SPECIAL september 2016
SAFELY TOGETHER This HSElife NL Special includes:
Unsafe circumstances don’t take a break
from Willem Caljouw, head of the Global Center of Expertise for Lifting & Hoisting and Mobile Heavy Equipment of Shell
Good preparation is half the work! Using 'barriers' for safe hoisting
Situational awareness in the field and at the office! Concerns to be aware of the risks
... and more!
UNSAFE CIRCUMSTANCES
don't take a break Every day Royal Dutch Shell plc carries out 100.000 hoisting and lifting operations worldwide. “A very high percentage goes well, but unsafe circumstances don’t take a break,” says Willem Caljouw, head of the Global Center of Expertise for Lifting & Hoisting and Mobile Heavy Equipment of Shell.
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Willem talks about the rise of the Center of Expertise, how to maintain your knowledge and he gives his view on safe hoisting and lifting operations.
“The Global Center of Expertise was set up in December 2013. The reason for the rise of this knowledge center was the frequent number of hoisting and lifting incidents in our industry. We want the Shell’s operating companies to pay a lot of attention to this. The main goal is to make sure that nobody gets hurt, so no personal injury. That is very important to us. We want everyone to go back home safe and sound after work. Furthermore, incidents are costly.”
“No one goes to work with the intention of causing an accident that day.”
What is the strength of the knowledge center? “To exchange information and to share best practices
in my network who’s available and has the insight and the
and incident investigations, worldwide,” says Willem.
knowledge of the specific activities. If necessary, someone
“We outsource many activities. This means that our own
from the network can also assist on the spot. So to quickly
detailed knowledge of hoisting and lifting and mobile heavy
help people is also the strength of the knowledge center.”
equipment will fade. We want the people who work in the
Willem says that the network has managed to develop and
plants and on platforms to have easy access to industry
maintain a much higher knowledge level in a very short
practices on hoisting and lifting. So we have a worldwide
period of time and that he is proud of that. “We have our own
network of internal and external experts.” Willem gives an
accreditation system with which we support our knowledge
example: “There’s a difficult hoisting job in the Philippines
network. This enables us to give the same advice in sixteen
which is being outsourced. The Person in Charge in the
languages.”
Philippines contacts me and says that he’d like to have an independent check carried out first. I then look for someone
Which mistakes are often made in the preparation of hoisting and lifting operations? “In the preparation there is often insufficient attention to
The soil is saturated and is basically unable to withstand the
changing conditions,” says Willem. “Here’s an example: We
load from the crane. The 500 kilograms load is being lifted
lift a load that weighs 500 kilograms. That load is located far
and the crane falls over as it sinks into the soft ground. So
away in an installation. We rent an 80-ton crane with a long
someone should have realized that hazardous situations
boom of sixty meters. There’s a lift plan, a permit to work
can be caused by changing weather conditions.”
and we position the crane as shown in the drawing. Then circumstances change because it rained the day before. No one noticed that the soil condition has changed significantly.
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How do you ensure that someone does pay attention to changing circumstances? “We have developed the ’10 Questions for safe Lifting &
plan can always overview everything. We want him to go to
Hoisting', in sixteen languages. People must answer these
the location before permanently submitting the lift plan. In
questions before they start working. So they must carry out
addition, the Person in Charge of the lift operations must
a last minute risk analysis.” Willem says that you should
pay attention to safety awareness during a toolbox meeting.
also pay attention to the process between planning and
You simply can’t rule out that changes occur in the process
execution. “One of the questions is: is there a current lift plan,
between making a lift plan and the execution.”
a task risk analysis and does everyone understand the job and the precautions? No one at the office who makes a lift
Which mistakes are often made during hoisting and lifting operations? Willem says that experience can work against you. “Incidents
goes to work with the intention of causing an accident that
happen because people sometimes think ‘I’m doing this
day. But be aware that, in hoisting and lifting operations, you
for twenty years and I do it well’. At that moment I see that
can’t beat the laws of physics.”
