JHA Valve Leak Test and Repair

Job Hazard Analysis Form Work Order Details: Work Order No.: Work Order Description:

90008313

Revision:

0

30HICA-102 Valve leak test and repair

Summary of Scope:

Specific Requirements:

Non stock Material

External Resources

Potential Clash with Other Activities

Crane Required

Shipping

Shutdown

Permit Required

Work Order Only

Isolation Required

Signature

Date

Schedule: Prepared by:

Review Required By: Discipline (tick if required)

Comments

BSM (MM/MMH/MMT/MME/MMO) HSSE

Technology Mechanical Engineering Instruments Electrical Operations Clearance Issuer Fire & Hazard Inspector Other: System Custodian

Binder Colour Coding: Operations

Instruments

Electrical

Mechanical

IPS Rejuvenation Project Work Pack Work Order Details: Work Order No.:

90008313

Work Order Description:


Revision:

Index: 1.

Schedule Control Sheet

2.

Gant chart of work order operations schedule

3.

Photographs of Equipment / Work Site

4.

Work Site Controls a. Permit to Work b. Job Hazard Analysis Sheet c. Task Risk Assessment d. Certificates (As Applicable) i. Isolation ii. Gas Test iii. Vessel Entry iv. De-Isolation for Test v. Hot Work

5.

SAP Work Order

6.

Equipment Drawings

7.

Check Sheets

8.

Material Certification

9.

Reference Documentation

10. Work Order Close Out Report / Lesson Learnt

0

TASK RISK ASSESSMENT / JOB HAZARD ANALYSIS

Erect scaffolding

Shifting / Mobilize of Scaffolding Material

Un-inspected scaffolding material

Falling object

Injury to personnel.

Scaffolding contractor staff

2

CInc ide nt ha s 4 C

Action parties

#Secure the material Civil supervisor while shifting on and Job vehicle or trolley. supervisor # Shifting of the scaffold clamps from ground level to top platform through lifting bag with secured rope only. # Ensure that shifting of the scffolding pipe by one person at a time on one staircase.

Injury to personnel

adjacent 3 work groups

me # Ensure that all Civil supervisor diu scaffolding material is and Job m being inspected and supervisor tested by SMDS. ( civil )

Injury to personnel

adjacent work groups

me # Use basket or diu appropriate bag for m transporting small items to / from height.

Injury to personnel


Civil supervisor and Job supervisor

4

C me # Ensure items to be Civil supervisor diu hoisted up or down are and Job m properly rigged and supervisor secured. # Ensure the use of tag line to control movement of items during hoisting. # Ensure the use of head protection. #Barricade the area at ground level when work at height is in progress # Ensure the scaffold supervisor is at site supervising the works.. Ensure all hand tools are secured during work at height. # Ensure a pre job safety briefing on dropped objects is given to all workers # Ensure no work is conducted directly below scaffolding erection works

C

Unsuitable location

Obstruct access & Work group egress to work location

2

Unstable and Uneven ground condition

Injury to personnel and Scaffolding damage of property. contractor staff

2

Falling from height

C lo w

List all controls Required

lo # Ensure the exact Civil supervisor w scaffolding location and Job where possible before supervisor the Turn Around and perform site inspection for any observation.

C- lo #Check and confirm Inc w the footing of scaffold ide are rested on even nt concrete floor. ha #Ensure the use of s base plate. oc Conduct Toolbox talk cur before erection. red in co mp an y


Injury to Personnel

Any staff working on the platform

4

C me #Check and ensure the Civil supervisor diu use of inspected safety and Job m harness with double supervisor lanyard and anchored at a strong point.

Injury to Personnel

Work group

4

C me #Ensure 100% tie off diu during shifting of m personnel.


