Industrial Health and Safety Mini Project # 01

University of Engineering and Technology (UET), Peshawar

Industrial Health and Safety-Mini-Project:

Names:

1. Mohammad Hamza Awan (17PWMEC4279)

2. Fawad Ali (17PWMEC4278)
3. Mehran Meer (17PWMEC4303)
4. Ameer Hamza (17PWMEC4284)

Department: Mechanical

Subject: Industrial Health and Safety

Submitted to: Dr. Sadiq Khattak

Page | 1
Industrial Health and Safety Mini Project # 01

Contents
Industrial Health and Safety: ........................................................................................................................ 4
Introduction: ............................................................................................................................................. 4
Why we chose Oil and Gas Sector for our report? ................................................................................... 4
Hazards in Oil and Gas Sectors: ................................................................................................................ 4
Introduction to ISO 45001: ........................................................................................................................... 5
ISO 45001 in Oil and Gas: .......................................................................................................................... 5
Implementation: ....................................................................................................................................... 6
Implementation ISO 45001 In OGDCL:.......................................................................................................... 6
1. Risk Management: ............................................................................................................................ 6
Purpose: ................................................................................................................................................ 6
Risk Quantification: ............................................................................................................................... 6
Risk Evaluation: ..................................................................................................................................... 6
Hierarchy of Control:............................................................................................................................. 7
Risk Management Team: ...................................................................................................................... 7
• Location Risk Management:.......................................................................................................... 7
• Corporate Risk Management Team: ............................................................................................. 8
2. Job Vulnerability and Hazard Analysis: ............................................................................................. 8
Purpose: ................................................................................................................................................ 8
Requirement for JVA/JHA: .................................................................................................................... 9
JVA/JHA Development Team: ............................................................................................................... 9
JVA/JHA Responsibilities: ...................................................................................................................... 9
3. Legal and Other Requirement:........................................................................................................ 10
Access of Other Regularity and Other Department: ........................................................................... 10
News and Modified Activities: ............................................................................................................ 10
4. HSE Objectives and Management Program: ................................................................................... 11
Five Years Strategies HSE Plan: ........................................................................................................... 11
Annual HSE Plan: ................................................................................................................................. 12
HSE Objectives and Targets: ............................................................................................................... 12
Setting Objectives and Targets: .......................................................................................................... 12
HSE Management Program: ................................................................................................................ 13

Page | 2
Industrial Health and Safety Mini Project # 01

Final Review and Closeout: ..................................................................................................................... 13

Conclusion: .............................................................................................................................................. 14

Page | 3
Industrial Health and Safety Mini Project # 01

Industrial Health and Safety:

Introduction:
Industrial Health and Safety has gained more importance and attention in the recent years in
Oil and Gas sectors for protecting human health and the environment in this potentially more
dangerous and hazardous sector. Improving the Health and Safety procedures should be the
main concern for any industry, and safety protocols and policies should be carefully
investigated for the industry being assessed. The identification and implementation of the
methodologies that are contextually driven and specialized for each industry is what every
industry should be aiming for.

Why we chose Oil and Gas Sector for our report?

This industry involves high risk activities including but not limited to exploration, production,
and processing of highly flammable & explosive materials also in:

• Massive manpower, heavy-complicated-expensive machinery, and extensive support

system.
• High investment (could be > 1 Billion USD) and long payback period (could be > 10 years)
• Strategic and vital industry.
• Remote and Harsh Environment.
• Accident consequences could be catastrophic, in terms of number of casualties,
environment pollution, loss of investment, and reputation damage.

