16565asda5-HSE-Manual
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HEALTH, SAFETY & ENVIRONMENT DEPARTMENT
Issue 02, Rev 05
ADGAS HSE MANUAL
Date: August 2006
CONTENTS AND REVISION
Chapter No. 0
ABU DHABI GAS LIQUEFACTION COMPANY LIMITED
HEALTH, SAFETY & ENVIRONMENT MANUAL
HEALTH, SAFETY AND ENVIRONMENT DEPARTMENT
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HEALTH, SAFETY & ENVIRONMENT DEPARTMENT
Issue 02, Rev 05
ADGAS HSE MANUAL
Date: August 2006
CONTENTS AND REVISION
Chapter No. 0
HSE MANUAL TABLE OF CONTENTS 0
CONTENTS AND REVISION ................................................................................................................... 5 0.1 0.2
1
GUIDE TO THE MANUAL ....................................................................................................................... 9 1.1 1.2 1.3 1.4
2
UNITED ARAB EMIRATES LEGISLATION .................................................................................. 22 HEALTH SAFETY AND ENVIRONMENT POLICY STATEMENT .................................................. RESPONSIBILITIES ......................................................................................................................... 25 SAFETY COMMITTEES................................................................................................................... 31 MEETINGS ........................................................................................................................................ 42 EMPLOYEE INVOLVEMENT ......................................................................................................... 43 PLANNED INSPECTIONS................................................................................................................ 44 QUALITY ASSURANCE .................................................................................................................. 52 DIVISIONAL STANDING INSTRUCTIONS ................................................................................... 53 TASK RISK ASSESSMENT ..................................................................................................................... 54 AREA AUTHORITIES ...................................................................................................................... 71 MANAGEMENT OF CHANGE ........................................................................................................ 77
GENERAL AND PERSONAL SAFETY ................................................................................................. 83 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 3.9 3.10 3.11 3.12 3.13 3.14 3.15 3.16
4
INTRODUCTION ................................................................................................................................ 9 USING THE MANUAL ..................................................................................................................... 11 MAINTENANCE OF THE MANUAL .............................................................................................. 14 ABBREVIATIONS AND ACRONYMS............................................................................................ 15
SAFETY MANAGEMENT ....................................................................................................................... 22 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 2.10 2.11 2.12
3
RECORD OF REVISIONS ................................................................................................................... 5 REVISION REQUEST ......................................................................................................................... 7
SAFETY INDUCTION ...................................................................................................................... 83 VISITORS .......................................................................................................................................... 84 RESTRICTED AREAS ...................................................................................................................... 86 HAZARDOUS AREAS AND ZONES ............................................................................................... 86 HOUSEKEEPING .............................................................................................................................. 90 WASTE MANAGEMENT ................................................................................................................. 91 PERSONAL SAFETY ........................................................................................................................ 95 SAFETY SIGNS AND BARRIERS ................................................................................................... 96 PERSONAL PROTECTIVE EQUIPMENT ..................................................................................... 100 MANUAL HANDLING ................................................................................................................... 111 HEARING CONSERVATION ......................................................................................................... 118 EYE SAFETY PROGRAMME ........................................................................................................ 123 VEHICLES AND BICYCLES .......................................................................................................... 125 HEAT DISORDERS ......................................................................................................................... 129 SAFE ACCESS AND WORK PLACES ........................................................................................... 133 OFFICE SAFETY ............................................................................................................................. 137
HAZARDOUS SUBSTANCES ............................................................................................................... 145 4.1 4.2 4.3 4.4 4.5
INTRODUCTION ............................................................................................................................ 145 HAZARDOUS SUBSTANCE CONTROL ...................................................................................... 148 RESTRICTED MATERIALS ........................................................................................................... 150 RISK AND CONTROLS .................................................................................................................. 152 CHEMICAL HANDLING ................................................................................................................ 155
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4.6 4.7 4.8 4.9 4.10 4.11 4.12 5
Chapter No. 0
WORK WITH HARMFUL CONTACTS ......................................................................................... 158 LABELLING HAZARDOUS SUBSTANCES ................................................................................ 166 COMPRESSED GASES ................................................................................................................... 170 OTHER DANGEROUS SUBSTANCES.......................................................................................... 180 RADIOACTIVE SOURCES ............................................................................................................ 187 PLANT PRODUCT HAZARDS....................................................................................................... 205 HAZARDOUS SUBSTANCES DISPOSAL .................................................................................... 214