Recovery Measures

# Communicate to control room and shift manager will activate the emergency response.

Action parties

Severity

Population at Risk

RESIDUAL RISK

Barriers

Likelihood Risk Rating

INITIAL RISK Severity

Hazard Description & Effect

Hazard / Risk Consequence Description


HAZARD Job Steps

TRA/JHA NO.: CREATED DATE: NEXT REVIEW DATE:

90008313 REVISION: 0 30HICA-102 Valve leak test and repair Majang, Michael Chai, Rudy, Paul Asam

WORK ORDER NUMBER: WORK ORDER DESCRIPTION: GROUP MEMBERS:

ALARP (Y/N)



1

D

Non compliance of the procedure

Injury to Personnel


4


Scaffolding contractor staff / Company staff Scaffolding contractor staff / Company staff

3

c me # Follow the standard diu prodedure of erection m of scaffolding and work at height. D me # Ensure the use of diu three point contacts m while using the ladder.


ALL STAFF

2

D me # Check and confirm diu that scaffolding is m certified safe for access. Green tag( Safe to use tag to be display) C lo # Stop the work w immediately.

Field operator

3

D me # Ensure that a valid diu Permit to work is m obtained for the job. # Ensure the depressurization and draining is being done as per operation procedure. # Ensure that CO is less than 25 PPM and Methane is less than 3% during draining and depreesurization. D me #Wear Disposable diu coveralls when m performing insulation removal. Disposable D Wear specific type of me dust mask as diu prescribed by MSDS m

Injury to personnel

Un-inspected scaffold. Injury to personnel

Foul weather

Injury to personnel.

Population at Risk

3

Depressurize and cooling down

Expoure of CO, N2 and Injury to personnel. traces of waxes.

Removal of insulation

Exposure to insulation

Chronic health problems or skin irritation

Insulation contractors

2


Chronic health problems or skin irritation


2

Sharp edges of removed cladding

Cuts to fingers/hands


1

4 Access at height for insulation reinstatement

falling from height

falling object

Injury to personnel



4

4


Injury to personnel

Fire hazard

Injury to personnel

Release of Injury to personnel uncontrolled instrument air from tubing


lo # Ensure the w scaffolding supervisor is present during time of erection.# Ensure that scaffolding is being erected as per the work requirement. # Ensure that scaffolding is "fit for purpose"

Action parties

Recovery Measures



Civil supervisor and Job supervisor Field operator, Panel man ans AGT.

Civil supervisor / #Communicate to Job supervisor control room and shift manager will activate Job supervisor the emergency

C

Ensure all insulation Lo contractors wear semi- Job supervisor w leather gloves All insulation B contractors to wear and tie off safety Me harness when diu Job supervisor accessing scaffolding m which may require working outside the safe working platform C me All hand tools to be job supervisor diu secured using a m lanyard when working at height C #All cladding/insulation removed which will not be reused to be lowered to ground level me using secured rope. diu job supervisor #All cladding to be m reused needs to be tied to a secure anchor point to prevent it being blown off by wind



4

C

Instrument staff and contractor staff

2

C

# All removed job supervisor insulation to be wet in me water and placed in diu plastic bag and remove m from the location immediately. lo # Ensure the pressure w is released fully before disconnect the tube. # Use of proper PPEs during disconnection. Safety goggles is compulsory during release the pressure.

Instrument supervisor and instrument contractor

#Communicate to control room and shift manager will activate the emergency response.

Action parties

Severity

Collapse of Scaffolding



Inappropriate method of erection


Fall from height

Removal of instrument parts

RESIDUAL RISK

Barriers

Severity

INITIAL RISK Likelihood Risk Rating

HAZARD Job Steps




ALARP (Y/N)


2

C


Action parties

Short circuit

Damage to property

Removal of heat tracing (EHT)

Live electrical cables

Electrocution

Electrical contractor

4

Unbolting

Trap pressure/ Over exertion

Injury to personnel

Mechanical contractor staff

2 C- lo # Ensure no trap Job supervisor Inc w pressure is in system. ide # Check and ensure nt right tools are used. ha # Check and ensure s the distance between oc the work platform and cur work is appropriate red (sufficient reach). in # Ensure the follow up co of " Bolting procedure". mp an y

