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Agenda
• • • • • • •

Dua Safety Pause Opening by AbS & MAW Safety Alert by RSM Safety Workshop Presentation TA Safety Message by NDB & KMK Closing Remarks by ANd, MYR & INK
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Contents
• • • • • • •

Objective Overall Safety Statistics Previous Turnaround Safety Statistics Cost of Ignorance (Pics) Injury Analysis for 2011 & 2012 Focus Areas Non Tolerant Items List How to Start & Finish the Job Safely

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Objective “Injury Free Turnaround”
• •

Zero Fire 100% Compliance to Operating Procedures and Safe Work Practices Maintain Operating Discipline

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Overall Safety Statistics
12 10 8 6 4 2 0

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# of Incidents

12 10 8 6 4 2 0

# of Incidents

Overall Safety Statistics
Parameter On the Job LWI On the Job RWC+MTC On the Job 1st Aid Case Contractor LWI Contractor RWC+MTC Cont. 1st Aid Cases Fire Near miss 2003 2004 2005 2006 2007 2008 2009 2010 2011 Sep 2012

Nil Nil 2 Nil 4 5 6 148

Nil 1 3 Nil 4 5 4 159

Nil 3 10 Nil 11 9 13 158

1 6 1 2 9 6 9 174

Nil 1 4 Nil 6 9 14 175

Nil 1 3 1 2 14 11 191

Nil 1 4 Nil 6 11 7 374

Nil 3 3 Nil 1 14 6 311

Nil 1 4 Nil 6 15 7 502

Nil 1 7 Nil 4 7 6 385

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Turnarounds Safety Statistics
Description 2004
Nil 21 48 200 454 207 470 73 166

2005
04 39 280 356 289 368 130 165 31

2009
02 192 439 291 661 197 447 78 177

Fires

Near Misses Near Misses/Million -Man Hours Unsafe Acts/ Conditions UA & UC/ Million- Man Hours PPE Violations PPE Violations/ Million Man-Hours Work Permit Violations Work Permit Violations/ Million ManHours

Description
Combined Recordable Injuries EFert Contractor Combined 1st Aid Cases EFert Contractor

2004
1 Nil 1(MTC) 0 Nil Nil

2005
2 1(MTC) 1(RWC) 6 Nil 6

2009
0 0 0 1 Nil 1

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Cost of Negligence

Pinched between coupling hub and guard while removing load coupling on GT-601.

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Cost of Negligence

FM technician got injured when his right hand thumb got pinched

Hot cooling water splash occurred on right hand of the contract pipe fitter resulting in burns during head cover removal of E-2540

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Cost of Negligence

Slipping from the stairs while in a hurry; twisted his ankle

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Cost of Negligence

Second degree burns resulting from inadvertent touching of dislocated steam tracing during PHT-2503 MFL v/v operation

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Cost of Negligence

During filter top cover bolts loosening activity, the cover flew away due to pressure inside the filter. 02 workers fell down, one of them got affected by the Urea Solution. This incident took place at Fines dissolving facility

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EFERT Injury

Employee

Recordable

(MTC)

On January 13, 2012 at around 0630 hrs, while working on GT-604 the Efert employee injured his left thumb while hammering. He sustained left thumb nail bed laceration( Blackening of nail and mild bleeding) with partial avulsion of nail and compression fracture of tip of distal phalynx of left thumb.

Conclusion:

Misjudgment by technician while hammering the dowel pin resulted in this injury. Carelessness and Casual attitude on part of the technician resulted in this incident and work permit violation. Self imposed hurry on part of the technician was a contributing factor. Use of mechanical means could have avoided this incident (for example use of a wise grip or other similar tool)

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Contract Employee Recordable (RWC) Injury

On Feb. 21, 2012 at about 0430 hrs, a contract employee's left hand small finger got injured while he was trying to remove a stuck bag in between the conveyor (CO-306B) and the idle roller (installed between two conveyors) at Bagging Line BL-302.

