LEARNINGS FROM SHUTDOWN MISTAKES & CONCERNS.pptx

PROCESS PLANT SHUTDOWN SAFETY

1. FIRE & SAFETY DEPARTMENT

2. Shutdown Planning

3. Tool box talk record /register not maintained at all sites. Daily Housekeeping before start of job and after completion of job not done. Drum storage/ management a major concern Major Safety Concerns/ Non-compliance

4. Major Non Compliance Scaffolds: Checklist for scaffold not filled by contractor & IOCL Engg . Poor condition of scaffolds No base plate No tag , no railing, no proper platform, use of corroded/ bent pipes. No use of ladder for access Job without work permit and clearance

5. Hot works: No use of flash back arrestors on acetylene / oxygen cylinders Damaged/ jointed gas cutting hoses No use of valve caps on transported/ idle cylinders No protection against fall of spark Helper without any eye protection Major Non Compliance

6. Grinding : Without wheel guard Without face shield Helper using grinding job Spark not arrested at site Major Non Compliance

7. Major Non Compliance Working at Height: Workers working at height without safety harness/ not anchoring their harness. Poor condition of safety harness Use of old screw type harness instead of hook type No provision of life line for working at pipe racks/ cable racks. No access for approaching at pipe racks / cable racks.

8. Vehicular: Parking of vehicle at improper places. Entry of vehicle in plant without permit Flag man not available Fake/ No driving license with driver LMV driving license holder , drive HMV vehicle . Driving above speed limits Helpers driving vehicle instead of driver Poor tyre condition. Poor condition of trailers or hydra Area not barricaded. Slippers/ wooden blocks being used under crane jacks Guide rope not provided for suspended load Hydra/ Crane without reversing horn. Major Non Compliance

9. Lifting Tools/ Tackles: Transportation of material with Hydra/ crane No area barricading before lifting job. Limit switches of hydra not working. No SWL/ DOT marking on hydras. No safety latch on hooks There is no correlation of lifting tools & tackles with their certificate. Lifting tools used only as per judgment. Poor condition of canvas slings Major Non Compliance

10. Confined Space: No record of persons going in & coming out during confined space entry. No dedicated stand by person outside confined space Workers not aware of hazards inside particular vessel/ column etc/ no took box talk Major Non Compliance

11. Excavation: No barricading of excavated area. Road excavated without road blockage permit. Excavation permit not renewed after expiry Excavated material kept near excavation site. Sometimes excavation done without taking permit Escape ladder not used in excavated pit/trench People walk on piled up earth , having chances to slip and fall in trench Water accumulation in excavated pit/trench from open fire water nozzle Accumulation of oil and water in trench , if not stopped/checked Major Non Compliances

12. Hydro Jetting: No area barricading No face shield No coverall No foot valve No stand by person Slippery area/ Chocked drains Firewater misuse/ wastage without any job Major Non Compliance

13. Work Permit: Doing job without any permit Job without clearance. Clearance given on expired permit . Permit conditions are not full-filled like fire water hose / stand by person etc. Major Non Compliance

14. Scaffold safety measures Right-Angle (Double, 90 Degree, Load Bearing, or Standard) Coupler A load bearing coupler used for connecting two tubes together at right angles. It is a critical component in the scaffold structure and must resist both slip and distortion. After Before

15. BOX CLAMP : End-to-End (Sleeve) Coupler : A device used for externally joining two (2) scaffold tubes co-axially end to end. The steel divider is located centrally to ensure equal insertion of each tube. After Before

16. LADDER CLAMP : A device used for externally joining Ladder fitting on scaffold After Before

17. Base Plate:  A steel plate providing a flat bearing surface with a spigot or screw jack for distributing the load from posts (standards). It has an integral spigot and fixing holes for use with sills. After Before

18. Top rail Mid rail Without top and mid rail Guardrail system : Each person who could fall more than 1.8 m. (6 ft.) shall be protected from falling by means of guardrail systems or personal fall arrest systems. After Before

19. Toe boards : shall have no more than 6 mm. (1/4”) gap above the working surface and should withstand a force of at least 23 kg (50 lbs). After Before

20. Fabricated Scaffold Plank, Deck, or Platform A scaffold platform unit equipped with end hooks that engage the scaffold bearer (transom). Used wire for plank locked After Before

21. “Safety On Wheels” Immediate Corrective Action Agency/ W.O : Sandip Nanavati/24823166 Location: DHDS Pump House Area Safety on wheels: Gujarat Refinery new initiative for contractors safety (PPEs Compliance at site).

22. Contractor worker Helmet Testing

23. Contractor worker Helmet Testing on 20.6.2018 TOTAL NO. OF HELMETS – 54 HELMET PASS IN TEST – 16 HELMET FAIL IN TEST – 38 BEFORE AFTER

24. TOTAL NO. OF HELMETS – 54 HELMET PASS IN TEST – 16 HELMET FAIL IN TEST – 38 chart of various agencies found defective/ non standard helmets provided to the workers

25. “P reventable accidents,if not prevented due to our negligence , it is nothing short of a murder’’ Dr. S.Radhakrishnan

26. DON’T ROLL THE DICE!!! Practice proper procedures Make sure everything is safe before anybody goes in!