Quality & HSE Brochure

Quality & HSE Brochure 1

Quality & HSE Brochure Business Unit Power Plants

2 Quality & HSE Brochure

Contact Information / Emergency Numbers

Secondary Emergency Measures:Emergency Service (EXOP)+49 7531 94 216 11 (save this number on your mobile!)Call this number in case of emergency. The emergency service will arrange help, assist in critical security situations and coordinate evacuation procedures.

Project: Name Country

Division HSE BU-P: Name Tel. No.

Division HSE on site: Name Tel. No.

Project Manager: Name Tel. No.

Immediate emergency numbers:

Local Fire Fighters: Tel. No.

Local Emergency/

Rescue Service: Tel. No.

Contact Data of respective HSE Services

Ansprechpartner:

HSE management: Peter Wittmann (PQH) Tel: +49 821 322-4735Quality management: Andreas Sturm (PQM) Tel: +49 821 322-4432Quality assurance: Thomas Lauchner (PQO) Tel: +49 821 322-1171


Content

Contact Information / Emergency Numbers 2Editorial 4What is Quality? 6What is HSE? 7Quality - for what? 8HSE - for what? 9How is Quality Ensured? 10How is Safety Ensured? 11Total Quality Management 12Continuous Improvement 13Main Business Process of BU Power 14Strategy 16Acquisition 17Engineering 18Procurement 19Shipment 20Construction Site 21Commissioning 22Service 23Project Management 24Quality and HSE in Support 25Reporting Chains in Case of Quality Deviation 26Reporting Chain in Case of Accident, Incident and Near Miss 28Procedure in Case of Accident / Incident 29Procedure in Case of Product Safety Risks 30Travel Arrangements 32… on a New Construction Site 33The Most Important Documents on Site 34Reporting HSE 35The STOP Principle 36Dangers on Construction Sites 38Specific Dangers during Commissioning 40HSE-relevant Symbols and their Meaning 42Company Guideline from 2013 52Notes 57


Dear reader,

Security is a human right.Quality is required, it is a fact.Health is not everything, but without health everything is nothing. Environmental protection and sustainability, we owe it to our children. Your knowledge and experience in these fields are our most important resources. For this reason we invest in your skills, safety and the environment.We follow the principle of “safety first!”-safety always comes first!

The four targets from MAN Diesel & Turbo are: Safety Quality Adherence to delivery dates and CostsYour safety is our number one priority.

Therefore, we take into consideration the occupational safety and health from the beginning of our planning and decisions.

We analyze the risks and hazards in all work areas, solve them or reduce them to a minimum. We promote preventive measures to improve the safety and health of our employees.HSE and quality, both require your personal commitment.

Your commitment and your sense of responsibility to the company and the prod-uct is reflected in the quality of your work. We are no spectators and no background actors who stand beside and watch while the train is passing by.

MAN Diesel & Turbo expects from all its employees to aim at the same targets and ideals as the company. YOUR motivation and YOUR innovation force are the base of the entrepreneurial success of MAN Diesel & Turbo. Quality, such as HSE, are our main targets.

Editorial


It‘s a great advantage in life to be the one who already acts while the others are still talking

John F. Kennedy

The greatest of all follies is to sacrifice health,

for whatever it may be.Arthur Schopenhauer (1788-1860),

german philosoph

In one half of our life we sacrificeour health to earn money

In the other half, we sacrificemoney to recover health

Voltaire (1694-1778)

5. Mose, 22. 8

Qualit y

Qualit y is the return of the customer

Dr. Günther Schreiber

Who has stoppedgetting better has stopped being good Philipp Rosenthal

Qualit y begins by putting the customer‘s satisfaction at the center of our thinking John F. Akers

Qualit y doesn‘t arise by chance, it must be planned!

