The Journey to EHS Excellence

Transcription

1 The Journey to EHS Excellence Contractor Safety Training 150 years

2 Agenda Welcome and Introduction General Safety Rules Use of BASF Equipment Mobile Equipment Contractor Work Areas PPE Safe Work Planning and Permits Pre-Construction Checklists Pre-Task Safety Plans Big 5 Permits Background Checks RC Audit 2

3 What is the Journey to EHS Excellence? The Journey is a multi-year commitment by all North American BASF business units to improve the EHS programs. The primary goals are to: Make BASF as an industry leader in EHS. Improve the safety culture. Involve employee at all levels of the organization. Measure performance, share information, set goals. INTERNAL 3

4 On what is our Journey based? We are the industry leader in EHS practices and performance. The safety and health of people are paramount. This is the foundation of our beliefs. We lead by example. We are the embodiment of responsible behavior in industry. A Zero Incident Mindset (ZIM) is the cornerstone of our culture. Sustainable Development is integral to our business strategies. Every individual in our organization demonstrates commitment to our Values and Beliefs: Together, we Walk the Talk. 4

5 Expectations for our Employees and Contractors 150 years Understand the EHS rules within our plant and make a point to not only comply, but to give input/ideas/suggestions. Report all incidents and participate in the follow-up investigation. Do the little things to be safer, since contractors will often be in a new environment: watch your step/clearances, wear PPE, look over each job carefully, request help/clarification. If you have ideas to make us more safe, please communicate them! Be positive example for safety. 5

6 Use of BASF Equipment Only BASF employees may use BASF vehicles and equipment. Common examples: forklifts, manlifts, golf carts, ladders Liability of equipment failure causing contractor injuries Liability of contractors having incidents (damaging equipment, near misses, injuries) while using BASF equipment BASF cannot train or certify contractors to use BASF equipment. If Contractor work activity involves using this equipment to perform the tasks in job scope, include in the quote/bid. BASF has and will continue to support incidental use of forklifts and manlifts. Examples are: Moving equipment/pallets to general work area Re-spotting equipment if congestions/obstacles are an issue Hauling debris to dumpster 6

7 Golf Carts Safe Operation Good Condition Horn Required - use horn at all doors Backup horns required by May 1 Charge in designated/approved non-electrical classification area Contractor Shed: GW, Renfro Corner of Warehouse: Covan Battery charger cannot be stored on the golf cart 7

8 Aerial Lift Requirements Using aerial lifts, boom lifts, scissors lift, etc. Harnesses and lanyards are required at all times. Harnesses and lanyards are required during traveling, even if you are below six feet. Basic Rule: If you are in the basket or on hand rails, have your harness on, and tie off your lanyard. Daily Inspection 8

9 Contractor Work Area Map of General Areas next slide Area beside Maintenance Shop Material staging and delivery can still be designated for other areas of the sitecan identify in the Pre-Construction meetings No truck traffic around Bldg. 89 nor behind the cooling tower always use the gates Parking near Security Guard House Smoking in designated areas only outside canteen and outside office parking area only if accompanied by a BASF Maintenance employee who can badge in/out door with security badge: this door cannot be propped open 9

10 150 years Maintenance Shop and Contractor Sheds 10

11 Plant-Wide PPE When working in the plant, including walking throughout the plant, the minimum requirements are: Hard Hats Safety Glasses Long Sleeved Shirts; clothing in good condition Steel Toe Shoes NO CELL PHONES - If you are driving into the plant, your cell phones(s) must be turned off and stowed in your glove boxes. Issues Electrical Classification - Intrinsically safe - we have several areas that are Class1. Div1. at the Mauldin Plant. Security Cameras are not allowed within the fence line unless approved. Phones are a distraction. 11

12 Exempt Areas for PPE Office Areas Canteens Locker Rooms Maintenance Break Area Smoking Areas You must wear basic PPE in all other areas. (hard hats, safety glasses, steel toe shoes, long sleeves) 12

13 Contractors Responsibilities Identify PPE required for the job during the pre-construction meeting. The Contractor s employer shall assign PPE. This includes all PPE such as safety glasses, face shields, gloves all types, sleeves, aprons, harnesses, beam clamps, etc. You must inspect PPE before each use and replace it if it is not in good condition. BASF will not supply PPE to contractors. 13

