Health and Safety Executive

Work in major hazard industries

Introduction

3.1 Much of HSE's work is about the management of health and safety in high hazard industries and the control of major hazard events - the prevention of major incidents where the health and safety of many people, whether workers or members of the public, is affected.

3.2 The approach to regulation of major hazards is characterised by requiring the duty holder to identify the main hazards, the likelihood of them happening, and the measures in place to eliminate or control and mitigate them, setting these out in a report (often called a Safety Case). HSE evaluates the adequacy of these measures through assessment of the safety case or report and inspection. In the case of Offshore, Gas Conveyance in pipelines and Railways, the safety case has to be accepted by HSE prior to operations commencing at the major hazard sites. Should the safety case prove inadequate formal enforcement action may be invoked to prohibit the operation.

3.3 HSE has recently published a discussion document (DD) on regulating higher hazards. This explores the issues and principles underlying the legislative framework for major hazards as exemplified by the offshore, chemicals, rail and nuclear regimes. The DD had the objective of increasing transparency, stimulating discussion and seeking views on the approaches adopted. In light of the views submitted we will look again at the principles followed and consider if we need to review aspects of them.

3.4 The ultimate goal is to have no incidents with catastrophic effects. The rarity of major incidents in these industries highlights the importance of identifying proxy measures to provide assurance that risks are under control. HSE therefore needs to measure the frequency of events which might trigger a major hazard incident.

3.5 The sorts of measures which may be used include the frequency of incidents with the potential to escalate to major incidents eg signals passed at danger (SPADs) or RIDDOR dangerous occurrences such as hydrocarbon releases on offshore installations. More work is being done to refine these measures of initiating events.

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Railways

3.6 In 2001/02 and beyond, our work in seeking to secure improved standards of health and safety on the railways will be driven forward by a major review of working methods and by operational work targeted at the prevention of catastrophic failures and the improvement of compliance. In short, seeking, through duty holders, to ensure best practice is applied much more widely across the industry. Our activities will be facilitated by a further expansion in the size of the Railway Inspectorate, to around 200 staff in post, and improved targeting of resources based on better intelligence concerning the operation of the railway system. This expansion will place considerable demands upon HSE in terms of ensuring that arrangements for management, training and development are in place.

3.7 HSE will play its full part in current initiatives to improve the operation of the railways being taken forward by the Strategic Rail Authority (SRA) and the Office of the Rail Regulator (ORR). Both these organisations are required by legislation to consult HSE on safety aspects of their work. Memoranda of Understanding (MoU) between the three organisations have been developed to ensure good communications. For example, the SRA has consulted HSE on re-franchising proposals and the ORR consults HSE on its periodic reviews on charging arrangements within the industry. HSE will also be taking forward major initiatives on trespass and vandalism and, jointly with the Department for Education and Skills (DfES) and the SRA, on the improvement of arrangements to secure competent and skilled staff within the railway industry. In taking forward these initiatives HSE will remain mindful of its duty to use the law to secure good practice within the context of what is reasonably practicable.

3.8 The railway industry is currently undergoing a considerable period of development and our plans will have to be reviewed in the light of several factors:

  • the Government's 2010 Transport Plan which seeks a major increase in both passenger and rail usage;
  • the creation of the SRA, which is commencing a major refranchising programme;
  • the conclusions of the two public inquiries established by the HSC following the Ladbroke Grove disaster in October 1999. The Ladbroke Grove Rail Inquiry, which looked at the immediate factors surrounding the disaster and wider safety management issues within the industry, and the Joint Inquiry into train protection systems chaired by Professor Uff and Lord Cullen. Reports are expected during 2001; and
  • the need to implement European Directives on interoperability (through running of trains across national borders) which will have consequences for our initial integrity work and train protection systems.

3.9 Four particular themes under which our work will be driven forward are:

  • prevention of catastrophic failures;
  • improving health and safety of those working on or using the railways;
  • policy and strategic development work; and changing attitudes:
  • improving the safety culture in the industry.

