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Shell U.K.

Limited

21st July 2009

Report : EP200907328245
Filing key :

HAZID AND RISK ASSESSMENT
REPORT FOR THE USE OF ALLOY
SCAFFOLDING ON OFFSHORE
FACILITIES
FINAL REPORT
First Issue

Keywords:
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HAZID AND RISK ASSESSMENT REPORT FOR THE USE OF ALLOY SCAFFOLDING ON OFFSHORE FACILITIES Page i Distribution List Name EP200907328245 Reference July 2009 .

Alan Sherriff (EPE-P-ED) Philip Brunton (EPE-S-HU) July 2009 EP200907328245 . Accepted by. Signed : Signed : Chris Grant (EPE-P-FP) Chris Wilson (EPE-P-ED) Field Productivity Team Safety Engineering Team Leader Reviewed by.Page ii HAZID AND RISK ASSESSMENT REPORT FOR THE USE OF ALLOY SCAFFOLDING ON OFFSHORE FACILITIES Authorised For Issue Prepared by.

......................................... 4 PURPOSE OF HAZID AND RISK ASSESSMENT ......................................................... 5 ATTACHMENTS...................................................................................................................................................HAZID AND RISK ASSESSMENT REPORT FOR THE USE OF ALLOY SCAFFOLDING ON Page iii OFFSHORE FACILITIES Contents BACKGROUND................................................... 5 KEY FINDINGS AND CONCLUSIONS .............................. 5 ACTION CLOSE-OUT .................................................................. 6 APPENDIX 1 WORKSHEETS EP200907328245 July 2009 .....................................................

Page 4 HAZID AND RISK ASSESSMENT REPORT FOR THE USE OF ALLOY SCAFFOLDING ON OFFSHORE FACILITIES BACKGROUND A Lean/Kaizen event was held on Brent Charlie during September 2008 which established a number of improvement opportunites to improve HSE risk exposure and efficiency of platform scaffolding operations. reduced manual handling and transportation wastes due to more strategic storage of materials and also the use of alloy scaffold materials. Brent Charlie had previously been testing an alloy system scaffold however the Kaizen event established this was not fot for purpose due to its fixed dimensions and as a result the use alloy scaffold tube was identified and developed as an opportunity. July 2009 EP200907328245 . In summary these opportunities included better planning. Susequent performance tracking and analysis has demonstrated the improvements on Brent Charlie have reduce carrying of materials by 50% and the overall task time per m3 of scaffold has reduced by 32%.

SORT4 Delivery Manager with Chris Grant. It was concluded from the risk assessment that there are no safety reasons why aluminium alloy scaffolding should not be used on offshore facilities provided the controls identified in the worksheets are adhered to. EP200907328245 July 2009 . The purpose of this HAZID/risk assessment was to determine what hazards there are associated with using aluminium alloy scaffolding systems offshore compared to the current practice of using steel scaffolding systems. This primarily concerns the use of scaffolding systems in Zone 1 hazardous areas and areas where it could be exposed to mecury contamination. A brainstorming session was used to prompt discussion of potential hazards. The worksheets recording the discussion from the HAZID and risk assessment are included as Appendix 1. Field Productivity Team acting as close-out coordinator. A presentation prepared by SORT4 addressing some of the safety concerns raised is attached to the document. Aberdeen. Unless otherwise agreed with the co-ordinator. ACTION CLOSE-OUT The following actions were raised during the HAZID and risk assessment session.HAZID AND RISK ASSESSMENT REPORT FOR THE USE OF ALLOY SCAFFOLDING ON Page 5 OFFSHORE FACILITIES PURPOSE OF HAZID AND RISK ASSESSMENT st A hazard identification (HAZID) exercise and risk assessment was completed on 1 July 2009 at Tullos. Responsibility for the close-out of the actions rests with Roger Esson. all actions should be st targeted for completion by 1 September 2009. The potential consequences and effects of these hazards were considered along with the controls in place to manage them and a qualitative assessment was made of the residual risks with these controls in place The following personnel attended the HAZID: Name Role Chris Wilson Safety Engineering Team Leader Chris Grant Field Productivity Team Scott Fraser Brent Operations Support Andy Fairnie SORT4 Delivery Manager (Brent) Roger Esson SORT4 Delivery Manager (CNNS) Hamid Iravani Corrosion Engineer Keith Greenwood Sort 4 SHEQC Advisor KEY FINDINGS AND CONCLUSIONS A number of safety concerns about the use of aluminium alloy scaffolding in an offshore environment were addressed during the HAZID and risk assessement.