14 Contractor s Pre-Construction Checklist Use as a construction Kickoff meeting for Capital projects. 14

15 Contractor s Pre-Construction Checklist Use as a construction Kickoff meeting for Capital projects. This typically occurs 1-2 weeks before construction starts. 15

16 Contractor s Pre-Construction Checklist Use as a construction Kickoff meeting for Capital projects. This typically occurs 1-2 weeks before construction starts. It is required at the beginning of each job even if the contractor has been on site. 16

17 Contractor s Pre-Construction Checklist Use as a construction Kickoff meeting for Capital projects. This typically occurs 1-2 weeks before construction starts. It is required at the beginning of each job even if the contractor has been on site. If a change in personnel occurs, either from the contractor or BASF, you must do the Pre- Construction checklist again. 17

18 Contractor s Pre-Task Safety Plan Form Use this form for contractor or vendor jobs covered through the work order system. Job Activity: Foreman: Name List each person covered by this PTSP Initial Company: Date: Completed By: Hot Work Safe Work Job Scope Understood Lines drained & purged Personal Protective Equipment Safety Glasses Face Shields Job Preparation Tasks LT&T Verified Flammability Check Body Harness Electrical PPE Contractor Pre-Task Safety Plan (PTSP) "My Plan for a Safe Job" MSDS Reviewed Communicated work to others in area Gloves Kevlar Sleeves Types of Hazards "Expect the Unexpected" Circle all that apply Access: Congested area, Uneven ground, Slippery surfaces Caught In / Struck by: Sharp objects, Pinch points, Hot/cold surfaces, Open holes, Overhead workers, Struck by objects Environment: Noise, Dust, Weather, Lighting, Heat, Wet areas, Wind, Plant Processes Ergonomic: Bad body position, Improper body position (awkward objects or work position), Excessive force (heavy objects, torque), Excessive repetition, Excessive duration, Over-reaching Other All PPE Inspected and in Good Condition? Tools and Equipment List all tools and equipment required for the task All Equipment Inspected and in Good Condition? GFCI Protection must be provided by contractor for all electric hand tools and devices Elevated Work Plan List the tie-off plan for any elevated work BASF Contact must observe initial lift Falls: To a lower level, At the same level, Floor or wall opening, Unprotected perimeter, Climbing Hazardous Material: Burns, Exposure, Inhalation, Splashing, Fumes, Spills, Airborne Particles Other Hazards: Safety Reminders Housekeeping-must keep area clean/free of debris Report Near Miss/First Aid/Injuries Immediately No Electronic Equipment (i.e. cell phones) Non-English Speaking Workers-Inerpreters Required at all times Fire Watch-Must be provided; sole activity for this individual Vehicle Rules-park outside gate, walk in, unless truck necessary List Safeguards to Control/Eliminate Hazards Could objects fall from elevated heights? Evacuation Point: Guard House or Admin Bldg Front Parking Nearest Fire Extinguisher Nearest Eye Wash Nearest Pull Station Working Hours: Safety is a value, not just another priority! 18

19 Contractor s Pre-Task Safety Plan Form Use this form for contractor or vendor jobs covered through the work order system. Us this form when meeting with a contractor or vendor at the time of the quote. Job Activity: Foreman: Name List each person covered by this PTSP Initial Company: Date: Completed By: Hot Work Safe Work Job Scope Understood Lines drained & purged Personal Protective Equipment Safety Glasses Face Shields Other Job Preparation Tasks LT&T Verified Flammability Check Body Harness Electrical PPE All PPE Inspected and in Good Condition? Tools and Equipment List all tools and equipment required for the task All Equipment Inspected and in Good Condition? GFCI Protection must be provided by contractor for all electric hand tools and devices Elevated Work Plan List the tie-off plan for any elevated work BASF Contact must observe initial lift Contractor Pre-Task Safety Plan (PTSP) "My Plan for a Safe Job" MSDS Reviewed Communicated work to others in area Gloves Kevlar Sleeves Types of Hazards "Expect the Unexpected" Circle all that apply Access: Congested area, Uneven ground, Slippery surfaces Caught In / Struck by: Sharp objects, Pinch points, Hot/cold surfaces, Open holes, Overhead workers, Struck by objects Environment: Noise, Dust, Weather, Lighting, Heat, Wet areas, Wind, Plant Processes Ergonomic: Bad body position, Improper body position (awkward objects or work position), Excessive force (heavy objects, torque), Excessive repetition, Excessive duration, Over-reaching Falls: To a lower level, At the same level, Floor or wall opening, Unprotected perimeter, Climbing Hazardous Material: Burns, Exposure, Inhalation, Splashing, Fumes, Spills, Airborne Particles Other Hazards: Safety Reminders Housekeeping-must keep area clean/free of debris Report Near Miss/First Aid/Injuries Immediately No Electronic Equipment (i.e. cell phones) Non-English Speaking Workers-Inerpreters Required at all times Fire Watch-Must be provided; sole activity for this individual Vehicle Rules-park outside gate, walk in, unless truck necessary List Safeguards to Control/Eliminate Hazards Could objects fall from elevated heights? Evacuation Point: Guard House or Admin Bldg Front Parking Nearest Fire Extinguisher Nearest Eye Wash Nearest Pull Station Working Hours: Safety is a value, not just another priority! 19

