PG DIPLOMA IN OCCUPATIONAL HEALTH SAFETY AND

ENVIRONMENT
(JNTE)
CENTRE FOR HEALTH SAFETY AND ENVIRONMENT

CERTIFICATE

This is to certify that project report entitled “A STUDY ON OHSE IN KUWAIT

INTEGRATED PETROLEUM INDUSTERIES COMPANY” being submitted by”
SEERAM ANUDEEP in partial fulfilment for the course in JNTE (PG DIPLOMA
IN OCCUPATIONAL HEALTH SAFETY AND ENVIRONMENT)

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 PG DIPLOMA IN OCCUPATIONAL HEALTH SAFETY & ENVIRONMENT

PROJECT

1. Scope: To conduct risk assessment for activities in FLUOR CORPORATION (KIPIC LNG
PROJECT).

2. Objectives: To identify the activities which, and conduct hazard identification & Risk assessment
by using risk matrix. To check the compliance with industry best practices like OHSAS 18001. ISO
45001, ISO 14001, HSG65, ILO OSH 2001, KUWAIT federal regulations.

3. Project Team:

1. P. UGANDHAR PHANI VARMA – Project Coordinator

2. SEERAM ANUDEEP –

4. Findings: Find the findings and control measures in the attached annexure.

Student 1 Student 2
Name of student SEERAM ANUDEEP
Hall ticket no
Project company FLUOR CORPORATION

Date of project
Submission of project
Signature

ATC CENTER FOR HEALTH SAFETY & ENVIRONMENT

Project Coordinator
name & sign

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A STUDY ON OCCUPATIONAL HEALTH
SAFETY AND ENVIRONMENT IN KUWAIT
INTEGRATED PETROLEUM
INDUSTERIES COMPANY (KIPIC)

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Kipic Introduction:

The kipic Al-Zour refinery project is a greenfield, environmentally driven project and part of
Kuwait’s National Development Plan. The plan sets out the nation’s long-term development
priorities, including the aim to position the country as a global hub for the refining and
petrochemicals industry. It is an ambitious world-scale project delivering new grassroots, state-of-the-
art refinery, with the flexibility to refine a wide range of crude oils and for further development into
an integrated refinery and petrochemical complex.

The refinery is approximately 90 kilometers south of Kuwait City, and is one of the largest refineries
built in one phase, with a capacity to process 615,000 barrels per day (bpd) of a wide slate of Kuwait
domestic crude oils, including Kuwait export crude and Kuwait heavy crude.

The refinery is at the forefront of new technology adoption to comply with stringent environmental
regulations to protect the local environment. It is configured to produce 225,000 bpd of
low Sulphur fuel oil (LSFO) to meet the Ministry of Electricity and Water (MEW) fuel demand for
domestic power stations, significantly reducing SOx emissions produced from the power stations by
75% from current levels. The refinery will also produce 340,000 bpd of the latest environmentally
friendly ultra-low sulfur diesel fuel, jet fuel and Kerosene for export to global markets, and naphtha
feedstock for local petrochemical plants. The project is being implemented in five EPC packages

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involving the construction of main and support process units, utilities and offsites, tankage, and
marine facilities’

Introduction including overview of area inspected and activities taking

place:

The Health and safety inspection was carried out by me on 5 th November 2021 at FLUOR
CORPORATION (KIPIC LNG PROJECT). It is one of the leading EPC, construction and project
management company with more than a two decades of rich and varied experience in executing
landmark projects. This FLUOR CORPORATION company dealing with a big project. The location

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of this Project is at sec-02, AL ZOUR (khiran) It is just 50 kilometers away from the city. Total
value of this project is 950 million $. Which is to be completed in 30 months.

