The role of standardization in safety management – A case study of a major oil & gas company

This article discusses the strengths and weaknesses of various kinds of standardization, when applied to the field of safety management. Recently, there are signs that organizations operating in high risk environments take further steps towards standardization. On the positive side, standardization has the potential to enhance the predictability of normal operations as well as facilitating the transfer of lessons learnt across organizational contexts. On the negative side, standardization is by definition a strategy for dealing with known hazards and accident scenarios. We discuss how too strong an emphasis on standardization can involve unintended negative consequences for organizations’ crisis-handling capabilities.     

Exploring oil and gas industry workers’ knowledge and information needs

Many incident reports and much research literature have concluded that incident rates in high-hazard industries can be reduced by enhancing the knowledge and information sources available to workers. However, a sparsity of published research reporting workers' perspectives on the value of information and knowledge sources in different operational situations potentially limits the effectiveness of interventions aimed at improving human responses to process safety performance. In response, this work seeks to understand how frontline oil and gas industry workers, responsible for managing process safety and other risks in their hazardous workplaces, rely on their own knowledge, the knowledge of others and information provided to manage different operating scenarios. A set of open and closed-ended survey questions were distributed to workers at several upstream and downstream oil and gas companies. Statistical analysis of 133 responses revealed interesting insights relating to participants’ experience levels, decision making practices and perceptions on the importance of various information and knowledge sources in different operating circumstances. The data revealed differences in the sources of knowledge relied upon by experienced and less experienced workers. Experienced workers rely on their own knowledge in both routine and potentially high-impact scenarios. Less experienced workers also rely on their own knowledge for routine decisions however they reported seeking out external knowledge and information in potentially high-impact scenarios. The data suggests that interventions to improve safety by enhancing the availability of knowledge and information sources are less likely to affect experienced workers and alternate strategies might be needed. However, such interventions might be effective if they are focused on supporting newer workers.     

Cost–benefit analysis approach for the management of industrial safety in chemical and petrochemical industry

The high complexity of chemical and petrochemical installations determines a complex safety management of these establishments, therefore, there is a need to find innovative solutions to guarantee the prevention of failures and losses of containment from process equipment. In this frame, the use of the API Risk Based Inspection (RBI) assessment approach permits a significant reduction of maintenance costs and, simultaneously, the increase of plant's reliability and availability. To increase the level of industrial safety, a proper selection of measures is also needed, even if the adoption of such measures poses costs. Given that resources for the companies are usually limited, a comparison amongst various solutions has to be done with the aim to find the best one, based on a comparison of costs and benefit. To this scope, recently a software, named Inspection Manager, has been developed by ANTEA and implemented thanks to a cooperation with the University of Padova (Italy). The Inspection Manager provides support in the application of the RBI approach by means of the use of plant-specific data, which are stored in its database; its further implementation, presented in this paper, has made it able to support also cost-benefit analysis and, thus, the selection of measures to be adopted to prevent accidental events causing the release of hazardous materials. A case-study is presented to test the new functionality of the tool; after the identification of the most effective measures, a careful cost-benefit assessment has been executed as a basis for decision-making.     

Occupational risk assessment in construction industry – Overview and reflection

The construction industry is plagued by occupational risky situations and poor working conditions. Occupational risk assessment (ORA) on workplace sites is the first and key step to achieve adequate safety levels, particularly to support decision-making in safety programs. Most construction safety efforts are applied informally under the premise that simply allocating more resources to safety management will improve safety on site. Moreover, there are many traditional methods to address ORA, but few have been adapted and validated for use in the construction industry, particularly in the design stage, for which traditional approaches do not give adequate answers. This paper presents a state-of-the-art on ORA traditional methods, for the construction industry, discussing their limitations and pointing advantages of using fuzzy sets approaches to deal with ill-defined situations.     

