2020 年 10 月 IG1 考试

Scenario
You have a dual role as an experienced and respected Process Operator and a
representative of workers at a large, high hazard site, run by an international
chemical manufacturing organization.

The organization has a reputation for having a world-class health and safety
culture, with many other industries using them as a benchmark. It is a legally
compliant organization that sets clear objectives and checks that they are met. It
employs and retains motivated workers who are aware of their clearly defined and
documented responsibilities and want to continuously improve in their roles.
Absence and sickness rates are low.

The organization listens to workers when they raise concerns and responds
professionally to external customer complaints. The organization also takes pride
in recording low accident and incident rates and investigating any near misses to
learn lessons and prevent more serious outcomes. Across the organization, there
are clear lines of internal and external communication. This allows effective
resolution of complaints. The organization is fully insured even though the
premium is high. The organization conducts frequent internal audits and is also
externally audited.

The process you operate is running at a reduced production rate, due to a technical
problem with a large storage tank containing a highly toxic product. You have an
idea what the problem is, but knowing the limits of your authority, you feel the
issue should be escalated to someone more senior. Local site managers, engineers,
supervisors, and operators meet to discuss the situation. They conclude that the
tank has an internal blockage, that would normally require a complete process
shutdown to clear. However, the planned maintenance shutdown is 12-months
away. They decide to seek advice from the corporate management team to explore
whether there is a different solution that would resolve the blockage problem, but
keep production going.

The local site and corporate management teams meet by video conference. The
corporate management team includes a very experienced senior engineer with
25-years’ company service. This engineer has overseen process plant
modifications, at many international sites, with zero lost-time incidents. They all
agreed that modifications could safely be made to the tank, without the need to
shut it down, and that the necessary resources would be made available for this
work.
The senior engineer is sent to the site to advise on, and manage, the changes that
are needed to the tank; and on the day of arrival presents a solution to you. You
are unfamiliar with the technology to be used for the modification and your
reaction is one of disbelief, and you politely ask if the engineer is serious. The
engineer invites you to a meeting to conduct a systematic and detailed risk
assessment of the tank modification task. The Health and Safety Adviser, worker
representatives, and Plant Manager will also be at the meeting.

At the meeting, the engineer introduces the proposed tank modification and leads
the risk assessment exercise. The risk assessment includes consideration of the
highly toxic chemical, the release of which would be catastrophic for workers, as
well as people in adjacent businesses, residential houses, and schools.

The engineer confirms that this proposed modification method is a safe and widely
used solution where the safety improvements are worth the cost. The risk
assessment then continues with discussion and agreement on risk evaluation,
existing control measures, and any additional control measures necessary. Some of
these control measures include safe systems of work, a permit-to-work system,
supplementary emergency arrangements, and suitable induction training for all
contractors. Collectively, these precautions and control measures reduce high risk
to low risk.

A summary of the risk assessment is circulated to all workers likely to be affected

by the proposed modification. The full version of the risk assessment will be made
available on request.

Before commencing the work, a permit-to-work is issued to the contractors

carrying out the tank modification. The permit-to-work includes an explanation
about the associated risk assessment and how the plant has been safely prepared
for this non-routine modification. The contract workers accept the permit-to-work
with the necessary precautions, including wearing of specified personal protective
equipment. Precautions listed on the permit-to-work are also communicated to
all contractors and other plant workers who may be affected. The permit-to-work
explains that precautions will be enforced, along with any other site rules, by
active monitoring. This will be done while you carry out routine plant checks and
simultaneously check on the progress of the modification.

To confirm safe working and clarify overall expectations, you, along with an
independent site contact have been nominated to monitor and liaise with the
contractors. The independent site contact will also actively monitor and check
additional expectations, such as contractor site entry and exit control, resolution of
any queries, and the supervision standard. You and the independent site contact
will check to see whether the modification work is being controlled and is
progressing as planned. This is consistent with the organization’s safe system of
work based on the findings of the risk assessment and the method statement
provided by the contractor, the aim is to complete the job safely without incident.

