Unit IG2: Risk assessment

Part 1: Background

Include in here the organisation’s name* and location* and number of workers. You must then go on to give a description of the main
activities/products/services carried out. You must also describe the area to be risk assessed e.g ., whole site, and anything else that
you consider relevant (approximately 150 to 200 words):
The organisation that was selected for the risk assessment was Pakistan Petroleum Limited. It is located in Karachi, Pakistan. The total number of
workers employed by the organisation are nearly 3000. It has decades of experience in exploration and production of oil and gas components. It
has 48 exploration blocks out of which 28 are PPL-operated and the rest of the 20 are partner-operated. It contributes around 20 percent to the
total natural gas production of the country. Major products of this company include crude oil, Liquified Petroleum Gas (LPG) and Natural Gas Liquid
(NGL).
The areas under risk assessment were the production, processing, workshops and storage areas. The shift pattern was a single shift starting from
9 am to 6 pm. The area under risk assessment was 235,000 square yards. The activities that were being performed at site were cutting, welding,
grinding, hydro jetting, nitrogen purging, hot bolting, crane lifting and working at heights and confined spaces. It has various certifications that
include ISO 9001, 14001 and OHSAS 18001.
You must now give a brief outline on how you completed the risk assessment (approximately 200 words):
The risk assessment was completed in multiple phases.
1. During the first phase, I visited the plant and observed all the activities that were being carried out on a routine basis. Investigated multiple
activities and inspected them according to health and safety standards. I interviewed all the workers, engineers and supervisors regarding the
health and safety standards and practices being followed by the company.
2. I issued a various questionnaire on health and safety to the workers and engineers to analyse the safety performance of the company.
3. I reviewed different documentation related to health and safety. The accident reports, near-miss reports, ill health cases, safe working man-
hours, complaint record and audit reports.
4. After all of this research, I checked multiple health and safety websites like HSE UK, IOSH, OSHA, ISO and many others to dig deep into
the information of Health and safety and to prepare a fine and effective risk assessment report. The links are as follows:
https://www.osha.gov/SLTC/oilgaswelldrilling/safetyhazards.html
https://www.hse.gov.uk/fireandexplosion/workplace.htm
https://www.ilo.org/global/standards/subjects-covered-by-international-labour-standards/occupational-safety-and-health/lang--en/index.htm
After all the research, external and internal, I decided on the revised and additional control measures. All the control measures were decided
according to the health and safety standards. Following links were consulted:
https://iosh.com/resources-and-research/our-resources/extra-resources-out-of-sight-out-of-mind/out-of-sight-out-of-mind-hazards-and-risks/
https://www.hse.gov.uk/toolbox/managing/managingtherisks.htm

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 * If you’re worried about confidentiality, you can invent a false name and location for your organisation but, all other information provided must be
factual.

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 Part 2: Risk Assessment

Organisation name: Pakistan Petroleum Limited (PPL)

Date of assessment: 11 September, 2020
Scope of risk assessment: Production, processing, workshops and storage areas

Hazard Who might be harmed What are you already doing? What further controls/actions are Timescales for
category and and how? required? further actions Responsible
hazard to be person’s job
completed title
(within …)
Hazardous Workers in the refining The workers were wearing PPE 1. Workers must be given a H2S 3 weeks Activity
substance section might be harmed. during their activity. personal toxic clip to monitor supervisor
(1,2,4,6)
the gas concentration.
The workers Workers were working Only one plant fixed gas 2. PP15 respirator or BA trolley 1 month Safety
were working without any respiratory monitor was present at plant. must be available in the Manager
in the refining equipment and personal (1,2,3,5,7)
refining section.
unit where monitors. If the
they had concentration of H2S had 3. Gas alarms must be installed to
1 month Safety officer
exposure of reached 100ppm it would alarm the workers of exceeded (4,6)
H2S. kill the sense of smell concentration of H2S
known as Immediate 4. H2S zone classification must be 2 weeks
Danger to Life and Health reminded to all the workers
(IDLH). It might result in during TBTs.
death at 1000ppm. 5. Best Monitor (BM) 25 must be 2 months
issued to workers for instant
monitoring of multiple gases.
6. Proper inspection should be 5 days
carried out on a regular basis.
7. Self-Contained Breathing 2 months
Apparatus (SCBA) rescuers
must be available for
emergency situations.

