nebosh award in health, safety & environment for …rrc trainer packs are designed to aid...

NEBOSH Award in Health, Safety & Environment For the Process

Industries UNIT PS1

Process Safety

Sample Trainer Pack

RRC Trainer Packs are designed to aid delivery of face-to-face, or classroom-taught, courses by tutors approved by the relevant awarding body (e.g. NEBOSH, IOSH, IEMA).The full pack –of which this is a sample – includes the following resources:

• An electronic copy of the RRC student textbook (course notes) for the course, supplied for use by the tutor as reference only.

• A ‘helicopter’ plan (MS Word) – an overview of how the course will be delivered over its duration. • Daily lesson plans (MS Word) – a suggested breakdown of how the detailed subjects specified in the qualification

syllabus will be covered on each day of the course • Slides (MS PowerPoint) – full-colour slides addressing the subjects specified in, and following the structure of, the

qualification syllabus. • Depending on the course, some Packs also contain additional resources, to be used at the tutor’s discretion.

Some third-party resources may be suggested in the Lesson Plans, or in the notes to the slides – for example, video footage, further reading, etc. These are not essential and they are not included as part of the licensed Trainer Pack – it is up to the tutor to source the suggested material, should he or she wish to do so.

This ‘Sample Trainer Pack’ contains a selection of pages from a lesson plan, a number of corresponding slides, and the relevant pages from the course textbook. These pages and slides are representative of the presentation, design and language of the full materials.

If you like what you see and wish to order a complete Trainer Pack for the course you want to deliver, please contact RRC’s customer advisors on +44 208 944 3100, or e-mail [email protected]

Lesson Plan Front Sheet

Tutor:

Course Title and Topic: NEBOSH Award in Health, Safety & Environment in the Process Industries

Venue:

Date & Time:

Number of Adult Learners: Knowledge/Ability assumed: Students should have completed the HSW1 module prior to attendance on this course which will give them a basic understanding of general HSE issues.

Lesson Aims - the aims of the session are to: As per syllabus guide. Objectives (learning outcomes) - by the end of the session students should be able to: As per syllabus guide

Brief reasoning for the way the lesson has been planned: The following are guidelines on how the course should be taught. Different tutors obviously have different styles and experiences and these should be taken into account when delivering the course. To keep the students interested a variety of different methods should be used and the tutor should not rely solely on PowerPoint (PPT) slides. Time should also be given to students to practice exam questions. In addition to learning about HSE this is a key part of the overall course aims.

PI Award Lesson Plan v1 Page 2 of 17 © RRC International RRC SAMPLE MATERIAL

Equipment/Aids to be used:

• Computer (with DVD and sound capability), data projector, flipcharts/whiteboard. • Use of PPT presentations. Though PPT slides exist for most (if not all) subjects covered, they should be used judiciously rather than exclusively. • Internet access. • Students are provided with a set of printed course notes at the beginning of the course. • Prepared Workshop sheets are available for most elements of the course. • Use relevant questions from e-learning assignment (sample exam paper) as source of revision questions.

NEBOSH Process Industries Award (PS1 & PS2) Day 1 APPROX. TIMING

CONTENT AND TUTOR ACTIVITY AIDS AND EQUIPMENT STUDENT ACTIVITY

0900 - 0915 Icebreaker (who they are, why here, what hoping to get out of it)

Talking about themselves and listening

0915 - 0925 Introduction to the course – overview and aims.

Flip chart, NEBOSH Syllabus guide Listening

0925 - 0935 Run through structure of course using course notes as a prompt.

Internet access and student resource CD

Listening, taking notes and asking questions

PS1 ELEMENT 1 FOUNDATIONS of PROCESS SAFETY 0935 –1030 Learning outcomes for element 1

Importance of regulatory frameworks COMAH CDM Discuss with students which of the above are relevant to their workplace. Human Factors Define human factors Ask students what affects behaviour while at work and capture results on a flipchart.

PPT and flip chart Listening, taking notes and asking questions


APPROX. TIMING

CONTENT AND TUTOR ACTIVITY AIDS AND EQUIPMENT STUDENT ACTIVITY

Briefly describe ergonomics

1030-1045 MORNING BREAK 1045-1230

Unintended actions: Slips, lapses and mistakes Intended Actions: Violations Ensure that examples are used of each of these to aid student understanding. Pertinent examples are provided in the course notes. Adequate controls for twilight night working: Discuss that is significant factor in most major accidents ask students why risk is increased when night working and capture results on flipchart. Competence: Define competence and how it is achieved. Third party control Write on flipchart the three main elements of controlling contractors (i.e. selecting the contractor, planning the work and monitoring the work) leaving a gap between each. Ask students for examples of how each one can be achieved and write on flipchart in correct section. PS1 E1 Workshop Summarise Element 1

PPT and Flipchart PS1 E1 Workshop Sheet

Listening, taking notes and asking questions Contributing to workshop.