3.10 We will be working with stakeholders to set baselines, agree monitoring procedures and targets for the outcomes in each of the themes.

Prevention of catastrophic failures

Train Protection strategy

3.11 Work will include:

  • monitoring of industry programmes for fitment of Train Protection and Warning System equipment; and
  • development of a major industry/HSE working group to review arrangements for the train protection systems generally, including the impact of the conclusions of the Joint Inquiry into Train Protection Systems and relevant European Directives.

Outcome

Establishment of a national train protection strategy with targets for reducing the consequences of SPADs including the development of regulations if appropriate.

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Securing compliance through the New Railway Safety Case Regime

3.12 Following the introduction of the new Railway (Safety Case) Regulations 2000, HSE will take forward a programme for assessing new and revised safety cases for compliance with the new regulations, and an inspection programme of key issues to check duty holders' compliance with their accepted safety cases. We will engage with duty holders and other stakeholders to:

  • develop new field procedures for assessment, acceptance and for planning subsequent interventions;
  • assess each safety case to the extent necessary to ensure that the requirements of the regulations are met, in particular seeking improvements in risk assessment and its effective linkage to management arrangements and control;
  • assess all documents submitted under the regulations;
  • undertake targeted planned inspections of railway operations to validate compliance with selected key aspects of accepted safety cases;
  • consider Audit Reports from Railway Safety (a Railtrack subsidiary company who will be required to submit assessment of railways safety cases to HSE); and
  • consider enforcement action to secure compliance where necessary.

Outcome

More meaningful, measurable and usable safety cases from the railway industry, and better compliance with the railway safety cases.

Initial integrity (safe by design) of new and altered works

3.13 The aim is to ensure that duty holders have processes and standards in place for the introduction of new and altered railway works, plant, and equipment that is safe, reduces risks and protects people. Also that such works are delivered to these standards. HSE will seek the above assurance through the administration of statutory obligations in respect of 'Approval' under the Railways and Other Transport Systems (Approval of Works, Plant and Equipment Regulations) 1994 (ROTS). The future of this work will be reviewed in the light of the HSC's discussion exercise on permissioning regimes and the introduction of legislation implementing European Directives.

Outcome

Assessment of approximately 400 to 500 schemes including Thameslink 2000, Channel Tunnel Rail Link, West Coast Main Line, the East London Line of London Underground, Virgin Cross Country and West Coast new trains. Most of these will be subject to staged and final inspection before qualifying for approval.

Improving the health and safety of those working on or using the railways

3.14 A risk based inspection programme to monitor compliance with health and safety legislation will be implemented which will be based on information received under the new safety case regime. Field inspectors will undertake a substantial programme of work, targeting resources to greatest advantage. The objectives will include reductions in incidents, injuries (to passengers, workers and other members of the public) and to promote best practice. The programme will include:

  • a joint industry campaign seeking to prevent trespass and vandalism including further development of the poster, video and school visit campaign begun in 1999, and co-ordinated by, the HSC's Rail Industry Advisory Committee (RIAC).

Outcome

Enhanced awareness among school age children of the dangers of trespass and vandalism and a consequent reduction in related accidents and incidents.

  • monitoring arrangements for maintaining the infrastructure, including track, signalling, embankments, tunnels and structures.

Outcome

To ensure the industry has an appropriate maintenance regime to secure safety of the infrastructure.

  • on London Underground in particular, inspecting the arrangements for ensuring passenger safety at the platform to train interface.

Outcome

A reduction in the number of accidents to passengers whilst boarding and alighting from trains.

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Policy and strategic development

3.15 Major reports setting out a range of fundamental recommendations have been, or are in the process of being, prepared and published, and the HSC will be taking forward action, in conjunction with Government, the other railway regulatory bodies and the industry. Over the next three years we will:

  • monitor the implementation by industry of the recommendations of Professor Uff's report on the Southall train accident;
  • receive Lord Cullen's two reports on the Ladbroke Grove accident and safety management in the industry and the Joint Inquiry into Train Protection Systems, study and assimilate their recommendations and develop plans on how to take them forward; and
  • develop a data-base of all accident inquiry recommendations as a means to monitor progress.

