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Management of Workplace Safety, Health and

Environment

CN3135

Soh Guat Hiong

10/21/2015 NUS CN3135 SHE Management 2

Learning Outcomes

1. Describe the elements of SS506: Part 3: 2013 for Chemical Industry

2. Meet legal requirements of SHE management

3. Application of permit to work system


SHE Management System

• A systematic process for managing SHE, providing for goal setting, planning, performance measurements, and clear management commitments and direction

• Helps create a safer work environment, provide a measureable system to verify SHE performance, improve business opportunities, and enhance an organisation’s reputation and image

710/21/2015 NUS CN3135 SHE Management

SHE Management Systems

A commitment by the organisation to:

• Provide a safe and health workplace for employees and contractors

• Identify workplace hazards, conduct risk assessment and control of all risks

• Managers, supervisors and employees be actively involved to prevent incidents and ill-health at the workplace

• Provide information and training for employees at all levels so they can work safely

• Audit and review the SHE management system


Workplaces to Implement WSHMS

2nd Schedule, WSH (Safety and Health Management System and Auditing) Regulations 2009

• Worksite

• Shipyard

• Manufacturing of metal products, machinery or equipment with >100 workers

• Manufacturing or processing of petroleum, petroleum products, petrochemicals or petrochemical products

• Bulk storage of toxic or flammable liquid >5000m3


Workplaces to Implement WSHMS under WSHA

• Manufacture of fluorine, chlorine, hydrogen fluoride, carbon monoxide and synthetic polymers

• Manufacturing of pharmaceutical products or intermediaries

• Manufacturing of semi-conductor wafers

• Audit to be conducted once every 2 years


Workplace Safety and Health (Registration of Factories) Regulations


Examples of SHE MS

• SS506: Part 1: 2009 Occupational Safety and Health Management Systems – Requirements

• SS506: Part 1: 2009 Occupational Safety and Health Management Systems – Guidelines for Implementation

• SS506: Part 3 : 2013 Requirements for Chemical Industry

• OHSAS 18001 : 2007 Occupational Safety and Health Management System

• ISO14001: 2004 Environmental Management Systems (revision due in 2015)


Plan-Do-Check-Act Cycle


Establish

objectives

and

Processes

Implement

Processes

Monitor and

measure

processes

against policy,

objectives &

legal /other

requirements

Take Actions to

Continually Improve

OSH Performance

Commitment

to OSH

a) Occupational Safety and Health Policy

• Top management endorsement

• Appropriate to nature and scale of OSH risks

• Comply with legal and other requirements

• Communicated to all employees and other stakeholders under control of organisation

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Key Requirements of SS506: Part 3 : 2013



• Highest Standards of Performance, Business Excellence

• We will adhere to the highest standards for the safe operation of facilities and the protection of our environment, our employees, our customers and the people of the communities in which we do business. We will manage security as we do safety.

• We will strengthen our businesses by making safety, health and environmental issues an integral part of all business activities and by continuously striving to align our businesses with public expectations.

DuPont Position Statement on Safety, Health, and Environment Commitment


• Committed to Zero Injuries, Illnesses, and Incidents

• We believe that all injuries and occupational illnesses, as well as safety and environmental incidents, are preventable, and are committed to a goal of zero for all of them. We will promote off-the-job safety for our employees.

• We will assess the environmental impact of each facility we propose to construct or acquire and will design, build, operate and maintain all our facilities and transportation equipment so they are safe, secure and acceptable to local communities and protect the environment.

• We will be prepared for emergencies and will provide leadership to assist our local communities to improve their emergency preparedness

DuPont Position Statement on Safety, Health, and Environment Commitment

Petrochemical Corporation of Singapore

• Process Safety Policy• Process safety leadership from top management level,

discussing process safety in board meetings, such as reviewing process safety indicators and performance.

• Demonstrating visibility and visible commitment of top management, through site visits and open dialogues.

