00-ZA-E-G85802_00

ARABIYAH & HASBAH OFFSHORE & ONSHORE FACILITIES Contract No: 6600026283 (OOK) Contract No: 6600026284 (IK) HAZARD IDENTIFICATION and RISK ASSESSMENT (HIRA) PLAN for FABRICATION ACTIVITIES at KARIMUN Fabrication Yard Contract No: 6600026283 (OOK)

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AMENDMENTS AND REVISIONS

Amendment and revision

Date

Page

Description

Project Director

X1

14.11.11

All

Issued for IDC

GS

A

17.11.11

All

Issued for COMPANY Comments / Approval

GS

00

04.12.11

All

Issued For Construction (IFC)

GS


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INDEX

AMENDMENTS AND REVISIONS ...............................................................................................................................2 INDEX............................................................................................................................................................................3 1.

DEFINITIONS AND ACRONYMS.......................................................................................................................5 1.1 1.2

2.

CONTRACTUAL DEFINITIONS AND ABBREVIATIONS .............................................................................................5 ACRONYMS ......................................................................................................................................................6 REFERENCE RULES, CODES AND STANDARDS .........................................................................................7

2.1 2.2 2.3 2.4

CODES AND STANDARDS ..................................................................................................................................7 LEGAL FRAMEWORK .........................................................................................................................................7 COMPANY DOCUMENTS ....................................................................................................................................8 CONTRACTOR DOCUMENTS ..............................................................................................................................8

3.

SCOPE OF DOCUMENT ....................................................................................................................................8

4.

PROJECT OVERVIEW & BRIEF SCOPE OF WORK .......................................................................................9

5.

RESPONSIBILITIES .........................................................................................................................................12 5.1 5.2 5.3 5.4 5.5 5.6 5.7 5.8 5.9

6.

PROJECT DIRECTOR .......................................................................................................................................12 PROJECT MANAGER .......................................................................................................................................12 CONSTRUCTION MANAGER..............................................................................................................................12 PROJECT HSE MANAGER (RA CHAIRMAN / TEAM LEADER) ..............................................................................13 FABRICATION HSE MANAGER (DEPUTY RA CHAIRMAN / TEAM LEADER) ...........................................................14 YARD HSE PERSONNEL .................................................................................................................................14 SUPERVISORS ................................................................................................................................................15 INDIVIDUAL HIRA TEAM MEMBERS ..................................................................................................................15 PEOPLE EXECUTING THE WORK ......................................................................................................................15 HAZARD IDENTIFICATION AND RISK ASSESSMENT METHODOLOGY ...................................................15

6.1

HIRA 6 KEY STAGES ......................................................................................................................................16 6.1.1 Task Identification & Preparation For HIRA............................................................................................16 6.1.2 Hazard Identification ...............................................................................................................................17 6.1.3 Identifying Who / What Might Be Harmed...............................................................................................17 6.1.4 Quantifying The Risk...............................................................................................................................17 6.1.5 Applying Control Measures.....................................................................................................................18 6.1.6 Re-Appraising The Residual Risk ...........................................................................................................19 6.2 RISK ASSESSMENT REGISTER .........................................................................................................................19 6.3 IMPLEMENT CONTROLS AND UNDERTAKE TASK ...............................................................................................20 6.4 STOPPING THE JOB ........................................................................................................................................20

ARABIYAH & HASBAH OFFSHORE & ONSHORE FACILITIES Contract No: 6600026283 (OOK) Contract No: 6600026284 (IK) HAZARD IDENTIFICATION and RISK ASSESSMENT (HIRA) PLAN for FABRICATION ACTIVITIES at KARIMUN Fabrication Yard Contract No: 6600026283 (OOK) 7.

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ATTACHMENTS ...............................................................................................................................................20 ATTACHMENT 1 – RISK ASSESSMENT FLOW CHART ....................................................................................................21 ATTACHMENT 2 – JSA FORM (FORM AH-0076) .........................................................................................................22 ATTACHMENT 3 – HIRA FORM (FORM AH-0077) .......................................................................................................23 ATTACHMENT 4 – RA MATRIX (2 PAGES) ...................................................................................................................24 ATTACHMENT 5 – RISK ASSESSMENT REGISTER FORM (FORM AH-0078) ...................................................................26 ATTACHMENT 6 – HIRA SHEETS FOR THE SOW........................................................................................................27


1.

DEFINITIONS AND ACRONYMS

1.1

CONTRACTUAL DEFINITIONS AND ABBREVIATIONS

COMPANY

Saudi Arabian Oil Company (SAUDI ARAMCO)

CONTRACTOR

SAIPEM S.p.A. (including SNAMPROGETTI S.A.

SAIPEM

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Indonesia

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KARIMUN

Branch)

/

SUBCONTRACTOR

Any organization selected and awarded by CONTRACTOR to either supply certain Project materials / equipment / services or whom a part of the WORK has been subcontracted.

MAIN CONTRACT

Contract awarded by COMPANY to CONTRACTOR

SUBCONTRACT

Contract signed by SUBCONTRACTOR and CONTRACTOR for the performance of a certain portion of the WORK within the Project.

PROJECT

Al WASIT Gas Program Development Project - ARABIYAH & HASBAH Offshore and Onshore Facilities.

SITE

Any location at which Project Works are to be performed.

COMPETENCE

The ability to perform an activity efficiently and to expected standards.

COMPETENT PERSON (HIRA Team Leader)

EVENT

A person who is suitably qualified (whether by experience, training or both) to carry out the work or function described in the relevant regulation. In the particular case of HIRA, a Competent Person is a person who, by reason of their training, knowledge and experience, is considered capable of adequately identifying the Hazards and assessing the HSE Risk associated with the task(s). Term to define all Accidents, Incidents and Near Misses occurred during CONTRACTOR and Subcontractors activities.

INCIDENT

General term to define an unplanned work-related event or chain of events, which has caused or could have caused injury to people, damage to property and / or to the environment, or loss of process. An Incident can be an Accident or a Near Miss.

ACCIDENT

It is an incident which has given rise to injury, ill health or fatality.

NEAR MISS

It is a hazardous event / incident which, under slightly different circumstances, could have caused an accident affecting people or an incident affecting property or the environment.

ILL HEALTH

Identifiable, adverse physical or mental condition arising from and/or made worse by a work activity and/or work-related situation.

HAZARD IDENTIFICATION and RISK ASSESSMENT (HIRA)

A formal HSE Risk Management technique used to identify the hazards associated with all steps of a job, to assess the risks arising from those hazards, to identify and implement mitigation measures (controls) in order to eliminate or reduce the risks and to ensure that the residual risk level achieved is ALARP.

CONTROLS

Precautionary measures which reduce or eliminate the risk.

HAZARD

A condition in the workplace, its surroundings, equipment or a method of carrying out an activity which has the potential to cause harm.

HAZARD IDENTIFICATION

Process of recognizing that a hazard exists and defining its characteristics.


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HAZARD EFFECT

The potential outcome/consequences of the relevant hazard.

LIKELIHOOD

The expectation, possibility or chance of something happening. Sometimes, it is referred to as a probability or frequency.

RESIDUAL RISK

The risk that remains after all identified control measures have been put in place.

RISK

Combination of the Likelihood of a hazard occurrence and the Severity of the outcome that can be caused by the event.

RISK RATING

A means of expressing the risk of a task in terms of a value that represents both its likelihood and severity.

FATALITY

Term to define a death resulting from a Work Related Injury, regardless of the time intervening between the injury and the death. Fatalities are included when calculating the number of Lost Time Injuries and Frequency Rate.

JOB

A complete work activity that may involve a number of tasks.

TASK

An individual work assignment being a job, or part of a job, carried out by one or more persons.

JOB SAFETY ANALYSIS (JSA)

A procedure used to identify, analyze and record the steps involved in performing a specific job, the existing or potential safety hazards associated with each step, and the recommended action(s) / controls(s) that will eliminate or reduce these hazards and the risk of a work-related injury.

TOOL-BOX TALK (TBT)

Brief (10 – 15 minutes) meeting, focused on particular HSE issues, conducted prior to work commencing by a supervising person, whose responsibility is to ensure that the appropriate information is given to work force in order to promote awareness and understanding of all the potential hazards which may affect the safe, efficient and environmentally sound job completion.

1.2

ACRONYMS

HSE

Health, Safety and Environment

HSEMS

HSE Management System

SIKB

SAIPEM Indonesia KARIMUN Branch

SOW

Scope of Work

HIRA

Hazard Identification and Risk Assessment

LPP

Loss Prevention Plan

PPE

Personal Protective Equipment

HAZID

Hazard Identification

RA

Risk Assessment

JSA

Job Safety Analysis

ALARP

As Low As Reasonably Practicable

SIMOPS

Simultaneous Operations

ARABIYAH & HASBAH OFFSHORE & ONSHORE FACILITIES Contract No: 6600026283 (OOK) Contract No: 6600026284 (IK) HAZARD IDENTIFICATION and RISK ASSESSMENT (HIRA) PLAN for FABRICATION ACTIVITIES at KARIMUN Fabrication Yard Contract No: 6600026283 (OOK) ARBI

Arabiyah

HSBH

Hasbah

IIP

Intermediate Injection Platform

TP

Tie-in Platform

WHP

Wellhead Platform

ICCP

Impressed Current Cathodic Protection

GOSP

Gas Oil Separation Plant

DCS

Distribution Control System

CCR

Central Control Room

SCADA

Supervisory Control And Data Acquisition

MRJN

MARJAN Offshore Field

2.

REFERENCE RULES, CODES AND STANDARDS

2.1

CODES AND STANDARDS

Ref

Document Number

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Title

/1/

BS EN ISO 14001:2004

Environmental Management Systems - Requirements with Guidance for Use

/2/

BS ISO 14004:2004

Environmental Management Systems - General Guidelines on Principles, Systems and Support Techniques

/3/

BS OHSAS 18001:2007

Occupational Health and Safety Management Systems - Requirements

2.2

LEGAL FRAMEWORK

The content of this Hazard Identification & Risk Assessment Plan is in compliance with the main applicable laws, regulations, guidelines and guidance documents on Hazard Identification & Risk Assessment (HIRA) in the Government of Indonesia, as described below:  General Occupational Health and Safety Regulation Acts No. 1 / 1970 - Issued by Indonesia, Presidency of Industrial Occupational Health and Safety Regulation This Acts is provides the regulatory basis for occupational health and safety regulation and requirements of industrial activities in Indonesia.  Regulation of Minister Manpower of Indonesia No. PER. 05/MEN/1996 Occupational Health and Safety Management System. - issued by Government of Indonesia. The purpose of this regulation is to provide guideline in identifying hazards at workplace and to implement the necessary control measures in order to attain a risk which is tolerable and as low as reasonably practicable (ALARP).

ARABIYAH & HASBAH OFFSHORE & ONSHORE FACILITIES Contract No: 6600026283 (OOK) Contract No: 6600026284 (IK) HAZARD IDENTIFICATION and RISK ASSESSMENT (HIRA) PLAN for FABRICATION ACTIVITIES at KARIMUN Fabrication Yard Contract No: 6600026283 (OOK) 2.3

Ref

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COMPANY DOCUMENTS

Document Number

Title

Contract No. 6600026283 (OOK) between ARAMCO OVERSEAS COMPANY B.V. and SAIPEM S.p.A. 2.4

Ref

CONTRACTOR DOCUMENTS

Document Number

Title

SAIPEM Corporate Standard /4/

STD-COR-HSE-016-E

HSE Risk Assessment

Project Documents /5/

00-ZA-E-G85820

Loss Prevention Plan for Fabrication Activities (OOK)

/6/

00-ZA-E-G85819

Permit To Work Procedure for Fabrication Activities (OOK)

/7/

00-ZA-E-G85817

HSE Induction and Training for Fabrication Activities (OOK)

SAIPEM Indonesia KARIMUN Branch Documents /8/

MAN-SIKB-HSE-001

Occupational Health and Safety Management Manual

/9/

GP-SIKB-HSE-002

HSE Legislation and Other Requirements Review

3.

SCOPE OF DOCUMENT

The purpose of this Hazard Identification and Risk Assessment Plan (hereinafter referred to as HIRA Plan) is to identify, assess and mitigate the hazards and risks associated with CONTRACTOR fabrication SOW at Karimun Fabrication Yard and to ensure that all actions resulting from risk assessment activities are adequately managed and physically implemented before the operations take place, so as to ensure that No Harm to People and No Damage to Asset and to the Environment will occur. HIRA process is appropriate for evaluation of any task where the hazards, associated risks and relevant control measures need to be assessed. This HIRA process only concerns identification of hazards and assessment of risks which may be present in carrying out work activities. It is not intended to address other risks associated with general business, contractual issues or project management. HIRA should normally be a team workshop, with the size and make-up of the team being selected to reflect the particularities and complexity of the task. No work should be carried out, unless a suitable and sufficient Risk Assessment has been conducted and duly formalized.


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HIRA Plan is a live document and must be read in conjunction with the LPP for Fabrication Activities at Karimun Fabrication Yard (Doc. No. 00-ZA-E-G85820) and overall CONTRACTOR work schedule, which will be regularly reviewed and updated as necessary. This process of HSE Risk Management involves:  IDENTIFYING THE HAZARDS which are the potential causes of harm, associated with the tasks about to be undertaken (hazards could include, but are not limited to, substances, parts of a machine, forms of energy, method of work, human factors and work situations)  ASSESSING THE RISKS which can arise from hazards (risk is a measure of the probability that harm from a particular hazard will occur combined with the severity of the most likely outcome)  IDENTIFYING SUITABLE CONTROL MEASURES (both preventative and contingency) to eliminate the hazard or control unacceptable hazard effects.  RECORDING the results of the above activities.  IMPLEMENTING MITIGATION MEASURES at the worksite.  ENSURING THAT RESIDUAL RISKS ARE AS LOW AS REASONABLY PRACTICABLE (ALARP).

4.

PROJECT OVERVIEW & BRIEF SCOPE OF WORK

Arabiyah & Hasbah Offshore and Onshore facilities are part of the WASIT Gas Program (WGP), which will produce approximately 2,500 MMSCFD of raw Khuff gas in order to support the KSA strategy to meet the increasing IK demand for sales gas. Processing Arabiyah and Hasbah gas is expected to produce 3,050 MMSCFD (1,450 MMSCFD for Arabiyah and 1,600 MMSCFD for Hasbah) of dry gas. The facilities to be fabricated and installed include new offshore gas production and Tie-in Platforms, one Intermediate Injection Platform, pipelines, both offshore and onshore, as well as the associated power supply and telecommunication system. Arabiyah and Hasbah are offshore fields located in Arabian Gulf, approximately 150 kilometers northeast of Jubail and 250 kilometers north of Dhahran. The fields lay in medium-depth waters in range of 40-60 meters. The new Arabiyah-Hasbah gas offshore platforms will be installed some 150-180 kilometers north east of the WASIT Gas Plant. Each of the single wellhead offshore platforms will connect to a field Tie-in Platform (one Tie-in Platform will be installed for each field). The gas from each field will be transported through dedicated subsea and onshore pipelines to the WASIT Gas Plant where new treating facilities will produce 1,700 MMSCFD of sales gas and 4200 MTD of sulphur. A MEG Injection System is planned to transport continuously MEG and corrosion inhibitor from the onshore treatment plant to each Tie-in Platform to protect each trunkline against hydrates and corrosion. The corrosion inhibited MEG will be pumped offshore via an offshore pipeline to an IIP (ARBI TP-2) and then continues to ARBI TP-1 and HSBH TP-1 via two separate pipelines. Solvent Injection is required on each WHP upstream of choke valves to avoid the deposition of elemental sulphur along the production sealines. The Solvent Sulphur System will be actually designed for Hasbah Field only. However, future provision should be taken into account to allow the possibility of adding such facilities also to Arabiyah Field.

ARABIYAH & HASBAH OFFSHORE & ONSHORE FACILITIES Contract No: 6600026283 (OOK) Contract No: 6600026284 (IK) HAZARD IDENTIFICATION and RISK ASSESSMENT (HIRA) PLAN for FABRICATION ACTIVITIES at KARIMUN Fabrication Yard Contract No: 6600026283 (OOK) HASBAH FIELD

Package “C” HIPPS OFFSHORE SCOPE OF WORK

HSBH‐23

SAUDI ARABIA WATERS

BO RD E HSBH‐21

R LIN E

Rev. 00

Date: 04.12.2011 Page 10 of 27

IRAN WATERS

HSBH‐22 HSBH‐20 HSBH‐25

HSBH‐24

• SEVEN (7) 12” CLAD FLOWLINES & RISERS TOTAL LENGTH: ~18km • SEVEN (7) UMBILICALS TOTAL LENGTH ~22km

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• TIE-IN PLATFORM WITH FLARE SYSTEM (TP-1 JACKET 2389t, TP-1 TOPSIDE 4225t) • SEVEN (7) WELLHEAD PLATFORM TOPSIDES (701t EACH)

HSBH‐19

• 36”HSBH TRUNKLINE 125.5km & 4”SOLVENT PIGGYBACK FOR 70.3km • 10”MEG LINE 70.4km • 36”HSBH TRUNKLINE 125.5km & 6” SOLVENT PIGGYBACK FOR 55.4km • 36”ARBI TRUNKLINE 128.7km • 12”MEG LINE 55.4km

15 k CA V C BL OM E 5 PO 2k SIT m E

ARABIYAH FIELD HSBH TP-1

ARBI‐9

ARBI‐8

BO RD E

ARBI‐7

KP0 WD 45m

ARBI‐4

R L INE

ARBI‐6

~KP70 WD 25m

DREDGING/TRENCHING • OFFSHORE ACCESS CHANNEL ~630m • SHORE APPROACH ~3km

ARBI‐5

KP0 WD 51m

~KP125

IT POS COM m 15kV 1k 3 E ABU ALI CABL

KHURSANIYAH

WASIT PLANT

E

ARBI TP-1

• TIE-IN PLATFORM WITH FLARE SYSTEM (TP-1 JACKET 2577t, TP-1 TOPSIDE 3902t) • SIX (6) WELLHEAD PLATFORM TOPSIDES (662t EACH) • SIX (6) 12” CLAD FLOWLINES & RISERS TOTAL LENGTH: ~20km • SIX (6) 15kV COMPOSITE CABLES TOTAL LENGTH ~24km • 36”ARBI TRUNKLINE 128.7km • 10”MEG LINE 73.4km • 15 kV COMPOSITE CABLE 75km

ONSHORE PIPELINES 30km PER LINE

• TIE-IN PLATFORM (TP-2) JACKET 466t, TOPSIDE 711t

The Scope Of Work (SOW) for Arabiyah & Hasbah Offshore and Onshore facilities shall include engineering, procurement of equipment and materials, fabrication, transportation, installation, hook-up, testing and precommissioning for the following: Arabiyah Offshore facilities:  Six (6) Decks for new Wellhead Platforms (jackets built and pre-installed by others).  One (1) Tie-in Platform (ARBI TP-1) including jacket, deck and flare system (bridge, bridge support jackets and flare boom).  One (1) Intermediate MEG Injection Platform (ARBI TP-2) including jacket and deck.  One (1) 36”OD & 130-km long offshore internally coated Arabiyah trunkline from beach valve station to ARBI TP1. The Work includes the dredged shore pull trenches.  One (1) 12”OD & 75-km long offshore internally coated MEG injection pipeline from beach valve station to ARBI TP-2 IIP. The Work includes the dredged shore pull trenches.  One (1) 10.75”OD & 50-km long internally coated MEG injection pipeline from ARBI TP-2 IIP to the ARBI TP-1.


