BECHTEL INTERNATIONAL INC.

CASE STUDY
Atlantic LNG Trinidad Train 4 Project
Benchmark
Subcontractor Safety Performance
Through
Leadership and Ownership
PRE - 1996

2005 CPI CONFERENCE

PRESENT

Leadership of Tomorrow Bridging the Gap

Presented by
Tom Hill
DaCosta Kirton
Geoff Cislo

OBJECTIVES
1. Agree that world class Safety Performance is
possible in countries that do not have world class
safety regulations
2. Validate the importance of strong leadership skills in
implementing a zero accident program
3. It is possible to overcome cultural / social
stereotypes that can negatively affect Safety
Performance

2005 CPI CONFERENCE

Leadership of Tomorrow Bridging the Gap

OBJECTIVES
4. Concur that continuous Safety improvement
requires management /supervision to be on the
field" making it happen not in the stands cheering
5. You can implement a People Based Safety
program that works, in a culture with no previous
experience

2005 CPI CONFERENCE

Leadership of Tomorrow Bridging the Gap

TRINIDAD & TOBAGO

BACKGROUND
- British control in the 19th
century.
- Independence in 1962.
- One of the most
prosperous in the
Caribbean thanks largely
to petroleum and natural
gas production and
processing.
- Located in the Caribbean
between the Caribbean
Sea and the North Atlantic
Ocean and is northeast of
Venezuela.
2005 CPI CONFERENCE

Leadership of Tomorrow Bridging the Gap

TRINIDAD & TOBAGO

- It covers a total area of 5128 sq km
and is slightly smaller than
Delaware.
- 590,000 Trinbagonians make up the
Labour force
- Trinidad & Tobago has a population
of 1,275,700 persons:

40.3% consist of East Indian

39.5% consist of of African

18.4% consist of a Mixed origin
0.6% consist of Caucasian
1.2% consist of Chinese and
other races.
2005 CPI CONFERENCE

Leadership of Tomorrow Bridging the Gap

Safety and Health, Goals and Targets, and

Expectations
TRINIDAD TRAIN 4 PROJECT GOALS

SAFETY & HEALTH:

Achieve zero incidents by providing a work environment where Safety Performance is optimized and risks
are managed to prevent accidents during Plant Construction and Operation.
LNG PRODUCTION:

Meet or exceed Trinidad Train 4 Project performance guarantees and availability.

SCHEDULE:

Achieve takeover of the facilities on or before the schedule completion :

Train 4
TBD

Tank 4
TBD

Obtain full commitment from all contractor personnel, subcontractors and project team.
COST:

Reduce Project Costs for all Stakeholders.

QUALITY:

Design, engineer, procure, construct, commission and bring into operation an LNG plant that meets or
exceeds project requirements and industry standards that will produce LNG safely and cost effectively
throughout the design life of the plant.

WORKING RELATIONSHIPS:

Create and maintain mutual relationships characterized by open communication, trust, honesty and
commitment to shared goals.
ENVIRONMENTAL:

Design, construct and operate a plant in conformance with current Government of Trinidad & Tobago
standards and international environmental guidelines and practices consistent with the LNG industry both in
Trinidad & Tobago and worldwide.

Establish or reinforce environmental policies that make positive social and economic impacts on the
surrounding areas.

Secure all permits & licenses from regulating authorities in a timely manner to meet project schedule

Project Goals
- Achieve ZERO incidents by
providing a work environment
where Safety Performance is
optimized and risks are managed
to prevent accidents during plant
Construction and Operation.
MEETING / EXCEEDING
CUSTOMER EXPECTATIONS
VIDEO

2005 CPI CONFERENCE

Leadership of Tomorrow Bridging the Gap

Safety and Health, Goals and Targets

Project Performance Measurement Values

Threshold
Value

Target
Value

Stretch Value

RECORDABLE

1.00

0.55

0.25

LTA

0.20

0.10

0.00

Developed by customer and included in

contract
Basis for rewarding performance as part of
Incentive program
Threshold value = Upper Boundary value that
must not be exceeded to earn incentive
payment.
2005 CPI CONFERENCE

Leadership of Tomorrow Bridging the Gap

Safety and Health, Goals and Targets

Target Value = Midpoint value required to earn the
incentive payment.
Stretch Value = Lower Boundary value required to earn
the incentive payment.

