hazard identification, risk assessment & safe working ......2013/10/13 · task: -...

C&P Engineering Services Ltd Ref. 13.2.11 Rev. 1 31.07.12 of 16

C&P ENGINEERING SERVICES LTD

INSTRUMENTATION & ELECTRICAL ENGINEERS Gorseinon Road, Gorseinon, Swansea, SA4 9GE

Telephone: 01792 897002 Fax: 01792 895193 Email: [email protected] www.cpengineering.co.uk

Hazard Identification, Risk Assessment & Safe Working Procedure for Installation of Instruments and Instrument

Tubing

Project Title:

Site Address: Cardiff Road, Barry, South Glamorgan, CF63 2YL

Client: Dow Corning Ltd

PO Number:

Work Location:

Assessed By:

Print Name Signature Date Assessed Assessment Review Date

Paul Bunyan

18/02/2014 17/02/2015

Approved By:

Print Name Signature Date Approved

Richard Jenkins

Steve Tossell





Hazard Identification

Physical Hazards Y Physical Hazards (Continued) Y Fire Hazards Y

Airborne Dust / Fumes Explosive Materials

Access / Egress Flammable / Combustible Materials

Adverse Weather Conditions Flammable Atmospheres

Aggression/Violence Pyrophoric Material

Bullying Sources of Ignition

Collapse of Equipment / Materials Static Electricity

Confined Space Entry

Crane Movements / Lifting

Display Screen Equipment

Drowning

Electricity - Electric Shock / Burns

Entanglement

Equipment / Materials Other Hazards – Specify Below Vulnerable Groups

Falling Objects / Materials from Height Environment - Waste Disposal

Falls from Height (Working at Height) Process Pipework Expectant and Nursing Mothers

Gas Cylinders Impulse Lines / Tubing Lone Workers

Gasses Young Persons

High Pressures

High Ambient Temperature

Hot Surfaces

Housekeeping / Slips, Trips& Falls

Low Ambient Temperature

Manual Handling / Ergonomic Biological Hazards

Moving Equipment/Machinery Blood Borne Pathogens / Body Fluids

Noise Hygiene/Welfare

Operating / Driving MEWP‟s Legionella

Oxygen Depletion / Enrichment Leptospirosis (Weils Disease)

Pneumatics / Hydraulics

Poor Lighting

Radiation

Sharp Objects Chemical Hazards

Stress Asbestos

Struck By / Against Corrosive Chemicals

Trapping Points Harmful Chemicals

Underground Services Irritant Chemicals

Uneven Work Surfaces Odorous/Noxious Chemicals

Use of Hand Tools / Power Tools Toxic Chemicals

Vehicles/Transport

Vibration





Risk Assessment Task: - “Installation of Instruments and Instrument Tubing” The following risk assessment has been completed to ensure adequate controls are in place to eliminate or reduce the risk to as low as is reasonably practicable. In considering who may be harmed we have included C&P Employees, but for each task, depending on where it takes place, then further consideration should be given to others who may be affected by our activities e.g. other contractors. L = Likelihood HR = Hazard Rating (with NO controls in place). C = Consequence RR = Risk Rating (with controls in Place).

HAZARDS L C HR WHO MAY BE HARMED

CONTROL MEASURES TO REDUCE THE RISK TO AS LOW AS IS REASONABLY PRACTICABLE

L C RR

1. Airborne Dust - Some plants may expose technicians to windborne dust.

5 3 15 C&P Employees

Safety glasses or goggles to be worn at all times. 1 3 3

2.Access and Egress on site 5 5 25 C&P Employees

Site Induction prior to job commencement. Authorisation to Work (permit) from client. Access and egress to each work area will be by roadways, fixed walkways and platforms at each process plant area. Access to some instruments may require working at height.

For working at height hazard controls please refer to C&P document reference 2.14.1 Working at Height Policy.

1 5 5







L C RR

3.Adverse Weather Conditions. Extremes of weather such as ice, snow, heavy rain, lightning storm etc. This is particularly important when working at height, using ladders, accessing/egressing steps and plant, driving on site.


PPE in the form of warm clothing, good quality safety boots, waterproof exterior clothing. Ability to postpone jobs in extreme weather conditions i.e. high winds, torrential rain when working at height

1 3 3

4.Working in Confined Spaces 5 5 25 C&P Employees

Site Induction. Site Authorisation to Work Permit. Confined Spaces permit. C&P watchman. Emergency rescue plan in place. RPE available and to be worn depending on „confined space‟. Resuscitation equipment on standby. Specific tools required (discuss with Plant personnel).

Only trained and certified C&P operatives to enter confined spaces.

