Managing Safe Work

at
Chevron Mining

Chevron Mining Inc.

Table of Contents

Introduction.................................................................................................................... 1

Tenets of Operation ..................................................................................................... 2

Stop Work Authority .................................................................................................... 3

Types of Work – Definitions......................................................................................... 4

SWP / JSA / SOP – Definitions................................................................................... 5

Think Incident Free / Self Performed Safety Assessment.................................... 6

Hazard Identification Tool............................................................................................ 7

Pre-Shift, Pre-Use and Planned General Inspections............................................. 8

Lockout / Tagout / Tryout . ......................................................................................... 9

Manual Material Handling............................................................................................ 10

Hand Safety Program................................................................................................... 11

Working at Heights........................................................................................................ 12

Lifting and Rigging........................................................................................................ 13

Excavation and Trenching............................................................................................ 14

Confined Space Entry................................................................................................... 15

Hot Work.......................................................................................................................... 16

Electrical Safe Work...................................................................................................... 17

Permit to Work............................................................................................................... 18

Simultaneous Operations............................................................................................. 19

Management of Change................................................................................................ 20

Workplace Observation Program................................................................................ 21

Version: 1.0 - 01/01/10

Table of Contents
Managing Safe Work Handbook

The Chevron Mining Managing Safe Work Handbook is provided to assist you in
safely performing your daily work assignments in support of our journey to an
Incident and Injury Free (IIF) workplace where all employees go home safely to their
families at the end of every shift.

This handbook provides an overview of the tools available to safely manage

your work; Tenets of Operation, Stop Work Authority, Safety Programs, Safe
Work Practices, Job Safety Analysis, Standard Operating Procedures, Workplace
Inspections, Management of Change and Workplace Observations.

It is up to all personnel to make an assessment of the inherent risks in their work

assignments using the Think Incident Free – Self Performed Safety Assessment
(TIF/SPSA) procedure to determine what other tools and safeguards should be
applied to safely perform the task.

Performing “Every Task – The Right Way – Every Time” is a personal choice
requiring your commitment along with the desire and discipline to use these tools to
ensure your safety and the safety of those around you.

The tools listed in this handbook are supported by OE processes, programs,

practices and procedures that contain additional detail. These are available from
your supervisor or OE/safety department. If you determine one of the tools in this
handbook should be used, and you are not familiar with or feel comfortable applying
the tool, please contact your supervisor, OE/safety department or site subject
matter expert for assistance.

Thanks for performing “Every Task – The Right Way – Every Time”,

Dave Partridge – VP, OE & Technical Services

Mark Premo – Senior VP - Operations

Fred Nelson – President

1
 Tenets
Table ofofContents
Operation

What are the Tenets of Operation:

• The original Tenets of Operation were identified from a root cause study of
Chevron’s refining operations
• They are a behavioral Top Ten list of lessons learned
• Tenets emphasize high risk areas of our business. When we are not operating
(behaving) in accordance with these, the probability of an event is increased
• Tenets have now been adopted as a fundamental “Code of Conduct” for our
daily behaviors, not only for refining but for the entire company
• The Tenets have two underlying principles:
- “Do it safely or not at all”
- “There is always time to do it right”

Requirements:
All personnel apply the Tenets of Operation as a part of their daily decision
making process.

2
Table of Contents
Stop Work Authority

The purpose of Stop Work Authority (SWA) is

to immediately stop all unsafe activities that
threaten the safety and health of the workforce,
put the environment in peril or create an
operational incident. Stop Work Authority
establishes the “authority and obligation” of any
individual to stop work when an unsafe condition
or unsafe act could result in an undesirable event.

Stop Work Authority uses a Stop, Notify,

Evaluate, Correct and Resume approach to
prevent incidents and establish an Incident and
Injury Free (IIF) culture.

Stop Work Authority is an expression of the care

and concern for and by the workforce. Stop Work
Authority must be supported by everyone.

