'Keeping OSH on track: Spotting Hazards and Risk in a Complex

Environment'

How would you do it?

Tony Cox: CMIOSH David Butler: CMIOSH HSM Network Rail

17 October 2019

See 2nd slide for update

Note to viewers using this pdf (22/10/19)

• This icon indicates links to videos. These require an internet connection to function and were current at the time of publication (22/10/19)

• Feedback from delegate groups now included (Session 2).

• Additional material covered during the session is now included at the end.

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Speakers

• Tony Cox: CMIOSH Health & Safety consultant.More than forty years employed by the Regulator first as HM Inspector of Factories then as HM Inspector of Railways encompassing developments in UK & EU health & safety pre-Robens until retirement in the current decade. Became a IOSH RSP in 1989 and a Chartered Member in 2005. Experience in investigation, inspection and enforcement in most industry, service and railway sectors during that time.

• David Butler: CMIOSH H&S Manager (Strategic) Network Rail High OutputTrack RenewalsA business studies graduate, chartered H&S practitioner and former member of the Institute of Industrial Accident Investigation (MIIAI), I have been advising on H&S for over 15 years. I have experience in UK railway Railtrack, Railway Safety , RSSB, logistics and warehousing and retail – Royal Mail, Parcel Force and Amazon. Former chair of the Parcel Carriers’ Safety Association. Contributed to High Output achieving the British Safety Council 5 Star Audit award and Sword of Honour 3 years running.

Introduction

• Recent branch planning meeting –how we could help members to be more confident when encountering situations well outside of their comfort zone

• Chiltern is not a specialist group but we came up with railway situation which we felt most if not all, are likely to be unfamiliar.

• The example is real and we expect you to use first principles to identify the various issues – and at the end David will tell you what actually has happened.

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Introduction continued..

• The situation could arise as part of investigation, audit or even regulatory enforcement.

• expect tables to pool H&S experiences and to work as a group.

• Our time will be broadly divided into 3 sessions:

Session 1: basic analysis and feedback. Followed by discussion on findings and greater speaker explanation.

Session 2: Further analysis and feedback

Session 3: Where are we now?

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Setting the scene

• Network Rail currently has 20000 miles of track covering the UK.

• Our railways are one of the most intensively used in the world – much of the infrastructure was laid down in the 19 century.

• It needs regular maintenance to keep the trains running – the scene of teams working trackside is going with introduction of mechanised inspection and maintenance equipment with better specification of materials and design of equipment used. And a lot of work now takes place at night.

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Setting the scene

• Most of it is ballasted track where the rails are supported on a base or foundation of crushed stone. Sleepers are used to keep the rails in gauge using fastenings, usually clips. Ballast ensures the rail is kept level and allows drainage.

Setting the scene

• Network Rail uses a number specialised machines tofor track maintenance or replacement.

• Ballast: HIGH OUTPUT BALLAST CLEANER (HOBC).

• There are now 4 HOBC machines in the country costing about £20million each - sufficient to cover the routes including conductor rail DC (Southern).

• They are normally used at night. After setting up you probably on get 1hour or less work before the track has to be handed back to the operational railway.

• At first sight it all seems complicated but..

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HOBC Machine

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HOBC Machine

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HOBC Machine

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HOBC Machine

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HOBC Machine

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HOBC Machine

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HOBC Machine

• Cutter bar arrangement and installation (Photo)

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HOBC Machine

• Video of BCS in operation (2010)

• The whole working unit can be over ½ Mile (.8km) long.

• Staffing: team of 50-70 people are required per shift to operate the unit (depends on condition of old ballast, extent of possession available etc etc). 8-12 will be operators and managers/supervisors.

• Each shift costs around £100-150k to run (missed/cancelled shifts are thus expensive).

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Over to you

• Think outside the box – there are at least 16 areas of potential interest.

• Some of these are interrelated

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Session 2

Delegate Feedback I

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Delegate Feedback II

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I. Risks which were later provided by the speakers in summary

• Dust and RCS

• Noise

• Travel and Fatigue

• Communications between different teams

• Movement of machinery

• Any (Adjacent) lines open/open line working

• Rail operations

• Time constraints

• Permit to work systems

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II. Risks which were later provided by the speakers in summary

• Machinery safety

• Slips trips falls, lighting

• Contractor management

• Training

• Geography and worksite characteristics – proximity to line side neighbours

• Welfare arrangements.

• PPE

• Electricity

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III. Risks which were later provided by the speakers in summary

• Working at Height

• Projectiles (ballast)

• Manual handling

• Asbestos (ACM)

• Biological hazards

• Environmental hazards

• Trespass/security/level crossings

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Session 3

• High Output Track renewals to day

https://youtu.be/4AomnSbnwus

• Site briefings today

https://network-rail.wistia.com/medias/gxm8ahsaiu

Watch from mins 1:07 until to mins 12:26

Session 3 – Where is Network Rail today ?

What’s changed? Fatigue & Occupational Road Risk

What’s changed? Open Line Working & ALO

https://network-rail.wistia.com/medias/ycaeytygsk

Dust: the problem illustrated

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1) CoSHH Assessment, how does the

substance cause, harm, to who, where, when

2) Precautionary Approach –

Blanket approach to PPE controls

3) Commissioned RCS Monitoring

and Analysis

4) Began Learning –

implementing changes

What’s changed? Dust

First Steps

Daily exposure

limit…

What’s changed? RPE/PPE

What’s changed? Training

• RPE Use

• Buddy system wipe down and storage

• Maintenance of RPE - replacing filters,

• Face fit testing – for FFP3 and Airfed RPE

• Trained - Face fit testers

• Health awareness

• Maintaining training records – for a

competence Alien to Network Rail

What’s changed? Processes

What’s changed? Engineered Solutions

What’s changed? Eliminate at Source

Quarry ProcessLoad and

Transport to MHDs

Store pending demand

Load and Deliver to site

Process into Track/ reuse

existing

Remove Spoil and transport

to MHD

Clean Down and Prepare

Train

We are Leading not Lagging

Still Challenges & Opportunities ahead – no room for complacency!

Your Thoughts ? …?

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Closing Summary

Additional material

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Silica dust follow up after visit

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• Part of ORR presentation to Network Rail 10/10

Making a point – regulator visit with air fed RPE (2010)

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HOBC Comms: Site presentation

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Presentation given to ORR on site oncomms requirements. Once the BCS reaches the work site it is no longer operated under railway rules In still needs contact on the lower 3 separate levels.

Tamper (see BCS arrangements in slide 8)

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Diagrams

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Fresh Ballast system

RM900-RT Work Unit

Ballast Screen

Diagrams

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Spoil Waggons (interconnected)

Fresh Ballast waggons (interconnected)