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 One (1) 6"OD & 75-km long offshore elemental sulfur solvent injection pipeline from beach valve station to ARBI TP-2 IIP. The Work includes the dredged shore pulls trenches.  Six (6) internally clad 12”OD high pressure gas flowlines from the wellhead platforms to ARBI TP-1.  One (1) 4” OD flexible and subsea valve skid connecting ARBI TP-2 IIP to 36” OD Arabiyah trunk line.  Six (6) composite submarine cables (15kV power with an internal fiber optic core) from ARBI TP-1 to Wellhead Platforms.  One (1) 43-km long composite submarine cable (15kV power with an internal fiber optic core) from shore at Abu Ali to ARBI TP-2 IIP. Work includes a dredged shore approach and onshore cable tie-in at Abu Ali GOSP.  One (1) 50-km long composite submarine cable (15kV power with an internal fiber optic core) from ARBI TP-1 to ARBI TP-2 IIP.  Eight (8) ICCP systems for ARBI TP-1.  Two (2) ICCP systems for ARBI TP-2 IIP.  Four (4) ICCP systems for each Wellhead Platform.  Six (6) Wellhead Hook Ups, pre-commissioning and SCADA integration for Arabiyah Wellhead Platforms. Arabiyah Onshore facilities:  One (1) 36”OD & 30-km long onshore trunkline for Arabiyah from shoreline to WASIT Gas Plant (WGP) including installation of valves station on the beach, scraping receiving facilities at WGP.  One (1) 12”OD & 30-km long MEG onshore pipeline from shoreline to WASIT Gas Plant (WGP) including installation of valves station on the beach, scraping receiving facilities at WGP.  DCS at Manifa CCR.  One (1) 6"OD & 30-km long elemental sulfur solvent onshore pipeline from shoreline to WASIT Gas Plant (WGP) including installation of valves station on the beach, scraping receiving facilities at WGP. Hasbah Offshore facilities:  Seven (7) Decks for new Wellhead Platforms (jackets built and pre-installed by others)  One (1) Tie-in Platform (HSBH TP-1) including jacket, deck and flare system (bridge, bridge support jackets and flare boom).  One (1) 36”OD & 131-km long offshore internally coated Hasbah trunkline from beach valve station to HSBH TP1. The Work includes the dredged shore pull trenches.  One (1) 10.75”OD & 50-km long internally coated MEG injection pipeline from ARBI TP-2 IIP to the HSBH TP-1.  Seven (7) internally clad 12”OD high pressure gas flowlines from the wellhead platforms to HSBH TP-1.  One (1) 4" & 50-km long elemental sulfur solvent injection pipeline from ARBI TP-2 IIP to the HSBH TP- 1.  One (1) 4” OD flexible and subsea valve skid connecting ARBI TP-2 IIP to 36” OD Hasbah trunkline.  Seven (7) composite submarine cables (15kV power with an internal fiber optic core and tubes for elemental sulfur solvent injection) from HSBH TP-1 to Wellhead Platforms (with a total length of approximately 35km).  One (1) 45-km long composite submarine cable (15kV power with an internal fiber optic core) from MRJN GOSP-2 to HSBH TP-1.  Eight (8) ICCP systems for HSBH TP-1.  Four (4) ICCP systems for each Wellhead Platforms.  Seven (7) Wellhead Hook Ups, pre-commissioning and SCADA integration for Hasbah Wellhead Platforms. Hasbah Onshore facilities:  One (1) 36”OD & 30-km long onshore trunkline for Hasbah from shoreline to WASIT Gas Plant (WGP) including installation of valves station on the beach, scraping receiving facilities at WGP.


5.

RESPONSIBILITIES

5.1

PROJECT DIRECTOR

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The Project Director has the Overall and Final Responsibility for HSE and all project activities. His responsibilities will be the following:  Demonstrates visible, strong and proactive leadership and commitment towards HSE and does lead by example.  Ensures, throughout the project activities, that a safe working culture, where EVERYONE has both the authority and responsibility to STOP THE JOB if there is any doubt about the safety of the operation, is in place and adhered to at all times by all CONTRACTOR and Subcontractor personnel.  Approves this HIRA Plan and its future amendments and revisions.  Allocates adequate human, technical and financial recourses for the correct implementation of this HIRA Plan.  Ensures that this HIRA Plan is implemented throughout the work activities.  Represents the Main Interface with COMPANY for all matters.  Defines the project team, discussing with relevant responsible persons the resources available/required for the project.  Ensures all relevant personnel are aware of CONTRACTOR and COMPANY HSE policies, standards and commitment to providing a safe, healthy and environmentally sound workplace for all employees.  Makes continuous efforts towards motivating CONTRACTOR and Subcontractor personnel to take an active part in HSE issues. 5.2

PROJECT MANAGER

The Project Manager has to ensure that all work activities under his control are carried out in accordance with CONTRACTOR and COMPANY HSE Policy. His responsibilities will include the following:  Demonstrates visible, strong and proactive leadership and commitment towards HSE and does lead by example.  Ensures, throughout the areas of responsibility, that a safe working culture, where EVERYONE has both the authority and responsibility to STOP THE JOB if there is any doubt about the safety of the operation, is in place and adhered to at all times by all CONTRACTOR and Subcontractor personnel.  Ensures that this HIRA Plan is followed throughout his area of responsibility within the project activities.  Provides support to the HSE Department, as and whenever needed.  Ensures liaison with HSE Management for specialist advice.  Establish, in conjunction with HSE Management, the HIRA team necessary for each job.  Ensures adequate HSE training of personnel to assure competency at work.  Ensures that risk assessments are undertaken within his area of responsibility and all actions arising from these risk assessments are implemented. Hence, he must ensure that no job is carried out, unless it has been properly risk assessed and the relevant Risk Assessment has been duly documented.  Keeps, with assistance from Site HSE Personnel, an up-to-date Risk Assessment Register for all activities within his sphere of responsibility (refer to Paragraph 6.2 of this HIRA Plan). 5.3

CONSTRUCTION MANAGER

The Construction Manager reports to the Project Manager and has to ensure that all work activities under his control are carried out in accordance with CONTRACTOR and COMPANY HSE Policy. His responsibilities will include the following:  Demonstrates visible, strong and proactive leadership and commitment towards HSE and does lead by example.


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 Ensures, throughout the areas of responsibility, that a safe working culture, where EVERYONE has both the authority and responsibility to STOP THE JOB if there is any doubt about the safety of the operation, is in place and adhered to at all times by all CONTRACTOR and Subcontractor personnel.  Ensures that this HIRA Plan is followed throughout his area of responsibility within the project activities.  Provides support to the HSE Department, as and whenever needed.  Ensures liaison with HSE Management for specialist advice.  Establishes, in conjunction with HSE Management, the HIRA team necessary for each job.  Ensures adequate HSE training of personnel to assure competency at work.  Ensures that risk assessments are undertaken within his area of responsibility and all actions arising from these risk assessments are implemented. Hence, he must ensure that no job is carried out, unless it has been properly risk assessed and the relevant Risk Assessment has been duly documented. 5.4

PROJECT HSE MANAGER (RA CHAIRMAN / TEAM LEADER)

The Project HSE Manager reports to the Project Director and will formally advise SAIPEM CORPORATE and Project / Line Management with regard to health and safety at work and protection of the environment, including the requirements of the latest local legislation of authorities governing these matters. In case the Project HSE Manager cannot attend / chair certain Risk Assessment meetings, he will delegate the authority to the Fabrication HSE Manager, who will act, on his behalf, as HIRA Team Leader. In addition to an advisory / consultancy role, he is responsible to:  Liaise, on behalf of the CONTRACTOR, with appointed COMPANY HSE Representative(s).  Ensure that CONTRACTOR hazard identification and risk management performance is satisfactory and that suitable and sufficient Risk Assessment is timely and duly conducted, and correctly formalized, for all work scopes.  Communicate the HIRA Plan requirements and strategies to Project Management, Supervisors, Employees and Subcontractors.  Review and approve this HIRA Plan for hazard identification and risk management, which includes objectives and commitment to risk management.  Exercise judgment with respect to the economic value of the proposed risk controls and approve expenditure.  Review standards, plans and procedures in conjunction with Departmental Managers in order to improve the HSE Risk Management System.  Monitor the applicability of HSE legislation as it applies to the CONTRACTOR.  Advise Senior, Departmental and Project Managers on HSE legislation and Approved Codes Of Practice related to HIRA process, and give guidance to the Line Management.  Monitor that control measures are implemented to reduce the likelihood of a risk occurring to As Low As Reasonably Practicable (ALARP).  Evaluate the Subcontractors capabilities with respect to their HIRA management and ability to fulfill the specified requirements of the SOW.  Take measures against Subcontractors, if the solution of non-conformances arisen from HSE Audit(s) is not completed satisfactorily by the proposed / agreed deadline.  Monitor that Management Of Change issues are correctly addressed and the relevant Risk Assessments are reviewed at Management level, prior to the change taking place. As a HIRA Team Leader, he will be responsible also to:  Ensure that the team understands the assessment process and what its objectives are.  Lead the team and take responsibility for the quality of the HIRA.


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 Ensure that the assessment team includes personnel with all the necessary knowledge and competence for the task involved.  Ensure that the team is guided systematically through the assessment process and are kept on track.  Ensure that the HIRA includes a worksite visit where necessary and practicable.  Ensure that the outcome of the assessment is agreed by all in the assessment team.  Ensure that the assessment is recorded and added to the record of assessments carried out at the facility.  Ensure that the results of the assessment are communicated effectively to the people carrying out the work.  Ensure that a member of the team will initiate the Risk Assessment Register and keep it updated.  Ensure the HIRA Meetings schedule is managed and kept updated.  When the identified risk can affect the project objectives (cost, schedule, quality), inform the relevant Project Manager and the Project Director. 5.5

FABRICATION HSE MANAGER (DEPUTY RA CHAIRMAN / TEAM LEADER)

Fabrication HSE Manager reports to the Project HSE Manager with functional reporting to the Project Manager and assists other departments on HSE requirements. His responsibilities will be to:  Liaise, on behalf of the CONTRACTOR, with appointed COMPANY HSE Representative(s), as well as local government authorities or agencies.  Promote CONTRACTOR HSE Management System by personal example.  Act as RA Chairman / Team Leader, whenever authorized by the Project HSE Manager.  Ensure that suitable and sufficient Risk Assessments are timely and duly conducted for the work scopes under his sphere of responsibility. Participate in Risk Assessment meetings as required.  Communicate the HIRA Plan requirements and strategies to Project Management, Supervisors, Employees and Subcontractors.  Monitor that control measures are implemented to reduce the likelihood of a risk occurring to As Low As Reasonably Practicable (ALARP).  Evaluate the Subcontractors capabilities with respect to their HIRA management and ability to fulfill the specified requirements of the SOW.  Monitor that Management Of Change issues are correctly addressed and the relevant Risk Assessments are reviewed at Management level, prior to the change taking place. 5.6

YARD HSE PERSONNEL

The yard HSE Personnel include HSE Lead and HSE Officers, and their responsibilities are to:  Actively participate in the RA, as and when requested, and ensure the HIRA process is correctly followed by both CONTRACTOR and Subcontractors personnel.  Provide HIRA training to Supervisors and work force whenever necessary.  Help to identify hazards and control measures to reduce the likelihood of an incident/accident occurring.  Assist in the identification of any deficiencies in the work process and possible improvements.  Ensure that control measures are implemented to reduce the likelihood of a risk occurring to As Low As Reasonably Practicable (ALARP).  Assist Project Manager in maintaining an up-to-date Risk Assessment Register (refer to Paragraph 6.2 of this HIRA Plan).  Ensure all completed HIRA sheets / forms are saved in PDF and properly recorded in the Risk Assessment Register.


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SUPERVISORS

The principal responsibilities of Supervisors are to:  Ensure, throughout their areas of responsibility, that a safe working culture, where EVERYONE has both the authority and responsibility to STOP THE JOB if there is any doubt about the safety of the operation, is in place and adhered to at all times by all CONTRACTOR and Subcontractor personnel.  Review each task and identify what level of risk assessment is required.  Ensure that all tasks undertaken within their area of responsibility are assessed to identify any hazard that may cause harm to personnel or damage to property or the environment.  Ensure that control measures are implemented to reduce the likelihood of a risk occurring to As Low As Reasonably Practicable (ALARP).  Ensure that any potential improvements highlighted during the HIRA process are reviewed and addressed / implemented as appropriate.  Communicate details of the HIRA to the work team, allocating individual responsibilities for job tasks and control measures.  Ensure that all members of the work team have the opportunity to identify further hazards and controls.  Ensure that before work commences, all work team members are in agreement with the details of the HIRA and the proposed control measures.  Ensure that any lessons learned are captured to improve the task and / or the HIRA. 5.8

INDIVIDUAL HIRA TEAM MEMBERS

Individual HIRA team members must have adequate knowledge of the task being risk assessed and are to:  Actively participate in the HIRA.  Help to identify hazards and control measures to reduce the likelihood of an incident/accident occurring.  Assist in the identification of any deficiencies in the work process and possible improvements. 5.9

PEOPLE EXECUTING THE WORK

The assessment is of little value, unless its outcome is communicated to the personnel completing the work, and complied with by these personnel. After being briefed on the HIRA outcome, personnel in the work team are responsible for:  Understanding the hazards and control measures associated with the task.  Sharing knowledge and contributing towards the pre-task talk or TBT or in any other convenient meeting.  Actively monitoring their worksites and surroundings for changes in hazards present.  Stopping the work at any time where they are concerned about safety.  Identifying any lessons learned from the job and feeding these back through their Supervisor.

6.

HAZARD IDENTIFICATION AND RISK ASSESSMENT METHODOLOGY

HIRA is a process where potential hazards which arise from specific work activities are identified and their consequential effects on the HSE are assessed and mitigated, so as to ensure that the residual risk level achieved is ALARP. A detailed process flowchart for the completion of a HIRA is shown in Attachment 1. In line with SAIPEM Corporate HSE Risk Assessment Standard (refer to Paragraph 2.4 of this HIRA Plan), a new risk assessment may not be required for every task. Where a task has previously been risk assessed, or is covered by a procedure, it may not need a new risk assessment. Where this is the case, the previous assessment or


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procedure should be reviewed to ensure that the hazards and controls are still relevant and that any site or job specific controls are identified. Prior to undertaking a task, appropriate approval must be sought and a pre-task talk or TBT must be held. At this point, it is essential to communicate the hazards, risks, controls and individual responsibilities to the rest of the work team and engage everyone involved in the final stage of the risk assessment process. The latter is an important opportunity for the whole work team to identify any additional hazards and controls, especially those specific to the actual site and local conditions. Once the task commences, it is of utmost importance to monitor the worksite for any CHANGE in conditions that might alter the hazards, risk levels and controls in place. If there is any concern, stop the work, re-assess the controls and, if necessary, re-plan and re-assess the task. The extent of the controls identified will depend upon the level of risk associated with the task. The higher the risk is, the greater the degree of control must be. This is illustrated in Figure 1. Figure 1 – Risk Control Model

6.1

HIRA 6 KEY STAGES

The Hazard Identification and Risk Assessment (HIRA) procedure comprises 6 key steps which are: 1. Task Identification 2. Hazard Identification 3. Identifying who/what might be harmed 4. Quantifying the risk 5. Applying control measures 6. Re-appraising the residual risk 6.1.1

Task Identification & Preparation For HIRA

Prior to commencing the HIRA, the team should carry out preparatory work to ensure that its members have sufficient background information on which to base their judgments. This should include reviewing the overall work scope and breaking it down into a sequence of tasks.


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It may be useful to write down the steps that are to be taken, making notes for discussion during the HIRA session, and so enable a constructive decision to finally emerge. The team should visit the worksite, where possible. This is important in order to see the physical layout of the area and current site conditions. Particular attention should be given to other worksites and equipment in the area and its surroundings. Other activities taking place, or planned to take place, at the same time as the task to be performed should also be identified, as they could impact on the HIRA. When carrying out the preparatory work, the team should consider the following:  What is the purpose of the task?  What are the critical activities necessary to perform the task?  Who is going to carry out the task and are they capable / skilled enough?  When is the task to be executed? Could it be done at a different time (i.e. during a shutdown)?  Where is the task to be performed? Could it be carried out in a safer location (i.e. in a workshop)?  Are there SIMOPS that may have a significant safety impact on the task (e.g. other tasks occurring as part of the same work scope, or other work in an adjacent area)?  What are the characteristics of the plant and systems directly involved? For low-risk tasks, performed by competent people, no formal recorded risk assessment is required as the individual’s competency and skill covers this. However, a JSA and a TBT will still be compulsory, in order for a lowrisk task to commence. The JSA Form (FORM AH-0076) is provided in Attachment 2. 6.1.2

Hazard Identification

The HIRA Team should list all significant hazards and then review them to determine what foreseeable effects they could cause if not eliminated or controlled. This should be done by way of a full group discussion under the direction of the HIRA Team Leader to ensure that all members are given adequate opportunity to express their views. The HIRA Team Leader must allocate sufficient time to allow all hazards to be identified and assessed, in order for considered decisions to be reached. A Hazard and Effects / Consequences table is a useful prompt to ensure that no hazards are missed. An example of such a table is included in Figure 2. 6.1.3

Identifying Who / What Might Be Harmed

Once all hazards associated with the task are established, the associated hazard effects will be identified and considered. This stage of the process must consider the harm that could possibly occur to people, environment, property (plant, equipment, etc.) and CONTRACTOR business / reputation. The HIRA Form should, at this stage, be updated to include hazard effects associated with the identified hazards. The HIRA Form (FORM AH-0077) is provided in Attachment 3. 6.1.4

Quantifying The Risk

The next phase is to assess the level of the risk associated with each hazard of the task. This is done by a risk rating exercise using a Risk Assessment Matrix, as shown in Attachment 4. The HIRA Team will rate the risk for each hazard and hazard effect identified and written on the HIRA Form. The risk rating will be specified using the terms shown in the Risk Assessment Matrix by assessing the Likelihood of occurrence (L) and the Severity of the hazard (S), in order to give an overall Risk Rating (R): S x L = R


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The HIRA Team must then systematically work through the hazards and associated risk rating in order to identify all standard control measures that should be in place to mitigate the risk to an acceptable level. These controls will be listed on the HIRA Worksheet in the column “Standard Control Measures”. Figure 2 – Example of Hazard and Effects / Consequences Table

6.1.5

Applying Control Measures

Once the risk rating has been determined, the next stage is to identify the controls that are required to reduce / control the risk. In identifying control measures, consideration should be given to:  The task.  The people involved.  What tools, equipment and materials are to be used.  The working environment. The HIRA Team must work systematically through the list of hazards to specify all the methods needed to control each of the associated risks. These measures should be based on good safe working practice in order to reduce the residual risks to ALARP. A control guidelines hierarchy may be used to assist in this process. Once all the standard controls have been identified to reduce the risk, the following final questions should be asked:  Have all the necessary control measures been fully / effectively identified?  Are any additional competencies required to complete the task?  Is the risk effectively controlled? When the controls have been identified, the risk evaluation matrix should be revisited to establish the level of residual risk once these controls are in place.

Example of Hazard and Effects / Consequences Table

EXAMPLE

PEOPLE

MATERIALS

ENVIRONMENT

PROCESS

HAZARD -

EXAMPLE

Insufficient Supervision New/Inexperience Personnel Visitors/Unauthorised Personnel Inadequate Communications Insufficient Resources Competence

PERSONAL INJURY OR DEATH

-

Hazardous Substances Radioactive Substances Flammable Explosive Substances Dimension/Weight Waste

-

Confined Space Working at High Noise Temperature Lighting Ventilation Vibration Weather Extremes

-

Incorrect Procedure Process Emergency Arrangements Inadequate Planning Lack of Training Lack of Information/Instruction/Supervision No or Inadequate Risk Assessment

AN EVENT ENVIRONMENTAL IMPACT

HAZARD EFFECTS / CONSEQUENCES



Physical

Lacerations Abrasion Crush/Nip Injuries Burns Muscular Skeletal



-

Occupational Illness

-

RSI Asbestosis Dermatitis Hazardous Substance Exposures



Psychological

- Stress



Pollution

- Air - Water - Land

      

EQUIPMENT/PROPERTY DAMAGE



Social Effects Flora/Fauna Excess Waste Financial Liability Fires/Explosions Structural Failures Dropped Object Damage Financial

- Loss of Production - Repair/Replacement Cost - Reputation

ARABIYAH & HASBAH OFFSHORE & ONSHORE FACILITIES Contract No: 6600026283 (OOK) Contract No: 6600026284 (IK) HAZARD IDENTIFICATION and RISK ASSESSMENT (HIRA) PLAN for FABRICATION ACTIVITIES at KARIMUN Fabrication Yard Contract No: 6600026283 (OOK) 6.1.6

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Re-Appraising The Residual Risk

An assessment of the residual risks should be made for each of the hazards on the basis that all control measures have been put in place. If the residual risk is unacceptable, additional control measures should be identified. If further control measures reduce the risk to the ALARP level, they should then be recorded with the new residual risk rating. If further control measures cannot reduce the risk to the ALARP level, the task must not proceed and the team must refer back to their manager/supervisor. If the residual risk is ALARP, the HIRA Team will recommend that the work should go ahead, with the identified control measures in place. However, it is essential that agreement is a unanimous decision of the whole team. A consideration for the acceptability of risk is that the greater the perceived risk for any particular hazard, the greater the number and quality of independent controls. Consideration should also be given to the possibility of combined effects from the interaction of several different hazards. 6.2

RISK ASSESSMENT REGISTER

As described above, the findings of the HIRA must be documented on a HIRA form, which will be numbered and recorded in a sequential order into the Risk Assessment Register. The Risk Assessment Register Form (FORM AH0078) is provided in Attachment 5. The custodian of the Risk Assessment Register is the Project Manager or his delegated authority. Site HSE Personnel will have the duty to assist the Project Manager in regularly updating the Risk Assessment Register. The purpose of the Risk Assessment Register is to provide:  A means of recording the risks associated with working operations that are identified during the course of business.  A means of relating those risks to CONTRACTOR executive management, and, where practicable, to the operational employees.  A means of tracking actions arising from the identification of the risks and of tracking the design of management systems provided to deal with the risks (covering prevention, detection / protection, mitigation and contingency / recovery).  A means of tracking the assumptions made which have policy and procedural implications regarding corporate operations and of the actions arising from them.  A demonstration that the risks associated with the project objectives are adequately covered and that the policy and procedural requirements are closed out. The Risk Assessment Register will be updated when:  Significant changes are made to the working operations or business objectives such that additional risks are introduced.  A new hazard / risk, which could lead to a new loss potential scenario with different hazard effects, is identified. Then a new HIRA is to be conducted, documented and included in this Risk Assessment Register.  Errors are detected in the Risk Assessment Register.


