HEALTH SAFETY &

ENVIRONMENT

My Understanding of HSE System

At Lotte Chemical Pakistan

Limited (LCPL)

BY: SUHAIL AHMED RAHUJO

INTERNEE-HSE

PPTA PLANT,

LOTTE CHEMICAL PAKISTAN LIMITED

(LCPL)

PURPOSE OF THE REPORT

This Report is based on One-day Safety Induction Session given by Mr. Shuaib Iqbal ,General Manager and Safety Officer at Technical Training Center in its Conference Room. Based on information presented by Him and possible gathered information by me, I have got an ample data presenting here.

KEY FUNCTIONS OF HSE

DEPARTMENT

AUDITING

COMPLIANCE

MONITORING

The key responsibility of HSE department is to

look after the HSE related rules and regulations

and updating the auditing procedures, to check if

all procedures are compliance with company’s

laws and then continuous monitoring of all the

procedures being followed at LCPL.

If there is any violation occur at any department at PLCL, then HSE department is not responsible. But that department is responsible where such violation occur.

Top Management only see HSE is updating the HSE procedures to all department or not.

FIRST THING TO BE ASKED AT

PLCLFirst thing to be asked at Pakistan Lotte

Chemical Limited is about HSE.

Its very important to note that safety at PPTA

Plant has the highest priority.

There is ZERO LEVEL Injury Policy.

Safety is not compromised at any cost.

HEALTH AT WORKPLACE

Health at any workplace means the work

related health.

Health at PLCL is highly focused which is

shown by the commitment of the Top

Management and extraordinary steps taken by

the HSE Department.

All workers whether permanent or Non-

permanent or contractors are given equally

importance here at PLCL.

HEALTH ASSESSMENT

Every worker who work 8 hours/day must go

through the process of health assessment at

PLCL.

Health Assessment at PLCL occur once per

year.

Based on the Health Assessment of workers,

different medical tests are carried out which

ensures the fitness of the workers.

RESPONSIBILITY OF HSE

DEPARTMENT

Responsibility of HSE Department is;

To ensure sound policies.

To ensure safety of Workers, Plants and

Environment.

To ensure RCMS(Responsibility Care

Management System) Procedure.

To ensure OHSAS, ISO 14001, ISO 9001

Standards.

MANDATORAY TRAININGS

Fire emergency trainings

Toxic emergency trainings

ERT (Emergency Response Team) is responsible

to carry out and assess all mandatory trainings.

ERT have their specific teams which carry out

their duties in three shifts.

ERT follow and report to HSE department.

ROUTINE ACTIVITIES BY HSE

1. PROCEDURES:

There are total 115 procedures are being implemented at PLCL.

LCPL HSE Data Base is regularly maintained on the basis of observation of different events and accidents and accident investigation procedures.

2. AUDITING:

Operational audits

Specialist audits

Management audits

Product Stewardship audits (Related to Commercial Department)

OHSAS 18001, ISO 14001 ,ISO 9001 Audits

Internal Audits

3. REGULAR MEETINGS:

Daily Morning Meetings

Monday Communication Meetings

Monthly ECM(Executive Committee Meeting)

Quarterly Business HSE Meeting

Quarterly Location HSE Meeting(Organized by Location Heads.)

4. REGULAR REPORTS:

Monthly Man-hour Report

Immediate Reporting

MRO

HSE Report

Weekly LE/SUSA Audits Reports

Overhaul Reports

Hearing Conversation Reports(only sent to

Head of Dept where workers work for 8 hours)

Chemical and Radiation Exposure Reports.

These Reports are the legal requirements of

PNRA(Pakistan Nuclear Regulatory

Authority).

Monthly chemical and exposure reports are

being sent to PNRA.

5.ENVIRONMENTAL

PROTECTION:

In coordination with Technical Training Center, following are the applications of latest HSE Management Techniques.

Hazardous Studies

Hazardous Risk Analysis

Periodic Hazardous Review

Hygiene Surveys

Effluent Monitoring

Radiation Protection Management

Sludge comes out of plant is utilized by

forming gas with China Company.

Bio sludge comes from plant is utilized by

Faisalabad Agriculture University.

Environmental Protection Agency (EPA) has

Also close coordination with PPTA.

45 MILLION MAN-HOUR.......HOW!!!

How PLCL achieved the record of 45 million

man-hour without LTC!

It is briefly describes in the following slides.

LCPL COMMITMENT

Committed to achieve continuous improvement in HSE&S which is demonstrated in HSE Policy and set out standards.

LCPL commitment is shown by the following main points.

1. provide safe and healthy workplace for staff and contractors.

1. Act responsibility towards the Communities and Environment.

3. Continuous improvement

3. Individual and collective commitment to

these principles.

HSE MANAGEMENT SYSTEM

HSE Management system comprises of the

following main elements.

HSE Policy

HSE&S Standards

Guidelines

Local RCM Procedures

Auditing

HSE&S Improvement Plans

All above areas are checked yearly and at the

end of the year, letter of assurance is written to

check all systems are compliance according to

legal requirements.

Policy is changed if either;

I. We deviate from our own system.

II. If new law/Standard come or to follow.

HSE POLICY

PLCL has the following policies regarding

Health Safety and Environment.

