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20100324 3rd Edition Corporate SHE Management System Manual | Occupational Safety And Health | Risk Management
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Copyright is a property right which all authors have in relation to the works which they create. It is a right to stop others copying or exploiting in various ways authors' works without permission. Copyright in this publication is vested in Petroplus Marketing A.G. Permission for anyone, including other subsidiaries within the Petroplus Group, to copy or reproduce any part of it should first be obtained from the PETROPLUS Group.
Safety, Health and Environmental (SHE) Management System Manual
List of hard copies to be issued (registered)
Copy No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 Location Zug Zug Teesside Teesside Coryton BRC BRC BRC BRC Coryton Coryton Cressier Cressier Ingolstadt Ingolstadt Petit Couronne Petit Couronne Reichstett Reichstett Teesside Teesside Zug Zug Role Chief Operating Officer Refining General Manager Corporate SHE Manager Corporate Safety Specialist Corporate Safety Specialist Corporate Environment Specialist Corporate SHE Specialist Refinery Manager Refinery Manager Refinery Manager Refinery Manager Refinery Manager Refinery Manager Refinery Manager Refinery Manager Refinery Manager Refinery Manager Refinery Manager Refinery Manager Terminal Manager Terminal Manager Technical Manager Projects and Capital Program Current Holder C Kuchta P Senkbeil C Platt D Pinder R Graham S Cobben L Van Berendonck M Mazenauer M Mazenauer J Barden J Barden G Vollin G Vollin G Fischer G Fischer P Billant P Billant C Philipponeau C Philipponeau P Grange P Grange L Pelsez R Arthur
CONTENTS PART 1: CORPORATE SHE MANAGEMENT SYSTEM
SECTION 1 2 3 4 SUBJECT
INTRODUCTION SHE MANAGEMENT FRAMEWORK SHE PERFORMANCE OBJECTIVES MONITORING CONFORMANCE WITH CORPORATE SHE MANAGEMENT SYSTEM STANDARDS
PART 2: STANDARDS
SECTION SUBJECT
1. RDSHE1: LEADERSHIP AND COMMITMENT 2. RDSHE2: SHE PLANS, MANAGEMENT, RESOURCES AND LEGAL COMPLIANCE 3. RDSHE3: COMMUNICATION AND CONSULTATION 4. RDSHE4: SHE TRAINING, AWARENESS AND COMPETENCY 5. RDSHE5: OCCUPATIONAL HEALTH AND WELLBEING 6. RDSHE6: SUBSTANCE HAZARDS 7. RDSHE7: NEW PLANT, BUILDINGS, EQUIPMENT AND PROCESS DESIGN 8. RDSHE8: MANAGEMENT OF CHANGE 9. RDSHE9: ASSURANCE 10. RDSHE10: SYSTEMS OF WORK 11. RDSHE11: PLANT OPERATION 12. RDSHE12: MANAGEMENT OF CONTRACTORS AND SUPPLIERS 13. RDSHE13: ENVIRONMENTAL IMPACT 14. RDSHE14: EMERGENCY PREPARDNESS 15. RDSHE15: SHE RISK MANAGEMENT 16. RDSHE16: INCIDENT INVESTIGATION AND FOLLOW UP 17. RDSHE17: SHE PERFORMANCE REPORTING 18. RDSHE18: MONITORING OF SHE PERFORMANCE
It is the organization’s view that effective SHE performance is the foundation upon which all other business priorities are based. An emphasis shall always be placed on the SHE issues associated with any activity which is to be undertaken. It shall be clear that operating costs, production requirements, product quality and other priorities shall not be allowed to compromise SHE performance. The Third Edition of the manual supersedes the Second Edition. This Third Edition has been issued following consultation and discussions across the organization. During the review process, the objective has been to ensure that this manual continues to build upon existing good practices and learning from previous experiences. A number of key changes are highlighted below: • • • • • • • • • Updating has been undertaken to reflect the latest organisational changes (November 2009) together with the related modified reporting requirements. In terms of SHE management system structures, the Corporate SHE Committee and the SHE Management Framework appear for the first time. The Letter of Assurance process has now been discontinued and has been removed from this manual. The Petroplus triangle which shows how Operational excellence can only be based on the establishment of a firm foundation of SHE excellence is included in the Introduction. In order to improve leadership and governance of SHE processes, there is now a requirement for each site to appoint a member of their management team to be responsible for each standard within this manual. There has been an increase in the focus on process safety which has been reflected in a number of modified standards. A new standard on “SHE risk management” has been created to ensure that systems are in place to identify, assess and appropriately mitigate SHE risks. There is a more detailed standard highlighting expectations with regards to monitoring SHE Performance across the organization which includes auditing processes. A more detailed standard setting the expectations of investigation and follow-up of SHE incidents has been developed to ensure that root causes are more effectively identified and evaluated so as to prevent recurrent incidents. A Glossary of SHE terms has been included for the first time.
Personal Responsibility Everyone who works with us and for us has a personal responsibility to prevent harm to themselves. monitoring. Health and Environment (SHE) working conditions into our daily operating practices. We do this within all levels of the company. HEALTH AND THE ENVIRONMENT
We recognise that an excellent SHE performance cannot be achieved without the involvement and contribution of every individual within the business. All Petroplus companies are required to adhere to the corporate expectations and to comply with laws and regulations applicable in each working location. We are individually and collectively committed to these principles and expect all who work in our business to behave in accordance with them. Our working procedures and practices are focused on the prevention of any kind of incident and consequently. The Prevention of Harm to the Environment We believe that by operating our business in the most efficient way we can reduce the impact on the environment and the neighbors that surround our operating entities. To fulfil our SHE obligations and to meet the high standards set by the Company’s Executive Committee required in all areas of safety. auditing. At Petroplus we emphasize the integration of sustainable Safety. and occupational illnesses are preventable and that incident reporting and investigation are of fundamental importance in their prevention. and Occupational Illnesses We believe that all injuries. Auditing. others and the environment will we be able to deliver the level of SHE performance which we desire.THE PETROPLUS COMMITMENT TO SAFETY. The Prevention of Injuries. others and the environment. Only through each employee assuming responsibility to prevent. incidents. conducting reviews and implementing corrective actions to ensure full compliance with the principles of the Corporate SHE Management System. on the improvement of working conditions at every location. contractors. Continuous Improvement and Commitment SHE improvements form an integral part of the development of our business opportunities. sampling. SHE Policy Compliance with Relevant Company Policies and the Law We have set clear expectations within our Corporate SHE Management System Manual. the community and our business and assets. harm to themselves. These sustainable SHE working conditions lead to control and reduction of SHE risks for our employees. health and environment there is a need for continuous improvement and commitment by everybody.
Jean-Paul Vettier Chief Executive Officer January 2010
Chris Platt Corporate SHE Manager
. Monitoring and Corrective Action Petroplus are committed to setting objectives and targets. Our aim is to work in harmony with our surroundings and to provide economic benefit to the local communities. as far as reasonably practicable. Incidents.
PART 1: CORPORATE SHE MANAGEMENT SYSTEM
SECTION 1 2 3 SUBJECT
INTRODUCTION SHE MANAGEMENT FRAMEWORK SHE PERFORMANCE OBJECTIVES 4 MONITORING CONFORMANCE WITH CORPORATE SHE MANAGEMENT SYSTEM STANDARDS
• the SHE Management Framework. this means protecting the safety and health of those who work with us and for us and respecting the needs of the environment in which we operate.
1. with robust risk-based SHE management systems operated by risk aware individuals. equipment and infrastructure. To help Petroplus meet our commitments to SHE.0
1. This means that SHE performance forms the foundation of the continuity of our business.2
SHE PRINCIPLES We believe that our operations should have fundamentally safe well-designed plant.1
PETROPLUS VISION The Petroplus vision is that we should manage all of our operational activities in such a way that the SHE impact is “Zero Harm” Specifically.1.
. we have developed: • the Petroplus SHE Triangle which demonstrates our SHE principles. and • the Corporate SHE Management System Manual.
APPLICATION The Corporate SHE Management System Manual applies to all personnel and assets within Petroplus. It sets the Group’s SHE expectations which all Petroplus entities must comply with. The Manual specifies a number of mandatory requirements to be incorporated in the SHE management systems of the Petroplus entities. These requirements are in addition to any local or national legal requirements and shall be delivered through local SHE procedures as necessary. The principles of the Corporate SHE Management System Manual shall be used in any merger or acquisition process to assist in identification of potential SHE risks and liabilities associated with facilities and businesses prior to them becoming part of the Petroplus Group.
SCOPE The Corporate SHE Management System Manual contains standards that cover the marketing and distribution through to refining and the entire lifecycle of operations from planning, operation, decommissioning and remediation.
MANAGEMENT REVIEW Authorization The Corporate SHE Management System Manual has been prepared by the Corporate SHE Department on behalf of Petroplus and has been authorized by the Chief Executive Officer and the Executive Committee. Review and Revision of the Manual The Corporate SHE Department is responsible for arranging the review and updating of this manual on a periodic basis to ensure that the document remains current and valid. This will be carried out in consultation with Petroplus stakeholders such as SHE professionals and line managers. Document Control This Corporate SHE Management System Manual is held on the SHE Portal of Sharepoint. Any copy printed from the system will be classified as an uncontrolled copy. Enquiries and Correspondence All enquiries and correspondence concerning interpretation of this manual should be addressed to the Corporate SHE Department.
THE SHE MANAGEMENT FRAMEWORK
The SHE Management Framework defines roles and responsibilities of the corporate and functional organizations to help Petroplus drive towards “Zero Harm”. The corporate organization defines and communicates requirements in relation to vision, principles and SHE Policy and standards for managing the safety, health and environmental risks associated with our business activities. The Petroplus entities implement and incorporate the corporate requirements into their business activities.
Petroplus Board Executive Committee Corporate SHE
Corporate function will define and communicate SHE requirements, including Corporate SHE Policy and Corporate SHE Management System containing clear non-negotiable SHE standards. This will require sufficient resourcing, communication and setting of corporate key performance indicators.
LEADERSHIP Petroplus SHE vision and principles Corporate SHE Policy, Corporate SHE Management system
MONITORING Corporate SHE Committee Corporate SHE Review program Third Party
Petroplus Entities
LEADERSHIP Petroplus SHE vision and principles Corporate SHE Management system and local SHE Management Systems
Entities will implement the requirements of the Corporate SHE Management System. This will require sufficient resourcing, communication and setting of business specific key performance indicators and operational safety plans.
MONITORING Corporate SHE Review program Local Audit Management System
LEADERSHIP Senior managers and supervisors must lead by example and demonstrate behaviours that will drive continual improvement in SHE performance. Managers and supervisors must set high standards for SHE, actively engage with the workforce, and identify and correct unsafe behaviors or situations. All unsafe practices and incidents will be investigated to understand what happened and why. All necessary steps will be taken to prevent a recurrence and learning shall be communicated to ensure that all Petroplus entities benefit from the outcomes of these investigations. Managers and supervisors at all levels in the organization have a responsibility to abide by the principles as defined by the standards. They must be embraced and embedded into the organization and, as leaders, managers and supervisors must pursue the development of a safety culture which reflects our vision and principles. We believe that everybody should understand their SHE responsibilities and clear accountabilities should be established.
SHE POLICY The Petroplus Corporate SHE Policy defines the organization’s SHE strategy and corporate governance structure for managing SHE risks within the company.
SHE STANDARDS A set of common mandatory standards have been developed that are incorporated into the Corporate SHE Management System Manual. Functional line managers at all levels have the responsibility of implementing and maintaining the standards. The standards form the basis for the development, improvement and application of comprehensive, integrated SHE Management systems throughout all operations. The standards have been developed from pre-existing Petroplus standards and industry recognised good practice. These standards principally identify duties to have systems to ensure safe and environmentally responsible management of activities, in certain specific areas of SHE risk. There must be both: i) systems in place and ii) effective compliance with those systems, in order to satisfy this requirement. In a number of areas of SHE risk, these requirements are specified in detail as a result of: a) b) c) A need for uniform practices across Petroplus. A need to emphasise certain issues which might give rise to a long term corporate business risk. An understanding that in certain areas, compliance with government regulations may not be sufficient to deliver the level of performance and liability limitation which the Company requires.
The SHE Standards are to be found in Part 2 of this manual.
LOCAL SHE MANAGEMENT SYSTEMS The SHE standards are implemented via local SHE Management systems which define the arrangements in place for managing SHE risks. The SHE Management systems need to incorporate local legal requirements and also take into account good management practice.
personal safety and the environment and targets have been established which are regularly monitored.3. Specific Key Performance Indicators (KPIs) have been set for process safety. The KPIs set are both leading and lagging indicators to ensure that proactive as well as reactive monitoring of the organization’s performance is carried out.
SHE PERFORMANCE OBJECTIVES
Petroplus believes that by setting objectives it will drive continuous improvement in SHE performance across the organization. The KPIs set by the Corporate SHE Department will be reviewed on a periodic basis to ensure that they remain current and valid.
The SHE Review process is led and managed by Corporate SHE. The Company’s Internal Audit department will review the Corporate SHE Review policies and processes and provide assurance to the Audit Committee of Petroplus that the Corporate SHE Reviews are conducted in accordance with appropriate standards and methodologies. the visible condition of hardware. process safety related incidents. accidents. loss of containment and to be environmentally responsible. The Corporate SHE Review process utilizes the knowledge.0
MONITORING CONFORMANCE WITH CORPORATE SHE MANAGEMENT SYSTEM STANDARDS
The Petroplus Board of Directors and the Company’s Executive Committee seek assurance of compliance to the SHE standards contained within the Corporate SHE Management System and the process of continual improvement. Health and Environment Reviews are aimed to assist all Petroplus entities to proactively identify areas of improvement in their SHE management systems and to prevent injury. As such the Corporate SHE Review process has been developed as a means of assuring that comprehensive risk-based management systems are in place at all facilities. the content of records and the knowledge and views of personnel.
. The Corporate SHE Review process involves a review of management system arrangements. This acts as a catalyst for learning and sharing across the organization. skill and experience of people across the Petroplus Group by involving them in the fieldwork of the SHE Review process. The Corporate SHE Reviews are conducted using a ‘risk based’ approach so as to ensure that they are focused on the issues that are most important to the organization. incidences of occupational related illnesses. The Corporate Safety.4.
EQUIPMENT AND PROCESS DESIGN 8. RDSHE8: MANAGEMENT OF CHANGE 9. RDSHE7: NEW PLANT. RDSHE5: OCCUPATIONAL HEALTH AND WELLBEING 6. RESOURCES AND LEGAL COMPLIANCE 3. RDSHE16: INCIDENT INVESTIGATION AND FOLLOW UP 17.PART 2: STANDARDS
1. MANAGEMENT. RDSHE15: SHE RISK MANAGEMENT 16. RDSHE11: PLANT OPERATION 12. RDSHE14: EMERGENCY PREPARNESS 15. RDSHE3: COMMUNICATION AND CONSULTATION 4. AWARENESS AND COMPETENCY 5. RDSHE18: MONITORING OF SHE PERFORMANCE
. RDSHE17: SHE PERFORMANCE REPORTING 18. RDSHE12: MANAGEMENT OF CONTRACTORS AND SUPPLIERS 13. RDSHE9: ASSURANCE 10. RDSHE2: PLANNING. RDSHE10: SYSTEMS OF WORK 11. RDSHE6: SUBSTANCE HAZARDS 7. RDSHE1: LEADERSHIP AND COMMITMENT 2. RDSHE13: ENVIRONMENTAL IMPACT 14. RDSHE4: SHE TRAINING.
