Sharing the Learnings Contractor HSE MS Audit April

Sharing the Learnings Contractor HSE MS Audit April 2009 Rising to the challenge

Purpose To share with PDO and Contractor Community the learnings from Contractor HSE MS Audit Rising to the challenge

Leadership and Commitment § Involvement, leadership and periodic review of HSE Performance at site management level lacking. § Designated Site Managers not available at some locations. § Improper handover of responsibilities and authorities from Site Managers to Acting Site Managers

Organization, Responsibilities, Resources, Standards, and Documentation There a number of Organization charts which are not in line with the actual set-ups resulting in unclear roles, responsibilities, authorities and reporting. HSE critical positions not identified and Competence evaluation of persons occupying these positions not evident. Inadequate sub-Contractor Management: Gaps in fitness to work, Equipment maintenance, leave of personnel, consequence management.

Organization, Responsibilities, Resources, Standards, and Documentation • Food Handler’s certifications from Municipality not available/expired. • Fitness to work certification not available/not complete for some personnel.

Hazard and Effects Management Process • There is inadequate understanding and application of the Hazard and Effects Management Process. • Job HSE plan is a download of standard hazards. It is being used as tick list. This is not reviewed for additional hazards & hence does not include relevant hazards and controls. E. g. : use of MEK in bonding, fibreglass grinding • According to permit applicant, inclusion of such hazards not acceptable. Rising to the challenge

Planning and Procedures • Emergency procedures not tested • Personnel unaware of key roles assigned in documented Emergency Response Plans eg: Rescue Team Leader, Evacuation Team Leader • Non-functional emergency shut-off for gas supply to kitchen, inappropriate modifications on the gas supply system impacting on the emergency shut off • PDO Medical emergency procedure not available to Medic for co-ordination with PDO clinic in case of emergencies

Planning and Procedures • Asset integrity maintenance programmes not defined, some assets in unsafe state of maintenance. e. g. – Water tank corroded and top portion partially detached. Water tank Supporting structure in state of severe corrosion – Water supply pump leaking and not maintained, canopy pillars corroded – Live Electric panels have grass growing into it and cable core exposed – Inappropriate handling of calibrated Safety Relief valves

Implementation and Monitoring • Reactive HSE Performance Indicators are monitored and reported, however, there is no measurement of achievement of proactive targets. • Records of daily driver check records for defects, passenger manifest for vehicles, journey call-back records at intermediate points, sub-contractor fitness to work records, daily personnel deployment etc. are not readily traceable.

Implementation and Monitoring • Learnings from incidents not propagated to avoid recurrence. Many evidences at site of similar problems as very recent incidents. • STOP data analysis not evident to identify and focus on repeated/important unsafe acts. • Corrective actions from identified findings not always traceably closed out.

Implementation and Monitoring § Food Safety Management in and around food preparation and catering areas not in accordance with HACCP system, e. g. § doors which cannot be closed tight, cracked floor tiles harbouring dirt, blocked drainages within kitchen, grease trap not maintained, open septic tank cover nearby, presence of insects including flies and cockroaches in food handling areas, inadequate air exchange , etc

Implementation and Monitoring • There is no evidence of check of Potable Water obtained from far away sources and transported by Road tankers since 2007 for conformity to potable water standards. • Radiographic nuclear source storage is not licensed. Rising to the challenge

Implementation and Monitoring • There are no clear documented instructions on Commuting Policy. • Journey plans for passenger buses do not identify the passengers travelling in the vehicle. • Driver-reported cases of vehicle defects not tracked for completion. • Verification of centre of gravity of water tanker and sewage tanker not available • Call backs by drivers not traceable for intermediate stops. • There are some vehicles fitted with IVMS. The trial started 2 years ago. Data downloads from IVMS for analysing driver behaviour and feedback not evident. Rising to the challenge

Implementation and Monitoring • Home made lifting equipment in use without appropriate testing/certification. • Slings certification status not available Rising to the challenge

Implementation and Monitoring • House Keeping, the first barrier in HSE, in storage and work areas not monitored and maintained. • Hazardous and flammable chemicals are stored in 20’ container without identification in close proximity to the workshop where welding is being underatken. Electrical fittings not appropriate to the flammable atmosphere from stored materials. SHOC cards not available for the chemicals. • Hazardous waste management is not implemented with appropriate traceability

Auditing and Corrective Action • Action Items from audits not followed up for closure. • HACCP Audits not being carried out as required for Food Handling • Competence for HSE Audit team setup not defined

Management Review • Management Review action items identified are not being reviewed in subsequent meetings for closeout. Hence, many outstanding actions • No target dates sets for closeouts.