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1. F&O and PPM ESH Management Review
October 13, 2005 Facility & OperationsandProcurement & Property Management FY 2005
Environment, Safety & Health Management Review
2. F&O and PPM ESH Management Review
October 13, 2005 Environment Management SystemW. Chaloupka, Management RepresentativeOccupational Safety & Health Management SystemR. Costa, Management Representative
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October 13, 2005 Why are we here? The purpose of this review is to:
Reflect upon our past performance to identify:
Strengths
Weaknesses
opportunities for improvement
Discuss our path forward
Meet the requirements of ISO 14001, Environmental Management System
Meet the requirements of OHSAS 18001, Occupational Safety & Health Management System
Have coffee and breakfast on Andy
4. F&O and PPM ESH Management Review
October 13, 2005 Agenda Introduction of EMS & OSH Team Members
FY 2005 Summary of Objectives and Targets
Assessments
F&O Tier I Program
Environmental Performance
Occupational Safety & Health Performance
FY 2005 Cost Summary
Sr. Management Evaluation
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October 13, 2005 EMS & OSH Team Members
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October 13, 2005 FY 2005Summary ofObjective & Targets
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October 13, 2005 Objective: Compliance
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October 13, 2005 Objective: Operational Performance
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October 13, 2005 Objective: Operational Performance
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October 13, 2005 Objective: Operational Performance
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October 13, 2005 Objective: Pollution Prevention
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October 13, 2005 Objective: Injury Free Work Place
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October 13, 2005 Objective: Continual Improvement
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October 13, 2005 Objective: Continual Improvement
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October 13, 2005 Assessments
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October 13, 2005 Assessments(Internal & External) SBMS topics assessed
Beryllium
Confined Spaces
Construction Safety
Emergency Preparedness
Environmental Assessments
Environmental Monitoring
Electrical Safety
Lockout/Tagout
Tier I Inspections Hazardous Waste Management
Integrated Assessment
Internal Controlled Documents
Lifting Safety
NEPA & Cultural Resource Evaluation
OSH Assessments
Records Management
Spill Response
Work Planning & Control
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October 13, 2005 Non-Conformance Procedures are not being reviewed within established periods
A current copy of the SPDES permit was not posted at the STP
Non-conformances with NFPA 70E compliance
Non-conformances with material handling compliance
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October 13, 2005 Summary of Actions Resulting from Assessments Procedure revisions
Risk assessments updated
Contract language revised
BNL Health & Safety Plan
BNL Health & Safety Plan Template revised
Contractor Health & Safety Plan Revised
Arc Flash analyses
ADS generated
Training
Electrical Safety training
Toolbox meetings held
LOTO training
Rigging training
Contractor Vendor Orientation handouts updated
Permit postings updated
Sink postings updated
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October 13, 2005 F&O Tier I Program
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October 13, 2005 Tier 1 Purpose Identify unsafe work conditions and/or poor environmental conditions of the work area and during work activities and to implement documented corrective actions to prevent recurrence. Assure compliance with EMS & OHSAS metrics and requirements.
Monitor worker assignments to ensure safe work practices and verify applicable procedures are being followed.
Increase the safety and environmental awareness of individual employees by involving them in the inspection process.
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October 13, 2005 Tier 1 Inspections Facility Inspections – typical of BNL’s OSHA type inspections. Evaluates area safety/environmental conditions, checklist provided.
Jobsite Inspections – Evaluate work practices, procedures, roving work area conditions, checklist provided.
Vehicular Inspections – newly instituted to address worker concerns over quality of vehicles and suitability for intended use. Includes SS auto mechanic for customer service purposes. Checklist developed, still in revision.
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October 13, 2005 Results Integrated with BNL’s Tier 1 trending data collection, some unique issues are also captured for EP. Includes ECR or WMR in process.
Jobsite inspections are unique to F&O and tracked in C/A database for trending by F&O.
Equipment inspections are under pilot implementation, shows improved commitment to worker issues and demonstrates continual improvement.
