Safety Management-Objective

Safety Management-Objective • To standardize the procedures which should be followed consistently • It covers all aspects of the plant,facilities like equipment,human beings & procedures

Safety –An Attitude • Attitude gives rise to behavior patterns & may develop as a HABIT • HABIT • ABIT remains if you cut H • BIT remains if you cut further A • IT remains if you cut further B

Safety Management-Elements • Safety Organizations • Employee’s participation • Safety Hazard Information • Operating Procedures • Training • Incident Investigatio • Compliance Audit

Safety Organization Safety Policy • Duly approved by Board Of Directors • Expresses intentions & commitments from Top Management Safety Committee • Should be formed in each plant • Should meet at least once in two months • Time bound program for implementation of suggestions

Definitions Accident • An undesired event or sequence of events causing injury,illness that either were missed earlier or require new controls(Policies,procedures,or Personal Protective Equipment) Incident • An incident is an unplanned ,undesired event that hinders completion of a task and may cause injury or other damage. Near Miss • Near misses describes incidents where given a slight shift in time or distance injury ,ill health or damage easily could have occurred but did not happened in this round.

Causes of Accidents

Basic Postulates of Accidents 0.3% Major Injury Incidents 1 Minor Injury Incidents 8.8% 29 No Injury Incidents 90.9% 300 90.9 % of the unsafe acts produce no injury but unsafe act continues. 8.8% of the cases may range from a minor bruise to physical immobility 0.3% is the fatal disaster Continuing unsafe act will lead to a Major Disaster

Unsafe Acts-Reasons • Attitude • Lack of training • Fatigue • Rush Job & Short Cuts • Over Confidence • Lack of Knowledge • Sickness • Lack of Skill • Use of alcohol or drugs

UNSAFE ACTS • Unsafe Acts • · Filling without earthing/Bonding • · Working at Height- No PPE • · Mixing Chemicals- No PPE • · Safety controls Bye passed. • · Master switch TT not in Off position • · Helper driving TT- No Licence • · Reversing without helper help • · Drain Valve in tank Farm kept open • · All Nuts/ Bolts onFLP Junction Box not tightened. • · Smoking/ Naked lights

Unsafe Conditions • Poor Designs • Bad Maintenance Practices • Use of Substandard Material/Equipment • Missing guards on Pumps and Motor Shafts,Too Steep Ladders

UNSAFE CONDITIONS • Leaks • Loose/ Hanging Wires • Use Of PVC hoses • Double Pole wiring on TT missing • Ht of Platform Low. Can hit head • Corroded steps • Round steps • Angle of Ladder too steep • Railing on tank Missing • Excavation- Shoring not done • Toe Board At height not provided • Slippery floors/ Plat farms

Blind Flange not installed Tools left on Gantry/ Platform over flow line on FR Tank Choked Earthing / Bonding wires broken Double Earthing on Motors Missing Corroded FLP Plate on Junction BOX Double compression gland Missing on FLP Eqpt Conduits of wiring missing

ROOT CAUSE ANALYSIS • General principles of root cause analysis • 1. Aiming corrective measures at root causes is more effective than merely treating the symptoms of a problem. • 2. To be effective, RCA must be performed systematically, and conclusions must be backed up by evidence. • 3. There is usually more than one root cause for any given problem.

General process for performing root cause analysis 1.Define the problem. 2. Gather data/evidence. 3. Identify issues that contributed to the problem. 4. Find root causes. 5. Develop solution recommendations. Implement the solutions.[ Root Cause Analysis Tools

1. 5 Whys • My car will not start. (the problem) • Why? The battery is dead. (first why) • Why? The alternator is not functioning. (second why) • Why? The alternator has broken beyond repair. (third why) • Why? The alternator is well beyond its useful service life and has never been replaced. (fourth why) • Why? I have not been maintaining my car according to the recommended service schedule. (fifth why, root cause)

1.Barrier Analysis 2. Change Analysis 3. Causal Factor Tree Analysis 4. Failure mode and effects analysis 5. Event Tree Analysis 6. Fault Tree Analysis

Part Function Failure Mode Effect of Failure Severity Rating Potential Cause of Failure Occurrence Rating Possible Means of Detection Detection Rating RPN Preventative Actions to be Taken

Fault tree analysis In the technique known as "fault tree analysis", an undesired effect is taken as the root ('top event') of a tree of logic. Then, each situation that could cause that effect is added to the tree as a series of logic expressions. When fault trees are labelled with actual numbers about failure probabilities, which are often in practice unavailable because of the expense of testing, computer programs can calculate failure probabilities from fault trees.

. An Event Tree starts from an undesired initiator (loss of critical supply, component failure etc) and follows possible further system events through to a series of final consequences. As each new event is considered, a new node on the tree is added with a split of probabilities of taking either branch. The probabilities of a range of 'top events' arising from the initial event can then be seen.

Cost of Accidents • Cost of Lost time to injured persons • Cost pf time lost by other employees • Cost of time spent by Medical staff • Cost to Employer • Incidental cost due to interference with production • Cost that occurs in consequences of the excitement or weakened morale • Overhead cost while the injured employee is non performer • Cost under employees welfare & benefit scheme

Investigative Procedure-1 • Define the scope of the investigation. • Select the investigators. Assign specific tasks to each (preferably in writing). • Present a preliminary briefing to the investigating team, including: • Description of the accident, with damage estimates. • Normal operating procedures. • Maps (local and general). • Location of the accident site. • List of witnesses.

