SHELL RESTRICTED

Trading & Supply

Construction HAZID Workshop Report

Mogas Pipeline Project at Shikarpur & Machike

Document History
Date Issue Reason for change Author Verifier Approver
0 Issue for Review Ahsan Maqbool -
1 -

All paper copies are uncontrolled.

 Table of Contents
1 Introduction .............................................................................................. 3
1.1 General ....................................................................................................................... 3
1.2 Project Background ................................................................................................... 3
1.3 Objective..................................................................................................................... 3

2 Hazards Identification (HAZID) ................................................................. 5

2.1 HAZID Scope .............................................................................................................. 5
2.2 HAZID Methodology ................................................................................................... 5
2.3 Risk Ranking .............................................................................................................. 5
2.4 HAZID Participants .................................................................................................... 7
2.5 HAZID Result .............................................................................................................. 7

ii
1 Introduction
1.1 General
Shell Pakistan ltd (SPL) considers HSSE as an important aspect of their projects; in that
sense the risks have to be managed to as low as reasonably practicable (ALARP) in any
stage of the project. The hazard identification (HAZID) is the method that Shell uses to
identify the hazards, in this case for the construction stage of the project, in order to assess
existing barriers and recommend additional actions, as applicable.
1.2 Project Background
SKP Pipeline:
Existing 875 Meter & 10” diameter pipeline is currently used for HSD (SKP-01, SKP-02
and SKP-07) receipt from PARCO.
Currently two MOGAS tanks (SKP-04 & SKP-05) are being used for S&H of MOGAS
through road tank lorries and there is no provision to take MOGAS receipt in any of the
above-mentioned tanks through existing PARCO pipeline.
PARCO has started developing its Mogas storage at their Shikarpur location and enhancing
it capability to transport Mogas through pipeline. Once the facility at PAPCO is ready then
Mogas can be stock transferred through their tanks in Shikarpur via pipeline. To manage
this change, it is required to construct new pipeline (dedicated for Mogas) from PARCO
terminal to Shell Shikarpur Terminal and connect with existing storage or newly
constructed tanks.
The cost saving while receiving product through pipe compared to trucks will be realized,
there will not be any changes in volumes due to this project.
MCH Pipeline:
Existing 1.5 KM & 12” diameter Parco pipeline is currently used for HSD (MCH-01, MCH-
02) receipt from PARCO.
Currently three MOGAS tanks (MCH-06, MCH-07 & MCH-08) are being used for S&H of
MOGAS through road tank lorries and there is no provision to take MOGAS receipt in any
of the above-mentioned tanks through existing PARCO pipeline.
PARCO is in process of conversion of its existing Machike-Faisalabad-Mehmoodkot (MFM)
Pipeline into dual service i.e., transport HSD and Mogas both from the same existing
pipeline. The said conversion will be commissioned in first/second quarter of year 2019.
After commissioning, PARCO will deliver Mogas to Oil Marketing Companies (OMCs)
through pipeline at Machike region
The permanent work to be realized under this scope is listed as follows:
 Design for New Pipeline from PARCO to SPL along with its connection with all the
existing MOGAS tanks for MOGAS receipt as per shell standards.
 CP System for New Pipeline
 New Nozzles in Mogas tank with diffuser.

1.3 Objective
The objective of the Construction HAZID is to identify the hazardous occurrences, their
causes and potential consequences for personnel, assets and the environment resulting from
the operations related to the work scope for the facility. The purpose of the HAZID is to

3
review the engineering procedures and to assess whether all measures are in place to ensure
that the installation activities are performed in a safe and environmentally friendly way.
Where safeguards are in place to prevent or mitigate the hazardous situation, these are listed
and where safeguards are judged to be insufficient, additional measures/actions are
proposed.

4
2 Hazards Identification (HAZID)
2.1 HAZID Scope
The scope of the Construction HAZID is limited to the following construction work packs
for the infrastructure project:
 New Pipeline inside PARCO scope along with its connection inside PARCO premises
 New Pipeline from PARCO to SPL
 New pipeline connection with all the existing MOGAS tanks for MOGAS receipt.
 HDD for NHA crossing.

