risk management and hse culture in gep gassco hse · pdf filelinde ag engineering division 3...
TRANSCRIPT
DH / July 2013 / &AX-Q-WM 1005 (EN).ppt Linde AG Engineering Division 2
Agenda
• Risk Management in EPC Projects
• Risk Management - Incident Statistics in GEP
• General Risk Management Methods used by Linde
• Life Saving Rules / Golden Rules of Safety
• HSE Culture – Follow-up of 2013 Program
• Selected GEP Incidents
• SIF Incidents
DH / July 2013 / &AX-Q-WM 1005 (EN).ppt Linde AG Engineering Division 3
Risk Management – Construction vs. Plant
Operation
Plant Operation
Fixed Locations
Large Quantities Processed
Substance Hazards
Smaller Manning
Low Fluctuation
Many Routine Activities
….
Construction
Changing Site Conditions
Flexible Application
Variety in Substances
Large Inhomogenous Team
High Fluctuation
Frequently Changing tasks
…
DH / July 2013 / &AX-Q-WM 1005 (EN).ppt Linde AG Engineering Division 4
Risk Management - Introduction
General Procedures, Golden Rules of Safety
Overall Subcontractiong Strategy
Risk Identification / Avoiding Risks
Subcontractor Selection
Activities / Method Statements
PTW Co-ordination
Supervision of Work
Verification of Risks
Investigations of Incidents
Experience and General Know-how on Execution
Safe Work Behaviour
DH / July 2013 / &AX-Q-WM 1005 (EN).ppt Linde AG Engineering Division
GEP – Incident Statistics
Total Incidents: 70
Total Observations: 903
DH / July 2013 / &AX-Q-WM 1005 (EN).ppt Linde AG Engineering Division
LTI 3 %
MTC 3 % FAC
6 %
NM 11 %
UC 37 %
PD 20 %
ENV 20 %
Incident Classification at Emden Project
Incidents Emden Project
• LTI: Lost Time Incident
• MTC: Medical Treatment Case
• FAC: First Aid Case
• NM: Near Miss
• UC: Unsafe Condition
• PD: Property Damage
• ENV: Environmental Damage
DH / July 2013 / &AX-Q-WM 1005 (EN).ppt Linde AG Engineering Division
Non-SIF Incidents
90 %
LTI 14%
UC 86%
SIF 10%
SIF Incidents at Emden Project
Potential Severe Injury or Fatality Incidents
• Overall Number of SIF Incidents in Emden Project so far: 7 (2 incidents in 2013, 5 in 2014)
DH / July 2013 / &AX-Q-WM 1005 (EN).ppt Linde AG Engineering Division 8
Linde Risk Management System
1.
Establish a safe
system of work
2.
Approve the safe
system of work
3.
Implement &
check the safe
system of work
LOW or MIDDLE Risk Activities HIGH Risk Activities
General
Work Permit
Safety Walks Toolbox Talks Audits Induction
Supervision HSE Inspections Trainings Incentives
NO INCIDENT
Risk Assessment
(generic, standard)
Job Safety Analysis
(specific, individual)
HSE Coordination
(e.g. coordination
plan, meetings)
Special Work Permits
„Work Permits for
High Hazard Activities“
Work Permit System
Check of preconditions by permit issuer before permit is issued
DH / July 2013 / &AX-Q-WM 1005 (EN).ppt Linde AG Engineering Division 9
Life Saving Rules / Golden Rules of Safety
• More then 80% of all incidents come from the violation of few simple rules
• High effort in implementation is justified by the high number of incidents
• Typical violations involve long term routine
• Avoid the "I just quickly …" mentality
• In the GEP project, both rule systems are mandatory by the HSE Program Site
• Compliance for Linde personnel is required for all job related activities, e.g.
defensive driving for commuting
DH / July 2013 / &AX-Q-WM 1005 (EN).ppt Linde AG Engineering Division 10
Gassco Life-Saving Rules
• Work under a valid work
permit
• Obtain authorization before
overriding or disabling
safety-critical equipment
• Obtain authorization before
entering a confined space
• Obtain authorization before
starting excavation activities
• Prevent dropped objects
• Protect yourself against a
fall when working at a
height
• Conduct gas tests when
required
• Verify isolation measures
before work begins and use
the specified protecting
equipment
• Follow the prescribed lift plan
• Position yourself in a safe
zone in relation to moving and
energized equipment
• Comply with all site-specific
traffic rules and regulations
DH / July 2013 / &AX-Q-WM 1005 (EN).ppt Linde AG Engineering Division 12
Gassco Life-Saving Rules
Obtain authorization before entering
a confined space
DH / July 2013 / &AX-Q-WM 1005 (EN).ppt Linde AG Engineering Division
Linde Approach -The Golden Rules of Safety
"Linde Engineering will avoid harm to people, society and the
environment while providing quality products and services to our
customers."
