GPS Process Stakeholder Interfaces 202211 1

Process Safety Stakeholder process interfaces
Thomas Seidl
22th of November 2022
www.lenzing.com 18.11.2021- 1
Process Safety Management @ Lenzing Group
Leadership
Risk
Identification
Risk Review and The Process Safety
Management Improvement
& Assessment Management System fulfills
PS Culture Process Operating Incident
the process safety
Knowledge Procedures
Compliance
Management
Investigation
requirements related to
with Hazard Safe Work Error
standards Identification
& Risk
Practices Management
Culture Governance
PS Analyses
competency Asset
Integrity KPI`s
Assurance
Workforce
Contractor
Involvement
Management Audit Services
Stakeholder
Outreach Training Management
Review
Management
of Change
MOC
Emergency
Management
Lenzing Group Processes
Safety, Health & Environmental Services
Safety,
Health &
Environment
Services
PSM Interfaces regarding Risk Management - CAPEX
Technical
Risk
Management
Hazard
Process Management
Identification Emergency Asset
Safety of Change
& Risk Management Integrity
Management MOC
Analyses
CAPEX CAPEX- Plant

Process OPEX LTO Seveso Maintenance
(GCP) Process Services
(GCP)
Hazard Ident & RA are performed (HAZOP, FMEA, Fire- & Explosion protection) based on the concept
or on the basic engineering design in a joint approach of all stakeholder. RA`s are always done in a
team approach of production, engineering, maintenance, technology, process safety (SHE concept).
Risk Analysis (Hazop, FMEA, Fire- and Explosion Analysis)
Legal requirements (LTO) for Risk Analysis:

EU Directives requires for all process risks a systematic Risk Analysis approach
like HAZOP study. The same is given for Machines (Machinery Directives)
Fire and Explosion risks must be defined according to the Seveso directive in a
systematic approach (RA).
The international standards IEC61511/61508 and ISO13849 requires a systematic
approach to define the risk as defined in ISO31000. This standard are legal
standards for Asia (China, Indonesia, Thailand,..) and also for the EU and the
USA. ISO13849 is already an approved standard for Brazil as well.
All Risk analysis are integrated in the CAPEX process and GCP process related to
new/modified units. In case site service is performing modifications the MOC
process integrates Risk Analysis in the same way as GCP.
Risk Analysis (Hazop, FMEA, Fire- and Explosion Analysis)
Legal requirements (LTO) for Risk Analysis:

Each Risk Analysis according to Process & Occupational safety is performed by
all related stakeholder like
Production
Site Service
Engineering RA-Team
Safety Experts
During the joint approach each team defines the necessary safeguards according
to legal safety levels (IEC61511-3 Annex D) and Lenzing standards (follows the
legal standards).
PSM Interfaces regarding MOC – CAPEX
Management
of change
Hazard
Process Management
Identification Emergency
Safety of Change
& Risk Management
Management MOC
Analyses
The Seveso Directive of the EU requires

CAPEX CAPEX-
RA`s related to Process Risks,
Process OPEX LTO Seveso
Machinery Risk, Fire- & Explosion
(GCP) Process
protection.
(GCP)
Hazard Ident & RA are performed (HAZOP, FMEA, Fire- & Explosion protection) based on the concept
or on the basic engineering design in a joint approach of all stakeholder. RA`s are always done in a
team approach of production, engineering, maintenance, technology, process safety (SHE concept).
PSM Interfaces regarding MOC - OPEX
MOC
Hazard
Process
Identification Emergency
Safety MOC
& Risk Management
Management
Analyses
Report The Seveso Directive of the EU requires