Managers at all levels will be expected to support and promote the site’s SHE management system to ensure that activities on site are managed safely and with respect for the environment.RDSHE 1 – LEADERSHIP AND COMMITMENT
SUMMARY OF STANDARD Site Managers and their Management Teams are ultimately accountable for the safety. deadline or quality considerations. Principles to be followed All sites shall formally define and document the SHE accountabilities and responsibilities of all levels of management. health and the environmental of their site. Site Management shall integrate SHE expectations into business planning and decision making processes. have clear responsibility to set priorities for SHE and lead the commitment to ensure continual performance improvement in this area. and all contractors. Site Management shall adopt formal processes that recognise. supervisory level employees. Site Management shall define and consistently enforce site SHE rules. the appointee is to provide sponsorship for the any actions which are recommended. ensuring that documented systems are in place to deliver expectations.
. All activities on site should be managed safely and with respect for the environment through an effective SHE Management System. of all supervisory level employees. it will be the appointee’s role to ensure compliance with the Corporate SHE Management System and to bring non-compliances to the attention of the management team if they occur. Where incident root causes relate to learning in an appointee’s nominated standard. All sites shall have a management appointee to act as a sponsor for each standard within this document. Key aspects of these roles involve implementation and maintenance of an effective SHE management system. reinforce and reward desired SHE outcomes. All activities on site are to comply with the Corporate SHE Management System. 1. and contractors understand the importance of their roles in delivering SHE on site. For each standard.1 RESPONSIBILITIES Duty Site Managers shall ensure that all members of management. Timely planning and communication is considered to be key to ensuring that SHE related activities are not compromised by cost.
supervisory level employees. The SHE Management System should be consistent with internationally recognised SHE management system standards such as OHSAS 18001 and ISO 14001. Principles to be followed The SHE Management System should: a) b) c) Contain a published SHE Policy Statement as a visible demonstration of leadership by the Site Manager. All sites shall have clearly defined roles. for example. Supervisors. such as SHE audit programmes are in place to ensure continual improvement in SHE performance. such as audits and inspections. All sites shall have arrangements in place to manage the SHE risks associated with the operation of the site. Principles to be followed Site Management. These shall be defined. policies. and contractor representatives shall proactively demonstrate their commitment to SHE compliance by participating in SHE performance programmes. procedures and operating instructions. documented and communicated to all persons. Site Management shall be visible in the field and utilise their time to demonstrate SHE leadership and commitment. 1. This shall include engaging with the workforce and contractors. Establish clear SHE goals and objectives to measure SHE performance on site. responsibilities and accountabilities at all levels and functions on site to ensure effective implementation of the SHE Management System. Employees and Contractors at all levels shall demonstrate the highest standards of SHE risk awareness and shall be held accountable for the impact of their actions in terms of SHE performance through the Petroplus Performance Management Process.
.1. All sites shall ensure that proactive processes. Managers.3 THE PREPARATION OF A LOCAL SHE MANAGEMENT SYSTEM Duty Site Managers shall ensure that a SHE Management System is developed and reviewed on a periodic basis to foster continual improvement to be made. Site Management shall allocate competent resources to maintain SHE Management Systems on site.2 MANAGEMENT AND SUPERVISORY BEHAVIOURS Duty All levels of management and supervisory level employees shall lead by example in terms of the behaviours they wish employees and contractors to follow.
. to make sure that they remain relevant and appropriate to the nature and extent of the associated SHE risks.f)
All sites shall ensure that processes are in place to ensure the effective review of the SHE Management System on a periodic basis.
documented. ranked according to urgency together with accountabilities clearly defined.g. employees and contractors to comply with the SHE policies. regulatory and other SHE compliance requirements are identified. using a risk-based approach (see Corporate SHE 003). the law and to discharge their SHE policy responsibilities. RESOURCES AND LEGAL COMPLIANCE
SUMMARY OF STANDARD In order to ensure continuous improvement of SHE performance targets and objectives are integrated into the overall business planning process and deployed throughout the organization. technical and financial) shall be available and employed to assist management. MANAGEMENT.
. priorities and targets should be communicated and understood by all appropriate personnel. including contractors. priorities and numerical targets for the forthcoming year. priorities. which shall form part of a longer term SHE compliance improvement programme. 2.
The SHE Improvement Plan should be reviewed on an annual basis to ensure that goals. maintained.. A review of current SHE compliance performance and results of relevant audits and inspections.2 SAFETY. Action plans for specific tasks to be undertaken to improve performance. human. accessible. targets. HEALTH AND ENVIRONMENTAL IMPROVEMENT PLANS Duty Site Managers shall prepare and issue an annual SHE compliance improvement plan.1 LEGAL REQUIREMENTS Duty Site Managers shall ensure that all applicable legal. communicated. SHE Improvement Plans should be prepared in consultation with employees and their representatives.RDSHE 2 – SHE PLANS. and established timescales remain appropriate. Principles to be followed The SHE Improvement Plan should include: a) The establishment of formal and measurable goals. understood and complied with. resources (e. These goals. 2.
Site Managers should have processes which effectively integrate asset life plans with SHE investment needs.
The annual budget review for each site should make explicit reference to the summarised SHE Improvement Plan.5 INSURANCE LIABILITY MANAGEMENT Duty Site Managers shall manage their activities in order to ensure that insurance policies in respect of Property Damage (PD). in collaboration with the Corporate Insurance Manager. 2. A particular activity will be to ensure that the annual insurance coverage renewals processes are conducted efficiently. identifying cost implications and priorities.3 SHE INPUT TO ANNUAL BUDGET REVIEW AND ASSET LIFE PLANS Duty Site Managers shall ensure that when assessing the SHE input into the annual budget review an adequate risk assessment is carried out to ensure the following: a) b) Adequate manpower resources are identified. Adequate SHE information is supplied to justify cost implications. Recommendations will then be carried out to the timescales agreed with the insurer. The draft recommendations will be assessed and a process will then be managed to ensure that those recommendations in the final report are fully agreed. Following site visits by brokers and insurer’s representatives. Business Interruption (BI).2.4 RESOURCES Duty All sites shall ensure that adequate resources (human. In order to achieve this. Employers Liability (EL) and Public Liability (PL) can be obtained on as favourable terms as possible. 2. technical and financial) are made available and deployed to ensure that goals. This will require that action plans arising from brokers’ and insurers’ visits are actively managed in consultation with Petroplus’ Corporate Insurance Managers and those parties. priorities and numerical targets can reasonably be achieved.
. a draft report will be issued to the site management team for consideration. Principles to be followed: a) An individual shall be identified at each site as responsible for co-ordination of insurance matters.
All sites shall establish and maintain effective and appropriate forums for the regular consultation and communication of SHE matters. good practices and improvement opportunities. participation and communication of matters relating to SHE compliance at all levels and functions within the operation.RDSHE 3 – COMMUNICATION AND CONSULTATION
SUMMARY OF STANDARD All sites shall proactively communicate. The process shall involve all appropriate personnel. contractors and suppliers and shall formally define and communicate to appropriate personnel the arrangements for employee safety representation. Key topics process shall include the sharing of lessons learned. The processes shall also include the sharing of information with other sites and the corporate organization. 3. The consultation. The consultation and participation process shall be an interactive process allowing for two way dialogue. Principles to be followed: All sites shall develop and implement formal processes to ensure effective consultation. consult and involve all appropriate employees and contractors in matters of safety. participation and communication processes shall be reviewed on a regular basis with all applicable personnel to evaluate their effectiveness and to ensure they remain relevant and appropriate. monitor and report on the effectiveness of current safety systems and performance. These shall involve all relevant personnel and shall be used as a mechanism to track. health and the environment.1 ROUTINE COMMUNICATION PROCESSES Duty Site Managers shall ensure that they have processes to ensure effective consultation and communication of SHE compliance matters with all employees and contractors on a continual basis.
qualification. This shall include regulatory SHE training requirements. 4. AWARENESS & COMPETENCY
SUMMARY OF STANDARD SHE Training needs shall be identified and training shall be carried out to ensure that plant is operated and work is conducted with proper regard for SHE compliance. The SHE training management system should include SHE awareness and competence programmes. shall be identified. awareness and competencies of all relevant personnel prior to employment. Site Management shall ensure training shall take into consideration all changes to the operations and personnel that may impact upon SHE. including refresher training. positions and job functions have the required SHE competencies formally defined in terms of appropriate skills.
. Site Management shall ensure general and specific training needs. Specifically issues such as changing roles and returning from absence shall be addressed.1 TRAINING OF PERSONNEL Duty Site Managers shall ensure that all organisational roles.RDSHE 4 – SHE TRAINING. accessible and maintained. Site Management shall ensure that individual SHE training needs shall be managed through the Petroplus performance management process. Site Management shall be accountable for identifying training needs and developing and implementing a formal SHE training management system. prioritised and delivered to ensure adequate levels of competency before work activities are undertaken.2 TRAINING OF SHE PERSONNEL Site Managers shall ensure that personnel specifically employed to work within a SHE role hold a formal recognised SHE qualification and should participate in continual professional development within the field of SHE. training and experience. contractors and visitors shall be documented. Site Management shall ensure that processes are in place to ensure the effective review of HER training management systems to ensure that they remain relevant and appropriate to the nature and extent of the associated SHE risks. which are applicable to all relevant levels and functions within the operation. 4. The effectiveness of the training shall be monitored. Training records for employees. Site Management shall ensure that their recruitment and selection policies specifically consider SHE training.
The induction programmes shall be appropriate to the nature and extent of the hazards and risks associated with the site operations.3
TRAINING OF CONTRACTORS Duty All sites shall have formal systems in place to ensure that all contractors and suppliers are competent to perform their activities safely when engaged by Petroplus or acting on behalf of Petroplus.4
SHE INDUCTION TRAINING Duty All sites shall implement a formal induction programme for employees.4. contractors and visitors.
including the effects of shift work. noise. the health risk profile should include specific controls to ensure that the following occupational health hazard categories are appropriately managed:
Biological (i. workplace stress etc. Identification of the specific health surveillance required for the health hazards and causes of ill health related to work on site. To protect the health of employees and others who work on our sites systems.1 THE PREVENTION OF OCCUPATIONAL ILL HEALTH Duty Site Managers shall ensure that the occupational health related risks on their sites are reduced to as low a level as is reasonably practicable. water systems with a risk of legionella and ionizing radiation see RDSHE 6 Substance Hazards. musculo-skeletal disorders.e. benzene) Ergonomic (i.RDSHE 5 – OCCUPATIONAL HEALTH AND WELLBEING
SUMMARY OF STANDARD Maintaining a healthy workforce is essential to operating our sites efficiently. procedures and facilities shall be established. There shall be systems in place for proactive health promotion on site to ensure the well being of employees. vibration) Workplace environment (i. maintained and monitored to manage the occupational health risks on site.
. including those arising from manual handling activities or use of display screen equipment) Physical (i. fatigue.
At a minimum.) Chemical (i. Principles to be followed: There shall be a health risk profile in place that contains the following information:
Identification of the health hazards and causes of ill health related to work on site. Identification of the functions that could potentially be exposed to the health hazards recognised.e. An assessment of the likely exposure and impact of the health hazards during specific tasks or activities undertaken in the work environment and identification of all precautions necessary to minimise exposure. 5.e.e. Identification of the training required for employees on the prevention of exposure to the health hazards and causes of ill health related to work on site. temperature)
For the management of asbestos.e.
A program of proactive sampling of the main health hazards identified on site. Principles to be followed: There shall be a health surveillance system in place that contains the following:
A health assessment of individuals at pre-placement. Principles to be followed: Systems and facilities shall be established for immediate first aid such as:
Provision of a suitable number of professionally trained first aid providers.
.3 THE PROMOTION OF HEALTH Duty Site Managers shall ensure that there are systems in place to promote the health and well being of employees on site. A process to collate ill health statistics and the review of any relationship of ill health to work. A defined schedule of specific health surveillance requirements in accordance with the health hazards identified in the sites’ health risk profile. Good standards for workplace and personal hygiene practices. Other emergency response equipment.
5. Provision of an independent employee assistance program.
5. Provision of safety showers. Dedicated treatment rooms. Principles to be followed: Systems and facilities shall be established for:
Proactive routine health monitoring to monitor aspects of health during the course of employment.2
PROVISION OF HEALTH SURVEILANCE Duty Site Managers shall ensure that there are systems in place to monitor the management of occupational exposure related health risks and the well being of employees during the course of their employment.4
THE TREATMENT OF ACCIDENTS AND ILLNESS OCCURRING AT WORK Duty Site Managers shall ensure that accidents and illnesses occurring at work receive timely treatment carried out by appropriately trained persons.5. Eye wash bottles. Health education and health promotion activities.
Principles to be followed: Systems and facilities shall be established for:
Rehabilitating sick or injured workers. Facilitating medical referrals to physiotherapists and other specialized treatment. First-aid providers to assist with the immediate treatment of accidents and illness in the absence of an occupational health professional
At each site a suitably trained person should be appointed who will receive hazard data for all materials used on site and communicate same to site personnel as appropriate. Petroplus.Disclosure of Medical Information Site Managers shall have a documented statement describing the management of medical confidentiality. Ensuring that employees who are off work due to illness for extended periods of time are referred for assessment by the occupational health function upon their return to work. and medical staff. any first aid treatment given on site.5 THE RESTORATION OF HEALTH Duty Site Managers shall ensure that active support is given to individuals to recover from illhealth as soon as possible.
5. Principles to be followed: a) Resources Each site shall assess its requirements for professional support from:
An Occupational Health Physician.
.5. c) Ethics . This will be in accordance with local regulatory requirements and practice and will address the rights and obligations of the employee. b) Medical Records Medical records should be retained in accordance with local or national requirements. Records should be retained for at least 30 years after the termination of employment. Nurses or Advisors. but should include. at a minimum.6 PROFESSIONAL ASPECTS OF HEALTH CARE Duty Site Managers shall ensure that there is adequate provision of health care on site and that health care on site is managed responsibly and in accordance with this policy and legal requirements.
It should be noted that there may well be local regulatory limitations on some or all of these reasons for testing.5. Principles to be followed:
The consumption of drugs or alcohol on site can pose a significant risk to the safe operation of plant and facilities and to sound and reliable judgment in employees. The procedure will recognise both the personal rights of the individual and the obligations of Petroplus to provide a safe site. there are likely to be clearly defined limits to the action that can be taken in each location. Management teams shall investigate any cases where a drug or alcohol use problem is suspected and to take measures to control its impact. Site Managers shall ensure that limits of activity at each location are understood by the management team.