Methods to determine the mine gas explosibility – An overview

Mine gas explosions present a serious safety threat in the worldwide mining industry. Since the beginning of mining, many coal miners have been killed due to the explosions. Accordingly, on a regular basis, mine operators should get air samples from the underground atmosphere. At the same time, monitoring and tracking the explosibility of the air sample should be done as a timely matter to avoid any potential explosions. All these works can provide very important information to assist the mine operators to well understand the mine atmospheric status and its trends. In additional, when facing the coal spontaneous combustion, mine fire events, or other chemical reactions related mine accidents, determination of explosibility is a definitely significant work for the safety of miners and mine rescue personnel especially when planning and implementing any mine rescue strategies. For many years, mining engineers and researchers have developed a number of methods for assessing the explosibility of the air–gas-mixture. Their research results provide a baseline for judgments of the mine gas explosibility and in determining the extent of change. In this paper, main popular and typical methods used in mining industry to determine the mine gas explosibility are introduced and reviewed. Case demonstrations for each method are also shown and can be used to instruct readers to understand how to apply them. Finally, a brief discussion about the current methods is presented and some preliminary suggestions are also listed for the further improvements in the future research.     

A new-generation safety contest in the construction industry – A long-term evaluation of a real-life intervention

A new-generation safety campaign has been taking place in southern Finland since 1997. The Finnish Construction Employer’s Association together with trade unions, safety inspectorates, and other institutions have been organising a safety contest based on the standardised TR-observation method. Safety inspectors conduct evaluation visits without previous notice to the sites, and best performing companies and sites are rewarded at annually held public seminars. Even though participation is voluntary, more than 70% of the total number of construction sites in the target area have participated in the contest, and the results have been successful. Deficiencies in protection against falling have decreased by 63%, in order and tidiness by 69%, and in working habits by 51%. The effectiveness is also evident in the accident figures. An estimated 4000 accidents and three fatalities are prevented each year, while other parts of the country during the same period show no improvement in accident risk. A key success factor may be the adoption among firms of a new, standardised safety monitoring method which has been used effectively by senior management teams. The method employs a combination of penalties and incentives in order to set and enforce new safety targets. Another success factor is the close co-operation between the construction industry, labour organisations and safety authorities.     

Testing of dust clouds for the electrostatic-spark ignition hazard in industry. Need for a modified approach?

Current standard test methods for electric-spark minimum ignition energies (MIEs) of dust clouds in air require that a series inductance of at least 1–2 mH be included in the electric-spark discharge circuit. The reason is to prolong the spark discharge duration and thus minimize the spark energy required for ignition. However, when assessing the minimum electrostatic energy ½CU² for dust cloud ignition by accidental electrostatic-spark discharges, current testing standards require that the series inductance of at least 1–2 mH be removed from the spark discharge circuit. No other changes of apparatus and test procedure are required. The present paper questions whether this simple approach is always adequate. The reason is that in practice in industry accidental electrostatic-spark discharge circuits may contain large ohmic resistances due to corrosion, poor electrical grounding connections, poorly electrically conducting construction materials etc. The result is increased spark discharge durations and reduced mechanical disturbance of the dust cloud by the blast wave emitted by the spark. Therefore, testing for minimum ½CU² for ignition by accidental electrostatic spark discharges may not only require removal of the series inductance of 1–2 mH from the standard MIE spark discharge circuit. Additional tests may be needed with one or more quite large series resistances R_s inserted into the spark discharge circuit. The present paper proposes a modified standard test procedure for measurement of the minimum electrostatic-spark ignition energy of dust clouds that accounts for these effects.     

CNG cylinder burst in a bus during gas filling – Lesson learned

An accident leading to bursting of a compressed natural gas (CNG) cylinder fitted to a passenger bus in India resulted one person died and four persons injured. This paper presents the incident, the human factor involved, safety issues and lesson learned.     

Systems thinking in a gas explosion accident – lessons learned from Taiwan

On July 31, 2014, at around 23:57, several huge explosions occurred that lasted for 2 h in Kaohsiung City, Taiwan. As a result of a gas leak from a ruptured underground pipeline, the catastrophic incident destroyed more than 6 km of roads, killed 32 people, injured 321 people, and damaged 3259 buildings. Pipeline explosions have been reported as a repeatedly occurring problem, indicating that (1) complex systems are difficult to manage and control, and (2) humans are unable to effectively learn from experiences of accidents. Initial analyses results reveal that root causes of this incident were a combination of a series of complex chain reactions, which eventually led to propylene leakage and explosion. This is a systematic problem, which can hardly be investigated or analyzed by traditional research approaches. Based on the investigation reports and “systems thinking” method, this study develops causal loop diagrams for the Kaohsiung gas explosion to explore the root causes of the disaster. The research results indicate that (1) this pipeline explosion incident was the result of the chain reactions and was the output of a complex system; (2) the mental model of “production first” and “experience gap” were the root causes of the disaster; and (3) to achieve a higher safety standard, continuous education to improve the mental model of “safety first and safety over production” are essential. The findings of this study may contribute toward the improvement of the standard operating procedure for disaster management and preventing similar incidents in the future.     