Bolt & Nut Jammed

Extra physical effort required for work

Mechanical contractor staff

3

C- lo # Ensure no hot work Inc w is used for removing ide jammed bolt and nut. nt # Adopt proper work ha posture. s # Use hacksaw for oc coldcut. cur red in co mp an y

Falling blind / bolts/tools

Injury to personnel or damage of property

Mechanical contractor and adjacent work groups

4

C- Me #Conduct a pre job Inc diu safety briefing. ide m #Secure all hand tools nt # Cordon off the ha working area below. s # Ensure the no work oc is being carried out cur diredtly below the red Installation. in # Ensure no loose co object on the grating. mp Must be contained in an the container. y

Used of WD40 & Similar

Fire hazard

Contractor staff

2

Unauthorised crane entry without gas test

Injury to personnel and All staff damage of property.

Crane arrangement

Non compliance/ Non availability of lifting plan

Injury to personnel and Mechanical damage of property. contractor staff

3

Instrument supervisor and instrument contractor B me # Ensure a valid permit MME/53 diu to work is obtained for m the job . #Ensure electrical heat tracing has been isolated # Ensure usage of proper PPEs for the job.

C

lo # Ensure that cable is w isolated from marshelling rack.

Job supervisor Contractor workers Job Supervisor Job Supervisor

lo Limit the amount of w WD40 or similar at the worksite and work platform. Check and ensure no hot work in the vicinity.

C- me # Ensure every vehicle Inc diu entry with permit to ide m work and with gas test. nt #Ensure that crane is ha tested and certified by s SMDS. oc # Ensure that crane is cur approved with red inspection sticker. in co mp # Ensure that Lifting plan is in place and complied with procedure if load is 1 Ton and above . lo # Ensure that lifting 2 C w plan is in place if any blind lift/ obstrction lift is there at any weight.

#Field Operator and AGT # Mechanical staff and job supervisor

Mechanical supervisor and Job Supervisor

Recovery Measures

Action parties

Severity

Population at Risk

RESIDUAL RISK

Barriers






HAZARD Job Steps




ALARP (Y/N)


Offset centre gravity

Uncontrolled lifting opearation

Failure of cranne

3

me # Ensure the operation Mechanical diu is carried out in a well- supervisor and m coordinated manner. Job Supervisor # Ensure only experienced crane operator is used or under close supervision. c # Ensure the crane is adjusted such that its center of gravity is directly below the hook used. # Ensure the lifting plan is placed and followed properly.

3

D

Damage of property Mechanical and Injury to personnel contractor staff/ company staff

Damage of property Mechanical and Injury to personnel contractor staff/ company staff Delay to operation. Mechanical Injury to personnel. contractor Damage to property staff/ company staff

3

Toppling of crane

Overloading of crane

Failure of lifting gears and applieances

me # Check and ensure a diu qualified lifting m supervisor is on site to supervise the operation. me # Check and ensure diu the crane used has m valid certificate. # Check and ensure all safety devices of the crane are functioning. D # Check and ensure the daily inspection of the crane is properly carried out prior to the rigging and lifting.


2


2


3


C

Action parties

Mechanical supervisor and Job Supervisor

Mecchanical supervisor and Job Supervisor

# Check and ensure Mecchanical the capacity of the supervisor and crane used is sufficient Job Supervisor for the operation. # Check and ensure all outriggers are fully extended and secured on solid ground. # Check and ensure all safety devices are lo functioning and not w bypassed. # Check and ensure the crane is operating within its safe working radius. # Check and ensure the crane is not overloaded.

# Check and ensure the crane has sufficient capacity for the lo operation prior to w commencement of the entire operation.

Mecchanical supervisor and Job Supervisor C and Crane operator and signal man and qualified rigger # Check and ensure all Mecchanical lifting gears and lifting supervisor and appliances used have Job Supervisor valid certificates. and Crane # Check and ensure operator and the SWL of all lifting signal man and gears / appliances qualified rigger used can withstand the load of the operation. # Check and ensure all lifting gears and lifting appliances used have Me no visible defects / D diu damage. m # Adopt appropriate work position to prevent being hurt by the sling / shackle/ chain block fails. # Ensure and check that all safety lock is available with good condition at lifting gears.

