section_13-gulf_spic_presentation_final

Report
GS started its operations in 1997. It was formed by SPIC- SMO from India and Dan Holding Group of
Kuwait with 49 % & 51 % partnership respectively. In 2004, GS became a 100 % Kuwaiti Company. GS
provides full range of Engineering, Procurement, Construction, Operations & Maintenance services for Oil
& Gas, Power, Petrochemicals, Fertilizers and Industrial Sectors.
Experienced
Management
Team
Large Fleet of
Equipment &
Facilities
Reputed
Client Base
KEY
HIGHLIGHTS
Focus On
Quality &
HSE
Proven
Execution
Capability
Financial
Capability
Engineering, Procurement & Construction of Grass Root
Plants
Operation & Maintenance of Gathering Centers, Boosting
Stations, Refineries, Chemicals, Petrochemicals & Power
Plants
Major Revamp and Retrofit of Existing Plants
Breakup of Services
Engineering
9%
GS’s specialized services are:


Maintenance
36%
Construction
55%


Turbo Machinery Maintenance
services
Annual & Turnaround Maintenance
Shutdowns
Trouble Shooting & Condition
Monitoring services
Detailed Engineering Designs
Total Manpower – 3211
170
91
1765
Engineering
1185
Head office
Maintenance
Projects
Workshop 1- Shuaiba East, Kuwait
Area [m2]:10,000 Sq.m
EOT Crane :20 Ton, 1 Crane
Workshop 2 - Shuaiba East, Kuwait
Area [m2] :6,000 Sq.m
EOT Crane :10 Ton, 2 Cranes
Pipe Welding Shop
Machine Shop
Fabrication Shop
Valve Reconditioning & Testing
Turbo machinery Maintenance
Heat Exchangers Retubing
Seals Recondition & Repair Shop
Instrumentation Calibration
Yard - Shuaiba East, Kuwait
Area [m2] :36,000 Sq.Meter
(Approx)
Scaffolding Material Storage
Sandblasting
Painting
OHSAS
18001:2007
Occupational
Health & Safety
Management
Standard
ISO
9001: 2008
Quality
Management
System
ISO 14001:2004
Environmental
Management
System
TRACE Certification
for
Business Ethics
Member of
British Safety
Council
Replacement of Valves in MAB Refinery
Design , Fabrication & Erection of New
Incinerator Stacks (2 Nos) of 110M
height at TGTU (Unit 24) at MAB
Refinery
Client
: Kuwait National Petroleum Company
Client
: Kuwait National Petroleum Company
Year
: 2012 - 2016
Year
: 2010-2013
Value
: KD 3,269,970
Value
: KD 9,199,800
Ongoing
Scope
: The scope of this contract is to replace
the existing 171 Control & 6 Manual flangeless
valves with double flange valves along with
associated E&I Works in different units of MAB
Refinery
Volume of Work : Total Valves
Piping
Construction
: 177 Nos
: 6000 ID
Commsissioning
Scope
: Design and construction / erection of two
110M height Carbon Steel Stacks in the new location
with all accessories.
Volume of Work : Equipment
: 475 ton
Steel structure
: 17 ton
Piping
: 1800 ID
Electrical Cable
: 5000 Lm
Instrument Cable : 18000 Lm
EPC
Aromatics off plot works, General
Construction Contract, Kuwait Paraxylene
Production Company
OL2K - Mechanical Infrastructure
(M1) Package, Equate Petrochemicals
Client :Kuwait Paraxylene Production Company
Client
: EQUATE Petrochemicals
Year
: 2007 - 2012
Year
: 2008-2009
Value
: KD 15,101,084
Value
: KD 10,437,836
Completed
Scope
: Construction of Aromatics off plot facilities
(General Construction Contract ) for KPPC.
Completed
Scope
: Procurement & Construction of Complete
Pipe rack & piping installation, associated Civil works
& Electrical works for infrastructure project intended
to support the construction of Petrochemical
Manufacturing facility by DOW-PIC
Volume of Work : Steel Structural : 2992 ton
Equipment
: 9300 ton
Piping
: 215,140 ID
