Gazpromneft-Noyabrskneftegaz launched an initiative to hold a Safety Day in contractor organizations. Its implementation is carried out within the framework of the program to achieve the strategic “Goal - Zero”*. The management team of the enterprise conducts on-site communication sessions at production facilities for oil service employees. As part of the dialogue, the assessment of potential risks and the application of the “5 steps” methodology in daily work are discussed. There is an exchange of experience in ensuring industrial safety and accident prevention.
All organizations working at the fields of Gazpromneft-Noyabrskneftegaz are involved in the Safety Day. In June, enterprise managers visited 52 organizations at 87 production facilities. The total number of workers involved in Safety Day has already exceeded 2,100 people.
Pavel Kryukov, General Director of Gazpromneft-Noyabrskneftegaz, emphasized: “The key task of this initiative is not to identify violations of safety requirements, but to set up an effective system of measures to ensure it. And here the task of the enterprise management is to act as an experienced coach and mentor. Regular, weekly safety days at the fields and personal participation of management will help promote a culture of safe work performance both among the company’s own employees and among the company’s partners.”
REFERENCE:
*In accordance with the Gazprom Neft strategy in the field of industrial safety, the main goal has been set - “Goal - Zero”: no harm to people, the environment and property when performing work.
**The “Five Steps” technique is a simple and understandable algorithm for deciding whether a worker can safely perform the upcoming work or not:
1. Pause and think about the work;
2. Identify the hazards and possible consequences;
3. Decide how to protect yourself and others from danger;
4. Decide what to do in case of emergency;
5. Decide whether to start or continue work.
1. Do not carry out any work without a written work order, an authorization order when performing high-risk work.
2. Do not enter or start working in mine workings in the absence of fastenings and in the presence of dangerous overhangs of pieces of rock mass until the mine workings are brought to a safe condition.
3. Do not enter the drilling and blasting area.
4. When working at height, use personal protective equipment and insurance, fence off the danger zone to avoid falling objects and injuring people.
5. When performing work, use serviceable and certified personal and collective protective equipment.
6. Do not stand or perform work under suspended loads when operating lifting mechanisms.
7. Do not approach moving or operating vehicles until the vehicle has come to a complete stop and contact has been established with the driver.
8. Repair and maintenance work with any type of energy (electric, compressed air, steam, water, etc.) should be carried out using blocking devices.
9. Follow the established route to and from the workplace. Do not enter the exhausted workings during underground work.
10. When performing work, use proper equipment and tools.
Five security steps:
1. Do I understand my task order? Do I understand all the risks involved?
2.Is my route to my workplace safe?
3.All my tools are in good working order. All my equipment and fixtures are in good working order.
4. My workplace is safe.
5.I am aware of all the work going on around my workplace.
2 Health and safety requirements before starting work
2.1 Foreman of the section (shift) of the MPC control center:
Conducts “hazard identification and risk assessment” at each workplace and eliminates identified risks;
Issues a work order - a task for the smelters of the MPC control center to carry out work at the PV;
Familiarizes employees with incoming documents (newsletters, telephone messages, messages, orders, instructions on the MPC);
Checks the medical examination book of registered employees;
Checks the pre-shift medical examination (alcotest) of overhead crane operators and the electrician on duty;
Introduces the register of risks of possible injury;
Surveys employees on their knowledge of 10 k.p.b. and 5 sh.b., security policies, orders issued by the BMZ, orders issued by the MPC;
Checks the availability of PPE for workers;
2.2. Before starting work, workers must:
Pass a medical examination for those registered or undergo a pre-shift medical examination (alcotest);
View special clothing, which must be in good condition, fastened with all buttons;
It is mandatory to have personal protective equipment, i.e. a helmet, mittens, a respirator, earplugs, a cloth jacket, cloth trousers and a protective shield;
Receive a written work order - an assignment to carry out work in accordance with these instructions;
Familiarize yourself with incoming documents (newsletters, telephone messages, messages, orders, instructions on the MPC);
Familiarize yourself with the register of risks of possible injury;
Know 10 k.p.b. and 5 sh.b., security policy, orders issued by the BMZ, orders issued by the MPC;
Use PPE in accordance with industry standards specified in the work instructions for the professions of PU MPC;
If a risk of possible injury is identified, the employee fills out signal sheet located at the site (shift) foreman of the MPC PU, having notified the site’s engineering and technical personnel, put signal sheet in the box provided for this purpose.
