Speaker: S. Veerasingam Vice-President Malaysian Society

Speaker: S. Veerasingam Vice-President Malaysian Society for Occupational Safety and Health (MSOSH)

Managing Safety and Health Risk - Objectives To ensure that: The hazards inherent in the operations have been systematically identified and assessed and are fully understood at the appropriate levels in the organisation Arrangements are in place to control these hazards and to deal with the consequences should the need arise The necessary information, training, auditing and improvement process are in place

HSE Risk - Definition Risk Consequence resulting from the release of a hazard x Probability of the occurrence of that event

Effects of Safety and Health Hazards Identify Are people exposed to harm resulting from the company’s operations? Assess What are the causes, consequences & effects? How likely is the loss of control? What is the risk & is it ALARP? Control Can the causes be eliminated? What controls are needed & can they be effective? Recover Can the potential consequences & effects be mitigated? What are the recovery measures required? Are the recovery capabilities suitable & sufficient?

Step 1- Hazard Identify all HAZARDS

HAZARD - Definition Hazard is defined as: Anything that has the potential to cause harm, ill health and injury, damage to property, products or the environment, production losses or increase liabilities Hazard At workplace categorized: Physical, Chemical, Biological & Physcosocial

Hazard - examples Chemical Hydrocarbon under pressure Smoke Toxic material Volatile fluids in tanks Physical Moving road tankers / vehicles Elevated objects Noise People working at heights High voltage

Hazard - examples Biological Toxicological lab (catering facility at distant work station) Physcosocial Working outside the country without family members.

Step 2 - Top Event List Top Events or Incidents which will result when hazards are released and relate them to the hazards identified

Top Event - definition Top Event is defined as: The incident which occurs as a result of the hazard being released Hazard Top Event (Incident)

Top Event - examples Loss of containment Electrical shock Fall from heights Exposure to toxic material Exposure to radioactive material Effluent discharge into waterways Emissions of toxic gases

Step 3 - Consequences List consequences which result from hazard being released

Consequence - definition Consequence is defined as: An event or chain of events that results from the hazard being released People Hazard Top Event (Incident) Asset Damage Environment Reputation

Consequences - examples Serious injury Death Latent illness or disease which has long gestation period Property damage - own or public Environmental damage Loss of reputation leading to loss in current and prospective business Loss of revenue - paying for compensation, medical expenses, production loss or deferment

Step 4 - Hazard register Compile a Hazards & Effects register listing Hazards, Top Event & Consequences HAZARDS & EFFECTS REGISTER Risk Remedial Initial Final Hazard Threats Barriers Top Recovery Consequences Rating Event Measures Risk Risk Action Required P A E R X X X X X X X X X X X X

Step 5 -Risk ranking Using the Risk Matrix & brainstorming techniques rank the hazards and consequences based on the probabilities of the Top Event occurring

RISK MATRIX CONSEQUENCE INCREASING PROBABILITY A RATING PEOPLE 0 No injury 1 Slight injury 2 Minor injury 3 Major injury 4 Single fatality 5 ASSETS No damage RM Slight damage RM Minor damage RM Local damage RM Major damage RM Multiple Extensive fatalities damage RM ENVIRONMENT REPUTATION No impact No impact Slight impact Slight impact Minor impact Limited impact Localised impact Considerable impact Major impact Major national Massive impact Major international NEVER HEARD OF IN INDUSTRY B HEARD OF INCIDENT IN INDUSTRY C INCIDENT HAS OCCURRED IN OUR COMPANY D HAPPENS SEVERAL TIMES PER YEAR IN CO. E HAPPENS SEVERAL TIMES PER YEAR AT LOCATION Manage for Continuous Inprovement Demonstrate ALARP INTOLERABLE Incorporate Risk Reduction measures Prepare HSE Case

Ranking Risk Probability HAZARDS & EFFECTS REGISTER Risk Remedial Initial Final Hazard Threats Barriers Top Recovery Consequences Rating Event Measures Risk Risk Action Required P A E R X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X

Consequence - definition Harm to people No. Description 0 No Injury or damage to Health 1 Slight Injury or health effects (including first aid case and medical traement case) -Not affecting work performance or causing disability 2 Minor injury or health effects(Lost Time Injury) - Affecting work performance, such as restriction to work activities (Restricted Workday Case) or a need to take a few days to fully recover(Lost Workday Case). Limited health effects are reversible e.g. skin irritation, food poisoning. 3. Major injury or health effects ( including Permanent Partial Disability) - Affecting work performance in the longer term,such as prolonged absence from work. Irreversible health damage without loss of life, e.g. noise induced hearing loss, chronic back injuries 4. Single fatality- From accident or occupational illness ( poisoning, cancer) 5. Multiple fatalities - From accident or occupational illness(poisoning, cancer)

