PROCESS SAFETY MANAGEMENT

February, 2011
Agenda

HSE Vision

Process Safety Management

HSE Monitoring & Readiness

Lesson Learn from HSE TA Management

PERTAMINA 1
 NOI = 0
HSE Vision:
Proper = Biru
To achieve no harm TRIR = 0.95
to people, asset or environment

Initiative HSE
Kehandalan Improvement
Performance

/Readiness (RWW Project,

Fire CEMS & Limbah
Reliability HSE Process B3)
Protection
and integrity of management technology MSDS
Equipment
equipment system
APR HAZOPS
(Accelerate PSSR
Preventive Mechanical
Response Integrity
Sustainability

Leadership
Reliability PSM (CSMS,
Initiative Organization capability Safe Work
Mgmt. Practice :
HSE culture Release
Equipment
Procedure,MOC,
Pengawasan & Training, Pelaksanaan Emergency
Intervensi Upskilling & Drill Program SIIP Response,
langsung melalui pada pekerja Industrial
SWAT/Sweeping, (Compliance APD, Hygiene)
HSE, Operasi,
SIKA, SWAT,
Safety TBKD dan Mitra SML
Committee Frontline Motivation & (Rekomendasi
Kerja / Kontraktor
Meeting secara Management Proper Mgmt.)
terprogram Consequences, JSI,
Near miss report)) Rekomendasi
Risk Survey
Audit Mgmt.
SUMBER: HSE RU VI PERTAMINA
Agenda

HSE Vision

Process Safety Management

HSE Monitoring & Readiness

Lesson Learn from HSE TA Management

PERTAMINA 3
PROGRAM MKP
TEKNOLOGI
1. Informasi Keselamatan Proses (Process Safety Information)
2. Analisa Bahaya Proses (Process Hazard Analysis)
3. Keterpaduan Mekanik (Mechanical Integrity)
4. Review Keselamatan Pra Start-Up (Pre Start Up Safety Review)

KESELAMATAN KERJA
5. Keselamatan Kerja Kontraktor (Contractor Safety)
6. Izin Kerja Aman (Safe Work Practices / Hot Work Permit)
7. Prosedur Operasi (Operating Procedures)
8. Pelatihan Pekerja (Training)
9. Partisipasi Pekerja (Employee Participation)
MANAJEMEN
10. Manajemen Perubahan (Management of Change)
11. Penanggulangan Keadaan Darurat (Emergency Response)
12. Kesehatan Lingkungan Kerja (Industrial Hygiene)
13. Penyelidikan Kejadian (Incident Investigation)
14. Audit Manajemen Keselamatan Proses (Auditing)
4
PIE CHART

Informasi Keselamatan Kerja

Keselamatan Kontraktor

Analisa bahaya
Proses Izin Kerja Aman

Prosedur Operasi
Keterpaduan Mekanik

Pelatihan Pekerja

RKPSU

Partisipasi Pekerja

Manajemen Perubahan
Penanggulangan Keadaan Darurat

Kesehatan Lingkungan Kerja

Penyelidikan Kejadian

Audit

5
CSMS Implementation

Tahap Tahap
Bank
Administrasi Implementasi
Data

Risk Assessment Pre Job Activity

Feedback
Pra Qualification Work in Progress

Selection Final Evaluation

PERTAMINA
Agenda

HSE Vision

Process Safety Management

HSE Monitoring & Readiness

Lesson Learn from HSE TA Management

PERTAMINA 7
HSE Monitoring & Readiness

Description Action By Time Note

SYSTEM MONITORING HSE

Field Coordination Safety Insp,HSE Daily Safety Work

Meeting CO,GSI & ME Area Practise & Process

Plant Patrol HSE Man - Shift 2 kali per Shift Minimize unsafe act
& unsafe condition
Inspeksi HSE
SWAT Mgmt. & Sec. Head 1 kali per Minggu/Mg APD & SIKA

Join Superv. Insp. Safety Insp,HSE 2 kali per Bulan/Area Process Safety
CO,GSI & ME Area
Nearmiss reporting Individu 7 laporan per Process Safety
orang/tahun