CATEGORY
OSHA RECORDABLE
LTA
FATALITIES
CUSTOMER SATISFACTION

2005 CPI CONFERENCE

WEIGHT %

20
20
30
30

Leadership of Tomorrow Bridging the Gap

EXISTING CONDITIONS /FACTORS AFFECTING

SAFETY PERFORMANCE
TRINIDAD AND TOBAGO HAS NO CURRENT ES&H
REGULATIONS

Proposed 2003 Draft HSE Bill still to be signed.

TRINIDAD AND TOBAGO COST OF ACCIDENTS 1976-1998

Direct Cost = US$ 25,000,000 (Source: National Insurance Board)

Indirect Cost = US$ 100,000,000
Total Cost

2005 CPI CONFERENCE

= US$ 125,000,000

Leadership of Tomorrow Bridging the Gap

CII ZERO INJURY TECHNIQUES

IMPLEMENTED
MANAGEMENT COMMITMENT

WORKING RELATIONSHIPS

GOALS:

Create and maintain mutual relationships characterized by open communication, trust,

honesty and commitment to shared goals.

STRATEGIES:

Conduct a survey (minimum every 3 - 6 months) in Site, Houston, Port of Spain and key
interfaces .

If survey result less than 85% , conduct a follow up teambuilding session.

If survey result greater than 85%, have a team celebration.

Provide Bechtel/ALNG/ Phillips Leadership Training to assist in developing a high

performance team.

TARGETS:

Survey results: Threshold 75% ; Target 85% ; Stretch 100%

- Working Relationship

- Resources
- Transfer of Technology
- Accept Ownership of Safety Process
- Incident investigation
- Zero Accident Team
(HSE Governance Committee)

VIDEO

2005 CPI CONFERENCE

Leadership of Tomorrow Bridging the Gap

SAFETY & HEALTH

CII ZERO INJURY TECHNIQUES

IMPLEMENTED

GOAL:

Achieve zero incidents by providing a work environment where Safety Performance is optimized and risks are
managed to prevent accidents during Plant Construction and Operation.

STRATEGIES:

Implement an effective behaviour based Safety and Health Program.

Fully comply with Atlantic LNG Safety and Health requirements.

Raise the level of Safety Awareness.

Control exposure to risks.

Increase management involvement in the safety process.

Perform Quarterly Safety & Health Management Audits.

Conduct Weekly Safety Inspections/Assessment.

Provide New Hire Orientation for 100% of the workforce.

Provide Job Safety Analysis training ( 100% of supervisory staff).

Conduct Environmental Awareness training ( 100% of workforce).

Conduct Random Drug Screening ( 1% of workforce).

Conduct Joint Emergency Evacuation/ Exercises ( 1 per Quarter).

RISK REDUCTION METHOD

- Pre-project and Pre-planning
- Training and Education
- Accident-Incident Management
- Drug Alcohol Program
- People Based Safety
- Audits / Inspections

VIDEO

2005 CPI CONFERENCE

Leadership of Tomorrow Bridging the Gap

CII ZERO INJURY TECHNIQUES

IMPLEMENTED
RECOGNITION AND REWARDS
- Attendance Incentive
- Safety Incentive
- Fringe Incentive
- (S.H.O.T) Safe Habits Observation Team
Incentive
- Contractor Performance Incentive

SUSTAINABILITY
- Customer Satisfaction
- Future work

2005 CPI CONFERENCE

Leadership of Tomorrow Bridging the Gap

Safety Performance Summary

1st August 2002 30th June 2005
OSHA Recordables

10

Lost Time Accident (LTA)

Lost workdays

1059

Days without LTA

Manhours without LTA

10,444,057

Manhours without OSHA 6,346,342

Recordables

Start of construction : 1st August 2002

Manpower on site: 3,300 workers
TRAIN 4

RECORDABLE
LTA

2005 CPI CONFERENCE

THRESHOLD
VALUE

TARGET
VALUE

STRETCH
VALUE

RESULTS

1.0

0.55

0.25

0.19

0.20

0.10

0.00

0.0

Leadership of Tomorrow Bridging the Gap

Subcontractor Safety Performance (Project to Date)