INTRODUCTION ............................................................................................................................ 216 GENERAL RESPONSIBILITIES .................................................................................................... 216 PERMIT AUTHORITIES................................................................................................................. 217 WHEN IS A PERMIT REQUIRED .................................................................................................. 218 PERMIT SUBMISSION ................................................................................................................... 219 TYPES OF PERMIT ......................................................................................................................... 219 PERMIT GAS TESTING.................................................................................................................. 222 TRAINING ....................................................................................................................................... 223 AUDITING OF THE PERMIT TO WORK SYSTEM...................................................................... 223
INTRODUCTION ............................................................................................................................ 227 PRELIMINARY CONSIDERATIONS ............................................................................................ 227 WELDING, CUTTING, BURNING, BRAZING AND SOLDERING ............................................ 229 GAS WELDING AND CUTTING ................................................................................................... 232 ELECTRIC ARC WELDING AND CUTTING ............................................................................... 235 PLASMA CUTTING SYSTEM ....................................................................................................... 237 BLAST CLEANING AND PAINTING............................................................................................ 238 PORTABLE TOOL IGNITION RISKS ............................................................................................ 242 STATIC ELECTRICITY .................................................................................................................. 245 PORTABLE GAS DETECTORS ..................................................................................................... 248
INTRODUCTION ............................................................................................................................ 273 RISK ASSESSMENT ....................................................................................................................... 274 ISOLATION AND GAS FREEING ................................................................................................. 276 SAFE WORKING ENVIRONMENT............................................................................................... 277 ENTRY REQUIREMENTS.............................................................................................................. 281 PROTECTIVE AND RESCUE EQUIPMENT ................................................................................. 286 CANCELLATION OF PERMIT ...................................................................................................... 287 HOT AND NAKED FLAME WORK HAZARDS ........................................................................... 287
PIPELINES, TANKS AND VESSELS ................................................................................................... 295 8.1 8.2 8.3
9
CONTENTS AND REVISION
CONFINED SPACE ENTRY ................................................................................................................. 273 7.1 7.2 7.3 7.4 7.5 7.6 7.7 7.8
8
Date: August 2006
HOT AND NAKED FLAME WORK .................................................................................................... 227 6.1 6.2 6.3 6.4 6.5 6.6 6.7 6.8 6.9 6.10
7
ADGAS HSE MANUAL
PERMIT TO WORK SYSTEM ............................................................................................................. 216 5.1 5.2 5.3 5.4 5.5 5.6 5.7 5.8 5.9
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Issue 02, Rev 05
PIPELINES ....................................................................................................................................... 295 TANKS AND VESSELS .................................................................................................................. 304 SAFETY VALVES ........................................................................................................................... 312
MAINTENANCE SAFETY .................................................................................................................... 317 9.1 9.2 9.3 9.4 9.5
ELECTRICAL .................................................................................................................................. 317 LIFTING APPLIANCES AND EQUIPMENT ................................................................................. 332 SCAFFOLDING AND LADDERS .................................................................................................. 342 MACHINERY SAFEGUARDS ....................................................................................................... 357 EXCAVATIONS .............................................................................................................................. 365
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9.6 9.7 9.8 9.9 10
CONTENTS AND REVISION
Chapter No. 0
DIVING OPERATIONS................................................................................................................... 367 WORK OVER WATER.................................................................................................................... 369 WORK ON ROOFS .......................................................................................................................... 378 WORK AT HEIGHT ........................................................................................................................ 384
INTRODUCTION ............................................................................................................................ 389 DEFINITIONS ................................................................................................................................. 389 REPORTING .................................................................................................................................... 390 INITIATING AUTHORITY............................................................................................................. 391 MANAGEMENT ROLE .................................................................................................................. 391 HSED ROLE ..................................................................................................................................... 392 FOLLOW-UP PROCEDURE ........................................................................................................... 392 STATUTORY REQUIREMENTS- REPORTABLE ACCIDENTS ................................................ 393 NOTIFICATION TO OTHER AUTHORITIES ............................................................................... 393 IN-HOUSE NOTIFICATION ...................................................................................................... 394 MOTOR VEHICLE ACCIDENTS .............................................................................................. 394 BOARDS OF ENQUIRY ............................................................................................................. 395 INSURANCE REPORTING ........................................................................................................ 396 NEAR-MISS REPORTING ......................................................................................................... 396 REPORTING OF SERIOUS HSE INCIDENTS TO ADNOC ..................................................... 397
