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Safety From The System Brieﬁng Pack

Contents

• Introduction

3-4

• Advice

• Safety Connect

• Permit To Work

• Lock Out, Tag Out

• Point Touch Verbalise

• Competence

• Setting To Work

• Challenge it Stop it Own it

• Verify Containment

• Risk Assessment - System Hazards

Introduction

Risk Assessment

Permit to Work

Verify Containment

Lock Out Tag Out

Containment Counts Challenge

Point Touch Verbalise

POW-RESET

Competence

Introduction This briefing pack has been developed as part of our Safety From The System Campaign. Safety From The System is an industry wide requirement that, if not adequately managed and controlled, can lead to significant injuries or loss. To ensure that we avoid or mitigate the impact of unwanted events associated with Safety From The System, we have developed a campaign to heighten awareness of the hazards and the controls that are essential to eradicate or mitigate the consequences of such events across all of our operations. Altrad has adopted the philosophy that all accidents, incidents and ill health can be significantly reduced by the provision of adequate information, instruction, training and supervision. The pack forms part of the campaign material and should be used in conjunction with any other materials developed, such as within our corporate memory and local “learning From Experience”. It is essential that the information contained within this pack is provided to all Altrad personnel who may undertake work which has the potential to exposed them to ‘system’ hazards. All facility, site and project managers are responsible for ensuring that they facilitate the establishment of a documented programme for the communication of these briefs to those personnel in their charge. Ideally the most senior person on site should deliver this communication, however when this is not possible a suitable substitute, who is in a position of authority may deputise. Each brief is to be delivered at a separate session, in line with a programme of communication that aligns with the work schedule/programme but at no greater than weekly intervals. Ideally one Safety From The System brief every week, however it is recognised that for “Short-term works” an accelerated programme may be required in order to deliver the full content of this pack. A record of the briefing sessions should be maintained locally at site. The delivery of the information contained within this pack will be the subject to audit performed either by internal or external parties.

Advice Those responsible for delivering the information contained within this pack to our employees must ensure that they have prepared for the talk and are fully conversant with the information they are responsible for delivering. Allow 10-15 minutes to deliver a session on each topic within this pack, ensuring adequate time is allowed for feedback from those attending the brief. When delivering the brief, add to the content by using personal experiences, or points of relevance to the site where the brief is being delivered. Additional information can address both best practice and instances where there are opportunities for improvement – use the content from our corporate memory to bring these talks to life! Those delivering the brief must ensure that a record has been made of those attending it and provide a copy of that record to their local HS&E Team. As with all verbal communications, those delivering the brief should: • • • •

Know the topic Talk clearly and concisely Talk honestly and from the heart Make the session interactive – ask questions of the audience to test their understanding • Allow the audience to ask questions • Ensure they are aware of the importance of the information being provided If any doubt about any of the content, please seek further advice from your local HS&E support.

Safety Connect

Permit To Work A Permit to Work (PTW) is far more than paperwork - it’s a critical safety control. Permits exist because the task involves hazards that must be identified, managed, and clearly communicated before work begins If the permit process is rushed or ignored, the risk of a serious incident increases. Even a “quick five-minute job” can lead to harm if the PTW controls are not fully and rigorously followed. A Permit to Work (PTW) helps keep us safe by improving: • Planning – making sure all required controls are in place before starting • Communication – ensuring operations, maintenance, contractors, and supervisors share the same understanding • Awareness – confirming everyone knows the hazards and the safe sequence of work Everyone involved must: • Read and understand the permit • Sign on before starting (and sign off when finished) • Follow the controls exactly as written • Ask questions if anything is unclear • Stop work if conditions change or something doesn’t feel right Has anyone experienced a situation where there were issues with a Permit, conditions changed and the permit needed to be updated? Why the PTW Process Matters A work party had received and signed onto a permit, reviewed hazards, and completed the Altrad setting-to-work process. The permit stated that isolations were in place — and the shift technician verbally confirmed the conveyor was isolated. However, when the cover was removed, the conveyor was still live. The work party did the right thing - they stopped work, reported it to the technician who then arranged for the conveyor to be isolated remotely by the control room. This is a reminder: the permit is a control, not a guarantee. Verification is essential, and speaking up is critical. What can we do as a team to improve our permit practices? Remember: If your name is on it, you are responsible for working safely under it.

