Petroleum Development Oman L.L.C.€¦ · Keep all barriers/gates to hydrocarbon/process handling facilities closed; open only to those with a valid access permit. Ensure control

Printed: 19/02/2018 Printed copies of this document should be treated as information of temporary value and destroyed after use

Petroleum Development Oman L.L.C.

Mabrouk Central Processing Facility (MCPF)

Document ID HRA

Document Type

Security Restricted

Discipline

Document Owner

Month and Year of Issue November 30, 2017

Version 4.0

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 40


Document Authorisation

Document Owners Document Custodian

To be filled Petrizzo, Jose MCOH1

Revision History

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

prior to these are held on file by the Document Custodian.

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 cur-rent. For assistance, contact the Document Custodian.

2. Users are encouraged to participate in the ongoing improvement of this document by providing construc-tive 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

1.0 24 April 2014 Jose F.Petrizzo

Ref. Ind: MCOH1 PDO GAS PLANTS Issued for approval

2.0 16 June 2014 Jose F.Petrizzo

Ref. Ind: MCOH1

Updated to include Lekhwair Gas Plant Project

3.0 26 September

2016

Jose F.Petrizzo

Ref. Ind: MCOH1

Updated to include Zauliyah Gas Plant Project

4.0 30 November

2017

Jose F.Petrizzo,

MCOH/1


Review health Risks and control. Perform specific

HRAs for each plant.

Page 3 of 40


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 40


Table of Contents

0. INTRODUCTION TO THE HRA REPORT 5

1. HRA SCOPE 5

2. HRA TEAM 8

3. REMEDIAL ACTIONS 9

4. HEALTH HAZARD INVENTORY AND DETAILED RISK APPRAISALS 11

5. CONTROL STATEMENTS FOR LOW RAM HAZARDS 35

6. GENERIC CONTROLS AND RECOVERY MEASURES 36

APPENDIX 1: DEFINITIONS 37

APPENDIX 2: RISK ASSESSMENT MATRIX 399

APPENDIX 3: LIST OF SPECIFIC JOBS INCLUDED 40

Page 5 of 40

Printed copies of this document should be treated as information of temporary value and destroyed after use Printed: 19/02/2018

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

The Mabrouk field is located approximately 45 km South West of the Saih Rawl field and 35 km North West of the Barik field. Figure 1 shows the location of the Mabrouk field. There is little local population, with only Beduine settlements scattered sparsely around the area surrounding the MCPF. The area is a desert plain, comprising alluvial gravel fans arising from several wadis. Figure 1 illustrates Mabrouk Field location.

Figure 1: Mabrouk Field location.

Page 6 of 40


Figure 2 illustrates the MCPF interfaces with the gas gathering system and plants.

Figure 2: MCPF Interfaces with the Gas Gathering System and Gas plants

The main objectives of the MCPF are to:

Receive oil, water and gas from Mabrouk wells.

Separate gas and gross liquid (crude oil / water).

Compress the separated gas and export it to SR-CPP.

Pump the gross liquid (crude oil / water) to Saih Rawl Oil station (SROS).

MCPF includes the following main facilities:

Off-plot gathering facilities.

Inlet separators.

Gas compression facilities.

Gross liquid export facilities. Figure 3 illustrates the MCPF Block flow diagram.

Figure 3: MCPF Block Flow diagram

Page 7 of 40


Principal Production Operator Accountabilities are:

Perform visual inspection of all facilities and equipment as part of daily checks.

Perform visual inspection of all wellhead facilities and equipment as part of daily checks.

Perform routine inspection of pipelines and flow lines to ensure all are on sleepers and report abnormalities or leaks to leaders/supervisors.

Verify that a monthly routine inspection of all rotating equipment is performed in accordance with rotating equipment maintenance and inspection procedures.

Carry out testing and maintenance of all LPG equipment including hoses and connections and report any ab-normalities to leaders/supervisors.

Carry out visual inspections of all LPG equipment including hoses and connections in accordance with inspec-tion schedule.

Review the LO/LC register for its accuracy and completeness. Ensure LO/LC register is updated to reflect cur-rent operating conditions.

