RPNC151982

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Encourage workers to express concerns and suggest
improvements on health and
safety issues (for example, through safety talks, m
eetings, or consultation with
contractor supervisor).
7. SAFE WORK PRACTICE
The Safe Work Practice (SWP) includes:
1)
Safe work practices – General
2)
Safe work practices – hand lancing
3)
Safe work practices – flex-lancing
Safe work practices – General:
Personal protective equipment
When performing any high pressure washing activity,
protect operator from hazards by
wearing the following personal protective equipment
(PPE):
Safety Helmet
Safety Shoes
Face shield
Hydrojetting Suit (PVC/ TST/ Turtle)
Hand protection (rubber gloves)
When indicated in the hazard/risk assessment, addit
ional personal protective equipment
may be required. Safety garments specifically desig
ned to protect workers from exposure to
chemical substances, heat, cold, noise, and so on m
ay be required where other controls do
not adequately protect workers.
Crew size
At least three workers should be involved in a high
pressure washing operation:
A pump operator to control the high pressure pump
A lance operator to control the cleaning lance
A third worker to assist as necessary by
–– Managing hoses
–– Providing relief
–– Controlling access to the work area
–– Establishing effective communication with the pu
mp operator
where there is no line of sight between the pump op
erator and the lance operator.
RPNC151982
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Where the contractors SOP do not specify the minimu
m number of workers required, a risk
assessment must be done to determine the requiremen
t. Where there is direct line of sight
between the pump operator and the lance operator, i
t may be possible to use a crew of only
two workers.
Pre-use inspections
Pre-use inspections of all high pressure washing eq
uipment and components must be done.
Inspections should include, at minimum,
• The items identified in the operator’s manual
• The rejection criteria for each inspectional ite
m
Rated components
The maximum allowable working pressure (MAWP) of an
y high pressure component is
determined by the manufacturer based on engineering
principles and anticipated operating
parameters. Where components of differing MAWP will
be used within a high pressure
system, a pressure limiting device (engineered cont
rol) should be used to limit the system
pressure to no more than the lowest MAWP of any com
ponent. The use of administrative
controls alone (matching nozzle size to pump output
to limit pressure) does not provide
effective control of an over pressurization situati
on in the event of an upset condition (such
as a plugged nozzle).
Whip checks
Hoses must be connected by means of properly rated
couplings, with “whip checks” in place.
A whip check is a short length of reinforced nylon
cloth or cable looped over each end of two
hoses that are connected by a coupling. Whip checks
are designed to prevent the ends of
the hoses from whipping around if the coupling brea
ks.
Hose layout
Hoses should be laid out to avoid areas of frequent
foot traffic or areas where mobile
equipment may cause damage to the hoses. Where poss
ible, suspend hoses over
doorways, avoid stairwells, and lay hoses next to b
uilding walls. Hoses that are suspended
must be tied off in a manner that prevents excessiv
e sway, avoids undue strain on fittings,
and does not create short-radius bends in the hose.
Worker positioning
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Work activities should be planned to provide reason
able access to the equipment being
cleaned. Overhead work should be avoided as it can
cause unstable worker positioning, can
lead to musculoskeletal injury, and is highly ineff
icient.
Work platforms
Adequately sized work platforms must be used to pro
vide workers with safe access to
elevated work areas. Work from ladders or surfaces
not intended for workers can lead to
loss of control of high pressure washing lances.
Work area
The work area must be clearly identified and contro
lled with effective signage and barrier
tape to restrict access to authorized workers only.
Additional personnel or physical barriers
may be required to restrict access to areas not vis
ible to the operators. Barricading tape
shall be provided in open area and hard tin sheet b
arrier upto 4 M. Height shall be provided
in occupied area.
Safe work practices- Hand Lancing
Hazards
Where manual high pressure washing is used for clea
ning surfaces (such as tank walls,
vessels, or exterior surfaces of equipment), the pr
ocess is known as “hand lancing.” Other
common terms are “shotgunning,” “blasting,” and “gu
nning”.