.ppt (Compr.Page 6 HAZID AND RISK ASSESSMENT REPORT FOR THE USE OF ALLOY SCAFFOLDING ON OFFSHORE FACILITIES ATTACHMENTS Presentation prepared by SORT4 addressing concerns raised about the use of aluminuium alloy scaffolding systems in an offshore environment. July 2009 EP200907328245 .. Scaffold Alum Alloy.

HAZID AND RISK ASSESSMENT REPORT FOR THE USE OF ALLOY SCAFFOLDING ON Page 7 OFFSHORE FACILITIES APPENDIX 1 HAZARD IDENTIFICATION WORKSHEETS EP200907328245 July 2009 .

and this should be considered before they are used in a Zone 1 area. This mechanism is the most probable as it requires much lower impact energies (1-5 Joules) to initiate the spark. oily rags should be identified and removed prior to scaffold erection/dismantling. Subsequent impact sparking may occur from striking a previously deposited aluminium smear resulting from an earlier impact of an aluminium object on a rusted steel surface. Risk assessment for use of alloy in zone 1 areas to be built in to ISSOW system.g. The third mechanism is friction sparking.g. Alloy scaffold should not be used in Zone 0 classified ares unless the plant has been shutdown and hydrocarbon free.g. .Page 8 HAZID AND RISK ASSESSMENT REPORT FOR THE USE OF ALLOY SCAFFOLDING ON OFFSHORE FACILITIES HAZARD Incendive sparking Incendive sparking is initiated by an exothermic reduction of iron oxide (in the form of rust) by aluminium particles. CONTROLS RISK ASSESSMENT ACTION As per rcommended guidance in Hazardous Are Code IP15 “Standards for electrical and nonelectrical equipment for use in hazardous areas place restrictions on the use of light metals on the outside of equipment to prevent this risk. The first is single impact sparking and requires relatively high energy (minimum 300 Joules). Allloy scaffolding is already being used in other areas of the offshore industry e. To manage this risk it is recommended that Cat 2 hot work Work Control Certificate (WCC) is used for alloy scaffold in zone 1 areas. Once scaffold is built/in place risk is negligible. Grant to action with Production Services ISSOW owners. Any other flammable materials e. Norway and there is no evidence that incendive sparking is a source of ignition of hydrocarbon releases. The main risk associated with incendive sparking is associated with erection and dismantling of alloy scaffolding rather during it’s use for work activities. For the same reason. This is covered by the Cat 2 Hot Work WCC within Zone 1 areas for erection and dismantle only. Three basic mechanisms produce the pre-requisite conditions for incendive sparking. EP200907328245 C. This type of sparking is most unlikely to occur as the temperature caused by sparking are July 2009 POTENTIAL CONSEQUENCES Ignition risk in flammable gas environment Ignition of other flammable materials e. oily rags.” Based on the controls outlined the risk of incendive spark igniting flammable gas cloud on our facilities is considered to be very low and is acceptable. the use of aluminium ladders or scaffolding may create an ignition source. ACTION 1 Communicate requirement for Cat 2 Hot Work WCC for alloy scaffold use in Zone 1 areas.