DRUG AND ALCOHOL MANAGEMENT Duty Site Managers shall establish a procedure for the identification and management of drug and alcohol use problems in so far as any such use may affect an individual’s performance at work. Drug and alcohol testing will be of greatest effectiveness in reducing the impact on the company’s interests. Full consultation with the workforce at each site supported by a clear policy will be required to provide management with maximum scope for action in response to incidents. However. It is entirely unacceptable for the consumption of non-prescription drugs and/or alcohol on site. if it can be carried out:  Before employment with the company begins  On a random basis during employment  “With cause” for example following an incident or in those instances where an employee or contractor may be reasonably believed to be under the influence of drugs or alcohol. as well as causing serious health effects.
transported. stored. used and disposed of in accordance with local and national regulatory requirements. transported.RDSHE 6 – SUBSTANCE HAZARDS
SUMMARY OF STANDARD All hazardous substances and chemicals need to be appropriately managed on site.3
SAFETY DATA SHEETS Duty Site Managers shall ensure appropriate information is maintained to enable all materials used on site or manufactured for sale. used and disposed of in accordance with local and national regulatory requirements. recorded and monitored in accordance with local and international regulatory requirements. such as identifying safe systems of work and the use of personal protective equipment etc Risks are to be communicated to employees.1) Water systems with a risk of legionella Ionizing radiation
6. labelled.2
USE OF HAZARDOUS SUBSTANCES Duty Site Managers shall ensure all workplace exposure limits for relevant materials and physical agents are adhered to. 6. Formal systems need to be in place to ensure that all materials contained. used. stored. produced on site or manufactured for sale are properly classified. to be properly handled.
Principles to be followed Site Managers shall ensure that the hazards associated with the substances used on site are subject to the following:
An assessment of the potential exposure during application Mitigation by implementing control measures. handled. There must be adequate communication of any exposure limits to all those who are potentially exposed to the hazardous substance.1 INFRASTRUCTURE HAZARDS There shall be specific management systems in place to ensure that the following infrastructure hazards are appropriately controlled on site:
Asbestos (see RDSHE 10. contractors and customers as appropriate Adequate training is to be provided to employees and contractors on the safe use and handling of hazardous substances
Activities on site will be carried out in compliance with the data sheet. the change is subjected to a formal management of change process. 6.
. Sites shall have systems in place to ensure a SDS is compiled in accordance with Annex II of EU regulation 1907/2006/EC (REACH) for each petroleum product.Principles to be followed Sites shall have a system in place to manage Safety Data Sheet (SDS) obtained from suppliers of chemicals. and documentation for distribution of products (For example EU regulation EC/1272/2008 on classification. labelling and packaging). All materials that do not have workplace exposure limits assigned to them or do not require a SDS do not need to be subject to a formal management of change process. Principles to be followed regarding EU regulation 907/2006/EC (REACH) Under REACH legislation registration dossiers for substances which are produced or imported need to be produced. 6. This will be required during the Pre-registration phase for substances and also when new materials are introduced to business activities. safety and the environment can be reduced.3 REVIEW OF SUBSTANCE HAZARDS Duty Site Managers shall ensure that when a new material is introduced to the site or whenever the use of a material on site is changed or whenever a different material is substituted. 6. safety and environmental considerations. Sites shall on a periodic basis review the materials used on site to identify if they are still required and whether they remain an acceptable option taking into account occupational health. Elimination/substitution of materials should be considered where the impact on occupational health.5 CHEMICALS REGULATION Duty Site Managers shall ensure implementation of obligations arising from new chemicals regulations. additive and other imported chemicals that is being manufactured on the site or being imported to the site for delivery to customers. labelling.4 CLASSIFICATION AND LABELLING Duty Site Managers shall ensure compliance with legislative requirements in respect of the classification. Any changes made should be communicated as appropriate. The information contained in the SDS shall be made available to employees and contractors as appropriate.
. Site Managers shall ensure that site procedures are reviewed and updated in order to comply with all relevant obligations arising from REACH.Site Managers will provide adequate resource and information to ensure that registration dossiers are created and submitted in accordance with the requirements of REACH.
EQUIPMENT. this study may conclude that further SHE assessments are not required. plants. Studies shall be carried out in order to eliminate or reduce risks to “as low as reasonably practicable (ALARP)”. A Commissioning Manager shall be appointed who will be responsible and accountable for the commissioning of a project including all SHE aspects. where instrumented protection changes or additions are part of the project Design review of the as built project The depth and breadth of the relevant risk assessments and hazard studies will be determined by the nature of the project. BUILDINGS.RDSHE 7 – NEW PLANT. Design and construction shall be in accordance with relevant engineering guidelines. Principles to be followed • A Project Manager shall be appointed who will be responsible and accountable for the implementation of a project from inception to completion of commissioning.
An assessment of the SHE implications of a project shall be conducted. Commissioning procedures and checklists including formal acceptance of the project from the commissioning Manager by the operations team. AND PROCESS DESIGN
SUMMARY OF STANDARD There shall be formal systems for the management of projects and the design of all new facilities. including: a) A pre-sanction SHE assessment for inclusion with the expenditure proposal. including all SHE aspects. These will need to be systematic and should include.1 SHE ASPECTS OF PROJECTS Duty Site Managers shall ensure that SHE risks are fully considered and addressed at all stages in the management of projects. but not be limited to: • • • Hazard and Operability (HAZOP) studies where changes to the process or its control are involved Safety Integrity Level (SIL) assessments.
. 7. equipment and processes. In exceptional circumstances. More detailed SHE studies as the detailed design progresses after sanction. in accordance with IEC 61511. Appropriate post-commissioning checks to review whether the project has been implemented safely and with low environmental impact and also whether the project has had any unforeseen impacts on other activities such as operations or maintenance. buildings. c) d) e) Appropriate pre-commissioning checks. local codes and regulations.
A Project SHE Dossier should be assembled for a project. then these residual risks should be recorded. No significant changes in population. Prior to the use and location of temporary buildings a formal study must take place to ensure that acceptable protection is provided to the occupants from an identified explosion. including temporary accommodation. The master Project SHE Dossier should be filed by the Project Manager for future reference and review The Project Manager must ensure that the changes made by the project have been explained.Any significant departure from the above five processes should be authorised by the Site Engineering Manager or equivalent. land use. Identified unacceptable risks have to be eliminated. fire or release of toxic material.2 LOCATION AND USE OF BUILDINGS Duty Site Managers shall ensure that management responsibilities and arrangements are in place for authorising changes in population and the location and use of buildings. Where any significant hazards to people or the environment remain.
. Developments and development proposals external to the site are required to be monitored so that appropriate action can be taken to minimise impact on existing and proposed refinery activities. which includes a record of all Hazard Studies and the Environmental Impact Statement together with other relevant SHE data. Principles to be followed Arrangements shall take into account the hazards and risks to buildings and those persons within such buildings who are associated with both the existing activities or any proposed new activity. This risk assessment should take the form of a formal occupied buildings study. 7. wherever this is reasonably practicable. It is a key principle that projects which interact with and/or entail modifications to existing plant should not compromise the SHE standards of the plant concerned. operating instructions written and operating staff trained in the use of newly installed equipment. Risk assessments must be carried out by competent personnel who have received appropriate training. or minimised. or plant on the site should take place without formal risk assessment and written approval from the Site Manager.
corridors. Site Managers shall ensure that all those in positions of leadership including Shift Team Leaders. A management of change (MOC) system helps ensure that changes do not inadvertently introduce new hazards or unknowingly increase the risk of existing hazards. operations or off site activities. Any material change to manning levels on the plants
. They shall further ensure that personnel are aware that authorisation is required from Site managers with authority before any plant change is implemented. The introduction of new substances into part of the process or plant equipment. Any change to buildings. action management plans implemented and all changes properly engineered and recorded. Necessary risk assessments using the corporate risk assessment matrix shall be carried out. appropriate design considerations made. roadways or railways which could affect their fitness for purpose or the safety of personnel who work in or around them. link lines. steam or piped services. In addition. or which could affect the control or integrity of the plant or storage facility in any foreseeable transient or steady running situation. pipelines. 8.1 THE DEFINITION OF “PLANT CHANGE” OR “MODIFICATION” Duty To ensure that when a modification is made the risk of a process safety incident is not increased Site Managers shall ensure that all personnel are aware of what constitutes a plant change or modification and also of the need to carry out risk assessments on plant changes or modifications. Any alteration or change in specification. drains. Shift Supervisors. including the removal or addition of equipment. Modification definition: • Any change in the approved method of operation as described by the plant operating instructions. structures. whether temporary or permanent. to plant hardware or a component there of. There shall be arrangements in place to ensure that both permanent and temporary change is managed in such a way that it does not compromise SHE. Shift Managers and all technical and managerial staff are trained in the use of the site plant change or modification system. which is either in contact with process fluids.RDSHE 8 – MANAGEMENT OF CHANGE
SUMMARY OF STANDARD Managing change over the life of a facility is one of the essential elements of Process Safety.
e. An alteration to the process flow. 18. Addition. and any other types which are installed for personnel /equipment protection. 14. pressure or composition of such fluids. 6. 11.g.
Exclusions: 1. the operation or design conditions of a pipeline. A change to plant/office layouts which involves doors/means of escape/fire fighting equipment or the installation of temporary or permanent buildings. size or shape of any component which is in contact with process fluids. 10. or supervision of. removal. alarms or relief devices. injecting quick setting epoxy resins into leaking joints. The circumstances and conditions under which such a repair may be carried out shall be clearly specified in an established maintenance procedure. A change to the setting of trips. centralisation of control rooms). or for any modification to operating plants which will alter. 5. A relocation or reduction in number of. 15. 4. smoke. any change in the layout or configuration of a roadway or railway. 4. A change in electrical/instrument equipment design. temperature. a system for monitoring the reinstatement of
. These are not considered to be modifications. 3. Temporary repairs e. 2. A change in material of construction. A change to any plant protective system such as shutdown. but should only be made by competent Control and Electrical personnel or by a Process Control Engineer. directly or indirectly.g. such as settings of “Process Alerts” which are designed to be “aids” to operating teams and hence will be altered in line with plant configuration. fire. 3. A change in the means of permanent support of plant items. Any substantial change to the amounts or composition of emissions or any change to the means of disposal of effluents or any change which affects its notification to the Environmental / Safety or Inspection authorities A change to the process control computer's software or hardware. equipment or procedural changes related to a transportable container or road or rail tanker or for storage or any material under pressure. layout or materials of construction. Process changes within the approved method of operation. 12. or any other change which affects the existing arrangements. i. A change which will require alteration of the existing P&I diagram of the plant. modification. 16. clamping or heat exchanger tube plugging. temperature. 17. 9.Examples of modifications: 1. Introduction of a new process material. pressure or composition outside known operating experience. steam or piped services or which could affect the flow. people (e. a repair. Permanent shutdown and demolition of plant and buildings. 13. change of use or abandonment of a pipeline. Changes in instrument controller parameters. Replacement of a plant hardware component by a new component of identical design. Where these are the responsibility of Petroplus. pipe work and fittings or means of temporary support such as installed lifting appliances and lifting beams. A change to a pipe or cable route within a pipe bridge or corridor. Where these are the responsibility of Petroplus. 8. A repair to an existing item of equipment or plant component which represents a departure from the existing design. 7. toxic gas. 2.
These circumstances and the required authorisations should be specified. A systematic assessment of introduced risk including occupational safety.3
TEMPORARY REPAIRS TO PLANT AND EQUIPMENT
Duty Site Managers shall ensure that all temporary repairs are properly assessed. Communication to people likely to be affected by the modification and where appropriate specific training and validation.
There may be certain exceptional circumstances where work may be undertaken without following the prescribed modification procedure. business interruption etc. process safety. engineering line diagrams and operating instructions etc. If after a period of operation the change is not performing as design / definition then a review of the causes of this underperformance should be undertaken. Approval of design and construction method and confirmation of installation by the manager responsible for the operation of the equipment or process.
8. prior to commissioning.2
the repair to the original design standard shall be established and the repair shall be authorised by a nominated engineer. health. Updating of process knowledge including relevant engineering records. recorded and replaced by a permanent repair as soon as is reasonably practical.
.8. authorised. and then approved by a competent person who is independent of the assessment. THE CONTROL OF MODIFICATIONS Duty Site Managers shall ensure that a system to control modifications is in place that ensures any proposed changes are properly reviewed and authorised and that the implementation of risk controls appropriate to the proposed change are in place before implementation. environment. Principles to be followed Modifications shall be subject to the following: a) b) c) Clear definition Individual registration and recording. Commissioning review and acceptance by the manager responsible for the operation of the equipment or process.
Principles to be followed The following issues will need to be taken into consideration whenever roles are changed. assess and manage the risks associated with changes to individual personnel and to the organisation. Temporary repairs should be replaced at the earliest practicable opportunity. abolished.4 SUBSTANCE HAZARDS See RDSHE 6. This is especially important when these involve manning levels of operating teams.Principles to be followed Each temporary repair and the procedure for carrying it out should be assessed and approved by an authorising engineer before the repair work is started unless the equipment/contents have been previously defined as being a low hazard system There shall be a system to record all temporary repairs and specifies an expected reversal date and which requires periodic review of all temporary repairs. new personnel are appointed or personnel leave employment for whatever reason.
. combined. skills and experience Training requirements Handover management Succession planning
Such processes will not be required for minor changes in responsibilities and or job descriptions. 8.1. Key issues to be considered will involve: • • • • • • Minimum staffing requirements Loss of corporate knowledge Possession of relevant competencies.5 PERSONNEL AND ORGANISATIONAL CHANGES
Duty Site Managers shall establish appropriate processes to identify.
…) ?--> procedures? Are deficiencies assigned to an owner. In order to ensure safe process operation.1 SHE ASSURANCE PROGRAMMES Duty Maintaining containment of hazardous materials and ensuring that safety systems work when needed are two of the primary process safety responsibilities of any facility. equipment and premises are undertaken to ensure continued fitness for purpose and compliance with regulatory requirements. ook flare-. Dit gebeurt conform procedure 06-WER-0003 Actie Risk Rating Actionee Kurt verzamelt infoOK Andere risk assessment processen (gevaar vr terrorisme.Fuel gas en sweet gas systemen. beveiliging instalatie. via Process Hazard Review. Where deficiencies are identified these must be assigned to an owner who shall be responsible for mitigation of the risks. Arrangements must be in place to ensure that periodic reviews of hazards and routine inspections of plant. To achieve this Site Managers shall implement a SHE Assurance programme for existing operations. and tracked until completion. HAZOP revalidation. Daarnaast doen we ook vlinderdasstudies op de meest risicovolle onderdelen uit de installatie. Hazop gebeurt volgens procedure 06 WER 0002. or other equivalent risk assessment processes. the health and safety of personnel and the minimum practicable adverse environmental impact all facilities need to be maintained to an appropriate standard.ana te vragen bij Marina of Koen Verlackt Marina Hazop gebeurt 5-jaarlijks op alle systemen (proces en offsites) In de offsites voornamelijk de eenheden waar manipulaties gebeuren zoals belading en blending. Ton vraagt bij Ronny Stijleman waarmee rekening wordt gehouden a)
. Op proces komen alle units aan bod. Principles to be followed The SHE Assurance Programme shall ensure the following: Hazards are identified and their associated risks are assessed. resp for mitigation of the risk and tracking until completion? Actie Risk Rating Actionee Kurt kijkt na wat we allemaal hebben. 9. 9.RDSHE 9 – ASSURANCE
SUMMARY OF STANDARD Assurance helps to ensure that equipment is properly designed. installed in accordance with specifications and remains fit for purpose until it is retired.1. It is therefore a critical element of Process Safety.