2 5 10

5.Overhead Crane Movements causing struck by injuries. (Linked with working at height)


Where overhead cranes move overhead, either isolate cranes (plant to isolate or with their permission) or bellman required to alert Employees to stop work and move away from area.

1 5 5

6.Electricity - Contact with „live‟ electrical components causing electrical shock, burns or electrocution.


Only qualified and competent persons to work on electrical equipment.

All work on electrical equipment only to be carried out following isolation.

C&P Employees are competent to undertake the isolations. This must either be done at the local sub-station or at the fuse board.

For safe isolation please refer to C&P document reference 13.1.3 Safe Isolation Procedure for DEAD working on LV and ELV.

1 5 5







L C RR

7.Objects falling from Height


Permanent metal toe boards on process plant working platforms and on MEWP‟s. Good housekeeping across whole plant. When working at height area below to be cordoned off by use of bunting and signage to at least 10 metres. Items secured when being transported in a MEWP basket.

Discussion to take place at Induction to prevent other workers/contractors working immediately above Employees.

Where overhead cranes move overhead, either isolate cranes (plant to isolate or with their permission) or bellman required to alert Employees to stop work and move away from area.

2 5 10

8.Falling from Height (Working at Height) 5 5 25 C&P Employees

Where access to work area only requires a “step up” of a few centimetres then this can be achieved on most levels. Where the need to work at height exposes the individual to a fall to danger then additional controls will need to be in place. These will involve scaffolding platforms. MEWP to be supplied and maintained to a high standard. Trained and certificated C&P operatives to operate the MEWP.

Where Instruments are at height and close to platform edges then scaffold extensions should be requested. The scaffold extensions should be erected by recognised Scaffolding Company. Stepladders with handrails and Fibre glass ladders can be used in many locations where the work is of short

2 5 10







L C RR

duration and the height to work at is relatively low, ladders can be secured or footed and supported.

When working from stepladders near to platform edges and there has been NO scaffolding extensions attached to the handrail then full body fall arrest harnesses should be worn. Full body fall arrest harnesses are a last resort and should be worn in conjunction with other controls for working at height.

9.Gas / Oxygen Depletion


Individual gas monitors and procedures for evacuation from Process Areas. Regular Operational checks for gas leaks by trained and competent operators. Regular Planned Maintenance checks and repairs by client.

Site Inductions.

1 5 5

10.Impulse Lines /Pneumatics/Hydraulics- high pressure, corrosive chemicals


Where instruments involve impulse lines / pneumatics /hydraulics, they MUST be isolated prior to work commencement. Ensure isolation valves at tapping points are closed, isolate impulse lines at instrument manifold (if differential pressure ensure equalising valve is only opened AFTER closing high pressure and low pressure isolation valves and prior to opening drain valves/bleed screws. Be careful to open drain valves/bleed screws very slowly in the first instance and wear goggles and appropriate gloves whilst doing so)Do NOT assume impulse lines / pneumatics/hydraulics have been isolated – physically check i.e. tapping point isolation valves are closed, instrument manifold valves are closed, drain valves/bleed screws are open - open drain valves/bleed screws very slowly.

1 5 5







L C RR

11.Process Piping – In-line instruments, high pressure, corrosive chemicals


Where instruments are mounted in process lines i.e. “in-line” the process lineMUST be isolated and flushed out / cleaned / purged / spaded off (by client). C&P employees to discuss this with the client to make sure all precautions have been taken and Work Permit to include these precautions prior to work commencement.

1 5 5

12.Hot Surfaces 5 3 15 C&P Employees

Hot pipe work lagged/insulated. Signage.

If working on high temperature instrumentation, allow cooling if possible and wear protective gloves.

1 3 2

13.Slips, Trips and Falls due to poor housekeeping


Good housekeeping practices across site by the client provides for a safe place of work. Clear concrete pathways, roadways and signage. Painted walkways. Good safety footwear. Audits by Plant personnel. C&P standards in housekeeping, safety contacts provided and more specific training. Removal of all waste.

1 5 5

14.Manual Handling – carrying of equipment ladders, tools etc.

3 3 9 C&P Employees

Calibration instruments and hand tools are relatively lightweight (tools to be carried in single tool box). Removal of some Control Valves may be heavy. Individuals trained in Manual Handling techniques. Help required from Plant personnel or second C&P Calibration technician. Avoid Manual Handling where possible.

1 3 3

15.Moving Machinery / Entanglement / Trapping points - controlled by Client


Variety of operating machinery could be present in process areas. All moving parts to be guarded. No access beyond any guard or barrier protecting machinery. Permit to work in all plants.

