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UNIVERSITI TEKNIK L M L YSI MEL K

Safety Assessment in Petrochemical Industry:

Study on Planning Procedure in Health Safety

Environment Management System

Thesis submitted in accordance with the requirements of the

Universiti Teknikal Malaysia Melaka for the Bachelor Degree of Manufacturing

Engineering in Manufacturing Process

Wan M ohd Hafsham Bin Wan Hanafi

Faculty o f Manufacturing Engineering

May 2 7

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BSTR CT

This report is about the study o f health safety and environment management

system in petrochemical industry. We know that the petrochemical industry is

highly risk industry with involve chem ical reaction hazardous material flammable

explosion and an y other risk that are can occur to the staff o r the contractor for the

company while doing their job. Thus through this study I would like to evaluate the

HSEMS programm e o r planning in obtain the risk and hazard occur in petrochemical

industry whether it can avoid or a t least

c n

keep away the risk fiom their staffs and

contractors .As we know managem ent level is the important section that manages

the entire activity for the company whether in business sector or other sector such

s

health safety and welfare for the workers. In safety matters normally health and

safety centre will manage the whole safety thing for their staf f and activity. Before

other safety method to e taken it must

e

start with planning for safety system to

analyze what is the risk and action to

e

taken or to provide the workers fiom the

injuries.Through this study I hope that w e can know that all activity in th e

petrochemical industry is under control with health and safety management to

e

taken by the company. This a lso can help us to know more about the industry.

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BSTR K

Laporan ini adalah kajian mengenai sistem pengumsan kesihatan

keselamatan d n alarn sekitar dalam industri petrokimia.Sebagaimana yang

diketahui indusrti petrokimia merupakan industri yang berisiko tinggi dengan

melibatkan pelbagai jenis tindakbalas kimiqbahan mudah terbakar dan pelbagai

risiko lain yang boleh mengundang bahaya kepada pekerja ataupun kontraktor

terlibat.Jadi peringkat pengurusan adalah bahagian paling penting yang

menguruskan operasi syarikat.Dalam ha1 berkaitan keselamatan biasanya pusat

kesihatan dan keselamatan yang akan menguruskan hal-ha1 keselamatan seluruh

kakitangan mereka.Dalam sistem pengumsan keselamatan ini perancangan

merupakan antara langkah yang paling penting sebelum memulakan

operasi.Jadi melalui kajian ini saya berharap yang kita boleh mengetahui bahawa

semua aktiviti dalam industri petrokimia adalah dapat dikawal dengan adanya sistem

pengurusan kesihatan dan keselamatan yang diguna pakai oleh syarikat.Ia juga boleh

membantu kita dalam mendalami isu-isu keselamatan dalam industri ini

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CHAPTER 1

INTRODUCTION

1 1 Introduction

The oil and petrochemical industry accounts for a minor share of the

manufacturing sector in the Malaysia. The industry, however, is potentially more

hazardous than many other industries. This is because many feedstocks, intermediate

products and finished products are flammable and their inventories involve large

quantities. Some of the process operations involve high temperature and pressure.

Hence fires and explosions are always potential hazards. Other potential hazards

associated with the industry arise from the handling and storage of toxic and

corrosive chemicals.

Safety is the most important thing in every sector whether it is dangerously

categorizing sector or not including in petrochemical industry. In everything we do,

safety assessment must

e

the first agenda that we should know and handle while the

worst case situation happens. According to the safety assessment, it is synonym with

act and regulation

in

Malaysia that is a guideline and information references for the

factories and the workers as an individuals who have responsible in this sector

especially in petrochemical industry.

One of the main regulation that was exist in Malaysia is Factory and

Machinery Act 1967 revise-1988) that was probably state that the company or

factory must follow the regulation in this act

to

prevent the entire hazardous and

worst situation in factory. After the advent of the Bhopal disaster in 1984, Factory

and Machinery department set up a special task force known as major hazard units to

carry out special inspection with all factories dealing with hazardous chemicals.

