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Safety Task Analysis Card (STAC) Training

Safety Task Analysis Card (STAC) Training. Pre-Task Analysis. Pre-task Analysis is the behavior of… Thinking about the task to be performed Thinking about the hazards associated with those tasks Thinking about ways to eliminate and control those hazards

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Safety Task Analysis Card (STAC) Training

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  1. Safety Task Analysis Card (STAC) Training Updated 3/2013

  2. Pre-Task Analysis • Pre-task Analysis is the behavior of… • Thinking about the task to be performed • Thinking about the hazards associated with those tasks • Thinking about ways to eliminate and control those hazards • This Pre-task Analysis is then documented by filling out a STAC card

  3. Why do we do STACS? • Eliminate injuries • It has been proven that since the implementation of this tool there has been a reduction in the OSHA rate • Identify tasks from job scope • Identify hazards associated with each task • Identify ways to eliminate and control those hazards

  4. STACS Must Always Be filled Out At The Job Site • STACS should be reviewed, updated, or re-STAC when conditions change • Change in weather • Change in job scope • Change in surroundings • Etc…

  5. Issues and Expectations • ISSUE • Job with no STAC • EXPECTATION • All Maintenance, Contractors, and Engineering Solutions working on any job on the Dow site must have a correct, current STAC to cover that job. It is the responsibility of the employee, his supervisor, and the contractor safety contact to make sure this happens

  6. Issues and Expectations • ISSUE • Same STAC card being copied day after day • EXPECTATION • To complete an adequate job of task analysis each individual must take a “fresh” look at each job each day to be completed, the hazards associated with that job and any surrounding conditions that may impact the safety of the individual worker or other members of the crew. This can not be accomplished by copying yesterday’s STAC.

  7. Issues and Expectations • ISSUE • STAC being filled out at the beginning of the day and not making changes later in the day as the job scope changes. • EXPECTATION • Each individual’s STAC must be current and identify those tasks being accomplished at any given time during the day. As tasks are added or changed the STAC must reflect those additions or changes.

  8. Issues and Expectations • ISSUE • Foreman/Crew leader signing off on poor STAC cards: tasks too broad, hazards not specific, little or no effort to identify eliminations or controls. • EXPECTATION • It is the responsibility of the Foreman/Crew leader to verify the STAC is of good quality before signing/approving the STAC card.

  9. Foreman/Superintendent Accountability • Foreman/Superintendent will be held accountable for the quality of their employees’ STAC cards. STAC cards are encouraged to be turned in to foreman/crew leader at the end of shift and given to the Safety Contact and retained for audit purposes. STAC cards should be kept by the company for 7 days.

  10. Unacceptable Observations • An unacceptable observation will be issued to your company for the following, but not limited to: • Task being performed is not listed on STAC • No/wrong date on STAC • Foreman/Crew Leader not signed off on STAC • Employee conducting hands on work not having STAC • No STAC insert or wrong date on STAC insert • Task too broad

  11. HOW TO COMPLETE A STAC

  12. Outside of STAC

  13. Safety Task Analysis Card (STAC) I commit to follow the rules, policies and procedures under all circumstances and will not take any shortcuts for any reason. Today's Date:______________ Start Time:_____________ My Name: _________________________________________ My Company Name: _______________________________ My Foreman/Crew Leader/Coach:___________________ My Job Location: __________________________________ I listed all co-workers in my crew and before beginning work I will discuss hazards, eliminations and controls so we do not get injured or cause any incidents. ___________________________________________________ ___________________________________________________ At Risk Employee Only Information: Yes or No I started the At-Risk program on: Date ________________ I have completed the At-Risk test: Date________________ Job Site Emergency Plan: 1. What Chemicals am I working around: (List) ____________________________________________ ____________________________________________________ 2. What is the wind direction: (check often) 7am/pm ___________ 9:30am/pm______ 12:30am/pm _______ 2am/pm_________ 3. Evacuation assembly point is______________________ 4. Nearest eye wash/shower station is:________________ 5. Nearest intercom or means of communication Location is:______________________________________ ____________________________________________________ 6. Control Room or Work Authorizer’s Phone # is: ____________________________________________________ Initial Information Worker must have correct date and time, specific job location, and members of co-workers in the crew At Risk Information This section is ONLY for “at risk” employees. If your are not an “at risk” employee just circle “No” Job Site Emergency Plan Worker must fill out all chemicals in the working area that he/she may have the potential for exposure to Wind Direction The worker should check wind direction frequently and note on STAC card (could be after breaks or lunch or obvious weather change) Phone Number The worker should list the control room or the work authorizer’s phone number Outside of STAC

