Management of Workplace Safety, Health and Environment: CN3135 Soh Guat Hiong

Management of Workplace
Safety, Health and

Environment
CN3135
Soh Guat Hiong
10/21/2015
NUS CN3135 SHE Management
Learning Outcomes
1. Describe the elements of SS506: Part 3:
2013 for Chemical Industry
2. Meet legal requirements of SHE
management
3. Application of permit to work system
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SHE Management System

A systematic process for managing SHE, providing for
goal setting, planning, performance measurements,
and clear management commitments and direction
Helps create a safer work environment, provide a
measureable system to verify SHE performance,
improve business opportunities, and enhance an
organisations reputation and image
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SHE Management Systems

A commitment by the organisation to:
Provide a safe and health workplace for employees and
contractors
Identify workplace hazards, conduct risk assessment and
control of all risks
Managers, supervisors and employees be actively
involved to prevent incidents and ill-health at the
workplace
Provide information and training for employees at all
levels so they can work safely
Audit and review the SHE management system
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Workplaces to Implement WSHMS

2nd Schedule, WSH (Safety and Health Management
System and Auditing) Regulations 2009
Worksite
Shipyard
Manufacturing of metal products, machinery or
equipment with >100 workers
Manufacturing or processing of petroleum, petroleum
products, petrochemicals or petrochemical products
Bulk storage of toxic or flammable liquid >5000m3
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Workplaces to Implement
WSHMS under WSHA
Manufacture of fluorine, chlorine, hydrogen
fluoride, carbon monoxide and synthetic
polymers
Manufacturing of pharmaceutical products or
intermediaries
Manufacturing of semi-conductor wafers
Audit to be conducted once every 2 years
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10
Workplace Safety and Health

(Registration of Factories) Regulations
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11
Examples of SHE MS
SS506: Part 1: 2009 Occupational Safety and Health
Management Systems Requirements
SS506: Part 1: 2009 Occupational Safety and Health

Management Systems Guidelines for Implementation
SS506: Part 3 : 2013 Requirements for Chemical Industry
OHSAS 18001 : 2007 Occupational Safety and Health
Management System
ISO14001: 2004 Environmental Management Systems (revision
due in 2015)
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12
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13
Plan-Do-Check-Act Cycle
Take Actions to
Continually Improve
OSH Performance
Commitment
to OSH
Monitor and
measure
processes
against policy,
objectives &
legal /other
requirements
Establish
objectives
and
Processes
Implement
Processes
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Key Requirements of SS506: Part 3 : 2013

a) Occupational Safety and Health Policy
Top management endorsement
Appropriate to nature and scale of OSH risks
Comply with legal and other requirements
Communicated to all employees and other
stakeholders under control of organisation
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15
DuPont Position Statement on Safety, Health,

and Environment Commitment
Highest Standards of Performance, Business
Excellence
We will adhere to the highest standards for the safe
operation of facilities and the protection of our
environment, our employees, our customers and the
people of the communities in which we do business.
We will manage security as we do safety.
We will strengthen our businesses by making safety,
health and environmental issues an integral part of all
business activities and by continuously striving to align
our businesses with public expectations.
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16
DuPont Position Statement on Safety, Health,

and Environment Commitment
Committed to Zero Injuries, Illnesses, and Incidents
We believe that all injuries and occupational illnesses, as
well as safety and environmental incidents, are preventable,
and are committed to a goal of zero for all of them. We will
promote off-the-job safety for our employees.
We will assess the environmental impact of each facility we
propose to construct or acquire and will design, build,
operate and maintain all our facilities and
transportation equipment so they are safe, secure and
acceptable to local communities and protect the
environment.
We will be prepared for emergencies and will provide
leadership to assist our local communities to improve their
emergency preparedness
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Petrochemical Corporation of Singapore

Process Safety Policy
Process safety leadership from top management level,
discussing process safety in board meetings, such as
reviewing process safety indicators and performance.
Demonstrating visibility and visible commitment of top
management, through site visits and open dialogues.
Providing a positive, trusting and open culture where PCS
employees and workers are encouraged to speak out
without fear or reprisal and their views on safety.
Enhancing engineered and administrative safeguards that
act to achieve or maintain a safe state of process.
Process safety improvement plan identifying priorities for
ensuring system and safeguards retain their integrity, with
continual improvement.
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Petrochemical Corporation of Singapore