Product Stewardship Policy

Smoking Policy

Mobile Phone Policy

Substance Abuse Policy

Policy to Deal with Fraud

Sustainability Policy

HSE STANDARDS, GUIDELINES

AND PROCEDURES

There are 21PLCL HSE&S Standards.

There are 77PLCL HSE&S Guidelines.

There are 115 PLCL HSE&S Procedures

MONITORING PROGRAMS

Different monitoring programs are being the

part of HSE Management Systems. These

monitoring programs are regularly watched

out. The list of the monitoring programs are

enlisted in the next slide.

Annual Health Assessment Program

Hygiene Monitoring Program

Radiation Workers Monitoring Program

Hearing Conversation Program

HSE&S Training Program

ANNUAL HEALTH ASSESSMENT

PROGRAM

In this annually assessment of health of

workers occur in core meeting.

Purpose of the meeting is to monitor the health

issues of the workers and solve them.

HYGEINE MONITORING

PROGRAM

In this monitoring of the health of the workers are being carried out which are exposed to;

Dust

Chemicals

Radiations

RADIATION WORKERS

MONITORING PROGRAM

In this inspection occur if any worker is exposed to radiation or likely to be exposed.

Safety measurements and procedures are being discussed in meeting and reports are being prepared based on data received by workers exposed to high ionized area or radiation exposed environment.

Such data also shared with Pakistan Nuclear Regular Authority (PNRA)

HEARING CONVERSATION

PROGRAM

If workers exposed with hearing problem then its assessed and PPE’S provided i.e. hearing protectors such as Ear Pins and Ear Muffs to the workers so that no permanent hearing loss may occur.

Hearing problems are particularly monitored and checked if any worker working in high frequency sound environment and not wearing ear protectors.

If any worker caught then the respective

department head is laid to be responsible and

the caught worker is sent to inspection and

have to go through and pass the safety

induction.

HSE&S TRAININGS PROGRAM

In this section of HSE&S, meeting has been

planned to discuss about various hazardous

that has great risk of injuries.

Trainings of workers, working in different

areas of plants are monitored and inspected

regularly.

PPE’S and other Safety stuff are regularly

inspected and tested.

ERT Team regularly gets practiced via different

drills and trainings.

Fire Alarm and Toxic Alarm System are inspected

and tested.

Note: Fire Alarm/Toxic Alarm rings every

Friday at 10 am to check if the system is in

proper way and working efficiently.

EMERGENCY SCENARIO

There are 6 types of Emergencies at PLCL

Site.

For all those, there are specific emergency

preparedness programs are being implemented

and followed. These emergencies types are

described in the next slide.

Fire Emergency

Toxic Emergency

Medical Emergency

Radiation Emergency

Distribution Emergency

Crisis Emergency

FIRE SAFETY AT PPTA PLANT

Fire Safety at PPTA has given very especial

focus.

There are different Fire Safety Components,

Fire Water System, Fire Detection System,

Fixed Fire Protection System, Moveable Fire

Fighting Arrangements etc that aid in

preventing the fire hazardous and mitigate all

fire related problems.

FIRE SAFETY COMPONNENTS

Three main Fire safety components are being used at PPTA Plant. These are as follows:

Fire Detectors

Circuits

Mimic Panel or Local Panel

FIRE WATER SYSTEM

• PLCL adopts very nice system of water gathered and accumulated at different sites within or Plant Surroundings.. These are;

Fire Water Storage Tank

Fire Water Heeder

Fire Water Pumps

Fire Hydrants

Fire Hose Reeds

Water Ground Monitors

MOBIL FIRE FIGHTING

ARRANGEMENTS

HSE Department also look after those

arrangements of Fire Safety which can be

carried out at any time at any place because

such fire safety arrangements are moveable.

Such fire fighting arrangements are as follows;

Fixed Extinguishers

DCP Trailers 250 kg

Fire Buckets

DCP 50 kg Trolley

Fix Exit Tank

120 Litter Foam Trolley

Breathy Apparatus/Breathy Apparatus Trolley

FIRE DETECTION SYSTEM

There are different fire detector systems that

detect different hazardous and automatically

monitor the emergency situations. Those

detectors are;

Smoke Detector

Heat Detector

Gas Detector

FIXED FIRE PROTECTION

SYSTEM

Fixed fire protection systems are installed at

different locations within the Plant or its

surrounding areas in order to further facilitate

the fire fighters to overcome the emergency

situations and mitigate all possible hazardous.

Such fixed fire hydrants systems are very

beneficial against fire hazardous.

Following are the types of Fixed Fire

Protection Systems.

Ground Water Monitor

Fire Hydrants

Fire Hose Reed

Foam Tank

ENTRY OF NEW CHEMICAL AT PPTA

PLANT

If any new chemical come for use then we

perform the two tasks which is a part of

HSE&S Management System.

1. MSDS

2. Risk Assessment

CONTROL ROOM

ALERT!!! If any event you experience at the

vicinity of PLCL related to Toxic Gas or Fire,

then immediately call to the Control Room No

shown in the following;

222

PLEASE READ THIS

IF YOU THINK SAFETY IS

TOO EXPENSIVE!

THEN

TRY FOR ACCIDENT!!!

GOOD BYE…….!!!!

PREPARED BY: SUHAIL AHMED RAHUJO

M.Phil Scholar (Environmental Science) at University of Sindh.

Email: suhaileia2013@gmail.comCell # 0333-4548138