HSE-004 - Rev 0 PDF

NIOC
EXPLORATION DIRECTORATE
Section II
NIOC Drilling Standards
B: HSE
HSE-004: MACHINERY – WORKING
ENVIRONMENT ANALYSIS
AND DOCUMENTATION
Revision-0
22.05.2004
Toos Earth Science Technology
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standards, neither Toos nor ARM will assume liability for any accident or economic
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Toos Earth Science Technology Machinery – Working ….. NIOC HSE-004
Revision-0 22.05.2004
Client:
Contract no: 81163
NIOC, Exploration Directorate
Access: Document category: Date:
Revision-0
NIOC EXP, internal Standard 22.05.2004
Title:
Machinery – Working Environment analysis and Documentation, NIOC HSE-004

Keywords:
Summary:
This NIOC EXP standard addresses methods for working environment analysis and
documentation of machinery according to machinery regulations and the normative references.
The methods may also be used for other technical products having similar hazards. The scope
and objectives of this standard are elaborated in Appendix A1.
Date
Action Name Assignment Date received
finalized
Accepted for use
Signature
Accepted for use
Signature
Verified
Signature
Verified
Signature
Read and verified
Verified
Signature
Prepared by Rolf K. Bratli
Signature 22.05.2004
National Iranian Oil Company Page 1 of 43

Exploration Directorate
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TABLE OF CONTENTS
1. SCOPE .......................................................................................................................3
2 NORMATIVE REFERENCES ................................................................................4
3 DEFINITIONS AND ABBREVIATIONS...............................................................5
3.1 Definitions............................................................................................................5
3.2 Abbreviations.......................................................................................................6
4 RESPONSIBILITIES .................................................................................................7
4.1 Contractors...........................................................................................................7
4.2 Suppliers .............................................................................................................8
4.2.1 Supplier of Machinery .................................................................................8
4.2.2 Supplier of Sub-assembly .............................................................................8
5 WORKING ENVIRONMENT DOCUMENTATION.............................................9
5.1 General................................................................................................................9
5.2 Risk Assessments.................................................................................................9
5.3 Working Environment Design Reviews ............................................................10
5.4 Chemical Inventory and Safety Data Sheets......................................................11
5.5 Noise and Vibration Data...................................................................................11
5.5.1 Noise Data Sheets .......................................................................................11
5.5.2 Vibration Data.............................................................................................12
6 RISK ASSESSMENT...............................................................................................14
6.1 Process overview ...............................................................................................14
6.2 Determine responsibilities .................................................................................15
6.3 Determine machinery limits (step 1)..................................................................16
6.4 Establish assessment team (step 2) ....................................................................16
6.5 Identify and describe manual tasks (step 3).......................................................17
6.6 Identify and describe hazards (step 4) ...............................................................17
6.7 Estimate and evaluate risk (step 5) ....................................................................18
APPENDIX A BASIC CONCEPTS (INFORMATIVE) ............................................22
A.1 Scope and Objectives ........................................................................................22
A.2 WE Requirements, Analysis and Documentation.............................................23
A.3 Methods to remove hazards of machinery ........................................................26
APPENDIX B NOISE AND VIBRATION MEASUREMENTS (INFORMATIVE) 28
B.1 Noise Verification Measurements.....................................................................28
B.2 Structure borne Noise........................................................................................29
APPENDIX C DETERMINATION OF WORKING ENVIRONMENT (WE)
DOCUMENTATION RESPONSIBILITIES (INFORMATIVE) ...............................30
APPENDIX D HAZARDS AND HAZARDOUS SITUATIONS ..............................31
(INFORMATIVE) .......................................................................................................31
APPENDIX E: FORM FOR DOCUMENTATION OF RISK...................................33
APPENDIX F FORM FOR CHEMICAL INVENTORY (INFORMATIVE) ...........34
APPENDIX G WORKING ENVIRONMENT (WE) DESIGN REVIEW
CHECKLIST (INFORMATIVE) ................................................................................35
G1. REQUIREMENT ..............................................................................................35
G2. REFERENCES..................................................................................................35
G3. STATUS............................................................................................................36
G4. COMMENTS ....................................................................................................36

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1. SCOPE
This NIOC EXP standard addresses methods for working environment analysis and
documentation of machinery according to machinery regulations and the normative
references.
The methods may also be used for other technical products having similar hazards.
The scope and objectives of this standard are elaborated in Appendix A1.

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2 NORMATIVE REFERENCES
The following standards include provisions, which through reference in this text
constitute provisions of this NIOC EXP standard. Latest issue of the references shall
be used unless otherwise agreed. Other recognized standards may be used provided it
can be shown that they meet or exceed the requirements of the standards referenced
below.
NS-EN 292 – Part 1: Safety of Machinery - Basic Concepts, General
Principles for Design - Part 1: Basic Terminology,
Methodology
NS-EN 292 – Part 2: Safety of Machinery - Basic Concepts, General
Principles for Design – Part 2: Technical Principles and
Specifications (as amended)
NS-EN 1050: Safety of Machinery - Principles for Risk Assessment
NIOC HSE-002: Working Environment

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3 DEFINITIONS AND ABBREVIATIONS

3.1 Definitions
Declaration of Conformity: The Declaration is issued by the manufacturer of
machinery, or his representative, to document
conformity with the requirements of Machinery
regulations.
Declaration of Incorporation: The Declaration is issued by the manufacturer of
sub-assembly, or his representative, to document
conformity with the requirements of Machinery
regulations.
Design review: A systematic and documented examination of a
design to evaluate its capability to fulfill specific
requirements.
Machinery: As defined in Machinery regulations, the term
Machinery comprises various types of individual
machines and assembly of machines,
distinguished by the ability to perform a specific
application, as well as interchangeable
equipment.
Risk Assessment: A documented and systematic process of
identification and assessment of hazards related
to specified work tasks, including estimation of
frequency and consequence of accidents /
harmful effects for the personnel involved. Risk
assessments are used as a basis for evaluation of
the need for and selection of safety measures.
Safety Data Sheet: Documentation of the safety, health and
environment hazards of a chemical product
according to the regulations relating to
‘Compilation and distribution of safety data
sheets for dangerous chemicals’.