• Providing a positive, trusting and open culture where PCS employees and workers are encouraged to speak out without fear or reprisal and their views on safety.

• Enhancing engineered and administrative safeguards that act to achieve or maintain a safe state of process.

• Process safety improvement plan identifying priorities for ensuring system and safeguards retain their integrity, with continual improvement.


Petrochemical Corporation of Singapore

• Process Safety Policy

• Implementing an integrated set of leading and lagging performance indicators, which are periodically updated.

• Comprehensive maintenance program and timely rectification of faults with adequate repairs.

• Suitable training and transfer of knowledge and learning of good practices.

• Reviewing industry incidents and recommendations across major hazard sectors for learning lessons and improvement.

• Recognizing changes and ensuring that they are appropriately documented, reviewed, approved and communicated.


b) Planning

⁻ Hazard identification, risk assessment and risk control

⁻ Legal and other requirements

⁻ Setting objectives and programmes



• Hazard Identification, Risk Assessment and Control

• Proactively identify all hazard sources, situations or acts that has potential to cause harm

• Routine and non-routine activities (including emergencies)

• Human behaviour, capabilities and other human factors

• Infrastructure, equipment and materials used

• New, including changes made

• Control measures and mitigation methods for worst case scenario

• Applicable legal requirements



• Hazard Identification, Risk Assessment and Control

• Process Safety Information required

Hazards of chemicals – Toxicity, PELs, physical/chemical properties. Get from Safety Data Sheet

Technology of process – Process flow diagram, inventory, operational limits, WSH consequences of deviation

Equipment, hardware and facility – Safety system, interlocks, detection, suppression systems, materials of construction, P&IDs, relief system, ventilation system design



Risk Assessment• Hazard Identification:

⁻ Physical (e.g. fire, noise, ergonomics, heat, radiation)

⁻ Mechanical (e.g. moving parts, rotating parts)

⁻ Electrical (e.g. voltage, current, static charge, magnetic fields)

⁻ Chemical (e.g., flammables, toxics, corrosives, reactive materials)

⁻ Biological (e.g., blood-borne pathogens, virus)

⁻ Psychosocial (e.g., stress, fatigue)


Risk Evaluation

Likelihood

Severity

Rare -

1

Remote -

2

Occasional -

3

Frequent -

4

Almost

Certain - 5

Catastrophic - 5 5 10 15 20 25

Major - 4 4 8 12 16 20

Moderate - 3 3 6 9 12 15

Minor -2 2 4 6 8 10

Negligible - 1 1 2 3 4 5


Source: Code of Practice on Risk Management, Workplace Safety and Health Council


Risk level Risk

Acceptability

Recommended Actions

Low Acceptable • No additional risk control

measures

• Frequent review and

monitoring of hazards

Medium Tolerable • Ensure risk level is reduced

to as low as reasonably

practicable

• Interim risk control

measures

Risk Evaluation


Risk Evaluation


Risk

level

Risk

Acceptability

Recommended Actions

High Not Acceptable • High Risk level must be

reduced to at least Medium

Risk before work starts

• No interim risk control

measures

• If practicable, hazard should be

eliminated before work starts

• Management review required

before work starts


Tools for hazard identification and risk evaluation

What-if Checklist

Job Safety Analysis

FMEA

Fault Tree Analysis

HAZOP



Risk Control • Elimination – eliminate the hazard eg. use

mechanical lifter instead of manual lifting

• Substitution – substitute with a less hazardous equipment or material eg. use bore piling instead of hammer piling for a less noisy operation

• Engineering control – use physical means to control the hazard eg. local exhaust ventilation to remove chemical hazard at source, install enclosure over machine to reduce exposure to loud noise



Risk Control• Administrative control – implement safe work

procedures, permit-to-work system, job rotation, install warning signages

• Personal protective equipment – use as last resort eg. safety helmet, safety glasses, respirators, protective clothing and gloves, safety boots.