5 Formal Presentations to ALD each year
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October 13, 2005 Tier 1 Facility Inspections F&O Total Facility Inspections – 291/yr
F&O Total Jobsite Inspections – 25 /yr
EP 20/yr
SC 1/yr
SS 4/yr
Equipment Inspections
EP 2/yr
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October 13, 2005 F&O Tier I Trends 2004
18 No deficiency
3 Observation 2005
79 No deficiency
89 Observation
F&O also trends
Equipment/Vehicle
General Safety
Other
Unsafe Practice
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October 13, 2005
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October 13, 2005 Environmental Performance
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October 13, 2005 Significant Environmental Aspect Summary Regulated Industrial Waste
Hazardous Waste
Radioactive Waste
Mixed Waste
Regulated Medical Waste
Atmosphere Discharges
Liquid Discharge
Chemical Storage – non-rad
Universal Waste
Positive Aspects
Waste Water Treatment
Building Demolitions
Recycling
Green Purchasing
LEEDS Certification
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October 13, 2005 Ground Water Contamination Operate facilities in a manner that is protective of groundwater quality
Sewage Treatment Plant (approximately 15% of treated water recharges directly to groundwater below filter beds)
Major Petroleum Facility / Central Steam Facility (petroleum storage and transfer)
Motor Pool (gasoline storage and vehicle maintenance)
Service Station (gasoline storage and vehicle maintenance)
Live Fire Range and Shotgun Range (Lead)
Groundwater surveillance programs are in place at each facility. Annual monitoring costs = $45,000.
Monitoring results indicate that current operational and engineered controls are effective. Routine detection of low-level contamination is from historical operations.
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October 13, 2005 Spill Trends
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October 13, 2005 Corrective Actions Resulting From Spills A diesel generator was stored on soil and its fuel tank overflowed due to thermal expansion
Replace 10% rule with 75% as measured by fuel gauge, complete
Designate temporary storage area – 610, complete
Develop a permanent storage area with containment, in work
Communicate spill prevention practices to BNL employees engaged in fuel transfers, complete
Develop and deliver a Spill prevention toolbox for EP, in work
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October 13, 2005 SPDES SPDES Outfalls for which F&O is responsible
Outfall 001 (STP discharge to the Peconic River)
Outfall 001E, (Boiler blow down from Bldg. 244, 405, etc., reported by the Steam Shop quarterly
Outfall 005 (Recharge Basin HS) receives predominately storm water runoff, minimal cooling tower blowdown and once-through cooling water from the NSLS, the Chemistry Department, and the EENS Department)
Outfall 007 (Recharge Basin HX) receives filter backwash water from the Water Treatment Plant.
Outfall 010 (Central Steam Facility (CSF) recharge basin) receives storm water runoff from the CSF area.
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October 13, 2005 SPDES
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October 13, 2005 SPDES FY 05 Exceedences
Outfall 001 (STP discharge to the Peconic River)
2/7/05: total nitrogen concentration of 12.7 mg/L, which exceeds the permit limit of 10 mg/L. Samples collected by the NYSDEC on February 8 had similar results of 11.3 mg/L. The composite samples collected on March 7 and 9, 2005 had total nitrogen concentrations of 13.3 and 9.3 mg/L respectively.
3/7/05: total nitrogen concentration of 13.1 mg/L, which exceeds the permit limit of 10 mg/L. The composite sample collected on March 9, 2005 had a total nitrogen concentration of 9.3 mg/L.
The cause of these exceedances was due to a normally closed primary valve from the primary clarified effluent channel that was leaking significantly. The valve body was separated from the wall of the concrete channel allowing treated wastewater to flow back into the effluent chamber from the secondary clarified.
Corrective action was to temporarily repair the valve until it was permanently removed and the effluent piping plugged. The valve was not needed for routine operations.
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October 13, 2005 SPDES FY 05 Exceedences
Outfall 001 (STP discharge to the Peconic River)
2/4/5: Ammonia concentration of 3.7 mg/L, which exceeds the permit limit of 2 mg/L.
