18062_Innovative Risk Management on the Barzan Onshore Project (final)

18062-MS

Innovative Risk Management on the Barzan

Onshore Project

Robert DeHart II, RasGas Barzan Onshore Project

Johnny Brand, JGC Barzan Onshore Project

Introduction (What is Barzan?)

OBJECTIVE

• Develop a sour gas processing facility, located

within Ras Laffan Industrial City, Qatar

• Provide natural gas for Qatar’s domestic market

• Vital to help fuel the growth for Qatar’s

development

Slide 2

18062 • Innovative Risk Management on the Barzan Onshore Project • Robert DeHart / Johnny Brand

PROJECT EXECUTION

• A joint venture between Qatar

Petroleum and ExxonMobil

Barzan Limited with RasGas

Company Limited© entrusted as

the developer and operator and

JGC as the Engineering,

Procurement and Construction

(EPC) contractor for the work

Introduction (Construction Progress)

Slide 3


Pre -Early Site Works - 2010

Post Early Site Works - 2011 Barzan Site - 2012 Barzan Site - 2013

Barzan Site - 2014

Introduction (Barzan Overview)

Slide 4


CONSTRUCTION WORK SCOPE

• 3.8 million inch-diameter shop and field welding

• 42,151 tonnes of steel structures

• 4.1 million metres of electrical and instrumentation cable

• Work carried out on 800 acres of fenced site

• Erection of a 172 metre flare stack (tallest in Ras Laffan)

CHALLENGES

• Workforce peaked at 30,000 workers with 8 major sub-contractors

• 45 nationalities with 20 primary languages spoken

• 6 months of high temperatures and humidity with heat index at 50

or higher on most days from mid-May thru mid-September

Introduction (Record and System)

Slide 5


SAFETY RECORD

• The project has completed 200 million man-hours on 10 Nov 2014

with world-class safety performance.

• Comparison is shown below with KPI’s of the International Oil & Gas

Producers 2012 annual report (Global and Middle East Region)

Indicator Barzan

(as of 25 Oct 2014) OGP Global OGP Middle East

Fatality Accident Rate 0 0.005 0.004 Lost Time Injury Rate 0.006 0.096 0.05 Total Recordable Incident Rate 0.181 0.348 0.204

HOW DID WE GET THERE?

Cornerstones of the Safety, Health, Environment & Security (SHE&S)

programme are:

• SHE&S Management System

• SHE&S Training

• Worksite Hazard Identification

• Observation and Intervention

• Worker Recognition Programme

• Worker Welfare

Introduction (Safety Culture)

Slide 6


MANAGEMENT COMMITTMENT

• Active engagement with the workers at site / visible to the workforce

• Daily Tool Box Talk / Task Instruction attendance by management

• Bi-Monthly management safety walk with project management team / EPC

Contractor / Sub-Contractors

• IIF (Incident and Injury Free) activities such as: site walks for day and night

shifts; having lunch in the camps with workers; “frequent” handshakes and

greetings to engage with workers at site and in the camps; etc.

WORKER INVOLVEMENT

• Various tools used to instill responsibility within all levels of the project

workforce, including “stop work intervention cards”

• Continual demonstration of genuine care and concern for the workers

• Creating safety ownership through positive interactions

• Observation and intervention programme involving workers and supervisors

• Workers’ responsibilities for their own safety, and the safety of others

Emergency Response and Coordination (Introduction)

Slide 7


WHY IS IT IMPORTANT?

• Site with 30,000 workers / 5,000 vehicles and equipment

• Daily work at height and confined space work (day and night)

• Potential for injuries and worker illnesses

• Detailed emergency response plans developed and implemented

• Regular testing and drills of plans and procedures

Emergency Response and Coordination (Overview)

Slide 8


EMERGENCY COORDINATION

• Established a Security Operations Centre

(SOC) and Incident Coordination Centre (ICC)

• SOC operates 24 / 7 and receives and

coordinates all incident and emergency calls

• Provides updates through SMS text system and

mobilises response teams

EMERGENCY RESPONSE

• Mobilised and trained a 10 man rope and confined space rescue team and

10 medical responders

• The team is based in 3 locations at site and responds 24 / 7 to emergencies

Emergency and Coordination (Achievements)

Slide 9


EMERGENCY COORDINATION

• 2,995 emergency calls logged (SOC reports)

• 18 ICC call outs with the Project Incident

Management Team

EMERGENCY RESPONSE

• 4,382 confined space entry and working at

height task inspections

• 640 confined space Permit To Work protocol

surveys completed

• 737 training hours spent

• 24 rescues from height carried out (two at

the 40+ metre level)

Health Management (Introduction)

Slide 10



• The manpower on site is similar to a small town (30,000)

• Worker welfare is a top priority for the project

• Wide variety of health risks (construction and commissioning)

• Chronic illnesses

• Communicable diseases

• Potential for injuries and illness both on site and in camp

Health Management (Overview)

Slide 11


HEALTH MANAGEMENT SYSTEM

The key functions of the Health Department include (but not limited to)

• Pre-employment screening

• Absence management

• Fitness and return to work

• Health monitoring

• Counselling and rehabilitation

• Heat stress management

• Drug and alcohol management

The project organisation and resources

• 100 medical staff (nurses / doctors)

• 6 medical facilities at site and camp

• 12 response vehicles (SUV’s)

Health Management (Overview)

Slide 12


• Health & Communicable Disease

Risk Assessments

• Camp Health and Welfare

• Fitness for Duty

• Occupational Hygiene

• Absence Management

• Heat Stress Management

• Medical Facilities Procedures

• Infection Control

• Potable Water

• Alcohol and Drug Monitoring

• Respiratory and Hearing

Protection

HEALTH MANAGEMENT SYSTEM

The following documents provide the framework for health management

Health Management (Achievements)

