Basic HSE Oil & Gas Processing PDF

BASIC HEALTH AND SAFETY IN OIL AND GAS PROCESSING Atuhura Nickson +256 775 706586 [email protected]  DESCRIBE PROCEDURES FOR SAFE WORKING PRACTICES IN AN OIL AND GAS PROCESSING ENVIRONMENT INTRODUCTION TO MANUAL HANDLING Manual handling is any task...

BASIC HEALTH AND SAFETY IN OIL AND GAS PROCESSING Atuhura Nickson +256 775 706586 [email protected]  DESCRIBE PROCEDURES FOR SAFE WORKING PRACTICES IN AN OIL AND GAS PROCESSING ENVIRONMENT INTRODUCTION TO MANUAL HANDLING Manual handling is any task where people physically move, handle or shift materials and objects. Examples of manual handling include: Lifting boxes on or off storage racks or shelves Carrying a package Pushing furniture or tools Sliding an object out from the floor. Pulling an object into a better position Types of injuries Damage to the spine, back muscles and Abdominal hernia ligaments Crushed limbs Amputations Muscle strains and joint wear Risks for your back Short term: Acute back injury from unique event (i.e. lifting too heavy, or in bad position) Long term: Chronic fragility/vulnerability of column Invalidity from back pain Great impact on your personal, professional and social life. Causes of injuries Overexertion - handling a load beyond the body’s capability. Repetitive actions - continually repeating certain movements or maintaining a body position for long periods. Poor workplace layout - encourages unsafe work postures and unnecessary manual handling. Incorrect technique - incorrect body positions and movements. Some ways to reduce manual handling tasks are by: Planning your work area Getting help from someone to carry heavy objects Using mechanical aids, such as hand trolleys, to move objects Finding the best possible position Safe manual lifting Size up the load to make sure it is not too heavy or too large. Assess the load to check contents will not move. Adopt a stable footing. Bend your knees and reach down to the load. Keep your back straight as you lower yourself. Grip the load with both hands.  Brace your stomach and buttock muscles. Slowly push up with your legs and keep your back straight. Never bend at the waist, always bend at the knees - it makes the job ten times easier on your back. When carrying a load, you should: Keep the load close to your body Keep the load at no more than waist to chest height Take short steps. If a load is too heavy or too large for you to lift and carry on your own, use a mechanical aid, or get someone else to assist you. To use a four-wheeled lifting aids, such as Carts and Platform Trucks: Push, rather than pull, the cart. Be aware of traffic in front of you. Allow an adequate stopping distance At the destination, secure the cart so it won’t roll. When pushing a load, you should: Place your feet apart with one well behind the other Lean forward Gradually apply your body weight Push forward with your rear foot to set the load in motion. When pulling a load, you should: Place your feet apart with one well behind the other Lay back into the line of pull Gradually apply your body weight Push backward with your front foot to set the load in motion. The Individual, Strength Is your strength height & fitness appropriate to the task? Everyone’s different! Have you been trained for the task? If you need training or information, ask your supervisor. The Load, Shape Do I need someone to help me lift? Ask for help, check the weight by tipping it and communicate clearly then check that everyone involved feels comfortable carrying the load. The Load, Hazards Do not carry large objects that will obstruct your view It is important that your field of vision is clear when lifting lowering and carrying Look out for sharp edges The Environment, Layout Is the lighting good Can the workplace be reorganized?  Obstructions should be cleared to provide enough space for correct positioning of the load. The Environment, Ground condition Is the floor uneven, slippery or unstable? Check the floor for hazards such as, oil, steps or spillage The Environment, Temperature Perspiration on hands can reduce grip Hand gloves should be used to ensure better grip Whatever you are lifting or moving: Use appropriate personal protective equipment Take special precautions when handling chemicals and hazardous materials  WORK AT HEIGHT 'Work at height' means work in any place where, if there were no precautions in place, a person could fall a distance liable to cause personal injury (i.e. a fall through a fragile roof). Scaffolding Awareness Scaffolding is a temporary work platform used for working at heights. Height is defined as anything greater than 1.8m. Falling from height remains the single greatest cause of severe injury and or death in the construction and Refining industry. Single most expensive cost related injury. Here is a simple equation for determining the required distance: Lanyard Length – The length of the lanyard or retractable device connected to the harness anchorage point. Deceleration Distance – The distance between the start of the fall to when the fall arrest system engages. OSHA limits this distance to 3.5 feet or less. Work Height – The height where the work is taking place. Safety Factor – Additional safety distance below the worker. The height and weight of the worker should also be considered when determining fall clearance.  CONFINED SPACES Confined space is space that: Is large enough & so configured that employee can bodily enter & perform assigned work Has limited or restricted means for entry or exit (i.e. tanks, vessels, silos, pits, vaults or hoppers) Is not designed for continuous employee occupancy. Issues of confined space The accidents related to work within a confined space are most of the time serious accidents or fatalities. Most of these fatalities were related to a deficiency in oxygen or to a presence of toxic gasses or flammables. 60% of these victims were workers who tried to rescue without having the necessary knowledge and equipment. Example of confined spaces A reservoir, a silo, a tank, a bunker, a chamber, a dome, a pit, a sewer, a pipe, a chimney, manhole, wagon or tanker truck etc. Employers responsibility The employer has the responsibility to draw up an inventory of all his confined spaces and to do the risk assessment, by a qualified person, to issue the safety work procedure which should be strictly followed. He has also to assure that the workers have the knowledge, an adequate training or experience in order to perform the work safely. Moreover, he has to provide them with the appropriate work and personal protective equipment which should be in good overall conditions. Oxygen deficiency The air normally contains 21% of oxygen. When the concentration in oxygen is less than 19.5% in the air, it is forbidden to enter a confined space. Thorough displacement of oxygen by other gases Many gasses, mainly inert gases (argon, nitrogen, carbon dioxide, etc.), the gasses used in the portable fire extinguishers, and refrigeration gasses, can displace the oxygen. Effects of oxygen on human body 23,5 %: Atmosphere rich in oxygen. Superior limit from which it is forbidden to enter 21,0 %: Normal oxygen concentration 19,5 %: Minimum concentration to enter in a confined space without a respirator self-rescue apparatus or with an air supply respirator 12 % to 16 %: Spasmodic breathing, anxiety, abnormal fatigue when doing some movements, insufficient concentration to keep a flame in ignition 10 % to 11 %: Acceleration in breathing and heart rate, euphoria, headaches. 6 % to 10 %: Nauseas and vomiting, inability of moving freely, possibility of loss of consciousness and collapse while being conscious Less than 6 %: Breathing failure followed by heart failure, death in a few minutes. Oxygen Enriched Atmospheres Enriched Oxygen levels cause flammable and combustible materials to burn violently when ignited. ▪ Hair, clothing, materials, etc. ▪ Oil-soaked clothing and materials. Never use pure oxygen to purge/vent equipment. Never store or place compressed tanks in a confined space Toxic substances atmosphere A toxic atmosphere contains gasses, vapors or smoke well-known to have noxious (harmful) effects on human body. The toxic effect is independent from the oxygen concentration. If possible, try avoiding confined spaces ✓ The first question to ask when elaborating a Contingency Plan in confined spaces is the following: Could we avoid entering in confined spaces? ✓ Are there all sorts of methods allowing to achieve the same results without entering in a confined space? For instance, the use of cameras and Robotic equipment. Qualified persons: The attendant Individual stationed outside one or more permit spaces who monitors authorized entrants & performs all attendant’s duties assigned in employer’s permit for confined space program. Duties of Attendants Know hazards that may be faced during entry Aware of possible behavioural effects of hazard exposure in authorized entrants Continuously maintain accurate count of authorized entrants Remain outside permit space during entry operations until relieved by another attendant Communicate with authorized entrants Monitor activities inside & outside space Summon rescue & other emergency services Perform non-entry rescues as specified by employer's rescue procedure Perform no duties that might interfere with primary duty to monitor & protect authorized entrants The attendant should not enter in the confined space to make the rescue if all the conditions mentioned below are not respected: o He is also trained to enter in the confined space to make the rescue. o He has the personal protective equipment required. o He is replaced by another attendant. Authorized Entrant Duties of Authorized Entrants  Know hazards that may be faced during entry, including information on mode, signs or symptoms & consequences of exposure.  