1 5 5







L C RR

16.Noise


Certain areas of plant will require mandatory Hearing Protection in the form of Ear Defenders.

Ear defenders to be worn prior to and during time spent in these areas.

Signage.

1 3 3

17.Operating/driving MEWPS on site


Trained and competent operators holding certificate for Driving and operating MEWPS.

Equipment to be fully maintained and inspected.

Driver to use harness at all times when driving on site or when working from MEWP basket at height.

When stationary prior to work commencing outriggers must be fully deployed on solid, level ground. If ground is soft or uneven, boards are to be placed under outrigger legs.

Whilst working at height, operator is to control movement of basket from the basket and not the floor.

Operators working from basket not to over-reach or lean out of basket.

Under no circumstance are operators to exit the MEWP basket as a means of access to a place above ground level (except in an emergency). All loose equipment placed in the basket for use will be secured to ensure they cannot fall. The area around the base of a MEWP will be bunted and have cones to prevent collision from other vehicles and road users and also to prevent

1 5 5







L C RR

persons working or walking underneath.

18.Lighting 5 5 25 C&P Employees

Good plant lighting. Where plant lighting is poor, obtain temporary lighting, torch or head lamp may be used in non-hazardousareas (non-explosive atmosphere check with client personnel).

If working in potentially explosive atmosphere, torch or headlamp may be used providing they are certified to be used in explosive atmospheres. Permission to be granted by Client personnel and hot work permit may also be required.

1 5 5

19.Use of hand tools and power tools/ Entanglement / Trapping points – most calibration tools are not powered but there may be a requirement to use powered tools in the workshop or laboratory.


Drills and other power tools will be battery operated. Where this is not reasonably practicable then low voltage mains will be required (110v). See electrical controls above. PAT testing of mains operated tools. Secure cables. Non-Adjustable Spanners required in some plants (check at Induction).

No loose clothing or jewellery near to rotating chuck.

All hand tools to be clean and in good working order.

1 5 5

20. Vehicles and Transport – travel to site and use on site internal roads

5 5 25 C&P Employees, other road users

Use of company vehicles. Fully maintained vehicles with current MOT and insurance. Competent drivers holding appropriate licence for the vehicle. Vehicle pre-flight checks. All calibration equipment and tools stored safely in vehicle. Restricted access to site – only authorised vehicles. Road signs, road traffic standards, high way code. Pedestrian crossings. Park in designated parking areas only.

2 5 10







L C RR

21. Legionella 2 5 10 C&P Employees

Depending on site location of instruments to be calibrated. Client to provide information on potential Legionella presence by providing COSHH risk assessments. Wearing of RPE.

1 5 5

22.Contact with Chemicals on site - Different Process areas manufacture and use different types of chemicals i.e. toxic, corrosive, harmful etc.


Comprehensive Permit to work form required for all jobs undertaken on chemical sites. Client to provide details of hazards and precautions necessary for each process area including COSHH risk assessments.PPE in the form of chemical gloves to be worn on some sites.

1 4 4

23.Fire- flammable atmospheres, sources of ignition


No sources of ignition to be used or taken on to plant areas without a valid Work Permit for the task Some situations may require minor hot work but it is very unlikely. Agree any hot work necessary with client – agree permit required for hot work. Fire extinguishers and fire watchmen at area of hot work. Trained competent operators. Familiarisation with Plant specific Emergency Procedures and assembly points.

1 5 5

24.Lone Workers - Many of the Routine Operational checks are required to be completed by one person. Lone Workers, if injured, are more likely to go undetected and could exacerbate the seriousness of the injury due to delays in rescue and treatment.


Trained and competent operators. Personal radio or mobile phone (if working in potentially explosive atmosphere equipment MUST be certified). Personal gas monitor in some plants. Plant alarms. Call stations.

C&P lone worker policy and established protocol to call in to supervisor at regular intervals.

1 5 5

25. Environment - waste disposal 2 4 8 Environment Responsibly dispose of all generated waste by using client‟s on site recycling facilities.

