Petroleum Development Oman L.L.C. FAHUD OIL PRODUCTION ... · The Health Risk Assessment (HRA) report is used by PDO to process and store health related information. The report starts

Page 1 of 59

Printed: 23/01/2019 Printed copies of this document should be treated as information of temporary value and destroyed after use

Petroleum Development Oman L.L.C.

FAHUD OIL PRODUCTION STATIONS

Document ID HRA

Document Type Risk Report

Security Restricted

Discipline Occupational Health

Document Owner ONO1F

Month and Year of Issue Nov/2018

Version 2.0

Keywords Occupational Health, Industrial Hygiene, Health hazards,

Copyright: This document is the property of Petroleum Development Oman, LLC. Neither the whole nor

any part of this document may be disclosed to others or reproduced, stored in a retrieval system, or

transmitted in any form by any means (electronic, mechanical, reprographic recording or otherwise) without

prior written consent of the owner.

Page 2 of 59

Printed copies of this document should be treated as information of temporary value and destroyed after use Printed: 23/01/2019

Document Authorisation

Document Owners Document Custodian

ONO1F Petrizzo, Jose MCOH1

Revision History

The following is a brief summary of the four most recent revisions to this document. The Document

Custodian holds details of all revisions prior to these on file.

User Notes:

1. A controlled copy of the current version of this document is on PDO's live link. Before making reference to this document, it is the user's responsibility to ensure that any hard copy, or electronic copy, is current. For assistance, contact the Document Custodian.

2. Users are encouraged to participate in the ongoing improvement of this document by providing constructive feedback.

Related Business Processes & CMF Documents

Related Business Processes

Code Business Process (EPBM 4.0)

Parent Document(s)

Doc. No. Document Title

Version

No.

Month & Year Author’s Name and

Title

Scope / Remarks

2.0 30 Nov 2018 Jassasi, Shiboun

MCOH5


Issued for approval

1.0 19 May 2014 Jose F. Petrizzo

Ref. Ind: MCOH1

FAHUD OIL PRODUCTION AREA

Linked with SP-1231, 1230 and 1234

Page 3 of 59


Other Related CMF Document(s)

Doc. No. Document Title

SP-1194 Chemical Management

SP 1230 Medical Examination, Treatment and Facilities

SP-1231 Occupational Health

SP-1232 Public Health

SP-1233 Drugs and Alcohol Policy

SP-1234 Personal Protective Equipment

PR-1243 Medical Emergency Response

PR-1418 Reporting and investigation of HSE incidents (Incident Notification, Reporting

and Follow-up Procedure Part 1)

PR-2108 Fit testing for Respirator Users

PR-2109 Legionella Management Program

PR-2111 Manual Material Handling

Page 4 of 59


Table of Contents

0. INTRODUCTION TO THE HRA REPORT 5

1. HRA SCOPE 5

2. HRA TEAM 9

3. REMEDIAL ACTIONS 10

4. HEALTH HAZARD INVENTORY AND DETAILED RISK APPRAISALS 17

5. CONTROL STATEMENTS FOR LOW RAM HAZARDS 53

6. GENERIC CONTROLS AND RECOVERY MEASURES 55

APPENDIX 1: DEFINITIONS 56

APPENDIX 2: RISK ASSESSMENT MATRIX 58

APPENDIX 3: LIST OF SPECIFIC JOBS INCLUDED 59

Page 5 of 59


0. Introduction to the HRA report

The Health Risk Assessment (HRA) report is used by PDO to process and store health

related information.

The report starts with a description of the scope of the HRA and the persons involved in

sections 1 and 2. The remedial actions from the HRA are presented in report section 3, and

are sorted by priority. Section 4 provides information from the detailed appraisals. The focus

here is on High and Medium RAM rated risks. Section 5 lists the status of the Low RAM rated

risks that were reviewed during the HRA. Section 6 provides an overview of generally

applicable controls and recovery measures. The report concludes with definitions and a

diagram of the RAM risk matrix in appendices 1 and 2. Appendix 3 contains an overview of

the detailed risk appraisals and their page numbers.

1. HRA Scope

General The Fahud assets comprise a number of oilfields and associated facilities located in central Oman. This area is a desert plain, comprising alluvial gravel fans arising from a number of wadis. There is little local population, with only Bedu settlements scattered sparsely around the area.The climate is typical Arabian desert, with little rainfall, but when it does rain it often results in widespread flooding and non-negotiable roads for short periods. Temperatures reach a maximum of around 50°C in summer and a minimum of 10°C in winter. High winds, causing sand storms (Shamal) occur frequently. The area has very sparse vegetation, mostly small shrubs, with some small trees found in wadis. Wildlife is also limited, with occasional large mammals such as camels encountered. Smaller mammals, such as desert foxes and gerbils, are known to be present but are rarely seen. Scope of Fahud Facilities & Activities The scope of the HSE Case for Fahud operations covers the following facilities and operations: Gathering Stations (Fahud B/C/D/E/F & Natih) Gathering stations are facilities enabling the oil accumulation from a number of wells to be appraised and the associated gas to be removed, and boosted for local gas lift, if required. These facilities typically comprise of a manifold, separator vessels, pumps for transferring oil, compressors for raising gas pressures, and flare stacks for emergency or excess gas flaring. All gathering stations connected to the electricity grid; in addition there are diesel engine driven electricity generators situated at Fahud West Field.. They are designed for nominal manning (usually 1 operator). Production Stations (MLPS) Main Oil Line Pumping Station (MLPS) is a facility that pumps gathered oil to North Oil Crude Stabilizer (NOCS) and then to the terminal storage tanks (MAF). Oil from Fahud – B/C/D/E and Natih is sent to the dehydration tanks and pumped into a crude stabilizer (NOCS) using the MLPS booster pump. North Oman Crude Stabilization (NOCS) Plant The primary purpose of the NOCS Plant is to control the sub-atmospheric true vapour pressure (TVP) of the crude oil stream flowing out of Fahud to Mina- AI-Fahal in order to provide protection to the floating roof storage tanks at Mina-Al-Fahal. A secondary purpose of the facility is to enhance the hydrocarbon recovery at the field facilities and thereby reduce flaring. Vapour pressure control of the incoming live crude is achieved via a single stage vacuum flash operation which removes the lighter hydrocarbons from the crude stream. The flashed gas is then compressed and cooled to produce a liquid feed stream for the stabilizer column which removes the methane and ethane components. This removal of the methane and ethane allows retention of increased volumes of the propane, butane and pentane components in the liquid phase thereby increasing the overall hydrocarbon recovery, while maintaining the sub atmospheric vapour pressure for safe storage. The off-gases from the process plant are routed to Fahud power plant as fuel. Process facilities at NOCS Plant

Page 6 of 59


consist of three vacuum separator trains, three liquid ring vacuum compressor trains, a main gas compressor and NGL stabilization system. The entire facility is designed to process 70,000 m3(st)/d (dry) live crude. The NOCS Plant receives live crude streams from the Yibal, Lekhwair and third parties. The NOCS Plant also receives dead crude from Fahud/Natih from MLPS Dehydration Tanks via MLPS booster pumps discharge. All streams are mixed in the inlet manifold and fed to vacuum separation trains of NOCS plant. Three vacuum separators have been designed for 35,000 m3(st)/d crude feed. These are arranged in a duty/duty/standby mode. Vacuum in the separators is created by each of the two liquid ring vacuum compressors, each sized for 50% duty. The off-gases are further compressed in the main gas compressor. The condensate generated during this stage in the process, is fed to the stabilizer unit, which removes methane and ethane. The stabilized NGL is subsequently cooled and spiked into the crude outflow. The entire plant is controlled to maintain an upper limit of 100 kPa(a) in summer and 110 kPa(a) in winter TVP of the outgoing crude stream at the Mina-AI-Fahal receiving temperature. The lighter sour gases from the condensate stabilization system are routed either to Fahud Power Plant as fuel or to an air assisted elevated flare system. The flare is sized for 696,000 m3. Summer Operation Normally two oil separators, two liquid ring compressors, main gas compressor train and stabilizer column are in operation. Recovered NGL, after stabilization, is spiked into the suction of Fahud MLPS shipping pumps along with the stabilized crude after mixing via a static mixer. Winter Operation In winter the recovered NGL is recycled back into the inlet manifold of vacuum separators. In the case of an NOCS plant shutdown (long term), NGL injection at Yibal, Lekhwair and third parties are to be suspended. The incoming crude is tested for TVP and if it is found to be below 100 kPa(a), it is directed to the Fahud MLPS Dehydration Tanks or Mina al Fahal (MAF).

