Introduction - Safe Work Practices

EHS Training OPGC
for
Supervisor Safety
Environment, Health and Safety Training
1st March 2016
Managing Risks Profitably
EHS Training for
OPGC
Introduction to Project
& Accident Prevention
Chola MS Risk Services
March 15, 2016
2
Supervisor Safety Training Program
This program consist of 24 Modules for OSHA 30 Hrs
Introduction to Project & Accident Prevention
Roles and Responsibilities of Supervisor
Applicable Indian Regulations for Construction
Hazard Identification
HIRA & JSA (Work Package)
Hazard Communication
Hazardous Materials
Lead Safety in the Workplace
Personal Protective Equipment
Excavation

EHS Training for OPGC March 15, 2016
3
Use of Explosives in the Workplace
Concrete and Masonry Construction
Stairways and Ladder
Scaffolds
Fall Protection
Electrical Safety
Hand and Power Tools
Welding & Gas cutting
Fire Protection in Construction site
Material Handling and Storage

4
Cranes & Rigging
Motor Vehicle and Use of Hydra crane
Struck by and Caught in between hazards
Confined Space
Final Exam

5
Topics in this course
Module 1 Intro to Project & Accident Prevention
EHS Objectives
Roles and Responsibilities
Accident Prevention
Risk Assessment and Job Safety Analysis
Safe Work Practices through Permit to Work system
Training and Communication
EHS Inspections
Project Safety Guidelines
Conclusion

6
Objectives
At the end of this course you will
Understand the EHS objectives, Roles & Responsibilities
Accident Prevention & Safety Culture
Understand the importance of Risk assessment and Job Safety Analysis
Understand what is Permit to Work System
Understand the expectations for carrying out EHS inspections

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EHS Objectives
World class EHS performance is a key strategic objective
Safety is to be considered on an equal level with budget, schedule and
quality!
All persons at site have an ownership & responsibility for EHS
Each person has key duties defined and management is responsible to
ensure these are undertaken
Vigilance is required from everyone at site to ensure safety of the works

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Project Management
Provide individuals the opportunity, responsibility and accountability
Our EPC and contractors have both contractual and moral obligations to adopt our vision
The contractor will integrate our vision within its project management organization, its
supervisors, and its employees into the concept of a wholly safe and effective work environment
Work with each contractor to make our vision a reality
Invest in what is necessary to achieve this vision

9
Site Supervisors
Ensure compliance with the project safety rules and procedures
Conduct regular EHS inspections
Implement remedial measures to reduce or eliminate unsafe acts or conditions
Provide information, instruction ,training and supervise employees in safer methods of work
Reporting and investigating accidents / Incidents that occur and provide employees with
information about hazards and precautions applicable to the site
Stop the work when it is unsafe to continue

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Your Role As A Supervisor!
Supervisors play a key role
Supervisors must handle many challenges
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EHS Training for OPGC
Your Role In Accident Prevention
Training & Communicating your team
Role Modeling
Enforcing the rules
Coaching your team
Conducting hazard assessments
Conducting accident investigations
EHS Training for OPGC 12

You Set The Example
Follow all the rules

Encourage all management to follow all the rules.
The little things count as much as the big things
No exceptions
Be consistent and dont play favorites
Your team will watch you and if your words dont match your deeds
will ignore your words!
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Site Managers have plenty of reasons to justify
accidents
Number is Up
Carelessness People Error
ACCIDENT
Cost of doing
Act of God
Business
Philosophy of HSE Triangle

Moving towards Excellence Stage 5
Certainty
Stage 4
High
Wisdom
Sustainability
Stage 3
Behavior based
Enlightenment
Stage 2 Interventions
Stage 1 Awakening Self Assessments
Crisis (Cosmetic) Improvement program
Management Measurement Program
Supporting MIS
Satisfaction Surveys,
ISO 9000. ISO 14001, OHSAS 18001
Business Processes Mapped
SHEQ Strategic Planning
Ad-Hoc Risk Assessments
Ad-hoc Training
Ad-Hoc Management Reviews
Ad-Hoc Annual Audits
Low
Crisis Management
EHS Training for OPGC Time 10 12 Years
Where we are and Where we want to go-
a Constant Dilemma for Corporate?
GENERATIVE
HSE is how we do business
round here
PROACTIVE
Safety Values and Values drive
continuous improvement
CALCULATIVE
We have systems in place to
manage all hazards
REACTIVE
Safety is important, we do a lot
every time we have an accident
PATHOLOGICAL
Who cares as long as were not
caught
Evolution of Safety Culture

