management report of hse training area - reficar project - february 2012 - july 2015

A World of Solutions

Health, Safety & Environmental

Education & Training Academy

MANAGEMENT REPORTHSE & HRT Training Area

February 2012 – July 2015

1. Geographic Location

2. Physical Infrastructure

3. Organization Chart

4. HSE Corporate Policy and the Role of the HSE Training Area

5. Matrixes of HSE Trainings by Role

6. Current HSE Trainings offered in the HSE Training Center

7. Experience with Certified Training Programs for High Risk Tasks (HRT)

8. Support for Technical Training programs

9. SIPP Trainings

10. HSE Orientation of ECOPETROL S.A.

11. HSE Trainings based on the CMS Procedures

12. HSE Trainings Reports & Controls

13. HSE Training Passports & Wallet Cards

14. Safekeeping of the Records of the HSE/HRT Trainings

What will you see?

MANAGEMENT REPORT

HSE Training Area

February 2012 – February 2015

1.

Geographic Location

CARTAGENA REFINERY EXPANSION PROJECT

CARTAGENA REFINERY

EXPANSION PROJECT

2.

Physical Infrastructure

3.

Organization Chart

SCHEDULING OF

HSE/HRT TRAININGS

FABIAN MORENO

HSE/HRT TRAINERS

JOSE E. MORENO

JUAN F. MEJIA

TOMAS ESTRADA

WILLIAM BENDEK

RODRIGO ALCAZAR

ADMINISTRATION

OF RECORDS OF

HSE/HRT

TRAININGS

FRANCISCO LEMOS

HERNANDO STEEL

MANZUR

HSE & HRT TRAINING AREA MANAGERJAIME RUIZ VARGAS

ORGANIZATION CHARTUVAE – HSE/HRT TRAINING AREA

HSE TRAINING AREA MANAGEMENT

JAIME RUIZ VARGAS

HSE/HRT Training Area Manager

Master of Integrated Management Systems (HSEQ) and Corporate Social Responsibility,Occupational Health Specialist with valid License in Occupational Safety and Health,Industrial Engineer, PhD in Renewable Energy (Ongoing), with over 26 years experience inthe Petrochemical and Construction Industries, Occupational Risk Assurance (ARL),University Professor and external consultant for Private Companies. Internal Auditor ISO9000, ISO 14000 and OSHAS 18000. Safe Work at Heights (SWH) Coordinator. Qualifiedunder OSHA Standards 510 and 500 and experience in Oil & Gas Industry.

HSE/HRT TRAINERS

JOSE E MORENO

HSE/HRT Trainer

Occupational Health Professional with valid License in Occupational Safety and Health,SWH certified trainer with over 20 years experience in the Construction Industry,Occupational Risk Assurance (ARLs), and external consultant for Private Companies. SafeWork at Heights (SWH) Coordinator. Qualified under OSHA Standards 510 and 500 andexperience in Oil & Gas Industry.

TOMAS ESTRADA

HSE/HRT Trainer

Pharmaceutical chemist, Occupational Health Specialist with valid License in OccupationalSafety and Health, SWH certified trainer with over 20 years experience in theConstruction, Chemical and Wood Industries and external consultant for ARLs. Safe Workat Heights (SWH) Coordinator. Qualified under OSHA Standards 510 and 500 andexperience in Oil & Gas Industry.

Professional Profile


HSE/HRT TRAINERS

JUAN F. MEJIA HSE/HRT Trainer

Occupational Health Professional with valid License in Occupational Safety and Health, SWHcertified trainer with over 20 years experience in the Construction Industry, Occupational RiskAssurance (ARLs), and external consultant for Private Companies. Safe Work at Heights (SWH)Coordinator. Qualified under OSHA Standards 510 and 500 and experience in Oil & Gas Industry.Bilingual.

RODRIGO ALCAZAR

HSE/HRT Trainer

HSE/HRT Trainer with extensive experience as Supervisor and Operator and Maintenance ofCranes, Forklifts, AWP and Telehanders, Rigging Operations. Competent in English, with over 25years experience in the Construction and Mining Industries, Projects and as Cranes, Forklifts,AWP and Telehanders, Rigging Operations Trainer. Safe Work at Heights (SWH) Coordinator.

