Essar Steel Approach towards Process Safety Management (PSM)

Transcription

1 Essar Steel Approach towards Process Safety Management (PSM)

2 Who we are: Essar Steel India Ltd., Hazira

3 Hazira: Process Flow

4 HSE Policy & Systems Essar Steel strongly believes in the saying Nothing is more important than the Safety & Health of people who work in the plant The foundation of our Strong HSE Management System are HSE Policy Safety Mandates A Fatality Prevention Tool HSE Cardinal Rules HSE Code of Conduct Directly emphasizing that HSE is at the center of our business planning, designing and decision making process Now let us witness how we approach towards Process Safety Management System.

5 PSM Culture PSM Culture = f (Technology, Facility & People)

6 PSM Governance Structure

7 PSM Roles & Responsibilities PSM cell acts as a think-tank and assisting Operations Dept. Manager (Process) will monitor process parameters & health of the plants. He will design minor modifications & carry out major modifications / expansions with coordination of design group & Plant personnel. Manager (Engineering) will carry out Engineering jobs for minor / medium modifications with coordination of design group & Plant personnel. Manager (Inspection) will check the health of equipments like pipelines, columns, vessels, furnaces, tanks etc. It will inspect all of them at periodical intervals & give recommendations for their replacement/repair.

8 Monthly HSE Review Meeting at Department Level

9 Monthly Apex Committee Meeting

10 Monthly Plant HSE Engineers Review Meeting

11 PSM Elements Technology Facility People Process Safety Information Process Hazard Analysis Standard Operating Procedures Mechanical Integrity Management of Change Pre-Start up Safety Review Training Contractors Safety Management Employee Participation Incident Investigation Work Permit System Compliance Audit

12 Where we were in 2010? Essar Engaged Competent Third Party Auditor to carry-out Gap Analysis of PSM Systems Third Party Audit Outcome Average score 55%

13 Implementation of Process Safety Management System PSM Workshop to the Senior Leadership Team & Company Employees Formation of PSM CELL- Headed by Director of Facility & VP & Head, HSE Apex Team To lead the PSM elements. PSM Core Operating team and sub-committees in each department for Continuous improvement. PSM ROADMAP Rolled-out PSM Guidelines Launched Online PSM Portal, PSM Library, Mangement of Change PSM Elements incorporated in our Standard Operating Procedures Screening of PSM Video Films across the Facility Internal Self-Assessment & Cross Functional Audit of all PSM elements in respective departments by Core PSM Members. External Audit of PSM to assess our PSM Implementation & Improvement areas

14 Process Safety Measurement Tools PSM Leading Indicators: 1) Asset integrity 2) Management of change 3) Process Safety Training PSM Lagging Indicators: 1) Process related injuries 2) Releases of hazardous material or energy from plant equipment 3) Fires 4) Explosions

15 Rolled Out PSM Guidelines This document contains the guiding steps for Process Safety Management implementation.

16 Online PSM Portal & Library PSM Portal Launched: Process safety management Online Portal made accessible to all members of the organization, incorporating Standard Operating Procedures, Leading & Lagging Indicators, PSM resources, PSM Library as per model of CCPS (Centre for Chemical Process Safety)..

17 Online Near Miss Portal

18 Online Safety Action Memo (SAM) Portal

19 Online MOC (Management of Change)

20 Safety Guide for COREX, BLAST FURNACE & ASU

21 Gas Safety Manual Gas Safety Manual Safety Guides on CO Hazards & Mitigation Measures

22 PSM Elements incorporated in our SOP To align the PSM elements to our production & regular activities, they have been incorporated in our S.O.P. so that every individual is well aware of its requirements and its implementation.

23 Screening of PSM Video Films across the facility This Video Films provides an in-depth study of each PSM element. It introduces each PSM element in Case studies and exercises are screened throughout the Clips to illustrate interpretations of the requirements and demonstrate ways to develop an effective PSM program, including several video based case studies.

24 PSM Campaigns to evoke involvement among of all levels of employees and associates.

25 Proactive Measures / Leading Indicators One Day Safety Officer Concept One Day Safety Officer Concept In order to demonstrate visible commitment & involvement of Plant Managers towards Safety, one innovative Safety Practice One Day Safety Officer concept has been initiated. To understand the dynamics of Safety Function & Responsibility, each Manager will perform the role of a Safety Officer, as per his schedule/convenience. In short they wear the cap of a Safety Officer. Plant HSE Engineers Plant HSE Engineers are the extended arms of HSE Department. They ensure the deliverables on HSE in their respective department for the period of 6 months. Theme Based HSE Drives To bring uniformity across the Essar Steel Hazira Complex & streamlining HSE process, we have identified monthly HSE themes like Safety Mandates, Electrical Safety, Work Permit System, Crane Safety etc. which are being focused by all the departments, on monthly basis.