There are four main hazards when hand lancing:
Operator contact with the water jet due to modific
ation of equipment.
Loss of control of the jetting gun due to poor fo
oting and positioning, exposing others
to risk of contact with the water jet.
Component failure due to improper use, exposing t
he operator tocontact from high
pressure water or damaged parts
Failure to maintain an adequate safe work zone, e
xposing other workers to risk of
contact with the water jet or debris
The object to be cleaned must not be hand-held or
secured with the foot or another
body part. Small objects must be securely fastened
to a vice or similar tool.
When hand lancing, the operator should always mai
ntain a body position that affords
the greatest control of the lance.
Where multiple lance operators are cleaning in a r
estricted area eg. workshop, a
physical barrier should be installed or safe work p
rocedures developed to ensure that
adequate spacing is maintained between the workers.
Work areas must be maintained and cleared of debri
s to provide firm footing for
workers.
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Lighting and ventilation of confined spaces must b
e adequate to ensure that workers
have good visibility and clean, respirable air.
Reaction forces should be considered and regulated
based on the ability of the
worker to maintain control of the jetting gun. Wher
e a higher reaction force is
required, consider the use of mechanical devices to
 complete the task.
Never use the jetting gun as a pry bar or in any o
ther fashion that would place undue
stress on any part of the gun.
Never modify the jetting gun with shorter barrel
lengths than originally equipped or
with trigger devices. Only a manufacturer’s authori
zed modifications are acceptable.
Never leave a high pressure system unattended. Alw
ays disengage the high
pressure pump when workers will not be in the immed
iate work area.
Never point a jetting gun at anyone, whether unde
r pressure or not.
Never use a device or tool to hold down the trigg
er on a jetting gun. The trigger must
always be operated by hand only.
Pump, augers and conveyors
Ensure that equipment is locked out when there is a
ny risk of workers or high pressure
washing equipment coming in contact with rotating o
r moving components.
Confined spaces
Ensure that the confined space risk assessment inc
ludes the potential for release or
creation of hazardous air contaminants. When high p
ressure water is used to clean a
surface, toxic materials can be released as fine, a
irborne particles. Use appropriate
respiratory protection as identified in a risk asse
ssment.
Ensure that lighting is designed for use in wet ap
plications and is powered by an
electrical panel with appropriate ground fault circ
uit interrupters.
Safe work practices- Flex Lancing
The use of high pressure water to clean the interna
l surfaces of tubes or piping is called flex-
lancing.
Hazards
Where high pressure washing is used for cleaning th
e internal surfaces of tubes or piping
(e.g., heaters, evaporators, and process piping), t
he process is known as flex-lancing. For
RPNC151982
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pipes that are long or that have bends in them, a f
lexible lance (or flex-lance) is usually
employed. The flex-lance is typically a hose with a
n inside diameter between
⅛
inch and ½
inch. A self-propelled cleaning head or nozzle atta
ched to the end of the flex-lance is
inserted into the pipe or tube and moves forward th
rough the pipe or tube as water blasts out
in different directions under high pressure.
There are four main hazards when flex-lancing:
The operator loses control of the flex-lance when
cleaning near the open end of the
pipe, and the nozzle exits the pipe.
The nozzle turns around inside the pipe (line reve
rsal) and exits the open end.
The nozzle exits the far (open) end of the pipe, e
xposing other workers to the risk of
contact with a water jet.
There is not enough room between the nozzle and th
e wall of the tube or pipe to
allow water or debris to pass. Pressure builds up,
and the flex-lance is forced
backward, toward the operator. (This situation is c
alled “hydraulicing.”)
General
The flex-lance operator should stand in a position
that is safe and allows control of
the flex-lance.
The flex-lance operator must always maintain contr
ol of the flex-lance.
The flex-lance operator must operate the foot dump
valve. The operator can react
more quickly than any other worker if the pressure
must be decreased quickly.