Properly use equipment and trained.  Communicate with attendant as necessary to enable attendant to monitor entrant status & enable attendant to alert entrants of need to evacuate space. Do not enter a confined space without hands-on training in use of equipment. Respiratory protection Breathing apparatus are not required when atmospheric conditions in the confined space are compatible with the following criteria: ❑ Oxygen concentration higher than 19.5% and lower than 23.5%, ❑ Gas or flammable vapors concentration lower than 10% of the Lower Explosive Limit (L.E.L.), If the atmospheric conditions do not correspond to the standards previously mentioned. The area should be considered as being hazardous or as an area representing an immediate danger for the health and life. A special equipment should then be used (Robotic Equipment). The respiratory protection choice is done by a gradual elimination of the inappropriate respirators according to the current conditions. Supplied Air Respirators  During Confined space rescue, conventional SCBA’s size often makes it difficult to use.  SCBA small enough to pass through narrow openings may limit duration of its air supply to impractical levels. I Must, Do’s for confined space ❖ Ensure a safety watcher is present and communication devices are working. ❖ The safety watcher continuously monitors the in/out movement during the task. ❖ The safety watcher communicates with the workers in the confined space. ❖ In the case of an emergency, the safety watcher calls the rescue team. ❖ Read and understand the emergency plan. ❖ Everyone involved in a confined space task must know precisely what to do in an emergency. ❖ Emergency and rescue devices should be available whenever work is carried out in a confined space. I MUST NOT ❖ Enter a confined space without authorization / confined space permit. No authorization / permit = No entry to a confined space Confined space intervention = Special permit. ❖ Work in a confined space on my own. The worker and the watcher must be in constant permanent contact.  WORKING WITH ELECTRICITY An average of one worker is electrocuted on the job every day. There are four main types of electrical injuries: Electrocution (death due to electrical shock) Electrical shock Burns Falls Electrical Shock Received when current passes through the body Severity of the shock depends on: Path of current through the body Amount of current flowing through the body Length of time the body is in the circuit. How is an electrical shock received? When two wires have different potential differences (voltages), current will flow if they are connected together. If you come into contact with an energized (live) wire, and you are also in contact with the grounded wire, current will pass through your body, and YOU WILL RECEIVE A SHOCK. Electrical Burns Most common shock-related, nonfatal injury. Occurs when you touch electrical wiring or equipment that is improperly used or maintained. Typically occurs on the hands Very serious injury that needs immediate attention Falls Electric shock can also cause indirect or secondary injuries Workers in elevated locations who experience a shock can fall, resulting in serious injury or death Inadequate Wiring Hazards A hazard exists when a conductor is too small to safely carry the current. Example: using a portable tool with an extension cord that has a wire too small for the tool. The tool will draw more current than the cord can handle, causing overheating and a possible fire without tripping the circuit breaker. The circuit breaker could be the right size for the circuit but not for the smaller-wire extension cord. Wire gauge measures wires ranging in size from number 36 to 0 American wire gauge (AWG). Overload Hazards If too many devices are plugged into a circuit, the current will heat the wires to a very high temperature, which may cause a fire If the wire insulation melts, arcing may occur and cause a fire in the area where the overload exists, even inside a wall. Grounding Hazards Metal parts of an electrical wiring system that we touch, should be at zero volts relative to ground earthing system. Housings of motors, appliances or tools that are plugged into improperly grounded circuits may become energized. If you come into contact with an improperly grounded electrical device, YOU WILL BE SHOCKED. Overhead Powerline Hazards Most people don’t realize that overhead powerlines are usually not insulated. Powerline workers need special training and personal protective equipment (PPE) to work safely. Do not use metal ladders, instead, use fiberglass ladders. Beware of powerlines when you work with ladders and scaffolding. Electrical Protective Devices These devices shut off electricity flow in the event of an overload or ground-fault in the circuit. Include fuses, circuit breakers, and ground-fault circuit-interrupters (GFCI’s). Fuses and circuit breakers are overcurrent devices. When there is too much current: Fuses melt Circuit breakers trip open. Grounding Path Earthing provides a low resistance way of discharging electricity to the ground in case of current leakage. This means that during an electric shock, the current passes through the "earth" wire and is prevented from entering the human body and causing injury. Hand-Held Electric Tools Hand-held electric tools pose a potential danger because they make continuous good contact with the hand. To protect you from shock, burns, and electrocution, tools must: Have a three-wire cord with ground and be plugged into a grounded receptacle, or Be double insulated, or Be powered by a low-voltage isolation transformer Guarding of Live Parts Must enclose or guard electric equipment in locations where it would be exposed to physical damage. Cabinets, Boxes, and Fittings Junction boxes, pull boxes and fittings must have approved covers. Unused openings in cabinets, boxes and fittings must be closed (no missing knockouts). Use of Flexible Cords One third of Electrocutions are connected with the use of Flexible Electrical cord. Excessive strain can cause: Exposed Live conductor and electric shock. Broken earth connection and loss of protection from electric shock Over heating can be caused by: Cord reels operated rolled up. Loose connections Location Hazards: Damage from Mechanical, Heat or Chemical, Water on connections. Before you use extension cords and portable equipment check that: ✓ Cords and Equipment have a current test tag and are not damaged. Check for cuts, holes, exposed cores or signs of overheating. ✓ Cords are heavy duty grade, correct current rating, maximum length of 25m and are fully unwound. ✓ The power supply is protected by an GFCI. If any doubts check with the Electrical Supervisor. Handle carefully. Yours and others Safety depends on it. Treat all extension cords and portable equipment with commonsense care: ✓ Remove plugs by their body (switch off first). ✓ Pack equipment away for transport and between use. Pack Cords separately or use Cord Reels. Unwind before use. ✓ Check regularly and maintain. ✓ Relocate or protect from Hazards Protect the cords and they will protect you ✓ Relocate Cords or protect from Hazards. ✓ Support Cords off the ground where they run more than 10m, are out of view or cross passageways. ✓ Relocate away from wet areas.  PROCEDURES FOR WORKING WITH HAZARDOUS CHEMICALS Refinery processing hazards The incorrect use of hazardous chemicals can have catastrophic results to the health and safety of workers, the plant infrastructure and equipment and the environment. Therefore, it is crucial that you understand how to receive, handle and store chemicals safely. What is a hazardous chemical? A “HCS" or "hazardous chemical substance" is any toxic, harmful, corrosive, irritant or asphyxiant (suffocating) substance or a mixture of such substances for which: ❑ a work-related exposure limit is required; or ❑ a work-related exposure limit is not required, but which creates a hazard to health. Hazardous chemical Chemical hazards are present when you are exposed to any chemical preparation in the workplace in any form (solid, liquid or gas). They can either cause a fire, an explosion, and/ or a health hazard. They may be toxic, corrosive, cause chemical burns, or even explode upon contact or exposure to air. To receive, handle and store chemicals (in dry or liquid form) safely and efficiently, an operator must be familiar with the chemical's specific characteristics, the intended use of the chemical, the proper handling procedures, and the proper method of control in case there is an accident or an emergency. Characteristics of chemicals Toxicity The toxicity of a material is how poisonous, or toxic, it is. Non-toxic materials can also be hazardous, but they are not deadly. Exposure to toxic materials can result in burns, respiratory problems, and even death. Viscosity The viscosity of a material is its resistance to flow. More viscous liquids are thicker and have more resistance to flow than thinner, less viscous liquids. More viscous liquid products often require pumping or pressurising to make them flow. Volatility The volatility of a liquid refers to how easily it can become a vapour. Liquids with high vapour pressures are more volatile than liquids with low vapour pressures. Because most vapours ignite easily, a