Process Safety Policy
Implementing an integrated set of leading and lagging
performance indicators, which are periodically updated.
Comprehensive maintenance program and timely
rectification of faults with adequate repairs.
Suitable training and transfer of knowledge and
learning of good practices.
Reviewing industry incidents and recommendations
across major hazard sectors for learning lessons and
improvement.
Recognizing changes and ensuring that they are
appropriately documented, reviewed, approved and
communicated.
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b) Planning
Hazard identification, risk
assessment and risk control
Legal and other requirements
Setting objectives and programmes
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Hazard Identification, Risk Assessment and
Control
Proactively identify all hazard sources, situations or acts
that has potential to cause harm
Routine and non-routine activities (including emergencies)
Human behaviour, capabilities and other human factors
Infrastructure, equipment and materials used
New, including changes made
Control measures and mitigation methods for worst case
scenario
Applicable legal requirements
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Hazard Identification, Risk Assessment and Control
Process Safety Information required
Hazards of chemicals Toxicity, PELs, physical/chemical

properties. Get from Safety Data Sheet
Technology of process Process flow diagram, inventory,
operational limits, WSH consequences of deviation
Equipment, hardware and facility Safety system,
interlocks, detection, suppression systems, materials of
construction, P&IDs, relief system, ventilation system design
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Risk Assessment
Hazard Identification:
Physical (e.g. fire, noise, ergonomics, heat,
radiation)
Mechanical (e.g. moving parts, rotating parts)
Electrical (e.g. voltage, current, static charge,
magnetic fields)
Chemical (e.g., flammables, toxics, corrosives,
reactive materials)
Biological (e.g., blood-borne pathogens, virus)
Psychosocial (e.g., stress, fatigue)
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Risk Evaluation
Likelihood
Rare - Remote - Occasional - Frequent -
Almost
Severity
Certain - 5
Catastrophic - 5
10
15
20
25
Major - 4
12
16
20
Moderate - 3
12
15
Minor -2
10
Negligible - 1
Source: Code of Practice on Risk Management, Workplace Safety and Health Council
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Risk Evaluation
Risk level
Risk
Acceptability
Recommended Actions
Low
Acceptable
No additional risk control

measures
Frequent review and
monitoring of hazards
Medium
Tolerable
Ensure risk level is reduced

to as low as reasonably
practicable
Interim risk control
measures
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Risk Evaluation
Risk
level
High
Risk
Acceptability
Not Acceptable
Recommended Actions
High Risk level must be

reduced to at least Medium
Risk before work starts
No interim risk control
measures
If practicable, hazard should be
eliminated before work starts
Management review required
before work starts
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Tools for hazard identification and risk evaluation
What-if Checklist
Job Safety Analysis
FMEA
Fault Tree Analysis
HAZOP
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Risk Control
Elimination eliminate the hazard eg. use
mechanical lifter instead of manual lifting
Substitution substitute with a less hazardous
equipment or material eg. use bore piling instead of
hammer piling for a less noisy operation
Engineering control use physical means to
control the hazard eg. local exhaust ventilation to
remove chemical hazard at source, install
enclosure over machine to reduce exposure to loud
noise
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Risk Control
Administrative control implement safe work
procedures, permit-to-work system, job rotation,
install warning signages
Personal protective equipment use as last
resort eg. safety helmet, safety glasses, respirators,
protective clothing and gloves, safety boots.
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Ongoing review to:
Assess effectiveness of control measures
Identify any new hazards which may arise from
changes in operation
Respond to feedback from employees
Findings from any incident investigation and
emergency situation
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Legal and Other Requirements
Applicable legal and other requirements
WSH requirements from clients or industry
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Meeting Legal Requirements

