Process Safety Management
Process Safety Management GRI 403-2 (2018), 403-4 (2018), 403-7 (2018)
GC uses Process Safety Management as a part of our GC Management System (GCMS). The system covers all processes from design to operations, using a Hazard and Operability Study (HAZOP) as well as a Bow Tie Validation process to conduct risk assessments. The objective is to ensure a proper plan for risk management, prevention, and control in production processes, both for normal operations and emergencies, while carrying our constant reviews and updates on the emergency plan, maintaining performance standards and developing efficient and safe production processes.
GC Management System (GCMS)
Process Risk Management, Prevention and Control GRI 403-2 (2018)
GC has adopted the Hazard and Operability Study (HAZOP) to assess risks in the production process and prioritize them. This technique contemplates hazards that could potentially occur in the production process to seek risk prevention methods and control possible disruptions in the operating system. It also establishes plans to mitigate any severe impacts from potential incidents (Prioritization and integration of action plans with quantified targets to address those risks). Process risks are assessed to authenticate the efficiency of current safety systems and install additional equipment or occur effect changes to the production process. The entire procedure has been assigned under the responsibility and governance of the Technical Safety and PSM Team to ensure efficiency throughout the production process.
GC HAZOP Study Process
According to the occupational health and safety risk and hazard evaluation in 2025 key risks detected include 1) Safety Risk (Process Safety Event): leakage of hazardous chemicals posing risks to operational safety and serious accidents resulting in injuries or fatalities, and 2) Safety Risk (Personal): risk of accidents from factory operation activities, turnaround activities, construction projects and other supporting activities that may lead to accidents and work-related injuries or fatalities.
Furthermore, Operational Area Core Team (OACT) and Process Safety Management Taskforce (PSMT) have been appointed for each production unit to drive Process Safety Management and support each working area. This contributes to GC’s target of becoming the leader that can maintain international standard in OHS within chemical industry.
Moreover, GC has conducted measures for managing reliability and integrity of machineries at all factories and established Reliability Improvement Team (RIT). Machineries at all factories will be assessed through the Asset Integrity Assessment by an internal specialist, to analyze and set an improvement plan for reliability and integrity. The improvement plan covers all factors, which are potential causes of accidents as well as reducing the number of unplanned shutdowns.
Process Safety Projects GRI 403-2 (2018), 403-4 (2018)
GC continuously raises safety standards in production processes by applying technology in operations while comprehensively developing and upgrading numerous successful pilot projects. GC has conducted numerous process safety projects, such as Enhancing Plant PSM Committee Performance, Operation Risk Management Risk Treatment to Prevent LOPC, and Align Field Risk Assessment (FRA) Good Practices.
To ensure the company’s production processes are safe and comply with the laws and internationally-recognized standards.
Smart Process Safety Event (PSE) Project
GC has developed a digital system to support maximum efficiency and effectiveness in Integrity Operating Window (IOW) management. This digital system tracks the Process Safety Near Miss (PSE Tier3b), from which data is used to monitor and predict accident probabilities and establish appropriate risk mitigation measures. This contributes to the prevention of equipment damage or production process disruption. Furthermore, the system can be adapted to evaluate the equipment age and plan for inspections
Enhance the Field Risk Assessment (FRA) Alignment Process Project GRI 403-7 (2018)
GC has collaborated with DuPont on conducting a Field Risk Assessment (FRA) and organizing training for employees to understand and identify the risks from any deviation from standards of production activity. The FRA is expected to increase the effectiveness of Barrier of Protection and reduce risk in process safety, particularly in 3 dimensions: Personnel, Facilities and Technology.
GC enhanced the implementation of Field Risk Assessment (FRA) by aligning good practices and developing competencies for employees at the operating level and enabling their risk sensing skills in the workplace or work process. This was achieved through the use of the Field Risk Assessment Library (FRA Library), a database designed to strengthen proactive risk prevention in the workplace.
