Issue 12
January 2017
G SAFE
In this Issue
Leadership Talk
QHSE Achievements
2016 HSE performance
2017 HSE KPIs Corporate & Project
2016 QHSE report 2017 HSEcampaign KPIs Corporate & Project
Quality & HSE topic of the edition
HSE alert- Lesson Learnt
Blood donation camp 2016
QHSE Quiz
Leadership Talk
Dear All, I take this opportunity through “GSAFE”, to wish you all once again a Very Happy and Safe New Year ahead. Galfar as a company always in the forefront for promoting QHSE as core value and in turn ensuring operational and business excellence, and its sustainability. The year 2016 was an another wonderful year in terms of HSE performance, where no major work related accidents occurred. Our HSE System and Practices were audited by British Safety Council, UK and has awarded 3 star rating. The award we received from QGBC as a “Green Building Contractor” in the Qatar Sustainability Awards 2016 was another feather in our cap. In 2016 four of our following large projects achieved major Safety Milestone of working without LTI. - The Flowline contract which we are doing for the past 16 years achieved 10.81 million safe manhours, - Doha South Sewage Treatment plant expansion project achieved 7.7 million safe manhours - Energy center being built for one of the FIFA stadiums achieved 3 million Safe manhours - Infrastructure project in progress for Manateq achieved 1 million safe manhours On Quality front, Doha South STP project was awarded MEED Quality Award under Power and Water Project of the year category. This is the third consecutive year Galfar is bagging MEED Quality Awards for our various projects. All these achievements were possible through various leading/proactive initiatives such as, rigorous trainings, awareness campaigns, Inspections, audits and compliance to various HSE Procedures laid by our own QHSE team and clients. This quarterly magazine “GSAFE” also one such proactive initiative taken by the QHSE to communicate & Consult QHSE initiatives and QHSE-KPIs across the company. I fully recognize that our first priority is the personal safety of our employees, client, subcontractors and all those who associate with Galfar Al Misnad, while we conduct our business activities. It is the responsibility of each and every one at Galfar to ensure, our policies and procedures are practiced to sustain and bring continual improvements in all areas. It’s our moral responsibility to ensure that all the stakeholders in the supply chain of our business complies to the local legal, statutory and QHSE Management System requirements. I advise QHSE team to intensely drive all Quality, Health, Safety and Environment initiatives across the company to sustain and further improve our QHSE performance and reach higher milestones. I urge all the Galfarians to set example in understanding and practicing the QHSE procedures to make our workplace safer and better organization to work continuously.
Satish G Pillai Executive Director
HSE Achievements
Project 66440 recently celebrated the milestone achievement of 1 Million safe man-hours without any LTI, This event was graced by the Executive Director of Galfar and Director Projects of Manateq and all other senior personnel from Manateq, Dorch Qatar and Galfar. Project 88 620 – Energy Center- Khalifa stadium on 29th December 2016 reached its another HSE milestone of 3 million safe man-hours without any LTI.
Wishing 66440 & 88620 project team to keep up the good job to improve HSE performance further and reach higher milestones
HSE Achievements
We Galfar bagged the “Qatar Sustainability Awards-2016 on the Green Building Contractor – Category” organized by the Qatar Green Building Council. It’s a proud moment for Galfar to be the winner in the sustainability domain among other competitors.