Hazards in Oil and Gas Sectors:

• Pressure hazards (high pressure oil/gas from reservoir, inside pipes & vessels, high
pressure steam from boiler)
• Temperature hazards (high temperature at compressor discharge pipe, low temperature
at liquid nitrogen tank)
• Motion hazards (rotating drill pipes, rotating motor shaft, swing object during lifting)
• Chemical hazards (corrosion inhibitor, lube oil)
• Electrical hazards (lightning, electric work)
• Gravity hazards (slip, fall, falling object, heavy lifting)
• Noise hazards (high noise at compressor area)
• Hazardous atmosphere (gas release from vent, sulfide acid inside gas)
Page | 4
Industrial Health and Safety Mini Project # 01

• Confined space hazards (work inside pressure vessel)

• Excavation hazards (laying buried onshore pipe)
• Sharp object hazards (work with grinding machine)
• Water & Underwater hazards (scaffolding work above sea, subsea pipeline inspection)
• Radioactive hazards (welding inspection by X-ray)
• Manual Handling hazards (wrong position during manual lifting)

Introduction to ISO 45001:

ISO 45001 is an international standard that stipulates requirements for an occupational health
and safety management system.

An occupational health and safety management system, or OHSMS, is the set of rules, policies,
processes, plans and practices that an organization uses to protect people’s health and safety in
the workplace. Every organization’s OHSMS is unique. It must take the organization’s legal
framework, relevant hazards, and processes into account. However, certain principles and
elements are common to all successful health and safety systems. ISO 45001 represents best
practices for an OHSMS. It helps organizations establish, implement and maintain effective
health and safety systems, without missing any important elements.

ISO 45001 in Oil and Gas:

Companies within the industry of oil and gas operate within the domain of being considered
high-risk industries and therefore typically have risk management systems in place, while others
are compliant with OHSAS 18001.

ISO 45001 has been devised in such a way that it aligns with existing integrated management
systems. On an operational level of management, oil and gas companies usually seek to put in
place processes and procedures that deal with the practical challenges of safety critical
elements, ageing life expectancy and asset integrity management. ISO 45001 focuses on the
“risk and opportunities” approach to risk management, such that controlling risks creates
opportunities for improved occupational health and safety performance and improvements in
the OH&S management system itself. Top executives in oil and gas will have a new challenge
under ISO 45001 – a responsibility to oversee, show commitment, accept accountability,
liability and provide sufficient resources to create and implement a totally integrated OH&S
management system within the organization.

Page | 5
Industrial Health and Safety Mini Project # 01

Implementation:
• Get commitment and support from senior management.
• Engage the whole business with good internal communication.
• Compare your existing systems with ISO 45001 requirements.
• Establish an implementation team to get the best results.
• Map out and share roles, responsibilities and timescales.

Implementation ISO 45001 In OGDCL:

Now we are heading towards implementing process of the ISO 45001 in Oil and Gas
Development Company Limited. OGDCL most of the plants are already ISO 45001 certified.

For implementing this standard, we have to develop a certain HSE planning, which includes

1. Risk Management
2. Hazards Analysis
3. Legal and other Requirement
4. Objectives and Management Program

1. Risk Management:
Purpose:
This document has been prepared with an objective of identifying hazards, assessing the
vulnerabilities (risks) and implementing effective control measures to prevent or reduce the
likelihood of their occurrence to As Low As Reasonably Practicable (ALARP).

Risk Quantification:
Risk is calculated as Risk Rating = Probability x Consequence

To calculate risks objectively for each activity, numbers are assigned to the probability and
consequence

Risk Evaluation:
When the multiple of probability and consequence is between or equal to 15 and 25, the risk
shall be considered High.

When the multiple of probability and consequence is between or equal to 8 and 14, the risk
shall be considered Medium.

When the multiple of probability and consequence is between or equal to 1 and 7, the risk shall
be considered Low.

Page | 6
Industrial Health and Safety Mini Project # 01

Hierarchy of Control:
Risks shall be managed by using following risk control hierarchy:

• Elimination:
Elimination is removal of hazard by eliminating a requirement to carry out the task, use
of particular equipment or use of a chemical.
• Substitution:
Substitution is replacement of the material; plant; equipment; process; or work practice
with a less hazardous one.
• Engineering Control:
reduce the reliance of human factors; engineering controls can be redesign of
equipment, redesign of process or increase of automation. Engineering controls also
include change in lay out, separation distance, ventilation, guards, enclosures, firewalls
etc.
• Administrative Control:
Administrative controls are the procedural aspects of managing risks, such as planned
and preventive maintenance. Programs, Standard Operating Procedures (SOPs), Work
Permit System and competence of personnel

• Personal Protective Equipment:

(PPE) is the last and least effective method because it relies on human behavior.

