Instruction for preventing workplace fatalities Objective, Background and Context 2 Presentation Title 01/12/2010 (optional) Background Corporate Vale has established a set of Global Golden Rules. These Golden Rules demonstrates our values, starting with Life Matters Most These Golden Rules are instructions Primary Fatality Prevention Controls that are critically important to prevent fatalities. If followed, these instructions would have prevented 80% of the fatalities in our global business. Zero harm for everyone depends on our shared commitment to the highest standards of care at all times and in all circumstances Many of you will recognize these instructions, as they originate from well established Health & Safety Management System programs (Operational Controls) in place in the Base Metals. Such as: Zero Energy State / Identify, Tag, Lock, Check Confined Space Working at Heights WHMIS Management of Change
3 Context These instructions are intended for all people who work for or on behalf of Vale. Instructions to prevent work-related fatal incidents. These rules come to mind, either as a reminder to yourself or as a supervisors reminder every time you or someone else are required to work in situations involving these conditions Information everyone must be capable of applying while working. Knowledgeable on the content Skilled in the application Attitude a desire to follow and promote these instructions Instructions that you can expect and depend on others to comply with and others can depend on you to comply with. A basis to stop work and reassess if the instruction is not implemented to manage risk properly - to As Low As Reasonably Achievable - ALARA
4 IMPORTANT
If you can not follow through on any of the following instructions you are about to review STOP WORK & CONTACT YOUR SUPERVISOR 5 Learning Objectives At the end of this review you will be able to: Summarize the reasons why the Golden Rules are important to all people in all workplaces in our company Identify the Golden Rules as they apply to you
6 7 . WHY? What are the Golden Rules Category Primary Instruction Basic Requirements Only perform work that you are trained, qualified, authorized and fit to perform. Working at Heights Where there is a hazard of falling 1.8 meters or more, approved , maintained and certified equipment for fall arrest and travel restraint must be used. Mobile Equipment and Light Vehicles Always use mobile equipment and light vehicles for the purpose they were designed for and adhere to site pedestrian / vehicle traffic rules. Energy and Equipment Isolation Only work on equipment if all energy sources have been identified, tagged appropriately, locked with your personal lock and tested to ensure the they are at a zero energy state. Lifting and Mechanical Handling Always use authorized, maintained appropriate and certified lifting devices capable of lifting a load in a controlled manner and safeguard against encroachment under suspended loads by pedestrians and mobile equipment. Confined Spaces Only enter a confined space if you are trained, qualified and authorized and after having reviewed the permit. Surface and Underground Mining Only enter areas you are authorized to do so. Equipment Safeguarding Only trained and qualified personnel may alter equipment safeguards after having received authorization. Chemicals and Hazardous Substances Only handle hazardous substances in accordance with prescribed controls. Management of Change Always conduct a management of change assessment before implementing any temporary or permanent change (process, equipment or facility). Vale 10 Golden Rules Basic Requirements Only perform work that you are trained, qualified, authorized and fit to perform.
Trained and qualified means you have received training provided or recognized by (if the training is external) the organization. Persons performing work must know and understand the hazards, the procedures to be applied when performing the work and how risk associated with the hazards is to be managed. Authorized means that the job must be assigned by organization supervision and, where required, have a signed off work permit in place before proceeding. Authorization will include a review of the hazards associated with the job, the controls that must be applied and assurances that proper controls are in place. Fit means a person must meet the physical and mental requirements of the work on the day that it is assigned, be unaffected by drugs or alcohol. These basic requirements are a pre-requisite for each of the following instructions. Guidance Working at Heights Where there is a hazard of falling 1.8 meters or more, approved , maintained and certified equipment for fall arrest and/or travel restraint must be used.
Working at height standards are applied for any height that is equal to or greater than 1.8 meters (6 feet) above the ground or level lower than this where there is risk of injury from falling while performing work. . Guidance 1.8m 6 feet Working at Heights Questions to determine if Risk is at ALARA Have the people involved in the work had the necessary training? Are they Qualified? Are they Authorized? Is a JHA/SSA required for this work? If required, has a work permit been issued has it been reviewed with all participants? Are full body harnesses being used for people working above 1.8 meters? Lanyards and shock absorbers in place? Double lanyards for 100% tie off? Are appropriate anchors being used? Is there a Rescue Plan to minimize suspension trauma? SCAFFOLDS Do scaffolds have handrails and toe boards? Have scaffolds been constructed by competent personnel? Are scaffolds authorized for use?
