One Source, Many Solutions JV Industrial Companies
Houston Business Roundtable Safety Excellence Awards Best Practices
JV Industrial Companies Turnarounds Fabrication Engineering New Construction Procurement Catalyst and Chemical Cleaning JVIC Service Offerings 25,000 Current / Former Craft 3,100 Daily Average Manpower Employee Base Office Locations Corporate JVIC group operations in seven states Corporate Headquarters – Pasadena, Texas Five Fabrication Facilities 16 US Locations
JVIC Best Practices Initiative to Improve Safety Culture September 2010-February 2011- Executive committee produced and implemented the following programs. Complete rewrite of Supervisor Training- major emphasis on Foreman Expectations, safety culture; Develop and Implement new Permit Recipient Training course Rewrite Task Safety Analysis forms, develop scoring and training tools Develop scanning/report system for CARE cards Implement www.asafejv.com online portal/database for reporting all Preliminary Incident Notification and Management Affects Safety Culture information, and data analysis/report tool to allow trend analysiswww.asafejv.com
JVIC Best Practices Initiative to Improve Safety Culture Revise dispatch/hiring process. Begin larger analysis of overall process of evaluating/ranking employees and dispatching based on work history rather than field supervisor request Revise MASC requirements and refine process to provide more safety- focused Management presence in the field. Develop Stop Work Authority cards, provide training and education in field to promote employee ability to enforce safety culture and stop work if unsafe. Develop standard set of company Core Values, around safety focus, to ensure all divisions aligned and to establish a standard to measure consistency. Create client and employee project evaluations of adherence to core values to measure consistency across organization.
JVIC Best Practices Initiative to Improve Safety Culture Review and improve SIRC meeting process to ensure employees involved in an incident, along with foreman, GF, and supervisor meet with management committee after an incident. Develop Foreman Evaluation process to measure foreman performance in adherence to Core Values. Develop standard mandatory project kick off meeting tool focusing on safety and foreman expectations.
JVIC Best Practices Items highlighted for the audit team PIN process TSA program
JVIC Best Practices Items highlighted by the audit team Welder’s University Foreman’s Bootcamp Stop Work Authority
JVIC Best Practices PIN details Preliminary Incident Notification (PIN) is a tool to provide JVIC Management with immediate initial notification and basic preliminary information for any injury, safety related incident or unsafe act/violation. The following situations warrant a PIN Distribution: Any injury regardless of severity Any non-injury incident, property damage, unsafe act or policy violation Major safety rules violation Violation against policy of discrimination or harassment Release or spills of chemicals or process products Equipment or tool accidents or failures Any Near Miss (unintended event)
JVIC Best Practices PIN details Follow-up details One hour notification Classified as either OPEN or CLOSED Weekly report out to review outstanding items Annual data trending
JVIC Best Practices Standing Task Safety Analysis A pre-written TSA for standard tasks, bolting, exchangers, welding, towers, etc. The standing TSA is reviewed by the crew prior to the work. Task Safety Analysis A TSA addressing specific hazards of the area and the work. The TSA is written at the work site after identifying the hazards. A TSA is required for all tasks except administrative tasks. TSA details
JVIC Best Practices TSA details Description of the task to be performed: Install Blinds at Vessel D-101 Task StepsHazardsControls/Mitigation/Elimination 1. Access flange location.1A. 1B. Fall due to incomplete guardrail at platform 3. 1A. Tie off to 6” pipe.. 2. Unbolt flange.2A. Release of hazardous liquid or vapor. 2B. Falling tools, studs, nuts, blinds. 2C. Headknocker – 6 inch pipe above work location. 2A. Supplied Air Respiratory Protection. 2A. Slicker suit 2A. Unbolt studs away from body position – retighten if pressure present. 2B. Secure tools, studs and nuts in tool bag. 2B. Lay blinds flat on platform. 2B. Barricade ground area below platform. 2C. Mark 6 inch pie with red warning tape. 3. Spread flanges and insert blind.3A. Hand pinchpoints @ 12 inch flange.3A. 3A. Keep hands out of pinchpoint locations. 3A. Talk to each other about what you are going to do. 3B. Mitigate hazard by using flange spreader. 4. Area hazards4A. Work by other contractors in the area. 4B. Material stored in work area. 4A. Separate work areas by barricades. 4A. Schedule work to eliminate multiple level work. 4B. Eliminate hazard by removing material TSA EXAMPLE 1
JVIC Best Practices TSA details THE SCAN / TSA PROCESS SCAN the work area to identify area hazards and hazards specific to the task. SCAN Survey the surroundings for potential hazard and unsafe conditions Look at the work with a critical eye. Identify “traps” that could cause trouble Prepare for the unexpected SCAN Consider how your actions could create a hazard (Unsafe Acts) Are the appropriate procedures being followed? Have all the hazards been eliminated or mitigated? Have all hazards been properly marked or barricaded?