Consequence - definition Damage to Asset No. Description 0 Zero Damage 1 Slight damage - No disruption to operation 2 Minor damage - Brief disruption 3. Local damage - Partial shutdown 4. Major damage - Partial operation loss 5. Extensive damage - Substantial or total loss of operations

Consequence - definition Effect on the Environment No. Description 0 Zero effect - No environmental damage. No cahange in environment. No financial consequences 1 Slight effect - Local environment damage. Within the fence and within systems. Negligible financial consequences 2 Minor effect - Contamination. Damage sufficiently large to attack the environment. Single exceedance of statutory or prescribed criterion. Single complaint. No permanent effect on the environment. 3. Localised effect - Limited loss of discharges of known toxicity. Repeated exceedance of statutory or prescribed limit. Affecting neighbourhood. 4. Major effect - Severe environmental damage. The company is required to take extensive measures to restore the contaminated environment to its original state. Extended exceedance of statutory or prescribed limits 5. Massive effect - Persistent severe environmental damage or severe nuisance extending over a large area. In terms of commercial or recreational use of nature conservancy, a major economic loss for the company. Constant, high exceedance of statutory or prescribed limits.

Consequence - definition Impact on Reputation No. Description 0 No impact - No public awareness. 1 Slight impact - Public awareness may exist, but there is no public concern. 2 Limited impact - Some local public concern. Some local media and / or local political attention with potentially adverse aspects for company operations. 3. Considerable impact - Regional public concern. Extensive adverse attention in local media. Slight national media and/ or local / regional political attention. Adverse stance of local government and / or action groups. 4. National impact - National public concern. Extensive adverse attention in the national media. Regional / national policies with potentially restrictive measures and / or impact on grant of licences. Mobilisation of action groups. 5. International impact - International public attention. Extensive adverse attention in international media. National / International policies with potentially severe impact on access to new areas, grants of licences and / or tax legislation

Step 6 - Threats For all hazards and consequences which have been ranked as HIGH risks, identify all threats or causes which can release the hazard to become a top event

Threat - definition Threat is defined as: A possible cause that will release the hazard to become a top eventincludes thermal, biological, electrical, chemical, kinetic, climatic, radiation or human factors People Threat Hazard Threat Threat Top Event (Incident) Asset Damage Environment Reputation

Threat - examples High temperature Corrosion Bacteria Overpressure Erosion High voltage Ultraviolet radiation Environmental conditions Human incompetence Design / process unknowns

Step 7 - Barriers Determine Barriers for each threat

Barrier - definition A Barrier is defined as : A measure which is put in to prevent the release of a hazard or to prevent the occurrence of a top event once the hazard is released barriers may be physical or non- physical Threat Hazard People Barrier Barrier Threat Barrier Barrier Threat Barrier Barrier Top Event (Incident) Asset Damage Environment Reputation

Barrier - examples Guards or protective shields e.g. protective coatings, corrosion inhibitors, machine guards, fencing etc. Pressure / safety relief valves High temperature cut-off switches Correct / valid operating procedures Time delays in processes Lowering speeds of equipment Carrying maintenance when it is due Reducing congestion in operating areas

Step 8 - Recovery Measures Determine the Recovery Measures to reduce the impact of the Consequences due to the occurrence of the Top Event

Recovery Measures Activity or Condition which causes hazard release Recovery Measures Incident Proactive control H A Z A R D T H R E A T B A R R I E R TOP EVENT C O N T A I N M E N T M I T I G A T I O N P A E R Consequences R E S T O R A T I O N

Recovery Measures - examples Gas, fire & smoke alarms Emergency Shutdown systems Firewater deluge systems Fire and blast walls Emergency Response plans, training & drills Business Resumption Plans

Step 9 - Escalation factors Identify Escalation Factors which will reduce the effectiveness or operation of the barriers or recovery measures and implement additional measures to compensate for these factors

Escalation Factors - definition Escalation Factors are defined as: Conditions that lead to increased risk due to loss of barriers or loss of recovery measures especially life saving or mitigating capabilities Threat Hazard Threat Threat Barrier Barrier Recovery Measures People Barrier Barrier Recovery Measures Asset Damage Barrier Barrier Escalation controls Top Event (Incident) Recovery Measures Environment Recovery Measures Reputation

Escalation Controls - Examples Abnormal operating condition e.g critical standby equipment is under maintenance during an emergency Plant operating outside the design envelope Extreme environmental conditions - may not allow the activation of planned recovery measures Incorrect operation of the plant due to unavailability of updated operating procedures Human error due to lack of competence or ineffective training

Use the ALARP principle to test whether the controls are sufficient

AS LOW AS REASONABLY PRACTICABLE AS LOW AS REASONABLY PRACTICABLE (ALARP) PRINCIPLE Risk cannot be justified on any grounds A L A R P Risk is undertaken if a benefit is desired No need for detailed demonstration TOLERABLE IF: Reduction impracticle or cost/gain grossly disproportionate Cost exceed improvement

