Risk assessment form

Name of assessor Ch. Ahmed Moawad Date 05.05.2020

10:00 am PVC Unit – Egyptian Petrochemical Co.

Time Work area

Maintenance of Reactor-5 agitator (Reactor with Top manhole, agitator and 9 m depth for the conversion of VCM to PVC )
Task being assessed

New risk
rating
How might Existing risk Risk rating (Residual) Action/ Action/
What is the Who might be
people be control Additional controls monitored by monitored by
hazard? harmed?
harmed? measures whom? when?
L C R L C R

1) Hazardous
atmosphere

- Chemical Entrants and Multiple Fatality - Issuing 4 5 20 - Flushing all lines and 1 3 3 Before entering
hazard through nearby workers. confined space the reactor with water the C.S
Exposure to entry permit. then decrease pressure Area
Toxic gases like by vacuum compressor supervisor,
VCM - Gas to atm. pressure then
monitoring Purging by steam to
before the job. eliminate any trace of
toxic gas.
- Negative - Positive mechanical maintenance Before and
mechanical isolations by blinds Supervisor During the job
isolation by and valves for all in/out
valves only lines according to
P&ID.
- Mechanical Before the job
Ventilation (blowers)
for sufficient time.
- provide MSDS of VCM HSE officer
-Continuous gas Before and
monitoring. during the job.
- TBT should be done.
- Only authorized and
trained personnel are
allowed to enter CS.
-Stand by man and During the job.
rescue equipment
 (SCBA, Life Line,
Radio, First aid kit)
shall be available at
manhole.
- Safety signs shall be
install highlighting the
possible presence of
hazardous atmosphere.
-work area should be
barricaded.
- Inspected and Entrant Before and
certified Air-Supplied during the job.
Breathing RPE should
be used.

- Fire Hazard Entrants and Serious burns, - Issuing 4 5 20 - Flushing all lines and 1 5 5 Area Before the job
from flammable nearby workers. multiple fatality, confined space the reactor with water supervisor
gases property entry permit. then decrease pressure
damage and/or by vacuum compressor
environmental - Gas to atm. pressure then
pollution. monitoring Purging by steam to
before the job. eliminate any trace of
flammable gas.
- Negative - Positive mechanical Job During the job.
mechanical isolations by blinds supervisor
isolation by and valves for all in/out
valves only lines according to
P&ID.
- All equipment
(Blowers) should be
certified EX-proof).
- Using anti-spark
tools. Before and
- Fire watcher and HSE officer during the job.
suitable fire
extinguishers in place.
- Continuous gas
monitoring.
-work area should be
barricaded.
- Prevent SIMOPS.
- TBT should be done.
- Ensure wearing full
PPE specially fire
retardant coveralls.
- Work Entrants Multiple fatality - Issuing 3 5 15 - Positive mechanical 1 4 4 Job Before and
environment or confined space isolation. supervisor during the job.
Asphyxiation entry permit. - Personal oxygen
hazards due to detector with entrants.
lack of oxygen - Gas - Decrease the number
monitoring of entrants as possible. HSE officer
before the job. - using Air supplied
breathing devices.
- Negative - Stand by man and
mechanical rescue equipment
isolation by (SCBA & Life Line,
valves only Radio, First Aid Kit)
shall be available at
manhole.
2- Exposure to Entrants and Serious Injury C.S permit 4 4 16 -Decrease the pressure 1 2 2 Area Before the job
high pressure nearby workers. or Fatality issued. to atm. pressure by supervisor
/ Property vacuum compressor.
damage. - Open all vents and
drains before starting
the job.
- Ensure that the HSE officer Before the job
pressure inside the
reactor is zero from
pressure gauge or DCS
operator.
-Work area should be During the job
barricaded.
- Open manhole or maintenance
flanges bolts slowly Supervisor
and start from the
opposite point from Before and
worker body. during the job.
- All pressurized gas
cylinder should be kept
out of the C.S.
- Competent workers to
do the job.
- TBT to be done. Before the job.
 New risk
rating
How might Existing risk Risk rating (Residual) Action/ Action/
What is the Who might be
people be control Additional controls monitored by monitored by
hazard? harmed?
harmed? measures whom? when?
L C R L C R

3- Electrical and Entrants Serious injury - Cold Permit 3 5 15 -Positive Electrical 1 5 5 Area Before the job.
Mechanical or fatality and electrical Isolation from supervisor,
hazard from isolation substation. electrical
sudden certificate are - Implementation of supervisor
operation of issued LOTO system. and
mixer inside the - Negative - Ensure the right mixer maintenance
reactor. electrical has been isolated by supervisor
isolation from trying to operate it from
local switch. local switch and also
ensure from tag
number.
- Decrease the number
of entrants.
-TBT should be done.
- Work done by
competent persons
4- Slipping and Entrants Injury No control 4 2 8 - Elimination of unused 1 2 2 Job Before and
tripping measures exist. tools and materials. supervisor during the job.
hazards from - Housekeeping for the
wires and tools C.S.
inside C.S. - Provide adequate
lighting.
- Decrease the number
of entrants.
- Wires and cables
entered from special
opening away from
entrants’ movements.
- Use adequate PPE
(safety shoes anti Entrants
slippery)
5- Falling Entrants Injury Unfixed and 4 3 12 - Use inspected and 2 2 4 Job Before and
Hazards when uninspected well-fixed ladder. supervisor during the job.
entering the ladder. - Competent persons.
reactor from top - Use of Tripods with
manhole. hoist, lifeline, and full
body harness.
- Use ladder with 3 - Entrants
points of contacts.
- Use PPE ( Safety
shoes and gloves)

6- Poor lighting Entrants Injury Opened 3 3 9 - provide adequate and 1 2 2 Area Before and
manhole safe lighting (Ex-proof supervisor during the job.
and connected to 24 or
12 V electrical sources.
- Inspection of HSE officer Before and
insulation of all wires. during the job.
7- Emergency All worker Injury No control 3 4 12 - All workers must 1 2 2 All workers Continuous
case measures exist follow the proper
Damage to emergency procedures
equipment - All workers must
follow HSE
Fatality representative
instructions.
- Drill plan must be
implemented. HSE officer
- Check emergency
equipment on regular
basis
- Access ways must be
cleared all the time.
- Ensure all workers are
inducted and aware of
Emergency cases
response
- Warning signs
- Assembly points are
well defined
- Fire Extinguisher and
SCBA to be provided
Review date 01.01.2021 Signature Ahmed Gamal

Gulf
Training Provider name
 Motor

- Polymerization reactor
with top manhole, 9 m depth and
agitator for mixing and distribution
of reactants

-It converts vinyl chloride monomer

(VCM) which is toxic and flammable
to Poly vinyl chloride (PVC) powder
used in many industries.