Requirements:
All personnel will apply Stop Work Authority where appropriate.

3
 Types ofContents
Table of Work — Definitions

Routine Work is a work activity that takes place on a regular frequency: the
employee is always familiar with the job steps, PPE required, potential hazards and
critical actions necessary to work safely.

Non-Routine Work is a work activity that takes place infrequently: the employee has
not performed the work often enough to be completely familiar with the job steps,
PPE required, potential hazards or critical actions necessary to work safely.

Low Risk Work is a work activity that does not pose any unusual hazards, require
special PPE, require special tools or equipment or involve activities identified as
Safe Work Practices (SWPs). The employee can safely perform Low Risk Work
without using special hazard assessment tools and risk management controls.

High Risk Work is a work activity that involves one or more of the following SWPs or
has inherent risks that supervisors or workers consider high risk:
• Lockout/Tagout/Tryout - LOTO – (when not part of routine work)
• Working at Heights
• Lifting and Rigging
• Excavation and Trenching
• Confined Space Entry
• Hot Work
• Electrical Safe Work (when not part of routine work)
• Permit to Work (for work involving multiple SWPs and permits)
• Simultaneous Operations – SIMOPS (where multiple work groups interface)
• Other high risk work as identified by each business unit (BU)

Requirements:
Regardless of the work classifications described above, TIF/SPSA will be applied
to all work to ensure all tasks are assessed and performed safely.

4
Table
SWP /ofJSA
Contents
/ SOP – Definitions

A Safe Work Practice (SWP) is a single-focus procedure that describes how a

specific work activity shall be managed and completed to ensure safe work. Work
involving SWP activities is typically considered High Risk Work. Use of SWPs should
be applied on a fit for purpose basis to manage the hazards of the work.

SWPs can be used immediately before performing High Risk Work, reviewed
routinely to maintain familiarization with job hazards or used as a task training aid
for new and refresher training.

A Job Safety Analysis (JSA) is a structured approach to identify and address the
potential hazards of a specific job. A JSA considers all job steps, special PPE required
to safely perform each step, the potential hazards of the work and the critical actions
necessary to eliminate, reduce and manage hazards to safely do the work.

Formal JSAs are developed for Non-Routine Work or High Risk Work, on a fit for
purpose basis, where a JSA will provide value in keeping employees, facilities and
the environment safe.

JSAs can be used immediately before performing Non-Routine Work or High Risk
Work, reviewed routinely to maintain familiarization with job hazards or used as a
task training aid for new and refresher training.

Field JSAs may be developed on the spot to address Non-Routine Work or High Risk
Work where a Formal JSA is not available. Once the work is completed a Field JSA
may be converted to a Formal JSA if it is likely that the same job will take place again.

A Standard Operating Procedure (SOP) is a written step-by-step procedure for

completing a given task, whether low or high risk. SOPs may include instructions
related to operations, maintenance or other types of work. An SOP is used to
provide a consistent approach to performing a specific task. SOPs should be
referenced to identify job steps and potential job hazards when developing JSAs.

SOPs can be reviewed immediately before performing the work, reviewed routinely
to maintain familiarization with job procedures or used as a task training aid for new
and refresher training.

Requirements:
All personnel will apply the tools defined above as needed for each work activity.

5
 Think Incident
Table of Free / Self Performed Safety Assessment
Contents

The purpose of the Think Incident Free / Self Performed Safety Assessment
(TIF/SPSA) Safe Work Practice is to provide a tool to “size up the task” and ensure
the work can be completed safely. It is also a re-assessment tool if there are
changes to the original task.

Requirements:
1. Evaluate all tasks before starting work by reviewing and taking action on the
four steps of TIF/SPSA:
• Planning
• Proper Tools and Equipment
• Training
• State of Mind

2. Use TIF/SPSA to foster an Incident & Injury Free (IIF) culture where:
• Safety is a core value for the entire workforce
• Our belief is “No one gets hurt”
• Everyone goes home safely, every day
• Everyone shows “Care and Concern” for each other

6
Table
HazardofIdentification
Contents Tool

The Hazard Identification Tool provides

a method to identify energy sources in
your work environment, their potential
risks and options to eliminate the risks
before work commences.

