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HSE training matrices templates for grassroots posts in petroleum and petrochemical enterprises

HSE training matrices templates for grassroots posts in petroleum and petrochemical enterprises Pet. Sci. (2017) 14:560–569 DOI 10.1007/s12182-017-0169-y ORIGINAL PAPER Special Issue: Safety in the Oil & Gas Industry HSE training matrices templates for grassroots posts in petroleum and petrochemical enterprises 1 1 2 • • Shao-Lin Qiu Lai-Bin Zhang Mu Liu Handling editor: Jian Shuai Received: 12 December 2016 / Published online: 4 July 2017 The Author(s) 2017. This article is an open access publication Abstract This paper aims to standardize health, safety and 1 Introduction environment (HSE) training matrices for effectively iden- tifying training requirements and enhancing job compe- Statistical data in recent years indicate that more than 80% of tency of grassroots posts in petroleum and petrochemical incidents and accidents affecting production safety, environ- enterprises. After an investigation into HSE training per- ment pollution and staff health in petroleum and petrochem- formance in petroleum and petrochemical enterprises, HSE ical enterprises were caused by illegal operations by training matrices templates for 239 grassroots posts grassroots staff with weak HSE awareness and competency involving 22 primary petroleum and petrochemical disci- (Bush and Ingram 1996; Gitomer 2012;Graduate Schoolof plines were developed based on the technical requirements Chinese Academy of Social Sciences 2002;Hu 2012;Jing of HSE training matrices templates and the studies of 2012; Shafiababy et al. 2007;Wang et al. 2008; Wen et al. template development processes and technical methods at 2012;Yao 2011). HSE training is an important means to grassroots level. Applications of these templates in 12 publicize corporate HSE policies and improve employees’ companies demonstrate their effectiveness in improving HSE knowledge and skills and their abilities in job-related risk HSE training and management for grassroots posts, identification and control. It is also an integral part of HSE strengthening risk control and promoting the application of management system and a significant measure to ensure job HSE system and tools in grassroots units. under control, build HSE culture and continuously improve HSE performance. HSE training for grassroots posts in Keywords Petroleum and petrochemical enterprise  domestic and foreign petroleum and petrochemical industries Grassroots posts  HSE  Training matrices  Template mainly has the following four problems: (1) Training content and post demands are not consistent; (2) Training methods are simple and boring, making trainees reluctant to accept them; (3) Positive initiatives for attending training are not strong, without direct relation to staff performance assessment; and (4) Responsibilities of training management are not clear, even none is fixed be in charge of training management in some corporation, so it is difficult to implement linear responsibility. However, so far, no training matrices based on & Mu Liu HSE technical requirements of grassroots posts are available paulday@163.com in China to specific professional classifications (He 2013; China University of Petroleum (Beijing), Beijing 102249, Kernberg 2014;Li 2010; Shevchenko and Kudryavtsev 2012; China Weldy et al. 2014; Yao et al. 2011, 2012; Zhang et al. 2016). CNPC Research Institute of Safety and Environment Since 2007, Chinese oil enterprises began to introduce and Technology, Beijing 102206, China explore HSE training matrices management tools, promote HSE training in grassroots units with HSE training matrices as Edited by Yan-Hua Sun 123 Pet. Sci. (2017) 14:560–569 561 the basic carrier and implement ‘‘training-on-demand’’ mod- jobs, such as oil production, oil gathering and transportation, els to meet job HSE needs (Carr et al. 2000; Finke 2004; Graff refining, petrochemistry, gas stations, oil storage, drilling, and Karsten 2012;Yang et al. 2013). Through effective downhole operations, geophysical exploration, well logging, identification, HSE training matrices can be an effective tool surface construction and equipment manufacturing. to link HSE training needs and posts and acquire clear instructions on training contents, grasp level, training fre- 2.2 Operability quency, etc. (Ahmed and Kolachi 2013; Falkenstein et al, 2016; Puhakainen and Siponen 2010;Yan 2011; Zia et al. HSE training matrices templates for grassroots posts shall 2014). It spells out HSE training requirements in an adequate, have adequate operability. They should be specific to target vivid, clear and concise manner. However, more applications posts and specify procedures required for every workplace. of HSE training matrices demonstrate deficiencies such as Training content should be detailed down to the smallest unreasonable design, inaccurate identification of training need unit of an operation. and lack of consistency of posts with competence, which restricts the role of HSE training matrices (Hogan et al 2014). 2.3 Generality Facing the fact that training status is not completely based on real needs of enterprises, it is necessary to research and The development process of HSE training matrices tem- develop HSE training matrices templates which should be plates for grassroots posts should be standardized by operative, general and suitable for the competency and defining business types, breaking down operation, mini- requirements of grassroots posts and bring a positive effect on mizing operating unit and specifying training period, form, the application of HSE training matrices. This paper studies trainer and mastery of training content, etc. HSE training matrices templates based on technical require- ments and following the professional classification of grass- 2.4 Suitability roots posts and designs training content, period and methods. Using these templates, hierarchical responsibilities could HSE training matrices templates for grassroots posts should be implemented and training requirements and technical include necessary training content for meeting specific job support measures are defined. Applications of these templates competency, design appropriate training methods and pro- have proved that they can effectively solve training problems vide training courses and training materials consistent with of grassroots posts and significantly improve training grassroots posts. After being trained, all trainees should performance. grasp job skills, understand and be able to control job risks. 