There are different types of hazard; chemical, mechanical, electrical, biological, physical, ergonomic, process, environmental, etc. A hazard can have multiple precautions to mitigate the risks associated with the hazard. A hazard can also be marked as a hazardous material in which case health, flammability, reactivity, or contact ratings and the reference to the safety data sheet (SDS) or material safety data sheet (MSDS) can be entered.
Hazards are used across a number of HSE applications;
- Risk Assessments (HSE) – Risk table window, multiple hazards and precautions can be entered.
- Work Order Tracking (HSE) – Safety Plan tab, multiple hazards and precautions and hazardous materials can be entered.
- Incidents (HSE) – Risk and Consequence section, a single hazard can be entered.
- Permit to Work (HSE) – Hazards and Isolations tab, there is a Hazardous Materials sub tab where multiple records can be entered. A Risk Assessment can also be entered, and this shows the associated hazards and precautions, but hazards/precautions cannot be entered directly to the permit to work.
- MOC (HSE) – MOC Details section, a single hazard can be entered.
- Item Master (HSE) – Item/Organization Details action, a single hazard can be entered.
- Certifications (HSE) – Certification Details section, a single hazard can be entered.
In the Isolation Management (HSE) application you can enter a risk assessment, and this shows the associated hazards and precautions, but hazards/precautions cannot be entered directly.
The standard Maximo Safety Plan application allows multiple hazards and precautions and hazardous materials to be entered. A safety plan can also have Tag Out / Lock Out sequences, but these are first associated with a hazard.
An HSE client is unlikely to use a Safety Plan, instead they would use the Risk Assessment (HSE) application which has Hazards, Precautions and Tag Out / Lock Out sequences. Multiple risk assessments can be added to the job plan header and a single risk assessment added at the task level, these are copied through to the work order when the job plan is applied. Isolation Management (HSE) or Permit to Work (HSE) applications can also identify the Tag Out / Lock Out sequences that are needed.
One exception where a safety plan may be used is if the Maximo client is also using Maximo Anywhere and there was a requirement to display the hazards, precautions and tag out / lock out sequences on the Anywhere Work Execution (mobile) application. Currently there isn’t a way of doing this with the HSE module except through configuration to add the records into the standard work order tables provided so that they can be downloaded to the Maximo Anywhere mobile application.
The Tag Outs tab on the Hazards (HSE) application has no New Row button. This tab may not be used because the association between a Hazard and a Tag Out is made in the Safety Plan application and the safety plan may not be used by HSE clients.
A hazard is defined at the Organization level, this is because the safety data sheets are country or region specific. Precautions and Lock Out / Tag Out sequences are defined at the Site level.
There are a number of changes to the Hazards (HSE) application. One immediate difference that will be seen is that there is a Specification tab, a hazard can be classified. There are no changes to either the Precautions or Tag Out tabs.
- Environmental Aspect – A checkbox to indicate that the hazard has the potential to impact the environment. If this is checked then the Precautions added to the hazard should have the Environmental Control checkbox checked. It doesn’t stop you from adding precautions where this is not checked, however, if the Environmental Aspect is left unchecked and there are already precautions on the hazard then checking this field will give an error if any precaution is not marked as an Environment Control.
- Direct Environmental Aspect – A checkbox to indicate that the hazard has the potential to impact the environment and the organisation has direct control over how much of this takes place. For example, gas emissions from a chimney. If it is left unchecked it could indicate that the organization has no control over how much this hazard effects the environment.
- Owner – This read-only field is set by using the Take Ownership or Select Owner actions. There is no ownership history.
- Owner Group – This read-only field is set by using the Select Owner action and using the Person Groups tab.
An image of the Hazard can be displayed. The image is added using the Add/Modify Image action.
- Method of Identification – The method in which the hazard was identified. There is a value list with values of Audit Report, Hazard Report, Hazard and Operability Study, Incident Report, Job Safety Assessment, Management of Change, Risk Assessment, Safety Case.
- Hazard Source – The source of the hazard. There is a value list with values of Chemical, Electrical, Gravity, Mechanical, Noise, Pressure, Thermal.
- Reference – A reference for the hazard most likely to be the reference associated with the field Method of Identification (24 characters).
- Regulation – The regulation associated with the hazard. There is a Select Value and Go To Regulatory Compliance (HSE). To be selected the regulation needs to be in Active state and have its Applies To field set to HAZARD or GENERIC.
- Operating Procedure – The operating procedure associated with the hazard. There is a Select Value and Go To Operating Procedures (HSE). To be selected the operating procedure must be at Active state.
- Configuration Item – The configuration item associated with the hazard. There is a Select Value and Go To Configuration Items.
- Product Name – The product name associated with the hazard (100 characters). There is no associated value list.
- Classification – A hazard can be classified. To be selected a classification needs to be set-up with a Class Use With object of HAZARD. There is also a Specifications tab for storing the attributes associated with the classification. The standard menu has Select Classification, Clear Classification and Go To Classifications.
- Class Description – An alternate way of finding the classification by searching on its description, there is a Select Value dialog. When a classification has been found the description is displayed here and the Classification field is populated.
- Category – The category of the hazard. There is a value list with values of Facilities, Materials, Process, Transportation.
Hazardous Material Information section
- Certificate Type – The type of certificate required for the hazardous material. There is a Select Value and Go To Permit and Certificate Types (HSE). To be selected the permit and certificate type must be in Active state.