1. risico 3C nagaan of er voldoende safeguardings aanwezig zijn om binnen design te blijven Risk Rating gemiddeld tot hoger—3B Aanpak en/of procedure voor opvolging van de safeguarding Risk Rating gemiddeld tot hoger—3B Actie Risk Rating Actionee Ton schrijft op wat we nu hebben & hoe we binnen het window dienen te blijven  Risk Rating ?? c)
. fire.1. Andere units/systemen zullen nadien volgen. Koen vind dit een gap.b)
Appropriate safeguarding shall be provided and maintained to prevent the release of hazardous material or a sudden release of energy and to ensure high availability of critical safety or utility systems that prevent or mitigate major hazard events. TRV’s -> dekkingsgraad werd in het verleden nagekeken beschikbare documenten?--> Bart ESD systemen worden periodiek gecontroleerd en getest procedures? Idem voor safeties en TRV’s  procedure?--> nog te officialiseren wie is verantwoordelijk voor wat en hoe worden periodiciteiten bepaald. ze is al 12 jaar oud en er zijn merkwaardige verschillen tussen beide studies. Redenen van de vernieuwde studie: Laatste studie gebeurde door Technip en Kellogg.Koen vindt dit een gap risico 1D Systems and procedures exist to operate critical equipment safely within design criteria to maintain its integrity. 9. Voor de betrouwbaarhedssudie U600 wordt dit mee bekeken. Eerst worden de verschillende scenario’s bepaald voor de studie (blocked inn. toch een gemiddeld risico) Gapsafeties van de sferen er bij op flare systeem-.--> actieplan zoals voor U600 waar het design van alle items wordt opgelijst en kritisch wordt bekeken ook voor de andere eenheden uitvoeren Risk Rating gemiddeld tot hoger. Door MA’s (vooral reïnstrumentatie) is er sindsdien heel wat gewijzigd mbt flare… Deze volledige studie zal 4 a 5 jaar in beslag nemen Ton bekijkt: Dekkingsgraad instrumentele beveiliging dient ook gereviewed te worden. Dit gebeurt normaal periodiek dmv HAZOP studies. Daarna zal hij unit per unit alle safeties bekijken (U600 duurt 4 maanden).…).b provided OK. gecoördineerd door Marina.c procedures to operate critical eq within their design. Ton kijkt ook de pocedure voor nazicht ESD systemen na ( 12-PRO0003) FilipTRV’s &safeties procedure officialiseren (Risk Ratinglaag tot gemiddeld risico 4D) & procedure voor trevitesten (Risk Ratingis geen gap. alle items zijn voorzien van safeties.
9. Ook nog een procedure voor trevitesten te schrijven Actie Risk Rating Actionee Bart kijkt na of de studie vd dekkingsgraag TRV’s makkelijk beschikbaar kan worden gesteld Koen is bezig met nazicht safeties nav huidige doorzetten info opgevraagd Externe specialist zal dit doen. Nadat alle units aan beurt kwamen wordt het volledige flaresysteem bekeken en indien er nog ruimte is wordt gekeken of de safeties van de sferen er bij kunnen.
9. information.d)
Appropriate persons are provided and given sufficient tools. systems and procedures competently. Misschien een meeting inleggen met Serge en Bart erbij om na te gaan hoe het bij de anderen gebeurt datum klaar
Systems designed to contain hazardous materials or protect against their release shall be installed and commissioned in accordance with the processes defined in RDSHE 7 and then operated in line with RDSHE 11. which will be retained for the life of the equipment. Nakijken of afmelding na aanpassen docs door tekenkamer gebeurt door registratie tekenkamer Risk Rating gemiddeld tot laag – 4B – 4C Ton kijkt na Ook voor instrumentele beveiligingen en  bespreken hoe dit binnen tekenkamer IEI gebeurt en hoe alles in IN tools komt en wanneer dit gebeurt. Na ontwerp worden de gegevens door de betrokken vakingenieurs nagekeken Actie Risk Rating Actionee Bart kijkt na of dit in de globale bestelspecificatie wordt beschreven (Na ontwerp worden de gegevens door de betrokken vakingenieurs nagekeken).d-?? 9. supervision and training to operate.
. MAINTENANCE AND OPERATION Systems designed to contain hazardous materials or protect against their release shall be designed to internationally recognised codes. Procedure voor flow van documenten bij nieuwbouw (is er en zit in vivaldi) & hoe registreren dat deze documenten wel degelijk op de afgesproken plaatsen terecht komen Ook voor instrumetele beveiligingen en  bespreken hoe dit binnen tekenkamer IEI gebeurt en hoe alles in IN tools komt en wanneer dit gebeurt Actie Risk Rating Actionee Bart denkt over  hoe registreren dat deze documenten wel degelijk op de afgesproken plaatsen terecht komen. Exchangers  beschreven in procedure? Leidingen beschreven in procedure? Actie Risk Rating Actionee ontwerpcodes zijn voldoende gedefinieerd & gebouwd door internationaal erkende ontwerpersOK Systems designed to contain hazardous materials or protect against their release shall be manufactured and tested to specifications agreed by the responsible member of the site team (usually the Site Engineer or equivalent) and the organisation shall be supplied with supporting documentation. inspect and maintain the equipment.2 GENERAL REQUIREMENTS FOR PLANT ENGINEERING DESIGN.1.
9.2 Ontwerpcodes voor SV’s? ESD systemen?  in een procedure? Drukvaten.
Hoe resultaten van het onderzoek beoordelen. Dient binnen 5 maanden na uitvoering van de inwendige inspectie. (A) Risk Rating>hoger daarom prio aan uitwerken van een systeem. the matter shall be referred to management team level for review and a decision regarding the appropriate authority for approval. Inspections shall be performed by suitably experienced and qualified personnel and shall be performed before the due date. zo nodig correctieve acties initiëren volgens de inspectieaanbevelingsprocedure of aanvullende onderzoeken. Inspectiefrequentie en review gebeuren conform de wettelijke bepalingen en risico gebaseerd OK In procedure nog te beschrijven hoe periodiciteit voor inwendige inspecties dient te worden geëvalueerd. When any of the above cannot be carried out. voldoende ervaring en opleiding) RTD  visueel opleidingsprocedure  Risk Rating gemiddeld. o o UT appn & leidn  review dmv trending procedure in de maak (A) Risk Rating->laag (enkel procedure) – 3D UT Op tanks nog een systeem & procedure uit te werken.Commissioned according RDSHE 7 & operated accoring RDRSHA 11 wordt in deze twee hoofdstukken behandeld Actie Risk Rating Actionee The frequency and nature of reviews and inspections shall be decided based on regulatory requirements and the risks of equipment failure. periodic review of routine inspections gebeurt 1 procedure te schijven voor review voor alle onderzoeksmethoden.--> nakijken per CC of er wijzigingen dienen te gebeuren Risk Rating->gemiddeld – 3D
Risk Rating Actionee Filip & Kurt Inspecties door gekwalificeerd personeel BRCOK (enkel visuele inspecties. (A) Risk Rating->laag (enkel procedure). procedure heeft lagere prio (B)3C-3B Andere UT(A) (B) – 3D Inw inspectie nog een systeem & procedure uit te werken.3C-3B
. Merkteken in mape aan te brengen telkens na iedere review & lijst van nog te reviewen inwendige inspecties =(A). inspectiefrequentie en plandatum toevoegen en/of herbeoordelen. Review rapporten gebeurt reeds consequent (C) – 3D Uitwendige inspecties(A) (C) – 3D SBN’s conform procedure (C) – 3D CUI nog een systeem & procedure uit te werken (A) (C) – 3D Andere onderzoeken (A) (C) – 3D
Systeem uitwerken voor periodieke reassessment van de RBI/HPI studie.
--> Risk Rating gemiddeld. Risk Rating gemiddeld– 3D  andere???-->actie uitwerken en implementeren Risk Rating gemiddeld– 3D  IVT?? actie uitwerken en implementeren  Risk Rating gemiddeld– 3D ESD testen  gebeurt door eigen mensen en Cegelec procedure - wat vermeldt deze ivm qualificaties?--> niets. Archivering van documenten flow in procedure vastleggen voor nieuwbouw & MA’sis in orde procedure vermelden  actie Bart Re-rating volgens MA procedureis OK In het verleden gebeurde dit niet steeds met een voldoende gefundeerde studie Voor U600 wordt dit bekeken met voldoende assistentie van externe deskundigen. details of subsequent modification and or repair and inspection records relating to equipment. Plant and equipment shall be operated within the original design envelope unless an engineering study leads to subsequent re-rating. Indien we daarbuiten gaan  procedure Soms worden additieven geïnjecteerd upstream (crudes/condensaat) Actie  Filip/Tonopvragen operating window Bij navraag bleek emma al allerlei naar Ton te hebben toegestuurd  Opstellen operating window Risk Rating gemiddeld tot groot-3B-3C
. Andere units volgen. This process will be accompanied by provision of documentation and updating of engineering records. in accordance with RDSHE8. plant and facilities shall be retained.andere via levelsprocedure voor ever green en voor BRC raadpleegbaar houden Anderenvisueel procedure te schrijven hoe te werk te gaan bij selectie (CV vooraf voorleggen en archiveren). Bij de werkvoorbereiding van de ESD test wordt dit geval per geval door de werkvoorbereider bepaald en beschreven geen gap Electrical systems keuringen door Vincotte procedure wat vermeldt deze ivm qualificaties? Wanneer due date overschreden dreigt te worden dispensatieprocedure 13-PRO-0011 “Verzekeren van de integriteit van de BRC-installaties” & 13-FOR-003OK Hoe gebeurt dit mbt overdue ESD testen & Elektrische systemen? Actie Risk Rating Actionee Kurt en Filip om dit verder uit te werken en met IEI &IEE opnemen (jan bosmans)uiterlijk tegen……… Individual equipment files containing appropriate original documentation. actieschema op te stellen  Kurt?—3B-3C Mbt verwerken van andere crudes of stoken van Andre fuels/gas  Iedere raffinaderij dient een operating window te hebben voor crudes/condensaat.
Is ook al hoger besproken Principles to be followed As a requirement of the maintenance process for pressure vessels.3 Duty Dient volgens mij reeds in andere hoofdstukken behandeld te worden (Hst 7 &11).2. inspected. commissioned. Er zal ook gekeken mbt de injectie van chemicaliën (welke aanwezig / in dienst. Ok All maintenance on pressure vessels should be to internationally recognised codes and recorded for the life of the equipment. Geen voldoende informatie stroom wanneer bepaalde windows niet gerespecteerd kunnen worden en hoe er op dient gereageerd te worden Integriteitsbewakingspunten Voor U 600 zal Kurt die meenemen bij het functional team. §2 deferrement alleen via engineering assessment door inspectieing. Inspections may only be deferred before the due date is reached and then only on the basis of an acceptable outcome of an engineering assessment. modified and retired in accordance with the requirements of section 9. manufactured. §1 Opleiding inspecteurs om meer naar staat isolatie van leidingen en apparaten te kijken en waar nodig suggesties/aanbevelingen te schrijven Actie door Kurt/Filip (opleidingsprocedure RTD’ers & procedure) Risk Rating gemiddeld-3C-3B Inspections will be carried out in line with professional engineering assessments of corrosion or erosion rates and minimum allowable wall thicknesses. 9. en ook Technisch directeur ondertekent mee het formulier. Ondertekening ook door site manager is OK Pressure systems operating after their due inspection dates will be recorded in monthly KPIs and routinely audited. periodic routine inspections shall be undertaken to assure their ongoing fitness for purpose. installed. This deferral process will be authorised by designated members of the site’s management team (usually the Site Engineer or equivalent and Site Manager). operated. procedure om binnen window te blijven  Risk Rating gemiddeld tot groot3B-3C Operations will be kept within the original design envelope by use of equipment such as relief valves or instrumented protective systems.…) 9./ functie/frequentie/opvolging. §5 procedure voor archivering van onderhoudswerken (lasherstellingen)
.3 PRESSURE SYSTEMS (INCLUDING BOTH VESSELS & PIPEWORK) Duty Site Managers shall implement processes to ensure that pressure systems are correctly designed. maintained.
Mape als registratiesysteem voor historisch onderhoud Hoe consequent up to date houden?-> hersteldossiers tot bij inspectie? Actie door Kurt/Filip & Bart (systeem en procedure uitwerken) Risk Rating gemiddeld tot laag – 4B
construction. operated.5 LIFTING EQUIPMENT Duty Site Managers shall implement processes to ensure that lifting equipment is designed. significant harm to any person or to the environment.5
. -->Hoe doen we dit? hebben we procedures om dit te borgen? 9. deels. Fitness for purpose will include their design. 9.9. classification. monitoring. and modified in line with the principles described in section 9. procedures? graag uitleg) . registration. This includes all failures or malfunctions which could result in a fire. danger to life. Elektrisch bijspringen van elektrisch aangedreven oliepompen wordt nog niet getest All critical machine systems should be designed.2.2. commissioned. explosion or toxic release from the discharge of hazardous materials. periodically examined. maintenance and modification. deels. periodic examination. Verder zijn er ook de thermografie onderzoeken en de olieanalyses Voor alle inspecties heeft Guy een opvolgingsprogramma met plandata. installed. maar geen procedure. Flow Serve is betrokken bij opvolgen van seal lekkages. All critical machine systems need to be registered.4 CRITICAL MACHINE SYSTEMS Mail met vragen verstuurd naar Gerrit ik zit hopelijk vrijdag namiddag 1500-1600 uur met gerit samen om hierover en over andere punten te praten Duty Site Managers shall implement processes to identify critical or vital machine systems through detailed assessment of SHE and business interruption risk to ensure their continued fitness for purpose. testing. Veso lijsten voor machines bestaan en worden beheerd door Guy Mertens Condition monitorig gebeurt foor Guy Mertens. installed. manufactured. commissioned. commissioning. operated within their design limits and have their protective systems tested regularly (hebben we dat? Volledig. overspeed testen. manufactured. mede op basis van de veso lijst (freq vibratiemonitoring is VESO klasse gerelateerd). procedures? graag uitleg) Gap mbt protective system test. Overspeed trip testing of all turbines shall be carried out after modification or having been dismantled for maintenance. inspected and modified in accordance with the principles described in section 9. (hebben we dat? Volledig. Actie  Systeem uitwerken om VESO lijst up to date te brengen en te houden (waarschijnlijk gekoppeld aan MA procedure)  risico 3D  Werkwijze voor bepaling van plandata en review ervan uitwerken in een richtlijn (risico 3D) In bijlage de volledige uitleg van Gerrit (ook de triptesten procedure) Principles to be followed A critical machine system is a machine system which has been assessed to present unacceptable consequences if the machine or its protective system should fail.
installed. De balken aan de exchangers U700 waar loopkatten kunnen worden gehangen om eventueel bundles meet e trekken zijn niet gelabeld. verwijzingen nr. vapours or dusts is suitable for that duty and that it is designed. hijsvermogen) Risk Rating gemiddeld – 3C Actie davits  Risk Rating gemiddeld
Each permanently installed piece of lifting equipment shall have a unique identifier attached. Al deze werken worden door het erkend organisme (AIB Vincotte) gecontroleerd. commissioned.3-D Systeem uitwerken om na te gaan of alle vast geplaatste hijsmiddelen in keuringsprogramma zitten (bv. Actie opnemen in richtlijn keuren hef en hijswerkruigen (13-PRO-0006) Filip Risk Rating gemiddeld tot klein – 3D Retroactieve actie  Filip & MarinoRisk Rating gemiddeld tot klein – 3D 9. Bij volgende rondgangen zal hier een overzicht worden van opgemaakt.