Safety Management System Vs. Safety Culture
The culture of the organization is much more

Job Safety Analysis
A JSA is a technique of screening job tasks as a way to identify hazards before they
occur.
It focuses on the relationship between the worker, the task, the tools and the work
environment
When conducting a Job Safety Analysis you'll need to take a fresh look at the way
things are done at your work place.
Just because "We've been doing it this way for 20 years," doesn't mean that a
hazard doesn't exist.

22
Job Safety Analysis
Four basic steps in carrying out JHA
1. selecting the job to be analyzed
2. breaking the job down into a sequence of steps
3. identifying potential hazards
4. determining preventive measures to overcome these hazards

23
Job Safety Analysis
Once the job is identified, you must break it into key components or sub-tasks and then
identify and list all the hazards associated with each subtask.
What can go wrong?
What are the consequences?
How could a problem happen?

24
Purpose of Job Safety Analysis
The main aim of the JSA is to protect workers health and safety.
And it is also helps to minimize the possibility of the workers or the environment
being harmed due to work-related activities.
To provide a systemized and standardized approach to the identification of hazards,
evaluation of associated risks and determination of risk control measures to reduce
risk to acceptable levels.

25
When should JSA Be Conducted
Ongoing activity
New activity
Change in activity
that could affect health and safety of operatives

26
Risk Assessment
Risk assessment is the process of:
Identifying hazards,
Analyzing / Evaluating the associated risk,
Determining appropriate ways to eliminate or control the hazard

27
Risk Assessment
Risk assessment helps to.
Determine if existing control measures are adequate or if more should be done.
Prevent injuries or illnesses when done at the design or planning stage.
Prioritize hazards and control measures .

28
Difference between JSA and RA
The basic difference is that Risk Assessment involves the additional step of assessing
the severity and frequency of the hazard and giving it a risk ranking.

29
Identify Control Measures
Eliminate Administrative Controls
o Avoiding work at height o Work rotation, rest breaks
Substitute o Preventative maintenance
o Less hazardous substances o Isolation procedures
o Battery powered tools o Training
o Cold work for hot work o Signage
Engineering Controls PPE
o Guarding and enclosure o Hearing
o Exclusion zones o Head
o Lock out systems o Foot
o Eye
o Hand
30
Principle of Crocodile Identify the Risk

Principle of Crocodile Evaluate the Risk

Principle of Crocodile Eliminate the Risk

Principle of Crocodile Substitute the Risk

Principle of Crocodile Isolate the Risk

Principle of Crocodile Use PPEs

Principle of Crocodile Or else.Run away !!!

Safe Work Practices Permit to Work System
It is a formal written system used to control hazards and manage risks associated with
maintenance and other non-routine work.
What is a non-routine work? - Any activity that is not fully described in any operating procedure.
A Permit is a document which specifies the work to be done and the precautions to be taken.

38
Permit to Work System
Why?
To Ensure Communication is smooth and clear between the parties involved
To Protect personnel from hazards and hazardous environments
Eg. control of hazardous energy through lockout tagout
To Protect against mishaps that could have catastrophic secondary effects
Eg. hot tapping lines and equipment
To Control special hazards
Eg. Hazardous chemical release
To Prevent unauthorized impairment of safety systems
Eg. fire hydrant system impairment

39
Who is authorized to issue a permit?
Sufficiently knowledgeable about the process
Understands the hazards of the job at hand and the precautions necessary
Capable of safely handing over the equipment/area for non-routine work
Trained and competent in issuing the permit
Who is authorized to receive a permit?