The outcome of the HAZID workshop is recorded in the worksheets, which detail the
following:
 Hazard
 Scenario/Risk Description.
 Worst Credible Consequences
 Risk ranking for each hazard (using RAM)
 Feasibilities to drive down the risks/Mitigations/ Evaluations
2.2 HAZID Methodology
It was suggested to consider HAZID during constructability review workshop for the same
project covered project scope from all aspects e.g. Traffic Management, Logistics, L&H,
Excavation, Hot Work, Confined Space Entry, Welfare Facilities, Equipment Maneuvering
and handling.

2.3 Risk Ranking

Each identified hazard was ranked according to the approved Shell HSSE risk matrix given
in Appendix A. The risk matrix is divided into four risk categories (People, Assets,
Community and Environment). Definitions for each consequence category are given in
Appendix B.
The Ranking of the identified Hazards followed the follows criteria:
 Consequence is ranked without barriers
 Likelihood is specific to the description of the consequence; barriers are accounted for

5
 Appendix A – Risk Assessment Matrix

*PTD = Permanent Total Disability

A scale of consequences from ‘0’ to ‘5’ is used to indicate increasing severity. The consequences are those of credible
scenarios (taking the prevailing circumstances into consideration) that can develop from the release of a hazard. The
potential consequences, rather than the actual ones, are used. These can be thought of as the consequences that could
have resulted from the released hazard if circumstances had been less favorable.
After assessing the potential outcome, the likelihood on the horizontal axis is estimated based on historical evidence or
experience that such consequences have materialized within the industry, the company or a smaller unit. Note that this
should not be confused with the likelihood that the hazard is released; it is the likelihood of the estimated consequences
occurring.

6
2.4 HAZID Participants
The HAZID session was held on 09th May 2019 with a multi-disciplinary team from Shell project
team and facilitated by the Regional Construction Safety Lead. The participants are as per the
following table;

No Name Discipline Company

1. Munir Ahmed Project Manager Shell
2. Ungku -Nor Fazilah Regional Construction Safety Lead Shell
3. Shell Project Team Zeeshan Waheed, Farhan Ahmed, Ahsan Maqbool, Azhar ul PEC
Islam, Tariq Sohail, Abdul Saleem
4. Contractor’s Project Imtiaz Ahmed, Nazir, Faisal, Ahmed Saeed, Javed, Abdul Petrocon
Team Waheed, Waseem, Taimoor Ali;

2.5 HAZID Result

The worksheets used to record the discussion is as under:

7
 HSSE RAM Risk
Description of Hazard, Worst Credible Barriers / Safeguards / Recommendations/
Guideword Responsible
Project Risk or Issue Consequence Mitigations P A E C Actions

Equipment Hydrocarbon- there are
various live pipeline with
various hydrocarbon
outside and between
Parco and Shirkapur
Terminal during pipeline
installation (excavations,
lifting activities, vehicles
movement)
Drop object on the 1. Designated Route 2B 3B 2C 2B 1. Tagline to be Project Manager
pipeline, 2. Banks Man provided for any lift.
rupture/damage other 3. Follow Speed Limit 2. Pre-job meeting to
existing pipelines that 4. Avoid unnecessary be conducted.
can cause leak and movement. 3. Active ERP to be in
explosion. 5. Barricade Area place.
6. Competent Workforce
7. Certified and pre-inspected
Equipment
8. Proper Load securing

Wrong equipment/tool Fire/explosion 1. U/G Utility Scanning 4C 4C 2C NA 1. Pre-job meeting to Project Manager
used during excavations leading to fatality and 2. Certified and pre-inspected be conducted.
(manual digging, flange asset damage Equipment 2. Active ERP to be in
connections) that can 3. Safe working Distance place.
cause spark, damage other between the work force. 3. Continuous
equipment and possibly 4. Specific Tools and supervision
cause personnel injury. equipment.
5. Barricade Area
6. Trained Workforce

Explosion or spark from Fire/explosion 1. For confine space activity Ex 4C 4C 2C NA 1.TBM to be Project Manager
using non-ex proof leading to fatality and Rated Equipment are used. conducted
equipment. asset damage 2. Continuous gas monitoring 2. ERP to be in place
via aerial monitors / gas
detectors
3. Certified and pre-inspected
Equipment

