Mazary -- Session 714 - Serious injury

Serious Injury & Fatality (SIF) Prevention and Operational Risk Management

Session 714

[email protected], CSP, CHMM

Senior Safety Consultant, DuPont

mailto:[email protected]





DuPont Sustainable Solutions

Introduction – Why Risk?

Serious Injury & Fatality (SIF)

SIF Prevention

1) SIF Hazard Identification

2) Risk Controls \ Barriers

3) Communication

4) Sustainability

Electric Shock Example

AG

END

A

Copyright ©2014 E. I. du Pont de Nemours and Company. All rights reserved. The DuPont Oval Logo, DuPont™, and The miracles of science™ are registered trademarks or trademarks of DuPont or its affiliates. DuPont Sustainable Solutions

DuPont Sustainable Solutions Copyright ©2014 E. I. du Pont de Nemours and Company. All rights reserved. The DuPont Oval Logo, DuPont™, and The miracles of science™ are registered trademarks or trademarks of DuPont or its affiliates. DuPont Sustainable Solutions Copyright ©2014 E. I. du Pont de Nemours and Company. All rights reserved. The DuPont Oval Logo, DuPont™, and The miracles of science™ are registered trademarks or trademarks of DuPont or its affiliates. DuPont Sustainable Solutions

Must become more agile in today’s rapidly

changing economy.

Business

Seek Risk Mitigation Increase Productivity

DuPont Sustainable Solutions Copyright ©2014 E. I. du Pont de Nemours and Company. All rights reserved. The DuPont Oval Logo, DuPont™, and The miracles of science™ are registered trademarks or trademarks of DuPont or its affiliates. DuPont Sustainable Solutions

Companies are increasingly scrutinized by

investors, regulators, the public and the media.

Operational Performance


Proper management

and mitigation of

operational risk

Can prevent adverse business impact

Can drive profitability



Effective operational

risk management

Lowers operating costs

Reduces losses

Increases customer satisfaction

Optimizes insurance coverage and premiums

Exceeds regulatory compliance



Companies that focus on managing and reducing risk

rather than driving compliance to systems

or procedures are

THE MOST EFFECTIVE



PREVENTION PLAN

For SIF’s

Serious Injuries & Fatalities

Serious Injury?

Problem?

4 Step Prevention Plan



Class Exercise A


1. Significant blood loss

2. First degree skin burn

3. CPR or external defibrillator

4. Chest or abdominal trauma affecting vital organs

5. Laceration\Cut requiring bandage

6. Loss of consciousness

7. Amputations involving bone loss

8. Paralysis

9. Dizziness

10. Heat Exhaustion

11. Herniated Disc

Which are NOT a Serious Injury?


1. Significant blood loss

2. First degree skin burn

3. CPR or external defibrillator

4. Chest or abdominal trauma affecting vital organs

5. Laceration\Cut requiring bandage

6. Loss of consciousness

7. Amputations involving bone loss

8. Paralysis

9. Dizziness

10. Heat Exhaustion

11. Herniated Disc

These are NOT a Serious Injury?


SERIOUS INJURY/ILLNESS

KEY TERMINOLOGY

1. Life-threatening

injury/illness:

2. Life-changing

injury/illness:

- - - - - - - - - - - - - - - - - - - - - - - - - -

Any injury or illness that resulted in:


What

Problem?


How is your safety program doing?


Class Exercise B


1,484 Oil & Gas Fatal Incidents


How is the Fatal Rate?


PROBLEM?

People are still making

mistakes and the

wrong decisions

In spite of improved

overall performance:

serious injuries and

fatalities still happen



The Operational Risk Management Funnel

Differentiated Risk Management

All Hazards

Low Hazards

High Hazards

Very High Hazards

Safety Management Systems


Serious Injury & Fatality (SIF) Prevention Process

SIF Hazards Identification

Risk Evaluation & Reduction

Communication

Sustainable Improvements

STEP 1

STEP 2

STEP 3

STEP 4


Identifying

SIF Hazards

Actual

Potential


Step 1: SIF Hazards Identification

Site Safety Data

Industry

Site Field Audits

Site-Specific SIF Hazards


Class Exercise C


Site Safety Data: Investigation Reports

Date Hazard Actual Injured

Workers

Potential Injured

Workers

SIF Priority Yes or No

2011

Crane Drops 5 lb. Load 20 ft.

1 3

?

2012

Slip & Same Level Fall

1 3

?

2014

Leg Burn: 1st degree

1 1

?

2015

Confined Space Welding Fire

0 2

?


