Borouge Risk Assessment Criteria

PROJECT PROCEDURE

TAKREER PROJECT No 5578 Agreement no 07-5578-F-1

RUWAIS REFINERY EXPANSION PROJECT

COMPANY Doc. No. 5578-PC-PA-003 ENG Doc. 25418-000-G01-GHX-00001

Rev. 1

RUWAIS REFINERY EXPANSION PROJECT

FRONT END ENGINEERING DESIGN

HSE PLAN

INTERNATIONAL BECHTEL CO LTD.

THE DESIGN OR PART THEREOF CONTAINED IN THIS DOCUMENT WAS DEVELOPED FOR TAKREER AND MAY BE UTILISED BY TAKREER FOR ANY PURPOSE RELATING TO THE CONSTRUCTION, MAINTENANCE OR OPERATION OF THE PROJECT. INTELLECTUAL PROPERTY RIGHTS IN THE DESIGN OR INFORMATION CONTAINED HEREIN REMAINS THE PROPERTY OF INTERNATIONAL BECHTEL CO. LTD..

ELECTRONIC DOCUMENTS ARE CONTROLLED. ANY PRINTED COPY WILL BE UNCONTROLLED AND MAY BECOME OUTDATED

TAKREER

TAKREER PROJECT No 5578

HSE PLAN

Agreement no 07-5578-F-1

COMPANY Doc. No. 5578-PC-PA-003 ENG Doc. 25418-000-G01-GHX-00001

RUWAIS REFINERY EXPANSION PROJECT

Rev. 1

This page records the revision status of this document All previous issues are hereby superseded and are to be destroyed.

NOTES: Revisions after Rev. 1 are denoted as follows: (a)

By a vertical line in the right-hand margin adjacent to the revised text. The revision number is displayed adjacent to the right hand side of the revision line, or

(b)

By a triangle symbol for graphics, the revision number being denoted within the symbol positioned adjacent to the revision.

(c)

CHKD = DISC = PD =

REV

DATE

0 1

7-2-08 8-4-08

Checked by Project Functional Manager, or nominee; (Corporate) Functional Manager, or designee; CONTRACTOR's Project Director, or designee

REASON FOR ISSUE ISSUED FOR APPROVAL ISSUED FOR FEED

BY

CHKD

GMB GMB

BW BW

DISC MS PAL

APPROVED PD PMC COMPANY JDR JDR

Signed (Initials)

ELECTRONIC DOCUMENTS ARE CONTROLLED. ANY PRINTED COPY WILL BE UNCONTROLLED AND MAY BECOME OUTDATED 25418-000-G01-GHX-00001.doc

Page 2 of 26

TAKREER

HSE PLAN

TAKREER PROJECT No 5578 Agreement no 07-5578-F-1

RUWAIS REFINERY EXPANSION PROJECT

COMPANY Doc. No. 5578-PC-PA-003 ENG Doc. 25418-000-G01-GHX-00001

Rev. 1

CONTENTS

1.

PURPOSE .......................................................................................................................... 4

2.

BACKGROUND.................................................................................................................. 4

3.

SCOPE ............................................................................................................................... 5

4.

REFERENCES ................................................................................................................... 6

5.

DEFINITIONS ..................................................................................................................... 7

6.

RESPONSIBILITIES........................................................................................................... 8

7.

INSTRUCTIONS ................................................................................................................. 9

8.

ATTACHMENTS............................................................................................................... 20

ELECTRONIC DOCUMENTS ARE CONTROLLED. ANY PRINTED COPY WILL BE UNCONTROLLED AND MAY BECOME OUTDATED 25418-000-G01-GHX-00001.doc

Page 3 of 26

TAKREER

HSE PLAN

TAKREER PROJECT No 5578 Agreement no 07-5578-F-1

RUWAIS REFINERY EXPANSION PROJECT

1.

COMPANY Doc. No. 5578-PC-PA-003 ENG Doc. 25418-000-G01-GHX-00001

Rev. 1

PURPOSE ENGINEER is committed to proactive safety management for all projects as an integral part of its corporate culture and core values. ENGINEER believes that all accidents are preventable and the purpose of this Health Safety and Environmental Management Plan (hereafter HSE Plan) is to facilitate ENGINEER in delivering a completed project safe in design, safe in construction and safe in operation for the Ruwais Refinery Expansion Project for TAKREER in Abu Dhabi, United Arab Emirates (UAE).

2.

BACKGROUND The Abu Dhabi Oil Refining Company (Takreer) is involved in refining Crude Oil and Condensate and supply of petroleum products to domestic and international markets. Takreer’s refining facilities include two refineries; the Abu Dhabi Refinery and Ruwais. The existing Ruwais Refinery is located in the Ruwais Industrial Complex, located on the Arabian Gulf, approximately 250 kilometres west of Abu Dhabi city. Other plants located in the same complex are GASCO, Fertil and Borouge. The General Utilities Plant (GUP) supplies cooling water and power to the whole Ruwais Industrial Complex. Takreer is planning a new refinery to be built adjacent to the existing refinery at Ruwais; the Ruwais Refinery Expansion (RRE) project. The most likely location for the RRE is to the west of the existing Industrial Complex. The objective of the RRE is to produce maximum propylene, along with ‘fuels’ type distillate products (jet, diesel), with minimal residual products, and a low amount of gasoline. The scope of the refinery is expected to include: • • • • • • • • • • • • •

Crude distillation Saturated Gas Plant including Naphtha stabilisation/splitting, and LPG splitting Kerosene Hydrotreating Diesel Hydrotreating Residue Fluid Catalytic Cracker (RFCC) with high olefin yield Unsaturated Gas Plant including Naphtha stabilisation/splitting Unsaturated LPG treating Propylene recovery Ethylene recovery RFCC C4 preparation units Olefin conversion unit Alkylation Unit Butane Isomerisation

ELECTRONIC DOCUMENTS ARE CONTROLLED. ANY PRINTED COPY WILL BE UNCONTROLLED AND MAY BECOME OUTDATED 25418-000-G01-GHX-00001.doc

