OGP 6.54 246 Loss Costing Guidelines 1996
OGP 6.54 246 Loss Costing Guidelines 1996
OGP 6.54 246 Loss Costing Guidelines 1996
This report has been prepared for the E&P Forum by their Safety, Health
Authors
and Personnel Competence Committee through their Loss Cost
Methodology Task Force.
The Oil Industry International Exploration & Production Forum (E&P Forum)
The E&P Forum
is an international association of oil companies and petroleum industry
organisations formed in 1974. It was established to represent its mem-
bers’ interests at the International Maritime Organisation and other special-
ist agencies of the United Nations, and to governmental and other interna-
tional bodies concerned with regulating the exploration and production of
oil and gas. While maintaining this activity, the Forum now concerns itself
with all aspects of exploration and production operations, with particular
emphasis on safety of personnel and protection of the environment, and
seeks to establish industry positions with regard to such matters.
Whilst every effort has been made to ensure the accuracy of the infor-
Disclaimer
mation contained in this publication, neither E&P Forum nor any of its
members will assume liability for any use made thereof.
CONTENTS
INTRODUCTION 2
BACKGROUND 4
CONCLUSION 16
GLOSSARY OF DEFINITIONS 17
REFERENCES 20
APPENDIX 1 21
APPENDIX 2 22
APPENDIX 3 23
APPENDIX 4 25
APPENDIX 5 28
LOSS COSTING GUIDELINES
INTRODUCTION
Work-related incidents and illnesses cause considerable suffering and, on
occasion, financial hardship to the worker and his/her immediate family.
While companies implement safeguards that are reasonably practicable, it
is critical to a company’s financial success and the well-being of its
employees and their families that such safeguards are prudently applied.
The Health, Safety and Environment (HSE) manager is then able to use
the economic argument to demonstrate that incident prevention may be
cost-effective. In addition to saving money, the company is also reducing
pain and suffering by having an effective system of incident prevention.
The economic argument therefore lends support to both the legal—by the
use of economic sanctions—and the humanitarian arguments. The eco-
nomic case centres on knowledge of the cost of incidents occurring
within a company’s sphere of operations. The next step in the process is
to consider how to establish the costs of incidents.
For many E&P companies this development process has involved a transi-
tion from the more traditional reactive approach to HSE work to the adop-
tion of a loss prevention/control strategy. Loss control is anything done to
reduce loss from the risks of business. This is viewed as a response to a
changing situation and need, and the process has certain characteristics
and emphases. Loss prevention focuses on concerns with depth of tech-
nology and associated major hazards; it places a strong emphasis on man-
agement and management controls; it is a systems rather than a trial-and-
error approach; and it is particularly concerned to avoid loss of containment.
Large scale losses such as those arising from major fires, explosions, or
pollution of the environment, are very visible and some have been costed
on an individual basis, e.g. the Piper Alpha disaster is estimated to have
cost in excess of $3 billion, including $1.2 million in direct insurance pay-
outs, and a 1987 refinery fire in the UK in which one person died, cost
$80 million in property damage, and a further $80 million due to business
interruption. Less well understood however, is the nature and extent of
losses from incidents of a more ‘routine’ nature: incidents which injure
2
INTRODUCTION
but do not cause fatalities; which damage plant and assets and interrupt
the business processes. Loss costing study results published to date
clearly illustrate the magnitude of financial losses being incurred as a result
of ineffective loss control.
For example, the overall cost to the British economy of all work-related
incidents and worker ill-health is estimated to be between $9 billion and
$18 billion. This is equivalent to between 1 per cent and 2 per cent of
Gross Domestic Product (GDP)(1). The socio-economic costs of the most
common work incidents and illness in Denmark have been calculated at
$3375 million, or 2.5 per cent of Denmark’s GDP. The data for Finland,
Sweden and Norway is similar or slightly higher(2). Pilot studies undertaken
between October 1990 and February 1991 on an offshore production facil-
ity on the UK Continental Shelf identified total incident-related losses
equating to $6 million on an annual basis, or to shutting down the plat-
form’s production for one day a week(3).