OSH star enterprise pilot scheme——a partnership approach to improve the safety performance of construction industry in Hong Kong SAR

Background: The Occupational Safety and Health Council(OSHC) is committed to improve the safety performance of the high risk construction industry.In the past three years,about 40% of the fatal accidents in the construction industry were related to Renovation,Maintenance,Alteration and Addition(RMAA).Due to the poor safety record,some of the RMAA contractors have difficulty in obtaining the Employees’ Compensation Insurance(ECI) cover in the market,or if they could obtain the ECI,the premium rate would be exceedingly high.In view of this,the OSHC,the Labour Department jointly launched"OSH Star Enterprise-Pilot Scheme on Safety Accreditation for the RMAA Industry",which prompts the industry to take practicable safety measures to improve the safety of working environment and reduce occupational injuries.The program also helps the stakeholders and insurers to identify safety-conscious contractors and thereby provide them with a favourable premium rate under the Employees’ Compensation Insurance Residual Scheme(ECIRS).Objectives: The OSHC launches the Pilot Scheme to improve the safety performance of the RMAA industry through providing safety training,subsidizing enterprise to purchase safety equipment and providing safety audit.We also use financial incentive to encourage RMAA enterprises to join the Pilot Scheme-for those who are accredited as "OSH Star Enterprise"could receive a premium discount from the ERIRS when obtaining the ECI.The scheme also differentiates those safety-conscious and law-abiding enterprises from the poor performers,which helps the industry and public identifying the RMAA contractors who pay attention to work safety.Methods: The Pilot Scheme targets RMAA enterprises that employ less than 50 employees in Hong Kong.A three-pronged approach is used to improve the safety performance of the RMAA industry: the Pilot Scheme provides(1) financial support for the RMAA contractors to buy a transportable temporary anchor device and full body safety harness and its anchor system;(2) safety training     

Implementation of safety management systems in Hong Kong construction industry – A safety practitioner's perspective

IntroductionIn the 1980s, the safety management system (SMS) was introduced in the construction industry to mitigate against workplaces hazards, reduce the risk of injuries, and minimize property damage. Also, the Factories and Industrial Undertakings (Safety Management) Regulation was introduced on 24 November 1999 in Hong Kong to empower the mandatory implementation of a SMS in certain industries including building construction. Therefore, it is essential to evaluate the effectiveness of the SMS in improving construction safety and identify the factors that influence its implementation in Hong Kong.MethodA review of the current state-of-the-practice helped to establish the critical success factors (CSFs), benefits, and difficulties of implementing the SMS in the construction industry, while structured interviews were used to establish the key factors of the SMS implementation.ResultsResults of the state-of-the-practice review and structured interviews indicated that visible senior commitment, in terms of manpower and cost allocation, and competency of safety manager as key drivers for the SMS implementation. More so, reduced accident rates and accident costs, improved organization framework, and increased safety audit ratings were identified as core benefits of implementing the SMS. Meanwhile, factors such as insufficient resources, tight working schedule, and high labor turnover rate were the key challenges to the effective SMS implementation in Hong Kong.Practical applicationsThe findings of the study were consistent and indicative of the future development of safety management practice and the sustainable safety improvement of Hong Kong construction industry in the long run.     