  14. Immediately report any incident or emergency situation to the facility you are working at! In plant phone / Emergency call: 66666 Non-Emergency: 82112 Outside plant location phone / 979-238-2112 Chemical Emergency Communication GAS RELEASE – Continuous Blast -------------------------- Cancels safe work permits. Sounded only by the department at the point of release ALERT – Series of Short Blasts -- -- -- -- -- -- Evacuate according to your permits EVACUATE – Series of 3 Short Blasts --- --- --- Evacuate according to your Unit Emergency Plan ALL CLEAR – Series of 3 Long Blasts ------ ------ ------ Return to work area and have all work permits renewed before work is resumed Level Alert System Chemical Emergency Communication Impact – A Safety or Health Hazard Level 0 An incident is in progress, which can be handled with the boundaries of the block/unit. No impact is anticipated outside of the block/unit. Level 1 An incident is in progress, which can be handled within the boundaries of the plant site. No impact is anticipated outside of the site. Level 2 An incident is in progress, which appears that it can be handled within the boundaries of the plant site. However, the community could be affected. Level 3 An incident is in progress, which will affect areas outside of the plant site. A full emergency condition exists for areas outside of the site. Emergency Information Provided for Reference Emergency/non-emergency phone numbers for inside/outside plant Chemical Emergency Horn Information (Gas Release, Alert, Evacuate, All Clear) Chemical Emergency Impact Levels (0,1,2,3) Outside of STAC

  15. Communication What hazards from your job need to be communicated to other workers in the area: List:________________________________________________ ____________________________________________________ ____________________________________________________Personal Protective Equipment What is the required PPE that I will need to use to protect me from being injured: List:________________________________________________ ___________________________________________________ Mobile Equipment Hazards List all mobile equipment you have been trained for and will be operating on this job: (Forklift, Aerial Lift, Truck, etc…) ___________________________________________________ ___________________________________________________ ____________________________________________________ What are the hazards in the area that I am operating this equipment? (piperack, power lines, critical equipment, uneven surfaces, etc…) ____________________________________________________ ____________________________________________________ Hand Safety These are my potential hand hazards and this is what I will do to mitigate these hazards: ____________________________ ____________________________________________________ ____________________________________________________ What is your reason for working safe today? ___________________________________________________ ____________________________________________________ Foreman/Crew leader/Coach reviewing and approving STAC: Signature:_________________________ Date:___________ Communication Worker should list any hazards that could come into play with other workers in the area. (ex. Overhead work, hydroblasting, hot work, etc) Personal Protective Equipment Worker should list ALL PPE required to perform their task safely Mobile Equipment Hazards For any mobile equipment being used in the task the worker should be fully trained and listed in this section Workers should list any hazards in the area of using this equipment Hand Safety Worker should list potential hand hazards and list his/her plans to mitigate these hazards Making it Personal Worker should note his/her reason for working safely today STAC Card Approval Foreman/Crew leader/Coach should sign here once he has reviewed the card and agrees it is a quality STAC card Outside of STAC

  16. Inside of STAC

  17. List Job Description: __________________________ List 3-4 specific job tasks below and also address the special emphasis Task 1. ______________________________________________ ______________________________________________ ______________________________________________ ______________________________________________ Task 2. ______________________________________________ ______________________________________________ ______________________________________________ ______________________________________________ Task 3. ______________________________________________ ______________________________________________ ______________________________________________ ______________________________________________ Task 4. ______________________________________________ ______________________________________________ ______________________________________________ ______________________________________________ Special Emphasis: _____________________________________________ ______________________________________________ _______________________________________________________ Worker must list his/her job description Worker must list 3-4 SPECIFIC job tasks Examples of Specific Tasks Cut 1” rebar with metal hacksaw Cut 12” alloy pipe with band saw from existing pipe rack Examples of too broad of tasks Cut rebar/tie rebar Cut pipe, grind pipe Special Emphasis Worker will be required to address the special emphasis when provided one by Contractor Safety or by the facility Inside of STAC

