Does the worker do a check of equipment or systems prior to hand over, acceptance, startup or change in process conditions so as not to put themselves and others at risk? Are there set procedures to be followed by worker before commencing task? Does the worker have appropriate permits for job? Is the permit correctly filled out? Does worker inspect equipment and area before and after job?

Examples:

• While repairing overhead piping, the scaffolding was certified, the relevant work permits and tool box form were displayed.
• While operator was starting up 01MP32 Ammonia Transfer Pump, operator ensures that all bleeds were closed and all valves were lined up according to SOP.
• When worker was washing down the plant area, whip checks were placed at all points of utility hose connection.

Does the worker lock, tag, and try source of energy prior to performing task on equipment? Are keys placed in the lockout box and locked out by all relevant departments? Have all persons working on the equipment signed the LTT log book? Is the source of electrical energy isolated and locked out when working on electrical equipment? Is the source of pressurized fluids isolated, locked out and lines de-pressured prior to line opening? Are mechanical sources such as springs blocked and locked before working in the area? Has the equipment been isolated from the main energy source?

Examples:

• While working on a motor-driven pump, the motor’s breaker was open and LTT. The pump was isolated, de-pressured and all associated valves were LTT in the required position as per SOP.
• While working on 103J Compressor, the compressor train was correctly LTT, all locks from maintenance and operations were placed on the LTT box and its custodian key placed in the master key box. The LTT log book was also filled out and signed by all persons working on the compressor train.

Does the worker ensure that a “Bump” test was conducted and recorded on the permit? Are the gas tests conducted within the mandatory testing period as stated on the permit? Did the gas tester sign the permit and the serial number of the gas test meter recorded on the permit? Does the worker ensure that a gas test was conducted on the nearby drains, sewers, pits, valve stems, seals or glands within the 50 feet radius? Is there any combustible material located within 50 feet of the job? Are there any combustible materials located beyond 50 feet, but within sufficient range to become ignited by sparks? Is it possible for sparks generated from any job conducted at a height that can fall onto equipment? Is there a designated fire watch, with a certified and inspected fire extinguisher and running water on site? Does the designated fire watch know that he/she has to remain a minimum of 30 minutes after the job is completed to monitor for any smoldering embers or fire?

Examples:

• While preparing to cut piping with a torch, the following safety systems were on site - a competent fire watch, a certified fire extinguisher and a source of water. Also the general work permit, hot work permit and a tool box form were on display.
• While conducting repairs to the Urea Ship loader, 03LD302 hand railings, a “Bump” test was conducted and recorded by the operator, gas testing was conducted and recorded at 4 hour intervals, water was available for immediate use if required and the fire watch remained on site for 30 minutes after the task was completed to monitor the area for any signs of smoldering or fire.

Is the vessel/confined space completely isolated from all sources of motive power and blinded? Is the vessel thoroughly purged and free from sludge and other deposits? Is the vessel free from sources of flammable or toxic materials? Does it have adequate means of entry/exit? Does the vessel have adequate ventilation, and if so, is it cooled down to working temperature? Is an explosive meter test done and recorded on the permit (0% LEL) by the gas tester? Is an oxygen test done and recorded on the permit (more than 20%) by the gas tester? Is there a competent safety observer/hole-watch located at the entry point of the confined space? Does the permit have all the required signatures including that for an inert entry? Does the worker/safety observer have the right safety equipment for the entry? Are all the names of the persons entering the vessel clearly displayed with the permit? Has a rescue plan been done to safely/effectively rescue the worker in an emergency situation?

Examples:

• Before entering 102E (CO2 stripper) the safety observer logged the entrants name and time and gave him/her a personal O2 meter.
• While worker was carrying out welding repairs to 2002U (Steam boiler) mud drum, an extraction fan was placed at the opposite end to ensure proper ventilation.
• When workers were preparing in removing internal from inside Urea Stripper 01E101, the operator ensures that an extractor fan is positioned at the bottom man way.

Are the underground drawings used to determine the location of piping and cables? Is the excavation site properly shored up to prevent cave-in? Is the site checked after rain to ensure that the shoring is still intact? Is a Confined Space Permit done prior to entering excavation to do work? Is a specific rescue plan in place before workers enter the excavation site?

