HSE On Projects - Ian Sutton

HSE (Health, Safety & Environmental) on Projects
Ian Sutton
Society of Petroleum Engineers - April 13, 2005
[email protected]
Copyright © AMEC Paragon. 2005. All rights reserved.
Organization Of This Presentation
1. Background
2. Defining HSE
3. Roles of the HSE Group
4. Project Work and HSE
5. The HSE Professional
HSE on Projects. Copyright © AMEC Paragon 2005. 2

All Rights Reserved.
Background to This Presentation
§ HSE Literature / Regulations often

Oriented toward Operations
– HSE work often on projects
– Operations personnel often on projects
§ Large Projects
§ Grass-roots / Greenfield
§ Interfaces
– Piping
– Instruments
– People
§ Structured Project Management
– Phase / Gate System
– Project Execution Plan
§ HSE a Separate Function
‘Safety’ to ‘Operational Excellence’
§ Safety / Environmental
– Up to 1990s
– Occupational focus
– Environmental rules
§ Process Safety Management
– 1990s
– Management systems
– Not just ‘safety’
– Performance-Based / Non-Prescriptive
§ HSE
– 1990s to present
– Integration of elements
– Broader concept of risk
§ Operational Excellence
Project Environment
Continuous / Steady Project

Operations
Steady State Dynamic / Changing

Project Environment

Operations
Commodity-Like Product Unique Product or Service

Project Environment

Operations
Commodity-Like Product Unique Product or Service
On-Going / Long Duration Finite Time / Shorter Duration

Representative Projects
§ Design, fabrication, construction, installation,

commissioning and start-up of a new facility;
§ Retrofit or revamp of an operating unit or of a major

equipment item – possibly due to an HSE issue;
§ Major maintenance or turnaround activity;
§ Implementation of a new management system - say

Management of Change

HSE Issues and Goals
§ The Role of the HSE Professional

– Delivering Analyses / Reports
– Project Management Support
– Auditor / Reviewer
• Independent auditor
• Ombudsman
§ Overlap with Other Disciplines

§ Integration with the Project
Execution Plan

Overlap With Other Disciplines
§ Everyone Is In HSE
– Structural: Design for Personnel Safety
– Instruments: Design to Avoid Environmental Release
– Piping: Insulate for Noise to Avoid Health Problems
§ Other HSE-Related Disciplines
– Human Factors
– Quality
– Security
§ HSE Often Has a Holistic View of the Project
– Can identify interface difficulties
– Can help identify needs
– HSE manager can help with multi-disciplinary
coordination
Example of Overlap (Fire Protection) – 1
HSE (Fire Protection) Engineering Discipline

Responsibility (1) Responsibility
Fireproof structural steel Structural
Layout for escape routes Facilities
Fire water systems Piping / Facilities
Fire-fighting equipment Facilities
Alarm and shutdown systems Instruments and Control
Vapor detection systems Instruments and Control
(1) As provided by Watrous (2005)HSE on Projects. Copyright © AMEC Paragon 2005. 11

Example of Overlap (Fire Protection) – 2
HSE (Fire Protection) Responsibility Engineering Discipline

Responsibility
Heating / ventilating (smoke) Civil / Structural / Facilities
Electrical classification Electrical
Emergency response plans Operations / Maintenance
Fire size / duration Process
Fire and blast simulations Structural / Civil
Regulations / standards Contracts

1. Background
2. Defining HSE

Defining HSE
§ Health / Safety / Environment

§ HSE / HES / SHE / EHS
§ Human Factors
§ Quality: HSEQ
§ Security: HSEQS

Environmental
§ Affects Everyone, Everything (all

life forms), Everywhere
§ Timeline: Years to Decades
§ Tends to be regulatory driven:
– EPA
– MMS
– World Bank
§ Usually Prescriptive

Health
§ Workers and the immediate

community
§ Timeline: months to years
§ Wide range of regulations
– OSHA
– EPA
§ Often driven by litigation (e.g.,
asbestos)