Lock Out, Tag Out (LOTO) Lock Out, Tag Out - or LOTO - is one of the most important things we do when we’re working on or near live plant. Whether it’s gaining access, doing maintenance, or carrying out routine servicing, LOTO is what keeps us safe when equipment could move, start, or release energy. LOTO is about making sure the equipment is properly shut down, isolated from every energy source, and can’t be restarted while we’re working on or next to it. It’s not just about electrical power. Energy can come from many sources: mechanical movement, hydraulic or pneumatic pressure, stored energy, heat, chemicals, even gravity. If it can move, shift or release something unexpectedly, it needs to be controlled. When we apply LOTO, we physically lock the isolation point so it can’t be operated, and we attach a tag showing who put it on and why. That tag is basically saying to everyone: “This equipment is out of service - don’t start it, don’t energise it.” Why does this matter? Because unexpected movement or start-up can lead to serious, life changing injuries - everything from electric shock and crushing to burns, amputations, or chemical exposure or worse. So think about it: • What could happen if something isn’t isolated properly, or if someone removes a lock before it’s safe? • Have you ever seen or heard of an incident where poor LOTO practice led to a problem? Case Study (Non Altrad Event) - Hydraulic Press Crush Injury A maintenance tech was working on a hydraulic press that looked shut down. The power was disconnected, and the work order was approved. But here’s what was missed: stored hydraulic energy was still trapped in the cylinder. When the worker started maintenance, that trapped energy released, and the press crushed the worker’s hand. This wasn’t just an error; it was a complete breakdown in energy control procedures. By providing lockout / tagout programs, training and enforcement, these incidents and many others can be avoided. This is why we say: If it’s not locked and tagged, it’s not safe to work on.

Point, Touch, Verbalise Three Words. One Safe Outcome. Before any task, whether we’re scaffolding, painting, insulating or working on electrical or mechanical systems, we need absolute certainty that we’ve positively identified what we are working on, that we are all focused on the same item and understand where the hazards lie. Point, Touch, Verbalise gives us that certainty. It removes assumptions and keeps us protected from system hazards. POINT - directly at the exact item: the valve, line, panel, emergency stop, isolation point, or hazard. Check tags, labels, line numbers, or markers. Why: People often think they’re talking about the same item - until they point. Pointing removes assumptions and visually confirms alignment. TOUCH - Physically touch the item you’re about to work on or avoid. Why: Equipment can look similar, sit close together, or be partially hidden. Touching confirms the correct item in the real world, not in memory or assumption. VERBALISE- Clearly state what the item is - and have the other person repeat it back. Why: Saying it out loud ensures shared understanding. No silent assumptions. No mismatched expectations. While walking down the job, a Permit Engineer shows an Altrad Supervisor several emergency stop buttons that must not be activated during a scaffold build. They POINT to each button, they TOUCH them to confirm the exact units, they VERBALISE together: “These three emergency stops - avoid contact during work.” Now both people share the same mental picture. Clear alignment. No assumptions. No mistakes. Discussion Points Have you ever seen a situation where Altrad and the client disagreed on a plant item - what caused the confusion? Have you ever arrived at a job and realised the item in front of you wasn’t the one you expected - What helped correct the mistake? How often do we assume understanding instead of speaking it out loud? Could that assumption lead to a serious error? Three Words. One Safe Outcome: Point, Touch, Verbalise.

Competence Competence isn’t just having a ticket or having “done it before”. It’s a blend of: • • • • • •

Training – you’ve been shown how to do it Skills – you can do it correctly Knowledge – you understand the task and the hazards Experience – you’ve done it enough to be conﬁdent and capable Attitude & Behaviour – you take the job seriously and follow the rules Physical Capability – you are ﬁt and able to do the task safely

To be competent, you must not only know what you know - but also be aware of what you don’t know. The key question everyone should ask before starting any task: “Is there anything about this job that I don’t fully understand?” If the answer is yes, or even maybe, you may not be competent for that task yet and that’s the moment to stop and speak up. Why Competence Matters (especially with system hazards) Think about hazards like: • Stored energy (hydraulic, pneumatic, electrical, mechanical, thermal) • Product under pressure • Chemical energy • Equipment with residual movement or tension With these hazards, a small knowledge gap can create a big safety risk. Competence ensures that the right person, with the right controls, is doing the work safely. A technician is asked to depressurise a line. They’ve isolated equipment before but haven’t worked on this particular system. They’re unsure where the ﬁnal residual pressure point is. • What should they do? • At what point should they stop and ask for support? • Who is responsible for making sure they are competent - them, or the supervisor, or both? What tasks on site today would you not allow a new person to site do without close supervision? Competence is a shared responsibility, always have the courage to speak up if ever in any doubt.

Setting to Work Every one of us plays a part in the Setting to Work process. It’s there to make sure the job is properly planned, the hazards are understood, and that we all know exactly what is required before we start work. A key part of this is the Point of Work – Reset (POWR).This must be completed at the workface, just before the task begins. Even if one person completes the form, every team member must be involved, must contribute, and must agree with what’s written. This is how we make sure: • All hazards have been identified • Controls are in place and still effective • Nothing new or unexpected has emerged • Everyone understands the plan and their responsibilities Your signature has value. No one should sign unless they’ve taken part and genuinely agree with the POWR. Supervisors are expected to check in regularly, review the POWR with the team, and record these checks during the shift. These check-ins aren't about policing they’re about making sure the job stays safe as conditions change. • Why is it important that everyone is involved in the POW Reset, not just the person completing the form? • What local hazards are commonly identified during a POW Reset? Recently, during a routine task, the team completed the POWR and identified all expected hazards. However, when walking the job, someone noticed a new trip hazard created by overnight housekeeping activities. Because the team had paused to assess the actual work area, the hazard was spotted, controlled, and the job continued safely. This goes to show that POWR isn’t paperwork - it’s an extra layer of awareness that keeps us safe.