Page 4 of 26

TAKREER

HSE PLAN

TAKREER PROJECT No 5578 Agreement no 07-5578-F-1

RUWAIS REFINERY EXPANSION PROJECT

• • • •

COMPANY Doc. No. 5578-PC-PA-003 ENG Doc. 25418-000-G01-GHX-00001

Rev. 1

Whole Cracked Naphtha hydrotreating Benzene Reduction scheme Hydrogen production Unit Sulphur Facilities

In addition the following Offsites and Utilities facilities are required: • • • • • • • • • • • • •

Steam and condensate systems Boiler feed Water Supply Sea/fresh Cooling Water system Fuel gas, Air and Nitrogen systems Product Blending systems Feed, intermediate and product tankage Product loading jetty and berths Effluent and Waste Water Treatment Draining and Sewer system Flare System Fire Prevention and Control system Power import and distribution Control Room, Administration and other buildings

There will also be some limited interfaces with the existing refinery for the disposal of some products from RRE as well as a connection from the existing refinery for LPG supply.

3.

SCOPE This HSE Plan describes ‘the arrangements’ for implementing the COMPANY’s and ENGINEER’s Corporate HSE Policies (see Attachment 1) and COMPANY’s strategic HSE objectives (see Attachment 2). The scope of this HSE Plan covers the HSE management of the Project Front End Engineering Design (FEED) and its associated activities in general; and specifically the ENGINEER personnel working in the FEED execution offices (Hammersmith and New Delhi) or temporarily visiting or resident in third party undertakings such as the existing Ruwais Refinery, proposed job site, Licensors offices, local utility providers, and the like. The HSE Management System described by this Plan revolves around 10 main elements as listed below:

ELECTRONIC DOCUMENTS ARE CONTROLLED. ANY PRINTED COPY WILL BE UNCONTROLLED AND MAY BECOME OUTDATED 25418-000-G01-GHX-00001.doc

Page 5 of 26

TAKREER

HSE PLAN

TAKREER PROJECT No 5578 Agreement no 07-5578-F-1

RUWAIS REFINERY EXPANSION PROJECT

• • • • • • • • • •

COMPANY Doc. No. 5578-PC-PA-003 ENG Doc. 25418-000-G01-GHX-00001

Rev. 1

Encourage Positive Behaviour Plan Organise and Communicate Apply Standards and Procedures Develop Competency and Well Being Manage External Relationships Manage Hazards and Risks Manage Change Manage Incident Response Learn from experience Audit and Review

The Project HSE Plan is intended to be a ‘living’ document, and so it will be reviewed and periodically revised as necessary to cover changes in work scope, execution plans or HSE risk associated. The minimum acceptable requirements for each of the elements of the HSE Plan for this project are discussed in the sections below.

4.

REFERENCES The following are the references used to prepare the HSE plan. They are implicitly incorporated into the plan, which shall be complied with unless otherwise agreed: UAE Federal Law No. 24 (1999) Protection and Development of the Environment (and subsequent executive regulations) UAE Federal Law No.8 (1980) Regulations of Labour Relations ADNOC Manual of Codes of Practice, ‘HSE Administration Systems’, ADNOC-COPV1-01 ADNOC Manual of Codes of Practice, ‘Code of Practice on HSEIA Requirement’, ADNOC-COPV102 ADNOC Manual of Codes of Practice, ‘Pollution Prevention and Control’, ADNOC-COPV2-02 ADNOC Code of Practice, ‘Control of Major Accident Hazards (COMAH)’, ADNOC-COPV5-01 ADNOC Code of Practice, ‘Code of Practice on Environmental Impact Assessment’, ADNOC-COPV2-01 TAKREER Health, Safety and Environmental Management System (HSE MS) Manual TAKREER HSE Control Procedure HSE-CP24 ‘Hazard Identification’ TAKREER HSE Control Procedure HSE-CP25 ‘HSE Risk Assessment’ TAKREER HSE Control Procedure HSE-CP26 ‘Health, Safety and Environment Impact Assessment’

ELECTRONIC DOCUMENTS ARE CONTROLLED. ANY PRINTED COPY WILL BE UNCONTROLLED AND MAY BECOME OUTDATED 25418-000-G01-GHX-00001.doc

Page 6 of 26

TAKREER

TAKREER PROJECT No 5578

HSE PLAN

Agreement no 07-5578-F-1

RUWAIS REFINERY EXPANSION PROJECT

COMPANY Doc. No. 5578-PC-PA-003 ENG Doc. 25418-000-G01-GHX-00001

Rev. 1

International Codes and Standards including ISO 9001(2000) and ISO 14001 (1996) Occupational Health and Safety Management Systems - OHSAS 18001/BS 8800 Bechtel HSE Management Process, HSE Plan Development, 2HA-H11D-00001 Bechtel HSE Management Process, HSE Performance Monitoring and Reporting Requirements, 2HAH17D-00001 Bechtel HSE Management Process, HSE Self Assessment, 2HA-H12D-00001

5.

DEFINITIONS ACGIH

American Conference of Government Industrial Hygienists

ALARP

As Low as Reasonably Practicable

BAT

Best Available Techniques

EIA

Environmental Impact Assessment

EPC

Engineering, Procurement and Construction

FEED

Front End Engineering Design

HAZID

Hazard Identification Study

HAZOP

Hazard and Operability Study

HSEIA

Health, Safety and Environmental Impact Assessment

PFD

Process Flow Diagram

P&ID

Piping and Instrumentation Diagram

QRA

Quantitative Risk Assessment

RACI

Responsible / Accountable / Consult / Inform

SIL

Safety Integrity Level

ELECTRONIC DOCUMENTS ARE CONTROLLED. ANY PRINTED COPY WILL BE UNCONTROLLED AND MAY BECOME OUTDATED 25418-000-G01-GHX-00001.doc

Page 7 of 26

TAKREER

HSE PLAN

TAKREER PROJECT No 5578 Agreement no 07-5578-F-1

RUWAIS REFINERY EXPANSION PROJECT

6.