3.16 Health and safety policy issues relating to the railways are not viewed in isolation from the similar issues that arise in respect of other transport modes. We are working to ensure that so far as possible a consistent approach is taken, thus assisting wider Government policy on transport issues. We thus take forward within an integrated organisational structure policy on occupational aspects of road safety, marine safety, aviation safety and railway safety. We seek to align our general policy approach with that of relevant Government Departments and other regulatory bodies, including the Civil Aviation Authority (CAA), Maritime and Coastguard Agency (MCA), ORR and SRA.

Outcome

Development of action plans based on the railway safety reports by Professor Uff and Lord Cullen.

3.17 RIAC is currently the most broadly representative body within the industry involving operator, unions and passenger representatives. The HSC is currently reviewing the operation of its advisory committees and will consider ways of enhancing the operation of RIAC.

Outcome

Improved working methods within RIAC.

Changing attitudes: improving the safety culture

3.18 Developing the competence of those working within the railway industry is a key challenge for the next few years. The HSE will work closely with SRA, DfES, the Railway Industry Training Council and industry stakeholders to develop appropriate plans and schemes of competency assessment. We will also review the operation of the Railways (Safety Critical Work) Regulations 1994.

Outcome

Increased numbers of railway workers holding relevant National Vocational Qualifications (NVQ) or assessed against appropriate schemes.

Gas Conveyance and on shore major hazard pipelines

3.19 The Gas Safety (Management) Regulations (GSMR) aims, by a safety case permissioning regime, to ensure the integrity of the gas distribution network and ensuring emergency arrangements are in place to deal with a major gas leak. HSE assess the safety of major hazard pipelines by examining their design and integrity under the Pipeline Safety Regulations.

Control of Major Accident Hazards Regulations (COMAH)

3.20 COMAH was introduced on 1 April 1999 and aims to prevent and mitigate major chemical accidents which could harm people and the environment. It is enforced by the HSE and the Environment Agency (EA) in England and Wales and HSE and the Scottish Environmental Protection Agency (SEPA) in Scotland, acting jointly as the Competent Authority (CA). The CA has a statutory duty to:

  • assess safety reports within a set time and convey their conclusions to operators;
  • prohibit operations if there are serious deficiencies in the measures to prevent or mitigate the consequences of a major incident;
  • investigate major accidents; and
  • establish an inspection programme for all COMAH establishments.

3.21 Over the last ten years there have been 50 major accidents at establishments now covered by COMAH. Of these, six involved death or serious injuries to workers, 14 less serious injuries to employees, and four injuries to people off-site. The number is expected to rise because of the extended scope of COMAH and the inclusion of accidents to the environment. The occurrence of near miss serious incidents is much higher and it is largely a matter of chance whether they result in injury.

3.22 There are currently 450 top tier sites and 1200 lower tier sites. More establishments will be brought into scope with the full application of COMAH to explosives and the extension of the dangerous classification to other substances. The priority for the next three years is to implement and enforce COMAH working effectively with the constituent parts of the CA. The work we plan to do will include:

  • assessment of safety reports for top tier COMAH sites;
  • the review and use of major accident protection policies for lower tier sites; review site emergency plans;
  • review land use planning policy and procedures for LA consultation about developments around major hazard sites; and
  • verification Inspections to reconcile claims made in safety reports with the conditions which exist on site.

Target

By 2004 a reduction of 20% in RIDDOR dangerous occurrences and COMAH Regulation 21 major accidents (accident of sufficient seriousness to require notification to the European Commission).

