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UNIVERSITI TEKNIKAL MALAYSIA MELAKA

Safety Assessment in Petrochemical Industry: A


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 Mohd Hafsham Bin Wan Hanafi

Faculty of Manufacturing Engineering


May 2007

ABSTRACT

This report is about the study of health, safety and environment management
system, in petrochemical industry. We know that the petrochemical industry is
highly risk industry with involve chemical reaction, hazardous material, flammable
explosion and any other risk that are can occur to the staff or the contractor for the
company while doing their job. Thus, through this study I would like to evaluate the
HSEMS programme or planning in obtain the risk and hazard occur in petrochemical

industry whether it can avoid or at least can keep away the risk fiom their staffs and
contractors .As we know, management level is the important section that manages
the entire activity for the company whether in business sector or other sector such as
health, safety and welfare for the workers. In safety matters, normally health and
safety centre will manage the whole safety thing for their staff and activity. Before
other safety method to be taken it must be start with planning for safety system to
analyze what is the risk and action to be taken or to provide the workers fiom the
injuries.Through this study I hope that we can know that all activity in the
petrochemical industry is under control with health and safety management to be
taken by the company. This also can help us to know more about the industry.

ABSTRAK

Laporan ini adalah kajian mengenai sistem pengumsan kesihatan,


keselamatan dan 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

merupakan

antara

sistem

langkah

yang

pengumsan
paling

keselamatan
penting

ini,perancangan

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

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 be 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.

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. A 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[ 1 41.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.

1.2

Scope of Project
This project is 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 compare to other industries. So the major scope of this
project is 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, hamdous management 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 to make sure our job is smooth. So in the industry, especially in
highly risk, petrochemical industry must have the planning and preparation in
anything have done to make 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 manage and control the risk and hazard in the workplace.
Many people did not know the important of the HSEMS 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 is not suitable to the job 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

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

1.5

Company 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

: 76300

City

: Sungai Udang

State

:Melaka

Country

: MALAYSIA

Phone

:4-606-352 2020

Toll fiee

: 1 800 88 2019

Fax

: 4-606-3522552

MDICEO

:Mr. Colin Wong Hee Huing

Date Incorp

: 19 September 1987

Principal Activity

: Refining of crude oil

Business Activity
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

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

Objective
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.

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

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

between 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 1 shows one particular
view of the systems approach proposed by Slappendel et a1.(1993).This model are
also include in the petrochemical industry.

THE WORK SYSTEM

Employee
Management or
Design Error

Characteristic

PNatural
Factors

_,

Hazard
A

Job Characteristics

Equipment & Tools

Operator
Error

Physical Environment

Figure 1 :Model of causal factors in occupational injuries [ 1 31

Accident1
Injury

2.3

Definition of 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[! 5 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: [ 1 51
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


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

guard rail on scaffolding. A 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.

2.4

Health, safety 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
sufficientlygeneric 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 an 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.

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 2 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.

slrategk
d,jecwes

Rfudon,
ares and
nwtatlon

44

iI,
'I4

!aderr-

ad

!i

'.

/C

unmbwn
lluotbR

MI
risk
rgement

5*

4
II4

a u d i t

---- -Figure 2: 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

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 [ 1 81. 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 1 2 1
i. are consistent with those of any parent company;

ii. are 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.

are implemented and maintained at all organizational levels;

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;

vi. control of activities whilst corrective actions are 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 are
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.

2.5.4 Evaluation and Risk Management

Identify hazard and effects

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

Figure 3: The essential steps of hazard management [ 14 1

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

should cover activities fiom inception (e.g. prior to acreage acquisition) through to
abandonment and disposal. The identification should include consideration of: [ 1 81
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.
iii. 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;

v.
vi.

be conducted according to appropriate and documented methods;


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.

Planning

2.5.5

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

HSE culture;
vii.

mechanisms to provide feedback to personnel on HSE performance;

viii.

processes to recognize good personal and team HSE performance (e.g.


safety award schemes);

ix.

mechanism for evaluation and follow-up.

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 [ I 41. Reactive monitoring provides information on incidents (including nearmiss 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.

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: [ 1 81
i. Specific activities and areas to be 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.
iii. 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.

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 be 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" I 1 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

such as production and maintenance that lead to cost effective management for a
successful company 1 1 7 I. 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.
~ccountabilityfor 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

12 years of operation, over 5 million tonnes of ammonia and 5 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 free 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) 15 I. 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.

Operating Procedures

2.8

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 [ 131. The procedures also advise how to safely start up and
shutdown the operation.

Plant Safety and Environmental Design Aspects

2.9

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: 1 8 j
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 PLC 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.

2.10 Maintenance Features and Inspection


A well established maintenance program which covers predictive, preventive

and corrective maintenance jobs is in place. A 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: I I I '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, NDT (nondestructive 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-toWork (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

iv.

Electrical

v.

Crane 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 are the important part of Risk Management
that recognizes. Risk Management is a process that involves assessing the risks that

arise in workplace, putting sensible health and safety measures in place to control
them and then making sure they work in practice. Systems uses are such as below:
[91

i.

Accident 1 Incident Reporting

ii.

Audits and Inspection

iii.

Risk Management

iv.

Permit-to-Work System

v.

Systematic Hazard identification and Hazard analysis are all effective


tools to reduce the likelihood of 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 or 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 to ensure the most valuable asset, workforce is protected.
This method is the most straightforward for most organisations to make a risk
assessment.The step in risk assessment are such as below: [ 151
i. Identie hazards
ii. Decide who might be harmed and how

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 of Sensible Risk Management


1. Sensible risk management is about: [4]

Ensuring that workers and the public are 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 is likely to lead to
robust action
Enabling individuals to understand that as well as the right to protection, they
also have to exercise responsibility
2. Sensible risk management is not about:
Cteating a totally risk free society
Generating useless paperwork mountains
Scaring people by exaggerating or publicising trivial risks
Stopping important recreational and learning activities for individuals where
the risks are managed
Reducing protection of people from risks that cause real harm and suffering

2.12.2 Safety Audits and Regular Inspection


The main objectives of safety audits and inspections are the following:

i.

Assist in identifying any hazards

ii.

Highlights any weakness in our existing hazard controls

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