2 Technical requirements for template 3 Process and technical methods of template development development Application of HSE training matrices to strengthen HSE After analyzing the HSE training performance in petroleum training for grassroots posts is very different in training and petrochemical enterprises, and combing the technical mode, form design, requirement analysis and application requirements for developing HSE training matrices, the effect in Chinese oil enterprises. To identify basic training following development process of HSE training matrices requirements and develop general HSE training matrices for grassroots units was proposed (Fig. 1). templates for key posts in different disciplines (MacDuffie 2007; Montreuil 1996; Nor 2009; Glushenkov 2009; Sha- 3.1 Technical preparation dlovskiy and Kovaliov 2013; Shafiabady et al. 2007), the following requirements should be considered: These data should be prepared as the base for HSE training matrices development, including applicable laws and reg- 2.1 Scope ulations for related disciplines, grassroots posts, job descriptions and responsibilities, staff structure, available HSE training matrices templates for grassroots posts should equipment and facilities, processes, procedures. cover primary business activities in petroleum and petro- chemical enterprises, such as exploration and development, 3.2 Division of management units refining and petrochemistry, marketing, natural gas and pipelines, engineering technology, surface construction and Aiming at production and management characteristics, job equipment manufacturing. The specific HSE training matri- management units should be divided in consideration of ces template for every business type should cover primary related equipment and facilities, processes and (or) 123 562 Pet. Sci. (2017) 14:560–569 Training needs survey Prepare technical Divide basis management units Steps Hazard breakdown Streamline identification and operation items risk assessment Training needs analysis and Continuous Training needs confirmation improvement analysis General HSE Controlled production HSE knowledge, Basic job skills knowledge management process methods and tools If required Operating procedures Training needs Training courseware optimization confirmation development Development of training Training requirements matrix templates setting Training Training Training Training Trainer hours period method effect Development of training matrix templates Fig. 1 Development process of HSE training matrices for grassroots units worksites. For example, oil production activity can be divi- equipment and facilities, conduct hazard identification and ded into 30 management units in accordance with specific risk assessment and develop risk control measures using the scope of work, job description, workflow, equipment and job safety analysis (JSA) method, to ensure that the whole facilities. Table 1 shows the management unit list. process risk management, risk control and emergency response measures are brought into the training needs, laying 3.3 Analysis of operations the foundation for job training matrices application. To meet the requirements for keeping every operation 3.5 Training requirement analysis relatively independent and complete, operational risks can be identified and control measures can be implemented, According to job responsibilities, operating procedures, risk and management units should be detailed to the most basic control and emergency response measures, job-related activities. In Table 2, 30 management units in oil produc- training requirements are analyzed and determined. Training tion can be broken down into 245 activities. requirements mainly involve the following four aspects. 3.4 Hazard identification and risk assessment 3.5.1 General HSE knowledge For each activity, it is recommended to break down operating The general part of HSE training matrices, i.e., general procedures or how to dismantle key components of HSE knowledge closely related to staff’s activities, daily 123 Pet. Sci. (2017) 14:560–569 563 Table 1 Job management unit list of oil production S/N Management unit S/N Management unit 1 Pumping unit installation, uninstallation, transportation, operation, 16 Water buffer tank operation and maintenance monitoring, adjustment and maintenance 2 Screw pump operation, adjustment and maintenance 17 Water tank maintenance 3 Oil well operation, monitoring and maintenance 18 Centrifugal pump installation, operation and maintenance 4 Christmas tree maintenance 19 Processes in oil gathering and transportation room, and accessories maintenance 5 Well test 20 Operation and maintenance of gas /oil vacuum/phase change furnace 6 Metering separator operation, monitoring and maintenance 21 Processes in furnace operating room and accessories maintenance 7 Maintenance of processes and fittings in the production allocation room 22 Pump operation and maintenance in deep water well 8 High-pressure injection pump (piston pump) operation and maintenance 23 Test and analysis of produced oil 9 Injection well operation, monitoring and maintenance 24 Electrical equipment and facilities maintenance 10 Maintenance of processes and fittings in the water distribution room 25 Maintenance equipment inspection, operation and maintenance 11 Two-phase separator operation and maintenance 26 Inspection tour 12 Three-phase separator operation and maintenance 27 Upgrading and fixing of oil/gas/water pipelines 13 Oil skimmer operation and maintenance 28 General accessories maintenance 14 Dryer operation and maintenance 29 Single-well tank installation, operation, maintenance and adjustment 15 Air purifier operation and maintenance 