GE Oil & Gas

Hazard Heat Map

Training
Lufkin Industries
Purpose
• EHS in partnership with facility and operational
personnel gain a clear understanding of the
hazards that exists within the work environment.
• Evaluate hazards in relation to the perceived risk
of causing harm to persons or the environment
• Establish priorities for removing hazards from the
work environment
Method
• All locations with 10+ employees. One HM per location and
Field Service operation.
• Utilize cross functional review methodology with EHS,
Management/Supervisors and Operational personnel
• Establish small working team (no more than 5 people) to walk
the facility and identify potential hazards
• List all hazards on white board/flip chart or similar and review
with team to agree, group and refine core hazards
• Follow the methodology in the following slides to complete
the Heat Map
• Submit completed Heat Map to Ty Thornton by no later than
Friday 9/27/2013.
Definitions
The art of observation…

OVERRIDER
OVERRIDER
The
Thefirst
firststep
stepisis
actually
actually
recognizing
recognizing
that
thatyou
youhave
haveaa
problem!
problem!
 Hazard – the potential to cause harm
Risk – the probability of that harm being
realized
Types of Hazards
Physical
Machinery, equipment, ergonomics, noise, heat/cold,
light/dark etc.
Chemical
Toxics, corrosives, irritants, flammables, dusts
Biological
Body fluids, rodents/pests, mold, vegetation
Psychological
Stress, emotional, workplace violence
Hazard Heat Maps
There are THREE aspects to the Hazard Heat Map

High Risk
High Risk
Operations
Operations
& Top
& Top
Operational
Heat
Heat Tail Risks
Tail Risks
Operational
Hazards
Hazards Map
Map

Manage-
Manage-
ment
ment
of Change
of Change
 GE Oil & Gas -Site Name Risk Management

High Risk Operations and Top Operational Hazards

Tail Risks
1 2 3 4 5 6

1
High

2
Frequency

3 Major changes planned /

underway

4
Low

Gray = routine operation / activity

Blue = non-routine operation /
activity
Low Potential Consequence (without mitigants) High Striped = at Customer location

9
GE Oil & Gas / 2013 Session E
Proprietary & Confidential – All Rights Reserved
Top Operational Hazards

This part of the Heat Map

shows the hazards at your
site/operations arranged by
consequences and frequency.
Tail Risks

Tail risks are potential

incidents which may Defined as:
have: High consequence & low
• Significant off-site
probability events
consequences
• Substantial operational impacts
Management of Change

Anticipated changes to process,

equipment or operations should
always be considered understand
affects on existing hazards or
creation of new ones.
Mapping
Mapping Output
Output

High Risk Operations are operations

classified as High Risk under H&S Element
13.

Top Operational Hazards are hazards or

operations that present potentially
significant hazards. Refer to previous
incidents, near misses etc. to provide
guidance.

Arrange the risks by potential severity of

consequences and frequency.
Output
Mapping Output

Arrangemen Color
Arrangemen Arrange the Color
coding:
t should Arrange the coding:
t shouldthat hazards
assume hazards • Gray: Routine
assume thatdo directionally • Gray: Routine
operation
defenses directionally
defenses door and in operation
• Blue: non-
not exist and in to • Blue: non-
notwould
exist or relation routine
not relation to routine
operation
would not each other.
function. each other. operation
• Striped:
function. • Striped:
Customer
Customer
location
location
Frequency
• The activity occurs or is expected to
• The activity occurs or is expected to
High Rows 1 & occur at least on a monthly basis
2 occur at leastweekly
(monthly, on a monthly
or daily)basis
or
(monthly, weekly or
involves 11 or more daily) or
involves 11 or more

Place a number Frequency can be

Place a number Frequency can be • The activity occurs or is expected to
below the hazard the: • The activity occurs or is expected to
occur three or more times during the
below the hazard the: Medium Rows occur threeyear
or more times during the
as a descriptor or • Number of hazards calendar but less frequently
as a descriptor or • Number of hazards 3&4 calendar year butorless
than monthly frequently
involves 6 to 10
• Number of employees
indication of • Number of employees than monthly or involves 6 to 10
indication of exposed to the hazard employees
frequency. exposed to the hazard employees
frequency. • Frequency of activity
• Frequency of activity

• The activity is expected to occur

Low • The activity is expected to occur
once or twice during the calendar
once
yearorortwice during
involves thefewer
5 or calendar
Row 5 year or involves 5 or fewer
employees
employees

Guidelinesonly:
Guidelines only:Frequency
Frequencyisisdetermined
determinedby
bythe
thesite/business
site/business
Mapping Output
1 2 3 4 5 6