26 Proactive Measures / Leading Indicators Mass Sensitizing Safety Awareness sessions Mass Safety Awareness sessions was organized for Sensitizing and interacting on the shop floor, so as to engage the personnel to work towards producing steel in a clean, healthy & safe workplace with the cooperation of all the stakeholders The Main Aim of the Program is information sharing, Learning from past incidents of Essar and other industries and gathering Feedback from the associates and employees at shop floor. I am Leader I will Demonstrate my Commitment To show the accountability towards HSE I am Leader & I will Demonstrate my Commitment involving 112 Senior Executives initiated Cross Functional HSE Audit by Senior Leadership: HSE Audits carried out to measure HSE Performance of various Departments against established goals

27 Proactive Measures / Leading Indicators HSE Thrust Drives HSE Drives are the special Safety Audit drives conducted in Plants involving the respective Plant HODs, Section Heads, Plant Engineers and Safety coordinator etc. to create a sense of belongingness towards Safety. The main benefit of these HSE Drive program is to identify potential Safety hazards / Environmental impacts & violations so that facilities can correct them before they result in to accidents / incidents. Most importantly, timely correction will prevent injury to employees and contractors. ensure a productive and HSE friendly workplace. BBS Journey Behaviour Based Safety Journey across entire Steel Hazira Plant, by the engagement of External Experts so as to bring about a change in the Beliefs,Values & Attitudes of people towards implementing the best in class HSE Practices & Initiatives. HSE Seminars / Workshops / Knowledge Sharing Sessions HSE Seminars / Workshops / Knowledge Sharing Sessions carried out on the Topics of Radiation Safety, Safety in Material Handling, Safety Management System, Environment Management System etc. for promoting HSE Awareness amongst employees

28 Employees Engagement Trainings & Competency for Company Employees Level 1 Online HSE Training: Online HSE Training for all Levels of employees Level 2 Class Room HSE Training Five days HSE Induction Training for new joiners (DET s/ GETs/ MTs) Two days certified training for Laterals Level 3 Rotational Training: Plant HSE Managers are pulled out for a period of 6 months in HSE and put through rigorous training. They ensure the deliverables on Safety in their respective departments Specific Training: Specific Training imparted on various Risk Assessment methods, Process Hazard Analysis, Work Permit System, Incident Investigations, Contractor Safety Management, Standard Operating Procedures, Work at Height, Material Handling, LOTO, Legal requirements, Behavioral Based Safety, Environmental Legislation etc. by internal & external experts. Defensive Driving Training (DDT) program is made compulsory for all the drivers to undergo this program followed by on the road assessment.

29 Trainings & Competency for Contractor Employees 1 Day Certified HSE Induction Training for Contractor Employees Competency Assessment & Certified Crane Operator Training Competency Assessment & Certified Rigger Training Competency Assessment & Certified Work at Height Training 16 days On the Job Safety Induction Training for contractors after Screening &Selection Sr. Description Period 1 Classroom Induction training as per the departmental Module. Do s and Don ts of their plant premises Brief about Past incidents happened in the plant 1 Day 2 Site visits as per the departmental module Work at Height Training Confined Space entry training 3 Days 3 HIRAC, SOPs, SMPs, Awareness Emergency Preparedness for respective Plant Safety Mandates & Work Permit System Interaction with Area In charge/ HOD before deputation to on the job training. 2 Days HSE Directive for Penalty - Safety Non-compliance 4 On Job training in the department 3 Days a. Class Room b. Site Visit 7 Days

30 HSE TRAININGS UNDER THE ROOF OF JAGRUTI, GYANDEEP, KSHITIJ, SHIKSHA, NAVCHETANA, TAKSHILA, SUGAM, NALANDA, PAATHSALA, PARAMARSH, AVARTAN, SUVIDHYA, GYANAYAN, ADHYAYAN, GYANDEEP AT VARIOUS PLANTS / DEPARTMENTS

31 Contractors HSE Management System Contractor Capability Assessment Carried Out With Respect To HSE Requirements Prior To Award of Contract and Post Award of Contract Ensuring Commitment and Compliance of our Contractors in relation to our HSE Policy. HSE Directive for Penalty for Safety non-compliance & accidents for contractors Monitored Contractors HSE Performance through: Half-yearly Contractors HSE Performance Audit Conducting tripartite meeting for Contractors Conducting Bi-Monthly HSE Communication meet HSE Induction movie introduced for Contractor Workers Mandatory Competency Assessment for Safety Critical Jobs (e.g. Crane Operators, Riggers, Working at Height etc.)

