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Hazard Recognition and Risk Analysis
Safety in Construction Design
Larsen & Toubro – E&C Division
Sudhir Mishra
Every single worker deserves to
go home to his family in the same
condition he arrived in!!!!
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Hazard Recognition and Risk Analysis
Safety Credo
ZERO INCIDENT
CREDO
No work related ill-health
No occupational accident & material damage
No harm to the environment
No personal injuries
• Block 5 Development Package 14, MOQ
• 9 Well platform project, ONGC• Songo Songo, Tanzania
ACHIEVEMENTS1 million man-hours without LTA in
All operations OHSAS 18001 and
ISO 14001 certified
2Larsen & Toubro – E&C Division
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Hazard Recognition and Risk Analysis
Construction Accidents
56% falls from height
21% trapped by something collapsing or overturning
10% struck by a moving vehicle
5% contact with electricity or electrical discharge
4% struck by a flying/falling object during machine lifting of materials
3% contact with moving machinery or material being machined
1% exposure to a hot or harmful substance
Co
nstr
ucti
on
Sit
e
Safe
ty
Larsen & Toubro – E&C Division
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Hazard Recognition and Risk Analysis
4
DANGER! AN
ACCIDENT WAITING
TO OCCUR!
No Fall Protection.
Scaffold missing
planking. Competent
Person?
DON’T GET CAUGHT IN THE DROP ZONE
FALLS KILL
DON’T BECOME A
STATISTIC !!
Larsen & Toubro – E&C Division
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Hazard Recognition and Risk Analysis
5
Excessive
overhang on
planks
Guardrails
missing on
working levels
No fall
protection
Larsen & Toubro – E&C Division
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Hazard Recognition and Risk Analysis
?? Reduced Inlet Piping
Anything wrong
here?
Reduced
Inlet Piping
Larsen & Toubro – E&C Division
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Hazard Recognition and Risk Analysis
?? Plugged Bellows, Failed Inspection, Maintenance
Bellows plugged
in spite of sign
Anything wrong
here?
Failed
Inspection
Program
Signs of
Maintenance
Issues
Larsen & Toubro – E&C Division
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Hazard Recognition and Risk Analysis
?? Discharges Pointing DownAnything wrong
here?
Anything wrong
here?
Discharges
Pointing Down
Larsen & Toubro – E&C Division
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Hazard Recognition and Risk Analysis
?? Long Moment Arm
Anything wrong
here?
Long
Moment Arm
Larsen & Toubro – E&C Division
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Hazard Recognition and Risk Analysis
?? Will these bolts hold in a relief event
Anything wrong
here?
Will these
bolts hold
in a
relief event?
Larsen & Toubro – E&C Division
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Hazard Recognition and Risk Analysis
Flixborough1 June 1974
April 2006 ICAO Seminar Baku
•Modification Control
•Use suitably trained, educated
and responsible people
•Know what you don’t know
Larsen & Toubro – E&C Division
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Hazard Recognition and Risk Analysis
SevesoJuly 1976
Understanding safe state to leave reactions
Multiple layers of protection
Automated Reaction stop systems for exothermic systems
April 2006 ICAO Seminar Baku
Larsen & Toubro – E&C Division
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Hazard Recognition and Risk Analysis
Longford25 September 1998
Sale
Barry Beach
Marine Terminal
Long Island Point
Fractionation Plant,
Crude Oil Tank Farm
and Liquids Jetty
Longford
Gas & Oil Processing
Port
Phillip
Bay
c
Melbourne
Altona
Monotower
Sub-sea Well Oil Platform
Gas Platform
Concrete Structure
Barracouta Marlin
Snapper
Gooding
Compression (GTC)
c
c
• Training needs to impart and refresh knowledge.
• Must identify other hazards and provide relevant training.
•Corporate knowledge must be captured and kept alive
Larsen & Toubro – E&C Division
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Hazard Recognition and Risk Analysis
Major AccidentsPiper Alpha
• Deadliest Accident so far: 1988 Piper Alpha (167 fatalities)
• Caused by a Simple Mistake
• A Pressure Safety Valve was accidentally left open after Maintenance
• Plant started without knowing this
• Oil Fire ruptured Gas Riser leading to Massive Release of Gas
Larsen & Toubro – E&C Division
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Hazard Recognition and Risk Analysis
Piper Alpha
The Piper Alpha, as seen from a crew change helicopter, before the fire started.
Larsen & Toubro – E&C Division
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Hazard Recognition and Risk Analysis
Piper AlphaAll that remains of the oil platform after the devastating fire burns out.
Larsen & Toubro – E&C Division
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Hazard Recognition and Risk Analysis
Explosion on Transocean Rig
Deepwater Horizon Fire followed by the Rig sinking 24000 Gallons of Oil leaking from BOP Riser Worst Environmental Disaster in USA
Major AccidentsDeepwater Horizon Rig (2010)
17Larsen & Toubro – E&C Division
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Hazard Recognition and Risk Analysis
Deepwater Horizon Rig
The Deepwater Horizon Rig, before the fire Accident (2010).