Mobile Equipment and Light Vehicles Always use mobile equipment and light vehicles for the purpose they were designed for and adhere to site pedestrian / vehicle traffic rules.
An operator of a vehicle is required to: Check that the vehicle is fit for purpose. Adhere to site traffic rules including; speed limits, direction of travel on roadways, authorized roadways and wearing of seat belts. Eliminate distractions while driving Secure material being transported in a vehicle if occupants can be affected by its movement. Comply with vehicle and road restrictions in terms of load capacity and number of passengers. To safeguard against incident a pedestrian is required to: Give way to, and stand clear of, mobile equipment as this equipment has the right of way. Only approach a mobile equipment work area after the equipment operator has been alerted, and, has provided approval for proceeding through the mobile equipment work area. Guidance Mobile Equipment Questions to determine if Risk is at ALARA Any Vehicles Operators Trained? Authorized? Pre-use Check completed? Warning devices functioning? Brakes tested? Are loads secure? Are items inside the cab secured? Are seat belts in place and in use? Pit Vehicles Whip antenna with flag in place? Flashing cab light? Reflective markings? Two way radio functioning? Communication established as per protocol? Mobile Equipment Reversing Alarms? FOPS / ROPS in order? Pedestrians Aware they DO NOT have right of way? Make eye contact and get permission to approach any Mobile Equipment
Energy and Equipment Isolation Only work on equipment if all energy sources have been identified, tagged appropriately, locked with your personal lock and tested to ensure they are at a zero energy state. Energy sources include systems that incorporate compressed gas, pressurized hydraulics or pneumatics, process fluids and gasses, steam, water, gravity driven mechanisms and electrical sources.. When isolating sources of energy a person is required to: IDENTIFY all energy sources, TAG as required, LOCK with personal lock as required, CHECK to ensure that energy is at zero. Use personal lock(s) and tag(s) as you have been trained and authorized, in accordance with the site tagging and locking procedures. Before working on any equipment or in any vessel a person is required to: Check that all energy sources have been isolated and are locked out of service. Check that residual energy has been released. Apply tags and personal protection locks as required by the site isolation procedures.
Guidance Energy Sources How can the energy be controlled? BIOLOGICAL GRAVITATIONAL - PEOPLE PRESSURIZED OR STORED FIRE CHEMICAL GRAVITATIONAL - OBJ ECT EXPLOSIVES NOISE MUSCULOSKELETAL MECHANICAL STABILITY VIBRATION RADIATION ELECTRICAL THERMAL MACHINE - FIXED MACHINE - MOBILE 16 Isolation Questions to determine if Risk is at ALARA
Is there a procedure for isolating the energy source? Is the task non-routine or the conditions abnormal is a JHA/SSA required? Are people trained and authorized to complete the isolation procedure? Are others required Equipment Operators, Authorized Isolators? Is a Permit required? In the case of a group lock out, has the plan been reviewed with all involved? Are all aware of what their personal lock is protecting them from? Do tags provide the required information? What is the test to determine a zero energy state before work starts? Is there a plan in place to restore energy to the equipment or process? Are all aware of it? Are all clear of the area on start up expecting the unexpected? Lifting and Mechanical Handling Always use authorized, maintained, appropriate and certified lifting devices capable of lifting a load in a controlled manner and safeguard against encroachment under suspended loads by pedestrians and mobile equipment. Devices used for lifting purposes must be designed so that they are capable of lifting a load. When operating a lifting device a person is required to: Check that there is a risk assessment and lifting procedure for critical and non-routine lifts. Perform pre-operation inspections and checks on equipment and lifting accessories and that any lifting equipment safety devices are operational before a lift is made. Check that the load and reach does not exceed the capacity of the lifting equipment. Secure material being lifted to prevent it from falling. Check the path of movement is visually monitored at all times. Lifting must be performed such that people or equipment are prevented from passing under the load during movement. Guidance Lifting Questions to determine if Risk is at ALARA
Is the equipment operator, and others trained and authorized as required? Is a JHA/SSA required? Is a rigging plan in place for critical and non-routine lifts? Have communications protocol been established? Does everyone know their role and responsibility for the lift? Are the accessories checked and suitable for the lift? (slings, hooks, chains, clamps, shackles, rings) Is their lifting capacity known? Are the loads to be lifted within the capacities of lifting equipment? Is the lifting device being used as designed? Vertical lifts? Outriggers in place? Boom at appropriate lift angles? Is there a chance of people becoming positioned under the load? Will the load be moved while it is suspended? What is the plan to control this? Confined Space Only enter a confined space if you are trained, qualified and authorized and after having reviewed the permit. Confined space is a fully or partially enclosed space: A. that is not designed and constructed for