We, Galfar successfully renewed our existing GSAS service provider license and upgraded for Design & Build for District & Infrastructure scheme projects. Further we are on our process to upgrade our license on construction management
HSE Performance 2016 Safety while Fueling
HO 3% Plant 4%
Camp 4%
GFM 4%
Env Spill 0.4%
UD/PD 9% Building 21%
Business segment wise incident stats
FAC 20%
RWC 0.4%
MTC 6.9%
Incident Classification
Infra 18%
LTI 0.8%
E&I 22%
MEP 11%
O&G 13%
RTA 63.5%
Corporate HSE KPI 2016 Plan Vs. Actual LAGGING INDICATORS Fatality LTIFR
Target
Actual
0
0
< 0.6
0.1
340 Workers & 60 Staffs identified and recognized through monthly HSE incentives
LEADING INDICATORS ( PROACTIVE)
Target
Status
Implementing HSE management software
By Q2
Implementation in final stage
Introducing Internal Permit to Work system
by Q1
Implemented
Exclusive HSE training facility with dedicated trainer to improve the HSE Induction and other associated HSE trainings
by Q2
Pending
STOP observations: All HOD should do 1 STOP audit in a month and achieve the company level 75 % of participation
75%
30%
Incident Investigation: 100% completion of root cause analysis of all the injuries/High Potential incidents
>90%
100% on track
Adherence to Yearly HSE training Plan
>90%
70% achieved
Implementing BSC 5 Star Management system in any 2 projects and target for Sword of Honor Award.
2016
Achieved 3 star rating
Quarterly HSE magazine
Quarterly
achieved
HSE awareness theme â&#x20AC;&#x201C;minimum 4 campaigns
Quarterly
5 campaigns conducted
Adherence to HSE inspection plan of Camps and facilities
Quarterly
On track
IMS procedures review inline with ISO 14001: 2015 standards
2016
In progress
Know our HSE KPI for 2017
LEADING INDICATORS ( PROACTIVE)
TARGET
Launching QHSE Software-GSAFE and stabilizing the process
Q1
Exclusive HSE training facility with dedicated trainer to improve the HSE Induction and other associated HSE trainings
Implement by Q2
STOP observations: All HOD should do 1 STOP audit in a month and achieve the company level 75 % of participation
75% participation
International Safety award 2017 from BSC,UK & BSC 5 star Implementation
Targeting in 2017
Periodical health check up of all employees
2017
Incident Investigation: 100% completion of RCA of all the injuries/HIPO incidents
>90%
Adherence to Yearly HSE training Plan
>90%
Quarterly QHSE magazine
Quarterly
HSE awareness theme Quarterly
Quarterly
Adherence to HSE inspection plan of Camps and facilities
Quarterly
Sustaining Internal PTW process through audits
Quarterly
Sub contractors- QHSE guidelines manual
Q1 2017
Review of IMS procedures in line with the new standard ISO 14001:2015
2017
Certification - Sustainablity in construction management
2017
LAGGING INDICATORS
TARGET
Fatality
0
LTIFR
<0.4
Since 2014 we are driving HSE across the company through corporate HSE KPIs, These KPIs are not just on the incident reduction, but also identified leading indicators to improve overall HSE management systems and performance. The performance against each KPIs are communicated quarterly through this GSAFE for each employee to understand and contribute in the improvement process.