If a danger of causing a threat to the life or health of workers is identified, it is necessary to fill out employee refusal form and hand over to the foreman of the section (shift) of the MPC PU, then, until the inconsistencies are eliminated at the workplace, receive another written order - an assignment from the foreman of the section (shift) of the PU MPC;
Before starting work, it is imperative to make sure that there are no unauthorized persons in the smelters’ work area;
Check the serviceability of the tools;
Check the sufficiency and correctness of safety measures for TB;
Familiarize yourself with the condition of the equipment, the moving parts of the units should be protected, but should not impede the filling process of the previous shift, paying special attention to quality and performance;
In winter, make sure there is no ice on the sites;
Use (times) anti-slip agents;
Reliability of fastening and serviceability of fences;
Check the cleanliness of the workplace;
Check the serviceability of the sound and light alarm;
Check the lighting of the workplace;
Check the supply of refractory clay and plugs;
Operation of ventilation devices;
Lack of dampness and fuel oil on working areas near the furnaces.
2.3 General fire safety requirements:
For fire safety purposes, workplaces in the workshop are equipped with shields with fire extinguishing equipment;
Free access to fire extinguishing means must be ensured;
It is prohibited to bring matches, lighters, lanterns and other sources of fire into the area of explosions and fire-hazardous industries;
Smoking strictly in certain places;
The use of fire-fighting equipment and inventory for production and other needs not related to fire-fighting is prohibited;
2.3.1 Employee actions in case of fire:
In the room where the fire broke out, drafts must not be created, since the influx of fresh air only intensifies the combustion, so windows and doors in this room should be closed;
Opening windows and doors is only possible to save people, evacuate material assets, and extinguish a fire. To prevent the spread of fire, if it has just begun, it is necessary to immediately turn on the ventilation in the room and shut off the gas, oil, gasoline, and oil pipelines.
When leaving a burning room, you must not create turmoil and panic, maintain calm and order, which will ensure a successful evacuation.
To make breathing easier, cover your nose and mouth with a handkerchief moistened with water;
Each employee of the MPC is obliged, in case of detection of a fire, to report this to the fire department, inform the shift foreman and then begin to extinguish the fire with primary fire extinguishing means;
There is a single fire brigade call number “101”;
At BMZ, in addition to this number, you can call the fire brigade by calling “4-75-11”.
2.4 Characteristics of work:
Maintenance of furnaces and outlets when releasing the melt, monitoring their condition, the condition of siphons, tuyeres, caissons, chutes and other equipment;
Washing and cleaning the bathtub from deposits;
Adjusting the height of melting products in the siphon;
Control of copper content in slag and matte;
Release of slag and matte;
Maintenance of auxiliary equipment;
Inspection, cleaning of tuyeres and tapholes, monitoring their operation, blasting mode, level of slag and melt in the furnaces;
Replacement of tapholes;
Cleaning the workplace;
Regulation of the position of the electrodes of electric furnaces, the temperature or intensity of the combustion process, and the flow of water into the caissons;
Signaling for slag release;
Preparation of gutters, slag bowls and preparation of refractory materials;
Participation in cleaning loading and slag windows, thresholds;
Slinging boxes;
Release of slag, matte, filling of outlet holes, slag windows, thresholds, gutters, cutting and sealing of tapholes, replacement of the hole plate, settling tanks, molds and bypass of electrodes under the guidance of a more highly qualified smelter;
Preparing the heel.
Determination of suitability for work, drying, heating and cleaning of molds, ladles, chutes;
Installation, removal and cleaning of spray nozzles;
A safe company is an effective company. This is an axiom for global business. One of the most important components of ensuring production safety is the ability to assess existing risks and make effective decisions to minimize them.
A person risks every day, hour, minute, second of his life. This is not an exaggeration. Even a simple trip to the cinema threatens us with misfortunes - from a minor injury from falling down the stairs to death as a result of a traffic accident. What can we say about working in the kitchen or workshop. However, accidents rarely occur. The thing is that every second we assess the impending danger, immediately develop ways to reduce the risk (usually to zero), implement the decisions made... and ultimately remain safe and sound.