3
LOSS COSTING GUIDELINES
BACKGROUND
The health, safety and environmental policies and strategic business
objectives of E&P companies invariably state that they wish to conduct
activities in such a manner as to take foremost account of the health and
safety of employees and other persons who may be affected by such
activities, and to give proper regard to conservation of the environment.
Losses occur from incident and work-related ill health, from property and
equipment damage, rework, failure to meet quality standards, and
lost/missed opportunities. Losses are seldom caused by a single factor or
event. They are almost always result in loss in human, process, quality,
environment, property, and always financial terms.
4
BENEFITS OF AN EFFECTIVE LOSS-COSTING METHODOLOGY
BENEFITS OF AN EFFECTIVE
LOSS-COSTING METHODOLOGY
As profit margins are reduced in the business world due to intense com-
petition, tight markets, and use of expensive new technologies, the identi-
fication and reduction of losses becomes an ever more essential aspect of
business survival.
Loss costing can help focus the attention of key members of an organisation
on the real business priorities. It can then influence attitudes and thinking on
how tasks or processes can be changed and improved to reduce future
potential losses and also improve the Health, Safety and Environmental
Management Systems (HSE-MS) within the organisation.
Some of the prime drivers for adoption of an incident loss costing process
are therefore:
● Incident loss cost control. This process should be considered a integral
component of the business value chain. It can maximise the value
created by the organisation.
● Incident loss costing should also be recognised as a key element of
the loss prevention process.
5
LOSS COSTING GUIDELINES
“Safety is, without doubt, the most crucial investment we can make. And
the question is not what it costs us, but what it saves”.
(Robert E. McKee, Conoco)
6
LOSS COST CATEGORIES
In many instances when an incident does occur, the costs of the incident are
usually absorbed into the running costs of the company, and will not routinely
be itemised on an individual asset/operating unit budget. Neither will many of
the indirect costs be specifically allocated. The direct costs, e.g. insurance
premiums, certain forms of employer’s liability, etc, will generally be adminis-
tered from a parent company fund. Thus, under many accounting systems
currently employed in the E&P industry, incident costs are not charged to
individual budgets, whereas incident preventative measures invariably are.
Under this strategy, the asset/line manager has no real need to determine
the financial costs of incidents. Consequently, the process of demonstrat-
ing positive cost benefit analysis to justify investment in risk reducing/inci-
dent prevention measures is somewhat undermined. The majority of
remedial measures will tend to continue to be implemented on legal or
humanitarian grounds.
People
● personal injuries, illness or fatalities
● occupational illness
Assets
● physical damage to assets
● loss of production
● opportunity costs
Environment
● environmental damage
Reputation
● loss of reputation
Others
● incident investigation costs, and implementation of recommendations
● legal costs and fines
7
LOSS COSTING GUIDELINES
When loss cost data is collated and compared with the capital and/or
operational costs or the net profit, it is then seen to be a very significant
cost factor which needs to be managed. Its reduction can make a very
significant contribution to the bottom line. For instance, it can represent
40 per cent of maintenance costs due to abuse, misuse, under use, and
accidental damage to plant and machinery in some organisations.
8
LOSS COSTING DEFINITIONS
Using these definitions as the basis for incident loss cost categorisations,
comparisons can be made of the ratios of direct to indirect costs.
Based on recent incident loss costing studies within the E&P industry, this
ratio can be illustrated by an iceberg containing the total costs of incidents,
including those indirect costs hidden below the waterline.
9
LOSS COSTING GUIDELINES
Most companies know how much, and what types of insurance cover
they hold. By applying loss costing methodology, the subsequent
improvement of loss prevention and control of performance enhances the
potential for adjustment of insurance premium loading.
Loss cost expenditure can continue to occur many years after an incident
or production loss. Some loss costs are very easy to define and estimate.
Others are very hard to specify. Total accuracy is not essential, but it is
important to gain a general picture of the probable losses being sustained
to assist management to reduce these by subsequent, cost-benefit justi-
fied remedial measures.