COMPANY Doc. No. 5578-PC-PA-003 ENG Doc. 25418-000-G01-GHX-00001

Rev. 1

RESPONSIBILITIES 6.1

Project Director

The Project Director is accountable for the implementation of the HSE Management System and its subsequent performance. The Project Director shall ensure that adequate budget and resources are in place for effective HSE management on the project. He shall actively participate in the development and implementation of the HSE Management System on the project and encourage proactive communication and line management ownership of HSE matters. He shall ensure that adequate communications and coordination is in place to advise all relevant parties of HSE risks or concerns as they are identified.

6.2

Project Management Team

The Project Management Team comprises collectively the Project Engineering Manager, Project Procurement Manager, Project Controls Manager, Project Construction Manager, Project Quality Manager, Project Engineers, Project HSE Manager and the Lead Discipline Engineers and their counterparts New Delhi office. This team shall abide by the requirements of the HSE Plan and take an active role in its implementation and future development and its dissemination to their respective disciplines and supervisees. They shall assist the Project HSE Manager by drawing to his attention any changes in the work scope or circumstance that may add to the risk associated with the project execution or to the personnel engaged.

6.3

Project HSE Manager

The Project HSE Manager owns the HSE management system applied on the project and is responsible for its satisfactory implementation. The HSE Manager shall also liaise with the HSE ‘Champion’ appointed in the New Delhi execution office to ensure that the HSE Plan is satisfactorily implemented there. The HSE Manager shall advise the project management team how best to achieve HSE objectives stipulated in this plan and supporting procedures. The Project HSE Manager shall review and update (if necessary) the HSE Plan at regular intervals during the FEED. Revision of the HSE Plan may be necessary if the FEED work scope or other circumstance changes the risk associated with the project execution or to the personnel engaged. The HSE Manager shall, with the assistance of the project Lead Environmental Engineer and the Lead Process Safety Engineer in London, coordinate the Health, Safety and Environmental Impact Assessment (HSEIA) Report for the project. As preparation of the HSEIA Report is intended to be subcontracted to a Consultant, the HSEIA Manager will prepare the technical scope of work, manage the Consultant on a day-to-day basis and coordinate with the other engineering disciplines to ensure that input documents are made available to the Consultant in a timely fashion. The HSEIA Manager will monitor the performance of the Consultant to ensure that the work is done to schedule and cost.

ELECTRONIC DOCUMENTS ARE CONTROLLED. ANY PRINTED COPY WILL BE UNCONTROLLED AND MAY BECOME OUTDATED 25418-000-G01-GHX-00001.doc

Page 8 of 26

TAKREER

HSE PLAN

TAKREER PROJECT No 5578 Agreement no 07-5578-F-1

RUWAIS REFINERY EXPANSION PROJECT

COMPANY Doc. No. 5578-PC-PA-003 ENG Doc. 25418-000-G01-GHX-00001

Rev. 1

The HSE manager will also actively participate in project reviews where health and safety is a critical issue, e.g. plot plan, HAZID/ENVID, HAZOP, SIL reviews and the like. The project HSE Manager shall maintain the project HSE Hazard and Effects Register (see section 7).

6.4

HSE ‘Champion’ (New Delhi)

The HSE Champion in is responsible for ensuring that the project HSE Plan is satisfactorily implemented in the New Delhi FEED execution office.

6.5

Lead Process Safety Engineer

The Lead Process Safety Engineer will primarily manage the safety of design for the project and will consult with the HSE Manager as necessary to ensure that the HSE objectives of this Plan and the inputs to the HSEIA process are met. The Lead Process Safety Engineer will be responsible for developing the Process Safety Philosophy for the project.

6.6

Lead Environmental Engineer

The Lead Environmental Engineer will primarily manage the environmental design for the project and will consult with the HSE Manager as necessary to ensure that the HSE objectives of this Plan and the inputs to the HSEIA process are met. The Lead Environmental Engineer will be responsible for developing the Environmental Philosophy for the project.

6.7

Team Members

The project Team Members comprise any project personnel including those specifically mentioned above. All team members have a responsibility to safeguard their own health and safety and those of others and protect the environment. Team members should report any project HSE related issue to their supervisor or to the HSE Manager for resolution.

7.

INSTRUCTIONS 7.1

Encourage Positive Behaviour Encouraging positive behaviours is considered to be a line management responsibility requiring active participation of all levels of management and supervision. Therefore the project shall ensure that health, safety and environment publicity tools appropriate to the project phase and target audience are developed. Examples of HSE publicity tools might include:

ELECTRONIC DOCUMENTS ARE CONTROLLED. ANY PRINTED COPY WILL BE UNCONTROLLED AND MAY BECOME OUTDATED 25418-000-G01-GHX-00001.doc

Page 9 of 26

TAKREER

HSE PLAN

TAKREER PROJECT No 5578 Agreement no 07-5578-F-1

RUWAIS REFINERY EXPANSION PROJECT

COMPANY Doc. No. 5578-PC-PA-003 ENG Doc. 25418-000-G01-GHX-00001

Rev. 1

•

Start every meeting with a safety topic.

•

Bulletin boards for HSE posters and achievements.

•

Personal safety plans.

•

HSE orientation and induction for project personnel.

•

HSE observation scheme so personnel can make suggestions to improve health, safety or the environment for the project.

Recognition instils enthusiasm and reinforcement for safe behaviour, and so project management shall provide timely recognition of HSE achievements of project personnel during the execution of the work. Key Performance Indicators (KPIs) and Key Performance Measures (KPMs) shall be developed to monitor HSE performance during the execution of the Project. These KPIs shall be SMART i.e. Specific, Measurable, Achievable, Relevant and Time-based. Applicable Key Performance Indicators are shown in Attachment 2. The project shall develop and implement a method of self-assessment to review and feed back HSE performance and the application of the HSE Plan. The self-assessment tool shall take each element of the ten major components of the HSE Management System and through a series of pre-set criteria or questions to identify HSE performance strengths and weaknesses. The project self-assessment team shall comprise, as a minimum, senior project management typically including the Project Manager, Project Engineering Manager, Project Controls manager, HSE Manager, Procurement Manager, Design Institute Coordinator and Construction Manager.