Findings from inspections form part of the overall health and safety performance
review. The performance review enables an overall assessment of opportunities
for continuous improvement within the site and reveals any need for change.
Questions and answers：
Task 1: Comment on the organization’s health and safety morals
Answer:- My comments on the organization’s health and safety morals as a
process operator & worker representative of this international chemical
manufacturing organization are as follows:-

The organization provides an ethical way to do work by providing good

health and safety culture: It has a world-class health and safety culture, which is
used as a benchmark by other industries.

The organization considers humanitarian ground as its moral

responsibility to provide a safe workplace:
The organization listens to workers when they raise concerns and responds
professionally to external customer complaints.
The organization is fully insured even though the premium is high to safeguard the
interest of both employee and employer.

The organization has a moral obligation not to cause harm to others:

They employ motivated workers who were aware of their clearly defined and
documented responsibilities. As a result, absenteeism and sickness rates are low.
Management employed an experienced expert engineer from a corporate team
with zero lost time incident to oversee the process of tank modifications.

The organization has moral reasons and societal expectations of providing

occupational accident and disease-free work environment to all workers so that
everyone returning home happily in a healthy condition:
The organization conducts frequent internal audits and is also externally audited to
maintain good health and safety management.
Conducted detailed risk assessment of the tank modification task of highly toxic
chemicals for protecting workers, as well as people in adjacent businesses,
residential houses, and schools.

The organization has an approach to do in a right way to do the things rightly:

For this, they comply with all legal rules and sets clear objectives and checks to
meet the goals, defined internal and external communication for effective
resolution of complaints.
There is equality and the right to live for all workers and equal treatment in
aspects of health and safety. Workers get killed when health and safety are not
managed properly managed:
Organizations investigate any near misses to learn lessons and prevent more
serious outcomes. As a result, very low accident and incident rates were recorded.

Task 2: Comment on the evidence from the scenario that would

contribute to the effectiveness of the roles and responsibilities
Answer:- Following evidence contribute to the effectiveness of my roles and
responsibilities as dual role Process Operator and worker’s representative:

As I have dual roles and responsibilities, I have the advantage of knowing the
process better and if any issues related to health safety are observed I
shall immediately approach senior management for possible safe
solution. When a technical problem with a large storage tank containing a highly
toxic product arises, I immediately informed the senior management.

As constituents of safety committee personnel as worker’s representatives,

the technical issue is consulted with local site managers, engineers, supervisors,
and operators and also with the corporate team to have a safe solution for tank
modification work.

To understand the risks associated with the work, meeting with a senior engineer for
specialist advise conducting a systematic and detailed risk assessment of the tank
modification task.

Providing supervision to workers and contractors for implementation of control

measures like safe system of work, permit to work, and suitable emergency
arrangement for tank modification work. Circulation of risk assessment to all workers
who may be affected by the proposed tank modification.

I will also inspect the work and enforce to

allocate adequate resources being issued to the contractors as agreed in the permit to
work, like wearing of specified personal protective equipment.

As I have been nominated with an independent site contact to confirm and

monitoring safe working and consultation with the contractor. I will participate
inactive monitoring by doing the inspection for contractor site entry and exit control,
resolution of any queries, and the supervision standard.
I will enforce organization’s safe systems of work procedures based on the
findings of the risk assessment and the method statement provided by the
contractor to complete the tank modification job safely without incident.

Task3: Based on the scenario only, what are the indicators of health and
safety culture in the organization?
Answer:- The indicators of health and safety culture in the organization
shows positive as mentioned below:

Incidents or Accident records: Organisation conducts proper investigating of

any near misses to learn lessons and prevent more serious outcomes as a result low
accidents and incident rates were recorded.

Absenteeism: The organization employs motivated workers who are ware of

their roles and responsibilities, as a result, less absence from work is reported.

Sickness rates: Since world-class health & safety culture is provided with
implementation of the safe system of work, allocation of proper PPE, lesson
learned from the investigation, the sickness rate is less recorded.

Staff turnover rate: As workers are motivated and experienced, fewer incidents
and low accidents were reported in high hazard site, workers morale is high less
staff turnover is reported

No Blame culture: No fear of reprisal to the workers and are encouraged to report
concerns on health and safety aspects. Across the organization, there are clear
lines of internal and external communication was defined for the effective
resolution of complaints.

