US Pipelines & Logistics Contractor Toolkit

Transcription

1 US Pipelines & Logistics Contractor Toolkit Contents Q Golden Rules spotlight Energy isolation WYE? What s Your Exposure? HSSE safety share Trailer safety awareness Lessons learned Root cause analysis: Electrical high potential incident Chemical splash Good Catch/Near Miss highlights Contractor Management Onboarding tool HSSE Goals No accidents. No harm to people. No damage to the environment. USPL Contractor Toolkit Q Page 1

2 Golden Rules spotlight Energy isolation Electrical safety There have been three significant incidents in the last few months involving high voltage: Wind Energy (injury) Team of three injured when visual inspection went further than scope and testing tool was used on equipment. USPL (near miss) Contractor working in high voltage cabinet assumed to be de-energized while it was still energized. Whiting (injury) Two employees injured when working with a power distribution center. Energy Isolation is a Golden Rule of Safety. Following proper energy isolation procedures, verifying effective isolation, and wearing proper personal protective equipment will provide protection to people while working on electrical systems. Non-flame retardant hoodie a crew member was wearing over FR clothing during Wind incident. High energy electrical work When entering areas or working on electrical systems where the potential for high energy represents a risk of electric arc flash or shock (i.e. opening electrical cabinets and electrical switch gear cubicles) all personnel must ensure that: Equipment is treated as energized until DEFINITIVELY and PHYSICALLY proven to be de-energized and locked out. Only qualified persons perform tasks such as testing, troubleshooting, and voltage measurements. Personal Protective Equipment rated for, or higher than, the potential arc flash is worn. All power sources to the equipment are isolated. Lock out/ Tag out locks and tags are applied as required. Test equipment is rated, calibrated and confirmed to be working correctly on a known energised line, immediately before and after testing lines are deenergised. Above all else, when working with high energy electrical equipment, never assume and stay within the work scope. When in doubt, STOP the job. Scene of Whiting arc flash incident. Discussion: Who is qualified to work on electrical equipment at your location? What other precautions can be taken to ensure safety when working with electrical equipment? USPL Contractor Toolkit Q Page 2

3 WYE? What s Your Exposure? Introduced in the Q Contractor Toolkit, WYE? is a behaviour-based system that encourages you to listen to the voice inside your head to help identify and eliminate any hazard. It can also assist in starting a safety conversations between co-workers by asking the simple question: What s Your Exposure? Every day, each one of us conducts multiple risk assessments without even realizing it: Is it safe to turn left at the intersection? Can I safely cross the street? What shoes do I wear for the activity? Do I have enough time to pass that car? Is the pizza too hot to eat? and many, many, many more! During an assessment, big or small, each of us does three things: 1) Identify the Hazard: Hazard Identification Ask Yourself Do I see it? 2) Assess the Risk: Risk Perception Ask Yourself Do I understand it? 3) Accept or Decline the Risk: Risk Tolerance Ask Yourself Do I accept it? WYE? also increases awareness of human factors: physical capability or experience, complacency, overconfidence in equipment or PPE, urgency in completing the task to get to the next one or leave for the day, and personal issues or distractions. By utilizing WYE? you will: Identify hazards and then act to eliminate them and other exposures in your work area through dynamic risk assessments. Keep your mind focused on actions by listening and using self-talk. Create and environment that prompts to all you to stop unsafe work. WYE? Helps advance USPL s safety culture, maintain safety s high value and keep us all safe. USPL Contractor Toolkit Q Page 3

4 HSSE safety share Trailer safety awareness Recently, a USPL contractor experienced a first aid injury while working with a trailer. Be sure to look for these important safety labels when pulling a trailer: The pinch point warning tag was missing from the trailer leg where the laborer was injured. If the tag was on the trailer leg, the person would have been alerted of the hazard. This injury should be a reminder to everyone who pulls trailers. Warning labels are on the equipment for your protection. Take a moment during your pre-trip inspection to read and be aware of the hazards that have been identified by the manufacturer. If the labels are damaged or faded, please replace them. When renting a trailer, take additional time during the inspection to read the posted warning labels and be aware of the hazards associated with the equipment. Drive smart, drive safe. Andy Gattermeyer USPL Road Safety Advisor USPL Contractor Toolkit Q Page 4