30 Logistics support and management Table 2 List of basic activities in oil production (partial) S/N Basic activity S/N Basic activity 2.1 Installation of pumping unit 2.3 Oil well operation, monitoring and maintenance 2.1.1 Overall installation of pumping unit 2.3.1 Measurement of tubing pressure 2.1.2 Assembly and disassembly of pumping unit 2.3.2 Measurement of casing pressure 2.3.3 Well sampling 2.2 Screw pump operation, adjustment and maintenance 2.3.4 Adjustment of collision avoidance distance for pumping well 2.2.1 Screw pump start-up 2.2.2 Screw pump shutdown 2.4 Well test life and jobs and that should be mastered, includes job- 3.5.3 Controlled production management process related laws and regulations, job HSE risks, equipment and material used, emergency response and prevention mea- According to the training requirements set for controlled production management, all employees should understand sures and typical incidents as shown in Table 3. or master related controlled management requirements 3.5.2 Basic job skills applicable to their jobs and apply them to HSE manage- ment, which mainly includes related controlled manage- Professional skills of HSE training matrices refer to the ment activities and contents, e.g., permit-to-work training contents set specifically to a job based on job management, process and equipment management, man- requirement analysis. It mainly includes training in oper- agement of change and contractor management. ation procedures, such as technical skills for equipment management, operational activities and processes 3.5.4 HSE knowledge, methods and tools (Table 4). Through training, employees can grasp job-re- lated skills, hazard identification and risk control methods, According to the training requirements set for an HSE emergency response procedures, etc. management system, all employees are required to 123 564 Pet. Sci. (2017) 14:560–569 Table 3 JSA before well shut-in (example) Unit Unit name All hazards and risks and the corresponding measures to eliminate, mitigate and control these hazards and risks have been discussed, understood and confirmed by all personnel involved in this job, including emergency response measures, so the work can be started. Duty holder Brief description of the task Procedure Hazard(s) Risk control measure(s) Emergency response measure(s) 1. Check work preparation and 1. Mechanical injury 1. Wear necessary personal 1. First-aid kit available on the recorded data protective equipment (PPE) site and send to the medical clinic in the work area in serious cases 2. Notify central control room 1. Mechanical injury 1. Wear necessary PPE and 1. First-aid kit available on the (CCR) and close secondary stand aside while operating site and send to the medical nozzles and then primary valves clinic in the work area in nozzles on site serious cases 3. Remote/on-site well shut-in 1. Suffocation injury: Entry 1. Entry into the valve chamber 1. Once a suffocation injury into cellar valve chamber shall comply with the occurs, the monitoring may cause suffocation due to Regulations on Entry into personnel shall immediately gas leakage Cellar Valve Chamber by wear positive pressure Gas Production Crew breathing apparatus and 2. Mechanical injury enter the valve chamber to 2. Wear necessary PPE; stand move the injured out and aside while operating valves; give first-aid treatment. do not stand near Christmas tree and pipelines; do not 2. Once a mechanical injury open the back door of the occurs, immediately give hydraulic control cabinet first-aid treatment, and then send to the medical clinic in the work area 4. Long shut-in: Close all 1. Mechanical injury 1. Wear necessary PPE and 1. First-aid kit available on the nozzles, hydraulic wing stand aside while operating site and send to the medical valves, manual wing valves, valves clinic in the work area in hydraulic master valves, serious cases manual master valves and downhole safety valves, and decide the branch pressure according to real situations; report well shut-in to CCR and record valve switch status understand or master related national, industrial and cor- responsibilities, training requirement, courses and trainees porate HSE requirements which mainly include basic HSE as shown in Table 6. knowledge, tools and methods, e.g., JSA, job cycle analysis (JCA), safety observation and communication, and safety 3.7 Training outline (if required) experience sharing. Besides, all employees should be able to apply HSE management methods and tools to routine Training outlines should be consistent, relatively complete, HSE work using with their HSE knowledge. simple and concise (Table 2). Materials like video, audio and photographs can be used to illustrate HSE principles 3.6 Training requirements and training matrices and practices in order to attract trainees to interactive development participation. Training requirements set up training goals and perfor- 3.8 Optimization of operating procedures mance indicators. Four points of every post, training requirement, namely duration, frequency and trainers Training contents should be determined based on operating (Table 5), should be defined and specific HSE training procedures. It is recommended to use tools and methods matrices should be established based on job such as JCA and JSA to analyze the effectiveness of job- 123 Pet. Sci. (2017) 14:560–569 565 Table 4 Job skills for oil production (partial) S/N Group/post Well group Pump station Geology group Mechanic group Logistics Remarks group (Job) Training Group Juniors Night Data Group Pump Boiler Group Laboratory Tester Group Mechanic Electrician Electric Driver Other content leader shift recorder leader leader technician leader welding 2 Job-related basic skills 2.1 Installation, operation, adjustment and maintenance of pumping unit 2.2.1 Inspection of •• • • • • • • • • pumping unit 2.1.2 Well start-up/shut- •• • • • • • • • in 2.1.3 Replacing belt •• • • • • • 2.1.4 Collision • •• • • avoidance distance adjustment 2.1.5 Balance •• • • adjustment 2.1.6 Stroke adjustment •• • 2.1.7 Stroke frequency •• • • adjustment 2.1.8 Walking beam •• • adjustment 2.1.9 Replacing crane •• • pin 2.1.10 Replacing wire •• • rope 2.1.11 Brake replacing •• • (repair) 2.1.12 Maintenance •• • (filling lubricants and fastening screws) 2.1.13 Oil well operation, •• • • • monitoring and maintenance 2.2 Oil well inspection 2.2.1 Oil well start-up •• • • • • • • and shut-in 2.2.2 Gas measurement •• • • • • • in oil well 2.2.3 Casing pressure •• • • • measurement 566 Pet. Sci. (2017) 14:560–569 related procedures which should be revised when neces- sary. To keep continuous improvement in training work, training matrices should be improved in accordance with the revision of operating procedures. 