Professional Documents
Culture Documents
DESPRLK.KJSA002
KorangiandKeamariPRLTanks Hazard
Poorcommunication betweenworkparties. Inexperiencedpersons/lack ofsafetyawareness Heatstress Noise
JSATitle: Activity:
TANKREPAIRWORK
ErectionandrepairworkofTanks Date 05/12/2012
Repair work of existing tanks, bolting, unbolting, removal / erection of shell bottom & roof plates , including removal of existing structure and pipes spools / nozzles , stair and NDT Radiography work
ResidualRisk H M L L
VehiclesMovement
Workpermitfromtheclient,withallconcurringpartiessignatures approvalmustbeobtainedpriortostartofworkanddisplaywork permitatsite Safetyrequirementsstatedontheworkpermitmustbeavailableonsite andstrictlyfollowed Toolboxtalkshallbeconductedtoallpersonnelonsite&documented beforestartofwork. AppropriatePPEshallbewornbyallpersonnelatsite. AssignedtraineddedicatedBanksmanforjobwithreflectivejacket. Nowaternoworkpolicyshallbefollowed. WorkScheduleaccordingtoheatIndex Earprotectionshallbewornwhererequired. Noisemeterwillbemadeavailableatsite. Maintenanceofequipmentonregularbasis. Useofwelltrainedlicenseddrivers. Vehiclemovementsonsiteshallbecontrolledbybanksmanandspeed limitsaretobefollowed. Appropriatesignagetobeprovided.
DESPRLK.KJSA002
KorangiandKeamariPRLTanks
JSATitle: Activity:
TANKREPAIRWORK
ErectionandrepairworkofTanks Date 05/12/2012
Repair work of existing tanks, bolting, unbolting, removal / erection of shell bottom & roof plates , including removal of existing structure and pipes spools / nozzles , stair and NDT Radiography work
Activity Hazard Transportationof Failureofequipment Shellplate&Misc /crane/Trailer/Pickup/ Tanksmaterialsfrom Trucketc yard/storeware Roadtrafficaccident housetoWork duringtransportationof location Tanksshellplatesand ByUsingCrane othermaterial. ,Trailer,BoomTruck Pickupetc Bodypartinjuryduring loadingandunloading operation
Uncontrolled Risk ControlMeasures H M L M ConducttoolboxtalkandLMRApriortostartofworkatthe specificlocation. Ensuresatisfactoryconditionofequipment,properly inspected,stickerPlacedandforappropriatecolorcode. Allrigginggearshallbecertified. Syntheticbeltornylonslingshallbeusedinsteadofsteel wireropeforholdingofmaterial. Ensurecraneoperatorsandriggersfullyunderstandallwork tasksandhazards. Loadshallbesecuredonthetrailerbedtoprevent accidentalfall. Craneoperatorshallhavethethirdparty,certifiedand applicablelicense. Usepropertaglineduringloading/offloadingmaterial. AccessrouteshallbesurveyedbeforetransportingtheShell Plates,pipes&supportmaterialetc. Barricadewithappropriatesignboardontheeffectivearea. Riggersshallbeexperiencedandthirdpartycertified.
ResidualRisk H M L L
DESPRLK.KJSA002
KorangiandKeamariPRLTanks Hazard Pinchpoint. Vehiclehittheexisting facility .
TANKREPAIRWORK
ErectionandrepairworkofTanks Date 05/12/2012
Repair work of existing tanks, bolting, unbolting, removal / erection of shell bottom & roof plates , including removal of existing structure and pipes spools / nozzles , stair and NDT Radiography work
ControlMeasures
ResidualRisk H M L
Useleatherglovesforhandprotection. Keepawaybodyparts(hand,feet,head,etc)fromtheline offire(LOF). Suitablelengthoftrailershallbearrangedaccordingto lengthofShellPlates,pipespools,supportsetc. Redflagatthebackendoflongpipespoolshallbe provided. Sitespecifictrafficrulesshallbefollowed. Allvehiclemovementswillbecontrolledbyacertifiedbanks man. Banksmanshallbeprovidedforreversingvehicle.
