MECHANICAL TRAINING

Robert Shisoka
Hydrocarbon Management Consultancy

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Overview
Group Introduction House Rules Safety Activities 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, to Work 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 Direct Benefit from All the Work Done at a Site on Completion. Contractor A Person Who is a Self-Employed Person and/or Employee of that Person Who is Engaged for Work on a Work Site by the Main Contractor. Sub-contractor A Person Who is a Self-employed Person and/or Employee of that Person Who is Engaged 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 Task such as Window Cleaning.

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Such as to Carry Out a Small Refurbishment or Maintenance Task Long Term Continuing Function such as Catering or Security. 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.

Medium Term

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Plant & Equipment Conforms with Statutory
Requirements & 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 & Environment in 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 or Operation INCIDENT Undesired Event, Could or Does Result in Loss COMMON MISCONCEPTION Accidents Cant be Prevented

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FACT Accidents & Incidents Dont Just Happen They are Caused MANAGING CONTRACTORS
Analysis has Shown: Most Incidents Occur Because of PEOPLE Failures. 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
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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

HSE Management Audits Risk Management Not Clear on Shop Floor

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ACCIDENT RATIO
CONSEQUENCES
FATALITY LOST TIME INJURY LTI RESTRICTED WORK/MEDICAL TREATMENT FIRST AID CASE

1
10
20 25

NOTE: TOP FIVE ARE MEASURES OF OUR FAILURES. THEY ARE AFTER THE FACT.

NEAR-MISS

PROPERTY DAMAGE

30 600

RESULT

UNSAFE ACT/CONDITION

CONTROL

MANAGEMENT

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TYPICAL SITE HAZARDS

Falls from Heights

Dangerous Goods

Overhead Power-lines

Underground Services

Mobile Plant

Excavations

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OMC AIM IN CONTRACTOR SAFETY
ZERO INCIDENTS

No Harm on Health, No Property Damage or Loss on OMC or Contractor Side Continuous Reinforcement, Change in Attitudes/Perceptions Providing Guidelines & Techniques for Observing & Correcting Unsafe Acts & Conditions Consistent Message that Safety is a Priority to the Organization Unsafe Acts & Conditions Will Not be Tolerated Leading by Examples Management Commitments Overcome a Safety is Not My Responsibility Mentality Safety Leadership by Supervisors Turn a Negative Situation into a Positive Learning Experience

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 Contractors are 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 Selection Pre-qualification

2.Contract Preparation 3.Contract Award

4.Orientation & Training

5.Monitoring & Auditing 6.Post-Contract Evaluation

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4 SOURCES OF ACCIDENTS & INCIDENTS

ENVIRONMENT EQUIPMENT

PEOPLE

MATERIAL

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4 SOURCES OF ACCIDENTS & INCIDENTS
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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4 SOURCES OF ACCIDENTS & INCIDENTS
ENVIRONMENT Lighting Climate Weather Security LOSS PERSONAL HARM Major Injury Major Illness Serious Injury Serious Illness Minor Injury Minor Illness

PROPERTY DAMAGE Catastrophic Major Serious Minor

PROCESS LOSS Catastrophic Major Serious Minor

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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 Step All 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 with Training Requirements. Significant Number of RCAs have Lack of Training Listed as a Near Root Cause.

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Contractor High Turnover Rate Creating Additional Cost to Contractors & OMCs Due to Retraining. Level Playing Field.

BEHAVIROL PROGRAM DEVELOPMENT

HSE MS IN PLACE.
Job Hazard Analysis HSE Self Appraisal Observation Techniques Site Visits Permit to Work System Contract/ Contractor Management Hazardous Situation Unsafe Act reporting HEMP Tools Violation Survey Trends/ Benchmarking Incident Investigation Incident Reporting

Workplans

HSE Standards & Procedures Competency Programs Audits Reviews

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HEARTS & MINDS - Bring HSE MS TO LIFE & BEYOND

Manage the System

Lead the Culture

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3 KEY ELEMENTS OF ROADMAP FOR BEHAVIROL & CULTURAL CHANGE
We Work Safely Because We are Motivated To Do the Right Things Naturally, Not Just Because We are Told To. We Want to Make Interventions & Actively Participate in Improvement Activities.

We Understand & Accept There is a Fair System for Reward & Discipline

We Understand & Accept What Should be Done & Know What is Expected of Us

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LIFE SAVING RULES

Work with a Valid Work Permit When Required Conduct Gas Tests When Required Verify Isolation Before Work Begins & Use the Specified Life Protecting Equipment Obtain Authorization Before Entering a Confined Space Obtain Authorization Before Overriding or Disabling Safety Critical Equipment Protect Yourself Against a Fall When Working at Height

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11

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Do Not Walk Under a Suspended Load

Do Not Smoke Outside Designated Smoking Areas

No Alcohol or Drugs While Working or Driving

While Driving, do Not Use Your Phone & Do Not Exceed Speed Limits

Wear Your Seat Belt

Follow Prescribed Journey Managemen Plan

HAZARD IDENTIFICATION
Job Safety Analysis is a Process to: 1. Document Each Step of a Job 2. ID Specific Existing/ Potential Hazards & Risks of Each Step 3. Determine Best Means to Specifically Eliminate or Control Hazards/Risks 4. Document Workers Responsibilities 5. Communicate to All Workers the Following: Job Tasks Job Hazards Job Controls Individual Responsibilities

HEALTH
Hazard Communication HAZCOM/MSDS Program

Purpose of Program is to Ensure that All Known Potential Hazards at the Workplace are Communicated to All Employees
Compliance Includes: Container Labeling Maintaining MSDS Workplace Chemical Inventory Employee Information & Training Concerning Hazards & Controls for Safe Product Handling

CONTRACTORS
THE BASICS Contractors Should Know: The Premises Routines & Work Patterns Risks Arising from Premises & Work

CONTRACTORS
Contractor Should Know: Risks Arising from His/Her Own Activities

How to Control Those Risks

Capabilities & Skills of His/Her Employees Capabilities & Skills of His/her Subcontractors

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THE LAW
Employment Act 2007 Occupational Safety & Health Act 2007

Work Injury Benefits Act 2007

Energy Act 2006 Provide Good Framework

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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 Will be 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 Practices HSE MANAGEMENT SYSTEM Contractors Without Effective Management of HSE Cannot Succeed Execution of HSE is a Line Management Responsibility

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ADVICE

If Its Free; Its Advice.

If You Pay for It, Its Consulting

If You Can Use Either One, Its A Miracle!

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ANY QUESTIONS?