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The hazards is something that can cause harm and risk is the probability of

the hazard causing harm.Then the outcome is the result of when the hazard causes

ham.The Factory and Machinery Department is presently known as Department of

Occupational, Safety and Health @OSH).This department is to enforce the principle

law of OSHA, CIMAH regulation, to assess report and emergency plan besides to

conduct the accident investigation in factory and company.

The government is seriously to take care of the safety issue in any working

area whether in factory or not. To improve this statement, we can see that many act

and regulation was done by government to make sure all the factories and company

not take for granted with this issue because it will involved the human or the

worker s life. For example we have Control of Industrial Major Accident Hazard

(CIMAH) Regulations, Occupational Safety and Health Act 1994 (OSHA) and so

many more regulation and act that exist in Malaysia to make sure all the workers are

in better safety, health and welfare.

But in this safety issue, the company is the important parties in managing and

handling the safety issue to their activity. few years ago, on

25

December 1997, an

incident occurred at a petrochemical plant in east Malaysia. Although the company

managed to control the consequences of the incident it was found out the

management errors contributed to the incident. The technical, operational and

organizational errors started and accumulated during an incubation period estimated

to be four years[l2].All the company s activity will be monitor by the specific

department to make sure all the safety rules and regulation are to be taken to avoid

any other injury to the workers and contractors. Many big companies have their own

safety management but its all

base

on the standard health, safety and environment

management system provide fiom

E P

forum 1994

4

.Although there

are

important differences in the detailed handling of safety and environmental issues,

safety and environmental management are tending to converge towards the system

based of IS0

9000.

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1 2 Scope of Project

This project

s

about to study the safety aspect in petrochemical industry

including oil and gas industry especially in Malaysia. The petrochemical industry is

the most dangerous industry com pare to other industries. S o the m ajor scope of this

project

s

specifically involve in management safety and health

in petrochemical

industries such as how to manage and plan the programme for

worker in safety

aspect, working environment, handling flammable material, major hazard

installation, h a m d o u s man agemen t and all the other aspect that exist in the factory.

In doing this project, it required for the industry visit to make a real learning

situation.

1 3 Problem Statement

The main problems that are want to focus in this project paper is the safety

issue in petrochemical industry that are including many people as a workers.This

project also was proposed to study safety level comply in Petrochemical Plant

especially in health and safety management system. The entire thing we do should

have a planning t o make sure our jo b is smooth. S o in the industry, especially in

highly risk, petrochemical industry must have the planning and preparation in

anything have done to ma ke sure all the risk and hazard can be manage without any

problem. Health safety and environment management system is the centres for the

industry in man age and control the risk and hazard in the workplace.

Many people did not know the important of the HS EMS especially in the

industry. Although people know the HSEMS, but they do not care about this issue

and do not observe and manage this system well. People who responsible did not

audit the system and also not revise all the thing in the HSEMS.As a result, when the

system i s not suitable to th e jo b or specified business, many incident or accident will

occur in the workplace because all the risk and hazard are not manage well. Worker

doesn t know the safety procedure in handling material or workers may

be

doesn t

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know where their emergency plan. There are so many risks

in

the workplace. If we

manage and plan what we do, we can make the risk and hazard less than before.

1 4 ompany

background

Company Name

PETRONAS Penapisan (Melaka) Sdn Bhd

Acronym PP (M) SB

Shareholding 100

Business Activity Oil

Contact Managing DirectorICEO

Address

Bangunan Pentadbiran Persiaran Penapisan

Postal code

City

State

Country

Phone

Toll

fi

Fax

MDICEO

Date Incorp

Principal Activity

76300

Sungai Udang

Melaka

MALAYSIA

4-606-352 2020

800 882019

4-606-3522552

Mr. Colin Wong

ee

Huing

19 September 987

Refining of crude oil

1 5 Business ctivity

PETRONAS Melaka Refinery Complex consists of two refineries.