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Shall: Verbal form used to indicate requirements

strictly to be followed in order to conform to the
standard and from which no deviation is
permitted, unless accepted by all involved
parties.
Should: Verbal form used to indicate that among several
possibilities one is recommended as particularly
suitable, without mentioning or excluding
others, or that a certain course of action is
preferred but not necessarily required.
Sub-assembly: A machine that cannot function independently,
and that is intended for incorporation into
machinery.
Working Environment: As defined in NIOC HSE-002:
3.2 Abbreviations
PO: Purchase Order

WE: Working Environment

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4 RESPONSIBILITIES
The following responsibilities apply with respect to execution of analysis and delivery
of working Environment (WE) documentation for machinery:
4.1 Contractors
The responsibilities of a company working as a Contractor for NIOC EXP according
to a contract are described below. Various contract strategies may apply, including
engineering, procurement, construction, installation, and/or commissioning. Typical
deliveries from principal Contractors are offshore platforms, pipelines, and sub-sea
installations. A principal Contractor may use various sub-contractors. Typical
deliveries from sub-contractors are living quarters, drilling modules, and process
modules.
For each subject Machinery, within Contractor’s scope of work, the Contractor shall
ensure that the boundaries of Machinery and sub-assemblies and the responsibilities
for issue of statutory declarations and indicators (e.g. instructions, CE-marking) are
defined.
Further, the Contractor shall ensure that the requirements for WE documentation are
determined and specified in sub-contract and/or Purchase Orders (POs); cf. clause 5.
The Contractor shall also:
Provide the interface information necessary for execution of Risk
Assessments (e.g. information’s regarding control systems, utility systems,
energy supply) to sub-contractors and/or Suppliers.
Specify risk estimation criteria other than the criteria in clause 6.7, if
necessary to meet the risk acceptance criteria for the overall occupational
accident risk in the area.
Specify noise level limits on noise data sheets, request the procedures for
verification of Supplier guaranteed noise levels, and request necessary
vibration data; cf. clause 5.5.
Ensure that working environment documentation of adequate quality are
received from sub-contractors and/or Suppliers.
Forward aggregated WE documentation to Client.

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4.2 Suppliers
4.2.1 Supplier of Machinery
Supplier of Machinery is responsible for the safety of the machine and for providing
the ‘Declaration of Conformity’ and the ‘Instructions’ issued according to Machinery
regulations; cf. clause 5.1.
Further, the Supplier shall ensure that the necessary WE analysis of subject
Machinery are executed and documented.
The Supplier shall also:
Identify the interface information necessary for execution of risk assessments
(e.g. information regarding control systems, energy supply), and request any
lacking information from Contractor;
Identify and implement all WE requirements applicable to design, construction
and documentation of subject delivery; cf. NIOC HSE-002 and normative
references hereto, and the basic concepts outlined in Appendix A2;
Define sub-suppliers’ responsibilities for WE documentation in POs;
Ensure that documentation of adequate quality is received from sub-suppliers.
As specified in sub-contract or PO, the Supplier shall compile and provide the
required technical WE documentation; cf. clause 5.
4.2.2 Supplier of Sub-assembly

Supplier of sub-assembly is responsible for the safety of the sub-assembly and for
providing the ‘Declaration of Incorporation’ issued according to machinery
regulations. As specified in PO, the Supplier shall provide the documentation
necessary to demonstrate conformity with machinery regulations, normative
standards, and other WE requirements.

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5 WORKING ENVIRONMENT DOCUMENTATION

5.1 General
As stipulated in the Machinery regulations, subject Machinery shall bear CE marking
and the following documentation shall be provided:
‘Declaration of Conformity’.
‘Instructions’ for safe use, etc. Instructions for regular use and maintenance by
operators shall be both in Farsi and uage.
Additional technical WE documentation is required according to the regulations and
normative standards applicable to offshore machinery. Requirements and
responsibilities for provision of WE documentation shall be determined and
documented. If not otherwise agreed in sub-contract or PO, the aggregated WE
documentation for subject machinery shall include:
Risk assessment report; cf. clause 5.2.
WE design reviews checklists; cf. clause 5.3.
Inventory and safety data sheets for chemicals; cf. clause 5.4.
Noise data sheets and vibration data; cf. clause 5.5.
Basic concepts regarding WE requirements, analysis and documentation are
elaborated in Appendix A2. A typical form for documenting the requirements for WE
documentation and responsibility determinations is included in Appendix C.
5.2 Risk Assessments

The technical documentation to the ‘Declaration of Conformity’ shall include a
description of the methods chosen to remove hazards of the machinery. Risk
assessments to examine the hazards and specify necessary safety measures are an
integral part of these methods; cf. Appendix A3. Risk assessments shall be executed
during development of the design, to ensure integration of safety and conformity with
the functional WE requirements applicable to subject machinery.
A method for risk assessments during design of machinery, is described in more detail
in clause 6 of this standard.
The risk assessments of machinery shall be documented in risk assessment reports,
providing information about any:

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Dangerous manual tasks / interactions; cf. clause 6.5

Hazards and hazardous situations / events; cf. clause 6.6
Risk estimates; cf. clause 6.7
Safety measures in design and/or operations; cf. clause 6.7
A typical form for documenting risk assessments is included in Appendix E. In
addition to the risk assessment method described in clause 6, there may be needs for
special methods to analyze hazards and estimate risks of complex and/or safety
critical machinery. Methods outlined in NS-EN 1050 and NIOC HSE-002 are referred
to, e.g.: NIOC standard Page 12 of 54.
Other references related to risk assessment are:
Failure Mode and Effects Analysis (FMEA) or Fault Tree Analysis (FTA), to
document reliability of control and safety systems; cf. NS-EN 1050 Appendix
B
Ergonomic job / task analysis, to document risks of muscle-skeletal injuries;
cf. NIOC HSE-002 clause 4.9.4 and Appendix I.
Crisis Intervention in Offshore Production (CRIOP) analysis, to document
man-machine interface of control rooms; cf. NIOC HSE-002 clause 4.9.5 and
Appendix I
Chemical handling analysis, to document risks of exposure to hazardous
chemicals; cf. NIOC HSE-002 clause 4.9.6 and Appendix I.
5.3 Working Environment Design Reviews
Design reviews are required to verify conformity with the specific WE requirements
applicable to subject machinery and to identify any needs for corrective measures.
Such WE design reviews shall be executed during development of the design, and
shall be documented by completion of checklists.
To provide input to the design, a first design review should be performed as part of
early engineering, and this checklist should at least be updated prior to construction.
The personnel/team performing WE design reviews shall have adequate working
environment qualifications, and shall be familiar with operation and maintenance
activities associated with the machinery.
A typical WE design review checklist for offshore machinery, based on specific WE
requirements in the normative references, is included in Appendix G.