4 Application and improvement in HSE training matrices templates 4.1 Results of templates development Using the technical methods above, 239 grassroots posts in 22 primary disciplines in petroleum and petrochemical industries (based on an investigation of 12 petroleum and petrochemical enterprises) were studied, and based on which 983 management units covering 4566 activities were proposed and defined, and accordingly, 239 HSE training matrices and 1726 training outlines were established. 4.2 Templates application Application of these HSE training matrices templates was used in an oil field company and obtained the following results: 1. These HSE training matrices templates for grassroots posts can standardize job requirements and compe- tency building, make HSE training for grassroots posts standard, systematic and scientific, enhance on-site risk management and control levels, improve job operating procedures and enlarge the application of HSE man- agement tools and methods. 2. These HSE training matrices embody job-related basic HSE training requirements. Training is given by line managers. Training contents focus on safety and environmental risks on specific work and are concise, understandable, operable and interesting. 3. With appropriate incentive mechanism, all employees at all levels are active to pursue their initiatives and participate in development and revision of operating procedures and training matrices. This practice is supported and understood by all employees. 4. Dynamic management and sustainable improvement in the HSE training matrices make them adapt to changing management structure processes. 4.3 Future improvement Analysis of the actual applications of these HSE training matrices templates indicates that future improvement can be carried out in the following aspects: Table 4 continued S/N Group/post Well group Pump station Geology group Mechanic group Logistics Remarks group (Job) Training Group Juniors Night Data Group Pump Boiler Group Laboratory Tester Group Mechanic Electrician Electric Driver Other content leader shift recorder leader leader technician leader welding 2.2.4 Oil well sampling •• • • • 2.2.5 Pressure buildup •• • • • 2.2.6 Washing well •• • • • • • 2.2.7 Disposal of •• • • • • coagulated pipes 2.2.8…• • • • • • Pet. Sci. (2017) 14:560–569 567 Table 5 Typical HSE training matrices for oil production juniors (partial) S/N Training description Duration Frequency Method Requirement Trainer (hours) 1 General HSE knowledge 1.1 HSE responsibilities, rights and obligations 0.50 Every Lecturing or Mastery Group leader/HSE 1 year meeting officer 1.2 Crude oil HSE knowledge 0.25 Every Lecturing Mastery Group leader/HSE 3 years officer 1.3 Gas HSE knowledge 0.25 Every Lecturing Mastery Group leader/HSE 3 years officer 1.4 Emergency escape knowledge 0.50 Every Lecturing ? Mastery Group leader/HSE 1 year field officer 1.5 2 Basic job skills 2.1 Operation, maintenance and adjustment of pumping unit 2.1.1 Start-up and shutdown of pumping unit 0.50 3 years Lecturing ? Mastery Group leader/HSE field officer 2.1.2 Replacing the belt of a pumping unit 0.5 3 years Lecturing ? Mastery Group leader/HSE field officer 2.1.3 Pumping unit maintenance (fill lubricants and 0.50 3 years Lecturing ? Mastery Group leader/HSE fasten screws) field officer 2.1.4 3 Controlled management process 3.1 Permit to work 0.50 3 years Lecturing ? Understanding Squad leader or HSE field officer 3.2 Lock out and tag out 0.50 3 years Lecturing ? Mastery Squad leader or HSE field officer 3.3 4 HSE knowledge, methods and tools 4.1 JSA 0.25 3 years Lecturing or Understanding Squad leader or HSE meeting officer 4.2 Site management 0.50 3 years Lecturing or Mastery Squad leader or HSE meeting officer 4.3 Table 6 Training outlines Outlines for basic job skills Outlines for controlled management Outlines for HSE knowledge, methods and procedure tools 1. Pre-job preparation 1. Basic definitions 1. Basic definitions and explanations 2. Procedures (hazard identification and risk 2. Management process and requirements 2. Why promote? control) 3. Typical cases 3. How to implement effectively? 3. Emergency response and accident prevention 4. Cautions 4. Cautions and summary (cases) 1. The department in charge of training should fully play 2. As different enterprises have different organizations, a leading role in strengthening the compliance with the production techniques, equipment, facilities, alloca- enterprise’s overall human resource management poli- tions of posts and responsibilities, businesses and cies, unifying the management of output interfaces and activities, they have different requirements for job- effectively integrating various resources. related HSE competency. The generality of the HSE 123 568 Pet. Sci. (2017) 14:560–569 Carr JE, Nicolson AC, Higbee TS. Evaluation of a brief multiple- training matrices templates may not meet specific stimulus preference assessment in a naturalistic context. J Appl requirements. Therefore, as equipment, technologies Behav Anal. 2000;33:353–7. doi:10.1901/jaba.2000.33-353. and processes upgrade, the templates should be Falkenstein M, Gajewski PD, Michael F, Patrick DG. 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HSE training matrices templates for grassroots posts in petroleum and petrochemical enterprises

Qiu, Shao-Lin; Zhang, Lai-Bin; Liu, Mu
Petroleum Science , Volume 14 (3) – Jul 4, 2017
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Springer Journals
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Copyright © 2017 by The Author(s)