Qualit y is fitness for use!Josef M. Juran

The power is in the qualit y Friedrich Nietzsche

and not of the product

The prevention of accidents must not be taken as a provision of Law,but as a dictate of human obligation and economic senseWerner von Siemens, 1848

When thou buildest a new house,then thou shalt make a battlement for thy roof,

than thou bring not blood upon thine house,

if any man fall from thence

Everyone has a right to lifeand phyical integrity

HSE

Constitution, Art. 2, par 2

Josef M. Juran


Quality is commonly understood as product quality! But quality is not only that!Quality includes all processes and tasks that lead to a high quality product::

Contract quality Are the contracts clear and without any doubts? Procurement quality Are all orders correct and the deliveries error free? Quality specifications Are the requirements in the specification exact, complete and documented? Quality of settlement Have all internal and external interfaces been called upon and operated? Manufacturing quality Is the production on time, accurate and documented? Test and measurement quality Are tests and measurements within the specification on time and documented? Shipping Quality Is the shipment on time? Is the appropriate type of packaging, preservation and transportation ensured? Service quality Are all external and internal customers satisfied?

The primary target is the customer’s satisfaction via sustainable product quality

What is Quality?

Contract

Service

Testand

Measurement

ShippingQualityCustomersatisfactionManufacturing

Specifications

Procurement

Settlement


What is HSE?

HSE is commonly understood as occupational safety ! But HSE is not only that!HSE is the english abbreviation for Health, Safety and Environment and includes all activities and measures to achieve the business objectives in health protection, oc-cupational safety and environmental protection as well as their documentation.

Analysis Analyse work system (work, machines, assembly operations, assembly operations of environmentally relevant plants etc.) and identify hazards Assessment Assess and evaluate the hazards identified in the analysis Set Targets Set human, technical and organizational objectives Development of alternative solutions according to the STOP Principle View the regulations to be applied and work out possible solutions Selecting of one solution Develop proposals for appropriate solutions as a decision base for the employers Implementation of the solution Implementation of measures Effectiveness control and optimization Check, adjust and improve system continuously

The primary target is the customer’s satisfaction by preventing accidents and protecting the environment.

Analysis

HSECustomersatisfaction

Effectivenesscontrol

Assessment

Developsolutions

Implementsolutions

Set targets

Optimization


The customer wants quality!If the properties (as-is) of a product conforms to or exceed the requirements (target) of the customer, he will be satisfied:

All employees must have the same understanding of quality Quality means satisfied customers Satisfied customers will come back Satisfied customers are willing to pay for quality Quality costs money To remove poor quality is even more expensive

... that means: Quality concenes everyone from the very beginning! Quality depends on each and every one! It is exemplified in this way by the management!

Everyone always produces results with impeccable quality in the context of its pro-cesses and transmits it to his partners working with internal and external customers.Only in this way customer’s satisfaction can be achieved.

Quality - for what?

safety

costs

quality

adherenceto delivery dates

customer‘s trust

profitable company

customer‘s satisfaction

secure obs


Safety is a human right!A good HSE management contributes to the safety, efficiency and quality of the company and leads to a high standing by customers and in the society.It is measurable and becomes itself a quality characteristic:

Efficiency in all processes Reduced deficiency times and no standstill Neither damage to persons nor damage to property Trained, competent employees Good reputation on the market = competitive advantage Customer’s trust

... that means: Safety concenes everyone! Security depends on each and every one! It is exemplified in this way by the management!

Everyone has a right to proper health, occupational and environmental protection, but also the responsibility towards himself and towards his partners. Only in this way customer’s satisfaction can be achieved.

HSE - for what?

socialprestige

motivatedemployees

adherence

to delivery dates

HSE

customer‘s satisfaction customer‘s trust

profitable company

safe obs


How is Quality Ensured?

Everyone is responsible for the quality of his achievements and work!For example, here are some checkpoints:

Can the delivery be effected according to the contract?Do the products comply with the requirements of market and customers?Are the orders complete and documented?Are only valid documents and data used?Is only the material used complying with the the contract’s specifications?Are the products provided by the customer carefully treated?Are materials and products marked and retraceable at any time?Is any known error repeated for a second time?Where all goods, documents, drawings, specifications etc. checked for completeness and operability?Is the manufactured quality subsequently affected by handling, packaging, storage or shipping?Are defective products blocked?Is the inspection status visible at any time?Are measurement errors and incorrect decisions prevented?Are there enough checks and controls?


How is Safety Ensured?