liquid that is highly volatile must be handled with care to prevent fires or explosions. Highly volatile liquids are generally carried in tanks designed to handle high pressures. These liquids may also require vapour recovery systems to prevent vapours from escaping into the atmosphere. If vapours escape, they pollute the air and increase the risk of a fire or explosion. Effects of temperature changes As temperature increases, chemicals (in liquid form) in a tank expand. This expansion is referred to as thermal expansion. When a liquid is loaded into a tank, some space must be allowed for thermal expansion, so the tank should not be filled all the way to the top. The amount of space required for thermal expansion depends on the liquid. Before a tank car or truck is unloaded, the tank gauging records should be checked to find how much space is available in the storage tank. If temperature gets too low, some liquids may lose their ability to flow. These liquids are usually carried in insulated tanks that may include heating coils or panels. Effects of pressure changes During loading and unloading, a vacuum may occur inside a tank. When a vacuum is created, there is no pressure left inside the tank, and the tank may be crushed by the air pressure outside of it. This condition is known as "pulling a vacuum." To prevent it, vacuum vents are used to allow air into the tank to equalise pressures during loading and unloading. Static electricity Static electricity is another factor that can affect the handling of bulk chemicals. When certain liquids, such as flammable products, are transferred, static electricity can be a hazard. As the product is transferred, a difference in electrical potential can build up between the fill line or piping that the liquid flows through and the tank that is being loaded or unloaded. This build-up of electrical potential increases the chances of electrostatic sparking. If sparking occurs near a tank's open man- way, where a mix of air and volatile vapours may exist, it creates a fire and explosion hazard. A common way to deal with the problem of static electricity is to use a grounding cable. A grounding cable draws off electricity to ground. The cable should be securely attached before the man-way of the tank is opened, and it should remain in place until the man-way is closed. When a grounding cable is properly attached, one end is connected to the metal frame of the tank, and the other end is connected to a metal structure or piping that is separate from the tank. Environmental hazards Hazardous chemicals can cause pollution and may contaminate the environment with materials that interfere with human health, quality of life and the natural functioning of living organisms and their physical surroundings. For example: ecosystems such as forests, wetlands, coral reefs and rivers perform many important services for the earth’s environment. They provide a friendly environment for plants and animals, improve water and air quality and supply food and medicine for everybody. When working with chemicals, many environmental hazards can be controlled by doing the following: Check for leaks and spillages. Check for gas emissions. Check to ensure that solid wastes have been removed. Chemical safety guidelines Always take great care when handling chemicals. Before you start working with an unfamiliar substance, spend some time reading about its properties. Do not allow any chemical to come into contact with your skin (hands, arms, or face). Never pour any liquid into waste bins. Never dispose of any chemical in a drain unless you are sure that it is safe and will not dangerously pollute sewage waters or air in the laboratory. Chemicals should never be put into unlabelled containers. Never try to clean a container with unknown substances. Good ventilation is important at all times when working with gases and/ or vapours. Check to ensure chemicals are safely stored. Ensure that there are no chemical spills or leakages. A Material Safety Data Sheet (MSDS) A Material Safety Data Sheet (MSDS) is a detailed chemical document to help you choose safe products, handle chemicals safely and act correctly in an emergency. MSDSs are normally prepared by the manufacturers or suppliers of chemical. Companies manufacturing or using chemicals should keep a copy of the MSDS of each chemical in such a place that anybody can quickly find it. Some companies keep them displayed on a wall or notice board, others keep them in a file, while many companies also keep electronic copies. The most important things you should know are: where to find the correct MSDS and where to find, and how to use the personal safety and emergency information in the MSDS. Specific information in the msds Despite these differences, MSDSs are normally written in English and will nearly always contain the following sections: Chemical identity: The name of the chemical as well as any alternative names, common names, chemical formulas and other methods of identifying the chemical are listed. Hazardous ingredients: This section indicates the hazardous properties of the chemical. Physical and chemical characteristics: Properties of the chemical such as boiling and freezing points, density, vapour pressure, specific gravity, solubility, volatility, the product's general appearance and odour are listed. Fire fighting measures: The chances that a fire or an explosion can occur are indicated as well as the best way to prevent and fight a fire. Reactivity data: Other chemicals and substances with which it reacts and hazardous products that may form from the reaction are listed. Personal protective equipment Most chemical containers will display pictograms indicating the correct personal protective equipment (PPE) to wear when working with the chemical.  HAZARDS AWARENESS H2S, TOXIC SUBSTANCES, EXTREME WEATHER CONDITIONS According to the Environmental Protection Agency (EPA) a hazardous substance is one that is ignitable, corrosive, reactive, and toxic. A toxic substance is a substance or waste that when ingested or absorbed can be fatal and harmful to the human body. When working with chemical hazards and toxic substances Always use the least amount of any substance necessary to do the job. Report any signs of illness or overexposure immediately to the supervisor. Ensure the suitable emergency equipment for fires, spills and leaks are readily available. Prevent the release of toxic vapour's, dusts, mists or gases into the workplace air. Example of some toxic substances Hexavalent Odourless, tasteless metallic element used in industry. Hexavalent chromium can irritate the chromium nose, throat, and lungs. Repeated or prolonged exposure can damage the mucous membranes of the nasal passages and result in ulcers. In severe cases, exposure causes perforation of the septum (the wall separating the nasal passages). It can be removed by reverse osmosis. Hydrogen Hydrogen sulphide is the form of sulphur where the sulphur atom is in the reduced state (S–) sulphide rather than oxidised state (S+). The gas is highly toxic, colourless, flammable and in low concentrations it has an unpleasant smell like that of rotten eggs. In higher concentrations it has no odour at all which makes it even more dangerous. H2S often results from the bacterial breakdown of organic matter in the absence of oxygen, such as in swamps and sewers. It also occurs in volcanic gases, natural gas and some hot water springs Coming from living organisms. Isocyanates Isocyanates include compounds classified as potential human carcinogens and known to cause cancer in animals. The main effects of hazardous exposures are occupational asthma and other lung problems, as well as irritation of the eyes, nose, throat, and skin. It is found in polyurethane paints, coatings, foams, glues and flooring. Certain tasks, such as spraying, can produce very high exposure to isocyanates. Lead Lead is a toxic metal whose widespread use has caused extensive environmental contamination and health problems in many parts of the world. It is a cumulative toxicant that affects multiple body systems, including the neurologic, hematologic, gastrointestinal, cardiovascular, and renal systems. Lead can be found in all parts of our environment – the air, the soil, the water, and even inside our homes. Much of our exposure comes from human activities including the use of fossil fuels including past use of leaded gasoline, some types of industrial facilities and past use of lead- based paint in homes. Mercury Mercury exists in various forms: elemental (or metallic); inorganic (e.g. mercuric chloride); and organic (e.g., methyl- and ethyl mercury), which all have different toxic effects, including on the nervous, digestive and immune systems, and on lungs, kidneys, skin and eyes. Mercury is found in air, water and soil. It becomes airborne when rocks erode, volcanoes erupt, and soil decomposes. Mercury then circulates in the atmosphere and is redistributed throughout the environment. Metals, toxic. Toxic metals are harmful to humans and other organisms even at low concentration. Water- soluble toxic metals include arsenic, cadmium, lead, mercury, barium, chromium and silver. Some, such as arsenic, cadmium, lead and mercury, are particularly hazardous. Industries with high potential exposures include construction work, most smelter operations, radiator repair shops, and firing ranges. Common sources of mercury exposure include mining,  production, and transportation of mercury, as well as mining and refining of gold and silver ores. Methylene Is a colourless liquid that can harm the eyes, skin, liver, and heart. Exposure can cause chloride drowsiness, dizziness, numbness and tingling limbs, and nausea. It may cause cancer. (CH2Cl2) Methylene chloride does not occur naturally in the environment. Methylene chloride is used as an industrial solvent and as a paint stripper. It may also be found in some aerosol and pesticide products and is used in the manufacture of photographic film. WHAT ARE THE 4 MAIN TYPES OF EXTREME WEATHER CONDITIONS? Weather-related extreme events are often short-lived and include heat waves, freezes, heavy downpours, tornadoes, tropical cyclones and floods. 