INTRODUCTION ............................................................................................................................ 421 GENERAL SAFETY ........................................................................................................................ 421 GLASSWARE .................................................................................................................................. 422 SAFETY EQUIPMENT AND PPE .................................................................................................. 423 NAKED LIGHTS ............................................................................................................................. 424 SMOKING, FOOD AND DRINK .................................................................................................... 424 CHEMICAL USE ............................................................................................................................. 424 LABELLING .................................................................................................................................... 426 ULTRA VIOLET (UV) RADIATION .............................................................................................. 427 SAMPLE DESPATCH ................................................................................................................. 427 WASTE DISPOSAL .................................................................................................................... 427 GAS CYLINDERS ....................................................................................................................... 428 ELECTRICITY ............................................................................................................................ 429 FIRST AID ................................................................................................................................... 430 CRYOGENIC MATERIALS ....................................................................................................... 430 MERCURY .................................................................................................................................. 430
OFF THE JOB SAFETY ......................................................................................................................... 433 12.1 12.2 12.3 12.4 12.5
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Date: August 2006
LABORATORY SAFETY ...................................................................................................................... 421 11.1 11.2 11.3 11.4 11.5 11.6 11.7 11.8 11.9 11.10 11.11 11.12 11.13 11.14 11.15 11.16
12
ADGAS HSE MANUAL
ACCIDENT INVESTIGATIONS........................................................................................................... 389 10.1 10.2 10.3 10.4 10.5 10.6 10.7 10.8 10.9 10.10 10.11 10.12 10.13 10.14 10.15
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FIRE PRECAUTIONS IN ACCOMMODATION UNITS ON DAS ISLAND ................................ 433 FIRE PRECAUTIONS AT HOME ................................................................................................... 434 SAFETY IN THE HOME ................................................................................................................. 436 SPORT AND RECREATION........................................................................................................... 437 DRIVING ......................................................................................................................................... 437
MANAGEMENT OF HSE IN PROJECTS ........................................................................................... 440 13.1 13.2 13.3
INTRODUCTION ............................................................................................................................ 440 SCOPE .............................................................................................................................................. 440 GUIDANCE ..................................................................................................................................... 440
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HEALTH, SAFETY & ENVIRONMENT DEPARTMENT
Issue 02, Rev 05
ADGAS HSE MANUAL
Date: August 2006
CONTENTS AND REVISION
Chapter No. 0
0 CONTENTS AND REVISION 0.1 RECORD OF REVISIONS
Page Number
Date of issue
REV
August 2006
01
Issue 02. Complete Manual update
25.11.2007
02
ADGAS HSE Policty updated.
All
25.11.2007
02
Replaced Title PROM by PM.
126
25/11/2007
02
Sub-section 3.12.8 updated.
378
25/11/2007
02
Sub-Section 9.9.1 updated.
384
25/11/2007
02
Added figure 10-15 in Sub-section 10.3.
384
25/11/2007
02
Added paragraph on Accidents occurred in non-industrial area in the sub-section 10.3.
388
25/11/2007
02
Added figure 10-16 in both 10.11.1.1 & 2 sub sections.
Chapter 10
25/11/2007
02
Added 3 figures (figure 10-15, 10-16 & 10-17).
Chapter 4
25/11/2007
02
Corrected the word MSV with MSV in the …section 4.10.
Chapter 13
31/12/2007
02
Section 13.1.3 completely updated and all of the figures changed with new tables from 13.1 to 13.5.
Chapter 2
08/01/2009
03
Section 2.11.7 changed the area authority for 501/502.
Chapter 10 08/01/2009
03
-Section 10.2 updated the definitions for near miss and incident.
ALL
Revision Details
-Section 10.14 title of this section updated. Doc. Number
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Page Number
Date of issue
Issue 02, Rev 05
ADGAS HSE MANUAL
Date: August 2006
CONTENTS AND REVISION
Chapter No. 0
REV
Revision Details
Chapter 2
10/06/2009
04
Section 2.11.7 tables 2.14 and 2.15 HOPL & MGTS titles updated
Chapter 2
10/06/2009
04
ADGAS HSE Policy Update
Chapter 8
18/06/2009
04
Section 8.2.3.2 amended by adding requirement for the area to be cordoned off
Chapter 3
24/06/09
04
Plant manager Title corrected
Chapter 2
21/04/10
05
ADGAS HSE Policy Update
Chapter 10
21/04/10
05
-Section 10.2 definitions of accident and Near miss updated. -Terms of reference for the BOE amended to add the nomination of a member from HR Division.
All
21/04/10
05
Amended the footnote related to the revision No. in all pages.
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Issue 02, Rev 05
ADGAS HSE MANUAL
Date: August 2006
CONTENTS AND REVISION
Chapter No. 0
0.2 REVISION REQUEST Name
Designation
Location
Date
Text Referred to
Chapter
Section
Page(s)
Revision type Tick one or more
Add _
Delete _
Modify _
Details of suggested change (add sheets if necessary including photocopy of original text with notations
Signature - Originator
Date
Instructions: 1. Photocopy this page and write in your proposed revision 2. Send completed Revision Request to Manager Health, Safety and Environment (MHSE) after approval by Division/Department Manager.