PETRONAS Penapisan (Melaka) Sdn. Bhd. (PP(M)SB), a 100 owned subsidiary

of PETRONAS is the owner of PSR-1. PSR-I is a hydro skimming refinery and is

designed to process 100,000 barrels per stream day (BPSD) of light and sweet crude

and condensates. Malaysian Refining Company (MRC) a joint venture company of

PETRONAS and Conoco Phillips of USA, is the owner of PSR-2. PSR-2 is a

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complex conversion refinery and is designed to process 100,000 BPSD of sour and

heavy crudes, including low sulfir waxy residue from PSR-1. To maximize the

synergy of the facilities, PSR-1 and PSR-2 are partially integrated and share the

utilities and other common facilities. Products produced by the

two

refineries

include; petroleum gas LPG), naphtha, gasoline, kerosene, diesel, low sulphur waxy

residue LSWR), hel oil, coke, and sulphur. PP M)SB manages and operates both

PSR-1 and PSR-2

1 5

bjective

In doing this project, we should know the main objective of the work that we

do. In this project the main objectives are as stated follows:

i

To understand safety issues which is involve in the petrochemical, oil and

gas industry

ii To assess the high risk process in the petrochemical industry

iii. To study about the health, safety and environment management system

implement at selected company or industry.

iv. To analyze the benefit of implementation of health, safety and environment

management system.

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CHAPTER 2

LITERATURE REVIEW

2 1 Introduction

The provisions in OSHA 1994 are applicable to all types of hazards and risks

that

are

present in all places of work, except in the armed forces and on board ship.

The Occupational Safety and Health Classification, Packaging and Labeling of

Hazardous Chemicals) Regulation 1997 provides comprehensive provisions on

classification, packaging and labeling of hazardous chemicals. The Occupational

Safety and Health Use and Standard of Exposure of Chemicals Hazardous to

Health) Regulations

2000,

control the use and permissible exposure limits of

chemicals hazardous to health. The provisions of the Factories and Machinery Act

1967 FMA 1967)

are

applicable to all hazards that

are

present in factories

[2]

Occupational

safety

and health OSH) is a cross-disciplinary area concerned

with protecting the safety, health and welfare of people engaged in work or

employment. As a

secondary

effect OSH may also protect employers, customers,

suppliers, and members of the public who may experience an impact from the

workplace environment.

2 2

Main factors of the accident in Industry

A variety of theories and models have been proposed to explain and predict

accidents. Most of that only consider some of the factors that contribute to the

accidents, for example social environment. Probably the most comprehensive

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model,the systems approach,is also one that is compatible with the human factors

approach.

The systems approach assumes that accident occur because of the interaction

etween

system components

[

I3

].It is assumed that some factors are closely or

directly involved in task performance and therefore are direct causal factors in

Safety-Thesefactors include characteristics of:

a) the employee performing a task

b) the task itself

c) any equipment directly or indirectly used in the task.

Other factors also impact safety at workplace. These can be categorized as

sociaYpsycological factors and environmental factors. Figure shows one particular

view of the systems approach proposed by Slappendel et a1. 1993).This model are

also include in the petrochemical industry.

Figure Model of causal factors in occupational injuries

3

Managementor

Design Error

THE

WOR

YSTEM

Employee

Characteristic

Job Characteristics

Equipment Tools

Physical Environment

Natural

Factors

P

Accident

Injury

Operator

Error

Hazard

-

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2 3

Definition

o

Safety Hazard and

Risk

Safety is the state of being safe, the condition of being protected against

physical, social, spiritual, financial, political, emotional, occupational, psychological

or other types or consequences of failure, damage, error, accidents, ham or any other

event which could

be considered dangerous[ 1 Protection is from both the cause

and from exposure to something that is not safe. It can include physical protection or

that of possessions. Safety is often in relation to some guarantee of a standard of

insurance to the quality and unharmful function of a thing or organization.