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IMPLEMENT CONTROLS AND UNDERTAKE TASK

Once the HIRA Team is satisfied that all the hazards have been identified and that suitable controls have been put in place to reduce the risk to an acceptable level, they can then undertake the task. Although controls may have been implemented, the work team should not become complacent. By monitoring on an ongoing basis, the team should always be aware of any changes in personnel (e.g. shift change), conditions at the worksite, or if the HIRA is found to be incomplete or incorrect. 6.4

STOPPING THE JOB

Any individual has the authority and responsibility to STOP THE JOB if there is any doubt with respect to the safety of the operations. If anyone concerned about the safety of a task stops the job, that person’s decision must be supported, even if it turns out to be based on false reasoning. Being critical of a decision in such circumstances will increase the likelihood of the next job not being stopped when perhaps it should have been. It is essential that all persons involved in an activity are made fully aware that they have both the authority and the responsibility to stop the job if there is any doubt about the safety of the operation. Supervisors have a crucial role in this area. They must make clear to all individuals in the work team that they will be fully supported when taking action to stop the job. An individual who stops the job when there is a concern over the safety of the activity should be recognized as doing their job correctly. Any concerns a supervisor may have regarding productivity must not be expressed at this time.

SAFETY MUST ALWAYS TAKE PRIORITY. The task must be resumed ONLY when the re-assessment indicates that the risks can be made ALARP.

7.

ATTACHMENTS

Attachment 1 – Risk Assessment Flow Chart Attachment 2 – JSA Form (FORM AH-0076) Attachment 3 – HIRA Form (FORM AH-0077) Attachment 4 - Risk Assessment Matrix Attachment 5 - Risk Assessment Register Form (FORM AH-0078) Attachment 6 – HIRA Sheets for the SOW (see NOTE below)

NOTE: Attachment 6 contains the initial (draft) HIRA sheets relevant to the SOW. Prior to works commencement, CONTRACTOR relevant team Representatives, in conjunction with the assigned COMPANY Representatives, will conduct a hazard identification tour. Final HIRA sheets will be then reviewed at a dedicated HIRA Review Meeting held upon completion of the hazard identification tour.


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ATTACHMENT 1 – RISK ASSESSMENT FLOW CHART DefinetheJob

Work Request

DEFINE PARAMETERS OF WORK Determine exactly what the work will involve. Identtify the competencies required to assess the risk.

CATEGORISE TASK Review task and identify RA is required.

PREVIOUSLY ASSESSED TASK Previously assessed or covered by procedures.

NEW TASK Any task not previously performed or assessed

LOW-RISK TASK Performed by competent person

RISK ASSESSMENT Review risk assessment and/or procedure for adequacy.

IDENTIFY AND FORM RA TEAM Team must be familiar with the RA process and have sufficient knowledge of the work involved.

NO FORMAL RECORDED ASSESSMENT REQUIRED Covered by individual's competency and skill.

IS RISK ASSESSMENT STILL RELEVANT?

PREPARE FOR RA Break down job into component tasks. Carry out iniyial review of hazards and potential methods of mitigation.

NO

IDENTIFY HAZARDS Significant hazards should be identified and effects determined.

IDENTIFY HAZARD EFFECTS Impact on those involved in the task or in close proximity should be considered.

DOCUMENT AND RECORD Document review process and any additional controls identified.

IDENTIFY RISK RATINGS Express risk as a value which can be judged if within acceptable limits.

RiskAssessm ent

NO ADDITIONAL CONTROLS Identify any additional controls specific to the task, location and personnel involved.

IDENTIFY STANDARD/ADDITIONAL CONTROLS Identify measures to reduce/control the risk.

ARE CONTROLS ADEQUATE AND RISK ACCEPTABLE?

NO

YES

RA TEAM AGREEMENT TO PROCEED

NO

DO NOT START JOB

YES

Approval andCom m unication

DOCUMENT AND RECORDS Maintain a complete and accurate record of the whole assessment process.

APPROVAL TO PROCEED Seek appropriate approval to proceed with the task. RE-ASSESS IF REQUIRED

DO NOT START JOB

NO

AGREEMENT TO PROCEED

YES COMMUNICATE (TOOLBOX TALK) Communicate to work team and identify any final controls during toolbox talk.

FEEDBACK

DOCUMENT AND RECORD Maintain a complete and accurate record of the whole assessment process.

CAPTURE LESSONS LEARNED Update procedures/risk assessment etc.

STOP MONITOR WORKSITE FOR CHANGE

DoTask

RE-ASSESS IF REQUIRED

ARABIYAH & HASBAH OFFSHORE & ONSHORE FACILITIES Contract No: 6600026283 (OOK) Contract No: 6600026284 (IK) HAZARD IDENTIFICATION and RISK ASSESSMENT (HIRA) PLAN for FABRICATION ACTIVITIES at KARIMUN Fabrication Yard Contract No: 6600026283 (OOK) ATTACHMENT 2 – JSA FORM (FORM AH-0076)

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JOB SAFETY ANALYSIS (JSA) FORM

FORM AH-0076 Rev.0

ACTIVITY:

Date: 19.07.2011

JSA ID: Step

Hazard

Control Measures to be Enforced

JSA Prepared by

Team Leader check

Name:

Name:

Date:

Date:

Signature:

Signature:

Page 1 of 1

Remark / Action

ARABIYAH & HASBAH OFFSHORE & ONSHORE FACILITIES Contract No: 6600026283 (OOK) Contract No: 6600026284 (IK) HAZARD IDENTIFICATION and RISK ASSESSMENT (HIRA) PLAN for FABRICATION ACTIVITIES at KARIMUN Fabrication Yard Contract No: 6600026283 (OOK) ATTACHMENT 3 – HIRA FORM (FORM AH-0077)

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HAZARD IDENTIFICATION & RISK ASSESSMENT (HIRA) FORM FORM AH-0077 Rev.0

TASK: Activity ID

Date: 19.07.2011

HIRA ID: Activity Description

Hazard

Hazard Effect

Risk Value SxL=R

S

HIRA Team Members Members:

L

Standard Control Measures

Residual Risk Level SxL=R

S

R

L

HIRA Team Leader

Project Manager

Name:

Name:

Date:

Date:

Signature:

Signature:

Page 1 of 1

R

Additional Controls and Risk Reduction Measures to be developed

ARABIYAH & HASBAH OFFSHORE & ONSHORE FACILITIES Contract No: 6600026283 (OOK) Contract No: 6600026284 (IK) HAZARD IDENTIFICATION and RISK ASSESSMENT (HIRA) PLAN for FABRICATION ACTIVITIES at KARIMUN Fabrication Yard Contract No: 6600026283 (OOK) ATTACHMENT 4 – RA MATRIX (2 PAGES)

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SAIPEM CORPORATE RISK ASSESSMENT MATRIX RISK ASSESSMENT MATRIX HAZARD SEVERITY (CONSEQUENCE)

1 Minor

LIKELIHOOD (PROBABILITY)

A Unlikely

B Remote

C Possible

D Probable

E Very Likely

Could only occur under a freak combination of factors. AC (less frequent -5 than 10 )

May occur only in exceptional -5 circumstances. AC (10 -4 to 10 )

Could occur at some time. -4 -2 AC (10 to 10 )

Would no require extraordinary factors to occur at some time. AC -2 -1 (10 to 10 )

Almost certain to happen if conditions remain -1 unchanged. AC (10 to 1)

A1

B1

C1

D1

E1

A2

B2

C2

D2

E2

A3

B3

C3

D3

E3

A4

B4

C4

D4

E4

A5

B5

C5

D5

E5

Minor Injury / Minimal pollution effect / No loss time / No internal disruption / No downtime

2 Low Injury which requires medical attention / 1-3 day loss time / Minor pollution effect / Minor internal disruption / 1 Day downtime

3 Medium Potentially life threatening Injury causing temporary disability (e.g. fractures) and/or requiring medivac / Potential long term absence / Pollution with some onsite/offsite impact / Disruption possibly requiring outside help to manage / Downtime between 1 and 7 days

4 High Major life threatening injury or causing permanent disability (e.g loss of limb) / Incomplete recovery / Pollution with significant impact / Very serious business disruption / Up to 4 weeks downtime

5 Major Fatality or multiple fatalities, or multiple life threatening injuries causing permanent disabilities / Massive pollution with significant recovery work / catastrophic business impact and national/global media interest / Over 1 month downtim

LOW (L)

Any task that has this risk ranking is generally acceptable. The work environment and methodology presents minimal risks to personnel (see A1, B1, C1, A2, B2, A3, A4 on the above matrix)

MEDIUM (M)

Any task that has this risk ranking is only acceptable if the Risk is As Low As Reasonably Practicable (ALARP). ALARP assessments should be completed by suitably qualified and experienced persons. Personnel completing tasks which are in this band should be fully aware of the risks which exist and the control measures put in place to minimise them (see D1, E1, C2, D2, E2, B3, C3, B4, C4, A5, B5 on the above matrix).

HIGH (H)

Any task that has this risk ranking must not be completed. It should be refined or further control measures put in place to reduce risk (see D3, E3, D4, E4, C5, D5, E5 on the above matrix).

ARABIYAH & HASBAH OFFSHORE & ONSHORE FACILITIES Contract No: 6600026283 (OOK) Contract No: 6600026284 (IK) HAZARD IDENTIFICATION and RISK ASSESSMENT (HIRA) PLAN for FABRICATION ACTIVITIES at KARIMUN Fabrication Yard Contract No: 6600026283 (OOK) Detailed Definitions of Hazard Severity

Detailed Definitions of Likelihood

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LIKELIHOOD

Detail Definitions of Likelihood A Unlikely

An incident which is not expected to occur under any normal circumstances and would only result from a combination of extremely improbable factors. The probability of an “Unlikely” incident occurring is regarded as less frequent than 10-5 per year.

B Remote

An incident is not expected to occur under normal circumstances but may occur under exceptional circumstances. The probability of a “Remote” incident occurring is regarded as being between 10-5 and 10-4 per year.

C Possible

An incident which has the possibility of occurring under normal circumstances. The probability of a “Possible” incident occurring is regarded as being between 10-4 and 102 per year.

D Probable

An incident which is likely to occur at some point or regularly during normal circumstances and would require no extraordinary factors for its occurrence. The probability of a “Probable” incident occurring is regarded as being between 10-2 and 10-1 per year.

E Very Likely

An incident which is almost certain going occur during normal circumstances if conditions remain unchanged. The probability of a “Very Likely” incident occurring is regarded as being between 10-1 and 1 per year.

Detailed Definitions of Hazard Severity

HAZARD SEVERITY

RISK TYPE

PERSONNEL RISK

ENVIRONMENTAL IMPACT

AFFECTED

DOWNTIME

SOCIO – POLITICAL / REPUTATION

1 MINOR

Minor Injury (e.g. First Aid) – No Loss Time

Minimal pollution effect, contained locally

None

None

No internal disruption.

2 LOW

Injury/ Minor health effects require treatment by medically qualified person, effects are reversible - Short term absence from work, complete recovery.

Minor pollution, slight impact, negligible remedial/ recovery work.

Discipline

1 Day

Minor internal disruption. Limited community impact or interest. Reportable to Regulatory Authorities.

3 MEDIUM

Potentially life threatening injury causing temporary disability / Major health effect to individual requiring medivac to hospital facilities. Potential long term absence.

Pollution with some onsite/offsite impact & recovery work, possible outside assistance required to contain. Some local and possible regional media interest.

Local Unit / Project

1-7 Days

Internal disruption that could require outside help to manage. Community discussion, adverse local or financial publicity. Lawsuits possible.

4 HIGH

Major life threatening injury or Major health effects to several persons. Long term absence with incomplete recovery/permanent disability

Significant pollution with offsite impact & recovery work. Local / Regional and possible National media interest.

Business Unit

4 Weeks

Serious internal disruption adversely affecting ongoing business and requiring third party help to manage. Widespread interest, adverse shareholder and broker reaction, lawsuits possible.

5 MAJOR

Fatality or multiple fatalities, multiple permanent disabling injuries from occupational illness or injury.

Massive pollution with significant site impact & recovery work. Regional / National and possible Global media interest.

Corporate

> 1 Month

Very serious business disruption and impact on company operations. National / International media interest, adverse publicity and heavy selling pressure. Litigation certain and potential for Director Criminal Charges

ARABIYAH & HASBAH OFFSHORE & ONSHORE FACILITIES Contract No: 6600026283 (OOK) Contract No: 6600026284 (IK) HAZARD IDENTIFICATION and RISK ASSESSMENT (HIRA) PLAN for FABRICATION ACTIVITIES at KARIMUN Fabrication Yard Contract No: 6600026283 (OOK) ATTACHMENT 5 – RISK ASSESSMENT REGISTER FORM (FORM AH-0078)

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RISK ASSESSMENT REGISTER FORM

FORM AH-0078

Project Work Package:

Rev.0

Risk Assessment Results HIRA ID.

Activity

Hazard

Rating


Page 1 of 1

Date: 19.07.2011 Follow Up

Appointed Responsible Person

Due Date

Last Update

Status

ARABIYAH & HASBAH OFFSHORE & ONSHORE FACILITIES Contract No: 6600026283 (OOK) Contract No: 6600026284 (IK) HAZARD IDENTIFICATION and RISK ASSESSMENT (HIRA) PLAN for FABRICATION ACTIVITIES at KARIMUN Fabrication Yard Contract No: 6600026283 (OOK) ATTACHMENT 6 – HIRA SHEETS FOR THE SOW

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TASK: Transporting Project Material Activity ID

Activity Description

Hazard

HIRA ID: Hazard Effect

Risk Value SxL=R S L R


Residual Risk Level SxL=R S L R


Transporting Project Material by using Multi Wheel Transport to Erection Place (Brace Members, Legs, Plates and Beams) Preparation to Transport material to erection place by Multi Wheel Transport

Inadequate access for Multi Wheel during transportation

 Delayed work schedule  Strike to adjacent structures  Property damage  Strike to electrical panels  Injury to personnel  Electrocution or fire

Wet or unsuitable road condition

 Equipment stuck to ground  Material dropped  Property Damage  Personal Injury

inadequate competency of the Multi Wheel operator

 Personal Injury  Collision with other passing vehicles  Dropped materials  Personal injury  Delayed schedule  Dropped objects  Damage to property  Delayed work execution  Personal Injury

Defective multi wheel equipment

Date: 19.07.2011

2

B

2

B

2

C

2

B

 Ensure route is identified, the road shall have adequate load bearing capacity and any precautions required are taken  Competent operator having the SIO, Experience, skill to operate the multi wheel  Certified Multi Wheel vehicles  Operator is Medically fit for the task  Direct supervision  Awareness trainings  Ensure route is identified, the road shall have adequate load bearing capacity and any precautions required are taken

1

B

1

B

 Supervision to ensure competent and certified operator assigned 

1

B

 Awareness Trainings  Direct supervision  Proper restraining and adequate strength of device  Personnel are to deployed to control the traffic flow

1

B

Page 1 of 8




Manual handling

HIRA ID:

Hazard Unsecured loads

Individual not suitable to work

Slip, trip and falls

Hazard Effect

Adequate supervision may not be available

Improper restraining and stacking material Noise during material relocation


     

Dropped load Personal Injury Work delay Personal Injury Property Damage Delayed work execution

4

C

2

B

    

4

C

2

C



Dislocation Amputation Fracture Sprain/Strain Work -related musculoskeletal disorder Delayed work execution Property Damage Crush Injury Delayed work Material not secured Improper stacking of materials Personal injury

      

Dropped materials Material damage Personal injury Delayed work Hearing loss Loss of concentration Stress

2

C

3

B



Delivery of Material to Erection Area(transportation and placement)

Date: 19.07.2011

    

Standard Control Measures  The materials are to be lashed adequately to ensure they are properly secured from falling    

Residual Risk Level SxL=R S L R 2 B

Health Certificate HSE Induction Awareness Training Supervisor shall ensure that their workers are in good condition Guarding System Access to work area free from obstruction Unused material are to be removed from work area All open man holes, sharp edges equipped with guarding system Applicable signage Toolbox talk prior start of activity PPE

1

B

1

B

 Direct supervision shall be ensured at all times

1

B

 Awareness trainings for all the crew  Competent operator  Direct supervision

1

B

 All personnel must use hearing protection while entering the fabrication, assembly and piping workshops

1

B

      

Page 2 of 8


Manual handling training shall be given to the workers involved in this project




Date: 19.07.2011

HIRA ID:

Hazard

Hazard Effect

Weights of material to be unloaded may not be known.

    

Material placement method may cause problems for riggers to connect rigging for lifting

   

Unauthorized personal enter the lifting area

 Stuck by falling objects 


Lifting failure Dropped materials Property damage Injury to personnel Delayed work execution

3

C

Pinch injuries Delayed work Improper rigging Material striking the adjacent structures  Material damage

2

C

2

C

Standard Control Measures  Weights of materials to be confirmed  Crane is suitable for purpose and in sound condition  Suitable lifting gear to be used basing on the weight of the material to be handled  Supervision to ensure correct rigging equipment used  Competent riggers  Awareness trainings  Competent supervision  Supervision to ensure correct rigging equipment used  Supervision to ensure competent certified operators are assigned  Crane is suitable for purpose and in sound condition  Experienced and competent riggers are to be engaged for the task  Awareness trainings for the crew  Barricade the lifting area or deploy a spotter  Adequate supervision

Page 3 of 8


1

B

1

B





HIRA ID:

Hazard Stacked Material collapse

Unsuitable travel path

Inclement Weather

Date: 19.07.2011

Hazard Effect    

Crushing injury Personal injury Damaged materials Delay in work execution

 Equipment sunk into ground  Operator thrown out of the equipment  Dropped materials  Personal injury

 Poor visibility  Collision  Hit a stationary Object  Hit a person  Property Damage  Personal Injury

Risk Value SxL=R S L R 4

D

3

C

3

D

Standard Control Measures  Supervision to plan tasks, identify and control hazards, supervise for compliance to instructions  Material placement to be assessed for potential hazards and controls implemented  The availability, condition, adequacy and use of chocks to be confirmed  Supervision to plan & ensure proper methods are applied  Supervisor to ensure the path of travel is fit for use  Information passed to all the crew  Material are to be properly loaded avoiding the tilting or dropping  Road condition to dictate the speed  Competent operator  Awareness trainings  Ground conditions dictates the speed  Work shall be stopped  Rotating lights shall be ON  Competent Operator  Direct supervision

Page 4 of 8

Residual Risk Level SxL=R S L R 2 2

2

B

2

B





HIRA ID:

Hazard Peoples vehicle interface

Date: 19.07.2011

Hazard Effect      

Material struck Property Damage Amputation Fracture Sprain/Strain Delayed work execution


C

Standard Control Measures  Yard Speed Limit is to be followed  Traffic Signs are to be obeyed.  Road survey to be performed prior transporting the material  Toolbox talk prior start of activity  PPE to be used at all times



Transporting Project Material by using Forklift Transport to Erection Place(Brace Members, Legs,, Plates and Beams) Loading of erection materials onto forklift

Unqualified operator Drooped Materials

 Persons struck by the forklift while reversing  Property Damage  Personal Injury  Person hit while forklift is reversing

4

C

 Nobody under suspended load  Only qualified person to be involved in the lifting activity  Banks man to guide the operator and reverse alarms fitted and working  Visual inspection of all the lifting structural members before lifting done Conduct Toolbox Talks before lifting done by Supervisor  Suitable PPE is used at all times  Operator has valid certificate (SIO) to operate the forklift  Operator in possession of latest maintenance record

2

B

Compliance with WI-SIKB-HSE-014 LIFTING OPERATIONS 20 KMP speed limits on site. Only trained and certificated employees authorized to use forklift trucks. Flashing lights fitted to all forklift trucks. Reversing bleeper fitted to all forklift trucks. Daily safety checks to be made by each driver/designated Person and documented. Statutory Thorough Examination conducted on forklifts annually.

Page 5 of 8




Hazard

Date: 19.07.2011


Loss control of forklift

Mechanical failure of forklift

 Equipment damage  Crush Injury  Equipment collapse

Contact with other structure or building

 Structure/material damage while reversing  Personal injury

Unsuitable travel path

 Equipment sunk into ground  Forklift skid  Dropped materials  Operator thrown out of the equipment  Material thrown out of the fork lift


C

4

D

3

C

3

C

Standard Control Measures  Visual inspection of all the lifting structural members before lifting done  Operator has valid certificate (SIO) to operate the forklift  Operator in possession of latest maintenance record  Check the forklift prior to use  Valid certificate of forklift  Operator fit to operate forklift  Pre-use checklist for forklift  Periodic maintenance  Banksman assistance while reversing  Reverse alarm on forklift and audible  Vehicle fit for-purpose  Driver in possession of latest maintenance record  Driver fully concentrate during operating forklift  Awareness trainings  Effective Supervision  Supervisor to ensure the path of travel is fit for use.  Around conditions dictates the speed of the forklift.  Seat restrainer belt to be used at all times.  Materials are to be properly loaded avoiding the tilting or dropping.  Competent Operator.  Awareness trainings.  Adequate supervision

Page 6 of 8

Residual Risk Level SxL=R S L R 1 C

2

B

1

C

2

B





Hazard High Temperature (excessively hot weather)

Inclement weather

Delivery of Material to Erection Area (transportation and placement)

Adequate supervision may not be available

Improper restraining and stacking material Noise during material relocation .