Everyone is responsible for the quality of his achievements and work!For example, here are some checkpoints:

Can the delivery be effected according to the contract?Do the products comply with the requirements of market and customers?Are the orders complete and documented?Are only valid documents and data used?Is only the material used complying with the the contract’s specifications?Are the products provided by the customer carefully treated?Are materials and products marked and retraceable at any time?Is any known error repeated for a second time?Where all goods, documents, drawings, specifications etc. checked for completeness and operability?Is the manufactured quality subsequently affected by handling, packaging, storage or shipping?Are defective products blocked?Is the inspection status visible at any time?Are measurement errors and incorrect decisions prevented?Are there enough checks and controls?

Everyone must ensure maximum security at his workplace!For example, here are some checkpoints:

Are suppliers suitable and audited according to HSE?Have suitable suppliers been selected in terms of HSE, quality and costs?Is the risk and hazard analysis accurate and complete?Have all employees been trained according to their task?Are all escape routes clearly marked on the site?Are all danger areas on site defined and secured?Is the storage of material on site according to regulations?Have the construction site rules and instructions been established?Has the work directives been carried out?Are all work instructions on site being available and implemented?


Total Quality Management

Total Quality Management (TQM) means that all processes, from the product’s conception to the end of the life circle of the plant are permanently optimized.

This is done under the focus:

Creating additional value for customer, the company and its employees

To ensure long-term customer satisfaction

To develop the awareness of every employee of his quality responsibility, to product, project and process

To raise the awareness of the executives as the actual carriers of TQM

The TQM focuses on:

Product quality Corrective actions Final termination of error at the supplier

Project quality Lessons Learned Improvements for following projects

Process quality Continous Improvement

Optimization of processes and interfaces

Customer focus Query of customers What does the customer want?

Staff focus Coaching and communication

Competency enhancement

Benchmark To learn by others New ideas for improvement

Creating value for the customer

Leading with vision, inspiration and integrity

Managing with prozessesBeing successful through

the employees

Promoting innovation and creativity

Building partnerships

Taking responsibility fora sustainable future

Achieving balanced results


Total Quality Management (TQM) means that all processes, from the product’s conception to the end of the life circle of the plant are permanently optimized.

This is done under the focus:

Creating additional value for customer, the company and its employees

To ensure long-term customer satisfaction

To develop the awareness of every employee of his quality responsibility, to product, project and process

To raise the awareness of the executives as the actual carriers of TQM

The TQM focuses on:

Product quality Corrective actions Final termination of error at the supplier

Project quality Lessons Learned Improvements for following projects

Process quality Continous Improvement

Optimization of processes and interfaces

Customer focus Query of customers What does the customer want?

Staff focus Coaching and communication

Competency enhancement

Benchmark To learn by others New ideas for improvement

Continuous Improvement

... that means:

Continuous Improvement (CI) is an integral part of TQM Each employee is required to report opportunities for improvement

They are achieved by quality coordinators (QC) with the support of Continuous Improvement Managers (CIM) implemented in the departments

Lessons Learned Meetings occur in the course of project execution CI issues will be implemented on the basis of the Power Circle

Errors are used as opportunities for improvement The improvements must flow back into the organization

Further information about Total Quality Management, Continuous Improvement and Lessons Learned can be found on Atlas!

POWERCircle

Revieweffectivity

Problemdescription

Whatroot cause?

Ownerdefinition

Executeimprovements

“One who has stopped getting better, has stopped being good!” ...Philipp Rosenthal

The Power Circle


Main Business Process of BU Power

Engineering Procurement

Strategy

Project AcquisitionStrategy

Project specific execution and surveillance

AcqusitionStrategy

Project Execution

Project Pre-Planning

Service

CommissioningShipment ServiceConstruction site

Plant operation field monitorin


Project Execution

To keep an eye on safety, environment and quality in every process step is necessary for a reliable product quality!


Engineering Procurement

Strategy

Project AcquisitionStrategy


AcqusitionStrategy

Project Execution

Project Pre-Planning

Service

CommissioningShipment ServiceConstruction site

Plant operation field monitorin


Project Execution

To ensure safety, environment and quality in every process step is the task of every individual emplyee!


Strategy

Target markets are to be defined

Local conditions and requirements are to be included

Target technologies are be defined

Local partners / suppliers are to be identified and selected

Strategic plans are to be created

Results are to be commented on and communicated

! Strategy is the way to the future!