Rapat Operasi Mgmt. 1 kali per Minggu Operational Safety

HSE Committee
Mgmt. 1 kali Per Bulan HSSE High Issue

PERTAMINA
8
SAFETY WORK PLAN 2011
Safety Improvement Implementation Program

Ruang lingkup Rencana atau prosedur Lead responsibility

MWT Dilaksanakan oleh Management Pusat setiap SAFETY INSPECTOR

6 bulan sekali dan dimonitor oleh
management terkait di RU VI
SWAT Dibuat Jadual setiap bulan melibatkan PIC SAFETY
seluruh manajemen dan dimonitor oleh HSE.
Lebih kepada perbaikan unsafe action
Compliance APD Dilaksanakan setiap 2 minggu dan SFT INSP & HSE CO
melibatkan manajemen di pintu masuk kilang
& Sweeping

Compliance & Melaksanakan observasi & Intervensi SIKA LEAD & HSE CO
serta porsentase SIKA close
Audit SIKA

JSI Melaksanakan JSI bersama produksi & ME Safety TIM

Area

Bulan K3 Nasional
Agenda RU VI dan Surat dari Depnaker TEAM & PANITIA

Field Coordination Rapat di masing masing area produksi Safety Tim

Meeting
Safety Coordination Rapat pagi & Coord safety inspector Safety Tim
Meeting mengenai pekerjaan kritikal

PEKA / Nearmiss PEKA individual safety inspektor Safety Tim

SUMBER: HSE RU VI PERTAMINA

Agenda

HSE Vision

Process Safety Management

HSE Monitoring & Readiness

Lesson Learn from HSE TA Management

10
 Lesson Learnt From HSE TA Management
For Each Job, Hazards and Mitigating Actions Were Identified
Prior to TA execution During TA execution
JSA Safety
Risk ass- PPE reqt Contractor Routine Pre-startup
Critical Contractor inspector Equipment
essment identific- safety safety Safety
equipment selection outsourc- Release
on job list ation training activities Review
review ing

Job list compiled in Apr Re-screen job list using Criteria Filter Equipment base on Consequence and
2009 by TA Team* Identify Hazard, Assess Risk, Increasing likelihood
Control and Recovery

Consequences Increasing Likelihood

A B C D E
Never Heard more ones more ones more ones
per year in per year per year at
Severity

Environment
company at location location in

Reputation
in company

People

Assets
company
Identify Hazard Assess Risk
No Injury or No damage No Effect No Impact
0 health effect 0 0 0 0 0

Slight injury Slight Sliight Slight

HEMP ALARP ? 1 or health damage Effect Impact 0 0 0 0 0
effect
Minor injury Minor Minor Minor
or health Damage Effect Impact
2 1 1 0 0 0
effect
Recovery Control Major injury Moderate Moderate Moderate
3 or health Damage Effect Impact 0 1 4 1 0
effect
PTD or up to 3 Major Major Major
4 fatalities Damage Effect Impact 0 0 0 0 0

More then 3 Massive Massive Massive

5 fatalities Damage Effect Impact 0 0 2 3 0

Number of equipment being hazard identified : 166 Number of Critical Equipment based on HEMP : 5
HEMP is a structured and systematic analysis methodology involving the Identification, Assessment and Control of hazards and the Recovery
from effects caused by a release of the hazards. All four components are essential for proper hazard management

SUMBER: RU VI HEMP TA Team PERTAMINA

Top 11 Critical Equipment

Prior to TA execution During TA execution

JSA Safety
Risk ass- PPE reqt Contractor Routine Pre-startup
Critical Contractor inspector Equipment
essment identific- safety safety Safety
equipment selection outsourc- Release
on job list ation training activities Review
review ing

No Unit Tag Number Description Activity Hazard Mitigation PIC

1 31 31-R-101 Reactor Skimming katalyst NHT 2.200 Flammable, pyrite, Ensure Freeing gas (N2 HSC
Kg (level bed 29 Cm ) iritasi purging)
Improve proses decontaminasi Conduct Gas test
pada saat skimming. Ensure Positive pressure with
N2 injection
Conduct Toxic + oksigen test HSE
Ensure availability of full body Ren MPS/
harness HSE ?
2 31 31-V-107 Sulfide Cleaning vessel DMDS Flammable, Toxic, Ensure Freeing gas (Steaming HSC
storage Iritasi out & N2 Purging)
vessel Strong odour Conduct Gas test
Ensure Neutralizing with
NaOCl/Kerosene
Ensure availability of Ren MPS /
Fullmask/faceshield and HSE ?
Protective Clothing