Recovery Measures

Action parties

Severity

Population at Risk

RESIDUAL RISK

Barriers






HAZARD Job Steps




ALARP (Y/N)


Swinging of load

Damage of property Mechanical and Injury to personnel contractor staff/ company staff 3

Lifting

Communication breakdown

Damage of property Mechanical 3 and Injury to personnel contractor staff/ company staff

Foul weather

Poor Visibility / Lighting All staff / heavy wind speed.

Non compliance/ Non availability of lifting plan

Injury to personnel and Mechanical damage of property. & contractor staff

2

2

Falling from lifting beam

Injury to personnel and Mechanical damage of property. contractor staff and job supervisor 3

Obstruction during removing of blind and spade

Damage of property Mechanical and Injury to personnel contractor staff and job supervisor Hit against moving the Injury to personnel Mechanical spade contractor staff and job supervisor

3

3

CV removal Blind off open end

Hit by falling objects (bolts and nuts)

Injury to personnel

Pinch point

Injury to health

Falling blind / bolts/tools


Mechanical contractor and adjacent Mechanical staff and contractor staff Mechanical contractor and adjacent

3

2

4


me # Check and ensure diu only qualified crane m operator is used. # Use tag lines to control the load. D # Ensure that area is barricaded and signage posted to prevent access to unauthorised personnel. D

me # Ensure only one diu authorized lifting m supervisor is giving instructions. # Use walkie-talkie for verbal communication (language used must be understood by all parties involved). # Check and ensure only qualified signalman is used for giving signals. # Perform a pre-job safety briefing to all involved.

C lo w

C

# To cease the lifting operation under controlled condition.

# Ensure that Lifting plan is in place and complied with procedure if load is 1 lo Ton and above . w # Ensure that lifting plan is in place if any blind lift/ obstrction lift is there at any weight.

Action parties

Recovery Measures

Mecchanical supervisor and Job Supervisor and Crane operator and signal man and qualified rigger

Mecchanical supervisor and Job Supervisor and Crane operator and signal man and qualified rigger

Mechanical supervisor and Job Supervisor and signal man and qualified rigger Mechanical staff # Communicate to and job supervisor control room and shift manager will activate the emergency response.

# Ensure that condition Mechanical staff of lifting beam is safe and job supervisor for mounting the chain block on the lifting Me beam. C diu # Ensure usage of m proper slings during lifting of CV on the beam.

# Ensure and check Me that during removing of C diu CV all structures are m safe. # Ensure the operation is well coordinated and Me controlled. C diu # Perform pre Job m safety meeting

# Please check aobove step #Barricade the area below the work place # Be away from trap pressure. # Ensure Toolbox talk is carried out for specially for pinch C Me point. #Conduct a pre job diu safety briefing. m #Secure all hand tools # Cordon off the C Me diu m C lo w

Mechanical staff and job supervisor

Mechanical staff and job supervisor

Job supervisor

Job supervisor

Job supervisor Contractor workers Job Supervisor

#Communicate to control room and shift manager will activate the emergency

Action parties

Severity

Population at Risk

RESIDUAL RISK

Barriers






HAZARD Job Steps




ALARP (Y/N)


Transport to workshop


D#Check with the person Ha in charge of the route pp to be used and road en closures if any. s # Check and ensure se the work areas are ver barricaded. al #Use signal man as tim and when required. Me es #Check and ensure per diu personnel are well ye m clear of moving truck or ar forklift. in # Ensure during lifting a and road transportation Co in internal process road mp shall be guided by an operation. y

Hit by truck, Forklift


Mechanical contractor staff / Adjacent work group.

3

Fire hazard due to spark from vehicle


Mechanical contractor staff / Adjac ent work group.

5

C me # Ensure gas testing is Mechanical and diu conducted by AGT job supervisor m prior to entry in process road.