Site Safety Data: Investigation Reports

Date Hazard Actual Injured

Workers

Potential Injured

Workers

SIF Priority Yes or No

2011

Crane Drops 5 lb. Load 20 ft.

1 3

YES

2012

Slip & Same Level Fall

1 3

NO

2014

Leg Burn: 1st degree

1 1

NO

2015

Confined Space Welding Fire

0 2

YES


Common SIF Hazards Dropped Objects

Toxic Materials/Environment

Caught In/Between

Elevation Fall

Industrial Truck

Motor Vehicle

Fire/Explosion

Workplace Violence

Electrical Energy



Dropped Objects

• Tools Dropped

• Tool Tethering



Toxic Materials /

Environment

• Confined Spaces

• Toxic Chemicals



Caught In / Between

• Excavation

• Pulled into Machines



Elevation Fall

(Falls from above)



Industrial Truck

• Backhoe

• Forklifts

• Dump Trucks



Motor Vehicle

• Business

• Rentals

• Fleet



Fire / Explosion



Workplace Violence

• Work Alone

• Work Remote

• With Public

• Cash $

• At Night



Electrical Energy


Cawley, J.C., Brenner, B.C., Occupational Electrical Injury Statistics for the US, 2003-2009, Conference Record, 2012 IEEE IAS Electrical Safety Workshop, January 30-February 3, 2012, Daytona, FL


Contact with Overhead Power Lines


Contact with Electrical Components


Contact when using Machine, Tool, Appliance or Light Fixture


½ of electrocution fatalities are “other” workers and NOT Electrical workers

Electrical workers

Other workers

Not just Electricians


Low frequency…

but Very High Consequence

Low frequency

• <0.2% of non-fatal

lost time injuries

High Consequence 2010 US BLS data


Co

ntr

ol E

ffective

ne

ss

Hierarchy of Hazard Control Measures

from ANSI Z10

Elimination

Eliminate the hazard during design

Personal Protective Equipment

Available, effective, easy to use

Substitution

Substitution of less hazardous equipment,

system or energy

Administrative Controls

Planning processes, training, permits, safe work practices,

maintenance systems, communications, and work management

Engineering Controls

Design options that automatically reduces risk

Warnings

Automatic or manual, permanent or temporary, visible or audible

warning systems, signs, barriers and labels

Life

Cycle

Valu

e

Hierarchy of Risk Control Measures from ANSI Z10 Most Effective

Control

Least Effective Control


Class Exercise D


Climb 20 foot ladder, outdoors to read pressure gauge, in H2S Plant

Hazard Controls Description

Elimination

Substitution

Engineering

Warnings

Administrative 1 - Procedures 2 - Training

PPE 1 - H2S Personal Monitor 2 - Full Body Harness 3 - SCBA


Climb 20 foot ladder, outdoors to read pressure gauge, in H2S Plant

Hazard Controls Description

Elimination Remote pressure read out at ground level

Substitution

Engineering Replace ladder with stairs & handrails

Warnings

Administrative 1 - Procedures 2 - Training

PPE 1 - H2S Personal Monitor 2 - Full Body Harness 3 - SCBA


RISK EVALUATION \ ASSESSMENT SIF Hazard Example:

Overhead Electric Power Line Contact

CURRENT BARRIERS \ CONTROLS

WEAKNESSES \ HOLES

ADDITIONAL BARRIERS \ CONTROLS

Procedures Training Non-conductive

Tag Lines Planned Outages Clearance

Restrictions LOTO

Contractor & Delivery

Contractor Orientation

Daily Briefing


Bowtie Diagram

Event

Haz

ard

Threat 1

Threat 2

Threat 3

Threat X

…

Consequence 1

Consequence 2

Consequence 3

Consequence X

…

Control Measures Recovery Measures

Escalation Factor

Escalation Control Escalation

Factor


Step 3: Communication

COMMUNICATE & TRAIN

(Affected Employees & Contractors)

New SIF Hazards

New Hazard Controls/Barriers (Risk Reductions)

Potential SIF Incident Metrics

Safety Management

Systems (SMS) Improvements


Step 4: Sustainable Improvements

ANNUALLY

DAILY

MOC

Serious Injury & Fatality Prevention Process Re-evaluation

I

M

P

R

O

V

E

M

E

N

T

S


The REAL Reason we Identify SIF Hazards

And

Minimize Risk

through

Effective

Hazard Controls & Barriers


Questions

YOUR FEEDBACK IS IMPORTANT!

Session Evaluations can be completed:

On the Safety 2016 App

Using the link in the email reminder you

will receive at the end of each day

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Mazary -- Session 714 - Serious injury

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