7.2

Plan, Organise and Communicate 7.2.1 Planning All HSE deliverables applicable to the project shall be identified and published within the project schedule. There are many deliverables prepared by Process, Process Systems, Process Safety, Environmental engineering disciplines active on this project which comprise health, safety and environmental content. It is not the intent to list all of them within this document. However specific deliverables, tasks and activities developed by the HSE discipline (in effect the HSE Manager) are given below: • • • • •

HSE Plan Orientation and induction training HSE risk assessment (for project travellers) HSE leaflet (for project travellers) Hazard and Effects Register procedure and reports

ELECTRONIC DOCUMENTS ARE CONTROLLED. ANY PRINTED COPY WILL BE UNCONTROLLED AND MAY BECOME OUTDATED 25418-000-G01-GHX-00001.doc

Page 10 of 26

TAKREER

HSE PLAN

TAKREER PROJECT No 5578 Agreement no 07-5578-F-1

RUWAIS REFINERY EXPANSION PROJECT

COMPANY Doc. No. 5578-PC-PA-003 ENG Doc. 25418-000-G01-GHX-00001

Rev. 1

HSE deliverables shall be aligned with COMPANY HSE management systems, mission, vision and values statement, HSE Control Procedures, and ADNOC Codes of practice where relevant.

7.2.2 Organise The organisation chart for the project is given in Attachment 3 and shows the relationships and reporting lines between the various project personnel. The HSE Manager reports directly to the Project Director. The RACI chart given in Attachment 4 defines the role, responsibility, and accountability of key project personnel for HSE tasks and deliverables.

7.2.3 Communicate The project shall publish its Key Performance Indicators (KPIs) and safety performance on the project notice board. Poster campaigns for heath and safety awareness will be run as appropriate. The minutes of all formal HSE meetings between COMPANY/PMC and ENGINEER shall be recorded for review and approval by COMPANY/PMC. ENGINEER shall ensure that all formal HSE meetings between the project team and Licensors, or the HSEIA consultant, are recorded as appropriate for review and approval. ENGINEER shall include project HSE performance as part of its formal monthly reports to COMPANY/PMC. The project shall also report its safety record as required by the Bechtel Core Process CP 104 and issue the corporate Monthly Safety Performance Report (MSPR) by the 5th day of each month.

7.3

Apply Standards and procedures

The project shall comply with, or exceed, the requirements of all the relevant health, safety and environmental laws, regulations and guidelines as follows: •

U.A.E Federal Law No 24, Protection and Development of the Environment, 1999, and subsequent executive regulations.

•

U.A.E Federal Law No 8, Regulation of Labour Relations.

•

COMPANY design standards and guidelines.

•

ADNOC Health Safety and Environmental Management Manual Codes of Practice.

•

International marine agreements and protocols to which the U.A.E is a party.

•

COMPANY HSE Control Procedures

ELECTRONIC DOCUMENTS ARE CONTROLLED. ANY PRINTED COPY WILL BE UNCONTROLLED AND MAY BECOME OUTDATED 25418-000-G01-GHX-00001.doc

Page 11 of 26

TAKREER

HSE PLAN

TAKREER PROJECT No 5578 Agreement no 07-5578-F-1

RUWAIS REFINERY EXPANSION PROJECT

COMPANY Doc. No. 5578-PC-PA-003 ENG Doc. 25418-000-G01-GHX-00001

Rev. 1

The following additional standards shall apply to managing health, safety and environmental issues relating to the ENGINEER’s home offices environments: •

Bechtel OG&C GBU ES&H Management Procedures.

•

Bechtel Environment Safety and Health (BESH) Core Processes.

Notwithstanding the codes and standards referred to above good engineering and health and safety practice shall be exercised at all times.

7.4

Develop Competency and Well Being

This Section describes how competency and well-being shall be developed and maintained. Where project personnel are discussed this is taken to mean ENGINEER employees. COMPANY/PMC representatives will be invited to participate in project HSE development initiatives. Project management shall allocate sufficient and qualified HSE resources to satisfy its obligations under the HSE requirements for this project and shall periodically review resource allocation to ensure that the HSE requirements for this project can continue to be met. All project personnel shall be given sufficient information and training, and the necessary authority and resources, to perform their duties in a competent, healthy and safe manner. ENGINEER shall provide competent HSE engineers, managers and advisors at senior level to support the project management throughout the entire course of the project work scope. At each of the office locations designated as execution centres (London and New Delhi) the Project Director and the Project Engineering Manager respectively, shall have responsibility for ensuring that their local office has in place the various HSE safeguards as a matter of local office policy. This shall include but not be limited to: •

Fire precautions and appropriate extinguishers

•

Regular fire drills and designated muster areas.

•

First Aid provision and arrangements for competent persons to administer.

•

Emergency and routine hospitalisation facilities.

•

Adequate insurance cover for all reasonably foreseeable risks.

•

Security provisions to allow secure working environments.

The project execution offices shall also issue to all permanent and occasional staff suitable safety information leaflets/booklets to inform these persons of the various provisions. Where the local representative of the office location is aware of local security difficulties, e.g. transportation or criminal matters, that person shall be charged to effectively draw the attention of all routine/itinerant staff to that problem. Method of communication shall be formal but applicable to the circumstances.

ELECTRONIC DOCUMENTS ARE CONTROLLED. ANY PRINTED COPY WILL BE UNCONTROLLED AND MAY BECOME OUTDATED 25418-000-G01-GHX-00001.doc

Page 12 of 26

TAKREER

HSE PLAN

TAKREER PROJECT No 5578 Agreement no 07-5578-F-1

RUWAIS REFINERY EXPANSION PROJECT

COMPANY Doc. No. 5578-PC-PA-003 ENG Doc. 25418-000-G01-GHX-00001

Rev. 1

Specifically the project execution offices shall arrange project HSE orientation and induction for all personnel beginning work on the project (COMPANY/PMC representatives will be invited to participate). The orientation and induction shall be given by the project HSE Manager (or HSE ‘Champion’) and cover the following topics: •

Office safety refresher

•

Project Introduction

•

HSE guidance for project travellers

•

Key project HSE risks

•

Q&A

The project shall furnish any personnel visiting operating oil & gas, utility plant or the like with suitable and sufficient personal protective equipment (PPE) in accordance with the recommendations of a formal risk assessment for the tasks or activities to be carried out.

