Hazard Identification & Task Risk Assessment

BP Pakistan Exploration & Production, Inc. Rev. No. HAZARD IDENTIFICATION & TASK RISK ASSESSMENT

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DOCUMENT CONTROL Revision Record Revision No.

Revision Date

Section / Page

Description & Reason for amendment

1

Dec. 05, 2005

Various

To bring in line with CoW Standard, revised PTW procedure, and in response to various audits recommendations & feedbacks. Also the risk evaluation criteria have been modified to 5 x 5 matrix.

2

August 18, 2007

Various

To clarify sections relating to Roles, Responsibilities, Accountabilities and Competencies to further align with the CoW Standard and to incorporate the Group HITRA Draft Guidelines.

Document No.:

PRO/SFTY/018

Issue Date:

August 18, 2007

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TABLE OF CONTENTS 1.0

INTRODUCTION .......................................................................................................... 3

2.0

PURPOSE AND SCOPE .............................................................................................. 3

3.0

LINKAGE WITH OTHER PROCEDURES AND STANDARDS ................................... 3

4.0

DEFINITIONS ............................................................................................................... 4

5.0

ROLES AND RESPONSIBILITIES .............................................................................. 5

6.0

TRAINING AND COMPETENCY ................................................................................. 7

7.0

HITRA PROCESS OVERVIEW .................................................................................... 9

8.0 8.1 8.2 8.3 8.4 8.5 8.6 8.7 8.8 8.9 8.10 8.11 8.12 8.13 8.14 8.15 8.16 8.17 8.18 8.19 8.20 8.21

PROCEDURE ............................................................................................................ 10 WORK REQUEST.......................................................................................................... 11 CHECK TASK CATEGORY ............................................................................................. 11 PERFORM LEVEL-1 TRA.............................................................................................. 11 DEFINE TASK PARAMETERS ......................................................................................... 12 PERFORM LEVEL-2 TRA.............................................................................................. 12 FORM TRA TEAM ........................................................................................................ 12 BREAK DOWN OF TASK INTO ACTIVITIES ...................................................................... 14 IDENTIFY HAZARDS ...................................................................................................... 14 IDENTIFY HAZARD EFFECTS (CONSEQUENCES) ............................................................ 14 DEFINE RISK RATING ................................................................................................... 15 IDENTIFY CONTROLS.................................................................................................... 18 CONTROLS ADEQUATE ................................................................................................ 21 RESIDUAL RISK ACCEPTABLE ...................................................................................... 22 AGREEMENT ON RISKS AND CONTROLS ....................................................................... 22 DOCUMENT AND RECORD ............................................................................................ 22 REVIEW OF TRA.......................................................................................................... 23 COMMUNICATION ......................................................................................................... 23 IMPLEMENT CONTROLS ................................................................................................ 22 CARRY OUT THE TASK................................................................................................. 24 MONITOR FOR CONDITION CHANGE .............................................................................. 24 RECORD LESSONS LEARNED ....................................................................................... 24

APPENDIX 1 - TASK RISK ASSESSMENT FLOWCHART................................................. 25 APPENDIX 2 - TASK CATEGORIZATION CHART ............................................................. 25 APPENDIX 3 - HAZARD CHECKLIST ................................................................................. 27 APPENDIX 4 - RISK ASSESSMENT SAMPLE.................................................................... 32 APPENDIX 5 - TRA FORM ................................................................................................... 35

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1.0

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INTRODUCTION Pre-job risk assessment is a key element of the BP Group Standard for the Control of Work (Element 5 – Assess and manage the risks), the BP Golden Rules of Safety (Getting the Basics Right) as well as the Getting HSE Right Management Framework (Element 2 – Risk Assessment and Management). The identification and control of risk is an essential pre-requisite to ensure safe execution of work activity and secure compliance with the requirements of health and safety legislation. The process comprises the following three basic stages: •

hazard identification – identifying hazards which could cause harm.

•

risk assessment – assessing the risk that may arise from hazards.

•

risk control – deciding on suitable measures to eliminate or control risk.

The Control of Work Group Standard states that: “Tasks shall not be conducted without being risk assessed.” This document is intended to provide the information and guidance to develop the systems necessary to effectively identify the hazards and manage the risks associated with work activities. 2.0

PURPOSE AND SCOPE The purpose of this procedure is to provide guidelines to the user of Hazard Identification and Task Risk Assessment (HITRA) within Pakistan Performance Unit Operations. The procedure shall be used to identify the potential hazards, assess the risks involved and identify the controls and precautions necessary to reduce the risk to ‘as low as reasonable practicable (ALARP)’ level before undertaking the work safely. This procedure shall apply to all operations of BP Pakistan, and also to its contractors and sub-contractors where procedure does not exist. This procedure shall be used for Level 1 and Level 2 tasks to mitigate potential hazards by assessing the risks involved in carrying out the task and providing controls to reasonably practicable level.

3.0

LINKAGE WITH OTHER PROCEDURES AND STANDARDS This procedure has linkages with the following procedures, rules, standards and regulations. a) BP Group Standard for the Control of Work (Element – 5) b) BP Getting HSE Right Management Framework (Element – 2) c) BP Golden Rules of Safety (Getting the Basics Right) d) BP Pakistan Procedure on Permit to Work (PRO/SFTY/005)

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TERMINOLOGY

Hazard

The potential or condition to cause harm, including ill health and injury, damage to property, plant, products or the environment, production losses or increased liabilities.

Hazard Effect [Consequence]

The harm or consequence which takes place due to the realization of the hazard.

Probability

Likelihood of an event occurring, and resulting in specified Hazard Effect or consequence.