1 2 2





Risk Matrix

First Aid Injury no disruption of activity

Minor Injury (preventing activity for one day)

Suffering (preventing activity for 3 days or longer

Major injury Fatal

Certain 5 10 15 20 25

Probable 4 8 12 16 20

Likely 3 6 9 12 15

Possible 2 4 6 8 10

Unlikely 1 2 3 4 5

Acceptable (1-5) No further action but ensure controls are maintained Adequate (6-15) Look to improve at next review Unacceptable (16-25) Stop activity and make immediate improvements

Safe Working Procedure Final Risk Rating The risk rating for the activity of “Instrumentation & Tubing” has a final Risk rating of “10“, if all the controls are applied at all times. Failure to implement the controls will lead to a higher risk of injury. The level of 10 is tolerable (yellow section 10-15) but improvements should be made to reduce the overall risk down to acceptable (Green section 1 - 4). This Risk assessment needs to be reviewed in the next 12 months (see review date). Persons and Competency All the C&P Engineering employees who install piping and containment must have been taken through this SWP and must sign the register to demonstrate that they understand the controls and how they are to be applied. Supervisor to plan the job by visiting site beforehand and calculating the piping routes

PPE Requirements Safety Footwear with minimum 200 Joules toe cap. The ankles must be protected. General Proban treated overalls General purpose gloves over surgical nitrile gloves (depending on the task). Safety helmet – centurion or equivalent Safety glasses or safety over-glasses to be worn if wearing their own prescription glasses. Goggles are mandatory in chemical splash areas. Ear Defenders are mandatory in certain process areas. High visibility waistcoat. Additional PPE dependent on local conditions. Plant Status Depending on where the job is being carried out, plant will quite likely be working. Mechanical and electrical isolations may be required for installation of piping and instrumentation. All systems to be worked on should





be isolated and tagged locked out accordingly in line with site procedures. No C&P personnel to break into existing lines and all first breaks to be carried out by the client where required. Permits, Certificates or Registers A general permit to work is required for all work locations and access onto process plant. Any isolation will be recorded on this permit. A separate hot work permit is required for battery operated equipment. Access and Egress Before accessing any part of a process plant then an authorisation from the client will be required and their permit to work procedure will be followed. Access and egress will be by recognised walkways, pavements, road crossings, stairways. Instrument Installation

1. Report to the permit office before accessing process plant areas. Obtain a site permit to work and comply with all requirements stated and explained verbally by the issuer. Additional PPE stated as well as mandatoryPPE must be worn. Agree access and egress routes. Agree any isolation required before commencing work.

2. Where process plant isolations are required, obtain an isolation permit from the site personnel on completion of the relevant isolation, confirming that the correct isolation has been made.

3. If a local isolation is adequate, obtain permission from site personnel prior to carrying out the isolation.

4. Follow C&P manual handling guidelines when taking instruments to the work site.

5. Where instruments involve impulse lines / pneumatics / hydraulics, they MUST be isolated prior to work commencement. Ensure isolation valves at tapping points are closed, isolate impulse lines at instrument manifold (if differential pressure ensure equalising valve is only opened AFTER closing high pressure and low pressure isolation valves and prior to opening drain valves/bleed screws. Be careful to open drain valves/bleed screws very slowly in the first instance and wear goggles and appropriate gloves whilst doing so)

6. Do NOT assume impulse lines / pneumatics / hydraulics have been isolated – physically check i.e. tapping point isolation valves are closed, instrument manifold valves are closed, drain valves/bleed screws are open - open drain valves/bleed screws very slowly.

7. Where instruments are mounted in process lines i.e. “in-line” the process line MUST be isolated and flushed out / cleaned / purged / spaded off (by client). C&P employees to discuss this with the client to make sure all precautions have been taken and work permit to include these precautions prior to work commencement.

8. If working on high temperature instrumentation, allow cooling if possible and wear protective gloves.

9. Remove the instrument concerned, and if being replaced, install new instrument in its place.

10. Discuss with the permit issuer when the works are complete and following the above procedure in reverse if reinstating the lines. Ensure any spades or line breaks are reinstated by the client or their representative, including any isolations made by them.

11. If the installation is new, then install the instrument where identified utilising the supplied brackets and fixing bolts. Follow the manufacturers‟ recommended procedures for installation.





12. If required, mount enclosure boxes or instrument stands, prior to taking the instrument to the work site.

13. If large valves require installation, then ensure qualified personnel are present such as the client‟s mechanical team to assist with lifting the item, and bolting into position.

14. If the installed item requires any instrument tubing, then the following procedures need to be followed.

Procedure for Tubing Installation.

1. Wear the PPE that is required for the particular process area that you will be working in. N.B. There is minimum requirement as highlighted in the PPE section above for all areas. Ensure that PPE is in good condition and affords adequate protection.

2. Report to the permit office before accessing site. Obtain a client permit to work and comply with all

requirements stated and explained verbally by the issuer. Additional PPE stated must be worn. Agree access and egress routes.

