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Abdullah G. Al-Harthy  Al-Jubail , KSA, September ,  2021

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Best practice Sharing KEMYA  OCVM  Program  Process Safety  Environment Protection  Safe Work Practices

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Provide Manufacturing Sites Leadership with a  Layered Verification  process to focus on the most critical OIMS elements and barriers’  effectiveness  in order to prevent occurrence of Level 1 Process Safety and/or Personnel Safety incidents .

A  global SHE experts was set-up to :  Analyze the common causes of Level 1 incidents in EM and the industry    Assess  the reasons for failures to apply/follow defined SHE requirements

OCVM  Stand for  O IMS  C ritical  V erification and  M easurement

One  standard Management Leadership  framework  to ensure by all level of the organization the effectiveness of the Critical SHE elements that prevent major events to  happen 53 OCVM’s  identified with Recommended Practices ( RP’s ) Awareness  One pagers  developed for each OCVM OKV  (Operator Knowledge Verification),  Global T1BP’s   and  FV  (Field Verification) checklists of the OCVMs to ensure quality and consistency

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In-Line Checks performed within executing  organization( FLS,  Mgr ) Predominantly shift / Business team Off-Line Independent SME checks  Senior Line Mgt or SME Built In Base level of system requirements expected OKVs Tests and verifies Operators Knowledge Field Effectiveness Checklists (FV’s) Assesses and verifies field effectiveness V&Ms Tools Requirements Accountability KPIs Metrics generated from In-Line/Off-Line checks Driver Mechanism Method used for analysing & correcting V&M health e.g. stewardship mtgs Owner Single owner acct’able for V&M health “ Recommended” for T1BP/GMOPs

53 OCVM’s                                         “ Requirement “   T1BP or GMOP  OIMS Standard

“ Recommended” Parts of  Requirements

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OIMS  Critical Verification and Measurement (OCVM)  Overview

Provide Kemya with  a  Layered Verification process  to focus on the most critical OIMS elements and barriers’ effectiveness in order to prevent occurrence of  Fatalities  from Process  Safety and/or Personnel Safety incidents.

53  OCVMS Global Field verification checklist  ( FVC ) 30 Mandatory  T1  BP checklist 9 Global Operator knowledge verification ( OKV )  checklist 16 Quality Example of Checks 7

Expected base level system  &  controls that are built  into  the work process  design

R eal-time  verification performed within the  task executing group

Management & Experts independent  of  the task

Built-in work processes stewardship  –  OIC holds system sponsors and administrators accountable for ensuring Kemya management system meets minimum Recommended Practice for each OCVM area. In-line execution excellence  –  E ach  PMT and Department execute the defined system requirements for each OCVM and appropriate quality checks carried out during execution.  Off-line Audit schedule compliance &  findings   –  Report Total # of audits completed, % compliance to schedule, audits with finding. Kemya Management Team drives site alignment, consistency and quality with the performance standard

Additional  supporting  m aterials: Focused Training modules Awareness One pagers

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Process Safety walkthrough program carried out to discover process safety risk in the  fileld .   This  program serve as a proactive tool to identify process Safety concerns in the field & appropriate recommendations developed to eliminate Process safety incidents . This  initiative enhance process safety interventions culture among various interested parties such as (Operations, Maintenance, technical etc.) which continuously strive to achieve Zero process Safety incidents.

PROCESS SAFETY
Avoid the RISK
Transfer the RISK
Reduce the RISK
Accent the RISK
Accept
Red U Ce
Avoi&

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Safe Operating Committee (SOC) is a technically oriented group of company employees established to review, monitor and approve (as required) deviation  from design  standards, higher risk jobs, higher risk procedures covering all the site's risk management activities in facility design, operation and maintenance.  SOC  is a steering committee to provide risk control and guidance.

Sr. SOC charter  Designation  1.  Chairman: Operations Director 2.  Secretary: Process Safety Manager  3.  Team  Members: Site Personnel safety Engineer ( as Applicable) ,   SHEMS/OIMS Sponsor (if SOC is related to EHSS Standard Deviation),   Affected Area  team members

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Leader must Complete the following training courses  : ExxonMobil   Refining & Chemical's, Process Hazard and Operability ( "HAZOP" course ) Fundamentals of Safety Engineering” course, the EMCC "Safety Engineering Technology" course, or their  equivalents. Risk Assessment and Management” course if the HAZOP findings will be risk assessed by the HAZOP team or an equivalent training for the risk prioritization tool utilized by the HAZOP team  . Participate in at least one Knowledge-based HAZOP as a team member prior to leading a HAZOP to demonstrate an understanding of the overall HAZOP process . Lead a Knowledge-based HAZOP under the supervision of a qualified HAZOP leader to demonstrate competency in an understanding of the HAZOP methodology, team facilitation, safety engineering, and hazard recognition .