Conclusion:

Deviation from the safe work practices / norms by the contract employee using sub standard tool for the activity. Unavailability of SOP for such non routine / routine manual activities and JDs for contractors. No check / system in place to ensure availability of skilled contractor manpower as a replacement for their regular skilled workers. Random USLs performing highly critical jobs like stitching, bagging etc. Relatively low understanding of the MOC protocol at the Unit and a tendency to over look potential hazards, resulting in inability to identify potential

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Contract Employee Recordable (RWC) Injury
On May 04, 2012 at around 0215 hrs, PMS-2 level boy was coming down from PM&S building-2 after checking the levels of hoppers, he slipped from stairs near hoppers floor. The individual tried to get up & walk but due to severe pain was unable to move.

Conclusion:
In general the investigation team thinks that this injury could have been easily saved by maintaining safe work practices & utilization of proper PPEs for the jobs & job environment. To reduce injury risk on permanent basis, mechanical integrity related points for the dust collection system, air handling system & faulty level indications are also recommended to be handled on priority.

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Contract Employee Recordable (RWC) Injury
On 31st July 2012 at 0745 hours , the right little finger of a contract Scaffolder got injured while shifting scaffolding pipe at ENCOP project.

Conclusion:

Scaffolder was himself aware of wrong method of material removal. Continued with this action on will. The Scaffolder did not judge distance between pipe & container. Nor it was highlight by its supervisor. No communication was done to site Incharge, prior to start of job. Team started job on their will. Scaffolding supervisor did not responded timely to correct wrong method of material removal.

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Contract Employee Recordable (RWC) Injury
On Sep.18, 2012 at about 1515 hrs, While handing over the grinder to welder, the grinder rotating disc touch his right hand index finger, result in his finger got cut 1.5 cm long.

Conclusion:

Scaffolder was himself aware of wrong method of material removal. Continued with this action on will. The Scaffolder did not judge distance between pipe & container. Nor it was highlight by its supervisor. No communication was done to site Incharge, prior to start of job. Team started job on their will. Scaffolding supervisor did not responded timely to correct wrong method of material removal.

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Recordable Injuries of 2012
S. #
1

Date
13-Jan-12

Tag No.
INJ2012-1 INJ2012-4

Area
URUT-1

Inj Class

Title

Description

MTC Injury to Efert On 13th January at around 6:30 am while working on GTEmployee at 604 the Efert employee injured his left thumb while Utilities-1 hammering. RWC RWC to contract employee at PM&S1 On 21st of Feb, 2012 at about 04:30 hrs, while normal bagging and loading operation was in progress at PM&S -1, a contract employee's left hand small finger got injured while he was trying to remove a stuck bag in between the conveyor (CO-306B) and the idle roller (installed between two conveyors) at Bagging Line BL302. On May 04, 2012 at around 0215 hrs, PMS-2 level boy was coming down from PM&S building-2 after checking the levels of hoppers, he slipped from stairs near hoppers floor. The individual tried to get up & walk but due to severe pain was unable to move.

2

21-Feb-12

PM&S

3

04-May-12

INJ2012-12

PM&S

RWC RWC Case to Contractor Employee at PM&S

4

31-Jul-12

INJ2012-16 INJ2012-18

ENCOP

RWC RWC to contract On July 31, 2012 at 745 hours , the right little finger of a contract Employee at Scaffolder got injured while shifting scaffolding pipe ENCOP MTC MTC to Contractor Employee at ENCOP On Sep.18, 2012 at about 1515 hrs, A USL was shifting grinder from one platform to another scaffolding platform installed south of R-2501. While he was handing over the grinder to welder, the grinder accidentally started and as a result his right hand index finger got cut.