  18. List Job Description: __________________________ List 3-4 specific job tasks below and also address the special emphasis Task 1. ______________________________________________ ______________________________________________ ______________________________________________ ______________________________________________ Task 2. ______________________________________________ ______________________________________________ ______________________________________________ ______________________________________________ Task 3. ______________________________________________ ______________________________________________ ______________________________________________ ______________________________________________ Task 4. ______________________________________________ ______________________________________________ ______________________________________________ ______________________________________________ Special Emphasis: _____________________________________________ ______________________________________________ _______________________________________________________ TASKS Workers should list tasks that are considered to be high risk activities. Some low risk tasks may not be considered a task: Get permit Prepare tools Set up job site Housekeeping Clean up area Walk the job site Inside of STAC

  19. LIST THE HAZARD(S) FOUND FOR EACH TASK AND ADDRESS ONE LINE OF FIRE FOR EACH. Also identify the hazards for the Special Emphasis 1A. ___________________________________________________ ____________________________________________________ 1B. ___________________________________________________ ____________________________________________________ LOF __________________________________________________ ____________________________________________________ 2A. ___________________________________________________ ____________________________________________________ 2B. ___________________________________________________ ____________________________________________________ LOF __________________________________________________ ____________________________________________________ 3A._________________________________________________ ____________________________________________________ 3B. ___________________________________________________ ____________________________________________________ LOF __________________________________________________ ____________________________________________________ 4A_________________________________________________ ____________________________________________________ 4B_________________________________________________ ____________________________________________________ LOF __________________________________________________ ____________________________________________________ 1. ____________________________________________________ ____________________________________________________ 2. ____________________________________________________ ____________________________________________________ HAZARDS Worker must list hazards that are specific to the tasks Examples of Specific Hazards Strain to back while lifting scaffold boards Cuts to hands from burrs on pipe Tripping over air hoses in area Examples of Non-Specific Hazards Slips/Trips Cuts Strains Worker must also list a Line of Fire for each task identified Example – Pinch points to hands while moving pipe to jack stand Inside of STAC

  20. HOW CAN THE HAZARD BE ELIMINATED? HOW CAN THE HAZARD BE CONTROLLED? E1A __________________________________________________ C1A __________________________________________________ E1B __________________________________________________ C1B __________________________________________________ E/LOF ________________________________________________ C/LOF ________________________________________________ E2A __________________________________________________ C2A __________________________________________________ E2B __________________________________________________ C2B __________________________________________________ E/LOF ________________________________________________ C/LOF ________________________________________________ E3A __________________________________________________ C3A __________________________________________________ E3B __________________________________________________ C3B __________________________________________________ E/LOF ________________________________________________ C/LOF ________________________________________________ E4A __________________________________________________ C4A __________________________________________________ E4B __________________________________________________ C4B __________________________________________________ E/LOF ________________________________________________ C/LOF ________________________________________________ E1 ___________________________________________________ C1 ___________________________________________________ E2 ___________________________________________________ C2 ___________________________________________________ ELIMINATION & CONTROL Elimination is the removal of the hazard from the work area Control is the reduction of the risk associated with the hazard (PPE, etc.) Worker must list an elimination and control for every specific hazard and line of fire identified Examples of Elimination – Use rigging to lift heavy load File sharp edges before handling pipe Examples of Control – Minimize lifting loads/use proper lifting techniques Wear leather gloves when handling pipe Inside of STAC

  21. STAC Scoring System • Why have a STAC Scoring System? • To measure strength and progress in task analysis – Individual and Company • To identify weak points and address with focused training/coaching