Know our HSE KPI for 2017
Project HSE - Key Performance Indicators Proactive KPI'S â&#x20AC;&#x201C; Leading Indicators
Target
HSE Induction training
100%
Project HSE Training Plan adherence
> 90%
Adherence to PTW process
100%
Weekly HSE walkthrough along with construction team
Weekly once
Client/consultant Inspection : Action close out in 4 days or less
100%
Vehicle & Equipment Inspection before deploying at site
100%
Closure of Internal HSE actions identified through daily weekly inspections
>90%
Compliance to weekly/ Monthly HSE inspections ( Welfare & HSE) STOP audit by the senior management ( PM & Above) Weekly HSE meeting Chaired by PM involving sub contractors Investigation of Injuries and high potential incidents
Weekly Monthly Once Weekly 100%
Monthly Incentive program
Monthly
HSE awareness campaign
Quarterly
Monitoring of water, energy, fuel consumption , waste disposal
Monthly
Emergency prepardeness drill
Reactive KPI'S â&#x20AC;&#x201C; Lagging Indicators
Once in 6 months
Target
Fatality
0
Lost time Injury frequency rate
0
The above mentioned KPIs are applicable to all the projects to improve the system and sustain the results. Specific to the site, there can be an additional HSE KPIs or management programs. Responsibility lies with each and every individual to understand and be a part of these positive HSE initiatives. Project leads are requested to involve yourself in lead these KPIs to stabilize and standardize our project HSE management across all the projects. HSE Leads in each project shall monitor the KPI weekly basis and submit monthly reports to corporate HSE
HSE Campaigns Report
We, the team Galfar knows, can make a significant difference in the HSE performance through the HSE Campaigns. In the year 2016, we had four informative HSE campaigns for our employees. And we planned the programme, two at both half's of 2016 respectively. We scheduled four campaigns on Jan, June, July and Nov of 2016 and executed as planned. In 2016, we had four different HSE campaigns at almost all our project sites and including at our camps. The HSE campaigns designed with Awareness training sessions, inspections, continuous monitoring and other motivating techniques. Highlights of the monthly HSE campaigns, are mentioned below → January 16 - 600 personnel trained through Road safety awareness program at HO, Project sites and camps. Defensive driving technique training sessions organized for Drivers and vehicle holders. 138 employees rewarded including LDDD, HDD, Operators and 6 staffs. This was conducted along with our Plant Department. → June 16 - Around 650 personnel trained. 250 saplings planted. Drawing competition event for “Shantiniketan school and our own employee’s children” on the theme of “Go wild for life”
Drive Safe campaign Jan’16
Environmental Awareness campaign June 16
HSE Campaigns Report Safety while Fueling
Heat stress prevention campaign July 16
→ July 16 – Heat stress prevention – Awareness training sessions included with Heat stress causes, symptoms and response during emergency and work timings were demonstrated to work personnel. Inspection to ensure the Drinking water and Rest shelter facilities at all of our sites → November 16 - Health and Hygiene specific awareness training sessions were conducted by Qatar red crescent personnel at Ummsalal, Wukair, Dukhan and Shehaniya camps. Nearly 800 personnel were trained through this campaign. Health & Hygiene related leaflets, kits were distributed to employees. Management team thank everyone who contributed and made active participation in these campaigns and made this initiative as successful one and encourage all to be active in all the future campaigns as well.
Health & Hygiene Campaign Nov 16
Quality Week Campaign
Quality week program conducted across the company to drive quality awareness with a theme of â&#x20AC;&#x2DC;Do it first time rightâ&#x20AC;? and it was well organized and acknowledged by all, during the campaign various technical trainings and group discussions covering all disciplines such as civil, electrical, mechanical, buildings and awareness quiz conducted through online questionnaire, further in all the sites our employees took oath to follow the quality for ever entrusting ourselves for the better products turning an Improved customer satisfaction. Employees who won the quality quiz program were recognized with trophy and certificates .
Quality topic of the edition
Typical Hot Tap
Hot tapping or pressure tapping, is the method of making a connection to existing piping or pressure vessels without the interruption of emptying that section of pipe or vessel. This means that a pipe or tank can continue to be in operation whilst maintenance or modifications are being done to it. The process is also used to drain off pressurized casing fluids, add test points or various sensors such as temperature and pressure. Hot taps can range from a ½ inch hole designed for something as simple as quality control testing, up to a 86 inch tap for the installation of a variety of ports, valves, t-sections or other pipes. Hot tapping is also the first procedure in line stopping, where a hole saw is used to make an opening in the pipe, so a line plugging head can be inserted.