. Deze worden niet gebruikt en worden best verwijderd MA initiëren om ze er af te halen Risk Rating gemiddeld.Alles dient geborgd met de MA procedure. Deze is voldoende dekkend voor alle werken op BRC. manufactured. Er is een opvolgingsprocedure (12-PRO-0002) waar onderandere ook de opvolging van gebreken en inbreuken wordt beschreven. Wettelijke bepalingen Alle elektrische werken gebeuren conform AREI. Davits van mangatflenzen worden nog niet geïnspecteerd gapeenmalige inspectierondgang en oplijsten waar acties Risk Rating gemiddeld – 3-C Boven op sommige kolommen (+-20 stuks) staan grote davits.6 ELECTRICAL SAFETY IN HAZARDOUS AREAS Duty Site Managers shall implement processes to ensure that electrical equipment for use in areas that may contain flammable gases. Niet voor davits Niet allen gelabeldbv.2. inspected and modified in accordance with the principles described in section 9. Door opschrift max. Bespreken met Jan Bosmans procedures. Periodieke inspectie gebeurt door EDTC (Erkend organisme) volgens de wettelijke bepalingen.
including PLCs. Actie  Kurt en Filip Uitzoeken hoe het bij de zusters gebeurt. commissioned. Ook niet vergeten dat deze systemen een grote mate van zelfcontrole hebben. and modified in line with the principles described in section 9. In gebruiksfase worden de veiligheden periodiek getest (ESD testen) conform 12PRO-0003 9. Kurt & Filip) Inspectieprogramma Civil dient nog volledig te worden uitgewerkt. operated. Na Installatie worden deze systemen steeds gecommissioned. verwijzingen nr. When installed. Hiervan zijn documenten beschikbaar.9. inspection. Bespreken met Jan Bosmans & Carl Heirman procedures.2.2D Wat met ondergrondse leidingen en sewer systems Sewers werden eenmalig geïnspecteerd bij de hervergunning in 2000. installation. micro-processor applications and distributed control systems are registered and periodically reviewed. modification and repair of civil works such as structures. registration.9 CIVIL STRUCTURES Duty Site Managers shall implement processes to ensure that the design. manufacture. Aankoopspecificatie is TSI-006 9. These assessments shall be used in the. Er wordt twee maandelijks samen gezeten om hiertoe te komen programma & procedures Risk Rating gemiddeld tot groot (voor bepaalde inspecties) daarom binnen dit inspectieprogramma prioriteit te geven aan de grotere risico’s – 1D. Bespreken met Jan Bosmans procedures. installed. modified. commissioning. bunds. repaired as such.2. Wettelijke bepalingen Wijzigingen aan nieuwe installaties gebeuren volgens 11-PRO-0002. Bart. wat de beste technieken zijn. fixed fire protection associated with structures shall be considered as an integral part of the structure and inspected.8 PROGRAMMABLE ELECTRONIC SYSTEMS Duty Site Managers shall implement processes to ensure that Programmable Electronic Systems (PES).7
SAFETY INSTRUMENTED PROTECTIVE SYSTEMS Duty
Site Managers shall implement processes to ensure that instrumented protective systems installed for process safety are identified and assessed to demonstrate that they provide the required availability and robustness to mitigate the identified event. pipebridges. Actie  werkroep (Bert. They shall also be manufactured. actieprogramma en procedures uitwerken en implementeren Risk Rating gemiddeld – 3C
. operation. and proof testing of the systems in accordance with the principles described in section 9. Testen gebeurt volgens vaste intervallen zoals opgenomen in de SIL database. verwijzingen nr. Ondergrondse leidingen worden niet opgevolgd. . drains and sewers are adequate to avoid the loss of chemical containment or major incident from failure of the civil works. design. supervisory computers. Wettelijke bepalingen Design gebeurt zoals periodiek behandeld in de periodieke HAZOP studies en zoals in de SIL studies.
tested. Periodieke inspectie gebeurt Nakijken of alle druk-vacuum breakers op de tanks allen periodiek worden getest Zie 9. vacuum breakers and their associated pipework systems. TRV’s -> dekkingsgraad werd in het verleden nagekeken beschikbare documenten?--> Bart ESD systemen worden periodiek gecontroleerd en getest procedures? Idem voor safeties en TRV’s  procedure?--> nog te officialiseren wie is verantwoordelijk voor wat en hoe worden periodiciteiten bepaald. Ook nog een procedure voor trevitesten te schrijven Actie Risk Rating Actionee Bart kijkt na of de studie vd dekkingsgraag TRV’s makkelijk beschikbaar kan worden gesteld Koen is bezig met nazicht safeties nav huidige doorzetten info opvragen Ton bekijkt: Dekkingsgraad instrumentele beveiliging dient ook gereviewed te worden. Voor de betrouwbaarhedssudie U600 wordt dit mee bekeken. inspected. operated. This may include flare headers. Dit alles dient geborgd met de MA procedure. Actie wordt om deze best practice te implementeren (uitvoerings. alle items zijn voorzien van safeties. commissioned.
. are designed.9. operated. Daarnaast gebeuren eveneens andere niet wettelijke opvolgings.en proceduretechnisch) Risk Rating gemiddeld – 2D 9. maintained.b hoort in feite hier thuis provided OK. maintained and modified in accordance with the principles described in section 9.3 above. knock out drums.2. commissioned.10
LOW PRESSURE STORAGE TANKS Duty
Site Managers shall implement processes to ensure that vessels that are outside of the scope of section 9. vents. overflows. constructed. Periodieke inspectie gebeurt door Erkend milieudeskundige volgens de wettelijke bepalingen.11 RELIEF AND BLOWDOWN SYSTEMS Duty Site Managers shall implement processes to ensure that relief and blowdown devices. verified for change of duty and retired in accordance with the principles described in section 9. inspected. Relief pipework systems are defined as the line from the item protected to the device and from the device to the final release point. scrubbers etc. modified. constructed.wanddiktemetingen Actie  Kurt en Filip Er volgt een peer assist bijeenkomst welke een aanzet gaat vormen tot een best practice voor RBI bij opslagtanks.1.2. Dit alles dient geborgd met de MA procedure. such as those tanks used for the storage of raw materials. intermediates and products are designed.
Andere units/systemen zullen nadien volgen. where this is assessed as not possible it must be de-inventoried and physically disconnected from running assets. Eerste draft hebben we van Teesside Oplijsten buiten dienst zijnde delen Procedure uitvoeren
Risk Rating gemiddeld tot groot – 2D-3D
. Ton kijkt ook de pocedure voor nazicht ESD systemen na FilipTRV’s  procedure officialiseren (Risk Ratinglaag tot gemiddeld) & procedure voor trevitesten (Risk Ratinggemiddeld)
9. Procedure te schrijven hoe om te gaan met buiten dienst zijnde delen. Access to these units should be restricted. Where redundant units remain they should be clearly identified in plant and engineering records and periodically inspected to ensure structural integrity. Redundant equipment should be removed. safety and health of individuals or surrounding environment.12
REDUNDANT PLANT AND EQUIPMENT Site Managers shall implement processes to ensure that redundant plant and equipment are managed so that they do not pose a threat to the process safety of remaining assets.
Safe systems of work shall be established and maintained to ensure the safety and health of people and the protection of the environment. 10.
.2 Work activities are planned. • • • • 10.1 GENERAL WORK PERMITS a) Site “permit to work” procedures must define. how they are issued.
PERMITS TO WORK Duty Site Managers shall implement a “permit to work” system to be used in all circumstances where there is a transfer of responsibility of plant or equipment to a third party. The competencies and training requirements of those with responsibilities for operation of the permit system. The training requirements and responsibilities of individuals are clearly defined. Detailed instructions for how permits are written. Risks shall be eliminated or reduced as far as is reasonably practicable.RDSHE 10 – SYSTEMS OF WORK
SUMMARY OF STANDARD Safe work systems are used to control hazards and manage risk associated with maintenance. and for multiple permits dependant on the same isolation(s). (Provision of operating instructions is detailed in RD SHE 11. Detailed instructions to cover the situation where work is not complete when the validity of the permit expires. Hazards are identified. How the permit system is used for multiple tasks involving the same equipment or in the same location.2. • • • • • • The situations in which permits to work must be used. accepted.1). Control measures shall be implemented and monitoring programmes organised to deliver safe and environmentally responsible work.
10. Risks are assessed and effective controls put in place. Principles to be followed Procedures shall be written to ensure that.1 SAFE AND ENVIRONMENTALLY RESPONSIBLE SYSTEMS OF WORK Duty Site Managers shall implement an integrated system of procedures and permits that help protect workers from work place hazards and prevent the sudden release of process materials or energy during non-routine work activities. The responsibilities of those involved in the operation of the permit system. construction and other non-routine work not covered by operating procedures. handed back and how they are cancelled.
b) The Basic Permit to work must include. E.• •
The types of activities or situations in which additional written procedures. • • • • • • The situations in which a hot work permit is required. Requirements for the isolation of equipment in preparation of equipment for hot work. Requirements for the provision of fire watch personnel and their responsibilities during the work. References to additional instructions or risk assessments. with flammable gas detectors checked and calibrated by competent persons. Requirements for hot work on equipment which is on line. Requirements for atmosphere testing where flammable vapours could be present by trained persons.g. Details of the precautions to be taken by those doing the work to minimise the risks during the activity.
. Requirements for the provision of fire fighting equipment during the hot work. e. Specialist permits must include but are not limited to. issued and how they are handed back or cancelled.  The training requirements and responsibilities of hot work permit issuers. Any additional requirements required during shutdowns or turnarounds. Additional PPE.
10. including where possible the unique equipment identification number(s) or the workplace identification tags attached.  Entry to confined spaces. • A precise description of the work covered by the permit. are required. Locations for signatures of those persons responsible for issue.2 HOT WORK PERMITS a) Hot work permit procedures must define. office cleaning activities. Detailed instructions for how hot work permits are written. gas detectors etc.  Hot work. accepted. References to any associated specialist permits to work. The types of high risk activity for which specialist permits are required.  Excavation activities. such as a written job method.2. Requirements for the provision of screening around hot work to control sparks.
b) Hot work permits must include. acceptance and hand back. The time the permit was issued and the period of time for which it is valid.
The types of work that are exempted from the requirements of permit to work.g.
Reference to the written rescue plan. including where possible the use of unique equipment identification number(s) or the workplace identification tags attached. issued and how they are handed back or cancelled. acceptance and hand back. The results of atmosphere testing and the signature of the person who carried out the test. Requirements for monitoring the atmosphere during the confined space entry.4 EXCAVATION PERMITS a) Excavation permit procedures must define. Signature locations for issue. accepted. including where possible the unique equipment identification number(s) or the workplace identification tags attached.
. The training requirements and responsibilities of confined space permit issuers. Requirements for entry point signs to control access to the confined space. The period of time for which the permit is valid. that atmosphere testing has been satisfactorily completed and those precautions to control entry and for rescue are in place before entry. acceptance and hand back. The signature of the person who carried out the atmosphere test. • A precise description of the area to be entered.2.•
A precise description of the work covered by the permit. confirmation that fire prevention and protection requirements have been met prior to issue of the permit.2. Requirements for the isolation of equipment in preparation for entry and during entry.3 CONFINED SPACE ENTRY PERMITS a) Confined space entry permit procedures must define.
b) Confined space entry permits must include. Signature locations for issue. Confirmation that isolations are in place. Detailed requirements for the contents of a written rescue plan. Detailed instructions on the provision and duties of attendants to monitor those inside the confined space.
10. • • • • The situations in which a confined space entry permit is required. with equipment checked and calibrated by competent persons (both for oxygen content and any other potential contaminants). The period of time for which the atmosphere test and hence the permit is valid. Detailed instructions for how confined space entry permits are written. including atmosphere analysis where flammable vapours could be present. Requirements for checking the atmosphere in the confined space before entry by qualified persons.
Detailed instructions for how excavation permits are written. • • • • • • 10. Power-operated mobile work platforms. acceptance and hand back. Vacuum trucks. Principles to be followed There shall be procedures covering control and use of the following equipment: a) b) c) d) e) f) g) h) i) j) k) l) m) n) Personal protective equipment.3 A precise description of the work area covered by the permit. Scaffolding. drains. Compressed air tools. High pressure water wash equipment. The training requirements and responsibilities of excavation permit issuers. Abrasive wheels and grinding machines. electrical cables and contaminated ground by competent persons in relation to the proposed excavation. Electrical equipment on site
The situations in which an excavation permit is required. Cranes and other heavy or abnormal vehicles on site. Requirements for ensuring that excavations cannot collapse during work.
b) Excavation permits must include. Signature locations for issue. The period of time for which the permit is valid. Motor vehicles on site. Fork lift trucks. Fixed and portable gas detectors. Requirements for ensuring that any necessary isolations have been identified and applied.
SAFE AND ENVIRONMENTALLY RESPONSIBLE USE OF EQUIPMENT Duty Site Managers shall ensure systems and procedures are put in place to ensure the safe and environmentally responsible use of equipment. Machinery guarding. Confirmation that any isolations required are in place. Confirmation of the location of any pipes. Railways and railway vehicles. Details of the precautions to be taken by those doing the work. Requirements for identification and checking of underground pipelines. issued and how they are handed back or cancelled. drains. cables or contaminated ground in the work area before beginning.
healthy. and safe condition. but all of the above activities require formal procedures. including contractors shall be adequately trained in these systems. Housekeeping.
Plugs and caps. 10.4 MAINTENANCE OF PLANT AREAS. (Also refer to RDSHE 9 Assurance) Principles to be followed There shall be procedures for the maintenance of the following systems: a) b) c) d) Temporary accommodation. Principles to be followed There shall be systems to ensure the safety of the following: a) b) Non-Manufacturing Locations.
All relevant personnel including contractors shall be adequately trained in the above procedures. All relevant personnel.5 MAINTENANCE OF OFFICES AND LABORATORIES Duty Site Managers shall ensure that offices and laboratories are maintained in a clean. Laboratories or similar workplaces. 10. Work at heights Safe storage of packed chemicals and products in warehouses. WORKSHOPS AND STORES Duty Site Managers shall provide systems to ensure that all plant areas have been risk assessed and are maintained in a safe condition until demolished. This is not a comprehensive list.
and can confirm that the process responds in an expected manner. trip and relief functions. kept up-todate. as a minimum. start-up. 11. Start up and shutdown instructions should be written in a step wise manner and include sign off capability against each appropriate step to ensure that no step is omitted or duplicated especially during changes in operational personnel. Operating procedures complement systems of work and assurance procedures which are addressed in RDSHE 10 and RDSHE9 respectively. can verify that controls are in place. Operating instructions should take due account of the complexity. shutdown and loss of services. by reviewing on a periodic basis and also as necessary in the light of learning from operating experience and incidents. Principles to be followed (a) (b) Operating instructions shall define the “safe working envelope” of the plant and how this is protected by alarm.
