HAZARDS AND EFFECTS MANAGEMENT PROCESS (HEMP) PETRONAS PDB RETAIL STATIONS Hazards and Effects Register (HER) Bowtie for Major Risks Critical Activity Catalogue (CAC) Remedial Action Plan (RAP) Safety Critical Elements (SCE) Signature Signature Signature Signature Rev. 07 Issue Date Nov-20 Next Review Date Nov-25 Name Designation Azureen Azita Bt Abdullah Head (Retail Sales & Operations) M Farid B Mustafa Business Technical Authority Ian Malcolm Cruddas Head (Non Fuel Business) Name Designation Prepared by: Name Designation Wan Jing Loo (Jesslyn) Executive (HSE Risk) Azwan Kamarudin Technician II (HSE Risk) M Safrizan B Mohamad Manager (HSE Risk) Reviewed/ Validated by: Approved by: Endorsed by Name Designation Manager (Retail Engineering & Resolution) Huszailelawati Daley Bt M Hassim Open 07/10/20 26/11/2020 26/11/2020
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HAZARDS AND EFFECTS MANAGEMENT PROCESS (HEMP)
PETRONAS PDB RETAIL STATIONS
Hazards and Effects Register (HER)
Bowtie for Major Risks
Critical Activity Catalogue (CAC)
Remedial Action Plan (RAP)
Safety Critical Elements (SCE)
Signature
Signature
Signature
Signature
Rev. 07 Issue Date Nov-20 Next Review Date Nov-25
Name Designation
Azureen Azita Bt Abdullah Head (Retail Sales & Operations)
M Farid B Mustafa Business Technical Authority
Ian Malcolm Cruddas Head (Non Fuel Business)
Name Designation
Prepared by:
Name Designation
Wan Jing Loo (Jesslyn) Executive (HSE Risk)
Azwan Kamarudin Technician II (HSE Risk)
M Safrizan B Mohamad Manager (HSE Risk)Reviewed/ Validated
by:
Approved by:
Endorsed by
Name Designation
Manager (Retail Engineering & Resolution)Huszailelawati Daley Bt M Hassim
Open
07/10/20
26/11/2020
26/11/2020
wanjing.loo
Stamp
1
IMPACT
LIK
ELIH
OO
D
* For chronic health effects
Open
Hazard.
No.Hazard Activity Location / Source of Hazard Threats
Top EventConsequences P E A R
Risk
RatingRisk Category Remarks
H-01
1. Storage of LPG cylinder for sale 1. LPG storage cage
1. Cylinder tampered (Vandalism , theft)
2. Impact due to hit by moving vehicle
3. Defect on LPG cylinder seal/ valve
during receiving
LOC
Asset damage
FireA4 - A2 A2 A4 Low
References:
1. PS Jln Datuk Ismail Hashim
2. PS Sg Dua
3. PS Tmn Putra Indah
4. PS Pengkalan Utama
Control:
1. Anti-theft/ anti-climb storage cage with lock
2. Construction of bolard pole at LPG storage cage
3. Installation of safety signage to alert customer
4. Daily visual inspection on LPG cylinder
1. Handling of LPG cylinder 1. LPG cylinder 1. Hit by LPG cylinderHit by the cylinder
Injury B2 B2 Low
H-02
2.01 Lube and seal oil 1. Maintenance of air compressor (maintained by vendor)
2. Car servicing at workshop (by third party)
1. Compressor lubrication system for air
compresor of tyre inflator
2. Lube bay/ workshop
1. Leakage of compressor head
2. Improper handling of scheduled waste
at lube bay
LOC Soil and water contamination
- C1 - - C1 Low
Assumption:
Minor spill happen at all workshop operation
Control:
1. Concrete floor
2. Spill kit
1. Storage of diesel product in underground tank
2. Transfer of diesel product from underground storage tank to dispenser via
pipeline
3. Diesel dispensing by customer
4. Receiving of diesel from road tanker
1. Diesel underground storage tank
2. Product piping and fitting
3. Diesel receiving point
4. Diesel dispenser
5. Diesel receiving hose connection
6. Diesel storage and dispensing on
floating barge (Sarawak & Langkawi
harbour)
1. Tank system defect & corrosion
(corrosiveness of diesel)
2. Failure pipe, joint and fittings (including
gasket)
3. Overfill during customer refueling and
product offloading
4. Loose connection at offloading
5. Unsafe customer action e.g. hose
pulled away, hit dispenser with vehicle
LOC Soil and water contamination
- E3 E1 E2 E3 Very High
References:
1. PS Tun Mustapha, Labuan (2018, 10k liters)
2. gasket related incident
Control:
1. Double wall storage tank and piping sistem
2. Selection of material and design as per PDB PS Design Standard
3. Overfill sensor at nozzle
4. Sump containment
5. Break away coupling
6. Camlock Coupling
7. Mechanical leak detector
8. Ground water monitoring well
9. Oil interceptor
10. Oil spill kit
11. Emergency response