Electrical
: 123,749 Lm
Instrument
: 73,152 Lm
Volume of Work : Structural
Piping
Construction
Construction
: 4,702 ton
: 219,910 ID
Maintenance Services of Production
Facilities for South Kuwait Areas
Client
: Kuwait Oil Company
Year
: 2010 - 2015
Value
: KD 27,850,000
Ongoing
Scope
: Five Years Mechanical, Electrical and
Instrumentation Maintenance Services of Production
Facilities for South Kuwait Areas for Kuwait Oil
Company
Manpower Mobilized :
Maintenance
621
Five years Mechanical Maintenance
Contract, MAB Refinery
Client
: Kuwait National Petroleum Company
Year
: 2010 - 2015
Value
: KD 26,490,006
Ongoing
Scope
: Complete Preventive, Predictive and
routine Maintenance of Mechanical Systems of Mina
Abdullah Refinery
Manpower Mobilized :
Maintenance
564
For Completing 30 Million Manhours
without Lost time Injury in KOC West Kuwait
Fields
GCC Health, Safety, Environment Excellence
Award 2013 (Gold Award),
American Society of Safety Engineers –
Kuwait Chapter
HSE Rolling Trophy (2011-2012)
Mechanical Maintenance Contract, MAB
Refinery, KNPC
CEO HSE Award (2012),
Kuwait Petroleum Corporation
C& MD Annual HSE Award (Gold
Award), Mechanical
Maintenance Contract, MAB
Refinery, KNPC
At GS, we aspire to deliver a value added products to our customers with excellent
quality, efficiency, HSE and cost effectiveness.
Quality
Efficiency
Safety
Client
Satisfaction
Cost
Effectiveness
International Clients
GCC Clients
Kuwait Govt. Clients
Associates
CLIENTS
&
ASSOCIATES
Olefins II – Kuwait
Gulf Spic General Trading & Contracting Co W.L.L. Kuwait.
Date : 25.09.2013
Venue: Responsible Care @Dubai UAE
…a new approach towards Excellence in SAFETY
HSE Policy (Documented Commitment)
Demonstrating
COMMITMENT
Through
COMMUNICATION
Engaging
TEAMWORK
Providing
CONTINUAL
IMPROVEMENT
14
A company of Focus, Vision & Values
HSE Objectives & Goals (HSEMS Effectiveness)
15
HSE Objectives
• To achieve 10 Million continuous accident -free man hours in a year.
• To strive for a “Zero accident” workplace.
• To Minimize the Environmental Impact of Project / Service Activities.
• To train all employees for better understanding and awareness
HSE.
• To visibly demonstrate leadership & Commitment to HSE by Senior
Management.
HSE Goals
To achieve Zero Lost work day cases.
• To report and review all Near misses /HSE improvement Suggestions.
• To achieve Zero Environmental Impacts (i.e. unplanned discharges and
spillages).
•
A company of Focus, Vision & Values
Organization Chart (Management Commitment)
16
Chairman
Deputy Chairman /
CEO
Sr.Director
(Projects & Maint.)
Director
( Projects & Maint.)
Manager
Estimation /
Project
Control
Manager
HSE
Manager
Tech.Support
Managers
Construction
Manager
Contract
Manager
QA/QC
Manager
Administration
A company of Focus, Vision & Values
Workforce Mobilization
17
Kuwait Arrival
Accommodation /
Residency Facilities
Arrangements
HSE Induction
PPE’s
Distribution
Gate Pass /
Mobilization
HSE Trainings
Technical
Trainings
Competency
Trainings
A company of Focus, Vision & Values
Accommodation Facilities
18
GULF SPIC ensures that the living accommodation is of a high standard that
promotes wellness for a comfortable and safe living space. Gulf Spic provides high
quality food and cleanliness that allows the workers to maintain a healthy environment
outside of the work location. This also ensures the workers are well rested and
prepared to meet the difficult climatic conditions of summer and challenging work of
Shutdowns and Maintenance.