Figure 1: Fahud Gathering Station Schematic Layout.

Page 7 of 59


Principal Production Operator and helper Accountabilities are:

Perform routine inspection of pipelines and flow lines to ensure all are on sleepers and report abnormalities or leaks to ONO/14 Production Supervisor.

Perform regular visual inspections of all wellheads and facilities.

Verify that all contractors have sufficient number of trained and certified first aiders available on site in accordance with company procedure.

Perform operator rounds.

Ensure all portable equipment brought on site is certified and complies with hazardous area classification requirements.

Ensure portable equipment brought to site is certified in accordance with Control of Portable Temporary Equipment Procedures (PR-1960).

Monitor tank levels via DCS.

Review the LO/LC register for its accuracy and completeness.

Ensure LO/LC register is updated to reflect current operating conditions.

Keep all barriers/gates to hydrocarbon/process handling facilities closed; allow access only to those with a valid access permit.

Verify the availability/provision of banksman during lifting activities and any heavy machinery movements within the vicinity of hydrocarbon and process facility and incorporate this requirement to job HSE plan.

Prevent the start of any activity requiring isolation if the tag out procedure is not implemented.

Maintain the overrides log book for the station.

Restrict vehicle and personnel access to site through PTW system.

Respond to alarms and isolate/shutdown equipment as required.

Close manual isolation as required in emergency if deemed safe to do so via risk assessment.

Ensure head count of personnel is conducted at muster areas in the event of station evacuation.

Report missing persons to LECB and initiate search and rescue in accordance with company ERP.

Verify that all permit holders conduct TBTs in accordance with company PTW authorization process and company procedure.

Ensure Permit Holder provides sufficient levels of supervision for HSE critical activities.

Perform spot checks on PTW holder cards to ensure permit conditions are implemented.

Stop all work not complying with PTW forms.

Verify through spot checks that PTW forms are completed correctly.

Verify that all visitors to site are provided with a site introduction prior to site access. Ensure site introduction includes hazards specific to site.

Principal Production Coordinator and Area Supervisor Accountabilities are:

Make safe well location and prepare handover certificate for well engineering.

For high pressure wells ensure SSSV is closed and surface equipment is isolated and depressurized prior to handover to well engineering.

Verify that operations are performed within the design operating envelope in accordance with POMs.

Verify speed limits are displayed on entry sign boards speed limits are imposed on site.

Verify that clean-up and remediation plans of Hydrocarbon spillage are developed and the manpower and resource requirements assessed on the basis of credible scenarios.

Provide authorisation for low risk temporary overrides.

Verify that all PDO personnel required to use vehicles are provided with defensive driving training, including refresher training every 2 years.

Verify that all employees are familiar with POMs and operating procedures, and that tasks are carried out as per job specific procedures.

Page 8 of 59


Verify that all personnel (PDO and contractor) have undertaken PTW training and passed the area interview prior to undertaking activities under PTW system.

Verify that all visitors to site are provided with a site introduction prior to site access. Ensure site introduction includes hazards specific to site.

Verify that all personnel have received H2S and HSE training.

Ensure that all personnel are aware of the hazards and hazard management arrangements for Fahud.

Initiate updates to POMs and operating procedures to ensure they accurately reflect current organization and operating position.

Ensure through PTW authorization process that any excavation activity goes through excavation certification approval process.

Verify sampling and testing of the crude composition performed by UIK/11.

Ensure that annulus pressure is monitored manually where transmitters are not installed.

Perform real time annulus pressure monitoring.

Ensure periodic maintenance of wellhead including cellar condition (i.e. sand removal) is performed by well maintenance team and ad hoc local team.

Ensure manual sampling of TVP is performed and analysis reported to ONO/1F.

Ensure MOPO is implemented for operations. Ensure operating limits are followed.

Verity that all PTW requirements are met before signing / authorizing the work.

Restrict vehicle access to site through PTW system.

Ensure that all personnel performing manual tank dipping are appropriately trained and competent to perform the task.

Ensure that manual tank dipping is performed in accordance with company procedure, utilizing intrinsically safe equipment.

Verify through PTW authorization process that an adequate lifting plan has been prepared.

Verify the hazards and control measures for any heavy lifting over hydrocarbon containing equipment have been identified and assure that they are incorporate in Job HSE Plan / PTW and implemented.

Verify and approve requests for temporary overrides of instruments and valves.

Verify through site supervision and spot checks that the job HSE Plan for heavy lifting over hydrocarbon inventories has been implemented.

Verify that LO/LC register is implemented by operations and subject to regular update.

Perform routine compliance checks to verify that the LO/LC register is implemented and maintained.

Ensure Lifting and Hoisting Procedure (PR-1708) is implemented for all lifts. Verify that PTW applicant/holder are authorized for the specific activity.

Verify that PTW applicant/holder are authorized for the specific activity.

Page 9 of 59


2. HRA Team

Responsible for HRA: Petrizzo, Jose MCOH1

Team members: Jassasi, Shiboun MCOH5

Adwani, Haitham MCOH6

Saadi, Abdulhameed ONO151F

Al Habsi, Salim ONO151F

Hinai, Ahmed ONO141F

Bulushi, Faisal ONO151F

Kumaresan,Chellam ONO141F

Sudheesh Puthiyadavan, Padinchare ONO141F

Page 10 of 59


3. Remedial Actions

Priority Work Area / Job Risk, Exposure Rating and Scenario Recommended Remedial Action / Date / Resp.

2

“D” (DELTA) Gathering

Station PRODUCTION OPERATOR

Noise High During routine operations

Provide (blue) mandatory Sign for "Use of HPE" for the following areas:

1. K-5071 (near the staircase) 2. P-0503/04 3. E-0511 & E-0-512

Resp: ONO1F

Date: 01/02/2019

“F” (FOXTROTE) Gathering Station

PRODUCTION OPERATOR

Provide (blue) mandatory Sign for "Use of HPE" for the following areas:

1. North-West of E-5708 2. East of E-5721/22/23 3. K-5705 & V-5745/46/47/48 4. West of K-5701 for its PCFs (V-5701/02/03/04

side) 5. West of K-5702 for its PCFs (V-5705/06/07/08



side)

For the instrument Air K-5750 – Arrange to repair the Isolation valve for Line ‘C’ (57-XV-885) located (near the yellow filters) in West of the Cooler fan for IA K-5750.

Resp: ONO1F

Date: 01/02/2019

Page 11 of 59



2

”C” (Charlie) GATHERING STATION PRODUCTION OPERATOR

Noise High During routine operations

Install extra blue) mandatory Sign for "Use of HPE" for K-516 & 517.

Resp: ONO1F Date: 01/02/2019

“E” (ECHO) GATHERING STATION

PRODUCTION OPERATOR

Replace damage (blue) mandatory Sign for "Use of HPE" for K-5081 and install extra signs for each direction.