Date: 19.07.2011

HIRA ID: Hazard Effect  Health related illness  Stress  Improper handling of the equipment  Collision  Personal Injury  Dropped load  Collapse of the operator due to heat stress  Poor visibility  Collision  Hit a stationary Object  Hit a person  Personal Injury  Property Damage  Delayed work  Material not secured  Improper stacking of materials  Personal injury  Dropped materials  Material damage  Personal injury  Delayed work  Hearing loss  Loss of concentration  Stress


D

3

D

3

C

4

C

3

B

Standard Control Measures  Regular breaks to be taken  Adequate drinking water is available at all times  Toolbox talk prior start of activity  Awareness  Direct supervision  PPE


 Work shall be stopped when the weather condition is unsuitable  Rotating lights shall be ON  Competent Operator

2

B

 Ensure route is identified, the road shall have adequate load bearing capacity and any precautions required are taken

1

B

 Awareness trainings for all the crew  Competent operator  Direct supervision

2

C

 All personnel must use hearing protection while entering the fabrication, assembly and piping workshops

1

A

Page 7 of 8





HIRA ID:

Hazard

Hazard Effect

Unauthorized personal enter the area

Improper placing, Without arresting the lateral movement


Date: 19.07.2011

   

Pinch injuries Delayed work Improper rigging Material striking the adjacent structures  Material damage


C

Residual Risk Level SxL=R S L R 1 A

3

B

2


B

HIRA Team Leader

Project Manager

Name:

Name:

Date:

Date:

Signature:

Signature:

Page 8 of 8



TASK: Hot Work Activity ID


HIRA ID: Hazard

Hazard Effect

Risk Value SxL=R

S Preparation for flame cutting and welding

Inadequate access and egress

Inadequate lighting

Inadequate ventilation

Inexperienced personnel

Positioning of cutting and welding equipment

Date: 19.07.2011

hazards due to cable and hose routing

 Slips, trips and falls  Personal Injury  Property damage    

Slips, trips and falls Strike against objects Personal injury Health hazards

 Injuries  Exposed to physical, chemical and general hazards  Fire and explosion  Electric shock     

Slip, trips and fall Electric shock Strike against Property damage Personal injury

L

3

C

3

C

2

C

4

C

2

C


R



S

L

 The work premises shall be easily accessible and all obstructions and surplus materials to be cleared from the access.

3

A

 Adequate lighting (300 lux) shall be ensured prior to start of the works

3

A

 The risk of falling objects, moving machinery, over-head crane operation, site transport etc also to be considered while setting the welding location 

 Adequate ventilation shall be available, either fumes extractor or natural ventilation  The personnel shall be trained, qualified and competent for the assigned job.  The welder should follow instructions and applying lessons learned in training, working in a safe manner, maintaining concentration and awareness, and not “cutting corners.”  The hoses and cables shall be routed such a manner not posing trip hazard.  The welding and grinding cables shall not be passing through wet surfaces or sharp objects

2

B



4

A

Only workers with appropriate levels of competence and skill should do welding. They must know:  The right way to do the work  The hazards of the work  How to prevent those hazards causing harm.

2

B

Page 1 of 12

R




Date: 19.07.2011

HIRA ID: Hazard

Hazard Effect

Risk Value SxL=R

S Manual handling

Defective hand tools

L

     

Strain and sprain MSD Strike against Fall from height Material damage Delay in work schedule

4

C

   

Electric shock Fire Injury (e.g. burn) Work schedule delay

4

D


R


S

L

 Pulling and Pushing shall be eliminated and mechanical devises shall be used.  Training and competency of the workers to be in place  Working at height or on staging, there is a Potential risk of falling. Working with guardrails in place, wearing safety harnesses attached to an approved device  Keeping walkways and staging clear of obstructions.  Hazard awareness to all personnel through tool box meetings  Direct supervision

4

A

 The tools are to be inspected prior to use.  Periodic inspection of the electric tools by a competent person.  Competent workers  Training and awareness to be ensured  Direct supervision to be in place

4

A

Page 2 of 12

R

Additional Controls and Risk Reduction Measures to be developed  Prior identification of hazards in manual handling tasks, assess their significance and devise controls.  Moving, lifting, carrying etc., presents a high risk of injury if the things moved are heavy, large or Awkward, or not lifted,  Carried or moved properly.  Using specialized or dedicated lifting equipment and systems reduces the risk of injury.  Proper training in correct manual handling is to be undertaken, so that the risk of injury due to lifting or carrying, etc. can be reduced.  The manufacturer or supplier of the equipment recommendations for setting up the equipment, safe usage and maintenance should be followed




HIRA ID: Hazard

Hazard Effect

Risk Value SxL=R

S Grinder maximum speed greater than maximum speed of the grinding disc

Unsuitable welding machine and damaged cables

Flame cutting operation

Date: 19.07.2011

Incompetent operator

 Personal injury  Equipment damage

   

Electric shock Fire Material damage Injury (e.g. burn)

 Exposed to hot surfaces  Fire and explosion  Exposed to heat and radiation

L

3

D

4

D

3

C


R


S

L

 Wheels must be run within their indicated maximum running speed as per the manufacturers guidance  Maximum speed of grinding disc must greater than maximum speed of the grinding machine or same  Awareness training shall be given to the workers use of the grinding machine

3

A

 The cables and the equipment are to be inspected prior to use.  Periodic inspection by a competent person.  Preventive maintenance of the tools and equipment  Competent workers to be engaged  Training and awareness to be provided  Direct supervision to be ensured  Competent operator with adequate experienced and training  All combustible materials shall be cleared from the vicinity prior to start of hot work  Spark shall be contained  Defective equipment shall not be used  Keep appropriate fire extinguishers available and visible at all times.  Make sure staff is trained in the use. Of fire extinguishers

4

A

3

A

Page 3 of 12

R

Additional Controls and Risk Reduction Measures to be developed  Prior inspection shall be performed before installing the grinding disc onto grinding machine  Supervision

 Appropriate PPE shall be used  Mark hot surfaces as such. Better still, assume everything is hot.




Date: 19.07.2011

HIRA ID: Hazard

Hazard Effect

Risk Value SxL=R

S Lack of appropriate PPE

Lack of maintenance for compressed gas cylinders

 Eye injury  Exposure to health hazards-fumes and gases  Exposed to physical hazards-radiation, heat fire, noise,  Electric shock  Burns  Fire  Explosion  Personal injury

L

2

C

4

D


R


S

L

Competent and qualified operator Direct supervision Mandatory PPE shall be used The welder should follow instructions and applying lessons learned in training, working in a safe manner, maintaining concentration and awareness, and not “cutting corners.”

2

B

 Cylinders should be correctly labeled  Cylinders should be stored in a ventilated area  Cylinders should be properly secured against falls  Fuel gas cylinders and oxygen cylinders should be stored separately  Gas cylinders should be kept away from electrical apparatus and sources of heat  Acetylene cylinders should be stored upright  Gas cylinders should be regularly examined for signs of defects, rusting or leakage  Empty cylinders should be appropriately marked and stored with their valves closed.

4

A

   

Page 4 of 12

R

Additional Controls and Risk Reduction Measures to be developed  Appropriate PPE at all times  In addition to standard training, first-aiders in welding situations should know about the symptoms of electric shock, arc flash and the consequences of exposure to heated coatings on metals (e.g. when galvanized metal is welded).




Date: 19.07.2011

HIRA ID: Hazard

Hazard Effect

Risk Value SxL=R

S Lack of integrity of the compressed gas cylinders

 Fire  Explosion  Personal injury

Compressed gas cylinders not correctly used

 Fire or explosion  Personal injury  Damage to property

4

L D


R  Flashback arrestors must be fitted to fuel and oxygen bottles  The integrity of the equipment fitted to gas cylinders should be inspected routinely  Cylinders, cylinder valves, couplings, regulators, hoses and apparatus should be kept free of oily or greasy substances  Red should be used to identify acetylene (and other fuel gas) hoses, blue for oxygen hoses, and black for inert gas and air hoses  Copper piping should not be used with acetylene. Operators should know:  The correct assembly procedures for attaching equipment to gas cylinders  The correct procedures and materials (detergent, not soap) for leak testing  The correct procedures for lighting gas torches and shutting them off  The signs of a flashback, what to do in response, how to check if damage has occurred to equipment and the actions necessary if it has occurred  Never to crack a fuel gas cylinder valve near a source of ignition before a regulator is removed, to close the valve and release gas from it  NOT to use the oxygen cylinder to dust off clothing  NOT to use the oxygen to ‘sweeten’ the atmosphere.

Page 5 of 12


S

L

4

A

R





Date: 19.07.2011

HIRA ID: Hazard

Hazard Effect

Risk Value SxL=R

S 4

L D


R  The use of LPG should be avoided in holes and trenches, where it can pool at a low level  When welding or cutting operations are done within 10 meters of combustible materials or floor, ceiling or wall openings, are guards, barriers, or other precautions used to confine heat, sparks and slag  Fire watchers are present during and up to 30 minutes after the job is done  Combustible floors kept wet, covered by damp sand, or protected by fireresistant shields  Before hot work is begun, the used drums, barrels, tanks and other containers so thoroughly cleaned and purged that no substances remain that could explode, ignite or produce toxic vapors  Before welding or cutting , all hollow spaces and cavities vented and purged to release trapped air or gases  All gas regulators and operators’ overalls and gloves shall be free of oil and grease (that might react with oxygen from a cylinder).  The standard practice to avoid letting gas lines lie in confined spaces (in case leaks allow flammable/explosive concentrations of gas to build up)

Page 6 of 12


S

L

4

A

R

Additional Controls and Risk Reduction Measures to be developed First aid equipment for welders immediately available at all times




HIRA ID: Hazard

Hazard Effect

Risk Value SxL=R

S Nearby workers exposed to flame cutting hazards

Grinding operation

Date: 19.07.2011

Incompetent operator

Defective tools

   

Eye injuries Burns due to fire Electric shock Exposed to radiation

 Fire  Electric shock  Injuries due to disk bust  Eye injuries  Electric shock  Fire  Personal injury  Property damage

L

2

C

3

D

3

D


R


S

L

 Welding cables and hoses kept clear of passageways, ladders and stairways  Employees working nearby protected from arc flash by screens, booths or shields  Signs: “Danger, No Smoking, Matches, or Open Lights” or the equivalent posted  All hazardous materials properly labeled  The welder should follow instructions and applying lessons learned in training, working in a safe manner, maintaining concentration and awareness, and not “cutting corners.”

2

B

 Only competent workers to operate the grinding machine  Should have been training in safe operating procedures

3

A

 Regular inspection by a competent person  Awareness trainings  Supervision

3

A

Page 7 of 12

R


Appropriate PPE to be in use.




HIRA ID: Hazard

Hazard Effect

Risk Value SxL=R

S Welding operation

Date: 19.07.2011

Incompetent welder

Electricity

 Exposed to Chemical hazards like, welding fumes, inert gases, gas mixtures and solvents  Exposed to physical hazards like electrical, heat, radiation, fire, noise, hot surfaces, magnetic field  Exposed to general safety hazards like Overhead crane operations, falling objects, mobile equipment and transportation, moving machinery  Electric shock or electrocution.  Touching “live” wire cause burns

2

L D


R  The welder should have been trained, qualified and competent for the task  All parts of the body covered against ultraviolet and infrared rays and flash burns the dangers of arc flash through the side of the eye understood  The welder should follow instructions and applying lessons learned in training, working in a safe manner, maintaining concentration and awareness, and not “cutting corners.” 

 Ascertain if equipment has been properly installed by qualified electricians and maintained in good condition.  Examine and inspect power switches, equipment, terminals, connections, cables, inter-connectors and insulation for condition and current carrying capacity.  Examine the working area to check for potentially live structures or components and wet areas.

Page 8 of 12


S

L

2

B

R


 Ensuring that all electrical equipment is installed properly, in accordance with regulations, and is maintained in good condition are the normal control measures taken to prevent electrical Incidents. Welders should never remove panels from welding power sources and should always get a qualified electrician to investigate faults in Electrical equipment.




Date: 19.07.2011

HIRA ID: Hazard

Hazard Effect

Risk Value SxL=R

S

L


R


S  Welding equipment should have all side panels in place and secured; all terminals, connections and live components should be properly protected.  The current-carrying capacity of cables, interconnectors,  Terminals, etc., should be high enough to carry the maximum operating current. If they are not of sufficient capacity, then they may overheat, giving an increased risk of burns or starting a fire.  There should be a separate earthling conductor, unless the equipment requires only a welding return cable. Lack of an earthling conductor can give an increased risk of electric shock.  All welding cables, electrode holders, welding torches and guns, wire feed units, etc., should be in good condition and properly insulated. Any piece of equipment that is damaged or unsafe gives a potentially high risk of electric shock and should not be used until it is repaired and made safe.  There should be an easily accessible means of switching off the welding power source at the mains, in the event of an emergency. If here is no means of switching it off and a fault occurs, it may not be possible to isolate an electrical problem, giving an increased risk of electric shock, burn or fire.

Page 9 of 12

L

R

Additional Controls and Risk Reduction Measures to be developed  Using LVSD (low voltage safety devices) whenever  Possible when MMA welding reduces the risk of electric shock. They are particularly recommended when welding is taking place in confined spaces or other high-risk situations, such as wet environments, when the result of a shock could be particularly serious.  Wearing dry leather gloves, insulated footwear and other appropriate protective clothing is a practical risk control measure that can be taken by individual welders to reduce the risk of electric shock.




Date: 19.07.2011

HIRA ID: Hazard

Hazard Effect

Risk Value SxL=R

S

Radiation

Exposed to environmental hazards

 Burns to skin  Eye injury due to arc

   

Burns Heat stress Fire explosion

L

4

D

2

C

2

C


R



S

L

 Working in wet, damp or humid conditions should be avoided  Working on a fabrication that constitutes part of the electric circuit (as in shipbuilding) gives a potentially high risk of electric shock, since an electrical fault could result in the fabrication becoming “live.”  Protective equipment and clothing for the face, head, hands, arms and body are the normal risk control measures used to reduce exposure to radiation of the welder and others in the immediate vicinity of the process being used.  Training, qualification and competency of the welders for the task

4

A



2

B

 The risk of accidental burn injury is reduced if hot plates and welded components are marked “hot.”  All combustibles shall be removed from the immediate vicinity  Checking for and sealing leaks and ensuring all connections are sound prior to start of work  Firefighting equipment must be readily available.  Welding in or on tanks or vessels that have contained flammable substances, they must be purged to remove all traces of anything flammable or explosive

2

B

 Gas welding goggles or screens must have a filter shade that is suitable for the process and flame intensity. Using a filter shade that is too light gives an increased risk of glare and eyestrain.  Consult welding process health sheets and MSDSs for what type of radiation is emitted during use.  Handling hot items with suitable gloves removing all flammable materials reduces the risk.  Protective clothing must be in good condition to ensure no areas of skin are left exposed to heat, arcs or flames. Using correct protective clothing in good condition gives a low risk of burns, as skin is protected. 

Page 10 of 12

R




Date: 19.07.2011

HIRA ID: Hazard

Hazard Effect

Risk Value SxL=R

S Noise and vibration

Magnetic fields

Welding fumes

 Noise induced deafness  Distraction from work  Stress

 Heart to stop or slow down and this may induce fainting.

 Health hazards

L

2

C

1

C

2

C


R  Where noise levels exceed allowable levels as laid down warning notices will be required either at the machine/process or, if excessive generally throughout a workshop, at all entrances  Noise level measurements in dB (A) may need to be taken to identify where noise levels are excessive and also which operations are producing the highest noise levels.  Segregation of noisy processes  to one area of the workshop, away from the general work area,  Keep the welding cables together and to one side of them and not wrapping any electric leads around the body.  Welders fitted with peace-maker eliminate the risk by staying well away from welding power sources and cables.  Adequate ventilation and/or local fume extraction is provided.  Training, qualification and competency of the welder  Periodic health surveillance  Awareness sessions on health

Page 11 of 12


R


S

L

2

B

 Wearing of suitable ear protection reduces the risk of exposure to noise and damage to hearing. 

1

B

 Welders fitted with pacemakers can reduce exposure by using welding processes, like oxy-fuel gas welding, 

2

B

 Consult the MSDS for what is in the consumable and what fume is produced during welding.  the use of personal respiratory protective equipment such as respirators, welding hoods, etc.,  Periodic Sampling and analysis is the only way to detect what is in the fume and how much is in the welder’s breathing zone




HIRA ID: Hazard

Hazard Effect

Risk Value SxL=R

S Solvents


Date: 19.07.2011

 Exposed to toxic or irritant product  Fire  Chronic health hazard due to exposure to solvent vapours or concentration

3

L D


R  Storing flammable solvents well away from welding areas is an important control measure in reducing the risk of fire or explosion from heat and flames from welding.  Sitting of vapor degreasing plants well away from welding activity is a control measure that greatly reduces the risk of exposure to breakdown by-products.  Awareness and trainings for the welder


S

L

3

A

HIRA Team Leader

Project Manager

Name:

Name:

Date:

Date:

Signature:

Signature:

Page 12 of 12

R

Additional Controls and Risk Reduction Measures to be developed  Gather information and identify the solvents being used and whether they are in the immediate vicinity.  Consult MSDSs for the properties and potential hazards of each solvent.  Use of suitable respiratory protection will reduce the risk of inhalation of solvent vapors.


TASK: Non Destructive Testing (NDT) Activity ID


Hazard

Date: 19.07.2011






Carry out visual Inspection Preparation for visual Inspection 001

 Slips, trips and falls

 Personal Injury  Delay in work schedule

 Lack of access for elevations

 Fall from height  Delay in work schedule

 Fall from Height


 Struck by falling object


 Struck against structures


 Damaged floors, trailing cables, oil spills, water on floors, sloping surfaces, uneven steps, debris, etc. are to be controlled or cleared from the work premises  Applicable signage to be posted.  Spillages, if any, to be cleaned out  Competent person for visual inspection  Safety awareness  Competency Trainings

 Industrial standard scaffolds shall be provided  Safety Awareness  Competent supervision  Regular management visits  Industrial standard scaffolds shall be provided  Safety Awareness  Competent supervision  Safety awareness/Trainings  Surplus and unwanted materials from height to be removed  Regular inspections of heights  Safety awareness/Trainings  Barriers  Safety signage at the locations Page 1 of 34

All persons in the crew to be instructed that they are not required to work in any situation or with any equipment that they do not believe is safe (If personnel feel at risk they are to stop work, inform their supervisor of their concerns). Mandatory PPE (Coverall, Safety Helmet, Safety Glasses, Safety Shoes), Hand Protection.

