section_09-gpca_workshop_2013_q

Report
Presented by:
Ahmad Homssi
Environmental Manager
Qatar Chemical Company Limited
(Q-Chem)
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Q-Chem in Few Words
Qatar Chemical Company Limited (Q-Chem), Qatar Chemical
Company II Limited (Q-Chem II), Ras Laffan Olefins Company
Limited (RLOC), Qatar Chemical Shipping Company, and Qatar
Chemical Shipping Company II.
Operates both in Mesaieed Industrial City and Ras Laffan Industrial
City with over 1,200 employees and over 600 contractors.
Produces Ethylene, High and Medium Densities Polyethylene, 1Hexene, Normal Alpha Olefins, and Sulphur as By-product.
ISO-9001, ISO-14001, and RC-14001 certified at all operated
facilities.
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Responsible Care® Program at Q-Chem
Q-Chem joined GPCA in late 2009 and committed to implementing
the RC-14001® at all operated facilities in March 2010.
Q-Chem was authorized to use GPCA / RC logo upon completing
RC-14001® gap analysis in September 2010.
Q-Chem efforts focused on upgrading company Operation
Excellence (OE) Manual inherited from Chevron Philips Chemicals
to meet RC-14001® additional requirements.
Q-Chem had to adjust 100’s of plans, procedures, programs, systems,
and even contracts and work relations to satisfy RC-14001®.
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Q-Chem Responsible Care® Program and
Contractors Involvement
Contractors at Q-Chem are, but not limited to, suppliers of raw
materials, goods, maintenance services, shipping and products
distribution services, products storage and staging services,
consultancy services, and contracted customers, to mention few.
Q-Chem follow the OSHA standards strictly in all work aspects and
consider anyone working onsite (member of the house).
Q-Chem has safety culture awarded 5 times, including silver award
in 2011 and golden award in 2012 by Ministry of Energy and
Industry, Qatar, and 7 times award in environmental management
including GCC award in 2006.
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Q-Chem Responsible Care® Program and
Contractors Involvement
Contractors and Company Employees are equal in responsibilities
to safety, environmental, and security responsibilities.
Baseload Contractors share with Company Employees offices,
canteen, safety meetings, campaigns, and even FRC and other PPE.
We’re ~ 30 nationalities at Q-Chem, but talk one language, that is
SAFETY.
It is a MUST that contractors are actively involved in Job Hazards
Analysis, Toolbox Talks, Job Pre-starting Reviews, and signing PTW
ONLY when all are done.
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Q-Chem Responsible Care® Program and
Contractors Involvement
To ensure contractors full adherence to Q-Chem culture and high
standards, a lot of work was there for both parties.
Number of governing responsibilities, rules, regulations, standards,
and contracts had to be re-framed by Q-Chem and communicated to
contractors through training.
This was a success story.
The following slides will explain how and why.
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Q-Chem Responsible Care® Program and
Contractors Involvement – Pre-Contracting Stage
Accurate description of intended work scope and areas of work are
critical.
Designated Site Representative (DSR) shall include
information about all involved Risks upon issuing SOW for any new
or renewed contract.
Bidders (potential Contractors) given “Self Audit Questionnaire” and
requested to complete and submit with their bids along with specific
information for review, including:
 Copies of their Safety/Health programs and Policies;
 Training and orientation programs;
 Information regarding contractor’s Injury History; employee
injury/illness data for the previous three years
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Q-Chem Responsible Care® Program and
Contractors Involvement – Pre-Contracting Stage
Minimum Safety Metrics
 Zero Fatalities in previous 3 years at all locations worked by
the contractor
 Total Recordable Injury Rate (TRIR) ≤ 4.0
 Days Away From Work Rate (DAWR) ≤ 2.0
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Q-Chem Responsible Care® Program and
Contractors Involvement – Pre-Contracting Stage
Contractor pre-qualification included the bidding contractor’s safety
records, adopted safety programs, safety training of their personnel,
and use of database adopted Qatar-wide by Qatar Petroleum for
approved contractors.
All of that were done beside technical evaluation, commercial
evaluation, and legal evaluations.
Failure to meet any of these requirements would disqualify the
bidding contractor for being on shortlisted.
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Q-Chem Responsible Care® Program and
Contractors Involvement – Post Contracting Stage
Before Starting Any Work Onsite
All training must be completed before any work on-site
Following is the Q-Chem Contractors Training Matrix Summary
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Q-Chem Responsible Care® Program and
Contractors Involvement – Post Contracting Stage
Level (I)
Level (II)
Level (III)
Required for all Employees
or Contractors who:
Employee or Contractor who
does not meet the Level 1
criteria
For all visitors, vendors, and
delivery personnel, as well as
Contractor employees who
provide or supervise work
that does not involve
physical work activity (e.g.,
advisors,
consultants,
auditors, etc.).
