Objectives of SHE management during overhaul
Pharmaceutical enterprises annually equipment overhaul, short time, high temperature, heavy work task, if there is no effective SHE management, will inevitably occur accidents, causing losses to the enterprise and employees. Since joining DSM in April 2015, Jiangshan Pharmaceutical has been adhering to the 3P concept of “people, earth and profit”. Through careful preparation and careful construction, jiangshan pharmaceutical has created a good performance of no OSHA recordable accidents during the one-month overhaul in 2019.
Preparation before overhaul
Establish overhaul SHE management organization structure, make clear overhaul commander responsible for overhaul SHE performance. Designated overhaul construction SHE manager, in charge of SHE management during the overhaul. SHE person in charge of each area, responsible for daily on-site SHE work inspection, guidance and daily communication with contractors. Require contractor to set up SHE manager, participate in overhaul SHE overall management.
Make overhaul SHE construction plan, define safety target/performance. Project construction safety management personnel and SHE department of the company jointly prepare overhaul SHE construction plan. Set goals for overhauling SHE. Review key standards such as work permit system, site energy source isolation plan, scaffolding standards, PPE standards and requirements, working hours and overtime system, incident reporting, and communicate construction plans with contractors in advance.
Organize risk assessment for 801 construction projects, and conduct work safety analysis with workshop and construction side. Make it clear that the company’s personnel must be involved in formulating special construction plans for high-risk projects. All JSA and special construction plans must be prepared and approved prior to overhaul. Any changes to the approved JSA must be approved by the overhaul SHE management team.
Isolate all hazardous energy during overhaul. The implementation of Lockout/ Tagout/test (LOTOTO) management process and measures is an important control means to ensure the safety of overhaul. Overhaul THE SHE management team organizes and develops the site overhaul energy source isolation plan to ensure that it meets DSM’s latest requirements and applicability, and releases it before overhaul. According to the company’s production shutdown plan, each workshop makes a shutdown plan, including purging, cleaning and testing, and energy source isolation. Parking plan must be approved by relevant department/function. It is clear that after the completion of purging, cleaning, testing and energy source isolation, the workshop and the project construction party shall conduct joint inspection/testing and make written handover. The SHE department of the company shall participate in the workshop handover process by division of labor. The workshop designated personnel to check the implementation of isolation plan every day. After the handover, any change in on-site energy source isolation must be approved in accordance with the change management requirements in the isolation plan.
Formulate the operation permit management requirements during overhaul to ensure the application of overhaul conditions. Communicate with regional and contractor units in advance on the overhaul permit management system to ensure that the relevant parties understand the work permit system correctly. Review the work safety analysis (JSA) one day in advance according to the construction plan, and review the suitability on site again during the operation. The district and the contractor shall organize training for guardians, emphasize the duties and requirements of guardians on site, and train qualified guardians to post conspicuous signs.
SHE management during overhaul
Organize overhaul management team, overhaul project leader, maintenance leader, regional leader and contractor leader to attend the overhaul kickoff meeting, communicate overhaul SHE target /KPI and overhaul SHE management team structure. Make clear the meeting system in the overhaul, the key requirements of SHE, the reward and punishment system, review the main problems in the previous overhaul, and attract attention.
Organized more than 600 person-times of contractor training. Before training, review contractor’s qualification, contractor’s SHE performance, contractor’s special operation qualification, contractor’s insurance and medical certificate, etc. Set up a contractor training system in rotation, with one person responsible for contractor training every day. Organize special training for limited space, fire and other special operations. The contractor cannot enter the construction site if he fails the training assessment, and needs to be retrained. Qualified contractors can apply for access control cards, which set the cancellation period and access rights. The contractor who has passed the training shall post a hat sticker on the helmet to show that he has passed the training assessment.
More than 200 pieces of equipment entered by the contractor were checked, and all unqualified equipment were forbidden to enter the construction site. Put up the qualified label on the inspection equipment.
SHE inspection after overhaul
Each workshop set up a start-up preparation group to prepare for the resumption of production. The driving group meets regularly during the overhaul to review the progress of the work. Complete the start-up and test plan before each workshop starts, and submit it for approval. After the machinery is completed/before starting up, the project and local driving teams shall conduct inspections according to the pre-start safety review form, and SHE department of the company shall participate in the pre-start safety review by division of labor. To check the problem, immediately organize rectification, in order to meet 100% safe driving conditions.
Postpartum tissue SHE thematic examination was conducted. Organize process safety, occupational safety, SHE key equipment, occupational health, fire protection, environmental protection theme inspection. Select the key content according to the theme, make the inspection plan and division of labor, organize and rectify the problems found in time.
Post time: Oct-16-2021