Workplace Safety and Health Act
Came into effect 1st March 2006
Covers ALL workplaces
Managing WSH proactively. Requires
stakeholders to take reasonably practicable
measures to ensure S&H of workers and other
people affected by work being carried out
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3 Guiding Principles
Reduce risks at source - eliminate or
minimise risks created by stakeholders
Instil greater ownership of S & H
outcomes by industry
Higher penalties for poor safety
management
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Specify liabilities for a range of persons
at the workplace
Focus more on WSH goals and systems
Greater penalties for compromising
safety and health
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Examples: Convictions in 2015
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Subsidiary Legislation
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Key Requirements of SS506: Part 3: 2013

Objectives and Programmes
Set OSH objectives to meet commitment found
in OSH policy
Achieve objectives by implementing OSH
programmes
Programmes must have action plan, persons
responsible, resources required, tasks to be
performed and target completion dates
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Examples of objectives are:
Reduce noise level in the process plants to
below 85dBA
Achieve 100% attendance in WSH training
Organise 5 WSH programmes to increase
workers awareness to workplace safety and
health
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c) Implementation and Operation
Resources, roles, responsibility & accountability

Competence, training and awareness
Communication, participation and consultation
Operational control
Occupational health
Emergency preparedness and response
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Resources, Roles, Responsibility,
Accountability and Authority
Top management takes ultimate responsibility for
OSH and OSH management
Visible leadership
Performance based approach to achieve objective
All stakeholders take ownership of OSH outcomes
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In-house OSH Rules and Regulations
Operating procedures and safe work practices
Incident and hazard reporting
OSH training requirement
Use of personal protective equipment
Housekeeping and cleanliness
Fire prevention
Rules communicated, readily available to employees
and contractors
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Competence, Training and Awareness
Training needs identified for each level of employees
and contractors
Competence education, training, relevant
experience
OSH policy, safe work procedures and practices, OSH
hazards, roles and responsibilities & consequences of
departure from specified operating procedures
Effectiveness of training
Promotional OSH programs Improvement teams, tool
box meetings, talks
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Communication
OSH hazards and its OSH management
system should also be communicated to:
Employees
Contractors and suppliers
Visitors
Other external interested parties
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Participation and Consultation

Hazard identification, risk assessments and
controls
Incident investigation
Development of OSH policies and procedures
Changes that can affect OSH impact
Include contractors
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Operational Control
Used to manage OSH risks to an acceptable level and
comply with applicable legal and other requirements
To consider:
Routine operations, including maintenance
Non-routine operations start-up, shutdown,
foreseeable emergency operations (eg. chemical
spills)
Managing hazardous substances
Managing process safety requirements
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Operational Control
Include consequences of deviation, steps to
correct or avoid deviation and safety systems
and their function
Special precautions
Special or unique hazards eg dust
explosion, cryogenic liquids
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Pre-start up safety for new facilities and modified
facilities
Safe work procedures and practice include
permits-to-work
Mechanical integrity and reliability - check process
equipment to ensure that they are designed and
installed correctly
Control of hazardous substances
Occupational health hearing, respiratory protection,
ergonomics
Emergency preparedness and response (eg. chemical
spills)
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Management of Change
Means and methods to detect changes
Design basis for change
Analysis of possible OSH hazards apply
process hazard analysis
Authorisation requirements
Verification of change
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d) Checking
Systematic way to measure and monitor the
OSH performance on a regular basis
Performance measurement and monitoring
Calibration of instruments
Evaluation of compliance
OSH inspection
Incident investigation, non-conformity,
corrective action and preventive action
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Process Safety Indicators

Leading Indicators - monitor proactively the
effectiveness of risk control systems and provide
feedback on safety performance before an incident or
accident happens
Lagging Indicators when desired safety outcome
has failed. Monitor reactively the effectiveness of risk
control systems, identify gaps and weaknesses in
these systems, and report on incidents or accidents
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Process Safety Indicators Examples
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Swiss Cheese Model
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Conducting Root Cause Analysis
54
Incident Investigation
Root Cause Analysis Tools
Cause and Effect Analysis
5 WHYs
FMEA
Fault Tree
HAZOP
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Cause & Effect Analysis
56
CHEMICAL BURN DURING BLENDING OPERATION
Source: Case Studies: Chemical Industry, WSH Council
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Incident Investigation
Root Causes
Design problem
Control problem
Problems in operating procedure
Lack of maintenance
Management problems resources, bad
decisions
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Process Safety Hierarchy