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

Maintain the overrides log book for the station.

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.

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

Ensure control room operator monitors annulus via DCS.

In event of failure of flare ignition system, ignite flare manually using flare gun in accordance with company pro-cedures.

Verify compliance to speed limits within hydrocarbon facilities and stop/report any offenders.

Principal Production Supervisor Accountabilities are:

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

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

Verify that all heavy machinery movement within vicinity of process and hydrocarbon facilities is done by ap-proved contractors and in accordance with PDO PTW authorization process.

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

Verify that LO/LC register is implemented by operations and subject to regular update. Perform routine compli-ance checks to verify that the LO/LC register is implemented and maintained.

Perform regular field surveillance and ensure that sand accumulation on flow lines and interfield pipelines is removed as required.

Restrict vehicle access to site through PTW system.

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

Verify TVP is monitored online. Verify off spec condensate (TVP) is automatically routed to off spec storage tanks.

Develop, implement and update as required LPG Loading Procedures for all loading activities. Ensure proce-dures are included in POMs and comply with PTW system requirements.

Implement PDO Cold Venting Procedure at remote manifolds (pigging) and SRS (blowdown).

Mobilize sand suckers and JCBs to remove all accumulated sand.

Develop, implement and update as required start-up and shut-down procedures for planned start-ups/shutdowns. Ensure procedures are included in POMs.

Ensure all personnel report all major condensate spills to LEBC in accordance with company procedures.

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

Principal Production Coordinator Accountabilities are:

Approve requests for temporary overrides of overpressure instruments and valves.

Establish and provide speed limit sign boards inside process facilities and hydrocarbon areas.

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

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

Review request for operation variance waiver. Ensure all operation variance waivers are approved by Opera-tions Manager and Corporate Functional Discipline Head (Technical Authority). Monitor operation variance waiver to ensure it does not extend beyond prescribed time limits.

Verify sampling and testing of the LPG composition is performed on all on plot equipment and lines including the buried LPG line to ensure complying with process requirements.

Page 8 of 40


Verify sampling and testing of the condensate composition performed to ensure complying with process re-quirements.

Review and evaluate requests for temporary overrides of instruments and ESD valves for Qarn Alam and for Yibal.

Verify inflow testing of replaced gaskets is carried out for high pressure wells ensure SSSV is closed and sur-face equipment is isolated and depressured prior to handover to well engineering.

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

Ensure interface between gas and power operations at CPP IPS for planned startup/shut-down of HTF system.

Implement PDO H2S Management Procedures.

Develop implement and maintain the Gas Operations Contingency Plan. Verify that drills and exercises are car-ried out to test the effectiveness and relevance of the plan's contents.

Verify that when required (e.g. adverse weather) weather reports are communicated to all stations and are dis-played for employee information. Verify that operations follow conditions outlined in the Matrix of Permitted Op-erations.

Verify that sufficient resources are available for planned activities.

Ensure that adequate means for MEDEVAC are established for the field (i.e. air and road). Co-ordinate all MEDEVAC operations in the field. Perform regular MEDEVAC drills and exercises. Ensure that quarterly medi-cal drills and exercises are performed.

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

Verify that all personnel have undertaken PTW training and passed the area interview prior to undertaking ac-tivities under PTW system.

Verify that all personnel in field complete the Site induction.

3. HRA Team

Responsible for HRA: Petrizzo, Jose MCOH1 Al Adwani, Haitham MCOH6

Input Provided By: To be filled

Page 9 of 40


3. Remedial Actions

Priority Work Area / Job Risk, Exposure Rating and Scenario Recommended Remedial Action / Date / Resp. 1


Psychological Hazards and Stress

Medium Frequent organizational changes, tight schedules

1. Implement Resilience program- determined on need

of individual. Resp: Siddiqi, Saqib (MU61227) - GGE/16 Date: 30/09/2018

2

Operator/Supervisor/Coordinator/All Administrative functions including GNOC

Use of control Panels, Computer/Display

Screen Equipment

Medium Office jobs involving typing, mousing, reading and/viewing monitors

1. Provision of new ergonomic chairs for SR CPP CR.

Resp: Siddiqi, Saqib (MU61227) - GGE/16 Date: 30/09/2018

2


General Controls: Chemical Warning signals and SHOC cards Medium

1. Install new warning signals and updated SHOC cards

for all chemicals used in site.


