The Baker Panel Report - ABSA

Perhaps more significantly, BP’s data indicate that some hourly workers work overtime hours that the Panel believes is clearly excessive. Thefollowing table shows the percentage of overtime (expressed as a range) worked by the ten hourly workers with the highest amount of overtime ateach site:Table 12Percentage of Overtime by Ten Hourly Workers at Site with Highest Amount of OvertimeSite 2002 2003 2004 20051/1/06-6/30/06Carson 55-75 58-74 59-84 60-86 70-114Cherry Point 27-36 29-36 39-48 38-59 41-54Texas City 68-79 69-93 80-94 86-96 87-121Toledo N/A 39-93 33-48 42-56 N/AWhiting 64-96 72-116 74-89 73-99 83-127The average overtime data at each refinery suggest that the refineries have been understaffed at the operations and maintenance functions foryears. In addition, the overtime percentages shown in Table 12 above suggest that the refineries’ management of overtime has not beeneffective to avoid excessive overtime. Some hourly workers worked more overtime than non-overtime in 2006, and the trend does not appear tobe improving.The Panel’s concern about excessive work hours is not limited to hourly employees and contractors. Although BP apparently does not closelytrack the hours that salaried refinery personnel work, the Panel’s review suggests that some managers and other non-hourly personnel workexcessive hours. In addition to the Mogford Report, which notes that many supervisors had been working for extended periods leading up to theTexas City ISOM accident, a variety of other BP documents reflect concerns about certain personnel working excessive hours. For example, theJune 19, 2003 meeting minutes from the HSSE-PSM Committee for the Toledo refinery reflect these concerns:Twice recently, lab employees were forced to work 24 hours straight. They were offered accommodations such as a cabride home and back to retrieve their vehicles. However, fatigue is a common cause of accidents in the workplace. ACircadian Technologies survey was cited which stated that the lack of sleep for 20—22 hours has the same effect as ablood alcohol level of .08.The Panel does not believe that any bright lines delineate excessive overtime from non-excessive overtime. While the Panel is not aware of anyrefining industry norms or benchmarks for overtime, the Panel is aware that guidelines, standards, and restrictions on working excessive hoursexist in other industries (such as nuclear generation and airlines) that involve hazardous operations. The Panel believes it is appropriate toconsider a particular worker’s position and working conditions in assessing whether overtime or other extended hours can be worked withoutcompromising process safety and increasing risks. Nonetheless, the Panel believes that BP’s average rates of overtime for operations andmaintenance personnel, and in particular the overtime rates for certain workers, are excessive and may compromise process safety.Corporate Safety Culture C 88