Process Safety Strategies
Inherent Completely eliminate or significantly
reduce hazards
Passive Safety feature added does not
require action by any device or person eg.
secondary containment, welded fittings vs
flanges
Active Add safety shutdown systems eg.
safety interlocks
Procedural Standard operating procedures,
emergency response procedures, rules,
training
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Designs for Process Safety

Inherently safer designs permanently
eliminates and reduces hazards
Modification in one area may increase or
decrease risk in another area
Moderate: Use milder conditions
Substitute: Replace with less hazardous
chemicals
Minimise: Use smaller quantity
Simplify: Easy to use designs
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Eliminate Working at Height and Exposure

to Hazardous Chemicals
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Eliminate Working at Height and Exposure

to Hazardous Chemicals
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CHEMICAL SPLASH AT PROCESS PLANT

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In-line sampling of
chemicals. Prevent
air entering system
minimise spillage
64
Eliminate Exposure to Hazardous Chemicals

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ISO Tanker Work-at-Height
Scenario:
This work activity required the worker to climb-up and lay a hose to the top-opening
of the ISO Tanker. The worker accesses the top-opening via a ladder at the rear of
the ISO tanker. Current control measures include training, Safe Work Procedures
and the provision of a body harness
(of which the worker is not wearing) anchored to the top of the ISO tanker.
66
Possible Solution
67
Inert Blanketing of Head Space in Tanks
68
Prevent Static Build Up in Tanks and Pipe Lines
Use Radar Gauge to Measure

Liquid Level
69
Operating Procedures
Steps for each operating phase
Operating limits & consequences of
deviation
Engineering and administrative controls for
preventing exposures
Controls needed for safe operation
Permits required
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Permits
Control non-routine activities conducted in
potentially hazardous environmental
Description of hazards
Actions to be taken before and after work,
transition to normal operating mode
Communication of relevant information
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Hot Work Permit

Issued for all hot work operations conducted on
or near a process
Prevent ignition of flammable or combustible
gases, liquids or vapours
Welding, grinding, torch cutting, soldering,
brazing & any activities that produces flames,
sparks or excessive heat
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Hot Work Permit

Document fire prevention and protection
measures have been put in place prior to hot
work commencement
Indicate date(s) authorised for the hot work
Identify the object on which hot work is to be
performed
Valid for 1 shift
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Hot Work Permit

Use flammable gas detector to check LEL, UEL
exceedances
Remove all flammable or combustible materials within
35ft (about 12m) radius of hot work
Cover with flame retardant materials
Assign fire watch
Fire extinguisher in area
Compromised fire detection & protection system
smoke detector, sprinkler, alarms
Communication
Display of permit
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FLASH FIRE DURING CHARGING OF FLAMMABLE POWDER

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Lock Out/Tag Out

Prevents injuries or damage due to accidental
release of stored energy
ALL ENERGY SOURCES: Electrical,
gravitational, mechanical, pneumatic, thermal
and chemical
Unexpected motion or release
Permit or LOTO procedure
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Examples of LOTO Application
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Lock Out/Tag Out

De-energise equipment unplug electrical
connections, release pressurised lines, spring-loaded
devices, filled chemicals
Lock equipment, device, line to prevent re-activation
Tag equipment, device
Try to re-energise for verification
More than 1 worker use Gang Lock Device (HASP
lock)
1 person, 1 key
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Confined Space Entry

Called Vessel Entry (in textbook)
Enclosed area with limited means of access
Not for continuous occupation
Has restricted natural ventilation
Include tanks, manholes, pipes, pits and silos
May also have risk of fire and explosion or
engulfment by the material in vessel
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Examples
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Accident Cases Involving Confined Space
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Hazards in Confined Space

Insufficient oxygen
Substances already present
Residual petroleum vapour in storage tanks
Contents not adequately purged
Substances introduced during work processes
Cleaning chemicals/solvents (e.g. acetone,
trichloroethylene)
Paint fumes (e.g. toluene, xylene)
Substances agitated and released during entry
Sludge
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Hazards in Confined Space