2


Recovery Measures: Safety Showers and Eye washers Medium

1. Review all sites’ emergency showers and eyes wash-

ers and proceed to fix and adequate for purposes.


Page 10 of 40


Priority Work Area / Job Risk, Exposure Rating and Scenario Recommended Remedial Action / Date / Resp. 2


General Controls: Control Room facilities Housekeeping Low

1. Maintenance and clean schedules to be reviewed and

process improved.


3 Mabrouk Central Processing Facility (MCPF)

General Recovery Measures: Emergency response Low

1. Undertake assessments to ensure adequacy of the

existing emergency arrangement for Mabrouk Central Processing Facility (MCPF) including MEDEVAC.


3


General Controls: Wind Socks Low

1. Review all sites’ wind socks and replace damaged.


Page 11 of 40


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 are 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 - There is effective waste management process in place.

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 12 of 40




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 Route & Form of Exposure

Dermal


Eventually

Exposure Limit


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


Elimination Not applicable Substitution Not applicable

Isolation Not applicable Engineering In place

Procedural Controls In place PPE In place

Controls Effectiveness

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 13 of 40




Hazard Insect, spiders, scorpions, bees

RAM: Medium


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


Allergic reaction, secondary infection. RAM: 3B

Scenario During outdoors activities Route & Form of Exposure

Dermal Other


Eventually

Exposure Limit


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






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 14 of 40




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

Route & Form of Exposure

Inhalation


Daily 1 – 2 hours

Exposure Limit See PDO PR-2109


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

ALARP Status Yes ALARP Justification Controls in place/implemented Elimination, substitution,

isolation Not applicable


PPE Not applicable Controls Effectiveness

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 Recovery Measures Effectiveness



Page 15 of 40




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 Route & Form of Exposure


Daily 2 – 4 hours

Exposure Limit


Medium (50-100% OEL) The subjective opinion is that the unit is functioning within an expected range of variability for stress.

ALARP Status No ALARP Justification Improve communications and development of self skills to prevent stress Elimination, substitution,


Engineering Not applicable Procedural Controls Implement Resilience Program


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 Recovery Measures Effectiveness

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

Effective


Remedial Actions Priority Implement Resilience program determined on need of individual 1

Page 16 of 40




Hazard Heat Stress / Hot Temperature Differentials

RAM: Medium


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


Dermatitis. RAM: 2C

Scenario Exposure during outdoor activities Route & Form of Exposure


Daily 1 – 2 hours

Exposure Limit See 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%.






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 Recovery Measures Effectiveness



Page 17 of 40


Work Area – Sub Unit/Job/Job

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. Route & Form of Exposure


Eventually

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


Very Low (<10% OEL) Effective radiation management system in place by PDO



Isolation Not applicable Engineering Applicable



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 Recovery Measures Effectiveness

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


Page 18 of 40




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 Route & Form of Exposure


Daily 1 – 2 hours

Exposure Limit See TLvs ACGIH


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




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 19 of 40




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) Route & Form of Exposure


Daily 1 – 2 hours

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


Shut down condition

ALARP Status TO BE DEFINED ONCEOPERATIONS START ALARP Justification Controls need improvement Elimination, substitution Not applicable

Engineering Applicable. Cormpressors have isolation systems Procedural Controls In place

PPE In place


PPE-Hearing protection 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 Effective Monitoring: Noise mapping Effective Recovery Measures Effectiveness



Page 20 of 40




Hazard Whole Body Vibration

RAM: Medium


Muscular discomfort or fatigue, or tingling or numbness in the body. RAM: 1D


Lower back pain or lower lumbar disorders. RAM: 3D

Scenario While working in compressor’s areas Route & Form of Exposure


Daily 15 – 30 minutes

Exposure Limit PDO SP-1231


Low (10-50% OEL) Exposures average less than 1 hours/day. No data available.