 Physically enters the
process areas, and/or,
 Works on equipment that
affects the process units,
and/or,
 Performs a task that
involves a life critical
procedure
Training Shall be as per the
Global Training Matrix
Training Shall be as per the
Global Training Matrix
Level
III
Contractor
employees shall be escorted
at all times by a COMPANY
facility employee or a Level I
Contractor while in the
process area.
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Q-Chem Responsible Care® Program and
Contractors Involvement – Post Contracting Stage
Before Starting Any Work Onsite
Training Exams done for verification of understanding.
Training examination scores are minimum of 70% correct to pass
1 re-test is allowed per six month period
Contractor employee who is determined to be cheating during Level I
and Level II examinations will be disqualified from work.
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Q-Chem Responsible Care® Program and
Contractors Involvement – Post Contracting Stage
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Q-Chem Responsible Care® Program and
Contractors Involvement – Post Contracting Stage
Safety Group keeps monitoring contractor work activities and safety
performance and functions as the Contractor Safety Coordinator to
maintain a contractor safety program, including appropriate security
requirements, and conducting periodic safety meetings to address
contractor health and safety issues.
It is very important that contractors receive regular communication
and feedback relative to their safety performance and progress.
Watch  Listen  Ask  Note  Evaluate  Give Feedback 
Check  Adjust  Watch …..
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Q-Chem Responsible Care® Program and
Contractors Involvement – Post Contracting Stage
The contractor’s Designated Site Representative (DSR) ensures
that contract personnel are trained as necessary to perform their work
in a safe manner and monitors for compliance with applicable
policies, procedures, rules, and regulations.
DSR serves as the primary contact for all contractor incident,
accident, and injury reporting and recordkeeping. DSR periodically
reviews and evaluates contractor work performance and provides
appropriate feedback/ evaluation
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Q-Chem Responsible Care® Program and
Contractors Involvement – Post Contracting Stage
Company personnel reviews with contractor personnel the process
hazards and applicable procedures, policies, work practices, and
information necessary to perform their work in a safe manner.
Company personnel keep appropriate communications with
contractor personnel in the work area to ensure any changes in
process conditions, unit status, or other work activities are made
known to contractor personnel.
Company personnel periodically observe contractor work
performance and provide feedback to the assigned DSR, Contractor
Work Coordinator, and/or the Contractor Safety Coordinator.
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Q-Chem Responsible Care® Program and
Contractors Involvement – Building Culture
Unconscious
Competence
Conscious
Competence
Conscious
Behavior
Incompetence
Skill
Unconscious
Incompetence
Knowledge
Give Training
Build Skills
Improve Behaviors
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Q-Chem Responsible Care® Program and
Contractors Involvement – Standard Practices
Meetings for nested contractors are conducted on a monthly basis
attended by contractor employees and management representative,
contractor safety coordinators, and company representatives,.
Meetings for overseas contractors are conducted on a annual basis
attended by contractor management representatives, company senior
management and Public Relations (agents, distributors, shippers, etc).
Company representatives conducts periodic documented audits
online and feedback contractor performance to contractor
management, company management, safety, and contracts
engineering.
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Q-Chem Responsible Care® Program and
Contractors Involvement – Standard Practices
When “Heat Index” is > 36 C:
 Work / Rest Cycles based on index
value and workload.
 Everyone treated equally.
 There is always time to do it right.
 15 May to 31 October every year.
 Mitigation Plans (Pre-approved)
 Special arrangements for Ramadan
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Q-Chem Responsible Care® Program and
Contractors Involvement – Standard Practices
Customer Feedback and Empowerment Process
Q-Chem developed systems for
measuring customers satisfaction
including contractors, community,
buyers, etc:
Quality
Services
Logistic
 Customer Satisfaction is measure
of success.
 Customer Feedback is key for
designing improvements
 Everyone is encouraged to give
feedback and stop at-risk acts.
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Q-Chem Responsible Care® Program and
Contractors Involvement – Contractor Newsletter
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Q-Chem Responsible Care® Program and
Contractors Involvement – Win / Win Situation
100% completion of behavior-based safety
process (QSAFE) bonus metric.
Hence
improving trend of at-risk behaviors/
corrections needed noted on observations.
Zero recordable injuries ongoing for over 3
Year at RLOC and over 8 months at Q-Chem
and Q-Chem II. No Heat-Related Illnesses or
Injuries YTD
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Q-Chem Responsible Care® Program and
Contractors Involvement – Win / Win Situation
Among the 18 world-wide selected finalist for CPChem
Contractor Safety Excellence Award, 6 winners were
Q-Chem Contractors:
1- Draieh Logistic Services Co.
2- Peregrine Projects & Solutions
3- Trading & Agency Services
4- ISC Group Gulf
5- Specialized Transport
6- Insulation Engineering Co. (President Award)
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Any questions?
Following this presentation, if you still have any questions or inquiries, please contact Ahmad Homssi,
Environmental Manager, Qatar Chemical Company (Q-Chem) at office on
4476-7310 or e-mail < [email protected] >
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