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The checklist covers a broad specter of specific WE requirements. Thus, some

requirements may not be applicable for certain deliveries.
Completion of this checklist does not exempt Suppliers from the responsibility
to identify and verify other specific requirements applicable to subject
delivery, e.g. requirements in relevant type B European standards (to be
identified by Supplier).
Typical users of the checklist are the suppliers and sub-suppliers of machinery,
and also contractors with an overall responsibility for the design, e.g.
engineering companies.
The checklist may also be used for WE inspections during construction and
mechanical completion; cf. NIOC HSE-002 clause 4.11.
5.4 Chemical Inventory and Safety Data Sheets

All chemical substances and preparations that are contained within the machinery
boundaries and/or are planned to be used in connection with the machinery shall be
identified and documented in an inventory. Typical chemicals to be included are lube
oils, grease, and preservation chemicals. Information regarding intended use, location
and quantities shall be listed, along with reference to the safety data sheet. Also, the
potential for personnel exposure, as identified in risk assessments or WE design
reviews, shall be documented.
A typical chemical inventory form is included in Appendix F.
Chemicals that follow the installation offshore or are included in instructions for
operation and maintenance shall be documented on safety data sheets; cf. NIOC HSE-
002 clause 5.4.2.
The safety data sheets shall be in the Farsi language and approved through the quality
assurance scheme for such data sheets.
5.5 Noise and Vibration Data

5.5.1 Noise Data Sheets
For all potentially noisy machinery, noise data sheets with ‘Company specified data’
(noise level limits) are included in the inquiries; cf. NIOC HSE-002 clause 4.8.2. A

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typical noise data sheet is included in NIOC HSE-002 Appendix H.
One or more of the following noise data may be required:
Sound power level;
Sound pressure level at 1 m distance, free field condition;
Sound pressure level at operator’s position, free field condition.
During engineering, the noise data sheet for subject machinery shall be completed
with all the information required:
Equipment design data;
Guaranteed ‘Supplier data’ (noise levels), in the same format as the ‘Company
specified data’
Method for planned noise level test during fabrication (see below);
Description of all noise control measures that have been implemented in order
to achieve a low noise design and meet the specified data. The recommended
practice for the design of low noise machinery and equipment in standard ISO
11688 is referred to.
It should be stated whether the specified / guaranteed noise data applies to the
complete machinery or to specific components or sub-assemblies.
During fabrication, measurements to verify the guaranteed noise levels are required,
unless data from previous tests on standard machinery can be accepted. The
verification measurements shall be performed according to a documented test
procedure, and should be executed or witnessed by a qualified noise control engineer.
Recommended methods for noise level tests are described in Appendix B1. The
measurement results, incl. correction for measurement uncertainty, shall be
documented in the noise data sheet.
5.5.2 Vibration Data

Maximum limits for continuous whole body vibration from machinery are given in
NIOC
HSE-002, Appendix E. The limits cover the range 1 - 80 Hz.
When input data for structural vibration analysis are required, the following vibration
data shall be provided:
Frequency of revolution (rpm).
Unbalanced force and direction (N).

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Weight of rotor (kg or lbm).
Total weight of machinery, including frame (kg or lbm).
For vibration isolated machinery the following data shall also be provided:
Static and dynamic stiffness of each elastic support (N/m).
Resonance frequencies for lumped mass machinery on stiff foundation, 6
degrees of freedom.
a. Vertical translation frequency (Hz).
b. The highest of the six resonance frequencies (Hz).
The degree of vibration isolation obtained will depend on the stiffness of the deck. If a
specific value for vibration isolation insertion loss is required, the Supplier shall
specify a minimum stiffness value for the deck at the support positions in N/m.
If required, input data for analysis of structure borne noise from the machinery shall
be provided. The data shall be given as vibration levels at the supports. Recommended
methods for measurement and documentation of vibrations causing structure borne
noise are described in Appendix B2.

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6 RISK ASSESSMENT
6.1 Process overview
The main steps of a generally applicable method for risk assessments of machinery
are shown in Figure 1. The steps are discussed in more detail in clauses 6.2 - 6.7
below. Basic concepts regarding this method to remove hazards of machinery are
elaborated in Appendix A3. The process shall be documented; a typical form for
documentation of the assessment is included in Appendix E.
Figure 1 - Outline of the risk assessment process for machinery
The purpose of the risk assessment is to ensure timely implementation of necessary

safety measures. It is essential to perform an initial / coarse examination of hazards
and an assessment before layout freeze and placement of major purchase orders (POs)
for sub-deliveries.

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Responsibilities and limits should be determined before start of detailed engineering.

The other steps should be initiated during early engineering, and should be performed
and updated in more detail as the design develops and when modifications are
required.
Requirements for risk assessments, as part of the aggregated working environment
(WE) documentation, shall be specified in the PO. A risk assessment performed for a
previous
delivery can be accepted, provided that the assessment meets the requirements in this
standard and that the machinery design and operational modes are unchanged.
Previously performed risk assessments shall be documented, together with an
evaluation of the adequacy of this assessment for the recent application.
Extent and level of detail of the risk assessment, as well as needs for updates as the
design develops should be adapted to the category and complexity of the machinery /
equipment, manual tasks, and hazards involved.
6.2 Determine responsibilities

According to Machinery regulations, the manufacturer or his representative,
alternatively the vendor or the company responsible for assembling machines, is
responsible for executing risk assessments and issuing the Declaration of Conformity;
cf. Appendix A2. Each machinery on the installation shall be subject to the risk
assessment process, and for each machinery, the party responsible for executing and
documenting the risk assessment shall be identified and documented; cf. clause 5.1
and Appendix C. To achieve this, the boundaries between the various assembled
machines, individual machines, and sub-assemblies must be identified. In particular, it
is imperative to sort out interface issues and determine responsibilities with regard to
an assembly of machines.
An assembly of machines may comprise individual machines and sub-
assemblies which have to be assessed and documented both as part of the
assembled unit and separately, typically when the machine / sub-assembly
seen in isolation represents particular hazards, or when the design of the
individual machine / sub-assembly is critical to the safety of the assembled
unit.