Procedural Controls In place PPE Not applicable


Administrative controls, such as area restrictions and limited schedules - Periodic break part of job routine.

Effective

Training and information on hazard - Adequate hazard information and training provided. Early reporting of any discomfort encouraged.

Effective

Preventive maintenance - Preventive equipment maintenance to minimize level of vibration being carried out.

Effective

Fitness to Work - Fitness to Work medical certification protocol for Heavy Equipment Operators is in place to ensure that they are in optimum health. Process is managed by the site HSE supervisor.

Effective


Physiotherapy - Effective physiotherapy service locally available to manage musculoskeletal disorders.

Effective


Page 21 of 40



Operator/Supervisor/Coordinator/All Administrative functions including

GNOC

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. Route & Form of Exposure


Daily 6 – 8 hours

Exposure Limit


Medium (50-100% OEL) Ergonomic furniture is not provided. RSI symptoms are exceptional or not reported.

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


Engineering Applicable Procedural Controls In Place


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

Not 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 Recovery Measures Effectiveness

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

Remedial Actions Priority Provision of new ergonomic chairs for Yibal and remote CCR 2

Page 22 of 40



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.




Exposure Limit


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



Isolation Not applicable Engineering Lifting equipment

Procedural Controls In place 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 23 of 40




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 bac.k RAM: 3D

Scenario During routine field inspections Route & Form of Exposure


Eventually

Exposure Limit


Low (10-50% OEL)

ALARP Status Yes ALARP Justification Controls need improvement

Elimination, substitution, isolation

Not applicable.

Engineering In place but needs improvement

Procedural Controls In place

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 Recovery Measures Effectiveness



Remedial Actions Priority Provide mobile suitable platform to access valves at height over 1.8 m. 2

Page 24 of 40




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 Route & Form of Exposure


Daily 1–2 hours

Exposure Limit


Low (10-50% OEL)


Elimination Not applicable. Substitution Not applicable.

Isolation Not applicable. Engineering In place

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 Recovery Measures Effectiveness




Page 25 of 40


Work Area – Sub Unit Production Operator and Supervisor

Hazard Crude oil (contains low concentrations of Benzene in liquid phase)

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 routine inspection and sampling Route & Form of Exposure

Inhalation, Dermal, Splash Liquid



Exposure Limit


Low (10-50% OEL)



Engineering In place


PPE In place


Design and equipments; safety critical elements 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 mercury and how to handle them safely.

Effective

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

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 Recovery Measures Effectiveness


Safety Showers and eye washer. Not Effective Remedial Actions Priority

Page 26 of 40




Hazard Mercury

RAM: Medium


Very Toxic Acute: poisoning, neurological effects. Fatal if inhaled. RAM: 3B


Effects on kidneys and central nervous system, emotional and psychological disturbances. Recognized Development and Reproductive Human Toxicant. RAM: 3C

Scenario During Supervision of vessel/piping maintenance, intrusive operations and disposal of mercury


Liquid and vapor Inhalation an contact


Eventually

Exposure Limit TLVs ACGIH: 0,01 mg/m3 alkyl comp


Low (10-50% OEL)

ALARP Status Yes

ALARP Justification Controls in place/implemented


Not applicable



PPE In place


Ventilation-open space-General dilution. Effective Safety Manual and Written protocols: SP-1231, SP-2087, PR-1515. Effective

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

Effective


Effective





Safety Showers and eye washer. Not Effective

Remedial Actions Priority Finalize Traps installation in MRUs vessels upstream 1 Enhance supervision during intrusive maintenance tasks 2

Page 27 of 40




Hazard Corrosion Inhibitor (NALCO 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 Route & Form of Exposure

Inhalation, Dermal Liquid


Eventually

Exposure Limit


Low (10-50% OEL)





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







Page 28 of 40




Hazard Natural Gas Condensate (contains benzene)

Medium


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


IARC 1 - Human carcinogen. Damage to bone marrow and immune system, dermatitis. Dermatitis. May cause genetic damage. Recognized Development and Reproductive Human toxicant. RAM: 4B

Scenario During field operations - sampling Route & Form of Exposure

Inhalation, contact dermal Vapor, liquid


Eventually

Exposure Limit Benzene TLV ACGIH: TWA: 0.5 ppm / STEL: 2.5 ppm


Low (10-50% OEL)





Condensate handle and treatment facilities. 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 Condensates and how to handle them safely.