• Ongoing review to:• Assess effectiveness of control measures

• Identify any new hazards which may arise from changes in operation

• Respond to feedback from employees

• Findings from any incident investigation and emergency situation



• Legal and Other Requirements

• Applicable legal and other requirements

• WSH requirements from clients or industry



Meeting Legal Requirements

• Workplace Safety and Health Act

• Came into effect 1st March 2006

• Covers ALL workplaces

• Managing WSH proactively. Requires stakeholders to take reasonably practicable measures to ensure S&H of workers and other people affected by work being carried out




• 3 Guiding Principles

Reduce risks at source - eliminate or minimise risks created by stakeholders

Instil greater ownership of S & H outcomes by industry

Higher penalties for poor safety management




• Specify liabilities for a range of persons at the workplace

• Focus more on WSH goals and systems

• Greater penalties for compromising safety and health


Workplace Safety and Health Act

• Examples: Convictions in 2015


Subsidiary Legislation


• Objectives and Programmes

• Set OSH objectives to meet commitment found in OSH policy

• Achieve objectives by implementing OSH programmes

• Programmes must have action plan, persons responsible, resources required, tasks to be performed and target completion dates


Key Requirements of SS506: Part 3: 2013

• Examples of objectives are:

• Reduce noise level in the process plants to below 85dBA

• Achieve 100% attendance in WSH training

• Organise 5 WSH programmes to increase workers awareness to workplace safety and health




c) Implementation and Operation⁻ Resources, roles, responsibility & accountability

⁻ Competence, training and awareness

⁻ Communication, participation and consultation

⁻ Operational control

⁻ Occupational health

⁻ Emergency preparedness and response


• Resources, Roles, Responsibility, Accountability and Authority Top management takes ultimate responsibility for

OSH and OSH management

Visible leadership

Performance based approach to achieve objective

All stakeholders take ownership of OSH outcomes



• In-house OSH Rules and Regulations

Operating procedures and safe work practices

Incident and hazard reporting

OSH training requirement

Use of personal protective equipment

Housekeeping and cleanliness

Fire prevention

Rules communicated, readily available to employees and contractors



• Competence, Training and Awareness

• Training needs identified for each level of employees and contractors

• Competence – education, training, relevant experience

• OSH policy, safe work procedures and practices, OSH hazards, roles and responsibilities & consequences of departure from specified operating procedures

• Effectiveness of training

• Promotional OSH programs – Improvement teams, tool box meetings, talks



• Communication

• OSH hazards and its OSH management system should also be communicated to:

• Employees

• Contractors and suppliers

• Visitors

• Other external interested parties



• Participation and Consultation

• Hazard identification, risk assessments and controls

• Incident investigation

• Development of OSH policies and procedures

• Changes that can affect OSH impact

• Include contractors



• Operational Control

• Used to manage OSH risks to an acceptable level and comply with applicable legal and other requirements

• To consider:

Routine operations, including maintenance

Non-routine operations – start-up, shutdown, foreseeable emergency operations (eg. chemical spills)

Managing hazardous substances

Managing process safety requirements



• Operational Control

• Include consequences of deviation, steps to correct or avoid deviation and safety systems and their function

• Special precautions

• Special or unique hazards – eg dust explosion, cryogenic liquids



• Pre-start up safety for new facilities and modified facilities

• Safe work procedures and practice – include permits-to-work

• Mechanical integrity and reliability - check process equipment to ensure that they are designed and installed correctly

• Control of hazardous substances

• Occupational health – hearing, respiratory protection, ergonomics

• Emergency preparedness and response (eg. chemical spills)



• Management of Change

• Means and methods to detect changes

• Design basis for change

• Analysis of possible OSH hazards – apply process hazard analysis

• Authorisation requirements

• Verification of change



d) Checking

• Systematic way to measure and monitor the OSH performance on a regular basis

• Performance measurement and monitoring

• Calibration of instruments

• Evaluation of compliance

• OSH inspection

• Incident investigation, non-conformity, corrective action and preventive action