Main Oil Line Pumping Station (MLPS)

PRODUCTION OPERATOR

Crude Shipping P-0406 was generating abnormally high noise (whistling & horning form its motor area) – Arrange to plan / provide maintenance for P-0406.


North Oman Crude Stabilization (NOCS)

PRODUCTION OPERATOR

1. Provide (blue) mandatory Sign for "Use of HPE" for the following areas:

1) South, near of the Crude Oil Booster P-4101 & P-4102 & P-4103

2) Instrument Air K-4115 A/B 3) E-4107 area 4) F-4101 A & B area

Resp: ONO1F

Date: 01/02/2019

2 FAHUD OIL PRODUCTION STATIONS

Psychological Hazards and Stress

High

1. Implement resilience program

Resp: ONO1F+ MCOH1 Date: 30/12/2019

Page 12 of 59



2

“B” (BRAVO) GATHERING STATION

PRODUCTION OPERATOR

Chemicals Medium During routine operation

1. Install SHOC card Oxygen scavenger- EC6213A 2. Update SHOC card for corrosion inhibitor-EC1392A 3. Update SHOC card for Emulsifier. 4. Install SHOC card for Demulsifier- Phasetreat 14230. 5. Update SHOC card for Methanol. 6. Remove existing SHOC card for sulphuric acid

(chemical not in place).

Resp: ONO1F

Date: 30/01/2019

”C” (Charlie) GATHERING STATION PRODUCTION OPERATOR

1. Update SHOC card for corrosion inhibitor-EC1392A 2. Update SHOC card for Demulsifier- Phasetreat 14230. 3. Install SHOC card for Methanol. 4. Remove existing SHOC card for sulphuric acid



Page 13 of 59



2

“D” (DELTA) Gathering Station

PRODUCTION OPERATOR

Chemicals Medium During routine operations

1. Update SHOC card for corrosion inhibitor-EC1904A 2. Update SHOC card for corrosion inhibitor-EC1392A 3. Update SHOC card for Emulsifier. 4. Install SHOC card for Demulsifier- Phasetreat 14230. 5. Install SHOC card for scale inhibitor- KT170 & H2S

Scavenger-EC9021A. 6. Dispose Citric Acid container as it is not in use. 7. Remove existing SHOC card for sulphuric acid


Resp: ONO1F

Date: 30/01/2019

“E” (ECHO) GATHERING STATION

PRODUCTION OPERATOR

1. Study the feasibility to enclose the sever pit (T517) like other station to prevent emitting vapours.

2. Install SHOC card for corrosion inhibitor- EC1168 & Corexit7806.

3. Update SHOC card for corrosion inhibitor-EC1392A. 4. Update SHOC card for corrosion inhibitor- EC1168A. 5. Dispose redundant chemical. 6. Update SHOC card for Demulsifier- Phasetreat 14230

& 3265. 7. Update SHOC card for Methanol. 8. Remove existing SHOC card for sulphuric acid

(chemical not in place). Resp: ONO1F

Date: 30/02/2019

Page 14 of 59



2


PRODUCTION OPERATOR


1. Fix the leaking in corrosion inhibitor- EC1392A skid. 2. Install SHOC card for corrosion inhibitor-EC1392A in

chemical storage area. 3. Update SHOC card for corrosion inhibitor-EC1392A in

skid.



PRODUCTION OPERATOR

1. Install exhaust fan in chemical storage area. 2. Fix leak in corrosion inhibitor skid. 3. Update SHOC card for corrosion inhibitor-EC1304A. 4. Install SHOC card for Emulsifier and Biocides.

Resp: ONO1F

Date: 30/01/2019


PRODUCTION OPERATOR

1. Install exhaust fan in chemical storage area. 2. Fix leaking in P4108. 3. Update SHOC card for Biocides-EC6477A. 4. Remove not existing SHOC card for sulphuric acid.


Page 15 of 59



2

NATIH GATHERING STATION PRODUCTION OPERATOR


1. Fix leaking from tunnel and floating meter in K-613. 2. Fix leaking from seal side in P-601 & 602. 3. Install SHOC card for corrosion inhibitor-EC1392A. 4. Install SHOC card for corrosion inhibitor- EC1168a &

Corexit7806. 5. Install SHOC card for corrosion inhibitor- EC1168 &

Corexit7806. 6. Install SHOC card for Demulsifier- Phasetreat 14230. 7. Update SHOC card for Methanol. 8. Move Methanol to shielded area.



1. Install SHOC card for NiCa. 2. Update SHOC card for Potassium Hydroxide. 3. Install SHOC card for Diesel. 4. Update SHOC card for lube oil.

Resp: ONO1F

Date: 30/01/2019

Page 16 of 59



2


General Recovery Measures: Safety Showers and eye wash, windsocks.

Medium

1. According to GU-817:

Install eyewash in chemical storage area (NOCS).

Install safety shower close to corrosion inhibitor-EC1392A (F station).

Install safety shower close to demulsifier skid- Phasetreat14230 (C station).

Install safety shower close to Emulsifier skid (MLPS station).

Fix safety shower and eyewash near demulsifier skid (E and Natih station).

Fix eye shower near Scale inhibitor-KT170 skid (D station).

Fix safety shower pressure near Biocides-EC6477A skid (MLPS station).

Fix eyewash pressure in batteries room (All station).

Flush safety shower in weekly base. (All station)


2 PRODUCTION OPERATOR Generic Controls: House keeping

Low

1. Increase frequency of housekeeping in control room of all station. (Natih & E Station)


Page 17 of 59


4. Health Hazard Inventory and Detailed Risk Appraisals

Work Area – Sub Unit/Job


Hazard Food and water borne pathogens

RAM: Medium

Acute Potential Health Effects

Food poisoning; hepatitis A, amoebic dysentery, giardiasis, typhoid, cholera. RAM: 3D

Chronic Potential Health Effects

Carrier of disease without having symptoms. Note from IARC: Mycotoxins, or fungal toxins that contaminate many of the most frequently consumed foods and feeds worldwide, have the potential to contribute to adverse health effects in humans (cancer) even at low concentrations.

Scenario Food/and or drink is handled and provided to staff.

Route & Form of Exposure

Ingestion Liquid, solid

Frequency & Duration of Exposure

3 x Daily 1 - 2 hours

Exposure Limit

Exposure Rating & Justification

Low (10-50% OEL) Food Safety Management System in place.

ALARP Status Yes

ALARP Justification Controls in place/implemented

Elimination, Substitution, isolation

Not applicable

Engineering In place

Procedural Controls In place

PPE In place

Controls Effectiveness

Fitness to Work - Operating procedure requires that all food handlers be subjected to Food Handler's Fitness to Work (FTW) certification protocol.

Effective

Process design/equipment standards - Facility design conforms to standards. Effective

Sanitation / Disinfection - Dishes are machine washed with warm soapy water. Fruits and vegetables are also soaked/washed. General environment cleaned daily.

Effective

Sanitation / Disinfection - A Pest control program is in place to address site needs. The food facility manager aware of the basic principles of pest control.

Effective

Training and information on hazard - Key personnel such as the Camp boss and chef are professionals with adequate hazard training and information. Other cadres receive on-the job training with appropriate level of supervision. SMEs too do provide training on HACCP.

Effective

Written procedure/safe work practice Effective

Written procedure/safe work practice - A system is in place, which incorporates daily inspection of staff and facility as set out in protocol but no quarterly scheduled on external audit by SMEs.

Effective

Recovery Measures Effectiveness

Local Medical Services, first aid, Medical Emergency Response Plan. Effective

Remedial Actions Priority

Page 18 of 59




Hazard Infectious, venomous and dangerous animal bites

RAM: Medium


Severe wounds, tetanus, rabies, poisoning, acute renal failure and anaphylactic shock only for snakes. RAM: 4B


None known. RAM:

Scenario During outdoors activities


Dermal


Eventually

Exposure Limit


Very Low (<10% OEL) There has been no record of any significant exposures in the past seven years.

