DKIST Safety Review Safety Program Status

Steve Shimko

Safety Manager

August 26, 2014

Agenda

• Hazard assessments

• Safety by design

• Emergency preparedness

• Construction safety

• Safety staffing

• The year

Hazard assessments process

• Hazard Analysis Team (HAT) HAs

– GIS design specifics from Facility, FTS

– IT&C tasks - M1 Cell integration, TEOA Install etc..

• Residual Risk acceptance

• Add HA to DKIST System Requirements document

• Develop a compliance matrix for mitigations

Residual risk acceptance

Safety by design

• Final design safety issues

– Individually worked by COTR engineer, contractor, HAT, safety

– Some tracked in JIRA

– To be reviewed at Factory Acceptance Tests (FAT)

• Hazard analysis mitigation implementation – Visual inspections, functional test observations

• Operations and Maintenance manuals

Enclosure (pre) Factory Acceptance Test

Ladder arch girder fall protection

Arch girder stairway

Enclosure trap keys

Coudé rotator Factory Acceptance Test

LOTO

Covers

Hatches

Guarding

TMA rails

Emergency response

• Evacuation vehicle

– Outfitted with emergency equipment

• Haleakalā Emergency Medical Response Group

– Other sites not interested in joint training

• DKIST Emergency Medical Trainer

– Training refreshers for Maui staff

– New service provider to be evaluated

• Plans updated

Outfitting EEV

Confined space rescue

Haleakalā National

Park

Construction safety processes

• Implementation and sustainment

– POD – Plan of the Day

• Serial processing with each supervisor

• Draft flow down process developed

– AHA – Activity Hazard Analyses (or JSA etc.)

• Revised processes

– Daily / weekly documentation maintenance

• Some changes didn’t work out

POD flow down

Contractor Pre-work Performance

• Same contractors all last year • New sub contractors coming on board

– Applying SPEC-0030

Incidents

• One recordable injury

• One near miss

• Many first aid

Recordable injury

• Elbow scrape (minor) became infected

– Cable wrap work

– Multiple physician treatments

– Lost 7 days

– Occurred on mainland

Near miss incident

• Steel template 30 ft. dia. being constructed on ground stuck by forklift

– fell off its supports (~3 ft. high)

• Welder worker fell onto template from unexpected motion

– Sore shoulder

• No workers were contacted by work piece

Root causes

• Forklift backing up and turning on uneven ground in congested roadway area. – Operator was moving slowly, the forks dropped as

rear end rose, contacted the template, which fell quickly

• Insufficient lateral support for work piece stand

• Lack of equipment spotter congested area

• Workers not suspending work and standing clear when heavy equipment moves through their work area

Actions

• Site wide safety meeting held on operator and spotter requirements

• Ensure proper work piece securing • Clearing personnel when moving heavy

equipment / materials • Site inspected for unstable, unsecure or

insufficiently supported materials – Added to daily checklist

• Relocation of equipment to help relieve congested area

First aid incidents

8

2

1 1 1 1

DKIST Oversight

• Daily – Site open and site close inspection – Observations and inspections throughout the day – One-on-one training with S&H Reps – Friendly reminders

• Weekly – Summary report – Incidents reporting

• Near misses / Warnings / Corrective actions

• Monthly – Report to contractors on safety performance

• Needed actions and recommendations

Contractor Performance

• Safety & Environmental compliance training

– Updating JSAs and training - good

– Need more detailed employee training updates

• Fall Protection

• Scaffolds

• Need improvements on timely paperwork completion – Process sustainment

Stretch and bend

Lifting equipment

Location on job / lift description: ATST site

Date of lift: 7/31/14 Pro ject # ATST Type of crane AC435Demag

C rane P lacement: Any deviation from level compact surface in area? None

Electrical hazards in the area? None

Obstacles or obstructions to lift and swing? None

Swing direction and degree (boom swing) North to Northwest

Lif t arrangement: P lanned lif t path: Jib

Lift radius 64 ft. [ ] 360o

[ ] over front Erected [ ] Stored [X ]

[ ] over rear [ X ] over side Is Jib to be used: Yes [ ] No [ ]

Boom length 152 ft. Length of jib: ft.

Boom angle at lift 64 deg. Lif t path cleared? Angle of jib: deg.

Boom angle at set 64 deg. [ ] yes [ ] no Rated capacity o f jib: lbs.

Lo ad line: Whip line:

360o

41,000 lbs. Number of parts cable: 3 Number of parts cable:

Over side lbs. Size of cable: 7/ 8" Size of cable:

Over front lbs. Length 80ft x 3 Length

Over rear lbs. lbs/ft 1 lbs/ft

to tal weight: 240 lbs total weight: 0 lbs

Weight o f lif t Sling select io n

Weight o f load: 32,000 lbs. Type of arrangement

Weight o f lifting beam 0 lbs. Size 10 to n chain falls 4 ea 20000 cap 200 lbs

Weight o f rigging 385 lbs. Size 0 ea 0 cap 0 lbs

Weight o f auxiliary rigging 0 lbs. Size 0 ea 0 cap 0 lbs

A ddit io nal weight: Shackle select io n

Headache ball/ Load-block 1,400 lbs. Size 80 to n masterlink 1 ea 160000 cap 80 lbs