Examples:

• Before entering excavation to change isolation valves on Fire Water Ring, worker ensured that the shoring for the excavation had been checked and was adequate to prevent cave-in.
• While repairing leak on SCW underground piping, worker used Oxygen Monitor to continuously monitor conditions in the excavation.

Has a critical lift plan been done so as to minimize the potential of crane failure and/or catastrophic loss? Is the lift plan available to all personnel involved in the lift? Does this lift plan include the following: (lift height, size and weight of load, rigging plan, inspection procedures, communication methods, persons involved, etc.)? Has the crane operator been tested for controlled substances before the lift? Is the lift area properly barricaded with signage so as to alert everyone? Has an evaluation of all the hazards associated with the lift been done? Are all the required signatures on the lift plan?

Examples:

• While lifting 101C (Waste heat boiler) bundle from ground, the rigger used a tag line to keep the load under control.
• Before lifting 102B (Startup heater) coil from vessel, operator ensures that a safety meeting was conducted, area was cleared/barricaded, crane operator had been cleared to operate crane and the lift plan was attached to the permits.

Is the Arc Flash P.P.E. worn in good condition? Is the Arc Flash P.P.E used rated for the task on hand as per WARNING label? Is additional Arc Flash PPE readily available to meet the WARNING label CLASS? Does the worker have the correct permit for task (Energized or De-energized Electrical)? Has the equipment been verified to be in a de-energized condition and safe for maintenance work? Has the correct electrical equipment device been identified? Does the worker have the correct voltage rated tools and is it calibrated within the specified time?

Examples:

• While operating Isolator for 01-MP-1C motor starter, operator was outfitted with Arc Flash PPE requirements as per warning label located on the MS-1B 4160Volts board.
• While E&I Technicians were carrying out repairs to 02-MK-8A motor control circuit, workers were outfitted with Arc Flash PPE as per warning label while testing was carried out.

...

Examples:

• While E&I Technicians were carrying out repairs to 2201UJ1M motor control circuit, the work area was cordoned off with DANGER tape at the limited approach boundary.
• Before worker conducted repairs to 03LD302D motor control circuit, worker used the correct voltage tester e.g. multi-meter to verify circuit was de-energized.

Is the appropriate Fall Protection being utilized for the task being performed? Is it in good condition? When wearing safety harness does the worker hook lanyard to secure anchorage point? When working on elevations where there is no place to tie off does the worker use portable system to facilitate tie off? Are permanent platforms equipped with guardrails?

Examples:

• When erecting scaffolding to carry out air quality monitoring on the ID Fan stack, the worker donned safety harnesses correctly and tied off to secure anchorage point.
• When operating man lift the worker wore body harness with appropriate restraint system.
• • While operator was ascending ladder 102E Benfield Stripper, operator ensured that ladder gate was closed behind him.

Is the worker using the right type of tool and is it being used according to manufacturer’s design and intent? Is it the right size? Is the tool being used correctly? Is the tool being used in good condition? Is the tool inspected and certified?

Examples:

• While breaking bolts on 107J pump casing, worker used a striking end spanner.
• While removing tiles from 03 Control room, the worker used a chisel holder to hold the chisel.
• When operator was isolating valves on the BFW Low Flow Switch FISL7, the operator used an airplane ladder to reach valves.
• When using slings and chain block to remove G-718 pump element the worker ensured that they are inspected and certified.
• While cutting grass worker ensures that the guards were installed on the brush cutter.
• While using a grinder in the Fabrication Shop the worker ensured the grinder had no trigger lock on the switch, the handle and guard were secured onto the tool.

Does the tool, equipment or machinery and its components not perform consistently according to specifications or expectations? Does the tool, equipment or machinery create a hazard due to its failure?

Examples:

• Taking readings on steam turbine, all insulation were in place, preventing operator from exposures to burn.
• While operator was carrying out routine checks on compressor there were no excessive oil vapors due to leaks.

Is the worker positioned so that if something gives way, releases, sprays or falls, no contact will be made? Does the worker place all parts of body so that he/she will not be pinned, crushed, struck, sprayed or trapped by energy releases of any kind?