10
LOSS COSTING METHODOLOGY
The stand-alone data gathered at this stage of the process is of little value
from a loss control perspective (other than the immediate, bottom-line
financial significance), as no risk analysis will have been applied to gauge
the significance to and effect on the business.
The real value in gathering incident cost data derives from analysis of the
contributing incidents and their costs, consideration of a range of remedial
measures, and application of cost benefit analysis as the basis for incident
reduction and risk aversion measures. Using these definitions, compar-
isons can be made of the ratio of insured costs to uninsured costs at indi-
vidual company level. Indirect costs (as previously illustrated on the ice-
berg diagram) are a very important factor in the loss costing equation.
11
LOSS COSTING GUIDELINES
The actual loss costing process (see Appendix 1) commences with the
definition of the classification of incidents to be costed. Some specific
loss cost categories are included in the illustrative loss costing process
model outlined overleaf.
12
LOSS COSTING METHODOLOGY
DATA COLLECTION
What might have
What happened
Reporting and investigation system happened
13
LOSS COSTING GUIDELINES
CATEGORISATION, ANALYSIS
AND PRIORITISATION
The prime objective of a loss cost analysis is to identify significant loss.
Categorisation
Categorisation of the losses makes it easier to tackle the inherent prob-
lems/failures so that the loss is reduced, if not eliminated by improved
management. Also by using a series of recognisable categories the
effects of cumulative loss can be measured. It may identify an area of
continual loss of apparently little significance on an incident-by-incident
count, but for which the total loss may be significant.
The loss cost analysis is not an accurate financial record but a tool to indi-
cate areas of significant loss. Each incident that has been accepted into
the loss cost analysis (by complying with the selection criteria) needs to
have all loss costs recorded against each subcategory. Direct and indirect
costs need to be identified. The collection of costs may take many
months, and some indirect costs could still be accumulating after one or
more years.
Each company will have decided on the criteria it will use to conduct a
loss cost analysis. Appendices 2 and 5 (‘Risk Matrix’ and ‘Definition of
Consequence—Severity Rating for Risk’) provide further reference and
guidance. This will set limits of loss and perhaps specify these respec-
tively for the main categories of people, environment, assets and reputa-
tion. Each incident should be given a main type label identifying one of
these categories i.e., the incident might be a people incident, because the
effect of the incident is mainly concerned with people.
There will obviously be incidents which have effects across more than
one major category. Companies may wish to introduce a mix of cate-
gories in the incident type, in order to collect all associated loss costs
into the appropriate main categories. Hence even if the incident is
labelled an environment incident, people, asset and reputation loss costs
can be collected.
Companies may wish to include people loss costs which relate only to
their employees, their employees’ dependants and their contractors’ per-
sonnel. The criteria might also be set that only fatalities and major injuries
or industrial illness are analysed. Third-party loss costs are difficult to col-
lect and the company should decide whether these are significant enough
to be included.
Asset loss is primarily associated with the company’s property, plant and
equipment. An incident may also effect third party assets. In the criteria
decided by the company, the condition for including third party assets
should be clearly stated.
14
CATEGORISATION, ANALYSIS AND PRIORITISATION
Reputation loss cost is perhaps the most difficult to record. The effects of
lost reputation can result in short term or long term loss, and are difficult
to rectify.
The process starts with individual companies defining the incident classifi-
Analysis and Prioritisation
cations to be costed. Some suggested loss costing categories are outlined
in Appendix 4 to this guideline.
15
LOSS COSTING GUIDELINES
CONCLUSION
The financial costs of industrial incidents are quite staggering, with knock-
on negative impact on both the business and national GDP. At the per-
sonal level, industrial incidents can cause considerable suffering, trauma
and on occasion, severe financial hardship.
The incident loss costing processes developed from these Guidelines will
supplement existing company Health, Safety and Environmental
Management Systems in terms of monitoring performance, whilst improv-
ing bottom-line financial results, and could ultimately be used in setting
realistic targets and for E&P industry benchmarking purposes.