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Occupied buildings

3.23 A key programme will be carried out to improve the siting and design of occupied buildings on major hazard sites. This is to ensure:

  • that workers are not placed at any greater risk from site hazards by virtue of their having to occupy buildings on site, and to safeguard plant shut down in the event of an emergency; and
  • on explosive sites, to develop and implement standards for the design and location of occupied buildings within safe separation distances.

3.24 We will assess the design and location of occupied buildings at approximately 300 top tier COMAH establishments for compliance with the Chemical Industries Association guidance.

Target

By 2005 all occupied buildings to comply with Chemical Industry Association guidance on the design of occupied buildings for chemical manufacturing sites.

3.25 At licensed explosives sites distances between process and storage buildings in explosives factories are set out in the licence. But there are many instances of 'remote' operation when workers are located in, for example, an annex or compartment within the licence distance. There are no standards for the construction and location of such places and there have been explosions resulting in injuries to workers.

3.26 In consultation with the Explosives Industries Forum, we will carry out a survey of all buildings to identify those to be targeted, site licensees will be required to provide a risk assessment within an agreed time. standards will be set and a model for assessment developed, a programme of improvements will be agreed with industry, and guidance on standards of construction, distances and mitigatory features will be produced. This will reduce the risk to approximately 200 workers to an extent where there is a negligible risk of serious injury.

Target

To reduce the risk of serious injury to 10-30% of workers in remote operations.

Mining industry

3.27 Mining legislation requires an on-going commitment by HSE to ensure health and safety in mining and associated activities. Failure to properly control the coal mine environment can result in high consequence incidents. This is a key area of the management of risk in mines. We will undertake a programme of 400 planned inspections at large coal mines which includes investigation into the effectiveness of the control of risks from explosive dusts and gases. All reportable fire or ignition incidents will be investigated.

3.28 Other key programmes of work include:

  • assessment of musculoskeletal disorders (under the priority programme); and
  • control of respirable dust to prevent pneumoconiosis (see table 4.2)

Offshore industry

3.29 Major offshore initiatives to be carried out include:

  • Management of offshore process integrity - a three year programme to give greater emphasis to process integrity in order to reduce hydrocarbon escapes. This is a combined programme of process inspections and investigation of reportable releases. A report will be published this year identifying root causes and a continuing campaign to raise awareness amongst duty holders.

Target

By 31 March 2004 a 50% reduction in major and significant releases against a baseline of 139 major and significant releases.

  • Safety standards in floating production, storage and offtake installations operations (FPSO) - There are significant hazards involved in FPSO operations, including collision between production installations and vessels (eg storage or offtake vessels). This programme is designed to encourage the reduction in loss of station keeping events, one of the main initiating events, currently standing at seven per shuttle tanker per year. The programme will be delivered through a combination of specialist inspections and dissemination of good practice. The main focus will be on the management of FPSO operations.

Target

25% reduction in shuttle tanker loss of station keeping events by 2004.

  • Incorporation of health and safety in design - a three year programme focused on the design stages of major offshore projects. This will be achieved by HSE intervention, through the safety case assessment process at the design and construction stage and inspection of major new design, construction and modification projects.

Target

To improve management of safety in design, leading to 10% reduction in adverse findings in the assessment of design safety cases.

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Nuclear industry

3.30 HSE is responsible for regulation, through licensing, of the nuclear industry to ensure protection of the public and workers. The nuclear industry continues to present fresh challenges to effective regulation, particularly through the ageing of plant, the shift towards decommissioning and waste management programmes, the impact of electricity market reforms, and HSE's increasing responsibilities relating to Ministry of Defence (MOD) sites. HSE have authorised an increase in Nuclear Installations Inspectorate's (NII) complement, from 159 to 179 inspectors, to respond to these and other demands. We will work with others and seek advice from Nuclear Safety Advisory Committee (NuSAC), as necessary, on the implications of these trends for the effective working of the nuclear licensing regime.

3.31 Under the nuclear licensing regime inspectors will continue to inspect all 40 licensed nuclear sites in Great Britain to monitor compliance with all of the 36 nuclear licence conditions which includes the safety cases for operation of the sites.