Workplace safety is an important management responsibility in industry. To ensure

the safety and health of workers in a

business enterprise, managers establish a focus

on safety that can include elements such

as: [ 5

i management leadership and commitment

ii employee engagement

iii accountability

iv.

safety programs, policies, and plans

v. safety processes, procedures, and practices

vi safety goals and objectives

vii. safety inspections for workplace hazards

viii. safety program audits

ix. safety tracking metrics

x. hazard identification and control

xi.

safety committees to promote employee involvement

xii. safety education and training

xiii.

safety communications to maintain a high level of awareness on safety

hazard is anything with the potential to cause harm e.g. the absence of a

guard rail on scaffolding. risk is the likelihood that a hazard will cause a specified

harm to someone or something e.g. if the guard rail is missing it is likely that a

construction worker will fall off the scaffolding and break a bone.

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2 4

Health,

s fety

and Environment Management System HSEMS)

Health, safety and environment management system (HSEMS) is the

guideline use in in exploration and production operations of oil and gas by E P

Forum. The E P Forum is the international association

of

oil and

gas

companies and

industry organizations founded in 1974[l4]. It is concerned with all aspects of oil

and gas exploration and production having international implications, and in

particular with safety and health and environmental protection. Exploration and

production activities are subject to extensive legislation and regulation concerning

Occupational Health and Safety (OHS). All operators have OHS strategies to satisfy

their own operating and regulatory requirements, and Safety Management Systems

(SMS) are a principal component of such strategies. SMS guidelines have been

developed both by individual companies and by national and international bodies.

There is wide recognition of the benefits of objective or goal-setting

approaches to safety, a fundamental principle of the SMS approach which draws on

the management principles of the International Standard on Quality Systems, IS0

9000.Similarly, environmental aspects are subject to extensive regulation and

Environmental Management Systems (EMS) is used to control and manage

environmental impacts. Although there are important differences in the detailed

handling of safety and environmental issues, safety and environmental management

are tending to converge towards the systems model of

IS0 9000 lo]

The standard HSEMS that have been developed by the E P Forum is to

cover relevant Health, Safety and Environment (HSE) issues in a single document, to

make sure it relevant to the activities of the E P industry worldwide and also to

be

sufficiently generic to be adaptable to different companies and their cultures[

141

Besides the HSEMS also is important to recognize, and be applicable to the role of

contractors and subcontractors. Another purpose for the HSEMS standard is to

facilitate operation within the framework of legal requirements and also to facilitate

evaluation of operations to n international standard as appropriate.

Furthermore, the system are intended to make sure all the activity are in

control and besides can support the operation to avoid accident and incient in the

workplace.

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2.5

The Health, Safety and Environmental Management System

Model

The model of Health Safety and Environmental Management System which

forms the basis of the guidelines is shown schematically in the

figure

below.

Although this indicates a sequence of the HSEMS elements many of the stages will

in practice be addressed at the same time or revisited at different times. This is for

convenience and in no way implies that the HSEMS is distinct tiom the overall

management system of the facility or company.

slrateg

/

d , jecwes

Rfudon,

ares nd

i

,

4 4

I

I

nwta t lon

I

i aderr-

d

unmbwn

lluotbR

i

C

M

isk

I

.

rgement

a u d i t

Figure

:

The HSEMS model according to

E P

Forum

[ 1.1

Different health safety and environmental management systems and

strategies have been developed by different companies and organizations leading to

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a diversity of terminology. Most of the guidelines refer to an operating organization

directly responsible for HSE management and performance.

2 5 1 Leadership and commitment

Senior management of the company should provide strong, visible leadership

and commitment, and ensure that this commitment is translated into the necessary

resources, to develop, operate and maintain the HSEMS and to achieve the policy

and strategic objectives Management should ensure that

f i l l

account is taken of

HSE policy requirements and should provide support for local actions taken to

protect health, safety and the environment. The company should create and sustain a

company culture that supports the HSEMS, based on:

i

belief in the company s desire to improve HSE performance;

ii. motivation to improve personal HSE performance;

iii. acceptance of individual responsibility and accountability for HSE

performance;

iv. participation and involvement at all levels in HSEMS development;

v. commitment to an effective HSEMS.

Employees of both the company and its contractors should be involved in the

creation and maintenance of such a supportive culture.

