | 6 | 7 | 8 | 9 | 10 | 12 | 13 | 14 | 15 | |||||||||||||||||||||||
SAFETY Details(Meeting Local Regulations) | Direct Cost from Fire or Explosion | Community Impact | Environmental Impact | Material Released(Measured using the 1 Hour Rule) | |||||||||||||||||||||||||||||||||
Company Association Details | |||||||||||||||||||||||||||||||||||||
GHS | API - RP 754 | ||||||||||||||||||||||||||||||||||||
Company or Assocation Name | Headquarter Association | Location of Event Ex - City State amp Country | Date and Time of Event | Safety InjuryDid the Event result in a Recordable Lost Time Accident or Fatality or Hospital admission of anyone on or off siteUse Drop Down Menu | Safety InjuryIf yes please insert the total number of injuries | Safety InjuryFor puropses of utilizing the Severity Table please indicate the level of severity by chosing the MOST SEVERE classification that describes your incidentUse Drop Down Menu | Safety InjuryDid the incident involve Fatalities If so how many total fatalities If none enter Zero | Safety InjuryPlease Report Total Employee Hours for Calendar Year 2015 | Safety InjuryPlease Report Total Contractor Hours for Calendar Year 2015 | Direct Cost Did the Event result in Direct Damage CostUse Drop Down Menu | Direct Cost If so how muchAmount is in US DollarsUse Drop Down Menu | Community ImpactDid the event result inbull Officially declared shelter-in-place or officially declared evacuation (on or off site)ORbull Precautionary off site shelter in place or evacuation Use Drop Down Menu | Environmental ImpactDid the event result inAcute Environmental Remediation CostIf so indicate the amount in US DollarsUse Drop Down Menu | Material ReleasedDid the Event result in an Acute Release of material beyond one of the two threshold tablesIf so indicate which Threshold Table you used to make this determinationUse Drop Down Menu | Material ReleasedIf so indicate the amount released USING GHS CLASSIFICATION TABLEUse Drop Down Menu | Material ReleasedIf so indicate the amount released USING THE THRESHOLD TABLE FROM API RP-754Use Drop Down Menu | Material ReleasedIf available please indicate the material released | ||||||||||||||||||||
1 | ABC Chemical Company | American Chemistry Council | Washington DC - USA | January 4 2016 | Yes | 2 | middot Days Away From Work injury to an employee contractor or subcontractor or middot Injury requiring treatment beyond first aid to a third party | 0 | 5525000 | 1500250 | No | $2500 to $25000 | Yes le 3 hours | $2500 to $25000 | Yes - Using GHS TABLE | 40x le TQ lt 160x | NA | Chlorine | |||||||||||||||||||
2 | XYZ Chemical Company | American Chemistry Council | Washington DC - USA | 5-Jan-16 | Yes | 1 | middot Injury requiring treatment beyond first aid to an employee contractor or subcontractor | 0 | 5525000 | 1500250 | Yes | $2500 to $25000 | No | $2500 to $25000 | Yes - Using API RP 754 TABLE | NA | 3x le TQ lt 9x | Benzene | |||||||||||||||||||
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Zero or None | Yes - Duration Unknown | ||||||||||||||||||||||||||||||||||||
Processes | Mode of Operation | Type of material released | Status of Operation | ||||
REFINING | Start-up | Flammable | Open | ||||
Alkylation HF | Planned shutdown | Combustible | Closed | ||||
Alkylation sulfuric | Emergency shutdown | Toxic | |||||
BitumenResidAsphalt | Normal | Corrosive | Tier 1 Acute Releases | ||||
Calcining | Upset | Utilities | No Release | ||||
Coking | Turnaround | Other | Category 1 | ||||
Crude | Routine maintenance | Category 2 | |||||
Desulfurization | Temporary | Evacuation | Category 3 | ||||
FCC | Other | Yes | Category 4 | ||||
Gas Treating | No | Category 5 | |||||
Hydrogen | Point of Release | Category 6 | |||||
Hydrotreating | Pump | Fire | Category 7 | ||||
Hydrocracking | Compressor | Yes | Multiple Categories | ||||
Isom | BlowerFan | No | |||||
MarineJetty | Pressure Vessel | lt $2500 | |||||
Reforming | FilterCoalescer | ||||||
Sulfur recovery | Furnace | PRDs | |||||
Vapor recoverylight ends | Boiler | Directly to Atmosphere | |||||
Wastewater | Heat exchanger | via Downstream Destructive Device | |||||
REFINING amp PETROCHEMICAL | Cooling Tower | No | |||||
Tank FarmStorage FacilityOffsite | Piping system | Yes | |||||
UtilitiesSteam PlantCogeneration | Reactor | No | |||||
Other | Atmospheric tank | ||||||
PETROCHEMICAL | FlareRelief System | Acute release above thresholds | |||||
CO H2 | Other | Yes | |||||
LNG | No | ||||||
Methane | Events | ||||||
Methanol | No Tier 1 Events | Indoor Outdoor | |||||
Methyl Mercaptan | No Tier 2 Events | No Release | |||||
Formaldehyde | No Tier 1 or Tier 2 Events | Indoor | |||||
Formaldehyde derivatives | NA | Outdoor | |||||
Acetic Acid | |||||||
Acetic Acid derivatives | Event Type | ||||||
Ethane | Injury | ||||||
Ethylene | Fire | ||||||
Ethanol | Explosion | ||||||
Ethylene oxide | PRD Discharge | ||||||
Ethylene derivatives | Acute Release | ||||||
Polyethylene | |||||||
Ethylene dichloride | General | ||||||
Ethylene dichloride derivatives | Yes | ||||||
Ethyl benzene | No | ||||||
Ethyl benzene derivatives | |||||||
Polystyrene | |||||||
Styrene-Butadiene | |||||||
Propane | |||||||
Propylene | |||||||
Polypropylene | |||||||
Isopropanol | |||||||
Propylene oxide | |||||||
Propylene oxide derivatives | |||||||
Butane | |||||||
Isobutane | |||||||
Isobutene | |||||||
Butadiene | |||||||
MTBE | |||||||
ETBE | |||||||
Pentane | |||||||
Hexane | |||||||
Cyclohexane | |||||||
Hexanol | |||||||
Aromatics Derivatives | |||||||
Benzene | |||||||
Toluene | |||||||
Xylene | |||||||
Para Xylene | |||||||
Amines Derivatives | |||||||
TDA MDA IPDA etc | |||||||
Isocyanates | |||||||
Specialty Chemicals | |||||||
LoadingUnloading | |||||||
Pilot Plant |
Instructions | ||||||||||||||
Step 1 | Complete the Contact Tab with your contact information and company information | |||||||||||||
Be sure to note the region of your reporting (IE North America France Japan etc) | ||||||||||||||
Survey on Process Safety Events | ||||||||||||||
Step 2 | Complete the survey one line per Process Safety Event for your companyregion | |||||||||||||
ALL REPORTED DATA SHOULD BE FROM CALENDAR YEAR 2017 | ||||||||||||||
Step 3 | Return completed survey to | |||||||||||||
Company Name | ||||||||||||||
Contact Person | All Surveys Due by xxx date | |||||||||||||
Address | ||||||||||||||
Fax | ||||||||||||||
Telephone | ||||||||||||||
Region | ||||||||||||||
2016 | 2017 | 2018 | 2019 | 2020 | |||||
Feb - April RCLG PS Pilot Program May ndash Adjustmentsclarification to guidance document June Report outcomes of pilot program to RCLG and ICCA Board July - December middot RCLG associations consider guidance and develop reporting methodology for their memberships middot RCLG associations can request ICCA capacity building funds for PS reporting workshops for members if needed | Jan - Dec RCLG Association membership begin collecting PS data from their members Jan ndash Dec Associations hold workshops on Process Safety and performance reporting utilizing RCLG funds and experts if needed | Jan ndash Feb Reporting of process safety incidents to RCLG begins for associations with data (2017 data) April RCLG reviews outcomes challenges and raw data from the first reporting cycle (internally) June RCLG share draft data with ICCA Board July - December Update and adjust guidance as necessary Associations hold workshops on Process Safety and performance reporting utilizing RCLG funds and experts if needed | Jan ndash Feb Reporting of process safety incidents to RCLG begins for associations with data (2018 data) April RCLG reviews outcomes challenges and raw data from the second reporting cycle (internally) June RCLG share draft data with ICCA Board July - December Update and adjust guidance as necessary Associations hold workshops on Process Safety and performance reporting utilizing RCLG funds and experts if needed | Jan ndash Feb Reporting of process safety incidents to RCLG begins for all associations Process Safety incident reporting becomes part of the recommend base set of RCLG KPI metrics (2019 data) April RCLG reviews outcomes challenges and raw data from the second reporting cycle (internally consider external reporting) June RCLG share draft data with ICCA Board |
Name | Affiliation | ||
Peter Schmelzer | Bayer CEFIC - Chairman | ||
Americo Diniz Carvalho Neto | Braskem | ||
Bradford Johnson | American Chemistry Council | ||
David Cummings | DuPont | ||
Debra Phillips | American Chemistry Council | ||
Hans Schwarz | BASF | ||
Kathryn Walton | Plastics and Chemicals Industries Association | ||
Kazuyuki Akita | Japanese Chemical Industry Association | ||
Kelly Keim | ExxonMobil Chemical Company API Representative | ||
Kenan Stevick | Dow | ||
Kiyokazu Murata | Japanese Chemical Industry Association | ||
Larry Bowler | SABIC | ||
Lorna Young | Chemical Industry Association of Canada | ||
Louisa Nara | Center for Chemical Process Safety | ||
Associaccedilatildeo Brasileira da Induacutestria Quiacutemica | |||
Masatoshi Kumamoto | Japanese Chemical Industry Association | ||
Milton Lacerda | Petrobras | ||
Phil Scott | Chemical Industries Association | ||
Piet Knijff | DSM European Process Safety Centre | ||
Scott Donaldson and Eamon Chandler | Shell | ||
Scott Wallace | Olin Corporation | ||
Shakeel Kadri | Air Products and Chemicals Inc |
Event Incident Categories | |||||||||||
Severity Level | SafetyHuman Health | Direct Cost from Fire or Explosion | Material ReleaseWithin 1-Hr Period | Community Impact | Environmental Impact [off-site] | ||||||
Level 4 1 point | middot Injury requiring treatment beyond first aid to an employee contractor or subcontractor (Meets local regulations) | middot Resulting in Direct Damage Cost of $25 K le up to $25 K | middot Release volume between 1x le TQ lt 40x | middot Officially declared shelter-in-place or officially declared evacuation (on or off site) middot Precautionary off site shelter in place or evacuation le 3 hours | middot Acute Environmental Remediation Cost $25 K le up to $25 K | ||||||
Level 3 3 points | middot Days Away From Work injury to an employee contractor or subcontractor or middot Injury requiring treatment beyond first aid to a third party (Meets local regulations) | middot Resulting in Direct Damage Cost of $25 K le up to $250 K | middot Release volume between 40x le TQ lt 160x | middot Officially declared shelter-in-place or officially declared evacuation (on or off site) middot Precautionary off site shelter in place or evacuation 3 hours ge up to 12 hours | middot Acute Environmental Remediation Cost $25 K le up to $250 K | ||||||
Level 2 9 points | middot A fatality of an employee contractor or subcontractor or middot A hospital admission of a third party (Meets local regulations) | middot Resulting in Direct Damage Cost of $250 K le up to $25 MM | middot Release volume between 160x le TQ lt 640x | middot Officially declared shelter-in-place or officially declared evacuation (on or off site) middot Precautionary off site shelter in place or evacuation 12 hours ge up to 24 hours | middot Acute Environmental Remediation Cost $250 K le up to $25 MM | ||||||
Level 1 27 points | middot Multiple fatalities of employees contractors or subcontractors or middot multiple hospital admission of third parties or middot A fatality of a third party (Meets local regulations) | middot Resulting in Direct Damage Costs of ge $25 MM | middot Release volume ge 640x TQ | middot Officially declared shelter-in-place or officially declared evacuation (on or off site) middot Precautionary off site shelter in place or evacuation ge 24 hours | middot Acute Environmental Remediation Cost ge $25 MM |
It is recognized that threshold quantities given in kg and lb or in lb and bbl are not exactly equivalent Companies should select one of the pair and use it consistently for all recordkeeping activities | |
In determining the Threshold Release Category for a material one should first use the toxic (TIH Zone) or flammability (Flash Point and Boiling Point) or corrosiveness (Strong Acid or Base vs Moderate Acid or Base) characteristics Only when the hazard of the material is not expressed by those simple characteristics (eg reacts violently with water) is the UNDGL Packing Group used a Many materials exhibit more than one hazard Correct placement in Hazard Zone or Packing Group shall follow the rules of DOT 49 CFR 1732a [14] or UN Recommendations on the Transportation of Dangerous Goods Section 2 [12] See Annex F b A structure composed of four complete (floor to ceiling) walls floor and roof c For solutions not listed on the UNDG the anhydrous component shall determine the TIH zone or Packing Group classification The threshold quantity of the solution shall be back calculated based on the threshold quantity of the dry component weight d For mixtures where the UNDG classification is unknown the fraction of threshold quantity release for each component may be calculated If the sum of the fractions is equal to or greater than 100 the mixture exceeds the threshold quantity Where there are clear and independent toxic and flammable consequences associated with the mixture the toxic and flammable hazards are calculated independently See Annex E PSE Examples amp Questions 49 - 53 e A LOPC of Liquids with Flash Point gt 60 degC (140 degF) and 93 degC (200 degF) released at a temperature below Flash Point cannot be Tier 1 PSE based upon quantity released no matter the volume f A LOPC of a moderate acidbase cannot be Tier 1 PSE based upon quantity released no matter the volume |
Threshold Release Category | Material Hazard Classification acdef | Threshold Quantity (outdoor release) | Threshold Quantity (indoorb release) | ||||
T2-1 | TIH Zone A Materials | ge 05 kg (11 lb) | ge 025 kg (055 lb) | ||||
T2-2 | TIH Zone B Materials | ge 25 kg (55 lb) | ge 125 kg (275 lb) | ||||
T2-3 | TIH Zone C Materials | ge 10 kg (22 lb) | ge 5 kg (11 lb) | ||||
T2-4 | TIH Zone D Materials | ge 20 kg (44 lb) | ge 10 kg (22 lb) | ||||
T2-5 | Flammable Gases OR Liquids with Normal Boiling Point 35 degC (95 degF) and Flash Point 23 degC (73 degF) OR Other Packing Group I Materials (excluding acidsbases) | ge 50 kg (110 lb) | ge 25 kg (55 lb) | ||||
T2-6 | Liquids with Normal Boiling Point 35 degC (95 degF) and Flash Point 23 degC (73degF) OR Other Packing Group II Materials (excluding acidsbases) | ge 100 kg (220 lb)orge 07 bbl | ge 50 kg (110 lb)orge 035 bbl | ||||
T2-7 | Liquids with Flash Point 23 degC (73 degF) and 60 degC (140 degF) OR Liquids with Flash Point 60 degC (140 degF) released at a temperature at or above Flash Point OR strong acidsbases (see definition Refer to draft RP 754 document) OR UNDG Class 2 Division 22 (non-flammable non-toxic gases) excluding air OR Other Packing Group III Materials | ge 200 kg (440 lb)orge 14 bbl | ge 100 kg (220 lb)orge 07 bbl | ||||
T2-8 | Liquids with Flash Point 60 degC (140 degF) and 93 degC (200 degF) released at a temperature below Flash Point OR Moderate acidsbases | ge 1000 kg (2200 lb)orge 7 bbl | ge 500 kg (1100 lb)orge 35 bbl |
3
敬愛的 TRCA 會員
對於 ICCA (International Council of Chemical Associations 國際化學工業協會) 和責任照顧領
導群在制定這一項寶貴指引時的付出我們表達最深的感謝 我們很高興能夠為 TRCA帶來
這一項可作為保護傘的寶貴指引
製程安全是責任照顧制度的核心也是化學工業數十年來成熟的實踐我們不斷努力改善
管理程序以減少化學事故的發生量測對於製程安全管理是絕對至關重要的一環因為我
們無從改進沒有進行過量測的項目提報(製程安全指標)使得公司與協會得以分享最佳典
範在提高績效表現的同時減少環境足跡從事件中學習是改善製程安全達到低事件率的
關鍵我們的目標是再進一步降低製程安全事件率
儘管化工業長期以來一直在各地區追蹤與提報製程安全績效但此次製程安全事件提報的
建議將首度啟用更廣泛的基礎在全球提報製程安全績效提報部門將包括化學工業與石
化工業
我們邀請 TRCA 的所有會員在 2020 年前一同來推行這項提報指引我們也將致力於協助各
位達標國家化學工業協會在推廣最佳實務方面扮演重要角色我們期待他們向所屬會員
公司推動本指引
我們誠摯地希望這些指導方針將有助於台灣提升製程和工廠的安全
謹提供全球適用的指引原始檔案如下請參考
Patrick Vandenhoeke
責任照顧領導群主席
GUIDANCE FOR REPORTING ON THE ICCA GLOBALLY HARMONIZED PROCESS SAFETY METRICJune2016The Responsible Carereg Leadership Group
ContentsBackground2Executive Summary2Data to be reported by RCLG Associations to RCLG4Overview of ICCA Process Safety Event Criteria as a Flow Chart5Key Criteria for Reporting Process Safety Events to RCLG6Detailed Guidelines on Identifying a Process Safety Event7Table 1 ndash GHS Classification Table11Table 2 ndash API RP 754 Tier II Classification Table12Appendix A ndash Severity Table Using A Severity Weighting System is Encouraged for All Associations14Appendix B ndash Frequently Asked Questions16Appendix C ndash List of RCLG Taskforce Members22Appendix D ndash Detailed Schedule of Events23Appendix E ndash Optional Excel Reporting Form24
FIANL DRAFT
June 15 2016
The Responsible Carereg initiative began in 1985 and as the chemical industryrsquos commitment to continuous performance improvements Process Safety has been a pillar of Responsible Care since its inception and many regional approaches to tracking and reporting process safety performance have developed over the 30 years of Responsible Care implementation yet no globally harmonized system had been put into place In 2012 in the wake of several high profile process safety events the International Council of Chemical Associations (ICCA) Board of Directors directed the Responsible Care Leadership Group (RCLG) to develop a recommendation for a globally harmonized process safety performance reporting by no later than 2015
Throughout 2013 and 2014 a Taskforce comprised of multinational companies and RCLG associations chaired by Dr Peter Schmelzer Head of Health Safety and Environmental Protection Bayer HealthCare AG worked to develop a globally harmonized ICCA approach to process safety performance reporting A list of Taskforce members can be found in Appendix C During the same timeframe the American Petroleum Institute (API) also initiated a process to update its Recommend Practice 754 (RP-754) ndash Leading and Lagging Process Safety Metric Standard RP-754 is broadly used in the refining and petrochemical sector and in the Americas region to track process safety performance To optimize global adoption of a unified standard the RCLG Taskforce strived to achieve full harmonization of its recommendation with the revised API RP 754 metric expected to be finalized in the first quarter 2016
Executive SummaryAfter more than 2 years of discussion research debate and feasibility assessment the Process Safety Harmonization Taskforce recommends that ICCA adopt a process safety event rate metric The adoption of this metric would require each RCLG association to collect the number of process safety events experienced by their members on an annual basis as well as total number of worker hours (employees and contractors) experienced by their members each year The process safety event rate is the ratio of events to hours The Taskforce also recommends that reporting of these data points to the RCLG be phased in over the next 3 years allowing regions with the desire and ability to report immediately to do so while also allowing additional time to companies and organizations that are developing the ability to track these data for the first time
The criteria that determine whether a process-related event qualifies as a process safety event are based on a loss of primary containment of a chemical or a release of energy triggering thresholds any one of four impact areas 1) safetyhuman health consequences 2) direct cost due to damage from incident 3) community impact and 4) chemical release quantity (see the flow chart showing reporting triggers) These four impact areas in the recommended ICCA process safety event definition are identical to the impact areas in the RP-754 Tier II incident standard The thresholds for reporting are also identical in all areas with the exception of the chemical release quantity thresholds To address this difference the ICCA process safety event definition will allow companies the use of either the GHS-based reporting thresholds developed by ICCA for the chemical release criteria or the UN Dangerous Goods (UNDG)-based reporting thresholds used in the RP-754 standard for Tier II incidents The Taskforce believes that the two systems though different are comparably robust in the universe of chemicals covered and the severity of incidents captured by reporting While there will be relatively little difference in the numbers of events captured and reported using the two different threshold approaches there may be differences that would be most clearly seen at the company level based on raw material and product use hence the Taskforce cautions companies not to compare their results with companies that use a different chemical release threshold approach Regardless under the RCLG proposal companies can choose the chemical release thresholds by which they report in to their national and regional associations If associations are interested in translating results based on one reporting approach to another the RCLG will provide a translation table However given the complexity of this exercise and the need to access raw incident data the Taskforce does not believe that this adds value and recommends against it
The Taskforce believes that this proposal for process safety event reporting will enable broad-based global reporting of process safety performance across the chemical and petrochemical industries It will provide a roadmap for regions associations and companies that are currently not tracking process safety performance to recognize the benefits that tracking and reporting will bring For regions associations and companies that are already experienced in gathering process safety data this recommendation allows for broader global alignment and focus on continuous improvement in process safety performance The systems that are built to improve process safety performance are informed by robust process safety event data and this is the major objective of this initiative
Data to be reported by RCLG Associations to RCLGOn an annual basis RCLG Associations will be asked to report two data points into ICCA using the RCLG KPI Reporting Website on the schedule provided below
1Total Member Company Worker Hours for Association (employee and contractor)
2Total Number of Process Safety Events
ICCA will use the above two data points to report process safety performance in the form of Process Safety Event Rate (PSER) normalized per 100 employees where an employee works 2000 hours a year
(Total Events Total Hours) x 200000 = PSER
Recommended Reporting Schedule
The Taskforce recommends a phased-in approach for reporting process safety event rate Such a schedule will allow more experienced companies and associations to report in the next several years while allowing other companies and associations to begin reporting by 2019 RCLG Associations would be asked to report the two process safety event rate data points annually to the ICCA through the RCLG KPI metrics reporting system If you do not know your associationrsquos username and password please contact the RCLG
The proposed schedule for process safety event rate reporting by RCLG associations is as follows
April 2015RCLG considers Taskforce proposal
June 2015ICCA Board of Directors considers RCLG final recommendation
July 2015RCLG releases the first detailed reporting guidance document for associations and member companies
Feb 2016 RCLG Reporting RCLG initiates process safety reporting pilot program through association volunteers with updated an enhanced guidance document RCLG rolls out final guidance document in June 2016
2017RCLG Associations begin collecting data from its membership
2018-2019 RCLG Reporting Optional process safety data reporting by RCLG Associations
2020 ReportingRCLG includes process safety as a mandatory metric in the KPI reporting program
See Appendix D ndash Detailed Schedule of Events
Overview of ICCA Process Safety Event Criteria as a Flow ChartNO Does not meet the criteria for a Process Safety Event
Start
NO
NO
NO
Was a chemical substance or a chemical process directly involved
YES
YES
Release of material fire explosion or implosion fromat a chemical process unit
Incident in production distribution storage utilities pilot plants within a companyrsquos facility
YES
NO
Officially declared shelter in place or evacuation
Or Precautionary off site shelter in place or evacuation
Substance Release Thresholds met
Recordable injury
Or
hospital admission of people on or off site
Damage ge $2500direct costto company
NO
NO
NO
ICCA or API 754 Tier II chemical release thresholds exceeded
YES
YES
YES
Yes Reportable as a Process Safety Event
YES
Key Criteria for Reporting Process Safety Events to RCLGTotal Worker Hours
RCLG Associations should report the total number of employee hours worked for each member company in their association and the total number of contractor hours worked for each member company as a combined single number For the purposes of this guidance document each association should refer to their local and regional definitions for employee and contractor The goal for reporting total hours is to include all individuals who are involved with chemical manufacturing except where those individuals are tasked with major construction projects such as large scale investments with specific one-time project organizations created for design engineering and construction of new or significant expansion to existing process facilities When reporting total worker hours companies should report the same hours used for reporting personnel hours This way companies can have the same data set for occupational and process safety Personnel hours should include those hours from all chemical manufacturing operations not just from facilities where a process safety incident occurred
Process Safety Event
For the purposes of this ICCA Reporting a process safety event has occurred when
A When a chemical substance or a chemical process is directly involved AND
B The incident occurred in production distribution storage utility pilot plant within the site boundaries of companyrsquos facility AND
C There was a release of material or energy (eg fire explosion implosion) from a process unit AND
D One or more of the following Reporting Thresholds have been met
1 Safety Injury
middot Injury resulting in a Recordable Lost Time Accident or Fatality or Hospital admission of anyone on or off site OR
2 Direct Damage Cost
middot A fire explosion or clean up necessary to avoidremediate environmental damage resulting in a direct cost equal to or greater than $2500 USDs OR
3 Shelter in Place Evacuation
middot An officially declared shelter in place (on or off site) OR
middot An officially declared evacuation (on or off site) OR
middot A precautionary off site shelter in place or evacuation OR
4 Threshold Release
middot The material released meets one of the GHS thresholds in Table 1 (measured in amount released during one hour)
As an alternative companies can choose to use the release thresholds contained in the API RP-754 standard ndash Table 2 Note ndash Individuals who would like to view the API RP-754 Standard may purchase and download that standard at - Detailed Guidelines on Identifying a Process Safety Event A Chemical InvolvementWhen a chemical substance or chemical process is directly involved
A chemical or chemical process must have been directly involved in the event or incident For this purpose the term process is used broadly to include the equipment and technology needed for petrochemical production including reactors tanks piping boilers cooling towers refrigeration systems etc An incident with no direct chemical or process involvement eg an office building fire even if the office building is on a plant site is not reportable
B LocationThe incident occurred in production distribution storage utility pilot plant within the site boundaries of companyrsquos facility
The incident occurs in production distribution storage (including active storage areas such as warehouses ndash see FAQ section) utilities or pilot plants of a facility reporting metrics under these definitions This includes tank farms ancillary support areas (eg boiler houses and waste water treatment plants) and distribution piping under control of the site All reportable incidents occurring at a location will be reported by the company that is responsible for operating that location This applies to incidents that may occur in contractor work areas as well as other incidents At tolling operations and multi-party sites the company that operates the unit where the incident initiated should record the incident and count it in their reporting
C Release of MaterialThere was a release of material or energy (eg fire explosion implosion) from a process unit
Release of Material ndash an unplanned or uncontrolled release of any material including non-toxic and non-flammable materials (eg steam hot water nitrogen compressed CO2 or compressed air) from a process that results in consequences that exceed one or more of the 4 Reporting Thresholds listed in this document
A release to a flare or scrubber is still considered to be within the primary containment as long as the mitigation system (eg scrubber flare) is operated under normal conditions without any release above the thresholds defined for normal operation A release to a secondary containment (eg waste water treatment or dike) will qualify as a process safety event because the substance is leaving the primary process system
D ThresholdsOne or more of the following Reporting Thresholds must be met for reportable process safety events
1 Safety Injury
Injury resulting in a Recordable Lost Time Accident or Fatality or Hospital admission of anyone on or off site Recordable injuries are work-related injuries that results in any of the following death days away from work restricted work or transfer to another job medical treatment beyond first aid loss of consciousness or a significant injury diagnosed by a physician or other licensed health professional
Lost time injuries and fatalities that occur as a result of process related loss of primary containment fire or explosion are those that fit into one of the following categories
middot Employee (Lost time andor Fatality)
middot Contractor and Subcontractor (Lost time andor Fatality)
middot Third Party (Injuryillness resulting in Hospital Admission or Fatality)
Hospital Admission ndash formal acceptance by a hospital or other inpatient health care facility of a patient who is to be provided with room board and medical service in an area of the hospital or facility where patients generally reside at least overnight Treatment in the hospital emergency room or an overnight stay in the emergency room would not by itself qualify as a ldquohospital admissionrdquo
Examples of injury or fatality cases that would be reportable include a burn injury resulting from steam released during cleaning a physical injury from a cap blown off by pressure during a pressure test or a chemical burn from a spill while taking a sample Examples of injuries or fatality cases that would not be reportable include a fall from an elevated work station while performing maintenance a burn from a fire in a laboratory or office building or injuries from an excavation cave-in None of these cases are directly due to the release of energy or material from the process
2 Direct Damage CostA fire explosion or clean up necessary to avoidremediate environmental damage resulting in a direct cost equal to or greater than $2500 USDs
Costs to be considered for this threshold should be those costs directly attributed to the fire andor explosion such as the replacement value of equipment lost structures lost cost of repairs environmental cleanup (on and off site) emergency response andor fines Direct cost does not include indirect costs such as business opportunity losses loss of profits due to equipment outages cost of obtaining or operating temporary facilities or cost of obtaining replacement products to meet customer demand (product losses)
3 Shelter in Place Evacuation
An officially declared shelter in place or evacuation either on or off site OR a precautionary shelter in place or evacuation off site
For the purposes of this reporting an officially declared shelter in place or evacuation on or off site OR a precautionary shelter in place or evacuation is declared off site would trigger this threshold
Officially Declared ndash A declaration by a recognized community official (eg fire police civil defense emergency management) or delegate (eg Company official) authorized to order the community action (eg shelter-in-place evacuation)
Precautionary Declaration - A precautionary public response is a measure taken from an abundance of caution and issued by a recognized community official or delegate whom has reasonably determined that such an evacuation or shelter in place was necessary to protect the public health and safety
Shelter in Place ndash is the use of a structure and its indoor atmosphere to temporarily separate individuals from a hazardous outdoor atmosphere
Evacuation ndash the act or process of removing persons from a place for reasons of safety or protection
4 Threshold ReleaseAn acute release that exceeds one of the GHS thresholds in Table 1 or in the API 754 standard for Tier II process safety release thresholds in Table 2 (measured in amount released during one hour)
As mentioned in the Executive Summary the ICCA process safety event definition allows use of either GHS-based reporting thresholds developed by ICCA for the chemical release criteria or the UN Dangerous Goods (UNDG)-based reporting thresholds used in the RP-754 standard for Tier II incidents The GHS thresholds are listed in Table 1 It is intended for companies to decide which table to use and to allow companies the option to use one system globally
Acute Release ndash A release of flammable combustible or toxic chemicals from the primary containment (ie vessel or pipe) greater than the chemical release threshold quantities is described for GHS Classification Table 1 and in the API 754 standard for Tier II process safety release thresholds in Table 2
Pressure Relief Device Acute Releases defined above include releases to a properly designed and operating pressure relief device if a quantity is released greater than or equal to the threshold quantities in Table 1 OR in the API 754 standard for Tier II process safety release thresholds Table 2 that results in one or more of the following four consequences
1 Rainout
2 Discharge to a potentially unsafe location
3 A n on-site shelter-in-place or on-site evacuation excluding precautionary on-site shelter-Ain-place or on-site evacuation
4 Public protective measures (eg road closure) including precautionary public protective measures
Releases to a properly designed and operating pressure relief device (such as a flare scrubber etc) do not have to be reported if they do not meet one of the four criteria above
Individuals who would like to view the API RP-754 Standard may download that standard at -
httpwwwapiorgenvironment-health-and-safetyprocess-safetyprocess-safety-standardsstandard-rp-7541 Hour Rule
For the purpose of the reporting under this metric release thresholds are established for materials over a one-hour time frame If the release amount of a material reaches or exceeds the reporting threshold in a 1-hour time period or less it is reportable Typically acute releases occur in 1-hour or less If the duration of the release cannot be determined the duration should be assumed to be 1 hour
Primary Containment ndash A tank vessel pipe rail car or equipment intended to serve as the primary container or used for the transfer of the material Primary containers may be designed with secondary containment systems to contain and control the release Secondary containment systems include but are not limited to tank dikes curbing around process equipment drainage collection systems into segregated oily drain systems the outer wall of double walled tanks etc
Severity Table Severity weighting can provide additional useful information about process safety events that may help drive performance improvement Appendix A is the RCLG methodology for calculating a severity weight for process safety events Using Appendix A a severity weight for each process safety event may be calculated by summing the points associated with each consequence category The ICCA strongly encourages the use of a severity weighting system as the use of such a system increases the ability to communicate performance and is an easier way for our stakeholders to understand process safety events Also the severity weight will not be comparable among other process safety metric reporting formats
Table 2 ndash API RP 754 Tier II Classification Table
2
Appendix A ndash Severity Table Using A Severity Weighting System is Encouraged for All AssociationsSeverity Table (Appendix A) Details
Appendix A above is designed to be used with the GHS Classification System ONLY (Table 1) If your company is using the API RP 754 Tier II Process Safety Metric Threshold Table Table 2 in this document please use the API RP 754 Process Safety Severity Table It is important to state that the severity table in the API RP 754 Standard is for Tier 1 incidents only Comparing the relative severity of events using different tables will not be statistically valid
Acute Environmental Cost - Cost of short-term cleanup and material disposal associated with a PSE with off-site environmental impact Companies may choose to assign severity to costs associated with off-site environmental impacts in a separate category
Rate Adjusted Metrics
Utilizing the severity table described above there are a variety of rate-based metrics which can be generated These include
Process Safety Total Incident Rate (PSTIR) Total event incidents x 200000___
Total Worker Hours
Process Safety Incident Severity Rate (PSESR) (ie severity-weighted Process Safety incident rate formula)
Total severity score for all events incidents x 200000___
PSESR = Total Worker Hours
In determining this rate 1 point is assigned for each Level 4 incident attribute 3 points for each Level 3 attribute 9 points for each Level 2 attributes and 27 points for each Level 1 attributes Theoretically a process safety event could be assigned a minimum of 1 point (ie the incident meets the attributes of a Level 4 incident in only one category) or a maximum of 135 points (ie the incident meets the attributes of a Level 1 incident in each of the five categories)
PS Level ldquoXrdquo incident rate Total Severity Level ldquoXrdquo PS incidents x 200000
Total employee contractor amp subcontractor work hours
Where X can be the total count of Severity Level 4 3 2 or 1 incidents The severity level of an incident is the maximum severity rating of the five consequence categories
Normalization ndash In some associations and member companies process safety events are normalized on a lsquoper 100rsquo employee basis given that a one worker averages 2000 per year So to normalize on a lsquoper 100rsquo employee basis events are multiplied by 200000 worker hours In other associations and member companies events are normalized on a lsquoper 500rsquo employee basis and events are multiplied by 1000000 worker hours Associations and members should discuss this option and come to a conclusion together The above formulas are set at a lsquoper 100rsquo employee rate
15
(K = 1000 MM = 1000000) (For Environmental Impact companies and associations should agree on input criteria where definitions arenrsquot readily available)
Appendix B ndash Frequently Asked QuestionsApplicability
It is recommended that companies record and report Process Safety Events occurring at Company-owned or operated facilities except as noted below
1 PSEs that originated off Company property
2 Marine transport vessel incidents except when the vessel is connected to the facility for the purposes of crude or product transfer
3 Truck andor rail incidents except when the truck or rail car is connected to the facility for the purposes of crude or product transfer
4 Routine emissions that are allowable under permit or regulation
5 Underground contamination that had no process safety consequences Note The exclusion does not apply if the release resulted in an aboveground reportable PSE such as release of toxic vapors or pooling of flammable liquids
6 Office building incidents (eg office heating equipment explosions fires spills releases personnel injury or illness etc)
7 Personnel safety sliptripfall incidents that are not directly associated with evacuating from or responding to a loss of containment incident
8 Loss of Primary Containment (LOPC) incidents from ancillary equipment not connected to the process (eg small sample containers)
9 Planned and controlled drainage of material to collection or drain system designed for such service (Note Exclusion does not apply to an unintended and uncontrolled release of material from primary containment that flows to a collection or drain system)
10 Mechanical work being conducted outside of process units or in maintenance shops
Interpretations and Examples ndash Based on GHS Table 1
The following interpretations and examples have been prepared to help clarify areas of potential uncertainty in the evaluation of reportable Process Safety Incidents (PSE)
COMPANY PREMISES
1 A third-party truck loading a flammable product on Company Premises experiences a leak and subsequent fire and property loss damages of $7000 (direct costs) Although the truck is Operated-by-Others it is connected to the process The incident would be a reportable PSE if property losses in direct costs were equal to or greater than $2500 or some other PSE threshold was met or exceeded (eg a fatality)
2 Similar example as 1 The truck loaded with flammable product overturns in route out of the plant resulting in a fire and loss of the truck This would not be reported as a PSE since the truck is no longer connected to the plant
LOSS OF CONTAINMENT
3 A faulty tank gauge results in the overfilling of a product tank containing ldquoflammable liquidsrdquo Approximately 700 kg of liquid overflows into the tanks diked area This incident is a reportable PSE since it is an acute spill greater than 100 kgs regardless of secondary containment
4 A maintenance contractor opens a process valve and gets sprayed with sulfuric acid resulting in a severe burn and lost time injury This would be a reportable PSE It is an unintended event involving a material and a loss of containment For fatalities and days away from work injuries and illnesses there is no release threshold amount
5 An operator opens a quality control sample point to collect a routine sample of product and receives a bad hand laceration requiring stitches due to a broken glass bottle and misses the next day of work This is not a reportable PSE because it is not related to a loss of containment
ACUTE RELEASES
6 While troubleshooting a higher-than-expected natural gas flow rate operating personnel find a safety valve on the natural gas line that did not reseat properly and was relieving to the atmospheric vent stack through a knock-out drum Upon further investigation it is determined that a total of 100000 kg of natural gas was relieved at a steady rate over a 6 month period This is not a reportable PSE as the release rate (~10 kg per hour) is not ldquoacuterdquo (ie does not exceed the 100 kg TQ for flammable vapors per 1 hour time period)
FLARES amp EMISSION CONTROL DEVICES (eg scrubbers)
7 If a chemical is routed to a flare or emission control device (eg scrubber) it would not be classified as a PSE as long as that flare or control device operates as designed
8 If a scrubber is overwhelmed by a flowrate greater than the design of the scrubber system and discharges a chemical in excess of the reporting threshold it would be reported as a PSE as noted about in this document
As a note an upset emission from a permitted or regulated source ndash including pressure relieve devices - of a quantity greater than or equal to the threshold quantities in Table 1 or 2 in any one-hour period that results in one or more of the following four consequences
middot rainout
middot discharge to a potentially unsafe location
middot an on-site shelter-in-place or on-site evacuation excluding precautionary on-site shelter-in-place or on-site evacuation
middot public protective measures (eg road closure) including precautionary public protective measures
Should be reported as a PSE
SAFETY RELIEF DEVICE SYSTEM
9 There is a unit upset and the relief valve opens to an atmospheric vent which has been designed resulting in a gas release to the atmosphere with no adverse consequences This would not be a reportable PSE since vapors and gases released to atmosphere from safety valves high-pressure rupture disks and similar safety devices that are properly designed for that event per API Standard 521 or equivalent are excluded as long as the release did not result in (1) a liquid carryover that created a reportable PSE related to the liquid (eg lost time incident fatality a fire or explosion that caused $2500 or more of direct cost liquid release or toxic aerosol release at or above threshold amounts etc) or (2) activation of a shelter-in-place response on or off-site or (3) public protective measures be taken
10 There is a unit upset and the relief valve fails to open resulting in overpressure of the equipment and an acute release of flammable gas from a leaking flange The amount released is above the 100 kg (within 1 hour) threshold This is a reportable PSE Releases from flanges are not excluded from PSE reporting
DAYS AWAY FROM WORK INCIDENTS
11 An operator is walking then slips and falls to the floor and suffers a lost time injury The slipfall is due to weather conditions chronic oily floors and slippery shoes This is not a reportable PSE Personnel safety sliptripfall incidents that are not directly associated with evacuating from or responding to a loss of containment incident are specifically excluded from PSE reporting
12 Same as above except that the operator slipped and fell while responding to a small flammable liquid spill (eg less than 10 kg in 1 hour) This would be PSE reportable since the operator was responding to a loss of containment incident A PSE is reportable if the loss of primary containment occurs on Company Premises and results in a lost time incident or fatality For fatalities and lost time incidents there is no release threshold amount
13 Same as above except that the operator slipped and fell several hours after the incident had concluded This would not be PSE reportable The terms evacuating from and responding to in the reporting exclusion mean that the loss of containment and associated emergency response activities are on-going Slipstripfalls after the event have concluded (such as after-the-fact clean-up and remediation) are excluded from PSE reporting
14 A scaffold builder suffers a lost time injury after falling from a scaffold ladder while evacuating from a loss of containment incident on nearby equipment This is a reportable PSE
15 An operator walks past an improperly designed steam trap The steam trap releases and the operators ankle is burned by the steam resulting in a lost time injury This is a reportable PSE because even though the loss of containment was steam (vs hydrocarbon or chemical) the physical state of the material was such that it caused a lost time injury
16 An enclosure has been intentionally purged with nitrogen A contractor bypasses safety controls enters the enclosure and dies This is a reportable fatality but not a reportable PSE since there was no unplanned or uncontrolled loss of primary containment
17 Same as above except that nitrogen inadvertently leaked into the enclosure This would be a reportable PSE (and fatality) since there was a fatality associated with an unplanned loss of primary containment
18 An operator responding to an H2S alarm collapses and has a injury If the alarm was triggered by an actual unplanned or uncontrolled H2S LOPC the event would be a reportable PSE If the alarm was a false alarm the event would not be a reportable PSE because there was no actual release
PIPELINES
19 A pipeline leaks and releases 2000 lbs (900 kgs) of flammable vapor above ground within 1 hour However the release occurred in a remote location within the site The release is PSE reportable since remoteness is not a consideration
FIRES or ENERGY RELEASES NOT ASSOCIATED WITH CHEMICAL RELEASE
As a general rule a fire or energy release is reported as a PSE only if caused by chemical release or results in a chemical release in excess of the reporting quantities Examples include
20 An electrical fire impacts the operation of the process resulting in the release of 400 kg of toluene This event would be reported as a PSE since if the chemical release exceeds the 100 kg reporting threshold for toluene
21 An electrical fire loss of electricity or any other loss of utility occurs which may cause a plant shutdown and possibly incidental equipment damage greater than $2500 (eg damage to reactors or equipment due to inadequate shutdown) but does not create a chemical release greater than the threshold quantity or cause a fatality or serious injury This event would not be reported as a PSE since the equipment damage was not caused by a chemical process fireexplosion and there was not a chemical release greater than the threshold quantity
MARINE TRANSPORT VESSELS
22 A company operated Marine Transport Vessel has an onboard acute spill of combustible material greater than 100 kg The event is not PSE reportable since Marine Transport Vessel incidents are specifically excluded except when the vessel is connected to the refinery petrochemical or chemical manufacturing facility for the purposes of crude or product transfer
23 A third-party barge is being pushed by a tug and hits the company dock A barge compartment is breached and releases 1000 kg of diesel to the water The event is not a reportable PSE since the marine vessel was not berthed at the dock and actively involved in crude or product transfer operations
TRUCK AND RAIL
24 A company railcar derails and spills more than 1000 kg of gasoline while in transit The incident is not PSE reportable since rail incidents off company property are specifically excluded
25 A third-party trucktrailer overturns while in the Company Premises resulting in an acute spill of gasoline greater than 1000 kg The incident is not reported as a PSE reportable if the truck is no longer connected to the loadingunloading facilities However it is recommended that companies also have transportation incident metrics which would capture this event
26 A contract truck hauler is unloading caustic and the hose separates and generates an airborne aerosol andor liquid caustic spill of 2500 kg The event is a reportable PSE since the caustic TQ of 100 kg was exceeded and the truck was still connected to the loadingunloading facility immediately prior to the incident
OFFICE BUILDING
27 There is a boiler fire at the Main Office complex and direct cost damages totaled $75000 The incident is not PSE reportable since Office Building incidents are specifically excluded
MAN-MACHINE INTERFACE INCIDENTS
28 An operations technician is injured while working around the finishing equipment in a polymers plant The injury is caused by the mechanical man-machine interface with the equipment This would not be a reportable Process Safety Event because there was no loss of containment of hazardous material
MIXTURES
29 If a mixture by itself has a GHS classification you use that classification to determine the threshold If the mixture itself does not have a GHS-classification we go back to the individual components of the mixture and based on kg released per threshold group calculate a lsquoweightedrsquo contribution to the thresholds Example a release of 100 kg of a mixture in a one hour period that consists of 05 kg of a substance classified as acute toxic H300 45 kg of substance classified with H301 and 40 kg of a substance with another H-number and the remaining 55 kg of water with no GHS classification would be calculated as 051 + 4510 + 40100 = 05 + 045 + 04 = 135 is exceeding 1 and would be counted as a reportable process safety incident even though none of the individual hazardous components exceeded the threshold for the individual substance
DIRECT DAMAGE COSTS
30 Direct damage costs are considered for this threshold should be those costs directly attributed to the fire andor explosion such as the replacement value of equipment lost structures lost cost of repairs environmental cleanup emergency response andor fines Direct cost does not include indirect costs such as business opportunity losses loss of profits due to equipment outages cost of obtaining or operating temporary facilities or cost of obtaining replacement products to meet customer demand (product losses)
31 As an example a leak of flammable gas occurred in a vent line connected to a gas treatment system At the same time a failure in the process allowed air to enter in the same vent line An explosion occurred and the over pressure damaged the vent line and associated upstream equipment including a seal pot Nobody was hurt The cost for repair was about $12000 This is a PSE considering the cost to repair the equipment due to the explosion and fire
32 As an example after a PSE event a company releases 50 kg of a very special GHS Category 5 product which causes $2000 of damage to equipment The product released was a very special blend of materials and the company incurs over $50000 in materials associated with the product loss This event is not reportable as PSE since the reportable threshold for GHS Category 5 releases is 100 kgs and product losses do not count as Direct Damage Costs
NATURAL DISASTERS
33 Natural disasters can present substantial risks to chemical process operations and damage to plant equipment which may result in a loss of containment of hazardous substances Where the potential for one or more types of natural disasters is deemed relevant to plant operations process safety and operational systems shall address the applicable risk in terms of hazards and consequence analysis plant design operating procedures for loss of utilities and process shutdown and emergency planning and response
Types of natural disasters includes hurricanes and typhoons (including associated storm surge) floods tornadoes earthquakes derechos (straight line wind storms) wildfires volcanic eruptions tsunamis and avalanches
If your facility experiences a natural disaster that triggers one or more of the thresholds it should be reported as a process safety event
PRECAUTIONARY PUBLIC RESPONSE
34 A precautionary public response is a measure taken from an abundance of caution For example a company may require all workers to shelter-in-place in response to an LOPC independent of or prior to any assessment (eg wind direction distance from the LOPC etc) of the potential hazard to those worker For example a recognized community official (eg fire police civil defense emergency management) may order a community shelter-in-place evacuation or public protective measure (eg road closure) in the absence of information from a company experiencing a process safety event or lsquojust in casersquo the wind direction changes or due to the sensitive nature of the potentially affected population (eg school children the elderly)
ACTIVE WAREHOUSE
35 An active warehouse is an on-site warehouse that stores raw materials intermediates or finished products used or produced by a process From a process perspective an active warehouse is equivalent to a bulk storage tank Rather than being stored in a single large container the raw materials intermediates or finished products are stored in smaller containers (eg totes barrels pails etc)
Appendix C ndash List of RCLG Taskforce Members Luiz Shizuo Harayashiki19
Appendix D ndash Detailed Schedule of Events Appendix E ndash Optional Excel Reporting FormWhen member companies begin tracking process safety events a single form should be utilized for all member companies to make data analysis easier and to allow all members to work from the same tracking sheet The RCLG has developed an optional tracking sheet that members and associations can start with when developing their own tracking sheet
DOWNLOAD TRACKING SHEET HERE
This document consists of a contact page the survey itself and a lsquodo not editrsquo page where the drop down menu answer are stored
INTERNATIONAL
COUNCIL OF
CHEMICAL
ASSOCIATIONS
ICCA Process Safety
Event Tracking Sheetxlsx
GUIDANCE FOR REPORTING ON THE ICCA GLOBALLY HARMONIZED PROCESS SAFETY METRICJune2016The Responsible Carereg Leadership Group
ContentsBackground2Executive Summary2Data to be reported by RCLG Associations to RCLG4Overview of ICCA Process Safety Event Criteria as a Flow Chart5Key Criteria for Reporting Process Safety Events to RCLG6Detailed Guidelines on Identifying a Process Safety Event7Table 1 ndash GHS Classification Table11Table 2 ndash API RP 754 Tier II Classification Table12Appendix A ndash Severity Table Using A Severity Weighting System is Encouraged for All Associations14Appendix B ndash Frequently Asked Questions16Appendix C ndash List of RCLG Taskforce Members22Appendix D ndash Detailed Schedule of Events23Appendix E ndash Optional Excel Reporting Form24
FIANL DRAFT
June 15 2016
The Responsible Carereg initiative began in 1985 and as the chemical industryrsquos commitment to continuous performance improvements Process Safety has been a pillar of Responsible Care since its inception and many regional approaches to tracking and reporting process safety performance have developed over the 30 years of Responsible Care implementation yet no globally harmonized system had been put into place In 2012 in the wake of several high profile process safety events the International Council of Chemical Associations (ICCA) Board of Directors directed the Responsible Care Leadership Group (RCLG) to develop a recommendation for a globally harmonized process safety performance reporting by no later than 2015
Throughout 2013 and 2014 a Taskforce comprised of multinational companies and RCLG associations chaired by Dr Peter Schmelzer Head of Health Safety and Environmental Protection Bayer HealthCare AG worked to develop a globally harmonized ICCA approach to process safety performance reporting A list of Taskforce members can be found in Appendix C During the same timeframe the American Petroleum Institute (API) also initiated a process to update its Recommend Practice 754 (RP-754) ndash Leading and Lagging Process Safety Metric Standard RP-754 is broadly used in the refining and petrochemical sector and in the Americas region to track process safety performance To optimize global adoption of a unified standard the RCLG Taskforce strived to achieve full harmonization of its recommendation with the revised API RP 754 metric expected to be finalized in the first quarter 2016
After more than 2 years of discussion research debate and feasibility assessment the Process Safety Harmonization Taskforce recommends that ICCA adopt a process safety event rate metric The adoption of this metric would require each RCLG association to collect the number of process safety events experienced by their members on an annual basis as well as total number of worker hours (employees and contractors) experienced by their members each year The process safety event rate is the ratio of events to hours The Taskforce also recommends that reporting of these data points to the RCLG be phased in over the next 3 years allowing regions with the desire and ability to report immediately to do so while also allowing additional time to companies and organizations that are developing the ability to track these data for the first time
The criteria that determine whether a process-related event qualifies as a process safety event are based on a loss of primary containment of a chemical or a release of energy triggering thresholds any one of four impact areas 1) safetyhuman health consequences 2) direct cost due to damage from incident 3) community impact and 4) chemical release quantity (see the flow chart showing reporting triggers) These four impact areas in the recommended ICCA process safety event definition are identical to the impact areas in the RP-754 Tier II incident standard The thresholds for reporting are also identical in all areas with the exception of the chemical release quantity thresholds To address this difference the ICCA process safety event definition will allow companies the use of either the GHS-based reporting thresholds developed by ICCA for the chemical release criteria or the UN Dangerous Goods (UNDG)-based reporting thresholds used in the RP-754 standard for Tier II incidents The Taskforce believes that the two systems though different are comparably robust in the universe of chemicals covered and the severity of incidents captured by reporting While there will be relatively little difference in the numbers of events captured and reported using the two different threshold approaches there may be differences that would be most clearly seen at the company level based on raw material and product use hence the Taskforce cautions companies not to compare their results with companies that use a different chemical release threshold approach Regardless under the RCLG proposal companies can choose the chemical release thresholds by which they report in to their national and regional associations If associations are interested in translating results based on one reporting approach to another the RCLG will provide a translation table However given the complexity of this exercise and the need to access raw incident data the Taskforce does not believe that this adds value and recommends against it
The Taskforce believes that this proposal for process safety event reporting will enable broad-based global reporting of process safety performance across the chemical and petrochemical industries It will provide a roadmap for regions associations and companies that are currently not tracking process safety performance to recognize the benefits that tracking and reporting will bring For regions associations and companies that are already experienced in gathering process safety data this recommendation allows for broader global alignment and focus on continuous improvement in process safety performance The systems that are built to improve process safety performance are informed by robust process safety event data and this is the major objective of this initiative
On an annual basis RCLG Associations will be asked to report two data points into ICCA using the RCLG KPI Reporting Website on the schedule provided below
1Total Member Company Worker Hours for Association (employee and contractor)
2Total Number of Process Safety Events
ICCA will use the above two data points to report process safety performance in the form of Process Safety Event Rate (PSER) normalized per 100 employees where an employee works 2000 hours a year
(Total Events Total Hours) x 200000 = PSER
Recommended Reporting Schedule
The Taskforce recommends a phased-in approach for reporting process safety event rate Such a schedule will allow more experienced companies and associations to report in the next several years while allowing other companies and associations to begin reporting by 2019 RCLG Associations would be asked to report the two process safety event rate data points annually to the ICCA through the RCLG KPI metrics reporting system If you do not know your associationrsquos username and password please contact the RCLG
The proposed schedule for process safety event rate reporting by RCLG associations is as follows
April 2015RCLG considers Taskforce proposal
June 2015ICCA Board of Directors considers RCLG final recommendation
July 2015RCLG releases the first detailed reporting guidance document for associations and member companies
Feb 2016 RCLG Reporting RCLG initiates process safety reporting pilot program through association volunteers with updated an enhanced guidance document RCLG rolls out final guidance document in June 2016
2017RCLG Associations begin collecting data from its membership
2018-2019 RCLG Reporting Optional process safety data reporting by RCLG Associations
2020 ReportingRCLG includes process safety as a mandatory metric in the KPI reporting program
See Appendix D ndash Detailed Schedule of Events
NO Does not meet the criteria for a Process Safety Event
Start
NO
NO
NO
Was a chemical substance or a chemical process directly involved
YES
YES
Release of material fire explosion or implosion fromat a chemical process unit
Incident in production distribution storage utilities pilot plants within a companyrsquos facility
YES
NO
Officially declared shelter in place or evacuation
Or Precautionary off site shelter in place or evacuation
Substance Release Thresholds met
Recordable injury
Or
hospital admission of people on or off site
Damage ge $2500direct costto company
NO
NO
NO
ICCA or API 754 Tier II chemical release thresholds exceeded
YES
YES
YES
Yes Reportable as a Process Safety Event
YES
Total Worker Hours
RCLG Associations should report the total number of employee hours worked for each member company in their association and the total number of contractor hours worked for each member company as a combined single number For the purposes of this guidance document each association should refer to their local and regional definitions for employee and contractor The goal for reporting total hours is to include all individuals who are involved with chemical manufacturing except where those individuals are tasked with major construction projects such as large scale investments with specific one-time project organizations created for design engineering and construction of new or significant expansion to existing process facilities When reporting total worker hours companies should report the same hours used for reporting personnel hours This way companies can have the same data set for occupational and process safety Personnel hours should include those hours from all chemical manufacturing operations not just from facilities where a process safety incident occurred
Process Safety Event
For the purposes of this ICCA Reporting a process safety event has occurred when
A When a chemical substance or a chemical process is directly involved AND
B The incident occurred in production distribution storage utility pilot plant within the site boundaries of companyrsquos facility AND
C There was a release of material or energy (eg fire explosion implosion) from a process unit AND
D One or more of the following Reporting Thresholds have been met
1 Safety Injury
middot Injury resulting in a Recordable Lost Time Accident or Fatality or Hospital admission of anyone on or off site OR
2 Direct Damage Cost
middot A fire explosion or clean up necessary to avoidremediate environmental damage resulting in a direct cost equal to or greater than $2500 USDs OR
3 Shelter in Place Evacuation
middot An officially declared shelter in place (on or off site) OR
middot An officially declared evacuation (on or off site) OR
middot A precautionary off site shelter in place or evacuation OR
4 Threshold Release
middot The material released meets one of the GHS thresholds in Table 1 (measured in amount released during one hour)
When a chemical substance or chemical process is directly involved
A chemical or chemical process must have been directly involved in the event or incident For this purpose the term process is used broadly to include the equipment and technology needed for petrochemical production including reactors tanks piping boilers cooling towers refrigeration systems etc An incident with no direct chemical or process involvement eg an office building fire even if the office building is on a plant site is not reportable
B LocationThe incident occurred in production distribution storage utility pilot plant within the site boundaries of companyrsquos facility
The incident occurs in production distribution storage (including active storage areas such as warehouses ndash see FAQ section) utilities or pilot plants of a facility reporting metrics under these definitions This includes tank farms ancillary support areas (eg boiler houses and waste water treatment plants) and distribution piping under control of the site All reportable incidents occurring at a location will be reported by the company that is responsible for operating that location This applies to incidents that may occur in contractor work areas as well as other incidents At tolling operations and multi-party sites the company that operates the unit where the incident initiated should record the incident and count it in their reporting
C Release of MaterialThere was a release of material or energy (eg fire explosion implosion) from a process unit
Release of Material ndash an unplanned or uncontrolled release of any material including non-toxic and non-flammable materials (eg steam hot water nitrogen compressed CO2 or compressed air) from a process that results in consequences that exceed one or more of the 4 Reporting Thresholds listed in this document
A release to a flare or scrubber is still considered to be within the primary containment as long as the mitigation system (eg scrubber flare) is operated under normal conditions without any release above the thresholds defined for normal operation A release to a secondary containment (eg waste water treatment or dike) will qualify as a process safety event because the substance is leaving the primary process system
D ThresholdsOne or more of the following Reporting Thresholds must be met for reportable process safety events
1 Safety Injury
Injury resulting in a Recordable Lost Time Accident or Fatality or Hospital admission of anyone on or off site Recordable injuries are work-related injuries that results in any of the following death days away from work restricted work or transfer to another job medical treatment beyond first aid loss of consciousness or a significant injury diagnosed by a physician or other licensed health professional
Lost time injuries and fatalities that occur as a result of process related loss of primary containment fire or explosion are those that fit into one of the following categories
middot Employee (Lost time andor Fatality)
middot Contractor and Subcontractor (Lost time andor Fatality)
middot Third Party (Injuryillness resulting in Hospital Admission or Fatality)
Hospital Admission ndash formal acceptance by a hospital or other inpatient health care facility of a patient who is to be provided with room board and medical service in an area of the hospital or facility where patients generally reside at least overnight Treatment in the hospital emergency room or an overnight stay in the emergency room would not by itself qualify as a ldquohospital admissionrdquo
Examples of injury or fatality cases that would be reportable include a burn injury resulting from steam released during cleaning a physical injury from a cap blown off by pressure during a pressure test or a chemical burn from a spill while taking a sample Examples of injuries or fatality cases that would not be reportable include a fall from an elevated work station while performing maintenance a burn from a fire in a laboratory or office building or injuries from an excavation cave-in None of these cases are directly due to the release of energy or material from the process
2 Direct Damage CostA fire explosion or clean up necessary to avoidremediate environmental damage resulting in a direct cost equal to or greater than $2500 USDs
Costs to be considered for this threshold should be those costs directly attributed to the fire andor explosion such as the replacement value of equipment lost structures lost cost of repairs environmental cleanup (on and off site) emergency response andor fines Direct cost does not include indirect costs such as business opportunity losses loss of profits due to equipment outages cost of obtaining or operating temporary facilities or cost of obtaining replacement products to meet customer demand (product losses)
3 Shelter in Place Evacuation
An officially declared shelter in place or evacuation either on or off site OR a precautionary shelter in place or evacuation off site
For the purposes of this reporting an officially declared shelter in place or evacuation on or off site OR a precautionary shelter in place or evacuation is declared off site would trigger this threshold
Officially Declared ndash A declaration by a recognized community official (eg fire police civil defense emergency management) or delegate (eg Company official) authorized to order the community action (eg shelter-in-place evacuation)
Precautionary Declaration - A precautionary public response is a measure taken from an abundance of caution and issued by a recognized community official or delegate whom has reasonably determined that such an evacuation or shelter in place was necessary to protect the public health and safety
Shelter in Place ndash is the use of a structure and its indoor atmosphere to temporarily separate individuals from a hazardous outdoor atmosphere
Evacuation ndash the act or process of removing persons from a place for reasons of safety or protection
4 Threshold ReleaseAn acute release that exceeds one of the GHS thresholds in Table 1 or in the API 754 standard for Tier II process safety release thresholds in Table 2 (measured in amount released during one hour)
As mentioned in the Executive Summary the ICCA process safety event definition allows use of either GHS-based reporting thresholds developed by ICCA for the chemical release criteria or the UN Dangerous Goods (UNDG)-based reporting thresholds used in the RP-754 standard for Tier II incidents The GHS thresholds are listed in Table 1 It is intended for companies to decide which table to use and to allow companies the option to use one system globally
Acute Release ndash A release of flammable combustible or toxic chemicals from the primary containment (ie vessel or pipe) greater than the chemical release threshold quantities is described for GHS Classification Table 1 and in the API 754 standard for Tier II process safety release thresholds in Table 2
Pressure Relief Device Acute Releases defined above include releases to a properly designed and operating pressure relief device if a quantity is released greater than or equal to the threshold quantities in Table 1 OR in the API 754 standard for Tier II process safety release thresholds Table 2 that results in one or more of the following four consequences
1 Rainout
2 Discharge to a potentially unsafe location
3 A n on-site shelter-in-place or on-site evacuation excluding precautionary on-site shelter-Ain-place or on-site evacuation
4 Public protective measures (eg road closure) including precautionary public protective measures
Releases to a properly designed and operating pressure relief device (such as a flare scrubber etc) do not have to be reported if they do not meet one of the four criteria above
Individuals who would like to view the API RP-754 Standard may download that standard at -
httpwwwapiorgenvironment-health-and-safetyprocess-safetyprocess-safety-standardsstandard-rp-7541 Hour Rule
For the purpose of the reporting under this metric release thresholds are established for materials over a one-hour time frame If the release amount of a material reaches or exceeds the reporting threshold in a 1-hour time period or less it is reportable Typically acute releases occur in 1-hour or less If the duration of the release cannot be determined the duration should be assumed to be 1 hour
Primary Containment ndash A tank vessel pipe rail car or equipment intended to serve as the primary container or used for the transfer of the material Primary containers may be designed with secondary containment systems to contain and control the release Secondary containment systems include but are not limited to tank dikes curbing around process equipment drainage collection systems into segregated oily drain systems the outer wall of double walled tanks etc
Severity Table Severity weighting can provide additional useful information about process safety events that may help drive performance improvement Appendix A is the RCLG methodology for calculating a severity weight for process safety events Using Appendix A a severity weight for each process safety event may be calculated by summing the points associated with each consequence category The ICCA strongly encourages the use of a severity weighting system as the use of such a system increases the ability to communicate performance and is an easier way for our stakeholders to understand process safety events Also the severity weight will not be comparable among other process safety metric reporting formats
Table 1 ndash GHS Classification TableTable 2 ndash API RP 754 Tier II Classification Table
2
Appendix A ndash Severity Table Using A Severity Weighting System is Encouraged for All AssociationsSeverity Table (Appendix A) Details
Appendix A above is designed to be used with the GHS Classification System ONLY (Table 1) If your company is using the API RP 754 Tier II Process Safety Metric Threshold Table Table 2 in this document please use the API RP 754 Process Safety Severity Table It is important to state that the severity table in the API RP 754 Standard is for Tier 1 incidents only Comparing the relative severity of events using different tables will not be statistically valid
Acute Environmental Cost - Cost of short-term cleanup and material disposal associated with a PSE with off-site environmental impact Companies may choose to assign severity to costs associated with off-site environmental impacts in a separate category
Rate Adjusted Metrics
Utilizing the severity table described above there are a variety of rate-based metrics which can be generated These include
Process Safety Total Incident Rate (PSTIR) Total event incidents x 200000___
Total Worker Hours
Process Safety Incident Severity Rate (PSESR) (ie severity-weighted Process Safety incident rate formula)
Total severity score for all events incidents x 200000___
PSESR = Total Worker Hours
In determining this rate 1 point is assigned for each Level 4 incident attribute 3 points for each Level 3 attribute 9 points for each Level 2 attributes and 27 points for each Level 1 attributes Theoretically a process safety event could be assigned a minimum of 1 point (ie the incident meets the attributes of a Level 4 incident in only one category) or a maximum of 135 points (ie the incident meets the attributes of a Level 1 incident in each of the five categories)
PS Level ldquoXrdquo incident rate Total Severity Level ldquoXrdquo PS incidents x 200000
Total employee contractor amp subcontractor work hours
Where X can be the total count of Severity Level 4 3 2 or 1 incidents The severity level of an incident is the maximum severity rating of the five consequence categories
Normalization ndash In some associations and member companies process safety events are normalized on a lsquoper 100rsquo employee basis given that a one worker averages 2000 per year So to normalize on a lsquoper 100rsquo employee basis events are multiplied by 200000 worker hours In other associations and member companies events are normalized on a lsquoper 500rsquo employee basis and events are multiplied by 1000000 worker hours Associations and members should discuss this option and come to a conclusion together The above formulas are set at a lsquoper 100rsquo employee rate
15
(K = 1000 MM = 1000000) (For Environmental Impact companies and associations should agree on input criteria where definitions arenrsquot readily available)
Appendix B ndash Frequently Asked QuestionsApplicability
It is recommended that companies record and report Process Safety Events occurring at Company-owned or operated facilities except as noted below
1 PSEs that originated off Company property
2 Marine transport vessel incidents except when the vessel is connected to the facility for the purposes of crude or product transfer
3 Truck andor rail incidents except when the truck or rail car is connected to the facility for the purposes of crude or product transfer
4 Routine emissions that are allowable under permit or regulation
5 Underground contamination that had no process safety consequences Note The exclusion does not apply if the release resulted in an aboveground reportable PSE such as release of toxic vapors or pooling of flammable liquids
6 Office building incidents (eg office heating equipment explosions fires spills releases personnel injury or illness etc)
7 Personnel safety sliptripfall incidents that are not directly associated with evacuating from or responding to a loss of containment incident
8 Loss of Primary Containment (LOPC) incidents from ancillary equipment not connected to the process (eg small sample containers)
9 Planned and controlled drainage of material to collection or drain system designed for such service (Note Exclusion does not apply to an unintended and uncontrolled release of material from primary containment that flows to a collection or drain system)
10 Mechanical work being conducted outside of process units or in maintenance shops
Interpretations and Examples ndash Based on GHS Table 1
The following interpretations and examples have been prepared to help clarify areas of potential uncertainty in the evaluation of reportable Process Safety Incidents (PSE)
COMPANY PREMISES
1 A third-party truck loading a flammable product on Company Premises experiences a leak and subsequent fire and property loss damages of $7000 (direct costs) Although the truck is Operated-by-Others it is connected to the process The incident would be a reportable PSE if property losses in direct costs were equal to or greater than $2500 or some other PSE threshold was met or exceeded (eg a fatality)
2 Similar example as 1 The truck loaded with flammable product overturns in route out of the plant resulting in a fire and loss of the truck This would not be reported as a PSE since the truck is no longer connected to the plant
LOSS OF CONTAINMENT
3 A faulty tank gauge results in the overfilling of a product tank containing ldquoflammable liquidsrdquo Approximately 700 kg of liquid overflows into the tanks diked area This incident is a reportable PSE since it is an acute spill greater than 100 kgs regardless of secondary containment
4 A maintenance contractor opens a process valve and gets sprayed with sulfuric acid resulting in a severe burn and lost time injury This would be a reportable PSE It is an unintended event involving a material and a loss of containment For fatalities and days away from work injuries and illnesses there is no release threshold amount
5 An operator opens a quality control sample point to collect a routine sample of product and receives a bad hand laceration requiring stitches due to a broken glass bottle and misses the next day of work This is not a reportable PSE because it is not related to a loss of containment
ACUTE RELEASES
6 While troubleshooting a higher-than-expected natural gas flow rate operating personnel find a safety valve on the natural gas line that did not reseat properly and was relieving to the atmospheric vent stack through a knock-out drum Upon further investigation it is determined that a total of 100000 kg of natural gas was relieved at a steady rate over a 6 month period This is not a reportable PSE as the release rate (~10 kg per hour) is not ldquoacuterdquo (ie does not exceed the 100 kg TQ for flammable vapors per 1 hour time period)
FLARES amp EMISSION CONTROL DEVICES (eg scrubbers)
7 If a chemical is routed to a flare or emission control device (eg scrubber) it would not be classified as a PSE as long as that flare or control device operates as designed
8 If a scrubber is overwhelmed by a flowrate greater than the design of the scrubber system and discharges a chemical in excess of the reporting threshold it would be reported as a PSE as noted about in this document
As a note an upset emission from a permitted or regulated source ndash including pressure relieve devices - of a quantity greater than or equal to the threshold quantities in Table 1 or 2 in any one-hour period that results in one or more of the following four consequences
middot rainout
middot discharge to a potentially unsafe location
middot an on-site shelter-in-place or on-site evacuation excluding precautionary on-site shelter-in-place or on-site evacuation
middot public protective measures (eg road closure) including precautionary public protective measures
Should be reported as a PSE
SAFETY RELIEF DEVICE SYSTEM
9 There is a unit upset and the relief valve opens to an atmospheric vent which has been designed resulting in a gas release to the atmosphere with no adverse consequences This would not be a reportable PSE since vapors and gases released to atmosphere from safety valves high-pressure rupture disks and similar safety devices that are properly designed for that event per API Standard 521 or equivalent are excluded as long as the release did not result in (1) a liquid carryover that created a reportable PSE related to the liquid (eg lost time incident fatality a fire or explosion that caused $2500 or more of direct cost liquid release or toxic aerosol release at or above threshold amounts etc) or (2) activation of a shelter-in-place response on or off-site or (3) public protective measures be taken
10 There is a unit upset and the relief valve fails to open resulting in overpressure of the equipment and an acute release of flammable gas from a leaking flange The amount released is above the 100 kg (within 1 hour) threshold This is a reportable PSE Releases from flanges are not excluded from PSE reporting
DAYS AWAY FROM WORK INCIDENTS
11 An operator is walking then slips and falls to the floor and suffers a lost time injury The slipfall is due to weather conditions chronic oily floors and slippery shoes This is not a reportable PSE Personnel safety sliptripfall incidents that are not directly associated with evacuating from or responding to a loss of containment incident are specifically excluded from PSE reporting
12 Same as above except that the operator slipped and fell while responding to a small flammable liquid spill (eg less than 10 kg in 1 hour) This would be PSE reportable since the operator was responding to a loss of containment incident A PSE is reportable if the loss of primary containment occurs on Company Premises and results in a lost time incident or fatality For fatalities and lost time incidents there is no release threshold amount
13 Same as above except that the operator slipped and fell several hours after the incident had concluded This would not be PSE reportable The terms evacuating from and responding to in the reporting exclusion mean that the loss of containment and associated emergency response activities are on-going Slipstripfalls after the event have concluded (such as after-the-fact clean-up and remediation) are excluded from PSE reporting
14 A scaffold builder suffers a lost time injury after falling from a scaffold ladder while evacuating from a loss of containment incident on nearby equipment This is a reportable PSE
15 An operator walks past an improperly designed steam trap The steam trap releases and the operators ankle is burned by the steam resulting in a lost time injury This is a reportable PSE because even though the loss of containment was steam (vs hydrocarbon or chemical) the physical state of the material was such that it caused a lost time injury
16 An enclosure has been intentionally purged with nitrogen A contractor bypasses safety controls enters the enclosure and dies This is a reportable fatality but not a reportable PSE since there was no unplanned or uncontrolled loss of primary containment
17 Same as above except that nitrogen inadvertently leaked into the enclosure This would be a reportable PSE (and fatality) since there was a fatality associated with an unplanned loss of primary containment
18 An operator responding to an H2S alarm collapses and has a injury If the alarm was triggered by an actual unplanned or uncontrolled H2S LOPC the event would be a reportable PSE If the alarm was a false alarm the event would not be a reportable PSE because there was no actual release
PIPELINES
19 A pipeline leaks and releases 2000 lbs (900 kgs) of flammable vapor above ground within 1 hour However the release occurred in a remote location within the site The release is PSE reportable since remoteness is not a consideration
FIRES or ENERGY RELEASES NOT ASSOCIATED WITH CHEMICAL RELEASE
As a general rule a fire or energy release is reported as a PSE only if caused by chemical release or results in a chemical release in excess of the reporting quantities Examples include
20 An electrical fire impacts the operation of the process resulting in the release of 400 kg of toluene This event would be reported as a PSE since if the chemical release exceeds the 100 kg reporting threshold for toluene
21 An electrical fire loss of electricity or any other loss of utility occurs which may cause a plant shutdown and possibly incidental equipment damage greater than $2500 (eg damage to reactors or equipment due to inadequate shutdown) but does not create a chemical release greater than the threshold quantity or cause a fatality or serious injury This event would not be reported as a PSE since the equipment damage was not caused by a chemical process fireexplosion and there was not a chemical release greater than the threshold quantity
MARINE TRANSPORT VESSELS
22 A company operated Marine Transport Vessel has an onboard acute spill of combustible material greater than 100 kg The event is not PSE reportable since Marine Transport Vessel incidents are specifically excluded except when the vessel is connected to the refinery petrochemical or chemical manufacturing facility for the purposes of crude or product transfer
23 A third-party barge is being pushed by a tug and hits the company dock A barge compartment is breached and releases 1000 kg of diesel to the water The event is not a reportable PSE since the marine vessel was not berthed at the dock and actively involved in crude or product transfer operations
TRUCK AND RAIL
24 A company railcar derails and spills more than 1000 kg of gasoline while in transit The incident is not PSE reportable since rail incidents off company property are specifically excluded
25 A third-party trucktrailer overturns while in the Company Premises resulting in an acute spill of gasoline greater than 1000 kg The incident is not reported as a PSE reportable if the truck is no longer connected to the loadingunloading facilities However it is recommended that companies also have transportation incident metrics which would capture this event
26 A contract truck hauler is unloading caustic and the hose separates and generates an airborne aerosol andor liquid caustic spill of 2500 kg The event is a reportable PSE since the caustic TQ of 100 kg was exceeded and the truck was still connected to the loadingunloading facility immediately prior to the incident
OFFICE BUILDING
27 There is a boiler fire at the Main Office complex and direct cost damages totaled $75000 The incident is not PSE reportable since Office Building incidents are specifically excluded
MAN-MACHINE INTERFACE INCIDENTS
28 An operations technician is injured while working around the finishing equipment in a polymers plant The injury is caused by the mechanical man-machine interface with the equipment This would not be a reportable Process Safety Event because there was no loss of containment of hazardous material
MIXTURES
29 If a mixture by itself has a GHS classification you use that classification to determine the threshold If the mixture itself does not have a GHS-classification we go back to the individual components of the mixture and based on kg released per threshold group calculate a lsquoweightedrsquo contribution to the thresholds Example a release of 100 kg of a mixture in a one hour period that consists of 05 kg of a substance classified as acute toxic H300 45 kg of substance classified with H301 and 40 kg of a substance with another H-number and the remaining 55 kg of water with no GHS classification would be calculated as 051 + 4510 + 40100 = 05 + 045 + 04 = 135 is exceeding 1 and would be counted as a reportable process safety incident even though none of the individual hazardous components exceeded the threshold for the individual substance
DIRECT DAMAGE COSTS
30 Direct damage costs are considered for this threshold should be those costs directly attributed to the fire andor explosion such as the replacement value of equipment lost structures lost cost of repairs environmental cleanup emergency response andor fines Direct cost does not include indirect costs such as business opportunity losses loss of profits due to equipment outages cost of obtaining or operating temporary facilities or cost of obtaining replacement products to meet customer demand (product losses)
31 As an example a leak of flammable gas occurred in a vent line connected to a gas treatment system At the same time a failure in the process allowed air to enter in the same vent line An explosion occurred and the over pressure damaged the vent line and associated upstream equipment including a seal pot Nobody was hurt The cost for repair was about $12000 This is a PSE considering the cost to repair the equipment due to the explosion and fire
32 As an example after a PSE event a company releases 50 kg of a very special GHS Category 5 product which causes $2000 of damage to equipment The product released was a very special blend of materials and the company incurs over $50000 in materials associated with the product loss This event is not reportable as PSE since the reportable threshold for GHS Category 5 releases is 100 kgs and product losses do not count as Direct Damage Costs
NATURAL DISASTERS
33 Natural disasters can present substantial risks to chemical process operations and damage to plant equipment which may result in a loss of containment of hazardous substances Where the potential for one or more types of natural disasters is deemed relevant to plant operations process safety and operational systems shall address the applicable risk in terms of hazards and consequence analysis plant design operating procedures for loss of utilities and process shutdown and emergency planning and response
Types of natural disasters includes hurricanes and typhoons (including associated storm surge) floods tornadoes earthquakes derechos (straight line wind storms) wildfires volcanic eruptions tsunamis and avalanches
If your facility experiences a natural disaster that triggers one or more of the thresholds it should be reported as a process safety event
PRECAUTIONARY PUBLIC RESPONSE
34 A precautionary public response is a measure taken from an abundance of caution For example a company may require all workers to shelter-in-place in response to an LOPC independent of or prior to any assessment (eg wind direction distance from the LOPC etc) of the potential hazard to those worker For example a recognized community official (eg fire police civil defense emergency management) may order a community shelter-in-place evacuation or public protective measure (eg road closure) in the absence of information from a company experiencing a process safety event or lsquojust in casersquo the wind direction changes or due to the sensitive nature of the potentially affected population (eg school children the elderly)
ACTIVE WAREHOUSE
35 An active warehouse is an on-site warehouse that stores raw materials intermediates or finished products used or produced by a process From a process perspective an active warehouse is equivalent to a bulk storage tank Rather than being stored in a single large container the raw materials intermediates or finished products are stored in smaller containers (eg totes barrels pails etc)
Appendix C ndash List of RCLG Taskforce Members Luiz Shizuo Harayashiki19
Appendix D ndash Detailed Schedule of Events Appendix E ndash Optional Excel Reporting FormWhen member companies begin tracking process safety events a single form should be utilized for all member companies to make data analysis easier and to allow all members to work from the same tracking sheet The RCLG has developed an optional tracking sheet that members and associations can start with when developing their own tracking sheet
DOWNLOAD TRACKING SHEET HERE
This document consists of a contact page the survey itself and a lsquodo not editrsquo page where the drop down menu answer are stored
INTERNATIONAL
COUNCIL OF
CHEMICAL
ASSOCIATIONS
ICCA Process Safety
Event Tracking Sheetxlsx
4
敬愛的 TRCA 會員您好
謹代表 TRCA 藉此機會對 ICCA (International Council of Chemical Associations 國際化學業
協會)以及 RCLG (Responsible Care Leadership Group 責任照顧領導群)過去幾年來致於調
和製程安全指標所付出的與貢獻致上深深的謝忱
製程安全管理是化學業為關鍵重要的作製程安全指標的提報則是驗證製程安全
管理的核程過去數年來國際與國內化學業致於持續不斷的改進相關績效指
標的表現我們相信減少製程安全事件的發與是否進量測有絕對的關係因為我們無
從改進沒有進過量測的項因此藉由製程安全事件的提報將有效的協助會員公司
與國家協會分享 佳實務經驗並在這個過程中協助會員公司改善製程安全績效表現進
減少環境跡從事故事件中學習是改進製程安全管理的關鍵我們誠摯地希望藉由
製程安全指標提報能降低製程安全事件的發
TRCA 2015 年起籌組 Near Miss 試組並於當年起開始提報製程安全虛驚事件數
以做為未來全提報製程安全事件率的準備感謝試組台灣永光化學業(股)公司
台灣中油(股)公司國喬油化學(股)公司台灣科思創(股)公司奇美實業(股)公司台
橡(股)公司春油化學(股)公司春造樹脂廠(股)公司連化學業(股)公司
李榮化學業(股)公司以及台灣志氯化學(股)公司率先的努配合試為 2020 年全
提報製程安全事件指標提供了難能可貴的經驗
TRCA 為達成 ICCA 擬定 2020 年全提報的標訂於 2019 年開始試提報 2018 年數據
2018 年將陸續展開相關說明與教育訓練研討會議我們相信推 ICCA 全球調和製程安全
指標提報將能更有助於加強與改善台灣化業製程安全管理績效
讓我們起為化業更安全與環保的永續未來努吧
TRCA 責任照顧推委員會主席 Chairman Responsible Care Implementation Committee台灣志氯化學(股)公司總經理 President Taiwan Chlorine Industries Ltd
嚴堅正 Art Yen
5
背景
責任照顧倡議(Responsible Carereg initiative)發起於 1985年其目的在於展現化學工業界持續
改善績效的承諾自從責任照顧倡議開始實施以來製程安全(Process Safety)一直是責任
照顧倡議的核心基礎之一實施責任照顧 30 多年來許多地區已發展出追蹤及提報製程
安全績效的方法然而一直未能建立一套全球調和的提報系統由於一些重大製程安全
事件仍不斷發生在 2012 年國際化學工業協會(ICCA)董事會便責成責任照顧領導群
(RCLG)在 2015 年以前擬定一套全球調和的製程安全績效提報機制
2013-14 年間一個由跨國公司和 RCLG 各協會組成的專案小組正式成立該專案小組由
拜耳醫療保健公司(Bayer HealthCare AG)的衛生安全及環保總監 Peter Schmelzer 博士擔任
召集人其任務即是研擬一套全球調和的 ICCA 製程安全績效提報機制專案小組成員表
詳見附錄 C在此期間美國石油學會(API)也著手開始進行其 API RP 754 ndash領先及落後製程
安全指標標準(Leading and Lagging Process Safety Metric Standard)之修訂RP-754 被廣泛應
用於美洲地區的煉油及石化產業以追蹤製程安全績效為了推動全球採行統一的標準
RCLG 專案小組致力於將其所提出之建議案與預訂於 2016 年第一季完成修訂之 API RP 754
達到完全調和
執行摘要
經過兩年多的討論研究辯論及可行性評估製程安全調和化專案小組(PSHT)建議 ICCA
採行一套製程安全事件發生率指標採行這套指標需要 RCLG 各協會蒐集會員公司在一年
內所發生之製程安全事件次數和工作總時數(包括員工和承攬商)製程安全事件發生率即
事件數除以工作時數的比率專案小組建議向 RCLG 提報這些數據的要求將在未來三年
內分階段實施同意已具有意願和能力提報的地區立即開始提報數據同時也給予正在發
展追蹤數據能力以進行首次提報的公司和機構若干緩衝時間
判定製程相關事件是否符合製程安全事件定義的標準係以化學物質的一次阻絕設施失效
或能量釋放以致引起下列任何一個影響考量面的門檻為根據1) 安全人員健康後果2)
事故造成損失之直接成本3) 社區影響4) 化學物質洩漏量(請參見提報判定流程圖所
示)ICCA 所建議之製程安全事件定義的四個影響考量面與 RP-754Tier II 事故標準的影
響考量面是完全一樣的除了化學物質洩漏量提報門檻有所差異外其他三個影響考量面
6
的提報門檻也是一樣的為因應此一差異針對化學物質外洩量提報門檻ICCA 製程安
全事件定義將容許會員公司採用 ICCA 依據化學品全球調和制度(GHS)健康危害分級為基礎
所發展的提報標準或依據聯合國危險物品(UNDG)分類為基礎所定義之 RP-754 二級製程
安全事件(Tier II) 之提報標準專案小組相信這兩套制度之提報標準雖然有所差異但
從其所涵蓋之化學物質領域和提報事故嚴重程度看來兩者皆相當健全雖然採用這兩種
不同提報門檻所收集和提報的事件數差異相對不大但在公司方面從原料及產品使用的角
度看來兩者可能會有非常明顯的不同因此專案小組提醒會員公司勿將自己公司的
結果與採用不同化學物質洩漏量提報門檻的公司做比較無論如何根據 RCLG 的提議
會員公司可選擇化學物質洩漏門檻以向國家及地區協會進行提報如果各協會有興趣轉
換兩種不同提報方式的結果RCLG 可提供轉換表但由於轉換運算非常複雜且須取得
原始事故數據專案小組相信相互轉換的附加價值不大因此不建議協會採取此一做法
專案小組相信這項製程安全事件提報建議案可廣泛運用在化學及石化產業實施製程安
全績效提報這項提報制度將為目前尚未追蹤製程安全績效的地區協會和會員公司提
供一個指引讓他們可以體認追蹤及提報製程安全績效可以帶來的益處至於已在蒐集製
程安全數據的地區協會和會員公司此建議案將有助於他們更廣泛地與全球接軌並將
重點放在持續改善製程安全績效這些改善製程安全績效的制度仰賴的是可靠的製程安
全事件數據改善製程安全績效正是責任照顧倡議的主要目的
7
RCLG 各協會應向 RCLG 提報的數據
RCLG 各協會每年必須依照下文提供的時程透過 RCLG 關鍵績效指標(KPI)提報網站向
ICCA 提報兩個數據
1 協會所屬會員公司的總工作時數(包括員工和承攬商)
2 製程安全事件總數
ICCA 將利用上述兩個數據以製程安全事件發生率(PSER)的形式報告製程安全績效PSER
計算之常態化是以每 100 位員工每位員工一年工作 2000 小時為基準
(總事件數 總工作時數) x 200000 = PSER
建議之提報時程
針對提報製程安全事件發生率專案小組建議一種分階段導入的方法此一時程可讓更多
已具經驗的協會及公司立即實施提報同時容許其他協會及公司從 2019 年起開始提報
RCLG 各協會必須透過 RCLG KPI 指標提報系統(httpkpiresponsiblecareeu)每年向 ICCA
提報兩個製程安全事件發生率數據如果你不知道你所屬協會的使用者名稱和密碼請聯
絡 RCLG
建議 RCLG 協會提報製程安全事件發生率的時程如下
2015 年 4 月 RCLG 考量專案小組建議案
2015 年 6 月 ICCA 理事會考量 RCLG 的最終建議
2015 年 7 月 RCLG 頒布首份詳細的提報指引供協會及會員公司遵
循
2016 年 2 月 RCLG 提報 RCLG 更新及強化提報指引並針對自願參加的協會
開始實施製程安全試行提報計畫RCLG 於 2016 年 6 月
頒布最終指引
2017 年 RCLG 各協會開始向會員公司蒐集數據
2018-2019 年 RCLG 提報 RCLG 各協會可選擇地開始提報製程安全數據
2020 年提報 RCLG 於 KPI 提報計畫中將製程安全納入為一項強制性
指標
參見附錄 D ndash 詳細活動時程
8
ICCA 製程安全事件判定標準流程圖
事故是否發生在廠內之
生產配銷儲存公
用或試驗工廠
是 是
是
否
否 是否造成須通報工傷
或
廠內廠外人員住院治
療
損壞是否對
公司造成
ge $2500 美
元的直接成
本損失
官方是否宣告就地
避難或疏散或廠
外預防性就地避難
或疏散
否
是
否
是屬於須通報製程安全事件
是
否
是
是
開始
否不符合製程安全事件認定
標準
是否超過 ICCA 或 API
754 Tier II 化學物質洩
漏恕限值
否 發生化學物質外洩火
災或爆炸是否起因於
或發生在化學製程單元
是否直接涉及某種化學物
質或化學製程
否
9
須提報製程安全事件之重要標準
總工作時數
RCLG 各協會應以加總的單一數字提報其所屬會員公司的員工和承攬商總工作時數為達
成本指引之目的各協會應參考其本地和地區對員工及承攬商之定義提報總時數之目標
應納入涉及化學製造之所有個人然而參與主要興建工程專案之人員則不納入計算譬
如為新建或擴建既有製程設施之設計工程和施工而成立之一次性專案組織的大規模投資
案會員公司提報總工作時數時應與人事部門統計之員工工時一致如此各公司便能
取得相同的職業與製程安全數據員工工時應包括所有化學製造作業的工時而非僅計算
發生製程安全事故之廠區的工時
製程安全事件
為執行 ICCA 提報目的製程安全事件之定義條件如下(必須同時符合 ABCD 四個條
件)
A 直接涉及某種化學物質或化學製程且
B 事故發生在廠內之生產配銷儲存公用或試驗工廠且
C 製程單元發生物質洩漏或能量釋放(如火災爆炸和內爆)且
D 已達到以下提報門檻之一
1 安全 工傷
導致記錄性的傷害(OSHA)損失工時或死亡或廠內外任何人員因此
而須住院治療或
2 直接損失成本
火災爆炸或為避免補救環境損害之必要清理作業導致$2500 美元
以上的直接成本支出或
3 就地避難 疏散
官方宣告就地避難(廠內或廠外)或
官方宣告疏散(廠內或廠外)或
廠外預防性就地避難或疏散或
4 洩漏恕限值
物質洩漏程度已達表 1 所列之任一 GHS 恕限值(洩漏量以單位小時計
量)
此外各公司亦可選擇採用 API RP-754 標準中所列之洩漏恕限值(表 2)請注意如欲查
看 API RP-754 標準可登入以下網站購買及下載httpwwwapiorgoil-and-natural-
gashealth-and-safetyprocess-safetyprocess-safety-standards
10
製程安全事件判定準則
A 涉及化學品
直接涉及某種化學物質或化學製程
製程安全事件或事故必須直接涉及化學物質或化學製程就此而言ldquo製程rdquo一詞泛指包含
石化生產所需要之設備和技術包括反應器儲槽管線鍋爐冷卻水塔和冷凍系
統helliphellip等未直接涉及化學物質或製程的事件無須提報譬如辦公大樓起火(即使該辦公大
樓位在廠區內亦然)
B 地點
事故發生在廠內之生產配銷儲存公用或試驗工廠
發生在廠內之生產配銷儲存(包括活動儲存區如倉庫 ndash 參見ldquo常見問題集rdquo)公用及
試驗工廠凡符合提報指標及定義的事故包括在廠區管理下之槽罐區輔助支援區(如
鍋爐室和廢水處理廠)和配銷管線所有須提報之事件應由負責該事故地點運作的公司
負提報之責此一規定亦適用於發生在承攬商作業區域內的事故在代工作業和多方共同
作業廠區負責運作該發生事故單位的公司應記錄事故始末並將之納入其提報中
C 物質洩漏
製程單元發生物質外洩或能量釋放(如火災爆炸和內爆)
物質外洩 ndash 製程任何物質發生非預期或無法控制的洩漏或釋放包括非毒性及不可燃物質
(如蒸汽熱水氮氣壓縮二氧化碳或壓縮空氣)且達到本文件所列四類提報門檻之一
項或以上之後果
在防治系統(如洗滌塔或廢氣燃燒塔)正常運作狀況下只要沒有任何洩漏或排放量超過
法定許可值即使排放到廢氣燃燒塔或滌氣塔仍被視為處於一次阻絕設施內然若排
放到二次阻絕設施(如廢水處理或防溢堤)將被視為製程安全事件因為物質已離開主要製
程系統
11
D 提報門檻
須提報製程安全事件必須達到以下提報門檻之一
1 安全 工傷
導致記錄性傷害(OSHA)損失工時或死亡或廠內外任何人員因此而須住院治療
記錄性傷害是指與工作有關所造成的傷害導致死亡暫時全失能工作受限制或需調整職
務較輕傷害嚴重之醫療處理失去意識或經醫師或其他合格醫療專業人員診斷為重大
傷害
損失工時傷害和死亡是指因製程相關的一次阻絕設施失效火災或爆炸導致以下任何一種
結果
員工(損失工時或死亡)
承攬商及再承攬商 (損失工時或死亡)
第三方(如來賓訪客快遞員)(受傷疾病導致住院治療或死亡)
住院治療是指醫院或其他具有住院病患保健設施的醫療單位正式接受病患住院提供病患
食宿及醫療護理且病患接受治療至少留置至隔日僅在醫院急診室治療或過夜處理不屬
於ldquo住院治療rdquo的定義範圍
須提報之工傷或死亡事件例如在清理作業期間因蒸汽洩漏造成人員燒燙傷壓力測試期間
帽蓋因受壓脫落造成人員身體傷害或取樣作業時因物質外濺造成人員化學灼傷無須提
報之工傷或死亡事件例如在執行維修作業時從高處的工作台墜落實驗室或辦公大樓火災
造成人員燒燙傷或挖掘工程塌陷造成人員傷害這些案例均與因製程造成的能量釋放或