Contractor

Raghunath Singh
Paramount Transport
Pres-T-Con
Hafeez Karamath
(demob)
Damus
Damus Fire Water
Tank
B Joy Plumbing
Badrie and
Sons(Janitorial)
Badrie (Water)
Bechtel
CISL (equipment and
painting)
DMC
Gordon Winters
(demob)
Insertech

Job-hours
Project To
Date
(PTD)

No. OSHA
Recordable
Incident(s)

No. of
LTA(s)

698,831
598,723

3
1

0
0

327,350
411,660

1
2

0
0

2,004,475
13,286

3
0

0
0

77,783

3,929

37,820
887,845
334,109

0
0
0

0
0
0

1,256,167
51,502

0
0

0
0

92,202

2005 CPI CONFERENCE

0.85
0.33
0.61

0
0
0

0.19
0.29

0
0

0
0
0

0
0
0

0
0

0
0

0
0

0
0

Recordable LTA Accident

Incident
Rate
Rate

Leadership of Tomorrow Bridging the Gap

Subcontractor Safety Performance (Project to Date )

Contractor

Job-hours

Insulation
Trinidad Ltd
Joseph Badrie &
Sons (Special
Assignment)
Jusamco Pavers

86,119

No. OSHA
Recordable
Incident(s)

No. of
LTA(s)

23

165,508

Kentz OJs
Mammoet
Nuovo Pignone

564,177
58,115
2,205

0
0
0

0
0
0

Ratio (demob)
Ramdhansingh
ReadyMix
S&D
Construction
Shade
SIS
Sure Security

101,471
210,410
86,123
332,964

0
0
0
0

0
0
0
0

182,852
140,634
463,053

0
0
0

0
0
0

8,287
16,472

0
0

0
0

23,022
286,031

0
0

0
0

1,856

Thermodyn
Trinidad
Sanitation
Trintoplan
Westminster
Dredging
Wholesale
Electrical
Supply
William
Bartholomew

6,145

2005 CPI CONFERENCE

Recordable
LTA
Incident Accident
Rate
Rate
0

0
0
0
0
0
0
0

0
0
0
0
0
0
0

0
0
0
0
0

0
0
0
0
0

0
0

0
0

Leadership of Tomorrow Bridging the Gap

TRINIDAD TRAIN 4 PROJECT

Safety Perception Survey - 7/2004
NO. OF RESPONDERS / GROUP
CRAFT
(MANUAL)

CRAFT SUPER
(NON-MANUAL)

BECHTEL
(NONMANUAL)

CUSTOMER
(NONMANUAL)

380

54

179

13

% YES

% YES

% YES

% YES

79

89

89

77

86

87

90

92

83

80

91

77

Has your Supervisor required you to carry out any

job or task that you felt was not safe?

18

Do you think schedule takes priority over safety at

any time on this project?

44

22

27

23

94
77

91
81

93
89

85

AREA
Project Management Support of Safety
Procedures
Does Project Management visibly and actively
participate in the safety process?
Are supervisors supported by Project Management
in their decisions relating to safety?
Has Project Management's efforts encouraged you
to work more safely?
Schedule Priority Over Safety

Personal Commitment to Safety

Has your attitude toward safety gotten better since
you started working on this Project?
Do you think zero accidents are achievable?
2005 CPI CONFERENCE

Leadership of Tomorrow Bridging the Gap

92

TRINIDAD TRAIN 4 PROJECT

Safety Perception Survey - 7/2004
NO. OF RESPONDERS / GROUP

CRAFT
(MANUAL)

AREA
Do you feel this is your safety program?
Do you think employees are committed to achieving
zero accidents?
Supervisors Commitment / Support to Safety
Process
Does your Supervisor regularly discuss safety goals
and performance with employees?
Does your Supervisor show a personal interest in
having a safe job?
Do you think your foreman is committed to
achieving zero accidents?
Are you encouraged by your supervisor to participate
in the site's safety program?

CRAFT SUPER
(NON-MANUAL

BECHTEL
CUSTOMER
(NON(NONMANUAL
MANUAL

75

76

79

69

82

91

79

62

84

85

73

92

92

91

93

100

91

91

77

54

88

89

85

100

88

89

81

77

88

83

96

77

People Based Safety Increases Safety Awareness

Do you think Craft workers observing other Craft
workers to provide feedback on safe and risky
behaviors makes you more aware of safety?
New Hire Orientation Effective
Is the Project new employee safety orientation
efficient in preparing you for work on the
project?