The Scope of the work includes construction of civil, structural, internal finishes (common areas
and hand slope), boundary wall, external development works for the project, and management co-
ordination, and Supervision works for electrical low side, excavation, IT/LV, plumbing carpentry
works, welding, firefighting, HVAC, basement ventilation, gas piping, water treatment plant,
construction of tanks , water bodies including underneath works. This Project has 8 tanks with total
build-up area of around 1.77 million Sq.ft including basement, The man power is 2000.

Executive Summary:

The main objective of this inspection was to identify the prevalent HSE Hazards which may
cause ill health or human injury. While I am doing the inspection, I found some of the important and
dangerous Hazards in the workplace. The Hazards are listed below in the order according to their
importance. There are some other issues also discussed in their report which can reduce the accidents
and ill health by following recommendation. The following are the important issues we should
concentrate on.

Fire issues: Fire explosion can happen due to poor storage of flammable materials and
smoking cigarettes in the workplace. So, the issues should be controlled very immediately by taking
appropriate control measures like keeping strict rules for smoking and good storage of flammable
materials.

Sanitary issues: The bathrooms and toilets in the workplace are not well maintained it can
cause severe diseases to the workers.so to control this issue a good competent worker should be
appointed to clean the bathrooms and toilets daily and it should be maintained in a good hygienic
condition.

Electrical Hazards: A serious electrical shock can happen to the workers because of the
usage of concrete breaker in the wet environment. It can cause skin burns, Arcing and fire, and

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sometimes it leads to death.so control measures should be taken to control the Hazards. Management
should encourage battery powered equipment’s and provide appropriate PPE to the workers
immediately.

Mechanical Hazards: There will be a possibility of entanglement, cutting and other severe
injuries to the workers because of using guard less bench mounted circular saw blade. So, to control
this Hazard management should immediately provide safeguards to the equipment and implement
safe system of work.

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Main findings of the inspection:
Some of the main Hazards and unsafe practices in the workplace are highlighted here.
More details about the Hazards have been provided in this inspection report. Also includes costs for
the control measures. Here the management is breaching some regulations by following good health
and safety rules. The following are the main findings while doing inspections. They are

Fire Hazards: According to the observations 4 and 26. I found that smoking near workplace
and poor storage of flammable materials. This may cause explosion and fire. This may result in loss
of life and loss to the organization. So here organization here organization violated the legal
obligations. By providing all the control measures like Segregating the different types of waste
materials, safe storage of materials and providing separate smoking zones. This results in good
production and promotes good health and safety environment. estimated cost is 1200KD.

Sanitary issues: According to the observations I found that toilets and bathrooms are not well
cleaned. This may result in serious illness to the workers. it can increase absenteeism due to ill health
of the worker. So, the company will get loss in manpower and working hours.

It is a violation of legal regulations. So proper control measures like Appointing a person to clean the
toilets and bathrooms daily should be taken. estimated cost is around 600KD.

Electrical issues: In the observation It is found that concrete breaker is very frequently used in wet
environment. This might result in electrical shock. This might result in electric shock which results to
the skin burns, Arcing and fires etc.; There will be a property damage. This is a violation according to
the ILO-OHS-C167-1988 (Article 26); Rule 36 of Kuwait Electricity rules 1956 and electricity at
work regulations 1989. So the organization should take control measures like providing battery
powered equipment’s and also by reducing the voltage of equipment. proper PPE should be given to
the workers. Maintain good housekeeping to avoid wet environment in the workplace. By
implementing these control measures we can decrease or minimize the property damages, fire
accidents and injuries to the workers. Estimated cost is around 10000 KD.

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Mechanical Hazards: In observation I have found that a bench mounted circular saw blade is not
having any fixed guards. It can cause entanglement and cutting to the workers. So immediate control
measures should be taken for safeguarding the machines. The estimated cost is Approximately
800KD.

Conclusion:
This Health and Safety inspection was carried out with the intent of identifying the extent of
implementation of HSE systems in the company and the activities which have the highest

Possibilities to cause damages to our company. The workers are working in good manner in
the workplace. There are some Good Practices observed in the workplace like keeping fire
extinguishers, first aid centers in the workplace and providing good hygienic and quality food to the
workers.