Managing safety in hydropower projects in emerging markets – Experiences in developing from a reactive to a proactive approach

International companies investing in emerging markets need to address the management of safety under varying conditions. The paper presents an evaluation of the approaches taken by an international hydropower company in two different construction projects, one in India and one in the Philippines. In the first project, the company had to intervene as a reaction to poor safety and overall performance. Based on previous experiences, the company selected a proactive approach in the second project, involving use of the contracting process to ensure adequate conditions from the start of construction and onwards. The paper accounts for the safety performance results in the two projects and interprets them in relationship to external and internal influencing factors in the respective project. It is concluded that a proactive approach has the potential of delivering satisfactory safety results at moderate costs for follow-up. A reactive approach risks exposing the company to ethical and reputation risks due to a poor safety performance before the corrective actions have taken full effect. It is also resource demanding. Results demonstrate the feasibility of turning around a project’s safety performance also when preconditions are challenging.     

Experimental study on the suppression of gas explosion using the gas–solid suppressant of CO2/ABC powder

Gas explosion is the leading accident in underground coal mining in China. Using the self-improved 20 L spherical experimental system, the impacts of 8% CO₂, ABC powder at various concentrations and mixture of them on the suppression of mine gas explosion were investigated. The results indicate that cooperative synergism exists between ABC powder and CO₂. Their combination has a better effect than each of the two components acting alone, especially for the gas of larger concentration. When 0.25 g/L ABC powder was mixed with 8% CO₂, the explosion limits were reduced by about 55%, the time to reach the peak explosion pressure was prolonged 3.56 times on average. Meanwhile, the maximum explosion pressure declined on an average of 59.4% and the maximum explosion overpressure rising rate decreased on an average of 91.1%. A combination of 0.20 g/L ABC powder and 8% CO₂ completely suppressed 11% gas explosion. The explosion suppression mechanism of CO₂ and ABC powder were probed theoretically. CO₂ plays a key part in the whole explosion processes, and it can effectively suppress the forward reaction between gas and oxygen. While it is during the middle-later period of explosion processes that ABC powder plays a critical role. The particles decomposed from heated ABC powder such as nitrogen and phosphor will react with free radicals rapidly. Besides, atoms as N, P are capable of participating in chain reaction and reacting with active groups, significantly suppressing the gas explosion.     

Emergency response study for chemical releases in the high-tech industry in Taiwan—A semiconductor plant example

In the past two decades, there has been continuous investment and expansion of semiconductor, photoelectric panel, or solar cell plants in the high-tech industry. For example, establishing a semiconductor plant costs about US$ 3 billion. In addition, the output value of integrated circuits (IC) of Taiwan as a whole is estimated to be about US$ 5.215 billion, and globally of US$ 275.2 billion in 2008. A large amount and a variety of specialty gases or chemicals are applied during processes in high-tech facilities and these chemicals are characterized by inflammability, toxicity, and corrosiveness. Accidents may result once errors or leaks occur in any part of the supply chain, which consists of storage facilities, supply equipment, process machines, and tail gas elimination devices. Personnel casualties can result in serious situations. This study discusses the emergency response procedures and common response defects in semiconductor plants with a view to enhancing emergency response effects and capabilities, avoiding casualties, reducing property loss and shortening operation interruption.     

Prioritizing occupational injury prevention in the construction industry: injury severity or absence?

PROBLEM: National occupational injury prevention goals often prioritize the reduction of serious injuries. This study analyzed whether this prioritization is credible in respect to lost-time injuries and short and long term work absence, and the implications this has for injury severity-based versus injury absence-based prevention approaches. METHOD: The data consisted of national and work-site specific injury and absence data from construction workers in Denmark, including workers from the Copenhagen Metro construction sites, during the period 2000-2001. RESULTS AND IMPACT ON INDUSTRY AND GOVERNMENT: Absence length was significantly dependent on the type of injury. Sprains and strains were most prevalent and accounted for approximately one third of injuries and absence. Fractures accounted for one sixth of injuries and the greatest proportion of long-term absence. The results give credibility to the need for targeting sprains and strains in injury and absence prevention initiatives.     

