Primary Fatality Prevention Controls
Vale Global Golden Rules
Instruction for preventing workplace fatalities
Objective, Background and Context
2
Presentation Title – 01/12/2010 (optional)
Background
Corporate Vale has established a set of Global Golden Rules. These Golden Rules
demonstrates our values, starting with – “Life Matters Most”
These Golden Rules are instructions – Primary Fatality Prevention Controls that are
critically important to prevent fatalities.
If followed, these instructions would have prevented 80% of the fatalities in our
global business.
Zero harm for everyone depends on our shared commitment to the highest standards of
care at all times and in all circumstances
Many of you will recognize these instructions, as they originate from well established Health
& Safety Management System programs (Operational Controls) in place in the Base
Metals. Such as:
• Zero Energy State / Identify, Tag, Lock, Check
• Confined Space
• Working at Heights
• WHMIS
• Management of Change
3
Context
These instructions are intended for all people who work for or on behalf of Vale.
Instructions to prevent work-related fatal incidents. These rules come to mind, either as a
reminder to yourself or as a supervisor’s reminder every time you or someone else are
required to work in situations involving these conditions
Information everyone must be capable of applying while working.
•
Knowledgeable on the content
•
Skilled in the application
•
Attitude – a desire to follow and promote these instructions
Instructions that you can expect and depend on others to comply with and others can
depend on you to comply with.
A basis to stop work and reassess if the instruction is not implemented to manage risk
properly - to As Low As Reasonably Achievable - ALARA
4
IMPORTANT
If you can not follow through on any of the following
instructions you are about to review
STOP WORK & CONTACT YOUR SUPERVISOR
5
Learning Objectives
At the end of this review you will be able to:
• Summarize the reasons why the Golden Rules are important to all people in
all workplaces in our company
• Identify the Golden Rules as they apply to you
6
.
WHY?
7
What are the Golden Rules
Vale 10 Golden Rules
Category
Primary Instruction
Basic Requirements
Only perform work that you are trained, qualified, authorized and fit to perform.
Working at Heights
Where there is a hazard of falling 1.8 meters or more, approved , maintained and certified
equipment for fall arrest and travel restraint must be used.
Mobile Equipment and
Light Vehicles
Always use mobile equipment and light vehicles for the purpose they were designed for and
adhere to site pedestrian / vehicle traffic rules.
Energy and Equipment
Isolation
Only work on equipment if all energy sources have been identified, tagged appropriately,
locked with your personal lock and tested to ensure the they are at a zero energy state.
Lifting and Mechanical
Handling
Always use authorized, maintained appropriate and certified lifting devices capable of lifting
a load in a controlled manner and safeguard against encroachment under suspended loads
by pedestrians and mobile equipment.
Confined Spaces
Only enter a confined space if you are trained, qualified and authorized and after having
reviewed the permit.
Surface and
Underground Mining
Only enter areas you are authorized to do so.
Equipment
Safeguarding
Only trained and qualified personnel may alter equipment safeguards after having received
authorization.
Chemicals and
Hazardous Substances
Only handle hazardous substances in accordance with prescribed controls.
Management of
Change
Always conduct a management of change assessment before implementing any temporary
or permanent change (process, equipment or facility).
Basic Requirements
“Only perform work that you are trained, qualified, authorized and fit to perform.”
Guidance
• Trained and qualified means you have received training provided or
recognized by (if the training is external) the organization. Persons performing
work must know and understand the hazards, the procedures to be applied
when performing the work and how risk associated with the hazards is to be
managed.
• Authorized means that the job must be assigned by organization supervision
and, where required, have a signed off work permit in place before
proceeding.
• Authorization will include a review of the hazards associated with the job,
the controls that must be applied and assurances that proper controls are
in place.
• Fit means a person must meet the physical and mental requirements of the
work on the day that it is assigned, be unaffected by drugs or alcohol.
• These basic requirements are a pre-requisite for each of the following
instructions.
Working at Heights
“Where there is a hazard of falling 1.8 meters or more, approved , maintained and
certified equipment for fall arrest and/or travel restraint must be used.”
Guidance
• Working at height standards are applied for any height that is equal to or
greater than 1.8 meters (6 feet) above the ground or level lower than this
where there is risk of injury from falling while performing work.
.
1.8m
6 feet
Working at Heights – Questions to determine if Risk is at ALARA
 Have the people involved in the work had the necessary training? Are they
Qualified? Are they Authorized?
 Is a JHA/SSA required for this work?
 If required, has a work permit been issued – has it been reviewed with all
participants?
 Are full body harnesses being used for people working above 1.8 meters?