物質洩漏無直接關聯
2 直接損失成本
火災爆炸或為避免補救環境損害之必要清理作業導致$2500美元以上的直接成本支出
此提報門檻所考慮的成本應為可直接歸因於火災或爆炸的成本譬如設備及結構損壞的重
置成本修理成本環境清理(廠內及廠外)支出緊急應變和罰款直接成本不包括間接
成本譬如業務機會損失設備停機造成之利潤損失取得或運轉臨時設施之成本或為
滿足顧客需求取得替代產品的成本(產品損失)
12
3 就地避難 疏散
官方宣告就地避難或疏散(廠內或廠外)或廠外預防性就地避難或疏散
就提報目的而言官方宣告就地避難或疏散(廠內或廠外)或廠外預防性就地避難或疏散
即達到此提報門檻
官方宣告 ndash 由地方權責機關(如消防警察民防緊急應變管理部門)或經授權的代表(如
派駐公司官員)下達的社區行動(如就地避難或疏散)宣告
預防性宣告 ndash 預防性公眾應變是基於謹慎的態度所採取的一種措施權責地方主管機關或經
授權的代表經合理判斷認定為維護公眾健康及安全發布必須採取就地避難或疏散之預
防性措施
就地避難 ndash 利用結構體及其內部空氣以暫時讓人員與室外危害性氣體隔離
疏散 ndash 基於安全或防護理由讓人員離開某處所的行動或過程
4 洩漏恕限值
超過表 1 中所列 GHS 恕限值或表 2 中所列 API 754 標準 Tier II 製程安全洩漏恕限值之一的
急性洩漏事件(洩漏量以單位小時計量)
如ldquo執行摘要rdquo所述ICCA 製程安全事件之定義容許採用 ICCA 依據化學品全球調和制度
(GHS)健康危害分級為基礎所發展的提報標準或依據聯合國危險物品(UNDG)分類為基礎
所定義之 RP-754 二級製程安全事件(Tier II) 之提報標準GHS 恕限值詳見表 1各會員公司
可自行決定選擇哪一個表中的提報恕限值並在全球採用單一制度
ldquo急性rdquo洩漏 ndash易燃性可燃性或毒性化學物質從一次阻絕設施(如容器或管線)洩漏其
任一單位小時之洩漏量超過化學物質洩漏恕限量分述於表 1 中的 GHS 分類和表 2 中的
API 754 標準 Tier II 製程安全洩漏恕限值
洩壓裝置前述所定義之ldquo急性rdquo洩漏包括洩漏或排放至妥善設計且運作中的洩壓裝置若
洩漏或排放量達到表 1 中所列 GHS 恕限值或表 2 中所列 API 754 標準 Tier II 製程安全洩漏
恕限值且導致下列四種後果之任一項或以上之後果
1 二相排放或夾帶液體的排放液滴沉降至地面造成污染
2 排放至具潛在危險性的地點
3 廠內就地避難或疏散不包括預防性廠內就地避難或疏散
4 啟動公眾保護措施(如道路封閉)包括預防性公眾保護措施
13
洩漏或排放至妥善設計且運作中的洩壓裝置(如廢氣燃燒塔洗滌塔等)若其情況未達前
述四項標準中任何一項則不必提報
欲查看 API RP-754 標準可登入以下網站下載此標準httpwwwapiorgenvironment-
health-and-safetyprocess-safetyprocess-safety-standardsstandard-rp-754
一小時法則
為便於衡量此項指標提報與否洩漏恕限值是以物質在任一小時內之洩漏量為標準若任
一小時或更短時間內物質洩漏量達到或超過須提報恕限值該事故便屬於須提報的製程安
全事件急性洩漏事故通常不會超過一小時若無法確定洩漏持續時間則應假設其為一
小時
一次阻絕設施ndash 用來作為主要容器或用於運送或輸送物質之槽罐船隻管線軌道車
或設備主要容器在設計上可能包含二次阻絕設施系統以抑制及控制洩漏二次阻絕設
施系統包括(但不限於)儲槽防溢堤製程設備周遭的圍堵設施油水分離的排水收集系統
雙層儲槽的外壁等
嚴重程度表 ndash 嚴重程度加權可額外提供有關製程安全事件的有用資訊有助於帶動改善績
效附錄 A 為 RCLG 建議之製程安全事件嚴重程度加權計算方法根據附錄 A 的方法便
可藉由加總與各個後果類別關聯的分數計算出各製程安全事件的嚴重程度加權值ICCA
強烈建議採用嚴重程度加權制度因為此制度有助於提升溝通績效的能力也比較容易讓
利害關係人了解製程安全事件並且此嚴重程度加權值與其他製程安全績效指標提報方
式是不具相互比較性的
14
表 1 ndash GHS 分類表
物理性危害(GHS 2x)
洩漏恕限值(1 小時內)
STOTSpecific target organ toxicity(特定標的器官系統毒性物質)
15
表 2 ndash API RP 754 Tier II 分類表
洩漏恕限類別
物質危害性分類 acdef 恕限值
(戶外洩漏) 恕限值
(戶內b洩漏)
T2-1 TIH A 區物質 ge 05 kg (11 lb) ge 025 kg (055
lb)
T2-2 TIH B 區物質 ge 25 kg (55 lb) ge 125 kg (275
lb)
T2-3 TIH C 區物質 ge 10 kg (22 lb) ge 5 kg (11 lb)
T2-4 TIH D 區物質 ge 20 kg (44 lb) ge 10 kg (22 lb)
T2-5
易燃氣體 或 正常沸點 ≦ 35 (95 degF)閃火點lt23 (73 degF)的液體 或 其他包裝組別 I 類的物質 (酸鹼除外)
ge 50 kg (110 lb) ge 25 kg (55 lb)
T2-6
正常沸點 gt 35 degC (95 degF)閃火點 lt 23 degC (73degF)的液體 或 其他包裝組別 II 類的物質 (酸鹼除外)
ge 100 kg (220 lb) 或
ge 07 bbl
ge 50 kg (110 lb) 或
ge 035 bbl
T2-7
閃火點 gt 23 degC (73 degF)和 lt 60 degC (140 degF)的液體 或 閃火點 gt 60 degC (140 degF)的液體在閃火點或高於閃火點的溫度下洩漏 或 強酸鹼 (定義參見 RP 754 文件草案) 或 UNDG第2類第22部分 (不可燃無毒氣體)空氣除外 或 其他包裝組別 III 類的物質
ge 200 kg (440 lb) 或
ge 14 bbl
ge 100 kg (220 lb) 或
ge 07 bbl
T2-8
閃火點 gt 60 degC (140 degF) 和 lt 93 degC (200 degF)的液體在低於閃火點的溫度下洩漏 或 中度酸鹼
ge 1000 kg
(2200 lb) 或
ge 7 bbl
ge 500 kg
(1100 lb) 或
ge 35 bbl
TIH吸入性毒性危害物(Toxic Inhalation Hazard)
16
一般認為以公斤和磅或以磅和桶為單位的恕限值不盡等同各公司應該選用其中一組計量單位並在
所有紀錄文件中一體適用
在判定一種物質之洩漏恕限類別時首先應從物質之含吸入性毒性(TIH Zone)可燃性(閃火點和沸點)
或腐蝕性(強酸或鹼 vs中度酸或鹼)等特性來判別只有當物質的危險度無法利用上述簡單的特性來判別
時(如遇水反應劇烈)才採用UNDGL包裝組別
a 許多物質具有一種以上危險性正確的危險區(Hazard Zone)或包裝組別(Packing Group)歸屬應遵循DOT
49 CFR 1732a [14]或聯合國危險物品運輸建議書(UNRTDG)第2部分[12]的規定參見附錄F
b 具有四面完整牆(從地板到天花板)地板和屋頂的結構物
c 對於未列於UNDG的溶液無水成分將用TIH區或包裝組別分類溶液之恕限值將根據乾基重量之恕限
值反算
d 對於未知UNDG分類的混合物可計算每種成分在恕限值洩漏中的分量如果各種成分之分量的總和
等於或大於100即表示混合物超過門檻值若混合物有明顯且獨立的毒性及可燃性結果則可分
別計算毒性及可燃性危險度參見附錄EPSE實例amp問題 49ndash53
e 閃火點 gt 60 degC (140 degF) 和 lt 93 degC (200 degF)的液體在低於閃火點的溫度下洩漏無論洩漏量多寡其
一次阻絕設施失效(LOPC)均不屬於Tier 1製程安全事件(PSE)
f 中度酸鹼的一次阻絕設施失效無論洩漏量多寡均不屬於Tier 1製程安全事件
17 (K = 1000 MM = 1000000) (在環境影響類別方面若缺乏既有定義協會和會員公司應議定輸入標準)
附錄 A ndash 嚴重程度表鼓勵所有協會均採用嚴重程度加權制度
事件事故類別
嚴重程度等級
安全人體健康 火災或爆炸導致直接
成本 任 1 小時內物質洩
漏量 社區影響 環境影響[廠外]
4 級
1 分
對員工承攬商或再承攬商造成較輕傷害嚴重之傷害 (符合本地法規)
造成以下直接損失成本
美金$25 K ~ $25 K
洩漏量介於
1x le TQ lt 40x
官方宣告就地避難或疏散 (廠內或廠外) 預防性廠外就地避難或疏散
le 3 小時
重大環境整治成本
$25 K ~ $25 K
3 級
3 分
對員工承攬商或再承攬商造成之需要多日缺勤的傷害
對第三方造成之需要初步急救以外治療的傷害 (符合本地法規)
造成以下直接損失成本
$25 K ~ $250 K
洩漏量介於
40x le TQ lt 160x
官方宣告就地避難或疏散 (廠內或廠外)
預防性廠外就地避難或疏散
3 ~ 12 小時
重大環境整治成本
$25 K ~ $250 K
2 級
9 分
對員工承攬商或再承攬商造成 1 人死亡
對第三方造成 1 人住院治療
(符合本地法規)
造成以下直接損失成本
$250 K ~ $25 MM
洩漏量介於
160x le TQ lt 640x
官方宣告就地避難或疏散 (廠內或廠外)
預防性廠外就地避難或疏散
12 ~ 24 小時
重大環境整治成本
$250 K ~ $25 MM
1 級
27 分
對員工承攬商或再承攬商造成多人死亡
對第三方造成多人住院治療
對第三方造成 1 人死亡 (符合本地法規)
造成以下直接損失成本
ge $25 MM
洩漏量
ge 640x TQ
官方宣告就地避難或疏散 (廠內或廠外)
預防性廠外就地避難或疏散
ge 24 小時
重大環境整治成本
ge $25 MM
18 (K = 1000 MM = 1000000) (在環境影響類別方面若缺乏既有定義協會和會員公司應議定輸入標準)
嚴重程度表(附錄 A)細節說明
附錄 A 之設計目的僅適用於採用 GHS 分類制度(表 1)者如果你的公司係採用 API RP 754Tier II 製程安全指標提報恕限值表(表 2)請使用
API RP 754 製程安全嚴重程度表必須提醒的是依 API RP 754 的標準其嚴重程度表僅適用於一級(Tier I)事故去比較採用不同的嚴重度
表所評估出來的相對嚴重度並無統計上的意義
急性的環境成本 ndash 因製程安全事件造成廠外環境影響所導致之短期清理及物質處置的成本各會員公司可選擇將廠外環境影響相關成本另
外區分一個嚴重程度類別
比率調整指標
利用上述嚴重程度表可產生一系列以事件率為基礎的指標包括
製程安全總事件率 (PSTIR) 總事件次數 x 200000
總工作時數
製程安全事件嚴重程度率(PSESR) (即製程安全事件嚴重程度加權計算公式)
PSESR = 所有事件之總嚴重程度分數總合 x 200000
總工作時數
在計算此一比率時各 4 級事件被分配 1 分各 3 級事件被分配 3 分各 2 級事件被分配 9 分各 1 級事件被分配 27 分理論上每個
製程安全事件至少可分配到 1 分(亦即事件僅在一個類別符合第 4 級事件屬性)至多可分配到 135 分(亦即事件在所有五個類別中均符
合第 1 級事件屬性)
ldquoXrdquo級別製程安全事件率 嚴重度級別ldquoXrdquo之製程安全事件總數 x 200000
員工承攬商amp再承攬商總工作時數
X可以是嚴重度級別 432 或 1 級製程安全事件之總數事件之嚴重度等級是選用五類後果類別中之最嚴重等級
標準化 ndash 在某些協會和會員公司中製程安全事件是採 lsquo每 100 名rsquo員工每名員工每年平均工作時數為 2000 小時為基礎予以標準化因
此在lsquo每 100rsquo名rsquo員工的標準基礎上事件被乘以 200000 工作時數也有些其他協會和會員公司將標準化基礎設定為lsquo每 500 名rsquo員工
因此事件被乘以 1000000 工作時數協會和會員公司應就標準化基礎進行討論共同做成選項結論上述的公式設定為lsquo每 100 名rsquo員工
基礎
19
附錄 B ndash 常見問題集
適用性
我們建議會員公司記錄和提報在其所擁有或運作的工廠內發生的製程安全事件惟以下情況不須提報製
程安全事件
1 源自於公司廠區以外的製程安全事件
2 海上運輸船事故惟船隻為了輸送半成品或產品之目的已經與公司的設施相連接時發生的
事故仍須提報
3 卡車或軌道車事故惟卡車或軌道車為了輸送半成品或產品之目的已經與公司的設施相連
接時發生的事故仍須提報
4 許可證或法規容許之例行排放
5 不會造成製程安全危害的地下污染請注意若洩漏至地下導致地上發生須提報製程安全事
件如釋放出毒性蒸汽或致使易燃液體蓄積成池則不適用本排除條件
6 辦公建築事故(如辦公室暖氣設備爆炸火災外溢洩漏人員受傷或疾病等)
7 與疏散或一次阻絕設施失效無直接關聯之人員安全ldquo滑倒絆倒跌倒rdquo事故
8 沒有與製程相連接之輔助設備的一次阻絕設施(如小樣品瓶)失效事故
9 計劃中和在控制下的物質排放至設計用來收集或排放系統中(請注意物質從一次阻絕設施
在非計劃或非受控制情況下排放至收集或排放系統中則不適用本排除條件)
10 在製程區域外部或保養廠內執行之機械作業
說明與實例 ndash 以 GHS 表 1 為基礎
以下說明和實例有助於在評估須提報製程安全事件(PSE)時釐清可能存在的不確定部分
公司廠區
1 一輛第三方的卡車在公司廠區內卸載易燃產品時發生洩漏進而引起火災造成公司財物損失
$7000 美元(直接成本)雖然該卡車是ldquo由他人操作rdquo但其作業與製程相連接若公司的直接成
本財物損失達到或超過$2500 美元或已達到或超過其他 PSE 提報門檻(如1 人死亡)此事故即
屬於須提報的製程安全事件
2 與前例1 類似的例子載著易燃產品的卡車在廠外運輸途中翻覆引發火災並造成卡車毀損
該事故不屬於須提報的製程安全事件因為當時卡車並未與製程相連接
20
阻絕設施失效
3 儲槽液位計故障造成裝有ldquo易燃液體rdquo產品的儲槽外溢約 700 公斤的液體流入儲槽的防溢堤內
此事故屬於須提報的製程安全事件因為其ldquo急性rdquo洩漏量超過 100 公斤即使是阻絕在二次阻絕
設施防溢堤中亦然
4 一名從事維修工作的承攬商在開啟一個製程阻閥時被噴起的硫酸濺到造成嚴重灼傷和損失工
時的工傷此事故屬於須提報的製程安全事件因為它是涉及物質和一次阻絕設施失效的意外事
件對於因洩漏造成死亡和損工的工傷或疾病事故沒有洩漏恕限值
5 一名作業員開啟品管取樣點進行日常取樣作業時手部被一個破碎的玻璃瓶嚴重割破需要進行
縫合治療縫針造成第二天無法上班該事故不屬於須提報的製程安全事件因為它與一次阻絕
設施失效無關
ldquo急性rdquo洩漏
6 一名作業員在進行天然氣流量高於預期值之異常排除時發現天然氣管線上的一個安全閥門未適
當歸位因此天然氣經由氣液分離桶排放至排氣煙囪經進一步檢查作業員判斷在過去 6 個
月間總共有 100000 公斤天然氣以穩定的速率排放至大氣該事故不屬於須提報的製程安全事
件因為其洩漏速率(每小時約 10 公斤)不算ldquo急性rdquo洩漏(未超過易燃蒸汽每小時 100 公斤的恕限
值)
廢氣燃燒塔amp排放控制裝置 (如洗滌塔)
7 若化學物質被導引至廢氣燃燒塔或排放控制裝置(如洗滌塔)只要該廢氣燃燒塔或控制裝置運作在
正常設計範圍內便不屬於須提報的製程安全事件
8 若廢氣流速超過洗滌塔的設計負荷以致未經吸收的化學物質排出超過恕限值該事故屬於須提報
的製程安全事件(如本文註釋所述)
註釋自取得許可或妥善管理的裝置-包括釋壓裝置發生不預期的排放若 1 小時內洩漏量達到或
超過表 1 或表 2 所列的洩漏恕限值且導致下列四種後果之任一項或以上之後果該事故便屬於
須提報的製程安全事件
o 二相排放或夾帶液體的排放液滴沉降至地面造成污染
o 排放至具潛在危險性的地點)
o 廠內就地避難或疏散不包括預防性廠內就地避難或疏散
o 啟動公眾保護措施(如道路封閉)包括預防性公眾保護措施
21
安全洩壓裝置 系統
9 製程單元發生異常安全閥開啟將洩漏物質釋放到排氣口此釋壓排放裝置是依相關要求設計
的且氣體釋到大氣中並未造成不良後果這不是一個須提報的製程安全事件因為安全閥高
壓破裂盤以及類似的安全裝置是依據 API 521 或者同等的標準設計的且此排放並未造成 (1)
夾帶液體並導致須提報的製程安全事件的後果(譬如損失工時意外死亡火災或爆炸造成$2500
美元或以上的直接成本損失液體或毒性氣體洩漏量達到或超過恕限值(2) 啟動廠內或廠外就地
避難應變或(3)啟動公眾保護措施
10 製程單元發生異常安全閥並未開啟造成設備超壓易燃性氣體從一個法蘭處ldquo急性rdquo漏出來
洩露量超過 100 公斤(一小時內)的恕限值該事故屬於須提報的製程安全事件因為從法蘭處外
漏屬於製程安全事件應提報事項
損工事故
11 一名作業員走路時不慎滑倒造成損失工時之工傷滑倒原因為天氣狀況rdquo長期rdquo油垢的地面和
易滑鞋具該事故不屬於須提報的製程安全事件因為人員安全ldquo滑倒絆倒跌倒rdquo事故若非與
一次阻絕設施失效直接關聯的疏散或應變造成則不屬於須提報的製程安全事件
12 與前例相同的事件惟這次作業員跌倒是因為少量易燃液體外漏(如 1 小時內少於 10 公斤)在採取
相關應變措施時發生該事故屬於須提報的製程安全事件因為作業員係為了應變一次阻絕設施
失效的事故而跌倒若一次阻絕設施失效發生在公司廠區且造成失時工傷或死亡後果該事故
便屬於須提報的製程安全事件對於因洩漏造成死亡和損失工時之工傷事故沒有洩漏量門檻
13 與前例相同的事件惟這次作業員跌倒是在事件結束數小時之後該事故不屬於須提報的製程安
全事件在提報要件中所用的ldquo疏散rdquo和ldquo應變rdquo等術語指的是一次阻絕設施失效和相關緊急應變
活動正在持續中事件結束後滑倒絆倒跌倒(如ldquo事後rdquo清理和補救)不屬於須提報製程安全事件
14 工人在因附近設備一次阻絕設施失效在疏散過程中一名鷹架搭建工人從鷹架梯上跌落造成損
失工時之工傷該事故屬於須提報的製程安全事件
15 一名作業員行經一個設計不良的蒸汽卻水器時被外洩的蒸汽燙傷腳踝造成損失工時之工傷
該事故屬於須提報的製程安全事件因為雖然一次阻絕設施失效洩漏出的是蒸汽(而非碳氫化合物
或化學物質)但損失工時之工傷是由於洩漏物質的物理狀態所導致的
16 一個密閉空間依照計畫以氮氣吹清一名承攬商繞過安全管制進入該密閉空間因而死亡該事
故屬於須提報的死亡事件但不屬於須提報的製程安全事件因為其中不涉及非計劃或失控的一
次阻絕設施失效
17 情況同上惟這次氮氣是非刻意洩漏進入該局限空間該事故屬於須提報的製程安全事件(同時也
是一起死亡事件)因為該名承攬商的死亡與非計劃的一次阻絕設施失效有關
22
18 一名作業員因硫化氫(H2S)警報在進行應變處理時昏倒若警報確實是因非計劃或失控的 H2S 一次
阻絕設施失效的外洩事件該事故便屬於須提報的製程安全事件若警報是一個假警報則該事
故便不屬於須提報的製程安全事件因為沒有真正的化學品洩漏發生
管線
19 一條管線破漏1 小時內洩漏 2000 磅(900 公斤)易燃蒸氣到地面但洩漏位置在廠區內很偏僻的
地點該事故仍屬於須提報的製程安全事件因為ldquo偏僻rdquo不是提報與否的考量因素
與化學物質外洩無關之火災或能量釋放事故
一般通則而言唯有當火災或能量釋放事故是因化學物質洩漏所造成或其發生導致化學物質洩漏
超過提報恕限值這些事故才屬於須提報的製程安全事件實例包括
20 一場電氣火災影響製程操作導致甲苯洩漏 400 公斤該事故屬於須提報的製程安全事件因為
化學物質洩漏已超過甲苯的 100 公斤提報恕限值
21 發生電氣火災停電或任何公用資源供應中斷可能造成工廠停工及可能引起設備損失超過
$2500 美元(如因非正常停工導致反應器或設備損壞)但並未造成超過恕限值的化學物質洩漏
亦未造成死亡或嚴重工傷該事故不屬於須提報的製程安全事件因為設備損壞並非化學製程火
災爆炸造成且化學物質洩漏並未超過恕限值
海上運輸船
22 一艘由公司營運的海上運輸船在船上發生ldquo急性rdquo易燃物質外洩洩漏量超過 100 公斤該事故不
屬於須提報的製程安全事件因為除非海上運輸船是為了輸送半成品或產品而與煉油石化或化
學製造廠的設施相連接否則其洩漏事故便不被視為製程安全事件
23 一艘第三方駁船由一艘拖船推向碼頭結果撞上公司的碼頭駁船的一個船艙破裂且造成
1000 公斤柴油洩漏到海中該事故不屬於須提報的製程安全事件因為駁船當時並非停泊在碼
頭內且其作業並非在進行半成品或產品之輸送
卡車與軌道車
24 一輛公司的軌道車在運輸途中出軌造成超過 1000 公斤汽油洩漏該事故不屬於須提報的製程
安全事件因為在公司廠區外發生的軌道車事故不被視為與製程安全有關
23
25 一輛第三方卡車拖車在公司廠區內翻覆造成ldquo急性rdquo汽油洩漏超過 1000 公斤這事故不屬於須
提報的製程安全事件因為卡車拖車當時已不再與裝卸設備連接然而我們建議會員公司另
行訂定運輸安全事故指標將這類事故記錄下來
26 一位合約卡車作業者正在卸載液鹼時發生軟管脫落造成空氣中氣霧和或液鹼液洩漏 2500 公
斤該事故屬於須提報的製程安全事件因為洩漏量已超過液鹼的 100 公斤恕限值且事故發生
前卡車仍與裝卸設備相連接著
辦公建築
27 綜合辦公大樓發生鍋爐火災造成總計$75000 美元的直接成本損失該事故不屬於須提報的製
程安全事件因為辦公大樓事故不被視為與製程安全有關
人機介面事故
28 一名操作技術員在聚合物工廠的終端設備旁作業時受傷這傷害是因機械的人機介面的設備而
造成該事故不屬於須提報的製程安全事件因為技術員受傷並非因危險物質一次阻絕設施失效
而造成的
混合物
29 若混合物本身有 GHS 分類可利用其分類確定恕限值若混合物本身沒有 GHS 分類則可計算混
合物中每個單一組成分之洩漏量(公斤)相對於個別成分恕限值之比值作為其對混合物恕限值之
lsquo加權rsquo貢獻譬如若混合物在 1小時內的洩漏量為 100公斤其中包含 05公斤分類為劇毒 H300
的物質45 公斤分類為 H301 的物質40 公斤另一種分類為 H 開頭的物質其餘 55 公斤則為沒
有 GHS 分類的水分此混合物之計算式為051 + 4510 + 40100 = 05 + 045 + 04 = 135超過
1因此該事故被視為須提報的製程安全事件雖然混合物個別成分之洩漏量均未超過各該物質
本身的恕限值
直接損失成本
30 此一門檻所考慮的成本應為可直接歸因於火災或爆炸的成本譬如設備及結構損壞的重置成本
修理成本環境清理支出緊急應變和罰款直接成本不包括間接成本譬如業務機會損失設
備停機造成之利潤損失取得或運轉臨時設施之成本或為滿足顧客需求取得替代產品的成本
(產品損失)
24
31 範例連接到氣體處理系統的排放管發生易燃氣體外漏同時製程出現問題導致空氣進入同
一條排放管結果發生爆炸過高的壓力損壞了排放管及其相關上游設備包括一個密封罐並
未造成人員受傷修理成本約$12000 美元該事故屬於須提報的製程安全事件因為爆炸及火
災導致設備修理成本超過門檻
32 範例一次製程安全事件後公司又發生一種非常特殊的 GHS 第 5 類產品洩漏 50 公斤造成
$2000 美元的設備損失洩漏的產品是一種非常特別的混合物公司須負擔超過$50000 美元因
產品耗損而產生之材料成本該事故不屬於須提報的製程安全事件因為 GHS 第 5 類產品洩漏的
提報門檻為 100 公斤且產品耗損不被計入直接損失成本
天然災害
33 天然災害可能對化學製程作業構成重大風險且對製程設備造成損壞導致危害物質一次阻絕設
施失效當一種或多種天然災害被認為可能對工廠作業造成影響時製程安全和作業系統應從危
害及後果分析工廠機器設備設計公用設施失效及製程停工之操作程序緊急應變計畫及應變
措施等方面界定潛在風險進行防範
天然災害類型包括颶風及颱風(包括伴隨而來的風暴潮)水災龍捲風地震超強對流風暴(直
線風暴)野火火山爆發海嘯和山崩
若公司廠房設施遭遇天然災害且其後果觸發一種或以上提報門檻該事故便屬於須提報製程安
全事件
預防性公眾應變
34 預防性公眾應變是基於謹慎的態度所採取的一種措施譬如當發生一次阻絕設施失效時公司
可能在尚未進行任何評估(如方向與洩漏點的距離等等)前便要求全體工人就地避難又
如地方權責官員(如消防警察民防緊急應變管理部門)在獲報一家公司發生製程安全事件
後為防lsquo萬一rsquo風向改變或基於可能受到波及的人口敏感族群(如學童或老年人)可能在尚未接
獲明確資訊前便下令社區就地避難或疏散或採取公眾保護措施(如道路封閉)
製程附屬倉庫
35 製程附屬倉庫指的是位於廠內用於儲存將投入於生產製程或產自於製程之原料半成品或成品的
倉庫從製程的觀點看來製程附屬倉庫相當於一個大型儲槽但這些原料半成品或成品並不
是儲存在一的大型容器中而是裝在較小的容器裡(如太空包大桶桶罐等)
25
Appendix C ndash List of RCLG Taskforce Members
Name Affiliation
Peter Schmelzer Bayer CEFIC - Chairman
Americo Diniz Carvalho Neto Braskem
Bradford Johnson American Chemistry Council
David Cummings DuPont
Debra Phillips American Chemistry Council
Hans Schwarz BASF
Kathryn Walton Plastics and Chemicals Industries Association
Kazuyuki Akita Japanese Chemical Industry Association
Kelly Keim ExxonMobil Chemical Company API Representative
Kenan Stevick Dow
Kiyokazu Murata Japanese Chemical Industry Association
Larry Bowler SABIC
Lorna Young Chemical Industry Association of Canada
Louisa Nara Center for Chemical Process Safety
Luiz Shizuo Harayashiki Associaccedilatildeo Brasileira da Induacutestria Quiacutemica
Masatoshi Kumamoto Japanese Chemical Industry Association
Milton Lacerda Petrobras
Phil Scott Chemical Industries Association
Piet Knijff DSM European Process Safety Centre
Scott Donaldson and Eamon Chandler
Shell
Scott Wallace Olin Corporation
Shakeel Kadri Air Products and Chemicals Inc
26
附錄 D ndash 詳細活動時程表
2016 年 2017 年 2018 年 2019 年 2020 年
2 ndash 4 月
RCLG PS 先導計畫
5 月 ndash
針對準則進行調整釐清
6 月 向 RCLG 和 ICCA 董事會報
告先導計畫執行結果
7 ndash 12 月 RCLG 協會考量準
則並為其會員公司發展提報機制
如有需要RCLG可向 ICCA 申請能
力建立基金為會員公司舉辦製程安
全研習會
1 ndash 12 月
RCLG 協會開始向其會員公司蒐集製程安全數據
1 ndash 12 月
如有需要RCLG 各協會運用 RCLG 的基金及專
家舉辦製程安全及績效提報研習會
1 ndash 2 月
擁有數據的協會開始向RCLG 提報製程安全事件
(2017 年數據)
4 月 RCLG 檢討第一個提報循
環的結果挑戰及原始數據(內部)
6 月 RCLG 向 ICCA 董事會呈報
原始數據
7 ndash 12 月 必要時更新及調整準
則
如有需要RCLG 各協會運用 RCLG 的基金及專
家舉辦製程安全及績效提報研習會
1 ndash 2 月
擁有數據的協會開始向RCLG 提報製程安全事件
(2018 年數據)
4 月 RCLG 檢討第二個提報循
環的結果挑戰及原始數據(內部)
6 月 RCLG 向 ICCA 董事會呈報
原始數據
7 ndash 12 月 必要時更新及調整準
則
如有需要RCLG 協會運用 RCLG 的基金及專家
舉辦製程安全及績效提報研習會
1 ndash 2 月
所有協會開始向 RCLG 提報製程安全事件
製程安全事件提報成為
RCLG KPI 衡量指標建議基本集的一部分(2019 年數
據)
4 月 RCLG 檢討第二個提報循
環的結果挑戰及原始數據(內部考量外部提
報)
6 月 RCLG 向 ICCA 董事會呈報
原始數據
27
附錄 E ndash 選擇性 Excel 追蹤表
當會員公司開始追蹤製程安全事件時所有會員公司應採用單一表格以簡化數據分析同時讓所有公司均使用相同的追蹤表RCLG 設
計了一份選擇性追蹤表可供會員公司和協會先行利用之後他們可設計自己的追蹤表
在這裡下載追蹤表
ICCA Process Safety Event Tracking Sheetxlsx
本文件包含三個分頁分別是ldquo聯絡資料rdquoldquo調查表rdquo和儲存下拉式選單選項的ldquo請勿編輯rdquo分頁
備註
附錄 E 追蹤表僅供參考TRCA 將另行提供台灣版表格供會員公司提報
28
後語
台灣化學工業責任照顧協會(Taiwan Responsible Care Association TRCA)成立於 1998 年在台灣推行責任照顧制度已達 20 週年製造商成員
包括台灣主要上市上櫃化工公司會員公司化學品生產製造量約佔全國 80 2016 年台灣化工業的 Chemical Sales 仍站在全球第八名的位
置額度為 630 億歐元化工業總產值達到 34 兆新台幣提供國內 416 萬人工作機會
TRCA 扮演國內廠商與國際制度接軌的角色也是國內化工業與政府機關及利益相關者溝通的橋樑與管道TRCA 會員結構依業務性質分析
涵蓋石化生產化學品製造氣體生產倉儲運輸業化學品貿易業以及工程研發設計等公司TRCA 透過供應鏈及價值鏈推行責任
照顧制度組成毒性化學物質聯防組織協助法規溝通與研析會員名冊請參考 httpwwwtrcaorgtwtrcanwork2aspx
TRCA 於 2010 年成為 ICCA (International Council of Chemical Associations 國際化學工業協會)觀察員ICCA 成立於 1989 年是全球化工製造
業的聯合會也是化學工業與 UNEP OPCW 及 OECD 的交流窗口ICCA 與其會員協會及成員公司致力於邁向永續的未來確保人類健康與
環境安全與保護全球化工業擁有超過 4兆美元的價值影響所有經濟部門ICCA 的會員幾乎在全球每個國家都有商業活動在全球六大
洲推動創新並提供超過 2000 萬個工作機會
台灣化工業在全球占有重要的一席之地在國內產業鏈也位居關鍵位置無論對國內或國際都有身為地球村一員應盡之責我們期許藉由
製程安全指標提報能更進一步提升自我在工安衛生環保與永續發展等面向的績效表現
台灣化學工業責任照顧協會
10452 台北市中山區撫順街 8 號 7 樓
電話02-2585-0552
httpwwwtrcaorgtw
None | |
$2500 to $25000 | |
$25000 to $250000 | |
$250000 to $25000000 | |
More than $25000000 | |
Yes - Using GHS TABLE | |
Yes - Using API RP 754 TABLE | |
NO | |
NA | |
1x le TQ lt 40x | |
40x le TQ lt 160x | |
160x le TQ lt 640x | |
ge 640x TQ | |
Yes le 3 hours | |
Yes 3 hours ge 12 hours | |
Yes 12 hours ge 24 hours | |
Yes ge 24 hours | |
No | |
Small-scale | |
Medium-scale | |
Large-scale | |
No | |
Yes | |
No | |
middot Injury requiring treatment beyond first aid to an employee contractor or subcontractor | |
middot Days Away From Work injury to an employee contractor or subcontractor or middot Injury requiring treatment beyond first aid to a third party | |
middot A fatality of an employee contractor or subcontractor or middot A hospital admission of a third party | |
middot Multiple fatalities of employees contractors or subcontractors or middot multiple hospital admission of third parties or middot A fatality of a third party | |
NA | |
1x le TQ lt 3x | |
3x le TQ lt 9x | |
9x le TQ lt 27x | |
ge 27x TQ |
ICCA Process Safety Pilot Reporting ProgramFebruary 8 2016 | 1 | 2 | 3 | 4 | 5 | 6 | 7 | 8 | 9 | 10 | 12 | 13 | 14 | 15 | |||||||||||||||||||||||
SAFETY Details(Meeting Local Regulations) | Direct Cost from Fire or Explosion | Community Impact | Environmental Impact | Material Released(Measured using the 1 Hour Rule) | |||||||||||||||||||||||||||||||||
Company Association Details | |||||||||||||||||||||||||||||||||||||
GHS | API - RP 754 | ||||||||||||||||||||||||||||||||||||
Company or Assocation Name | Headquarter Association | Location of Event Ex - City State amp Country | Date and Time of Event | Safety InjuryDid the Event result in a Recordable Lost Time Accident or Fatality or Hospital admission of anyone on or off siteUse Drop Down Menu | Safety InjuryIf yes please insert the total number of injuries | Safety InjuryFor puropses of utilizing the Severity Table please indicate the level of severity by chosing the MOST SEVERE classification that describes your incidentUse Drop Down Menu | Safety InjuryDid the incident involve Fatalities If so how many total fatalities If none enter Zero | Safety InjuryPlease Report Total Employee Hours for Calendar Year 2015 | Safety InjuryPlease Report Total Contractor Hours for Calendar Year 2015 | Direct Cost Did the Event result in Direct Damage CostUse Drop Down Menu | Direct Cost If so how muchAmount is in US DollarsUse Drop Down Menu | Community ImpactDid the event result inbull Officially declared shelter-in-place or officially declared evacuation (on or off site)ORbull Precautionary off site shelter in place or evacuation Use Drop Down Menu | Environmental ImpactDid the event result inAcute Environmental Remediation CostIf so indicate the amount in US DollarsUse Drop Down Menu | Material ReleasedDid the Event result in an Acute Release of material beyond one of the two threshold tablesIf so indicate which Threshold Table you used to make this determinationUse Drop Down Menu | Material ReleasedIf so indicate the amount released USING GHS CLASSIFICATION TABLEUse Drop Down Menu | Material ReleasedIf so indicate the amount released USING THE THRESHOLD TABLE FROM API RP-754Use Drop Down Menu | Material ReleasedIf available please indicate the material released | ||||||||||||||||||||
1 | ABC Chemical Company | American Chemistry Council | Washington DC - USA | January 4 2016 | Yes | 2 | middot Days Away From Work injury to an employee contractor or subcontractor or middot Injury requiring treatment beyond first aid to a third party | 0 | 5525000 | 1500250 | No | $2500 to $25000 | Yes le 3 hours | $2500 to $25000 | Yes - Using GHS TABLE | 40x le TQ lt 160x | NA | Chlorine | |||||||||||||||||||
2 | XYZ Chemical Company | American Chemistry Council | Washington DC - USA | 5-Jan-16 | Yes | 1 | middot Injury requiring treatment beyond first aid to an employee contractor or subcontractor | 0 | 5525000 | 1500250 | Yes | $2500 to $25000 | No | $2500 to $25000 | Yes - Using API RP 754 TABLE | NA | 3x le TQ lt 9x | Benzene | |||||||||||||||||||
3 | |||||||||||||||||||||||||||||||||||||
4 | |||||||||||||||||||||||||||||||||||||
5 | |||||||||||||||||||||||||||||||||||||
6 | |||||||||||||||||||||||||||||||||||||
7 | |||||||||||||||||||||||||||||||||||||
8 | |||||||||||||||||||||||||||||||||||||
9 | |||||||||||||||||||||||||||||||||||||
10 | |||||||||||||||||||||||||||||||||||||
11 | |||||||||||||||||||||||||||||||||||||
12 | |||||||||||||||||||||||||||||||||||||
13 | |||||||||||||||||||||||||||||||||||||
14 | |||||||||||||||||||||||||||||||||||||
15 | |||||||||||||||||||||||||||||||||||||
16 | |||||||||||||||||||||||||||||||||||||
17 | |||||||||||||||||||||||||||||||||||||
18 | |||||||||||||||||||||||||||||||||||||
19 | |||||||||||||||||||||||||||||||||||||
20 | |||||||||||||||||||||||||||||||||||||
21 | |||||||||||||||||||||||||||||||||||||
22 | |||||||||||||||||||||||||||||||||||||
23 | |||||||||||||||||||||||||||||||||||||
24 | |||||||||||||||||||||||||||||||||||||
25 | |||||||||||||||||||||||||||||||||||||
Zero or None | Yes - Duration Unknown | ||||||||||||||||||||||||||||||||||||
Processes | Mode of Operation | Type of material released | Status of Operation | ||||
REFINING | Start-up | Flammable | Open | ||||
Alkylation HF | Planned shutdown | Combustible | Closed | ||||
Alkylation sulfuric | Emergency shutdown | Toxic | |||||
BitumenResidAsphalt | Normal | Corrosive | Tier 1 Acute Releases | ||||
Calcining | Upset | Utilities | No Release | ||||
Coking | Turnaround | Other | Category 1 | ||||
Crude | Routine maintenance | Category 2 | |||||
Desulfurization | Temporary | Evacuation | Category 3 | ||||
FCC | Other | Yes | Category 4 | ||||
Gas Treating | No | Category 5 | |||||
Hydrogen | Point of Release | Category 6 | |||||
Hydrotreating | Pump | Fire | Category 7 | ||||
Hydrocracking | Compressor | Yes | Multiple Categories | ||||
Isom | BlowerFan | No | |||||
MarineJetty | Pressure Vessel | lt $2500 | |||||
Reforming | FilterCoalescer | ||||||
Sulfur recovery | Furnace | PRDs | |||||
Vapor recoverylight ends | Boiler | Directly to Atmosphere | |||||
Wastewater | Heat exchanger | via Downstream Destructive Device | |||||
REFINING amp PETROCHEMICAL | Cooling Tower | No | |||||
Tank FarmStorage FacilityOffsite | Piping system | Yes | |||||
UtilitiesSteam PlantCogeneration | Reactor | No | |||||
Other | Atmospheric tank | ||||||
PETROCHEMICAL | FlareRelief System | Acute release above thresholds | |||||
CO H2 | Other | Yes | |||||
LNG | No | ||||||
Methane | Events | ||||||
Methanol | No Tier 1 Events | Indoor Outdoor | |||||
Methyl Mercaptan | No Tier 2 Events | No Release | |||||
Formaldehyde | No Tier 1 or Tier 2 Events | Indoor | |||||
Formaldehyde derivatives | NA | Outdoor | |||||
Acetic Acid | |||||||
Acetic Acid derivatives | Event Type | ||||||
Ethane | Injury | ||||||
Ethylene | Fire | ||||||
Ethanol | Explosion | ||||||
Ethylene oxide | PRD Discharge | ||||||
Ethylene derivatives | Acute Release | ||||||
Polyethylene | |||||||
Ethylene dichloride | General | ||||||
Ethylene dichloride derivatives | Yes | ||||||
Ethyl benzene | No | ||||||
Ethyl benzene derivatives | |||||||
Polystyrene | |||||||
Styrene-Butadiene | |||||||
Propane | |||||||
Propylene | |||||||
Polypropylene | |||||||
Isopropanol | |||||||
Propylene oxide | |||||||
Propylene oxide derivatives | |||||||
Butane | |||||||
Isobutane | |||||||
Isobutene | |||||||
Butadiene | |||||||
MTBE | |||||||
ETBE | |||||||
Pentane | |||||||
Hexane | |||||||
Cyclohexane | |||||||
Hexanol | |||||||
Aromatics Derivatives | |||||||
Benzene | |||||||
Toluene | |||||||
Xylene | |||||||
Para Xylene | |||||||
Amines Derivatives | |||||||
TDA MDA IPDA etc | |||||||
Isocyanates | |||||||
Specialty Chemicals | |||||||
LoadingUnloading | |||||||
Pilot Plant |
Instructions | ||||||||||||||
Step 1 | Complete the Contact Tab with your contact information and company information | |||||||||||||
Be sure to note the region of your reporting (IE North America France Japan etc) | ||||||||||||||
Survey on Process Safety Events | ||||||||||||||
Step 2 | Complete the survey one line per Process Safety Event for your companyregion | |||||||||||||
ALL REPORTED DATA SHOULD BE FROM CALENDAR YEAR 2017 | ||||||||||||||
Step 3 | Return completed survey to | |||||||||||||
Company Name | ||||||||||||||
Contact Person | All Surveys Due by xxx date | |||||||||||||
Address | ||||||||||||||
Fax | ||||||||||||||
Telephone | ||||||||||||||
Region | ||||||||||||||
None | |
$2500 to $25000 | |
$25000 to $250000 | |
$250000 to $25000000 | |
More than $25000000 | |
Yes - Using GHS TABLE | |
Yes - Using API RP 754 TABLE | |
NO | |
NA | |
1x le TQ lt 40x | |
40x le TQ lt 160x | |
160x le TQ lt 640x | |
ge 640x TQ | |
Yes le 3 hours | |
Yes 3 hours ge 12 hours | |
Yes 12 hours ge 24 hours | |
Yes ge 24 hours | |
No | |
Small-scale | |
Medium-scale | |
Large-scale | |
No | |
Yes | |
No | |
middot Injury requiring treatment beyond first aid to an employee contractor or subcontractor | |
middot Days Away From Work injury to an employee contractor or subcontractor or middot Injury requiring treatment beyond first aid to a third party | |
middot A fatality of an employee contractor or subcontractor or middot A hospital admission of a third party | |
middot Multiple fatalities of employees contractors or subcontractors or middot multiple hospital admission of third parties or middot A fatality of a third party | |
NA | |
1x le TQ lt 3x | |
3x le TQ lt 9x | |
9x le TQ lt 27x | |
ge 27x TQ |
ICCA Process Safety Pilot Reporting ProgramFebruary 8 2016 | 1 | 2 | 3 | 4 | 5 | 6 | 7 | 8 | 9 | 10 | 12 | 13 | 14 | 15 | |||||||||||||||||||||||
SAFETY Details(Meeting Local Regulations) | Direct Cost from Fire or Explosion | Community Impact | Environmental Impact | Material Released(Measured using the 1 Hour Rule) | |||||||||||||||||||||||||||||||||
Company Association Details | |||||||||||||||||||||||||||||||||||||
GHS | API - RP 754 | ||||||||||||||||||||||||||||||||||||
Company or Assocation Name | Headquarter Association | Location of Event Ex - City State amp Country | Date and Time of Event | Safety InjuryDid the Event result in a Recordable Lost Time Accident or Fatality or Hospital admission of anyone on or off siteUse Drop Down Menu | Safety InjuryIf yes please insert the total number of injuries | Safety InjuryFor puropses of utilizing the Severity Table please indicate the level of severity by chosing the MOST SEVERE classification that describes your incidentUse Drop Down Menu | Safety InjuryDid the incident involve Fatalities If so how many total fatalities If none enter Zero | Safety InjuryPlease Report Total Employee Hours for Calendar Year 2015 | Safety InjuryPlease Report Total Contractor Hours for Calendar Year 2015 | Direct Cost Did the Event result in Direct Damage CostUse Drop Down Menu | Direct Cost If so how muchAmount is in US DollarsUse Drop Down Menu | Community ImpactDid the event result inbull Officially declared shelter-in-place or officially declared evacuation (on or off site)ORbull Precautionary off site shelter in place or evacuation Use Drop Down Menu | Environmental ImpactDid the event result inAcute Environmental Remediation CostIf so indicate the amount in US DollarsUse Drop Down Menu | Material ReleasedDid the Event result in an Acute Release of material beyond one of the two threshold tablesIf so indicate which Threshold Table you used to make this determinationUse Drop Down Menu | Material ReleasedIf so indicate the amount released USING GHS CLASSIFICATION TABLEUse Drop Down Menu | Material ReleasedIf so indicate the amount released USING THE THRESHOLD TABLE FROM API RP-754Use Drop Down Menu | Material ReleasedIf available please indicate the material released | ||||||||||||||||||||
1 | ABC Chemical Company | American Chemistry Council | Washington DC - USA | January 4 2016 | Yes | 2 | middot Days Away From Work injury to an employee contractor or subcontractor or middot Injury requiring treatment beyond first aid to a third party | 0 | 5525000 | 1500250 | No | $2500 to $25000 | Yes le 3 hours | $2500 to $25000 | Yes - Using GHS TABLE | 40x le TQ lt 160x | NA | Chlorine | |||||||||||||||||||
2 | XYZ Chemical Company | American Chemistry Council | Washington DC - USA | 5-Jan-16 | Yes | 1 | middot Injury requiring treatment beyond first aid to an employee contractor or subcontractor | 0 | 5525000 | 1500250 | Yes | $2500 to $25000 | No | $2500 to $25000 | Yes - Using API RP 754 TABLE | NA | 3x le TQ lt 9x | Benzene | |||||||||||||||||||
3 | |||||||||||||||||||||||||||||||||||||
4 | |||||||||||||||||||||||||||||||||||||
5 | |||||||||||||||||||||||||||||||||||||
6 | |||||||||||||||||||||||||||||||||||||
7 | |||||||||||||||||||||||||||||||||||||
8 | |||||||||||||||||||||||||||||||||||||
9 | |||||||||||||||||||||||||||||||||||||
10 | |||||||||||||||||||||||||||||||||||||
11 | |||||||||||||||||||||||||||||||||||||
12 | |||||||||||||||||||||||||||||||||||||
13 | |||||||||||||||||||||||||||||||||||||
14 | |||||||||||||||||||||||||||||||||||||
15 | |||||||||||||||||||||||||||||||||||||
16 | |||||||||||||||||||||||||||||||||||||
17 | |||||||||||||||||||||||||||||||||||||
18 | |||||||||||||||||||||||||||||||||||||
19 | |||||||||||||||||||||||||||||||||||||
20 | |||||||||||||||||||||||||||||||||||||
21 | |||||||||||||||||||||||||||||||||||||
22 | |||||||||||||||||||||||||||||||||||||
23 | |||||||||||||||||||||||||||||||||||||
24 | |||||||||||||||||||||||||||||||||||||
25 | |||||||||||||||||||||||||||||||||||||
Zero or None | Yes - Duration Unknown | ||||||||||||||||||||||||||||||||||||
Processes | Mode of Operation | Type of material released | Status of Operation | ||||
REFINING | Start-up | Flammable | Open | ||||
Alkylation HF | Planned shutdown | Combustible | Closed | ||||
Alkylation sulfuric | Emergency shutdown | Toxic | |||||
BitumenResidAsphalt | Normal | Corrosive | Tier 1 Acute Releases | ||||
Calcining | Upset | Utilities | No Release | ||||
Coking | Turnaround | Other | Category 1 | ||||
Crude | Routine maintenance | Category 2 | |||||
Desulfurization | Temporary | Evacuation | Category 3 | ||||
FCC | Other | Yes | Category 4 | ||||
Gas Treating | No | Category 5 | |||||
Hydrogen | Point of Release | Category 6 | |||||
Hydrotreating | Pump | Fire | Category 7 | ||||
Hydrocracking | Compressor | Yes | Multiple Categories | ||||
Isom | BlowerFan | No | |||||
MarineJetty | Pressure Vessel | lt $2500 | |||||
Reforming | FilterCoalescer | ||||||
Sulfur recovery | Furnace | PRDs | |||||
Vapor recoverylight ends | Boiler | Directly to Atmosphere | |||||
Wastewater | Heat exchanger | via Downstream Destructive Device | |||||
REFINING amp PETROCHEMICAL | Cooling Tower | No | |||||
Tank FarmStorage FacilityOffsite | Piping system | Yes | |||||
UtilitiesSteam PlantCogeneration | Reactor | No | |||||
Other | Atmospheric tank | ||||||
PETROCHEMICAL | FlareRelief System | Acute release above thresholds | |||||
CO H2 | Other | Yes | |||||
LNG | No | ||||||
Methane | Events | ||||||
Methanol | No Tier 1 Events | Indoor Outdoor | |||||
Methyl Mercaptan | No Tier 2 Events | No Release | |||||
Formaldehyde | No Tier 1 or Tier 2 Events | Indoor | |||||
Formaldehyde derivatives | NA | Outdoor | |||||
Acetic Acid | |||||||
Acetic Acid derivatives | Event Type | ||||||
Ethane | Injury | ||||||
Ethylene | Fire | ||||||
Ethanol | Explosion | ||||||
Ethylene oxide | PRD Discharge | ||||||
Ethylene derivatives | Acute Release | ||||||
Polyethylene | |||||||
Ethylene dichloride | General | ||||||
Ethylene dichloride derivatives | Yes | ||||||
Ethyl benzene | No | ||||||
Ethyl benzene derivatives | |||||||
Polystyrene | |||||||
Styrene-Butadiene | |||||||
Propane | |||||||
Propylene | |||||||
Polypropylene | |||||||
Isopropanol | |||||||
Propylene oxide | |||||||
Propylene oxide derivatives | |||||||
Butane | |||||||
Isobutane | |||||||
Isobutene | |||||||
Butadiene | |||||||
MTBE | |||||||
ETBE | |||||||
Pentane | |||||||
Hexane | |||||||
Cyclohexane | |||||||
Hexanol | |||||||
Aromatics Derivatives | |||||||
Benzene | |||||||
Toluene | |||||||
Xylene | |||||||
Para Xylene | |||||||
Amines Derivatives | |||||||
TDA MDA IPDA etc | |||||||
Isocyanates | |||||||
Specialty Chemicals | |||||||
LoadingUnloading | |||||||
Pilot Plant |
Instructions | ||||||||||||||
Step 1 | Complete the Contact Tab with your contact information and company information | |||||||||||||
Be sure to note the region of your reporting (IE North America France Japan etc) | ||||||||||||||
Survey on Process Safety Events | ||||||||||||||
Step 2 | Complete the survey one line per Process Safety Event for your companyregion | |||||||||||||
ALL REPORTED DATA SHOULD BE FROM CALENDAR YEAR 2017 | ||||||||||||||
Step 3 | Return completed survey to | |||||||||||||
Company Name | ||||||||||||||
Contact Person | All Surveys Due by xxx date | |||||||||||||
Address | ||||||||||||||
Fax | ||||||||||||||
Telephone | ||||||||||||||
Region | ||||||||||||||
None | |
$2500 to $25000 | |
$25000 to $250000 | |
$250000 to $25000000 | |
More than $25000000 | |
Yes - Using GHS TABLE | |
Yes - Using API RP 754 TABLE | |
NO | |
NA | |
1x le TQ lt 40x | |
40x le TQ lt 160x | |
160x le TQ lt 640x | |
ge 640x TQ | |
Yes le 3 hours | |
Yes 3 hours ge 12 hours | |
Yes 12 hours ge 24 hours | |
Yes ge 24 hours | |
No | |
Small-scale | |
Medium-scale | |
Large-scale | |
No | |
Yes | |
No | |
middot Injury requiring treatment beyond first aid to an employee contractor or subcontractor | |
middot Days Away From Work injury to an employee contractor or subcontractor or middot Injury requiring treatment beyond first aid to a third party | |
middot A fatality of an employee contractor or subcontractor or middot A hospital admission of a third party | |
middot Multiple fatalities of employees contractors or subcontractors or middot multiple hospital admission of third parties or middot A fatality of a third party | |
NA | |
1x le TQ lt 3x | |
3x le TQ lt 9x | |
9x le TQ lt 27x | |
ge 27x TQ |
ICCA Process Safety Pilot Reporting ProgramFebruary 8 2016 | 1 | 2 | 3 | 4 | 5 | 6 | 7 | 8 | 9 | 10 | 12 | 13 | 14 | 15 | |||||||||||||||||||||||
SAFETY Details(Meeting Local Regulations) | Direct Cost from Fire or Explosion | Community Impact | Environmental Impact | Material Released(Measured using the 1 Hour Rule) | |||||||||||||||||||||||||||||||||
Company Association Details | |||||||||||||||||||||||||||||||||||||
GHS | API - RP 754 | ||||||||||||||||||||||||||||||||||||
Company or Assocation Name | Headquarter Association | Location of Event Ex - City State amp Country | Date and Time of Event | Safety InjuryDid the Event result in a Recordable Lost Time Accident or Fatality or Hospital admission of anyone on or off siteUse Drop Down Menu | Safety InjuryIf yes please insert the total number of injuries | Safety InjuryFor puropses of utilizing the Severity Table please indicate the level of severity by chosing the MOST SEVERE classification that describes your incidentUse Drop Down Menu | Safety InjuryDid the incident involve Fatalities If so how many total fatalities If none enter Zero | Safety InjuryPlease Report Total Employee Hours for Calendar Year 2015 | Safety InjuryPlease Report Total Contractor Hours for Calendar Year 2015 | Direct Cost Did the Event result in Direct Damage CostUse Drop Down Menu | Direct Cost If so how muchAmount is in US DollarsUse Drop Down Menu | Community ImpactDid the event result inbull Officially declared shelter-in-place or officially declared evacuation (on or off site)ORbull Precautionary off site shelter in place or evacuation Use Drop Down Menu | Environmental ImpactDid the event result inAcute Environmental Remediation CostIf so indicate the amount in US DollarsUse Drop Down Menu | Material ReleasedDid the Event result in an Acute Release of material beyond one of the two threshold tablesIf so indicate which Threshold Table you used to make this determinationUse Drop Down Menu | Material ReleasedIf so indicate the amount released USING GHS CLASSIFICATION TABLEUse Drop Down Menu | Material ReleasedIf so indicate the amount released USING THE THRESHOLD TABLE FROM API RP-754Use Drop Down Menu | Material ReleasedIf available please indicate the material released | ||||||||||||||||||||
1 | ABC Chemical Company | American Chemistry Council | Washington DC - USA | January 4 2016 | Yes | 2 | middot Days Away From Work injury to an employee contractor or subcontractor or middot Injury requiring treatment beyond first aid to a third party | 0 | 5525000 | 1500250 | No | $2500 to $25000 | Yes le 3 hours | $2500 to $25000 | Yes - Using GHS TABLE | 40x le TQ lt 160x | NA | Chlorine | |||||||||||||||||||
2 | XYZ Chemical Company | American Chemistry Council | Washington DC - USA | 5-Jan-16 | Yes | 1 | middot Injury requiring treatment beyond first aid to an employee contractor or subcontractor | 0 | 5525000 | 1500250 | Yes | $2500 to $25000 | No | $2500 to $25000 | Yes - Using API RP 754 TABLE | NA | 3x le TQ lt 9x | Benzene | |||||||||||||||||||
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Zero or None | Yes - Duration Unknown | ||||||||||||||||||||||||||||||||||||
Processes | Mode of Operation | Type of material released | Status of Operation | ||||
REFINING | Start-up | Flammable | Open | ||||
Alkylation HF | Planned shutdown | Combustible | Closed | ||||
Alkylation sulfuric | Emergency shutdown | Toxic | |||||
BitumenResidAsphalt | Normal | Corrosive | Tier 1 Acute Releases | ||||
Calcining | Upset | Utilities | No Release | ||||
Coking | Turnaround | Other | Category 1 | ||||
Crude | Routine maintenance | Category 2 | |||||
Desulfurization | Temporary | Evacuation | Category 3 | ||||
FCC | Other | Yes | Category 4 | ||||
Gas Treating | No | Category 5 | |||||
Hydrogen | Point of Release | Category 6 | |||||
Hydrotreating | Pump | Fire | Category 7 | ||||
Hydrocracking | Compressor | Yes | Multiple Categories | ||||
Isom | BlowerFan | No | |||||
MarineJetty | Pressure Vessel | lt $2500 | |||||
Reforming | FilterCoalescer | ||||||
Sulfur recovery | Furnace | PRDs | |||||
Vapor recoverylight ends | Boiler | Directly to Atmosphere | |||||
Wastewater | Heat exchanger | via Downstream Destructive Device | |||||
REFINING amp PETROCHEMICAL | Cooling Tower | No | |||||
Tank FarmStorage FacilityOffsite | Piping system | Yes | |||||
UtilitiesSteam PlantCogeneration | Reactor | No | |||||
Other | Atmospheric tank | ||||||
PETROCHEMICAL | FlareRelief System | Acute release above thresholds | |||||
CO H2 | Other | Yes | |||||
LNG | No | ||||||
Methane | Events | ||||||
Methanol | No Tier 1 Events | Indoor Outdoor | |||||
Methyl Mercaptan | No Tier 2 Events | No Release | |||||
Formaldehyde | No Tier 1 or Tier 2 Events | Indoor | |||||
Formaldehyde derivatives | NA | Outdoor | |||||
Acetic Acid | |||||||
Acetic Acid derivatives | Event Type | ||||||
Ethane | Injury | ||||||
Ethylene | Fire | ||||||
Ethanol | Explosion | ||||||
Ethylene oxide | PRD Discharge | ||||||
Ethylene derivatives | Acute Release | ||||||
Polyethylene | |||||||
Ethylene dichloride | General | ||||||
Ethylene dichloride derivatives | Yes | ||||||
Ethyl benzene | No | ||||||
Ethyl benzene derivatives | |||||||
Polystyrene | |||||||
Styrene-Butadiene | |||||||
Propane | |||||||
Propylene | |||||||
Polypropylene | |||||||
Isopropanol | |||||||
Propylene oxide | |||||||
Propylene oxide derivatives | |||||||
Butane | |||||||
Isobutane | |||||||
Isobutene | |||||||
Butadiene | |||||||
MTBE | |||||||
ETBE | |||||||
Pentane | |||||||
Hexane | |||||||
Cyclohexane | |||||||
Hexanol | |||||||
Aromatics Derivatives | |||||||
Benzene | |||||||
Toluene | |||||||
Xylene | |||||||
Para Xylene | |||||||
Amines Derivatives | |||||||
TDA MDA IPDA etc | |||||||
Isocyanates | |||||||
Specialty Chemicals | |||||||
LoadingUnloading | |||||||
Pilot Plant |
Instructions | ||||||||||||||
Step 1 | Complete the Contact Tab with your contact information and company information | |||||||||||||
Be sure to note the region of your reporting (IE North America France Japan etc) | ||||||||||||||
Survey on Process Safety Events | ||||||||||||||
Step 2 | Complete the survey one line per Process Safety Event for your companyregion | |||||||||||||
ALL REPORTED DATA SHOULD BE FROM CALENDAR YEAR 2017 | ||||||||||||||
Step 3 | Return completed survey to | |||||||||||||
Company Name | ||||||||||||||
Contact Person | All Surveys Due by xxx date | |||||||||||||
Address | ||||||||||||||
Fax | ||||||||||||||
Telephone | ||||||||||||||
Region | ||||||||||||||
2016 | 2017 | 2018 | 2019 | 2020 | |||||
Feb - April RCLG PS Pilot Program May ndash Adjustmentsclarification to guidance document June Report outcomes of pilot program to RCLG and ICCA Board July - December middot RCLG associations consider guidance and develop reporting methodology for their memberships middot RCLG associations can request ICCA capacity building funds for PS reporting workshops for members if needed | Jan - Dec RCLG Association membership begin collecting PS data from their members Jan ndash Dec Associations hold workshops on Process Safety and performance reporting utilizing RCLG funds and experts if needed | Jan ndash Feb Reporting of process safety incidents to RCLG begins for associations with data (2017 data) April RCLG reviews outcomes challenges and raw data from the first reporting cycle (internally) June RCLG share draft data with ICCA Board July - December Update and adjust guidance as necessary Associations hold workshops on Process Safety and performance reporting utilizing RCLG funds and experts if needed | Jan ndash Feb Reporting of process safety incidents to RCLG begins for associations with data (2018 data) April RCLG reviews outcomes challenges and raw data from the second reporting cycle (internally) June RCLG share draft data with ICCA Board July - December Update and adjust guidance as necessary Associations hold workshops on Process Safety and performance reporting utilizing RCLG funds and experts if needed | Jan ndash Feb Reporting of process safety incidents to RCLG begins for all associations Process Safety incident reporting becomes part of the recommend base set of RCLG KPI metrics (2019 data) April RCLG reviews outcomes challenges and raw data from the second reporting cycle (internally consider external reporting) June RCLG share draft data with ICCA Board |
Name | Affiliation | ||
Peter Schmelzer | Bayer CEFIC - Chairman | ||
Americo Diniz Carvalho Neto | Braskem | ||
Bradford Johnson | American Chemistry Council | ||
David Cummings | DuPont | ||
Debra Phillips | American Chemistry Council | ||
Hans Schwarz | BASF | ||
Kathryn Walton | Plastics and Chemicals Industries Association | ||
Kazuyuki Akita | Japanese Chemical Industry Association | ||
Kelly Keim | ExxonMobil Chemical Company API Representative | ||
Kenan Stevick | Dow | ||
Kiyokazu Murata | Japanese Chemical Industry Association | ||
Larry Bowler | SABIC | ||
Lorna Young | Chemical Industry Association of Canada | ||
Louisa Nara | Center for Chemical Process Safety | ||
Associaccedilatildeo Brasileira da Induacutestria Quiacutemica | |||
Masatoshi Kumamoto | Japanese Chemical Industry Association | ||
Milton Lacerda | Petrobras | ||
Phil Scott | Chemical Industries Association | ||
Piet Knijff | DSM European Process Safety Centre | ||
Scott Donaldson and Eamon Chandler | Shell | ||
Scott Wallace | Olin Corporation | ||
Shakeel Kadri | Air Products and Chemicals Inc |
Event Incident Categories | |||||||||||
Severity Level | SafetyHuman Health | Direct Cost from Fire or Explosion | Material ReleaseWithin 1-Hr Period | Community Impact | Environmental Impact [off-site] | ||||||
Level 4 1 point | middot Injury requiring treatment beyond first aid to an employee contractor or subcontractor (Meets local regulations) | middot Resulting in Direct Damage Cost of $25 K le up to $25 K | middot Release volume between 1x le TQ lt 40x | middot Officially declared shelter-in-place or officially declared evacuation (on or off site) middot Precautionary off site shelter in place or evacuation le 3 hours | middot Acute Environmental Remediation Cost $25 K le up to $25 K | ||||||
Level 3 3 points | middot Days Away From Work injury to an employee contractor or subcontractor or middot Injury requiring treatment beyond first aid to a third party (Meets local regulations) | middot Resulting in Direct Damage Cost of $25 K le up to $250 K | middot Release volume between 40x le TQ lt 160x | middot Officially declared shelter-in-place or officially declared evacuation (on or off site) middot Precautionary off site shelter in place or evacuation 3 hours ge up to 12 hours | middot Acute Environmental Remediation Cost $25 K le up to $250 K | ||||||
Level 2 9 points | middot A fatality of an employee contractor or subcontractor or middot A hospital admission of a third party (Meets local regulations) | middot Resulting in Direct Damage Cost of $250 K le up to $25 MM | middot Release volume between 160x le TQ lt 640x | middot Officially declared shelter-in-place or officially declared evacuation (on or off site) middot Precautionary off site shelter in place or evacuation 12 hours ge up to 24 hours | middot Acute Environmental Remediation Cost $250 K le up to $25 MM | ||||||
Level 1 27 points | middot Multiple fatalities of employees contractors or subcontractors or middot multiple hospital admission of third parties or middot A fatality of a third party (Meets local regulations) | middot Resulting in Direct Damage Costs of ge $25 MM | middot Release volume ge 640x TQ | middot Officially declared shelter-in-place or officially declared evacuation (on or off site) middot Precautionary off site shelter in place or evacuation ge 24 hours | middot Acute Environmental Remediation Cost ge $25 MM |
It is recognized that threshold quantities given in kg and lb or in lb and bbl are not exactly equivalent Companies should select one of the pair and use it consistently for all recordkeeping activities | |
In determining the Threshold Release Category for a material one should first use the toxic (TIH Zone) or flammability (Flash Point and Boiling Point) or corrosiveness (Strong Acid or Base vs Moderate Acid or Base) characteristics Only when the hazard of the material is not expressed by those simple characteristics (eg reacts violently with water) is the UNDGL Packing Group used a Many materials exhibit more than one hazard Correct placement in Hazard Zone or Packing Group shall follow the rules of DOT 49 CFR 1732a [14] or UN Recommendations on the Transportation of Dangerous Goods Section 2 [12] See Annex F b A structure composed of four complete (floor to ceiling) walls floor and roof c For solutions not listed on the UNDG the anhydrous component shall determine the TIH zone or Packing Group classification The threshold quantity of the solution shall be back calculated based on the threshold quantity of the dry component weight d For mixtures where the UNDG classification is unknown the fraction of threshold quantity release for each component may be calculated If the sum of the fractions is equal to or greater than 100 the mixture exceeds the threshold quantity Where there are clear and independent toxic and flammable consequences associated with the mixture the toxic and flammable hazards are calculated independently See Annex E PSE Examples amp Questions 49 - 53 e A LOPC of Liquids with Flash Point gt 60 degC (140 degF) and 93 degC (200 degF) released at a temperature below Flash Point cannot be Tier 1 PSE based upon quantity released no matter the volume f A LOPC of a moderate acidbase cannot be Tier 1 PSE based upon quantity released no matter the volume |
Threshold Release Category | Material Hazard Classification acdef | Threshold Quantity (outdoor release) | Threshold Quantity (indoorb release) | ||||
T2-1 | TIH Zone A Materials | ge 05 kg (11 lb) | ge 025 kg (055 lb) | ||||
T2-2 | TIH Zone B Materials | ge 25 kg (55 lb) | ge 125 kg (275 lb) | ||||
T2-3 | TIH Zone C Materials | ge 10 kg (22 lb) | ge 5 kg (11 lb) | ||||
T2-4 | TIH Zone D Materials | ge 20 kg (44 lb) | ge 10 kg (22 lb) | ||||
T2-5 | Flammable Gases OR Liquids with Normal Boiling Point 35 degC (95 degF) and Flash Point 23 degC (73 degF) OR Other Packing Group I Materials (excluding acidsbases) | ge 50 kg (110 lb) | ge 25 kg (55 lb) | ||||
T2-6 | Liquids with Normal Boiling Point 35 degC (95 degF) and Flash Point 23 degC (73degF) OR Other Packing Group II Materials (excluding acidsbases) | ge 100 kg (220 lb)orge 07 bbl | ge 50 kg (110 lb)orge 035 bbl | ||||
T2-7 | Liquids with Flash Point 23 degC (73 degF) and 60 degC (140 degF) OR Liquids with Flash Point 60 degC (140 degF) released at a temperature at or above Flash Point OR strong acidsbases (see definition Refer to draft RP 754 document) OR UNDG Class 2 Division 22 (non-flammable non-toxic gases) excluding air OR Other Packing Group III Materials | ge 200 kg (440 lb)orge 14 bbl | ge 100 kg (220 lb)orge 07 bbl | ||||
T2-8 | Liquids with Flash Point 60 degC (140 degF) and 93 degC (200 degF) released at a temperature below Flash Point OR Moderate acidsbases | ge 1000 kg (2200 lb)orge 7 bbl | ge 500 kg (1100 lb)orge 35 bbl |
None | |
$2500 to $25000 | |
$25000 to $250000 | |
$250000 to $25000000 | |
More than $25000000 | |
Yes - Using GHS TABLE | |
Yes - Using API RP 754 TABLE | |
NO | |
NA | |
1x le TQ lt 40x | |
40x le TQ lt 160x | |
160x le TQ lt 640x | |
ge 640x TQ | |
Yes le 3 hours | |
Yes 3 hours ge 12 hours | |
Yes 12 hours ge 24 hours | |
Yes ge 24 hours | |
No | |
Small-scale | |
Medium-scale | |
Large-scale | |
No | |
Yes | |
No | |
middot Injury requiring treatment beyond first aid to an employee contractor or subcontractor | |
middot Days Away From Work injury to an employee contractor or subcontractor or middot Injury requiring treatment beyond first aid to a third party | |
middot A fatality of an employee contractor or subcontractor or middot A hospital admission of a third party | |
middot Multiple fatalities of employees contractors or subcontractors or middot multiple hospital admission of third parties or middot A fatality of a third party | |
NA | |
1x le TQ lt 3x | |
3x le TQ lt 9x | |
9x le TQ lt 27x | |
ge 27x TQ |
ICCA Process Safety Pilot Reporting ProgramFebruary 8 2016 | 1 | 2 | 3 | 4 | 5 | 6 | 7 | 8 | 9 | 10 | 12 | 13 | 14 | 15 | |||||||||||||||||||||||
SAFETY Details(Meeting Local Regulations) | Direct Cost from Fire or Explosion | Community Impact | Environmental Impact | Material Released(Measured using the 1 Hour Rule) | |||||||||||||||||||||||||||||||||
Company Association Details | |||||||||||||||||||||||||||||||||||||
GHS | API - RP 754 | ||||||||||||||||||||||||||||||||||||
Company or Assocation Name | Headquarter Association | Location of Event Ex - City State amp Country | Date and Time of Event | Safety InjuryDid the Event result in a Recordable Lost Time Accident or Fatality or Hospital admission of anyone on or off siteUse Drop Down Menu | Safety InjuryIf yes please insert the total number of injuries | Safety InjuryFor puropses of utilizing the Severity Table please indicate the level of severity by chosing the MOST SEVERE classification that describes your incidentUse Drop Down Menu | Safety InjuryDid the incident involve Fatalities If so how many total fatalities If none enter Zero | Safety InjuryPlease Report Total Employee Hours for Calendar Year 2015 | Safety InjuryPlease Report Total Contractor Hours for Calendar Year 2015 | Direct Cost Did the Event result in Direct Damage CostUse Drop Down Menu | Direct Cost If so how muchAmount is in US DollarsUse Drop Down Menu | Community ImpactDid the event result inbull Officially declared shelter-in-place or officially declared evacuation (on or off site)ORbull Precautionary off site shelter in place or evacuation Use Drop Down Menu | Environmental ImpactDid the event result inAcute Environmental Remediation CostIf so indicate the amount in US DollarsUse Drop Down Menu | Material ReleasedDid the Event result in an Acute Release of material beyond one of the two threshold tablesIf so indicate which Threshold Table you used to make this determinationUse Drop Down Menu | Material ReleasedIf so indicate the amount released USING GHS CLASSIFICATION TABLEUse Drop Down Menu | Material ReleasedIf so indicate the amount released USING THE THRESHOLD TABLE FROM API RP-754Use Drop Down Menu | Material ReleasedIf available please indicate the material released | ||||||||||||||||||||
1 | ABC Chemical Company | American Chemistry Council | Washington DC - USA | January 4 2016 | Yes | 2 | middot Days Away From Work injury to an employee contractor or subcontractor or middot Injury requiring treatment beyond first aid to a third party | 0 | 5525000 | 1500250 | No | $2500 to $25000 | Yes le 3 hours | $2500 to $25000 | Yes - Using GHS TABLE | 40x le TQ lt 160x | NA | Chlorine | |||||||||||||||||||
2 | XYZ Chemical Company | American Chemistry Council | Washington DC - USA | 5-Jan-16 | Yes | 1 | middot Injury requiring treatment beyond first aid to an employee contractor or subcontractor | 0 | 5525000 | 1500250 | Yes | $2500 to $25000 | No | $2500 to $25000 | Yes - Using API RP 754 TABLE | NA | 3x le TQ lt 9x | Benzene | |||||||||||||||||||
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Zero or None | Yes - Duration Unknown | ||||||||||||||||||||||||||||||||||||
Processes | Mode of Operation | Type of material released | Status of Operation | ||||
REFINING | Start-up | Flammable | Open | ||||
Alkylation HF | Planned shutdown | Combustible | Closed | ||||
Alkylation sulfuric | Emergency shutdown | Toxic | |||||
BitumenResidAsphalt | Normal | Corrosive | Tier 1 Acute Releases | ||||
Calcining | Upset | Utilities | No Release | ||||
Coking | Turnaround | Other | Category 1 | ||||
Crude | Routine maintenance | Category 2 | |||||
Desulfurization | Temporary | Evacuation | Category 3 | ||||
FCC | Other | Yes | Category 4 | ||||
Gas Treating | No | Category 5 | |||||
Hydrogen | Point of Release | Category 6 | |||||
Hydrotreating | Pump | Fire | Category 7 | ||||
Hydrocracking | Compressor | Yes | Multiple Categories | ||||
Isom | BlowerFan | No | |||||
MarineJetty | Pressure Vessel | lt $2500 | |||||
Reforming | FilterCoalescer | ||||||
Sulfur recovery | Furnace | PRDs | |||||
Vapor recoverylight ends | Boiler | Directly to Atmosphere | |||||
Wastewater | Heat exchanger | via Downstream Destructive Device | |||||
REFINING amp PETROCHEMICAL | Cooling Tower | No | |||||
Tank FarmStorage FacilityOffsite | Piping system | Yes | |||||
UtilitiesSteam PlantCogeneration | Reactor | No | |||||
Other | Atmospheric tank | ||||||
PETROCHEMICAL | FlareRelief System | Acute release above thresholds | |||||
CO H2 | Other | Yes | |||||
LNG | No | ||||||
Methane | Events | ||||||
Methanol | No Tier 1 Events | Indoor Outdoor | |||||
Methyl Mercaptan | No Tier 2 Events | No Release | |||||
Formaldehyde | No Tier 1 or Tier 2 Events | Indoor | |||||
Formaldehyde derivatives | NA | Outdoor | |||||
Acetic Acid | |||||||
Acetic Acid derivatives | Event Type | ||||||
Ethane | Injury | ||||||
Ethylene | Fire | ||||||
Ethanol | Explosion | ||||||
Ethylene oxide | PRD Discharge | ||||||
Ethylene derivatives | Acute Release | ||||||
Polyethylene | |||||||
Ethylene dichloride | General | ||||||
Ethylene dichloride derivatives | Yes | ||||||
Ethyl benzene | No | ||||||
Ethyl benzene derivatives | |||||||
Polystyrene | |||||||
Styrene-Butadiene | |||||||
Propane | |||||||
Propylene | |||||||
Polypropylene | |||||||
Isopropanol | |||||||
Propylene oxide | |||||||
Propylene oxide derivatives | |||||||
Butane | |||||||
Isobutane | |||||||
Isobutene | |||||||
Butadiene | |||||||
MTBE | |||||||
ETBE | |||||||
Pentane | |||||||
Hexane | |||||||
Cyclohexane | |||||||
Hexanol | |||||||
Aromatics Derivatives | |||||||
Benzene | |||||||
Toluene | |||||||
Xylene | |||||||
Para Xylene | |||||||
Amines Derivatives | |||||||
TDA MDA IPDA etc | |||||||
Isocyanates | |||||||
Specialty Chemicals | |||||||
LoadingUnloading | |||||||
Pilot Plant |
Instructions | ||||||||||||||
Step 1 | Complete the Contact Tab with your contact information and company information | |||||||||||||
Be sure to note the region of your reporting (IE North America France Japan etc) | ||||||||||||||
Survey on Process Safety Events | ||||||||||||||
Step 2 | Complete the survey one line per Process Safety Event for your companyregion | |||||||||||||
ALL REPORTED DATA SHOULD BE FROM CALENDAR YEAR 2017 | ||||||||||||||
Step 3 | Return completed survey to | |||||||||||||
Company Name | ||||||||||||||
Contact Person | All Surveys Due by xxx date | |||||||||||||
Address | ||||||||||||||
Fax | ||||||||||||||
Telephone | ||||||||||||||
Region | ||||||||||||||
2016 | 2017 | 2018 | 2019 | 2020 | |||||
Feb - April RCLG PS Pilot Program May ndash Adjustmentsclarification to guidance document June Report outcomes of pilot program to RCLG and ICCA Board July - December middot RCLG associations consider guidance and develop reporting methodology for their memberships middot RCLG associations can request ICCA capacity building funds for PS reporting workshops for members if needed | Jan - Dec RCLG Association membership begin collecting PS data from their members Jan ndash Dec Associations hold workshops on Process Safety and performance reporting utilizing RCLG funds and experts if needed | Jan ndash Feb Reporting of process safety incidents to RCLG begins for associations with data (2017 data) April RCLG reviews outcomes challenges and raw data from the first reporting cycle (internally) June RCLG share draft data with ICCA Board July - December Update and adjust guidance as necessary Associations hold workshops on Process Safety and performance reporting utilizing RCLG funds and experts if needed | Jan ndash Feb Reporting of process safety incidents to RCLG begins for associations with data (2018 data) April RCLG reviews outcomes challenges and raw data from the second reporting cycle (internally) June RCLG share draft data with ICCA Board July - December Update and adjust guidance as necessary Associations hold workshops on Process Safety and performance reporting utilizing RCLG funds and experts if needed | Jan ndash Feb Reporting of process safety incidents to RCLG begins for all associations Process Safety incident reporting becomes part of the recommend base set of RCLG KPI metrics (2019 data) April RCLG reviews outcomes challenges and raw data from the second reporting cycle (internally consider external reporting) June RCLG share draft data with ICCA Board |
Name | Affiliation | ||
Peter Schmelzer | Bayer CEFIC - Chairman | ||
Americo Diniz Carvalho Neto | Braskem | ||
Bradford Johnson | American Chemistry Council | ||
David Cummings | DuPont | ||
Debra Phillips | American Chemistry Council | ||
Hans Schwarz | BASF | ||
Kathryn Walton | Plastics and Chemicals Industries Association | ||
Kazuyuki Akita | Japanese Chemical Industry Association | ||
Kelly Keim | ExxonMobil Chemical Company API Representative | ||
Kenan Stevick | Dow | ||
Kiyokazu Murata | Japanese Chemical Industry Association | ||
Larry Bowler | SABIC | ||
Lorna Young | Chemical Industry Association of Canada | ||
Louisa Nara | Center for Chemical Process Safety | ||
Associaccedilatildeo Brasileira da Induacutestria Quiacutemica | |||
Masatoshi Kumamoto | Japanese Chemical Industry Association | ||
Milton Lacerda | Petrobras | ||
Phil Scott | Chemical Industries Association | ||
Piet Knijff | DSM European Process Safety Centre | ||
Scott Donaldson and Eamon Chandler | Shell | ||
Scott Wallace | Olin Corporation | ||
Shakeel Kadri | Air Products and Chemicals Inc |
Event Incident Categories | |||||||||||
Severity Level | SafetyHuman Health | Direct Cost from Fire or Explosion | Material ReleaseWithin 1-Hr Period | Community Impact | Environmental Impact [off-site] | ||||||
Level 4 1 point | middot Injury requiring treatment beyond first aid to an employee contractor or subcontractor (Meets local regulations) | middot Resulting in Direct Damage Cost of $25 K le up to $25 K | middot Release volume between 1x le TQ lt 40x | middot Officially declared shelter-in-place or officially declared evacuation (on or off site) middot Precautionary off site shelter in place or evacuation le 3 hours | middot Acute Environmental Remediation Cost $25 K le up to $25 K | ||||||
Level 3 3 points | middot Days Away From Work injury to an employee contractor or subcontractor or middot Injury requiring treatment beyond first aid to a third party (Meets local regulations) | middot Resulting in Direct Damage Cost of $25 K le up to $250 K | middot Release volume between 40x le TQ lt 160x | middot Officially declared shelter-in-place or officially declared evacuation (on or off site) middot Precautionary off site shelter in place or evacuation 3 hours ge up to 12 hours | middot Acute Environmental Remediation Cost $25 K le up to $250 K | ||||||
Level 2 9 points | middot A fatality of an employee contractor or subcontractor or middot A hospital admission of a third party (Meets local regulations) | middot Resulting in Direct Damage Cost of $250 K le up to $25 MM | middot Release volume between 160x le TQ lt 640x | middot Officially declared shelter-in-place or officially declared evacuation (on or off site) middot Precautionary off site shelter in place or evacuation 12 hours ge up to 24 hours | middot Acute Environmental Remediation Cost $250 K le up to $25 MM | ||||||
Level 1 27 points | middot Multiple fatalities of employees contractors or subcontractors or middot multiple hospital admission of third parties or middot A fatality of a third party (Meets local regulations) | middot Resulting in Direct Damage Costs of ge $25 MM | middot Release volume ge 640x TQ | middot Officially declared shelter-in-place or officially declared evacuation (on or off site) middot Precautionary off site shelter in place or evacuation ge 24 hours | middot Acute Environmental Remediation Cost ge $25 MM |
It is recognized that threshold quantities given in kg and lb or in lb and bbl are not exactly equivalent Companies should select one of the pair and use it consistently for all recordkeeping activities | |
In determining the Threshold Release Category for a material one should first use the toxic (TIH Zone) or flammability (Flash Point and Boiling Point) or corrosiveness (Strong Acid or Base vs Moderate Acid or Base) characteristics Only when the hazard of the material is not expressed by those simple characteristics (eg reacts violently with water) is the UNDGL Packing Group used a Many materials exhibit more than one hazard Correct placement in Hazard Zone or Packing Group shall follow the rules of DOT 49 CFR 1732a [14] or UN Recommendations on the Transportation of Dangerous Goods Section 2 [12] See Annex F b A structure composed of four complete (floor to ceiling) walls floor and roof c For solutions not listed on the UNDG the anhydrous component shall determine the TIH zone or Packing Group classification The threshold quantity of the solution shall be back calculated based on the threshold quantity of the dry component weight d For mixtures where the UNDG classification is unknown the fraction of threshold quantity release for each component may be calculated If the sum of the fractions is equal to or greater than 100 the mixture exceeds the threshold quantity Where there are clear and independent toxic and flammable consequences associated with the mixture the toxic and flammable hazards are calculated independently See Annex E PSE Examples amp Questions 49 - 53 e A LOPC of Liquids with Flash Point gt 60 degC (140 degF) and 93 degC (200 degF) released at a temperature below Flash Point cannot be Tier 1 PSE based upon quantity released no matter the volume f A LOPC of a moderate acidbase cannot be Tier 1 PSE based upon quantity released no matter the volume |
Threshold Release Category | Material Hazard Classification acdef | Threshold Quantity (outdoor release) | Threshold Quantity (indoorb release) | ||||
T2-1 | TIH Zone A Materials | ge 05 kg (11 lb) | ge 025 kg (055 lb) | ||||
T2-2 | TIH Zone B Materials | ge 25 kg (55 lb) | ge 125 kg (275 lb) | ||||
T2-3 | TIH Zone C Materials | ge 10 kg (22 lb) | ge 5 kg (11 lb) | ||||
T2-4 | TIH Zone D Materials | ge 20 kg (44 lb) | ge 10 kg (22 lb) | ||||
T2-5 | Flammable Gases OR Liquids with Normal Boiling Point 35 degC (95 degF) and Flash Point 23 degC (73 degF) OR Other Packing Group I Materials (excluding acidsbases) | ge 50 kg (110 lb) | ge 25 kg (55 lb) | ||||
T2-6 | Liquids with Normal Boiling Point 35 degC (95 degF) and Flash Point 23 degC (73degF) OR Other Packing Group II Materials (excluding acidsbases) | ge 100 kg (220 lb)orge 07 bbl | ge 50 kg (110 lb)orge 035 bbl | ||||
T2-7 | Liquids with Flash Point 23 degC (73 degF) and 60 degC (140 degF) OR Liquids with Flash Point 60 degC (140 degF) released at a temperature at or above Flash Point OR strong acidsbases (see definition Refer to draft RP 754 document) OR UNDG Class 2 Division 22 (non-flammable non-toxic gases) excluding air OR Other Packing Group III Materials | ge 200 kg (440 lb)orge 14 bbl | ge 100 kg (220 lb)orge 07 bbl | ||||
T2-8 | Liquids with Flash Point 60 degC (140 degF) and 93 degC (200 degF) released at a temperature below Flash Point OR Moderate acidsbases | ge 1000 kg (2200 lb)orge 7 bbl | ge 500 kg (1100 lb)orge 35 bbl |
4
敬愛的 TRCA 會員您好
謹代表 TRCA 藉此機會對 ICCA (International Council of Chemical Associations 國際化學業
協會)以及 RCLG (Responsible Care Leadership Group 責任照顧領導群)過去幾年來致於調
和製程安全指標所付出的與貢獻致上深深的謝忱
製程安全管理是化學業為關鍵重要的作製程安全指標的提報則是驗證製程安全
管理的核程過去數年來國際與國內化學業致於持續不斷的改進相關績效指
標的表現我們相信減少製程安全事件的發與是否進量測有絕對的關係因為我們無
從改進沒有進過量測的項因此藉由製程安全事件的提報將有效的協助會員公司
與國家協會分享 佳實務經驗並在這個過程中協助會員公司改善製程安全績效表現進
減少環境跡從事故事件中學習是改進製程安全管理的關鍵我們誠摯地希望藉由
製程安全指標提報能降低製程安全事件的發
TRCA 2015 年起籌組 Near Miss 試組並於當年起開始提報製程安全虛驚事件數
以做為未來全提報製程安全事件率的準備感謝試組台灣永光化學業(股)公司
台灣中油(股)公司國喬油化學(股)公司台灣科思創(股)公司奇美實業(股)公司台
橡(股)公司春油化學(股)公司春造樹脂廠(股)公司連化學業(股)公司
李榮化學業(股)公司以及台灣志氯化學(股)公司率先的努配合試為 2020 年全
提報製程安全事件指標提供了難能可貴的經驗
TRCA 為達成 ICCA 擬定 2020 年全提報的標訂於 2019 年開始試提報 2018 年數據
2018 年將陸續展開相關說明與教育訓練研討會議我們相信推 ICCA 全球調和製程安全
指標提報將能更有助於加強與改善台灣化業製程安全管理績效
讓我們起為化業更安全與環保的永續未來努吧
TRCA 責任照顧推委員會主席 Chairman Responsible Care Implementation Committee台灣志氯化學(股)公司總經理 President Taiwan Chlorine Industries Ltd
嚴堅正 Art Yen
5
背景
責任照顧倡議(Responsible Carereg initiative)發起於 1985年其目的在於展現化學工業界持續
改善績效的承諾自從責任照顧倡議開始實施以來製程安全(Process Safety)一直是責任
照顧倡議的核心基礎之一實施責任照顧 30 多年來許多地區已發展出追蹤及提報製程
安全績效的方法然而一直未能建立一套全球調和的提報系統由於一些重大製程安全
事件仍不斷發生在 2012 年國際化學工業協會(ICCA)董事會便責成責任照顧領導群
(RCLG)在 2015 年以前擬定一套全球調和的製程安全績效提報機制
2013-14 年間一個由跨國公司和 RCLG 各協會組成的專案小組正式成立該專案小組由
拜耳醫療保健公司(Bayer HealthCare AG)的衛生安全及環保總監 Peter Schmelzer 博士擔任
召集人其任務即是研擬一套全球調和的 ICCA 製程安全績效提報機制專案小組成員表
詳見附錄 C在此期間美國石油學會(API)也著手開始進行其 API RP 754 ndash領先及落後製程
安全指標標準(Leading and Lagging Process Safety Metric Standard)之修訂RP-754 被廣泛應
用於美洲地區的煉油及石化產業以追蹤製程安全績效為了推動全球採行統一的標準
RCLG 專案小組致力於將其所提出之建議案與預訂於 2016 年第一季完成修訂之 API RP 754
達到完全調和
執行摘要
經過兩年多的討論研究辯論及可行性評估製程安全調和化專案小組(PSHT)建議 ICCA
採行一套製程安全事件發生率指標採行這套指標需要 RCLG 各協會蒐集會員公司在一年
內所發生之製程安全事件次數和工作總時數(包括員工和承攬商)製程安全事件發生率即
事件數除以工作時數的比率專案小組建議向 RCLG 提報這些數據的要求將在未來三年
內分階段實施同意已具有意願和能力提報的地區立即開始提報數據同時也給予正在發
展追蹤數據能力以進行首次提報的公司和機構若干緩衝時間
判定製程相關事件是否符合製程安全事件定義的標準係以化學物質的一次阻絕設施失效
或能量釋放以致引起下列任何一個影響考量面的門檻為根據1) 安全人員健康後果2)
事故造成損失之直接成本3) 社區影響4) 化學物質洩漏量(請參見提報判定流程圖所
示)ICCA 所建議之製程安全事件定義的四個影響考量面與 RP-754Tier II 事故標準的影
響考量面是完全一樣的除了化學物質洩漏量提報門檻有所差異外其他三個影響考量面
6
的提報門檻也是一樣的為因應此一差異針對化學物質外洩量提報門檻ICCA 製程安
全事件定義將容許會員公司採用 ICCA 依據化學品全球調和制度(GHS)健康危害分級為基礎
所發展的提報標準或依據聯合國危險物品(UNDG)分類為基礎所定義之 RP-754 二級製程
安全事件(Tier II) 之提報標準專案小組相信這兩套制度之提報標準雖然有所差異但
從其所涵蓋之化學物質領域和提報事故嚴重程度看來兩者皆相當健全雖然採用這兩種
不同提報門檻所收集和提報的事件數差異相對不大但在公司方面從原料及產品使用的角
度看來兩者可能會有非常明顯的不同因此專案小組提醒會員公司勿將自己公司的
結果與採用不同化學物質洩漏量提報門檻的公司做比較無論如何根據 RCLG 的提議
會員公司可選擇化學物質洩漏門檻以向國家及地區協會進行提報如果各協會有興趣轉
換兩種不同提報方式的結果RCLG 可提供轉換表但由於轉換運算非常複雜且須取得
原始事故數據專案小組相信相互轉換的附加價值不大因此不建議協會採取此一做法
專案小組相信這項製程安全事件提報建議案可廣泛運用在化學及石化產業實施製程安
全績效提報這項提報制度將為目前尚未追蹤製程安全績效的地區協會和會員公司提
供一個指引讓他們可以體認追蹤及提報製程安全績效可以帶來的益處至於已在蒐集製
程安全數據的地區協會和會員公司此建議案將有助於他們更廣泛地與全球接軌並將
重點放在持續改善製程安全績效這些改善製程安全績效的制度仰賴的是可靠的製程安
全事件數據改善製程安全績效正是責任照顧倡議的主要目的
7
RCLG 各協會應向 RCLG 提報的數據
RCLG 各協會每年必須依照下文提供的時程透過 RCLG 關鍵績效指標(KPI)提報網站向
ICCA 提報兩個數據
1 協會所屬會員公司的總工作時數(包括員工和承攬商)
2 製程安全事件總數
ICCA 將利用上述兩個數據以製程安全事件發生率(PSER)的形式報告製程安全績效PSER
計算之常態化是以每 100 位員工每位員工一年工作 2000 小時為基準
(總事件數 總工作時數) x 200000 = PSER
建議之提報時程
針對提報製程安全事件發生率專案小組建議一種分階段導入的方法此一時程可讓更多
已具經驗的協會及公司立即實施提報同時容許其他協會及公司從 2019 年起開始提報
RCLG 各協會必須透過 RCLG KPI 指標提報系統(httpkpiresponsiblecareeu)每年向 ICCA
提報兩個製程安全事件發生率數據如果你不知道你所屬協會的使用者名稱和密碼請聯
絡 RCLG
建議 RCLG 協會提報製程安全事件發生率的時程如下
2015 年 4 月 RCLG 考量專案小組建議案
2015 年 6 月 ICCA 理事會考量 RCLG 的最終建議
2015 年 7 月 RCLG 頒布首份詳細的提報指引供協會及會員公司遵
循
2016 年 2 月 RCLG 提報 RCLG 更新及強化提報指引並針對自願參加的協會
開始實施製程安全試行提報計畫RCLG 於 2016 年 6 月
頒布最終指引
2017 年 RCLG 各協會開始向會員公司蒐集數據
2018-2019 年 RCLG 提報 RCLG 各協會可選擇地開始提報製程安全數據
2020 年提報 RCLG 於 KPI 提報計畫中將製程安全納入為一項強制性
指標
參見附錄 D ndash 詳細活動時程
8
ICCA 製程安全事件判定標準流程圖
事故是否發生在廠內之
生產配銷儲存公
用或試驗工廠
是 是
是
否
否 是否造成須通報工傷
或
廠內廠外人員住院治
療
損壞是否對
公司造成
ge $2500 美
元的直接成
本損失
官方是否宣告就地
避難或疏散或廠
外預防性就地避難
或疏散
否
是
否
是屬於須通報製程安全事件
是
否
是
是
開始
否不符合製程安全事件認定
標準
是否超過 ICCA 或 API
754 Tier II 化學物質洩
漏恕限值
否 發生化學物質外洩火
災或爆炸是否起因於
或發生在化學製程單元
是否直接涉及某種化學物
質或化學製程
否
9
須提報製程安全事件之重要標準
總工作時數
RCLG 各協會應以加總的單一數字提報其所屬會員公司的員工和承攬商總工作時數為達
成本指引之目的各協會應參考其本地和地區對員工及承攬商之定義提報總時數之目標
應納入涉及化學製造之所有個人然而參與主要興建工程專案之人員則不納入計算譬
如為新建或擴建既有製程設施之設計工程和施工而成立之一次性專案組織的大規模投資
案會員公司提報總工作時數時應與人事部門統計之員工工時一致如此各公司便能
取得相同的職業與製程安全數據員工工時應包括所有化學製造作業的工時而非僅計算
發生製程安全事故之廠區的工時
製程安全事件
為執行 ICCA 提報目的製程安全事件之定義條件如下(必須同時符合 ABCD 四個條
件)
A 直接涉及某種化學物質或化學製程且
B 事故發生在廠內之生產配銷儲存公用或試驗工廠且
C 製程單元發生物質洩漏或能量釋放(如火災爆炸和內爆)且
D 已達到以下提報門檻之一
1 安全 工傷
導致記錄性的傷害(OSHA)損失工時或死亡或廠內外任何人員因此
而須住院治療或
2 直接損失成本
火災爆炸或為避免補救環境損害之必要清理作業導致$2500 美元
以上的直接成本支出或
3 就地避難 疏散
官方宣告就地避難(廠內或廠外)或
官方宣告疏散(廠內或廠外)或
廠外預防性就地避難或疏散或
4 洩漏恕限值
物質洩漏程度已達表 1 所列之任一 GHS 恕限值(洩漏量以單位小時計
量)
此外各公司亦可選擇採用 API RP-754 標準中所列之洩漏恕限值(表 2)請注意如欲查
看 API RP-754 標準可登入以下網站購買及下載httpwwwapiorgoil-and-natural-
gashealth-and-safetyprocess-safetyprocess-safety-standards
10
製程安全事件判定準則
A 涉及化學品
直接涉及某種化學物質或化學製程
製程安全事件或事故必須直接涉及化學物質或化學製程就此而言ldquo製程rdquo一詞泛指包含
石化生產所需要之設備和技術包括反應器儲槽管線鍋爐冷卻水塔和冷凍系
統helliphellip等未直接涉及化學物質或製程的事件無須提報譬如辦公大樓起火(即使該辦公大
樓位在廠區內亦然)
B 地點
事故發生在廠內之生產配銷儲存公用或試驗工廠
發生在廠內之生產配銷儲存(包括活動儲存區如倉庫 ndash 參見ldquo常見問題集rdquo)公用及
試驗工廠凡符合提報指標及定義的事故包括在廠區管理下之槽罐區輔助支援區(如
鍋爐室和廢水處理廠)和配銷管線所有須提報之事件應由負責該事故地點運作的公司
負提報之責此一規定亦適用於發生在承攬商作業區域內的事故在代工作業和多方共同
作業廠區負責運作該發生事故單位的公司應記錄事故始末並將之納入其提報中
C 物質洩漏
製程單元發生物質外洩或能量釋放(如火災爆炸和內爆)
物質外洩 ndash 製程任何物質發生非預期或無法控制的洩漏或釋放包括非毒性及不可燃物質
(如蒸汽熱水氮氣壓縮二氧化碳或壓縮空氣)且達到本文件所列四類提報門檻之一
項或以上之後果
在防治系統(如洗滌塔或廢氣燃燒塔)正常運作狀況下只要沒有任何洩漏或排放量超過
法定許可值即使排放到廢氣燃燒塔或滌氣塔仍被視為處於一次阻絕設施內然若排
放到二次阻絕設施(如廢水處理或防溢堤)將被視為製程安全事件因為物質已離開主要製
程系統
11
D 提報門檻
須提報製程安全事件必須達到以下提報門檻之一
1 安全 工傷
導致記錄性傷害(OSHA)損失工時或死亡或廠內外任何人員因此而須住院治療
記錄性傷害是指與工作有關所造成的傷害導致死亡暫時全失能工作受限制或需調整職
務較輕傷害嚴重之醫療處理失去意識或經醫師或其他合格醫療專業人員診斷為重大
傷害
損失工時傷害和死亡是指因製程相關的一次阻絕設施失效火災或爆炸導致以下任何一種
結果
員工(損失工時或死亡)
承攬商及再承攬商 (損失工時或死亡)
第三方(如來賓訪客快遞員)(受傷疾病導致住院治療或死亡)
住院治療是指醫院或其他具有住院病患保健設施的醫療單位正式接受病患住院提供病患
食宿及醫療護理且病患接受治療至少留置至隔日僅在醫院急診室治療或過夜處理不屬
於ldquo住院治療rdquo的定義範圍
須提報之工傷或死亡事件例如在清理作業期間因蒸汽洩漏造成人員燒燙傷壓力測試期間
帽蓋因受壓脫落造成人員身體傷害或取樣作業時因物質外濺造成人員化學灼傷無須提
報之工傷或死亡事件例如在執行維修作業時從高處的工作台墜落實驗室或辦公大樓火災
造成人員燒燙傷或挖掘工程塌陷造成人員傷害這些案例均與因製程造成的能量釋放或
物質洩漏無直接關聯
2 直接損失成本
火災爆炸或為避免補救環境損害之必要清理作業導致$2500美元以上的直接成本支出
此提報門檻所考慮的成本應為可直接歸因於火災或爆炸的成本譬如設備及結構損壞的重
置成本修理成本環境清理(廠內及廠外)支出緊急應變和罰款直接成本不包括間接
成本譬如業務機會損失設備停機造成之利潤損失取得或運轉臨時設施之成本或為
滿足顧客需求取得替代產品的成本(產品損失)
12
3 就地避難 疏散
官方宣告就地避難或疏散(廠內或廠外)或廠外預防性就地避難或疏散
就提報目的而言官方宣告就地避難或疏散(廠內或廠外)或廠外預防性就地避難或疏散
即達到此提報門檻
官方宣告 ndash 由地方權責機關(如消防警察民防緊急應變管理部門)或經授權的代表(如
派駐公司官員)下達的社區行動(如就地避難或疏散)宣告
預防性宣告 ndash 預防性公眾應變是基於謹慎的態度所採取的一種措施權責地方主管機關或經
授權的代表經合理判斷認定為維護公眾健康及安全發布必須採取就地避難或疏散之預
防性措施
就地避難 ndash 利用結構體及其內部空氣以暫時讓人員與室外危害性氣體隔離
疏散 ndash 基於安全或防護理由讓人員離開某處所的行動或過程
4 洩漏恕限值
超過表 1 中所列 GHS 恕限值或表 2 中所列 API 754 標準 Tier II 製程安全洩漏恕限值之一的
急性洩漏事件(洩漏量以單位小時計量)
如ldquo執行摘要rdquo所述ICCA 製程安全事件之定義容許採用 ICCA 依據化學品全球調和制度
(GHS)健康危害分級為基礎所發展的提報標準或依據聯合國危險物品(UNDG)分類為基礎
所定義之 RP-754 二級製程安全事件(Tier II) 之提報標準GHS 恕限值詳見表 1各會員公司
可自行決定選擇哪一個表中的提報恕限值並在全球採用單一制度
ldquo急性rdquo洩漏 ndash易燃性可燃性或毒性化學物質從一次阻絕設施(如容器或管線)洩漏其
任一單位小時之洩漏量超過化學物質洩漏恕限量分述於表 1 中的 GHS 分類和表 2 中的
API 754 標準 Tier II 製程安全洩漏恕限值
洩壓裝置前述所定義之ldquo急性rdquo洩漏包括洩漏或排放至妥善設計且運作中的洩壓裝置若
洩漏或排放量達到表 1 中所列 GHS 恕限值或表 2 中所列 API 754 標準 Tier II 製程安全洩漏
恕限值且導致下列四種後果之任一項或以上之後果
1 二相排放或夾帶液體的排放液滴沉降至地面造成污染
2 排放至具潛在危險性的地點
3 廠內就地避難或疏散不包括預防性廠內就地避難或疏散
4 啟動公眾保護措施(如道路封閉)包括預防性公眾保護措施
13
洩漏或排放至妥善設計且運作中的洩壓裝置(如廢氣燃燒塔洗滌塔等)若其情況未達前
述四項標準中任何一項則不必提報
欲查看 API RP-754 標準可登入以下網站下載此標準httpwwwapiorgenvironment-
health-and-safetyprocess-safetyprocess-safety-standardsstandard-rp-754
一小時法則
為便於衡量此項指標提報與否洩漏恕限值是以物質在任一小時內之洩漏量為標準若任
一小時或更短時間內物質洩漏量達到或超過須提報恕限值該事故便屬於須提報的製程安
全事件急性洩漏事故通常不會超過一小時若無法確定洩漏持續時間則應假設其為一
小時
一次阻絕設施ndash 用來作為主要容器或用於運送或輸送物質之槽罐船隻管線軌道車
或設備主要容器在設計上可能包含二次阻絕設施系統以抑制及控制洩漏二次阻絕設
施系統包括(但不限於)儲槽防溢堤製程設備周遭的圍堵設施油水分離的排水收集系統
雙層儲槽的外壁等
嚴重程度表 ndash 嚴重程度加權可額外提供有關製程安全事件的有用資訊有助於帶動改善績
效附錄 A 為 RCLG 建議之製程安全事件嚴重程度加權計算方法根據附錄 A 的方法便
可藉由加總與各個後果類別關聯的分數計算出各製程安全事件的嚴重程度加權值ICCA
強烈建議採用嚴重程度加權制度因為此制度有助於提升溝通績效的能力也比較容易讓
利害關係人了解製程安全事件並且此嚴重程度加權值與其他製程安全績效指標提報方
式是不具相互比較性的
14
表 1 ndash GHS 分類表
物理性危害(GHS 2x)
洩漏恕限值(1 小時內)
STOTSpecific target organ toxicity(特定標的器官系統毒性物質)
15
表 2 ndash API RP 754 Tier II 分類表
洩漏恕限類別
物質危害性分類 acdef 恕限值
(戶外洩漏) 恕限值
(戶內b洩漏)
T2-1 TIH A 區物質 ge 05 kg (11 lb) ge 025 kg (055
lb)
T2-2 TIH B 區物質 ge 25 kg (55 lb) ge 125 kg (275
lb)
T2-3 TIH C 區物質 ge 10 kg (22 lb) ge 5 kg (11 lb)
T2-4 TIH D 區物質 ge 20 kg (44 lb) ge 10 kg (22 lb)
T2-5
易燃氣體 或 正常沸點 ≦ 35 (95 degF)閃火點lt23 (73 degF)的液體 或 其他包裝組別 I 類的物質 (酸鹼除外)
ge 50 kg (110 lb) ge 25 kg (55 lb)
T2-6
正常沸點 gt 35 degC (95 degF)閃火點 lt 23 degC (73degF)的液體 或 其他包裝組別 II 類的物質 (酸鹼除外)
ge 100 kg (220 lb) 或
ge 07 bbl
ge 50 kg (110 lb) 或
ge 035 bbl
T2-7
閃火點 gt 23 degC (73 degF)和 lt 60 degC (140 degF)的液體 或 閃火點 gt 60 degC (140 degF)的液體在閃火點或高於閃火點的溫度下洩漏 或 強酸鹼 (定義參見 RP 754 文件草案) 或 UNDG第2類第22部分 (不可燃無毒氣體)空氣除外 或 其他包裝組別 III 類的物質
ge 200 kg (440 lb) 或
ge 14 bbl
ge 100 kg (220 lb) 或
ge 07 bbl
T2-8
閃火點 gt 60 degC (140 degF) 和 lt 93 degC (200 degF)的液體在低於閃火點的溫度下洩漏 或 中度酸鹼
ge 1000 kg
(2200 lb) 或
ge 7 bbl
ge 500 kg
(1100 lb) 或
ge 35 bbl
TIH吸入性毒性危害物(Toxic Inhalation Hazard)
16
一般認為以公斤和磅或以磅和桶為單位的恕限值不盡等同各公司應該選用其中一組計量單位並在
所有紀錄文件中一體適用
在判定一種物質之洩漏恕限類別時首先應從物質之含吸入性毒性(TIH Zone)可燃性(閃火點和沸點)
或腐蝕性(強酸或鹼 vs中度酸或鹼)等特性來判別只有當物質的危險度無法利用上述簡單的特性來判別
時(如遇水反應劇烈)才採用UNDGL包裝組別
a 許多物質具有一種以上危險性正確的危險區(Hazard Zone)或包裝組別(Packing Group)歸屬應遵循DOT
49 CFR 1732a [14]或聯合國危險物品運輸建議書(UNRTDG)第2部分[12]的規定參見附錄F
b 具有四面完整牆(從地板到天花板)地板和屋頂的結構物
c 對於未列於UNDG的溶液無水成分將用TIH區或包裝組別分類溶液之恕限值將根據乾基重量之恕限
值反算
d 對於未知UNDG分類的混合物可計算每種成分在恕限值洩漏中的分量如果各種成分之分量的總和
等於或大於100即表示混合物超過門檻值若混合物有明顯且獨立的毒性及可燃性結果則可分
別計算毒性及可燃性危險度參見附錄EPSE實例amp問題 49ndash53
e 閃火點 gt 60 degC (140 degF) 和 lt 93 degC (200 degF)的液體在低於閃火點的溫度下洩漏無論洩漏量多寡其
一次阻絕設施失效(LOPC)均不屬於Tier 1製程安全事件(PSE)
f 中度酸鹼的一次阻絕設施失效無論洩漏量多寡均不屬於Tier 1製程安全事件
17 (K = 1000 MM = 1000000) (在環境影響類別方面若缺乏既有定義協會和會員公司應議定輸入標準)
附錄 A ndash 嚴重程度表鼓勵所有協會均採用嚴重程度加權制度
事件事故類別
嚴重程度等級
安全人體健康 火災或爆炸導致直接
成本 任 1 小時內物質洩
漏量 社區影響 環境影響[廠外]
4 級
1 分
對員工承攬商或再承攬商造成較輕傷害嚴重之傷害 (符合本地法規)
造成以下直接損失成本
美金$25 K ~ $25 K
洩漏量介於
1x le TQ lt 40x
官方宣告就地避難或疏散 (廠內或廠外) 預防性廠外就地避難或疏散
le 3 小時
重大環境整治成本
$25 K ~ $25 K
3 級
3 分
對員工承攬商或再承攬商造成之需要多日缺勤的傷害
對第三方造成之需要初步急救以外治療的傷害 (符合本地法規)
造成以下直接損失成本
$25 K ~ $250 K
洩漏量介於
40x le TQ lt 160x
官方宣告就地避難或疏散 (廠內或廠外)
預防性廠外就地避難或疏散
3 ~ 12 小時
重大環境整治成本
$25 K ~ $250 K
2 級
9 分
對員工承攬商或再承攬商造成 1 人死亡
對第三方造成 1 人住院治療
(符合本地法規)
造成以下直接損失成本
$250 K ~ $25 MM
洩漏量介於
160x le TQ lt 640x
官方宣告就地避難或疏散 (廠內或廠外)
預防性廠外就地避難或疏散
12 ~ 24 小時
重大環境整治成本
$250 K ~ $25 MM
1 級
27 分
對員工承攬商或再承攬商造成多人死亡
對第三方造成多人住院治療
對第三方造成 1 人死亡 (符合本地法規)
造成以下直接損失成本
ge $25 MM
洩漏量
ge 640x TQ
官方宣告就地避難或疏散 (廠內或廠外)
預防性廠外就地避難或疏散
ge 24 小時
重大環境整治成本
ge $25 MM
18 (K = 1000 MM = 1000000) (在環境影響類別方面若缺乏既有定義協會和會員公司應議定輸入標準)
嚴重程度表(附錄 A)細節說明
附錄 A 之設計目的僅適用於採用 GHS 分類制度(表 1)者如果你的公司係採用 API RP 754Tier II 製程安全指標提報恕限值表(表 2)請使用
API RP 754 製程安全嚴重程度表必須提醒的是依 API RP 754 的標準其嚴重程度表僅適用於一級(Tier I)事故去比較採用不同的嚴重度
表所評估出來的相對嚴重度並無統計上的意義
急性的環境成本 ndash 因製程安全事件造成廠外環境影響所導致之短期清理及物質處置的成本各會員公司可選擇將廠外環境影響相關成本另
外區分一個嚴重程度類別
比率調整指標
利用上述嚴重程度表可產生一系列以事件率為基礎的指標包括
製程安全總事件率 (PSTIR) 總事件次數 x 200000
總工作時數
製程安全事件嚴重程度率(PSESR) (即製程安全事件嚴重程度加權計算公式)
PSESR = 所有事件之總嚴重程度分數總合 x 200000
總工作時數
在計算此一比率時各 4 級事件被分配 1 分各 3 級事件被分配 3 分各 2 級事件被分配 9 分各 1 級事件被分配 27 分理論上每個
製程安全事件至少可分配到 1 分(亦即事件僅在一個類別符合第 4 級事件屬性)至多可分配到 135 分(亦即事件在所有五個類別中均符
合第 1 級事件屬性)
ldquoXrdquo級別製程安全事件率 嚴重度級別ldquoXrdquo之製程安全事件總數 x 200000
員工承攬商amp再承攬商總工作時數
X可以是嚴重度級別 432 或 1 級製程安全事件之總數事件之嚴重度等級是選用五類後果類別中之最嚴重等級
標準化 ndash 在某些協會和會員公司中製程安全事件是採 lsquo每 100 名rsquo員工每名員工每年平均工作時數為 2000 小時為基礎予以標準化因
此在lsquo每 100rsquo名rsquo員工的標準基礎上事件被乘以 200000 工作時數也有些其他協會和會員公司將標準化基礎設定為lsquo每 500 名rsquo員工
因此事件被乘以 1000000 工作時數協會和會員公司應就標準化基礎進行討論共同做成選項結論上述的公式設定為lsquo每 100 名rsquo員工
基礎
19
附錄 B ndash 常見問題集
適用性
我們建議會員公司記錄和提報在其所擁有或運作的工廠內發生的製程安全事件惟以下情況不須提報製
程安全事件
1 源自於公司廠區以外的製程安全事件
2 海上運輸船事故惟船隻為了輸送半成品或產品之目的已經與公司的設施相連接時發生的
事故仍須提報
3 卡車或軌道車事故惟卡車或軌道車為了輸送半成品或產品之目的已經與公司的設施相連
接時發生的事故仍須提報
4 許可證或法規容許之例行排放
5 不會造成製程安全危害的地下污染請注意若洩漏至地下導致地上發生須提報製程安全事
件如釋放出毒性蒸汽或致使易燃液體蓄積成池則不適用本排除條件
6 辦公建築事故(如辦公室暖氣設備爆炸火災外溢洩漏人員受傷或疾病等)
7 與疏散或一次阻絕設施失效無直接關聯之人員安全ldquo滑倒絆倒跌倒rdquo事故
8 沒有與製程相連接之輔助設備的一次阻絕設施(如小樣品瓶)失效事故
9 計劃中和在控制下的物質排放至設計用來收集或排放系統中(請注意物質從一次阻絕設施
在非計劃或非受控制情況下排放至收集或排放系統中則不適用本排除條件)
10 在製程區域外部或保養廠內執行之機械作業
說明與實例 ndash 以 GHS 表 1 為基礎
以下說明和實例有助於在評估須提報製程安全事件(PSE)時釐清可能存在的不確定部分
公司廠區
1 一輛第三方的卡車在公司廠區內卸載易燃產品時發生洩漏進而引起火災造成公司財物損失
$7000 美元(直接成本)雖然該卡車是ldquo由他人操作rdquo但其作業與製程相連接若公司的直接成
本財物損失達到或超過$2500 美元或已達到或超過其他 PSE 提報門檻(如1 人死亡)此事故即
屬於須提報的製程安全事件
2 與前例1 類似的例子載著易燃產品的卡車在廠外運輸途中翻覆引發火災並造成卡車毀損
該事故不屬於須提報的製程安全事件因為當時卡車並未與製程相連接
20
阻絕設施失效
3 儲槽液位計故障造成裝有ldquo易燃液體rdquo產品的儲槽外溢約 700 公斤的液體流入儲槽的防溢堤內
此事故屬於須提報的製程安全事件因為其ldquo急性rdquo洩漏量超過 100 公斤即使是阻絕在二次阻絕
設施防溢堤中亦然
4 一名從事維修工作的承攬商在開啟一個製程阻閥時被噴起的硫酸濺到造成嚴重灼傷和損失工
時的工傷此事故屬於須提報的製程安全事件因為它是涉及物質和一次阻絕設施失效的意外事
件對於因洩漏造成死亡和損工的工傷或疾病事故沒有洩漏恕限值
5 一名作業員開啟品管取樣點進行日常取樣作業時手部被一個破碎的玻璃瓶嚴重割破需要進行
縫合治療縫針造成第二天無法上班該事故不屬於須提報的製程安全事件因為它與一次阻絕
設施失效無關
ldquo急性rdquo洩漏
6 一名作業員在進行天然氣流量高於預期值之異常排除時發現天然氣管線上的一個安全閥門未適
當歸位因此天然氣經由氣液分離桶排放至排氣煙囪經進一步檢查作業員判斷在過去 6 個
月間總共有 100000 公斤天然氣以穩定的速率排放至大氣該事故不屬於須提報的製程安全事
件因為其洩漏速率(每小時約 10 公斤)不算ldquo急性rdquo洩漏(未超過易燃蒸汽每小時 100 公斤的恕限
值)
廢氣燃燒塔amp排放控制裝置 (如洗滌塔)
7 若化學物質被導引至廢氣燃燒塔或排放控制裝置(如洗滌塔)只要該廢氣燃燒塔或控制裝置運作在
正常設計範圍內便不屬於須提報的製程安全事件
8 若廢氣流速超過洗滌塔的設計負荷以致未經吸收的化學物質排出超過恕限值該事故屬於須提報
的製程安全事件(如本文註釋所述)
註釋自取得許可或妥善管理的裝置-包括釋壓裝置發生不預期的排放若 1 小時內洩漏量達到或
超過表 1 或表 2 所列的洩漏恕限值且導致下列四種後果之任一項或以上之後果該事故便屬於
須提報的製程安全事件
o 二相排放或夾帶液體的排放液滴沉降至地面造成污染
o 排放至具潛在危險性的地點)
o 廠內就地避難或疏散不包括預防性廠內就地避難或疏散
o 啟動公眾保護措施(如道路封閉)包括預防性公眾保護措施
21
安全洩壓裝置 系統
9 製程單元發生異常安全閥開啟將洩漏物質釋放到排氣口此釋壓排放裝置是依相關要求設計
的且氣體釋到大氣中並未造成不良後果這不是一個須提報的製程安全事件因為安全閥高
壓破裂盤以及類似的安全裝置是依據 API 521 或者同等的標準設計的且此排放並未造成 (1)
夾帶液體並導致須提報的製程安全事件的後果(譬如損失工時意外死亡火災或爆炸造成$2500
美元或以上的直接成本損失液體或毒性氣體洩漏量達到或超過恕限值(2) 啟動廠內或廠外就地
避難應變或(3)啟動公眾保護措施
10 製程單元發生異常安全閥並未開啟造成設備超壓易燃性氣體從一個法蘭處ldquo急性rdquo漏出來
洩露量超過 100 公斤(一小時內)的恕限值該事故屬於須提報的製程安全事件因為從法蘭處外
漏屬於製程安全事件應提報事項
損工事故
11 一名作業員走路時不慎滑倒造成損失工時之工傷滑倒原因為天氣狀況rdquo長期rdquo油垢的地面和
易滑鞋具該事故不屬於須提報的製程安全事件因為人員安全ldquo滑倒絆倒跌倒rdquo事故若非與
一次阻絕設施失效直接關聯的疏散或應變造成則不屬於須提報的製程安全事件
12 與前例相同的事件惟這次作業員跌倒是因為少量易燃液體外漏(如 1 小時內少於 10 公斤)在採取
相關應變措施時發生該事故屬於須提報的製程安全事件因為作業員係為了應變一次阻絕設施
失效的事故而跌倒若一次阻絕設施失效發生在公司廠區且造成失時工傷或死亡後果該事故
便屬於須提報的製程安全事件對於因洩漏造成死亡和損失工時之工傷事故沒有洩漏量門檻
13 與前例相同的事件惟這次作業員跌倒是在事件結束數小時之後該事故不屬於須提報的製程安
全事件在提報要件中所用的ldquo疏散rdquo和ldquo應變rdquo等術語指的是一次阻絕設施失效和相關緊急應變
活動正在持續中事件結束後滑倒絆倒跌倒(如ldquo事後rdquo清理和補救)不屬於須提報製程安全事件
14 工人在因附近設備一次阻絕設施失效在疏散過程中一名鷹架搭建工人從鷹架梯上跌落造成損
失工時之工傷該事故屬於須提報的製程安全事件
15 一名作業員行經一個設計不良的蒸汽卻水器時被外洩的蒸汽燙傷腳踝造成損失工時之工傷
該事故屬於須提報的製程安全事件因為雖然一次阻絕設施失效洩漏出的是蒸汽(而非碳氫化合物
或化學物質)但損失工時之工傷是由於洩漏物質的物理狀態所導致的
16 一個密閉空間依照計畫以氮氣吹清一名承攬商繞過安全管制進入該密閉空間因而死亡該事
故屬於須提報的死亡事件但不屬於須提報的製程安全事件因為其中不涉及非計劃或失控的一
次阻絕設施失效
17 情況同上惟這次氮氣是非刻意洩漏進入該局限空間該事故屬於須提報的製程安全事件(同時也
是一起死亡事件)因為該名承攬商的死亡與非計劃的一次阻絕設施失效有關
22
18 一名作業員因硫化氫(H2S)警報在進行應變處理時昏倒若警報確實是因非計劃或失控的 H2S 一次
阻絕設施失效的外洩事件該事故便屬於須提報的製程安全事件若警報是一個假警報則該事
故便不屬於須提報的製程安全事件因為沒有真正的化學品洩漏發生
管線
19 一條管線破漏1 小時內洩漏 2000 磅(900 公斤)易燃蒸氣到地面但洩漏位置在廠區內很偏僻的
地點該事故仍屬於須提報的製程安全事件因為ldquo偏僻rdquo不是提報與否的考量因素
與化學物質外洩無關之火災或能量釋放事故
一般通則而言唯有當火災或能量釋放事故是因化學物質洩漏所造成或其發生導致化學物質洩漏
超過提報恕限值這些事故才屬於須提報的製程安全事件實例包括
20 一場電氣火災影響製程操作導致甲苯洩漏 400 公斤該事故屬於須提報的製程安全事件因為
化學物質洩漏已超過甲苯的 100 公斤提報恕限值
21 發生電氣火災停電或任何公用資源供應中斷可能造成工廠停工及可能引起設備損失超過
$2500 美元(如因非正常停工導致反應器或設備損壞)但並未造成超過恕限值的化學物質洩漏
亦未造成死亡或嚴重工傷該事故不屬於須提報的製程安全事件因為設備損壞並非化學製程火
災爆炸造成且化學物質洩漏並未超過恕限值
海上運輸船
22 一艘由公司營運的海上運輸船在船上發生ldquo急性rdquo易燃物質外洩洩漏量超過 100 公斤該事故不
屬於須提報的製程安全事件因為除非海上運輸船是為了輸送半成品或產品而與煉油石化或化
學製造廠的設施相連接否則其洩漏事故便不被視為製程安全事件
23 一艘第三方駁船由一艘拖船推向碼頭結果撞上公司的碼頭駁船的一個船艙破裂且造成
1000 公斤柴油洩漏到海中該事故不屬於須提報的製程安全事件因為駁船當時並非停泊在碼
頭內且其作業並非在進行半成品或產品之輸送
卡車與軌道車
24 一輛公司的軌道車在運輸途中出軌造成超過 1000 公斤汽油洩漏該事故不屬於須提報的製程
安全事件因為在公司廠區外發生的軌道車事故不被視為與製程安全有關
23
25 一輛第三方卡車拖車在公司廠區內翻覆造成ldquo急性rdquo汽油洩漏超過 1000 公斤這事故不屬於須
提報的製程安全事件因為卡車拖車當時已不再與裝卸設備連接然而我們建議會員公司另
行訂定運輸安全事故指標將這類事故記錄下來
26 一位合約卡車作業者正在卸載液鹼時發生軟管脫落造成空氣中氣霧和或液鹼液洩漏 2500 公
斤該事故屬於須提報的製程安全事件因為洩漏量已超過液鹼的 100 公斤恕限值且事故發生
前卡車仍與裝卸設備相連接著
辦公建築
27 綜合辦公大樓發生鍋爐火災造成總計$75000 美元的直接成本損失該事故不屬於須提報的製
程安全事件因為辦公大樓事故不被視為與製程安全有關
人機介面事故
28 一名操作技術員在聚合物工廠的終端設備旁作業時受傷這傷害是因機械的人機介面的設備而
造成該事故不屬於須提報的製程安全事件因為技術員受傷並非因危險物質一次阻絕設施失效
而造成的
混合物
29 若混合物本身有 GHS 分類可利用其分類確定恕限值若混合物本身沒有 GHS 分類則可計算混
合物中每個單一組成分之洩漏量(公斤)相對於個別成分恕限值之比值作為其對混合物恕限值之
lsquo加權rsquo貢獻譬如若混合物在 1小時內的洩漏量為 100公斤其中包含 05公斤分類為劇毒 H300
的物質45 公斤分類為 H301 的物質40 公斤另一種分類為 H 開頭的物質其餘 55 公斤則為沒
有 GHS 分類的水分此混合物之計算式為051 + 4510 + 40100 = 05 + 045 + 04 = 135超過
1因此該事故被視為須提報的製程安全事件雖然混合物個別成分之洩漏量均未超過各該物質
本身的恕限值
直接損失成本
30 此一門檻所考慮的成本應為可直接歸因於火災或爆炸的成本譬如設備及結構損壞的重置成本
修理成本環境清理支出緊急應變和罰款直接成本不包括間接成本譬如業務機會損失設
備停機造成之利潤損失取得或運轉臨時設施之成本或為滿足顧客需求取得替代產品的成本
(產品損失)
24
31 範例連接到氣體處理系統的排放管發生易燃氣體外漏同時製程出現問題導致空氣進入同
一條排放管結果發生爆炸過高的壓力損壞了排放管及其相關上游設備包括一個密封罐並
未造成人員受傷修理成本約$12000 美元該事故屬於須提報的製程安全事件因為爆炸及火
災導致設備修理成本超過門檻
32 範例一次製程安全事件後公司又發生一種非常特殊的 GHS 第 5 類產品洩漏 50 公斤造成
$2000 美元的設備損失洩漏的產品是一種非常特別的混合物公司須負擔超過$50000 美元因
產品耗損而產生之材料成本該事故不屬於須提報的製程安全事件因為 GHS 第 5 類產品洩漏的
提報門檻為 100 公斤且產品耗損不被計入直接損失成本
天然災害
33 天然災害可能對化學製程作業構成重大風險且對製程設備造成損壞導致危害物質一次阻絕設
施失效當一種或多種天然災害被認為可能對工廠作業造成影響時製程安全和作業系統應從危
害及後果分析工廠機器設備設計公用設施失效及製程停工之操作程序緊急應變計畫及應變
措施等方面界定潛在風險進行防範
天然災害類型包括颶風及颱風(包括伴隨而來的風暴潮)水災龍捲風地震超強對流風暴(直
線風暴)野火火山爆發海嘯和山崩
若公司廠房設施遭遇天然災害且其後果觸發一種或以上提報門檻該事故便屬於須提報製程安
全事件
預防性公眾應變
34 預防性公眾應變是基於謹慎的態度所採取的一種措施譬如當發生一次阻絕設施失效時公司
可能在尚未進行任何評估(如方向與洩漏點的距離等等)前便要求全體工人就地避難又
如地方權責官員(如消防警察民防緊急應變管理部門)在獲報一家公司發生製程安全事件
後為防lsquo萬一rsquo風向改變或基於可能受到波及的人口敏感族群(如學童或老年人)可能在尚未接
獲明確資訊前便下令社區就地避難或疏散或採取公眾保護措施(如道路封閉)
製程附屬倉庫
35 製程附屬倉庫指的是位於廠內用於儲存將投入於生產製程或產自於製程之原料半成品或成品的
倉庫從製程的觀點看來製程附屬倉庫相當於一個大型儲槽但這些原料半成品或成品並不
是儲存在一的大型容器中而是裝在較小的容器裡(如太空包大桶桶罐等)
25
Appendix C ndash List of RCLG Taskforce Members
Name Affiliation
Peter Schmelzer Bayer CEFIC - Chairman
Americo Diniz Carvalho Neto Braskem
Bradford Johnson American Chemistry Council
David Cummings DuPont
Debra Phillips American Chemistry Council
Hans Schwarz BASF
Kathryn Walton Plastics and Chemicals Industries Association
Kazuyuki Akita Japanese Chemical Industry Association
Kelly Keim ExxonMobil Chemical Company API Representative
Kenan Stevick Dow
Kiyokazu Murata Japanese Chemical Industry Association
Larry Bowler SABIC
Lorna Young Chemical Industry Association of Canada
Louisa Nara Center for Chemical Process Safety
Luiz Shizuo Harayashiki Associaccedilatildeo Brasileira da Induacutestria Quiacutemica
Masatoshi Kumamoto Japanese Chemical Industry Association
Milton Lacerda Petrobras
Phil Scott Chemical Industries Association
Piet Knijff DSM European Process Safety Centre
Scott Donaldson and Eamon Chandler
Shell
Scott Wallace Olin Corporation
Shakeel Kadri Air Products and Chemicals Inc
26
附錄 D ndash 詳細活動時程表
2016 年 2017 年 2018 年 2019 年 2020 年
2 ndash 4 月
RCLG PS 先導計畫
5 月 ndash
針對準則進行調整釐清
6 月 向 RCLG 和 ICCA 董事會報
告先導計畫執行結果
7 ndash 12 月 RCLG 協會考量準
則並為其會員公司發展提報機制
如有需要RCLG可向 ICCA 申請能
力建立基金為會員公司舉辦製程安
全研習會
1 ndash 12 月
RCLG 協會開始向其會員公司蒐集製程安全數據
1 ndash 12 月
如有需要RCLG 各協會運用 RCLG 的基金及專
家舉辦製程安全及績效提報研習會
1 ndash 2 月
擁有數據的協會開始向RCLG 提報製程安全事件
(2017 年數據)
4 月 RCLG 檢討第一個提報循
環的結果挑戰及原始數據(內部)
6 月 RCLG 向 ICCA 董事會呈報
原始數據
7 ndash 12 月 必要時更新及調整準
則
如有需要RCLG 各協會運用 RCLG 的基金及專
家舉辦製程安全及績效提報研習會
1 ndash 2 月
擁有數據的協會開始向RCLG 提報製程安全事件
(2018 年數據)
4 月 RCLG 檢討第二個提報循
環的結果挑戰及原始數據(內部)
6 月 RCLG 向 ICCA 董事會呈報
原始數據
7 ndash 12 月 必要時更新及調整準
則
如有需要RCLG 協會運用 RCLG 的基金及專家
舉辦製程安全及績效提報研習會
1 ndash 2 月
所有協會開始向 RCLG 提報製程安全事件
製程安全事件提報成為
RCLG KPI 衡量指標建議基本集的一部分(2019 年數
據)
4 月 RCLG 檢討第二個提報循
環的結果挑戰及原始數據(內部考量外部提
報)
6 月 RCLG 向 ICCA 董事會呈報
原始數據
27
附錄 E ndash 選擇性 Excel 追蹤表
當會員公司開始追蹤製程安全事件時所有會員公司應採用單一表格以簡化數據分析同時讓所有公司均使用相同的追蹤表RCLG 設
計了一份選擇性追蹤表可供會員公司和協會先行利用之後他們可設計自己的追蹤表
在這裡下載追蹤表
ICCA Process Safety Event Tracking Sheetxlsx
本文件包含三個分頁分別是ldquo聯絡資料rdquoldquo調查表rdquo和儲存下拉式選單選項的ldquo請勿編輯rdquo分頁
備註
附錄 E 追蹤表僅供參考TRCA 將另行提供台灣版表格供會員公司提報
28
後語
台灣化學工業責任照顧協會(Taiwan Responsible Care Association TRCA)成立於 1998 年在台灣推行責任照顧制度已達 20 週年製造商成員
包括台灣主要上市上櫃化工公司會員公司化學品生產製造量約佔全國 80 2016 年台灣化工業的 Chemical Sales 仍站在全球第八名的位
置額度為 630 億歐元化工業總產值達到 34 兆新台幣提供國內 416 萬人工作機會
TRCA 扮演國內廠商與國際制度接軌的角色也是國內化工業與政府機關及利益相關者溝通的橋樑與管道TRCA 會員結構依業務性質分析
涵蓋石化生產化學品製造氣體生產倉儲運輸業化學品貿易業以及工程研發設計等公司TRCA 透過供應鏈及價值鏈推行責任
照顧制度組成毒性化學物質聯防組織協助法規溝通與研析會員名冊請參考 httpwwwtrcaorgtwtrcanwork2aspx
TRCA 於 2010 年成為 ICCA (International Council of Chemical Associations 國際化學工業協會)觀察員ICCA 成立於 1989 年是全球化工製造
業的聯合會也是化學工業與 UNEP OPCW 及 OECD 的交流窗口ICCA 與其會員協會及成員公司致力於邁向永續的未來確保人類健康與
環境安全與保護全球化工業擁有超過 4兆美元的價值影響所有經濟部門ICCA 的會員幾乎在全球每個國家都有商業活動在全球六大
洲推動創新並提供超過 2000 萬個工作機會
台灣化工業在全球占有重要的一席之地在國內產業鏈也位居關鍵位置無論對國內或國際都有身為地球村一員應盡之責我們期許藉由
製程安全指標提報能更進一步提升自我在工安衛生環保與永續發展等面向的績效表現
台灣化學工業責任照顧協會
10452 台北市中山區撫順街 8 號 7 樓
電話02-2585-0552
httpwwwtrcaorgtw
None | |
$2500 to $25000 | |
$25000 to $250000 | |
$250000 to $25000000 | |
More than $25000000 | |
Yes - Using GHS TABLE | |
Yes - Using API RP 754 TABLE | |
NO | |
NA | |
1x le TQ lt 40x | |
40x le TQ lt 160x | |
160x le TQ lt 640x | |
ge 640x TQ | |
Yes le 3 hours | |
Yes 3 hours ge 12 hours | |
Yes 12 hours ge 24 hours | |
Yes ge 24 hours | |
No | |
Small-scale | |
Medium-scale | |
Large-scale | |
No | |
Yes | |
No | |
middot Injury requiring treatment beyond first aid to an employee contractor or subcontractor | |
middot Days Away From Work injury to an employee contractor or subcontractor or middot Injury requiring treatment beyond first aid to a third party | |
middot A fatality of an employee contractor or subcontractor or middot A hospital admission of a third party | |
middot Multiple fatalities of employees contractors or subcontractors or middot multiple hospital admission of third parties or middot A fatality of a third party | |
NA | |
1x le TQ lt 3x | |
3x le TQ lt 9x | |
9x le TQ lt 27x | |
ge 27x TQ |
ICCA Process Safety Pilot Reporting ProgramFebruary 8 2016 | 1 | 2 | 3 | 4 | 5 | 6 | 7 | 8 | 9 | 10 | 12 | 13 | 14 | 15 | |||||||||||||||||||||||
SAFETY Details(Meeting Local Regulations) | Direct Cost from Fire or Explosion | Community Impact | Environmental Impact | Material Released(Measured using the 1 Hour Rule) | |||||||||||||||||||||||||||||||||
Company Association Details | |||||||||||||||||||||||||||||||||||||
GHS | API - RP 754 | ||||||||||||||||||||||||||||||||||||
Company or Assocation Name | Headquarter Association | Location of Event Ex - City State amp Country | Date and Time of Event | Safety InjuryDid the Event result in a Recordable Lost Time Accident or Fatality or Hospital admission of anyone on or off siteUse Drop Down Menu | Safety InjuryIf yes please insert the total number of injuries | Safety InjuryFor puropses of utilizing the Severity Table please indicate the level of severity by chosing the MOST SEVERE classification that describes your incidentUse Drop Down Menu | Safety InjuryDid the incident involve Fatalities If so how many total fatalities If none enter Zero | Safety InjuryPlease Report Total Employee Hours for Calendar Year 2015 | Safety InjuryPlease Report Total Contractor Hours for Calendar Year 2015 | Direct Cost Did the Event result in Direct Damage CostUse Drop Down Menu | Direct Cost If so how muchAmount is in US DollarsUse Drop Down Menu | Community ImpactDid the event result inbull Officially declared shelter-in-place or officially declared evacuation (on or off site)ORbull Precautionary off site shelter in place or evacuation Use Drop Down Menu | Environmental ImpactDid the event result inAcute Environmental Remediation CostIf so indicate the amount in US DollarsUse Drop Down Menu | Material ReleasedDid the Event result in an Acute Release of material beyond one of the two threshold tablesIf so indicate which Threshold Table you used to make this determinationUse Drop Down Menu | Material ReleasedIf so indicate the amount released USING GHS CLASSIFICATION TABLEUse Drop Down Menu | Material ReleasedIf so indicate the amount released USING THE THRESHOLD TABLE FROM API RP-754Use Drop Down Menu | Material ReleasedIf available please indicate the material released | ||||||||||||||||||||
1 | ABC Chemical Company | American Chemistry Council | Washington DC - USA | January 4 2016 | Yes | 2 | middot Days Away From Work injury to an employee contractor or subcontractor or middot Injury requiring treatment beyond first aid to a third party | 0 | 5525000 | 1500250 | No | $2500 to $25000 | Yes le 3 hours | $2500 to $25000 | Yes - Using GHS TABLE | 40x le TQ lt 160x | NA | Chlorine | |||||||||||||||||||
2 | XYZ Chemical Company | American Chemistry Council | Washington DC - USA | 5-Jan-16 | Yes | 1 | middot Injury requiring treatment beyond first aid to an employee contractor or subcontractor | 0 | 5525000 | 1500250 | Yes | $2500 to $25000 | No | $2500 to $25000 | Yes - Using API RP 754 TABLE | NA | 3x le TQ lt 9x | Benzene | |||||||||||||||||||
3 | |||||||||||||||||||||||||||||||||||||
4 | |||||||||||||||||||||||||||||||||||||
5 | |||||||||||||||||||||||||||||||||||||
6 | |||||||||||||||||||||||||||||||||||||
7 | |||||||||||||||||||||||||||||||||||||
8 | |||||||||||||||||||||||||||||||||||||
9 | |||||||||||||||||||||||||||||||||||||
10 | |||||||||||||||||||||||||||||||||||||
11 | |||||||||||||||||||||||||||||||||||||
12 | |||||||||||||||||||||||||||||||||||||
13 | |||||||||||||||||||||||||||||||||||||
14 | |||||||||||||||||||||||||||||||||||||
15 | |||||||||||||||||||||||||||||||||||||
16 | |||||||||||||||||||||||||||||||||||||
17 | |||||||||||||||||||||||||||||||||||||
18 | |||||||||||||||||||||||||||||||||||||
19 | |||||||||||||||||||||||||||||||||||||
20 | |||||||||||||||||||||||||||||||||||||
21 | |||||||||||||||||||||||||||||||||||||
22 | |||||||||||||||||||||||||||||||||||||
23 | |||||||||||||||||||||||||||||||||||||
24 | |||||||||||||||||||||||||||||||||||||
25 | |||||||||||||||||||||||||||||||||||||
Zero or None | Yes - Duration Unknown | ||||||||||||||||||||||||||||||||||||
Processes | Mode of Operation | Type of material released | Status of Operation | ||||
REFINING | Start-up | Flammable | Open | ||||
Alkylation HF | Planned shutdown | Combustible | Closed | ||||
Alkylation sulfuric | Emergency shutdown | Toxic | |||||
BitumenResidAsphalt | Normal | Corrosive | Tier 1 Acute Releases | ||||
Calcining | Upset | Utilities | No Release | ||||
Coking | Turnaround | Other | Category 1 | ||||
Crude | Routine maintenance | Category 2 | |||||
Desulfurization | Temporary | Evacuation | Category 3 | ||||
FCC | Other | Yes | Category 4 | ||||
Gas Treating | No | Category 5 | |||||
Hydrogen | Point of Release | Category 6 | |||||
Hydrotreating | Pump | Fire | Category 7 | ||||
Hydrocracking | Compressor | Yes | Multiple Categories | ||||
Isom | BlowerFan | No | |||||
MarineJetty | Pressure Vessel | lt $2500 | |||||
Reforming | FilterCoalescer | ||||||
Sulfur recovery | Furnace | PRDs | |||||
Vapor recoverylight ends | Boiler | Directly to Atmosphere | |||||
Wastewater | Heat exchanger | via Downstream Destructive Device | |||||
REFINING amp PETROCHEMICAL | Cooling Tower | No | |||||
Tank FarmStorage FacilityOffsite | Piping system | Yes | |||||
UtilitiesSteam PlantCogeneration | Reactor | No | |||||
Other | Atmospheric tank | ||||||
PETROCHEMICAL | FlareRelief System | Acute release above thresholds | |||||
CO H2 | Other | Yes | |||||
LNG | No | ||||||
Methane | Events | ||||||
Methanol | No Tier 1 Events | Indoor Outdoor | |||||
Methyl Mercaptan | No Tier 2 Events | No Release | |||||
Formaldehyde | No Tier 1 or Tier 2 Events | Indoor | |||||
Formaldehyde derivatives | NA | Outdoor | |||||
Acetic Acid | |||||||
Acetic Acid derivatives | Event Type | ||||||
Ethane | Injury | ||||||
Ethylene | Fire | ||||||
Ethanol | Explosion | ||||||
Ethylene oxide | PRD Discharge | ||||||
Ethylene derivatives | Acute Release | ||||||
Polyethylene | |||||||
Ethylene dichloride | General | ||||||
Ethylene dichloride derivatives | Yes | ||||||
Ethyl benzene | No | ||||||
Ethyl benzene derivatives | |||||||
Polystyrene | |||||||
Styrene-Butadiene | |||||||
Propane | |||||||
Propylene | |||||||
Polypropylene | |||||||
Isopropanol | |||||||
Propylene oxide | |||||||
Propylene oxide derivatives | |||||||
Butane | |||||||
Isobutane | |||||||
Isobutene | |||||||
Butadiene | |||||||
MTBE | |||||||
ETBE | |||||||
Pentane | |||||||
Hexane | |||||||
Cyclohexane | |||||||
Hexanol | |||||||
Aromatics Derivatives | |||||||
Benzene | |||||||
Toluene | |||||||
Xylene | |||||||
Para Xylene | |||||||
Amines Derivatives | |||||||
TDA MDA IPDA etc | |||||||
Isocyanates | |||||||
Specialty Chemicals | |||||||
LoadingUnloading | |||||||
Pilot Plant |
Instructions | ||||||||||||||
Step 1 | Complete the Contact Tab with your contact information and company information | |||||||||||||
Be sure to note the region of your reporting (IE North America France Japan etc) | ||||||||||||||
Survey on Process Safety Events | ||||||||||||||
Step 2 | Complete the survey one line per Process Safety Event for your companyregion | |||||||||||||
ALL REPORTED DATA SHOULD BE FROM CALENDAR YEAR 2017 | ||||||||||||||
Step 3 | Return completed survey to | |||||||||||||
Company Name | ||||||||||||||
Contact Person | All Surveys Due by xxx date | |||||||||||||
Address | ||||||||||||||
Fax | ||||||||||||||
Telephone | ||||||||||||||
Region | ||||||||||||||
None | |
$2500 to $25000 | |
$25000 to $250000 | |
$250000 to $25000000 | |
More than $25000000 | |
Yes - Using GHS TABLE | |
Yes - Using API RP 754 TABLE | |
NO | |
NA | |
1x le TQ lt 40x | |
40x le TQ lt 160x | |
160x le TQ lt 640x | |
ge 640x TQ | |
Yes le 3 hours | |
Yes 3 hours ge 12 hours | |
Yes 12 hours ge 24 hours | |
Yes ge 24 hours | |
No | |
Small-scale | |
Medium-scale | |
Large-scale | |
No | |
Yes | |
No | |
middot Injury requiring treatment beyond first aid to an employee contractor or subcontractor | |
middot Days Away From Work injury to an employee contractor or subcontractor or middot Injury requiring treatment beyond first aid to a third party | |
middot A fatality of an employee contractor or subcontractor or middot A hospital admission of a third party | |
middot Multiple fatalities of employees contractors or subcontractors or middot multiple hospital admission of third parties or middot A fatality of a third party | |
NA | |
1x le TQ lt 3x | |
3x le TQ lt 9x | |
9x le TQ lt 27x | |
ge 27x TQ |
ICCA Process Safety Pilot Reporting ProgramFebruary 8 2016 | 1 | 2 | 3 | 4 | 5 | 6 | 7 | 8 | 9 | 10 | 12 | 13 | 14 | 15 | |||||||||||||||||||||||
SAFETY Details(Meeting Local Regulations) | Direct Cost from Fire or Explosion | Community Impact | Environmental Impact | Material Released(Measured using the 1 Hour Rule) | |||||||||||||||||||||||||||||||||
Company Association Details | |||||||||||||||||||||||||||||||||||||
GHS | API - RP 754 | ||||||||||||||||||||||||||||||||||||
Company or Assocation Name | Headquarter Association | Location of Event Ex - City State amp Country | Date and Time of Event | Safety InjuryDid the Event result in a Recordable Lost Time Accident or Fatality or Hospital admission of anyone on or off siteUse Drop Down Menu | Safety InjuryIf yes please insert the total number of injuries | Safety InjuryFor puropses of utilizing the Severity Table please indicate the level of severity by chosing the MOST SEVERE classification that describes your incidentUse Drop Down Menu | Safety InjuryDid the incident involve Fatalities If so how many total fatalities If none enter Zero | Safety InjuryPlease Report Total Employee Hours for Calendar Year 2015 | Safety InjuryPlease Report Total Contractor Hours for Calendar Year 2015 | Direct Cost Did the Event result in Direct Damage CostUse Drop Down Menu | Direct Cost If so how muchAmount is in US DollarsUse Drop Down Menu | Community ImpactDid the event result inbull Officially declared shelter-in-place or officially declared evacuation (on or off site)ORbull Precautionary off site shelter in place or evacuation Use Drop Down Menu | Environmental ImpactDid the event result inAcute Environmental Remediation CostIf so indicate the amount in US DollarsUse Drop Down Menu | Material ReleasedDid the Event result in an Acute Release of material beyond one of the two threshold tablesIf so indicate which Threshold Table you used to make this determinationUse Drop Down Menu | Material ReleasedIf so indicate the amount released USING GHS CLASSIFICATION TABLEUse Drop Down Menu | Material ReleasedIf so indicate the amount released USING THE THRESHOLD TABLE FROM API RP-754Use Drop Down Menu | Material ReleasedIf available please indicate the material released | ||||||||||||||||||||
1 | ABC Chemical Company | American Chemistry Council | Washington DC - USA | January 4 2016 | Yes | 2 | middot Days Away From Work injury to an employee contractor or subcontractor or middot Injury requiring treatment beyond first aid to a third party | 0 | 5525000 | 1500250 | No | $2500 to $25000 | Yes le 3 hours | $2500 to $25000 | Yes - Using GHS TABLE | 40x le TQ lt 160x | NA | Chlorine | |||||||||||||||||||
2 | XYZ Chemical Company | American Chemistry Council | Washington DC - USA | 5-Jan-16 | Yes | 1 | middot Injury requiring treatment beyond first aid to an employee contractor or subcontractor | 0 | 5525000 | 1500250 | Yes | $2500 to $25000 | No | $2500 to $25000 | Yes - Using API RP 754 TABLE | NA | 3x le TQ lt 9x | Benzene | |||||||||||||||||||
3 | |||||||||||||||||||||||||||||||||||||
4 | |||||||||||||||||||||||||||||||||||||
5 | |||||||||||||||||||||||||||||||||||||
6 | |||||||||||||||||||||||||||||||||||||
7 | |||||||||||||||||||||||||||||||||||||
8 | |||||||||||||||||||||||||||||||||||||
9 | |||||||||||||||||||||||||||||||||||||
10 | |||||||||||||||||||||||||||||||||||||
11 | |||||||||||||||||||||||||||||||||||||
12 | |||||||||||||||||||||||||||||||||||||
13 | |||||||||||||||||||||||||||||||||||||
14 | |||||||||||||||||||||||||||||||||||||
15 | |||||||||||||||||||||||||||||||||||||
16 | |||||||||||||||||||||||||||||||||||||
17 | |||||||||||||||||||||||||||||||||||||
18 | |||||||||||||||||||||||||||||||||||||
19 | |||||||||||||||||||||||||||||||||||||
20 | |||||||||||||||||||||||||||||||||||||
21 | |||||||||||||||||||||||||||||||||||||
22 | |||||||||||||||||||||||||||||||||||||
23 | |||||||||||||||||||||||||||||||||||||
24 | |||||||||||||||||||||||||||||||||||||
25 | |||||||||||||||||||||||||||||||||||||
Zero or None | Yes - Duration Unknown | ||||||||||||||||||||||||||||||||||||
Processes | Mode of Operation | Type of material released | Status of Operation | ||||
REFINING | Start-up | Flammable | Open | ||||
Alkylation HF | Planned shutdown | Combustible | Closed | ||||
Alkylation sulfuric | Emergency shutdown | Toxic | |||||
BitumenResidAsphalt | Normal | Corrosive | Tier 1 Acute Releases | ||||
Calcining | Upset | Utilities | No Release | ||||
Coking | Turnaround | Other | Category 1 | ||||
Crude | Routine maintenance | Category 2 | |||||
Desulfurization | Temporary | Evacuation | Category 3 | ||||
FCC | Other | Yes | Category 4 | ||||
Gas Treating | No | Category 5 | |||||
Hydrogen | Point of Release | Category 6 | |||||
Hydrotreating | Pump | Fire | Category 7 | ||||
Hydrocracking | Compressor | Yes | Multiple Categories | ||||
Isom | BlowerFan | No | |||||
MarineJetty | Pressure Vessel | lt $2500 | |||||
Reforming | FilterCoalescer | ||||||
Sulfur recovery | Furnace | PRDs | |||||
Vapor recoverylight ends | Boiler | Directly to Atmosphere | |||||
Wastewater | Heat exchanger | via Downstream Destructive Device | |||||
REFINING amp PETROCHEMICAL | Cooling Tower | No | |||||
Tank FarmStorage FacilityOffsite | Piping system | Yes | |||||
UtilitiesSteam PlantCogeneration | Reactor | No | |||||
Other | Atmospheric tank | ||||||
PETROCHEMICAL | FlareRelief System | Acute release above thresholds | |||||
CO H2 | Other | Yes | |||||
LNG | No | ||||||
Methane | Events | ||||||
Methanol | No Tier 1 Events | Indoor Outdoor | |||||
Methyl Mercaptan | No Tier 2 Events | No Release | |||||
Formaldehyde | No Tier 1 or Tier 2 Events | Indoor | |||||
Formaldehyde derivatives | NA | Outdoor | |||||
Acetic Acid | |||||||
Acetic Acid derivatives | Event Type | ||||||
Ethane | Injury | ||||||
Ethylene | Fire | ||||||
Ethanol | Explosion | ||||||
Ethylene oxide | PRD Discharge | ||||||
Ethylene derivatives | Acute Release | ||||||
Polyethylene | |||||||
Ethylene dichloride | General | ||||||
Ethylene dichloride derivatives | Yes | ||||||
Ethyl benzene | No | ||||||
Ethyl benzene derivatives | |||||||
Polystyrene | |||||||
Styrene-Butadiene | |||||||
Propane | |||||||
Propylene | |||||||
Polypropylene | |||||||
Isopropanol | |||||||
Propylene oxide | |||||||
Propylene oxide derivatives | |||||||
Butane | |||||||
Isobutane | |||||||
Isobutene | |||||||
Butadiene | |||||||
MTBE | |||||||
ETBE | |||||||
Pentane | |||||||
Hexane | |||||||
Cyclohexane | |||||||
Hexanol | |||||||
Aromatics Derivatives | |||||||
Benzene | |||||||
Toluene | |||||||
Xylene | |||||||
Para Xylene | |||||||
Amines Derivatives | |||||||
TDA MDA IPDA etc | |||||||
Isocyanates | |||||||
Specialty Chemicals | |||||||
LoadingUnloading | |||||||
Pilot Plant |
Instructions | ||||||||||||||
Step 1 | Complete the Contact Tab with your contact information and company information | |||||||||||||
Be sure to note the region of your reporting (IE North America France Japan etc) | ||||||||||||||
Survey on Process Safety Events | ||||||||||||||
Step 2 | Complete the survey one line per Process Safety Event for your companyregion | |||||||||||||
ALL REPORTED DATA SHOULD BE FROM CALENDAR YEAR 2017 | ||||||||||||||
Step 3 | Return completed survey to | |||||||||||||
Company Name | ||||||||||||||
Contact Person | All Surveys Due by xxx date | |||||||||||||
Address | ||||||||||||||
Fax | ||||||||||||||
Telephone | ||||||||||||||
Region | ||||||||||||||
5
背景
責任照顧倡議(Responsible Carereg initiative)發起於 1985年其目的在於展現化學工業界持續
改善績效的承諾自從責任照顧倡議開始實施以來製程安全(Process Safety)一直是責任
照顧倡議的核心基礎之一實施責任照顧 30 多年來許多地區已發展出追蹤及提報製程
安全績效的方法然而一直未能建立一套全球調和的提報系統由於一些重大製程安全
事件仍不斷發生在 2012 年國際化學工業協會(ICCA)董事會便責成責任照顧領導群
(RCLG)在 2015 年以前擬定一套全球調和的製程安全績效提報機制
2013-14 年間一個由跨國公司和 RCLG 各協會組成的專案小組正式成立該專案小組由
拜耳醫療保健公司(Bayer HealthCare AG)的衛生安全及環保總監 Peter Schmelzer 博士擔任
召集人其任務即是研擬一套全球調和的 ICCA 製程安全績效提報機制專案小組成員表
詳見附錄 C在此期間美國石油學會(API)也著手開始進行其 API RP 754 ndash領先及落後製程
安全指標標準(Leading and Lagging Process Safety Metric Standard)之修訂RP-754 被廣泛應
用於美洲地區的煉油及石化產業以追蹤製程安全績效為了推動全球採行統一的標準
RCLG 專案小組致力於將其所提出之建議案與預訂於 2016 年第一季完成修訂之 API RP 754
達到完全調和
執行摘要
經過兩年多的討論研究辯論及可行性評估製程安全調和化專案小組(PSHT)建議 ICCA
採行一套製程安全事件發生率指標採行這套指標需要 RCLG 各協會蒐集會員公司在一年
內所發生之製程安全事件次數和工作總時數(包括員工和承攬商)製程安全事件發生率即
事件數除以工作時數的比率專案小組建議向 RCLG 提報這些數據的要求將在未來三年
內分階段實施同意已具有意願和能力提報的地區立即開始提報數據同時也給予正在發
展追蹤數據能力以進行首次提報的公司和機構若干緩衝時間
判定製程相關事件是否符合製程安全事件定義的標準係以化學物質的一次阻絕設施失效
或能量釋放以致引起下列任何一個影響考量面的門檻為根據1) 安全人員健康後果2)
事故造成損失之直接成本3) 社區影響4) 化學物質洩漏量(請參見提報判定流程圖所
示)ICCA 所建議之製程安全事件定義的四個影響考量面與 RP-754Tier II 事故標準的影
響考量面是完全一樣的除了化學物質洩漏量提報門檻有所差異外其他三個影響考量面
6
的提報門檻也是一樣的為因應此一差異針對化學物質外洩量提報門檻ICCA 製程安
全事件定義將容許會員公司採用 ICCA 依據化學品全球調和制度(GHS)健康危害分級為基礎
所發展的提報標準或依據聯合國危險物品(UNDG)分類為基礎所定義之 RP-754 二級製程
安全事件(Tier II) 之提報標準專案小組相信這兩套制度之提報標準雖然有所差異但
從其所涵蓋之化學物質領域和提報事故嚴重程度看來兩者皆相當健全雖然採用這兩種
不同提報門檻所收集和提報的事件數差異相對不大但在公司方面從原料及產品使用的角
度看來兩者可能會有非常明顯的不同因此專案小組提醒會員公司勿將自己公司的
結果與採用不同化學物質洩漏量提報門檻的公司做比較無論如何根據 RCLG 的提議
會員公司可選擇化學物質洩漏門檻以向國家及地區協會進行提報如果各協會有興趣轉
換兩種不同提報方式的結果RCLG 可提供轉換表但由於轉換運算非常複雜且須取得
原始事故數據專案小組相信相互轉換的附加價值不大因此不建議協會採取此一做法
專案小組相信這項製程安全事件提報建議案可廣泛運用在化學及石化產業實施製程安
全績效提報這項提報制度將為目前尚未追蹤製程安全績效的地區協會和會員公司提
供一個指引讓他們可以體認追蹤及提報製程安全績效可以帶來的益處至於已在蒐集製
程安全數據的地區協會和會員公司此建議案將有助於他們更廣泛地與全球接軌並將
重點放在持續改善製程安全績效這些改善製程安全績效的制度仰賴的是可靠的製程安
全事件數據改善製程安全績效正是責任照顧倡議的主要目的
7
RCLG 各協會應向 RCLG 提報的數據
RCLG 各協會每年必須依照下文提供的時程透過 RCLG 關鍵績效指標(KPI)提報網站向
ICCA 提報兩個數據
1 協會所屬會員公司的總工作時數(包括員工和承攬商)
2 製程安全事件總數
ICCA 將利用上述兩個數據以製程安全事件發生率(PSER)的形式報告製程安全績效PSER
計算之常態化是以每 100 位員工每位員工一年工作 2000 小時為基準
(總事件數 總工作時數) x 200000 = PSER
建議之提報時程
針對提報製程安全事件發生率專案小組建議一種分階段導入的方法此一時程可讓更多
已具經驗的協會及公司立即實施提報同時容許其他協會及公司從 2019 年起開始提報
RCLG 各協會必須透過 RCLG KPI 指標提報系統(httpkpiresponsiblecareeu)每年向 ICCA
提報兩個製程安全事件發生率數據如果你不知道你所屬協會的使用者名稱和密碼請聯
絡 RCLG
建議 RCLG 協會提報製程安全事件發生率的時程如下
2015 年 4 月 RCLG 考量專案小組建議案
2015 年 6 月 ICCA 理事會考量 RCLG 的最終建議
2015 年 7 月 RCLG 頒布首份詳細的提報指引供協會及會員公司遵
循
2016 年 2 月 RCLG 提報 RCLG 更新及強化提報指引並針對自願參加的協會
開始實施製程安全試行提報計畫RCLG 於 2016 年 6 月
頒布最終指引
2017 年 RCLG 各協會開始向會員公司蒐集數據
2018-2019 年 RCLG 提報 RCLG 各協會可選擇地開始提報製程安全數據
2020 年提報 RCLG 於 KPI 提報計畫中將製程安全納入為一項強制性
指標
參見附錄 D ndash 詳細活動時程
8
ICCA 製程安全事件判定標準流程圖
事故是否發生在廠內之
生產配銷儲存公
用或試驗工廠
是 是
是
否
否 是否造成須通報工傷
或
廠內廠外人員住院治
療
損壞是否對
公司造成
ge $2500 美
元的直接成
本損失
官方是否宣告就地
避難或疏散或廠
外預防性就地避難
或疏散
否
是
否
是屬於須通報製程安全事件
是
否
是
是
開始
否不符合製程安全事件認定
標準
是否超過 ICCA 或 API
754 Tier II 化學物質洩
漏恕限值
否 發生化學物質外洩火
災或爆炸是否起因於
或發生在化學製程單元
是否直接涉及某種化學物
質或化學製程
否
9
須提報製程安全事件之重要標準
總工作時數
RCLG 各協會應以加總的單一數字提報其所屬會員公司的員工和承攬商總工作時數為達
成本指引之目的各協會應參考其本地和地區對員工及承攬商之定義提報總時數之目標
應納入涉及化學製造之所有個人然而參與主要興建工程專案之人員則不納入計算譬
如為新建或擴建既有製程設施之設計工程和施工而成立之一次性專案組織的大規模投資
案會員公司提報總工作時數時應與人事部門統計之員工工時一致如此各公司便能
取得相同的職業與製程安全數據員工工時應包括所有化學製造作業的工時而非僅計算
發生製程安全事故之廠區的工時
製程安全事件
為執行 ICCA 提報目的製程安全事件之定義條件如下(必須同時符合 ABCD 四個條
件)
A 直接涉及某種化學物質或化學製程且
B 事故發生在廠內之生產配銷儲存公用或試驗工廠且
C 製程單元發生物質洩漏或能量釋放(如火災爆炸和內爆)且