Risk

The likelihood that a specified undesired event will occur due to the realization of a hazard by, or during, work activities or by the products and services created by work activities. Risk is the combination of the Hazard Effect (Consequence) and Probability (likelihood of its occurrence).Risk = Hazard Effect (Consequence) x Probability (Likelihood of Occurrence).

Control

Control is the reduction in the level of risk by applying suitable safety measures.

ALARP

To reduce a risk to a level, which is "as low as reasonably practicable" and involves balancing reduction in risk against the time, trouble, difficulty, and the cost of achieving it.

Competency

The system to provide the information, instruction, training, and supporting communication's effort needed to meet the task needs.

Planning

Is used to describe the process by which the objectives and methods of implementing the health and safety policy are decided. It is concerned of allocating resources to achieve objectives and decide priorities. It ranges from general topics dealing with the direction of the whole organization to detailed issues concerned with standards setting and the control of specific risks.

Measuring

The collection of information about the implementation and effectiveness of plans and standards. This involves a variety of checking or ‘monitoring’ activities.

Task Risk Assessment

Also known as JSA (Job Safety Analysis) or JHA (Job Hazard Analysis). It is an organized and systematic effort to identify and analyze the significance of potential hazards of each manageable task associated with the materials, equipment, instrumentation, utilities, human actions (routine and non-routine), and external factors that might impact the process. (This is done by breaking the activity into manageable tasks) and then to identify suitable controls to ensure risks are reduced to an acceptable level and document risk assessment results.

Residual Risk

The Risk remaining after applying Control measures, and carrying out a reassessment of HE rating and Probability.

Auditing

The structured process of collecting independent information on the efficiency, effectiveness and reliability of the total safety management system and drawing up plans for corrective action.

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ROLES AND RESPONSIBILITIES The roles and associated responsibilities required to successfully deliver the HITRA process are described below. The roles and responsibilities described under each job title must be assigned to suitably competent, trained, knowledgeable and authoritative personnel for the HITRA process to work successfully. The necessary trainings and competencies required to effectively fulfil these roles and responsibilities are elaborated in Section 6.0 of this procedure.

5.1

Single Point Accountable Person(s) – (SPA) Operations Manager shall be the SPA for all field operations whereas the Support Services Team Leader shall be the SPA for the Karachi and Islamabad Offices. The SPA person shall be responsible for giving assurance to BPP Management that the correct procedure is being followed. He is the operational custodian of the HITRA procedure and is responsible for its up gradation, training and operation. He is the principal resource to provide support and advice on HITRA procedure and its implementation. He will be responsible for:

5.2

•

Ensuring that a Risk Assessment process is in place and is being followed consistently at the site / premises.

•

Reviewing and auditing the risk assessment process to ensure that the standard of risk assessments is maintained and areas of improvement are identified and implemented.

•

Approve any reviews / updates / revisions in the HITRA procedure in the light of experience gained and lessons learned.

•

Ensuring a process is in place to manage the appointment of competent persons to act as Authorising Signatories for Level 1 and Level 2 Risk Assessments.

•

Ensuring a process is in place to manage the appointment of competent persons to act as Level 1 Risk Assessment Completers.

•

Ensuring a process is in place to manage the appointment of competent persons to act as Level 2 Risk Assessment Team Leaders.

•

Assisting and advising all users of the HITRA procedure in its correct interpretation and implementation and maintenance of the HITRA system.

Level – 1 HITRA Completer This role is performed by those carrying out the work activity or Performing Authorities. The main responsibilities for this role are: •

Complete Level 1 Risk Assessments where required.

•

Ensure that adequate consultation has taken place (typically with the Area Authority and/or Permit Issuer).

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• 5.3

2

Ensure that appropriate authorisation has been obtained prior to the commencement of work.

Level – 2 HITRA Team Leader This role is normally performed by a person belonging to the Performing Team and being in a senior supervisory position with appropriate training and certification of the HITRA process as well as sufficient experience in the task to be performed. The main responsibilities for the Level - 2 HITRA Team Leader are:

5.4

•

Lead the Team responsible in performing a Level 2 HITRA to the process described in this document. Refer to Section 7.0.

•

Ensure the team understands the assessment process and what it is trying to achieve.

•

Take responsibility for maintaining the quality of the Risk Assessment and ensure that the assessment team includes personnel with all the necessary knowledge and competence for the task involved.

•

Ensure the Risk Assessment includes a worksite visit.

•

Ensure that all members of the Risk Assessment team have a full opportunity to contribute and that the details of the assessment are agreed by all team members.

•

Ensure that the details of the assessment are accurately recorded.

Level – 2 HITRA Team Member Level – 2 HITRA Team Members include representatives from the Performing Team as well as any additional members who can contribute to the Risk Assessment Process by virtue of their specialized knowledge and skills or relevant prior work experience. The responsibilities of the individual team members are to:

5.5

•

Actively participate in the Risk Assessment process.

•

Help identify hazards and control measures to remove or reduce the likelihood of an incident/accident happening.

•

Ensure they agree with the overall Risk Assessment before approval and that risks have been reduced as low as reasonably practicable.

People Carrying out the Work The responsibilities of the people carrying out the work are to: •

Understand the hazards and control measures associated with the task.

•

Participate and contribute in the pre-job toolbox talk / safety meeting.

•

Actively monitor the worksite and surroundings for change.

•

Stop the job at any time they are concerned about safety.

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•

Stop the job if they identify a hazard not recorded on the Risk Assessment and Permit to Work or Procedure.

•

Carry out work as defined in the Risk Assessment and Permit to Work or Procedure.

HITRA Authorizing Signatories The SPA Person (or delegated nominee) will appoint personnel competent to authorize completed Level 1 and Level 2 Risk Assessments. For Work Control Activities, this role would normally be performed by the Permit Issuer. For non Work Control Activities, this role would be performed by the Area Authority or his representative. A person authorising a Level 1 Risk Assessment will: •

Decide whether the risks can be controlled adequately by the proposed means, taking into account the controls required by any relevant local procedure and the competence of the person in charge.