© RRC International

NEBOSH Award in Health, Safety and Environment for the

Process Industries: Unit PS1 Element 1

The Foundations of Process Safety

RRC SAMPLE MATERIAL

© RRC International © RRC International

Learning Outcomes

• Identify the National and International Standards that organisations in the chemical process industry should follow

• Outline how human factors can affect

health and safety • Explain what is meant by competence and

its importance in process safety RRC SAMPLE M

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Legal Requirements Importance of Regulatory Frameworks

Seveso II directive origination • Accident at chemical plant in Italy 1976 • Release of dense cloud of dioxins • No fatalities • 2000 people treated for dioxin poisoning

Requirements • Notification by operator • Major accident prevention policy • Site safety report • Safety management system • Control of land use • Information to public • Accident reporting

RRC SAMPLE MATERIAL


COMAH

• Keep listed dangerous substances in quantities exceeding stated thresholds

• Use substances which are flammable, explosive, toxic or dangerous to the environment

• Top tier • Lower tier

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COMAH

Take all measures necessary to prevent or mitigate the effects of major accidents to people and the environment. Prepare a Major Accident Prevention Policy (MAPP), which should demonstrate that there is an adequate safety management system in place. Send details of the types and quantities of hazardous substances to the competent authority. Send a Site Safety Report to the authority for approval (‘top tier’ sites only).

RRC SAMPLE MATERIAL


CDM Regulations 2007

Construction (Design and Management) Regulations 2007 Notification of projects to the HSE where construction activities last over 30 days or involve more than 500 person-days Duty holders – client, designers, CDM co-ordinator, principal contractor and contractor

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Construction Phase Plan

Site description Management of the work Arrangements for controlling significant site risks The Health and Safety File

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Health & Safety File

Brief description of work. Residual hazards. Key structural principles. Hazardous material used. Information relevant to dismantling. Information on cleaning or maintenance of equipment. Services (electricity, gas, etc.). Information and as-built drawings regarding the structure and plant and equipment.

RRC SAMPLE MATERIAL

Legal Requirements

© RRC International Unit PS1 – Element 1: The Foundations of Process Safety | 1-31-2 | Unit PS1 – Element 1: The Foundations of Process Safety © RRC International © RRC International Unit PS1 – Element 1: The Foundations of Process Safety | 1-31-2 | Unit PS1 – Element 1: The Foundations of Process Safety © RRC International

KEY INFORMATION

• The Seveso II directive has been developed to control major accidents in the European Union.• The COMAH Regulations (Control of Major Accident Hazards Regulations 1999) cover the prevention of

major accidents in the process and other high hazard industries in Great Britain (note – these laws do not cover Northern Ireland). They apply to organisations storing specific quantities of dangerous substances on their site.

• All construction projects are subject to the Construction (Design and Management) Regulations 2007. These Regulations have many requirements, including the preparation of a ‘Construction Phase Plan’ and a ‘Health and Safety File’.

IMPORTANCE OF HEALTH AND SAFETY REGULATORY FRAMEWORKS FOR MAJOR HAZARD INDUSTRIES

Importance of International/National Standards for Major Hazard IndustriesOne of the key health and safety laws for process industries located within the European Union is the Seveso II directive (officially known as the Directive 96/82/EC on the control of major accident hazards). The main precursor for the original Seveso Directive was an accident at a chemical plant that manufactured pesticides and herbicides in Seveso Italy 1976. The accident resulted in the release of a dense cloud of a poisonous and cancer causing substance (a dioxin) into the air which although caused no fatalities resulted in the treatment of 2000 people for dioxin poisoning and the contamination of ten square miles of land. The original directive was adopted in 1982 with the Seveso II directive being adopted in 1996.

The Seveso II directive has a number of key requirements aimed at controlling major accident hazards, these include:

• The operator notifying a competent authority before starting activities.

• Development a major accident prevention policy.• Submission of a site safety report.• Development of a safety management system.• Controlling land use (e.g. location of new

establishments and nearby developments).• Providing information to the public.• Accident reporting.

The Seveso II directive has been mainly implemented in the UK under the Control of Major Accident Hazards Regulations 1999, commonly known as the COMAH Regulations.