3.32 HSE will continue to apply resources to carrying out enforcement responsibilities including the control of design, construction and commissioning of new plants and major modifications.

3.33 Our top priority will be to ensure that operating nuclear installations and those undergoing decommissioning, are operated, maintained and dismantled in a way which minimises the risks to workers and the public so far as reasonably practicable.

3.34 We will continue to support international nuclear safety initiatives. Following the entry into force of the Joint Convention on the Safety of Spent Fuel and Safety of radioactive waste (for which the UK's ratification is impending) HSE will complete the UK report on compliance. HSE will also assist DTI in completing the second national report on compliance with the Convention on Nuclear Safety. We are currently looking at best practice in the nuclear industry and other nuclear regulators in order to develop performance indicators which will demonstrate whether risks are being adequately managed in the nuclear sector.

3.35 We will continue to deliver, in conjunction with nuclear operators, an agreed programme of nuclear safety research.

3.36 Key programmes of work over the next three years include:

  • work with all relevant stakeholders and NuSAC to consider issues arising from DTI's Quinquennial Review of the United Kingdom Atomic Energy Authority (UKAEA);
  • consider actions needed to ensure adequate education and skills provision for the industry of the future;
  • the strengthening of effective co-operation with the EA and SEPA;
  • work to develop synergies, following agreement of an MoU with DTI's Office for Civil Nuclear Security; while assisting DTI to modernise the security legislative framework using health and safety regulations;
  • regulation of British Energy's proposal to make more effective use of its resources to operate their Scottish and English power stations;
  • regulation of the construction and commissioning of the nuclear submarine refuelling facilities at Devonport to ensure UK's strategic defence capability, in parallel with MOD's plans;
  • dealing with issues concerning decommissioning and radioactive waste management, including the Quinquennial Reviews of licensees' decommissioning strategies;
  • a programme of team and augmented inspections;
  • 37 periodic safety reviews at nuclear chemical plants;
  • review and assessment of some 37 Special Hazard Assessments under Ionising Radiation Regulations for nuclear submarine systems and facilities;
  • carry out an agreed programme of UK nuclear emergency exercises;
  • re-licensing of the merged Magnox Electric and British Nuclear Fuels Limited (BNFL) - by 31 May 2001;
  • regulation of the performance of the new licensee at Atomic Weapons Establishment (AWE) plc, and reporting to Ministers by 31 May 2001;
  • assessment of the strategy of high level liquid waste storage at Sellafield by 31 August 2001;
  • closing out of the findings of the safety audit of Dounreay by 28 September 2001 and of British Energy by 31 March 2002;
  • introduction of refined inspection programme to give indication of individual licensee performance by 31 March 2001;
  • monitor and review BNFL's programme for emptying its highly active liquid waste (HAL) tanks and increasing its vitrification capacity by 30 April 2002;
  • closing out findings of team inspections into Sellafield control and supervision by 31 December 2002;
  • to complete assessment of the Pre-construction Safety Report for the Dounreay Sodium and Potassium Disposal Plant by 31 December 2002;
  • the active commissioning of the Trident nuclear submarine facilities at Devonport by 31 March 2002; and
  • to have agreed criteria in place to allow permissioning to commence the delicensing of all, or part, of Rosyth Dockyard by 31 March 2004.

Outcome

The maintenance and improvement of safety standards at nuclear installations so as to prevent a major nuclear accident and to protect workers and the public from unnecessary exposure to ionising radiations.

Table 3.1 Selected outputs

  1999/00
outturn
(reference)
2000/01
plan
(reference)
2001/02
plan
2002/03
plan
2003/04
plan
Railways
'new' and revised safety cases
- - 237 218 201
Offshore
assessment of safety cases
121 170 124 124 124
Nuclear
nuclear licence actions
385 380 380 380 380
Onshore (chemicals, gas, explosives)
assessment of safety cases
185 100 277 90 25

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Updated 01.06.09