ra for n2he leak test_comment shahram

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2. Risk Assessment for Nitrogen Operations

(RA 006)

Generic Risk Assessment

Team Leader 25/1/2012

RA Member 4/5/2012

RA Member 3/5/2015

RA Member

Approved by

On-Site Review

1a 1b 1c 2a 2c 2d 2e 3c 3d 3e 3b 3f

No Activity Safety Hazard Possible Accident/ Ill-Health/Personal Risk

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1 General Trips, Slips and falls Personal Injury 3 2 6 3 1 3 Supervisor

Step over barriers to be used where practicable. Good housekeeping standards to always be

Attention drawn to potential hazard. Carry

RA-006

Signature

1.Hazard Identification 2. Risk Evaluation

Existing Risk Control

2b 3a

3.Risk Controls

Task:

Risk Assessment Team

Name

RA NumberNitrogen OperationsRISK LEVEL ACCEPTABILITY MATRIX

Additional Risk Control

Date Assessed

Last Review Date

Next Review Date

Approval Date

On-Site Review Date

Activity may proceed with existing risk controls.1-3 ACCEPTABLE

Activity may only proceed with additional risk controls that reduce the risk level.

4-12 TOLERABLE

Activity cannot proceed. Hazards must be eliminated by other means and a New Risk Assessment carried

out.Approval & Review 12-25 ALARM


Untrained Crane Operator, rigger or signalman

Personal Injury Equipment Damage

5 2 10 5 1 5Crane Operator,

Rigger & signalman

Crane Equipment FailurePersonal Injury

Equipment Damage5 2 10 5 1 5 Client

Lifting Equipment FailurePersonal Injury

Equipment Damage5 2 10 5 1 5

Crane Operator, Rigger &

signalman

Equipment not properly secured.



Rigger & signalman

Equipment swinging Personal Injury


Crane Operator, Rigger &

signalman

Untrained Driver. Personal Injury

Equipment Damage5 1 5 5 1 5 Forklift Operator

Any complex lifting operations require a written lifting plan. The plan will be

discussed with all personnel involved in the lift. Lifting operations to be highlighted

at VSCC/PSCC meeting

2 Crane Lifting

Good housekeeping standards to always be maintained. Route cables, hoses & wires correctly

out regular Inspections

Comply with Client Lifting Procedure

Ensure Load Properly Secured.

Trained personnel only to operate crane. Rigger/signalman must also be trained

Ensure proper communicatios are established eg Walkie talkies

Comply with Client Lifting Procedure Client to conduct equipment maintenance checks

Only certified lifting equipment to be used. (this equipment should be checked for general condition, suitability before use). Barricade affected lifting area when required

Assign watchman to patrol area

Tag Line fitted to equipment

Trained forklift drivers to operate equipment.

Comply with Client Lifting Procedure. Barrier area under load path

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- Unknown to local site regulations and requirements. - Incompetent personnel. - Conflic with work schdule - Wrong operation method

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-Require Name of RA members and Approval name - Update last review date

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Shall be highlight the color as Risk matrix

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- ZPQ Nitrogen Helium leak testProcedure approved by Company (PTTEPI) - Work plane schedule to be announced to all concerned parties - Project Specific Induction / Project SSHE Briefing all Nitrogen Helium leak test operation team prior to arrival at site. - Pre-start meeting to inform the crews on operation plan, Familiarization of Zawtika SSHE rules and regulations - Adequate lighting at nigh - Adequate PPE inclusive of fall arrestor -Provide proper egress and access

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SMOE CESCO

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- Equipment List & Certification in place - Check equipment and regular maintenance before use and report in place

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Certified Crane operator and Rigger / Signal man.

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SMOE CESCO

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SMOE

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Zawtika project

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SMOE CESCO

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Zawtika project

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- Barricading shall be erected prior to work. - No person under load/hook - Provide adequate lighting; - Competent Personnel; - Provide adequate PPE

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Zawtika project

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Certified Forklift driver

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SMOE CESCO


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2b 3a

3.Risk Controls


Overloading the forks. Personal Injury


Enviromental Conditions eg Wet or Uneven road surfaces

Equipment Damage 3 2 6 3 1 3 Forklift Operator

Fall from height Personal Injury 4 2 8 3 1 3 Supervisor

Dropped Objects Personal Injury 4 2 8 3 1 3 Supervisor

Rig up to wrong systemPersonal Injury Equipment Damage

3 2 6 3 1 3 Supervisor

3 Forklift Operations Keep loads within forklift rated capacity

Check forklift rated capacity & load weight prior to operation

Ensure all scaffolding has a valid Scaffolding Inspection Tag (Scaftag) Safety harnesses to be used as directed by Client Procedures. Ensure 3 point contact during climbing up/down the ladder and make sure the ladder place in a even surface.