D 已達到以下提報門檻之一
1 安全 工傷
導致記錄性的傷害(OSHA)損失工時或死亡或廠內外任何人員因此
而須住院治療或
2 直接損失成本
火災爆炸或為避免補救環境損害之必要清理作業導致$2500 美元
以上的直接成本支出或
3 就地避難 疏散
官方宣告就地避難(廠內或廠外)或
官方宣告疏散(廠內或廠外)或
廠外預防性就地避難或疏散或
4 洩漏恕限值
物質洩漏程度已達表 1 所列之任一 GHS 恕限值(洩漏量以單位小時計
量)
此外各公司亦可選擇採用 API RP-754 標準中所列之洩漏恕限值(表 2)請注意如欲查
看 API RP-754 標準可登入以下網站購買及下載httpwwwapiorgoil-and-natural-
gashealth-and-safetyprocess-safetyprocess-safety-standards
10
製程安全事件判定準則
A 涉及化學品
直接涉及某種化學物質或化學製程
製程安全事件或事故必須直接涉及化學物質或化學製程就此而言ldquo製程rdquo一詞泛指包含
石化生產所需要之設備和技術包括反應器儲槽管線鍋爐冷卻水塔和冷凍系
統helliphellip等未直接涉及化學物質或製程的事件無須提報譬如辦公大樓起火(即使該辦公大
樓位在廠區內亦然)
B 地點
事故發生在廠內之生產配銷儲存公用或試驗工廠
發生在廠內之生產配銷儲存(包括活動儲存區如倉庫 ndash 參見ldquo常見問題集rdquo)公用及
試驗工廠凡符合提報指標及定義的事故包括在廠區管理下之槽罐區輔助支援區(如
鍋爐室和廢水處理廠)和配銷管線所有須提報之事件應由負責該事故地點運作的公司
負提報之責此一規定亦適用於發生在承攬商作業區域內的事故在代工作業和多方共同
作業廠區負責運作該發生事故單位的公司應記錄事故始末並將之納入其提報中
C 物質洩漏
製程單元發生物質外洩或能量釋放(如火災爆炸和內爆)
物質外洩 ndash 製程任何物質發生非預期或無法控制的洩漏或釋放包括非毒性及不可燃物質
(如蒸汽熱水氮氣壓縮二氧化碳或壓縮空氣)且達到本文件所列四類提報門檻之一
項或以上之後果
在防治系統(如洗滌塔或廢氣燃燒塔)正常運作狀況下只要沒有任何洩漏或排放量超過
法定許可值即使排放到廢氣燃燒塔或滌氣塔仍被視為處於一次阻絕設施內然若排
放到二次阻絕設施(如廢水處理或防溢堤)將被視為製程安全事件因為物質已離開主要製
程系統
11
D 提報門檻
須提報製程安全事件必須達到以下提報門檻之一
1 安全 工傷
導致記錄性傷害(OSHA)損失工時或死亡或廠內外任何人員因此而須住院治療
記錄性傷害是指與工作有關所造成的傷害導致死亡暫時全失能工作受限制或需調整職
務較輕傷害嚴重之醫療處理失去意識或經醫師或其他合格醫療專業人員診斷為重大
傷害
損失工時傷害和死亡是指因製程相關的一次阻絕設施失效火災或爆炸導致以下任何一種
結果
員工(損失工時或死亡)
承攬商及再承攬商 (損失工時或死亡)
第三方(如來賓訪客快遞員)(受傷疾病導致住院治療或死亡)
住院治療是指醫院或其他具有住院病患保健設施的醫療單位正式接受病患住院提供病患
食宿及醫療護理且病患接受治療至少留置至隔日僅在醫院急診室治療或過夜處理不屬
於ldquo住院治療rdquo的定義範圍
須提報之工傷或死亡事件例如在清理作業期間因蒸汽洩漏造成人員燒燙傷壓力測試期間
帽蓋因受壓脫落造成人員身體傷害或取樣作業時因物質外濺造成人員化學灼傷無須提
報之工傷或死亡事件例如在執行維修作業時從高處的工作台墜落實驗室或辦公大樓火災
造成人員燒燙傷或挖掘工程塌陷造成人員傷害這些案例均與因製程造成的能量釋放或
物質洩漏無直接關聯
2 直接損失成本
火災爆炸或為避免補救環境損害之必要清理作業導致$2500美元以上的直接成本支出
此提報門檻所考慮的成本應為可直接歸因於火災或爆炸的成本譬如設備及結構損壞的重
置成本修理成本環境清理(廠內及廠外)支出緊急應變和罰款直接成本不包括間接
成本譬如業務機會損失設備停機造成之利潤損失取得或運轉臨時設施之成本或為
滿足顧客需求取得替代產品的成本(產品損失)
12
3 就地避難 疏散
官方宣告就地避難或疏散(廠內或廠外)或廠外預防性就地避難或疏散
就提報目的而言官方宣告就地避難或疏散(廠內或廠外)或廠外預防性就地避難或疏散
即達到此提報門檻
官方宣告 ndash 由地方權責機關(如消防警察民防緊急應變管理部門)或經授權的代表(如
派駐公司官員)下達的社區行動(如就地避難或疏散)宣告
預防性宣告 ndash 預防性公眾應變是基於謹慎的態度所採取的一種措施權責地方主管機關或經
授權的代表經合理判斷認定為維護公眾健康及安全發布必須採取就地避難或疏散之預
防性措施
就地避難 ndash 利用結構體及其內部空氣以暫時讓人員與室外危害性氣體隔離
疏散 ndash 基於安全或防護理由讓人員離開某處所的行動或過程
4 洩漏恕限值
超過表 1 中所列 GHS 恕限值或表 2 中所列 API 754 標準 Tier II 製程安全洩漏恕限值之一的
急性洩漏事件(洩漏量以單位小時計量)
如ldquo執行摘要rdquo所述ICCA 製程安全事件之定義容許採用 ICCA 依據化學品全球調和制度
(GHS)健康危害分級為基礎所發展的提報標準或依據聯合國危險物品(UNDG)分類為基礎
所定義之 RP-754 二級製程安全事件(Tier II) 之提報標準GHS 恕限值詳見表 1各會員公司
可自行決定選擇哪一個表中的提報恕限值並在全球採用單一制度
ldquo急性rdquo洩漏 ndash易燃性可燃性或毒性化學物質從一次阻絕設施(如容器或管線)洩漏其
任一單位小時之洩漏量超過化學物質洩漏恕限量分述於表 1 中的 GHS 分類和表 2 中的
API 754 標準 Tier II 製程安全洩漏恕限值
洩壓裝置前述所定義之ldquo急性rdquo洩漏包括洩漏或排放至妥善設計且運作中的洩壓裝置若
洩漏或排放量達到表 1 中所列 GHS 恕限值或表 2 中所列 API 754 標準 Tier II 製程安全洩漏
恕限值且導致下列四種後果之任一項或以上之後果
1 二相排放或夾帶液體的排放液滴沉降至地面造成污染
2 排放至具潛在危險性的地點
3 廠內就地避難或疏散不包括預防性廠內就地避難或疏散
4 啟動公眾保護措施(如道路封閉)包括預防性公眾保護措施
13
洩漏或排放至妥善設計且運作中的洩壓裝置(如廢氣燃燒塔洗滌塔等)若其情況未達前
述四項標準中任何一項則不必提報
欲查看 API RP-754 標準可登入以下網站下載此標準httpwwwapiorgenvironment-
health-and-safetyprocess-safetyprocess-safety-standardsstandard-rp-754
一小時法則
為便於衡量此項指標提報與否洩漏恕限值是以物質在任一小時內之洩漏量為標準若任
一小時或更短時間內物質洩漏量達到或超過須提報恕限值該事故便屬於須提報的製程安
全事件急性洩漏事故通常不會超過一小時若無法確定洩漏持續時間則應假設其為一
小時
一次阻絕設施ndash 用來作為主要容器或用於運送或輸送物質之槽罐船隻管線軌道車
或設備主要容器在設計上可能包含二次阻絕設施系統以抑制及控制洩漏二次阻絕設
施系統包括(但不限於)儲槽防溢堤製程設備周遭的圍堵設施油水分離的排水收集系統
雙層儲槽的外壁等
嚴重程度表 ndash 嚴重程度加權可額外提供有關製程安全事件的有用資訊有助於帶動改善績
效附錄 A 為 RCLG 建議之製程安全事件嚴重程度加權計算方法根據附錄 A 的方法便
可藉由加總與各個後果類別關聯的分數計算出各製程安全事件的嚴重程度加權值ICCA
強烈建議採用嚴重程度加權制度因為此制度有助於提升溝通績效的能力也比較容易讓
利害關係人了解製程安全事件並且此嚴重程度加權值與其他製程安全績效指標提報方
式是不具相互比較性的
14
表 1 ndash GHS 分類表
物理性危害(GHS 2x)
洩漏恕限值(1 小時內)
STOTSpecific target organ toxicity(特定標的器官系統毒性物質)
15
表 2 ndash API RP 754 Tier II 分類表
洩漏恕限類別
物質危害性分類 acdef 恕限值
(戶外洩漏) 恕限值
(戶內b洩漏)
T2-1 TIH A 區物質 ge 05 kg (11 lb) ge 025 kg (055
lb)
T2-2 TIH B 區物質 ge 25 kg (55 lb) ge 125 kg (275
lb)
T2-3 TIH C 區物質 ge 10 kg (22 lb) ge 5 kg (11 lb)
T2-4 TIH D 區物質 ge 20 kg (44 lb) ge 10 kg (22 lb)
T2-5
易燃氣體 或 正常沸點 ≦ 35 (95 degF)閃火點lt23 (73 degF)的液體 或 其他包裝組別 I 類的物質 (酸鹼除外)
ge 50 kg (110 lb) ge 25 kg (55 lb)
T2-6
正常沸點 gt 35 degC (95 degF)閃火點 lt 23 degC (73degF)的液體 或 其他包裝組別 II 類的物質 (酸鹼除外)
ge 100 kg (220 lb) 或
ge 07 bbl
ge 50 kg (110 lb) 或
ge 035 bbl
T2-7
閃火點 gt 23 degC (73 degF)和 lt 60 degC (140 degF)的液體 或 閃火點 gt 60 degC (140 degF)的液體在閃火點或高於閃火點的溫度下洩漏 或 強酸鹼 (定義參見 RP 754 文件草案) 或 UNDG第2類第22部分 (不可燃無毒氣體)空氣除外 或 其他包裝組別 III 類的物質
ge 200 kg (440 lb) 或
ge 14 bbl
ge 100 kg (220 lb) 或
ge 07 bbl
T2-8
閃火點 gt 60 degC (140 degF) 和 lt 93 degC (200 degF)的液體在低於閃火點的溫度下洩漏 或 中度酸鹼
ge 1000 kg
(2200 lb) 或
ge 7 bbl
ge 500 kg
(1100 lb) 或
ge 35 bbl
TIH吸入性毒性危害物(Toxic Inhalation Hazard)
16
一般認為以公斤和磅或以磅和桶為單位的恕限值不盡等同各公司應該選用其中一組計量單位並在
所有紀錄文件中一體適用
在判定一種物質之洩漏恕限類別時首先應從物質之含吸入性毒性(TIH Zone)可燃性(閃火點和沸點)
或腐蝕性(強酸或鹼 vs中度酸或鹼)等特性來判別只有當物質的危險度無法利用上述簡單的特性來判別
時(如遇水反應劇烈)才採用UNDGL包裝組別
a 許多物質具有一種以上危險性正確的危險區(Hazard Zone)或包裝組別(Packing Group)歸屬應遵循DOT
49 CFR 1732a [14]或聯合國危險物品運輸建議書(UNRTDG)第2部分[12]的規定參見附錄F
b 具有四面完整牆(從地板到天花板)地板和屋頂的結構物
c 對於未列於UNDG的溶液無水成分將用TIH區或包裝組別分類溶液之恕限值將根據乾基重量之恕限
值反算
d 對於未知UNDG分類的混合物可計算每種成分在恕限值洩漏中的分量如果各種成分之分量的總和
等於或大於100即表示混合物超過門檻值若混合物有明顯且獨立的毒性及可燃性結果則可分
別計算毒性及可燃性危險度參見附錄EPSE實例amp問題 49ndash53
e 閃火點 gt 60 degC (140 degF) 和 lt 93 degC (200 degF)的液體在低於閃火點的溫度下洩漏無論洩漏量多寡其
一次阻絕設施失效(LOPC)均不屬於Tier 1製程安全事件(PSE)
f 中度酸鹼的一次阻絕設施失效無論洩漏量多寡均不屬於Tier 1製程安全事件
17 (K = 1000 MM = 1000000) (在環境影響類別方面若缺乏既有定義協會和會員公司應議定輸入標準)
附錄 A ndash 嚴重程度表鼓勵所有協會均採用嚴重程度加權制度
事件事故類別
嚴重程度等級
安全人體健康 火災或爆炸導致直接
成本 任 1 小時內物質洩
漏量 社區影響 環境影響[廠外]
4 級
1 分
對員工承攬商或再承攬商造成較輕傷害嚴重之傷害 (符合本地法規)
造成以下直接損失成本
美金$25 K ~ $25 K
洩漏量介於
1x le TQ lt 40x
官方宣告就地避難或疏散 (廠內或廠外) 預防性廠外就地避難或疏散
le 3 小時
重大環境整治成本
$25 K ~ $25 K
3 級
3 分
對員工承攬商或再承攬商造成之需要多日缺勤的傷害
對第三方造成之需要初步急救以外治療的傷害 (符合本地法規)
造成以下直接損失成本
$25 K ~ $250 K
洩漏量介於
40x le TQ lt 160x
官方宣告就地避難或疏散 (廠內或廠外)
預防性廠外就地避難或疏散
3 ~ 12 小時
重大環境整治成本
$25 K ~ $250 K
2 級
9 分
對員工承攬商或再承攬商造成 1 人死亡
對第三方造成 1 人住院治療
(符合本地法規)
造成以下直接損失成本
$250 K ~ $25 MM
洩漏量介於
160x le TQ lt 640x
官方宣告就地避難或疏散 (廠內或廠外)
預防性廠外就地避難或疏散
12 ~ 24 小時
重大環境整治成本
$250 K ~ $25 MM
1 級
27 分
對員工承攬商或再承攬商造成多人死亡
對第三方造成多人住院治療
對第三方造成 1 人死亡 (符合本地法規)
造成以下直接損失成本
ge $25 MM
洩漏量
ge 640x TQ
官方宣告就地避難或疏散 (廠內或廠外)
預防性廠外就地避難或疏散
ge 24 小時
重大環境整治成本
ge $25 MM
18 (K = 1000 MM = 1000000) (在環境影響類別方面若缺乏既有定義協會和會員公司應議定輸入標準)
嚴重程度表(附錄 A)細節說明
附錄 A 之設計目的僅適用於採用 GHS 分類制度(表 1)者如果你的公司係採用 API RP 754Tier II 製程安全指標提報恕限值表(表 2)請使用
API RP 754 製程安全嚴重程度表必須提醒的是依 API RP 754 的標準其嚴重程度表僅適用於一級(Tier I)事故去比較採用不同的嚴重度
表所評估出來的相對嚴重度並無統計上的意義
急性的環境成本 ndash 因製程安全事件造成廠外環境影響所導致之短期清理及物質處置的成本各會員公司可選擇將廠外環境影響相關成本另
外區分一個嚴重程度類別
比率調整指標
利用上述嚴重程度表可產生一系列以事件率為基礎的指標包括
製程安全總事件率 (PSTIR) 總事件次數 x 200000
總工作時數
製程安全事件嚴重程度率(PSESR) (即製程安全事件嚴重程度加權計算公式)
PSESR = 所有事件之總嚴重程度分數總合 x 200000
總工作時數
在計算此一比率時各 4 級事件被分配 1 分各 3 級事件被分配 3 分各 2 級事件被分配 9 分各 1 級事件被分配 27 分理論上每個
製程安全事件至少可分配到 1 分(亦即事件僅在一個類別符合第 4 級事件屬性)至多可分配到 135 分(亦即事件在所有五個類別中均符
合第 1 級事件屬性)
ldquoXrdquo級別製程安全事件率 嚴重度級別ldquoXrdquo之製程安全事件總數 x 200000
員工承攬商amp再承攬商總工作時數
X可以是嚴重度級別 432 或 1 級製程安全事件之總數事件之嚴重度等級是選用五類後果類別中之最嚴重等級
標準化 ndash 在某些協會和會員公司中製程安全事件是採 lsquo每 100 名rsquo員工每名員工每年平均工作時數為 2000 小時為基礎予以標準化因
此在lsquo每 100rsquo名rsquo員工的標準基礎上事件被乘以 200000 工作時數也有些其他協會和會員公司將標準化基礎設定為lsquo每 500 名rsquo員工
因此事件被乘以 1000000 工作時數協會和會員公司應就標準化基礎進行討論共同做成選項結論上述的公式設定為lsquo每 100 名rsquo員工
基礎
19
附錄 B ndash 常見問題集
適用性
我們建議會員公司記錄和提報在其所擁有或運作的工廠內發生的製程安全事件惟以下情況不須提報製
程安全事件
1 源自於公司廠區以外的製程安全事件
2 海上運輸船事故惟船隻為了輸送半成品或產品之目的已經與公司的設施相連接時發生的
事故仍須提報
3 卡車或軌道車事故惟卡車或軌道車為了輸送半成品或產品之目的已經與公司的設施相連
接時發生的事故仍須提報
4 許可證或法規容許之例行排放
5 不會造成製程安全危害的地下污染請注意若洩漏至地下導致地上發生須提報製程安全事
件如釋放出毒性蒸汽或致使易燃液體蓄積成池則不適用本排除條件
6 辦公建築事故(如辦公室暖氣設備爆炸火災外溢洩漏人員受傷或疾病等)
7 與疏散或一次阻絕設施失效無直接關聯之人員安全ldquo滑倒絆倒跌倒rdquo事故
8 沒有與製程相連接之輔助設備的一次阻絕設施(如小樣品瓶)失效事故
9 計劃中和在控制下的物質排放至設計用來收集或排放系統中(請注意物質從一次阻絕設施
在非計劃或非受控制情況下排放至收集或排放系統中則不適用本排除條件)
10 在製程區域外部或保養廠內執行之機械作業
說明與實例 ndash 以 GHS 表 1 為基礎
以下說明和實例有助於在評估須提報製程安全事件(PSE)時釐清可能存在的不確定部分
公司廠區
1 一輛第三方的卡車在公司廠區內卸載易燃產品時發生洩漏進而引起火災造成公司財物損失
$7000 美元(直接成本)雖然該卡車是ldquo由他人操作rdquo但其作業與製程相連接若公司的直接成
本財物損失達到或超過$2500 美元或已達到或超過其他 PSE 提報門檻(如1 人死亡)此事故即
屬於須提報的製程安全事件
2 與前例1 類似的例子載著易燃產品的卡車在廠外運輸途中翻覆引發火災並造成卡車毀損
該事故不屬於須提報的製程安全事件因為當時卡車並未與製程相連接
20
阻絕設施失效
3 儲槽液位計故障造成裝有ldquo易燃液體rdquo產品的儲槽外溢約 700 公斤的液體流入儲槽的防溢堤內
此事故屬於須提報的製程安全事件因為其ldquo急性rdquo洩漏量超過 100 公斤即使是阻絕在二次阻絕
設施防溢堤中亦然
4 一名從事維修工作的承攬商在開啟一個製程阻閥時被噴起的硫酸濺到造成嚴重灼傷和損失工
時的工傷此事故屬於須提報的製程安全事件因為它是涉及物質和一次阻絕設施失效的意外事
件對於因洩漏造成死亡和損工的工傷或疾病事故沒有洩漏恕限值
5 一名作業員開啟品管取樣點進行日常取樣作業時手部被一個破碎的玻璃瓶嚴重割破需要進行
縫合治療縫針造成第二天無法上班該事故不屬於須提報的製程安全事件因為它與一次阻絕
設施失效無關
ldquo急性rdquo洩漏
6 一名作業員在進行天然氣流量高於預期值之異常排除時發現天然氣管線上的一個安全閥門未適
當歸位因此天然氣經由氣液分離桶排放至排氣煙囪經進一步檢查作業員判斷在過去 6 個
月間總共有 100000 公斤天然氣以穩定的速率排放至大氣該事故不屬於須提報的製程安全事
件因為其洩漏速率(每小時約 10 公斤)不算ldquo急性rdquo洩漏(未超過易燃蒸汽每小時 100 公斤的恕限
值)
廢氣燃燒塔amp排放控制裝置 (如洗滌塔)
7 若化學物質被導引至廢氣燃燒塔或排放控制裝置(如洗滌塔)只要該廢氣燃燒塔或控制裝置運作在
正常設計範圍內便不屬於須提報的製程安全事件
8 若廢氣流速超過洗滌塔的設計負荷以致未經吸收的化學物質排出超過恕限值該事故屬於須提報
的製程安全事件(如本文註釋所述)
註釋自取得許可或妥善管理的裝置-包括釋壓裝置發生不預期的排放若 1 小時內洩漏量達到或
超過表 1 或表 2 所列的洩漏恕限值且導致下列四種後果之任一項或以上之後果該事故便屬於
須提報的製程安全事件
o 二相排放或夾帶液體的排放液滴沉降至地面造成污染
o 排放至具潛在危險性的地點)
o 廠內就地避難或疏散不包括預防性廠內就地避難或疏散
o 啟動公眾保護措施(如道路封閉)包括預防性公眾保護措施
21
安全洩壓裝置 系統
9 製程單元發生異常安全閥開啟將洩漏物質釋放到排氣口此釋壓排放裝置是依相關要求設計
的且氣體釋到大氣中並未造成不良後果這不是一個須提報的製程安全事件因為安全閥高
壓破裂盤以及類似的安全裝置是依據 API 521 或者同等的標準設計的且此排放並未造成 (1)
夾帶液體並導致須提報的製程安全事件的後果(譬如損失工時意外死亡火災或爆炸造成$2500
美元或以上的直接成本損失液體或毒性氣體洩漏量達到或超過恕限值(2) 啟動廠內或廠外就地
避難應變或(3)啟動公眾保護措施
10 製程單元發生異常安全閥並未開啟造成設備超壓易燃性氣體從一個法蘭處ldquo急性rdquo漏出來
洩露量超過 100 公斤(一小時內)的恕限值該事故屬於須提報的製程安全事件因為從法蘭處外
漏屬於製程安全事件應提報事項
損工事故
11 一名作業員走路時不慎滑倒造成損失工時之工傷滑倒原因為天氣狀況rdquo長期rdquo油垢的地面和
易滑鞋具該事故不屬於須提報的製程安全事件因為人員安全ldquo滑倒絆倒跌倒rdquo事故若非與
一次阻絕設施失效直接關聯的疏散或應變造成則不屬於須提報的製程安全事件
12 與前例相同的事件惟這次作業員跌倒是因為少量易燃液體外漏(如 1 小時內少於 10 公斤)在採取
相關應變措施時發生該事故屬於須提報的製程安全事件因為作業員係為了應變一次阻絕設施
失效的事故而跌倒若一次阻絕設施失效發生在公司廠區且造成失時工傷或死亡後果該事故
便屬於須提報的製程安全事件對於因洩漏造成死亡和損失工時之工傷事故沒有洩漏量門檻
13 與前例相同的事件惟這次作業員跌倒是在事件結束數小時之後該事故不屬於須提報的製程安
全事件在提報要件中所用的ldquo疏散rdquo和ldquo應變rdquo等術語指的是一次阻絕設施失效和相關緊急應變
活動正在持續中事件結束後滑倒絆倒跌倒(如ldquo事後rdquo清理和補救)不屬於須提報製程安全事件
14 工人在因附近設備一次阻絕設施失效在疏散過程中一名鷹架搭建工人從鷹架梯上跌落造成損
失工時之工傷該事故屬於須提報的製程安全事件
15 一名作業員行經一個設計不良的蒸汽卻水器時被外洩的蒸汽燙傷腳踝造成損失工時之工傷
該事故屬於須提報的製程安全事件因為雖然一次阻絕設施失效洩漏出的是蒸汽(而非碳氫化合物
或化學物質)但損失工時之工傷是由於洩漏物質的物理狀態所導致的
16 一個密閉空間依照計畫以氮氣吹清一名承攬商繞過安全管制進入該密閉空間因而死亡該事
故屬於須提報的死亡事件但不屬於須提報的製程安全事件因為其中不涉及非計劃或失控的一
次阻絕設施失效
17 情況同上惟這次氮氣是非刻意洩漏進入該局限空間該事故屬於須提報的製程安全事件(同時也
是一起死亡事件)因為該名承攬商的死亡與非計劃的一次阻絕設施失效有關
22
18 一名作業員因硫化氫(H2S)警報在進行應變處理時昏倒若警報確實是因非計劃或失控的 H2S 一次
阻絕設施失效的外洩事件該事故便屬於須提報的製程安全事件若警報是一個假警報則該事
故便不屬於須提報的製程安全事件因為沒有真正的化學品洩漏發生
管線
19 一條管線破漏1 小時內洩漏 2000 磅(900 公斤)易燃蒸氣到地面但洩漏位置在廠區內很偏僻的
地點該事故仍屬於須提報的製程安全事件因為ldquo偏僻rdquo不是提報與否的考量因素
與化學物質外洩無關之火災或能量釋放事故
一般通則而言唯有當火災或能量釋放事故是因化學物質洩漏所造成或其發生導致化學物質洩漏
超過提報恕限值這些事故才屬於須提報的製程安全事件實例包括
20 一場電氣火災影響製程操作導致甲苯洩漏 400 公斤該事故屬於須提報的製程安全事件因為
化學物質洩漏已超過甲苯的 100 公斤提報恕限值
21 發生電氣火災停電或任何公用資源供應中斷可能造成工廠停工及可能引起設備損失超過
$2500 美元(如因非正常停工導致反應器或設備損壞)但並未造成超過恕限值的化學物質洩漏
亦未造成死亡或嚴重工傷該事故不屬於須提報的製程安全事件因為設備損壞並非化學製程火
災爆炸造成且化學物質洩漏並未超過恕限值
海上運輸船
22 一艘由公司營運的海上運輸船在船上發生ldquo急性rdquo易燃物質外洩洩漏量超過 100 公斤該事故不
屬於須提報的製程安全事件因為除非海上運輸船是為了輸送半成品或產品而與煉油石化或化
學製造廠的設施相連接否則其洩漏事故便不被視為製程安全事件
23 一艘第三方駁船由一艘拖船推向碼頭結果撞上公司的碼頭駁船的一個船艙破裂且造成
1000 公斤柴油洩漏到海中該事故不屬於須提報的製程安全事件因為駁船當時並非停泊在碼
頭內且其作業並非在進行半成品或產品之輸送
卡車與軌道車
24 一輛公司的軌道車在運輸途中出軌造成超過 1000 公斤汽油洩漏該事故不屬於須提報的製程
安全事件因為在公司廠區外發生的軌道車事故不被視為與製程安全有關
23
25 一輛第三方卡車拖車在公司廠區內翻覆造成ldquo急性rdquo汽油洩漏超過 1000 公斤這事故不屬於須
提報的製程安全事件因為卡車拖車當時已不再與裝卸設備連接然而我們建議會員公司另
行訂定運輸安全事故指標將這類事故記錄下來
26 一位合約卡車作業者正在卸載液鹼時發生軟管脫落造成空氣中氣霧和或液鹼液洩漏 2500 公
斤該事故屬於須提報的製程安全事件因為洩漏量已超過液鹼的 100 公斤恕限值且事故發生
前卡車仍與裝卸設備相連接著
辦公建築
27 綜合辦公大樓發生鍋爐火災造成總計$75000 美元的直接成本損失該事故不屬於須提報的製
程安全事件因為辦公大樓事故不被視為與製程安全有關
人機介面事故
28 一名操作技術員在聚合物工廠的終端設備旁作業時受傷這傷害是因機械的人機介面的設備而
造成該事故不屬於須提報的製程安全事件因為技術員受傷並非因危險物質一次阻絕設施失效
而造成的
混合物
29 若混合物本身有 GHS 分類可利用其分類確定恕限值若混合物本身沒有 GHS 分類則可計算混
合物中每個單一組成分之洩漏量(公斤)相對於個別成分恕限值之比值作為其對混合物恕限值之
lsquo加權rsquo貢獻譬如若混合物在 1小時內的洩漏量為 100公斤其中包含 05公斤分類為劇毒 H300
的物質45 公斤分類為 H301 的物質40 公斤另一種分類為 H 開頭的物質其餘 55 公斤則為沒
有 GHS 分類的水分此混合物之計算式為051 + 4510 + 40100 = 05 + 045 + 04 = 135超過
1因此該事故被視為須提報的製程安全事件雖然混合物個別成分之洩漏量均未超過各該物質
本身的恕限值
直接損失成本
30 此一門檻所考慮的成本應為可直接歸因於火災或爆炸的成本譬如設備及結構損壞的重置成本
修理成本環境清理支出緊急應變和罰款直接成本不包括間接成本譬如業務機會損失設
備停機造成之利潤損失取得或運轉臨時設施之成本或為滿足顧客需求取得替代產品的成本
(產品損失)
24
31 範例連接到氣體處理系統的排放管發生易燃氣體外漏同時製程出現問題導致空氣進入同
一條排放管結果發生爆炸過高的壓力損壞了排放管及其相關上游設備包括一個密封罐並
未造成人員受傷修理成本約$12000 美元該事故屬於須提報的製程安全事件因為爆炸及火
災導致設備修理成本超過門檻
32 範例一次製程安全事件後公司又發生一種非常特殊的 GHS 第 5 類產品洩漏 50 公斤造成
$2000 美元的設備損失洩漏的產品是一種非常特別的混合物公司須負擔超過$50000 美元因
產品耗損而產生之材料成本該事故不屬於須提報的製程安全事件因為 GHS 第 5 類產品洩漏的
提報門檻為 100 公斤且產品耗損不被計入直接損失成本
天然災害
33 天然災害可能對化學製程作業構成重大風險且對製程設備造成損壞導致危害物質一次阻絕設
施失效當一種或多種天然災害被認為可能對工廠作業造成影響時製程安全和作業系統應從危
害及後果分析工廠機器設備設計公用設施失效及製程停工之操作程序緊急應變計畫及應變
措施等方面界定潛在風險進行防範
天然災害類型包括颶風及颱風(包括伴隨而來的風暴潮)水災龍捲風地震超強對流風暴(直
線風暴)野火火山爆發海嘯和山崩
若公司廠房設施遭遇天然災害且其後果觸發一種或以上提報門檻該事故便屬於須提報製程安
全事件
預防性公眾應變
34 預防性公眾應變是基於謹慎的態度所採取的一種措施譬如當發生一次阻絕設施失效時公司
可能在尚未進行任何評估(如方向與洩漏點的距離等等)前便要求全體工人就地避難又
如地方權責官員(如消防警察民防緊急應變管理部門)在獲報一家公司發生製程安全事件
後為防lsquo萬一rsquo風向改變或基於可能受到波及的人口敏感族群(如學童或老年人)可能在尚未接
獲明確資訊前便下令社區就地避難或疏散或採取公眾保護措施(如道路封閉)
製程附屬倉庫
35 製程附屬倉庫指的是位於廠內用於儲存將投入於生產製程或產自於製程之原料半成品或成品的
倉庫從製程的觀點看來製程附屬倉庫相當於一個大型儲槽但這些原料半成品或成品並不
是儲存在一的大型容器中而是裝在較小的容器裡(如太空包大桶桶罐等)
25
Appendix C ndash List of RCLG Taskforce Members
Name Affiliation
Peter Schmelzer Bayer CEFIC - Chairman
Americo Diniz Carvalho Neto Braskem
Bradford Johnson American Chemistry Council
David Cummings DuPont
Debra Phillips American Chemistry Council
Hans Schwarz BASF
Kathryn Walton Plastics and Chemicals Industries Association
Kazuyuki Akita Japanese Chemical Industry Association
Kelly Keim ExxonMobil Chemical Company API Representative
Kenan Stevick Dow
Kiyokazu Murata Japanese Chemical Industry Association
Larry Bowler SABIC
Lorna Young Chemical Industry Association of Canada
Louisa Nara Center for Chemical Process Safety
Luiz Shizuo Harayashiki Associaccedilatildeo Brasileira da Induacutestria Quiacutemica
Masatoshi Kumamoto Japanese Chemical Industry Association
Milton Lacerda Petrobras
Phil Scott Chemical Industries Association
Piet Knijff DSM European Process Safety Centre
Scott Donaldson and Eamon Chandler
Shell
Scott Wallace Olin Corporation
Shakeel Kadri Air Products and Chemicals Inc
26
附錄 D ndash 詳細活動時程表
2016 年 2017 年 2018 年 2019 年 2020 年
2 ndash 4 月
RCLG PS 先導計畫
5 月 ndash
針對準則進行調整釐清
6 月 向 RCLG 和 ICCA 董事會報
告先導計畫執行結果
7 ndash 12 月 RCLG 協會考量準
則並為其會員公司發展提報機制
如有需要RCLG可向 ICCA 申請能
力建立基金為會員公司舉辦製程安
全研習會
1 ndash 12 月
RCLG 協會開始向其會員公司蒐集製程安全數據
1 ndash 12 月
如有需要RCLG 各協會運用 RCLG 的基金及專
家舉辦製程安全及績效提報研習會
1 ndash 2 月
擁有數據的協會開始向RCLG 提報製程安全事件
(2017 年數據)
4 月 RCLG 檢討第一個提報循
環的結果挑戰及原始數據(內部)
6 月 RCLG 向 ICCA 董事會呈報
原始數據
7 ndash 12 月 必要時更新及調整準
則
如有需要RCLG 各協會運用 RCLG 的基金及專
家舉辦製程安全及績效提報研習會
1 ndash 2 月
擁有數據的協會開始向RCLG 提報製程安全事件
(2018 年數據)
4 月 RCLG 檢討第二個提報循
環的結果挑戰及原始數據(內部)
6 月 RCLG 向 ICCA 董事會呈報
原始數據
7 ndash 12 月 必要時更新及調整準
則
如有需要RCLG 協會運用 RCLG 的基金及專家
舉辦製程安全及績效提報研習會
1 ndash 2 月
所有協會開始向 RCLG 提報製程安全事件
製程安全事件提報成為
RCLG KPI 衡量指標建議基本集的一部分(2019 年數
據)
4 月 RCLG 檢討第二個提報循
環的結果挑戰及原始數據(內部考量外部提
報)
6 月 RCLG 向 ICCA 董事會呈報
原始數據
27
附錄 E ndash 選擇性 Excel 追蹤表
當會員公司開始追蹤製程安全事件時所有會員公司應採用單一表格以簡化數據分析同時讓所有公司均使用相同的追蹤表RCLG 設
計了一份選擇性追蹤表可供會員公司和協會先行利用之後他們可設計自己的追蹤表
在這裡下載追蹤表
ICCA Process Safety Event Tracking Sheetxlsx
本文件包含三個分頁分別是ldquo聯絡資料rdquoldquo調查表rdquo和儲存下拉式選單選項的ldquo請勿編輯rdquo分頁
備註
附錄 E 追蹤表僅供參考TRCA 將另行提供台灣版表格供會員公司提報
28
後語
台灣化學工業責任照顧協會(Taiwan Responsible Care Association TRCA)成立於 1998 年在台灣推行責任照顧制度已達 20 週年製造商成員
包括台灣主要上市上櫃化工公司會員公司化學品生產製造量約佔全國 80 2016 年台灣化工業的 Chemical Sales 仍站在全球第八名的位
置額度為 630 億歐元化工業總產值達到 34 兆新台幣提供國內 416 萬人工作機會
TRCA 扮演國內廠商與國際制度接軌的角色也是國內化工業與政府機關及利益相關者溝通的橋樑與管道TRCA 會員結構依業務性質分析
涵蓋石化生產化學品製造氣體生產倉儲運輸業化學品貿易業以及工程研發設計等公司TRCA 透過供應鏈及價值鏈推行責任
照顧制度組成毒性化學物質聯防組織協助法規溝通與研析會員名冊請參考 httpwwwtrcaorgtwtrcanwork2aspx
TRCA 於 2010 年成為 ICCA (International Council of Chemical Associations 國際化學工業協會)觀察員ICCA 成立於 1989 年是全球化工製造
業的聯合會也是化學工業與 UNEP OPCW 及 OECD 的交流窗口ICCA 與其會員協會及成員公司致力於邁向永續的未來確保人類健康與
環境安全與保護全球化工業擁有超過 4兆美元的價值影響所有經濟部門ICCA 的會員幾乎在全球每個國家都有商業活動在全球六大
洲推動創新並提供超過 2000 萬個工作機會
台灣化工業在全球占有重要的一席之地在國內產業鏈也位居關鍵位置無論對國內或國際都有身為地球村一員應盡之責我們期許藉由
製程安全指標提報能更進一步提升自我在工安衛生環保與永續發展等面向的績效表現
台灣化學工業責任照顧協會
10452 台北市中山區撫順街 8 號 7 樓
電話02-2585-0552
httpwwwtrcaorgtw
None | |
$2500 to $25000 | |
$25000 to $250000 | |
$250000 to $25000000 | |
More than $25000000 | |
Yes - Using GHS TABLE | |
Yes - Using API RP 754 TABLE | |
NO | |
NA | |
1x le TQ lt 40x | |
40x le TQ lt 160x | |
160x le TQ lt 640x | |
ge 640x TQ | |
Yes le 3 hours | |
Yes 3 hours ge 12 hours | |
Yes 12 hours ge 24 hours | |
Yes ge 24 hours | |
No | |
Small-scale | |
Medium-scale | |
Large-scale | |
No | |
Yes | |
No | |
middot Injury requiring treatment beyond first aid to an employee contractor or subcontractor | |
middot Days Away From Work injury to an employee contractor or subcontractor or middot Injury requiring treatment beyond first aid to a third party | |
middot A fatality of an employee contractor or subcontractor or middot A hospital admission of a third party | |
middot Multiple fatalities of employees contractors or subcontractors or middot multiple hospital admission of third parties or middot A fatality of a third party | |
NA | |
1x le TQ lt 3x | |
3x le TQ lt 9x | |
9x le TQ lt 27x | |
ge 27x TQ |
ICCA Process Safety Pilot Reporting ProgramFebruary 8 2016 | 1 | 2 | 3 | 4 | 5 | 6 | 7 | 8 | 9 | 10 | 12 | 13 | 14 | 15 | |||||||||||||||||||||||
SAFETY Details(Meeting Local Regulations) | Direct Cost from Fire or Explosion | Community Impact | Environmental Impact | Material Released(Measured using the 1 Hour Rule) | |||||||||||||||||||||||||||||||||
Company Association Details | |||||||||||||||||||||||||||||||||||||
GHS | API - RP 754 | ||||||||||||||||||||||||||||||||||||
Company or Assocation Name | Headquarter Association | Location of Event Ex - City State amp Country | Date and Time of Event | Safety InjuryDid the Event result in a Recordable Lost Time Accident or Fatality or Hospital admission of anyone on or off siteUse Drop Down Menu | Safety InjuryIf yes please insert the total number of injuries | Safety InjuryFor puropses of utilizing the Severity Table please indicate the level of severity by chosing the MOST SEVERE classification that describes your incidentUse Drop Down Menu | Safety InjuryDid the incident involve Fatalities If so how many total fatalities If none enter Zero | Safety InjuryPlease Report Total Employee Hours for Calendar Year 2015 | Safety InjuryPlease Report Total Contractor Hours for Calendar Year 2015 | Direct Cost Did the Event result in Direct Damage CostUse Drop Down Menu | Direct Cost If so how muchAmount is in US DollarsUse Drop Down Menu | Community ImpactDid the event result inbull Officially declared shelter-in-place or officially declared evacuation (on or off site)ORbull Precautionary off site shelter in place or evacuation Use Drop Down Menu | Environmental ImpactDid the event result inAcute Environmental Remediation CostIf so indicate the amount in US DollarsUse Drop Down Menu | Material ReleasedDid the Event result in an Acute Release of material beyond one of the two threshold tablesIf so indicate which Threshold Table you used to make this determinationUse Drop Down Menu | Material ReleasedIf so indicate the amount released USING GHS CLASSIFICATION TABLEUse Drop Down Menu | Material ReleasedIf so indicate the amount released USING THE THRESHOLD TABLE FROM API RP-754Use Drop Down Menu | Material ReleasedIf available please indicate the material released | ||||||||||||||||||||
1 | ABC Chemical Company | American Chemistry Council | Washington DC - USA | January 4 2016 | Yes | 2 | middot Days Away From Work injury to an employee contractor or subcontractor or middot Injury requiring treatment beyond first aid to a third party | 0 | 5525000 | 1500250 | No | $2500 to $25000 | Yes le 3 hours | $2500 to $25000 | Yes - Using GHS TABLE | 40x le TQ lt 160x | NA | Chlorine | |||||||||||||||||||
2 | XYZ Chemical Company | American Chemistry Council | Washington DC - USA | 5-Jan-16 | Yes | 1 | middot Injury requiring treatment beyond first aid to an employee contractor or subcontractor | 0 | 5525000 | 1500250 | Yes | $2500 to $25000 | No | $2500 to $25000 | Yes - Using API RP 754 TABLE | NA | 3x le TQ lt 9x | Benzene | |||||||||||||||||||
3 | |||||||||||||||||||||||||||||||||||||
4 | |||||||||||||||||||||||||||||||||||||
5 | |||||||||||||||||||||||||||||||||||||
6 | |||||||||||||||||||||||||||||||||||||
7 | |||||||||||||||||||||||||||||||||||||
8 | |||||||||||||||||||||||||||||||||||||
9 | |||||||||||||||||||||||||||||||||||||
10 | |||||||||||||||||||||||||||||||||||||
11 | |||||||||||||||||||||||||||||||||||||
12 | |||||||||||||||||||||||||||||||||||||
13 | |||||||||||||||||||||||||||||||||||||
14 | |||||||||||||||||||||||||||||||||||||
15 | |||||||||||||||||||||||||||||||||||||
16 | |||||||||||||||||||||||||||||||||||||
17 | |||||||||||||||||||||||||||||||||||||
18 | |||||||||||||||||||||||||||||||||||||
19 | |||||||||||||||||||||||||||||||||||||
20 | |||||||||||||||||||||||||||||||||||||
21 | |||||||||||||||||||||||||||||||||||||
22 | |||||||||||||||||||||||||||||||||||||
23 | |||||||||||||||||||||||||||||||||||||
24 | |||||||||||||||||||||||||||||||||||||
25 | |||||||||||||||||||||||||||||||||||||
Zero or None | Yes - Duration Unknown | ||||||||||||||||||||||||||||||||||||
Processes | Mode of Operation | Type of material released | Status of Operation | ||||
REFINING | Start-up | Flammable | Open | ||||
Alkylation HF | Planned shutdown | Combustible | Closed | ||||
Alkylation sulfuric | Emergency shutdown | Toxic | |||||
BitumenResidAsphalt | Normal | Corrosive | Tier 1 Acute Releases | ||||
Calcining | Upset | Utilities | No Release | ||||
Coking | Turnaround | Other | Category 1 | ||||
Crude | Routine maintenance | Category 2 | |||||
Desulfurization | Temporary | Evacuation | Category 3 | ||||
FCC | Other | Yes | Category 4 | ||||
Gas Treating | No | Category 5 | |||||
Hydrogen | Point of Release | Category 6 | |||||
Hydrotreating | Pump | Fire | Category 7 | ||||
Hydrocracking | Compressor | Yes | Multiple Categories | ||||
Isom | BlowerFan | No | |||||
MarineJetty | Pressure Vessel | lt $2500 | |||||
Reforming | FilterCoalescer | ||||||
Sulfur recovery | Furnace | PRDs | |||||
Vapor recoverylight ends | Boiler | Directly to Atmosphere | |||||
Wastewater | Heat exchanger | via Downstream Destructive Device | |||||
REFINING amp PETROCHEMICAL | Cooling Tower | No | |||||
Tank FarmStorage FacilityOffsite | Piping system | Yes | |||||
UtilitiesSteam PlantCogeneration | Reactor | No | |||||
Other | Atmospheric tank | ||||||
PETROCHEMICAL | FlareRelief System | Acute release above thresholds | |||||
CO H2 | Other | Yes | |||||
LNG | No | ||||||
Methane | Events | ||||||
Methanol | No Tier 1 Events | Indoor Outdoor | |||||
Methyl Mercaptan | No Tier 2 Events | No Release | |||||
Formaldehyde | No Tier 1 or Tier 2 Events | Indoor | |||||
Formaldehyde derivatives | NA | Outdoor | |||||
Acetic Acid | |||||||
Acetic Acid derivatives | Event Type | ||||||
Ethane | Injury | ||||||
Ethylene | Fire | ||||||
Ethanol | Explosion | ||||||
Ethylene oxide | PRD Discharge | ||||||
Ethylene derivatives | Acute Release | ||||||
Polyethylene | |||||||
Ethylene dichloride | General | ||||||
Ethylene dichloride derivatives | Yes | ||||||
Ethyl benzene | No | ||||||
Ethyl benzene derivatives | |||||||
Polystyrene | |||||||
Styrene-Butadiene | |||||||
Propane | |||||||
Propylene | |||||||
Polypropylene | |||||||
Isopropanol | |||||||
Propylene oxide | |||||||
Propylene oxide derivatives | |||||||
Butane | |||||||
Isobutane | |||||||
Isobutene | |||||||
Butadiene | |||||||
MTBE | |||||||
ETBE | |||||||
Pentane | |||||||
Hexane | |||||||
Cyclohexane | |||||||
Hexanol | |||||||
Aromatics Derivatives | |||||||
Benzene | |||||||
Toluene | |||||||
Xylene | |||||||
Para Xylene | |||||||
Amines Derivatives | |||||||
TDA MDA IPDA etc | |||||||
Isocyanates | |||||||
Specialty Chemicals | |||||||
LoadingUnloading | |||||||
Pilot Plant |
Instructions | ||||||||||||||
Step 1 | Complete the Contact Tab with your contact information and company information | |||||||||||||
Be sure to note the region of your reporting (IE North America France Japan etc) | ||||||||||||||
Survey on Process Safety Events | ||||||||||||||
Step 2 | Complete the survey one line per Process Safety Event for your companyregion | |||||||||||||
ALL REPORTED DATA SHOULD BE FROM CALENDAR YEAR 2017 | ||||||||||||||
Step 3 | Return completed survey to | |||||||||||||
Company Name | ||||||||||||||
Contact Person | All Surveys Due by xxx date | |||||||||||||
Address | ||||||||||||||
Fax | ||||||||||||||
Telephone | ||||||||||||||
Region | ||||||||||||||
None | |
$2500 to $25000 | |
$25000 to $250000 | |
$250000 to $25000000 | |
More than $25000000 | |
Yes - Using GHS TABLE | |
Yes - Using API RP 754 TABLE | |
NO | |
NA | |
1x le TQ lt 40x | |
40x le TQ lt 160x | |
160x le TQ lt 640x | |
ge 640x TQ | |
Yes le 3 hours | |
Yes 3 hours ge 12 hours | |
Yes 12 hours ge 24 hours | |
Yes ge 24 hours | |
No | |
Small-scale | |
Medium-scale | |
Large-scale | |
No | |
Yes | |
No | |
middot Injury requiring treatment beyond first aid to an employee contractor or subcontractor | |
middot Days Away From Work injury to an employee contractor or subcontractor or middot Injury requiring treatment beyond first aid to a third party | |
middot A fatality of an employee contractor or subcontractor or middot A hospital admission of a third party | |
middot Multiple fatalities of employees contractors or subcontractors or middot multiple hospital admission of third parties or middot A fatality of a third party | |
NA | |
1x le TQ lt 3x | |
3x le TQ lt 9x | |
9x le TQ lt 27x | |
ge 27x TQ |
ICCA Process Safety Pilot Reporting ProgramFebruary 8 2016 | 1 | 2 | 3 | 4 | 5 | 6 | 7 | 8 | 9 | 10 | 12 | 13 | 14 | 15 | |||||||||||||||||||||||
SAFETY Details(Meeting Local Regulations) | Direct Cost from Fire or Explosion | Community Impact | Environmental Impact | Material Released(Measured using the 1 Hour Rule) | |||||||||||||||||||||||||||||||||
Company Association Details | |||||||||||||||||||||||||||||||||||||
GHS | API - RP 754 | ||||||||||||||||||||||||||||||||||||
Company or Assocation Name | Headquarter Association | Location of Event Ex - City State amp Country | Date and Time of Event | Safety InjuryDid the Event result in a Recordable Lost Time Accident or Fatality or Hospital admission of anyone on or off siteUse Drop Down Menu | Safety InjuryIf yes please insert the total number of injuries | Safety InjuryFor puropses of utilizing the Severity Table please indicate the level of severity by chosing the MOST SEVERE classification that describes your incidentUse Drop Down Menu | Safety InjuryDid the incident involve Fatalities If so how many total fatalities If none enter Zero | Safety InjuryPlease Report Total Employee Hours for Calendar Year 2015 | Safety InjuryPlease Report Total Contractor Hours for Calendar Year 2015 | Direct Cost Did the Event result in Direct Damage CostUse Drop Down Menu | Direct Cost If so how muchAmount is in US DollarsUse Drop Down Menu | Community ImpactDid the event result inbull Officially declared shelter-in-place or officially declared evacuation (on or off site)ORbull Precautionary off site shelter in place or evacuation Use Drop Down Menu | Environmental ImpactDid the event result inAcute Environmental Remediation CostIf so indicate the amount in US DollarsUse Drop Down Menu | Material ReleasedDid the Event result in an Acute Release of material beyond one of the two threshold tablesIf so indicate which Threshold Table you used to make this determinationUse Drop Down Menu | Material ReleasedIf so indicate the amount released USING GHS CLASSIFICATION TABLEUse Drop Down Menu | Material ReleasedIf so indicate the amount released USING THE THRESHOLD TABLE FROM API RP-754Use Drop Down Menu | Material ReleasedIf available please indicate the material released | ||||||||||||||||||||
1 | ABC Chemical Company | American Chemistry Council | Washington DC - USA | January 4 2016 | Yes | 2 | middot Days Away From Work injury to an employee contractor or subcontractor or middot Injury requiring treatment beyond first aid to a third party | 0 | 5525000 | 1500250 | No | $2500 to $25000 | Yes le 3 hours | $2500 to $25000 | Yes - Using GHS TABLE | 40x le TQ lt 160x | NA | Chlorine | |||||||||||||||||||
2 | XYZ Chemical Company | American Chemistry Council | Washington DC - USA | 5-Jan-16 | Yes | 1 | middot Injury requiring treatment beyond first aid to an employee contractor or subcontractor | 0 | 5525000 | 1500250 | Yes | $2500 to $25000 | No | $2500 to $25000 | Yes - Using API RP 754 TABLE | NA | 3x le TQ lt 9x | Benzene | |||||||||||||||||||
3 | |||||||||||||||||||||||||||||||||||||
4 | |||||||||||||||||||||||||||||||||||||
5 | |||||||||||||||||||||||||||||||||||||
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11 | |||||||||||||||||||||||||||||||||||||
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13 | |||||||||||||||||||||||||||||||||||||
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15 | |||||||||||||||||||||||||||||||||||||
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18 | |||||||||||||||||||||||||||||||||||||
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20 | |||||||||||||||||||||||||||||||||||||
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22 | |||||||||||||||||||||||||||||||||||||
23 | |||||||||||||||||||||||||||||||||||||
24 | |||||||||||||||||||||||||||||||||||||
25 | |||||||||||||||||||||||||||||||||||||
Zero or None | Yes - Duration Unknown | ||||||||||||||||||||||||||||||||||||
Processes | Mode of Operation | Type of material released | Status of Operation | ||||
REFINING | Start-up | Flammable | Open | ||||
Alkylation HF | Planned shutdown | Combustible | Closed | ||||
Alkylation sulfuric | Emergency shutdown | Toxic | |||||
BitumenResidAsphalt | Normal | Corrosive | Tier 1 Acute Releases | ||||
Calcining | Upset | Utilities | No Release | ||||
Coking | Turnaround | Other | Category 1 | ||||
Crude | Routine maintenance | Category 2 | |||||
Desulfurization | Temporary | Evacuation | Category 3 | ||||
FCC | Other | Yes | Category 4 | ||||
Gas Treating | No | Category 5 | |||||
Hydrogen | Point of Release | Category 6 | |||||
Hydrotreating | Pump | Fire | Category 7 | ||||
Hydrocracking | Compressor | Yes | Multiple Categories | ||||
Isom | BlowerFan | No | |||||
MarineJetty | Pressure Vessel | lt $2500 | |||||
Reforming | FilterCoalescer | ||||||
Sulfur recovery | Furnace | PRDs | |||||
Vapor recoverylight ends | Boiler | Directly to Atmosphere | |||||
Wastewater | Heat exchanger | via Downstream Destructive Device | |||||
REFINING amp PETROCHEMICAL | Cooling Tower | No | |||||
Tank FarmStorage FacilityOffsite | Piping system | Yes | |||||
UtilitiesSteam PlantCogeneration | Reactor | No | |||||
Other | Atmospheric tank | ||||||
PETROCHEMICAL | FlareRelief System | Acute release above thresholds | |||||
CO H2 | Other | Yes | |||||
LNG | No | ||||||
Methane | Events | ||||||
Methanol | No Tier 1 Events | Indoor Outdoor | |||||
Methyl Mercaptan | No Tier 2 Events | No Release | |||||
Formaldehyde | No Tier 1 or Tier 2 Events | Indoor | |||||
Formaldehyde derivatives | NA | Outdoor | |||||
Acetic Acid | |||||||
Acetic Acid derivatives | Event Type | ||||||
Ethane | Injury | ||||||
Ethylene | Fire | ||||||
Ethanol | Explosion | ||||||
Ethylene oxide | PRD Discharge | ||||||
Ethylene derivatives | Acute Release | ||||||
Polyethylene | |||||||
Ethylene dichloride | General | ||||||
Ethylene dichloride derivatives | Yes | ||||||
Ethyl benzene | No | ||||||
Ethyl benzene derivatives | |||||||
Polystyrene | |||||||
Styrene-Butadiene | |||||||
Propane | |||||||
Propylene | |||||||
Polypropylene | |||||||
Isopropanol | |||||||
Propylene oxide | |||||||
Propylene oxide derivatives | |||||||
Butane | |||||||
Isobutane | |||||||
Isobutene | |||||||
Butadiene | |||||||
MTBE | |||||||
ETBE | |||||||
Pentane | |||||||
Hexane | |||||||
Cyclohexane | |||||||
Hexanol | |||||||
Aromatics Derivatives | |||||||
Benzene | |||||||
Toluene | |||||||
Xylene | |||||||
Para Xylene | |||||||
Amines Derivatives | |||||||
TDA MDA IPDA etc | |||||||
Isocyanates | |||||||
Specialty Chemicals | |||||||
LoadingUnloading | |||||||
Pilot Plant |
Instructions | ||||||||||||||
Step 1 | Complete the Contact Tab with your contact information and company information | |||||||||||||
Be sure to note the region of your reporting (IE North America France Japan etc) | ||||||||||||||
Survey on Process Safety Events | ||||||||||||||
Step 2 | Complete the survey one line per Process Safety Event for your companyregion | |||||||||||||
ALL REPORTED DATA SHOULD BE FROM CALENDAR YEAR 2017 | ||||||||||||||
Step 3 | Return completed survey to | |||||||||||||
Company Name | ||||||||||||||
Contact Person | All Surveys Due by xxx date | |||||||||||||
Address | ||||||||||||||
Fax | ||||||||||||||
Telephone | ||||||||||||||
Region | ||||||||||||||
6
的提報門檻也是一樣的為因應此一差異針對化學物質外洩量提報門檻ICCA 製程安
全事件定義將容許會員公司採用 ICCA 依據化學品全球調和制度(GHS)健康危害分級為基礎
所發展的提報標準或依據聯合國危險物品(UNDG)分類為基礎所定義之 RP-754 二級製程
安全事件(Tier II) 之提報標準專案小組相信這兩套制度之提報標準雖然有所差異但
從其所涵蓋之化學物質領域和提報事故嚴重程度看來兩者皆相當健全雖然採用這兩種
不同提報門檻所收集和提報的事件數差異相對不大但在公司方面從原料及產品使用的角
度看來兩者可能會有非常明顯的不同因此專案小組提醒會員公司勿將自己公司的
結果與採用不同化學物質洩漏量提報門檻的公司做比較無論如何根據 RCLG 的提議
會員公司可選擇化學物質洩漏門檻以向國家及地區協會進行提報如果各協會有興趣轉
換兩種不同提報方式的結果RCLG 可提供轉換表但由於轉換運算非常複雜且須取得
原始事故數據專案小組相信相互轉換的附加價值不大因此不建議協會採取此一做法
專案小組相信這項製程安全事件提報建議案可廣泛運用在化學及石化產業實施製程安
全績效提報這項提報制度將為目前尚未追蹤製程安全績效的地區協會和會員公司提
供一個指引讓他們可以體認追蹤及提報製程安全績效可以帶來的益處至於已在蒐集製
程安全數據的地區協會和會員公司此建議案將有助於他們更廣泛地與全球接軌並將
重點放在持續改善製程安全績效這些改善製程安全績效的制度仰賴的是可靠的製程安
全事件數據改善製程安全績效正是責任照顧倡議的主要目的
7
RCLG 各協會應向 RCLG 提報的數據
RCLG 各協會每年必須依照下文提供的時程透過 RCLG 關鍵績效指標(KPI)提報網站向
ICCA 提報兩個數據
1 協會所屬會員公司的總工作時數(包括員工和承攬商)
2 製程安全事件總數
ICCA 將利用上述兩個數據以製程安全事件發生率(PSER)的形式報告製程安全績效PSER
計算之常態化是以每 100 位員工每位員工一年工作 2000 小時為基準
(總事件數 總工作時數) x 200000 = PSER
建議之提報時程
針對提報製程安全事件發生率專案小組建議一種分階段導入的方法此一時程可讓更多
已具經驗的協會及公司立即實施提報同時容許其他協會及公司從 2019 年起開始提報
RCLG 各協會必須透過 RCLG KPI 指標提報系統(httpkpiresponsiblecareeu)每年向 ICCA
提報兩個製程安全事件發生率數據如果你不知道你所屬協會的使用者名稱和密碼請聯
絡 RCLG
建議 RCLG 協會提報製程安全事件發生率的時程如下
2015 年 4 月 RCLG 考量專案小組建議案
2015 年 6 月 ICCA 理事會考量 RCLG 的最終建議
2015 年 7 月 RCLG 頒布首份詳細的提報指引供協會及會員公司遵
循
2016 年 2 月 RCLG 提報 RCLG 更新及強化提報指引並針對自願參加的協會
開始實施製程安全試行提報計畫RCLG 於 2016 年 6 月
頒布最終指引
2017 年 RCLG 各協會開始向會員公司蒐集數據
2018-2019 年 RCLG 提報 RCLG 各協會可選擇地開始提報製程安全數據
2020 年提報 RCLG 於 KPI 提報計畫中將製程安全納入為一項強制性
指標
參見附錄 D ndash 詳細活動時程
8
ICCA 製程安全事件判定標準流程圖
事故是否發生在廠內之
生產配銷儲存公
用或試驗工廠
是 是
是
否
否 是否造成須通報工傷
或
廠內廠外人員住院治
療
損壞是否對
公司造成
ge $2500 美
元的直接成
本損失
官方是否宣告就地
避難或疏散或廠
外預防性就地避難
或疏散
否
是
否
是屬於須通報製程安全事件
是
否
是
是
開始
否不符合製程安全事件認定
標準
是否超過 ICCA 或 API
754 Tier II 化學物質洩
漏恕限值
否 發生化學物質外洩火
災或爆炸是否起因於
或發生在化學製程單元
是否直接涉及某種化學物
質或化學製程
否
9
須提報製程安全事件之重要標準
總工作時數
RCLG 各協會應以加總的單一數字提報其所屬會員公司的員工和承攬商總工作時數為達
成本指引之目的各協會應參考其本地和地區對員工及承攬商之定義提報總時數之目標
應納入涉及化學製造之所有個人然而參與主要興建工程專案之人員則不納入計算譬
如為新建或擴建既有製程設施之設計工程和施工而成立之一次性專案組織的大規模投資
案會員公司提報總工作時數時應與人事部門統計之員工工時一致如此各公司便能
取得相同的職業與製程安全數據員工工時應包括所有化學製造作業的工時而非僅計算
發生製程安全事故之廠區的工時
製程安全事件
為執行 ICCA 提報目的製程安全事件之定義條件如下(必須同時符合 ABCD 四個條
件)
A 直接涉及某種化學物質或化學製程且
B 事故發生在廠內之生產配銷儲存公用或試驗工廠且
C 製程單元發生物質洩漏或能量釋放(如火災爆炸和內爆)且
D 已達到以下提報門檻之一
1 安全 工傷
導致記錄性的傷害(OSHA)損失工時或死亡或廠內外任何人員因此
而須住院治療或
2 直接損失成本
火災爆炸或為避免補救環境損害之必要清理作業導致$2500 美元
以上的直接成本支出或
3 就地避難 疏散
官方宣告就地避難(廠內或廠外)或
官方宣告疏散(廠內或廠外)或
廠外預防性就地避難或疏散或
4 洩漏恕限值
物質洩漏程度已達表 1 所列之任一 GHS 恕限值(洩漏量以單位小時計
量)
此外各公司亦可選擇採用 API RP-754 標準中所列之洩漏恕限值(表 2)請注意如欲查
看 API RP-754 標準可登入以下網站購買及下載httpwwwapiorgoil-and-natural-
gashealth-and-safetyprocess-safetyprocess-safety-standards
10
製程安全事件判定準則
A 涉及化學品
直接涉及某種化學物質或化學製程
製程安全事件或事故必須直接涉及化學物質或化學製程就此而言ldquo製程rdquo一詞泛指包含
石化生產所需要之設備和技術包括反應器儲槽管線鍋爐冷卻水塔和冷凍系
統helliphellip等未直接涉及化學物質或製程的事件無須提報譬如辦公大樓起火(即使該辦公大
樓位在廠區內亦然)
B 地點
事故發生在廠內之生產配銷儲存公用或試驗工廠
發生在廠內之生產配銷儲存(包括活動儲存區如倉庫 ndash 參見ldquo常見問題集rdquo)公用及
試驗工廠凡符合提報指標及定義的事故包括在廠區管理下之槽罐區輔助支援區(如
鍋爐室和廢水處理廠)和配銷管線所有須提報之事件應由負責該事故地點運作的公司
負提報之責此一規定亦適用於發生在承攬商作業區域內的事故在代工作業和多方共同
作業廠區負責運作該發生事故單位的公司應記錄事故始末並將之納入其提報中
C 物質洩漏
製程單元發生物質外洩或能量釋放(如火災爆炸和內爆)
物質外洩 ndash 製程任何物質發生非預期或無法控制的洩漏或釋放包括非毒性及不可燃物質
(如蒸汽熱水氮氣壓縮二氧化碳或壓縮空氣)且達到本文件所列四類提報門檻之一
項或以上之後果
在防治系統(如洗滌塔或廢氣燃燒塔)正常運作狀況下只要沒有任何洩漏或排放量超過
法定許可值即使排放到廢氣燃燒塔或滌氣塔仍被視為處於一次阻絕設施內然若排
放到二次阻絕設施(如廢水處理或防溢堤)將被視為製程安全事件因為物質已離開主要製
程系統
11
D 提報門檻
須提報製程安全事件必須達到以下提報門檻之一
1 安全 工傷
導致記錄性傷害(OSHA)損失工時或死亡或廠內外任何人員因此而須住院治療
記錄性傷害是指與工作有關所造成的傷害導致死亡暫時全失能工作受限制或需調整職
務較輕傷害嚴重之醫療處理失去意識或經醫師或其他合格醫療專業人員診斷為重大
傷害
損失工時傷害和死亡是指因製程相關的一次阻絕設施失效火災或爆炸導致以下任何一種
結果
員工(損失工時或死亡)
承攬商及再承攬商 (損失工時或死亡)
第三方(如來賓訪客快遞員)(受傷疾病導致住院治療或死亡)
住院治療是指醫院或其他具有住院病患保健設施的醫療單位正式接受病患住院提供病患
食宿及醫療護理且病患接受治療至少留置至隔日僅在醫院急診室治療或過夜處理不屬
於ldquo住院治療rdquo的定義範圍
須提報之工傷或死亡事件例如在清理作業期間因蒸汽洩漏造成人員燒燙傷壓力測試期間
帽蓋因受壓脫落造成人員身體傷害或取樣作業時因物質外濺造成人員化學灼傷無須提
報之工傷或死亡事件例如在執行維修作業時從高處的工作台墜落實驗室或辦公大樓火災
造成人員燒燙傷或挖掘工程塌陷造成人員傷害這些案例均與因製程造成的能量釋放或
物質洩漏無直接關聯
2 直接損失成本
火災爆炸或為避免補救環境損害之必要清理作業導致$2500美元以上的直接成本支出
此提報門檻所考慮的成本應為可直接歸因於火災或爆炸的成本譬如設備及結構損壞的重
置成本修理成本環境清理(廠內及廠外)支出緊急應變和罰款直接成本不包括間接
成本譬如業務機會損失設備停機造成之利潤損失取得或運轉臨時設施之成本或為
滿足顧客需求取得替代產品的成本(產品損失)
12
3 就地避難 疏散
官方宣告就地避難或疏散(廠內或廠外)或廠外預防性就地避難或疏散
就提報目的而言官方宣告就地避難或疏散(廠內或廠外)或廠外預防性就地避難或疏散
即達到此提報門檻
官方宣告 ndash 由地方權責機關(如消防警察民防緊急應變管理部門)或經授權的代表(如
派駐公司官員)下達的社區行動(如就地避難或疏散)宣告
預防性宣告 ndash 預防性公眾應變是基於謹慎的態度所採取的一種措施權責地方主管機關或經
授權的代表經合理判斷認定為維護公眾健康及安全發布必須採取就地避難或疏散之預
防性措施
就地避難 ndash 利用結構體及其內部空氣以暫時讓人員與室外危害性氣體隔離
疏散 ndash 基於安全或防護理由讓人員離開某處所的行動或過程
4 洩漏恕限值
超過表 1 中所列 GHS 恕限值或表 2 中所列 API 754 標準 Tier II 製程安全洩漏恕限值之一的
急性洩漏事件(洩漏量以單位小時計量)
如ldquo執行摘要rdquo所述ICCA 製程安全事件之定義容許採用 ICCA 依據化學品全球調和制度
(GHS)健康危害分級為基礎所發展的提報標準或依據聯合國危險物品(UNDG)分類為基礎
所定義之 RP-754 二級製程安全事件(Tier II) 之提報標準GHS 恕限值詳見表 1各會員公司
可自行決定選擇哪一個表中的提報恕限值並在全球採用單一制度
ldquo急性rdquo洩漏 ndash易燃性可燃性或毒性化學物質從一次阻絕設施(如容器或管線)洩漏其
任一單位小時之洩漏量超過化學物質洩漏恕限量分述於表 1 中的 GHS 分類和表 2 中的
API 754 標準 Tier II 製程安全洩漏恕限值
洩壓裝置前述所定義之ldquo急性rdquo洩漏包括洩漏或排放至妥善設計且運作中的洩壓裝置若
洩漏或排放量達到表 1 中所列 GHS 恕限值或表 2 中所列 API 754 標準 Tier II 製程安全洩漏
恕限值且導致下列四種後果之任一項或以上之後果
1 二相排放或夾帶液體的排放液滴沉降至地面造成污染
2 排放至具潛在危險性的地點
3 廠內就地避難或疏散不包括預防性廠內就地避難或疏散
4 啟動公眾保護措施(如道路封閉)包括預防性公眾保護措施
13
洩漏或排放至妥善設計且運作中的洩壓裝置(如廢氣燃燒塔洗滌塔等)若其情況未達前
述四項標準中任何一項則不必提報
欲查看 API RP-754 標準可登入以下網站下載此標準httpwwwapiorgenvironment-
health-and-safetyprocess-safetyprocess-safety-standardsstandard-rp-754
一小時法則
為便於衡量此項指標提報與否洩漏恕限值是以物質在任一小時內之洩漏量為標準若任
一小時或更短時間內物質洩漏量達到或超過須提報恕限值該事故便屬於須提報的製程安
全事件急性洩漏事故通常不會超過一小時若無法確定洩漏持續時間則應假設其為一
小時
一次阻絕設施ndash 用來作為主要容器或用於運送或輸送物質之槽罐船隻管線軌道車
或設備主要容器在設計上可能包含二次阻絕設施系統以抑制及控制洩漏二次阻絕設
施系統包括(但不限於)儲槽防溢堤製程設備周遭的圍堵設施油水分離的排水收集系統
雙層儲槽的外壁等
嚴重程度表 ndash 嚴重程度加權可額外提供有關製程安全事件的有用資訊有助於帶動改善績
效附錄 A 為 RCLG 建議之製程安全事件嚴重程度加權計算方法根據附錄 A 的方法便
可藉由加總與各個後果類別關聯的分數計算出各製程安全事件的嚴重程度加權值ICCA
強烈建議採用嚴重程度加權制度因為此制度有助於提升溝通績效的能力也比較容易讓
利害關係人了解製程安全事件並且此嚴重程度加權值與其他製程安全績效指標提報方
式是不具相互比較性的
14
表 1 ndash GHS 分類表
物理性危害(GHS 2x)
洩漏恕限值(1 小時內)
STOTSpecific target organ toxicity(特定標的器官系統毒性物質)
15
表 2 ndash API RP 754 Tier II 分類表
洩漏恕限類別
物質危害性分類 acdef 恕限值
(戶外洩漏) 恕限值
(戶內b洩漏)
T2-1 TIH A 區物質 ge 05 kg (11 lb) ge 025 kg (055
lb)
T2-2 TIH B 區物質 ge 25 kg (55 lb) ge 125 kg (275
lb)
T2-3 TIH C 區物質 ge 10 kg (22 lb) ge 5 kg (11 lb)
T2-4 TIH D 區物質 ge 20 kg (44 lb) ge 10 kg (22 lb)
T2-5
易燃氣體 或 正常沸點 ≦ 35 (95 degF)閃火點lt23 (73 degF)的液體 或 其他包裝組別 I 類的物質 (酸鹼除外)
ge 50 kg (110 lb) ge 25 kg (55 lb)
T2-6
正常沸點 gt 35 degC (95 degF)閃火點 lt 23 degC (73degF)的液體 或 其他包裝組別 II 類的物質 (酸鹼除外)
ge 100 kg (220 lb) 或
ge 07 bbl
ge 50 kg (110 lb) 或
ge 035 bbl
T2-7
閃火點 gt 23 degC (73 degF)和 lt 60 degC (140 degF)的液體 或 閃火點 gt 60 degC (140 degF)的液體在閃火點或高於閃火點的溫度下洩漏 或 強酸鹼 (定義參見 RP 754 文件草案) 或 UNDG第2類第22部分 (不可燃無毒氣體)空氣除外 或 其他包裝組別 III 類的物質
ge 200 kg (440 lb) 或
ge 14 bbl
ge 100 kg (220 lb) 或
ge 07 bbl
T2-8
閃火點 gt 60 degC (140 degF) 和 lt 93 degC (200 degF)的液體在低於閃火點的溫度下洩漏 或 中度酸鹼
ge 1000 kg
(2200 lb) 或
ge 7 bbl
ge 500 kg
(1100 lb) 或
ge 35 bbl
TIH吸入性毒性危害物(Toxic Inhalation Hazard)
16
一般認為以公斤和磅或以磅和桶為單位的恕限值不盡等同各公司應該選用其中一組計量單位並在
所有紀錄文件中一體適用
在判定一種物質之洩漏恕限類別時首先應從物質之含吸入性毒性(TIH Zone)可燃性(閃火點和沸點)
或腐蝕性(強酸或鹼 vs中度酸或鹼)等特性來判別只有當物質的危險度無法利用上述簡單的特性來判別
時(如遇水反應劇烈)才採用UNDGL包裝組別
a 許多物質具有一種以上危險性正確的危險區(Hazard Zone)或包裝組別(Packing Group)歸屬應遵循DOT
49 CFR 1732a [14]或聯合國危險物品運輸建議書(UNRTDG)第2部分[12]的規定參見附錄F
b 具有四面完整牆(從地板到天花板)地板和屋頂的結構物
c 對於未列於UNDG的溶液無水成分將用TIH區或包裝組別分類溶液之恕限值將根據乾基重量之恕限
值反算
d 對於未知UNDG分類的混合物可計算每種成分在恕限值洩漏中的分量如果各種成分之分量的總和
等於或大於100即表示混合物超過門檻值若混合物有明顯且獨立的毒性及可燃性結果則可分
別計算毒性及可燃性危險度參見附錄EPSE實例amp問題 49ndash53
e 閃火點 gt 60 degC (140 degF) 和 lt 93 degC (200 degF)的液體在低於閃火點的溫度下洩漏無論洩漏量多寡其
一次阻絕設施失效(LOPC)均不屬於Tier 1製程安全事件(PSE)
f 中度酸鹼的一次阻絕設施失效無論洩漏量多寡均不屬於Tier 1製程安全事件
17 (K = 1000 MM = 1000000) (在環境影響類別方面若缺乏既有定義協會和會員公司應議定輸入標準)
附錄 A ndash 嚴重程度表鼓勵所有協會均採用嚴重程度加權制度
事件事故類別
嚴重程度等級
安全人體健康 火災或爆炸導致直接
成本 任 1 小時內物質洩
漏量 社區影響 環境影響[廠外]
4 級
1 分
對員工承攬商或再承攬商造成較輕傷害嚴重之傷害 (符合本地法規)
造成以下直接損失成本
美金$25 K ~ $25 K
洩漏量介於
1x le TQ lt 40x
官方宣告就地避難或疏散 (廠內或廠外) 預防性廠外就地避難或疏散
le 3 小時
重大環境整治成本
$25 K ~ $25 K
3 級
3 分
對員工承攬商或再承攬商造成之需要多日缺勤的傷害
對第三方造成之需要初步急救以外治療的傷害 (符合本地法規)
造成以下直接損失成本
$25 K ~ $250 K
洩漏量介於
40x le TQ lt 160x
官方宣告就地避難或疏散 (廠內或廠外)
預防性廠外就地避難或疏散
3 ~ 12 小時
重大環境整治成本
$25 K ~ $250 K
2 級
9 分
對員工承攬商或再承攬商造成 1 人死亡
對第三方造成 1 人住院治療
(符合本地法規)
造成以下直接損失成本
$250 K ~ $25 MM
洩漏量介於
160x le TQ lt 640x
官方宣告就地避難或疏散 (廠內或廠外)
預防性廠外就地避難或疏散
12 ~ 24 小時
重大環境整治成本
$250 K ~ $25 MM
1 級
27 分
對員工承攬商或再承攬商造成多人死亡
對第三方造成多人住院治療
對第三方造成 1 人死亡 (符合本地法規)
造成以下直接損失成本
ge $25 MM
洩漏量
ge 640x TQ
官方宣告就地避難或疏散 (廠內或廠外)
預防性廠外就地避難或疏散
ge 24 小時
重大環境整治成本
ge $25 MM
18 (K = 1000 MM = 1000000) (在環境影響類別方面若缺乏既有定義協會和會員公司應議定輸入標準)
嚴重程度表(附錄 A)細節說明
附錄 A 之設計目的僅適用於採用 GHS 分類制度(表 1)者如果你的公司係採用 API RP 754Tier II 製程安全指標提報恕限值表(表 2)請使用
API RP 754 製程安全嚴重程度表必須提醒的是依 API RP 754 的標準其嚴重程度表僅適用於一級(Tier I)事故去比較採用不同的嚴重度
表所評估出來的相對嚴重度並無統計上的意義
急性的環境成本 ndash 因製程安全事件造成廠外環境影響所導致之短期清理及物質處置的成本各會員公司可選擇將廠外環境影響相關成本另
外區分一個嚴重程度類別
比率調整指標
利用上述嚴重程度表可產生一系列以事件率為基礎的指標包括
製程安全總事件率 (PSTIR) 總事件次數 x 200000
總工作時數
製程安全事件嚴重程度率(PSESR) (即製程安全事件嚴重程度加權計算公式)
PSESR = 所有事件之總嚴重程度分數總合 x 200000
總工作時數
在計算此一比率時各 4 級事件被分配 1 分各 3 級事件被分配 3 分各 2 級事件被分配 9 分各 1 級事件被分配 27 分理論上每個
製程安全事件至少可分配到 1 分(亦即事件僅在一個類別符合第 4 級事件屬性)至多可分配到 135 分(亦即事件在所有五個類別中均符
合第 1 級事件屬性)
ldquoXrdquo級別製程安全事件率 嚴重度級別ldquoXrdquo之製程安全事件總數 x 200000
員工承攬商amp再承攬商總工作時數
X可以是嚴重度級別 432 或 1 級製程安全事件之總數事件之嚴重度等級是選用五類後果類別中之最嚴重等級
標準化 ndash 在某些協會和會員公司中製程安全事件是採 lsquo每 100 名rsquo員工每名員工每年平均工作時數為 2000 小時為基礎予以標準化因
此在lsquo每 100rsquo名rsquo員工的標準基礎上事件被乘以 200000 工作時數也有些其他協會和會員公司將標準化基礎設定為lsquo每 500 名rsquo員工
因此事件被乘以 1000000 工作時數協會和會員公司應就標準化基礎進行討論共同做成選項結論上述的公式設定為lsquo每 100 名rsquo員工
基礎
19
附錄 B ndash 常見問題集
適用性
我們建議會員公司記錄和提報在其所擁有或運作的工廠內發生的製程安全事件惟以下情況不須提報製
程安全事件
1 源自於公司廠區以外的製程安全事件
2 海上運輸船事故惟船隻為了輸送半成品或產品之目的已經與公司的設施相連接時發生的
事故仍須提報
3 卡車或軌道車事故惟卡車或軌道車為了輸送半成品或產品之目的已經與公司的設施相連
接時發生的事故仍須提報
4 許可證或法規容許之例行排放
5 不會造成製程安全危害的地下污染請注意若洩漏至地下導致地上發生須提報製程安全事
件如釋放出毒性蒸汽或致使易燃液體蓄積成池則不適用本排除條件
6 辦公建築事故(如辦公室暖氣設備爆炸火災外溢洩漏人員受傷或疾病等)
7 與疏散或一次阻絕設施失效無直接關聯之人員安全ldquo滑倒絆倒跌倒rdquo事故
8 沒有與製程相連接之輔助設備的一次阻絕設施(如小樣品瓶)失效事故
9 計劃中和在控制下的物質排放至設計用來收集或排放系統中(請注意物質從一次阻絕設施
在非計劃或非受控制情況下排放至收集或排放系統中則不適用本排除條件)
10 在製程區域外部或保養廠內執行之機械作業
說明與實例 ndash 以 GHS 表 1 為基礎
以下說明和實例有助於在評估須提報製程安全事件(PSE)時釐清可能存在的不確定部分
公司廠區
1 一輛第三方的卡車在公司廠區內卸載易燃產品時發生洩漏進而引起火災造成公司財物損失
$7000 美元(直接成本)雖然該卡車是ldquo由他人操作rdquo但其作業與製程相連接若公司的直接成
本財物損失達到或超過$2500 美元或已達到或超過其他 PSE 提報門檻(如1 人死亡)此事故即
屬於須提報的製程安全事件
2 與前例1 類似的例子載著易燃產品的卡車在廠外運輸途中翻覆引發火災並造成卡車毀損
該事故不屬於須提報的製程安全事件因為當時卡車並未與製程相連接
20
阻絕設施失效
3 儲槽液位計故障造成裝有ldquo易燃液體rdquo產品的儲槽外溢約 700 公斤的液體流入儲槽的防溢堤內
此事故屬於須提報的製程安全事件因為其ldquo急性rdquo洩漏量超過 100 公斤即使是阻絕在二次阻絕
設施防溢堤中亦然
4 一名從事維修工作的承攬商在開啟一個製程阻閥時被噴起的硫酸濺到造成嚴重灼傷和損失工
時的工傷此事故屬於須提報的製程安全事件因為它是涉及物質和一次阻絕設施失效的意外事
件對於因洩漏造成死亡和損工的工傷或疾病事故沒有洩漏恕限值
5 一名作業員開啟品管取樣點進行日常取樣作業時手部被一個破碎的玻璃瓶嚴重割破需要進行
縫合治療縫針造成第二天無法上班該事故不屬於須提報的製程安全事件因為它與一次阻絕
設施失效無關
ldquo急性rdquo洩漏
6 一名作業員在進行天然氣流量高於預期值之異常排除時發現天然氣管線上的一個安全閥門未適
當歸位因此天然氣經由氣液分離桶排放至排氣煙囪經進一步檢查作業員判斷在過去 6 個
月間總共有 100000 公斤天然氣以穩定的速率排放至大氣該事故不屬於須提報的製程安全事
件因為其洩漏速率(每小時約 10 公斤)不算ldquo急性rdquo洩漏(未超過易燃蒸汽每小時 100 公斤的恕限
值)
廢氣燃燒塔amp排放控制裝置 (如洗滌塔)
7 若化學物質被導引至廢氣燃燒塔或排放控制裝置(如洗滌塔)只要該廢氣燃燒塔或控制裝置運作在
正常設計範圍內便不屬於須提報的製程安全事件
8 若廢氣流速超過洗滌塔的設計負荷以致未經吸收的化學物質排出超過恕限值該事故屬於須提報
的製程安全事件(如本文註釋所述)
註釋自取得許可或妥善管理的裝置-包括釋壓裝置發生不預期的排放若 1 小時內洩漏量達到或
超過表 1 或表 2 所列的洩漏恕限值且導致下列四種後果之任一項或以上之後果該事故便屬於
須提報的製程安全事件
o 二相排放或夾帶液體的排放液滴沉降至地面造成污染
o 排放至具潛在危險性的地點)
o 廠內就地避難或疏散不包括預防性廠內就地避難或疏散
o 啟動公眾保護措施(如道路封閉)包括預防性公眾保護措施
21
安全洩壓裝置 系統
9 製程單元發生異常安全閥開啟將洩漏物質釋放到排氣口此釋壓排放裝置是依相關要求設計
的且氣體釋到大氣中並未造成不良後果這不是一個須提報的製程安全事件因為安全閥高
壓破裂盤以及類似的安全裝置是依據 API 521 或者同等的標準設計的且此排放並未造成 (1)
夾帶液體並導致須提報的製程安全事件的後果(譬如損失工時意外死亡火災或爆炸造成$2500
美元或以上的直接成本損失液體或毒性氣體洩漏量達到或超過恕限值(2) 啟動廠內或廠外就地
避難應變或(3)啟動公眾保護措施
10 製程單元發生異常安全閥並未開啟造成設備超壓易燃性氣體從一個法蘭處ldquo急性rdquo漏出來
洩露量超過 100 公斤(一小時內)的恕限值該事故屬於須提報的製程安全事件因為從法蘭處外
漏屬於製程安全事件應提報事項
損工事故
11 一名作業員走路時不慎滑倒造成損失工時之工傷滑倒原因為天氣狀況rdquo長期rdquo油垢的地面和
易滑鞋具該事故不屬於須提報的製程安全事件因為人員安全ldquo滑倒絆倒跌倒rdquo事故若非與
一次阻絕設施失效直接關聯的疏散或應變造成則不屬於須提報的製程安全事件
12 與前例相同的事件惟這次作業員跌倒是因為少量易燃液體外漏(如 1 小時內少於 10 公斤)在採取
相關應變措施時發生該事故屬於須提報的製程安全事件因為作業員係為了應變一次阻絕設施
失效的事故而跌倒若一次阻絕設施失效發生在公司廠區且造成失時工傷或死亡後果該事故
便屬於須提報的製程安全事件對於因洩漏造成死亡和損失工時之工傷事故沒有洩漏量門檻
13 與前例相同的事件惟這次作業員跌倒是在事件結束數小時之後該事故不屬於須提報的製程安
全事件在提報要件中所用的ldquo疏散rdquo和ldquo應變rdquo等術語指的是一次阻絕設施失效和相關緊急應變
活動正在持續中事件結束後滑倒絆倒跌倒(如ldquo事後rdquo清理和補救)不屬於須提報製程安全事件
14 工人在因附近設備一次阻絕設施失效在疏散過程中一名鷹架搭建工人從鷹架梯上跌落造成損
失工時之工傷該事故屬於須提報的製程安全事件
15 一名作業員行經一個設計不良的蒸汽卻水器時被外洩的蒸汽燙傷腳踝造成損失工時之工傷
該事故屬於須提報的製程安全事件因為雖然一次阻絕設施失效洩漏出的是蒸汽(而非碳氫化合物
或化學物質)但損失工時之工傷是由於洩漏物質的物理狀態所導致的
16 一個密閉空間依照計畫以氮氣吹清一名承攬商繞過安全管制進入該密閉空間因而死亡該事
故屬於須提報的死亡事件但不屬於須提報的製程安全事件因為其中不涉及非計劃或失控的一
次阻絕設施失效
17 情況同上惟這次氮氣是非刻意洩漏進入該局限空間該事故屬於須提報的製程安全事件(同時也
是一起死亡事件)因為該名承攬商的死亡與非計劃的一次阻絕設施失效有關
22
18 一名作業員因硫化氫(H2S)警報在進行應變處理時昏倒若警報確實是因非計劃或失控的 H2S 一次
阻絕設施失效的外洩事件該事故便屬於須提報的製程安全事件若警報是一個假警報則該事
故便不屬於須提報的製程安全事件因為沒有真正的化學品洩漏發生
管線
19 一條管線破漏1 小時內洩漏 2000 磅(900 公斤)易燃蒸氣到地面但洩漏位置在廠區內很偏僻的
地點該事故仍屬於須提報的製程安全事件因為ldquo偏僻rdquo不是提報與否的考量因素
與化學物質外洩無關之火災或能量釋放事故
一般通則而言唯有當火災或能量釋放事故是因化學物質洩漏所造成或其發生導致化學物質洩漏
超過提報恕限值這些事故才屬於須提報的製程安全事件實例包括
20 一場電氣火災影響製程操作導致甲苯洩漏 400 公斤該事故屬於須提報的製程安全事件因為
化學物質洩漏已超過甲苯的 100 公斤提報恕限值
21 發生電氣火災停電或任何公用資源供應中斷可能造成工廠停工及可能引起設備損失超過
$2500 美元(如因非正常停工導致反應器或設備損壞)但並未造成超過恕限值的化學物質洩漏
亦未造成死亡或嚴重工傷該事故不屬於須提報的製程安全事件因為設備損壞並非化學製程火
災爆炸造成且化學物質洩漏並未超過恕限值
海上運輸船
22 一艘由公司營運的海上運輸船在船上發生ldquo急性rdquo易燃物質外洩洩漏量超過 100 公斤該事故不
屬於須提報的製程安全事件因為除非海上運輸船是為了輸送半成品或產品而與煉油石化或化
學製造廠的設施相連接否則其洩漏事故便不被視為製程安全事件
23 一艘第三方駁船由一艘拖船推向碼頭結果撞上公司的碼頭駁船的一個船艙破裂且造成
1000 公斤柴油洩漏到海中該事故不屬於須提報的製程安全事件因為駁船當時並非停泊在碼
頭內且其作業並非在進行半成品或產品之輸送
卡車與軌道車
24 一輛公司的軌道車在運輸途中出軌造成超過 1000 公斤汽油洩漏該事故不屬於須提報的製程
安全事件因為在公司廠區外發生的軌道車事故不被視為與製程安全有關
23
25 一輛第三方卡車拖車在公司廠區內翻覆造成ldquo急性rdquo汽油洩漏超過 1000 公斤這事故不屬於須
提報的製程安全事件因為卡車拖車當時已不再與裝卸設備連接然而我們建議會員公司另
行訂定運輸安全事故指標將這類事故記錄下來
26 一位合約卡車作業者正在卸載液鹼時發生軟管脫落造成空氣中氣霧和或液鹼液洩漏 2500 公
斤該事故屬於須提報的製程安全事件因為洩漏量已超過液鹼的 100 公斤恕限值且事故發生
前卡車仍與裝卸設備相連接著
辦公建築
27 綜合辦公大樓發生鍋爐火災造成總計$75000 美元的直接成本損失該事故不屬於須提報的製
程安全事件因為辦公大樓事故不被視為與製程安全有關
人機介面事故
28 一名操作技術員在聚合物工廠的終端設備旁作業時受傷這傷害是因機械的人機介面的設備而
造成該事故不屬於須提報的製程安全事件因為技術員受傷並非因危險物質一次阻絕設施失效
而造成的
混合物
29 若混合物本身有 GHS 分類可利用其分類確定恕限值若混合物本身沒有 GHS 分類則可計算混
合物中每個單一組成分之洩漏量(公斤)相對於個別成分恕限值之比值作為其對混合物恕限值之
lsquo加權rsquo貢獻譬如若混合物在 1小時內的洩漏量為 100公斤其中包含 05公斤分類為劇毒 H300
的物質45 公斤分類為 H301 的物質40 公斤另一種分類為 H 開頭的物質其餘 55 公斤則為沒
有 GHS 分類的水分此混合物之計算式為051 + 4510 + 40100 = 05 + 045 + 04 = 135超過
1因此該事故被視為須提報的製程安全事件雖然混合物個別成分之洩漏量均未超過各該物質
本身的恕限值
直接損失成本
30 此一門檻所考慮的成本應為可直接歸因於火災或爆炸的成本譬如設備及結構損壞的重置成本
修理成本環境清理支出緊急應變和罰款直接成本不包括間接成本譬如業務機會損失設
備停機造成之利潤損失取得或運轉臨時設施之成本或為滿足顧客需求取得替代產品的成本
(產品損失)
24
31 範例連接到氣體處理系統的排放管發生易燃氣體外漏同時製程出現問題導致空氣進入同
一條排放管結果發生爆炸過高的壓力損壞了排放管及其相關上游設備包括一個密封罐並
未造成人員受傷修理成本約$12000 美元該事故屬於須提報的製程安全事件因為爆炸及火
災導致設備修理成本超過門檻
32 範例一次製程安全事件後公司又發生一種非常特殊的 GHS 第 5 類產品洩漏 50 公斤造成
$2000 美元的設備損失洩漏的產品是一種非常特別的混合物公司須負擔超過$50000 美元因
產品耗損而產生之材料成本該事故不屬於須提報的製程安全事件因為 GHS 第 5 類產品洩漏的
提報門檻為 100 公斤且產品耗損不被計入直接損失成本
天然災害
33 天然災害可能對化學製程作業構成重大風險且對製程設備造成損壞導致危害物質一次阻絕設
施失效當一種或多種天然災害被認為可能對工廠作業造成影響時製程安全和作業系統應從危
害及後果分析工廠機器設備設計公用設施失效及製程停工之操作程序緊急應變計畫及應變
措施等方面界定潛在風險進行防範
天然災害類型包括颶風及颱風(包括伴隨而來的風暴潮)水災龍捲風地震超強對流風暴(直
線風暴)野火火山爆發海嘯和山崩
若公司廠房設施遭遇天然災害且其後果觸發一種或以上提報門檻該事故便屬於須提報製程安
全事件
預防性公眾應變
34 預防性公眾應變是基於謹慎的態度所採取的一種措施譬如當發生一次阻絕設施失效時公司
可能在尚未進行任何評估(如方向與洩漏點的距離等等)前便要求全體工人就地避難又
如地方權責官員(如消防警察民防緊急應變管理部門)在獲報一家公司發生製程安全事件
後為防lsquo萬一rsquo風向改變或基於可能受到波及的人口敏感族群(如學童或老年人)可能在尚未接
獲明確資訊前便下令社區就地避難或疏散或採取公眾保護措施(如道路封閉)
製程附屬倉庫
35 製程附屬倉庫指的是位於廠內用於儲存將投入於生產製程或產自於製程之原料半成品或成品的
倉庫從製程的觀點看來製程附屬倉庫相當於一個大型儲槽但這些原料半成品或成品並不
是儲存在一的大型容器中而是裝在較小的容器裡(如太空包大桶桶罐等)
25
Appendix C ndash List of RCLG Taskforce Members
Name Affiliation
Peter Schmelzer Bayer CEFIC - Chairman
Americo Diniz Carvalho Neto Braskem
Bradford Johnson American Chemistry Council
David Cummings DuPont
Debra Phillips American Chemistry Council
Hans Schwarz BASF
Kathryn Walton Plastics and Chemicals Industries Association
Kazuyuki Akita Japanese Chemical Industry Association
Kelly Keim ExxonMobil Chemical Company API Representative
Kenan Stevick Dow
Kiyokazu Murata Japanese Chemical Industry Association
Larry Bowler SABIC
Lorna Young Chemical Industry Association of Canada
Louisa Nara Center for Chemical Process Safety
Luiz Shizuo Harayashiki Associaccedilatildeo Brasileira da Induacutestria Quiacutemica
Masatoshi Kumamoto Japanese Chemical Industry Association
Milton Lacerda Petrobras
Phil Scott Chemical Industries Association
Piet Knijff DSM European Process Safety Centre
Scott Donaldson and Eamon Chandler
Shell
Scott Wallace Olin Corporation
Shakeel Kadri Air Products and Chemicals Inc
26
附錄 D ndash 詳細活動時程表
2016 年 2017 年 2018 年 2019 年 2020 年
2 ndash 4 月
RCLG PS 先導計畫
5 月 ndash
針對準則進行調整釐清
6 月 向 RCLG 和 ICCA 董事會報
告先導計畫執行結果
7 ndash 12 月 RCLG 協會考量準
則並為其會員公司發展提報機制
如有需要RCLG可向 ICCA 申請能
力建立基金為會員公司舉辦製程安
全研習會
1 ndash 12 月
RCLG 協會開始向其會員公司蒐集製程安全數據
1 ndash 12 月
如有需要RCLG 各協會運用 RCLG 的基金及專
家舉辦製程安全及績效提報研習會
1 ndash 2 月
擁有數據的協會開始向RCLG 提報製程安全事件
(2017 年數據)
4 月 RCLG 檢討第一個提報循
環的結果挑戰及原始數據(內部)
6 月 RCLG 向 ICCA 董事會呈報
原始數據
7 ndash 12 月 必要時更新及調整準
則
如有需要RCLG 各協會運用 RCLG 的基金及專
家舉辦製程安全及績效提報研習會
1 ndash 2 月
擁有數據的協會開始向RCLG 提報製程安全事件
(2018 年數據)
4 月 RCLG 檢討第二個提報循
環的結果挑戰及原始數據(內部)
6 月 RCLG 向 ICCA 董事會呈報
原始數據
7 ndash 12 月 必要時更新及調整準
則
如有需要RCLG 協會運用 RCLG 的基金及專家
舉辦製程安全及績效提報研習會
1 ndash 2 月
所有協會開始向 RCLG 提報製程安全事件
製程安全事件提報成為
RCLG KPI 衡量指標建議基本集的一部分(2019 年數
據)
4 月 RCLG 檢討第二個提報循
環的結果挑戰及原始數據(內部考量外部提
報)
6 月 RCLG 向 ICCA 董事會呈報
原始數據
27
附錄 E ndash 選擇性 Excel 追蹤表
當會員公司開始追蹤製程安全事件時所有會員公司應採用單一表格以簡化數據分析同時讓所有公司均使用相同的追蹤表RCLG 設
計了一份選擇性追蹤表可供會員公司和協會先行利用之後他們可設計自己的追蹤表
在這裡下載追蹤表
ICCA Process Safety Event Tracking Sheetxlsx
本文件包含三個分頁分別是ldquo聯絡資料rdquoldquo調查表rdquo和儲存下拉式選單選項的ldquo請勿編輯rdquo分頁
備註
附錄 E 追蹤表僅供參考TRCA 將另行提供台灣版表格供會員公司提報
28
後語
台灣化學工業責任照顧協會(Taiwan Responsible Care Association TRCA)成立於 1998 年在台灣推行責任照顧制度已達 20 週年製造商成員
包括台灣主要上市上櫃化工公司會員公司化學品生產製造量約佔全國 80 2016 年台灣化工業的 Chemical Sales 仍站在全球第八名的位
置額度為 630 億歐元化工業總產值達到 34 兆新台幣提供國內 416 萬人工作機會
TRCA 扮演國內廠商與國際制度接軌的角色也是國內化工業與政府機關及利益相關者溝通的橋樑與管道TRCA 會員結構依業務性質分析
涵蓋石化生產化學品製造氣體生產倉儲運輸業化學品貿易業以及工程研發設計等公司TRCA 透過供應鏈及價值鏈推行責任
照顧制度組成毒性化學物質聯防組織協助法規溝通與研析會員名冊請參考 httpwwwtrcaorgtwtrcanwork2aspx
TRCA 於 2010 年成為 ICCA (International Council of Chemical Associations 國際化學工業協會)觀察員ICCA 成立於 1989 年是全球化工製造
業的聯合會也是化學工業與 UNEP OPCW 及 OECD 的交流窗口ICCA 與其會員協會及成員公司致力於邁向永續的未來確保人類健康與
環境安全與保護全球化工業擁有超過 4兆美元的價值影響所有經濟部門ICCA 的會員幾乎在全球每個國家都有商業活動在全球六大
洲推動創新並提供超過 2000 萬個工作機會
台灣化工業在全球占有重要的一席之地在國內產業鏈也位居關鍵位置無論對國內或國際都有身為地球村一員應盡之責我們期許藉由
製程安全指標提報能更進一步提升自我在工安衛生環保與永續發展等面向的績效表現
台灣化學工業責任照顧協會
10452 台北市中山區撫順街 8 號 7 樓
電話02-2585-0552
httpwwwtrcaorgtw
None | |
$2500 to $25000 | |
$25000 to $250000 | |
$250000 to $25000000 | |
More than $25000000 | |
Yes - Using GHS TABLE | |
Yes - Using API RP 754 TABLE | |
NO | |
NA | |
1x le TQ lt 40x | |
40x le TQ lt 160x | |
160x le TQ lt 640x | |
ge 640x TQ | |
Yes le 3 hours | |
Yes 3 hours ge 12 hours | |
Yes 12 hours ge 24 hours | |
Yes ge 24 hours | |
No | |
Small-scale | |
Medium-scale | |
Large-scale | |
No | |
Yes | |
No | |
middot Injury requiring treatment beyond first aid to an employee contractor or subcontractor | |
middot Days Away From Work injury to an employee contractor or subcontractor or middot Injury requiring treatment beyond first aid to a third party | |
middot A fatality of an employee contractor or subcontractor or middot A hospital admission of a third party | |
middot Multiple fatalities of employees contractors or subcontractors or middot multiple hospital admission of third parties or middot A fatality of a third party | |
NA | |
1x le TQ lt 3x | |
3x le TQ lt 9x | |
9x le TQ lt 27x | |
ge 27x TQ |
ICCA Process Safety Pilot Reporting ProgramFebruary 8 2016 | 1 | 2 | 3 | 4 | 5 | 6 | 7 | 8 | 9 | 10 | 12 | 13 | 14 | 15 | |||||||||||||||||||||||
SAFETY Details(Meeting Local Regulations) | Direct Cost from Fire or Explosion | Community Impact | Environmental Impact | Material Released(Measured using the 1 Hour Rule) | |||||||||||||||||||||||||||||||||
Company Association Details | |||||||||||||||||||||||||||||||||||||
GHS | API - RP 754 | ||||||||||||||||||||||||||||||||||||
Company or Assocation Name | Headquarter Association | Location of Event Ex - City State amp Country | Date and Time of Event | Safety InjuryDid the Event result in a Recordable Lost Time Accident or Fatality or Hospital admission of anyone on or off siteUse Drop Down Menu | Safety InjuryIf yes please insert the total number of injuries | Safety InjuryFor puropses of utilizing the Severity Table please indicate the level of severity by chosing the MOST SEVERE classification that describes your incidentUse Drop Down Menu | Safety InjuryDid the incident involve Fatalities If so how many total fatalities If none enter Zero | Safety InjuryPlease Report Total Employee Hours for Calendar Year 2015 | Safety InjuryPlease Report Total Contractor Hours for Calendar Year 2015 | Direct Cost Did the Event result in Direct Damage CostUse Drop Down Menu | Direct Cost If so how muchAmount is in US DollarsUse Drop Down Menu | Community ImpactDid the event result inbull Officially declared shelter-in-place or officially declared evacuation (on or off site)ORbull Precautionary off site shelter in place or evacuation Use Drop Down Menu | Environmental ImpactDid the event result inAcute Environmental Remediation CostIf so indicate the amount in US DollarsUse Drop Down Menu | Material ReleasedDid the Event result in an Acute Release of material beyond one of the two threshold tablesIf so indicate which Threshold Table you used to make this determinationUse Drop Down Menu | Material ReleasedIf so indicate the amount released USING GHS CLASSIFICATION TABLEUse Drop Down Menu | Material ReleasedIf so indicate the amount released USING THE THRESHOLD TABLE FROM API RP-754Use Drop Down Menu | Material ReleasedIf available please indicate the material released | ||||||||||||||||||||
1 | ABC Chemical Company | American Chemistry Council | Washington DC - USA | January 4 2016 | Yes | 2 | middot Days Away From Work injury to an employee contractor or subcontractor or middot Injury requiring treatment beyond first aid to a third party | 0 | 5525000 | 1500250 | No | $2500 to $25000 | Yes le 3 hours | $2500 to $25000 | Yes - Using GHS TABLE | 40x le TQ lt 160x | NA | Chlorine | |||||||||||||||||||
2 | XYZ Chemical Company | American Chemistry Council | Washington DC - USA | 5-Jan-16 | Yes | 1 | middot Injury requiring treatment beyond first aid to an employee contractor or subcontractor | 0 | 5525000 | 1500250 | Yes | $2500 to $25000 | No | $2500 to $25000 | Yes - Using API RP 754 TABLE | NA | 3x le TQ lt 9x | Benzene | |||||||||||||||||||
3 | |||||||||||||||||||||||||||||||||||||
4 | |||||||||||||||||||||||||||||||||||||
5 | |||||||||||||||||||||||||||||||||||||
6 | |||||||||||||||||||||||||||||||||||||
7 | |||||||||||||||||||||||||||||||||||||
8 | |||||||||||||||||||||||||||||||||||||
9 | |||||||||||||||||||||||||||||||||||||
10 | |||||||||||||||||||||||||||||||||||||
11 | |||||||||||||||||||||||||||||||||||||
12 | |||||||||||||||||||||||||||||||||||||
13 | |||||||||||||||||||||||||||||||||||||
14 | |||||||||||||||||||||||||||||||||||||
15 | |||||||||||||||||||||||||||||||||||||
16 | |||||||||||||||||||||||||||||||||||||
17 | |||||||||||||||||||||||||||||||||||||
18 | |||||||||||||||||||||||||||||||||||||
19 | |||||||||||||||||||||||||||||||||||||
20 | |||||||||||||||||||||||||||||||||||||
21 | |||||||||||||||||||||||||||||||||||||
22 | |||||||||||||||||||||||||||||||||||||
23 | |||||||||||||||||||||||||||||||||||||
24 | |||||||||||||||||||||||||||||||||||||
25 | |||||||||||||||||||||||||||||||||||||
Zero or None | Yes - Duration Unknown | ||||||||||||||||||||||||||||||||||||
Processes | Mode of Operation | Type of material released | Status of Operation | ||||
REFINING | Start-up | Flammable | Open | ||||
Alkylation HF | Planned shutdown | Combustible | Closed | ||||
Alkylation sulfuric | Emergency shutdown | Toxic | |||||
BitumenResidAsphalt | Normal | Corrosive | Tier 1 Acute Releases | ||||
Calcining | Upset | Utilities | No Release | ||||
Coking | Turnaround | Other | Category 1 | ||||
Crude | Routine maintenance | Category 2 | |||||
Desulfurization | Temporary | Evacuation | Category 3 | ||||
FCC | Other | Yes | Category 4 | ||||
Gas Treating | No | Category 5 | |||||
Hydrogen | Point of Release | Category 6 | |||||
Hydrotreating | Pump | Fire | Category 7 | ||||
Hydrocracking | Compressor | Yes | Multiple Categories | ||||
Isom | BlowerFan | No | |||||
MarineJetty | Pressure Vessel | lt $2500 | |||||
Reforming | FilterCoalescer | ||||||
Sulfur recovery | Furnace | PRDs | |||||
Vapor recoverylight ends | Boiler | Directly to Atmosphere | |||||
Wastewater | Heat exchanger | via Downstream Destructive Device | |||||
REFINING amp PETROCHEMICAL | Cooling Tower | No | |||||
Tank FarmStorage FacilityOffsite | Piping system | Yes | |||||
UtilitiesSteam PlantCogeneration | Reactor | No | |||||
Other | Atmospheric tank | ||||||
PETROCHEMICAL | FlareRelief System | Acute release above thresholds | |||||
CO H2 | Other | Yes | |||||
LNG | No | ||||||
Methane | Events | ||||||
Methanol | No Tier 1 Events | Indoor Outdoor | |||||
Methyl Mercaptan | No Tier 2 Events | No Release | |||||
Formaldehyde | No Tier 1 or Tier 2 Events | Indoor | |||||
Formaldehyde derivatives | NA | Outdoor | |||||
Acetic Acid | |||||||
Acetic Acid derivatives | Event Type | ||||||
Ethane | Injury | ||||||
Ethylene | Fire | ||||||
Ethanol | Explosion | ||||||
Ethylene oxide | PRD Discharge | ||||||
Ethylene derivatives | Acute Release | ||||||
Polyethylene | |||||||
Ethylene dichloride | General | ||||||
Ethylene dichloride derivatives | Yes | ||||||
Ethyl benzene | No | ||||||
Ethyl benzene derivatives | |||||||
Polystyrene | |||||||
Styrene-Butadiene | |||||||
Propane | |||||||
Propylene | |||||||
Polypropylene | |||||||
Isopropanol | |||||||
Propylene oxide | |||||||
Propylene oxide derivatives | |||||||
Butane | |||||||
Isobutane | |||||||
Isobutene | |||||||
Butadiene | |||||||
MTBE | |||||||
ETBE | |||||||
Pentane | |||||||
Hexane | |||||||
Cyclohexane | |||||||
Hexanol | |||||||
Aromatics Derivatives | |||||||
Benzene | |||||||
Toluene | |||||||
Xylene | |||||||
Para Xylene | |||||||
Amines Derivatives | |||||||
TDA MDA IPDA etc | |||||||
Isocyanates | |||||||
Specialty Chemicals | |||||||
LoadingUnloading | |||||||
Pilot Plant |
Instructions | ||||||||||||||
Step 1 | Complete the Contact Tab with your contact information and company information | |||||||||||||
Be sure to note the region of your reporting (IE North America France Japan etc) | ||||||||||||||
Survey on Process Safety Events | ||||||||||||||
Step 2 | Complete the survey one line per Process Safety Event for your companyregion | |||||||||||||
ALL REPORTED DATA SHOULD BE FROM CALENDAR YEAR 2017 | ||||||||||||||
Step 3 | Return completed survey to | |||||||||||||
Company Name | ||||||||||||||
Contact Person | All Surveys Due by xxx date | |||||||||||||
Address | ||||||||||||||
Fax | ||||||||||||||
Telephone | ||||||||||||||
Region | ||||||||||||||
None | |
$2500 to $25000 | |
$25000 to $250000 | |
$250000 to $25000000 | |
More than $25000000 | |
Yes - Using GHS TABLE | |
Yes - Using API RP 754 TABLE | |
NO | |
NA | |
1x le TQ lt 40x | |
40x le TQ lt 160x | |
160x le TQ lt 640x | |
ge 640x TQ | |
Yes le 3 hours | |
Yes 3 hours ge 12 hours | |
Yes 12 hours ge 24 hours | |
Yes ge 24 hours | |
No | |
Small-scale | |
Medium-scale | |
Large-scale | |
No | |
Yes | |
No | |
middot Injury requiring treatment beyond first aid to an employee contractor or subcontractor | |
middot Days Away From Work injury to an employee contractor or subcontractor or middot Injury requiring treatment beyond first aid to a third party | |
middot A fatality of an employee contractor or subcontractor or middot A hospital admission of a third party | |
middot Multiple fatalities of employees contractors or subcontractors or middot multiple hospital admission of third parties or middot A fatality of a third party | |
NA | |
1x le TQ lt 3x | |
3x le TQ lt 9x | |
9x le TQ lt 27x | |
ge 27x TQ |
ICCA Process Safety Pilot Reporting ProgramFebruary 8 2016 | 1 | 2 | 3 | 4 | 5 | 6 | 7 | 8 | 9 | 10 | 12 | 13 | 14 | 15 | |||||||||||||||||||||||
SAFETY Details(Meeting Local Regulations) | Direct Cost from Fire or Explosion | Community Impact | Environmental Impact | Material Released(Measured using the 1 Hour Rule) | |||||||||||||||||||||||||||||||||
Company Association Details | |||||||||||||||||||||||||||||||||||||
GHS | API - RP 754 | ||||||||||||||||||||||||||||||||||||
Company or Assocation Name | Headquarter Association | Location of Event Ex - City State amp Country | Date and Time of Event | Safety InjuryDid the Event result in a Recordable Lost Time Accident or Fatality or Hospital admission of anyone on or off siteUse Drop Down Menu | Safety InjuryIf yes please insert the total number of injuries | Safety InjuryFor puropses of utilizing the Severity Table please indicate the level of severity by chosing the MOST SEVERE classification that describes your incidentUse Drop Down Menu | Safety InjuryDid the incident involve Fatalities If so how many total fatalities If none enter Zero | Safety InjuryPlease Report Total Employee Hours for Calendar Year 2015 | Safety InjuryPlease Report Total Contractor Hours for Calendar Year 2015 | Direct Cost Did the Event result in Direct Damage CostUse Drop Down Menu | Direct Cost If so how muchAmount is in US DollarsUse Drop Down Menu | Community ImpactDid the event result inbull Officially declared shelter-in-place or officially declared evacuation (on or off site)ORbull Precautionary off site shelter in place or evacuation Use Drop Down Menu | Environmental ImpactDid the event result inAcute Environmental Remediation CostIf so indicate the amount in US DollarsUse Drop Down Menu | Material ReleasedDid the Event result in an Acute Release of material beyond one of the two threshold tablesIf so indicate which Threshold Table you used to make this determinationUse Drop Down Menu | Material ReleasedIf so indicate the amount released USING GHS CLASSIFICATION TABLEUse Drop Down Menu | Material ReleasedIf so indicate the amount released USING THE THRESHOLD TABLE FROM API RP-754Use Drop Down Menu | Material ReleasedIf available please indicate the material released | ||||||||||||||||||||
1 | ABC Chemical Company | American Chemistry Council | Washington DC - USA | January 4 2016 | Yes | 2 | middot Days Away From Work injury to an employee contractor or subcontractor or middot Injury requiring treatment beyond first aid to a third party | 0 | 5525000 | 1500250 | No | $2500 to $25000 | Yes le 3 hours | $2500 to $25000 | Yes - Using GHS TABLE | 40x le TQ lt 160x | NA | Chlorine | |||||||||||||||||||
2 | XYZ Chemical Company | American Chemistry Council | Washington DC - USA | 5-Jan-16 | Yes | 1 | middot Injury requiring treatment beyond first aid to an employee contractor or subcontractor | 0 | 5525000 | 1500250 | Yes | $2500 to $25000 | No | $2500 to $25000 | Yes - Using API RP 754 TABLE | NA | 3x le TQ lt 9x | Benzene | |||||||||||||||||||
3 | |||||||||||||||||||||||||||||||||||||
4 | |||||||||||||||||||||||||||||||||||||
5 | |||||||||||||||||||||||||||||||||||||
6 | |||||||||||||||||||||||||||||||||||||
7 | |||||||||||||||||||||||||||||||||||||
8 | |||||||||||||||||||||||||||||||||||||
9 | |||||||||||||||||||||||||||||||||||||
10 | |||||||||||||||||||||||||||||||||||||
11 | |||||||||||||||||||||||||||||||||||||
12 | |||||||||||||||||||||||||||||||||||||
13 | |||||||||||||||||||||||||||||||||||||
14 | |||||||||||||||||||||||||||||||||||||
15 | |||||||||||||||||||||||||||||||||||||
16 | |||||||||||||||||||||||||||||||||||||
17 | |||||||||||||||||||||||||||||||||||||
18 | |||||||||||||||||||||||||||||||||||||
19 | |||||||||||||||||||||||||||||||||||||
20 | |||||||||||||||||||||||||||||||||||||
21 | |||||||||||||||||||||||||||||||||||||
22 | |||||||||||||||||||||||||||||||||||||
23 | |||||||||||||||||||||||||||||||||||||
24 | |||||||||||||||||||||||||||||||||||||
25 | |||||||||||||||||||||||||||||||||||||
Zero or None | Yes - Duration Unknown | ||||||||||||||||||||||||||||||||||||
Processes | Mode of Operation | Type of material released | Status of Operation | ||||
REFINING | Start-up | Flammable | Open | ||||
Alkylation HF | Planned shutdown | Combustible | Closed | ||||
Alkylation sulfuric | Emergency shutdown | Toxic | |||||
BitumenResidAsphalt | Normal | Corrosive | Tier 1 Acute Releases | ||||
Calcining | Upset | Utilities | No Release | ||||
Coking | Turnaround | Other | Category 1 | ||||
Crude | Routine maintenance | Category 2 | |||||
Desulfurization | Temporary | Evacuation | Category 3 | ||||
FCC | Other | Yes | Category 4 | ||||
Gas Treating | No | Category 5 | |||||
Hydrogen | Point of Release | Category 6 | |||||
Hydrotreating | Pump | Fire | Category 7 | ||||
Hydrocracking | Compressor | Yes | Multiple Categories | ||||
Isom | BlowerFan | No | |||||
MarineJetty | Pressure Vessel | lt $2500 | |||||
Reforming | FilterCoalescer | ||||||
Sulfur recovery | Furnace | PRDs | |||||
Vapor recoverylight ends | Boiler | Directly to Atmosphere | |||||
Wastewater | Heat exchanger | via Downstream Destructive Device | |||||
REFINING amp PETROCHEMICAL | Cooling Tower | No | |||||
Tank FarmStorage FacilityOffsite | Piping system | Yes | |||||
UtilitiesSteam PlantCogeneration | Reactor | No | |||||
Other | Atmospheric tank | ||||||
PETROCHEMICAL | FlareRelief System | Acute release above thresholds | |||||
CO H2 | Other | Yes | |||||
LNG | No | ||||||
Methane | Events | ||||||
Methanol | No Tier 1 Events | Indoor Outdoor | |||||
Methyl Mercaptan | No Tier 2 Events | No Release | |||||
Formaldehyde | No Tier 1 or Tier 2 Events | Indoor | |||||
Formaldehyde derivatives | NA | Outdoor | |||||
Acetic Acid | |||||||
Acetic Acid derivatives | Event Type | ||||||
Ethane | Injury | ||||||
Ethylene | Fire | ||||||
Ethanol | Explosion | ||||||
Ethylene oxide | PRD Discharge | ||||||
Ethylene derivatives | Acute Release | ||||||
Polyethylene | |||||||
Ethylene dichloride | General | ||||||
Ethylene dichloride derivatives | Yes | ||||||
Ethyl benzene | No | ||||||
Ethyl benzene derivatives | |||||||
Polystyrene | |||||||
Styrene-Butadiene | |||||||
Propane | |||||||
Propylene | |||||||
Polypropylene | |||||||
Isopropanol | |||||||
Propylene oxide | |||||||
Propylene oxide derivatives | |||||||
Butane | |||||||
Isobutane | |||||||
Isobutene | |||||||
Butadiene | |||||||
MTBE | |||||||
ETBE | |||||||
Pentane | |||||||
Hexane | |||||||
Cyclohexane | |||||||
Hexanol | |||||||
Aromatics Derivatives | |||||||
Benzene | |||||||
Toluene | |||||||
Xylene | |||||||
Para Xylene | |||||||
Amines Derivatives | |||||||
TDA MDA IPDA etc | |||||||
Isocyanates | |||||||
Specialty Chemicals | |||||||
LoadingUnloading | |||||||
Pilot Plant |
Instructions | ||||||||||||||
Step 1 | Complete the Contact Tab with your contact information and company information | |||||||||||||
Be sure to note the region of your reporting (IE North America France Japan etc) | ||||||||||||||
Survey on Process Safety Events | ||||||||||||||
Step 2 | Complete the survey one line per Process Safety Event for your companyregion | |||||||||||||
ALL REPORTED DATA SHOULD BE FROM CALENDAR YEAR 2017 | ||||||||||||||
Step 3 | Return completed survey to | |||||||||||||
Company Name | ||||||||||||||
Contact Person | All Surveys Due by xxx date | |||||||||||||
Address | ||||||||||||||
Fax | ||||||||||||||
Telephone | ||||||||||||||
Region | ||||||||||||||
7
RCLG 各協會應向 RCLG 提報的數據
RCLG 各協會每年必須依照下文提供的時程透過 RCLG 關鍵績效指標(KPI)提報網站向
ICCA 提報兩個數據
1 協會所屬會員公司的總工作時數(包括員工和承攬商)
2 製程安全事件總數
ICCA 將利用上述兩個數據以製程安全事件發生率(PSER)的形式報告製程安全績效PSER
計算之常態化是以每 100 位員工每位員工一年工作 2000 小時為基準
(總事件數 總工作時數) x 200000 = PSER
建議之提報時程
針對提報製程安全事件發生率專案小組建議一種分階段導入的方法此一時程可讓更多
已具經驗的協會及公司立即實施提報同時容許其他協會及公司從 2019 年起開始提報
RCLG 各協會必須透過 RCLG KPI 指標提報系統(httpkpiresponsiblecareeu)每年向 ICCA
提報兩個製程安全事件發生率數據如果你不知道你所屬協會的使用者名稱和密碼請聯
絡 RCLG
建議 RCLG 協會提報製程安全事件發生率的時程如下
2015 年 4 月 RCLG 考量專案小組建議案
2015 年 6 月 ICCA 理事會考量 RCLG 的最終建議
2015 年 7 月 RCLG 頒布首份詳細的提報指引供協會及會員公司遵
循
2016 年 2 月 RCLG 提報 RCLG 更新及強化提報指引並針對自願參加的協會
開始實施製程安全試行提報計畫RCLG 於 2016 年 6 月
頒布最終指引
2017 年 RCLG 各協會開始向會員公司蒐集數據
2018-2019 年 RCLG 提報 RCLG 各協會可選擇地開始提報製程安全數據
2020 年提報 RCLG 於 KPI 提報計畫中將製程安全納入為一項強制性
指標
參見附錄 D ndash 詳細活動時程
8
ICCA 製程安全事件判定標準流程圖
事故是否發生在廠內之
生產配銷儲存公
用或試驗工廠
是 是
是
否
否 是否造成須通報工傷
或
廠內廠外人員住院治
療
損壞是否對
公司造成
ge $2500 美
元的直接成
本損失
官方是否宣告就地
避難或疏散或廠
外預防性就地避難
或疏散
否
是
否
是屬於須通報製程安全事件
是
否
是
是
開始
否不符合製程安全事件認定
標準
是否超過 ICCA 或 API
754 Tier II 化學物質洩
漏恕限值
否 發生化學物質外洩火
災或爆炸是否起因於
或發生在化學製程單元
是否直接涉及某種化學物
質或化學製程
否
9
須提報製程安全事件之重要標準
總工作時數
RCLG 各協會應以加總的單一數字提報其所屬會員公司的員工和承攬商總工作時數為達
成本指引之目的各協會應參考其本地和地區對員工及承攬商之定義提報總時數之目標
應納入涉及化學製造之所有個人然而參與主要興建工程專案之人員則不納入計算譬
如為新建或擴建既有製程設施之設計工程和施工而成立之一次性專案組織的大規模投資
案會員公司提報總工作時數時應與人事部門統計之員工工時一致如此各公司便能
取得相同的職業與製程安全數據員工工時應包括所有化學製造作業的工時而非僅計算
發生製程安全事故之廠區的工時
製程安全事件
為執行 ICCA 提報目的製程安全事件之定義條件如下(必須同時符合 ABCD 四個條
件)
A 直接涉及某種化學物質或化學製程且
B 事故發生在廠內之生產配銷儲存公用或試驗工廠且
C 製程單元發生物質洩漏或能量釋放(如火災爆炸和內爆)且
D 已達到以下提報門檻之一
1 安全 工傷
導致記錄性的傷害(OSHA)損失工時或死亡或廠內外任何人員因此
而須住院治療或
2 直接損失成本
火災爆炸或為避免補救環境損害之必要清理作業導致$2500 美元
以上的直接成本支出或
3 就地避難 疏散
官方宣告就地避難(廠內或廠外)或
官方宣告疏散(廠內或廠外)或
廠外預防性就地避難或疏散或
4 洩漏恕限值
物質洩漏程度已達表 1 所列之任一 GHS 恕限值(洩漏量以單位小時計
量)
此外各公司亦可選擇採用 API RP-754 標準中所列之洩漏恕限值(表 2)請注意如欲查
看 API RP-754 標準可登入以下網站購買及下載httpwwwapiorgoil-and-natural-
gashealth-and-safetyprocess-safetyprocess-safety-standards
10
製程安全事件判定準則
A 涉及化學品
直接涉及某種化學物質或化學製程
製程安全事件或事故必須直接涉及化學物質或化學製程就此而言ldquo製程rdquo一詞泛指包含
石化生產所需要之設備和技術包括反應器儲槽管線鍋爐冷卻水塔和冷凍系
統helliphellip等未直接涉及化學物質或製程的事件無須提報譬如辦公大樓起火(即使該辦公大
樓位在廠區內亦然)
B 地點
事故發生在廠內之生產配銷儲存公用或試驗工廠
發生在廠內之生產配銷儲存(包括活動儲存區如倉庫 ndash 參見ldquo常見問題集rdquo)公用及
試驗工廠凡符合提報指標及定義的事故包括在廠區管理下之槽罐區輔助支援區(如
鍋爐室和廢水處理廠)和配銷管線所有須提報之事件應由負責該事故地點運作的公司
負提報之責此一規定亦適用於發生在承攬商作業區域內的事故在代工作業和多方共同
作業廠區負責運作該發生事故單位的公司應記錄事故始末並將之納入其提報中
C 物質洩漏
製程單元發生物質外洩或能量釋放(如火災爆炸和內爆)
物質外洩 ndash 製程任何物質發生非預期或無法控制的洩漏或釋放包括非毒性及不可燃物質
(如蒸汽熱水氮氣壓縮二氧化碳或壓縮空氣)且達到本文件所列四類提報門檻之一
項或以上之後果
在防治系統(如洗滌塔或廢氣燃燒塔)正常運作狀況下只要沒有任何洩漏或排放量超過
法定許可值即使排放到廢氣燃燒塔或滌氣塔仍被視為處於一次阻絕設施內然若排
放到二次阻絕設施(如廢水處理或防溢堤)將被視為製程安全事件因為物質已離開主要製
程系統
11
D 提報門檻
須提報製程安全事件必須達到以下提報門檻之一
1 安全 工傷
導致記錄性傷害(OSHA)損失工時或死亡或廠內外任何人員因此而須住院治療
記錄性傷害是指與工作有關所造成的傷害導致死亡暫時全失能工作受限制或需調整職
務較輕傷害嚴重之醫療處理失去意識或經醫師或其他合格醫療專業人員診斷為重大
傷害
損失工時傷害和死亡是指因製程相關的一次阻絕設施失效火災或爆炸導致以下任何一種
結果
員工(損失工時或死亡)
承攬商及再承攬商 (損失工時或死亡)
第三方(如來賓訪客快遞員)(受傷疾病導致住院治療或死亡)
住院治療是指醫院或其他具有住院病患保健設施的醫療單位正式接受病患住院提供病患
食宿及醫療護理且病患接受治療至少留置至隔日僅在醫院急診室治療或過夜處理不屬
於ldquo住院治療rdquo的定義範圍
須提報之工傷或死亡事件例如在清理作業期間因蒸汽洩漏造成人員燒燙傷壓力測試期間
帽蓋因受壓脫落造成人員身體傷害或取樣作業時因物質外濺造成人員化學灼傷無須提
報之工傷或死亡事件例如在執行維修作業時從高處的工作台墜落實驗室或辦公大樓火災
造成人員燒燙傷或挖掘工程塌陷造成人員傷害這些案例均與因製程造成的能量釋放或
物質洩漏無直接關聯
2 直接損失成本
火災爆炸或為避免補救環境損害之必要清理作業導致$2500美元以上的直接成本支出
此提報門檻所考慮的成本應為可直接歸因於火災或爆炸的成本譬如設備及結構損壞的重
置成本修理成本環境清理(廠內及廠外)支出緊急應變和罰款直接成本不包括間接
成本譬如業務機會損失設備停機造成之利潤損失取得或運轉臨時設施之成本或為
滿足顧客需求取得替代產品的成本(產品損失)
12
3 就地避難 疏散
官方宣告就地避難或疏散(廠內或廠外)或廠外預防性就地避難或疏散
就提報目的而言官方宣告就地避難或疏散(廠內或廠外)或廠外預防性就地避難或疏散
即達到此提報門檻
官方宣告 ndash 由地方權責機關(如消防警察民防緊急應變管理部門)或經授權的代表(如
派駐公司官員)下達的社區行動(如就地避難或疏散)宣告
預防性宣告 ndash 預防性公眾應變是基於謹慎的態度所採取的一種措施權責地方主管機關或經
授權的代表經合理判斷認定為維護公眾健康及安全發布必須採取就地避難或疏散之預
防性措施
就地避難 ndash 利用結構體及其內部空氣以暫時讓人員與室外危害性氣體隔離
疏散 ndash 基於安全或防護理由讓人員離開某處所的行動或過程
4 洩漏恕限值
超過表 1 中所列 GHS 恕限值或表 2 中所列 API 754 標準 Tier II 製程安全洩漏恕限值之一的
急性洩漏事件(洩漏量以單位小時計量)
如ldquo執行摘要rdquo所述ICCA 製程安全事件之定義容許採用 ICCA 依據化學品全球調和制度
(GHS)健康危害分級為基礎所發展的提報標準或依據聯合國危險物品(UNDG)分類為基礎
所定義之 RP-754 二級製程安全事件(Tier II) 之提報標準GHS 恕限值詳見表 1各會員公司
可自行決定選擇哪一個表中的提報恕限值並在全球採用單一制度
ldquo急性rdquo洩漏 ndash易燃性可燃性或毒性化學物質從一次阻絕設施(如容器或管線)洩漏其
任一單位小時之洩漏量超過化學物質洩漏恕限量分述於表 1 中的 GHS 分類和表 2 中的
API 754 標準 Tier II 製程安全洩漏恕限值
洩壓裝置前述所定義之ldquo急性rdquo洩漏包括洩漏或排放至妥善設計且運作中的洩壓裝置若
洩漏或排放量達到表 1 中所列 GHS 恕限值或表 2 中所列 API 754 標準 Tier II 製程安全洩漏
恕限值且導致下列四種後果之任一項或以上之後果
1 二相排放或夾帶液體的排放液滴沉降至地面造成污染
2 排放至具潛在危險性的地點
3 廠內就地避難或疏散不包括預防性廠內就地避難或疏散
4 啟動公眾保護措施(如道路封閉)包括預防性公眾保護措施
13
洩漏或排放至妥善設計且運作中的洩壓裝置(如廢氣燃燒塔洗滌塔等)若其情況未達前
述四項標準中任何一項則不必提報
欲查看 API RP-754 標準可登入以下網站下載此標準httpwwwapiorgenvironment-
health-and-safetyprocess-safetyprocess-safety-standardsstandard-rp-754
一小時法則
為便於衡量此項指標提報與否洩漏恕限值是以物質在任一小時內之洩漏量為標準若任
一小時或更短時間內物質洩漏量達到或超過須提報恕限值該事故便屬於須提報的製程安
全事件急性洩漏事故通常不會超過一小時若無法確定洩漏持續時間則應假設其為一
小時
一次阻絕設施ndash 用來作為主要容器或用於運送或輸送物質之槽罐船隻管線軌道車
或設備主要容器在設計上可能包含二次阻絕設施系統以抑制及控制洩漏二次阻絕設
施系統包括(但不限於)儲槽防溢堤製程設備周遭的圍堵設施油水分離的排水收集系統
雙層儲槽的外壁等
嚴重程度表 ndash 嚴重程度加權可額外提供有關製程安全事件的有用資訊有助於帶動改善績
效附錄 A 為 RCLG 建議之製程安全事件嚴重程度加權計算方法根據附錄 A 的方法便
可藉由加總與各個後果類別關聯的分數計算出各製程安全事件的嚴重程度加權值ICCA
強烈建議採用嚴重程度加權制度因為此制度有助於提升溝通績效的能力也比較容易讓
利害關係人了解製程安全事件並且此嚴重程度加權值與其他製程安全績效指標提報方
式是不具相互比較性的
14
表 1 ndash GHS 分類表
物理性危害(GHS 2x)
洩漏恕限值(1 小時內)
STOTSpecific target organ toxicity(特定標的器官系統毒性物質)
15
表 2 ndash API RP 754 Tier II 分類表
洩漏恕限類別
物質危害性分類 acdef 恕限值
(戶外洩漏) 恕限值
(戶內b洩漏)
T2-1 TIH A 區物質 ge 05 kg (11 lb) ge 025 kg (055
lb)
T2-2 TIH B 區物質 ge 25 kg (55 lb) ge 125 kg (275
lb)
T2-3 TIH C 區物質 ge 10 kg (22 lb) ge 5 kg (11 lb)
T2-4 TIH D 區物質 ge 20 kg (44 lb) ge 10 kg (22 lb)
T2-5
易燃氣體 或 正常沸點 ≦ 35 (95 degF)閃火點lt23 (73 degF)的液體 或 其他包裝組別 I 類的物質 (酸鹼除外)
ge 50 kg (110 lb) ge 25 kg (55 lb)
T2-6
正常沸點 gt 35 degC (95 degF)閃火點 lt 23 degC (73degF)的液體 或 其他包裝組別 II 類的物質 (酸鹼除外)
ge 100 kg (220 lb) 或
ge 07 bbl
ge 50 kg (110 lb) 或
ge 035 bbl
T2-7
閃火點 gt 23 degC (73 degF)和 lt 60 degC (140 degF)的液體 或 閃火點 gt 60 degC (140 degF)的液體在閃火點或高於閃火點的溫度下洩漏 或 強酸鹼 (定義參見 RP 754 文件草案) 或 UNDG第2類第22部分 (不可燃無毒氣體)空氣除外 或 其他包裝組別 III 類的物質
ge 200 kg (440 lb) 或
ge 14 bbl
ge 100 kg (220 lb) 或
ge 07 bbl
T2-8
閃火點 gt 60 degC (140 degF) 和 lt 93 degC (200 degF)的液體在低於閃火點的溫度下洩漏 或 中度酸鹼
ge 1000 kg
(2200 lb) 或
ge 7 bbl
ge 500 kg
(1100 lb) 或
ge 35 bbl
TIH吸入性毒性危害物(Toxic Inhalation Hazard)
16
一般認為以公斤和磅或以磅和桶為單位的恕限值不盡等同各公司應該選用其中一組計量單位並在
所有紀錄文件中一體適用
在判定一種物質之洩漏恕限類別時首先應從物質之含吸入性毒性(TIH Zone)可燃性(閃火點和沸點)
或腐蝕性(強酸或鹼 vs中度酸或鹼)等特性來判別只有當物質的危險度無法利用上述簡單的特性來判別
時(如遇水反應劇烈)才採用UNDGL包裝組別
a 許多物質具有一種以上危險性正確的危險區(Hazard Zone)或包裝組別(Packing Group)歸屬應遵循DOT
49 CFR 1732a [14]或聯合國危險物品運輸建議書(UNRTDG)第2部分[12]的規定參見附錄F
b 具有四面完整牆(從地板到天花板)地板和屋頂的結構物
c 對於未列於UNDG的溶液無水成分將用TIH區或包裝組別分類溶液之恕限值將根據乾基重量之恕限
值反算
d 對於未知UNDG分類的混合物可計算每種成分在恕限值洩漏中的分量如果各種成分之分量的總和
等於或大於100即表示混合物超過門檻值若混合物有明顯且獨立的毒性及可燃性結果則可分
別計算毒性及可燃性危險度參見附錄EPSE實例amp問題 49ndash53
e 閃火點 gt 60 degC (140 degF) 和 lt 93 degC (200 degF)的液體在低於閃火點的溫度下洩漏無論洩漏量多寡其
一次阻絕設施失效(LOPC)均不屬於Tier 1製程安全事件(PSE)
f 中度酸鹼的一次阻絕設施失效無論洩漏量多寡均不屬於Tier 1製程安全事件
17 (K = 1000 MM = 1000000) (在環境影響類別方面若缺乏既有定義協會和會員公司應議定輸入標準)
附錄 A ndash 嚴重程度表鼓勵所有協會均採用嚴重程度加權制度
事件事故類別
嚴重程度等級
安全人體健康 火災或爆炸導致直接
成本 任 1 小時內物質洩
漏量 社區影響 環境影響[廠外]
4 級
1 分
對員工承攬商或再承攬商造成較輕傷害嚴重之傷害 (符合本地法規)
造成以下直接損失成本
美金$25 K ~ $25 K
洩漏量介於
1x le TQ lt 40x
官方宣告就地避難或疏散 (廠內或廠外) 預防性廠外就地避難或疏散
le 3 小時
重大環境整治成本
$25 K ~ $25 K
3 級
3 分
對員工承攬商或再承攬商造成之需要多日缺勤的傷害
對第三方造成之需要初步急救以外治療的傷害 (符合本地法規)
造成以下直接損失成本
$25 K ~ $250 K
洩漏量介於
40x le TQ lt 160x
官方宣告就地避難或疏散 (廠內或廠外)
預防性廠外就地避難或疏散
3 ~ 12 小時
重大環境整治成本
$25 K ~ $250 K
2 級
9 分
對員工承攬商或再承攬商造成 1 人死亡
對第三方造成 1 人住院治療
(符合本地法規)
造成以下直接損失成本
$250 K ~ $25 MM
洩漏量介於
160x le TQ lt 640x
官方宣告就地避難或疏散 (廠內或廠外)
預防性廠外就地避難或疏散
12 ~ 24 小時
重大環境整治成本
$250 K ~ $25 MM
1 級
27 分
對員工承攬商或再承攬商造成多人死亡
對第三方造成多人住院治療
對第三方造成 1 人死亡 (符合本地法規)
造成以下直接損失成本
ge $25 MM
洩漏量
ge 640x TQ
官方宣告就地避難或疏散 (廠內或廠外)
預防性廠外就地避難或疏散
ge 24 小時
重大環境整治成本
ge $25 MM
18 (K = 1000 MM = 1000000) (在環境影響類別方面若缺乏既有定義協會和會員公司應議定輸入標準)
嚴重程度表(附錄 A)細節說明
附錄 A 之設計目的僅適用於採用 GHS 分類制度(表 1)者如果你的公司係採用 API RP 754Tier II 製程安全指標提報恕限值表(表 2)請使用
API RP 754 製程安全嚴重程度表必須提醒的是依 API RP 754 的標準其嚴重程度表僅適用於一級(Tier I)事故去比較採用不同的嚴重度
表所評估出來的相對嚴重度並無統計上的意義
急性的環境成本 ndash 因製程安全事件造成廠外環境影響所導致之短期清理及物質處置的成本各會員公司可選擇將廠外環境影響相關成本另
外區分一個嚴重程度類別
比率調整指標
利用上述嚴重程度表可產生一系列以事件率為基礎的指標包括
製程安全總事件率 (PSTIR) 總事件次數 x 200000
總工作時數
製程安全事件嚴重程度率(PSESR) (即製程安全事件嚴重程度加權計算公式)
PSESR = 所有事件之總嚴重程度分數總合 x 200000
總工作時數
在計算此一比率時各 4 級事件被分配 1 分各 3 級事件被分配 3 分各 2 級事件被分配 9 分各 1 級事件被分配 27 分理論上每個
製程安全事件至少可分配到 1 分(亦即事件僅在一個類別符合第 4 級事件屬性)至多可分配到 135 分(亦即事件在所有五個類別中均符
合第 1 級事件屬性)
ldquoXrdquo級別製程安全事件率 嚴重度級別ldquoXrdquo之製程安全事件總數 x 200000
員工承攬商amp再承攬商總工作時數
X可以是嚴重度級別 432 或 1 級製程安全事件之總數事件之嚴重度等級是選用五類後果類別中之最嚴重等級
標準化 ndash 在某些協會和會員公司中製程安全事件是採 lsquo每 100 名rsquo員工每名員工每年平均工作時數為 2000 小時為基礎予以標準化因
此在lsquo每 100rsquo名rsquo員工的標準基礎上事件被乘以 200000 工作時數也有些其他協會和會員公司將標準化基礎設定為lsquo每 500 名rsquo員工
因此事件被乘以 1000000 工作時數協會和會員公司應就標準化基礎進行討論共同做成選項結論上述的公式設定為lsquo每 100 名rsquo員工
基礎
19
附錄 B ndash 常見問題集
適用性
我們建議會員公司記錄和提報在其所擁有或運作的工廠內發生的製程安全事件惟以下情況不須提報製
程安全事件
1 源自於公司廠區以外的製程安全事件
2 海上運輸船事故惟船隻為了輸送半成品或產品之目的已經與公司的設施相連接時發生的
事故仍須提報
3 卡車或軌道車事故惟卡車或軌道車為了輸送半成品或產品之目的已經與公司的設施相連
接時發生的事故仍須提報
4 許可證或法規容許之例行排放
5 不會造成製程安全危害的地下污染請注意若洩漏至地下導致地上發生須提報製程安全事
件如釋放出毒性蒸汽或致使易燃液體蓄積成池則不適用本排除條件
6 辦公建築事故(如辦公室暖氣設備爆炸火災外溢洩漏人員受傷或疾病等)
7 與疏散或一次阻絕設施失效無直接關聯之人員安全ldquo滑倒絆倒跌倒rdquo事故
8 沒有與製程相連接之輔助設備的一次阻絕設施(如小樣品瓶)失效事故
9 計劃中和在控制下的物質排放至設計用來收集或排放系統中(請注意物質從一次阻絕設施
在非計劃或非受控制情況下排放至收集或排放系統中則不適用本排除條件)
10 在製程區域外部或保養廠內執行之機械作業
說明與實例 ndash 以 GHS 表 1 為基礎
以下說明和實例有助於在評估須提報製程安全事件(PSE)時釐清可能存在的不確定部分
公司廠區
1 一輛第三方的卡車在公司廠區內卸載易燃產品時發生洩漏進而引起火災造成公司財物損失
$7000 美元(直接成本)雖然該卡車是ldquo由他人操作rdquo但其作業與製程相連接若公司的直接成
本財物損失達到或超過$2500 美元或已達到或超過其他 PSE 提報門檻(如1 人死亡)此事故即
屬於須提報的製程安全事件
2 與前例1 類似的例子載著易燃產品的卡車在廠外運輸途中翻覆引發火災並造成卡車毀損
該事故不屬於須提報的製程安全事件因為當時卡車並未與製程相連接
20
阻絕設施失效
3 儲槽液位計故障造成裝有ldquo易燃液體rdquo產品的儲槽外溢約 700 公斤的液體流入儲槽的防溢堤內
此事故屬於須提報的製程安全事件因為其ldquo急性rdquo洩漏量超過 100 公斤即使是阻絕在二次阻絕
設施防溢堤中亦然
4 一名從事維修工作的承攬商在開啟一個製程阻閥時被噴起的硫酸濺到造成嚴重灼傷和損失工
時的工傷此事故屬於須提報的製程安全事件因為它是涉及物質和一次阻絕設施失效的意外事
件對於因洩漏造成死亡和損工的工傷或疾病事故沒有洩漏恕限值
5 一名作業員開啟品管取樣點進行日常取樣作業時手部被一個破碎的玻璃瓶嚴重割破需要進行
縫合治療縫針造成第二天無法上班該事故不屬於須提報的製程安全事件因為它與一次阻絕
設施失效無關
ldquo急性rdquo洩漏
6 一名作業員在進行天然氣流量高於預期值之異常排除時發現天然氣管線上的一個安全閥門未適
當歸位因此天然氣經由氣液分離桶排放至排氣煙囪經進一步檢查作業員判斷在過去 6 個
月間總共有 100000 公斤天然氣以穩定的速率排放至大氣該事故不屬於須提報的製程安全事
件因為其洩漏速率(每小時約 10 公斤)不算ldquo急性rdquo洩漏(未超過易燃蒸汽每小時 100 公斤的恕限
值)
廢氣燃燒塔amp排放控制裝置 (如洗滌塔)
7 若化學物質被導引至廢氣燃燒塔或排放控制裝置(如洗滌塔)只要該廢氣燃燒塔或控制裝置運作在
正常設計範圍內便不屬於須提報的製程安全事件
8 若廢氣流速超過洗滌塔的設計負荷以致未經吸收的化學物質排出超過恕限值該事故屬於須提報
的製程安全事件(如本文註釋所述)
註釋自取得許可或妥善管理的裝置-包括釋壓裝置發生不預期的排放若 1 小時內洩漏量達到或
超過表 1 或表 2 所列的洩漏恕限值且導致下列四種後果之任一項或以上之後果該事故便屬於
須提報的製程安全事件
o 二相排放或夾帶液體的排放液滴沉降至地面造成污染
o 排放至具潛在危險性的地點)
o 廠內就地避難或疏散不包括預防性廠內就地避難或疏散
o 啟動公眾保護措施(如道路封閉)包括預防性公眾保護措施
21
安全洩壓裝置 系統
9 製程單元發生異常安全閥開啟將洩漏物質釋放到排氣口此釋壓排放裝置是依相關要求設計
的且氣體釋到大氣中並未造成不良後果這不是一個須提報的製程安全事件因為安全閥高
壓破裂盤以及類似的安全裝置是依據 API 521 或者同等的標準設計的且此排放並未造成 (1)
夾帶液體並導致須提報的製程安全事件的後果(譬如損失工時意外死亡火災或爆炸造成$2500
美元或以上的直接成本損失液體或毒性氣體洩漏量達到或超過恕限值(2) 啟動廠內或廠外就地
避難應變或(3)啟動公眾保護措施
10 製程單元發生異常安全閥並未開啟造成設備超壓易燃性氣體從一個法蘭處ldquo急性rdquo漏出來
洩露量超過 100 公斤(一小時內)的恕限值該事故屬於須提報的製程安全事件因為從法蘭處外
漏屬於製程安全事件應提報事項
損工事故
11 一名作業員走路時不慎滑倒造成損失工時之工傷滑倒原因為天氣狀況rdquo長期rdquo油垢的地面和
易滑鞋具該事故不屬於須提報的製程安全事件因為人員安全ldquo滑倒絆倒跌倒rdquo事故若非與
一次阻絕設施失效直接關聯的疏散或應變造成則不屬於須提報的製程安全事件
12 與前例相同的事件惟這次作業員跌倒是因為少量易燃液體外漏(如 1 小時內少於 10 公斤)在採取
相關應變措施時發生該事故屬於須提報的製程安全事件因為作業員係為了應變一次阻絕設施
失效的事故而跌倒若一次阻絕設施失效發生在公司廠區且造成失時工傷或死亡後果該事故
便屬於須提報的製程安全事件對於因洩漏造成死亡和損失工時之工傷事故沒有洩漏量門檻
13 與前例相同的事件惟這次作業員跌倒是在事件結束數小時之後該事故不屬於須提報的製程安
全事件在提報要件中所用的ldquo疏散rdquo和ldquo應變rdquo等術語指的是一次阻絕設施失效和相關緊急應變
活動正在持續中事件結束後滑倒絆倒跌倒(如ldquo事後rdquo清理和補救)不屬於須提報製程安全事件
14 工人在因附近設備一次阻絕設施失效在疏散過程中一名鷹架搭建工人從鷹架梯上跌落造成損
失工時之工傷該事故屬於須提報的製程安全事件
15 一名作業員行經一個設計不良的蒸汽卻水器時被外洩的蒸汽燙傷腳踝造成損失工時之工傷
該事故屬於須提報的製程安全事件因為雖然一次阻絕設施失效洩漏出的是蒸汽(而非碳氫化合物
或化學物質)但損失工時之工傷是由於洩漏物質的物理狀態所導致的
16 一個密閉空間依照計畫以氮氣吹清一名承攬商繞過安全管制進入該密閉空間因而死亡該事
故屬於須提報的死亡事件但不屬於須提報的製程安全事件因為其中不涉及非計劃或失控的一
次阻絕設施失效
17 情況同上惟這次氮氣是非刻意洩漏進入該局限空間該事故屬於須提報的製程安全事件(同時也
是一起死亡事件)因為該名承攬商的死亡與非計劃的一次阻絕設施失效有關
22
18 一名作業員因硫化氫(H2S)警報在進行應變處理時昏倒若警報確實是因非計劃或失控的 H2S 一次
阻絕設施失效的外洩事件該事故便屬於須提報的製程安全事件若警報是一個假警報則該事
故便不屬於須提報的製程安全事件因為沒有真正的化學品洩漏發生
管線
19 一條管線破漏1 小時內洩漏 2000 磅(900 公斤)易燃蒸氣到地面但洩漏位置在廠區內很偏僻的
地點該事故仍屬於須提報的製程安全事件因為ldquo偏僻rdquo不是提報與否的考量因素
與化學物質外洩無關之火災或能量釋放事故
一般通則而言唯有當火災或能量釋放事故是因化學物質洩漏所造成或其發生導致化學物質洩漏
超過提報恕限值這些事故才屬於須提報的製程安全事件實例包括
20 一場電氣火災影響製程操作導致甲苯洩漏 400 公斤該事故屬於須提報的製程安全事件因為
化學物質洩漏已超過甲苯的 100 公斤提報恕限值
21 發生電氣火災停電或任何公用資源供應中斷可能造成工廠停工及可能引起設備損失超過
$2500 美元(如因非正常停工導致反應器或設備損壞)但並未造成超過恕限值的化學物質洩漏
亦未造成死亡或嚴重工傷該事故不屬於須提報的製程安全事件因為設備損壞並非化學製程火
災爆炸造成且化學物質洩漏並未超過恕限值
海上運輸船
22 一艘由公司營運的海上運輸船在船上發生ldquo急性rdquo易燃物質外洩洩漏量超過 100 公斤該事故不
屬於須提報的製程安全事件因為除非海上運輸船是為了輸送半成品或產品而與煉油石化或化
學製造廠的設施相連接否則其洩漏事故便不被視為製程安全事件
23 一艘第三方駁船由一艘拖船推向碼頭結果撞上公司的碼頭駁船的一個船艙破裂且造成
1000 公斤柴油洩漏到海中該事故不屬於須提報的製程安全事件因為駁船當時並非停泊在碼
頭內且其作業並非在進行半成品或產品之輸送
卡車與軌道車
24 一輛公司的軌道車在運輸途中出軌造成超過 1000 公斤汽油洩漏該事故不屬於須提報的製程
安全事件因為在公司廠區外發生的軌道車事故不被視為與製程安全有關
23
25 一輛第三方卡車拖車在公司廠區內翻覆造成ldquo急性rdquo汽油洩漏超過 1000 公斤這事故不屬於須
提報的製程安全事件因為卡車拖車當時已不再與裝卸設備連接然而我們建議會員公司另
行訂定運輸安全事故指標將這類事故記錄下來
26 一位合約卡車作業者正在卸載液鹼時發生軟管脫落造成空氣中氣霧和或液鹼液洩漏 2500 公
斤該事故屬於須提報的製程安全事件因為洩漏量已超過液鹼的 100 公斤恕限值且事故發生
前卡車仍與裝卸設備相連接著
辦公建築
27 綜合辦公大樓發生鍋爐火災造成總計$75000 美元的直接成本損失該事故不屬於須提報的製
程安全事件因為辦公大樓事故不被視為與製程安全有關
人機介面事故
28 一名操作技術員在聚合物工廠的終端設備旁作業時受傷這傷害是因機械的人機介面的設備而
造成該事故不屬於須提報的製程安全事件因為技術員受傷並非因危險物質一次阻絕設施失效
而造成的
混合物
29 若混合物本身有 GHS 分類可利用其分類確定恕限值若混合物本身沒有 GHS 分類則可計算混
合物中每個單一組成分之洩漏量(公斤)相對於個別成分恕限值之比值作為其對混合物恕限值之
lsquo加權rsquo貢獻譬如若混合物在 1小時內的洩漏量為 100公斤其中包含 05公斤分類為劇毒 H300
的物質45 公斤分類為 H301 的物質40 公斤另一種分類為 H 開頭的物質其餘 55 公斤則為沒
有 GHS 分類的水分此混合物之計算式為051 + 4510 + 40100 = 05 + 045 + 04 = 135超過
1因此該事故被視為須提報的製程安全事件雖然混合物個別成分之洩漏量均未超過各該物質
本身的恕限值
直接損失成本
30 此一門檻所考慮的成本應為可直接歸因於火災或爆炸的成本譬如設備及結構損壞的重置成本
修理成本環境清理支出緊急應變和罰款直接成本不包括間接成本譬如業務機會損失設
備停機造成之利潤損失取得或運轉臨時設施之成本或為滿足顧客需求取得替代產品的成本
(產品損失)
24
31 範例連接到氣體處理系統的排放管發生易燃氣體外漏同時製程出現問題導致空氣進入同
一條排放管結果發生爆炸過高的壓力損壞了排放管及其相關上游設備包括一個密封罐並
未造成人員受傷修理成本約$12000 美元該事故屬於須提報的製程安全事件因為爆炸及火
災導致設備修理成本超過門檻
32 範例一次製程安全事件後公司又發生一種非常特殊的 GHS 第 5 類產品洩漏 50 公斤造成
$2000 美元的設備損失洩漏的產品是一種非常特別的混合物公司須負擔超過$50000 美元因
產品耗損而產生之材料成本該事故不屬於須提報的製程安全事件因為 GHS 第 5 類產品洩漏的
提報門檻為 100 公斤且產品耗損不被計入直接損失成本
天然災害
33 天然災害可能對化學製程作業構成重大風險且對製程設備造成損壞導致危害物質一次阻絕設
施失效當一種或多種天然災害被認為可能對工廠作業造成影響時製程安全和作業系統應從危
害及後果分析工廠機器設備設計公用設施失效及製程停工之操作程序緊急應變計畫及應變
措施等方面界定潛在風險進行防範
天然災害類型包括颶風及颱風(包括伴隨而來的風暴潮)水災龍捲風地震超強對流風暴(直
線風暴)野火火山爆發海嘯和山崩
若公司廠房設施遭遇天然災害且其後果觸發一種或以上提報門檻該事故便屬於須提報製程安
全事件
預防性公眾應變
34 預防性公眾應變是基於謹慎的態度所採取的一種措施譬如當發生一次阻絕設施失效時公司
可能在尚未進行任何評估(如方向與洩漏點的距離等等)前便要求全體工人就地避難又
如地方權責官員(如消防警察民防緊急應變管理部門)在獲報一家公司發生製程安全事件
後為防lsquo萬一rsquo風向改變或基於可能受到波及的人口敏感族群(如學童或老年人)可能在尚未接
獲明確資訊前便下令社區就地避難或疏散或採取公眾保護措施(如道路封閉)
製程附屬倉庫
35 製程附屬倉庫指的是位於廠內用於儲存將投入於生產製程或產自於製程之原料半成品或成品的
倉庫從製程的觀點看來製程附屬倉庫相當於一個大型儲槽但這些原料半成品或成品並不
是儲存在一的大型容器中而是裝在較小的容器裡(如太空包大桶桶罐等)
25
Appendix C ndash List of RCLG Taskforce Members
Name Affiliation
Peter Schmelzer Bayer CEFIC - Chairman
Americo Diniz Carvalho Neto Braskem
Bradford Johnson American Chemistry Council
David Cummings DuPont
Debra Phillips American Chemistry Council
Hans Schwarz BASF
Kathryn Walton Plastics and Chemicals Industries Association
Kazuyuki Akita Japanese Chemical Industry Association
Kelly Keim ExxonMobil Chemical Company API Representative
Kenan Stevick Dow
Kiyokazu Murata Japanese Chemical Industry Association
Larry Bowler SABIC
Lorna Young Chemical Industry Association of Canada
Louisa Nara Center for Chemical Process Safety
Luiz Shizuo Harayashiki Associaccedilatildeo Brasileira da Induacutestria Quiacutemica
Masatoshi Kumamoto Japanese Chemical Industry Association
Milton Lacerda Petrobras
Phil Scott Chemical Industries Association
Piet Knijff DSM European Process Safety Centre
Scott Donaldson and Eamon Chandler
Shell
Scott Wallace Olin Corporation
Shakeel Kadri Air Products and Chemicals Inc
26
附錄 D ndash 詳細活動時程表
2016 年 2017 年 2018 年 2019 年 2020 年
2 ndash 4 月
RCLG PS 先導計畫
5 月 ndash
針對準則進行調整釐清
6 月 向 RCLG 和 ICCA 董事會報
告先導計畫執行結果
7 ndash 12 月 RCLG 協會考量準
則並為其會員公司發展提報機制
如有需要RCLG可向 ICCA 申請能
力建立基金為會員公司舉辦製程安
全研習會
1 ndash 12 月
RCLG 協會開始向其會員公司蒐集製程安全數據
1 ndash 12 月
如有需要RCLG 各協會運用 RCLG 的基金及專
家舉辦製程安全及績效提報研習會
1 ndash 2 月
擁有數據的協會開始向RCLG 提報製程安全事件
(2017 年數據)
4 月 RCLG 檢討第一個提報循
環的結果挑戰及原始數據(內部)
6 月 RCLG 向 ICCA 董事會呈報
原始數據
7 ndash 12 月 必要時更新及調整準
則
如有需要RCLG 各協會運用 RCLG 的基金及專
家舉辦製程安全及績效提報研習會
1 ndash 2 月
擁有數據的協會開始向RCLG 提報製程安全事件
(2018 年數據)
4 月 RCLG 檢討第二個提報循
環的結果挑戰及原始數據(內部)
6 月 RCLG 向 ICCA 董事會呈報
原始數據
7 ndash 12 月 必要時更新及調整準
則
如有需要RCLG 協會運用 RCLG 的基金及專家
舉辦製程安全及績效提報研習會
1 ndash 2 月
所有協會開始向 RCLG 提報製程安全事件
製程安全事件提報成為
RCLG KPI 衡量指標建議基本集的一部分(2019 年數
據)
4 月 RCLG 檢討第二個提報循
環的結果挑戰及原始數據(內部考量外部提
報)
6 月 RCLG 向 ICCA 董事會呈報
原始數據
27
附錄 E ndash 選擇性 Excel 追蹤表
當會員公司開始追蹤製程安全事件時所有會員公司應採用單一表格以簡化數據分析同時讓所有公司均使用相同的追蹤表RCLG 設
計了一份選擇性追蹤表可供會員公司和協會先行利用之後他們可設計自己的追蹤表
在這裡下載追蹤表
ICCA Process Safety Event Tracking Sheetxlsx
本文件包含三個分頁分別是ldquo聯絡資料rdquoldquo調查表rdquo和儲存下拉式選單選項的ldquo請勿編輯rdquo分頁
備註
附錄 E 追蹤表僅供參考TRCA 將另行提供台灣版表格供會員公司提報
28
後語
台灣化學工業責任照顧協會(Taiwan Responsible Care Association TRCA)成立於 1998 年在台灣推行責任照顧制度已達 20 週年製造商成員
包括台灣主要上市上櫃化工公司會員公司化學品生產製造量約佔全國 80 2016 年台灣化工業的 Chemical Sales 仍站在全球第八名的位
置額度為 630 億歐元化工業總產值達到 34 兆新台幣提供國內 416 萬人工作機會
TRCA 扮演國內廠商與國際制度接軌的角色也是國內化工業與政府機關及利益相關者溝通的橋樑與管道TRCA 會員結構依業務性質分析
涵蓋石化生產化學品製造氣體生產倉儲運輸業化學品貿易業以及工程研發設計等公司TRCA 透過供應鏈及價值鏈推行責任
照顧制度組成毒性化學物質聯防組織協助法規溝通與研析會員名冊請參考 httpwwwtrcaorgtwtrcanwork2aspx
TRCA 於 2010 年成為 ICCA (International Council of Chemical Associations 國際化學工業協會)觀察員ICCA 成立於 1989 年是全球化工製造
業的聯合會也是化學工業與 UNEP OPCW 及 OECD 的交流窗口ICCA 與其會員協會及成員公司致力於邁向永續的未來確保人類健康與
環境安全與保護全球化工業擁有超過 4兆美元的價值影響所有經濟部門ICCA 的會員幾乎在全球每個國家都有商業活動在全球六大
洲推動創新並提供超過 2000 萬個工作機會
台灣化工業在全球占有重要的一席之地在國內產業鏈也位居關鍵位置無論對國內或國際都有身為地球村一員應盡之責我們期許藉由
製程安全指標提報能更進一步提升自我在工安衛生環保與永續發展等面向的績效表現
台灣化學工業責任照顧協會
10452 台北市中山區撫順街 8 號 7 樓
電話02-2585-0552
httpwwwtrcaorgtw
None | |
$2500 to $25000 | |
$25000 to $250000 | |
$250000 to $25000000 | |
More than $25000000 | |
Yes - Using GHS TABLE | |
Yes - Using API RP 754 TABLE | |
NO | |
NA | |
1x le TQ lt 40x | |
40x le TQ lt 160x | |
160x le TQ lt 640x | |
ge 640x TQ | |
Yes le 3 hours | |
Yes 3 hours ge 12 hours | |
Yes 12 hours ge 24 hours | |
Yes ge 24 hours | |
No | |
Small-scale | |
Medium-scale | |
Large-scale | |
No | |
Yes | |
No | |
middot Injury requiring treatment beyond first aid to an employee contractor or subcontractor | |
middot Days Away From Work injury to an employee contractor or subcontractor or middot Injury requiring treatment beyond first aid to a third party | |
middot A fatality of an employee contractor or subcontractor or middot A hospital admission of a third party | |
middot Multiple fatalities of employees contractors or subcontractors or middot multiple hospital admission of third parties or middot A fatality of a third party | |
NA | |
1x le TQ lt 3x | |
3x le TQ lt 9x | |
9x le TQ lt 27x | |
ge 27x TQ |
ICCA Process Safety Pilot Reporting ProgramFebruary 8 2016 | 1 | 2 | 3 | 4 | 5 | 6 | 7 | 8 | 9 | 10 | 12 | 13 | 14 | 15 | |||||||||||||||||||||||
SAFETY Details(Meeting Local Regulations) | Direct Cost from Fire or Explosion | Community Impact | Environmental Impact | Material Released(Measured using the 1 Hour Rule) | |||||||||||||||||||||||||||||||||
Company Association Details | |||||||||||||||||||||||||||||||||||||
GHS | API - RP 754 | ||||||||||||||||||||||||||||||||||||
Company or Assocation Name | Headquarter Association | Location of Event Ex - City State amp Country | Date and Time of Event | Safety InjuryDid the Event result in a Recordable Lost Time Accident or Fatality or Hospital admission of anyone on or off siteUse Drop Down Menu | Safety InjuryIf yes please insert the total number of injuries | Safety InjuryFor puropses of utilizing the Severity Table please indicate the level of severity by chosing the MOST SEVERE classification that describes your incidentUse Drop Down Menu | Safety InjuryDid the incident involve Fatalities If so how many total fatalities If none enter Zero | Safety InjuryPlease Report Total Employee Hours for Calendar Year 2015 | Safety InjuryPlease Report Total Contractor Hours for Calendar Year 2015 | Direct Cost Did the Event result in Direct Damage CostUse Drop Down Menu | Direct Cost If so how muchAmount is in US DollarsUse Drop Down Menu | Community ImpactDid the event result inbull Officially declared shelter-in-place or officially declared evacuation (on or off site)ORbull Precautionary off site shelter in place or evacuation Use Drop Down Menu | Environmental ImpactDid the event result inAcute Environmental Remediation CostIf so indicate the amount in US DollarsUse Drop Down Menu | Material ReleasedDid the Event result in an Acute Release of material beyond one of the two threshold tablesIf so indicate which Threshold Table you used to make this determinationUse Drop Down Menu | Material ReleasedIf so indicate the amount released USING GHS CLASSIFICATION TABLEUse Drop Down Menu | Material ReleasedIf so indicate the amount released USING THE THRESHOLD TABLE FROM API RP-754Use Drop Down Menu | Material ReleasedIf available please indicate the material released | ||||||||||||||||||||
1 | ABC Chemical Company | American Chemistry Council | Washington DC - USA | January 4 2016 | Yes | 2 | middot Days Away From Work injury to an employee contractor or subcontractor or middot Injury requiring treatment beyond first aid to a third party | 0 | 5525000 | 1500250 | No | $2500 to $25000 | Yes le 3 hours | $2500 to $25000 | Yes - Using GHS TABLE | 40x le TQ lt 160x | NA | Chlorine | |||||||||||||||||||
2 | XYZ Chemical Company | American Chemistry Council | Washington DC - USA | 5-Jan-16 | Yes | 1 | middot Injury requiring treatment beyond first aid to an employee contractor or subcontractor | 0 | 5525000 | 1500250 | Yes | $2500 to $25000 | No | $2500 to $25000 | Yes - Using API RP 754 TABLE | NA | 3x le TQ lt 9x | Benzene | |||||||||||||||||||
3 | |||||||||||||||||||||||||||||||||||||
4 | |||||||||||||||||||||||||||||||||||||
5 | |||||||||||||||||||||||||||||||||||||
6 | |||||||||||||||||||||||||||||||||||||
7 | |||||||||||||||||||||||||||||||||||||
8 | |||||||||||||||||||||||||||||||||||||
9 | |||||||||||||||||||||||||||||||||||||
10 | |||||||||||||||||||||||||||||||||||||
11 | |||||||||||||||||||||||||||||||||||||
12 | |||||||||||||||||||||||||||||||||||||
13 | |||||||||||||||||||||||||||||||||||||
14 | |||||||||||||||||||||||||||||||||||||
15 | |||||||||||||||||||||||||||||||||||||
16 | |||||||||||||||||||||||||||||||||||||
17 | |||||||||||||||||||||||||||||||||||||
18 | |||||||||||||||||||||||||||||||||||||
19 | |||||||||||||||||||||||||||||||||||||
20 | |||||||||||||||||||||||||||||||||||||
21 | |||||||||||||||||||||||||||||||||||||
22 | |||||||||||||||||||||||||||||||||||||
23 | |||||||||||||||||||||||||||||||||||||
24 | |||||||||||||||||||||||||||||||||||||
25 | |||||||||||||||||||||||||||||||||||||
Zero or None | Yes - Duration Unknown | ||||||||||||||||||||||||||||||||||||
Processes | Mode of Operation | Type of material released | Status of Operation | ||||
REFINING | Start-up | Flammable | Open | ||||
Alkylation HF | Planned shutdown | Combustible | Closed | ||||
Alkylation sulfuric | Emergency shutdown | Toxic | |||||
BitumenResidAsphalt | Normal | Corrosive | Tier 1 Acute Releases | ||||
Calcining | Upset | Utilities | No Release | ||||
Coking | Turnaround | Other | Category 1 | ||||
Crude | Routine maintenance | Category 2 | |||||
Desulfurization | Temporary | Evacuation | Category 3 | ||||
FCC | Other | Yes | Category 4 | ||||
Gas Treating | No | Category 5 | |||||
Hydrogen | Point of Release | Category 6 | |||||
Hydrotreating | Pump | Fire | Category 7 | ||||
Hydrocracking | Compressor | Yes | Multiple Categories | ||||
Isom | BlowerFan | No | |||||
MarineJetty | Pressure Vessel | lt $2500 | |||||
Reforming | FilterCoalescer | ||||||
Sulfur recovery | Furnace | PRDs | |||||
Vapor recoverylight ends | Boiler | Directly to Atmosphere | |||||
Wastewater | Heat exchanger | via Downstream Destructive Device | |||||
REFINING amp PETROCHEMICAL | Cooling Tower | No | |||||
Tank FarmStorage FacilityOffsite | Piping system | Yes | |||||
UtilitiesSteam PlantCogeneration | Reactor | No | |||||
Other | Atmospheric tank | ||||||
PETROCHEMICAL | FlareRelief System | Acute release above thresholds | |||||
CO H2 | Other | Yes | |||||
LNG | No | ||||||
Methane | Events | ||||||
Methanol | No Tier 1 Events | Indoor Outdoor | |||||
Methyl Mercaptan | No Tier 2 Events | No Release | |||||
Formaldehyde | No Tier 1 or Tier 2 Events | Indoor | |||||
Formaldehyde derivatives | NA | Outdoor | |||||
Acetic Acid | |||||||
Acetic Acid derivatives | Event Type | ||||||
Ethane | Injury | ||||||
Ethylene | Fire | ||||||
Ethanol | Explosion | ||||||
Ethylene oxide | PRD Discharge | ||||||
Ethylene derivatives | Acute Release | ||||||
Polyethylene | |||||||
Ethylene dichloride | General | ||||||
Ethylene dichloride derivatives | Yes | ||||||
Ethyl benzene | No | ||||||
Ethyl benzene derivatives | |||||||
Polystyrene | |||||||
Styrene-Butadiene | |||||||
Propane | |||||||
Propylene | |||||||
Polypropylene | |||||||
Isopropanol | |||||||
Propylene oxide | |||||||
Propylene oxide derivatives | |||||||
Butane | |||||||
Isobutane | |||||||
Isobutene | |||||||
Butadiene | |||||||
MTBE | |||||||
ETBE | |||||||
Pentane | |||||||
Hexane | |||||||
Cyclohexane | |||||||
Hexanol | |||||||
Aromatics Derivatives | |||||||
Benzene | |||||||
Toluene | |||||||
Xylene | |||||||
Para Xylene | |||||||
Amines Derivatives | |||||||
TDA MDA IPDA etc | |||||||
Isocyanates | |||||||
Specialty Chemicals | |||||||
LoadingUnloading | |||||||
Pilot Plant |
Instructions | ||||||||||||||
Step 1 | Complete the Contact Tab with your contact information and company information | |||||||||||||
Be sure to note the region of your reporting (IE North America France Japan etc) | ||||||||||||||
Survey on Process Safety Events | ||||||||||||||
Step 2 | Complete the survey one line per Process Safety Event for your companyregion | |||||||||||||
ALL REPORTED DATA SHOULD BE FROM CALENDAR YEAR 2017 | ||||||||||||||
Step 3 | Return completed survey to | |||||||||||||
Company Name | ||||||||||||||
Contact Person | All Surveys Due by xxx date | |||||||||||||
Address | ||||||||||||||
Fax | ||||||||||||||
Telephone | ||||||||||||||
Region | ||||||||||||||
None | |
$2500 to $25000 | |
$25000 to $250000 | |
$250000 to $25000000 | |
More than $25000000 | |
Yes - Using GHS TABLE | |
Yes - Using API RP 754 TABLE | |
NO | |
NA | |
1x le TQ lt 40x | |
40x le TQ lt 160x | |
160x le TQ lt 640x | |
ge 640x TQ | |
Yes le 3 hours | |
Yes 3 hours ge 12 hours | |
Yes 12 hours ge 24 hours | |
Yes ge 24 hours | |
No | |
Small-scale | |
Medium-scale | |
Large-scale | |
No | |
Yes | |
No | |
middot Injury requiring treatment beyond first aid to an employee contractor or subcontractor | |
middot Days Away From Work injury to an employee contractor or subcontractor or middot Injury requiring treatment beyond first aid to a third party | |
middot A fatality of an employee contractor or subcontractor or middot A hospital admission of a third party | |
middot Multiple fatalities of employees contractors or subcontractors or middot multiple hospital admission of third parties or middot A fatality of a third party | |
NA | |
1x le TQ lt 3x | |
3x le TQ lt 9x | |
9x le TQ lt 27x | |
ge 27x TQ |
ICCA Process Safety Pilot Reporting ProgramFebruary 8 2016 | 1 | 2 | 3 | 4 | 5 | 6 | 7 | 8 | 9 | 10 | 12 | 13 | 14 | 15 | |||||||||||||||||||||||
SAFETY Details(Meeting Local Regulations) | Direct Cost from Fire or Explosion | Community Impact | Environmental Impact | Material Released(Measured using the 1 Hour Rule) | |||||||||||||||||||||||||||||||||
Company Association Details | |||||||||||||||||||||||||||||||||||||
GHS | API - RP 754 | ||||||||||||||||||||||||||||||||||||
Company or Assocation Name | Headquarter Association | Location of Event Ex - City State amp Country | Date and Time of Event | Safety InjuryDid the Event result in a Recordable Lost Time Accident or Fatality or Hospital admission of anyone on or off siteUse Drop Down Menu | Safety InjuryIf yes please insert the total number of injuries | Safety InjuryFor puropses of utilizing the Severity Table please indicate the level of severity by chosing the MOST SEVERE classification that describes your incidentUse Drop Down Menu | Safety InjuryDid the incident involve Fatalities If so how many total fatalities If none enter Zero | Safety InjuryPlease Report Total Employee Hours for Calendar Year 2015 | Safety InjuryPlease Report Total Contractor Hours for Calendar Year 2015 | Direct Cost Did the Event result in Direct Damage CostUse Drop Down Menu | Direct Cost If so how muchAmount is in US DollarsUse Drop Down Menu | Community ImpactDid the event result inbull Officially declared shelter-in-place or officially declared evacuation (on or off site)ORbull Precautionary off site shelter in place or evacuation Use Drop Down Menu | Environmental ImpactDid the event result inAcute Environmental Remediation CostIf so indicate the amount in US DollarsUse Drop Down Menu | Material ReleasedDid the Event result in an Acute Release of material beyond one of the two threshold tablesIf so indicate which Threshold Table you used to make this determinationUse Drop Down Menu | Material ReleasedIf so indicate the amount released USING GHS CLASSIFICATION TABLEUse Drop Down Menu | Material ReleasedIf so indicate the amount released USING THE THRESHOLD TABLE FROM API RP-754Use Drop Down Menu | Material ReleasedIf available please indicate the material released | ||||||||||||||||||||
1 | ABC Chemical Company | American Chemistry Council | Washington DC - USA | January 4 2016 | Yes | 2 | middot Days Away From Work injury to an employee contractor or subcontractor or middot Injury requiring treatment beyond first aid to a third party | 0 | 5525000 | 1500250 | No | $2500 to $25000 | Yes le 3 hours | $2500 to $25000 | Yes - Using GHS TABLE | 40x le TQ lt 160x | NA | Chlorine | |||||||||||||||||||
2 | XYZ Chemical Company | American Chemistry Council | Washington DC - USA | 5-Jan-16 | Yes | 1 | middot Injury requiring treatment beyond first aid to an employee contractor or subcontractor | 0 | 5525000 | 1500250 | Yes | $2500 to $25000 | No | $2500 to $25000 | Yes - Using API RP 754 TABLE | NA | 3x le TQ lt 9x | Benzene | |||||||||||||||||||
3 | |||||||||||||||||||||||||||||||||||||
4 | |||||||||||||||||||||||||||||||||||||
5 | |||||||||||||||||||||||||||||||||||||
6 | |||||||||||||||||||||||||||||||||||||
7 | |||||||||||||||||||||||||||||||||||||
8 | |||||||||||||||||||||||||||||||||||||
9 | |||||||||||||||||||||||||||||||||||||
10 | |||||||||||||||||||||||||||||||||||||
11 | |||||||||||||||||||||||||||||||||||||
12 | |||||||||||||||||||||||||||||||||||||
13 | |||||||||||||||||||||||||||||||||||||
14 | |||||||||||||||||||||||||||||||||||||
15 | |||||||||||||||||||||||||||||||||||||
16 | |||||||||||||||||||||||||||||||||||||
17 | |||||||||||||||||||||||||||||||||||||
18 | |||||||||||||||||||||||||||||||||||||
19 | |||||||||||||||||||||||||||||||||||||
20 | |||||||||||||||||||||||||||||||||||||
21 | |||||||||||||||||||||||||||||||||||||
22 | |||||||||||||||||||||||||||||||||||||
23 | |||||||||||||||||||||||||||||||||||||
24 | |||||||||||||||||||||||||||||||||||||
25 | |||||||||||||||||||||||||||||||||||||
Zero or None | Yes - Duration Unknown | ||||||||||||||||||||||||||||||||||||
Processes | Mode of Operation | Type of material released | Status of Operation | ||||
REFINING | Start-up | Flammable | Open | ||||
Alkylation HF | Planned shutdown | Combustible | Closed | ||||
Alkylation sulfuric | Emergency shutdown | Toxic | |||||
BitumenResidAsphalt | Normal | Corrosive | Tier 1 Acute Releases | ||||
Calcining | Upset | Utilities | No Release | ||||
Coking | Turnaround | Other | Category 1 | ||||
Crude | Routine maintenance | Category 2 | |||||
Desulfurization | Temporary | Evacuation | Category 3 | ||||
FCC | Other | Yes | Category 4 | ||||
Gas Treating | No | Category 5 | |||||
Hydrogen | Point of Release | Category 6 | |||||
Hydrotreating | Pump | Fire | Category 7 | ||||
Hydrocracking | Compressor | Yes | Multiple Categories | ||||
Isom | BlowerFan | No | |||||
MarineJetty | Pressure Vessel | lt $2500 | |||||
Reforming | FilterCoalescer | ||||||
Sulfur recovery | Furnace | PRDs | |||||
Vapor recoverylight ends | Boiler | Directly to Atmosphere | |||||
Wastewater | Heat exchanger | via Downstream Destructive Device | |||||
REFINING amp PETROCHEMICAL | Cooling Tower | No | |||||
Tank FarmStorage FacilityOffsite | Piping system | Yes | |||||
UtilitiesSteam PlantCogeneration | Reactor | No | |||||
Other | Atmospheric tank | ||||||
PETROCHEMICAL | FlareRelief System | Acute release above thresholds | |||||
CO H2 | Other | Yes | |||||
LNG | No | ||||||
Methane | Events | ||||||
Methanol | No Tier 1 Events | Indoor Outdoor | |||||
Methyl Mercaptan | No Tier 2 Events | No Release | |||||
Formaldehyde | No Tier 1 or Tier 2 Events | Indoor | |||||
Formaldehyde derivatives | NA | Outdoor | |||||
Acetic Acid | |||||||
Acetic Acid derivatives | Event Type | ||||||
Ethane | Injury | ||||||
Ethylene | Fire | ||||||
Ethanol | Explosion | ||||||
Ethylene oxide | PRD Discharge | ||||||
Ethylene derivatives | Acute Release | ||||||
Polyethylene | |||||||
Ethylene dichloride | General | ||||||
Ethylene dichloride derivatives | Yes | ||||||
Ethyl benzene | No | ||||||
Ethyl benzene derivatives | |||||||
Polystyrene | |||||||
Styrene-Butadiene | |||||||
Propane | |||||||
Propylene | |||||||
Polypropylene | |||||||
Isopropanol | |||||||
Propylene oxide | |||||||
Propylene oxide derivatives | |||||||
Butane | |||||||
Isobutane | |||||||
Isobutene | |||||||
Butadiene | |||||||
MTBE | |||||||
ETBE | |||||||
Pentane | |||||||
Hexane | |||||||
Cyclohexane | |||||||
Hexanol | |||||||
Aromatics Derivatives | |||||||
Benzene | |||||||
Toluene | |||||||
Xylene | |||||||
Para Xylene | |||||||
Amines Derivatives | |||||||
TDA MDA IPDA etc | |||||||
Isocyanates | |||||||
Specialty Chemicals | |||||||
LoadingUnloading | |||||||
Pilot Plant |
Instructions | ||||||||||||||
Step 1 | Complete the Contact Tab with your contact information and company information | |||||||||||||
Be sure to note the region of your reporting (IE North America France Japan etc) | ||||||||||||||
Survey on Process Safety Events | ||||||||||||||
Step 2 | Complete the survey one line per Process Safety Event for your companyregion | |||||||||||||
ALL REPORTED DATA SHOULD BE FROM CALENDAR YEAR 2017 | ||||||||||||||
Step 3 | Return completed survey to | |||||||||||||
Company Name | ||||||||||||||
Contact Person | All Surveys Due by xxx date | |||||||||||||
Address | ||||||||||||||
Fax | ||||||||||||||
Telephone | ||||||||||||||
Region | ||||||||||||||
8
ICCA 製程安全事件判定標準流程圖
事故是否發生在廠內之
生產配銷儲存公
用或試驗工廠
是 是
是
否
否 是否造成須通報工傷
或
廠內廠外人員住院治
療
損壞是否對
公司造成
ge $2500 美
元的直接成
本損失
官方是否宣告就地
避難或疏散或廠
外預防性就地避難
或疏散
否
是
否
是屬於須通報製程安全事件
是
否
是
是
開始
否不符合製程安全事件認定
標準
是否超過 ICCA 或 API
754 Tier II 化學物質洩
漏恕限值
否 發生化學物質外洩火
災或爆炸是否起因於
或發生在化學製程單元
是否直接涉及某種化學物
質或化學製程
否
9
須提報製程安全事件之重要標準
總工作時數
RCLG 各協會應以加總的單一數字提報其所屬會員公司的員工和承攬商總工作時數為達
成本指引之目的各協會應參考其本地和地區對員工及承攬商之定義提報總時數之目標
應納入涉及化學製造之所有個人然而參與主要興建工程專案之人員則不納入計算譬
如為新建或擴建既有製程設施之設計工程和施工而成立之一次性專案組織的大規模投資
案會員公司提報總工作時數時應與人事部門統計之員工工時一致如此各公司便能
取得相同的職業與製程安全數據員工工時應包括所有化學製造作業的工時而非僅計算
發生製程安全事故之廠區的工時
製程安全事件
為執行 ICCA 提報目的製程安全事件之定義條件如下(必須同時符合 ABCD 四個條
件)
A 直接涉及某種化學物質或化學製程且
B 事故發生在廠內之生產配銷儲存公用或試驗工廠且
C 製程單元發生物質洩漏或能量釋放(如火災爆炸和內爆)且
D 已達到以下提報門檻之一
1 安全 工傷
導致記錄性的傷害(OSHA)損失工時或死亡或廠內外任何人員因此
而須住院治療或
2 直接損失成本
火災爆炸或為避免補救環境損害之必要清理作業導致$2500 美元
以上的直接成本支出或
3 就地避難 疏散
官方宣告就地避難(廠內或廠外)或
官方宣告疏散(廠內或廠外)或
廠外預防性就地避難或疏散或
4 洩漏恕限值
物質洩漏程度已達表 1 所列之任一 GHS 恕限值(洩漏量以單位小時計
量)
此外各公司亦可選擇採用 API RP-754 標準中所列之洩漏恕限值(表 2)請注意如欲查
看 API RP-754 標準可登入以下網站購買及下載httpwwwapiorgoil-and-natural-
gashealth-and-safetyprocess-safetyprocess-safety-standards
10
製程安全事件判定準則
A 涉及化學品
直接涉及某種化學物質或化學製程
製程安全事件或事故必須直接涉及化學物質或化學製程就此而言ldquo製程rdquo一詞泛指包含
石化生產所需要之設備和技術包括反應器儲槽管線鍋爐冷卻水塔和冷凍系
統helliphellip等未直接涉及化學物質或製程的事件無須提報譬如辦公大樓起火(即使該辦公大
樓位在廠區內亦然)
B 地點
事故發生在廠內之生產配銷儲存公用或試驗工廠
發生在廠內之生產配銷儲存(包括活動儲存區如倉庫 ndash 參見ldquo常見問題集rdquo)公用及
試驗工廠凡符合提報指標及定義的事故包括在廠區管理下之槽罐區輔助支援區(如
鍋爐室和廢水處理廠)和配銷管線所有須提報之事件應由負責該事故地點運作的公司
負提報之責此一規定亦適用於發生在承攬商作業區域內的事故在代工作業和多方共同
作業廠區負責運作該發生事故單位的公司應記錄事故始末並將之納入其提報中
C 物質洩漏
製程單元發生物質外洩或能量釋放(如火災爆炸和內爆)
物質外洩 ndash 製程任何物質發生非預期或無法控制的洩漏或釋放包括非毒性及不可燃物質
(如蒸汽熱水氮氣壓縮二氧化碳或壓縮空氣)且達到本文件所列四類提報門檻之一
項或以上之後果
在防治系統(如洗滌塔或廢氣燃燒塔)正常運作狀況下只要沒有任何洩漏或排放量超過
法定許可值即使排放到廢氣燃燒塔或滌氣塔仍被視為處於一次阻絕設施內然若排
放到二次阻絕設施(如廢水處理或防溢堤)將被視為製程安全事件因為物質已離開主要製
程系統
11
D 提報門檻
須提報製程安全事件必須達到以下提報門檻之一
1 安全 工傷
導致記錄性傷害(OSHA)損失工時或死亡或廠內外任何人員因此而須住院治療
記錄性傷害是指與工作有關所造成的傷害導致死亡暫時全失能工作受限制或需調整職
務較輕傷害嚴重之醫療處理失去意識或經醫師或其他合格醫療專業人員診斷為重大
傷害
損失工時傷害和死亡是指因製程相關的一次阻絕設施失效火災或爆炸導致以下任何一種
結果
員工(損失工時或死亡)
承攬商及再承攬商 (損失工時或死亡)
第三方(如來賓訪客快遞員)(受傷疾病導致住院治療或死亡)
住院治療是指醫院或其他具有住院病患保健設施的醫療單位正式接受病患住院提供病患
食宿及醫療護理且病患接受治療至少留置至隔日僅在醫院急診室治療或過夜處理不屬
於ldquo住院治療rdquo的定義範圍
須提報之工傷或死亡事件例如在清理作業期間因蒸汽洩漏造成人員燒燙傷壓力測試期間
帽蓋因受壓脫落造成人員身體傷害或取樣作業時因物質外濺造成人員化學灼傷無須提
報之工傷或死亡事件例如在執行維修作業時從高處的工作台墜落實驗室或辦公大樓火災
造成人員燒燙傷或挖掘工程塌陷造成人員傷害這些案例均與因製程造成的能量釋放或
物質洩漏無直接關聯
2 直接損失成本
火災爆炸或為避免補救環境損害之必要清理作業導致$2500美元以上的直接成本支出
此提報門檻所考慮的成本應為可直接歸因於火災或爆炸的成本譬如設備及結構損壞的重
置成本修理成本環境清理(廠內及廠外)支出緊急應變和罰款直接成本不包括間接
成本譬如業務機會損失設備停機造成之利潤損失取得或運轉臨時設施之成本或為
滿足顧客需求取得替代產品的成本(產品損失)
12
3 就地避難 疏散
官方宣告就地避難或疏散(廠內或廠外)或廠外預防性就地避難或疏散
就提報目的而言官方宣告就地避難或疏散(廠內或廠外)或廠外預防性就地避難或疏散
即達到此提報門檻
官方宣告 ndash 由地方權責機關(如消防警察民防緊急應變管理部門)或經授權的代表(如
派駐公司官員)下達的社區行動(如就地避難或疏散)宣告
預防性宣告 ndash 預防性公眾應變是基於謹慎的態度所採取的一種措施權責地方主管機關或經