Un-inspected vehicle entry



5

Non complience of fire Injury to personnel or permit damage of property


5

B me # Ensure the vehicle diu has been inspected by m MME/43 for spark arrester. # Ensure that all vehicles have been complied with standard. B me # Ensure fire permit is diu in place for the vehicle m movement.

Servicing & overhaul

# Seprate procedure cover the risk

Transport to site

# See as above

Removal of blind

# See as above

Crane arrangement

# See as above

Lifting

# See as above

Mechanical and job supervisor , Logistic coordinator.

Mechanical and job supervisor

Job supervisor and Field operator

# See as above

Install CV Bolting & torque

Action parties

Insufficient tightening of bolt and nut

Affect the integrity of equipment

Mecahnical contractor staff

Falling the blind / bolts/tools

Injury to personnel


Insufficient tightening of bolt and nut

Affect the integrity of equipment

Mechanical staff and contractor staff

C#Ensure the use of Inc torque wrench (set at ide required torque) for nt tightening the bolts and ha lo nuts. 2 s w # Ensure the oc compliance of bolting cur procedure. red in co C#Ensure the tools are Inc secured. ide #Barricade the nt underneath area if ha work at height is in s me progress. oc 3 diu # Ensure the grating is cur m covered with red Tarpouline to prevent in the falling object. co mp an y C#Ensure the use of Inc torque wrench (set at ide required torque) for nt tightening the bolts and ha lo nuts. 2 s w # Ensure the oc compliance of bolting cur procedure. red in co

Job supervisor

Mechanical staff and Job supervisor

job supervisor

Recovery Measures

Action parties

Severity

Population at Risk

RESIDUAL RISK

Barriers






HAZARD Job Steps




ALARP (Y/N)


Install heat tracing (EHT)

Falling the blind / bolts/tools

Injury to personnel

Mechanical staff and contractor staff

Live electrical cables

Electrocution

Electrical contractor

CInc ide nt ha s oc 3 cur red in co mp an y 4 B


Action parties

#Ensure the tools are Mechanical secured. supervisor /Job #Barricade the supervisor underneath area if work at height is in me progress. diu # Ensure the grating is m covered with Tarpouline to prevent the falling object.

me # Ensure a valid permit MME/53 diu to work is obtained for m the job . #Ensure electrical heat tracing has been isolated # Ensure usage of proper PPEs for the job.

Install back instrument parts

# Seprate procedure cover the risk

Install insulation

# Please follow the job supervisor above the " Removal of Insulation step" Damage of EHT underneath the cladding and Electroculation

Injury to personnel

Insulator

2

C

lo # Ensure that in drill bit is w provided with stopper to prevent damage of EHT or cable. # Ensure tool box talk prior to work.

Job supervisor

Recovery Measures

Action parties

Severity

Population at Risk

RESIDUAL RISK

Barriers






HAZARD Job Steps




ALARP (Y/N)

IPS Rejuvenation Project Work Pack Work Order History: Work Order No.:

90008313



Revision: 0

Description Of Equipment As Found:

Activities Performed:

Equipment / Materials Used:

Testing / Calibration Results:

Condition Of Equipment Upon Completion:

Description Of Follow On Work: (Notification Numbers)

List Of Completed Attachments:

Prepared By:

Date:

Approved By:

Date:

Routine Work Order Validation Sheet Note: Complete required information 1.

Work Order No.:

90008313

2.



3.

Is Description adequate?

4.

Are Tag Numbers referenced and correct?