Surface damage to the oxide coating is self repairing. Inspection carried out by competent person. Alloy corrosion rates are significantly smaller than those for steel tube in an offshore environment. Users conform to scaff tag and erected scaffold register systems. Materials are inspected at time of build and dismantle. Poor Scaffold Integrity due to mixture of tube materials (Variation in dynamic properties of steel and alloy EP200907328245 Failure of scaffold structure with potential injury to personnel and damage to Steel tube and Aluminium tube shall not be mixed during Scaffold construction. 7g/m2 alloy versus 933g/m2 steel over an 8 year period. Tube conforms to European standards for temporary structures. Visual inspections of erected structures are carried out weekly. ACTION Roger Esson Erected structures have a maximum 2 year build life. Corrosion due to salty environment Degradation of material leading failure which could lead to possible collapse of scaffolding The oxide coating formed on Aluminium and its alloys makes them resistant to corrosion.HAZID AND RISK ASSESSMENT REPORT FOR THE USE OF ALLOY SCAFFOLDING ON OFFSHORE FACILITIES HAZARD POTENTIAL CONSEQUENCES CONTROLS Page 9 RISK ASSESSMENT ACTION much too low to cause ignition. Damaged materials are quarantined. Any degredation of the alloy will be a slow process. In a designed scaffold where July 2009 With adequate training. Any signs of corrosion will be picked up by routine inspections before it becomes critical. Incorporate guidance in to SORT4 procedures on how to identify corroded alloy tubes that need to be taken out of service. E.g. the obvious weight difference between steel and alloy tubes and inspection of the build should ensure the risk is very Incorporate guidance in to SORT4 procedures to ensure tube materials are not mixed .

Corrosion due to dissimilar metals. This should continue until we can assure ourselves this is not an issue. ACTION Roger Esson Human Factors –An erected alloy structure feels different to steel structure to walk on Personnel feel unsafe or uncomfortable Communication. Scaffold Design Engineer sign off is required. alloy tube and steel fitting fittings Failure of scaffold structure with potential injury to personnel and damage to equipment Scaffold is a temporary structure and Company procedures specify that the erection time should not exceed two years. This applies to scaffold structures used as lifting frames. Historical use of alloy lifting beams and alloy lifting beams and system scaffold on Brent Charlie has not identified any corrosion problems if the scaffold is dismantled within this timeframe. ACTION Andy Fairnie Incorporate guidance in to SORT4 procedures to monitor any corrosion at tube/fitting interface as part of inspections. Genuine concern which needs to be address through staff engagement Incorprate in to SORT4 Q&A engagement pack ACTION Roger Esson Manual handling issues due to perceived additional material requirements July 2009 Unfamiliar with build requirements and use of alloy tubing Scaffold structures constructed in line with contractor procedures – alloy bay sizes are the same as EP200907328245 Brent Charlie pilot use analysis shows material carry time has been reduced by 50% and Review locations of scaffold storage racks to ensure proximity to . Inspection carried out by competent person. Damaged materials are quarantined. should ensure the risk is managed. ACTION ACTION Roger Esson Scaff tag system should identify any build issues. Introducing a sampled inspection of fittings. Materials are inspected at time of build and dismantle. as part of the weekly scaff tag recertification process.Page 10 HAZID AND RISK ASSESSMENT REPORT FOR THE USE OF ALLOY SCAFFOLDING ON OFFSHORE FACILITIES HAZARD tubing) POTENTIAL CONSEQUENCES equipment CONTROLS ladder beams are used. Confirm Alloy/Steel corrosion is not an issue with the controls in place via Draugen experience. RISK ASSESSMENT low. familiarisation and understanding of the new system. Visual inspections of erected structures are carried out weekly.