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The principal Contractor shall initiate this activity, and shall ensure that allocation of
responsibilities are agreed by Suppliers and/or sub-contractors for all the various
machinery within his scope of work. Each Supplier has to evaluate to what extent his
delivery is made up of machinery / sub-assemblies from sub-suppliers, and determine
the corresponding risk assessment responsibilities.
6.3 Determine machinery limits (step 1)

The use, space and life time limitations of each subject machinery shall be identified
in detail, and any interface issues resolved, prior to commencing the risk assessment.
As relevant, the following information shall be collected and documented for the risk
assessment:
A. Description of the machinery (drawings, etc.).
B. Definition and description of interfaces concerning physical arrangements,
control system, power supply, and space requirements; e.g., by reviewing
layout / arrangement drawings, process and instrument diagram (P&ID),
electrical and instrument diagrams.
C. Assumptions about installation arrangements and ambient conditions (indoor /
outdoor climate, lighting, noise, vibration, etc.).
D. Machinery lifetime, e.g., mean time to change of components, sub-assemblies,
etc.
E. Assumptions about the user (qualifications, etc.)
F. Accident and health impairment statistics for subject or similar machinery.
6.4 Establish assessment team (step 2)

To execute the risk assessment, a qualified assessment team shall be organized. The
Supplier shall ensure that personnel representing the following competence participate
on the team:
Personnel familiar with operation and maintenance of the machinery;
Relevant engineering disciplines (e.g., layout, mechanical, instrument,
electrical);
Working environment specialist with adequate qualifications (e.g. in

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ergonomics and/or industrial hygiene), the manual tasks and hazards taken into
consideration.
Operations and maintenance personnel from the Client’s organization should be
invited to participate.
For machinery relying on the installation’s control and/or power supply systems for
vital safety functions, the principal contractor’s instrument / electrical discipline
should be invited as a member of the assessment team.
6.5 Identify and describe manual tasks (step 3)

Manual tasks and interactions where personnel may be present inside the danger zone
of the machinery shall be identified and used as a basis for risk estimation and
evaluation.
A step-by-step breakdown of the tasks / activities to a sufficient level of detail shall be
carried out and documented in the risk assessment form; cf. Appendix E (column 2).
The break down shall cover all operational modes and foreseeable uses, including:
1. Normal operation, incl. start up and shut down.
2. Cleaning.
3. Inspection, incl. fault diagnosis.
4. Maintenance, incl. repair and material handling.
Handling of foreseeable operational disturbances, malfunctions and / or misuse during
the various operational modes shall be subject to assessment. For remotely controlled
or automatic machinery, the possibility of personnel being in the danger zone in event
of a sudden start shall be included.
Regarding the requirements for analysis of workplaces and tasks, reference is made to
NIOC HSE-002 clause 4.9
6.6 Identify and describe hazards (step 4)

Hazards and hazardous situations / events associated with the various operational
modes of the machinery shall be identified, incl. both hazards resulting in injuries as
well as work related diseases.
For an initial risk assessment, typical hazards and hazardous situations to consider for
risk assessment are listed in Appendix D. For more detailed assessments, the

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description and examples of hazards and hazardous situations / events it is referred to
NS-EN 292-1 clause 4 and NS-EN 1050 Appendix A.
A description of each actual hazard and why a hazardous situation may arise shall be
documented in the risk assessment form; cf. Appendix E (column 3).
6.7 Estimate and evaluate risk (step 5)

Estimation of the risk from occupational accidents and/or lasting exposures serves as
a basis for identifying needs of remedial actions, incl. safety measures / safeguarding
in design. The risks are estimated and characterized by the assessment team, using
professional judgment, and any applicable rating criteria for the elements of risk. In
the estimation, existing design safety measures shall be considered, but not
operational measures such as the use of personal protective equipment.
For hazards that can result in occupational injuries, Table 1 shows a typical risk
matrix with rating criteria for the frequency of occurrence and consequences of
hazardous situations. The criteria shall be applied unless otherwise instructed by
Contractor. For each hazardous situation identified, the consequence (‘C’), frequency
(’F’), and the resulting risk (’R’) shall be documented in the risk assessment form; cf.
Appendix E (columns 4-6).
• First, the most serious consequence that from a realistic point of view may occur
shall be identified and rated on a scale from 1 to 4.
• Next, the expected frequency of the consequence shall be estimated, also on a scale
from 1 to 4. Frequency estimations are based on frequency and duration of work or
other presence inside danger zone of the machinery, probability of occurrence of the
hazardous situation, and possibility to avoid or limit the harm.
• Finally, the resulting risk shall be estimated and characterised as High, Medium or
Low.

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Table 1- Risk matrix for occupational accidents

Frequency
1 time per 100 1 time per 10 1 time per 10 times per
Consequence years or less years year year or more
(1) (2) (3) (4)
First-aid (1) Low Low Medium High
injury
Lost time Low Medium High High
(2)
injury
Permanent (3) Medium High High High
disability
Fatality (4) High High High High
For hazards where exposures can result in work-related diseases (e.g. ergonomics,
materials and substances), rating criteria for use in a risk matrix have not been
established and the judgment of the assessment team is referred to for risk
characterization. The exposure risk shall be estimated (as High, Medium or Low) and
documented; cf. Appendix E (column 6).
In case the Supplier has data related to the personnel’s’ overall exposures
during a work shift, he shall perform detailed ergonomic and/or chemical
handling analysis as specified Machinery - Working Environment Analysis
and Documentation HSE-005 in NIOC HSE-002 clause 4.9. Otherwise, he
shall state the need for such analysis to his customer.
Risk evaluation shall be carried out as outlined in Figure 2, to determine if risk
reduction is required or whether safety has been achieved. ‘High’ residual risks are
not acceptable. Within the ‘Medium’ risk range, safety measures shall be
implemented to lower the risk as far as reasonably practicable (the ALARP principle).
Safety measures shall be identified by considering the strategy for selection of safety
measures according to NS-EN 292; cf. Appendix A3. Changes in layout, selection of
safe sub-assemblies and components, and safeguarding shall be considered as
applicable, and the result of such evaluations shall be followed-up in design and
procurement.