ALARP Status Yes


Elimination Not applicable

Substitution Not applicable

Isolation Not applicable



PPE In place


Training and information on hazard - Adequate hazard information and training provided all.

Effective

Written procedure/safe work practice - Written site procedure discourages unauthorized night outing to minimize chance-meeting of reptiles.

Effective

Personal bite prevention - Workers are discouraged from night-time outings when reptiles are known to be more active.

Effective

Vector control measures - Periodic fumigation. Effective

PPE-Skin protection: gloves, clothing - Safety boots provided, which minimizes exposed body parts.

Effective


Local medical facilities, first aid, Medical Emergency Response Plan. Effective


Page 19 of 59




Hazard Insect, spiders, scorpions, bees

RAM: Medium


Irritation, inflammation, poisoning, anaphylactic shock. RAM: 3C


Allergic reaction, secondary infection. RAM: 3B

Scenario During outdoors activities


Dermal Other


Eventually

Exposure Limit


Very Low (<10% OEL) There has been no record of any significant exposures in the past seven years.

ALARP Status Yes







PPE In place


Training and information on hazard - Adequate hazard information and training provided all.

Effective

Written procedure/safe work practice. Effective

Personal bite prevention by using repellents. Effective

Vector control measures - Periodic fumigation. Effective

PPE-Skin protection: gloves, clothing - Safety boots provided, which minimizes exposed body parts.

Effective




Page 20 of 59




Hazard Legionella bacteria (waterborne)

RAM: Medium


Pontiac fever (mildest form of infection); Legionnaires’ disease – pneumonia (severest form of infection – may be fatal). RAM: 4B


Effects on lung function. RAM: 3B

Scenario Industrial/Domestic water supply: e.g. showers, faucets, eye wash stations, safety showers


Inhalation


Daily 1 – 2 hours

Exposure Limit See PDO PR-2109


Low (10-50% OEL) According to monitoring performed

ALARP Status Yes


Elimination, substitution, isolation

Not applicable



PPE Not applicable


Process design/equipment standards – split unit AC’s used in some offices. No water treatment plant with aerosol generation or cooling towers present on site.

Effective

Preventive maintenance – Biocides routinely applied, and there is no water outlet that stays unused for a whole day.

Effective

Preventive maintenance – There is program in place to periodically clean/empty accumulated water safety shows and eye wash.

Effective

Written procedure/safe work practice: PR-2109. Effective




Page 21 of 59




Hazard Psychological Hazards and Stress

RAM: High


Stress symptoms like headaches, high blood pressure, sleep disturbance, irritability, chest pain, difficulty breathing, severe pain, symptoms of shock. Fatigue, nausea, vomiting, dizziness, profuse sweating, thirst, visual difficulties, clenching of jaw, non specific aches. RAM: 2D


Anxiety, depression, absenteeism, severe gastrointestinal symptoms, heart attack. Suicide. IARC 2A - probably human carcinogen with shift work that involves circadian disruption. RAM: 4D

Scenario Frequent organizational changes, tight schedules



Daily 2 – 4 hours

Exposure Limit


Low (10-50% OEL)

ALARP Status No

ALARP Justification The subjective opinion is that the unit is functioning within an expected range of variability for stress.


Not applicable

Engineering Not applicable

Procedural Controls Implement Resilience Program

PPE Not applicable


Stress – generic organizational controls – Clear organizational structure and reporting lines; job descriptions, competence assurance framework linked to roles and responsibilities. Goals & Performance Appraisal and IDP processes are in place.

Effective

Anti-stress specific training program. Not effective


Employee Assistance Program / Counseling - Stress support program available to all staff and their families either in PDO medical facilities or external facilities.

Effective



1. Plan and Implement resilience program 2

Page 22 of 59




Hazard Heat Stress / Hot Temperature Differentials

RAM: Medium


Heat stroke leading to death (lesser symptoms: exhaustion, cramps, rash, and fatigue). RAM: 4C


Dermatitis. RAM: 2C

Scenario Exposure during outdoor activities



Daily 1 – 2 hours

Exposure Limit PDO SP-2222


Low (10-50% OEL) Outdoor activities where ambient temperature range between 36 and 45 degrees Celsius and Relative Humidity often not exceed 50%.

ALARP Status Yes







PPE In place


Training and information on hazard – Adequate information and training on causative factors and available controls provided.

Effective

Administrative controls, such as area restrictions and limited schedules – Potable cool water provided. Duration of work is managed to include frequent rest breaks where feasible. Cool rest area (air conditioned) provided for indoor workers.

Effective

Written procedure/safe work practice: SP-2222. Effective

Monitoring: Area Measurements. Effective




Page 23 of 59


Work Area – Sub Unit/Job/Job

FAHUD OIL PRODUCTION STATIONS - Production Operator and

Supervisor

Hazard NORM

RAM: Medium


None known


IARC 1 - Human carcinogen. Damage to reproductive system and blood cells. RAM: 4B

Scenario During supervision regarding intrusive maintenance tasks.



Eventually

Exposure Limit PDO SP-1170: 0.5 µSv/hr.


Low (10-50% OEL) Effective radiation management system in place by PDO

ALARP Status Yes





Engineering Applicable


PPE In place


Hazard identification by signs/warnings/labels – Radioactive source containers always carry standard ‘Radiation Hazard Warning’ label.

Effective

Training and information on hazard – Operators have appropriate level of hazard information and training.

Effective

Monitoring: Personal Measurements – Operators have instruments to ensure exposures are not above threshold limit values.

Effective

Written procedure/safe work practice: SP-1170. Effective


Medical Facilities in place, First Aid, Medical Emergency Response Plan. Effective


Page 24 of 59




Supervisor

Hazard Ultra violet light (UV) – wavelength 100 – 400 nm (non-ionizing radiation)

RAM: Medium


Skin burns, erythema (reddening of the skin) and darkening of the skin. Photokeratitis (painful condition caused by the inflammation of the cornea of the eye). Conjunctivitis (inflammation of the conjunctiva). Eye disorders with pain and discomfort ("flash burn", "arc eye"). RAM: 2C


IARC 1 - Human carcinogen (skin cancer). Skin aging. May cause pterygium, cataracts and macular degeneration. RAM: 4B

Scenario Outdoor work with high UV index



Daily 1 – 2 hours

Exposure Limit See TLvs ACGIH


Medium (10-50% OEL) Region UV index patterns range from moderate to high.

ALARP Status Yes



Not applicable



PPE In place


UV Radiation shields: roof//shelters Effective

PPE-Skin protection: gloves, clothing – Long-sleeved coveralls provided to all workers on site to minimize exposed body parts.

Effective

Training and information on hazard – Information on how people could be affected by inadequate protection from UV and controls presented to the locals.

Effective




Page 25 of 59



FAHUD OIL PRODUCTION STATIONS -Operator/Supervisor/Coordinator/All

Administrative functions

Hazard Use of control Panels, Computer/Display Screen Equipment

RAM: Medium


Muscular discomfort; eyestrain; soreness to soft tissues (e.g. wrist). RAM: 1D


Work-related upper limb disorders, repetitive strain injury. RAM: 3D

Scenario Office jobs involving typing, mousing, and/viewing monitor for > 6hour/day.



Daily 6 – 8 hours

Exposure Limit


Medium (50-100% OEL)

ALARP Status Yes

ALARP Justification Ergonomic furniture is provided. RSI symptoms are exceptional


Not applicable

Engineering Applicable

Procedural Controls In Place

PPE Not applicable


Ergonomically designed furniture & workstations – Ergonomic workstations and furniture are provided.