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Hazard Who might be harmed What are you already doing? What further controls/actions are Timescales for
category and and how? required? further actions Responsible
hazard to be person’s job
completed title
(within …)
Fire The mechanical Safety signs of fire hazards 1. Workers should be given 1 month Workshop
technician and the were placed in work shop. insulated PPE for cutting and supervisor
The was a workshop workers were welding. (1,4,5,6)
danger of fire likely to be harmed. Safety gloves and apron were 2. The provision of safety googles 1.5 month
in the given to the workers before any Safety manager
and Local Exhaust Ventilators
mechanical There were sparks arising activity. (1,2,3)
(LEVs) must be ensured at
workshop from the cutting activity.
during cutting There were flammable workplace. 2 weeks
activity. materials and debris 3. Backfire training must be given
around and the workers to the workshop workers. 1 week
did not have insulated 4. Passive fire protection
clothes. It would have led equipment must be given to all
to explosion and multiple workers. 3 days
injuries like cuts, burns 5. Proper housekeeping should be
and bruises or even done on a daily basis. 1 week
casualty. 6. Flammable sources of fire must
either be covered or removed
from the working area.

Work-related The driver and the The vehicle was inspected 1. The traffic routes must be 1 week Safety
driving pedestrians were likely to before the activity and the marked with paint. supervisor
be harmed. driving license was checked. (1,3,4,5,6)
2. The workers of the plant must 1 month
The truck be given highly visible clothing Safety
driver was Driver was driving on a The driver was third party to be seen from distance. manager (2,7)
driving on a muddy road at severe certified. 2 weeks
3. Safety signs must be placed
muddy road in wind speed. There were
high wind no safety signs and no after regular intervals.
speed. mirrors at blind spots. It 4. Proper lux level should be 1 week
would have led to over- maintained along the vehicle
turning and collisions routes.
resulting in muscle 5. Driving must be prohibited if 3 weeks

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Hazard Who might be harmed What are you already doing? What further controls/actions are Timescales for
category and and how? required? further actions Responsible
hazard to be person’s job
completed title
(within …)
damages and fractures. It wind speed exceeds 20 knots.
would also cause death 6. Drivers must be given adequate 3 days
on spot. rest breaks during shift. 1 month
7. GPS and CCTV cameras
should be installed on vehicles
to monitor the speed limit
instantaneously.
Slips and The Storage Area Toolbox talk was given to the 1. Safety signs of lift hazards 1 week Storage
trips workers were expected to workers about the safety must be placed all over the supervisor
be harmed. procedures of the Storage (3,4,5,6)
Storage Area.
The floor was Area. 2. Slip-resistant shoes issued to 1 month Safety
slippery in the Workers are carrying oil the Storage Area workers. manager
storage drums and the Drums for 3 days (1,2,6)
3. The walkways must be cleaned
section due to leaking oil. The workers Wearing personal protective
oil spillage. were not wearing slip- equipment while carrying oil free of debris and other waste
resistant shoes and there drums. materials.
were no safety signs of 4. Proper housekeeping must be 1 day
slip hazards. It would insured on a daily basis.
have caused the workers 5. Regular inspection and
to sleep or trip on the floor maintenance must be carried 5 days
causing backbone injuries out.
fine disorders or bone 6. Lightning should be maintained 2 weeks
fractures as well. at least at a minimum Lux
level.
Work at Workers working at height The scaffolding was inspected 1. Guardrails and toe boards must 1 month Activity
height might be harmed. before the activity. be installed on the working supervisor
(1,2,3,4,5)
platform to ensure your safety.
Workers Workers were working at The workers at height were 2. The application of the fall 3 weeks Safety
working at height and there were no given a proper Toolbox talk to arrester system must be manager
height on an guardrails and toe boards work safely at height. (1,2,3,6)
insured.