Considered a one time excursion based on compliance of additional samples collected.
May be related to previous condition
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October 13, 2005 SPDES FY 05 Exceedences
Outfall 001 (STP discharge to the Peconic River)
3/11/05: total copper concentration of 0.161 mg/L, which exceeds the permit limit of 0.15 mg/L. The composite sample collected on March 23, 2005, had a total copper concentration of 0.046 mg/L.
Considered a one time excursion based on compliance of additional samples collected.
Outfall 006A (HT Recharge Basins)
2/18/05: A sample collected had a pH of 9.39 SU which exceeds the permit limit of 9.0 SU. The pH was verified at 9.43 forty minutes later.
The cause of the exceedances was due to an overdose of hydroxide by the EP Water Treatment Facility at one of the eastern wells. The problem had been corrected by EP.
Corrective action was to improve Water Treatment Facility procedures to improve communication during abnormal occurrences and to address caustic additions.
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October 13, 2005 Maintenance Critical to Environmental Compliance WWTF:
UV Bulb replacement - Every 2 years
SCHREIBER Equipment
DO Monitor
Mechanical Components
CSF:
Stack Monitoring Equipment
Periodic Fireside Boiler Cleaning
MOSF / CBS
Containment Maintenance
Storage tanks
Planned inspections
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October 13, 2005 Drinking Water Water Quality
140 parameters monitored
13 Parameters Detected
Water Quality
Chlorides
Nitrates
Color
Sulfates
Organics
1,1,1 TCA
Haloacetic Acids (5)
Trihalomethanes
Metals
Iron
Manganese
Lead
Sodium
Rad
Beta Particle & Photon Activity
Tritium
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October 13, 2005 Recycling The goal was to maximize the amount of waste recycled
The measure was
Total tons of solid waste recycled X 100
Total tons of solid waste generated
61.7% achieved in FY 05
48.1% in FY 04
37.52% in FY 03
A tremendous amount of metal was recycled this FY, thereby significantly increasing the recycling percentage – Future percentage values will probably “not” be this high.
39. F&O and PPM ESH Management Review
October 13, 2005 FY 05 Environmental Improvements / Actions Purchased approximately $12,000 of mercury free replacement utility devices such as thermometers and thermostats (P2 funding). These units will be replaced in the field during EP maintenance.
Replaced Halon 1211 fire extinguishers (P2 funding)
Cost shared in the following pollution prevention projects:
901 regulator PCB draining
208 hopper demolition
Replacement of the 490 animal bedding disposal system (note: this installation work will continue through the beginning of ’06)
40. F&O and PPM ESH Management Review
October 13, 2005 FY 05 Environmental Improvements / Actions Purchased 5 aerosol can hole puncturing assemblies to minimize the generation of hazardous waste
Installed SONOXIDE treatment on CCWF Cooling Tower (Reduced Biocide Use)
Recovered 238 pounds of CFC-113 from the Building 511 chiller – this is a Class 1 Ozone Depleting Substance and helps the Lab to meet its’ EPA P-Track goal (P2 funding)
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October 13, 2005 FY 05 Environmental Improvements / Actions Purchased an in ground oil/water separator, which will be installed during FY 06, to capture oils from a grounds vehicle wash to be located by the 326 complex (P2 funding)
Drained and disposed of 28 transformers, which were held as spare inventory, thereby minimizing the potential for spill or leaks.
EP designed, manufactured and installed a contaminated waste tank for the Central Steam Facility. This allows the oil tube heating/cleaning condensate drains to be combined and flow through a simple type oil/water separator in case the tube develops a leak.
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October 13, 2005 FY 06 Planned Improvements / Actions Mercury found in Nessler reagent used to determine ammonia levels in SPT. Test methods are being changed to eliminate its use.