授權的代表經合理判斷認定為維護公眾健康及安全發布必須採取就地避難或疏散之預
防性措施
就地避難 ndash 利用結構體及其內部空氣以暫時讓人員與室外危害性氣體隔離
疏散 ndash 基於安全或防護理由讓人員離開某處所的行動或過程
4 洩漏恕限值
超過表 1 中所列 GHS 恕限值或表 2 中所列 API 754 標準 Tier II 製程安全洩漏恕限值之一的
急性洩漏事件(洩漏量以單位小時計量)
如ldquo執行摘要rdquo所述ICCA 製程安全事件之定義容許採用 ICCA 依據化學品全球調和制度
(GHS)健康危害分級為基礎所發展的提報標準或依據聯合國危險物品(UNDG)分類為基礎
所定義之 RP-754 二級製程安全事件(Tier II) 之提報標準GHS 恕限值詳見表 1各會員公司
可自行決定選擇哪一個表中的提報恕限值並在全球採用單一制度
ldquo急性rdquo洩漏 ndash易燃性可燃性或毒性化學物質從一次阻絕設施(如容器或管線)洩漏其
任一單位小時之洩漏量超過化學物質洩漏恕限量分述於表 1 中的 GHS 分類和表 2 中的
API 754 標準 Tier II 製程安全洩漏恕限值
洩壓裝置前述所定義之ldquo急性rdquo洩漏包括洩漏或排放至妥善設計且運作中的洩壓裝置若
洩漏或排放量達到表 1 中所列 GHS 恕限值或表 2 中所列 API 754 標準 Tier II 製程安全洩漏
恕限值且導致下列四種後果之任一項或以上之後果
1 二相排放或夾帶液體的排放液滴沉降至地面造成污染
2 排放至具潛在危險性的地點
3 廠內就地避難或疏散不包括預防性廠內就地避難或疏散
4 啟動公眾保護措施(如道路封閉)包括預防性公眾保護措施
13
洩漏或排放至妥善設計且運作中的洩壓裝置(如廢氣燃燒塔洗滌塔等)若其情況未達前
述四項標準中任何一項則不必提報
欲查看 API RP-754 標準可登入以下網站下載此標準httpwwwapiorgenvironment-
health-and-safetyprocess-safetyprocess-safety-standardsstandard-rp-754
一小時法則
為便於衡量此項指標提報與否洩漏恕限值是以物質在任一小時內之洩漏量為標準若任
一小時或更短時間內物質洩漏量達到或超過須提報恕限值該事故便屬於須提報的製程安
全事件急性洩漏事故通常不會超過一小時若無法確定洩漏持續時間則應假設其為一
小時
一次阻絕設施ndash 用來作為主要容器或用於運送或輸送物質之槽罐船隻管線軌道車
或設備主要容器在設計上可能包含二次阻絕設施系統以抑制及控制洩漏二次阻絕設
施系統包括(但不限於)儲槽防溢堤製程設備周遭的圍堵設施油水分離的排水收集系統
雙層儲槽的外壁等
嚴重程度表 ndash 嚴重程度加權可額外提供有關製程安全事件的有用資訊有助於帶動改善績
效附錄 A 為 RCLG 建議之製程安全事件嚴重程度加權計算方法根據附錄 A 的方法便
可藉由加總與各個後果類別關聯的分數計算出各製程安全事件的嚴重程度加權值ICCA
強烈建議採用嚴重程度加權制度因為此制度有助於提升溝通績效的能力也比較容易讓
利害關係人了解製程安全事件並且此嚴重程度加權值與其他製程安全績效指標提報方
式是不具相互比較性的
14
表 1 ndash GHS 分類表
物理性危害(GHS 2x)
洩漏恕限值(1 小時內)
STOTSpecific target organ toxicity(特定標的器官系統毒性物質)
15
表 2 ndash API RP 754 Tier II 分類表
洩漏恕限類別
物質危害性分類 acdef 恕限值
(戶外洩漏) 恕限值
(戶內b洩漏)
T2-1 TIH A 區物質 ge 05 kg (11 lb) ge 025 kg (055
lb)
T2-2 TIH B 區物質 ge 25 kg (55 lb) ge 125 kg (275
lb)
T2-3 TIH C 區物質 ge 10 kg (22 lb) ge 5 kg (11 lb)
T2-4 TIH D 區物質 ge 20 kg (44 lb) ge 10 kg (22 lb)
T2-5
易燃氣體 或 正常沸點 ≦ 35 (95 degF)閃火點lt23 (73 degF)的液體 或 其他包裝組別 I 類的物質 (酸鹼除外)
ge 50 kg (110 lb) ge 25 kg (55 lb)
T2-6
正常沸點 gt 35 degC (95 degF)閃火點 lt 23 degC (73degF)的液體 或 其他包裝組別 II 類的物質 (酸鹼除外)
ge 100 kg (220 lb) 或
ge 07 bbl
ge 50 kg (110 lb) 或
ge 035 bbl
T2-7
閃火點 gt 23 degC (73 degF)和 lt 60 degC (140 degF)的液體 或 閃火點 gt 60 degC (140 degF)的液體在閃火點或高於閃火點的溫度下洩漏 或 強酸鹼 (定義參見 RP 754 文件草案) 或 UNDG第2類第22部分 (不可燃無毒氣體)空氣除外 或 其他包裝組別 III 類的物質
ge 200 kg (440 lb) 或
ge 14 bbl
ge 100 kg (220 lb) 或
ge 07 bbl
T2-8
閃火點 gt 60 degC (140 degF) 和 lt 93 degC (200 degF)的液體在低於閃火點的溫度下洩漏 或 中度酸鹼
ge 1000 kg
(2200 lb) 或
ge 7 bbl
ge 500 kg
(1100 lb) 或
ge 35 bbl
TIH吸入性毒性危害物(Toxic Inhalation Hazard)
16
一般認為以公斤和磅或以磅和桶為單位的恕限值不盡等同各公司應該選用其中一組計量單位並在
所有紀錄文件中一體適用
在判定一種物質之洩漏恕限類別時首先應從物質之含吸入性毒性(TIH Zone)可燃性(閃火點和沸點)
或腐蝕性(強酸或鹼 vs中度酸或鹼)等特性來判別只有當物質的危險度無法利用上述簡單的特性來判別
時(如遇水反應劇烈)才採用UNDGL包裝組別
a 許多物質具有一種以上危險性正確的危險區(Hazard Zone)或包裝組別(Packing Group)歸屬應遵循DOT
49 CFR 1732a [14]或聯合國危險物品運輸建議書(UNRTDG)第2部分[12]的規定參見附錄F
b 具有四面完整牆(從地板到天花板)地板和屋頂的結構物
c 對於未列於UNDG的溶液無水成分將用TIH區或包裝組別分類溶液之恕限值將根據乾基重量之恕限
值反算
d 對於未知UNDG分類的混合物可計算每種成分在恕限值洩漏中的分量如果各種成分之分量的總和
等於或大於100即表示混合物超過門檻值若混合物有明顯且獨立的毒性及可燃性結果則可分
別計算毒性及可燃性危險度參見附錄EPSE實例amp問題 49ndash53
e 閃火點 gt 60 degC (140 degF) 和 lt 93 degC (200 degF)的液體在低於閃火點的溫度下洩漏無論洩漏量多寡其
一次阻絕設施失效(LOPC)均不屬於Tier 1製程安全事件(PSE)
f 中度酸鹼的一次阻絕設施失效無論洩漏量多寡均不屬於Tier 1製程安全事件
17 (K = 1000 MM = 1000000) (在環境影響類別方面若缺乏既有定義協會和會員公司應議定輸入標準)
附錄 A ndash 嚴重程度表鼓勵所有協會均採用嚴重程度加權制度
事件事故類別
嚴重程度等級
安全人體健康 火災或爆炸導致直接
成本 任 1 小時內物質洩
漏量 社區影響 環境影響[廠外]
4 級
1 分
對員工承攬商或再承攬商造成較輕傷害嚴重之傷害 (符合本地法規)
造成以下直接損失成本
美金$25 K ~ $25 K
洩漏量介於
1x le TQ lt 40x
官方宣告就地避難或疏散 (廠內或廠外) 預防性廠外就地避難或疏散
le 3 小時
重大環境整治成本
$25 K ~ $25 K
3 級
3 分
對員工承攬商或再承攬商造成之需要多日缺勤的傷害
對第三方造成之需要初步急救以外治療的傷害 (符合本地法規)
造成以下直接損失成本
$25 K ~ $250 K
洩漏量介於
40x le TQ lt 160x
官方宣告就地避難或疏散 (廠內或廠外)
預防性廠外就地避難或疏散
3 ~ 12 小時
重大環境整治成本
$25 K ~ $250 K
2 級
9 分
對員工承攬商或再承攬商造成 1 人死亡
對第三方造成 1 人住院治療
(符合本地法規)
造成以下直接損失成本
$250 K ~ $25 MM
洩漏量介於
160x le TQ lt 640x
官方宣告就地避難或疏散 (廠內或廠外)
預防性廠外就地避難或疏散
12 ~ 24 小時
重大環境整治成本
$250 K ~ $25 MM
1 級
27 分
對員工承攬商或再承攬商造成多人死亡
對第三方造成多人住院治療
對第三方造成 1 人死亡 (符合本地法規)
造成以下直接損失成本
ge $25 MM
洩漏量
ge 640x TQ
官方宣告就地避難或疏散 (廠內或廠外)
預防性廠外就地避難或疏散
ge 24 小時
重大環境整治成本
ge $25 MM
18 (K = 1000 MM = 1000000) (在環境影響類別方面若缺乏既有定義協會和會員公司應議定輸入標準)
嚴重程度表(附錄 A)細節說明
附錄 A 之設計目的僅適用於採用 GHS 分類制度(表 1)者如果你的公司係採用 API RP 754Tier II 製程安全指標提報恕限值表(表 2)請使用
API RP 754 製程安全嚴重程度表必須提醒的是依 API RP 754 的標準其嚴重程度表僅適用於一級(Tier I)事故去比較採用不同的嚴重度
表所評估出來的相對嚴重度並無統計上的意義
急性的環境成本 ndash 因製程安全事件造成廠外環境影響所導致之短期清理及物質處置的成本各會員公司可選擇將廠外環境影響相關成本另
外區分一個嚴重程度類別
比率調整指標
利用上述嚴重程度表可產生一系列以事件率為基礎的指標包括
製程安全總事件率 (PSTIR) 總事件次數 x 200000
總工作時數
製程安全事件嚴重程度率(PSESR) (即製程安全事件嚴重程度加權計算公式)
PSESR = 所有事件之總嚴重程度分數總合 x 200000
總工作時數
在計算此一比率時各 4 級事件被分配 1 分各 3 級事件被分配 3 分各 2 級事件被分配 9 分各 1 級事件被分配 27 分理論上每個
製程安全事件至少可分配到 1 分(亦即事件僅在一個類別符合第 4 級事件屬性)至多可分配到 135 分(亦即事件在所有五個類別中均符
合第 1 級事件屬性)
ldquoXrdquo級別製程安全事件率 嚴重度級別ldquoXrdquo之製程安全事件總數 x 200000
員工承攬商amp再承攬商總工作時數
X可以是嚴重度級別 432 或 1 級製程安全事件之總數事件之嚴重度等級是選用五類後果類別中之最嚴重等級
標準化 ndash 在某些協會和會員公司中製程安全事件是採 lsquo每 100 名rsquo員工每名員工每年平均工作時數為 2000 小時為基礎予以標準化因
此在lsquo每 100rsquo名rsquo員工的標準基礎上事件被乘以 200000 工作時數也有些其他協會和會員公司將標準化基礎設定為lsquo每 500 名rsquo員工
因此事件被乘以 1000000 工作時數協會和會員公司應就標準化基礎進行討論共同做成選項結論上述的公式設定為lsquo每 100 名rsquo員工
基礎
19
附錄 B ndash 常見問題集
適用性
我們建議會員公司記錄和提報在其所擁有或運作的工廠內發生的製程安全事件惟以下情況不須提報製
程安全事件
1 源自於公司廠區以外的製程安全事件
2 海上運輸船事故惟船隻為了輸送半成品或產品之目的已經與公司的設施相連接時發生的
事故仍須提報
3 卡車或軌道車事故惟卡車或軌道車為了輸送半成品或產品之目的已經與公司的設施相連
接時發生的事故仍須提報
4 許可證或法規容許之例行排放
5 不會造成製程安全危害的地下污染請注意若洩漏至地下導致地上發生須提報製程安全事
件如釋放出毒性蒸汽或致使易燃液體蓄積成池則不適用本排除條件
6 辦公建築事故(如辦公室暖氣設備爆炸火災外溢洩漏人員受傷或疾病等)
7 與疏散或一次阻絕設施失效無直接關聯之人員安全ldquo滑倒絆倒跌倒rdquo事故
8 沒有與製程相連接之輔助設備的一次阻絕設施(如小樣品瓶)失效事故
9 計劃中和在控制下的物質排放至設計用來收集或排放系統中(請注意物質從一次阻絕設施
在非計劃或非受控制情況下排放至收集或排放系統中則不適用本排除條件)
10 在製程區域外部或保養廠內執行之機械作業
說明與實例 ndash 以 GHS 表 1 為基礎
以下說明和實例有助於在評估須提報製程安全事件(PSE)時釐清可能存在的不確定部分
公司廠區
1 一輛第三方的卡車在公司廠區內卸載易燃產品時發生洩漏進而引起火災造成公司財物損失
$7000 美元(直接成本)雖然該卡車是ldquo由他人操作rdquo但其作業與製程相連接若公司的直接成
本財物損失達到或超過$2500 美元或已達到或超過其他 PSE 提報門檻(如1 人死亡)此事故即
屬於須提報的製程安全事件
2 與前例1 類似的例子載著易燃產品的卡車在廠外運輸途中翻覆引發火災並造成卡車毀損
該事故不屬於須提報的製程安全事件因為當時卡車並未與製程相連接
20
阻絕設施失效
3 儲槽液位計故障造成裝有ldquo易燃液體rdquo產品的儲槽外溢約 700 公斤的液體流入儲槽的防溢堤內
此事故屬於須提報的製程安全事件因為其ldquo急性rdquo洩漏量超過 100 公斤即使是阻絕在二次阻絕
設施防溢堤中亦然
4 一名從事維修工作的承攬商在開啟一個製程阻閥時被噴起的硫酸濺到造成嚴重灼傷和損失工
時的工傷此事故屬於須提報的製程安全事件因為它是涉及物質和一次阻絕設施失效的意外事
件對於因洩漏造成死亡和損工的工傷或疾病事故沒有洩漏恕限值
5 一名作業員開啟品管取樣點進行日常取樣作業時手部被一個破碎的玻璃瓶嚴重割破需要進行
縫合治療縫針造成第二天無法上班該事故不屬於須提報的製程安全事件因為它與一次阻絕
設施失效無關
ldquo急性rdquo洩漏
6 一名作業員在進行天然氣流量高於預期值之異常排除時發現天然氣管線上的一個安全閥門未適
當歸位因此天然氣經由氣液分離桶排放至排氣煙囪經進一步檢查作業員判斷在過去 6 個
月間總共有 100000 公斤天然氣以穩定的速率排放至大氣該事故不屬於須提報的製程安全事
件因為其洩漏速率(每小時約 10 公斤)不算ldquo急性rdquo洩漏(未超過易燃蒸汽每小時 100 公斤的恕限
值)
廢氣燃燒塔amp排放控制裝置 (如洗滌塔)
7 若化學物質被導引至廢氣燃燒塔或排放控制裝置(如洗滌塔)只要該廢氣燃燒塔或控制裝置運作在
正常設計範圍內便不屬於須提報的製程安全事件
8 若廢氣流速超過洗滌塔的設計負荷以致未經吸收的化學物質排出超過恕限值該事故屬於須提報
的製程安全事件(如本文註釋所述)
註釋自取得許可或妥善管理的裝置-包括釋壓裝置發生不預期的排放若 1 小時內洩漏量達到或
超過表 1 或表 2 所列的洩漏恕限值且導致下列四種後果之任一項或以上之後果該事故便屬於
須提報的製程安全事件
o 二相排放或夾帶液體的排放液滴沉降至地面造成污染
o 排放至具潛在危險性的地點)
o 廠內就地避難或疏散不包括預防性廠內就地避難或疏散
o 啟動公眾保護措施(如道路封閉)包括預防性公眾保護措施
21
安全洩壓裝置 系統
9 製程單元發生異常安全閥開啟將洩漏物質釋放到排氣口此釋壓排放裝置是依相關要求設計
的且氣體釋到大氣中並未造成不良後果這不是一個須提報的製程安全事件因為安全閥高
壓破裂盤以及類似的安全裝置是依據 API 521 或者同等的標準設計的且此排放並未造成 (1)
夾帶液體並導致須提報的製程安全事件的後果(譬如損失工時意外死亡火災或爆炸造成$2500
美元或以上的直接成本損失液體或毒性氣體洩漏量達到或超過恕限值(2) 啟動廠內或廠外就地
避難應變或(3)啟動公眾保護措施
10 製程單元發生異常安全閥並未開啟造成設備超壓易燃性氣體從一個法蘭處ldquo急性rdquo漏出來
洩露量超過 100 公斤(一小時內)的恕限值該事故屬於須提報的製程安全事件因為從法蘭處外
漏屬於製程安全事件應提報事項
損工事故
11 一名作業員走路時不慎滑倒造成損失工時之工傷滑倒原因為天氣狀況rdquo長期rdquo油垢的地面和
易滑鞋具該事故不屬於須提報的製程安全事件因為人員安全ldquo滑倒絆倒跌倒rdquo事故若非與
一次阻絕設施失效直接關聯的疏散或應變造成則不屬於須提報的製程安全事件
12 與前例相同的事件惟這次作業員跌倒是因為少量易燃液體外漏(如 1 小時內少於 10 公斤)在採取
相關應變措施時發生該事故屬於須提報的製程安全事件因為作業員係為了應變一次阻絕設施
失效的事故而跌倒若一次阻絕設施失效發生在公司廠區且造成失時工傷或死亡後果該事故
便屬於須提報的製程安全事件對於因洩漏造成死亡和損失工時之工傷事故沒有洩漏量門檻
13 與前例相同的事件惟這次作業員跌倒是在事件結束數小時之後該事故不屬於須提報的製程安
全事件在提報要件中所用的ldquo疏散rdquo和ldquo應變rdquo等術語指的是一次阻絕設施失效和相關緊急應變
活動正在持續中事件結束後滑倒絆倒跌倒(如ldquo事後rdquo清理和補救)不屬於須提報製程安全事件
14 工人在因附近設備一次阻絕設施失效在疏散過程中一名鷹架搭建工人從鷹架梯上跌落造成損
失工時之工傷該事故屬於須提報的製程安全事件
15 一名作業員行經一個設計不良的蒸汽卻水器時被外洩的蒸汽燙傷腳踝造成損失工時之工傷
該事故屬於須提報的製程安全事件因為雖然一次阻絕設施失效洩漏出的是蒸汽(而非碳氫化合物
或化學物質)但損失工時之工傷是由於洩漏物質的物理狀態所導致的
16 一個密閉空間依照計畫以氮氣吹清一名承攬商繞過安全管制進入該密閉空間因而死亡該事
故屬於須提報的死亡事件但不屬於須提報的製程安全事件因為其中不涉及非計劃或失控的一
次阻絕設施失效
17 情況同上惟這次氮氣是非刻意洩漏進入該局限空間該事故屬於須提報的製程安全事件(同時也
是一起死亡事件)因為該名承攬商的死亡與非計劃的一次阻絕設施失效有關
22
18 一名作業員因硫化氫(H2S)警報在進行應變處理時昏倒若警報確實是因非計劃或失控的 H2S 一次
阻絕設施失效的外洩事件該事故便屬於須提報的製程安全事件若警報是一個假警報則該事
故便不屬於須提報的製程安全事件因為沒有真正的化學品洩漏發生
管線
19 一條管線破漏1 小時內洩漏 2000 磅(900 公斤)易燃蒸氣到地面但洩漏位置在廠區內很偏僻的
地點該事故仍屬於須提報的製程安全事件因為ldquo偏僻rdquo不是提報與否的考量因素
與化學物質外洩無關之火災或能量釋放事故
一般通則而言唯有當火災或能量釋放事故是因化學物質洩漏所造成或其發生導致化學物質洩漏
超過提報恕限值這些事故才屬於須提報的製程安全事件實例包括
20 一場電氣火災影響製程操作導致甲苯洩漏 400 公斤該事故屬於須提報的製程安全事件因為
化學物質洩漏已超過甲苯的 100 公斤提報恕限值
21 發生電氣火災停電或任何公用資源供應中斷可能造成工廠停工及可能引起設備損失超過
$2500 美元(如因非正常停工導致反應器或設備損壞)但並未造成超過恕限值的化學物質洩漏
亦未造成死亡或嚴重工傷該事故不屬於須提報的製程安全事件因為設備損壞並非化學製程火
災爆炸造成且化學物質洩漏並未超過恕限值
海上運輸船
22 一艘由公司營運的海上運輸船在船上發生ldquo急性rdquo易燃物質外洩洩漏量超過 100 公斤該事故不
屬於須提報的製程安全事件因為除非海上運輸船是為了輸送半成品或產品而與煉油石化或化
學製造廠的設施相連接否則其洩漏事故便不被視為製程安全事件
23 一艘第三方駁船由一艘拖船推向碼頭結果撞上公司的碼頭駁船的一個船艙破裂且造成
1000 公斤柴油洩漏到海中該事故不屬於須提報的製程安全事件因為駁船當時並非停泊在碼
頭內且其作業並非在進行半成品或產品之輸送
卡車與軌道車
24 一輛公司的軌道車在運輸途中出軌造成超過 1000 公斤汽油洩漏該事故不屬於須提報的製程
安全事件因為在公司廠區外發生的軌道車事故不被視為與製程安全有關
23
25 一輛第三方卡車拖車在公司廠區內翻覆造成ldquo急性rdquo汽油洩漏超過 1000 公斤這事故不屬於須
提報的製程安全事件因為卡車拖車當時已不再與裝卸設備連接然而我們建議會員公司另
行訂定運輸安全事故指標將這類事故記錄下來
26 一位合約卡車作業者正在卸載液鹼時發生軟管脫落造成空氣中氣霧和或液鹼液洩漏 2500 公
斤該事故屬於須提報的製程安全事件因為洩漏量已超過液鹼的 100 公斤恕限值且事故發生
前卡車仍與裝卸設備相連接著
辦公建築
27 綜合辦公大樓發生鍋爐火災造成總計$75000 美元的直接成本損失該事故不屬於須提報的製
程安全事件因為辦公大樓事故不被視為與製程安全有關
人機介面事故
28 一名操作技術員在聚合物工廠的終端設備旁作業時受傷這傷害是因機械的人機介面的設備而
造成該事故不屬於須提報的製程安全事件因為技術員受傷並非因危險物質一次阻絕設施失效
而造成的
混合物
29 若混合物本身有 GHS 分類可利用其分類確定恕限值若混合物本身沒有 GHS 分類則可計算混
合物中每個單一組成分之洩漏量(公斤)相對於個別成分恕限值之比值作為其對混合物恕限值之
lsquo加權rsquo貢獻譬如若混合物在 1小時內的洩漏量為 100公斤其中包含 05公斤分類為劇毒 H300
的物質45 公斤分類為 H301 的物質40 公斤另一種分類為 H 開頭的物質其餘 55 公斤則為沒
有 GHS 分類的水分此混合物之計算式為051 + 4510 + 40100 = 05 + 045 + 04 = 135超過
1因此該事故被視為須提報的製程安全事件雖然混合物個別成分之洩漏量均未超過各該物質
本身的恕限值
直接損失成本
30 此一門檻所考慮的成本應為可直接歸因於火災或爆炸的成本譬如設備及結構損壞的重置成本
修理成本環境清理支出緊急應變和罰款直接成本不包括間接成本譬如業務機會損失設
備停機造成之利潤損失取得或運轉臨時設施之成本或為滿足顧客需求取得替代產品的成本
(產品損失)
24
31 範例連接到氣體處理系統的排放管發生易燃氣體外漏同時製程出現問題導致空氣進入同
一條排放管結果發生爆炸過高的壓力損壞了排放管及其相關上游設備包括一個密封罐並
未造成人員受傷修理成本約$12000 美元該事故屬於須提報的製程安全事件因為爆炸及火
災導致設備修理成本超過門檻
32 範例一次製程安全事件後公司又發生一種非常特殊的 GHS 第 5 類產品洩漏 50 公斤造成
$2000 美元的設備損失洩漏的產品是一種非常特別的混合物公司須負擔超過$50000 美元因
產品耗損而產生之材料成本該事故不屬於須提報的製程安全事件因為 GHS 第 5 類產品洩漏的
提報門檻為 100 公斤且產品耗損不被計入直接損失成本
天然災害
33 天然災害可能對化學製程作業構成重大風險且對製程設備造成損壞導致危害物質一次阻絕設
施失效當一種或多種天然災害被認為可能對工廠作業造成影響時製程安全和作業系統應從危
害及後果分析工廠機器設備設計公用設施失效及製程停工之操作程序緊急應變計畫及應變
措施等方面界定潛在風險進行防範
天然災害類型包括颶風及颱風(包括伴隨而來的風暴潮)水災龍捲風地震超強對流風暴(直
線風暴)野火火山爆發海嘯和山崩
若公司廠房設施遭遇天然災害且其後果觸發一種或以上提報門檻該事故便屬於須提報製程安
全事件
預防性公眾應變
34 預防性公眾應變是基於謹慎的態度所採取的一種措施譬如當發生一次阻絕設施失效時公司
可能在尚未進行任何評估(如方向與洩漏點的距離等等)前便要求全體工人就地避難又
如地方權責官員(如消防警察民防緊急應變管理部門)在獲報一家公司發生製程安全事件
後為防lsquo萬一rsquo風向改變或基於可能受到波及的人口敏感族群(如學童或老年人)可能在尚未接
獲明確資訊前便下令社區就地避難或疏散或採取公眾保護措施(如道路封閉)
製程附屬倉庫
35 製程附屬倉庫指的是位於廠內用於儲存將投入於生產製程或產自於製程之原料半成品或成品的
倉庫從製程的觀點看來製程附屬倉庫相當於一個大型儲槽但這些原料半成品或成品並不
是儲存在一的大型容器中而是裝在較小的容器裡(如太空包大桶桶罐等)
25
Appendix C ndash List of RCLG Taskforce Members
Name Affiliation
Peter Schmelzer Bayer CEFIC - Chairman
Americo Diniz Carvalho Neto Braskem
Bradford Johnson American Chemistry Council
David Cummings DuPont
Debra Phillips American Chemistry Council
Hans Schwarz BASF
Kathryn Walton Plastics and Chemicals Industries Association
Kazuyuki Akita Japanese Chemical Industry Association
Kelly Keim ExxonMobil Chemical Company API Representative
Kenan Stevick Dow
Kiyokazu Murata Japanese Chemical Industry Association
Larry Bowler SABIC
Lorna Young Chemical Industry Association of Canada
Louisa Nara Center for Chemical Process Safety
Luiz Shizuo Harayashiki Associaccedilatildeo Brasileira da Induacutestria Quiacutemica
Masatoshi Kumamoto Japanese Chemical Industry Association
Milton Lacerda Petrobras
Phil Scott Chemical Industries Association
Piet Knijff DSM European Process Safety Centre
Scott Donaldson and Eamon Chandler
Shell
Scott Wallace Olin Corporation
Shakeel Kadri Air Products and Chemicals Inc
26
附錄 D ndash 詳細活動時程表
2016 年 2017 年 2018 年 2019 年 2020 年
2 ndash 4 月
RCLG PS 先導計畫
5 月 ndash
針對準則進行調整釐清
6 月 向 RCLG 和 ICCA 董事會報
告先導計畫執行結果
7 ndash 12 月 RCLG 協會考量準
則並為其會員公司發展提報機制
如有需要RCLG可向 ICCA 申請能
力建立基金為會員公司舉辦製程安
全研習會
1 ndash 12 月
RCLG 協會開始向其會員公司蒐集製程安全數據
1 ndash 12 月
如有需要RCLG 各協會運用 RCLG 的基金及專
家舉辦製程安全及績效提報研習會
1 ndash 2 月
擁有數據的協會開始向RCLG 提報製程安全事件
(2017 年數據)
4 月 RCLG 檢討第一個提報循
環的結果挑戰及原始數據(內部)
6 月 RCLG 向 ICCA 董事會呈報
原始數據
7 ndash 12 月 必要時更新及調整準
則
如有需要RCLG 各協會運用 RCLG 的基金及專
家舉辦製程安全及績效提報研習會
1 ndash 2 月
擁有數據的協會開始向RCLG 提報製程安全事件
(2018 年數據)
4 月 RCLG 檢討第二個提報循
環的結果挑戰及原始數據(內部)
6 月 RCLG 向 ICCA 董事會呈報
原始數據
7 ndash 12 月 必要時更新及調整準
則
如有需要RCLG 協會運用 RCLG 的基金及專家
舉辦製程安全及績效提報研習會
1 ndash 2 月
所有協會開始向 RCLG 提報製程安全事件
製程安全事件提報成為
RCLG KPI 衡量指標建議基本集的一部分(2019 年數
據)
4 月 RCLG 檢討第二個提報循
環的結果挑戰及原始數據(內部考量外部提
報)
6 月 RCLG 向 ICCA 董事會呈報
原始數據
27
附錄 E ndash 選擇性 Excel 追蹤表
當會員公司開始追蹤製程安全事件時所有會員公司應採用單一表格以簡化數據分析同時讓所有公司均使用相同的追蹤表RCLG 設
計了一份選擇性追蹤表可供會員公司和協會先行利用之後他們可設計自己的追蹤表
在這裡下載追蹤表
ICCA Process Safety Event Tracking Sheetxlsx
本文件包含三個分頁分別是ldquo聯絡資料rdquoldquo調查表rdquo和儲存下拉式選單選項的ldquo請勿編輯rdquo分頁
備註
附錄 E 追蹤表僅供參考TRCA 將另行提供台灣版表格供會員公司提報
28
後語
台灣化學工業責任照顧協會(Taiwan Responsible Care Association TRCA)成立於 1998 年在台灣推行責任照顧制度已達 20 週年製造商成員
包括台灣主要上市上櫃化工公司會員公司化學品生產製造量約佔全國 80 2016 年台灣化工業的 Chemical Sales 仍站在全球第八名的位
置額度為 630 億歐元化工業總產值達到 34 兆新台幣提供國內 416 萬人工作機會
TRCA 扮演國內廠商與國際制度接軌的角色也是國內化工業與政府機關及利益相關者溝通的橋樑與管道TRCA 會員結構依業務性質分析
涵蓋石化生產化學品製造氣體生產倉儲運輸業化學品貿易業以及工程研發設計等公司TRCA 透過供應鏈及價值鏈推行責任
照顧制度組成毒性化學物質聯防組織協助法規溝通與研析會員名冊請參考 httpwwwtrcaorgtwtrcanwork2aspx
TRCA 於 2010 年成為 ICCA (International Council of Chemical Associations 國際化學工業協會)觀察員ICCA 成立於 1989 年是全球化工製造
業的聯合會也是化學工業與 UNEP OPCW 及 OECD 的交流窗口ICCA 與其會員協會及成員公司致力於邁向永續的未來確保人類健康與
環境安全與保護全球化工業擁有超過 4兆美元的價值影響所有經濟部門ICCA 的會員幾乎在全球每個國家都有商業活動在全球六大
洲推動創新並提供超過 2000 萬個工作機會
台灣化工業在全球占有重要的一席之地在國內產業鏈也位居關鍵位置無論對國內或國際都有身為地球村一員應盡之責我們期許藉由
製程安全指標提報能更進一步提升自我在工安衛生環保與永續發展等面向的績效表現
台灣化學工業責任照顧協會
10452 台北市中山區撫順街 8 號 7 樓
電話02-2585-0552
httpwwwtrcaorgtw
None | |
$2500 to $25000 | |
$25000 to $250000 | |
$250000 to $25000000 | |
More than $25000000 | |
Yes - Using GHS TABLE | |
Yes - Using API RP 754 TABLE | |
NO | |
NA | |
1x le TQ lt 40x | |
40x le TQ lt 160x | |
160x le TQ lt 640x | |
ge 640x TQ | |
Yes le 3 hours | |
Yes 3 hours ge 12 hours | |
Yes 12 hours ge 24 hours | |
Yes ge 24 hours | |
No | |
Small-scale | |
Medium-scale | |
Large-scale | |
No | |
Yes | |
No | |
middot Injury requiring treatment beyond first aid to an employee contractor or subcontractor | |
middot Days Away From Work injury to an employee contractor or subcontractor or middot Injury requiring treatment beyond first aid to a third party | |
middot A fatality of an employee contractor or subcontractor or middot A hospital admission of a third party | |
middot Multiple fatalities of employees contractors or subcontractors or middot multiple hospital admission of third parties or middot A fatality of a third party | |
NA | |
1x le TQ lt 3x | |
3x le TQ lt 9x | |
9x le TQ lt 27x | |
ge 27x TQ |
ICCA Process Safety Pilot Reporting ProgramFebruary 8 2016 | 1 | 2 | 3 | 4 | 5 | 6 | 7 | 8 | 9 | 10 | 12 | 13 | 14 | 15 | |||||||||||||||||||||||
SAFETY Details(Meeting Local Regulations) | Direct Cost from Fire or Explosion | Community Impact | Environmental Impact | Material Released(Measured using the 1 Hour Rule) | |||||||||||||||||||||||||||||||||
Company Association Details | |||||||||||||||||||||||||||||||||||||
GHS | API - RP 754 | ||||||||||||||||||||||||||||||||||||
Company or Assocation Name | Headquarter Association | Location of Event Ex - City State amp Country | Date and Time of Event | Safety InjuryDid the Event result in a Recordable Lost Time Accident or Fatality or Hospital admission of anyone on or off siteUse Drop Down Menu | Safety InjuryIf yes please insert the total number of injuries | Safety InjuryFor puropses of utilizing the Severity Table please indicate the level of severity by chosing the MOST SEVERE classification that describes your incidentUse Drop Down Menu | Safety InjuryDid the incident involve Fatalities If so how many total fatalities If none enter Zero | Safety InjuryPlease Report Total Employee Hours for Calendar Year 2015 | Safety InjuryPlease Report Total Contractor Hours for Calendar Year 2015 | Direct Cost Did the Event result in Direct Damage CostUse Drop Down Menu | Direct Cost If so how muchAmount is in US DollarsUse Drop Down Menu | Community ImpactDid the event result inbull Officially declared shelter-in-place or officially declared evacuation (on or off site)ORbull Precautionary off site shelter in place or evacuation Use Drop Down Menu | Environmental ImpactDid the event result inAcute Environmental Remediation CostIf so indicate the amount in US DollarsUse Drop Down Menu | Material ReleasedDid the Event result in an Acute Release of material beyond one of the two threshold tablesIf so indicate which Threshold Table you used to make this determinationUse Drop Down Menu | Material ReleasedIf so indicate the amount released USING GHS CLASSIFICATION TABLEUse Drop Down Menu | Material ReleasedIf so indicate the amount released USING THE THRESHOLD TABLE FROM API RP-754Use Drop Down Menu | Material ReleasedIf available please indicate the material released | ||||||||||||||||||||
1 | ABC Chemical Company | American Chemistry Council | Washington DC - USA | January 4 2016 | Yes | 2 | middot Days Away From Work injury to an employee contractor or subcontractor or middot Injury requiring treatment beyond first aid to a third party | 0 | 5525000 | 1500250 | No | $2500 to $25000 | Yes le 3 hours | $2500 to $25000 | Yes - Using GHS TABLE | 40x le TQ lt 160x | NA | Chlorine | |||||||||||||||||||
2 | XYZ Chemical Company | American Chemistry Council | Washington DC - USA | 5-Jan-16 | Yes | 1 | middot Injury requiring treatment beyond first aid to an employee contractor or subcontractor | 0 | 5525000 | 1500250 | Yes | $2500 to $25000 | No | $2500 to $25000 | Yes - Using API RP 754 TABLE | NA | 3x le TQ lt 9x | Benzene | |||||||||||||||||||
3 | |||||||||||||||||||||||||||||||||||||
4 | |||||||||||||||||||||||||||||||||||||
5 | |||||||||||||||||||||||||||||||||||||
6 | |||||||||||||||||||||||||||||||||||||
7 | |||||||||||||||||||||||||||||||||||||
8 | |||||||||||||||||||||||||||||||||||||
9 | |||||||||||||||||||||||||||||||||||||
10 | |||||||||||||||||||||||||||||||||||||
11 | |||||||||||||||||||||||||||||||||||||
12 | |||||||||||||||||||||||||||||||||||||
13 | |||||||||||||||||||||||||||||||||||||
14 | |||||||||||||||||||||||||||||||||||||
15 | |||||||||||||||||||||||||||||||||||||
16 | |||||||||||||||||||||||||||||||||||||
17 | |||||||||||||||||||||||||||||||||||||
18 | |||||||||||||||||||||||||||||||||||||
19 | |||||||||||||||||||||||||||||||||||||
20 | |||||||||||||||||||||||||||||||||||||
21 | |||||||||||||||||||||||||||||||||||||
22 | |||||||||||||||||||||||||||||||||||||
23 | |||||||||||||||||||||||||||||||||||||
24 | |||||||||||||||||||||||||||||||||||||
25 | |||||||||||||||||||||||||||||||||||||
Zero or None | Yes - Duration Unknown | ||||||||||||||||||||||||||||||||||||
Processes | Mode of Operation | Type of material released | Status of Operation | ||||
REFINING | Start-up | Flammable | Open | ||||
Alkylation HF | Planned shutdown | Combustible | Closed | ||||
Alkylation sulfuric | Emergency shutdown | Toxic | |||||
BitumenResidAsphalt | Normal | Corrosive | Tier 1 Acute Releases | ||||
Calcining | Upset | Utilities | No Release | ||||
Coking | Turnaround | Other | Category 1 | ||||
Crude | Routine maintenance | Category 2 | |||||
Desulfurization | Temporary | Evacuation | Category 3 | ||||
FCC | Other | Yes | Category 4 | ||||
Gas Treating | No | Category 5 | |||||
Hydrogen | Point of Release | Category 6 | |||||
Hydrotreating | Pump | Fire | Category 7 | ||||
Hydrocracking | Compressor | Yes | Multiple Categories | ||||
Isom | BlowerFan | No | |||||
MarineJetty | Pressure Vessel | lt $2500 | |||||
Reforming | FilterCoalescer | ||||||
Sulfur recovery | Furnace | PRDs | |||||
Vapor recoverylight ends | Boiler | Directly to Atmosphere | |||||
Wastewater | Heat exchanger | via Downstream Destructive Device | |||||
REFINING amp PETROCHEMICAL | Cooling Tower | No | |||||
Tank FarmStorage FacilityOffsite | Piping system | Yes | |||||
UtilitiesSteam PlantCogeneration | Reactor | No | |||||
Other | Atmospheric tank | ||||||
PETROCHEMICAL | FlareRelief System | Acute release above thresholds | |||||
CO H2 | Other | Yes | |||||
LNG | No | ||||||
Methane | Events | ||||||
Methanol | No Tier 1 Events | Indoor Outdoor | |||||
Methyl Mercaptan | No Tier 2 Events | No Release | |||||
Formaldehyde | No Tier 1 or Tier 2 Events | Indoor | |||||
Formaldehyde derivatives | NA | Outdoor | |||||
Acetic Acid | |||||||
Acetic Acid derivatives | Event Type | ||||||
Ethane | Injury | ||||||
Ethylene | Fire | ||||||
Ethanol | Explosion | ||||||
Ethylene oxide | PRD Discharge | ||||||
Ethylene derivatives | Acute Release | ||||||
Polyethylene | |||||||
Ethylene dichloride | General | ||||||
Ethylene dichloride derivatives | Yes | ||||||
Ethyl benzene | No | ||||||
Ethyl benzene derivatives | |||||||
Polystyrene | |||||||
Styrene-Butadiene | |||||||
Propane | |||||||
Propylene | |||||||
Polypropylene | |||||||
Isopropanol | |||||||
Propylene oxide | |||||||
Propylene oxide derivatives | |||||||
Butane | |||||||
Isobutane | |||||||
Isobutene | |||||||
Butadiene | |||||||
MTBE | |||||||
ETBE | |||||||
Pentane | |||||||
Hexane | |||||||
Cyclohexane | |||||||
Hexanol | |||||||
Aromatics Derivatives | |||||||
Benzene | |||||||
Toluene | |||||||
Xylene | |||||||
Para Xylene | |||||||
Amines Derivatives | |||||||
TDA MDA IPDA etc | |||||||
Isocyanates | |||||||
Specialty Chemicals | |||||||
LoadingUnloading | |||||||
Pilot Plant |
Instructions | ||||||||||||||
Step 1 | Complete the Contact Tab with your contact information and company information | |||||||||||||
Be sure to note the region of your reporting (IE North America France Japan etc) | ||||||||||||||
Survey on Process Safety Events | ||||||||||||||
Step 2 | Complete the survey one line per Process Safety Event for your companyregion | |||||||||||||
ALL REPORTED DATA SHOULD BE FROM CALENDAR YEAR 2017 | ||||||||||||||
Step 3 | Return completed survey to | |||||||||||||
Company Name | ||||||||||||||
Contact Person | All Surveys Due by xxx date | |||||||||||||
Address | ||||||||||||||
Fax | ||||||||||||||
Telephone | ||||||||||||||
Region | ||||||||||||||
None | |
$2500 to $25000 | |
$25000 to $250000 | |
$250000 to $25000000 | |
More than $25000000 | |
Yes - Using GHS TABLE | |
Yes - Using API RP 754 TABLE | |
NO | |
NA | |
1x le TQ lt 40x | |
40x le TQ lt 160x | |
160x le TQ lt 640x | |
ge 640x TQ | |
Yes le 3 hours | |
Yes 3 hours ge 12 hours | |
Yes 12 hours ge 24 hours | |
Yes ge 24 hours | |
No | |
Small-scale | |
Medium-scale | |
Large-scale | |
No | |
Yes | |
No | |
middot Injury requiring treatment beyond first aid to an employee contractor or subcontractor | |
middot Days Away From Work injury to an employee contractor or subcontractor or middot Injury requiring treatment beyond first aid to a third party | |
middot A fatality of an employee contractor or subcontractor or middot A hospital admission of a third party | |
middot Multiple fatalities of employees contractors or subcontractors or middot multiple hospital admission of third parties or middot A fatality of a third party | |
NA | |
1x le TQ lt 3x | |
3x le TQ lt 9x | |
9x le TQ lt 27x | |
ge 27x TQ |
ICCA Process Safety Pilot Reporting ProgramFebruary 8 2016 | 1 | 2 | 3 | 4 | 5 | 6 | 7 | 8 | 9 | 10 | 12 | 13 | 14 | 15 | |||||||||||||||||||||||
SAFETY Details(Meeting Local Regulations) | Direct Cost from Fire or Explosion | Community Impact | Environmental Impact | Material Released(Measured using the 1 Hour Rule) | |||||||||||||||||||||||||||||||||
Company Association Details | |||||||||||||||||||||||||||||||||||||
GHS | API - RP 754 | ||||||||||||||||||||||||||||||||||||
Company or Assocation Name | Headquarter Association | Location of Event Ex - City State amp Country | Date and Time of Event | Safety InjuryDid the Event result in a Recordable Lost Time Accident or Fatality or Hospital admission of anyone on or off siteUse Drop Down Menu | Safety InjuryIf yes please insert the total number of injuries | Safety InjuryFor puropses of utilizing the Severity Table please indicate the level of severity by chosing the MOST SEVERE classification that describes your incidentUse Drop Down Menu | Safety InjuryDid the incident involve Fatalities If so how many total fatalities If none enter Zero | Safety InjuryPlease Report Total Employee Hours for Calendar Year 2015 | Safety InjuryPlease Report Total Contractor Hours for Calendar Year 2015 | Direct Cost Did the Event result in Direct Damage CostUse Drop Down Menu | Direct Cost If so how muchAmount is in US DollarsUse Drop Down Menu | Community ImpactDid the event result inbull Officially declared shelter-in-place or officially declared evacuation (on or off site)ORbull Precautionary off site shelter in place or evacuation Use Drop Down Menu | Environmental ImpactDid the event result inAcute Environmental Remediation CostIf so indicate the amount in US DollarsUse Drop Down Menu | Material ReleasedDid the Event result in an Acute Release of material beyond one of the two threshold tablesIf so indicate which Threshold Table you used to make this determinationUse Drop Down Menu | Material ReleasedIf so indicate the amount released USING GHS CLASSIFICATION TABLEUse Drop Down Menu | Material ReleasedIf so indicate the amount released USING THE THRESHOLD TABLE FROM API RP-754Use Drop Down Menu | Material ReleasedIf available please indicate the material released | ||||||||||||||||||||
1 | ABC Chemical Company | American Chemistry Council | Washington DC - USA | January 4 2016 | Yes | 2 | middot Days Away From Work injury to an employee contractor or subcontractor or middot Injury requiring treatment beyond first aid to a third party | 0 | 5525000 | 1500250 | No | $2500 to $25000 | Yes le 3 hours | $2500 to $25000 | Yes - Using GHS TABLE | 40x le TQ lt 160x | NA | Chlorine | |||||||||||||||||||
2 | XYZ Chemical Company | American Chemistry Council | Washington DC - USA | 5-Jan-16 | Yes | 1 | middot Injury requiring treatment beyond first aid to an employee contractor or subcontractor | 0 | 5525000 | 1500250 | Yes | $2500 to $25000 | No | $2500 to $25000 | Yes - Using API RP 754 TABLE | NA | 3x le TQ lt 9x | Benzene | |||||||||||||||||||
3 | |||||||||||||||||||||||||||||||||||||
4 | |||||||||||||||||||||||||||||||||||||
5 | |||||||||||||||||||||||||||||||||||||
6 | |||||||||||||||||||||||||||||||||||||
7 | |||||||||||||||||||||||||||||||||||||
8 | |||||||||||||||||||||||||||||||||||||
9 | |||||||||||||||||||||||||||||||||||||
10 | |||||||||||||||||||||||||||||||||||||
11 | |||||||||||||||||||||||||||||||||||||
12 | |||||||||||||||||||||||||||||||||||||
13 | |||||||||||||||||||||||||||||||||||||
14 | |||||||||||||||||||||||||||||||||||||
15 | |||||||||||||||||||||||||||||||||||||
16 | |||||||||||||||||||||||||||||||||||||
17 | |||||||||||||||||||||||||||||||||||||
18 | |||||||||||||||||||||||||||||||||||||
19 | |||||||||||||||||||||||||||||||||||||
20 | |||||||||||||||||||||||||||||||||||||
21 | |||||||||||||||||||||||||||||||||||||
22 | |||||||||||||||||||||||||||||||||||||
23 | |||||||||||||||||||||||||||||||||||||
24 | |||||||||||||||||||||||||||||||||||||
25 | |||||||||||||||||||||||||||||||||||||
Zero or None | Yes - Duration Unknown | ||||||||||||||||||||||||||||||||||||
Processes | Mode of Operation | Type of material released | Status of Operation | ||||
REFINING | Start-up | Flammable | Open | ||||
Alkylation HF | Planned shutdown | Combustible | Closed | ||||
Alkylation sulfuric | Emergency shutdown | Toxic | |||||
BitumenResidAsphalt | Normal | Corrosive | Tier 1 Acute Releases | ||||
Calcining | Upset | Utilities | No Release | ||||
Coking | Turnaround | Other | Category 1 | ||||
Crude | Routine maintenance | Category 2 | |||||
Desulfurization | Temporary | Evacuation | Category 3 | ||||
FCC | Other | Yes | Category 4 | ||||
Gas Treating | No | Category 5 | |||||
Hydrogen | Point of Release | Category 6 | |||||
Hydrotreating | Pump | Fire | Category 7 | ||||
Hydrocracking | Compressor | Yes | Multiple Categories | ||||
Isom | BlowerFan | No | |||||
MarineJetty | Pressure Vessel | lt $2500 | |||||
Reforming | FilterCoalescer | ||||||
Sulfur recovery | Furnace | PRDs | |||||
Vapor recoverylight ends | Boiler | Directly to Atmosphere | |||||
Wastewater | Heat exchanger | via Downstream Destructive Device | |||||
REFINING amp PETROCHEMICAL | Cooling Tower | No | |||||
Tank FarmStorage FacilityOffsite | Piping system | Yes | |||||
UtilitiesSteam PlantCogeneration | Reactor | No | |||||
Other | Atmospheric tank | ||||||
PETROCHEMICAL | FlareRelief System | Acute release above thresholds | |||||
CO H2 | Other | Yes | |||||
LNG | No | ||||||
Methane | Events | ||||||
Methanol | No Tier 1 Events | Indoor Outdoor | |||||
Methyl Mercaptan | No Tier 2 Events | No Release | |||||
Formaldehyde | No Tier 1 or Tier 2 Events | Indoor | |||||
Formaldehyde derivatives | NA | Outdoor | |||||
Acetic Acid | |||||||
Acetic Acid derivatives | Event Type | ||||||
Ethane | Injury | ||||||
Ethylene | Fire | ||||||
Ethanol | Explosion | ||||||
Ethylene oxide | PRD Discharge | ||||||
Ethylene derivatives | Acute Release | ||||||
Polyethylene | |||||||
Ethylene dichloride | General | ||||||
Ethylene dichloride derivatives | Yes | ||||||
Ethyl benzene | No | ||||||
Ethyl benzene derivatives | |||||||
Polystyrene | |||||||
Styrene-Butadiene | |||||||
Propane | |||||||
Propylene | |||||||
Polypropylene | |||||||
Isopropanol | |||||||
Propylene oxide | |||||||
Propylene oxide derivatives | |||||||
Butane | |||||||
Isobutane | |||||||
Isobutene | |||||||
Butadiene | |||||||
MTBE | |||||||
ETBE | |||||||
Pentane | |||||||
Hexane | |||||||
Cyclohexane | |||||||
Hexanol | |||||||
Aromatics Derivatives | |||||||
Benzene | |||||||
Toluene | |||||||
Xylene | |||||||
Para Xylene | |||||||
Amines Derivatives | |||||||
TDA MDA IPDA etc | |||||||
Isocyanates | |||||||
Specialty Chemicals | |||||||
LoadingUnloading | |||||||
Pilot Plant |
Instructions | ||||||||||||||
Step 1 | Complete the Contact Tab with your contact information and company information | |||||||||||||
Be sure to note the region of your reporting (IE North America France Japan etc) | ||||||||||||||
Survey on Process Safety Events | ||||||||||||||
Step 2 | Complete the survey one line per Process Safety Event for your companyregion | |||||||||||||
ALL REPORTED DATA SHOULD BE FROM CALENDAR YEAR 2017 | ||||||||||||||
Step 3 | Return completed survey to | |||||||||||||
Company Name | ||||||||||||||
Contact Person | All Surveys Due by xxx date | |||||||||||||
Address | ||||||||||||||
Fax | ||||||||||||||
Telephone | ||||||||||||||
Region | ||||||||||||||
9
須提報製程安全事件之重要標準
總工作時數
RCLG 各協會應以加總的單一數字提報其所屬會員公司的員工和承攬商總工作時數為達
成本指引之目的各協會應參考其本地和地區對員工及承攬商之定義提報總時數之目標
應納入涉及化學製造之所有個人然而參與主要興建工程專案之人員則不納入計算譬
如為新建或擴建既有製程設施之設計工程和施工而成立之一次性專案組織的大規模投資
案會員公司提報總工作時數時應與人事部門統計之員工工時一致如此各公司便能
取得相同的職業與製程安全數據員工工時應包括所有化學製造作業的工時而非僅計算
發生製程安全事故之廠區的工時
製程安全事件
為執行 ICCA 提報目的製程安全事件之定義條件如下(必須同時符合 ABCD 四個條
件)
A 直接涉及某種化學物質或化學製程且
B 事故發生在廠內之生產配銷儲存公用或試驗工廠且
C 製程單元發生物質洩漏或能量釋放(如火災爆炸和內爆)且
D 已達到以下提報門檻之一
1 安全 工傷
導致記錄性的傷害(OSHA)損失工時或死亡或廠內外任何人員因此
而須住院治療或
2 直接損失成本
火災爆炸或為避免補救環境損害之必要清理作業導致$2500 美元
以上的直接成本支出或
3 就地避難 疏散
官方宣告就地避難(廠內或廠外)或
官方宣告疏散(廠內或廠外)或
廠外預防性就地避難或疏散或
4 洩漏恕限值
物質洩漏程度已達表 1 所列之任一 GHS 恕限值(洩漏量以單位小時計
量)
此外各公司亦可選擇採用 API RP-754 標準中所列之洩漏恕限值(表 2)請注意如欲查
看 API RP-754 標準可登入以下網站購買及下載httpwwwapiorgoil-and-natural-
gashealth-and-safetyprocess-safetyprocess-safety-standards
10
製程安全事件判定準則
A 涉及化學品
直接涉及某種化學物質或化學製程
製程安全事件或事故必須直接涉及化學物質或化學製程就此而言ldquo製程rdquo一詞泛指包含
石化生產所需要之設備和技術包括反應器儲槽管線鍋爐冷卻水塔和冷凍系
統helliphellip等未直接涉及化學物質或製程的事件無須提報譬如辦公大樓起火(即使該辦公大
樓位在廠區內亦然)
B 地點
事故發生在廠內之生產配銷儲存公用或試驗工廠
發生在廠內之生產配銷儲存(包括活動儲存區如倉庫 ndash 參見ldquo常見問題集rdquo)公用及
試驗工廠凡符合提報指標及定義的事故包括在廠區管理下之槽罐區輔助支援區(如
鍋爐室和廢水處理廠)和配銷管線所有須提報之事件應由負責該事故地點運作的公司
負提報之責此一規定亦適用於發生在承攬商作業區域內的事故在代工作業和多方共同
作業廠區負責運作該發生事故單位的公司應記錄事故始末並將之納入其提報中
C 物質洩漏
製程單元發生物質外洩或能量釋放(如火災爆炸和內爆)
物質外洩 ndash 製程任何物質發生非預期或無法控制的洩漏或釋放包括非毒性及不可燃物質
(如蒸汽熱水氮氣壓縮二氧化碳或壓縮空氣)且達到本文件所列四類提報門檻之一
項或以上之後果
在防治系統(如洗滌塔或廢氣燃燒塔)正常運作狀況下只要沒有任何洩漏或排放量超過
法定許可值即使排放到廢氣燃燒塔或滌氣塔仍被視為處於一次阻絕設施內然若排
放到二次阻絕設施(如廢水處理或防溢堤)將被視為製程安全事件因為物質已離開主要製
程系統
11
D 提報門檻
須提報製程安全事件必須達到以下提報門檻之一
1 安全 工傷
導致記錄性傷害(OSHA)損失工時或死亡或廠內外任何人員因此而須住院治療
記錄性傷害是指與工作有關所造成的傷害導致死亡暫時全失能工作受限制或需調整職
務較輕傷害嚴重之醫療處理失去意識或經醫師或其他合格醫療專業人員診斷為重大
傷害
損失工時傷害和死亡是指因製程相關的一次阻絕設施失效火災或爆炸導致以下任何一種
結果
員工(損失工時或死亡)
承攬商及再承攬商 (損失工時或死亡)
第三方(如來賓訪客快遞員)(受傷疾病導致住院治療或死亡)
住院治療是指醫院或其他具有住院病患保健設施的醫療單位正式接受病患住院提供病患
食宿及醫療護理且病患接受治療至少留置至隔日僅在醫院急診室治療或過夜處理不屬
於ldquo住院治療rdquo的定義範圍
須提報之工傷或死亡事件例如在清理作業期間因蒸汽洩漏造成人員燒燙傷壓力測試期間
帽蓋因受壓脫落造成人員身體傷害或取樣作業時因物質外濺造成人員化學灼傷無須提
報之工傷或死亡事件例如在執行維修作業時從高處的工作台墜落實驗室或辦公大樓火災
造成人員燒燙傷或挖掘工程塌陷造成人員傷害這些案例均與因製程造成的能量釋放或
物質洩漏無直接關聯
2 直接損失成本
火災爆炸或為避免補救環境損害之必要清理作業導致$2500美元以上的直接成本支出
此提報門檻所考慮的成本應為可直接歸因於火災或爆炸的成本譬如設備及結構損壞的重
置成本修理成本環境清理(廠內及廠外)支出緊急應變和罰款直接成本不包括間接
成本譬如業務機會損失設備停機造成之利潤損失取得或運轉臨時設施之成本或為
滿足顧客需求取得替代產品的成本(產品損失)
12
3 就地避難 疏散
官方宣告就地避難或疏散(廠內或廠外)或廠外預防性就地避難或疏散
就提報目的而言官方宣告就地避難或疏散(廠內或廠外)或廠外預防性就地避難或疏散
即達到此提報門檻
官方宣告 ndash 由地方權責機關(如消防警察民防緊急應變管理部門)或經授權的代表(如
派駐公司官員)下達的社區行動(如就地避難或疏散)宣告
預防性宣告 ndash 預防性公眾應變是基於謹慎的態度所採取的一種措施權責地方主管機關或經
授權的代表經合理判斷認定為維護公眾健康及安全發布必須採取就地避難或疏散之預
防性措施
就地避難 ndash 利用結構體及其內部空氣以暫時讓人員與室外危害性氣體隔離
疏散 ndash 基於安全或防護理由讓人員離開某處所的行動或過程
4 洩漏恕限值
超過表 1 中所列 GHS 恕限值或表 2 中所列 API 754 標準 Tier II 製程安全洩漏恕限值之一的
急性洩漏事件(洩漏量以單位小時計量)
如ldquo執行摘要rdquo所述ICCA 製程安全事件之定義容許採用 ICCA 依據化學品全球調和制度
(GHS)健康危害分級為基礎所發展的提報標準或依據聯合國危險物品(UNDG)分類為基礎
所定義之 RP-754 二級製程安全事件(Tier II) 之提報標準GHS 恕限值詳見表 1各會員公司
可自行決定選擇哪一個表中的提報恕限值並在全球採用單一制度
ldquo急性rdquo洩漏 ndash易燃性可燃性或毒性化學物質從一次阻絕設施(如容器或管線)洩漏其
任一單位小時之洩漏量超過化學物質洩漏恕限量分述於表 1 中的 GHS 分類和表 2 中的
API 754 標準 Tier II 製程安全洩漏恕限值
洩壓裝置前述所定義之ldquo急性rdquo洩漏包括洩漏或排放至妥善設計且運作中的洩壓裝置若
洩漏或排放量達到表 1 中所列 GHS 恕限值或表 2 中所列 API 754 標準 Tier II 製程安全洩漏
恕限值且導致下列四種後果之任一項或以上之後果
1 二相排放或夾帶液體的排放液滴沉降至地面造成污染
2 排放至具潛在危險性的地點
3 廠內就地避難或疏散不包括預防性廠內就地避難或疏散
4 啟動公眾保護措施(如道路封閉)包括預防性公眾保護措施
13
洩漏或排放至妥善設計且運作中的洩壓裝置(如廢氣燃燒塔洗滌塔等)若其情況未達前
述四項標準中任何一項則不必提報
欲查看 API RP-754 標準可登入以下網站下載此標準httpwwwapiorgenvironment-
health-and-safetyprocess-safetyprocess-safety-standardsstandard-rp-754
一小時法則
為便於衡量此項指標提報與否洩漏恕限值是以物質在任一小時內之洩漏量為標準若任
一小時或更短時間內物質洩漏量達到或超過須提報恕限值該事故便屬於須提報的製程安
全事件急性洩漏事故通常不會超過一小時若無法確定洩漏持續時間則應假設其為一
小時
一次阻絕設施ndash 用來作為主要容器或用於運送或輸送物質之槽罐船隻管線軌道車
或設備主要容器在設計上可能包含二次阻絕設施系統以抑制及控制洩漏二次阻絕設
施系統包括(但不限於)儲槽防溢堤製程設備周遭的圍堵設施油水分離的排水收集系統
雙層儲槽的外壁等
嚴重程度表 ndash 嚴重程度加權可額外提供有關製程安全事件的有用資訊有助於帶動改善績
效附錄 A 為 RCLG 建議之製程安全事件嚴重程度加權計算方法根據附錄 A 的方法便
可藉由加總與各個後果類別關聯的分數計算出各製程安全事件的嚴重程度加權值ICCA
強烈建議採用嚴重程度加權制度因為此制度有助於提升溝通績效的能力也比較容易讓
利害關係人了解製程安全事件並且此嚴重程度加權值與其他製程安全績效指標提報方
式是不具相互比較性的
14
表 1 ndash GHS 分類表
物理性危害(GHS 2x)
洩漏恕限值(1 小時內)
STOTSpecific target organ toxicity(特定標的器官系統毒性物質)
15
表 2 ndash API RP 754 Tier II 分類表
洩漏恕限類別
物質危害性分類 acdef 恕限值
(戶外洩漏) 恕限值
(戶內b洩漏)
T2-1 TIH A 區物質 ge 05 kg (11 lb) ge 025 kg (055
lb)
T2-2 TIH B 區物質 ge 25 kg (55 lb) ge 125 kg (275
lb)
T2-3 TIH C 區物質 ge 10 kg (22 lb) ge 5 kg (11 lb)
T2-4 TIH D 區物質 ge 20 kg (44 lb) ge 10 kg (22 lb)
T2-5
易燃氣體 或 正常沸點 ≦ 35 (95 degF)閃火點lt23 (73 degF)的液體 或 其他包裝組別 I 類的物質 (酸鹼除外)
ge 50 kg (110 lb) ge 25 kg (55 lb)
T2-6
正常沸點 gt 35 degC (95 degF)閃火點 lt 23 degC (73degF)的液體 或 其他包裝組別 II 類的物質 (酸鹼除外)
ge 100 kg (220 lb) 或
ge 07 bbl
ge 50 kg (110 lb) 或
ge 035 bbl
T2-7
閃火點 gt 23 degC (73 degF)和 lt 60 degC (140 degF)的液體 或 閃火點 gt 60 degC (140 degF)的液體在閃火點或高於閃火點的溫度下洩漏 或 強酸鹼 (定義參見 RP 754 文件草案) 或 UNDG第2類第22部分 (不可燃無毒氣體)空氣除外 或 其他包裝組別 III 類的物質
ge 200 kg (440 lb) 或
ge 14 bbl
ge 100 kg (220 lb) 或
ge 07 bbl
T2-8
閃火點 gt 60 degC (140 degF) 和 lt 93 degC (200 degF)的液體在低於閃火點的溫度下洩漏 或 中度酸鹼
ge 1000 kg
(2200 lb) 或
ge 7 bbl
ge 500 kg
(1100 lb) 或
ge 35 bbl
TIH吸入性毒性危害物(Toxic Inhalation Hazard)
16
一般認為以公斤和磅或以磅和桶為單位的恕限值不盡等同各公司應該選用其中一組計量單位並在
所有紀錄文件中一體適用
在判定一種物質之洩漏恕限類別時首先應從物質之含吸入性毒性(TIH Zone)可燃性(閃火點和沸點)
或腐蝕性(強酸或鹼 vs中度酸或鹼)等特性來判別只有當物質的危險度無法利用上述簡單的特性來判別
時(如遇水反應劇烈)才採用UNDGL包裝組別
a 許多物質具有一種以上危險性正確的危險區(Hazard Zone)或包裝組別(Packing Group)歸屬應遵循DOT
49 CFR 1732a [14]或聯合國危險物品運輸建議書(UNRTDG)第2部分[12]的規定參見附錄F
b 具有四面完整牆(從地板到天花板)地板和屋頂的結構物
c 對於未列於UNDG的溶液無水成分將用TIH區或包裝組別分類溶液之恕限值將根據乾基重量之恕限
值反算
d 對於未知UNDG分類的混合物可計算每種成分在恕限值洩漏中的分量如果各種成分之分量的總和
等於或大於100即表示混合物超過門檻值若混合物有明顯且獨立的毒性及可燃性結果則可分
別計算毒性及可燃性危險度參見附錄EPSE實例amp問題 49ndash53
e 閃火點 gt 60 degC (140 degF) 和 lt 93 degC (200 degF)的液體在低於閃火點的溫度下洩漏無論洩漏量多寡其
一次阻絕設施失效(LOPC)均不屬於Tier 1製程安全事件(PSE)
f 中度酸鹼的一次阻絕設施失效無論洩漏量多寡均不屬於Tier 1製程安全事件
17 (K = 1000 MM = 1000000) (在環境影響類別方面若缺乏既有定義協會和會員公司應議定輸入標準)
附錄 A ndash 嚴重程度表鼓勵所有協會均採用嚴重程度加權制度
事件事故類別
嚴重程度等級
安全人體健康 火災或爆炸導致直接
成本 任 1 小時內物質洩
漏量 社區影響 環境影響[廠外]
4 級
1 分
對員工承攬商或再承攬商造成較輕傷害嚴重之傷害 (符合本地法規)
造成以下直接損失成本
美金$25 K ~ $25 K
洩漏量介於
1x le TQ lt 40x
官方宣告就地避難或疏散 (廠內或廠外) 預防性廠外就地避難或疏散
le 3 小時
重大環境整治成本
$25 K ~ $25 K
3 級
3 分
對員工承攬商或再承攬商造成之需要多日缺勤的傷害
對第三方造成之需要初步急救以外治療的傷害 (符合本地法規)
造成以下直接損失成本
$25 K ~ $250 K
洩漏量介於
40x le TQ lt 160x
官方宣告就地避難或疏散 (廠內或廠外)
預防性廠外就地避難或疏散
3 ~ 12 小時
重大環境整治成本
$25 K ~ $250 K
2 級
9 分
對員工承攬商或再承攬商造成 1 人死亡
對第三方造成 1 人住院治療
(符合本地法規)
造成以下直接損失成本
$250 K ~ $25 MM
洩漏量介於
160x le TQ lt 640x
官方宣告就地避難或疏散 (廠內或廠外)
預防性廠外就地避難或疏散
12 ~ 24 小時
重大環境整治成本
$250 K ~ $25 MM
1 級
27 分
對員工承攬商或再承攬商造成多人死亡
對第三方造成多人住院治療
對第三方造成 1 人死亡 (符合本地法規)
造成以下直接損失成本
ge $25 MM
洩漏量
ge 640x TQ
官方宣告就地避難或疏散 (廠內或廠外)
預防性廠外就地避難或疏散
ge 24 小時
重大環境整治成本
ge $25 MM
18 (K = 1000 MM = 1000000) (在環境影響類別方面若缺乏既有定義協會和會員公司應議定輸入標準)
嚴重程度表(附錄 A)細節說明
附錄 A 之設計目的僅適用於採用 GHS 分類制度(表 1)者如果你的公司係採用 API RP 754Tier II 製程安全指標提報恕限值表(表 2)請使用
API RP 754 製程安全嚴重程度表必須提醒的是依 API RP 754 的標準其嚴重程度表僅適用於一級(Tier I)事故去比較採用不同的嚴重度
表所評估出來的相對嚴重度並無統計上的意義
急性的環境成本 ndash 因製程安全事件造成廠外環境影響所導致之短期清理及物質處置的成本各會員公司可選擇將廠外環境影響相關成本另
外區分一個嚴重程度類別
比率調整指標
利用上述嚴重程度表可產生一系列以事件率為基礎的指標包括
製程安全總事件率 (PSTIR) 總事件次數 x 200000
總工作時數
製程安全事件嚴重程度率(PSESR) (即製程安全事件嚴重程度加權計算公式)
PSESR = 所有事件之總嚴重程度分數總合 x 200000
總工作時數
在計算此一比率時各 4 級事件被分配 1 分各 3 級事件被分配 3 分各 2 級事件被分配 9 分各 1 級事件被分配 27 分理論上每個
製程安全事件至少可分配到 1 分(亦即事件僅在一個類別符合第 4 級事件屬性)至多可分配到 135 分(亦即事件在所有五個類別中均符
合第 1 級事件屬性)
ldquoXrdquo級別製程安全事件率 嚴重度級別ldquoXrdquo之製程安全事件總數 x 200000
員工承攬商amp再承攬商總工作時數
X可以是嚴重度級別 432 或 1 級製程安全事件之總數事件之嚴重度等級是選用五類後果類別中之最嚴重等級
標準化 ndash 在某些協會和會員公司中製程安全事件是採 lsquo每 100 名rsquo員工每名員工每年平均工作時數為 2000 小時為基礎予以標準化因
此在lsquo每 100rsquo名rsquo員工的標準基礎上事件被乘以 200000 工作時數也有些其他協會和會員公司將標準化基礎設定為lsquo每 500 名rsquo員工
因此事件被乘以 1000000 工作時數協會和會員公司應就標準化基礎進行討論共同做成選項結論上述的公式設定為lsquo每 100 名rsquo員工
基礎
19
附錄 B ndash 常見問題集
適用性
我們建議會員公司記錄和提報在其所擁有或運作的工廠內發生的製程安全事件惟以下情況不須提報製
程安全事件
1 源自於公司廠區以外的製程安全事件
2 海上運輸船事故惟船隻為了輸送半成品或產品之目的已經與公司的設施相連接時發生的
事故仍須提報
3 卡車或軌道車事故惟卡車或軌道車為了輸送半成品或產品之目的已經與公司的設施相連
接時發生的事故仍須提報
4 許可證或法規容許之例行排放
5 不會造成製程安全危害的地下污染請注意若洩漏至地下導致地上發生須提報製程安全事
件如釋放出毒性蒸汽或致使易燃液體蓄積成池則不適用本排除條件
6 辦公建築事故(如辦公室暖氣設備爆炸火災外溢洩漏人員受傷或疾病等)
7 與疏散或一次阻絕設施失效無直接關聯之人員安全ldquo滑倒絆倒跌倒rdquo事故
8 沒有與製程相連接之輔助設備的一次阻絕設施(如小樣品瓶)失效事故
9 計劃中和在控制下的物質排放至設計用來收集或排放系統中(請注意物質從一次阻絕設施
在非計劃或非受控制情況下排放至收集或排放系統中則不適用本排除條件)
10 在製程區域外部或保養廠內執行之機械作業
說明與實例 ndash 以 GHS 表 1 為基礎
以下說明和實例有助於在評估須提報製程安全事件(PSE)時釐清可能存在的不確定部分
公司廠區
1 一輛第三方的卡車在公司廠區內卸載易燃產品時發生洩漏進而引起火災造成公司財物損失
$7000 美元(直接成本)雖然該卡車是ldquo由他人操作rdquo但其作業與製程相連接若公司的直接成
本財物損失達到或超過$2500 美元或已達到或超過其他 PSE 提報門檻(如1 人死亡)此事故即
屬於須提報的製程安全事件
2 與前例1 類似的例子載著易燃產品的卡車在廠外運輸途中翻覆引發火災並造成卡車毀損
該事故不屬於須提報的製程安全事件因為當時卡車並未與製程相連接
20
阻絕設施失效
3 儲槽液位計故障造成裝有ldquo易燃液體rdquo產品的儲槽外溢約 700 公斤的液體流入儲槽的防溢堤內
此事故屬於須提報的製程安全事件因為其ldquo急性rdquo洩漏量超過 100 公斤即使是阻絕在二次阻絕
設施防溢堤中亦然
4 一名從事維修工作的承攬商在開啟一個製程阻閥時被噴起的硫酸濺到造成嚴重灼傷和損失工
時的工傷此事故屬於須提報的製程安全事件因為它是涉及物質和一次阻絕設施失效的意外事
件對於因洩漏造成死亡和損工的工傷或疾病事故沒有洩漏恕限值
5 一名作業員開啟品管取樣點進行日常取樣作業時手部被一個破碎的玻璃瓶嚴重割破需要進行
縫合治療縫針造成第二天無法上班該事故不屬於須提報的製程安全事件因為它與一次阻絕
設施失效無關
ldquo急性rdquo洩漏
6 一名作業員在進行天然氣流量高於預期值之異常排除時發現天然氣管線上的一個安全閥門未適
當歸位因此天然氣經由氣液分離桶排放至排氣煙囪經進一步檢查作業員判斷在過去 6 個
月間總共有 100000 公斤天然氣以穩定的速率排放至大氣該事故不屬於須提報的製程安全事
件因為其洩漏速率(每小時約 10 公斤)不算ldquo急性rdquo洩漏(未超過易燃蒸汽每小時 100 公斤的恕限
值)
廢氣燃燒塔amp排放控制裝置 (如洗滌塔)
7 若化學物質被導引至廢氣燃燒塔或排放控制裝置(如洗滌塔)只要該廢氣燃燒塔或控制裝置運作在
正常設計範圍內便不屬於須提報的製程安全事件
8 若廢氣流速超過洗滌塔的設計負荷以致未經吸收的化學物質排出超過恕限值該事故屬於須提報
的製程安全事件(如本文註釋所述)
註釋自取得許可或妥善管理的裝置-包括釋壓裝置發生不預期的排放若 1 小時內洩漏量達到或
超過表 1 或表 2 所列的洩漏恕限值且導致下列四種後果之任一項或以上之後果該事故便屬於
須提報的製程安全事件
o 二相排放或夾帶液體的排放液滴沉降至地面造成污染
o 排放至具潛在危險性的地點)
o 廠內就地避難或疏散不包括預防性廠內就地避難或疏散
o 啟動公眾保護措施(如道路封閉)包括預防性公眾保護措施
21
安全洩壓裝置 系統
9 製程單元發生異常安全閥開啟將洩漏物質釋放到排氣口此釋壓排放裝置是依相關要求設計
的且氣體釋到大氣中並未造成不良後果這不是一個須提報的製程安全事件因為安全閥高
壓破裂盤以及類似的安全裝置是依據 API 521 或者同等的標準設計的且此排放並未造成 (1)
夾帶液體並導致須提報的製程安全事件的後果(譬如損失工時意外死亡火災或爆炸造成$2500
美元或以上的直接成本損失液體或毒性氣體洩漏量達到或超過恕限值(2) 啟動廠內或廠外就地
避難應變或(3)啟動公眾保護措施
10 製程單元發生異常安全閥並未開啟造成設備超壓易燃性氣體從一個法蘭處ldquo急性rdquo漏出來
洩露量超過 100 公斤(一小時內)的恕限值該事故屬於須提報的製程安全事件因為從法蘭處外
漏屬於製程安全事件應提報事項
損工事故
11 一名作業員走路時不慎滑倒造成損失工時之工傷滑倒原因為天氣狀況rdquo長期rdquo油垢的地面和
易滑鞋具該事故不屬於須提報的製程安全事件因為人員安全ldquo滑倒絆倒跌倒rdquo事故若非與
一次阻絕設施失效直接關聯的疏散或應變造成則不屬於須提報的製程安全事件
12 與前例相同的事件惟這次作業員跌倒是因為少量易燃液體外漏(如 1 小時內少於 10 公斤)在採取
相關應變措施時發生該事故屬於須提報的製程安全事件因為作業員係為了應變一次阻絕設施
失效的事故而跌倒若一次阻絕設施失效發生在公司廠區且造成失時工傷或死亡後果該事故
便屬於須提報的製程安全事件對於因洩漏造成死亡和損失工時之工傷事故沒有洩漏量門檻
13 與前例相同的事件惟這次作業員跌倒是在事件結束數小時之後該事故不屬於須提報的製程安
全事件在提報要件中所用的ldquo疏散rdquo和ldquo應變rdquo等術語指的是一次阻絕設施失效和相關緊急應變
活動正在持續中事件結束後滑倒絆倒跌倒(如ldquo事後rdquo清理和補救)不屬於須提報製程安全事件
14 工人在因附近設備一次阻絕設施失效在疏散過程中一名鷹架搭建工人從鷹架梯上跌落造成損
失工時之工傷該事故屬於須提報的製程安全事件
15 一名作業員行經一個設計不良的蒸汽卻水器時被外洩的蒸汽燙傷腳踝造成損失工時之工傷
該事故屬於須提報的製程安全事件因為雖然一次阻絕設施失效洩漏出的是蒸汽(而非碳氫化合物
或化學物質)但損失工時之工傷是由於洩漏物質的物理狀態所導致的
16 一個密閉空間依照計畫以氮氣吹清一名承攬商繞過安全管制進入該密閉空間因而死亡該事
故屬於須提報的死亡事件但不屬於須提報的製程安全事件因為其中不涉及非計劃或失控的一
次阻絕設施失效
17 情況同上惟這次氮氣是非刻意洩漏進入該局限空間該事故屬於須提報的製程安全事件(同時也
是一起死亡事件)因為該名承攬商的死亡與非計劃的一次阻絕設施失效有關
22
18 一名作業員因硫化氫(H2S)警報在進行應變處理時昏倒若警報確實是因非計劃或失控的 H2S 一次
阻絕設施失效的外洩事件該事故便屬於須提報的製程安全事件若警報是一個假警報則該事
故便不屬於須提報的製程安全事件因為沒有真正的化學品洩漏發生
管線
19 一條管線破漏1 小時內洩漏 2000 磅(900 公斤)易燃蒸氣到地面但洩漏位置在廠區內很偏僻的
地點該事故仍屬於須提報的製程安全事件因為ldquo偏僻rdquo不是提報與否的考量因素
與化學物質外洩無關之火災或能量釋放事故
一般通則而言唯有當火災或能量釋放事故是因化學物質洩漏所造成或其發生導致化學物質洩漏
超過提報恕限值這些事故才屬於須提報的製程安全事件實例包括
20 一場電氣火災影響製程操作導致甲苯洩漏 400 公斤該事故屬於須提報的製程安全事件因為
化學物質洩漏已超過甲苯的 100 公斤提報恕限值
21 發生電氣火災停電或任何公用資源供應中斷可能造成工廠停工及可能引起設備損失超過
$2500 美元(如因非正常停工導致反應器或設備損壞)但並未造成超過恕限值的化學物質洩漏
亦未造成死亡或嚴重工傷該事故不屬於須提報的製程安全事件因為設備損壞並非化學製程火
災爆炸造成且化學物質洩漏並未超過恕限值
海上運輸船
22 一艘由公司營運的海上運輸船在船上發生ldquo急性rdquo易燃物質外洩洩漏量超過 100 公斤該事故不
屬於須提報的製程安全事件因為除非海上運輸船是為了輸送半成品或產品而與煉油石化或化
學製造廠的設施相連接否則其洩漏事故便不被視為製程安全事件
23 一艘第三方駁船由一艘拖船推向碼頭結果撞上公司的碼頭駁船的一個船艙破裂且造成
1000 公斤柴油洩漏到海中該事故不屬於須提報的製程安全事件因為駁船當時並非停泊在碼
頭內且其作業並非在進行半成品或產品之輸送
卡車與軌道車
24 一輛公司的軌道車在運輸途中出軌造成超過 1000 公斤汽油洩漏該事故不屬於須提報的製程
安全事件因為在公司廠區外發生的軌道車事故不被視為與製程安全有關
23
25 一輛第三方卡車拖車在公司廠區內翻覆造成ldquo急性rdquo汽油洩漏超過 1000 公斤這事故不屬於須
提報的製程安全事件因為卡車拖車當時已不再與裝卸設備連接然而我們建議會員公司另
行訂定運輸安全事故指標將這類事故記錄下來
26 一位合約卡車作業者正在卸載液鹼時發生軟管脫落造成空氣中氣霧和或液鹼液洩漏 2500 公
斤該事故屬於須提報的製程安全事件因為洩漏量已超過液鹼的 100 公斤恕限值且事故發生
前卡車仍與裝卸設備相連接著
辦公建築
27 綜合辦公大樓發生鍋爐火災造成總計$75000 美元的直接成本損失該事故不屬於須提報的製
程安全事件因為辦公大樓事故不被視為與製程安全有關
人機介面事故
28 一名操作技術員在聚合物工廠的終端設備旁作業時受傷這傷害是因機械的人機介面的設備而
造成該事故不屬於須提報的製程安全事件因為技術員受傷並非因危險物質一次阻絕設施失效
而造成的
混合物
29 若混合物本身有 GHS 分類可利用其分類確定恕限值若混合物本身沒有 GHS 分類則可計算混
合物中每個單一組成分之洩漏量(公斤)相對於個別成分恕限值之比值作為其對混合物恕限值之
lsquo加權rsquo貢獻譬如若混合物在 1小時內的洩漏量為 100公斤其中包含 05公斤分類為劇毒 H300
的物質45 公斤分類為 H301 的物質40 公斤另一種分類為 H 開頭的物質其餘 55 公斤則為沒
有 GHS 分類的水分此混合物之計算式為051 + 4510 + 40100 = 05 + 045 + 04 = 135超過
1因此該事故被視為須提報的製程安全事件雖然混合物個別成分之洩漏量均未超過各該物質
本身的恕限值
直接損失成本
30 此一門檻所考慮的成本應為可直接歸因於火災或爆炸的成本譬如設備及結構損壞的重置成本
修理成本環境清理支出緊急應變和罰款直接成本不包括間接成本譬如業務機會損失設
備停機造成之利潤損失取得或運轉臨時設施之成本或為滿足顧客需求取得替代產品的成本
(產品損失)
24
31 範例連接到氣體處理系統的排放管發生易燃氣體外漏同時製程出現問題導致空氣進入同
一條排放管結果發生爆炸過高的壓力損壞了排放管及其相關上游設備包括一個密封罐並
未造成人員受傷修理成本約$12000 美元該事故屬於須提報的製程安全事件因為爆炸及火
災導致設備修理成本超過門檻
32 範例一次製程安全事件後公司又發生一種非常特殊的 GHS 第 5 類產品洩漏 50 公斤造成
$2000 美元的設備損失洩漏的產品是一種非常特別的混合物公司須負擔超過$50000 美元因
產品耗損而產生之材料成本該事故不屬於須提報的製程安全事件因為 GHS 第 5 類產品洩漏的
提報門檻為 100 公斤且產品耗損不被計入直接損失成本
天然災害
33 天然災害可能對化學製程作業構成重大風險且對製程設備造成損壞導致危害物質一次阻絕設
施失效當一種或多種天然災害被認為可能對工廠作業造成影響時製程安全和作業系統應從危
害及後果分析工廠機器設備設計公用設施失效及製程停工之操作程序緊急應變計畫及應變
措施等方面界定潛在風險進行防範
天然災害類型包括颶風及颱風(包括伴隨而來的風暴潮)水災龍捲風地震超強對流風暴(直
線風暴)野火火山爆發海嘯和山崩
若公司廠房設施遭遇天然災害且其後果觸發一種或以上提報門檻該事故便屬於須提報製程安
全事件
預防性公眾應變
34 預防性公眾應變是基於謹慎的態度所採取的一種措施譬如當發生一次阻絕設施失效時公司
可能在尚未進行任何評估(如方向與洩漏點的距離等等)前便要求全體工人就地避難又
如地方權責官員(如消防警察民防緊急應變管理部門)在獲報一家公司發生製程安全事件
後為防lsquo萬一rsquo風向改變或基於可能受到波及的人口敏感族群(如學童或老年人)可能在尚未接
獲明確資訊前便下令社區就地避難或疏散或採取公眾保護措施(如道路封閉)
製程附屬倉庫
35 製程附屬倉庫指的是位於廠內用於儲存將投入於生產製程或產自於製程之原料半成品或成品的
倉庫從製程的觀點看來製程附屬倉庫相當於一個大型儲槽但這些原料半成品或成品並不
是儲存在一的大型容器中而是裝在較小的容器裡(如太空包大桶桶罐等)
25
Appendix C ndash List of RCLG Taskforce Members
Name Affiliation
Peter Schmelzer Bayer CEFIC - Chairman
Americo Diniz Carvalho Neto Braskem
Bradford Johnson American Chemistry Council
David Cummings DuPont
Debra Phillips American Chemistry Council
Hans Schwarz BASF
Kathryn Walton Plastics and Chemicals Industries Association
Kazuyuki Akita Japanese Chemical Industry Association
Kelly Keim ExxonMobil Chemical Company API Representative
Kenan Stevick Dow
Kiyokazu Murata Japanese Chemical Industry Association
Larry Bowler SABIC
Lorna Young Chemical Industry Association of Canada
Louisa Nara Center for Chemical Process Safety
Luiz Shizuo Harayashiki Associaccedilatildeo Brasileira da Induacutestria Quiacutemica
Masatoshi Kumamoto Japanese Chemical Industry Association
Milton Lacerda Petrobras
Phil Scott Chemical Industries Association
Piet Knijff DSM European Process Safety Centre
Scott Donaldson and Eamon Chandler
Shell
Scott Wallace Olin Corporation
Shakeel Kadri Air Products and Chemicals Inc
26
附錄 D ndash 詳細活動時程表
2016 年 2017 年 2018 年 2019 年 2020 年
2 ndash 4 月
RCLG PS 先導計畫
5 月 ndash
針對準則進行調整釐清
6 月 向 RCLG 和 ICCA 董事會報
告先導計畫執行結果
7 ndash 12 月 RCLG 協會考量準
則並為其會員公司發展提報機制
如有需要RCLG可向 ICCA 申請能
力建立基金為會員公司舉辦製程安
全研習會
1 ndash 12 月
RCLG 協會開始向其會員公司蒐集製程安全數據
1 ndash 12 月
如有需要RCLG 各協會運用 RCLG 的基金及專
家舉辦製程安全及績效提報研習會
1 ndash 2 月
擁有數據的協會開始向RCLG 提報製程安全事件
(2017 年數據)
4 月 RCLG 檢討第一個提報循
環的結果挑戰及原始數據(內部)
6 月 RCLG 向 ICCA 董事會呈報
原始數據
7 ndash 12 月 必要時更新及調整準
則
如有需要RCLG 各協會運用 RCLG 的基金及專
家舉辦製程安全及績效提報研習會
1 ndash 2 月
擁有數據的協會開始向RCLG 提報製程安全事件
(2018 年數據)
4 月 RCLG 檢討第二個提報循
環的結果挑戰及原始數據(內部)
6 月 RCLG 向 ICCA 董事會呈報
原始數據
7 ndash 12 月 必要時更新及調整準
則
如有需要RCLG 協會運用 RCLG 的基金及專家
舉辦製程安全及績效提報研習會
1 ndash 2 月
所有協會開始向 RCLG 提報製程安全事件
製程安全事件提報成為
RCLG KPI 衡量指標建議基本集的一部分(2019 年數
據)
4 月 RCLG 檢討第二個提報循
環的結果挑戰及原始數據(內部考量外部提
報)
6 月 RCLG 向 ICCA 董事會呈報
原始數據
27
附錄 E ndash 選擇性 Excel 追蹤表
當會員公司開始追蹤製程安全事件時所有會員公司應採用單一表格以簡化數據分析同時讓所有公司均使用相同的追蹤表RCLG 設
計了一份選擇性追蹤表可供會員公司和協會先行利用之後他們可設計自己的追蹤表
在這裡下載追蹤表
ICCA Process Safety Event Tracking Sheetxlsx
本文件包含三個分頁分別是ldquo聯絡資料rdquoldquo調查表rdquo和儲存下拉式選單選項的ldquo請勿編輯rdquo分頁
備註
附錄 E 追蹤表僅供參考TRCA 將另行提供台灣版表格供會員公司提報
28
後語
台灣化學工業責任照顧協會(Taiwan Responsible Care Association TRCA)成立於 1998 年在台灣推行責任照顧制度已達 20 週年製造商成員
包括台灣主要上市上櫃化工公司會員公司化學品生產製造量約佔全國 80 2016 年台灣化工業的 Chemical Sales 仍站在全球第八名的位
置額度為 630 億歐元化工業總產值達到 34 兆新台幣提供國內 416 萬人工作機會
TRCA 扮演國內廠商與國際制度接軌的角色也是國內化工業與政府機關及利益相關者溝通的橋樑與管道TRCA 會員結構依業務性質分析
涵蓋石化生產化學品製造氣體生產倉儲運輸業化學品貿易業以及工程研發設計等公司TRCA 透過供應鏈及價值鏈推行責任
照顧制度組成毒性化學物質聯防組織協助法規溝通與研析會員名冊請參考 httpwwwtrcaorgtwtrcanwork2aspx
TRCA 於 2010 年成為 ICCA (International Council of Chemical Associations 國際化學工業協會)觀察員ICCA 成立於 1989 年是全球化工製造
業的聯合會也是化學工業與 UNEP OPCW 及 OECD 的交流窗口ICCA 與其會員協會及成員公司致力於邁向永續的未來確保人類健康與
環境安全與保護全球化工業擁有超過 4兆美元的價值影響所有經濟部門ICCA 的會員幾乎在全球每個國家都有商業活動在全球六大
洲推動創新並提供超過 2000 萬個工作機會
台灣化工業在全球占有重要的一席之地在國內產業鏈也位居關鍵位置無論對國內或國際都有身為地球村一員應盡之責我們期許藉由
製程安全指標提報能更進一步提升自我在工安衛生環保與永續發展等面向的績效表現
台灣化學工業責任照顧協會
10452 台北市中山區撫順街 8 號 7 樓
電話02-2585-0552
httpwwwtrcaorgtw
None | |
$2500 to $25000 | |
$25000 to $250000 | |
$250000 to $25000000 | |
More than $25000000 | |
Yes - Using GHS TABLE | |
Yes - Using API RP 754 TABLE | |
NO | |
NA | |
1x le TQ lt 40x | |
40x le TQ lt 160x | |
160x le TQ lt 640x | |
ge 640x TQ | |
Yes le 3 hours | |
Yes 3 hours ge 12 hours | |
Yes 12 hours ge 24 hours | |
Yes ge 24 hours | |
No | |
Small-scale | |
Medium-scale | |
Large-scale | |
No | |
Yes | |
No | |
middot Injury requiring treatment beyond first aid to an employee contractor or subcontractor | |
middot Days Away From Work injury to an employee contractor or subcontractor or middot Injury requiring treatment beyond first aid to a third party | |
middot A fatality of an employee contractor or subcontractor or middot A hospital admission of a third party | |
middot Multiple fatalities of employees contractors or subcontractors or middot multiple hospital admission of third parties or middot A fatality of a third party | |
NA | |
1x le TQ lt 3x | |
3x le TQ lt 9x | |
9x le TQ lt 27x | |
ge 27x TQ |
ICCA Process Safety Pilot Reporting ProgramFebruary 8 2016 | 1 | 2 | 3 | 4 | 5 | 6 | 7 | 8 | 9 | 10 | 12 | 13 | 14 | 15 | |||||||||||||||||||||||
SAFETY Details(Meeting Local Regulations) | Direct Cost from Fire or Explosion | Community Impact | Environmental Impact | Material Released(Measured using the 1 Hour Rule) | |||||||||||||||||||||||||||||||||
Company Association Details | |||||||||||||||||||||||||||||||||||||
GHS | API - RP 754 | ||||||||||||||||||||||||||||||||||||
Company or Assocation Name | Headquarter Association | Location of Event Ex - City State amp Country | Date and Time of Event | Safety InjuryDid the Event result in a Recordable Lost Time Accident or Fatality or Hospital admission of anyone on or off siteUse Drop Down Menu | Safety InjuryIf yes please insert the total number of injuries | Safety InjuryFor puropses of utilizing the Severity Table please indicate the level of severity by chosing the MOST SEVERE classification that describes your incidentUse Drop Down Menu | Safety InjuryDid the incident involve Fatalities If so how many total fatalities If none enter Zero | Safety InjuryPlease Report Total Employee Hours for Calendar Year 2015 | Safety InjuryPlease Report Total Contractor Hours for Calendar Year 2015 | Direct Cost Did the Event result in Direct Damage CostUse Drop Down Menu | Direct Cost If so how muchAmount is in US DollarsUse Drop Down Menu | Community ImpactDid the event result inbull Officially declared shelter-in-place or officially declared evacuation (on or off site)ORbull Precautionary off site shelter in place or evacuation Use Drop Down Menu | Environmental ImpactDid the event result inAcute Environmental Remediation CostIf so indicate the amount in US DollarsUse Drop Down Menu | Material ReleasedDid the Event result in an Acute Release of material beyond one of the two threshold tablesIf so indicate which Threshold Table you used to make this determinationUse Drop Down Menu | Material ReleasedIf so indicate the amount released USING GHS CLASSIFICATION TABLEUse Drop Down Menu | Material ReleasedIf so indicate the amount released USING THE THRESHOLD TABLE FROM API RP-754Use Drop Down Menu | Material ReleasedIf available please indicate the material released | ||||||||||||||||||||
1 | ABC Chemical Company | American Chemistry Council | Washington DC - USA | January 4 2016 | Yes | 2 | middot Days Away From Work injury to an employee contractor or subcontractor or middot Injury requiring treatment beyond first aid to a third party | 0 | 5525000 | 1500250 | No | $2500 to $25000 | Yes le 3 hours | $2500 to $25000 | Yes - Using GHS TABLE | 40x le TQ lt 160x | NA | Chlorine | |||||||||||||||||||
2 | XYZ Chemical Company | American Chemistry Council | Washington DC - USA | 5-Jan-16 | Yes | 1 | middot Injury requiring treatment beyond first aid to an employee contractor or subcontractor | 0 | 5525000 | 1500250 | Yes | $2500 to $25000 | No | $2500 to $25000 | Yes - Using API RP 754 TABLE | NA | 3x le TQ lt 9x | Benzene | |||||||||||||||||||
3 | |||||||||||||||||||||||||||||||||||||
4 | |||||||||||||||||||||||||||||||||||||
5 | |||||||||||||||||||||||||||||||||||||
6 | |||||||||||||||||||||||||||||||||||||
7 | |||||||||||||||||||||||||||||||||||||
8 | |||||||||||||||||||||||||||||||||||||
9 | |||||||||||||||||||||||||||||||||||||
10 | |||||||||||||||||||||||||||||||||||||
11 | |||||||||||||||||||||||||||||||||||||
12 | |||||||||||||||||||||||||||||||||||||
13 | |||||||||||||||||||||||||||||||||||||
14 | |||||||||||||||||||||||||||||||||||||
15 | |||||||||||||||||||||||||||||||||||||
16 | |||||||||||||||||||||||||||||||||||||
17 | |||||||||||||||||||||||||||||||||||||
18 | |||||||||||||||||||||||||||||||||||||
19 | |||||||||||||||||||||||||||||||||||||
20 | |||||||||||||||||||||||||||||||||||||
21 | |||||||||||||||||||||||||||||||||||||
22 | |||||||||||||||||||||||||||||||||||||
23 | |||||||||||||||||||||||||||||||||||||
24 | |||||||||||||||||||||||||||||||||||||
25 | |||||||||||||||||||||||||||||||||||||
Zero or None | Yes - Duration Unknown | ||||||||||||||||||||||||||||||||||||
Processes | Mode of Operation | Type of material released | Status of Operation | ||||
REFINING | Start-up | Flammable | Open | ||||
Alkylation HF | Planned shutdown | Combustible | Closed | ||||
Alkylation sulfuric | Emergency shutdown | Toxic | |||||
BitumenResidAsphalt | Normal | Corrosive | Tier 1 Acute Releases | ||||
Calcining | Upset | Utilities | No Release | ||||
Coking | Turnaround | Other | Category 1 | ||||
Crude | Routine maintenance | Category 2 | |||||
Desulfurization | Temporary | Evacuation | Category 3 | ||||
FCC | Other | Yes | Category 4 | ||||
Gas Treating | No | Category 5 | |||||
Hydrogen | Point of Release | Category 6 | |||||
Hydrotreating | Pump | Fire | Category 7 | ||||
Hydrocracking | Compressor | Yes | Multiple Categories | ||||
Isom | BlowerFan | No | |||||
MarineJetty | Pressure Vessel | lt $2500 | |||||
Reforming | FilterCoalescer | ||||||
Sulfur recovery | Furnace | PRDs | |||||
Vapor recoverylight ends | Boiler | Directly to Atmosphere | |||||
Wastewater | Heat exchanger | via Downstream Destructive Device | |||||
REFINING amp PETROCHEMICAL | Cooling Tower | No | |||||
Tank FarmStorage FacilityOffsite | Piping system | Yes | |||||
UtilitiesSteam PlantCogeneration | Reactor | No | |||||
Other | Atmospheric tank | ||||||
PETROCHEMICAL | FlareRelief System | Acute release above thresholds | |||||
CO H2 | Other | Yes | |||||
LNG | No | ||||||
Methane | Events | ||||||
Methanol | No Tier 1 Events | Indoor Outdoor | |||||
Methyl Mercaptan | No Tier 2 Events | No Release | |||||
Formaldehyde | No Tier 1 or Tier 2 Events | Indoor | |||||
Formaldehyde derivatives | NA | Outdoor | |||||
Acetic Acid | |||||||
Acetic Acid derivatives | Event Type | ||||||
Ethane | Injury | ||||||
Ethylene | Fire | ||||||
Ethanol | Explosion | ||||||
Ethylene oxide | PRD Discharge | ||||||
Ethylene derivatives | Acute Release | ||||||
Polyethylene | |||||||
Ethylene dichloride | General | ||||||
Ethylene dichloride derivatives | Yes | ||||||
Ethyl benzene | No | ||||||
Ethyl benzene derivatives | |||||||
Polystyrene | |||||||
Styrene-Butadiene | |||||||
Propane | |||||||
Propylene | |||||||
Polypropylene | |||||||
Isopropanol | |||||||
Propylene oxide | |||||||
Propylene oxide derivatives | |||||||
Butane | |||||||
Isobutane | |||||||
Isobutene | |||||||
Butadiene | |||||||
MTBE | |||||||
ETBE | |||||||
Pentane | |||||||
Hexane | |||||||
Cyclohexane | |||||||
Hexanol | |||||||
Aromatics Derivatives | |||||||
Benzene | |||||||
Toluene | |||||||
Xylene | |||||||
Para Xylene | |||||||
Amines Derivatives | |||||||
TDA MDA IPDA etc | |||||||
Isocyanates | |||||||
Specialty Chemicals | |||||||
LoadingUnloading | |||||||
Pilot Plant |
Instructions | ||||||||||||||
Step 1 | Complete the Contact Tab with your contact information and company information | |||||||||||||
Be sure to note the region of your reporting (IE North America France Japan etc) | ||||||||||||||
Survey on Process Safety Events | ||||||||||||||
Step 2 | Complete the survey one line per Process Safety Event for your companyregion | |||||||||||||
ALL REPORTED DATA SHOULD BE FROM CALENDAR YEAR 2017 | ||||||||||||||
Step 3 | Return completed survey to | |||||||||||||
Company Name | ||||||||||||||
Contact Person | All Surveys Due by xxx date | |||||||||||||
Address | ||||||||||||||
Fax | ||||||||||||||
Telephone | ||||||||||||||
Region | ||||||||||||||
None | |
$2500 to $25000 | |
$25000 to $250000 | |
$250000 to $25000000 | |
More than $25000000 | |
Yes - Using GHS TABLE | |
Yes - Using API RP 754 TABLE | |
NO | |
NA | |
1x le TQ lt 40x | |
40x le TQ lt 160x | |
160x le TQ lt 640x | |
ge 640x TQ | |
Yes le 3 hours | |
Yes 3 hours ge 12 hours | |
Yes 12 hours ge 24 hours | |
Yes ge 24 hours | |
No | |
Small-scale | |
Medium-scale | |
Large-scale | |
No | |
Yes | |
No | |
middot Injury requiring treatment beyond first aid to an employee contractor or subcontractor | |
middot Days Away From Work injury to an employee contractor or subcontractor or middot Injury requiring treatment beyond first aid to a third party | |
middot A fatality of an employee contractor or subcontractor or middot A hospital admission of a third party | |
middot Multiple fatalities of employees contractors or subcontractors or middot multiple hospital admission of third parties or middot A fatality of a third party | |
NA | |
1x le TQ lt 3x | |
3x le TQ lt 9x | |
9x le TQ lt 27x | |
ge 27x TQ |
ICCA Process Safety Pilot Reporting ProgramFebruary 8 2016 | 1 | 2 | 3 | 4 | 5 | 6 | 7 | 8 | 9 | 10 | 12 | 13 | 14 | 15 | |||||||||||||||||||||||
SAFETY Details(Meeting Local Regulations) | Direct Cost from Fire or Explosion | Community Impact | Environmental Impact | Material Released(Measured using the 1 Hour Rule) | |||||||||||||||||||||||||||||||||
Company Association Details | |||||||||||||||||||||||||||||||||||||
GHS | API - RP 754 | ||||||||||||||||||||||||||||||||||||
Company or Assocation Name | Headquarter Association | Location of Event Ex - City State amp Country | Date and Time of Event | Safety InjuryDid the Event result in a Recordable Lost Time Accident or Fatality or Hospital admission of anyone on or off siteUse Drop Down Menu | Safety InjuryIf yes please insert the total number of injuries | Safety InjuryFor puropses of utilizing the Severity Table please indicate the level of severity by chosing the MOST SEVERE classification that describes your incidentUse Drop Down Menu | Safety InjuryDid the incident involve Fatalities If so how many total fatalities If none enter Zero | Safety InjuryPlease Report Total Employee Hours for Calendar Year 2015 | Safety InjuryPlease Report Total Contractor Hours for Calendar Year 2015 | Direct Cost Did the Event result in Direct Damage CostUse Drop Down Menu | Direct Cost If so how muchAmount is in US DollarsUse Drop Down Menu | Community ImpactDid the event result inbull Officially declared shelter-in-place or officially declared evacuation (on or off site)ORbull Precautionary off site shelter in place or evacuation Use Drop Down Menu | Environmental ImpactDid the event result inAcute Environmental Remediation CostIf so indicate the amount in US DollarsUse Drop Down Menu | Material ReleasedDid the Event result in an Acute Release of material beyond one of the two threshold tablesIf so indicate which Threshold Table you used to make this determinationUse Drop Down Menu | Material ReleasedIf so indicate the amount released USING GHS CLASSIFICATION TABLEUse Drop Down Menu | Material ReleasedIf so indicate the amount released USING THE THRESHOLD TABLE FROM API RP-754Use Drop Down Menu | Material ReleasedIf available please indicate the material released | ||||||||||||||||||||
1 | ABC Chemical Company | American Chemistry Council | Washington DC - USA | January 4 2016 | Yes | 2 | middot Days Away From Work injury to an employee contractor or subcontractor or middot Injury requiring treatment beyond first aid to a third party | 0 | 5525000 | 1500250 | No | $2500 to $25000 | Yes le 3 hours | $2500 to $25000 | Yes - Using GHS TABLE | 40x le TQ lt 160x | NA | Chlorine | |||||||||||||||||||
2 | XYZ Chemical Company | American Chemistry Council | Washington DC - USA | 5-Jan-16 | Yes | 1 | middot Injury requiring treatment beyond first aid to an employee contractor or subcontractor | 0 | 5525000 | 1500250 | Yes | $2500 to $25000 | No | $2500 to $25000 | Yes - Using API RP 754 TABLE | NA | 3x le TQ lt 9x | Benzene | |||||||||||||||||||
3 | |||||||||||||||||||||||||||||||||||||
4 | |||||||||||||||||||||||||||||||||||||
5 | |||||||||||||||||||||||||||||||||||||
6 | |||||||||||||||||||||||||||||||||||||
7 | |||||||||||||||||||||||||||||||||||||
8 | |||||||||||||||||||||||||||||||||||||
9 | |||||||||||||||||||||||||||||||||||||
10 | |||||||||||||||||||||||||||||||||||||
11 | |||||||||||||||||||||||||||||||||||||
12 | |||||||||||||||||||||||||||||||||||||
13 | |||||||||||||||||||||||||||||||||||||
14 | |||||||||||||||||||||||||||||||||||||
15 | |||||||||||||||||||||||||||||||||||||
16 | |||||||||||||||||||||||||||||||||||||
17 | |||||||||||||||||||||||||||||||||||||
18 | |||||||||||||||||||||||||||||||||||||
19 | |||||||||||||||||||||||||||||||||||||
20 | |||||||||||||||||||||||||||||||||||||
21 | |||||||||||||||||||||||||||||||||||||
22 | |||||||||||||||||||||||||||||||||||||
23 | |||||||||||||||||||||||||||||||||||||
24 | |||||||||||||||||||||||||||||||||||||
25 | |||||||||||||||||||||||||||||||||||||
Zero or None | Yes - Duration Unknown | ||||||||||||||||||||||||||||||||||||
Processes | Mode of Operation | Type of material released | Status of Operation | ||||
REFINING | Start-up | Flammable | Open | ||||
Alkylation HF | Planned shutdown | Combustible | Closed | ||||
Alkylation sulfuric | Emergency shutdown | Toxic | |||||
BitumenResidAsphalt | Normal | Corrosive | Tier 1 Acute Releases | ||||
Calcining | Upset | Utilities | No Release | ||||
Coking | Turnaround | Other | Category 1 | ||||
Crude | Routine maintenance | Category 2 | |||||
Desulfurization | Temporary | Evacuation | Category 3 | ||||
FCC | Other | Yes | Category 4 | ||||
Gas Treating | No | Category 5 | |||||
Hydrogen | Point of Release | Category 6 | |||||
Hydrotreating | Pump | Fire | Category 7 | ||||
Hydrocracking | Compressor | Yes | Multiple Categories | ||||
Isom | BlowerFan | No | |||||
MarineJetty | Pressure Vessel | lt $2500 | |||||
Reforming | FilterCoalescer | ||||||
Sulfur recovery | Furnace | PRDs | |||||
Vapor recoverylight ends | Boiler | Directly to Atmosphere | |||||
Wastewater | Heat exchanger | via Downstream Destructive Device | |||||
REFINING amp PETROCHEMICAL | Cooling Tower | No | |||||
Tank FarmStorage FacilityOffsite | Piping system | Yes | |||||
UtilitiesSteam PlantCogeneration | Reactor | No | |||||
Other | Atmospheric tank | ||||||
PETROCHEMICAL | FlareRelief System | Acute release above thresholds | |||||
CO H2 | Other | Yes | |||||
LNG | No | ||||||
Methane | Events | ||||||
Methanol | No Tier 1 Events | Indoor Outdoor | |||||
Methyl Mercaptan | No Tier 2 Events | No Release | |||||
Formaldehyde | No Tier 1 or Tier 2 Events | Indoor | |||||
Formaldehyde derivatives | NA | Outdoor | |||||
Acetic Acid | |||||||
Acetic Acid derivatives | Event Type | ||||||
Ethane | Injury | ||||||
Ethylene | Fire | ||||||
Ethanol | Explosion | ||||||
Ethylene oxide | PRD Discharge | ||||||
Ethylene derivatives | Acute Release | ||||||
Polyethylene | |||||||
Ethylene dichloride | General | ||||||
Ethylene dichloride derivatives | Yes | ||||||
Ethyl benzene | No | ||||||
Ethyl benzene derivatives | |||||||
Polystyrene | |||||||
Styrene-Butadiene | |||||||
Propane | |||||||
Propylene | |||||||
Polypropylene | |||||||
Isopropanol | |||||||
Propylene oxide | |||||||
Propylene oxide derivatives | |||||||
Butane | |||||||
Isobutane | |||||||
Isobutene | |||||||
Butadiene | |||||||
MTBE | |||||||
ETBE | |||||||
Pentane | |||||||
Hexane | |||||||
Cyclohexane | |||||||
Hexanol | |||||||
Aromatics Derivatives | |||||||
Benzene | |||||||
Toluene | |||||||
Xylene | |||||||
Para Xylene | |||||||
Amines Derivatives | |||||||
TDA MDA IPDA etc | |||||||
Isocyanates | |||||||
Specialty Chemicals | |||||||
LoadingUnloading | |||||||
Pilot Plant |
Instructions | ||||||||||||||
Step 1 | Complete the Contact Tab with your contact information and company information | |||||||||||||
Be sure to note the region of your reporting (IE North America France Japan etc) | ||||||||||||||
Survey on Process Safety Events | ||||||||||||||
Step 2 | Complete the survey one line per Process Safety Event for your companyregion | |||||||||||||
ALL REPORTED DATA SHOULD BE FROM CALENDAR YEAR 2017 | ||||||||||||||
Step 3 | Return completed survey to | |||||||||||||
Company Name | ||||||||||||||
Contact Person | All Surveys Due by xxx date | |||||||||||||
Address | ||||||||||||||
Fax | ||||||||||||||
Telephone | ||||||||||||||
Region | ||||||||||||||
10
製程安全事件判定準則
A 涉及化學品
直接涉及某種化學物質或化學製程
製程安全事件或事故必須直接涉及化學物質或化學製程就此而言ldquo製程rdquo一詞泛指包含
石化生產所需要之設備和技術包括反應器儲槽管線鍋爐冷卻水塔和冷凍系
統helliphellip等未直接涉及化學物質或製程的事件無須提報譬如辦公大樓起火(即使該辦公大
樓位在廠區內亦然)
B 地點
事故發生在廠內之生產配銷儲存公用或試驗工廠
發生在廠內之生產配銷儲存(包括活動儲存區如倉庫 ndash 參見ldquo常見問題集rdquo)公用及
試驗工廠凡符合提報指標及定義的事故包括在廠區管理下之槽罐區輔助支援區(如
鍋爐室和廢水處理廠)和配銷管線所有須提報之事件應由負責該事故地點運作的公司
負提報之責此一規定亦適用於發生在承攬商作業區域內的事故在代工作業和多方共同
作業廠區負責運作該發生事故單位的公司應記錄事故始末並將之納入其提報中
C 物質洩漏
製程單元發生物質外洩或能量釋放(如火災爆炸和內爆)
物質外洩 ndash 製程任何物質發生非預期或無法控制的洩漏或釋放包括非毒性及不可燃物質
(如蒸汽熱水氮氣壓縮二氧化碳或壓縮空氣)且達到本文件所列四類提報門檻之一
項或以上之後果
在防治系統(如洗滌塔或廢氣燃燒塔)正常運作狀況下只要沒有任何洩漏或排放量超過
法定許可值即使排放到廢氣燃燒塔或滌氣塔仍被視為處於一次阻絕設施內然若排
放到二次阻絕設施(如廢水處理或防溢堤)將被視為製程安全事件因為物質已離開主要製
程系統
11
D 提報門檻
須提報製程安全事件必須達到以下提報門檻之一
1 安全 工傷
導致記錄性傷害(OSHA)損失工時或死亡或廠內外任何人員因此而須住院治療
記錄性傷害是指與工作有關所造成的傷害導致死亡暫時全失能工作受限制或需調整職
務較輕傷害嚴重之醫療處理失去意識或經醫師或其他合格醫療專業人員診斷為重大
傷害
損失工時傷害和死亡是指因製程相關的一次阻絕設施失效火災或爆炸導致以下任何一種
結果
員工(損失工時或死亡)
承攬商及再承攬商 (損失工時或死亡)
第三方(如來賓訪客快遞員)(受傷疾病導致住院治療或死亡)
住院治療是指醫院或其他具有住院病患保健設施的醫療單位正式接受病患住院提供病患
食宿及醫療護理且病患接受治療至少留置至隔日僅在醫院急診室治療或過夜處理不屬
於ldquo住院治療rdquo的定義範圍
須提報之工傷或死亡事件例如在清理作業期間因蒸汽洩漏造成人員燒燙傷壓力測試期間
帽蓋因受壓脫落造成人員身體傷害或取樣作業時因物質外濺造成人員化學灼傷無須提
報之工傷或死亡事件例如在執行維修作業時從高處的工作台墜落實驗室或辦公大樓火災
造成人員燒燙傷或挖掘工程塌陷造成人員傷害這些案例均與因製程造成的能量釋放或
物質洩漏無直接關聯
2 直接損失成本
火災爆炸或為避免補救環境損害之必要清理作業導致$2500美元以上的直接成本支出
此提報門檻所考慮的成本應為可直接歸因於火災或爆炸的成本譬如設備及結構損壞的重
置成本修理成本環境清理(廠內及廠外)支出緊急應變和罰款直接成本不包括間接
成本譬如業務機會損失設備停機造成之利潤損失取得或運轉臨時設施之成本或為
滿足顧客需求取得替代產品的成本(產品損失)
12
3 就地避難 疏散
官方宣告就地避難或疏散(廠內或廠外)或廠外預防性就地避難或疏散
就提報目的而言官方宣告就地避難或疏散(廠內或廠外)或廠外預防性就地避難或疏散
即達到此提報門檻
官方宣告 ndash 由地方權責機關(如消防警察民防緊急應變管理部門)或經授權的代表(如
派駐公司官員)下達的社區行動(如就地避難或疏散)宣告
預防性宣告 ndash 預防性公眾應變是基於謹慎的態度所採取的一種措施權責地方主管機關或經
授權的代表經合理判斷認定為維護公眾健康及安全發布必須採取就地避難或疏散之預
防性措施
就地避難 ndash 利用結構體及其內部空氣以暫時讓人員與室外危害性氣體隔離
疏散 ndash 基於安全或防護理由讓人員離開某處所的行動或過程
4 洩漏恕限值
超過表 1 中所列 GHS 恕限值或表 2 中所列 API 754 標準 Tier II 製程安全洩漏恕限值之一的
急性洩漏事件(洩漏量以單位小時計量)
如ldquo執行摘要rdquo所述ICCA 製程安全事件之定義容許採用 ICCA 依據化學品全球調和制度
(GHS)健康危害分級為基礎所發展的提報標準或依據聯合國危險物品(UNDG)分類為基礎
所定義之 RP-754 二級製程安全事件(Tier II) 之提報標準GHS 恕限值詳見表 1各會員公司
可自行決定選擇哪一個表中的提報恕限值並在全球採用單一制度
ldquo急性rdquo洩漏 ndash易燃性可燃性或毒性化學物質從一次阻絕設施(如容器或管線)洩漏其
任一單位小時之洩漏量超過化學物質洩漏恕限量分述於表 1 中的 GHS 分類和表 2 中的
API 754 標準 Tier II 製程安全洩漏恕限值
洩壓裝置前述所定義之ldquo急性rdquo洩漏包括洩漏或排放至妥善設計且運作中的洩壓裝置若
洩漏或排放量達到表 1 中所列 GHS 恕限值或表 2 中所列 API 754 標準 Tier II 製程安全洩漏
恕限值且導致下列四種後果之任一項或以上之後果
1 二相排放或夾帶液體的排放液滴沉降至地面造成污染
2 排放至具潛在危險性的地點
3 廠內就地避難或疏散不包括預防性廠內就地避難或疏散
4 啟動公眾保護措施(如道路封閉)包括預防性公眾保護措施
13
洩漏或排放至妥善設計且運作中的洩壓裝置(如廢氣燃燒塔洗滌塔等)若其情況未達前
述四項標準中任何一項則不必提報
欲查看 API RP-754 標準可登入以下網站下載此標準httpwwwapiorgenvironment-
health-and-safetyprocess-safetyprocess-safety-standardsstandard-rp-754
一小時法則
為便於衡量此項指標提報與否洩漏恕限值是以物質在任一小時內之洩漏量為標準若任
一小時或更短時間內物質洩漏量達到或超過須提報恕限值該事故便屬於須提報的製程安
全事件急性洩漏事故通常不會超過一小時若無法確定洩漏持續時間則應假設其為一
小時
一次阻絕設施ndash 用來作為主要容器或用於運送或輸送物質之槽罐船隻管線軌道車
或設備主要容器在設計上可能包含二次阻絕設施系統以抑制及控制洩漏二次阻絕設
施系統包括(但不限於)儲槽防溢堤製程設備周遭的圍堵設施油水分離的排水收集系統
雙層儲槽的外壁等
嚴重程度表 ndash 嚴重程度加權可額外提供有關製程安全事件的有用資訊有助於帶動改善績
效附錄 A 為 RCLG 建議之製程安全事件嚴重程度加權計算方法根據附錄 A 的方法便
可藉由加總與各個後果類別關聯的分數計算出各製程安全事件的嚴重程度加權值ICCA
強烈建議採用嚴重程度加權制度因為此制度有助於提升溝通績效的能力也比較容易讓
利害關係人了解製程安全事件並且此嚴重程度加權值與其他製程安全績效指標提報方
式是不具相互比較性的
14
表 1 ndash GHS 分類表
物理性危害(GHS 2x)
洩漏恕限值(1 小時內)
STOTSpecific target organ toxicity(特定標的器官系統毒性物質)
15
表 2 ndash API RP 754 Tier II 分類表
洩漏恕限類別
物質危害性分類 acdef 恕限值
(戶外洩漏) 恕限值
(戶內b洩漏)
T2-1 TIH A 區物質 ge 05 kg (11 lb) ge 025 kg (055
lb)
T2-2 TIH B 區物質 ge 25 kg (55 lb) ge 125 kg (275
lb)
T2-3 TIH C 區物質 ge 10 kg (22 lb) ge 5 kg (11 lb)
T2-4 TIH D 區物質 ge 20 kg (44 lb) ge 10 kg (22 lb)
T2-5
易燃氣體 或 正常沸點 ≦ 35 (95 degF)閃火點lt23 (73 degF)的液體 或 其他包裝組別 I 類的物質 (酸鹼除外)
ge 50 kg (110 lb) ge 25 kg (55 lb)
T2-6
正常沸點 gt 35 degC (95 degF)閃火點 lt 23 degC (73degF)的液體 或 其他包裝組別 II 類的物質 (酸鹼除外)
ge 100 kg (220 lb) 或
ge 07 bbl
ge 50 kg (110 lb) 或
ge 035 bbl
T2-7
閃火點 gt 23 degC (73 degF)和 lt 60 degC (140 degF)的液體 或 閃火點 gt 60 degC (140 degF)的液體在閃火點或高於閃火點的溫度下洩漏 或 強酸鹼 (定義參見 RP 754 文件草案) 或 UNDG第2類第22部分 (不可燃無毒氣體)空氣除外 或 其他包裝組別 III 類的物質
ge 200 kg (440 lb) 或
ge 14 bbl
ge 100 kg (220 lb) 或
ge 07 bbl
T2-8
閃火點 gt 60 degC (140 degF) 和 lt 93 degC (200 degF)的液體在低於閃火點的溫度下洩漏 或 中度酸鹼
ge 1000 kg
(2200 lb) 或
ge 7 bbl
ge 500 kg
(1100 lb) 或
ge 35 bbl
TIH吸入性毒性危害物(Toxic Inhalation Hazard)
16
一般認為以公斤和磅或以磅和桶為單位的恕限值不盡等同各公司應該選用其中一組計量單位並在
所有紀錄文件中一體適用
在判定一種物質之洩漏恕限類別時首先應從物質之含吸入性毒性(TIH Zone)可燃性(閃火點和沸點)
或腐蝕性(強酸或鹼 vs中度酸或鹼)等特性來判別只有當物質的危險度無法利用上述簡單的特性來判別
時(如遇水反應劇烈)才採用UNDGL包裝組別
a 許多物質具有一種以上危險性正確的危險區(Hazard Zone)或包裝組別(Packing Group)歸屬應遵循DOT
49 CFR 1732a [14]或聯合國危險物品運輸建議書(UNRTDG)第2部分[12]的規定參見附錄F
b 具有四面完整牆(從地板到天花板)地板和屋頂的結構物
c 對於未列於UNDG的溶液無水成分將用TIH區或包裝組別分類溶液之恕限值將根據乾基重量之恕限
值反算
d 對於未知UNDG分類的混合物可計算每種成分在恕限值洩漏中的分量如果各種成分之分量的總和
等於或大於100即表示混合物超過門檻值若混合物有明顯且獨立的毒性及可燃性結果則可分
別計算毒性及可燃性危險度參見附錄EPSE實例amp問題 49ndash53
e 閃火點 gt 60 degC (140 degF) 和 lt 93 degC (200 degF)的液體在低於閃火點的溫度下洩漏無論洩漏量多寡其
一次阻絕設施失效(LOPC)均不屬於Tier 1製程安全事件(PSE)
f 中度酸鹼的一次阻絕設施失效無論洩漏量多寡均不屬於Tier 1製程安全事件
17 (K = 1000 MM = 1000000) (在環境影響類別方面若缺乏既有定義協會和會員公司應議定輸入標準)
附錄 A ndash 嚴重程度表鼓勵所有協會均採用嚴重程度加權制度
事件事故類別
嚴重程度等級
安全人體健康 火災或爆炸導致直接
成本 任 1 小時內物質洩
漏量 社區影響 環境影響[廠外]
4 級
1 分
對員工承攬商或再承攬商造成較輕傷害嚴重之傷害 (符合本地法規)
造成以下直接損失成本
美金$25 K ~ $25 K
洩漏量介於
1x le TQ lt 40x
官方宣告就地避難或疏散 (廠內或廠外) 預防性廠外就地避難或疏散
le 3 小時
重大環境整治成本
$25 K ~ $25 K
3 級
3 分
對員工承攬商或再承攬商造成之需要多日缺勤的傷害
對第三方造成之需要初步急救以外治療的傷害 (符合本地法規)
造成以下直接損失成本
$25 K ~ $250 K
洩漏量介於
40x le TQ lt 160x
官方宣告就地避難或疏散 (廠內或廠外)
預防性廠外就地避難或疏散
3 ~ 12 小時
重大環境整治成本
$25 K ~ $250 K
2 級
9 分
對員工承攬商或再承攬商造成 1 人死亡
對第三方造成 1 人住院治療
(符合本地法規)
造成以下直接損失成本
$250 K ~ $25 MM
洩漏量介於
160x le TQ lt 640x
官方宣告就地避難或疏散 (廠內或廠外)
預防性廠外就地避難或疏散
12 ~ 24 小時
重大環境整治成本
$250 K ~ $25 MM
1 級
27 分
對員工承攬商或再承攬商造成多人死亡
對第三方造成多人住院治療
對第三方造成 1 人死亡 (符合本地法規)
造成以下直接損失成本
ge $25 MM
洩漏量
ge 640x TQ
官方宣告就地避難或疏散 (廠內或廠外)
預防性廠外就地避難或疏散
ge 24 小時
重大環境整治成本
ge $25 MM
18 (K = 1000 MM = 1000000) (在環境影響類別方面若缺乏既有定義協會和會員公司應議定輸入標準)
嚴重程度表(附錄 A)細節說明
附錄 A 之設計目的僅適用於採用 GHS 分類制度(表 1)者如果你的公司係採用 API RP 754Tier II 製程安全指標提報恕限值表(表 2)請使用
API RP 754 製程安全嚴重程度表必須提醒的是依 API RP 754 的標準其嚴重程度表僅適用於一級(Tier I)事故去比較採用不同的嚴重度
表所評估出來的相對嚴重度並無統計上的意義
急性的環境成本 ndash 因製程安全事件造成廠外環境影響所導致之短期清理及物質處置的成本各會員公司可選擇將廠外環境影響相關成本另
外區分一個嚴重程度類別
比率調整指標
利用上述嚴重程度表可產生一系列以事件率為基礎的指標包括
製程安全總事件率 (PSTIR) 總事件次數 x 200000
總工作時數
製程安全事件嚴重程度率(PSESR) (即製程安全事件嚴重程度加權計算公式)
PSESR = 所有事件之總嚴重程度分數總合 x 200000
總工作時數
在計算此一比率時各 4 級事件被分配 1 分各 3 級事件被分配 3 分各 2 級事件被分配 9 分各 1 級事件被分配 27 分理論上每個
製程安全事件至少可分配到 1 分(亦即事件僅在一個類別符合第 4 級事件屬性)至多可分配到 135 分(亦即事件在所有五個類別中均符
合第 1 級事件屬性)
ldquoXrdquo級別製程安全事件率 嚴重度級別ldquoXrdquo之製程安全事件總數 x 200000
員工承攬商amp再承攬商總工作時數
X可以是嚴重度級別 432 或 1 級製程安全事件之總數事件之嚴重度等級是選用五類後果類別中之最嚴重等級
標準化 ndash 在某些協會和會員公司中製程安全事件是採 lsquo每 100 名rsquo員工每名員工每年平均工作時數為 2000 小時為基礎予以標準化因
此在lsquo每 100rsquo名rsquo員工的標準基礎上事件被乘以 200000 工作時數也有些其他協會和會員公司將標準化基礎設定為lsquo每 500 名rsquo員工
因此事件被乘以 1000000 工作時數協會和會員公司應就標準化基礎進行討論共同做成選項結論上述的公式設定為lsquo每 100 名rsquo員工
基礎
19
附錄 B ndash 常見問題集
適用性
我們建議會員公司記錄和提報在其所擁有或運作的工廠內發生的製程安全事件惟以下情況不須提報製
程安全事件
1 源自於公司廠區以外的製程安全事件
2 海上運輸船事故惟船隻為了輸送半成品或產品之目的已經與公司的設施相連接時發生的
事故仍須提報
3 卡車或軌道車事故惟卡車或軌道車為了輸送半成品或產品之目的已經與公司的設施相連
接時發生的事故仍須提報
4 許可證或法規容許之例行排放
5 不會造成製程安全危害的地下污染請注意若洩漏至地下導致地上發生須提報製程安全事
件如釋放出毒性蒸汽或致使易燃液體蓄積成池則不適用本排除條件
6 辦公建築事故(如辦公室暖氣設備爆炸火災外溢洩漏人員受傷或疾病等)
7 與疏散或一次阻絕設施失效無直接關聯之人員安全ldquo滑倒絆倒跌倒rdquo事故
8 沒有與製程相連接之輔助設備的一次阻絕設施(如小樣品瓶)失效事故
9 計劃中和在控制下的物質排放至設計用來收集或排放系統中(請注意物質從一次阻絕設施
在非計劃或非受控制情況下排放至收集或排放系統中則不適用本排除條件)
10 在製程區域外部或保養廠內執行之機械作業
說明與實例 ndash 以 GHS 表 1 為基礎
以下說明和實例有助於在評估須提報製程安全事件(PSE)時釐清可能存在的不確定部分
公司廠區
1 一輛第三方的卡車在公司廠區內卸載易燃產品時發生洩漏進而引起火災造成公司財物損失
$7000 美元(直接成本)雖然該卡車是ldquo由他人操作rdquo但其作業與製程相連接若公司的直接成
本財物損失達到或超過$2500 美元或已達到或超過其他 PSE 提報門檻(如1 人死亡)此事故即
屬於須提報的製程安全事件
2 與前例1 類似的例子載著易燃產品的卡車在廠外運輸途中翻覆引發火災並造成卡車毀損
該事故不屬於須提報的製程安全事件因為當時卡車並未與製程相連接
20
阻絕設施失效
3 儲槽液位計故障造成裝有ldquo易燃液體rdquo產品的儲槽外溢約 700 公斤的液體流入儲槽的防溢堤內
此事故屬於須提報的製程安全事件因為其ldquo急性rdquo洩漏量超過 100 公斤即使是阻絕在二次阻絕
設施防溢堤中亦然
4 一名從事維修工作的承攬商在開啟一個製程阻閥時被噴起的硫酸濺到造成嚴重灼傷和損失工
時的工傷此事故屬於須提報的製程安全事件因為它是涉及物質和一次阻絕設施失效的意外事
件對於因洩漏造成死亡和損工的工傷或疾病事故沒有洩漏恕限值
5 一名作業員開啟品管取樣點進行日常取樣作業時手部被一個破碎的玻璃瓶嚴重割破需要進行
縫合治療縫針造成第二天無法上班該事故不屬於須提報的製程安全事件因為它與一次阻絕
設施失效無關
ldquo急性rdquo洩漏
6 一名作業員在進行天然氣流量高於預期值之異常排除時發現天然氣管線上的一個安全閥門未適
當歸位因此天然氣經由氣液分離桶排放至排氣煙囪經進一步檢查作業員判斷在過去 6 個
月間總共有 100000 公斤天然氣以穩定的速率排放至大氣該事故不屬於須提報的製程安全事
件因為其洩漏速率(每小時約 10 公斤)不算ldquo急性rdquo洩漏(未超過易燃蒸汽每小時 100 公斤的恕限
值)
廢氣燃燒塔amp排放控制裝置 (如洗滌塔)
7 若化學物質被導引至廢氣燃燒塔或排放控制裝置(如洗滌塔)只要該廢氣燃燒塔或控制裝置運作在
正常設計範圍內便不屬於須提報的製程安全事件
8 若廢氣流速超過洗滌塔的設計負荷以致未經吸收的化學物質排出超過恕限值該事故屬於須提報
的製程安全事件(如本文註釋所述)
註釋自取得許可或妥善管理的裝置-包括釋壓裝置發生不預期的排放若 1 小時內洩漏量達到或
超過表 1 或表 2 所列的洩漏恕限值且導致下列四種後果之任一項或以上之後果該事故便屬於
須提報的製程安全事件
o 二相排放或夾帶液體的排放液滴沉降至地面造成污染
o 排放至具潛在危險性的地點)
o 廠內就地避難或疏散不包括預防性廠內就地避難或疏散
o 啟動公眾保護措施(如道路封閉)包括預防性公眾保護措施
21
安全洩壓裝置 系統
9 製程單元發生異常安全閥開啟將洩漏物質釋放到排氣口此釋壓排放裝置是依相關要求設計
的且氣體釋到大氣中並未造成不良後果這不是一個須提報的製程安全事件因為安全閥高
壓破裂盤以及類似的安全裝置是依據 API 521 或者同等的標準設計的且此排放並未造成 (1)
夾帶液體並導致須提報的製程安全事件的後果(譬如損失工時意外死亡火災或爆炸造成$2500
美元或以上的直接成本損失液體或毒性氣體洩漏量達到或超過恕限值(2) 啟動廠內或廠外就地
避難應變或(3)啟動公眾保護措施
10 製程單元發生異常安全閥並未開啟造成設備超壓易燃性氣體從一個法蘭處ldquo急性rdquo漏出來
洩露量超過 100 公斤(一小時內)的恕限值該事故屬於須提報的製程安全事件因為從法蘭處外
漏屬於製程安全事件應提報事項
損工事故
11 一名作業員走路時不慎滑倒造成損失工時之工傷滑倒原因為天氣狀況rdquo長期rdquo油垢的地面和
易滑鞋具該事故不屬於須提報的製程安全事件因為人員安全ldquo滑倒絆倒跌倒rdquo事故若非與
一次阻絕設施失效直接關聯的疏散或應變造成則不屬於須提報的製程安全事件
12 與前例相同的事件惟這次作業員跌倒是因為少量易燃液體外漏(如 1 小時內少於 10 公斤)在採取
相關應變措施時發生該事故屬於須提報的製程安全事件因為作業員係為了應變一次阻絕設施
失效的事故而跌倒若一次阻絕設施失效發生在公司廠區且造成失時工傷或死亡後果該事故
便屬於須提報的製程安全事件對於因洩漏造成死亡和損失工時之工傷事故沒有洩漏量門檻
13 與前例相同的事件惟這次作業員跌倒是在事件結束數小時之後該事故不屬於須提報的製程安
全事件在提報要件中所用的ldquo疏散rdquo和ldquo應變rdquo等術語指的是一次阻絕設施失效和相關緊急應變
活動正在持續中事件結束後滑倒絆倒跌倒(如ldquo事後rdquo清理和補救)不屬於須提報製程安全事件
14 工人在因附近設備一次阻絕設施失效在疏散過程中一名鷹架搭建工人從鷹架梯上跌落造成損
失工時之工傷該事故屬於須提報的製程安全事件
15 一名作業員行經一個設計不良的蒸汽卻水器時被外洩的蒸汽燙傷腳踝造成損失工時之工傷
該事故屬於須提報的製程安全事件因為雖然一次阻絕設施失效洩漏出的是蒸汽(而非碳氫化合物
或化學物質)但損失工時之工傷是由於洩漏物質的物理狀態所導致的
16 一個密閉空間依照計畫以氮氣吹清一名承攬商繞過安全管制進入該密閉空間因而死亡該事
故屬於須提報的死亡事件但不屬於須提報的製程安全事件因為其中不涉及非計劃或失控的一
次阻絕設施失效
17 情況同上惟這次氮氣是非刻意洩漏進入該局限空間該事故屬於須提報的製程安全事件(同時也
是一起死亡事件)因為該名承攬商的死亡與非計劃的一次阻絕設施失效有關
22
18 一名作業員因硫化氫(H2S)警報在進行應變處理時昏倒若警報確實是因非計劃或失控的 H2S 一次
阻絕設施失效的外洩事件該事故便屬於須提報的製程安全事件若警報是一個假警報則該事
故便不屬於須提報的製程安全事件因為沒有真正的化學品洩漏發生
管線
19 一條管線破漏1 小時內洩漏 2000 磅(900 公斤)易燃蒸氣到地面但洩漏位置在廠區內很偏僻的
地點該事故仍屬於須提報的製程安全事件因為ldquo偏僻rdquo不是提報與否的考量因素
與化學物質外洩無關之火災或能量釋放事故
一般通則而言唯有當火災或能量釋放事故是因化學物質洩漏所造成或其發生導致化學物質洩漏
超過提報恕限值這些事故才屬於須提報的製程安全事件實例包括
20 一場電氣火災影響製程操作導致甲苯洩漏 400 公斤該事故屬於須提報的製程安全事件因為
化學物質洩漏已超過甲苯的 100 公斤提報恕限值
21 發生電氣火災停電或任何公用資源供應中斷可能造成工廠停工及可能引起設備損失超過
$2500 美元(如因非正常停工導致反應器或設備損壞)但並未造成超過恕限值的化學物質洩漏
亦未造成死亡或嚴重工傷該事故不屬於須提報的製程安全事件因為設備損壞並非化學製程火
災爆炸造成且化學物質洩漏並未超過恕限值
海上運輸船
22 一艘由公司營運的海上運輸船在船上發生ldquo急性rdquo易燃物質外洩洩漏量超過 100 公斤該事故不
屬於須提報的製程安全事件因為除非海上運輸船是為了輸送半成品或產品而與煉油石化或化
學製造廠的設施相連接否則其洩漏事故便不被視為製程安全事件
23 一艘第三方駁船由一艘拖船推向碼頭結果撞上公司的碼頭駁船的一個船艙破裂且造成
1000 公斤柴油洩漏到海中該事故不屬於須提報的製程安全事件因為駁船當時並非停泊在碼
頭內且其作業並非在進行半成品或產品之輸送
卡車與軌道車
24 一輛公司的軌道車在運輸途中出軌造成超過 1000 公斤汽油洩漏該事故不屬於須提報的製程
安全事件因為在公司廠區外發生的軌道車事故不被視為與製程安全有關
23
25 一輛第三方卡車拖車在公司廠區內翻覆造成ldquo急性rdquo汽油洩漏超過 1000 公斤這事故不屬於須
提報的製程安全事件因為卡車拖車當時已不再與裝卸設備連接然而我們建議會員公司另
行訂定運輸安全事故指標將這類事故記錄下來
26 一位合約卡車作業者正在卸載液鹼時發生軟管脫落造成空氣中氣霧和或液鹼液洩漏 2500 公
斤該事故屬於須提報的製程安全事件因為洩漏量已超過液鹼的 100 公斤恕限值且事故發生
前卡車仍與裝卸設備相連接著
辦公建築
27 綜合辦公大樓發生鍋爐火災造成總計$75000 美元的直接成本損失該事故不屬於須提報的製
程安全事件因為辦公大樓事故不被視為與製程安全有關
人機介面事故
28 一名操作技術員在聚合物工廠的終端設備旁作業時受傷這傷害是因機械的人機介面的設備而
造成該事故不屬於須提報的製程安全事件因為技術員受傷並非因危險物質一次阻絕設施失效
而造成的
混合物
29 若混合物本身有 GHS 分類可利用其分類確定恕限值若混合物本身沒有 GHS 分類則可計算混
合物中每個單一組成分之洩漏量(公斤)相對於個別成分恕限值之比值作為其對混合物恕限值之
lsquo加權rsquo貢獻譬如若混合物在 1小時內的洩漏量為 100公斤其中包含 05公斤分類為劇毒 H300
的物質45 公斤分類為 H301 的物質40 公斤另一種分類為 H 開頭的物質其餘 55 公斤則為沒
有 GHS 分類的水分此混合物之計算式為051 + 4510 + 40100 = 05 + 045 + 04 = 135超過
1因此該事故被視為須提報的製程安全事件雖然混合物個別成分之洩漏量均未超過各該物質
本身的恕限值
直接損失成本
30 此一門檻所考慮的成本應為可直接歸因於火災或爆炸的成本譬如設備及結構損壞的重置成本
修理成本環境清理支出緊急應變和罰款直接成本不包括間接成本譬如業務機會損失設
備停機造成之利潤損失取得或運轉臨時設施之成本或為滿足顧客需求取得替代產品的成本
(產品損失)
24
31 範例連接到氣體處理系統的排放管發生易燃氣體外漏同時製程出現問題導致空氣進入同
一條排放管結果發生爆炸過高的壓力損壞了排放管及其相關上游設備包括一個密封罐並
未造成人員受傷修理成本約$12000 美元該事故屬於須提報的製程安全事件因為爆炸及火
災導致設備修理成本超過門檻
32 範例一次製程安全事件後公司又發生一種非常特殊的 GHS 第 5 類產品洩漏 50 公斤造成
$2000 美元的設備損失洩漏的產品是一種非常特別的混合物公司須負擔超過$50000 美元因
產品耗損而產生之材料成本該事故不屬於須提報的製程安全事件因為 GHS 第 5 類產品洩漏的
提報門檻為 100 公斤且產品耗損不被計入直接損失成本
天然災害
33 天然災害可能對化學製程作業構成重大風險且對製程設備造成損壞導致危害物質一次阻絕設
施失效當一種或多種天然災害被認為可能對工廠作業造成影響時製程安全和作業系統應從危
害及後果分析工廠機器設備設計公用設施失效及製程停工之操作程序緊急應變計畫及應變
措施等方面界定潛在風險進行防範
天然災害類型包括颶風及颱風(包括伴隨而來的風暴潮)水災龍捲風地震超強對流風暴(直
線風暴)野火火山爆發海嘯和山崩
若公司廠房設施遭遇天然災害且其後果觸發一種或以上提報門檻該事故便屬於須提報製程安
全事件
預防性公眾應變
34 預防性公眾應變是基於謹慎的態度所採取的一種措施譬如當發生一次阻絕設施失效時公司
可能在尚未進行任何評估(如方向與洩漏點的距離等等)前便要求全體工人就地避難又
如地方權責官員(如消防警察民防緊急應變管理部門)在獲報一家公司發生製程安全事件
後為防lsquo萬一rsquo風向改變或基於可能受到波及的人口敏感族群(如學童或老年人)可能在尚未接
獲明確資訊前便下令社區就地避難或疏散或採取公眾保護措施(如道路封閉)
製程附屬倉庫
35 製程附屬倉庫指的是位於廠內用於儲存將投入於生產製程或產自於製程之原料半成品或成品的
倉庫從製程的觀點看來製程附屬倉庫相當於一個大型儲槽但這些原料半成品或成品並不
是儲存在一的大型容器中而是裝在較小的容器裡(如太空包大桶桶罐等)
25
Appendix C ndash List of RCLG Taskforce Members
Name Affiliation
Peter Schmelzer Bayer CEFIC - Chairman
Americo Diniz Carvalho Neto Braskem
Bradford Johnson American Chemistry Council
David Cummings DuPont
Debra Phillips American Chemistry Council
Hans Schwarz BASF
Kathryn Walton Plastics and Chemicals Industries Association
Kazuyuki Akita Japanese Chemical Industry Association
Kelly Keim ExxonMobil Chemical Company API Representative
Kenan Stevick Dow
Kiyokazu Murata Japanese Chemical Industry Association
Larry Bowler SABIC
Lorna Young Chemical Industry Association of Canada
Louisa Nara Center for Chemical Process Safety
Luiz Shizuo Harayashiki Associaccedilatildeo Brasileira da Induacutestria Quiacutemica
Masatoshi Kumamoto Japanese Chemical Industry Association
Milton Lacerda Petrobras
Phil Scott Chemical Industries Association
Piet Knijff DSM European Process Safety Centre
Scott Donaldson and Eamon Chandler
Shell
Scott Wallace Olin Corporation
Shakeel Kadri Air Products and Chemicals Inc
26
附錄 D ndash 詳細活動時程表
2016 年 2017 年 2018 年 2019 年 2020 年
2 ndash 4 月
RCLG PS 先導計畫
5 月 ndash
針對準則進行調整釐清
6 月 向 RCLG 和 ICCA 董事會報
告先導計畫執行結果
7 ndash 12 月 RCLG 協會考量準
則並為其會員公司發展提報機制
如有需要RCLG可向 ICCA 申請能
力建立基金為會員公司舉辦製程安
全研習會
1 ndash 12 月
RCLG 協會開始向其會員公司蒐集製程安全數據
1 ndash 12 月
如有需要RCLG 各協會運用 RCLG 的基金及專
家舉辦製程安全及績效提報研習會
1 ndash 2 月
擁有數據的協會開始向RCLG 提報製程安全事件
(2017 年數據)
4 月 RCLG 檢討第一個提報循
環的結果挑戰及原始數據(內部)
6 月 RCLG 向 ICCA 董事會呈報
原始數據
7 ndash 12 月 必要時更新及調整準
則
如有需要RCLG 各協會運用 RCLG 的基金及專
家舉辦製程安全及績效提報研習會
1 ndash 2 月
擁有數據的協會開始向RCLG 提報製程安全事件
(2018 年數據)
4 月 RCLG 檢討第二個提報循
環的結果挑戰及原始數據(內部)
6 月 RCLG 向 ICCA 董事會呈報
原始數據
7 ndash 12 月 必要時更新及調整準
則
如有需要RCLG 協會運用 RCLG 的基金及專家
舉辦製程安全及績效提報研習會
1 ndash 2 月
所有協會開始向 RCLG 提報製程安全事件
製程安全事件提報成為
RCLG KPI 衡量指標建議基本集的一部分(2019 年數
據)
4 月 RCLG 檢討第二個提報循
環的結果挑戰及原始數據(內部考量外部提
報)
6 月 RCLG 向 ICCA 董事會呈報
原始數據
27
附錄 E ndash 選擇性 Excel 追蹤表
當會員公司開始追蹤製程安全事件時所有會員公司應採用單一表格以簡化數據分析同時讓所有公司均使用相同的追蹤表RCLG 設
計了一份選擇性追蹤表可供會員公司和協會先行利用之後他們可設計自己的追蹤表
在這裡下載追蹤表
ICCA Process Safety Event Tracking Sheetxlsx
本文件包含三個分頁分別是ldquo聯絡資料rdquoldquo調查表rdquo和儲存下拉式選單選項的ldquo請勿編輯rdquo分頁
備註
附錄 E 追蹤表僅供參考TRCA 將另行提供台灣版表格供會員公司提報
28
後語
台灣化學工業責任照顧協會(Taiwan Responsible Care Association TRCA)成立於 1998 年在台灣推行責任照顧制度已達 20 週年製造商成員
包括台灣主要上市上櫃化工公司會員公司化學品生產製造量約佔全國 80 2016 年台灣化工業的 Chemical Sales 仍站在全球第八名的位
置額度為 630 億歐元化工業總產值達到 34 兆新台幣提供國內 416 萬人工作機會
TRCA 扮演國內廠商與國際制度接軌的角色也是國內化工業與政府機關及利益相關者溝通的橋樑與管道TRCA 會員結構依業務性質分析
涵蓋石化生產化學品製造氣體生產倉儲運輸業化學品貿易業以及工程研發設計等公司TRCA 透過供應鏈及價值鏈推行責任
照顧制度組成毒性化學物質聯防組織協助法規溝通與研析會員名冊請參考 httpwwwtrcaorgtwtrcanwork2aspx
TRCA 於 2010 年成為 ICCA (International Council of Chemical Associations 國際化學工業協會)觀察員ICCA 成立於 1989 年是全球化工製造
業的聯合會也是化學工業與 UNEP OPCW 及 OECD 的交流窗口ICCA 與其會員協會及成員公司致力於邁向永續的未來確保人類健康與
環境安全與保護全球化工業擁有超過 4兆美元的價值影響所有經濟部門ICCA 的會員幾乎在全球每個國家都有商業活動在全球六大
洲推動創新並提供超過 2000 萬個工作機會
台灣化工業在全球占有重要的一席之地在國內產業鏈也位居關鍵位置無論對國內或國際都有身為地球村一員應盡之責我們期許藉由
製程安全指標提報能更進一步提升自我在工安衛生環保與永續發展等面向的績效表現
台灣化學工業責任照顧協會
10452 台北市中山區撫順街 8 號 7 樓
電話02-2585-0552
httpwwwtrcaorgtw
None | |
$2500 to $25000 | |
$25000 to $250000 | |
$250000 to $25000000 | |
More than $25000000 | |
Yes - Using GHS TABLE | |
Yes - Using API RP 754 TABLE | |
NO | |
NA | |
1x le TQ lt 40x | |
40x le TQ lt 160x | |
160x le TQ lt 640x | |
ge 640x TQ | |
Yes le 3 hours | |
Yes 3 hours ge 12 hours | |
Yes 12 hours ge 24 hours | |
Yes ge 24 hours | |
No | |
Small-scale | |
Medium-scale | |
Large-scale | |
No | |
Yes | |
No | |
middot Injury requiring treatment beyond first aid to an employee contractor or subcontractor | |
middot Days Away From Work injury to an employee contractor or subcontractor or middot Injury requiring treatment beyond first aid to a third party | |
middot A fatality of an employee contractor or subcontractor or middot A hospital admission of a third party | |
middot Multiple fatalities of employees contractors or subcontractors or middot multiple hospital admission of third parties or middot A fatality of a third party | |
NA | |
1x le TQ lt 3x | |
3x le TQ lt 9x | |
9x le TQ lt 27x | |
ge 27x TQ |
ICCA Process Safety Pilot Reporting ProgramFebruary 8 2016 | 1 | 2 | 3 | 4 | 5 | 6 | 7 | 8 | 9 | 10 | 12 | 13 | 14 | 15 | |||||||||||||||||||||||
SAFETY Details(Meeting Local Regulations) | Direct Cost from Fire or Explosion | Community Impact | Environmental Impact | Material Released(Measured using the 1 Hour Rule) | |||||||||||||||||||||||||||||||||
Company Association Details | |||||||||||||||||||||||||||||||||||||
GHS | API - RP 754 | ||||||||||||||||||||||||||||||||||||
Company or Assocation Name | Headquarter Association | Location of Event Ex - City State amp Country | Date and Time of Event | Safety InjuryDid the Event result in a Recordable Lost Time Accident or Fatality or Hospital admission of anyone on or off siteUse Drop Down Menu | Safety InjuryIf yes please insert the total number of injuries | Safety InjuryFor puropses of utilizing the Severity Table please indicate the level of severity by chosing the MOST SEVERE classification that describes your incidentUse Drop Down Menu | Safety InjuryDid the incident involve Fatalities If so how many total fatalities If none enter Zero | Safety InjuryPlease Report Total Employee Hours for Calendar Year 2015 | Safety InjuryPlease Report Total Contractor Hours for Calendar Year 2015 | Direct Cost Did the Event result in Direct Damage CostUse Drop Down Menu | Direct Cost If so how muchAmount is in US DollarsUse Drop Down Menu | Community ImpactDid the event result inbull Officially declared shelter-in-place or officially declared evacuation (on or off site)ORbull Precautionary off site shelter in place or evacuation Use Drop Down Menu | Environmental ImpactDid the event result inAcute Environmental Remediation CostIf so indicate the amount in US DollarsUse Drop Down Menu | Material ReleasedDid the Event result in an Acute Release of material beyond one of the two threshold tablesIf so indicate which Threshold Table you used to make this determinationUse Drop Down Menu | Material ReleasedIf so indicate the amount released USING GHS CLASSIFICATION TABLEUse Drop Down Menu | Material ReleasedIf so indicate the amount released USING THE THRESHOLD TABLE FROM API RP-754Use Drop Down Menu | Material ReleasedIf available please indicate the material released | ||||||||||||||||||||
1 | ABC Chemical Company | American Chemistry Council | Washington DC - USA | January 4 2016 | Yes | 2 | middot Days Away From Work injury to an employee contractor or subcontractor or middot Injury requiring treatment beyond first aid to a third party | 0 | 5525000 | 1500250 | No | $2500 to $25000 | Yes le 3 hours | $2500 to $25000 | Yes - Using GHS TABLE | 40x le TQ lt 160x | NA | Chlorine | |||||||||||||||||||
2 | XYZ Chemical Company | American Chemistry Council | Washington DC - USA | 5-Jan-16 | Yes | 1 | middot Injury requiring treatment beyond first aid to an employee contractor or subcontractor | 0 | 5525000 | 1500250 | Yes | $2500 to $25000 | No | $2500 to $25000 | Yes - Using API RP 754 TABLE | NA | 3x le TQ lt 9x | Benzene | |||||||||||||||||||
3 | |||||||||||||||||||||||||||||||||||||
4 | |||||||||||||||||||||||||||||||||||||
5 | |||||||||||||||||||||||||||||||||||||
6 | |||||||||||||||||||||||||||||||||||||
7 | |||||||||||||||||||||||||||||||||||||
8 | |||||||||||||||||||||||||||||||||||||
9 | |||||||||||||||||||||||||||||||||||||
10 | |||||||||||||||||||||||||||||||||||||
11 | |||||||||||||||||||||||||||||||||||||
12 | |||||||||||||||||||||||||||||||||||||
13 | |||||||||||||||||||||||||||||||||||||
14 | |||||||||||||||||||||||||||||||||||||
15 | |||||||||||||||||||||||||||||||||||||
16 | |||||||||||||||||||||||||||||||||||||
17 | |||||||||||||||||||||||||||||||||||||
18 | |||||||||||||||||||||||||||||||||||||
19 | |||||||||||||||||||||||||||||||||||||
20 | |||||||||||||||||||||||||||||||||||||
21 | |||||||||||||||||||||||||||||||||||||
22 | |||||||||||||||||||||||||||||||||||||
23 | |||||||||||||||||||||||||||||||||||||
24 | |||||||||||||||||||||||||||||||||||||
25 | |||||||||||||||||||||||||||||||||||||
Zero or None | Yes - Duration Unknown | ||||||||||||||||||||||||||||||||||||
Processes | Mode of Operation | Type of material released | Status of Operation | ||||
REFINING | Start-up | Flammable | Open | ||||
Alkylation HF | Planned shutdown | Combustible | Closed | ||||
Alkylation sulfuric | Emergency shutdown | Toxic | |||||
BitumenResidAsphalt | Normal | Corrosive | Tier 1 Acute Releases | ||||
Calcining | Upset | Utilities | No Release | ||||
Coking | Turnaround | Other | Category 1 | ||||
Crude | Routine maintenance | Category 2 | |||||
Desulfurization | Temporary | Evacuation | Category 3 | ||||
FCC | Other | Yes | Category 4 | ||||
Gas Treating | No | Category 5 | |||||
Hydrogen | Point of Release | Category 6 | |||||
Hydrotreating | Pump | Fire | Category 7 | ||||
Hydrocracking | Compressor | Yes | Multiple Categories | ||||
Isom | BlowerFan | No | |||||
MarineJetty | Pressure Vessel | lt $2500 | |||||
Reforming | FilterCoalescer | ||||||
Sulfur recovery | Furnace | PRDs | |||||
Vapor recoverylight ends | Boiler | Directly to Atmosphere | |||||
Wastewater | Heat exchanger | via Downstream Destructive Device | |||||
REFINING amp PETROCHEMICAL | Cooling Tower | No | |||||
Tank FarmStorage FacilityOffsite | Piping system | Yes | |||||
UtilitiesSteam PlantCogeneration | Reactor | No | |||||
Other | Atmospheric tank | ||||||
PETROCHEMICAL | FlareRelief System | Acute release above thresholds | |||||
CO H2 | Other | Yes | |||||
LNG | No | ||||||
Methane | Events | ||||||
Methanol | No Tier 1 Events | Indoor Outdoor | |||||
Methyl Mercaptan | No Tier 2 Events | No Release | |||||
Formaldehyde | No Tier 1 or Tier 2 Events | Indoor | |||||
Formaldehyde derivatives | NA | Outdoor | |||||
Acetic Acid | |||||||
Acetic Acid derivatives | Event Type | ||||||
Ethane | Injury | ||||||
Ethylene | Fire | ||||||
Ethanol | Explosion | ||||||
Ethylene oxide | PRD Discharge | ||||||
Ethylene derivatives | Acute Release | ||||||
Polyethylene | |||||||
Ethylene dichloride | General | ||||||
Ethylene dichloride derivatives | Yes | ||||||
Ethyl benzene | No | ||||||
Ethyl benzene derivatives | |||||||
Polystyrene | |||||||
Styrene-Butadiene | |||||||
Propane | |||||||
Propylene | |||||||
Polypropylene | |||||||
Isopropanol | |||||||
Propylene oxide | |||||||
Propylene oxide derivatives | |||||||
Butane | |||||||
Isobutane | |||||||
Isobutene | |||||||
Butadiene | |||||||
MTBE | |||||||
ETBE | |||||||
Pentane | |||||||
Hexane | |||||||
Cyclohexane | |||||||
Hexanol | |||||||
Aromatics Derivatives | |||||||
Benzene | |||||||
Toluene | |||||||
Xylene | |||||||
Para Xylene | |||||||
Amines Derivatives | |||||||
TDA MDA IPDA etc | |||||||
Isocyanates | |||||||
Specialty Chemicals | |||||||
LoadingUnloading | |||||||
Pilot Plant |
Instructions | ||||||||||||||
Step 1 | Complete the Contact Tab with your contact information and company information | |||||||||||||
Be sure to note the region of your reporting (IE North America France Japan etc) | ||||||||||||||
Survey on Process Safety Events | ||||||||||||||
Step 2 | Complete the survey one line per Process Safety Event for your companyregion | |||||||||||||
ALL REPORTED DATA SHOULD BE FROM CALENDAR YEAR 2017 | ||||||||||||||
Step 3 | Return completed survey to | |||||||||||||
Company Name | ||||||||||||||
Contact Person | All Surveys Due by xxx date | |||||||||||||
Address | ||||||||||||||
Fax | ||||||||||||||
Telephone | ||||||||||||||
Region | ||||||||||||||
None | |
$2500 to $25000 | |
$25000 to $250000 | |
$250000 to $25000000 | |
More than $25000000 | |
Yes - Using GHS TABLE | |
Yes - Using API RP 754 TABLE | |
NO | |
NA | |
1x le TQ lt 40x | |
40x le TQ lt 160x | |
160x le TQ lt 640x | |
ge 640x TQ | |
Yes le 3 hours | |
Yes 3 hours ge 12 hours | |
Yes 12 hours ge 24 hours | |
Yes ge 24 hours | |
No | |
Small-scale | |
Medium-scale | |
Large-scale | |
No | |
Yes | |
No | |
middot Injury requiring treatment beyond first aid to an employee contractor or subcontractor | |
middot Days Away From Work injury to an employee contractor or subcontractor or middot Injury requiring treatment beyond first aid to a third party | |
middot A fatality of an employee contractor or subcontractor or middot A hospital admission of a third party | |
middot Multiple fatalities of employees contractors or subcontractors or middot multiple hospital admission of third parties or middot A fatality of a third party | |
NA | |
1x le TQ lt 3x | |
3x le TQ lt 9x | |
9x le TQ lt 27x | |
ge 27x TQ |
ICCA Process Safety Pilot Reporting ProgramFebruary 8 2016 | 1 | 2 | 3 | 4 | 5 | 6 | 7 | 8 | 9 | 10 | 12 | 13 | 14 | 15 | |||||||||||||||||||||||
SAFETY Details(Meeting Local Regulations) | Direct Cost from Fire or Explosion | Community Impact | Environmental Impact | Material Released(Measured using the 1 Hour Rule) | |||||||||||||||||||||||||||||||||
Company Association Details | |||||||||||||||||||||||||||||||||||||
GHS | API - RP 754 | ||||||||||||||||||||||||||||||||||||
Company or Assocation Name | Headquarter Association | Location of Event Ex - City State amp Country | Date and Time of Event | Safety InjuryDid the Event result in a Recordable Lost Time Accident or Fatality or Hospital admission of anyone on or off siteUse Drop Down Menu | Safety InjuryIf yes please insert the total number of injuries | Safety InjuryFor puropses of utilizing the Severity Table please indicate the level of severity by chosing the MOST SEVERE classification that describes your incidentUse Drop Down Menu | Safety InjuryDid the incident involve Fatalities If so how many total fatalities If none enter Zero | Safety InjuryPlease Report Total Employee Hours for Calendar Year 2015 | Safety InjuryPlease Report Total Contractor Hours for Calendar Year 2015 | Direct Cost Did the Event result in Direct Damage CostUse Drop Down Menu | Direct Cost If so how muchAmount is in US DollarsUse Drop Down Menu | Community ImpactDid the event result inbull Officially declared shelter-in-place or officially declared evacuation (on or off site)ORbull Precautionary off site shelter in place or evacuation Use Drop Down Menu | Environmental ImpactDid the event result inAcute Environmental Remediation CostIf so indicate the amount in US DollarsUse Drop Down Menu | Material ReleasedDid the Event result in an Acute Release of material beyond one of the two threshold tablesIf so indicate which Threshold Table you used to make this determinationUse Drop Down Menu | Material ReleasedIf so indicate the amount released USING GHS CLASSIFICATION TABLEUse Drop Down Menu | Material ReleasedIf so indicate the amount released USING THE THRESHOLD TABLE FROM API RP-754Use Drop Down Menu | Material ReleasedIf available please indicate the material released | ||||||||||||||||||||
1 | ABC Chemical Company | American Chemistry Council | Washington DC - USA | January 4 2016 | Yes | 2 | middot Days Away From Work injury to an employee contractor or subcontractor or middot Injury requiring treatment beyond first aid to a third party | 0 | 5525000 | 1500250 | No | $2500 to $25000 | Yes le 3 hours | $2500 to $25000 | Yes - Using GHS TABLE | 40x le TQ lt 160x | NA | Chlorine | |||||||||||||||||||
2 | XYZ Chemical Company | American Chemistry Council | Washington DC - USA | 5-Jan-16 | Yes | 1 | middot Injury requiring treatment beyond first aid to an employee contractor or subcontractor | 0 | 5525000 | 1500250 | Yes | $2500 to $25000 | No | $2500 to $25000 | Yes - Using API RP 754 TABLE | NA | 3x le TQ lt 9x | Benzene | |||||||||||||||||||
3 | |||||||||||||||||||||||||||||||||||||
4 | |||||||||||||||||||||||||||||||||||||
5 | |||||||||||||||||||||||||||||||||||||
6 | |||||||||||||||||||||||||||||||||||||
7 | |||||||||||||||||||||||||||||||||||||
8 | |||||||||||||||||||||||||||||||||||||
9 | |||||||||||||||||||||||||||||||||||||
10 | |||||||||||||||||||||||||||||||||||||
11 | |||||||||||||||||||||||||||||||||||||
12 | |||||||||||||||||||||||||||||||||||||
13 | |||||||||||||||||||||||||||||||||||||
14 | |||||||||||||||||||||||||||||||||||||
15 | |||||||||||||||||||||||||||||||||||||
16 | |||||||||||||||||||||||||||||||||||||
17 | |||||||||||||||||||||||||||||||||||||
18 | |||||||||||||||||||||||||||||||||||||
19 | |||||||||||||||||||||||||||||||||||||
20 | |||||||||||||||||||||||||||||||||||||
21 | |||||||||||||||||||||||||||||||||||||
22 | |||||||||||||||||||||||||||||||||||||
23 | |||||||||||||||||||||||||||||||||||||
24 | |||||||||||||||||||||||||||||||||||||
25 | |||||||||||||||||||||||||||||||||||||
Zero or None | Yes - Duration Unknown | ||||||||||||||||||||||||||||||||||||
Processes | Mode of Operation | Type of material released | Status of Operation | ||||
REFINING | Start-up | Flammable | Open | ||||
Alkylation HF | Planned shutdown | Combustible | Closed | ||||
Alkylation sulfuric | Emergency shutdown | Toxic | |||||
BitumenResidAsphalt | Normal | Corrosive | Tier 1 Acute Releases | ||||
Calcining | Upset | Utilities | No Release | ||||
Coking | Turnaround | Other | Category 1 | ||||
Crude | Routine maintenance | Category 2 | |||||
Desulfurization | Temporary | Evacuation | Category 3 | ||||
FCC | Other | Yes | Category 4 | ||||
Gas Treating | No | Category 5 | |||||
Hydrogen | Point of Release | Category 6 | |||||
Hydrotreating | Pump | Fire | Category 7 | ||||
Hydrocracking | Compressor | Yes | Multiple Categories | ||||
Isom | BlowerFan | No | |||||
MarineJetty | Pressure Vessel | lt $2500 | |||||
Reforming | FilterCoalescer | ||||||
Sulfur recovery | Furnace | PRDs | |||||
Vapor recoverylight ends | Boiler | Directly to Atmosphere | |||||
Wastewater | Heat exchanger | via Downstream Destructive Device | |||||
REFINING amp PETROCHEMICAL | Cooling Tower | No | |||||
Tank FarmStorage FacilityOffsite | Piping system | Yes | |||||
UtilitiesSteam PlantCogeneration | Reactor | No | |||||
Other | Atmospheric tank | ||||||
PETROCHEMICAL | FlareRelief System | Acute release above thresholds | |||||
CO H2 | Other | Yes | |||||
LNG | No | ||||||
Methane | Events | ||||||
Methanol | No Tier 1 Events | Indoor Outdoor | |||||
Methyl Mercaptan | No Tier 2 Events | No Release | |||||
Formaldehyde | No Tier 1 or Tier 2 Events | Indoor | |||||
Formaldehyde derivatives | NA | Outdoor | |||||
Acetic Acid | |||||||
Acetic Acid derivatives | Event Type | ||||||
Ethane | Injury | ||||||
Ethylene | Fire | ||||||
Ethanol | Explosion | ||||||
Ethylene oxide | PRD Discharge | ||||||
Ethylene derivatives | Acute Release | ||||||
Polyethylene | |||||||
Ethylene dichloride | General | ||||||
Ethylene dichloride derivatives | Yes | ||||||
Ethyl benzene | No | ||||||
Ethyl benzene derivatives | |||||||
Polystyrene | |||||||
Styrene-Butadiene | |||||||
Propane | |||||||
Propylene | |||||||
Polypropylene | |||||||
Isopropanol | |||||||
Propylene oxide | |||||||
Propylene oxide derivatives | |||||||
Butane | |||||||
Isobutane | |||||||
Isobutene | |||||||
Butadiene | |||||||
MTBE | |||||||
ETBE | |||||||
Pentane | |||||||
Hexane | |||||||
Cyclohexane | |||||||
Hexanol | |||||||
Aromatics Derivatives | |||||||
Benzene | |||||||
Toluene | |||||||
Xylene | |||||||
Para Xylene | |||||||
Amines Derivatives | |||||||
TDA MDA IPDA etc | |||||||
Isocyanates | |||||||
Specialty Chemicals | |||||||
LoadingUnloading | |||||||
Pilot Plant |
Instructions | ||||||||||||||
Step 1 | Complete the Contact Tab with your contact information and company information | |||||||||||||
Be sure to note the region of your reporting (IE North America France Japan etc) | ||||||||||||||
Survey on Process Safety Events | ||||||||||||||
Step 2 | Complete the survey one line per Process Safety Event for your companyregion | |||||||||||||
ALL REPORTED DATA SHOULD BE FROM CALENDAR YEAR 2017 | ||||||||||||||
Step 3 | Return completed survey to | |||||||||||||
Company Name | ||||||||||||||
Contact Person | All Surveys Due by xxx date | |||||||||||||
Address | ||||||||||||||
Fax | ||||||||||||||
Telephone | ||||||||||||||
Region | ||||||||||||||
11
D 提報門檻
須提報製程安全事件必須達到以下提報門檻之一
1 安全 工傷
導致記錄性傷害(OSHA)損失工時或死亡或廠內外任何人員因此而須住院治療
記錄性傷害是指與工作有關所造成的傷害導致死亡暫時全失能工作受限制或需調整職
務較輕傷害嚴重之醫療處理失去意識或經醫師或其他合格醫療專業人員診斷為重大
傷害
損失工時傷害和死亡是指因製程相關的一次阻絕設施失效火災或爆炸導致以下任何一種
結果
員工(損失工時或死亡)
承攬商及再承攬商 (損失工時或死亡)
第三方(如來賓訪客快遞員)(受傷疾病導致住院治療或死亡)
住院治療是指醫院或其他具有住院病患保健設施的醫療單位正式接受病患住院提供病患
食宿及醫療護理且病患接受治療至少留置至隔日僅在醫院急診室治療或過夜處理不屬
於ldquo住院治療rdquo的定義範圍
須提報之工傷或死亡事件例如在清理作業期間因蒸汽洩漏造成人員燒燙傷壓力測試期間
帽蓋因受壓脫落造成人員身體傷害或取樣作業時因物質外濺造成人員化學灼傷無須提
報之工傷或死亡事件例如在執行維修作業時從高處的工作台墜落實驗室或辦公大樓火災
造成人員燒燙傷或挖掘工程塌陷造成人員傷害這些案例均與因製程造成的能量釋放或
物質洩漏無直接關聯
2 直接損失成本
火災爆炸或為避免補救環境損害之必要清理作業導致$2500美元以上的直接成本支出
此提報門檻所考慮的成本應為可直接歸因於火災或爆炸的成本譬如設備及結構損壞的重
置成本修理成本環境清理(廠內及廠外)支出緊急應變和罰款直接成本不包括間接
成本譬如業務機會損失設備停機造成之利潤損失取得或運轉臨時設施之成本或為
滿足顧客需求取得替代產品的成本(產品損失)
12
3 就地避難 疏散
官方宣告就地避難或疏散(廠內或廠外)或廠外預防性就地避難或疏散
就提報目的而言官方宣告就地避難或疏散(廠內或廠外)或廠外預防性就地避難或疏散
即達到此提報門檻
官方宣告 ndash 由地方權責機關(如消防警察民防緊急應變管理部門)或經授權的代表(如
派駐公司官員)下達的社區行動(如就地避難或疏散)宣告
預防性宣告 ndash 預防性公眾應變是基於謹慎的態度所採取的一種措施權責地方主管機關或經
授權的代表經合理判斷認定為維護公眾健康及安全發布必須採取就地避難或疏散之預
防性措施
就地避難 ndash 利用結構體及其內部空氣以暫時讓人員與室外危害性氣體隔離
疏散 ndash 基於安全或防護理由讓人員離開某處所的行動或過程
4 洩漏恕限值
超過表 1 中所列 GHS 恕限值或表 2 中所列 API 754 標準 Tier II 製程安全洩漏恕限值之一的
急性洩漏事件(洩漏量以單位小時計量)
如ldquo執行摘要rdquo所述ICCA 製程安全事件之定義容許採用 ICCA 依據化學品全球調和制度
(GHS)健康危害分級為基礎所發展的提報標準或依據聯合國危險物品(UNDG)分類為基礎
所定義之 RP-754 二級製程安全事件(Tier II) 之提報標準GHS 恕限值詳見表 1各會員公司
可自行決定選擇哪一個表中的提報恕限值並在全球採用單一制度
ldquo急性rdquo洩漏 ndash易燃性可燃性或毒性化學物質從一次阻絕設施(如容器或管線)洩漏其
任一單位小時之洩漏量超過化學物質洩漏恕限量分述於表 1 中的 GHS 分類和表 2 中的
API 754 標準 Tier II 製程安全洩漏恕限值
洩壓裝置前述所定義之ldquo急性rdquo洩漏包括洩漏或排放至妥善設計且運作中的洩壓裝置若
洩漏或排放量達到表 1 中所列 GHS 恕限值或表 2 中所列 API 754 標準 Tier II 製程安全洩漏
恕限值且導致下列四種後果之任一項或以上之後果
1 二相排放或夾帶液體的排放液滴沉降至地面造成污染
2 排放至具潛在危險性的地點
3 廠內就地避難或疏散不包括預防性廠內就地避難或疏散
4 啟動公眾保護措施(如道路封閉)包括預防性公眾保護措施
13
洩漏或排放至妥善設計且運作中的洩壓裝置(如廢氣燃燒塔洗滌塔等)若其情況未達前
述四項標準中任何一項則不必提報
欲查看 API RP-754 標準可登入以下網站下載此標準httpwwwapiorgenvironment-
health-and-safetyprocess-safetyprocess-safety-standardsstandard-rp-754
一小時法則
為便於衡量此項指標提報與否洩漏恕限值是以物質在任一小時內之洩漏量為標準若任
一小時或更短時間內物質洩漏量達到或超過須提報恕限值該事故便屬於須提報的製程安
全事件急性洩漏事故通常不會超過一小時若無法確定洩漏持續時間則應假設其為一
小時
一次阻絕設施ndash 用來作為主要容器或用於運送或輸送物質之槽罐船隻管線軌道車
或設備主要容器在設計上可能包含二次阻絕設施系統以抑制及控制洩漏二次阻絕設
施系統包括(但不限於)儲槽防溢堤製程設備周遭的圍堵設施油水分離的排水收集系統
雙層儲槽的外壁等
嚴重程度表 ndash 嚴重程度加權可額外提供有關製程安全事件的有用資訊有助於帶動改善績
效附錄 A 為 RCLG 建議之製程安全事件嚴重程度加權計算方法根據附錄 A 的方法便
可藉由加總與各個後果類別關聯的分數計算出各製程安全事件的嚴重程度加權值ICCA
強烈建議採用嚴重程度加權制度因為此制度有助於提升溝通績效的能力也比較容易讓
利害關係人了解製程安全事件並且此嚴重程度加權值與其他製程安全績效指標提報方
式是不具相互比較性的
14
表 1 ndash GHS 分類表
物理性危害(GHS 2x)
洩漏恕限值(1 小時內)
STOTSpecific target organ toxicity(特定標的器官系統毒性物質)
15
表 2 ndash API RP 754 Tier II 分類表
洩漏恕限類別
物質危害性分類 acdef 恕限值
(戶外洩漏) 恕限值
(戶內b洩漏)
T2-1 TIH A 區物質 ge 05 kg (11 lb) ge 025 kg (055
lb)
T2-2 TIH B 區物質 ge 25 kg (55 lb) ge 125 kg (275
lb)
T2-3 TIH C 區物質 ge 10 kg (22 lb) ge 5 kg (11 lb)
T2-4 TIH D 區物質 ge 20 kg (44 lb) ge 10 kg (22 lb)
T2-5
易燃氣體 或 正常沸點 ≦ 35 (95 degF)閃火點lt23 (73 degF)的液體 或 其他包裝組別 I 類的物質 (酸鹼除外)
ge 50 kg (110 lb) ge 25 kg (55 lb)
T2-6
正常沸點 gt 35 degC (95 degF)閃火點 lt 23 degC (73degF)的液體 或 其他包裝組別 II 類的物質 (酸鹼除外)
ge 100 kg (220 lb) 或
ge 07 bbl
ge 50 kg (110 lb) 或
ge 035 bbl
T2-7
閃火點 gt 23 degC (73 degF)和 lt 60 degC (140 degF)的液體 或 閃火點 gt 60 degC (140 degF)的液體在閃火點或高於閃火點的溫度下洩漏 或 強酸鹼 (定義參見 RP 754 文件草案) 或 UNDG第2類第22部分 (不可燃無毒氣體)空氣除外 或 其他包裝組別 III 類的物質
ge 200 kg (440 lb) 或
ge 14 bbl
ge 100 kg (220 lb) 或
ge 07 bbl
T2-8
閃火點 gt 60 degC (140 degF) 和 lt 93 degC (200 degF)的液體在低於閃火點的溫度下洩漏 或 中度酸鹼
ge 1000 kg
(2200 lb) 或
ge 7 bbl
ge 500 kg
(1100 lb) 或
ge 35 bbl
TIH吸入性毒性危害物(Toxic Inhalation Hazard)
16
一般認為以公斤和磅或以磅和桶為單位的恕限值不盡等同各公司應該選用其中一組計量單位並在
所有紀錄文件中一體適用
在判定一種物質之洩漏恕限類別時首先應從物質之含吸入性毒性(TIH Zone)可燃性(閃火點和沸點)
或腐蝕性(強酸或鹼 vs中度酸或鹼)等特性來判別只有當物質的危險度無法利用上述簡單的特性來判別
時(如遇水反應劇烈)才採用UNDGL包裝組別
a 許多物質具有一種以上危險性正確的危險區(Hazard Zone)或包裝組別(Packing Group)歸屬應遵循DOT
49 CFR 1732a [14]或聯合國危險物品運輸建議書(UNRTDG)第2部分[12]的規定參見附錄F
b 具有四面完整牆(從地板到天花板)地板和屋頂的結構物
c 對於未列於UNDG的溶液無水成分將用TIH區或包裝組別分類溶液之恕限值將根據乾基重量之恕限
值反算
d 對於未知UNDG分類的混合物可計算每種成分在恕限值洩漏中的分量如果各種成分之分量的總和
等於或大於100即表示混合物超過門檻值若混合物有明顯且獨立的毒性及可燃性結果則可分
別計算毒性及可燃性危險度參見附錄EPSE實例amp問題 49ndash53
e 閃火點 gt 60 degC (140 degF) 和 lt 93 degC (200 degF)的液體在低於閃火點的溫度下洩漏無論洩漏量多寡其
一次阻絕設施失效(LOPC)均不屬於Tier 1製程安全事件(PSE)
f 中度酸鹼的一次阻絕設施失效無論洩漏量多寡均不屬於Tier 1製程安全事件
17 (K = 1000 MM = 1000000) (在環境影響類別方面若缺乏既有定義協會和會員公司應議定輸入標準)
附錄 A ndash 嚴重程度表鼓勵所有協會均採用嚴重程度加權制度
事件事故類別
嚴重程度等級
安全人體健康 火災或爆炸導致直接
成本 任 1 小時內物質洩
漏量 社區影響 環境影響[廠外]
4 級
1 分
對員工承攬商或再承攬商造成較輕傷害嚴重之傷害 (符合本地法規)
造成以下直接損失成本
美金$25 K ~ $25 K
洩漏量介於
1x le TQ lt 40x
官方宣告就地避難或疏散 (廠內或廠外) 預防性廠外就地避難或疏散
le 3 小時
重大環境整治成本
$25 K ~ $25 K
3 級
3 分
對員工承攬商或再承攬商造成之需要多日缺勤的傷害
對第三方造成之需要初步急救以外治療的傷害 (符合本地法規)
造成以下直接損失成本
$25 K ~ $250 K
洩漏量介於
40x le TQ lt 160x
官方宣告就地避難或疏散 (廠內或廠外)
預防性廠外就地避難或疏散
3 ~ 12 小時
重大環境整治成本
$25 K ~ $250 K
2 級
9 分
對員工承攬商或再承攬商造成 1 人死亡
對第三方造成 1 人住院治療
(符合本地法規)
造成以下直接損失成本
$250 K ~ $25 MM
洩漏量介於
160x le TQ lt 640x
官方宣告就地避難或疏散 (廠內或廠外)
預防性廠外就地避難或疏散
12 ~ 24 小時
重大環境整治成本
$250 K ~ $25 MM
1 級
27 分
對員工承攬商或再承攬商造成多人死亡
對第三方造成多人住院治療
對第三方造成 1 人死亡 (符合本地法規)
造成以下直接損失成本
ge $25 MM
洩漏量
ge 640x TQ
官方宣告就地避難或疏散 (廠內或廠外)
預防性廠外就地避難或疏散
ge 24 小時
重大環境整治成本
ge $25 MM
18 (K = 1000 MM = 1000000) (在環境影響類別方面若缺乏既有定義協會和會員公司應議定輸入標準)
嚴重程度表(附錄 A)細節說明
附錄 A 之設計目的僅適用於採用 GHS 分類制度(表 1)者如果你的公司係採用 API RP 754Tier II 製程安全指標提報恕限值表(表 2)請使用
API RP 754 製程安全嚴重程度表必須提醒的是依 API RP 754 的標準其嚴重程度表僅適用於一級(Tier I)事故去比較採用不同的嚴重度
表所評估出來的相對嚴重度並無統計上的意義
急性的環境成本 ndash 因製程安全事件造成廠外環境影響所導致之短期清理及物質處置的成本各會員公司可選擇將廠外環境影響相關成本另
外區分一個嚴重程度類別
比率調整指標
利用上述嚴重程度表可產生一系列以事件率為基礎的指標包括
製程安全總事件率 (PSTIR) 總事件次數 x 200000
總工作時數
製程安全事件嚴重程度率(PSESR) (即製程安全事件嚴重程度加權計算公式)
PSESR = 所有事件之總嚴重程度分數總合 x 200000
總工作時數
在計算此一比率時各 4 級事件被分配 1 分各 3 級事件被分配 3 分各 2 級事件被分配 9 分各 1 級事件被分配 27 分理論上每個
製程安全事件至少可分配到 1 分(亦即事件僅在一個類別符合第 4 級事件屬性)至多可分配到 135 分(亦即事件在所有五個類別中均符
合第 1 級事件屬性)
ldquoXrdquo級別製程安全事件率 嚴重度級別ldquoXrdquo之製程安全事件總數 x 200000
員工承攬商amp再承攬商總工作時數
X可以是嚴重度級別 432 或 1 級製程安全事件之總數事件之嚴重度等級是選用五類後果類別中之最嚴重等級
標準化 ndash 在某些協會和會員公司中製程安全事件是採 lsquo每 100 名rsquo員工每名員工每年平均工作時數為 2000 小時為基礎予以標準化因
此在lsquo每 100rsquo名rsquo員工的標準基礎上事件被乘以 200000 工作時數也有些其他協會和會員公司將標準化基礎設定為lsquo每 500 名rsquo員工
因此事件被乘以 1000000 工作時數協會和會員公司應就標準化基礎進行討論共同做成選項結論上述的公式設定為lsquo每 100 名rsquo員工
基礎
19
附錄 B ndash 常見問題集
適用性
我們建議會員公司記錄和提報在其所擁有或運作的工廠內發生的製程安全事件惟以下情況不須提報製
程安全事件
1 源自於公司廠區以外的製程安全事件
2 海上運輸船事故惟船隻為了輸送半成品或產品之目的已經與公司的設施相連接時發生的
事故仍須提報
3 卡車或軌道車事故惟卡車或軌道車為了輸送半成品或產品之目的已經與公司的設施相連
接時發生的事故仍須提報
4 許可證或法規容許之例行排放
5 不會造成製程安全危害的地下污染請注意若洩漏至地下導致地上發生須提報製程安全事
件如釋放出毒性蒸汽或致使易燃液體蓄積成池則不適用本排除條件
6 辦公建築事故(如辦公室暖氣設備爆炸火災外溢洩漏人員受傷或疾病等)
7 與疏散或一次阻絕設施失效無直接關聯之人員安全ldquo滑倒絆倒跌倒rdquo事故
8 沒有與製程相連接之輔助設備的一次阻絕設施(如小樣品瓶)失效事故
9 計劃中和在控制下的物質排放至設計用來收集或排放系統中(請注意物質從一次阻絕設施
在非計劃或非受控制情況下排放至收集或排放系統中則不適用本排除條件)
10 在製程區域外部或保養廠內執行之機械作業
說明與實例 ndash 以 GHS 表 1 為基礎
以下說明和實例有助於在評估須提報製程安全事件(PSE)時釐清可能存在的不確定部分
公司廠區
1 一輛第三方的卡車在公司廠區內卸載易燃產品時發生洩漏進而引起火災造成公司財物損失
$7000 美元(直接成本)雖然該卡車是ldquo由他人操作rdquo但其作業與製程相連接若公司的直接成
本財物損失達到或超過$2500 美元或已達到或超過其他 PSE 提報門檻(如1 人死亡)此事故即
屬於須提報的製程安全事件
2 與前例1 類似的例子載著易燃產品的卡車在廠外運輸途中翻覆引發火災並造成卡車毀損
該事故不屬於須提報的製程安全事件因為當時卡車並未與製程相連接
20
阻絕設施失效
3 儲槽液位計故障造成裝有ldquo易燃液體rdquo產品的儲槽外溢約 700 公斤的液體流入儲槽的防溢堤內
此事故屬於須提報的製程安全事件因為其ldquo急性rdquo洩漏量超過 100 公斤即使是阻絕在二次阻絕
設施防溢堤中亦然
4 一名從事維修工作的承攬商在開啟一個製程阻閥時被噴起的硫酸濺到造成嚴重灼傷和損失工
時的工傷此事故屬於須提報的製程安全事件因為它是涉及物質和一次阻絕設施失效的意外事
件對於因洩漏造成死亡和損工的工傷或疾病事故沒有洩漏恕限值
5 一名作業員開啟品管取樣點進行日常取樣作業時手部被一個破碎的玻璃瓶嚴重割破需要進行
縫合治療縫針造成第二天無法上班該事故不屬於須提報的製程安全事件因為它與一次阻絕
設施失效無關
ldquo急性rdquo洩漏
6 一名作業員在進行天然氣流量高於預期值之異常排除時發現天然氣管線上的一個安全閥門未適
當歸位因此天然氣經由氣液分離桶排放至排氣煙囪經進一步檢查作業員判斷在過去 6 個
月間總共有 100000 公斤天然氣以穩定的速率排放至大氣該事故不屬於須提報的製程安全事
件因為其洩漏速率(每小時約 10 公斤)不算ldquo急性rdquo洩漏(未超過易燃蒸汽每小時 100 公斤的恕限
值)
廢氣燃燒塔amp排放控制裝置 (如洗滌塔)
7 若化學物質被導引至廢氣燃燒塔或排放控制裝置(如洗滌塔)只要該廢氣燃燒塔或控制裝置運作在
正常設計範圍內便不屬於須提報的製程安全事件
8 若廢氣流速超過洗滌塔的設計負荷以致未經吸收的化學物質排出超過恕限值該事故屬於須提報
的製程安全事件(如本文註釋所述)
註釋自取得許可或妥善管理的裝置-包括釋壓裝置發生不預期的排放若 1 小時內洩漏量達到或
超過表 1 或表 2 所列的洩漏恕限值且導致下列四種後果之任一項或以上之後果該事故便屬於
須提報的製程安全事件
o 二相排放或夾帶液體的排放液滴沉降至地面造成污染
o 排放至具潛在危險性的地點)
o 廠內就地避難或疏散不包括預防性廠內就地避難或疏散
o 啟動公眾保護措施(如道路封閉)包括預防性公眾保護措施
21
安全洩壓裝置 系統
9 製程單元發生異常安全閥開啟將洩漏物質釋放到排氣口此釋壓排放裝置是依相關要求設計
的且氣體釋到大氣中並未造成不良後果這不是一個須提報的製程安全事件因為安全閥高
壓破裂盤以及類似的安全裝置是依據 API 521 或者同等的標準設計的且此排放並未造成 (1)
夾帶液體並導致須提報的製程安全事件的後果(譬如損失工時意外死亡火災或爆炸造成$2500
美元或以上的直接成本損失液體或毒性氣體洩漏量達到或超過恕限值(2) 啟動廠內或廠外就地
避難應變或(3)啟動公眾保護措施
10 製程單元發生異常安全閥並未開啟造成設備超壓易燃性氣體從一個法蘭處ldquo急性rdquo漏出來
洩露量超過 100 公斤(一小時內)的恕限值該事故屬於須提報的製程安全事件因為從法蘭處外
漏屬於製程安全事件應提報事項
損工事故
11 一名作業員走路時不慎滑倒造成損失工時之工傷滑倒原因為天氣狀況rdquo長期rdquo油垢的地面和
易滑鞋具該事故不屬於須提報的製程安全事件因為人員安全ldquo滑倒絆倒跌倒rdquo事故若非與