JVIC Best Practices TSA details SCAN Analyze “What could go wrong?” Can weather conditions change the work environment? Too wet, too hot, a gusting wind Inexperienced personnel on the job Precautions in place in case of equipment failure Others working near by SCAN Notify your supervisor if you are unable to correct or eliminate the hazard Use the Stop Work Authority – You have the responsibility and authority to stop work that is not safe
JVIC Best Practices TSA details The specific task is defined and entered on the TSA form. Reference any Standing TSA or High Hazard TSA on the form Mitigation actions listed on a Standing TSA or High Hazard TSA do not have to be repeated on the TSA Addendum. The task is broken into steps. Hazards are identified for each step. Controls, recommended actions or procedures are identified for each hazard. Communicate SCAN and TSA information to all involved including a review of a Standing or High Hazard TSA. Writing a TSA is similar to accident investigation but rather than asking “What caused this incident?”, we ask “What could happen and what will prevent it?”
JVIC Best Practices TSA expectations A TSA will be completed for each permitted task. One permit - One task – One Company Depending upon the scope of the permit, more than one TSA may be needed TSAs will be reviewed with the crew in an open discussion format. Involvement and suggestions from the crew is expected. In addition to controlling a hazard, there is an expectation for hazard elimination. TSAs will be posted with the permit. Quality TSAs are an expectation of each Foreman. TSAs will be reviewed for quality in the field. At the completion of the work, all TSAs will be forwarded to the safety department for review and file. The accident investigation process includes a review of the TSA for the task that was being performed. The investigation asks, Was the hazard that caused the accident identified and were the controls in place?. TSAs will be audited and scored with feedback given to the Foreman/Supervisor. Composite TSA scores will be complied for each project.
JVIC Best Practices Welder’s University TRAINING PROGRAMS Training Programs range from 2-6 weeks. Advancement through the course will be dependent on individual performance. JVWU graduates are trained and mentored by industry professionals who have a reputation of being the best.
JVIC Best Practices HANDS ON TRAINING Safety Welding Safety, Personal Protective Equipment, Hexavalent Chromium Safety, Torch Safety and Operation, Oxy / Acetylene Cutting Procedures Basic Metallurgy, Welding Procedure Specifications, Filler Metal Control, Welder Responsibilities, Recognizing welding Discontinuities, Basic Isometric Drawings Advanced Welding Techniques GTAW / SMAW on Carbon Steel and numerous alloys, e.g., Inconel, Hastelloy, Monel, etc., practiced in an industrial simulated environment. Welder’s University details
JVIC Best Practices Foreman’s Bootcamp details Major project, kick-off meeting with all site foremen and supervisors JVIC has developed a standardized template customized for each client site Safety expectations are covered in addition to the following; JV Tool Handbook LOTO Environmental PPE First Line Breaks Welding Fall Protection Rigging Emergency Procedures Quality Job Quality Analysis (JQA) Flange Management Tagging System JVIC forms Code Work Document Control Integrity Personal Responsibility/Accountability
JVIC Best Practices Safety At Every Level: Our Behavior-Based Safety Program and continuous training form the foundation of our safety culture. Stop Work Card - Intervention