1. HURRICANES 2. EXTREME TEMPERATURES 3. EXTREME HEAT 4. EXTREME COLD CONTROL OF SPILLAGES, USE OF SPILL KITS CHEMICAL SPILL KIT You can clean up minor chemical spills where there are no injuries, that do not pose any threat of a fire and for which you have the proper training and proper protective equipment. Chemical absorbent pads or socks or neutralising powder can be used to quickly contain a spill. Use these items only if you are not in any danger. Often the best use of such a kit is to put the absorbent on the spill to contain the chemicals, then leave the room and secure the area until the proper authorities arrive to finish the clean-up. Is this an emergency? If you can clear up the leak on the spot it should not be regarded as an emergency. If you are not sure, consider it an emergency. The following are examples of spills and leaks that should be considered emergencies: FIRST RESPONSE TO A CHEMICAL SPILL Move away from the immediate area: The first person to notice the spill or leak should move away from the immediate area of the spill in order to evaluate the situation without breathing in any fumes from the chemical. Check the wind direction to ensure that you move downwind of the spill. This may not be necessary if it is a small spill of a harmless chemical. Try to identify the spill: Do so without placing yourself at risk. This includes identifying: ✓ The type of material spilled (e.g., from the label). ✓ The size of the spill and whether the leak has stopped. ✓ Whether two chemicals are involved in the leak and could react with each other. ✓ Any unusual features such as foaming, odour, fire, etc. PROCEDURES TO HANDLE MINOR CHEMICAL SPILLS Tell everyone in the immediate area about the spill. Avoid breathing in vapours/fumes from spill. Put on protective equipment, including safety goggles, suitable gloves, and longsleeved laboratory coat/overall. Confine spill to small area, i.e. stop it from spreading. Use appropriate materials to neutralise and absorb inorganic acids and bases. Clear up the chemical waste material, place in the appropriate container, and dispose as chemical waste. For other chemicals, absorb spill with vermiculite, dry sand, or absorbent pads. Clean spill area with water. PROCEDURES TO HANDLE MAJOR CHEMICAL SPILLS Attend to injured or contaminated persons and remove them from exposure. Alert people in the area to evacuate. If spilled material is flammable, turn off ignition and heat sources. Close doors to affected area. Call the emergency controller. Be prepared to tell the emergency controller the following: Your name and department/workplace Where the spill is located What chemical(s) are involved Nature of any injuries How much was spilled What control measures have been taken Wait for spill clean-up personnel to arrive.  GAS TESTING, REQUIREMENT FOR THE PERMIT TO WORK Gas testing is an essential activity that is crucial in ensuring the safety of workers in various industries. The process involves testing the air or gas in a specific area to identify any hazardous gases, vapours, or fumes that may pose a threat to human health or cause explosions or fires. The type of tests (e.g. explosive, oxygen, toxic,), together with their testing frequency must be entered on the permit. Periodic tests (as prescribed in the work permit) following the original test should be recorded on both copies where reasonably practicable but as a minimum on the field copy. When periodic gas testing is interrupted due to the work being stopped for a period of time, this should be recorded (non-Working Period) found at the rear of the work permit. Hot work For hot work, combustible gas measurements should be performed: Prior to commencement of hot work Periodically or continuously whilst hot work is in progress. The frequency of re-testing should be established based on the degree of hazard identified in the risk assessment or the nature of the task. Should any time task conditions or operating conditions change. When hot work commences after being stopped for a period of time and the potential exists for task conditions and/ or operating conditions to have changed (this should be entered on both copies). CONFINED SPACE ENTRY For all confined space entry, the atmosphere and any residual contents of the equipment or enclosure will be evaluated with regard to oxygen content, fire or explosion potential, and personal exposure (e.g. chemical, heat, cold, radiation). Entry into an “A” category confined space should only be permitted if the atmosphere of the confined space: Has an oxygen content greater than 20% and less than 23.5%. Has no detectable level of explosive vapour/ air mixture as tested by a “flammable gas” detector. Is free of toxic air contaminants and toxic substances. If the above conditions cannot be maintained for the duration of the task, the permit will be cancelled. When work commences after being stopped for a period of time and the potential exists for task conditions and/ or operating conditions to have changed a gas test should be performed before re- entry. (This should be entered on both copies). Using gas test equipment There are many different technologies available for testing gas. You should ensure that you know which methods are used in your workplace for different purposes. You will mainly only use portable gas detectors. These detectors have a probe that will react with the gas in the air. The probe then sends a signal to the machine that will display a reading. Interpreting gas levels The explosive and oxygen record section of the permit consists of specific columns and rows for recording purposes. The following table lists and explains the information in each column: One of the most important tasks that the gas tester will have to perform is to monitor the work environment with gas testing equipment to ensure the safety of everyone concerned. The main task in this regard is to know how to calibrate and use gas testing equipment and how to interpret the results.  NOISE AWARENESS Effects of noise exposure What loud noise can do? Exposure to loud noise will inevitably cause hearing loss over time. Loud noise damages or destroys the nerves in the inner ear. Another effect can be “tinnitus” or permanent ringing in the ear. When is Noise Too Loud? Noise is measured in units called “decibels” or “dBA”. If two people 1 Meter apart must shout to be heard, the background noise is too loud (above 85 decibels). Noise above 140 decibels cause pain and immediate hearing loss. Our ears can recover from short exposure to loud noise, but over time nerve damage will occur. The longer and louder the noise, the greater chance permanent damage will occur. There is really no such thing as “tough ears” or “getting used to it”. Hearing loss from noise exposure is usually not noticed because it is so gradual. Usually, a person loses the ability to hear higher pitches first. Often the first noticeable effect is difficulty in hearing speech. Effects of Noise Exposure Scientific studies have shown that hearing loss can occur when 8-hour average noise exposure exceeds 85 decibels. Types of hearing protection There are three types of hearing protection – earmuffs, earplugs and ear caps. Earmuffs and earplugs provide about equal protection, ear caps which are less common provide somewhat less protection. Earplugs are made of foam, rubber or plastic and are either one-size-fits-all or in sizes small, medium and large. Some are disposable, some are reusable. They are lightweight and require no maintenance. They are inserted into the ear canal. Earmuffs cover the whole ear and are preferred by some people. They have replaceable pads and some high-tech styles filter out specific noise pitches. They last longer than most plugs. How can you hear anything with earmuffs on? Using earmuffs or plugs in noisy areas actually makes it easier to hear coworkers or machinery. They reduce overwhelming loud background noise. They are similar to dark glasses that reduce the sun’s glare making it easier to see. Noise can cause serious permanent damage. ▪ This Damage is easy to avoid – use your PPE – and common sense! ▪ If you think you are being exposed to excessive noise – speak to your Supervisor or to your HSE Officer.  