Examples:

• While using workshop crane to lift relief valve, the worker stood away to avoid being pinned, struck or crushed if load swung or fell.
• When breaking flange bolts to insert blind on steam line, worker stood at the side to avoid contact with any escaping steam or condensate.

Does the worker inspect load prior to lifting? Does the worker seek assistance when lifting bulky or heavy loads? Does the worker use legs and keep back straight while lifting? Does the worker bend at the knees? Is lifting and bending done in a smooth motion without twisting at the waist?

Examples:

• When picking up a box of copy paper off the floor the worker bent at his knees and kept his back straight.
• While packing bearing in storage bin, the worker turned using his feet and did not twist at his torso.

Is the worker using available supports when ascending/descending? Does the worker walk up and down stairs one step at a time using handrails? When ascending/descending steep stairs and ladders does the worker face stairs/ladder and maintain three-point contact?

Examples:

• While climbing ladder on Condensate Stripper operator maintained three- point contact.
• While walking down stairs at 02 Plant Compressor house, worker maintained three-point contact and descended one step at a time.

Does the worker keep his eyes on his task and path? Does worker have a clear view of task and path? Does the worker ignore distractions while doing task? Does worker look in direction of travel? Is the worker vision unobstructed when in motion?

Examples:

• While making a critical lift, crane operator kept his eyes on the banks-man.
• While tightening bolt and nut on flange, the worker keeps his eyes on the task to ensure that the spanner was correctly fitted and did not slip.
• While worker is reinstalling casing bolts on 01MP5A ammonia pump, he focused on striking the spanner squarely.
• While walking on compressor deck operator watched for oil or slippery substances on walkway.
• When using a forklift to move pallets of potassium carbonate that obscured vision, worker reversed and focused on the direction of travel.

Are hands and feet kept away from clearances where they could become caught? Does the worker avoid putting himself in a position of being pinched or crushed between two or more objects?

Examples:

• When rigging container, worker kept his hands from being caught between the hook of the sling and eye of the container.
• While removing temporary support from under pipe, worker kept hands and feet clear of the pipe.

Are floors, stairs, platforms, grating, scaffolding and ladders firm, stable, level and steady?

Examples:

• While walking to plate exchangers on the 03 Plant, walkway was concreted.
• While operator was walking on 02 Primary Reformer all gratings were secured using holding down clamps.

Is the surface free of slip hazards such as moss and oil? Is the walkway free of trip hazards such as hoses, tubing, electrical cords and debris? Is the area free of clutter?

Examples:

• While operator was walking by SCW Pumps in OSBL there was no buildup of moss on the concreted surface.
• While welding piping in corridor, welding leads were hung on overhead racks and not left lying on the ground.
• Walking upstairs in the 03 Generator shed, stair treaders were painted with non-skid paint.

Are bolts and nuts placed in bins so that they do not create tripping or falling hazards? Are oily rags and insulation placed in bins designated for them?

Examples:

• When removing bolts from man way on 02 Condensate Stripper, worker placed bolts into drums so that they were not scattered about.
• While dismantling scaffolding, scaffold personnel placed clamps in bins, pipes and planks on racks.
• Walking upstairs in the 03 Generator shed, stair treaders were painted with non-skid paint.

Is the worker using the correct method of communication? Is the communication relevant, concise, and easy to understand? Does the worker communicate when his actions will affect the safety of others? Are workers involved in a task able to see and/or hear each other?

Examples:

• While using crane to lift piping the rigger used correct hand signals to direct crane operator. (Non-Verbal Communication).
• While changing catalyst in the 04 Converter, radio communication was maintained between the Confined Space Attendant and workers inside the vessel. (Verbal Communication).

Are barricades and signs in place to alert personnel? Are barricades in place to prevent entry into hazardous area? Are correct barricades being used?

Examples:

• While repairing leaking condensate lines on pipe-rack, notice signs and caution tape were used to warn workers that overhead work is in progress.
• While performing X-Ray testing on 03 CO2 Absorber, worker used radiation tape and flashing lights to cordon off affected area.
• Hard Barricades were placed around open pit for hydrant repair on 02 Plant.
• While carrying out excavation roadway in front tool stores, hard barriers was being used to prevent vehicles entering the worksite.

