mechanical training

8/13/2019 Mechanical Training

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MECHANICAL TRAINING

Robert Shisoka

Hydrocarbon Management Consultancy


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MECHANICAL TRAININGOverview

Group Introduction

House Rules

SafetyActivities Introduction

Aim

Factors Affecting Workplace Safety

Principles of Management

Accident Ratio Concept of Reducing Unsafe Acts

4 Sources of Accidents & Incidents

Incidents

Immediate Causes

Basic Causes Lack of Control

Cost of Accidents

Summary

Advice

Q & A


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GROUP INTRODUCTION

Briefly Describe:

Who You Are

Experience in Petroleum Industry

What You Hope to Get Out of This Course

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HOUSE RULES

Fire Alarm, Exists/Emergency Procedures

Welfare

Breaks & Refreshments

Mobile Phones (Please Switch Off)

Smoking

Wrap Up

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SAFETY IS FOR EVERYBODY, EVERYDAY, IN

EVERYWAY, ALL THE TIME!

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INTRODUCTION

Who is a Contractor ?

Someone Brought in by OMC as Client, toWork at OMC Premises , e.g.:

Maintenance & Repairs

Construction

Installation of Equipment

Catering

Cleaning

Security Measurement/Surveying

Not Employees or Temporary Employees

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CATEGORIES

Principle Contractor

The Person or Business Who has DirectBenefit from All the Work Done at a Site onCompletion.

Contractor

A Person Who is a Self-Employed Personand/or Employee of that Person Who isEngaged for Work on a Work Site by theMain Contractor.

Sub-contractor A Person Who is a Self-employed Person

and/or Employee of that Person Who isEngaged for Work on a Work Site by the

Contractor.

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Maintenance & Repairs

Construction

Installation of Equipment Catering

Cleaning

Security

Measurement/Surveying

Not Employees or Temporary Employees

TYPES OF CONTRACTORS

Different Types of Contractor Short Term - One Off For a Particular Task.

Short Term - Repetitive For a Recurring Tasksuch as Window Cleaning.

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Medium Term Such as to CarryOut a Small

Refurbishment or Maintenance Task Long Term Continuing Function

such as Catering orSecurity.

CONTRACTOR RESPONSIBILITIES Compliance with OSHA 2007.

Compliance with OMC Policies, Procedures &Standards.

Ensure Sub Contractors: Are Inducted to the OMC Site/Project.

Are Inducted into Applicable Safety Systems.

Maintain Qualifications/ Certifications

Appropriate to Their Functions.

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Plant & Equipment Conforms with StatutoryRequirements & OMC Policies, Procedures &

Standards.INTRODUCTION TO SAFETY CONCEPTS

ATTITUDES

What Affects Our Attitude?

Macho Image Fear of Failure

Fear of Recrimination

Lack of Understanding

Dangers or Consequences

Inappropriate Reward Systems

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FACTORS AFFECTING WORKPLACE SAFETY

Many Factors Affect Way Companies &

Contractors Look at Health, Safety & Environmentin the Oil & Gas Industry

Some of the Factors Include:

Customers

Technology Workplace Changes

Laws

Management Attitude

Traffic Equipment

Standards

Staff

Procedures

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PRINCIPLES OF MANAGEMENT

Planning

Organizing Leading

Controlling

SAFETY

Control of Accidental Loss

ACCIDENT

Undesired Event Results in Harm to People,Damage to Property or Loss to Process orOperation

INCIDENT

Undesired Event, Could or Does Result in Loss

COMMON MISCONCEPTION

Accidents Cant be Prevented

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Analysis has Shown: Most Incidents Occur Because of PEOPLEFailures.

Underlying Causes of People Failures:

Lack of Compliance to Procedures/Standards

Difficult to Move Away from Established Practices

Different Mind-set/Expectations Towards HSE Standards

HSE Not Always Right Priority

FACTAccidents & Incidents Dont Just Happen

They are CausedMANAGING CONTRACTORS

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Business Improvement Reviews Revealed:

Lack of Leadership to Motivate Development Needed on Front Line Supervisors

On Shop Floor: From Do Persons to Coachers.

More Work Needed on Human Factors

HSEManagement Audits

Risk Management Not Clear on Shop Floor

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ACCIDENT RATIO

RESULT

CONTROL

FIRST AID CASE

NEAR-MISSPROPERTYDAMAGE

UNSAFE ACT/CONDITION

FATALITY

LOST TIMEINJURY LTI

RESTRICTEDWORK/MEDICAL

TREATMENT

MANAGEMENT

NOTE: TOP FIVEARE MEASURES OFOUR FAILURES.THEY ARE AFTERTHE FACT.