ADMINISTRATIVE STAFF

FABIAN MORENO

SCHEDULING

OF HSE/HRT

TRAININGS

Telematic Engineer and Technologist in systematization of data, expert in databases, with over10 years experience in the Construction Industry and the Public Sector. Safe Work at Heights(SWH) Coordinator.

FRANCISCO LEMOS

ADMINISTRA

TION OF

RECORDS OF

HSE/HRT

TRAININGS

Architect with over 30 years experience in the construction industry and the chemicalindustry. Safe Work at Heights (SWH) Coordinator.

Occupational Health Technologist with valid License in Occupational Safety and Health, withover 3 years of experience in the construction industry and Metalwork. Safe Work at Heights(SWH) Coordinator. Qualified under OSHA Standards 510 and 500 and experience in Oil & GasIndustry.

HERNANDO STEEL


4.

HSE Corporate Policy

and the Role of the HSE

Training Area

HSE Corporate Policy of CB&I

HSE & HRT Training

Area supports the

compliance with HSE

Corporate Policy of

CB&I

5.

Matrixes of HSE

Trainings by Role

Since 2012, the 15 Matrixes of HSE Trainings were developed by Specialty and Position for all personnel of theCartagena Refinery Expansion Project– REFICAR, based on the requirements of OSHA and Colombian Legislation inOccupational Safety and Health. All are already published in the Corporate System of information management -IDOCs. An example of this HSE Training Matrixes is included in the following slide.

In 2012, the HSE/HRT Training Area Management developed the document “SAFETY EDUCATION AND TRAINING -Guideline Based on CMS-710-05-PR-01900 FOR THE CARTAGENA REFINERY EXPANSION PROJECT”, which supports theplanning effort of the HSE/HRT Training in the Expansion Project. It is presented in the following slide.

Based in these administrative tools described above, employee Fabian Moreno performs the following activities:

Develop and publish the HSE/HRT Trainings schedule on a weekly and monthly basis, sending the same to all areas of the REFICARExpansion Project.

Notify Block Managers, Area Managers, Superintendents, Supervisors, and General Foremen of the HSE Trainings that their workershave pending, when this training is scheduled, when the mandatory training expires, etc.

Coordinate with the employee Hernando Steel the preparation of the educational materials for each HSE/HRT Training scheduled(attendance lists, surveys, quality assessments, stickers for Hard Hats, Stickers for the HSE Training Wallet Card).

Process the List received from each HSE/HRT Trainer, inputting the data for each attendee approved in the HSE/HRT Course in thedaily HSE Training Matrix to be sent to all areas of the REFICAR Expansion Project. Then pass the same to employee FranciscoLemos for digitalization, indexing and physical filing.

Prepare weekly reports of Compliance Vs. Scheduling of HSE/HRT Trainings for HSE Training Area Management to be checkedbefore the same are sent to all areas of the REFICAR Expansion Project.

Monthly upgrade the Compliance Matrix of the HSE/HRT Trainings by Worker that is published in iDocs.

SCHEDULING OF CONTINUING EDUCATION AND

HSE/TAR TRAININGS

MATRIXES OF HSE TRAININGS

6.

Current HSE Trainings

offered in the UVAE-

HSE & HRT Training

Center

HSE TRAININGSBasic Rigging

Mobil Cranes Safety

Basic First Aids (with support from ARL

SURA)

Defensive Driving (with support from ARL

SURA)

Rescue in Confined Spaces (with support

from ARL SURA)

Safe Handling of Hazardous Materials (with

support from ARL SURA)

Safe Handling of Food (with support from

ARL SURA)

Confined Spaces Attendants/Entry

Confined Spaces - Supervisors

Power Tools

Hand Tools

Ergonomics

Excavations & Trenching Awareness

Stairways & Ladders

Scaffolds Competent Person

HSE Orientation

Lift Trucks & Powered Industrial Trucks

Control of Hazardous Energy

Safe Operation of the Utility Vehicle-

Kawasaki 4110 - MULE

Respiratory Protection Program

Supervisors Incident Prevention

Program - SIPP

Fall Protection & Inspection of

Harnesses and Lanyards

Job Safety Analysis (JSA)