1. Checking of ullage marker at road tanker
2. Product dipping
1. Road tanker man-hole
2. Diesel dipping point
1. Opening road tanker hatch
2. Opening dipping point
Exposure to VOC Health effects:
H304: May be fatal if swallowed and enters
airways (HR: 3)
H373: May cause damage to organs through
prolonged or repeated exposure (HR: 3)
H351: Suspected of causing cancer (HR: 3)
H315: Causes skin irritation (HR: 2)
H332: Harmful if inhaled (HR: 2)
B3 - - - B3 Low
Control:
1. Usage of PPE (Fask mask/ respirator)
1. Storage of petroluem gasoline product in underground tank
2. Transfer of petroleum gasoline from underground storage tank to dispenser
3. Petroleum gasoline dispensing by customer
4. Receiving of petroleum gasoline from road tanker
19.02 Excessive CO2 1. Release of CO2 fire suppressing agent (at hyperstation which used CO2
supression system at MSB room)
1. MSB Room 1. Automation failure/ valve/ sensor
malfunction
2. Improper isolation
Asphyxiation Injury/Fatality
B4 - - - B4 Medium
Control:
1. Indicator light at MSB room (station equiped with fire supression system)
2. Preventive maintenance of fire supression system (RAP)
16.03 Microwaves
Voltage > 50 V to 440 V in
cables in equipment
15.01 &
15.02
Asphyxiates
Electromagnetic radiation
Electricity
Open flame
Open
19.05 Fixed fire suppression agent 1. Release of Pyrogen fire suppressing agent (at hyperstation which used pyrogen
supression system at MSB room)
1. MSB room 1. Automation failure/ valve/ sensor
malfunction
2. Improper isolation
Asphyxiation Injury/Fatality
B4 - - - B4 Medium
Ref.:
1. External - Fatality due to accidental release of fire suppression agent
during maintenance at bank in Thailand
Control:
1. Indicator light at MSB room (station equiped with fire supression system
2. Preventive maintenance of fire supression system (RAP)
19.06 Smoke 1. Operation of Genset
2. Vehicle moving/ parking in forecourt area
1. Genset
2. Vehicle exhaust
1.Malfunction of Genset or vehicle Excessive CO more than
allowable limit
Localised air pollution
Illness related to respiratory system B2 B2 - - B2 Low
Control:
1. No smoking policy at PS
2. 'No smoking' signage at PS
H-20
20.02 &
20.10
Exhaust fumes
Carbon Monoxide
1. Operation of Genset
2. Operation of Diesel engine (at JKAL and Bentong RnR)
1. Genset
2. Diesel engine
1. Exhaust system leaking in engine room Inhalation of fume Illness related to respiratory system
B2 - - - B2 Low
Control:
1. Exhause pipe outlet ouside of enset building
20.04 Benzene
20.06 Welding fumes 1. Welding Arc welding 1. Poor ventilation Inhalation of welding fumes Personal illness with potential for metal fume
feverC2 - - - C2 Low
Control:
1. Use of PPE while welding
20.07 Tobacco smoke
20.08 HCFC 1. Operation and maintenance of air conditioning system 1. Refrigerant for Air conditioning system 1. Leaking of refrigerant Release of HCFC Ozone depletion- B2 - - B2 Low
Control:
1. Usage of only DOE-approved refrigerant gas
H-21
21.15 &
21.16
Alcohol-containing beverages & Non-
prescribed drugs
1. Any person entering PETRONAS premises or perform work and/or businesses for
or on behalf of PETRONAS, whilst under the influence of any Substance of Misuse;
2. Any person consuming, possessing, distributing, purchasing or selling any
Substance of Misuse whilst in PETRONAS premises without authorization from the
Management
Personnel 1. Person under alcohol or drug influence Human error Injury
Asset Damage
C2 - C1 - C2 Low
Control:
PETRONAS Substance Misuse Policy
21.17 Used engine oils (polycyclic aromatic
hydrocarbons)
1. Vehicle service at workshop/ lube bay 1. Workshop/ lube bay LOC Environmental pollution- C1 - - C1 Low
Control:
1. Proper management of scheduled waste
21.19 Grey and/or black water 1. Empty sewage tank using Indah Water Truck
2. Maintenance of WWTP for station not connected to main sewage system
1. Septic tank
2. WWTP
Exposure to toxic fumes Acute: Dizziness, nausea
A3 - - - A3 Low
Control:
1. Covered septic tank with goose neck
2. Fenced WWTP area
H-22
22.03 Cement dust 1. Maintenance of tiles, floor and forecort area. 1. Cement mixing
Inhalation of dust Personnel illness with potential for adversely
affecting respiratory system B2 - - - B2 Low
Control:
1. JSA
2. PPE usage