Requirements:
1. Before starting work evaluate all potential energy sources.

2. Remove the energy source if at all possible.

3. Prevent the release of energy through control of work activities.

4. Protect against the release of energy using appropriate lockout/tagout/tryout

procedures.

7
 Pre-Shift, Pre-Use and Planned General Inspections
Table of Contents

The purpose of Pre-Shift, Pre-Use and Planned General

Inspections is to ensure the work environment and
equipment to be used is safe and in proper operating
condition prior to starting work.

Pre-Shift Inspection: Inspect the work area prior to the start of the work shift or
prior to the start of a job assignment. These inspections focus on identifying unsafe
conditions in the work area.

Pre-Use Inspections: Personnel (typically equipment operators) perform inspections

of mobile or major stationary equipment using a formal checklist to identify unsafe
conditions or functional deficiencies. Other pre-use inspections should be made on
all tools and equipment with a focus on unsafe conditions or functional deficiencies.
This can be accomplished as a part of the TIF/SPSA procedure – Proper Tools and
Equipment section.

Planned General Inspections: A routine inspection is conducted by supervision

and/or union safety committees. These inspections focus on identifying unsafe
conditions and less safe behaviors in the workplace.

Requirements:
1. Perform the inspections defined above per regulatory requirements and
company guidelines.

2. Correct substandard conditions, functional deficiencies or less safe behaviors

found during any inspection in a timely manner based on the risk identified.

8
Table of Contents
Lockout / Tagout / Tryout

The purpose of the Lockout /Tagout/Tryout

(LOTO) Safe Work Practice is to establish
a procedure to lockout, tagout and tryout
all energy sources. This isolation prevents
unexpected start-up, energizing or release of
stored energy.

Requirements:
1. Before personnel perform maintenance on equipment where the unexpected
start-up, energizing or release of stored energy could occur and cause injury,
the equipment shall be isolated, rendered inoperative and the isolation tested.

2. Locks, accompanied by a tag, are the preferred method of isolating electrical

energy sources. Mechanical lockout of equipment can be achieved by locking
valves, installing blind flanges, removing couplings, physically blocking out
energy sources including air, hydraulic, gear drives, or suspended parts.

3. Lockout of electrical equipment must be at the main power supply because

lockout of control switches may leave other portions of the equipment
energized.

4. When personnel need to simultaneously perform work on equipment, each

person shall be protected by a separate, individual lock.

5. Designated lockout devices shall be identified as lockout devices and shall not
be used for other purposes.

6. All lockout equipment must be tagged to identify the person, date and reason
for the lockout.

7. All locked out equipment shall be tried-out (tested) for start-up or release of
energy before beginning work to ensure the energy source is properly isolated.

8. Each lockout device shall be removed by the person who applied the device.

9. Before lockout devices are removed, the person who applied the lockout device
shall inspect the work area to ensure equipment is operational, housekeeping is
in order, and all affected personnel are notified and safely positioned.

9
 Manual
Table ofMaterial
ContentsHandling

The purpose of the Manual Material Handling

(MMH) Safe Work Practice is to eliminate, reduce,
avoid and/or control potential risks and exposures
associated with the manual handling of materials.

Requirements:
1. Train personnel so they understand Manual Material Handling exposures
and proper material handling techniques and have the ability to make safe
decisions when faced with these exposures.

2. Whenever possible address Manual Material Handling exposures in the following

order:
• Eliminate the need to manually handle materials
• Avoid the need to manually handle materials
• Reduce the exposure with proper tools and equipment
• Control the exposure with proper material handling techniques

3. Reduce repetitive motion Manual Material Handling exposures by rotating job

assignments.