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HEALTH, SAFETY & ENVIRONMENT DEPARTMENT
ADGAS HSE MANUAL GUIDE TO THE MANUAL
Issue 02, Rev 05 Date: August 2006 Chapter No. 01
CHAPTER 1 CONTENTS 1
GUIDE TO THE MANUAL ....................................................................................................................... 9 1.1 INTRODUCTION ................................................................................................................................ 9 1.1.1 OBJECTIVES ................................................................................................................................... 9 1.1.2 SCOPE ............................................................................................................................................. 9 1.1.3 DEFINITIONS ................................................................................................................................ 10 1.1.4 SAFETY STANDARDS ................................................................................................................... 10 1.1.5 SAFE WORKING PRACTICES ...................................................................................................... 11 1.2 USING THE MANUAL ..................................................................................................................... 11 1.2.1 HIERARCHY OF HSE DOCUMENTATION ................................................................................. 12 1.2.2 AVAILABILITY OF THE MANUAL ............................................................................................... 12 1.2.3 ORGANISATION OF INFORMATION .......................................................................................... 12 1.2.4 NUMBERING ................................................................................................................................. 12 1.2.5 GRAPHICS ..................................................................................................................................... 13 1.2.6 FINDING INFORMATION ............................................................................................................ 13 1.3 MAINTENANCE OF THE MANUAL .............................................................................................. 14 1.3.1 RESPONSIBILITY .......................................................................................................................... 14 1.3.2 TRAINING ...................................................................................................................................... 14 1.3.3 REVISIONS .................................................................................................................................... 14 1.4 ABBREVIATIONS AND ACRONYMS............................................................................................ 15
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ADGAS HSE MANUAL GUIDE TO THE MANUAL
Issue 02, Rev 05 Date: August 2006 Chapter No. 01
1 GUIDE TO THE MANUAL 1.1 INTRODUCTION This Health, Safety and Environment Manual (HSEM) details the procedures by which Abu Dhabi Gas Liquefaction Company Ltd. (ADGAS) implements the Company’s Health Safety and Environment Policy and HSE Management System (HSEMS). It contains the minimum safety standards acceptable to ADGAS. The manual has been revised to comply with the ADGAS Corporate Policy and Procedure standard. It has also been revised to ensure consistency with the requirements specified in the ADNOC Codes of Practice and Guidelines on Health, Safety and Environment Management, and is now issued as REV No 01, 2006.
1.1.1 OBJECTIVES The objective of the ADGAS HSEM is to present in a clear and concise form the minimum requirements for Health, Safety and Environment for those responsible for the construction, operation and maintenance of the ADGAS Plant and equipment, and guidance for implementing these requirements. Inevitably this manual does not meet every situation precisely, and special regulations may have to be issued from time to time to deal with particular cases that may arise. It cannot be stressed too strongly that, in a difficult situation, the responsible person must consult higher Management rather than take risks.
1.1.2 SCOPE The manual covers the Health Safety and Environmental requirements of the company by the provision of information and references to allow all Divisions and Departments of ADGAS in Abu Dhabi and on Das Island to comply with the minimum safe working practices and safety standards required by ADGAS. These requirements are equally applicable to all Contractors, contracted facilities and services. The guidelines contained within this manual are based upon United Arab Emirates legislation, but do not supersede any acts or regulations. If a discrepancy arises between this manual and acts or regulations, then the latter must take precedence. Where specific UAE legislation does not exist and there are no relevant ADNOC Codes of Practice or Guidance, internationally accepted standards will be utilised.
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ADGAS HSE MANUAL GUIDE TO THE MANUAL
Issue 02, Rev 05 Date: August 2006 Chapter No. 01
1.1.3 DEFINITIONS The following terms are standard throughout this manual to define a condition or course of action; SHALL The word 'SHALL' expresses a mandatory requirement for a condition or course of action. SHOULD The word 'SHOULD' expresses a strongly recommended or preferred condition or course of action. MAY The word 'MAY' suggests a possible course of action or condition where other options are available. The following terms are also used within this and other ADGAS documents: QUALIFIED A person is qualified when he has taken a formal course of instruction (or has had equivalent experience) to enable him to carry out the task and has a certificate to show that his work has met the relevant standard. COMPETENT This applies to a person who has thorough training and/or experience, the skills and knowledge required to carry out the task to the satisfaction of ADGAS. AUTHORISED This term is used where a person has permission to carry out the task, both from external authorising bodies and internally by ADGAS or contractor management. RESPONSIBLE A Responsible Person is one who has specific responsibility for a particular type of task or for a worker engaged in that task (but not necessarily as his supervisor). DEPUTY Throughout this manual the use of the full post title is synonymous with the back to back Deputy for that post.