Reasons behind Hot-tap There are many reasons to made a Hot Tap. While is preferred to install nozzles during a turnaround, installing a nozzle with equipment in operation is sometimes advantageous, especially if it averts a costly shut down. Considerations before made a Hot-tap • A hot tap shall not be considered a routine procedure, but shall be used only when there is no practical alternative. • Hot Taps shall be installed by trained and experienced crews. • It should be noted that hot tapping of sour gas lines presents special health and metallurgical concerns and shall be done only to written operating company approved plans.0 • For each Hot-tap shall be ensured that the pipe that is drilled or sawed has sufficient wall thickness, which can be measured with ultrasonic thickness gauges. The existing pipe wall thickness (actual) needs to be at least equal to the required thickness for pressure plus a reasonable thickness allowance for welding. If the actual thickness is barely more than that required for pressure, then loss of containment at the weld pool is a risk. • Welding on in-service pipelines requires weld procedure development and qualification, as well as a highly trained workforce to ensure integrity of welds when pipelines are operating at full pressure and under full flow conditions.
Quality topic of the edition
Sequence of hot tap
Hot-tap set-up For a hot tap, there are three key components necessary to safely drill into a pipe; the fitting, the valve, and the hot tap machine. The fitting is attached to the pipe, mostly by welding. In many cases, the fitting is a Weldolet where a flange is welded, or a split tee with a flanged outlet (see image above). Onto this fitting, a valve is attached, and the hot tap machine is attached to the valve. For hot taps, new bolts, gaskets and a new valve should always be used when that components will become part of the permanent facilities and equipment. The fitting/valve combination should be pressure tested, to make sure that there are no structural problems with the fitting, and so that there are no leaks in the welds. The hot tap cutter, is a specialized type of hole saw, with a pilot bit in the middle, mounted inside of a hot tap adapter housing. The hot tap cutter is attached to a cutter holder. The tapping adapter will contain the pressure of the pipe system, while the pipe is being cut, it houses the cutter, and cutter holder, and bolts to the valve. Hot-tap Operation The Hot Tap is made in one continuous process, the machine is started, and the cut continues, until the cutter passes through the pipe wall, resulting in the removal of a section of pipe, known as the "coupon". The coupon is normally retained on one or more u-wires, which are attached to the pilot bit. Once the cutter has cut through the pipe, the hot tap machine is stopped, the cutter is retracted into the hot tap adapter, and the valve is closed. Pressure is bled off from the inside of the Tapping Adapter, so that the hot tap machine can be removed from the line. The machine is removed from the line, and the new service is established.
HSE Topic of the edition In Today’s modern construction industry, Heavy equipment’s are an unavoidable matter. If we work around any kind of heavy equipment, we need to have a healthy respect for it. Most, if not all, equipment used in construction, is big and powerful - and for those reasons, inherently dangerous. And although most of us are well aware of the hazards involved, every year around the world there are still thousands of heavy equipment-related incidents that result in property damage or injuries and, unfortunately in some cases, fatalities. There’s never usually one simple reason or one type of person we can attribute heavy equipment-related incidents to - they can happen to seasoned operators as well as newly trained ones. Obviously every machine and every situation comes with its own set of hazards, but there are some general safety rules you can follow to help you end every work day safely. They are • Make sure you’ve been properly and sufficiently trained on the equipment you’re using by qualified, experienced people. • Be aware, stay alert and know equipment’s blind spots – whether you’re the operator or just working around it. • Communicate with people working around equipment – either via two-way radios or a spotter who’s been trained on standard hand signals. Never assume people know what you’re going to be doing. • Always wear high-visibility clothing and steel-toed boots. • Always wear your seat belt. It seems obvious, but it’s easily forgotten. In case of a rollover this can be a life saver. • Don't climb on or get off equipment while it's moving. • Never exceed the load that a machine is rated to carry. • Climb on and off equipment properly. Falls are still the number one cause of injury, so never jump off equipment and always use three-point contact (both feet and one hand or one foot and both hands on the holds at all times) when climbing on or off equipment. • Always do a walk around and inspect the equipment before you start using it. Check tires, tracks, components and other mechanisms for cracks, damage or anything caught in them. • Always load and unload equipment on level ground to reduce the risk of rollovers, and keep the area clear.