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Hazard Who might be harmed What are you already doing? What further controls/actions are Timescales for
category and and how? required? further actions Responsible
hazard to be person’s job
completed title
(within …)
unguarded present on the scaffolding 3. The safety nets must be applied
platform. on which they were at the bottom of the 2 weeks
standing. It would have scaffolding.
led to the fall of the 4. Work must not be carried out if
worker objects from the wind speed is greater than 5 days
height causing severe
20 knots.
injuries including bond
breakage, skull fracture 5. The ground must be levelled by
1 week
and even fatality. soil for Timber board
competition.
6. The scaffolding must be the
third party certified. 1 month
Electricity The electrical technician workers were given at TBT to 1. Workers must be given 2 months Electrical
might be harmed by high ensure a safe handling electrically isolated footwear Supervisor
Electrical voltage cables. distance from the cables. (2,3,5,6,7)
and clothing to work safely.
technicians 2. Non-conducting ladders should 3 weeks
were repairing The technicians were They were using non- be used while dealing with Safety
broken High working without electrical conducting tools to deal with manager
electricity.
Voltage and isolation of the cables and cables. 1 week (1,2,4,5)
un-insulated they were using steel 3. The ground pin must not be
cables. ladders to repair the removed.
cables. It might have led 4. Double insulated cables should 3 weeks
to physical contact be used for high voltages.
between the cables and 5. Residual current devices
technicians and they (RCDs) such as ground fault 1 month
might have received a circuit interrupter (GFCI) must
high electric shock that be installed to ensure human
would lead to seizure and safety.
electrocution. 3 days
6. Strict supervision and
inspection must be insured.
7. Safety signs regarding

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Hazard Who might be harmed What are you already doing? What further controls/actions are Timescales for
category and and how? required? further actions Responsible
hazard to be person’s job
completed title
(within …)
electrical hazards must be 2 weeks
placed at the workplace.
Vibrations The production area Workers work given the training 1. The vibration exposure time 1 week Safety
workers were expected to to maintain a safe handling must be strictly observed and supervisor
In the be harmed. distance from the machines. (1,2,3,4)
supervised to fulfil the safety
production Proper and sections were guidelines. Medical officer
section, the As the machines were carried out to check the 2. Mechanical isolation of the 1 month (6)
machine vibrating constantly, there exposure of vibrations.
Machines or vibrating parts
vibrating was a danger of Safety
constantly at a excessive exposure to must be done on regular basis.
manager (2,5)
high pace. vibration. It would have 3. Lubrication of the machines 3 days
resulted in stress and should be carried out regularly.
fatigue condition, muscle 4. The workers must be given
and joint damage, hand- tight clothing to work near the 1 month
arm vibration syndrome machines.
(HAVS) and carpal tunnel 5. Fixed, interlocked and the 3 weeks
syndrome. adjustable guard must be
installed around the machines.
6. Health surveillance should be 3 days
carried out to ensure your
workers' safety.
Confined The confined space A hole watcher was present 1. Emergency escape hood for PP 1 month Activity In
spaces workers what likely to be outside the confined space. 15 must be given to the charge (2,3,6)
harmed. confined space workers.
Workers were The worker was given a walkie Permit receiver
2. The workers must be given 1 week (5)
working in an Working in a toxic talkie to communicate with the safety goggles to work in
uninspected confined space. There hole watcher. Safety
confined space.
boiler in the were oxygen deficiency 1 month manager
basement. and toxic material in the 3. Insulated PPE must be issued
(1,2,3,4,6)
boiler. The workers were to the workers
not having respiratory 4. Self-contained breathing 2 months

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Hazard Who might be harmed What are you already doing? What further controls/actions are Timescales for
category and and how? required? further actions Responsible
hazard to be person’s job
completed title
(within …)
protective equipment apparatus (SCBA) rescuers
(RPE) and they did not must be available.
have protective clothing. It 1 week
5. Permit to work must be issued
would have led to for high risk activity.
breathing problems, 6. Emergency arrangement and 5 days
contact with contaminated
training must be well
material and resulting in
skin infection and burns, understood by the workers.
and death if the oxygen
deficiency was very low.
Health The refining area workers Workers were given adequate 1. Cool water facility must be 1 week Area
welfare and might be harmed by high rest break during their shift. given in the refining section for supervisor
work temperature. (1,2,4,5)
the workers.
environment The provision of a resting 2. Property inspections should be 3 days Safety
Workers were working in facility was provided at the carried out to analyse the manager
Workers the refining area and workplace. (3,4,5,6)
working atmosphere.
working in a there was no proper
very hot ventilation and cool water 3. Local exhaust ventilators
1.5 months
environment in facility in the section. It (LEVs) should be installed in
the refining would have resulted in the refining section to ensure
area. dehydration, stress, proper ventilation.
muscle cramps and heat 4. Heat resources must be 2 weeks
stroke. shielded to reduce heat
exposure to the workers.
5. The high-temperature oil pipes 1 week
must be lagged to reduce heat
levels.
6. Workers must be given 1 month
clothing to sweat freely in
high-temperature zones.