DESPRLK.KJSA002
KorangiandKeamariPRLTanks
JSATitle: Activity:
TANKREPAIRWORK
ErectionandrepairworkofTanks Date 05/12/2012
Repair work of existing tanks, bolting, unbolting, removal / erection of shell bottom & roof plates , including removal of existing structure and pipes spools / nozzles , stair and NDT Radiography work
Uncontrolled Risk Hazard H M L Heavy spools may slip and H fall on employees feet/legs Falling of bolts/nuts from height and usage of damaged /non-standard tools HandInjury Pressurizedequipments Fallingofperson DamagestoGasket, threadsofboltsand seat. Riskofboxupwithout Finalclearancefrom PRL
ControlMeasures
ResidualRisk H M L L
UseChainblocksandlowertoground. Oneendofthechainblockstobeengagedtohook provided. Usecorrectsizespannersandkeepthebolts/nutsinabag andtietheotherendofspanners/toolswithanylonropeto asupporttoavoidfallingwhileinuse. Ensurethatblindwastieoffwithropeorprotectedagainst fallonperson.. Usechainblocks,engagethecover/blindtothehook. Transfertheentireloadtothechainblocks,remove remainingboltsandlowertheblindtotheground. ShifttheBlind/covertosafeplaceawayfromthetank. UseproperPPEs(gloves) Makesurethatequipmentwillbedepressurizedbefore startofactivity,countercheckwithareaauthority. Useharnesswhileworkingatheightand100%tiepolicy mustbefollowed. Horizontalliftingatalltimesafterplacingthenewgasketto
DESPRLK.KJSA002
KorangiandKeamariPRLTanks Hazard Overtensioning Fallingofmaterialsand usageofdamaged /nonstandardtools
TANKREPAIRWORK
ErectionandrepairworkofTanks Date 05/12/2012
Repair work of existing tanks, bolting, unbolting, removal / erection of shell bottom & roof plates , including removal of existing structure and pipes spools / nozzles , stair and NDT Radiography work
ControlMeasures
ResidualRisk H M L L
bedone. Ensuretestedandcertifiedchainblocksandslingsareused. Obtainboxupclearancefromprocess,inspection,operation andmaintenance Followstamicarbontensioningprocedure. Usecorrectsizespannersandkeepthebolts/nutsinabag andtietheotherendofspanners/toolswithanylonropeto asupporttoavoidfallingwhileinuse. Allpersonnelworkinginconfinedspacemusthave confinedspacetraining. PRLconfinedspaceprocedureshallbefollowed. Holewatcherisattentiveallthetimeduringconfined spaceactivity.LightingprovidedinCSEtobe24V. Easycommunicationbetweenholewatcherandsupervisor isestablishedallthetime. Ensurethatpassageandtransportroutisclearduring confinedspaceactivities.Properaccess/agreesshouldbe
4.
Confinedspaceentry.
Oxygendeficiency
DESPRLK.KJSA002
KorangiandKeamariPRLTanks Hazard accumulationoftoxic gases
TANKREPAIRWORK
ErectionandrepairworkofTanks Date 05/12/2012
Repair work of existing tanks, bolting, unbolting, removal / erection of shell bottom & roof plates , including removal of existing structure and pipes spools / nozzles , stair and NDT Radiography work
ControlMeasures
ResidualRisk H M L
Physicalhazards
Improperstackingof material
maintained. GastesttobedonebyAGTpriortoenteringintothe confinedspace. Atrainedandqualifiedindividualshouldoutsidethetank withtheresponsibilityofensuringthesafetyofauthorized entrants(Fabricator,Fitter,Weldere.tc)throughthe performancepreentrybriefing,checkingandinspecting PPE,equipmentandtoolsandperformingregular monitoringinensuringpersonworkinginsidepiperemains safeforentryandoccupation. Awrittenrescueplanthathasprovisionforconductinga timelyrescueofindividualsworkinginsidethepipe (ConfinedSpace)shouldbekeptonsite.Raisingthealarm intheeventofanemergencyusingtheradio/mobile phonesprovidedtothem. Ensureeffectivecommunicationsystemsfortheentryare tested. Properlightshouldbeprovidedlessthan25v. Allmaterialstackproperandcategorywise.
DESPRLK.KJSA002
KorangiandKeamariPRLTanks Hazard Unauthorized entrant
TANKREPAIRWORK
ErectionandrepairworkofTanks Date 05/12/2012
Repair work of existing tanks, bolting, unbolting, removal / erection of shell bottom & roof plates , including removal of existing structure and pipes spools / nozzles , stair and NDT Radiography work
ControlMeasures
ResidualRisk H M L
5.
Failureofequipment.
Fallofobjects/ Swinging.