2005 CPI CONFERENCE

Leadership of Tomorrow Bridging the Gap

Project Management Team Commitment /

Ownership
-Leadership role in ES&H
-Positive Working relationships
with customers and
subcontractors
-Work Execution Philosophy: for
us (Bechtel) to be successful,
we have to make our
Subcontractors successful

2005 CPI CONFERENCE

Leadership of Tomorrow Bridging the Gap

Project Management Team Commitment /

Ownership
- Mandatory attendance at plan of the
day and Tool box meetings
VIDEO

Bechtel International Inc.

Atlantic LNG Expansion Projects
Job Nos.: 24560
Environmental, Safety & Health
Department

(4th July 2005)

The Train 4 Project has worked 10,444,057 hours as of
th
25 June 2005 without a lost time injury. The last
recordable was on the 23rd May 2005. We have had ten
(10) OSHA Recordable to date.
Please pay attention to the following:
Permits Application for work permits must be
turned into Bechtel Safety Department at least 24 hrs
in advance.
Access The ISBL is becoming a parking lot for
personal cars. Please do not park in the process areas.
Lockout / tag out Reminder, all persons involved in
working on systems must perform visual checks (for
tags and locks).
Valves/Cables Tags on valves and other equipment
are being removed, anyone caught removing tags will
face disciplinary action.
Color code The color code for this quarter (July
September) is BLUE

2005 CPI CONFERENCE

- Provide resources and staffing level of

one (1 ) Safety Representative / 50
workers minimum
- Bechtel, Customer, Subcontractor
Weekly Management Safety Walk
downs per area
- Increased Management attendance /
participation via Specially prepared
Monday Management Safety Talk

Leadership of Tomorrow Bridging the Gap

Project Management Team Commitment /

Ownership
- Zero Accident Team is the
HSE Governance Committee
- Mission Statement A
committee of your Company's
most Senior Management
personnel who meet twice
monthly to hold discussions
on providing guidance,
assistance and leadership to
all employees on the jobsite
on the Projects Safety and
Health Program

2005 CPI CONFERENCE

Leadership of Tomorrow Bridging the Gap

RISK REDUCTION METHODS

RAISING LEVEL OF SAFETY
AWARENESS
Naming on Plot Plan and Drawing the
Permanent Plant Roads/Streets with a
Safety Related Name :
-Zero Tolerance
-Safe Way blvd
-Done Done Road
-Hard Hat Lane
-Toe Board Alley
- Walk the Talk
VIDEO

2005 CPI CONFERENCE

Leadership of Tomorrow Bridging the Gap

RISK REDUCTION METHODS

TRANSFER OF TECHNOLOGY

VIDEO

2005 CPI CONFERENCE

OSHA 10 hours training to craft apprentice

Teaching evening classes on / off jobsite
Advisor to Emergency Management Authority
EX-Chairman of Safety Council of Trinidad
and Tobago South West Chapter
Permanent Representative on NonGovernmental Organization Area Hospital

Leadership of Tomorrow Bridging the Gap

RISK REDUCTION METHODS

ROAD SAFETY AWARENESS

2005 CPI CONFERENCE

Leadership of Tomorrow Bridging the Gap

RISK REDUCTION AUDIT INSPECTIONS

QUARTERLY INSPECTION ON RIGGING /
LIFTING EQUIPMENT
-Colour code by quarter
-Fluorescent paint/tape
-Security tie/seals on heavy use rigging
1st
QUARTER

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2nd
QUARTER

3rd
QUARTER

Leadership of Tomorrow Bridging the Gap

4th
QUARTER

RISK REDUCTION TRAINING AND

EDUCATION
REDESIGNED
ORIENTATION /
PROCESS

- To provide information on
Safety, Quality, Industrial
Relations, Timekeeping,
Health, security, ISPS,
Badging
-Increased attention and
Interest