In principle, this is a risk management model that works in the same way in any company or industrial enterprise. Only business has to deal with an incomparably large number of inputs, and the cost of an erroneous decision can be calculated in colossal sums, environmental disasters and sometimes human lives. Therefore, progressive companies pay the closest attention to building a risk management system in the field of industrial safety. Gazprom Neft is also actively involved in this work.
Risks by ranking
In order to talk about risk management, it is worth understanding what risk actually is. There are many definitions, and each official document regulating this area in one way or another gives its own. “Risk is a consequence of the influence of uncertainty on the achievement of set goals” - this is, for example, the GOST R 51897–2011 standard “Risk Management. Terms and Definitions". And this is Federal Law-184 “On Technical Regulation”: “Risk is the probability of harm to the life or health of citizens, the property of individuals or legal entities, state or municipal property, the environment, the life and health of animals and plants, taking into account the severity of this harm.” Gazprom Neft has adopted and enshrined in the company standard the following formulation: “The occurrence of an undesirable event, a combination of the likelihood of a hazardous event or impact occurring and the severity (injury or impairment of health, damage to the environment and property) that may be caused by such an event or impact.” .
Let us make a reservation that we are talking only about risks in the field of industrial and environmental safety, labor protection and civil protection (HSE risks), since there are a huge number of other types of dangers and uncertainties - financial, investment, organizational, and so on.
Risks associated with the human factor can only be reduced by changing behavioral patterns
In turn, HSE risks are divided into two large groups: professional and man-made. The first are caused by the impact of harmful or dangerous production factors on the employee during the performance of his duties. For example, the possibility that a person working at height may fall down is an occupational hazard. Technogenic risks - the dangers that production technologies bring with them - can affect the entire society. “According to international statistics, the frequency of occurrence of professional risks is much higher than technological ones, but the consequences of incidents associated with this category are much lighter,” said Oleg Nikolaenko, head of the industrial and environmental safety department at Gazprom Neft.
A scheme for ranking the consequences of incidents according to their severity is unlikely to be significant for a person who finds himself in the role of a victim, but it is extremely important for building a competent risk management system. For example, as practice shows, significant damage to the company’s economy is caused by loss of ability to work by employees, emergency failure of equipment, and damage to property.
Human factor
The notorious human factor is the cause of the vast majority of industrial accidents. The roots of this group of risks lie primarily in human psychology, which is why they are leveled with the help of technologies for changing people’s behavioral patterns, supported by various training programs. That is, in general, we are talking about the transformation of corporate culture.
“Transformation of culture is a long process, but it is a path that must be followed,” noted Tatyana Yurchenkova, head of personnel training, competency development, and safety culture at Gazprom Neft. - Today, safety has become the main corporate value of the company, and we try to convey to everyone that preserving life and health is more important than solving any production problems. We must teach employees to correctly assess risks in order to prevent incidents from occurring, but at the same time not to cause damage to the company through unjustified production stops.”
It was this task that formed the basis of the solution called “5 steps,” which allows a person to competently assess the situation, and he must do this every day. In order for a technique to become a rule of life, it, according to Oleg Nikolaenko, must be simple and logical: “Our problem is that we explain simple things to people in too much difficulty. When a person hears such formulations as “risk assessment, risk management,” he automatically forms the idea that these are some complex processes that require special knowledge. Now we deliberately simplify the instructions, offering simple and understandable tools, such as “5 steps”. With their help, we simply tell everyone: stop five steps before the production facility, think about what dangers you face in connection with performing a specific job, what you must do to prevent the danger from becoming a real incident, what you will do if changes will occur in the process.”
However, the matter, of course, is not limited to just changing the psychology of people. The likelihood of risks associated with the human factor being realized is reduced by various organizational measures. For example, the system of access to work excludes people who do not have the necessary competencies to perform it or who have not undergone the appropriate training. Beginners should pay special attention. And the use of modern personal protective equipment is designed to reduce the severity of the consequences of incidents if they do happen.
Elena Ilyukhina,
Deputy General Director of Gazprom Neft for Legal and Corporate Issues:
All aspects of production involve risks. Process safety risk management begins with the assessment and design of new facilities and does not end until they are decommissioned. Each employee must be able to assess risks to life, consequences for assets and the environment, and organize work for themselves and their subordinates in such a way as to mitigate them.
