Mechanical Training
Transcript of 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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4 SOURCES OF ACCIDENTS & INCIDENTS
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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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4 SOURCES OF ACCIDENTS & INCIDENTS
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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
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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
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THE BASICS
Contractors ShouldKnow:
The Premises
Routines & WorkPatterns
Risks Arising fromPremises & Work
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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
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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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