PRO-1400-0000-001 Hazard Identification Risk Assessment and Risk Management
PRO-1400-0000-001 Hazard Identification Risk Assessment and Risk Management
PRO-1400-0000-001 Hazard Identification Risk Assessment and Risk Management
No: PRO-1400-0000-001
Procedure for Hazard Identification,
Rev. 0 Page1 of 15
Risk Assessment and Risk
Management Date: 12 February 2015
Procedure for
Hazard Identification, Risk Assessment
and Risk Management
Revision
Date Prepared by Reviewed by Approved by
No.
Wilson George,
0 Jacobus
12 February Mal Coates Lowther- QA/QC Manager
Nieuwenhuijze,
2015 Rolton Services JLT
Department Project Director
Heads/Managers/Leads
Wilson George,
Jacobus
25 November Mal Coates Lowther- QA/QC Manager
A Nieuwenhuijze,
2014 Rolton Services JLT Department Project Director
Heads/Managers/Leads
Doc. No: PRO-1400-0000-001
Procedure for Hazard Identification,
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Risk Assessment and Risk
Management Date: 12 February 2015
1 PURPOSE ...................................................................................................................... 3
2 SCOPE........................................................................................................................... 3
3 INTRODUCTION ............................................................................................................ 3
4 REFERENCES ............................................................................................................... 3
5 DEFINITIONS................................................................................................................. 3
6 RESPONSIBILITIES....................................................................................................... 5
7 QUANTITATIVE RISK ASSESSMENT METHODOLOGIES ........................................... 6
8 QUALITATIVE RISK ASSESSMENT PROCEDURE ...................................................... 6
7.1 Five Steps to Risk Assessment ...................................................................................... 6
7.2 Risk Matrix ..................................................................................................................... 6
7.3 Risk Assessment Using Checklists ................................................................................. 7
7.4 Risk Register / Risk Assessments .................................................................................. 7
7.5 Training to conduct risk assessments ............................................................................. 7
7.6 Inputs into the Risk Assessment Process ....................................................................... 7
7.7 Outputs of the Risk Assessment Process ....................................................................... 8
7.8 Determining that risk has been reduced ALARP ............................................................. 8
7.9 Risk Assessment Records .............................................................................................10
9 RISK MANAGEMENT ...................................................................................................10
8.1 Reducing Risk ...............................................................................................................10
8.2 General Guide for Managing Risks ................................................................................10
8.3 Monitoring the effectiveness of risk management arrangements ...................................11
10 TYPICAL HAZARDS .....................................................................................................11
11 RISK MATRIX ...............................................................................................................15
12 FORMS .........................................................................................................................15
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Risk Assessment and Risk
Management Date: 12 February 2015
1 PURPOSE
Duqm Refinery recognises that achieving the goals of the Health and Safety Policy first requires
an understanding of the risks of its activities during normal (e.g. operation of the plant),
abnormal (e.g. repair of equipment) and emergency situations.
This Procedure outlines the requirements for risk assessments. In addition to being a key
process in order to enable the Company to achieve the aims of its Health and Safety Policy, this
procedure is intended to comply with legislative requirements.
The Company aims to manage all reasonably foreseeable risks to as low as reasonably
practicable, as defined by the company Risk Matrix.
2 SCOPE
The Scope of this procedure extends to any facility under the direct or indirect control of Duqm
Refinery and its Contractors (engaged by Duqm Refinery to execute work on behalf of the
Company) irrespective of location. This scope also includes vendors, manufacturers and
transportation (land or sea) Contractors. The procedure will focus on the following;
Relevant reference standards
When risk assessments are required
Key definitions to enable management and employees to understand important risk
assessment concepts
Responsibilities
How to conduct a risk assessment
acceptable risk level
Steps to be taken to eliminate hazards or otherwise reduce the risk
Typical hazards to be considered when conducting risk assessments
3 INTRODUCTION
This Procedure is intended to ensure that personnel working for the Company participate in, or
understand, risk assessment processes relating to their work and arrangements for managing
risks to their health and safety.