•

Initiate the need to complete a Level 2 Risk Assessment if they are not completely assured that the risks will be adequately controlled and believes a more rigorous risk assessment is required.

A person authorising a Level 2 Risk Assessment will: •

Accept the level of residual risk.

•

Confirm that the risk assessment was carried out by a team with the appropriate level of expertise.

•

Confirm that the risk assessment team has taken appropriate guidance on health, safety and environmental legislation and consequent limits on operation (e.g., environmental consents).

6.0

TRAINING AND COMPETENCY

6.1

Training HITRA methodologies are not complex, but they do rely on wide work-related underpinning knowledge and experience. This includes experience of: •

relevant hazards

•

realistic consequences

•

good quality and effective controls

All personnel involved in the HITRA process should undertake the following basic training: •

definitions – hazard, risk, consequences, likelihood, controls, hierarchy of controls, risk matrix

•

the principles of TRA and the process used

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•

when to conduct Level 1 and 2 Risk Assessments

•

other types of Risk Assessment – generic, JSA, quantified, major hazard, environmental, etc

•

Risk Assessment tools – e.g. checklists

•

expectations of Team members - need to contribute personal experience, reach agreement or record divergent views

•

responsibilities after TRA is completed – at task location, identifying changes, etc

Before selection for training, Level 2 HITRA Team Leaders should be able to demonstrate wide knowledge of the work environment and relevant tasks. Although checklists and other generic tools are available, the Team Leader has to use these with informed judgement. 6.2

Proven Competency / Certification All personnel involved in the use of the HITRA process or procedures shall be trained and / or assessed as competent to the appropriate level as elaborated in the following training grid. Role

1-day Awareness Training

2-day Training + Certification

Level 1 HITRA Completer

Yes

No

Level 2 HITRA Team Leader

No

Yes

Level 2 HITRA Team Member

Yes

No

HITRA Authorizing Signatories

No

Yes

The required competency of all relevant personnel should be confirmed during the planning process for a particular task. The SPA Person (or delegated nominee) should ensure that new personnel have the required competencies properly certified from acceptable source or third parties. Having undergone the appropriate training and having been assessed competent to carry out the relevant duties, Authorised Signatories and Level 2 Risk Assessment Team Leaders can only take on these roles when they have been duly certified and authorised. 6.3

Records Records of attendance reference/verification.

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competency

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Reassessment and Refresher Training For those considered experienced, re-assessment of competence should occur at a frequency of not more than 2 years. If someone is absent from an operational role in the HITRA system for more than 12 months, they should undergo both refresher training and competence reassessment.

7.0

HITRA PROCESS OVERVIEW The BP Golden Rules – Getting the Basics Right and the Control of Work Group Standard, Element – 5 require application of the risk assessment principles. The three key steps in risk assessment are: 1. Identify the hazards. 2. Evaluate the hazards - decide who or what might be harmed and how. 3. Mitigate the hazards - assess the risks against a standard/benchmark and decide whether the hazard can be removed, substituted or controlled. Task Risk Assessment is a tool for reducing the probability and consequence of accidents at work. Therefore, all work/tasks should be analyzed to identify the hazards present, assess the risks involved, and identify the controls necessary to undertake the work safely. The number and varieties of tasks carried out within BP are very large and there is a correspondingly wide range of risks involved. This means that, for practical reasons, the extent of assessment of any particular case has to be balanced against the type of risk so that the greatest effort is focused in the areas of most severe risk. Consequently, the TRA has been divided into two levels i.e. Level –1 and Level –2.

7.1

Level-1 Level 1 is a broad overview of the task by a competent person(s) – typically the Performing Authority – to identify all significant hazards involved and appropriate controls which are required to let the job to proceed. A Level-1 Task Risk Assessment involves a review of the task by the performing person in consultation with his Team Leader, Superintendent or Supervisor or Area Authority to identify the hazards associated with the task and appropriate control measures required for managing these hazards. The Team Leader, Superintendent or Supervisor must decide whether the risks can be controlled adequately by the proposed means, taking into account the controls required by any relevant procedure and the competence of the person-in-charge. Once the task is identified as low risk, it shall be forwarded for approval to proceed. If the Team Leader, Superintendent or Supervisor is not completely assured that the risks will be adequately controlled by proposed means and are medium or high risks, he shall ask for level-2 task risk assessment. Level 1 TRA must be carried out for the following: (a)

All new activities.

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(b)

All jobs at planning and design stage.

(c)

Repeated activities, if condition is changed.

(d)

Annual review of TRAs for repeated activities.

2

A new risk assessment will not be required for every task. Where a task has previously been assessed and/or is covered by a procedure, it may not need a new risk assessment. Where this is the case, the previous assessment or procedure should be reviewed to ensure that the hazards and controls are still relevant and that any site or job specific controls are identified. If condition is changed or an incident occurs while the procedure or previously assessed TRA is in use, the whole procedure, including the risk assessment, must be reviewed before it is re-issued. For low risk tasks performed by competent people, no formal recorded risk assessment is required as it is covered by the individual’s competency and skill. 7.2

Level- 2 Level 2 is a more structured semi-quantitative assessment which is required when competent person judges that there are greater hazards or complexities associated with the task which require more rigorous assessment. A Level 2 TRA is carried out by a team. The following are considered high-risk activities that require level 2 TRA, written procedures, and Permit to Work (PTW) as well: a)

Confined Space Entry including vessel / tank cleaning, sandblasting or desludging.

b)

Trench Excavation or pit more than 4 feet deep or other ground penetration such as piling.

c)

Working at height, including erection of scaffolding or structures, where serious injury is likely in case of a fall (2m is normally taken as the guide height, where the fall would be onto flat ground, but lower heights will be relevant where a fall would be onto other surfaces)

d)

Hot work in Hazardous Areas.

e)

Failure to meet minimum isolations requirement.

f)

Complex and complicated lifting operations involving multiple suspensions or lifting over live plant.

g)

High potential source of ignition.

h)

Any activities involving potential exposure to H2S.

i)

Where multiple protective devices are removed or inhibited from a system.

j)

Simultaneous operations like well operation adjacent to operating plant.

k)

Mud plugging and hot tapping for tanks or main oil & gas lines.

l)

Planned deviation from an existing policy, procedure or practice.