Use of association rules to explore cause–effect relationships in occupational accidents in the Taiwan construction industry

Most models of the incidence of occupational accidents in the construction industry are composed of multiple factors. Although statistical techniques can be used to infer cause-and-effect relationships among these factors, the large number of factors involved and the complexity of the relationships among them make it difficult for managers to identify potential hazards in construction projects and thus develop effective safety procedures. This study addresses this problem by using the association-rule method of data mining in performing an analysis of 1347 accidents in the Taiwan construction industry during the period 2000–2007. The association-rule method enables potential cause-and-effect relationships to be identified among the many factors that play a role in occupational accidents in the construction industry. The study finds that such accidents tend to occur when certain combinations of hazards are present – especially working in high places without protective measures, loss of balance when in motion, failure to use protective equipment, insufficient experience, and injurious contact with unstable structures. These hazards are especially evident in small enterprises with less than 10 persons. The results can help management to formulate effective safety policies with regard to management shortcomings and staff training.     

Safety management in different high-risk domains – All the same?

In view of safety management being introduced in more and more industries, the aim of this paper is to discuss what different high-risk industries can learn from each other and what limits for generalizing safety management methods within and across industries exist. After presenting core components of safety management, three attributes crucial to any organization’s functioning are described, which also affect the way safety management systems should be designed, run, and assessed. These attributes are (1) the kinds of safety to be managed, (2) the general approach to managing uncertainty as a hallmark of organizations that manage safety, and (3) the regulatory regime within which safety is managed. By discussing safety management in the context of these three attributes, contingencies are outlined that can help decision-makers in companies to tailor safety management to their own situation and support regulators in drawing up and evaluating safety management requirements for different industries while also promoting learning between different high-risk domains. Standards and procedures, safety training, incident reporting and investigation, and safety culture are taken as examples to illustrate why and how different aspects of organizational functioning should be taken into account when designing and evaluating safety management systems or elements thereof.     

Relation between senior managers’ safety leadership and safety behavior in the Chinese petrochemical industry

Senior managers in organizations are authorized and obliged to maintain organizational safety. However, to date, little research has considered the relation of senior managers' safety leadership to safety behavior. This study addresses this gap by using path analysis to confirm the validity of a hypothetical model that relates six dimensions of senior managers' safety leadership to two safety behaviors through the safety climate in the petrochemical industry. A questionnaire survey was sent randomly to workers (other than senior managers) in two petrochemical companies in China, and data from 155 usable responses were compiled for the path analysis. Results indicate that in the petrochemical industry, senior managers' safety leadership has a positive impact on safety behavior, and the safety climate plays an intermediary role between them. From the perspective of the dimensions of senior managers' safety leadership and safety behavior, safety concern has the greatest positive effect on safety compliance. Moreover, safety vision has the greatest positive impact on safety participation, whereas safety inspiration and safety awards and punishment have negative effects on safety compliance. Personal character does not directly influence any dimension of safety behavior but indirectly does so by influencing the safety climate. On the basis of these results, measures of improving senior managers' safety leadership in the petrochemical industry are presented to help improve the overall safety performance of the industry. A new view is provided for the petrochemical industry in China to suggest that senior managers’ safety leadership can be treated earnestly.     

Perceived benefits of applying Pay for Safety Scheme (PFSS) in construction – A factor analysis approach

In recent years, construction safety has been a hot topic in Hong Kong. The Government of the Hong Kong Special Administrative Region (HKSAR) has launched different safety measures to improve the prevailing safety performance of the construction industry. The Pay for Safety Scheme (PFSS) has emerged as one of the major safety initiatives launched within the public sector construction industry since 1996. It aims to encourage the safety awareness by taking the contractor’s pricing for safety-related items out from the consideration of competitive bidding. The objective is to provide a concise review of the prevailing application of PFSS in Hong Kong in general, and to identify and analyse the key benefits of PFSS in construction through an industry-wide empirical questionnaire survey in particular. Altogether, 145 industrial practitioners who have derived extensive hands-on experience with the PFSS construction projects participated in the survey to indicate their levels of agreement to those 14 key benefits identified which were measured and analysed by factor analysis. The results of factor analysis indicated that the 14 individual benefits of implementing PFSS were consolidated under four underlying factors: (1) Enhancing safety climate and attitude; (2) Promoting effective safety-related communication; (3) Streamlining the safety procedures; and (4) Ensuring adequate safety training. A wider application of PFSS should be encouraged with a view to achieving better safety performance within the industry. It is recommended that a similar scheme to PFSS currently applied in Hong Kong may be developed for implementation in other regions or countries for international comparisons.