The document describes the Barzan Onshore Project in Qatar, which involves developing a sour gas processing facility. It discusses four key areas of innovative risk management: emergency response coordination, health management, man-machine interface, and heat stress management. The project has achieved world-class safety results with over 200 million man-hours completed with no fatalities or lost time injuries. It highlights the safety culture and systems established in emergency response, health services, traffic safety, and heat mitigation that have contributed to this strong safety performance on the large-scale construction project.

1. 18062-MS
Innovative Risk Management on the Barzan
Onshore Project
Robert DeHart II, RasGas Barzan Onshore Project
Johnny Brand, JGC Barzan Onshore Project

2. Introduction (What is Barzan?)
OBJECTIVE
• Develop a sour gas processing facility, located
within Ras Laffan Industrial City, Qatar
• Provide natural gas for Qatar’s domestic market
• Vital to help fuel the growth for Qatar’s
development
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18062 • Innovative Risk Management on the Barzan Onshore Project • Robert DeHart / Johnny Brand
PROJECT EXECUTION
• A joint venture between Qatar
Petroleum and ExxonMobil
Barzan Limited with RasGas
Company Limited© entrusted as
the developer and operator and
JGC as the Engineering,
Procurement and Construction
(EPC) contractor for the work

3. Introduction (Construction Progress)
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18062 • Innovative Risk Management on the Barzan Onshore Project • Robert DeHart / Johnny Brand
Pre -Early Site Works - 2010
Post Early Site Works - 2011Barzan Site - 2012Barzan Site - 2013
Barzan Site - 2014

4. Introduction (Barzan Overview)
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18062 • Innovative Risk Management on the Barzan Onshore Project • Robert DeHart / Johnny Brand
CONSTRUCTION WORK SCOPE
• 3.8 million inch-diameter shop and field welding
• 42,151 tonnes of steel structures
• 4.1 million metres of electrical and instrumentation cable
• Work carried out on 800 acres of fenced site
• Erection of a 172 metre flare stack (tallest in Ras Laffan)
CHALLENGES
• Workforce peaked at 30,000 workers with 8 major sub-contractors
• 45 nationalities with 20 primary languages spoken
• 6 months of high temperatures and humidity with heat index at 50
or higher on most days from mid-May thru mid-September

5. Introduction (Record and System)
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18062 • Innovative Risk Management on the Barzan Onshore Project • Robert DeHart / Johnny Brand
SAFETY RECORD
• The project has completed 200 million man-hours on 10 Nov 2014
with world-class safety performance.
• Comparison is shown below with KPI’s of the International Oil & Gas
Producers 2012 annual report (Global and Middle East Region)
Indicator
Barzan
(as of 25 Oct 2014)
OGP Global OGP Middle East
Fatality Accident Rate 0 0.005 0.004
Lost Time Injury Rate 0.006 0.096 0.05
Total Recordable Incident Rate 0.181 0.348 0.204
HOW DID WE GET THERE?
Cornerstones of the Safety, Health, Environment & Security (SHE&S)
programme are:
• SHE&S Management System
• SHE&S Training
• Worksite Hazard Identification
• Observation and Intervention
• Worker Recognition Programme
• Worker Welfare

6. Introduction (Safety Culture)
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18062 • Innovative Risk Management on the Barzan Onshore Project • Robert DeHart / Johnny Brand
MANAGEMENT COMMITTMENT
• Active engagement with the workers at site / visible to the workforce
• Daily Tool Box Talk / Task Instruction attendance by management
• Bi-Monthly management safety walk with project management team / EPC
Contractor / Sub-Contractors
• IIF (Incident and Injury Free) activities such as: site walks for day and night
shifts; having lunch in the camps with workers; “frequent” handshakes and
greetings to engage with workers at site and in the camps; etc.
WORKER INVOLVEMENT
• Various tools used to instill responsibility within all levels of the project
workforce, including “stop work intervention cards”
• Continual demonstration of genuine care and concern for the workers
• Creating safety ownership through positive interactions
• Observation and intervention programme involving workers and supervisors
• Workers’ responsibilities for their own safety, and the safety of others

7. Emergency Response and Coordination (Introduction)
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18062 • Innovative Risk Management on the Barzan Onshore Project • Robert DeHart / Johnny Brand
WHY IS IT IMPORTANT?
• Site with 30,000 workers / 5,000 vehicles and equipment
• Daily work at height and confined space work (day and night)
• Potential for injuries and worker illnesses
• Detailed emergency response plans developed and implemented
• Regular testing and drills of plans and procedures