1.1.4 SAFETY STANDARDS The ADGAS minimum safety standards can be increased at a supervisor's discretion if deemed necessary, but not diminished. Temporary alternative standards must not be implemented without the approval of the PM and the MHSE.
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ADGAS HSE MANUAL
Issue 02, Rev 05 Date: August 2006
GUIDE TO THE MANUAL
Chapter No. 01
Approval will only be granted if other safeguards are introduced which will maintain the established work management system. If an existing safety standard is to be permanently and significantly diminished, approval must be obtained from the PM and MHSE.
1.1.5 SAFE WORKING PRACTICES The Permit to Work is the main tool used to assist in coordinating safe working practices on site and is referred to throughout this manual It is not the Permit to Work itself, but the control over the activity and the precautions taken, which will ensure that work is conducted safely. Other necessary elements contributing to safe working include: · · · · · ·
communication with all work groups to ensure no conflicting work activities effective planning training workers skills supervision performance monitoring Note The fact that a Permit to Work is issued for a particular job does not relieve, in any way, the person(s) carrying out the work of the responsibility for ensuring that it is conducted safely. If an unsafe condition arises, work should be stopped and the condition reported immediately.
1.2 USING THE MANUAL The overall hierarchy of HSE Documentation within ADGAS and its relationship to ADNOC is shown in Figure 1-1.
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ADGAS HSE MANUAL
Issue 02, Rev 05 Date: August 2006
GUIDE TO THE MANUAL
Chapter No. 01
1.2.1 HIERARCHY OF HSE DOCUMENTATION The Hierarchy of the HSE Management Documentation ADNOC HSE POLICY and HSEMS
ADGAS HSE POLICY
ADGAS HSEMS
ADGAS HSE MANUAL
MAINTENANCE SIs and PROCEDURES
OPERATIONS SIs and PROCEDURES
ENGINEERING DIVISION SIs and PROCEDURES
DEPARTMENTAL SIs and PROCEDURES
Figure 1-1: Hierarchy of HSE Documentation
1.2.2 AVAILABILITY OF THE MANUAL The Manual is made available in two formats: · ·
A microsoft word version of the latest issue posted in the HSED's intranet site A HTML version, mirroring the microsoft word version, and posted in the HSED's intranet site
The HTML version provides a user friendly format in which references, to other parts of the Manual and other documents in the ADGAS intranet, are hyperlinked. The microsoft word version is the definitive version of the manual and is also suitable for providing uncontrolled printed versions of the Manual.
1.2.3 ORGANISATION OF INFORMATION The Manual is divided into thirteen Chapters, 0 to 13. Chapter 0 contains the overall Manual Contents List and QA Sheets.
1.2.4 NUMBERING · · · ·
The chapter number identifies the chapters as they appear sequentially in the manual The section number identifies the sections sequentially within the chapter Subject headings and topic headings are also numbered and may be found listed with their page number in each chapter Table of Contents Pages are numbered sequentially within each chapter, not sequentially through the manual.
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1.2.5 GRAPHICS Illustrations, tables, forms and colour plates are numbered sequentially within each section and titled Table or Figure.
1.2.6 FINDING INFORMATION Look in the Manual Table of Contents at the front of the Manual to see if the general subject is covered in the manual and in which chapter it is located. Each chapter within the body of the manual has its own Chapter Table of Contents with subjects and topics listed by page number. 1.2.6.1 WARNING, CAUTIONS AND NOTES Where it is necessary to highlight potentially hazardous situations, critical procedures or matters of concern which may not be obvious, notation appears in the text as follows: Warning A warning is used where failure to follow an instruction could result in a major accident Caution A caution is used where failure to follow an instruction could result in AN ACCIDENT or creation of a serious hazard Note A note is used to draw attention to any matter of concern that may not be obvious, or to a procedure that enables the job to be performed more safely or effectively. Further Information This summarises references to other sections and information. 1.2.6.2 REFERENCES References, to other parts of the Manual and other documents in the ADGAS intranet are contained throughout the Manual, and references in the Intranet HTML version are hyperlinked. 1.2.6.3 REVISIONS All revisions will be referenced and detailed in Chapter 0 of the Manual.
