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Your Voice in Prevention Your Voice in Prevention through Design (PtD)through Design (PtD)

Paul S. Adams, PhD, PE, CSP, CPEPaul S. Adams, PhD, PE, CSP, CPESenior ConsultantSenior Consultant

Applied Safety & Ergonomics, Inc.Applied Safety & Ergonomics, Inc.

Presentation OutlinePresentation Outline

�� Prevention through Design (PtD) ConceptsPrevention through Design (PtD) Concepts

�� PtD Benchmarking data for water utilitiesPtD Benchmarking data for water utilities

�� Barriers to PtD processes in water utilitiesBarriers to PtD processes in water utilities

�� A model PtD process for water utilitiesA model PtD process for water utilities

�� Examples of Best Practices in utility designExamples of Best Practices in utility design

�� Future activities and researchFuture activities and research

�� QuestionsQuestions

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Safety Through DesignSafety Through Design

“The integration of hazard identification and risk

assessment methods early in the design and

engineering stages and the taking of the actions

necessary so that the risks of injury or damage

are at an acceptable level.”

(Safety Through Design published July 1999)

(The term “Safety through Design” was replaced with “Prevention through

Design” or “PtD” by the NIOSH initiative about 5 years later.)

Designing to a minimum level of risk Designing to a minimum level of risk -- i.e., acceptable riski.e., acceptable risk

Knowledge

Culture

Proactive Prevention

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Retrofit and

Operational

Accommodation

DesignDesign

Prevention through Design

Retrofit and

Operational

Accommodation

OPERATION

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

MAINTENANCE

BUILDDESIGNBUSINESS CONCEPTS

DECOMMISION----------------------

RECYCLE

PREVENTION

THROUGH

DESIGN

RETROFIT

COST OF SAFETY

IMPLEMENTATION

EASE OF SAFETY

IMPLEMENTATION

Moving Safety Upstream in the Facility Life-cycle Reduces Total Project Cost and Makes it Easier to

Operate Safely

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�� Inherently safer facilities and operationsInherently safer facilities and operations

�� Significant reduction in serious injuries, illnesses, Significant reduction in serious injuries, illnesses, damage to property/equipmentdamage to property/equipment

�� Lower operating costsLower operating costs

�� Increased productivityIncreased productivity

�� Decreased workers compensation and business Decreased workers compensation and business interruption costsinterruption costs

�� Easier EH&S program managementEasier EH&S program management

BenefitsBenefits

PtD Process ConceptPtD Process Concept

�� Conventional Design ApproachConventional Design Approach: Engineer applies his/her : Engineer applies his/her

knowledge and skill to design systems that perform as knowledge and skill to design systems that perform as

well as he /she knows how to make them.well as he /she knows how to make them.

�� PtD ApproachPtD Approach: Apply as much of the : Apply as much of the organization’sorganization’s

knowledge and experience as possible in the design knowledge and experience as possible in the design

process to minimize risk and enhance system process to minimize risk and enhance system

performance.performance.

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Typical PtD Process in General IndustryTypical PtD Process in General Industry

1.1. Develop safety specifications or FitnessDevelop safety specifications or Fitness--ForFor--Use Criteria Use Criteria (FFU’s)(FFU’s)

2.2. Work with design team during design Work with design team during design –– informal reviewsinformal reviews

3.3. Design Safety Review near completion of designDesign Safety Review near completion of design

4.4. Constructability ReviewConstructability Review

5.5. Commissioning inspectionCommissioning inspection

Where Engineering is Performed in Water Where Engineering is Performed in Water Utilities Utilities

(Preliminary Study Results)(Preliminary Study Results)

�� 12 (75%) organizations perform engineering and project 12 (75%) organizations perform engineering and project management functions both internally and externallymanagement functions both internally and externally

�� 1 (6%) performed projects exclusively internally1 (6%) performed projects exclusively internally

�� 3 (19%) did not use internal resources for design at all3 (19%) did not use internal resources for design at all

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Safety Dept. Role in PtD for Organizations Safety Dept. Role in PtD for Organizations Utilizing Utilizing InternalInternal Resources for DesignResources for Design

�� 54% always include safety specifications or fitness for 54% always include safety specifications or fitness for use (FFU) criteria for internal design projectsuse (FFU) criteria for internal design projects

�� 23% indicated they never include safety specs or FFUs 23% indicated they never include safety specs or FFUs on internal design projectson internal design projects

�� 50% (6 of 12 respondents) always or often conduct 50% (6 of 12 respondents) always or often conduct design safety reviews on capital projects.design safety reviews on capital projects.