2
Potential Consequences
Potential
Frequency

Potential Potential
Level D
High

Level B & C Level A

3 Incident: Incident: Incident:

4
Low

Low Potential Consequence (without barriers or mitigants)

High
Potential Consequences
Level D Level B •• Injury
Injury requiring
requiring an an employee/contractor
employee/contractor to to be
be

Incident • First-aid, incipient stage fire or

minor property damage,
Incident
admitted
admitted to
•• Multiple
to aa hospital
Multiple recordable
incident
incident
hospital
recordable injuries
injuries from
from aa single
single
•• Compliance
Compliance statusstatus determinations
determinations voluntarily
voluntarily
• Short-term business interruption
reported
reported to to aa regulatory
regulatory agency
agency resulting
resulting in
in
with little or no cost to business, business interruption greater than 7
business interruption greater than 7 days and days and

Column • Non-reportable spill, Columns damage

damage or
•• A
A waste
or related
waste water
related cost
water or
cost <$1
or air
<$1 million,
million,
air exceedance,
exceedance, fire,
fire, explosion
explosion

1 2 or 3 or spill/release requiring offsite assistance.

or spill/release requiring offsite assistance.

Level A
Level C • Recordable Injury
• Incident that results in business
Incident
•• Fatality
Fatality
•• A
A permanent
permanent total
total disability
disability

Incident
•• Incident
Incident reported to aa regulatory
reported to regulatory agency
agency that
interruption >2 and <7 days, s results
results in
related
in business
business interruption
cost of >$1
interruption >1
million,
related cost of >$1 million,
>1 month
that
month and
and
damage and related cost <$250k, •• Incident
Incident that
that results
results in
in impact
impact to
to the
the community
community
Column • A fire, explosion, spill/release
requiring assistance from onsite
or
or environment
an
environment beyond
interruption
beyond fence-line,
of public
fence-line, that
service
that triggers
and/or
an interruption of public service and/or
triggers

s 2 or 3 emergency response Columns precautionary

precautionary community
such as
community protective
evacuations or
protective measures
sheltering
measures
in-place
such as evacuations or sheltering in-place

4, 5 or 6
Risks: Non-Routine vs. Routine
Routine vs. Non Routine determination is made by the business or site.

Annual
• •Annual
maintenance
maintenance
• Daily activity Non- shutdown
shutdown
Routine • Daily activity
using
using Plant
Routine • •Plant
Example
authorized
authorized Example construction
constructionoror
s
workforce
workforce s modification
modification
Commissioning
• •Commissioning
ofofnew
newoperation
operation
Management of Change

Changes that are anticipated or

Riskthat
planned HeatmayMap
have– aMajor
major
impact on the facility
Changes
Examples:
• New operations
• Expansion or plant closure
• Increase or decrease in workforce
• Major capital expenditure
• New Product Introduction or loss of product line
Finished Product
GE Oil & Gas -Artificial Lift – Oklahoma City, Overview
OK
Plant Manager: Chester Fry EHS Manager: Zack McCloud
• In current position since: 04/01/11 • In current position since: 06/03/13
• Attended OMT: 05/23/12 • % of time on EHS: 100%
• Other full-time EHS: 0

OKC-MFG Organizational Overview

.
Eng
Business trend
• Growth business / expanding global markets
SP S ESP
New technology roll-out?
• Automated stator straightener
D
VS • Automated shaft polishing
• Power cable management
• Forklift telemetry

Biggest Customers (top 3)

• ExxonMobil
Quick Stats:
• Kuwait Oil Company
GE Employees: 546
• Pan American LLC
Distribution: 307 Salary / 239 hourly
Contractors: 14 How does team ensure that SRA’s (or local equivalent)
Hours worked: Current Year – 370K / Prior Year – 1,163K are completed in compliance with local law ?
EHS Resources: 1 GE; 0 Contracted • Manufacturing develops “standard work” documents
with the EHS team to ensure compliance
22
GE Oil & Gas / 2013 Session E
Index Proprietary & Confidential – All Rights Reserved
 GE Oil & Gas -Artificial Lift – Oklahoma City, Risk Management
OK
Operation’s Heat Map
High Risk Operations and Top Operational Hazards
1 2 3 4 5 6 Tail Risks
1 Crane & • FM rating not applicable
High

Maintenance Hoist Machine

Repairs Operations Safety 1 • Severe Weather
(LOTO / Guarding)
2 4 Link
2 Powered
Chemical Industrial High Major changes planned / underway
Usage Truck Voltage • Power / Cable Management
Operation 1
• Ergonomic focus
Frequency