Process Safety Indicators

• Leading Indicators - monitor proactively the

effectiveness of risk control systems and provide

feedback on safety performance before an incident or

accident happens

• Lagging Indicators – when desired safety outcome

has failed. Monitor reactively the effectiveness of risk

control systems, identify gaps and weaknesses in

these systems, and report on incidents or accidents


• Process Safety Indicators Examples



Swiss Cheese Model


../../Videos urls/Videos/Part 2 The Swiss Cheese model.exe

../../Videos urls/Videos/Part 2 The Swiss Cheese model.exe

Conducting Root Cause Analysis

54

Incident Investigation

• Root Cause Analysis Tools

Cause and Effect Analysis

5 WHYs

FMEA

Fault Tree

HAZOP


56

Cause & Effect Analysis


CHEMICAL BURN DURING BLENDING OPERATION

Source: Case Studies: Chemical Industry, WSH Council

Incident Investigation

• Root CausesDesign problem

Control problem

Problems in operating procedure

Lack of maintenance

Management problems – resources, bad decisions


Process Safety Hierarchy

• Inherent – Completely eliminate or significantly reduce hazards

• Passive – Safety feature added does not require action by any device or person eg. secondary containment, welded fittings vs flanges

• Active – Add safety shutdown systems eg. safety interlocks

• Procedural – Standard operating procedures, emergency response procedures, rules, training


Process Safety Strategies

Designs for Process Safety

• Inherently safer designs – permanently eliminates and reduces hazards

• Modification in one area may increase or decrease risk in another area

Moderate: Use milder conditions

Substitute: Replace with less hazardous chemicals

Minimise: Use smaller quantity

Simplify: Easy to use designs



Eliminate Working at Height and Exposure

to Hazardous Chemicals




CHEMICAL SPLASH AT PROCESS PLANT

64

In-line sampling of

chemicals. Prevent

air entering system –

minimise spillage


Eliminate Exposure to Hazardous Chemicals


ISO Tanker Work-at-Height

Scenario:

This work activity required the worker to climb-up and lay a hose to the top-opening

of the ISO Tanker. The worker accesses the top-opening via a ladder at the rear of

the ISO tanker. Current control measures include training, Safe Work Procedures

and the provision of a body harness

(of which the worker is not wearing) anchored to the top of the ISO tanker.

66

Possible Solution

67

68

Inert Blanketing of Head Space in Tanks

69

Prevent Static Build Up in Tanks and Pipe Lines

Use Radar Gauge to Measure

Liquid Level

Operating Procedures

• Steps for each operating phase

• Operating limits & consequences of deviation

• Engineering and administrative controls for preventing exposures

• Controls needed for safe operation

• Permits required


Permits

• Control non-routine activities conducted in potentially hazardous environmental

• Description of hazards

• Actions to be taken – before and after work, transition to normal operating mode

• Communication of relevant information


Hot Work Permit• Issued for all hot work operations conducted on

or near a process

• Prevent ignition of flammable or combustible gases, liquids or vapours

• Welding, grinding, torch cutting, soldering, brazing & any activities that produces flames, sparks or excessive heat


Hot Work Permit

• Document fire prevention and protection measures have been put in place prior to hot work commencement

• Indicate date(s) authorised for the hot work

• Identify the object on which hot work is to be performed

• Valid for 1 shift


Hot Work Permit• Use flammable gas detector to check LEL, UEL

exceedances

• Remove all flammable or combustible materials within 35ft (about 12m) radius of hot work

• Cover with flame retardant materials

• Assign fire watch

• Fire extinguisher in area

• Compromised fire detection & protection system –smoke detector, sprinkler, alarms