4. Perform workplace observations to ensure that efforts are being made to

eliminate, avoid, reduce and control Manual Material Handling exposures.

10
Table
Hand of Contents
Safety Program

The purpose of the Hand Safety Program is to promote

awareness of hand injury risks and hand safety.
Historically, hands are the most frequently injured
body part in Chevron Mining.

The program:
• Provides tools to promote awareness of hand safety and hand protection
• Provides special glove types for various high risk activities
• Provides alternate cutting devices to replace folding and straight blade knives
• Encourages sharing of best practices across the company to reduce the
frequency and severity of hand injuries

Requirements:
1. Train personnel so they understand Hand Safety exposures and have the ability
to make safe decisions when faced with these exposures.

2. Use special glove types for high risk cutting activities.

3. Use alternative cutting devices instead of straight blade knifes.

Detailed information on the Hand Safety Program can be found on the Chevron
Mining Web Site or obtained from your local OE/safety department.

11
 Working at Heights

The purpose of the Working at Heights

Safe Work Practice is to ensure that
work at heights is performed in a safe
and controlled manner by establishing
safeguards to remove fall potential and
prevent falls.

Requirements:
1. Exhaust all work-at-grade alternatives before beginning working at heights.

2. Hazards associated with working at heights shall be identified and mitigated

prior to beginning work.

3. Fall hazards must be identified and personnel must be protected by fall

prevention or fall protection systems.

4. Working at heights equipment must be inspected periodically to ensure that it

is in good condition and safe to use.

5. Persons wearing fall-arrest systems must use 100 percent tie off and must not
work alone.

6. Scaffolding must be designed, erected, inspected, labeled and dismantled by

competent persons.

7. Rescue personnel must be trained and competent at high-access rescue

techniques, have the ability to perform their responsibilities, have the correct
rescue equipment at the work location and have a rescue plan in place before
any Work at Heights begins.

12
Table
Liftingofand
Contents
Rigging

The purpose of the Lifting and Rigging

Safe Work Practice is to ensure
that lifting and rigging work (either
horizontally or vertically) is performed
in a safe and controlled manner.

Requirements:
1. Hazards associated with horizontal or vertical lifting and rigging shall be
identified and mitigated prior to beginning work.

2. Personnel must complete the steps necessary to properly and safely prepare
the job site and equipment before the start of work. (i.e. develop lift plan if
required for non-routine or heavy lifts)

3. Ensure lifting and rigging equipment is certified for use and in good working
order through pre-use inspections.

4. Confirm the weight of the object and ensure all the equipment can safely
handle the load.

5. Establish the loads center of gravity and appropriate balance point for lifting
and placement.

6. Rig loads appropriately and ensure loads are free of possible restraints prior to
the beginning of the lift.

7. Use tag lines to control loads when appropriate.

13
 Excavation and Trenching
Table of Contents

The purpose of the Excavation and

Trenching Safe Work Practice is to ensure
that excavation and trenching work is
performed in a safe and controlled manner.

Requirements:
1. An excavation and trenching permit is required whenever work is conducted
that may adversely affect the health, environment, safety, efficiency, or
reliability of personnel or assets.

2. Hazards associated with excavations shall be identified and mitigated prior to

beginning work using the TIF/SPSA procedure or an excavation and trenching
permit.

3. Complete the steps necessary to properly and safely prepare the jobsite and
equipment for the start of work.

4. Protect personnel who enter excavations by using support systems (e.g.,

shoring, bracing, sloping, benching, or shields). Only qualified persons may
design and construct excavation support systems.

5 Inspect excavation shoring or bracing systems daily, prior to the start of each
shift and after any significant hazard-increasing event such as rainstorm,
snowstorm, earthquake, etc.

6. Cease all work in the excavation if conditions change until the situation is
evaluated and any necessary precautions have been taken to safeguard
personnel.