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m)

Waste Management (Handling and disposal of NORM wastes, asbestos etc).

n)

Road transportation of crude oil / condensate.

o)

Any other activities where risk assessment is medium and high.

HITRA PROCEDURE The first part of the procedure is to establish what it will involve, once the task is identified. The initial appraisal should identify the need of special safety assessment and identify at the outset, if it is obvious that the task cannot be carried out safely. If the hazards are not reconciled at this stage, the task should be rejected or redefined. The Task Risk Assessment procedure is shown in the flow chart (Appendix-1) and following sections give guideline to each stage of the process.

8.1

Work Request Work request can be in the form of written or verbal request to carry out any work. The originator of the work request can be from any department of Pakistan PU.

8.2

Check Task Category Once the parameters of a task are defined, the task should be categorized in either Level 1 or Level 2 as defined in section 7.0. (See also Appendix-2 – Task Categorization Chart).

8.3

Perform Level-1 TRA A Level 1 TRA involves a review of the task by the performing person in consultation with another authorised and competent person – this would typically be the Area Authority and/or Line Supervisor. The review purpose is to identify and agree the hazards associated with the task and appropriate control measures required for managing these hazards. The Authorised Signatory must decide whether the risks can be controlled adequately by the proposed means, taking into account the requirements of any relevant procedure and the competence of the performing person. The Level 1 TRA will need to be recorded. Typically, for work being controlled using a permit, the Level 1 TRA will be incorporated directly into the permit document. Otherwise, a suitable record of the task, identified hazards, controls, authorisation, etc. should be completed. When the task is considered to have an acceptably low risk, it shall be approved to proceed using the agreed controls. However, if the Authorised Signatory is not completely assured that the risks will be adequately controlled by the proposed means, they shall ask for a more detailed, Level 2 Task Risk Assessment to be carried out. A new risk assessment will not necessarily be required for every task, as routine tasks could be covered by a generic risk assessment or a procedure (as long as that procedure is based on a documented risk assessment). Also a non-routine task may have previously been assessed. For such tasks, the previous assessment may be reviewed to ensure that the hazards and controls are still relevant and that any

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necessary location-specific and time-specific controls are included. If conditions have changed, the RA should be reviewed and revised before it is re-used. The Team Leader, Superintendent or Supervisor must decide whether the risks can be controlled adequately by the proposed means, taking into account the controls required by any relevant local procedure and the competence of the person in charge. If the Team Leader, Superintendent or Supervisor is not completely assured that the risks will be controlled adequately by these measures and feels a more rigorous assessment is required, then he must inform the performing person of the work and request a Level 2 Assessment. 8.4

Define Task Parameters When a work request is received, the task parameters should be defined clearly to determine exactly what the task would involve. This is the responsibility of the site supervisor i.e. the person responsible for seeing that work is carried out. In case of tasks at design stage, Project Team Leader / Project Engineer / MOC coordinator is responsible. Following are to be considered while defining the parameters of a task:

8.5

•

The need for any special safety studies or assessments (e.g. manual handling).

•

If the hazards cannot be reconciled and it is obvious that carrying out of task is unsafe, it should be immediately discarded or redefined.

•

What personal competency requirements are needed of those who will assess the risks and perform the task

•

What types of equipment are needed?

Perform Level-2 TRA The objective of the Level 2 TRA is to: •

assemble a team of persons with intimate knowledge and expertise of the task (including knowledge of the task location)

•

examine all the hazards associated with the task in a structured way

•

devise a set of controls which will ensure an acceptable level of risk is achieved

•

use external experts (e.g. specialist vendors) where necessary

In case of larger tasks, turnarounds or projects, early work should be undertaken to identify potential tasks requiring Level 2 assessments in order to allow adequate time for the TRA to be planned and completed. A Level-2 assessment must be carried out by a Team and can be done at any stage in the process. It shall be carried out, when it is believed that significant risks exist and such risk can not be adequately controlled without more rigorous assessment Document No.:

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and the application of additional controls. Level-2 TRA is mandatory for activities defined in section 7.2 8.6

Form TRA Team Job performing Team Leader or his nominee shall nominate TRA team and the leader of the team – a BPP trained, certified competent and authorized person. This team shall have a minimum of three members. Team members must be familiar with the TRA process and have intimate knowledge of the work activities and environment and the tools and equipment to be used to make informed judgments of the risks involved and measures to mitigate them. Depending on the complexity and size of the Task involved, a team might include the following people, in addition to the leader: •

A Representative or supervisor of the contractor carrying out the job

•

Technician(s)

•

Delivery / Service Team Engineer(s)

•

HSE representative

•

Other members of the workforce or persons external to the site who may have specialist knowledge or experience which could help with the Assessment.

This requires knowledge and experience of the area, plant, equipment or system to be worked on and awareness of the hazards involved and the potential consequences, and knowledge of company’s HSE procedures. The team shall have personnel who: •

Are responsible for the task.

•

Are competent to conduct TRAs and have the ability to facilitate the process.

•

Have sufficient knowledge, expertise and understanding of hazards.

