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ESH Program Status

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ESH Program Status. Steve Hoey NSLS-II ESH Manager Conventional Facilities Advisory Committee Review November 9-10, 2009. Agenda. Best in Class Goal 9/30/09 Construction Accident ESH Program Elements Construction Risks & Controls IAO Assessment. - PowerPoint PPT Presentation
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1 BROOKHAVEN SCIENCE ASSOCIATES ESH Program Status Steve Hoey NSLS-II ESH Manager Conventional Facilities Advisory Committee Review November 9-10, 2009
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Page 1: ESH Program Status

1 BROOKHAVEN SCIENCE ASSOCIATES

ESH Program Status

Steve HoeyNSLS-II ESH Manager

Conventional Facilities Advisory Committee ReviewNovember 9-10, 2009

Page 2: ESH Program Status

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Agenda

• Best in Class Goal

• 9/30/09 Construction Accident

• ESH Program Elements

• Construction Risks & Controls

• IAO Assessment

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Project ESH Vision – “Best in Class”• A strong ESH program is essential to the safety of the workers

and the successful completion of the project• We believe all accidents and injuries are preventable and we

strive to establish an injury free work environment • ESH is being fully integrated into the project and managed as

tightly as quality, cost, and schedule• We are committed to a strong Integrated Safety Management

System for the project• Safe working conditions and practices are an absolute

requirement for all staff and contractors

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Plan to Achieve “Vision”• Build on successful ISM/EMS/OHSAS programs and make use of lessons

learned from recent BNL & DOE construction activities (SNS, CFN, RSB)

• Clearly establish and articulate expectations via the Project Construction ESH Plan, ESH Management Plan, Request for Proposal & daily interface with contractor

• Select contractors who have demonstrated excellent safety performance and are committed to continuous improvement

• Flow down expectations to sub-contractors

• Partner with the contractor and subs to assure success

• Hold contractor accountable for performance

• Adequately staff construction safety oversight

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Description of Accident

On Wednesday, September 30, 2009, at approximately 8:45 AM, a contractor laborer working at the NSLS-II construction site was struck by a load of rebar steel resulting in a compound fracture of the lower right leg below the knee.

The contractor was transported to a local area hospital for treatment. The treatment of the injured party has gone well and a full recovery is anticipated. He was released from the hospital on Oct 6.

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Immediate Actions on Day of Accident

• Stand-down of construction site to inform staff of the event• Suspension of all rebar mechanical material handling

activities involving a Lull• Management walk down of site• A post-incident fact-finding meeting was conducted• Charge written and membership identified for an

independent construction safety investigation team to perform a thorough investigation, determine causal factors, identify corrective actions, and make recommendations

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Immediate Corrective Actions• Conducted on-site (retraining session for mechanical material handling and

instituted specific PHA’s for rebar material handling• Torcon required concrete subcontractor (Macedos) to bring a full-time field safety

superintendent• BNL senior management met with Torcon senior management on Oct 6 to discuss

expectations for safety and further corrective actions• Torcon Corporate Safety Manager is on-site full-time to support development of

Torcon corrective action plan & supplement on-site ESH Mgr until such a time that second full time field safety inspector can be identified

• Instituted daily meetings between Torcon field and safety staff and NSLS-II safety and construction management staff

• NSLS-II is accelerating the hiring an additional full-time construction safety engineer to supplement the two currently on site

• Torcon meeting with union Business Managers to convey ESH expectations and training/qualification requirements

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Ring Building Construction ESH Program• Pro-active ESH program elements for this project

• 851 compliant Occupational Med Program (credited with saving one life thus far)

• On-site medical professional >50 workers (EMT)– The EMT was the first responder to incident and provided immediate care

• Detailed worker ESH orientation (Bi-lingual)• Worker Safety Committee – represents each sub, meets weekly• Routine tool box safety meetings• Routine third party insurance evaluations (Liberty Mutual & Zurich)• Internal & External Audit/Assessment program• Routine ESH Meeting including contractor, BHSO, Lab CSE, and SME’s• Contractor Controlled Insurance Program (CCIP)

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Site Work Controls

• All work performed in accordance with BNL’s SBMS:• Under an approved Permit or the GC Safety Health and