3. Travel to the building/site area by company vehicle if necessary and park appropriately.

4. Where tubing or containmentto support tubing is delivered in bundlesby lorry, then arrangements

must be made prior for off-loading. A HIAB or Fork Lift Truck may be required to off-load. Ensure lifting plan and a competent person in charge of lifting operation has organised the lift. Ensure sufficient space created to off-load in a suitable accessible position as near to the site of work as possible.

5. Where a HIAB is used then a „lifting Plan‟ must be created prior to commencement of job.

Driver/operator to be fully trained and competent in HIAB lifting operation.

6. Where a mobile crane is required to off-load tubing at height, then the load must be secured. Area around crane to be cordoned off. A banksman will ensure that all persons are clear during crane lift and that all other persons are aware of the lifting activity. Only a competent person trained in slinging techniques to attach lifting slings. Lifting equipment must be to the approved standard with certification of testing and thorough examination. Lifting plan required for mobile crane and a competent person in charge of Lifting operation.

7. Cut banding strap once the bundles have been positioned on site. Stand clear as sections may

spring open.

8. Two men to carry individual bundles into position. Where 3 metre smaller lengths are being used, then two men are still required to bundles especially if carrying them up stairways etc. Where tubing has been purposely cut to size or are of short lengths, then this can be done by one person.

9. If tubing is required to be positioned vertically and are 6 metres in length, then they should be

handled by two persons. Scaffolding should be erected at specific heights to allow easy handling of the lengths. Where it is too difficult to erect scaffolding then one man should be positioned at height and the other below to assist with the installation. Where anyone needs to lean over to manipulate them into position then they must wear a fall arrest harness.

10. The tubing could be temporarily tied in position whilst the permanent brackets to support the tubeis

installed. Where no permanent brackets are in situ, then these need to be installed or welded in place, preferably before the support trays/unistruts are fitted. In some areas where it is difficult to attach permanent support brackets then pipe clamps can be used to clamp unistruts to fixed hand





railings with client‟s permission, ready to support the tubing. The appropriate clamps can then be fitted to the support work ready for the tubes.

11. Tubing can be fitted from a stepladder providing the top of the ladder has handrails fitted. The step

ladder must be erected on level, stable ground. If at height and close to a platform edge then a fall arrest harness must be worn. Scaffolding may also be erected on top of the handrail as an extension.

12. Install appropriate clamps onto the supports and install tubing accordingly.

13. If it requires bending or setting, ensure the bender is in good working order, prior to use.

14. Carry out appropriate flushing or pressure testing of the tubes, if identified within the specification.

15. If tubing is required to tap in points, ensure the isolation process stated above is followed prior to

installation.

16. If a new line has been installed, ensure the correct tap in point is identified prior to installation.

17. If instrument air/nitrogen is required to the item, gain permission from the permit issuer prior to any supply being turned on.

18. On completion of the job all waste material to be removed from site and re-used or disposed of responsibly.

19. When installation is complete, ensure the permit is cancelled.





Emergency Procedures – Telephone 3333 Internally In the event of an emergency and depending on the site and access to such, the emergency services should be called using the internal emergency number. Raising the alarm is our first priority. All C&P employees must report to their appropriate place of safety, if the alarms aresounded. You must stay at this location and report to the Client representative. Follow the directions of the Client personnel in charge at the muster point. Lifting an eye wash station or stepping on a safety shower will raise alarm to DC Control, who will send assistance to the areaaccordingly.

Dow Corning Alarm Signals Klaxon 3 seconds on 3 seconds off – Major Incident All personnel to report to their nearest muster point indoors immediately. Swipe badge on Muster Reader. Fire Alarm Bells All personnel to report to their nearest fire assembly point outside immediately. Blue Flashing Light -Outside a Building No personnel to enter the building until advised by a DCL member. Audible Alarm and Red Flashing Light on Process Plant All personnel to make their work area safe and leave the area. No return until advised by a DCL Member. Note: If the last page of this document is not attached do not worry as it does not contain any relevant information regarding the SWP. The last page is a register of signatories and is intended to be detached and returned to Gorseinon head office for filing.





Hazard Identification, Risk Assessment & Safe Working Procedure for Instrument Calibration on Client’s Site in Situ (and at Client’s Workshop).

The above document has been read and explained to me by my supervisor. I the undersigned understand the controls and how they are to be applied.

Print Name Signature Date

The following comments/queries were raised and discussed with my supervisor (Please insert below any concerns, comments or views which may identify additional problems):

** THIS PAGE IS TO BE SIGNED, DATED, DETACHED AND RETURNED TO GORSEINON HEAD OFFICE A.S.A.P. (VIA FAX, EMAIL, POST OR HAND) **

hazard identification, risk assessment & safe working ......2013/10/13 · task: -...

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