Flammable Substances introduced
Cleaning chemicals
Paint fumes
Leakages from adjacent tanks/pipes
Ignition sources introduced
Welding/cutting operations
Spark generation
Static discharge
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Common Atmospheric Hazards
Source: Confined Space Safety Guidebook for Supervisors and Workers, WSH Council
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Legal Requirements
Identification/ record/ warning signs/ information of all confined
spaces at the workplace
Evaluation of need for entry

Safe means of access to and exist from confined space;
Safe practices for opening entrance of a confined space;
Sufficient and suitable lighting for entry into or work
Adequate ventilation to sustain life before entry and during work in
a confined space
Procedures and control of entry into a confined space including
gas testing
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Confined space entry permit issue on daily basis
Isolate equipment LOTO
Continuous monitoring of oxygen concentration
>19.5%
Confined space attendant
Communications process
Rescue procedure
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Acceptable limits for the atmospheric test are:
Reading
Permissible Levels
Oxygen
19.5 % Vol. to 23.5 % Vol.
Flammable
gases
and 10% Lower Explosive Limit
vapours
(LEL)
Toxic gases and vapours
Permissible Exposure Limit
(PEL) values
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Geometry of the space and physical properties of the gases different at different level
Source: Technical Advisory on Working Safely in Confined Spaces, WSH Council
91

Ventilation for confined space Space ventilated and tested prior to
entry. Continuous ventilation to ensure contaminants do not build up to a
dangerous level.
Source: Technical Advisory on Working Safely in Confined Spaces, WSH Council
92
93
Going Beyond Compliance
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VISION
ZERO
Zero Harm
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Tutorial Questions
Questions 13-8 and 13-21

Watch the 2 videos listed below. What
recommendations can you give to prevent similar
accidents from happening?
a) Dupont Hot Work Accident in 2012

https://www.youtube.com/watch?v=PqskpvPejeU
b) Xcel Energy Company Confined Space Accident
https://www.youtube.com/watch?v=BeaX0IRjyd8
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Steel Pipes Dimensions - ANSI

Schedule 40
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Thank You

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Management of Workplace

Safety, Health and

NUS CN3135 SHE Management

NUS CN3135 SHE Management

NUS CN3135 SHE Management

NUS CN3135 SHE Management

NUS CN3135 SHE Management

SHE Management System

NUS CN3135 SHE Management

SHE Management Systems

NUS CN3135 SHE Management

Workplaces to Implement WSHMS

NUS CN3135 SHE Management

NUS CN3135 SHE Management

Workplace Safety and Health

NUS CN3135 SHE Management

SS506: Part 1: 2009 Occupational Safety and Health

NUS CN3135 SHE Management

NUS CN3135 SHE Management

NUS CN3135 SHE Management

Key Requirements of SS506: Part 3 : 2013

NUS CN3135 SHE Management

DuPont Position Statement on Safety, Health,

NUS CN3135 SHE Management

DuPont Position Statement on Safety, Health,

NUS CN3135 SHE Management

Petrochemical Corporation of Singapore

NUS CN3135 SHE Management

Petrochemical Corporation of Singapore

NUS CN3135 SHE Management

Key Requirements of SS506: Part 3 : 2013

NUS CN3135 SHE Management

Key Requirements of SS506: Part 3 : 2013

NUS CN3135 SHE Management

Key Requirements of SS506: Part 3 : 2013

Process Safety Information required

Hazards of chemicals Toxicity, PELs, physical/chemical

NUS CN3135 SHE Management

NUS CN3135 SHE Management

Rare - Remote - Occasional - Frequent -

NUS CN3135 SHE Management

No additional risk control

Ensure risk level is reduced

NUS CN3135 SHE Management

High Risk level must be

NUS CN3135 SHE Management

Key Requirements of SS506: Part 3 : 2013

NUS CN3135 SHE Management

Key Requirements of SS506: Part 3 : 2013

NUS CN3135 SHE Management

Key Requirements of SS506: Part 3 : 2013

NUS CN3135 SHE Management

Key Requirements of SS506: Part 3 : 2013

NUS CN3135 SHE Management

Key Requirements of SS506: Part 3 : 2013

NUS CN3135 SHE Management

Meeting Legal Requirements

NUS CN3135 SHE Management