SUMBER: RU VI HSE KLBB TA Team PERTAMINA

 For Each Job will be Made JSA

Prior to TA execution During TA

execution
JSA Safety Pre-
Risk ass- PPE pro- Contracto Routine
Critical Contracto inspector Equipmen startup
essment curement r safety safety
equipment r selection outsourc- t Release Safety
on job list policy training activities
review ing Review

Select criticality Select Criticality Equipment analyze by HEMP method ( Hazard Effect Management Process )
equipment

Define Type Of Equipment : Instrument, Electrical, Rotating Equipment, Stationary Equipment

Define type of and Civil.
equipment

Break the job down a sequence of task and record each task no more than ten sequence of task
Deploy step of
work Identification Hazard Consequence resulting from :
Incident, accident and potential emergency situation
Identification Past, current and planned activities
hazard Situation in production process or in the provision af a service
consequences Planned and reactive work
Specific tasks

Preventive Preventive Action by elimination of hazard, engineering and Administrative control and PPE
action

Approval and Approval and communicate the Job Safety Analysis to employees who will be performing the job
Communicate

SUMBER: RU VI HSE, KLBB TA Team, RU VI EngPEM PERTAMINA

Contractor Selection Based On Detailed Requirements

Prior to TA execution During TA

execution
JSA Safety Pre-
Risk ass- PPE pro- Contracto Routine
Critical Contracto inspector Equipmen startup
essment curement r safety safety
equipment r selection outsourc- t Release Safety
on job list policy training activities
review ing Review

Item to be assess
Risk
assessment
NO MAIN ITEM DESCRIPTION

Conduct pre- HSE POLICY

MANAGEMENT
qualification 1 HSE ORGANIZATION
COMMITMENT
SOCIALIZATION HSE POLICY
TRAINING AND TRAINING MATRIX AND COMPETENCE
Contractor 2
DEVELOPMENT FIRST AID AND MEDICHAL CHECK UP
selection STANDART OPERATING PROCEDURE
PROCEDURE AND SAFE WORK PRACTISE
3
Pre-job REGULATION EMERGENCY PROCEDURE
activity SAFETY CHECK LIST
PERSONAL PROTECTIVE EQUIPMENT
TOOLS AND
4 MAINTENANCE AND CERTIFICATION
Work in EQUIPMENT
HAZARDOUS HANDLING
progress 5 HSE PERFORMANCE HSE STATISTIC LAST TWO YEARS

Final
evaluation

SUMBER: RU VI HSE, KLBB TA Team PERTAMINA

HSE Recommends Having Contractor Provide General PPE and Pertamina Provide Specific PPE

Prior to TA execution During TA execution

JSA Safety
Risk ass- PPE Contractor Routine Pre-startup
Critical Contractor inspector Equipment
essment Procureme safety safety Safety
equipment selection outsourc- Release
on job list nt Policy training activities Review
review ing

Recommen

Option Advantage Disadvantage Next step requirement

1 General PPE provided by Kontraktor Jumlah peralatan Pinjam unit lain

Contractor and Specific bertanggung jawab khusus terbatas Sewa
PPE provided by untuk penyediaan Pengadaan
Pertamina RU VI PPE standard dan
Balongan Pertamina hanya
mengontrol.

2 General & Specific PPE Pertamina hanya Hanya perusahaan List Contractor TA dari
provided by Contractor mengontrol spesifikasi tertentu yang masuk Unit lain
APD kualifikasi

3 General & Specific PPE
provided by Pertamina RU
VI Balongan
PPE yang digunakan
sesuai spesifikasi
Biaya pengadaan PPE Penyiapan Budget
menjadi besar dan Prosedur peminjaman
Setelah TA dan perawatan
memerlukan Tempat penyimpanan
perawatan dan tempat
penyimpanan PPE.

SUMBER: RU VI HSE, KLBB TA Team PERTAMINA

Safety Training Will Be Conducted Two Months Before Execution; Wide Range Of Topics To Be Covered

Prior to TA execution During TA execution

JSA Safety
Risk ass- PPE reqt Contractor Routine Pre-startup
Critical Contractor inspector Equipment
essment identific- safety safety Safety
equipment selection outsourc- Release
on job list ation training activities Review
review ing