Acquisition

Customer requirements are to be considered

Local requirements are to be included

For pricing suitable suppliers are be included

A risk management is to be executed

Contracts are to be negotiated

! Customer satisfaction ensures sucess!


Engineering

Customer, contract and local requirements are to be implemented

Engineering-documentation is to create on time and to be approved

Internal and external interfaces are to be inquired and to be operated

Deviation management is to be executed

Dates and costs have to be observed

“As built” documentation is to be created

! Providing the technical leadership!


Procurement

Suppliers are to be selected due to technical suitability as well as quality and HSE capability

The order with delivery of the complete order documents to the supplier is to be raisedDates are to be monitored in coordination to quality and HSE inspections (Expediting)

After the quality and HSE release, the supplies are to be retrieved

The supplier’s qualification must constantly be checked

If errors occur, corrective measures are to be captured

Errors must be claimed

A claim management is to be executed

! Co-determining for the product quality!


Shipment

A transport company must be selected

An adequate conservation is necessary to be defined

The suitable packaging must be determined

The suitable mode of transportation must be determined

A safe interim storage is to be ensured

The suitable transportation route must be determined

A safe storage on site is to be ensured

! Report damage in transit immediately!For this, use the form control sheet FK 0917!


Travel security and guidelines on occupational safety must be respected

The construction site is to be secured

A risk analysis for occupational safety is to be conducted

Construction process and building organization is to be defined

Installation instructions must be followed

Requirements for occupational safety must be followed and monitored

Tests according to the quality plan are to be conducted

The site documentation is to be created

The employees on site must be trained according to their application

! Report errors and construction deviations immediately!For this, use the form control sheet FK 0917!

Construction Site


Commissioning


A risk analysis for scope of work is tobe conductes

During commissioning the respective specifications and requirements must be respected

During commissioning the respective tests are to be conducted

The commissioning documentation is to be created

The plant must be handed over to the customer

! Report errors and damages of the plant immediately!For this, use the form control sheet FK 0917!


Service


A risk analysis for scope of work is to be conducted

Maintenance and warranty services are to be performed

A field monitoring is to be conducted

A product monitoring is to be conducted

A customer information is to be carried out

If needed, customer is to be warned

! Report errors and damages of the plant immediately!For this, use the form control sheet FK 0917!


Project Management

All internal and external interfaces are to be informed regularely and sufficently

A well-regulated communication to the customer is to be ensured

A clear distribution of responsibilities is to be ensured

Awareness for quality and safety in daily business must be present

Agreed communication channels and escalation levels must be observed

! The face in the project!


Quality and HSE in Support

Quality Assurance HSE Management Quality Management

Project Quality Plan Occupational Safety

Process Management

Supplier Audit and Approval

Environmental Protection

Document Management

Inspection- and Test planning

HSE Planning Guideline Management

Execution of Inspections (FAT and SAT)*

HSE Training Certification

Supplier Qualification

Hazard Assessment

Continuous Improvement

Interface to Claim Management

Lessons Learned

! Quality ensures sucess!

* FAT = Factory Acceptance Test SAT = Site Acceptance Test


Reporting Chains in Case of Quality Deviation

Immediate and Long-TermMeasures

eworkin eworkin finished

FAT Deviation

Q-Inspector

Approval for Shipment

MeasuresResponsible

PQ-DeviationManager

Supplier

Q-Inspector

PCM

FAP

Px-intern

POC

Construction Site

Lessons Learned

for Information

Q-Repeat

PQImmediate

and Long-Termmeasure

PQ DeviationManager

Service

Information

Customer

Supplier

Service

Import and Communicate

Action Plan

DamageReport

Receipt and Transfer

Service

Entry in PCM Data Base

if needed: APS

ActionPlan

Measures

ResponsibleCustomer


PQ

PQ DeviationManager

if needed: APS

Supplier

QCM / Supervisor

FAPLessons Learned

Q-DeviationSAT

PO

if needed: Claim Management

ConstructionSite

SAT Deviation

Responsible

Immediate and Long-TermMeasures

via PCM Data BaseProject Management

via PCM Data Base

FAP Involvementof all Stakeholders

Measures

if needed:APS

PQImmediate

and Long-Termmeasure

PQ DeviationManager

Service

Information

Customer

Supplier

Service

Import and Communicate

Action Plan

DamageReport

Receipt and Transfer

Service

Entry in PCM Data Base

if needed: APS

ActionPlan

Measures

ResponsibleCustomer


Reporting Chain in Case of Accident, Incident and Near Miss

Accident > 3 days lost time

Area of reporting for minor Accidents and

near misses

Serious accidents and serious near

misses

Signalling from witness / employee

Accident, Incident, Near Miss

Management PO

Safety Officer MAN AUG (Dept. WE)