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1.3 MAINTENANCE OF THE MANUAL 1.3.1 RESPONSIBILITY The HSE Department (HSED) is the custodian of this manual and is responsible for its maintenance and periodic upgrading. HSED will work closely with divisional and departmental managers and designated manual holders to ensure the following: · ·
The establishment and promotion of procedures for maintaining the manual the co-ordination of revisions
1.3.2 TRAINING Formal training on the HSEM will be conducted as part of the primary safety induction course for all new employees and employees being relocated to Das Island. Sections of this manual will also be periodically discussed at safety meetings and as part of the general training programme. Contractors involved in work activities on Das Island must also be given a briefing on the contents and correct use of the HSEM by the relevant Job Officer and must, before starting work, be able to demonstrate competency in understanding the relevant aspects of the contents and correct application of the manual. Note When HP and SE-GS require to issue copies of the HSEM to contractors under their control, they should be printed when required and given to the contractor. Awareness and ongoing compliance with the HSEM's requirements and the validity of the manual will be achieved by regular HSED audits of both ADGAS and Contractors activities. The success of the manual in forming safe work place habits and providing a high level of safety management will only be achieved through referral to the manual and by the application of the listed safe work practices by all employees.
1.3.3 REVISIONS Personnel may initiate changes or add new text material by: · · ·
completing a Revision Request form (see Chapter 00 - Revision and Distribution ) attaching the suggested text, graphics or photographs sending the form and new text to the HSED
1.3.3.1 REVISION REVIEW The HSED will acknowledge, review and consider all new material for inclusion in the manual. The originators will be advised of the outcome of the request. Approved Doc. Number
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Chapter No. 01
material will be published as a revision or as a bulletin if the revision is urgent, to be incorporated later into this manual. Types of Revisions The HSED will make required changes to the manual by issuing to manual holders: · ·
normal revisions (on a periodical basis) and bulletins (urgent revisions)
1.3.3.2 MANUAL UPDATE The HSED together with division/department managers and manual holders will periodically revise the manual by incorporating planned revisions with all current bulletins. Note Where any uncertainties exist regarding the revision of the manual contact HSED for further clarification
1.4 ABBREVIATIONS AND ACRONYMS ac AFFF AGT ANSI ATC barg BA BCF BDV BS BTM CABA CAF CCB CCTV CID CM CO CO2 CWS dB(A) dc DC DECR
Alternating Current Aqueous Film Forming Foam Authorised Gas Tester American National Standard Institute Alcohol Type Concentrate Gauge Pressure in Bars Breathing Apparatus/Ball Valve Bromochlorodifluoromethane Extinguishant Blowdown valve British Standard Bromochlorotrifluoromethane Extinguishant Compressed Air Breathing Apparatus Compressed Asbestos Fibre Central Control Building Closed Circuit Television Corrosion & Inspection Department Commissioning Manager Carbon Monoxide Carbon Dioxide Central Workshop Noise Level 'A' scale Decibels Direct Current Day Controller Das Emergency Control Room
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ADGAS HSE MANUAL GUIDE TO THE MANUAL DIFS DV ECS EFR EPPM ES ESCR ESD ESLO E&TSM ETSD Ex. Ex. 'd' Ex. 'i' F&G HAZOP HAZAN HC&I HED HDE HDO HEE HF HMO HMSD HO HOM HOPL HOW HP HPE&T HPO hp HSEE (Trng) HSE HSED HSEM HSEMS H2S HVAC Hz ION ID IDLH IR IS
Issue 02, Rev 05 Date: August 2006 Chapter No. 01
Das Island Fire Service Deluge Valve Engineering Commissioning Superintendent Earth Fault Relay Emergency Plans and Procedures Manual Emergency Stop Emergency Services Control Room (Fire Service) Emergency Shutdown Emergency Services Liaison Operator Engineering & Technical Services Manager Engineering & Technical Services Department Explosion Proof Flameproof Certification Intrinsically Safe Certification Fire and Gas Hazard and Operability Study Hazard Analysis Head of Corrosion & Inspection Head of Engineering Department Head of Development Engineering Head of Das Operations Health and Environment Engineer High Frequency Head of Materials Operations Head of Medical Services, Das Head of Operations Head of Maintenance Head of Shutdown and Planning Head of Workshops Head of Projects/High Pressure Head of Process Engineering & Technology Head of Process Horsepower Health, Safety and Environment Engineer (Training) Health and Safety Engineer Health, Safety and Environment Department Health, Safety and Environment Manual Health, Safety and Environment Management System Hydrogen Sulphide Heating, Ventilation, Air Conditioning Hertz (frequency) Ionising Internal Diameter Immediately Dangerous to Life and Health Infrared Radiation Intrinsically Safe
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ADGAS HSE MANUAL GUIDE TO THE MANUAL ISRS ISS JSA kPa I LA LC50 LD50 LEL LNG LP LPG LS LSM MDI(S) MHSE mm MOLSA MPa MPI MRU MSDS MV N2 NDT Non-IS NPS NPT NTF NRV O2 OC OD ODS OMO OP OSS P&ID P&TM PA PABX PC PCV PCS PFD Perc