Keep the length of hose between the flex-lance ope
rator and the pipe or tube as
short as possible. Long hoses store a great deal of
energy, and flex-lances have a
tendency to recoil.
Use a work platform or scaffold to provide stable
footing if the flexlance operator
needs to be raised to a safe working position. The
platform must have enough room
for the flex-lance operator to operate the foot dum
p valve and maintain control of the
flex-lance.
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Keep the working surface, including any platform o
r scaffold, clear of debris that may
accumulate during the cleaning process.
Depressurize the flex-lance before removing it fro
m a pipe or tube.
Use a stinger when completing any flex-lance clean
ing. The stinger must be long
enough to ensure that the nozzle cannot turn back o
n itself inside the pipe (line
reversal). Generally, a stinger with a length equal
to the maximum inside diameter of
the pipe will prevent a line reversal.
Never place your hand over a jetting nozzle.
To help avoid hydraulicing, use a hose and nozzle
assembly with a diameter no
larger than two-thirds the inside diameter of the t
ube or pipe.
8. RISK ASSESSMENT AND CONTROLS
Written safe work procedures are required for all h
igh pressure washing operations. The
foundation of an effective safe work procedure is a
comprehensive risk assessment/ JSA.
A risk assessment helps to determine the likelihood
that hazards will lead to an injury or
occupational disease based on three primary factors
:
The probability of a hazardous event’s occurrence
A person’s exposure time to a hazardous event
The consequence of the hazardous event’s occurrenc
e
Conducting a risk assessment for each type or proce
ss of a high pressure washing task is
essential in identifying the relative risk to worke
rs from any of the hazards. Once risk factors
are identified, effective controls can be implement
ed to protect workers.
As shown in the following table, a typical hierarch
y of controls considers several steps in the
effort to eliminate or reduce worker exposure to ha
zards.
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9. FIELD EXECUTION
The Hydrojetting Machine at all times should have
safety equipment in tested and
good working condition.
Pressure Gauges, Safety Valves etc. should be cali
brated. Verify the Calibration &
Test certificates.
HP Hoses should have valid test certificate for Pr
essure Test (Marked with
MAWP)and visually checked for cuts /damage etc., be
fore putting it in use every
time.
Engineer- In – Charge or his nominated engineer sh
all carry out following checks on
arrival of any hydro jetting machine at our site as
per the checklist (Annex.-1-
Preventive Checks for Hydro jetting Machine).
Visual Inspection of the hydrojetting machine & Ac
cessories.
Above checks/ inspection will be carried out after
every three months of deployment
of the machine at site.
Check the details of experience /training provided
by the contractor.
Contractor’s Manpower deployed on hydro jetting jo
b should have minimum of 3
years working experience of hydro jetting operation
. Persons must have undergone
detailed training about working of the machine and
accessories like HP lances, HP
hoses, Safety valve, Pressure gauges etc.
Contractor will be required to give a written con
firmation about experience of hydro
jetting operators
.
Contractor’s manpower will undergo Safety Inductio
n training Program conducted by
Fire & Safety Dept. before issuing the entry gate p
ass.
Hydojetting operation shall be carried out under h
ot work permit. Take other permit
as applicable (Height, confined space etc.)
Personnel involved in hydro jetting must wear PVC/
TST/Turtle suit, face shield, Gum
boots, rubber gloves besides other regular PPEs.
If the hydro jetting machine and other electrical
fittings are not flame proof , it shall
be kept in a safe area.
The area around the hydro jetting should be proper
ly cordoned with barricading tape/
tin sheet to prevent unauthorized persons entering
into hydro jetting area.
No person, authorised or unauthorised should stand
in the opposite direction of hydro
jetting. i.e. when the lance is inserted inside the
tube bundle of exchanger , opposite
end of the tube bundle should be hard barricaded so
that no person goes in the
danger zone.
Hydojetting operator should ensure that HP lances
& water jets are never directed
towards persons.