HAZID AND RISK ASSESSMENT REPORT FOR THE USE OF ALLOY SCAFFOLDING ON OFFSHORE FACILITIES HAZARD POTENTIAL CONSEQUENCES CONTROLS steel scaffold bays. ACTION worksite. Any signs of corrosion will be picked up by Incorporate guidance in to SORT4 procedures on how to identify corroded . Page 11 RISK ASSESSMENT overall task time reduced by 30% through the use of alloy tube and strategic storage locations. Non slip gloves such as Showa 310 or 377 should be used accoding to wearther conditions. especially chlorides marginally reduces durability but Aluminium July 2009 Any degredation of the alloy will be a slow process. ACTION Roger Esson Site supervision to ensure rules are adhered to. With adequate training and supervision the risk is very low. Alloy tube corrosion while in storage EP200907328245 Failure of scaffold structure with potential injury to personnel The occurrence of salts. This means the number of materials is the same. Incorporate in to training & awareness session to provide guidance on number of tubes to be carried. Incorporate alloy bay size guidance in to SORT4 procedures and commincate requiremts with offshore scaffolder staff ACTION Roger Esson Manual handling issues due to an increased number of alloy tubes being carried Injury to personnel caused by carrying too many tubes (which are much lighter than steel) The use of Aluminium tube reduces the Manual Handling impacts. therefore no extra manual handling. Envrionmental conditions should be assessed as part of worksite task risk assessment. Tubes may be slippery when wet Introducing guidance/caps on number of tubes to be carried. as the Aluminium tube is approximately one third the density of steel. Alloy tube 30% of steel weight.

Norway and there is no evidence that Mercury exposure is an issue. . Allloy scaffolding is already being used in other areas of the offshore industry e. N2 spread bund is non load bearing Mercury test are carried out prior to any vessel entry activities. Based on the controls outlined the risk of significant mercury exposue on our facilities is considered to be very low and is acceptable.g.Page 12 HAZID AND RISK ASSESSMENT REPORT FOR THE USE OF ALLOY SCAFFOLDING ON OFFSHORE FACILITIES HAZARD POTENTIAL CONSEQUENCES and damage to equipment CONTROLS is generally better than Carbon Steel RISK ASSESSMENT routine inspections before it becomes critical See above corrosion mitigation. ACTION Roger Esson Erosion of Alloy scaffold tube due to exposure to blasting activities July 2009 Failure of scaffold structure with potential injury to personnel Control measures in place for blasting to prevent damage caused by inadvertent blasting of EP200907328245 Task risk assessment and site contols ensure scaffold structures are not exposed to None required. special precautions should be taken to ensure no mercury spills occur. Link to ISSOW controls. Any alloy tube exposed to hydrocarbon spills should be removed and inspected. SORT4 to verify impact of Mercury impact on alloy tubing based on exposure levels on Shell installations by end of August 2009. ACTION alloy tubes that need to be taken out of service. ACTION Roger Esson Very low likelihood of liquid nitrogen coming in to contact with alloy scaffold due to bund design. Degradation of Alloy scaffold tube due to exposure to liquid nitrogen Failure of scaffold structure with potential injury to personnel and damage to equipment N2 spreads bunded as per procedures Degradation of Alloy scaffold tube due to exposure to mercury Failure of scaffold structure with potential injury to personnel and damage to equipment Hydrorcarbon systems are flushed and purged prior to any breaching. In the interim. None required. Incorporate guidance in to SORT4 procedures on how to identify corroded alloy tubes that need to be taken out of service.

HAZID AND RISK ASSESSMENT REPORT FOR THE USE OF ALLOY SCAFFOLDING ON OFFSHORE FACILITIES HAZARD POTENTIAL CONSEQUENCES and damage to equipment CONTROLS If any tube is blasted the job should be stopped and structure inspected. EP200907328245 RISK ASSESSMENT blasting. the scaffold tubes July 2009 Page 13 ACTION . Damaged materials are quarantined. Visual inspections of erected structures are carried out weekly. Inspection carried out by competent person.

Page 14 HAZID AND RISK ASSESSMENT REPORT FOR THE USE OF ALLOY SCAFFOLDING ON OFFSHORE FACILITIES July 2009 EP200907328245 .