Permit to Work (PTW)

Mechanized and Marine Equipment

Welding, Cutting and Heating

Excavations & Trenching Competent

Person

Powered Arial Work Platform (AWP)

AWP – Functional Tests

NFPA 70E – Electrical Safety of

Employees in the Workplace

Program of Safety Based Behavior -

(I-CARE)

Hand Protection

Safe Use of Fire Extinguishers (include

Practice)

Safe Handling of Anhydrous Ammonia

Safe Operations with Suspended Scaffolds

Type SKYCLIMBER

Course of foment of Work Safe, Clean and

Healthy (HSE Orientation of ECOPETROL

S.A.)

Safety with Horizontal y Vertical Life Lines

Safe Operation of Trenchers

Safe Operation of AIR TUGGER

Abrasive Blasting Safety

Painting Safety

Work Area Hazard Assessment Process

Safe Operations with Over Cranes

Certification Program for Crane Operators

and Supervisors (with BUREAU VERITAS

INTERNATIONAL – COLOMBIA)

Flaggers

CONTINUING EDUCATION PROGRAMS AND HSE / HRT TRAINING COURSES

HRT CERTIFIED TRAINING COURSES

Safe Work at Heights - SWAH

Types of Certificated Courses currently

offeredDuration

Basic Administrative Level for Area Heads 7.5 Hours

Basic Operative Level 6 Hours

Advanced Level 30 Hours

Retraining in Advanced Level 15 Hours

Coordinator of Safe Work at Heights 80 Hours


Future Certified Training Courses

SAFE WORK WITH BOILERS

SAFE WORK IN CONFINED SPACES

SAFE WORK IN EXCAVATIONS & TRENCHES

SAFE WORK WITH RADIATION

SAFE WORK WITH SCAFFOLDS

SAFE WORK WITH HAZARDOUS ENERGY

SAFE HOT WORK

SAFE WORK WITH CRANES & RIGGING OPERATIONS

SAFE WORK WITH HAZARDOUS MATERIALS

SAFE WORK IN MINING


7.

Experience with

Certified Training

Programs for High

Risk Tasks (HRT)

SPECIAL PROGRAM OF CERTIFIED TRAINING IN SAFE

WORK AT HEIGHTS

PHASE 1AGREEMENT BETWEEN SENA - REFICAR S.A. - CBI

COLOMBIANA S.A.

May - July 2012

SPECIAL PROGRAM OF CERTIFIED

FORMATION IN WORK AT HEIGHTS IN

AGREEMENT BETWEEN

SENA-REFICAR-CB&I

2012

WAH Certification: Training program to certifiedskills for Work at Heights under Resolution 3673of 2008 issued by the Ministry of SocialProtection of Colombia. We trained ourpersonnel in the Advanced, Intermediate andRecertification levels.

We trained approximately 2473 people in these3 levels from May to July 2012.

PEOPLE TRAINED:

SAFE WORK AT HEIGHTS WORK COMPETENCIES

ADVANCED INTERMEDIATE RECERTIFICATION

Sticker for Hard Hat -

Identification as trained and

certified person in the Work

Competency for WAH

according the WAH

Standard of the SENA.



authorized person in the Fall

Protection Procedure of CB&I,

based on OSHA.


TRAINING IN SAFE WORK AT HEIGHTS

2012

IMAGES OF THE THEORETICAL TRAINING - REQUIREMENTS OF

RESOLUTION 3673 OF 2008

SPECIAL PROGRAM OF CERTIFIED TRAINING IN SAFE WORK AT HEIGHTS

IMAGES OF THE THEORETICAL / PRACTICAL TRAINING -

BASIC FIRST AIDS AND RESCUE

SPECIAL PROGRAM OF CERTIFIED TRAINING IN SAFE WORK AT HEIGHTS

IMAGES OF THE PRACTICAL TRAINING - RESCUE



IMAGES OF THE PRACTICAL TRAINING – WAH



SPECIAL PROGRAM OF CERTIFIED TRAINING IN SAFE

WORK AT HEIGHTS

PHASE 2

Agreement with the MINISTRY OF LABOR OF COLOMBIA – Approval of the Unit of

Vocational Learning in the Company – UVAE of CB&I COLOMBIANA S.A.