Check condition of body harness before use

4

Adherence to safe Operating Procedures. Not using forklift during bad weather

Hard barriers c/w ‘kick boards’ to be erected around open hatches. Signs and barriers to be erected to prevent access to all relevant immediate and adjacent work areas.

Keep tools and equipment well away from open hatches.Persons must not work above others below & persons must not work with others working above.Good housekeeping standards to be maintained on work-site at all times.

Working at height

Test Pack Workbook to be signed by Client

Line walk system prior to rig up. Ensure it matches the test pack/line number

Incorrect Use Of Hand tools Personal injury 2 2 4 2 1 2 Supervisor

Manual Handling Personal Injury 3 2 6 2 2 4 Supervisor

Blocking escape routes with cables, hoses or wires

Personal Injury 2 1 2 2 1 2

Hose connections coming undone

Personal Injury 3 2 6 3 1 3 Supervisor

Incompatible/ faulty fittings Leaking hoses 3 2 6 3 1 3 Supervisor

5

Use correct and compatible connections at all times. Check that the correct ratings of fittings are being used. Carry out visual inspection on fittings.

Always use whip checks on all hose connections. Carry out visual inspection on fittings and hoses. Use certified hoses only

Check condition of hand tools before use

Rig up

Trained Personnel.All equipment checked for suitability.

Carry out air test

Use certified & tagged whipchecks

Ensure proper routing using arches, S hooks etc

Personnel made aware of Manual Handling Hazards

Supervisor and worker jointly review the work method and plan activites

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- Use of banks man and forklift with reverse alarm / sound horn to warn others - Position equipment correctly. - Trained & Certified Operators with certified lifting equipment. - Ensure suitable ground condition. - Be aware of the movements of forklifts

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SMOE CESCO

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- PTW System - JSA / Tool box

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- Certified lifting equipment

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ShahramV

Note

Screw and Thread connections to be checked for tightness before any pressure apply.


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3.Risk Controls


6 Air Test Hose,Fitting, Pipework FailureUncontrolled Pressure Release. Personal Injury

3 2 6 2 1 2 Supervisor Testing operations to be highlighted at VSCC/PSCC meeting

Explosion. 5 2 10 5 1 5 Supervisor

Uncontrolled Pressure Release. Personal Injury Equipment Damage


Fire 4 2 8 4 1 4 Supervisor

LN2 Spillage 3 2 6 3 1 3 SupervisorEffective Emergency Response in place

Barricade affected area where required. Assign watchman to patrol area

Preventative Maintenance Schedule in operation, Access to area restricted

Pump/Tank Catastrophic Failure

Effective Emergency Response in place

Effective Spillage controls in place e.g. bunding.

Always use whip checks and on all air connections. Carry out visual inspection on fittings and hoses. Use certified hoses only. Use correct and compatible connections at all times. Check that the correct ratings of fittings are being used.

Preventative Maintenance Schedule in operation, Access to area restricted Patrol area to check for leaks


Access to area restricted. Fire extinguisher on standby.


LN2 Spillage 3 2 6 3 1 3 Supervisor

Noise PollutionInconvenience to adjacent workers/ Hearing loss


Pipe work FailureUncontrolled Pressure Release. Personal Injury Equipment Damage


Hose RuptureUncontrolled Pressure Release. Personal Injury Equipment Damage


Fitting FailureUncontrolled Pressure Release. Personal Injury Equipment Damage


Noise Pollution During VentingInconvenience to adjacent workers/ Hearing loss


Do not run engine unless requiredMaintain engine according to schedules. Use correct PPE. Access to area restricted



7ANitrogen Operations

using N2 Pump


Assign watchman to patrol area.

All equipment checked for suitability.Only in date certified equipment to be used Effective Spillage controls in place e.g. bunding. Access to area restricted Use whipchecks as required


bunding. Access to area restricted Wear correct PPE

All equipment checked for suitability.Access to area restrictedOnly in date certified equipment to be used. Use of Correct PPE.