RADIATION AWARENESS Radioactivity is the release of energy from the decay of the nuclei of certain kinds of atoms and isotopes. Atomic nuclei consist of protons and neutrons bound together in tiny bundles at the centre of atoms. Unstable nucleus has Protons number different from the Neutrons number. Natural radioactivity: Cosmic radiation & Terrestrial radiation Artificial radioactivity: Sealed sources, Nuclear power plant, Radiation therapy Sources of natural & artificial radiation 1. Cosmic rays 5. Industrial sources 2. Radon 6. Medicine application 3. Radiation from earth crust 7. Radiation resulting from nuclear 4. Internal sources installation operation Types of Radiations The first type, Alpha, is made up of two neutrons and two protons bound together identically to the nucleus of a Helium atom (i.e. without the electrons). Beta radiation is made up of an electron with high energy and speed. Beta radiation is more hazardous because it can also cause ionization of living cells. Gamma rays are high frequency, very short wavelength electromagnetic waves with no mass and no charge. They are emitted by a decaying nucleus so that it can let out energy that allows it to become more stabilized as an atom. Regulation/Exposure limits and zonings Regulation ALARA Principle - Optimization Principle Exposure to ionizing radiation resulting from a nuclear activity or intervention should be kept as low as is reasonably achievable given the state of technology, economic and social factors and, where appropriate, of the medical purpose Limitation Principle: Exposure of a person to ionizing radiation resulting from a nuclear activity can not be the sum of the doses beyond the limits set by regulation. Unless that person is the subject of an exhibition for medical purposes or biomedical research. Justification Principle No nuclear activity should be carried out at least that its use produces a benefit. Internal & external exposure Internal exposure. Radioactive particles from entering the inside of the body and can be attached permanently. Internal exposure: Inhalation & Ingestion Iodine–131 (Beta particles) Thyroid Cesium–137 (Gamma rays) Muscle and Soft Tissue Plutonium-239 (Alpha particles) Lung Liver Bone External exposure. The radioactive source remains outside and irradiates the whole body for a limited time. Effects Immediate effects: Tissue destruction Long term effects: Cancers & Hereditary diseases Radiation prevention principles Protection principle ALARA: As Low As Reasonably Achievable 𝐽 𝑚2 Activity: 1 Gy = 1 𝐾𝑔 = 1 𝑠2 𝑖 𝑑2 Distance: Inverse square law 𝐼 = 𝐷2 where I-intensity & d, D – distance Time Shielding Dosimetric monitoring Passive monitoring Reliable means of monitoring: Time shift & High detection threshold (100 µSv) Operational monitoring Direct and continuous means of monitoring– Alarm thresholds existence– “Very low” detection threshold (1 µSv) Reactivity of the operator Alpha & Beta meters Alpha & Beta radiations  Dose rate Cts/s (counts per second) Detecting the presence of particles Radiameter Gamma rays Dose rate µSv/h Use for zonings NORM Natural Occurring Radioactivity Material is called NORM. That means radioactivity is Natural. Irradiation is exposing an object to radiation. Two contamination ways Internal External Use your PPE to be protected Sealed sources A sealed radioactive source is a container of encapsulated radioactive material. The capsule of a sealed source is strong enough to: Maintain leak tightness under the conditions of use for which the source was designed  Contain the radioactive material under normal operating condition Contain the radioactive material under foreseeable mishaps Radiography Waste The waste is packaged to minimize the risk of contamination spread. Pending their removal from the site, they are tagged and stored on a secure area. Suitable labels are affixed to the packaging. Unsealed sources Unsealed sources are sources whose structure and packaging in normal conditions of use do not prevent dispersion of the radioactive substance in the environment. Competent person in radiation protection Make a preliminary assessment to identify the nature and extent of the risk. Define the appropriate protective measures and check their relevance to the dosimetry results. Identify situations or operatory modes likely to cause over-dose. Define the means required if abnormal situation. What to do in case of emergency? Dispersion Notify the Competent person in radiation protection. Define and materialize largely contaminated area. Absorb excess liquid with absorbent paper or vermiculite. Decontaminate the area with suitable detergent, going outside towards the center of this area.  Check with a suitable probe the effectiveness of decontamination. Control the hands, clothing and shoes. Body contamination Ask for help if needed. Remove contaminated clothing immediately. Wash thoroughly with soap and water parts of the body, do not damage skin. Check the decontamination efficiency. Notify the competent person in radiation protection and the doctor.  DESCRIBE METHODS OF ENSURING EFFECTIVE COMMUNICATION IN AN OIL AND GAS PROCESSING ENVIRONMENT Refineries normally use three types of communications equipment: ❑ sound powered telephone ❑ portable two-way radio ❑ standard telephone Sound Powered Telephone The sound powered telephone works with the sound of your voice. Use the sound powered telephone for routine communication with the control room. For example, you may use it to report a problem with equipment. If the supervising operator from the control room calls you, the sound powered telephone activates a horn. The horn tells you to answer the call. You will find a sound powered telephone in all areas of the refinery. It is installed in a call box. Keep the call box clean so that the telephone is also clean and safe to use. During a refinery emergency, use a sound powered telephone to communicate. If you are in a remote area, use the portable two-way radio. A sound powered telephone has two components: call bell button handset Call Bell Button: Press the Call Bell button to make a call. When the other person picks up the phone, press the transmit button to connect the call. Then start talking. Handset: Use the handset to talk. The handset has a Transmit button. Press and hold the Transmit button while you are talking. Release the Transmit button when you want to listen to the other person. Check the Call Bell button regularly. If it is broken or missing, tell your supervising operator. Portable two-way radio A portable two-way radio is a handset. Use the portable two-way radio in areas where you do not have a sound powered telephone or you are in a remote area. For example, if you need step-by-step instructions from the supervising operator to perform an emergency procedure and cannot leave the worksite to go to the sound powered telephone. During a refinery emergency, you must stop all communication on your portable two-way radio, unless you have to report the emergency or if the supervising operator tells you to call someone. The eight main components of a portable two-way radio are: ❑ on-off/end key ❑ rotary knob ❑ push-to-talk button ❑ loudspeaker/microphone ❑ Antenna ❑ battery charger ❑ battery cell  THE ROLE, THE OPERATOR’S JOB As we have just said, the role of the operator is essential on the sites. Indeed, it is both the “eye” and the “arm” of the control room. In addition, he has a role of monitoring the installations and the personnel, who work and travel on the units. An observation role This role is essential and permanent. It allows: ❖ To avoid the risk of accidents and damage to equipment. Indeed, it is necessary to anticipate possible problems likely to appear by being able to notice any abnormal development. To do this, the operator must observe changes in the behaviour of the equipment, level control, changes in noise, pressure, temperature, the appearance of leaks, etc. ❖ To ensure the proper functioning of the equipment. By recording the functional parameters of local installations (meters, levels, recorders, etc.), he will be able to report discrepancies to his supervisor. This will allow maintenance to take place preventatively. ❖ In addition, this observation role will make it possible to anticipate developments in the process and thus report any malfunction of the process which has not been observed by the control room. ❖ To control the start and stop phases of the equipment (example: Pump changeover). ❖ To ensure the cleanliness of the installations e.g.: rags lying around, fire hose not stored, etc. An action role The operator will have to carry out a certain number of tasks daily but also occasionally in the event of an emergency or work on the installations. These actions will be process: As part of the “process”, he will have to put valves in position during proper functioning tests, but also during start-ups and shutdowns of the installations or even on orders from the control room. He will be in charge of taking samples concerning, among other things, the wells under test, finished products, sea discharges, etc. These samples confirm or not the proper functioning of the units., after laboratory analyses. He will control the good operation of the pumps chemical products as well as the volumes injected. He will participate in testing new equipment or installations. It will carry out specific operations (example: Pipe scraping). Maintenance As far as maintenance is concerned, it is, supervised by a chief operator, who will provide the facilities assigned to him. Likewise, he must put the equipment back into service after ensuring that the maintenance operation is carried out correctly and after having checked the correct alignment of the equipment or installation. He will carry out PM and CM, preventive and corrective maintenance tasks which are his responsibility. (example: cleaning filters). A supervisory role This is an important role for the operator, and it is through this operation that he will be able to detect any possible risks. This surveillance is linked to a temporary activity. It relates to: The installations: The operator will carry out this monitoring, during the work for example to avoid any risk of accident (example: grating not put back in place at the end of the