22.14 Oil based sludges
H-24
24.01 Food-borne bacteria (e.g E. coli) 1. Customer consuming contaminated / expired food provided/sold at station 1. Food to Go (packed food)
Barrier 1Automatic Tank Gauging (ATG) installation*for selected PS based on risk identified by PDB
EF 11. Failure/ malfunction of ATG
EFC 11. Fuel Inventory Management Report (FIMR) Monitoring2. Daily inspection by Dealer based on Mystation HSSE Daily Checklist3. Tank inspection and maintenance as per PDB ITPM for ATG
Barrier 2Double wall steel-jacketed tank of underground tank with fiber-reinforced outer layer
EF 11. Improper installation2. Damage during transportation3. Manufacturing defects
EF21. Containment failure
EFC 11. Testing and commissioning as per Inspection and Testing Plan (ITP) during installation and commissioning for new tank
EFC21. Tank inspection and maintenance as per PDB ITPM for Double wall steel tank2. Fuel Inventory Management (FIMR) Report3. Daily inspection by Dealer based on Mystation HSSE Daily Checklist
Threat 2
Failure of pipe, joint and fitting
Barrier 1Material selection of fitting, gasket and pipe system*will change to electrofusion welding type for KPS pipe and fitting moving forward
EF 11. Incompatible material
EF21. Loose connection
EFC 11. Piping system design as per Petronas Petrol Station Technical Standard (PSTS), Chapter 6.0 Mechanical Piping2. MOC for material and design changes
EFC21. QA/ QC by engineers
Threat 3
Overfill during product offloading
Barrier 1Ullage monitoring through daily dipping activity
EF 11. Inaccurate dipping data
EFC 11. Dipping methodology as per requirement in Offloading Procedure
Barrier 2Daily key in Stock in Automatic Stock Replenishment (ASR) System on daily basis
EF 11.Failure to key in by Dealer
Threat 4
Overfill during customer refueling
Barrier 1Overfill sensor at nozzle
EF 1Malfunction of overfill sensor at nozzle spout
EFC 1Inspection and testing as per ITPM for nozzle spout
ConsequenceSpill to the environment, fire, injury , asset damage
EFC 11. Integrity or functionality of MLD/ ELD as per PDB PS Design Standard; PDB Station Inspection & Maintenance Plan
SCE1. Fireman switch
SCE1. Tank sump2. Dispenser sump
EFC 11. Consequence Management
SCE1. Oil interceptor
SCEATG
SCEDouble wall steel-jacketed underground tank
Barrier 2Double wall piping
EF 11. Improper installation2. Leak within the wall is not detected3. Piping failure
EFC 11. Testing and commissioning as per PDB PS Commissioning Work Procedure2. Inspection of fuel presence in "bleed tube"3. Daily inspection by Dealer based on Mystation HSSE Daily Checklist
EFC 11. Inspection of ball float vent valve as per ITPM
SCEBall float vent valve
Barrier 4Offloading Procedure
EF 11.Noncompliance to procedure
EFC 11. Consequence Management
SCEOverfill sensor
Threat 5
Unsafe customer action, e.g. hose pulled away, hit dispenser with vehicle
Barrier 1Breakaway coupling
EF 1Malfunction / failure of breakaway coupling
EFC 1Inspection and testing as per ITPM for breakaway coupling
SCEBreakaway coupling
Threat 6
Loose connection during offloading
Barrier 2Shear Valve
EF 1Malfunction / failure of valve actuator lever
EFC 1Inspection and testing as per ITPM for Dispenser
SCEShear valve
Barrier 1Camlock coupling (under FMD)
EF 1Camlock coupling fail or not fully clipped
EFC 11. Supervised offloading as per Tatacara Penurunan Bahan Semakan 52. Monthly inspection as per Pemeriksaan lori Tangki Multi Product in Road Tanker Operation Guideline
SCE1. MLD/ ELD
SCE1. ESB
SCE1. Oil spill kit2. Fire extinguisher
Barrier 3Epoxy coating in the internal surface of underground tank for Euro 5 diesel*applicable for new supply tank
EF 11. Improper installation2. Manufacturing defects
EFC 11. Testing and commissioning as per Inspection and Testing Plan (ITP) during installation and commissioning for new tank2. QA/ QC by engineers
Open
6.01 Personnel at Height > 2m
Fall from Height
Threat 1
Improper construction of scaffolding (erection/ dismantling)
Barrier 1PDB Working at Height (WAH) Procedure
EF 11. Procedure not updated/ communicated/ complied with
EFC 11. Periodic review of procedure2. WAH training3. Consequence Management
Barrier 2Review and approval of scaffold design by competent person