Housing without crowding of workers.

Hygienic Food ( Ministry of

Purified Drinking Water and Clean Sanitary facilities.

Fitness Centre.

Recreation centre that allows communications with distant families.

Library
Health Approved Food Handler & Catering Co ).
(Social journals and News papers in Arabic, English,Hindi,Tamil, Malayalam & Telugu).
A company of Focus, Vision & Values
HSE Trainings
19
Trainings

Basic Induction.

HSE Training.

Technical Training.

Competency Training.
A company of Focus, Vision & Values
HSE Training Matrix
20
Duration Hrs
Engineer
Supervisor
Foremen
Welder, Fabricators, Shop
Fitters
General Fitters / lab
Truck, LV,HV Drivers & Equip.
Operator
Scaffolders & Insuatlators
Mason, bar bender &
carpenter
Office staff
SAFETY, HEALTH, ENVIRONMENT MANDATORY TRAINING MATRIX
1
Safety Induction
2
X
X
X
X
X
X
X
X
X
2
Emergency Evacuation
1
X
X
X
X
X
X
X
X
X
3
Basic First Aid
1
X
X
X
X
X
X
X
X
X
4
PPEs Usage
1
X
X
X
X
X
X
X
X
X
5
Scaffolding & High elevation job
1
X
X
X
X
X
X
6
Electrical Safety
1
X
X
X
X
7
Fire Prevention
1
X
X
X
X
X
8
Work Permit System
1
X
X
X
X
X
X
9
X
X
X
X
S.No
Training Topics
X
Material handling
1
X
X
10
Confined Space Safety
1
X
X
X
11
Traffic Safety &Safe Driving
1
X
X
X
12
Accident Reporting & Investigation
1
X
X
X
13
Environment Awareness
1
X
X
X
14
Hand tools /power Tools Safety
1
15
Hazard communication
1
X
X
16
Office Safety
1
17
Occupational Health
1
18
Job Safety Analysis
1
X
X
19
Crane and Rigging
1
X
20
Welding and Cutting
1
X
21
Others – As required
1
Prepared by:
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
Approved by:
A company of Focus, Vision & Values
HSE Training Schedule
21
1
Safety Induction
850
2
Emergency Evacuation
850
3
Basic First Aid
100
4
Personal Protective Equipment
850
5
Scaffolding & High elevation job
100
6
Electrical Safety
850
7
Fire Prevention
850
8
Work Permit System
9
Material Handling
300
10
Excavation and trenching & Confined Space Entry
100
11
Traffic Safety & Safe Driving
12
Accident Reporting & Investigation.
13
Environmental Awareness
100
14
Hand Tools / Power tools Safety
525
15
Hazard Communication
850
16
Office Safety
17
Occupational Health
18
Job Safety Analysis
19
Crane and Rigging
20
Welding and Cutting
21
Others – as required
PREPARED BY:
Dec
Nov
Oct
Sep
Aug
Jul
Jun
May
Apr
No. of Empl.
Mar
Training Topics
Feb
S No
Jan
ANNUAL SAFETY TRAINING SCHEDULE
60
60
60
20
850
40
APPROVED BY:
A company of Focus, Vision & Values
HSE Training Passport
22
A company of Focus, Vision & Values
During Gulf Spic HSE Training
23
A company of Focus, Vision & Values
Technical Training
S.
No
24
Course Title
1
Blinding and De-blinding
2
Multi Lock Procedures
3
Pump Over Hauling
4
Welding and Cutting procedures
5
Scaffolding erection & dismantling
procedures
•
Identified by Gulf Spic Divisional Engineers
•
Implemented through Technical training
Schedule
•
Improving Competency
•
Investing in people
•
Providing Clients with a SAFER workforce.
A company of Focus, Vision & Values
Pre task ( Tool Box ) Meeting … (Further Training)
25
•
Conducted by
:
Job Supervisor
•
Witnessed by
:
HSE Representatives
•
When
:
Prior to starting the job
•
Topic
:
Based on that day’s
site Activities.
•
Participants
: All employees
•
Location
:
All Project sites/
Maintenance Shelter,
Work shops and Shut
down sites
•
Frequency of Pre task ( Tool Box )Talk
conducted
:
DAILY
A company of Focus, Vision & Values
Competency Training - MAB
26
•
Identified by Safety Department reviewed and supported by Management.
•
Implemented by GS in coordination with Clients approved Third Party trainers
S. No
Course Title
Trainer
1
Crane Operation
ABS Group Inc (Kuwait)
2
Forklift Operation
ABS Group Inc (Kuwait)
3
Scaffolding (Train the Trainer)
Scaffolding Training Institute (Houston)
4
Defensive Driving
Lloyds British Training Services (Kuwait)
5
Bundle Puller Operation
MAUS (Italia)
A company of Focus, Vision & Values
Safety Promotion Programs
•
Award for HSE Quiz winners
•
Award for best HSE posters & slogan competition
•
Award for best near miss, substandard acts &
conditions reports
•
Award for reporting best HSE suggestions
•
Award for best work permit executor.
•
World Environment day celebrations
•
Exclusive short term safety promotional programs
for shutdowns.
27
A company of Focus, Vision & Values
Incidents – Our Initiatives in MAB (Lessons Learnt)
28
Analysis of incidents that occurred during various Mechanical Maintenance activities in MAB has
resulted in identifying the causes and we have duly initiated Corrective actions & Pro-active
approach.
Root Causes:
• Inadequate Job Knowledge.
• Failure to follow the Safe work practices .
• No risk Assessment Carried out.
• Lack of communication between the working personnel.
• Failure to follow the Supervisor’s instruction.
Our Initiatives:
• Technical Training Programs are imparted to different crafts by Job Engineer / Supervisor.
• Strong Instructions given to Job Engineer / Supervisor that no critical jobs are carried out without
Work permit Risk Assessment .
• Client with Contractor Safety Representative’s involvement in Work Permit Risk Assessment .
• Work permit Risk Assessment Training conducted for all Job Engineers/Supervisors.
• Lessons learnt from incidents are communicated to all levels of employees through Tool box Talks /
Monthly HSE Internal Meetings / Training Programs.
• Employees are instructed to strictly adhere to Job Supervisor’s job instructions with safety as priority.
A company of Focus, Vision & Values
Environment Plan in Gulf Spic
29
A dedicated environment engineer assigned to comply KEPA Environmental procedures