Risk Management Team:

Risk Management Team should be formed:

i. Location Risk management

ii. Corporate Risk Management

• Location Risk Management:

Location Risk Management Team shall be responsible to develop Location Risk Register.
Location Risk Register shall contain a detailed list of all existing or potential hazards (and must
cover all activities, processes and services) using Risk Assessment Planning which may trail
employing techniques suggested as follows or as appropriate;

• Brainstorming
• HSE Inspections (Monitoring)
• Process Hazard Analysis
• UBUC (Hazard) Identification/ HSE Top Card Analysis
• Job Vulnerability/ Hazard Analysis

Page | 7
Industrial Health and Safety Mini Project # 01

• HSE & Technical Audits

• Shutdown/ Breakdown/ Accidents/ Incidents History

Sectional ICs shall be responsible to communicate the identified risks to the employees working
in their Sections or contractors as the case may be. Communication of hazards and their
associated risks shall be carried out by following means or as appropriate:

• Risk Register
• Toolbox Talks
• Signboards/ Posters Training/ Awareness Sessions
• Color Coding
• Circulars

• Corporate Risk Management Team:

GM HSE/ RM shall be responsible to develop/ consolidate Corporate Risk Register based on
Locations’ Risk Registers. The corporate Risk Register shall include only those activities which
have been identified as “Significant (Major)” i.e. within Risk Rating 15-25 in the Locations’ Risk
Registers.

Managing Director shall be responsible to ensure that the identified Major Risks are
communicated to the employees and stakeholders by publishing annual Corporate Risk Register
on OGDCL website

Corporate Risk Management Team shall review the Risk Register “annually”. Furthermore,
Corporate Risk Register must be reviewed when there is:

• A change in the nature of the activities / processes / services takes place.

• Development in appreciation of the relevant hazards and risks e.g. new guidance or
legislation.
• Incidence of major accident.

2. Job Vulnerability and Hazard Analysis:

Purpose:
A JVA/ JHA shall be intended to provide a structured approach to identifying hazards and
incorporating controls measures for those hazards related to tasks.

JVA/ JHA shall be required for any task performed under a Permit to Work (PTW). However,
there may be exceptions; In such cases, the rationale for not conducting a JVA/ JHA should be
clearly stated on the PTW template.

Page | 8
Industrial Health and Safety Mini Project # 01

Requirement for JVA/JHA:

Jobs with the worst accident history shall have priority and should be analyzed first.

JVA/ JHA will be based upon following factors:

Frequency of Accidents: a job has repeatedly caused near hits or accidents is a candidate for
JVA / JHA. Rate of Disabling

Injuries: Every job that has caused disabling injuries should be given a JVA / JHA.

Severity Potential: Some jobs may not have a history of accidents but may have the potential
for a severe injury (high impact ratings).

New Jobs: Analyses of new jobs and jobs where changes have been made in processes and
procedures should follow.

SIMOPS (Simultaneous Operations) Jobs: Jobs that involve a number of functional groups or
disciplines.

JVA/JHA Development Team:

The Team shall constitute of the following members:

• Team Lead: Representative from exploration, construction, seismic, production,

maintenance or drilling (depending on the scope of work). This person should be
experienced in the work and at least at supervisor level.
• Representative(s) at the “hands on” level – ideally, the Job Supervisor who will directly
oversee the execution of the Job
• Technical specialists / engineers who can bring additional knowledge to the assessment
(if required) Location HSE Rep. (if required)
• At a minimum one representative from every discipline or contractor involved in
execution of job

JVA/JHA Responsibilities:
• It shall be the responsibility of Job Supervisor to coordinate and conduct JVA / JHA prior
to execution of the task.
• Location HSE Representative shall communicate the requirements laid down in this
procedure to all employees and contractor’s management.
• For activities to be carried out by projects personnel or any contractor inside plant
boundary / live areas / process areas (i.e. Brown field), all risk assessments shall be
reviewed and endorsed by Permit Issuer.