Slide 13


KEY ACHIEVEMENTS

The Health Department completed the following activities as of 25 Oct 2014

• 61,375 fitness to work exams

• 1,570,324 consultations carried out: at site MAC and in the 3 camp clinics

• 898,860 daily alcohol screening (critical positions)

• 25,491 random alcohol screenings

• 33,572 “worker presentations” (illnesses) in the 3 camp clinics

• 2,419 chronic illness patients identified, registered and managed

• 737 cases of communicable diseases identified, registered and managed

Man-Machine Interface (Introduction)

Slide 14



• More than 5,000 vehicles and equipment during peak

• High exposure to pedestrian traffic hazards (30,000 persons)

• Initial low pedestrian safety awareness of site workforce

• High potential impact and frequency of exposure = high risk

• Example = Bus Drop off + pick up (6 x per day) x 25,000 direct workers

Man-Machine Interface (Overview)

Slide 15


MAN-MACHINE INTERFACE SYSTEM KEY ELEMENTS

• Pedestrian safety programme developed

• All vehicles fitted with In Vehicle Monitoring System (IVMS) units

• Inspection and maintenance system for all vehicles and equipment

• Panel setup to review traffic violations

• Bus and equipment rodeo programme

• Banksman and flagman mandatory for equipment / crane movement

Man-Machine Interface (Achievements)

Slide 16


KEY ACHIEVEMENTS

• 7,300 plus vehicles and equipment inspected

• 1,976 IVMS units fitted with 2,262 registered IVMS users

• 95.1 million kilometres driven to date without a serious road traffic

accident

• Over 2,000 flagman and equipment operators jointly trained

• 300 participants in the bus rodeo programme

• More than 1,600 participants in the man-machine rodeo programme

• Over 50,000 multi-language (8 different languages) “Pedestrian and

Vehicle Safety” brochures published and issued site-wide

• 1,709 cases reviewed by the traffic panel

Heat Stress Management (Introduction)

Slide 17



• Heat Stress season in Qatar (April 1-October 31)

• High heat index in excess of 50 during peak summer months

• Humidity levels reach 90 % and temperatures reach 450C

• Site manpower working through the summer months

• “High risk activities” – scaffolding, work at height, confined space

PREVENTIVE HEAT STRESS WORK PRACTICES TO MINIMIZE THE

EFFECT OF HEAT EXPOSURE

FLAG

COLOR

HEAT

INDEX

WORK

: REST

PERIO

D (min)

WATER

CONSUMPTION

(1 Cup = 250 ml)

CONTROL EXAMPLES

GREEN 27 – 31 50 : 10 1 Cup every 20

Minutes

Continuous Visual

monitoring of workers in

direct sun and heavy work

YELLOW 32 – 38 40 : 10 1 Cup every 20

Minutes No Working alone

ORANGE

39 – 49 30 : 10 1 Cup every 15

Minutes Work under Shade

50 – 53 20 : 10 1 Cup every 10

Minutes

Elevated and Confined

Space Work Stopped

RED ≥54

STOP WORK (Note: Safety/Integrity Critical Activities will be

allowed to continue subject to maximum 20 min. of work and

minimum of 20 min. rest all as per approved risk assessment and

proper control measures in place. This will be done through

normal PTW. (Exclusions applies to all emergency response

teams.)

Heat Stress Management (Overview)

Slide 18


HEAT STRESS MANAGEMENT SYSTEM

The programme control measures include engineering, administrative,

personal and high risk control measures. The innovative areas include

• Fluid replacement

• Acclimatisation

• Food and drink supplements

• PPE (Personal Protective Equipment)

• High risk activities

• Heat stress monitors

• Mandatory refresher training

• Weekly management review meetings

Heat Stress Management (Achievements)

Slide 19


Key achievements

The key accomplishments included;

• 50% reduction in heat illness frequency from 2013 to 2014

• No serious illnesses / injuries

• Refresher training carried out for 30,000 persons

Hea

t S

tre

ss F

req

ue

ncy R

ate

(H

SF

R)

an

d

Hea

t In

de

x (

HI)

A

ve

rag

e

No.

of H

ea

t S

tre

ss (

HS

) C

ase

s

Conclusion

Slide 20


Achievements, Awards and Recognition

• Most significant achievement is the safety culture established on the

project

• The project delivered world class results to date and the four elements that

were covered in this paper significantly contributed to this result

• 130M man-hours without a LTI from July 11, 2012 to March 23, 2014

• Held six camp concert celebrations to recognise workers for 20M, 50M,

80M, 100M, 130M (million man-hour LTI free) and “Finish Strong” camp

celebration – all concerts held with professional entertainers

• Barzan EPC Contractor awarded Qatar Petroleum’s “Gold Award” for

SHE&S Excellence and Innovation for 2012 and 2013

• Barzan EPC Contractor awarded the British Safety Council International

Merit Award for 2014

• SPE Oil & Gas Facilities Journal, October 2014, Vol. 3, No. 5, pp. 53-64,

“Barzan Onshore - Gas - Facilities Construction – Attaining Excellence thru

a Comprehensive SHE&S Management System”… see www.spe.org/ogf

http://www.spe.org/ogf

Thank You / Questions

Slide 21

18062_Innovative Risk Management on the Barzan Onshore Project (final)

Documents

Transcript of 18062_Innovative Risk Management on the Barzan Onshore Project (final)