Level of compliance with health and safety rules: organization complies with all
rules and regulations. For this, they set specific objectives and regular checks were
made to achieve the targets.

Procedures: The importance is given to the implementation of control measures

like safe systems of work, a permit-to-work system, supplementary emergency
arrangements after detailed risk assessment were conducted for tank modification
work.

Importance to Risk Assessment: Detailed risk assessment is conducted for tank

modification work considering the highly toxic chemical and its release which
would be catastrophic for workers, as well as people in adjacent businesses,
residential houses, and schools. A summary of the risk assessment is circulated to
all workers likely to be affected by the proposed tank modification work.

Complaints about working conditions: The organization listens to workers when

they raise concerns. Organisation also responds professionally to external
customer complaints about effective resolution.

Strong leadership & Management: Organisation provides world-class health &

safety culture which is used as a benchmark by other industries. The organization
is fully insured even though the premium is high to safeguard the interests of both
employee and employer.

Adequate allocation of resources: Organisation employed experienced an expert

engineer from the corporate management team with zero lost time incident to
oversee the process of tank modification works. Management has also enforced
necessary precautions, including the wearing of specified personal protective
equipment to the contractor as part of the permit to work conditions.

Worker consultation & participation: Competent experienced process operator

as representative of the worker. Due to this, the worker can easily approach and
give feedbacks related to health & safety aspects. Since worker representative is
experienced operator, he can easily understand the technical problem of operation
and can easily approach the senior management for possible solutions.

Prompt investigation of incidents and accidents: Organisations investigate of

all near misses to learn lessons and prevent more serious outcomes. The
organization conducts frequent internal audits and is also externally audited to
comply with all non-conformities related to incidents and accidents

Commitment to H&S at all levels: To confirm safe working and clarify overall
expectations of permit to work, organization nominated worker representative and
an independent site contact to monitor and liaise with the contractors.

Teamwork (Peer Group) among all levels of management: There is a

possibility Peer group pressure can be harnessed to encourage good safety-related
behavior. As an organization review its health and safety performances from the
findings of active monitoring inspections for continuous improvement
opportunities can be sourced.

Task 4: Other than a general improvement of health and safety, what

specific reasons are there for this organization to learn lessons from
incidents?
Answer:- Specific reasons organization can learn lessons from incidents are:
Prevent future accident: Organisation can prevent future accident-related to tank
modification to prevent blockages by learning lessons obtained during the
implementation of permit to work system. A new modification process may help
the organization to perform without doing a shutdown.

To increase awareness and competence: Suitable training modules will be

available to the organization for implementing the tank modification work, which
was learned from the previous tank modification incidents. This will safeguard
employees from highly toxic chemicals and may reduce worker sickness rates.

Prevent reoccurrence: To remove the blockage of the tank available solution of

the tank will be present in the organization. Modifications can be safely made to
the tank and that all the necessary resources will be available for this work in the
future.

Improves business reputation: Organisation can set new health & safety
benchmarking standards for others for implementing a safe system of work
related to tank modification without complete process shutdown.

Reduce Staff turnover rate: By learning lessons workers will be more aware,
more motivated and have more confidence in the system, so the staff turnover rate
will reduce.

Cost-effectiveness in managing risks: By understanding the underlying and root

causes from the incident, health and safety risk can be managed cost-effectively.

Comparison of own system: Knowledge learned from incidents will allow for
comparison with the effectiveness of own systems.

Encourage creative solution: Workers, supervisors, operators, managers

involved in modification work will have hands-on experience and can provide
opinions and creative solutions for further tank modification processes.

Improve organization key performance Indicator: From the findings of active

monitoring inspections, opportunities for continuous improvement can be
implemented. Site managers, engineers, supervisors, and operators will be aware
of new risks. New performance indicators can be assigned for managing health
and safety systems.