•

Will be involved in carrying out the task.

The team shall discuss and carry out preparatory work, job plan review to ensure that the team members have sufficient background information on which to base their judgment. The team member shall visit the work site to see the physical layout of the area and current site conditions. Particular attention shall be given to other plants or equipment in the area. It shall also be noticed that other adjacent activities are not planned to take place at the same time as the task to be performed as they could impact the TRA. The team leader shall make arrangements for the team to work as a group and shall ensure that there is adequate space for examination of drawings and that sufficient time is allocated to reach a rational decision. Note – the Control of Work Group Standard states that:

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All Risk Assessment teams must include at least one representative from the workforce assigned to carry out the task being assessed. Where more than one team is assigned to carry out the work, a representative from each should be included. 8.7

Break Down of Task into Activities Once the team is prepared to proceed for actual risk assessment, they shall break down the task into individual activities, if a task consists of more than one activity. This will allow the team to identify the hazards of individual activity instead of the whole task. The task shall comprise of distinct activities neither having unnecessary large number of activities to make the TRA process complex, nor too general so the activities containing potential hazards are omitted or overlooked. (For instance, isolation process may be either electrical/control/mechanical/ or process. Each isolation process may encounter different type of hazard, and may be conducted by different work disciplines).

8.8

Identify Hazards The team shall list down all significant hazards in a particular activity and then review them to determine what foreseeable effects they could cause if not eliminated or controlled. This should be done by way of full group discussion under the direction of the TRA team leader to ensure that all members are given adequate opportunity to express their views. To identify the hazard, following aspects of the task should be considered as minimum: •

Characteristics of the plant and systems directly involved, e.g. pressure, noise, temperature, voltage, H2S, toxic chemicals, foam, sand, wax, sludge, scale, etc.

•

Sensitivity of the location, within the site / installation caused by proximity to other HSE critical plant or systems, e.g. HVAC intakes, flare header, separator, risers, ESDVs, escape routes, fire pumps, or large process inventories such as pipelines, vessels or tanks, etc.

•

Possibilities of interaction, between simultaneous activities within the task itself, or any other, unrelated task taking place nearby which require close coordination in term of cooperate emergency response procedures.

•

Consider the hazard effects of, and actions to be taken in the event of an emergency. Refer to the BP Group Standard for the Control of Work (Element 5).

The team shall note down all the hazards identified for each activity so the consequences can be identified. A generic hazards checklist is provided as a guide in Appendix 3. 8.9

Identify Hazard Effects (Consequences) Once all the hazards associated with the task are established, the consequences or hazard effects caused by each hazard (i.e. harm which could possibly occur) and people who may be affected need to be identified and considered as well as those directly involved in the task. The effects or consequences of each hazard, which may

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be more than one, shall be identified and recorded in TRA form (See Appendix 5). While writing Hazard Effects, care should be taken to be as specific as possible, i.e. one should avoid expressions such as ‘personal injury’ in the Hazard Effect’s column. 8.10

Define Risk Rating Risk rating is a means whereby the risks associated with a particular task can be expressed as a value and so judged whether to be within acceptable limits. The risk created by each hazard on list should be evaluated according to: •

The worst, reasonably credible severity of the hazard effects, should anything go wrong, based on (What if? Then), i.e., how severe the consequences could be, realistically. (Almost all hazards could result in death but most realistic outcome should be considered. For example, it is remotely possible that someone falling off a chair in an office may be killed, but the most probable result is bruising or a fractured bone). See Table 8.10.1.

•

The probability of the hazard being realized and resulting in the specified hazard effect. See Table 8.10.2.

It is important to consider property damage and environmental impact and not just personal injury. The matrix method of making these evaluations helps to focus attention on the most serious risks. For the purposes of consistency this matrix should be used when assessing risk. RISK (R) = Hazard Effect (HE) x Probability (P)

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8.10.1 Hazard Effect Rating (HE) or Severity

HAZARD EFFECT

HAZARD EFFECT RATING

VERY HIGH

PEOPLE

MULTIPLE FATALITIES

FATAL INJURY HIGH

MEDIUM

LOW

VERY LOW

Document No.:

PERMANENT DISABILITY

LOST TIME HOSPITALIZATION TEMPORARY DISABILITY

NO LOST TIME NO HOSPITALIZATION FIRST AID

SIMPLE FIRST AID

FACILITIES

LOST PRODUCTION

ENVIRONMENT

MAJOR DAMAGE

MAJOR DAMAGE

TOTAL LOSS OF PRIMARY CONTAINMENT.

LOSS > $ 10 MILLION

LOSS > $ 10 MILLION

SIGNIFICANT DAMAGE

SIGNIFICANT DAMAGE

LOSS $ 01 MILLION TO $10 MILLION

LOSS $ 01 MILLION TO $10 MILLION

MODERATE DAMAGE

MODERATE DAMAGE

LOSS $100K TO $ 01 MILLION

LOSS $100K TO $ 01 MILLION

MINOR DAMAGE

MINOR DAMAGE

LOSS $10K TO $ 100K

LOSS $10K TO $ 100K

LOSS 6 feet (including erection of structures for this work) d) Hot Work in Hazardous Areas e) Failure to meet minimum isolation requirements f) Complex lifting operations involving multiple suspensions or lifting near live plant g) Any activity with potential H2S exposure h) Where multiple protective devices are removed or inhibited from a system i) Simultaneous operations j) Mud plugging and Hot tapping k) Deviation from an existing policy, procedure, or practice l) Mandatory for activities where risk assessment is medium or high m) Well intervention

8.7 LOW RISK IDENTIFY HAZARDS for each activity

8.8 FIND ASSOCIATED HAZARDS for each activity

LEVEL-1

8.8

a) All new activities b) All jobs at planning and design stage c) Repeated activities, if condition is changed d) Annual review for repeated activities

IDENTIFY CONSEQUENCES for each activity

8.9 DEFINE RISK RATINGS

8.10 IDENTIFY CONTROLS

8.11 NO CONTROLS ADEQUATE?

8.12

YES

RESIDUAL RISK ACCEPTABLE?

