9.2 Process and Plant Safety

We aim to design and operate our processes and facilities in such a way that they do not pose any inappropriate risks to employees, the environment or the community. To improve the safety of our production facilities and processes worldwide, Bayer is continually working to further develop the safety culture and the corresponding standards for identifying and evaluating the associated risks. At the same time, we promote the skills of relevant employees on a regular basis. The corresponding Bayer Group Regulation “Process and Plant Safety” specifies globally harmonized procedures and standards.

Online annex: 3-9.2-1:

limited assurance

In a key move to maintain and raise safety awareness, the globally binding training program for all Bayer employees who are able to influence process and plant safety in their work environment has been further enhanced. The process and plant safety training program is firmly anchored in the subgroups’ HSEQ stands for health, safety, environment and quality. management systems. Both traditional and web-based training has been established for tradespeople and chemical technicians in the production facilities.

The organization and staffing levels of the Bayer Group’s central competence center for process and plant safety, together with the Group HSEQ Platform for Process and Plant Safety, in Leverkusen, Germany, have been strengthened. Together with the regional competence centers in Shanghai, China, and Kansas City, Missouri, United States, it works closely together in a professional network with plant safety experts from production sites all over the world. To improve our risk analysis process, an additional system audit on the content and completeness of our safety reviews was conducted this year on a trial basis. This quality improvement measure is due to be rolled out across HealthCare and CropScience next year and will be mandatory.

Online annex: 3-9.2-2:

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Our experts work in international working groups of the European Chemical Industry Council (CEFIC) and the American Petroleum Institute with the goal of developing a global reporting standard for key performance indicators in plant safety. We also are involved in an intensive exchange of experiences nationally and internationally in this area at an industrial level.

Group target 2020:

reduction of 30% in process and plant safety incidents (LoPC-IR)

A globally standardized KPI for plant safety incidents, Loss of Primary Containment (LoPC), applies to all Bayer plants and is integrated into Group-wide safety reporting. LoPC refers, for example, to chemicals in amounts above defined thresholds leaking from their primary container, such as pipelines, pumps, tanks or drums, and is thus an indicator of incidents in production facilities. We use the LoPC Incident Rate (LoPC-IR) to determine the number of LoPC incidents per 200,000 working hours in areas relevant to plant safety. In 2015, this was 0.22 (2014: 0.23).

Rate of Plant Safety Incidents (LoPC-IR)

 

 

2012

 

2013

 

2014

 

2015

LoPC-IR (Loss of Primary Containment Incident Rate)

 

0.38

 

0.35

 

0.23

 

0.22

More information on the procedures in the case of LoPC incidents can be found in:

Online annex: 3-9.2-3:

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The causes of every reported incident are carefully analyzed. The evaluations indicate areas where there is room for further improving the safety of existing facilities. The results of the cause analysis are published across the Group. The introduction of both the LoPC-IR parameter and the globally established training program mentioned above is helping us raise employees’ safety awareness.

The reporting level is set so low that even material and energy leaks that have no impact on employees, neighbors or the environment are systematically recorded and reported. This approach is in line with our commitment to maintaining the integrity of our facilities at all times.

The global, comprehensive Bayer Emergency Response System (BayERS) is an overarching early warning system for the Group. The subgroups and service companies have integrated their internal reporting procedures into BayERS and adapted them to it.

Online annex: 3-9.2-4:

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The handling of unusual incidents is the responsibility of the local crisis organization / emergency response team. For this purpose, organizational precautions with defined responsibilities and procedures have been implemented at the sites / in the countries. Depending on the situation, these involve business partners and the local community around the sites.