Has clear understanding of what has to be done
The hazards associated with it
Knows the mitigating measures
Capable of checking if it is safe to work
Trained and competent
Permit handing over system should be in place for a successful Work Permit System

40
Permit to Work System ensures that the following activities are carried out safely.
Hot work
Confined Space entry
Excavation
Lock Out Tag Out
Work at Height
Lifting
Cold Work
Vehicle Entry
Simultaneous Operations

41
OPGC II Work Permit

42
OPGC II Work Permit

43
OPGC II Work Permit

44
OPGC II Work Permit

45
OPGC I Work Permit

46
OPGC I Work Permit

47
OPGC I Work Permit

48
OPGC I Work Permit

49
OPGC PTW Job Slip

50
OPGC PTW Job Slip

51
OPGC PTW Job Slip

52
OPGC PTW Job Slip

53
Permit to Work System Hot Work
Hot work is an activity which may produce enough heat/spark to ignite a flammable mixture or
flammable substance. (OSHA 1910.252)
Grinding
Brazing
Soldering
Cutting
Welding
Painting

54
Permit to Work System Hot Work
Availability of fire extinguishing equipment suitable for the location
CO2 or DCP or water fog in case of Hydrogen fire
The atmosphere is tested.
Checking of LEL (H2 4%)
No Flammable or combustible material in the hot work area
The gas cutting equipment is checked
Hoses are checked and without leaks
Pressure Regulator is checked
The welding machine and cables are checked
Machine grounding is ensured
Ground connections are mechanically and electrically adequate

55
Permit to Work System Confined Space
Characteristics of Confined Space
Limited means of entry or egress
Low oxygen content ( < 19.5%)
Depletion due to some reaction
Inside steel tanks and vessels were rust forms
Not designed for continuous occupancy
Contains or has the potential to contain a hazardous atmosphere
Poisonous gas, fumes or vapors can be formed.
Contains a material that has the potential to engulf an entrant
Has walls that converge inward or floors that slope downward
May contain other serious physical hazards like unguarded machines or live wires

56
Permit to Work System Confined Space
Authorized personnel shall enter
Specify manhole watcher
Contact point in the event of an emergency
Specify any physical hazards in the confined space
Mechanical and Electrical isolation of equipment has been ensured

57
Permit to Work System Excavation
OSHA defines an excavation as any man-made cut, cavity, trench, or depression in the earth's surface formed
by earth removal.
Why PTW for excavation?

Specify means of excavation
Manually (hand shovels)/Machinery (jack-hammer)
Exact area to be excavated
Check underground services
Electrical/Instrumentation cables
Process pipes
Cordoning of excavated area
Suitable means for entry and escape (>1.2 m)

58
Permit to Work System Lockout and Tagout
What is Lockout & Tagout?
The placement of a lockout/tagout device on an energy isolating device.
To ensure that the energy isolating device and the equipment being controlled cannot be
operated
Lockout device: A device such as a lock to hold an energy isolating device in the safe
position. Lock and key, blank flanges, bolted slip blinds.
Tagout device: A warning device to indicate that the energy isolating device and the
equipment being controlled may not be operated.

59
Electricity
live or Moving
stored machinery
parts
Stored
Stored heat ,
mechanical
Hazardous
movement
chemicals in
in
pipelines
machinery

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When should LOTO be carried out?
An employee is required to place any part of his or her body into an area on a machine or piece of
equipment where work is actually performed upon the material being processed (point of
operation) or where an associated danger zone exists during a machine operating cycle. [OSHA
1910.147]
Why?
Hazards associated
Unexpected activation
Re-energization
Release of stored energy (pressure in a vessel)

61
Blind flange
Some
examples of
Lockout
Electrical lockout Valve Lockout & Tagout

Case Study- Improper filling In of permit
Two fitters were sprayed with 98% sulphuric acid while removing an accumulator
from an acid pump to repair a seal. Pressure on the discharge side of the pump had
not been vented, although their permit-to-work indicated that the line had been
cleared.