Effective

Training and information on hazard – Adequate hazard information and training on prevention of RSI is communicated to all users.

Effective

Ergonomic workplace assessment Effective


RSI Case management - RSI guidance available. Referral to specialist by Physician where necessary.

Effective

Physiotherapy - Effective physiotherapy service available at no cost to PDO workers. Effective


Page 26 of 59



FAHUD OIL PRODUCTION STATIONS - Production Operator

Hazard Manual Handling – Lifting, Lowering

RAM: Medium


Acute strain or sprain to muscles and joints. RAM: 3C


Chronic muscular-skeletal disorders. RAM: 3D

Scenario Lifting, carrying, pushing, pulling and positioning box, packages and equipment.



Daily 30 – 60 minutes

Exposure Limit


Low (10-50% OEL) Weights do not exceed 20kg eventually lifted, carried, or positioned.

ALARP Status Yes





Engineering Lifting equipment


PPE Not applicable


Mechanical lifting devices – Mechanical load handling devices provided on site. Effective

Training and information on hazard – Information and training appropriate to hazard level provided.

Effective





Page 27 of 59




Supervisor

Hazard Noise

RAM: Medium


Loud steady noise: temporary threshold shift. Impact noise: rupture of eardrum; acoustic trauma. RAM: 2C


Noise induced hearing loss (permanent threshold shift); tinnitus (ringing in ears). RAM: 2D

Scenario Noisy equipment on site (pumps, compressors, engines)



Daily 1 – 2 hours

Exposure Limit PDO SP-1231: 85 dB(A)


High (>100% OEL) Ambient noise levels often higher than 85 dB(A) in some work locations

ALARP Status No

ALARP Justification Controls need improvement

Elimination, substitution, Isolation

Not applicable

Engineering Applicable. Compressors have isolation systems


PPE In place


PPE-Hearing protection – Hearing protection provided but it’s not selected not derived from appropriate objective measurement.

Effective

Training and information on hazard – Adequate training and information on the effects of noise and available means of protection provided to the workers.

Effective

Area Warning signals Not Effective

Monitoring: Noise mapping performed during 2017 Effective



Page 28 of 59



“D” (DELTA) Gathering Station

Provide (blue) mandatory Sign for "Use of HPE" for the following areas: 1) K-5071 (near the staircase) 2) P-0503/04 3) E-0511 & E-0-512


Provide (blue) mandatory Sign for "Use of HPE" for the following areas: 1) North-West of E-5708 2) East of E-5721/22/23 3) K-5705 & V-5745/46/47/48 4) West of K-5701 for its PCFs (V-5701/02/03/04 side) 5) West of K-5702 for its PCFs (V-5705/06/07/08 side) 6) West of K-5703 for its PCFs (V-5709/10/11/12 side) 7) West of K-5704 for its PCFs (V-5713/14/15/16 side)

For the instrument Air K-5750 – Arrange to repair the Isolation valve for Line ‘C’ (57-XV-885) located (near the yellow filters) in West of the Cooler fan for IA K-5750.

”C” (Charlie) GATHERING STATION

Install extra blue) mandatory Sign for "Use of HPE" for K-516 & 517. “E” (ECHO) GATHERING STATION

Replace damage (blue) mandatory Sign for "Use of HPE" for K-5081 and install extra signs for each direction.


Crude Shipping P-0406 was generating abnormally high noise (whistling & horning form its motor area) – Arrange to plan / provide maintenance for P-0406.


2. Provide (blue) mandatory Sign for "Use of HPE" for the following areas: 1) South, near of the Crude Oil Booster P-4101 & P-4102 & P-4103 2) Instrument Air K-4115 A/B 3) E-4107 area 4) F-4101 A & B area

2

Page 29 of 59




Supervisor

Hazard Awkward Posture of the Shoulder, Neck, Back (not associated with force)

RAM: Medium


Muscular discomfort or fatigue, strain or sprain. RAM: 3C


Chronic musculo-skeletal disorders of the shoulder neck or back RAM: 3D

Scenario During routine field inspections



Eventually

Exposure Limit


Low (10-50% OEL)

ALARP Status Yes



Not applicable.



PPE Not applicable


Ergonomically designed according to HFE DEP’s. Effective

Training and information on hazard - Adequate hazard information and training on prevention of injuries is communicated to all users.

Effective

Ergonomic workplace assessment. Effective





Page 30 of 59




Supervisor

Hazard Kneeling, Squatting, Standing on 1 leg, Contact Stress on legs due low

and high walking displacement

RAM: Medium


Muscular fatigue or discomfort may include numbness in the legs. RAM: 1C


Lower body joint disorder. RAM: 3D

Scenario Contact stress on legs while stand by performing routine inspections



Daily 1–2 hours

Exposure Limit


Low (10-50% OEL)

ALARP Status Yes


Elimination Not applicable.

Substitution Not applicable.

Isolation Not applicable.


Procedural Controls In place.

PPE Not applicable.


Ergonomically designed according to HFE DEP’s Effective

Administrative controls, such as area restrictions and limited schedules – periodically breaks.

Effective

Training and information on hazard – Workers have adequate hazard information and training.

Effective

Ergonomic workplace assessment. Effective





Page 31 of 59


Work Area – Sub Unit FAHUD OIL PRODUCTION STATIONS - Production Operator and

Supervisor

Hazard Crude oil

RAM: Medium


Irritant to eyes, skin and respiratory tract. H2S effects at low levels: irritation of respiratory system and loss of smell sense RAM: 2C


IARC 1 - Human carcinogen, because contains benzene RAM: 4C

Scenario During sampling


Inhalation, Dermal, Splash Liquid


Daily 30 – 60 minutes

Exposure Limit


Medium (50-100% OEL)

ALARP Status No




Isolation In place

Engineering Need improvement


PPE In place


Training and information on hazard and task – adequate information and training on possible health effects of exposure to chemicals and how to handle them safely

Effective

PPE-Skin and eye protection: gloves, clothing and H2S detectors Effective

Safety Manual, Written protocols Effective

Hazard identification by signs/warnings/labels – readily identifiable with labels, SHOC cards/SDS.

Effective


Medical Facilities in place, First Aid, Medical Emergency Response Plan Effective

Safety Showers and eye washer Effective


1. Fix leaking in P4108 (NOCS Station). 2. Fix leaking from tunnel and floating meter in K-613 (Natih station). 3. Fix leaking from seal side in P-601 & 602 (Natih Station). 4. Study the feasibility to enclose the sever pit (T517) like other station to

prevent emitting vapours (E Station).

2

Page 32 of 59


Work Area FAHUD OIL PRODUCTION STATIONS - Production Operators

Hazard Hydrogen Sulphide containing streams with H2S > 1000 ppm mole (600

mg/kg) or >100 ppm vapour space

RAM: Medium


Inhalation: Can irritate the nose and throat. Can harm the nervous system. Symptoms may include headache, nausea, dizziness, drowsiness and confusion. A severe exposure can cause unconsciousness. Skin Contact: Causes mild to severe irritation. Symptoms include pain, redness, and swelling. Can be absorbed through the skin, but harmful effects are not expected. Any skin contact will also involve significant inhalation exposure. Eye Contact: Causes mild to severe irritation. Symptoms include sore, red eyes, and tearing. The vapour also irritates the eyes. Ingestion: Harmful. VERY ACUTE TOXIC: Chemical asphyxiation causing respiratory paralysis, irritant; unconsciousness, fatality RAM: 4C


Damage to nasal tissues. RAM: 2B

Scenario During routine inspection task


Inhalation Gas


Eventually

Exposure Limit 5 ppm


Low (10-50% OEL)

ALARP Status Yes

ALARP Justification No reported cases, controls in place



Isolation In place


Procedural Controls In place.