In this report the most significant Hazards are poor storage of flammable materials, smoking
in workplace, electrical issues, sanitary issues and mechanical Hazards. These issues need to get
minimized and controlled. By keeping strict rules in the workplace. The control measures include
training, safeguards, using battery powered equipment’s, Good storage of flammable materials,
rehabilitation centers in the workplace. These control measures have high impact and very low in
cost.

There are some breaches of legal laws are identified. If the company doesn’t notice this there
will be actions taken by the enforcement agency. As a result of this the company should face
prosecutions in the court and pay fines. In addition, there will be compensations paid to the injured
workers. so, the company should follow all the legal requirements to avoid these losses.

I Truly believe that these recommendations in this report will help to reduce the direct costs
and indirect costs associated with the accidents and ill health to workers and compliance as per legal
law.

These recommendations will promote good working condition in the workplace and good
morale to the workers. Finally, there will be a happy work force.

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Observations Control measures Timescale
Priority Risk
Hazards and consequences Immediate and longer-term actions
(H,M,U
Immediate Action: Visitor was immediately Immediate
1.Hazard: Visitor vehicle found M summoned and was asked to move the
parked on the pedestrian vehicle to the designated area.
crossing
Close to the entrance of the Long- Term Action: Visitors should be One Month.
plant. mandatorily informed by the security to park
the vehicles in the respective areas.
Consequence: Pedestrians will
use undesignated path for Management should ensure that the visitors' Three Months.
moving into the plant or even out instruction card comprises of all the critical
of the plant. Other vehicles might details regarding the vehicle movement, and
run over them or even hit injuries they should be briefed about the content in the
might occur. card by the security supervisor and the
security personnel should ensure that they
have parked in the respective slots.

H Immediate: Tanker was stopped from being

reversed. Immediate.
2. Hazard: Large tanker Operators were asked to keep away from
vehicles was being reversed Operators were asked to keep away from the Immediate.
close to the inlet pipes of the maneuvering areas of the tankers.
lube oil loading bay pump which
was live, without a signalman. Transport /dispatch supervisor was informed to One Day.
provide a signalman on immediate basis.
Consequences: Tanker might
hit the inlet pipes or the live Long-Term Action: All tanker drivers must One month.
pumps resulting into spillages. undergo safe maneuvering training.
Tanker might run over the
Loading bay operators. Transport/ dispatch supervisor should be given Three Months.
strict instructions to make provisions for
a Signalman with each tanker at all the time.
Six Months.
Management was advised to provide some
engineered controls like reversing sensors
with cameras.