• Communication

• Display of permit




FLASH FIRE DURING CHARGING OF FLAMMABLE POWDER

Lock Out/Tag Out

• Prevents injuries or damage due to accidental release of stored energy

• ALL ENERGY SOURCES: Electrical, gravitational, mechanical, pneumatic, thermal and chemical

• Unexpected motion or release

• Permit or LOTO procedure



Examples of LOTO Application

Lock Out/Tag Out

• De-energise equipment – unplug electrical connections, release pressurised lines, spring-loaded devices, filled chemicals

• Lock equipment, device, line to prevent re-activation

• Tag equipment, device

• Try to re-energise for verification

• More than 1 worker – use Gang Lock Device (HASP lock)

• 1 person, 1 key


../../Videos urls/Videos/WSHC Video/Amputation.VOB

../../Videos urls/Videos/WSHC Video/Amputation.VOB

Confined Space Entry

• Called Vessel Entry (in textbook)

• Enclosed area with limited means of access

• Not for continuous occupation

• Has restricted natural ventilation

• Include tanks, manholes, pipes, pits and silos

• May also have risk of fire and explosion or engulfment by the material in vessel


Examples


Accident Cases Involving Confined Space


Hazards in Confined Space• Insufficient oxygen

• Substances already present

– Residual petroleum vapour in storage tanks

– Contents not adequately purged

• Substances introduced during work processes

– Cleaning chemicals/solvents (e.g. acetone, trichloroethylene)

– Paint fumes (e.g. toluene, xylene)

• Substances agitated and released during entry –Sludge


Hazards in Confined Space

• Flammable Substances introduced

– Cleaning chemicals

– Paint fumes

– Leakages from adjacent tanks/pipes

• Ignition sources introduced

– Welding/cutting operations

– Spark generation

– Static discharge


Common Atmospheric Hazards


Source: Confined Space Safety Guidebook for Supervisors and Workers, WSH Council

Confined Space Entry• Legal Requirements

• Identification/ record/ warning signs/ information of all confined spaces at the workplace

• Evaluation of need for entry

• Safe means of access to and exist from confined space;

• Safe practices for opening entrance of a confined space;

• Sufficient and suitable lighting for entry into or work

• Adequate ventilation to sustain life before entry and during work in a confined space

• Procedures and control of entry into a confined space including gas testing



• Confined space entry permit issue on daily basis

• Isolate equipment – LOTO

• Continuous monitoring of oxygen concentration >19.5%

• Confined space attendant

• Communications process

• Rescue procedure



Reading Permissible Levels

Oxygen ≥ 19.5 % Vol. to ≤ 23.5 % Vol.

Flammable gases and

vapours

≤ 10% Lower Explosive Limit

(LEL)

Toxic gases and vapours ≤ Permissible Exposure Limit

(PEL) values

Acceptable limits for the atmospheric test are:


Confined Space Entry• Geometry of the space and physical properties of the gases -

different at different level

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Source: Technical Advisory on Working Safely in Confined Spaces, WSH Council


• Ventilation for confined space – Space ventilated and tested prior to entry. Continuous ventilation to ensure contaminants do not build up to a dangerous level.

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Source: Technical Advisory on Working Safely in Confined Spaces, WSH Council


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Going Beyond Compliance


Zero Harm

VISION

ZERO


Tutorial Questions• Questions 13-8 and 13-21

• Watch the 2 videos listed below. What recommendations can you give to prevent similar accidents from happening?

a) Dupont Hot Work Accident in 2012https://www.youtube.com/watch?v=PqskpvPejeU

b) Xcel Energy Company Confined Space Accident

https://www.youtube.com/watch?v=BeaX0IRjyd8


https://www.youtube.com/watch?v=PqskpvPejeU

https://www.youtube.com/watch?v=BeaX0IRjyd8


Steel Pipes Dimensions - ANSI

Schedule 40

http://www.engineeringtoolbox.com/ansi-steel-pipes-d_305.html

Thank You

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