PPE In place


Training and information on hazard and task - adequate information and training on possible health effects of exposure to chemicals and how to handle them safely

Effective

PPE – Respirators and rig walkers, H2S detectors Effective

PPE-Skin and eye protection: gloves, clothing. Effective

Safety Manual, Written protocols Effective

Hazard identification by signs/warnings/labels - readily identifiable with labels, SHOC cards/SDS.

Effective


Safety Showers and eye washer Effective



Page 33 of 59


Work Area “B” (Bravo) Gathering Station -Production Operator

Hazard Oxygen scavenger (EC6213A)

RAM: Medium


Irritant to eyes and respiratory tract RAM: 2B


Respiratory sensitization, asthma. Limited evidence of carcinogenicity (IARC 3). RAM: 3C

Scenario Filling oxygen scavenger to the system Route & Form of Exposure

Inhalation, Dermal Liquid


Eventually

Exposure Limit


Low (10-50% OEL)

ALARP Status NO ALARP Justification Control Need improvement

Engineering Elimination, Substitution

Procedural Controls PPE

Not applicable

Not applicable Current procedures adequate. Adequate



Effective

PPE – Respirators and SCBA Effective

PPE-Skin and eye protection: gloves, clothing. Effective Safety Manual, Written protocols Effective


Not Effective



Safety Showers and eye washer Effective Remedial Actions Priority

1. Install SHOC card 2

Page 34 of 59



Main Oil Line Pumping Station (MLPS)-Production Operator

Hazard Corrosion Inhibitor (EC1304A)

RAM: Medium


Harmful if inhaled. Causes serious eye irritation. Harmful in contact with skin. May be fatal if swallowed and enters airways. RAM: 3B


IARC 2B - Possible human carcinogen. Hemolytic anemia and cataracts. Suspected Development and Reproductive human Toxicant. RAM: 4B

Scenario Supervision of filling task. During maintenance operations




Eventually

Exposure Limit


Low (10-50% OEL)

ALARP Status No



Not applicable



PPE In place


Pump transfer Effective

Safety Manual and Written protocols Effective

Training and information on hazard and task: adequate information and training on possible health effects of exposure to chemicals and how to handle them safely.

Effective


Not Effective

PPE – Respirators. Effective

PPE- Skin protection: gloves. Effective

PPE- Skin protection: clothing. Effective

PPE- Eye protection: face shield, glasses. Effective

Monitoring: Personal Measurements. Effective



Safety Showers and eye washer. Effective


1. Update SHOC card. 2. Fix the leak in the skid.

2

Page 35 of 59



“D” (DELTA) GATHERING STATION-Production Operator


RAM: Medium









Eventually

Exposure Limit


Low (10-50% OEL)

ALARP Status No



Not applicable



PPE In place





Effective


Not Effective





Monitoring Personal Measurements. Effective





1. Update SHOC card. 2

Page 36 of 59





RAM: Medium









Eventually

Exposure Limit


Low (10-50% OEL)

ALARP Status No



Not applicable



PPE In place





Effective


Not Effective








Safety Showers and eye washer. Not Effective


1. Update SHOC card (B, C, D, E & F station). 2. Install SHOC card (Natih & F station). 3. Install safety shower according to GU-817. (F station). 4. Fix leaking in corrosion inhibitor skid (F station).

2

Page 37 of 59



NATIH GATHERING STATION & “E” (ECHO) GATHERING STATION -

Production Operator

Hazard Corrosion Inhibitor (EC1168A and Corexit 7806)

RAM: Medium









Eventually

Exposure Limit


Low (10-50% OEL)

ALARP Status No



Not applicable



PPE In place





Effective


Not Effective










1. Install SHOC card (EC1168A and Corexit 7806). 2. Flush safety shower according to GU-817.

2

Page 38 of 59



“E” (ECHO) GATHERING STATION - Production Operator

Hazard Corrosion Inhibitor (EC1392A & EC1168A)

RAM: Medium









Eventually

Exposure Limit


Low (10-50% OEL)

ALARP Status No



Not applicable



PPE In place





Effective


Not Effective










1. Update SHOC card 2. Dispose redundant chemical. 3. Flush safety shower according to GU-817.

2

Page 39 of 59


Work Area/Job FAHUD OIL PRODUCTION STATIONS - Production Operators

Hazard Nickel/Cadmium (as insoluble compounds) Batteries

RAM: Medium


Irritant to skin, eyes and respiratory tract. RAM: 2B


Human carcinogen (IARC 1), skin and respiratory sensitizer. Suspected reprotoxic substance. RAM: 4C

Scenario During battery exchange


Inhalation, contact Solid


Eventually

Exposure Limit


Very Low (<10% OEL)

ALARP Status No



Not applicable



PPE In place


Confining in special area. Recipient closed. Effective

Safety Manual and Written protocols. Effective


Effective


Not Effective






Eye washer. Effective


1. Install SHOC card

2

Page 40 of 59



Hazard Sodium hydroxide

RAM: Medium


Very Toxic Acute: Corrosive to eyes, skin and respiratory tract. May cause pulmonary edema RAM: 3C


Delayed corrosive effect on skin and respiratory system. RAM: 2B

Scenario During battery exchange


Inhalation, contact Solid


Eventually

Exposure Limit


Low (10-50% OEL)

ALARP Status No



Not applicable



PPE In place


Confining in special area. Recipient closed. Effective



Effective


Not Effective






Eye washer. Not Effective


1. Update SHOC card. 2. Fix eyewash pressure. 3. Remove not existing SHOC card (Sulphuric acid)

2

Page 41 of 59




Hazard Simple Asphyxiants- Nitrogen, Mercaptans, Helium, Oxygen, Hydrogen

(gas cylinders)

RAM: Medium


Chemical Asphyxiants RAM: 4C


Scenario During supervision of cylinder installation task


Inhalation Gas


Eventually

Exposure Limit


Very Low (<10% OEL)

ALARP Status Yes


Elimination, substitution Not Applicable



PPE In place


Proper warehouse .Ventilation-General dilution. Effective


Training and information on hazard and task: adequate information and training on possible health effects of exposure to chemicals and how to handle them safely

Effective


Effective







Page 42 of 59




Hazard Demulsifier (Phasetreat 14230) (Phasetreat 3265)

RAM: Medium


Causes severe skin burns and eye damage. Causes serious eye damage. May cause respiratory irritation. May cause drowsiness or dizziness. May be fatal if swallowed and enters airways. RAM: 3B


IARC 2B - Possible human carcinogen. RAM: 4B





Eventually

Exposure Limit


Low (10-50% OEL)

ALARP Status No



Not applicable but substance must be restricted in use



PPE In place


Pump transfer (System) Effective



Effective


Not Effective










1. Update SHOC card (C & E station, Phasetreat 14230). 2. Update SHOC card (E station, Phasetreat 3265). 3. Install SHOC card (Phasetreat 3265, B station). 4. Install SHOC card (Phasetreat 14230, D & Natih station). 5. Fix eyewash and safety shower (E station) 6. Fix safety shower near Demulsifier skid (Phasetreat 14230, Natih Station). 7. Install safety shower according to GU-817 (C station, Phasetreat 14230).

2

Page 43 of 59




- Production Operator

Hazard Emulsifier

RAM: Medium


Causes severe skin burns and eye damage. Causes serious eye damage. May cause respiratory irritation. May cause drowsiness or dizziness. May be fatal if swallowed and enters airways. RAM: 3B


IARC 2B - Possible human carcinogen. RAM: 4B





Eventually

Exposure Limit


Low (10-50% OEL)

ALARP Status No






PPE In place





Effective


Not Effective










1. Install SHOC card (MLPS) 2. Install exhaust fan in chemical storage room (MLPS). 3. Update SHOC card (D & B station). 4. Install safety shower according to GU-817 (MLPS).