. These shall include. They should be managed as controlled documents. Operating instructions should be readily accessible to employees. They should further define the actions required of operators in the event that the plant moves outside the safe working envelope. hazards. Operating instructions shall define emergency response actions required by the plant team. When process excursions occur.RDSHE 11 – PLANT OPERATION
SUMMARY OF STANDARD Plant operation and management must be conducted in a deliberate and structured manner. normal operation.1 PLANT AND EQUIPMENT OPERATING INSTRUCTIONS Duty Site Managers shall ensure that there are written operating instructions for plant and equipment and that these instructions are complied with. protective equipment and controls in sufficient detail that operators understand the hazards. Systems of operation must describe the process. tools. alerts and ultimately shutdown systems should be installed to prevent process safety or environmental incidents from occurring. hazard and risk and of the competence of the operating personnel. Clear operating instructions for plant and equipment should be provided for all activities in planned operations and foreseeable unplanned and emergency operations where it is important to follow a specified practice or sequence. including specifying when management would expect the plant to be evacuated of all non-essential personnel.
The incidence of alarms should be monitored and reviewed by operating management on a monthly basis.2
TRIPS AND ALARMS Duty Site Managers shall ensure that plants are operated within the envelope defined by trips and alarms. activation of one of these devices should be regarded as signifying an unacceptable operating condition and should result in an appropriate rapid response from the whole operating team. Operating instructions shall explain the actions to be taken in the event that alarms are activated. The handover must include but not limited to. Unexpected events that happened during the shift.
11. Routine operation of the plant should not require it to be taken into an alarmed state. with a target of no more than 10 alarms per hour per panel operator.
RESPONSE TO ALARMS Duty Site Managers shall ensure that operator response to alarms is appropriate to their criticality. product transfers etc Alarm inhibits and trip overrides in place over shift change.4
HANDOVER Duty Site Managers shall ensure that a structured written handover takes place between outgoing and oncoming shift teams. Returning the plant to a non-alarmed state should take priority over all other non-urgent activities. A trip and alarm philosophy document shall describe the systems required to ensure that all trips and alarms are effectively assessed. Where plants are provided with Extra High or Extra Low alarms. Systems and procedures shall ensure that trips and alarms shall not be by-passed or key-defeated without written authorisation and then only in clearly defined circumstances with alternative protective arrangements in place.
11.    A detailed review of the status of partially completed start up or shut down operating instructions. stating that every alarm requires a response to bring the plant back within the operating envelope.11. Authorisation paperwork associated with trip and alarm defeats must be available in a form that enables review and understanding by the operating team. displayed and maintained according to their criticality.
lines of consultation and communication roles. All sites shall appoint specific representatives to act as a focal point for the management and the oversight of the key contractor and suppliers employed on site. accountabilities and system interfaces between contractors and suppliers and the site management. Competent suppliers and contractors shall be selected.RDSHE 12 – MANAGEMENT OF CONTRACTORS AND SUPPLIERS
SUMMARY OF STANDARD Safe operation and maintenance of Petroplus facilities requires controls over the use of contracted services and suppliers. monitored and supplied with sufficient information on the sites and the operational hazards to ensure that the safety and health of their employees is not put at risk by site activities. 12. All contractors and suppliers are to be subject to a risk based evaluation prior to contractual arrangements being established. Contracts shall provide Petroplus with the ability to terminate the contractual relationship with a contractor for unacceptable SHE compliance. Principles to be followed All sites shall have a formal contractor management system in place which is appropriate to the nature and extent of the associated risks.
. occupational diseases and environmental incidents involving contractors should also be agreed as a condition of the contract. In order to achieve this. The requirement for reporting and the investigation of accidents. This evaluation shall consider the nature of their products. Monitoring shall take place during the conduct of the contractor activities to ensure the maintenance of high standards of safety performance. activities or services provided and previous safety performance. This representative shall review contractor and supplier SHE compliance and liaise with the contractor and supplier management to ensure continuous improvement in their SHE management systems. raw materials and services shall be specified and monitored to satisfy SHE requirements. Contractor management systems shall contain documented reporting relationships. including relevant regulations. Contractors and suppliers shall be required to provide sufficient information to ensure that the safety and health of Petroplus employees and others is not put at risk or environmental compliance compromised. Contractor management systems shall include the requirement for formal contractual safety arrangements to be in place to ensure that their activities are carried out in accordance with regulatory requirements. Site Managers shall ensure the purchase and supply of equipment. the SHE implications of all aspects of work carried out by others on behalf of Petroplus shall be properly assessed and managed.1 THE USE OF CONTRACTORS AND SUPPLIERS Duty Site Managers shall implement systems and processes to ensure that work carried out by contractors and suppliers is both safe and environmentally responsible. responsibilities.
There shall be mechanisms in place to notify contractors and suppliers of specific hazards associated with the site applicable to the works to be undertaken (i. The contractor’s activities should be audited and monitored regularly against any method statement or other clearly understood criteria.
There shall be arrangements for the evaluation and risk assessment of equipment. suitable records should be kept and only those individuals should be permitted to undertake the work.e. There shall be a requirement for all contractors and suppliers to have formal SHE Management systems in place.
It is the contractor's duty to supervise his own employees and Petroplus should not assume this responsibility unless it is specifically agreed in the contract. provide suitably detailed job methods so that the SHE compliance implications may be assessed by the company.
. There shall be processes in place to ensure the effective review of the sites contractor management system to ensure that it remains relevant and appropriate to the nature and extent of the associated risks.
Arrangements for contractors and suppliers to undertake their activities based upon risk assessment methodologies which reflect legal obligations. to ensure their suitability for use and to prevent the introduction of safety hazards and risks. the contractor must provide adequate information. There shall be processes in place to ensure that the planning of turnarounds and shutdowns includes details of how to manage contractors and suppliers appropriately. materials or services prior to purchase. hire or lease. asbestos). instruction and training to all the individuals concerned. where appropriate.
Where Petroplus has notified the contractor of the potential hazards associated with the site.
It is the contractor’s duty to. The following requirements must be included in their SHE Management System: Arrangements and responsibilities for the selection and use of sub-contractors and the SHE monitoring of their activities. This shall be performed by competent persons.
Emissions to air (including CO2). this assessment will form part of permit applications or periodic reporting in accordance with permit requirements or legislation. Noise and/or vibration levels. Odours. 13. There must be procedures in place to identify and manage processes where the groundwater. Potential impact from major incidents. The assessment shall take into account the results of environmental monitoring.RDSHE 13 – ENVIRONMENTAL IMPACT
SUMMARY OF STANDARD Petroplus has undertaken to ensure that the activities in all aspects of the company’s operations do not cause any adverse effect on the environment. shutdown and overhauls:
Emissions to water. for normal operations.1 THE ENVIRONMENTAL IMPACT ASSESSMENT Duty Site Managers shall develop and maintain an assessment of the environmental load or footprint resulting from activities on their sites. land in and around the company’s facilities could be harmed by the company’s operations and to monitor the interaction between the company’s operations and the environment. Emissions to land. Usage of natural resources. Visual impacts. surface water. start-up. In many cases. air. frequency or emission level when available and a brief description of fate or effect in the environment. Principles to be followed The Environmental Impact Assessment should address the following.
For this purpose the environmental load or footprint for any type of emission shall include a quantity. Waste disposal. such as energy and natural water.
. land. air and surface water in and around the company’s facilities. The assessment should include the significance and consequences of the identified emissions and relate them to any relevant environmental quality standards or guidelines and (anticipated) emission level values. Another key part of the assessment will be the arrangements to minimise the risks of contamination of groundwater.
a strategy should be developed that ensures the progressive achievement of improvement and compliance. Principles to be followed Operations are to be managed in a way that avoids the contamination of land. 13. or whenever a change in emission level values or legislation can be anticipated. Monitoring results will be communicated to relevant departments and.The assessment shall be updated whenever a material change in operations or knowledge occurs. There should be arrangements for preventing and containing any spillages and for providing effective clean-up.2 Duty Site Managers shall implement a programme to monitor the environmental impact of their activities and to take any corrective action necessary to ensure that they remain within the limits relevant to any government issued permits. Soil or groundwater contamination near potential sources and in case relevant migration or exposure risk is identified. and groundwater. surface water. or consent limits imposed by relevant legislation. and to identify improvement opportunities.
13. Requirements related to permits or other agreements with authorities. and groundwater and to ensure that any spillage or leakage of chemicals or effluent that could cause significant environmental harm is prevented from reaching the environmental receptors. need to protect land. if necessary. equipment and structure design. changes made to the operations of the site to ensure continued operation within permit limits or consent limits. dependent on value of monitoring and availability of techniques. Design of new installations and management of change of existing installations. Analyses necessary for ensuring continued operation within permit limits or consent limits. Monitoring shall include:
Parameters that are suspected to have a significant environmental impact.
. surface water. Principles to be followed A monitoring plan and schedule shall be developed and managed by competent persons.3
LAND AND WATER PROTECTION Duty Site Managers shall have arrangements in place for the protection of land and water which recognise the need for environmentally responsible site operations. Analytical results of sampling will be communicated on an agreed basis to the regulatory authorities. For existing installations. See RDSHE 7 New plant.
pumps. leaks and contamination and remedial actions taken. Any spillage of liquid hydrocarbons or other hazardous materials on unmade ground or water and any other uncontained spillage of such materials > 5 litres . surface water. and groundwater contamination shall be inspected and maintained on a regular basis. or groundwater contamination to the lowest extent possible. Date of a baseline investigation to determine the status of soil and groundwater contamination. preventing soil. Reports of assessments of contamination. This record will demonstrate that any contamination resulting from new spills has been removed or otherwise dealt with in an appropriate way. Date of acquisition of the site by Petroplus. The plan shall include the arrangements and equipment available for an effective response. Each site should identify. sumps. sewers. monitoring and remedial activities undertaken. or having a function in.
. this shall be properly documented and include measures taken to prevent any environmental impact.All infrastructures designed for. If a contamination can not be removed (e. or other remediation measures. Permits.. Any contamination resulting from new spills shall in principle be removed. protective containment. orders and minutes with external organisations including regulators. See RDSHE 9 Assurance. should be recorded as an incident allowing appropriate follow up. drains.
The record shall be suitable for minimising the liability for soil. This includes pavement. Documentation should further record: • • • • Details of historical land use and historical contamination. curbing. for technical reasons). possible other hazards and risks to human health and the environment and the need for further investigation. An ongoing record shall be maintained of spillages. control. assess and at regular intervals review. For this purpose “new spills” shall have the meaning of spills occurred after one of the following dates whichever is the earliest: • • • Date of entry into force of the obligation for the operator of the site to remediate contamination resulting from current operations.g. surface water. Site plan with monitoring wells and references to entries in the spill record.
A spill contingency plan shall be available for a brief identification of the risks of failing secondary containment and major pollution of off site water or land.
such as from neighbouring facilities. Most incidents will be minor in nature and will be managed close to the scene by the on site team. which may affect assets or personnel on the site. Incidents that are more serious in nature i. from a remote location if this is justified by the nature and scope of the incident.
. environmental contamination or pollution Principles a) Assessments shall be made of the type and scale of all reasonably foreseeable onsite and off-site incidents where Petroplus has or may be considered to have responsibility for operation. These shall be included in site safety reports and shall be the subject of Pre-Incident Plans based on a systematic approach to risk assessment and management. This will include off-site pipelines where Petroplus has direct responsibility or where pipeline issues can have a direct impact on site activities.e. or having the potential to lead to. shall be managed by the senior on-site manager in the role of the “Site Main Controller”.1 EMERGENCY PLANS Duty Site Managers shall ensure that emergency plans are developed to be able respond to all categories of reasonably foreseeable on-site incidents. Categories of incident include. Written procedures shall define the actions to be taken by specified job holders and by all other persons on site in the event of such incidents.  Fire  Explosions  Toxic Releases  Injuries to persons on the site  Rescue of personnel and other persons on the site  Oil spill leading to. Arrangements put in place shall include links with the public emergency services and voluntary co-operative schemes. regularly exercised and reviewed.RDSHE 14 – EMERGENCY PREPARDNESS
SUMMARY OF STANDARD The consequences of any particular incident can be significantly reduced with effective emergency management and response capabilities.2). For this reason. other than through the cessation of oil flow. Plans shall be communicated. Priority should always be given to minimising the risk to persons at the scene of any incident. the nature and scale of all reasonably foreseeable emergencies shall be identified and adequate systems and procedures to deal with them shall be implemented. and any credible off-site incidents. 14. those classified as “Major Incidents” (see 14. b) c)
in consultation with your Petroplus Law Department Attorney. there should be a means of warning people on site and if necessary. Legal support shall. There should be arrangements for maintaining effective communications with the emergency services if the incident develops further. If these indicate missing persons. Emergency procedures should include the arrangements for notifying the regulators and other authorities where necessary and for keeping them informed of developments. Evacuation procedures should be established and assembly points should be designated in safe areas. roll calls should be held to identify positively the whereabouts of all individuals known to be on-site. which should be given serious consideration in consultation with local law enforcement officials. be engaged to deal with investigations. search and rescue procedures should be initiated. The purpose of such support in preparation for an incident should include ensuring that relevant site historical information is kept up to date for use in advising those making any statement.2
EMERGENCY ARRANGEMENTS AND RESOURCES Duty Site Managers shall ensure that arrangements are in place to deliver emergency plans Principles a) b) c) In the event of an emergency.
h) 14. regulatory compliance.d)
Procedures shall be established to define the processes by which incidents of increasing seriousness are escalated to Major Incidents within the site organisation. There should be arrangements for summoning assistance from the Fire. Each site should consider the need for procedures for dealing with threats of terrorist or direct action. As part of the emergency response. Loepfe & Partners have associates in the UK. Public Relations support of a local nature should be available either through refinery staff or as a contracted service to the Site Manager. Ambulance and Police (and other law enforcement) Services and mutual aid services. and assist with Public Relations Support efforts. During planning.
. full consideration should be given to the restoration and recovery activities following any incident. as necessary. off-site. This support would be backed up in the event of a Major Incident by Loepfe & Partners of Zug who have a contract with the Corporate Communications Manager for this purpose. law enforcement officials who may seek access to the site. Germany and Belgium.
it is the responsibility of the Site Main Controller to declare the immediate incident closed and to notify the appropriate parties of this decision. Where incidents which could attract media attention are identified. Based on this information.4
EMERGENCY EXERCISES AND PRACTICES Duty Site Managers shall ensure that plans are exercised and practised to ensure that they can be delivered when required. this will be the Refining General Manager).3
EMERGENCY TRAINING Duty Site Managers shall ensure that emergency training needs are assessed and that training is conducted. there should be arrangements for appropriate briefings to be provided. then it may be completed and issued on the authority of the Site Main Controller.
14. any written statement will need to be approved by the relevant Head of Department with review by and support from the local and corporate legal teams. where practicable.g) h) i)
There should be arrangements for the prompt treatment of any person injured on site and for the provision of necessary medical back up. b) All those who may have specified roles in emergency procedures should be given appropriate regular training. There should be arrangements for mitigating.
14. solid or gaseous emissions which could cause environmental damage. Following an incident. arrangements for assessing their impact should be made.