一次阻絕設施失效直接關聯的疏散或應變造成則不屬於須提報的製程安全事件
12 與前例相同的事件惟這次作業員跌倒是因為少量易燃液體外漏(如 1 小時內少於 10 公斤)在採取
相關應變措施時發生該事故屬於須提報的製程安全事件因為作業員係為了應變一次阻絕設施
失效的事故而跌倒若一次阻絕設施失效發生在公司廠區且造成失時工傷或死亡後果該事故
便屬於須提報的製程安全事件對於因洩漏造成死亡和損失工時之工傷事故沒有洩漏量門檻
13 與前例相同的事件惟這次作業員跌倒是在事件結束數小時之後該事故不屬於須提報的製程安
全事件在提報要件中所用的ldquo疏散rdquo和ldquo應變rdquo等術語指的是一次阻絕設施失效和相關緊急應變
活動正在持續中事件結束後滑倒絆倒跌倒(如ldquo事後rdquo清理和補救)不屬於須提報製程安全事件
14 工人在因附近設備一次阻絕設施失效在疏散過程中一名鷹架搭建工人從鷹架梯上跌落造成損
失工時之工傷該事故屬於須提報的製程安全事件
15 一名作業員行經一個設計不良的蒸汽卻水器時被外洩的蒸汽燙傷腳踝造成損失工時之工傷
該事故屬於須提報的製程安全事件因為雖然一次阻絕設施失效洩漏出的是蒸汽(而非碳氫化合物
或化學物質)但損失工時之工傷是由於洩漏物質的物理狀態所導致的
16 一個密閉空間依照計畫以氮氣吹清一名承攬商繞過安全管制進入該密閉空間因而死亡該事
故屬於須提報的死亡事件但不屬於須提報的製程安全事件因為其中不涉及非計劃或失控的一
次阻絕設施失效
17 情況同上惟這次氮氣是非刻意洩漏進入該局限空間該事故屬於須提報的製程安全事件(同時也
是一起死亡事件)因為該名承攬商的死亡與非計劃的一次阻絕設施失效有關
22
18 一名作業員因硫化氫(H2S)警報在進行應變處理時昏倒若警報確實是因非計劃或失控的 H2S 一次
阻絕設施失效的外洩事件該事故便屬於須提報的製程安全事件若警報是一個假警報則該事
故便不屬於須提報的製程安全事件因為沒有真正的化學品洩漏發生
管線
19 一條管線破漏1 小時內洩漏 2000 磅(900 公斤)易燃蒸氣到地面但洩漏位置在廠區內很偏僻的
地點該事故仍屬於須提報的製程安全事件因為ldquo偏僻rdquo不是提報與否的考量因素
與化學物質外洩無關之火災或能量釋放事故
一般通則而言唯有當火災或能量釋放事故是因化學物質洩漏所造成或其發生導致化學物質洩漏
超過提報恕限值這些事故才屬於須提報的製程安全事件實例包括
20 一場電氣火災影響製程操作導致甲苯洩漏 400 公斤該事故屬於須提報的製程安全事件因為
化學物質洩漏已超過甲苯的 100 公斤提報恕限值
21 發生電氣火災停電或任何公用資源供應中斷可能造成工廠停工及可能引起設備損失超過
$2500 美元(如因非正常停工導致反應器或設備損壞)但並未造成超過恕限值的化學物質洩漏
亦未造成死亡或嚴重工傷該事故不屬於須提報的製程安全事件因為設備損壞並非化學製程火
災爆炸造成且化學物質洩漏並未超過恕限值
海上運輸船
22 一艘由公司營運的海上運輸船在船上發生ldquo急性rdquo易燃物質外洩洩漏量超過 100 公斤該事故不
屬於須提報的製程安全事件因為除非海上運輸船是為了輸送半成品或產品而與煉油石化或化
學製造廠的設施相連接否則其洩漏事故便不被視為製程安全事件
23 一艘第三方駁船由一艘拖船推向碼頭結果撞上公司的碼頭駁船的一個船艙破裂且造成
1000 公斤柴油洩漏到海中該事故不屬於須提報的製程安全事件因為駁船當時並非停泊在碼
頭內且其作業並非在進行半成品或產品之輸送
卡車與軌道車
24 一輛公司的軌道車在運輸途中出軌造成超過 1000 公斤汽油洩漏該事故不屬於須提報的製程
安全事件因為在公司廠區外發生的軌道車事故不被視為與製程安全有關
23
25 一輛第三方卡車拖車在公司廠區內翻覆造成ldquo急性rdquo汽油洩漏超過 1000 公斤這事故不屬於須
提報的製程安全事件因為卡車拖車當時已不再與裝卸設備連接然而我們建議會員公司另
行訂定運輸安全事故指標將這類事故記錄下來
26 一位合約卡車作業者正在卸載液鹼時發生軟管脫落造成空氣中氣霧和或液鹼液洩漏 2500 公
斤該事故屬於須提報的製程安全事件因為洩漏量已超過液鹼的 100 公斤恕限值且事故發生
前卡車仍與裝卸設備相連接著
辦公建築
27 綜合辦公大樓發生鍋爐火災造成總計$75000 美元的直接成本損失該事故不屬於須提報的製
程安全事件因為辦公大樓事故不被視為與製程安全有關
人機介面事故
28 一名操作技術員在聚合物工廠的終端設備旁作業時受傷這傷害是因機械的人機介面的設備而
造成該事故不屬於須提報的製程安全事件因為技術員受傷並非因危險物質一次阻絕設施失效
而造成的
混合物
29 若混合物本身有 GHS 分類可利用其分類確定恕限值若混合物本身沒有 GHS 分類則可計算混
合物中每個單一組成分之洩漏量(公斤)相對於個別成分恕限值之比值作為其對混合物恕限值之
lsquo加權rsquo貢獻譬如若混合物在 1小時內的洩漏量為 100公斤其中包含 05公斤分類為劇毒 H300
的物質45 公斤分類為 H301 的物質40 公斤另一種分類為 H 開頭的物質其餘 55 公斤則為沒
有 GHS 分類的水分此混合物之計算式為051 + 4510 + 40100 = 05 + 045 + 04 = 135超過
1因此該事故被視為須提報的製程安全事件雖然混合物個別成分之洩漏量均未超過各該物質
本身的恕限值
直接損失成本
30 此一門檻所考慮的成本應為可直接歸因於火災或爆炸的成本譬如設備及結構損壞的重置成本
修理成本環境清理支出緊急應變和罰款直接成本不包括間接成本譬如業務機會損失設
備停機造成之利潤損失取得或運轉臨時設施之成本或為滿足顧客需求取得替代產品的成本
(產品損失)
24
31 範例連接到氣體處理系統的排放管發生易燃氣體外漏同時製程出現問題導致空氣進入同
一條排放管結果發生爆炸過高的壓力損壞了排放管及其相關上游設備包括一個密封罐並
未造成人員受傷修理成本約$12000 美元該事故屬於須提報的製程安全事件因為爆炸及火
災導致設備修理成本超過門檻
32 範例一次製程安全事件後公司又發生一種非常特殊的 GHS 第 5 類產品洩漏 50 公斤造成
$2000 美元的設備損失洩漏的產品是一種非常特別的混合物公司須負擔超過$50000 美元因
產品耗損而產生之材料成本該事故不屬於須提報的製程安全事件因為 GHS 第 5 類產品洩漏的
提報門檻為 100 公斤且產品耗損不被計入直接損失成本
天然災害
33 天然災害可能對化學製程作業構成重大風險且對製程設備造成損壞導致危害物質一次阻絕設
施失效當一種或多種天然災害被認為可能對工廠作業造成影響時製程安全和作業系統應從危
害及後果分析工廠機器設備設計公用設施失效及製程停工之操作程序緊急應變計畫及應變
措施等方面界定潛在風險進行防範
天然災害類型包括颶風及颱風(包括伴隨而來的風暴潮)水災龍捲風地震超強對流風暴(直
線風暴)野火火山爆發海嘯和山崩
若公司廠房設施遭遇天然災害且其後果觸發一種或以上提報門檻該事故便屬於須提報製程安
全事件
預防性公眾應變
34 預防性公眾應變是基於謹慎的態度所採取的一種措施譬如當發生一次阻絕設施失效時公司
可能在尚未進行任何評估(如方向與洩漏點的距離等等)前便要求全體工人就地避難又
如地方權責官員(如消防警察民防緊急應變管理部門)在獲報一家公司發生製程安全事件
後為防lsquo萬一rsquo風向改變或基於可能受到波及的人口敏感族群(如學童或老年人)可能在尚未接
獲明確資訊前便下令社區就地避難或疏散或採取公眾保護措施(如道路封閉)
製程附屬倉庫
35 製程附屬倉庫指的是位於廠內用於儲存將投入於生產製程或產自於製程之原料半成品或成品的
倉庫從製程的觀點看來製程附屬倉庫相當於一個大型儲槽但這些原料半成品或成品並不
是儲存在一的大型容器中而是裝在較小的容器裡(如太空包大桶桶罐等)
25
Appendix C ndash List of RCLG Taskforce Members
Name Affiliation
Peter Schmelzer Bayer CEFIC - Chairman
Americo Diniz Carvalho Neto Braskem
Bradford Johnson American Chemistry Council
David Cummings DuPont
Debra Phillips American Chemistry Council
Hans Schwarz BASF
Kathryn Walton Plastics and Chemicals Industries Association
Kazuyuki Akita Japanese Chemical Industry Association
Kelly Keim ExxonMobil Chemical Company API Representative
Kenan Stevick Dow
Kiyokazu Murata Japanese Chemical Industry Association
Larry Bowler SABIC
Lorna Young Chemical Industry Association of Canada
Louisa Nara Center for Chemical Process Safety
Luiz Shizuo Harayashiki Associaccedilatildeo Brasileira da Induacutestria Quiacutemica
Masatoshi Kumamoto Japanese Chemical Industry Association
Milton Lacerda Petrobras
Phil Scott Chemical Industries Association
Piet Knijff DSM European Process Safety Centre
Scott Donaldson and Eamon Chandler
Shell
Scott Wallace Olin Corporation
Shakeel Kadri Air Products and Chemicals Inc
26
附錄 D ndash 詳細活動時程表
2016 年 2017 年 2018 年 2019 年 2020 年
2 ndash 4 月
RCLG PS 先導計畫
5 月 ndash
針對準則進行調整釐清
6 月 向 RCLG 和 ICCA 董事會報
告先導計畫執行結果
7 ndash 12 月 RCLG 協會考量準
則並為其會員公司發展提報機制
如有需要RCLG可向 ICCA 申請能
力建立基金為會員公司舉辦製程安
全研習會
1 ndash 12 月
RCLG 協會開始向其會員公司蒐集製程安全數據
1 ndash 12 月
如有需要RCLG 各協會運用 RCLG 的基金及專
家舉辦製程安全及績效提報研習會
1 ndash 2 月
擁有數據的協會開始向RCLG 提報製程安全事件
(2017 年數據)
4 月 RCLG 檢討第一個提報循
環的結果挑戰及原始數據(內部)
6 月 RCLG 向 ICCA 董事會呈報
原始數據
7 ndash 12 月 必要時更新及調整準
則
如有需要RCLG 各協會運用 RCLG 的基金及專
家舉辦製程安全及績效提報研習會
1 ndash 2 月
擁有數據的協會開始向RCLG 提報製程安全事件
(2018 年數據)
4 月 RCLG 檢討第二個提報循
環的結果挑戰及原始數據(內部)
6 月 RCLG 向 ICCA 董事會呈報
原始數據
7 ndash 12 月 必要時更新及調整準
則
如有需要RCLG 協會運用 RCLG 的基金及專家
舉辦製程安全及績效提報研習會
1 ndash 2 月
所有協會開始向 RCLG 提報製程安全事件
製程安全事件提報成為
RCLG KPI 衡量指標建議基本集的一部分(2019 年數
據)
4 月 RCLG 檢討第二個提報循
環的結果挑戰及原始數據(內部考量外部提
報)
6 月 RCLG 向 ICCA 董事會呈報
原始數據
27
附錄 E ndash 選擇性 Excel 追蹤表
當會員公司開始追蹤製程安全事件時所有會員公司應採用單一表格以簡化數據分析同時讓所有公司均使用相同的追蹤表RCLG 設
計了一份選擇性追蹤表可供會員公司和協會先行利用之後他們可設計自己的追蹤表
在這裡下載追蹤表
ICCA Process Safety Event Tracking Sheetxlsx
本文件包含三個分頁分別是ldquo聯絡資料rdquoldquo調查表rdquo和儲存下拉式選單選項的ldquo請勿編輯rdquo分頁
備註
附錄 E 追蹤表僅供參考TRCA 將另行提供台灣版表格供會員公司提報
28
後語
台灣化學工業責任照顧協會(Taiwan Responsible Care Association TRCA)成立於 1998 年在台灣推行責任照顧制度已達 20 週年製造商成員
包括台灣主要上市上櫃化工公司會員公司化學品生產製造量約佔全國 80 2016 年台灣化工業的 Chemical Sales 仍站在全球第八名的位
置額度為 630 億歐元化工業總產值達到 34 兆新台幣提供國內 416 萬人工作機會
TRCA 扮演國內廠商與國際制度接軌的角色也是國內化工業與政府機關及利益相關者溝通的橋樑與管道TRCA 會員結構依業務性質分析
涵蓋石化生產化學品製造氣體生產倉儲運輸業化學品貿易業以及工程研發設計等公司TRCA 透過供應鏈及價值鏈推行責任
照顧制度組成毒性化學物質聯防組織協助法規溝通與研析會員名冊請參考 httpwwwtrcaorgtwtrcanwork2aspx
TRCA 於 2010 年成為 ICCA (International Council of Chemical Associations 國際化學工業協會)觀察員ICCA 成立於 1989 年是全球化工製造
業的聯合會也是化學工業與 UNEP OPCW 及 OECD 的交流窗口ICCA 與其會員協會及成員公司致力於邁向永續的未來確保人類健康與
環境安全與保護全球化工業擁有超過 4兆美元的價值影響所有經濟部門ICCA 的會員幾乎在全球每個國家都有商業活動在全球六大
洲推動創新並提供超過 2000 萬個工作機會
台灣化工業在全球占有重要的一席之地在國內產業鏈也位居關鍵位置無論對國內或國際都有身為地球村一員應盡之責我們期許藉由
製程安全指標提報能更進一步提升自我在工安衛生環保與永續發展等面向的績效表現
台灣化學工業責任照顧協會
10452 台北市中山區撫順街 8 號 7 樓
電話02-2585-0552
httpwwwtrcaorgtw
None | |
$2500 to $25000 | |
$25000 to $250000 | |
$250000 to $25000000 | |
More than $25000000 | |
Yes - Using GHS TABLE | |
Yes - Using API RP 754 TABLE | |
NO | |
NA | |
1x le TQ lt 40x | |
40x le TQ lt 160x | |
160x le TQ lt 640x | |
ge 640x TQ | |
Yes le 3 hours | |
Yes 3 hours ge 12 hours | |
Yes 12 hours ge 24 hours | |
Yes ge 24 hours | |
No | |
Small-scale | |
Medium-scale | |
Large-scale | |
No | |
Yes | |
No | |
middot Injury requiring treatment beyond first aid to an employee contractor or subcontractor | |
middot Days Away From Work injury to an employee contractor or subcontractor or middot Injury requiring treatment beyond first aid to a third party | |
middot A fatality of an employee contractor or subcontractor or middot A hospital admission of a third party | |
middot Multiple fatalities of employees contractors or subcontractors or middot multiple hospital admission of third parties or middot A fatality of a third party | |
NA | |
1x le TQ lt 3x | |
3x le TQ lt 9x | |
9x le TQ lt 27x | |
ge 27x TQ |
ICCA Process Safety Pilot Reporting ProgramFebruary 8 2016 | 1 | 2 | 3 | 4 | 5 | 6 | 7 | 8 | 9 | 10 | 12 | 13 | 14 | 15 | |||||||||||||||||||||||
SAFETY Details(Meeting Local Regulations) | Direct Cost from Fire or Explosion | Community Impact | Environmental Impact | Material Released(Measured using the 1 Hour Rule) | |||||||||||||||||||||||||||||||||
Company Association Details | |||||||||||||||||||||||||||||||||||||
GHS | API - RP 754 | ||||||||||||||||||||||||||||||||||||
Company or Assocation Name | Headquarter Association | Location of Event Ex - City State amp Country | Date and Time of Event | Safety InjuryDid the Event result in a Recordable Lost Time Accident or Fatality or Hospital admission of anyone on or off siteUse Drop Down Menu | Safety InjuryIf yes please insert the total number of injuries | Safety InjuryFor puropses of utilizing the Severity Table please indicate the level of severity by chosing the MOST SEVERE classification that describes your incidentUse Drop Down Menu | Safety InjuryDid the incident involve Fatalities If so how many total fatalities If none enter Zero | Safety InjuryPlease Report Total Employee Hours for Calendar Year 2015 | Safety InjuryPlease Report Total Contractor Hours for Calendar Year 2015 | Direct Cost Did the Event result in Direct Damage CostUse Drop Down Menu | Direct Cost If so how muchAmount is in US DollarsUse Drop Down Menu | Community ImpactDid the event result inbull Officially declared shelter-in-place or officially declared evacuation (on or off site)ORbull Precautionary off site shelter in place or evacuation Use Drop Down Menu | Environmental ImpactDid the event result inAcute Environmental Remediation CostIf so indicate the amount in US DollarsUse Drop Down Menu | Material ReleasedDid the Event result in an Acute Release of material beyond one of the two threshold tablesIf so indicate which Threshold Table you used to make this determinationUse Drop Down Menu | Material ReleasedIf so indicate the amount released USING GHS CLASSIFICATION TABLEUse Drop Down Menu | Material ReleasedIf so indicate the amount released USING THE THRESHOLD TABLE FROM API RP-754Use Drop Down Menu | Material ReleasedIf available please indicate the material released | ||||||||||||||||||||
1 | ABC Chemical Company | American Chemistry Council | Washington DC - USA | January 4 2016 | Yes | 2 | middot Days Away From Work injury to an employee contractor or subcontractor or middot Injury requiring treatment beyond first aid to a third party | 0 | 5525000 | 1500250 | No | $2500 to $25000 | Yes le 3 hours | $2500 to $25000 | Yes - Using GHS TABLE | 40x le TQ lt 160x | NA | Chlorine | |||||||||||||||||||
2 | XYZ Chemical Company | American Chemistry Council | Washington DC - USA | 5-Jan-16 | Yes | 1 | middot Injury requiring treatment beyond first aid to an employee contractor or subcontractor | 0 | 5525000 | 1500250 | Yes | $2500 to $25000 | No | $2500 to $25000 | Yes - Using API RP 754 TABLE | NA | 3x le TQ lt 9x | Benzene | |||||||||||||||||||
3 | |||||||||||||||||||||||||||||||||||||
4 | |||||||||||||||||||||||||||||||||||||
5 | |||||||||||||||||||||||||||||||||||||
6 | |||||||||||||||||||||||||||||||||||||
7 | |||||||||||||||||||||||||||||||||||||
8 | |||||||||||||||||||||||||||||||||||||
9 | |||||||||||||||||||||||||||||||||||||
10 | |||||||||||||||||||||||||||||||||||||
11 | |||||||||||||||||||||||||||||||||||||
12 | |||||||||||||||||||||||||||||||||||||
13 | |||||||||||||||||||||||||||||||||||||
14 | |||||||||||||||||||||||||||||||||||||
15 | |||||||||||||||||||||||||||||||||||||
16 | |||||||||||||||||||||||||||||||||||||
17 | |||||||||||||||||||||||||||||||||||||
18 | |||||||||||||||||||||||||||||||||||||
19 | |||||||||||||||||||||||||||||||||||||
20 | |||||||||||||||||||||||||||||||||||||
21 | |||||||||||||||||||||||||||||||||||||
22 | |||||||||||||||||||||||||||||||||||||
23 | |||||||||||||||||||||||||||||||||||||
24 | |||||||||||||||||||||||||||||||||||||
25 | |||||||||||||||||||||||||||||||||||||
Zero or None | Yes - Duration Unknown | ||||||||||||||||||||||||||||||||||||
Processes | Mode of Operation | Type of material released | Status of Operation | ||||
REFINING | Start-up | Flammable | Open | ||||
Alkylation HF | Planned shutdown | Combustible | Closed | ||||
Alkylation sulfuric | Emergency shutdown | Toxic | |||||
BitumenResidAsphalt | Normal | Corrosive | Tier 1 Acute Releases | ||||
Calcining | Upset | Utilities | No Release | ||||
Coking | Turnaround | Other | Category 1 | ||||
Crude | Routine maintenance | Category 2 | |||||
Desulfurization | Temporary | Evacuation | Category 3 | ||||
FCC | Other | Yes | Category 4 | ||||
Gas Treating | No | Category 5 | |||||
Hydrogen | Point of Release | Category 6 | |||||
Hydrotreating | Pump | Fire | Category 7 | ||||
Hydrocracking | Compressor | Yes | Multiple Categories | ||||
Isom | BlowerFan | No | |||||
MarineJetty | Pressure Vessel | lt $2500 | |||||
Reforming | FilterCoalescer | ||||||
Sulfur recovery | Furnace | PRDs | |||||
Vapor recoverylight ends | Boiler | Directly to Atmosphere | |||||
Wastewater | Heat exchanger | via Downstream Destructive Device | |||||
REFINING amp PETROCHEMICAL | Cooling Tower | No | |||||
Tank FarmStorage FacilityOffsite | Piping system | Yes | |||||
UtilitiesSteam PlantCogeneration | Reactor | No | |||||
Other | Atmospheric tank | ||||||
PETROCHEMICAL | FlareRelief System | Acute release above thresholds | |||||
CO H2 | Other | Yes | |||||
LNG | No | ||||||
Methane | Events | ||||||
Methanol | No Tier 1 Events | Indoor Outdoor | |||||
Methyl Mercaptan | No Tier 2 Events | No Release | |||||
Formaldehyde | No Tier 1 or Tier 2 Events | Indoor | |||||
Formaldehyde derivatives | NA | Outdoor | |||||
Acetic Acid | |||||||
Acetic Acid derivatives | Event Type | ||||||
Ethane | Injury | ||||||
Ethylene | Fire | ||||||
Ethanol | Explosion | ||||||
Ethylene oxide | PRD Discharge | ||||||
Ethylene derivatives | Acute Release | ||||||
Polyethylene | |||||||
Ethylene dichloride | General | ||||||
Ethylene dichloride derivatives | Yes | ||||||
Ethyl benzene | No | ||||||
Ethyl benzene derivatives | |||||||
Polystyrene | |||||||
Styrene-Butadiene | |||||||
Propane | |||||||
Propylene | |||||||
Polypropylene | |||||||
Isopropanol | |||||||
Propylene oxide | |||||||
Propylene oxide derivatives | |||||||
Butane | |||||||
Isobutane | |||||||
Isobutene | |||||||
Butadiene | |||||||
MTBE | |||||||
ETBE | |||||||
Pentane | |||||||
Hexane | |||||||
Cyclohexane | |||||||
Hexanol | |||||||
Aromatics Derivatives | |||||||
Benzene | |||||||
Toluene | |||||||
Xylene | |||||||
Para Xylene | |||||||
Amines Derivatives | |||||||
TDA MDA IPDA etc | |||||||
Isocyanates | |||||||
Specialty Chemicals | |||||||
LoadingUnloading | |||||||
Pilot Plant |
Instructions | ||||||||||||||
Step 1 | Complete the Contact Tab with your contact information and company information | |||||||||||||
Be sure to note the region of your reporting (IE North America France Japan etc) | ||||||||||||||
Survey on Process Safety Events | ||||||||||||||
Step 2 | Complete the survey one line per Process Safety Event for your companyregion | |||||||||||||
ALL REPORTED DATA SHOULD BE FROM CALENDAR YEAR 2017 | ||||||||||||||
Step 3 | Return completed survey to | |||||||||||||
Company Name | ||||||||||||||
Contact Person | All Surveys Due by xxx date | |||||||||||||
Address | ||||||||||||||
Fax | ||||||||||||||
Telephone | ||||||||||||||
Region | ||||||||||||||
None | |
$2500 to $25000 | |
$25000 to $250000 | |
$250000 to $25000000 | |
More than $25000000 | |
Yes - Using GHS TABLE | |
Yes - Using API RP 754 TABLE | |
NO | |
NA | |
1x le TQ lt 40x | |
40x le TQ lt 160x | |
160x le TQ lt 640x | |
ge 640x TQ | |
Yes le 3 hours | |
Yes 3 hours ge 12 hours | |
Yes 12 hours ge 24 hours | |
Yes ge 24 hours | |
No | |
Small-scale | |
Medium-scale | |
Large-scale | |
No | |
Yes | |
No | |
middot Injury requiring treatment beyond first aid to an employee contractor or subcontractor | |
middot Days Away From Work injury to an employee contractor or subcontractor or middot Injury requiring treatment beyond first aid to a third party | |
middot A fatality of an employee contractor or subcontractor or middot A hospital admission of a third party | |
middot Multiple fatalities of employees contractors or subcontractors or middot multiple hospital admission of third parties or middot A fatality of a third party | |
NA | |
1x le TQ lt 3x | |
3x le TQ lt 9x | |
9x le TQ lt 27x | |
ge 27x TQ |
ICCA Process Safety Pilot Reporting ProgramFebruary 8 2016 | 1 | 2 | 3 | 4 | 5 | 6 | 7 | 8 | 9 | 10 | 12 | 13 | 14 | 15 | |||||||||||||||||||||||
SAFETY Details(Meeting Local Regulations) | Direct Cost from Fire or Explosion | Community Impact | Environmental Impact | Material Released(Measured using the 1 Hour Rule) | |||||||||||||||||||||||||||||||||
Company Association Details | |||||||||||||||||||||||||||||||||||||
GHS | API - RP 754 | ||||||||||||||||||||||||||||||||||||
Company or Assocation Name | Headquarter Association | Location of Event Ex - City State amp Country | Date and Time of Event | Safety InjuryDid the Event result in a Recordable Lost Time Accident or Fatality or Hospital admission of anyone on or off siteUse Drop Down Menu | Safety InjuryIf yes please insert the total number of injuries | Safety InjuryFor puropses of utilizing the Severity Table please indicate the level of severity by chosing the MOST SEVERE classification that describes your incidentUse Drop Down Menu | Safety InjuryDid the incident involve Fatalities If so how many total fatalities If none enter Zero | Safety InjuryPlease Report Total Employee Hours for Calendar Year 2015 | Safety InjuryPlease Report Total Contractor Hours for Calendar Year 2015 | Direct Cost Did the Event result in Direct Damage CostUse Drop Down Menu | Direct Cost If so how muchAmount is in US DollarsUse Drop Down Menu | Community ImpactDid the event result inbull Officially declared shelter-in-place or officially declared evacuation (on or off site)ORbull Precautionary off site shelter in place or evacuation Use Drop Down Menu | Environmental ImpactDid the event result inAcute Environmental Remediation CostIf so indicate the amount in US DollarsUse Drop Down Menu | Material ReleasedDid the Event result in an Acute Release of material beyond one of the two threshold tablesIf so indicate which Threshold Table you used to make this determinationUse Drop Down Menu | Material ReleasedIf so indicate the amount released USING GHS CLASSIFICATION TABLEUse Drop Down Menu | Material ReleasedIf so indicate the amount released USING THE THRESHOLD TABLE FROM API RP-754Use Drop Down Menu | Material ReleasedIf available please indicate the material released | ||||||||||||||||||||
1 | ABC Chemical Company | American Chemistry Council | Washington DC - USA | January 4 2016 | Yes | 2 | middot Days Away From Work injury to an employee contractor or subcontractor or middot Injury requiring treatment beyond first aid to a third party | 0 | 5525000 | 1500250 | No | $2500 to $25000 | Yes le 3 hours | $2500 to $25000 | Yes - Using GHS TABLE | 40x le TQ lt 160x | NA | Chlorine | |||||||||||||||||||
2 | XYZ Chemical Company | American Chemistry Council | Washington DC - USA | 5-Jan-16 | Yes | 1 | middot Injury requiring treatment beyond first aid to an employee contractor or subcontractor | 0 | 5525000 | 1500250 | Yes | $2500 to $25000 | No | $2500 to $25000 | Yes - Using API RP 754 TABLE | NA | 3x le TQ lt 9x | Benzene | |||||||||||||||||||
3 | |||||||||||||||||||||||||||||||||||||
4 | |||||||||||||||||||||||||||||||||||||
5 | |||||||||||||||||||||||||||||||||||||
6 | |||||||||||||||||||||||||||||||||||||
7 | |||||||||||||||||||||||||||||||||||||
8 | |||||||||||||||||||||||||||||||||||||
9 | |||||||||||||||||||||||||||||||||||||
10 | |||||||||||||||||||||||||||||||||||||
11 | |||||||||||||||||||||||||||||||||||||
12 | |||||||||||||||||||||||||||||||||||||
13 | |||||||||||||||||||||||||||||||||||||
14 | |||||||||||||||||||||||||||||||||||||
15 | |||||||||||||||||||||||||||||||||||||
16 | |||||||||||||||||||||||||||||||||||||
17 | |||||||||||||||||||||||||||||||||||||
18 | |||||||||||||||||||||||||||||||||||||
19 | |||||||||||||||||||||||||||||||||||||
20 | |||||||||||||||||||||||||||||||||||||
21 | |||||||||||||||||||||||||||||||||||||
22 | |||||||||||||||||||||||||||||||||||||
23 | |||||||||||||||||||||||||||||||||||||
24 | |||||||||||||||||||||||||||||||||||||
25 | |||||||||||||||||||||||||||||||||||||
Zero or None | Yes - Duration Unknown | ||||||||||||||||||||||||||||||||||||
Processes | Mode of Operation | Type of material released | Status of Operation | ||||
REFINING | Start-up | Flammable | Open | ||||
Alkylation HF | Planned shutdown | Combustible | Closed | ||||
Alkylation sulfuric | Emergency shutdown | Toxic | |||||
BitumenResidAsphalt | Normal | Corrosive | Tier 1 Acute Releases | ||||
Calcining | Upset | Utilities | No Release | ||||
Coking | Turnaround | Other | Category 1 | ||||
Crude | Routine maintenance | Category 2 | |||||
Desulfurization | Temporary | Evacuation | Category 3 | ||||
FCC | Other | Yes | Category 4 | ||||
Gas Treating | No | Category 5 | |||||
Hydrogen | Point of Release | Category 6 | |||||
Hydrotreating | Pump | Fire | Category 7 | ||||
Hydrocracking | Compressor | Yes | Multiple Categories | ||||
Isom | BlowerFan | No | |||||
MarineJetty | Pressure Vessel | lt $2500 | |||||
Reforming | FilterCoalescer | ||||||
Sulfur recovery | Furnace | PRDs | |||||
Vapor recoverylight ends | Boiler | Directly to Atmosphere | |||||
Wastewater | Heat exchanger | via Downstream Destructive Device | |||||
REFINING amp PETROCHEMICAL | Cooling Tower | No | |||||
Tank FarmStorage FacilityOffsite | Piping system | Yes | |||||
UtilitiesSteam PlantCogeneration | Reactor | No | |||||
Other | Atmospheric tank | ||||||
PETROCHEMICAL | FlareRelief System | Acute release above thresholds | |||||
CO H2 | Other | Yes | |||||
LNG | No | ||||||
Methane | Events | ||||||
Methanol | No Tier 1 Events | Indoor Outdoor | |||||
Methyl Mercaptan | No Tier 2 Events | No Release | |||||
Formaldehyde | No Tier 1 or Tier 2 Events | Indoor | |||||
Formaldehyde derivatives | NA | Outdoor | |||||
Acetic Acid | |||||||
Acetic Acid derivatives | Event Type | ||||||
Ethane | Injury | ||||||
Ethylene | Fire | ||||||
Ethanol | Explosion | ||||||
Ethylene oxide | PRD Discharge | ||||||
Ethylene derivatives | Acute Release | ||||||
Polyethylene | |||||||
Ethylene dichloride | General | ||||||
Ethylene dichloride derivatives | Yes | ||||||
Ethyl benzene | No | ||||||
Ethyl benzene derivatives | |||||||
Polystyrene | |||||||
Styrene-Butadiene | |||||||
Propane | |||||||
Propylene | |||||||
Polypropylene | |||||||
Isopropanol | |||||||
Propylene oxide | |||||||
Propylene oxide derivatives | |||||||
Butane | |||||||
Isobutane | |||||||
Isobutene | |||||||
Butadiene | |||||||
MTBE | |||||||
ETBE | |||||||
Pentane | |||||||
Hexane | |||||||
Cyclohexane | |||||||
Hexanol | |||||||
Aromatics Derivatives | |||||||
Benzene | |||||||
Toluene | |||||||
Xylene | |||||||
Para Xylene | |||||||
Amines Derivatives | |||||||
TDA MDA IPDA etc | |||||||
Isocyanates | |||||||
Specialty Chemicals | |||||||
LoadingUnloading | |||||||
Pilot Plant |
Instructions | ||||||||||||||
Step 1 | Complete the Contact Tab with your contact information and company information | |||||||||||||
Be sure to note the region of your reporting (IE North America France Japan etc) | ||||||||||||||
Survey on Process Safety Events | ||||||||||||||
Step 2 | Complete the survey one line per Process Safety Event for your companyregion | |||||||||||||
ALL REPORTED DATA SHOULD BE FROM CALENDAR YEAR 2017 | ||||||||||||||
Step 3 | Return completed survey to | |||||||||||||
Company Name | ||||||||||||||
Contact Person | All Surveys Due by xxx date | |||||||||||||
Address | ||||||||||||||
Fax | ||||||||||||||
Telephone | ||||||||||||||
Region | ||||||||||||||
12
3 就地避難 疏散
官方宣告就地避難或疏散(廠內或廠外)或廠外預防性就地避難或疏散
就提報目的而言官方宣告就地避難或疏散(廠內或廠外)或廠外預防性就地避難或疏散
即達到此提報門檻
官方宣告 ndash 由地方權責機關(如消防警察民防緊急應變管理部門)或經授權的代表(如
派駐公司官員)下達的社區行動(如就地避難或疏散)宣告
預防性宣告 ndash 預防性公眾應變是基於謹慎的態度所採取的一種措施權責地方主管機關或經
授權的代表經合理判斷認定為維護公眾健康及安全發布必須採取就地避難或疏散之預
防性措施
就地避難 ndash 利用結構體及其內部空氣以暫時讓人員與室外危害性氣體隔離
疏散 ndash 基於安全或防護理由讓人員離開某處所的行動或過程
4 洩漏恕限值
超過表 1 中所列 GHS 恕限值或表 2 中所列 API 754 標準 Tier II 製程安全洩漏恕限值之一的
急性洩漏事件(洩漏量以單位小時計量)
如ldquo執行摘要rdquo所述ICCA 製程安全事件之定義容許採用 ICCA 依據化學品全球調和制度
(GHS)健康危害分級為基礎所發展的提報標準或依據聯合國危險物品(UNDG)分類為基礎
所定義之 RP-754 二級製程安全事件(Tier II) 之提報標準GHS 恕限值詳見表 1各會員公司
可自行決定選擇哪一個表中的提報恕限值並在全球採用單一制度
ldquo急性rdquo洩漏 ndash易燃性可燃性或毒性化學物質從一次阻絕設施(如容器或管線)洩漏其
任一單位小時之洩漏量超過化學物質洩漏恕限量分述於表 1 中的 GHS 分類和表 2 中的
API 754 標準 Tier II 製程安全洩漏恕限值
洩壓裝置前述所定義之ldquo急性rdquo洩漏包括洩漏或排放至妥善設計且運作中的洩壓裝置若
洩漏或排放量達到表 1 中所列 GHS 恕限值或表 2 中所列 API 754 標準 Tier II 製程安全洩漏
恕限值且導致下列四種後果之任一項或以上之後果
1 二相排放或夾帶液體的排放液滴沉降至地面造成污染
2 排放至具潛在危險性的地點
3 廠內就地避難或疏散不包括預防性廠內就地避難或疏散
4 啟動公眾保護措施(如道路封閉)包括預防性公眾保護措施
13
洩漏或排放至妥善設計且運作中的洩壓裝置(如廢氣燃燒塔洗滌塔等)若其情況未達前
述四項標準中任何一項則不必提報
欲查看 API RP-754 標準可登入以下網站下載此標準httpwwwapiorgenvironment-
health-and-safetyprocess-safetyprocess-safety-standardsstandard-rp-754
一小時法則
為便於衡量此項指標提報與否洩漏恕限值是以物質在任一小時內之洩漏量為標準若任
一小時或更短時間內物質洩漏量達到或超過須提報恕限值該事故便屬於須提報的製程安
全事件急性洩漏事故通常不會超過一小時若無法確定洩漏持續時間則應假設其為一
小時
一次阻絕設施ndash 用來作為主要容器或用於運送或輸送物質之槽罐船隻管線軌道車
或設備主要容器在設計上可能包含二次阻絕設施系統以抑制及控制洩漏二次阻絕設
施系統包括(但不限於)儲槽防溢堤製程設備周遭的圍堵設施油水分離的排水收集系統
雙層儲槽的外壁等
嚴重程度表 ndash 嚴重程度加權可額外提供有關製程安全事件的有用資訊有助於帶動改善績
效附錄 A 為 RCLG 建議之製程安全事件嚴重程度加權計算方法根據附錄 A 的方法便
可藉由加總與各個後果類別關聯的分數計算出各製程安全事件的嚴重程度加權值ICCA
強烈建議採用嚴重程度加權制度因為此制度有助於提升溝通績效的能力也比較容易讓
利害關係人了解製程安全事件並且此嚴重程度加權值與其他製程安全績效指標提報方
式是不具相互比較性的
14
表 1 ndash GHS 分類表
物理性危害(GHS 2x)
洩漏恕限值(1 小時內)
STOTSpecific target organ toxicity(特定標的器官系統毒性物質)
15
表 2 ndash API RP 754 Tier II 分類表
洩漏恕限類別
物質危害性分類 acdef 恕限值
(戶外洩漏) 恕限值
(戶內b洩漏)
T2-1 TIH A 區物質 ge 05 kg (11 lb) ge 025 kg (055
lb)
T2-2 TIH B 區物質 ge 25 kg (55 lb) ge 125 kg (275
lb)
T2-3 TIH C 區物質 ge 10 kg (22 lb) ge 5 kg (11 lb)
T2-4 TIH D 區物質 ge 20 kg (44 lb) ge 10 kg (22 lb)
T2-5
易燃氣體 或 正常沸點 ≦ 35 (95 degF)閃火點lt23 (73 degF)的液體 或 其他包裝組別 I 類的物質 (酸鹼除外)
ge 50 kg (110 lb) ge 25 kg (55 lb)
T2-6
正常沸點 gt 35 degC (95 degF)閃火點 lt 23 degC (73degF)的液體 或 其他包裝組別 II 類的物質 (酸鹼除外)
ge 100 kg (220 lb) 或
ge 07 bbl
ge 50 kg (110 lb) 或
ge 035 bbl
T2-7
閃火點 gt 23 degC (73 degF)和 lt 60 degC (140 degF)的液體 或 閃火點 gt 60 degC (140 degF)的液體在閃火點或高於閃火點的溫度下洩漏 或 強酸鹼 (定義參見 RP 754 文件草案) 或 UNDG第2類第22部分 (不可燃無毒氣體)空氣除外 或 其他包裝組別 III 類的物質
ge 200 kg (440 lb) 或
ge 14 bbl
ge 100 kg (220 lb) 或
ge 07 bbl
T2-8
閃火點 gt 60 degC (140 degF) 和 lt 93 degC (200 degF)的液體在低於閃火點的溫度下洩漏 或 中度酸鹼
ge 1000 kg
(2200 lb) 或
ge 7 bbl
ge 500 kg
(1100 lb) 或
ge 35 bbl
TIH吸入性毒性危害物(Toxic Inhalation Hazard)
16
一般認為以公斤和磅或以磅和桶為單位的恕限值不盡等同各公司應該選用其中一組計量單位並在
所有紀錄文件中一體適用
在判定一種物質之洩漏恕限類別時首先應從物質之含吸入性毒性(TIH Zone)可燃性(閃火點和沸點)
或腐蝕性(強酸或鹼 vs中度酸或鹼)等特性來判別只有當物質的危險度無法利用上述簡單的特性來判別
時(如遇水反應劇烈)才採用UNDGL包裝組別
a 許多物質具有一種以上危險性正確的危險區(Hazard Zone)或包裝組別(Packing Group)歸屬應遵循DOT
49 CFR 1732a [14]或聯合國危險物品運輸建議書(UNRTDG)第2部分[12]的規定參見附錄F
b 具有四面完整牆(從地板到天花板)地板和屋頂的結構物
c 對於未列於UNDG的溶液無水成分將用TIH區或包裝組別分類溶液之恕限值將根據乾基重量之恕限
值反算
d 對於未知UNDG分類的混合物可計算每種成分在恕限值洩漏中的分量如果各種成分之分量的總和
等於或大於100即表示混合物超過門檻值若混合物有明顯且獨立的毒性及可燃性結果則可分
別計算毒性及可燃性危險度參見附錄EPSE實例amp問題 49ndash53
e 閃火點 gt 60 degC (140 degF) 和 lt 93 degC (200 degF)的液體在低於閃火點的溫度下洩漏無論洩漏量多寡其
一次阻絕設施失效(LOPC)均不屬於Tier 1製程安全事件(PSE)
f 中度酸鹼的一次阻絕設施失效無論洩漏量多寡均不屬於Tier 1製程安全事件
17 (K = 1000 MM = 1000000) (在環境影響類別方面若缺乏既有定義協會和會員公司應議定輸入標準)
附錄 A ndash 嚴重程度表鼓勵所有協會均採用嚴重程度加權制度
事件事故類別
嚴重程度等級
安全人體健康 火災或爆炸導致直接
成本 任 1 小時內物質洩
漏量 社區影響 環境影響[廠外]
4 級
1 分
對員工承攬商或再承攬商造成較輕傷害嚴重之傷害 (符合本地法規)
造成以下直接損失成本
美金$25 K ~ $25 K
洩漏量介於
1x le TQ lt 40x
官方宣告就地避難或疏散 (廠內或廠外) 預防性廠外就地避難或疏散
le 3 小時
重大環境整治成本
$25 K ~ $25 K
3 級
3 分
對員工承攬商或再承攬商造成之需要多日缺勤的傷害
對第三方造成之需要初步急救以外治療的傷害 (符合本地法規)
造成以下直接損失成本
$25 K ~ $250 K
洩漏量介於
40x le TQ lt 160x
官方宣告就地避難或疏散 (廠內或廠外)
預防性廠外就地避難或疏散
3 ~ 12 小時
重大環境整治成本
$25 K ~ $250 K
2 級
9 分
對員工承攬商或再承攬商造成 1 人死亡
對第三方造成 1 人住院治療
(符合本地法規)
造成以下直接損失成本
$250 K ~ $25 MM
洩漏量介於
160x le TQ lt 640x
官方宣告就地避難或疏散 (廠內或廠外)
預防性廠外就地避難或疏散
12 ~ 24 小時
重大環境整治成本
$250 K ~ $25 MM
1 級
27 分
對員工承攬商或再承攬商造成多人死亡
對第三方造成多人住院治療
對第三方造成 1 人死亡 (符合本地法規)
造成以下直接損失成本
ge $25 MM
洩漏量
ge 640x TQ
官方宣告就地避難或疏散 (廠內或廠外)
預防性廠外就地避難或疏散
ge 24 小時
重大環境整治成本
ge $25 MM
18 (K = 1000 MM = 1000000) (在環境影響類別方面若缺乏既有定義協會和會員公司應議定輸入標準)
嚴重程度表(附錄 A)細節說明
附錄 A 之設計目的僅適用於採用 GHS 分類制度(表 1)者如果你的公司係採用 API RP 754Tier II 製程安全指標提報恕限值表(表 2)請使用
API RP 754 製程安全嚴重程度表必須提醒的是依 API RP 754 的標準其嚴重程度表僅適用於一級(Tier I)事故去比較採用不同的嚴重度
表所評估出來的相對嚴重度並無統計上的意義
急性的環境成本 ndash 因製程安全事件造成廠外環境影響所導致之短期清理及物質處置的成本各會員公司可選擇將廠外環境影響相關成本另
外區分一個嚴重程度類別
比率調整指標
利用上述嚴重程度表可產生一系列以事件率為基礎的指標包括
製程安全總事件率 (PSTIR) 總事件次數 x 200000
總工作時數
製程安全事件嚴重程度率(PSESR) (即製程安全事件嚴重程度加權計算公式)
PSESR = 所有事件之總嚴重程度分數總合 x 200000
總工作時數
在計算此一比率時各 4 級事件被分配 1 分各 3 級事件被分配 3 分各 2 級事件被分配 9 分各 1 級事件被分配 27 分理論上每個
製程安全事件至少可分配到 1 分(亦即事件僅在一個類別符合第 4 級事件屬性)至多可分配到 135 分(亦即事件在所有五個類別中均符
合第 1 級事件屬性)
ldquoXrdquo級別製程安全事件率 嚴重度級別ldquoXrdquo之製程安全事件總數 x 200000
員工承攬商amp再承攬商總工作時數
X可以是嚴重度級別 432 或 1 級製程安全事件之總數事件之嚴重度等級是選用五類後果類別中之最嚴重等級
標準化 ndash 在某些協會和會員公司中製程安全事件是採 lsquo每 100 名rsquo員工每名員工每年平均工作時數為 2000 小時為基礎予以標準化因
此在lsquo每 100rsquo名rsquo員工的標準基礎上事件被乘以 200000 工作時數也有些其他協會和會員公司將標準化基礎設定為lsquo每 500 名rsquo員工
因此事件被乘以 1000000 工作時數協會和會員公司應就標準化基礎進行討論共同做成選項結論上述的公式設定為lsquo每 100 名rsquo員工
基礎
19
附錄 B ndash 常見問題集
適用性
我們建議會員公司記錄和提報在其所擁有或運作的工廠內發生的製程安全事件惟以下情況不須提報製
程安全事件
1 源自於公司廠區以外的製程安全事件
2 海上運輸船事故惟船隻為了輸送半成品或產品之目的已經與公司的設施相連接時發生的
事故仍須提報
3 卡車或軌道車事故惟卡車或軌道車為了輸送半成品或產品之目的已經與公司的設施相連
接時發生的事故仍須提報
4 許可證或法規容許之例行排放
5 不會造成製程安全危害的地下污染請注意若洩漏至地下導致地上發生須提報製程安全事
件如釋放出毒性蒸汽或致使易燃液體蓄積成池則不適用本排除條件
6 辦公建築事故(如辦公室暖氣設備爆炸火災外溢洩漏人員受傷或疾病等)
7 與疏散或一次阻絕設施失效無直接關聯之人員安全ldquo滑倒絆倒跌倒rdquo事故
8 沒有與製程相連接之輔助設備的一次阻絕設施(如小樣品瓶)失效事故
9 計劃中和在控制下的物質排放至設計用來收集或排放系統中(請注意物質從一次阻絕設施
在非計劃或非受控制情況下排放至收集或排放系統中則不適用本排除條件)
10 在製程區域外部或保養廠內執行之機械作業
說明與實例 ndash 以 GHS 表 1 為基礎
以下說明和實例有助於在評估須提報製程安全事件(PSE)時釐清可能存在的不確定部分
公司廠區
1 一輛第三方的卡車在公司廠區內卸載易燃產品時發生洩漏進而引起火災造成公司財物損失
$7000 美元(直接成本)雖然該卡車是ldquo由他人操作rdquo但其作業與製程相連接若公司的直接成
本財物損失達到或超過$2500 美元或已達到或超過其他 PSE 提報門檻(如1 人死亡)此事故即
屬於須提報的製程安全事件
2 與前例1 類似的例子載著易燃產品的卡車在廠外運輸途中翻覆引發火災並造成卡車毀損
該事故不屬於須提報的製程安全事件因為當時卡車並未與製程相連接
20
阻絕設施失效
3 儲槽液位計故障造成裝有ldquo易燃液體rdquo產品的儲槽外溢約 700 公斤的液體流入儲槽的防溢堤內
此事故屬於須提報的製程安全事件因為其ldquo急性rdquo洩漏量超過 100 公斤即使是阻絕在二次阻絕
設施防溢堤中亦然
4 一名從事維修工作的承攬商在開啟一個製程阻閥時被噴起的硫酸濺到造成嚴重灼傷和損失工
時的工傷此事故屬於須提報的製程安全事件因為它是涉及物質和一次阻絕設施失效的意外事
件對於因洩漏造成死亡和損工的工傷或疾病事故沒有洩漏恕限值
5 一名作業員開啟品管取樣點進行日常取樣作業時手部被一個破碎的玻璃瓶嚴重割破需要進行
縫合治療縫針造成第二天無法上班該事故不屬於須提報的製程安全事件因為它與一次阻絕
設施失效無關
ldquo急性rdquo洩漏
6 一名作業員在進行天然氣流量高於預期值之異常排除時發現天然氣管線上的一個安全閥門未適
當歸位因此天然氣經由氣液分離桶排放至排氣煙囪經進一步檢查作業員判斷在過去 6 個
月間總共有 100000 公斤天然氣以穩定的速率排放至大氣該事故不屬於須提報的製程安全事
件因為其洩漏速率(每小時約 10 公斤)不算ldquo急性rdquo洩漏(未超過易燃蒸汽每小時 100 公斤的恕限
值)
廢氣燃燒塔amp排放控制裝置 (如洗滌塔)
7 若化學物質被導引至廢氣燃燒塔或排放控制裝置(如洗滌塔)只要該廢氣燃燒塔或控制裝置運作在
正常設計範圍內便不屬於須提報的製程安全事件
8 若廢氣流速超過洗滌塔的設計負荷以致未經吸收的化學物質排出超過恕限值該事故屬於須提報
的製程安全事件(如本文註釋所述)
註釋自取得許可或妥善管理的裝置-包括釋壓裝置發生不預期的排放若 1 小時內洩漏量達到或
超過表 1 或表 2 所列的洩漏恕限值且導致下列四種後果之任一項或以上之後果該事故便屬於
須提報的製程安全事件
o 二相排放或夾帶液體的排放液滴沉降至地面造成污染
o 排放至具潛在危險性的地點)
o 廠內就地避難或疏散不包括預防性廠內就地避難或疏散
o 啟動公眾保護措施(如道路封閉)包括預防性公眾保護措施
21
安全洩壓裝置 系統
9 製程單元發生異常安全閥開啟將洩漏物質釋放到排氣口此釋壓排放裝置是依相關要求設計
的且氣體釋到大氣中並未造成不良後果這不是一個須提報的製程安全事件因為安全閥高
壓破裂盤以及類似的安全裝置是依據 API 521 或者同等的標準設計的且此排放並未造成 (1)
夾帶液體並導致須提報的製程安全事件的後果(譬如損失工時意外死亡火災或爆炸造成$2500
美元或以上的直接成本損失液體或毒性氣體洩漏量達到或超過恕限值(2) 啟動廠內或廠外就地
避難應變或(3)啟動公眾保護措施
10 製程單元發生異常安全閥並未開啟造成設備超壓易燃性氣體從一個法蘭處ldquo急性rdquo漏出來
洩露量超過 100 公斤(一小時內)的恕限值該事故屬於須提報的製程安全事件因為從法蘭處外
漏屬於製程安全事件應提報事項
損工事故
11 一名作業員走路時不慎滑倒造成損失工時之工傷滑倒原因為天氣狀況rdquo長期rdquo油垢的地面和
易滑鞋具該事故不屬於須提報的製程安全事件因為人員安全ldquo滑倒絆倒跌倒rdquo事故若非與
一次阻絕設施失效直接關聯的疏散或應變造成則不屬於須提報的製程安全事件
12 與前例相同的事件惟這次作業員跌倒是因為少量易燃液體外漏(如 1 小時內少於 10 公斤)在採取
相關應變措施時發生該事故屬於須提報的製程安全事件因為作業員係為了應變一次阻絕設施
失效的事故而跌倒若一次阻絕設施失效發生在公司廠區且造成失時工傷或死亡後果該事故
便屬於須提報的製程安全事件對於因洩漏造成死亡和損失工時之工傷事故沒有洩漏量門檻
13 與前例相同的事件惟這次作業員跌倒是在事件結束數小時之後該事故不屬於須提報的製程安
全事件在提報要件中所用的ldquo疏散rdquo和ldquo應變rdquo等術語指的是一次阻絕設施失效和相關緊急應變
活動正在持續中事件結束後滑倒絆倒跌倒(如ldquo事後rdquo清理和補救)不屬於須提報製程安全事件
14 工人在因附近設備一次阻絕設施失效在疏散過程中一名鷹架搭建工人從鷹架梯上跌落造成損
失工時之工傷該事故屬於須提報的製程安全事件
15 一名作業員行經一個設計不良的蒸汽卻水器時被外洩的蒸汽燙傷腳踝造成損失工時之工傷
該事故屬於須提報的製程安全事件因為雖然一次阻絕設施失效洩漏出的是蒸汽(而非碳氫化合物
或化學物質)但損失工時之工傷是由於洩漏物質的物理狀態所導致的
16 一個密閉空間依照計畫以氮氣吹清一名承攬商繞過安全管制進入該密閉空間因而死亡該事
故屬於須提報的死亡事件但不屬於須提報的製程安全事件因為其中不涉及非計劃或失控的一
次阻絕設施失效
17 情況同上惟這次氮氣是非刻意洩漏進入該局限空間該事故屬於須提報的製程安全事件(同時也
是一起死亡事件)因為該名承攬商的死亡與非計劃的一次阻絕設施失效有關
22
18 一名作業員因硫化氫(H2S)警報在進行應變處理時昏倒若警報確實是因非計劃或失控的 H2S 一次
阻絕設施失效的外洩事件該事故便屬於須提報的製程安全事件若警報是一個假警報則該事
故便不屬於須提報的製程安全事件因為沒有真正的化學品洩漏發生
管線
19 一條管線破漏1 小時內洩漏 2000 磅(900 公斤)易燃蒸氣到地面但洩漏位置在廠區內很偏僻的
地點該事故仍屬於須提報的製程安全事件因為ldquo偏僻rdquo不是提報與否的考量因素
與化學物質外洩無關之火災或能量釋放事故
一般通則而言唯有當火災或能量釋放事故是因化學物質洩漏所造成或其發生導致化學物質洩漏
超過提報恕限值這些事故才屬於須提報的製程安全事件實例包括
20 一場電氣火災影響製程操作導致甲苯洩漏 400 公斤該事故屬於須提報的製程安全事件因為
化學物質洩漏已超過甲苯的 100 公斤提報恕限值
21 發生電氣火災停電或任何公用資源供應中斷可能造成工廠停工及可能引起設備損失超過
$2500 美元(如因非正常停工導致反應器或設備損壞)但並未造成超過恕限值的化學物質洩漏
亦未造成死亡或嚴重工傷該事故不屬於須提報的製程安全事件因為設備損壞並非化學製程火
災爆炸造成且化學物質洩漏並未超過恕限值
海上運輸船
22 一艘由公司營運的海上運輸船在船上發生ldquo急性rdquo易燃物質外洩洩漏量超過 100 公斤該事故不
屬於須提報的製程安全事件因為除非海上運輸船是為了輸送半成品或產品而與煉油石化或化
學製造廠的設施相連接否則其洩漏事故便不被視為製程安全事件
23 一艘第三方駁船由一艘拖船推向碼頭結果撞上公司的碼頭駁船的一個船艙破裂且造成
1000 公斤柴油洩漏到海中該事故不屬於須提報的製程安全事件因為駁船當時並非停泊在碼
頭內且其作業並非在進行半成品或產品之輸送
卡車與軌道車
24 一輛公司的軌道車在運輸途中出軌造成超過 1000 公斤汽油洩漏該事故不屬於須提報的製程
安全事件因為在公司廠區外發生的軌道車事故不被視為與製程安全有關
23
25 一輛第三方卡車拖車在公司廠區內翻覆造成ldquo急性rdquo汽油洩漏超過 1000 公斤這事故不屬於須
提報的製程安全事件因為卡車拖車當時已不再與裝卸設備連接然而我們建議會員公司另
行訂定運輸安全事故指標將這類事故記錄下來
26 一位合約卡車作業者正在卸載液鹼時發生軟管脫落造成空氣中氣霧和或液鹼液洩漏 2500 公
斤該事故屬於須提報的製程安全事件因為洩漏量已超過液鹼的 100 公斤恕限值且事故發生
前卡車仍與裝卸設備相連接著
辦公建築
27 綜合辦公大樓發生鍋爐火災造成總計$75000 美元的直接成本損失該事故不屬於須提報的製
程安全事件因為辦公大樓事故不被視為與製程安全有關
人機介面事故
28 一名操作技術員在聚合物工廠的終端設備旁作業時受傷這傷害是因機械的人機介面的設備而
造成該事故不屬於須提報的製程安全事件因為技術員受傷並非因危險物質一次阻絕設施失效
而造成的
混合物
29 若混合物本身有 GHS 分類可利用其分類確定恕限值若混合物本身沒有 GHS 分類則可計算混
合物中每個單一組成分之洩漏量(公斤)相對於個別成分恕限值之比值作為其對混合物恕限值之
lsquo加權rsquo貢獻譬如若混合物在 1小時內的洩漏量為 100公斤其中包含 05公斤分類為劇毒 H300
的物質45 公斤分類為 H301 的物質40 公斤另一種分類為 H 開頭的物質其餘 55 公斤則為沒
有 GHS 分類的水分此混合物之計算式為051 + 4510 + 40100 = 05 + 045 + 04 = 135超過
1因此該事故被視為須提報的製程安全事件雖然混合物個別成分之洩漏量均未超過各該物質
本身的恕限值
直接損失成本
30 此一門檻所考慮的成本應為可直接歸因於火災或爆炸的成本譬如設備及結構損壞的重置成本
修理成本環境清理支出緊急應變和罰款直接成本不包括間接成本譬如業務機會損失設
備停機造成之利潤損失取得或運轉臨時設施之成本或為滿足顧客需求取得替代產品的成本
(產品損失)
24
31 範例連接到氣體處理系統的排放管發生易燃氣體外漏同時製程出現問題導致空氣進入同
一條排放管結果發生爆炸過高的壓力損壞了排放管及其相關上游設備包括一個密封罐並
未造成人員受傷修理成本約$12000 美元該事故屬於須提報的製程安全事件因為爆炸及火
災導致設備修理成本超過門檻
32 範例一次製程安全事件後公司又發生一種非常特殊的 GHS 第 5 類產品洩漏 50 公斤造成
$2000 美元的設備損失洩漏的產品是一種非常特別的混合物公司須負擔超過$50000 美元因
產品耗損而產生之材料成本該事故不屬於須提報的製程安全事件因為 GHS 第 5 類產品洩漏的
提報門檻為 100 公斤且產品耗損不被計入直接損失成本
天然災害
33 天然災害可能對化學製程作業構成重大風險且對製程設備造成損壞導致危害物質一次阻絕設
施失效當一種或多種天然災害被認為可能對工廠作業造成影響時製程安全和作業系統應從危
害及後果分析工廠機器設備設計公用設施失效及製程停工之操作程序緊急應變計畫及應變
措施等方面界定潛在風險進行防範
天然災害類型包括颶風及颱風(包括伴隨而來的風暴潮)水災龍捲風地震超強對流風暴(直
線風暴)野火火山爆發海嘯和山崩
若公司廠房設施遭遇天然災害且其後果觸發一種或以上提報門檻該事故便屬於須提報製程安
全事件
預防性公眾應變
34 預防性公眾應變是基於謹慎的態度所採取的一種措施譬如當發生一次阻絕設施失效時公司
可能在尚未進行任何評估(如方向與洩漏點的距離等等)前便要求全體工人就地避難又
如地方權責官員(如消防警察民防緊急應變管理部門)在獲報一家公司發生製程安全事件
後為防lsquo萬一rsquo風向改變或基於可能受到波及的人口敏感族群(如學童或老年人)可能在尚未接
獲明確資訊前便下令社區就地避難或疏散或採取公眾保護措施(如道路封閉)
製程附屬倉庫
35 製程附屬倉庫指的是位於廠內用於儲存將投入於生產製程或產自於製程之原料半成品或成品的
倉庫從製程的觀點看來製程附屬倉庫相當於一個大型儲槽但這些原料半成品或成品並不
是儲存在一的大型容器中而是裝在較小的容器裡(如太空包大桶桶罐等)
25
Appendix C ndash List of RCLG Taskforce Members
Name Affiliation
Peter Schmelzer Bayer CEFIC - Chairman
Americo Diniz Carvalho Neto Braskem
Bradford Johnson American Chemistry Council
David Cummings DuPont
Debra Phillips American Chemistry Council
Hans Schwarz BASF
Kathryn Walton Plastics and Chemicals Industries Association
Kazuyuki Akita Japanese Chemical Industry Association
Kelly Keim ExxonMobil Chemical Company API Representative
Kenan Stevick Dow
Kiyokazu Murata Japanese Chemical Industry Association
Larry Bowler SABIC
Lorna Young Chemical Industry Association of Canada
Louisa Nara Center for Chemical Process Safety
Luiz Shizuo Harayashiki Associaccedilatildeo Brasileira da Induacutestria Quiacutemica
Masatoshi Kumamoto Japanese Chemical Industry Association
Milton Lacerda Petrobras
Phil Scott Chemical Industries Association
Piet Knijff DSM European Process Safety Centre
Scott Donaldson and Eamon Chandler
Shell
Scott Wallace Olin Corporation
Shakeel Kadri Air Products and Chemicals Inc
26
附錄 D ndash 詳細活動時程表
2016 年 2017 年 2018 年 2019 年 2020 年
2 ndash 4 月
RCLG PS 先導計畫
5 月 ndash
針對準則進行調整釐清
6 月 向 RCLG 和 ICCA 董事會報
告先導計畫執行結果
7 ndash 12 月 RCLG 協會考量準
則並為其會員公司發展提報機制
如有需要RCLG可向 ICCA 申請能
力建立基金為會員公司舉辦製程安
全研習會
1 ndash 12 月
RCLG 協會開始向其會員公司蒐集製程安全數據
1 ndash 12 月
如有需要RCLG 各協會運用 RCLG 的基金及專
家舉辦製程安全及績效提報研習會
1 ndash 2 月
擁有數據的協會開始向RCLG 提報製程安全事件
(2017 年數據)
4 月 RCLG 檢討第一個提報循
環的結果挑戰及原始數據(內部)
6 月 RCLG 向 ICCA 董事會呈報
原始數據
7 ndash 12 月 必要時更新及調整準
則
如有需要RCLG 各協會運用 RCLG 的基金及專
家舉辦製程安全及績效提報研習會
1 ndash 2 月
擁有數據的協會開始向RCLG 提報製程安全事件
(2018 年數據)
4 月 RCLG 檢討第二個提報循
環的結果挑戰及原始數據(內部)
6 月 RCLG 向 ICCA 董事會呈報
原始數據
7 ndash 12 月 必要時更新及調整準
則
如有需要RCLG 協會運用 RCLG 的基金及專家
舉辦製程安全及績效提報研習會
1 ndash 2 月
所有協會開始向 RCLG 提報製程安全事件
製程安全事件提報成為
RCLG KPI 衡量指標建議基本集的一部分(2019 年數
據)
4 月 RCLG 檢討第二個提報循
環的結果挑戰及原始數據(內部考量外部提
報)
6 月 RCLG 向 ICCA 董事會呈報
原始數據
27
附錄 E ndash 選擇性 Excel 追蹤表
當會員公司開始追蹤製程安全事件時所有會員公司應採用單一表格以簡化數據分析同時讓所有公司均使用相同的追蹤表RCLG 設
計了一份選擇性追蹤表可供會員公司和協會先行利用之後他們可設計自己的追蹤表
在這裡下載追蹤表
ICCA Process Safety Event Tracking Sheetxlsx
本文件包含三個分頁分別是ldquo聯絡資料rdquoldquo調查表rdquo和儲存下拉式選單選項的ldquo請勿編輯rdquo分頁
備註
附錄 E 追蹤表僅供參考TRCA 將另行提供台灣版表格供會員公司提報
28
後語
台灣化學工業責任照顧協會(Taiwan Responsible Care Association TRCA)成立於 1998 年在台灣推行責任照顧制度已達 20 週年製造商成員
包括台灣主要上市上櫃化工公司會員公司化學品生產製造量約佔全國 80 2016 年台灣化工業的 Chemical Sales 仍站在全球第八名的位
置額度為 630 億歐元化工業總產值達到 34 兆新台幣提供國內 416 萬人工作機會
TRCA 扮演國內廠商與國際制度接軌的角色也是國內化工業與政府機關及利益相關者溝通的橋樑與管道TRCA 會員結構依業務性質分析
涵蓋石化生產化學品製造氣體生產倉儲運輸業化學品貿易業以及工程研發設計等公司TRCA 透過供應鏈及價值鏈推行責任
照顧制度組成毒性化學物質聯防組織協助法規溝通與研析會員名冊請參考 httpwwwtrcaorgtwtrcanwork2aspx
TRCA 於 2010 年成為 ICCA (International Council of Chemical Associations 國際化學工業協會)觀察員ICCA 成立於 1989 年是全球化工製造
業的聯合會也是化學工業與 UNEP OPCW 及 OECD 的交流窗口ICCA 與其會員協會及成員公司致力於邁向永續的未來確保人類健康與
環境安全與保護全球化工業擁有超過 4兆美元的價值影響所有經濟部門ICCA 的會員幾乎在全球每個國家都有商業活動在全球六大
洲推動創新並提供超過 2000 萬個工作機會
台灣化工業在全球占有重要的一席之地在國內產業鏈也位居關鍵位置無論對國內或國際都有身為地球村一員應盡之責我們期許藉由
製程安全指標提報能更進一步提升自我在工安衛生環保與永續發展等面向的績效表現
台灣化學工業責任照顧協會
10452 台北市中山區撫順街 8 號 7 樓
電話02-2585-0552
httpwwwtrcaorgtw
None | |
$2500 to $25000 | |
$25000 to $250000 | |
$250000 to $25000000 | |
More than $25000000 | |
Yes - Using GHS TABLE | |
Yes - Using API RP 754 TABLE | |
NO | |
NA | |
1x le TQ lt 40x | |
40x le TQ lt 160x | |
160x le TQ lt 640x | |
ge 640x TQ | |
Yes le 3 hours | |
Yes 3 hours ge 12 hours | |
Yes 12 hours ge 24 hours | |
Yes ge 24 hours | |
No | |
Small-scale | |
Medium-scale | |
Large-scale | |
No | |
Yes | |
No | |
middot Injury requiring treatment beyond first aid to an employee contractor or subcontractor | |
middot Days Away From Work injury to an employee contractor or subcontractor or middot Injury requiring treatment beyond first aid to a third party | |
middot A fatality of an employee contractor or subcontractor or middot A hospital admission of a third party | |
middot Multiple fatalities of employees contractors or subcontractors or middot multiple hospital admission of third parties or middot A fatality of a third party | |
NA | |
1x le TQ lt 3x | |
3x le TQ lt 9x | |
9x le TQ lt 27x | |
ge 27x TQ |
ICCA Process Safety Pilot Reporting ProgramFebruary 8 2016 | 1 | 2 | 3 | 4 | 5 | 6 | 7 | 8 | 9 | 10 | 12 | 13 | 14 | 15 | |||||||||||||||||||||||
SAFETY Details(Meeting Local Regulations) | Direct Cost from Fire or Explosion | Community Impact | Environmental Impact | Material Released(Measured using the 1 Hour Rule) | |||||||||||||||||||||||||||||||||
Company Association Details | |||||||||||||||||||||||||||||||||||||
GHS | API - RP 754 | ||||||||||||||||||||||||||||||||||||
Company or Assocation Name | Headquarter Association | Location of Event Ex - City State amp Country | Date and Time of Event | Safety InjuryDid the Event result in a Recordable Lost Time Accident or Fatality or Hospital admission of anyone on or off siteUse Drop Down Menu | Safety InjuryIf yes please insert the total number of injuries | Safety InjuryFor puropses of utilizing the Severity Table please indicate the level of severity by chosing the MOST SEVERE classification that describes your incidentUse Drop Down Menu | Safety InjuryDid the incident involve Fatalities If so how many total fatalities If none enter Zero | Safety InjuryPlease Report Total Employee Hours for Calendar Year 2015 | Safety InjuryPlease Report Total Contractor Hours for Calendar Year 2015 | Direct Cost Did the Event result in Direct Damage CostUse Drop Down Menu | Direct Cost If so how muchAmount is in US DollarsUse Drop Down Menu | Community ImpactDid the event result inbull Officially declared shelter-in-place or officially declared evacuation (on or off site)ORbull Precautionary off site shelter in place or evacuation Use Drop Down Menu | Environmental ImpactDid the event result inAcute Environmental Remediation CostIf so indicate the amount in US DollarsUse Drop Down Menu | Material ReleasedDid the Event result in an Acute Release of material beyond one of the two threshold tablesIf so indicate which Threshold Table you used to make this determinationUse Drop Down Menu | Material ReleasedIf so indicate the amount released USING GHS CLASSIFICATION TABLEUse Drop Down Menu | Material ReleasedIf so indicate the amount released USING THE THRESHOLD TABLE FROM API RP-754Use Drop Down Menu | Material ReleasedIf available please indicate the material released | ||||||||||||||||||||
1 | ABC Chemical Company | American Chemistry Council | Washington DC - USA | January 4 2016 | Yes | 2 | middot Days Away From Work injury to an employee contractor or subcontractor or middot Injury requiring treatment beyond first aid to a third party | 0 | 5525000 | 1500250 | No | $2500 to $25000 | Yes le 3 hours | $2500 to $25000 | Yes - Using GHS TABLE | 40x le TQ lt 160x | NA | Chlorine | |||||||||||||||||||
2 | XYZ Chemical Company | American Chemistry Council | Washington DC - USA | 5-Jan-16 | Yes | 1 | middot Injury requiring treatment beyond first aid to an employee contractor or subcontractor | 0 | 5525000 | 1500250 | Yes | $2500 to $25000 | No | $2500 to $25000 | Yes - Using API RP 754 TABLE | NA | 3x le TQ lt 9x | Benzene | |||||||||||||||||||
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Zero or None | Yes - Duration Unknown | ||||||||||||||||||||||||||||||||||||
Processes | Mode of Operation | Type of material released | Status of Operation | ||||
REFINING | Start-up | Flammable | Open | ||||
Alkylation HF | Planned shutdown | Combustible | Closed | ||||
Alkylation sulfuric | Emergency shutdown | Toxic | |||||
BitumenResidAsphalt | Normal | Corrosive | Tier 1 Acute Releases | ||||
Calcining | Upset | Utilities | No Release | ||||
Coking | Turnaround | Other | Category 1 | ||||
Crude | Routine maintenance | Category 2 | |||||
Desulfurization | Temporary | Evacuation | Category 3 | ||||
FCC | Other | Yes | Category 4 | ||||
Gas Treating | No | Category 5 | |||||
Hydrogen | Point of Release | Category 6 | |||||
Hydrotreating | Pump | Fire | Category 7 | ||||
Hydrocracking | Compressor | Yes | Multiple Categories | ||||
Isom | BlowerFan | No | |||||
MarineJetty | Pressure Vessel | lt $2500 | |||||
Reforming | FilterCoalescer | ||||||
Sulfur recovery | Furnace | PRDs | |||||
Vapor recoverylight ends | Boiler | Directly to Atmosphere | |||||
Wastewater | Heat exchanger | via Downstream Destructive Device | |||||
REFINING amp PETROCHEMICAL | Cooling Tower | No | |||||
Tank FarmStorage FacilityOffsite | Piping system | Yes | |||||
UtilitiesSteam PlantCogeneration | Reactor | No | |||||
Other | Atmospheric tank | ||||||
PETROCHEMICAL | FlareRelief System | Acute release above thresholds | |||||
CO H2 | Other | Yes | |||||
LNG | No | ||||||
Methane | Events | ||||||
Methanol | No Tier 1 Events | Indoor Outdoor | |||||
Methyl Mercaptan | No Tier 2 Events | No Release | |||||
Formaldehyde | No Tier 1 or Tier 2 Events | Indoor | |||||
Formaldehyde derivatives | NA | Outdoor | |||||
Acetic Acid | |||||||
Acetic Acid derivatives | Event Type | ||||||
Ethane | Injury | ||||||
Ethylene | Fire | ||||||
Ethanol | Explosion | ||||||
Ethylene oxide | PRD Discharge | ||||||
Ethylene derivatives | Acute Release | ||||||
Polyethylene | |||||||
Ethylene dichloride | General | ||||||
Ethylene dichloride derivatives | Yes | ||||||
Ethyl benzene | No | ||||||
Ethyl benzene derivatives | |||||||
Polystyrene | |||||||
Styrene-Butadiene | |||||||
Propane | |||||||
Propylene | |||||||
Polypropylene | |||||||
Isopropanol | |||||||
Propylene oxide | |||||||
Propylene oxide derivatives | |||||||
Butane | |||||||
Isobutane | |||||||
Isobutene | |||||||
Butadiene | |||||||
MTBE | |||||||
ETBE | |||||||
Pentane | |||||||
Hexane | |||||||
Cyclohexane | |||||||
Hexanol | |||||||
Aromatics Derivatives | |||||||
Benzene | |||||||
Toluene | |||||||
Xylene | |||||||
Para Xylene | |||||||
Amines Derivatives | |||||||
TDA MDA IPDA etc | |||||||
Isocyanates | |||||||
Specialty Chemicals | |||||||
LoadingUnloading | |||||||
Pilot Plant |
Instructions | ||||||||||||||
Step 1 | Complete the Contact Tab with your contact information and company information | |||||||||||||
Be sure to note the region of your reporting (IE North America France Japan etc) | ||||||||||||||
Survey on Process Safety Events | ||||||||||||||
Step 2 | Complete the survey one line per Process Safety Event for your companyregion | |||||||||||||
ALL REPORTED DATA SHOULD BE FROM CALENDAR YEAR 2017 | ||||||||||||||
Step 3 | Return completed survey to | |||||||||||||
Company Name | ||||||||||||||
Contact Person | All Surveys Due by xxx date | |||||||||||||
Address | ||||||||||||||
Fax | ||||||||||||||
Telephone | ||||||||||||||
Region | ||||||||||||||
None | |
$2500 to $25000 | |
$25000 to $250000 | |
$250000 to $25000000 | |
More than $25000000 | |
Yes - Using GHS TABLE | |
Yes - Using API RP 754 TABLE | |
NO | |
NA | |
1x le TQ lt 40x | |
40x le TQ lt 160x | |
160x le TQ lt 640x | |
ge 640x TQ | |
Yes le 3 hours | |
Yes 3 hours ge 12 hours | |
Yes 12 hours ge 24 hours | |
Yes ge 24 hours | |
No | |
Small-scale | |
Medium-scale | |
Large-scale | |
No | |
Yes | |
No | |
middot Injury requiring treatment beyond first aid to an employee contractor or subcontractor | |
middot Days Away From Work injury to an employee contractor or subcontractor or middot Injury requiring treatment beyond first aid to a third party | |
middot A fatality of an employee contractor or subcontractor or middot A hospital admission of a third party | |
middot Multiple fatalities of employees contractors or subcontractors or middot multiple hospital admission of third parties or middot A fatality of a third party | |
NA | |
1x le TQ lt 3x | |
3x le TQ lt 9x | |
9x le TQ lt 27x | |
ge 27x TQ |
ICCA Process Safety Pilot Reporting ProgramFebruary 8 2016 | 1 | 2 | 3 | 4 | 5 | 6 | 7 | 8 | 9 | 10 | 12 | 13 | 14 | 15 | |||||||||||||||||||||||
SAFETY Details(Meeting Local Regulations) | Direct Cost from Fire or Explosion | Community Impact | Environmental Impact | Material Released(Measured using the 1 Hour Rule) | |||||||||||||||||||||||||||||||||
Company Association Details | |||||||||||||||||||||||||||||||||||||
GHS | API - RP 754 | ||||||||||||||||||||||||||||||||||||
Company or Assocation Name | Headquarter Association | Location of Event Ex - City State amp Country | Date and Time of Event | Safety InjuryDid the Event result in a Recordable Lost Time Accident or Fatality or Hospital admission of anyone on or off siteUse Drop Down Menu | Safety InjuryIf yes please insert the total number of injuries | Safety InjuryFor puropses of utilizing the Severity Table please indicate the level of severity by chosing the MOST SEVERE classification that describes your incidentUse Drop Down Menu | Safety InjuryDid the incident involve Fatalities If so how many total fatalities If none enter Zero | Safety InjuryPlease Report Total Employee Hours for Calendar Year 2015 | Safety InjuryPlease Report Total Contractor Hours for Calendar Year 2015 | Direct Cost Did the Event result in Direct Damage CostUse Drop Down Menu | Direct Cost If so how muchAmount is in US DollarsUse Drop Down Menu | Community ImpactDid the event result inbull Officially declared shelter-in-place or officially declared evacuation (on or off site)ORbull Precautionary off site shelter in place or evacuation Use Drop Down Menu | Environmental ImpactDid the event result inAcute Environmental Remediation CostIf so indicate the amount in US DollarsUse Drop Down Menu | Material ReleasedDid the Event result in an Acute Release of material beyond one of the two threshold tablesIf so indicate which Threshold Table you used to make this determinationUse Drop Down Menu | Material ReleasedIf so indicate the amount released USING GHS CLASSIFICATION TABLEUse Drop Down Menu | Material ReleasedIf so indicate the amount released USING THE THRESHOLD TABLE FROM API RP-754Use Drop Down Menu | Material ReleasedIf available please indicate the material released | ||||||||||||||||||||
1 | ABC Chemical Company | American Chemistry Council | Washington DC - USA | January 4 2016 | Yes | 2 | middot Days Away From Work injury to an employee contractor or subcontractor or middot Injury requiring treatment beyond first aid to a third party | 0 | 5525000 | 1500250 | No | $2500 to $25000 | Yes le 3 hours | $2500 to $25000 | Yes - Using GHS TABLE | 40x le TQ lt 160x | NA | Chlorine | |||||||||||||||||||
2 | XYZ Chemical Company | American Chemistry Council | Washington DC - USA | 5-Jan-16 | Yes | 1 | middot Injury requiring treatment beyond first aid to an employee contractor or subcontractor | 0 | 5525000 | 1500250 | Yes | $2500 to $25000 | No | $2500 to $25000 | Yes - Using API RP 754 TABLE | NA | 3x le TQ lt 9x | Benzene | |||||||||||||||||||
3 | |||||||||||||||||||||||||||||||||||||
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24 | |||||||||||||||||||||||||||||||||||||
25 | |||||||||||||||||||||||||||||||||||||
Zero or None | Yes - Duration Unknown | ||||||||||||||||||||||||||||||||||||
Processes | Mode of Operation | Type of material released | Status of Operation | ||||
REFINING | Start-up | Flammable | Open | ||||
Alkylation HF | Planned shutdown | Combustible | Closed | ||||
Alkylation sulfuric | Emergency shutdown | Toxic | |||||
BitumenResidAsphalt | Normal | Corrosive | Tier 1 Acute Releases | ||||
Calcining | Upset | Utilities | No Release | ||||
Coking | Turnaround | Other | Category 1 | ||||
Crude | Routine maintenance | Category 2 | |||||
Desulfurization | Temporary | Evacuation | Category 3 | ||||
FCC | Other | Yes | Category 4 | ||||
Gas Treating | No | Category 5 | |||||
Hydrogen | Point of Release | Category 6 | |||||
Hydrotreating | Pump | Fire | Category 7 | ||||
Hydrocracking | Compressor | Yes | Multiple Categories | ||||
Isom | BlowerFan | No | |||||
MarineJetty | Pressure Vessel | lt $2500 | |||||
Reforming | FilterCoalescer | ||||||
Sulfur recovery | Furnace | PRDs | |||||
Vapor recoverylight ends | Boiler | Directly to Atmosphere | |||||
Wastewater | Heat exchanger | via Downstream Destructive Device | |||||
REFINING amp PETROCHEMICAL | Cooling Tower | No | |||||
Tank FarmStorage FacilityOffsite | Piping system | Yes | |||||
UtilitiesSteam PlantCogeneration | Reactor | No | |||||
Other | Atmospheric tank | ||||||
PETROCHEMICAL | FlareRelief System | Acute release above thresholds | |||||
CO H2 | Other | Yes | |||||
LNG | No | ||||||
Methane | Events | ||||||
Methanol | No Tier 1 Events | Indoor Outdoor | |||||
Methyl Mercaptan | No Tier 2 Events | No Release | |||||
Formaldehyde | No Tier 1 or Tier 2 Events | Indoor | |||||
Formaldehyde derivatives | NA | Outdoor | |||||
Acetic Acid | |||||||
Acetic Acid derivatives | Event Type | ||||||
Ethane | Injury | ||||||
Ethylene | Fire | ||||||
Ethanol | Explosion | ||||||
Ethylene oxide | PRD Discharge | ||||||
Ethylene derivatives | Acute Release | ||||||
Polyethylene | |||||||
Ethylene dichloride | General | ||||||
Ethylene dichloride derivatives | Yes | ||||||
Ethyl benzene | No | ||||||
Ethyl benzene derivatives | |||||||
Polystyrene | |||||||
Styrene-Butadiene | |||||||
Propane | |||||||
Propylene | |||||||
Polypropylene | |||||||
Isopropanol | |||||||
Propylene oxide | |||||||
Propylene oxide derivatives | |||||||
Butane | |||||||
Isobutane | |||||||
Isobutene | |||||||
Butadiene | |||||||
MTBE | |||||||
ETBE | |||||||
Pentane | |||||||
Hexane | |||||||
Cyclohexane | |||||||
Hexanol | |||||||
Aromatics Derivatives | |||||||
Benzene | |||||||
Toluene | |||||||
Xylene | |||||||
Para Xylene | |||||||
Amines Derivatives | |||||||
TDA MDA IPDA etc | |||||||
Isocyanates | |||||||
Specialty Chemicals | |||||||
LoadingUnloading | |||||||
Pilot Plant |
Instructions | ||||||||||||||
Step 1 | Complete the Contact Tab with your contact information and company information | |||||||||||||
Be sure to note the region of your reporting (IE North America France Japan etc) | ||||||||||||||
Survey on Process Safety Events | ||||||||||||||
Step 2 | Complete the survey one line per Process Safety Event for your companyregion | |||||||||||||
ALL REPORTED DATA SHOULD BE FROM CALENDAR YEAR 2017 | ||||||||||||||
Step 3 | Return completed survey to | |||||||||||||
Company Name | ||||||||||||||
Contact Person | All Surveys Due by xxx date | |||||||||||||
Address | ||||||||||||||
Fax | ||||||||||||||
Telephone | ||||||||||||||
Region | ||||||||||||||
13
洩漏或排放至妥善設計且運作中的洩壓裝置(如廢氣燃燒塔洗滌塔等)若其情況未達前
述四項標準中任何一項則不必提報
欲查看 API RP-754 標準可登入以下網站下載此標準httpwwwapiorgenvironment-
health-and-safetyprocess-safetyprocess-safety-standardsstandard-rp-754
一小時法則
為便於衡量此項指標提報與否洩漏恕限值是以物質在任一小時內之洩漏量為標準若任
一小時或更短時間內物質洩漏量達到或超過須提報恕限值該事故便屬於須提報的製程安
全事件急性洩漏事故通常不會超過一小時若無法確定洩漏持續時間則應假設其為一
小時
一次阻絕設施ndash 用來作為主要容器或用於運送或輸送物質之槽罐船隻管線軌道車
或設備主要容器在設計上可能包含二次阻絕設施系統以抑制及控制洩漏二次阻絕設
施系統包括(但不限於)儲槽防溢堤製程設備周遭的圍堵設施油水分離的排水收集系統
雙層儲槽的外壁等
嚴重程度表 ndash 嚴重程度加權可額外提供有關製程安全事件的有用資訊有助於帶動改善績
效附錄 A 為 RCLG 建議之製程安全事件嚴重程度加權計算方法根據附錄 A 的方法便
可藉由加總與各個後果類別關聯的分數計算出各製程安全事件的嚴重程度加權值ICCA
強烈建議採用嚴重程度加權制度因為此制度有助於提升溝通績效的能力也比較容易讓
利害關係人了解製程安全事件並且此嚴重程度加權值與其他製程安全績效指標提報方
式是不具相互比較性的
14
表 1 ndash GHS 分類表
物理性危害(GHS 2x)
洩漏恕限值(1 小時內)
STOTSpecific target organ toxicity(特定標的器官系統毒性物質)
15
表 2 ndash API RP 754 Tier II 分類表
洩漏恕限類別
物質危害性分類 acdef 恕限值
(戶外洩漏) 恕限值
(戶內b洩漏)
T2-1 TIH A 區物質 ge 05 kg (11 lb) ge 025 kg (055
lb)
T2-2 TIH B 區物質 ge 25 kg (55 lb) ge 125 kg (275
lb)
T2-3 TIH C 區物質 ge 10 kg (22 lb) ge 5 kg (11 lb)
T2-4 TIH D 區物質 ge 20 kg (44 lb) ge 10 kg (22 lb)
T2-5
易燃氣體 或 正常沸點 ≦ 35 (95 degF)閃火點lt23 (73 degF)的液體 或 其他包裝組別 I 類的物質 (酸鹼除外)
ge 50 kg (110 lb) ge 25 kg (55 lb)
T2-6
正常沸點 gt 35 degC (95 degF)閃火點 lt 23 degC (73degF)的液體 或 其他包裝組別 II 類的物質 (酸鹼除外)
ge 100 kg (220 lb) 或
ge 07 bbl
ge 50 kg (110 lb) 或
ge 035 bbl
T2-7
閃火點 gt 23 degC (73 degF)和 lt 60 degC (140 degF)的液體 或 閃火點 gt 60 degC (140 degF)的液體在閃火點或高於閃火點的溫度下洩漏 或 強酸鹼 (定義參見 RP 754 文件草案) 或 UNDG第2類第22部分 (不可燃無毒氣體)空氣除外 或 其他包裝組別 III 類的物質
ge 200 kg (440 lb) 或
ge 14 bbl
ge 100 kg (220 lb) 或
ge 07 bbl
T2-8
閃火點 gt 60 degC (140 degF) 和 lt 93 degC (200 degF)的液體在低於閃火點的溫度下洩漏 或 中度酸鹼
ge 1000 kg
(2200 lb) 或
ge 7 bbl
ge 500 kg
(1100 lb) 或
ge 35 bbl
TIH吸入性毒性危害物(Toxic Inhalation Hazard)
16
一般認為以公斤和磅或以磅和桶為單位的恕限值不盡等同各公司應該選用其中一組計量單位並在
所有紀錄文件中一體適用
在判定一種物質之洩漏恕限類別時首先應從物質之含吸入性毒性(TIH Zone)可燃性(閃火點和沸點)
或腐蝕性(強酸或鹼 vs中度酸或鹼)等特性來判別只有當物質的危險度無法利用上述簡單的特性來判別
時(如遇水反應劇烈)才採用UNDGL包裝組別
a 許多物質具有一種以上危險性正確的危險區(Hazard Zone)或包裝組別(Packing Group)歸屬應遵循DOT
49 CFR 1732a [14]或聯合國危險物品運輸建議書(UNRTDG)第2部分[12]的規定參見附錄F
b 具有四面完整牆(從地板到天花板)地板和屋頂的結構物
c 對於未列於UNDG的溶液無水成分將用TIH區或包裝組別分類溶液之恕限值將根據乾基重量之恕限
值反算
d 對於未知UNDG分類的混合物可計算每種成分在恕限值洩漏中的分量如果各種成分之分量的總和
等於或大於100即表示混合物超過門檻值若混合物有明顯且獨立的毒性及可燃性結果則可分
別計算毒性及可燃性危險度參見附錄EPSE實例amp問題 49ndash53
e 閃火點 gt 60 degC (140 degF) 和 lt 93 degC (200 degF)的液體在低於閃火點的溫度下洩漏無論洩漏量多寡其
一次阻絕設施失效(LOPC)均不屬於Tier 1製程安全事件(PSE)
f 中度酸鹼的一次阻絕設施失效無論洩漏量多寡均不屬於Tier 1製程安全事件
17 (K = 1000 MM = 1000000) (在環境影響類別方面若缺乏既有定義協會和會員公司應議定輸入標準)
附錄 A ndash 嚴重程度表鼓勵所有協會均採用嚴重程度加權制度
事件事故類別
嚴重程度等級
安全人體健康 火災或爆炸導致直接
成本 任 1 小時內物質洩
漏量 社區影響 環境影響[廠外]
4 級
1 分
對員工承攬商或再承攬商造成較輕傷害嚴重之傷害 (符合本地法規)
造成以下直接損失成本
美金$25 K ~ $25 K
洩漏量介於
1x le TQ lt 40x
官方宣告就地避難或疏散 (廠內或廠外) 預防性廠外就地避難或疏散
le 3 小時
重大環境整治成本
$25 K ~ $25 K
3 級
3 分
對員工承攬商或再承攬商造成之需要多日缺勤的傷害
對第三方造成之需要初步急救以外治療的傷害 (符合本地法規)
造成以下直接損失成本
$25 K ~ $250 K
洩漏量介於
40x le TQ lt 160x
官方宣告就地避難或疏散 (廠內或廠外)
預防性廠外就地避難或疏散
3 ~ 12 小時
重大環境整治成本
$25 K ~ $250 K
2 級
9 分
對員工承攬商或再承攬商造成 1 人死亡
對第三方造成 1 人住院治療
(符合本地法規)
造成以下直接損失成本
$250 K ~ $25 MM
洩漏量介於
160x le TQ lt 640x
官方宣告就地避難或疏散 (廠內或廠外)
預防性廠外就地避難或疏散
12 ~ 24 小時
重大環境整治成本
$250 K ~ $25 MM
1 級
27 分
對員工承攬商或再承攬商造成多人死亡
對第三方造成多人住院治療
對第三方造成 1 人死亡 (符合本地法規)
造成以下直接損失成本
ge $25 MM
洩漏量
ge 640x TQ
官方宣告就地避難或疏散 (廠內或廠外)
預防性廠外就地避難或疏散
ge 24 小時
重大環境整治成本
ge $25 MM
18 (K = 1000 MM = 1000000) (在環境影響類別方面若缺乏既有定義協會和會員公司應議定輸入標準)
嚴重程度表(附錄 A)細節說明
附錄 A 之設計目的僅適用於採用 GHS 分類制度(表 1)者如果你的公司係採用 API RP 754Tier II 製程安全指標提報恕限值表(表 2)請使用
API RP 754 製程安全嚴重程度表必須提醒的是依 API RP 754 的標準其嚴重程度表僅適用於一級(Tier I)事故去比較採用不同的嚴重度
表所評估出來的相對嚴重度並無統計上的意義
急性的環境成本 ndash 因製程安全事件造成廠外環境影響所導致之短期清理及物質處置的成本各會員公司可選擇將廠外環境影響相關成本另
外區分一個嚴重程度類別
比率調整指標
利用上述嚴重程度表可產生一系列以事件率為基礎的指標包括
製程安全總事件率 (PSTIR) 總事件次數 x 200000
總工作時數
製程安全事件嚴重程度率(PSESR) (即製程安全事件嚴重程度加權計算公式)
PSESR = 所有事件之總嚴重程度分數總合 x 200000
總工作時數
在計算此一比率時各 4 級事件被分配 1 分各 3 級事件被分配 3 分各 2 級事件被分配 9 分各 1 級事件被分配 27 分理論上每個
製程安全事件至少可分配到 1 分(亦即事件僅在一個類別符合第 4 級事件屬性)至多可分配到 135 分(亦即事件在所有五個類別中均符
合第 1 級事件屬性)
ldquoXrdquo級別製程安全事件率 嚴重度級別ldquoXrdquo之製程安全事件總數 x 200000
員工承攬商amp再承攬商總工作時數
X可以是嚴重度級別 432 或 1 級製程安全事件之總數事件之嚴重度等級是選用五類後果類別中之最嚴重等級
標準化 ndash 在某些協會和會員公司中製程安全事件是採 lsquo每 100 名rsquo員工每名員工每年平均工作時數為 2000 小時為基礎予以標準化因
此在lsquo每 100rsquo名rsquo員工的標準基礎上事件被乘以 200000 工作時數也有些其他協會和會員公司將標準化基礎設定為lsquo每 500 名rsquo員工
因此事件被乘以 1000000 工作時數協會和會員公司應就標準化基礎進行討論共同做成選項結論上述的公式設定為lsquo每 100 名rsquo員工
基礎
19
附錄 B ndash 常見問題集
適用性
我們建議會員公司記錄和提報在其所擁有或運作的工廠內發生的製程安全事件惟以下情況不須提報製
程安全事件
1 源自於公司廠區以外的製程安全事件
2 海上運輸船事故惟船隻為了輸送半成品或產品之目的已經與公司的設施相連接時發生的
事故仍須提報
3 卡車或軌道車事故惟卡車或軌道車為了輸送半成品或產品之目的已經與公司的設施相連
接時發生的事故仍須提報
4 許可證或法規容許之例行排放
5 不會造成製程安全危害的地下污染請注意若洩漏至地下導致地上發生須提報製程安全事
件如釋放出毒性蒸汽或致使易燃液體蓄積成池則不適用本排除條件
6 辦公建築事故(如辦公室暖氣設備爆炸火災外溢洩漏人員受傷或疾病等)
7 與疏散或一次阻絕設施失效無直接關聯之人員安全ldquo滑倒絆倒跌倒rdquo事故
8 沒有與製程相連接之輔助設備的一次阻絕設施(如小樣品瓶)失效事故
9 計劃中和在控制下的物質排放至設計用來收集或排放系統中(請注意物質從一次阻絕設施
在非計劃或非受控制情況下排放至收集或排放系統中則不適用本排除條件)
10 在製程區域外部或保養廠內執行之機械作業
說明與實例 ndash 以 GHS 表 1 為基礎
以下說明和實例有助於在評估須提報製程安全事件(PSE)時釐清可能存在的不確定部分
公司廠區
1 一輛第三方的卡車在公司廠區內卸載易燃產品時發生洩漏進而引起火災造成公司財物損失
$7000 美元(直接成本)雖然該卡車是ldquo由他人操作rdquo但其作業與製程相連接若公司的直接成
本財物損失達到或超過$2500 美元或已達到或超過其他 PSE 提報門檻(如1 人死亡)此事故即
屬於須提報的製程安全事件
2 與前例1 類似的例子載著易燃產品的卡車在廠外運輸途中翻覆引發火災並造成卡車毀損
該事故不屬於須提報的製程安全事件因為當時卡車並未與製程相連接
20
阻絕設施失效
3 儲槽液位計故障造成裝有ldquo易燃液體rdquo產品的儲槽外溢約 700 公斤的液體流入儲槽的防溢堤內
此事故屬於須提報的製程安全事件因為其ldquo急性rdquo洩漏量超過 100 公斤即使是阻絕在二次阻絕
設施防溢堤中亦然
4 一名從事維修工作的承攬商在開啟一個製程阻閥時被噴起的硫酸濺到造成嚴重灼傷和損失工
時的工傷此事故屬於須提報的製程安全事件因為它是涉及物質和一次阻絕設施失效的意外事
件對於因洩漏造成死亡和損工的工傷或疾病事故沒有洩漏恕限值
5 一名作業員開啟品管取樣點進行日常取樣作業時手部被一個破碎的玻璃瓶嚴重割破需要進行
縫合治療縫針造成第二天無法上班該事故不屬於須提報的製程安全事件因為它與一次阻絕
設施失效無關
ldquo急性rdquo洩漏
6 一名作業員在進行天然氣流量高於預期值之異常排除時發現天然氣管線上的一個安全閥門未適
當歸位因此天然氣經由氣液分離桶排放至排氣煙囪經進一步檢查作業員判斷在過去 6 個
月間總共有 100000 公斤天然氣以穩定的速率排放至大氣該事故不屬於須提報的製程安全事
件因為其洩漏速率(每小時約 10 公斤)不算ldquo急性rdquo洩漏(未超過易燃蒸汽每小時 100 公斤的恕限
值)
廢氣燃燒塔amp排放控制裝置 (如洗滌塔)
7 若化學物質被導引至廢氣燃燒塔或排放控制裝置(如洗滌塔)只要該廢氣燃燒塔或控制裝置運作在
正常設計範圍內便不屬於須提報的製程安全事件
8 若廢氣流速超過洗滌塔的設計負荷以致未經吸收的化學物質排出超過恕限值該事故屬於須提報
的製程安全事件(如本文註釋所述)
註釋自取得許可或妥善管理的裝置-包括釋壓裝置發生不預期的排放若 1 小時內洩漏量達到或
超過表 1 或表 2 所列的洩漏恕限值且導致下列四種後果之任一項或以上之後果該事故便屬於
須提報的製程安全事件
o 二相排放或夾帶液體的排放液滴沉降至地面造成污染
o 排放至具潛在危險性的地點)
o 廠內就地避難或疏散不包括預防性廠內就地避難或疏散
o 啟動公眾保護措施(如道路封閉)包括預防性公眾保護措施
21
安全洩壓裝置 系統
9 製程單元發生異常安全閥開啟將洩漏物質釋放到排氣口此釋壓排放裝置是依相關要求設計
的且氣體釋到大氣中並未造成不良後果這不是一個須提報的製程安全事件因為安全閥高
壓破裂盤以及類似的安全裝置是依據 API 521 或者同等的標準設計的且此排放並未造成 (1)
夾帶液體並導致須提報的製程安全事件的後果(譬如損失工時意外死亡火災或爆炸造成$2500
美元或以上的直接成本損失液體或毒性氣體洩漏量達到或超過恕限值(2) 啟動廠內或廠外就地
避難應變或(3)啟動公眾保護措施
10 製程單元發生異常安全閥並未開啟造成設備超壓易燃性氣體從一個法蘭處ldquo急性rdquo漏出來
洩露量超過 100 公斤(一小時內)的恕限值該事故屬於須提報的製程安全事件因為從法蘭處外
漏屬於製程安全事件應提報事項
損工事故
11 一名作業員走路時不慎滑倒造成損失工時之工傷滑倒原因為天氣狀況rdquo長期rdquo油垢的地面和
易滑鞋具該事故不屬於須提報的製程安全事件因為人員安全ldquo滑倒絆倒跌倒rdquo事故若非與
一次阻絕設施失效直接關聯的疏散或應變造成則不屬於須提報的製程安全事件
12 與前例相同的事件惟這次作業員跌倒是因為少量易燃液體外漏(如 1 小時內少於 10 公斤)在採取
相關應變措施時發生該事故屬於須提報的製程安全事件因為作業員係為了應變一次阻絕設施
失效的事故而跌倒若一次阻絕設施失效發生在公司廠區且造成失時工傷或死亡後果該事故
便屬於須提報的製程安全事件對於因洩漏造成死亡和損失工時之工傷事故沒有洩漏量門檻
13 與前例相同的事件惟這次作業員跌倒是在事件結束數小時之後該事故不屬於須提報的製程安
全事件在提報要件中所用的ldquo疏散rdquo和ldquo應變rdquo等術語指的是一次阻絕設施失效和相關緊急應變
活動正在持續中事件結束後滑倒絆倒跌倒(如ldquo事後rdquo清理和補救)不屬於須提報製程安全事件
14 工人在因附近設備一次阻絕設施失效在疏散過程中一名鷹架搭建工人從鷹架梯上跌落造成損
失工時之工傷該事故屬於須提報的製程安全事件
15 一名作業員行經一個設計不良的蒸汽卻水器時被外洩的蒸汽燙傷腳踝造成損失工時之工傷
該事故屬於須提報的製程安全事件因為雖然一次阻絕設施失效洩漏出的是蒸汽(而非碳氫化合物
或化學物質)但損失工時之工傷是由於洩漏物質的物理狀態所導致的
16 一個密閉空間依照計畫以氮氣吹清一名承攬商繞過安全管制進入該密閉空間因而死亡該事
故屬於須提報的死亡事件但不屬於須提報的製程安全事件因為其中不涉及非計劃或失控的一
次阻絕設施失效
17 情況同上惟這次氮氣是非刻意洩漏進入該局限空間該事故屬於須提報的製程安全事件(同時也
是一起死亡事件)因為該名承攬商的死亡與非計劃的一次阻絕設施失效有關
22
18 一名作業員因硫化氫(H2S)警報在進行應變處理時昏倒若警報確實是因非計劃或失控的 H2S 一次
阻絕設施失效的外洩事件該事故便屬於須提報的製程安全事件若警報是一個假警報則該事
故便不屬於須提報的製程安全事件因為沒有真正的化學品洩漏發生
管線
19 一條管線破漏1 小時內洩漏 2000 磅(900 公斤)易燃蒸氣到地面但洩漏位置在廠區內很偏僻的
地點該事故仍屬於須提報的製程安全事件因為ldquo偏僻rdquo不是提報與否的考量因素
與化學物質外洩無關之火災或能量釋放事故
一般通則而言唯有當火災或能量釋放事故是因化學物質洩漏所造成或其發生導致化學物質洩漏
超過提報恕限值這些事故才屬於須提報的製程安全事件實例包括
20 一場電氣火災影響製程操作導致甲苯洩漏 400 公斤該事故屬於須提報的製程安全事件因為
化學物質洩漏已超過甲苯的 100 公斤提報恕限值
21 發生電氣火災停電或任何公用資源供應中斷可能造成工廠停工及可能引起設備損失超過
$2500 美元(如因非正常停工導致反應器或設備損壞)但並未造成超過恕限值的化學物質洩漏
亦未造成死亡或嚴重工傷該事故不屬於須提報的製程安全事件因為設備損壞並非化學製程火
災爆炸造成且化學物質洩漏並未超過恕限值
海上運輸船
22 一艘由公司營運的海上運輸船在船上發生ldquo急性rdquo易燃物質外洩洩漏量超過 100 公斤該事故不
屬於須提報的製程安全事件因為除非海上運輸船是為了輸送半成品或產品而與煉油石化或化
學製造廠的設施相連接否則其洩漏事故便不被視為製程安全事件
23 一艘第三方駁船由一艘拖船推向碼頭結果撞上公司的碼頭駁船的一個船艙破裂且造成
1000 公斤柴油洩漏到海中該事故不屬於須提報的製程安全事件因為駁船當時並非停泊在碼
頭內且其作業並非在進行半成品或產品之輸送
卡車與軌道車
24 一輛公司的軌道車在運輸途中出軌造成超過 1000 公斤汽油洩漏該事故不屬於須提報的製程
安全事件因為在公司廠區外發生的軌道車事故不被視為與製程安全有關
23
25 一輛第三方卡車拖車在公司廠區內翻覆造成ldquo急性rdquo汽油洩漏超過 1000 公斤這事故不屬於須
提報的製程安全事件因為卡車拖車當時已不再與裝卸設備連接然而我們建議會員公司另
行訂定運輸安全事故指標將這類事故記錄下來
26 一位合約卡車作業者正在卸載液鹼時發生軟管脫落造成空氣中氣霧和或液鹼液洩漏 2500 公
斤該事故屬於須提報的製程安全事件因為洩漏量已超過液鹼的 100 公斤恕限值且事故發生
前卡車仍與裝卸設備相連接著
辦公建築
27 綜合辦公大樓發生鍋爐火災造成總計$75000 美元的直接成本損失該事故不屬於須提報的製
程安全事件因為辦公大樓事故不被視為與製程安全有關
人機介面事故
28 一名操作技術員在聚合物工廠的終端設備旁作業時受傷這傷害是因機械的人機介面的設備而
造成該事故不屬於須提報的製程安全事件因為技術員受傷並非因危險物質一次阻絕設施失效
而造成的
混合物
29 若混合物本身有 GHS 分類可利用其分類確定恕限值若混合物本身沒有 GHS 分類則可計算混
合物中每個單一組成分之洩漏量(公斤)相對於個別成分恕限值之比值作為其對混合物恕限值之
lsquo加權rsquo貢獻譬如若混合物在 1小時內的洩漏量為 100公斤其中包含 05公斤分類為劇毒 H300
的物質45 公斤分類為 H301 的物質40 公斤另一種分類為 H 開頭的物質其餘 55 公斤則為沒
有 GHS 分類的水分此混合物之計算式為051 + 4510 + 40100 = 05 + 045 + 04 = 135超過
1因此該事故被視為須提報的製程安全事件雖然混合物個別成分之洩漏量均未超過各該物質
本身的恕限值
直接損失成本
30 此一門檻所考慮的成本應為可直接歸因於火災或爆炸的成本譬如設備及結構損壞的重置成本
修理成本環境清理支出緊急應變和罰款直接成本不包括間接成本譬如業務機會損失設
備停機造成之利潤損失取得或運轉臨時設施之成本或為滿足顧客需求取得替代產品的成本
(產品損失)
24
31 範例連接到氣體處理系統的排放管發生易燃氣體外漏同時製程出現問題導致空氣進入同
一條排放管結果發生爆炸過高的壓力損壞了排放管及其相關上游設備包括一個密封罐並
未造成人員受傷修理成本約$12000 美元該事故屬於須提報的製程安全事件因為爆炸及火
災導致設備修理成本超過門檻
32 範例一次製程安全事件後公司又發生一種非常特殊的 GHS 第 5 類產品洩漏 50 公斤造成
$2000 美元的設備損失洩漏的產品是一種非常特別的混合物公司須負擔超過$50000 美元因
產品耗損而產生之材料成本該事故不屬於須提報的製程安全事件因為 GHS 第 5 類產品洩漏的
提報門檻為 100 公斤且產品耗損不被計入直接損失成本
天然災害
33 天然災害可能對化學製程作業構成重大風險且對製程設備造成損壞導致危害物質一次阻絕設
施失效當一種或多種天然災害被認為可能對工廠作業造成影響時製程安全和作業系統應從危
害及後果分析工廠機器設備設計公用設施失效及製程停工之操作程序緊急應變計畫及應變
措施等方面界定潛在風險進行防範
天然災害類型包括颶風及颱風(包括伴隨而來的風暴潮)水災龍捲風地震超強對流風暴(直
線風暴)野火火山爆發海嘯和山崩
若公司廠房設施遭遇天然災害且其後果觸發一種或以上提報門檻該事故便屬於須提報製程安
全事件
預防性公眾應變
34 預防性公眾應變是基於謹慎的態度所採取的一種措施譬如當發生一次阻絕設施失效時公司
可能在尚未進行任何評估(如方向與洩漏點的距離等等)前便要求全體工人就地避難又
如地方權責官員(如消防警察民防緊急應變管理部門)在獲報一家公司發生製程安全事件
後為防lsquo萬一rsquo風向改變或基於可能受到波及的人口敏感族群(如學童或老年人)可能在尚未接
獲明確資訊前便下令社區就地避難或疏散或採取公眾保護措施(如道路封閉)
製程附屬倉庫
35 製程附屬倉庫指的是位於廠內用於儲存將投入於生產製程或產自於製程之原料半成品或成品的
倉庫從製程的觀點看來製程附屬倉庫相當於一個大型儲槽但這些原料半成品或成品並不
是儲存在一的大型容器中而是裝在較小的容器裡(如太空包大桶桶罐等)
25
Appendix C ndash List of RCLG Taskforce Members
Name Affiliation
Peter Schmelzer Bayer CEFIC - Chairman
Americo Diniz Carvalho Neto Braskem
Bradford Johnson American Chemistry Council
David Cummings DuPont
Debra Phillips American Chemistry Council
Hans Schwarz BASF
Kathryn Walton Plastics and Chemicals Industries Association
Kazuyuki Akita Japanese Chemical Industry Association
Kelly Keim ExxonMobil Chemical Company API Representative
Kenan Stevick Dow
Kiyokazu Murata Japanese Chemical Industry Association
Larry Bowler SABIC
Lorna Young Chemical Industry Association of Canada
Louisa Nara Center for Chemical Process Safety
Luiz Shizuo Harayashiki Associaccedilatildeo Brasileira da Induacutestria Quiacutemica
Masatoshi Kumamoto Japanese Chemical Industry Association
Milton Lacerda Petrobras
Phil Scott Chemical Industries Association
Piet Knijff DSM European Process Safety Centre
Scott Donaldson and Eamon Chandler
Shell
Scott Wallace Olin Corporation
Shakeel Kadri Air Products and Chemicals Inc
26
附錄 D ndash 詳細活動時程表
2016 年 2017 年 2018 年 2019 年 2020 年
2 ndash 4 月
RCLG PS 先導計畫
5 月 ndash
針對準則進行調整釐清
6 月 向 RCLG 和 ICCA 董事會報
告先導計畫執行結果
7 ndash 12 月 RCLG 協會考量準
則並為其會員公司發展提報機制
如有需要RCLG可向 ICCA 申請能
力建立基金為會員公司舉辦製程安
全研習會
1 ndash 12 月
RCLG 協會開始向其會員公司蒐集製程安全數據
1 ndash 12 月
如有需要RCLG 各協會運用 RCLG 的基金及專
家舉辦製程安全及績效提報研習會
1 ndash 2 月
擁有數據的協會開始向RCLG 提報製程安全事件
(2017 年數據)
4 月 RCLG 檢討第一個提報循
環的結果挑戰及原始數據(內部)
6 月 RCLG 向 ICCA 董事會呈報
原始數據
7 ndash 12 月 必要時更新及調整準
則
如有需要RCLG 各協會運用 RCLG 的基金及專
家舉辦製程安全及績效提報研習會
1 ndash 2 月
擁有數據的協會開始向RCLG 提報製程安全事件
(2018 年數據)
4 月 RCLG 檢討第二個提報循
環的結果挑戰及原始數據(內部)
6 月 RCLG 向 ICCA 董事會呈報
原始數據
7 ndash 12 月 必要時更新及調整準
則
如有需要RCLG 協會運用 RCLG 的基金及專家
舉辦製程安全及績效提報研習會
1 ndash 2 月
所有協會開始向 RCLG 提報製程安全事件
製程安全事件提報成為
RCLG KPI 衡量指標建議基本集的一部分(2019 年數
據)
4 月 RCLG 檢討第二個提報循
環的結果挑戰及原始數據(內部考量外部提
報)
6 月 RCLG 向 ICCA 董事會呈報
原始數據
27
附錄 E ndash 選擇性 Excel 追蹤表
當會員公司開始追蹤製程安全事件時所有會員公司應採用單一表格以簡化數據分析同時讓所有公司均使用相同的追蹤表RCLG 設
計了一份選擇性追蹤表可供會員公司和協會先行利用之後他們可設計自己的追蹤表
在這裡下載追蹤表
ICCA Process Safety Event Tracking Sheetxlsx
本文件包含三個分頁分別是ldquo聯絡資料rdquoldquo調查表rdquo和儲存下拉式選單選項的ldquo請勿編輯rdquo分頁
備註
附錄 E 追蹤表僅供參考TRCA 將另行提供台灣版表格供會員公司提報
28
後語
台灣化學工業責任照顧協會(Taiwan Responsible Care Association TRCA)成立於 1998 年在台灣推行責任照顧制度已達 20 週年製造商成員
包括台灣主要上市上櫃化工公司會員公司化學品生產製造量約佔全國 80 2016 年台灣化工業的 Chemical Sales 仍站在全球第八名的位
置額度為 630 億歐元化工業總產值達到 34 兆新台幣提供國內 416 萬人工作機會
TRCA 扮演國內廠商與國際制度接軌的角色也是國內化工業與政府機關及利益相關者溝通的橋樑與管道TRCA 會員結構依業務性質分析
涵蓋石化生產化學品製造氣體生產倉儲運輸業化學品貿易業以及工程研發設計等公司TRCA 透過供應鏈及價值鏈推行責任
照顧制度組成毒性化學物質聯防組織協助法規溝通與研析會員名冊請參考 httpwwwtrcaorgtwtrcanwork2aspx
TRCA 於 2010 年成為 ICCA (International Council of Chemical Associations 國際化學工業協會)觀察員ICCA 成立於 1989 年是全球化工製造
業的聯合會也是化學工業與 UNEP OPCW 及 OECD 的交流窗口ICCA 與其會員協會及成員公司致力於邁向永續的未來確保人類健康與
環境安全與保護全球化工業擁有超過 4兆美元的價值影響所有經濟部門ICCA 的會員幾乎在全球每個國家都有商業活動在全球六大
洲推動創新並提供超過 2000 萬個工作機會
台灣化工業在全球占有重要的一席之地在國內產業鏈也位居關鍵位置無論對國內或國際都有身為地球村一員應盡之責我們期許藉由
製程安全指標提報能更進一步提升自我在工安衛生環保與永續發展等面向的績效表現
台灣化學工業責任照顧協會
10452 台北市中山區撫順街 8 號 7 樓
電話02-2585-0552
httpwwwtrcaorgtw
None | |
$2500 to $25000 | |
$25000 to $250000 | |
$250000 to $25000000 | |
More than $25000000 | |
Yes - Using GHS TABLE | |
Yes - Using API RP 754 TABLE | |
NO | |
NA | |
1x le TQ lt 40x | |
40x le TQ lt 160x | |
160x le TQ lt 640x | |
ge 640x TQ | |
Yes le 3 hours | |
Yes 3 hours ge 12 hours | |
Yes 12 hours ge 24 hours | |
Yes ge 24 hours | |
No | |
Small-scale | |
Medium-scale | |
Large-scale | |
No | |
Yes | |
No | |
middot Injury requiring treatment beyond first aid to an employee contractor or subcontractor | |
middot Days Away From Work injury to an employee contractor or subcontractor or middot Injury requiring treatment beyond first aid to a third party | |
middot A fatality of an employee contractor or subcontractor or middot A hospital admission of a third party | |
middot Multiple fatalities of employees contractors or subcontractors or middot multiple hospital admission of third parties or middot A fatality of a third party | |
NA | |
1x le TQ lt 3x | |
3x le TQ lt 9x | |
9x le TQ lt 27x | |
ge 27x TQ |
ICCA Process Safety Pilot Reporting ProgramFebruary 8 2016 | 1 | 2 | 3 | 4 | 5 | 6 | 7 | 8 | 9 | 10 | 12 | 13 | 14 | 15 | |||||||||||||||||||||||
SAFETY Details(Meeting Local Regulations) | Direct Cost from Fire or Explosion | Community Impact | Environmental Impact | Material Released(Measured using the 1 Hour Rule) | |||||||||||||||||||||||||||||||||
Company Association Details | |||||||||||||||||||||||||||||||||||||
GHS | API - RP 754 | ||||||||||||||||||||||||||||||||||||
Company or Assocation Name | Headquarter Association | Location of Event Ex - City State amp Country | Date and Time of Event | Safety InjuryDid the Event result in a Recordable Lost Time Accident or Fatality or Hospital admission of anyone on or off siteUse Drop Down Menu | Safety InjuryIf yes please insert the total number of injuries | Safety InjuryFor puropses of utilizing the Severity Table please indicate the level of severity by chosing the MOST SEVERE classification that describes your incidentUse Drop Down Menu | Safety InjuryDid the incident involve Fatalities If so how many total fatalities If none enter Zero | Safety InjuryPlease Report Total Employee Hours for Calendar Year 2015 | Safety InjuryPlease Report Total Contractor Hours for Calendar Year 2015 | Direct Cost Did the Event result in Direct Damage CostUse Drop Down Menu | Direct Cost If so how muchAmount is in US DollarsUse Drop Down Menu | Community ImpactDid the event result inbull Officially declared shelter-in-place or officially declared evacuation (on or off site)ORbull Precautionary off site shelter in place or evacuation Use Drop Down Menu | Environmental ImpactDid the event result inAcute Environmental Remediation CostIf so indicate the amount in US DollarsUse Drop Down Menu | Material ReleasedDid the Event result in an Acute Release of material beyond one of the two threshold tablesIf so indicate which Threshold Table you used to make this determinationUse Drop Down Menu | Material ReleasedIf so indicate the amount released USING GHS CLASSIFICATION TABLEUse Drop Down Menu | Material ReleasedIf so indicate the amount released USING THE THRESHOLD TABLE FROM API RP-754Use Drop Down Menu | Material ReleasedIf available please indicate the material released | ||||||||||||||||||||
1 | ABC Chemical Company | American Chemistry Council | Washington DC - USA | January 4 2016 | Yes | 2 | middot Days Away From Work injury to an employee contractor or subcontractor or middot Injury requiring treatment beyond first aid to a third party | 0 | 5525000 | 1500250 | No | $2500 to $25000 | Yes le 3 hours | $2500 to $25000 | Yes - Using GHS TABLE | 40x le TQ lt 160x | NA | Chlorine | |||||||||||||||||||
2 | XYZ Chemical Company | American Chemistry Council | Washington DC - USA | 5-Jan-16 | Yes | 1 | middot Injury requiring treatment beyond first aid to an employee contractor or subcontractor | 0 | 5525000 | 1500250 | Yes | $2500 to $25000 | No | $2500 to $25000 | Yes - Using API RP 754 TABLE | NA | 3x le TQ lt 9x | Benzene | |||||||||||||||||||
3 | |||||||||||||||||||||||||||||||||||||
4 | |||||||||||||||||||||||||||||||||||||
5 | |||||||||||||||||||||||||||||||||||||
6 | |||||||||||||||||||||||||||||||||||||
7 | |||||||||||||||||||||||||||||||||||||
8 | |||||||||||||||||||||||||||||||||||||
9 | |||||||||||||||||||||||||||||||||||||
10 | |||||||||||||||||||||||||||||||||||||
11 | |||||||||||||||||||||||||||||||||||||
12 | |||||||||||||||||||||||||||||||||||||
13 | |||||||||||||||||||||||||||||||||||||
14 | |||||||||||||||||||||||||||||||||||||
15 | |||||||||||||||||||||||||||||||||||||
16 | |||||||||||||||||||||||||||||||||||||
17 | |||||||||||||||||||||||||||||||||||||
18 | |||||||||||||||||||||||||||||||||||||
19 | |||||||||||||||||||||||||||||||||||||
20 | |||||||||||||||||||||||||||||||||||||
21 | |||||||||||||||||||||||||||||||||||||
22 | |||||||||||||||||||||||||||||||||||||
23 | |||||||||||||||||||||||||||||||||||||
24 | |||||||||||||||||||||||||||||||||||||
25 | |||||||||||||||||||||||||||||||||||||
Zero or None | Yes - Duration Unknown | ||||||||||||||||||||||||||||||||||||
Processes | Mode of Operation | Type of material released | Status of Operation | ||||
REFINING | Start-up | Flammable | Open | ||||
Alkylation HF | Planned shutdown | Combustible | Closed | ||||
Alkylation sulfuric | Emergency shutdown | Toxic | |||||
BitumenResidAsphalt | Normal | Corrosive | Tier 1 Acute Releases | ||||
Calcining | Upset | Utilities | No Release | ||||
Coking | Turnaround | Other | Category 1 | ||||
Crude | Routine maintenance | Category 2 | |||||
Desulfurization | Temporary | Evacuation | Category 3 | ||||
FCC | Other | Yes | Category 4 | ||||
Gas Treating | No | Category 5 | |||||
Hydrogen | Point of Release | Category 6 | |||||
Hydrotreating | Pump | Fire | Category 7 | ||||
Hydrocracking | Compressor | Yes | Multiple Categories | ||||
Isom | BlowerFan | No | |||||
MarineJetty | Pressure Vessel | lt $2500 | |||||
Reforming | FilterCoalescer | ||||||
Sulfur recovery | Furnace | PRDs | |||||
Vapor recoverylight ends | Boiler | Directly to Atmosphere | |||||
Wastewater | Heat exchanger | via Downstream Destructive Device | |||||
REFINING amp PETROCHEMICAL | Cooling Tower | No | |||||
Tank FarmStorage FacilityOffsite | Piping system | Yes | |||||
UtilitiesSteam PlantCogeneration | Reactor | No | |||||
Other | Atmospheric tank | ||||||
PETROCHEMICAL | FlareRelief System | Acute release above thresholds | |||||
CO H2 | Other | Yes | |||||
LNG | No | ||||||
Methane | Events | ||||||
Methanol | No Tier 1 Events | Indoor Outdoor | |||||
Methyl Mercaptan | No Tier 2 Events | No Release | |||||
Formaldehyde | No Tier 1 or Tier 2 Events | Indoor | |||||
Formaldehyde derivatives | NA | Outdoor | |||||
Acetic Acid | |||||||
Acetic Acid derivatives | Event Type | ||||||
Ethane | Injury | ||||||
Ethylene | Fire | ||||||
Ethanol | Explosion | ||||||
Ethylene oxide | PRD Discharge | ||||||
Ethylene derivatives | Acute Release | ||||||
Polyethylene | |||||||
Ethylene dichloride | General | ||||||
Ethylene dichloride derivatives | Yes | ||||||
Ethyl benzene | No | ||||||
Ethyl benzene derivatives | |||||||
Polystyrene | |||||||
Styrene-Butadiene | |||||||
Propane | |||||||
Propylene | |||||||
Polypropylene | |||||||
Isopropanol | |||||||
Propylene oxide | |||||||
Propylene oxide derivatives | |||||||
Butane | |||||||
Isobutane | |||||||
Isobutene | |||||||
Butadiene | |||||||
MTBE | |||||||
ETBE | |||||||
Pentane | |||||||
Hexane | |||||||
Cyclohexane | |||||||
Hexanol | |||||||
Aromatics Derivatives | |||||||
Benzene | |||||||
Toluene | |||||||
Xylene | |||||||
Para Xylene | |||||||
Amines Derivatives | |||||||
TDA MDA IPDA etc | |||||||
Isocyanates | |||||||
Specialty Chemicals | |||||||
LoadingUnloading | |||||||
Pilot Plant |
Instructions | ||||||||||||||
Step 1 | Complete the Contact Tab with your contact information and company information | |||||||||||||
Be sure to note the region of your reporting (IE North America France Japan etc) | ||||||||||||||
Survey on Process Safety Events | ||||||||||||||
Step 2 | Complete the survey one line per Process Safety Event for your companyregion | |||||||||||||
ALL REPORTED DATA SHOULD BE FROM CALENDAR YEAR 2017 | ||||||||||||||
Step 3 | Return completed survey to | |||||||||||||
Company Name | ||||||||||||||
Contact Person | All Surveys Due by xxx date | |||||||||||||
Address | ||||||||||||||
Fax | ||||||||||||||
Telephone | ||||||||||||||
Region | ||||||||||||||
None | |
$2500 to $25000 | |
$25000 to $250000 | |
$250000 to $25000000 | |
More than $25000000 | |
Yes - Using GHS TABLE | |
Yes - Using API RP 754 TABLE | |
NO | |
NA | |
1x le TQ lt 40x | |
40x le TQ lt 160x | |
160x le TQ lt 640x | |
ge 640x TQ | |
Yes le 3 hours | |
Yes 3 hours ge 12 hours | |
Yes 12 hours ge 24 hours | |
Yes ge 24 hours | |
No | |
Small-scale | |
Medium-scale | |
Large-scale | |
No | |
Yes | |
No | |
middot Injury requiring treatment beyond first aid to an employee contractor or subcontractor | |
middot Days Away From Work injury to an employee contractor or subcontractor or middot Injury requiring treatment beyond first aid to a third party | |
middot A fatality of an employee contractor or subcontractor or middot A hospital admission of a third party | |
middot Multiple fatalities of employees contractors or subcontractors or middot multiple hospital admission of third parties or middot A fatality of a third party | |
NA | |
1x le TQ lt 3x | |
3x le TQ lt 9x | |
9x le TQ lt 27x | |
ge 27x TQ |
ICCA Process Safety Pilot Reporting ProgramFebruary 8 2016 | 1 | 2 | 3 | 4 | 5 | 6 | 7 | 8 | 9 | 10 | 12 | 13 | 14 | 15 | |||||||||||||||||||||||
SAFETY Details(Meeting Local Regulations) | Direct Cost from Fire or Explosion | Community Impact | Environmental Impact | Material Released(Measured using the 1 Hour Rule) | |||||||||||||||||||||||||||||||||
Company Association Details | |||||||||||||||||||||||||||||||||||||
GHS | API - RP 754 | ||||||||||||||||||||||||||||||||||||
Company or Assocation Name | Headquarter Association | Location of Event Ex - City State amp Country | Date and Time of Event | Safety InjuryDid the Event result in a Recordable Lost Time Accident or Fatality or Hospital admission of anyone on or off siteUse Drop Down Menu | Safety InjuryIf yes please insert the total number of injuries | Safety InjuryFor puropses of utilizing the Severity Table please indicate the level of severity by chosing the MOST SEVERE classification that describes your incidentUse Drop Down Menu | Safety InjuryDid the incident involve Fatalities If so how many total fatalities If none enter Zero | Safety InjuryPlease Report Total Employee Hours for Calendar Year 2015 | Safety InjuryPlease Report Total Contractor Hours for Calendar Year 2015 | Direct Cost Did the Event result in Direct Damage CostUse Drop Down Menu | Direct Cost If so how muchAmount is in US DollarsUse Drop Down Menu | Community ImpactDid the event result inbull Officially declared shelter-in-place or officially declared evacuation (on or off site)ORbull Precautionary off site shelter in place or evacuation Use Drop Down Menu | Environmental ImpactDid the event result inAcute Environmental Remediation CostIf so indicate the amount in US DollarsUse Drop Down Menu | Material ReleasedDid the Event result in an Acute Release of material beyond one of the two threshold tablesIf so indicate which Threshold Table you used to make this determinationUse Drop Down Menu | Material ReleasedIf so indicate the amount released USING GHS CLASSIFICATION TABLEUse Drop Down Menu | Material ReleasedIf so indicate the amount released USING THE THRESHOLD TABLE FROM API RP-754Use Drop Down Menu | Material ReleasedIf available please indicate the material released | ||||||||||||||||||||
1 | ABC Chemical Company | American Chemistry Council | Washington DC - USA | January 4 2016 | Yes | 2 | middot Days Away From Work injury to an employee contractor or subcontractor or middot Injury requiring treatment beyond first aid to a third party | 0 | 5525000 | 1500250 | No | $2500 to $25000 | Yes le 3 hours | $2500 to $25000 | Yes - Using GHS TABLE | 40x le TQ lt 160x | NA | Chlorine | |||||||||||||||||||
2 | XYZ Chemical Company | American Chemistry Council | Washington DC - USA | 5-Jan-16 | Yes | 1 | middot Injury requiring treatment beyond first aid to an employee contractor or subcontractor | 0 | 5525000 | 1500250 | Yes | $2500 to $25000 | No | $2500 to $25000 | Yes - Using API RP 754 TABLE | NA | 3x le TQ lt 9x | Benzene | |||||||||||||||||||
3 | |||||||||||||||||||||||||||||||||||||
4 | |||||||||||||||||||||||||||||||||||||
5 | |||||||||||||||||||||||||||||||||||||
6 | |||||||||||||||||||||||||||||||||||||
7 | |||||||||||||||||||||||||||||||||||||
8 | |||||||||||||||||||||||||||||||||||||
9 | |||||||||||||||||||||||||||||||||||||
10 | |||||||||||||||||||||||||||||||||||||
11 | |||||||||||||||||||||||||||||||||||||
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24 | |||||||||||||||||||||||||||||||||||||
25 | |||||||||||||||||||||||||||||||||||||
Zero or None | Yes - Duration Unknown | ||||||||||||||||||||||||||||||||||||
Processes | Mode of Operation | Type of material released | Status of Operation | ||||
REFINING | Start-up | Flammable | Open | ||||
Alkylation HF | Planned shutdown | Combustible | Closed | ||||
Alkylation sulfuric | Emergency shutdown | Toxic | |||||
BitumenResidAsphalt | Normal | Corrosive | Tier 1 Acute Releases | ||||
Calcining | Upset | Utilities | No Release | ||||
Coking | Turnaround | Other | Category 1 | ||||
Crude | Routine maintenance | Category 2 | |||||
Desulfurization | Temporary | Evacuation | Category 3 | ||||
FCC | Other | Yes | Category 4 | ||||
Gas Treating | No | Category 5 | |||||
Hydrogen | Point of Release | Category 6 | |||||
Hydrotreating | Pump | Fire | Category 7 | ||||
Hydrocracking | Compressor | Yes | Multiple Categories | ||||
Isom | BlowerFan | No | |||||
MarineJetty | Pressure Vessel | lt $2500 | |||||
Reforming | FilterCoalescer | ||||||
Sulfur recovery | Furnace | PRDs | |||||
Vapor recoverylight ends | Boiler | Directly to Atmosphere | |||||
Wastewater | Heat exchanger | via Downstream Destructive Device | |||||
REFINING amp PETROCHEMICAL | Cooling Tower | No | |||||
Tank FarmStorage FacilityOffsite | Piping system | Yes | |||||
UtilitiesSteam PlantCogeneration | Reactor | No | |||||
Other | Atmospheric tank | ||||||
PETROCHEMICAL | FlareRelief System | Acute release above thresholds | |||||
CO H2 | Other | Yes | |||||
LNG | No | ||||||
Methane | Events | ||||||
Methanol | No Tier 1 Events | Indoor Outdoor | |||||
Methyl Mercaptan | No Tier 2 Events | No Release | |||||
Formaldehyde | No Tier 1 or Tier 2 Events | Indoor | |||||
Formaldehyde derivatives | NA | Outdoor | |||||
Acetic Acid | |||||||
Acetic Acid derivatives | Event Type | ||||||
Ethane | Injury | ||||||
Ethylene | Fire | ||||||
Ethanol | Explosion | ||||||
Ethylene oxide | PRD Discharge | ||||||
Ethylene derivatives | Acute Release | ||||||
Polyethylene | |||||||
Ethylene dichloride | General | ||||||
Ethylene dichloride derivatives | Yes | ||||||
Ethyl benzene | No | ||||||
Ethyl benzene derivatives | |||||||
Polystyrene | |||||||
Styrene-Butadiene | |||||||
Propane | |||||||
Propylene | |||||||
Polypropylene | |||||||
Isopropanol | |||||||
Propylene oxide | |||||||
Propylene oxide derivatives | |||||||
Butane | |||||||
Isobutane | |||||||
Isobutene | |||||||
Butadiene | |||||||
MTBE | |||||||
ETBE | |||||||
Pentane | |||||||
Hexane | |||||||
Cyclohexane | |||||||
Hexanol | |||||||
Aromatics Derivatives | |||||||
Benzene | |||||||
Toluene | |||||||
Xylene | |||||||
Para Xylene | |||||||
Amines Derivatives | |||||||
TDA MDA IPDA etc | |||||||
Isocyanates | |||||||
Specialty Chemicals | |||||||
LoadingUnloading | |||||||
Pilot Plant |
Instructions | ||||||||||||||
Step 1 | Complete the Contact Tab with your contact information and company information | |||||||||||||
Be sure to note the region of your reporting (IE North America France Japan etc) | ||||||||||||||
Survey on Process Safety Events | ||||||||||||||
Step 2 | Complete the survey one line per Process Safety Event for your companyregion | |||||||||||||
ALL REPORTED DATA SHOULD BE FROM CALENDAR YEAR 2017 | ||||||||||||||
Step 3 | Return completed survey to | |||||||||||||
Company Name | ||||||||||||||
Contact Person | All Surveys Due by xxx date | |||||||||||||
Address | ||||||||||||||
Fax | ||||||||||||||
Telephone | ||||||||||||||
Region | ||||||||||||||
14
表 1 ndash GHS 分類表
物理性危害(GHS 2x)
洩漏恕限值(1 小時內)
STOTSpecific target organ toxicity(特定標的器官系統毒性物質)
15
表 2 ndash API RP 754 Tier II 分類表
洩漏恕限類別
物質危害性分類 acdef 恕限值
(戶外洩漏) 恕限值
(戶內b洩漏)
T2-1 TIH A 區物質 ge 05 kg (11 lb) ge 025 kg (055
lb)
T2-2 TIH B 區物質 ge 25 kg (55 lb) ge 125 kg (275
lb)
T2-3 TIH C 區物質 ge 10 kg (22 lb) ge 5 kg (11 lb)
T2-4 TIH D 區物質 ge 20 kg (44 lb) ge 10 kg (22 lb)
T2-5
易燃氣體 或 正常沸點 ≦ 35 (95 degF)閃火點lt23 (73 degF)的液體 或 其他包裝組別 I 類的物質 (酸鹼除外)
ge 50 kg (110 lb) ge 25 kg (55 lb)
T2-6
正常沸點 gt 35 degC (95 degF)閃火點 lt 23 degC (73degF)的液體 或 其他包裝組別 II 類的物質 (酸鹼除外)
ge 100 kg (220 lb) 或
ge 07 bbl
ge 50 kg (110 lb) 或
ge 035 bbl
T2-7
閃火點 gt 23 degC (73 degF)和 lt 60 degC (140 degF)的液體 或 閃火點 gt 60 degC (140 degF)的液體在閃火點或高於閃火點的溫度下洩漏 或 強酸鹼 (定義參見 RP 754 文件草案) 或 UNDG第2類第22部分 (不可燃無毒氣體)空氣除外 或 其他包裝組別 III 類的物質
ge 200 kg (440 lb) 或
ge 14 bbl
ge 100 kg (220 lb) 或
ge 07 bbl
T2-8
閃火點 gt 60 degC (140 degF) 和 lt 93 degC (200 degF)的液體在低於閃火點的溫度下洩漏 或 中度酸鹼
ge 1000 kg
(2200 lb) 或
ge 7 bbl
ge 500 kg
(1100 lb) 或
ge 35 bbl
TIH吸入性毒性危害物(Toxic Inhalation Hazard)
16
一般認為以公斤和磅或以磅和桶為單位的恕限值不盡等同各公司應該選用其中一組計量單位並在
所有紀錄文件中一體適用
在判定一種物質之洩漏恕限類別時首先應從物質之含吸入性毒性(TIH Zone)可燃性(閃火點和沸點)
或腐蝕性(強酸或鹼 vs中度酸或鹼)等特性來判別只有當物質的危險度無法利用上述簡單的特性來判別
時(如遇水反應劇烈)才採用UNDGL包裝組別
a 許多物質具有一種以上危險性正確的危險區(Hazard Zone)或包裝組別(Packing Group)歸屬應遵循DOT
49 CFR 1732a [14]或聯合國危險物品運輸建議書(UNRTDG)第2部分[12]的規定參見附錄F
b 具有四面完整牆(從地板到天花板)地板和屋頂的結構物
c 對於未列於UNDG的溶液無水成分將用TIH區或包裝組別分類溶液之恕限值將根據乾基重量之恕限
值反算
d 對於未知UNDG分類的混合物可計算每種成分在恕限值洩漏中的分量如果各種成分之分量的總和
等於或大於100即表示混合物超過門檻值若混合物有明顯且獨立的毒性及可燃性結果則可分
別計算毒性及可燃性危險度參見附錄EPSE實例amp問題 49ndash53
e 閃火點 gt 60 degC (140 degF) 和 lt 93 degC (200 degF)的液體在低於閃火點的溫度下洩漏無論洩漏量多寡其
一次阻絕設施失效(LOPC)均不屬於Tier 1製程安全事件(PSE)
f 中度酸鹼的一次阻絕設施失效無論洩漏量多寡均不屬於Tier 1製程安全事件
17 (K = 1000 MM = 1000000) (在環境影響類別方面若缺乏既有定義協會和會員公司應議定輸入標準)
附錄 A ndash 嚴重程度表鼓勵所有協會均採用嚴重程度加權制度
事件事故類別
嚴重程度等級
安全人體健康 火災或爆炸導致直接
成本 任 1 小時內物質洩
漏量 社區影響 環境影響[廠外]
4 級
1 分
對員工承攬商或再承攬商造成較輕傷害嚴重之傷害 (符合本地法規)
造成以下直接損失成本
美金$25 K ~ $25 K
洩漏量介於
1x le TQ lt 40x
官方宣告就地避難或疏散 (廠內或廠外) 預防性廠外就地避難或疏散
le 3 小時
重大環境整治成本
$25 K ~ $25 K
3 級
3 分
對員工承攬商或再承攬商造成之需要多日缺勤的傷害
對第三方造成之需要初步急救以外治療的傷害 (符合本地法規)
造成以下直接損失成本
$25 K ~ $250 K
洩漏量介於
40x le TQ lt 160x
官方宣告就地避難或疏散 (廠內或廠外)
預防性廠外就地避難或疏散
3 ~ 12 小時
重大環境整治成本
$25 K ~ $250 K
2 級
9 分
對員工承攬商或再承攬商造成 1 人死亡
對第三方造成 1 人住院治療
(符合本地法規)
造成以下直接損失成本
$250 K ~ $25 MM
洩漏量介於
160x le TQ lt 640x
官方宣告就地避難或疏散 (廠內或廠外)
預防性廠外就地避難或疏散
12 ~ 24 小時
重大環境整治成本
$250 K ~ $25 MM
1 級
27 分
對員工承攬商或再承攬商造成多人死亡
對第三方造成多人住院治療
對第三方造成 1 人死亡 (符合本地法規)
造成以下直接損失成本
ge $25 MM
洩漏量
ge 640x TQ
官方宣告就地避難或疏散 (廠內或廠外)
預防性廠外就地避難或疏散
ge 24 小時
重大環境整治成本
ge $25 MM
18 (K = 1000 MM = 1000000) (在環境影響類別方面若缺乏既有定義協會和會員公司應議定輸入標準)
嚴重程度表(附錄 A)細節說明
附錄 A 之設計目的僅適用於採用 GHS 分類制度(表 1)者如果你的公司係採用 API RP 754Tier II 製程安全指標提報恕限值表(表 2)請使用
API RP 754 製程安全嚴重程度表必須提醒的是依 API RP 754 的標準其嚴重程度表僅適用於一級(Tier I)事故去比較採用不同的嚴重度
表所評估出來的相對嚴重度並無統計上的意義
急性的環境成本 ndash 因製程安全事件造成廠外環境影響所導致之短期清理及物質處置的成本各會員公司可選擇將廠外環境影響相關成本另
外區分一個嚴重程度類別
比率調整指標
利用上述嚴重程度表可產生一系列以事件率為基礎的指標包括
製程安全總事件率 (PSTIR) 總事件次數 x 200000
總工作時數
製程安全事件嚴重程度率(PSESR) (即製程安全事件嚴重程度加權計算公式)
PSESR = 所有事件之總嚴重程度分數總合 x 200000
總工作時數
在計算此一比率時各 4 級事件被分配 1 分各 3 級事件被分配 3 分各 2 級事件被分配 9 分各 1 級事件被分配 27 分理論上每個
製程安全事件至少可分配到 1 分(亦即事件僅在一個類別符合第 4 級事件屬性)至多可分配到 135 分(亦即事件在所有五個類別中均符
合第 1 級事件屬性)
ldquoXrdquo級別製程安全事件率 嚴重度級別ldquoXrdquo之製程安全事件總數 x 200000
員工承攬商amp再承攬商總工作時數
X可以是嚴重度級別 432 或 1 級製程安全事件之總數事件之嚴重度等級是選用五類後果類別中之最嚴重等級
標準化 ndash 在某些協會和會員公司中製程安全事件是採 lsquo每 100 名rsquo員工每名員工每年平均工作時數為 2000 小時為基礎予以標準化因
此在lsquo每 100rsquo名rsquo員工的標準基礎上事件被乘以 200000 工作時數也有些其他協會和會員公司將標準化基礎設定為lsquo每 500 名rsquo員工
因此事件被乘以 1000000 工作時數協會和會員公司應就標準化基礎進行討論共同做成選項結論上述的公式設定為lsquo每 100 名rsquo員工
基礎
19
附錄 B ndash 常見問題集
適用性
我們建議會員公司記錄和提報在其所擁有或運作的工廠內發生的製程安全事件惟以下情況不須提報製
程安全事件
1 源自於公司廠區以外的製程安全事件
2 海上運輸船事故惟船隻為了輸送半成品或產品之目的已經與公司的設施相連接時發生的
事故仍須提報
3 卡車或軌道車事故惟卡車或軌道車為了輸送半成品或產品之目的已經與公司的設施相連
接時發生的事故仍須提報
4 許可證或法規容許之例行排放
5 不會造成製程安全危害的地下污染請注意若洩漏至地下導致地上發生須提報製程安全事
件如釋放出毒性蒸汽或致使易燃液體蓄積成池則不適用本排除條件
6 辦公建築事故(如辦公室暖氣設備爆炸火災外溢洩漏人員受傷或疾病等)
7 與疏散或一次阻絕設施失效無直接關聯之人員安全ldquo滑倒絆倒跌倒rdquo事故
8 沒有與製程相連接之輔助設備的一次阻絕設施(如小樣品瓶)失效事故
9 計劃中和在控制下的物質排放至設計用來收集或排放系統中(請注意物質從一次阻絕設施
在非計劃或非受控制情況下排放至收集或排放系統中則不適用本排除條件)
10 在製程區域外部或保養廠內執行之機械作業
說明與實例 ndash 以 GHS 表 1 為基礎
以下說明和實例有助於在評估須提報製程安全事件(PSE)時釐清可能存在的不確定部分
公司廠區
1 一輛第三方的卡車在公司廠區內卸載易燃產品時發生洩漏進而引起火災造成公司財物損失
$7000 美元(直接成本)雖然該卡車是ldquo由他人操作rdquo但其作業與製程相連接若公司的直接成
本財物損失達到或超過$2500 美元或已達到或超過其他 PSE 提報門檻(如1 人死亡)此事故即
屬於須提報的製程安全事件
2 與前例1 類似的例子載著易燃產品的卡車在廠外運輸途中翻覆引發火災並造成卡車毀損
該事故不屬於須提報的製程安全事件因為當時卡車並未與製程相連接
20
阻絕設施失效
3 儲槽液位計故障造成裝有ldquo易燃液體rdquo產品的儲槽外溢約 700 公斤的液體流入儲槽的防溢堤內
此事故屬於須提報的製程安全事件因為其ldquo急性rdquo洩漏量超過 100 公斤即使是阻絕在二次阻絕
設施防溢堤中亦然
4 一名從事維修工作的承攬商在開啟一個製程阻閥時被噴起的硫酸濺到造成嚴重灼傷和損失工
時的工傷此事故屬於須提報的製程安全事件因為它是涉及物質和一次阻絕設施失效的意外事
件對於因洩漏造成死亡和損工的工傷或疾病事故沒有洩漏恕限值
5 一名作業員開啟品管取樣點進行日常取樣作業時手部被一個破碎的玻璃瓶嚴重割破需要進行
縫合治療縫針造成第二天無法上班該事故不屬於須提報的製程安全事件因為它與一次阻絕
設施失效無關
ldquo急性rdquo洩漏
6 一名作業員在進行天然氣流量高於預期值之異常排除時發現天然氣管線上的一個安全閥門未適
當歸位因此天然氣經由氣液分離桶排放至排氣煙囪經進一步檢查作業員判斷在過去 6 個
月間總共有 100000 公斤天然氣以穩定的速率排放至大氣該事故不屬於須提報的製程安全事
件因為其洩漏速率(每小時約 10 公斤)不算ldquo急性rdquo洩漏(未超過易燃蒸汽每小時 100 公斤的恕限
值)
廢氣燃燒塔amp排放控制裝置 (如洗滌塔)
7 若化學物質被導引至廢氣燃燒塔或排放控制裝置(如洗滌塔)只要該廢氣燃燒塔或控制裝置運作在
正常設計範圍內便不屬於須提報的製程安全事件
8 若廢氣流速超過洗滌塔的設計負荷以致未經吸收的化學物質排出超過恕限值該事故屬於須提報
的製程安全事件(如本文註釋所述)
註釋自取得許可或妥善管理的裝置-包括釋壓裝置發生不預期的排放若 1 小時內洩漏量達到或
超過表 1 或表 2 所列的洩漏恕限值且導致下列四種後果之任一項或以上之後果該事故便屬於
須提報的製程安全事件
o 二相排放或夾帶液體的排放液滴沉降至地面造成污染
o 排放至具潛在危險性的地點)
o 廠內就地避難或疏散不包括預防性廠內就地避難或疏散
o 啟動公眾保護措施(如道路封閉)包括預防性公眾保護措施
21
安全洩壓裝置 系統
9 製程單元發生異常安全閥開啟將洩漏物質釋放到排氣口此釋壓排放裝置是依相關要求設計
的且氣體釋到大氣中並未造成不良後果這不是一個須提報的製程安全事件因為安全閥高
壓破裂盤以及類似的安全裝置是依據 API 521 或者同等的標準設計的且此排放並未造成 (1)
夾帶液體並導致須提報的製程安全事件的後果(譬如損失工時意外死亡火災或爆炸造成$2500
美元或以上的直接成本損失液體或毒性氣體洩漏量達到或超過恕限值(2) 啟動廠內或廠外就地
避難應變或(3)啟動公眾保護措施
10 製程單元發生異常安全閥並未開啟造成設備超壓易燃性氣體從一個法蘭處ldquo急性rdquo漏出來
洩露量超過 100 公斤(一小時內)的恕限值該事故屬於須提報的製程安全事件因為從法蘭處外
漏屬於製程安全事件應提報事項
損工事故
11 一名作業員走路時不慎滑倒造成損失工時之工傷滑倒原因為天氣狀況rdquo長期rdquo油垢的地面和
易滑鞋具該事故不屬於須提報的製程安全事件因為人員安全ldquo滑倒絆倒跌倒rdquo事故若非與
一次阻絕設施失效直接關聯的疏散或應變造成則不屬於須提報的製程安全事件
12 與前例相同的事件惟這次作業員跌倒是因為少量易燃液體外漏(如 1 小時內少於 10 公斤)在採取
相關應變措施時發生該事故屬於須提報的製程安全事件因為作業員係為了應變一次阻絕設施
失效的事故而跌倒若一次阻絕設施失效發生在公司廠區且造成失時工傷或死亡後果該事故
便屬於須提報的製程安全事件對於因洩漏造成死亡和損失工時之工傷事故沒有洩漏量門檻
13 與前例相同的事件惟這次作業員跌倒是在事件結束數小時之後該事故不屬於須提報的製程安
全事件在提報要件中所用的ldquo疏散rdquo和ldquo應變rdquo等術語指的是一次阻絕設施失效和相關緊急應變
活動正在持續中事件結束後滑倒絆倒跌倒(如ldquo事後rdquo清理和補救)不屬於須提報製程安全事件
14 工人在因附近設備一次阻絕設施失效在疏散過程中一名鷹架搭建工人從鷹架梯上跌落造成損
失工時之工傷該事故屬於須提報的製程安全事件
15 一名作業員行經一個設計不良的蒸汽卻水器時被外洩的蒸汽燙傷腳踝造成損失工時之工傷
該事故屬於須提報的製程安全事件因為雖然一次阻絕設施失效洩漏出的是蒸汽(而非碳氫化合物
或化學物質)但損失工時之工傷是由於洩漏物質的物理狀態所導致的
16 一個密閉空間依照計畫以氮氣吹清一名承攬商繞過安全管制進入該密閉空間因而死亡該事
故屬於須提報的死亡事件但不屬於須提報的製程安全事件因為其中不涉及非計劃或失控的一
次阻絕設施失效
17 情況同上惟這次氮氣是非刻意洩漏進入該局限空間該事故屬於須提報的製程安全事件(同時也
是一起死亡事件)因為該名承攬商的死亡與非計劃的一次阻絕設施失效有關
22
18 一名作業員因硫化氫(H2S)警報在進行應變處理時昏倒若警報確實是因非計劃或失控的 H2S 一次
阻絕設施失效的外洩事件該事故便屬於須提報的製程安全事件若警報是一個假警報則該事
故便不屬於須提報的製程安全事件因為沒有真正的化學品洩漏發生
管線
19 一條管線破漏1 小時內洩漏 2000 磅(900 公斤)易燃蒸氣到地面但洩漏位置在廠區內很偏僻的
地點該事故仍屬於須提報的製程安全事件因為ldquo偏僻rdquo不是提報與否的考量因素
與化學物質外洩無關之火災或能量釋放事故
一般通則而言唯有當火災或能量釋放事故是因化學物質洩漏所造成或其發生導致化學物質洩漏
超過提報恕限值這些事故才屬於須提報的製程安全事件實例包括
20 一場電氣火災影響製程操作導致甲苯洩漏 400 公斤該事故屬於須提報的製程安全事件因為
化學物質洩漏已超過甲苯的 100 公斤提報恕限值
21 發生電氣火災停電或任何公用資源供應中斷可能造成工廠停工及可能引起設備損失超過
$2500 美元(如因非正常停工導致反應器或設備損壞)但並未造成超過恕限值的化學物質洩漏
亦未造成死亡或嚴重工傷該事故不屬於須提報的製程安全事件因為設備損壞並非化學製程火
災爆炸造成且化學物質洩漏並未超過恕限值
海上運輸船
22 一艘由公司營運的海上運輸船在船上發生ldquo急性rdquo易燃物質外洩洩漏量超過 100 公斤該事故不
屬於須提報的製程安全事件因為除非海上運輸船是為了輸送半成品或產品而與煉油石化或化
學製造廠的設施相連接否則其洩漏事故便不被視為製程安全事件
23 一艘第三方駁船由一艘拖船推向碼頭結果撞上公司的碼頭駁船的一個船艙破裂且造成
1000 公斤柴油洩漏到海中該事故不屬於須提報的製程安全事件因為駁船當時並非停泊在碼
頭內且其作業並非在進行半成品或產品之輸送
卡車與軌道車
24 一輛公司的軌道車在運輸途中出軌造成超過 1000 公斤汽油洩漏該事故不屬於須提報的製程
安全事件因為在公司廠區外發生的軌道車事故不被視為與製程安全有關
23
25 一輛第三方卡車拖車在公司廠區內翻覆造成ldquo急性rdquo汽油洩漏超過 1000 公斤這事故不屬於須
提報的製程安全事件因為卡車拖車當時已不再與裝卸設備連接然而我們建議會員公司另
行訂定運輸安全事故指標將這類事故記錄下來
26 一位合約卡車作業者正在卸載液鹼時發生軟管脫落造成空氣中氣霧和或液鹼液洩漏 2500 公
斤該事故屬於須提報的製程安全事件因為洩漏量已超過液鹼的 100 公斤恕限值且事故發生
前卡車仍與裝卸設備相連接著
辦公建築
27 綜合辦公大樓發生鍋爐火災造成總計$75000 美元的直接成本損失該事故不屬於須提報的製
程安全事件因為辦公大樓事故不被視為與製程安全有關
人機介面事故
28 一名操作技術員在聚合物工廠的終端設備旁作業時受傷這傷害是因機械的人機介面的設備而
造成該事故不屬於須提報的製程安全事件因為技術員受傷並非因危險物質一次阻絕設施失效
而造成的
混合物
29 若混合物本身有 GHS 分類可利用其分類確定恕限值若混合物本身沒有 GHS 分類則可計算混
合物中每個單一組成分之洩漏量(公斤)相對於個別成分恕限值之比值作為其對混合物恕限值之
lsquo加權rsquo貢獻譬如若混合物在 1小時內的洩漏量為 100公斤其中包含 05公斤分類為劇毒 H300
的物質45 公斤分類為 H301 的物質40 公斤另一種分類為 H 開頭的物質其餘 55 公斤則為沒
有 GHS 分類的水分此混合物之計算式為051 + 4510 + 40100 = 05 + 045 + 04 = 135超過
1因此該事故被視為須提報的製程安全事件雖然混合物個別成分之洩漏量均未超過各該物質
本身的恕限值
直接損失成本
30 此一門檻所考慮的成本應為可直接歸因於火災或爆炸的成本譬如設備及結構損壞的重置成本
修理成本環境清理支出緊急應變和罰款直接成本不包括間接成本譬如業務機會損失設
備停機造成之利潤損失取得或運轉臨時設施之成本或為滿足顧客需求取得替代產品的成本
(產品損失)
24
31 範例連接到氣體處理系統的排放管發生易燃氣體外漏同時製程出現問題導致空氣進入同
一條排放管結果發生爆炸過高的壓力損壞了排放管及其相關上游設備包括一個密封罐並
未造成人員受傷修理成本約$12000 美元該事故屬於須提報的製程安全事件因為爆炸及火
災導致設備修理成本超過門檻
32 範例一次製程安全事件後公司又發生一種非常特殊的 GHS 第 5 類產品洩漏 50 公斤造成
$2000 美元的設備損失洩漏的產品是一種非常特別的混合物公司須負擔超過$50000 美元因
產品耗損而產生之材料成本該事故不屬於須提報的製程安全事件因為 GHS 第 5 類產品洩漏的
提報門檻為 100 公斤且產品耗損不被計入直接損失成本
天然災害
33 天然災害可能對化學製程作業構成重大風險且對製程設備造成損壞導致危害物質一次阻絕設
施失效當一種或多種天然災害被認為可能對工廠作業造成影響時製程安全和作業系統應從危
害及後果分析工廠機器設備設計公用設施失效及製程停工之操作程序緊急應變計畫及應變
措施等方面界定潛在風險進行防範
天然災害類型包括颶風及颱風(包括伴隨而來的風暴潮)水災龍捲風地震超強對流風暴(直
線風暴)野火火山爆發海嘯和山崩
若公司廠房設施遭遇天然災害且其後果觸發一種或以上提報門檻該事故便屬於須提報製程安
全事件
預防性公眾應變
34 預防性公眾應變是基於謹慎的態度所採取的一種措施譬如當發生一次阻絕設施失效時公司
可能在尚未進行任何評估(如方向與洩漏點的距離等等)前便要求全體工人就地避難又
如地方權責官員(如消防警察民防緊急應變管理部門)在獲報一家公司發生製程安全事件
後為防lsquo萬一rsquo風向改變或基於可能受到波及的人口敏感族群(如學童或老年人)可能在尚未接
獲明確資訊前便下令社區就地避難或疏散或採取公眾保護措施(如道路封閉)
製程附屬倉庫
35 製程附屬倉庫指的是位於廠內用於儲存將投入於生產製程或產自於製程之原料半成品或成品的
倉庫從製程的觀點看來製程附屬倉庫相當於一個大型儲槽但這些原料半成品或成品並不
是儲存在一的大型容器中而是裝在較小的容器裡(如太空包大桶桶罐等)
25
Appendix C ndash List of RCLG Taskforce Members
Name Affiliation
Peter Schmelzer Bayer CEFIC - Chairman
Americo Diniz Carvalho Neto Braskem
Bradford Johnson American Chemistry Council
David Cummings DuPont
Debra Phillips American Chemistry Council
Hans Schwarz BASF
Kathryn Walton Plastics and Chemicals Industries Association
Kazuyuki Akita Japanese Chemical Industry Association
Kelly Keim ExxonMobil Chemical Company API Representative
Kenan Stevick Dow
Kiyokazu Murata Japanese Chemical Industry Association
Larry Bowler SABIC
Lorna Young Chemical Industry Association of Canada
Louisa Nara Center for Chemical Process Safety
Luiz Shizuo Harayashiki Associaccedilatildeo Brasileira da Induacutestria Quiacutemica
Masatoshi Kumamoto Japanese Chemical Industry Association
Milton Lacerda Petrobras
Phil Scott Chemical Industries Association
Piet Knijff DSM European Process Safety Centre
Scott Donaldson and Eamon Chandler
Shell
Scott Wallace Olin Corporation
Shakeel Kadri Air Products and Chemicals Inc
26
附錄 D ndash 詳細活動時程表
2016 年 2017 年 2018 年 2019 年 2020 年
2 ndash 4 月
RCLG PS 先導計畫
5 月 ndash
針對準則進行調整釐清
6 月 向 RCLG 和 ICCA 董事會報
告先導計畫執行結果
7 ndash 12 月 RCLG 協會考量準
則並為其會員公司發展提報機制
如有需要RCLG可向 ICCA 申請能
力建立基金為會員公司舉辦製程安
全研習會
1 ndash 12 月
RCLG 協會開始向其會員公司蒐集製程安全數據
1 ndash 12 月
如有需要RCLG 各協會運用 RCLG 的基金及專
家舉辦製程安全及績效提報研習會
1 ndash 2 月
擁有數據的協會開始向RCLG 提報製程安全事件
(2017 年數據)
4 月 RCLG 檢討第一個提報循
環的結果挑戰及原始數據(內部)
6 月 RCLG 向 ICCA 董事會呈報
原始數據
7 ndash 12 月 必要時更新及調整準
則
如有需要RCLG 各協會運用 RCLG 的基金及專
家舉辦製程安全及績效提報研習會
1 ndash 2 月
擁有數據的協會開始向RCLG 提報製程安全事件
(2018 年數據)
4 月 RCLG 檢討第二個提報循
環的結果挑戰及原始數據(內部)
6 月 RCLG 向 ICCA 董事會呈報
原始數據
7 ndash 12 月 必要時更新及調整準
則
如有需要RCLG 協會運用 RCLG 的基金及專家
舉辦製程安全及績效提報研習會
1 ndash 2 月
所有協會開始向 RCLG 提報製程安全事件
製程安全事件提報成為
RCLG KPI 衡量指標建議基本集的一部分(2019 年數
據)
4 月 RCLG 檢討第二個提報循
環的結果挑戰及原始數據(內部考量外部提
報)
6 月 RCLG 向 ICCA 董事會呈報
原始數據
27
附錄 E ndash 選擇性 Excel 追蹤表
當會員公司開始追蹤製程安全事件時所有會員公司應採用單一表格以簡化數據分析同時讓所有公司均使用相同的追蹤表RCLG 設
計了一份選擇性追蹤表可供會員公司和協會先行利用之後他們可設計自己的追蹤表
在這裡下載追蹤表
ICCA Process Safety Event Tracking Sheetxlsx
本文件包含三個分頁分別是ldquo聯絡資料rdquoldquo調查表rdquo和儲存下拉式選單選項的ldquo請勿編輯rdquo分頁
備註
附錄 E 追蹤表僅供參考TRCA 將另行提供台灣版表格供會員公司提報
28
後語
台灣化學工業責任照顧協會(Taiwan Responsible Care Association TRCA)成立於 1998 年在台灣推行責任照顧制度已達 20 週年製造商成員
包括台灣主要上市上櫃化工公司會員公司化學品生產製造量約佔全國 80 2016 年台灣化工業的 Chemical Sales 仍站在全球第八名的位
置額度為 630 億歐元化工業總產值達到 34 兆新台幣提供國內 416 萬人工作機會
TRCA 扮演國內廠商與國際制度接軌的角色也是國內化工業與政府機關及利益相關者溝通的橋樑與管道TRCA 會員結構依業務性質分析
涵蓋石化生產化學品製造氣體生產倉儲運輸業化學品貿易業以及工程研發設計等公司TRCA 透過供應鏈及價值鏈推行責任
照顧制度組成毒性化學物質聯防組織協助法規溝通與研析會員名冊請參考 httpwwwtrcaorgtwtrcanwork2aspx
TRCA 於 2010 年成為 ICCA (International Council of Chemical Associations 國際化學工業協會)觀察員ICCA 成立於 1989 年是全球化工製造
業的聯合會也是化學工業與 UNEP OPCW 及 OECD 的交流窗口ICCA 與其會員協會及成員公司致力於邁向永續的未來確保人類健康與
環境安全與保護全球化工業擁有超過 4兆美元的價值影響所有經濟部門ICCA 的會員幾乎在全球每個國家都有商業活動在全球六大
洲推動創新並提供超過 2000 萬個工作機會
台灣化工業在全球占有重要的一席之地在國內產業鏈也位居關鍵位置無論對國內或國際都有身為地球村一員應盡之責我們期許藉由
製程安全指標提報能更進一步提升自我在工安衛生環保與永續發展等面向的績效表現
台灣化學工業責任照顧協會
10452 台北市中山區撫順街 8 號 7 樓
電話02-2585-0552
httpwwwtrcaorgtw
None | |
$2500 to $25000 | |
$25000 to $250000 | |
$250000 to $25000000 | |
More than $25000000 | |
Yes - Using GHS TABLE | |
Yes - Using API RP 754 TABLE | |
NO | |
NA | |
1x le TQ lt 40x | |
40x le TQ lt 160x | |
160x le TQ lt 640x | |
ge 640x TQ | |
Yes le 3 hours | |
Yes 3 hours ge 12 hours | |
Yes 12 hours ge 24 hours | |
Yes ge 24 hours | |
No | |
Small-scale | |
Medium-scale | |
Large-scale | |
No | |
Yes | |
No | |
middot Injury requiring treatment beyond first aid to an employee contractor or subcontractor | |
middot Days Away From Work injury to an employee contractor or subcontractor or middot Injury requiring treatment beyond first aid to a third party | |
middot A fatality of an employee contractor or subcontractor or middot A hospital admission of a third party | |
middot Multiple fatalities of employees contractors or subcontractors or middot multiple hospital admission of third parties or middot A fatality of a third party | |
NA | |
1x le TQ lt 3x | |
3x le TQ lt 9x | |
9x le TQ lt 27x | |
ge 27x TQ |
ICCA Process Safety Pilot Reporting ProgramFebruary 8 2016 | 1 | 2 | 3 | 4 | 5 | 6 | 7 | 8 | 9 | 10 | 12 | 13 | 14 | 15 | |||||||||||||||||||||||
SAFETY Details(Meeting Local Regulations) | Direct Cost from Fire or Explosion | Community Impact | Environmental Impact | Material Released(Measured using the 1 Hour Rule) | |||||||||||||||||||||||||||||||||
Company Association Details | |||||||||||||||||||||||||||||||||||||
GHS | API - RP 754 | ||||||||||||||||||||||||||||||||||||
Company or Assocation Name | Headquarter Association | Location of Event Ex - City State amp Country | Date and Time of Event | Safety InjuryDid the Event result in a Recordable Lost Time Accident or Fatality or Hospital admission of anyone on or off siteUse Drop Down Menu | Safety InjuryIf yes please insert the total number of injuries | Safety InjuryFor puropses of utilizing the Severity Table please indicate the level of severity by chosing the MOST SEVERE classification that describes your incidentUse Drop Down Menu | Safety InjuryDid the incident involve Fatalities If so how many total fatalities If none enter Zero | Safety InjuryPlease Report Total Employee Hours for Calendar Year 2015 | Safety InjuryPlease Report Total Contractor Hours for Calendar Year 2015 | Direct Cost Did the Event result in Direct Damage CostUse Drop Down Menu | Direct Cost If so how muchAmount is in US DollarsUse Drop Down Menu | Community ImpactDid the event result inbull Officially declared shelter-in-place or officially declared evacuation (on or off site)ORbull Precautionary off site shelter in place or evacuation Use Drop Down Menu | Environmental ImpactDid the event result inAcute Environmental Remediation CostIf so indicate the amount in US DollarsUse Drop Down Menu | Material ReleasedDid the Event result in an Acute Release of material beyond one of the two threshold tablesIf so indicate which Threshold Table you used to make this determinationUse Drop Down Menu | Material ReleasedIf so indicate the amount released USING GHS CLASSIFICATION TABLEUse Drop Down Menu | Material ReleasedIf so indicate the amount released USING THE THRESHOLD TABLE FROM API RP-754Use Drop Down Menu | Material ReleasedIf available please indicate the material released | ||||||||||||||||||||
1 | ABC Chemical Company | American Chemistry Council | Washington DC - USA | January 4 2016 | Yes | 2 | middot Days Away From Work injury to an employee contractor or subcontractor or middot Injury requiring treatment beyond first aid to a third party | 0 | 5525000 | 1500250 | No | $2500 to $25000 | Yes le 3 hours | $2500 to $25000 | Yes - Using GHS TABLE | 40x le TQ lt 160x | NA | Chlorine | |||||||||||||||||||
2 | XYZ Chemical Company | American Chemistry Council | Washington DC - USA | 5-Jan-16 | Yes | 1 | middot Injury requiring treatment beyond first aid to an employee contractor or subcontractor | 0 | 5525000 | 1500250 | Yes | $2500 to $25000 | No | $2500 to $25000 | Yes - Using API RP 754 TABLE | NA | 3x le TQ lt 9x | Benzene | |||||||||||||||||||
3 | |||||||||||||||||||||||||||||||||||||
4 | |||||||||||||||||||||||||||||||||||||
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25 | |||||||||||||||||||||||||||||||||||||
Zero or None | Yes - Duration Unknown | ||||||||||||||||||||||||||||||||||||
Processes | Mode of Operation | Type of material released | Status of Operation | ||||
REFINING | Start-up | Flammable | Open | ||||
Alkylation HF | Planned shutdown | Combustible | Closed | ||||
Alkylation sulfuric | Emergency shutdown | Toxic | |||||
BitumenResidAsphalt | Normal | Corrosive | Tier 1 Acute Releases | ||||
Calcining | Upset | Utilities | No Release | ||||
Coking | Turnaround | Other | Category 1 | ||||
Crude | Routine maintenance | Category 2 | |||||
Desulfurization | Temporary | Evacuation | Category 3 | ||||
FCC | Other | Yes | Category 4 | ||||
Gas Treating | No | Category 5 | |||||
Hydrogen | Point of Release | Category 6 | |||||
Hydrotreating | Pump | Fire | Category 7 | ||||
Hydrocracking | Compressor | Yes | Multiple Categories | ||||
Isom | BlowerFan | No | |||||
MarineJetty | Pressure Vessel | lt $2500 | |||||
Reforming | FilterCoalescer | ||||||
Sulfur recovery | Furnace | PRDs | |||||
Vapor recoverylight ends | Boiler | Directly to Atmosphere | |||||
Wastewater | Heat exchanger | via Downstream Destructive Device | |||||
REFINING amp PETROCHEMICAL | Cooling Tower | No | |||||
Tank FarmStorage FacilityOffsite | Piping system | Yes | |||||
UtilitiesSteam PlantCogeneration | Reactor | No | |||||
Other | Atmospheric tank | ||||||
PETROCHEMICAL | FlareRelief System | Acute release above thresholds | |||||
CO H2 | Other | Yes | |||||
LNG | No | ||||||
Methane | Events | ||||||
Methanol | No Tier 1 Events | Indoor Outdoor | |||||
Methyl Mercaptan | No Tier 2 Events | No Release | |||||
Formaldehyde | No Tier 1 or Tier 2 Events | Indoor | |||||
Formaldehyde derivatives | NA | Outdoor | |||||
Acetic Acid | |||||||
Acetic Acid derivatives | Event Type | ||||||
Ethane | Injury | ||||||
Ethylene | Fire | ||||||
Ethanol | Explosion | ||||||
Ethylene oxide | PRD Discharge | ||||||
Ethylene derivatives | Acute Release | ||||||
Polyethylene | |||||||
Ethylene dichloride | General | ||||||
Ethylene dichloride derivatives | Yes | ||||||
Ethyl benzene | No | ||||||
Ethyl benzene derivatives | |||||||
Polystyrene | |||||||
Styrene-Butadiene | |||||||
Propane | |||||||
Propylene | |||||||
Polypropylene | |||||||
Isopropanol | |||||||
Propylene oxide | |||||||
Propylene oxide derivatives | |||||||
Butane | |||||||
Isobutane | |||||||
Isobutene | |||||||
Butadiene | |||||||
MTBE | |||||||
ETBE | |||||||
Pentane | |||||||
Hexane | |||||||
Cyclohexane | |||||||
Hexanol | |||||||
Aromatics Derivatives | |||||||
Benzene | |||||||
Toluene | |||||||
Xylene | |||||||
Para Xylene | |||||||
Amines Derivatives | |||||||
TDA MDA IPDA etc | |||||||
Isocyanates | |||||||
Specialty Chemicals | |||||||
LoadingUnloading | |||||||
Pilot Plant |
Instructions | ||||||||||||||
Step 1 | Complete the Contact Tab with your contact information and company information | |||||||||||||
Be sure to note the region of your reporting (IE North America France Japan etc) | ||||||||||||||
Survey on Process Safety Events | ||||||||||||||
Step 2 | Complete the survey one line per Process Safety Event for your companyregion | |||||||||||||
ALL REPORTED DATA SHOULD BE FROM CALENDAR YEAR 2017 | ||||||||||||||
Step 3 | Return completed survey to | |||||||||||||
Company Name | ||||||||||||||
Contact Person | All Surveys Due by xxx date | |||||||||||||
Address | ||||||||||||||
Fax | ||||||||||||||
Telephone | ||||||||||||||
Region | ||||||||||||||
None | |
$2500 to $25000 | |
$25000 to $250000 | |
$250000 to $25000000 | |
More than $25000000 | |
Yes - Using GHS TABLE | |
Yes - Using API RP 754 TABLE | |
NO | |
NA | |
1x le TQ lt 40x | |
40x le TQ lt 160x | |
160x le TQ lt 640x | |
ge 640x TQ | |
Yes le 3 hours | |
Yes 3 hours ge 12 hours | |
Yes 12 hours ge 24 hours | |
Yes ge 24 hours | |
No | |
Small-scale | |
Medium-scale | |
Large-scale | |
No | |
Yes | |
No | |
middot Injury requiring treatment beyond first aid to an employee contractor or subcontractor | |
middot Days Away From Work injury to an employee contractor or subcontractor or middot Injury requiring treatment beyond first aid to a third party | |
middot A fatality of an employee contractor or subcontractor or middot A hospital admission of a third party | |
middot Multiple fatalities of employees contractors or subcontractors or middot multiple hospital admission of third parties or middot A fatality of a third party | |
NA | |
1x le TQ lt 3x | |
3x le TQ lt 9x | |
9x le TQ lt 27x | |
ge 27x TQ |
ICCA Process Safety Pilot Reporting ProgramFebruary 8 2016 | 1 | 2 | 3 | 4 | 5 | 6 | 7 | 8 | 9 | 10 | 12 | 13 | 14 | 15 | |||||||||||||||||||||||
SAFETY Details(Meeting Local Regulations) | Direct Cost from Fire or Explosion | Community Impact | Environmental Impact | Material Released(Measured using the 1 Hour Rule) | |||||||||||||||||||||||||||||||||
Company Association Details | |||||||||||||||||||||||||||||||||||||
GHS | API - RP 754 | ||||||||||||||||||||||||||||||||||||