Since March 2014 until July 31st, 2015

SPECIAL PROGRAM OF CERTIFICATED TRAINING IN

SAFE WORK AT HEIGHTS IN AGREEMENT BETWEEN

THE MINISTRY OF LABOR OF COLOMBIA AND CB&I

COLOMBIANA S.A.

We trained and Certified the WAH Labor Competency, as required by

Resolution 1409 of 2012 issued by the Ministry of Labor of Colombia, in

the UVAE of CB&I Colombiana S.A., for 11,422 people of CB&I and

other Companies at different levels (Advanced, Retraining in Advanced,

Basic Administrative for Area Heads and WAH Coordinators), from April

2014, in Courses in Spanish and English.

TSA COURSE LEVELS # PERSONS

SWH ADVANCED LEVEL 9567

SWH ADVANCED LEVEL /English 50

SWH BASIC OPERATIVE LEVEL 20

SWH RETRAINING ADVANCED LEVEL 1600

SWH BASIC ADMINISTRATIVE LEVEL 14

SWH COORDINADOR 171

TOTAL 11422

LEVEL TRAINING TRAINED

ADVANCED LEVEL 9567

RETRAINING LEVEL ADVANCED 1600

BASIC ADMNISTRATIVE/OPERATIVE LEVEL 34

WAH COORDINATOR 171

34

0

1000

2000

3000

4000

5000

6000

7000

ADVANCEDLEVEL

RETRAININLEVEL

ADVANCED

ADMNISTRATIVELEVEL

COORDINATORWAH

9567

1600

34 171

TRAINED PERSONNEL - WAH


SAFE WORK AT HEIGHTS – PHASE 2

35

COMPANY

TRAINED

PERSONNEL

CB&I 10822

OTHERS 600

0

1000

2000

3000

4000

5000

6000

7000

8000

CB&I OTHERS

10.822

600

TRAINED PERSONNEL



36

OTHER

COMPANIES

TRAINED

PERSONNEL

REFICAR/ICG 559

ECOPETROL 6

GE 8

IQS 8

Sicelub 1

SULZER 1

SURA 3

ABB 7

RTH 1

SEWON 13

020406080

100120140160180

559

6 8 8 1 1 3 7 113



Resources of the HSE Training Center to operate as

an UVAE since April 2014 until July 31st, 2015

TRAINING SPACES

PRACTICE AREAS



SPECIALIZED RESCUE GROUP - OF CBI

COLOMBIANA S.A.

Rescue Drills

Rescue Drills



Medical Care for Emergencies during WAH

Trainings

Clinic with Level 2 / 3 of Complexity for attention of First Aids

cases. Located in Camp 2, serving the public during business

hours. Staffed by doctors, nurses and paramedics. There are 4

ambulances available for the Expansion Project.

Satellite Clinic located in the HSE Training Center, staffed

with a Paramedic.

1

2

1

1

2

2



certified person in the Work

Competency for WAH under

Resolution 1409 of 2012 issued

by the Ministry of Labor of

Colombia


TRAINING IN SAFE WORK AT HEIGHTSApril 2014 - July 31st, 2015

Example of Certificate issued to a Worker

who passed the WAH Course – Advanced

Level, in the UVAE – HSE Training Center

of CBI Colombiana S.A., in the Expansion

Project REFICAR.

8.

Support for Technical

Training programs

SUPPORT FOR TECHNICAL TRAINING

PROGRAMS

Training in various disciplines in alternatetraining centers in agreement with INEM andSENA. We trained approximately 2785 people ofscaffolding, boilermaker, carpentry, welding,rebar, concrete finishing, insulation, painting,rigging, pipefitting, mechanical, electrical,ironworking, and instrumentation disciplines, inHSE ORIENTATION and HSE Procedures of theCMS of CB&I.