16
GLOSSARY OF DEFINITIONS
GLOSSARY OF DEFINITIONS
Direct Costs Those costs resulting from an incident which are cov-
ered by insurance policies by the organisation.
17
LOSS COSTING GUIDELINES
Lost Workday LWC are all non-fatal cases that involve days unfit
Cases (LWC) for work on any day after the day of the occupa-
tional injury.
18
GLOSSARY OF DEFINITIONS
Lost Workdays The total number of calendar days after the day of the
occupational injury on which the employees involved
in cases were unfit and did not work.
Potential Loss Potential loss cost can be that estimated cost which
Cost would have occurred as a result of a ‘near miss’. The
estimated cost can be either direct or indirect. It must
be recognised that as a result of a ‘near miss’ actual
expenditure can occur in taking remedial action to avoid
future reoccurrence.
Near Miss A near miss is an incident which did not result in injury
or illness, and/or damage (loss) to assets, the environ-
ment or third party (ies).
19
LOSS COSTING GUIDELINES
REFERENCES
(1) The costs to the British economy of work accidents and work-related
ill health. HSE. Books, 1995. (ISBN 0 7176 0666 X)
(3) The Costs of Accidents at Work. HSE. Health and Safety Series book-
let, HS(G)96. (ISBN 0 11 886374 6)
20
APPENDIX 1
APPENDIX 1
Loss Costing Process Model
Direct/indirect costs:
CATEGORISATION AND Application of risk matrix
‘what might have
QUANTIFICATION OF COSTS (see Appendix 2)
happened’
21
LOSS COSTING GUIDELINES
APPENDIX 2
Risk Matrix Example
RISK MATRIX
Increasing Probability
Consequence A B C D E
Incident Incident
Incident occurs happens
Incident Incident has several several
never heard of occured times per time per
heard of in EP in our year in our year at
Rating People Assets Environment Image in world industry company company location
0 No No No No
injury damage effect impact
22
APPENDIX 3
APPENDIX 3
Incident Loss Recording Matrix
People
Fatality costs
Medical treatment
Medivac
Chronic occupational health
Unproductive payroll
Increased payroll—more overtime/staff
Worker compensation
Recruitment
Training
Loss of morale in workforce
Production loss—breakdown as below
Remedial actions
Investigation
Legal
Insurance
Fines, penalties
TOTALS
Environment
Product loss
Business disruption
Improvement—plant/facilities
Evacuation
Waste management
Media response
Remedial actions, clean up
Personnel—breakdown as above
Studies, assessments—EIAs audits
Investigation
Legal
Insurance
continued …
23
LOSS COSTING GUIDELINES
Environment (continued)
Fines, penalties
Increased regulation, legislation
Improvement—emergency response
TOTALS
Assets
Asset loss
Equipment loss
Production loss—breakdown as below
Business disruption
Replacement—rebuild
Remedial actions
Personnel—breakdown as above
Environment—breakdown as above
Investigation
Studies, assessments—audits
Legal
Insurance
TOTALS
Production loss
Barrels deferred
Production losses
Lost sales
Personnel—breakdown as above
Remedial action
Legal
Fines, penalties
TOTALS
Reputation
Public relations liaison
Emergency response facilities
Share value loss
Business licences revoked
Increased regulations, legislation
Response to pressure groups
Customer support loss
TOTALS
GRAND TOTALS
24
APPENDIX 4
APPENDIX 4
Examples of Loss Cost Subcategories
People
● Fatality Costs: Costs associated with returning the victim to home
base. Burial costs. Family compensation. Company death benefits.
(Note: pension payments to next-of-kin should not be included.)
● Medical Treatment: Costs of hospitalisation, surgery, therapy, after-care.
● Medivac: Cost of transporting the injured or sick to a doctor or hospital;
transport may be required to repatriate the victim home.
● Chronic Occupational Health: Treatment costs, reduced output from
victim, pension payments enhanced, compensation.
● Unproductive Payroll: Injured, sick employees who cannot work or are
under-employed, but are paid as though fully employed. Company may
decide on a fixed figure to reduce administrative overhead in
calculating actual costs per incident.