Company or Assocation Name | Headquarter Association | Location of Event Ex - City State amp Country | Date and Time of Event | Safety InjuryDid the Event result in a Recordable Lost Time Accident or Fatality or Hospital admission of anyone on or off siteUse Drop Down Menu | Safety InjuryIf yes please insert the total number of injuries | Safety InjuryFor puropses of utilizing the Severity Table please indicate the level of severity by chosing the MOST SEVERE classification that describes your incidentUse Drop Down Menu | Safety InjuryDid the incident involve Fatalities If so how many total fatalities If none enter Zero | Safety InjuryPlease Report Total Employee Hours for Calendar Year 2015 | Safety InjuryPlease Report Total Contractor Hours for Calendar Year 2015 | Direct Cost Did the Event result in Direct Damage CostUse Drop Down Menu | Direct Cost If so how muchAmount is in US DollarsUse Drop Down Menu | Community ImpactDid the event result inbull Officially declared shelter-in-place or officially declared evacuation (on or off site)ORbull Precautionary off site shelter in place or evacuation Use Drop Down Menu | Environmental ImpactDid the event result inAcute Environmental Remediation CostIf so indicate the amount in US DollarsUse Drop Down Menu | Material ReleasedDid the Event result in an Acute Release of material beyond one of the two threshold tablesIf so indicate which Threshold Table you used to make this determinationUse Drop Down Menu | Material ReleasedIf so indicate the amount released USING GHS CLASSIFICATION TABLEUse Drop Down Menu | Material ReleasedIf so indicate the amount released USING THE THRESHOLD TABLE FROM API RP-754Use Drop Down Menu | Material ReleasedIf available please indicate the material released | ||||||||||||||||||||
1 | ABC Chemical Company | American Chemistry Council | Washington DC - USA | January 4 2016 | Yes | 2 | middot Days Away From Work injury to an employee contractor or subcontractor or middot Injury requiring treatment beyond first aid to a third party | 0 | 5525000 | 1500250 | No | $2500 to $25000 | Yes le 3 hours | $2500 to $25000 | Yes - Using GHS TABLE | 40x le TQ lt 160x | NA | Chlorine | |||||||||||||||||||
2 | XYZ Chemical Company | American Chemistry Council | Washington DC - USA | 5-Jan-16 | Yes | 1 | middot Injury requiring treatment beyond first aid to an employee contractor or subcontractor | 0 | 5525000 | 1500250 | Yes | $2500 to $25000 | No | $2500 to $25000 | Yes - Using API RP 754 TABLE | NA | 3x le TQ lt 9x | Benzene | |||||||||||||||||||
3 | |||||||||||||||||||||||||||||||||||||
4 | |||||||||||||||||||||||||||||||||||||
5 | |||||||||||||||||||||||||||||||||||||
6 | |||||||||||||||||||||||||||||||||||||
7 | |||||||||||||||||||||||||||||||||||||
8 | |||||||||||||||||||||||||||||||||||||
9 | |||||||||||||||||||||||||||||||||||||
10 | |||||||||||||||||||||||||||||||||||||
11 | |||||||||||||||||||||||||||||||||||||
12 | |||||||||||||||||||||||||||||||||||||
13 | |||||||||||||||||||||||||||||||||||||
14 | |||||||||||||||||||||||||||||||||||||
15 | |||||||||||||||||||||||||||||||||||||
16 | |||||||||||||||||||||||||||||||||||||
17 | |||||||||||||||||||||||||||||||||||||
18 | |||||||||||||||||||||||||||||||||||||
19 | |||||||||||||||||||||||||||||||||||||
20 | |||||||||||||||||||||||||||||||||||||
21 | |||||||||||||||||||||||||||||||||||||
22 | |||||||||||||||||||||||||||||||||||||
23 | |||||||||||||||||||||||||||||||||||||
24 | |||||||||||||||||||||||||||||||||||||
25 | |||||||||||||||||||||||||||||||||||||
Zero or None | Yes - Duration Unknown | ||||||||||||||||||||||||||||||||||||
Processes | Mode of Operation | Type of material released | Status of Operation | ||||
REFINING | Start-up | Flammable | Open | ||||
Alkylation HF | Planned shutdown | Combustible | Closed | ||||
Alkylation sulfuric | Emergency shutdown | Toxic | |||||
BitumenResidAsphalt | Normal | Corrosive | Tier 1 Acute Releases | ||||
Calcining | Upset | Utilities | No Release | ||||
Coking | Turnaround | Other | Category 1 | ||||
Crude | Routine maintenance | Category 2 | |||||
Desulfurization | Temporary | Evacuation | Category 3 | ||||
FCC | Other | Yes | Category 4 | ||||
Gas Treating | No | Category 5 | |||||
Hydrogen | Point of Release | Category 6 | |||||
Hydrotreating | Pump | Fire | Category 7 | ||||
Hydrocracking | Compressor | Yes | Multiple Categories | ||||
Isom | BlowerFan | No | |||||
MarineJetty | Pressure Vessel | lt $2500 | |||||
Reforming | FilterCoalescer | ||||||
Sulfur recovery | Furnace | PRDs | |||||
Vapor recoverylight ends | Boiler | Directly to Atmosphere | |||||
Wastewater | Heat exchanger | via Downstream Destructive Device | |||||
REFINING amp PETROCHEMICAL | Cooling Tower | No | |||||
Tank FarmStorage FacilityOffsite | Piping system | Yes | |||||
UtilitiesSteam PlantCogeneration | Reactor | No | |||||
Other | Atmospheric tank | ||||||
PETROCHEMICAL | FlareRelief System | Acute release above thresholds | |||||
CO H2 | Other | Yes | |||||
LNG | No | ||||||
Methane | Events | ||||||
Methanol | No Tier 1 Events | Indoor Outdoor | |||||
Methyl Mercaptan | No Tier 2 Events | No Release | |||||
Formaldehyde | No Tier 1 or Tier 2 Events | Indoor | |||||
Formaldehyde derivatives | NA | Outdoor | |||||
Acetic Acid | |||||||
Acetic Acid derivatives | Event Type | ||||||
Ethane | Injury | ||||||
Ethylene | Fire | ||||||
Ethanol | Explosion | ||||||
Ethylene oxide | PRD Discharge | ||||||
Ethylene derivatives | Acute Release | ||||||
Polyethylene | |||||||
Ethylene dichloride | General | ||||||
Ethylene dichloride derivatives | Yes | ||||||
Ethyl benzene | No | ||||||
Ethyl benzene derivatives | |||||||
Polystyrene | |||||||
Styrene-Butadiene | |||||||
Propane | |||||||
Propylene | |||||||
Polypropylene | |||||||
Isopropanol | |||||||
Propylene oxide | |||||||
Propylene oxide derivatives | |||||||
Butane | |||||||
Isobutane | |||||||
Isobutene | |||||||
Butadiene | |||||||
MTBE | |||||||
ETBE | |||||||
Pentane | |||||||
Hexane | |||||||
Cyclohexane | |||||||
Hexanol | |||||||
Aromatics Derivatives | |||||||
Benzene | |||||||
Toluene | |||||||
Xylene | |||||||
Para Xylene | |||||||
Amines Derivatives | |||||||
TDA MDA IPDA etc | |||||||
Isocyanates | |||||||
Specialty Chemicals | |||||||
LoadingUnloading | |||||||
Pilot Plant |
Instructions | ||||||||||||||
Step 1 | Complete the Contact Tab with your contact information and company information | |||||||||||||
Be sure to note the region of your reporting (IE North America France Japan etc) | ||||||||||||||
Survey on Process Safety Events | ||||||||||||||
Step 2 | Complete the survey one line per Process Safety Event for your companyregion | |||||||||||||
ALL REPORTED DATA SHOULD BE FROM CALENDAR YEAR 2017 | ||||||||||||||
Step 3 | Return completed survey to | |||||||||||||
Company Name | ||||||||||||||
Contact Person | All Surveys Due by xxx date | |||||||||||||
Address | ||||||||||||||
Fax | ||||||||||||||
Telephone | ||||||||||||||
Region | ||||||||||||||
15
表 2 ndash API RP 754 Tier II 分類表
洩漏恕限類別
物質危害性分類 acdef 恕限值
(戶外洩漏) 恕限值
(戶內b洩漏)
T2-1 TIH A 區物質 ge 05 kg (11 lb) ge 025 kg (055
lb)
T2-2 TIH B 區物質 ge 25 kg (55 lb) ge 125 kg (275
lb)
T2-3 TIH C 區物質 ge 10 kg (22 lb) ge 5 kg (11 lb)
T2-4 TIH D 區物質 ge 20 kg (44 lb) ge 10 kg (22 lb)
T2-5
易燃氣體 或 正常沸點 ≦ 35 (95 degF)閃火點lt23 (73 degF)的液體 或 其他包裝組別 I 類的物質 (酸鹼除外)
ge 50 kg (110 lb) ge 25 kg (55 lb)
T2-6
正常沸點 gt 35 degC (95 degF)閃火點 lt 23 degC (73degF)的液體 或 其他包裝組別 II 類的物質 (酸鹼除外)
ge 100 kg (220 lb) 或
ge 07 bbl
ge 50 kg (110 lb) 或
ge 035 bbl
T2-7
閃火點 gt 23 degC (73 degF)和 lt 60 degC (140 degF)的液體 或 閃火點 gt 60 degC (140 degF)的液體在閃火點或高於閃火點的溫度下洩漏 或 強酸鹼 (定義參見 RP 754 文件草案) 或 UNDG第2類第22部分 (不可燃無毒氣體)空氣除外 或 其他包裝組別 III 類的物質
ge 200 kg (440 lb) 或
ge 14 bbl
ge 100 kg (220 lb) 或
ge 07 bbl
T2-8
閃火點 gt 60 degC (140 degF) 和 lt 93 degC (200 degF)的液體在低於閃火點的溫度下洩漏 或 中度酸鹼
ge 1000 kg
(2200 lb) 或
ge 7 bbl
ge 500 kg
(1100 lb) 或
ge 35 bbl
TIH吸入性毒性危害物(Toxic Inhalation Hazard)
16
一般認為以公斤和磅或以磅和桶為單位的恕限值不盡等同各公司應該選用其中一組計量單位並在
所有紀錄文件中一體適用
在判定一種物質之洩漏恕限類別時首先應從物質之含吸入性毒性(TIH Zone)可燃性(閃火點和沸點)
或腐蝕性(強酸或鹼 vs中度酸或鹼)等特性來判別只有當物質的危險度無法利用上述簡單的特性來判別
時(如遇水反應劇烈)才採用UNDGL包裝組別
a 許多物質具有一種以上危險性正確的危險區(Hazard Zone)或包裝組別(Packing Group)歸屬應遵循DOT
49 CFR 1732a [14]或聯合國危險物品運輸建議書(UNRTDG)第2部分[12]的規定參見附錄F
b 具有四面完整牆(從地板到天花板)地板和屋頂的結構物
c 對於未列於UNDG的溶液無水成分將用TIH區或包裝組別分類溶液之恕限值將根據乾基重量之恕限
值反算
d 對於未知UNDG分類的混合物可計算每種成分在恕限值洩漏中的分量如果各種成分之分量的總和
等於或大於100即表示混合物超過門檻值若混合物有明顯且獨立的毒性及可燃性結果則可分
別計算毒性及可燃性危險度參見附錄EPSE實例amp問題 49ndash53
e 閃火點 gt 60 degC (140 degF) 和 lt 93 degC (200 degF)的液體在低於閃火點的溫度下洩漏無論洩漏量多寡其
一次阻絕設施失效(LOPC)均不屬於Tier 1製程安全事件(PSE)
f 中度酸鹼的一次阻絕設施失效無論洩漏量多寡均不屬於Tier 1製程安全事件
17 (K = 1000 MM = 1000000) (在環境影響類別方面若缺乏既有定義協會和會員公司應議定輸入標準)
附錄 A ndash 嚴重程度表鼓勵所有協會均採用嚴重程度加權制度
事件事故類別
嚴重程度等級
安全人體健康 火災或爆炸導致直接
成本 任 1 小時內物質洩
漏量 社區影響 環境影響[廠外]
4 級
1 分
對員工承攬商或再承攬商造成較輕傷害嚴重之傷害 (符合本地法規)
造成以下直接損失成本
美金$25 K ~ $25 K
洩漏量介於
1x le TQ lt 40x
官方宣告就地避難或疏散 (廠內或廠外) 預防性廠外就地避難或疏散
le 3 小時
重大環境整治成本
$25 K ~ $25 K
3 級
3 分
對員工承攬商或再承攬商造成之需要多日缺勤的傷害
對第三方造成之需要初步急救以外治療的傷害 (符合本地法規)
造成以下直接損失成本
$25 K ~ $250 K
洩漏量介於
40x le TQ lt 160x
官方宣告就地避難或疏散 (廠內或廠外)
預防性廠外就地避難或疏散
3 ~ 12 小時
重大環境整治成本
$25 K ~ $250 K
2 級
9 分
對員工承攬商或再承攬商造成 1 人死亡
對第三方造成 1 人住院治療
(符合本地法規)
造成以下直接損失成本
$250 K ~ $25 MM
洩漏量介於
160x le TQ lt 640x
官方宣告就地避難或疏散 (廠內或廠外)
預防性廠外就地避難或疏散
12 ~ 24 小時
重大環境整治成本
$250 K ~ $25 MM
1 級
27 分
對員工承攬商或再承攬商造成多人死亡
對第三方造成多人住院治療
對第三方造成 1 人死亡 (符合本地法規)
造成以下直接損失成本
ge $25 MM
洩漏量
ge 640x TQ
官方宣告就地避難或疏散 (廠內或廠外)
預防性廠外就地避難或疏散
ge 24 小時
重大環境整治成本
ge $25 MM
18 (K = 1000 MM = 1000000) (在環境影響類別方面若缺乏既有定義協會和會員公司應議定輸入標準)
嚴重程度表(附錄 A)細節說明
附錄 A 之設計目的僅適用於採用 GHS 分類制度(表 1)者如果你的公司係採用 API RP 754Tier II 製程安全指標提報恕限值表(表 2)請使用
API RP 754 製程安全嚴重程度表必須提醒的是依 API RP 754 的標準其嚴重程度表僅適用於一級(Tier I)事故去比較採用不同的嚴重度
表所評估出來的相對嚴重度並無統計上的意義
急性的環境成本 ndash 因製程安全事件造成廠外環境影響所導致之短期清理及物質處置的成本各會員公司可選擇將廠外環境影響相關成本另
外區分一個嚴重程度類別
比率調整指標
利用上述嚴重程度表可產生一系列以事件率為基礎的指標包括
製程安全總事件率 (PSTIR) 總事件次數 x 200000
總工作時數
製程安全事件嚴重程度率(PSESR) (即製程安全事件嚴重程度加權計算公式)
PSESR = 所有事件之總嚴重程度分數總合 x 200000
總工作時數
在計算此一比率時各 4 級事件被分配 1 分各 3 級事件被分配 3 分各 2 級事件被分配 9 分各 1 級事件被分配 27 分理論上每個
製程安全事件至少可分配到 1 分(亦即事件僅在一個類別符合第 4 級事件屬性)至多可分配到 135 分(亦即事件在所有五個類別中均符
合第 1 級事件屬性)
ldquoXrdquo級別製程安全事件率 嚴重度級別ldquoXrdquo之製程安全事件總數 x 200000
員工承攬商amp再承攬商總工作時數
X可以是嚴重度級別 432 或 1 級製程安全事件之總數事件之嚴重度等級是選用五類後果類別中之最嚴重等級
標準化 ndash 在某些協會和會員公司中製程安全事件是採 lsquo每 100 名rsquo員工每名員工每年平均工作時數為 2000 小時為基礎予以標準化因
此在lsquo每 100rsquo名rsquo員工的標準基礎上事件被乘以 200000 工作時數也有些其他協會和會員公司將標準化基礎設定為lsquo每 500 名rsquo員工
因此事件被乘以 1000000 工作時數協會和會員公司應就標準化基礎進行討論共同做成選項結論上述的公式設定為lsquo每 100 名rsquo員工
基礎
19
附錄 B ndash 常見問題集
適用性
我們建議會員公司記錄和提報在其所擁有或運作的工廠內發生的製程安全事件惟以下情況不須提報製
程安全事件
1 源自於公司廠區以外的製程安全事件
2 海上運輸船事故惟船隻為了輸送半成品或產品之目的已經與公司的設施相連接時發生的
事故仍須提報
3 卡車或軌道車事故惟卡車或軌道車為了輸送半成品或產品之目的已經與公司的設施相連
接時發生的事故仍須提報
4 許可證或法規容許之例行排放
5 不會造成製程安全危害的地下污染請注意若洩漏至地下導致地上發生須提報製程安全事
件如釋放出毒性蒸汽或致使易燃液體蓄積成池則不適用本排除條件
6 辦公建築事故(如辦公室暖氣設備爆炸火災外溢洩漏人員受傷或疾病等)
7 與疏散或一次阻絕設施失效無直接關聯之人員安全ldquo滑倒絆倒跌倒rdquo事故
8 沒有與製程相連接之輔助設備的一次阻絕設施(如小樣品瓶)失效事故
9 計劃中和在控制下的物質排放至設計用來收集或排放系統中(請注意物質從一次阻絕設施
在非計劃或非受控制情況下排放至收集或排放系統中則不適用本排除條件)
10 在製程區域外部或保養廠內執行之機械作業
說明與實例 ndash 以 GHS 表 1 為基礎
以下說明和實例有助於在評估須提報製程安全事件(PSE)時釐清可能存在的不確定部分
公司廠區
1 一輛第三方的卡車在公司廠區內卸載易燃產品時發生洩漏進而引起火災造成公司財物損失
$7000 美元(直接成本)雖然該卡車是ldquo由他人操作rdquo但其作業與製程相連接若公司的直接成
本財物損失達到或超過$2500 美元或已達到或超過其他 PSE 提報門檻(如1 人死亡)此事故即
屬於須提報的製程安全事件
2 與前例1 類似的例子載著易燃產品的卡車在廠外運輸途中翻覆引發火災並造成卡車毀損
該事故不屬於須提報的製程安全事件因為當時卡車並未與製程相連接
20
阻絕設施失效
3 儲槽液位計故障造成裝有ldquo易燃液體rdquo產品的儲槽外溢約 700 公斤的液體流入儲槽的防溢堤內
此事故屬於須提報的製程安全事件因為其ldquo急性rdquo洩漏量超過 100 公斤即使是阻絕在二次阻絕
設施防溢堤中亦然
4 一名從事維修工作的承攬商在開啟一個製程阻閥時被噴起的硫酸濺到造成嚴重灼傷和損失工
時的工傷此事故屬於須提報的製程安全事件因為它是涉及物質和一次阻絕設施失效的意外事
件對於因洩漏造成死亡和損工的工傷或疾病事故沒有洩漏恕限值
5 一名作業員開啟品管取樣點進行日常取樣作業時手部被一個破碎的玻璃瓶嚴重割破需要進行
縫合治療縫針造成第二天無法上班該事故不屬於須提報的製程安全事件因為它與一次阻絕
設施失效無關
ldquo急性rdquo洩漏
6 一名作業員在進行天然氣流量高於預期值之異常排除時發現天然氣管線上的一個安全閥門未適
當歸位因此天然氣經由氣液分離桶排放至排氣煙囪經進一步檢查作業員判斷在過去 6 個
月間總共有 100000 公斤天然氣以穩定的速率排放至大氣該事故不屬於須提報的製程安全事
件因為其洩漏速率(每小時約 10 公斤)不算ldquo急性rdquo洩漏(未超過易燃蒸汽每小時 100 公斤的恕限
值)
廢氣燃燒塔amp排放控制裝置 (如洗滌塔)
7 若化學物質被導引至廢氣燃燒塔或排放控制裝置(如洗滌塔)只要該廢氣燃燒塔或控制裝置運作在
正常設計範圍內便不屬於須提報的製程安全事件
8 若廢氣流速超過洗滌塔的設計負荷以致未經吸收的化學物質排出超過恕限值該事故屬於須提報
的製程安全事件(如本文註釋所述)
註釋自取得許可或妥善管理的裝置-包括釋壓裝置發生不預期的排放若 1 小時內洩漏量達到或
超過表 1 或表 2 所列的洩漏恕限值且導致下列四種後果之任一項或以上之後果該事故便屬於
須提報的製程安全事件
o 二相排放或夾帶液體的排放液滴沉降至地面造成污染
o 排放至具潛在危險性的地點)
o 廠內就地避難或疏散不包括預防性廠內就地避難或疏散
o 啟動公眾保護措施(如道路封閉)包括預防性公眾保護措施
21
安全洩壓裝置 系統
9 製程單元發生異常安全閥開啟將洩漏物質釋放到排氣口此釋壓排放裝置是依相關要求設計
的且氣體釋到大氣中並未造成不良後果這不是一個須提報的製程安全事件因為安全閥高
壓破裂盤以及類似的安全裝置是依據 API 521 或者同等的標準設計的且此排放並未造成 (1)
夾帶液體並導致須提報的製程安全事件的後果(譬如損失工時意外死亡火災或爆炸造成$2500
美元或以上的直接成本損失液體或毒性氣體洩漏量達到或超過恕限值(2) 啟動廠內或廠外就地
避難應變或(3)啟動公眾保護措施
10 製程單元發生異常安全閥並未開啟造成設備超壓易燃性氣體從一個法蘭處ldquo急性rdquo漏出來
洩露量超過 100 公斤(一小時內)的恕限值該事故屬於須提報的製程安全事件因為從法蘭處外
漏屬於製程安全事件應提報事項
損工事故
11 一名作業員走路時不慎滑倒造成損失工時之工傷滑倒原因為天氣狀況rdquo長期rdquo油垢的地面和
易滑鞋具該事故不屬於須提報的製程安全事件因為人員安全ldquo滑倒絆倒跌倒rdquo事故若非與
一次阻絕設施失效直接關聯的疏散或應變造成則不屬於須提報的製程安全事件
12 與前例相同的事件惟這次作業員跌倒是因為少量易燃液體外漏(如 1 小時內少於 10 公斤)在採取
相關應變措施時發生該事故屬於須提報的製程安全事件因為作業員係為了應變一次阻絕設施
失效的事故而跌倒若一次阻絕設施失效發生在公司廠區且造成失時工傷或死亡後果該事故
便屬於須提報的製程安全事件對於因洩漏造成死亡和損失工時之工傷事故沒有洩漏量門檻
13 與前例相同的事件惟這次作業員跌倒是在事件結束數小時之後該事故不屬於須提報的製程安
全事件在提報要件中所用的ldquo疏散rdquo和ldquo應變rdquo等術語指的是一次阻絕設施失效和相關緊急應變
活動正在持續中事件結束後滑倒絆倒跌倒(如ldquo事後rdquo清理和補救)不屬於須提報製程安全事件
14 工人在因附近設備一次阻絕設施失效在疏散過程中一名鷹架搭建工人從鷹架梯上跌落造成損
失工時之工傷該事故屬於須提報的製程安全事件
15 一名作業員行經一個設計不良的蒸汽卻水器時被外洩的蒸汽燙傷腳踝造成損失工時之工傷
該事故屬於須提報的製程安全事件因為雖然一次阻絕設施失效洩漏出的是蒸汽(而非碳氫化合物
或化學物質)但損失工時之工傷是由於洩漏物質的物理狀態所導致的
16 一個密閉空間依照計畫以氮氣吹清一名承攬商繞過安全管制進入該密閉空間因而死亡該事
故屬於須提報的死亡事件但不屬於須提報的製程安全事件因為其中不涉及非計劃或失控的一
次阻絕設施失效
17 情況同上惟這次氮氣是非刻意洩漏進入該局限空間該事故屬於須提報的製程安全事件(同時也
是一起死亡事件)因為該名承攬商的死亡與非計劃的一次阻絕設施失效有關
22
18 一名作業員因硫化氫(H2S)警報在進行應變處理時昏倒若警報確實是因非計劃或失控的 H2S 一次
阻絕設施失效的外洩事件該事故便屬於須提報的製程安全事件若警報是一個假警報則該事
故便不屬於須提報的製程安全事件因為沒有真正的化學品洩漏發生
管線
19 一條管線破漏1 小時內洩漏 2000 磅(900 公斤)易燃蒸氣到地面但洩漏位置在廠區內很偏僻的
地點該事故仍屬於須提報的製程安全事件因為ldquo偏僻rdquo不是提報與否的考量因素
與化學物質外洩無關之火災或能量釋放事故
一般通則而言唯有當火災或能量釋放事故是因化學物質洩漏所造成或其發生導致化學物質洩漏
超過提報恕限值這些事故才屬於須提報的製程安全事件實例包括
20 一場電氣火災影響製程操作導致甲苯洩漏 400 公斤該事故屬於須提報的製程安全事件因為
化學物質洩漏已超過甲苯的 100 公斤提報恕限值
21 發生電氣火災停電或任何公用資源供應中斷可能造成工廠停工及可能引起設備損失超過
$2500 美元(如因非正常停工導致反應器或設備損壞)但並未造成超過恕限值的化學物質洩漏
亦未造成死亡或嚴重工傷該事故不屬於須提報的製程安全事件因為設備損壞並非化學製程火
災爆炸造成且化學物質洩漏並未超過恕限值
海上運輸船
22 一艘由公司營運的海上運輸船在船上發生ldquo急性rdquo易燃物質外洩洩漏量超過 100 公斤該事故不
屬於須提報的製程安全事件因為除非海上運輸船是為了輸送半成品或產品而與煉油石化或化
學製造廠的設施相連接否則其洩漏事故便不被視為製程安全事件
23 一艘第三方駁船由一艘拖船推向碼頭結果撞上公司的碼頭駁船的一個船艙破裂且造成
1000 公斤柴油洩漏到海中該事故不屬於須提報的製程安全事件因為駁船當時並非停泊在碼
頭內且其作業並非在進行半成品或產品之輸送
卡車與軌道車
24 一輛公司的軌道車在運輸途中出軌造成超過 1000 公斤汽油洩漏該事故不屬於須提報的製程
安全事件因為在公司廠區外發生的軌道車事故不被視為與製程安全有關
23
25 一輛第三方卡車拖車在公司廠區內翻覆造成ldquo急性rdquo汽油洩漏超過 1000 公斤這事故不屬於須
提報的製程安全事件因為卡車拖車當時已不再與裝卸設備連接然而我們建議會員公司另
行訂定運輸安全事故指標將這類事故記錄下來
26 一位合約卡車作業者正在卸載液鹼時發生軟管脫落造成空氣中氣霧和或液鹼液洩漏 2500 公
斤該事故屬於須提報的製程安全事件因為洩漏量已超過液鹼的 100 公斤恕限值且事故發生
前卡車仍與裝卸設備相連接著
辦公建築
27 綜合辦公大樓發生鍋爐火災造成總計$75000 美元的直接成本損失該事故不屬於須提報的製
程安全事件因為辦公大樓事故不被視為與製程安全有關
人機介面事故
28 一名操作技術員在聚合物工廠的終端設備旁作業時受傷這傷害是因機械的人機介面的設備而
造成該事故不屬於須提報的製程安全事件因為技術員受傷並非因危險物質一次阻絕設施失效
而造成的
混合物
29 若混合物本身有 GHS 分類可利用其分類確定恕限值若混合物本身沒有 GHS 分類則可計算混
合物中每個單一組成分之洩漏量(公斤)相對於個別成分恕限值之比值作為其對混合物恕限值之
lsquo加權rsquo貢獻譬如若混合物在 1小時內的洩漏量為 100公斤其中包含 05公斤分類為劇毒 H300
的物質45 公斤分類為 H301 的物質40 公斤另一種分類為 H 開頭的物質其餘 55 公斤則為沒
有 GHS 分類的水分此混合物之計算式為051 + 4510 + 40100 = 05 + 045 + 04 = 135超過
1因此該事故被視為須提報的製程安全事件雖然混合物個別成分之洩漏量均未超過各該物質
本身的恕限值
直接損失成本
30 此一門檻所考慮的成本應為可直接歸因於火災或爆炸的成本譬如設備及結構損壞的重置成本
修理成本環境清理支出緊急應變和罰款直接成本不包括間接成本譬如業務機會損失設
備停機造成之利潤損失取得或運轉臨時設施之成本或為滿足顧客需求取得替代產品的成本
(產品損失)
24
31 範例連接到氣體處理系統的排放管發生易燃氣體外漏同時製程出現問題導致空氣進入同
一條排放管結果發生爆炸過高的壓力損壞了排放管及其相關上游設備包括一個密封罐並
未造成人員受傷修理成本約$12000 美元該事故屬於須提報的製程安全事件因為爆炸及火
災導致設備修理成本超過門檻
32 範例一次製程安全事件後公司又發生一種非常特殊的 GHS 第 5 類產品洩漏 50 公斤造成
$2000 美元的設備損失洩漏的產品是一種非常特別的混合物公司須負擔超過$50000 美元因
產品耗損而產生之材料成本該事故不屬於須提報的製程安全事件因為 GHS 第 5 類產品洩漏的
提報門檻為 100 公斤且產品耗損不被計入直接損失成本
天然災害
33 天然災害可能對化學製程作業構成重大風險且對製程設備造成損壞導致危害物質一次阻絕設
施失效當一種或多種天然災害被認為可能對工廠作業造成影響時製程安全和作業系統應從危
害及後果分析工廠機器設備設計公用設施失效及製程停工之操作程序緊急應變計畫及應變
措施等方面界定潛在風險進行防範
天然災害類型包括颶風及颱風(包括伴隨而來的風暴潮)水災龍捲風地震超強對流風暴(直
線風暴)野火火山爆發海嘯和山崩
若公司廠房設施遭遇天然災害且其後果觸發一種或以上提報門檻該事故便屬於須提報製程安
全事件
預防性公眾應變
34 預防性公眾應變是基於謹慎的態度所採取的一種措施譬如當發生一次阻絕設施失效時公司
可能在尚未進行任何評估(如方向與洩漏點的距離等等)前便要求全體工人就地避難又
如地方權責官員(如消防警察民防緊急應變管理部門)在獲報一家公司發生製程安全事件
後為防lsquo萬一rsquo風向改變或基於可能受到波及的人口敏感族群(如學童或老年人)可能在尚未接
獲明確資訊前便下令社區就地避難或疏散或採取公眾保護措施(如道路封閉)
製程附屬倉庫
35 製程附屬倉庫指的是位於廠內用於儲存將投入於生產製程或產自於製程之原料半成品或成品的
倉庫從製程的觀點看來製程附屬倉庫相當於一個大型儲槽但這些原料半成品或成品並不
是儲存在一的大型容器中而是裝在較小的容器裡(如太空包大桶桶罐等)
25
Appendix C ndash List of RCLG Taskforce Members
Name Affiliation
Peter Schmelzer Bayer CEFIC - Chairman
Americo Diniz Carvalho Neto Braskem
Bradford Johnson American Chemistry Council
David Cummings DuPont
Debra Phillips American Chemistry Council
Hans Schwarz BASF
Kathryn Walton Plastics and Chemicals Industries Association
Kazuyuki Akita Japanese Chemical Industry Association
Kelly Keim ExxonMobil Chemical Company API Representative
Kenan Stevick Dow
Kiyokazu Murata Japanese Chemical Industry Association
Larry Bowler SABIC
Lorna Young Chemical Industry Association of Canada
Louisa Nara Center for Chemical Process Safety
Luiz Shizuo Harayashiki Associaccedilatildeo Brasileira da Induacutestria Quiacutemica
Masatoshi Kumamoto Japanese Chemical Industry Association
Milton Lacerda Petrobras
Phil Scott Chemical Industries Association
Piet Knijff DSM European Process Safety Centre
Scott Donaldson and Eamon Chandler
Shell
Scott Wallace Olin Corporation
Shakeel Kadri Air Products and Chemicals Inc
26
附錄 D ndash 詳細活動時程表
2016 年 2017 年 2018 年 2019 年 2020 年
2 ndash 4 月
RCLG PS 先導計畫
5 月 ndash
針對準則進行調整釐清
6 月 向 RCLG 和 ICCA 董事會報
告先導計畫執行結果
7 ndash 12 月 RCLG 協會考量準
則並為其會員公司發展提報機制
如有需要RCLG可向 ICCA 申請能
力建立基金為會員公司舉辦製程安
全研習會
1 ndash 12 月
RCLG 協會開始向其會員公司蒐集製程安全數據
1 ndash 12 月
如有需要RCLG 各協會運用 RCLG 的基金及專
家舉辦製程安全及績效提報研習會
1 ndash 2 月
擁有數據的協會開始向RCLG 提報製程安全事件
(2017 年數據)
4 月 RCLG 檢討第一個提報循
環的結果挑戰及原始數據(內部)
6 月 RCLG 向 ICCA 董事會呈報
原始數據
7 ndash 12 月 必要時更新及調整準
則
如有需要RCLG 各協會運用 RCLG 的基金及專
家舉辦製程安全及績效提報研習會
1 ndash 2 月
擁有數據的協會開始向RCLG 提報製程安全事件
(2018 年數據)
4 月 RCLG 檢討第二個提報循
環的結果挑戰及原始數據(內部)
6 月 RCLG 向 ICCA 董事會呈報
原始數據
7 ndash 12 月 必要時更新及調整準
則
如有需要RCLG 協會運用 RCLG 的基金及專家
舉辦製程安全及績效提報研習會
1 ndash 2 月
所有協會開始向 RCLG 提報製程安全事件
製程安全事件提報成為
RCLG KPI 衡量指標建議基本集的一部分(2019 年數
據)
4 月 RCLG 檢討第二個提報循
環的結果挑戰及原始數據(內部考量外部提
報)
6 月 RCLG 向 ICCA 董事會呈報
原始數據
27
附錄 E ndash 選擇性 Excel 追蹤表
當會員公司開始追蹤製程安全事件時所有會員公司應採用單一表格以簡化數據分析同時讓所有公司均使用相同的追蹤表RCLG 設
計了一份選擇性追蹤表可供會員公司和協會先行利用之後他們可設計自己的追蹤表
在這裡下載追蹤表
ICCA Process Safety Event Tracking Sheetxlsx
本文件包含三個分頁分別是ldquo聯絡資料rdquoldquo調查表rdquo和儲存下拉式選單選項的ldquo請勿編輯rdquo分頁
備註
附錄 E 追蹤表僅供參考TRCA 將另行提供台灣版表格供會員公司提報
28
後語
台灣化學工業責任照顧協會(Taiwan Responsible Care Association TRCA)成立於 1998 年在台灣推行責任照顧制度已達 20 週年製造商成員
包括台灣主要上市上櫃化工公司會員公司化學品生產製造量約佔全國 80 2016 年台灣化工業的 Chemical Sales 仍站在全球第八名的位
置額度為 630 億歐元化工業總產值達到 34 兆新台幣提供國內 416 萬人工作機會
TRCA 扮演國內廠商與國際制度接軌的角色也是國內化工業與政府機關及利益相關者溝通的橋樑與管道TRCA 會員結構依業務性質分析
涵蓋石化生產化學品製造氣體生產倉儲運輸業化學品貿易業以及工程研發設計等公司TRCA 透過供應鏈及價值鏈推行責任
照顧制度組成毒性化學物質聯防組織協助法規溝通與研析會員名冊請參考 httpwwwtrcaorgtwtrcanwork2aspx
TRCA 於 2010 年成為 ICCA (International Council of Chemical Associations 國際化學工業協會)觀察員ICCA 成立於 1989 年是全球化工製造
業的聯合會也是化學工業與 UNEP OPCW 及 OECD 的交流窗口ICCA 與其會員協會及成員公司致力於邁向永續的未來確保人類健康與
環境安全與保護全球化工業擁有超過 4兆美元的價值影響所有經濟部門ICCA 的會員幾乎在全球每個國家都有商業活動在全球六大
洲推動創新並提供超過 2000 萬個工作機會
台灣化工業在全球占有重要的一席之地在國內產業鏈也位居關鍵位置無論對國內或國際都有身為地球村一員應盡之責我們期許藉由
製程安全指標提報能更進一步提升自我在工安衛生環保與永續發展等面向的績效表現
台灣化學工業責任照顧協會
10452 台北市中山區撫順街 8 號 7 樓
電話02-2585-0552
httpwwwtrcaorgtw
None | |
$2500 to $25000 | |
$25000 to $250000 | |
$250000 to $25000000 | |
More than $25000000 | |
Yes - Using GHS TABLE | |
Yes - Using API RP 754 TABLE | |
NO | |
NA | |
1x le TQ lt 40x | |
40x le TQ lt 160x | |
160x le TQ lt 640x | |
ge 640x TQ | |
Yes le 3 hours | |
Yes 3 hours ge 12 hours | |
Yes 12 hours ge 24 hours | |
Yes ge 24 hours | |
No | |
Small-scale | |
Medium-scale | |
Large-scale | |
No | |
Yes | |
No | |
middot Injury requiring treatment beyond first aid to an employee contractor or subcontractor | |
middot Days Away From Work injury to an employee contractor or subcontractor or middot Injury requiring treatment beyond first aid to a third party | |
middot A fatality of an employee contractor or subcontractor or middot A hospital admission of a third party | |
middot Multiple fatalities of employees contractors or subcontractors or middot multiple hospital admission of third parties or middot A fatality of a third party | |
NA | |
1x le TQ lt 3x | |
3x le TQ lt 9x | |
9x le TQ lt 27x | |
ge 27x TQ |
ICCA Process Safety Pilot Reporting ProgramFebruary 8 2016 | 1 | 2 | 3 | 4 | 5 | 6 | 7 | 8 | 9 | 10 | 12 | 13 | 14 | 15 | |||||||||||||||||||||||
SAFETY Details(Meeting Local Regulations) | Direct Cost from Fire or Explosion | Community Impact | Environmental Impact | Material Released(Measured using the 1 Hour Rule) | |||||||||||||||||||||||||||||||||
Company Association Details | |||||||||||||||||||||||||||||||||||||
GHS | API - RP 754 | ||||||||||||||||||||||||||||||||||||
Company or Assocation Name | Headquarter Association | Location of Event Ex - City State amp Country | Date and Time of Event | Safety InjuryDid the Event result in a Recordable Lost Time Accident or Fatality or Hospital admission of anyone on or off siteUse Drop Down Menu | Safety InjuryIf yes please insert the total number of injuries | Safety InjuryFor puropses of utilizing the Severity Table please indicate the level of severity by chosing the MOST SEVERE classification that describes your incidentUse Drop Down Menu | Safety InjuryDid the incident involve Fatalities If so how many total fatalities If none enter Zero | Safety InjuryPlease Report Total Employee Hours for Calendar Year 2015 | Safety InjuryPlease Report Total Contractor Hours for Calendar Year 2015 | Direct Cost Did the Event result in Direct Damage CostUse Drop Down Menu | Direct Cost If so how muchAmount is in US DollarsUse Drop Down Menu | Community ImpactDid the event result inbull Officially declared shelter-in-place or officially declared evacuation (on or off site)ORbull Precautionary off site shelter in place or evacuation Use Drop Down Menu | Environmental ImpactDid the event result inAcute Environmental Remediation CostIf so indicate the amount in US DollarsUse Drop Down Menu | Material ReleasedDid the Event result in an Acute Release of material beyond one of the two threshold tablesIf so indicate which Threshold Table you used to make this determinationUse Drop Down Menu | Material ReleasedIf so indicate the amount released USING GHS CLASSIFICATION TABLEUse Drop Down Menu | Material ReleasedIf so indicate the amount released USING THE THRESHOLD TABLE FROM API RP-754Use Drop Down Menu | Material ReleasedIf available please indicate the material released | ||||||||||||||||||||
1 | ABC Chemical Company | American Chemistry Council | Washington DC - USA | January 4 2016 | Yes | 2 | middot Days Away From Work injury to an employee contractor or subcontractor or middot Injury requiring treatment beyond first aid to a third party | 0 | 5525000 | 1500250 | No | $2500 to $25000 | Yes le 3 hours | $2500 to $25000 | Yes - Using GHS TABLE | 40x le TQ lt 160x | NA | Chlorine | |||||||||||||||||||
2 | XYZ Chemical Company | American Chemistry Council | Washington DC - USA | 5-Jan-16 | Yes | 1 | middot Injury requiring treatment beyond first aid to an employee contractor or subcontractor | 0 | 5525000 | 1500250 | Yes | $2500 to $25000 | No | $2500 to $25000 | Yes - Using API RP 754 TABLE | NA | 3x le TQ lt 9x | Benzene | |||||||||||||||||||
3 | |||||||||||||||||||||||||||||||||||||
4 | |||||||||||||||||||||||||||||||||||||
5 | |||||||||||||||||||||||||||||||||||||
6 | |||||||||||||||||||||||||||||||||||||
7 | |||||||||||||||||||||||||||||||||||||
8 | |||||||||||||||||||||||||||||||||||||
9 | |||||||||||||||||||||||||||||||||||||
10 | |||||||||||||||||||||||||||||||||||||
11 | |||||||||||||||||||||||||||||||||||||
12 | |||||||||||||||||||||||||||||||||||||
13 | |||||||||||||||||||||||||||||||||||||
14 | |||||||||||||||||||||||||||||||||||||
15 | |||||||||||||||||||||||||||||||||||||
16 | |||||||||||||||||||||||||||||||||||||
17 | |||||||||||||||||||||||||||||||||||||
18 | |||||||||||||||||||||||||||||||||||||
19 | |||||||||||||||||||||||||||||||||||||
20 | |||||||||||||||||||||||||||||||||||||
21 | |||||||||||||||||||||||||||||||||||||
22 | |||||||||||||||||||||||||||||||||||||
23 | |||||||||||||||||||||||||||||||||||||
24 | |||||||||||||||||||||||||||||||||||||
25 | |||||||||||||||||||||||||||||||||||||
Zero or None | Yes - Duration Unknown | ||||||||||||||||||||||||||||||||||||
Processes | Mode of Operation | Type of material released | Status of Operation | ||||
REFINING | Start-up | Flammable | Open | ||||
Alkylation HF | Planned shutdown | Combustible | Closed | ||||
Alkylation sulfuric | Emergency shutdown | Toxic | |||||
BitumenResidAsphalt | Normal | Corrosive | Tier 1 Acute Releases | ||||
Calcining | Upset | Utilities | No Release | ||||
Coking | Turnaround | Other | Category 1 | ||||
Crude | Routine maintenance | Category 2 | |||||
Desulfurization | Temporary | Evacuation | Category 3 | ||||
FCC | Other | Yes | Category 4 | ||||
Gas Treating | No | Category 5 | |||||
Hydrogen | Point of Release | Category 6 | |||||
Hydrotreating | Pump | Fire | Category 7 | ||||
Hydrocracking | Compressor | Yes | Multiple Categories | ||||
Isom | BlowerFan | No | |||||
MarineJetty | Pressure Vessel | lt $2500 | |||||
Reforming | FilterCoalescer | ||||||
Sulfur recovery | Furnace | PRDs | |||||
Vapor recoverylight ends | Boiler | Directly to Atmosphere | |||||
Wastewater | Heat exchanger | via Downstream Destructive Device | |||||
REFINING amp PETROCHEMICAL | Cooling Tower | No | |||||
Tank FarmStorage FacilityOffsite | Piping system | Yes | |||||
UtilitiesSteam PlantCogeneration | Reactor | No | |||||
Other | Atmospheric tank | ||||||
PETROCHEMICAL | FlareRelief System | Acute release above thresholds | |||||
CO H2 | Other | Yes | |||||
LNG | No | ||||||
Methane | Events | ||||||
Methanol | No Tier 1 Events | Indoor Outdoor | |||||
Methyl Mercaptan | No Tier 2 Events | No Release | |||||
Formaldehyde | No Tier 1 or Tier 2 Events | Indoor | |||||
Formaldehyde derivatives | NA | Outdoor | |||||
Acetic Acid | |||||||
Acetic Acid derivatives | Event Type | ||||||
Ethane | Injury | ||||||
Ethylene | Fire | ||||||
Ethanol | Explosion | ||||||
Ethylene oxide | PRD Discharge | ||||||
Ethylene derivatives | Acute Release | ||||||
Polyethylene | |||||||
Ethylene dichloride | General | ||||||
Ethylene dichloride derivatives | Yes | ||||||
Ethyl benzene | No | ||||||
Ethyl benzene derivatives | |||||||
Polystyrene | |||||||
Styrene-Butadiene | |||||||
Propane | |||||||
Propylene | |||||||
Polypropylene | |||||||
Isopropanol | |||||||
Propylene oxide | |||||||
Propylene oxide derivatives | |||||||
Butane | |||||||
Isobutane | |||||||
Isobutene | |||||||
Butadiene | |||||||
MTBE | |||||||
ETBE | |||||||
Pentane | |||||||
Hexane | |||||||
Cyclohexane | |||||||
Hexanol | |||||||
Aromatics Derivatives | |||||||
Benzene | |||||||
Toluene | |||||||
Xylene | |||||||
Para Xylene | |||||||
Amines Derivatives | |||||||
TDA MDA IPDA etc | |||||||
Isocyanates | |||||||
Specialty Chemicals | |||||||
LoadingUnloading | |||||||
Pilot Plant |
Instructions | ||||||||||||||
Step 1 | Complete the Contact Tab with your contact information and company information | |||||||||||||
Be sure to note the region of your reporting (IE North America France Japan etc) | ||||||||||||||
Survey on Process Safety Events | ||||||||||||||
Step 2 | Complete the survey one line per Process Safety Event for your companyregion | |||||||||||||
ALL REPORTED DATA SHOULD BE FROM CALENDAR YEAR 2017 | ||||||||||||||
Step 3 | Return completed survey to | |||||||||||||
Company Name | ||||||||||||||
Contact Person | All Surveys Due by xxx date | |||||||||||||
Address | ||||||||||||||
Fax | ||||||||||||||
Telephone | ||||||||||||||
Region | ||||||||||||||
None | |
$2500 to $25000 | |
$25000 to $250000 | |
$250000 to $25000000 | |
More than $25000000 | |
Yes - Using GHS TABLE | |
Yes - Using API RP 754 TABLE | |
NO | |
NA | |
1x le TQ lt 40x | |
40x le TQ lt 160x | |
160x le TQ lt 640x | |
ge 640x TQ | |
Yes le 3 hours | |
Yes 3 hours ge 12 hours | |
Yes 12 hours ge 24 hours | |
Yes ge 24 hours | |
No | |
Small-scale | |
Medium-scale | |
Large-scale | |
No | |
Yes | |
No | |
middot Injury requiring treatment beyond first aid to an employee contractor or subcontractor | |
middot Days Away From Work injury to an employee contractor or subcontractor or middot Injury requiring treatment beyond first aid to a third party | |
middot A fatality of an employee contractor or subcontractor or middot A hospital admission of a third party | |
middot Multiple fatalities of employees contractors or subcontractors or middot multiple hospital admission of third parties or middot A fatality of a third party | |
NA | |
1x le TQ lt 3x | |
3x le TQ lt 9x | |
9x le TQ lt 27x | |
ge 27x TQ |
ICCA Process Safety Pilot Reporting ProgramFebruary 8 2016 | 1 | 2 | 3 | 4 | 5 | 6 | 7 | 8 | 9 | 10 | 12 | 13 | 14 | 15 | |||||||||||||||||||||||
SAFETY Details(Meeting Local Regulations) | Direct Cost from Fire or Explosion | Community Impact | Environmental Impact | Material Released(Measured using the 1 Hour Rule) | |||||||||||||||||||||||||||||||||
Company Association Details | |||||||||||||||||||||||||||||||||||||
GHS | API - RP 754 | ||||||||||||||||||||||||||||||||||||
Company or Assocation Name | Headquarter Association | Location of Event Ex - City State amp Country | Date and Time of Event | Safety InjuryDid the Event result in a Recordable Lost Time Accident or Fatality or Hospital admission of anyone on or off siteUse Drop Down Menu | Safety InjuryIf yes please insert the total number of injuries | Safety InjuryFor puropses of utilizing the Severity Table please indicate the level of severity by chosing the MOST SEVERE classification that describes your incidentUse Drop Down Menu | Safety InjuryDid the incident involve Fatalities If so how many total fatalities If none enter Zero | Safety InjuryPlease Report Total Employee Hours for Calendar Year 2015 | Safety InjuryPlease Report Total Contractor Hours for Calendar Year 2015 | Direct Cost Did the Event result in Direct Damage CostUse Drop Down Menu | Direct Cost If so how muchAmount is in US DollarsUse Drop Down Menu | Community ImpactDid the event result inbull Officially declared shelter-in-place or officially declared evacuation (on or off site)ORbull Precautionary off site shelter in place or evacuation Use Drop Down Menu | Environmental ImpactDid the event result inAcute Environmental Remediation CostIf so indicate the amount in US DollarsUse Drop Down Menu | Material ReleasedDid the Event result in an Acute Release of material beyond one of the two threshold tablesIf so indicate which Threshold Table you used to make this determinationUse Drop Down Menu | Material ReleasedIf so indicate the amount released USING GHS CLASSIFICATION TABLEUse Drop Down Menu | Material ReleasedIf so indicate the amount released USING THE THRESHOLD TABLE FROM API RP-754Use Drop Down Menu | Material ReleasedIf available please indicate the material released | ||||||||||||||||||||
1 | ABC Chemical Company | American Chemistry Council | Washington DC - USA | January 4 2016 | Yes | 2 | middot Days Away From Work injury to an employee contractor or subcontractor or middot Injury requiring treatment beyond first aid to a third party | 0 | 5525000 | 1500250 | No | $2500 to $25000 | Yes le 3 hours | $2500 to $25000 | Yes - Using GHS TABLE | 40x le TQ lt 160x | NA | Chlorine | |||||||||||||||||||
2 | XYZ Chemical Company | American Chemistry Council | Washington DC - USA | 5-Jan-16 | Yes | 1 | middot Injury requiring treatment beyond first aid to an employee contractor or subcontractor | 0 | 5525000 | 1500250 | Yes | $2500 to $25000 | No | $2500 to $25000 | Yes - Using API RP 754 TABLE | NA | 3x le TQ lt 9x | Benzene | |||||||||||||||||||
3 | |||||||||||||||||||||||||||||||||||||
4 | |||||||||||||||||||||||||||||||||||||
5 | |||||||||||||||||||||||||||||||||||||
6 | |||||||||||||||||||||||||||||||||||||
7 | |||||||||||||||||||||||||||||||||||||
8 | |||||||||||||||||||||||||||||||||||||
9 | |||||||||||||||||||||||||||||||||||||
10 | |||||||||||||||||||||||||||||||||||||
11 | |||||||||||||||||||||||||||||||||||||
12 | |||||||||||||||||||||||||||||||||||||
13 | |||||||||||||||||||||||||||||||||||||
14 | |||||||||||||||||||||||||||||||||||||
15 | |||||||||||||||||||||||||||||||||||||
16 | |||||||||||||||||||||||||||||||||||||
17 | |||||||||||||||||||||||||||||||||||||
18 | |||||||||||||||||||||||||||||||||||||
19 | |||||||||||||||||||||||||||||||||||||
20 | |||||||||||||||||||||||||||||||||||||
21 | |||||||||||||||||||||||||||||||||||||
22 | |||||||||||||||||||||||||||||||||||||
23 | |||||||||||||||||||||||||||||||||||||
24 | |||||||||||||||||||||||||||||||||||||
25 | |||||||||||||||||||||||||||||||||||||
Zero or None | Yes - Duration Unknown | ||||||||||||||||||||||||||||||||||||
Processes | Mode of Operation | Type of material released | Status of Operation | ||||
REFINING | Start-up | Flammable | Open | ||||
Alkylation HF | Planned shutdown | Combustible | Closed | ||||
Alkylation sulfuric | Emergency shutdown | Toxic | |||||
BitumenResidAsphalt | Normal | Corrosive | Tier 1 Acute Releases | ||||
Calcining | Upset | Utilities | No Release | ||||
Coking | Turnaround | Other | Category 1 | ||||
Crude | Routine maintenance | Category 2 | |||||
Desulfurization | Temporary | Evacuation | Category 3 | ||||
FCC | Other | Yes | Category 4 | ||||
Gas Treating | No | Category 5 | |||||
Hydrogen | Point of Release | Category 6 | |||||
Hydrotreating | Pump | Fire | Category 7 | ||||
Hydrocracking | Compressor | Yes | Multiple Categories | ||||
Isom | BlowerFan | No | |||||
MarineJetty | Pressure Vessel | lt $2500 | |||||
Reforming | FilterCoalescer | ||||||
Sulfur recovery | Furnace | PRDs | |||||
Vapor recoverylight ends | Boiler | Directly to Atmosphere | |||||
Wastewater | Heat exchanger | via Downstream Destructive Device | |||||
REFINING amp PETROCHEMICAL | Cooling Tower | No | |||||
Tank FarmStorage FacilityOffsite | Piping system | Yes | |||||
UtilitiesSteam PlantCogeneration | Reactor | No | |||||
Other | Atmospheric tank | ||||||
PETROCHEMICAL | FlareRelief System | Acute release above thresholds | |||||
CO H2 | Other | Yes | |||||
LNG | No | ||||||
Methane | Events | ||||||
Methanol | No Tier 1 Events | Indoor Outdoor | |||||
Methyl Mercaptan | No Tier 2 Events | No Release | |||||
Formaldehyde | No Tier 1 or Tier 2 Events | Indoor | |||||
Formaldehyde derivatives | NA | Outdoor | |||||
Acetic Acid | |||||||
Acetic Acid derivatives | Event Type | ||||||
Ethane | Injury | ||||||
Ethylene | Fire | ||||||
Ethanol | Explosion | ||||||
Ethylene oxide | PRD Discharge | ||||||
Ethylene derivatives | Acute Release | ||||||
Polyethylene | |||||||
Ethylene dichloride | General | ||||||
Ethylene dichloride derivatives | Yes | ||||||
Ethyl benzene | No | ||||||
Ethyl benzene derivatives | |||||||
Polystyrene | |||||||
Styrene-Butadiene | |||||||
Propane | |||||||
Propylene | |||||||
Polypropylene | |||||||
Isopropanol | |||||||
Propylene oxide | |||||||
Propylene oxide derivatives | |||||||
Butane | |||||||
Isobutane | |||||||
Isobutene | |||||||
Butadiene | |||||||
MTBE | |||||||
ETBE | |||||||
Pentane | |||||||
Hexane | |||||||
Cyclohexane | |||||||
Hexanol | |||||||
Aromatics Derivatives | |||||||
Benzene | |||||||
Toluene | |||||||
Xylene | |||||||
Para Xylene | |||||||
Amines Derivatives | |||||||
TDA MDA IPDA etc | |||||||
Isocyanates | |||||||
Specialty Chemicals | |||||||
LoadingUnloading | |||||||
Pilot Plant |
Instructions | ||||||||||||||
Step 1 | Complete the Contact Tab with your contact information and company information | |||||||||||||
Be sure to note the region of your reporting (IE North America France Japan etc) | ||||||||||||||
Survey on Process Safety Events | ||||||||||||||
Step 2 | Complete the survey one line per Process Safety Event for your companyregion | |||||||||||||
ALL REPORTED DATA SHOULD BE FROM CALENDAR YEAR 2017 | ||||||||||||||
Step 3 | Return completed survey to | |||||||||||||
Company Name | ||||||||||||||
Contact Person | All Surveys Due by xxx date | |||||||||||||
Address | ||||||||||||||
Fax | ||||||||||||||
Telephone | ||||||||||||||
Region | ||||||||||||||
16
一般認為以公斤和磅或以磅和桶為單位的恕限值不盡等同各公司應該選用其中一組計量單位並在
所有紀錄文件中一體適用
在判定一種物質之洩漏恕限類別時首先應從物質之含吸入性毒性(TIH Zone)可燃性(閃火點和沸點)
或腐蝕性(強酸或鹼 vs中度酸或鹼)等特性來判別只有當物質的危險度無法利用上述簡單的特性來判別
時(如遇水反應劇烈)才採用UNDGL包裝組別
a 許多物質具有一種以上危險性正確的危險區(Hazard Zone)或包裝組別(Packing Group)歸屬應遵循DOT
49 CFR 1732a [14]或聯合國危險物品運輸建議書(UNRTDG)第2部分[12]的規定參見附錄F
b 具有四面完整牆(從地板到天花板)地板和屋頂的結構物
c 對於未列於UNDG的溶液無水成分將用TIH區或包裝組別分類溶液之恕限值將根據乾基重量之恕限
值反算
d 對於未知UNDG分類的混合物可計算每種成分在恕限值洩漏中的分量如果各種成分之分量的總和
等於或大於100即表示混合物超過門檻值若混合物有明顯且獨立的毒性及可燃性結果則可分
別計算毒性及可燃性危險度參見附錄EPSE實例amp問題 49ndash53
e 閃火點 gt 60 degC (140 degF) 和 lt 93 degC (200 degF)的液體在低於閃火點的溫度下洩漏無論洩漏量多寡其
一次阻絕設施失效(LOPC)均不屬於Tier 1製程安全事件(PSE)
f 中度酸鹼的一次阻絕設施失效無論洩漏量多寡均不屬於Tier 1製程安全事件
17 (K = 1000 MM = 1000000) (在環境影響類別方面若缺乏既有定義協會和會員公司應議定輸入標準)
附錄 A ndash 嚴重程度表鼓勵所有協會均採用嚴重程度加權制度
事件事故類別
嚴重程度等級
安全人體健康 火災或爆炸導致直接
成本 任 1 小時內物質洩
漏量 社區影響 環境影響[廠外]
4 級
1 分
對員工承攬商或再承攬商造成較輕傷害嚴重之傷害 (符合本地法規)
造成以下直接損失成本
美金$25 K ~ $25 K
洩漏量介於
1x le TQ lt 40x
官方宣告就地避難或疏散 (廠內或廠外) 預防性廠外就地避難或疏散
le 3 小時
重大環境整治成本
$25 K ~ $25 K
3 級
3 分
對員工承攬商或再承攬商造成之需要多日缺勤的傷害
對第三方造成之需要初步急救以外治療的傷害 (符合本地法規)
造成以下直接損失成本
$25 K ~ $250 K
洩漏量介於
40x le TQ lt 160x
官方宣告就地避難或疏散 (廠內或廠外)
預防性廠外就地避難或疏散
3 ~ 12 小時
重大環境整治成本
$25 K ~ $250 K
2 級
9 分
對員工承攬商或再承攬商造成 1 人死亡
對第三方造成 1 人住院治療
(符合本地法規)
造成以下直接損失成本
$250 K ~ $25 MM
洩漏量介於
160x le TQ lt 640x
官方宣告就地避難或疏散 (廠內或廠外)
預防性廠外就地避難或疏散
12 ~ 24 小時
重大環境整治成本
$250 K ~ $25 MM
1 級
27 分
對員工承攬商或再承攬商造成多人死亡
對第三方造成多人住院治療
對第三方造成 1 人死亡 (符合本地法規)
造成以下直接損失成本
ge $25 MM
洩漏量
ge 640x TQ
官方宣告就地避難或疏散 (廠內或廠外)
預防性廠外就地避難或疏散
ge 24 小時
重大環境整治成本
ge $25 MM
18 (K = 1000 MM = 1000000) (在環境影響類別方面若缺乏既有定義協會和會員公司應議定輸入標準)
嚴重程度表(附錄 A)細節說明
附錄 A 之設計目的僅適用於採用 GHS 分類制度(表 1)者如果你的公司係採用 API RP 754Tier II 製程安全指標提報恕限值表(表 2)請使用
API RP 754 製程安全嚴重程度表必須提醒的是依 API RP 754 的標準其嚴重程度表僅適用於一級(Tier I)事故去比較採用不同的嚴重度
表所評估出來的相對嚴重度並無統計上的意義
急性的環境成本 ndash 因製程安全事件造成廠外環境影響所導致之短期清理及物質處置的成本各會員公司可選擇將廠外環境影響相關成本另
外區分一個嚴重程度類別
比率調整指標
利用上述嚴重程度表可產生一系列以事件率為基礎的指標包括
製程安全總事件率 (PSTIR) 總事件次數 x 200000
總工作時數
製程安全事件嚴重程度率(PSESR) (即製程安全事件嚴重程度加權計算公式)
PSESR = 所有事件之總嚴重程度分數總合 x 200000
總工作時數
在計算此一比率時各 4 級事件被分配 1 分各 3 級事件被分配 3 分各 2 級事件被分配 9 分各 1 級事件被分配 27 分理論上每個
製程安全事件至少可分配到 1 分(亦即事件僅在一個類別符合第 4 級事件屬性)至多可分配到 135 分(亦即事件在所有五個類別中均符
合第 1 級事件屬性)
ldquoXrdquo級別製程安全事件率 嚴重度級別ldquoXrdquo之製程安全事件總數 x 200000
員工承攬商amp再承攬商總工作時數
X可以是嚴重度級別 432 或 1 級製程安全事件之總數事件之嚴重度等級是選用五類後果類別中之最嚴重等級
標準化 ndash 在某些協會和會員公司中製程安全事件是採 lsquo每 100 名rsquo員工每名員工每年平均工作時數為 2000 小時為基礎予以標準化因
此在lsquo每 100rsquo名rsquo員工的標準基礎上事件被乘以 200000 工作時數也有些其他協會和會員公司將標準化基礎設定為lsquo每 500 名rsquo員工
因此事件被乘以 1000000 工作時數協會和會員公司應就標準化基礎進行討論共同做成選項結論上述的公式設定為lsquo每 100 名rsquo員工
基礎
19
附錄 B ndash 常見問題集
適用性
我們建議會員公司記錄和提報在其所擁有或運作的工廠內發生的製程安全事件惟以下情況不須提報製
程安全事件
1 源自於公司廠區以外的製程安全事件
2 海上運輸船事故惟船隻為了輸送半成品或產品之目的已經與公司的設施相連接時發生的
事故仍須提報
3 卡車或軌道車事故惟卡車或軌道車為了輸送半成品或產品之目的已經與公司的設施相連
接時發生的事故仍須提報
4 許可證或法規容許之例行排放
5 不會造成製程安全危害的地下污染請注意若洩漏至地下導致地上發生須提報製程安全事
件如釋放出毒性蒸汽或致使易燃液體蓄積成池則不適用本排除條件
6 辦公建築事故(如辦公室暖氣設備爆炸火災外溢洩漏人員受傷或疾病等)
7 與疏散或一次阻絕設施失效無直接關聯之人員安全ldquo滑倒絆倒跌倒rdquo事故
8 沒有與製程相連接之輔助設備的一次阻絕設施(如小樣品瓶)失效事故
9 計劃中和在控制下的物質排放至設計用來收集或排放系統中(請注意物質從一次阻絕設施
在非計劃或非受控制情況下排放至收集或排放系統中則不適用本排除條件)
10 在製程區域外部或保養廠內執行之機械作業
說明與實例 ndash 以 GHS 表 1 為基礎
以下說明和實例有助於在評估須提報製程安全事件(PSE)時釐清可能存在的不確定部分
公司廠區
1 一輛第三方的卡車在公司廠區內卸載易燃產品時發生洩漏進而引起火災造成公司財物損失
$7000 美元(直接成本)雖然該卡車是ldquo由他人操作rdquo但其作業與製程相連接若公司的直接成
本財物損失達到或超過$2500 美元或已達到或超過其他 PSE 提報門檻(如1 人死亡)此事故即
屬於須提報的製程安全事件
2 與前例1 類似的例子載著易燃產品的卡車在廠外運輸途中翻覆引發火災並造成卡車毀損
該事故不屬於須提報的製程安全事件因為當時卡車並未與製程相連接
20
阻絕設施失效
3 儲槽液位計故障造成裝有ldquo易燃液體rdquo產品的儲槽外溢約 700 公斤的液體流入儲槽的防溢堤內
此事故屬於須提報的製程安全事件因為其ldquo急性rdquo洩漏量超過 100 公斤即使是阻絕在二次阻絕
設施防溢堤中亦然
4 一名從事維修工作的承攬商在開啟一個製程阻閥時被噴起的硫酸濺到造成嚴重灼傷和損失工
時的工傷此事故屬於須提報的製程安全事件因為它是涉及物質和一次阻絕設施失效的意外事
件對於因洩漏造成死亡和損工的工傷或疾病事故沒有洩漏恕限值
5 一名作業員開啟品管取樣點進行日常取樣作業時手部被一個破碎的玻璃瓶嚴重割破需要進行
縫合治療縫針造成第二天無法上班該事故不屬於須提報的製程安全事件因為它與一次阻絕
設施失效無關
ldquo急性rdquo洩漏
6 一名作業員在進行天然氣流量高於預期值之異常排除時發現天然氣管線上的一個安全閥門未適
當歸位因此天然氣經由氣液分離桶排放至排氣煙囪經進一步檢查作業員判斷在過去 6 個
月間總共有 100000 公斤天然氣以穩定的速率排放至大氣該事故不屬於須提報的製程安全事
件因為其洩漏速率(每小時約 10 公斤)不算ldquo急性rdquo洩漏(未超過易燃蒸汽每小時 100 公斤的恕限
值)
廢氣燃燒塔amp排放控制裝置 (如洗滌塔)
7 若化學物質被導引至廢氣燃燒塔或排放控制裝置(如洗滌塔)只要該廢氣燃燒塔或控制裝置運作在
正常設計範圍內便不屬於須提報的製程安全事件
8 若廢氣流速超過洗滌塔的設計負荷以致未經吸收的化學物質排出超過恕限值該事故屬於須提報
的製程安全事件(如本文註釋所述)
註釋自取得許可或妥善管理的裝置-包括釋壓裝置發生不預期的排放若 1 小時內洩漏量達到或
超過表 1 或表 2 所列的洩漏恕限值且導致下列四種後果之任一項或以上之後果該事故便屬於
須提報的製程安全事件
o 二相排放或夾帶液體的排放液滴沉降至地面造成污染
o 排放至具潛在危險性的地點)
o 廠內就地避難或疏散不包括預防性廠內就地避難或疏散
o 啟動公眾保護措施(如道路封閉)包括預防性公眾保護措施
21
安全洩壓裝置 系統
9 製程單元發生異常安全閥開啟將洩漏物質釋放到排氣口此釋壓排放裝置是依相關要求設計
的且氣體釋到大氣中並未造成不良後果這不是一個須提報的製程安全事件因為安全閥高
壓破裂盤以及類似的安全裝置是依據 API 521 或者同等的標準設計的且此排放並未造成 (1)
夾帶液體並導致須提報的製程安全事件的後果(譬如損失工時意外死亡火災或爆炸造成$2500
美元或以上的直接成本損失液體或毒性氣體洩漏量達到或超過恕限值(2) 啟動廠內或廠外就地
避難應變或(3)啟動公眾保護措施
10 製程單元發生異常安全閥並未開啟造成設備超壓易燃性氣體從一個法蘭處ldquo急性rdquo漏出來
洩露量超過 100 公斤(一小時內)的恕限值該事故屬於須提報的製程安全事件因為從法蘭處外
漏屬於製程安全事件應提報事項
損工事故
11 一名作業員走路時不慎滑倒造成損失工時之工傷滑倒原因為天氣狀況rdquo長期rdquo油垢的地面和
易滑鞋具該事故不屬於須提報的製程安全事件因為人員安全ldquo滑倒絆倒跌倒rdquo事故若非與
一次阻絕設施失效直接關聯的疏散或應變造成則不屬於須提報的製程安全事件
12 與前例相同的事件惟這次作業員跌倒是因為少量易燃液體外漏(如 1 小時內少於 10 公斤)在採取
相關應變措施時發生該事故屬於須提報的製程安全事件因為作業員係為了應變一次阻絕設施
失效的事故而跌倒若一次阻絕設施失效發生在公司廠區且造成失時工傷或死亡後果該事故
便屬於須提報的製程安全事件對於因洩漏造成死亡和損失工時之工傷事故沒有洩漏量門檻
13 與前例相同的事件惟這次作業員跌倒是在事件結束數小時之後該事故不屬於須提報的製程安
全事件在提報要件中所用的ldquo疏散rdquo和ldquo應變rdquo等術語指的是一次阻絕設施失效和相關緊急應變
活動正在持續中事件結束後滑倒絆倒跌倒(如ldquo事後rdquo清理和補救)不屬於須提報製程安全事件
14 工人在因附近設備一次阻絕設施失效在疏散過程中一名鷹架搭建工人從鷹架梯上跌落造成損
失工時之工傷該事故屬於須提報的製程安全事件
15 一名作業員行經一個設計不良的蒸汽卻水器時被外洩的蒸汽燙傷腳踝造成損失工時之工傷
該事故屬於須提報的製程安全事件因為雖然一次阻絕設施失效洩漏出的是蒸汽(而非碳氫化合物
或化學物質)但損失工時之工傷是由於洩漏物質的物理狀態所導致的
16 一個密閉空間依照計畫以氮氣吹清一名承攬商繞過安全管制進入該密閉空間因而死亡該事
故屬於須提報的死亡事件但不屬於須提報的製程安全事件因為其中不涉及非計劃或失控的一
次阻絕設施失效
17 情況同上惟這次氮氣是非刻意洩漏進入該局限空間該事故屬於須提報的製程安全事件(同時也
是一起死亡事件)因為該名承攬商的死亡與非計劃的一次阻絕設施失效有關
22
18 一名作業員因硫化氫(H2S)警報在進行應變處理時昏倒若警報確實是因非計劃或失控的 H2S 一次
阻絕設施失效的外洩事件該事故便屬於須提報的製程安全事件若警報是一個假警報則該事
故便不屬於須提報的製程安全事件因為沒有真正的化學品洩漏發生
管線
19 一條管線破漏1 小時內洩漏 2000 磅(900 公斤)易燃蒸氣到地面但洩漏位置在廠區內很偏僻的
地點該事故仍屬於須提報的製程安全事件因為ldquo偏僻rdquo不是提報與否的考量因素
與化學物質外洩無關之火災或能量釋放事故
一般通則而言唯有當火災或能量釋放事故是因化學物質洩漏所造成或其發生導致化學物質洩漏
超過提報恕限值這些事故才屬於須提報的製程安全事件實例包括
20 一場電氣火災影響製程操作導致甲苯洩漏 400 公斤該事故屬於須提報的製程安全事件因為
化學物質洩漏已超過甲苯的 100 公斤提報恕限值
21 發生電氣火災停電或任何公用資源供應中斷可能造成工廠停工及可能引起設備損失超過
$2500 美元(如因非正常停工導致反應器或設備損壞)但並未造成超過恕限值的化學物質洩漏
亦未造成死亡或嚴重工傷該事故不屬於須提報的製程安全事件因為設備損壞並非化學製程火
災爆炸造成且化學物質洩漏並未超過恕限值
海上運輸船
22 一艘由公司營運的海上運輸船在船上發生ldquo急性rdquo易燃物質外洩洩漏量超過 100 公斤該事故不
屬於須提報的製程安全事件因為除非海上運輸船是為了輸送半成品或產品而與煉油石化或化
學製造廠的設施相連接否則其洩漏事故便不被視為製程安全事件
23 一艘第三方駁船由一艘拖船推向碼頭結果撞上公司的碼頭駁船的一個船艙破裂且造成
1000 公斤柴油洩漏到海中該事故不屬於須提報的製程安全事件因為駁船當時並非停泊在碼
頭內且其作業並非在進行半成品或產品之輸送
卡車與軌道車
24 一輛公司的軌道車在運輸途中出軌造成超過 1000 公斤汽油洩漏該事故不屬於須提報的製程
安全事件因為在公司廠區外發生的軌道車事故不被視為與製程安全有關
23
25 一輛第三方卡車拖車在公司廠區內翻覆造成ldquo急性rdquo汽油洩漏超過 1000 公斤這事故不屬於須
提報的製程安全事件因為卡車拖車當時已不再與裝卸設備連接然而我們建議會員公司另
行訂定運輸安全事故指標將這類事故記錄下來
26 一位合約卡車作業者正在卸載液鹼時發生軟管脫落造成空氣中氣霧和或液鹼液洩漏 2500 公
斤該事故屬於須提報的製程安全事件因為洩漏量已超過液鹼的 100 公斤恕限值且事故發生
前卡車仍與裝卸設備相連接著
辦公建築
27 綜合辦公大樓發生鍋爐火災造成總計$75000 美元的直接成本損失該事故不屬於須提報的製
程安全事件因為辦公大樓事故不被視為與製程安全有關
人機介面事故
28 一名操作技術員在聚合物工廠的終端設備旁作業時受傷這傷害是因機械的人機介面的設備而
造成該事故不屬於須提報的製程安全事件因為技術員受傷並非因危險物質一次阻絕設施失效
而造成的
混合物
29 若混合物本身有 GHS 分類可利用其分類確定恕限值若混合物本身沒有 GHS 分類則可計算混
合物中每個單一組成分之洩漏量(公斤)相對於個別成分恕限值之比值作為其對混合物恕限值之
lsquo加權rsquo貢獻譬如若混合物在 1小時內的洩漏量為 100公斤其中包含 05公斤分類為劇毒 H300
的物質45 公斤分類為 H301 的物質40 公斤另一種分類為 H 開頭的物質其餘 55 公斤則為沒
有 GHS 分類的水分此混合物之計算式為051 + 4510 + 40100 = 05 + 045 + 04 = 135超過
1因此該事故被視為須提報的製程安全事件雖然混合物個別成分之洩漏量均未超過各該物質
本身的恕限值
直接損失成本
30 此一門檻所考慮的成本應為可直接歸因於火災或爆炸的成本譬如設備及結構損壞的重置成本
修理成本環境清理支出緊急應變和罰款直接成本不包括間接成本譬如業務機會損失設
備停機造成之利潤損失取得或運轉臨時設施之成本或為滿足顧客需求取得替代產品的成本
(產品損失)
24
31 範例連接到氣體處理系統的排放管發生易燃氣體外漏同時製程出現問題導致空氣進入同
一條排放管結果發生爆炸過高的壓力損壞了排放管及其相關上游設備包括一個密封罐並
未造成人員受傷修理成本約$12000 美元該事故屬於須提報的製程安全事件因為爆炸及火
災導致設備修理成本超過門檻
32 範例一次製程安全事件後公司又發生一種非常特殊的 GHS 第 5 類產品洩漏 50 公斤造成
$2000 美元的設備損失洩漏的產品是一種非常特別的混合物公司須負擔超過$50000 美元因
產品耗損而產生之材料成本該事故不屬於須提報的製程安全事件因為 GHS 第 5 類產品洩漏的
提報門檻為 100 公斤且產品耗損不被計入直接損失成本
天然災害
33 天然災害可能對化學製程作業構成重大風險且對製程設備造成損壞導致危害物質一次阻絕設
施失效當一種或多種天然災害被認為可能對工廠作業造成影響時製程安全和作業系統應從危
害及後果分析工廠機器設備設計公用設施失效及製程停工之操作程序緊急應變計畫及應變
措施等方面界定潛在風險進行防範
天然災害類型包括颶風及颱風(包括伴隨而來的風暴潮)水災龍捲風地震超強對流風暴(直
線風暴)野火火山爆發海嘯和山崩
若公司廠房設施遭遇天然災害且其後果觸發一種或以上提報門檻該事故便屬於須提報製程安
全事件
預防性公眾應變
34 預防性公眾應變是基於謹慎的態度所採取的一種措施譬如當發生一次阻絕設施失效時公司
可能在尚未進行任何評估(如方向與洩漏點的距離等等)前便要求全體工人就地避難又
如地方權責官員(如消防警察民防緊急應變管理部門)在獲報一家公司發生製程安全事件
後為防lsquo萬一rsquo風向改變或基於可能受到波及的人口敏感族群(如學童或老年人)可能在尚未接
獲明確資訊前便下令社區就地避難或疏散或採取公眾保護措施(如道路封閉)
製程附屬倉庫
35 製程附屬倉庫指的是位於廠內用於儲存將投入於生產製程或產自於製程之原料半成品或成品的
倉庫從製程的觀點看來製程附屬倉庫相當於一個大型儲槽但這些原料半成品或成品並不
是儲存在一的大型容器中而是裝在較小的容器裡(如太空包大桶桶罐等)
25
Appendix C ndash List of RCLG Taskforce Members
Name Affiliation
Peter Schmelzer Bayer CEFIC - Chairman
Americo Diniz Carvalho Neto Braskem
Bradford Johnson American Chemistry Council
David Cummings DuPont
Debra Phillips American Chemistry Council
Hans Schwarz BASF
Kathryn Walton Plastics and Chemicals Industries Association
Kazuyuki Akita Japanese Chemical Industry Association
Kelly Keim ExxonMobil Chemical Company API Representative
Kenan Stevick Dow
Kiyokazu Murata Japanese Chemical Industry Association
Larry Bowler SABIC
Lorna Young Chemical Industry Association of Canada
Louisa Nara Center for Chemical Process Safety
Luiz Shizuo Harayashiki Associaccedilatildeo Brasileira da Induacutestria Quiacutemica
Masatoshi Kumamoto Japanese Chemical Industry Association
Milton Lacerda Petrobras
Phil Scott Chemical Industries Association
Piet Knijff DSM European Process Safety Centre
Scott Donaldson and Eamon Chandler
Shell
Scott Wallace Olin Corporation
Shakeel Kadri Air Products and Chemicals Inc
26
附錄 D ndash 詳細活動時程表
2016 年 2017 年 2018 年 2019 年 2020 年
2 ndash 4 月
RCLG PS 先導計畫
5 月 ndash
針對準則進行調整釐清
6 月 向 RCLG 和 ICCA 董事會報
告先導計畫執行結果
7 ndash 12 月 RCLG 協會考量準
則並為其會員公司發展提報機制
如有需要RCLG可向 ICCA 申請能
力建立基金為會員公司舉辦製程安
全研習會
1 ndash 12 月
RCLG 協會開始向其會員公司蒐集製程安全數據
1 ndash 12 月
如有需要RCLG 各協會運用 RCLG 的基金及專
家舉辦製程安全及績效提報研習會
1 ndash 2 月
擁有數據的協會開始向RCLG 提報製程安全事件
(2017 年數據)
4 月 RCLG 檢討第一個提報循
環的結果挑戰及原始數據(內部)
6 月 RCLG 向 ICCA 董事會呈報
原始數據
7 ndash 12 月 必要時更新及調整準
則
如有需要RCLG 各協會運用 RCLG 的基金及專
家舉辦製程安全及績效提報研習會
1 ndash 2 月
擁有數據的協會開始向RCLG 提報製程安全事件
(2018 年數據)
4 月 RCLG 檢討第二個提報循
環的結果挑戰及原始數據(內部)
6 月 RCLG 向 ICCA 董事會呈報
原始數據
7 ndash 12 月 必要時更新及調整準
則
如有需要RCLG 協會運用 RCLG 的基金及專家
舉辦製程安全及績效提報研習會
1 ndash 2 月
所有協會開始向 RCLG 提報製程安全事件
製程安全事件提報成為
RCLG KPI 衡量指標建議基本集的一部分(2019 年數
據)
4 月 RCLG 檢討第二個提報循
環的結果挑戰及原始數據(內部考量外部提
報)
6 月 RCLG 向 ICCA 董事會呈報
原始數據
27
附錄 E ndash 選擇性 Excel 追蹤表
當會員公司開始追蹤製程安全事件時所有會員公司應採用單一表格以簡化數據分析同時讓所有公司均使用相同的追蹤表RCLG 設
計了一份選擇性追蹤表可供會員公司和協會先行利用之後他們可設計自己的追蹤表
在這裡下載追蹤表
ICCA Process Safety Event Tracking Sheetxlsx
本文件包含三個分頁分別是ldquo聯絡資料rdquoldquo調查表rdquo和儲存下拉式選單選項的ldquo請勿編輯rdquo分頁
備註
附錄 E 追蹤表僅供參考TRCA 將另行提供台灣版表格供會員公司提報
28
後語
台灣化學工業責任照顧協會(Taiwan Responsible Care Association TRCA)成立於 1998 年在台灣推行責任照顧制度已達 20 週年製造商成員
包括台灣主要上市上櫃化工公司會員公司化學品生產製造量約佔全國 80 2016 年台灣化工業的 Chemical Sales 仍站在全球第八名的位
置額度為 630 億歐元化工業總產值達到 34 兆新台幣提供國內 416 萬人工作機會
TRCA 扮演國內廠商與國際制度接軌的角色也是國內化工業與政府機關及利益相關者溝通的橋樑與管道TRCA 會員結構依業務性質分析
涵蓋石化生產化學品製造氣體生產倉儲運輸業化學品貿易業以及工程研發設計等公司TRCA 透過供應鏈及價值鏈推行責任
照顧制度組成毒性化學物質聯防組織協助法規溝通與研析會員名冊請參考 httpwwwtrcaorgtwtrcanwork2aspx
TRCA 於 2010 年成為 ICCA (International Council of Chemical Associations 國際化學工業協會)觀察員ICCA 成立於 1989 年是全球化工製造
業的聯合會也是化學工業與 UNEP OPCW 及 OECD 的交流窗口ICCA 與其會員協會及成員公司致力於邁向永續的未來確保人類健康與
環境安全與保護全球化工業擁有超過 4兆美元的價值影響所有經濟部門ICCA 的會員幾乎在全球每個國家都有商業活動在全球六大
洲推動創新並提供超過 2000 萬個工作機會
台灣化工業在全球占有重要的一席之地在國內產業鏈也位居關鍵位置無論對國內或國際都有身為地球村一員應盡之責我們期許藉由
製程安全指標提報能更進一步提升自我在工安衛生環保與永續發展等面向的績效表現
台灣化學工業責任照顧協會
10452 台北市中山區撫順街 8 號 7 樓
電話02-2585-0552
httpwwwtrcaorgtw
None | |
$2500 to $25000 | |
$25000 to $250000 | |
$250000 to $25000000 | |
More than $25000000 | |
Yes - Using GHS TABLE | |
Yes - Using API RP 754 TABLE | |
NO | |
NA | |
1x le TQ lt 40x | |
40x le TQ lt 160x | |
160x le TQ lt 640x | |
ge 640x TQ | |
Yes le 3 hours | |
Yes 3 hours ge 12 hours | |
Yes 12 hours ge 24 hours | |
Yes ge 24 hours | |
No | |
Small-scale | |
Medium-scale | |
Large-scale | |
No | |
Yes | |
No | |
middot Injury requiring treatment beyond first aid to an employee contractor or subcontractor | |
middot Days Away From Work injury to an employee contractor or subcontractor or middot Injury requiring treatment beyond first aid to a third party | |
middot A fatality of an employee contractor or subcontractor or middot A hospital admission of a third party | |
middot Multiple fatalities of employees contractors or subcontractors or middot multiple hospital admission of third parties or middot A fatality of a third party | |
NA | |
1x le TQ lt 3x | |
3x le TQ lt 9x | |
9x le TQ lt 27x | |
ge 27x TQ |
ICCA Process Safety Pilot Reporting ProgramFebruary 8 2016 | 1 | 2 | 3 | 4 | 5 | 6 | 7 | 8 | 9 | 10 | 12 | 13 | 14 | 15 | |||||||||||||||||||||||
SAFETY Details(Meeting Local Regulations) | Direct Cost from Fire or Explosion | Community Impact | Environmental Impact | Material Released(Measured using the 1 Hour Rule) | |||||||||||||||||||||||||||||||||
Company Association Details | |||||||||||||||||||||||||||||||||||||
GHS | API - RP 754 | ||||||||||||||||||||||||||||||||||||
Company or Assocation Name | Headquarter Association | Location of Event Ex - City State amp Country | Date and Time of Event | Safety InjuryDid the Event result in a Recordable Lost Time Accident or Fatality or Hospital admission of anyone on or off siteUse Drop Down Menu | Safety InjuryIf yes please insert the total number of injuries | Safety InjuryFor puropses of utilizing the Severity Table please indicate the level of severity by chosing the MOST SEVERE classification that describes your incidentUse Drop Down Menu | Safety InjuryDid the incident involve Fatalities If so how many total fatalities If none enter Zero | Safety InjuryPlease Report Total Employee Hours for Calendar Year 2015 | Safety InjuryPlease Report Total Contractor Hours for Calendar Year 2015 | Direct Cost Did the Event result in Direct Damage CostUse Drop Down Menu | Direct Cost If so how muchAmount is in US DollarsUse Drop Down Menu | Community ImpactDid the event result inbull Officially declared shelter-in-place or officially declared evacuation (on or off site)ORbull Precautionary off site shelter in place or evacuation Use Drop Down Menu | Environmental ImpactDid the event result inAcute Environmental Remediation CostIf so indicate the amount in US DollarsUse Drop Down Menu | Material ReleasedDid the Event result in an Acute Release of material beyond one of the two threshold tablesIf so indicate which Threshold Table you used to make this determinationUse Drop Down Menu | Material ReleasedIf so indicate the amount released USING GHS CLASSIFICATION TABLEUse Drop Down Menu | Material ReleasedIf so indicate the amount released USING THE THRESHOLD TABLE FROM API RP-754Use Drop Down Menu | Material ReleasedIf available please indicate the material released | ||||||||||||||||||||
1 | ABC Chemical Company | American Chemistry Council | Washington DC - USA | January 4 2016 | Yes | 2 | middot Days Away From Work injury to an employee contractor or subcontractor or middot Injury requiring treatment beyond first aid to a third party | 0 | 5525000 | 1500250 | No | $2500 to $25000 | Yes le 3 hours | $2500 to $25000 | Yes - Using GHS TABLE | 40x le TQ lt 160x | NA | Chlorine | |||||||||||||||||||
2 | XYZ Chemical Company | American Chemistry Council | Washington DC - USA | 5-Jan-16 | Yes | 1 | middot Injury requiring treatment beyond first aid to an employee contractor or subcontractor | 0 | 5525000 | 1500250 | Yes | $2500 to $25000 | No | $2500 to $25000 | Yes - Using API RP 754 TABLE | NA | 3x le TQ lt 9x | Benzene | |||||||||||||||||||
3 | |||||||||||||||||||||||||||||||||||||
4 | |||||||||||||||||||||||||||||||||||||
5 | |||||||||||||||||||||||||||||||||||||
6 | |||||||||||||||||||||||||||||||||||||
7 | |||||||||||||||||||||||||||||||||||||
8 | |||||||||||||||||||||||||||||||||||||
9 | |||||||||||||||||||||||||||||||||||||
10 | |||||||||||||||||||||||||||||||||||||
11 | |||||||||||||||||||||||||||||||||||||
12 | |||||||||||||||||||||||||||||||||||||
13 | |||||||||||||||||||||||||||||||||||||
14 | |||||||||||||||||||||||||||||||||||||
15 | |||||||||||||||||||||||||||||||||||||
16 | |||||||||||||||||||||||||||||||||||||
17 | |||||||||||||||||||||||||||||||||||||
18 | |||||||||||||||||||||||||||||||||||||
19 | |||||||||||||||||||||||||||||||||||||
20 | |||||||||||||||||||||||||||||||||||||
21 | |||||||||||||||||||||||||||||||||||||
22 | |||||||||||||||||||||||||||||||||||||
23 | |||||||||||||||||||||||||||||||||||||
24 | |||||||||||||||||||||||||||||||||||||
25 | |||||||||||||||||||||||||||||||||||||
Zero or None | Yes - Duration Unknown | ||||||||||||||||||||||||||||||||||||
Processes | Mode of Operation | Type of material released | Status of Operation | ||||
REFINING | Start-up | Flammable | Open | ||||
Alkylation HF | Planned shutdown | Combustible | Closed | ||||
Alkylation sulfuric | Emergency shutdown | Toxic | |||||
BitumenResidAsphalt | Normal | Corrosive | Tier 1 Acute Releases | ||||
Calcining | Upset | Utilities | No Release | ||||
Coking | Turnaround | Other | Category 1 | ||||
Crude | Routine maintenance | Category 2 | |||||
Desulfurization | Temporary | Evacuation | Category 3 | ||||
FCC | Other | Yes | Category 4 | ||||
Gas Treating | No | Category 5 | |||||
Hydrogen | Point of Release | Category 6 | |||||
Hydrotreating | Pump | Fire | Category 7 | ||||
Hydrocracking | Compressor | Yes | Multiple Categories | ||||
Isom | BlowerFan | No | |||||
MarineJetty | Pressure Vessel | lt $2500 | |||||
Reforming | FilterCoalescer | ||||||
Sulfur recovery | Furnace | PRDs | |||||
Vapor recoverylight ends | Boiler | Directly to Atmosphere | |||||
Wastewater | Heat exchanger | via Downstream Destructive Device | |||||
REFINING amp PETROCHEMICAL | Cooling Tower | No | |||||
Tank FarmStorage FacilityOffsite | Piping system | Yes | |||||
UtilitiesSteam PlantCogeneration | Reactor | No | |||||
Other | Atmospheric tank | ||||||
PETROCHEMICAL | FlareRelief System | Acute release above thresholds | |||||
CO H2 | Other | Yes | |||||
LNG | No | ||||||
Methane | Events | ||||||
Methanol | No Tier 1 Events | Indoor Outdoor | |||||
Methyl Mercaptan | No Tier 2 Events | No Release | |||||
Formaldehyde | No Tier 1 or Tier 2 Events | Indoor | |||||
Formaldehyde derivatives | NA | Outdoor | |||||
Acetic Acid | |||||||
Acetic Acid derivatives | Event Type | ||||||
Ethane | Injury | ||||||
Ethylene | Fire | ||||||
Ethanol | Explosion | ||||||
Ethylene oxide | PRD Discharge | ||||||
Ethylene derivatives | Acute Release | ||||||
Polyethylene | |||||||
Ethylene dichloride | General | ||||||
Ethylene dichloride derivatives | Yes | ||||||
Ethyl benzene | No | ||||||
Ethyl benzene derivatives | |||||||
Polystyrene | |||||||
Styrene-Butadiene | |||||||
Propane | |||||||
Propylene | |||||||
Polypropylene | |||||||
Isopropanol | |||||||
Propylene oxide | |||||||
Propylene oxide derivatives | |||||||
Butane | |||||||
Isobutane | |||||||
Isobutene | |||||||
Butadiene | |||||||
MTBE | |||||||
ETBE | |||||||
Pentane | |||||||
Hexane | |||||||
Cyclohexane | |||||||
Hexanol | |||||||
Aromatics Derivatives | |||||||
Benzene | |||||||
Toluene | |||||||
Xylene | |||||||
Para Xylene | |||||||
Amines Derivatives | |||||||
TDA MDA IPDA etc | |||||||
Isocyanates | |||||||
Specialty Chemicals | |||||||
LoadingUnloading | |||||||
Pilot Plant |
Instructions | ||||||||||||||
Step 1 | Complete the Contact Tab with your contact information and company information | |||||||||||||
Be sure to note the region of your reporting (IE North America France Japan etc) | ||||||||||||||
Survey on Process Safety Events | ||||||||||||||
Step 2 | Complete the survey one line per Process Safety Event for your companyregion | |||||||||||||
ALL REPORTED DATA SHOULD BE FROM CALENDAR YEAR 2017 | ||||||||||||||
Step 3 | Return completed survey to | |||||||||||||
Company Name | ||||||||||||||
Contact Person | All Surveys Due by xxx date | |||||||||||||
Address | ||||||||||||||
Fax | ||||||||||||||
Telephone | ||||||||||||||
Region | ||||||||||||||
None | |
$2500 to $25000 | |
$25000 to $250000 | |
$250000 to $25000000 | |
More than $25000000 | |
Yes - Using GHS TABLE | |
Yes - Using API RP 754 TABLE | |
NO | |
NA | |
1x le TQ lt 40x | |
40x le TQ lt 160x | |
160x le TQ lt 640x | |
ge 640x TQ | |
Yes le 3 hours | |
Yes 3 hours ge 12 hours | |
Yes 12 hours ge 24 hours | |
Yes ge 24 hours | |
No | |
Small-scale | |
Medium-scale | |
Large-scale | |
No | |
Yes | |
No | |
middot Injury requiring treatment beyond first aid to an employee contractor or subcontractor | |
middot Days Away From Work injury to an employee contractor or subcontractor or middot Injury requiring treatment beyond first aid to a third party | |
middot A fatality of an employee contractor or subcontractor or middot A hospital admission of a third party | |
middot Multiple fatalities of employees contractors or subcontractors or middot multiple hospital admission of third parties or middot A fatality of a third party | |
NA | |
1x le TQ lt 3x | |
3x le TQ lt 9x | |
9x le TQ lt 27x | |
ge 27x TQ |
ICCA Process Safety Pilot Reporting ProgramFebruary 8 2016 | 1 | 2 | 3 | 4 | 5 | 6 | 7 | 8 | 9 | 10 | 12 | 13 | 14 | 15 | |||||||||||||||||||||||
SAFETY Details(Meeting Local Regulations) | Direct Cost from Fire or Explosion | Community Impact | Environmental Impact | Material Released(Measured using the 1 Hour Rule) | |||||||||||||||||||||||||||||||||
Company Association Details | |||||||||||||||||||||||||||||||||||||
GHS | API - RP 754 | ||||||||||||||||||||||||||||||||||||
Company or Assocation Name | Headquarter Association | Location of Event Ex - City State amp Country | Date and Time of Event | Safety InjuryDid the Event result in a Recordable Lost Time Accident or Fatality or Hospital admission of anyone on or off siteUse Drop Down Menu | Safety InjuryIf yes please insert the total number of injuries | Safety InjuryFor puropses of utilizing the Severity Table please indicate the level of severity by chosing the MOST SEVERE classification that describes your incidentUse Drop Down Menu | Safety InjuryDid the incident involve Fatalities If so how many total fatalities If none enter Zero | Safety InjuryPlease Report Total Employee Hours for Calendar Year 2015 | Safety InjuryPlease Report Total Contractor Hours for Calendar Year 2015 | Direct Cost Did the Event result in Direct Damage CostUse Drop Down Menu | Direct Cost If so how muchAmount is in US DollarsUse Drop Down Menu | Community ImpactDid the event result inbull Officially declared shelter-in-place or officially declared evacuation (on or off site)ORbull Precautionary off site shelter in place or evacuation Use Drop Down Menu | Environmental ImpactDid the event result inAcute Environmental Remediation CostIf so indicate the amount in US DollarsUse Drop Down Menu | Material ReleasedDid the Event result in an Acute Release of material beyond one of the two threshold tablesIf so indicate which Threshold Table you used to make this determinationUse Drop Down Menu | Material ReleasedIf so indicate the amount released USING GHS CLASSIFICATION TABLEUse Drop Down Menu | Material ReleasedIf so indicate the amount released USING THE THRESHOLD TABLE FROM API RP-754Use Drop Down Menu | Material ReleasedIf available please indicate the material released | ||||||||||||||||||||
1 | ABC Chemical Company | American Chemistry Council | Washington DC - USA | January 4 2016 | Yes | 2 | middot Days Away From Work injury to an employee contractor or subcontractor or middot Injury requiring treatment beyond first aid to a third party | 0 | 5525000 | 1500250 | No | $2500 to $25000 | Yes le 3 hours | $2500 to $25000 | Yes - Using GHS TABLE | 40x le TQ lt 160x | NA | Chlorine | |||||||||||||||||||
2 | XYZ Chemical Company | American Chemistry Council | Washington DC - USA | 5-Jan-16 | Yes | 1 | middot Injury requiring treatment beyond first aid to an employee contractor or subcontractor | 0 | 5525000 | 1500250 | Yes | $2500 to $25000 | No | $2500 to $25000 | Yes - Using API RP 754 TABLE | NA | 3x le TQ lt 9x | Benzene | |||||||||||||||||||
3 | |||||||||||||||||||||||||||||||||||||
4 | |||||||||||||||||||||||||||||||||||||
5 | |||||||||||||||||||||||||||||||||||||
6 | |||||||||||||||||||||||||||||||||||||
7 | |||||||||||||||||||||||||||||||||||||
8 | |||||||||||||||||||||||||||||||||||||
9 | |||||||||||||||||||||||||||||||||||||
10 | |||||||||||||||||||||||||||||||||||||
11 | |||||||||||||||||||||||||||||||||||||
12 | |||||||||||||||||||||||||||||||||||||
13 | |||||||||||||||||||||||||||||||||||||
14 | |||||||||||||||||||||||||||||||||||||
15 | |||||||||||||||||||||||||||||||||||||
16 | |||||||||||||||||||||||||||||||||||||
17 | |||||||||||||||||||||||||||||||||||||
18 | |||||||||||||||||||||||||||||||||||||
19 | |||||||||||||||||||||||||||||||||||||
20 | |||||||||||||||||||||||||||||||||||||
21 | |||||||||||||||||||||||||||||||||||||
22 | |||||||||||||||||||||||||||||||||||||
23 | |||||||||||||||||||||||||||||||||||||
24 | |||||||||||||||||||||||||||||||||||||
25 | |||||||||||||||||||||||||||||||||||||
Zero or None | Yes - Duration Unknown | ||||||||||||||||||||||||||||||||||||
Processes | Mode of Operation | Type of material released | Status of Operation | ||||
REFINING | Start-up | Flammable | Open | ||||
Alkylation HF | Planned shutdown | Combustible | Closed | ||||
Alkylation sulfuric | Emergency shutdown | Toxic | |||||
BitumenResidAsphalt | Normal | Corrosive | Tier 1 Acute Releases | ||||
Calcining | Upset | Utilities | No Release | ||||
Coking | Turnaround | Other | Category 1 | ||||
Crude | Routine maintenance | Category 2 | |||||
Desulfurization | Temporary | Evacuation | Category 3 | ||||
FCC | Other | Yes | Category 4 | ||||
Gas Treating | No | Category 5 | |||||
Hydrogen | Point of Release | Category 6 | |||||
Hydrotreating | Pump | Fire | Category 7 | ||||
Hydrocracking | Compressor | Yes | Multiple Categories | ||||
Isom | BlowerFan | No | |||||
MarineJetty | Pressure Vessel | lt $2500 | |||||
Reforming | FilterCoalescer | ||||||
Sulfur recovery | Furnace | PRDs | |||||
Vapor recoverylight ends | Boiler | Directly to Atmosphere | |||||
Wastewater | Heat exchanger | via Downstream Destructive Device | |||||
REFINING amp PETROCHEMICAL | Cooling Tower | No | |||||
Tank FarmStorage FacilityOffsite | Piping system | Yes | |||||
UtilitiesSteam PlantCogeneration | Reactor | No | |||||
Other | Atmospheric tank | ||||||
PETROCHEMICAL | FlareRelief System | Acute release above thresholds | |||||
CO H2 | Other | Yes | |||||
LNG | No | ||||||
Methane | Events | ||||||
Methanol | No Tier 1 Events | Indoor Outdoor | |||||
Methyl Mercaptan | No Tier 2 Events | No Release | |||||
Formaldehyde | No Tier 1 or Tier 2 Events | Indoor | |||||
Formaldehyde derivatives | NA | Outdoor | |||||
Acetic Acid | |||||||
Acetic Acid derivatives | Event Type | ||||||
Ethane | Injury | ||||||
Ethylene | Fire | ||||||
Ethanol | Explosion | ||||||
Ethylene oxide | PRD Discharge | ||||||
Ethylene derivatives | Acute Release | ||||||
Polyethylene | |||||||
Ethylene dichloride | General | ||||||
Ethylene dichloride derivatives | Yes | ||||||
Ethyl benzene | No | ||||||
Ethyl benzene derivatives | |||||||
Polystyrene | |||||||
Styrene-Butadiene | |||||||
Propane | |||||||
Propylene | |||||||
Polypropylene | |||||||
Isopropanol | |||||||
Propylene oxide | |||||||
Propylene oxide derivatives | |||||||
Butane | |||||||
Isobutane | |||||||
Isobutene | |||||||
Butadiene | |||||||
MTBE | |||||||
ETBE | |||||||
Pentane | |||||||
Hexane | |||||||
Cyclohexane | |||||||
Hexanol | |||||||
Aromatics Derivatives | |||||||
Benzene | |||||||
Toluene | |||||||
Xylene | |||||||
Para Xylene | |||||||
Amines Derivatives | |||||||
TDA MDA IPDA etc | |||||||
Isocyanates | |||||||
Specialty Chemicals | |||||||
LoadingUnloading | |||||||
Pilot Plant |
Instructions | ||||||||||||||
Step 1 | Complete the Contact Tab with your contact information and company information | |||||||||||||
Be sure to note the region of your reporting (IE North America France Japan etc) | ||||||||||||||
Survey on Process Safety Events | ||||||||||||||
Step 2 | Complete the survey one line per Process Safety Event for your companyregion | |||||||||||||
ALL REPORTED DATA SHOULD BE FROM CALENDAR YEAR 2017 | ||||||||||||||
Step 3 | Return completed survey to | |||||||||||||
Company Name | ||||||||||||||
Contact Person | All Surveys Due by xxx date | |||||||||||||
Address | ||||||||||||||
Fax | ||||||||||||||
Telephone | ||||||||||||||
Region | ||||||||||||||
17 (K = 1000 MM = 1000000) (在環境影響類別方面若缺乏既有定義協會和會員公司應議定輸入標準)
附錄 A ndash 嚴重程度表鼓勵所有協會均採用嚴重程度加權制度
事件事故類別
嚴重程度等級
安全人體健康 火災或爆炸導致直接
成本 任 1 小時內物質洩
漏量 社區影響 環境影響[廠外]
4 級
1 分
對員工承攬商或再承攬商造成較輕傷害嚴重之傷害 (符合本地法規)
造成以下直接損失成本
美金$25 K ~ $25 K
洩漏量介於
1x le TQ lt 40x
官方宣告就地避難或疏散 (廠內或廠外) 預防性廠外就地避難或疏散
le 3 小時
重大環境整治成本
$25 K ~ $25 K
3 級
3 分
對員工承攬商或再承攬商造成之需要多日缺勤的傷害
對第三方造成之需要初步急救以外治療的傷害 (符合本地法規)
造成以下直接損失成本
$25 K ~ $250 K
洩漏量介於
40x le TQ lt 160x
官方宣告就地避難或疏散 (廠內或廠外)
預防性廠外就地避難或疏散
3 ~ 12 小時
重大環境整治成本
$25 K ~ $250 K
2 級
9 分
對員工承攬商或再承攬商造成 1 人死亡
對第三方造成 1 人住院治療
(符合本地法規)
造成以下直接損失成本
$250 K ~ $25 MM
洩漏量介於
160x le TQ lt 640x
官方宣告就地避難或疏散 (廠內或廠外)
預防性廠外就地避難或疏散
12 ~ 24 小時
重大環境整治成本
$250 K ~ $25 MM
1 級
27 分
對員工承攬商或再承攬商造成多人死亡
對第三方造成多人住院治療
對第三方造成 1 人死亡 (符合本地法規)
造成以下直接損失成本
ge $25 MM
洩漏量
ge 640x TQ
官方宣告就地避難或疏散 (廠內或廠外)
預防性廠外就地避難或疏散
ge 24 小時
重大環境整治成本
ge $25 MM
18 (K = 1000 MM = 1000000) (在環境影響類別方面若缺乏既有定義協會和會員公司應議定輸入標準)
嚴重程度表(附錄 A)細節說明
附錄 A 之設計目的僅適用於採用 GHS 分類制度(表 1)者如果你的公司係採用 API RP 754Tier II 製程安全指標提報恕限值表(表 2)請使用
API RP 754 製程安全嚴重程度表必須提醒的是依 API RP 754 的標準其嚴重程度表僅適用於一級(Tier I)事故去比較採用不同的嚴重度
表所評估出來的相對嚴重度並無統計上的意義
急性的環境成本 ndash 因製程安全事件造成廠外環境影響所導致之短期清理及物質處置的成本各會員公司可選擇將廠外環境影響相關成本另
外區分一個嚴重程度類別
比率調整指標
利用上述嚴重程度表可產生一系列以事件率為基礎的指標包括
製程安全總事件率 (PSTIR) 總事件次數 x 200000
總工作時數
製程安全事件嚴重程度率(PSESR) (即製程安全事件嚴重程度加權計算公式)
PSESR = 所有事件之總嚴重程度分數總合 x 200000
總工作時數
在計算此一比率時各 4 級事件被分配 1 分各 3 級事件被分配 3 分各 2 級事件被分配 9 分各 1 級事件被分配 27 分理論上每個
製程安全事件至少可分配到 1 分(亦即事件僅在一個類別符合第 4 級事件屬性)至多可分配到 135 分(亦即事件在所有五個類別中均符
合第 1 級事件屬性)
ldquoXrdquo級別製程安全事件率 嚴重度級別ldquoXrdquo之製程安全事件總數 x 200000
員工承攬商amp再承攬商總工作時數
X可以是嚴重度級別 432 或 1 級製程安全事件之總數事件之嚴重度等級是選用五類後果類別中之最嚴重等級
標準化 ndash 在某些協會和會員公司中製程安全事件是採 lsquo每 100 名rsquo員工每名員工每年平均工作時數為 2000 小時為基礎予以標準化因
此在lsquo每 100rsquo名rsquo員工的標準基礎上事件被乘以 200000 工作時數也有些其他協會和會員公司將標準化基礎設定為lsquo每 500 名rsquo員工
因此事件被乘以 1000000 工作時數協會和會員公司應就標準化基礎進行討論共同做成選項結論上述的公式設定為lsquo每 100 名rsquo員工
基礎
19
附錄 B ndash 常見問題集
適用性
我們建議會員公司記錄和提報在其所擁有或運作的工廠內發生的製程安全事件惟以下情況不須提報製
程安全事件
1 源自於公司廠區以外的製程安全事件
2 海上運輸船事故惟船隻為了輸送半成品或產品之目的已經與公司的設施相連接時發生的
事故仍須提報
3 卡車或軌道車事故惟卡車或軌道車為了輸送半成品或產品之目的已經與公司的設施相連
接時發生的事故仍須提報
4 許可證或法規容許之例行排放
5 不會造成製程安全危害的地下污染請注意若洩漏至地下導致地上發生須提報製程安全事
件如釋放出毒性蒸汽或致使易燃液體蓄積成池則不適用本排除條件
6 辦公建築事故(如辦公室暖氣設備爆炸火災外溢洩漏人員受傷或疾病等)
7 與疏散或一次阻絕設施失效無直接關聯之人員安全ldquo滑倒絆倒跌倒rdquo事故
8 沒有與製程相連接之輔助設備的一次阻絕設施(如小樣品瓶)失效事故
9 計劃中和在控制下的物質排放至設計用來收集或排放系統中(請注意物質從一次阻絕設施
在非計劃或非受控制情況下排放至收集或排放系統中則不適用本排除條件)
10 在製程區域外部或保養廠內執行之機械作業
說明與實例 ndash 以 GHS 表 1 為基礎
以下說明和實例有助於在評估須提報製程安全事件(PSE)時釐清可能存在的不確定部分
公司廠區
1 一輛第三方的卡車在公司廠區內卸載易燃產品時發生洩漏進而引起火災造成公司財物損失
$7000 美元(直接成本)雖然該卡車是ldquo由他人操作rdquo但其作業與製程相連接若公司的直接成
本財物損失達到或超過$2500 美元或已達到或超過其他 PSE 提報門檻(如1 人死亡)此事故即
屬於須提報的製程安全事件
2 與前例1 類似的例子載著易燃產品的卡車在廠外運輸途中翻覆引發火災並造成卡車毀損
該事故不屬於須提報的製程安全事件因為當時卡車並未與製程相連接
20
阻絕設施失效
3 儲槽液位計故障造成裝有ldquo易燃液體rdquo產品的儲槽外溢約 700 公斤的液體流入儲槽的防溢堤內
此事故屬於須提報的製程安全事件因為其ldquo急性rdquo洩漏量超過 100 公斤即使是阻絕在二次阻絕
設施防溢堤中亦然
4 一名從事維修工作的承攬商在開啟一個製程阻閥時被噴起的硫酸濺到造成嚴重灼傷和損失工
時的工傷此事故屬於須提報的製程安全事件因為它是涉及物質和一次阻絕設施失效的意外事
件對於因洩漏造成死亡和損工的工傷或疾病事故沒有洩漏恕限值
5 一名作業員開啟品管取樣點進行日常取樣作業時手部被一個破碎的玻璃瓶嚴重割破需要進行
縫合治療縫針造成第二天無法上班該事故不屬於須提報的製程安全事件因為它與一次阻絕
設施失效無關
ldquo急性rdquo洩漏
6 一名作業員在進行天然氣流量高於預期值之異常排除時發現天然氣管線上的一個安全閥門未適
當歸位因此天然氣經由氣液分離桶排放至排氣煙囪經進一步檢查作業員判斷在過去 6 個
月間總共有 100000 公斤天然氣以穩定的速率排放至大氣該事故不屬於須提報的製程安全事
件因為其洩漏速率(每小時約 10 公斤)不算ldquo急性rdquo洩漏(未超過易燃蒸汽每小時 100 公斤的恕限
值)
廢氣燃燒塔amp排放控制裝置 (如洗滌塔)
7 若化學物質被導引至廢氣燃燒塔或排放控制裝置(如洗滌塔)只要該廢氣燃燒塔或控制裝置運作在
正常設計範圍內便不屬於須提報的製程安全事件
8 若廢氣流速超過洗滌塔的設計負荷以致未經吸收的化學物質排出超過恕限值該事故屬於須提報
的製程安全事件(如本文註釋所述)
註釋自取得許可或妥善管理的裝置-包括釋壓裝置發生不預期的排放若 1 小時內洩漏量達到或
超過表 1 或表 2 所列的洩漏恕限值且導致下列四種後果之任一項或以上之後果該事故便屬於
須提報的製程安全事件
o 二相排放或夾帶液體的排放液滴沉降至地面造成污染
o 排放至具潛在危險性的地點)
o 廠內就地避難或疏散不包括預防性廠內就地避難或疏散
o 啟動公眾保護措施(如道路封閉)包括預防性公眾保護措施
21
安全洩壓裝置 系統
9 製程單元發生異常安全閥開啟將洩漏物質釋放到排氣口此釋壓排放裝置是依相關要求設計
的且氣體釋到大氣中並未造成不良後果這不是一個須提報的製程安全事件因為安全閥高
壓破裂盤以及類似的安全裝置是依據 API 521 或者同等的標準設計的且此排放並未造成 (1)
夾帶液體並導致須提報的製程安全事件的後果(譬如損失工時意外死亡火災或爆炸造成$2500
美元或以上的直接成本損失液體或毒性氣體洩漏量達到或超過恕限值(2) 啟動廠內或廠外就地
避難應變或(3)啟動公眾保護措施
10 製程單元發生異常安全閥並未開啟造成設備超壓易燃性氣體從一個法蘭處ldquo急性rdquo漏出來
洩露量超過 100 公斤(一小時內)的恕限值該事故屬於須提報的製程安全事件因為從法蘭處外
漏屬於製程安全事件應提報事項
損工事故
11 一名作業員走路時不慎滑倒造成損失工時之工傷滑倒原因為天氣狀況rdquo長期rdquo油垢的地面和
易滑鞋具該事故不屬於須提報的製程安全事件因為人員安全ldquo滑倒絆倒跌倒rdquo事故若非與
一次阻絕設施失效直接關聯的疏散或應變造成則不屬於須提報的製程安全事件
12 與前例相同的事件惟這次作業員跌倒是因為少量易燃液體外漏(如 1 小時內少於 10 公斤)在採取
相關應變措施時發生該事故屬於須提報的製程安全事件因為作業員係為了應變一次阻絕設施
失效的事故而跌倒若一次阻絕設施失效發生在公司廠區且造成失時工傷或死亡後果該事故
便屬於須提報的製程安全事件對於因洩漏造成死亡和損失工時之工傷事故沒有洩漏量門檻
13 與前例相同的事件惟這次作業員跌倒是在事件結束數小時之後該事故不屬於須提報的製程安
全事件在提報要件中所用的ldquo疏散rdquo和ldquo應變rdquo等術語指的是一次阻絕設施失效和相關緊急應變
活動正在持續中事件結束後滑倒絆倒跌倒(如ldquo事後rdquo清理和補救)不屬於須提報製程安全事件
14 工人在因附近設備一次阻絕設施失效在疏散過程中一名鷹架搭建工人從鷹架梯上跌落造成損
失工時之工傷該事故屬於須提報的製程安全事件
15 一名作業員行經一個設計不良的蒸汽卻水器時被外洩的蒸汽燙傷腳踝造成損失工時之工傷
該事故屬於須提報的製程安全事件因為雖然一次阻絕設施失效洩漏出的是蒸汽(而非碳氫化合物
或化學物質)但損失工時之工傷是由於洩漏物質的物理狀態所導致的
16 一個密閉空間依照計畫以氮氣吹清一名承攬商繞過安全管制進入該密閉空間因而死亡該事
故屬於須提報的死亡事件但不屬於須提報的製程安全事件因為其中不涉及非計劃或失控的一
次阻絕設施失效
17 情況同上惟這次氮氣是非刻意洩漏進入該局限空間該事故屬於須提報的製程安全事件(同時也
是一起死亡事件)因為該名承攬商的死亡與非計劃的一次阻絕設施失效有關
22
18 一名作業員因硫化氫(H2S)警報在進行應變處理時昏倒若警報確實是因非計劃或失控的 H2S 一次
阻絕設施失效的外洩事件該事故便屬於須提報的製程安全事件若警報是一個假警報則該事
故便不屬於須提報的製程安全事件因為沒有真正的化學品洩漏發生
管線
19 一條管線破漏1 小時內洩漏 2000 磅(900 公斤)易燃蒸氣到地面但洩漏位置在廠區內很偏僻的
地點該事故仍屬於須提報的製程安全事件因為ldquo偏僻rdquo不是提報與否的考量因素
與化學物質外洩無關之火災或能量釋放事故
一般通則而言唯有當火災或能量釋放事故是因化學物質洩漏所造成或其發生導致化學物質洩漏
超過提報恕限值這些事故才屬於須提報的製程安全事件實例包括
20 一場電氣火災影響製程操作導致甲苯洩漏 400 公斤該事故屬於須提報的製程安全事件因為
化學物質洩漏已超過甲苯的 100 公斤提報恕限值
21 發生電氣火災停電或任何公用資源供應中斷可能造成工廠停工及可能引起設備損失超過
$2500 美元(如因非正常停工導致反應器或設備損壞)但並未造成超過恕限值的化學物質洩漏
亦未造成死亡或嚴重工傷該事故不屬於須提報的製程安全事件因為設備損壞並非化學製程火
災爆炸造成且化學物質洩漏並未超過恕限值
海上運輸船
22 一艘由公司營運的海上運輸船在船上發生ldquo急性rdquo易燃物質外洩洩漏量超過 100 公斤該事故不
屬於須提報的製程安全事件因為除非海上運輸船是為了輸送半成品或產品而與煉油石化或化
學製造廠的設施相連接否則其洩漏事故便不被視為製程安全事件
23 一艘第三方駁船由一艘拖船推向碼頭結果撞上公司的碼頭駁船的一個船艙破裂且造成
1000 公斤柴油洩漏到海中該事故不屬於須提報的製程安全事件因為駁船當時並非停泊在碼
頭內且其作業並非在進行半成品或產品之輸送
卡車與軌道車
24 一輛公司的軌道車在運輸途中出軌造成超過 1000 公斤汽油洩漏該事故不屬於須提報的製程
安全事件因為在公司廠區外發生的軌道車事故不被視為與製程安全有關
23
25 一輛第三方卡車拖車在公司廠區內翻覆造成ldquo急性rdquo汽油洩漏超過 1000 公斤這事故不屬於須
提報的製程安全事件因為卡車拖車當時已不再與裝卸設備連接然而我們建議會員公司另
行訂定運輸安全事故指標將這類事故記錄下來
26 一位合約卡車作業者正在卸載液鹼時發生軟管脫落造成空氣中氣霧和或液鹼液洩漏 2500 公
斤該事故屬於須提報的製程安全事件因為洩漏量已超過液鹼的 100 公斤恕限值且事故發生
前卡車仍與裝卸設備相連接著
辦公建築
27 綜合辦公大樓發生鍋爐火災造成總計$75000 美元的直接成本損失該事故不屬於須提報的製
程安全事件因為辦公大樓事故不被視為與製程安全有關
人機介面事故
28 一名操作技術員在聚合物工廠的終端設備旁作業時受傷這傷害是因機械的人機介面的設備而
造成該事故不屬於須提報的製程安全事件因為技術員受傷並非因危險物質一次阻絕設施失效
而造成的
混合物
29 若混合物本身有 GHS 分類可利用其分類確定恕限值若混合物本身沒有 GHS 分類則可計算混
合物中每個單一組成分之洩漏量(公斤)相對於個別成分恕限值之比值作為其對混合物恕限值之
lsquo加權rsquo貢獻譬如若混合物在 1小時內的洩漏量為 100公斤其中包含 05公斤分類為劇毒 H300
的物質45 公斤分類為 H301 的物質40 公斤另一種分類為 H 開頭的物質其餘 55 公斤則為沒
有 GHS 分類的水分此混合物之計算式為051 + 4510 + 40100 = 05 + 045 + 04 = 135超過
1因此該事故被視為須提報的製程安全事件雖然混合物個別成分之洩漏量均未超過各該物質
本身的恕限值
直接損失成本
30 此一門檻所考慮的成本應為可直接歸因於火災或爆炸的成本譬如設備及結構損壞的重置成本
修理成本環境清理支出緊急應變和罰款直接成本不包括間接成本譬如業務機會損失設
備停機造成之利潤損失取得或運轉臨時設施之成本或為滿足顧客需求取得替代產品的成本
(產品損失)
24
31 範例連接到氣體處理系統的排放管發生易燃氣體外漏同時製程出現問題導致空氣進入同
一條排放管結果發生爆炸過高的壓力損壞了排放管及其相關上游設備包括一個密封罐並
未造成人員受傷修理成本約$12000 美元該事故屬於須提報的製程安全事件因為爆炸及火
災導致設備修理成本超過門檻
32 範例一次製程安全事件後公司又發生一種非常特殊的 GHS 第 5 類產品洩漏 50 公斤造成
$2000 美元的設備損失洩漏的產品是一種非常特別的混合物公司須負擔超過$50000 美元因
產品耗損而產生之材料成本該事故不屬於須提報的製程安全事件因為 GHS 第 5 類產品洩漏的
提報門檻為 100 公斤且產品耗損不被計入直接損失成本
天然災害
33 天然災害可能對化學製程作業構成重大風險且對製程設備造成損壞導致危害物質一次阻絕設
施失效當一種或多種天然災害被認為可能對工廠作業造成影響時製程安全和作業系統應從危
害及後果分析工廠機器設備設計公用設施失效及製程停工之操作程序緊急應變計畫及應變
措施等方面界定潛在風險進行防範
天然災害類型包括颶風及颱風(包括伴隨而來的風暴潮)水災龍捲風地震超強對流風暴(直
線風暴)野火火山爆發海嘯和山崩
若公司廠房設施遭遇天然災害且其後果觸發一種或以上提報門檻該事故便屬於須提報製程安
全事件
預防性公眾應變
34 預防性公眾應變是基於謹慎的態度所採取的一種措施譬如當發生一次阻絕設施失效時公司
可能在尚未進行任何評估(如方向與洩漏點的距離等等)前便要求全體工人就地避難又
如地方權責官員(如消防警察民防緊急應變管理部門)在獲報一家公司發生製程安全事件
後為防lsquo萬一rsquo風向改變或基於可能受到波及的人口敏感族群(如學童或老年人)可能在尚未接
獲明確資訊前便下令社區就地避難或疏散或採取公眾保護措施(如道路封閉)
製程附屬倉庫
35 製程附屬倉庫指的是位於廠內用於儲存將投入於生產製程或產自於製程之原料半成品或成品的
倉庫從製程的觀點看來製程附屬倉庫相當於一個大型儲槽但這些原料半成品或成品並不
是儲存在一的大型容器中而是裝在較小的容器裡(如太空包大桶桶罐等)
25
Appendix C ndash List of RCLG Taskforce Members
Name Affiliation
Peter Schmelzer Bayer CEFIC - Chairman
Americo Diniz Carvalho Neto Braskem
Bradford Johnson American Chemistry Council
David Cummings DuPont
Debra Phillips American Chemistry Council
Hans Schwarz BASF
Kathryn Walton Plastics and Chemicals Industries Association
Kazuyuki Akita Japanese Chemical Industry Association
Kelly Keim ExxonMobil Chemical Company API Representative
Kenan Stevick Dow
Kiyokazu Murata Japanese Chemical Industry Association
Larry Bowler SABIC
Lorna Young Chemical Industry Association of Canada
Louisa Nara Center for Chemical Process Safety
Luiz Shizuo Harayashiki Associaccedilatildeo Brasileira da Induacutestria Quiacutemica
Masatoshi Kumamoto Japanese Chemical Industry Association
Milton Lacerda Petrobras
Phil Scott Chemical Industries Association
Piet Knijff DSM European Process Safety Centre
Scott Donaldson and Eamon Chandler
Shell
Scott Wallace Olin Corporation
Shakeel Kadri Air Products and Chemicals Inc
26
附錄 D ndash 詳細活動時程表
2016 年 2017 年 2018 年 2019 年 2020 年
2 ndash 4 月
RCLG PS 先導計畫
5 月 ndash
針對準則進行調整釐清
6 月 向 RCLG 和 ICCA 董事會報
告先導計畫執行結果
7 ndash 12 月 RCLG 協會考量準
則並為其會員公司發展提報機制
如有需要RCLG可向 ICCA 申請能
力建立基金為會員公司舉辦製程安
全研習會
1 ndash 12 月
RCLG 協會開始向其會員公司蒐集製程安全數據
1 ndash 12 月
如有需要RCLG 各協會運用 RCLG 的基金及專
家舉辦製程安全及績效提報研習會
1 ndash 2 月
擁有數據的協會開始向RCLG 提報製程安全事件
(2017 年數據)
4 月 RCLG 檢討第一個提報循
環的結果挑戰及原始數據(內部)
6 月 RCLG 向 ICCA 董事會呈報
原始數據
7 ndash 12 月 必要時更新及調整準
則
如有需要RCLG 各協會運用 RCLG 的基金及專
家舉辦製程安全及績效提報研習會
1 ndash 2 月
擁有數據的協會開始向RCLG 提報製程安全事件
(2018 年數據)
4 月 RCLG 檢討第二個提報循
環的結果挑戰及原始數據(內部)
6 月 RCLG 向 ICCA 董事會呈報
原始數據
7 ndash 12 月 必要時更新及調整準
則
如有需要RCLG 協會運用 RCLG 的基金及專家
舉辦製程安全及績效提報研習會
1 ndash 2 月
所有協會開始向 RCLG 提報製程安全事件
製程安全事件提報成為
RCLG KPI 衡量指標建議基本集的一部分(2019 年數
據)
4 月 RCLG 檢討第二個提報循
環的結果挑戰及原始數據(內部考量外部提
報)
6 月 RCLG 向 ICCA 董事會呈報
原始數據
27
附錄 E ndash 選擇性 Excel 追蹤表
當會員公司開始追蹤製程安全事件時所有會員公司應採用單一表格以簡化數據分析同時讓所有公司均使用相同的追蹤表RCLG 設
計了一份選擇性追蹤表可供會員公司和協會先行利用之後他們可設計自己的追蹤表
在這裡下載追蹤表
ICCA Process Safety Event Tracking Sheetxlsx
本文件包含三個分頁分別是ldquo聯絡資料rdquoldquo調查表rdquo和儲存下拉式選單選項的ldquo請勿編輯rdquo分頁
備註
附錄 E 追蹤表僅供參考TRCA 將另行提供台灣版表格供會員公司提報
28
後語
台灣化學工業責任照顧協會(Taiwan Responsible Care Association TRCA)成立於 1998 年在台灣推行責任照顧制度已達 20 週年製造商成員
包括台灣主要上市上櫃化工公司會員公司化學品生產製造量約佔全國 80 2016 年台灣化工業的 Chemical Sales 仍站在全球第八名的位
置額度為 630 億歐元化工業總產值達到 34 兆新台幣提供國內 416 萬人工作機會
TRCA 扮演國內廠商與國際制度接軌的角色也是國內化工業與政府機關及利益相關者溝通的橋樑與管道TRCA 會員結構依業務性質分析
涵蓋石化生產化學品製造氣體生產倉儲運輸業化學品貿易業以及工程研發設計等公司TRCA 透過供應鏈及價值鏈推行責任
照顧制度組成毒性化學物質聯防組織協助法規溝通與研析會員名冊請參考 httpwwwtrcaorgtwtrcanwork2aspx
TRCA 於 2010 年成為 ICCA (International Council of Chemical Associations 國際化學工業協會)觀察員ICCA 成立於 1989 年是全球化工製造
業的聯合會也是化學工業與 UNEP OPCW 及 OECD 的交流窗口ICCA 與其會員協會及成員公司致力於邁向永續的未來確保人類健康與
環境安全與保護全球化工業擁有超過 4兆美元的價值影響所有經濟部門ICCA 的會員幾乎在全球每個國家都有商業活動在全球六大
洲推動創新並提供超過 2000 萬個工作機會
台灣化工業在全球占有重要的一席之地在國內產業鏈也位居關鍵位置無論對國內或國際都有身為地球村一員應盡之責我們期許藉由
製程安全指標提報能更進一步提升自我在工安衛生環保與永續發展等面向的績效表現
台灣化學工業責任照顧協會
10452 台北市中山區撫順街 8 號 7 樓
電話02-2585-0552
httpwwwtrcaorgtw
None | |
$2500 to $25000 | |
$25000 to $250000 | |
$250000 to $25000000 | |
More than $25000000 | |
Yes - Using GHS TABLE | |
Yes - Using API RP 754 TABLE | |
NO | |
NA | |
1x le TQ lt 40x | |
40x le TQ lt 160x | |
160x le TQ lt 640x | |
ge 640x TQ | |
Yes le 3 hours | |
Yes 3 hours ge 12 hours | |
Yes 12 hours ge 24 hours | |
Yes ge 24 hours | |
No | |
Small-scale | |
Medium-scale | |
Large-scale | |
No | |
Yes | |
No | |
middot Injury requiring treatment beyond first aid to an employee contractor or subcontractor | |
middot Days Away From Work injury to an employee contractor or subcontractor or middot Injury requiring treatment beyond first aid to a third party | |
middot A fatality of an employee contractor or subcontractor or middot A hospital admission of a third party | |
middot Multiple fatalities of employees contractors or subcontractors or middot multiple hospital admission of third parties or middot A fatality of a third party | |
NA | |
1x le TQ lt 3x | |
3x le TQ lt 9x | |
9x le TQ lt 27x | |
ge 27x TQ |
ICCA Process Safety Pilot Reporting ProgramFebruary 8 2016 | 1 | 2 | 3 | 4 | 5 | 6 | 7 | 8 | 9 | 10 | 12 | 13 | 14 | 15 | |||||||||||||||||||||||
SAFETY Details(Meeting Local Regulations) | Direct Cost from Fire or Explosion | Community Impact | Environmental Impact | Material Released(Measured using the 1 Hour Rule) | |||||||||||||||||||||||||||||||||
Company Association Details | |||||||||||||||||||||||||||||||||||||
GHS | API - RP 754 | ||||||||||||||||||||||||||||||||||||
Company or Assocation Name | Headquarter Association | Location of Event Ex - City State amp Country | Date and Time of Event | Safety InjuryDid the Event result in a Recordable Lost Time Accident or Fatality or Hospital admission of anyone on or off siteUse Drop Down Menu | Safety InjuryIf yes please insert the total number of injuries | Safety InjuryFor puropses of utilizing the Severity Table please indicate the level of severity by chosing the MOST SEVERE classification that describes your incidentUse Drop Down Menu | Safety InjuryDid the incident involve Fatalities If so how many total fatalities If none enter Zero | Safety InjuryPlease Report Total Employee Hours for Calendar Year 2015 | Safety InjuryPlease Report Total Contractor Hours for Calendar Year 2015 | Direct Cost Did the Event result in Direct Damage CostUse Drop Down Menu | Direct Cost If so how muchAmount is in US DollarsUse Drop Down Menu | Community ImpactDid the event result inbull Officially declared shelter-in-place or officially declared evacuation (on or off site)ORbull Precautionary off site shelter in place or evacuation Use Drop Down Menu | Environmental ImpactDid the event result inAcute Environmental Remediation CostIf so indicate the amount in US DollarsUse Drop Down Menu | Material ReleasedDid the Event result in an Acute Release of material beyond one of the two threshold tablesIf so indicate which Threshold Table you used to make this determinationUse Drop Down Menu | Material ReleasedIf so indicate the amount released USING GHS CLASSIFICATION TABLEUse Drop Down Menu | Material ReleasedIf so indicate the amount released USING THE THRESHOLD TABLE FROM API RP-754Use Drop Down Menu | Material ReleasedIf available please indicate the material released | ||||||||||||||||||||
1 | ABC Chemical Company | American Chemistry Council | Washington DC - USA | January 4 2016 | Yes | 2 | middot Days Away From Work injury to an employee contractor or subcontractor or middot Injury requiring treatment beyond first aid to a third party | 0 | 5525000 | 1500250 | No | $2500 to $25000 | Yes le 3 hours | $2500 to $25000 | Yes - Using GHS TABLE | 40x le TQ lt 160x | NA | Chlorine | |||||||||||||||||||
2 | XYZ Chemical Company | American Chemistry Council | Washington DC - USA | 5-Jan-16 | Yes | 1 | middot Injury requiring treatment beyond first aid to an employee contractor or subcontractor | 0 | 5525000 | 1500250 | Yes | $2500 to $25000 | No | $2500 to $25000 | Yes - Using API RP 754 TABLE | NA | 3x le TQ lt 9x | Benzene | |||||||||||||||||||
3 | |||||||||||||||||||||||||||||||||||||
4 | |||||||||||||||||||||||||||||||||||||
5 | |||||||||||||||||||||||||||||||||||||
6 | |||||||||||||||||||||||||||||||||||||
7 | |||||||||||||||||||||||||||||||||||||
8 | |||||||||||||||||||||||||||||||||||||
9 | |||||||||||||||||||||||||||||||||||||
10 | |||||||||||||||||||||||||||||||||||||
11 | |||||||||||||||||||||||||||||||||||||
12 | |||||||||||||||||||||||||||||||||||||
13 | |||||||||||||||||||||||||||||||||||||
14 | |||||||||||||||||||||||||||||||||||||
15 | |||||||||||||||||||||||||||||||||||||
16 | |||||||||||||||||||||||||||||||||||||
17 | |||||||||||||||||||||||||||||||||||||
18 | |||||||||||||||||||||||||||||||||||||
19 | |||||||||||||||||||||||||||||||||||||
20 | |||||||||||||||||||||||||||||||||||||
21 | |||||||||||||||||||||||||||||||||||||
22 | |||||||||||||||||||||||||||||||||||||
23 | |||||||||||||||||||||||||||||||||||||
24 | |||||||||||||||||||||||||||||||||||||
25 | |||||||||||||||||||||||||||||||||||||
Zero or None | Yes - Duration Unknown | ||||||||||||||||||||||||||||||||||||
Processes | Mode of Operation | Type of material released | Status of Operation | ||||
REFINING | Start-up | Flammable | Open | ||||
Alkylation HF | Planned shutdown | Combustible | Closed | ||||
Alkylation sulfuric | Emergency shutdown | Toxic | |||||
BitumenResidAsphalt | Normal | Corrosive | Tier 1 Acute Releases | ||||
Calcining | Upset | Utilities | No Release | ||||
Coking | Turnaround | Other | Category 1 | ||||
Crude | Routine maintenance | Category 2 | |||||
Desulfurization | Temporary | Evacuation | Category 3 | ||||
FCC | Other | Yes | Category 4 | ||||
Gas Treating | No | Category 5 | |||||
Hydrogen | Point of Release | Category 6 | |||||
Hydrotreating | Pump | Fire | Category 7 | ||||
Hydrocracking | Compressor | Yes | Multiple Categories | ||||
Isom | BlowerFan | No | |||||
MarineJetty | Pressure Vessel | lt $2500 | |||||
Reforming | FilterCoalescer | ||||||
Sulfur recovery | Furnace | PRDs | |||||
Vapor recoverylight ends | Boiler | Directly to Atmosphere | |||||
Wastewater | Heat exchanger | via Downstream Destructive Device | |||||
REFINING amp PETROCHEMICAL | Cooling Tower | No | |||||
Tank FarmStorage FacilityOffsite | Piping system | Yes | |||||
UtilitiesSteam PlantCogeneration | Reactor | No | |||||
Other | Atmospheric tank | ||||||
PETROCHEMICAL | FlareRelief System | Acute release above thresholds | |||||
CO H2 | Other | Yes | |||||
LNG | No | ||||||
Methane | Events | ||||||
Methanol | No Tier 1 Events | Indoor Outdoor | |||||
Methyl Mercaptan | No Tier 2 Events | No Release | |||||
Formaldehyde | No Tier 1 or Tier 2 Events | Indoor | |||||
Formaldehyde derivatives | NA | Outdoor | |||||
Acetic Acid | |||||||
Acetic Acid derivatives | Event Type | ||||||
Ethane | Injury | ||||||
Ethylene | Fire | ||||||
Ethanol | Explosion | ||||||
Ethylene oxide | PRD Discharge | ||||||
Ethylene derivatives | Acute Release | ||||||
Polyethylene | |||||||
Ethylene dichloride | General | ||||||
Ethylene dichloride derivatives | Yes | ||||||
Ethyl benzene | No | ||||||
Ethyl benzene derivatives | |||||||
Polystyrene | |||||||
Styrene-Butadiene | |||||||
Propane | |||||||
Propylene | |||||||
Polypropylene | |||||||
Isopropanol | |||||||
Propylene oxide | |||||||
Propylene oxide derivatives | |||||||
Butane | |||||||
Isobutane | |||||||
Isobutene | |||||||
Butadiene | |||||||
MTBE | |||||||
ETBE | |||||||
Pentane | |||||||
Hexane | |||||||
Cyclohexane | |||||||
Hexanol | |||||||
Aromatics Derivatives | |||||||
Benzene | |||||||
Toluene | |||||||
Xylene | |||||||
Para Xylene | |||||||
Amines Derivatives | |||||||
TDA MDA IPDA etc | |||||||
Isocyanates | |||||||
Specialty Chemicals | |||||||
LoadingUnloading | |||||||
Pilot Plant |
Instructions | ||||||||||||||
Step 1 | Complete the Contact Tab with your contact information and company information | |||||||||||||
Be sure to note the region of your reporting (IE North America France Japan etc) | ||||||||||||||
Survey on Process Safety Events | ||||||||||||||
Step 2 | Complete the survey one line per Process Safety Event for your companyregion | |||||||||||||
ALL REPORTED DATA SHOULD BE FROM CALENDAR YEAR 2017 | ||||||||||||||
Step 3 | Return completed survey to | |||||||||||||
Company Name | ||||||||||||||
Contact Person | All Surveys Due by xxx date | |||||||||||||
Address | ||||||||||||||
Fax | ||||||||||||||
Telephone | ||||||||||||||
Region | ||||||||||||||
None | |
$2500 to $25000 | |
$25000 to $250000 | |
$250000 to $25000000 | |
More than $25000000 | |
Yes - Using GHS TABLE | |
Yes - Using API RP 754 TABLE | |
NO | |
NA | |
1x le TQ lt 40x | |
40x le TQ lt 160x | |
160x le TQ lt 640x | |
ge 640x TQ | |
Yes le 3 hours | |
Yes 3 hours ge 12 hours | |
Yes 12 hours ge 24 hours | |
Yes ge 24 hours | |
No | |
Small-scale | |
Medium-scale | |
Large-scale | |
No | |
Yes | |
No | |
middot Injury requiring treatment beyond first aid to an employee contractor or subcontractor | |
middot Days Away From Work injury to an employee contractor or subcontractor or middot Injury requiring treatment beyond first aid to a third party | |
middot A fatality of an employee contractor or subcontractor or middot A hospital admission of a third party | |
middot Multiple fatalities of employees contractors or subcontractors or middot multiple hospital admission of third parties or middot A fatality of a third party | |
NA | |
1x le TQ lt 3x | |
3x le TQ lt 9x | |
9x le TQ lt 27x | |
ge 27x TQ |
ICCA Process Safety Pilot Reporting ProgramFebruary 8 2016 | 1 | 2 | 3 | 4 | 5 | 6 | 7 | 8 | 9 | 10 | 12 | 13 | 14 | 15 | |||||||||||||||||||||||
SAFETY Details(Meeting Local Regulations) | Direct Cost from Fire or Explosion | Community Impact | Environmental Impact | Material Released(Measured using the 1 Hour Rule) | |||||||||||||||||||||||||||||||||
Company Association Details | |||||||||||||||||||||||||||||||||||||
GHS | API - RP 754 | ||||||||||||||||||||||||||||||||||||
Company or Assocation Name | Headquarter Association | Location of Event Ex - City State amp Country | Date and Time of Event | Safety InjuryDid the Event result in a Recordable Lost Time Accident or Fatality or Hospital admission of anyone on or off siteUse Drop Down Menu | Safety InjuryIf yes please insert the total number of injuries | Safety InjuryFor puropses of utilizing the Severity Table please indicate the level of severity by chosing the MOST SEVERE classification that describes your incidentUse Drop Down Menu | Safety InjuryDid the incident involve Fatalities If so how many total fatalities If none enter Zero | Safety InjuryPlease Report Total Employee Hours for Calendar Year 2015 | Safety InjuryPlease Report Total Contractor Hours for Calendar Year 2015 | Direct Cost Did the Event result in Direct Damage CostUse Drop Down Menu | Direct Cost If so how muchAmount is in US DollarsUse Drop Down Menu | Community ImpactDid the event result inbull Officially declared shelter-in-place or officially declared evacuation (on or off site)ORbull Precautionary off site shelter in place or evacuation Use Drop Down Menu | Environmental ImpactDid the event result inAcute Environmental Remediation CostIf so indicate the amount in US DollarsUse Drop Down Menu | Material ReleasedDid the Event result in an Acute Release of material beyond one of the two threshold tablesIf so indicate which Threshold Table you used to make this determinationUse Drop Down Menu | Material ReleasedIf so indicate the amount released USING GHS CLASSIFICATION TABLEUse Drop Down Menu | Material ReleasedIf so indicate the amount released USING THE THRESHOLD TABLE FROM API RP-754Use Drop Down Menu | Material ReleasedIf available please indicate the material released | ||||||||||||||||||||
1 | ABC Chemical Company | American Chemistry Council | Washington DC - USA | January 4 2016 | Yes | 2 | middot Days Away From Work injury to an employee contractor or subcontractor or middot Injury requiring treatment beyond first aid to a third party | 0 | 5525000 | 1500250 | No | $2500 to $25000 | Yes le 3 hours | $2500 to $25000 | Yes - Using GHS TABLE | 40x le TQ lt 160x | NA | Chlorine | |||||||||||||||||||
2 | XYZ Chemical Company | American Chemistry Council | Washington DC - USA | 5-Jan-16 | Yes | 1 | middot Injury requiring treatment beyond first aid to an employee contractor or subcontractor | 0 | 5525000 | 1500250 | Yes | $2500 to $25000 | No | $2500 to $25000 | Yes - Using API RP 754 TABLE | NA | 3x le TQ lt 9x | Benzene | |||||||||||||||||||
3 | |||||||||||||||||||||||||||||||||||||
4 | |||||||||||||||||||||||||||||||||||||
5 | |||||||||||||||||||||||||||||||||||||
6 | |||||||||||||||||||||||||||||||||||||
7 | |||||||||||||||||||||||||||||||||||||
8 | |||||||||||||||||||||||||||||||||||||
9 | |||||||||||||||||||||||||||||||||||||
10 | |||||||||||||||||||||||||||||||||||||
11 | |||||||||||||||||||||||||||||||||||||
12 | |||||||||||||||||||||||||||||||||||||
13 | |||||||||||||||||||||||||||||||||||||
14 | |||||||||||||||||||||||||||||||||||||
15 | |||||||||||||||||||||||||||||||||||||
16 | |||||||||||||||||||||||||||||||||||||
17 | |||||||||||||||||||||||||||||||||||||
18 | |||||||||||||||||||||||||||||||||||||
19 | |||||||||||||||||||||||||||||||||||||
20 | |||||||||||||||||||||||||||||||||||||
21 | |||||||||||||||||||||||||||||||||||||
22 | |||||||||||||||||||||||||||||||||||||
23 | |||||||||||||||||||||||||||||||||||||
24 | |||||||||||||||||||||||||||||||||||||
25 | |||||||||||||||||||||||||||||||||||||
Zero or None | Yes - Duration Unknown | ||||||||||||||||||||||||||||||||||||
Processes | Mode of Operation | Type of material released | Status of Operation | ||||
REFINING | Start-up | Flammable | Open | ||||
Alkylation HF | Planned shutdown | Combustible | Closed | ||||
Alkylation sulfuric | Emergency shutdown | Toxic | |||||
BitumenResidAsphalt | Normal | Corrosive | Tier 1 Acute Releases | ||||
Calcining | Upset | Utilities | No Release | ||||
Coking | Turnaround | Other | Category 1 | ||||
Crude | Routine maintenance | Category 2 | |||||
Desulfurization | Temporary | Evacuation | Category 3 | ||||
FCC | Other | Yes | Category 4 | ||||
Gas Treating | No | Category 5 | |||||
Hydrogen | Point of Release | Category 6 | |||||
Hydrotreating | Pump | Fire | Category 7 | ||||
Hydrocracking | Compressor | Yes | Multiple Categories | ||||
Isom | BlowerFan | No | |||||
MarineJetty | Pressure Vessel | lt $2500 | |||||
Reforming | FilterCoalescer | ||||||
Sulfur recovery | Furnace | PRDs | |||||
Vapor recoverylight ends | Boiler | Directly to Atmosphere | |||||
Wastewater | Heat exchanger | via Downstream Destructive Device | |||||
REFINING amp PETROCHEMICAL | Cooling Tower | No | |||||
Tank FarmStorage FacilityOffsite | Piping system | Yes | |||||
UtilitiesSteam PlantCogeneration | Reactor | No | |||||
Other | Atmospheric tank | ||||||
PETROCHEMICAL | FlareRelief System | Acute release above thresholds | |||||
CO H2 | Other | Yes | |||||
LNG | No | ||||||
Methane | Events | ||||||
Methanol | No Tier 1 Events | Indoor Outdoor | |||||
Methyl Mercaptan | No Tier 2 Events | No Release | |||||
Formaldehyde | No Tier 1 or Tier 2 Events | Indoor | |||||
Formaldehyde derivatives | NA | Outdoor | |||||
Acetic Acid | |||||||
Acetic Acid derivatives | Event Type | ||||||
Ethane | Injury | ||||||
Ethylene | Fire | ||||||
Ethanol | Explosion | ||||||
Ethylene oxide | PRD Discharge | ||||||
Ethylene derivatives | Acute Release | ||||||
Polyethylene | |||||||
Ethylene dichloride | General | ||||||
Ethylene dichloride derivatives | Yes | ||||||
Ethyl benzene | No | ||||||
Ethyl benzene derivatives | |||||||
Polystyrene | |||||||
Styrene-Butadiene | |||||||
Propane | |||||||
Propylene | |||||||
Polypropylene | |||||||
Isopropanol | |||||||
Propylene oxide | |||||||
Propylene oxide derivatives | |||||||
Butane | |||||||
Isobutane | |||||||
Isobutene | |||||||
Butadiene | |||||||
MTBE | |||||||
ETBE | |||||||
Pentane | |||||||
Hexane | |||||||
Cyclohexane | |||||||
Hexanol | |||||||
Aromatics Derivatives | |||||||
Benzene | |||||||
Toluene | |||||||
Xylene | |||||||
Para Xylene | |||||||
Amines Derivatives | |||||||
TDA MDA IPDA etc | |||||||
Isocyanates | |||||||
Specialty Chemicals | |||||||
LoadingUnloading | |||||||
Pilot Plant |
Instructions | ||||||||||||||
Step 1 | Complete the Contact Tab with your contact information and company information | |||||||||||||
Be sure to note the region of your reporting (IE North America France Japan etc) | ||||||||||||||
Survey on Process Safety Events | ||||||||||||||
Step 2 | Complete the survey one line per Process Safety Event for your companyregion | |||||||||||||
ALL REPORTED DATA SHOULD BE FROM CALENDAR YEAR 2017 | ||||||||||||||
Step 3 | Return completed survey to | |||||||||||||
Company Name | ||||||||||||||
Contact Person | All Surveys Due by xxx date | |||||||||||||
Address | ||||||||||||||
Fax | ||||||||||||||
Telephone | ||||||||||||||
Region | ||||||||||||||
18 (K = 1000 MM = 1000000) (在環境影響類別方面若缺乏既有定義協會和會員公司應議定輸入標準)
嚴重程度表(附錄 A)細節說明
附錄 A 之設計目的僅適用於採用 GHS 分類制度(表 1)者如果你的公司係採用 API RP 754Tier II 製程安全指標提報恕限值表(表 2)請使用
API RP 754 製程安全嚴重程度表必須提醒的是依 API RP 754 的標準其嚴重程度表僅適用於一級(Tier I)事故去比較採用不同的嚴重度
表所評估出來的相對嚴重度並無統計上的意義
急性的環境成本 ndash 因製程安全事件造成廠外環境影響所導致之短期清理及物質處置的成本各會員公司可選擇將廠外環境影響相關成本另
外區分一個嚴重程度類別
比率調整指標
利用上述嚴重程度表可產生一系列以事件率為基礎的指標包括
製程安全總事件率 (PSTIR) 總事件次數 x 200000
總工作時數
製程安全事件嚴重程度率(PSESR) (即製程安全事件嚴重程度加權計算公式)
PSESR = 所有事件之總嚴重程度分數總合 x 200000
總工作時數
在計算此一比率時各 4 級事件被分配 1 分各 3 級事件被分配 3 分各 2 級事件被分配 9 分各 1 級事件被分配 27 分理論上每個
製程安全事件至少可分配到 1 分(亦即事件僅在一個類別符合第 4 級事件屬性)至多可分配到 135 分(亦即事件在所有五個類別中均符
合第 1 級事件屬性)
ldquoXrdquo級別製程安全事件率 嚴重度級別ldquoXrdquo之製程安全事件總數 x 200000
員工承攬商amp再承攬商總工作時數
X可以是嚴重度級別 432 或 1 級製程安全事件之總數事件之嚴重度等級是選用五類後果類別中之最嚴重等級
標準化 ndash 在某些協會和會員公司中製程安全事件是採 lsquo每 100 名rsquo員工每名員工每年平均工作時數為 2000 小時為基礎予以標準化因
此在lsquo每 100rsquo名rsquo員工的標準基礎上事件被乘以 200000 工作時數也有些其他協會和會員公司將標準化基礎設定為lsquo每 500 名rsquo員工
因此事件被乘以 1000000 工作時數協會和會員公司應就標準化基礎進行討論共同做成選項結論上述的公式設定為lsquo每 100 名rsquo員工
基礎
19
附錄 B ndash 常見問題集
適用性
我們建議會員公司記錄和提報在其所擁有或運作的工廠內發生的製程安全事件惟以下情況不須提報製
程安全事件
1 源自於公司廠區以外的製程安全事件
2 海上運輸船事故惟船隻為了輸送半成品或產品之目的已經與公司的設施相連接時發生的
事故仍須提報
3 卡車或軌道車事故惟卡車或軌道車為了輸送半成品或產品之目的已經與公司的設施相連
接時發生的事故仍須提報
4 許可證或法規容許之例行排放
5 不會造成製程安全危害的地下污染請注意若洩漏至地下導致地上發生須提報製程安全事
件如釋放出毒性蒸汽或致使易燃液體蓄積成池則不適用本排除條件
6 辦公建築事故(如辦公室暖氣設備爆炸火災外溢洩漏人員受傷或疾病等)
7 與疏散或一次阻絕設施失效無直接關聯之人員安全ldquo滑倒絆倒跌倒rdquo事故
8 沒有與製程相連接之輔助設備的一次阻絕設施(如小樣品瓶)失效事故
9 計劃中和在控制下的物質排放至設計用來收集或排放系統中(請注意物質從一次阻絕設施
在非計劃或非受控制情況下排放至收集或排放系統中則不適用本排除條件)
10 在製程區域外部或保養廠內執行之機械作業
說明與實例 ndash 以 GHS 表 1 為基礎
以下說明和實例有助於在評估須提報製程安全事件(PSE)時釐清可能存在的不確定部分
公司廠區
1 一輛第三方的卡車在公司廠區內卸載易燃產品時發生洩漏進而引起火災造成公司財物損失
$7000 美元(直接成本)雖然該卡車是ldquo由他人操作rdquo但其作業與製程相連接若公司的直接成
本財物損失達到或超過$2500 美元或已達到或超過其他 PSE 提報門檻(如1 人死亡)此事故即
屬於須提報的製程安全事件
2 與前例1 類似的例子載著易燃產品的卡車在廠外運輸途中翻覆引發火災並造成卡車毀損
該事故不屬於須提報的製程安全事件因為當時卡車並未與製程相連接
20
阻絕設施失效
3 儲槽液位計故障造成裝有ldquo易燃液體rdquo產品的儲槽外溢約 700 公斤的液體流入儲槽的防溢堤內
此事故屬於須提報的製程安全事件因為其ldquo急性rdquo洩漏量超過 100 公斤即使是阻絕在二次阻絕
設施防溢堤中亦然
4 一名從事維修工作的承攬商在開啟一個製程阻閥時被噴起的硫酸濺到造成嚴重灼傷和損失工
時的工傷此事故屬於須提報的製程安全事件因為它是涉及物質和一次阻絕設施失效的意外事
件對於因洩漏造成死亡和損工的工傷或疾病事故沒有洩漏恕限值
5 一名作業員開啟品管取樣點進行日常取樣作業時手部被一個破碎的玻璃瓶嚴重割破需要進行
縫合治療縫針造成第二天無法上班該事故不屬於須提報的製程安全事件因為它與一次阻絕
設施失效無關
ldquo急性rdquo洩漏
6 一名作業員在進行天然氣流量高於預期值之異常排除時發現天然氣管線上的一個安全閥門未適
當歸位因此天然氣經由氣液分離桶排放至排氣煙囪經進一步檢查作業員判斷在過去 6 個
月間總共有 100000 公斤天然氣以穩定的速率排放至大氣該事故不屬於須提報的製程安全事
件因為其洩漏速率(每小時約 10 公斤)不算ldquo急性rdquo洩漏(未超過易燃蒸汽每小時 100 公斤的恕限
值)
廢氣燃燒塔amp排放控制裝置 (如洗滌塔)
7 若化學物質被導引至廢氣燃燒塔或排放控制裝置(如洗滌塔)只要該廢氣燃燒塔或控制裝置運作在
正常設計範圍內便不屬於須提報的製程安全事件
8 若廢氣流速超過洗滌塔的設計負荷以致未經吸收的化學物質排出超過恕限值該事故屬於須提報
的製程安全事件(如本文註釋所述)
註釋自取得許可或妥善管理的裝置-包括釋壓裝置發生不預期的排放若 1 小時內洩漏量達到或
超過表 1 或表 2 所列的洩漏恕限值且導致下列四種後果之任一項或以上之後果該事故便屬於
須提報的製程安全事件
o 二相排放或夾帶液體的排放液滴沉降至地面造成污染
o 排放至具潛在危險性的地點)
o 廠內就地避難或疏散不包括預防性廠內就地避難或疏散
o 啟動公眾保護措施(如道路封閉)包括預防性公眾保護措施
21
安全洩壓裝置 系統
9 製程單元發生異常安全閥開啟將洩漏物質釋放到排氣口此釋壓排放裝置是依相關要求設計
的且氣體釋到大氣中並未造成不良後果這不是一個須提報的製程安全事件因為安全閥高
壓破裂盤以及類似的安全裝置是依據 API 521 或者同等的標準設計的且此排放並未造成 (1)
夾帶液體並導致須提報的製程安全事件的後果(譬如損失工時意外死亡火災或爆炸造成$2500
美元或以上的直接成本損失液體或毒性氣體洩漏量達到或超過恕限值(2) 啟動廠內或廠外就地
避難應變或(3)啟動公眾保護措施
10 製程單元發生異常安全閥並未開啟造成設備超壓易燃性氣體從一個法蘭處ldquo急性rdquo漏出來
洩露量超過 100 公斤(一小時內)的恕限值該事故屬於須提報的製程安全事件因為從法蘭處外
漏屬於製程安全事件應提報事項
損工事故
11 一名作業員走路時不慎滑倒造成損失工時之工傷滑倒原因為天氣狀況rdquo長期rdquo油垢的地面和
易滑鞋具該事故不屬於須提報的製程安全事件因為人員安全ldquo滑倒絆倒跌倒rdquo事故若非與
一次阻絕設施失效直接關聯的疏散或應變造成則不屬於須提報的製程安全事件
12 與前例相同的事件惟這次作業員跌倒是因為少量易燃液體外漏(如 1 小時內少於 10 公斤)在採取
相關應變措施時發生該事故屬於須提報的製程安全事件因為作業員係為了應變一次阻絕設施
失效的事故而跌倒若一次阻絕設施失效發生在公司廠區且造成失時工傷或死亡後果該事故
便屬於須提報的製程安全事件對於因洩漏造成死亡和損失工時之工傷事故沒有洩漏量門檻
13 與前例相同的事件惟這次作業員跌倒是在事件結束數小時之後該事故不屬於須提報的製程安
全事件在提報要件中所用的ldquo疏散rdquo和ldquo應變rdquo等術語指的是一次阻絕設施失效和相關緊急應變
活動正在持續中事件結束後滑倒絆倒跌倒(如ldquo事後rdquo清理和補救)不屬於須提報製程安全事件
14 工人在因附近設備一次阻絕設施失效在疏散過程中一名鷹架搭建工人從鷹架梯上跌落造成損
失工時之工傷該事故屬於須提報的製程安全事件
15 一名作業員行經一個設計不良的蒸汽卻水器時被外洩的蒸汽燙傷腳踝造成損失工時之工傷
該事故屬於須提報的製程安全事件因為雖然一次阻絕設施失效洩漏出的是蒸汽(而非碳氫化合物
或化學物質)但損失工時之工傷是由於洩漏物質的物理狀態所導致的
16 一個密閉空間依照計畫以氮氣吹清一名承攬商繞過安全管制進入該密閉空間因而死亡該事
故屬於須提報的死亡事件但不屬於須提報的製程安全事件因為其中不涉及非計劃或失控的一
次阻絕設施失效
17 情況同上惟這次氮氣是非刻意洩漏進入該局限空間該事故屬於須提報的製程安全事件(同時也
是一起死亡事件)因為該名承攬商的死亡與非計劃的一次阻絕設施失效有關
22
18 一名作業員因硫化氫(H2S)警報在進行應變處理時昏倒若警報確實是因非計劃或失控的 H2S 一次
阻絕設施失效的外洩事件該事故便屬於須提報的製程安全事件若警報是一個假警報則該事
故便不屬於須提報的製程安全事件因為沒有真正的化學品洩漏發生
管線
19 一條管線破漏1 小時內洩漏 2000 磅(900 公斤)易燃蒸氣到地面但洩漏位置在廠區內很偏僻的
地點該事故仍屬於須提報的製程安全事件因為ldquo偏僻rdquo不是提報與否的考量因素
與化學物質外洩無關之火災或能量釋放事故
一般通則而言唯有當火災或能量釋放事故是因化學物質洩漏所造成或其發生導致化學物質洩漏
超過提報恕限值這些事故才屬於須提報的製程安全事件實例包括
20 一場電氣火災影響製程操作導致甲苯洩漏 400 公斤該事故屬於須提報的製程安全事件因為
化學物質洩漏已超過甲苯的 100 公斤提報恕限值
21 發生電氣火災停電或任何公用資源供應中斷可能造成工廠停工及可能引起設備損失超過
$2500 美元(如因非正常停工導致反應器或設備損壞)但並未造成超過恕限值的化學物質洩漏
亦未造成死亡或嚴重工傷該事故不屬於須提報的製程安全事件因為設備損壞並非化學製程火
災爆炸造成且化學物質洩漏並未超過恕限值
海上運輸船
22 一艘由公司營運的海上運輸船在船上發生ldquo急性rdquo易燃物質外洩洩漏量超過 100 公斤該事故不
屬於須提報的製程安全事件因為除非海上運輸船是為了輸送半成品或產品而與煉油石化或化
學製造廠的設施相連接否則其洩漏事故便不被視為製程安全事件
23 一艘第三方駁船由一艘拖船推向碼頭結果撞上公司的碼頭駁船的一個船艙破裂且造成
1000 公斤柴油洩漏到海中該事故不屬於須提報的製程安全事件因為駁船當時並非停泊在碼
頭內且其作業並非在進行半成品或產品之輸送
卡車與軌道車
24 一輛公司的軌道車在運輸途中出軌造成超過 1000 公斤汽油洩漏該事故不屬於須提報的製程
安全事件因為在公司廠區外發生的軌道車事故不被視為與製程安全有關
23
25 一輛第三方卡車拖車在公司廠區內翻覆造成ldquo急性rdquo汽油洩漏超過 1000 公斤這事故不屬於須
提報的製程安全事件因為卡車拖車當時已不再與裝卸設備連接然而我們建議會員公司另
行訂定運輸安全事故指標將這類事故記錄下來
26 一位合約卡車作業者正在卸載液鹼時發生軟管脫落造成空氣中氣霧和或液鹼液洩漏 2500 公
斤該事故屬於須提報的製程安全事件因為洩漏量已超過液鹼的 100 公斤恕限值且事故發生
前卡車仍與裝卸設備相連接著
辦公建築
27 綜合辦公大樓發生鍋爐火災造成總計$75000 美元的直接成本損失該事故不屬於須提報的製
程安全事件因為辦公大樓事故不被視為與製程安全有關
人機介面事故
28 一名操作技術員在聚合物工廠的終端設備旁作業時受傷這傷害是因機械的人機介面的設備而
造成該事故不屬於須提報的製程安全事件因為技術員受傷並非因危險物質一次阻絕設施失效
而造成的
混合物
29 若混合物本身有 GHS 分類可利用其分類確定恕限值若混合物本身沒有 GHS 分類則可計算混
合物中每個單一組成分之洩漏量(公斤)相對於個別成分恕限值之比值作為其對混合物恕限值之
lsquo加權rsquo貢獻譬如若混合物在 1小時內的洩漏量為 100公斤其中包含 05公斤分類為劇毒 H300
的物質45 公斤分類為 H301 的物質40 公斤另一種分類為 H 開頭的物質其餘 55 公斤則為沒
有 GHS 分類的水分此混合物之計算式為051 + 4510 + 40100 = 05 + 045 + 04 = 135超過
1因此該事故被視為須提報的製程安全事件雖然混合物個別成分之洩漏量均未超過各該物質
本身的恕限值
直接損失成本
30 此一門檻所考慮的成本應為可直接歸因於火災或爆炸的成本譬如設備及結構損壞的重置成本
修理成本環境清理支出緊急應變和罰款直接成本不包括間接成本譬如業務機會損失設
備停機造成之利潤損失取得或運轉臨時設施之成本或為滿足顧客需求取得替代產品的成本
(產品損失)
24
31 範例連接到氣體處理系統的排放管發生易燃氣體外漏同時製程出現問題導致空氣進入同
一條排放管結果發生爆炸過高的壓力損壞了排放管及其相關上游設備包括一個密封罐並
未造成人員受傷修理成本約$12000 美元該事故屬於須提報的製程安全事件因為爆炸及火
災導致設備修理成本超過門檻
32 範例一次製程安全事件後公司又發生一種非常特殊的 GHS 第 5 類產品洩漏 50 公斤造成
$2000 美元的設備損失洩漏的產品是一種非常特別的混合物公司須負擔超過$50000 美元因
產品耗損而產生之材料成本該事故不屬於須提報的製程安全事件因為 GHS 第 5 類產品洩漏的
提報門檻為 100 公斤且產品耗損不被計入直接損失成本
天然災害
33 天然災害可能對化學製程作業構成重大風險且對製程設備造成損壞導致危害物質一次阻絕設
施失效當一種或多種天然災害被認為可能對工廠作業造成影響時製程安全和作業系統應從危
害及後果分析工廠機器設備設計公用設施失效及製程停工之操作程序緊急應變計畫及應變
措施等方面界定潛在風險進行防範
天然災害類型包括颶風及颱風(包括伴隨而來的風暴潮)水災龍捲風地震超強對流風暴(直
線風暴)野火火山爆發海嘯和山崩
若公司廠房設施遭遇天然災害且其後果觸發一種或以上提報門檻該事故便屬於須提報製程安
全事件
預防性公眾應變
34 預防性公眾應變是基於謹慎的態度所採取的一種措施譬如當發生一次阻絕設施失效時公司
可能在尚未進行任何評估(如方向與洩漏點的距離等等)前便要求全體工人就地避難又
如地方權責官員(如消防警察民防緊急應變管理部門)在獲報一家公司發生製程安全事件
後為防lsquo萬一rsquo風向改變或基於可能受到波及的人口敏感族群(如學童或老年人)可能在尚未接
獲明確資訊前便下令社區就地避難或疏散或採取公眾保護措施(如道路封閉)
製程附屬倉庫
35 製程附屬倉庫指的是位於廠內用於儲存將投入於生產製程或產自於製程之原料半成品或成品的
倉庫從製程的觀點看來製程附屬倉庫相當於一個大型儲槽但這些原料半成品或成品並不
是儲存在一的大型容器中而是裝在較小的容器裡(如太空包大桶桶罐等)
25
Appendix C ndash List of RCLG Taskforce Members
Name Affiliation
Peter Schmelzer Bayer CEFIC - Chairman
Americo Diniz Carvalho Neto Braskem
Bradford Johnson American Chemistry Council
David Cummings DuPont
Debra Phillips American Chemistry Council
Hans Schwarz BASF
Kathryn Walton Plastics and Chemicals Industries Association
Kazuyuki Akita Japanese Chemical Industry Association
Kelly Keim ExxonMobil Chemical Company API Representative
Kenan Stevick Dow
Kiyokazu Murata Japanese Chemical Industry Association
Larry Bowler SABIC
Lorna Young Chemical Industry Association of Canada
Louisa Nara Center for Chemical Process Safety
Luiz Shizuo Harayashiki Associaccedilatildeo Brasileira da Induacutestria Quiacutemica
Masatoshi Kumamoto Japanese Chemical Industry Association
Milton Lacerda Petrobras
Phil Scott Chemical Industries Association
Piet Knijff DSM European Process Safety Centre
Scott Donaldson and Eamon Chandler
Shell
Scott Wallace Olin Corporation
Shakeel Kadri Air Products and Chemicals Inc
26
附錄 D ndash 詳細活動時程表
2016 年 2017 年 2018 年 2019 年 2020 年
2 ndash 4 月
RCLG PS 先導計畫
5 月 ndash
針對準則進行調整釐清
6 月 向 RCLG 和 ICCA 董事會報
告先導計畫執行結果
7 ndash 12 月 RCLG 協會考量準
則並為其會員公司發展提報機制
如有需要RCLG可向 ICCA 申請能
力建立基金為會員公司舉辦製程安
全研習會
1 ndash 12 月
RCLG 協會開始向其會員公司蒐集製程安全數據
1 ndash 12 月
如有需要RCLG 各協會運用 RCLG 的基金及專
家舉辦製程安全及績效提報研習會
1 ndash 2 月
擁有數據的協會開始向RCLG 提報製程安全事件
(2017 年數據)
4 月 RCLG 檢討第一個提報循
環的結果挑戰及原始數據(內部)
6 月 RCLG 向 ICCA 董事會呈報
原始數據
7 ndash 12 月 必要時更新及調整準
則
如有需要RCLG 各協會運用 RCLG 的基金及專
家舉辦製程安全及績效提報研習會
1 ndash 2 月
擁有數據的協會開始向RCLG 提報製程安全事件
(2018 年數據)
4 月 RCLG 檢討第二個提報循
環的結果挑戰及原始數據(內部)
6 月 RCLG 向 ICCA 董事會呈報
原始數據
7 ndash 12 月 必要時更新及調整準
則
如有需要RCLG 協會運用 RCLG 的基金及專家
舉辦製程安全及績效提報研習會
1 ndash 2 月
所有協會開始向 RCLG 提報製程安全事件
製程安全事件提報成為
RCLG KPI 衡量指標建議基本集的一部分(2019 年數
據)
4 月 RCLG 檢討第二個提報循
環的結果挑戰及原始數據(內部考量外部提
報)
6 月 RCLG 向 ICCA 董事會呈報
原始數據
27
附錄 E ndash 選擇性 Excel 追蹤表
當會員公司開始追蹤製程安全事件時所有會員公司應採用單一表格以簡化數據分析同時讓所有公司均使用相同的追蹤表RCLG 設
計了一份選擇性追蹤表可供會員公司和協會先行利用之後他們可設計自己的追蹤表
在這裡下載追蹤表
ICCA Process Safety Event Tracking Sheetxlsx
本文件包含三個分頁分別是ldquo聯絡資料rdquoldquo調查表rdquo和儲存下拉式選單選項的ldquo請勿編輯rdquo分頁
備註
附錄 E 追蹤表僅供參考TRCA 將另行提供台灣版表格供會員公司提報
28
後語
台灣化學工業責任照顧協會(Taiwan Responsible Care Association TRCA)成立於 1998 年在台灣推行責任照顧制度已達 20 週年製造商成員
包括台灣主要上市上櫃化工公司會員公司化學品生產製造量約佔全國 80 2016 年台灣化工業的 Chemical Sales 仍站在全球第八名的位
置額度為 630 億歐元化工業總產值達到 34 兆新台幣提供國內 416 萬人工作機會
TRCA 扮演國內廠商與國際制度接軌的角色也是國內化工業與政府機關及利益相關者溝通的橋樑與管道TRCA 會員結構依業務性質分析
涵蓋石化生產化學品製造氣體生產倉儲運輸業化學品貿易業以及工程研發設計等公司TRCA 透過供應鏈及價值鏈推行責任
照顧制度組成毒性化學物質聯防組織協助法規溝通與研析會員名冊請參考 httpwwwtrcaorgtwtrcanwork2aspx
TRCA 於 2010 年成為 ICCA (International Council of Chemical Associations 國際化學工業協會)觀察員ICCA 成立於 1989 年是全球化工製造
業的聯合會也是化學工業與 UNEP OPCW 及 OECD 的交流窗口ICCA 與其會員協會及成員公司致力於邁向永續的未來確保人類健康與
環境安全與保護全球化工業擁有超過 4兆美元的價值影響所有經濟部門ICCA 的會員幾乎在全球每個國家都有商業活動在全球六大
洲推動創新並提供超過 2000 萬個工作機會
台灣化工業在全球占有重要的一席之地在國內產業鏈也位居關鍵位置無論對國內或國際都有身為地球村一員應盡之責我們期許藉由
製程安全指標提報能更進一步提升自我在工安衛生環保與永續發展等面向的績效表現
台灣化學工業責任照顧協會
10452 台北市中山區撫順街 8 號 7 樓
電話02-2585-0552
httpwwwtrcaorgtw
None | |
$2500 to $25000 | |
$25000 to $250000 | |
$250000 to $25000000 | |
More than $25000000 | |
Yes - Using GHS TABLE | |
Yes - Using API RP 754 TABLE | |
NO | |
NA | |
1x le TQ lt 40x | |
40x le TQ lt 160x | |
160x le TQ lt 640x | |
ge 640x TQ | |
Yes le 3 hours | |
Yes 3 hours ge 12 hours | |
Yes 12 hours ge 24 hours | |
Yes ge 24 hours | |
No | |
Small-scale | |
Medium-scale | |
Large-scale | |
No | |
Yes | |
No | |
middot Injury requiring treatment beyond first aid to an employee contractor or subcontractor | |
middot Days Away From Work injury to an employee contractor or subcontractor or middot Injury requiring treatment beyond first aid to a third party | |
middot A fatality of an employee contractor or subcontractor or middot A hospital admission of a third party | |
middot Multiple fatalities of employees contractors or subcontractors or middot multiple hospital admission of third parties or middot A fatality of a third party | |
NA | |
1x le TQ lt 3x | |
3x le TQ lt 9x | |
9x le TQ lt 27x | |
ge 27x TQ |
ICCA Process Safety Pilot Reporting ProgramFebruary 8 2016 | 1 | 2 | 3 | 4 | 5 | 6 | 7 | 8 | 9 | 10 | 12 | 13 | 14 | 15 | |||||||||||||||||||||||
SAFETY Details(Meeting Local Regulations) | Direct Cost from Fire or Explosion | Community Impact | Environmental Impact | Material Released(Measured using the 1 Hour Rule) | |||||||||||||||||||||||||||||||||
Company Association Details | |||||||||||||||||||||||||||||||||||||
GHS | API - RP 754 | ||||||||||||||||||||||||||||||||||||
Company or Assocation Name | Headquarter Association | Location of Event Ex - City State amp Country | Date and Time of Event | Safety InjuryDid the Event result in a Recordable Lost Time Accident or Fatality or Hospital admission of anyone on or off siteUse Drop Down Menu | Safety InjuryIf yes please insert the total number of injuries | Safety InjuryFor puropses of utilizing the Severity Table please indicate the level of severity by chosing the MOST SEVERE classification that describes your incidentUse Drop Down Menu | Safety InjuryDid the incident involve Fatalities If so how many total fatalities If none enter Zero | Safety InjuryPlease Report Total Employee Hours for Calendar Year 2015 | Safety InjuryPlease Report Total Contractor Hours for Calendar Year 2015 | Direct Cost Did the Event result in Direct Damage CostUse Drop Down Menu | Direct Cost If so how muchAmount is in US DollarsUse Drop Down Menu | Community ImpactDid the event result inbull Officially declared shelter-in-place or officially declared evacuation (on or off site)ORbull Precautionary off site shelter in place or evacuation Use Drop Down Menu | Environmental ImpactDid the event result inAcute Environmental Remediation CostIf so indicate the amount in US DollarsUse Drop Down Menu | Material ReleasedDid the Event result in an Acute Release of material beyond one of the two threshold tablesIf so indicate which Threshold Table you used to make this determinationUse Drop Down Menu | Material ReleasedIf so indicate the amount released USING GHS CLASSIFICATION TABLEUse Drop Down Menu | Material ReleasedIf so indicate the amount released USING THE THRESHOLD TABLE FROM API RP-754Use Drop Down Menu | Material ReleasedIf available please indicate the material released | ||||||||||||||||||||