Know the Safe Zone
HSE Alert
Incident Description During backfilling activities, a tipper truck loaded with sand tipped over on the side while maneuvering in the Project premises. The Incident happened when the driver was reversing and suddenly, the left side back tires slipped off the road to a loose soil area with sloppy / uneven surfaces and fell towards the driver’s side. The driver came out safely without a scratch and there was no injury recorded. The front windscreen and the left side window glass of the Tipper Truck were broken.
Incident type Dangerous Occurrence Causes could be for the incident • Uneven and sloppy roads • Poor supervision and inadequate Assessment • No supervision of work • Improper unloading process in tipper • Non compliance of safe work procedure • In experienced operator
Learnings and safe practice to be adopted •
Driver / operator should be conscious about the anticipated hazards of job (Workplace environment – path condition to safe drive, space to drive, turns, load of the vehicle)
•
Workplace shall be assessed prior to the start of activity to enable the safe execution
•
Speed limits shall be followed
•
Competent personnel shall be deployed as banks-man for heavy construction equipment
•
No person should be allowed near the critical loading/unloading activities
•
Defensive driving technique shall be provided to all drivers
•
All vehicle drivers / users and equipment operators shall be encouraged and instructed to wear seat belts when in operation
Health Corner
Blood Donation Drive - 2016 GAEC NO
Blood donation camp organized on 24th November 2016 by Galfar Medical team at Umsalal Ali clinic. 131 Employees volunteered and donated blood.
Thanks to all the donors, participants and volunteers and our appreciation to Admin and medical team for organizing the program.
NAME
GAEC NO
24206 22513
Edgar Glenn Canales Rahul Sreekumar
23098 20057
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NAME Rup Lal Jonson Sanjay Pilla Kishor Raju Matthew Ginesh Shivarama Ashok Kashmiri Lal Jamaluddin Tanweer Alam Jaswinder Singh Thangaiha Avas Miah Suresh Kumar Goji Job Kishore Singh Joseph Thious Raju Singh Ks Assis Rakesh Ray Prabhakaran S Arif Hossain Anish K R Kanakesh Tomy George Iqbal Singh Ram Lal Narayansamy Senthil Kumar Nirmal Nair Jithin Joy Dinesh Babu Panachikalalil Mahamad Karim M Suzan Mia Ansu AP Shyam Kumar Raju Komban Bina Ram Dhirendra Padam Bahadur Rajeshwar Rao Bibin B Md Daluad Hosain Venkatesan K Binu John Santhosh EM George Raju Netranandappa U Syam Krishnan GP Afsal K.A Viswambharan V Balram Chaudhari Nagaraja K Ratheesh K. Manoj K.B Shiju K.V Harminder Singh Mukesh V.M Joju Ponthokku Parsha Ramulu Aer Jeo Gursant Singh Paul Pandan Shiju Gopinathan
QHSE Quiz Corner
Mr. Rajeshwar Rao
Mr. Mohamed Imran
Winners of the last edition HSE Quiz
Mr. Manish Narayanan
Answers to the last edition quiz 1.a 2. Monitoring & Measuring Equipment 3.c 4.b 5.Portable Appliance Test
Quiz for this edition
1. When should all incidents be reported as per our IMSP 27? a) Within 4 hours of the incident occurring b) Within 2 days of the incident occurring c)Within 7 days of the incident occurring d) Only if the employee requests it 2. Three point contact means ladder has to be attached at three points. a) True b) False 3. What does a risk assessment tell you? a) How to report incidents b) The working hours of the organization c) How to do the job safely d) All of the above 4.
The picture represents a. Unsafe act b. Unsafe condition c) Both
5. What is PDCA Stands for in any management system ? _____________________
Join our upcoming drive safe campaign 2017
Post Box No: 22170, Doha, State of Qatar Kindly post your suggestion & feedback on this magazine to venkat@galfarqatar.com.qa