2 5 2 Policy and Strategic Objective

The company s management should define and document its HSE policies

and strategic objectives and ensure that they:

1 2 1

i

are consistent with those of any parent company;

ii. re relevant to its activities, products and services, and their effects on

HSE;

iii. are consistent with the company s other policies;

iv. have equal importance with the company s other policies and objectives;

V

re implemented and maintained at all organizational levels;

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vi. are publicly available;

vii. commit the company to meet or exceed all relevant regulatory and

legislative requirements;

viii. apply responsible standards of its own where laws and regulations do not

exist;

ix. commit the company to reduce the risks and hazards to health, safety and

the environment of its activities, products and services to levels which are

as low

as

reasonably practicable;

x

provide for the setting of HSE objectives that commit the company to

continuous efforts to improve HSE performance.

The company should establish and periodically review strategic HSE objectives.

Such objectives should be consistent with the company s policy and reflect the

activities, relevant HSE hazards and effects, operational and business requirements,

and the views of employees, contractors, customers and companies engaged in

similar activities.

2 5 3 Organization Resources and Documentation

Successful handling of Health, Safety and Environment matters is a line

responsibility, requiring the active participation of all levels of management and

supervision; this should

be

reflected in the organizational structure and allocation of

resources. The company should define, document and communicate with the aid of

organizational diagrams where appropriate the roles, responsibilities, authorities and

interrelations necessary to implement the HSEMS, including but not limited to:

1 11

i

provision of resources and personnel for HSEMS development and

implementation;

ii. initiation of action to ensure compliance with HSE policy;

iii

acquisition, interpretation and provision of information on HSE matters;

iv. identification and recording of corrective actions and opportunities to

improve HSE performance;

v. recommendation, initiation or provision of mechanisms for improvement,

and verification of their implementation;

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vi. control of activities whilst corrective actions re being implemented;

vii. control of emergency situations.

The company should stress to all employees their individual and collective

responsibility for

HSE

performance. It should also ensure that personnel are

competent and have the necessary authority and resources to perform their duties

effectively. The organizational structure and allocation of responsibilities should

reflect the responsibility of line managers at all levels for developing, implementing

and maintaining the

HSEMS

in their particular areas. The structure should describe

the relationships between:

i

Different operating divisions.

ii

Operating divisions and supporting services whether the services re

provided on the same facility or from a larger corporate organization).

iii

Onshore and offshore organizations.

iv. Employees and contractors.

v. Partners in joint activities.

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2 5 4

valuation and isk Management

Figure 3: The essential steps of hazard management

4

Identify hazard and effects

The company should maintain procedures to identify systematically the

hazards and effects which may affect or arise from its activities and from the

materials which are used or encountered in them. The scope of the identification

Establish screening criteria

IdentifL

applicable

statutory

requirements

Evaluate hazards and effects

Document significant hazards and effects

and applicable statutory requirement

Set detailed objectives and

performances criteria

Identify and evaluate risk

reduction measures

Implement selected risk reduction

measures

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should cover activities fiom inception e.g. prior to acreage acquisition) through to

abandonment and disposal.

The

identification should include consideration of:

8

i. Planning, construction and commissioning i.e. asset acquisition,

development and improvement activities).

ii

Routine and non-routine operating conditions, including shut-down,

maintenance and start-up.

iii. Incidents and potential emergency situations, including those arising from:

Product/material containment failures.

Structural failure.

Climatic, geophysical and other external natural events.

Sabotage and breaches of security.

Human factors including breakdowns in the HSEMS.

iv. Decommissioning, abandonment, dismantling and disposal.

v. Potential hazards and effects associated with past activities.

Personnel at all organizational levels should be appropriately involved in the

identification of hazards and effects

12

].Besides, procedures should

be

maintained

to evaluate assess) risks and effects from identified hazards against screening

criteria, taking account of probabilities of occurrence and severity of consequences

for:

i

People.

ii

Environment.

i i i Assets.