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The operational precautions necessary to reach an acceptable residual risk shall be

identified.
These may include adherence to certain job procedures, use of personal protective
equipment, permit to work system, etc.
If additional hazards are created when new safety measures are applied, they shall be
added to the list of hazards, and the risk shall be estimated and evaluated.
Design safety measures and safeguarding, operational precautions is expected to be
implemented by the user, and the residual risk shall be documented in the risk
assessment form; cf. Appendix E (columns 7, 8, and 9, 10, 11, respectively).

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Figure 2 – Breakdown of Step 5 Risk estimation and evaluation

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APPENDIX A BASIC CONCEPTS (INFORMATIVE)
A.1 Scope and Objectives

This NIOC standard describes rational methods for necessary working environment
(WE) analysis of machinery design (i.e. risk assessments and design reviews) and
documentation of conformity with WE requirements applicable to offshore
machinery.
The described allocation of responsibilities, review and assessment processes, and
formats of documentation addresses the basic regulatory requirements, normative
standards, and expectations of major Clients in the offshore industry.
The standard is applicable to the design of machinery; cf. definition of machinery in
clause 3.1 of this standard. It is recommended to apply the standard, by means of a
contractual requirement, also to sub-assemblies and technical products (equipment /
appliances) having similar hazards as machinery.
As use of the methods for sub-assemblies and other technical products not formally
defined, as machinery is optional, only the term machinery is used in the standard.
Suppliers (i.e. manufacturers and/or vendors) of offshore machinery, sub-assemblies
and other technical products are the primary users of the methods of the standard. The
purpose is to assist the Suppliers in meeting regulatory and contractual requirements
for WE analysis and documentation during design, and to ensure quality and
consistency of the WE documentation aggregated in the as-built documentation
handed over to Client.
By proper implementation of the standard and incorporation of the safety measures
identified by the risk assessment, the Supplier will meet the offshore industry’s
expectations for:
Integration of safety into design of subject machinery; cf. the essential health
and safety requirements in Machinery regulations §7 and Appendix I, and WE
requirements in other relevant regulations, standards and codes.
Description of the methods chosen to remove the hazards of subject
machinery; cf. requirements for technical documentation to the Declaration of
Conformity in Machinery regulations §9.2 and Appendix V.

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Documentation of WE analysis, noise and vibration control, and hazardous

chemicals for subject machinery; cf. NIOC HSE-002.
A.2 WE Requirements, Analysis and Documentation

Machinery delivered for use on offshore installations shall comply with the
requirements stipulated in the Machinery regulations. This implies that the machinery
shall be designed and constructed according to the principles of safety integration, in
compliance with the essential health and safety requirements (i.e. WE requirements)
applicable to subject machinery.
Applicable WE requirements shall be identified based on assessment of the hazards
associated with the machinery. Functional WE requirements are stipulated in
Machinery regulations Appendix I. Requirements relevant to the design and delivery
of offshore machinery, including functional and specific
WE requirements and principles for analysis / verification and documentation of
machinery safety, are also set out in other regulations, standards and codes, e.g.:
Working Environment Act chapters II and IV;
Regulations re. Systematic follow-up of the Working Environment in
Petroleum Activities (the ‘SAM regulation’, stipulated by Norwegian
Petroleum Directorate);
NIOC standards; e.g. HSE-002 Working Environment;
ISO quality standards; e.g. ISO 9001, clause 4.4 and 4.6;
Contractual requirements to subject machinery and documentation
deliverables.
WE requirements has to be managed according to common quality assurance
principles. Rational methods for analysis / verification of conformity and integration
of safety in the design (i.e. methods to remove hazards) are selected based on a
breakdown of the WE requirements into:
1. Functional (goal / target oriented) requirements

A risk assessment process is used to analyze / verify the design and specify the
safety measures necessary to eliminate or reduce non-acceptable risks; cf. clauses
5.2 and 6 of this standard.

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2. Specific (prescriptive / measurable) requirements

A WE design review process utilizing checklists is used to identify non-
conformities and the need for corrective measures; cf. ISO 9001, and clause 5.3
and Appendix G of this standard.
The breakdown of the WE requirement and analysis / verification methods are
outlined in
Figure A1 below. According to the Machinery regulations, conformity with applicable
WE requirements shall be documented. The manufacturer or his representative,
alternatively the vendor or the company responsible for assembling machines, shall
work out the statutory documentation prior to placing machinery on the market.
For machinery, a ‘Declaration of Conformity’ shall be issued and CE marking
shall be applied. Technical documentation demonstrating compliance with the
WE requirements, incl. a description of the methods chosen to remove the
hazards of subject machinery (cf. Appendix A3), shall be drawn up prior to
issue of this declaration; cf. Machinery regulations §9, Appendix II.A, and
Appendix V.
For a sub-assembly, a ‘Declaration of Incorporation’ shall be issued, incl.
Information prohibiting use until a ‘Declaration of Conformity’ has been
issued for the assembled machinery; cf. Machinery regulations §8 and
Appendix II.B.
Also, machinery shall be provided with statutory indicators, incl. ‘Instructions’ with
information necessary for safe use, maintenance, etc.; cf. Machinery regulations
Appendix I, no.1.7.4.
Additional WE documentation is required to demonstrate the integration of safety into
design of subject machinery and to meet the offshore industry’s expectations for WE
documentation; cf. NIOC HSE-002, clauses 5.3.1 (machinery), 4.9 (WE analysis),
4.8.2 (noise and vibration control), and 4.9.6 / 5.4.2 (hazardous chemicals).
• The statutory technical documentation describing the methods chosen to remove
hazards (i.e. the risk assessment and the WE design review processes) shall be
provided, to demonstrate the quality of the WE analysis and conformity with
functional and specific WE requirements in regulations and normative standards.
• Data on noise and vibration control and hazardous chemicals shall be provided,

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among others to facilitate analysis of the machinery’s impact on the overall WE of the
installation / areas and personnel exposures.
The Supplier is responsible for providing the aggregated WE documentation.

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Figure A1 – Breakdown of WE requirements and analysis methods
A.3 Methods to remove hazards of machinery

The preferred method for removing hazards associated with machinery is an iterative
process of risk assessments to examine the hazards, followed, when necessary, by
specification of safety measures to eliminate or reduce the risk, To verify conformity
with specific WE requirements, a design review is also required; cf. ISO 9001, and
clause 5.3 and Appendix G of this standard.
A hazard is a source of possible injury or damage to
health. Hazards may affect worker health through both
occupational accidents and lasting exposures, resulting
in occupational injury and/or work related disease.
A hazard is associated with a danger zone, the zone
within and/or around machinery in which a person
encounters risk of injury or damage to health. A
hazardous situation with potential for harm arises when
a person enters the danger zone and is exposed to the
hazard. Figure A2 illustrates the need for safety measures to protect persons from
hazards in a danger zone. Examples of machinery hazards and hazardous situations
are listed in Appendix D.