7. Guard, barricade and label excavation sites to avoid inadvertent access.

14
Table of Contents
Confined Space Entry

The purpose of the Confined Space Entry Safe

Work Practice is to ensure the safety of personnel
entering the two types of confined spaces:
“Confined Space” and “Permit Required Confined
Space” (PRCS). The difference between the two
types of confined spaces is the degree of hazard
and requirements for entry.

A “Confined Space” is defined as a space that has limited or restricted means for
entry or exit and it is not designed for continuous employee occupancy. Confined
spaces include, but are not limited to, underground vaults, tanks, storage bins,
manholes, pits, silos, process vessels, and pipelines.

A “Permit Required Confined Space” (PRCS) is defined as a confined space which

could exhibit any of the following hazards:
• Contains, or has a potential to contain, a hazardous atmosphere
• Contains a material that has the potential for engulfing an entrant
• Has an internal configuration such that an entrant could be trapped
or asphyxiated by inwardly converging walls or by a floor which slopes
downward and tapers to a smaller cross section
• Contains any other recognized serious safety or health hazard

Requirements:
1. Each BU will evaluate the workplace to determine if any spaces are Permit
Required Confined Spaces and inform employees who could be exposed by
posting signs and providing training.

2. PRCS entry will be controlled by a Confined Space Entry Permit.

3. For non-permit required Confined Spaces, applicable sections of the Confined

Space Entry Permit will be used based on the inherent risk.

15
 Hot Work

The purpose of the Hot Work Safe

Work Practice is to enable hot work to
be performed with mitigation in place
to address all risks that could cause
incidents (fires or explosions) or injuries.

Requirements:
1. A Hot Work Permit must be developed prior to initiating any work activity that
introduces an ignition source to a job site that has the potential for ignition of
flammable materials or vapors.

2. Personnel performing work shall be trained and responsible to recognize Hot

Work situations, request a Hot Work Permit (HWP) when required and use Stop
Work Authority should a Hot Work situation arise during work.

3. Hazards associated with Hot Work shall be identified and mitigated prior to
beginning work.

4. Before Hot Work is initiated, a Hot Work Permit must be completed along with
the steps necessary to properly and safely prepare the jobsite and equipment
for the start of work.

5. Stop all Hot Work if a hazardous situation is identified and restart only after
the necessary precautions have been taken to safeguard personnel and assets.

16
Table of Contents
Electrical Safe Work

The purpose of the Electrical Safe Work Practice

is to provide guidance in safely performing
electrical work to ensure employees who work
on or near electrical equipment identify, assess
and comply with the requirements for performing
electrical work.

Before After

Requirements:
1. Maintain electrical systems and electrical equipment in a safe condition.

2. Electrical work will only be performed by qualified electrical personnel.

3. All individuals performing electrical work must have clearly defined roles.
When selecting personnel for electrical work, consideration should be given to
their level of experience.

4. Persons who perform electrical work at coal mines are required to receive
annual electrical refresher training approved by the Mine Safety and Health
Administration.

5. Persons who perform electrical work at metal/non-metal mines are required to

receive training as specified by the regulations in the State where the mine is
located.

6. Electrical training should be site specific and attended by persons in charge of

electrical workers as well as persons who perform the work.

7. Persons performing electrical work will use the appropriate specialized PPE as
warranted by the risk level of the work.

17
 Permit to Work

The purpose of the Permit to Work

(PTW) Safe Work Practice is to provide
a procedure that ensures work permits
are used when necessary to safely
manage work with mitigation in place
to address all risks that could cause
incidents or injuries.