Does the worker modify and/or adjust work station, area, equipment or tools to help achieve neutral and/or supported wrist, neck, back or legs posture? Does the worker keep upper torso aligned with legs when performing standing tasks? When exposed to ergonomic risks (static or repetitive work, awkward or forceful work) does the worker deliberately break up the stress by changing positions, moving, stopping activity or stretching?

Examples:

• While operating forklift, worker torso and neck are vertical and in line, the thighs were horizontal and the legs are vertical.
• While opening/ closing outlet block valve of MDEA absorber 101E, operator used portable platform to properly position himself to prevent over extension.
• While using pneumatic tool to remove 1 3\4” bolts from waste heat boiler, worker changed his position frequently to relieve the stress on his feet and arms.
• While using jackhammer to remove concrete to access leaking Fresh Cooling Water underground piping by E-716’s on the 03 Plant, the worker took frequent breaks.
• While operators were closing 103J Steam Extraction block valve, operators took turns closing valve so as to break the stress.

Is the work area lighted such that the objects, equipment and people associated with the task are clearly visible?

Examples:

• While working on the Atomizing Air Blower in Granulation Building, the area of work was properly illuminated.
• While changing refractory in the Primary Reformer radiant section, adequate lighting was provided.

Examples:

• While welding, worker was wearing safety helmet with welding mask. Worker ensured that shell is not cracked, burnt, broken and suspension was not broken/frayed.
• While wearing Safety Headwear, it was donned with the peak in front to properly protect the worker..

Examples:

• While grinding piping, the worker used a face shield.
• While re-batching chemicals the operator used a face shield and goggles.
• When using prescription safety glasses, the worker ensured that the side shields were in place.
• While working at night the worker wore safety glasses with clear lens.

Examples:

• While working on the MCC board, the worker wore the rated ARC Flash clothing.
• When re-batching the high pH chemical tank the worker donned a full chemical splash suit, rubber boots and neoprene gloves.
• While doing checks onto the plant, operator wore shirt into pants as he may pass close to rotating equipment.
• While workers are painting Cap Stand on SPN 1, worker donned life vest.

Examples:

• While insulating turbine with Kaowool the worker wore appropriate respirator.
• While taking reactor outlet sample, worker used a full face respirator.

Examples:

• While washing the plant with a chemical cleaner the worker was wearing knee high rubber boots.
• While operator was walking toward the 03 Control Room, he wore his steel tip boots.

Examples:

• When operating a jackhammer the worker was wearing earplugs/ear muffs.
• When operator is walking from the Urea Control room to the Demin Control room, he wears his earplugs.

Examples:

• While installing a bearing the worker wore mechanical gloves.
• When welding on the package boiler, the worker and his assistant were wearing the long armed welder’s leather gloves.

Does the worker use appropriate tools when topping up or filling oil in equipment? Does the worker use drum/container to catch contaminants when bleeding or de-pressuring pumps or vessels? Does the worker ensure that equipment in use is not leaking or spilling contaminants unto the ground? Does the worker ensure that drums are properly labeled as to their contents, area of origin and date? Does the worker ensure that paint cans, chemical pails/containers are punctured at their bases prior to disposal?

Examples:

• When worker was bleeding oil sump for moisture he used a container to catch all liquid and ensured that there was no spillage onto ground.
• The worker used a container for containment of liquid while maintenance work was being conducted on the pump.

Does the worker ensure that ammonia being de-pressured is piped to flare? Does the worker ensure that catalyst or insulation that is being removed is properly contained so that loose particles are not blown into the atmosphere? Does the worker ensure that dust from sandblasting operations is properly contained and not released to open atmosphere? Does the worker use diesel equipment with exhaust emission that is free from visible smoke?

Examples:

• During anhydrous ammonia sampling, the employee ensured that ammonia vapours were not bled to atmosphere but via the vapour line.
• The worker ensured that the portable air compressor was fitted with an emission system and free from visible smoke during operation.

Does the worker use absorbing agents to remove spilled formaldehyde or oil before it gets into waterways? Does the worker contain spilled urea granules before washing area? Does the worker ensure that ammonia being drained does not get into waterways?

Examples:

• During routine checks the worker checked the sluice gate to ensure that it was adjusted to prevent oil escaping with the outflow.
• Product handling personnel collected and bagged spilled urea granules before washing conveyor system.