Safety
§ Generally Workers Only

§ Timeline: immediate
§ Types of Safety:
– Occupational
– System
– Behavior-based
§ Regulations Often Non-
Prescriptive / Performance-Based

1. Background
2. Defining HSE

Roles of the HSE Group
1. Project Support
1. Develop project standards, e.g., philosophies
2. Prepare deliverables
3. Support other disciplines
4. Understand latest external standards / regulations
5. Safety on the project
2. Formal Risk Assessment
3. Independent Reviewer
1. Verify standards being met
1. External (regulations / codes)
2. Internal
2. Ombudsman

HSE: Safety on the Project
§ Office Safety
§ Fabrication
– Control can be a problem
– Directly related to number of inspectors
§ Construction
§ Installation

Independent Reviewer
§ Verification / Audit
– External standards
– Internal standards
– Report outside the normal project management chain
§ Professional Review
§ Ombudsman
– Information provided by others
– Allows for free and open communication of issues and
opportunities
– Strive for an atmosphere that is:
• Fair
• Open
• Accountable
1. Background
2. Defining HSE

HSE Project Matrix
HSE Management Project Phase

Elements
I II III IV V
1 Participation
2 Information
3 Hazards Analysis
4 Management of Change
5 Procedures
16 Regulations/Codes/Standards
Matrix Elements
§ Project Phase
§ HSE Management Element
§ HSE Activity

Project Phases
Phase I – Concept Selection

Phase II – Preliminary Design (FEED)
Phase III – Detailed Engineering
Phase IV – Fabrication, Construction,
Installation
Phase V – Commissioning, Start-Up

Phase I: Concept Selection
§ Pre-Front End Engineering § Determine if safety or

Design, or pre-FEED environmental factors are
§ Identify and Assess likely to have a major effect
Opportunities on the project, or on the
schedule.
§ Process Selection
§ Environmental Impact
§ Evaluation of Economic Statements can take a long
Feasibility time to complete, and
§ ‘Go’ / ‘No-Go’ Decision substantially change the
scope of the project

Phase I - Typical HSE Activities
§ HSE Plan § Process Hazards Analysis

§ HSE Aims and Goals Plan (What-If)
§ Safety Critical Issues § Regulatory Issues
§ Risk Acceptance Criteria § Codes and Standards
(ALARP) § Simultaneous Operations
§ Risk Assessment of Major Issues
Concepts § Human Factors Criteria
§ Risk Matrix § Flaring Criteria
§ Risk Register § Behavioral Safety Philosophy

Phase II: Select From Alternatives
§ Preliminary or Front End § All major HSE issues that

Engineering Design (FEED) could affect the project
§ Establish Design Basis should have been resolved

Phase II – Typical HSE Activities
§ Preliminary Noise Study § Preliminary Health Program

§ Preliminary Fire Study § Checklist Studies (say 30)
§ Preliminary Explosion Study § What-If Studies
§ Preliminary Toxic Gas § Third Party Interfaces
Dispersion Study § HSE Audit Plan
§ Preliminary Smoke Study § Project Behavioral Safety
§ Preliminary Hazardous Area Plan
Classification

Phase III: Final Design / Detailed Engineering
§ Detailed “nuts and bolts” § Final HAZOP

design
§ All FEED issues should be
resolved

Phase III – Typical HSE Activities
§ Design HAZOP § Hazardous Area

§ Gas Dispersion Study Classification
§ Fire / Explosion Study § Management of Change
program
§ Noise Study
§ Smoke / Ventilation Study

Phase IV: Fabrication / Construction / Installation
§ Multiple Contractors § HSE mostly concerned with