2

Page 44 of 59


Work Area/Job Main Oil Line Pumping Station (MLPS) - Production Operator

Hazard Biocides (EC6477A)

RAM: Low


Base on substances presence RAM: 2B


Based on substances presence: Systemic effects RAM: 2B

Scenario Cooling water tower additive, water treatment, production well treatment, i.e. sodium/calcium hypochlorite as inorganic.




Weekly 1 - 2 hours

Exposure Limit


Medium (50 - 100% OEL)

ALARP Status No ALARP Justification Controls need improvement Elimination, Substitution Not applicable


Procedural Controls well implemented

PPE Adequate



Effective


PPE-Skin and eye protection: gloves, clothing. Effective Safety Manual, Written protocols Effective


Not Effective



Safety shower and Eye washer Not effective

Remedial Actions Priority 1. Update SHOC card. 2. Fix safety shower pressure. 3. Flush emergency safety showers every week according to PDO GU-817

2

Page 45 of 59


Work Area/Job Main Oil Line Pumping Station (MLPS) - Production Operator

Hazard PH correction (Steamate NAO840)

RAM: Medium


Base on substances presence: Irritant to eyes, skin and respiratory tract RAM: 2B


Based on substances presence: Systemic effects RAM: 4B

Scenario Boiler feed water treatment plants, steam production, ph corrector, ph controller




Weekly 1 - 2 hours

Exposure Limit


Medium (50 - 100% OEL)

ALARP Status Yes ALARP Justification Controls in pace/ implemented Elimination, Substitution Not applicable


Procedural Controls well implemented

PPE Adequate



Effective


PPE-Skin and eye protection: gloves, clothing. Effective Safety Showers and eye washer Effective Hazard identification by signs/warnings/labels - readily identifiable with labels, SHOC cards/SDS.

Effective



Safety shower and Eye washer Effective


Page 46 of 59



FAHUD OIL PRODUCTION STATIONS - - Production Operator

Hazard METHANOL

RAM: Low


Irritant to eyes, skin and respiratory tract. CNS effects, unconsciousness. Can cause blindness. RAM: 3B


Dermatitis, persistent or recurring headaches, impaired vision. Suspected reprotoxic substance. RAM: 3B

Scenario Hydrate control, field operations (hydrates, inhibitor. Auxiliary chemical, storage (bulk and drums), truck delivery and transfer




Eventually

Exposure Limit


Low (10-50% OEL)

ALARP Status No






PPE In place





Effective


Not Effective










1. Install SHOC card (C station). 2. Update SHOC card (Natih, B & E station). 3. Move Methanol to shielded area (Natih station).

2

Page 47 of 59


Work Area “D” (DELTA) GATHERING STATION- Production Operator

Hazard Scale Inhibitor (KT170)

RAM: Medium


Corrosive to eyes, skin and respiratory tract. Can cause kidney failure, brain damage or blindness. RAM: 3B


Defatting of the skin, dermatitis. Effects on CNS RAM: 2B

Scenario Used during crude production Route & Form of Exposure



Eventually

Exposure Limit


Low (10-50% OEL)

ALARP Status No ALARP Justification Controls need improvement Elimination, substitution,

isolation Not Applicable



PPE In place


Confined recipient. Effective Ventilation-General dilution: A/C. Effective Safety Manual and Written protocols. Effective


Effective


Not Effective

PPE- Respirators Effective


PPE- Skin protection: clothing. Effective PPE- Eye protection: face shield, glasses. Effective



Safety shower and Eye washer. Not Effective Remedial Actions Priority

1. Install SHOC card. 2. Fix eyewash.

2

Page 48 of 59


Work Area “D” (DELTA) GATHERING STATION- Production Operator

Hazard H2S scavenger (EC9021A)

RAM: Medium


Corrosive to eyes, skin and respiratory tract. Can be fatal by inhalation or skin absorption. Can effect liver, kidney or CNS. RAM: 4B


IARC 2A - Probably human carcinogen. Skin sensitizer, damage to liver, kidney and CNS. Suspected Development and Reproductive Human Toxicant RAM: 4B

Scenario used in hydrocarbon and chemical processing Route & Form of Exposure



Eventually

Exposure Limit


Low (10-50% OEL)

ALARP Status No ALARP Justification Controls need improvement Elimination, substitution,

isolation Not Applicable



PPE In place


Confined recipient. Effective Ventilation-General dilution: A/C. Effective Safety Manual and Written protocols. Effective


Effective


Not Effective

PPE- Respirators Effective


PPE- Skin protection: clothing. Effective PPE- Eye protection: face shield, glasses. Effective



Safety shower and Eye washer. Effective Remedial Actions Priority

1. Install SHOC card. 1

Page 49 of 59



Hazard Diesel, Distillates, Gas Oils and Heating Oils

RAM: Medium


Irritant to respiratory tract (by inhalation of mist) and eyes. Contains organic solvents which in case of overexposure may depress the central nervous system Causing dizziness and intoxication. May be fatal if swallowed and enters airways. RAM: 3C


IARC 2B Possible human carcinogen. Suspected Development and Reproductive human Toxicant. May cause damage to the following organs: Blood. Liver.Thymus. Defeating of the skin, dermatitis RAM: 4B

Scenario Distillate process streams, separated crude oil distillates, and marketed fuel products. Storage tanks, separator vessels, vehicle fuel.


Inhalation, Dermal, splash Liquid


Occasionally (in field area)

Exposure Limit 100 mg/m3 (as total hydrocarbon)


LOW (10-50% OEL) Contracted workers do fuel handling (loading in storage tank & vehicles).

ALARP Status No

ALARP Justification Control need improvement

Elimination, Substitution Not applicable

Engineering Control Not applicable

Procedural Controls Current procedures adequate.

PPE Adequate


Hazard identification – readily identification with labels, SHOC cards/SDS Not Effective

Safety manual, written protocols, personal hygiene practice. Effective

Training and information on hazard and task- adequate training on health hazard & control measures to minimize exposure.

Effective

PPE-Skin protection: gloves, clothing - Appropriate gloves are readily available for use where direct contact is deemed probable

Effective




1. Install SHOC card 2

Page 50 of 59



Hazard Natural Gas Condensate RAM: Medium


Irritation of the eyes and respiratory tract, CNS depression RAM: 2C


Human carcinogen (IARC 1), damage to bone marrow and immune system, dermatitis. RAM: 4B

Scenario During field operations sampling Route & Form of Exposure

Inhalation, contact dermal Vapor


Eventually

Exposure Limit


Low (10-50% OEL) No data to determine exposure level but several controls in place

ALARP Status Yes ALARP Justification Controls are effective/ implemented

Elimination Elimination not practicable. Substitution Substitution not practicable.

Procedural Controls PPE

Protocols in place Adequate



Effective


PPE-Skin and eye protection: gloves, clothing. Effective Safety Showers and eye washer Effective Safety Manual, Written protocols Effective


Effective




Page 51 of 59




Hazard Combustion particulates/toxic smoke (including Diesel exhaust and CO2)

RAM: Medium


Irritation of eyes and respiratory tract. RAM: 2C


IARC 2A - Probably human carcinogenic. CO2 is a suspected development and reproductive human toxicant. RAM: 4B

Scenario During burning of condensates and other gases Route & Form of Exposure

Inhalation, contact Particle


Eventually

Exposure Limit


Very Low (<10% OEL)

ALARP Status Yes ALARP Justification Controls are in place

Elimination, Substitution, isolation

Not applicable

Engineering Applicable Procedural Controls In place

PPE In place


Open space – natural ventilation. Effective Flare System. Effective Safety Manual and Written protocols. Effective


Effective


Effective


PPE- Skin protection: clothing. Effective PPE- Eye protection: face shield, glasses. Effective Environmental Monitoring. Effective Recovery Measures Effectiveness



Page 52 of 59




Hazard Unknown chemicals during an emergency

RAM: Medium


Various including irritation, asphyxiation, burns (if corrosive). RAM: 4B


Dependant of the chemical potential damage (systemic, carcinogen). RAM: 4B

Scenario During an emergency (fire, reactions, combustion)


Inhalation Gas


Eventually

Exposure Limit


Very Low (<10% OEL)

ALARP Status Yes



Not applicable



PPE In place


Open space – natural ventilation. Effective



Effective


Effective




Environmental Monitoring. Effective



Respiratory Protection and SCBA Effective


Page 53 of 59


5. Control statements for Low RAM Hazards

Work Area – Sub Unit/Job Hazard CONTROLS NEED IMPROVEMENT? MORE DETAILED ASSESSMENT?