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Protect electrical cables or temporary electrical
connections passing through area
from being hit by water jet.
Hydrojetting machine is driven by a 3 phase, 440V,
75-150 kW rating electrical motor
.The 3 phase power connection to the electrical mo
tor shall be carried out by a
competent electrical technician in the plant Electr
ical supervisor in the plant will
check & ensure the same.
The cable used for power supply to the motor should
be of correct capacity, without
joints and properly terminated in the junction boxe
s or switches at both ends.
Machine should have proper fuse & switch etc. of sp
ecified rating.
The electrical equipment should have proper insulat
ion values and double earthing
connections to prevent electrical shock even in wet
conditions/water splashing etc,
common on site during the jetting operations.
Diesel engine operated hydro jetting machines shoul
d have flame arrestor on
exhaust of diesel engine and should be used in hydr
ocarbon free area. Hot permit
must be taken before start of hydro jetting operati
on/ start of engine.
Apply back-out preventers where there is a change
of hose/ nozzle rebounding.
Tool Box talk shall be given to workers and superv
isors before commencement of the
job.
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Annexure – 1
Preventive Checks for Hydrojetting Machine
Contractor's Name :
Machine
S.No. :
Date of checking :
Rat
ing :
Sr. No.
Checks Description
Remark
I Motor and Control Panel Checks:
1
Insulation resistance value of the motor
2
Winding resistance value of the motor
3
Electrical power cable termination
4
Earthing provision (Double earthing)
5
Wiring termination
6
Relay setting
7
Insulation resistance valve of the panel
8
Monsoon protection.
II
Power & Fluid End Checks:
1
Thoroughly clean equipment, area form oil & d
irt.
2
Check free rotation of the pump after removin
g guard and refix.
3
Check coupling condition for any cracks, dama
ges, etc.
4
Check the condition and level of gear box oil
.
5
Clean pump suction strainer and filter.
6
Check plunger pump for any packing leakages.
7
Check for any leaks from fluid end gland.
III Accessory Checks
1
Check physically the condition of Flexible ho
se, wear of lance, Nozzle head
2
Check for the tightness of connecting joints
and coupling of alliances, dump valve,
regulating valve and flexible hose. (Only standard
fittings, spares and hoses supplied
by the manufacturer to be used)
3
Check physically operation of dump valve, High
Pressure shut off valve and
regulating valve.
4
Hydro testing of flexible hose at rated press
ure of the equipment - check report.
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5
Gun Nozzle O ring and trigger operation to be
checked at low hydro pressure. (If
being used in the machine)
6
Calibration of safety valve, pressure gauges at
rated pressure of the equipment -
check report.
IV
Checks during trial and before operation of the
machine
1
Check for operation of ON/Off isolator switch
.
2
Motor abnormal sound and vibration if any
3
coupling abnormal sound, if any
4
Gear box and pump abnormal sound, vibration and
bearing temperature.
6
Check functioning of dump valve, pressure reg
ulating valve, pressure gauge.
7
Check the surrounding area is cordoned off an
d no other operation is undergoing in
vicinity.
8
Clean visibility of panel standby person and
operator.
ANY OTHER ABNORMALITIES:
___________________________________________________
______________________
___________________________________________________
______________________
CHECKED BY:
MECHANICAL MAINT.
ELECTRICAL MAINT.
NOTE
1.
Equipment should not be operated at equipment ra
ted pressure continuously but
10% less. Safe operating pressure shall be 10% less
than rated.
2.
All Personal Protective Equipment viz. Helmet, F
ace shield, Goggles, Wet suit jacket
and pants, safety rubber gloves, gum boots with met
al foot guards should be used.
3.
Details of authorised personnel and supervisor
working shall be available with shift in
charge.
4.
Standby person shall be continuously available
at panel to switch off the unit as
required.
Certified for operation:
YES/NO-
MECHANICAL
ELECTRICAL
SIGNATURE
NAME