• Safety is one of our foundational principles which underpin our decisions, actions
and behaviours, as defined in The Linde Spirit. Our commitment to Safety is evident
in our QHSE Policy.
• The safety and health of our colleagues, customers, business partners and communities in
which we do business is our number one priority.
• Everyone who works for, or with, Linde is responsible for taking care for their own personal
safety and also for the safety of those around them. In addition, Line Managers have
specific responsibilities for employees and other people working under their direct
supervision.
• Every employee, contractor, or any other person involved with Linde (e.g. our customers,
neighbours and other third parties) should be able to go about their work or business
without being harmed.
. 13
DH / July 2013 / &AX-Q-WM 1005 (EN).ppt Linde AG Engineering Division
The Golden Rules of Safety
1. INCIDENT REPORTING:
We will report and investigate incidents so that the causes can be identified
and corrected, and learning shared.
2. DRIVING & VEHICLES:
We will operate our vehicles safely and responsibly at all times and use the safety equipment provided.
3. PERMIT TO WORK:
We will use the Permit to Work system where necessary to ensure hazards and risks are understood and controlled.
4. WORKING AT HEIGHT:
We will only work at height when the required safety measures to prevent falls are in place.
5. LIFTING OPERATIONS:
We will ensure lifting operations utilising cranes or other lifting devices are carried out safely.
6. CONTRACTOR MANAGEMENT:
We will select and manage our contractors so that they meet Linde Group’s safety requirements.
7. ENGINEERING MANAGEMENT OF CHANGE:
We will only proceed with technical changes to process plants and process equipment when an Engineering Management of Change process addressing the safety risks has been completed.
14
DH / July 2013 / &AX-Q-WM 1005 (EN).ppt Linde AG Engineering Division 15
Example – Driving & Vehicles
We will operate our vehicles safely and responsibly at all times and use the
safety equipment provided.
— We will operate our vehicles within the speed limit and at speeds that are safe for
the prevailing weather, traffic or road conditions.
— We will wear seatbelts in all seating positions at all times whilst the vehicle is
moving.
— We will not drive under the influence of alcohol or drugs.
— We will not drive when we are suffering from fatigue or tiredness.
— We will ensure that our vehicles are fit for purpose and in safe working order.
— We will ensure that our vehicles do not exceed manufacturer’s load specifications
and that loads are correctly secured.
DH / July 2013 / &AX-Q-WM 1005 (EN).ppt Linde AG Engineering Division 16
Example - Driving and Vehicles
- First training for all employees
- Defines driver requirements, vehicle requirements, pasenger requirements,
incident reporting
- Drivers need: Annual Driving Safety Training, Defensive Driving Training every
four years
- Vehicles need some technical safety standard in addition to legal requirtements
- Passengers shall inspect vehicle and driver prior to use
DH / July 2013 / &AX-Q-WM 1005 (EN).ppt Linde AG Engineering Division 18
2013 - Linde's Safety Culture Elements at GEP:
Implementation Plan
No. Action Resp. Implementation
Plan
Status
A General
A1 Posters of QHSE Policy, Golden Rules and Life Saving Rules Lead /Site HSE Done
A2 Train and implement SIF concept Lead /Site HSE Until 15.11.2013 Done
B Competence
B1 HSE in depth training (LE/contractor GEP site management ) Lead /Site HSE Ofa Found unsuitable Open
B2 Develop & implement comprehension checks (induction training) Lead /Site HSE Since cw 47 Done
B3 Monthly HSE topics
(Excavations & Trenches)
Lead /Site HSE Posters
B4 Golden Rules of Safety Stand Down (PTW) Site Manager Done
B5 Site HSE Manual for all site management personnel Lead /Site HSE On site until 26.11.2013 Done
B6 Site HSE Booklet for all site personnel Lead /Site HSE Done
DH / July 2013 / &AX-Q-WM 1005 (EN).ppt Linde AG Engineering Division 19
2013 - Linde's Safety Culture Elements at GEP:
Implementation Plan
No. Action Resp. Implementation
Plan
Status
C Visible Leadership