Page | 9
Industrial Health and Safety Mini Project # 01

• In green field (development of new facility / construction sites / projects) outside of

plant boundary; all JVAs/ JHAs shall be reviewed and endorsed by designated person as
authorized by Location IC.

3. Legal and Other Requirement:

HSE Department shall be responsible for identifying the applicable regulatory and other
requirements.

HSE Regulatory Requirements shall include the national/ local regulations related to
environment, occupational health & safety. These may include:

• Directorate General Petroleum Concession (DGPC) Guidelines

• Oil & Gas Safety Regulations (Mines Act)
• IEE/EIA Regulations (Pakistan Environmental Protection Act)
• Oil and Gas Regulatory Authority (OGRA) Rules & Regulations
• Exploration and Production Rules (Petroleum Act)
• National Environmental Quality Standards [NEQS] Rules[Pakistan Environment Act]
• Electricity Rules [Electricity Act]
• Wildlife Protection Ordinance [Federal/ Provincial]
• Explosives Rules
• Pakistan Nuclear Regulatory Authority (PNRA) Regulatory Guides  All applicable laws,
regulations and other requirements shall be listed in the Regulatory Requirements
Matrix, which is maintained by the HSE Department

Access of Other Regularity and Other Department:

Information related to regulatory and other requirements shall be obtained by contacting the
regulatory bodies, browsing the official websites or through industrial associations.
HSE Department shall track legislative and regulatory developments applicable to the oil & gas
industry and area where the facility is located. The information shall be acquired from internal
and external sources.
HSE Department shall respond to the applicable changes by updating the Regulatory
Requirements Matrix. The format of Regulatory Requirements Matrix is mentioned below:

News and Modified Activities:

Changes to, and development of new activities, processes and services may change OGDCL
legal and regulatory obligations. Such changes include:

• Changes in processes and technology, and introduction of new processes/ material

substitution;
• Increase, reduction, or modification of the point of sources of emissions and discharges;

Page | 10
Industrial Health and Safety Mini Project # 01

• Changes in the inventory of chemicals and other regulated substances;

• Significant expansion or reduction in business activities;
• Facilities addition or relocation.
• Temporary projects, such as construction, installation of new equipment

Departmental heads shall be responsible for identifying changes in activities, processes and
services that may change the facility's legal and regulatory obligations, and to communicate the
same to the HSE Department/ Section.

Relevant changes may also be identified by the Location HSE Management Review Committee
(MRC) meetings or by internal or external audits of the HSE System.

The HSE Department shall review the reported changes and determine their legal and
regulatory impact and impact. When the change triggers new regulatory requirements, the
Regulatory Requirements Matrix shall be updated accordingly.

Based on the changes / amendments in the legislative requirements, HSE Department / Section
shall seek any change(s) in the Risk Register and any need to modify & implement relevant HSE
Objectives and Management Programs in consultation with all stakeholders

4. HSE Objectives and Management Program:

Five Years Strategies HSE Plan:

The Five Year Strategic HSE Plan shall be the cornerstone of HSE Planning and Goal Setting.
Development of Five year plan shall be of strategic process because it involves the best way to
respond to the circumstances of business environment whether or not these are known with
any degree of certainty. Being strategic, means being clear about objectives, being aware of the
organization’s objectives and resources, and incorporating both to be able to respond to a
dynamic environment.
The process shall be about planning as it involves intentionally setting goals (i.e. choosing a
desired future) and developing an approach to achieving those goals. The process of developing
the Five-year plan shall involve strategic thinking and this means asking “are we doing the right
things”. More precisely it means making an assessment using three key requirements of
strategic thinking: -

• A definite purpose (end) be in mind.

• An understanding of the business environment risks (particularly the forces that impact
or impede the fulfillment of that purpose);
• Creativity in developing effective responses to those forces.

Page | 11
Industrial Health and Safety Mini Project # 01

Annual HSE Plan:

The annual plan is the next level down from the five year strategic plan and can be more
detailed. The Five Year Strategic HSE Plan states what company intends to achieve while the
Annual HSE Plan sets specific HSE Goals & Targets.