. If an outline written press statement has been pre-approved by the relevant Head of Department (for refinery based incidents. including the activation of off-site monitoring. recorded and reviewed to ensure that individuals are aware of their roles and responsibilities in the event they are called upon. If no preapproval has been granted. the effects of liquid. arrangements for minimising their effects should be agreed with the external emergency services and other relevant authorities. Principles a) Each person who comes on to an operating site should be made aware of the basic emergency procedures and the actions that they are required to take in the event that the alarm is raised. Where incidents are identified as having potential off-site consequences. At this point. arrangements for the restoration and recovery phase of the management of the incident should be made.
this will include periodic exercise of response to release of hydrocarbon from a typical pipe. Site Managers shall ensure that procedures exist to manage such “Major Incidents”. they will be able to decide if implementation of the Crisis Management Plan is appropriate. This might apply as a result of an inability to bring the incident under control within a limited timescale or because the implications or results are significant and require communication. • • CORP-SHE-001 “Major Incident Response Procedure” The Emergency Contact list
These documents are to be found on Sharepoint under the SHE Portal. In planning for such incidents. a very small percentage will require additional responses from others in the Petroplus organisation. Principles to be followed a) Corporate senior management responsibilities in the event of a Major Incident together with contact details are summarised in the following two documents. pool fire and tank seal roof fire.5 MAJOR INCIDENT MANAGEMENT Duty Whilst most incidents will be within the capabilities of sites to manage both in respect of the incident itself and its repercussions and implications. where appropriate. In particular. each one of which will be managed by a named individual: • “Operational” – The Incident Controller at the location of the incident manages the direct response to the incident itself. b) Petroplus recognises three levels of response to incidents. reporting of the incident to corporate Petroplus management immediately following the decision to declare a Major Incident.Principles a) Emergency exercises should be carried out regularly and should be based on incident scenarios identified in pre-incident plans. as a priority. c) Reviews of exercises or practices shall be published and. This process will allow the relevant Head of Department in consultation with other Petroplus corporate management to respond to the strategic implications of the incident. At a minimum. 14. the lessons from such practices should be incorporated in revised procedures and shared with all relevant personnel. Such procedures shall include.
. b) Restoration and recovery exercises shall be included on a periodic basis to ensure that this phase of incident management is covered.
however. or multiple reportable injuries. Product contamination having a direct SHE related impact on customers or public. or potentially serious. serious. Likelihood of media interest or significant adverse public reaction. for example the relevant Refining General Manager. serious adverse effects to people or major damage to property or the environment. it is important that a Petroplus representative attends the scene as soon as possible. railcar. Corporate SHE Manager. All Major Incidents shall be reported IMMEDIATELY following declaration of a Major Incident to the corporate representative assuming the role of Strategic Response Manager. the local representative should be of sufficient knowledge and experience to be able to assume a role equivalent to Site Main Controller in terms of authority. • • Involving fatal. the Corporate Communications Manager and the Group Insurance Manager. or waterborne vessel incidents can be complicated. The Site Main Controller is responsible for on-going communications with off-site senior management and with the local regulators and authorities. or causing. usually the Site Manager. The focus of the Site Main Controller’s concerns will be the consequences of the incident. It has serious. Liabilities in the event of truck transport. the Strategic Response Manager (SRM) manages the issues of company reputation. explosion or release of material potentially causing. railcar. the Corporate Legal team. which has sufficient business repercussions that it is escalated to the level of Major Incident. • “Strategic” – When a Major Incident has been declared. the legal implications and coordination of other company functional links. c) Declaration of a Major Incident is a site responsibility based on the guidelines below. The SRM shall initiate immediate onward reporting including notification to the Executive Committee. In general. or waterborne vessel incident occurs. or potentially significant. probably from Zug. the Site Main Controller. sabotage or direct action by terrorist or pressure groups. if an incident has one of the following characteristics. Involving kidnapping.• “Tactical” – In the event that an incident is declared to be a Major Incident. In this he/she will need to think “one hour ahead” and about the off-site implications of the incident. it would justify categorisation as a Major Incident. The strategic response will initially be managed remotely. Resulting in fire. Normally the relevant Head of Department (HOD). Marketing Manager or Shipping Manager would fulfil this role. legal repercussions for Petroplus. It is not possible to be fully prescriptive with respect to the nature of Major Incidents as they can vary in nature.
• • • • • d)
If a truck transport. but the SRM may well conclude that relocation to the site is appropriate after a period of time. at the location of the incident assumes command of all local activities. With significant. environmental off-site impact. to the extent that local legislation permits.
. but where appropriate.
. this is likely to require a minimum of 3 people at each site to be trained.
14. above. communication from the site shall be as required by the Crisis Management Team. b) Fire Protection Appropriate separation distances should be provided and maintained between potential sources of fire and equipment or facilities that could be affected. Requirements in the event of media briefings are referred to above in paragraph 14. the Shipping Manager and Corporate SHE Manager have access to Oil Spill Response Ltd (OSRL).2 i.6
FIRE SAFETY MANAGEMENT Duty Site Managers shall ensure that any assessments of the fire hazards associated with the site are carried out and periodically reviewed. With respect to Major Incidents. Site Main Controllers should be trained to give public statements and have achieved the necessary standard of competence. the fire assessment could be carried out as part of the Hazard Studies. further escalation to “Company Crisis” would be possible on the authorisation of an Executive Committee member. Contact details are provided in CORP–SHE–001 and contact should be made through the above links with that company. Principles to be followed In addition to the requirements contained with section 14. For new plant. Site Managers shall have measures in place to allow them to meet the needs of the CMT in these circumstances. In the event of a major oil spill. or other high profile shipping incident. Any briefing should always have the approval of the SRM.1. it is more likely that pro-active briefings will be necessary with the local population and media. Following the initial response to the Major Incident an investigation team shall be established using the guidance contained within CORP–SHE–002 “Investigation of Serious Incidents”. This company has global reach and a capability to provide expert assistance around the clock. In such cases. due to the severe implications of a Major Incident. together with the appropriate means of handling such materials so that fire can be avoided. the strategic aspects of the incident would be managed by a Crisis Management Team (CMT) comprised of senior managers from the Company. Arrangements must be made to support such briefings.g)
Where deemed necessary. the following topics should be considered under the fire hazard assessment: a) Fire Prevention The fire and explosion hazards of materials used on site should be made known to those who work with them. the Corporate Communications Manager and the Corporate legal team. In order to provide 24/7 cover. In such an eventuality. of which Petroplus is a shareholder.
Fire fighting equipment should be inspected. There should be a system of ongoing liaison with the external fire brigade to ensure they are appropriately familiar with the site. hose reels etc) should be provided for use by personnel. tested and maintained according to defined procedures. On-site specialist fire fighting personnel and equipment should be provided as judged necessary. detail the actions to be taken to minimise harm to the environment from airborne or water borne contamination. d) Emergency Response Each site should have a system of raising an audible fire alarm which can be heard throughout the facility. The requirements for drainage and containment systems to cope with fire water should be assessed and appropriate provisions made. c) Fire Fighting Facilities Appropriate equipment (portable extinguishers. g) Fire Water Runoff There shall be an assessment of the risks to the environment from fire water runoff. The required response to fires (local fire fighting. where necessary. f) Suitably Qualified and Experienced Personnel Persons responsible for site fire safety management should have sufficient knowledge and awareness to discharge their responsibilities and know where to obtain additional professional support.
. taking into account possible harm to the environment. site fire brigade and assistance available from external emergency services. tested according to defined procedures. maintained and where appropriate.) should be defined in Fire Plans.Fire detection systems and passive and/or active fire protection measures should be provided as appropriate. Fire plans should. e) Adequate Means of Escape There should be a written and tested plan covering the means of evacuation of all site personnel in the event of a fire. Suitable systems should be established for notification of the on-site and/or external fire brigade or professional fire service. All fire protection and detection systems should be inspected. etc.
both before and during the work. Principles to be followed: All sites shall establish and maintain systems for the identification of SHE risks. are responsible for undertaking risk assessment on their activities. Site Managers shall ensure risk assessments can vary in complexity from a simple mental risk assessment to formal studies such as HAZOP and Quantified Risk Assessment. the assessment of these risks and the implementation of appropriate control measures to ensure that remaining risk is reduced to a tolerable level. processes and personnel. including contractors. Plans must be in place to reduce these risks to an acceptable level in a timely manner. communicating and managing the risks facing our organisation to ensure that the company meets its objectives.1 SHE RISK MANAGEMENT Duty Site Managers shall ensure that SHE risks are identified. Site Managers shall ensure written risk assessments are seen as a means of demonstrating that appropriate consideration has been given to the management of risks. an authority approval sign-off shall be in place which accepts the remaining risk. assessed and appropriately mitigated. Such demonstration is a vital aspect of our licence to operate and written risk assessments shall be produced for the most serious risks. When these residual risks are significant. The risk analysis shall define the residual risks which remain after the control measures have been put in place. where appropriate the site shall document the basis for continued operation. assessing. In the event that SHE risks defined by the corporate risk assessment matrix as “serious” are identified. The type of risk assessment required will depend on the risk being assessed.RDSHE 15 – SHE RISK MANAGEMENT
SUMMARY OF STANDARD Risk management is the active process of identifying. All SHE risk management processes shall be developed in consultation with competent persons and applied using a consistent approach and documented in a systematic way. Risk assessment processes shall be carried out on routine and non-routine activities and before changes to operations. Site Managers shall ensure all personnel. 1.
The interests of personnel. services. the design. Guidance for the use of the CRAM is contained within CORP-SHE-003. The hierarchy of control should be used to reduce the risk to tolerable levels. All sites shall ensure that the results of the SHE risk assessment processes are fully communicated to all relevant persons. competency and training requirements.
. suppliers.2 CORPORATE RISK MATRIX Duty Site Managers and their management teams shall ensure that hazards are risk assessed using the corporate risk assessment matrix (CRAM). all equipment and facilities. work organisation. visitors and local communities and neighbouring businesses should also form part of the overall SHE risk assessment process. commissioning and operation of the workplace and human behaviour as appropriate.Sites shall ensure methods used for identification of SHE risks and their assessments are appropriate to the nature and extent of the task. changes to products. procedures. The results of SHE risk assessment processes should be considered when establishing awareness. implemented and maintained by competent persons and shall include the prioritisation and classification of risks to determine the level of significance. 1. SHE risk assessment processes shall consider routine and non-routine activities. contractors. Where work activities are involved this shall be before the start of the activity. These methods shall be formally developed. planned and unplanned changes. installations.
may or may not have been sufficiently investigated to prevent the current incident. Investigations should identify and prioritise corrective and preventative actions to reduce or eliminate the risk and recurrence of a similar incident. 16. The root cause techniques used should take into consideration human factors by determining the reason for any intentional or unintentional human behaviour determined during the investigation process as being potentially contributing factors to the incident.
. A process for managing lessons learnt from SHE incidents is also an important part of preventing incidents from occurring on site. Where it is established that a repeat incident has occurred. a review of actions associated with previous events. Investigations should identify the contributing factors. All investigations should be recorded on the IMPACT system. immediate and root causes of the incident as a basis for recommendations to prevent recurrence. Investigations should be conducted by competent persons who have received adequate training.RDSHE 16 – INCIDENT INVESTIGATION AND FOLLOW-UP
SUMMARY OF STANDARD Arrangements for the investigation and follow-up of SHE incidents need to be in place to ensure that incidents are sufficiently investigated and to identify root causes of such incidents so that actions may be taken. This should include any persons involved in the incident whenever possible. to prevent a similar occurrence. Where appropriate following completion of an incident investigation the results of the root cause analysis undertaken shall be recorded in accordance with the Corporate Root Cause Verification Model in IMPACT. and preventative action steps recommended from prior incidents. Principles to be followed The minimum level of investigation carried out following an incident should be in accordance with IMPACT system requirements.1 THE INVESTIGATION OF SHE INCIDENTS Duty Site Managers shall ensure that all incidents are investigated appropriately and in a timely manner following such incidents. as needed. Each Investigation lead should consult with the site’s Petroplus Attorney to ensure that legal defences are not compromised during initial and further internal and external investigation processes. All sites shall ensure that competent management level employee(s) sign off the investigation process to demonstrate that an appropriate review and assessment has been undertaken as appropriate.
such as ‘high learning events’ are communicated to the other sites within Petroplus.2
THE MANAGEMENT OF CORRECTIVE ACTIONS FOLLOWING SHE INCIDENTS Duty Site Managers shall ensure that corrective and preventative actions are identified and implemented following an incident investigation. Principles to be followed Any corrective or preventative action identified during an investigation shall be thoroughly reviewed prior to implementation to ensure that the action is appropriate to the nature and extent of the hazards and associated risk. Each action identified should be reviewed against the appropriate standard in the Corporate SHE Management System Manual to identify any gaps in current management systems. All sites should use the IMPACT system to physically track action items to ensure that they have been adequately completed and implemented. A periodic review of the effectiveness of corrective and preventative actions shall be undertaken. In the event of a significant incident or near miss work shall cease and shall only be allowed to continue once the necessary actions. All recommended action steps are to be recorded on the IMPACT system and followed up until completed. including re-evaluation of any relevant risk assessments. There should also be a periodic review of control measures implemented to ensure that they remain effective and appropriate. there shall be systems in place to effectively communicate this information to all relevant personnel. Each site should have mechanisms in place to ensure that important SHE information.
. such as lessons learned that have been communicated from Corporate SHE and other Petroplus sites are acted upon accordingly. A record should be kept of actions taken to prevent recurrence of the condition that caused the complaint. have been undertaken to reduce the risk of recurrence. See RDSHE 3 Communication. This information shall be reported to management to assist in identifying and assessing the existing or proposed additional control measures. Work shall only be permitted to recommence following formal authorisation from appropriate level of management. There should be procedures to investigate all complaints from members of the public and report back to the complainant on the outcome of the investigation.16.
THE COMMUNICATION OF SHE INCIDENTS Duty Each site should ensure that important SHE information. Where an action has been identified that results in a change to existing systems or procedures. All relevant information following an incident investigation will be gathered and analysed to identify lessons learned and to identify major trends on a periodic basis.
Harm to a member of the public or justified complaints from the public. A breach of or non-compliance with any SHE related legislation. contractors hired by Petroplus and visitors to premises controlled by the company.
. Site Managers shall comply with all national incident reporting requirements. all work related incidents including incidents with the potential to cause: a) Work related injuries and occupational illnesses to Petroplus employees (including whilst travelling on company business). Petroplus Legal Department. 17.
Site Managers shall ensure that there are systems in place to record the numbers of hours worked by employees and contractors working for the company. Arrangements for recording and reporting SHE performance information and statistics to Corporate should be in place at each site. Chief Operating Officer. Clearly defined and consistent corporate reporting criteria should be in place. Corporate SHE Manager. 17. Damage to plant. material or the environment.RDSHE 17 – SHE PERFORMANCE REPORTING
SUMMARY OF STANDARD The SHE performance of the company shall be monitored to identify any trends to enable continual improvement in SHE performance. Principles to be followed Each site will report SHE incidents: a) Immediately by telephone or in person and by e-mail notification to all to the Chief Executive Officer.2 SHE PERFORMANCE REPORTING Duty Site Managers shall ensure that the following SHE performance reporting requirements are adhered to. More detail can be found in the glossary. Hours worked should be calculated separately for company and contractor personnel. The Petroplus approach to categorisation of incidents is based on OSHA categories. The number of hours worked when calculated for employees should include paid overtime and training. and Refining General Manager.1 DUTIES TO RECORD SHE RELATED INCIDENTS Duty Site Managers shall ensure that systems are in place to record within the IMPACT system.