7.5

Manage External Relationships

The key external interfaces for the project will be with the COMPANY/PMC representatives at the proposed job site in the Ruwais Industrial Complex and the third party consultants conducting the HSEIA, on-shore geotechnical and topographic surveys, and off-shore bathymetric and geotechnical surveys. The Process Licensors are contracted by the COMPANY. There are not anticipated to be any Long Lead Items for the project at present and therefore HSE performance evaluation of potential LLI Suppliers is not applicable at this time. The third party HSEIA consultant will be subject to an HSE review as part of the HSEIA Tender evaluation. With the exception of field based environment baseline studies, most of the HSEIA work scope will be performed in the ENGINEER’s London office with the HSEIA consultant ‘embedded’ within the ENGINEER’s project team under the direct supervision of the ENGINEER HSE Manager. Where visits are organised to the job site, ENGINEER and any other parties, such the HSEIA consultant, will be under the supervision of the Ruwais site personnel and expected to abide by their instructions as regards HSE matters.

7.6

Manage Hazards and Risks 7.6.1 General The objectives of safety related activities in all phases of the Project will be to ensure, as far as practicable, the safety of those who will be involved in the design, fabrication, construction, commissioning, operation and maintenance of the plant. The object of this work is to define both qualitatively and where appropriate, quantitatively, the design features, and the emergency and

ELECTRONIC DOCUMENTS ARE CONTROLLED. ANY PRINTED COPY WILL BE UNCONTROLLED AND MAY BECOME OUTDATED 25418-000-G01-GHX-00001.doc

Page 13 of 26

TAKREER

HSE PLAN

TAKREER PROJECT No 5578 Agreement no 07-5578-F-1

RUWAIS REFINERY EXPANSION PROJECT

COMPANY Doc. No. 5578-PC-PA-003 ENG Doc. 25418-000-G01-GHX-00001

Rev. 1

protective systems and equipment which can provide the most benefit in terms of risk reduction in accordance with the ALARP (As Low As Reasonably Practicable) principle. The ALARP level represents the point, objectively assessed, at which the time, trouble, difficulty and cost of further reduction measures becomes unreasonably disproportionate to the additional risk reduction obtained. In addition to any legislative framework, specific safety and environmental studies will be undertaken, the intent of which will be to identify hazards and assess their significance and the likely consequences. The work shall be aimed at supporting the appropriate design solutions, which shall ensure that the exposure of personnel or the environment to the hazards and consequent risks shall be as low as reasonable practicable.

7.6.2 HSEIA An HSE Impact Assessment (HSEIA) Report will be prepared for the project addressing the FEED design for HSE integrity. The HSEIA Report will present an overview of anticipated HSE hazards, impacts and associated levels which are based on analysis of relatively broad HSE information of conceptual technical design and the environment in which the project will be located in accordance with ADNOC-COPV1-02 ‘Health, Safety and Environmental Impact Assessment Requirements’. The report will make recommendations regarding the HSE issues that must be addressed in subsequent project phases i.e. detailed design and construction. The main components of the HSEIA are an Environmental Impact Statement (EIS), Control of Major Accident Hazards (COMAH), and an Occupational Health Risk Assessment (OHRA) Report. All HSEIA related reports (e.g. QRA, COMAH, OHRA) shall be submitted to COMPANY (HSED) for review and comment.

7.6.3 Occupational Health Occupational health risks shall be identified and assessed in a systemic manner during the design process so that appropriate exposure controls can be implemented. The hierarchy of exposure controls adopted by the project design are: • the elimination of hazardous materials; • reduction or substitution where elimination is not feasible; • isolation of personnel from possible exposures by the use of closed systems where technically achievable balanced by the practicality and economics of such control measures; • administrative measures such as procedures, methods and supervision; • the use of personal protective equipment should be considered the last resort. The project design shall adopt the ADNOC Group Standards for exposure to hazardous agents. These occupational exposure limits are based on the ACGIH Threshold Limit Values (TLVs) for chemical substances, physical (e.g. noise, vibration, ionising and non ionising radiation, thermal radiation) and biological agents (e.g. e-coli), and published annually. ELECTRONIC DOCUMENTS ARE CONTROLLED. ANY PRINTED COPY WILL BE UNCONTROLLED AND MAY BECOME OUTDATED 25418-000-G01-GHX-00001.doc

Page 14 of 26

TAKREER

TAKREER PROJECT No 5578

HSE PLAN

Agreement no 07-5578-F-1

COMPANY Doc. No. 5578-PC-PA-003 ENG Doc. 25418-000-G01-GHX-00001

RUWAIS REFINERY EXPANSION PROJECT

Rev. 1

Certain substances are prescribed by the ADNOC group and these are detailed in ADNOCCOPV2-02, common examples are: • • •

Asbestos containing materials Polychlorinated Biphenyl (PCB) containing products or equipment Ozone depleting substances (e.g. CFC/Halons)

Biological hazards such as the growth of bacteria in potable water systems, exposure to Legionella bacteria and SRBs (Sulphur Reducing Bacteria) in emergency shower and firewater systems shall be controlled by the implementation of good international design practices. Ergonomic design shall be applied to the layout of the control work stations. The location and orientation of instruments, panels, valves and the like where operators will need access for operation, maintenance or shut-down/start-up activities should be arranged to aid ease of work and personnel safety.

7.6.3.1.

Occupational Health Risk Assessment

As part of the HSEIA an Occupational Health Risk Assessment (OHRA) will be completed by a competent and certified industrial hygienist. The purpose of the OHRA is to ensure that any risks to occupational health have been systematically identified and suitable action has been taken in the FEED phase of the project design, or will be taken the detailed engineering phase as appropriate, to mitigate these risks and to protect construction workers or the eventual operators of the facility.