YES

APPROVAL TO PROCEED

NO 8.13

8.16

* 8.17

AGREEMENT ON RISKS & CONTROLS

TRA COPIES TO ALL INVOLVED

8.14 DOCUMENT & RECORD

8.15

IMPLEMENT CONTROLS

8.18

STOP

8.19

MONITOR FOR CONDITION CHANGE

CARRY OUT TASK

RE-ASSESS IF REQUIRED

8.20 RECORD LESSONS LEARNED

IF CONDITIONS CHANGE

8.21

* IN CASE OF LEVEL 2 TRA.

Document No.:

PRO/SFTY/018

Issue Date:

August 18, 2007

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BP Pakistan Exploration & Production, Inc. Rev. No. HAZARD IDENTIFICATION & TASK RISK ASSESSMENT

2

APPENDIX 2 - TASK CATEGORIZATION CHART Go down the list until you can answer YES, then follow the arrow to determine the TRA Level required YES →

¾

Confined Space Entry sandblasting or de-sludging

¾

Hot work in Hazardous areas

¾

Working at Heights more than 6 feet

¾

Narrow excavation or pit

→

¾

Trench Excavation or pit more than 4 feet deep.

→

¾

Erecting of scaffold or structure at height in excess of 6 feet

→

¾

Using high potential sources of ignition inside tank bund wall area, for gas blowout / flare lines, or for oil & gas well casing repair.

→

¾

Failure to meet minimum positive isolations requirement.

→

¾

Complex and complicated lifting operations involving multiple suspensions or lifting over live plant, near overhead pipelines or power-lines.

→

¾

Multiple protective/safety devices are removed or inhibited from a system

→

¾

Any activities involving uncontrolled potential exposure to H2S

→

¾

Simultaneous operations like well operation adjacent to operating plant

→

¾

Mud plugging and hot tapping for tanks or main oil & gas lines.

→

¾

Deviation from an existing procedure or practice

→

¾

Any other activities where risk assessment is medium and high

→

including

vessel/tanks,

cleaning,

→ →

LEVEL 2 - TRA & PTW SYSTEM IS MANDATORY ¾

All new activities

→

¾

All jobs at planning and design stage

→

¾

Repeated activities, if condition is changed

→

¾

Annual review of TRAs for repeated activities

→

LEVEL 1 - TRA & PTW SYSTEM MAY OR MAY NOT BE REQUIRED

Document No.:

PRO/SFTY/018

Issue Date:

August 18, 2007

Page 26 of 38

BP Pakistan Exploration & Production, Inc. Rev. No. HAZARD IDENTIFICATION & TASK RISK ASSESSMENT

2

APPENDIX 3 - HAZARD CHECKLIST A- Hazards associated with plant and equipment Category Mechanical

Electrical

Pressure

Document No.:

Examples of Hazards Two moving parts, one moving part and a fixed surface Conveyor belt and drive V belt and pulley Power press "In running nips" Mangle Guillotine Scissors Stapler Using hammer Something that may strike or stab someone or can be struck against Moving vehicle Drill Sewing machine Hypodermic needle Pendulum Crane hook Something sharp or with a rough surface Knife, chisel, saw, etc. Fan blade Circular saw blade Sanding belt Abrasive wheel Hover mower blade Drill chuck and bit Power take off shaft Pipe threading machine Abrasive wheel Cartridge tool Using hammer and chisel Abrasive wheel Electricity above 240v Electricity 240v Electricity 110v Extra low volt electricity Static Batteries Compressed air Compressed gas Steam Vacuum Hydraulic system PRO/SFTY/018

Issue Date:

Hazard Effects Trapping (crushing, pressing, drawing in and shearing injuries)

Impact (includes puncture)

Contact (Cutting, friction or abrasion)

Entanglement (rotating parts)

Ejection (of work piece or part of tool) Shock/burn/fire/ Explosion

Ignition sources Release of energy (Explosion/injection/ implosion)

August 18, 2007

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BP Pakistan Exploration & Production, Inc. Rev. No. HAZARD IDENTIFICATION & TASK RISK ASSESSMENT

Category Stored energy

Thermal

Radiation Ionizing radiation Non ionizing radiation

Noise Vibration

Stability

Overload/ Defective due to mechanical failure

Document No.:

Examples of Hazards Springs under tension Springs under compression Hoist platform cage Conveyor tension weight Raised tipper lorry body Counterweight Load carried by crane Hot surface Using blow lamp Welding flame/arc Refrigerant Steam X Rays α or β radiation Neutrons Micro wave Radio frequency Laser Ultra violet Infra red Noise > 85 dB(A) Pneumatic drill Operation of plant Using Jackhammer Inadequate crane base Fork lift truck on slope Machine not bolted down Mobile scaffold too high Scaffold not tied Crane overload Chain sling Eye bolt overload Scaffold overload Hopper overload

PRO/SFTY/018

Issue Date:

2

Hazard Effects Flying/Falling materials

Burns/fires/scalds/ frostbite

Burns, cancer

Burns

Hearing loss, tinnitus, etc. Vibration white finger, whole body effects Crushing

Crushing

August 18, 2007

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BP Pakistan Exploration & Production, Inc. Rev. No. HAZARD IDENTIFICATION & TASK RISK ASSESSMENT

2

B - Hazards associated with materials and substances Category FIRE/EXPLOSION Combustion

Increased Combustion Flammable substances (inc. Highly and Extremely Flammable) See also explosive below