continuous human occupancy, and, B. in which atmospheric hazards may occur because of its construction, location, or contents, or because on the work that is to be done in it. Only people who are specifically trained and qualified to work in a confined space can enter. When a confined space entry is necessary a completed and authorized entry permit is required. When working in a confined space a person is required to: Check that a confined space attendant (guard) is stationed at the entry of the confined space to monitor the people working inside, people exiting and the capability to initiate emergency response; Monitor the atmosphere in accordance with the permit and/or hazard assessment in confined spaces during work and exit the confined space to reassess risk and controls should a change in atmosphere occur; Work strictly in accordance with the confined space procedures Guidance Confined Space Questions to determine if Risk is at ALARA Is there a permit in place? Has it been reviewed by all involved in the confined space? Are all people trained and authorized? Are all energy sources tagged and locked out? Is there anyway for substances to enter the confined space? Material? Liquid? Chemical? Gas? Will atmospheric testing occur? What is the atmospheric testing in place to determine? Are conditions acceptable? Can conditions change? Will burning be conducted inside the confined space? Is a burning permit in place? Are there heat related reactions with previously stored substances that can occur? Is the confine space guarded? Entry allowed and exit monitored by the Attendant? Secured during breaks or off shift? Is there a rescue plan? Is necessary emergency response equipment in place? Surface and Underground Mining Only enter areas you are authorized to do so. Restricted areas in mining facilities include: Underground: Areas of unsupported ground. Areas where air conditions are tested as, or suspected to be foul. Inactive mining areas Underground areas where hang-ups of mined material and/or accumulations of water at ore passes, chutes, silos, bunkers and stockpiles in the absence of formal procedures to control inherent risks. Surface Mine pit benches areas, at the base and crest of high walls, mining faces, dumps and blasting areas or the base of stockpiles. Draw points below stockpiles in surface mining (e.g. accessed via tunnels or inclined ramps) or access stockpiles without site specific entry procedures. Mining excavations or trenches where the sidewalls have not been properly supported. Detonation locations, in either type of mining, just prior or after a blast taking place.
Guidance Surface and Underground Mining 23 How to recognize Underground restricted areas
Single Guardrail Understand the hazard Keep out if unqualified to manage the hazard Cautionary use OK to work
Double Guardrail Keep out Supervisors permission only to enter Extreme hazard or needs a special procedure etc
Screen Barricade Keep out Supervisors permission only to enter (and usually accompanied) Extreme hazard of longer duration Needs a special procedure and special protective gear
Restricted Areas Questions to determine if Risk is at ALARA Are people aware of the local restricted area procedure? Do people know what to look for and how to respond? If work team is conducting work outside of their home location do they know the procedure for creating or identifying a restricted work area? Is the appropriate signage in place? Can it be read? Is the guarding mechanism (rope, chain, flagging) secure? Clearly visible? Completely encompass the area of concern? Equipment Safeguarding Only trained and qualified personnel may alter equipment safeguards after having received authorization. (alter = disable, remove, adjust, test) . Guidance NOTE: There will be occasions when it is a requirement to perform tests or make adjustments to equipment with the pre-planned disabling of safeguarding devices. This type of work may only be performed with pre- authorization and under controlled circumstances (Management of Change, JHA/SSA, Local Procedures). Most types of machinery including mechanized lifting devices have operable protection devices designed to prevent harmful incidents to people. Therefore, during normal operation, machinery is only to be operated with protection devices in place and tested operable (as applicable). These include: Physical Guarding Instrumented Protection Devices Emergency Shutoff Systems
Equipment Safe Guarding - Examples Can you think of something you might use or have seen at home that is guarded this way? 26 Nip Points Other Safe Guards include, Emergency stops, zero speed switches, emergency pull cords, level sensors.. Equipment Safeguards Questions to determine if Risk is at ALARA Are safeguards in place? Rotating Equipment? Pinch Points? Emergency Pull Cords? Emergency Stops? Do the guards provide the protection they were designed for? Have the safeguards been inspected? Tested? Maintained as required? Are emergency shutoffs clearly visible? Identified? Accessible? Is there a procedure in place for rings? Long hair? Bracelets? Chains? Earrings? Loose clothing? Is there machinery or equipment that requires additional guards? Are fixed protection devices only removed with the machine or equipment identified, tagged, locked out and checked? Are repair, cleaning, adjusting and inspection activities only performed when the machines are identified, tagged, locked and checked, unless their movement is essential to these activities? What controls are in place to manage the risk of exposed hazard(s)?