Title V stack testing at CSF
Vehicle wash facility
Continue installing mercury free utility devices
Continue halon removal and disposal
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October 13, 2005 Stake Holder ConcernsAir Monitoring Exceedances
Three 6-minute exceedances due to soot blowing from 8/4 to 10/4 (57 operating days)
Fifteen apparent 6-minute exceedances due to soot blowing from 7/18 to 8/3 (14 operating days)
Action Taken to Improve Regulatory Compliance
Changed the soot blowing cycle on Boiler 6 on 8/4/05
Boiler 6 has ten individual soot blower units
Boiler 7 has four individual soot blower units
Prior to 8/4/05 individual soot blowers operated in succession (no gaps)
Beginning 8/4/05 there were 7-minute gaps between the start of individual soot blowers
Boiler 7 did not operate
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October 13, 2005 Stake Holder ConcernsDrinking Water Brown Water cannot be good
Supplied water fine is low in iron
Iron from distribution system and Building piping
Water main and building Flushing
Lead and Copper
Run water until cold
Change faucets and “Pig Tails”
Water Fountains out of service
Water must be bad
Replacement of Water Fountains
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October 13, 2005 Occupational Safety & Health Performance
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October 13, 2005 FY 04 Record of Decision Status
Continue employee involvement in OSH programs through review and development of Job and Facility Risk Assessments
Achieved (more details later on)
Review existing processes and systems to focus resources on areas of highest risk to achieve F&O’s goals for safety and work performance
Grouped training sessions to be held in January, to be piloted in Plant Engineering
Working with RadCon to implement a Whole Body Count sampling program
Working to “right size” other training requirements (e.g., Confined Space, Crane and Forklift Qualifications)
Combine EMS and OSH Management Review into a single Management Review
Happening today!!
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October 13, 2005 FY 04 Record of Decision Status
Implement training and qualification recommendations from the Material Handling Committee
In progress (more details later on)
Continue to monitor Traffic Safety performance measures
Reviewed each quarter with F&O ALD and Division management
Part of management performance measures
ESH coordinator to work with OMC and IH to ensure that supervisors better understand need for medical surveillance.
Dr. Falco and John Peters provided a review of these requirements during F&O’s FY 04 Management Retreat
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October 13, 2005 Activities(the short list) Driving
Walking
Using hand held tools, including powered tools
Concrete and masonry work
Troubleshooting and testing energized equipment
Work in or near vehicle traffic
Maintenance and work in manholes
Work at heights
Cabinetmaking
Maintenance and repair of machinery / equipment
Erection of scaffolds
Carpentry
Refrigeration, air conditioner and heating repair and maintenance
Water treatment
Waste water treatment
Chilled water production
Inspections
Site Security
Construction work
Site maintenance
Lamp cleaning
Metal work
Plumbing
Rigging
Material handling / lifting
Pesticide application
Steam distribution
Machining
Manufacturing
Welding
Metal work
Custodial work
Mail distribution
Conference services
Auto repair and service
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October 13, 2005 Common Hazards Airborne particulates – asbestos, lead, silica, etc.
Animal / insect bites, scratches, stings
Animal / rodent and bird droppings
Asphyxiation / ODH
Bloodborne pathogens
Burns
Cave-in while working in an excavation
Confined space
Cuts / scrapes / struck against
Electrical energy
Elevated areas
Ergonomic hazards
Fatigue
Fire
Hazardous or toxic material / chemical exposures Ionizing radiation exposure – x-rays, neutron, gamma, beta
Manual material handling, lifting / moving heavy objects, rigging
Noise
Non-ionizing radiation
Obstructed / tight work space
Poisonous plants
Poor indoor air quality
Potential energy – overhead object
Rotating parts
Striking utility
Temperature extremes
Vehicle collision
Walking / working surfaces
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October 13, 2005 FY 2005 Days Away Restricted Transferred (DART)
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October 13, 2005 FY 2005 Total Recordable Case Rate (TRCR)
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October 13, 2005 Five Year Injury Trend
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October 13, 2005 F&O Directorate Five Year Injury Trend