 Lanyards and shock absorbers in place? Double lanyards for 100% tie off?
 Are appropriate anchors being used?
 Is there a Rescue Plan to minimize suspension trauma?
SCAFFOLDS
 Do scaffolds have handrails and toe boards?
 Have scaffolds been constructed by competent personnel?
 Are scaffolds authorized for use?
Mobile Equipment and Light Vehicles
“Always use mobile equipment and light vehicles for the purpose they were designed for
and adhere to site pedestrian / vehicle traffic rules.””
Guidance
• An operator of a vehicle is required to:
• Check that the vehicle is fit for purpose.
• Adhere to site traffic rules including; speed limits, direction of travel on
roadways, authorized roadways and wearing of seat belts.
• Eliminate distractions while driving
• Secure material being transported in a vehicle if occupants can be
affected by its movement.
• Comply with vehicle and road restrictions in terms of load capacity and
number of passengers.
• To safeguard against incident a pedestrian is required to:
• Give way to, and stand clear of, mobile equipment as this equipment has
the right of way.
• Only approach a mobile equipment work area after the equipment
operator has been alerted, and, has provided approval for proceeding
through the mobile equipment work area.
Mobile Equipment– Questions to determine if Risk is at ALARA
Any Vehicles
 Operators Trained? Authorized?
 Pre-use Check completed? Warning devices functioning? Brakes tested?
 Are loads secure? Are items inside the cab secured?
 Are seat belts in place and in use?
Pit Vehicles
 Whip antenna with flag in place? Flashing cab light? Reflective markings?
 Two way radio functioning? Communication established as per protocol?
Mobile Equipment
 Reversing Alarms?
□ FOPS / ROPS in order?
Pedestrians
 Aware they DO NOT have right of way?
 Make eye contact and get permission to approach any Mobile Equipment
Energy and Equipment Isolation
“Only work on equipment if all energy sources have been identified, tagged
appropriately, locked with your personal lock and tested to ensure they are at a zero
energy state.”
Guidance
• Energy sources include systems that incorporate compressed gas,
pressurized hydraulics or pneumatics, process fluids and gasses, steam,
water, gravity driven mechanisms and electrical sources..
• When isolating sources of energy a person is required to:
• IDENTIFY all energy sources, TAG as required, LOCK with personal lock
as required, CHECK to ensure that energy is at zero.
• Use personal lock(s) and tag(s) as you have been trained and authorized,
in accordance with the site tagging and locking procedures.
• Before working on any equipment or in any vessel a person is required to:
• Check that all energy sources have been isolated and are locked out of
service.
• Check that residual energy has been released.
• Apply tags and personal protection locks as required by the site isolation
procedures.
Energy Sources – How can the energy be controlled?
MUSCULOSKELETAL
PRESSURIZED
OR STORED
VIBRATION
THERMAL
STABILITY
FIRE
BIOLOGICAL
RADIATION
GRAVITATIONAL OBJECT
NOISE
CHEMICAL
MECHANICAL
MACHINE - MOBILE
ELECTRICAL
EXPLOSIVES
16
MACHINE - FIXED
GRAVITATIONAL
- PEOPLE
Isolation – Questions to determine if Risk is at ALARA
 Is there a procedure for isolating the energy source? Is the task non-routine or
the conditions abnormal – is a JHA/SSA required?
 Are people trained and authorized to complete the isolation procedure? Are
others required – Equipment Operators, Authorized Isolators? Is a Permit
required?
 In the case of a group lock out, has the plan been reviewed with all involved?
Are all aware of what their personal lock is protecting them from?
 Do tags provide the required information?
 What is the test to determine a zero energy state before work starts?
 Is there a plan in place to restore energy to the equipment or process? Are all
aware of it? Are all clear of the area on start up – expecting the unexpected?
Lifting and Mechanical Handling
“Always use authorized, maintained, appropriate and certified lifting devices capable of
lifting a load in a controlled manner and safeguard against encroachment under
suspended loads by pedestrians and mobile equipment.”
Guidance
• Devices used for lifting purposes must be designed so that they are capable of
lifting a load.
• When operating a lifting device a person is required to:
• Check that there is a risk assessment and lifting procedure for critical and
non-routine lifts.
• Perform pre-operation inspections and checks on equipment and lifting
accessories and that any lifting equipment safety devices are operational
before a lift is made.
• Check that the load and reach does not exceed the capacity of the lifting
equipment.
• Secure material being lifted to prevent it from falling.
• Check the path of movement is visually monitored at all times.
• Lifting must be performed such that people or equipment are prevented from
passing under the load during movement.