20 Contractor s Pre-Task Safety Plan Form Use this form for contractor or vendor jobs covered through the work order system. Us this form when meeting with a contractor or vendor at the time of the quote. This form helps to jointly assess safety issues at the initial job review. Job Activity: Foreman: Name List each person covered by this PTSP Initial Company: Date: Completed By: Hot Work Safe Work Job Scope Understood Lines drained & purged Personal Protective Equipment Safety Glasses Face Shields Other Job Preparation Tasks LT&T Verified Flammability Check Body Harness Electrical PPE All PPE Inspected and in Good Condition? Tools and Equipment List all tools and equipment required for the task All Equipment Inspected and in Good Condition? GFCI Protection must be provided by contractor for all electric hand tools and devices Elevated Work Plan List the tie-off plan for any elevated work BASF Contact must observe initial lift Contractor Pre-Task Safety Plan (PTSP) "My Plan for a Safe Job" MSDS Reviewed Communicated work to others in area Gloves Kevlar Sleeves Types of Hazards "Expect the Unexpected" Circle all that apply Access: Congested area, Uneven ground, Slippery surfaces Caught In / Struck by: Sharp objects, Pinch points, Hot/cold surfaces, Open holes, Overhead workers, Struck by objects Environment: Noise, Dust, Weather, Lighting, Heat, Wet areas, Wind, Plant Processes Ergonomic: Bad body position, Improper body position (awkward objects or work position), Excessive force (heavy objects, torque), Excessive repetition, Excessive duration, Over-reaching Falls: To a lower level, At the same level, Floor or wall opening, Unprotected perimeter, Climbing Hazardous Material: Burns, Exposure, Inhalation, Splashing, Fumes, Spills, Airborne Particles Other Hazards: Safety Reminders Housekeeping-must keep area clean/free of debris Report Near Miss/First Aid/Injuries Immediately No Electronic Equipment (i.e. cell phones) Non-English Speaking Workers-Inerpreters Required at all times Fire Watch-Must be provided; sole activity for this individual Vehicle Rules-park outside gate, walk in, unless truck necessary List Safeguards to Control/Eliminate Hazards Could objects fall from elevated heights? Evacuation Point: Guard House or Admin Bldg Front Parking Nearest Fire Extinguisher Nearest Eye Wash Nearest Pull Station Working Hours: Safety is a value, not just another priority! 20