Permit to Work System Work at Heights
A person could fall a distance that can cause personal injury. (HSE UK)
Working at height if
Work above 1.8 m (OSHA); 2 m (HSE)
Working on a ladder or a flat roof
Could fall through a fragile surface
Could fall into an opening in the floor or a hole in the ground

64
Permit to Work System Work at Heights
Three simple rules for WAH
Avoid work at height if possible
Prevent falls by proper selection of access equipment
Minimise impact of fall
Check weather conditions
Mesh on scaffold to prevent falling objects
Plan for emergencies and rescue

65
Permit to Work System Lifting
Lifting permit is required
For usage of crane, forklift or other lifting equipment.
Why PTW for lifting?

To
Check the condition of the plant or equipment to be worked upon
Safe route to the designated area
Lifting equipment is checked and has valid certificate
No lifting after daylight hrs without authorization
No lifting to be permitted if wind speed is high (VALUE)
For entry into hazardous area Vehicle Entry Permit
Riggers presence must during all lifting activities

66
Training and Communication
Site EHS Induction Training
EHS Visitor Training
Construction Supervision EHS Training
Tool Box Talks and Pre Job Briefings
Detailed Specific Safety Training

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EHS Inspection
Documented weekly EHS inspections must be carried out by all supervisors
Promote self-identification safety & environmental non-compliance issues
Inspection should be using a checklist format and last for approx 1 hour
The EHS department will co-ordinate and the area supervisors will inspect using an
inspection schedule
EHS Discrepancy Reports must be produced for serious violations
All deviations should be entered in the action tracking register

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Conclusion
To achieve the EHS objectives:
Take Ownership of Safety!
All persons on site need to be proactive in EHS to establish an EHS culture
All safety procedures need to be followed at site at all times
All personnel have the responsibility to stop where its not safe to continue

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This is just a beginning . Many more such
efforts are required for building good safety
culture in the construction sector of India.
Peoples attitudes and opinions have been formed over
decades of life and
cannot be changed by having a
few meetings or giving a few lectures
- Mao Tse Tung

Chola MS Risk Offices:
CHOLAMANDALAM MS RISK SERVICES LTD. Chennai | Mumbai | New Delhi | Gurgaon |
PARRY HOUSE, 4TH FLOOR Kuwait & Singapore [Partner Offices]
NO.2, NSC BOSE ROAD, PARRYS, CHENNAI 600 001
Phone: 044 3044 5400 Fax: 044 3044 5550
inquiry@cholams.murugappa.com
www.cholarisk.com

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EHS Training OPGC

Chola MS Risk Services

Chola MS Risk Services

Chola MS Risk Services

Chola MS Risk Services

Accident Prevention & Safety Culture

Understand the importance of Risk assessment and Job Safety Analysis

Understand what is Permit to Work System

Understand the expectations for carrying out EHS inspections

Chola MS Risk Services

Chola MS Risk Services

Chola MS Risk Services

Chola MS Risk Services

Supervisors play a key role

Supervisors must handle many challenges

Enforcing the rules

Coaching your team

Conducting hazard assessments

Conducting accident investigations

EHS Training for OPGC 12

Follow all the rules

EHS Training for OPGC

EHS Training for OPGC

The culture of the organization is much more

Chola MS Risk Services

1. selecting the job to be analyzed

2. breaking the job down into a sequence of steps

3. identifying potential hazards

4. determining preventive measures to overcome these hazards

Chola MS Risk Services

What can go wrong?

What are the consequences?

How could a problem happen?

Chola MS Risk Services

Chola MS Risk Services

Chola MS Risk Services

Analyzing / Evaluating the associated risk,

Determining appropriate ways to eliminate or control the hazard

Chola MS Risk Services

Prevent injuries or illnesses when done at the design or planning stage.

Prioritize hazards and control measures .

Chola MS Risk Services

Chola MS Risk Services

EHS Training for OPGC

EHS Training for OPGC

EHS Training for OPGC

EHS Training for OPGC

EHS Training for OPGC

EHS Training for OPGC

EHS Training for OPGC

Chola MS Risk Services

Chola MS Risk Services

Who is authorized to receive a permit?

Chola MS Risk Services

Chola MS Risk Services

Chola MS Risk Services

Chola MS Risk Services

Chola MS Risk Services

Chola MS Risk Services

Chola MS Risk Services

Chola MS Risk Services

Chola MS Risk Services

Chola MS Risk Services