It should

be

noted that any evaluation technique provides results which

themselves may

be

subject to a range of uncertainties. Consequently formal risk

evaluation techniques are used in conjunction with the judgments of experienced

personnel, regulators and the community [9].Risk evaluation should:

131

i

include effects of activities, products and services;

ii

address effects and risks arising fiom both human and hardware factors;

iii

solicit input from personnel directly involved with the risk area;

iv.

be

conducted by qualified and competent personnel;

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v.

be

conducted according to appropriate and documented methods;

vi.

be

updated at specified intervals.

Evaluation of health and safety risks and effects should include, where

appropriate, consideration of:

i Fire and explosion.

ii

Impacts and collisions.

iii. Drowning, asphyxiation and electrocution.

iv. Chronic and acute exposure to chemical, physical and biological agents.

v. Ergonomic factors.

2 5 5 Planning

The company should maintain, within its overall work programme, plans for

achievingHS objectives and performance criteria. These plans should include:

i

a clear description of the objectives;

ii

designation of responsibility for setting and achieving objectives and

performance criteria at each relevant function and level of the

organization;

iii

the means by which they are to

be

achieved;

iv. resource requirements;

v. time scales for implementation;

vi. programmes for motivating and encouraging personnel toward a suitable

HS culture;

vii.

mechanisms to provide feedback to personnel on

HS

performance;

viii.

processes to recognize

good

personal and team

HSE

performance e.g.

safety award schemes);

ix.

mechanism for evaluation and follow-up.

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2 5 6

Implementation and monitoring

The company should maintain procedures for monitoring relevant aspects of

HSE performance and for establishing and maintaining records of the results. For

each relevant activity or area, the company should:

i identifj and document the monitoring information to be obtained, and

specify the accuracy required of results;

ii specifL and document monitoring procedures, and locations and

frequencies of measurement;

iii

establish, document and maintain measurement quality control procedures;

iv. establish and document procedures for data handling and interpretation;

v. establish and document actions to

be

taken when results breach

performance criteria

vi. assess and document the validity of affected data when monitoring

systems are found to

be

malfunctioning;

vii. safeguard measurement systems from unauthorized adjustments or

damage.

Procedures are required for both active and reactive monitoring. Active

monitoring provides information in the absence of any incident, ill-health or damage

to the receiving environment. It includes checking that

HSEMS

requirements e.g.

procedures) are being complied with, and that objectives and performance criteria are

met [

41

Reactive monitoring provides information on incidents including near-

miss incidents, ill-health or environmental damage) that have occurred and provides

insights into the means of preventing similar incidents in the future.

2 5 7 Auditing and reviewing

The company should maintain procedures for audits to

be

carried out, as a

normal part of business control, in order to determine:

i

Whether or not

HSE

management system elements and activities conform

to planned armngements, and are implemented effectively.

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ii

The effective functioning of the HSEMS in hlfilling the company s HSE

policy, objectives and performance criteria.

iii. Compliance with relevant legislative requirements.

iv. Identification of areas for improvement, leading to progressively better

HSE management.

For this purpose, it should maintain an audit plan, dealing with the following:

8

i

Specific activities and areas to

e

audited. Audits should cover the

operation of the HSEMS and the extent of its integration into line activities,

and should specifically address the following elements of the HSEMS

model:

organization, resources and documentation;

evaluation and risk management;

planning;

implementation and monitoring.

ii

Frequency of auditing specific activitieslareas. Audits should be scheduled

on the basis of the contribution or potential contribution of the activity

concerned to HSE performance, and the results of previous audits.

i i i Responsibilities for auditing specific acthitiedareas.

Audit protocols and procedures should

be

established and maintained. The

following points should be covered:

i. Allocation of resources to the auditing process.

ii. Personnel requirements and specifically that the audit team has:

adequate independence from activities audited to enable objective and

impartial judgement;

the necessary expertise in relevant disciplines;

support, if necessary, from a wider range of specialists.

iii. Methodologies for conducting and documenting the audits, which may

involve the use of questionnaires, checklists, interviews, measurements and

direct observations, depending on the nature of the function being audited.

