Professional Documents
Culture Documents
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
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
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
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
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
Acronym
: PP (M) SB
Shareholding
: 100%
Business
: Activity Oil
Contact
: Managing DirectorICEO
Address
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
Date Incorp
: 19 September 1987
Principal Activity
Business Activity
PETRONAS Melaka Refinery Complex consists of two refineries.
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
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
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.
Employee
Management or
Design Error
Characteristic
PNatural
Factors
_,
Hazard
A
Job Characteristics
Operator
Error
Physical Environment
Accident1
Injury
2.3
ii.
employee engagement
iii.
accountability
iv.
v.
vi.
vii.
viii.
ix.
x.
xi.
xii.
xiii.
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
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
slrategk
d,jecwes
Rfudon,
ares and
nwtatlon
44
iI,
'I4
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ad
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'.
/C
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MI
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rgement
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4
II4
a u d i t
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.
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.
implementation;
ii. initiation of action to ensure compliance with HSE policy;
iii. acquisition, interpretation and provision of information on HSE matters;
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.
IdentifL
applicable
statutory
requirements
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,
ii.
address effects and risks arising fiom both human and hardware factors;
iii.
solicit input from personnel directly involved with the risk area;
iv.
v.
vi.
Evaluation of health and safety risks and effects should include, where
appropriate, consideration of:
i. Fire and explosion.
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.
iii.
iv.
resource requirements;
v.
vi.
HSE culture;
vii.
viii.
ix.
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.
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
2.6
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
2.7
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.
2.9
All plants have been study on hazard and operability (Hazop) during the
design phase.
ii.
iii.
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.
i.
ii.
iii.
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.
ii.
Vessel entry
iii.
Excavation
iv.
Electrical
v.
Crane Work
vi.
Scaffolding
vii.
viii.
Working at heights.
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.
ii.
iii.
Risk Management
iv.
Permit-to-Work System
v.
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
i.
ii.