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October 13, 2005 Emergency Services Five Year Injury Trend
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October 13, 2005 Central Fabrication Services Five Year Injury Trend
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October 13, 2005 Plant Engineering Five Year Injury Trend
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October 13, 2005 Plant Engineering Improving Trends Recordable 2004 (26) to (13)
DART 2004 (15) to 2005 (7)
First Aids 2004 (15) to 2005 (19)
DAW & RWD performance
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October 13, 2005 Plant Engineering 2004-2005 Troublesome Activities 18 Walking-related (11 recordable)
2004 -2005 164 RWD, 277 DAW
2005 Total RWD+DAW = 78 days
10 Work w/o PPE (1 eyes - 4 DAW)
6 Repetitive work motion (4 recordable)
2 cases 4 LWD + 180 LWD
6 Lift & Lower (1 case 48 LWD)
11 Push & Pull/Reach (1 case 16 LWD)
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October 13, 2005 Safeguards & Security Five Year Injury Trend
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October 13, 2005 Staff Services Five Year Injury Trend
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October 13, 2005 Actions From Safety & Health Investigations Injury investigations are conducted with line management involvement
Actions tracked to completion in the F&O FATS
Summary of actions:
Performed ergonomic reviews
Toolbox presentations
Repair / maintenance
Reviewed procedures with supervisors and identified tools needed
Revised procedures
Conducted IH monitoring
Provided new postings
Changed PPE requirements
Update risk assessments
62. F&O and PPM ESH Management Review
October 13, 2005 OHSAS Program Performance We currently have 189 Job Risk Assessments
During FY 2005
15 Risk assessment updated
39 New added
22 added for Staff Services
15 in process
Goal was to update / add / review 48 by end of FY
54 was achieved
With the current total of 189 Job Risk Assessments and the additional ones that will be generated by the remaining Divisions we must be aggressive in reviewing these assessments to achieve the 3 year review cycle.
Every risk assessment and subsequent revisions involve worker participation.
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October 13, 2005 OHSAS Program Performance Improvements Resulting from Risk Assessments
Machine Safety
9 new JRAs
Shop Safety Procedure created
Polishing Procedure developed
Guarding developed and implemented
Safety Zones created around machines with moving tables
Signage improved
Training conducted
Revised sign changing procedure at main gate
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October 13, 2005 OHSAS Program Performance
Improvements Resulting from Risk Assessments
Re-designed the Cooling Tower to reduce back strain to workers during maintenance operations
Provided workers with spiky shoe covers to prevent slips in snow and ice
Installed a ramp at building 479
Clarified use and type of PPE
Implemented process to allow workers to use bee/wasp spray
Stocking tick spray in tool crib
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October 13, 2005 OHSAS Program Performance Improvements Resulting from Risk Assessments
Installed signage warning of slip hazards
Purchased self propelled mechanical scraper to remove rugs
Various toolboxes on safety issues
Eye wash stations installed
Restricted use of certain vehicles during inclement weather
Started salting truck decks when icy
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October 13, 2005 OHSAS Program Performance Improvements Resulting from Risk Assessments
Updated safety procedures for:
Inspections
Use of fall protection
Manlifts usage
LOTO when working within 10 foot area of power line
Restrict use of Manlifts based on weather conditions
Created a procedure for Fuel Truck Loading and dispensing
Improved catwalk ladder way at fuel truck loading and dispensing area
Purchase ergonomically safety tools for interior painting
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October 13, 2005 Other Improvements / Actions Taken Implemented a certification program for gas cylinders purchased from vendors to eliminate the possibility of contamination
Conducted 100 noise survey’s within F&O
Air quality assessments were conducted by F&O in the BNL mail room and fire house resulting in several corrective actions (i.e., improving ventilation, portable air cleaner, improved house cleaning, etc.)
Additional resources dedicated to snow / ice removal to reduce slips and falls on-site, $600,000 was spent in FY 2005 over last year.
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October 13, 2005 Other Improvements / Actions Taken
All Apartment area steps, landings and rails were assessed/inspected and repairs implemented, as needed.
