Risk management and HSE culture in construction of GEP

Risk Management and HSE Culture in
GEP
GASSCO HSE Summit 2014
A. Garayhi
Haugesund, 23.10.2014
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
Linde AG Engineering Division
2
DH / July 2013 / &AX-Q-WM 1005 (EN).ppt
Risk Management – Construction vs. Plant
Operation
Plant Operation
Construction
Fixed Locations
Changing Site Conditions
Large Quantities Processed
Flexible Application
Substance Hazards
Variety in Substances
Smaller Manning
Large Inhomogenous Team
Low Fluctuation
High Fluctuation
Many Routine Activities
Frequently Changing tasks
….
…
Linde AG Engineering Division
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Risk Management - Introduction
Safe Work Behaviour
Investigations of Incidents
Verification of Risks
Supervision of Work
PTW Co-ordination
Activities / Method Statements
Subcontractor Selection
Overall Subcontractiong Strategy
Risk Identification / Avoiding Risks
General Procedures, Golden Rules of Safety
Experience and General Know-how on Execution
Linde AG Engineering Division
4
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GEP – Incident Statistics
Total Incidents:
Total Observations:
Linde AG Engineering Division
70
903
DH / July 2013 / &AX-Q-WM 1005 (EN).ppt
Incidents Emden Project
Incident Classification
at Emden Project
LTI
3%
• LTI: Lost Time Incident
MTC
3 % FAC
6%
• MTC: Medical Treatment Case
• FAC: First Aid Case
NM
11 %
ENV
20 %
• NM: Near Miss
• UC: Unsafe Condition
• PD: Property Damage
• ENV: Environmental Damage
PD
20 %
UC
37 %
Linde AG Engineering Division
DH / July 2013 / &AX-Q-WM 1005 (EN).ppt
Potential Severe Injury or Fatality Incidents
SIF Incidents
Non-SIF
Incidents
90 %
at Emden Project
LTI
14%
SIF
10%
UC
86%
• Overall Number of SIF Incidents in Emden Project so far: 7 (2 incidents in 2013, 5 in 2014)
Linde AG Engineering Division
DH / July 2013 / &AX-Q-WM 1005 (EN).ppt
Linde Risk Management System
NO INCIDENT
3.
Implement &
check the safe
system of work
Safety Walks
Toolbox Talks
Audits
Supervision
HSE Inspections
Induction
Trainings
Incentives
Check of preconditions by permit issuer before permit is issued
Work Permit System
2.
Approve the safe
system of work
1.
Establish a safe
system of work
Special Work Permits
General
Work Permit
Risk Assessment
(generic, standard)
„Work Permits for
High Hazard Activities“
HSE Coordination
(e.g. coordination
plan, meetings)
LOW or MIDDLE Risk Activities
Linde AG Engineering Division
Job Safety Analysis
(specific, individual)
HIGH Risk Activities
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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
Linde AG Engineering Division
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Gassco Life-Saving Rules
• Work under a valid work
permit
• Conduct gas tests when
required
• Obtain authorization before
overriding or disabling
safety-critical equipment
• Verify isolation measures
before work begins and use
the specified protecting
equipment
• Obtain authorization before
entering a confined space
• Follow the prescribed lift plan
• Obtain authorization before
starting excavation activities
• Position yourself in a safe
zone in relation to moving and
energized equipment
• Prevent dropped objects
• Comply with all site-specific
traffic rules and regulations
• Protect yourself against a
fall when working at a
height
Linde AG Engineering Division
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Gassco Life-Saving Rules
?
Linde AG Engineering Division
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Gassco Life-Saving Rules
Obtain authorization before entering
a confined space
Linde AG Engineering Division
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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.
Linde AG Engineering Division
.
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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.
Linde AG Engineering Division
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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.
Linde AG Engineering Division
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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
Linde AG Engineering Division
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HSE Culture
Linde AG Engineering Division
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2013 - Linde's Safety Culture Elements at GEP:
Implementation Plan
No.
Action
A
General
A1
Posters of QHSE Policy, Golden Rules and Life Saving Rules
Lead /Site HSE
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
B6
Site HSE Booklet for all site personnel
Lead /Site HSE
Linde AG Engineering Division
Resp.
18
Implementation
Plan
Status
Done
On site until 26.11.2013
Done
Done
DH / July 2013 / &AX-Q-WM 1005 (EN).ppt
2013 - Linde's Safety Culture Elements at GEP:
Implementation Plan
No. Action
Resp.
Implementation Status
Plan
10.12.2013
C
Visible Leadership
C1
Lead Safe Training
Head/Lead HSE
C2
LUCAS implementation
Site Manager
Done
C3
Management Safety Walks
Site Manager
Done
C4
Open Safety Dialogue
Site Manager
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
Linde AG Engineering Division
19
Calendar week 50
Started and Continued
Started, negative
feedback from site
personnel
DH / July 2013 / &AX-Q-WM 1005 (EN).ppt
Next Step in Culture Development The Need for Behaviour Based Safety Concepts
Bradley Curve – Employee Behaviour
Reactive
• Safety by Natural
Instinct
• Compliance is the
Goal
• Delegated to Safety
Manager
• Lack of Management
Involvement
Linde AG Engineering Division
Dependent
• Management
Commitment
• Condition of
Employment
• Fear/Discipline
• Rules/Procedures
• Supervisor Control,
Emphasis, and Goals
• Value All People
• Training
Independent
• Personal Knowledge,
Commitment, and
Standards
• Internalization
• Personal Value
• Care for Self
• Practice, Habits
• Individual Recognition
Interdependent
•
•
•
•
•
Help Others Conform
Others’ Keeper
Networking Contributor
Care for Others
Organizational Pride
DH / July 2013 / &AX-Q-WM 1005 (EN).ppt
Next Step - The Linde Engineering
Behaviour Based Safety (BBS) Concept - BeSafe!
1.
BeSafe!
Trainings
6.
BeSafe!
Communi
-cation
2.
BeSafe!
Tools
BeSafe!
Concept
5.
BeSafe!
Behaviours
3.
BeSafe!
Programs
Performanc
e Award
4.
BeSafe!
Reports
Status July 2014
Linde AG Engineering Division
DH / &AX-Q-WM 1021 (EN)
DH / July 2013 / &AX-Q-WM 1005 (EN).ppt
Unsafe Act – Improper Rigging
Linde AG Engineering Division
22
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Unsafe Act – Man Under Lifted Load
Linde AG Engineering Division
23
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Property Damage – Fire in Kitchen
Linde AG Engineering Division
24
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Near Miss – Pipe Fell off its Support during
Transport
Linde AG Engineering Division
25
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Incidents Emden Project
Linde AG Engineering Division
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Incidents Emden Project
Linde AG Engineering Division
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SIF Incidents
Cause of SIF
at Emden Project
Electricity
14 %
Others
29 %
Stumble,
Slip, Fall
14 %
Fall from
height
14 %
Object of SIF
at Emden Project
Falling material
29 %
Others
14 %
Electr. Tool
14 %
Transport
Machines
(Forklift etc.)
29 %
Crane
29 %
Equipment, Pipe
14 %
Linde AG Engineering Division
DH / July 2013 / &AX-Q-WM 1005 (EN).ppt
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
Linde AG Engineering Division
DH / July 2013 / &AX-Q-WM 1005 (EN).ppt
Thank you
for your attention.

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