Report to BG (MDT-DE)

Project Manager

Site /Comm.Manager MAN

PQH-AUG

If applic. HSE-Manager (site) MAN

Report to customer (reg.

contract)

Emergency response chain First Aid/Emergency

Medic/Emergency Rescue Service/Fire Brigade

Board of Management

If applic. signalling to

insurance

Management BU P

If applic. HSE-Manager local Organization

If applic. CEO local

Organization

If applic. local Authoroties

Step 1-4

Step 5

Step 6-7

* Comment: If a function is unstaffed (dottet box), the precursor takes over this tasks, usually the site manager

Further information can be found on Atlas and in FK 3851


Procedure in Case of Accident / Incident

1. Secure the accident area

2. Save out of danger zone (self-protection comes first!)3. Call emergency service Where’s happened? What’s happened? How many are involved in the accident? Who is calling?

Wait for further questions!4. Perform first aid5. Organize support6. Collect initial information about the accident7. Note reporting chain! 8. Perform report9. Analysis of accident10. Develop and implement measures


Procedure in Case of Product Safety RisksS

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Legend:

A product safety incident must be reported immediately to the APS*. The APS creates appropriate measures for maximum product safety.He ensures that the developed measures are also seized to achieve the highest level of product safety.

The APS is made up of members of the Engineering and Quality departments of Business Units and representatives of Group Quality, Group Legal and Group HSSE.

The tasks of APS are:

Checking all MDT product safety incidents and proposals for preventive measuresChecking and deciding of all outstanding recall or warning actionsChecking and releasing of the annual product safety report to the managementEnsuring proper documentation of all product safety incidentsAdapting existing product safety processesRevising and further developing of “ early warning systems “ for product safety issuesThe MDT Management monitors the APS activities and decisions.

This enables a flexible and efficient reaction to any possible weaknesses in product or processes.

Further information can be found on Atlas and in MDT 10.101

! In any case, your manager is your first contact person ! You can inform the APS directly by e -mail : [email protected]!

*APS = working team for product safety

employee APS clearinghouse

APSstakeholder/

management/ AR

Q or engineering

BU-/Servicespecific team and process to

master thesafety risk


First necessary steps before going abroad!

Consult the facility doctor regarding necessary vaccinations

Make the G35 medical check for assignments abroad

Ask for country-typical health risks

Ask for other necessary medical checks

Get the first aid kit from facility doctor (including mosquito spray)

Receive individual medical information for your trip abroad

Get a permission to enter the site

Get your required HSE-Training (MDT-HSE Check (general and country/site specific)

Check the custom requirements (allowed import and export of personal goods)

Get contact data of your direct superior on site

Inform your direct superior about your arrival

Get your Personal Protection Equipment (PPE)

Get your personal safety logbook and keep it always with you

Travel Arrangements


First necessary steps to do on a new construction site!

Immediately contact your assigned superior on site

Ask for responsible HSE Manager

Get a site specific induction from HSE Manager

Wear your site specific Personal Protection Equipment (PPE)

Ask for a clean and hygienic place to store your food and beverages

Have a look into sanitary facilities

Ask for hygienic facilities to store your clothes

Get sun cream and mosquito spray from medical facility on site

Get information regarding poisonous animals on site and respective prevention measures

Familiarize yourself with the site specific HSE rules like: Behaviour in case of emergency Emergency numbers, emergency services, alarm signals Traffic rules on site Work permits (e.g. for hot work, Lockout/Tagout etc.) Prohibitions (e.g. smoking etc.) and bids Requirements (e.g. wearing safety glasses etc.) Sufficient number of first aiders in your team

… on a New Construction Site


The Most Important Documents on Site

In case of accident / incident:Immediately inform the HSE department of BU-POWER by phone!Only then can we support you!