Environment program– Site access permits for general access– Rad work permit for soil monitoring

• Specific SOP, e.g, equipment inspection, safety inspections• Torcon Project ESH Site Specific Program

– Meets BNL’s “model” program– Defines elements such as inspections, tool box mtgs, industrial

hygiene monitoring, Occ Med program etc– Phase Hazard Analysis developed to identify and control hazards

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Construction ESH Plan

• The GC was required to submit a written ESH Plan for review and approval before work began. Plan consistent with the requirements established in the NSLS-II Construction Project ESH Plan (model plan)

• Plan ensures that;• Personnel possess the necessary experience, skills and training• Resources are effectively allocated to address ESH considerations• Hazards are evaluated prior to work• Engineering or administrative controls are in place• Line management responsibilities are clear• Clear and unambiguous lines of authority and responsibility for assuring ESH

compliance• Plan was reviewed and approved by Project, Lab and BHSO

Site HASP template upgraded to mimic NSLS-II model

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ESH Management Plan for Construction

• “ESH Management Plan for Construction” has been developed to;• Define specific roles, responsibilities and reporting

mechanisms of project, contractor, DOE and Lab oversight staff.

• Establishes “call down” procedure for emergencies • Establishes reporting criteria • Identifies key procedures for construction site (i.e., daily

construction inspection, stop work etc)

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Site Access, Security & Orientation• Contractor access is via main gate, down

Princeton Ave directly to site. (peak population 300-350)

• Analysis done in conjunction with Security to evaluate traffic flow and contingencies• Concluded main gate could handle flow and peaks• Early arrival and departure of contractors

• Site is fully fenced, access is via South end of site (some utility work beyond fence)

• CVO & Badging moved to construction site trailer eliminates 3 stops.

• Restrictive policy for authorized access• These controls have been working well

Page 13: ESH Program Status

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On-Site Safety Coverage• Continuous coverage by NSLS-II Construction Safety Engineers and Torcon

Safety Manager• Daily visits by NSLS-II ES&H Manager (increased since accident)• Weekly visits by Lab Construction Safety Engineer (increased since accident)• Periodic visits by NSLS-II Project Director, Assistant Project Director and

other NSLS-II & lab management• Weekly visits by BHSO CSE (Increased since accident)• Periodic visits by Liberty Mutual and Zurich Insurance• 2 time/week concrete sub Risk Manager site visits• Changes due to accident include;

• full time concrete sub field safety inspection and Torcon addition of full time field safety inspector

• Project is in the process of adding a third CSE

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Emergency Response•Covered by Torcon Safety Health and Environment Program

•BNL developed Local Emergency Plan required by SBMS

•Torcon and BNL LEP are coordinated

•Assignment of Local Emergency Coordinators (BNL)

•Construction site muster points

•Shelter in place (Building 735)

•Project specific call down process to notify management and DOE

•Pre- Emergency Planning was a significant positive factor in the accident

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Environmental ControlsEnhanced environmental controls, all equipment parked on hard surface or tarped.

Perimeter silt fencing

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NSLS-II Specific ES&H Procedures

• Adopted from existing Plant Engineering Program:• Heavy Equipment Inspection• Rigging Inspection• Safety Inspections• Site Access for Visitors and Guests• Stop Work and Work Interruptions• Permits• Heat Stress• Reporting of Events• Construction Safety Audits (new since accident)

- Controlled documents

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Category Description Risk Ranking ManagementESH Design

(ESH-02)

Major change driven by ESH design Oversight or changing regulation (ring bldg and tech equipment)

LOW Formal Design Reviews; SME input; Extensive use of Lessons Learned

ESH Site Prep

(ESH-Low-01)

Legacy contamination identified during excavation, protected species impacting construction

LOW Extensive site evaluation; Monitoring of protected species

ESH Construction

(ESH-01)

Minor or major injury or mishap, conventional construction, R&D Ops through technical equipment installation

HIGH ESH Construction Plan (HASP); Contractor Pre-qualification; Safety Incentive; Dedicated CSE’s, contractor qualification; work planning & control

ESH Risk Analysis & Management

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Site Prep – Legacy Issues•Remnants of a known 1978-81 geothermal/solar experiment unearthed during excavation on 5/6.