Safety Dept. Role in PtD for Organizations Safety Dept. Role in PtD for Organizations Utilizing Utilizing ExternalExternal Resources for DesignResources for Design

�� 50% require the designer to incorporate “all necessary 50% require the designer to incorporate “all necessary and appropriate” safety standards and features in and appropriate” safety standards and features in contractcontract

�� 21% develop and provide site and project specific safety 21% develop and provide site and project specific safety requirements to design contractorsrequirements to design contractors

�� 21% do not provide safety requirements to design 21% do not provide safety requirements to design contractorscontractors

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Use of Safety Reviews on Externally Designed Use of Safety Reviews on Externally Designed ProjectsProjects

�� 43% (6 of 14) always conduct safety43% (6 of 14) always conduct safety--focused design focused design reviewsreviews

�� 29% rarely or never conducts safety reviews29% rarely or never conducts safety reviews

�� 14% occasionally conducted reviews14% occasionally conducted reviews

�� 14% did not know or left reviews to the discretion of the 14% did not know or left reviews to the discretion of the external design firmexternal design firm

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Where are water utilities today?Where are water utilities today?

�� Most utilities owned by municipalities Most utilities owned by municipalities -- Many exempt from Many exempt from OSHAOSHA

�� Most design/engineering work performed by outside firmsMost design/engineering work performed by outside firms

�� Safety considerations frequently not a high priority when Safety considerations frequently not a high priority when designing water facilitiesdesigning water facilities

�� Water utilities largely unWater utilities largely un--informed regarding PtD concept informed regarding PtD concept and valueand value

�� No PtD provisions written into many design contractsNo PtD provisions written into many design contracts

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Major Challenges/HurdlesMajor Challenges/Hurdles

�� Organizational culture/attitudesOrganizational culture/attitudes

�� Awareness of PtD processes by engineeringAwareness of PtD processes by engineering

�� Lack of technical expertise in safety Lack of technical expertise in safety

�� Training engineersTraining engineers

�� Allocating time for safety reviewsAllocating time for safety reviews

Unique Challenges for Water UtilitiesUnique Challenges for Water Utilities

�� Most “Capital” projects designed by outside contractorsMost “Capital” projects designed by outside contractors

�� Safety, Operability, Maintainability often not drivers in design Safety, Operability, Maintainability often not drivers in design processprocess

�� Procurement policies require “Low Cost Bidder”Procurement policies require “Low Cost Bidder”

�� Keen attention to SecurityKeen attention to Security

�� Senior Manager not engaged in safety process/performance Senior Manager not engaged in safety process/performance

�� Safety not included in manager performance evaluationsSafety not included in manager performance evaluations

�� Liberal leave/returnLiberal leave/return--toto--work policies work policies

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Reliance on External EngineeringReliance on External Engineering

�� Sponsoring utility often not knowledgeable in PtD process and valueSponsoring utility often not knowledgeable in PtD process and value

�� Safety, Operability, Maintainability often not drivers for engineering Safety, Operability, Maintainability often not drivers for engineering service providersservice providers

�� Water utility design/engineering contractors may lack knowledge Water utility design/engineering contractors may lack knowledge and value of PtD processand value of PtD process

�� Design process doesn’t ask the right questionsDesign process doesn’t ask the right questions

�� Will this work?….instead of:Will this work?….instead of:

�� How will you access and maintain the process/equipment?How will you access and maintain the process/equipment?

�� Current contracts and specifications don’t provide detailed Current contracts and specifications don’t provide detailed expectations for safety performance expectations for safety performance

PtD for Water Utilities PtD for Water Utilities -- MetricsMetrics

�� Primary performance metrics are Quality, Volume and Pressure Primary performance metrics are Quality, Volume and Pressure

�� Not $$$, although this has recently changed for many utilitiesNot $$$, although this has recently changed for many utilities

�� Primary “Currency” is “Wrench Time” Primary “Currency” is “Wrench Time”

�� Direct/indirect costs of incidents typically not trackedDirect/indirect costs of incidents typically not tracked

�� Most utilities do not have a Safety Management System in place to Most utilities do not have a Safety Management System in place to track performancetrack performance

�� Limited audit capabilities/systemsLimited audit capabilities/systems

�� Safety enforcement issues are commonSafety enforcement issues are common

�� Poor incident investigation techniques Poor incident investigation techniques –– Limited root cause analysisLimited root cause analysis