people often make very rough decisions.” Willem gives another example: “During hoisting operations it becomes clear that the centre of gravity is in a different place than we expect. This means that the load behaves differently. The load tips. People’s natural reaction is to use their hands or their body to counterbalance. Usually that goes wrong. We have a ‘hands off policy’. This means that people must use push and pull sticks. These are sticks with a grip on them allowing people, for example, to rotate a load in the right direction. People’s natural reaction has to do with the fact that they are always looking for solutions to continue the work and to do it well. And that you must respect. No one
How do you ensure that employees maintain their knowledge? “In order to work safely you must maintain your knowledge. If you open today’s newspaper, you read a lot about the Olympics. Tomorrow something else happens and the focus on the Olympics is gone. We use Reflective Learning in order to hold the attention. It’s a good way to maintain and transfer knowledge. In practice, this means that managers and employees discuss a specific theme during the work preparation and, for example, use photos. People have better substantive discussions on safety when they are being involved personally. This gives both managers and employees insight into (potential) unsafe situations and together they determine which (proactive) measures they should take to prevent unsafe situations. So you learn faster
someone in Singapore shares the lessons from an incident
from and with each other. Therefore knowledge will be
that happened there with teams worldwide.”
retained longer. It sometimes happens, for example, that
“In hoisting and lifting operations, you can’t beat the laws of physics.”
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What is reflective learning? Reflective learning is a learning method which leads to behavioural change and taking the proper safety measures. Reflecting means thinking back and seeing the full picture, thinking about ourselves, our behaviour or activity. Research shows that reflective learning is the most effective way to learn from incidents because it stimulates behavioural change and concrete action in the own working environment.
How do you use your network for sharing knowledge? “I compare my network with an onion. There’s a core of
includes several current topics. For example the lifting
about twenty people who share information very directly
accident in Alphen aan de Rijn. The Dutch Safety Board
almost every week through email about what's happening
publishes a report on this accident which I share worldwide.
here and there in the world. We speak to each other on a
But if, for example, LEEA, IOGP, OPITO, NOGEPA, OSHA or
monthly basis. Around them is a layer of about fifty people.
HSElife NL publishes an interesting article too, I share it with
Those are my accredited Subject Matter Experts. They are
a large group of people. Also, this way we want to maintain
in the mailing system and maintain their own business
the highest possible degree of attention.”
connections. Around them is a layer of about 450 people who receive my newsletter every month. The newsletter
Willem is to retire at the end of this year. Which valuable lessons would you like to give to the new generation? “Don’t do things you don’t understand. Despite all the
awareness.” Finally, Willem says that you should always be
pressure to work faster and more efficiently, in hoisting
alert to unsafe situations. “Safety must be the top priority,
and lifting operations you don’t get a second chance. I
24/7!”
always say: when a crane falls over, it really falls over, there’s no stopping it! Make sure that you get an insight into the
Arnold van den Dool will be the successor of Willem Caljouw
working conditions. So, also pay attention to situational
at the end of this year.
Safety must be the top priority, 24/7!