Testing operations to be highlighted at VSCC/PSCC meeting. MSDS Sheet for LN2 should be available so that correct PPE can be supplied

Use correct PPE. Access to area restricted Assign watchman to patrol area

Effective Spillage controls in place e.g. bunding. Access to area restricted Wear correct PPE

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SomsakN

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- Approved procedure to follow. - PTW / Tool box talk - Lock out / Tag out - Competent operators - Use of over - rated hose & Fitting, use of cryogenic materials. - N2 storage / Pumping within bunded area - Well ventilated work area - Warning signs and barriers, Only authorised personnel to be allowed in. - Operation Pressure shall be increased step by step at 25%, 50%, 100% of pressure. - Leak test shall be checked between each step. - Correct PPE Certified equipment - Pre tested equipment - Controlled venting via suitably sized double block & bleed - Control of discharge temperature - PRV. certified - PRV's must have 10% higher pop up set pressure to the line test pressure required. - Whip checks on hoses - Pressure gauges used at both ends of test package to ensure all pressure is beld off the system.

ShahramV

Note

if any leak occurred during the test/ equipment must be depressurized before rectification

ShahramV

Note

Before Testing all welding joints required RT Survey


1a 1b 1c 2a 2c 2d 2e 3c 3d 3e 3b 3f


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2b 3a

3.Risk Controls


Pipe work Failure

Uncontrolled Pressure Release. Personal Injury Equipment Damage Oil Spillage

3 2 6 3 1 3 SupervisorTesting operations to be highlighted at VSCC/PSCC meeting.

Hose Rupture

Uncontrolled Pressure Release. Personal Injury Equipment Damage Oil Spillage


Fitting FailureUncontrolled Pressure Release. Personal Injury Equipment Damage


Noise Pollution During Pressuisation/Venting

Inconvenience to adjacent workers/ Hearing loss



7B

Use correct PPE. Access to area restricted

Testing operations to be highlighted at VSCC/PSCC meeting.

Effective Spillage controls in place e.g. bunding. Access to area restricted Wear correct PPE


All equipment checked for suitability.Only in date certified equipment to be used Effective Spillage controls in place e.g. bunding. Access to area restricted Use whipchecks as required




Nitrogen Operations using Gas Bottles



All equipment checked for suitability.Access to area restrictedOnly in date certified equipment to be used. Use of Correct PPE.

8 Rig down

Manual Handling Personal Injury 3 2 6 2 2 4 SupervisorSupervisor and worker jointly review the

work method and plan activitesPersonnel made aware of Manual Handling Hazards

8 Rig down

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- Approved procedure to follow. - PTW / Tool box talk - Lock out / Tag out - Competent operators - Use of over - rated hose & Fitting, use of cryogenic materials. - N2 storage / Pumping within bunded area - Well ventilated work area - Warning signs and barriers, Only authorised personnel to be allowed in. - Operation Pressure shall be increased step by step at 25%, 50%, 100% of pressure. - Leak test shall be checked between each step. - Correct PPE Certified equipment - Pre tested equipment - Controlled venting via suitably sized double block & bleed - Control of discharge temperature - PRV. certified - PRV's must have 10% higher pop up set pressure to the line test pressure required. - Whip checks on hoses - Pressure gauges used at both ends of test package to ensure all pressure is beld off the system.

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3. Risk Assessment for Pressure Testing

(RA 009)

Risk Assessment

PRESSURE TESTING

Team Leader 25/1/2012

RA Member 4/5/2012

RA Member 3/5/2015

RA Member

Approved by

On-Site Review

1a 1b 1c 2a 2c 2d 2e 3b 3c 3d 3e 3f


Severity

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Remarks


On-Site Review Date

Addiional Risk Control

Approval Date

3a

3.Risk Controls

Step over barriers to be used where practicable. Good housekeeping standards to always be

Attention drawn to potential hazard. Carry out regular Inspections

Date Assessed

Last Review Date

Next Review Date

2b

Signature

Approval & Review

RA Number

Risk Assessment Team

NameRISK LEVEL ACCEPTABILITY MATRIX

RA-009



Task:

1-3 ACCEPTABLEActivity may proceed with existing

risk controls.

Activity may only proceed with additional risk controls that reduce

the risk level.4-12 TOLERABLE

Activity cannot proceed. Hazards must be eliminated by other means and a New Risk Assessment carried

out.

12-25 ALARM


Untrained Crane Operator, rigger or signalman



Rigger & signalman

Crane Equipment FailurePersonal Injury

Equipment Damage5 2 10 5 1 5 Client

Lifting Equipment FailurePersonal Injury


Crane Operator, Rigger & signalman

Equipment not properly secured.



Rigger & signalman

Equipment swinging Personal Injury


Crane Operator, Rigger & signalman

Any complex lifting operations require a written lifting plan. The plan will be

discussed with all personnel involved in the lift. Lifting operations to be highlighted

at VSCC/PSCC meeting

2 Crane Lifting

Comply with Client Lifting Procedure Tag Line fitted to equipment

Comply with Client Lifting Procedure Client to conduct equipment maintenance checks

Only certified lifting equipment to be used. (this equipment should be checked for general condition, suitability before use).