4 REFERENCES
Duqm Refinery Health & Safety Policy
Duqm Refinery HSMS Procedures and associated forms
Oman Labor Law
Ministry of Manpower 2008, Regulation of Occupational Safety and Health for
Establishments Governed by the Labor Law
OHSAS 18001:2007
5 DEFINITIONS
Acceptable Risk: Using the company Risk Assessment Matrix1 as a guide to severity and
frequency, the Company has determined that any risk in the Low / Green zone is acceptable
(value of 1-3).
ALARP: As Low As Reasonably Practicable: Risk has been reduced to ALARP if the effort
and/or expense of mitigating that risk become disproportionate to the benefit.
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Risk Assessment and Risk
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Competence: A combination of skills, knowledge, education, training and aptitude which means
a person is able to perform an activity to an expected standard.
Consequence / Severity: The potential outcome of the hazardous event in terms of injury, ill-
health, damage or cost.
Controls: This procedure defines the controls established by Dqum Refinery for the
management and mitigation of risk. Addition risk controls may include but may not be limited to;
Engineering of equipment to mitigate risks associated with ventilation, guarding, vibration,
noise and ergonomics.
Design of equipment to ensure simultaneous operations and the operation of other
equipment has been assessed and mitigated.
Process system reconfiguration where interface problems exist
Training of employees who are to Supervise and execute the work
In all situations where additional risk controls are implemented such as those listed above they
shall be included in the risk and mitigation documentation that is compiled by members of the
task team and maintained at the work location for easy reference.
Elimination: Complete removal of a hazard.
Harm: Acute or chronic injury or ill-health to people.
Hazard: Source, situation or act (or combination of these) which has the potential to cause
harm. There are five broad categories of hazards – physical, chemical, biological, ergonomic
and psychological.
Hazard Effect: The potential effect of hazards on people.
Isolation/Segregation: Activities undertaken to isolate a hazard from impacting on people (e.g.
isolation procedures for low hanging cables, lock-out/tag-out, segregated storage areas)
Likelihood: The probability or potential frequency of a hazard being realized.
Operational safety: the condition of having acceptable risk to life, health, property, or
environment caused by a system or subsystem in an operational environment. This requires the
identification of hazards, assessment of risk, determination of mitigating measures, and
acceptance of residual risk
PPE: (Personal Protective Equipment): Equipment which is worn to protect the wearer from
immediate hazards.
Procedures/Administration: Working methods used to mitigate risks. These should only be
used where elimination, substitution and isolation have already been implemented, and are
often used to manage low risk activities being done by competent people.
Quantitative Assessment: Objective risk assessment conducted by specialists with results
expressed numerically or graphically, where probabilities are calculated for the likelihood of a
hazard being realized. These are addressed through Engineering and Design Processes.
Quantitative assessments may also be implemented for occupational health and safety hazards
such as noise, toxic substances, flammable gases / vapours and vibration,
Qualitative Assessment: A subjective method of assessment based on the judgement of
experienced and competent personnel, where risk is assigned a value of Low, Medium or High.
This is the type of risk assessment to be conducted for Duqm Refinery activities.
Reduction in Personnel / Time Exposure: Reducing the risks to workers by minimizing the
amount of time personnel are exposed to a hazard such as noise, repetitive motion, vibration,
heat, some chemical hazards, etc.
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Residual Risk: The risk that remains after all the identified control measures have been put in
place.
Risk: The result of the Hazard Consequence / Severity multiplied by the Likelihood of its
occurrence (whether of a single unwanted event leading to injury or ill-health, or of a chronic
exposure leading to ill-health).
Risk Assessment: A careful examination of anything in the workplace which could cause injury
or ill-health. The Risk Assessment should take into account the effectiveness of any existing
controls. If the risk is determined to be too high, action to reduce the risk must be taken.
Risk Reduction Hierarchy: A hierarchy of actions which must be undertaken to reduce risk to
ALARP. (Each term is explained later):
Eliminate hazard
Reduce or replace the hazard
Prevent contact with the hazard
Safe system of work (SSOW – procedures, training, warning signs, etc.)
PPE
Substitute : Using a less hazardous material or work method in order to reduce risk.
Tolerable Risk: Using the company Risk Assessment Matrix2 as a guide to severity and
frequency, the Company has determined that any risk in the Moderate / Yellow zone is
acceptable (value of 4-6).