Rescuearrangementshallbemadewhileworkingmore thanfivemeterinsidelargeboresize. PRLSHE&SProcedureshallbefollowed. Closesupervisionrequiredwhileworkinginside. Executetheworkunderclosesupervisionandpresenceof holewatcher. Properairsupplytobeprovidedorairmoverwillbe provided. Properventilationshallbethere. Workingcrewshellbetrainedforconfinedspaceworking. Certifiedandcolorcodedliftinggearstobeused. Equipmentshallbeinspectedpriortousebycompetent person. Competentandcertifiedoperatorandrigger&HiVisjacket fortheRigger. Barricadetheliftingarea/swingradiusandplacesafety cautionboards. Ensurethattheloadisadequatelysecuredandfixedtothe
DESPRLK.KJSA002
KorangiandKeamariPRLTanks Hazard Overloading.
TANKREPAIRWORK
ErectionandrepairworkofTanks Date 05/12/2012
Repair work of existing tanks, bolting, unbolting, removal / erection of shell bottom & roof plates , including removal of existing structure and pipes spools / nozzles , stair and NDT Radiography work
ControlMeasures
ResidualRisk H M L
Fallingfromthelifting beam.
hook. Thesafetylatchonthehookmustbecorrectlyclosed. LiftwithinSWL(Safeworkingload). Usetaglinestocontroltheliftingload. Supportstowhichliftinggearsareattachedshallbestrong enoughtowithstandtheliftingload.Andcertifiedby3rd party. Donotleavetheloadsuspended. Neverstand/walkon/underliftingload. Approvedliftingplantobefollowed. Experiencedhoist/craneoperatorshallbeassigned. Useproperliftingtechniques. Securealltools/objects.Useappropriatehandgloves. Allpersonnelworkinginconfinedspacemusthaveconfined spacetraining.Obtainconfinedspaceentrypermit. PRLConfinedspaceprocedureshallbefollowed. Holewatcherisattentiveatallthetimeandestablishgood
DESPRLK.KJSA002
KorangiandKeamariPRLTanks Hazard Physicaland atmospherichazards.
TANKREPAIRWORK
ErectionandrepairworkofTanks Date 05/12/2012
Repair work of existing tanks, bolting, unbolting, removal / erection of shell bottom & roof plates , including removal of existing structure and pipes spools / nozzles , stair and NDT Radiography work
ControlMeasures
ResidualRisk H M L
6.
communicationduringconfinedspaceactivity.Lighting providedinCSEtobe24V. Adequateventilationtobeprovided. Easycommunicationbetweenholewatcherandsupervisor isestablishedallthetime. Ensurethatpassageandtransportroutisclearduring confinedspaceactivities.Properaccess/agreesshallbe maintained. NotifiedtotheERT(EmergencyResponseteam)priorto starttheactivity. Worktobeexecutedunderclosesupervisionatalltimes. GastesttobedonebyAGTpriortoenteringintothe confinedspace. L
DESPRLK.KJSA002
KorangiandKeamariPRLTanks Hazard fitting,tacking, grindingetc.
TANKREPAIRWORK
ErectionandrepairworkofTanks Date 05/12/2012
Repair work of existing tanks, bolting, unbolting, removal / erection of shell bottom & roof plates , including removal of existing structure and pipes spools / nozzles , stair and NDT Radiography work
ControlMeasures
ResidualRisk H M L
Activity UsageofPower brushforinternal cleaning,electrical Grinding,drill machine,Cuttingset etc, Usageofgas cylinderfor preheating. Repairworkof
existingtanks, Removal / Erection ,shell bottom & roof plates,including removalofexisting structureandpipes spools / nozzles and stair etc
Keepfireextinguisherstandby. Barricadeworkareaandplacethepropersignboards. Allpersonnelworkinginconfinedspacemusthaveconfined spacetraining. PRLconfinedspaceprocedureshallbefollowed. Provideproperrespiratorypersonnelprotectiveequipment. Properearthlingshallbeprovidedfortheelectrical equipment. GrindingandcuttingdisctobeasperRPMratiowith machine.Andmakesurethedatesofcutting/Grindingdisc arenotexpiredandnodamage. Grinding/Cuttingmachinewithdeadmanswitch. Faceshieldmustbeusedforcutting/grindingactivity. Areashallbefreefromcombustible/flammablematerial. Firewatchershallbeplacedforoverheadworking. AllElectricalequipmentshallbeinspectedandcolorcoded. (I.e.Cords,Plugsetc).