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Earth Sciences; Mineral Resources; Industrial Chemistry/Chemical Engineering; Industrial and Production Engineering; Energy Economics
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1672-5107
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10.1007/s12182-017-0169-y
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Abstract

Pet. Sci. (2017) 14:560–569 DOI 10.1007/s12182-017-0169-y ORIGINAL PAPER Special Issue: Safety in the Oil & Gas Industry HSE training matrices templates for grassroots posts in petroleum and petrochemical enterprises 1 1 2 • • Shao-Lin Qiu Lai-Bin Zhang Mu Liu Handling editor: Jian Shuai Received: 12 December 2016 / Published online: 4 July 2017 The Author(s) 2017. This article is an open access publication Abstract This paper aims to standardize health, safety and 1 Introduction environment (HSE) training matrices for effectively iden- tifying training requirements and enhancing job compe- Statistical data in recent years indicate that more than 80% of tency of grassroots posts in petroleum and petrochemical incidents and accidents affecting production safety, environ- enterprises. After an investigation into HSE training per- ment pollution and staff health in petroleum and petrochem- formance in petroleum and petrochemical enterprises, HSE ical enterprises were caused by illegal operations by training matrices templates for 239 grassroots posts grassroots staff with weak HSE awareness and competency involving 22 primary petroleum and petrochemical disci- (Bush and Ingram 1996; Gitomer 2012;Graduate Schoolof plines were developed based on the technical requirements Chinese Academy of Social Sciences 2002;Hu 2012;Jing of HSE training matrices templates and the studies of 2012; Shafiababy et al. 2007;Wang et al. 2008; Wen et al. template development processes and technical methods at 2012;Yao 2011). HSE training is an important means to grassroots level. Applications of these templates in 12 publicize corporate HSE policies and improve employees’ companies demonstrate their effectiveness in improving HSE knowledge and skills and their abilities in job-related risk HSE training and management for grassroots posts, identification and control. It is also an integral part of HSE strengthening risk control and promoting the application of management system and a significant measure to ensure job HSE system and tools in grassroots units. under control, build HSE culture and continuously improve HSE performance. HSE training for grassroots posts in Keywords Petroleum and petrochemical enterprise  domestic and foreign petroleum and petrochemical industries Grassroots posts  HSE  Training matrices  Template mainly has the following four problems: (1) Training content and post demands are not consistent; (2) Training methods are simple and boring, making trainees reluctant to accept them; (3) Positive initiatives for attending training are not strong, without direct relation to staff performance assessment; and (4) Responsibilities of training management are not clear, even none is fixed be in charge of training management in some corporation, so it is difficult to implement linear responsibility. However, so far, no training matrices based on & Mu Liu HSE technical requirements of grassroots posts are available paulday@163.com in China to specific professional classifications (He 2013; China University of Petroleum (Beijing), Beijing 102249, Kernberg 2014;Li 2010; Shevchenko and Kudryavtsev 2012; China Weldy et al. 2014; Yao et al. 2011, 2012; Zhang et al. 2016). CNPC Research Institute of Safety and Environment Since 2007, Chinese oil enterprises began to introduce and Technology, Beijing 102206, China explore HSE training matrices management tools, promote HSE training in grassroots units with HSE training matrices as Edited by Yan-Hua Sun 123 Pet. Sci. (2017) 14:560–569 561 the basic carrier and implement ‘‘training-on-demand’’ mod- jobs, such as oil production, oil gathering and transportation, els to meet job HSE needs (Carr et al. 2000; Finke 2004; Graff refining, petrochemistry, gas stations, oil storage, drilling, and Karsten 2012;Yang et al. 2013). Through effective downhole operations, geophysical exploration, well logging, identification, HSE training matrices can be an effective tool surface construction and equipment manufacturing. to link HSE training needs and posts and acquire clear instructions on training contents, grasp level, training fre- 2.2 Operability quency, etc. (Ahmed and Kolachi 2013; Falkenstein et al, 2016; Puhakainen and Siponen 2010;Yan 2011; Zia et al. HSE training matrices templates for grassroots posts shall 2014). It spells out HSE training requirements in an adequate, have adequate operability. They should be specific to target vivid, clear and concise manner. However, more applications posts and specify procedures required for every workplace. of HSE training matrices demonstrate deficiencies such as Training content should be detailed down to the smallest unreasonable design, inaccurate identification of training need unit of an operation. and lack of consistency of posts with competence, which restricts the role of HSE training matrices (Hogan et al 2014). 2.3 Generality Facing the fact that training status is not completely based on real needs of enterprises, it is necessary to research and The development process of HSE training matrices tem- develop HSE training matrices templates which should be plates for grassroots posts should be standardized by operative, general and suitable for the competency and defining business types, breaking down operation, mini- requirements of grassroots posts and bring a positive effect on mizing operating unit and specifying training period, form, the application of HSE training matrices. This paper studies trainer and mastery of training content, etc. HSE training matrices templates based on technical require- ments and following the professional classification of grass- 2.4 Suitability roots posts and designs training content, period and methods. Using these templates, hierarchical responsibilities could HSE training matrices templates for grassroots posts should be implemented and training requirements and technical include necessary training content for meeting specific job support measures are defined. Applications of these templates competency, design appropriate training methods and pro- have proved that they can effectively solve training problems vide training courses and training materials consistent with of grassroots posts and significantly improve training grassroots posts. After being trained, all trainees should performance. grasp job skills, understand and be able to control job risks. 