Lifting – Questions to determine if Risk is at ALARA
 Is the equipment operator, and others trained and authorized as required?
 Is a JHA/SSA required? Is a rigging plan in place for critical and non-routine
lifts?
 Have communications protocol been established? Does everyone know their
role and responsibility for the lift?
 Are the accessories checked and suitable for the lift? (slings, hooks, chains,
clamps, shackles, rings) Is their lifting capacity known?
 Are the loads to be lifted within the capacities of lifting equipment?
 Is the lifting device being used as designed? Vertical lifts? Outriggers in
place? Boom at appropriate lift angles?
 Is there a chance of people becoming positioned under the load? Will the load
be moved while it is suspended? What is the plan to control this?
Confined Space
“Only enter a confined space if you are trained, qualified and authorized and after
having reviewed the permit.”
Guidance
• Confined space is a fully or partially enclosed space:
A. that is not designed and constructed for continuous human occupancy, and,
B. in which atmospheric hazards may occur because of its construction, location, or
contents, or because on the work that is to be done in it.
• Only people who are specifically trained and qualified to work in a confined
space can enter.
• When a confined space entry is necessary a completed and authorized entry
permit is required.
• When working in a confined space a person is required to:
– Check that a confined space attendant (guard) is stationed at the entry of the
confined space to monitor the people working inside, people exiting and the
capability to initiate emergency response;
– Monitor the atmosphere in accordance with the permit and/or hazard assessment in
confined spaces during work and exit the confined space to reassess risk and
controls should a change in atmosphere occur;
– Work strictly in accordance with the confined space procedures
Confined Space – Questions to determine if Risk is at ALARA
 Is there a permit in place? Has it been reviewed by all involved in the confined
space? Are all people trained and authorized?
 Are all energy sources tagged and locked out? Is there anyway for substances
to enter the confined space? Material? Liquid? Chemical? Gas?
 Will atmospheric testing occur? What is the atmospheric testing in place to
determine? Are conditions acceptable? Can conditions change?
 Will burning be conducted inside the confined space? Is a burning permit in
place? Are there heat related reactions with previously stored substances that
can occur?
 Is the confine space guarded? Entry allowed and exit monitored by the
Attendant? Secured during breaks or off shift?
 Is there a rescue plan? Is necessary emergency response equipment in place?
Surface and Underground Mining
“Only enter areas you are authorized to do so.”
Guidance
Restricted areas in mining facilities include:
•
•
•
Underground:
•
Areas of unsupported ground.
•
Areas where air conditions are tested as, or suspected to be foul.
•
Inactive mining areas
•
Underground areas where hang-ups of mined material and/or accumulations
of water at ore passes, chutes, silos, bunkers and stockpiles in the absence of
formal procedures to control inherent risks.
Surface
•
Mine pit benches areas, at the base and crest of high walls, mining faces,
dumps and blasting areas or the base of stockpiles.
•
Draw points below stockpiles in surface mining (e.g. accessed via tunnels or
inclined ramps) or access stockpiles without site specific entry procedures.
•
Mining excavations or trenches where the sidewalls have not been properly
supported.
Detonation locations, in either type of mining, just prior or after a blast taking place.
Surface and Underground Mining
How to recognize Underground restricted areas
Single Guardrail
• Understand the
hazard
• Keep out if unqualified
to manage the hazard
• Cautionary use – OK
to work
23
Double Guardrail
• Keep out
• Supervisor’s
permission only to
enter
• Extreme hazard or
needs a special
procedure etc
Screen Barricade
• Keep out
• Supervisor’s permission
only to enter (and
usually accompanied)
• Extreme hazard of
longer duration
• Needs a special
procedure and special
protective gear
Restricted Areas – Questions to determine if Risk is at ALARA
 Are people aware of the local restricted area procedure? Do people know what
to look for and how to respond?
 If work team is conducting work outside of their home location do they know
the procedure for creating or identifying a restricted work area?
 Is the appropriate signage in place? Can it be read? Is the guarding
mechanism (rope, chain, flagging) secure? Clearly visible? Completely
encompass the area of concern?
Equipment Safeguarding
“Only trained and qualified personnel may alter equipment safeguards after having
received authorization.” (alter = disable, remove, adjust, test)
.
Guidance
• NOTE: There will be occasions when it is a requirement to perform tests or
make adjustments to equipment with the pre-planned disabling of
safeguarding devices. This type of work may only be performed with preauthorization and under controlled circumstances (Management of Change,
JHA/SSA, Local Procedures).
• Most types of machinery including mechanized lifting devices have operable
protection devices designed to prevent harmful incidents to people.