8. Emergency Response and Coordination (Overview)
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18062 • Innovative Risk Management on the Barzan Onshore Project • Robert DeHart / Johnny Brand
EMERGENCY COORDINATION
• Established a Security Operations Centre
(SOC) and Incident Coordination Centre (ICC)
• SOC operates 24 / 7 and receives and
coordinates all incident and emergency calls
• Provides updates through SMS text system and
mobilises response teams
EMERGENCY RESPONSE
• Mobilised and trained a 10 man rope
and confined space rescue team and
10 medical responders
• The team is based in 3 locations at
site and responds 24 / 7 to
emergencies

9. Emergency and Coordination (Achievements)
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18062 • Innovative Risk Management on the Barzan Onshore Project • Robert DeHart / Johnny Brand
EMERGENCY COORDINATION
• 2,995 emergency calls logged (SOC reports)
• 18 ICC call outs with the Project Incident
Management Team
EMERGENCY RESPONSE
• 4,382 confined space entry and working at
height task inspections
• 640 confined space Permit To Work protocol
surveys completed
• 737 training hours spent
• 24 rescues from height carried out (two at
the 40+ metre level)

10. Health Management (Introduction)
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18062 • Innovative Risk Management on the Barzan Onshore Project • Robert DeHart / Johnny Brand
WHY IS IT IMPORTANT?
• The manpower on site is similar to a small town (30,000)
• Worker welfare is a top priority for the project
• Wide variety of health risks (construction and commissioning)
• Chronic illnesses
• Communicable diseases
• Potential for injuries and illness both on site and in camp

11. Health Management (Overview)
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18062 • Innovative Risk Management on the Barzan Onshore Project • Robert DeHart / Johnny Brand
HEALTH MANAGEMENT SYSTEM
The key functions of the Health Department include (but not limited to)
• Pre-employment screening
• Absence management
• Fitness and return to work
• Health monitoring
• Counselling and rehabilitation
• Heat stress management
• Drug and alcohol management
The project organisation and resources
• 100 medical staff (nurses / doctors)
• 6 medical facilities at site and camp
• 12 response vehicles (SUV’s)

12. Health Management (Overview)
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18062 • Innovative Risk Management on the Barzan Onshore Project • Robert DeHart / Johnny Brand
• Health & Communicable Disease
Risk Assessments
• Camp Health and Welfare
• Fitness for Duty
• Occupational Hygiene
• Absence Management
• Heat Stress Management
• Medical Facilities Procedures
• Infection Control
• Potable Water
• Alcohol and Drug Monitoring
• Respiratory and Hearing
Protection
HEALTH MANAGEMENT SYSTEM
The following documents provide the framework for health management

13. Health Management (Achievements)
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18062 • Innovative Risk Management on the Barzan Onshore Project • Robert DeHart / Johnny Brand
KEY ACHIEVEMENTS
The Health Department completed the following activities as of 25 Oct 2014
• 61,375 fitness to work exams
• 1,570,324 consultations carried out: at site MAC and in the 3 camp clinics
• 898,860 daily alcohol screening (critical positions)
• 25,491 random alcohol screenings
• 33,572 “worker presentations” (illnesses) in the 3 camp clinics
• 2,419 chronic illness patients identified, registered and managed
• 737 cases of communicable diseases identified, registered and managed

14. Man-Machine Interface (Introduction)
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18062 • Innovative Risk Management on the Barzan Onshore Project • Robert DeHart / Johnny Brand
WHY IS IT IMPORTANT?
• More than 5,000 vehicles and equipment during peak
• High exposure to pedestrian traffic hazards (30,000 persons)
• Initial low pedestrian safety awareness of site workforce
• High potential impact and frequency of exposure = high risk
• Example = Bus Drop off + pick up (6 x per day) x 25,000 direct workers

15. Man-Machine Interface (Overview)
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18062 • Innovative Risk Management on the Barzan Onshore Project • Robert DeHart / Johnny Brand
MAN-MACHINE INTERFACE SYSTEM KEY ELEMENTS
• Pedestrian safety programme developed
• All vehicles fitted with In Vehicle Monitoring System (IVMS) units
• Inspection and maintenance system for all vehicles and equipment
• Panel setup to review traffic violations
• Bus and equipment rodeo programme
• Banksman and flagman mandatory for equipment / crane movement