Mandatory training in Working at height

Mandatory PPE shall be in use

Mandatory PPE shall be in use

 Caught between two moving parts

 Body injury  Delay in work schedule

 Barriers/guards at all moving or rotating parts of machinery  Applicable signage to be posted.  Awareness and trainings

Exposed to site Environmental hazards  Exposed to Heat

 Fall from Height  Heat stress / exhaustion  Personal Injury

 Noise exposure

 Noise induced deafness  Lack of concentration on work

 Dust inhalation

 Health hazard

 Exposed to Electrical hazards

 Shock / burns Electrocution  Fall from height  Personal injury

 Slip and fall due to Slippery surfaces

 Personal Injury  Fall from height

/

 Adequate cool drinking water to be provided  Job rotations /periodic rest  Awareness trainings  Health Monitoring/survey  Health Risk assessments  JSEA Effective supervision  for new job locations  Necessary signage  Health Monitoring/survey  Health Risk assessments  Awareness trainings  Effective supervision  Minimize dust/vapor/fumes production from the work place  LEV system to be used where applicable  Regular cleaning and decontamination of the work site  Natural ventilation to be ensured  Awareness trainings  Effective supervision  Awareness trainings  Defective cords and extension shall not be in use  Only competent electrician to repair the damaged cords/leads  Fall protection should be periodically inspected by competent person  Effective supervision at all times  Spills, if any to be immediately wiped.  Fall protection to be in use while working at height  JSEA for new job locations  Safety awareness

Page 2 of 34

While working at height protection shall be ensured

fall

Hearing protection shall be used at high noise levels locations

Dust mask shall be worn

Regular inspection of electrical installations by a competent person

 Exposure to hazardous substances

 Health hazards  Skin, eye and respiratory irritation  Personal Injury  Work schedule delay  Work related disease

B

4

M

            

002

Method of work

 Lack of information / Instruction and training  Wrong method adopted for work execution  Wrong Posture  Phobia  Manual handling  Repetitive movement  Lack of supervision

   

Personal Injury Material damage Stress Delay in work execution  Back injury/hernia  Work related upper limb disorders  MSD,HAVS

D

2

M

        

Page 3 of 34

Minimize dust/vapor/fumes production LEV system to be used where required Information and instructions are given Restricted workplace entry for outsiders Eating and smoking are not allowed in the work premises during the work activity Regular cleaning and decontamination to be ensured MSDS awareness is provided for the crew handling the hazardous substances Natural ventilation is in place Provision of washing facilities Substituted safer materials from the hazardous materials in use Awareness trainings for the crew Effective supervision Regular Inspection of work places by management Emergency preparedness Adequate rest periods Defined competency level Defined responsibilities Defined performance standard Adequate information and instructions Audit performance Adequate trainings and information Adequate supervision

A

4

L

Mandatory PPE shall be worn at all times COSHH assessment conducted for worksite hazardous substances Hazard communication is conducted for the crew handling the hazardous substances

C

1

L

003

Lone working

004

Working at height

 No information given to supervisor  Young and incompetent worker  Communication not established  No lighting arrangements  Lack of information and training

 Accident, injury,  Delayed assistance in emergency  Delayed work schedule

 Falls from height  Strike against fixed structures  Using a defective scaffold  Defective ladder used  Fall protection not used  Struck by falling objects  Slips, trips and falls from elevations  Fall into open gratings

 Personal Injury  Property damage  Delay in work schedule  Decreased employee morale

 Human error

 Personal Injury  Material damage  Delay in work execution  Exposed to work related hazards

C

2

M

D

3

H

D

4

H

 Only agreed risk tasks to be undertaken, Avoid high risk activities (e.g. working at height)  Notify manager/supervisor of start time and when finished.  Reduce time spent working alone so far as is reasonably practicable.  Means to summon assistance close to hand, mobile phone carried.  Notify staff on site of location / estimated duration of task if working on site remote from others.  Adequate security in place.  External lighting adequate  Key holders should be strictly controlled and numbers kept to a minimum.  Competent person assigned for the job  Mandatory Working at height trainings should have been undergone by the Inspector  Scaffolds which are being used shall be with Scaff-Tag(Green Tag)  Grating openings are to be guarded and signage posted  Scaffolding usage awareness by the Inspector  Adequate and sufficient lighting arrangements for night works  Cable management at height to be such slip and, trip hazards are eliminated.  Loose materials are to be contained or removed from height  Surplus and off-cut materials are to be cleared from the height/scaffolds.  If equipment is used at height, shall be secured from falling  Effective supervision shall be in place  Emergency preparedness shall be in place  Adequate rest periods for the inspector  Defined competency level  Defined responsibilities  Defined performance standard  Adequate information and instructions  Audit performance  Adequate trainings  Adequate supervision

Page 4 of 34

B

2

L

Consideration given to staff at increased risk i.e. new or young worker, inexperienced staff etc. and lone working activities avoided where practicable.

C

3

M

PTW obtained, if required PPE Shall be as per the work activity requirements The procedure for Night works (WI-SIKB-HSE-020)shall strictly followed Location specific Risk Assessment shall be in place prior to working at height

C

4

M

Selection of competent, skilled and experienced personnel for the task

005

006

Entry into confined space

Using Mobile Elevated work platform To gain height

 Asphyxiation  Lack of proper access and egress  Exposed to Environmental hazards  Exposure to harmful substances  Slips, trips and falls  Lack of adequate lighting arrangements  Lack of training and awareness  Working alone  Lack of communication  Lack of standby person  Lack of proper arrangements to work at height

 Personal Injury  Delayed work schedule  Property damage  Electrocution

 Incompetent Operator  Defective MEWP  Falls from height  Strike against objects / structures  Struck by falling objects  Ejection from the MEWP basket  Exposed to environmental hazards  MEWP Collapse 

 Personal Injury  Equipment damage  Delay in work schedule  Bone fracture  Sprain/strain  Work relates stress  Health hazards due to exposure to environmental hazards

D

D

4

3

H

H

 Trained in Mandatory Confines Space Entry Training  Medially fit to work in confined space  Atmospheric monitoring of confined space prior to entry  Certified scaffolding is erected by competent scaffolders and provided with scaff tag  Fall protection is used  Forced ventilation if required  Safety watch/stand by person  Equipment positively isolated(LOTO)  Adequate lighting is to be ensured  Ladders are to be secured to a fixed or rigid structure  Protection of floor openings/Gratings and safety signage posted  Never to work alone  Good Communication to be maintained  Safe access/egress provided  Tool box meeting prior to entry  Direct supervision  Emergency Preparedness

C

 Certified equipment is to be used.  Periodic Preventive maintenance of the MEWP is in place  Competent Operator having in possession of SIO,  Follow the prescribed SWL of the basket  MEWP Shall be positioned on a firm and level ground  Obstructions in the path of travel to be corrected, if any  Good communication to be established with the ground crew  Adequate and sufficient lighting arrangements for night work  Awareness trainings for those involved  Direct supervision  Emergency preparedness

C

Page 5 of 34

4

M

PTW obtained after the risk assessment / JSEA conducted All required PPE is in use Location specific Risk Assessment shall be in place prior to working at height

3

M

Appropriate PPE to be used during operation

Good communication, preferably radio to be established Location specific Risk Assessment shall be in place prior to working at height

Carry out Liquid Penetrant test Pre clean the test area

 Flash fire due to application of cleaner close to hot surfaces  (Post Weld Heat Treatment, Welding joints)  Struck by flying metal particles  Contact with hot surfaces  Inadequate access  Unqualified workers  Material fall from height  Fall from height  Slips, trips and falls

 Mist or vapor will irritate respiratory tract a  Burns duet to contact with hot surfaces  Eye and skin irritation  Fall from height  Burns injuries due to  contact with hot surfaces 

 COSHH and MSDS documents shall be available  Qualified and competent technician to perform the test  Physically qualified technician to perform the inspection reliably  He shall be aware of job related hazards and safety precautions  Good ventilation is to be maintained  Mandatory Working at Height trainings was undergone by the crew/inspector  Trained and competent Inspector  Good housekeeping to be maintained  Fire precautions shall be in place  Scaffold erected to the industrial accepted standards  Fall protection is used  Instruction/information and trainings are provided  Any spill shall be cleaned immediately to avoid slipping hazard  Trained first aider to be available with the crew and shall be equipped with first aid kit  Direct supervision

Page 6 of 34

Permit to work shall be in place

COSHH assessment should be conducted Mandatory PPE to be worn. Eye protection designed protect against liquid splash respiratory protections meet the requirements

to

shall

For skin protection cotton or cotton synthetic overalls or coveralls are normally suitable for the task

Penetrant application

 Improper test techniques used  Materials contaminated or improperly manufactured  Fast evaporating vapors can reach hazardous levels  Aerosol cans exposed to exposed to hot weather conditions  Operator exposed to wavelength radiation  Aerosol bust due to high temperature will cause splash of chemicals  Extraneous light sources  Irritate skin by removing natural skin oil  Struck by flying metal particles  Chemical splash on face  Contact with hot surfaces  Inadequate access  Unqualified worker  Material fall from height  Fall from height  Slips, trips and falls

 Dizziness and nausea if inhaled  Short wavelength radiation will cause a condition known as photo keratitis followed by conjunctivitis

Health hazards  Central Nervosa system(CNS)depress ion and target organ effect if over exposed  Excessive overexposure may cause giddiness, dizziness, headache, nausea and in extreme cases,  Unconsciousness and respiratory depression.  Overexposure may cause eye and skin redness.  May cause eye, skin and respiratory irritation. Aspiration hazard if swallowed.  Eye fatigue  Head ache or nausea, tiredness or pain in the chest

 Quality control of incoming penetrant processing materials, as well as quality control of in –use inspection for reliable penetrant inspection programme  Qualified and competent technician to perform the test  Physically qualified technician to perform the inspection reliably  He shall be aware of job related hazards and safety precautions  Do not store at temperatures above 100°F (38°C).  Handling: Do not use near heat, sparks or open flame.  Do not puncture or incinerate container  Use only in a well  Ventilated area.  Penetrant shall be applied wearing neoprene gloves to avoid cont Store away from heat, sparks or open flame. act with skin  Avoid contact with skin and eyes. Wash hands before eating and smoking  The penetrant shall be kept away from clothes  Mandatory Working at Height trainings was undergone by the crew/inspector  Trained and competent Inspector  Good housekeeping to be maintained  Fire precautions shall be in place  Scaffold erected to the industrial standard  Fall protection is used  Instruction/information and trainings are provided  Hazard communication training on the aerosols for all those involved  Any spill shall be cleaned immediately  The used aerosol cans to be disposed as Hazardous Waste Material  Direct supervision

Page 7 of 34

COSHH assessment should be conducted Mandatory PPE to be worn. Eye protection designed protect against liquid splash respiratory protections meet the requirements

to

shall

For skin protection cotton or cotton synthetic overalls or coveralls are normally suitable for the task

Developer application

 Improper test techniques used  Materials contaminated or improperly manufactured  Fast evaporating vapors can reach hazardous levels  Aerosol cans exposed to hot weather conditions  Flash Fire when applied neat to hot surfaces  Chemical splash

 Quality control of incoming penetrant processing materials, as well as quality control of in –use inspection for reliable penetrant inspection programme  Qualified and competent technician to perform the test  Physically qualified technician to perform the inspection reliably  He shall be aware of job related hazards and safety precautions  Do not store at temperatures above 100°F (38°C).  Handling: Do not use near heat, sparks or open flame.  Do not puncture or incinerate container  Use only in a well  Ventilated area.  Penetrant shall be applied wearing neoprene gloves to avoid cont Store away from heat, sparks or open flame. act with skin  Avoid contact with skin and eyes. Wash hands before eating and smoking  The penetrant shall be kept away from clothes  Mandatory Working at Height trainings was undergone by the crew/inspector  Trained and competent Inspector  Good housekeeping to be maintained  Fire precautions shall be in place  Scaffold erected to the industrial standard  Fall protection is used  Instruction/information and trainings are provided  Hazard communication training on the aerosols for all those involved  Any spill shall be cleaned immediately  The used aerosol cans to be disposed as Hazardous Waste Material  Direct supervision 

Page 8 of 34

COSHH assessment should be conducted Mandatory PPE to be worn. Eye protection designed to protect against liquid splash respiratory protections shall meet the requirements For skin protection cotton or cotton synthetic overalls or coveralls are normally suitable for the task

Inspection

Clean up and disposal of materials

 Exposed to chemical hazards  Struck by flying metal particles  Material fall from height  Slips, trips and falls  Lack of proper access  Defective scaffolds  Darkness

 Health hazards due to exposure to chemicals  Fall from height  Personal Injury  Property damage  Delay in work schedule

 Exposed to chemical hazard  Slips, trips and falls  Contact with Hot surfaces  Noise  Exposure to physical hazards in work place

 Personal Injury  Health hazards due to exposure to chemicals  Noise induced deafness 

 Quality control of incoming penetrant processing materials, as well as quality control of in –use inspection for reliable penetrant inspection programme  Qualified and competent technician to perform the test  Physically qualified technician to perform the inspection reliably  He shall be aware of job related hazards and safety precautions  Do not store at temperatures above 100°F (38°C).  Use only in a well  Ventilated area.  Penetrant shall be applied wearing neoprene gloves to avoid cont Store away from heat, sparks or open flame. act with skin  Avoid contact with skin and eyes. Wash hands before eating and smoking  The penetrant shall be kept away from clothes  Mandatory Working at Height trainings was undergone by the crew/inspector  Trained and competent Inspector  Good housekeeping to be maintained  Scaffold erected to the industrial standard  Fall protection is used  Instruction/information and trainings are provided  Hazard communication training on the aerosols for all those involved  Any spill shall be cleaned immediately  The used aerosol cans to be disposed as Hazardous Waste Material  Direct supervision  Trained in mandatory working at heights  Area to be well ventilated  Scaffold shall be Industrial standard  Fall arrest equipment in use  Hazard communication should have been conducted for the chemicals in use.  Good Housekeeping  Information, Instruction and training for the worker shall be provided Page 9 of 34

COSHH assessments and MSDS Documentation to be available. Approprate PPE to be in use

Magnetic Particle Inspection Carry work equipment to work location

        

Clean and degrease test area

      

Testing

    

Clean up the area

   

Vehicle accident Unsecured load Manual handling Lack of access to elevations Slips, trips and falls Hit by falling objects Contact with electricity Fall from height Exposed to physical hazards at work site Fall from height chemical handling Exposed to physical hazards Spools falling or rolling Hit by falling object Slips ,trips and falls Working on hot surfaces Fall from height Chemicals handling Electrical UV Radiation Working on hot surfaces Fall from height Chemical handling Working on hot surfaces

Personal Injury Strains Electric shocks Material Damage Delay in work schedule

 Competent workers to be assigned for the task  Securing the load  Competent driver and road worthy vehicle in use.  Awareness in manual handling  Scaffolding to access work at height shall be industrial standard  Information, instruction and training to the workers

Appropriate PPE in use

 Injury  Health hazard due to exposure to chemicals  Burns  Electrocution 

 Scaffold erected to Industry standard  Chocking the spools prior to work commencing  Awareness  Instruction, information and training for the individuals

COSHH assessment and MSDS documentation available Appropriate PPE in use

    

Page 10 of 34

Taking back the equipment to store

   

Vehicle accident Unsecured load Manual handling Slips ,trips and falls  Hit by falling objects  Fall from height

 Damage equipment  Personal injury  Back pain  electrocution

to

 Vehicle in road worthy condition and periodic maintenance carried out  Trained driver  Securing the load  Mechanical aids for handling load  Scaffolding erected to industrial standard

Ultrasonic Inspection Moving the equipment to the work area Pre-clean the area to be tested Ultrasonic Inspection

Cleaning the area after testing

Carry out Radiography test

Page 11 of 34

COSHH assessment and MSDS documentation available Appropriate PPE to be worn

007

Preparation for Radiography activity

 Non compliance of Indonesia controls and precautions and  Permit to Work System for Site Radiography

 Exposure to radiation  Unsuspecting personnel exposed to radiation  contravene the National regulations  Environmental degradation 

D

5

H

 Competent and authorized crew to be deployed  Copies of local rules shall be provided so as to adhere to the control measures and precautions required;  Any existing Site Client rules and procedures shall be adhered to;  Subcontractor Competent Person is to be responsible for the control and safety of handling of ionizing sources (i.e. Radiation Representative).  Radiography areas, or other areas where radioactive materials are in use, shall be effectively cordoned off to prevent access to personnel.  Radiation is three dimensional, therefore areas above and below must also be included in controlled areas;  These areas shall be prominently signed on a yellow background.  The barriers, where appropriate, shall be further identified by yellow flashing lights  Controlled areas will be where the dose rate (instantaneous) exceeds 7.5 micro severest;  Regular monitoring and leak testing shall be carried out on any sealed radioactive source;  Notification of Radiography shall be initiated  Information shall be provided to HSE and posted on Notice Board at site.  Awareness trainings for those involved in the work activity  Direct supervision  Emergency Preparedness at all times

Page 12 of 34

B

5

M Permit To Work Procedures are to be strictly followed (00-ZA-E-G85819)

The SIKB Yard Operations Manager / Production Manager / HSE Manager shall liaise with the Competent Person in cocoordinating the provision of local control rules to ensure effective safety precautions are taken; Plant pre-start checks to be completed. Report any safety related faults to supervision. All personnel to be involved in a pre-start toolbox meeting each day. Review this JSEA to ensure site conditions and hazards do not require further control measures to be implemented. Permits to be arranged as required.

008

Night work

 Working in dark environments  Fall into openings  Slips ,trips and falls  Strike against electrical panels  Strike against fixed structures  Struck by falling objects  Caught between moving parts

      

Equipment damage Personal injury Electrocution Fire Work schedule delay Work related stress Strike against

C

5

H

 Adequate and sufficient lighting facility for night work to be in place  Qualified maintenance staff to deployed for night work for catering to the electrical related failures  All the crew members shall be fit for work and alert  Electrical system shall be properly grounded  Outside work activity shall be restricted during rain  Electrical cables for outdoor work

C

4

M

The procedure for Night works (WI-SIKB-HSE-020)shall strictly followed

Proper ELCB to be installed and regular inspection by a competent person of all electrical installations Diesel generator shall be provided with adequate fuel for all night shift work Radio communication to be established Strict adherence to site sped limits during the night Competent driver to be in place Defensive driving to be practiced Rain coats/umbrellas to be provided to the crew.

Mandatory PPE shall be used  Qualifications of the persons involved in the activity is inadequate

 Exposed to radiation  Local population and other workers on site are exposed  Contravening Indonesia Regulations  Delayed work schedule  Waste of time, energy and materials  Sub standard quality of the output

 Qualified personnel meeting the Indonesian regulations  Mandatory trainings should be conducted on Emergency response procedures, Awareness of radiography, Permit To work procedures  Awareness on statuary requirements of Indonesian rules and regulations 

Page 13 of 34

Shall carry out their responsibilities in line with approved procedures; Report any abnormality observed during work to the Radiation Protection Supervisor.

Management and Control on site are inadequate.

 Number of Supervisors and Management on site insufficient to control activities  Sub standard quality of work executed  Confusion among the work crew  Delayed work schedule  Work related stress

Roles and responsibilities not clearly defined.

 Exposure to radiation  Personal injury  Confusion among the work crew  Delayed work schedule  Work related stress  Exposure to radiation  Delayed medical attention  Work related incident  Work related stress

Inadequate emergency response.

E

3

H

E

4

H

 Organization chart is identified and suitable personnel are deployed prior to the start of work.  Management and supervisors have received appropriate training  Roles and responsibilities are defined and method statements are available.  First Aid training for HSE officers.  Dedicated medical facilities on site and Medevac plan.  Spill response team available.  All crew are competent and skilled  Direct supervision  Roles and responsibilities of Permit to work shall be strictly followed as stated in PTW Procedure(00-ZA-E-G85819)  Roles and responsibilities in case of Emergency response procedures shall be strictly followed as stated (00-ZA-EG85803)  Adequate planning should be in place  Competent person is in charge of the activity  Training in emergency response procedures (00-ZA-E-G85803) for all the crew members  Periodic drills and exercises for the involved crew

E

2

M

C

2

M

Radiography awareness(WI-SIKBHSE-032) shall be strictly followed

Periodic Emergency drill are to be conducted so as to familiarize all the involved in emergency preparedness To be witness by the Management

Periodic management HSE inspections 009

Transporting the Radiography source From Subcontractor storage premise to work location and personal mobilization

 Loss of the radiography source  Vehicle collision  Public exposed to radiation  Traffic obstructions  Inexperienced driver  Unfit transport vehicle in use  Adverse weather conditions

 Contravening the Indonesian Regulations  Public exposure to radiation  Damage to radiographic source  Work schedule delay  Collision on road  Damage to the vehicle  Injury to personnel

D

4

H

 Standard Operation Procedures for radiography source transportation by vehicle  Trained/ certified vehicle driver  Trained /certified radiography crew  Advance planning for the tasks  Certified Vehicle in use  Vehicle in good condition  Driver in possession of required licenses  Driver awareness including distance from vehicle  Emergency preparedness

Page 14 of 34

C

4

M

010

Setting up Radiographic equipment

 Loss of the radiography source  Vehicle collision  Other workers exposed to radiation  Traffic obstructions  Inexperienced driver  Unfit transport vehicle in use  Adverse weather conditions  Injuries from equipment falling on personnel  Personnel not competent and qualified.  Isotopes and its container not certified.  Lack of adequate lighting arrangement  Slip trips and falls Manual Handling

 Contravening the Indonesian Regulations  Public exposure to radiation  Damage to radiographic source  Work schedule delay  Collision on road  Damage to the vehicle  Injury to personnel 

 Radiographic Source damage  Exposure To Radiation  Personal injury  Strike against  Struck by  Fall into grating openings 

      

Personal Injury Sprains/strains Bone fracture Material damage MSD Hernia Delayed work schedule  Strike against fixed structures  Work related stress 

D

4

H

C

5

H

C

3

M

 Standard Operation Procedures for radiography source transportation by vehicle to be followed  Trained/ certified vehicle driver  Trained /certified radiography crew  Advance planning  Certified Vehicle in use  Vehicle in good condition  Driver awareness including distance from vehicle  Emergency preparedness

C

4

M

 Certified equipment in use  Certified and competent person for the task  Radiation monitors are in good working order and turned on.  Current calibrated survey meter is in use  emergency tool kit is available  Radiation Protection Supervisor is present during operations.  radiation monitors, Film badges  Electroscope are worn or used. 