Requirements:
A Permit to Work must be developed before starting any work that requires the use
of multiple work permits as identified by the safe work practices listed below. This
ensures that risks from individual safe work practices and permits are coordinated
under an umbrella Permit to Work.
• Hot Work Permit
• Confined Space Work/Entry Permit
• Excavation Work Permit
• Working at Heights Permit
• LOTO - Stored Energy Permit (high voltage work)
• Lifting and Rigging (permit required for heavy or specialized lifts)
• Electrical Work (permit required for specialized high voltage work)
• Other BU specific permits or safe work practices considered appropriate by
the work supervisor or worker

18
Table of Contents
Simultaneous Operations

The purpose of the Simultaneous

Operations (SIMOPS) procedure
outlined in the Permit to Work Safe
Work Practice is to identify situations
where Simultaneous Operations
are taking place and, if deemed
appropriate, develop a Permit to Work
to assist in coordinating activities
between work groups.

Examples of potential SIMOPS situations are listed below:

• Construction work in an operating area
• Contractors working with or among employees
• Multiple contractors working on a project
• Multiple departments working on a project
• Startup of a new system within an existing operating area
• Turnover of a project from a contractor or department to operations

Requirements:
1. A Permit to Work should be issued when Simultaneous Operation situations
arise where close coordination between work groups is beneficial.

2. The person in charge of the operating area or project where the work is being
performed will determine if a Simultaneous Operations - Permit to Work will
add value in coordinating and completing the work in a safe and controlled
manner.

19
 Management of Change
Table of Contents

The purpose of the Management of Change Process (MOC) Process is to provide a

standard process for managing change that considers the effects of a change on
safety, environment, health, reliability and efficiency. The process is designed to
ensure all change activities (operational, organizational and business process) are
reviewed, approved, communicated and documented to eliminate the likelihood of
incidents prior to, during and following the change.

For the purposes of the MOC process, a change is defined as a deviation from an
existing condition (operational, organizational or business process) and includes
changes by the introduction of new equipment or conditions, modified equipment
or conditions, new or modified ways of operating, significant organizational or
significant business process modifications. MOC changes can be permanent,
temporary or emergency.

Requirements:
1. If the work you are undertaking falls into a Management of Change category,
contact your supervisor and site subject matter expert for guidance.

2. Use the MOC procedure flow chart and forms to develop the information and
actions required to properly address a change.

3. Implement the actions identified during the MOC procedure to ensure the
change happens in a safe and controlled condition.

4. Communicate changes to those personnel impacted by the change.

5. Document all changes, including updates to any facility information. (drawings,

electrical diagrams, flow diagrams, P&ID’s, etc.)

20
Table of Contents
Workplace Observation Program

The purpose of the Workplace Observation Program, commonly referred to as

IIF in Action or Behavioral Based Safety, is to provide a fundamental system for
protecting employees’ safety using behavior-based methods that:
• Maximize use of positive reinforcement, such as praising and rewarding the
use of “More Safe” behaviors
• Emphasize proactive activities, such as identification of “At-Risk or Less-
Safe” behaviors
• Capitalize on the job expertise of employees
• Integrate workplace observations with daily business activities
• Practice “providing direction from the top down while solving problems from
the bottom up”
• Maximize sharing of lessons learned and best practices throughout the
organization

Requirements:
1. Each BU will have a BBS or IIF in Action program.

2. All employees will be trained in the purpose and use of the program.

3. BUs will track, analyze and report monthly the number of observations, more
safe and less safe behaviors.

4. Based on the observation data, BUs will identify and implement behavior
improvement activities.

21
Operational Excellence
Operational Excellence is the systematic management of
safety, health, environment, reliability and efficiency to
achieve world-class performance.

OE Vision
To be recognized and admired by industry and the
communities in which we operate as world-class in safety,
health, environment, reliability and efficiency

OE Objectives
• Achieve an injury-free work place.
• Promote a healthy workplace and mitigate significant
health risks.
• Eliminate spills and environmental incidents. Identify and
mitigate key environmental risks.
• Operate incident-free with industry-leading asset reliability.
• Maximize the efficient use of resources and assets.

Chevron Mining Inc.

116 Inverness Drive East, Suite 207
Englewood, Colorado 80112