7.6.4 Safety The design principle adopted on the project shall be to maintain integrity of the facilities such that no uncontrolled loss of containment occurs. In practice this means that plant and facilities are safeguarded; passive physical barriers prevent impact from vehicles; reliable control systems are in place, plant and equipment can be isolated by automatic emergency shut-down systems and depressurised if necessary through relief valves to appropriately sized flare systems. Continuous sources of ignition, such as fired heaters, should be installed in non-hazardous areas. Maintaining adequate separation distances within units, and between plant areas, assists natural ventilation and dispersal of flammable vapours, and less congestion in process areas potentially reduces explosion overpressures. The escalation of an incident from one plant area to another is also reduced. The grading of the area around vessels and reactors with large hydrocarbon inventories shall be arranged to prevent liquid pools or spread of flammable liquid from one process area to another. Additional measures such as fire, gas and toxic release detection and protection will be installed.

ELECTRONIC DOCUMENTS ARE CONTROLLED. ANY PRINTED COPY WILL BE UNCONTROLLED AND MAY BECOME OUTDATED 25418-000-G01-GHX-00001.doc

Page 15 of 26

TAKREER

TAKREER PROJECT No 5578

HSE PLAN

Agreement no 07-5578-F-1

RUWAIS REFINERY EXPANSION PROJECT

COMPANY Doc. No. 5578-PC-PA-003 ENG Doc. 25418-000-G01-GHX-00001

Rev. 1

The Process Safety Philosophy project document number 25418-1000-3DC-GEU-Y0001 describes the aspects of safe process design in more detail. Fundamental to a safe plant is an inherently safe design and key safety studies will be undertaken during the project to identify safety hazards, assess risks and amend or modify the process design accordingly. These safety studies are described below.

7.6.4.1.

Hazard Identification (HAZID/ENVID) Studies

The purpose of the HAZID/ENVID study is to identify major health, safety or environmental hazards and risks associated with the facility and will take a very wide unconstrained perspective of the overall development. The study will be carried out when the first preliminary layouts and PFDs for the design become available. The HAZID/ENVID will be conducted in accordance with project procedure document number 25418-000-GPP-GHX-00172 aligned with COMPANY document HSE-CP24 ‘Hazard Identification’.

7.6.4.2.

Hazard and Operability (HAZOP) Studies

The purpose of a HAZOP is to provide a systematic qualitative identification of process hazards and potential operating problems arising from potential process deviations. The HAZOP is used to question every part of the process to discover what deviations from the intention of the design may occur and what their causes and consequences may be. Project design HAZOPs will be conducted on P&IDs when the process data and optimisation, control systems and control loops, and fire and gas and protection engineering is complete. The HAZOP will be conducted in accordance with project procedure document number 25418-000-GPP-GHX-00173. The standard proprietary HAZOP software used by ENGINEER is PrimaTech PHAWorks version 5.

7.6.4.3.

Safety Integrity Level (SIL) Studies

The purpose of the Safety Integrity Level Analysis (SIL) is to identify failures in the control system that could lead to personnel injury or loss of life, usually due to loss of containment of a substance hazardous to health. Project SIL studies are normally conducted after HAZOP and may follow on directly.

ELECTRONIC DOCUMENTS ARE CONTROLLED. ANY PRINTED COPY WILL BE UNCONTROLLED AND MAY BECOME OUTDATED 25418-000-G01-GHX-00001.doc

Page 16 of 26

TAKREER

TAKREER PROJECT No 5578

HSE PLAN

Agreement no 07-5578-F-1

COMPANY Doc. No. 5578-PC-PA-003 ENG Doc. 25418-000-G01-GHX-00001

RUWAIS REFINERY EXPANSION PROJECT

Rev. 1

The SIL studies will be conducted in accordance with project procedure document number 25418-000-GPP-GHX-00174 aligned with International Standards IEC 61508 and 61511. ENGINEER does not use proprietary software for SIL analysis as standard practice.

7.6.4.4.

Risk Tolerability

The following Risk Tolerability Criteria have been adopted by the project and are aligned with COMPANY document HSE-CP25 ‘HSE Risk Assessment’. The acceptability of risk and ALARP demonstration are to be assessed against these criteria. In addition to providing a demonstration that risks are ALARP the following risk targets will be utilised when quantitative risk analyses are applied: Workers IR = 1 in 50,000 or below (IR < 2 x 10-5) Unacceptable IR = 1 in 1,000 or above (IR > 1 x 10-3) Acceptable IR = 1 in 100,000 or below (IR < 1 x 10-5) Where IR = Individual Risk (fatality per person/yr) Benchmark

Public IR = 1 in 100,000 or below (IR < 1 x 10-5) IR = 1 in 10,000 or above (IR > 1 x 10-4) IR = 1 in 1,000,000 or below (IR < 1 x 10-6)

The F-N curve for Societal Fatal Risk is given in HSE-CP25.

7.6.4.5.

Quantitative Risk Assessment Study

A Quantitative Risk Assessment (QRA) will be conducted for the project as part of the HSEIA Report. The purpose of the Quantitative Risk Assessment (QRA) is to assess personnel risk posed by plant layout and potential hazard scenarios. Event tree analysis is used as the central QRA tool to organise a representative set of possible outcomes from all hazard scenarios developed in the risk analysis and to assign the contribution which each initial hazardous event makes towards each outcome. Probabilities of causalities are estimated at each step in the event tree as events escalate from the initiating event to the ultimate outcome of having to evacuate the facilities. The primary outputs of the risk assessment are predictions of fatality rates (IRPA) for members of groups of personnel at risk. The Individual Risk Per Annum (IRPA) considered tolerable is given in the section above. The QRA study will be conducted in accordance with project procedure document number 25418-000-GPP-GHX-00175. ENGINEER does not use proprietary software for QRA analysis as standard practice.

ELECTRONIC DOCUMENTS ARE CONTROLLED. ANY PRINTED COPY WILL BE UNCONTROLLED AND MAY BECOME OUTDATED 25418-000-G01-GHX-00001.doc

Page 17 of 26

TAKREER

HSE PLAN

TAKREER PROJECT No 5578 Agreement no 07-5578-F-1

RUWAIS REFINERY EXPANSION PROJECT

7.6.4.6.