32 Competency Matrix for Contractors Competency Matrix - Contractor Associates S. Requirem No. ent Type Category Area Minimum Age on Joining (Years) Minimum Qualification Min. Work experien ce (Years) Valid License / Certificate Specific safety training Medical Fitness Remark 1 Statutory Operator-Fork Lift Plant 23 10th pass 5 HMV (License approved by State Govt.) 1.HSE & F Induction Training 2.Pre-assessment training 1.Fitness Certificate. 2.Ear & Eye Test Certificate 3.Colour Blindness Test. On the job Training 2 Statutory Operator-Excavator Plant 23 10th pass 5 HMV (License approved by State Govt.) 1.HSE & F Induction Training 2.Pre-assessment training 1.Fitness Certificate. 2.Ear & Eye Test Certificate 3.Colour Blindness Test. For the Hot metal handling operator once in a Six month eye vision to be checked. 3 Statutory Technician-Electrical- Junior (Jr.) Electrician Plant 20 ITI 2 Educational + Experience Certificate + Wireman License approved by State Govt 1.HSE & F Induction Training 2.Job specific safety 3.W@H 1.Fitness Certificate. 2.Ear & Eye Test Certificate 3.Colour Blindness Test. On the job Training Implemented Competency Matrix for 95 Categories

33 Bi- Monthly Contractor Safety Communication Meet

34 Weekly Rigger Competency Assessment & Training

35 Certified Work at Height & Scaffolding Trainings

36 Implementation of Behaviour Based Safety Journey BBS Workshops to the Senior Leadership Team Formation of BBS Steering Committee Identified department wise BBS Lead Trainers Launched Online Web-portal for Behavior Based Safety (BBS) BBS committees for developing BBS Observers BBS committee for Contractor developing Contractor Observers BBS Supporting Team for Promoting BBS through Displaying BBS Signages / BBS Stickers / Caps.

37 Online Web-portal for Behavior Based Safety (BBS)

38 Glimpse of BBS Training Sessions

39 Implementation of Safety Index Safety Index - A Strategic deployment tool for measuring and monitoring Safety Performance of Respective departments (Composite Index of Leading & Lagging Indicators) Minimum Level for Safety Index is 95% for Individual departments The Departments who have achieved less then 95% Safety Index are considered as nonperformer for the particular month.

40 Review of Safety Index by Steering Committee Steering Committee headed by CEO & MD. Frequency Once in a month.

41 World Steel Safety Day & Month Celebration

42 Reactive Measures / Lagging Indicators Accidents Statistics Monitoring and presentation in Monthly HSE & other Business meetings. Safety Time Out Sessions: After occurrence of severe accident/incidents/fatality, a session for those who are directly involved or exposed to similar activities are required to come out from day to day activity and assemble away from their work place to impart them the information (s) & learning from the accidents to prevent the reoccurrence. Effective Accident Investigation by Senior Management Team though Root Cause Analysis methodology. Well prepared & Sound Emergency Response Plans in place and the same executed by rigorous mock drills on various incident scenarios. Safety Alerts are circulated through s & also published on HSE portal.

43 Safety Time-Out Session by CEO & MD

44 Incident Reporting Procedures All the incident like HIPO Near Miss, Process Incidents, FAC, MTC, LTI, FATAL are thoroughly investigated by investigation team. In case of any incident happened at any plant: FIR to be submitted within 01 hours. other wise 01 marks will be deducted from HSE Index. Alert to be submitted within 24 hours. otherwise 01 marks will be deducted Accident Investigation Report to be submitted within 01 week. otherwise 01 marks will be deducted Action Taken Reports to be completed within given timeframe - otherwise 01 marks will be deducted per month from HSE Index. In case of any injury like MTC, LTI reporting of the injured person to be done after medical certification of Certified Medical Officer. Other wise 0.1 Marks per day will be deducted from the HSE Index till the person is joined in the plant.

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46 Way Forward : PSM Journey Continued. Review of Start-up And Shut-down Procedure Review of Logic and Interlocks with the Process Operator Review of Process P & IDs 2015 to 2017 Review of the Equipment drawing, Process flow Diagram & Final Process and Instrument Diagrams Revisiting and Updating of Process Safety Data Review of Burner Management System Review of Hazop Study Review of Dangerous Failures Not Resulted Into Incident

47 THANK YOU