5

18-Sep-12

ENCOP

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Potential
S. #
1

2012Tag No. Date
17-Feb-12 INJ-2012-3

Recordable
Inj Class
FAC

Injuries
Description

of

Area
PM&S

Title

First Aid Case to On Feb. 17, 2012 at about 1445 hrs, WPP Consignement Efert Employee at personel while going on M/cycle at the East side of New Bulk PM&S Store of PM&S slipped over spilled urea prills. First Aid Case to On Feb 27,2012 at 1355 hrs, Area operator slipped while Efert Employee at coming to the duty on motor cycle at the South side road of Plant-2 RO building of Plant-II First Aid Case to On Mar.16, 2012 at about 1715 hrs, while closing the door Efert Employee at between RO PLC room and operator sitting area, fingers of the UTY-3 area operator got pinched between the door and door frame. Two middle fingers of the left hand received minor cuts with slight pressing of the thumb nail. First Aid Case to On April 26, 2012 at about 0930 hrs, Nail was penetrated into Efert Employee at the sole of the right shoe of the SSG, while walking in plant Check post area. The Senior Security Guard tried to remove that nail with his hand resulted into pricking his right thumb. First Aid Case to On June 12, 2012 at about 1630 hrs, hot urea solution Efert Employee at splashed over the right hand of area operator during priming Urea-3 & startup of Urea Solution Pump, MP-06A.
First Aid Case to On June 16, 2012 at about 1725 hrs, a contract Pallaydar (Shoukat Ali) Contractor Employee fell down in between loading truck and mobile platform at TL-3000. at PM&S Incident was occurred while a flat bed truck # JU-3641 was being loaded at TL-3000 (PM&S-2). For loading last dham /danda , mobile platform installed at its back. During loading mobile platform moved away from truck bed and pallaydar fell down in between this gape from the height of 4 ft.

2

27-Feb-12 INJ-2012-5

Amm-3

FAC

3

16-Mar-12 INJ-2012-6

Uty-3

FAC

4

26-Apr-12 INJ-2012-11 Security CheckPost

FAC

5

12-Jun-12 INJ-2012-13

Urea-3

FAC

6

16-Jun-12

INJ-2012-14

PM&S

FAC

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Injury Analysis 2011 & 2012
Activity Wise FAC Injuries Analysis

94% injuries due to pinch / cut / hitting 6% injuries due to hot splash

Recordable Injuries Analysis

34% injuries due to hot splash 22% each injuries due to pinch / cut / hitting, Slip

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Injury Analysis 2011 & 2012
Root Cause Wise

FAC Injuries Analysis
32% injuries due to Carelessness 26% injuries due to Hardware issue 15% injuries due to lack of supervision 8% injuries due to JCC / Procedure was not done

Recordable Injuries Analysis

27% injuries due to Lack of Supervision

21% each injuries due to Hardware issue, 10/14/12Carelessness, JCC/Procedure

Injury Analysis 2011 & 2012
Body Parts Injury Comparison

55% Hands injuries 13% Legs injuries 8% 4% each Knee, Arm and Foot each body and face

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Focus Areas
• • • • • • •

ERS PPEs Work Permit Compliance Hand Over and Take over Lock out & Tag out Incident / Near miss Reporting Working at Heights
Climbing)
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(Scaffolds, Ladders,

Focus Areas

Tools

(Grinder, Hammers, rope ladders etc…) (Slips, trips, falls and fires)


Housekeeping

Don’t Block the access of Fire Fighting / Safety Equipments Anger Rush & Hurriedness Unattended Contract Manpower
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• • • •

USLs Management

(Sleeping at Plant Sites, careful job assignment etc...)

Non Tolerant Items List

PPE non compliance

Safety rules violation Improper emergency response Non compliance of SWPs Mobile phone usage in prohibited area Lock / wire cutting without authorization Work permit violation Usage of defective tools, sling, lifting gears & full body harness Use of unchecked / uninspected equipment's Use of improper or un-certified scaffolding Non compliance of full body harness protocol

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How to Start & Finish
• • •

Dua at Shacks Proper H/O & T/O between shifts 05 min Mandatory TBT at the job
location(Fill Checklist)

• • • • •

Validate Work permits Ensure LOTO End to End Job Pre-Planning Use Certified & Healthy Tools
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How to Start & Finish
• • • • • • •

Enhanced Field Supervision Self Auditing Supervisors to conduct MSAs Housekeeping during the job Tea / Lunch Breaks Follow TA JCC Matrix Follow QA/QC guidelines Capture activities in logbook

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Thanks !
BEST OF LUCK For a Safe & Successful Turnaround-2012

10/14/12

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