work). The staff: He will be in charge of monitoring people working on the site. He will ensure the conformity of the equipment used by the works and maintenance teams. He will have to mark and control the lifting and radio firing operations. He will monitor people new to the site and help them with their companion training. A “reporting” role The report is a vital role for the operating operator. It must be clear and as concise as possible. It is in the way of reporting that the interventions which follow will be carried out in good conditions. THE DIFFERENT TASKS OF OPERATORS In this chapter we will talk not only about the operator's tasks but also those of the chief operator (CO), this in order to ensure that everyone remains in their role. In addition, the position of CO is the position just above them, so they will often be called upon to hold it in their career development. The indications given below are not rules and may be different depending on the subsidiary. General description The operator is responsible for visits to production facilities to carry out daily readings and adjustments of operating parameters. He is also responsible for maintenance and 1st degree interventions. Description of tasks Return the installations to service in accordance with the general operating and safety instructions. Recording of daily parameters and change of diagrams. Produce reports in the absence of the cinematographer, write visit reports. Adjust the operating parameters in accordance with the instructions: pressures, flow rates, temperatures, product injections. Ensure maintenance and 1st degree interventions. Ensure the procedure for launching and receiving the scrapers. Participation in security tests. Ensure the passage of wells under testing in accordance with the program. Take samples following the operating instructions. Participate in the provision of equipment for work, in accordance with the safety instructions that it applies and enforces by the contracted companies during their interventions Checking and maintaining security equipment. Participate in the repair of production equipment. Ensure the cleanliness of facilities Verification and monitoring of chemicals. Participate in specific OPPS, TIPS operations. Participate in the start-ups of new installations. Collect elements for drafting specific reports and daily, weekly, monthly reports Inform your direct superiors of any anomalies observed.  LEGISLATION RELEVANT TO OIL AND GAS PROCESSING The petroleum (exploration, development and production) (health, safety and environment) regulations, 2016. part ii—general health, safety and working environment requirements part iii—occupational hazards part iv—electrical installations part v—working environment in facilities and during petroleum activities part vi—safety appliances, equipment materials, devices and clothing part vii—fire and explosion protection in facilities during petroleum activities part viii—emergency preparedness part ix—safety requirements for plants and equipment. part x—medical facilities and first aid services. part xi—handling, investigation, recording and reporting of incident, hazard or incident Occupational Safety & Health Act, 2006 part iii—general duties, obligations and responsibilities of employers part iv—general duties of employers and the self-employed part vi—duties, rights and responsibilities of workers part vii—registration of workplaces part viii—health and welfare part ix—general safety requirements part x—fire preparedness part xi—machinery, plant and equipment part xii—hazardous materials part xiii—chemical safety and special provisions part xiv—offences, penalties and legal proceedings National Environment Act, No. 5 of 2019 Part II—Institutional arrangements Part III—Funds of the authority and the national environment Fund Part IV—environmental Planning. Part v—management of the green environment Part VI—sound management of Chemicals and Product Control Part VII—Control of Pollution and environmental emergency Preparedness Part VIII—management of Waste Part IX—establishment of environmental standards Part X—environmental and socIal assessment Part XI—environmental Easements Part XII—environmental Compliance and enforcement Part XIII—Judicial Proceedings Part XIV—environmental Information and literacy Part XV—International obligations Part XVI—offences, Penalties, Fees, Fines and other Charges National Environment (Environmental and Social Assessment) Regulations, 2020 Part II – Projects Requiring Submission of Project Briefs Part III—Projects Requiring Scoping and Environmental and Social Impact Study Part IV—General Provisions relating to Certificate of Approval of Environmental and Social impact Assessment Part V—Environmental Risk Assessment Part VI—Mitigation Hierarchy, Payment for Ecosystem Services and Environmental Management and Monitoring plan Part VII—Transboundary Environmental and Social Assessments  DESCRIBE THE PURPOSE OF SAFETY PROCEDURES/ DOCUMENTATION Purpose of permit to work Ensure all the PTW phases are respected and correctly followed by all personnel involved. Define the roles and responsibilities in this process. Identify hazards linked to the work and evaluate the risk along the permit to work process. Ensure that precautions are recommended, implemented and maintained up to the end of the work. Coordinate the works, to avoid conflict of access or interferences of activities. Define the maximum validity period and the required complementary certificates for a permit to work. FIELD OF APPLICATION The provisions of this procedure apply to all TE’s sites, activities and operations. This procedure has to be transposed in a dedicated site instruction to provide methods for permit to works specific to certain contexts: work on sites without industrial operations (e.g. offices, living facilities, Logistic base…). In case of coexistence with a work permit between TE and a contractor (for example, supply vessel, barge and drilling platform), a "Bridging Document" is prepared to define the application areas of each system, and thus managing the interfaces between both parties, throughout the duration of the work. Notwithstanding the above indications, the Responsible for Safety and Environment on Site (RSES) Site Health, Safety Environment Manager may decide at his sole discretion to cover any work by a PTW, if the RSES feels necessary to better control the risk of such work. Types of permit to work Depending on the type and complexity of the work, the work may be performed using one of the following forms: ▪ Standard Permit to work form; ▪ Routine permit form; (or simplified PTW); ▪ Or work that is authorized without PTW but via a Verbal instruction. Permit to work validity period When the validity period of a PTW has expired, the work concerned cannot begin or be continued without a new permit to work. A permit to work for cold work or hot work without naked flame shall expire 14 days after the opening date (within 24 hours after approval date) and may be reduced at RSES discretion. COLD PERMIT TO WORK The cold permit to work provisions apply by default to all types of works other than those covered by a more specific form and jobs not involving a naked flame, potential source of ignition (sparks etc.). HOT PERMIT TO WORK (A AND B) The Hot permit to work provisions apply when work involves actual or potential sources of ignition, namely: Jobs involving Naked flame spark or heat-producing sources (flame cutting, welding, grinding), unless used inside workshops or areas specifically designed for that purpose and not located in the vicinity of any hazardous area. The respective Hot permit is then rated as “Naked Flame” (Hot Permit to work A);  Jobs involving “Non naked flame” Covers Other potential sources of ignition (hand tools, equipment not or no more intrinsically safe), located or used inside or nearby a hazardous area, and that cannot be isolated. The respective Hot permit is then rated as “Non naked flame” (Hot Permit to work B). ROUTINE PERMIT A simplified Permit to work, is used only for recurrent and low risk work that does not generate any co- activity or simultaneous operations. The routine permit shall be used: For regular or routine operating activities (carried out several times a year). For a duration of at least 7 days To be supported by approved procedures and routine job forms. Carried out by employees or contracted staff who are adequately trained and experienced and are part of the permanent organization in place at the location (core team). Their risk assessment clearly shows that they do not involve unusual hazards or high rated risks. Supported by an approved Job Risk Assessment, as per procedure. WORK ON VERBAL INSTRUCTIONS The min requirements for verbal authorization are: ▪ Activities which are part of the regular operation of the installation and its equipment, in line with the design specifications and within the operating limits prescribed by the manufacturers. ▪ They are supported by suitable plans / schedules, procedures, instructions, checklists, and operating manuals. ▪ They are included on the list of the types of activities that may be carried out on verbal / written instructions. ▪ Inhibition / overriding of safety systems are not required to perform the activity. ▪ Activity is relatively simple to perform. ▪ Activity is re-occurring on a regular base. ▪ Activities shall be performed by regular crew only ▪ No electrical, process/mechanical or personal isolations required. Any activity requiring isolation cannot be executed under verbal instruction. COMPLEMENTARY PERMITS Specific operations require the use of complementary permits or specific authorizations in addition to any permit to work. Such as, but not limited to: Confined space entry permit ICSS and package inhibition Electrical isolation sheet Industrial radiography/x-ray permit Process / mechanical isolation Working with NORM Critical lifts plans Excavation permit Safety inhibit / override permit Mooring ROV & diving operations In case of Simultaneous Operations, the permit to working system may be adapted as part of the SIMOPS dossier.  