Module Objective Lead of Module

1 Safety Induction Pengenalan Dasar Safety HSE

2 Overview HSE Rule & Regulation Pengenalan tentang peraturan Safety HSE Refining
3 Safety Behaviour Change for APD Implementasi Observasi dan Intervensi APD HSE
4 Explosion Demo & pengukuran Gas (CO2, Pengetahuan tentang Gas flamable dan toxic HSE
Flamable & Toxic)
5 Electrical Safety& Electrical Area Pengetahuan tentang Klasifikasi Area elektrik HSE Refining
Clasification
6 Job Safety Analysis Analisa bahaya sesuai urutan pekerjaan MPS
7 Permit to work Proses Ijin Kerja HSE
8 Working in confined space Mengetahui Cara kerja aman di ruang terbatas HSE
9 Working at height Mengetahui Cara kerja aman di ketinggian MPS
10 Hazardous classification Mengetahui klasifikasi Bahaya di Kilang PE
11 Safe work practice Pengenalan tentang praktek kerja aman HSE
NOTE : General module for all contractor and Pertamina PIC
Contractor will
Specific module base on type of equipment
be represented
by Foreman and
SUMBER: RU VI HSE safety man PERTAMINA
Training and assessment has been conducted to managers and Pertamina supervisors

Events Objectives People Evidence

Management To align management Manager and section
Alignment workshop on roles and head
responsibilities during
TA

Training for L1 To upskill operators Supervisors selected

on TA Brick, 8 Steps from MPS,
and Tool Production,
ME/Workshop, HSE

Assessment for L1 To assess the Supervisors selected

understanding and from MPS,
readiness for TA Production,
execution ME/Workshop, HSE

L1 and L2 safety To ensure Pertamina people

training understanding safety involved in TA KLBB
requirements and
processes

SOURCE: OPI PERTAMINA 17

Safety training has also been conducted for contractor supervisors and workers

Events Objectives People Evidence

Contractor To ensure Supervisors and
Supervisor safety understanding safety safety man for
training requirements and contractors
processes

Contractor kick-off Align on job track Contractor

meeting Align on safety supervisors together
and risk with Pertamina
Toolkit meetings supervisors

Contractor workers To ensure Contractor workers

training understanding safety
requirements and
processes
Toolbox meetings

SOURCE: RU-VI TA KLBB team PERTAMINA 18

Safety passport system designed to ensure that only ceritified workers allowed to work on site

Passport certification system Passport inspection system

Passport for staff performing Security and safety alignment

critical tasks Passport training to be
Employee Profile Critical Task Hazard Modules
(L1, L2 & L3 related to critical task) completed before worker
Name : No Tag No Module Certification Date Evaluator Evaluator
Please
paste Employee No : requirement fulfilled name/
title
signature
badge issued
Worki ng Draft - Last Modifi ed 3/28/2010 3:18:19 PM

Worki ng Draft - Last Modifi ed 3/28/2010 3:18:19 PM

your photo
RU : 1 Reactor Handling flammable Proof of Elmizar
here

31-R-101 material during workshop MA3

Area : 32-R- skimming catalyst attendance
101/2/3/4
Department : Scaffolding Proof of
Elmizar
management inside workshop MA3

Toolbox checks
MPS Reliability Eng & Dev confined space attendance
Printed

Printed
ME Production Workshop Catalyst handling Proof of
Elmizar
HSE Procurement Others workshop MA3
attendance
Role in TA :

Passport checks as part of

2 Vessel Handling pyrite, Proof of
Endra
Coordinator Contractor Supervisor 32-V-101 31- flammable, explosive workshop Wasis
Supervisor Contractor Worker V-104 61-V- material during attendance MA3
202 cleaning
Foremen/Operator
McKinsey & Company | 1 McKinsey & Company | 5

Passport for staff performing toolbox meetings to ensure

non-critical tasks workers have received relevant
Stamping after
Employee Profile Core Modules
training Only certified
No Module Certification requirement Date
fulfilled
Evaluator
name/
Evaluator
signature training is
workers allowed
Name :
Please title
paste Employee No : 1 Basic TA Proof of workshop attendance Sancoyo
Worki ng Draft - Last Modifi ed 3/28/2010 3:20:23 PM

Worki ng Draft - Last Modifi ed 3/28/2010 3:20:23 PM

completed

your photo Safety Module Mgr HSE

RU :

Security audit
here
2 TA Brick Proof of workshop attendance Togar M
Area :
on site