1 | ABC Chemical Company | American Chemistry Council | Washington DC - USA | January 4 2016 | Yes | 2 | middot Days Away From Work injury to an employee contractor or subcontractor or middot Injury requiring treatment beyond first aid to a third party | 0 | 5525000 | 1500250 | No | $2500 to $25000 | Yes le 3 hours | $2500 to $25000 | Yes - Using GHS TABLE | 40x le TQ lt 160x | NA | Chlorine | |||||||||||||||||||
2 | XYZ Chemical Company | American Chemistry Council | Washington DC - USA | 5-Jan-16 | Yes | 1 | middot Injury requiring treatment beyond first aid to an employee contractor or subcontractor | 0 | 5525000 | 1500250 | Yes | $2500 to $25000 | No | $2500 to $25000 | Yes - Using API RP 754 TABLE | NA | 3x le TQ lt 9x | Benzene | |||||||||||||||||||
3 | |||||||||||||||||||||||||||||||||||||
4 | |||||||||||||||||||||||||||||||||||||
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15 | |||||||||||||||||||||||||||||||||||||
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20 | |||||||||||||||||||||||||||||||||||||
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22 | |||||||||||||||||||||||||||||||||||||
23 | |||||||||||||||||||||||||||||||||||||
24 | |||||||||||||||||||||||||||||||||||||
25 | |||||||||||||||||||||||||||||||||||||
Zero or None | Yes - Duration Unknown | ||||||||||||||||||||||||||||||||||||
Processes | Mode of Operation | Type of material released | Status of Operation | ||||
REFINING | Start-up | Flammable | Open | ||||
Alkylation HF | Planned shutdown | Combustible | Closed | ||||
Alkylation sulfuric | Emergency shutdown | Toxic | |||||
BitumenResidAsphalt | Normal | Corrosive | Tier 1 Acute Releases | ||||
Calcining | Upset | Utilities | No Release | ||||
Coking | Turnaround | Other | Category 1 | ||||
Crude | Routine maintenance | Category 2 | |||||
Desulfurization | Temporary | Evacuation | Category 3 | ||||
FCC | Other | Yes | Category 4 | ||||
Gas Treating | No | Category 5 | |||||
Hydrogen | Point of Release | Category 6 | |||||
Hydrotreating | Pump | Fire | Category 7 | ||||
Hydrocracking | Compressor | Yes | Multiple Categories | ||||
Isom | BlowerFan | No | |||||
MarineJetty | Pressure Vessel | lt $2500 | |||||
Reforming | FilterCoalescer | ||||||
Sulfur recovery | Furnace | PRDs | |||||
Vapor recoverylight ends | Boiler | Directly to Atmosphere | |||||
Wastewater | Heat exchanger | via Downstream Destructive Device | |||||
REFINING amp PETROCHEMICAL | Cooling Tower | No | |||||
Tank FarmStorage FacilityOffsite | Piping system | Yes | |||||
UtilitiesSteam PlantCogeneration | Reactor | No | |||||
Other | Atmospheric tank | ||||||
PETROCHEMICAL | FlareRelief System | Acute release above thresholds | |||||
CO H2 | Other | Yes | |||||
LNG | No | ||||||
Methane | Events | ||||||
Methanol | No Tier 1 Events | Indoor Outdoor | |||||
Methyl Mercaptan | No Tier 2 Events | No Release | |||||
Formaldehyde | No Tier 1 or Tier 2 Events | Indoor | |||||
Formaldehyde derivatives | NA | Outdoor | |||||
Acetic Acid | |||||||
Acetic Acid derivatives | Event Type | ||||||
Ethane | Injury | ||||||
Ethylene | Fire | ||||||
Ethanol | Explosion | ||||||
Ethylene oxide | PRD Discharge | ||||||
Ethylene derivatives | Acute Release | ||||||
Polyethylene | |||||||
Ethylene dichloride | General | ||||||
Ethylene dichloride derivatives | Yes | ||||||
Ethyl benzene | No | ||||||
Ethyl benzene derivatives | |||||||
Polystyrene | |||||||
Styrene-Butadiene | |||||||
Propane | |||||||
Propylene | |||||||
Polypropylene | |||||||
Isopropanol | |||||||
Propylene oxide | |||||||
Propylene oxide derivatives | |||||||
Butane | |||||||
Isobutane | |||||||
Isobutene | |||||||
Butadiene | |||||||
MTBE | |||||||
ETBE | |||||||
Pentane | |||||||
Hexane | |||||||
Cyclohexane | |||||||
Hexanol | |||||||
Aromatics Derivatives | |||||||
Benzene | |||||||
Toluene | |||||||
Xylene | |||||||
Para Xylene | |||||||
Amines Derivatives | |||||||
TDA MDA IPDA etc | |||||||
Isocyanates | |||||||
Specialty Chemicals | |||||||
LoadingUnloading | |||||||
Pilot Plant |
Instructions | ||||||||||||||
Step 1 | Complete the Contact Tab with your contact information and company information | |||||||||||||
Be sure to note the region of your reporting (IE North America France Japan etc) | ||||||||||||||
Survey on Process Safety Events | ||||||||||||||
Step 2 | Complete the survey one line per Process Safety Event for your companyregion | |||||||||||||
ALL REPORTED DATA SHOULD BE FROM CALENDAR YEAR 2017 | ||||||||||||||
Step 3 | Return completed survey to | |||||||||||||
Company Name | ||||||||||||||
Contact Person | All Surveys Due by xxx date | |||||||||||||
Address | ||||||||||||||
Fax | ||||||||||||||
Telephone | ||||||||||||||
Region | ||||||||||||||
None | |
$2500 to $25000 | |
$25000 to $250000 | |
$250000 to $25000000 | |
More than $25000000 | |
Yes - Using GHS TABLE | |
Yes - Using API RP 754 TABLE | |
NO | |
NA | |
1x le TQ lt 40x | |
40x le TQ lt 160x | |
160x le TQ lt 640x | |
ge 640x TQ | |
Yes le 3 hours | |
Yes 3 hours ge 12 hours | |
Yes 12 hours ge 24 hours | |
Yes ge 24 hours | |
No | |
Small-scale | |
Medium-scale | |
Large-scale | |
No | |
Yes | |
No | |
middot Injury requiring treatment beyond first aid to an employee contractor or subcontractor | |
middot Days Away From Work injury to an employee contractor or subcontractor or middot Injury requiring treatment beyond first aid to a third party | |
middot A fatality of an employee contractor or subcontractor or middot A hospital admission of a third party | |
middot Multiple fatalities of employees contractors or subcontractors or middot multiple hospital admission of third parties or middot A fatality of a third party | |
NA | |
1x le TQ lt 3x | |
3x le TQ lt 9x | |
9x le TQ lt 27x | |
ge 27x TQ |
ICCA Process Safety Pilot Reporting ProgramFebruary 8 2016 | 1 | 2 | 3 | 4 | 5 | 6 | 7 | 8 | 9 | 10 | 12 | 13 | 14 | 15 | |||||||||||||||||||||||
SAFETY Details(Meeting Local Regulations) | Direct Cost from Fire or Explosion | Community Impact | Environmental Impact | Material Released(Measured using the 1 Hour Rule) | |||||||||||||||||||||||||||||||||
Company Association Details | |||||||||||||||||||||||||||||||||||||
GHS | API - RP 754 | ||||||||||||||||||||||||||||||||||||
Company or Assocation Name | Headquarter Association | Location of Event Ex - City State amp Country | Date and Time of Event | Safety InjuryDid the Event result in a Recordable Lost Time Accident or Fatality or Hospital admission of anyone on or off siteUse Drop Down Menu | Safety InjuryIf yes please insert the total number of injuries | Safety InjuryFor puropses of utilizing the Severity Table please indicate the level of severity by chosing the MOST SEVERE classification that describes your incidentUse Drop Down Menu | Safety InjuryDid the incident involve Fatalities If so how many total fatalities If none enter Zero | Safety InjuryPlease Report Total Employee Hours for Calendar Year 2015 | Safety InjuryPlease Report Total Contractor Hours for Calendar Year 2015 | Direct Cost Did the Event result in Direct Damage CostUse Drop Down Menu | Direct Cost If so how muchAmount is in US DollarsUse Drop Down Menu | Community ImpactDid the event result inbull Officially declared shelter-in-place or officially declared evacuation (on or off site)ORbull Precautionary off site shelter in place or evacuation Use Drop Down Menu | Environmental ImpactDid the event result inAcute Environmental Remediation CostIf so indicate the amount in US DollarsUse Drop Down Menu | Material ReleasedDid the Event result in an Acute Release of material beyond one of the two threshold tablesIf so indicate which Threshold Table you used to make this determinationUse Drop Down Menu | Material ReleasedIf so indicate the amount released USING GHS CLASSIFICATION TABLEUse Drop Down Menu | Material ReleasedIf so indicate the amount released USING THE THRESHOLD TABLE FROM API RP-754Use Drop Down Menu | Material ReleasedIf available please indicate the material released | ||||||||||||||||||||
1 | ABC Chemical Company | American Chemistry Council | Washington DC - USA | January 4 2016 | Yes | 2 | middot Days Away From Work injury to an employee contractor or subcontractor or middot Injury requiring treatment beyond first aid to a third party | 0 | 5525000 | 1500250 | No | $2500 to $25000 | Yes le 3 hours | $2500 to $25000 | Yes - Using GHS TABLE | 40x le TQ lt 160x | NA | Chlorine | |||||||||||||||||||
2 | XYZ Chemical Company | American Chemistry Council | Washington DC - USA | 5-Jan-16 | Yes | 1 | middot Injury requiring treatment beyond first aid to an employee contractor or subcontractor | 0 | 5525000 | 1500250 | Yes | $2500 to $25000 | No | $2500 to $25000 | Yes - Using API RP 754 TABLE | NA | 3x le TQ lt 9x | Benzene | |||||||||||||||||||
3 | |||||||||||||||||||||||||||||||||||||
4 | |||||||||||||||||||||||||||||||||||||
5 | |||||||||||||||||||||||||||||||||||||
6 | |||||||||||||||||||||||||||||||||||||
7 | |||||||||||||||||||||||||||||||||||||
8 | |||||||||||||||||||||||||||||||||||||
9 | |||||||||||||||||||||||||||||||||||||
10 | |||||||||||||||||||||||||||||||||||||
11 | |||||||||||||||||||||||||||||||||||||
12 | |||||||||||||||||||||||||||||||||||||
13 | |||||||||||||||||||||||||||||||||||||
14 | |||||||||||||||||||||||||||||||||||||
15 | |||||||||||||||||||||||||||||||||||||
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17 | |||||||||||||||||||||||||||||||||||||
18 | |||||||||||||||||||||||||||||||||||||
19 | |||||||||||||||||||||||||||||||||||||
20 | |||||||||||||||||||||||||||||||||||||
21 | |||||||||||||||||||||||||||||||||||||
22 | |||||||||||||||||||||||||||||||||||||
23 | |||||||||||||||||||||||||||||||||||||
24 | |||||||||||||||||||||||||||||||||||||
25 | |||||||||||||||||||||||||||||||||||||
Zero or None | Yes - Duration Unknown | ||||||||||||||||||||||||||||||||||||
Processes | Mode of Operation | Type of material released | Status of Operation | ||||
REFINING | Start-up | Flammable | Open | ||||
Alkylation HF | Planned shutdown | Combustible | Closed | ||||
Alkylation sulfuric | Emergency shutdown | Toxic | |||||
BitumenResidAsphalt | Normal | Corrosive | Tier 1 Acute Releases | ||||
Calcining | Upset | Utilities | No Release | ||||
Coking | Turnaround | Other | Category 1 | ||||
Crude | Routine maintenance | Category 2 | |||||
Desulfurization | Temporary | Evacuation | Category 3 | ||||
FCC | Other | Yes | Category 4 | ||||
Gas Treating | No | Category 5 | |||||
Hydrogen | Point of Release | Category 6 | |||||
Hydrotreating | Pump | Fire | Category 7 | ||||
Hydrocracking | Compressor | Yes | Multiple Categories | ||||
Isom | BlowerFan | No | |||||
MarineJetty | Pressure Vessel | lt $2500 | |||||
Reforming | FilterCoalescer | ||||||
Sulfur recovery | Furnace | PRDs | |||||
Vapor recoverylight ends | Boiler | Directly to Atmosphere | |||||
Wastewater | Heat exchanger | via Downstream Destructive Device | |||||
REFINING amp PETROCHEMICAL | Cooling Tower | No | |||||
Tank FarmStorage FacilityOffsite | Piping system | Yes | |||||
UtilitiesSteam PlantCogeneration | Reactor | No | |||||
Other | Atmospheric tank | ||||||
PETROCHEMICAL | FlareRelief System | Acute release above thresholds | |||||
CO H2 | Other | Yes | |||||
LNG | No | ||||||
Methane | Events | ||||||
Methanol | No Tier 1 Events | Indoor Outdoor | |||||
Methyl Mercaptan | No Tier 2 Events | No Release | |||||
Formaldehyde | No Tier 1 or Tier 2 Events | Indoor | |||||
Formaldehyde derivatives | NA | Outdoor | |||||
Acetic Acid | |||||||
Acetic Acid derivatives | Event Type | ||||||
Ethane | Injury | ||||||
Ethylene | Fire | ||||||
Ethanol | Explosion | ||||||
Ethylene oxide | PRD Discharge | ||||||
Ethylene derivatives | Acute Release | ||||||
Polyethylene | |||||||
Ethylene dichloride | General | ||||||
Ethylene dichloride derivatives | Yes | ||||||
Ethyl benzene | No | ||||||
Ethyl benzene derivatives | |||||||
Polystyrene | |||||||
Styrene-Butadiene | |||||||
Propane | |||||||
Propylene | |||||||
Polypropylene | |||||||
Isopropanol | |||||||
Propylene oxide | |||||||
Propylene oxide derivatives | |||||||
Butane | |||||||
Isobutane | |||||||
Isobutene | |||||||
Butadiene | |||||||
MTBE | |||||||
ETBE | |||||||
Pentane | |||||||
Hexane | |||||||
Cyclohexane | |||||||
Hexanol | |||||||
Aromatics Derivatives | |||||||
Benzene | |||||||
Toluene | |||||||
Xylene | |||||||
Para Xylene | |||||||
Amines Derivatives | |||||||
TDA MDA IPDA etc | |||||||
Isocyanates | |||||||
Specialty Chemicals | |||||||
LoadingUnloading | |||||||
Pilot Plant |
Instructions | ||||||||||||||
Step 1 | Complete the Contact Tab with your contact information and company information | |||||||||||||
Be sure to note the region of your reporting (IE North America France Japan etc) | ||||||||||||||
Survey on Process Safety Events | ||||||||||||||
Step 2 | Complete the survey one line per Process Safety Event for your companyregion | |||||||||||||
ALL REPORTED DATA SHOULD BE FROM CALENDAR YEAR 2017 | ||||||||||||||
Step 3 | Return completed survey to | |||||||||||||
Company Name | ||||||||||||||
Contact Person | All Surveys Due by xxx date | |||||||||||||
Address | ||||||||||||||
Fax | ||||||||||||||
Telephone | ||||||||||||||
Region | ||||||||||||||
19
附錄 B ndash 常見問題集
適用性
我們建議會員公司記錄和提報在其所擁有或運作的工廠內發生的製程安全事件惟以下情況不須提報製
程安全事件
1 源自於公司廠區以外的製程安全事件
2 海上運輸船事故惟船隻為了輸送半成品或產品之目的已經與公司的設施相連接時發生的
事故仍須提報
3 卡車或軌道車事故惟卡車或軌道車為了輸送半成品或產品之目的已經與公司的設施相連
接時發生的事故仍須提報
4 許可證或法規容許之例行排放
5 不會造成製程安全危害的地下污染請注意若洩漏至地下導致地上發生須提報製程安全事
件如釋放出毒性蒸汽或致使易燃液體蓄積成池則不適用本排除條件
6 辦公建築事故(如辦公室暖氣設備爆炸火災外溢洩漏人員受傷或疾病等)
7 與疏散或一次阻絕設施失效無直接關聯之人員安全ldquo滑倒絆倒跌倒rdquo事故
8 沒有與製程相連接之輔助設備的一次阻絕設施(如小樣品瓶)失效事故
9 計劃中和在控制下的物質排放至設計用來收集或排放系統中(請注意物質從一次阻絕設施
在非計劃或非受控制情況下排放至收集或排放系統中則不適用本排除條件)
10 在製程區域外部或保養廠內執行之機械作業
說明與實例 ndash 以 GHS 表 1 為基礎
以下說明和實例有助於在評估須提報製程安全事件(PSE)時釐清可能存在的不確定部分
公司廠區
1 一輛第三方的卡車在公司廠區內卸載易燃產品時發生洩漏進而引起火災造成公司財物損失
$7000 美元(直接成本)雖然該卡車是ldquo由他人操作rdquo但其作業與製程相連接若公司的直接成
本財物損失達到或超過$2500 美元或已達到或超過其他 PSE 提報門檻(如1 人死亡)此事故即
屬於須提報的製程安全事件
2 與前例1 類似的例子載著易燃產品的卡車在廠外運輸途中翻覆引發火災並造成卡車毀損
該事故不屬於須提報的製程安全事件因為當時卡車並未與製程相連接
20
阻絕設施失效
3 儲槽液位計故障造成裝有ldquo易燃液體rdquo產品的儲槽外溢約 700 公斤的液體流入儲槽的防溢堤內
此事故屬於須提報的製程安全事件因為其ldquo急性rdquo洩漏量超過 100 公斤即使是阻絕在二次阻絕
設施防溢堤中亦然
4 一名從事維修工作的承攬商在開啟一個製程阻閥時被噴起的硫酸濺到造成嚴重灼傷和損失工
時的工傷此事故屬於須提報的製程安全事件因為它是涉及物質和一次阻絕設施失效的意外事
件對於因洩漏造成死亡和損工的工傷或疾病事故沒有洩漏恕限值
5 一名作業員開啟品管取樣點進行日常取樣作業時手部被一個破碎的玻璃瓶嚴重割破需要進行
縫合治療縫針造成第二天無法上班該事故不屬於須提報的製程安全事件因為它與一次阻絕
設施失效無關
ldquo急性rdquo洩漏
6 一名作業員在進行天然氣流量高於預期值之異常排除時發現天然氣管線上的一個安全閥門未適
當歸位因此天然氣經由氣液分離桶排放至排氣煙囪經進一步檢查作業員判斷在過去 6 個
月間總共有 100000 公斤天然氣以穩定的速率排放至大氣該事故不屬於須提報的製程安全事
件因為其洩漏速率(每小時約 10 公斤)不算ldquo急性rdquo洩漏(未超過易燃蒸汽每小時 100 公斤的恕限
值)
廢氣燃燒塔amp排放控制裝置 (如洗滌塔)
7 若化學物質被導引至廢氣燃燒塔或排放控制裝置(如洗滌塔)只要該廢氣燃燒塔或控制裝置運作在
正常設計範圍內便不屬於須提報的製程安全事件
8 若廢氣流速超過洗滌塔的設計負荷以致未經吸收的化學物質排出超過恕限值該事故屬於須提報
的製程安全事件(如本文註釋所述)
註釋自取得許可或妥善管理的裝置-包括釋壓裝置發生不預期的排放若 1 小時內洩漏量達到或
超過表 1 或表 2 所列的洩漏恕限值且導致下列四種後果之任一項或以上之後果該事故便屬於
須提報的製程安全事件
o 二相排放或夾帶液體的排放液滴沉降至地面造成污染
o 排放至具潛在危險性的地點)
o 廠內就地避難或疏散不包括預防性廠內就地避難或疏散
o 啟動公眾保護措施(如道路封閉)包括預防性公眾保護措施
21
安全洩壓裝置 系統
9 製程單元發生異常安全閥開啟將洩漏物質釋放到排氣口此釋壓排放裝置是依相關要求設計
的且氣體釋到大氣中並未造成不良後果這不是一個須提報的製程安全事件因為安全閥高
壓破裂盤以及類似的安全裝置是依據 API 521 或者同等的標準設計的且此排放並未造成 (1)
夾帶液體並導致須提報的製程安全事件的後果(譬如損失工時意外死亡火災或爆炸造成$2500
美元或以上的直接成本損失液體或毒性氣體洩漏量達到或超過恕限值(2) 啟動廠內或廠外就地
避難應變或(3)啟動公眾保護措施
10 製程單元發生異常安全閥並未開啟造成設備超壓易燃性氣體從一個法蘭處ldquo急性rdquo漏出來
洩露量超過 100 公斤(一小時內)的恕限值該事故屬於須提報的製程安全事件因為從法蘭處外
漏屬於製程安全事件應提報事項
損工事故
11 一名作業員走路時不慎滑倒造成損失工時之工傷滑倒原因為天氣狀況rdquo長期rdquo油垢的地面和
易滑鞋具該事故不屬於須提報的製程安全事件因為人員安全ldquo滑倒絆倒跌倒rdquo事故若非與
一次阻絕設施失效直接關聯的疏散或應變造成則不屬於須提報的製程安全事件
12 與前例相同的事件惟這次作業員跌倒是因為少量易燃液體外漏(如 1 小時內少於 10 公斤)在採取
相關應變措施時發生該事故屬於須提報的製程安全事件因為作業員係為了應變一次阻絕設施
失效的事故而跌倒若一次阻絕設施失效發生在公司廠區且造成失時工傷或死亡後果該事故
便屬於須提報的製程安全事件對於因洩漏造成死亡和損失工時之工傷事故沒有洩漏量門檻
13 與前例相同的事件惟這次作業員跌倒是在事件結束數小時之後該事故不屬於須提報的製程安
全事件在提報要件中所用的ldquo疏散rdquo和ldquo應變rdquo等術語指的是一次阻絕設施失效和相關緊急應變
活動正在持續中事件結束後滑倒絆倒跌倒(如ldquo事後rdquo清理和補救)不屬於須提報製程安全事件
14 工人在因附近設備一次阻絕設施失效在疏散過程中一名鷹架搭建工人從鷹架梯上跌落造成損
失工時之工傷該事故屬於須提報的製程安全事件
15 一名作業員行經一個設計不良的蒸汽卻水器時被外洩的蒸汽燙傷腳踝造成損失工時之工傷
該事故屬於須提報的製程安全事件因為雖然一次阻絕設施失效洩漏出的是蒸汽(而非碳氫化合物
或化學物質)但損失工時之工傷是由於洩漏物質的物理狀態所導致的
16 一個密閉空間依照計畫以氮氣吹清一名承攬商繞過安全管制進入該密閉空間因而死亡該事
故屬於須提報的死亡事件但不屬於須提報的製程安全事件因為其中不涉及非計劃或失控的一
次阻絕設施失效
17 情況同上惟這次氮氣是非刻意洩漏進入該局限空間該事故屬於須提報的製程安全事件(同時也
是一起死亡事件)因為該名承攬商的死亡與非計劃的一次阻絕設施失效有關
22
18 一名作業員因硫化氫(H2S)警報在進行應變處理時昏倒若警報確實是因非計劃或失控的 H2S 一次
阻絕設施失效的外洩事件該事故便屬於須提報的製程安全事件若警報是一個假警報則該事
故便不屬於須提報的製程安全事件因為沒有真正的化學品洩漏發生
管線
19 一條管線破漏1 小時內洩漏 2000 磅(900 公斤)易燃蒸氣到地面但洩漏位置在廠區內很偏僻的
地點該事故仍屬於須提報的製程安全事件因為ldquo偏僻rdquo不是提報與否的考量因素
與化學物質外洩無關之火災或能量釋放事故
一般通則而言唯有當火災或能量釋放事故是因化學物質洩漏所造成或其發生導致化學物質洩漏
超過提報恕限值這些事故才屬於須提報的製程安全事件實例包括
20 一場電氣火災影響製程操作導致甲苯洩漏 400 公斤該事故屬於須提報的製程安全事件因為
化學物質洩漏已超過甲苯的 100 公斤提報恕限值
21 發生電氣火災停電或任何公用資源供應中斷可能造成工廠停工及可能引起設備損失超過
$2500 美元(如因非正常停工導致反應器或設備損壞)但並未造成超過恕限值的化學物質洩漏
亦未造成死亡或嚴重工傷該事故不屬於須提報的製程安全事件因為設備損壞並非化學製程火
災爆炸造成且化學物質洩漏並未超過恕限值
海上運輸船
22 一艘由公司營運的海上運輸船在船上發生ldquo急性rdquo易燃物質外洩洩漏量超過 100 公斤該事故不
屬於須提報的製程安全事件因為除非海上運輸船是為了輸送半成品或產品而與煉油石化或化
學製造廠的設施相連接否則其洩漏事故便不被視為製程安全事件
23 一艘第三方駁船由一艘拖船推向碼頭結果撞上公司的碼頭駁船的一個船艙破裂且造成
1000 公斤柴油洩漏到海中該事故不屬於須提報的製程安全事件因為駁船當時並非停泊在碼
頭內且其作業並非在進行半成品或產品之輸送
卡車與軌道車
24 一輛公司的軌道車在運輸途中出軌造成超過 1000 公斤汽油洩漏該事故不屬於須提報的製程
安全事件因為在公司廠區外發生的軌道車事故不被視為與製程安全有關
23
25 一輛第三方卡車拖車在公司廠區內翻覆造成ldquo急性rdquo汽油洩漏超過 1000 公斤這事故不屬於須
提報的製程安全事件因為卡車拖車當時已不再與裝卸設備連接然而我們建議會員公司另
行訂定運輸安全事故指標將這類事故記錄下來
26 一位合約卡車作業者正在卸載液鹼時發生軟管脫落造成空氣中氣霧和或液鹼液洩漏 2500 公
斤該事故屬於須提報的製程安全事件因為洩漏量已超過液鹼的 100 公斤恕限值且事故發生
前卡車仍與裝卸設備相連接著
辦公建築
27 綜合辦公大樓發生鍋爐火災造成總計$75000 美元的直接成本損失該事故不屬於須提報的製
程安全事件因為辦公大樓事故不被視為與製程安全有關
人機介面事故
28 一名操作技術員在聚合物工廠的終端設備旁作業時受傷這傷害是因機械的人機介面的設備而
造成該事故不屬於須提報的製程安全事件因為技術員受傷並非因危險物質一次阻絕設施失效
而造成的
混合物
29 若混合物本身有 GHS 分類可利用其分類確定恕限值若混合物本身沒有 GHS 分類則可計算混
合物中每個單一組成分之洩漏量(公斤)相對於個別成分恕限值之比值作為其對混合物恕限值之
lsquo加權rsquo貢獻譬如若混合物在 1小時內的洩漏量為 100公斤其中包含 05公斤分類為劇毒 H300
的物質45 公斤分類為 H301 的物質40 公斤另一種分類為 H 開頭的物質其餘 55 公斤則為沒
有 GHS 分類的水分此混合物之計算式為051 + 4510 + 40100 = 05 + 045 + 04 = 135超過
1因此該事故被視為須提報的製程安全事件雖然混合物個別成分之洩漏量均未超過各該物質
本身的恕限值
直接損失成本
30 此一門檻所考慮的成本應為可直接歸因於火災或爆炸的成本譬如設備及結構損壞的重置成本
修理成本環境清理支出緊急應變和罰款直接成本不包括間接成本譬如業務機會損失設
備停機造成之利潤損失取得或運轉臨時設施之成本或為滿足顧客需求取得替代產品的成本
(產品損失)
24
31 範例連接到氣體處理系統的排放管發生易燃氣體外漏同時製程出現問題導致空氣進入同
一條排放管結果發生爆炸過高的壓力損壞了排放管及其相關上游設備包括一個密封罐並
未造成人員受傷修理成本約$12000 美元該事故屬於須提報的製程安全事件因為爆炸及火
災導致設備修理成本超過門檻
32 範例一次製程安全事件後公司又發生一種非常特殊的 GHS 第 5 類產品洩漏 50 公斤造成
$2000 美元的設備損失洩漏的產品是一種非常特別的混合物公司須負擔超過$50000 美元因
產品耗損而產生之材料成本該事故不屬於須提報的製程安全事件因為 GHS 第 5 類產品洩漏的
提報門檻為 100 公斤且產品耗損不被計入直接損失成本
天然災害
33 天然災害可能對化學製程作業構成重大風險且對製程設備造成損壞導致危害物質一次阻絕設
施失效當一種或多種天然災害被認為可能對工廠作業造成影響時製程安全和作業系統應從危
害及後果分析工廠機器設備設計公用設施失效及製程停工之操作程序緊急應變計畫及應變
措施等方面界定潛在風險進行防範
天然災害類型包括颶風及颱風(包括伴隨而來的風暴潮)水災龍捲風地震超強對流風暴(直
線風暴)野火火山爆發海嘯和山崩
若公司廠房設施遭遇天然災害且其後果觸發一種或以上提報門檻該事故便屬於須提報製程安
全事件
預防性公眾應變
34 預防性公眾應變是基於謹慎的態度所採取的一種措施譬如當發生一次阻絕設施失效時公司
可能在尚未進行任何評估(如方向與洩漏點的距離等等)前便要求全體工人就地避難又
如地方權責官員(如消防警察民防緊急應變管理部門)在獲報一家公司發生製程安全事件
後為防lsquo萬一rsquo風向改變或基於可能受到波及的人口敏感族群(如學童或老年人)可能在尚未接
獲明確資訊前便下令社區就地避難或疏散或採取公眾保護措施(如道路封閉)
製程附屬倉庫
35 製程附屬倉庫指的是位於廠內用於儲存將投入於生產製程或產自於製程之原料半成品或成品的
倉庫從製程的觀點看來製程附屬倉庫相當於一個大型儲槽但這些原料半成品或成品並不
是儲存在一的大型容器中而是裝在較小的容器裡(如太空包大桶桶罐等)
25
Appendix C ndash List of RCLG Taskforce Members
Name Affiliation
Peter Schmelzer Bayer CEFIC - Chairman
Americo Diniz Carvalho Neto Braskem
Bradford Johnson American Chemistry Council
David Cummings DuPont
Debra Phillips American Chemistry Council
Hans Schwarz BASF
Kathryn Walton Plastics and Chemicals Industries Association
Kazuyuki Akita Japanese Chemical Industry Association
Kelly Keim ExxonMobil Chemical Company API Representative
Kenan Stevick Dow
Kiyokazu Murata Japanese Chemical Industry Association
Larry Bowler SABIC
Lorna Young Chemical Industry Association of Canada
Louisa Nara Center for Chemical Process Safety
Luiz Shizuo Harayashiki Associaccedilatildeo Brasileira da Induacutestria Quiacutemica
Masatoshi Kumamoto Japanese Chemical Industry Association
Milton Lacerda Petrobras
Phil Scott Chemical Industries Association
Piet Knijff DSM European Process Safety Centre
Scott Donaldson and Eamon Chandler
Shell
Scott Wallace Olin Corporation
Shakeel Kadri Air Products and Chemicals Inc
26
附錄 D ndash 詳細活動時程表
2016 年 2017 年 2018 年 2019 年 2020 年
2 ndash 4 月
RCLG PS 先導計畫
5 月 ndash
針對準則進行調整釐清
6 月 向 RCLG 和 ICCA 董事會報
告先導計畫執行結果
7 ndash 12 月 RCLG 協會考量準
則並為其會員公司發展提報機制
如有需要RCLG可向 ICCA 申請能
力建立基金為會員公司舉辦製程安
全研習會
1 ndash 12 月
RCLG 協會開始向其會員公司蒐集製程安全數據
1 ndash 12 月
如有需要RCLG 各協會運用 RCLG 的基金及專
家舉辦製程安全及績效提報研習會
1 ndash 2 月
擁有數據的協會開始向RCLG 提報製程安全事件
(2017 年數據)
4 月 RCLG 檢討第一個提報循
環的結果挑戰及原始數據(內部)
6 月 RCLG 向 ICCA 董事會呈報
原始數據
7 ndash 12 月 必要時更新及調整準
則
如有需要RCLG 各協會運用 RCLG 的基金及專
家舉辦製程安全及績效提報研習會
1 ndash 2 月
擁有數據的協會開始向RCLG 提報製程安全事件
(2018 年數據)
4 月 RCLG 檢討第二個提報循
環的結果挑戰及原始數據(內部)
6 月 RCLG 向 ICCA 董事會呈報
原始數據
7 ndash 12 月 必要時更新及調整準
則
如有需要RCLG 協會運用 RCLG 的基金及專家
舉辦製程安全及績效提報研習會
1 ndash 2 月
所有協會開始向 RCLG 提報製程安全事件
製程安全事件提報成為
RCLG KPI 衡量指標建議基本集的一部分(2019 年數
據)
4 月 RCLG 檢討第二個提報循
環的結果挑戰及原始數據(內部考量外部提
報)
6 月 RCLG 向 ICCA 董事會呈報
原始數據
27
附錄 E ndash 選擇性 Excel 追蹤表
當會員公司開始追蹤製程安全事件時所有會員公司應採用單一表格以簡化數據分析同時讓所有公司均使用相同的追蹤表RCLG 設
計了一份選擇性追蹤表可供會員公司和協會先行利用之後他們可設計自己的追蹤表
在這裡下載追蹤表
ICCA Process Safety Event Tracking Sheetxlsx
本文件包含三個分頁分別是ldquo聯絡資料rdquoldquo調查表rdquo和儲存下拉式選單選項的ldquo請勿編輯rdquo分頁
備註
附錄 E 追蹤表僅供參考TRCA 將另行提供台灣版表格供會員公司提報
28
後語
台灣化學工業責任照顧協會(Taiwan Responsible Care Association TRCA)成立於 1998 年在台灣推行責任照顧制度已達 20 週年製造商成員
包括台灣主要上市上櫃化工公司會員公司化學品生產製造量約佔全國 80 2016 年台灣化工業的 Chemical Sales 仍站在全球第八名的位
置額度為 630 億歐元化工業總產值達到 34 兆新台幣提供國內 416 萬人工作機會
TRCA 扮演國內廠商與國際制度接軌的角色也是國內化工業與政府機關及利益相關者溝通的橋樑與管道TRCA 會員結構依業務性質分析
涵蓋石化生產化學品製造氣體生產倉儲運輸業化學品貿易業以及工程研發設計等公司TRCA 透過供應鏈及價值鏈推行責任
照顧制度組成毒性化學物質聯防組織協助法規溝通與研析會員名冊請參考 httpwwwtrcaorgtwtrcanwork2aspx
TRCA 於 2010 年成為 ICCA (International Council of Chemical Associations 國際化學工業協會)觀察員ICCA 成立於 1989 年是全球化工製造
業的聯合會也是化學工業與 UNEP OPCW 及 OECD 的交流窗口ICCA 與其會員協會及成員公司致力於邁向永續的未來確保人類健康與
環境安全與保護全球化工業擁有超過 4兆美元的價值影響所有經濟部門ICCA 的會員幾乎在全球每個國家都有商業活動在全球六大
洲推動創新並提供超過 2000 萬個工作機會
台灣化工業在全球占有重要的一席之地在國內產業鏈也位居關鍵位置無論對國內或國際都有身為地球村一員應盡之責我們期許藉由
製程安全指標提報能更進一步提升自我在工安衛生環保與永續發展等面向的績效表現
台灣化學工業責任照顧協會
10452 台北市中山區撫順街 8 號 7 樓
電話02-2585-0552
httpwwwtrcaorgtw
None | |
$2500 to $25000 | |
$25000 to $250000 | |
$250000 to $25000000 | |
More than $25000000 | |
Yes - Using GHS TABLE | |
Yes - Using API RP 754 TABLE | |
NO | |
NA | |
1x le TQ lt 40x | |
40x le TQ lt 160x | |
160x le TQ lt 640x | |
ge 640x TQ | |
Yes le 3 hours | |
Yes 3 hours ge 12 hours | |
Yes 12 hours ge 24 hours | |
Yes ge 24 hours | |
No | |
Small-scale | |
Medium-scale | |
Large-scale | |
No | |
Yes | |
No | |
middot Injury requiring treatment beyond first aid to an employee contractor or subcontractor | |
middot Days Away From Work injury to an employee contractor or subcontractor or middot Injury requiring treatment beyond first aid to a third party | |
middot A fatality of an employee contractor or subcontractor or middot A hospital admission of a third party | |
middot Multiple fatalities of employees contractors or subcontractors or middot multiple hospital admission of third parties or middot A fatality of a third party | |
NA | |
1x le TQ lt 3x | |
3x le TQ lt 9x | |
9x le TQ lt 27x | |
ge 27x TQ |
ICCA Process Safety Pilot Reporting ProgramFebruary 8 2016 | 1 | 2 | 3 | 4 | 5 | 6 | 7 | 8 | 9 | 10 | 12 | 13 | 14 | 15 | |||||||||||||||||||||||
SAFETY Details(Meeting Local Regulations) | Direct Cost from Fire or Explosion | Community Impact | Environmental Impact | Material Released(Measured using the 1 Hour Rule) | |||||||||||||||||||||||||||||||||
Company Association Details | |||||||||||||||||||||||||||||||||||||
GHS | API - RP 754 | ||||||||||||||||||||||||||||||||||||
Company or Assocation Name | Headquarter Association | Location of Event Ex - City State amp Country | Date and Time of Event | Safety InjuryDid the Event result in a Recordable Lost Time Accident or Fatality or Hospital admission of anyone on or off siteUse Drop Down Menu | Safety InjuryIf yes please insert the total number of injuries | Safety InjuryFor puropses of utilizing the Severity Table please indicate the level of severity by chosing the MOST SEVERE classification that describes your incidentUse Drop Down Menu | Safety InjuryDid the incident involve Fatalities If so how many total fatalities If none enter Zero | Safety InjuryPlease Report Total Employee Hours for Calendar Year 2015 | Safety InjuryPlease Report Total Contractor Hours for Calendar Year 2015 | Direct Cost Did the Event result in Direct Damage CostUse Drop Down Menu | Direct Cost If so how muchAmount is in US DollarsUse Drop Down Menu | Community ImpactDid the event result inbull Officially declared shelter-in-place or officially declared evacuation (on or off site)ORbull Precautionary off site shelter in place or evacuation Use Drop Down Menu | Environmental ImpactDid the event result inAcute Environmental Remediation CostIf so indicate the amount in US DollarsUse Drop Down Menu | Material ReleasedDid the Event result in an Acute Release of material beyond one of the two threshold tablesIf so indicate which Threshold Table you used to make this determinationUse Drop Down Menu | Material ReleasedIf so indicate the amount released USING GHS CLASSIFICATION TABLEUse Drop Down Menu | Material ReleasedIf so indicate the amount released USING THE THRESHOLD TABLE FROM API RP-754Use Drop Down Menu | Material ReleasedIf available please indicate the material released | ||||||||||||||||||||
1 | ABC Chemical Company | American Chemistry Council | Washington DC - USA | January 4 2016 | Yes | 2 | middot Days Away From Work injury to an employee contractor or subcontractor or middot Injury requiring treatment beyond first aid to a third party | 0 | 5525000 | 1500250 | No | $2500 to $25000 | Yes le 3 hours | $2500 to $25000 | Yes - Using GHS TABLE | 40x le TQ lt 160x | NA | Chlorine | |||||||||||||||||||
2 | XYZ Chemical Company | American Chemistry Council | Washington DC - USA | 5-Jan-16 | Yes | 1 | middot Injury requiring treatment beyond first aid to an employee contractor or subcontractor | 0 | 5525000 | 1500250 | Yes | $2500 to $25000 | No | $2500 to $25000 | Yes - Using API RP 754 TABLE | NA | 3x le TQ lt 9x | Benzene | |||||||||||||||||||
3 | |||||||||||||||||||||||||||||||||||||
4 | |||||||||||||||||||||||||||||||||||||
5 | |||||||||||||||||||||||||||||||||||||
6 | |||||||||||||||||||||||||||||||||||||
7 | |||||||||||||||||||||||||||||||||||||
8 | |||||||||||||||||||||||||||||||||||||
9 | |||||||||||||||||||||||||||||||||||||
10 | |||||||||||||||||||||||||||||||||||||
11 | |||||||||||||||||||||||||||||||||||||
12 | |||||||||||||||||||||||||||||||||||||
13 | |||||||||||||||||||||||||||||||||||||
14 | |||||||||||||||||||||||||||||||||||||
15 | |||||||||||||||||||||||||||||||||||||
16 | |||||||||||||||||||||||||||||||||||||
17 | |||||||||||||||||||||||||||||||||||||
18 | |||||||||||||||||||||||||||||||||||||
19 | |||||||||||||||||||||||||||||||||||||
20 | |||||||||||||||||||||||||||||||||||||
21 | |||||||||||||||||||||||||||||||||||||
22 | |||||||||||||||||||||||||||||||||||||
23 | |||||||||||||||||||||||||||||||||||||
24 | |||||||||||||||||||||||||||||||||||||
25 | |||||||||||||||||||||||||||||||||||||
Zero or None | Yes - Duration Unknown | ||||||||||||||||||||||||||||||||||||
Processes | Mode of Operation | Type of material released | Status of Operation | ||||
REFINING | Start-up | Flammable | Open | ||||
Alkylation HF | Planned shutdown | Combustible | Closed | ||||
Alkylation sulfuric | Emergency shutdown | Toxic | |||||
BitumenResidAsphalt | Normal | Corrosive | Tier 1 Acute Releases | ||||
Calcining | Upset | Utilities | No Release | ||||
Coking | Turnaround | Other | Category 1 | ||||
Crude | Routine maintenance | Category 2 | |||||
Desulfurization | Temporary | Evacuation | Category 3 | ||||
FCC | Other | Yes | Category 4 | ||||
Gas Treating | No | Category 5 | |||||
Hydrogen | Point of Release | Category 6 | |||||
Hydrotreating | Pump | Fire | Category 7 | ||||
Hydrocracking | Compressor | Yes | Multiple Categories | ||||
Isom | BlowerFan | No | |||||
MarineJetty | Pressure Vessel | lt $2500 | |||||
Reforming | FilterCoalescer | ||||||
Sulfur recovery | Furnace | PRDs | |||||
Vapor recoverylight ends | Boiler | Directly to Atmosphere | |||||
Wastewater | Heat exchanger | via Downstream Destructive Device | |||||
REFINING amp PETROCHEMICAL | Cooling Tower | No | |||||
Tank FarmStorage FacilityOffsite | Piping system | Yes | |||||
UtilitiesSteam PlantCogeneration | Reactor | No | |||||
Other | Atmospheric tank | ||||||
PETROCHEMICAL | FlareRelief System | Acute release above thresholds | |||||
CO H2 | Other | Yes | |||||
LNG | No | ||||||
Methane | Events | ||||||
Methanol | No Tier 1 Events | Indoor Outdoor | |||||
Methyl Mercaptan | No Tier 2 Events | No Release | |||||
Formaldehyde | No Tier 1 or Tier 2 Events | Indoor | |||||
Formaldehyde derivatives | NA | Outdoor | |||||
Acetic Acid | |||||||
Acetic Acid derivatives | Event Type | ||||||
Ethane | Injury | ||||||
Ethylene | Fire | ||||||
Ethanol | Explosion | ||||||
Ethylene oxide | PRD Discharge | ||||||
Ethylene derivatives | Acute Release | ||||||
Polyethylene | |||||||
Ethylene dichloride | General | ||||||
Ethylene dichloride derivatives | Yes | ||||||
Ethyl benzene | No | ||||||
Ethyl benzene derivatives | |||||||
Polystyrene | |||||||
Styrene-Butadiene | |||||||
Propane | |||||||
Propylene | |||||||
Polypropylene | |||||||
Isopropanol | |||||||
Propylene oxide | |||||||
Propylene oxide derivatives | |||||||
Butane | |||||||
Isobutane | |||||||
Isobutene | |||||||
Butadiene | |||||||
MTBE | |||||||
ETBE | |||||||
Pentane | |||||||
Hexane | |||||||
Cyclohexane | |||||||
Hexanol | |||||||
Aromatics Derivatives | |||||||
Benzene | |||||||
Toluene | |||||||
Xylene | |||||||
Para Xylene | |||||||
Amines Derivatives | |||||||
TDA MDA IPDA etc | |||||||
Isocyanates | |||||||
Specialty Chemicals | |||||||
LoadingUnloading | |||||||
Pilot Plant |
Instructions | ||||||||||||||
Step 1 | Complete the Contact Tab with your contact information and company information | |||||||||||||
Be sure to note the region of your reporting (IE North America France Japan etc) | ||||||||||||||
Survey on Process Safety Events | ||||||||||||||
Step 2 | Complete the survey one line per Process Safety Event for your companyregion | |||||||||||||
ALL REPORTED DATA SHOULD BE FROM CALENDAR YEAR 2017 | ||||||||||||||
Step 3 | Return completed survey to | |||||||||||||
Company Name | ||||||||||||||
Contact Person | All Surveys Due by xxx date | |||||||||||||
Address | ||||||||||||||
Fax | ||||||||||||||
Telephone | ||||||||||||||
Region | ||||||||||||||
None | |
$2500 to $25000 | |
$25000 to $250000 | |
$250000 to $25000000 | |
More than $25000000 | |
Yes - Using GHS TABLE | |
Yes - Using API RP 754 TABLE | |
NO | |
NA | |
1x le TQ lt 40x | |
40x le TQ lt 160x | |
160x le TQ lt 640x | |
ge 640x TQ | |
Yes le 3 hours | |
Yes 3 hours ge 12 hours | |
Yes 12 hours ge 24 hours | |
Yes ge 24 hours | |
No | |
Small-scale | |
Medium-scale | |
Large-scale | |
No | |
Yes | |
No | |
middot Injury requiring treatment beyond first aid to an employee contractor or subcontractor | |
middot Days Away From Work injury to an employee contractor or subcontractor or middot Injury requiring treatment beyond first aid to a third party | |
middot A fatality of an employee contractor or subcontractor or middot A hospital admission of a third party | |
middot Multiple fatalities of employees contractors or subcontractors or middot multiple hospital admission of third parties or middot A fatality of a third party | |
NA | |
1x le TQ lt 3x | |
3x le TQ lt 9x | |
9x le TQ lt 27x | |
ge 27x TQ |
ICCA Process Safety Pilot Reporting ProgramFebruary 8 2016 | 1 | 2 | 3 | 4 | 5 | 6 | 7 | 8 | 9 | 10 | 12 | 13 | 14 | 15 | |||||||||||||||||||||||
SAFETY Details(Meeting Local Regulations) | Direct Cost from Fire or Explosion | Community Impact | Environmental Impact | Material Released(Measured using the 1 Hour Rule) | |||||||||||||||||||||||||||||||||
Company Association Details | |||||||||||||||||||||||||||||||||||||
GHS | API - RP 754 | ||||||||||||||||||||||||||||||||||||
Company or Assocation Name | Headquarter Association | Location of Event Ex - City State amp Country | Date and Time of Event | Safety InjuryDid the Event result in a Recordable Lost Time Accident or Fatality or Hospital admission of anyone on or off siteUse Drop Down Menu | Safety InjuryIf yes please insert the total number of injuries | Safety InjuryFor puropses of utilizing the Severity Table please indicate the level of severity by chosing the MOST SEVERE classification that describes your incidentUse Drop Down Menu | Safety InjuryDid the incident involve Fatalities If so how many total fatalities If none enter Zero | Safety InjuryPlease Report Total Employee Hours for Calendar Year 2015 | Safety InjuryPlease Report Total Contractor Hours for Calendar Year 2015 | Direct Cost Did the Event result in Direct Damage CostUse Drop Down Menu | Direct Cost If so how muchAmount is in US DollarsUse Drop Down Menu | Community ImpactDid the event result inbull Officially declared shelter-in-place or officially declared evacuation (on or off site)ORbull Precautionary off site shelter in place or evacuation Use Drop Down Menu | Environmental ImpactDid the event result inAcute Environmental Remediation CostIf so indicate the amount in US DollarsUse Drop Down Menu | Material ReleasedDid the Event result in an Acute Release of material beyond one of the two threshold tablesIf so indicate which Threshold Table you used to make this determinationUse Drop Down Menu | Material ReleasedIf so indicate the amount released USING GHS CLASSIFICATION TABLEUse Drop Down Menu | Material ReleasedIf so indicate the amount released USING THE THRESHOLD TABLE FROM API RP-754Use Drop Down Menu | Material ReleasedIf available please indicate the material released | ||||||||||||||||||||
1 | ABC Chemical Company | American Chemistry Council | Washington DC - USA | January 4 2016 | Yes | 2 | middot Days Away From Work injury to an employee contractor or subcontractor or middot Injury requiring treatment beyond first aid to a third party | 0 | 5525000 | 1500250 | No | $2500 to $25000 | Yes le 3 hours | $2500 to $25000 | Yes - Using GHS TABLE | 40x le TQ lt 160x | NA | Chlorine | |||||||||||||||||||
2 | XYZ Chemical Company | American Chemistry Council | Washington DC - USA | 5-Jan-16 | Yes | 1 | middot Injury requiring treatment beyond first aid to an employee contractor or subcontractor | 0 | 5525000 | 1500250 | Yes | $2500 to $25000 | No | $2500 to $25000 | Yes - Using API RP 754 TABLE | NA | 3x le TQ lt 9x | Benzene | |||||||||||||||||||
3 | |||||||||||||||||||||||||||||||||||||
4 | |||||||||||||||||||||||||||||||||||||
5 | |||||||||||||||||||||||||||||||||||||
6 | |||||||||||||||||||||||||||||||||||||
7 | |||||||||||||||||||||||||||||||||||||
8 | |||||||||||||||||||||||||||||||||||||
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10 | |||||||||||||||||||||||||||||||||||||
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23 | |||||||||||||||||||||||||||||||||||||
24 | |||||||||||||||||||||||||||||||||||||
25 | |||||||||||||||||||||||||||||||||||||
Zero or None | Yes - Duration Unknown | ||||||||||||||||||||||||||||||||||||
Processes | Mode of Operation | Type of material released | Status of Operation | ||||
REFINING | Start-up | Flammable | Open | ||||
Alkylation HF | Planned shutdown | Combustible | Closed | ||||
Alkylation sulfuric | Emergency shutdown | Toxic | |||||
BitumenResidAsphalt | Normal | Corrosive | Tier 1 Acute Releases | ||||
Calcining | Upset | Utilities | No Release | ||||
Coking | Turnaround | Other | Category 1 | ||||
Crude | Routine maintenance | Category 2 | |||||
Desulfurization | Temporary | Evacuation | Category 3 | ||||
FCC | Other | Yes | Category 4 | ||||
Gas Treating | No | Category 5 | |||||
Hydrogen | Point of Release | Category 6 | |||||
Hydrotreating | Pump | Fire | Category 7 | ||||
Hydrocracking | Compressor | Yes | Multiple Categories | ||||
Isom | BlowerFan | No | |||||
MarineJetty | Pressure Vessel | lt $2500 | |||||
Reforming | FilterCoalescer | ||||||
Sulfur recovery | Furnace | PRDs | |||||
Vapor recoverylight ends | Boiler | Directly to Atmosphere | |||||
Wastewater | Heat exchanger | via Downstream Destructive Device | |||||
REFINING amp PETROCHEMICAL | Cooling Tower | No | |||||
Tank FarmStorage FacilityOffsite | Piping system | Yes | |||||
UtilitiesSteam PlantCogeneration | Reactor | No | |||||
Other | Atmospheric tank | ||||||
PETROCHEMICAL | FlareRelief System | Acute release above thresholds | |||||
CO H2 | Other | Yes | |||||
LNG | No | ||||||
Methane | Events | ||||||
Methanol | No Tier 1 Events | Indoor Outdoor | |||||
Methyl Mercaptan | No Tier 2 Events | No Release | |||||
Formaldehyde | No Tier 1 or Tier 2 Events | Indoor | |||||
Formaldehyde derivatives | NA | Outdoor | |||||
Acetic Acid | |||||||
Acetic Acid derivatives | Event Type | ||||||
Ethane | Injury | ||||||
Ethylene | Fire | ||||||
Ethanol | Explosion | ||||||
Ethylene oxide | PRD Discharge | ||||||
Ethylene derivatives | Acute Release | ||||||
Polyethylene | |||||||
Ethylene dichloride | General | ||||||
Ethylene dichloride derivatives | Yes | ||||||
Ethyl benzene | No | ||||||
Ethyl benzene derivatives | |||||||
Polystyrene | |||||||
Styrene-Butadiene | |||||||
Propane | |||||||
Propylene | |||||||
Polypropylene | |||||||
Isopropanol | |||||||
Propylene oxide | |||||||
Propylene oxide derivatives | |||||||
Butane | |||||||
Isobutane | |||||||
Isobutene | |||||||
Butadiene | |||||||
MTBE | |||||||
ETBE | |||||||
Pentane | |||||||
Hexane | |||||||
Cyclohexane | |||||||
Hexanol | |||||||
Aromatics Derivatives | |||||||
Benzene | |||||||
Toluene | |||||||
Xylene | |||||||
Para Xylene | |||||||
Amines Derivatives | |||||||
TDA MDA IPDA etc | |||||||
Isocyanates | |||||||
Specialty Chemicals | |||||||
LoadingUnloading | |||||||
Pilot Plant |
Instructions | ||||||||||||||
Step 1 | Complete the Contact Tab with your contact information and company information | |||||||||||||
Be sure to note the region of your reporting (IE North America France Japan etc) | ||||||||||||||
Survey on Process Safety Events | ||||||||||||||
Step 2 | Complete the survey one line per Process Safety Event for your companyregion | |||||||||||||
ALL REPORTED DATA SHOULD BE FROM CALENDAR YEAR 2017 | ||||||||||||||
Step 3 | Return completed survey to | |||||||||||||
Company Name | ||||||||||||||
Contact Person | All Surveys Due by xxx date | |||||||||||||
Address | ||||||||||||||
Fax | ||||||||||||||
Telephone | ||||||||||||||
Region | ||||||||||||||
20
阻絕設施失效
3 儲槽液位計故障造成裝有ldquo易燃液體rdquo產品的儲槽外溢約 700 公斤的液體流入儲槽的防溢堤內
此事故屬於須提報的製程安全事件因為其ldquo急性rdquo洩漏量超過 100 公斤即使是阻絕在二次阻絕
設施防溢堤中亦然
4 一名從事維修工作的承攬商在開啟一個製程阻閥時被噴起的硫酸濺到造成嚴重灼傷和損失工
時的工傷此事故屬於須提報的製程安全事件因為它是涉及物質和一次阻絕設施失效的意外事
件對於因洩漏造成死亡和損工的工傷或疾病事故沒有洩漏恕限值
5 一名作業員開啟品管取樣點進行日常取樣作業時手部被一個破碎的玻璃瓶嚴重割破需要進行
縫合治療縫針造成第二天無法上班該事故不屬於須提報的製程安全事件因為它與一次阻絕
設施失效無關
ldquo急性rdquo洩漏
6 一名作業員在進行天然氣流量高於預期值之異常排除時發現天然氣管線上的一個安全閥門未適
當歸位因此天然氣經由氣液分離桶排放至排氣煙囪經進一步檢查作業員判斷在過去 6 個
月間總共有 100000 公斤天然氣以穩定的速率排放至大氣該事故不屬於須提報的製程安全事
件因為其洩漏速率(每小時約 10 公斤)不算ldquo急性rdquo洩漏(未超過易燃蒸汽每小時 100 公斤的恕限
值)
廢氣燃燒塔amp排放控制裝置 (如洗滌塔)
7 若化學物質被導引至廢氣燃燒塔或排放控制裝置(如洗滌塔)只要該廢氣燃燒塔或控制裝置運作在
正常設計範圍內便不屬於須提報的製程安全事件
8 若廢氣流速超過洗滌塔的設計負荷以致未經吸收的化學物質排出超過恕限值該事故屬於須提報
的製程安全事件(如本文註釋所述)
註釋自取得許可或妥善管理的裝置-包括釋壓裝置發生不預期的排放若 1 小時內洩漏量達到或
超過表 1 或表 2 所列的洩漏恕限值且導致下列四種後果之任一項或以上之後果該事故便屬於
須提報的製程安全事件
o 二相排放或夾帶液體的排放液滴沉降至地面造成污染
o 排放至具潛在危險性的地點)
o 廠內就地避難或疏散不包括預防性廠內就地避難或疏散
o 啟動公眾保護措施(如道路封閉)包括預防性公眾保護措施
21
安全洩壓裝置 系統
9 製程單元發生異常安全閥開啟將洩漏物質釋放到排氣口此釋壓排放裝置是依相關要求設計
的且氣體釋到大氣中並未造成不良後果這不是一個須提報的製程安全事件因為安全閥高
壓破裂盤以及類似的安全裝置是依據 API 521 或者同等的標準設計的且此排放並未造成 (1)
夾帶液體並導致須提報的製程安全事件的後果(譬如損失工時意外死亡火災或爆炸造成$2500
美元或以上的直接成本損失液體或毒性氣體洩漏量達到或超過恕限值(2) 啟動廠內或廠外就地
避難應變或(3)啟動公眾保護措施
10 製程單元發生異常安全閥並未開啟造成設備超壓易燃性氣體從一個法蘭處ldquo急性rdquo漏出來
洩露量超過 100 公斤(一小時內)的恕限值該事故屬於須提報的製程安全事件因為從法蘭處外
漏屬於製程安全事件應提報事項
損工事故
11 一名作業員走路時不慎滑倒造成損失工時之工傷滑倒原因為天氣狀況rdquo長期rdquo油垢的地面和
易滑鞋具該事故不屬於須提報的製程安全事件因為人員安全ldquo滑倒絆倒跌倒rdquo事故若非與
一次阻絕設施失效直接關聯的疏散或應變造成則不屬於須提報的製程安全事件
12 與前例相同的事件惟這次作業員跌倒是因為少量易燃液體外漏(如 1 小時內少於 10 公斤)在採取
相關應變措施時發生該事故屬於須提報的製程安全事件因為作業員係為了應變一次阻絕設施
失效的事故而跌倒若一次阻絕設施失效發生在公司廠區且造成失時工傷或死亡後果該事故
便屬於須提報的製程安全事件對於因洩漏造成死亡和損失工時之工傷事故沒有洩漏量門檻
13 與前例相同的事件惟這次作業員跌倒是在事件結束數小時之後該事故不屬於須提報的製程安
全事件在提報要件中所用的ldquo疏散rdquo和ldquo應變rdquo等術語指的是一次阻絕設施失效和相關緊急應變
活動正在持續中事件結束後滑倒絆倒跌倒(如ldquo事後rdquo清理和補救)不屬於須提報製程安全事件
14 工人在因附近設備一次阻絕設施失效在疏散過程中一名鷹架搭建工人從鷹架梯上跌落造成損
失工時之工傷該事故屬於須提報的製程安全事件
15 一名作業員行經一個設計不良的蒸汽卻水器時被外洩的蒸汽燙傷腳踝造成損失工時之工傷
該事故屬於須提報的製程安全事件因為雖然一次阻絕設施失效洩漏出的是蒸汽(而非碳氫化合物
或化學物質)但損失工時之工傷是由於洩漏物質的物理狀態所導致的
16 一個密閉空間依照計畫以氮氣吹清一名承攬商繞過安全管制進入該密閉空間因而死亡該事
故屬於須提報的死亡事件但不屬於須提報的製程安全事件因為其中不涉及非計劃或失控的一
次阻絕設施失效
17 情況同上惟這次氮氣是非刻意洩漏進入該局限空間該事故屬於須提報的製程安全事件(同時也
是一起死亡事件)因為該名承攬商的死亡與非計劃的一次阻絕設施失效有關
22
18 一名作業員因硫化氫(H2S)警報在進行應變處理時昏倒若警報確實是因非計劃或失控的 H2S 一次
阻絕設施失效的外洩事件該事故便屬於須提報的製程安全事件若警報是一個假警報則該事
故便不屬於須提報的製程安全事件因為沒有真正的化學品洩漏發生
管線
19 一條管線破漏1 小時內洩漏 2000 磅(900 公斤)易燃蒸氣到地面但洩漏位置在廠區內很偏僻的
地點該事故仍屬於須提報的製程安全事件因為ldquo偏僻rdquo不是提報與否的考量因素
與化學物質外洩無關之火災或能量釋放事故
一般通則而言唯有當火災或能量釋放事故是因化學物質洩漏所造成或其發生導致化學物質洩漏
超過提報恕限值這些事故才屬於須提報的製程安全事件實例包括
20 一場電氣火災影響製程操作導致甲苯洩漏 400 公斤該事故屬於須提報的製程安全事件因為
化學物質洩漏已超過甲苯的 100 公斤提報恕限值
21 發生電氣火災停電或任何公用資源供應中斷可能造成工廠停工及可能引起設備損失超過
$2500 美元(如因非正常停工導致反應器或設備損壞)但並未造成超過恕限值的化學物質洩漏
亦未造成死亡或嚴重工傷該事故不屬於須提報的製程安全事件因為設備損壞並非化學製程火
災爆炸造成且化學物質洩漏並未超過恕限值
海上運輸船
22 一艘由公司營運的海上運輸船在船上發生ldquo急性rdquo易燃物質外洩洩漏量超過 100 公斤該事故不
屬於須提報的製程安全事件因為除非海上運輸船是為了輸送半成品或產品而與煉油石化或化
學製造廠的設施相連接否則其洩漏事故便不被視為製程安全事件
23 一艘第三方駁船由一艘拖船推向碼頭結果撞上公司的碼頭駁船的一個船艙破裂且造成
1000 公斤柴油洩漏到海中該事故不屬於須提報的製程安全事件因為駁船當時並非停泊在碼
頭內且其作業並非在進行半成品或產品之輸送
卡車與軌道車
24 一輛公司的軌道車在運輸途中出軌造成超過 1000 公斤汽油洩漏該事故不屬於須提報的製程
安全事件因為在公司廠區外發生的軌道車事故不被視為與製程安全有關
23
25 一輛第三方卡車拖車在公司廠區內翻覆造成ldquo急性rdquo汽油洩漏超過 1000 公斤這事故不屬於須
提報的製程安全事件因為卡車拖車當時已不再與裝卸設備連接然而我們建議會員公司另
行訂定運輸安全事故指標將這類事故記錄下來
26 一位合約卡車作業者正在卸載液鹼時發生軟管脫落造成空氣中氣霧和或液鹼液洩漏 2500 公
斤該事故屬於須提報的製程安全事件因為洩漏量已超過液鹼的 100 公斤恕限值且事故發生
前卡車仍與裝卸設備相連接著
辦公建築
27 綜合辦公大樓發生鍋爐火災造成總計$75000 美元的直接成本損失該事故不屬於須提報的製
程安全事件因為辦公大樓事故不被視為與製程安全有關
人機介面事故
28 一名操作技術員在聚合物工廠的終端設備旁作業時受傷這傷害是因機械的人機介面的設備而
造成該事故不屬於須提報的製程安全事件因為技術員受傷並非因危險物質一次阻絕設施失效
而造成的
混合物
29 若混合物本身有 GHS 分類可利用其分類確定恕限值若混合物本身沒有 GHS 分類則可計算混
合物中每個單一組成分之洩漏量(公斤)相對於個別成分恕限值之比值作為其對混合物恕限值之
lsquo加權rsquo貢獻譬如若混合物在 1小時內的洩漏量為 100公斤其中包含 05公斤分類為劇毒 H300
的物質45 公斤分類為 H301 的物質40 公斤另一種分類為 H 開頭的物質其餘 55 公斤則為沒
有 GHS 分類的水分此混合物之計算式為051 + 4510 + 40100 = 05 + 045 + 04 = 135超過
1因此該事故被視為須提報的製程安全事件雖然混合物個別成分之洩漏量均未超過各該物質
本身的恕限值
直接損失成本
30 此一門檻所考慮的成本應為可直接歸因於火災或爆炸的成本譬如設備及結構損壞的重置成本
修理成本環境清理支出緊急應變和罰款直接成本不包括間接成本譬如業務機會損失設
備停機造成之利潤損失取得或運轉臨時設施之成本或為滿足顧客需求取得替代產品的成本
(產品損失)
24
31 範例連接到氣體處理系統的排放管發生易燃氣體外漏同時製程出現問題導致空氣進入同
一條排放管結果發生爆炸過高的壓力損壞了排放管及其相關上游設備包括一個密封罐並
未造成人員受傷修理成本約$12000 美元該事故屬於須提報的製程安全事件因為爆炸及火
災導致設備修理成本超過門檻
32 範例一次製程安全事件後公司又發生一種非常特殊的 GHS 第 5 類產品洩漏 50 公斤造成
$2000 美元的設備損失洩漏的產品是一種非常特別的混合物公司須負擔超過$50000 美元因
產品耗損而產生之材料成本該事故不屬於須提報的製程安全事件因為 GHS 第 5 類產品洩漏的
提報門檻為 100 公斤且產品耗損不被計入直接損失成本
天然災害
33 天然災害可能對化學製程作業構成重大風險且對製程設備造成損壞導致危害物質一次阻絕設
施失效當一種或多種天然災害被認為可能對工廠作業造成影響時製程安全和作業系統應從危
害及後果分析工廠機器設備設計公用設施失效及製程停工之操作程序緊急應變計畫及應變
措施等方面界定潛在風險進行防範
天然災害類型包括颶風及颱風(包括伴隨而來的風暴潮)水災龍捲風地震超強對流風暴(直
線風暴)野火火山爆發海嘯和山崩
若公司廠房設施遭遇天然災害且其後果觸發一種或以上提報門檻該事故便屬於須提報製程安
全事件
預防性公眾應變
34 預防性公眾應變是基於謹慎的態度所採取的一種措施譬如當發生一次阻絕設施失效時公司
可能在尚未進行任何評估(如方向與洩漏點的距離等等)前便要求全體工人就地避難又
如地方權責官員(如消防警察民防緊急應變管理部門)在獲報一家公司發生製程安全事件
後為防lsquo萬一rsquo風向改變或基於可能受到波及的人口敏感族群(如學童或老年人)可能在尚未接
獲明確資訊前便下令社區就地避難或疏散或採取公眾保護措施(如道路封閉)
製程附屬倉庫
35 製程附屬倉庫指的是位於廠內用於儲存將投入於生產製程或產自於製程之原料半成品或成品的
倉庫從製程的觀點看來製程附屬倉庫相當於一個大型儲槽但這些原料半成品或成品並不
是儲存在一的大型容器中而是裝在較小的容器裡(如太空包大桶桶罐等)
25
Appendix C ndash List of RCLG Taskforce Members
Name Affiliation
Peter Schmelzer Bayer CEFIC - Chairman
Americo Diniz Carvalho Neto Braskem
Bradford Johnson American Chemistry Council
David Cummings DuPont
Debra Phillips American Chemistry Council
Hans Schwarz BASF
Kathryn Walton Plastics and Chemicals Industries Association
Kazuyuki Akita Japanese Chemical Industry Association
Kelly Keim ExxonMobil Chemical Company API Representative
Kenan Stevick Dow
Kiyokazu Murata Japanese Chemical Industry Association
Larry Bowler SABIC
Lorna Young Chemical Industry Association of Canada
Louisa Nara Center for Chemical Process Safety
Luiz Shizuo Harayashiki Associaccedilatildeo Brasileira da Induacutestria Quiacutemica
Masatoshi Kumamoto Japanese Chemical Industry Association
Milton Lacerda Petrobras
Phil Scott Chemical Industries Association
Piet Knijff DSM European Process Safety Centre
Scott Donaldson and Eamon Chandler
Shell
Scott Wallace Olin Corporation
Shakeel Kadri Air Products and Chemicals Inc
26
附錄 D ndash 詳細活動時程表
2016 年 2017 年 2018 年 2019 年 2020 年
2 ndash 4 月
RCLG PS 先導計畫
5 月 ndash
針對準則進行調整釐清
6 月 向 RCLG 和 ICCA 董事會報
告先導計畫執行結果
7 ndash 12 月 RCLG 協會考量準
則並為其會員公司發展提報機制
如有需要RCLG可向 ICCA 申請能
力建立基金為會員公司舉辦製程安
全研習會
1 ndash 12 月
RCLG 協會開始向其會員公司蒐集製程安全數據
1 ndash 12 月
如有需要RCLG 各協會運用 RCLG 的基金及專
家舉辦製程安全及績效提報研習會
1 ndash 2 月
擁有數據的協會開始向RCLG 提報製程安全事件
(2017 年數據)
4 月 RCLG 檢討第一個提報循
環的結果挑戰及原始數據(內部)
6 月 RCLG 向 ICCA 董事會呈報
原始數據
7 ndash 12 月 必要時更新及調整準
則
如有需要RCLG 各協會運用 RCLG 的基金及專
家舉辦製程安全及績效提報研習會
1 ndash 2 月
擁有數據的協會開始向RCLG 提報製程安全事件
(2018 年數據)
4 月 RCLG 檢討第二個提報循
環的結果挑戰及原始數據(內部)
6 月 RCLG 向 ICCA 董事會呈報
原始數據
7 ndash 12 月 必要時更新及調整準
則
如有需要RCLG 協會運用 RCLG 的基金及專家
舉辦製程安全及績效提報研習會
1 ndash 2 月
所有協會開始向 RCLG 提報製程安全事件
製程安全事件提報成為
RCLG KPI 衡量指標建議基本集的一部分(2019 年數
據)
4 月 RCLG 檢討第二個提報循
環的結果挑戰及原始數據(內部考量外部提
報)
6 月 RCLG 向 ICCA 董事會呈報
原始數據
27
附錄 E ndash 選擇性 Excel 追蹤表
當會員公司開始追蹤製程安全事件時所有會員公司應採用單一表格以簡化數據分析同時讓所有公司均使用相同的追蹤表RCLG 設
計了一份選擇性追蹤表可供會員公司和協會先行利用之後他們可設計自己的追蹤表
在這裡下載追蹤表
ICCA Process Safety Event Tracking Sheetxlsx
本文件包含三個分頁分別是ldquo聯絡資料rdquoldquo調查表rdquo和儲存下拉式選單選項的ldquo請勿編輯rdquo分頁
備註
附錄 E 追蹤表僅供參考TRCA 將另行提供台灣版表格供會員公司提報
28
後語
台灣化學工業責任照顧協會(Taiwan Responsible Care Association TRCA)成立於 1998 年在台灣推行責任照顧制度已達 20 週年製造商成員
包括台灣主要上市上櫃化工公司會員公司化學品生產製造量約佔全國 80 2016 年台灣化工業的 Chemical Sales 仍站在全球第八名的位
置額度為 630 億歐元化工業總產值達到 34 兆新台幣提供國內 416 萬人工作機會
TRCA 扮演國內廠商與國際制度接軌的角色也是國內化工業與政府機關及利益相關者溝通的橋樑與管道TRCA 會員結構依業務性質分析
涵蓋石化生產化學品製造氣體生產倉儲運輸業化學品貿易業以及工程研發設計等公司TRCA 透過供應鏈及價值鏈推行責任
照顧制度組成毒性化學物質聯防組織協助法規溝通與研析會員名冊請參考 httpwwwtrcaorgtwtrcanwork2aspx
TRCA 於 2010 年成為 ICCA (International Council of Chemical Associations 國際化學工業協會)觀察員ICCA 成立於 1989 年是全球化工製造
業的聯合會也是化學工業與 UNEP OPCW 及 OECD 的交流窗口ICCA 與其會員協會及成員公司致力於邁向永續的未來確保人類健康與
環境安全與保護全球化工業擁有超過 4兆美元的價值影響所有經濟部門ICCA 的會員幾乎在全球每個國家都有商業活動在全球六大
洲推動創新並提供超過 2000 萬個工作機會
台灣化工業在全球占有重要的一席之地在國內產業鏈也位居關鍵位置無論對國內或國際都有身為地球村一員應盡之責我們期許藉由
製程安全指標提報能更進一步提升自我在工安衛生環保與永續發展等面向的績效表現
台灣化學工業責任照顧協會
10452 台北市中山區撫順街 8 號 7 樓
電話02-2585-0552
httpwwwtrcaorgtw
None | |
$2500 to $25000 | |
$25000 to $250000 | |
$250000 to $25000000 | |
More than $25000000 | |
Yes - Using GHS TABLE | |
Yes - Using API RP 754 TABLE | |
NO | |
NA | |
1x le TQ lt 40x | |
40x le TQ lt 160x | |
160x le TQ lt 640x | |
ge 640x TQ | |
Yes le 3 hours | |
Yes 3 hours ge 12 hours | |
Yes 12 hours ge 24 hours | |
Yes ge 24 hours | |
No | |
Small-scale | |
Medium-scale | |
Large-scale | |
No | |
Yes | |
No | |
middot Injury requiring treatment beyond first aid to an employee contractor or subcontractor | |
middot Days Away From Work injury to an employee contractor or subcontractor or middot Injury requiring treatment beyond first aid to a third party | |
middot A fatality of an employee contractor or subcontractor or middot A hospital admission of a third party | |
middot Multiple fatalities of employees contractors or subcontractors or middot multiple hospital admission of third parties or middot A fatality of a third party | |
NA | |
1x le TQ lt 3x | |
3x le TQ lt 9x | |
9x le TQ lt 27x | |
ge 27x TQ |
ICCA Process Safety Pilot Reporting ProgramFebruary 8 2016 | 1 | 2 | 3 | 4 | 5 | 6 | 7 | 8 | 9 | 10 | 12 | 13 | 14 | 15 | |||||||||||||||||||||||
SAFETY Details(Meeting Local Regulations) | Direct Cost from Fire or Explosion | Community Impact | Environmental Impact | Material Released(Measured using the 1 Hour Rule) | |||||||||||||||||||||||||||||||||
Company Association Details | |||||||||||||||||||||||||||||||||||||
GHS | API - RP 754 | ||||||||||||||||||||||||||||||||||||
Company or Assocation Name | Headquarter Association | Location of Event Ex - City State amp Country | Date and Time of Event | Safety InjuryDid the Event result in a Recordable Lost Time Accident or Fatality or Hospital admission of anyone on or off siteUse Drop Down Menu | Safety InjuryIf yes please insert the total number of injuries | Safety InjuryFor puropses of utilizing the Severity Table please indicate the level of severity by chosing the MOST SEVERE classification that describes your incidentUse Drop Down Menu | Safety InjuryDid the incident involve Fatalities If so how many total fatalities If none enter Zero | Safety InjuryPlease Report Total Employee Hours for Calendar Year 2015 | Safety InjuryPlease Report Total Contractor Hours for Calendar Year 2015 | Direct Cost Did the Event result in Direct Damage CostUse Drop Down Menu | Direct Cost If so how muchAmount is in US DollarsUse Drop Down Menu | Community ImpactDid the event result inbull Officially declared shelter-in-place or officially declared evacuation (on or off site)ORbull Precautionary off site shelter in place or evacuation Use Drop Down Menu | Environmental ImpactDid the event result inAcute Environmental Remediation CostIf so indicate the amount in US DollarsUse Drop Down Menu | Material ReleasedDid the Event result in an Acute Release of material beyond one of the two threshold tablesIf so indicate which Threshold Table you used to make this determinationUse Drop Down Menu | Material ReleasedIf so indicate the amount released USING GHS CLASSIFICATION TABLEUse Drop Down Menu | Material ReleasedIf so indicate the amount released USING THE THRESHOLD TABLE FROM API RP-754Use Drop Down Menu | Material ReleasedIf available please indicate the material released | ||||||||||||||||||||
1 | ABC Chemical Company | American Chemistry Council | Washington DC - USA | January 4 2016 | Yes | 2 | middot Days Away From Work injury to an employee contractor or subcontractor or middot Injury requiring treatment beyond first aid to a third party | 0 | 5525000 | 1500250 | No | $2500 to $25000 | Yes le 3 hours | $2500 to $25000 | Yes - Using GHS TABLE | 40x le TQ lt 160x | NA | Chlorine | |||||||||||||||||||
2 | XYZ Chemical Company | American Chemistry Council | Washington DC - USA | 5-Jan-16 | Yes | 1 | middot Injury requiring treatment beyond first aid to an employee contractor or subcontractor | 0 | 5525000 | 1500250 | Yes | $2500 to $25000 | No | $2500 to $25000 | Yes - Using API RP 754 TABLE | NA | 3x le TQ lt 9x | Benzene | |||||||||||||||||||
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4 | |||||||||||||||||||||||||||||||||||||
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25 | |||||||||||||||||||||||||||||||||||||
Zero or None | Yes - Duration Unknown | ||||||||||||||||||||||||||||||||||||
Processes | Mode of Operation | Type of material released | Status of Operation | ||||
REFINING | Start-up | Flammable | Open | ||||
Alkylation HF | Planned shutdown | Combustible | Closed | ||||
Alkylation sulfuric | Emergency shutdown | Toxic | |||||
BitumenResidAsphalt | Normal | Corrosive | Tier 1 Acute Releases | ||||
Calcining | Upset | Utilities | No Release | ||||
Coking | Turnaround | Other | Category 1 | ||||
Crude | Routine maintenance | Category 2 | |||||
Desulfurization | Temporary | Evacuation | Category 3 | ||||
FCC | Other | Yes | Category 4 | ||||
Gas Treating | No | Category 5 | |||||
Hydrogen | Point of Release | Category 6 | |||||
Hydrotreating | Pump | Fire | Category 7 | ||||
Hydrocracking | Compressor | Yes | Multiple Categories | ||||
Isom | BlowerFan | No | |||||
MarineJetty | Pressure Vessel | lt $2500 | |||||
Reforming | FilterCoalescer | ||||||
Sulfur recovery | Furnace | PRDs | |||||
Vapor recoverylight ends | Boiler | Directly to Atmosphere | |||||
Wastewater | Heat exchanger | via Downstream Destructive Device | |||||
REFINING amp PETROCHEMICAL | Cooling Tower | No | |||||
Tank FarmStorage FacilityOffsite | Piping system | Yes | |||||
UtilitiesSteam PlantCogeneration | Reactor | No | |||||
Other | Atmospheric tank | ||||||
PETROCHEMICAL | FlareRelief System | Acute release above thresholds | |||||
CO H2 | Other | Yes | |||||
LNG | No | ||||||
Methane | Events | ||||||
Methanol | No Tier 1 Events | Indoor Outdoor | |||||
Methyl Mercaptan | No Tier 2 Events | No Release | |||||
Formaldehyde | No Tier 1 or Tier 2 Events | Indoor | |||||
Formaldehyde derivatives | NA | Outdoor | |||||
Acetic Acid | |||||||
Acetic Acid derivatives | Event Type | ||||||
Ethane | Injury | ||||||
Ethylene | Fire | ||||||
Ethanol | Explosion | ||||||
Ethylene oxide | PRD Discharge | ||||||
Ethylene derivatives | Acute Release | ||||||
Polyethylene | |||||||
Ethylene dichloride | General | ||||||
Ethylene dichloride derivatives | Yes | ||||||
Ethyl benzene | No | ||||||
Ethyl benzene derivatives | |||||||
Polystyrene | |||||||
Styrene-Butadiene | |||||||
Propane | |||||||
Propylene | |||||||
Polypropylene | |||||||
Isopropanol | |||||||
Propylene oxide | |||||||
Propylene oxide derivatives | |||||||
Butane | |||||||
Isobutane | |||||||
Isobutene | |||||||
Butadiene | |||||||
MTBE | |||||||
ETBE | |||||||
Pentane | |||||||
Hexane | |||||||
Cyclohexane | |||||||
Hexanol | |||||||
Aromatics Derivatives | |||||||
Benzene | |||||||
Toluene | |||||||
Xylene | |||||||
Para Xylene | |||||||
Amines Derivatives | |||||||
TDA MDA IPDA etc | |||||||
Isocyanates | |||||||
Specialty Chemicals | |||||||
LoadingUnloading | |||||||
Pilot Plant |
Instructions | ||||||||||||||
Step 1 | Complete the Contact Tab with your contact information and company information | |||||||||||||
Be sure to note the region of your reporting (IE North America France Japan etc) | ||||||||||||||
Survey on Process Safety Events | ||||||||||||||
Step 2 | Complete the survey one line per Process Safety Event for your companyregion | |||||||||||||
ALL REPORTED DATA SHOULD BE FROM CALENDAR YEAR 2017 | ||||||||||||||
Step 3 | Return completed survey to | |||||||||||||
Company Name | ||||||||||||||
Contact Person | All Surveys Due by xxx date | |||||||||||||
Address | ||||||||||||||
Fax | ||||||||||||||
Telephone | ||||||||||||||
Region | ||||||||||||||
None | |
$2500 to $25000 | |
$25000 to $250000 | |
$250000 to $25000000 | |
More than $25000000 | |
Yes - Using GHS TABLE | |
Yes - Using API RP 754 TABLE | |
NO | |
NA | |
1x le TQ lt 40x | |
40x le TQ lt 160x | |
160x le TQ lt 640x | |
ge 640x TQ | |
Yes le 3 hours | |
Yes 3 hours ge 12 hours | |
Yes 12 hours ge 24 hours | |
Yes ge 24 hours | |
No | |
Small-scale | |
Medium-scale | |
Large-scale | |
No | |
Yes | |
No | |
middot Injury requiring treatment beyond first aid to an employee contractor or subcontractor | |
middot Days Away From Work injury to an employee contractor or subcontractor or middot Injury requiring treatment beyond first aid to a third party | |
middot A fatality of an employee contractor or subcontractor or middot A hospital admission of a third party | |
middot Multiple fatalities of employees contractors or subcontractors or middot multiple hospital admission of third parties or middot A fatality of a third party | |
NA | |
1x le TQ lt 3x | |
3x le TQ lt 9x | |
9x le TQ lt 27x | |
ge 27x TQ |
ICCA Process Safety Pilot Reporting ProgramFebruary 8 2016 | 1 | 2 | 3 | 4 | 5 | 6 | 7 | 8 | 9 | 10 | 12 | 13 | 14 | 15 | |||||||||||||||||||||||
SAFETY Details(Meeting Local Regulations) | Direct Cost from Fire or Explosion | Community Impact | Environmental Impact | Material Released(Measured using the 1 Hour Rule) | |||||||||||||||||||||||||||||||||
Company Association Details | |||||||||||||||||||||||||||||||||||||
GHS | API - RP 754 | ||||||||||||||||||||||||||||||||||||
Company or Assocation Name | Headquarter Association | Location of Event Ex - City State amp Country | Date and Time of Event | Safety InjuryDid the Event result in a Recordable Lost Time Accident or Fatality or Hospital admission of anyone on or off siteUse Drop Down Menu | Safety InjuryIf yes please insert the total number of injuries | Safety InjuryFor puropses of utilizing the Severity Table please indicate the level of severity by chosing the MOST SEVERE classification that describes your incidentUse Drop Down Menu | Safety InjuryDid the incident involve Fatalities If so how many total fatalities If none enter Zero | Safety InjuryPlease Report Total Employee Hours for Calendar Year 2015 | Safety InjuryPlease Report Total Contractor Hours for Calendar Year 2015 | Direct Cost Did the Event result in Direct Damage CostUse Drop Down Menu | Direct Cost If so how muchAmount is in US DollarsUse Drop Down Menu | Community ImpactDid the event result inbull Officially declared shelter-in-place or officially declared evacuation (on or off site)ORbull Precautionary off site shelter in place or evacuation Use Drop Down Menu | Environmental ImpactDid the event result inAcute Environmental Remediation CostIf so indicate the amount in US DollarsUse Drop Down Menu | Material ReleasedDid the Event result in an Acute Release of material beyond one of the two threshold tablesIf so indicate which Threshold Table you used to make this determinationUse Drop Down Menu | Material ReleasedIf so indicate the amount released USING GHS CLASSIFICATION TABLEUse Drop Down Menu | Material ReleasedIf so indicate the amount released USING THE THRESHOLD TABLE FROM API RP-754Use Drop Down Menu | Material ReleasedIf available please indicate the material released | ||||||||||||||||||||
1 | ABC Chemical Company | American Chemistry Council | Washington DC - USA | January 4 2016 | Yes | 2 | middot Days Away From Work injury to an employee contractor or subcontractor or middot Injury requiring treatment beyond first aid to a third party | 0 | 5525000 | 1500250 | No | $2500 to $25000 | Yes le 3 hours | $2500 to $25000 | Yes - Using GHS TABLE | 40x le TQ lt 160x | NA | Chlorine | |||||||||||||||||||
2 | XYZ Chemical Company | American Chemistry Council | Washington DC - USA | 5-Jan-16 | Yes | 1 | middot Injury requiring treatment beyond first aid to an employee contractor or subcontractor | 0 | 5525000 | 1500250 | Yes | $2500 to $25000 | No | $2500 to $25000 | Yes - Using API RP 754 TABLE | NA | 3x le TQ lt 9x | Benzene | |||||||||||||||||||
3 | |||||||||||||||||||||||||||||||||||||
4 | |||||||||||||||||||||||||||||||||||||
5 | |||||||||||||||||||||||||||||||||||||
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7 | |||||||||||||||||||||||||||||||||||||
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22 | |||||||||||||||||||||||||||||||||||||
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24 | |||||||||||||||||||||||||||||||||||||
25 | |||||||||||||||||||||||||||||||||||||
Zero or None | Yes - Duration Unknown | ||||||||||||||||||||||||||||||||||||
Processes | Mode of Operation | Type of material released | Status of Operation | ||||
REFINING | Start-up | Flammable | Open | ||||
Alkylation HF | Planned shutdown | Combustible | Closed | ||||
Alkylation sulfuric | Emergency shutdown | Toxic | |||||
BitumenResidAsphalt | Normal | Corrosive | Tier 1 Acute Releases | ||||
Calcining | Upset | Utilities | No Release | ||||
Coking | Turnaround | Other | Category 1 | ||||
Crude | Routine maintenance | Category 2 | |||||
Desulfurization | Temporary | Evacuation | Category 3 | ||||
FCC | Other | Yes | Category 4 | ||||
Gas Treating | No | Category 5 | |||||
Hydrogen | Point of Release | Category 6 | |||||
Hydrotreating | Pump | Fire | Category 7 | ||||
Hydrocracking | Compressor | Yes | Multiple Categories | ||||
Isom | BlowerFan | No | |||||
MarineJetty | Pressure Vessel | lt $2500 | |||||
Reforming | FilterCoalescer | ||||||
Sulfur recovery | Furnace | PRDs | |||||
Vapor recoverylight ends | Boiler | Directly to Atmosphere | |||||
Wastewater | Heat exchanger | via Downstream Destructive Device | |||||
REFINING amp PETROCHEMICAL | Cooling Tower | No | |||||
Tank FarmStorage FacilityOffsite | Piping system | Yes | |||||
UtilitiesSteam PlantCogeneration | Reactor | No | |||||
Other | Atmospheric tank | ||||||
PETROCHEMICAL | FlareRelief System | Acute release above thresholds | |||||
CO H2 | Other | Yes | |||||
LNG | No | ||||||
Methane | Events | ||||||
Methanol | No Tier 1 Events | Indoor Outdoor | |||||
Methyl Mercaptan | No Tier 2 Events | No Release | |||||
Formaldehyde | No Tier 1 or Tier 2 Events | Indoor | |||||
Formaldehyde derivatives | NA | Outdoor | |||||
Acetic Acid | |||||||
Acetic Acid derivatives | Event Type | ||||||
Ethane | Injury | ||||||
Ethylene | Fire | ||||||
Ethanol | Explosion | ||||||
Ethylene oxide | PRD Discharge | ||||||
Ethylene derivatives | Acute Release | ||||||
Polyethylene | |||||||
Ethylene dichloride | General | ||||||
Ethylene dichloride derivatives | Yes | ||||||
Ethyl benzene | No | ||||||
Ethyl benzene derivatives | |||||||
Polystyrene | |||||||
Styrene-Butadiene | |||||||
Propane | |||||||
Propylene | |||||||
Polypropylene | |||||||
Isopropanol | |||||||
Propylene oxide | |||||||
Propylene oxide derivatives | |||||||
Butane | |||||||
Isobutane | |||||||
Isobutene | |||||||
Butadiene | |||||||
MTBE | |||||||
ETBE | |||||||
Pentane | |||||||
Hexane | |||||||
Cyclohexane | |||||||
Hexanol | |||||||
Aromatics Derivatives | |||||||
Benzene | |||||||
Toluene | |||||||
Xylene | |||||||
Para Xylene | |||||||
Amines Derivatives | |||||||
TDA MDA IPDA etc | |||||||
Isocyanates | |||||||
Specialty Chemicals | |||||||
LoadingUnloading | |||||||
Pilot Plant |
Instructions | ||||||||||||||
Step 1 | Complete the Contact Tab with your contact information and company information | |||||||||||||
Be sure to note the region of your reporting (IE North America France Japan etc) | ||||||||||||||
Survey on Process Safety Events | ||||||||||||||
Step 2 | Complete the survey one line per Process Safety Event for your companyregion | |||||||||||||
ALL REPORTED DATA SHOULD BE FROM CALENDAR YEAR 2017 | ||||||||||||||
Step 3 | Return completed survey to | |||||||||||||
Company Name | ||||||||||||||
Contact Person | All Surveys Due by xxx date | |||||||||||||
Address | ||||||||||||||
Fax | ||||||||||||||
Telephone | ||||||||||||||
Region | ||||||||||||||
21
安全洩壓裝置 系統
9 製程單元發生異常安全閥開啟將洩漏物質釋放到排氣口此釋壓排放裝置是依相關要求設計
的且氣體釋到大氣中並未造成不良後果這不是一個須提報的製程安全事件因為安全閥高
壓破裂盤以及類似的安全裝置是依據 API 521 或者同等的標準設計的且此排放並未造成 (1)
夾帶液體並導致須提報的製程安全事件的後果(譬如損失工時意外死亡火災或爆炸造成$2500
美元或以上的直接成本損失液體或毒性氣體洩漏量達到或超過恕限值(2) 啟動廠內或廠外就地
避難應變或(3)啟動公眾保護措施
10 製程單元發生異常安全閥並未開啟造成設備超壓易燃性氣體從一個法蘭處ldquo急性rdquo漏出來
洩露量超過 100 公斤(一小時內)的恕限值該事故屬於須提報的製程安全事件因為從法蘭處外
漏屬於製程安全事件應提報事項
損工事故
11 一名作業員走路時不慎滑倒造成損失工時之工傷滑倒原因為天氣狀況rdquo長期rdquo油垢的地面和
易滑鞋具該事故不屬於須提報的製程安全事件因為人員安全ldquo滑倒絆倒跌倒rdquo事故若非與
一次阻絕設施失效直接關聯的疏散或應變造成則不屬於須提報的製程安全事件
12 與前例相同的事件惟這次作業員跌倒是因為少量易燃液體外漏(如 1 小時內少於 10 公斤)在採取
相關應變措施時發生該事故屬於須提報的製程安全事件因為作業員係為了應變一次阻絕設施
失效的事故而跌倒若一次阻絕設施失效發生在公司廠區且造成失時工傷或死亡後果該事故
便屬於須提報的製程安全事件對於因洩漏造成死亡和損失工時之工傷事故沒有洩漏量門檻
13 與前例相同的事件惟這次作業員跌倒是在事件結束數小時之後該事故不屬於須提報的製程安
全事件在提報要件中所用的ldquo疏散rdquo和ldquo應變rdquo等術語指的是一次阻絕設施失效和相關緊急應變
活動正在持續中事件結束後滑倒絆倒跌倒(如ldquo事後rdquo清理和補救)不屬於須提報製程安全事件
14 工人在因附近設備一次阻絕設施失效在疏散過程中一名鷹架搭建工人從鷹架梯上跌落造成損
失工時之工傷該事故屬於須提報的製程安全事件
15 一名作業員行經一個設計不良的蒸汽卻水器時被外洩的蒸汽燙傷腳踝造成損失工時之工傷
該事故屬於須提報的製程安全事件因為雖然一次阻絕設施失效洩漏出的是蒸汽(而非碳氫化合物
或化學物質)但損失工時之工傷是由於洩漏物質的物理狀態所導致的
16 一個密閉空間依照計畫以氮氣吹清一名承攬商繞過安全管制進入該密閉空間因而死亡該事
故屬於須提報的死亡事件但不屬於須提報的製程安全事件因為其中不涉及非計劃或失控的一
次阻絕設施失效
17 情況同上惟這次氮氣是非刻意洩漏進入該局限空間該事故屬於須提報的製程安全事件(同時也
是一起死亡事件)因為該名承攬商的死亡與非計劃的一次阻絕設施失效有關
22
18 一名作業員因硫化氫(H2S)警報在進行應變處理時昏倒若警報確實是因非計劃或失控的 H2S 一次
阻絕設施失效的外洩事件該事故便屬於須提報的製程安全事件若警報是一個假警報則該事
故便不屬於須提報的製程安全事件因為沒有真正的化學品洩漏發生
管線
19 一條管線破漏1 小時內洩漏 2000 磅(900 公斤)易燃蒸氣到地面但洩漏位置在廠區內很偏僻的
地點該事故仍屬於須提報的製程安全事件因為ldquo偏僻rdquo不是提報與否的考量因素
與化學物質外洩無關之火災或能量釋放事故
一般通則而言唯有當火災或能量釋放事故是因化學物質洩漏所造成或其發生導致化學物質洩漏
超過提報恕限值這些事故才屬於須提報的製程安全事件實例包括
20 一場電氣火災影響製程操作導致甲苯洩漏 400 公斤該事故屬於須提報的製程安全事件因為
化學物質洩漏已超過甲苯的 100 公斤提報恕限值
21 發生電氣火災停電或任何公用資源供應中斷可能造成工廠停工及可能引起設備損失超過
$2500 美元(如因非正常停工導致反應器或設備損壞)但並未造成超過恕限值的化學物質洩漏
亦未造成死亡或嚴重工傷該事故不屬於須提報的製程安全事件因為設備損壞並非化學製程火
災爆炸造成且化學物質洩漏並未超過恕限值
海上運輸船
22 一艘由公司營運的海上運輸船在船上發生ldquo急性rdquo易燃物質外洩洩漏量超過 100 公斤該事故不
屬於須提報的製程安全事件因為除非海上運輸船是為了輸送半成品或產品而與煉油石化或化
學製造廠的設施相連接否則其洩漏事故便不被視為製程安全事件
23 一艘第三方駁船由一艘拖船推向碼頭結果撞上公司的碼頭駁船的一個船艙破裂且造成
1000 公斤柴油洩漏到海中該事故不屬於須提報的製程安全事件因為駁船當時並非停泊在碼
頭內且其作業並非在進行半成品或產品之輸送
卡車與軌道車
24 一輛公司的軌道車在運輸途中出軌造成超過 1000 公斤汽油洩漏該事故不屬於須提報的製程
安全事件因為在公司廠區外發生的軌道車事故不被視為與製程安全有關
23
25 一輛第三方卡車拖車在公司廠區內翻覆造成ldquo急性rdquo汽油洩漏超過 1000 公斤這事故不屬於須
提報的製程安全事件因為卡車拖車當時已不再與裝卸設備連接然而我們建議會員公司另
行訂定運輸安全事故指標將這類事故記錄下來
26 一位合約卡車作業者正在卸載液鹼時發生軟管脫落造成空氣中氣霧和或液鹼液洩漏 2500 公
斤該事故屬於須提報的製程安全事件因為洩漏量已超過液鹼的 100 公斤恕限值且事故發生
前卡車仍與裝卸設備相連接著
辦公建築
27 綜合辦公大樓發生鍋爐火災造成總計$75000 美元的直接成本損失該事故不屬於須提報的製
程安全事件因為辦公大樓事故不被視為與製程安全有關
人機介面事故
28 一名操作技術員在聚合物工廠的終端設備旁作業時受傷這傷害是因機械的人機介面的設備而
造成該事故不屬於須提報的製程安全事件因為技術員受傷並非因危險物質一次阻絕設施失效
而造成的
混合物
29 若混合物本身有 GHS 分類可利用其分類確定恕限值若混合物本身沒有 GHS 分類則可計算混
合物中每個單一組成分之洩漏量(公斤)相對於個別成分恕限值之比值作為其對混合物恕限值之
lsquo加權rsquo貢獻譬如若混合物在 1小時內的洩漏量為 100公斤其中包含 05公斤分類為劇毒 H300
的物質45 公斤分類為 H301 的物質40 公斤另一種分類為 H 開頭的物質其餘 55 公斤則為沒
有 GHS 分類的水分此混合物之計算式為051 + 4510 + 40100 = 05 + 045 + 04 = 135超過
1因此該事故被視為須提報的製程安全事件雖然混合物個別成分之洩漏量均未超過各該物質
本身的恕限值
直接損失成本
30 此一門檻所考慮的成本應為可直接歸因於火災或爆炸的成本譬如設備及結構損壞的重置成本
修理成本環境清理支出緊急應變和罰款直接成本不包括間接成本譬如業務機會損失設
備停機造成之利潤損失取得或運轉臨時設施之成本或為滿足顧客需求取得替代產品的成本
(產品損失)
24
31 範例連接到氣體處理系統的排放管發生易燃氣體外漏同時製程出現問題導致空氣進入同
一條排放管結果發生爆炸過高的壓力損壞了排放管及其相關上游設備包括一個密封罐並
未造成人員受傷修理成本約$12000 美元該事故屬於須提報的製程安全事件因為爆炸及火
災導致設備修理成本超過門檻
32 範例一次製程安全事件後公司又發生一種非常特殊的 GHS 第 5 類產品洩漏 50 公斤造成
$2000 美元的設備損失洩漏的產品是一種非常特別的混合物公司須負擔超過$50000 美元因
產品耗損而產生之材料成本該事故不屬於須提報的製程安全事件因為 GHS 第 5 類產品洩漏的
提報門檻為 100 公斤且產品耗損不被計入直接損失成本
天然災害
33 天然災害可能對化學製程作業構成重大風險且對製程設備造成損壞導致危害物質一次阻絕設
施失效當一種或多種天然災害被認為可能對工廠作業造成影響時製程安全和作業系統應從危
害及後果分析工廠機器設備設計公用設施失效及製程停工之操作程序緊急應變計畫及應變
措施等方面界定潛在風險進行防範
天然災害類型包括颶風及颱風(包括伴隨而來的風暴潮)水災龍捲風地震超強對流風暴(直
線風暴)野火火山爆發海嘯和山崩
若公司廠房設施遭遇天然災害且其後果觸發一種或以上提報門檻該事故便屬於須提報製程安
全事件
預防性公眾應變
34 預防性公眾應變是基於謹慎的態度所採取的一種措施譬如當發生一次阻絕設施失效時公司
可能在尚未進行任何評估(如方向與洩漏點的距離等等)前便要求全體工人就地避難又
如地方權責官員(如消防警察民防緊急應變管理部門)在獲報一家公司發生製程安全事件
後為防lsquo萬一rsquo風向改變或基於可能受到波及的人口敏感族群(如學童或老年人)可能在尚未接
獲明確資訊前便下令社區就地避難或疏散或採取公眾保護措施(如道路封閉)
製程附屬倉庫
35 製程附屬倉庫指的是位於廠內用於儲存將投入於生產製程或產自於製程之原料半成品或成品的
倉庫從製程的觀點看來製程附屬倉庫相當於一個大型儲槽但這些原料半成品或成品並不
是儲存在一的大型容器中而是裝在較小的容器裡(如太空包大桶桶罐等)
25
Appendix C ndash List of RCLG Taskforce Members
Name Affiliation
Peter Schmelzer Bayer CEFIC - Chairman
Americo Diniz Carvalho Neto Braskem
Bradford Johnson American Chemistry Council
David Cummings DuPont
Debra Phillips American Chemistry Council
Hans Schwarz BASF
Kathryn Walton Plastics and Chemicals Industries Association
Kazuyuki Akita Japanese Chemical Industry Association
Kelly Keim ExxonMobil Chemical Company API Representative
Kenan Stevick Dow
Kiyokazu Murata Japanese Chemical Industry Association
Larry Bowler SABIC
Lorna Young Chemical Industry Association of Canada
Louisa Nara Center for Chemical Process Safety
Luiz Shizuo Harayashiki Associaccedilatildeo Brasileira da Induacutestria Quiacutemica
Masatoshi Kumamoto Japanese Chemical Industry Association
Milton Lacerda Petrobras
Phil Scott Chemical Industries Association
Piet Knijff DSM European Process Safety Centre
Scott Donaldson and Eamon Chandler
Shell
Scott Wallace Olin Corporation
Shakeel Kadri Air Products and Chemicals Inc
26
附錄 D ndash 詳細活動時程表
2016 年 2017 年 2018 年 2019 年 2020 年
2 ndash 4 月
RCLG PS 先導計畫
5 月 ndash
針對準則進行調整釐清
6 月 向 RCLG 和 ICCA 董事會報
告先導計畫執行結果
7 ndash 12 月 RCLG 協會考量準
則並為其會員公司發展提報機制
如有需要RCLG可向 ICCA 申請能
力建立基金為會員公司舉辦製程安
全研習會
1 ndash 12 月
RCLG 協會開始向其會員公司蒐集製程安全數據
1 ndash 12 月
如有需要RCLG 各協會運用 RCLG 的基金及專
家舉辦製程安全及績效提報研習會
1 ndash 2 月
擁有數據的協會開始向RCLG 提報製程安全事件
(2017 年數據)
4 月 RCLG 檢討第一個提報循
環的結果挑戰及原始數據(內部)
6 月 RCLG 向 ICCA 董事會呈報
原始數據
7 ndash 12 月 必要時更新及調整準
則
如有需要RCLG 各協會運用 RCLG 的基金及專
家舉辦製程安全及績效提報研習會
1 ndash 2 月
擁有數據的協會開始向RCLG 提報製程安全事件
(2018 年數據)
4 月 RCLG 檢討第二個提報循
環的結果挑戰及原始數據(內部)
6 月 RCLG 向 ICCA 董事會呈報
原始數據
7 ndash 12 月 必要時更新及調整準
則
如有需要RCLG 協會運用 RCLG 的基金及專家
舉辦製程安全及績效提報研習會
1 ndash 2 月
所有協會開始向 RCLG 提報製程安全事件
製程安全事件提報成為
RCLG KPI 衡量指標建議基本集的一部分(2019 年數
據)
4 月 RCLG 檢討第二個提報循
環的結果挑戰及原始數據(內部考量外部提
報)
6 月 RCLG 向 ICCA 董事會呈報
原始數據
27
附錄 E ndash 選擇性 Excel 追蹤表
當會員公司開始追蹤製程安全事件時所有會員公司應採用單一表格以簡化數據分析同時讓所有公司均使用相同的追蹤表RCLG 設
計了一份選擇性追蹤表可供會員公司和協會先行利用之後他們可設計自己的追蹤表
在這裡下載追蹤表
ICCA Process Safety Event Tracking Sheetxlsx
本文件包含三個分頁分別是ldquo聯絡資料rdquoldquo調查表rdquo和儲存下拉式選單選項的ldquo請勿編輯rdquo分頁
備註
附錄 E 追蹤表僅供參考TRCA 將另行提供台灣版表格供會員公司提報
28
後語
台灣化學工業責任照顧協會(Taiwan Responsible Care Association TRCA)成立於 1998 年在台灣推行責任照顧制度已達 20 週年製造商成員
包括台灣主要上市上櫃化工公司會員公司化學品生產製造量約佔全國 80 2016 年台灣化工業的 Chemical Sales 仍站在全球第八名的位
置額度為 630 億歐元化工業總產值達到 34 兆新台幣提供國內 416 萬人工作機會
TRCA 扮演國內廠商與國際制度接軌的角色也是國內化工業與政府機關及利益相關者溝通的橋樑與管道TRCA 會員結構依業務性質分析
涵蓋石化生產化學品製造氣體生產倉儲運輸業化學品貿易業以及工程研發設計等公司TRCA 透過供應鏈及價值鏈推行責任
照顧制度組成毒性化學物質聯防組織協助法規溝通與研析會員名冊請參考 httpwwwtrcaorgtwtrcanwork2aspx
TRCA 於 2010 年成為 ICCA (International Council of Chemical Associations 國際化學工業協會)觀察員ICCA 成立於 1989 年是全球化工製造
業的聯合會也是化學工業與 UNEP OPCW 及 OECD 的交流窗口ICCA 與其會員協會及成員公司致力於邁向永續的未來確保人類健康與
環境安全與保護全球化工業擁有超過 4兆美元的價值影響所有經濟部門ICCA 的會員幾乎在全球每個國家都有商業活動在全球六大
洲推動創新並提供超過 2000 萬個工作機會
台灣化工業在全球占有重要的一席之地在國內產業鏈也位居關鍵位置無論對國內或國際都有身為地球村一員應盡之責我們期許藉由
製程安全指標提報能更進一步提升自我在工安衛生環保與永續發展等面向的績效表現
台灣化學工業責任照顧協會
10452 台北市中山區撫順街 8 號 7 樓
電話02-2585-0552
httpwwwtrcaorgtw
None | |
$2500 to $25000 | |
$25000 to $250000 | |
$250000 to $25000000 | |
More than $25000000 | |
Yes - Using GHS TABLE | |
Yes - Using API RP 754 TABLE | |
NO | |
NA | |
1x le TQ lt 40x | |
40x le TQ lt 160x | |
160x le TQ lt 640x | |
ge 640x TQ | |
Yes le 3 hours | |
Yes 3 hours ge 12 hours | |
Yes 12 hours ge 24 hours | |
Yes ge 24 hours | |
No | |
Small-scale | |
Medium-scale | |
Large-scale | |
No | |
Yes | |
No | |
middot Injury requiring treatment beyond first aid to an employee contractor or subcontractor | |
middot Days Away From Work injury to an employee contractor or subcontractor or middot Injury requiring treatment beyond first aid to a third party | |
middot A fatality of an employee contractor or subcontractor or middot A hospital admission of a third party | |
middot Multiple fatalities of employees contractors or subcontractors or middot multiple hospital admission of third parties or middot A fatality of a third party | |
NA | |
1x le TQ lt 3x | |
3x le TQ lt 9x | |
9x le TQ lt 27x | |
ge 27x TQ |
ICCA Process Safety Pilot Reporting ProgramFebruary 8 2016 | 1 | 2 | 3 | 4 | 5 | 6 | 7 | 8 | 9 | 10 | 12 | 13 | 14 | 15 | |||||||||||||||||||||||
SAFETY Details(Meeting Local Regulations) | Direct Cost from Fire or Explosion | Community Impact | Environmental Impact | Material Released(Measured using the 1 Hour Rule) | |||||||||||||||||||||||||||||||||
Company Association Details | |||||||||||||||||||||||||||||||||||||
GHS | API - RP 754 | ||||||||||||||||||||||||||||||||||||
Company or Assocation Name | Headquarter Association | Location of Event Ex - City State amp Country | Date and Time of Event | Safety InjuryDid the Event result in a Recordable Lost Time Accident or Fatality or Hospital admission of anyone on or off siteUse Drop Down Menu | Safety InjuryIf yes please insert the total number of injuries | Safety InjuryFor puropses of utilizing the Severity Table please indicate the level of severity by chosing the MOST SEVERE classification that describes your incidentUse Drop Down Menu | Safety InjuryDid the incident involve Fatalities If so how many total fatalities If none enter Zero | Safety InjuryPlease Report Total Employee Hours for Calendar Year 2015 | Safety InjuryPlease Report Total Contractor Hours for Calendar Year 2015 | Direct Cost Did the Event result in Direct Damage CostUse Drop Down Menu | Direct Cost If so how muchAmount is in US DollarsUse Drop Down Menu | Community ImpactDid the event result inbull Officially declared shelter-in-place or officially declared evacuation (on or off site)ORbull Precautionary off site shelter in place or evacuation Use Drop Down Menu | Environmental ImpactDid the event result inAcute Environmental Remediation CostIf so indicate the amount in US DollarsUse Drop Down Menu | Material ReleasedDid the Event result in an Acute Release of material beyond one of the two threshold tablesIf so indicate which Threshold Table you used to make this determinationUse Drop Down Menu | Material ReleasedIf so indicate the amount released USING GHS CLASSIFICATION TABLEUse Drop Down Menu | Material ReleasedIf so indicate the amount released USING THE THRESHOLD TABLE FROM API RP-754Use Drop Down Menu | Material ReleasedIf available please indicate the material released | ||||||||||||||||||||
1 | ABC Chemical Company | American Chemistry Council | Washington DC - USA | January 4 2016 | Yes | 2 | middot Days Away From Work injury to an employee contractor or subcontractor or middot Injury requiring treatment beyond first aid to a third party | 0 | 5525000 | 1500250 | No | $2500 to $25000 | Yes le 3 hours | $2500 to $25000 | Yes - Using GHS TABLE | 40x le TQ lt 160x | NA | Chlorine | |||||||||||||||||||
2 | XYZ Chemical Company | American Chemistry Council | Washington DC - USA | 5-Jan-16 | Yes | 1 | middot Injury requiring treatment beyond first aid to an employee contractor or subcontractor | 0 | 5525000 | 1500250 | Yes | $2500 to $25000 | No | $2500 to $25000 | Yes - Using API RP 754 TABLE | NA | 3x le TQ lt 9x | Benzene | |||||||||||||||||||
3 | |||||||||||||||||||||||||||||||||||||
4 | |||||||||||||||||||||||||||||||||||||
5 | |||||||||||||||||||||||||||||||||||||
6 | |||||||||||||||||||||||||||||||||||||
7 | |||||||||||||||||||||||||||||||||||||
8 | |||||||||||||||||||||||||||||||||||||
9 | |||||||||||||||||||||||||||||||||||||
10 | |||||||||||||||||||||||||||||||||||||
11 | |||||||||||||||||||||||||||||||||||||
12 | |||||||||||||||||||||||||||||||||||||
13 | |||||||||||||||||||||||||||||||||||||
14 | |||||||||||||||||||||||||||||||||||||
15 | |||||||||||||||||||||||||||||||||||||
16 | |||||||||||||||||||||||||||||||||||||
17 | |||||||||||||||||||||||||||||||||||||
18 | |||||||||||||||||||||||||||||||||||||
19 | |||||||||||||||||||||||||||||||||||||
20 | |||||||||||||||||||||||||||||||||||||
21 | |||||||||||||||||||||||||||||||||||||
22 | |||||||||||||||||||||||||||||||||||||
23 | |||||||||||||||||||||||||||||||||||||
24 | |||||||||||||||||||||||||||||||||||||
25 | |||||||||||||||||||||||||||||||||||||
Zero or None | Yes - Duration Unknown | ||||||||||||||||||||||||||||||||||||
Processes | Mode of Operation | Type of material released | Status of Operation | ||||
REFINING | Start-up | Flammable | Open | ||||
Alkylation HF | Planned shutdown | Combustible | Closed | ||||
Alkylation sulfuric | Emergency shutdown | Toxic | |||||
BitumenResidAsphalt | Normal | Corrosive | Tier 1 Acute Releases | ||||
Calcining | Upset | Utilities | No Release | ||||
Coking | Turnaround | Other | Category 1 | ||||
Crude | Routine maintenance | Category 2 | |||||
Desulfurization | Temporary | Evacuation | Category 3 | ||||
FCC | Other | Yes | Category 4 | ||||
Gas Treating | No | Category 5 | |||||
Hydrogen | Point of Release | Category 6 | |||||
Hydrotreating | Pump | Fire | Category 7 | ||||
Hydrocracking | Compressor | Yes | Multiple Categories | ||||
Isom | BlowerFan | No | |||||
MarineJetty | Pressure Vessel | lt $2500 | |||||
Reforming | FilterCoalescer | ||||||
Sulfur recovery | Furnace | PRDs | |||||
Vapor recoverylight ends | Boiler | Directly to Atmosphere | |||||
Wastewater | Heat exchanger | via Downstream Destructive Device | |||||
REFINING amp PETROCHEMICAL | Cooling Tower | No | |||||
Tank FarmStorage FacilityOffsite | Piping system | Yes | |||||
UtilitiesSteam PlantCogeneration | Reactor | No | |||||
Other | Atmospheric tank | ||||||
PETROCHEMICAL | FlareRelief System | Acute release above thresholds | |||||
CO H2 | Other | Yes | |||||
LNG | No | ||||||
Methane | Events | ||||||
Methanol | No Tier 1 Events | Indoor Outdoor | |||||
Methyl Mercaptan | No Tier 2 Events | No Release | |||||
Formaldehyde | No Tier 1 or Tier 2 Events | Indoor | |||||
Formaldehyde derivatives | NA | Outdoor | |||||
Acetic Acid | |||||||
Acetic Acid derivatives | Event Type | ||||||
Ethane | Injury | ||||||
Ethylene | Fire | ||||||
Ethanol | Explosion | ||||||
Ethylene oxide | PRD Discharge | ||||||
Ethylene derivatives | Acute Release | ||||||
Polyethylene | |||||||
Ethylene dichloride | General | ||||||
Ethylene dichloride derivatives | Yes | ||||||
Ethyl benzene | No | ||||||
Ethyl benzene derivatives | |||||||
Polystyrene | |||||||
Styrene-Butadiene | |||||||
Propane | |||||||
Propylene | |||||||
Polypropylene | |||||||
Isopropanol | |||||||
Propylene oxide | |||||||
Propylene oxide derivatives | |||||||
Butane | |||||||
Isobutane | |||||||
Isobutene | |||||||
Butadiene | |||||||
MTBE | |||||||
ETBE | |||||||
Pentane | |||||||
Hexane | |||||||
Cyclohexane | |||||||
Hexanol | |||||||
Aromatics Derivatives | |||||||
Benzene | |||||||
Toluene | |||||||
Xylene | |||||||
Para Xylene | |||||||
Amines Derivatives | |||||||
TDA MDA IPDA etc | |||||||
Isocyanates | |||||||
Specialty Chemicals | |||||||
LoadingUnloading | |||||||
Pilot Plant |
Instructions | ||||||||||||||
Step 1 | Complete the Contact Tab with your contact information and company information | |||||||||||||
Be sure to note the region of your reporting (IE North America France Japan etc) | ||||||||||||||
Survey on Process Safety Events | ||||||||||||||
Step 2 | Complete the survey one line per Process Safety Event for your companyregion | |||||||||||||
ALL REPORTED DATA SHOULD BE FROM CALENDAR YEAR 2017 | ||||||||||||||
Step 3 | Return completed survey to | |||||||||||||
Company Name | ||||||||||||||
Contact Person | All Surveys Due by xxx date | |||||||||||||
Address | ||||||||||||||
Fax | ||||||||||||||
Telephone | ||||||||||||||
Region | ||||||||||||||
None | |
$2500 to $25000 | |
$25000 to $250000 | |
$250000 to $25000000 | |
More than $25000000 | |
Yes - Using GHS TABLE | |
Yes - Using API RP 754 TABLE | |
NO | |
NA | |
1x le TQ lt 40x | |
40x le TQ lt 160x | |
160x le TQ lt 640x | |
ge 640x TQ | |
Yes le 3 hours | |
Yes 3 hours ge 12 hours | |
Yes 12 hours ge 24 hours | |
Yes ge 24 hours | |
No | |
Small-scale | |
Medium-scale | |
Large-scale | |
No | |
Yes | |
No | |
middot Injury requiring treatment beyond first aid to an employee contractor or subcontractor | |
middot Days Away From Work injury to an employee contractor or subcontractor or middot Injury requiring treatment beyond first aid to a third party | |
middot A fatality of an employee contractor or subcontractor or middot A hospital admission of a third party | |
middot Multiple fatalities of employees contractors or subcontractors or middot multiple hospital admission of third parties or middot A fatality of a third party | |
NA | |
1x le TQ lt 3x | |
3x le TQ lt 9x | |
9x le TQ lt 27x | |
ge 27x TQ |
ICCA Process Safety Pilot Reporting ProgramFebruary 8 2016 | 1 | 2 | 3 | 4 | 5 | 6 | 7 | 8 | 9 | 10 | 12 | 13 | 14 | 15 | |||||||||||||||||||||||
SAFETY Details(Meeting Local Regulations) | Direct Cost from Fire or Explosion | Community Impact | Environmental Impact | Material Released(Measured using the 1 Hour Rule) | |||||||||||||||||||||||||||||||||
Company Association Details | |||||||||||||||||||||||||||||||||||||
GHS | API - RP 754 | ||||||||||||||||||||||||||||||||||||
Company or Assocation Name | Headquarter Association | Location of Event Ex - City State amp Country | Date and Time of Event | Safety InjuryDid the Event result in a Recordable Lost Time Accident or Fatality or Hospital admission of anyone on or off siteUse Drop Down Menu | Safety InjuryIf yes please insert the total number of injuries | Safety InjuryFor puropses of utilizing the Severity Table please indicate the level of severity by chosing the MOST SEVERE classification that describes your incidentUse Drop Down Menu | Safety InjuryDid the incident involve Fatalities If so how many total fatalities If none enter Zero | Safety InjuryPlease Report Total Employee Hours for Calendar Year 2015 | Safety InjuryPlease Report Total Contractor Hours for Calendar Year 2015 | Direct Cost Did the Event result in Direct Damage CostUse Drop Down Menu | Direct Cost If so how muchAmount is in US DollarsUse Drop Down Menu | Community ImpactDid the event result inbull Officially declared shelter-in-place or officially declared evacuation (on or off site)ORbull Precautionary off site shelter in place or evacuation Use Drop Down Menu | Environmental ImpactDid the event result inAcute Environmental Remediation CostIf so indicate the amount in US DollarsUse Drop Down Menu | Material ReleasedDid the Event result in an Acute Release of material beyond one of the two threshold tablesIf so indicate which Threshold Table you used to make this determinationUse Drop Down Menu | Material ReleasedIf so indicate the amount released USING GHS CLASSIFICATION TABLEUse Drop Down Menu | Material ReleasedIf so indicate the amount released USING THE THRESHOLD TABLE FROM API RP-754Use Drop Down Menu | Material ReleasedIf available please indicate the material released | ||||||||||||||||||||
1 | ABC Chemical Company | American Chemistry Council | Washington DC - USA | January 4 2016 | Yes | 2 | middot Days Away From Work injury to an employee contractor or subcontractor or middot Injury requiring treatment beyond first aid to a third party | 0 | 5525000 | 1500250 | No | $2500 to $25000 | Yes le 3 hours | $2500 to $25000 | Yes - Using GHS TABLE | 40x le TQ lt 160x | NA | Chlorine | |||||||||||||||||||
2 | XYZ Chemical Company | American Chemistry Council | Washington DC - USA | 5-Jan-16 | Yes | 1 | middot Injury requiring treatment beyond first aid to an employee contractor or subcontractor | 0 | 5525000 | 1500250 | Yes | $2500 to $25000 | No | $2500 to $25000 | Yes - Using API RP 754 TABLE | NA | 3x le TQ lt 9x | Benzene | |||||||||||||||||||
3 | |||||||||||||||||||||||||||||||||||||
4 | |||||||||||||||||||||||||||||||||||||
5 | |||||||||||||||||||||||||||||||||||||
6 | |||||||||||||||||||||||||||||||||||||
7 | |||||||||||||||||||||||||||||||||||||
8 | |||||||||||||||||||||||||||||||||||||
9 | |||||||||||||||||||||||||||||||||||||
10 | |||||||||||||||||||||||||||||||||||||
11 | |||||||||||||||||||||||||||||||||||||
12 | |||||||||||||||||||||||||||||||||||||
13 | |||||||||||||||||||||||||||||||||||||
14 | |||||||||||||||||||||||||||||||||||||
15 | |||||||||||||||||||||||||||||||||||||
16 | |||||||||||||||||||||||||||||||||||||
17 | |||||||||||||||||||||||||||||||||||||
18 | |||||||||||||||||||||||||||||||||||||
19 | |||||||||||||||||||||||||||||||||||||
20 | |||||||||||||||||||||||||||||||||||||
21 | |||||||||||||||||||||||||||||||||||||
22 | |||||||||||||||||||||||||||||||||||||
23 | |||||||||||||||||||||||||||||||||||||
24 | |||||||||||||||||||||||||||||||||||||
25 | |||||||||||||||||||||||||||||||||||||
Zero or None | Yes - Duration Unknown | ||||||||||||||||||||||||||||||||||||
Processes | Mode of Operation | Type of material released | Status of Operation | ||||
REFINING | Start-up | Flammable | Open | ||||
Alkylation HF | Planned shutdown | Combustible | Closed | ||||
Alkylation sulfuric | Emergency shutdown | Toxic | |||||
BitumenResidAsphalt | Normal | Corrosive | Tier 1 Acute Releases | ||||
Calcining | Upset | Utilities | No Release | ||||
Coking | Turnaround | Other | Category 1 | ||||
Crude | Routine maintenance | Category 2 | |||||
Desulfurization | Temporary | Evacuation | Category 3 | ||||
FCC | Other | Yes | Category 4 | ||||
Gas Treating | No | Category 5 | |||||
Hydrogen | Point of Release | Category 6 | |||||
Hydrotreating | Pump | Fire | Category 7 | ||||
Hydrocracking | Compressor | Yes | Multiple Categories | ||||
Isom | BlowerFan | No | |||||
MarineJetty | Pressure Vessel | lt $2500 | |||||
Reforming | FilterCoalescer | ||||||
Sulfur recovery | Furnace | PRDs | |||||
Vapor recoverylight ends | Boiler | Directly to Atmosphere | |||||
Wastewater | Heat exchanger | via Downstream Destructive Device | |||||
REFINING amp PETROCHEMICAL | Cooling Tower | No | |||||
Tank FarmStorage FacilityOffsite | Piping system | Yes | |||||
UtilitiesSteam PlantCogeneration | Reactor | No | |||||
Other | Atmospheric tank | ||||||
PETROCHEMICAL | FlareRelief System | Acute release above thresholds | |||||
CO H2 | Other | Yes | |||||
LNG | No | ||||||
Methane | Events | ||||||
Methanol | No Tier 1 Events | Indoor Outdoor | |||||
Methyl Mercaptan | No Tier 2 Events | No Release | |||||
Formaldehyde | No Tier 1 or Tier 2 Events | Indoor | |||||
Formaldehyde derivatives | NA | Outdoor | |||||
Acetic Acid | |||||||
Acetic Acid derivatives | Event Type | ||||||
Ethane | Injury | ||||||
Ethylene | Fire | ||||||
Ethanol | Explosion | ||||||
Ethylene oxide | PRD Discharge | ||||||
Ethylene derivatives | Acute Release | ||||||
Polyethylene | |||||||
Ethylene dichloride | General | ||||||
Ethylene dichloride derivatives | Yes | ||||||
Ethyl benzene | No | ||||||
Ethyl benzene derivatives | |||||||
Polystyrene | |||||||
Styrene-Butadiene | |||||||
Propane | |||||||
Propylene | |||||||
Polypropylene | |||||||
Isopropanol | |||||||
Propylene oxide | |||||||
Propylene oxide derivatives | |||||||
Butane | |||||||
Isobutane | |||||||
Isobutene | |||||||
Butadiene | |||||||
MTBE | |||||||
ETBE | |||||||
Pentane | |||||||
Hexane | |||||||
Cyclohexane | |||||||
Hexanol | |||||||
Aromatics Derivatives | |||||||
Benzene | |||||||
Toluene | |||||||
Xylene | |||||||
Para Xylene | |||||||
Amines Derivatives | |||||||
TDA MDA IPDA etc | |||||||
Isocyanates | |||||||
Specialty Chemicals | |||||||
LoadingUnloading | |||||||
Pilot Plant |
Instructions | ||||||||||||||
Step 1 | Complete the Contact Tab with your contact information and company information | |||||||||||||
Be sure to note the region of your reporting (IE North America France Japan etc) | ||||||||||||||
Survey on Process Safety Events | ||||||||||||||
Step 2 | Complete the survey one line per Process Safety Event for your companyregion | |||||||||||||
ALL REPORTED DATA SHOULD BE FROM CALENDAR YEAR 2017 | ||||||||||||||
Step 3 | Return completed survey to | |||||||||||||
Company Name | ||||||||||||||
Contact Person | All Surveys Due by xxx date | |||||||||||||
Address | ||||||||||||||
Fax | ||||||||||||||
Telephone | ||||||||||||||
Region | ||||||||||||||
22
18 一名作業員因硫化氫(H2S)警報在進行應變處理時昏倒若警報確實是因非計劃或失控的 H2S 一次
阻絕設施失效的外洩事件該事故便屬於須提報的製程安全事件若警報是一個假警報則該事
故便不屬於須提報的製程安全事件因為沒有真正的化學品洩漏發生
管線
19 一條管線破漏1 小時內洩漏 2000 磅(900 公斤)易燃蒸氣到地面但洩漏位置在廠區內很偏僻的
地點該事故仍屬於須提報的製程安全事件因為ldquo偏僻rdquo不是提報與否的考量因素
與化學物質外洩無關之火災或能量釋放事故
一般通則而言唯有當火災或能量釋放事故是因化學物質洩漏所造成或其發生導致化學物質洩漏
超過提報恕限值這些事故才屬於須提報的製程安全事件實例包括
20 一場電氣火災影響製程操作導致甲苯洩漏 400 公斤該事故屬於須提報的製程安全事件因為
化學物質洩漏已超過甲苯的 100 公斤提報恕限值
21 發生電氣火災停電或任何公用資源供應中斷可能造成工廠停工及可能引起設備損失超過
$2500 美元(如因非正常停工導致反應器或設備損壞)但並未造成超過恕限值的化學物質洩漏
亦未造成死亡或嚴重工傷該事故不屬於須提報的製程安全事件因為設備損壞並非化學製程火
災爆炸造成且化學物質洩漏並未超過恕限值
海上運輸船
22 一艘由公司營運的海上運輸船在船上發生ldquo急性rdquo易燃物質外洩洩漏量超過 100 公斤該事故不
屬於須提報的製程安全事件因為除非海上運輸船是為了輸送半成品或產品而與煉油石化或化
學製造廠的設施相連接否則其洩漏事故便不被視為製程安全事件
23 一艘第三方駁船由一艘拖船推向碼頭結果撞上公司的碼頭駁船的一個船艙破裂且造成
1000 公斤柴油洩漏到海中該事故不屬於須提報的製程安全事件因為駁船當時並非停泊在碼
頭內且其作業並非在進行半成品或產品之輸送
卡車與軌道車
24 一輛公司的軌道車在運輸途中出軌造成超過 1000 公斤汽油洩漏該事故不屬於須提報的製程
安全事件因為在公司廠區外發生的軌道車事故不被視為與製程安全有關
23
25 一輛第三方卡車拖車在公司廠區內翻覆造成ldquo急性rdquo汽油洩漏超過 1000 公斤這事故不屬於須
提報的製程安全事件因為卡車拖車當時已不再與裝卸設備連接然而我們建議會員公司另
行訂定運輸安全事故指標將這類事故記錄下來
26 一位合約卡車作業者正在卸載液鹼時發生軟管脫落造成空氣中氣霧和或液鹼液洩漏 2500 公
斤該事故屬於須提報的製程安全事件因為洩漏量已超過液鹼的 100 公斤恕限值且事故發生
前卡車仍與裝卸設備相連接著
辦公建築
27 綜合辦公大樓發生鍋爐火災造成總計$75000 美元的直接成本損失該事故不屬於須提報的製
程安全事件因為辦公大樓事故不被視為與製程安全有關
人機介面事故
28 一名操作技術員在聚合物工廠的終端設備旁作業時受傷這傷害是因機械的人機介面的設備而
造成該事故不屬於須提報的製程安全事件因為技術員受傷並非因危險物質一次阻絕設施失效
而造成的
混合物
29 若混合物本身有 GHS 分類可利用其分類確定恕限值若混合物本身沒有 GHS 分類則可計算混
合物中每個單一組成分之洩漏量(公斤)相對於個別成分恕限值之比值作為其對混合物恕限值之
lsquo加權rsquo貢獻譬如若混合物在 1小時內的洩漏量為 100公斤其中包含 05公斤分類為劇毒 H300
的物質45 公斤分類為 H301 的物質40 公斤另一種分類為 H 開頭的物質其餘 55 公斤則為沒
有 GHS 分類的水分此混合物之計算式為051 + 4510 + 40100 = 05 + 045 + 04 = 135超過
1因此該事故被視為須提報的製程安全事件雖然混合物個別成分之洩漏量均未超過各該物質
本身的恕限值
直接損失成本
30 此一門檻所考慮的成本應為可直接歸因於火災或爆炸的成本譬如設備及結構損壞的重置成本
修理成本環境清理支出緊急應變和罰款直接成本不包括間接成本譬如業務機會損失設
備停機造成之利潤損失取得或運轉臨時設施之成本或為滿足顧客需求取得替代產品的成本
(產品損失)
24
31 範例連接到氣體處理系統的排放管發生易燃氣體外漏同時製程出現問題導致空氣進入同
一條排放管結果發生爆炸過高的壓力損壞了排放管及其相關上游設備包括一個密封罐並
未造成人員受傷修理成本約$12000 美元該事故屬於須提報的製程安全事件因為爆炸及火
災導致設備修理成本超過門檻
32 範例一次製程安全事件後公司又發生一種非常特殊的 GHS 第 5 類產品洩漏 50 公斤造成
$2000 美元的設備損失洩漏的產品是一種非常特別的混合物公司須負擔超過$50000 美元因
產品耗損而產生之材料成本該事故不屬於須提報的製程安全事件因為 GHS 第 5 類產品洩漏的
提報門檻為 100 公斤且產品耗損不被計入直接損失成本
天然災害
33 天然災害可能對化學製程作業構成重大風險且對製程設備造成損壞導致危害物質一次阻絕設
施失效當一種或多種天然災害被認為可能對工廠作業造成影響時製程安全和作業系統應從危
害及後果分析工廠機器設備設計公用設施失效及製程停工之操作程序緊急應變計畫及應變
措施等方面界定潛在風險進行防範
天然災害類型包括颶風及颱風(包括伴隨而來的風暴潮)水災龍捲風地震超強對流風暴(直
線風暴)野火火山爆發海嘯和山崩
若公司廠房設施遭遇天然災害且其後果觸發一種或以上提報門檻該事故便屬於須提報製程安
全事件
預防性公眾應變
34 預防性公眾應變是基於謹慎的態度所採取的一種措施譬如當發生一次阻絕設施失效時公司
可能在尚未進行任何評估(如方向與洩漏點的距離等等)前便要求全體工人就地避難又
如地方權責官員(如消防警察民防緊急應變管理部門)在獲報一家公司發生製程安全事件
後為防lsquo萬一rsquo風向改變或基於可能受到波及的人口敏感族群(如學童或老年人)可能在尚未接
獲明確資訊前便下令社區就地避難或疏散或採取公眾保護措施(如道路封閉)
製程附屬倉庫
35 製程附屬倉庫指的是位於廠內用於儲存將投入於生產製程或產自於製程之原料半成品或成品的
倉庫從製程的觀點看來製程附屬倉庫相當於一個大型儲槽但這些原料半成品或成品並不
是儲存在一的大型容器中而是裝在較小的容器裡(如太空包大桶桶罐等)
25
Appendix C ndash List of RCLG Taskforce Members
Name Affiliation
Peter Schmelzer Bayer CEFIC - Chairman
Americo Diniz Carvalho Neto Braskem
Bradford Johnson American Chemistry Council
David Cummings DuPont
Debra Phillips American Chemistry Council
Hans Schwarz BASF
Kathryn Walton Plastics and Chemicals Industries Association
Kazuyuki Akita Japanese Chemical Industry Association
Kelly Keim ExxonMobil Chemical Company API Representative
Kenan Stevick Dow
Kiyokazu Murata Japanese Chemical Industry Association
Larry Bowler SABIC
Lorna Young Chemical Industry Association of Canada
Louisa Nara Center for Chemical Process Safety
Luiz Shizuo Harayashiki Associaccedilatildeo Brasileira da Induacutestria Quiacutemica
Masatoshi Kumamoto Japanese Chemical Industry Association
Milton Lacerda Petrobras
Phil Scott Chemical Industries Association
Piet Knijff DSM European Process Safety Centre
Scott Donaldson and Eamon Chandler
Shell
Scott Wallace Olin Corporation
Shakeel Kadri Air Products and Chemicals Inc
26
附錄 D ndash 詳細活動時程表
2016 年 2017 年 2018 年 2019 年 2020 年
2 ndash 4 月
RCLG PS 先導計畫
5 月 ndash
針對準則進行調整釐清
6 月 向 RCLG 和 ICCA 董事會報
告先導計畫執行結果
7 ndash 12 月 RCLG 協會考量準
則並為其會員公司發展提報機制
如有需要RCLG可向 ICCA 申請能
力建立基金為會員公司舉辦製程安
全研習會
1 ndash 12 月
RCLG 協會開始向其會員公司蒐集製程安全數據
1 ndash 12 月
如有需要RCLG 各協會運用 RCLG 的基金及專
家舉辦製程安全及績效提報研習會
1 ndash 2 月
擁有數據的協會開始向RCLG 提報製程安全事件
(2017 年數據)
4 月 RCLG 檢討第一個提報循
環的結果挑戰及原始數據(內部)
6 月 RCLG 向 ICCA 董事會呈報
原始數據
7 ndash 12 月 必要時更新及調整準
則
如有需要RCLG 各協會運用 RCLG 的基金及專
家舉辦製程安全及績效提報研習會
1 ndash 2 月
擁有數據的協會開始向RCLG 提報製程安全事件
(2018 年數據)
4 月 RCLG 檢討第二個提報循
環的結果挑戰及原始數據(內部)
6 月 RCLG 向 ICCA 董事會呈報
原始數據
7 ndash 12 月 必要時更新及調整準
則
如有需要RCLG 協會運用 RCLG 的基金及專家
舉辦製程安全及績效提報研習會
1 ndash 2 月
所有協會開始向 RCLG 提報製程安全事件
製程安全事件提報成為
RCLG KPI 衡量指標建議基本集的一部分(2019 年數
據)
4 月 RCLG 檢討第二個提報循
環的結果挑戰及原始數據(內部考量外部提
報)
6 月 RCLG 向 ICCA 董事會呈報
原始數據
27
附錄 E ndash 選擇性 Excel 追蹤表
當會員公司開始追蹤製程安全事件時所有會員公司應採用單一表格以簡化數據分析同時讓所有公司均使用相同的追蹤表RCLG 設
計了一份選擇性追蹤表可供會員公司和協會先行利用之後他們可設計自己的追蹤表
在這裡下載追蹤表
ICCA Process Safety Event Tracking Sheetxlsx
本文件包含三個分頁分別是ldquo聯絡資料rdquoldquo調查表rdquo和儲存下拉式選單選項的ldquo請勿編輯rdquo分頁
備註
附錄 E 追蹤表僅供參考TRCA 將另行提供台灣版表格供會員公司提報
28
後語
台灣化學工業責任照顧協會(Taiwan Responsible Care Association TRCA)成立於 1998 年在台灣推行責任照顧制度已達 20 週年製造商成員
包括台灣主要上市上櫃化工公司會員公司化學品生產製造量約佔全國 80 2016 年台灣化工業的 Chemical Sales 仍站在全球第八名的位
置額度為 630 億歐元化工業總產值達到 34 兆新台幣提供國內 416 萬人工作機會
TRCA 扮演國內廠商與國際制度接軌的角色也是國內化工業與政府機關及利益相關者溝通的橋樑與管道TRCA 會員結構依業務性質分析
涵蓋石化生產化學品製造氣體生產倉儲運輸業化學品貿易業以及工程研發設計等公司TRCA 透過供應鏈及價值鏈推行責任
照顧制度組成毒性化學物質聯防組織協助法規溝通與研析會員名冊請參考 httpwwwtrcaorgtwtrcanwork2aspx
TRCA 於 2010 年成為 ICCA (International Council of Chemical Associations 國際化學工業協會)觀察員ICCA 成立於 1989 年是全球化工製造
業的聯合會也是化學工業與 UNEP OPCW 及 OECD 的交流窗口ICCA 與其會員協會及成員公司致力於邁向永續的未來確保人類健康與
環境安全與保護全球化工業擁有超過 4兆美元的價值影響所有經濟部門ICCA 的會員幾乎在全球每個國家都有商業活動在全球六大
洲推動創新並提供超過 2000 萬個工作機會
台灣化工業在全球占有重要的一席之地在國內產業鏈也位居關鍵位置無論對國內或國際都有身為地球村一員應盡之責我們期許藉由
製程安全指標提報能更進一步提升自我在工安衛生環保與永續發展等面向的績效表現
台灣化學工業責任照顧協會
10452 台北市中山區撫順街 8 號 7 樓
電話02-2585-0552
httpwwwtrcaorgtw
None | |
$2500 to $25000 | |
$25000 to $250000 | |
$250000 to $25000000 | |
More than $25000000 | |
Yes - Using GHS TABLE | |
Yes - Using API RP 754 TABLE | |
NO | |
NA | |
1x le TQ lt 40x | |
40x le TQ lt 160x | |
160x le TQ lt 640x | |
ge 640x TQ | |
Yes le 3 hours | |
Yes 3 hours ge 12 hours | |
Yes 12 hours ge 24 hours | |
Yes ge 24 hours | |
No | |
Small-scale | |
Medium-scale | |
Large-scale | |
No | |
Yes | |
No | |
middot Injury requiring treatment beyond first aid to an employee contractor or subcontractor | |
middot Days Away From Work injury to an employee contractor or subcontractor or middot Injury requiring treatment beyond first aid to a third party | |
middot A fatality of an employee contractor or subcontractor or middot A hospital admission of a third party | |
middot Multiple fatalities of employees contractors or subcontractors or middot multiple hospital admission of third parties or middot A fatality of a third party | |
NA | |
1x le TQ lt 3x | |
3x le TQ lt 9x | |
9x le TQ lt 27x | |
ge 27x TQ |
ICCA Process Safety Pilot Reporting ProgramFebruary 8 2016 | 1 | 2 | 3 | 4 | 5 | 6 | 7 | 8 | 9 | 10 | 12 | 13 | 14 | 15 | |||||||||||||||||||||||
SAFETY Details(Meeting Local Regulations) | Direct Cost from Fire or Explosion | Community Impact | Environmental Impact | Material Released(Measured using the 1 Hour Rule) | |||||||||||||||||||||||||||||||||
Company Association Details | |||||||||||||||||||||||||||||||||||||
GHS | API - RP 754 | ||||||||||||||||||||||||||||||||||||
Company or Assocation Name | Headquarter Association | Location of Event Ex - City State amp Country | Date and Time of Event | Safety InjuryDid the Event result in a Recordable Lost Time Accident or Fatality or Hospital admission of anyone on or off siteUse Drop Down Menu | Safety InjuryIf yes please insert the total number of injuries | Safety InjuryFor puropses of utilizing the Severity Table please indicate the level of severity by chosing the MOST SEVERE classification that describes your incidentUse Drop Down Menu | Safety InjuryDid the incident involve Fatalities If so how many total fatalities If none enter Zero | Safety InjuryPlease Report Total Employee Hours for Calendar Year 2015 | Safety InjuryPlease Report Total Contractor Hours for Calendar Year 2015 | Direct Cost Did the Event result in Direct Damage CostUse Drop Down Menu | Direct Cost If so how muchAmount is in US DollarsUse Drop Down Menu | Community ImpactDid the event result inbull Officially declared shelter-in-place or officially declared evacuation (on or off site)ORbull Precautionary off site shelter in place or evacuation Use Drop Down Menu | Environmental ImpactDid the event result inAcute Environmental Remediation CostIf so indicate the amount in US DollarsUse Drop Down Menu | Material ReleasedDid the Event result in an Acute Release of material beyond one of the two threshold tablesIf so indicate which Threshold Table you used to make this determinationUse Drop Down Menu | Material ReleasedIf so indicate the amount released USING GHS CLASSIFICATION TABLEUse Drop Down Menu | Material ReleasedIf so indicate the amount released USING THE THRESHOLD TABLE FROM API RP-754Use Drop Down Menu | Material ReleasedIf available please indicate the material released | ||||||||||||||||||||
1 | ABC Chemical Company | American Chemistry Council | Washington DC - USA | January 4 2016 | Yes | 2 | middot Days Away From Work injury to an employee contractor or subcontractor or middot Injury requiring treatment beyond first aid to a third party | 0 | 5525000 | 1500250 | No | $2500 to $25000 | Yes le 3 hours | $2500 to $25000 | Yes - Using GHS TABLE | 40x le TQ lt 160x | NA | Chlorine | |||||||||||||||||||
2 | XYZ Chemical Company | American Chemistry Council | Washington DC - USA | 5-Jan-16 | Yes | 1 | middot Injury requiring treatment beyond first aid to an employee contractor or subcontractor | 0 | 5525000 | 1500250 | Yes | $2500 to $25000 | No | $2500 to $25000 | Yes - Using API RP 754 TABLE | NA | 3x le TQ lt 9x | Benzene | |||||||||||||||||||
3 | |||||||||||||||||||||||||||||||||||||
4 | |||||||||||||||||||||||||||||||||||||
5 | |||||||||||||||||||||||||||||||||||||
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8 | |||||||||||||||||||||||||||||||||||||
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10 | |||||||||||||||||||||||||||||||||||||
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14 | |||||||||||||||||||||||||||||||||||||
15 | |||||||||||||||||||||||||||||||||||||
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17 | |||||||||||||||||||||||||||||||||||||
18 | |||||||||||||||||||||||||||||||||||||
19 | |||||||||||||||||||||||||||||||||||||
20 | |||||||||||||||||||||||||||||||||||||
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22 | |||||||||||||||||||||||||||||||||||||
23 | |||||||||||||||||||||||||||||||||||||
24 | |||||||||||||||||||||||||||||||||||||
25 | |||||||||||||||||||||||||||||||||||||
Zero or None | Yes - Duration Unknown | ||||||||||||||||||||||||||||||||||||
Processes | Mode of Operation | Type of material released | Status of Operation | ||||
REFINING | Start-up | Flammable | Open | ||||
Alkylation HF | Planned shutdown | Combustible | Closed | ||||
Alkylation sulfuric | Emergency shutdown | Toxic | |||||
BitumenResidAsphalt | Normal | Corrosive | Tier 1 Acute Releases | ||||
Calcining | Upset | Utilities | No Release | ||||
Coking | Turnaround | Other | Category 1 | ||||
Crude | Routine maintenance | Category 2 | |||||
Desulfurization | Temporary | Evacuation | Category 3 | ||||
FCC | Other | Yes | Category 4 | ||||
Gas Treating | No | Category 5 | |||||
Hydrogen | Point of Release | Category 6 | |||||
Hydrotreating | Pump | Fire | Category 7 | ||||
Hydrocracking | Compressor | Yes | Multiple Categories | ||||
Isom | BlowerFan | No | |||||
MarineJetty | Pressure Vessel | lt $2500 | |||||
Reforming | FilterCoalescer | ||||||
Sulfur recovery | Furnace | PRDs | |||||
Vapor recoverylight ends | Boiler | Directly to Atmosphere | |||||
Wastewater | Heat exchanger | via Downstream Destructive Device | |||||
REFINING amp PETROCHEMICAL | Cooling Tower | No | |||||
Tank FarmStorage FacilityOffsite | Piping system | Yes | |||||
UtilitiesSteam PlantCogeneration | Reactor | No | |||||
Other | Atmospheric tank | ||||||
PETROCHEMICAL | FlareRelief System | Acute release above thresholds | |||||
CO H2 | Other | Yes | |||||
LNG | No | ||||||
Methane | Events | ||||||
Methanol | No Tier 1 Events | Indoor Outdoor | |||||
Methyl Mercaptan | No Tier 2 Events | No Release | |||||
Formaldehyde | No Tier 1 or Tier 2 Events | Indoor | |||||
Formaldehyde derivatives | NA | Outdoor | |||||
Acetic Acid | |||||||
Acetic Acid derivatives | Event Type | ||||||
Ethane | Injury | ||||||
Ethylene | Fire | ||||||
Ethanol | Explosion | ||||||
Ethylene oxide | PRD Discharge | ||||||
Ethylene derivatives | Acute Release | ||||||
Polyethylene | |||||||
Ethylene dichloride | General | ||||||
Ethylene dichloride derivatives | Yes | ||||||
Ethyl benzene | No | ||||||
Ethyl benzene derivatives | |||||||
Polystyrene | |||||||
Styrene-Butadiene | |||||||
Propane | |||||||
Propylene | |||||||
Polypropylene | |||||||
Isopropanol | |||||||
Propylene oxide | |||||||
Propylene oxide derivatives | |||||||
Butane | |||||||
Isobutane | |||||||
Isobutene | |||||||
Butadiene | |||||||
MTBE | |||||||
ETBE | |||||||
Pentane | |||||||
Hexane | |||||||
Cyclohexane | |||||||
Hexanol | |||||||
Aromatics Derivatives | |||||||
Benzene | |||||||
Toluene | |||||||
Xylene | |||||||
Para Xylene | |||||||
Amines Derivatives | |||||||
TDA MDA IPDA etc | |||||||
Isocyanates | |||||||
Specialty Chemicals | |||||||
LoadingUnloading | |||||||
Pilot Plant |
Instructions | ||||||||||||||
Step 1 | Complete the Contact Tab with your contact information and company information | |||||||||||||
Be sure to note the region of your reporting (IE North America France Japan etc) | ||||||||||||||
Survey on Process Safety Events | ||||||||||||||
Step 2 | Complete the survey one line per Process Safety Event for your companyregion | |||||||||||||
ALL REPORTED DATA SHOULD BE FROM CALENDAR YEAR 2017 | ||||||||||||||
Step 3 | Return completed survey to | |||||||||||||
Company Name | ||||||||||||||
Contact Person | All Surveys Due by xxx date | |||||||||||||
Address | ||||||||||||||
Fax | ||||||||||||||
Telephone | ||||||||||||||
Region | ||||||||||||||
None | |
$2500 to $25000 | |
$25000 to $250000 | |
$250000 to $25000000 | |
More than $25000000 | |
Yes - Using GHS TABLE | |
Yes - Using API RP 754 TABLE | |
NO | |
NA | |
1x le TQ lt 40x | |
40x le TQ lt 160x | |
160x le TQ lt 640x | |
ge 640x TQ | |
Yes le 3 hours | |
Yes 3 hours ge 12 hours | |
Yes 12 hours ge 24 hours | |
Yes ge 24 hours | |
No | |
Small-scale | |
Medium-scale | |
Large-scale | |
No | |
Yes | |
No | |
middot Injury requiring treatment beyond first aid to an employee contractor or subcontractor | |
middot Days Away From Work injury to an employee contractor or subcontractor or middot Injury requiring treatment beyond first aid to a third party | |
middot A fatality of an employee contractor or subcontractor or middot A hospital admission of a third party | |
middot Multiple fatalities of employees contractors or subcontractors or middot multiple hospital admission of third parties or middot A fatality of a third party | |
NA | |
1x le TQ lt 3x | |
3x le TQ lt 9x | |
9x le TQ lt 27x | |
ge 27x TQ |
ICCA Process Safety Pilot Reporting ProgramFebruary 8 2016 | 1 | 2 | 3 | 4 | 5 | 6 | 7 | 8 | 9 | 10 | 12 | 13 | 14 | 15 | |||||||||||||||||||||||
SAFETY Details(Meeting Local Regulations) | Direct Cost from Fire or Explosion | Community Impact | Environmental Impact | Material Released(Measured using the 1 Hour Rule) | |||||||||||||||||||||||||||||||||
Company Association Details | |||||||||||||||||||||||||||||||||||||
GHS | API - RP 754 | ||||||||||||||||||||||||||||||||||||
Company or Assocation Name | Headquarter Association | Location of Event Ex - City State amp Country | Date and Time of Event | Safety InjuryDid the Event result in a Recordable Lost Time Accident or Fatality or Hospital admission of anyone on or off siteUse Drop Down Menu | Safety InjuryIf yes please insert the total number of injuries | Safety InjuryFor puropses of utilizing the Severity Table please indicate the level of severity by chosing the MOST SEVERE classification that describes your incidentUse Drop Down Menu | Safety InjuryDid the incident involve Fatalities If so how many total fatalities If none enter Zero | Safety InjuryPlease Report Total Employee Hours for Calendar Year 2015 | Safety InjuryPlease Report Total Contractor Hours for Calendar Year 2015 | Direct Cost Did the Event result in Direct Damage CostUse Drop Down Menu | Direct Cost If so how muchAmount is in US DollarsUse Drop Down Menu | Community ImpactDid the event result inbull Officially declared shelter-in-place or officially declared evacuation (on or off site)ORbull Precautionary off site shelter in place or evacuation Use Drop Down Menu | Environmental ImpactDid the event result inAcute Environmental Remediation CostIf so indicate the amount in US DollarsUse Drop Down Menu | Material ReleasedDid the Event result in an Acute Release of material beyond one of the two threshold tablesIf so indicate which Threshold Table you used to make this determinationUse Drop Down Menu | Material ReleasedIf so indicate the amount released USING GHS CLASSIFICATION TABLEUse Drop Down Menu | Material ReleasedIf so indicate the amount released USING THE THRESHOLD TABLE FROM API RP-754Use Drop Down Menu | Material ReleasedIf available please indicate the material released | ||||||||||||||||||||