To maintain qualifications a Knowledge-based HAZOP leader must: Lead a Knowledge-based HAZOP at least once every two years . Study the changes to the HAZOP methodologies when they are published.  Study the changes to the Knowledge-based HAZOP reference list updates . Study changes to the risk assessment process that is employed by the HAZOP.

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Key Skills of HAZOP Team Members SUGGESTED on the HAZOP Team REQUIRED HAZOP Team Leader Process Design / Technology Operations** Technical Contact HAZOP Team Members   Experience level; years 10 * 5 * > 5 1/2 20 (team total) Knowledge of ExxonMobil safety policies and concepts Must Good Good Basic Must Received formal HAZOP training Must Optional Optional Optional Must Participated in other HAZOPs Must Optional Optional Optional Must Has experience in operations of unit being reviewed by the HAZOP Basic Basic Must Basic Must Knowledge of ExxonMobil Design Practices and Global Practices Basic Must Basic Basic Must Knowledge of Risk Assessment or Prioritization process to be used Must Good Basic Optional Must

Matrix of HAZOP Team Members requirements.(core)

* HAZOP Team Leader and Process Design/Technology experience should total at least 15 years. ** Operations experience must be on unit being reviewed. TOH requires qualification both on console and in the field For Re-Do HAZOP reviews, The Hazop Team leader Shall  not  be from the operating department involved.

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Scenario Management is a rigorous approach to manage higher consequence potential
scenarios and the safeguards in place to prevent them
Scenario Generation and
Assessment
Critical Safeguard Register
and Health
Sites create &
maintain an
mentory of major
hazards
Identify & understand Critical safeguards Scenarios & ffitical Verify overall scenario
higher consequence
are defined &
safeguards are known mgmt health
scenarios & identib' performance criteria iS and actively managed
scenario owners
established
Critical safeguard
owners identified
Validate field
effectiveness of
crmcal safeguards

Are we safe because we do we RA and PHAs?

Are we safe after we complete actions coming out of these assessments?

EPS requires  rigorous maintenance of the most critical safeguards  and  enhancement of operator and line management knowledge and awareness

We learned from big incidents that process safety management requires continuous efforts by all layers of the organization. EPS manages to bring life to our work processes to protect our people.

Piper Alpha
1 67 deat h s
23 deaths
T City
5 deaths
Deep W' ater
deaths

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The realisation that some loss of containment scenarios can have very severe consequences impacting:  Workers t hird parties Environment the Site’s reputation the Company’s reputation The need therefore to understand: All the loss of containment scenarios that can have the severest consequences All the safeguards that combine to prevent and mitigate these consequences How to react to a degraded safeguard The need for training and strong competency in: Operating high hazard processes Inspecting and maintaining high hazard equipment Plus: Learning from incidents and continuous improvement

Highest Consequence Scenarios Human failure model Precise execution Knowledge verification of operators Scenario recognition  Safeguard health  Knowledge verification of leaders

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spen6ajes
souanbøsuo
spen6ajes
spezeH

Define Scenarios & owner Identify Critical Safeguard ( CSG) & Owner Document / Update EPS   dashboard Communicate / Train the team Start  verifying CSG + Field assessment

Trailermoveswhile
mnnected
and/or moisture in
hose
Incorrect hose
material
Hosedamagedurirg
positionirgct
unloading
Excessive pressure
on isomntair.er
certification
Hose
speclfitatlm
supply
Driver safe
working
practices
hose
Procedure
Incl.unloading
tasks ind
checks, drynes
verificationart
mice test
mechanical
Bromine
detection
Brominewater
anddump
pit
ERT Response
Plan for B'
release
Ind.
Toxic bromine
•eleanth
Cisite&offsite
consequence

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“ KEMYA has  a great commitment   and  effort towards complying with   environmental regulation, protecting  the environment and promoting  sustainable development.  We  have   to  maintain  a  culture  of  integrity and   compliance ”

What is KEMYA IWW TRACING   TOOL? Simple visual tool to trace waste water network of plant  units  and   spot  contamination potentials,  thus helping  to mitigate waste water  contamination beyond allowable   limits.