COMPANY Doc. No. 5578-PC-PA-003 ENG Doc. 25418-000-G01-GHX-00001

Rev. 1

Control of Major Accident Hazards

A Control of Major Accidents Hazards (COMAH) Report will be conducted for the project as part of the HSEIA Report in accordance with ADNOC Code of Practice, ‘Control of Major Accident Hazards (COMAH)’, ADNOC-COPV5-01.

7.6.4.7.

Hazard and Effects Register

The project shall set up a Hazard and Effects Register (HAER) to be ‘owned’ by the project HSE Manager. The purpose of the HAER is to maintain a record for all HSE hazards and effects associated with the project, site or operation. Typically hazards or effects identified in the project HAZID/ENVID, QRA, OHRA, COMAH, and EIA or any other study may populate the HAER. The HAER records the source of the hazard, the hazard involved, qualitative assessment of the risk, safeguards to eliminate or mitigate risk, actions, responsibilities and status information. The risk shall be evaluated in accordance with ADNOC methodology. Entries in the register shall usually be made after completion of specific studies or formal assessments as described above, but may be made at any time. All project team members shall be actively encouraged to contribute to the register. Major Accident Hazards (High Risk), captured in the HAER, will be subject to comprehensive analysis such the hazard ‘Bow-tie’ approach as part of the Hazards and Effects Management Process (HEMP).

7.6.5 Environment Environmental impact arising from development of the facilities will be described in a formal Environmental Impact Statement (EIS) arising out of the Environmental Impact Assessment (EIA) process. The EIS shall be part of the HSEIA Report and conducted in accordance with ADNOC-COPV2-01 ‘Code of Practice on Environmental Impact Assessment’. The EIS will identify all planned significant environmental impacts and describe how Best Available Techniques (BAT) is used to eliminate or mitigate the impact. Conclusions and recommendations made in the EIS will be included in the project design documents where applicable. The design principles adopted on the project shall address, as appropriate, emissions to air, aqueous emissions, and waste management. The specific limits and standards applied to these emissions are given in the project Environmental Philosophy document number 25418-0000V0Y-H000-V0001. The key environmental issues to be considered during the FEED are:

ELECTRONIC DOCUMENTS ARE CONTROLLED. ANY PRINTED COPY WILL BE UNCONTROLLED AND MAY BECOME OUTDATED 25418-000-G01-GHX-00001.doc

Page 18 of 26

TAKREER

HSE PLAN

TAKREER PROJECT No 5578 Agreement no 07-5578-F-1

RUWAIS REFINERY EXPANSION PROJECT

•

• • • • •

• • •

7.7

COMPANY Doc. No. 5578-PC-PA-003 ENG Doc. 25418-000-G01-GHX-00001

Rev. 1

Certain materials shall be prohibited in accordance with COMPANY document HSECP11 ‘Prohibited Substances’ (i.e. halons, CFC and HCFC emissions, asbestos, PCB’s, Tetraethyl Lead and hydrazine). Venting of process materials shall be prohibited (case-by-case exceptions may be granted if shown to be ALARP). Equipment noise shall be managed in accordance with the COMPANY Design Standards (DGSs). Compliance with ambient air quality standards shall be verified by air dispersion modelling (this will part of the EIA). Treatment of refinery waste water (process and domestic) shall meet relevant compliance standards for discharge. The drainage network shall be designed to good engineering principles and crossconnection of pressurised (close drain) and unpressurised drains (open drain) shall not be permitted. The design shall provide adequate protection from contamination with refinery raw materials or products for soil and groundwater. The premise for acceptable handling and disposal of waste materials to be carried forward into the execution phase of the project. Visual impact of the new facilities.

Management of Change

The project shall develop and implement a suitable Management of Change procedure in alignment with COMPANY document HSE-CP26 ‘Health, Safety and Environmental Impact Assessment (HSEIA)’. The project shall ensure through the implementation of this procedure that the HSE impact of any change shall be properly identified and communicated to all concerned. The Management of Change procedure shall include the following: •

The technical basis for the change

•

Impact of the change on work HSE: process, procedures or personnel

•

Necessary modifications to existing or new operating procedures

•

The process safety methodology used to analyse the change

•

Authorisation for change

•

How the change is communicated

The Project Management Team shall ensure that all changes having a potential impact upon HSE are brought to the prompt attention of the HSE Manager and the responsible engineer, as applicable, for assessment and review. The project shall not implement changes with a potential impact on HSE without proper review and approval.

ELECTRONIC DOCUMENTS ARE CONTROLLED. ANY PRINTED COPY WILL BE UNCONTROLLED AND MAY BECOME OUTDATED 25418-000-G01-GHX-00001.doc

Page 19 of 26

TAKREER

HSE PLAN

TAKREER PROJECT No 5578 Agreement no 07-5578-F-1

RUWAIS REFINERY EXPANSION PROJECT

7.8

COMPANY Doc. No. 5578-PC-PA-003 ENG Doc. 25418-000-G01-GHX-00001

Rev. 1

Learn from Experience

The Project shall develop and implement a system to report, analyse and remedy HSE related events.

7.8.1 HSE Performance Self-Assessment The Project shall apply a system of HSE Self-Assessment on a regular basis as described in Section 7.1. This shall permit the project management team to regularly review HSE performance, identify areas of good practice or for improvement, and allocate resources as necessary to drive improvement.

7.8.2

HSE Key Performance Indicators and Measures

The Project shall set Key Performance Indicators (KPIs) and Key Performance Measures (KPMs) for its HSE performance as described in Section 7.1. This shall permit the project management team to regularly review HSE performance, and identify areas of good practice or for improvement, and allocate resources as necessary to drive improvement.

7.9

Audit and Review

The project shall provide time and resources for HSE audits and reviews conducted by COMPANY/PMC should they wish to do so. The project shall be periodically audited from within ENGINEER’s own organization for compliance with ENGINEER OG&C Global Business Unit HSE management procedures. The Project Management Team shall ensure that any corrective actions arising from HSE audits and reviews are implemented as soon as reasonably possible.

8.