TOPIC FOCUS

The COMAH Regulations

These Regulations apply to premises which:

• Keep listed dangerous substances in quantities exceeding stated thresholds.

• Use substances which are flammable, explosive, toxic or dangerous to the environment.

COMAH differentiates between those sites deemed to be of higher risk (‘top tier’), due to the quantities of dangerous substances stored or used, and lower risk sites (‘lower tier’).

Operators of establishments covered by COMAH must:

• Take all measures necessary to prevent or mitigate the effects of major accidents to people and the environment. Demonstration of the presence of adequate safety measures is a key part of the process.

• Prepare a Major Accident Prevention Policy (MAPP), which should demonstrate that there is an adequate safety management system in place.

• Send details of the types and quantities of hazardous substances to the competent authority.

• Send a Site Safety Report to the authority for approval (‘top tier’ sites only).

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Legal Requirements

© RRC International Unit PS1 – Element 1: The Foundations of Process Safety | 1-51-4 | Unit PS1 – Element 1: The Foundations of Process Safety © RRC International

Guidance has also been prepared by the United Nations Environment Programme that sets out a framework for prevention and preparedness of chemical accidents.

MORE…

The UNEP guidance document ‘a flexible framework for addressing chemical accident prevention and preparedness’ can be found at:

www.unep.fr/scp/sp/saferprod/pdf/UN_Flexible_Framework_WEB_FINAL.pdf

GLOSSARY

COMPETENT AUTHORITY

The Health and Safety Executive (HSE) and the Environment Agency which jointly enforce the COMAH Regulations.

MORE…

www.hse.gov.uk/comah/

CONSTRUCTION (DESIGN AND MANAGEMENT) REGULATIONS 2007Construction projects in process industries usually involve many different parties in a collaborative effort. All parties have an important role to play in ensuring that:

• The project is carried out safely.• The end result (the structure) is safe. All construction projects are subject to the Construction (Design and Management) Regulations 2007 (CDM Regulations). These Regulations are split into various parts, some of which deal with the practical control of construction work. All parts of the Regulations apply to notifiable projects.

Notifiable ProjectsRequirements of the Regulations include notification of projects to the HSE where construction activities last over 30 days or involve more than 500 person-days.

For such notifiable projects the CDM Regulations identify five duty holders who have a part to play in ensuring safety:

• Client - for whom the project is being carried out.• Designers or architects - who specify the finished

structure.• CDM Co-ordinator - who assists the client during the

planning and construction phases of the project. • Principal Contractor - who manages the construction

phase of the project.

• Contractors - who carry out specific types of work under the direction of the Principal Contractor.

The Regulations require the preparation of a ‘Construction Phase Plan’ and a ‘Health and Safety File’ for the finished structure.

GLOSSARY

CONSTRUCTION PHASE PLAN

The health and safety management plan for the construction phase of the project.

HEALTH AND SAFETY FILE

Contains information about the new or modified structure that the client needs to know.

TOPIC FOCUS

CONSTRUCTION PHASE PLAN

The plan will be started by the CDM Co-ordinator and then developed by the Principal Contractor. Typical contents would include:

• Site description:

– Including project description and existing site plans.

• Management of the work:

– Management structure. – Management arrangements, e.g. for site

induction and accident reporting. – Site rules. – Fire and emergency procedures.

• Arrangements for controlling significant site risks:

– Safety risks, e.g. fall prevention. – Health risks, e.g. removal of asbestos.

• The Health and Safety File:

– Arrangements for gathering and storing information.

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Legal Requirements


TOPIC FOCUS

HEALTH AND SAFETY FILE

The CDM Co-ordinator is responsible for preparing and updating the Health and Safety File.

Typical content would include:

• Brief description of work.• Residual hazards.• Key structural principles.• Hazardous material used.• Information relevant to dismantling.• Information on cleaning or maintenance of

equipment.• Services (electricity, gas, etc.).• Information and as-built drawings regarding the

structure and plant and equipment.

TOPIC FOCUS

The Regulations assign the following duties to each party:

• The Client should ensure that:

– All other parties are competent. – Adequate information is passed on to the

other duty holders. – Work does not start until a Construction

Phase Plan for the project exists. – Adequate arrangements are made to

ensure health, safety and welfare during the construction phase.

– Any structure intended for use as a workplace complies with the Workplace (Health, Safety and Welfare) Regulations 1992.

(Continued)

TOPIC FOCUS

• The Designers should ensure that:

– The Client is aware of his duties under the CDM Regulations.