5. Procedure - required? - attached? - sufficient and correct? 6. Is the Shutdown Code correct? 7. Is the Responsibility Code correct? 8. Are additional resources required - e.g. Specialist? 9. Does the Routine require Special Tools or Equipment 10. Are Materials required - is there a BOM attached? - are these adequate for the work being undertaken? 11. Special Lifting Equipment or Arrangements required? 12. Is Manhour allocation / estimate correct? 13. PMR amendment required: (attach separate sheet if necessary) Z6 Type Notification Number(s) Raised: 14. Completed By: Name & Signature

Date

Risk Assessment Matrix CONSEQUENCE

INCREASING LIKELIHOOD

Severity

A

B

C

D

E

Has happened Has happened in the at SMDS or Has happened Never heard of heard of in … Organization more than more than in … industry industry or more than once per year once per year once per year in the at SMDS in the industry organization

People

Asset

Environment

Reputation

0

No health effect/injury

No damage

No Effect

No impact

0A

0B

0C

0D

0E

1

Slight health effect/injury

Slight Damage

Slight Effect

Slight impact

1A

1B

1C

1D

1E

Minor Damage

Minor Effect

Minor impact

2A

2B

2C

2D

2E

Localised Damage

Localised Effect

Considerable impact

3A

3B

3C

3D

3E

Major Damage

Major Effect

National impact

4A

4B

4C

4D

4E

Massive Effect

International impact

5A

5B

5C

5D

5E

2

3

4

5

Minor health effect/injury Major health effect/injury

PTD* or 1 to 3 fatalities

Multiple fatalities Extensive Damage

*Permanent Total Disability

Risk Assessment Matrix Consequence - Category Definition Harm to People

Environmental Effect

0 No injury or health effect

0

Slight injury or health effects not affecting work performance and not affecting daily life activities. Examples: First aid cases and medical treatment cases. Exposure to 1 health hazards that give rise to noticable discomfort, mild irritation or transient effects reversible after exposure stops. Minor injury or health effects (Lost Time injury) - Affecting work performance, such as restriction to activities (Restricted Work Case or Occupational Illness) or a need to 2 take a few days to fully recover (Lost Workday Case). Minor health effects, which are reversible, e.g. skin irritation, food poisoning. Major injury or health effects (including Permanent Partial Disability and Occupational Illness). Affecting work performance in the longer term, such as a prolonged 3 absence from work. Irreversible health damage without loss of life, e.g. noise induced hearing loss chronic back injuries, sensitisation, hand/arm vibration syndrome, repetitive strain injury. Permanent Total Disability or one to three fatalities - From an accident or 4 occupational illness. Irreversible health damage with serious disability or death, e.g. corrosive burns, heat stroke, cancer (small exposed population)

5

Multiple fatalities - From an accident or occupational illness (e.g. chemical asphyxiation or cancer (large exposed population)

1

2

3

4

5

Asset Damage and other Consequential Business Losses (100% costs, USD)

Impact of Reputation

0 Zero damage

0

1 Slight damage - No disruption to operation (costs less than 10,000)

1

2 Minor damage - Brief disruption (costs less than 100,000)

2

3 Local damage - Partial shutdown (can be restarted but costs up to 1,000,000)

3

4 Major damage - Partial operation loss (2 weeks shutdown costs up to 10,000,000)

4

5

Extensive damage - Substantial or total loss of operation (costs in excess of 10,000,000)

5

The figures in the tables above should not be combined for deriving the value of a human life!!

sequence - Category Definition Environmental Effect Zero effect - No environmental damage. No financial consequences. Slight effect - Slight environment damage, within the fence and within the systems. Negligible financial consequences. Minor effect - Sufficiently large contamination or discharge to damage to attack the environment, but no lasting effect. Single breaches of statutory or prescribed limit, or single complaint. Localised effect - Limited discharges affecting the neighbourhood and damaging the environment. Repeated breaches of statutory or prescribed limit, or many complaints. Major effect - Severe environmental damage. The company is required to take extensive measures to restore the damage environment. Extended breaches of statutory or prescribed limit, or widespread nuisance. Massive effect - Persistent severe environment damage or severe nuisance extending over a large area. Loss of commercial, or recreational use or nature conservancy resulting in major financial consequences for the company. Ongoing breaches well above statutory or prescribed limits. Impact of Reputation Zero effect - No public awareness.

Slight impact - Public awareness may exist, but there is no public concern.

JHA Valve Leak Test and Repair

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