2005 CPI CONFERENCE

Leadership of Tomorrow Bridging the Gap

RISK REDUCTION PEOPLE BASED SAFETY

INNOVATIVE APPROACH ON
IMPLEMTATION PROCESS
- STAGE 1 100% BECHTEL NON
-

2005 CPI CONFERENCE

MANUAL
STAGE 2 50% BECHTEL /
SUBCONTRACTOR NONMANUAL
STAGE 3 100% CRAFT
CROSS CRAFT CONTROL
PRE-ACCEPTANCE ENVIRONMENT

Leadership of Tomorrow Bridging the Gap

RISK REDUCTION ACCIDENT

MANAGEMENT
INCIDENT INVESTIGATION
- Integrated Investigation Team for High /potential
Incidents Investigation with Bechtel, customer,
subcontractor
- Management trained in how to perform Root
Cause Analysis from start of project and retrained
as construction progressed.

2005 CPI CONFERENCE

Leadership of Tomorrow Bridging the Gap

RISK REDUCTION DRUG AND ALCOHOL PROGRAM

TYPE

NO.
TESTS

POSITIVE
RESULTS %

WEEKLY
WEEKLY
3 TIMES/WEEK

2,861
557
1,023

0.9%
1.5%
0.8%

SPECIAL(MAJOR
HOLIDAYS)

EVENT

16,086

0.7%

CAUSE(INCIDENTS)
CAUSE (SUSPICION

EVENT
EVENT

140
7

5%
28.6%

RANDOM TESTING
NIGHT SHIFT
NEW HIRE CHECKS

2005 CPI CONFERENCE

FREQUENCY

Leadership of Tomorrow Bridging the Gap

RISK REDUCTION TRAINING AND

EDUCATION
ZERO TOLERANCE ON
FALL PROTECTION
VIOLATION
-100% of Workers required to work in
elevated areas must attend and
pass the Bechtel 5(five) hour Fall
Protection Workshop
- Consequences for not tying off
-100% Tie-Off Matrix
-Vertical Anchor Points using wire
rope loops

2005 CPI CONFERENCE

Leadership of Tomorrow Bridging the Gap

RISK REDUCTION TRAINING AND EDUCATION

ESTABLISH MINIMUM REQUIREMENTS for ES&H
PERSONNEL
- 5 Years Experience
- OSHA 30 hours construction
Safety course
- Blood Borne Pathogen Training
- CPR / FIRST AID (current)

2005 CPI CONFERENCE

Leadership of Tomorrow Bridging the Gap

RISK REDUCTION TRAINING AND EDUCATION

CREATED SUPPLY TO MEET
DEMAND
-ES&H Assistants Training Program to
provide Trained Personnel for future
work. Off project poaching created
demand
-Mentoring
-Training and development
-Transfer of Technology

2005 CPI CONFERENCE

Leadership of Tomorrow Bridging the Gap

RISK REDUCTION INITIATIVES

-TO REDUCE THE NUMBER OF NEAR MISS AND FIRST AID
INCIDENTS BY 75% FOR THE NEXT MILLION HOURS WORKED

2005 CPI CONFERENCE

Leadership of Tomorrow Bridging the Gap

REDUCTION METHODS -AGGRESSIVE

MEDICAL CASE MANAGEMENT
- OCCUPATIONAL HEALTH NURSES AND EMTS
- EMPLOYEES CAN GET EXTRA SICK LEAVE DAYS
EASILY
- IMPLEMENTED RETURN TO WORK POLICY
- All WORKERS MUST BE SEEN BY NURSE BEFORE
SEEKING OFFSITE MEDICAL ASSISTANCE.

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Leadership of Tomorrow Bridging the Gap

RECOGNITION / REWARDS
- Subcontractors Companies receive a Certificate of
Completion and a Write- Up in the local Newspaper.
- Gifts and Achievement certificates at Million Man hours
Milestone 1,3,5,7,10 and completion of the project.
- Workers receive incentives for attendance, working safe, and
making observation as members of PBS

2005 CPI CONFERENCE

Leadership of Tomorrow Bridging the Gap

CII ZERO INJURY TECHNIQUES

IMPLEMENTED
SUSTAINABILITY

-The project has received an A rating in ES&H Compliance from

our customer
- Assist in winning other LNG Work in other companies
PRE - 1996

2005 CPI CONFERENCE

PRESENT

Leadership of Tomorrow Bridging the Gap