– A CDM Co-ordinator has been appointed for notifiable projects.

– The design minimises health and safety risks to:

– the construction workers;

– those who will occupy the structure on completion; and

– those involved in cleaning and maintenance.

– The design for a structure intended for use as a workplace complies with the Workplace (Health, Safety and Welfare) Regulations 1992.

• The CDM Co-ordinator should ensure that:

– The Client is advised on: – The adequacy of the arrangements put in

place by other duty holders.

– The appointment of competent contractors and designers.

– The HSE are notified of the project. – Proper co-operation and co-ordination takes

place during the design and planning process. – The Health and Safety File is prepared and

passed to the Client at the end of the project.• The Principal Contractor should ensure that:

– A Construction Phase Plan for the project exists.

– The construction phase of the project is carried out safely.

– The site is secure. – All contractors are working to the site rules. – All contractors receive site-specific induction

training.• The Contractors should ensure that they:

– Work to site rules. – Co-operate with the main contractor.

MORE…

http://www.hse.gov.uk/construction/cdm.htm

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Legal Requirements


REVISION QUESTIONS

1. Name two requirements of the COMAH Regulations.

2. What are the duties of the CDM Co-ordinator?

(Suggested Answers are at the end.)RRC SAMPLE

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Human Factors

© RRC International Unit PS1 – Element 1: The Foundations of Process Safety | 1-71-6 | Unit PS1 – Element 1: The Foundations of Process Safety © RRC International © RRC International Unit PS1 – Element 1: The Foundations of Process Safety | 1-71-6 | Unit PS1 – Element 1: The Foundations of Process Safety © RRC International

KEY INFORMATION

• ‘Human Factors’ is defined as the interaction between the main factors (job, individual and organisation) that affect human performance while at work.

• Human factors that influence work activities must be determined to gain an understanding of the reasons why people behave as they do while at work.

• Unintended actions (actions that were not intended to be carried out) include slips, lapses and mistakes.• Actions that are intended include violations, e.g. a deliberate breach of procedures and rules.

WHAT IS MEANT BY HUMAN FACTORS AND ERGONOMICS

Human Factors

GLOSSARY

HUMAN FACTORS

Defined by the HSE as the interaction between the main factors that affect human performance while at work. The main factors are classed as the job, the individual and the organisation.

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Human Factors


TOPIC FOCUS

In an organisation that has a high level of management, human factors would constitute:

• The job - this is fitted to the strengths and weaknesses of the person/team that is carrying it out. This is fitting the job to the human. Examples might include ensuring that machinery, control and display devices, tools, etc. are all designed correctly.

• The individual - the organisation should select individuals who are suitable for the needs of the job. This is known as fitting the human to the job. They must have the correct skills, knowledge, experience and training.

• The organisation - responsibility for all work (including design) is taken by the organisation management. This will include developing an effective safety management system, encouraging good safety culture by displaying commitment and generally consulting with employees. A good organisation will also learn from accidents and near misses and take into account the latest thinking on health and safety issues.

Factors Which Influence Behaviour

GLOSSARY

SAFETY CULTURE

Can be defined as the shared attitudes, values, beliefs and behaviours relating to health and safety. The safety culture of an organisation is the way that everyone within the organisation thinks and feels about health and safety and how this translates into their behaviour.

NEAR MISS

An unplanned, unwanted event that had the potential to lead to injury, damage or loss (but did not, in fact, do so).

ErgonomicsErgonomics is concerned with the interaction between people and:

• The tools, equipment or machinery that they are using (e.g. the ease of use of control panels).

• The workplace environment (e.g. suitability of lighting).• Organisational factors (e.g. shift patterns, hours of

work).The aim of ergonomics is to minimise ill-health effects and optimise efficiency by adapting the workplace to suit the individual. This means taking into account both a person’s physical attributes (such as height, shape, muscle strength, etc.) and their mental attributes (processing speed, decision-making ability, etc.). For example, ergonomic principles can be applied to a manual handling operation to reduce the risk of injury.

THE IMPORTANCE OF HUMAN FACTORSHuman factors cannot just be dismissed as being a result of carelessness, because this:

• Results in blame of the worker. • Fails to identify the underlying or true cause and

subsequently actions required to correct the situation. The human factors that influence work activities must be determined to gain an understanding of the reasons why people behave as they do while at work. If this can be determined then poor behaviour can be:

• Corrected by identifying and removing the cause of the behaviour.

• Anticipated, so that changes can be implemented to decrease the likelihood of it occurring.

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