FAHUD OIL PRODUCTION STATIONS (Control Room)

Indoor climate No


Fungus/mold growth, or bioaerosols No


Virus of colds, influenza, and Norovirus No

Production Operators and Supervisors

Histoplasma Capsulatum No

FAHUD OIL PRODUCTION STATIONS (indoors-outdoors)

Visible light (too much; too little) - wavelength 400 - 780 nm (non-ionizing radiation)

No


Infrared (IR) – wavelength 780 1 mm (non-ionizing radiation)

No


Radiowave/Microwave radiation - wavelength 1 mm - 30 km (non-ionizing radiation)

No


Extremely Low Frequency magnetic radiation (ELF) - wavelength: > 30 km (non-ionizing radiation)

No


Detergents No


Solvents / Degreasers No


Hydrocarbons, VOC (total vapor) No


Particulates (total, not classified) No


Hydrocarbon Gas (EP), Hydrocarbons Light (<C5's) (e.g. Methane, LPG)

No


Lubricating Oils, C16-C35 Hydrocarbons (includes oil mist and glycerin) and Greases (< 3%PCAH Content). Includes oil mist and glycerin

No


AFFF foam extinguisher No

Production Operators ABC dry powder No

Production Operators Manmade or synthetic vitreous fibres No


Produced water for hydrocarbon production (brines)

No


Water softener salt (NaCl) No


Lubricant Oils, C16-C35 Hydrocarbons and Greases (< 3%PCAH Content). Includes oil mist and glycerine

Yes, see remedial action for chemicals


Hydrocarbon gas, liquid and H2S (off plot)

No


Hydrocarbon gas and H2S (on plot - flaring / venting)

No


Crude oil under pressure (on plot) No


Steam production and distribution system - HP, HT steam

No

Page 54 of 59


Work Area – Sub Unit/Job Hazard CONTROLS NEED IMPROVEMENT? MORE DETAILED ASSESSMENT?


Methanol Yes see specific appraisal


Solisep MPT150 No


CITRIC ACID Yes, see remedial action for chemicals

Page 55 of 59


6. Generic Controls and Recovery Measures



Structural integrity: Surface Structures, Heavy lift cranes and mechanical handling, HFE design

Effective

Process containment: pressure vessels, heat exchangers, rotating equipments, piping system, pipelines, relief system, well containment, cathodic protection

Not Effective

Ignition control: certified electrical equipment, earth bonding, flare ignition control system Effective

Detection system: fire and gas Effective

Protection system: Emergency shutdown, sand filters, chemical injection, fire water pumps, ring main, foam injection, blanked gas, closed drain systems.

Effective

DCS/SCADA systems Effective

Shutdown system: ESD system, depressurization, HIPPs, pipeline isolation valves, process isolation, relief and blow-down system.

Effective

Maintenance Integrity Execution (MIE) Effective

Permit to Work (PTW) system Effective

Warehouse and shelters: Separate containing. Non-reactive containers. Effective

Order and housekeeping. Not Effective

Asset Register Verification, HSE audits, Inspections and reviews. Effective

Plant Operation Manual. Effective

HSE studies and assessments Effective

HSE meetings (rules, protocols, LFI’s) Effective

Area restrictions and limited schedules - Availability of air-conditioned offices on site, cool rest areas and drinking water

Effective

Operations Competence, Development and Assurance system Effective


Emergency response: escape/evacuation routes, designated areas, communication system, UPS, power and lighting, locations of fire/gas alarms, fire extinguishers, fire blankets and open hazardous system, decontamination system.

Not Effective

Personal survival equipment (SCBA) and escape hoods Effective

Remedial Actions

See Section 3.

Page 56 of 59


Appendix 1: Definitions Acute Health Effect Health Effect that occurs immediately or a short time (seconds to hours) following exposure, such as heat stroke, chemical burns and asphyxiation. Agent See Hazard ALARP - As Low As Reasonably Applicable The point at which the cost (in time, money and effort) of further Risk reduction is grossly disproportionate to the Risk reduction achieved. Barrier A Risk Control or a Recovery Measure. Barriers provide the means of preventing an Event or Incident, or of mitigating the Consequences. A Barrier can be an item of equipment or a human intervention, and can also be a Control on an Escalation Factor. Chronic Health Effect Health Effect that occurs gradually over a long period of time (months or years), generally following repeated and prolonged exposure. In specific cases a short term exposure may result in a chronic health effect. Consequence An Effect on people, assets, the environment or reputation as a result of a Hazard being released. Control A means of preventing an Incident. Controls can be engineering, procedural or behavioural. Critical Activity An activity necessary for the development, implementation or maintenance of a Barrier established for managing Hazards with RAM red Risks. Effect The Consequence of the release of a Hazard. Escalation Factor A situation, condition or circumstance that may lead to the partial or full failure of a Barrier. Event An Incident that occurs when a Hazard is released. Exposure Limit The airborne concentration of chemical agents and levels of physical agents to which nearly all workers may be repeatedly exposed day after day without adverse Effect. Exposure Rating The chance of over-exposure to a health hazard when compared against agreed control standards. The exposure rating is evaluated as Very Low, Low, Medium or High. Hazard An agent with the potential to cause harm to people, damage to Assets, or an Impact on the environment or reputation. Health Hazard A factor of a physical, chemical, biological, ergonomic or psychological nature with the potential to cause harm to the health of people. HRA - Health Risk Assessment

Page 57 of 59


A process of identifying, evaluating, controlling and managing Health Risks, associated with work to prevent acute and chronic health Effects. Incident An unplanned Event or chain of Events that has, or could have, resulted in injury or illness or damage to Assets, the environment or reputation. Likelihood The probability that a specified Consequence will happen. OEL – Occupational Exposure Limit The airborne concentration of chemical agents and levels of physical agents to which nearly all workers may be repeatedly exposed day after day without adverse effect. RAM - Risk Assessment Matrix A tool used to assess the Consequences and Risks of Hazards to HSSE. The results are referred to as a RAM Severity rating and a RAM Risk rating. Recovery Measure A Barrier that reduces the Consequences of the release of a Hazard as a result of an Incident. Recovery Measures can be engineering, procedural or behavioral measures. Remedial Action Plan RAP - A Plan to implement corrective action items. Risk The combination of the Consequence of a specific Hazard being released and the Likelihood of it happening. Risk Assessment The process of identifying the Consequences of the Worst Case Credible Scenario arising from the release of a Hazard, and estimating the Likelihood of that scenario. Severity A level of Consequence on the RAM on a scale of 0 to 5. TBD To be determined.

Page 58 of 59


Appendix 2: Risk Assessment Matrix

Page 59 of 59


Appendix 3: List of Jobs included

Production Operators

Production Supervisor

Production Coordinator

Administrative jobs (e.g. managers, planners)

Helpers and trainees

Note: Maintenance personnel/jobs/tasks are included in PDO Maintenance HRAs (North and South)