Risk Management and HSE Culture in GEP GASSCO HSE · PDF fileLinde AG Engineering Division 3...

Risk Management and HSE Culture in

GEP

GASSCO HSE Summit 2014

A. Garayhi

Haugesund, 23.10.2014

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


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

…


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


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


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)


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


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


Gassco Life-Saving Rules

• Work under a valid work

permit

• Obtain authorization before

overriding or disabling

safety-critical equipment


entering a confined space


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



?



Obtain authorization before entering

a confined space


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


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


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.


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


HSE Culture


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


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


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


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


Unsafe Act – Improper Rigging


Unsafe Act – Man Under Lifted Load


Property Damage – Fire in Kitchen


Near Miss – Pipe Fell off its Support during

Transport


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


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

Thank you

for your attention.

Risk Management and HSE Culture in GEP GASSCO HSE · PDF fileLinde AG Engineering Division 3...

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