CONSEQUENCES 1

10

20

30

25

600

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TYPICAL SITE HAZARDS

Dangerous Goods

ExcavationsMobile Plant

Overhead Power-linesFalls from Heights

Underground Services

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OMC AIM IN CONTRACTOR SAFETY

No Harm on Health, No Property Damage or

Loss on OMC or Contractor Side

Continuous Reinforcement, Change inAttitudes/PerceptionsProviding Guidelines & Techniques forObserving & Correcting Unsafe Acts &Conditions

Consistent Message that Safety is a Priorityto the OrganizationUnsafe Acts &Conditions Will Not be ToleratedLeadingby ExamplesManagement CommitmentsOvercome a

Safety is Not My Responsibility MentalitySafety Leadership by SupervisorsTurn aNegative Situation into a Positive LearningExperience

ZERO INCIDENTS

CULTURAL CHANGE

STRATEGY

LETS DO IT IN A DIFFERENT (SAFER) WAY

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CONTRACTOR HSE MANAGEMENT - MISSION

Connecting

Build Meaningful Relationships with Contractors

Assessing

Appraisal & Monitoring to Verify that Contractorsare Aligned with OMCs HSE-MS & Expectations

to Achieve Goal Zero

Improving Increase Influence, Expectations & Performance

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CONTRACTOR SAFETY vs. PROCESS SAFETY MANAGEMENT

1.Contractor SelectionPre-qualification

2.Contract Preparation

3.Contract Award

4.Orientation & Training

5.Monitoring & Auditing

6.Post-ContractEvaluation

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4 SOURCES OF ACCIDENTS & INCIDENTS

MATERIAL

ENVIRONMENT

EQUIPMENT PEOPLE

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PEOPLE

Acts & Omissions Lack of Training

Both Management & Staff

Provide Human Element

EQUIPMENT

Often Blamed

Normally Relates to Incorrect Use or Maintenance

MATERIAL

Too Hot

Too Cold

Toxic

Caustic

Acidic

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ENVIRONMENT

Lighting Climate

Weather

Security

LOSS

PERSONAL HARM PROPERTY DAMAGE PROCESS LOSS

Major Injury Catastrophic Catastrophic

Major Illness Major Major

Serious Injury Serious Serious

Serious Illness Minor Minor

Minor Injury

Minor Illness

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WHAT CAN GO WRONG?

WHAT CAN CAUSE IT?

WHAT CAN WE DO TO PREVENT?

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BACKGROUND

Each Step Builds on Previous StepAll are Necessary for Safety Working

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COST OF ACCIDENTS

Injury & Illness Costs

Medical

Compensation Costs (Insured Costs)

Property Damage (Uninsured Costs)

Building Damage

Tool and Equipment Damage

Product & Material Damage

Production Delays and Interruptions

Legal Expenses

Expenditure on Emergency Supplies

Interim Equipment Rentals

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Miscellaneous Costs (Uninsured Costs)

Investigation Time

Wages Paid for Lost Time

Cost of Hiring & Training Replacement staff

Overtime

Extra Supervisory Time

Clerical Time

Loss of Business & Goodwill

OIL INDUSTRY TRAINING CONCERNS

Operators have Not Been Consistent withTraining Requirements.

Significant Number of RCAs have Lack ofTraining Listed as a Near Root Cause.

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Contractor High Turnover Rate CreatingAdditional Cost to Contractors & OMCs Due to

Retraining. Level Playing Field.

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BEHAVIROL PROGRAM DEVELOPMENT


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BEHAVIROL PROGRAM DEVELOPMENT

JobHazard

Analysis Workplans

Trends/Benchmarking

ViolationSurvey

Hazardous SituationUnsafe Act reporting

Audits

Reviews

Incident InvestigationIncident Reporting

Contract/

ContractorManagement

CompetencyPrograms

Permit to

Work System

HSE SelfAppraisal

Site Visits

ObservationTechniques

HSE Standards& Procedures

HEMPTools

HSEMS IN PLACE.