8
 Vehicles (trucks, cranes,
lorry and etc.) not having
spark arrestors that can
cause fire/explosion in the
terminal.
Mobilization of (From Workshop to
Material and Site)
Manpower Loaded Vehicle or Trucks
with excessive load over
speeding and unsecured
tie-off of material, uneven
and loose surface.
9
Fire/explosion 1. Provision of flame arrestor, 4B 4B 2B 3B 1. ERP to be in place. Project Manager
leading to fatality and spark arrestor is mandatory.
asset damage 2. Inspection of each vehicle by
competent person before
mobilization using checklist.
Drop Object, 4C 4C NA 3C 1. Journey Project Manager
overturning, collision 1. Speed control Policy as per Management Plan to
can cause fatality, NHA be followed
fire explosion and 2. SWL of the vehicle to be 2. Contractor to
asset damage, considered, provide ERP for
Rupture/ Damage to 3. Competent and licensed outside terminal.
the nearby drivers to be assigned.
infrastructure. Slip 4. Proper Load securing.
and stuck of the 5. Pre-inspected Vehicles.
vehicles. 6. Vehicle fitness certificate
assurance.
7. Designated route to be
followed,
8. Even leveling and grading of
the surface to avoid slip and
stuck.
9. Trained bank man to
assigned for guidance of the
drivers (at project site).
(Inside Terminal)
Loaded Vehicle or Trucks
with excessive load over
speeding and unsecured
tie-off of material, uneven
and loose surface.
Blind spot at turnings
Drop Object, 4C 4C NA 1C 1.Prior information / Project Manager
overturning, collision 1.. Speed control Policy as per Permission from & Terminal Ops
can cause fatality, Shell (10km/h). Operations for vehicle
fire explosion and 2. SWL of the vehicle to be entry.
asset damage, considered, 2. Journey
Rupture/ Damage to 3. Competent and licensed Management Plan to
the nearby drivers to be assigned. be followed
infrastructure. Slip 4. Proper Load securing.
and stuck of the 5. Pre-inspected Vehicles.
vehicles. 6. Vehicle fitness certificate
assurance.
7. Designated route to be
followed,
8. Even leveling and grading of
the surface to avoid slip and
stuck.
9. Trained bank man to
assigned for guidance of the
drivers (at project site).
10
 Offloading of materials Drop/ rolling 1. Even surfaces to be 2D 2D NA NA 1.LITE technique to Project Manager
manually and Objects. Slip/ trip/ provided/prepared with proper be followed for
mechanically. Poor fall. Pinch point and wedges/ stoppers to avoid material handling.
choice of material hand injury/ Back slipping/ rolling. 2. Only trained and
stacking. Wrong posture spraint. Restriction of 2. Material stacking at inducted staff shall be
of manual handling. emergency exit. designated area agreed with permitted
Wrong technique of Falling object. ops.
lifting and hoisting. Equipment collapses. 3. Barricade is provided with
Failure of lifting Asset Damage. proper material segregation and
equipment. Loose objects. Personnel injury. tagging.
Uneven surface. 4. Approved proper lifting and
Unskilled staff. hoisting plan is followed.
5, Certified equipment and
trained staff is assigned for
L&H.

Construction of site Personnel Injuries / 2D 2D NA NA 1. LITE to be followed Project Manager

office/ laydown area and fatigue. Asset/ 1. Job specific PPEs. for manual handling.
welfare facility. property damage. 2. Ground Leveling. 2. Ensure good
Wrong posture of manual Slip / trip / fall on 3. Adequate lighting. housekeeping.
handling, Sharp edges. same level. 4. Proper ventilation via 3. Keep emergency
Uneven surface. Poor Suffocation. exhaust. exit obstruction-free.
lighting and ventilation. Collision due to lack 5. ELCB to be provided.
Poor cable management. of vision. Short 6. ensure good housekeeping.
Poor housekeeping. circuiting leading to 7. Maintaining appropriate
Restricted access and fire. Delay in hygiene.
Egress, unhygienic emergency recovery.
conditions. Occupational illness.