5 Root cause analysis Mokena electrical HIPO Recently completed investigation In late March 2017, an electrical services contractor arrived at the Mokena pipeline station to continue an electrical maintenance and testing project. The ATW and the lockout/tagout procedures for the day were discussed at the pre-job meeting. After the meeting, the contractor crew split up and proceeded to their work areas, except for one Trainee Technician who took a short break before joining his two co-workers at the location of their assignment. What went wrong? When the trainee arrived at the worksite, he was told to finish cleaning a 480 volt fused disconnect that his co-workers had already opened and begun working on. The co-workers left the work area to get some other equipment they needed. The trainee finished cleaning the disconnect, and proceeded to another disconnect he thought needed maintenance based on his recollection from the pre-job meeting. The trainee operated the second disconnect, then opened the door and began removing fuses. This disconnect was not in scope and was energized. When the trainee opened the disconnect, the lights inside the building shut off until an emergency generator started and restored power to the circuit downstream of the disconnect. The contractor foreman immediately came out of the building, realized the trainee was working on the wrong disconnect, and stopped the work. The AO was notified and all work was stopped. That afternoon, the lockouts were removed and the station was placed back in service. The event was a near miss with the potential for a fatality, making this a High Potential incident for BP. Discussion: Do you need to take any immediate actions to prevent a similar near miss? Many qualified electricians have personal stories of near misses they have experienced, share them and learn from others? Lessons Learned While USPL processes were followed, this near miss reveals gaps that need to be closed. Incident investigation recommendations include: 1. Require and verify that all electrical contractor workers have received NFPA 70E training, and training on the contractor s Electrical Safety Program. 2. Require electrical contractors to identify any unqualified workers on their team. Describe how those workers will be supervised so they are not performing tasks for which they are unqualified. 3. Make sure all members of the workforce participate in a walk down for that day s scope of work. 4. Add adjacent energized electrical equipment as a potential hazard to consider on the ATW. 5. Add a requirement to mark de-energized and adjacent energized electrical equipment when working on locked-out electrical equipment. USPL Contractor Toolkit Q Page 5

6 Root cause analysis Chemical splash Recently completed investigation In early February, 2017, the Oil Water Separator (OWS) at the a terminal malfunctioned which resulted in OWS discharge parameter levels outside of acceptable range. An air operated double diaphragm pump was used to transfer OWS water during the re-circulating and removal from service processes. During operation of the diaphragm pump, the work crew experienced repeated icing and freeze-up of the pump. In an attempt to remedy the pump freeze-up condition, methanol was added to the air system. However, continual re -occurrence of pump icing freeze-ups prompted the work crew to design and attach a valve/piping arrangement to the pump that facilitated manual delivery of the methanol without the need to remove the air hose. What went wrong? On February 22, during a subsequent use of the double diaphragm pump with the valve/piping arrangement, a technician attempted to add more methanol to the air line by opening the methanol delivery valve on the pump while keeping the air shut-off valve closed. As he opened the methanol delivery valve, trapped pressure in the piping pushed methanol out of the fill pipe and upward toward the Technician. Some of the ejected methanol splashed into the Technician s face and eyes. Total volume of methanol released was approximately 12 ounces. The Technician was assisted to an eyewash station in the Terminal Office where his eyes were flushed for 15 minutes and then an additional 15 minutes. He was then transported to a medical clinic where he was assessed and treated for injury to his left eye. Treatment included prescriptive medicine in the form of eye drops. He was released with work restrictions on chemical use and handling. Work restrictions were lifted after 7 days. The Technician has made a full recovery. Lessons Learned The investigation team determined the technician s failure to recognize the potential for trapped pressure in the piping between the air shut-off valve and the pump as a contributor to the incident. Additionally, his unfamiliarity with the operation of a diaphragm pump and the methanol injection method compounded the potential for an incident. This led to the following recommendations: reviewing the hazard recognition practices with employees investigating alternative solutions to control icing problems with diaphragm pumps reviewing the PPE policy and matrix with employees. Discussion: Think of a time when you modified a job procedure to overcome an obstacle. Can you think of hazards now that you didn t identify then? How might you do things differently in the future? What do you think the criteria should be for involving other people in a procedure change? USPL Contractor Toolkit Q Page 6