B

5

M

 The worker shall be physical fit for the task  As far as possible heavy loads are to be handled by mechanical devises  Suitable and experienced crew.  Adequate knowledge and experience  Adequate and sufficient lighting arrangements  All floor openings protected an warning signs posted  Cable management is in place  Trainings on manual handling  Effective supervision

C

Page 15 of 34

The recommended Personnel Protective Equipment (PPE) is worn. Communication arrangements are in place

1

L

JSEA/risk assement should have been conducted and the associated hazards were informed to the crew in advance

011

Conducting radiography

 Working in dark

   

 Source becomes stuck out (Exposure to Radiation)

 Exposure to radiation  Exposure of Radiation to other personnel  Electrocution / shock / burns  Fire

Fall from height Slips, trips and falls Electrocution Struck against fixed structure  Falls into openings

D

4

H

D

5

H

 Identification of the location and hazards to be carried out prior to start of work during night  Adequate and sufficient lighting arrangements are in place  Grating openings are adequately covered and signage in place  Cable management is in place  Emergency preparedness   Certified equipment in use  Competent working crew  RSO shall be monitoring the work activity at all times  Barriers and signs are erected and monitored prior to radiographic exposure.  A minimum of two qualified personnel perform radiographic operations.  Sign denoting the radiation  Protection Supervisor is available on strategic places on site.  Radiography-covering lights are on.  Watcher to ensure unauthorized personnel are entering to the hazardous zone  Supervision is in place

C

4

M

C

4

M

Emergency Contact List to be available and posted. Adequate supervision. Announcing of radiography works by loud speakers or megaphone. Emergency tool kit for Isotopes recovery shall be available Suitable barriers shall be erected. Warning lights, rope barriers with radiation warning pennant, warning signs (with radiation symbol to be installed. Dose rate at the perimeter of the barricades shall not exceed 0.75mR/hr. Personal dosimeter record shall be check regularly. Radiation Protection Officer shall have sufficient knowledge in the event of Isotopes Emergency Plan. Compliance of Radiation safe Work Procedure.

012

Removal and Storage of Radiographic Equipment after exposure

 Injuries from falling equipment on personnel  Contingency may happen during transport of Isotopes.  Manual handling 

 Exposure to Radiation  Struck by falling objects  Stuck against fixed structure  Slips ,trips and falls  MSD  Strains/sprains  Back pain  Work related Stress 

C

5

H

 Equipment is in good working condition and defective equipment to be repair immediately.  Procedures are adhered to  Storage pit available to store the isotope.  emergency tool kit and storage container available and on site prior to any radiography  Unqualified personnel are not allowed inside the barriers.  All monitoring devices are available and worn or used. 

Page 16 of 34

B

5

M Isotopes Pit Storage shall have protection against theft, increment weather and unauthorized operation. Padlock keys shall be held in custody by authorized persons or the designated RPS. Names & contact number were displayed prominently at the Storage Pit area.

013

Developing of Radiographic Film

 Injuries to personnel form working in a dark room  Electric shock from lights, driers, equipment etc.  Environmental hazards

 Personal Injury  Electrocution / shock / burns  Slips trips and falls  Exposure to harmful chemicals and substances  Health hazards due to exposure  Environmental degradation

D

3

H

D

4

H

 Competent dark room developer  Adequate trainings  Information and awareness on safety issues  Safe Operating Procedure is strictly followed  MSDS for chemicals used available and COSHH assessment conducted  And personnel are aware of the associated chemical hazard  not to use any electrical items whilst in wet conditions  Hazardous waste to be handled and disposed as per the required regulation

D

2

M

 Test pack drawings shall be checked for details of module, location & and line ID.  Each line shall be provided with an ID.  The test line will be barricaded with flagging & warning signs.  Test Engineer will review the checklist & line for completeness of each checklist item and sign off when satisfied.

C

2

M

Hydro test and pneumatic test activities 014

Preparation of Test Packs

 Failure to identify correct test lines, isolations, test pressures, etc.

 Delayed work schedule

 Pre & Post Hydro checklist items may not be adequate or not addressed properly  Permit to Work may not be available or inadequate  SIMOPS with other pressure testing or other fabrication requirements may not be properly evaluated & controlled



 Permit To Work is TO be obtained  All PTW performing authorities shall be trained

 Delayed work schedule  Cancellation of the planned activity

 The Hydro Test Engineer is responsible for notification to the project and yard management of the test time and location,  Inspecting the area immediately before the test for clearance of personnel and any hazards associated with the test process. E.G the possible release of water over electrical equipment

Page 17 of 34

Personnel Protective Equipment (PPE) are worn

015

016

Working at height

Install Test Equipment Test Equipment shall include; Mechanical test plugs (Grip Tight) (Include plug restraining device on stainless steel tests)

   

 Safe access and egress  Competent and trained personnel shall perform the job.  Full body harness connected by Static line provided where in need  Certified equipment/Cherry picker  Certified scaffold  not steep on top the structure  Good working platform (Toe board & boards without gaps)  Fire precautions  Good housekeeping  Exclusive zone, barrier off  Signs, precaution falling objects  Job rotation during heat exposure   Test Engineer will review the checklist & line for completeness of each checklist item and sign off when satisfied.

Fall from height Falling objects Slips and trips Collapse of scaffold  Fire  Heat stress  Phobia

 Personal Injury  Possible fatality  Delayed work schedule  Bad Publicity  Loss of morale

 The equipment selected is unsuitable for the intended purpose or condition, unacceptable or used improperly

      

Hose failure Gauges failure Release of pressure Personal injury Electrocution Slips ,trips and falls Delayed work schedule

 Manifolds may not be built for pressure required, not tested or certified.  The high pressure pump type, condition & safety features maybe inadequate (Safety release valve).

   

Personal Injury Release of pressure Material damage Delayed work schedule

 An air driven pump shall be used. A mechanical inspection shall be performed before use.  Each manifold will be confirmed as certified and sufficient for task

    

Personal Injury Release of pressure Hose bust Electric shock Delayed work schedule

 Certified compressor shall be in use  Test certificates shall be available when needed  Qualified and trained operatives  Adequate knowledge and experience for all those involved in the activity  Direct supervision

D

D

3

4

H

H

Page 18 of 34

C

4

L

Mandatory compliance with WI-SIKB-HSE-021 Scaffolding WI-SIKB-HSE-067 Working at Height WI-SIKB-HSE-024 Working with Hand tool

D

2

M

 Test plugs may blow out due to improper installation or handling, improper knowledge of manufactures requirements & specifications

 Personal Injury  Release of pressure  Delayed work schedule  Material damage

 Water lines & connectors maybe inadequate PSI rating, securing method inadequate. Hoses causing obstruction/trip hazard

 Release of pressure  Hose burst  Whip hazard from the disengaged hose joints  Personal injury  Delayed work  Schedule  Sip, trip and fall  Material damage  Personal injury  Delayed work  Schedule  Material damage  Excess pressure  Failure of hoses  Release of pressure

 Gauges may indicate pressure in PSI when KPA is required. Gauges maybe miss read. Gauges maybe out of calibration

 Mechanical lifting of large flanges performed by non trained riggers. Improper light rigging practices

     

Personal injury Back injury Muscle sprains Dropped load Material damage Delayed work schedule

 Only persons trained in the correct use of such plugs shall be allowed to install plugs.  Plugs will be checked for damage before installation  Plugs will not be used in pipe with internal coating.  The torque shall be ensured according to manufactures requirements.  Pipe ends fitted with plugs must be kept clear of personnel during pressurization. Restraining device to be installed on stainless steel lines.  Pressurized Plug release area must be barricaded and Keep Out signs posted  The test engineer shall ensure the suitability of the PSI rating, securing the hoses, house routing so as to ensure trip hazards are eliminated/controlled  Good housekeeping at all times

 All gauges will be confirmed as indicating KPA.  Employees will receive refresher awareness of the corrected reading requirements immediately before each test.  Gauges will be confirmed as in calibration  PSI rating, hose standard & connection method will be confirmed as adequate with safe access provided  Manual handling procedure (WI-SIKBHSE-016 shall strictly to be followed  All mechanical lifting of flanges will be performed by rigging experienced personnel. Riggers will assist.



Page 19 of 34

017

High Pressure Hydro Pump Manifolds Water lines & connectors

 Manual lifting maybe performed improperly or with flanges too heavy for employees to handle.

    

Back injury Dropped load Slip, trip and falls Material damage Delayed work schedule

 Numerous bolts, gaskets and flanges cause housekeeping problems and become dropped object hazards  Manual wrenches & sockets condition inadequate or used improperly

   

Slip, trip and falls Electrocution Material damage Delayed work schedule

 Insufficient flagging area or warning signs provided for line and test equipment locations.  Safe access to each line work location not provided causing a fall hazard or improper line checks

 Inadequate torque given  Blind flange blown off  Release of high pressure  Personal injury  Property damage  Slips, trips and falls  Entry of unauthorized personnel   Personal injury  Delayed work schedule        

Pressure release Slips trips and falls Fall from height Fall into grating openings Struck against fixed structure Electrocution/shock Injury Delayed work schedule

 Manual handling procedure (WI-SIKBHSE-016 shall strictly to be followed  All mechanical lifting of flanges will be performed by rigging experienced personnel. Riggers will assist.  All flanges above 25 kg will be mechanically maneuvered. Correct body positioning and lifting techniques to be used. Only one person to control lifting activity  Bolts, gaskets and small flanges & tools shall be positioned in a secure area to prevent falling.  Boxes will be used to contain items as required.  Good housekeeping at all times

D

4

H

 All hand tools shall l be checked for suitability and condition by supervision before issue.  Hand tool users shall check condition before use.  Spot checks by Project Management Team shall be done at periodic intervals  Sufficient flagging and signs will be provided by supervision. Area & distance from test line flagged off will be confirmed as sufficient by engineer. Area shall be controlled to ensure only essential personnel enter test area  Piping Superintendent shall be responsible for planning safe access to each required work location. (Upper and lower vents, etc) Supervision shall be responsible for maintaining safe access/egress.

Page 20 of 34

C

4

M

 Lighting not sufficient for night time testing

 Installation method of various test equipment not adequate

018

Filling and Pressurization of system with water

 Manual handling of Torque Wrenches & sockets

   

 Flagging & Warning signs

 Inadequate warning signs  Unauthorized person entering the test zone  Slip trips and fall hazards

 Filling & pressurization may commence before the status ready and checklist is signed off.

 Test failure  Hose bust  Release of high pressure  Personal injury  Delayed work schedule  Slips, trips and falls  Electrocution/shock  Personal injury  Ejected part hit and damage property  Delayed work

 Residual air may compress and cause unplanned plug release

 Light surveys will be conducted of work locations. Adequate lighting shall be in place Prior to work commences

 Fall from height  Strike against structures  Slips and trips  Electrocution/shock  Material dropped  Material damage  Pressure release  Hose bust  Electrocution  Slips trips and falls  Delayed work  Personal injury

Dropped flanges Personal injury Damaged parts Delayed work

D

3

H

 Entire hose run to be checked prior to pressurization.  Hose tied down at regular interval.  Whip checks at all joints.  Pre Test Checklists shall be signed off after correct installation completed & verbal confirmation of readiness received  Competent crew  Information/instruction and trainings provided  Direct supervision  Emergency preparedness  Entire work area to be cordoned off  A watcher to ensure unauthorized personnel are not entering  Competent flag man  The signage to be in both English and Bahasa languages  Awareness trainings for the crew  Direct supervision  Emergency preparedness  Hydro test Engineer will not authorize commencement of filing and pressurizing until a signed off checklist is available

 The residual air to be confirmed evacuated from the system prior to testing

Page 21 of 34

Mechanical devises to be used for handling heavy objects and manual handling to be avoided for heavy materials as far as possible

C

3

M

019

Depressurize system.

 The restricted flagged off test area may be entered by personnel

 Exposure to high stored pressure  Personal injury  Delayed work

 Pressurization limits or sequence may be exceeded or not followed

 Test failure  Hose burst  Release of high pressure water jet  Personal injure  Material damage  Personal injury  Electrocution  Slips trips and falls  Delayed work execution

 Burst hose, over pressurized hose, fittings or release of line. Leaky or failed gasket. Lines plug leakage or failure.  Accidental release of pressurized water.  Unauthorized personnel working on system. Personnel in area of test.  System over pressure  Uncontrolled Water discharge  Incomplete draining of system. Water trapped downstream of check valves & in valve cavities.  Depressurizatio n of system may not be fully completed

 All unauthorized personnel shall be cleared from the off the restricted barricaded / sign posted area before work commences and area controlled during task. Pressurized Plug release area must be barricaded and Keep Out signs posted  Sequence and final safety review shall be discussed at pre task meeting with test crew to ensure pressure requirements, sequence and shut down pressurization arrangements in case of burst hose or other incidents.  Pressurization will cease and situation reevaluated by test engineer.  Testing crew to be familiar with the system.  System checked against marked up P & ID’s and ISO.

 Personal injury  Property damage  Work delay  Injury due to accidental release of pressure

D

3

H

 Barrier off all accessible vent outlets. Direct relief lines to safe areas (over side, upwards) away from people, equipment & electrical systems.  All work carried out under controlled permit to work system. Restricted access to area (signs & barriers erected). Area patrolled by testing crew



 Discharging of water to be controlled, within the barricade area



 Electrical appliance below to be removed or protected with plastic sheet

 Possible trapped pressure areas highlighted in P &IDs and ISO.

 Trapped pressure areas checked for complete depressurization by test supervision. System gauges checked & confirmed zero pressure reading.

Page 22 of 34

C

3

M

020

021

Flushing and Drying

Removal of installation test equipment, warning signs and barriers

 Debris from lines maybe released during flushing causing injury.

 Water released may wet employees, cause slip and fall hazards, or contact electrical equipment causing electrical hazards  Mechanical lifting of large flanges maybe performed by non trained riggers. Improper light rigging practices  Manual lifting maybe performed improperly or with flanges too heavy for employees to handle.  Numerous bolts, gaskets and flanges may cause housekeeping problems and become dropped object hazards



E

3

H

C

5

H

 Discharge area to be adequately flagged off and restricted access sign provided. All personnel to be warned to stay clear of discharge outlets, area to be controlled  Discharging of water to be controlled, preferably within the barricade area. All personnel to be warned to stay clear of discharge outlets, area to be controlled  Electrical appliance below to be removed or protected with plastic sheet  controlled, preferably within the barricaded area  Electrical appliance below to be removed or protected with plastic sheet  All personnel to be warned to stay clear of discharge outlets and area to be controlled

E

2

M

 All mechanical lifting of flanges will be performed by rigging by experienced riggers

B

4

M

 Manual handling procedure (WI-SIKBHSE-016) shall strictly to be followed  All flanges above 25 kg shall be mechanically handled.

 Bolts, gaskets and small flanges and tools shall be positioned in a secure area to prevent falling. Boxes will be used to contain items as required

Page 23 of 34

 Water released may wet employees, cause slip and fall hazards, or contact electrical equipment causing electrical hazards  Unused flagging area or warning signs maybe left in line and test equipment locations.

 All barriers,signages are to be removed and stored for next use

Pneumatic Testing 022

Prepare Pneumatic test Procedure & Task Risk Assessment

.

Preparation of Test Packs Preparation of Test Equipment Test Equipment shall include; Welded Test Caps

 Procedure & Task Risk Assessment maybe inadequate, unknown, not understood or not followed.

D

4

H

 There shall be an approved procedure in place  The Task Risk Assessment to be prepared, checked and approved by all involved & TRA to be distributed to all involved for implementation.  All employees involved in pneumatic testing to review TRA to ensure understand and to provide any feedback.  Safety and supervision to perform ongoing checks for compliance.

High/Medium Pressure Air Compressors  Failure to identify correct test lines, isolations, test pressures, etc  Pre & Post pneumatic checklist items may not be adequate or not addressed properly

 The Test Engineer shall check the Test pack drawings and for details of module, location & and line ID. Each line shall be provided with an ID. The test line will be barricaded with flagging & warning signs  Test Engineer will review the checklist & line for completeness of each checklist item and sign off when satisfied. 

Page 24 of 34

C

4

M

023

Working at height

024

Air Cylinder Packs complete with lines, gauges and regulators

 A Permit to Work may not be available or inadequate  SIMOPS with other pressure testing or other fabrication requirements may not be properly evaluated & controlled.  Unsafe access and egress  Unsuitable scaffold  Defective ladders  Inexperienced working crew  Slips and trips from elevations  Floor openings  Electrical

 Design, material or installation method maybe inadequate  Improper type or design for purpose. Mechanical condition maybe inadequate. Safety features may not be provided or inadequate  Cylinders may fail under pressure; leak or design may not be suitable

   

Personal Injury Falls from height Strike against Struck by falling objects  Fall into open gratings  Electrocution / shock / burn

D

3

H

D

3

H

 The Pneumatic Test Supervisor is responsible for raising a Permit to Work  All PTW approvers shall be trained on each shift  The Pneumatic Test Engineer is responsible for notification to the project, the PTW Coordinator and yard management of the test time and location.  Inspecting the area immediately before the test for clearance of personnel and any hazards associated with the test process.  Safe access and egress  Competent and trained personnel shall perform the job.  Full body harness connected by Static line provided where in need  Certified equipment/Cherry picker  Certified scaffold  not steep on top the structure  Good working platform (Toe board & boards without gaps)  Fire precautions  Good housekeeping  Exclusive zone, barrier off  Signs, precaution falling objects  Job rotation during heat exposure  Engineering have reviewed design and approved as fit for purpose and for suitability, safety features and reliability were verified.  The lines, gauges and regulators are designed beyond working requirements. Gauges shall be all full safety pattern type 

 All cylinder shall be with certification and color coded

Page 25 of 34

C

3

M

D

2

L

 Lines, gauges & regulators may not be suitable design for purpose or inadequate safety features  Correct pressure rating, design and condition may not be adequate, installation method maybe incorrect  Non safety pattern gauges maybe used, improper design or capacity and PSI maybe used outside of requirements  Gauges maybe misread or improperly installed or wrong gauges installed  Valves maybe not designed for gasses. The valve exhaust maybe located of designed as that injury may result.  The PSV discharge volume maybe insufficient that over pressure may occur of choked flow conditions.  The number of PSV’s provided maybe inadequate

 Correct pressure rating, design and condition will be confirmed. Certified and tested new hoses shall only be used. Installation shall be confirmed as correct by supervision. High Pressure hoses and connectors shall be checked visually for signs of damage by the users  Only safety pattern gauges shall be used .Design and capacity shall be confirmed by engineers as suitable for purpose. Certification and calibration of gauges shall be available. kPa verses PSI awareness training shall be completed with all operators.  The Test Engineer shall ensure each PSV is suitable and fit for purpose & installed correctly. Exhaust silencers shall be installed where ever practical. The number of PSV’s shall be confirmed 

 Capacity engineer



 

Page 26 of 34

shall

be

confirmed

by

025

High pressure hoses & connectors for field application

 The valve discharge noise may cause employees  Hearing loss  Wrong blind flange, gasket or bolts maybe used or correct ones installed improperly. The condition or design maybe inadequate  Wrenches & associated hoses maybe wrong design, capacity, improper condition or used improperly.  Gauges on wrenches and tentioners maybe not be KPA calibrated.  Condition or size of sockets maybe inadequate  Flagging and warning signs may not be provided, maybe too close to hazard or maybe ignored & restricted area entered by personnel.  Flagging & signs maybe left in improper position causing housekeeping problems

 Hearing protection shall be enforced. 

D

4

L

 Correct blind flange, gasket or bolts & installation shall be confirmed by engineers. ASME standards shall apply. Bolt installation sequence and tension torque values shall be applied by competent persons   Wrenches & associated hoses design, capacity shall be approved by test engineer. Condition shall be checked prior to each use.  Condition & used improperly shall be verified by engineer and supervision.  The caps shall meet ASME standards & 100% welding NDT.  Gauges shall be standard confirmed.  Condition of gauges and hoses shall be confirmed as adequate or size 

 Suitable secure area shall be ensured & restricted access signs provided by the Test Engineer. Refilling equipment shall meet ASME standard. All equipment shall be tested and pre tested before operation. Operators & supervision shall receive training and be declared competent. This shall be documented.   All flagging and signs to be located such a manner not causing housekeeping issues and shall be posted at strategic locations  Supervisor has to ensure the adequacy of the flagging and signage’s

Page 27 of 34

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4

M

026

Forklift use

027

Exclusion Zone Flagging & Warning signs

028

Install Test Equipment

 Forklift unfit for use  The fork operator incompetent

 The equipment selected may not be suitable for purpose or condition unacceptable, installed or used improperly  Test caps may blow out due to improper installation or handling improper knowledge of manufactures requirements & specifications  Air lines & connectors maybe inadequate pressure rating, securing method inadequate.  Hoses causing obstruction/trip hazard.

D

3

H

D

5

H

D

4

H

 Forklift shall be used with regular maintenance and daily checklist. Operator shall be confirmed licensed and competent

C

3

M



B

5

M

 All equipment will be confirmed as adequate by the test engineer. Competent experienced personnel will be selected by supervisor. 

D

2

M

 Only persons trained in the correct use of such Caps shall be allowed to install caps.  Caps will be checked for damage before installation  Caps will not be used in pipe with internal coating.  The torque shall be ensured according to manufactures requirements.  Pipe ends fitted with plugs must be kept clear of personnel during pressurization.

