Contractor Safety in Plants
Contractors do a large share of maintenance, turnaround and construction work in refineries, chemical plants, mills and factories. They also suffer a large share of the injuries. They work in unfamiliar areas, with unfamiliar hazards, alongside operations. Clear communication and shared responsibility between the host plant and contractor are the keys to getting everyone home.
- Contractors
- Plant Managers
- Safety Coordinators
- Operators
- Project Supervisors
Why contractors are at higher risk
- They don't know the plant's hazards, alarms, layout and rules.
- Plant operations continue around them, with process hazards such as flammable gases, toxic chemicals and high pressure. See Process Safety Management.
- Short, high-pressure schedules and shift work lead to shortcuts and fatigue.
- Different employers with different safety programs and training can cause gaps. See Multi-Employer Worksites.
What the host plant must do
- Under OSHA's PSM standard (29 CFR 1910.119(h)), the host employer must evaluate contractors' safety records and programs when selecting them, inform them of the hazards of the process, emergency plans and safe work practices, control the entry of contractors into covered process areas, and keep injury and illness logs for contract workers in their area.
- Provide site orientation covering hazards, rules, permits, alarms, evacuation, muster points, restricted areas and who to call.
- Operate a permit system for hot work, confined space entry, line breaking, excavation, lockout, and others. See Permit to Work, Hot Work Permits and Group Lockout.
- Coordinate contractor work with operations and other contractors, including simultaneous operations (SIMOPS).
- Provide emergency response information and conduct drills including contractors.
- Use management of change and pre-job reviews. See Management of Change.
What contractors must do
- Train employees for the work and the plant's hazards, and document training. Ensure workers know the rules before entering.
- Follow the plant's safety rules and permits in addition to their own program and OSHA requirements.
- Tell the host about hazards the contractor brings and any incidents. Report injuries and near misses promptly.
- Provide competent supervision and qualified people, with the right PPE and equipment.
- Be honest in pre-qualification about incident rates, citations and programs.
- Use lockout and personal locks. Don't work on equipment without the plant's authorization and a verified isolation.
Good practices for workers
- Attend the orientation and ask questions. Know the alarms, muster point, nearest safety shower and exits.
- Carry required PPE such as hard hat, safety glasses, FR clothing, gloves, boots, hearing protection and gas monitors. Use a respirator if needed.
- Do a pre-job safety review (JSA/JHA) with the operator and crew, and review the permit. See Job Hazard Analysis.
- Don't work outside the permit or in other areas. Stay in the authorized zone.
- Report leaks, odors, alarms and unusual conditions at once, and stop work if things change.
- Know your stop work authority. Any worker can and should stop unsafe work.
- Don't operate plant valves or equipment unless authorized.
- Housekeeping: keep the work area clean, leave no tools or materials in the way.
Contractor safety checklist
- I attended the plant orientation and know alarms, muster points and restricted areas
- Permits are in place and I stay within them
- Equipment is locked out with my own lock and verified
- We did a pre-job hazard review and wear the required PPE
- I know I can stop work and report hazards without penalty
Standards & references
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