Incorporating Prevention through Design Methods into the Design - PowerPoint PPT Presentation

Incorporating Prevention through Design Methods into the Design & Re-design Process Frank M. Renshaw, PhD, CIH, CSP NIOSH PtD Conference Washington, D.C. August 23, 2011 Bayberry EHS Consulting, LLC 1

P REVENTION THROUGH D ESIGN I NITIATIVE A S YSTEMATIC , S TEP-BY - S TEP A PPROACH Step 3 Monitor the Impact of PtD on Eliminating Hazards & Minimizing Risks Step 2 Incorporate PtD into Work Processes and Health & Safety Management Systems Step 1 Create Awareness of PtD in All Sectors, Organizations , Agencies & Schools Bayberry EHS Consulting, LLC 2

P REVENTION THROUGH D ESIGN M ETHODS Eliminating Hazards & Controlling Risks at the Source or as Early as Possible in the Life Cycle Method Including Design & Re-design of New & Existing Facilities, Equipment, Tools, Processes, Method Products & Work Methods Including Prevention Methods in All Designs that Impact Workers Method and others on the Premises Bayberry EHS Consulting, LLC 3

Capital Project Process (CPP) The mechanism used within an organization to manage the development and execution of capital projects from idea conception through start-up and process optimization. Bayberry EHS Consulting, LLC 4

Coatings Manufacturing Plant 5

Waste Water Treatment Unit Bayberry EHS Consulting, LLC 6

New Technical Center Bayberry EHS Consulting, LLC 7

Eliminating Open Systems 8

Retrofitting Laboratory Hoods 9 Bayberry EHS Consulting, LLC

New Acquisition - Completion - Start-up Bayberry EHS Consulting, LLC 10

Key Partners Safety Services Project Leader Industrial Hygiene Project Team Occupational Health Services Specialist Engineer Environmental Services Site Manager Security Project Owner Company Fire Brigade Technical Services/Maintenance Safety Contractor Engineering Safety Coordinator Design Safety Coordinator Construction Notified Body/Official Organizations Public/Community Fire Brigade Insurance Contractor Bayberry EHS Consulting, LLC 11

Incorporating PtD Methods into CPP - Key Essentials - • Setting Policy & Standards • Establishing Work Processes & Procedures Policy Standards • Applying Tools Work Processes & Practices & Procedures Tools & Practices Bayberry EHS Consulting, LLC 12

Incorporating PtD Methods into CPP - Key Essentials - • Setting Policy & Standards • Establishing Work Processes & Procedures Policy Standards • Applying Tools Work Processes & Practices & Procedures Tools & Practices Bayberry EHS Consulting, LLC 13

Incorporating PtD into EHS Policy Pole Vault Approach Steady Climb Approach Bayberry EHS Consulting, LLC 14

XYZ Company Model Environmental, Health, and Safety Policy* The XYZ Company is the world’s leading manufacturer of ___ products. Our environmental, health, and safety values are of the utmost importance to us. They are embodied in the guiding principles set forth in this policy. They reflect our respect and care for the environment, our employees, contractors, customers and communities. We are committed to incorporating these values into everything we do as we seek to improve the quality of life and the environment through our products and services. Our Guiding Principles are: • We will design our businesses, processes and products with full consideration for the needs of the present global community and the impact of our design decisions on the ability of future generations to meet their needs. • We will include “Prevention through Design” considerations in the design and redesign of all facilities, equipment, processes, work methods and products, and will incorporate methods of safe design into all phases of hazard and risk mitigation. • We will continuously review and improve our worldwide operations, processes, and products, with the goal of making them free of adverse environmental, health, and safety impacts for all of our stakeholders. • We will meet or exceed all applicable laws, regulations, and XYZ Company standards. • --------- • --------- Every employee and contractor is responsible for compliance with this policy. We will audit our performance and the Board of Directors will monitor our commitments and progress. _________________ *Adapted from the former Bayberry EHS Consulting, LLC 15 President/CEO/Chairman Rohm and Haas Company