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iv. Procedures for reporting audit findings in a controlled manner to those

responsible for the activitylarea audited, who should take timely action on

reported corrective actions and opportunities for improvement. Reporting

should address:

conformity or nonconformity of the HSEMS elements with specified

requirements;

effectiveness of the implemented HSEMS in enabling objectives and

performance criteria to be met;

implementation and effectiveness of corrective actions from previous

audits;

conclusions and recommendations.

v System for auditing and tracking implementation status of audit

recommendations.

vi. Distribution and control of audit reports.

2 6

The Importance of the Management Function ( Driving

from

the

Top )

Commitment to safety management must be driven from the highest level of

management. The policies relating to safety, health and environment shall be

developed to give a clear company commitment to these important areas. The 'Safety

Policy' developed by the management and the company 'Mission Statement' clearly

establish company's commitment at the highest level to ensure the establishment of a

safe healthy work environment for all employees. Petrochemical industry is

potentially hazardous in nature

181

However, these hazards can

e

properly

controlled through good and safe engineering design, safe working practices and safe

operational procedures together with commitment of a well trained workforce. In

fact, all accidents, in principle, can be prevented. This is achieved through, what is

termed managing safety

01.

'Managing safety' is an integral and essential responsibility for a successfUl

company. In fact, the accident and fire prevention are the very elements in activities

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such as production and maintenance that lead to cost effective management for a

successful company 7 Safety is also a moral and legal obligation. For these

reasons, company safety policies should

be

clear and should specifL objectives for

the protection of its workers, the external population and the environment.

~ccountability for safety is included in job training and job descriptions and

disciplinary action may be taken for on-the-job safety infringements. Safety of the

individual and others CaMOt

be

delegated. Everyone has a responsibility towards

safety.

In Bahrain, Gulf Petrochemical Industries Co has safely produced during its

2 years of operation, over 5 million tonnes of ammonia and million tonnes of

methanol without accident or fatal injuries and no fires involving more than the use

of an extinguisher or steam

[ I 81

In reality, it is the implementation of essential

system controls by both management and the workforce that keep people

environmentally

fr from risks and hazards. The involvement of management in

safety awareness and training remains a permanent feature of the company s

commitment to continued safety improvement.

2 7 Operating Management System

Even before pre-commissioning, commissioning and start-up of the complex,

it was felt necessary that the safety base for hture activities should be established.

All the activities of the company were encompassed and issued under the title of the

Operating Management System (OMS)

5

The OMS is a collection of management

procedures which establish actions and inter-relations of the various units depicted in

company s organization chart. OMS has been conceived as an instrument of

management for supplying the Operations, Maintenance, Technical Services

Departments and the Fire, Safety and the Plant Security Section with adequate

general directions and guidelines. These procedures set out the necessary controls as

an integral and essential part of the Management of Safety, together with other

primary aspects such as maintenance, production, engineering and inspection

activities using safety controls and proper code of practices.

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2 8

Operating Procedures

The operating procedures

are

the heart of understanding how to operate the

plants safely and in environmentally friendly way. These procedures help minimize

the risks of accidents by stipulating the correct manner in which the process should

be

operated consistently

13

1 The procedures also advise how to safely start up and

shutdown the operation.

2 9

Plant Safety and Environmental Design Aspects

Safety and environmental issues would need a special consideration. These

issues were categorized as top priority during design and construction phases of the

existing complex. The plants have been designed and engineered with high safety

and environmental standards and features:

8

i

All plants have been study on hazard and operability (Hazop) during the

design phase.

ii

The

process is monitored and controlled

by

the state-of-the-art distributed

control systems (DCS).

iii

To enhance safe shutdown of the process during emergencies, there is a

HIMA shutdown control system for the existing complex and the latest

technology

PL

systems in the urea plant and the package units.

iv

Necessary isolation, control and pressure relief valves are provided on all

equipment.

v.

The plants are engineered with the best of international codes of practices.

vi.

The main control building and urea control room are blast-proof design.

vii.

All operations and maintenance are carried out using the documented

standard operating and maintenance procedures.

viii.

All the emuents are treated and gas releases are controlled, flaredvented

safely and in accordance with standards incorporated in the design phases.