2 Technical requirements for template 3 Process and technical methods of template development development Application of HSE training matrices to strengthen HSE After analyzing the HSE training performance in petroleum training for grassroots posts is very different in training and petrochemical enterprises, and combing the technical mode, form design, requirement analysis and application requirements for developing HSE training matrices, the effect in Chinese oil enterprises. To identify basic training following development process of HSE training matrices requirements and develop general HSE training matrices for grassroots units was proposed (Fig. 1). templates for key posts in different disciplines (MacDuffie 2007; Montreuil 1996; Nor 2009; Glushenkov 2009; Sha- 3.1 Technical preparation dlovskiy and Kovaliov 2013; Shafiabady et al. 2007), the following requirements should be considered: These data should be prepared as the base for HSE training matrices development, including applicable laws and reg- 2.1 Scope ulations for related disciplines, grassroots posts, job descriptions and responsibilities, staff structure, available HSE training matrices templates for grassroots posts should equipment and facilities, processes, procedures. cover primary business activities in petroleum and petro- chemical enterprises, such as exploration and development, 3.2 Division of management units refining and petrochemistry, marketing, natural gas and pipelines, engineering technology, surface construction and Aiming at production and management characteristics, job equipment manufacturing. The specific HSE training matri- management units should be divided in consideration of ces template for every business type should cover primary related equipment and facilities, processes and (or) 123 562 Pet. Sci. (2017) 14:560–569 Training needs survey Prepare technical Divide basis management units Steps Hazard breakdown Streamline identification and operation items risk assessment Training needs analysis and Continuous Training needs confirmation improvement analysis General HSE Controlled production HSE knowledge, Basic job skills knowledge management process methods and tools If required Operating procedures Training needs Training courseware optimization confirmation development Development of training Training requirements matrix templates setting Training Training Training Training Trainer hours period method effect Development of training matrix templates Fig. 1 Development process of HSE training matrices for grassroots units worksites. For example, oil production activity can be divi- equipment and facilities, conduct hazard identification and ded into 30 management units in accordance with specific risk assessment and develop risk control measures using the scope of work, job description, workflow, equipment and job safety analysis (JSA) method, to ensure that the whole facilities. Table 1 shows the management unit list. process risk management, risk control and emergency response measures are brought into the training needs, laying 3.3 Analysis of operations the foundation for job training matrices application. To meet the requirements for keeping every operation 3.5 Training requirement analysis relatively independent and complete, operational risks can be identified and control measures can be implemented, According to job responsibilities, operating procedures, risk and management units should be detailed to the most basic control and emergency response measures, job-related activities. In Table 2, 30 management units in oil produc- training requirements are analyzed and determined. Training tion can be broken down into 245 activities. requirements mainly involve the following four aspects. 3.4 Hazard identification and risk assessment 3.5.1 General HSE knowledge For each activity, it is recommended to break down operating The general part of HSE training matrices, i.e., general procedures or how to dismantle key components of HSE knowledge closely related to staff’s activities, daily 123 Pet. Sci. (2017) 14:560–569 563 Table 1 Job management unit list of oil production S/N Management unit S/N Management unit 1 Pumping unit installation, uninstallation, transportation, operation, 16 Water buffer tank operation and maintenance monitoring, adjustment and maintenance 2 Screw pump operation, adjustment and maintenance 17 Water tank maintenance 3 Oil well operation, monitoring and maintenance 18 Centrifugal pump installation, operation and maintenance 4 Christmas tree maintenance 19 Processes in oil gathering and transportation room, and accessories maintenance 5 Well test 20 Operation and maintenance of gas /oil vacuum/phase change furnace 6 Metering separator operation, monitoring and maintenance 21 Processes in furnace operating room and accessories maintenance 7 Maintenance of processes and fittings in the production allocation room 22 Pump operation and maintenance in deep water well 8 High-pressure injection pump (piston pump) operation and maintenance 23 Test and analysis of produced oil 9 Injection well operation, monitoring and maintenance 24 Electrical equipment and facilities maintenance 10 Maintenance of processes and fittings in the water distribution room 25 Maintenance equipment inspection, operation and maintenance 11 Two-phase separator operation and maintenance 26 Inspection tour 12 Three-phase separator operation and maintenance 27 Upgrading and fixing of oil/gas/water pipelines 13 Oil skimmer operation and maintenance 