Conduct Aspects and Impacts assessment of our activities
Ensure Proper collection, segregation , labeling and disposal of wastes as per KEPA
Procedures.
Provide Training to all workmen cadre employees in terms of solid waste management &
EMS (ISO-14001).
Promote environmental awareness activities to all workmen cadre employees and ensure their
active participation.
Ensure the availability of hazardous & Non-hazardous waste collection bins as appropriate.
Strive to minimize gaseous emission by proper maintenance of vehicles & equipments.
Sl. No
Audit Criteria
Frequency
1
EMS Awareness (ISO –14001)
Monthly
2
Solid waste Management
Monthly
3
Env. Site Inspection
Weekly
4
Env. Promotional Activities
Yearly
A company of Focus, Vision & Values
Occupational Health Practices In Gulf Spic
30
•
The GULF SPIC HSE Policy states that Occupational Health and Personal
protection of the employee is precedence over its business interests. Accordingly, all
the employees will undergo:
•
Pre – Employment Medical Examination.
•
Periodical Medical Examination.
•
Confined Space Entry Medical Examination.
•
ALL mandatory health examinations related to their occupation in Industrial
Medical Center (IMC),Ministry of Health and as prescribed by the Clients.
A company of Focus, Vision & Values
Behavior Based Safety
31
GULF SPIC recognizes the importance of the
Behavior Based Safety (BBS) for enhancing Safety
Culture by way of changing the attitude and behavior
of the employees. In this aspect, BBS Trainings are
conducted on a regular schedule. The Supervisory
personnel are trained as BBS Observers and Awareness
Training given to all Engineers/Supervisors.
Employees are motivated to carry out BBS
Observations as a part of their activity to identify AtRisk behaviors and to take appropriate corrective
action.
GULF SPIC Has awarded By KNPC MAB Refinery as
Best BBS Implementation for the year 2010-2011.
A company of Focus, Vision & Values
Awards / Accolades – Current Project
S. No
Project
Awards
32
Company
Year
1
Mechanical Maintenance Services at
MAB
Rolling trophy Award for Fy 201011 & 2011-12
Kuwait National Petroleum
Company (KNPC)
2011 & 2012
2
Mechanical Maintenance Services at
MAB
KPC CEO Golden Award Fy
2010-11
Kuwait Petroleum company
( KPC)
2010-11
3
Mechanical Maintenance Services at
MAB
&
Installation Of NEW Flare gas recovery
Unit at MAA Refinery
C&MD GOLD Award at site level
contractors FY 2010-11
Kuwait National Petroleum
Company (KNPC)
2010-11
4
Engineering and Construction
Silver Award –GGC HSE
excellence Award
American Society of Safety
Engineers(ASSE) –Kuwait
Chapter
2011-12
5
Mechanical Maintenance Services at
MAB
Winner in Best department of
Behavior Based Safety(BBS) SOLAR implementation
Kuwait National Petroleum
Company (KNPC)
2010-11
6
Mechanical Maintenance Services at
MAB
Appreciation for successfully
accomplished the On –stream
refractory repairs (worldwide
first) of MAB crude Heater on the
second time.
Kuwait National Petroleum
Company (KNPC)
2010-11
A company of Focus, Vision & Values
HSE Plan for next four years MAB (Continual Improvement)
33
Further to HSE Plan, We are focusing the HSE awareness activities for next five years.
•
To circulate Safety Alert and communicate Near Miss Events within 24 hrs of occurrence.
•
To Organize Special HSE Promotional Program during Shut down/Start up Period as to
address the increased risk of additional short term manpower (new hires).
•
To Celebrate The World Environment Day on 5th June of Every year.
•
To celebrate when we achieve every one million man-hours without Lost work day case.
•
To Plant trees on every new Gulf Spic Site office to show our Green Environment.
•
To distribute Gulf Spic HSE hand book to every new employee.
•
To organize HSE Campaigns & Annual Safety Day.
A company of Focus, Vision & Values
34
- Demand for SKILLED workers is
growing.
- Demand by Clients for to have fully
trained workers prior to contract is
growing.
- GCC Contractors are focusing on same
location for workers mostly India.
- Restrictions by Ministries and Embassies
are making Visa Requirements more
difficult therefore longer mobilization
time is required.
A company of Focus, Vision & Values
35
Gulf Spic’s Leadership is committed to ….
Putting the Welfare & Safety of People and
reducing the Impacts to OUR Environment
FIRST
THANK YOU
A company of Focus, Vision & Values

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