Challenge It, Stop It, Own It! Stop Work Authority - Everyone Has It. Everyone Must Use It. It means anyone - regardless of role, trade, or seniority - can stop a job the moment something looks, feels, sounds or even smells unsafe. It’s a vital tool to help us prevent unwanted events. Workplaces change fast. Permits don’t always reﬂect real-time conditions. Weak signals often appear before something goes wrong. Using Stop Work Authority keeps us ahead of the hazard. Trust Your Senses. If something looks, sounds, or smells wrong, it probably is. Conditions Change, A permit may be valid at 7:30 AM… but the job may be unsafe at 8:00 AM. Stay alert and reassess continuously. Stop Work = Protection. Stopping work is never the wrong decision. No blame. No pressure. No consequences. Your authority is supported and expected. A scaffold team is preparing to enter a tank. The Permit to Work says it’s safe to enter. The conﬁned space paperwork requires no ventilation or monitoring. But as they approach, they smell an unusual odour. They STOP immediately, report it, and wait. Their quick action prevents exposure to a potentially unknown atmosphere. Weak signal spotted. Hazard avoided. Job safe. What “weak signals” have you noticed on jobs before? Odours, heat, vibration, unusual noises, unexpected product, residue, pressure changes. Would you personally stop work if you sensed something wasn’t right? If not - what would stop you? Do we routinely verify permit conditions, or do we trust the paperwork too much? Do you feel empowered to challenge the PTW or supervisor if reality doesn’t match the permit? What would help make that easier? If in doubt - call it out. Stopping the job is not a disruption. It’s leadership. It’s protection. It’s how we keep each other safe.

Verify Containment Before we start any job, there’s one question we must be able to answer with confidence: Are hazards from the system fully contained? “Verify Containment” isn’t about trusting paperwork, permits, or assuming everything is fine, just because someone else has said so. It’s about physically checking - with your own eyes - that everything holding back energy, pressure, or hazardous substances is properly in place and doing its job. That means confirming things like: • Barriers and guards are fixed and secure • Exposed electrical equipment and cables are protected • Isolations are actually applied, valves are locked off; blanks, blinds, and seals are correctly installed • There are no leaks, weeps, or defects present • The system is genuinely de-energised, depressurised, or drained Can anyone recall and unwanted event – even a near miss, that was a result of us failing to verify containment? A mechanical team were tasked with removing three safety valves as part of the ongoing safety-valve scope for the shutdown. The three valves had been identified and tagged by the client, and this was reviewed during the pre-job visit. Altrad’s setting-to-work process was completed in accordance with the relevant procedure. During the breaking of containment, the team detected slight pressure at the flange. Exercising their Stop Work Authority, the mechanical team halted the task and notified the client of their concerns. Following this, the team were stood down, the permit returned and an investigation initiated. In simple terms: Don’t guess. Don’t assume. Verify Containment at the workface. Because if containment fails - even a small amount - people can get hurt. If containment cannot be verified, then the work does not start - NO EXCEPTIONS.

Risk Assessment - System Hazards Why Risk Assessment Matters A risk assessment isn’t just paperwork - it’s how we stay safe from hazards that can seriously injure people, especially those linked to: • Stored energy – hydraulic, pneumatic, thermal, electrical, mechanical • Pressurised product – liquids, gases, chemicals • Residual system hazards – trapped pressure, movement, tension, temperature A good risk assessment helps us to: • • • •

Identify hazards before we’re exposed to them Understand the risks speciﬁc to the system we’re working on or near Put effective controls in place to prevent harm Adjust and re-evaluate when conditions or circumstances change

Because the status of systems can change, people can move into the area unexpectedly, product can remain trapped in pipework, temperatures can rise, or pressures can shift - risk assessment must continue throughout the job. We must all remain vigilant throughout the duration of any activity. What stored-energy or product hazards could appear unexpectedly if a job changes halfway through today or tomorrow? Whilst moving materials using a plant hoist, a stillage containing scaffolding equipment struck a ﬁxed handrail. This made the load unstable, causing several scaffold components to fall. These components then landed on a forklift truck from another company that had entered the area shortly beforehand. The incident occurred because the task had not been properly planned or adequately risk assessed. Essential risk controls-such as designated exclusion zones, clear load-path planning, and coordination between different work parties-were either missing or not effectively implemented. What should you do if site or system conditions change once work has started? When it comes to your safety – A Risk Assessment is your best investment!