As a result of a dust hazard identified by electricians in the Apartments electrical baseboard heating a cleaning program was implemented
Replaced incandescent work lights in the motor pool with portable LED lamps to remove hazard potential caused by incandescent bulbs near fuel and trip hazard by their cords
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October 13, 2005 Employee Concerns (Just a few) Wet floors from mopping during peak use time in 452
Cleaning moved to non-peak time
Securement of equipment of contractor’s vehicle
Securement was found to be acceptable
Fall hazard from climbing over a railing from a Manlift to access a platform
A gate was installed
Confined Space Gas Monitors being used after hours without Bump test/Calibration
Automated Bump test/Calibration equipment purchased and personnel trained in its use.
Icy walkway in front of entrance door to AGS circle
Rain gutter installed to prevent water runoff and freezing on the walkway
Disconnecting means for the outside Unit at Building 480 (not within sight of the equipment door and tinted windows block the view)
New outdoor disconnects installed to facilitate LOTO when servicing equipment
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October 13, 2005 Other Stakeholder Concerns Injuries from sports
Replaced bases in softball fields to a design that would reduce injury when sliding into them
Added padded wall mats in gym
Added safety padding to Referee stand
Installed non-skid flooring around pool
Replaced worn park benches
Improved cleaning and sanitation in locker rooms with the an upgrade in custodial equipment
Power washer
Floor scrubber
Vacuum
Voltage converts for foreign visitors made available at the Housing Office and at the BERA store.
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October 13, 2005 Noise Surveys Identified all areas owned by F&O and work performed
Prioritized the list by identifying the highest risk areas and tasks
Plan developed, all Divisions were included in surveys
Results entered into Compliance Suite
Corrective Actions added into F&O FATS
100 Surveys completed
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October 13, 2005 Hoisting and Rigging Improvements Personnel Development
Utilizing outside vendor training services
Provided securement training to all O&M Site personnel
40 Hour rigging training to all Riggers and 2 Heavy Equipment Maintenance & Operators (HEMOs)
Mobile crane training for selected HEMOs
Skill enhancement training for Master Rigger and qualified 7 new Master Riggers
Developing a qualification standard for each Rigger and HEMO
Equipment
Periodic material handling equipment inspections are now being performed
Reorganized the rigging equipment area and created a rigging loft
Load testing all cranes
Phasing out old equipment
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October 13, 2005 Actions Planned for FY 06
Strive to continue to lower injury rates
ZERO INJURIES IS OUR GOAL!
Create a directorate procedure for working on or near roads
OHSAS
Achieve OHSAS 18001 registration for Staff Services
Continue implement OHSAS 18001
Emergency Services
Safeguards & Security
Procurement & Property Management
Implement the use of Ground Penetrating Radar for excavations
Continue implementing hoisting and rigging improvements
Continue closing OSHA action items
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October 13, 2005 FY 2005 Cost Summary
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October 13, 2005 F&O FY 05 Cost Summary
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October 13, 2005 Sr. Management Evaluation
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October 13, 2005 Sr. Management Questions Are the Management Systems effective in achieving policy commitments?
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October 13, 2005 Sr. Management Questions Are the Management Systems effective in achieving objectives, targets and performance measures?
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October 13, 2005 Sr. Management Questions Are the Management Systems adequate in terms of:
Identifying significant aspects, hazards and impacts?
Resource allocation?
Information systems?
Organizational issues – staff expertise; procedural requirements?
If yes, record the decision; in no record recommendations
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October 13, 2005 Sr. Management Questions Are the objectives, targets and performance measures for these management systems suitable in terms of:
Injuries / illnesses and environmental impacts?
Concerns of stakeholders?
Current and future regulatory requirements?
Business interests; technological capability?
Internal organizational or process changes?
Should additional objectives, targets or performance measures be established?
If yes, record the decision; in no record recommendations
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October 13, 2005 Sr. Management Questions Recommended revisions to:
ESSH policy and commitments?
Objectives, Targets and Performance Measures?
Occupational safety and health or environmental related management systems?
If yes, record the decision; in no record recommendations
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October 13, 2005 Any remaining issues?
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October 13, 2005 Thank you for your participation!