RISK ASSESSMENT Purpose of risk assessments o Identify potential hazards o Evaluate the potential Risk for personnel, the environment and the asset o Determine appropriate and sufficient control measures to reduce risks to an ALARP level o Develop an action plan to implement the compensatory measures FIELD OF APPLICATION General case: The provisions of this procedure are applicable to all sites and operations under the control of the Company (except otherwise stated in a specific instruction). They apply to jobs, which are considered to be safety critical in terms of risks that they may cause: o Personnel injury o Asset, material or o Media impact. o Environmental damages production losses o Impact on safety critical o Impact on integrity, element o Impact on compliance, Hazard identification A PTW is based on a risk analysis: Identification of the potential hazards of the activity to be performed Defined the types of “high risk work” according to the risk analysis. For “high risk work” the approving authority and the performing authority visit the work site (called: Joint Visit for “High Risk Work”) as part of the permit to work preparation process. The visit is used to complete the risk analysis. Means and tools used Installations and products present, or potentially present Configuration of the work execution site and surrounding environment Potential Interferences generated by identified simultaneous operations or co activities. The Five Step Risk Management Process 1. Assess Hazards 4. Implement Controls 2. Make Decisions 5. Supervise 3. Identify Hazards  SAFETY HSE AUDITS A safety audit is the review of safety provisions for employees and the public. The purpose is to identify any potential hazards in procedures, policies, or equipment. A safety audit is like a report card to let you know how well your company is performing at following safety rules and regulations within the refinery. Challenges in Oil Refineries Oil refineries are complex and high-risk operations that require constant monitoring to ensure that they comply with regulatory requirements and operate safely. Auditing is a crucial tool that helps ensure that the refinery is running as it should, identifying any discrepancies or non-compliance issues that require action. Traditional auditing of oil refineries, however, can be challenging due to a number of factors. We will discuss some of these challenges in the following slides. The complexity of refinery operations Oil refineries are complex operations with a multitude of processes, systems, and equipment. The sheer volume of data generated by the refinery can be overwhelming for auditors, who need to be familiar with all aspects of the operation. A typical refinery can produce several different types of fuel, each of which requires different processes and equipment, making the audit process even more complex. Safety concerns Safety is a major concern in the oil refinery industry. Refineries are high-risk operations that handle hazardous materials and require specialized equipment and procedures to minimize the risk of accidents. Auditors need to be familiar with these procedures and equipment to ensure that the refinery is operating safely. However, there is always a risk of accidents, and auditors need to be aware of these risks and take appropriate precautions. Regulatory requirements Oil refineries are subject to a range of regulatory requirements at both the state and federal level. Auditors need to be familiar with these requirements and ensure that the refinery is in compliance. Compliance with regulations can be challenging due to the complexity of the operations and the constantly changing nature of the regulations. Maintenance and repair Oil refineries require regular maintenance and repair to keep the equipment running smoothly. Auditors need to ensure that maintenance and repair schedules are being followed and that any repairs or upgrades are being carried out in accordance with the regulatory requirements. Auditors need to be familiar with the equipment and processes used in the refinery to ensure that the maintenance and repair work is done correctly. Environmental concerns Oil refineries have a significant impact on the environment, and auditors need to ensure that the refinery is operating in compliance with environmental regulations. Auditors need to be familiar with the environmental regulations that apply to the refinery and ensure that the refinery is taking steps to minimize its environmental impact. Data management Oil refineries generate large amounts of data, and auditors need to be able to analyse this data to identify any discrepancies or non-compliance issues. However, managing this data can be challenging due to the sheer volume of information that needs to be processed. Staff training Auditors need to be familiar with the equipment, processes, and procedures used in the refinery to carry out their work effectively. However, this requires significant training and ongoing education to keep up with changes in the industry. Auditors need to have a solid understanding of the oil refinery industry to carry out their work effectively. Benefits of auditing in oil refinery Auditing is an independent evaluation of a refinery’s management system, processes, procedures, and performance, designed to ensure compliance with regulations and industry standards. o Meet customer requirements o Improvements o Reduce rework and rejections, which o Effective work processes reduces costs o Identify potential issues o Meet legal requirements Compliance Auditing plays a significant role in ensuring safety compliance in oil refineries. The safety of workers and the environment is of utmost importance in any refinery operation. Auditing helps in identifying gaps and areas of improvement in safety processes and systems. It also helps in ensuring that safety standards are being adhered to, and the necessary corrective actions are taken to address safety concerns. How to conduct an HSE Audit? o Identify the areas to audit within your organization. o Determine the scope and objectives of the audit. o Assemble an audit team or hire an independent third-party organization. o Review relevant safety standards and regulations. Conducting an Audit o Inspect physical conditions, equipment, and work environment. o Review safety protocols, procedures, and documentation. o Engage with employees to gauge their awareness and understanding of safety measures. o Identify risks, hazards, and areas for improvement. Post Audit Activities o Compile audit findings and observations. o Propose solutions to address identified issues. o Facilitate improvements and enhance safety practices.  L OCK-O UT AND T AG-O UT (LOTO) PROCEDURES Lock-out procedure A lock-out device is a safety device. You use it to make sure that no one accidentally operates the equipment which has been locked out. There are two types of lock-out device. One is a multiple-lock device. The other is a chain with a lock. Pre-warning of maintenance work. When maintenance work is done it is essential that measures are taken to protect the personnel and the equipment. One way of warning others not to use equipment that is isolated is to tag the equipment. Equipment that will be inspected must be tagged before maintenance work is done. This is usually done when the equipment is isolated for repairs. These tags are to warn others that the particular component must not be repositioned and if someone works on that equipment they could be injured and equipment could be damaged. Each lock-out device has one key. The key is kept in the lock-out cabinet. The cabinet is in the supervising operator’s office or the operator shelter or office. The lock-out procedure includes: ❑ locking out of equipment ❑ removing the lock from equipment However, operators may have to de-energise electrical systems, depressurise pressurised systems and drain fluid systems. Tags such as those shown below are hung on valves, control switches and circuit breakers after the equipment has been isolated. Summary A work permit and job cards are documents that guide the workers to perform their work in safe and controlled manner. It ensures that all safety measures are taken and the correct PPE is worn. However, before work is done the area and equipment must be made safe. One way of doing so is to ensure that the equipment is properly tagged and warning signs are placed that prevent others from working on isolated equipment. When maintenance is done, certain precautions need to be taken to protect personnel and equipment. For example, some pressurised systems must be depressurised, some valves must be turned off to isolate equipment that will be maintained and some fluid systems will have to be drained. (safe-making procedure). After you install a lock, nobody will be able to use the equipment. ELECTRICAL ISOLATION OF EQUIPMENT Before any maintenance can be done on electrical equipment, the equipment must be isolated (i.e. the electricity supply to the equipment must be discontinued/cut). This is done by following an electrical lockout procedure. In some cases, a circuit breaker will be pulled or isolated to make it impossible to operate the equipment being worked on. This lockout procedure creates a safe working environment when working with electrical equipment. The lockout logs provide information such as who locked out the power source and when the lockout occurred. These along with the keys are usually found in the control room. An example of an electrical equipment lock-out procedure:  The person responsible for maintenance should be contacted by production, that person must send an electrician or authorised person to carry out the job.  