Investigative Procedure-2 • Events that preceded the accident. • Visit the accident site to get updated information. • Inspect the accident site. • Secure the area. Do not disturb the scene unless a hazard exists. • Prepare the necessary sketches and photographs. Label each carefully and keep accurate records. • Interview each victim and witness. Also interview those who were present before the accident and those who arrived at the site shortly after the accident. Keep accurate records of each interview. Use a tape recorder if desired and if approved.

Investigative Procedure-3 Determine • What was not normal before the accident? • Where the abnormality occurred. • When it was first noted. • How it occurred. • Analyze the data obtained & repeat any of the step if necessary

Investigative Procedure-4 Determine • Why the accident occurred. • A likely sequence of events and probable causes (direct, indirect, basic). • Alternative sequences. • Check each sequence against the data from step • Determine the most likely sequence of events and the most probable causes. • Conduct a post-investigation briefing. • Prepare a summary report, including the recommended actions to prevent a recurrence. Distribute the report according to applicable instructions. • Investigation is only complete once the final report is prepared after complete analysis.

Fact Finding • From witnesses ,Reports & observations • Inspection of Sites • Record pre accident conditions,the accident sequence & post accident sequence • Document the location,victims,witnesses,machinery,energy source & hazardous materials • Apply scientific data collection with the help of physical/chemical principles.

Interviews-1 • Appoint a speaker for the group. • Get preliminary statements as soon as possible from all witnesses. • Locate the position of each witness on a master chart (including the direction of view). • Arrange for a convenient time and place to talk to each witness. • Explain the purpose of the investigation (accident prevention) and put each witness at ease. • Listen, let each witness speak freely, and be courteous and considerate. • Take notes without distracting the witness. Use a tape recorder only with consent of the witness. • Use sketches and diagrams to help the witness. • Emphasize areas of direct observation. Label hearsay accordingly. • Be sincere and do not argue with the witness.

Interviews-2 • Record the exact words used by the witness to describe each observation. • Do not "put words into a witness' mouth." • Word each question carefully and be sure the witness understands. • Identify the qualifications of each witness (name, address, occupation, years of experience, etc.). • Supply each witness with a copy of his or her statements. Signed statements are desirable.

Problem Solving Techniques Change Analysis • Define the problem (What happened?). • Establish the norm (What should have happened?). • Identify, locate, and describe the change (What, where, when, to what extent). • Specify what was and what was not affected. • Identify the distinctive features of the change. • List the possible causes. • Select the most likely causes. Job Safety Analysis • It is a part of accident prevention group. • Breaks a job into basic steps & and identifies the hazards associated with each step • It is a part of investigation to determine the events and conditions that led to the accidents

Report of Investigation-1 Background Information • Where & When the accidents Occurred • Who and what were involved • Operating personnel and other witnesses Background Information Analysis • Sequence of Events • Extent of Damage • Accident Type • Agency or Source(of Energy or hazardous material} Discussions • Direct causes (energy sources; hazardous materials) • Indirect causes (unsafe acts and conditions) • Basic causes (management policies; personal or environmental factors) Recommendations for immediate & long term • Basic causes • Indirect causes • Direct causes

Accident Reporting Internal Reporting • All types of fires, minor or major, at Locations. • Accidents of own TT’s • Fatal accidents at locations • All accidents involving own employees, contractor’s employees on duty anywhere. • Accidents involving Trucks carrying Petroleum Products. • Oil Spill.

First Information Report of Accident • Name of the Location • Site of Accident : • Date and Time of Accident : • Brief of Events including : • Status at the time of reporting • Actions being taken, potential • Hazards (if any) • Probable reason(s) of Accidents : • No. Of casualty (if any) - Own employees : • Others • No. Of injured persons - Own employees: • Others • Extent of damage to Plant/Machinery, : • Structures/buildings/public property • Impact on operations : • Assistance (if required) : • Remarks : • Signature & Designation :

Accident Reporting to OISD • All fire incidents, which has lasted for more than 15 minutes or resulted in shutdown of the unit. • OR • Any incident involving fatality • OR • Incident involving property loss of more than Rs. 5.0 Lac. • OR • Blow out / Explosion • The above incidents to be reported immediately on phone at Office/ Residence. • This should be followed by fax giving available information at the earliest. • This should be followed by detailed report of the incident within 24 hours of the incident. • The HQ will submit detailed reports to OISD. • Reporting To MOP&NG And OCC • Reporting to MOP&NG and OCC will be by HQ.

Accident Reporting to Chief Controller of Explosives • In case of occurrence of a major fire/accident, inform CCE immediately / telegraphically or by telex followed by a detailed letter within 24 hours of its occurrence. • As per section no.27 of Petroleum Act 1934 & 200 of Petroleum Rules 2002, the notice of an accident required to be given to • (a) To the Chief Controller by telephone / fax and also by telegram followed within 24 hours by a letter giving particulars of the occurrence • (b) The nearest Magistrate or to the officer in-charge of the nearest police station.

Accident Reporting to The Office Of Directorate of factories • As per section no.88 of Factories Act –1948 (notice of accidents), where in any factory, accident occurs which causes death or bodily injury by reason of which the person injured is prevented from working for a period of 48 hours or more immediately inform to the Chief Inspector. • If the accident is fatal or such serious nature that it is likely to prove fatal, notice shall be sent to the District Magistrate or sub-Divisional Officer and officer in-charge of the nearest police station. • The Accident Register And Dangerous Occurrences to maintained as per the Form 30- rule 123 of Maharashtra Factories Rules 1963. • The Accident Report to be maintained as per the Form 24- rule 115 of Maharashtra Factories Rules 1963.

Safety Management • Safety at Design Stage • Safety Education • Safety Enthusiasm • Safety Enforcement Total Safety concept in an organization shall be based on above 4 E’s

Safety Management-Objective