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Risk is a function of the severity of the possible injury or damage to health and the
probability of occurrence of that harm, as determined by the frequency and duration
of exposure, the probability of occurrence of the hazardous situation, and the
possibility to avoid or limit the harm.
Risk assessments include risk analysis (i.e. determination of the limits of the
machinery, hazard identification, and risk estimation of hazardous situations) and risk
evaluation to determine if risk reduction is required or whether safety has been
achieved.
Risk assessments to specify appropriate safety measures are applicable to hazards
resulting in both occupational injuries as well as work related diseases.
The strategy and priorities for selecting safety measures are stipulated below:
1. Risk reduction by design, i.e. removal of the hazard or limitation of the risk.
2. Safeguarding against hazards by design, i.e. establishment of barriers between
the hazard and the person, thereby preventing the person to get in contact with
the danger zone, see Fig. A.2
3. Information concerning safe work methods, personal protective equipment and
work permits as a requisite to warn users about residual risks
4. Additional precautions shall also be considered, including emergency stops,
escape possibilities, isolation, safe access, etc;
According to the statutory principles of safety integration, lower priority safety
measures shall not be selected before all possible measures of higher priority have
been evaluated and, if feasible, have been implemented.

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APPENDIX B NOISE AND VIBRATION

MEASUREMENTS (INFORMATIVE)
B.1 Noise Verification Measurements
Verification measurements according to a documented test procedure shall be carried
out during fabrication; cf. NIOC HSE-002 clause 4.8.2.
For measurements of free field sound pressure levels at specified positions, the
standards in the (NS-EN) ISO 11200 series should be used. Alternatively, specific
product standards based on these main standards may be used. When the machine is
installed in a room, the noise level will be higher than in a free field. The standard
stipulates corrections for the reflected noise caused by the room, so that free field
values can be calculated. NS-EN ISO 11201 with engineering grade of accuracy is
recommended.
Concerning measurements of sound pressure level at operators position, e.g. inside a
crane cabin, standardized methods are preferred. However, specific written
procedures may be used.
For sound power measurements, standards in the NS-EN ISO 3740 series or NS-EN
ISO 9614 series should be used. Alternatively, specific product standards based on
these main standards may be used. Standards with engineering grade of accuracy, NS-
EN ISO 3744 or NS-EN ISO 9614-2, are recommended.
The condition for verification of the guaranteed noise level (Lg) is:
Lg ≤ L + K
Where L is the measured value in dB(A) and K is the measurement uncertainty; cf.
NS-EN ISO 4871. The sum of L + K shall be presented in the noise data sheet.
The uncertainty value K depends on the grade of accuracy for the measurement
method. The K-value is to be specified from the supplier, and is his responsibility.
However, the following values may be used as typical values:
Measurement method Correction K

Accuracy (dB)
Engineering grade 1-2
Survey grade 2-4

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B.2 Structure borne Noise

Vibration from the machinery supports will always be transmitted to adjacent areas
and radiate noise, i.e. structure borne noise. In work areas, structure borne noise may
usually be neglected compared to air transmitted noise. There are exceptions,
however, and especially in living quarters and control rooms the structure borne noise
level should be evaluated.
The input data for analysis of structure borne noise from machinery shall be given as
vibration level at the supports.
For vibration isolated machinery the vibration shall be measured on the top of the
vibration isolators. The vibration level in these positions are, for medium and high
frequencies, independent of the stiffness of the deck, and is easy to control by
measurements. The mean value of the vibration level of all the support points shall be
given in octave bands from 31.5 to 2000 Hz. Data should be given as velocity level
dB relative to 5×10-8 m/s.
For a machine that is fastened directly to the deck, the vibration level at the support
points will depend on the stiffness and other details of the deck and support points.
Vibration shall be measured at the carrying frames as near as possible to the machine
support points. The mean value of vibration on the supports shall be given, as
specified above. These data are only valuable if the details of the deck, frames and
supports, in which the measurements are taken, are described in detail.

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APPENDIX C DETERMINATION OF WORKING

ENVIRONMENT (WE) DOCUMENTATION
RESPONSIBILITIES (INFORMATIVE)
Typical form for documenting the determinations regarding responsibilities and
requirements for aggregated WE documentation. Additional WE documentation may
be specified in contract / PO. Included are examples for a complex machinery
assembly (A) and a safety critical, but non-noisy sub-assembly (B).

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APPENDIX D HAZARDS AND HAZARDOUS

SITUATIONS
(INFORMATIVE)
Typical hazards and hazardous situations / events associated with machinery that
should be considered for risk assessments. The checklist is based largely on the
descriptions of hazards in NS-EN 292-1 clause 4 (numbers of corresponding clauses
in brackets), and also on NS-EN 1050 Appendix A1.
Mechanical [4.2]
Crushing
Shearing / cutting / stabbing / puncture
Entanglement / drawing-in / trapping
Impacts
Friction / abrasion
High pressure fluid ejection
Falling / ejected objects
Slipping / tripping / falling persons
Loss of stability / overturning
Electrical [4.3]
Live parts (direct / indirect contact)
Electrostatic discharge
Thermal [4.4]
Hot surfaces (contact)
Flames / explosions (contact)
Heat sources (radiation)
Cold stress (outdoor work)
Noise [4.5]
Excessive noise (dangerous to hearing)
Failure of control systems / circuit
1
The examples of hazards etc. in NS-EN 1050 Appendix A also includes cross-references to the
essential health and safety requirements in Machinery regulations in Machinery regulations Appendix I
(i.e. NS-EN 292-2/A1 Appendix A), and to clauses in NS-EN 292-1 and NS-EN 292-2.