6 RESPONSIBILITIES
Management shall:
Provide sufficient resources (manpower, material/equipment, finance) to ensure that the
risks to personnel can be reduced to ALARP.
Only authorise work or projects when they are satisfied that the risk has been suitably
mitigated or controlled.
HSE Manager shall:
Ensure suitable and sufficient assessment of risks to the health and safety of employees, or
any third parties affected by our work activities.
Ensure that risk assessments are suitably recorded, reviewed and maintained.
Provide training and guidance on conducting risk assessments.
Train supervisors and workers in how to conduct risk assessments
Verify risk assessments are suitable and sufficient
Supervisors shall:
Ensure that risk assessments are conducted within their area of responsibility
Maintain the hazard register
Track corrective actions identified in risk assessments to closure
Maintain records of risk assessments
Ensure that risk assessments are reviewed as required.
Provide appropriate information, instruction and training to ensure competence of
employees with regard to the risks to their health and safety.
Employees shall:
Participate in risk assessments for their work activity or location
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Understand the hazards and control measures associated with their work activity / location.
Attend training as required
7 QUANTITATIVE RISK ASSESSMENT METHODOLOGIES
Duqm will implement a variety of risk assessment methodologies throughout the life cycle of the
plant (design, construction, modification, operation, turnarounds, decommissioning). These
include but are not limited to;
Addressing process safety issues through tools such as risk management assessments and
activities (eg. HAZOP, HAZID, Safety Case; Fault Tree Analysis);
Implementation of inherent fail-safe designs (eg. asset integrity and reliability);
Identification of key control measures and manage accountability;
Inclusion of redundant processes to control both hardware, systems and procedures;
Monitoring activities, management follow-up and close-out tracking systems.
These methodologies, their implementation, assessment, approval and monitoring are
implemented through Engineering, Design, Construction and Management of Change
processes and are documented separately by the relevant Refinery Department.
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In some cases, the risk assessment may be completed by using an approved checklist and
identifying corrective actions to reduce risk without completing the risk assessment process.
Therefore, the Company has provided checklists for the following;
Display screen equipment / workstation ergonomics
Office facilities
Lifting operations
Reasonably foreseeable hazards / risks associated with the location, work environment and
work activities
Legal and other requirements (what hazards are specifically required to be managed and
how)
Information on incidents and accidents both within the company and in external
organisations with similar risk profiles.
Non-conformances
Management system audit results
Communications / complaints from personnel and other interested parties
Information from consultation with workers, review and improvement activities in
the workplace
Information on industry practice, typical hazards related to Company activities,
incidents and accidents having occurred in similar organisations
Existing health conditions of the workers involved (if relevant)
Information on the facilities and activities of the company work sites. This may include :
Site Plan(s)
Information on hazardous materials (e.g. chemicals or waste products)
Monitoring data (e.g. noise)
Workplace environmental data
If the risk rating remains Moderate after the risk assessment process then it can proceed with
management approval. In some cases, the task will need to be controlled through the Permit to
Work system. Before the task starts, a Pre-job Safety Briefing / Tool Box Talk must be carried
out to verify that all personnel are aware of the risks and required controls.
Tasks with a rating of 15-25 are considered to be High (Tolerable, value of 8-12) or Extreme
Risk (Unacceptable, value of 15-25) and require completion of a detailed risk assessment. If the
risk rating remains High after the risk assessment process, the task must be further evaluated
and must not start without Senior Management approval.
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Hazard
Physical hazard Hazard effect / potential to result in
Severity
ignition in flammable / explosive
atmosphere – hot work
Fire / explosion – source of
ignition in flammable / explosive
atmosphere - static discharge
Ionising Radiation – radioactive Depends on energy source, duration
sources – alpha, beta, gamma, and frequency of the exposure - 2-4
x-ray systemic effects on human body
Non-ionising Radiation – ultra-
Eye disease / cataracts 3
violet (from sunlight)
Non-ionising Radiation – ultra-
Arc eye / eye disease / cataracts 3
violet (from welding)
Acute: Scald, burn, blister
Temperature extremes – very hot
Chronic: heat stress / exhaustion
or very cold surfaces or working 3
leading to fatigue, ill-health and
conditions
potential for death.
Primary effect: Hearing threshold shift
3
(long-term damage).