Chemicals and Hazardous Substances Only handle hazardous substances in accordance with prescribed controls. Guidance People who handle hazardous substances must be trained and qualified to recognize and enact the controls necessary for each type of hazardous material they may have to handle.
What is the name of the legislated system we have in place to identify and control hazardous substances? WHMIS
What do these letters stand for? Workplace Hazardous Materials Information System
What does MSDS stand for? Material Safety Data Sheet Chemicals and Hazardous Substances Only handle hazardous substances in accordance with prescribed controls. Guidance
Material Safety Data Sheets (MSDS) will be available and reviewed as required so that individuals recognize the hazards, understand the precautions, are able to follow the instructions and can apply the controls.
Internal procedures for hazardous substances with reference to the appropriate MSDS shall be in place for transporting, processing, mixing, handling, storing or planning the disposal of these materials.
Persons working with hazardous substances and chemicals or in areas where they are used shall have access to emergency equipment, be aware of emergency procedures and able to implement them as defined.
Chemicals and Hazardous Substances Compressed Gas Flammable Oxidizer Poisonous Toxic Biohazard Corrosive Reactive 30 So how well do you know your WHMIS symbols?
Hazardous Substances Questions to determine if Risk is at ALARA Are people Trained, Qualified and Authorized to work with the hazardous substance? Is there an inventory of hazardous substances? Is there a MSDS for the hazardous material Is there a procedure or JHA/SSA for the task involving the hazardous substance? As part of the plan for the task has the MSDS been reviewed? In the language of the user of the product? Is Personal Protective Equipment (PPE) required? Is it specific for the task? Protective Eyewear Goggles, Face shield, Specialized clothing? Specific Respirator cartridge? Are there specific notifications of hazardous substance use? (Emergency Services, First Aid, Medical, Health) Is emergency response equipment readily available? Eyewash stations, Showers? Fume hoods connected to exhaust fans? Appropriate Fire Extinguishers? Management of Change Always conduct a management of change assessment before implementing any temporary or permanent change (process, equipment or facility). Guidance A change management program shall exist for all organizations and its application is required to define, review and approve any type of change that occurs in the workplace.
Change of many kinds take place in the workplace. Recognizing a change and then taking the necessary steps to manage any potential risks is a requirement of everyone who works within the organization.
In addition to permanent changes, small changes (such as revising the set point of an instrument) or temporary changes that are applied for over short time periods to manage a system deviation / transition or even a change in kind must comply with the site Management of Change program approval process for: Facilities : any infrastructure at a workplace site. Processes : systems and operating processes. Equipment : mobile and stationary equipment used in processing.