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Vibration [4.6]
Excessive whole-body vibration
Excessive hand-arm vibration
Radiation [4.7]
Low frequency electromagnetic fields
Radio frequencies / micro-waves
Infra-red / visible / ultra-violet light
Lasers
Ionizing X-rays, γ-rays, ion beams, etc.
Materials and substances [4.8]
Dangerous fluids / aerosols (contact)
Dangerous gases / vapors / mist / fume / dust (inhalation)
Fire / explosion hazards
Biological hazards
Ergonomics* [4.9]
Monotonous / excessive muscular load
Work in fixed / static postures
Work in kneeling / squatting / lying positions
Work with hand above shoulder / below knees
Continuous asymmetric load on body
* Hazards from neglecting ergonomic principles in design
Hazardous situations / events
Break-up during operation [4.2]
Intervention in combined machinery [4.2]
Noise interfering with communication [4.5]
Inadequate design / location / identification
Manual controls and displays [4.9]
Mental overload / underload / stress [4.9]
Malfunction from human errors [4.9]
Failure of power supply

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APPENDIX E: FORM FOR DOCUMENTATION OF RISK
ASSESSMENTS (INFORMATIVE)
* Risk estimation according to clause 6.7: C – Consequence (1-4) / F – Frequency (1-4) / R – Risk (H – high, M – medium, L – low)

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APPENDIX F FORM FOR CHEMICAL INVENTORY (INFORMATIVE)

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APPENDIX G WORKING ENVIRONMENT (WE) DESIGN REVIEW CHECKLIST

(INFORMATIVE)
Checklist for performing design reviews of offshore machinery, to verify conformity with specific WE design requirements and to identify any
needs for corrective actions.
User guide / legend to the checklist columns:
G1. REQUIREMENT
A short description of the requirement is given, with actual dimensions where this is applicable.
G2. REFERENCES
Reference to the standard or code where the requirement is stipulated.

NIOC Standard Referenced Norwegian Standard (to be changed with equivalent Iranian standard)
NIOC C-002 Architectural components and equipment NS-EN 292 Safety of machinery – Basic concepts, general principles for
design (Parts 1 - 2)
NIOC HSE-001 Design principles – Technical safety NS-EN 349 Safety of machinery – Minimum gaps to avoid crushing of
parts of the human body
NIOC HSE-002 Working Environment NS-EN 626 Safety of machinery – Reduction of risks to health from
hazardous substances (Part 1)
NIOC HSE-003 Design principles – Environmental care prEN 12437 Safety of machinery – Permanent means of access to
machinery and industrial plants (Parts 1 - 4)

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G3. STATUS
Indication of machinery status and result of review.
OK: Fully in compliance with the referred standard or code.
AR: Action required.
NCP: Non-conformity, action pending.
NCA: Non-conformity, action approved.
NA: Requirement not applicable for the specific delivery.
G4. COMMENTS
All actions necessary to meet requirements stipulated in regulations, standards and codes should be noted. Status indications AR, NCP and
NCA shall be followed by a comment.

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REQUIREMENT REFERENCES STATUS COMMENTS

1. ACCESS
1.1 Horizontal/vertical distances
1.1.1 Are horizontal workspaces for fixed equipment minimum NIOC HSE-002, Appendix B
700 mm?
1.1.2 Are centre heights of control devices for standing NIOC HSE-002, Appendix B
operations (including valve handles) max. 1800 mm above base
?
Are the centre heights of control devices for controls in daily
use and for controls where access in an emergency is required
900-1500 mm above base?
1.1.3 Are visual displays located 1100-2000 mm above floor NIOC HSE-002, Appendix B
level?
1.1.4 Are electrical contacts and switches located 900-1500 mm NIOC HSE-002, Appendix B
above floor level?
1.1.5 Are access ways to permanently and intermittently NIOC HSE-002, Appendix B
manned workplaces min. 900 mm wide?
1.1.6 Are vertical clearances in access ways min. 2100 mm? NIOC HSE-002, Appendix B
1.1.7 Are vertical clearances in work areas and stairs min. 2300 NIOC HSE-002, Appendix B
mm? NIOC C-002, 5.7
1.1.8 Is space between fixed cabinets and floor min. 250 mm NIOC HSE-002, Appendix B
(or preferably;
fixed on floor without space underneath)?
1.2 Pipes and flanges
1.2.1 Are spaces between pipe bottoms and floor min. 150 mm? NIOC HSE-002, Appendix B
1.2.2 Are spaces between external diameter of flanges and fixed NIOC HSE-002, Appendix B
obstructions min. 250 mm?
1.3 Guardrails
1.3.1 Are guardrails provided on elevations higher than 800 NIOC HSE-002, Appendix B
mm?

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1.3.2 Is height from floor to top of the guardrail min. 1000 mm? NIOC HSE-002, Appendix B
prEN 12437
1.3.3 Is free space between handrail, knee rail and toe plate not NIOC HSE-002, Appendix B
more than 380 mm? prEN 12437
Are minimum two knee rails included?
1.3.4 Are toeboards of min. 100 mm height provided on NIOC HSE-002, Appendix B
passageways located over frequented areas and open sea? prEN 12437
Is the opening between floor and toe board max. 15mm?
1.3.5 Is diameter of handrails within the range 25–50mm? NIOC HSE-002, Appendix B
prEN 12437
1.3.6 Are stairways, stepladders and inclined ladders provided NIOC HSE-002, 5.1.2
with continuous railing on both sides, from the top to the lower NIOC C-002, 5.8
level and safely terminated at both ends?
1.3.7 Is distance between handrails and any obstruction min. 75 NIOC C-002, 5.8
mm?
1.4 Stairs
1.4.1 Are stairs or ladders provided where there is a change of NIOC HSE-002, Appendix B
elevation exceeding 350 mm and access is required?
1.4.2 Are stairs provided where daily access is required? NIOC HSE-002, 5.1.2
prEN 12437
1.4.3 Is width of stairway passage min. 1000 mm, as measured NIOC C-002, 5.2
between the inside of handrails (or min. 1200 mm for access to
more than two levels)?
1.4.4 Is the inclination of stairways within the range 21° - 45° ? NIOC HSE-002, Appendix B
(Recommended range 30° - 38°) prEN 12437
1.4.5 Are the following requirements for steps met:
a) Height riser (h) ¡Ü 250 mm
b) Going (g) ¡Ý 100 mm
c) 600 mm ¡Ü g+2h ¡Ü 660 mm
prEN 12437
1.5 Ladders and Stepladders