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International Safety Rating System Installations Shift Supervisor Job Safety Analysis Kilopascal Litre/s Legal advisor Lethal Concentration for 50% exposed population Lethal Dose for 50% exposed population Lower Explosive Limit Liquefied Natural Gas Low Pressure Liquefied Petroleum Gas Lab Supervisor Lead Safety Man Manager Das Island (Services) Manager HSE DEpartment Millimetres Ministry of Labour and Social Affairs Megapascal Magnetic Particle Inspection Mercury Recovery Unit Material Safety Data Sheet Medium Voltage Nitrogen Non Destructive Testing Non Intrinsically Safe National Pipe Straight Thread National Pipe Taper Thread New Tank Farm Non Return Valve Oxygen Operations Co-ordinator Operations Division/ Outside Diameter Ozone Depleting Substance(s) Operations & Maintenance Office Operator Operations Shift Superintendent Piping & Instrument Diagram Personnel & Training Manager Public Address System Private Automatic Branch Exchange Production Controller/Portable Computer Pressure Control Valve Permit Co-ordination Supervisor Process Flow Diagram Powered Emergency Release Coupling
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PGI Planned General Inspections pH Acidity and Alkalinity Measure PLC Programmable Logic Controller POSSUM Personnel Offshore Supervisory Management system PP Production Programmer PPE Personal Protective Equipment ppm Parts Per Million PMED Plant Maintenance and Engineering Division PM&EM Plant Maintenance & Engineering Manager PPE Personal Protective Equipment MP Plant Manager PSCE Process Shift Charge Engineer PSS Power Shift Supervisor PSV Pressure Safety Valve QMB Quarry Maintenance Base RPS Radiological Protection Supervisor rpm Revolutions Per Minute SAE Society of Automotive Engineers SAP System Application Products SAVER Self Activated Valve Escape Respirator SCBA Self Contained Breathing Apparatus SC Superintendent of Contracts SDV Shutdown Valve SE Safety Engineer sec. Second (time) SEE Senior Electrical Engineer SEGS Senior Engineer General Services SES Storage & Export Superintendent SF&RS (D) Supdt. Fire & Rescue Services (Das) SG Specify Gravity SHEE Senior, Health and Environment Engineer SHSEE(Ops) Senior Health, Safety and Environment Engineer (Operations) SHSEE(Tech)Senior Health, Safety and Environment Engineer (Technical) SI Standing Instruction/Système Internationale d'Unités (Metric System) SIE Senior Instrument Engineer SME Senior Mechanical Engineer SMF Synthetic Mineral Fibre SMOD Senior Medical Officer, Das SOV Solenoid Operated Valve SRR Self Rescue Respirator. SSE(D) Senior Safety Engineer (Das) ADMA-OPCO ST Safety Technician SPC Supreme Petroleum Council SPE Senior Process Engineer SPIE Senior Plant Inspection Engineer. Doc. Number
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ADGAS HSE MANUAL GUIDE TO THE MANUAL SSS STEL SWAF SWL t T&DC TFCR TLV-C TLV-STEL TLV-TWA TSS UEL UHF UPS US USCE UV V Vac Vdc VDU VHF W WBGTI WG
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Steam Shift Supervisor Short Term Exposure Limit Spiral Wound Asbestos Fibre Safe Working Load Tonne Training and Development Co-ordinator Tank Farm Control Room Threshold Limit Value-Ceiling Threshold Limit Value-Short term Exposure Limit Threshold Limit Value - Time Weighted Average Train Shift Supervisor Upper Explosive Limit Ultra High Frequency Uninterruptible Power Supply Utilities Superintendent Utilities Shift Charge Engineer Ultraviolet (Radiation) Volts Volts Alternating Current. Volts Direct Current Visual Display Unit Very High Frequency Watts Wet Bulb Globe Temperature Index Water Gauge (pressure)
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CHAPTER 2 CONTENTS 2
SAFETY MANAGEMENT ....................................................................................................................... 22 2.1 UNITED ARAB EMIRATES LEGISLATION .................................................................................. 22 2.1.1 INTRODUCTION ........................................................................................................................... 22 2.1.2 FEDERAL LAW No.8, YEAR 1980 (As amended 1986)................................................................. 22 2.1.3 MINISTERIAL DECISION NO.32 OF 1982 .................................................................................. 22 2.1.4 ADDITIONAL MEASURES ............................................................................................................ 23 2.1.5 ARABIC AUTHORITATIVE VERSION .......................................................................................... 23 2.2 HEALTH SAFETY AND ENVIRONMENT POLICY STATEMENT ........ ERROR! BOOKMARK NOT DEFINED. 2.3 RESPONSIBILITIES ......................................................................................................................... 25 2.3.1 INTRODUCTION ........................................................................................................................... 25 2.3.2 GENERAL MANAGER ................................................................................................................... 25 2.3.3 PLANT MANAGER ........................................................................................................................ 25 2.3.4 DIVISIONAL AND DEPARTMENTAL MANAGERS ..................................................................... 25 2.3.5 MANAGER HEALTH, SAFETY and ENVIRONMENT .................................................................. 26 2.3.6 SUPERINTENDENTS/SUPERVISORS .......................................................................................... 26 2.3.7 EMPLOYEES ................................................................................................................................. 27 2.3.8 CONTRACT EMPLOYEES ............................................................................................................ 28 2.4 SAFETY COMMITTEES................................................................................................................... 31 2.4.1 INTRODUCTION ........................................................................................................................... 