Load line 240 lbs. Size 35 to n shackle 1 ea 70000 cap 25 lbs

Whip line 0 lbs. Size 25 to n shackle 4 ea 50000 cap 20 lbs

Jib deduction 0 lbs. Wieght o f rigging: 385 lbs

A llo wance: A uxilliary rigging:

Unaccounted material 0 lbs. Come-a-long 0 ea 0 cap 0 lbs

T o tal weight: 34,025 lbs. Chainfall 0 ea 0 cap 0 lbs

Other 0 ea 0 cap 0 lbs

% o f crane capacity*: 83% Weight o f auxilliary rigging: 0 lbs

Source of load weight: Verified test lift

Weights verified by: William Shelburne

P R E-LIF T C H EC K LIST YES / N O YES / N O

1. M atting acceptable? [ X] [ ] 8. Experienced operator? [ ] [ ]

2. Outriggers fully extended? [ X ] [ ] 9. Experienced flagman? [ ] [ ]

3. Crane in good condition? [ X ] [ ] 10. Qualified rigger? [ ] [ ]

4. Swing room? [ X ] [ ] 11. Load chart in crane? [ ] [ ]

5. Head room checked? [ X ] [ ] 12. Wind conditions:

6. M ax counterweights used? (X) 13. Crane inspected by:

7. Tag line used? (X) 14. Functional test o f crane by:

Sketch Required! 10%

Special instructions or restrictions for crane, rigging, lift, etc.

1 Job supervisor 3. William Shelburne PM /Superintendent

2 Operator reviewed 4 IISN HSSE

* M ultiple crane lifts require a separate lift plan for each crane. Any changes in configuration, placement, rigging, etc. require that a new plan be developed.

LIFTING PLANNOTE: A LIFT PLAN MUST BE COMPLETED FOR EACH LIFT OR SERIES OF LIFTS FROM ONE LOCATION

Unacco unted M aterial=

*(If load exceeds 75 % of rated capacity, attach sketch rigging plan, crane placement and swing path .)

(center pin of crane to center o f lift)

R ated capacity o f crane:

Document updates

• Updated and new – Confined Space Program

– Training Plan

– Emergency plans

– Updated altitude health and environmental

• Need updates – Project Specific Safety Orientations

• Still need new – Respiratory Protection Program et al

Training

• Completed Training Plan

– Implementation

• OSHA 10 hour construction safety

– On-line procured

• Driving Safety, Respiratory Protection

– Updated

• Emergency medical drills

– Simple drills monthly

Process improvements

• Daily Inspection checklist revised – Lessons learned checklist items

• Vehicle safety inspection checklist – Scheduled maintenance frequency increased

• Forklift, Heavy equipment, Aerial Work Platform inspection checklist created

• Accident/Incident Reporting process on line – Automatically emailed to the personnel’s Manager and

Safety

• Positive reinforcement system – Safety recognition hard hat stickers

New check in sign

Safety trailer use

Environmental

• NPDES maintenance

• Environmental protection deficiency

– Co-mingling food waste and construction waste

– Corrected

Storm monitoring

Hurricanes and Tropical Storms Preparedness Guide DKIST utilizes National Hurricane Center’s Wind Speed Probabilities “bloom” as guidelines for our

planning and Civil Defense announcements as thresholds to trigger actions

ALERT

CAT.

Storm Wind Speed

Probabilities

Possibility Good (40-50%) Actions

Tropical Storm

Winds ≥ 39 mph

Enters the Central Pacific

Management to monitor the storm via the internet or radio/news.

Review sec 9.2 Determine critical staff possibly needed and allow

them leave to prepare personal matters so they can be available

during if NWS issues Watch (48 hrs) or Warning (36 hrs)

4

Tropical Storm

Winds ≥ 39 mph

Any time within 72 hours

Management to review our Hurricane and Storm protocols

All Staff - monitor the storm via the internet or radio/news

3

Tropical Storm

Winds ≥ 58 mph (50 kts)

Any time within 48 hours

Management to determine if there are special circumstances that

would trigger early below actions – storm is moving fast, very strong

or large, moving unpredictably, occurring during weekends or holidays,

or other as appropriate

Civil Defense

Announcements Summit Site Remote Operations Building

2

Hurricane Watch

Winds ≥ 74 mph

Any time within 48 hours

Implement Adverse Summit

Weather Process, Cancel

Operations, Optional

Evacuation of Summit

Implement ROB Adverse Weather

Process (TBD)

1

Hurricane Warning

Winds ≥ 74 mph

Any time within 36 hours

Evacuate Summit Evacuate ROB

Other Civil Defense Announcements

Flash Flood Watch

Possible in the area, stay

alert

Staff to individually to ask permission to be released from work site, depending on their circumstance

Flash Flood Warning

Imminent or occurring, take

immediate action

Staff to individually to ask permission to be released from work site, depending on their circumstance

Safety staffing issues

• Safety Officer left the project in January

– Delayed some program development and implementation actions

– Priority to ensure adequate site safety support and monitoring of the site work

• Safety Technician hired in June

– Construction Safety Officer experience

– EMT and Firefighter experience

Since the last Safety Review

17 Jun 2013

21 Aug 2013

Sep 18 2013

18 Oct 2013

20 Nov 2013

12 Dec 2013

16 Jan 2013

20 Feb 2013

13 March 2014

17 April 2014

16 May 2014

23 June 2014

17 July 2014

20 August 2014

Safety Recognition Award Stickers

Mahalo!

• Questions ?