21 Contractor s Pre-Task Safety Plan Form Use this form for contractor or vendor jobs covered through the work order system. Us this form when meeting with a contractor or vendor at the time of the quote. This form helps to jointly assess safety issues at the initial job review. Job Activity: Foreman: Name List each person covered by this PTSP Initial Company: Date: Completed By: Hot Work Safe Work Job Preparation Tasks Personal Protective Equipment All PPE Inspected and in Good Condition? Tools and Equipment List all tools and equipment required for the task GFCI Protection must be provided by contractor for all electric hand tools and devices Contractor Pre-Task Safety Plan (PTSP) "My Plan for a Safe Job" Types of Hazards "Expect the Unexpected" Circle all that apply Access: Congested area, Uneven ground, Slippery surfaces Caught In / Struck by: Sharp objects, Pinch points, Hot/cold surfaces, Open holes, Overhead workers, Struck by objects Environment: Noise, Dust, Weather, Lighting, Heat, Wet areas, Wind, Plant Processes Ergonomic: Bad body position, Improper body position (awkward objects or work position), Excessive force (heavy objects, torque), Excessive repetition, Excessive duration, Over-reaching Falls: To a lower level, At the same level, Floor or wall opening, Unprotected perimeter, Climbing Hazardous Material: Burns, Exposure, Inhalation, Splashing, Fumes, Spills, Airborne Particles Other Hazards: Safety Reminders Housekeeping-must keep area clean/free of debris Report Near Miss/First Aid/Injuries Immediately No Electronic Equipment (i.e. cell phones) Non-English Speaking Workers-Inerpreters Required at all times Fire Watch-Must be provided; sole activity for this individual Elevated Work Plan Vehicle Rules-park outside gate, walk in, unless truck necessary This form assists the permit List the tie-off plan for any elevated work List Safeguards to Control/Eliminate Hazards BASF Contact must observe initial lift writer for Safe Work to identify Evacuation Point: Guard House or Admin Bldg Front Parking Nearest Fire Extinguisher Nearest Eye Wash specific hazards and qualifies Nearest Pull Station Working Hours: Could objects fall from elevated heights? the job scope at the time of Safety is a value, not just another priority! execution. 21 Job Scope Understood Lines drained & purged Safety Glasses Face Shields Other LT&T Verified Flammability Check Body Harness Electrical PPE MSDS Reviewed Communicated work to others in area Gloves Kevlar Sleeves All Equipment Inspected and in Good Condition?

22 Overview of Permits BASF Mauldin uses the following procedures and permits known as the Big 5: Safe Work Hot Work Lock Out / Tag Out (LOTO) Line Breaking Confined Space Only the owning departments (that department responsible for equipment and day-to-day work in the area) can manipulate any equipment with the only exception by permission being granted by one of the permits above. New Permit for Drilling and Excavation for 2015 Lifting and Rigging Permit - goal to develop and roll out in Q

23 Overview of Safe Work Service / Maintenance Work is a separate or different activity from operations work. (BASF s philosophy on equipment ownership) Safe Work Permits can be combined with other permits, e.g. Hot Work, Line Breaking, etc. Requires permit issuer and permit acceptor to visit the area where work is to be performed If any conditions written on the permit change, revalidation is required. 23

24 Permit Issuance Must be within 2 hours of work starting If work is suspended for 2 hours, permit must be re-issued If a Safe Work Permit is issued to a crew, BASF issues it to the Foreman or Team Lead. The Foreman or Team Lead is responsible for reviewing it with his/her crew. By the Permit Acceptor signing the permit, he/she is certifying that all of the people on the permit have been trained to use equipment / PPE and agree to conditions of permit. On the reverse side of the permit, all personnel who are working under the permit must sign acknowledging they understand the requirements of the permit. 24

25 Overview of Hot Work What is Hot Work? Hot work is Flame- or Spark-Producing Hot Work welding, grinding, cutting, burning, brazing, soldering Non-rated Electrical Equipment Hot Work in electrically classified areas Vehicle Access in electrically classified areas 25

26 Overview of Hot Work Fire Watch Duties One s only responsibility is to perform fire watch. (cannot perform any other tasks) Be present in the area during the entire duration of hot work and at least ½ an hour after completion. Be equipped with fire fighting equipment (fire extinguisher). Shut down hot work if you observe a hazardous condition. Be knowledgeable in site Emergency Response procedures and be able to implement them. When continuous air monitoring is required, you must record readings every hour on the permit. 26

27 Overview of Lock Out / Tag Out A Lock Out / Tag Out permit must be issued when performing a job that has the possibility of unexpected or unintentional release of energy that could cause injury. The Owning Department shall perform locking out of equipment, but it is the responsibility of the service personnel to put their lock on the equipment or the lock box and sign the permit. 27

28 Overview of Line Breaking What is Line Breaking? Line Breaking is opening/separation/removal of equipment to a point at which it can be positively determined that no residual materials (liquid, gas, solid) or pressure are present or are controlled to the extent that they no longer pose a hazard to personnel. When is a permit needed? No personnel, including Operating/Owning Department personnel, shall perform a Line Break without the prior written authorization in the form of a permit issued by an Owning Department representative. 28