ATTACHMENTS Attachment 1(a) -TAKREER HSE Policy Attachment 1(b) - ENGINEER’s Corporate HSE Policy Attachment 2 - TAKREER Strategic Health, Safety and Environmental Objectives Attachment 3 - Project Key Performance Indicators Attachment 4 - Project Organisation Attachment 5 - RACI chart

ELECTRONIC DOCUMENTS ARE CONTROLLED. ANY PRINTED COPY WILL BE UNCONTROLLED AND MAY BECOME OUTDATED 25418-000-G01-GHX-00001.doc

Page 20 of 26

TAKREER

HSE PLAN

TAKREER PROJECT No 5578 Agreement no 07-5578-F-1

RUWAIS REFINERY EXPANSION PROJECT

COMPANY Doc. No. 5578-PC-PA-003 ENG Doc. 25418-000-G01-GHX-00001

Rev. 1

Attachment 1(a) – TAKREER HSE Policy

ELECTRONIC DOCUMENTS ARE CONTROLLED. ANY PRINTED COPY WILL BE UNCONTROLLED AND MAY BECOME OUTDATED 25418-000-G01-GHX-00001.doc

Page 21 of 26

TAKREER

HSE PLAN

TAKREER PROJECT No 5578 Agreement no 07-5578-F-1

RUWAIS REFINERY EXPANSION PROJECT

COMPANY Doc. No. 5578-PC-PA-003 ENG Doc. 25418-000-G01-GHX-00001

Rev. 1

Attachment 1(b) – ENGINEER’s Corporate HSE Policy

ELECTRONIC DOCUMENTS ARE CONTROLLED. ANY PRINTED COPY WILL BE UNCONTROLLED AND MAY BECOME OUTDATED 25418-000-G01-GHX-00001.doc

Page 22 of 26

TAKREER

HSE PLAN

TAKREER PROJECT No 5578 Agreement no 07-5578-F-1

RUWAIS REFINERY EXPANSION PROJECT

COMPANY Doc. No. 5578-PC-PA-003 ENG Doc. 25418-000-G01-GHX-00001

Rev. 1

Attachment 2 - TAKREER Strategic Health, Safety Environmental Objectives

ELECTRONIC DOCUMENTS ARE CONTROLLED. ANY PRINTED COPY WILL BE UNCONTROLLED AND MAY BECOME OUTDATED 25418-000-G01-GHX-00001.doc

Page 23 of 26

TAKREER

TAKREER PROJECT No 5578

HSE PLAN

Agreement no 07-5578-F-1

COMPANY Doc. No. 5578-PC-PA-003 ENG Doc. 25418-000-G01-GHX-00001

RUWAIS REFINERY EXPANSION PROJECT

Rev. 1

Attachment 3 - Project Key Performance Indicators and Measures

KPI

1 2

Personal HSE Contracts or Plans are developed for all management staff and key personnel Review, update and progress of the Personal HSE contracts or Plans

Target 100 % of key management team Quarterly

Responsible Persons

Project Management Team HSE Manager/Champion

3

Project self assessment reviews and performance update

4

Review and update HSE Plan

Quarterly

HSE Manager

5

Report Waste and Energy usage for EMS reporting

Monthly

HSE Manager

6

Project HSE travel leaflet

Issued to 100% project personnel travelling

HSE Manager & Project Admin Assistant

7

Project orientation and induction

100 % project personnel

Project Director & HSE Manager/Champion

8

HSE briefings and awareness presentations

Start Month 4, then quarterly

Project Director & HSE Manager/Champion

9

Prepare project HSE Performance report.

10

Project Floor Safety Inspections

Bi-monthly

Monthly Bi-monthly

Project Management Team

HSE Manager Project Management Team

KPM

Target

1

Project Related Incidents (injury, environment damage, property loss)

Zero

Project Management Team

2

Issue HSEIA Report to COMPANY

FEED completion date

Project Management Team

Responsible Persons

ELECTRONIC DOCUMENTS ARE CONTROLLED. ANY PRINTED COPY WILL BE UNCONTROLLED AND MAY BECOME OUTDATED 25418-000-G01-GHX-00001.doc

Page 24 of 26

TAKREER

HSE PLAN

TAKREER PROJECT No 5578 Agreement no 07-5578-F-1

RUWAIS REFINERY EXPANSION PROJECT

COMPANY Doc. No. 5578-PC-PA-003 ENG Doc. 25418-000-G01-GHX-00001

Rev. 1

Attachment 4 – Project Organisation

ELECTRONIC DOCUMENTS ARE CONTROLLED. ANY PRINTED COPY WILL BE UNCONTROLLED AND MAY BECOME OUTDATED 25418-000-G01-GHX-00001.doc

Page 25 of 26

TAKREER

TAKREER PROJECT No 5578

HSE PLAN

Agreement no 07-5578-F-1

COMPANY Doc. No. 5578-PC-PA-003 ENG Doc. 25418-000-G01-GHX-00001

RUWAIS REFINERY EXPANSION PROJECT

Rev. 1

Project Manager

Project HSE Manager

Project Eng. Manager

Proj. Constr. Manager

Project Procurement Manager

Team Members

Attachment 5 – RACI chart

HSE Policy

A

R

C

C

C

I

HSE Plan

A

R

C

C

C

I

HSE Orientation & Training

A

R

C

C

C

I

HSE publicity

A

R

-

-

-

I

HSE self-assessments

A

R

R

R

R

-

KPIs and reporting

A

R

R

R

R

I

HSE Hazard and Effects Register

A

R

-

-

-

I

TASKS AND ACTIVITIES

Abbreviations are defined as: A – Accountable i.e. the person who has the ultimate responsibility. R – Responsible i.e. the person (people) who must do the work or ensure that is completed. Where more than one person has responsibility they are shown with shared responsibility. C – Consult i.e. the person(s) who must be consulted to finalise the document or activity. They may have input in terms of comments or participation in the activity. I – Inform i.e. those people who must be informed about the activity, both before it occurs and afterwards in a summary of main findings

ELECTRONIC DOCUMENTS ARE CONTROLLED. ANY PRINTED COPY WILL BE UNCONTROLLED AND MAY BECOME OUTDATED 25418-000-G01-GHX-00001.doc

Page 26 of 26