28 General accessories maintenance 14 Dryer operation and maintenance 29 Single-well tank installation, operation, maintenance and adjustment 15 Air purifier operation and maintenance 30 Logistics support and management Table 2 List of basic activities in oil production (partial) S/N Basic activity S/N Basic activity 2.1 Installation of pumping unit 2.3 Oil well operation, monitoring and maintenance 2.1.1 Overall installation of pumping unit 2.3.1 Measurement of tubing pressure 2.1.2 Assembly and disassembly of pumping unit 2.3.2 Measurement of casing pressure 2.3.3 Well sampling 2.2 Screw pump operation, adjustment and maintenance 2.3.4 Adjustment of collision avoidance distance for pumping well 2.2.1 Screw pump start-up 2.2.2 Screw pump shutdown 2.4 Well test life and jobs and that should be mastered, includes job- 3.5.3 Controlled production management process related laws and regulations, job HSE risks, equipment and material used, emergency response and prevention mea- According to the training requirements set for controlled production management, all employees should understand sures and typical incidents as shown in Table 3. or master related controlled management requirements 3.5.2 Basic job skills applicable to their jobs and apply them to HSE manage- ment, which mainly includes related controlled manage- Professional skills of HSE training matrices refer to the ment activities and contents, e.g., permit-to-work training contents set specifically to a job based on job management, process and equipment management, man- requirement analysis. It mainly includes training in oper- agement of change and contractor management. ation procedures, such as technical skills for equipment management, operational activities and processes 3.5.4 HSE knowledge, methods and tools (Table 4). Through training, employees can grasp job-re- lated skills, hazard identification and risk control methods, According to the training requirements set for an HSE emergency response procedures, etc. management system, all employees are required to 123 564 Pet. Sci. (2017) 14:560–569 Table 3 JSA before well shut-in (example) Unit Unit name All hazards and risks and the corresponding measures to eliminate, mitigate and control these hazards and risks have been discussed, understood and confirmed by all personnel involved in this job, including emergency response measures, so the work can be started. Duty holder Brief description of the task Procedure Hazard(s) Risk control measure(s) Emergency response measure(s) 1. Check work preparation and 1. Mechanical injury 1. Wear necessary personal 1. First-aid kit available on the recorded data protective equipment (PPE) site and send to the medical clinic in the work area in serious cases 2. Notify central control room 1. Mechanical injury 1. Wear necessary PPE and 1. First-aid kit available on the (CCR) and close secondary stand aside while operating site and send to the medical nozzles and then primary valves clinic in the work area in nozzles on site serious cases 3. Remote/on-site well shut-in 1. Suffocation injury: Entry 1. Entry into the valve chamber 1. Once a suffocation injury into cellar valve chamber shall comply with the occurs, the monitoring may cause suffocation due to Regulations on Entry into personnel shall immediately gas leakage Cellar Valve Chamber by wear positive pressure Gas Production Crew breathing apparatus and 2. Mechanical injury enter the valve chamber to 2. Wear necessary PPE; stand move the injured out and aside while operating valves; give first-aid treatment. do not stand near Christmas tree and pipelines; do not 2. Once a mechanical injury open the back door of the occurs, immediately give hydraulic control cabinet first-aid treatment, and then send to the medical clinic in the work area 4. Long shut-in: Close all 1. Mechanical injury 1. Wear necessary PPE and 1. First-aid kit available on the nozzles, hydraulic wing stand aside while operating site and send to the medical valves, manual wing valves, valves clinic in the work area in hydraulic master valves, serious cases manual master valves and downhole safety valves, and decide the branch pressure according to real situations; report well shut-in to CCR and record valve switch status understand or master related national, industrial and cor- responsibilities, training requirement, courses and trainees porate HSE requirements which mainly include basic HSE as shown in Table 6. knowledge, tools and methods, e.g., JSA, job cycle analysis (JCA), safety observation and communication, and safety 3.7 Training outline (if required) experience sharing. Besides, all employees should be able to apply HSE management methods and tools to routine Training outlines should be consistent, relatively complete, HSE work using with their HSE knowledge. simple and concise (Table 2). Materials like video, audio and photographs can be used to illustrate HSE principles 3.6 Training requirements and training matrices and practices in order to attract trainees to interactive development participation. Training requirements set up training goals and perfor- 3.8 Optimization of operating procedures mance indicators. Four points of every post, training requirement, namely duration, frequency and trainers Training contents should be determined based on operating (Table 5), should be defined and specific HSE training procedures. It is recommended to use tools and methods matrices should be established based on job such as JCA and JSA to analyze the effectiveness of job- 123 Pet. Sci. (2017) 14:560–569 565 Table 4 Job skills for oil production (partial) S/N Group/post Well group Pump station Geology group Mechanic group Logistics Remarks group (Job) Training Group Juniors Night Data Group Pump Boiler Group Laboratory Tester Group Mechanic Electrician Electric Driver Other content leader shift recorder leader leader technician leader welding 2 Job-related basic skills 2.1 Installation, operation, adjustment and maintenance of pumping unit 2.2.1 Inspection of •• • • • • • • • • pumping unit 2.1.2 Well start-up/shut- •• • • • • • • • in 2.1.3 Replacing belt •• • • • • • 2.1.4 Collision • •• • • avoidance distance adjustment 2.1.5 Balance •• • • adjustment 2.1.6 Stroke adjustment •• • 2.1.7 Stroke frequency •• • • adjustment 2.1.8 Walking beam •• • adjustment 2.1.9 Replacing crane •• • pin 2.1.10 Replacing wire •• • rope 2.1.11 Brake replacing •• • (repair) 2.1.12 Maintenance •• • (filling lubricants and fastening screws) 2.1.13 Oil well operation, •• • • • monitoring and maintenance 2.2 Oil well inspection 2.2.1 Oil well start-up •• • • • • • • and shut-in 2.2.2 Gas measurement •• • • • • • in oil well 2.2.3 Casing pressure •• • • • measurement 566 Pet. Sci. (2017) 14:560–569 related procedures which should be revised when neces- sary. To keep continuous improvement in training work, training matrices should be improved in accordance with the revision of operating procedures. 