470

152

89

299

88136

40

300332

185

253

89

202150

TRAINING INEM & SENA CENTERS

17%6%

3%

11%

3%5%1%

11%12%

7%

9%3% 7% 5%

TRAINING INEM & SENA CENTERS

SCAFFOLDING BOILERMAKER CARPENTRY

WELDING CONCRETE FINISHING INSULATION

PAINTING RIGGING PIPEFITTING

MECHANICAL ELECTRICAL IRONWORKING

INSTRUMENTATION TANK BUILDER

9.

Supervisor Incident

Prevention Program

(SIPP)

Specialized training program for all Supervision, of CB&I Constructionand HSE and Subcontractor Companies working in the REFICARExpansion Project.

Development of these courses in the expansion project since 2011, inEnglish and Spanish.

All the material in the SIPP Manuals, originally in English, wastranslated to Spanish by Colombian translators and then reviewed andedited by our HSE Trainers. Its contents is constantly updated in orderto be up-to-date with the changes in CMS, and therefore, offer onlycurrent information for the attendees of a new SIPP cycle. It is thesame procedure that we follow with the rest of the HSE Trainings, inSpanish and English.

Since February 2012 until present day, the SIPP trainings aredeveloped in the HSE Training Center, with a great budget savings forCB&I and the REFICAR Expansion Project.

SUPERVISOR INCIDENT PREVENTION

PROGRAM – SIPP TRAININGS

0

200

400

600

800

1000

1200

20112012

20132014

1178

569

810786

PEOPLE TRAINED BETWEEN 2011 - 2015

SIPP TRAININGS



0

200

400

600

800

1000

CBI SUBCONTRACTORS

819

258

SIPP TRAINING 2011

0

100

200

300

400

500

600

CBI SUBCONTRACTORS

555

14

SIPP TRAINING 2012

0

100

200

300

400

500

600

700

CBI SUBCONTRACTORS

694

116

SIPP TRAINING 2013

0

200

400

600

800

CBI SUBCONTRACTORS

717

69

SIPP TRAINING 2014



SIPP TRAINING COURSES FOR SUBCONTRACTOR

PERSONNEL

2011 - 2015

596 PEOPLE TRAINED FROM SUBCONTRACTOR

COMPANIES

0

20

40

60

80

100

120

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10.

HSE Orientation of ECOPETROL S.A.

PROMOTION OF SAFE, CLEAN AND

HEALTHY WORK

(HSE Orientation of ECOPETROL S.A.)

Another point to note in the work of the HSE Training area, isthe subject of the HSE ECOPETROL ORIENTATION. This trainingis a requirement for those who are employed by CB&I orsubcontractors which must perform their duties within theEcopetrol Refinery.

The HSE Training Area of CBI Colombiana S.A. has coordinatedthe trainings for around 13,800 people in the HSEORIENTATION OF ECOPETROL S.A.

Courses Delivered:

2009 – 2010: only CB&I instructors

2011 – 2013 (Since February): CB&I and Iinstructors of theColombian Safety Council

2013 (since March): Instructors of Consorcio FTSLS.

0

1000

2000

3000

4000

5000

2009 2010 2011 2012 2013 2014

31 158

1616

3114

4406 4470

HSE ORIENTATION OF ECOPETROL SA -TRAINED PEOPLE

YEAR TRAINED PEOPLE

2009 31

2010 158

2011 1616

2012 3114

2013 4406

2014 4470

0

500

1000

1500

2000

2500

13 18169

1065 1072

2032

QUARTER PEOPLE TRAINED

I QUARTER 2009 13

I QUARTER 2010 18

I QUARTER 2011 169

I QUARTER 2012 1065

I QUARTER 2013 1072

I QUARTER 2014 2032

PROMOTION OF SAFE, CLEAN AND HEALTHY WORK

(HSE Orientation of ECOPETROL S.A.)

11.

HSE Trainings

based on CMS

Procedures

HSE Trainings based on CMS

Procedures

In addition to the above, we have trained people of the Expansion

Project in different CMS Procedures. During last year, on

average, every day about 10-13 HSE Trainings were developed, with an

average of 400 people per Day.