•Glycol pumped out and cleared by NYDEC

•Undocumented (pre-BNL) tank discovered on 5/19.

•20-25 gallons pumped out (kerosene and water)

•Contaminated soil remediated approximately 20-25 yards

•NYDEC approved remediation and cleared site

Historical Artifacts discovered and preserved

Page 19: ESH Program Status

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Site Prep - Migratory BirdsKilldeer & Canadian Geese have begun nesting on site

NYS Fish and Wildlife are called in to remove Killdeer nests BNL Licensed to remove Geese nests

Eggs

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Project Safety Record

Hours Worked

Recordable Cases

Recordable Rate

TRCTARGET

DART Cases

Dart Rate

DART TARGET

NSLS-II Pre FY09

341,101 0 0 0 0

NSLS-II FY09 Hours

320,396 1 .62 .65 0 0 .25

Contractor 60,208 3 9.96 1.5 2 6.64 .6

Total Project to Date

661,497 4 1.21 .65 2 .60 .25

Injury Data

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Description:Sub-Contractor employee to ModSpace (Sub to Torcon the NSLS-II Ring Building Contractor) was descending from a eight foot step ladder after taking measurements to install an outside seal between two trailer sections. The worker missed the fourth step of the ladder and fell to the ground landing upright on his right foot. The worker was descending facing the ladder and not carrying any equipment, the ladder was on stable ground. He sustained a fractured right heel as a result of this fall. The contractor had recently gone through Contractor Vendor Orientation and the Torcon site specific training which both address ladder safety.

Cause: > The worker missed the fourth step on the ladder as he was descending facing the ladder

Location: NSLS-II Project Site

Injury : Fractured Right Heel

DART Case & Occurrence NSLS-II Project April 16, 2009

Accidents – April 2009

Corrective Actions: > The General Contractor conducted a tool box safety talk on this incident> CVO training and the Torcon site indoctrination will discuss this incident> Increased surveillance by Torcon of all site activities> Incident will negatively impact Torcon’s safety incentive for period one (3/09-3/10)

Contractor Injury

DART Injury

NSLS-II Project

April 16, 2009

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Contractor Injury

Description:Sub-Contractor employee (Hink Electric) was unloading conduit elbow pieces from a supply truck. He was carrying a conduit on his right shoulder to a pallet located on the ground. As he started bending down to place the conduit on the pallet, his right foot slipped in the sandy soil causing him to lose control of conduit which slipped down lower to the ground. The piece landed on the pallet, flipped up on the elbow, and the end of the conduit struck him in the mouth. He sustained a cut lip and chipped tooth. This is an OSHA Recordable due to the chipped (fractured) tooth. Cause:> Lost footing on loose soil

Location: NSLS-II Project Site

Injury : Cut Lip & Chipped Tooth

Recordable InjuryNSLS-II Project July 16, 2009

Accidents – July 2009

Corrective Actions:> Special meeting of the project Safety Committee was held to discuss lessons learned.> The General Contractor conducted a tool box safety talk on this incident> Re-evaluated the worksite to assure that ramps and walkways are properly established

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Construction Hazard Controls

Site 6’ Fall Projection Rule

Material handling approved lifting fixtures & tag lines

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Construction Hazard Controls

Rebar caps or rails used on all potential impalement hazards and horizontal protrusions

Mandatory PPE, Hard Hat, Safety Glasses, Safety Shoes & high visibility shirts/vests

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Construction Hazard Controls

Ramps and defined access into formed areas

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Construction Hazard Controls

Defined Walkways provide safe access & egress from work areas

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Construction Hazard Controls

Dedicated Laborer’s for improved housekeeping

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Independent Audit & Oversight

• Laboratory Director has commissioned BNL Independent Audit and Oversight to conduct a “Construction Safety Program Review” for NSLS-II

• SME’s from IA&O, ESH Directorate, Liberty Mutual• Three Phases

• Phase One – Review of documentation and requirements - Complete• Phase Two – Field Observations of training, tool box mtgs, qualifications

etc. - Complete• Phase Three – Field Observations of work in progress and compliance

to plans and management observations - Ongoing• Phase one began 6/2009 – Phase three complete 11/09• Will continue periodic site visits by Liberty Mutual


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