Overview TA Mgr

Department : Passed assessment with score

3.0 Mgr _____

MPS Reliability Eng & Dev

Passport checks to be
Printed 3/12/2010 3:30:02 PM

Printed 3/12/2010 3:30:02 PM

3 TA Proof of workshop attendance Togar M

ME Production Workshop

8-step TA Mgr
HSE Procurement Others Process
Passed assessment with score

Role in TA : 3.0 Mgr _____

4 TA Proof of workshop attendance Togar M
Coordinator Contractor Supervisor

Critical Path/ TA Mgr

Supervisor
Foremen/Operator
Contractor Worker

McKinsey & Company | 1

Critical List
Passed assessment with score

3.0 Mgr _____

McKinsey & Company | 2
conducted at security
Passport for contract workers checkpoints to spot-check
Employee Profile Core Module workers for passports
Name :
Please
paste Employee No : Module Certification requirement Date fulfilled Evaluator Evaluator
Worki ng Draft - Last Modifi ed 3/28/2010 3:15:35 PM

SWAT audits
Wor ki ng Draft - Last Modified 3/28/2010 3:15:35 PM

name/ title signature

your photo
RU :
here
Area :
Basic TA Proof of workshop Sancoyo
Department :

Passport checks included as

Safety Module attendance Mgr HSE

Reliability
Printed

MPS Eng & Dev

Printed

ME Production Workshop
HSE Procurement Others
Role in TA :
Coordinator
Supervisor
Foremen/Operator
Contractor Supervisor
Contractor Worker part of SWAT audit
McKinsey & Company | 2
McKinsey & Company | 1

SOURCE: OPI PERTAMINA 19

Procedures For Handover Are Not Available To Date; Cross Functional Team Will Put Together

Prior to TA execution During TA execution

JSA Safety
Risk ass- PPE reqt Contractor Routine Pre-startup
Critical Contractor inspector Equipment
essment identific- safety safety Safety
equipment selection outsourc- Release
on job list ation training activities Review
review ing

Departments Procedure
involved available Dari lesson learn equipment release sebelumnya masih ada
celah yang menyebabkan terjadinya kecelakaan karena belum
adanya kejelasan proses serah terima equipment. Oleh
Equipment Production karena itu perlu dibuat prosedur equipment release yang
cool down terdiri dari item-item sebagai berikut :

Production No Kegiatan keterangan PI

Steaming out/
1. Risk Assesment C
dekontaminasi Potensi bahaya/resiko Prod/PE/HSE

Production,
Blind System 2. Mitigasi Tindakan yang telah Prod/PE
ME, HSE dilakukan untuk
mengeliminir risk
Production, Blm
Equipment ME, HSE, 3. Blind system Isolasi Prod/HSE/MA
ada
Release PE equipment/system

4. Kondisi kontaminan Pemeriksaan kadar Prod/HSE

ME
Execution terakhir ketika kontaminan
diserahkan
Prosedur shut down dan
equipment release akan diplot di 5. Berita serah terima Kontrol equipment Prod/HSE/MA
primavera bersama timeframe release
pelaksanaan TA
SUMBER: RU VI HSE, KLBB TA Team PERTAMINA 20
Safety Activity During TA

Tool Box Meeting di Lapangan Pembacaan JSA & Doa

PERTAMINA
SUMBER: HSE RU VI TA Team
Routine safety activities during TA execution will focus on continuous inspection and supervision of
work

Key routine safety Level of

activities Frequency Supervision Number needed
Equipment check 4 times per day or Safety Inspector Per Equipment
As required

Grand Safety Talk Day One TA Management 1 times

Safety Inspector Daily Safety Inspector Per area

Meeting

Safety Talk/ Toolbox Before job starts Execution Per job

meeting Supervisor

Safety KPI review Weekly OPI HSE Per Area

Management Weekly Manager Per Area

walkabout

SOURCE: RU-VI TA KLBB team PERTAMINA 22

 Jangan biarkan menjadi sekedar slogan
BUD/PE/2010

23
PERTAMINA
 LATIHAN PERENCANAAN SESUAI POAC ( Plan Organisasi Action
Control )

1. Coba buat perencanaan suatu pekerjaan cleaning tanki Crude

sesuai POAC berikut urutanya / tahapan dalam scope HSE

Contoh :

1. Persiapan administrasi
1. Pengosongan isi tanki ke tanki slop dilihat dari aspek SIKA.
2. Pengawasan pekerja dan aspek lindungan lingkungan dsb.

Silahkan mencoba !
BUD/PE/2010

24
PERTAMINA