Larsen & Toubro – E&C Division
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Hazard Recognition and Risk Analysis
Deepwater Horizon Rig
Capsizes (2010)
Larsen & Toubro – E&C Division
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Hazard Recognition and Risk Analysis
Bombay High offshore installation 2005: Risk assessment
identified that the installation was vulnerable to ship
collision because a critical pipe was unprotected. Work was
planned to build a guard around the pipe.
Larsen & Toubro – E&C Division
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Hazard Recognition and Risk Analysis
On 28 July 2005 the dive support vessel collided with the
installation, the edge of the vessel’s heli-deck cut the pipe.
10 employees (from 220) and 40% of India's crude oil supply
were lost.
The hazards identified in risk assessment are real and require action
Larsen & Toubro – E&C Division
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Hazard Recognition and Risk Analysis
LOAD OUT
MHN RD N-14 PLATFORM
Larsen & Toubro – E&C Division
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Hazard Recognition and Risk Analysis
When Finished……Past Glory Restored
MHN RD N-14 PLATFORM
Larsen & Toubro – E&C Division
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Hazard Recognition and Risk Analysis
Common failures can be
avoided by
robust design
Larsen & Toubro – E&C Division
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Hazard Recognition and Risk Analysis
Successful Thought is One Thought Away From Normal Thought….
Larsen & Toubro – E&C Division
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Hazard Recognition and Risk Analysis
Structural/ Environmental
Causes:
Structural failures due to
extreme weather
Corrosion
Inadequate design
Crane boom collision
Consequences:
Asset damage
Multiple fatalities / injuries
Larsen & Toubro – E&C Division
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Hazard Recognition and Risk Analysis
Platform Destroyed by Drifting SEMI
Larsen & Toubro – E&C Division
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Hazard Recognition and Risk Analysis
When accidents occur, structures withstand till the rescue arrives…..
Subsea intervention is expensive and shall be minimized
Excessive deflections are cause of worry….
Larsen & Toubro – E&C Division
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Hazard Recognition and Risk Analysis
Inadequate Deck Height
due to Subsidence
The seafloor at this
location has subsided 10
feet. The (+)10 is at the
waterline.
Larsen & Toubro – E&C Division
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Hazard Recognition and Risk Analysis
Mitigation
Before
After
After
40’ 54’
Reduce Consequence of Failure
1. Reduce Load on Platform
2. Increase Strength of Platform
Larsen & Toubro – E&C Division
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Hazard Recognition and Risk Analysis
Horizontal Exhaust of WHRE
Before After
Vertical Exhaust (25 m from deck plate)
Helideck
Job: Modification of Exhaust Duct to Prevent Hot Air during Chopper Take-off
Larsen & Toubro – E&C Division
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Hazard Recognition and Risk Analysis
Exposed Hot Oil Line
Crane Pedestal Line Protective Shed Structure
Before After
Job: Protective Shed Installation for Hot Oil Lines (NQO-NQP Bridge)
Larsen & Toubro – E&C Division
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Hazard Recognition and Risk Analysis
Deteriorated Heat Insulation
Replaced with new A-60 Rated Insulation
Before After
Job: Insulation below switch gear, control rooms and transformer rooms
Larsen & Toubro – E&C Division
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Hazard Recognition and Risk Analysis
Before After
New Staircase InstalledNo Secondary Staircase for Emergency
Job: Additional Staircase for Emergency from TG Top to Control Room
Larsen & Toubro – E&C Division
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Hazard Recognition and Risk Analysis
Inherently Safer Design, Green Chemistry
and Green Engineering
Green Chemistry
and Engineering
Inherently
Safer
Design
Larsen & Toubro – E&C Division
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Hazard Recognition and Risk Analysis
Ability to Influence Safety
Conceptual Design
Detailed Engineering
Procurement
Construction
Start-up
High
Low
Ability to
Influence
Safety
Project Schedule
Larsen & Toubro – E&C Division
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Hazard Recognition and Risk Analysis
Design Hazard Management
Inherent Safety
Appraise Select Define Execute Operate
Engineered Safety Procedural
Safety
Larsen & Toubro – E&C Division
Behavioral
Safety
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Hazard Recognition and Risk Analysis
Design Verification Process L&T
Design
KickoffDesign
Internal
Review
Issue for
Construction
External
Review
Trade contractor
involvement
• Establish design for
safety expectations
• Include construction and
operation perspective
• Identify design for safety
process and tools
• QA/QC
• Cross-discipline
review
• Focused safety review
• Owner review
Larsen & Toubro – E&C Division
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Hazard Recognition and Risk Analysis
Designin
Projects
Procurement
Engineering
QC at
Yard
Execution
Client/CA
TPIExternal BodiesInternal Bodies
CA:-Certifying Agency
