Project Safety

This post is about 2 aspects of “project safety” – safety during the installation and safety of the finished project.

Installation safety
You’re probably on top of this, but here are a few highlights, whether it’s contractors or your own in-house folks:

• Clearly-defined daily work scope. Whether you start the day with an official work permitting process, a quick huddle, or you depend on the contractor’s JSA process, each day’s work scope should be clear to everyone involved. That includes you (project engineer/manager), the foreman, and your Operations folks in the area. No surprises.
• Hot Work – anything that makes a spark. Welding, torch work, grinding – you should have a robust hot work permit process, and your installation folks should have someone on firewatch with a fire extinguisher. All combustibles should be cleaned up before the work starts.
• Welding machines – be sure you have adequate ventilation in the area and the welders shut them down when not in use. CO builds up faster than you’d expect. I suggest you put an air monitor out there.
• Gloves, safety glasses, fall protection harnesses, face shields – stay on top of your workers’ PPE. Especially after breaks and lunch. I know you don’t want to be “that guy.” Too bad – it’s part of the job.
• Barricade tape – when in doubt, tape off the work areas. Red (keep out) or yellow (ask first) tape can keep folks out that don’t need to be there.

Equipment/Machine safety
Here I’m talking about the safety of the finished project.
You really need your HSE folks or someone that knows what they’re looking at to review the design well before installation starts. You don’t want a bunch of new action items added on the PSSR on the last week of the installation. (e.g., “Hey, the spacing on these stairs isn’t OSHA compliant.” That’s a couple days.)

• Stairs, ladders, handrails, hoists and cranes – OSHA has specific requirements for these. Your contractors will probably catch any major deviations and raise questions if you have a decent relationship. (Do your part to keep a good relationship!) Most engineers in the US will be familiar with the requirements, but if you’re getting equipment from overseas? Better check.
• Machine guarding – review the design and walk the installation early and often. Look for any places where someone could reach into a piece of equipment, even if you think they would never have a reason to do so.
• Ergonomics – Have you reviewed the design of your equipment and process to ensure the operators will be working safely? Minimize lifting and manual handling.
• Maintenance – is the equipment safe and easy to access for maintenance? Speaking of relationships – maintenance can make or break a project engineer. Make ‘em happy; well, at least don’t give them a reason to be unhappy.
• Sharp edges – check all those hand rails and guards for sharp edges.
• LOTO – do you have Lock-Out points (disconnects, switches) for all the equipment?
• Tie-off points for fall protection?
• Grounding – electrical grounding but additional grounding and bonding if you’re in classified areas (vapors, combustible dust, fibers and flyings.)
• Are you adding equipment that has oil or hydraulic fluid? HSE needs to know quantities. Over a certain amount, you need spill containment.
• New raw materials? Let your HSE folks know.

When I was a younger project engineer, I was not interested (enough) in all the OSHA and TCEQ requirements – “somebody else’s job.” Then I spent 7+ years as an HSE Manager. Save yourself some rework and change orders! Talk to your HSE or safety folks early in the design phase and prior to and during installation.

As always, if you need some outside help, from somebody who has done projects and HSE, email or DM me! I can help you! I can review your design, discuss your installation plans, and help you spot any issues before it’s too late.