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Observations
Priority Risk
Hazards and consequences
3. Hazard: Operators were
found manually rolling the half
full drums into the trailer using
the sloped loading ramps.
Consequences: Drums might
slip and rollover onto their legs
resulting in sprain and strain
injuries or even minor fractures.
Drum caps can break if it hits
the structures nearby resulting
into spills.
4. Hazard: Unused drum caps
were found lying on the paths of
forklifts.
Consequences: Drum caps
might get stuck into the tires of
the forklift resulting in
uncontrolled movement of the
forklift
This can also lead to accidents
like hitting the operators nearby.
Control measures Timescale
H, M,L Immediate and longer-term actions
/
Immediate: Operators were asked to Immediate
M suspend the activity immediately.
Forklift’s operators were instructed to load the Immediate.
half full drums into the trailer.
Long-term Actions: All operators in the One month.
trailers loading bay should be strictly
instructed to not do manual handling of the
drums.
Safety training programs should be Three months.
conducted to ensure that the loading bay
supervisors understand the importance of
safe handling of drums using forklifts only.
M Immediate: Drum line supervisors were Immediate.
advised to remove the unused drum caps
immediately.
Long- term Action: Housekeeping during the Three months.
operations should be improved by creating
awareness sessions and inspections by the
Line engineers and the plant managers.
Designated areas for secured storing of the
materials like caps close to the filling lines One month.
should be ensured.
Movement of such loose materials should be Three months.
critically supervised.
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Observations
Hazards and consequences
5. Emergency contact numbers
were clearly displayed in various
locations of the plant.
6. Hazard: Handrails were
found missing from the corner of
the landing platform towards the
control room.
Consequences: Staff
accessing the control room can
fall from height resulting in fatal
injuries or even death.
Control measures Timescale
Priority Risk
(H,M,Ll Immediate and longer-term actions
Good Practice: A commendable action done
by the management to ensure quick response
to any emergencies.
Immediate.
H Immediate: Maintenance supervisor was
informed to close the access and place 'do
not access' signage and re-route them
through another stair access temporarily.
One Day.
Hard barricading at the missing space
should be done until the handrails are
fabricated and replaced.
Long-term actions: One month.
Control room staff should attend refresher
training on the safe practices adopted in the
plant. They should be trained on the
importance of reporting an unsafe condition
immediately.
Three Months.
Maintenance technicians involved in routine
plant stairway access inspections should
meticulously verify the conditions proactively
and do the rectifications immediately or do the
needful arrangements.
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Observations
Priority Risk
Hazards and consequences
(H, M,L)
7. Hazard: Transport Contractor
staff found standing on the top of
the lube oil tanker without any
fall protection to open the lids of
the tanker.
Consequences: Falling from
Height on to the concrete
pavement and succumb fatal
fractures to the limbs or other
bodily injuries and even death.
Staff might slip and also fall
into the tanker
Control measures Timescale
Immediate and longer-term actions
H Immediate: Contractor staff was instructed to Immediate.
safely descent the tanker top. He was warned
for not using the certified scaffolding structure
provided to access the top of the tankers. He
as further advised to use the full body
harness.
Bulk loading bay supervisor should ensure One Week.
that the contractor staff does not get on to the
tanker without the fall protection
Long term Action:
Plant managers should involve contractors One Month
and bulk loading bay operators in identifying
the risks and mitigating them.
Management should make provisions for Six Months.
permanent horizontal lifeline and approved
inertia reel (one of the standard personal fall
protection system) which the contractors
should be able to connect themselves before
climbing the tanker tops.
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Observations
Hazards and consequences
8. Hazard: One of the Drum
filling line operator was found
repairing a drain valve from the
filling line without shutting off the
pressurized filling line for lube oil
which is also hot.
Incompetent Operator.
Consequences: Lack of
isolation on the pressurized line
can lead to major spillages.
Ingestion of hot lube oil can
cause severe damage to the
internal organs of the operator.
Burns and scalding.
Incompetency of the operator
can result in the use of
inadequate/ inappropriate tools
for the work. And lack of
awareness can lead him to
follow procedures which is not
the standard.
Control measures Timescale
Priority
Risk Immediate and longer-term actions
(H,M,L)
H Immediate: Operator was instructed to stop Immediate.