adverse System RA`s related to Process Risks,
events, LTO Seveso
orientated Machinery Risk, Fire- & Explosion
control RCA protection.
measures
All Process Safety incidents PSI`s and fire shall be documented via SHEARS and reported to all levels
of the management.
RCA are performed together with the related persons from production and site services
Learnings out of incidents defines best practices models, which will be documented in our manuals.
PSM Interfaces regarding Incidents - OPEX
Investigate
Process Error
Incident Process
Safety Management KPI`s
Investigation Knowledge
Management Culture Management
Report
adverse Report Best
System
events, adverse practices
orientated
control events model
RCA
measures
All Process Safety incidents PSI`s and fire shall be documented via SHEARS and reported to all levels
of the management.
RCA are performed together with the related persons from production and site services
Learnings out of incidents defines best practices models, which will be documented in our manuals.
PSM Interfaces regarding Asset - OPEX
Asset Risks
Process
Safety Asset
Management Integrity
Plant
Maintenance
Services
Process Safety is supporting the risk matrix and the risk calculation of our assets for risk based
inspections of static equipment which is a fundamental process to avoid big releases
PSM Interfaces regarding quality assurance
Compliance
Audit
Process
Safety Internal Audit External
Management Audit
Self-
Assessment 3rd Party
system Audit
Internal audits will be performed on site and remote via the self-assessment process.
External audits are done with a 3rd party. The PSM system of GPS will be audited according to
ISO31000 and according the management system defined by CCPS as part of an improvement
schema.
Backup
Process Safety Leadership
Leadership pillar:
• All levels of the organisation shall have a deep understanding about the Process Safety
Management (PSM) segments
• Compliance with standard guarantees LTO
• Every level in the related organization has the right knowledge of process safety (PS) which is
required for the job and all levels understand their accountability and responsibility related to
PS clear.
• Every level in the related organisation shall be involved in process safety processes to
integrate all level of process knowledge.
• PS shall provide a PS network to inform about PS topics frequently, see PS Manuals and the
Lenzing group portal for PS
• Describe responsibility, accountability and interfaces for the PS related organisation of the
company.
Process Safety Risk Identification & Assessment
Risk Identification & Assessment pillar:
• Process Safety provides knowledge management documents (CS2-, SO2-, LY Manual) and
keep it up to date. Inform the organisation about standardized safety measures via the manual.
• Technical Risk Management based on ISO31000 related to risk control. Risk analysis (HAZOP,
FMEA, Fire- and Explosion protection studies.
• Define necessary action out of Risk Analysis during Concept/Basic engineering phase by
CAPEX and MOC projects
• Supervise and validate all safety actions during implementation during PSSR (Pre-Start-
up-safety-Review)
• Inspect, test and re-validate safeguards during the operations phase
Process Safety Risk Management
Risk Management pillar:
• Process Safety defines, creates and support all functions in the organisation related to
necessary safety critical standards, procedures and guidelines within the scope of the process
safety management system.
• Define safe work practise to reduce the risk level during engineering, operation and
maintenance work.
• Support maintenance with a standardized risk matrix, related to risk based inspection
programs.
• Verify engineering design during CAPEX and MOC projects
• Define process safety requirements for contractor companies within the contractor
management process
Process Safety Risk Management
Risk Management pillar:
• Define a training program and train the organisation for deep understanding of process safety
requirements and culture. Train expert function in all related PS expert processes
• Verify the safety risk level in any kind of changes (Management of Change Process)
• Define preventive and mitigating measures to keep the risk of operation below a tolerable level
and guarantee LTO.
Process Safety Review and Improvement
Review and Improvement pillar:
• Process Safety is part of process safety related incident investigation teams and work out
corrective action, inform all sites and related function regarding the necessary improvements
• Perform Root cause investigation to strengthen our safety system approach
• Process Safety has to define lagging and leading indicator to improve the PSM and make it
transparent for all levels in the organisation (PSI, sPSI, Fire, PIMS monitoring program-
Safeguard demand ratio per site)
• Implement an internal and external audit system to guarantee a constant improvement is given
• A management review process shows to the managing board of Lenzing and to site
management the performance of the process safety management system.

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Process Safety Stakeholder process interfaces

CAPEX CAPEX- Plant

Legal requirements (LTO) for Risk Analysis:

Legal requirements (LTO) for Risk Analysis:

The Seveso Directive of the EU requires

Report The Seveso Directive of the EU requires

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