EF 11. Design not reviewed and approved by competent person
EFC 11. Include the specific requirement for design review and approval by competent person in contract.2. Verification of design review by contract owner
Threat 2
Loss of balance/ uneven platform surface
Barrier 1PDB WAH procedure
EF 11. WAH procedure not updated/ communicated/ complied with
EFC 11. Periodic review of WAH procedure2. Consequence Management
Threat 3
Noncompliance with requirements
Barrier 1Work supervision at site by Dealer/ Supervisor
EFC 1Mandatorize WAH training for personnel as part of PTW requirement
ConsequenceFatality/ major injury
Barrier 2Emergency Response (ER)
EF 1Unavailability of WAH Rescue Plan
EFC 11. Verification of ER Plan prior to PTW application2. WAH Training
Barrier 1Full body harness
EF 1Defected/ damaged safety harness/ lanyard
EFC 11. WAH Training2. Regular inspection of safety harness and lanyard prior use
Barrier 2Fall protection system, i.e. guardrail/ anti -slip surface
EF 11. Poor condition of fall protection system
EFC 11. Regular inspection of fall protection system through UA/ UC2. Preventive Maintenance
*Road tanker related shall be covered under FMD
Barrier 3Scaffold erected by competent scaffolder
EF 11. Scaffolder does not meet competency requirement
EFC 11. Verify competency by checking scaffolder's certificate2. Include specific requirement for scaffolder in contract
Barrier 4Inspection by certified scaffold inspector
EF 11. Scaffold inspector does not meet competency requirement
EFC 11. Verify competency by checking scaffold inspector's certificate2. Include specific requirement for scaffold inspector in contract
Open
8.08 Land Transportation
Hit by Vehicle
Threat 1
Loss of control by vehicle and unsafe condition (e.g uneven driveway, unsafe ingress entrance & egress exist, ponding during raining, standing within driver's blind spot, improper parking of vehicles)
Barrier 1Traffic controller at forecourt to alert pedestrian on vehicle movement
EF 11. KP not available at forecourt
EFC 11. Requirement of minimum KP on duty at the forecourt
Barrier 2PPE- Reflective vest for personnel working at forecourt
EF 11. Unavailability of reflective vest
EFC 11. Periodic check on the adequacy of PPE at station
ConsequenceFatality/ major injury
Barrier 2Emergency Response (ER)
EF 11. Emergency contact number not updated
EFC 11. Check the validity of emergency contact number as per DKSH checklist (monthly)2. Conduct emergency exercise & drill
Barrier 1: Impact Protection- Bollard pole in front of Kedai Mesra, diesel standalone, dispenser and offloading area- "Dog Bone" at dispenser island
EF 11. Damaged impact protection
EFC 11. Immediate report of any damaged impact protection for immediate rectification
Barrier 3Forecourt safety features, i.e. dedicated ingress entrance and egress exit, even driveway at station compound
EF 11. Failure/ damaged/ deteriorated ingres and egress, driveway
EFC 11. Immediate report of any damaged impact protection for immediate rectification2. Corrective maintenance of driveway by contractors upon reporting into MESRALINK by the dealer
Open
15.01 & 15.02 Voltage> 50V to 440V in Cables in
Equipment
Electrical Current Leakage
Threat 1
Ineffective energy isolation
Barrier 1Energy Isolation Procedure
EF 11. Procedure not complied with/ updated/ communicated
EFC 11. Periodic review of procedure2. Energy isolation training & refresher (every 3 years)3. Consequence Management
Threat 2
Water and debris ingress
Barrier 1Ingress Protection (IP) compliance, i.e. for Switch Board , IP41 for indoor use (in enclosed buildings) and IP55 for outdoor use, as defined in IEC 60529
EF 11. Unauthorized modification of IP Rating
EFC 11. MOC for change of degree of rating and protection
Threat 3
Exposed live parts and cable connection & poor wiring works, e.g. defective insulation, ineffective bonding& grounding, wrong color coding
Barrier 1Insulation Resistance (IR) Test performed during execution of Inspection and Servicing Contract
EF 11. Failure to perform IR Test as per activity schedule (Inspection & Servicing Contract)
EFC 11. Schedule and report monitoring by Regional Engineer (RE)
Threat 4
Substandard equipment and wiring