Emergency Plan1): Contains the most important emergency numbers

Shall be displayed on the notice board of the site HSE Plan1): Contains general HSE site issuesContains detailed descriptions like working hours, HSE Personnel and special work procedures (e.g. scaffoldings, working at height etc.)Risk Analysis/Risk Evaluation3)4): Detailed analysis of potentially occuring risks Evaluation of hazards on site Safety/prevention measures to reduce or even eliminate risks.A risk analysis shall exist for every specific work place!Standard Operating Procedures (SOP) 1): For the use of chemicals as well as for operating equipment and tools Contains the potential risks, preventive measures, handling of emergency case The first aid requirements, the recycling and the environmental requirementsLockout/Tagout (LoTo) and Work Permits 3)4): Serve for the coordination of works with high danger Shall be applied in due timeShall be approved by the responsible HSE ManagerAre valid for a defined time frameNeed to be renewed after expirationFor works with high danger like : Hot work, working in confined spaces electrical work, working at heightsOperating Instructions2)3): Shall be created for works on site Shall include the following: work procedures, the work equipment and machinesQuality requirements, and all requirements and measures regarding safety, health and environmentOperating instructions have to be issued to the HSE Manager in due time to be checked and approved and have to be held available on site.Responsible: 1)HSE manager 2)Site manager 3)Supervisor 4)Construction manager


Reporting HSE

a) Projects with MAN HSE Manager

FK-Sheets shall be used as reporting tool, the most important are listed as follows:

FK 3800 HSE Daily Report FK 3802 Weekly Report FK 3803 Monthly Report FK 3818 Hazardous Substances FK 3830 List of Work Permits FK 3876 Accident/Incident Report ….

Please inform yourself in the MAN Intranet (Atlas)!

The reporting of the HSE Manager on site is to be sent to the department HSE BU-P in Augsburg. Certain HSE coordinators make the analysis of the reports.

b) Projects without MAN HSE Manager

The overall weekly report shall be completed by the supervisor and sent to Augsburg. The weekly report contains all HSE-relevant information. Accidents and incidents have to be reported by using the FK Sheet 3876.

! In case of accident / incident:Immediately inform the HSE department of BU-POWER by phone!Only then can we support you!


S = Substitution T = Technical Measures O = Organizational Measures P = Personal Protection Measures The STOP Principle is to be performed in exactly that sequence:

Try to substitute (replace) first, then apply technical measures, then organiza-tional measures, and last, if none of these before mentioned are applicable, take personal measures like wearing PPE

Substitution: Priority OneAvoid risk!Try to replace e.g. dangerous chemicals by using other, non harming chemicals

Technical Measures: Priority TwoWhen Priority One can not be applied, then technical measures shall be applied as supplement like e.g. scaffolds for working at height, barriers for excavation etc

Organizational Measures: Priority Three When Priority One and Two can not be applied, then organiza-tional measures shall be applied as supplement:e.g. reduction of exposition time, time management

Application of PPE: Priority Four(helmet, safety glasses, protective gloves, breathing protection, rope protection etc.) When Priority One to Three can not be ap-plied, then personal measures shall be applied as supplement

The STOP Principle



Dangers on Construction Sites

! Get site instruction in advance! On the site it is always required to wear a safety helmet and safety shoes!In marked areas safety glasses are obligatory!

Fall:Protect yourself and others against fall with scaffoldings, barriers etc.Use personal protection equipment like harness (only in connection with organized altitude protection), if none of these technical measures applyStab:Keep away from and protect sharp and peaked parts (e.g. protect vertical reinforcement bars with cap etc.), helmetDrown when working on water: ALWAYS use life vests, even if sufficient fall protection existsTrip, Slip, Fall:Slippery surfaces have to be avoidedUse only adequate slip-preventing surfaces for pathways and stainwaysKeep your work place clean and in orderAvoid tripping pointsIn the case of trip detection, please inform or warn the HSE manager or your colleagues


OverwhelmNever enter pits which are not securedDo not enter silos if you are not certain that they still may contain material or that they are currently filled with materialBurns: Do not touch hot surfacesIf your recognize unprotected hot surface without warning, inform the HSE Manager or your colleaguesStick to the measures from work permit, follow safety precautionsUse suncream to prevent sunburnChemical burn (Safety Data Sheet has to be available):Use Breathing protection, safey glasses and protective glovesStick to the measures from work permit, follow safety precautionsLoss of hazardous substances:Keep binding agent ready when using environmentally hazardous substancesUse breathing protection, safety glasses and protective glovesFire: Leave the building immediately,take anything awayMove ducked or creeping, because of lower heat and smoke exposureClose every door on your wayMake colleagues aware of the dangerMake an emergency call


Specific Dangers during Commissioning

! Whenever responsibilities and processes are not well defined, specific risks may occur.