Therefore, during normal operation, machinery is only to be operated with
protection devices in place and tested operable (as applicable).
These include:
– Physical Guarding
– Instrumented Protection Devices
– Emergency Shutoff Systems
Equipment Safe Guarding - Examples
Nip Points
Can you think of something you
might use or have seen at home
that is guarded this way?
Other Safe Guards include,
Emergency stops, zero
speed switches, emergency
pull cords, level sensors…..
26
Equipment Safeguards– Questions to determine if Risk is at ALARA
 Are safeguards in place? Rotating Equipment? Pinch Points? Emergency Pull
Cords? Emergency Stops?
 Do the guards provide the protection they were designed for?
 Have the safeguards been inspected? Tested? Maintained as required?
 Are emergency shutoffs clearly visible? Identified? Accessible?
 Is there a procedure in place for rings? Long hair? Bracelets? Chains?
Earrings? Loose clothing?
 Is there machinery or equipment that requires additional guards?
 Are fixed protection devices only removed with the machine or equipment
identified, tagged, locked out and checked?
 Are repair, cleaning, adjusting and inspection activities only performed when
the machines are identified, tagged, locked and checked, unless their
movement is essential to these activities? What controls are in place to
manage the risk of exposed hazard(s)?
Chemicals and Hazardous Substances
“Only handle hazardous substances in accordance with prescribed controls.”
Guidance
• People who handle hazardous substances must be trained and qualified to
recognize and enact the controls necessary for each type of hazardous
material they may have to handle.
• What is the name of the legislated system we have in place to identify and
control hazardous substances?
• WHMIS
• What do these letters stand for?
• Workplace Hazardous Materials Information System
• What does MSDS stand for?
• Material Safety Data Sheet
Chemicals and Hazardous Substances
“Only handle hazardous substances in accordance with prescribed controls.”
Guidance
• Material Safety Data Sheets (MSDS) will be available and reviewed as
required so that individuals recognize the hazards, understand the
precautions, are able to follow the instructions and can apply the controls.
• Internal procedures for hazardous substances with reference to the
appropriate MSDS shall be in place for transporting, processing, mixing,
handling, storing or planning the disposal of these materials.
• Persons working with hazardous substances and chemicals or in areas where
they are used shall have access to emergency equipment, be aware of
emergency procedures and able to implement them as defined.
Chemicals and Hazardous Substances
• So how well do you know your WHMIS symbols?
30
Compressed
Gas
Flammable
Oxidizer
Poisonous
Toxic
Biohazard
Corrosive
Reactive
Hazardous Substances– Questions to determine if Risk is at ALARA
 Are people Trained, Qualified and Authorized to work with the hazardous
substance?
 Is there an inventory of hazardous substances? Is there a MSDS for the
hazardous material
 Is there a procedure or JHA/SSA for the task involving the hazardous
substance?
 As part of the plan for the task has the MSDS been reviewed? In the language
of the user of the product?
 Is Personal Protective Equipment (PPE) required? Is it specific for the task?
Protective Eyewear – Goggles, Face shield, Specialized clothing? Specific
Respirator cartridge?
 Are there specific notifications of hazardous substance use? (Emergency
Services, First Aid, Medical, Health)
 Is emergency response equipment readily available? Eyewash stations,
Showers? Fume hoods connected to exhaust fans? Appropriate Fire
Extinguishers?
Management of Change
“Always conduct a management of change assessment before implementing any
temporary or permanent change (process, equipment or facility).”
Guidance
• A change management program shall exist for all organizations and its
application is required to define, review and approve any type of change that
occurs in the workplace.
• Change of many kinds take place in the workplace. Recognizing a change
and then taking the necessary steps to manage any potential risks is a
requirement of everyone who works within the organization.
• In addition to permanent changes, small changes (such as revising the set
point of an instrument) or temporary changes that are applied for over short
time periods to manage a system deviation / transition or even a “change in
kind” must comply with the site Management of Change program approval
process for:
– Facilities : any infrastructure at a workplace site.
– Processes : systems and operating processes.
– Equipment : mobile and stationary equipment used in processing.
Management of Change– Questions to determine if Risk is at
ALARA
 Do people understand Management of Change (MoC)?
 Do people know the triggers for the Management of Change process?
 Is this a “change in kind”?
 Has a risk assessment been completed to understand the impact of the
change? Chemical? Structural? Design? Process? Training? RISK?
 If a purchased or warehoused replacement piece looks or feels different, will
people inquire about MoC?
 Have all the notifications been made for a temporary or permanent change?
Operators? Maintainers? Purchasing? Learning & Development, Health, safety
and Environment? 6Suppliers?