At the same time, we should not forget that most of the work directly related to production, and therefore with increased danger, in the oil industry is traditionally carried out by contracting organizations. This means that risks must also be controlled on the side of counterparties. Today, Gazprom Neft is actively introducing new approaches to relationships with contractors, covering the entire perimeter of contractual relations, from selection to evaluation of completed work. And in many ways, the success of the partnership depends on the quality of the counterparty company’s risk management system, its level of maturity in the field of HSE and its willingness to change in accordance with Gazprom Neft safety standards.
People and machines
Technological risks are no longer psychology. The directions for their reduction lie primarily in the areas of organization, design, analysis, and statistics. Moreover, solutions that ensure maximum safety, taking into account all the nuances, should be laid down at a very early stage, when process facilities are just being designed, and cover their entire life cycle, right up to dismantling and disposal. All world industrial leaders do this, and it is this concept that Gazprom Neft also uses in its projects today. A striking example is the new Arctic fields, which are now being put into operation one after another.
"Five Steps"
Moreover, several years ago the company became a pioneer in this direction, together with the Russian Union of Industrialists and Entrepreneurs, initiating at the legislative level the introduction of a risk-based approach into the processes of design, construction and operation of industrial facilities.
“Through an open government, we have made changes to Federal Law 116 “On industrial safety of an organizational nature. For example, the system of access to work excludes people who do not have the necessary competencies to perform it or who have not undergone the appropriate training. Beginners should pay special attention. And the use of modern personal protective equipment is designed to reduce the severity of the consequences of incidents if they do happen.”
Determining the level of risk
Risk management system in the world
oil and gas companies
At the design stage, almost 90% of technological risks are leveled out or reduced to the lowest possible residual level. However, even at the stage of operation of facilities, there are many risk management tools - from conducting acceptance tests to using modern systems for monitoring technological parameters, diagnosing equipment, introducing progressive schemes for planning and carrying out repairs. A large layer of this work is included in one of the independent areas of development of the Gazprom Neft operational management system -.
However, it is obvious that decisions made within the risk management system, especially those related to minimizing man-made hazards, are often quite resource-intensive. Therefore, one of the large-scale initiatives in this area that the company is implementing today is linking the risk management system with budgeting. “We must clearly show a tool for assessing the possible consequences of undesirable events, their likelihood, and the effectiveness of the measures taken,” explained the head of the industrial safety department at Gazprom Neft. “In addition to updating assessment tools, the initiative will determine the procedure for budgeting the necessary funds based on identifying and ranking HSE risks to reduce them to an acceptable level, and also introduce an environmental risk management system.”
By the way, it was precisely the insufficient connection between the risk management and budgeting processes that the experts who carried out diagnostics of the HSE management system at Gazprom Neft identified as one of the important identified shortcomings. And this is really important, since underestimation and, therefore, underfunding of the risk reduction program can lead to an increase in the number and severity of the consequences of incidents. In turn, excessive investments, worsening the economics of projects, will not bring benefits. This is exactly what the ALARP* principle says: risk mitigation measures should be intensified until the costs (organizational, financial and time) begin to increase significantly without creating significant additional benefits (which makes these additional measures unreasonable and impractical).
Alexey Yankevich,
Deputy General Director of Gazprom Neft for Economics and Finance:
Every manager must understand that by devoting time and resources to safety risk management, they are investing in the future of the company. In the long run, industrial safety is good business.
In general, the experts came to the conclusion that a high-quality approach to risk management exists at Gazprom Neft, but the risk management system is not fully implemented into the company’s operating activities. Obviously, the solution to this problem largely lies in the field of management. People key to business and production must themselves have sufficient competencies to effectively manage risks - only in this case every technological and professional decision will be justified. Training such decision makers at all levels, from foreman to senior managers, has become a separate initiative as part of the process of building a risk assessment and management system at Gazprom Neft.
This system is the cornerstone of industrial safety, the level of development of which, in turn, largely determines the efficiency of the entire business.
The competence of specialists at all levels is the key to compliance with industrial safety rules
*ALARP principle (as low as reasonably practical) is a principle that determines the minimum acceptable level of risk
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