● Increased Payroll: More overtime/staff: additional payroll costs to
employ personnel to replace injured/sick employees, additional
overtime to cover low productivity of injured/sick, or to make up
production shortfall due to incident.
● Worker Compensation: Payments made to victims to compensate
injuries/sickness, resettlement payments if employee is no longer fit to
work.
● Recruitment: Cost incurred to recruit new employees to replace those
involved in the incident. They may be temporary recruits or long-term.
● Training: Costs to train new employees taken on to replace those
involved in the incident—retraining of employees shown necessary by
the incident.
● Loss of Morale in Workforce: Some incidence may cause the
workforce concern and stress, and the overall morale of the workforce
can be reduced; this in turn may effect production or require morale-
boosting initiatives. These costs will be difficult to quantify.
● Production Loss: Breakdown as below.
● Remedial Actions: All those costs necessary to rectify the failures
identified as causing the incident, possible redesign costs of
equipment, commissions studies to overcome identified weaknesses.
● Investigation: The costs incurred investigating the incident, i.e. the
payroll component of personnel taken away from their usual work to
conduct the investigation, their travel expenses and accommodation
costs; and time lost by witnesses being questioned about the incident.
● Legal: Cost of employing legal advice required as a result of the
incident; possible court actions.
● Insurance: Additional premiums as a result of assessed liability due to
the incident.
● Fines, penalties: Any payments resulting from the incident—usually
these costs would be paid to authorities.
Environment
● Product Loss: This is broken down under Production Loss.
● Business Disruption: Those losses caused by the incident, e.g.
additional cost to company of supplying customers from another site;
unproductive equipment and plant.
● Improvements to plant/facilities: Costs to make improvements in
equipment, plant or site deemed necessary as a result of investigating
the incident.
25
LOSS COSTING GUIDELINES
Assets
● Asset Loss: The true cost of assets destroyed by the incident.
● Equipment Loss: The cost of equipment damaged or destroyed—
companies may have a standard figure or may use depreciated book
values.
● Production Loss—Breakdown as below.
● Business Disruption: Those losses caused by the incident, e.g.
additional cost to company of supplying customers from another site;
unproductive equipment and plant.
● Replacement/Rebuild: The total cost of purchase and positioning
replacement assets for those destroyed by the incident; rebuild costs
may include redesign, specialist advice. The costs of labour to repairs
on site should be recorded under the appropriate People category. It
may be necessary to charter special transport to get replacements on
site in timely manner. There may be temporary hire costs of
replacement equipment.
● Remedial Actions: The costs incurred by undertaking all the recovery
actions necessary, e.g. hiring cleanup facilities, redesigning/modifying
equipment, plant, storage.
● Personnel: Breakdown as above.
26
APPENDIX 4
Production Loss
● Barrels Deferred: The differential in cost of lost production at date of
incident compared to cost of replacement production at time of supply.
● Production Losses
● Lost Sales: Losses due to clients cancelling orders because the
incident has disrupted supply. Could also be long-term where client
loses faith in company’s ability because of incident.
● Personnel: Breakdown as above.
● Remedial Actions: The costs incurred by undertaking all the recovery
actions necessary, e.g. hiring cleanup facilities, redesigning/modifying
equipment, plant, storage.
● Legal: Cost of employing legal advice required as a result of the
incident; possible court actions.
● Fines, Penalties: Any payments resulting from the incident—usually
these costs would be paid to authorities.
Reputation
● Public Relations Liaison: The costs of setting up a liaison with the
media or clients to rectify or overcome the negative effects to the
company’s reputation as a result of the incident.
● Emergency Response Facilities: Costs of carrying out improvements in
emergency responses directly attributable to company’s reputation.
Note that these may not be considered necessary from the point of
view of mitigating future incidents but may be necessary to allay public
or client fears.
● Share Value Loss: The reduction in market value of the company as a
direct result of the incident.
● Business Licences Revoked: The total cost implications to the
company of having its business suspended or permanently revoked.