§ Ultimately Have to Accept occupational and behavioral
Lack of Control issues

Phase IV – Typical HSE Activities
§ Safety Induction Program § Record-Keeping

§ Inspection Program § HSE Audit

Phase V: Commission / Start-Up
§ Facility On-Stream § Operating Procedures

§ Training
§ Management of Change
§ Prestartup Safety Review

Phase V – Typical HSE Activities
§ Operating Procedures § HSE Audits

§ Maintenance Procedures § Prestartup Safety Review
§ Training Records

HSE Project Matrix

Elements
I II III IV V
1 Participation
2 Information
3 Hazards Analysis
5 Procedures
Management Elements - 1
§ Derived from Industry-Standard

Program
– EPA
– OSHA
– API 75
§ Many Organizations Adopted This
Approach
§ Modern Systems Expanded
– Quality
– Security
– Human Factors

Management Elements – 2
1. Participation / Accountability / 9. Safe Work Practices

Leadership 10. Prestartup / Restart Review
2. Technical and Organizational
Information 11. Emergency Planning and
Response
3. Hazards Analysis
12. Incident Investigation and
4. Management of Change Analysis
5. Operating and Maintenance 13. Audits and Assessments
Procedures
14. Regulations, Codes and
6. Training and Education Standards
7. System / Mechanical Integrity 15. Reliability / Quality Control
8. Contract Work 16. Communication / Security
HSE Project Matrix

Elements
I II III IV V
1 Participation
2 Information
3 Hazards Analysis
5 Procedures
HSE Activities Within Each Matrix
1. Who are the principal HSE ‘customers / clients’?
2. What codes and standards apply?
3. What are the typical HSE deliverables and reports?
4. Is a formal risk analysis required?
5. What support can HSE provide to other disciplines, including record-
keeping?
6. What documents and information generated by other departments are
needed by the HSE group?
7. What impact could the HSE group could have on the cost and
schedule of the overall project?
8. What resources (people and money) are needed at each phase for
HSE work?
9. Is there an HSE audit protocol?
10. Is there an HSE review
HSE onchecklist?
Projects. Copyright © AMEC Paragon 2005. 40
Who Are The HSE Customers / Clients on a
Project?
§ Corporate
– Regulations
– Company Standards
§ Project Director
§ Project Managers
§ Engineering Managers
§ Facility Managers
– Operations
– Maintenance

Total Potential Activities
§ Five Project Phases

§ Sixteen HSE Elements
§ Ten HSE Activities
Total 5 x 16 x 10
= 800 Items

1. Background
2. Defining HSE

The HSE Professional: A Paragon
"What a piece of work is man! how

noble in reason! how infinite in
faculty! in form and moving how
express and admirable! in action
how like an angel! in apprehension
how like a god! the beauty of the
world, the paragon of animals!"

The HSE Professional On A Project
§ Eclectic
– Understand many disciplines - but not an expert in them
– Engineering background
– Holistic
§ Lots of Experience: Field and Design
§ Good Communicator
– Written reports
– Oral presentations
– Training
§ Good Network
– Consultants
– Part-time workers
§ Willing to Take a Stand
– ‘Comfort the Afflicted / Afflict the Comfortable’
– Needs to know the organization
§ Self-Starter
– on‘ Projects.
HSE Think Copyright
the Unthinkable ‘ 2005.
© AMEC Paragon 45
– “ Crash ” meetings
Conclusions
§ Three Major Roles

– Support to other disciplines
– Technical work
– Review / Assessment of the overall project
§ Organize Around Three Elements:
– Project phases
– HSE management elements
– Deliverables and activities
§ HSE Management is Broad in Scope

Example 1
1. Phase I; 14. Regulations
4. Deliverable: Environmental Impact Statement
Project Phase
I II III IV V
1 Participation
2 Information
14 Regulations, Codes, Stds
16 Communication/Security

Example 2
2. Phase II; 7. Mechanical Integrity
3. Risk Analysis: What-If / Checklist
Project Phase
I II III IV V
1 Participation
2 Information
7 Mechanical Integrity