Oxidizing substance

Dust explosions

HEALTH HAZARDS Corrosive/Irritating materials Particles

Vapors

Fumes

Gases

Document No.:

Examples of Hazards Timber stack Paper sore Grease Plastic foam Oxygen enrichment Petrol Propane gas Crude oil Methane LPG LNG Hydrogen Carbon Monoxide Organic peroxide Potassium permanganate Nitric acid Explosive material Detonators Some oxidizing agents Highly flammable gas in confined space Wood dust Sulfur dust Coal dust Flour Aluminum powder Sulfuric acid Caustic soda Ammonia Asbestos fibers Silica dust Wood dust Iron dust Benzene Toluene Acetone Some solvents Lead fume Rubber fume Asphalt fume Carbon Monoxide Hydrogen Sulfide Sulfur dioxide

PRO/SFTY/018

Issue Date:

Hazard Effects Burns

Burns Burns

Burns

Burns

Skin effects

Lung effects

Acute and chronic effects on health

Acute and chronic effects on health (local and systemic effects) Acute and chronic effects on health

August 18, 2007

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BP Pakistan Exploration & Production, Inc. Rev. No. HAZARD IDENTIFICATION & TASK RISK ASSESSMENT

Mists

Category Asphyxiants

Health hazard by ingestion

Hazards by contact

ENVIRONMENTAL HAZARDS Hazardous waste storage and disposal

Oil mist Printing ink mist Detergents Aerosols Examples of Hazards Nitrogen Carbon dioxide Argon Toxic, harmful, corrosive and irritant liquids All harmful aerosols Polluted water Contaminated food and drink Sward Rough timber Concrete blocks Molten metal Frozen food Crude/Condensate transportation Storage of hazardous sludge/material in pits NORM waste (scales, sludge)

2

Acute and chronic effects on health

Hazard Effects Acute and chronic effects on health Burns to upper alimentary tract Poisoning

Cuts, abrasions

Burns, Frostbite Groundwater / Soil pollution

C- Hazards associated with the place of work Category Pedestrian Access

Work at heights

Obstructions Stacking/Storing

Document No.:

Examples of Hazards Damaged floors Trailing cables Oil spills Water on floors Debris Wet grass Sloping surface Uneven steps Changes in floor levels Fragile roof Edge of roof Work on ladder Erecting scaffold Hole in floor Low headroom Sharp projections High stacks Insecure stacks Inadequate racking Stacking at heights

PRO/SFTY/018

Issue Date:

Hazard Effects Tripping, slipping

Falls

Striking against Falling materials

August 18, 2007

Page 30 of 38

BP Pakistan Exploration & Production, Inc. Rev. No. HAZARD IDENTIFICATION & TASK RISK ASSESSMENT

Work over/near liquids, dusts, etc.

Emergencies

2

Fall into a substances, drowning, poisoning, suffocation, etc.

Tank Reservoir Sump Sewer Work over water Locked exits Obstructed egress Long exit route

Trapping in fire

D. Hazards associated with methods of work Category Manual handling

Repetitive movements

Posture

Hazard Effects Back injury, hernia, etc.

Example of Hazard Lifting Lowering Carrying Pushing Pulling Hot / Cold loads Rough loads Live loads – persons Keyboard work Using screwdriver Using hammer and chisel Bricklaying Seated work Work above head height Work at floor level

Work related upper limb disorders

Work related upper limb disorders, stress, etc.

E. Hazards associated with the working environment Category Light (NB: Also increases risk of contact other hazards) Temperature

Confined spaces

Document No.:

Example of Hazard Glare Poor lighting Stroboscopic effect Arc welding Molten metal Work in furnace Cold room Outdoor work Hot weather Cold weather Wind chill factor Work in rain, snow, etc. Work in tank Chimney, stack Pit Basement Unventilated room Vessel Excavation PRO/SFTY/018

Issue Date:

Hazard Effects Eye strain, arc eye and cataracts

Heat stress, hypothermia Heat stress, sunburn, melanoma, hypothermia, etc.

Asphyxiation, explosion, poisoning, claustrophobia, etc.

August 18, 2007

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BP Pakistan Exploration & Production, Inc. Rev. No. HAZARD IDENTIFICATION & TASK RISK ASSESSMENT

Ventilation

2

“Sick Building Syndrome”, nausea, tiredness, etc.

Fumes Odors Tobacco smoke

F. Hazards associated with work organization Category Contractors

Organization of work

Work in public area

Document No.:

Example of Hazard Work above employees Use of harmful substances Contractors’ welding Process fumes Services (e.g. underground electricity cables) Stored hazardous materials Monotonous work Stress Too much work Lack of control of job Work too demanding Trailing cables Traffic/ Plant / Rig movement Work above public Drilling near dwelling area

PRO/SFTY/018

Issue Date:

Hazard Effects Injuries and ill health to employees by contractors work Injuries and ill health to contractors’ employees by work in premises Injuries to employees

Injuries and ill health of public

August 18, 2007

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BP Pakistan Exploration & Production, Inc. Rev. No. HAZARD IDENTIFICATION & TASK RISK ASSESSMENT

2

APPENDIX 4 - RISK ASSESSMENT SAMPLES Confined Spaces Description of Task This general assessment and arrangements covers the general principles for work within confined spaces in the work of cleaning or de-sludging of crude oil/slop oil vessels/tanks by an organization’s employees or contractor’s. A confined space is defined as any place, including any chamber, tank, silo, pit, sewer, flue, well, or other similar space in which, by virtue of its enclosed nature, there arises a reasonably foreseeable specified risk. As a consequence it is likely that the confined space will have restricted natural ventilation, will have limited means of access and egress and would not be intended for the continual occupancy by persons at work. Persons at Risk Personnel carrying out cleaning work in confined spaces are especially at risk. In the event of fires or explosions occurring as a result of work in confined space, all persons inside the tank and others outside may be at risk. Hazards Hazards associated with confined spaces fall into two categories. 1.

