Safe Maintenance Athens , 4 July 2011 Bernhard Thier, Cefic Responsible Care Manager

1. Safe Maintenance Athens, 4 July 2011 Bernhard Thier, Cefic Responsible Care Manager

2. EU-OHSA Campaign on Maintenance • Target: 25% reduction of accidents rate by 2012 • Maintenance workers at increased risk: • 10-15% of all fatal accidents at work and 15-20% of all accidents related to maintenance • The EU-OSHA campaign messages: • 1. Maintenance = essential to keep the working environment safe & healthy • 2. Maintenance = high-risk activity that has to be performed in a safe way • Higher exposure of maintenance workers to dangerous substances • Higher exposure to noise, vibration and radiation • Maintenance workers often perform physically demanding work • Indications of higher risk of occupational diseases (e.g. musculoskeletal disorders)

3. Risks & Dangerous Substances • High risk of all types of accidents • Related to work equipment and machine maintenance, e.g. crushing by moving machinery, unexpected start-up • Falls from height, accidents involving falling objects • Electrocution, electrical shocks, burns • Confined spaces, asphyxiation • Explosion, fire • Exposure to dangerous substances (in many industries) • Electric arc welding, lubrication and cleaning of machinery • Working in car repair shops • Waste treatment plants • Maintenance of industrial installations where hazardous chemicals are present

4. Risks & Subcontracting • Maintenance-specific risks • Working alongside a running process and in close contact with machinery • Involves disassembly and reassembly of complicated machinery • Non-routine tasks & exceptional conditions • Changing tasks and working environments • Working under time-pressure • Subcontracting (maintenance is very often subcontracted) • Aggravating factor in terms of safety and health • Maintenance operations are often carried out on customer sites which are unfamiliar to the workers • Workers carry out operations very independently, making decisions by themselves • Working alone, working during the nights • Many subcontracting companies to operate simultaneously on sites

5. Maintenance Success Factors • Management commitment and safety culture in the organisation • Involvement and participation of the workers • A well-conducted risk assessment • Preventive measures according to the prevention hierarchy, combination of preventive measures • Safe work procedures and clear guidelines • Effective and continuous communication • Continuous improvement/development • Safety and health training • Maintenance included in the health and safety management system

6. EU-OHSA Campaign Materials • Report on „Maintenance and OSH –A statistical picture‟ (online) • Factsheets – for workers and for employers, statistical picture in 22 languages • A collection of good practice examples published in 2010 • E-facts on specific topics online • Campaign website • Maintenance thematic webpage • NAPO video on safe maintenance (link)

7. EU-OHSA Campaign on Maintenance • Visit the Campaign website http://hw.osha.europa.eu • More about maintenance: http://osha.europa.eu/en/topics/maintenance

8. Ammonia, 9 bar? • Benzene? Maintenance Work in a Chemical Plant What is a maintenance worker facing? • Need to disassemble the pump • What is inside? • Ethylene, -102°C? • Empty??? • What does “empty” mean? • Sure this is the right pump ???

9. Work specific hazards: • welding fumes, sharp • edges, sparks, …. Interaction hazards: other workers Maintenance company Location specific hazards: chemicals, noise, …. What Types of Hazards? Owner, work coordinator

10. Example BASF: Three Key Elements • Permit to work system • Contractor qualification • Thorough work preparation

11. Example BASF: Permit to Work System

12. Example BASF: Permit to Work System • Main goals: • Assess all specific hazards • Document necessary measures before the work can start reduce risks to a minimum • Specify necessary measures to be taken during the work protect workers from residual risks • NO maintenance job is done without a written permission! • Production always gives permission to start a job • Different permits for different types of work • Suggesting specific hazards and measures • Normal work and line breaking • Hot work • Work in confined spaces • Excavation work • …

13. Example BASF: Permit to Work System • Permit issuer is an experienced, trained worker (mostly shift supervisor) • Permit receiver (contractor) is trained on how to use BASF permits (e-learning with test) • All workers are informed about the required measures by their supervisor • Special precautions • 4-eye principle : Hazard assessment and measures are checked twice e.g. for confined space entry and hot work (shift supervisor and plant manager) • Last minute check : Permit hand-over in the field e.g. for line breaking activities(Production worker directlyto maintenance worker)

14. Example BASF: Contractors Selection:only companies with good safety performance & safety management system Contractor selection • Safety evaluation • Periodically for on site contractors • After completion for project contractors Required safety training (1 week basic training; certified training on critical tasks e.g. explosion/oxygen measurements; site specific training before access on site Basic training before access Kick-off safety meeting Kick-off safety meeting (training on specific project related hazards and measures) BASF Mentor “translates” relevant site rules for on-site contractors Mentor as coaching Additional training Work execution Evaluation

15. Example BASF: Thorough Work Preparation

16. Example BASF: Thorough Work Preparation • Work preparation: Split the maintenance job in its different steps to create a detailed work plan; think of all necessary safety aids for each step; request necessary permits for each step • Scheduling: Avoid interaction hazards between different jobs; check availability of workers and materials • Plant preparation: Prepare permits; take all necessary measures before start of the work; evaluate additional hazards due to urgent (not planned) work; issue permit if all measures are taken • Work execution: Apply measures on work permit; workers to confirm about all necessary information; safety observations by BASF; safety tours by contractor Work plan Scheduling Plant preparation Work execution Plant Line-up

17. Many Thanks for Your Attention! Questions? Contact Cefic: bth@cefic.be Contact BASF: johnny.nobels@basf.com