● Increased Regulations, Legislation: Because of the incident,
regulations maybe tightened which result in additional costs to the
company to ensure they comply.
● Response to Pressure Groups: As a result of the incident Pressure
Groups might start campaigns to cause adverse public reaction
towards the company. The company may incur cost in combating such
campaigns, e.g. setting up special reaction teams; conducting public
demonstrations; lobbying members of government.
● Customer Support Loss: Loss of reputation can cause customers to
withdraw their support—reduce or stop orders, withdraw privileges—
these will have a cost impact which should be recorded.
27
LOSS COSTING GUIDELINES
APPENDIX 5
Definition of Consequence—Severity Rating for Risk
1 Slight injury/illness Not detrimental to individual employability Slight damage No disruption to the
or to the performance of present work. process, minimum cost
Agents which are not hazardous to health. of repair (below $10,000)
2 Minor injury/illness Detrimental to the performance of Minor damage Possible brief disruption
present work, such as curtailment of of the process; isolation
activities or some days’ absence to of equipment for repair
recover fully, maximum 1 week. (estimated cost below
Agents which have limited health effects $100,000)
which are reversible, e.g. irritants, many
food poisoning bacteria.
3 Major injury/illness Leading to permanent partial disablement Local damage Plant partly down;
or unfitness for work, or detrimental to process can (possibly)
performance of work over extended be restarted.
period, e.g. long-term absence. (Estimated cost of
Agents which are capable of irreversible repair below
damage without serious disability, $1,000,000)
e.g. noise, poorly-designed manual
handling tasks.
4 Single fatality/ Also includes the possibility of multiple Major damage Partial loss of plant; plant
permanent total fatalities (maximum 3) in close succession shutdown (for at most 2
disability or due to the incident, e.g. explosion. weeks and/or estimated
unfitness for work Agents which are capable of irreversible repair costs below
(small exposed damage with serious disability or death, e.g. $10,000,000)
population) corrosives, known human carcinogens.
5 Multiple fatalities May include 4 fatalities in close Extensive damage Total loss of the plant;
succession due to the incident, or multiple extensive damage
fatalities (4 or more) each at different (estimated cost of repair
points and/or with different activities. exceeds $10,000,000)
Agents with potential to cause multiple
fatalities, e.g. chemicals with acute toxic
effects (e.g., hydrogen sulphide, carbon
monoxide, known human carcinogens).
* Assets are understood as referring to: the oil and gas reservoirs, production facilities, pipelines, money, capital, and other company, contractor
and third party property.
28
APPENDIX 6
2 Minor Contamination; damage <100 100–1000 Limited Some local public concern;
effect sufficiently large to attack impact slight local media and/or
the environment; single local political attention with
exceedence of statutory or potentially negative aspects
prescribed criteria; single for Opco operations.
complaint; no permanent effect
on the environment.
3 Local Limited loss of discharges of 100– 1000– Consider- Regional public concern.
effect known toxicity; repeated 1000 10,000 able Extensive negative attention
exceedence of statutory or impact in local media; slight national
prescribed limit and beyond media and/or local/regional
fence/neighbourhood. political attention with
possibly negative stance of
local government and/or
action groups.
4 Major Severe environmental damage; 1000– 10,000– Major National public concern.
effect the Opco is required to take 10,000 100,000 national Extensive negative attention
extensive measures to restore impact in national media and/or
the contaminated environment to regional/national policies with
ts original state. Extended potentially restrictive
exceedence of statutory or measures and/or impact on
prescribed limit. grant of licences, mobilisation
of action groups.
5 Massive Persistent severe environmental >10,000 >100,000 Major International public attention.
effect damage or severe nuisance inter- Extensive negative attention
extending over a large area. national in international media and
In terms of commercial or impact national/ international policies
recreational use or nature with potentially sever impact
conservancy, a major economic on access to new areas,
loss for the Opco. Constant high grants of licences and/or tax
exceedence of statutory or legislation.
prescribed limit.
* Incidents relating to air, noise, light and soil vibrations should be addressed on the basis of export judgement and, in the case of uncertainty,
local expertise may be called in.
29