7 Good Catch/Near Miss highlights What makes a great good catch / near miss? See something observe a potentially unsafe condition Say something report the near miss to the appropriate parties Do something apply corrective action or follow-up An observed behavior that differs from the expected safe way of working. A condition of equipment, procedure, process operations, or working environment that could either result in an incident or make an incident more likely and/or severe. Contractor performing work not included on ATW Good catch: Construction contractor was spray painting a LOTO box this task was not discussed or included on the ATW. The work was stopped and a conversation was held with the worker and their supervisor. Contractor was instructed on the proper method to add work to the ATW and the importance of documenting all activities to ensure all hazards are properly addressed. Discussion: What additional hazard was introduced by using the spray paint? What impact would this hazard have with SIMOPS? Roll-off Delivery Good catch: Subcontractor delivering roll-off boxes showed up with two boxes on one truck. One was set inside of the other and on its side. There was not going to be a safe/proper way to unload it, so the crew refused the delivery and told the driver to go back and have the load properly placed before returning. Discussion: What could have happened if the roll-off box was unloaded in this condition on the job site? An observed behavior that differs from the expected safe way of working. Not Wearing Proper PPE Good Catch: Employee brought some extra clock springs, metal marking bands and kits to have on hand at job site. While starting to unload them into the job trailer, another employee reached to assist. That employee was not wearing gloves. They immediately got their gloves from their back pocket s and put them on apologizing for not having them on. They had just taken them off to thumb through some paperwork when they notices the other employee at the door and, without thinking, reached out to help. Honest mistake but confirms our need to look out for each other as well as ourselves. Discussion: Describe a situation where someone did not have the proper PPE on for a task. How did you address the situation? Report any near miss to the appropriate BP site contact. USPL Contractor Toolkit Q Page 7

8 Contractor Management Onboarding tool Safety is NOT silent! USPL is rolling out a new contractor onboarding tool so everyone understands the importance each individual regarding the safe execution of work. Whether a contractor or BP-badged employee, each person has the responsibility to use their voice in order to help keep each other safe. BP provides guidance and tools to perform safe work in the foundational core of BP Values (Safety, Respect, Excellence, Courage, and One Team) and in the rules of the road discussed in the Golden Rules of Safety. Each person s voice becomes more critical as you move up the pyramid. Active participation by everyone on the team is essential for a solid, meaningful ATW discussion at the morning tailgate where critical work tasks are evaluated for hazards. Throughout the day, everyone should continually ask What s Your Exposure? of themselves and others in order to stay focused on the task at hand and remember to keep your head in the game by eliminate distractions. Finally, the last line of defense against an injury or unsafe act is YOU! Every single person on the job site has the responsibility to have courage to Stop Work if something doesn t feel or look right. We, in USPL, considers it a success when someone stops the job and we expect your personal commitment to Stop the Job whenever you deem necessary. To learn more about these important concepts, feel free to contact anyone leading an ATW discussion at a jobsite or any of the BP contacts listed on page 10 of this toolkit. USPL Contractor Toolkit Q Page 8

9 Contractor Management Onboarding tool You are in control! Active participation in each of the programs listed above (Golden Rules of Safety, Control of Work, WYE? and Stop Work) is essential to achieving a safe work environment. Think about the day s tasks and determine which procedures apply from the Golden Rules of Safety. Go ahead and review if needed. It takes courage to speak up BEFORE something goes wrong. Be vocal in the ATW discussions. Remain focused on the task by using the WYE? program. Pause from the task if you are distracted. Process through the risks. Plan the course of action, then proceed with the work if deemed safe to do so. Stop the Job by telling jobsite leaders if something doesn t look or feel right to you. You are the last safety barrier before an injury occurs! USPL Contractor Toolkit Q Page 9

10 Contractor Management **NEW Contractor Website** In an effort to better share information, USPL has developed a new Contractor Website. In it, you ll find information regarding our Golden Rules of Safety, HSSE policies, Contractor Toolkits, links to relevant forms and tools used in the field, as well as the latest reports of safety incidents and shared learnings. We intend to keep this link relevant to work in the field and provide current information for the contractor community. Stop in often as this will be a vital pipeline of information! To access the site click on the following link: Statistics As of June 16, 2017, USPL had 275 connected contractors in ISNetworld: 61 A 150 B 21 C (9 on variance) 43 D Key BP Contacts Karen Jacobson Contractor Management Coordinator karen.jacobson@bp.com Mary Anderson EPIC HSSE Project Coordinator andersm3@bp.com Ray Wood HSSE Manager woodrs@bp.com Tom Wedryk Safety Advisor thomas.wedryk@bp.com USPL Contractor Toolkit Q Page 10