Assoc Prof Dr Zakaria Man

TOPIC LECTURE 1 : INTRODUCTION : WHY HSE?

CODE

: CCB2012/CBB2012

Assoc. Prof. Dr. Zakaria Man, Dr. Oh Pei Ching Assoc. Prof Dr. Nor Hisham Hamid, Mohammad Amin Shoushtari, Ir. Idris Ibrahim
OBJECTIVE : STUDENTS SHOULD BE ABLE TO UNDERSTAND THE BASIC PRINCIPLES OF OCCUPATIONAL HSE, IN TERMS OF MANAGEMENT, HAZARD IMPACT, IDENTIFICATION, CONTROL AND PREVENTION

Course Background
Subject Status : Core

Credit : 2 hrs
Assessment : Assignments : 40 % Final Exam : 60 %
REMINDER:

Each student can and has to register and attend ONLY one lecture slot throughout the semester You are not allowed to change after 2nd week You will be barred from taking the final exam if you missed 3 lectures during the semester.

Assignments -1 -2 -3
Quizzes Final Exam
Quizzes:

15% 5% 10% 10 % 60%

TWO (2) quizzes to be given by each lecturer or at least ONE(1) quiz every week. To be given in the last 5 minutes of the class.

Course Synopsis
Introduction to HSE Regulations and Standards Environmental Management System Safety Analysis and Prevention Noise and Vibration Hazards Fire, Ergonomic Hazards and Life Safety Heat, Temperature & Pressure Hazards Mechanical Hazards and Machine Safeguarding Accident,Causation and Investigation Electrical and Radiation Hazards Emergency Response Plans Promoting HSE

Petrochemical Plant

Kertih Integrated Petrochemical Complex

TYPICAL LIFE OF A PROCESS PLANT

Birth Design
2 years
Strong market demand, Product changes, Energy efficient, Environmental concerns

2 years

Construction

Commissioning
1 month

Debottlenecking
15 years Making More money

Production
Making money

Decommissioning

Dead

Project Schedule
Months 3 6 9 12 15 18 21 24 27 30 33 36 39 42 45 48 Technology selection Project economic evaluation Prepare EPCC Bid Package EPCC evaluation + award Detail engineering First award of long lead equipment Packages bidding & award Site preparation Civil construction Installation of long lead items Mechanical completion Precommissioning Commissioning First product Plant acceptance test

Detail Engineering
Process optimization is a trade off between capital

and operating cost. Equipment sizing and selections Hazop (safety & hazards analysis) Piping design Process & equipment layout Instrument & process control

PROCESS DESIGN ELEMENTS Human factors Process Design Economics Safety Practicality Technically sound

WHY HSE?

Accidents and ill-health at work impact not only on the lives of individual workers, families and potential for future work, but also the business, the productivity and profitability of their enterprises and ultimately of the society.

The Grounds for HSE

Why Have a Good HSE Program?

A Good HSE Program Has Long Term Benefits for the Company and Its Employees

Importance of Loss Prevention

The first duty of a business is to survive. The guiding principle of business economics is not the maximization of profits - it is the avoidance of loss. Peter Drucker

The Skys the limit

Loss Prevention
Human Loss

Time/Revenue Loss

Asset Loss

Information Loss

The Cost is Substantial

For every $1 of injury/Illness costs there is:

- $5 to $50 of damage costs

-$1 to $3 of miscellaneous uninsured costs A range of 6 to 53 times as much

At 10% net an additional $1,000,000 of revenue is required to pay for a $100,000 accident.

Hidden High Cost of Accidents

US Industrial Accidents 1995:
16% Medical Costs

6600 Fatalities 3,600,000 LT Injury / Illness 120,000,000 lost workdays Total Cost: $119.4 Billion $ 28,000

50% Wages & Productivity Losses 9% Emergency Response & Investigation Costs 3% Property Damage 22% Administrative Costs

Cost per Fatality: $790,000 Cost per injury: Total US Industrial Profit in 1995 was ~$450 Billion

Cost of Accidents = 26.5% of Profit !!

How Does It All Fit Together?

Hazard Catalog Hazard
Any object, product, physical condition, or physical effect that has the potential to cause an undesired event.
Air Transport Biohazard/Illness Drugs & Alcohol Electrical Explosives Fire/Flammable Human (Security, Crime, Terrorism) Unsecured Data/Information Land Transport Machinery/Equipment/Hand tools Natural Phenomenon Noise/Nuisance Gravitational Potential Energy (Stepping, Handling, Lifting) Pressure Radiation Temperature Toxic/Corrosive/Hazardous Chemicals Vibration Water Transport

+
Activity

Activity, action , human presence

=
Risk
A measure of the likelihood of occurrence of an undesired event (activity frequency plus event probability) and the potential severity of the consequences. Undesired incident resulting in a loss harm to people and/or damage to vehicles, facilities, assets and/or damage to the environment and/or

Event

HSE

Consequences
(Loss)
Non Productive Time (NPT) and/or Long term effect Loss of revenue and/or Failure in process delivery and/or Failure of a product and/or Damage to reputation and potential loss of future work

PPE in the Risk Control Process

PPE

Specific PPE Considerations

Jewelry and Accessories
Body Protection Eye Protection Head Protection Foot Protection

Hand Protection
Fall Protection

Hearing Protection
Electrical Protection

Respiratory Protection
Drowning Protection

The Well-dressed Worker!