Page 28 of 34

 Gauges may indicate pressure in PSI when KPA is required. Gauges maybe miss read. Gauges maybe out of calibration. Red tagged gauges for only hydro testing maybe used by mistake  Mechanical lifting of large flanges maybe performed by non trained riggers. Improper light rigging practices

 kPa pressure rating, hose standard & connection method will be confirmed as adequate.  All gauges will be confirmed as indicating kPa. Employees will receive refresher awareness of the corrected reading requirements immediately before each test. Gauges will be confirmed as in calibration  Only safety pattern gauges will be used for pneumatic testing. Action all, Test Engineer & supervision

 Manual lifting may be performed improperly or with flanges too heavy for employees to handle

 All flanges above 25 kg will be mechanically maneuvered; supervision will ensure compliance. Correct body positioning and lifting techniques to be used. Only one person to coordinate lifting involving more than one person  All mechanical lifting of flanges will be performed by rigging experienced personnel.  Bolts, gaskets and small flanges & tools will be positioned in a secure area to prevent falling. Boxes will be used to contain items as required. Provision of boxes is the Test Engineer responsibility.

 Numerous bolts, gaskets and flanges maybe cause housekeeping problems and become dropped object hazards  Safe access to each line work location may not be provided causing a fall hazard or improper line checks

 All flanges above 25 kg will be mechanically maneuvered; supervision will ensure compliance. Correct body positioning and lifting techniques to be used. Only one person to coordinate lifting involving more than one person.

 Safe access provided.  Piping Superintendent shall be responsible for planning safe access to each required work location. (Upper and lower vents, etc) Supervision shall be responsible for maintaining safe access/egress

Page 29 of 34

 All hand tools will be checked for suitability and condition by supervision before issue. Hand tool users shall check condition before use. Spot checks by Project Management Team will be carried out  Sufficient flagging and signs will be provided by supervision. Area & distance from test line flagged off will be confirmed as sufficient by engineer. Area shall be controlled to ensure only essential personnel enter test area must be barricaded to a safe distance and Keep Out signs posted  Lighting requirement surveys shall be conducted of work locations. Adequate lighting will provided before work commences

 Manual wrenches & sockets condition maybe inadequate or used improperly  Insufficient flagging area or warning signs maybe provided for line and test equipment locations  Lighting may not be sufficient for night time testing  Installation method of various test equipment may not be adequate

028

Filling and Pressurization of system with air.

 Filling & pressurization may commence before the status ready checklist is signed off  The restricted flagged off test area may be entered by personnel   Injection point maybe closed.

C

5

H

 Entire hose run to be checked prior to pressurization. Hose tied down at regular interval. Whip checks at all joints. Pre Test Checklists will be signed off as correct installation completed & verbal confirmation of readiness received  Pneumatic test Engineer will not authorize commencement of filing and pressurizing until a signed off checklist is available   All unauthorized personnel will be confirmed as clear of restricted barricaded / sign posted area before work commences and area controlled during task.  Authorized personnel shall be made know to HSE and Test Engineer  Final refill check will include the injection point.

Page 30 of 34

B

5

M

 Sequence and final safety review will take place at pre task meeting with test employees to ensure pressure requirements, sequence and shut down pressurization arrangements in case of burst hose or other incidents. Test engineer will supervise for all compliance  Pressurization will cease and situation reevaluated by test engineer.  Testing crew familiar with the system. System checked against marked up P & ID’s and ISO

 Pressurization limits or sequence may be exceeded or not followed 

029

Depressurize system.

 Burst hose, over pressurized hose, fittings or release of line. Leaky or failed gasket. Lines leakage or failure.  Accidental release of air pressure   Unauthorized personnel working on system.  Uncontrolled air discharge  Incomplete draining of system  Air released may injure employees, Noise hazard will exist  Depressurizatio n of system may not be fully completed

D

4

H

 Barrier off all accessible vent outlets. Direct relief lines to safe areas (over side, upwards) away from people & equipment. Supervision to comply.  All work carried out under controlled permit to work system.  Restricted access to area (signs & barriers erected). Area patrolled by testing crew.  Discharging of air to be controlled.   Discharging of air to be controlled.  Area barricade. All personnel to be warned to stay clear of discharge outlets, area to be controlled. Hearing protection to be worn  Trapped pressure areas checked for complete depressurization by test supervision. System gauges checked & confirmed zero pressure reading.  Possible trapped pressure areas highlighted in P & IDs and ISO

Page 31 of 34

C

4

H

030

Air Blowing Install air hoses from COMPRESSOR AND AIR RECIEVER to required line locations lines

 Hoses condition, pressure rating, maybe inadequate. Installation method may result in hose whipping or connection release during OPERATION  Spools may require a blind flange to be installed to re direct blowing  Air.  Blind flanges design, material, standards, used may not be engineering approved.  The flange installation method may be inadequate and not approved by engineering.  Work method agreed to by engineering and test supervision maybe not understood and followed  Debris from lines maybe released during blowing causing injury.

D

3

H

 The air hoses shall be inspected by a competent person for condition, rating, installation method, and whip checks to prevent incidents. 

 Engineering to approve the use of all shop made tools and equipment required to complete the task.  Test supervision to control compliance  Engineering to approve the use of all shop made tools and equipment required to complete the task.  Test supervision to control compliance  Test supervision to deliver proper job instructions and follow up to confirm understanding and compliance.

 Discharge area to be adequately flagged off and restricted access sign provided. All personnel to be warned to stay clear of discharge outlets, area to be flagged, sign posted and controlled

Page 32 of 34

C

3

M

 Air released may injure employees, Noise hazard will exist

031

Removal of installation test equipment

 Mechanical lifting of large flanges maybe performed by non trained riggers. Improper light rigging practices  Manual lifting maybe performed improperly or with flanges too heavy for employees to handle.  Numerous bolts, gaskets and flanges maybe cause housekeeping problems and become dropped object hazards  Manual wrenches & sockets condition maybe inadequate or used improperly

   

Exposure to Noise Hit by Flying debris Dust exposure Disturbed visibility

D

3

M

 Inspected by competent persons on an agreed frequency.  Hose areas to be barricaded with flagging.  Discharging of air to be controlled. Warning siren to be sounded  Area barricade. All personnel to be warned to stay clear of discharge outlets, area to be controlled.  Hearing protection to be worn.  All mechanical lifting of flanges will be performed by experienced personnel. Riggers will assist.

 All flanges above 25 kg mechanically maneuvered.

will be

 Bolts, gaskets and small flanges and tools will be positioned in a secure area to prevent falling. Boxes will be used to contain items as required.

 All hand tools will be checked for suitability and condition by supervision before issue. All tools to be checked in good condition by user

Page 33 of 34

C

3

M

 Unused flagging area or warning signs maybe may be left in line and test equipment locations.


 Used barriers & signs to be properly stored for re use

HIRA Team Leader

Project Manager

Name:

Name:

Date:

Date:

Signature:

Signature:

Page 34 of 34

HAZARD IDENTIFICATION & RISK ASSESSMENT (HIRA) FORM FORM AH-0077 Rev.0 TASK: Erection

Date: 19.07.2011

HIRA ID:

Erection of Diagonal/Horizontal Bracings using a crane Activity ID

Activity Description Access and Egress

Hazard

 Incomplete scaffolding access  and egress to tower  Fall from height

Hazard Effect

 Personal Injury  Property Damage

Risk Value SxL=R S L R 5 C


 Supervision to ensure proper access   

 Poor condition /

 Personal injury

5

C

 

 Worker injured

5

C

 Supervision to remind workers not to

damaged ladder

 Tripping and Falling

Mobilizing the Crane and lifting accessories

 Crane not suitable for the task

 Lifting accessories are not color coded or inspection certificates  Not available

and egress are in place. Use access tower. Supervision to ensure all access ladders on scaffoldings are inspected and green tag before being used. Always facing the ladders when climbing and descending. Using of MEWP when in need. Supervision to ensure all access ladders on scaffoldings are inspected and green tag before being used.

       

Toppling of crane Property damage Injury to personnel Delayed work schedule Failure of the lift Property damage Injury to personnel Delayed work schedule

3

B

3

C

carry tools/equipment when climbing and descending the ladders.  Always facing the ladders when climbing and descending.  Lifting superintendent shall ensure suitably rated crane is assigned for the job

 All lifting accessories in use shall have the current color coding and inspection certificates shall be available when in need

Page 1 of 18


Additional Controls and Risk Reduction Measures to be developed Only competent scaffolder allowed to erect the scaffolding structure Full body harness shall be used while working at height

1

B

Damage ladder shall be removed from site

1

B

Ladder safety training shall be given to the worker

2

A

Lifting plan shall developed by engineering

1

B

Rigger who perform the activity shall be trained


Date: 19.07.2011

HIRA ID:



Hazard

 Crane certification is invalid

 Crane operator not suitable or qualified to operate the crane

 The rigger is not qualified

Setting –up the crane

 Uneven or bad ground condition

Hazard Effect

                 

Crane failure Property damage Injury to personnel Delayed work schedule Crane toppling Load drop Injury to personnel Material damage Delayed work schedule Dropped materials Personal injury Damaged materials Delay in work progress Crane toppling Dropped load Injury to personnel Damaged property Delay in progress



 Current and valid crane certification

area

 Striking against the installations.  Personal injury

Additional Controls and Risk Reduction Measures to be developed Checklist shall be provided

shall be available when needed

4

B

 The crane operator shall be in

1

B

1

A

1

B

1

B

possession of the required licenses and certifications  He should have underwent trainings

4

C

 Only experienced and qualified rigger to be deployed for the task

3

C

 Prior inspection of the ground by the   

 In- adequate work


2

D

 

lifting supervisor To be ensured that the load bearing capacity of the ground is suitable to the task. Metal sheets to be positioned under the outriggers if needed Compaction of the ground before the work commences Prior selection of the location Adequate clearances from the permanent installations

 Page 2 of 18

Training shall be developed for the riggers


Date: 19.07.2011

HIRA ID:



Hazard

 Conflicting adjacent

Hazard Effect

 Personal injury


work

 Obstruction for safe operation of crane

 Bad weather conditions

 Unauthorized

 Crane damage  Damage to     

installations Personal Injury Delay in work Crane toppling Injury to personnel Delay in work

Personal injury

 Sharp edges and

 Good coordination among the working

3

C

group to be maintained  Permit to work shall be obtained  suitable place to be ensured  If possible the obstructions shall be removed or else

3

B

 Weather conditions to be ascertained 

3

D

personnel inside the lifting zone

Lifting Gears Preparation (Manual Handling)


 

Personal injury

2

C



heavy slings weight



  

before work commences Manufactures guidelines to be followed during high wind conditions The lifting zone to be barricaded and signage posted All unauthorized personnel and those not connected with the lifting operations shall be removed from the lifting zone Wherever possible loads shall be covered or packed in such a way so as not to harm the carrier. Personnel shall wear suitable hand protection to reduce the possibility of harm. Kinetic method of lifting to be followed (I.e. Lifting the load with back straight and only bending the knees) In case weight is more than 25 Kg individual to take help of the other person or mechanical device.

Page 3 of 18


1

2

1

B

1

B

1

C

Additional Controls and Risk Reduction Measures to be developed Briefing shall be given before commencing the job Inspection shall be carried out before commencing the lifting activity

Manual handling training shall be provided


Date: 19.07.2011

HIRA ID:



Hazard

 Trip hazards and

Hazard Effect Personal injury


C

Part of body scratch or squeezed

Installation of Lifting gears from crane hook to the bracing’s lifting point

 Slips, trips and falls


 Ensure lifting gear inspection and installation is free of tripping hazard.

 Ensure PPE (Helmet, safety glasses,  Personal injury

1

D

  

 Limbs squeeze while

 Personal Injury

2

C



sling installation

  Wrong hitch in use.




2

B

hand gloves and safety shoes) provided adequately and use correctly. Works areas shall kept clean and tidy Access routes shall be kept clear at all times. Ensure PPE (Helmet, safety glasses, hand gloves and safety shoes) provided adequately and use correctly. Skilled/ trained and experienced riggers to be deployed for the guy wire installation work under supervision. Hand protection to be used.

 The hitch shall be suiting to the job performed  Qualified rigger to be assigned

Page 4 of 18

1

C

1

C

1

B



Date: 19.07.2011

HIRA ID:


Activity Description Lifting operation

Hazard

 Improper coordination during the lift

Hazard Effect

 Personal injury  Property damage  And Fatality 


C


 Crane Radius shall positioned as per the requirement

trained operator to operate the crane

 Dedicated rigger for crane shall provide

 and falling

 Uncontrolled lift 

 Falling load  Personal injury  Property damage  Load collapse  Damage to material  Personal injury


 Only qualified riggers and competence/



 Lifted load sliding

Residual Risk Level SxL=R S L R 2 b

4

C

  

4

C

 

including fatality

   

signal to control the boom cranes during positioning and lifting operation. Ensure the crane twisting area shall keep clear and no obstruction material or equipment Proper Coordination via tool box meeting and radio to be maintained. Experienced rigger to be assigned The lifting accessories were inspected prior to use Keep clear the lifting area during lifting operation Align crane lifting block at the centre of Gravity (COG) before lifting. Lift the load slowly until approximately 1 feet from support and maintain this position until load stable Tag lines of 1” diameter shall be utilized to avoid the load from swinging. Riggers must be competent and qualified The lift must be supervised by only one qualified and competence person Set a separate radio frequency Communication from other RF users

Page 5 of 18

3

C

3

1

Training shall be given to the riggers who perform the lifting activity


Date: 19.07.2011

HIRA ID:



Hazard

 Unauthorized people

Hazard Effect

 Personal Injury


B


 Barrier off area prior to commencing

in the lifting area

 Crane Failure


operations.

 Property damage  Injury to personnel  Delay in progress

4

D

 Only trained operator/ competent    

1

C

1

C

personnel shall operate the crane Crane certificate and lifting gears color coding shall check to ensure that they are still valid All equipment shall be inspected for damage prior to use All equipment shall be of adequate rating to perform

Rollout Row A/B by using multi crane operation Roll-Out preparation

 Severe weather conditions causing crane lifting hazards fall and slip hazards.  Rain and wind may cause slippery conditions or air borne objects.  Health hazards due to exposure to rain and cold

 Load collapse  Injury to personnel  Property damage

3

C

 Weather condition to be monitored. Line supervision is responsible for providing warning and stopping work as required during periods of adverse weather or excessive wind for crane operation.  Rain coats to be provided where required

Page 6 of 18



Date: 19.07.2011

HIRA ID:



Hazard

 Roll-out drawings

 





 

and procedures may not be adequate, understood, and followed. Risk Assessment / HAZID was not distributed Task Risk Assessment may not be known or implemented Maximum work may not have been completed at ground level to avoid work at height to eliminate or reduce risk Re work of scaffolding may result due to improper evaluation or requirements by scaffolders and engineering groups Structural integrity of A may not be adequate Or complete before roll out

Hazard Effect

 Delay in work


B

progress  Injury to personnel  Load collapse

 Fall from height  Personal injury  Falling objects

 Delay in work

Dropped load Property damage Personal injury Delay in work progress

 Roll- out Procedure and Task Risk


Assessment will be approved by management.  Check list will be developed and followed  HAZID required actions will be issued to all for implementation.  Line management and supervisors will ensure compliance with procedures

3

B

 Maximum work will be completed at

1

B

2

1

1

B

ground level whenever practical.

2

C

progress

   



 Scaffolding will be installed other than at roll-out clash locations.  Engineering and scaffolding personnel to ensure scaffolding requirements are properly evaluated and planned to prevent rework

4

C

 Panels and temporary braces will be completely welded-out, NDT and structural integrity confirmed

Page 7 of 18

Related documents shall be available at the location


Date: 19.07.2011

HIRA ID:



Hazard

 Selected carnage are not suitable, boom configuration inappropriate, certification not current, incorrectly positioned, condition inadequate, load indicators not calibrated.

 Cranes operation area may not be clear of obstructions, ground preparation and compaction inadequate  Crane operators, riggers selected may not be competent to perform their responsibilities.  They may be unaware of the hazards  Individual crane operators may not be aware of the loading requirements on their crane at various stages of the roll-out

Hazard Effect


    

Crane collapse Property damage Injury to personnel Delay in work progress

3

   

Crane collapse Material damage Personal injury Delay in work progress

2

    

Crane collapse, Miss communication Personal injury Property damage Delay in work progress

2

C


 Engineering and rigging supervision


will confirm the suitability, configuration, placement of cranes.  Operator will complete their daily check list.  Asset supervisor will confirm cranes condition-including load indicators,  Any changes in the drawings must be approved by project management. C

 Crane operating areas will be

1

C

2

B

inspected and confirmed clear of obstructions, ground preparation.  Compaction to be confirmed adequate.

B

 Only proven competent and  

 

experienced crane and operators, riggers are selected for the roll out All will be reminded of the hazards involved prior to commencing the roll out Individual crane operators will be issued the loading required on their crane at the various stages of the roll out. Rigging superintendent will confirm the individual crane loading at the various stages of the roll out with the operation. Rigging certification checked prior to use

Page 8 of 18



Date: 19.07.2011

HIRA ID:




Hazard

Hazard Effect

 Maneuvering

 Property damage  Personal injury

3



2

equipment may strike objects or personnel  Rigging equipment and slinging may not be as designed by the engineering  Installed improperly, out of certification or poor condition  Hand injuries may result while handling of heavy rigging gear

 Pre installed scaffolds not secure, roll out clash checks not completed properly  Loose items may be left on the scaffold

C


 Watchers must be used in restricted areas and visibility problem areas

B

 Engineering department shall ensure

    Hit by falling objects  Personal injury


2

B

  

the correct selection, installation and condition of each pieces of rigging equipment in accordance with the drawings. Any changes to the drawings will be approved by the project management All shackles and split pins installed as required Prevention of hand injuries to be emphasized during the Tool Box Meeting Pre installed scaffold will be checked and confirmed as secure. Roll out clash checks completed properly Checks for loose items on the scaffolding will be conducted.

Page 9 of 18

1

B

1

B

Additional Controls and Risk Reduction Measures to be developed Clear visual and audible warning sign to provide


Date: 19.07.2011

HIRA ID:



Hazard

Hazard Effect

 Inadequate number

 Miss communication  Delay in work

  



of radios available for the numbers of riggers and crane operators Required channel availability, radios condition and Battery charge status may be not suitable Total roll out weight incorrectly evaluated due to scaffolding being incomplete Insufficient exclusion zone resulting in personnel being exposed to the hazards of the roll out

 Insufficient or misplaced pad eyes fitted to A or B to allow proper jacking and pulling during the fit up


A

 Adequate number of suitably charged radios in good condition will be confirmed and provided  Spare charged batteries to be available as required

schedule





2

B

 Total weight includes all scaffold, all

1

B

2

B

2

B

though all scaffolds may not be built

 Hit by falling objects  Personal injury 

    

Lift collapse Crane collapse Property damage Injury to personnel Delay in work schedule

3

3

B

C

 Exclusive zone calculated in accordance with Quality Plan and exclusion zone drawing to be approved prior to start of the task  The number of persons within the exclusive zone to be kept to a minimum.  Only those operating equipment or directing the equipment will be approved  The position and number of pad eyes to be surveyed and reviewed to minimize the amount of welding at height

Page 10 of 18



Date: 19.07.2011

HIRA ID:



Hazard

 The pre roll out









inspection may not be completed properly by all those identified as responsible They may arrive too late to location or delegate this responsibility Riggers may install the rigging without advising by the engineers. All personnel involved in the roll out may not attend the pre-roll out safety briefing During the forward maneuvering and hoisting the cranes may not be coordinated, over loading may exist and fall lines may not be kept vertical

Hazard Effect

 Property damage  Injury to personnel  Delayed work


C

   

final hazards and controls not being communicated and auctioned Property damage Crane collapse Injury to personnel Delayed work schedule

 All personnel listed in the check list must be on site early enough to complete a proper and detailed inspection.  Engineering will ensure each item of rigging is correct as per drawing prior to installation or lift

schedule

 This may result in



2

B

 Al personnel involved must attend the

1

B

1

C

roll out pre roll out safety briefing  Hazards and required controls will be communicated and auctioned. 2

C

 The Rigging superintendent assisted by the riggers for each crane will closely monitore forward maneuvering and hoisting the cranes to ensure crane coordination and safe lifting

Page 11 of 18

Additional Controls and Risk Reduction Measures to be developed Lifting supervisor shall ensure correct lifting appliance are used for the activity


Date: 19.07.2011

HIRA ID:



Hazard

 Crane operators may not properly monitor their load indicators and individual crane operators crane load charts during the various stages of the roll out or warn the rigging superintendent if over or under loading reading exists  Load on tie back system not monitored or fowl during the roll out putting undue load  The tie back winches cannot be finally controlled

Hazard Effect

 Property damage  Delayed work


B

3

C

2

B

schedule

  The transfer of the load from cranes to the tie back system may result in shock loading and failure of the tie back system