Confidence to Various Stakeholders: Lesson learned from the tank modification

incident will bring confidence to various stakeholders on health and safety
management system.
Task 5: Based on the scenario only, comment on whether the risk
assessment is ‘suitable and sufficient in the following areas:- (a) who
might be affected. (b) the precautions are reasonable, and the
remaining risk is low
Answer 5(a):- As per HSG65 Risk assessment is suitable and sufficient as it
is completed and headed by a competent very experienced senior
engineer who has 25 years of experience from a corporate management team with
zero lost time incident for tank modification work. Health and safety adviser,
worker representatives and plant managers were also involved during the
preparation of risk assessment.

The risk assessment considers activities taking consideration of who might be

harmed and affected due to the tank modification. Risk consideration of
the highly toxic chemical, the release of which could harm the workers, as well
as people in adjacent businesses, residential houses, and schools. Risk
assessment also considers all contractors and other plant workers who may be
affected due to the tank modification work.

Answer 5(b):- As per HSG65 Risk assessment is suitable and sufficient as

systematic and detailed risk assessment of the tank modification task is completed
and headed by competent experienced senior engineer involving Health and
safety adviser, worker representatives and plant manager. Risk assessment
considers highly toxic chemicals and their release, which could affect the
workers, people in adjacent businesses, residential houses and schools. The
proposed modification method is a safe and widely used solution where
the safety improvements are worth the cost. It also includes risk evaluation,
existing and additional control measures like safe systems of work, a
permit-to-work system, supplementary emergency arrangements, and
suitable induction training for all contractors. Implementation of these
precautions and control measures reduce high risk to low risk.

A summary of the risk assessment is circulated to all workers likely to be

affected by the proposed modification. Permit to work requirement with the
necessary precautions, including wearing of specified personal protective
equipment was communicated to the contractor involved in tank modification
work.

For active monitoring of safe working, experienced process operator along with
independent site contact has been nominated.

Task 6: Why should a PTW be used to help manage this storage tank
modification?
Answer:- Permit to Work (PTW) system to be used to manage this storage
tank modification for the following reasons:

PTW is a formally documented safety procedure, forming the part of safe system of
work, which ensures the necessary action to be taken before and after work to
prevent injuries to personnel from accident.

PTW system normally considered most appropriate to non-routine operations. Tank

modification work is a non-routine work which usually planned during a planned
maintenance shutdown.

Risk consideration of the higher the toxic chemical, the release of which
could harm the workers, as well as people in adjacent businesses, residential
houses, and schools in the risk assessment shows tank modification work is a
high-risk activity. This can be managed by the PTW system.

PTW system is required when two or more individuals or groups need to

coordinate activities to complete the job safely. Involvement of contractors
carrying out the tank modification and all contractors and other plant workers
where co-ordination is required for control of the contractor site entry and exit.

PTW system will ensure proper training and instructions are provided to the
contractors and workers before work execution.

PTW system will ensure an explanation of the associated risk of tank

modification, how the work is safely prepared and what necessary precautions,
control measures were provided. Wearing of specified personal protective
equipment by contract workers is required. The supplementary emergency
arrangement is available at the site.

PTW system will ensure monitoring and auditing to ensure that the system
works as intended as specified in the organization’s safe system of work based
on the findings of the risk assessment and the method statement provided by
the contractor.

PTW system ensures clear identification of who may authorize particular jobs
and who is responsible for specifying the necessary precautions to confirm
safe working. Dual role experienced process operator & worker representative
along with independent site contact has been nominated.
Task 7: Based on the scenario only, discuss how effectively the
contractors will be managed by the organization during the
modification

Answer:- The organization will effectively manage the contractors during the
modification work by following:

Planning the work: Safe system of work of an organization like permit to work
requirement based on the findings of risk assessment and the method a statement
provided by the contractor will be exchanged with each other. Contractor must be
given basic site information of the workplace like site entry and exit control
systems, supervision standard, supplementary emergency arrangements related to
tank modification works.

Co-ordinating the work: During the work, there should not any mismatch of
priority. Permit-to-work is issued to the contractors and it is accepted by them.
Necessary precautions, including wearing of specified personal protective
equipment and precautions of permit to work are communicated to all the
affected contractors and workers.