Barricade affected lifting area when required. Assign watchman to patrol area

Trained personnel only to operate crane. Rigger/signalman must also be trained

Ensure proper communicatios are established eg Walkie talkies

Comply with Client Lifting Procedure. Barrier area under load path

Ensure Load Properly Secured.

Good housekeeping standards to always be maintained. Route cables, hoses & wires correctly

out regular Inspections

1 of 4

SomsakN

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- Control of discharge temperature - PRV. certified - PRV's must have 10% higher pop up set pressure to the line test pressure required.

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-Require Name of RA members and Approval name - Update last review date

SomsakN

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- Unknown to local site regulations and requirements. - Incompetent personnel. - Conflic with work schdule - Wrong operation method

SomsakN

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SomsakN

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Shall be highlight the color as Risk matrix

SomsakN

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Certified Crane operator and Rigger / Signal man.

SomsakN

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- Equipment List & Certification in place - Check equipment and regular maintenance before use and report in place

SomsakN

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- Barricading shall be erected prior to work. - No person under load/hook - Provide adequate lighting; - Competent Personnel; - Provide adequate PPE

SomsakN

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SMOE

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SMOE CESCO

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SMOE CESCO

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SMOE CESCO

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SMOE CESCO

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Zawtika project

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Zawtika project

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Zawtika project

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- ZPQ Nitrogen Helium leak testProcedure approved by Company (PTTEPI) - Work plane schedule to be announced to all concerned parties - Project Specific Induction / Project SSHE Briefing all Nitrogen Helium leak test operation team prior to arrival at site. - Pre-start meeting to inform the crews on operation plan, Familiarization of Zawtika SSHE rules and regulations - Adequate lighting at nigh - Adequate PPE inclusive of fall arrestor -Provide proper egress and access

SomsakN

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Risk Assessment

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RemarksAddiional Risk Control

3a

3.Risk Controls

2b



Untrained Driver. Personal Injury


Overloading the forks. Personal Injury


Enviromental Conditions eg Wet or Uneven road surfaces

Equipment Damage 3 2 6 3 1 3 Forklift Operator

Fall from height Personal Injury 4 2 8 3 1 3 Supervisor

Dropped Objects Personal Injury 4 2 8 3 1 3 Supervisor

3 Forklift Operations

Hard barriers c/w ‘kick boards’ to be erected around open hatches. Signs and barriers to be erected to prevent access to all relevant immediate and adjacent work areas.

Keep tools and equipment well away from open hatches.Persons must not work above others below & persons must not work with others working above.Good housekeeping standards to be maintained on work-site at all times.

Adherence to safe Operating Procedures. Not using forklift during bad weather

Ensure all scaffolding has a valid Scaffolding Inspection Tag (Scaftag) Safety harnesses to be used as directed by Client Procedures. Ensure 3 point contact during climbing up/down the ladder and make sure the ladder place in a even surface.

Check condition of body harness before use

Trained forklift drivers to operate equipment.

Keep loads within forklift rated capacityCheck forklift rated capacity & load weight prior to operation

4 Working at height

Rig up to wrong systemPersonal Injury Equipment Damage




Blocking escape routes with cables, hoses or wires

Personal Injury 2 1 2 2 1 2

Hose connections coming undone

Personal Injury 3 2 6 3 1 3 Supervisor

Incompatible/ faulty fittings Leakage 3 2 6 3 1 3 Supervisor

5

Ensure proper routing using arches, S hooks etc

Always use whip checks on all connections. Carry out visual inspection on fittings and hoses. Use tested & certified hoses only

Rig up


Test Pack Workbook to be signed by Client

Use certified & tagged whipchecks

Use correct and compatible connections at all times. Check that the correct ratings of fittings are being used. Carry out visual inspection on fittings.