  22. STAC Scoring System

  23. Outstanding STAC • Safety Task Analysis Card (STAC) • I commit to follow the rules, policies and procedures • under all circumstances and will not take any shortcuts • for any reason. • Today's Date:_3/15/13_______ Start Time:__7:00 AM____ • My Name: ____John Smith___________________________ • My Company Name: ___The Pipe Company___________________ • My Foreman/Crew Leader/Coach:_ Joe Safety___________ • My Job Location: ___A-1800____________________________ • I listed all co-workers in my crew and before • beginning work I will discuss hazards, eliminations • and controls so we do not get injured or cause any • incidents. • ___T. Newton , B. Alexander, J. Finley____________________ • ___________________________________________________ • At Risk Employee Only Information: Yes or No • I started the At-Risk program on: Date ________________ • I have completed the At-Risk test: Date________________ • Job Site Emergency Plan: • 1. What Chemicals am I working around: • (List) ___Chlorine, Hydrogen, and Caustic_______________ • _____________________________________________________ • 2. What is the wind direction: (check often) • 7am/pm ___S________ 9:30am/pm__S____ • 12:30am/pm __SW_____ 2am/pm__N_______ • 3. Evacuation assembly point is___A-1800 Permit Building____ • 4. Nearest eye wash/shower station is:__#16 in SE Corner by D-101_____ • 5. Nearest intercom or means of communication • Location is:___Intercom west of safety shower (use a number if available)________________ • _____________________________________________________ • 6. Control Room or Work Authorizer’s Phone # is: • ___8-5555_____________________________________________

  24. Outstanding STAC • Communication • What hazards from your job need to be communicated to • other workers in the area: • List: Sparks in the area from grinding and welding Maintain a safe distance_____ • _when possible___________________________________________________ • Personal Protective Equipment • What is the required PPE that I will need to use to protect • me from being injured: • List: Hard hat, steel toe shoes, side shields, hearing protection, • gloves, and escape respirator, Face Shield___________________________ • Mobile Equipment Hazards • List all mobile equipment you have been trained for and will • be operating on this job: (Forklift, Aerial Lift, Truck, etc…) • Will be using a fork lift to remove pipe and steel off of flatbed_ • truck and locate into lay down area_____________________ • ____________________________________________________ • What are the hazards in the area that I am operating this • equipment? (pipe rack, power lines, critical equipment, • uneven surfaces, etc…) • Will have to move pipe into tight area with pumps and critical_ • equipment in area, verify its on the Permit for Critical equipment_ • Hand Safety • These are my potential hand hazards and this is what I will • do to mitigate these hazards: Burns to hands- Allow pipe to cool • and wear leather gloves. Crush hands- Don’t put hands between • pipe and jack stand_______________________________________ • What is your reason for working safe today? • I have a wife and two children that I want to see grow up • ____________________________________________________ • Foreman/Crew leader/Coach reviewing and • approving STAC: • Signature: Joe Safety Date: 1/15/13___________

  25. Outstanding STAC • List Job Description: Install 8” galv. pipe into pipe rack List the Hazards Found for Each Task How Can the Hazard be Eliminated? • List 3-4 specific job tasks below and also address and Address One Line of Fire for Each How Can the Hazard be Controlled? the special emphasis Also identify the hazards for the Special • Emphasis • Task 1. Unload Pipe With fork lift 1A. Caution when backing up equipment, vehicle and People E1A Use mechanical lifting device_____ • Layout 8” pipe to be cut to size1A. Muscle sprains from lifting pipe into jack standsE1A Use mechanical lifting device_____ • C1A Get help and use proper lifting techniques • 1B. Loud noises in process areas from running pumps, E1B Loud noises can not be eliminated • steam blowing, and crane running C1B Wear earplugs in affected areas • LOF Pinch points to hands and feet from moving pipe E/LOF Use tag line when moving pipe • into jack stand C/LOF No hands between pipe and jack stand • Task 2.Cut 8” pipe with band saw 2A. Metal shavings in eyes from cutting pipe with saw E2A Cut below eye level and work up wind • C2A Wear goggles when using band saw (above) 2B. Wrist strain from prolong use of band saw E2B Cut in neutral position, waist high C2B Take breaks, alternate person cutting • LOF Cuts to hands or body while band saw in motion E/LOF Position body away from Saw impact • C/LOF No adjustments on saw unless it is unplugged • Task 3. Use 4” 7” grinder to smooth out ends and shape3A. Cuts to body from sharp Grinder kickback E3A Allow pipe to cool and avoid touching pipe • a bevel C2 Barricade areas around grinding and cutting • C3A Wear leather gloves and long sleeves 3B. Potential fire to paper, wood from sparks in process • E3B Remove trash and wood from area • C3B Wet down floor and use fire watch LOF Cuts/Abrasions to hands or arms from grinding wheel E/LOFKeep both hands on grinder handle C/LOF Make sure wheel is tight and guard in place • Task 4. Rig pipe from jack stand and fly into rack4A. Dropping load from improper rigging/defective E4A Use rigging plan/inspect equipment • chokers C4A Warn others and barricade area • 4B. Trips/falls from extension cords/uneven areas E4B Clean work site before making lift • Where is the Threading machine in the task? C4B Avoid walking on uneven areas • LOF Pinch points to hands while repositioning E/LOF Communicate with operator 100% of time • chokers or shackles C/LOF Wear leather gloves while handling slings • Special Emphasis: Housekeeping 1. Tripping over threading machine extension cordsE1 Avoid placing cords inwalk ways • 2. Slipping on loose material from grinding/cutting E2 Sweep area frequently • C1 Flag all tripping hazards/note on JEP (NOT FOR HAZARDS)