The work request should be made by an authorised person from production; he/ she should also provide the E (for electricity) padlock and key.  Once the electrician (or authorised electrical person) arrives at the switch point; the authorised person must make sure that the equipment is not being used by communicating with the control room via radio.  The authorised person must also verify that the tag (site) number and the description on the work request is the same as that on the electrical equipment that is isolated.  The authorised person and electrician must both check the tag (site) number and description of equipment, and they must both agree that the details are correct. The authorised person must then move away to a safe place (at least 6 metres away).  The electrician will ensure that the ON/ OFF indication is OFF, and the amp-meter reading is zero. He/ she must lock the switch to the open position with the E padlock and all open push-bars must be screened off.  The work request must be signed by the electrician to ensure that isolation is completed.  The keys for the locks used during isolation are to be hooked onto a key-holder in the production office and a register for the keys must be signed.  Electrical equipment and control circuits can be quite complex. The isolated equipment may need to be tested for safety by being bumped according to workplace procedures. This is known as a bump test.  The bump test must be approved by a senior person (the section leader or the group leader) from production and acceptable isolation and test instructions must be completed. MECHANICAL ISOLATION OF EQUIPMENT  The authorised person (who submits the work request) must make sure that the valves are closed and the system is depressurised.  The production personnel will make a work request together with and M Mechanical (for) lock and chain to an authorised mechanical person who will isolate and lock out the equipment.  The authorised person from production, together with an outside official (e.g. someone who renders a service to the holder of the permit) must go the equipment and  check that the information on the work request is the same as the information on the equipment; this must be further verified with the control room via radio.  Once the equipment identification is complete the valves/valves are locked in a closed position.  The authorised person from production take the M lock key and work request to the production office. Summary Electrical and mechanical isolation is an important process in ensuring that the equipment is safe for working on. Mechanical isolation procedure includes depressurising pressurised systems, closing and locking valves and draining fluid systems. Once the isolation procedure is complete the equipment is locked with an M-lock and chain. Isolating equipment electrically is done by an electrician or an electrically qualified person. That person will ensure that the power is switched off and the amp meter reading is zero. Once the isolation procedure is complete the equipment is locked with an E-padlock and chain. Because control circuits can be complex, a bump test may need to be done on the equipment to make sure that there is no current running through it.  DEMONSTRATE SAFE WORKING PRACTICES IN AN OIL AND GAS PROCESSING ENVIRONMENT Hse meeting Meeting conducted by CSR / HSE Team on a weekly / monthly basis to address general HSE topics and specific topics regarding general activities, Management or Site expectations. Toolbox talk / meeting Meeting conducted by the Supervisor to his entire team to present on one hand the daily work program and on the other hand on a weekly basis a safety topic linked to his activity Pre-job meeting Information talk conducted before each task and on work site by the Foreman to his team to discuss about the task, hazards, risks and preventive measures to apply. The Goal of Toolbox talk presentation  Inform workers of new company procedures or changes  Identify new hazards and review existing hazards  Develop / review work processes  Develop / review protective or preventive measures  Discuss / review accident and incident data  Employee participation / feedback on safety matters  Communication Short training sessions  Awareness (client, group, subsidiary, …) These meetings can be done in a variety of ways but are typically a brief (10 minutes) interactive discussion meeting on something safety related Toolbox Topics are used to cover a variety of short safety training subjects and to remind employees each day before they go to work, the importance of being safe. How to perform Toolbox talk Organization / progress  General information  Examples  Questions to generate discussion Introduction One of the easiest ways for Supervisors to communicate the importance of safety on the job is through toolbox meeting. Remember to keep your talk informal, use your own words and style in promoting and leading the discussion. Unsafe acts typically account for 90% of all accidents. Training plan for toolbox meeting Preparation  Know your topic  List what equipment you will require or what documents you may need to refer to in your talk  Suitable place that is free of distractions (e.g. noise, pedestrian traffic, …) Giving the talk  Be clear about the message you want to send and list your key points.  Your talk will be more meaningful if you talk about situations / incidents that illustrate the points you want to make, these may include accidents, near misses, good or bad practices that you have observed.  Active participation by workers will ensure a more effective talk.  Plan some key questions that will start people thinking about safety issues.  Use open-ended questions which encourage workers to identify hazards and suggest possible solutions.  List a summary of the main points to make at the end of your talk. This is an opportunity to mention work practices that need to change or to reinforce important points already discussed.  Don’t forget to thank your staff for their interest and enthusiasm. Engaging employees in conversations around various safety topics helps safety be at the forefront of their minds throughout the workday. Selection of Personal Protective Equipment Employers have duties concerning the provision and use of personal protective equipment (PPE) at work. PPE protects the user against health or safety risks at work. Examples of PPE include items such as safety helmets, gloves, eye protection, high-visibility clothing, safety footwear, safety harnesses and respiratory protective equipment (RPE). Its important that you are able to select, supervise, use and clean PPE relevant to every job aspect. Maintain the workspace in a clean and tidy manner In the oil and gas processing workplaces, its important to keep the working environment clean and tidy through proper housekeeping. House keeping refers to the routine cleaning and organizing of the workplace. In simple terms it means Everything in its own place at all times. Orderly conditions in the workplace should be maintained on a consistent basis. Ways of maintaining the workspace clean and tidy -Put tools back in rack after use -Sweep up or wash off any mud as soon as possible -Keep cables, slings, chains, rope coiled up and off the floor when not in use -Do not allow oil to collect on the rig floor -Do not block fire extinguishers -Do not block emergency exits -Keep all trash and unused parts off the floor The 5S concept 5S in housekeeping refers to the implementation of the 5S methodology for maintaining clean, safe, and efficient workplaces. The term originates from five Japanese words, each beginning with the letter “s,” hence the name 5S. 1. Sort (Seiri) The first step involves sorting all items in a work area, such as cleaning materials, brooms, vacuum cleaners, and anything used for work. Employees must separate unnecessary items and only keep the ones needed for their tasks. 2. Set in Order (Seiton). This step focuses on making every item or tool needed for work much easier to access. It involves organizing tools and materials in specific and logical locations to smoothen out workflows. 3. Shine (Seiso) Conducting a thorough cleanup campaign is essential. Regular cleaning ensures workspaces remain tidy, clutter-free, and safe. Eliminating dust, dirt, and debris contributes to a pleasant and efficient environment. 4. Standardize (Seiketsu) Consistency is key. Establishing routines and standards for housekeeping tasks ensures a high quality of work. When everyone follows the same procedures, it becomes easier to maintain cleanliness and safety. 5. Sustain (Shitsuke) 5S isn’t a one-time event. It’s a long-term commitment to maintaining standards. Encourage continuous improvement by integrating these principles into your overall workflow. When everyone on the team fully commits to following these principles, the benefits are substantial.