Carry out low pressure test




Line walk system prior to rig up. Ensure it matches the test pack/line number

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SomsakN

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Certified Forklift driver

SomsakN

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- Use of banks man and forklift with reverse alarm / sound horn to warn others - Position equipment correctly. - Trained & Certified Operators with certified lifting equipment. - Ensure suitable ground condition. - Be aware of the movements of forklifts

SomsakN

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- PTW System - JSA / Tool box

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- Certified lifting equipment

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SMOE CESCO

Risk Assessment

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3a

3.Risk Controls

2b







Water Spillage 3 2 6 3 1 3 Supervisor



High Pressure Hose RuptureUncontrolled Pressure Release. Personal Injury Equipment Damage


Hydrotesting Pressure Testing using Water

6A

Effective Spillage controls in place e.g. bunding. Access to area restricted

All equipment checked for suitability.Access to area restrictedOnly in date certified equipment to be used

Effective Emergency Response in place Standby diaphragm pump to remove spill






Access to area restricted.Signs & barriers in place Operations to be highlighted at

VSCC/PSCC meeting. PTW may be required

Operations to be highlighted at VSCC/PSCC meeting.

PTW required

Effective Emergency Response in place Stand by tray/ container to collect any leak water Stand by diaphragm pump to pump out leak water





High Pressure Fitting FailureUncontrolled Pressure Release. Personal Injury Equipment Damage






Oil Spillage 3 2 6 3 1 3 Supervisor



6BPressure Testing

using Oil






Effective Spillage controls in place e.g. bunding. Access to area restricted

Access to area restricted.Signs & barriers in place

Effective Emergency Response in place Stand by tray/ container to collect any leak oil Stand by diaphragm pump to pump out leak oil

Effective Emergency Response in place Standby diaphragm pump to remove spill





water

Operations to be highlighted at VSCC/PSCC meeting.

PTW required

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- Approved procedure to follow. - PTW / Tool box talk - Lock out / Tag out - Competent operators - Warning signs and barriers, Only authorised personnel to be allowed in. - Operation Pressure shall be increased step by step at 25%, 50%, 100% of pressure. - Correct PPE Certified equipment - Pre tested equipment - Control of discharge temperature - PRV. certified - PRV's must have 10% higher pop up set pressure to the line test pressure required. - Test pack and test pressure approved by company - Communication between pump controller and all personel to be tested prior to commencement of test - Whip checks on hoses. - Pressure gauges used at both ends of test package to ensure all pressure is beld off the system.

Risk Assessment

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3a

3.Risk Controls

2b






5 2 10 5 1 5 SupervisorOperations to be highlighted at VSCC/PSCC meeting. PTW required

Noise Pollution Possible NID Risk 3 2 6 3 1 3 Supervisor








Effective Emergency Response in place Access to area restricted. Fire extinguisher on standby. Effective Emergency Response in place



Do not run engine unless requiredUse correct PPE. Access to area restricted


Maintain engine according to schedules.




Liquid Nitrogen Spillage 4 2 8 3 2 6 Supervisor







Gas Venting Possible NID Risk 3 1 3 3 1 3



6CPressure Testing

using Air(Pneumatic) or Nitrogen

All equipment checked for suitability.Signs & barriers in placeOnly in date certified equipment to be used

Assign watchman to patrol area. Preventative Maintenance Schedule in operation

Use of Correct PPE.Access to area restricted near vent point


7 Rig down

Assign watchman to patrol area. Preventative Maintenance Schedule in operation

Effective Spillage controls in place Access to area restricted

Charged Water Hose on standby




Assign watchman to patrol areaAccess to area restricted.Signs & barriers in place

All equipment checked for suitability.Signs & barriers in placeOnly in date certified equipment to be used


Extra Care when pressure testing with Air or Gas due to higher stored energy Operations to be highlighted at VSCC/PSCC meeting. PTW required

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SomsakN

Text Box

- Approved procedure to follow. - PTW / Tool box talk - Lock out / Tag out - Competent operators - Use of over - rated hose & Fitting, use of cryogenic materials. - N2 storage / Pumping within bunded area - Well ventilated work area - Warning signs and barriers, Only authorised personnel to be allowed in. - Operation Pressure shall be increased step by step at 25%, 50%, 100% of pressure. - Leak test shall be checked between each step. - Correct PPE Certified equipment - Pre tested equipment - Controlled venting via suitably sized double block & bleed - Control of discharge temperature - PRV. certified - PRV's must have 10% higher pop up set pressure to the line test pressure required. - Whip checks on hoses - Test pack and test pressure approved by company - Communication between pump controller and all personel to be tested prior to commencement of test - Whip checks on hoses. - Pressure gauges used at both ends of test package to ensure all pressure is beld off the system.

ShahramV

Note

The Vessel should not be approached for close Inspection until the Test Pressure has been reduced.

ShahramV

Note

At > 20 bar no Personnel allowed nearer than 25 meters of the Test Area.

ra for n2he leak test_comment shahram

Documents

risk controlstask

new risk assessment

lifting area

existing risk controls

additional risk controls

written lifting plan

nitrogen operations

approval review