The Annual HSE Plan shall be rolled out on the start of each year and then subsequently every
year. The Annual HSE Plan shall be: Developed by GM HSE; reviewed and agreed by HODs /
management team member.

HSE Objectives and Targets:

All locations shall establish HSE Objectives & Targets based on Annual HSE Plan. As next level
down from the Annual HSE Plan, the location HSE Plan shall be much more detailed with all
Objectives and Targets further subdivided into actions and responsibilities i.e. Management
Programs (Strategy). Progress – actual versus planned – shall be monitored and discussed in
HSE Management Review Committee (MRC) Meetings.  The Location HSE Plan shall be
developed and rolled out within one month of the rollout of Annual HSE Plan. The Location HSE
Plan shall: Derive its inputs from Annual HSE Plan; based on the results of HSE Risk Assessment
activities, HSE Section in consultation with the Sectional ICs, shall set the Objectives & Targets
to control the Significant Risk Ratings. These shall be reviewed by the concerned Sectional IC
and then discussed in the Location HSE MRC meetings, where they may be approved. The
approved targets shall be kept with the HSE Department/ Section and displayed on notice
boards, bulletin boards, and/ or electronic/ print media for easy access to employees and
stakeholders. Progress reviewed by Location Management on fortnightly / monthly basis

Setting Objectives and Targets:

The objectives shall define the goals to be achieved given in subjective terms and the target is
the measurable and specific indicator related to objective. Overall following SMART approach
shall be adopted:

• Simple
• M: Measurable
• A: Attainable
• R: Realistic
• T: Time-bound

While executing SMART approach, impact (risk) control hierarchy shall be used to fill the HSE
variances (as appeared from the results of HSE Risk Assessment); the detail is tabulated below
(not exhaustive):

Page | 12
Industrial Health and Safety Mini Project # 01

First Layer (IPL1) – Prevention through Engineering Controls: focuses on the source of
vulnerabilities & threats and at designing the job and conditions to eliminate or reduce their
exposure

Second Layer (IPL2) – Mitigation through Engineering Controls: focuses on the aftermath of
impact at initial level to eliminate or reduce its spread

Third Layer (IPL3) – Administrative Controls: focuses on limiting the exposure to vulnerabilities
& threats by controlling through practices

Fourth Layer (IPL4): Educational Controls  Fifth Layer (IPL5): Personal Protective Equipment
(PPE)

HSE Management Program:

For each HSE objective and associated targets, the concerned Departmental/ Sectional head in
consultation with HSE Department/ Section shall establish the Management Program (Strategy)
to achieve the objective and target. HSE Management Programs shall be defined on the
Objective Sheet, which includes:

• HSE objective and targets that are to be achieved.

• Areas/ departments where the program needs to be implemented;
• Methods and means to achieve the objective.
• Responsibility for defining and implementing the program. e) Timeframe for completing
the program and/or its elements or phases;

Location HSE MRC shall review and discuss the HSE Management Programs for
implementation. Planning, implementation and review of HSE

Management Programs shall offer reassurance with regard to:

• ongoing compliance with regulatory requirements,

• ongoing training of field personnel,
• minimization of the volume and toxicity of the wastes and prevention of accidents &
• appropriateness/ feasibility of the program itself

Final Review and Closeout:

HSE Department/ Section shall monitor the progress of HSE Management Programs on
fortnightly basis or as deem practical depending upon the nature of case and reports it to the
management immediately or in the Location HSE Management Review Committee (MRC)
meetings. Progress shall be recorded on the HSE Management Program Sheet.

Page | 13
Industrial Health and Safety Mini Project # 01

When an HSE Management Program achieves its objectives and targets, the results shall be
reported to the Location HSE Management Review Committee (MRC), which reviews and
verifies the implementation of the management program and if found satisfactory, shall close
out the management program

The achievement of HSE Objectives and Targets shall also be reported in the Location HSE
Management Review Committee (MRC) meetings.

Conclusion:
After reviewing the clauses given in the ISO 45001 and comparing the standards followed in our
selected industry OGDCL, we have concluded that OGDCL follows most of the standards. The
Health and Safety policies are one of the core principles of the industry.

Page | 14