3 Manual
Material • Machine guarding
Handling
3 9 3

4
Painting Hydrogen Heat Working at
Operations Sulfide Exhaustion Heights
Low

5
Pick Up at Hydrostatic
Confined Gray = routine operation / activity
Customer Norm Hot Work Testing
Spaces Blue = non-routine operation /
Location Link
activity

Low Potential Consequence (without mitigants) High

First Aid Recordable Near Miss

23
GE Oil & Gas / 2013 Session E
Index Proprietary & Confidential – All Rights Reserved
Summary
Steps
• Develop cross functional team
• Conduct site walk through
• Brainstorm & align on Hazards
• Establish Frequency & Consequences
• Complete Heat Map
• Submit to local EHS within 30 days
Templates & Examples
 GE Oil & Gas -Site Name Risk Management

High Risk Operations and Top Operational Hazards

Tail Risks
1 2 3 4 5 6

1
High

2
Frequency

3 Major changes planned /

underway

4
Low

Gray = routine operation / activity

Blue = non-routine operation /
activity
Low Potential Consequence ( without controls ) High Striped = at Customer location

28
GE Oil & Gas / 2013 Session E
Proprietary & Confidential – All Rights Reserved
 GE Oil & Gas - TM Mfg Florence, Italy Risk Management
Plant Manager: Giulio Ardini EHS Manager: Alessandro Cambi
• In current position since: 10/17/2011 • In current position since: 01/01/1995
• Attended PMT: 04/21/2004 • % of time on EHS: 100%
• Other full-time EHS Staff: #4

High Risk Operations and Top Operational Hazards Tail Risks

FM Global Rating • Pressurized gas
High

Over Speed
Crane &
explosion from
Testing turbo
Heavy lifts
compressor
testing

• Heavy
Forklift Pressure transportation
Operation testing Risk Mark score: 17 (12)
Potential score: 63
26% of Potential Score
Frequency

Truck Traffic
Maintenance
Maintenance &
Requiring
Heavy
Transport
Lock-Out Major changes planned / underway
Tag-Out
• New CO/CE External Test Bed
Welding
Hot Work in • New CO/CE Pressure Test Work Station
Waste Water Operations & String Test
Rotor Work at
Treatment Hot Works /Pressurized
Assemby Height • New Impeller Spin-Test Bunker
Plant non Routine gas loop
Activity

Welding Legend:
Construction Confined
Low

Operations &
Radiography Excavation Space Entry
Hot Works
Test Activities Permit access Gray = Routine Activity
Routine
Activity
Blue = Non routine Activity
Low Potential Consequence (without mitigants) High
High Risk Operation
29
GE Oil & Gas / 2013 Session E
Index Proprietary & Confidential – All Rights Reserved
 TM
GE Oil & Massa
Gas - Risk Management Heat Map 2013 Revalidation
Plant Manager: Guido Tongiani EHS Manager: Alessandro Sboro
• In current position since: 01/2012 • In current position since: 10/1997
• Attended OMT: 04/2011 • % of time on EHS: 100 %
• Other full-time EHS # 3
High Risk Operations and Top Operational Hazards
Tail Risks
Welding
String •Pressurized gas FM Global Rating
Operations Work at
Test explosion from FM Global provides comprehensive global
High

& Hot Height commercial and industrial property

/Pressurized
Works turbo compressor insurance
gas circuit
testing
Risk Mark score: 38
•Heavy
Massive transportation Potential score: 81
Truck Traffic
Contractors Crane & Industry average: 56
& Forklift
Use Heavy lifts
Frequency

Maintenance
Heavy
Requiring High
transportatio # 16 reccomandations by FM
Lock-Out Pressure just completed in last months
n
Tag-Out Operations

Major changes planned / underway

Hot Works • New enclosed workstations for casing and piping
pressure testing aligned new EHS standard
Low

• Area for big compressor testing activation (Area 61)

Confined
Constructio
Radiograp (Permit) • Plant SUVA tanks and mixture separation plant
n/
hic Tests Space Entry
Excavation
• Layout review for subsea product development

• Module construction sites rebuilding

Low Potential Consequence (without mitigants) High
Update vs 2012 Gray = Routine Activity • Recife Yard (Brazil) facility realization
assessment
Blue = Non routine Activity MoC Monitoring Process
 GE Oil & Gas - GS Field Services Risk Management
Operations Leader: James Betzwieser EHS Program Manager: Denise Avanzati
•In current position since: December 2010 • In current position since: Aug 2012
•Attended OMT: August ‘11 • % of time on EHS: 100%
•Operation VPP/GS Status: OHSAS 18001 (Jun ‘10) • Other full-time EHS staff: #15
Operations Leader: Federico Cangioli
•In current position since: Jan 2013
•Attended OMT: April ’04
•EHS Committee member