Everyone who receives specific HSE Training is included in the HSE Training Matrix Record and in

CINTELLATE.

The UVAE - HSE Training Center - has 8 HSE Trainers, 2 of them are bilingual, 4 are Occupational HealthSpecialists, 2 are Occupational Health Professionals.

For the WAH Project – Phase 2, the UVAE hired another 5 WAH Trainers, 1 of them is bilingual, and 2 WAHTrainings Coordinator.

In the 2013, with the same number of trainers as 2011, we trained 3.76 times more people than in 2011, inCMS procedures.

At the same time, in addition to the number of trainings offered, we worked hard in order to guarantee thequality of the trainings in CMS procedures, with a permanent effort by our HSE Trainers to be updated withthe latest versions of CMS PROCEDURES and the OSHA and the Colombian MINISTRY OF LABORrequirements, all of this with a splendid effect on the HSE formation that we offer the workers of theExpansion Project.

This great effort in creating awareness of the Hazards and Risks of the works in Construction activities wasreflected in the fact that we didn’t have any Fatalities, Permanent Disability and only had Permanent Partialdisability due to a different kind of incident with loss, among more than 36,000 workers of the REFICARExpansion Project, who have passed through our HSE/HRT Training Containers.

This great effort in in creating awareness of the Hazards and Risks of the works in Construction activities alsopermitted providing great support for our HSE partners in the different units of the Expansion Project.

At this moment, the UVAE - HSE/HRT Training Center - has optimized its personnel structure to develop workwith only four (4) HSE Trainers, and 3 people in administrative support.

HSE Trainings based on CMS

Procedures

57

GRAPHICS

TRAINED PEOPLE – CMS PROCEDURES

59

TRAINED PEOPLE – CMS PROCEDURES

JANUARY – DECEMBER 2014

12.

HSE Trainings Reports

& Controls

HSE TRAINING REPORTS &

CONTROLS

Since 2012, due to the large increase of the personnel on theproject, we implemented a control and identification systemof personnel trained in different subjects. The systemconsisted of a series of stickers that were distributed to eachperson once a course was completed successfully.

We developed stickers for the personnel that passed thecourses of Fall Protection, Work Permits, Confined Spaces,Respiratory Protection, Excavations, Lockout/Tagout,Scaffolding Competent Person, etc. See some examples ofthese stickers in the following slide.

13.

HSE Training

Passports & Wallet

Cards

HSE TRAINING PASSPORTS & WALLET

CARDS

In late 2012, we proposed a new training verification system. The HSETraining Passport, which is personal. The book has a series of pages to placea sticker with all the trainings that the person has completed successfully,and includes the date of completion, and the name of the HSE Trainer.

The passports were issued since February 2013 until May 2014,approximately 10,000 HSE Training Passports have been printed anddelivered.

The ongoing search of up-to-date knowledge of a better way to help to HSEPersonnel to control if a worker completed the mandatory training requiredby CMS to develop a task, gave way the New Field Identification Program ofthe HSE TRAINING WALLET CARDS, that have been issued since July 2014,initially, for the workers that passed the WAH Certified Courses. To date, wehave already handed out more than 11,000 HSE TRAINING WALLET CARDSfor personnel of CB&I and Subcontractor Companies!!!

HSE TRAINING PASSPORTS & WALLET

CARDS

HSE TRAINING

PASSPORTS

HSE TRAINING WALLET CARDS

14.

Safekeeping of the

HSE & HRT Training

Records

The deliverable product of an HSE Training Area are the records of HSE/HRTTrainings, which are usually composed of:

Attendance Lists

Exams, Workshops

Quality Assessments of the HSE/HRT Trainings

All this information in its physical version is organized and available inContainers 4 and 8 to be used by the Company as needed in case of legalrequirements.

This delicate and vital task is developed in our UVAE - HSE/HRT Training Centerby the Administrative personnel, Francisco Lemos and Hernando Steel.

The Administrative employee Hernando Steel is also responsible forpopulating the application CINTELLATE.

Safekeeping of the HSE/HRT Training

Records

Thanks for your kind

attention!

A World of Solutions 69

management report of hse training area - reficar project - february 2012 - july 2015

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