1 | ABC Chemical Company | American Chemistry Council | Washington DC - USA | January 4 2016 | Yes | 2 | middot Days Away From Work injury to an employee contractor or subcontractor or middot Injury requiring treatment beyond first aid to a third party | 0 | 5525000 | 1500250 | No | $2500 to $25000 | Yes le 3 hours | $2500 to $25000 | Yes - Using GHS TABLE | 40x le TQ lt 160x | NA | Chlorine | |||||||||||||||||||
2 | XYZ Chemical Company | American Chemistry Council | Washington DC - USA | 5-Jan-16 | Yes | 1 | middot Injury requiring treatment beyond first aid to an employee contractor or subcontractor | 0 | 5525000 | 1500250 | Yes | $2500 to $25000 | No | $2500 to $25000 | Yes - Using API RP 754 TABLE | NA | 3x le TQ lt 9x | Benzene | |||||||||||||||||||
3 | |||||||||||||||||||||||||||||||||||||
4 | |||||||||||||||||||||||||||||||||||||
5 | |||||||||||||||||||||||||||||||||||||
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24 | |||||||||||||||||||||||||||||||||||||
25 | |||||||||||||||||||||||||||||||||||||
Zero or None | Yes - Duration Unknown | ||||||||||||||||||||||||||||||||||||
Processes | Mode of Operation | Type of material released | Status of Operation | ||||
REFINING | Start-up | Flammable | Open | ||||
Alkylation HF | Planned shutdown | Combustible | Closed | ||||
Alkylation sulfuric | Emergency shutdown | Toxic | |||||
BitumenResidAsphalt | Normal | Corrosive | Tier 1 Acute Releases | ||||
Calcining | Upset | Utilities | No Release | ||||
Coking | Turnaround | Other | Category 1 | ||||
Crude | Routine maintenance | Category 2 | |||||
Desulfurization | Temporary | Evacuation | Category 3 | ||||
FCC | Other | Yes | Category 4 | ||||
Gas Treating | No | Category 5 | |||||
Hydrogen | Point of Release | Category 6 | |||||
Hydrotreating | Pump | Fire | Category 7 | ||||
Hydrocracking | Compressor | Yes | Multiple Categories | ||||
Isom | BlowerFan | No | |||||
MarineJetty | Pressure Vessel | lt $2500 | |||||
Reforming | FilterCoalescer | ||||||
Sulfur recovery | Furnace | PRDs | |||||
Vapor recoverylight ends | Boiler | Directly to Atmosphere | |||||
Wastewater | Heat exchanger | via Downstream Destructive Device | |||||
REFINING amp PETROCHEMICAL | Cooling Tower | No | |||||
Tank FarmStorage FacilityOffsite | Piping system | Yes | |||||
UtilitiesSteam PlantCogeneration | Reactor | No | |||||
Other | Atmospheric tank | ||||||
PETROCHEMICAL | FlareRelief System | Acute release above thresholds | |||||
CO H2 | Other | Yes | |||||
LNG | No | ||||||
Methane | Events | ||||||
Methanol | No Tier 1 Events | Indoor Outdoor | |||||
Methyl Mercaptan | No Tier 2 Events | No Release | |||||
Formaldehyde | No Tier 1 or Tier 2 Events | Indoor | |||||
Formaldehyde derivatives | NA | Outdoor | |||||
Acetic Acid | |||||||
Acetic Acid derivatives | Event Type | ||||||
Ethane | Injury | ||||||
Ethylene | Fire | ||||||
Ethanol | Explosion | ||||||
Ethylene oxide | PRD Discharge | ||||||
Ethylene derivatives | Acute Release | ||||||
Polyethylene | |||||||
Ethylene dichloride | General | ||||||
Ethylene dichloride derivatives | Yes | ||||||
Ethyl benzene | No | ||||||
Ethyl benzene derivatives | |||||||
Polystyrene | |||||||
Styrene-Butadiene | |||||||
Propane | |||||||
Propylene | |||||||
Polypropylene | |||||||
Isopropanol | |||||||
Propylene oxide | |||||||
Propylene oxide derivatives | |||||||
Butane | |||||||
Isobutane | |||||||
Isobutene | |||||||
Butadiene | |||||||
MTBE | |||||||
ETBE | |||||||
Pentane | |||||||
Hexane | |||||||
Cyclohexane | |||||||
Hexanol | |||||||
Aromatics Derivatives | |||||||
Benzene | |||||||
Toluene | |||||||
Xylene | |||||||
Para Xylene | |||||||
Amines Derivatives | |||||||
TDA MDA IPDA etc | |||||||
Isocyanates | |||||||
Specialty Chemicals | |||||||
LoadingUnloading | |||||||
Pilot Plant |
Instructions | ||||||||||||||
Step 1 | Complete the Contact Tab with your contact information and company information | |||||||||||||
Be sure to note the region of your reporting (IE North America France Japan etc) | ||||||||||||||
Survey on Process Safety Events | ||||||||||||||
Step 2 | Complete the survey one line per Process Safety Event for your companyregion | |||||||||||||
ALL REPORTED DATA SHOULD BE FROM CALENDAR YEAR 2017 | ||||||||||||||
Step 3 | Return completed survey to | |||||||||||||
Company Name | ||||||||||||||
Contact Person | All Surveys Due by xxx date | |||||||||||||
Address | ||||||||||||||
Fax | ||||||||||||||
Telephone | ||||||||||||||
Region | ||||||||||||||
23
25 一輛第三方卡車拖車在公司廠區內翻覆造成ldquo急性rdquo汽油洩漏超過 1000 公斤這事故不屬於須
提報的製程安全事件因為卡車拖車當時已不再與裝卸設備連接然而我們建議會員公司另
行訂定運輸安全事故指標將這類事故記錄下來
26 一位合約卡車作業者正在卸載液鹼時發生軟管脫落造成空氣中氣霧和或液鹼液洩漏 2500 公
斤該事故屬於須提報的製程安全事件因為洩漏量已超過液鹼的 100 公斤恕限值且事故發生
前卡車仍與裝卸設備相連接著
辦公建築
27 綜合辦公大樓發生鍋爐火災造成總計$75000 美元的直接成本損失該事故不屬於須提報的製
程安全事件因為辦公大樓事故不被視為與製程安全有關
人機介面事故
28 一名操作技術員在聚合物工廠的終端設備旁作業時受傷這傷害是因機械的人機介面的設備而
造成該事故不屬於須提報的製程安全事件因為技術員受傷並非因危險物質一次阻絕設施失效
而造成的
混合物
29 若混合物本身有 GHS 分類可利用其分類確定恕限值若混合物本身沒有 GHS 分類則可計算混
合物中每個單一組成分之洩漏量(公斤)相對於個別成分恕限值之比值作為其對混合物恕限值之
lsquo加權rsquo貢獻譬如若混合物在 1小時內的洩漏量為 100公斤其中包含 05公斤分類為劇毒 H300
的物質45 公斤分類為 H301 的物質40 公斤另一種分類為 H 開頭的物質其餘 55 公斤則為沒
有 GHS 分類的水分此混合物之計算式為051 + 4510 + 40100 = 05 + 045 + 04 = 135超過
1因此該事故被視為須提報的製程安全事件雖然混合物個別成分之洩漏量均未超過各該物質
本身的恕限值
直接損失成本
30 此一門檻所考慮的成本應為可直接歸因於火災或爆炸的成本譬如設備及結構損壞的重置成本
修理成本環境清理支出緊急應變和罰款直接成本不包括間接成本譬如業務機會損失設
備停機造成之利潤損失取得或運轉臨時設施之成本或為滿足顧客需求取得替代產品的成本
(產品損失)
24
31 範例連接到氣體處理系統的排放管發生易燃氣體外漏同時製程出現問題導致空氣進入同
一條排放管結果發生爆炸過高的壓力損壞了排放管及其相關上游設備包括一個密封罐並
未造成人員受傷修理成本約$12000 美元該事故屬於須提報的製程安全事件因為爆炸及火
災導致設備修理成本超過門檻
32 範例一次製程安全事件後公司又發生一種非常特殊的 GHS 第 5 類產品洩漏 50 公斤造成
$2000 美元的設備損失洩漏的產品是一種非常特別的混合物公司須負擔超過$50000 美元因
產品耗損而產生之材料成本該事故不屬於須提報的製程安全事件因為 GHS 第 5 類產品洩漏的
提報門檻為 100 公斤且產品耗損不被計入直接損失成本
天然災害
33 天然災害可能對化學製程作業構成重大風險且對製程設備造成損壞導致危害物質一次阻絕設
施失效當一種或多種天然災害被認為可能對工廠作業造成影響時製程安全和作業系統應從危
害及後果分析工廠機器設備設計公用設施失效及製程停工之操作程序緊急應變計畫及應變
措施等方面界定潛在風險進行防範
天然災害類型包括颶風及颱風(包括伴隨而來的風暴潮)水災龍捲風地震超強對流風暴(直
線風暴)野火火山爆發海嘯和山崩
若公司廠房設施遭遇天然災害且其後果觸發一種或以上提報門檻該事故便屬於須提報製程安
全事件
預防性公眾應變
34 預防性公眾應變是基於謹慎的態度所採取的一種措施譬如當發生一次阻絕設施失效時公司
可能在尚未進行任何評估(如方向與洩漏點的距離等等)前便要求全體工人就地避難又
如地方權責官員(如消防警察民防緊急應變管理部門)在獲報一家公司發生製程安全事件
後為防lsquo萬一rsquo風向改變或基於可能受到波及的人口敏感族群(如學童或老年人)可能在尚未接
獲明確資訊前便下令社區就地避難或疏散或採取公眾保護措施(如道路封閉)
製程附屬倉庫
35 製程附屬倉庫指的是位於廠內用於儲存將投入於生產製程或產自於製程之原料半成品或成品的
倉庫從製程的觀點看來製程附屬倉庫相當於一個大型儲槽但這些原料半成品或成品並不
是儲存在一的大型容器中而是裝在較小的容器裡(如太空包大桶桶罐等)
25
Appendix C ndash List of RCLG Taskforce Members
Name Affiliation
Peter Schmelzer Bayer CEFIC - Chairman
Americo Diniz Carvalho Neto Braskem
Bradford Johnson American Chemistry Council
David Cummings DuPont
Debra Phillips American Chemistry Council
Hans Schwarz BASF
Kathryn Walton Plastics and Chemicals Industries Association
Kazuyuki Akita Japanese Chemical Industry Association
Kelly Keim ExxonMobil Chemical Company API Representative
Kenan Stevick Dow
Kiyokazu Murata Japanese Chemical Industry Association
Larry Bowler SABIC
Lorna Young Chemical Industry Association of Canada
Louisa Nara Center for Chemical Process Safety
Luiz Shizuo Harayashiki Associaccedilatildeo Brasileira da Induacutestria Quiacutemica
Masatoshi Kumamoto Japanese Chemical Industry Association
Milton Lacerda Petrobras
Phil Scott Chemical Industries Association
Piet Knijff DSM European Process Safety Centre
Scott Donaldson and Eamon Chandler
Shell
Scott Wallace Olin Corporation
Shakeel Kadri Air Products and Chemicals Inc
26
附錄 D ndash 詳細活動時程表
2016 年 2017 年 2018 年 2019 年 2020 年
2 ndash 4 月
RCLG PS 先導計畫
5 月 ndash
針對準則進行調整釐清
6 月 向 RCLG 和 ICCA 董事會報
告先導計畫執行結果
7 ndash 12 月 RCLG 協會考量準
則並為其會員公司發展提報機制
如有需要RCLG可向 ICCA 申請能
力建立基金為會員公司舉辦製程安
全研習會
1 ndash 12 月
RCLG 協會開始向其會員公司蒐集製程安全數據
1 ndash 12 月
如有需要RCLG 各協會運用 RCLG 的基金及專
家舉辦製程安全及績效提報研習會
1 ndash 2 月
擁有數據的協會開始向RCLG 提報製程安全事件
(2017 年數據)
4 月 RCLG 檢討第一個提報循
環的結果挑戰及原始數據(內部)
6 月 RCLG 向 ICCA 董事會呈報
原始數據
7 ndash 12 月 必要時更新及調整準
則
如有需要RCLG 各協會運用 RCLG 的基金及專
家舉辦製程安全及績效提報研習會
1 ndash 2 月
擁有數據的協會開始向RCLG 提報製程安全事件
(2018 年數據)
4 月 RCLG 檢討第二個提報循
環的結果挑戰及原始數據(內部)
6 月 RCLG 向 ICCA 董事會呈報
原始數據
7 ndash 12 月 必要時更新及調整準
則
如有需要RCLG 協會運用 RCLG 的基金及專家
舉辦製程安全及績效提報研習會
1 ndash 2 月
所有協會開始向 RCLG 提報製程安全事件
製程安全事件提報成為
RCLG KPI 衡量指標建議基本集的一部分(2019 年數
據)
4 月 RCLG 檢討第二個提報循
環的結果挑戰及原始數據(內部考量外部提
報)
6 月 RCLG 向 ICCA 董事會呈報
原始數據
27
附錄 E ndash 選擇性 Excel 追蹤表
當會員公司開始追蹤製程安全事件時所有會員公司應採用單一表格以簡化數據分析同時讓所有公司均使用相同的追蹤表RCLG 設
計了一份選擇性追蹤表可供會員公司和協會先行利用之後他們可設計自己的追蹤表
在這裡下載追蹤表
ICCA Process Safety Event Tracking Sheetxlsx
本文件包含三個分頁分別是ldquo聯絡資料rdquoldquo調查表rdquo和儲存下拉式選單選項的ldquo請勿編輯rdquo分頁
備註
附錄 E 追蹤表僅供參考TRCA 將另行提供台灣版表格供會員公司提報
28
後語
台灣化學工業責任照顧協會(Taiwan Responsible Care Association TRCA)成立於 1998 年在台灣推行責任照顧制度已達 20 週年製造商成員
包括台灣主要上市上櫃化工公司會員公司化學品生產製造量約佔全國 80 2016 年台灣化工業的 Chemical Sales 仍站在全球第八名的位
置額度為 630 億歐元化工業總產值達到 34 兆新台幣提供國內 416 萬人工作機會
TRCA 扮演國內廠商與國際制度接軌的角色也是國內化工業與政府機關及利益相關者溝通的橋樑與管道TRCA 會員結構依業務性質分析
涵蓋石化生產化學品製造氣體生產倉儲運輸業化學品貿易業以及工程研發設計等公司TRCA 透過供應鏈及價值鏈推行責任
照顧制度組成毒性化學物質聯防組織協助法規溝通與研析會員名冊請參考 httpwwwtrcaorgtwtrcanwork2aspx
TRCA 於 2010 年成為 ICCA (International Council of Chemical Associations 國際化學工業協會)觀察員ICCA 成立於 1989 年是全球化工製造
業的聯合會也是化學工業與 UNEP OPCW 及 OECD 的交流窗口ICCA 與其會員協會及成員公司致力於邁向永續的未來確保人類健康與
環境安全與保護全球化工業擁有超過 4兆美元的價值影響所有經濟部門ICCA 的會員幾乎在全球每個國家都有商業活動在全球六大
洲推動創新並提供超過 2000 萬個工作機會
台灣化工業在全球占有重要的一席之地在國內產業鏈也位居關鍵位置無論對國內或國際都有身為地球村一員應盡之責我們期許藉由
製程安全指標提報能更進一步提升自我在工安衛生環保與永續發展等面向的績效表現
台灣化學工業責任照顧協會
10452 台北市中山區撫順街 8 號 7 樓
電話02-2585-0552
httpwwwtrcaorgtw
None | |
$2500 to $25000 | |
$25000 to $250000 | |
$250000 to $25000000 | |
More than $25000000 | |
Yes - Using GHS TABLE | |
Yes - Using API RP 754 TABLE | |
NO | |
NA | |
1x le TQ lt 40x | |
40x le TQ lt 160x | |
160x le TQ lt 640x | |
ge 640x TQ | |
Yes le 3 hours | |
Yes 3 hours ge 12 hours | |
Yes 12 hours ge 24 hours | |
Yes ge 24 hours | |
No | |
Small-scale | |
Medium-scale | |
Large-scale | |
No | |
Yes | |
No | |
middot Injury requiring treatment beyond first aid to an employee contractor or subcontractor | |
middot Days Away From Work injury to an employee contractor or subcontractor or middot Injury requiring treatment beyond first aid to a third party | |
middot A fatality of an employee contractor or subcontractor or middot A hospital admission of a third party | |
middot Multiple fatalities of employees contractors or subcontractors or middot multiple hospital admission of third parties or middot A fatality of a third party | |
NA | |
1x le TQ lt 3x | |
3x le TQ lt 9x | |
9x le TQ lt 27x | |
ge 27x TQ |
ICCA Process Safety Pilot Reporting ProgramFebruary 8 2016 | 1 | 2 | 3 | 4 | 5 | 6 | 7 | 8 | 9 | 10 | 12 | 13 | 14 | 15 | |||||||||||||||||||||||
SAFETY Details(Meeting Local Regulations) | Direct Cost from Fire or Explosion | Community Impact | Environmental Impact | Material Released(Measured using the 1 Hour Rule) | |||||||||||||||||||||||||||||||||
Company Association Details | |||||||||||||||||||||||||||||||||||||
GHS | API - RP 754 | ||||||||||||||||||||||||||||||||||||
Company or Assocation Name | Headquarter Association | Location of Event Ex - City State amp Country | Date and Time of Event | Safety InjuryDid the Event result in a Recordable Lost Time Accident or Fatality or Hospital admission of anyone on or off siteUse Drop Down Menu | Safety InjuryIf yes please insert the total number of injuries | Safety InjuryFor puropses of utilizing the Severity Table please indicate the level of severity by chosing the MOST SEVERE classification that describes your incidentUse Drop Down Menu | Safety InjuryDid the incident involve Fatalities If so how many total fatalities If none enter Zero | Safety InjuryPlease Report Total Employee Hours for Calendar Year 2015 | Safety InjuryPlease Report Total Contractor Hours for Calendar Year 2015 | Direct Cost Did the Event result in Direct Damage CostUse Drop Down Menu | Direct Cost If so how muchAmount is in US DollarsUse Drop Down Menu | Community ImpactDid the event result inbull Officially declared shelter-in-place or officially declared evacuation (on or off site)ORbull Precautionary off site shelter in place or evacuation Use Drop Down Menu | Environmental ImpactDid the event result inAcute Environmental Remediation CostIf so indicate the amount in US DollarsUse Drop Down Menu | Material ReleasedDid the Event result in an Acute Release of material beyond one of the two threshold tablesIf so indicate which Threshold Table you used to make this determinationUse Drop Down Menu | Material ReleasedIf so indicate the amount released USING GHS CLASSIFICATION TABLEUse Drop Down Menu | Material ReleasedIf so indicate the amount released USING THE THRESHOLD TABLE FROM API RP-754Use Drop Down Menu | Material ReleasedIf available please indicate the material released | ||||||||||||||||||||
1 | ABC Chemical Company | American Chemistry Council | Washington DC - USA | January 4 2016 | Yes | 2 | middot Days Away From Work injury to an employee contractor or subcontractor or middot Injury requiring treatment beyond first aid to a third party | 0 | 5525000 | 1500250 | No | $2500 to $25000 | Yes le 3 hours | $2500 to $25000 | Yes - Using GHS TABLE | 40x le TQ lt 160x | NA | Chlorine | |||||||||||||||||||
2 | XYZ Chemical Company | American Chemistry Council | Washington DC - USA | 5-Jan-16 | Yes | 1 | middot Injury requiring treatment beyond first aid to an employee contractor or subcontractor | 0 | 5525000 | 1500250 | Yes | $2500 to $25000 | No | $2500 to $25000 | Yes - Using API RP 754 TABLE | NA | 3x le TQ lt 9x | Benzene | |||||||||||||||||||
3 | |||||||||||||||||||||||||||||||||||||
4 | |||||||||||||||||||||||||||||||||||||
5 | |||||||||||||||||||||||||||||||||||||
6 | |||||||||||||||||||||||||||||||||||||
7 | |||||||||||||||||||||||||||||||||||||
8 | |||||||||||||||||||||||||||||||||||||
9 | |||||||||||||||||||||||||||||||||||||
10 | |||||||||||||||||||||||||||||||||||||
11 | |||||||||||||||||||||||||||||||||||||
12 | |||||||||||||||||||||||||||||||||||||
13 | |||||||||||||||||||||||||||||||||||||
14 | |||||||||||||||||||||||||||||||||||||
15 | |||||||||||||||||||||||||||||||||||||
16 | |||||||||||||||||||||||||||||||||||||
17 | |||||||||||||||||||||||||||||||||||||
18 | |||||||||||||||||||||||||||||||||||||
19 | |||||||||||||||||||||||||||||||||||||
20 | |||||||||||||||||||||||||||||||||||||
21 | |||||||||||||||||||||||||||||||||||||
22 | |||||||||||||||||||||||||||||||||||||
23 | |||||||||||||||||||||||||||||||||||||
24 | |||||||||||||||||||||||||||||||||||||
25 | |||||||||||||||||||||||||||||||||||||
Zero or None | Yes - Duration Unknown | ||||||||||||||||||||||||||||||||||||
Processes | Mode of Operation | Type of material released | Status of Operation | ||||
REFINING | Start-up | Flammable | Open | ||||
Alkylation HF | Planned shutdown | Combustible | Closed | ||||
Alkylation sulfuric | Emergency shutdown | Toxic | |||||
BitumenResidAsphalt | Normal | Corrosive | Tier 1 Acute Releases | ||||
Calcining | Upset | Utilities | No Release | ||||
Coking | Turnaround | Other | Category 1 | ||||
Crude | Routine maintenance | Category 2 | |||||
Desulfurization | Temporary | Evacuation | Category 3 | ||||
FCC | Other | Yes | Category 4 | ||||
Gas Treating | No | Category 5 | |||||
Hydrogen | Point of Release | Category 6 | |||||
Hydrotreating | Pump | Fire | Category 7 | ||||
Hydrocracking | Compressor | Yes | Multiple Categories | ||||
Isom | BlowerFan | No | |||||
MarineJetty | Pressure Vessel | lt $2500 | |||||
Reforming | FilterCoalescer | ||||||
Sulfur recovery | Furnace | PRDs | |||||
Vapor recoverylight ends | Boiler | Directly to Atmosphere | |||||
Wastewater | Heat exchanger | via Downstream Destructive Device | |||||
REFINING amp PETROCHEMICAL | Cooling Tower | No | |||||
Tank FarmStorage FacilityOffsite | Piping system | Yes | |||||
UtilitiesSteam PlantCogeneration | Reactor | No | |||||
Other | Atmospheric tank | ||||||
PETROCHEMICAL | FlareRelief System | Acute release above thresholds | |||||
CO H2 | Other | Yes | |||||
LNG | No | ||||||
Methane | Events | ||||||
Methanol | No Tier 1 Events | Indoor Outdoor | |||||
Methyl Mercaptan | No Tier 2 Events | No Release | |||||
Formaldehyde | No Tier 1 or Tier 2 Events | Indoor | |||||
Formaldehyde derivatives | NA | Outdoor | |||||
Acetic Acid | |||||||
Acetic Acid derivatives | Event Type | ||||||
Ethane | Injury | ||||||
Ethylene | Fire | ||||||
Ethanol | Explosion | ||||||
Ethylene oxide | PRD Discharge | ||||||
Ethylene derivatives | Acute Release | ||||||
Polyethylene | |||||||
Ethylene dichloride | General | ||||||
Ethylene dichloride derivatives | Yes | ||||||
Ethyl benzene | No | ||||||
Ethyl benzene derivatives | |||||||
Polystyrene | |||||||
Styrene-Butadiene | |||||||
Propane | |||||||
Propylene | |||||||
Polypropylene | |||||||
Isopropanol | |||||||
Propylene oxide | |||||||
Propylene oxide derivatives | |||||||
Butane | |||||||
Isobutane | |||||||
Isobutene | |||||||
Butadiene | |||||||
MTBE | |||||||
ETBE | |||||||
Pentane | |||||||
Hexane | |||||||
Cyclohexane | |||||||
Hexanol | |||||||
Aromatics Derivatives | |||||||
Benzene | |||||||
Toluene | |||||||
Xylene | |||||||
Para Xylene | |||||||
Amines Derivatives | |||||||
TDA MDA IPDA etc | |||||||
Isocyanates | |||||||
Specialty Chemicals | |||||||
LoadingUnloading | |||||||
Pilot Plant |
Instructions | ||||||||||||||
Step 1 | Complete the Contact Tab with your contact information and company information | |||||||||||||
Be sure to note the region of your reporting (IE North America France Japan etc) | ||||||||||||||
Survey on Process Safety Events | ||||||||||||||
Step 2 | Complete the survey one line per Process Safety Event for your companyregion | |||||||||||||
ALL REPORTED DATA SHOULD BE FROM CALENDAR YEAR 2017 | ||||||||||||||
Step 3 | Return completed survey to | |||||||||||||
Company Name | ||||||||||||||
Contact Person | All Surveys Due by xxx date | |||||||||||||
Address | ||||||||||||||
Fax | ||||||||||||||
Telephone | ||||||||||||||
Region | ||||||||||||||
None | |
$2500 to $25000 | |
$25000 to $250000 | |
$250000 to $25000000 | |
More than $25000000 | |
Yes - Using GHS TABLE | |
Yes - Using API RP 754 TABLE | |
NO | |
NA | |
1x le TQ lt 40x | |
40x le TQ lt 160x | |
160x le TQ lt 640x | |
ge 640x TQ | |
Yes le 3 hours | |
Yes 3 hours ge 12 hours | |
Yes 12 hours ge 24 hours | |
Yes ge 24 hours | |
No | |
Small-scale | |
Medium-scale | |
Large-scale | |
No | |
Yes | |
No | |
middot Injury requiring treatment beyond first aid to an employee contractor or subcontractor | |
middot Days Away From Work injury to an employee contractor or subcontractor or middot Injury requiring treatment beyond first aid to a third party | |
middot A fatality of an employee contractor or subcontractor or middot A hospital admission of a third party | |
middot Multiple fatalities of employees contractors or subcontractors or middot multiple hospital admission of third parties or middot A fatality of a third party | |
NA | |
1x le TQ lt 3x | |
3x le TQ lt 9x | |
9x le TQ lt 27x | |
ge 27x TQ |
ICCA Process Safety Pilot Reporting ProgramFebruary 8 2016 | 1 | 2 | 3 | 4 | 5 | 6 | 7 | 8 | 9 | 10 | 12 | 13 | 14 | 15 | |||||||||||||||||||||||
SAFETY Details(Meeting Local Regulations) | Direct Cost from Fire or Explosion | Community Impact | Environmental Impact | Material Released(Measured using the 1 Hour Rule) | |||||||||||||||||||||||||||||||||
Company Association Details | |||||||||||||||||||||||||||||||||||||
GHS | API - RP 754 | ||||||||||||||||||||||||||||||||||||
Company or Assocation Name | Headquarter Association | Location of Event Ex - City State amp Country | Date and Time of Event | Safety InjuryDid the Event result in a Recordable Lost Time Accident or Fatality or Hospital admission of anyone on or off siteUse Drop Down Menu | Safety InjuryIf yes please insert the total number of injuries | Safety InjuryFor puropses of utilizing the Severity Table please indicate the level of severity by chosing the MOST SEVERE classification that describes your incidentUse Drop Down Menu | Safety InjuryDid the incident involve Fatalities If so how many total fatalities If none enter Zero | Safety InjuryPlease Report Total Employee Hours for Calendar Year 2015 | Safety InjuryPlease Report Total Contractor Hours for Calendar Year 2015 | Direct Cost Did the Event result in Direct Damage CostUse Drop Down Menu | Direct Cost If so how muchAmount is in US DollarsUse Drop Down Menu | Community ImpactDid the event result inbull Officially declared shelter-in-place or officially declared evacuation (on or off site)ORbull Precautionary off site shelter in place or evacuation Use Drop Down Menu | Environmental ImpactDid the event result inAcute Environmental Remediation CostIf so indicate the amount in US DollarsUse Drop Down Menu | Material ReleasedDid the Event result in an Acute Release of material beyond one of the two threshold tablesIf so indicate which Threshold Table you used to make this determinationUse Drop Down Menu | Material ReleasedIf so indicate the amount released USING GHS CLASSIFICATION TABLEUse Drop Down Menu | Material ReleasedIf so indicate the amount released USING THE THRESHOLD TABLE FROM API RP-754Use Drop Down Menu | Material ReleasedIf available please indicate the material released | ||||||||||||||||||||
1 | ABC Chemical Company | American Chemistry Council | Washington DC - USA | January 4 2016 | Yes | 2 | middot Days Away From Work injury to an employee contractor or subcontractor or middot Injury requiring treatment beyond first aid to a third party | 0 | 5525000 | 1500250 | No | $2500 to $25000 | Yes le 3 hours | $2500 to $25000 | Yes - Using GHS TABLE | 40x le TQ lt 160x | NA | Chlorine | |||||||||||||||||||
2 | XYZ Chemical Company | American Chemistry Council | Washington DC - USA | 5-Jan-16 | Yes | 1 | middot Injury requiring treatment beyond first aid to an employee contractor or subcontractor | 0 | 5525000 | 1500250 | Yes | $2500 to $25000 | No | $2500 to $25000 | Yes - Using API RP 754 TABLE | NA | 3x le TQ lt 9x | Benzene | |||||||||||||||||||
3 | |||||||||||||||||||||||||||||||||||||
4 | |||||||||||||||||||||||||||||||||||||
5 | |||||||||||||||||||||||||||||||||||||
6 | |||||||||||||||||||||||||||||||||||||
7 | |||||||||||||||||||||||||||||||||||||
8 | |||||||||||||||||||||||||||||||||||||
9 | |||||||||||||||||||||||||||||||||||||
10 | |||||||||||||||||||||||||||||||||||||
11 | |||||||||||||||||||||||||||||||||||||
12 | |||||||||||||||||||||||||||||||||||||
13 | |||||||||||||||||||||||||||||||||||||
14 | |||||||||||||||||||||||||||||||||||||
15 | |||||||||||||||||||||||||||||||||||||
16 | |||||||||||||||||||||||||||||||||||||
17 | |||||||||||||||||||||||||||||||||||||
18 | |||||||||||||||||||||||||||||||||||||
19 | |||||||||||||||||||||||||||||||||||||
20 | |||||||||||||||||||||||||||||||||||||
21 | |||||||||||||||||||||||||||||||||||||
22 | |||||||||||||||||||||||||||||||||||||
23 | |||||||||||||||||||||||||||||||||||||
24 | |||||||||||||||||||||||||||||||||||||
25 | |||||||||||||||||||||||||||||||||||||
Zero or None | Yes - Duration Unknown | ||||||||||||||||||||||||||||||||||||
Processes | Mode of Operation | Type of material released | Status of Operation | ||||
REFINING | Start-up | Flammable | Open | ||||
Alkylation HF | Planned shutdown | Combustible | Closed | ||||
Alkylation sulfuric | Emergency shutdown | Toxic | |||||
BitumenResidAsphalt | Normal | Corrosive | Tier 1 Acute Releases | ||||
Calcining | Upset | Utilities | No Release | ||||
Coking | Turnaround | Other | Category 1 | ||||
Crude | Routine maintenance | Category 2 | |||||
Desulfurization | Temporary | Evacuation | Category 3 | ||||
FCC | Other | Yes | Category 4 | ||||
Gas Treating | No | Category 5 | |||||
Hydrogen | Point of Release | Category 6 | |||||
Hydrotreating | Pump | Fire | Category 7 | ||||
Hydrocracking | Compressor | Yes | Multiple Categories | ||||
Isom | BlowerFan | No | |||||
MarineJetty | Pressure Vessel | lt $2500 | |||||
Reforming | FilterCoalescer | ||||||
Sulfur recovery | Furnace | PRDs | |||||
Vapor recoverylight ends | Boiler | Directly to Atmosphere | |||||
Wastewater | Heat exchanger | via Downstream Destructive Device | |||||
REFINING amp PETROCHEMICAL | Cooling Tower | No | |||||
Tank FarmStorage FacilityOffsite | Piping system | Yes | |||||
UtilitiesSteam PlantCogeneration | Reactor | No | |||||
Other | Atmospheric tank | ||||||
PETROCHEMICAL | FlareRelief System | Acute release above thresholds | |||||
CO H2 | Other | Yes | |||||
LNG | No | ||||||
Methane | Events | ||||||
Methanol | No Tier 1 Events | Indoor Outdoor | |||||
Methyl Mercaptan | No Tier 2 Events | No Release | |||||
Formaldehyde | No Tier 1 or Tier 2 Events | Indoor | |||||
Formaldehyde derivatives | NA | Outdoor | |||||
Acetic Acid | |||||||
Acetic Acid derivatives | Event Type | ||||||
Ethane | Injury | ||||||
Ethylene | Fire | ||||||
Ethanol | Explosion | ||||||
Ethylene oxide | PRD Discharge | ||||||
Ethylene derivatives | Acute Release | ||||||
Polyethylene | |||||||
Ethylene dichloride | General | ||||||
Ethylene dichloride derivatives | Yes | ||||||
Ethyl benzene | No | ||||||
Ethyl benzene derivatives | |||||||
Polystyrene | |||||||
Styrene-Butadiene | |||||||
Propane | |||||||
Propylene | |||||||
Polypropylene | |||||||
Isopropanol | |||||||
Propylene oxide | |||||||
Propylene oxide derivatives | |||||||
Butane | |||||||
Isobutane | |||||||
Isobutene | |||||||
Butadiene | |||||||
MTBE | |||||||
ETBE | |||||||
Pentane | |||||||
Hexane | |||||||
Cyclohexane | |||||||
Hexanol | |||||||
Aromatics Derivatives | |||||||
Benzene | |||||||
Toluene | |||||||
Xylene | |||||||
Para Xylene | |||||||
Amines Derivatives | |||||||
TDA MDA IPDA etc | |||||||
Isocyanates | |||||||
Specialty Chemicals | |||||||
LoadingUnloading | |||||||
Pilot Plant |
Instructions | ||||||||||||||
Step 1 | Complete the Contact Tab with your contact information and company information | |||||||||||||
Be sure to note the region of your reporting (IE North America France Japan etc) | ||||||||||||||
Survey on Process Safety Events | ||||||||||||||
Step 2 | Complete the survey one line per Process Safety Event for your companyregion | |||||||||||||
ALL REPORTED DATA SHOULD BE FROM CALENDAR YEAR 2017 | ||||||||||||||
Step 3 | Return completed survey to | |||||||||||||
Company Name | ||||||||||||||
Contact Person | All Surveys Due by xxx date | |||||||||||||
Address | ||||||||||||||
Fax | ||||||||||||||
Telephone | ||||||||||||||
Region | ||||||||||||||
24
31 範例連接到氣體處理系統的排放管發生易燃氣體外漏同時製程出現問題導致空氣進入同
一條排放管結果發生爆炸過高的壓力損壞了排放管及其相關上游設備包括一個密封罐並
未造成人員受傷修理成本約$12000 美元該事故屬於須提報的製程安全事件因為爆炸及火
災導致設備修理成本超過門檻
32 範例一次製程安全事件後公司又發生一種非常特殊的 GHS 第 5 類產品洩漏 50 公斤造成
$2000 美元的設備損失洩漏的產品是一種非常特別的混合物公司須負擔超過$50000 美元因
產品耗損而產生之材料成本該事故不屬於須提報的製程安全事件因為 GHS 第 5 類產品洩漏的
提報門檻為 100 公斤且產品耗損不被計入直接損失成本
天然災害
33 天然災害可能對化學製程作業構成重大風險且對製程設備造成損壞導致危害物質一次阻絕設
施失效當一種或多種天然災害被認為可能對工廠作業造成影響時製程安全和作業系統應從危
害及後果分析工廠機器設備設計公用設施失效及製程停工之操作程序緊急應變計畫及應變
措施等方面界定潛在風險進行防範
天然災害類型包括颶風及颱風(包括伴隨而來的風暴潮)水災龍捲風地震超強對流風暴(直
線風暴)野火火山爆發海嘯和山崩
若公司廠房設施遭遇天然災害且其後果觸發一種或以上提報門檻該事故便屬於須提報製程安
全事件
預防性公眾應變
34 預防性公眾應變是基於謹慎的態度所採取的一種措施譬如當發生一次阻絕設施失效時公司
可能在尚未進行任何評估(如方向與洩漏點的距離等等)前便要求全體工人就地避難又
如地方權責官員(如消防警察民防緊急應變管理部門)在獲報一家公司發生製程安全事件
後為防lsquo萬一rsquo風向改變或基於可能受到波及的人口敏感族群(如學童或老年人)可能在尚未接
獲明確資訊前便下令社區就地避難或疏散或採取公眾保護措施(如道路封閉)
製程附屬倉庫
35 製程附屬倉庫指的是位於廠內用於儲存將投入於生產製程或產自於製程之原料半成品或成品的
倉庫從製程的觀點看來製程附屬倉庫相當於一個大型儲槽但這些原料半成品或成品並不
是儲存在一的大型容器中而是裝在較小的容器裡(如太空包大桶桶罐等)
25
Appendix C ndash List of RCLG Taskforce Members
Name Affiliation
Peter Schmelzer Bayer CEFIC - Chairman
Americo Diniz Carvalho Neto Braskem
Bradford Johnson American Chemistry Council
David Cummings DuPont
Debra Phillips American Chemistry Council
Hans Schwarz BASF
Kathryn Walton Plastics and Chemicals Industries Association
Kazuyuki Akita Japanese Chemical Industry Association
Kelly Keim ExxonMobil Chemical Company API Representative
Kenan Stevick Dow
Kiyokazu Murata Japanese Chemical Industry Association
Larry Bowler SABIC
Lorna Young Chemical Industry Association of Canada
Louisa Nara Center for Chemical Process Safety
Luiz Shizuo Harayashiki Associaccedilatildeo Brasileira da Induacutestria Quiacutemica
Masatoshi Kumamoto Japanese Chemical Industry Association
Milton Lacerda Petrobras
Phil Scott Chemical Industries Association
Piet Knijff DSM European Process Safety Centre
Scott Donaldson and Eamon Chandler
Shell
Scott Wallace Olin Corporation
Shakeel Kadri Air Products and Chemicals Inc
26
附錄 D ndash 詳細活動時程表
2016 年 2017 年 2018 年 2019 年 2020 年
2 ndash 4 月
RCLG PS 先導計畫
5 月 ndash
針對準則進行調整釐清
6 月 向 RCLG 和 ICCA 董事會報
告先導計畫執行結果
7 ndash 12 月 RCLG 協會考量準
則並為其會員公司發展提報機制
如有需要RCLG可向 ICCA 申請能
力建立基金為會員公司舉辦製程安
全研習會
1 ndash 12 月
RCLG 協會開始向其會員公司蒐集製程安全數據
1 ndash 12 月
如有需要RCLG 各協會運用 RCLG 的基金及專
家舉辦製程安全及績效提報研習會
1 ndash 2 月
擁有數據的協會開始向RCLG 提報製程安全事件
(2017 年數據)
4 月 RCLG 檢討第一個提報循
環的結果挑戰及原始數據(內部)
6 月 RCLG 向 ICCA 董事會呈報
原始數據
7 ndash 12 月 必要時更新及調整準
則
如有需要RCLG 各協會運用 RCLG 的基金及專
家舉辦製程安全及績效提報研習會
1 ndash 2 月
擁有數據的協會開始向RCLG 提報製程安全事件
(2018 年數據)
4 月 RCLG 檢討第二個提報循
環的結果挑戰及原始數據(內部)
6 月 RCLG 向 ICCA 董事會呈報
原始數據
7 ndash 12 月 必要時更新及調整準
則
如有需要RCLG 協會運用 RCLG 的基金及專家
舉辦製程安全及績效提報研習會
1 ndash 2 月
所有協會開始向 RCLG 提報製程安全事件
製程安全事件提報成為
RCLG KPI 衡量指標建議基本集的一部分(2019 年數
據)
4 月 RCLG 檢討第二個提報循
環的結果挑戰及原始數據(內部考量外部提
報)
6 月 RCLG 向 ICCA 董事會呈報
原始數據
27
附錄 E ndash 選擇性 Excel 追蹤表
當會員公司開始追蹤製程安全事件時所有會員公司應採用單一表格以簡化數據分析同時讓所有公司均使用相同的追蹤表RCLG 設
計了一份選擇性追蹤表可供會員公司和協會先行利用之後他們可設計自己的追蹤表
在這裡下載追蹤表
ICCA Process Safety Event Tracking Sheetxlsx
本文件包含三個分頁分別是ldquo聯絡資料rdquoldquo調查表rdquo和儲存下拉式選單選項的ldquo請勿編輯rdquo分頁
備註
附錄 E 追蹤表僅供參考TRCA 將另行提供台灣版表格供會員公司提報
28
後語
台灣化學工業責任照顧協會(Taiwan Responsible Care Association TRCA)成立於 1998 年在台灣推行責任照顧制度已達 20 週年製造商成員
包括台灣主要上市上櫃化工公司會員公司化學品生產製造量約佔全國 80 2016 年台灣化工業的 Chemical Sales 仍站在全球第八名的位
置額度為 630 億歐元化工業總產值達到 34 兆新台幣提供國內 416 萬人工作機會
TRCA 扮演國內廠商與國際制度接軌的角色也是國內化工業與政府機關及利益相關者溝通的橋樑與管道TRCA 會員結構依業務性質分析
涵蓋石化生產化學品製造氣體生產倉儲運輸業化學品貿易業以及工程研發設計等公司TRCA 透過供應鏈及價值鏈推行責任
照顧制度組成毒性化學物質聯防組織協助法規溝通與研析會員名冊請參考 httpwwwtrcaorgtwtrcanwork2aspx
TRCA 於 2010 年成為 ICCA (International Council of Chemical Associations 國際化學工業協會)觀察員ICCA 成立於 1989 年是全球化工製造
業的聯合會也是化學工業與 UNEP OPCW 及 OECD 的交流窗口ICCA 與其會員協會及成員公司致力於邁向永續的未來確保人類健康與
環境安全與保護全球化工業擁有超過 4兆美元的價值影響所有經濟部門ICCA 的會員幾乎在全球每個國家都有商業活動在全球六大
洲推動創新並提供超過 2000 萬個工作機會
台灣化工業在全球占有重要的一席之地在國內產業鏈也位居關鍵位置無論對國內或國際都有身為地球村一員應盡之責我們期許藉由
製程安全指標提報能更進一步提升自我在工安衛生環保與永續發展等面向的績效表現
台灣化學工業責任照顧協會
10452 台北市中山區撫順街 8 號 7 樓
電話02-2585-0552
httpwwwtrcaorgtw
None | |
$2500 to $25000 | |
$25000 to $250000 | |
$250000 to $25000000 | |
More than $25000000 | |
Yes - Using GHS TABLE | |
Yes - Using API RP 754 TABLE | |
NO | |
NA | |
1x le TQ lt 40x | |
40x le TQ lt 160x | |
160x le TQ lt 640x | |
ge 640x TQ | |
Yes le 3 hours | |
Yes 3 hours ge 12 hours | |
Yes 12 hours ge 24 hours | |
Yes ge 24 hours | |
No | |
Small-scale | |
Medium-scale | |
Large-scale | |
No | |
Yes | |
No | |
middot Injury requiring treatment beyond first aid to an employee contractor or subcontractor | |
middot Days Away From Work injury to an employee contractor or subcontractor or middot Injury requiring treatment beyond first aid to a third party | |
middot A fatality of an employee contractor or subcontractor or middot A hospital admission of a third party | |
middot Multiple fatalities of employees contractors or subcontractors or middot multiple hospital admission of third parties or middot A fatality of a third party | |
NA | |
1x le TQ lt 3x | |
3x le TQ lt 9x | |
9x le TQ lt 27x | |
ge 27x TQ |
ICCA Process Safety Pilot Reporting ProgramFebruary 8 2016 | 1 | 2 | 3 | 4 | 5 | 6 | 7 | 8 | 9 | 10 | 12 | 13 | 14 | 15 | |||||||||||||||||||||||
SAFETY Details(Meeting Local Regulations) | Direct Cost from Fire or Explosion | Community Impact | Environmental Impact | Material Released(Measured using the 1 Hour Rule) | |||||||||||||||||||||||||||||||||
Company Association Details | |||||||||||||||||||||||||||||||||||||
GHS | API - RP 754 | ||||||||||||||||||||||||||||||||||||
Company or Assocation Name | Headquarter Association | Location of Event Ex - City State amp Country | Date and Time of Event | Safety InjuryDid the Event result in a Recordable Lost Time Accident or Fatality or Hospital admission of anyone on or off siteUse Drop Down Menu | Safety InjuryIf yes please insert the total number of injuries | Safety InjuryFor puropses of utilizing the Severity Table please indicate the level of severity by chosing the MOST SEVERE classification that describes your incidentUse Drop Down Menu | Safety InjuryDid the incident involve Fatalities If so how many total fatalities If none enter Zero | Safety InjuryPlease Report Total Employee Hours for Calendar Year 2015 | Safety InjuryPlease Report Total Contractor Hours for Calendar Year 2015 | Direct Cost Did the Event result in Direct Damage CostUse Drop Down Menu | Direct Cost If so how muchAmount is in US DollarsUse Drop Down Menu | Community ImpactDid the event result inbull Officially declared shelter-in-place or officially declared evacuation (on or off site)ORbull Precautionary off site shelter in place or evacuation Use Drop Down Menu | Environmental ImpactDid the event result inAcute Environmental Remediation CostIf so indicate the amount in US DollarsUse Drop Down Menu | Material ReleasedDid the Event result in an Acute Release of material beyond one of the two threshold tablesIf so indicate which Threshold Table you used to make this determinationUse Drop Down Menu | Material ReleasedIf so indicate the amount released USING GHS CLASSIFICATION TABLEUse Drop Down Menu | Material ReleasedIf so indicate the amount released USING THE THRESHOLD TABLE FROM API RP-754Use Drop Down Menu | Material ReleasedIf available please indicate the material released | ||||||||||||||||||||
1 | ABC Chemical Company | American Chemistry Council | Washington DC - USA | January 4 2016 | Yes | 2 | middot Days Away From Work injury to an employee contractor or subcontractor or middot Injury requiring treatment beyond first aid to a third party | 0 | 5525000 | 1500250 | No | $2500 to $25000 | Yes le 3 hours | $2500 to $25000 | Yes - Using GHS TABLE | 40x le TQ lt 160x | NA | Chlorine | |||||||||||||||||||
2 | XYZ Chemical Company | American Chemistry Council | Washington DC - USA | 5-Jan-16 | Yes | 1 | middot Injury requiring treatment beyond first aid to an employee contractor or subcontractor | 0 | 5525000 | 1500250 | Yes | $2500 to $25000 | No | $2500 to $25000 | Yes - Using API RP 754 TABLE | NA | 3x le TQ lt 9x | Benzene | |||||||||||||||||||
3 | |||||||||||||||||||||||||||||||||||||
4 | |||||||||||||||||||||||||||||||||||||
5 | |||||||||||||||||||||||||||||||||||||
6 | |||||||||||||||||||||||||||||||||||||
7 | |||||||||||||||||||||||||||||||||||||
8 | |||||||||||||||||||||||||||||||||||||
9 | |||||||||||||||||||||||||||||||||||||
10 | |||||||||||||||||||||||||||||||||||||
11 | |||||||||||||||||||||||||||||||||||||
12 | |||||||||||||||||||||||||||||||||||||
13 | |||||||||||||||||||||||||||||||||||||
14 | |||||||||||||||||||||||||||||||||||||
15 | |||||||||||||||||||||||||||||||||||||
16 | |||||||||||||||||||||||||||||||||||||
17 | |||||||||||||||||||||||||||||||||||||
18 | |||||||||||||||||||||||||||||||||||||
19 | |||||||||||||||||||||||||||||||||||||
20 | |||||||||||||||||||||||||||||||||||||
21 | |||||||||||||||||||||||||||||||||||||
22 | |||||||||||||||||||||||||||||||||||||
23 | |||||||||||||||||||||||||||||||||||||
24 | |||||||||||||||||||||||||||||||||||||
25 | |||||||||||||||||||||||||||||||||||||
Zero or None | Yes - Duration Unknown | ||||||||||||||||||||||||||||||||||||
Processes | Mode of Operation | Type of material released | Status of Operation | ||||
REFINING | Start-up | Flammable | Open | ||||
Alkylation HF | Planned shutdown | Combustible | Closed | ||||
Alkylation sulfuric | Emergency shutdown | Toxic | |||||
BitumenResidAsphalt | Normal | Corrosive | Tier 1 Acute Releases | ||||
Calcining | Upset | Utilities | No Release | ||||
Coking | Turnaround | Other | Category 1 | ||||
Crude | Routine maintenance | Category 2 | |||||
Desulfurization | Temporary | Evacuation | Category 3 | ||||
FCC | Other | Yes | Category 4 | ||||
Gas Treating | No | Category 5 | |||||
Hydrogen | Point of Release | Category 6 | |||||
Hydrotreating | Pump | Fire | Category 7 | ||||
Hydrocracking | Compressor | Yes | Multiple Categories | ||||
Isom | BlowerFan | No | |||||
MarineJetty | Pressure Vessel | lt $2500 | |||||
Reforming | FilterCoalescer | ||||||
Sulfur recovery | Furnace | PRDs | |||||
Vapor recoverylight ends | Boiler | Directly to Atmosphere | |||||
Wastewater | Heat exchanger | via Downstream Destructive Device | |||||
REFINING amp PETROCHEMICAL | Cooling Tower | No | |||||
Tank FarmStorage FacilityOffsite | Piping system | Yes | |||||
UtilitiesSteam PlantCogeneration | Reactor | No | |||||
Other | Atmospheric tank | ||||||
PETROCHEMICAL | FlareRelief System | Acute release above thresholds | |||||
CO H2 | Other | Yes | |||||
LNG | No | ||||||
Methane | Events | ||||||
Methanol | No Tier 1 Events | Indoor Outdoor | |||||
Methyl Mercaptan | No Tier 2 Events | No Release | |||||
Formaldehyde | No Tier 1 or Tier 2 Events | Indoor | |||||
Formaldehyde derivatives | NA | Outdoor | |||||
Acetic Acid | |||||||
Acetic Acid derivatives | Event Type | ||||||
Ethane | Injury | ||||||
Ethylene | Fire | ||||||
Ethanol | Explosion | ||||||
Ethylene oxide | PRD Discharge | ||||||
Ethylene derivatives | Acute Release | ||||||
Polyethylene | |||||||
Ethylene dichloride | General | ||||||
Ethylene dichloride derivatives | Yes | ||||||
Ethyl benzene | No | ||||||
Ethyl benzene derivatives | |||||||
Polystyrene | |||||||
Styrene-Butadiene | |||||||
Propane | |||||||
Propylene | |||||||
Polypropylene | |||||||
Isopropanol | |||||||
Propylene oxide | |||||||
Propylene oxide derivatives | |||||||
Butane | |||||||
Isobutane | |||||||
Isobutene | |||||||
Butadiene | |||||||
MTBE | |||||||
ETBE | |||||||
Pentane | |||||||
Hexane | |||||||
Cyclohexane | |||||||
Hexanol | |||||||
Aromatics Derivatives | |||||||
Benzene | |||||||
Toluene | |||||||
Xylene | |||||||
Para Xylene | |||||||
Amines Derivatives | |||||||
TDA MDA IPDA etc | |||||||
Isocyanates | |||||||
Specialty Chemicals | |||||||
LoadingUnloading | |||||||
Pilot Plant |
Instructions | ||||||||||||||
Step 1 | Complete the Contact Tab with your contact information and company information | |||||||||||||
Be sure to note the region of your reporting (IE North America France Japan etc) | ||||||||||||||
Survey on Process Safety Events | ||||||||||||||
Step 2 | Complete the survey one line per Process Safety Event for your companyregion | |||||||||||||
ALL REPORTED DATA SHOULD BE FROM CALENDAR YEAR 2017 | ||||||||||||||
Step 3 | Return completed survey to | |||||||||||||
Company Name | ||||||||||||||
Contact Person | All Surveys Due by xxx date | |||||||||||||
Address | ||||||||||||||
Fax | ||||||||||||||
Telephone | ||||||||||||||
Region | ||||||||||||||
None | |
$2500 to $25000 | |
$25000 to $250000 | |
$250000 to $25000000 | |
More than $25000000 | |
Yes - Using GHS TABLE | |
Yes - Using API RP 754 TABLE | |
NO | |
NA | |
1x le TQ lt 40x | |
40x le TQ lt 160x | |
160x le TQ lt 640x | |
ge 640x TQ | |
Yes le 3 hours | |
Yes 3 hours ge 12 hours | |
Yes 12 hours ge 24 hours | |
Yes ge 24 hours | |
No | |
Small-scale | |
Medium-scale | |
Large-scale | |
No | |
Yes | |
No | |
middot Injury requiring treatment beyond first aid to an employee contractor or subcontractor | |
middot Days Away From Work injury to an employee contractor or subcontractor or middot Injury requiring treatment beyond first aid to a third party | |
middot A fatality of an employee contractor or subcontractor or middot A hospital admission of a third party | |
middot Multiple fatalities of employees contractors or subcontractors or middot multiple hospital admission of third parties or middot A fatality of a third party | |
NA | |
1x le TQ lt 3x | |
3x le TQ lt 9x | |
9x le TQ lt 27x | |
ge 27x TQ |
ICCA Process Safety Pilot Reporting ProgramFebruary 8 2016 | 1 | 2 | 3 | 4 | 5 | 6 | 7 | 8 | 9 | 10 | 12 | 13 | 14 | 15 | |||||||||||||||||||||||
SAFETY Details(Meeting Local Regulations) | Direct Cost from Fire or Explosion | Community Impact | Environmental Impact | Material Released(Measured using the 1 Hour Rule) | |||||||||||||||||||||||||||||||||
Company Association Details | |||||||||||||||||||||||||||||||||||||
GHS | API - RP 754 | ||||||||||||||||||||||||||||||||||||
Company or Assocation Name | Headquarter Association | Location of Event Ex - City State amp Country | Date and Time of Event | Safety InjuryDid the Event result in a Recordable Lost Time Accident or Fatality or Hospital admission of anyone on or off siteUse Drop Down Menu | Safety InjuryIf yes please insert the total number of injuries | Safety InjuryFor puropses of utilizing the Severity Table please indicate the level of severity by chosing the MOST SEVERE classification that describes your incidentUse Drop Down Menu | Safety InjuryDid the incident involve Fatalities If so how many total fatalities If none enter Zero | Safety InjuryPlease Report Total Employee Hours for Calendar Year 2015 | Safety InjuryPlease Report Total Contractor Hours for Calendar Year 2015 | Direct Cost Did the Event result in Direct Damage CostUse Drop Down Menu | Direct Cost If so how muchAmount is in US DollarsUse Drop Down Menu | Community ImpactDid the event result inbull Officially declared shelter-in-place or officially declared evacuation (on or off site)ORbull Precautionary off site shelter in place or evacuation Use Drop Down Menu | Environmental ImpactDid the event result inAcute Environmental Remediation CostIf so indicate the amount in US DollarsUse Drop Down Menu | Material ReleasedDid the Event result in an Acute Release of material beyond one of the two threshold tablesIf so indicate which Threshold Table you used to make this determinationUse Drop Down Menu | Material ReleasedIf so indicate the amount released USING GHS CLASSIFICATION TABLEUse Drop Down Menu | Material ReleasedIf so indicate the amount released USING THE THRESHOLD TABLE FROM API RP-754Use Drop Down Menu | Material ReleasedIf available please indicate the material released | ||||||||||||||||||||
1 | ABC Chemical Company | American Chemistry Council | Washington DC - USA | January 4 2016 | Yes | 2 | middot Days Away From Work injury to an employee contractor or subcontractor or middot Injury requiring treatment beyond first aid to a third party | 0 | 5525000 | 1500250 | No | $2500 to $25000 | Yes le 3 hours | $2500 to $25000 | Yes - Using GHS TABLE | 40x le TQ lt 160x | NA | Chlorine | |||||||||||||||||||
2 | XYZ Chemical Company | American Chemistry Council | Washington DC - USA | 5-Jan-16 | Yes | 1 | middot Injury requiring treatment beyond first aid to an employee contractor or subcontractor | 0 | 5525000 | 1500250 | Yes | $2500 to $25000 | No | $2500 to $25000 | Yes - Using API RP 754 TABLE | NA | 3x le TQ lt 9x | Benzene | |||||||||||||||||||
3 | |||||||||||||||||||||||||||||||||||||
4 | |||||||||||||||||||||||||||||||||||||
5 | |||||||||||||||||||||||||||||||||||||
6 | |||||||||||||||||||||||||||||||||||||
7 | |||||||||||||||||||||||||||||||||||||
8 | |||||||||||||||||||||||||||||||||||||
9 | |||||||||||||||||||||||||||||||||||||
10 | |||||||||||||||||||||||||||||||||||||
11 | |||||||||||||||||||||||||||||||||||||
12 | |||||||||||||||||||||||||||||||||||||
13 | |||||||||||||||||||||||||||||||||||||
14 | |||||||||||||||||||||||||||||||||||||
15 | |||||||||||||||||||||||||||||||||||||
16 | |||||||||||||||||||||||||||||||||||||
17 | |||||||||||||||||||||||||||||||||||||
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20 | |||||||||||||||||||||||||||||||||||||
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22 | |||||||||||||||||||||||||||||||||||||
23 | |||||||||||||||||||||||||||||||||||||
24 | |||||||||||||||||||||||||||||||||||||
25 | |||||||||||||||||||||||||||||||||||||
Zero or None | Yes - Duration Unknown | ||||||||||||||||||||||||||||||||||||
Processes | Mode of Operation | Type of material released | Status of Operation | ||||
REFINING | Start-up | Flammable | Open | ||||
Alkylation HF | Planned shutdown | Combustible | Closed | ||||
Alkylation sulfuric | Emergency shutdown | Toxic | |||||
BitumenResidAsphalt | Normal | Corrosive | Tier 1 Acute Releases | ||||
Calcining | Upset | Utilities | No Release | ||||
Coking | Turnaround | Other | Category 1 | ||||
Crude | Routine maintenance | Category 2 | |||||
Desulfurization | Temporary | Evacuation | Category 3 | ||||
FCC | Other | Yes | Category 4 | ||||
Gas Treating | No | Category 5 | |||||
Hydrogen | Point of Release | Category 6 | |||||
Hydrotreating | Pump | Fire | Category 7 | ||||
Hydrocracking | Compressor | Yes | Multiple Categories | ||||
Isom | BlowerFan | No | |||||
MarineJetty | Pressure Vessel | lt $2500 | |||||
Reforming | FilterCoalescer | ||||||
Sulfur recovery | Furnace | PRDs | |||||
Vapor recoverylight ends | Boiler | Directly to Atmosphere | |||||
Wastewater | Heat exchanger | via Downstream Destructive Device | |||||
REFINING amp PETROCHEMICAL | Cooling Tower | No | |||||
Tank FarmStorage FacilityOffsite | Piping system | Yes | |||||
UtilitiesSteam PlantCogeneration | Reactor | No | |||||
Other | Atmospheric tank | ||||||
PETROCHEMICAL | FlareRelief System | Acute release above thresholds | |||||
CO H2 | Other | Yes | |||||
LNG | No | ||||||
Methane | Events | ||||||
Methanol | No Tier 1 Events | Indoor Outdoor | |||||
Methyl Mercaptan | No Tier 2 Events | No Release | |||||
Formaldehyde | No Tier 1 or Tier 2 Events | Indoor | |||||
Formaldehyde derivatives | NA | Outdoor | |||||
Acetic Acid | |||||||
Acetic Acid derivatives | Event Type | ||||||
Ethane | Injury | ||||||
Ethylene | Fire | ||||||
Ethanol | Explosion | ||||||
Ethylene oxide | PRD Discharge | ||||||
Ethylene derivatives | Acute Release | ||||||
Polyethylene | |||||||
Ethylene dichloride | General | ||||||
Ethylene dichloride derivatives | Yes | ||||||
Ethyl benzene | No | ||||||
Ethyl benzene derivatives | |||||||
Polystyrene | |||||||
Styrene-Butadiene | |||||||
Propane | |||||||
Propylene | |||||||
Polypropylene | |||||||
Isopropanol | |||||||
Propylene oxide | |||||||
Propylene oxide derivatives | |||||||
Butane | |||||||
Isobutane | |||||||
Isobutene | |||||||
Butadiene | |||||||
MTBE | |||||||
ETBE | |||||||
Pentane | |||||||
Hexane | |||||||
Cyclohexane | |||||||
Hexanol | |||||||
Aromatics Derivatives | |||||||
Benzene | |||||||
Toluene | |||||||
Xylene | |||||||
Para Xylene | |||||||
Amines Derivatives | |||||||
TDA MDA IPDA etc | |||||||
Isocyanates | |||||||
Specialty Chemicals | |||||||
LoadingUnloading | |||||||
Pilot Plant |
Instructions | ||||||||||||||
Step 1 | Complete the Contact Tab with your contact information and company information | |||||||||||||
Be sure to note the region of your reporting (IE North America France Japan etc) | ||||||||||||||
Survey on Process Safety Events | ||||||||||||||
Step 2 | Complete the survey one line per Process Safety Event for your companyregion | |||||||||||||
ALL REPORTED DATA SHOULD BE FROM CALENDAR YEAR 2017 | ||||||||||||||
Step 3 | Return completed survey to | |||||||||||||
Company Name | ||||||||||||||
Contact Person | All Surveys Due by xxx date | |||||||||||||
Address | ||||||||||||||
Fax | ||||||||||||||
Telephone | ||||||||||||||
Region | ||||||||||||||
25
Appendix C ndash List of RCLG Taskforce Members
Name Affiliation
Peter Schmelzer Bayer CEFIC - Chairman
Americo Diniz Carvalho Neto Braskem
Bradford Johnson American Chemistry Council
David Cummings DuPont
Debra Phillips American Chemistry Council
Hans Schwarz BASF
Kathryn Walton Plastics and Chemicals Industries Association
Kazuyuki Akita Japanese Chemical Industry Association
Kelly Keim ExxonMobil Chemical Company API Representative
Kenan Stevick Dow
Kiyokazu Murata Japanese Chemical Industry Association
Larry Bowler SABIC
Lorna Young Chemical Industry Association of Canada
Louisa Nara Center for Chemical Process Safety
Luiz Shizuo Harayashiki Associaccedilatildeo Brasileira da Induacutestria Quiacutemica
Masatoshi Kumamoto Japanese Chemical Industry Association
Milton Lacerda Petrobras
Phil Scott Chemical Industries Association
Piet Knijff DSM European Process Safety Centre
Scott Donaldson and Eamon Chandler
Shell
Scott Wallace Olin Corporation
Shakeel Kadri Air Products and Chemicals Inc
26
附錄 D ndash 詳細活動時程表
2016 年 2017 年 2018 年 2019 年 2020 年
2 ndash 4 月
RCLG PS 先導計畫
5 月 ndash
針對準則進行調整釐清
6 月 向 RCLG 和 ICCA 董事會報
告先導計畫執行結果
7 ndash 12 月 RCLG 協會考量準
則並為其會員公司發展提報機制
如有需要RCLG可向 ICCA 申請能
力建立基金為會員公司舉辦製程安
全研習會
1 ndash 12 月
RCLG 協會開始向其會員公司蒐集製程安全數據
1 ndash 12 月
如有需要RCLG 各協會運用 RCLG 的基金及專
家舉辦製程安全及績效提報研習會
1 ndash 2 月
擁有數據的協會開始向RCLG 提報製程安全事件
(2017 年數據)
4 月 RCLG 檢討第一個提報循
環的結果挑戰及原始數據(內部)
6 月 RCLG 向 ICCA 董事會呈報
原始數據
7 ndash 12 月 必要時更新及調整準
則
如有需要RCLG 各協會運用 RCLG 的基金及專
家舉辦製程安全及績效提報研習會
1 ndash 2 月
擁有數據的協會開始向RCLG 提報製程安全事件
(2018 年數據)
4 月 RCLG 檢討第二個提報循
環的結果挑戰及原始數據(內部)
6 月 RCLG 向 ICCA 董事會呈報
原始數據
7 ndash 12 月 必要時更新及調整準
則
如有需要RCLG 協會運用 RCLG 的基金及專家
舉辦製程安全及績效提報研習會
1 ndash 2 月
所有協會開始向 RCLG 提報製程安全事件
製程安全事件提報成為
RCLG KPI 衡量指標建議基本集的一部分(2019 年數
據)
4 月 RCLG 檢討第二個提報循
環的結果挑戰及原始數據(內部考量外部提
報)
6 月 RCLG 向 ICCA 董事會呈報
原始數據
27
附錄 E ndash 選擇性 Excel 追蹤表
當會員公司開始追蹤製程安全事件時所有會員公司應採用單一表格以簡化數據分析同時讓所有公司均使用相同的追蹤表RCLG 設
計了一份選擇性追蹤表可供會員公司和協會先行利用之後他們可設計自己的追蹤表
在這裡下載追蹤表
ICCA Process Safety Event Tracking Sheetxlsx
本文件包含三個分頁分別是ldquo聯絡資料rdquoldquo調查表rdquo和儲存下拉式選單選項的ldquo請勿編輯rdquo分頁
備註
附錄 E 追蹤表僅供參考TRCA 將另行提供台灣版表格供會員公司提報
28
後語
台灣化學工業責任照顧協會(Taiwan Responsible Care Association TRCA)成立於 1998 年在台灣推行責任照顧制度已達 20 週年製造商成員
包括台灣主要上市上櫃化工公司會員公司化學品生產製造量約佔全國 80 2016 年台灣化工業的 Chemical Sales 仍站在全球第八名的位
置額度為 630 億歐元化工業總產值達到 34 兆新台幣提供國內 416 萬人工作機會
TRCA 扮演國內廠商與國際制度接軌的角色也是國內化工業與政府機關及利益相關者溝通的橋樑與管道TRCA 會員結構依業務性質分析
涵蓋石化生產化學品製造氣體生產倉儲運輸業化學品貿易業以及工程研發設計等公司TRCA 透過供應鏈及價值鏈推行責任
照顧制度組成毒性化學物質聯防組織協助法規溝通與研析會員名冊請參考 httpwwwtrcaorgtwtrcanwork2aspx
TRCA 於 2010 年成為 ICCA (International Council of Chemical Associations 國際化學工業協會)觀察員ICCA 成立於 1989 年是全球化工製造
業的聯合會也是化學工業與 UNEP OPCW 及 OECD 的交流窗口ICCA 與其會員協會及成員公司致力於邁向永續的未來確保人類健康與
環境安全與保護全球化工業擁有超過 4兆美元的價值影響所有經濟部門ICCA 的會員幾乎在全球每個國家都有商業活動在全球六大
洲推動創新並提供超過 2000 萬個工作機會
台灣化工業在全球占有重要的一席之地在國內產業鏈也位居關鍵位置無論對國內或國際都有身為地球村一員應盡之責我們期許藉由
製程安全指標提報能更進一步提升自我在工安衛生環保與永續發展等面向的績效表現
台灣化學工業責任照顧協會
10452 台北市中山區撫順街 8 號 7 樓
電話02-2585-0552
httpwwwtrcaorgtw
None | |
$2500 to $25000 | |
$25000 to $250000 | |
$250000 to $25000000 | |
More than $25000000 | |
Yes - Using GHS TABLE | |
Yes - Using API RP 754 TABLE | |
NO | |
NA | |
1x le TQ lt 40x | |
40x le TQ lt 160x | |
160x le TQ lt 640x | |
ge 640x TQ | |
Yes le 3 hours | |
Yes 3 hours ge 12 hours | |
Yes 12 hours ge 24 hours | |
Yes ge 24 hours | |
No | |
Small-scale | |
Medium-scale | |
Large-scale | |
No | |
Yes | |
No | |
middot Injury requiring treatment beyond first aid to an employee contractor or subcontractor | |
middot Days Away From Work injury to an employee contractor or subcontractor or middot Injury requiring treatment beyond first aid to a third party | |
middot A fatality of an employee contractor or subcontractor or middot A hospital admission of a third party | |
middot Multiple fatalities of employees contractors or subcontractors or middot multiple hospital admission of third parties or middot A fatality of a third party | |
NA | |
1x le TQ lt 3x | |
3x le TQ lt 9x | |
9x le TQ lt 27x | |
ge 27x TQ |
ICCA Process Safety Pilot Reporting ProgramFebruary 8 2016 | 1 | 2 | 3 | 4 | 5 | 6 | 7 | 8 | 9 | 10 | 12 | 13 | 14 | 15 | |||||||||||||||||||||||
SAFETY Details(Meeting Local Regulations) | Direct Cost from Fire or Explosion | Community Impact | Environmental Impact | Material Released(Measured using the 1 Hour Rule) | |||||||||||||||||||||||||||||||||
Company Association Details | |||||||||||||||||||||||||||||||||||||
GHS | API - RP 754 | ||||||||||||||||||||||||||||||||||||
Company or Assocation Name | Headquarter Association | Location of Event Ex - City State amp Country | Date and Time of Event | Safety InjuryDid the Event result in a Recordable Lost Time Accident or Fatality or Hospital admission of anyone on or off siteUse Drop Down Menu | Safety InjuryIf yes please insert the total number of injuries | Safety InjuryFor puropses of utilizing the Severity Table please indicate the level of severity by chosing the MOST SEVERE classification that describes your incidentUse Drop Down Menu | Safety InjuryDid the incident involve Fatalities If so how many total fatalities If none enter Zero | Safety InjuryPlease Report Total Employee Hours for Calendar Year 2015 | Safety InjuryPlease Report Total Contractor Hours for Calendar Year 2015 | Direct Cost Did the Event result in Direct Damage CostUse Drop Down Menu | Direct Cost If so how muchAmount is in US DollarsUse Drop Down Menu | Community ImpactDid the event result inbull Officially declared shelter-in-place or officially declared evacuation (on or off site)ORbull Precautionary off site shelter in place or evacuation Use Drop Down Menu | Environmental ImpactDid the event result inAcute Environmental Remediation CostIf so indicate the amount in US DollarsUse Drop Down Menu | Material ReleasedDid the Event result in an Acute Release of material beyond one of the two threshold tablesIf so indicate which Threshold Table you used to make this determinationUse Drop Down Menu | Material ReleasedIf so indicate the amount released USING GHS CLASSIFICATION TABLEUse Drop Down Menu | Material ReleasedIf so indicate the amount released USING THE THRESHOLD TABLE FROM API RP-754Use Drop Down Menu | Material ReleasedIf available please indicate the material released | ||||||||||||||||||||
1 | ABC Chemical Company | American Chemistry Council | Washington DC - USA | January 4 2016 | Yes | 2 | middot Days Away From Work injury to an employee contractor or subcontractor or middot Injury requiring treatment beyond first aid to a third party | 0 | 5525000 | 1500250 | No | $2500 to $25000 | Yes le 3 hours | $2500 to $25000 | Yes - Using GHS TABLE | 40x le TQ lt 160x | NA | Chlorine | |||||||||||||||||||
2 | XYZ Chemical Company | American Chemistry Council | Washington DC - USA | 5-Jan-16 | Yes | 1 | middot Injury requiring treatment beyond first aid to an employee contractor or subcontractor | 0 | 5525000 | 1500250 | Yes | $2500 to $25000 | No | $2500 to $25000 | Yes - Using API RP 754 TABLE | NA | 3x le TQ lt 9x | Benzene | |||||||||||||||||||
3 | |||||||||||||||||||||||||||||||||||||
4 | |||||||||||||||||||||||||||||||||||||
5 | |||||||||||||||||||||||||||||||||||||
6 | |||||||||||||||||||||||||||||||||||||
7 | |||||||||||||||||||||||||||||||||||||
8 | |||||||||||||||||||||||||||||||||||||
9 | |||||||||||||||||||||||||||||||||||||
10 | |||||||||||||||||||||||||||||||||||||
11 | |||||||||||||||||||||||||||||||||||||
12 | |||||||||||||||||||||||||||||||||||||
13 | |||||||||||||||||||||||||||||||||||||
14 | |||||||||||||||||||||||||||||||||||||
15 | |||||||||||||||||||||||||||||||||||||
16 | |||||||||||||||||||||||||||||||||||||
17 | |||||||||||||||||||||||||||||||||||||
18 | |||||||||||||||||||||||||||||||||||||
19 | |||||||||||||||||||||||||||||||||||||
20 | |||||||||||||||||||||||||||||||||||||
21 | |||||||||||||||||||||||||||||||||||||
22 | |||||||||||||||||||||||||||||||||||||
23 | |||||||||||||||||||||||||||||||||||||
24 | |||||||||||||||||||||||||||||||||||||
25 | |||||||||||||||||||||||||||||||||||||
Zero or None | Yes - Duration Unknown | ||||||||||||||||||||||||||||||||||||
Processes | Mode of Operation | Type of material released | Status of Operation | ||||
REFINING | Start-up | Flammable | Open | ||||
Alkylation HF | Planned shutdown | Combustible | Closed | ||||
Alkylation sulfuric | Emergency shutdown | Toxic | |||||
BitumenResidAsphalt | Normal | Corrosive | Tier 1 Acute Releases | ||||
Calcining | Upset | Utilities | No Release | ||||
Coking | Turnaround | Other | Category 1 | ||||
Crude | Routine maintenance | Category 2 | |||||
Desulfurization | Temporary | Evacuation | Category 3 | ||||
FCC | Other | Yes | Category 4 | ||||
Gas Treating | No | Category 5 | |||||
Hydrogen | Point of Release | Category 6 | |||||
Hydrotreating | Pump | Fire | Category 7 | ||||
Hydrocracking | Compressor | Yes | Multiple Categories | ||||
Isom | BlowerFan | No | |||||
MarineJetty | Pressure Vessel | lt $2500 | |||||
Reforming | FilterCoalescer | ||||||
Sulfur recovery | Furnace | PRDs | |||||
Vapor recoverylight ends | Boiler | Directly to Atmosphere | |||||
Wastewater | Heat exchanger | via Downstream Destructive Device | |||||
REFINING amp PETROCHEMICAL | Cooling Tower | No | |||||
Tank FarmStorage FacilityOffsite | Piping system | Yes | |||||
UtilitiesSteam PlantCogeneration | Reactor | No | |||||
Other | Atmospheric tank | ||||||
PETROCHEMICAL | FlareRelief System | Acute release above thresholds | |||||
CO H2 | Other | Yes | |||||
LNG | No | ||||||
Methane | Events | ||||||
Methanol | No Tier 1 Events | Indoor Outdoor | |||||
Methyl Mercaptan | No Tier 2 Events | No Release | |||||
Formaldehyde | No Tier 1 or Tier 2 Events | Indoor | |||||
Formaldehyde derivatives | NA | Outdoor | |||||
Acetic Acid | |||||||
Acetic Acid derivatives | Event Type | ||||||
Ethane | Injury | ||||||
Ethylene | Fire | ||||||
Ethanol | Explosion | ||||||
Ethylene oxide | PRD Discharge | ||||||
Ethylene derivatives | Acute Release | ||||||
Polyethylene | |||||||
Ethylene dichloride | General | ||||||
Ethylene dichloride derivatives | Yes | ||||||
Ethyl benzene | No | ||||||
Ethyl benzene derivatives | |||||||
Polystyrene | |||||||
Styrene-Butadiene | |||||||
Propane | |||||||
Propylene | |||||||
Polypropylene | |||||||
Isopropanol | |||||||
Propylene oxide | |||||||
Propylene oxide derivatives | |||||||
Butane | |||||||
Isobutane | |||||||
Isobutene | |||||||
Butadiene | |||||||
MTBE | |||||||
ETBE | |||||||
Pentane | |||||||
Hexane | |||||||
Cyclohexane | |||||||
Hexanol | |||||||
Aromatics Derivatives | |||||||
Benzene | |||||||
Toluene | |||||||
Xylene | |||||||
Para Xylene | |||||||
Amines Derivatives | |||||||
TDA MDA IPDA etc | |||||||
Isocyanates | |||||||
Specialty Chemicals | |||||||
LoadingUnloading | |||||||
Pilot Plant |
Instructions | ||||||||||||||
Step 1 | Complete the Contact Tab with your contact information and company information | |||||||||||||
Be sure to note the region of your reporting (IE North America France Japan etc) | ||||||||||||||
Survey on Process Safety Events | ||||||||||||||
Step 2 | Complete the survey one line per Process Safety Event for your companyregion | |||||||||||||
ALL REPORTED DATA SHOULD BE FROM CALENDAR YEAR 2017 | ||||||||||||||
Step 3 | Return completed survey to | |||||||||||||
Company Name | ||||||||||||||
Contact Person | All Surveys Due by xxx date | |||||||||||||
Address | ||||||||||||||
Fax | ||||||||||||||
Telephone | ||||||||||||||
Region | ||||||||||||||
None | |
$2500 to $25000 | |
$25000 to $250000 | |
$250000 to $25000000 | |
More than $25000000 | |
Yes - Using GHS TABLE | |
Yes - Using API RP 754 TABLE | |
NO | |
NA | |
1x le TQ lt 40x | |
40x le TQ lt 160x | |
160x le TQ lt 640x | |
ge 640x TQ | |
Yes le 3 hours | |
Yes 3 hours ge 12 hours | |
Yes 12 hours ge 24 hours | |
Yes ge 24 hours | |
No | |
Small-scale | |
Medium-scale | |
Large-scale | |
No | |
Yes | |
No | |
middot Injury requiring treatment beyond first aid to an employee contractor or subcontractor | |
middot Days Away From Work injury to an employee contractor or subcontractor or middot Injury requiring treatment beyond first aid to a third party | |
middot A fatality of an employee contractor or subcontractor or middot A hospital admission of a third party | |
middot Multiple fatalities of employees contractors or subcontractors or middot multiple hospital admission of third parties or middot A fatality of a third party | |
NA | |
1x le TQ lt 3x | |
3x le TQ lt 9x | |
9x le TQ lt 27x | |
ge 27x TQ |
ICCA Process Safety Pilot Reporting ProgramFebruary 8 2016 | 1 | 2 | 3 | 4 | 5 | 6 | 7 | 8 | 9 | 10 | 12 | 13 | 14 | 15 | |||||||||||||||||||||||
SAFETY Details(Meeting Local Regulations) | Direct Cost from Fire or Explosion | Community Impact | Environmental Impact | Material Released(Measured using the 1 Hour Rule) | |||||||||||||||||||||||||||||||||
Company Association Details | |||||||||||||||||||||||||||||||||||||
GHS | API - RP 754 | ||||||||||||||||||||||||||||||||||||
Company or Assocation Name | Headquarter Association | Location of Event Ex - City State amp Country | Date and Time of Event | Safety InjuryDid the Event result in a Recordable Lost Time Accident or Fatality or Hospital admission of anyone on or off siteUse Drop Down Menu | Safety InjuryIf yes please insert the total number of injuries | Safety InjuryFor puropses of utilizing the Severity Table please indicate the level of severity by chosing the MOST SEVERE classification that describes your incidentUse Drop Down Menu | Safety InjuryDid the incident involve Fatalities If so how many total fatalities If none enter Zero | Safety InjuryPlease Report Total Employee Hours for Calendar Year 2015 | Safety InjuryPlease Report Total Contractor Hours for Calendar Year 2015 | Direct Cost Did the Event result in Direct Damage CostUse Drop Down Menu | Direct Cost If so how muchAmount is in US DollarsUse Drop Down Menu | Community ImpactDid the event result inbull Officially declared shelter-in-place or officially declared evacuation (on or off site)ORbull Precautionary off site shelter in place or evacuation Use Drop Down Menu | Environmental ImpactDid the event result inAcute Environmental Remediation CostIf so indicate the amount in US DollarsUse Drop Down Menu | Material ReleasedDid the Event result in an Acute Release of material beyond one of the two threshold tablesIf so indicate which Threshold Table you used to make this determinationUse Drop Down Menu | Material ReleasedIf so indicate the amount released USING GHS CLASSIFICATION TABLEUse Drop Down Menu | Material ReleasedIf so indicate the amount released USING THE THRESHOLD TABLE FROM API RP-754Use Drop Down Menu | Material ReleasedIf available please indicate the material released | ||||||||||||||||||||
1 | ABC Chemical Company | American Chemistry Council | Washington DC - USA | January 4 2016 | Yes | 2 | middot Days Away From Work injury to an employee contractor or subcontractor or middot Injury requiring treatment beyond first aid to a third party | 0 | 5525000 | 1500250 | No | $2500 to $25000 | Yes le 3 hours | $2500 to $25000 | Yes - Using GHS TABLE | 40x le TQ lt 160x | NA | Chlorine | |||||||||||||||||||
2 | XYZ Chemical Company | American Chemistry Council | Washington DC - USA | 5-Jan-16 | Yes | 1 | middot Injury requiring treatment beyond first aid to an employee contractor or subcontractor | 0 | 5525000 | 1500250 | Yes | $2500 to $25000 | No | $2500 to $25000 | Yes - Using API RP 754 TABLE | NA | 3x le TQ lt 9x | Benzene | |||||||||||||||||||
3 | |||||||||||||||||||||||||||||||||||||
4 | |||||||||||||||||||||||||||||||||||||
5 | |||||||||||||||||||||||||||||||||||||
6 | |||||||||||||||||||||||||||||||||||||
7 | |||||||||||||||||||||||||||||||||||||
8 | |||||||||||||||||||||||||||||||||||||
9 | |||||||||||||||||||||||||||||||||||||
10 | |||||||||||||||||||||||||||||||||||||
11 | |||||||||||||||||||||||||||||||||||||
12 | |||||||||||||||||||||||||||||||||||||
13 | |||||||||||||||||||||||||||||||||||||
14 | |||||||||||||||||||||||||||||||||||||
15 | |||||||||||||||||||||||||||||||||||||
16 | |||||||||||||||||||||||||||||||||||||
17 | |||||||||||||||||||||||||||||||||||||
18 | |||||||||||||||||||||||||||||||||||||
19 | |||||||||||||||||||||||||||||||||||||
20 | |||||||||||||||||||||||||||||||||||||
21 | |||||||||||||||||||||||||||||||||||||
22 | |||||||||||||||||||||||||||||||||||||
23 | |||||||||||||||||||||||||||||||||||||
24 | |||||||||||||||||||||||||||||||||||||
25 | |||||||||||||||||||||||||||||||||||||
Zero or None | Yes - Duration Unknown | ||||||||||||||||||||||||||||||||||||
Processes | Mode of Operation | Type of material released | Status of Operation | ||||
REFINING | Start-up | Flammable | Open | ||||
Alkylation HF | Planned shutdown | Combustible | Closed | ||||
Alkylation sulfuric | Emergency shutdown | Toxic | |||||
BitumenResidAsphalt | Normal | Corrosive | Tier 1 Acute Releases | ||||
Calcining | Upset | Utilities | No Release | ||||
Coking | Turnaround | Other | Category 1 | ||||
Crude | Routine maintenance | Category 2 | |||||
Desulfurization | Temporary | Evacuation | Category 3 | ||||
FCC | Other | Yes | Category 4 | ||||
Gas Treating | No | Category 5 | |||||
Hydrogen | Point of Release | Category 6 | |||||
Hydrotreating | Pump | Fire | Category 7 | ||||
Hydrocracking | Compressor | Yes | Multiple Categories | ||||
Isom | BlowerFan | No | |||||
MarineJetty | Pressure Vessel | lt $2500 | |||||
Reforming | FilterCoalescer | ||||||
Sulfur recovery | Furnace | PRDs | |||||
Vapor recoverylight ends | Boiler | Directly to Atmosphere | |||||
Wastewater | Heat exchanger | via Downstream Destructive Device | |||||
REFINING amp PETROCHEMICAL | Cooling Tower | No | |||||
Tank FarmStorage FacilityOffsite | Piping system | Yes | |||||
UtilitiesSteam PlantCogeneration | Reactor | No | |||||
Other | Atmospheric tank | ||||||
PETROCHEMICAL | FlareRelief System | Acute release above thresholds | |||||
CO H2 | Other | Yes | |||||
LNG | No | ||||||
Methane | Events | ||||||
Methanol | No Tier 1 Events | Indoor Outdoor | |||||
Methyl Mercaptan | No Tier 2 Events | No Release | |||||
Formaldehyde | No Tier 1 or Tier 2 Events | Indoor | |||||
Formaldehyde derivatives | NA | Outdoor | |||||
Acetic Acid | |||||||
Acetic Acid derivatives | Event Type | ||||||
Ethane | Injury | ||||||
Ethylene | Fire | ||||||
Ethanol | Explosion | ||||||
Ethylene oxide | PRD Discharge | ||||||
Ethylene derivatives | Acute Release | ||||||
Polyethylene | |||||||
Ethylene dichloride | General | ||||||
Ethylene dichloride derivatives | Yes | ||||||
Ethyl benzene | No | ||||||
Ethyl benzene derivatives | |||||||
Polystyrene | |||||||
Styrene-Butadiene | |||||||
Propane | |||||||
Propylene | |||||||
Polypropylene | |||||||
Isopropanol | |||||||
Propylene oxide | |||||||
Propylene oxide derivatives | |||||||
Butane | |||||||
Isobutane | |||||||
Isobutene | |||||||
Butadiene | |||||||
MTBE | |||||||
ETBE | |||||||
Pentane | |||||||
Hexane | |||||||
Cyclohexane | |||||||
Hexanol | |||||||
Aromatics Derivatives | |||||||
Benzene | |||||||
Toluene | |||||||
Xylene | |||||||
Para Xylene | |||||||
Amines Derivatives | |||||||
TDA MDA IPDA etc | |||||||
Isocyanates | |||||||
Specialty Chemicals | |||||||
LoadingUnloading | |||||||
Pilot Plant |
Instructions | ||||||||||||||
Step 1 | Complete the Contact Tab with your contact information and company information | |||||||||||||
Be sure to note the region of your reporting (IE North America France Japan etc) | ||||||||||||||
Survey on Process Safety Events | ||||||||||||||
Step 2 | Complete the survey one line per Process Safety Event for your companyregion | |||||||||||||
ALL REPORTED DATA SHOULD BE FROM CALENDAR YEAR 2017 | ||||||||||||||
Step 3 | Return completed survey to | |||||||||||||
Company Name | ||||||||||||||
Contact Person | All Surveys Due by xxx date | |||||||||||||
Address | ||||||||||||||
Fax | ||||||||||||||
Telephone | ||||||||||||||
Region | ||||||||||||||
26
附錄 D ndash 詳細活動時程表
2016 年 2017 年 2018 年 2019 年 2020 年
2 ndash 4 月
RCLG PS 先導計畫
5 月 ndash
針對準則進行調整釐清
6 月 向 RCLG 和 ICCA 董事會報
告先導計畫執行結果
7 ndash 12 月 RCLG 協會考量準
則並為其會員公司發展提報機制
如有需要RCLG可向 ICCA 申請能
力建立基金為會員公司舉辦製程安
全研習會
1 ndash 12 月
RCLG 協會開始向其會員公司蒐集製程安全數據
1 ndash 12 月
如有需要RCLG 各協會運用 RCLG 的基金及專
家舉辦製程安全及績效提報研習會
1 ndash 2 月
擁有數據的協會開始向RCLG 提報製程安全事件
(2017 年數據)
4 月 RCLG 檢討第一個提報循
環的結果挑戰及原始數據(內部)
6 月 RCLG 向 ICCA 董事會呈報
原始數據
7 ndash 12 月 必要時更新及調整準
則
如有需要RCLG 各協會運用 RCLG 的基金及專
家舉辦製程安全及績效提報研習會
1 ndash 2 月
擁有數據的協會開始向RCLG 提報製程安全事件
(2018 年數據)
4 月 RCLG 檢討第二個提報循
環的結果挑戰及原始數據(內部)
6 月 RCLG 向 ICCA 董事會呈報
原始數據
7 ndash 12 月 必要時更新及調整準
則
如有需要RCLG 協會運用 RCLG 的基金及專家
舉辦製程安全及績效提報研習會
1 ndash 2 月
所有協會開始向 RCLG 提報製程安全事件
製程安全事件提報成為
RCLG KPI 衡量指標建議基本集的一部分(2019 年數
據)
4 月 RCLG 檢討第二個提報循
環的結果挑戰及原始數據(內部考量外部提
報)
6 月 RCLG 向 ICCA 董事會呈報
原始數據
27
附錄 E ndash 選擇性 Excel 追蹤表
當會員公司開始追蹤製程安全事件時所有會員公司應採用單一表格以簡化數據分析同時讓所有公司均使用相同的追蹤表RCLG 設
計了一份選擇性追蹤表可供會員公司和協會先行利用之後他們可設計自己的追蹤表
在這裡下載追蹤表
ICCA Process Safety Event Tracking Sheetxlsx
本文件包含三個分頁分別是ldquo聯絡資料rdquoldquo調查表rdquo和儲存下拉式選單選項的ldquo請勿編輯rdquo分頁
備註
附錄 E 追蹤表僅供參考TRCA 將另行提供台灣版表格供會員公司提報
28
後語
台灣化學工業責任照顧協會(Taiwan Responsible Care Association TRCA)成立於 1998 年在台灣推行責任照顧制度已達 20 週年製造商成員
包括台灣主要上市上櫃化工公司會員公司化學品生產製造量約佔全國 80 2016 年台灣化工業的 Chemical Sales 仍站在全球第八名的位
置額度為 630 億歐元化工業總產值達到 34 兆新台幣提供國內 416 萬人工作機會
TRCA 扮演國內廠商與國際制度接軌的角色也是國內化工業與政府機關及利益相關者溝通的橋樑與管道TRCA 會員結構依業務性質分析
涵蓋石化生產化學品製造氣體生產倉儲運輸業化學品貿易業以及工程研發設計等公司TRCA 透過供應鏈及價值鏈推行責任
照顧制度組成毒性化學物質聯防組織協助法規溝通與研析會員名冊請參考 httpwwwtrcaorgtwtrcanwork2aspx
TRCA 於 2010 年成為 ICCA (International Council of Chemical Associations 國際化學工業協會)觀察員ICCA 成立於 1989 年是全球化工製造
業的聯合會也是化學工業與 UNEP OPCW 及 OECD 的交流窗口ICCA 與其會員協會及成員公司致力於邁向永續的未來確保人類健康與
環境安全與保護全球化工業擁有超過 4兆美元的價值影響所有經濟部門ICCA 的會員幾乎在全球每個國家都有商業活動在全球六大
洲推動創新並提供超過 2000 萬個工作機會
台灣化工業在全球占有重要的一席之地在國內產業鏈也位居關鍵位置無論對國內或國際都有身為地球村一員應盡之責我們期許藉由
製程安全指標提報能更進一步提升自我在工安衛生環保與永續發展等面向的績效表現
台灣化學工業責任照顧協會
10452 台北市中山區撫順街 8 號 7 樓
電話02-2585-0552
httpwwwtrcaorgtw
None | |
$2500 to $25000 | |
$25000 to $250000 | |
$250000 to $25000000 | |
More than $25000000 | |
Yes - Using GHS TABLE | |
Yes - Using API RP 754 TABLE | |
NO | |
NA | |
1x le TQ lt 40x | |
40x le TQ lt 160x | |
160x le TQ lt 640x | |
ge 640x TQ | |
Yes le 3 hours | |
Yes 3 hours ge 12 hours | |
Yes 12 hours ge 24 hours | |
Yes ge 24 hours | |
No | |
Small-scale | |
Medium-scale | |
Large-scale | |
No | |
Yes | |
No | |
middot Injury requiring treatment beyond first aid to an employee contractor or subcontractor | |
middot Days Away From Work injury to an employee contractor or subcontractor or middot Injury requiring treatment beyond first aid to a third party | |
middot A fatality of an employee contractor or subcontractor or middot A hospital admission of a third party | |
middot Multiple fatalities of employees contractors or subcontractors or middot multiple hospital admission of third parties or middot A fatality of a third party | |
NA | |
1x le TQ lt 3x | |
3x le TQ lt 9x | |
9x le TQ lt 27x | |
ge 27x TQ |
ICCA Process Safety Pilot Reporting ProgramFebruary 8 2016 | 1 | 2 | 3 | 4 | 5 | 6 | 7 | 8 | 9 | 10 | 12 | 13 | 14 | 15 | |||||||||||||||||||||||
SAFETY Details(Meeting Local Regulations) | Direct Cost from Fire or Explosion | Community Impact | Environmental Impact | Material Released(Measured using the 1 Hour Rule) | |||||||||||||||||||||||||||||||||
Company Association Details | |||||||||||||||||||||||||||||||||||||
GHS | API - RP 754 | ||||||||||||||||||||||||||||||||||||
Company or Assocation Name | Headquarter Association | Location of Event Ex - City State amp Country | Date and Time of Event | Safety InjuryDid the Event result in a Recordable Lost Time Accident or Fatality or Hospital admission of anyone on or off siteUse Drop Down Menu | Safety InjuryIf yes please insert the total number of injuries | Safety InjuryFor puropses of utilizing the Severity Table please indicate the level of severity by chosing the MOST SEVERE classification that describes your incidentUse Drop Down Menu | Safety InjuryDid the incident involve Fatalities If so how many total fatalities If none enter Zero | Safety InjuryPlease Report Total Employee Hours for Calendar Year 2015 | Safety InjuryPlease Report Total Contractor Hours for Calendar Year 2015 | Direct Cost Did the Event result in Direct Damage CostUse Drop Down Menu | Direct Cost If so how muchAmount is in US DollarsUse Drop Down Menu | Community ImpactDid the event result inbull Officially declared shelter-in-place or officially declared evacuation (on or off site)ORbull Precautionary off site shelter in place or evacuation Use Drop Down Menu | Environmental ImpactDid the event result inAcute Environmental Remediation CostIf so indicate the amount in US DollarsUse Drop Down Menu | Material ReleasedDid the Event result in an Acute Release of material beyond one of the two threshold tablesIf so indicate which Threshold Table you used to make this determinationUse Drop Down Menu | Material ReleasedIf so indicate the amount released USING GHS CLASSIFICATION TABLEUse Drop Down Menu | Material ReleasedIf so indicate the amount released USING THE THRESHOLD TABLE FROM API RP-754Use Drop Down Menu | Material ReleasedIf available please indicate the material released | ||||||||||||||||||||
1 | ABC Chemical Company | American Chemistry Council | Washington DC - USA | January 4 2016 | Yes | 2 | middot Days Away From Work injury to an employee contractor or subcontractor or middot Injury requiring treatment beyond first aid to a third party | 0 | 5525000 | 1500250 | No | $2500 to $25000 | Yes le 3 hours | $2500 to $25000 | Yes - Using GHS TABLE | 40x le TQ lt 160x | NA | Chlorine | |||||||||||||||||||
2 | XYZ Chemical Company | American Chemistry Council | Washington DC - USA | 5-Jan-16 | Yes | 1 | middot Injury requiring treatment beyond first aid to an employee contractor or subcontractor | 0 | 5525000 | 1500250 | Yes | $2500 to $25000 | No | $2500 to $25000 | Yes - Using API RP 754 TABLE | NA | 3x le TQ lt 9x | Benzene | |||||||||||||||||||
3 | |||||||||||||||||||||||||||||||||||||
4 | |||||||||||||||||||||||||||||||||||||
5 | |||||||||||||||||||||||||||||||||||||
6 | |||||||||||||||||||||||||||||||||||||
7 | |||||||||||||||||||||||||||||||||||||
8 | |||||||||||||||||||||||||||||||||||||
9 | |||||||||||||||||||||||||||||||||||||
10 | |||||||||||||||||||||||||||||||||||||
11 | |||||||||||||||||||||||||||||||||||||
12 | |||||||||||||||||||||||||||||||||||||
13 | |||||||||||||||||||||||||||||||||||||
14 | |||||||||||||||||||||||||||||||||||||
15 | |||||||||||||||||||||||||||||||||||||
16 | |||||||||||||||||||||||||||||||||||||
17 | |||||||||||||||||||||||||||||||||||||
18 | |||||||||||||||||||||||||||||||||||||
19 | |||||||||||||||||||||||||||||||||||||
20 | |||||||||||||||||||||||||||||||||||||
21 | |||||||||||||||||||||||||||||||||||||
22 | |||||||||||||||||||||||||||||||||||||
23 | |||||||||||||||||||||||||||||||||||||
24 | |||||||||||||||||||||||||||||||||||||
25 | |||||||||||||||||||||||||||||||||||||
Zero or None | Yes - Duration Unknown | ||||||||||||||||||||||||||||||||||||
Processes | Mode of Operation | Type of material released | Status of Operation | ||||
REFINING | Start-up | Flammable | Open | ||||
Alkylation HF | Planned shutdown | Combustible | Closed | ||||
Alkylation sulfuric | Emergency shutdown | Toxic | |||||
BitumenResidAsphalt | Normal | Corrosive | Tier 1 Acute Releases | ||||
Calcining | Upset | Utilities | No Release | ||||
Coking | Turnaround | Other | Category 1 | ||||
Crude | Routine maintenance | Category 2 | |||||
Desulfurization | Temporary | Evacuation | Category 3 | ||||
FCC | Other | Yes | Category 4 | ||||
Gas Treating | No | Category 5 | |||||
Hydrogen | Point of Release | Category 6 | |||||
Hydrotreating | Pump | Fire | Category 7 | ||||
Hydrocracking | Compressor | Yes | Multiple Categories | ||||
Isom | BlowerFan | No | |||||
MarineJetty | Pressure Vessel | lt $2500 | |||||
Reforming | FilterCoalescer | ||||||
Sulfur recovery | Furnace | PRDs | |||||
Vapor recoverylight ends | Boiler | Directly to Atmosphere | |||||
Wastewater | Heat exchanger | via Downstream Destructive Device | |||||
REFINING amp PETROCHEMICAL | Cooling Tower | No | |||||
Tank FarmStorage FacilityOffsite | Piping system | Yes | |||||
UtilitiesSteam PlantCogeneration | Reactor | No | |||||
Other | Atmospheric tank | ||||||
PETROCHEMICAL | FlareRelief System | Acute release above thresholds | |||||
CO H2 | Other | Yes | |||||
LNG | No | ||||||
Methane | Events | ||||||
Methanol | No Tier 1 Events | Indoor Outdoor | |||||
Methyl Mercaptan | No Tier 2 Events | No Release | |||||
Formaldehyde | No Tier 1 or Tier 2 Events | Indoor | |||||
Formaldehyde derivatives | NA | Outdoor | |||||
Acetic Acid | |||||||
Acetic Acid derivatives | Event Type | ||||||
Ethane | Injury | ||||||
Ethylene | Fire | ||||||
Ethanol | Explosion | ||||||
Ethylene oxide | PRD Discharge | ||||||
Ethylene derivatives | Acute Release | ||||||
Polyethylene | |||||||
Ethylene dichloride | General | ||||||
Ethylene dichloride derivatives | Yes | ||||||
Ethyl benzene | No | ||||||
Ethyl benzene derivatives | |||||||
Polystyrene | |||||||
Styrene-Butadiene | |||||||
Propane | |||||||
Propylene | |||||||
Polypropylene | |||||||
Isopropanol | |||||||
Propylene oxide | |||||||
Propylene oxide derivatives | |||||||
Butane | |||||||
Isobutane | |||||||
Isobutene | |||||||
Butadiene | |||||||
MTBE | |||||||
ETBE | |||||||
Pentane | |||||||
Hexane | |||||||
Cyclohexane | |||||||
Hexanol | |||||||
Aromatics Derivatives | |||||||
Benzene | |||||||
Toluene | |||||||
Xylene | |||||||
Para Xylene | |||||||
Amines Derivatives | |||||||
TDA MDA IPDA etc | |||||||
Isocyanates | |||||||
Specialty Chemicals | |||||||
LoadingUnloading | |||||||
Pilot Plant |
Instructions | ||||||||||||||
Step 1 | Complete the Contact Tab with your contact information and company information | |||||||||||||
Be sure to note the region of your reporting (IE North America France Japan etc) | ||||||||||||||
Survey on Process Safety Events | ||||||||||||||
Step 2 | Complete the survey one line per Process Safety Event for your companyregion | |||||||||||||
ALL REPORTED DATA SHOULD BE FROM CALENDAR YEAR 2017 | ||||||||||||||
Step 3 | Return completed survey to | |||||||||||||
Company Name | ||||||||||||||
Contact Person | All Surveys Due by xxx date | |||||||||||||
Address | ||||||||||||||
Fax | ||||||||||||||
Telephone | ||||||||||||||
Region | ||||||||||||||
None | |
$2500 to $25000 | |
$25000 to $250000 | |
$250000 to $25000000 | |
More than $25000000 | |
Yes - Using GHS TABLE | |
Yes - Using API RP 754 TABLE | |
NO | |
NA | |
1x le TQ lt 40x | |
40x le TQ lt 160x | |
160x le TQ lt 640x | |
ge 640x TQ | |
Yes le 3 hours | |
Yes 3 hours ge 12 hours | |
Yes 12 hours ge 24 hours | |
Yes ge 24 hours | |
No | |
Small-scale | |
Medium-scale | |
Large-scale | |
No | |
Yes | |
No | |
middot Injury requiring treatment beyond first aid to an employee contractor or subcontractor | |
middot Days Away From Work injury to an employee contractor or subcontractor or middot Injury requiring treatment beyond first aid to a third party | |
middot A fatality of an employee contractor or subcontractor or middot A hospital admission of a third party | |
middot Multiple fatalities of employees contractors or subcontractors or middot multiple hospital admission of third parties or middot A fatality of a third party | |
NA | |
1x le TQ lt 3x | |
3x le TQ lt 9x | |
9x le TQ lt 27x | |
ge 27x TQ |
ICCA Process Safety Pilot Reporting ProgramFebruary 8 2016 | 1 | 2 | 3 | 4 | 5 | 6 | 7 | 8 | 9 | 10 | 12 | 13 | 14 | 15 | |||||||||||||||||||||||
SAFETY Details(Meeting Local Regulations) | Direct Cost from Fire or Explosion | Community Impact | Environmental Impact | Material Released(Measured using the 1 Hour Rule) | |||||||||||||||||||||||||||||||||
Company Association Details | |||||||||||||||||||||||||||||||||||||
GHS | API - RP 754 | ||||||||||||||||||||||||||||||||||||
Company or Assocation Name | Headquarter Association | Location of Event Ex - City State amp Country | Date and Time of Event | Safety InjuryDid the Event result in a Recordable Lost Time Accident or Fatality or Hospital admission of anyone on or off siteUse Drop Down Menu | Safety InjuryIf yes please insert the total number of injuries | Safety InjuryFor puropses of utilizing the Severity Table please indicate the level of severity by chosing the MOST SEVERE classification that describes your incidentUse Drop Down Menu | Safety InjuryDid the incident involve Fatalities If so how many total fatalities If none enter Zero | Safety InjuryPlease Report Total Employee Hours for Calendar Year 2015 | Safety InjuryPlease Report Total Contractor Hours for Calendar Year 2015 | Direct Cost Did the Event result in Direct Damage CostUse Drop Down Menu | Direct Cost If so how muchAmount is in US DollarsUse Drop Down Menu | Community ImpactDid the event result inbull Officially declared shelter-in-place or officially declared evacuation (on or off site)ORbull Precautionary off site shelter in place or evacuation Use Drop Down Menu | Environmental ImpactDid the event result inAcute Environmental Remediation CostIf so indicate the amount in US DollarsUse Drop Down Menu | Material ReleasedDid the Event result in an Acute Release of material beyond one of the two threshold tablesIf so indicate which Threshold Table you used to make this determinationUse Drop Down Menu | Material ReleasedIf so indicate the amount released USING GHS CLASSIFICATION TABLEUse Drop Down Menu | Material ReleasedIf so indicate the amount released USING THE THRESHOLD TABLE FROM API RP-754Use Drop Down Menu | Material ReleasedIf available please indicate the material released | ||||||||||||||||||||
1 | ABC Chemical Company | American Chemistry Council | Washington DC - USA | January 4 2016 | Yes | 2 | middot Days Away From Work injury to an employee contractor or subcontractor or middot Injury requiring treatment beyond first aid to a third party | 0 | 5525000 | 1500250 | No | $2500 to $25000 | Yes le 3 hours | $2500 to $25000 | Yes - Using GHS TABLE | 40x le TQ lt 160x | NA | Chlorine | |||||||||||||||||||
2 | XYZ Chemical Company | American Chemistry Council | Washington DC - USA | 5-Jan-16 | Yes | 1 | middot Injury requiring treatment beyond first aid to an employee contractor or subcontractor | 0 | 5525000 | 1500250 | Yes | $2500 to $25000 | No | $2500 to $25000 | Yes - Using API RP 754 TABLE | NA | 3x le TQ lt 9x | Benzene | |||||||||||||||||||
3 | |||||||||||||||||||||||||||||||||||||
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25 | |||||||||||||||||||||||||||||||||||||
Zero or None | Yes - Duration Unknown | ||||||||||||||||||||||||||||||||||||
Processes | Mode of Operation | Type of material released | Status of Operation | ||||
REFINING | Start-up | Flammable | Open | ||||
Alkylation HF | Planned shutdown | Combustible | Closed | ||||
Alkylation sulfuric | Emergency shutdown | Toxic | |||||
BitumenResidAsphalt | Normal | Corrosive | Tier 1 Acute Releases | ||||
Calcining | Upset | Utilities | No Release | ||||
Coking | Turnaround | Other | Category 1 | ||||
Crude | Routine maintenance | Category 2 | |||||
Desulfurization | Temporary | Evacuation | Category 3 | ||||
FCC | Other | Yes | Category 4 | ||||
Gas Treating | No | Category 5 | |||||
Hydrogen | Point of Release | Category 6 | |||||
Hydrotreating | Pump | Fire | Category 7 | ||||
Hydrocracking | Compressor | Yes | Multiple Categories | ||||
Isom | BlowerFan | No | |||||
MarineJetty | Pressure Vessel | lt $2500 | |||||
Reforming | FilterCoalescer | ||||||
Sulfur recovery | Furnace | PRDs | |||||
Vapor recoverylight ends | Boiler | Directly to Atmosphere | |||||
Wastewater | Heat exchanger | via Downstream Destructive Device | |||||
REFINING amp PETROCHEMICAL | Cooling Tower | No | |||||
Tank FarmStorage FacilityOffsite | Piping system | Yes | |||||
UtilitiesSteam PlantCogeneration | Reactor | No | |||||
Other | Atmospheric tank | ||||||
PETROCHEMICAL | FlareRelief System | Acute release above thresholds | |||||
CO H2 | Other | Yes | |||||
LNG | No | ||||||
Methane | Events | ||||||
Methanol | No Tier 1 Events | Indoor Outdoor | |||||
Methyl Mercaptan | No Tier 2 Events | No Release | |||||
Formaldehyde | No Tier 1 or Tier 2 Events | Indoor | |||||
Formaldehyde derivatives | NA | Outdoor | |||||
Acetic Acid | |||||||
Acetic Acid derivatives | Event Type | ||||||
Ethane | Injury | ||||||
Ethylene | Fire | ||||||
Ethanol | Explosion | ||||||
Ethylene oxide | PRD Discharge | ||||||
Ethylene derivatives | Acute Release | ||||||
Polyethylene | |||||||
Ethylene dichloride | General | ||||||
Ethylene dichloride derivatives | Yes | ||||||
Ethyl benzene | No | ||||||
Ethyl benzene derivatives | |||||||
Polystyrene | |||||||
Styrene-Butadiene | |||||||
Propane | |||||||
Propylene | |||||||
Polypropylene | |||||||
Isopropanol | |||||||
Propylene oxide | |||||||
Propylene oxide derivatives | |||||||
Butane | |||||||
Isobutane | |||||||
Isobutene | |||||||
Butadiene | |||||||
MTBE | |||||||
ETBE | |||||||
Pentane | |||||||
Hexane | |||||||
Cyclohexane | |||||||
Hexanol | |||||||
Aromatics Derivatives | |||||||
Benzene | |||||||
Toluene | |||||||
Xylene | |||||||
Para Xylene | |||||||
Amines Derivatives | |||||||
TDA MDA IPDA etc | |||||||
Isocyanates | |||||||
Specialty Chemicals | |||||||
LoadingUnloading | |||||||
Pilot Plant |
Instructions | ||||||||||||||
Step 1 | Complete the Contact Tab with your contact information and company information | |||||||||||||
Be sure to note the region of your reporting (IE North America France Japan etc) | ||||||||||||||
Survey on Process Safety Events | ||||||||||||||
Step 2 | Complete the survey one line per Process Safety Event for your companyregion | |||||||||||||
ALL REPORTED DATA SHOULD BE FROM CALENDAR YEAR 2017 | ||||||||||||||
Step 3 | Return completed survey to | |||||||||||||
Company Name | ||||||||||||||
Contact Person | All Surveys Due by xxx date | |||||||||||||
Address | ||||||||||||||
Fax | ||||||||||||||
Telephone | ||||||||||||||
Region | ||||||||||||||
27
附錄 E ndash 選擇性 Excel 追蹤表
當會員公司開始追蹤製程安全事件時所有會員公司應採用單一表格以簡化數據分析同時讓所有公司均使用相同的追蹤表RCLG 設
計了一份選擇性追蹤表可供會員公司和協會先行利用之後他們可設計自己的追蹤表
在這裡下載追蹤表
ICCA Process Safety Event Tracking Sheetxlsx
本文件包含三個分頁分別是ldquo聯絡資料rdquoldquo調查表rdquo和儲存下拉式選單選項的ldquo請勿編輯rdquo分頁
備註
附錄 E 追蹤表僅供參考TRCA 將另行提供台灣版表格供會員公司提報
28
後語
台灣化學工業責任照顧協會(Taiwan Responsible Care Association TRCA)成立於 1998 年在台灣推行責任照顧制度已達 20 週年製造商成員
包括台灣主要上市上櫃化工公司會員公司化學品生產製造量約佔全國 80 2016 年台灣化工業的 Chemical Sales 仍站在全球第八名的位
置額度為 630 億歐元化工業總產值達到 34 兆新台幣提供國內 416 萬人工作機會
TRCA 扮演國內廠商與國際制度接軌的角色也是國內化工業與政府機關及利益相關者溝通的橋樑與管道TRCA 會員結構依業務性質分析
涵蓋石化生產化學品製造氣體生產倉儲運輸業化學品貿易業以及工程研發設計等公司TRCA 透過供應鏈及價值鏈推行責任
照顧制度組成毒性化學物質聯防組織協助法規溝通與研析會員名冊請參考 httpwwwtrcaorgtwtrcanwork2aspx
TRCA 於 2010 年成為 ICCA (International Council of Chemical Associations 國際化學工業協會)觀察員ICCA 成立於 1989 年是全球化工製造
業的聯合會也是化學工業與 UNEP OPCW 及 OECD 的交流窗口ICCA 與其會員協會及成員公司致力於邁向永續的未來確保人類健康與
環境安全與保護全球化工業擁有超過 4兆美元的價值影響所有經濟部門ICCA 的會員幾乎在全球每個國家都有商業活動在全球六大
洲推動創新並提供超過 2000 萬個工作機會
台灣化工業在全球占有重要的一席之地在國內產業鏈也位居關鍵位置無論對國內或國際都有身為地球村一員應盡之責我們期許藉由
製程安全指標提報能更進一步提升自我在工安衛生環保與永續發展等面向的績效表現
台灣化學工業責任照顧協會
10452 台北市中山區撫順街 8 號 7 樓
電話02-2585-0552
httpwwwtrcaorgtw
None | |
$2500 to $25000 | |
$25000 to $250000 | |
$250000 to $25000000 | |
More than $25000000 | |
Yes - Using GHS TABLE | |
Yes - Using API RP 754 TABLE | |
NO | |
NA | |
1x le TQ lt 40x | |
40x le TQ lt 160x | |
160x le TQ lt 640x | |
ge 640x TQ | |
Yes le 3 hours | |
Yes 3 hours ge 12 hours | |
Yes 12 hours ge 24 hours | |
Yes ge 24 hours | |
No | |
Small-scale | |
Medium-scale | |
Large-scale | |
No | |
Yes | |
No | |
middot Injury requiring treatment beyond first aid to an employee contractor or subcontractor | |
middot Days Away From Work injury to an employee contractor or subcontractor or middot Injury requiring treatment beyond first aid to a third party | |
middot A fatality of an employee contractor or subcontractor or middot A hospital admission of a third party | |
middot Multiple fatalities of employees contractors or subcontractors or middot multiple hospital admission of third parties or middot A fatality of a third party | |
NA | |
1x le TQ lt 3x | |
3x le TQ lt 9x | |
9x le TQ lt 27x | |
ge 27x TQ |
ICCA Process Safety Pilot Reporting ProgramFebruary 8 2016 | 1 | 2 | 3 | 4 | 5 | 6 | 7 | 8 | 9 | 10 | 12 | 13 | 14 | 15 | |||||||||||||||||||||||
SAFETY Details(Meeting Local Regulations) | Direct Cost from Fire or Explosion | Community Impact | Environmental Impact | Material Released(Measured using the 1 Hour Rule) | |||||||||||||||||||||||||||||||||
Company Association Details | |||||||||||||||||||||||||||||||||||||
GHS | API - RP 754 | ||||||||||||||||||||||||||||||||||||
Company or Assocation Name | Headquarter Association | Location of Event Ex - City State amp Country | Date and Time of Event | Safety InjuryDid the Event result in a Recordable Lost Time Accident or Fatality or Hospital admission of anyone on or off siteUse Drop Down Menu | Safety InjuryIf yes please insert the total number of injuries | Safety InjuryFor puropses of utilizing the Severity Table please indicate the level of severity by chosing the MOST SEVERE classification that describes your incidentUse Drop Down Menu | Safety InjuryDid the incident involve Fatalities If so how many total fatalities If none enter Zero | Safety InjuryPlease Report Total Employee Hours for Calendar Year 2015 | Safety InjuryPlease Report Total Contractor Hours for Calendar Year 2015 | Direct Cost Did the Event result in Direct Damage CostUse Drop Down Menu | Direct Cost If so how muchAmount is in US DollarsUse Drop Down Menu | Community ImpactDid the event result inbull Officially declared shelter-in-place or officially declared evacuation (on or off site)ORbull Precautionary off site shelter in place or evacuation Use Drop Down Menu | Environmental ImpactDid the event result inAcute Environmental Remediation CostIf so indicate the amount in US DollarsUse Drop Down Menu | Material ReleasedDid the Event result in an Acute Release of material beyond one of the two threshold tablesIf so indicate which Threshold Table you used to make this determinationUse Drop Down Menu | Material ReleasedIf so indicate the amount released USING GHS CLASSIFICATION TABLEUse Drop Down Menu | Material ReleasedIf so indicate the amount released USING THE THRESHOLD TABLE FROM API RP-754Use Drop Down Menu | Material ReleasedIf available please indicate the material released | ||||||||||||||||||||
1 | ABC Chemical Company | American Chemistry Council | Washington DC - USA | January 4 2016 | Yes | 2 | middot Days Away From Work injury to an employee contractor or subcontractor or middot Injury requiring treatment beyond first aid to a third party | 0 | 5525000 | 1500250 | No | $2500 to $25000 | Yes le 3 hours | $2500 to $25000 | Yes - Using GHS TABLE | 40x le TQ lt 160x | NA | Chlorine | |||||||||||||||||||
2 | XYZ Chemical Company | American Chemistry Council | Washington DC - USA | 5-Jan-16 | Yes | 1 | middot Injury requiring treatment beyond first aid to an employee contractor or subcontractor | 0 | 5525000 | 1500250 | Yes | $2500 to $25000 | No | $2500 to $25000 | Yes - Using API RP 754 TABLE | NA | 3x le TQ lt 9x | Benzene | |||||||||||||||||||
3 | |||||||||||||||||||||||||||||||||||||
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25 | |||||||||||||||||||||||||||||||||||||
Zero or None | Yes - Duration Unknown | ||||||||||||||||||||||||||||||||||||
Processes | Mode of Operation | Type of material released | Status of Operation | ||||
REFINING | Start-up | Flammable | Open | ||||
Alkylation HF | Planned shutdown | Combustible | Closed | ||||
Alkylation sulfuric | Emergency shutdown | Toxic | |||||
BitumenResidAsphalt | Normal | Corrosive | Tier 1 Acute Releases | ||||
Calcining | Upset | Utilities | No Release | ||||
Coking | Turnaround | Other | Category 1 | ||||
Crude | Routine maintenance | Category 2 | |||||
Desulfurization | Temporary | Evacuation | Category 3 | ||||
FCC | Other | Yes | Category 4 | ||||
Gas Treating | No | Category 5 | |||||
Hydrogen | Point of Release | Category 6 | |||||
Hydrotreating | Pump | Fire | Category 7 | ||||
Hydrocracking | Compressor | Yes | Multiple Categories | ||||
Isom | BlowerFan | No | |||||
MarineJetty | Pressure Vessel | lt $2500 | |||||
Reforming | FilterCoalescer | ||||||
Sulfur recovery | Furnace | PRDs | |||||
Vapor recoverylight ends | Boiler | Directly to Atmosphere | |||||
Wastewater | Heat exchanger | via Downstream Destructive Device | |||||
REFINING amp PETROCHEMICAL | Cooling Tower | No | |||||
Tank FarmStorage FacilityOffsite | Piping system | Yes | |||||
UtilitiesSteam PlantCogeneration | Reactor | No | |||||
Other | Atmospheric tank | ||||||
PETROCHEMICAL | FlareRelief System | Acute release above thresholds | |||||
CO H2 | Other | Yes | |||||
LNG | No | ||||||
Methane | Events | ||||||
Methanol | No Tier 1 Events | Indoor Outdoor | |||||
Methyl Mercaptan | No Tier 2 Events | No Release | |||||
Formaldehyde | No Tier 1 or Tier 2 Events | Indoor | |||||
Formaldehyde derivatives | NA | Outdoor | |||||
Acetic Acid | |||||||
Acetic Acid derivatives | Event Type | ||||||
Ethane | Injury | ||||||
Ethylene | Fire | ||||||
Ethanol | Explosion | ||||||
Ethylene oxide | PRD Discharge | ||||||
Ethylene derivatives | Acute Release | ||||||
Polyethylene | |||||||
Ethylene dichloride | General | ||||||
Ethylene dichloride derivatives | Yes | ||||||
Ethyl benzene | No | ||||||
Ethyl benzene derivatives | |||||||
Polystyrene | |||||||
Styrene-Butadiene | |||||||
Propane | |||||||
Propylene | |||||||
Polypropylene | |||||||
Isopropanol | |||||||
Propylene oxide | |||||||
Propylene oxide derivatives | |||||||
Butane | |||||||
Isobutane | |||||||
Isobutene | |||||||
Butadiene | |||||||
MTBE | |||||||
ETBE | |||||||
Pentane | |||||||
Hexane | |||||||
Cyclohexane | |||||||
Hexanol | |||||||
Aromatics Derivatives | |||||||
Benzene | |||||||
Toluene | |||||||
Xylene | |||||||
Para Xylene | |||||||
Amines Derivatives | |||||||
TDA MDA IPDA etc | |||||||
Isocyanates | |||||||
Specialty Chemicals | |||||||
LoadingUnloading | |||||||
Pilot Plant |
Instructions | ||||||||||||||
Step 1 | Complete the Contact Tab with your contact information and company information | |||||||||||||
Be sure to note the region of your reporting (IE North America France Japan etc) | ||||||||||||||
Survey on Process Safety Events | ||||||||||||||
Step 2 | Complete the survey one line per Process Safety Event for your companyregion | |||||||||||||
ALL REPORTED DATA SHOULD BE FROM CALENDAR YEAR 2017 | ||||||||||||||
Step 3 | Return completed survey to | |||||||||||||
Company Name | ||||||||||||||
Contact Person | All Surveys Due by xxx date | |||||||||||||
Address | ||||||||||||||
Fax | ||||||||||||||
Telephone | ||||||||||||||
Region | ||||||||||||||
None | |
$2500 to $25000 | |
$25000 to $250000 | |
$250000 to $25000000 | |
More than $25000000 | |
Yes - Using GHS TABLE | |
Yes - Using API RP 754 TABLE | |
NO | |
NA | |
1x le TQ lt 40x | |
40x le TQ lt 160x | |
160x le TQ lt 640x | |
ge 640x TQ | |
Yes le 3 hours | |
Yes 3 hours ge 12 hours | |
Yes 12 hours ge 24 hours | |
Yes ge 24 hours | |
No | |
Small-scale | |
Medium-scale | |
Large-scale | |
No | |
Yes | |
No | |
middot Injury requiring treatment beyond first aid to an employee contractor or subcontractor | |
middot Days Away From Work injury to an employee contractor or subcontractor or middot Injury requiring treatment beyond first aid to a third party | |
middot A fatality of an employee contractor or subcontractor or middot A hospital admission of a third party | |
middot Multiple fatalities of employees contractors or subcontractors or middot multiple hospital admission of third parties or middot A fatality of a third party | |
NA | |
1x le TQ lt 3x | |
3x le TQ lt 9x | |
9x le TQ lt 27x | |
ge 27x TQ |
ICCA Process Safety Pilot Reporting ProgramFebruary 8 2016 | 1 | 2 | 3 | 4 | 5 | 6 | 7 | 8 | 9 | 10 | 12 | 13 | 14 | 15 | |||||||||||||||||||||||
SAFETY Details(Meeting Local Regulations) | Direct Cost from Fire or Explosion | Community Impact | Environmental Impact | Material Released(Measured using the 1 Hour Rule) | |||||||||||||||||||||||||||||||||
Company Association Details | |||||||||||||||||||||||||||||||||||||
GHS | API - RP 754 | ||||||||||||||||||||||||||||||||||||
Company or Assocation Name | Headquarter Association | Location of Event Ex - City State amp Country | Date and Time of Event | Safety InjuryDid the Event result in a Recordable Lost Time Accident or Fatality or Hospital admission of anyone on or off siteUse Drop Down Menu | Safety InjuryIf yes please insert the total number of injuries | Safety InjuryFor puropses of utilizing the Severity Table please indicate the level of severity by chosing the MOST SEVERE classification that describes your incidentUse Drop Down Menu | Safety InjuryDid the incident involve Fatalities If so how many total fatalities If none enter Zero | Safety InjuryPlease Report Total Employee Hours for Calendar Year 2015 | Safety InjuryPlease Report Total Contractor Hours for Calendar Year 2015 | Direct Cost Did the Event result in Direct Damage CostUse Drop Down Menu | Direct Cost If so how muchAmount is in US DollarsUse Drop Down Menu | Community ImpactDid the event result inbull Officially declared shelter-in-place or officially declared evacuation (on or off site)ORbull Precautionary off site shelter in place or evacuation Use Drop Down Menu | Environmental ImpactDid the event result inAcute Environmental Remediation CostIf so indicate the amount in US DollarsUse Drop Down Menu | Material ReleasedDid the Event result in an Acute Release of material beyond one of the two threshold tablesIf so indicate which Threshold Table you used to make this determinationUse Drop Down Menu | Material ReleasedIf so indicate the amount released USING GHS CLASSIFICATION TABLEUse Drop Down Menu | Material ReleasedIf so indicate the amount released USING THE THRESHOLD TABLE FROM API RP-754Use Drop Down Menu | Material ReleasedIf available please indicate the material released | ||||||||||||||||||||
1 | ABC Chemical Company | American Chemistry Council | Washington DC - USA | January 4 2016 | Yes | 2 | middot Days Away From Work injury to an employee contractor or subcontractor or middot Injury requiring treatment beyond first aid to a third party | 0 | 5525000 | 1500250 | No | $2500 to $25000 | Yes le 3 hours | $2500 to $25000 | Yes - Using GHS TABLE | 40x le TQ lt 160x | NA | Chlorine | |||||||||||||||||||
2 | XYZ Chemical Company | American Chemistry Council | Washington DC - USA | 5-Jan-16 | Yes | 1 | middot Injury requiring treatment beyond first aid to an employee contractor or subcontractor | 0 | 5525000 | 1500250 | Yes | $2500 to $25000 | No | $2500 to $25000 | Yes - Using API RP 754 TABLE | NA | 3x le TQ lt 9x | Benzene | |||||||||||||||||||
3 | |||||||||||||||||||||||||||||||||||||
4 | |||||||||||||||||||||||||||||||||||||
5 | |||||||||||||||||||||||||||||||||||||
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10 | |||||||||||||||||||||||||||||||||||||
11 | |||||||||||||||||||||||||||||||||||||
12 | |||||||||||||||||||||||||||||||||||||
13 | |||||||||||||||||||||||||||||||||||||
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15 | |||||||||||||||||||||||||||||||||||||
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17 | |||||||||||||||||||||||||||||||||||||
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Zero or None | Yes - Duration Unknown | ||||||||||||||||||||||||||||||||||||
Processes | Mode of Operation | Type of material released | Status of Operation | ||||
REFINING | Start-up | Flammable | Open | ||||
Alkylation HF | Planned shutdown | Combustible | Closed | ||||
Alkylation sulfuric | Emergency shutdown | Toxic | |||||
BitumenResidAsphalt | Normal | Corrosive | Tier 1 Acute Releases | ||||
Calcining | Upset | Utilities | No Release | ||||
Coking | Turnaround | Other | Category 1 | ||||
Crude | Routine maintenance | Category 2 | |||||
Desulfurization | Temporary | Evacuation | Category 3 | ||||
FCC | Other | Yes | Category 4 | ||||
Gas Treating | No | Category 5 | |||||
Hydrogen | Point of Release | Category 6 | |||||
Hydrotreating | Pump | Fire | Category 7 | ||||
Hydrocracking | Compressor | Yes | Multiple Categories | ||||
Isom | BlowerFan | No | |||||
MarineJetty | Pressure Vessel | lt $2500 | |||||
Reforming | FilterCoalescer | ||||||
Sulfur recovery | Furnace | PRDs | |||||
Vapor recoverylight ends | Boiler | Directly to Atmosphere | |||||
Wastewater | Heat exchanger | via Downstream Destructive Device | |||||
REFINING amp PETROCHEMICAL | Cooling Tower | No | |||||
Tank FarmStorage FacilityOffsite | Piping system | Yes | |||||
UtilitiesSteam PlantCogeneration | Reactor | No | |||||
Other | Atmospheric tank | ||||||
PETROCHEMICAL | FlareRelief System | Acute release above thresholds | |||||
CO H2 | Other | Yes | |||||
LNG | No | ||||||
Methane | Events | ||||||
Methanol | No Tier 1 Events | Indoor Outdoor | |||||
Methyl Mercaptan | No Tier 2 Events | No Release | |||||
Formaldehyde | No Tier 1 or Tier 2 Events | Indoor | |||||
Formaldehyde derivatives | NA | Outdoor | |||||
Acetic Acid | |||||||
Acetic Acid derivatives | Event Type | ||||||
Ethane | Injury | ||||||
Ethylene | Fire | ||||||
Ethanol | Explosion | ||||||
Ethylene oxide | PRD Discharge | ||||||
Ethylene derivatives | Acute Release | ||||||
Polyethylene | |||||||
Ethylene dichloride | General | ||||||
Ethylene dichloride derivatives | Yes | ||||||
Ethyl benzene | No | ||||||
Ethyl benzene derivatives | |||||||
Polystyrene | |||||||
Styrene-Butadiene | |||||||
Propane | |||||||
Propylene | |||||||
Polypropylene | |||||||
Isopropanol | |||||||
Propylene oxide | |||||||
Propylene oxide derivatives | |||||||
Butane | |||||||
Isobutane | |||||||
Isobutene | |||||||
Butadiene | |||||||
MTBE | |||||||
ETBE | |||||||
Pentane | |||||||
Hexane | |||||||
Cyclohexane | |||||||
Hexanol | |||||||
Aromatics Derivatives | |||||||
Benzene | |||||||
Toluene | |||||||
Xylene | |||||||
Para Xylene | |||||||
Amines Derivatives | |||||||
TDA MDA IPDA etc | |||||||
Isocyanates | |||||||
Specialty Chemicals | |||||||
LoadingUnloading | |||||||
Pilot Plant |
Instructions | ||||||||||||||
Step 1 | Complete the Contact Tab with your contact information and company information | |||||||||||||
Be sure to note the region of your reporting (IE North America France Japan etc) | ||||||||||||||
Survey on Process Safety Events | ||||||||||||||
Step 2 | Complete the survey one line per Process Safety Event for your companyregion | |||||||||||||
ALL REPORTED DATA SHOULD BE FROM CALENDAR YEAR 2017 | ||||||||||||||
Step 3 | Return completed survey to | |||||||||||||
Company Name | ||||||||||||||
Contact Person | All Surveys Due by xxx date | |||||||||||||
Address | ||||||||||||||
Fax | ||||||||||||||
Telephone | ||||||||||||||
Region | ||||||||||||||
28
後語
台灣化學工業責任照顧協會(Taiwan Responsible Care Association TRCA)成立於 1998 年在台灣推行責任照顧制度已達 20 週年製造商成員
包括台灣主要上市上櫃化工公司會員公司化學品生產製造量約佔全國 80 2016 年台灣化工業的 Chemical Sales 仍站在全球第八名的位
置額度為 630 億歐元化工業總產值達到 34 兆新台幣提供國內 416 萬人工作機會
TRCA 扮演國內廠商與國際制度接軌的角色也是國內化工業與政府機關及利益相關者溝通的橋樑與管道TRCA 會員結構依業務性質分析
涵蓋石化生產化學品製造氣體生產倉儲運輸業化學品貿易業以及工程研發設計等公司TRCA 透過供應鏈及價值鏈推行責任
照顧制度組成毒性化學物質聯防組織協助法規溝通與研析會員名冊請參考 httpwwwtrcaorgtwtrcanwork2aspx
TRCA 於 2010 年成為 ICCA (International Council of Chemical Associations 國際化學工業協會)觀察員ICCA 成立於 1989 年是全球化工製造
業的聯合會也是化學工業與 UNEP OPCW 及 OECD 的交流窗口ICCA 與其會員協會及成員公司致力於邁向永續的未來確保人類健康與
環境安全與保護全球化工業擁有超過 4兆美元的價值影響所有經濟部門ICCA 的會員幾乎在全球每個國家都有商業活動在全球六大
洲推動創新並提供超過 2000 萬個工作機會
台灣化工業在全球占有重要的一席之地在國內產業鏈也位居關鍵位置無論對國內或國際都有身為地球村一員應盡之責我們期許藉由
製程安全指標提報能更進一步提升自我在工安衛生環保與永續發展等面向的績效表現
台灣化學工業責任照顧協會
10452 台北市中山區撫順街 8 號 7 樓
電話02-2585-0552
httpwwwtrcaorgtw
台灣化學工業責任照顧協會
10452 台北市中山區撫順街 8 號 7 樓
電話02-2585-0552
httpwwwtrcaorgtw