29 Overview of Line Breaking Line Breaking Permit Issuance will include the Owning Dept. Rep. and all service personnel involved in the line breaking and will be reviewed at the worksite: 1. Review LOTO verifying each Tag # and Lock in the field against LOTO permit. 2. Verify the complexity of the system. 3. Verify PPE requirements taking into account other lines in the vicinity of the line break. 4. Identify preparation and cleaning measures on the permit. 5. One may exercise an option to review the formal isolation plan. 29

30 Overview of Confined Spaces A confined space is defined as any equipment, sump, or trench that Can be complete entered by a person s whole body Has limited or restricted means of egress Is not designed for continuous personnel occupancy 30

31 Overview of Confined Spaces All confined space entries require permitting. At no time should any part of one s body enter into a confined space without a permit. All entrants and attendants must be trained in confined space entry and have their certification with them at the time of permitting. 31

32 Overview of Drilling and Excavation Drilling and Excavation Procedure, Safety Manual, Section 9.05 Applies to any on site drilling in the earth Applies to any excavation >4 inches Ground Breaking Permit Must be completed before starting any ground breaking activities It is primarily the responsibility of Project Manager and Maintenance Planner to initiate the Ground Breaking permit. Will require additional protective systems for any excavations that go deeper than 4 feet 32

33 Background Verification For each contractor working at the site, we will need a Contractor Background Verification Certificate ONLY that verifies that a background check has been performed in accordance with BASF requirements. If the Contractor is in PICS, they are already aware of the requirements of conducting a background check; however, they may not have read PICS thoroughly enough to realize that the Verification Form is required. Who is a Contractor? Applicability is defined in BC , which states that a contractor is a non-employee engaged through a thirdparty agency for the performance of specific functions. These individuals: perform services with the general oversight of the company, and generally do not but may perform services for third parties at the same time. 33

34 ISSUE: What does the form require? (It is very straightforward.) 150 years 34

35 The Contractor must receive the form letter in advance. The letter will instruct them where to send the form. 150 years For your employees who are expected to work at our site, please furnish the attached Contractor Background Verification Certificate via or in a sealed envelope marked Confidential at least 48 hours before the start date of your employee working at our site (excluding weekends and holidays). certificates to: kimberly.patty@basf.com (preferred) or Sealed envelope marked Confidential mailed or hand delivered to: BASF Corporation 1520 Old Stage Road Mauldin, SC Attn: Kim Patty If you have questions about the background verification process, contact: Kim Patty Or Mike Gantt

36 What will happen going forward? As we communicate to contractors, verification forms should be arriving to K. Patty, who will then enter them: 1. Contractor arrives. 2. Security will check contractor spreadsheet on G: drive to confirm that the verification form is complete. 3. If yes, no issues exist. 4. If no, Security will do the following: Call the contractor s contact person to notify him/her that the contractor cannot come onto the site. You will then have to work with the contractor s company to reschedule for another day. 36

37 General Safety Reminders Housekeeping - Keep your area clean. PPE - Store it properly. Do not have any medicine visible. Do not have any food or drink or smokeless tobacco or wrappers/bottles in contractor the work area, on golf carts, in tool boxes, in buckets, etc. GMP Rules prohibit use because of contamination of packaging/products and also attracting rodents. HAZCOM prohibits because consumption of trace chemicals on food/drink if taken into process areas. Knife Policy: Only retractable knives are allowed. No pocket knives or box cutters are allowed. No PPE (hardhats, gloves, etc.) in canteens. Keep PPE outside. Store ladders properly. Chain cylinders correctly. All aerosol cans must be stored in a flammables cabinet. Remove them from your contractor area. 37

38 Aerosol Cans: Store in Flammables Cabinet. You can t leave these in drawers, on shelves, or on tables. 150 years 38

39 PPE Storage: Respirators need to be in bags. General Housekeeping: Clean drawers and shelves. 150 years 39

40 PPE Storage: Dust respirators should remain in a box and thrown away after use. Aprons/raincoats should not obstruct fire extinguishers. 150 years 40

41 Shields must have clear visibility. Use electrical cords/extension cords ONLY as TEMPORARY power. Store them after each use. 150 years 41

42 Compressed Gas Cylinder Storage: Chain without slack. 150 years 42

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