Effective


Effective







Page 29 of 40



Production Operator

Hazard Diesel

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. Defatting of the skin, dermatitis. RAM: 4B

Scenario During filling supervision Route & Form of Exposure

Inhalation, Dermal, splash Liquid


Weekly 1 hour

Exposure Limit


Low (10-50% OEL)



Not applicable


PPE In place


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


Effective


Effective


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




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Work Area/Job Production Operator and Supervisor

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 Route & Form of Exposure

Inhalation, contact Solid


Eventually

Exposure Limit


Very Low (<10% OEL)



Not applicable


PPE In place


Confining in special area. Recipient closed. Effective Safety Manual and Written protocols. Effective


Effective


Effective




Eye washer. Effective


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Work Area Production Operator

Hazard Caustics (Strong Alkalis) – Sodium Hydroxide

RAM: Medium


Delayed corrosive to skin and eyes. Respiratory irritant, may cause pulmonary edema. RAM: 3C


Corrosive effect on skin and respiratory system. RAM: 2B

Scenario During supervision of battery refill Route & Form of Exposure

Inhalation, Dermal Liquid


Eventually

Exposure Limit


Low (10-50% OEL)


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



Eye washer. Effective


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Production Operator

Hazard Simple Asphyxiants- Nitrogen-inert blanket gas, Mercaptans, Helium,

Oxygen, Hydrogen (gas cylinders)

RAM: Medium


Chemical Asphyxiants RAM: 4C


Scenario During supervision of cylinder installation task Route & Form of Exposure

Inhalation Gas


Eventually

Exposure Limit


Very Low (<10% OEL)

ALARP Status Yes ALARP Justification Controls in place/implemented Elimination, substitution Not Applicable



PPE In place


Proper warehouse .Ventilation-General dilution. 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


Effective





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

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


Low (10-50% OEL)



Not applicable


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


Safety Showers and eye washer Effective


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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) Route & Form of Exposure

Inhalation Gas


Eventually

Exposure Limit


Very Low (<10% OEL)





Open space – natural ventilation. 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

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

Respiratory Protection and SCBA Effective


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5. Control statements for Low RAM Hazards

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

Mabrouk Central Processing Facility (MCPF) (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

Mabrouk Central Processing Facility (MCPF) (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


Triethylene Glycol (TEG)

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


ABC powder and CO2 No

Production Operators Man made or synthetic vitreous fibers No


Produced water for hydrocarbon pro-duction (brines)

No

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6. Generic Controls and Recovery Measures

Work Area Mabrouk Central Processing Facility (MCPF) Controls Effectiveness

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, fired heaters, cathodic protection

Effective

Ignition control: certified electrical equipment, earth bonding, flare ignition control system Effective Detection system: fire, heat, gas, H2S and smoke, security, water measurements Effective Protection system: sand filters. Chemical injection, ESD Not Effective DCS/SACADA systems Effective Shutdown system: depressurization, HIPPs Insufficient info Material and integrity management system Not evidence Maintenance Integrity Execution (MIE) Effective Permit to Work (PTW) system Effective

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

Asset Register Verification, HSE audits, Inspections and reviews Effective

Plant Operation Manual Effective HSE studies and assessments (HAZID, HAZOP, QRA, FERM) Not 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 Recovery Measures Effectiveness

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

Not Effective

Personal survival equipment (SCBA). Effective Remedial Actions See Section 3.

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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 behavioral. 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.

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HRA - Health Risk Assessment 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 39 of 40


Appendix 2: Risk Assessment Matrix

Page 40 of 40


Appendix 3: List of Jobs included

Production Operators

Production Supervisor

Production Coordinator

GNOC Operators

Administrative jobs (e.g. managers, planners)

Helpers and trainees

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