the activity.
Line supervisor was instructed to raise Immediate.
maintenance request for any repairs and
malfunctions in the line.
Maintenance team was instructed to address One Day.
the issue on a priority basis.
Long- term actions:
Importance of performing· Isolations on the Three Months.
pressurized lines to be reiterated through
formal and demonstrative training to all the
staff directly involved in the process of
production and maintenance. Strict
compliance to LOTO should be addressed in
daily toolbox meetings.
Preventive maintenance schedules for the Six months.
pipeline valves should be audited to check
efficiency of the work carried out and avoid
such malfunctions.
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Observations
Hazards and consequences
9. Hazards: Hot lube oil was
overflowing from the lube
blenders. Overflow switches
and the sensors connected to it
was not working.
Consequences: Spillages, Hot
lube can damage other
connected instruments. Severe
burns, ingestion resulting in
damaging the internal organs.
10. Hazard: Unguarded
conveyor motors close to the
pail filling lines were observed.
Consequences: Entanglement
and finger amputations due to
exposed rotating parts.
Control measures Timescale
Priority Risk
(H, M,L) Immediate and longer-term actions
H Immediate: Blender operators were advised Immediate.
to shut off the emergency shut off switches to
stop the blenders and the connected pumps.
Secondary containment like Drip trays and Immediate.
spill kits were mobilized to contain the hot
oil.
Maintenance team was summoned to Immediate.
investigate the concern and identify the cause
for the failure of the overflow switches.
Long-term Actions: Preventive One month.
maintenance schedules for monitoring and
controlling instruments should be carefully
done to avoid such major mishaps.
Supervision of preventive maintenance One month.
activities like these should be ensured.
Management should conduct detailed plant Three months.
audits to identify such critical gaps and
remedy them accordingly.
M
Immediate Action: Supervisor was asked to
shut of the conveyor Immediately. And inform
the maintenance team to install the guards.
Filling line supervisor was warned for not
reporting a potentially unsafe condition.
Long-term Action: Plant manager was
informed to instruct the production line
supervisors to be more vigilant and report
any defects to immediately. Failure to do so
would result in serious disciplinary actions.
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Observations
Priority Risk
Hazards and consequences
(H, M,L)
11.Hazard: Grease Found
oozing out of the cut pieces of
the pipes that were stacked on
the soil close to the work area.
Consequences: Contamination
of soil due to oozing grease from
cut pieces of the pipes.
Contamination of the ground
water. Slips and trips resulting in
physical injuries.
Control measures Timescale
Immediate and longer-term actions
Long term Action: Management should Six Months.
critically involve and designate the
maintenance supervisors and technicians for
a time bound response for any maintenance
requests raised.
Immediate Action: The refurbishment One day.
H contractors were immediately advised to
contain the oozing grease into a polythene
bag or a drip tray.
They were also instructed to clean up all the One day.
grease that had oozed out in various
locations throughout the line of work.
Long-term Action:
Contractor supervisor was advised to stack One month.
the cut pieces of pipe in a bunded area with
impermeable membranes.
Grease production unit mangers and Three months.
engineers should ensure to empty the lines
and purge them clean before handing it
over to the contractors for refurbishment
works.
Management should carefully examine the One month.
method statement and risk assessment of the
activity and suggest necessary actions.
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Observations
Priority Risk
Hazards and consequences
{H,M,L)
12. Hazard: Gas welding of the
instrument lines close to the PIG
(pipeline inspection and gauging)
receiver area was being carried
out with puddles of mineral base
oils around it.
Consequences: The condition
can initiate a fire due to sparks,
welding spatters and puddles
of base oil nearby. Damaging
the PIG receiver and injuring
the ship duty operators.
It can quickly spread and
become fatal to all the
employees of the plant.
Observations
Priority Risk
Control measures Timescale
Immediate and longer-term actions
H Immediate Action: Welding activity was Immediate
suspended by issuing a STOP card (A
system in place to give authority to anyone
who witnesses an unsafe act or condition
which can escalate to become life
threatening.)
Production engineer was informed to clear Immediate
the puddles of oil from the vicinity.
Maintenance technicians were warned to not One day
carry out any hot works until and unless the
oil puddles and any other combustible
materials are cleared off.
Long-term Actions: Management should Six Months
implement 'Zero Tolerance' policy against
such deliberate actions by responsible