High Risk Operations and Top Operational Hazards

Customer
Tail Risks
Driver
(bypass
High

Safety • Uncontrolled release of H2S

High

process & lack

of /Transportatio • Dust explosion potential
coordination) n

Health Risk
Major changes planned /
Work at underway
Country /
Fatigue Lifting & Height Explosive
Extreme
conditions Rigging - gasses • New Global Ops GM
climatic
Offshore • New Regionalized organization
conditions
• Site Mgrs pool
Frequency

• Manpower COE
Frequency

Jobs @ Gas Turbines • Increase volume / people

Isolation
construction Commissionin
(LOTO) • Training Academy
sites g

Confined Stretched Hydrogen Gray = routine operation / activity

Electrical risk
Spaces Entry schedule Sulfide Blue = non-routine operation / activity
Striped = at Customer location
Low
Low

Pin= FSEs inputs

Asbestos
Containing Third Parties Impact link
Materials 31
GE Oil & Gas / 2013 Session E
Proprietary & Confidential – All Rights Reserved
Low Potential Consequence (without mitigants) High
 GE Oil & Gas - Operational Risk Management

High Risk Operations and Top Operational Hazards - Offshore Tail Risks
Pinch Pints
Ergonomics / (Assembly/
Transportation to Gas/Produced
Rig – Helicopter Slinging & Lifting
Manual Handling Disassembly/
Transfer Operations
fluid leak
operations Running
High

Equipment)

Pressure Testing Stored Energy Fire Events Rig Explosion

Operations (Rig Adverse Weather (Pneumatic,
Floor & Down Conditions Hydraulic, Pre
Hole) Charge Nitrogen)

Pressure Test Low

Volume (Tree Exposure to Noise Pressure Testing –
voids, Control >85db High Volume
Pods)
Major changes planned /
Frequency

underway
Concurrent
Simulations/
Dropped Objects LOTO – IWOCS • Wellstream Construction (WCS)
Operations
division moving from Wellstream
to Subsea Services
Norm
Transportation to Hydrogen Sulphide • Investment for additional
(radioactivity) / Moon Pool (Over Working at
Chemical
Rig – Boat
side Working) Height
Exposure – intervention services
Transfers Drilling Operations
Exposure
Low

Lack of Rig
Hand Arm High Voltage
Living Quarters / Long Hours Awareness/
Vibration Operations (
Syndrome
Canteen Worked (Fatigue)
Controls)
familarisation Gray = routine operation / activity
Blue = non-routine operation / activity
Red = Client/Customer/Rig Operator
Low Potential Consequence (without mitigates) High

Return to Action Plan

32
GE Oil & Gas / 2013 Session E
Index Proprietary & Confidential – All Rights Reserved
GE Power and Water – Schenectady, NY Risk Management
Plant Manager: Edward Stefanik EHS Manager: John Little
In current position since: (3/2012) In current position since: 10/2012
Attended OMT: 9/2012 % of time on EHS: (100%)
High Risk Operations and Top Operational Hazards Other full-time EHS staff: (7)
FM Global Rating
Occ Flammable Ergonomics High Machine Crane Operations
Noise Material Voltage Guarding
Exposure Use Testing
High

2 4 1 2 5
2 3
7
Laser Class Hazardous Compressed Powered Confined LOTO Tasks
3B or higher Materials/ Gasses. Industrial Space Entry
(5) Waste Trucks -230 entries-
Storage

1 1
Frequency

1
* 100 yr. Flood Plain Reclassification
Ionizing Induction Hot Work Working at High Voltage
Radiation Brazing Heights Electrical Work –
(8) Arc Flash Tail Risks
1 2 1. Piping Inspection and Flushing Program.
2. Sprinkler protection for Bldg. 281, test and
Asbestos Excavation Line Breaking Generator Test Basement.
removal works (78) 3. Ignitable liquid waste consolidation area.

16 Projects
Low

4 Inspections
Major changes planned / underway
1
• Generator Test Rebuild
Low Potential Consequence (without barriers or mitigants) High • Hazardous Waste Storage
• Autoclave upgrades
• Integration of Service Work
First Aid Recordable Near Miss
Gray = routine operation / activity
Blue
• = non-routine operation / activity
Page 33 Striped = at Customer location