  26. Acceptable STAC • List Job Description: Install 8” galv. pipe into pipe rack List the Hazards Found for Each Task How Can the Hazard be Eleminated? • List 3-4 specific job tasks below and also address and Address One Line of Fire for Each How Can the Hazard be Controlled? the special emphasis Also identify the hazards for the Special • Emphasis • Task 1. Layout 8” pipe to be cut to size1A. Muscle sprains from lifting pipe E1A Use mechanical lifting device_ • C1A Get help • 1B. Loud noises in process areas E1B Loud noises can not be eliminated C1B Wear earplugs • LOF Pinch points to hands and feet from moving pipe E/LOF Use tag line • into jack stand C/LOF No hands between pipe and jack stand • Task 2. Cut 8” pipe with band saw 2A. Metal shavings in eyes E2A Work up wind • C2A Wear goggles 2B. Wrist strain from prolong use of band saw E2B Cut in neutral position C2B Take breaks • LOF Cuts to hands or body while band saw in motion E/LOF Position body away from impact • C/LOF No adjustments on saw unless it is unplugged • Task 3. Rig pipe from jack stand and fly into rack 3A. Dropping load from improper rigging/defective E3A Inspect equipment • chokers C3A Barricade area • 3B. Trips/falls from extension cords/uneven areas E3B Clean work site before making lift • C3B Avoid walking on uneven areas • LOF Pinch points to hands while repositioning E/LOF Communicate with operator 100% of time • chokers or shackles C/LOF Wear leather gloves • Special Emphasis: Housekeeping 1. Tripping over threading machine extension cords E1 Avoid placing cords inwalk ways • C1 Flag all tripping hazards/note on JEP • 2. Slipping on loose material from grinding/cutting E2 Sweep area frequently • C2 Barricade areas around grinding and cutting

  27. Unacceptable STAC • List Job Description: Install 8” galv. pipe into pipe rack List the Hazards Found for Each Task How Can the Hazard be Eleminated? • List 3-4 specific job tasks below and also address and Address One Line of Fire for Each How Can the Hazard be Controlled? the special emphasis Also identify the hazards for the Special • Emphasis • Task 1. Layout pipe1A. Muscle sprainsE1A Use lifting device_ • C1A Get help • 1B. Loud noises E1B Can not be eliminated C1B Wear earplugs • LOF Pinch points E/LOF Use tag line • C/LOF No hands between pipe and jack stand • Task 2. Cut pipe 2A. Metal shavings in eyes E2A Work up wind • C2A Wear goggles 2B. Wrist strain E2B Better position C2B Take breaks • LOF Cuts E/LOF Better position • C/LOF No adjustments on saw unless it is unplugged • Task 3. Rig pipe 3A. Dropping load E3A Inspect equipment • C3A Barricade area • 3B. Trips/falls E3B Housekeeping • C3B Walk carefully • LOF Pinch points E/LOF Communicate • C/LOF Wear gloves • Special Emphasis: Housekeeping 1. Tripping over threading machine extension cords E1 Avoid placing cords inwalk ways • C1 Flag all tripping hazards/note on JEP • 2. Slipping on loose material from grinding/cutting E2 Sweep area frequently • C2 Barricade areas around grinding and cutting

  28. Practice Time • Please take this time to practice filling out a quality STAC card. • Each person should fill out a STAC card for a job that he/she might perform in the field.

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