DESPRLK.KJSA002
KorangiandKeamariPRLTanks Hazard
TANKREPAIRWORK
ErectionandrepairworkofTanks Date 05/12/2012
Repair work of existing tanks, bolting, unbolting, removal / erection of shell bottom & roof plates , including removal of existing structure and pipes spools / nozzles , stair and NDT Radiography work
ControlMeasures
ResidualRisk H M L
Cylinderstorage.
Allportableelectricalequipments/cablesshallbeapproved declaredsafetouse.Allelectricalequipmenttobe groundedproperly. Ensureelectricalcablesareprotectedfromwater/spilled liquid UsecorrectPPEs(Leathergloves,SafetyGlassesforthe task). Ensureallcylindersaresecuredandcappedwithmetal chaininappropriatetrolleys. Protectivecovershallbeinplacewhilecylindersnotinuse. Gascylinderstobesecuredcorrectlyduringtransportation. Gascylinderssecuredverticallyandprotectedfromdirect sunlight/heat,greaseandanyoilyitems. Alwaysusetrolleytoshiftthecylinders. CylinderkeyshallbekeptwithCylindersandvalvecapplace afteruse. Ensurethatcylinderhosesdonotcomeincontactwithhot surface/greaseoilysubstance.
DESPRLK.KJSA002
KorangiandKeamariPRLTanks Hazard Backfire/fireexplosion
TANKREPAIRWORK
ErectionandrepairworkofTanks Date 05/12/2012
Repair work of existing tanks, bolting, unbolting, removal / erection of shell bottom & roof plates , including removal of existing structure and pipes spools / nozzles , stair and NDT Radiography work
ControlMeasures
ResidualRisk H M L
DonotiethehoseswithGItiewire. Ensurehosesareingoodconditionandwellguardedagainst anypossiblerunoverbyvehiclesorpossiblematerial transfer Allgasblowinghoses/weldingtorchesshallbeprovidedwith flashbackarresterand(NRV)nonreturnablevalve. Pressuregaugesshallbeinworkingconditionandno damage. Gascylindershallbestoredseparately.Oxygenand acetyleneseparately. Allpersonnelworkinginconfinedspacemusthaveconfined spacetraining. PRLconfinedspaceprocedureshallbefollowed. ToolboxtalkwillbeconductedbySupervisor. Supervisorwillberesponsibletocompletesafeactivitypre Checklistsheetdailybeforestartofwork. UseappropriatePPESasperjobrequirement. Maintaingoodhousekeepingtoavoidinjuries.
DESPRLK.KJSA002
KorangiandKeamariPRLTanks Hazard Dropofmaterial. Keepingloadawayfrom body Muscularskeletaldisease, Backpain Liftingbybendingback Liftingunmanageable load
TANKREPAIRWORK
ErectionandrepairworkofTanks Date 05/12/2012
Repair work of existing tanks, bolting, unbolting, removal / erection of shell bottom & roof plates , including removal of existing structure and pipes spools / nozzles , stair and NDT Radiography work
ControlMeasures
ResidualRisk H M L
Planbeforemanuallifting Usemanualhandling/liftingAidsliketrolleyetc. Ensurenoobstructionatjobpoint,access/egress Whenlongperiodofmanualhandlingisrequired,give appropriatebreaks. Keeptheloadasclosetobodyaspossible. Movefeetratherthantwistingbackduringmanual handling. Avoidwearingtightclothingwhichmayrestrictbody movement Ensurestronggrippingduringmanualhandling Bendyourkneesandnotbackduringmanualhandling/ lifting Uselegsathepivotpointtoraiseorlowerbodywiththe backstraightenedwhenliftingorloweringload Shouldersshouldbekeptlevel. Lookahead,notdownattheload,onceithasbeenheld
DESPRLK.KJSA002
KorangiandKeamariPRLTanks Hazard Exhaustion/Fatigue
TANKREPAIRWORK
ErectionandrepairworkofTanks Date 05/12/2012
Repair work of existing tanks, bolting, unbolting, removal / erection of shell bottom & roof plates , including removal of existing structure and pipes spools / nozzles , stair and NDT Radiography work
ControlMeasures
ResidualRisk H M L
7.