4 Application and improvement in HSE training matrices templates 4.1 Results of templates development Using the technical methods above, 239 grassroots posts in 22 primary disciplines in petroleum and petrochemical industries (based on an investigation of 12 petroleum and petrochemical enterprises) were studied, and based on which 983 management units covering 4566 activities were proposed and defined, and accordingly, 239 HSE training matrices and 1726 training outlines were established. 4.2 Templates application Application of these HSE training matrices templates was used in an oil field company and obtained the following results: 1. These HSE training matrices templates for grassroots posts can standardize job requirements and compe- tency building, make HSE training for grassroots posts standard, systematic and scientific, enhance on-site risk management and control levels, improve job operating procedures and enlarge the application of HSE man- agement tools and methods. 2. These HSE training matrices embody job-related basic HSE training requirements. Training is given by line managers. Training contents focus on safety and environmental risks on specific work and are concise, understandable, operable and interesting. 3. With appropriate incentive mechanism, all employees at all levels are active to pursue their initiatives and participate in development and revision of operating procedures and training matrices. This practice is supported and understood by all employees. 4. Dynamic management and sustainable improvement in the HSE training matrices make them adapt to changing management structure processes. 4.3 Future improvement Analysis of the actual applications of these HSE training matrices templates indicates that future improvement can be carried out in the following aspects: Table 4 continued S/N Group/post Well group Pump station Geology group Mechanic group Logistics Remarks group (Job) Training Group Juniors Night Data Group Pump Boiler Group Laboratory Tester Group Mechanic Electrician Electric Driver Other content leader shift recorder leader leader technician leader welding 2.2.4 Oil well sampling •• • • • 2.2.5 Pressure buildup •• • • • 2.2.6 Washing well •• • • • • • 2.2.7 Disposal of •• • • • • coagulated pipes 2.2.8…• • • • • • Pet. Sci. (2017) 14:560–569 567 Table 5 Typical HSE training matrices for oil production juniors (partial) S/N Training description Duration Frequency Method Requirement Trainer (hours) 1 General HSE knowledge 1.1 HSE responsibilities, rights and obligations 0.50 Every Lecturing or Mastery Group leader/HSE 1 year meeting officer 1.2 Crude oil HSE knowledge 0.25 Every Lecturing Mastery Group leader/HSE 3 years officer 1.3 Gas HSE knowledge 0.25 Every Lecturing Mastery Group leader/HSE 3 years officer 1.4 Emergency escape knowledge 0.50 Every Lecturing ? Mastery Group leader/HSE 1 year field officer 1.5 2 Basic job skills 2.1 Operation, maintenance and adjustment of pumping unit 2.1.1 Start-up and shutdown of pumping unit 0.50 3 years Lecturing ? Mastery Group leader/HSE field officer 2.1.2 Replacing the belt of a pumping unit 0.5 3 years Lecturing ? Mastery Group leader/HSE field officer 2.1.3 Pumping unit maintenance (fill lubricants and 0.50 3 years Lecturing ? Mastery Group leader/HSE fasten screws) field officer 2.1.4 3 Controlled management process 3.1 Permit to work 0.50 3 years Lecturing ? Understanding Squad leader or HSE field officer 3.2 Lock out and tag out 0.50 3 years Lecturing ? Mastery Squad leader or HSE field officer 3.3 4 HSE knowledge, methods and tools 4.1 JSA 0.25 3 years Lecturing or Understanding Squad leader or HSE meeting officer 4.2 Site management 0.50 3 years Lecturing or Mastery Squad leader or HSE meeting officer 4.3 Table 6 Training outlines Outlines for basic job skills Outlines for controlled management Outlines for HSE knowledge, methods and procedure tools 1. Pre-job preparation 1. Basic definitions 1. Basic definitions and explanations 2. Procedures (hazard identification and risk 2. Management process and requirements 2. Why promote? control) 3. Typical cases 3. How to implement effectively? 3. Emergency response and accident prevention 4. Cautions 4. Cautions and summary (cases) 1. The department in charge of training should fully play 2. As different enterprises have different organizations, a leading role in strengthening the compliance with the production techniques, equipment, facilities, alloca- enterprise’s overall human resource management poli- tions of posts and responsibilities, businesses and cies, unifying the management of output interfaces and activities, they have different requirements for job- effectively integrating various resources. related HSE competency. The generality of the HSE 123 568 Pet. Sci. (2017) 14:560–569 Carr JE, Nicolson AC, Higbee TS. Evaluation of a brief multiple- training matrices templates may not meet specific stimulus preference assessment in a naturalistic context. J Appl requirements. Therefore, as equipment, technologies Behav Anal. 2000;33:353–7. doi:10.1901/jaba.2000.33-353. and processes upgrade, the templates should be Falkenstein M, Gajewski PD, Michael F, Patrick DG. 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Petroleum Science – Springer Journals

Published: Jul 4, 2017

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