C1 Lead Safe Training Head/Lead HSE 10.12.2013 Started and Continued
C2 LUCAS implementation Site Manager Done
C3 Management Safety Walks Site Manager Done
C4 Open Safety Dialogue Site Manager Calendar week 50 Started, negative
feedback from site
personnel
C5 Toolbox Talks Contractors Done
C6 Safety Moments Proj/Site Mgr Done
C7 Monthly HSE&Q Coordination Meeting Project Mgr Done
C8 Weekly HSE meeting Site Manager Done
C9 Daily coordination meeting Site Manager Done
C10 Definition and reporting of KPIs Lead /Site HSE Calendar week 50 Done
D Behavioural Safety
D1 "Act Safe" Training (all construction personnel) Head/Lead HSE January 2014 Currently reviewed by
Linde Engineering HQ
D2 Peer reviews on worker level Contractors January 2014 Currently reviewed by
Linde Engineering HQ
D3 Safety Appreciation Scheme Site Manager January 2014 Started
DH / July 2013 / &AX-Q-WM 1005 (EN).ppt Linde AG Engineering Division
Next Step in Culture Development -
The Need for Behaviour Based Safety Concepts
• Management Commitment • Condition of Employment • Fear/Discipline • Rules/Procedures • Supervisor Control, Emphasis, and Goals • Value All People • Training
• Personal Knowledge, Commitment, and Standards • Internalization • Personal Value • Care for Self • Practice, Habits • Individual Recognition
• Help Others Conform • Others’ Keeper • Networking Contributor • Care for Others • Organizational Pride
Dependent Independent Reactive
• Safety by Natural Instinct
• Compliance is the Goal
• Delegated to Safety Manager
• Lack of Management Involvement
Interdependent
Bradley Curve – Employee Behaviour
DH / July 2013 / &AX-Q-WM 1005 (EN).ppt Linde AG Engineering Division
Next Step - The Linde Engineering
Behaviour Based Safety (BBS) Concept - BeSafe!
DH / &AX-Q-WM 1021 (EN) Status July 2014
BeSafe! Concept
1. BeSafe!
Trainings
2. BeSafe!
Tools
3. BeSafe!
Programs
4. BeSafe! Reports
5. BeSafe!
Performance Award
6. BeSafe!
Communi-cation
Behaviours
DH / July 2013 / &AX-Q-WM 1005 (EN).ppt Linde AG Engineering Division 22
Unsafe Act – Improper Rigging
DH / July 2013 / &AX-Q-WM 1005 (EN).ppt Linde AG Engineering Division 23
Unsafe Act – Man Under Lifted Load
DH / July 2013 / &AX-Q-WM 1005 (EN).ppt Linde AG Engineering Division 24
Property Damage – Fire in Kitchen
DH / July 2013 / &AX-Q-WM 1005 (EN).ppt Linde AG Engineering Division 25
Near Miss – Pipe Fell off its Support during
Transport
DH / July 2013 / &AX-Q-WM 1005 (EN).ppt Linde AG Engineering Division
Stumble, Slip, Fall
14 %
Fall from height 14 %
Falling material 29 %
Others 29 %
Electricity 14 %
Cause of SIF at Emden Project
Electr. Tool 14 %
Crane 29 %
Equipment, Pipe 14 %
Transport Machines
(Forklift etc.) 29 %
Others 14 %
Object of SIF at Emden Project
SIF Incidents
DH / July 2013 / &AX-Q-WM 1005 (EN).ppt Linde AG Engineering Division
SIF Incidents Emden Project
Date Classification Description Course Object Injury
01.10.2013 LTI On the road to the location, the truck got stuck. The
bulldozer driver tried to level the area in front of the
truck after a sign by the truck driver. During this
activity, the truck driver left his truck and walked round
the corner to the front of his truck and was hit by the
bulldozer
Others Transport
Machine
fracture
11.11.2013 UC A worker was hooking on a container without being
secured against falling from height. The used crane
hooks were bent and not inspected accordingly.
Fall from
height
Transport
Machine
01.03.2014 UC a 220V extension cable was found on site with the
plug lying in a water filled trip tray. The cable was
connected to the power supply.
Electricity Elec. Tool
11.03.2014 UC a repair employee was seen on top of a piling rig
standing on the parapet. He was secured with PPE
against falling from height.
Stumble,
Slip, Fall
Equipment,
Pipe
03.08.2014 UC A rigger was standing underneath the lifted load Falling
Material
Crane
04.09.2014 UC A wooden beam was rigged incorrectly, the center of
gravity was not observed
Falling
Material
Crane
09.09.2014 UC A worker entered the cable tunnel in Utility building to
remove the remaining water with a water vaccuum
cleaner. Requirements for confined space were not
followed.
Others Others