Example 3
3. Phase III; 3. Hazards Analysis
8. Resources: HAZOP Team
Project Phase
I II III IV V
1 Participation
2 Information
3 Hazards Analysis
7 Mechanical Integrity

Example 4
4. Phase IV; 4. Management of Change
4. Support to Other Disciplines
Project Phase
I II III IV V
1 Participation
2 Information
3 Hazards Analysis

Example 5
5. Phase V; 5. Operating Procedures
3. Deliverable
Project Phase
I II III IV V
1 Participation
2 Information
5 Operating Procedures


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HSE (Health, Safety & Environmental) on Projects

HSE on Projects. Copyright © AMEC Paragon 2005. 2

§ HSE Literature / Regulations often

Continuous / Steady Project

HSE on Projects. Copyright © AMEC Paragon 2005. 5

Continuous / Steady Project

Commodity-Like Product Unique Product or Service

HSE on Projects. Copyright © AMEC Paragon 2005. 6

Continuous / Steady Project

Commodity-Like Product Unique Product or Service

On-Going / Long Duration Finite Time / Shorter Duration

HSE on Projects. Copyright © AMEC Paragon 2005. 7

§ Design, fabrication, construction, installation,

§ Retrofit or revamp of an operating unit or of a major

§ Major maintenance or turnaround activity;

§ Implementation of a new management system - say

HSE on Projects. Copyright © AMEC Paragon 2005. 8

§ The Role of the HSE Professional

§ Overlap with Other Disciplines

HSE on Projects. Copyright © AMEC Paragon 2005. 9

HSE (Fire Protection) Engineering Discipline

(1) As provided by Watrous (2005)HSE on Projects. Copyright © AMEC Paragon 2005. 11

HSE (Fire Protection) Responsibility Engineering Discipline

HSE on Projects. Copyright © AMEC Paragon 2005. 12

HSE on Projects. Copyright © AMEC Paragon 2005. 13

§ Health / Safety / Environment

HSE on Projects. Copyright © AMEC Paragon 2005. 14

§ Affects Everyone, Everything (all

HSE on Projects. Copyright © AMEC Paragon 2005. 15

§ Workers and the immediate

HSE on Projects. Copyright © AMEC Paragon 2005. 16

§ Generally Workers Only

HSE on Projects. Copyright © AMEC Paragon 2005. 17

HSE on Projects. Copyright © AMEC Paragon 2005. 18

HSE on Projects. Copyright © AMEC Paragon 2005. 19

HSE on Projects. Copyright © AMEC Paragon 2005. 20

HSE on Projects. Copyright © AMEC Paragon 2005. 22

HSE Management Project Phase

HSE on Projects. Copyright © AMEC Paragon 2005. 24

Phase I – Concept Selection

HSE on Projects. Copyright © AMEC Paragon 2005. 25

§ Pre-Front End Engineering § Determine if safety or

HSE on Projects. Copyright © AMEC Paragon 2005. 26

§ HSE Plan § Process Hazards Analysis

HSE on Projects. Copyright © AMEC Paragon 2005. 27

§ Preliminary or Front End § All major HSE issues that

HSE on Projects. Copyright © AMEC Paragon 2005. 28

§ Preliminary Noise Study § Preliminary Health Program

HSE on Projects. Copyright © AMEC Paragon 2005. 29

§ Detailed “nuts and bolts” § Final HAZOP

HSE on Projects. Copyright © AMEC Paragon 2005. 30

§ Design HAZOP § Hazardous Area

HSE on Projects. Copyright © AMEC Paragon 2005. 31

§ Multiple Contractors § HSE mostly concerned with

HSE on Projects. Copyright © AMEC Paragon 2005. 32

§ Safety Induction Program § Record-Keeping

HSE on Projects. Copyright © AMEC Paragon 2005. 33

§ Facility On-Stream § Operating Procedures

HSE on Projects. Copyright © AMEC Paragon 2005. 34