Management of Change Questions to determine if Risk is at ALARA Do people understand Management of Change (MoC)? Do people know the triggers for the Management of Change process? Is this a change in kind? Has a risk assessment been completed to understand the impact of the change? Chemical? Structural? Design? Process? Training? RISK? If a purchased or warehoused replacement piece looks or feels different, will people inquire about MoC? Have all the notifications been made for a temporary or permanent change? Operators? Maintainers? Purchasing? Learning & Development, Health, safety and Environment? 6Suppliers? What about SafeProduction? Where do these controls fit in our North Atlantic Health & Safety Management System? PLANNING Activities associated with developing plans to control hazards and mitigate risks IMPLEMENTATION & OPERATION Activities associated with execution of hazard control and risk mitigation - Accountabilities and visible activities to - Control of S&H workplace hazards and risk demonstrate leadership mitigation during business operations - Employee S&H functional training to manage hazards. - Describe means of communication - Involvement of employees and their reps in of S&H information specific S&H activities (ie. JHSC) REVIEW Activities associated with Senior Management review to determine if Safety & Health objectives/targets and policy have been met. - Review of: - Audits - Performance Results - Risk Assessment - Progress on meeting objectives and planned commitments RISK MANAGEMENT IDENTIFY LEGAL AND OTHER REQUIREMENTS - S&H legislation identified and monitored - Corporate Requirements BUSINESS PLANNING - Set objectives and targets to meet Policy and Goals - Develop plan to achieve objectives (ex. MSDs, Managing Critical Risks, SHMS execution, Felt Leadership) SETTING OBJECTIVES, MEASURES AND TARGETS AND DEVELOPING PLANS Other Inputs - Business Goals - Results of Management Review - Audit findings - S&H performance - Improvement Goals - Employee S&H Surveys - Incident Review MANAGEMENT REVIEW ACCOUNTABILITIES AND LEADERSHIP PRACTICES OPERATIONAL CONTROL TRAINING COMMUNICATION EMERGENCY MANAGEMENT Ex. Confined Space Program, ZES Program, Health and Medical Programs, Fatal Risk Stds, Critical Procedures CONTRACTOR MANAGEMENT DOCUMENTATION CHECKING AND CORRECTIVE ACTION Activities associated with checking to see if hazards are controlled and risks are mitigated and correcting problems to prevent future accident/incidents - Monitoring of leading and lagging indicators associated with objectives - Audit of S&H Management system - Monitoring of S&H plans - Compliance Audit - Incident/non-conformance Reporting and investigation and follow-up of corrective action - Communication of lessons learned to prevent recurrences - Recognition of exemplary performance - NO REPEATS in S&H of employees or groups MONITORING OF PERFORMANCE INCIDENT MANAGEMENT AUDIT RECORDS RECOGNITION Safety, Health, Env. Policy Safety and Health Management System Overview MAJOR HAZARD RISK REGISTER PROJECTS, CHANGES, INCIDENTS/NEAR MISS RA FOR JOB PROCEDURES OR PLAN INFORMAL RA WRAC, BTA, PHR HAZOP ,BTA, PHR JSA, JTA SLAM, EMPLOYEE INVOLVEMENT Golden Rules and SafeProduction 36 Plan all work with risk management Golden Rules help us to answer 3 main questions of managing risk: What can go wrong? Golden Rules highlight areas of severe consequence 80% of previous fatalities How bad could it be? Fatality X Likely (if rules not followed) = Extreme Risk What needs to be done to control it? Follow the direction provided in the primary instruction know the related operational controls Accept Boundaries In order to ensure that the risk associated with the most hazardous aspects of our industry is managed to ALARA we must establish boundaries with specific instruction. The Golden Rules are the instructions. They originate from the Operational Controls element in the Health & Safety Management System. The instructions are a critical step to enable us to complete the work with zero harm. (See ALARA) Care for Each Other work as a Team Establishing, implementing and promoting Golden Rules demonstrates our care for one another. Not having these instructions in place and following them can result in the very real possibility of losing a colleague and impacting all of those associated with the team member Family, Friends, Co-workers. We have to look out for one another. Lead by Example We can all lead at least one person ourselves. The truth is that we often set the example for many others new people and less experienced workers. We owe it to ourselves and each other to commit to understanding and following the Golden Rules. Our demonstration of following the Golden rules sets the example for all to learn.
If you can not follow through on any of the instructions you just reviewed STOP WORK & CONTACT YOUR SUPERVISOR
37 Learning Objectives At the end of this review you will be able to: Summarize the reasons why the Golden Rules are important to all people in all workplaces in our company Identify the Golden Rules as they apply to you