Step 10 Complete the Hazard Analysis and the Hazards & Effects Register

Full hazard analysis Proactive Controls Threat Hazard Threat Threat Reactive Controls Barrier Barrier Recovery Measures People Barrier Barrier Recovery Measures Asset Damage Barrier Barrier Escalation controls Top Event (Incident) Recovery Measures Environment Recovery Measures Reputation

Completed Hazards & Effects Register HAZARDS & EFFECTS REGISTER Risk Remedial Initial Final Hazard Threats Barriers Top Recovery Consequences Rating Event Measures Risk Risk Action Required P A E R X X X X X X X X X X X X X X X C5 X X X X D4,5 E3,4,5 X X X X X X C5 X X X X D4,5 E3,4,5 X X X X X X X X X

Step 11 Link Barriers and Recovery Measure controls to HSE Critical Activities which are part of Business Activities

HSE Critical Activities HSE Critical Activities are the activities that require to be carried out to ensure the effectiveness and correct operation of the Barriers and Recovery Measures at all times These activities are broken down into tasks For all these tasks, standards have to be specified and clear & valid procedures should be available Competency requirements for the staff to carry out the task and also for the supervisors should be made clear. Where there are gaps, they should be sent for training

Step 10 Performance Measures Hazard Barrier Standards Procedures Reports Inputs Control Top Event Recovery Measures HSE critical task HSE Critical activity Staff Competency Consequences Outputs Supervisor Design & Construction Operations Maintenance Inspection Business Activity

Activity – Hazard relationship Input Output Performance criteria Maint. procedures Maint. Strategy Failure record Tank repair report Trend on corrosion of tank Responsible party Activity Execute maintenance Task Maintain tanks Barrier External coating of tanks Threat External corrosion Maint. Mgr. Technician Competence 10 yrs maint exp. 3 yrs operations exp. 5 yrs experience Tech. training Example on Barrier Hazard Hydrocarbon liquid under pressure in tanks

Activity – Hazard relationship Input Output Performance criteria Govt. Regulations ERP/Oil spill response plan Emergency Drill report Trend in emergency response Responsible party Activity HSE support activity Task ERP drill Recovery Measure Emergency Response plan Consequence Oil spill Hazard Hydrocarbon liquid under pressure in tanks HSE Mgr. Competence Exp. Firefighting & oil spill response HSE Technician Competent to Operate response equipment Example on Recovery Measure 51

Control Assess Recovery Identify Examples Of Identifying & Managing Safety and Health Risk

Examples Of Identifying & Managing Safety and Health Risk Hazard Moving Vehicle Threat Slippery Road Barrier Slow Down Top Event Loss of Control Recovery Measures Consequences ABS Accident, Injuries, Fatalities

Incompetent driver Not sure discharge procedure Poor attitude Spill/contamination Loss of containment Stop work order Company’s reputation ER procedure Bund-wall Supervision (unloading into skid tank) Threat 1 Diesel Refined hydrocarbon Training Supervision Design of skid tank Consequence n Threat 2 Threat 3 Barriers Top Event Threat 4 Threat n Recovery Preparedness Measures Consequence 3 Consequence 2 Multiple supplier non standard fittings Bundwall valve open Escalation factors (saboteur) Consequence 1 C O N S E Q U E N

x x x x x x x x x x x x x x x x x x x x x x x x x x x

The Children & the Bull Hazard the bull Top Event Loss of containment (escape of bull) Threats Controls/Barriers Escalation Factors – corroded fence – galvanised material – acid rain – rotting posts – treated wood – metal posts – termites, age – corrosion – bull leans on fence – barbed wire – anger (state of mind) – Red Ball, barking dog – bull charges fence – barbed wire, 4 strands – metal posts – electric fence – yelling child, dog – falling tree limbs – prune trees – weather, age, insects – gate unlatched/open – sign, lock – ability to read, – vandalism

The Children & the Bull Consequences multiple fatalites Top Event Loss of containment (escape of bull) Recovery Measures dog attack bull Esalation. Factors dog not trained Escalation Factor Controls send for regular training run to car panic situation shoot the bull failed to fire carry out simulation exercise Regular service of gun climb tree Height phobia Therapy and practice run in different directions panic situation carry out simulation exercise

Coincident or Not ? If, ABC D EFGHI J K L M N O PQ R S T U V W X Y Z Equals, 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 Then, K N O W L E D G E 11 14 15 23 12 5 4 7 5 96% H A R D W O R K 8 1 18 4 23 15 18 11 98% Both are important, but the total falls just short of 100% But, A T T I T U D E 1 20 20 9 20 21 4 5 100% Safety really is about attitude. Make 100% Safe Behavior your choice both ON and OFF the job

THANK YOU