11
 Manpower Mobilization. Personnel Injury. Proper site induction 2D 2D NA NA Avoid unnecessary Project Manager
Medically unfit / Slip / trip/ Fall. Designated Route movement.
underage handicapped / Collision with Banks Man with Vehicle
overaged. vehicles. Competent and Trained
Unawareness of worksite Workforce
Only Medically fit Workers are
allowed.

Civil Construction Excavation. Serious Injury Provision of Sloping to be 3C 2C 1C 1C Active ERP to be in Project Manager
Cave In leading to fatality considered. place.
Underground Utilities Electrocution Scanning and marking of
Bio Hazard Slip/Trip/Personnel underground utilities
Underground Water Bed Fall Maximum coverage of exposed
Inappropriate Access and body parts (PPEs)
Egress Dewatering to be preferred first
Un attended digging Provision of Adequate means of
Nearby Heavy Vehicle access
movement. Continuous Monitoring
Area Cordon-off with proper
labelling
Unauthorized Access not
Allowed

12
Mechanical Lifting & Hoisting Serious Only 3rd Party Certified and 4B 3B NA 1B Stop Work Policy to Project Manager
Construction Equipment Failure Injury/Multiple Pre-Inspected Equipment to be be applied in case of
Drop Objects Fatalities used. High Wind, Rain,
Suspended Load Asset Damage Cordon-off area of Crane Sand Storm, etc.
Poor Ground Condition Swing and Unstable activity.
Unauthorized Entry Weight due to High Unauthorized entry is not
Under Ground Utility Wind Speed causing allowed in barricaded area.
Incompetent Staff accident. Pre- visual Site Assessment to
Limited Visibility ensure safe maneuvering and
increasing the chance operation of equipment.
of collision Only Certified and Trained
Staff to be allowed for lifting
and hoisting activity.
Approved L&H Plan to be
followed.

Joint Fit-up and Fire Explosion Clean the area for all 4B 3B 2B NA Continuous gas Project Manager
Welding Electrocution combustible material before monitoring with
Sparks. Burn and Cut starting the hot work. authorized gas tester.
Short Circuit. Personnel Injury Only 3rd party certified and
Hot Surface. Lower/ Upper Limb preinserted tools & equipment
Manual Material Disorder to be used.
Handling. Eye Irritation Adequate PPE's to be provided.
Poor Posture of Working. lungs Infection LITE technique to be followed
Equipment Hearing Impairment. for material handling.
Malfunctioning. Welding Habitat to be
Welding Light and provided/canopy.
Smoke/Fumes. Frequent breaks.
Noise. Only qualified and trained staff
Line of Fire (LoF). to be deployed.
Incompetent staff. Use of ELCB in the electrical
panel/board and earthing to be
provided as well.

13
RT Fatality. Certified personnel from 4B 2B 4B 4B RT shall be performed Project Manager
Exposure to radioactive Carcinogenesis. government authorities. in night time outside
radiation Permanent disability, PNRA Sop to be strictly the terminal
followed. Availability of PTW
Cordon off the area in from ops to be align
accordance of the survey meter. prior to be performing
Watchmen to stop unauthorized RT.
access.
Warning light to be installed. Dossie meter and
Dedicated vehicle for survey meter to be
transportation of Source. available at time of
Adequate PPEs (Coverall, activity.
helmet, Safety Gloves, glasses,
Safety Shoes)

Grit Blasting in Severe Personnel Use of certified equipment and 3B 2B 2B NA Project Manager
Contractor workshop Injury. tools with pre-inspection to be
Rupture of hose. Asset Damage. allowed.
Detachment of hose. Hearing Impairment. Use whip Latch.
Malfunctioning of Eye irritation. Demonstration of dead man
equipment. switch to be before
Malfunctioning of dead commencement of job.
man switch. Specific PPE's to be provided.
Dust LITE to be followed for manual
Manual Handling handling.
Exposure to pressurized Canopy / hard barricade to be
nozzle provide in order to avoid
Noise. exposure.
Poor visibility. Avoid dust containment with in
Line Of fire (LOF) canopy.