Noise above 85dB(A) for more
Secondary effect : poor
than 8 hours
communication leading to human 2
failure, stress
Primary effect: Pain. Temporary or
permanent deafness. Tinnitus - 3
leading to stress and depression.
Noise at or above 97dB for very
Secondary effect: poor
short time (minutes)
communication leading to human
3
failure; failure to hear warning alarms
or instructions.
Diminished reactions, illness, brain
Lack of oxygen 4-5
damage, death
Violence Stress, injury, death 4-5
Poor road conditions Vehicle overturn / crash leading to
4-5
Excessive speed injury
Hazard
Ergonomic hazard Hazard effect / potential to result in
Severity
Cumulative trauma disorder, repetitive
Repetitive motion / movements 3
strain injury, disability
Back / neck ache, circulation problems,
Static posture 2
fatigue
Awkward posture Circulatory problems, pain, tingling, etc. 2
Mechanical obstruction (e.g.
hard edge of desk or work Circulatory problems, pain, tingling, etc. 2
bench)
Hazardous manual handling
such as Exertion: strains, sprains, pain,
backache, slipped disks, etc.
Lifting more than 25kg 3-4
Dropped loads : crushes, fractures,
lifting and twisting
etc.
bending
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Hazard
Chemical hazard Hazard effect / potential to result in
Severity
Burns, disfigurement, asphyxiation
Acid 4
(vapour)
Burns, disfigurement, asphyxiation
3
Alkali (vapour)
Allergic reactions (dermatitis, etc.) 3
Local or systemic effects; allergic
Inhalable dusts (from 10 – 100
reactions (e.g. asthma), lung disease, 3-4
microns)
permanent disability, early death
Local or systemic effects; Lung
Respirable dusts (smaller than
disease, permanent disability, early 3-4
7 microns)
death
Respirable fibres (e.g. Lung disease, permanent disability,
3-4
asbestos) early death
Temporary or permanent ill-health.
Poison / Toxins (man-made) 4-5
Death.
Toxic atmosphere (e.g. H2S) 4-5
Acute effect : Irritation, respiratory
Above STEL (15 minute limit) 2-3
reaction, burns
Chronic effect : dermatitis, industrial
Above LTEL (8 hour limit) 3-4
asthma, pneumonia
At or above IDLH Asphyxiation, brain damage, fatality 4-5
Nausea, headaches, fatigue, lung
Welding fumes disease, diseases of the central 3
nervous system
Vapours – hydrocarbon, Narcosis – drowsiness, dizziness,
3
solvents, etc. fatigue, confusion, leading to human
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Hazard
Chemical hazard Hazard effect / potential to result in
Severity
failure. Potential for dependency /
substance abuse.
Vapours, gases, dusts in
ignitable concentrations (refer to Fire / explosion 4-5
Classified Areas)
Irritants Acute reaction such as itching, burning 2
Acute or chronic reactions. Harmful
Harmful substances often target specific organs 3
or body systems.
Hazard
Biological hazard Hazard effect / potential to result in
Severity
Bacteria (e.g. e.coli, salmonella, Illness, vomiting, diarrhoea, lung
3
staphylococci, legionella) disease, etc.
Virus (common cold, ‘flu, swine Illness, disease (contagious between
3
flu, etc.) humans)
Potential for illness, disease (may be
Virus - H5N1, SARS, MERS, 3
contagious between humans)
Virus – Blood-borne pathogens, Illness, disease, social stigma, etc.
4
hepatitis, HIV/AIDS Ebola (contagious between humans)
Funghi (moulds, spores, etc.) Illness (e.g. asthma) 3
Toxins from bites (insect, snake,
Illness, possible allergic reaction 3-4
scorpion
Hazard
Psychological hazard Hazard effect / potential to result in
Severity
Stress Diminished responses; human failure 3
Violence (or threat of violence) (errors, mistakes); reduced 3
performance. Stress can also lead to
physical effects such as hypertension,
Phobias / fears 3
headaches, diabetes and behavioural
change
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Management Date: 12 February 2015
11 RISK MATRIX
Duqm
12 FORMS
FRM-1400-0000-001-01 Risk Assessment Form
FRM-1400-0000-001-02 Risk Matrix