Multiple injuries sustained by employees. Any incident causing. Note: The Site Main Controller must talk to a Corporate Manager acting as Strategic Response Manager. long term. contractors working on behalf of the company or third parties whilst on a Petroplus controlled premises that are likely to result in medical treatment. Physical damage not involving a major incident if production has been affected for more than two hours. significant adverse effects.Major incidents include. Any process safety related incident where the business impact is likely to exceed US$2M (CRAM severity level I). Any environmental incident with potential widespread. rather than simply leaving a message: b) The same day by telephone to the Refining General Manager or the Corporate SHE Manager in person and by e-mail notification to both Managers:
A single major injury to an individual.
See RDSHE 14 and CORP-SHE-001 Major Incident Response Procedure for more details. Any process safety related incident where the business impact is likely to exceed $500K (CRAM severity level II). but are not limited to:
The death of an employee. contractor working on behalf of the company or third party whilst on a Petroplus controlled premises. Any environmental incident with potential localized. significant media/public attention at national or international level or potential reputational damage. medium term.
. Any incident involving product contamination to customer products. Any sabotage/direct action to any premises controlled by the company and any kidnapping of any Petroplus employee or contractor working on behalf of the company. Notification of prosecution by a SHE regulatory authority or if a SHE regulatory authority serves an enforcement notice on site. Any incident causing significant media/public attention at a local level or potential reputational damage. or potentially causing. significant adverse effects.
Annually Site Managers shall report the following information to Corporate SHE for inclusion in the Annual Operations Performance Report for the Company’s Board of Directors:
A summary of the all incidents that have occurred at the site. analysis of root causes.
All lost work incidents. Any complaint received from neighboring properties or the local community.
Monthly Site Managers shall report the following information on a monthly basis to Refining General Management and Corporate SHE to allow the SHE performance of the company to be monitored:
Process safety indicator values and safety statistics required by the monthly Stewardship Report. This will include information on frequency rates. restricted work incidents. including any LOPC and non-compliances. The number of road incidents on site. Any breach of or non-compliance with any operating permit consent limits. All losses such as financial impact on the company arising from a plant based 'non-major' incident > $100K (CRAM severity level III). All incidents which had an (potential) impact on the environment.c)
Weekly Site Managers shall ensure that all incidents and near misses are captured within the IMPACT system and appropriate incidents are submitted for inclusion in the SHE Conference call. Corporate SHE shall compile the SHE Conference call submissions for review by the Corporate Operations and Site Management Team. medical treatment cases and first aid cases and major near misses. Environmental indicator values required by the monthly Stewardship Report. Material for inclusion in the Site Managers submission will include.
. and implications and corrective actions. Personal safety indicator values and safety statistics required by the monthly Stewardship Report. Any process safety related incident. trends.
A summary of all issues associated with regulatory compliance. The summary should also include details of all current and new SHE-related litigation that has occurred during the year. This will summarize all contacts with the regulatory authorities and will provide specific information about any statutory notices and breaches of consent.
1MONITORING. frequency. department audits. It helps management to identify areas of improvement so that action can be taken to minimise the potential of an incident occurring and to demonstrate compliance with legislative requirements and the Corporate SHE Management System Manual. access compliance and identify necessary improvements and to share good practice.2AUDITS All sites shall establish. visibly felt leadership. Principles to be followed All sites shall establish and maintain programs to monitor and measure SHE performance on a periodic basis. Audit programs should be reviewed on a periodic basis to ensure that they remain applicable and relevant. contractor audits and third party audits. safety plans) for responding to and for the monitoring of actions resulting from the audit program to ensure that issues are completed appropriately and in a timely manner.
.3REVIEW All sites shall have formal process (e. roles and responsibilities for conducting audits and reporting results. AUDITS AND REVIEW Duty Site Managers shall ensure that SHE performance is monitored. 18. audited and reviewed to identify trends. The findings from audits shall be analysed and utilised in the process for continual improvement. Audit programs should include SHE management system audits. appropriate technical audits. 18. 18. behavioural audits. competencies.g. document and maintain a formal audit program that ensures the effective monitoring of conformance to the standards contained within the Corporate SHE Management System Manual. The audit programs shall be based upon a risk based approach. methodologies. the results of previous audits and be appropriate to the nature and scale of the hazards and associated risks. The criteria shall be consistent with the principles used in internationally recognised management system standards such as ISO 14001. monitor progress. mentoring and coaching are demonstrated. Management shall be actively engaged in appropriate audits ensuring effective. The program shall be defined in terms of scope. ISO 9001 and OHSAS 18001.RDSHE 18 – MONITORING OF SHE PERFORMANCE
SUMMARY OF STANDARD The monitoring of SHE Performance is an essential aspect of business operations.
experience. Damage to Company Reputation A situation which could result in negative impact on company reputation as a result of an incident or near miss. Critical Operating Instructions Operating Instructions. Complaint (environmental) A complaint has been classified as a justified complaint received from the outside community. plant start-up. The negative impact can be in the form of adverse attention from media or action groups or public concern about company activities. Breach of any SHE Related Legislation or Governmental Regulation Any matter which has to be reported to local government officials or national regulators which is not covered by any other Corporate reporting requirement. including emissions or emission limit values. shutdown. or time periods for satisfying improvement conditions. list the steps for a given task and describe the manner in which the steps are to be performed. complex or infrequent tasks and action in the event of alarms and trips etc. skills and attitude to do the intended role or activity. They are specific to individual pieces of plant equipment. including neighbouring companies. as described in environmental regulations. are comprehensive written procedures (including procedures that are stored electronically and printed on demand) for operating plant and equipment. Explosion
. which are related to any environmental impact to which the company might have contributed. Environmental Exceedance An exceedance is a measure of the number of formal breeches or exceedances of any consent or permit limit. Complaints from employees or contractors being on site and complaints that were addressed mistakenly to the company and can be rejected. persons or authorities.PART 3: GLOSSARY OF TERMS
An authority approval sign-off A person who has been officially designated as competent to give approvals or sign off on a document. Competent Person A person who has suitable qualification. permits and orders. Multiple complaints all arising from one single (no repeat) event can be counted as one complaint. They are designed for use by the operating team and include detailed information on all aspects including normal operation.
oil soaked insulation. regardless of the time between the incident causing the injury or exposure or causing illness occurring and the death. This may occur either within equipment (overpressure explosion) or in the atmosphere (vapour cloud explosion). Any non work related death of an employee. plasters etc Using hot or cold therapy Using non ridged means of support such as elastic bandages Using temporary immobilization devices while transporting an person who requires treatment • Using eye patches • Removing foreign bodies from the eye using irrigation or cotton swab Removing splinters or other foreign material from areas other that the eye by irrigation.g. Fire An incident that requires the use of fire fighting equipment or other extinguishing means e. Fatality A death resulting from a work related injury or occupational illness.g. Fires with no visible flame. tweezers. Hierarchy of Control • • • • • •
. First Aid Case (FAC) Any single treatment and on going observation of a minor injury that does not typically require medical treatment by a medical physician. shut off fuel or switch off electricity supply. contractor working on behalf of the company or third party whilst on a Petroplus controlled premises should be reported to Corporate Operations Management but not recorded as a fatality with regards to SHE performance data. e. should also be included. flushing or soaking wounds on the surface of the skin Using wound coverings such as bandages. cotton swabs or other simple means • Draining of fluid of a blister • Using massages (excluding physiotherapy treatment etc) • Drinking fluids for relief of heat stress For injuries that do not fit the criteria as defined further guidance on First Aid Cases can be found on the OSHA website. By the nature of the injury sustained. such treatment and observation is considered a First Aid Case even if provided by a physician or registered medical professional personnel.An incident which results in a rapid increase in pressure caused by the ignition of flammable vapours. The following injuries are classified as First Aid Cases: Using medication at non-prescription strength Administering tetanus immunizations Cleaning.
or could have. Each step should be considered in order: elimination. information. resulted in injury or illness or damage to assets. safe systems of work. company assets or the reputation of the company. major or serious on the Corporate Risk Assessment Matrix. Injury A wound or other condition of the body caused by external force including stress or strain. quality or reliability incidents which had no potential or actual SHE consequence. substitution. Lost Work Incident Frequency (LWIF) The number of lost time incidents per 200. This is to include the following: • • • • Pressure vessels Piping systems Atmospheric storage tanks Relief devices
Medical Treatment Case (MTC) An incident is classified as a Medical Treatment Case when the treatment received by a person who has sustained a work related injury goes beyond the first aid
.The following hierarchy of control should be used to manage risks. Critical plant and equipment. The injury is identifiable as to time and place of occurrence and member or function of the body affected. Incident An unplanned event or chain of events that has. and continued safe operation. Plant and equipment is defined as being relied upon to ensure safe containment of hazardous materials and stored energy. reduction. training. good housekeeping. Incidents do not include operations. 000 working hours. Major Injury Injuries with actual consequences to the company that rate as severe. Lost Work Incident (LWI) A work related injury or occupational illness which results in the person being unable to work on any day(s) after the injury or illness regardless of whether the person was scheduled to work. instruction. and is caused by a specific event or series of events within a single day or work shift. maintenance. supervision and personal protective equipment. Mechanical Integrity Inspections This can be defined as inspections carried out to measure the effectiveness of the process safety management system to ensure that critical plant and equipment is functional. isolation. the environment.
such as x-ray are not classified as a medical treatment. The alarms should be processed in such a manner as to avoid operator overload at all times (alarm floods). unless there are exceptional circumstances the reversal date must be no longer then the time to the next overhaul.
. Diagnostic procedures. the signatories must review the status of the modification to ensure that: • • circumstances have not changed that either invalidate the original risk assessment. Near Miss An incident that could have caused illness. There shall be a system which records all temporary modifications. injury or damage to assets. the environment or company reputation. but did not have such results. increase hazards or negate mitigation steps put in place against identified hazards. The alarm processing should ensure that fleeting or repeating alarms do not result in operator overload even under the most severe conditions. Minor Injury Injuries with actual consequences to the company that rate as significant on the Corporate Risk Assessment Matrix. Number of alarms per DCS Berth This metric is a measure of the time a distributed control system (DCS) or panel operator has to be aware of an alarm review if action is needed in response to the alarm and take the required action. Medical treatment does not include first aid treatment even if a physician or registered professional personnel provide this. Number of Temporary Modifications Overdue This metric is a measure of the effectiveness of the process safety management system to ensure that temporary modifications are reversed in a safe and timely manner and they do not become permanent changes without further appropriate risk assessment.treatment provided. Must This is an instruction and requires action to be taken. and mitigation steps or controls put in place originally remain in place. The reversal date should not be extended automatically. This system must include an anticipated reversal date. or consequential business loss. If the temporary modification has not been signed-off as removed by the specified reversal date then this should be flagged as overdue.
or from working the full work day that he or she would otherwise have been scheduled to work. Critical operating instructions are defined as those provided for start up. Review A review should occur at a defined frequency to assess the validity of the instruction. other than one resulting from an injury that is caused by or mainly caused by exposures at work. shutdown and emergency use. If a physician or registered medical professional personnel recommends that a person who has sustained a work related injury or illness should not perform routine functions of their job or should be given alternative functions to perform during a period of recuperation then this would be classified as a Restricted Work Incident. ingestion or direct contact. Premises controlled by the company Premises where Petroplus is the owner.If these requirements can not be satisfied. be signed off the document owner for the procedure to be reissued. structure or a building. or is otherwise responsible for the operation of property. • • • The sudden release of material above a threshold defined by the US Centre for Chemical Process Safety A fire or explosion resulting in direct cost >$25. A review of an instruction may be made. Occupational illnesses include acute and chronic illnesses or diseases that may be caused by inhalation. Occupational Illness Any work related abnormal condition or disorder affecting the health of an individual. absorption. at any point as deemed necessary but must again be signed off the document owner to be reissued. Permanent Total Disability (PTD) Any work related injury or occupational illness that permanently incapacitates an employee that results in termination of employment.000 to Petroplus A lost time injury or fatality
Restricted Work Incident (RWI) A work related injury or an occupational illness which results in the person being temporarily unable to perform routine functions of his or her job. Process Safety Incident An incident should be reported as a Process Safety Incident if it involves chemicals or chemical processes and also involves one or more of the following. then the status of the plant and the acceptability of continued operation should be reconsidered. outside of the formal review process.
. lessee.
any spillage of liquid hydrocarbons or other hazardous materials on unmade ground or water and any other spillage of such materials > 5 litres. Spill A spill is an unplanned or uncontrolled release of hydrocarbons or chemical substances to the ground or water.
Safety Instrumented System Testing This metric is a measure of the effectiveness of the process safety management system to ensure that safety instrumented protective systems are tested on a frequency associated with their criticality and reliability and often derived from SIL or LOPA assessment This involves the collection of data on the delivery of planned testing of Safety Instrumented Systems. whether on or off the road. Safety Instrumented Protective Systems Reliability This is defined as a measure of the effectiveness of the preventative maintenance programme for the Safety Instrumented Systems (SIS) on the refinery. i.e. According to the Corporate SHE Management System. Many process safety excursions are prevented by either an alarm alerting an operator to make manual intervention or a trip system automatically operating to return the system to a safe state. Trip and alarm systems. illness or damage to assets. should be recorded as an incident and an appropriate investigation carried out. The measurement is for those systems when tested would not have functioned as they were designed to do so and would not have provided intended protection from a process excursion. that has resulted in injury. Shall This is an instruction and requires action to be taken.
. irrespective of the cost of repair or responsibility for cause. the environment or the company’s reputation.Road Transport Incident An incident involving a vehicle driven by a company or contractor employee. Significant Extensive or important enough to merit attention. Should Is used to indicate an obligation or duty that requires action to be taken where reasonably practicable. It is therefore essential that these systems operate as intended and form an integral part of the preventative maintenance programme.
mobile generators.Third Parties Persons or organisations that are not employed by or contracted to a company or Contractor. 000 working hours. training and seminars are not included in the definition of absence. motorcycle or any unit under tow. A single exposure can give rise to several occupational illness cases. 000 working hours. caravans. Working Hours Hours worked by own staff and contractors. Total Recordable Incident Frequency (TRIF) The number of Total Reportable Incidents per 200. All other cases of absence such as pregnancy. bus. trailers.
Total Sickness Absence Absence from work on grounds of incapacity to work due to any sickness and injury. road tanker. heavy goods vehicle. childbirth. leave.g. Vehicle A vehicle is defined as a car. Cases involving no lost work or restricted work incidents and no medical treatment are included. light vehicle.
. restricted work incidents and medical treatment cases. Total Recordable Occupational Illness (TROI) The sum of all identified occupational illnesses. work related or not. Estimates should be used where contractor data is not available. e. expressed as percentage of total workdays available. Vehicle Kilometres Driven The number of vehicle kilometres travelled during work related activities whilst being driven by an employees or contractor working on behalf of the company. van. Total Recordable Incidents (TRI) The sum of all lost time incidents. Total Recordable Occupational Illness Frequency (TROIF) The number of occupational illnesses per 200.
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