As a basic rule:Insist on the importance of precise instructions, when something is not clearAssign responsibility for each person involved clearly Establish a Code of Conduct for each person involvedAsk the superior before starting workProtect non-involved persons by locking, barriers and warning noticesAll involved persons have to stick to the Lockout Tagout procedures

Working in confined spaces: Get entrance permitWork out a rescue scenario before starting to workMake sure that no harmful gases escapeNever work alone, one must be able to get help in case someone faints. If necessary, work with flagmen or rescue line.

! With regard to the special risks on construction sites, the responsible supervisor is required to coordinate the work of contracted companies!


Electric shock/Burn: While working with electrical installations, regulations have to be clearly defined for all persons involved Never remove locks and tags without permissionsNever switch on lines without definitely knowing that people are still working on themIf any doubt occurs, ask your superior or the Logout-Tagout managerNever touch cables, even if they are not visible under power, do not enter marked spacesKeep a distance of 5 m away from potentially live conductors by using digger or craneCrushing: Apply safety distance when working near moving partsWhile working on potentially moving parts, switch off the machine and secure the machine against resetting with a personal lockMedia Pipes: Never open media pipes under pressureSwitch media pipes only gradually depressurizedSecure media pipes against re-fillingPay attention to hazards regarding the various media (gas, light oil, etc.)


Mandatory Signs, Liability Association Regulations (BGV)

HSE-relevant Symbols and their Meaning

Use Ear Protection (BGV A8, GUV-V A8/M03)

Use Breathing Mask (BGV A8, GUV-V A8/M17)

Use Fall Protection (BGV A8, GUV-V A8/M18)

Use Foot Protection (BGV A8, GUV-V A8/M08)

Use Eye Protection (BGV A8, GUV-V A8/M04)

Use Face Protection (BGV A8, GUV-V A8/M13)

Use Gloves (BGV A8, GUV-V A8/M09)

For Pedestrians(BGV A8, GUV-V A8/M24)

Use Hand Rail(BGV A8, GUV-V A8/M12)

General Commandment Sign (BGV A8, GUV-V A8/M01)


Use Passage(BGV A8, GUV-V A8/M23)

Use Protection Apron(BGV A8, GUV-V A8/M26)

Disconnect be-fore Maintance or Repair (BGV A8, GUV-V A8/M21)

Use Protective Clothing (BGV A8, GUV-V A8/M10)

Use Protection Helmet (BGV A8, GUV-V A8/M14)

Use Life Vest (BGV A8, GUV-V A8/WSM01)

Wash Hands(BGV A8, GUV-V A8/M11)

Usesafety seat belts (BGV A8, GUV-V A8/M20)

Use Skin Protection (BGV A8, GUV-V A8/M22)

Use Reflektive Vest (BGV A8, GUV-V A8/M15)


AcidAcid EffectGHS 05

OxidatingGHS 03

Gas Bottle, Compressed GasesGHS 04

Danger of ExplosionGHS 01

Highly inflammableGHS 02

Hazard Pictograms, Globally Harmonized System (GHS)

Hazard Pictograms oldHazard Pictograms new


Danger to EnvironmentGHS 09

Danger to HealthGHS 08

Danger to HealthGHS 07

PoisonousDanger to LifeGHS 06

Hazard Pictogramms oldHazard Pictogramms new, GHS-Symbols


First Aid Signs

EmergencyTelephone (BGV A8, GUV-V A8/E07)

Emergency Exit (BGV A8, GUV-V A8/E17)

Doctor (BGV A8, GUV-V A8/E08)

Assembly Point (BGV A8, GUV-V A8/E11)

Eye Shower (BGV A8, GUV-V A8/E06)