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2.10

Maintenance Features and Inspection

well established maintenance program which covers predictive, preventive

and corrective maintenance jobs is in place. work-order management procedure is

in force which determines the further priorities for each job and which considers

safety as a top priority. The predictive and preventive maintenance covers critical

equipment to ensure the integrity of this equipment for safe operation. The

maintenance program encompasses the predictive side of the equipment monitoring

which includes:

1

i

Vibration monitoring of all the rotating equipment in the plant.

ii

Lubrication oil analysis of rotating equipment and insulation oil analysis

of electrical transformers to identify any deterioration of the oil

constituents.

iii

Thennographic surveys to identify hot spots on insulated equipment

tanks, reformer tubes, etc. are regularly undertaken.

Routine inspection is done as a preventive maintenance. It also ensures and

satisfies the safety of the equipment. Inspection covers the statutory requirement by

the government as well as internal quality inspection requirements. Inspection

techniques vary from measurement of vessel and pipe thickness,

N T

non-

destructive test) of welds and walls, to testing of safety valves.

2.11 Comprehensive Permit-to-Work System

In factory complex, any job is carried-out under a comprehensive Pennit-to-

Work

PTW)

system. This covers all aspects of controlling safety related issues to

personnel, equipment and the environment. The hazardous activities are closely

controlled by the Permit system to enhance safety and help avoid accidents.

PTW

is

applicable for the following activities in factory complex: [ I41

i

Hot and Cold work

ii Vessel entry

iii Excavation

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iv. Electrical

v. Cran e Work

vi. Scaffolding

vii. Lifting and Rigging

viii. Working at heights.

2 12 Hazard Identification and Risk Assessment

Hazard identification risk assessment and ultimately the setting of control

measures to prevent avoidable accidents

re

the important

part

of Risk Management

that recognizes. Risk Management is a process that involves assessing the risks that

rise

in workplace putting sensible health and safety measu res in place to control

them and then making sure they work in practice. Systems uses are such as below:

[91

i. Acc ident Incident Reporting

i i

Audits and Inspection

iii. Risk Managem ent

iv. Permit-to-Work System

v. Systematic Hazard identification and Hazard analys is are all effective

tools to reduce the likelihood o f an accident.

A

risk assessment is nothing more than a carehl examination of what

in

work could cause harm to people

so

that we can weigh up whether we have taken

enough precautions o r should do more to prevent harm.A risk assessment is an

important

step in protecting the workers and business

as

well as complying with the

law. It helps

us

focus on the risks that really matter in the workplace which

is

the

ones with the potential to cause real harm

[ 3 ]

For most that means simple cheap

and effective measures t o ensure the most valuable

asset

workforce is protected.

This method

is

the most straightforward fo r most organisations to make a risk

assessment.The step in risk assessment are such

as

below:

5

i. Id en ti e hazards

ii. Dec ide wh o might

be

harmed and how

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iii. Evaluate the risks and decide on precaution

iv. Record your findings and implement them

V

Review your assessment and update if necessary

2 12 1

Principles

o

Sensible Risk Management

1

Sensible risk managem ent is about:

[ ]

Ensuring that workers and the public a re properly protected

Providing overall benefit to society by balancing benefits and risks with a

focus on reducing real risks both those which arise more often and those with

serious consequences

Enabling innovation and learning not stifling them

Ensuring that those who create risks manage them responsibly and

understand that failure to manage real risks responsibly i s likely to lead to

robust action

Enabling individuals to understand that

s

well as the right to protection they

also have to exercise responsibility

2.

Sensible risk management is not about:

Cteating a totally risk fr society

Generating useless paperwork m ountains

Scaring people by exaggerating or publicising trivial risks

Stopping important recreational and learning activities for individuals where

the risks

re

managed

Reducing protection o f people from risks that

c use

real harm and suffering

2 12 2 Safety Audits and Regular Inspection

The main objectives of safety aud its and inspections a re the following:

i

Assist in identifying any hazards

ii. Highlights any weakness in ou r existing hazard controls

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