Inspections(NDT) PWHT,Radiography
Inexperienceperson Radiation
Chemicalhazard
securely. Materialhandlingtoolsorequipment,suchasbarrowsand trolleys,shouldhavehandleheightsthatarebetweenthe shoulderandwaist. Suchtoolsorequipmentshouldbewellmaintained,with wheelsthatrunsmoothly. Assistanceshouldbeprovidedtohandlersnegotiatinga slopeorramp. Loadsshouldtraveloverasmooth&evensurface. Onlytrainedandcertifiedpersonneltobeallowedto performingofNDTactivities. PersonaldosymeterforallinvolvedinRadiographyactivity. Certified,Calibratedandproperlytaggedequipmentstobe usedforNDT.Colorcodingtobeverified. NootherpersonallowedtoenteringinNDTtestingarea. Areatobebarricadedwithsignboard.Exclusivezoneasper procedure. Supervisortoconfirmthattestperformerisinfully
DESPRLK.KJSA002
KorangiandKeamariPRLTanks Activity
TANKREPAIRWORK
ErectionandrepairworkofTanks Date 05/12/2012
Repair work of existing tanks, bolting, unbolting, removal / erection of shell bottom & roof plates , including removal of existing structure and pipes spools / nozzles , stair and NDT Radiography work
ControlMeasures
ResidualRisk H M L
8.
Minormaintenance work,Connection /Disconnectionand OperationofDiesel Generatorset/ Weldingmachines /ovens/Distribution boards/grinderfor powersupplypurpose includingrepairwork.
Fire/Explosion Sparks.
Spillageoffuel/Oil
ElectricShock
protectedclothingandequippedwithallnecessaryPPE, followallrequirementofNDTasperprojectspecification. ProperPPEshallbeused. Fireextinguishershallbeprovidedatsite. Electricboardshallbeinspectedbyqualifiedelectrician priortouse. Whenelectricmaintenanceorrepairworkisrequired assignedatrainedelectricianforthejob. Colorcodedelectrictoolsshallbeused. Obtainallnecessaryapprovalspriortostartthejob. Standbyfireextinguisher/Firewatcher. Barricadethearea. SWITCHOFFDG(Dieselgenerator)ifanyemergencyalarmis sounded.Switchofftheenginewhilefueling. Fuelingwillbedoneindaytime. Ensurenoconflictingjobsinvicinitybeforestartofjob. DGmusthavePRLinspectionsticker.
DESPRLK.KJSA002
KorangiandKeamariPRLTanks Hazard
TANKREPAIRWORK
ErectionandrepairworkofTanks Date 05/12/2012
Repair work of existing tanks, bolting, unbolting, removal / erection of shell bottom & roof plates , including removal of existing structure and pipes spools / nozzles , stair and NDT Radiography work
ControlMeasures
ResidualRisk H M L
Workingduring extendedhour/night
10
EmergencyProcedure /Response
Ensurealllightsareintrinsicallysafeandarepreinspected. Closesupervisionduringactivity. Onlycompetentelectriciantoperformthejob. Properearthingshallbeprovided. AdequatelightingatworkareaandAccess/Egressarea. Emergencyroutetomusterpointtobeclearlyilluminated. Propercablemanagement Useclearsafetyglassfornightworkforgoodvisibility. WarningLightsandsignboards. TrainedFlagmanforequipmentmovementprovidedwith signaltorch. Closesupervisionrequiredwhileworkinginnightshift. EducatetheworkforceaboutEmergencyProcedure. Allsafetysignboardshallbedisplayedproperlyatsite. IncaseofanyEmergencyallworkwillbestopped,Shut downallrunningequipment&Machineriesandreportedto MusterPoint
DESPRLK.KJSA002
KorangiandKeamariPRLTanks Hazard ImproperAccess/Egress
TANKREPAIRWORK
ErectionandrepairworkofTanks Date 05/12/2012
Repair work of existing tanks, bolting, unbolting, removal / erection of shell bottom & roof plates , including removal of existing structure and pipes spools / nozzles , stair and NDT Radiography work
ControlMeasures
ResidualRisk H M L
11. Housekeeping
Tripsandfall
SharpObjects
Equipmentdamage
ProperAccess&Egressshallbeavailable. AllWorkforcesshallknowtheMusterPointlocation. PRLEmergencyProceduretobefollowed. Emergency#00000000 PRL Medical#00000000 Allwastegeneratedshallbecontainedanddisposedoffin designatedwasteskips. Donotstorematerials/equipmentsinsidetheplantarea. UseProperPersonalprotectiveequipmentforhandlingof waste. Allmaterialsshallberemovedfromthesitetoasafe storagelocationimmediatelyafterthework.