Barrier 1Design compliance to Electrical Act 1990 and Electrical Regulation 1994 and relevant standard, i.e. PDB PSTS
EF 11. Design not reviewed and approved by competent person
EFC 11. Include specific requirement for design review by competent person in contract2. Verification of design review by contract owner3. Review of equipment and wiring design by competent person
ConsequenceElectrocution, fire
Barrier 2Earthing resistance not more than 4ohm for MSB and 10ohm for LPS
EF 11.Ineffective of earthing and bonding system due to corrosion and missing equipment (i.e. copper tape)
EFC 11. Inspection and Servicing testing performed on earth resistance and advised effectiveness of the system2. Schedule and report monitoring by Regional Engineer (RE)
Barrier 1Rated 30mA Earth-Leakage Circuit Breaker (ELCB) for protection againts electrical leakage current for Switch Socket Outlet (SSO) and 100mA for others, as per Regulation 36 in Electrical Regulation 1994
EF 11. Inaccurate rating of ELCB
EFC 11. Inspection and Servicing contract to advise on the accurate rating for ELCB2. Schedule and report monitoring by Regional Engineer (RE)
Barrier 2Visual inspection by competent Visiting Engineer, in accordance to Regulation 66, Electricity Supply Act 1990
EF 11. Failure to perform visual inspection as per scheduled
EFC 11. Schedule and report monitoring by Regional Engineer (RE)
Barrier 3Continuity Resistance not more than 1ohm for bonding at all metalic structure
EF 11. Ineffective of bonding system due to corrosion and missing equipment (i.e. copper cable)
EFC 11. Inspection and Servicing testing performed on bonding continuity and advised effectiveness of the system2. Schedule and report monitoring by Regional Engineer (RE)
SCEELCB & its accurate rating
Note: IP rating refers to the level of protection offered by an electrical enclosure against solid and liquid. In an environment where dust/ water could damage electronic component, a sealed enclosure is used to prevent such ingress and safeguard the electronics.
Note: ELCB is a safety device used in electrical installation with high Earth impedance and interrupt the circuit if a dangerous voltage is detected.
Barrier 4Emergency Response (ER)
EF 1Unavailability of Rescue Plan
EFC 11. Verification of ER Plan prior to PTW application
Piping is double wall type 1. Verify testing and commissioning as per ITP
2. Conduct Preventive Maintenance as per PDB
PS Design Standard, Chapter 25.0 Maintenance
and Inspection Plan
1. 100% compliance with PDB PS Design Standard
2. 100% compliance of changes managed
through MOC
3. 100% completion of ITPM Checklist
1. PDB PS Design Standard, drawings
2. Equipment/ manufacturer (OEM)
manual/ specification
3. ITPM Checklist
1. Approved MOC
2. ITPM Report
1. Discipline engineers, i.e.
Mechanical & inspection enginners
(from TSD)
2. Regional Engineer (RE)
1. Respective SKG training
2. Manufacturer/ OEM training on
piping
Ullage monitoring through dipping
activity
1. Conduct dipping activity as per procedure 1. 100% compliance of dipping conduct prior to
product offloading
1. Conversion table
2. Dip stick
1.Record in Dipping Book 1. Dealer 1. ASAS Training & refresher
Daily key in stock in Automatic Stock
Replenishment (ASR) System on daily
basis
1. Key in stock in ASR System 1. 100% completion of key in on daily basis 1. Dipping Record 1. Updated Inventory system 1. Dealer 1. ASAS Training & refresher
Tank overfill protection- Ball float vent
valve
1. Verify ITPM Report conducted for Ball float
vent valve
1. 100% completion of ITPM as per scheduled 1. ITPM Checklist 1. ITPM Report 1. Regional Engineer (RE)
2. Regional Technician (RT)
1. Manufacturer/ OEM training on
Ball float vent valve
Offloading Procedure 1. Offloading execution in accordance to
To discuss with Real Estate on the implementation of controls/ barriers, i.e. Double Wall Tank/
Double Wall Piping for DODO PS
L HSED & Real Estate May-22
2 Hazard 25.05 Loud Steady Noise> 85dB To conduct Generic Noise Risk Assessment at PS M HSED Sep-21
3 CAC - T2 (Voltage): Water and debris ingress To develop communication pack for compliance of Ingress Protection (IP), e.g. poster, flyer etc. L TSD- Electrical Team Mar-22