TPI:-Third Party Inspection Agency
Marketing
Commissioning
L&T Design Interfaces Methodology
Larsen & Toubro – E&C Division
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Hazard Recognition and Risk Analysis
Example of Integral RelationFire Protection
QHSE Engineering
Fireproof Structural Steel Structural
Layout for Escape Routes Facilities
Fire Water Systems Piping / Facilities
Fire-fighting Equipment Facilities
Alarm and Shutdown
Systems
Instruments and Control
Vapour Detection Systems Instruments and Control
Larsen & Toubro – E&C Division
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Hazard Recognition and Risk Analysis
Example of Integral RelationFire Protection (Contd)
QHSE Engineering
Heating / Ventilating
(smoke)
Civil / Structural /
Facilities
Electrical Classification Electrical
Emergency response
plans
Operations / Maintenance
Fire size / duration Process
Fire and blast simulations Structural / Civil
Regulations / standards Contracts
Larsen & Toubro – E&C Division
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Hazard Recognition and Risk Analysis
Example of Integral RelationOther Examples (Contd)
QHSE Projects
Safety of Barges Incorporate Safety
Clauses in Barge Contract
Safety at Site Incorporate Safety
Clauses in Subcontracts
Safety at Site Yard Disciplinary Protocol
Safety of Equipment Safety Specs in
Procurement
Larsen & Toubro – E&C Division
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Hazard Recognition and Risk Analysis
QHSE Studies
Preliminary Noise Study Preliminary Health Program
Preliminary Fire Study Checklist Studies (say 30)
Preliminary Explosion Study What-If Studies
Preliminary Toxic Gas Third Party Interfaces
Dispersion Study QHSE Audit Plan
Preliminary Smoke Study Project Behavioral Safety Plan
Preliminary Hazardous Area
Classification
Larsen & Toubro – E&C Division
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Hazard Recognition and Risk Analysis
QHSE Studies
Design HAZOP Hazardous Area
ClassificationGas Dispersion StudyManagement of ChangeFire / Explosion Studyprogram
Noise Study
Smoke / Ventilation Study
Larsen & Toubro – E&C Division
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Hazard Recognition and Risk Analysis
Safety culture improvement
Technical improvement
Safety management
focused on
employees
Time
Inju
ries
Focus on people
Larsen & Toubro – E&C Division
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Hazard Recognition and Risk Analysis
Risk Containment at L&T
Highest priority to people
Behavior based safety management
PTW and JSA in place
Training & Courses for employees
Identify High Risk Activities
Action Plan Development
Governance Structure Facilitation
Safety Field Audit (SFA) – Including training on
the tool and field coaching
Implementation of Action Plan
46Larsen & Toubro – E&C Division
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Hazard Recognition and Risk Analysis
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Hazard Recognition and Risk Analysis
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Hazard Recognition and Risk Analysis
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Hazard Recognition and Risk Analysis
Safety Tool Box Talk
Larsen & Toubro – E&C Division
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Hazard Recognition and Risk Analysis
CCTV INSTALLED ON TOP OF ELEVATOR
CCTV Monitoring
Larsen & Toubro – E&C Division
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Hazard Recognition and Risk Analysis
Hard Barricading for Ground Movement
Larsen & Toubro – E&C Division
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Hazard Recognition and Risk Analysis
Safety Nets
Larsen & Toubro – E&C Division
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Hazard Recognition and Risk Analysis
Safety Instructions in Cabins
Larsen & Toubro – E&C Division
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Hazard Recognition and Risk Analysis
We always:• Comply with all applicable safety rules and regulations• Operate within design or environmental limits• Use/Involve right tools, equipment, procedures and people for the
job• Ensure safety devices are in place and functioning• Follow instructions and ask in case of doubt• Correct & report unsafe conditions, near misses and even minor
Injuries• Keep the job site clean and orderly• Follow written procedures for high risk and unusual situations• Use, maintain and repair equipment by authorized personnel only• Meet customers’ requirements and specifications
There is always time to do it right
Tenets of Operational Excellence
Larsen & Toubro – E&C Division
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Hazard Recognition and Risk Analysis
L&T Policy on Contractor Management
Contractors HSE capability checks at the time of RFQ.
Internal audit and verification of fitness for employment in terms of resources.
Verification of certification and interviewing the employees to assess the competency level.
Assessment of HSE documentation system and HSE statistics
Larsen & Toubro – E&C Division
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Hazard Recognition and Risk Analysis
Structural marvels are created on everyday basis…
Larsen & Toubro – E&C Division
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Hazard Recognition and Risk Analysis
Challenging Journey of Offshore Structures …
Thank you
Larsen & Toubro – E&C Division