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1.5.1 Is the inclination of: NIOC HSE-002, Appendix B
- fixed ladders within the range 76° - 90° ? prEN 12437
- fixed stepladders within the range 46° - 75° ?
1.5.2 Is the width between upright bearers at least 400 mm? NIOC HSE-002, Appendix B
prEN 12437
1.5.3 Is there a horizontal clearance of 650 mm in front of NIOC HSE-002, Appendix B
ladders, and a horizontal clearance of 200 mm behind the front prEN 12437
of the rungs (150 mm for discontinuous obstacles)?
1.5.4 Are rungs evenly spaced, with vertical spacing min. 250 NIOC HSE-002, Appendix B
mm and max 300 mm. prEN 12437
Are rungs provided with a non-slip surface?
1.5.5 Are safety cages, starting at height 2200 - 3000 mm, NIOC HSE-002, Appendix B
provided for ladders higher than 3000 mm? prEN 12437
1.5.6 Is there a rest landing arranged at each 6000 mm for NIOC HSE-002, Appendix B
ladders above 10,000 mm? prEN 12437
1.6 Gates
1.6.1 Are self-closing gates arranged at the top of ladders? NIOC HSE-002, 5.1.2
prEN 12437
1.7 Hatches and manways
1.7.1 Do hatches provided have an access opening of min. NIOC HSE-002, Appendix B
800x800 mm (min. 600x600 mm for access to cofferdams and
tanks from floor/platform)?
1.7.2 Are access openings in vertical partitions into cofferdams, NIOC HSE-002, 5.1.2
tanks etc. equipped with hand grips on both sides above the
opening ?
1.7.3 Are inspection hatches side hinged ? NIOC HSE-002, 5.2.1.2
1.7.4 Are openings in deck larger than 100x100 mm secured by NIOC HSE-002, Appendix B
guard-rail or similar?
1.8 Door
1.8.1 Do doors have a clear opening of at least 750 mm width NIOC C-002, 6.1
and 2050 mm height?

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2. MATERIAL HANDLING
2.1 Is enough space provided for use of lifting and transport NIOC HSE-002, 5.2.1.1
gear where lifting or transport of single items of more than 25
kg is required?
3. ERGONOMICS
3.1 Is the height of ta ble top for seated work within the range NIOC HSE-002, Appendix B
680-750 mm, and easily adjustable from work position?
3.2 Is the height of table top for standing work within the range NIOC HSE-002, Appendix B
800-1050 m, and easily adjustable from work position?
3.3 Is operation of handles and push buttons with gloves NS-EN 292-2
possible?
4. ILLUMINATION
4.1 Is lighting according to applicable illumination NIOC HSE-002, Appendix A
requirements provided inside enclosed packages and on
packages with more than two levels?
5. NOISE AND VIBRATION
5.1 Are project specific noise requirements for subject Project’s Noise data sheet
machinery met? based on NIOC HSE-002, 5.5
and Appendix A
5.2 Are project specific vibration requirements for subject Project’s requirements based
machinery met? on NIOC HSE-002, 5.5,
Appendix A and Appendix E
6. SAFETY PRECAUTIONS
6.1 Are anti-skid surfaces provided in access ways and work NS-EN 292-1, 4.2
areas? NIOC HSE-002, 5.1.2
6.2 Is protection against personnel contact with hot surfaces NIOC HSE-002, 5.3.2
above 70°C and cold surfaces below -10°C provided? NS-EN 292-1, 4.4
6.3 Are dead end corridors and platforms exceeding 5 m length NIOC S-DP-001, 7.2
provided with min. 2 exits?

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NS-EN 349
6.4 Are safe distances between possible moving objects
exceeding the
following minimum gaps to avoid crushing of the body parts at
risk:
• Body > 500 mm
• Head > 300 mm
• Leg > 180 mm
• Foot > 120 mm
• Toe > 50 mm
• Arm > 120 mm
• Hand > 100 mm
• Finger > 25 mm
7. HAZARDOUS SUBSTANCES
7.1 Are Safety Data Sheets, approved according to the Iranian NIOC HSE-002, 5.4.2
regulation, for all chemicals delivered or instructed to be used NS-EN 626-1
with the machinery?
7.2 Are none of the prohibited substances included in the NIOC HSE-002, 5.4.2 and
machinery’s chemical inventory? Appendix D.1
7.3 Are drip trays provided under all sampling / filling points NIOC HSE-002, 5.4.1
and other places where spillage might occur? NIOC HSE-003
7.4 Are emissions from machinery controlled and in NIOC HSE-002, 5.4.3
compliance with NIOC requirements regarding threshold limit NS-EN 626-1
values?


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NIOC

Toos Earth Science Technology

Machinery – Working Environment analysis and Documentation, NIOC HSE-004

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3 DEFINITIONS AND ABBREVIATIONS

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Shall: Verbal form used to indicate requirements

PO: Purchase Order

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4.2.2 Supplier of Sub-assembly

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5 WORKING ENVIRONMENT DOCUMENTATION

5.2 Risk Assessments

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 Dangerous manual tasks / interactions; cf. clause 6.5

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 The checklist covers a broad specter of specific WE requirements. Thus, some

5.4 Chemical Inventory and Safety Data Sheets

5.5 Noise and Vibration Data

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5.5.2 Vibration Data

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Figure 1 - Outline of the risk assessment process for machinery

The purpose of the risk assessment is to ensure timely implementation of necessary

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Responsibilities and limits should be determined before start of detailed engineering.

6.2 Determine responsibilities

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6.3 Determine machinery limits (step 1)

6.4 Establish assessment team (step 2)

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6.5 Identify and describe manual tasks (step 3)

6.6 Identify and describe hazards (step 4)

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6.7 Estimate and evaluate risk (step 5)

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Table 1- Risk matrix for occupational accidents

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The operational precautions necessary to reach an acceptable residual risk shall be

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Figure 2 – Breakdown of Step 5 Risk estimation and evaluation

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APPENDIX A BASIC CONCEPTS (INFORMATIVE)

A.1 Scope and Objectives

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 Documentation of WE analysis, noise and vibration control, and hazardous

A.2 WE Requirements, Analysis and Documentation

1. Functional (goal / target oriented) requirements

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2. Specific (prescriptive / measurable) requirements

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Figure A1 – Breakdown of WE requirements and analysis methods

A.3 Methods to remove hazards of machinery

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APPENDIX B NOISE AND VIBRATION

Dangerous manual tasks / interactions; cf. clause 6.5

The checklist covers a broad specter of specific WE requirements. Thus, some

Documentation of WE analysis, noise and vibration control, and hazardous