Wear the appropriate clothing:
coveralls Jeans/workpants and long sleeved shirt Safety-toed shoes or work-boots Take off all Jewelry!

Do not wear loose-fitting clothes

Wear the required PPE

see next slide!

Do not wear jewelry

rings, ear-rings, pendants can become trapped by machinery!

Secure your hair if it is long!

Before a Machine does it for you!

Personal Protective Equipment

Signs and Floor Markings should indicate specific PPE required

Wear all required PPE for the particular work activity such as:
hard hat gloves safety glasses/goggles ear protectors

Radiation Badge (Personnel Dosimeter) is required to work in a workshop where sources are present!

Are you Fit to Work???

Physical and mental fitness are important for safety while working
Many accidents are caused by
Physical illness mental stress

Keep fit through regular exercise and good eating habits

Many drugs (prescription and otherwise) impair attentiveness, coordination and reaction speed.
These can make it unsafe to operate vehicles or machinery and work in hazardous environments Do not use any drugs without express written medical authorization.

Smoking is not only hazardous to your health, but is dangerous in the workplace
Smoking is generally prohibited in the workplace

MELAKA REFINERY CHANGE VISION & JOURNEY

MELAKA CHANGE VISION AND STRATEGIC THRUSTS

A License to Operate

GLOBAL CHAMPIONSHIP
THE BEST REFINERY IN ASIA-PACIFIC REGION
HSE EXCELLENCE OPERATIONAL EXCELLENCE ACHIEVE SUPERIOR PERFORMANCE RECOGNISED BY THE SOLOMON BENCHMARKING VALUE CREATION CREATE SUSTAINABLE VALUE THROUGH ASSET OPTIMISATION AND CAPACITY EXPANSION

VISION

CORE PILLARS

ACHIEVE HSE EXCELLENCE THROUGH EFFECTIVE IMPLEMENTATION OF HSE-MS

PRECURSORS

BUILD LEADERSHIP
INSTITUTIONALISE CAPABILITY

INCULCATE OUTPERFORMING MINDSET & BEHAVIOUR

MELAKA REFINERY CHANGE VISION & JOURNEY

JOURNEY TOWARDS HSE CENTER OF EXCELLENCE Maximizing Value Creation
Maintain excellent HSE performance Achieve excellent HSE performance for major project construction Intensify emergency response readiness Inculcate Behavioral Safety Extend HSE-MS to contractors Implement Carbon Management System

Center of Excellence
Excellent HSE-MS performance Process Safety Culture Behavioral Safety Culture Proactive HSE Risk Management Environmental Sustainability

Performance Gap Closure

Development and effective implementation of HSE-MS Achieve ISO 14001 & OHSAS 18001 certification Effective stakeholder relation management

03/04

07/08

09/10

11/12

LEADERSHIP & COMMITMENT

HSE COMMITTEES HSE STEERING COMMITTEE
Chaired by MD/CEO

HSEMS Leadership Committee

Chaired by SGM Plant Division

Area HSE Committee (8 Areas)

Chaired by Asset Manager

Community Relation Management Committee

Chaired by GM Engineering

Contractor Safety Committee

Chaired by GM Engineering

HSE Awareness Committee

Lead by KAPENAS Chairman

Behavioral Safety Team

Lead by KAPENAS Secretary

Meeting frequency - HSE SC - Other HSE committee

: Every 2 months : Monthly

LEADERSHIP & COMMITMENT

COMMITMENT TOWARDS EXCELLENCE ENVIRONMENTAL PERFORMANCE Our HSE policy We shall conduct our business in a responsible manner that safeguards people, the community, property and the environment 11 guiding principles that support this policy and HSE Management system to meet this commitment. One of the guiding principle: To proactively identify and continuously taking step in conserving the environment via effective waste management, energy & loss management and minimization of land, air and water pollution.
People Environment Assets Reputation

Schlumberger Corporate Mission Statement

Our QHSE mission is to ensure that quality, health, safety, security and environmental considerations remain top priorities for management and for all employees. Prevention of accidental risk and loss from process failure becomes a recognized, integral part of our continuous improvement culture.