Where do these controls fit in our North
Atlantic Health & Safety Management
System?
What about SafeProduction?
Safety and Health Management System Overview
PLANNING
Safety,
Health,
Env.
Policy
Activities associated with developing plans to control hazards and
mitigate risks
RISK
MANAGEMENT
BUSINESS PLANNING
MAJOR HAZARD RISK
REGISTER
WRAC,
BTA,
PHR
PROJECTS, CHANGES,
INCIDENTS/NEAR MISS
HAZOP
,BTA,
PHR
RA FOR JOB
PROCEDURES OR PLAN
JSA,
JTA
INFORMAL RA
SETTING OBJECTIVES,
MEASURES AND
TARGETS AND
DEVELOPING PLANS
- Set objectives and targets to meet
Policy and Goals
- Develop plan to achieve
objectives
(ex. MSD’s, Managing Critical Risks,
SHMS execution, Felt Leadership)
SLAM,
IDENTIFY LEGAL AND
OTHER REQUIREMENTS
- S&H legislation identified
and monitored
- Corporate Requirements
IMPLEMENTATION & OPERATION
Activities associated with execution of hazard control and risk mitigation
ACCOUNTABILITIES AND
LEADERSHIP PRACTICES
- Accountabilities and visible activities to
demonstrate leadership
TRAINING
- Employee S&H functional training
to manage hazards.
COMMUNICATION
Other Inputs
- Business Goals
- Results of Management Review
- Audit findings
- S&H performance
- Improvement Goals
- Employee S&H Surveys
- Incident Review
- Describe means of communication
of S&H information
EMERGENCY
MANAGEMENT
OPERATIONAL CONTROL
- Control of S&H workplace hazards and risk
mitigation during business operations
Ex. Confined Space Program, ZES
Program, Health and Medical
Programs, Fatal Risk Std’s, Critical
Procedures
CONTRACTOR
MANAGEMENT
EMPLOYEE
INVOLVEMENT
- Involvement of employees and their reps in
specific S&H activities (ie. JHSC)
DOCUMENTATION
CHECKING AND CORRECTIVE ACTION
REVIEW
Activities associated with Senior Management review to determine if
Safety & Health objectives/targets and policy have been met.
MANAGEMENT REVIEW
- Review of:
- Audits
- Performance Results
- Risk Assessment
- Progress on meeting objectives and planned commitments
Activities associated with checking to see if hazards are controlled and risks are
mitigated and correcting problems to prevent future accident/incidents
MONITORING OF
PERFORMANCE
- Monitoring of leading and lagging
indicators associated with objectives
- Monitoring of S&H plans
INCIDENT MANAGEMENT
- Incident/non-conformance
Reporting and investigation and follow-up
of corrective action
- Communication of lessons learned to prevent
recurrences
- NO REPEATS
AUDIT
- Audit of S&H Management system
- Compliance Audit
RECORDS
RECOGNITION
- Recognition of exemplary performance
in S&H of employees or groups
Golden Rules and SafeProduction
Plan all work with risk management
Golden Rules help us to answer 3 main questions of managing risk:
What can go wrong? – Golden Rules highlight areas of severe
consequence – 80% of previous fatalities
How bad could it be? – Fatality X Likely (if rules not followed) = Extreme Risk
What needs to be done to control it? – Follow the direction provided in
the primary instruction – know the related operational controls
Accept Boundaries
In order to ensure that the risk associated with the most hazardous
aspects of our industry is managed to ALARA we must establish
boundaries with specific instruction. The Golden Rules are the
instructions. They originate from the Operational Controls element in the
Health & Safety Management System. The instructions are a critical step
to enable us to complete the work with zero harm. (See ALARA)
Care for Each Other – work as a Team
Establishing, implementing and promoting Golden Rules demonstrates
our care for one another. Not having these instructions in place and
following them can result in the very real possibility of losing a colleague
and impacting all of those associated with the team member – Family,
Friends, Co-workers. We have to look out for one another.
Lead by Example
We can all lead at least one person – ourselves. The truth is that we often
set the example for many others – new people and less experienced
workers. We owe it to ourselves and each other to commit to
understanding and following the Golden Rules. Our demonstration of
following the Golden rules sets the example for all to learn.
36
If you can not follow through on any of the instructions you just
reviewed
STOP WORK & CONTACT YOUR SUPERVISOR
37
Learning Objectives
At the end of this review you will be able to:
• Summarize the reasons why the Golden Rules are important to all people in
all workplaces in our company
• Identify the Golden Rules as they apply to you
• ANY QUESTIONS?
38