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Model PtD Process for Water UtilitiesModel PtD Process for Water Utilities(From (From Water Utility Safety and Health: Review of Best PracticesWater Utility Safety and Health: Review of Best Practices -- WaterRF Project #3104)WaterRF Project #3104)

1.1. Project specification and safety scopingProject specification and safety scoping

2.2. Intermediate design reviewIntermediate design review

3.3. 90% review90% review

4.4. Commissioning inspectionCommissioning inspection

Project Specification:Project Specification: ParticipantsParticipants

�� Project Manager (PM)Project Manager (PM)

�� Construction Manager (CM)Construction Manager (CM)

�� Plant ManagerPlant Manager

�� Experienced Operator(s)Experienced Operator(s)

�� Experienced Maintenance Representative(s)Experienced Maintenance Representative(s)

�� SafetySafety

�� SecuritySecurity

�� EnvironmentalEnvironmental

�� PurchasingPurchasing

�� Public Relations / External Affairs (PR)Public Relations / External Affairs (PR)

�� Finance (Risk management & capital planning)Finance (Risk management & capital planning)

�� Information Technology (Control systems)Information Technology (Control systems)

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Intermediate and 90% Design Intermediate and 90% Design Reviews:Reviews: ParticipantsParticipants

�� All participants from All participants from Project SpecificationProject Specification phasephase

�� Experienced Operations and Maintenance personnelExperienced Operations and Maintenance personnel

�� Disinterested engineerDisinterested engineer

�� SchedulingScheduling

Commissioning: Commissioning: ParticipantsParticipants

�� Operations and Maintenance field personnel who will be Operations and Maintenance field personnel who will be expected to work with the systems, or who have expected to work with the systems, or who have experience with similar systemsexperience with similar systems

�� Project ManagerProject Manager

�� Plant Engineer (if different than the PM)Plant Engineer (if different than the PM)

�� Utility Plant ManagerUtility Plant Manager

�� Construction ManagerConstruction Manager

�� Site Superintendent (if different than the CM)Site Superintendent (if different than the CM)

�� Local Safety/Environmental Manager/CoordinatorLocal Safety/Environmental Manager/Coordinator

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Assisting Engineers Assisting Engineers duringduring DesignDesign

�� Understand the objectivesUnderstand the objectives

�� Provide tools; e.g., checklists with explanationsProvide tools; e.g., checklists with explanations

�� Reference specific codes, company standards, global Reference specific codes, company standards, global standards, and technical sourcesstandards, and technical sources

Common Technical IssuesCommon Technical Issues

�� Permit Required Confined SpacesPermit Required Confined Spaces

�� Elevated Work Elevated Work -- Fall ProtectionFall Protection

�� Hazardous Materials ExposureHazardous Materials Exposure

�� Electrical Safety/Arc FlashElectrical Safety/Arc Flash

�� Human Factors/ErgonomicsHuman Factors/Ergonomics

�� Material HandlingMaterial Handling

�� AccessAccess

�� Work Zone Work Zone -- Vehicle SafetyVehicle Safety

�� ExcavationsExcavations

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Path ForwardPath Forward

�� Develop technical competence within Engineering community and Develop technical competence within Engineering community and water utilities regarding PtDwater utilities regarding PtD

�� Develop technical competency within Safety community regarding Develop technical competency within Safety community regarding PtDPtD

�� Implementation of Safety Management Systems (e.g. ANSI ZImplementation of Safety Management Systems (e.g. ANSI Z--10)10)

�� Develop and require PtD process for public contractsDevelop and require PtD process for public contracts

�� Engineer to Deliver ProcessEngineer to Deliver Process

�� Include safety requirements in FitnessInclude safety requirements in Fitness--forfor--Use criteriaUse criteria

�� Require engineers to facilitate plan/spec review sessions with Require engineers to facilitate plan/spec review sessions with Operations/Maintenance personnel at Intermediate and 90% reviewsOperations/Maintenance personnel at Intermediate and 90% reviews

�� Document findings and recommendationsDocument findings and recommendations

�� Develop metrics to drive the processDevelop metrics to drive the process

Concept Behind PtD MetricConcept Behind PtD Metric

Safety Concern #1 – Risk

•Severe/catastrophic incidents

•Frequent incidents

Safety Concern #2 - Cost of Risk Control

•Cost of Compliance

•Cost of Doing the Job Safely (e.g. equip.)

Engineers Design:Facility Features

Processes

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Questions???Questions???