Objective: To map the wastewater sources, wastewater network in each plant   and  interfaces  with  other respective  business units  to promotes effective  wastewater management   system.

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KAISAR SAYED   HASSAN Executive Vice   President

“ The proactive approach to  environmental issues  will  not only  ensure environmental objectives   and   regulatory  framework are met,  but   also enhances engagement  with  employees, which will  pave way for  developing organizational  capabilities ”

Scope: Cover all wastewater in Elastomer plants as 1st phase , Olefin and   polymer  plants as  2nd   phase.

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“ IWW TRACING  TOOL  is a  simple   visual  tool to  trace waste  water  network  of  plant units and  spot  contamination  potentials, thus helping to  proactively   taking  measures  and mitigate  waste  water  contamination beyond  allowable   limits   ”

SALEH  A.   AL-HAIFAN Sr. Manager,   EHSS Advantages & Expected   Results:: Easily identify and isolate potential source(s) in case of any upset in the  system. Aids quick decision-making for mitigating contaminations and develop  preventive/ corrective  actions. Cost optimization and  efforts  by  reducing number of  re-sampling   and ensure business   continuity. Enhance knowledge and awareness for  front-liners  by adding it in JQP and  department’s ECM   . Perform effective wastewater operation and maintain its   infrastructure. Proactively take measures to prevent any  non-compliance   events. Support SABIC/KEMYA strategic plan for sustainable operation by  supporting the community and   environment.

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Tracing  tools   have  been posted in  supervisors   office

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Kemya Generates from  Halubuyel  plant around 1,700 tons of spent caustic residual, and it was sent to incineration facility post commissioning, later on 2019 started to send it to recycle facility with a rate of (960 SAR/ton) costing Kemya around 1,632,000 SAR/year Background

Circular from RC been sent to all Jubail affiliates to stop sending waste to recycle facility in Dammam, and to send spent caustic waste to WMF in Jubail, which been dealt with as incineration with a rate of (2,096 SAR/ton) which will cost Kemya around 3,563,200 SAR/year RC Circular

Samples been collected and analyzed for the content of spent caustic waste, and showed minor presence of organic material which supported Kemya in negotiation with WMFs to alter method of disposing Analysis and Alternatives

Kemya were able to revise the rate from (2,096 SAR/ton) to (491 SAR/ton) by changing method of handling to chemical treatment which will cost Kemya around 834,700 SAR/year, which is cost saving of around 2,728,500 SAR/year Conclusion

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I feel strongly
Emotional
I believe it is
fha nnlu
Spiritual
I understand
its importance
Intellectual
I do it to keep
my job
I do it to satisfy
my boss
Political

Which level  are you at ? What  about  your team ?

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The Gold Standard For Effective S afety  D iscussion

Assess Test if worker understands the hazards of the task & what is the worst that could happen to them Example questions Describe the task you are doing? What are the hazards? What is the worst thing that could happen? Analyse Test if worker has thought about & identified appropriate mitigations to control the hazards Example questions What mitigation have you put in place? Why did you chose that mitigation? Is that the most appropriate mitigation? Act Test if worker has put in place & is working to their mitigations Example questions What are you going to do differently? Are you following any procedures/standards Have you done everything to ensure this job progresses without loss.

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Work  place conditions,  EHS and behavior  observations are monitored through  PBO,  to determine how effectively Kemya identify, analyze and manage  risks The system acts as a vehicle to acknowledge/ recognize safe performance as well as to coach subordinates in safety leadership  behaviors

Every  employee and long-term key position contractor personnel shall develop a Personal EHSS Plan addressing safety responsibilities, objectives and key actions  Employees’ respective superiors will review the compliance and implementation of personal EHS plan, semiannually

Effectively  apply safety management tools & systems for achieving safety excellence Develop strong leadership with competence and commitment  Strive to continuously improve Safety, Health and Environment performance

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Contractor working environment and control

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Service contractor individual scorecard (SCIS )