- Certification – The certificate associated with the hazard. There is a Select Value and Go To Certifications (HSE). To be selected the certificate must be in Active state and must be created for the same organization as the hazard. It need not be of the same Permit and Certificate Type and it need not reference the Hazard.
Risk Assessment section
- Risk Assessment – The risk assessment associated with this hazard. There is a Select Value and Go To Risk Assessments (HSE). To be selected the risk assessment must be in Active state.
- Risk Assessment Category – The category of risk associated with this hazard. This has a value list with values of Task Already Assessed, New Task requires Assessment, Risk Assessment Not Required, Risk Assessment at Task Level. This is the same ALN Domain (PLUSGRISKASSESSCAT) that is found on the Risk Assessment (HSE) and Work Order Tracking (HSE) applications.
- Risk Ranking – This read-only field shows the most significant risk ranking on the risk assessment. Default values are very high, high, medium, low.
- Risk Based Priority – This read-only field shows the most significant risk-based priority on the risk assessment. Default values are 1,2 and 3.
- Comments – A comment associated with the risk assessment (200 characters).
Safety Data Sheet Summary Tab
- Safety Data Sheet Reference – The reference for the SDS/MSDS that contains detailed information about the hazard (50 characters). This field has a long description shown in the Details section.
- Vendor Contact Information – The contact information of the vendor associated with the Safety Data Sheet (50 characters). There is no link to the Companies application, but this can be provided through configuration.
- Hazard Summary – This is a long description which can provide details of the hazard. It is not the long description associated with the Hazard’s description.
- Safety Data Sheet Summary – This is a long description which can hold an extended summary of the Safety Data Sheet details.
This is the same layout as will be found in the Hazards application in base Maximo.
Tag Outs Tab
This is the same layout as will be found in the Hazards application in base Maximo. There is no New Row button as hazards are associated to Tag Out / Lock Out sequences from the Safety Plan application. The Tag Out references a location or asset and is therefore at the Site level.
This is the standard Specification tab seen in many Maximo applications. The standard Classification functionality can create the hazard description from the entered classification and attribute values.
- Take Ownership
- Select Owner
- Add/Modify Image
Precautions can be used for safety reasons to mitigate the hazard, they can also be used for environmental controls. Precautions are always associated with a hazard, but they exist at the site level rather than the organization level. Therefore, the same Precaution may exist multiple times but with different Site IDs.
There are a few additional fields added to the HSE version of this application.
- Type – The type of precaution taken to reduce or eliminate a hazard. There is a value list with values of Control, Environmental, Personal Safety, Process Safety, Security.
- Category – The category of a barrier associated with the precaution. For example, a containment barrier can prevent the release of liquids. There is a value list with values of Process Containment, Detection System, Emergency Response, Ignition Control, Life Saving, Protection System, Safety Climate, Shutdown System, Structural Integrity.
- Safety Critical Element – A reference to an element that is critical to safety in order to meet an associated regulation. There is a value list supported by ALN domain PLUSGSAFETYCRITREF which will need to be configured before use.
- Personal – A checkbox to indicate that the precaution is personal. For example, wearing googles, or protective boots.
- Environmental Control – A checkbox to indicate that the precaution is for environmental control.
Lock Out / Tag Out Plan (HSE)
The Lock Out / Tag Out Plan (HSE) application is used for electrical, mechanical or process isolation of locations and assets, although electrical is probably the most common. These are sometimes referred to as LOTO plans. The aim of a LOTO plan is to eliminate injuries and fatalities associated with hazardous energy while performing maintenance or service activities. This is an area that may have a regulation, for example in the USA, OSHA standard Control of Hazardous Energy – 29 CFR 1910.147. There is likely to be a LOTO register for a site with LOTO procedures defined specific to equipment or an area.
The LOTO plan may require a valve, breaker or other equipment being physically locked and a visible tag being added to the equipment to show that it is locked-out and who holds the physical key. A LOTO plan may involve:
- Announcing an intention to shut off equipment or area
- Identifying the safety related equipment that need to be isolated
- Isolating the energy sources
- Adding a physical lock and tag to the energy sources so that they cannot be turned on
- Prove that the equipment isolation is effective
When the last step has been achieved then maintenance work can start. When maintenance has been completed there is also a reverse process to follow that removes the tags and locks and allows the equipment to be re-energized.
A Lock Out / Tag Out Plan record requires an Asset or Location to be entered. The Lock Out / Tag Out Plan (HSE) application has a few additional fields.
- Active – This checkbox indicates that the LOTO Plan is ready to be used in other applications. There is no status field or status history, just this checkbox.
- Type – The type of lock out/ tag out procedure. This field has a value list with values of Electrical, Mechanical, Alarm Override, Process.
- Long Term Isolation – A checkbox to indicate whether the asset or location will require long term isolation.
- LOTO Reference Drawing – A drawing/document reference that shows the lock out / tag out process.
- Required State – This standard field has been hidden in the HSE version of the application.
Lock Out / Tag Out Operations table window
In the Operations table window a Location, Asset or Device Description must be entered, but only one of these for each operation. The Apply Sequence is the sequence used in the isolation. The Remove Sequence is the sequence used after maintenance when the tags and locks are being removed. There is one additional HSE field.
- Isolation Method – The method of isolation used. This field has a value list with values of Blank, Disconnect, Spade, Tag.