Barrow (BGV A8, GUV-V A8/E04)

First Aid(BGV A8, GUV-V A8/E03

Defibillator,Automatic, External (BGV A8, GUV-V A8/E17)

Rescue Way, Right (BGV A8, GUV-V A8/E13)

Emergency shower(BGV A8, GUV-V A8/E12)

Emergency Exit(BGV A8, GUV-V A8/E19)

Emergency with Escape Ladder(BGV A8, GUV-V A8/E16)


Fire Protection Signs

Equipment for Fire Fighting(BGV A8, GUV-V A8/F07)

Direction (Bottom Right) (BGV A8, GUV-V A8/F02)

Fire Alert Telephone (BGV A8, GUV-V A8/F06)

Fire Extinguisher (BGV A8, GUV-V A8/F05)

Ladder (BGV A8, GUV-V A8/F04)

Fire Detector (manually) (BGV A8, GUV-V A8/F08)

Fire Hose (BGV A8, GUV-V A8/F03)

Direction (Left) (BGV A8, GUV-V A8/F02)

Direction (Bottom Left) (BGV A8, GUV-V A8/F02)

Direction (Right) (BGV A8, GUV-V A8/F02)


Prohibition Signs

Entrance for unauthorizised Persons Forbidden (BGV A8, GUV-V A8/P06)

Mobiles Forbidden (BGV A8, GUV-V A8/P13)

Smoking Forbidden (BGV A8, GUV-V A8/P02)

Fire, open Light and Smoking Forbidden (BGV A8, GUV-V A8/P03)

Do not enter with Cardiac Stimulator (BGV A8, GUV-V A8/P07)

Eating and Drinking Forbidden (BGV A8, GUV-V A8/P22)

Wearing Protection Gloves Forbidden(BGV A8, GUV-V A8/P28)

General Prohibition Sign(BGV A8, GUV-V A8/P01)

For Pedestrians Forbidden (BGV A8, GUV-V A8/P04)

No potable Water(BGV A8, GUV-V A8/P05)

Heavy Loads Forbidden(BGV A8, GUV-V A8/P12)

Extinguish with Water Forbidden(BGV A8, GUV-V A8/P11)


Symbols Personal Protection Equipment (PPE)

Protection against mechanical Danger

Protection against statical Electricity

Protection against Coldness

Protection against Chainsaws

Protection against Slices and Stabs

Protection against chemical Dangers

Protection against Heat and Flames

ManualInstruction manual

Protection against ionizising Rayons

Protection against bacteriological Contamination


Warning Sings

Danger of Fall (BGV A8, GUV-V A8/W08)

Danger of Squeezing (BGV A8, GUV-V A8/W23)

Acid Agents(Corrosive) (BGV A8, GUV-V A8/W08)

Danger of Floating Load (BGV A8, GUV-V A8/W15)

Danger Zone (BGV A8, GUV-V A8/W01)

Danger of X-Rays (BGV A8, GUV-V A8/W04)

Danger of Poisonous Substances (BGV A8, GUV-V A8/W16)

Radioactive or ionisizing Rays or Substances (BGV A8, GUV-V A8/W05)

Danger of Fire Harzardous Substances (BGV A8, GUV-V A8/W01

Danger of not ionizing Rays (BGV A8, GUV-V A8/W05)

Danger of explosible Atmosphere (BGV A8, GUV-V A8/W21)

Danger of Automatic Start-Up (BGV A8, GUV-V A8/W18)


Danger of Explosives (BGV A8, GUV-V A8/W02)

Danger of Electrical Current (BGV A8, GUV-V A8/W12)

Danger of Biohazard (BGV A8, GUV-V A8/W09)

Danger of oxidizing substances (BGV A8, GUV-V A8/W11)

Danger of Gasbottles (BGV A8, GUV-V A8/W29)

Danger of Obsta-cles on the Floor (BGV A8, GUV-V A8/W07)

Danger of Low Temperature and Frost (BGV A8, GUV-V A8/W10)

Danger of magnetic Field (BGV A8, GUV-V A8/W06)

Danger of Hot Surfaces (BGV A8, GUV-V A8/W17)

Slip Hazard (BGV A8, GUV-V A8/W11)


Company Guideline from 2013






Notes