OHS Management System Standard* 3.1 Management Leadership 5.1 OHSMS Operational Elements 3.1.2 OHS Policy 5.1.2 Design Review and Management of Change The organization’s top management shall The organization shall establish and implement establish a documented occupational health and processes which incorporate Prevention safety policy as the foundation for the OHSMS. through Design concepts t o identify, and take This policy shall include a commitment to: appropriate steps to prevent or otherwise control hazards and reduce potential risks associated with: A. Protection and continual improvement of employee health and safety; A. New processes or operations at the design stage; B. Inclusion of “Prevention through B. Changes to its existing operations, products, Design” considerations in design and services or suppliers. redesign of all facilities, equipment, The process for design reviews and management of processes, work methods and change shall include: products, and incorporation of safe a. Identification of tasks and related health and safety hazards as early as possible in the life design methods into all phases of cycle of facilities, equipment, processes, hazard and risk mitigation ; work methods and products ; C. Effective employee participation; b. Consideration of hazards associated with human D. Conformance with the organization’s health factors; and safety requirements; and Consideration of control measures, taking into E. Compliance with applicable laws and c. regulations. account the hierarchy of controls; d. Review of applicable regulations, codes and *Proposed Amendments to ANSI/AIHA Z10-2005 16 standards;

Incorporating PtD Methods into CPP - Key Essentials - • Setting Policy & Standards • Establishing Work Processes & Procedures Policy Standards • Applying Tools Work Processes & Practices & Procedures Tools & Practices Bayberry EHS Consulting, LLC 17

Capital Project Process Summary Map Stage Gates End of FEL Internal/External Stage Gates 2i Stage Stage Stage Stage Stage Stage Stage Stage 0 1 2 3 4 5 6 7 Initiation Project Select Option and Detail the Design & Construct. Start-up Close-out Deliberation Conceptual Estimate Option Procure Ongoing Activities: VEP’s, Performance Measurements, Quality Audits, Progress Reporting, Cost and Schedule Control, Total Value Added = Decision Gate 2i = Agree to proceed on “selected option”. = Progress / Status Gate 2 = Conceptual estimate review and approval - agreement to move into detail the option. Bayberry EHS Consulting, LLC 18

STAGE 2 STAGE 4 STAGE 5 STAGE 6 STAGE 1 STAGE 3 CPP Select/Detail Construction Start-up Closeout Project Design/ Option Deliberation Procurement Project mission, Finalized goals Updated goals Detailed Commissioning & Closeout Plan initial goals and and objectives and objectives construction plan start-up plan and 6.1.1 objectives, scope 2.1.1 3.1.1 and schedule detailed schedule 1.1.1 4.1.1 5.1.1 Generate & initial Select best option, P&IDs, mechanical, Construction roles Operating rates Final acceptance screen of options finalized project electrical, civil, & communication documented documentation 1.1.2 scope document structural, control plan 5.1.2 6.1.2 (IBL/OBL) system programs all 4.1.2 2.1.2 complete 3.1.2 Key Project execution Project execution Detailed spare Facility mechanically Facility operating to Project critique, strategy plan parts list complete (approved specifications customer feedback, Project 1.1.3 2.1.3 3.1.3 for commissioning) 5.1.3 closeout report Execution 4.1.3 6.1.3 & Afford to spend Finalized design All equipment As-built, quality Revised operating Appropriate model basis, process purchase orders assurance, spare and maintenance learnings & design Design 1.1.4 description, PFDs, issued parts, turnover procedures, and ideas communicated Deliverables P&IDs, control 3.1.4 documentation documentation for 6.1.4 philosophy, site plan, 4.1.4 design changes list of materials, (as-built) issued major equipment 5.1.4 quotes/bids 2.1.4 Order of Magnitude Finalized economic Cost compliance Construction cost Revised start-up Project & equipment estimate analysis & AR report report cost estimate files submitted to 1.1.5 submitted 3.1.5 4.1.5 5.1.5 facility 2.1.5 6.1.5 Prevention through Prevention through Prevention through Prevention through Prevention through Prevention through Design principles in Design compliance Design compliance Design compliance Design compliance Design compliance project scope 2.1.6 3.1.6 4.1.6 5.1.6 documentation 1.1.6 6.1.6 Bayberry EHS Consulting, LLC 19