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Good preparation is half the work! That is certainly true for hoisting and lifting operations. If it goes wrong, there is little more you can do in the field, and serious incidents can happen as we have recently seen in Alphen aan de Rijn (see item elsewhere in this magazine). During the design process and during the preparations for a lifting job, you can raise several 'barriers' to reduce the chances of accidents. By making a smart design and using alternatives, you may have fewer (risky) hoisting and lifting operations. The machine's design is also a major concern. Is it usable? And when things go wrong, you can also ensure that there are sufficient tools to intervene and/or to ensure that people and installations are not affected. Examples to think of are: • Rollover Protection • Safety Cut-Off Devices • Dead Man switches • Load Moment Indicator • Visibility Mirrors • Taglines • In Vehicle Monitoring System • Data Logger • Collision Avoidance Devices • Exclusion Zones • Boundary Markers • Berms made of soil • Ensuring that there is enough material for barriers
An active role for the human barrier After all the preparation, an active role of the people on site is critical to prevent accidents. To be and to stay alert is a must. Because we can all make mistakes, paying attention to each other and helping each other is very important. The HSElife NL 'We Care' program can help. Use that Toolbox and Last Minute Risk Analysis to discuss all risks and to keep each other on the ball. Concerns are: • Operating in accordance with procedures • Surveillance, operator rounds and routine inspection • Using inspection lists (like a pilot on a plane does time and time again) • Authorization of temporary and mobile equipment • Acceptance of handover or restart of equipment • Response to alarms and emergencies • Situational Awareness (not being in the Line of Fire!) - see item elsewhere in this special • Being always alert and PAUZE, Step back, when needed • Site Communications (Verbal & Non-Verbal) • Use of and respect for Signalers • Fitness for Duty
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A good supervisor has an overview of the process A task of the supervisor is to ensure that the permit to work process is properly monitored. It’s important to ensure that the Task Risk Analysis and Last Minute Risk Analysis are of good quality and are used effectively. It’s also his responsibility to ensure that the right people with the skills that are needed for the job, are available. When there are changes or to be prepared for emergencies is also part of the deal.
Other critical processes that he/she should monitor: • Site/Job Planning • Constructability Reviews • Equipment Selection • Company Standards & Equipment Operating Procedures • Maintenance & Inspections of Equipment & the site • Certification of materials and Equipment • Worksite Hazard Assessment & Control
Only together we can lift safely!
Safe lifting with excavators We see it often and is also practical. Digging a hole and, for example, placing a tank in it. Also, the loading and unloading of material with an excavator is very tempting to do. Fast and cheap. HOWEVER, the excavator must be suitable for it! The crane’s design must be suitable (and please note that the excavator bucket is usually not included in the design). The driver must always follow the manufacturer's instructions and it’s important that the excavator has a weight meter, otherwise the driver has insufficient information. The driver must also have followed specific training. Experience of how and with which one must hoist is critical, especially taking into account that he should not lift too high. In the industry several good guidelines are available.
USE THESE! > 7
Situational awareness in the field and at the office! We often think of situational awareness to issues on site. Where is that truck or crane going to? How does that load move? What could go wrong? And if it goes wrong can I be affected? Also, at the office, one can ask these questions and imagine what could go wrong on a location! A good designer and work planner does nothing other than that. Here are some concerns: SITUATIONAL AWARENESS AT THE OFFICE
SITUATIONAL AWARENESS AT THE SITE
While designing • Limit potential lifting and hoisting risks as much as possible in the design • Involve an expert in the project in sufficient time to discuss all the lifting and hoisting risks • Check everything during the various design reviews Imagine all the 'Line of Fire'-risks
Before commencing the work • Discuss the 'Line of Fire'-risks during the Toolbox Talk or Last Minute Risk Assessment • Ensure that the access to the work area is well protected and that the work area is cordoned off properly • Inspect the area where you are going to work • Make sure that the equipment and tools to be used have been inspected
During work preparation • Make sure you understand the situation at the location • Visit the location and the workplace and check out the situation • Consider how the task can be performed with minimal ‘Line of Fire'-risks • Make sure that the right equipment and the right tools are available at the location • Choose the equipment and the tools that cause as little 'Line of Fire'-risks as possible
INTERNATIONAL HOISTING AND LIFTING STANDARDS? IOGP
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ASME – B30.2
API – DW 2.7.1/2.7.3
During the execution of the work • Be alert to what is happening around you, what is above you and to changes in circumstances • Imagine the ‘Lines of Fire’ - which could pose a risk for you? • Check if there are objects that could drop and could hit you (never walk under a suspended load) • STOP, and take a timeout and check whether anything has changed in the area • Pay attention to each other and care for each other are there other employees in the ‘Line of Fire’? • Respect the person responsible for the work (‘Person in Charge’) • Be convinced that the people involved in the work know what is expected of them and be convinced of their knowledge
HSElife NL Special is a publication of HSElife magazine. For more information visit hselifenl.com