HEARTS & MINDS Bring HSE MS TO LIFE & BEYOND


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HEARTS & MINDS - Bring HSE MS TO LIFE & BEYOND

Manage the System Lead the Culture

x

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We Understand& Accept WhatShould be Done& Know What is

Expected of Us

We Work Safely Because We are Motivated

To Do the Right Things Naturally, Not JustBecause We are Told To. We Want to MakeInterventions & Actively Participate inImprovement Activities.

We Understand& Accept Thereis a Fair Systemfor Reward &Discipline

3 KEY ELEMENTS OF ROADMAP FOR BEHAVIROL & CULTURAL CHANGE

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LIFE SAVING RULES


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LIFE SAVING RULES

Work with aValid WorkPermit WhenRequired

Conduct GasTests WhenRequired

Verify IsolationBefore WorkBegins & Use theSpecified Life

ProtectingEquipment

ObtainAuthorizationBeforeEntering a

ConfinedSpace

ObtainAuthorizationBefore Overridingor Disabling

Safety CriticalEquipment

Protect YourselfAgainst a FallWhen Workingat Height

Do Not WalkUnder aSuspendedLoad

Do Not SmokeOutsideDesignatedSmoking Areas

No Alcohol orDrugs WhileWorking orDriving

Wear YourSeat Belt

While Driving, doNot Use YourPhone & Do NotExceed SpeedLimits

Follow PrescribedJourney ManagemenPlan

1

7

2

8

3 5

11

6

129 10

4

HAZARD IDENTIFICATION


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HAZARD IDENTIFICATION

Job Safety Analysis is a Process to:

1. Document Each Stepof a Job

2. ID Specific Existing/Potential Hazards &Risks of Each Step

3. Determine Best Meansto SpecificallyEliminate or ControlHazards/Risks

4. Document WorkersResponsibilities

5. Communicate to AllWorkers the Following: Job Tasks Job Hazards Job Controls Individual

Responsibilities

HEALTH


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HEALTH

Hazard Communication HAZCOM/MSDS Program

Purpose of Program is to Ensure that All KnownPotential Hazards at the Workplace are Communicatedto All Employees

Compliance Includes:

Container Labeling Maintaining MSDS

Workplace Chemical Inventory Employee Information & Training

Concerning Hazards & Controls for SafeProduct Handling

CONTRACTORS


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THE BASICS

Contractors ShouldKnow:

The Premises

Routines & WorkPatterns

Risks Arising fromPremises & Work

CONTRACTORS

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Contractor Should Know:

Risks Arising from His/HerOwn Activities

How to Control Those Risks

Capabilities & Skills ofHis/Her Employees

Capabilities & Skills ofHis/her Subcontractors

CONTRACTORS

CONTRACTORS


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THE LAW

Employment Act 2007

Occupational Safety &

Health Act 2007

Work Injury Benefits Act2007

Energy Act 2006

Provide Good Framework

CONTRACTORS

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SUMMARY

Attitude and Awareness

P.O.L.C.Planning, Organizing, Leading,Controlling

P.E.ME.People, Equipment, Materials,Environment

Loss Causation Model Lack of Control Basic Cause Immediate

Cause

Loss Incident

Safety Integral Part of Work Environment

Safety Saves Money and Lives

Safety Management is Corporate Value

Participation of Everyone Essential

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WHILE RISKS EXIST:

Accidents and Injuries are Preventable

Each of Us has Personal Responsibility for Our

Safety and Safety of Others On and Off the Job.

SUMMARY

No Business Objective so Important that It Willbe Pursued at Sacrifice of Safety.

Safe Conduct of Operations Condition of

Employment.

A Job is Well Done Only if It is Done Safely.

Contractor Should have Best Safety Performance

in Oil Industry.

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EMPLOYEES MUST:

Follow Company Basic Safety Principles

TOWARDS ZERO. Is the Condition to Which Risks are Managed to

Acceptable Levels

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WHAT ARE OIL COMPANIES LOOKING FOR?

Long-term Business Opportunities with

Contractors Reduction of Total Cost of Operations

Best Combination of Health, Safety &Environment Performance, Service, Cost &

Inventory Management Capability to Comply with Regulatory & Other

Requirements

FACTORS INCLUDE

Cost Competitiveness Support Capabilities

Operating Procedures

Best Practices

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DELIVERABLES

Highly Qualified & Industry Leading Contractor

Transfer of Industry Best PracticesHSE MANAGEMENT SYSTEMContractors Without Effective Management ofHSE Cannot Succeed

Execution of HSE is a Line ManagementResponsibility

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ANY QUESTIONS?

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