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Hazard Who might be harmed What are you already doing? What further controls/actions are Timescales for
category and and how? required? further actions Responsible
hazard to be person’s job
completed title
(within …)
Load The Forklift truck driver 1. Safe load indicator device must 3 weeks Activity
Handling and the nearby workers be installed on the Forklift manager
equipment were likely to be harmed. (2,3,4,5,7)
truck.
2. The track and truck must be 2 days Safety
The Forklift The Forklift truck driver Training related to driving was
inspected before the activity manager
truck driver was over speeding the given to the driver regarding
regularly. (1,4,5,6,7)
was driving at vehicle and it was safety procedures. 1 day
a high speed exceeding the safe work 3. The maintenance of the Forklift
with load (SWL) guidelines. It The driver was third party truck should be e routinely
overloading would have caused an certified. done according to the
condition. accident with a pedestrian manufacturer
or nearby building recommendations. 1 week
causing scratches, burns 4. The safety speed limits must be
and fractures. strictly exercised i.e., 10-20
mph 2 weeks
5. Driving should be strictly
prohibited while the forks of
the FLT are raised.
1 month
6. The mirror should be placed at
the blind spots. 2 weeks
7. Banks man should be available
for proper signalling.

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 Part 3: Prioritise three actions and justification for the selection

You must pick the three highest priority/most urgent actions and justify your choice. Your justification must include moral, legal and
financial arguments (500 to 700 words); consideration of likelihood and probable severity of injury, ill-health and/or harm (150 to 250 words);
description of how effective each action is likely to be in controlling the risk (250 to 350 words).
1. Best Monitor (BM) 25 must be issued to workers for instant monitoring of multiple gases. (Hazard Category: Hazardous substance)
2. The provision of safety googles and Local Exhaust Ventilators (LEVs) must be ensured at workplace. (Hazard Category: Fire)
3. GPS and CCTV cameras should be installed on vehicles to monitor the speed limit instantaneously. (Hazard Category: Work-related
driving)

Moral Justification:

It is the moral as well as the ethical duty of the employer to provide safe plant and equipment for machinery to the workers and strictly
exercise the safety guidelines and standards. The occurrence of an accident not only injures the workers physically but also, he suffers
mentally as well as psychologically. It also has a negative impact on workers' families. So, the above-mentioned control measures must be
provided so that the workers can work safely at the workplace. It fulfils the moral responsibility of the employer. The provision of these control
measures will not only provide safety to the workers but also it will improve and enhance the performance of the industry.

Financial justification:

Industries have to face financial loss in case of accidents. The cost of an accident is much higher than the cost of implementing the safety
practices at the workplace. There are multiple direct and indirect costs associated with an accident. Direct costs include the cost of medical
check-up, first aid treatment, compensations, damaged products and machinery, rehabilitation cost, and the cost of lost time. Indirect costs
include the remedial cost, the cost against enforcement actions, increased insurance premiums, reduced Industrial Relations, damaged
public figure, and loss in face value and reputation. If the above-mentioned control measures are properly implemented, the cost of multiple
accidents can be avoided and the finances of the industry can be saved. It clearly justifies the financial argument of these control measures.

Legal justification:

According to global standards of health and safety, it is mandatory to cope with international as well as local regulations and laws of health
and safety. It is the legal responsibility of the industry to provide certain health and safety measures and ensure the best health and safety of
workplace and its employees. There are strict enforcement actions against industries which do not follow the legal requirements of the safety
local and certified safety bodies. In accordance with compliance, the industries are recognized around the globe foe their best safety
practices that are according to the legal standards.

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According to the ILO convention C-170 article 12, it is strictly stated that the removal of hazardous and contaminated materials or substances
from the confined spaces must be done before the activity is performed. The companies need to make sure that they apply appropriate
procedures to remove the hazardous and toxic chemicals.
According to the ILO convention C-167 article 29, it is strictly mentioned that the employer must make sure that the risk of fire is minimized. If
there is an outbreak of fire, fire-fighting arrangements must be put in place to control and eliminate the outbreak.
According to the ILO convention C-153 article 4, regarding hours of work and rest (Road Transport), the employer needs to make sure that
the drivers are given appropriate rest breaks when they have been driving for four hours. The drivers need to be third party certified and
medically inspected before driving.
All these legal requirements must be met and if there is any non-compliance with these requirements, strict enforcement actions will be taken
against the industry. The above mentioned legally justify the argument clearly.