14
 Lowering & Hoisting Serious Injury Only 3rd Party Certified and 4C 4C 3C 3C Approved L&H Plan Project Manager
Equipment Failure leading to fatality Pre-Inspected Equipment to be to be followed.
Drop Objects Asset Damage used.
Suspended Load leading to Cordon-off area of Crane
Poor Ground Condition hydrocarbon release activity.
Unauthorized Entry Swing and Unstable Unauthorized not allowed.
Under Ground Utility Weight due to High Pre- Site Assessment.
Incompetent Staff Wind Speed causing Site Scanning and Mark
accident. Underground Utilities.
Limited Visibility Stop Work Policy to be applied
increasing the chance in case of High Wind, Rain,
of collision Sand Storm, etc.
Only Certified and Trained
Staff to be allowed for lifting
and hoisting activity.

Horizontal Directional HDD Fatality/Serious Designated Route to be 4B 4B 3B 3B Follow NHA Project Manager
Drilling (HDD) Heavy Machinery Injury followed. (National Highway
Movement. Asset/equipment Competent and Trained Staff to Authority) Instructions
Un Even Surface. Damage. be assigned. as per NOC.
Misalignment of Hand Injury. Specific PPEs to be provided. Appropriate means of
Machine. Burn Earth Scanning. communication at
Sharp Edges. Certified and pre-inspected crossing to be utilized.
Underground Utilities. equipment to be utilized.
Equipment Failure. Area Cordon-Off.
Suspended Load. Only Guarded Rotary to be
Unguarded/Unattended allowed.
Rotary Parts. No Loose clothing allowed.
Entanglement. Minimum exposure of body
Chemical Exposure parts to be considered.
Traffic Interface Only competent and trained
Miscommunication crew to be assigned.
Biological Hazard
Incompetent Personnel
Unauthorized Entry
Line of Fire

15
Confined Spaces LOTO (Lock Out / Tag LOPC leading to fire. Authorized Personnel to be 4D 3D 4D 3D Individual Locks to be Project Manager
Out) fully Trained. installed by Ops and & Terminal Ops
Slippery Surface Isolation Plan to be marked and contractor.
Limited Space affixed nearby LO/TO Point
Untrained Staff and added in PTW.
LOPC (Loss of Primary Verification of LO/TO to be
Containment) done prior to commencement of
Personnel Fall. Activity.
Improper Lock Out/Tag
Out.

Degassing Fire and Explosion. Natural and Artificial 4D 3D 4D NA Continuous gas Project Manager
Presence of Flammable Fatality. Ventilation using Ex-Rated monitoring with & Terminal Ops
Gases/Vapors/Fumes. Asset Damage. Fans Only. authorized gas tester.
Oxygen Deficiency Slip/Trip/Fall.
Toxic Gases Suffocation Only Competent and trained
Limited Visibility staff to be allowed.
Slippery Surface

Weather Impact Heat Stress Dehydration Minimum Exposure to High 3C 3C NA NA Project Manager
High Wind Speed Fatality Heat hours (15 min breaks for
Sand Storm Serious Injury every two hours).
Heavy Rain Eye Irritation Plenty of Water to be provided.
Lungs Infection Stop work policy to be
Slip/Trip/Fall implemented in case severe
weather conditions
Wind Speed Monitoring for
Lifting and Hoisting.

Waste Decomposition Occupational Illness Disposal on Regular Basis 3B 2B 4B 4B Hazardous Waste to Project Manager
In-Appropriate Environmental Waste Segregation to be be handed over to
segregation. Contamination provided using Color coded Shell Approved Waste
Improper Handling Bad Odor bins. Management
In-Adequate Tagging Un-Hygienic Contractor.
Situation

16
Impact on Community Construction activity Occupational Community engagement prior 3B 3B 4B 4B Dedicated staff to be Project Manager
outside terminal involving sickness to the to start of work. assign for community
heavy machinery creating community leading to engagement.
vibration, noise, dust and reaction to stop
restricted movement of working.
nearby residents. Procession in return
of unease.
Threatened the
workers.
General Wrong PTW entry of personnel in 4B 4B 4B 4B Review of PTW to be Project Manager
inside/outside terminal restricted area for done by authorities. & Terminal Ops
working leading to All PTW shall be read
LPOC causing fire out during TBM.
and fatality.
Movement of workers careless behavior of hard barricade to be provided. 3B 3B NA NA Project Manager
nearby railway track and workers nearby
highway railway and highway
may lead to fatality.

17
18