16. Man-Machine Interface (Achievements)
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18062 • Innovative Risk Management on the Barzan Onshore Project • Robert DeHart / Johnny Brand
KEY ACHIEVEMENTS
• 7,300 plus vehicles and equipment inspected
• 1,976 IVMS units fitted with 2,262 registered IVMS users
• 95.1 million kilometres driven to date without a serious road traffic
accident
• Over 2,000 flagman and equipment operators jointly trained
• 300 participants in the bus rodeo programme
• More than 1,600 participants in the man-machine rodeo programme
• Over 50,000 multi-language (8 different languages) “Pedestrian and
Vehicle Safety” brochures published and issued site-wide
• 1,709 cases reviewed by the traffic panel

17. Heat Stress Management (Introduction)
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18062 • Innovative Risk Management on the Barzan Onshore Project • Robert DeHart / Johnny Brand
WHY IS IT IMPORTANT?
• Heat Stress season in Qatar (April 1-October 31)
• High heat index in excess of 50 during peak summer months
• Humidity levels reach 90 % and temperatures reach 450C
• Site manpower working through the summer months
• “High risk activities” – scaffolding, work at height, confined space
PREVENTIVE HEAT STRESS WORK PRACTICES TO MINIMIZE THE
EFFECT OF HEAT EXPOSURE
FLAG
COLOR
HEAT
INDEX
WORK
: REST
PERIO
D (min)
WATER
CONSUMPTION
(1 Cup = 250 ml)
CONTROL EXAMPLES
GREEN 27 – 31 50 : 10
1 Cup every 20
Minutes
Continuous Visual
monitoring of workers in
direct sun and heavy work
YELLOW 32 – 38 40 : 10
1 Cup every 20
Minutes
No Working alone
ORANGE
39 – 49 30 : 10
1 Cup every 15
Minutes
Work under Shade
50 – 53 20 : 10
1 Cup every 10
Minutes
Elevated and Confined
Space Work Stopped
RED ≥54
STOP WORK (Note: Safety/Integrity Critical Activities will be
allowed to continue subject to maximum 20 min. of work and
minimum of 20 min. rest all as per approved risk assessment and
proper control measures in place. This will be done through
normal PTW. (Exclusions applies to all emergency response
teams.)

18. Heat Stress Management (Overview)
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18062 • Innovative Risk Management on the Barzan Onshore Project • Robert DeHart / Johnny Brand
HEAT STRESS MANAGEMENT SYSTEM
The programme control measures include engineering, administrative,
personal and high risk control measures. The innovative areas include
• Fluid replacement
• Acclimatisation
• Food and drink supplements
• PPE (Personal Protective Equipment)
• High risk activities
• Heat stress monitors
• Mandatory refresher training
• Weekly management review meetings

19. Heat Stress Management (Achievements)
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18062 • Innovative Risk Management on the Barzan Onshore Project • Robert DeHart / Johnny Brand
Key achievements
The key accomplishments included;
• 50% reduction in heat illness frequency from 2013 to 2014
• No serious illnesses / injuries
• Refresher training carried out for 30,000 persons
HeatStressFrequencyRate(HSFR)and
HeatIndex(HI)Average
No.ofHeatStress(HS)Cases

20. Conclusion
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18062 • Innovative Risk Management on the Barzan Onshore Project • Robert DeHart / Johnny Brand
Achievements, Awards and Recognition
• Most significant achievement is the safety culture established on the
project
• The project delivered world class results to date and the four elements that
were covered in this paper significantly contributed to this result
• 130M man-hours without a LTI from July 11, 2012 to March 23, 2014
• Held six camp concert celebrations to recognise workers for 20M, 50M,
80M, 100M, 130M (million man-hour LTI free) and “Finish Strong” camp
celebration – all concerts held with professional entertainers
• Barzan EPC Contractor awarded Qatar Petroleum’s “Gold Award” for
SHE&S Excellence and Innovation for 2012 and 2013
• Barzan EPC Contractor awarded the British Safety Council International
Merit Award for 2014
• SPE Oil & Gas Facilities Journal, October 2014, Vol. 3, No. 5, pp. 53-64,
“Barzan Onshore - Gas - Facilities Construction – Attaining Excellence thru
a Comprehensive SHE&S Management System”… see www.spe.org/ogf

21. Thank You / Questions
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