Monitoring the work: Organisation will monitor the contractor’s work to ensure that
they are adhering to required H&S standards as stated in the permit to work, specified
personal protective equipment being used for tank modification work. Active
monitoring will be carried out to enforce precautions along with other site safety
rules as shared during the planning of work. Contractor site entry and exit control will
be verified, how supervision standards will be implemented. For managing work and
to communicate with the contractors, dual role experienced process operator &
worker representative along with independent site contact have been nominated.
Managing the Work: Nominated dual role experienced worker representative
along with independent site contact will be monitoring the modification work to
confirm safe working. They will ensure proper arrangements, adequate resources
like specified PPE were allocated to the workers, supplementary emergency
arrangements were made as planned. If any deviation is noted as per the safe
system of work based on risk assessment and method statement of contractor work
will be immediately stopped, the aim being to complete the job safely without
incident.

Task 8: The organization’s world-class reputation is partly due to

carrying out an annual health and safety performance review. What
types of information should this review consider?
Answer:- Annual health and safety performance review shall consider the
following types of information:
Legal compliances: Organisation must verify its legal requirement and its
compliances. Any changes to the law shall be recognized and if required specific
objectives to be set. The organization shall also consider statutory inspection
reports for conformity to health & safety standards. It is a legally compliant
organization that sets clear objectives and checks that they are met.

Active monitoring: Results from active monitoring like routine safety

inspection of premises, safety tours by senior management, safety survey
reports regarding implementation of specific precautions shall be reviewed for
their performances and effectiveness. During tank modification work permit to
work explains that precautions will be enforced along with any other site rules, by
active monitoring.

Reactive monitoring: Organisation shall review incident rate, absenteeism

rate, compensation claims, staff turnover rate to review poor health & safety
practices for possible improvements.

Accident & incident data: Incidents like near miss, property damage accidents,
lost-time accidents, and accident reports shall be reviewed for possible underlying
and root causes. An organization must verify the implementation of corrective
and preventive action and if any issue arises adequate resources shall be
provided.

Absence and sickness data: Absenteeism and sickness data shall be reviewed for
work-related Illnesses. If any work-related illness is reported, effective control
measures shall be implemented. Absence and sickness rates are low as the
organization employs motivated workers with clearly defined responsibility.

Training record: How the training needs are identified for all employees, workers,
and contractors. Management shall verify how refresher training was imparted
when the new process was introduced. Review of specific training requirements
like first aid and fire safety training. For tank modification work suitable
induction training for all contractors is designed as part of safe control measures.

Investigation reports: Review of investigation reports shall be done to verify

corrective and preventive measures were properly implemented. The
organization conducts proper investigating of any near misses to learn lessons and
prevent more serious outcomes as a result of low accident and incident rates were
recorded.

Risk assessments: Risk assessment shall be reviewed periodically for their

effectiveness, especially after incidents and accidents. Whether risk control
measures are suitable and sufficient. Systematic and detailed risk assessment of
the tank modification the task is completed and headed by competent
experienced senior engineer involving Health and safety adviser, worker
representatives, and plant manager.

Results of participation and consultation: A review of specific needs and

complaints from workers shall be done to identify the issues and how effective it
can be resolved. A competent experienced process operator was nominated as a
representative of the worker. The organization listens to workers when they raise
concerns and clear lines of internal communication defined to allow effective
resolution of complaints.

Previous management reviews: Implementation of the completion of actions

identified during previous reviews. Whether they were properly implemented and
how it improves the overall performance.

Achievement of objectives: Objectives defined by management are specific,

measurable, attainable realistic, and timely where specific targets have been set,
achievement can be measured. It is a legally compliant organization that sets clear
objectives and periodic checks were conducted to achieve the targets.

Audit reports: Internal and external audit findings should be reviewed, which
may provide detailed information on the safety management system and its
effectiveness. The organization conducts frequent internal audits and is also
externally audited.

Communications and complaints from external sources: Communication from

external sources like enforcement agencies, stakeholders shall be reviewed for
effective resolution. Organization responds professionally to external customer
complaints. Across the organization, there are clear lines of internal and external
communication are established for the effective resolution of complaints.

Review of external sources of information: Review of national legislations,

approved code of practices, HSE guidelines, safety standards of ISO, EU, ILO.
Manufacturer’s safe operating instruction for plant & machinery, Trade
Association and NGO reports for possible improvement in health & safety
performances.