Likelihood and severity:

1. Workers working in the refining section and they were exposed to exceeding H2S concentrations. The workers did not have a personal
toxic clip or any respiratory protective equipment. The likelihood of getting harmed was very high. If the concentration of the toxic gas
had been greater, the workers might have died. It resulted in a very high severity as well. Risk rating was high.
2. In the mechanical workshop, the cutting activity was being performed without proper safety precautions. Sparks for coming out of the
cutting machinery and the workers did not have any insulated PPE for cutting. There was no local exhaust ventilation in the workshop
so the likelihood of getting harmed or fire explosion was very high. The workers might have one themselves by the explosion or they
might have received severe injuries which made the severity very high. The risk rating was high.
3. The vehicle driver was driving on a muddy road at high speed. The weather condition was severe. There were no safety signs present
along the road and there was no proper system to monitor the vehicle speed. The likelihood of an accident was very high and so was the
severity. The risk rating was high.

Effectiveness of recommended control measures:

1. The application of best monitor (BM) 25 has been recommended for the instantaneous monitoring of multiple gases. Whenever the
concentration of H2S gas increases above the limit, the device vibrates and Beeps and the worker is instantly informed that the
workplace is no safer. It allows him to follow the emergency procedure and inform all the staff members to leave the area immediately.
It not only decreases the likelihood but also the severity of getting harmed becomes very low. It eventually lowers the risk rating to a
minimum value. It will take 2 months to implement the control measure.
2. The provision of safety goggles is very important during cutting activity. The sparks that are generated during cutting cannot come in
contact with the human eye. If the local exhaust ventilators (LEVs) are installed in the mechanical workshop, the likelihood of fire
ignition is minimised and there are no chances of fire explosion. It not only reduces the chances of ignition but also it will be a much
safer practice for or mechanical technicians. The risk rating as decided by using these control measures will be very low. It will take 1.5
month to make arrangements for the implementation.
3. It is highly recommended to install GPS and CCTV devices. GPS can be used to track the speed at which the vehicles are being

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 operated. CCTVs can be used to see the driving conditions for a vehicle driver. If there is high wind speed for the road is not proper, it
will easily be communicated to prohibit the driving. It will not only decrease the chances of the accident but also it will be informed to
the management to modify the traffic route. If the drivers try to over speed the vehicle, they will be instantly caught. The likelihood and
severity both become very low and the risk rating consequently results in a lower value. A time of 1 month is required for its
implementation.

Part 4: Review, communicate and check

You must now give a review date for your risk assessment and say why you have chosen this date (10 to 50 words).

The HSE policy of the company is that the risk assessment needs to be reviewed after 12 months. So, I recommend the review date to be 9th
of September,2021.

You must now indicate how the risk assessment findings will be communicated (including who needs to know the information) (100 to 150
words).

The findings of this risk assessment will be communicated to all the managers, supervisors, engineers and workers. First of all, a meeting will
be arranged with safety and finance manager of the plant and all the revised control measures and additional control my ears will be
discussed. The cost breakdown will be given to the finance manager. Multiple training meetings and seminars will be conducted to train the
workers and other employees regarding the new control measures. The activity manuals will be reprinted at given to the respective areas.
Safety signs will be placed in each and every section of the plant to make sure that the workers, engineers and technicians are effectively
reminded of hazards and safety procedures. In this way, all the findings will be communicated to all the employees of the company.

You must now indicate how you will follow-up on the risk assessment to check that the actions have been carried out (100 to 150 words).

I will visit the plant after the scheduled time of 3 months. Multiple observation, investigations and active monitoring will be carried out to
assess the safety performance of the company after the implementation of new control measures. If there is any shortcoming related to the
implementation, I'll talk to the finance manager to make the arrangements and implement the revised control measures. If I observe any non-
compliance after the implementation of control measures, the responsible person will be directly reported to the higher management. A new
inspection date will be decided and the continual improvement process will be initiated. This is how a follow-up of the risk assessment will be
carried out.

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