delegates of the company.
Top Management and plant managers should Two Months.
emphasize the importance of the instructions
and HAZID with respective control measures
identified on the permit- to
- work should be adhered without fail.
Awareness training sessions for all the Three Months.
operators involved in ship duty and the
maintenance supervisors responsible for
Carrying out hot works should be third party
trained.
Control measures Timescale
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 (H,M,L)
Hazards and consequences
13. Hazard: Tank farm
operator found standing on the
edges of the tank bund wall to
operate a diversion valve.
Consequence: Fall from the
height onto the nearby structures
and can succumb fatal fractures
and other bodily injuries.
14. Hazard: Thermic fluid line
without the insulation in various
locations, due to delay in
purchasing the insulation
material.
Hot surfaces are exposed.
Consequences: Possible
contact with the exposed parts
can lead to burns and scalding.
Immediate and longer-term actions
M Immediate: Operator was advised to get off Immediate
the bund wall immediately. He was advised to
use a MEWP or other means like mobile
scaffold to access the diversion valve.
Long- term action: Plant manager and One Month.
production engineers were asked to make
provisions for a access platform to operate
the diversion valves. Or relocate the diversion
valves to accessible heights by the operators.
Ergonomics' should be given utmost attention Six Months.
whilst design and installation stages. All As
built drawings should be revised to identify
the gaps and do the needful rectification as
needed.
H Immediate: All operators in the vicinity of the Immediate.
thermic fluid line were instructed to be
cautious to not get burnt or touch the hot
surfaces.
Maintenance technicians were informed One Day
about the unsafe conditions and advised to
insulate the exposed areas at the earliest.
Long- term Action:
Sourcing the insulation material should be One Month.
coordinated by the plant manager and
maintenance manager. A buffer should have
been maintained to avoid such
unprecedented delays.
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Observations
Priority Risk
Hazards and consequences
(H,M,L)
13. Hazard: Tank farm
operator found standing on the
edges of the tank bund wall to
operate a diversion valve.
Consequence: Fall from the
height onto the nearby structures
and can succumb fatal fractures
and other bodily injuries.
14. Hazard : Thermic fluid line
without the insulation in various
locations, due to delay in
purchasing the insulation
material.
Hot surfaces are exposed.
Consequences: Possible
contact with the exposed parts
can lead to burns and scalding.
Control measures Timescale
Immediate and longer-term actions
M Immediate: Operator was advised to get off Immediate
the bund wall immediately. He was advised to
use a MEWP or other means like mobile
scaffold to access the diversion valve.
Long- term action: Plant manager and One Month.
production engineers were asked to make
provisions for a access platform to operate
the diversion valves. Or relocate the diversion
valves to accessible heights by the operators.
Ergonomics' should be given utmost attention Six Months.
whilst design and installation stages. All As
built drawings should be revised to identify
the gaps and do the needful rectification as
needed.
H Immediate: All operators in the vicinity of the Immediate.
thermic fluid line were instructed to be
cautious to not get burnt or touch the hot
surfaces.
Maintenance technicians were informed One Day
about the unsafe conditions and advised to
insulate the exposed areas at the earliest.
Long- term Action:
Sourcing the insulation material should be One Month.
coordinated by the plant manager and
maintenance manager. A buffer should have
been maintained to avoid such
unprecedented delays.
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Observations
Priority Risk
Hazards and consequences
(H, M,L)
15.Hazard: Contractor staff
found working inside a Base oil
storage tank without a full body
harness connected to the
emergency retrieval lines.
Consequences: In case of an
emergency, retrieving him out
of the confined space will
become highly impossible
which can eventually lead to
his death.
Control measures Timescale
Immediate and longer-term actions
Plant inspection should be carried out by the Three months.
management team on a scheduled intervals to
identify such anomalies an address them at
the earliest.
H Immediate action: Contractor staff was Immediate.
instructed to come out of the base oil tank
immediately and wear his full body harness
and then connect the same to the Lifeline
prior to entering the confined space.
Long-term Action: All contractor staff One month.
should be trained on the hazards of the
confined space and strict supervision
should be ensured at all the time.
Managing contractors safely should be one of Three Months.
the priorities, this can be achieved by giving
them accurate information, instruction,
training and supervision.
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