In 2025, GC further enhanced the Field Risk Assessment (FRA) process by reviewing the FRA recommendation priority to align with the Maintenance Priority Matrix, driving the resolution and management of high priority risks. Additionally, a dashboard was developed to track FRA findings, particularly high priority FRA findings, to ensure that all FRA findings are fully addressed.
Strengthening Bow Tie Barrier Validation
GC has applied Bow Tie risk analysis to assess potential hazards or accidents as well as any impact that may lead to Major Accident Event (MAE). The company has improved the assessment of operational effectiveness in each bow tie by examining the data for accuracy and integrity, incorporating them into the annual process safety management’s internal audit process as the regulations of the Industrial Estate Authority of Thailand (IEAT) in order to ensure that the established measures are ready to prevent process safety incidents.
Enhancing Plant PSM Committee Performance
GC has elevated Process Safety Management (PSM) by reviewing the Readiness of Plant PSM Committee in terms of both Governance Process and Capability of the Plant PSM Committee continuously, to ensure proper and robust oversight according to established standards, as well as to stimulate Felt Leadership to drive Safety Culture. In 2025, the company implemented enhanced governance oversight for Process Safety operations of the Plant PSM Committee to ensure understanding of IEAT PSM legal requirements, leading to effective PSM system implementation, including understanding roles and responsibilities, and the ability to establish appropriate work plans and PSM strength indicators for each area, to elevate management oversight (PSM Governance) at all plants from Intermediate level (B) to Strong level (A).
Enhancing Life-Saving Rules: First Line Breaking Practice Compliance under Operation Risk Management (ORM) Risk Treatment to Prevent LOPC
GC has enhanced the monitoring and implementation of Risk Treatment measures under Operational Risk Management (ORM) to improve effectiveness. The company has designated First Line Breaking Practice as one of the Life-Saving Rules, establishing three mandatory requirements:
- Must not authorize contractors to loosen the first bolt without supervisor oversight
- Must verify isolation integrity
- Must wear appropriate Personal Protective Equipment (PPE)
These are in addition to the existing Life-Saving Rules:
- Use of fall protection equipment when working at heights
- Compliance with the work permit system
- Verification of isolation integrity
- Compliance with confined space work permit procedures
Furthermore, the company has provided training to review knowledge, understanding, and practical application at the plants. Additionally, the company conducted Compliance Checks on the implementation according to company standards and found 100%
Operation Risk Management (ORM): Strengthen mitigation barrier of Tank fire by ORM
GC reviews the adequacy and operational readiness of critical emergency response equipment, such as Fire Pumps, Deluge Systems, and Fire Suppression Systems, integrating systematic improvements through the Operation Risk Management (ORM) process, Pre-incident Plan reviews, and emergency response drills to ensure readiness. This includes establishing collaborative partnerships for responding to fires involving large raw material or product storage tanks among the group companies in the Map Ta Phut area.
In addition to the process safety operations mentioned above, the Company also has internal inspection systems covering occupational health and safety and environmental aspects, including Daily SHE Inspection. Safety Inspectors verify on-site communications for compliance with measures specified in the Job Safety and Environmental Analysis (JSEA). This includes inspecting work operations and supervisor readiness, equipment inspection, vehicle conditions, material handling within work areas, and housekeeping upon work completion, as well as infectious disease prevention and control measures. Safety Inspectors prepare a Daily SHE Inspection Report to report findings to relevant parties.
GC is committed to continuously developing process safety standards and monitoring and evaluating the performance of relevant departments to minimize the process safety incident rate, which is the company's safety management target, to the greatest extent possible.
Performance Summary
Process Safety Event Tier 1 (Case)
Target
Process Safety Event Tier 1
| Performance | Target | |||||
|---|---|---|---|---|---|---|
| 2022 | 2023 | 2024 | 2025 | 2025 | 2027 | |
| Process Safety Event Tier 1 (Case) | 2 | 1 | 0 | 0 | 0 | 0 |