Overall Performance :  May  = 96%   , YTD =  94%

HighEghts
NO Reportable Injury & First Aid
SISCO : Two LSR violations in June, No
BM meeting in May, 17 YTD at risk PBO's
and 1 unsafe act
AYTB: Monthly BM nEeting & 2nd quarter
BM walkthrough not conducted, S at risk
PBO's YTD
ICMS: No Quarter BM audit, PPE quarter
audit not done, Weekty rneetings in May
(50%) & PBO reporting (63% YTD)
YORK : Monthly BM meeting & 2nd
quarter BM walkthrough not conducted
Plant-tech : 2nd quarter BM meeting
and walkthrough not conducted, 13
YTD at risk PBO's
Involved Contractors At Risk PBO's
LAGGING INDICATOR
Injury R ate
PERFORMANCE
LAGING INDICATOR
LEADING INDICATOR
OVERALL SCORE
BUDDY MANAGER
NAME
PERFORMANCE
LAGING INDICATOR
LEADING INDICATOR
OVERALL SCORE
Inc
100%
A1-Mani
scc
A" cze
K-KEM
94%
LSR
100%
HANCO
100%.
UC
100%
34%
SSW Program
INDIVDUAL SCORECARD
100%
A1-sul.im.
35%
LEADING INDICATOR
100% 100% 100% 100% 100%
A1-sham
AYTB
KANOOZ
PLANT-TECH
RB HILTON
SENDAN
SGB
*sco
2
1
1
1
1
1
1
1
1.
'CMS
84%
Soy
SIS
100% 100%
HALA
SISCOAL-SAOIQ /// RISALI///I/HGONUIII"Z'
AXIS ANABEEB
100%.
100%.
HOHT"
100%
H OHTg
94%
100%.
NIA
73%
100%
100%.
N/A 100%
BUDDY MANAGER
KY..U;

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conucnv;
repodrg
w vowER
TÆnng
Wing Wt
TÆnng

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SHORT SERVICE WORKER PROGRAM – OVERVIEW

Short Service Worker (SSW)  New to Site  Permanent  On-Call Basis  Short Present  Worker (SPW)  Monitored by Company Staff  Display  Violate   Sticker on the Hard hat. Apply SSW V/S SSMP ratio (4:1) Educate SSW about site hazard and safe work practice. Use the SSW to SSMP assessment checklist to progress SSMP Track SSW –SSMP ratio and report to supervisor. Each 20 employees – One Mentor/Coach  Typically Safety Officers Display  Yellow Sticker on the Hard hat. Learn to identify the hazard Know the LSR rules Must not work alone Know your coach and Buddy (SSMP) Cannot act as group leader(Permit Receiver) and  Fire watch Stand by man Coaching period maximum       6-months  Not qualified within six months – out from site Supervisor  Mentor / Coach  LSR   Site Safety Matured Person (SSMP)  Display  Blue Sticker on the Hard hat Ensure SSW not work alone Apply SSW to SSMP ratio Responsible for SSW safety performance Get feed back  of SSW from SSMP-Buddy and Mentor/Coach Ensure SSW must be qualified as SSMP with in 6-months. Release SSW from site  those are not qualified with  in 6 – months Each 20 employees – one Supervisor Display  Green Sticker on the Hard hat. Ensure SSW must not work alone Intervene SSW at risk behavior Provide work guidance and assistance  Observe the SSW safety behavior. Report SSW safety performance to Mentor/Coach and supervisor. Each 4 SSW  employees – One SSMP This  process only applicable for contractors workers those who are performing  job at  site

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FRMP  CONTROL LAYERS MONITORING PROGRAM EFFECTIVENESS

A udit performed  as per plan  and findings rectification

Non-compliance  work scheduled and planed as per FRMP guideline

Task error  and  shortcut decreased   as Root Cause

Facilitation  of good supervision, work environment and  work schedule by FLS

FRMP is designed to be  established as a standalone program or part of other programs (Kemya case).

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Kemya best practices 

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 One  standard Management Leadership  framework  to ensure by all level of the organization the effectiveness of the Critical SHE elements that prevent major events to  happen 53 OCVM’s  identified with Recommended Practices ( RP’s ) Awareness  One pagers  developed for each OCVM OKV  (Operator Knowledge Verification),  Global T1BP’s   and  FV  (Field Verification) checklists of the OCVMs to ensure quality and consistency

Kemya best practices

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