Hazards associated with conditions which exist in the confined space before work take place, for example lack of oxygen, presence of pyrophoric iron sulfide scales on the inside shell, presence of sludge, and hydrogen sulfide gas.

2.

Hazards which can be introduced into the confined space by the work to be carried out, and by the equipment/tools and materials to be used, for example using sparking tools, electrical or pneumatic tools, artificial lighting, using cleaning detergents, etc.

The significant hazards associated with confined spaces are: •

Atmospheric hazards

•

Oxygen depletion

•

Toxic gases (H2S for example)

•

Simple suffocating hydrocarbon vapors

•

Flammable liquids/sludge/vapors/mists/gases

•

Pyrophoric iron sulfide

•

Electrical equipment

•

Hand tools

•

Detergents

Document No.:

PRO/SFTY/018

Issue Date:

August 18, 2007

Page 33 of 38

BP Pakistan Exploration & Production, Inc. Rev. No. HAZARD IDENTIFICATION & TASK RISK ASSESSMENT

•

Obstructions/barriers

•

Limited access/egress

•

Connected pipe-works/valves/pumps/stirrers/heaters

•

Water and other liquids

•

Heat

•

Scaffold/ladder/staging

•

Noise/humidity

•

Environment pollution

•

Poor lighting

•

Difficulty of rescue and emergency control

•

Biological hazards

•

Panic/claustrophobia/stress

2

Entry into confined space is a high-risk activity. A specified task risk assessment, job plan and written procedures will be required. PTWS and relevant Certificates (e.g. Isolation and Entry Certificates) is mandatory requirement in each work. The following arrangements are an indication of the measures to be considered to eliminate or reduce the risk of the hazards to an acceptable level and ALARP. The Team Leader must ensure that the equipment, facilities, and working practices are maintained to these standards by arranging inspections either personally or by a competent Superintendent or Supervisor. Arrangements Planning and Organization Before any operation commences, the Team Leader must establish if work in confined space is to be carried out and if so, must arrange for information from operation manuals, P&ID’s, site visit, risk assessments, sampling, equipment, working procedures, training, etc. to be provided, taking into account the hazards likely to be encountered. Training and Instruction Training will be provided through HSE department for all personnel required to carry out testing and monitoring of atmospheres and for operatives required to use breathing apparatus, rescue and permit procedures and any other equipment or procedures necessary. Toolbox Talk (TBT) will be given to personnel before commencing the work. Management Control Competent Persons Document No.:

PRO/SFTY/018

Issue Date:

August 18, 2007

Page 34 of 38

BP Pakistan Exploration & Production, Inc. Rev. No. HAZARD IDENTIFICATION & TASK RISK ASSESSMENT

2

The Superintendent / Supervisor will ensure that: •

Necessary equipment is available on site in accordance with planned procedures before any person is required to enter the confined space.

•

The planned procedures, including any permit to work systems, are carried out as planned and that only authorized persons are permitted to enter the confined space

•

A person is stationed outside the confined space at all times that work is taking place inside.

Care of Equipment and Arrangement of PPE The Superintendent / Supervisor will ensure that suitable storage facilities are provided for monitoring equipment and PPE. •

All equipment used for confined space work will be inspected by the user on each occasion, a thorough examination must be carried out every month by the supervisor and a record made of the examination. A more frequent examination may be required depending on the circumstances of the specific method statement.

•

All safety equipment must be regularly maintained and record in accordance with defined procedures. Any defects in equipment must be attended to immediately.

Procedures for Serious and Imminent Danger Rescue procedures for workers in a confined space must be defined in method statement, and rescue must be carried out by well-trained rescue team. Monitoring and Review Inspections An inspection of the work and precautions must be made by the Superintendent / Supervisor at least once every day that work continues in confined space. The Team Leader will carry out random inspections of confined space work. Risk Assessment Review This risk assessment and arrangements will be reviewed at intervals of one year at which any specific risk assessments and method statement will also be reviewed. A review will also take place after any reported complaint, incident or accident, or when there is a change in the activity.

Document No.:

PRO/SFTY/018

Issue Date:

August 18, 2007

Page 35 of 38

BP Pakistan Exploration & Production, Inc. Rev. No. HAZARD IDENTIFICATION & TASK RISK ASSESSMENT

TASK RISK ASSESSMENT FORM

APPENDIX – 5

1

DATE:

TASK TITLE: ACTIVITY:

LOCATION:

DESCRIPTION

S/No:

HAZARD

HAZARD EFFECT

RISK EVALUATION (Refer to Evaluation Form)

HE

P

R

CONTROLS

ACTIONS TO BE TAKEN DESCRIBE ACTION

MANPOWER

RESIDUAL RISK HE

P

ALARP

R

Y/N

EMERGENCY PROVISION REQUIRED: GENERAL COMMENTS: RISK ASSESSMENT APPROVAL I am satisfied that the safeguards put in place will reduce the level of risk NAMES OF TEAM MEMBERS

SIGNATURE

to an acceptable level and the task/action is permitted to proceed.

Risk Assessment Team Leader………………………...…Date……………Time………

HE= Hazard Effect

Document No.:

P= Probability

PRO/SFTY/018

R= Risk Rating

Issue Date:

Authorizing Signatory……………………………………Date……………Time………….. SHEET OF

August 18, 2007

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BP Pakistan Exploration & Production, Inc. Rev. No. HAZARD IDENTIFICATION & TASK RISK ASSESSMENT

Document No.:

PRO/SFTY/018

Issue Date:

August 18, 2007

1

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