 Damage to equipement  Injury to personnel

 Riggers will monitor the load cells

2

B

1

B

3

B

fitted to two tie back winches and report back to the rigging superintendent

schedule

 Property damage  Delay in work

 Crane operators shall be reminded to properly monitor their load indicators and individual crane load charts during the various stages of the roll out and immediately warn the rigging superintendent if over or under loading reading exists  The rigging superintendent will stop the roll out at various stages to check and confirm each crane is correctly loaded

schedule  Personal injury

 Property damage  Delay in work



4

C

 The winches are confirmed as being finely controlled and will be test run prior to the roll out  Winch operations will be monitored during roll out  The rigging superintendent will closely monitor the transfer of the load from cranes to the tie back system to prevent shock loading  The tie back winches will be gradually tensioned as approaching the balance point

Page 12 of 18



Date: 19.07.2011

HIRA ID:



Hazard

 Winch failure during roll out

Hazard Effect

 Property damage  Injury to personnel


C


 Pre-lift checks will be completed  Tested stand-by winch to be on


location

 Maintenance team to be available on site during roll out

 If a failed winch is replaced ,the  Rigging and

 Delay in work

scaffolding may clash during roll out

 Insufficient head height to allow forklift access to remove the concrete support blocks during roll out  Forklift may have insufficient space to maneuver properly  Personnel may be positioned too close to the forklift removing the concrete blocks  Persons who are not directly involved in the lifting may enter the exclusive zone

2

B

2

B

schedule



 Personal Injury

replacement winch will be corrected before the failed winch is disconnected  The mobile elevating work platform will be stand-by during the roll out to allow safer access and egress to rigging and scaffolding  The load will be lifted to a sufficient height to lift the tie back rigging and allow the forklift in to remove the concrete blocks

 The exclusive zone will be strictly enforced by project supervision and HSE during the roll out

Page 13 of 18

1

B

1

A



Date: 19.07.2011

HIRA ID:


Activity Description Working at heights

Hazard

 Falls from height  Strike against fixed structures

 Using a defective scaffold

 Defective ladder used

 Fall protection not

 Personal Injury  Property damage  Delay in work schedule  Decreased employee morale



4

D


 Competent person assigned for the job  Mandatory Working at height trainings  

used



objects



elevations



 Struck by falling  Slips and trips from  Fall into open gratings



Hazard Effect


    

should have been undergone by he Inspector Scaffolds which are being used shall be with Scaff-Tag(Green Tag) Rating openings are to be guarded and signage posted Scaffolding usage awareness by the Inspector Adequate and sufficient lighting arrangements for night works Cable management at height to be such slip and, trip hazards are eliminated. Loose materials are to be contained or removed from height Surplus and off-cut materials are to be cleared from the height/scaffolds. Lift equipment is used at height, shall be secured from falling Effective supervision shall be in place Emergency preparedness shall be in place

Page 14 of 18


Additional Controls and Risk Reduction Measures to be developed Location specific Risk Assessment shall be in place prior to working at height


Date: 19.07.2011

HIRA ID:


Activity Description Post Roll out

Hazard

 Slips ,trips and fall    

       

due to Poor house keeping Poor lighting Open holes and edges Walking and taking short cuts, climbing out side scaffold hand rails Failure to use full body harness or use them correctly Carrying materials on ladders Improper grating operations Wet or muddy steel Employees not looking where they are walking Fall due to Sub standard scaffold Scaffold not suitable for the task

Hazard Effect


D


 Housekeeping and cable management       

4

C


to be ensured to an acceptable standards Adequate lighting arrangements Survey for open holes Employees taking short cuts shall be subjected to 15 Non Negotiable Rules Ladders to be provided with ropes to lift and lower approved tool bags Acceptable grating operations Grating to wipe safety shoes shall be provided All employees will be reminded during the tool box safety meeting to mind their steps

 The scaffold is inspected daily  Scaffold suitability for task coordinated among the tradesmen and scaffolding supervisor  15 NNR to apply

Page 15 of 18

3

B

Additional Controls and Risk Reduction Measures to be developed Inspection shall be conducted before commencing the activity

Scaffold shall be certified by competent person every week


Date: 19.07.2011

HIRA ID:



Hazard

 Falls from height,  Scaffold damage  During removal of the main rigging and tie back rigging on the completion of the roll out  Dropped objects from overhead due to improper manual lifting  Poorly placed materials or tools and equipment

Hazard Effect




C


 Mobile Elevating Work Platform shall

over personnel due to lack of barricading or warning


be provided to allow safe access and egress to remove rigging



4

C

 Awareness of manually lifted objects   

 Crane loads lifted


 Potential dropped object  Injury to personnel

2

B

   

hazards to be raised at Tool box meetings Toe boards to be provided and awareness raised in this regard Regular housekeeping at heights for waste removal No loose materials to be placed above heights of scaffold toe boards All crane lifts shall be pre planned and coordinated with all trades in the area Lift area shall be controlled with either barricading and signs or Flag man posted to control The crane operator not to lift the loads in uncontrolled area

Page 16 of 18

3

B

1

B

Awareness training shall be given to the workers involved in the project


Date: 19.07.2011

HIRA ID:



Hazard

 Fire or explosion due to inadequate control of overhead hot work  Hazard to scaffold boards, tarpaulins, poor housekeeping, cables and flammable substances  Suspension trauma resulting due to inadequate emergency response

 Inability to evacuate

Hazard Effect




C

Components due to inadequate erection /dismantle or compliance with standards

 All hot work will be strictly controlled by all trades supervision.  Awareness to be raised during Tool box meetings  Hazard Identification tool box to be implemented  Emergency preparedness



2

C

 ERT shall be conducted suspension 



4

C

in the event of an emergency due to inadequate egress or lack of other requirements

 Dropped scaffolding



 



2

C



trauma response drills and be trained to rope rescue Workers to be educated on how to respond during emergency or exercise drill Emergency access and egress shall be provided via a bridge across to the tower. The adequacy will be tested during emergency drill and exercises within a short time after roll out Scaffolding supervisor shall ensure that scaffolding is erected and inspected by competent scaffolders in compliance with Indonesian standards

Page 17 of 18

1

B

2

B

1

C

Additional Controls and Risk Reduction Measures to be developed Regular inspection shall be conducted in daily basis before commencing the activity


Date: 19.07.2011

HIRA ID:



Hazard

 Insufficient light for

Hazard Effect




B

night shift operations

 Suitable welfare



2

A

measures like drinking water provision and toilet facilities are not provided



 Adequate and sufficient lighting arrangements shall be in place for night works  Stand by electrician for attending the electrical related requirements  Drinking water facilities are established and known to the workers and staff  Toilet facilities are available and known to the workers and staff


1

A

HIRA Team Leader

Project Manager

Name:

Name:

Date:

Date:

Signature:

Signature:

Page 18 of 18



TASK: Blasting and Painting Activities Activity ID

Activity Description Grit Blasting: Equipment and material mobilization

HIRA ID:

Hazard

Hazard Effect

Blocking walkways and emergency equipment

 Delay

Unpredictable other road users

            

Inadequate storage area

Load not secured

Bad Weather conditions

Date: 19.07.2011

in emergency response  Personal injuries

Collision with other vehicle Hit by the vehicle Falling materials Damaged materials Personal Injury Falling materials Damaged materials Personal Injury Muscle strain Delayed work execution Falling load Personal injury Damage to material

 Slips, trips and falls  Personal injury


D


 Review work areas, barricade the


sandblast and painting areas by mean of barricade.  Avoid blocking emergency equipment 3

B

  Review routes to be used for delivery to

3

A

2

A

Secure the load Load awareness Keep the speed limits Aware on uneven surfaces

3

A

Check weather forecast prior to start of the job

2

B

ensure minimum congestion existing construction activities  Road traffic signage 2

C

with

 Review the storage area prior to mobilizing the materials

3

C

3

D

      

Page 1 of 16





Hazard

Manual Handling

Failed to observe clearance

Over exertion Injuries

Fall from height

Date: 19.07.2011


                    

Back pain/Injury MSD Spill Slip, trip and fall Struck against Struck against Struck by objects Repetitive motion Material damage Back pain/Injury MSD Spill Slip, trip and fall Struck against Struck against Struck by objects Repetitive motion Material damage Personal Injury Material damage Delayed work execution


D


 Mechanical devises to be used for      

3

D

4

D

handling the materials Trained crew Availability of spill kit Regular cleaning Awareness and trainings Direct supervision

 Mechanical devises to be used for                  

Page 2 of 16


2

B

2

C

handling the materials Trained crew Availability of spill kit Regular cleaning Awareness and trainings Direct supervision

Good House keeping Adequate lighting Floor opening covered Edge protection/rails/barriers Certified scaffold Periodic cleaning Periodic Inspection Warning signs Mandatory PPE Warning signs





Non compliance with PPE requirements

Person not fit for manual handling

Stacking/ handling/ materials/ equipments

HIRA ID:

Hazard Physical stress

Date: 19.07.2011

Hazard Effect

               

Self inflicted injuries Fall from height Struck against Slips, trips and falls Exposed : Noise, Falling objects Hit by Eye injury Health hazards Slips, trips and falls Back pain MSD Falls Damaged materials Slip, trip and falls

Lack of information/instru ctions/Trainings

 Personal Injury  Damaged property  Delayed work execution

pinch points

 Personal injury


D

3

D

 Trained crew  Adequate rest periods  Direct supervision     

3

C

C

Mandatory PPE Awareness trainings Direct supervision at all times Strict compliance with `15 Negotiable Rules

        

Page 3 of 16

2

C

2

B

2

B


Disciplinary /Administrative action against the individual for repeated and willful violation

Nor

 Mechanical devises to be used for 

3



handling the materials Medically fit personnel are to be detailed for the task Direct supervision Awareness sessions conducted Manual handling assessment Mandatory trainings for all the crew Tool box meeting prior to start of work Awareness sessions conducted Effective supervision Use mechanical means to handling materials and equipment.

Hand Protection shall be in place




HIRA ID:

Hazard Improper stacking

Hazard Effect




 Material falling  Damaged materials  Personal injury  Inspection of the delivery place prior to

Inadequate storage area

material delivery

 Supervisor to check, assess and confirm that the area is free from obstructions, protrutions Housekeeping at the location may be inadequate

Handling hazardous materials-Paints, thinners, coating materials

Non compliance with PPE requirements

Flammable and Combustible materials not handled properly

Date: 19.07.2011

      

Falls Injuries to personal Spills Damage to property Delayed work execution Exposed to health hazards, Injuries

3

     

Fire Explosion Property damage Personal injuries Burns Delayed work execution

3

C

2

A

2

C

 Compliance with PPE usage 

D

 Adequate supervision  Adequate information and instructions to the crew

 Training in fire fighting  Fire prevention activities  Fire precautions

Page 4 of 16





HIRA ID:

Hazard Lack of awareness and competency of the involved crew

Hazard Effect

      

Personal injury Spills Health hazards Electrocution Fire Property damage Work delay

Fire hazards

 Property damage  Burn Injuries

Fire and explosion

 Property damage  Burn Injuries

Spills

Date: 19.07.2011

     

Exposure to health hazards Injuries due to falls Fire Electrocution Property damage Work delay



     

Adequate skill training Instructions/awareness provided Direct supervision Adequate skill training Instructions/awareness provided Direct supervision


3

C

4

C

2

B

3

D

2

C

Page 5 of 16


Regular Drills should be performed in monthly Basis




HIRA ID:

Hazard Stored close to ignition sources

Exposure to hazardous substance Emergency Procedures not known to the crew

Date: 19.07.2011

Hazard Effect

    

Fire and explosion Property damage Injuries Work delay


D

3

C

 Worsening the condition if

3

C



 The flammable materials shall be not      

 Health hazards

injured  Property damage


    

be kept close to electrical installations, ignition sources Natural ventilation Use approved store container. Limit store to a day usage. Barricade and post sign. Ensure the fire extinguisher availability Restricted and control access to the storage area No smoking enforcement Awareness trainings for the crew Direct supervision Competent crew Trainings and awareness

 Emergency Awareness in case of spill, fire and injury  Periodic emergency evacuation drills



Page 6 of 16


Additional Controls and Risk Reduction Measures to be developed Trained paining crew Permit To Work System MSDS to be followed

2

B

2

B



Activity Description Temporary power cords and air hoses Used for the activity

HIRA ID:

Hazard Damaged hoses/power tools

Hazard Effect

      

Tripping hazards Electrocution Burns Strike against fixed objects Fall from height Fire


C


 Supervisor and the crew to ensure the

          


tools and equipment are in good condition and fit to use prior to start of work Supervisor should ensure the work location is free from hazards prior to start of work Cable management Standard electrical cables and appliances for work in flammable area Electrical Earthing /Leak monitoring Whip restrain Warning signs to be posted Fire extinguisher in place Adequate lighting arrangements shall be in place Awareness trainings for the crew Effective supervision shall be in place

Wet/slippery surfaces Damaged electrical equipment / accessories like panels, plugs, cords, ELCB etc

Date: 19.07.2011

3

D

Page 7 of 16

2

B





HIRA ID:

Hazard

Hazard Effect



FILLING THE HOPPER WITH GRIT Lifting skip loaded with grit

 Defective lifting 











equipment and accessories Inadequate SWL of the lifting accessories Operator does not possess the required operating license Rigging gear may be of inadequate design or condition for purpose Riggers may not be adequately trained for purpose Position of the lifting equipment may not be proper

Date: 19.07.2011

 Hit by falling object  Material Damage  Struck by skip while load maneuverings hitting the fixed structures, Electrical Installations or any other stationary items  Persons struck by moving skip

 Skip



 Rigging gear to be checked for       

      

Page 8 of 16

suitability, condition and to be used as designed. Only qualified operators to be use crane Crane annual certification to be checked. Inspect rigging according to load rating. The lifting gear shall have the current inspection tag Rigging certification to be confirmed. Crane operator to keep all personnel clear of lift. Experienced and competent riggers to be present. Any new hires to be given proper instruction and be closely supervised. Weight of the load to be known Workout lifting plan Lift over personnel and be aware of the adjacent activities going on Tag lines to be used Ensure all caps checked and tightened to avoid spills kits are available Employees & Supervision to obey job instructions and monitor for compliance during work.






Hazard

 Lifting

    



 

attachments may be handled by incompetent personnel Spillage of diesel at the work place Lifting Lugs may be defective Weight is unknown Persons may enter the lifting zone Person may place body parts in material movement or placement pinch points Adequate supervision many not be available Exposure to Dust Exposure to High Noise levels

Date: 19.07.2011



C


 Supervision to plan tasks, identify and control hazards, supervise compliance to instructions  Dust and Noise protection

Page 9 of 16

for





Activity Description Setting pot in place

De-rigging

personnel  Hitting the structure  Dropped load  Blasting material spill

 Inadequate access of people during de- rigging  Riggers may not be adequately trained for purpose  Person may place body parts in material movement or placement pinch points

Working At Heights / Scaffolding

HIRA ID:

Hazard

 Hitting the

Individual not suited to work

Date: 19.07.2011

Hazard Effect

 Pinch points / crushing 

   


C

injury


 Tag line to be used for controlling the load

 PPE requirements are followed

Pinch point/ crushing injury Material Damage Personal Injury Delayed work execution

3

C

 Experienced and competent riggers to

    

 Mental


and

behavioral

2

2

B

1

A

be present. Any new hires to be given proper instruction and be closely supervised Employees & Supervision to follow job instructions and monitor for compliance during work. Tag lines required. Barricade in path of load. Awareness Trainings Direct supervision

B

disorder

Page 10 of 16





Hazard

Date: 19.07.2011






BLASTING OPERATION Blasting preparation and execution

 Air receiver



  

  

and compressor certificate may be not available. Compressor condition may be Not suiting for the job. Maintenance record may be not available. Housekeeping may be inadequate. Spillage of products may occur on ground. Area may not be cleared from obstruction Grit blast habitat may be inadequate. Competency and skill of the performing individual may be inadequate

 Equipment shall be examined by    

          

supervision before its use. Air Receiver certification must be available when required. Service record must be available when required. Equipment shall be examined daily before use. Certification shall be up to date and available when required. Regular housekeeping must be carried out and maintain at all times. Spill trays to be used during decantering. Supervision to ensure compliance Area shall be surveyed and acceptable before execution of the task. Screenings install to contain the airborne particles in opened area. Only experienced and skilled individual are to be assign to the task. Approved respiratory protection Hearing protection to be mandatory Adequate lighting by explosive proof lighting Full eye protection/ blast hood Fully boarded out platform cable-hose management Avoid working off ladders/ provide safe work platform Permit to Work requirement

Page 11 of 16

Strict compliance to be ensured for the following procedures: 00-ZA-E-G85804 Emergency Response plan 00-ZA-E-G85821 Waste Management Plan 00-ZA-E-G85827 Spill Response Plan 00-ZA-E-G85819 Permit To Work Procedure WI-SIKB-HSE-012 PERSONAL PROTECTIVEEQUIPMENT WI-SIKB-HSE-013 CONTROL AND USE OF HARMFUL SUBSTANCES WI-SIKB-HSE-016 MANUAL HANDLING WI-SIKB-HSE-031 HYGIENE AND HOUSEKEEPING WI-SIKB-HSE-035 GRIT BLASTING, COATING AND PAINTING OPERATIONS




Hazard

 Inhaling of

        

contaminated dust from grit blasting Hazardous noise Incompetent blast pot operators Incompetent blasting personnel Poor visibility Respiratory hazards Eye injury Slip and falls Falls from elevated work areas

Date: 19.07.2011



D


 Watchman standby for confined space entry

Page 12 of 16


Additional Controls and Risk Reduction Measures to be developed WI-SIKB-HSE-062 INDUSTRIAL HYGIENE



Activity Description Application of paint or other coatings

HIRA ID:

Hazard

 Paint maybe 





 

lead (Pb) base material. Inadequate storage area may cause paint cans to fall and spill on the ground. Material may be obstructing access way. (empty paint cans) Condition of equipment used may be inadequate. Supervision may be inadequate Unauthorized entry into the painting zone

Date: 19.07.2011

Hazard Effect

 Exposure          

to hazardous material Spills Access blocked Delay in work execution Material damage Exposure to Dust Exposure to Noise Fire/explosion Respiratory hazards Eye injury


D


 Selecting of paints shall be properly

           

studied by company QC and HSE MSDS required details to be known and implemented. Inspection of storage area to be carried out prior to material delivery. Access way must be clear from any obstruction. Each equipment operator to conduct daily equipment checks and preventive maintenance inspection prior to its use. Adequate supervision shall be available at all times. No hand phone to be used. No lighters or Smoking. Exhaust ventilation to be used to reduce level of flammable vapors. Continuously gas monitor by gas test man during coating/painting works inside the confines Space. All piping to be isolated and properly close to prevent flammable paint vapor traveling to other blocks. Watcher to be deployed during painting works Necessary signs to be posted Tool box talks conducted prior to start of the job

Page 13 of 16


Additional Controls and Risk Reduction Measures to be developed MSDS shall be available at the place of works COSHH assessment conducted Hazard Communication for the involved crew conducted PTW obtained



Activity Description Painting inside Painting work shop

Hazard



Competency and skilled of employee may be inadequate.

4

Certification of equipment may be unavailable.

2

C


 Only competent personnel are allowed


to use painting material.

B

 Equipment certification and service

1

A

records must be available if required. 3

B

 Supervision should monitor compliance. 

2

A

Storage area may be surrounded by harmful exposure that can damage the equipment. Disposal of used paint cans may be inadequate.

3

B

 Equipment storage area shall be clear

2

A

3

B

 Excess

paints must be disposed properly in accordance with the Hazardous waste disposal procedure.

2

A

Securing of used paint cans, rags and other waste materials may be inadequate.

3

B

 All paints shall be properly secured

2

A

Improper uses of respirator, wrong for the job, not change regularly.

3

2

A

PPE compliance may be inadequate.

Date: 19.07.2011

from any harmful element. Issues shall be dealt with appropriate measures

B

using paint lids.  Used Rags are to be disposed as off Hazardous waste and into appropriate waste collecting bins  Required respirator must be available for painters to utilize.  Supervisor to ensure the availability

Page 14 of 16





Hazard



Air filter cartridge may be inadequate.

3

Smoking policy may be inadequate inside the shop or around the paint store. Fire hazards

2

B


 Air filters cartridge shall be replaced as


per instruction from the manufacturer manual or as necessary. B

 Supervision shall monitor No Smoking

1

A

2

B

 Spill

used blasting media to be contained and disposed accordingly to allow good housekeeping  Spill free liquids that left over will be disposed off according to the guidelines  Spill free liquids that left over will be disposed of according to the guidelines  Disposed off according to yard environment standard

3

B

 Dismantle by competent scaffolder  Direct supervision  Competent person and fall protection

2

B

Policy with strict compliance.

3

C

 All hot works are not permitted during painting. Supervision to check and control. Permit to work procedures

ENVIRONMENTAL CONCERNS  Blasting media  Paints and

Date: 19.07.2011

Spillage

4

C

3

C

Coating materials  Contaminated container/ can/ buckets

DISMANTLING SCAFFOLD AND TOUCH UP PAINT Scaffolder manual handling

Material falling

Touch up paint

Falling hazards

with double lanyard

Page 15 of 16


HIRA Team Members

Members:

HIRA Team Leader

Project Manager

Name:

Name:

Date:

Date:

Signature:

Signature:

Page 16 of 16

00-ZA-E-G85802_00

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