31 2.4.2 HSE WORKPLACE COMMITTEE MEETINGS ............................................................................ 32 2.4.3 ADGAS PROJECTS SAFETY COMMITTEE ................................................................................. 38 2.4.4 ADNOC SAFE PRACTICE COMMITTEE ..................................................................................... 39 2.4.5 ADMA-OPCO SAFETY COMMITTEE .......................................................................................... 40 2.4.6 EMERGENCY COMMITTEE......................................................................................................... 40 2.4.7 HAZARDOUS AREA CLASSIFICATION COMMITTEE ............................................................... 41 2.4.8 MAJOR OVERHAUL SAFETY COMMITTEE ............................................................................... 42 2.5 MEETINGS ........................................................................................................................................ 42 2.5.1 WORKPLACE HSE TALK MEETINGS ......................................................................................... 42 2.5.2 SAFETY PROJECTS MEETINGS .................................................................................................. 42 2.5.3 TASK RISK ASSESSMENT MEETINGS ........................................................................................ 42 2.5.4 DEPARTMENTAL MEETING ....................................................................................................... 42 2.6 EMPLOYEE INVOLVEMENT ......................................................................................................... 43 2.6.1 NEAR MISS REPORTING and HSE SUGGESTION SCHEME ..................................................... 43 2.6.2 HSE QUIZ ...................................................................................................................................... 43 2.6.3 HSE MAN OF THE MONTH ......................................................................................................... 43 2.6.4 SPOTLIGHT ON HSE / HSE Flash ............................................................................................... 44 2.6.5 WORKPLACE HSE COMMITTEES .............................................................................................. 44 2.6.6 TOOL BOX TALKS ........................................................................................................................ 44 2.6.7 ADVANCED SAFETY AUDITS...................................................................................................... 44 2.7 PLANNED INSPECTIONS................................................................................................................ 44 2.7.1 INTRODUCTION ........................................................................................................................... 44 2.7.2 TYPE OF INSPECTION................................................................................................................. 45 2.7.3 INSPECTION RESPONSIBILITY .................................................................................................. 45 2.7.4 HAZARD CLASSIFICATION ......................................................................................................... 46 2.7.5 INSPECTION REPORT ................................................................................................................. 47 2.7.6 REPORT ANALYSIS AND RECORDS ........................................................................................... 48 2.8 QUALITY ASSURANCE .................................................................................................................. 52 2.8.1 MAINTENANCE OF QUALITY ..................................................................................................... 52 Doc. 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2.8.2 QUALITY CONTROL AND INSPECTION .................................................................................... 52 2.8.3 SAFETY AUDITS ........................................................................................................................... 52 2.9 DIVISIONAL STANDING INSTRUCTIONS ................................................................................... 53 2.9.1 OBJECTIVE ................................................................................................................................... 53 2.9.2 PREPARATION.............................................................................................................................. 53 2.9.3 DIVISIONS ..................................................................................................................................... 53 2.9.4 RESPONSIBILITY .......................................................................................................................... 54 2.10 TASK RISK ASSESSMENT ..................................................................................................................... 54 2.10.1 INTRODUCTION ...................................................................................................................... 54 2.10.2 WHAT SHOULD BE RISK ASSESSED? ................................................................................... 54 2.10.3 WHAT IS RISK?......................................................................................................................... 55 2.10.4 TASK RISK ASSESSMENT TEAM ............................................................................................. 55 2.10.5 CONDUCTING THE RISK ASSESSMENT ............................................................................... 56 2.10.6 THE QUALITATIVE RISK MATRIX ......................................................................................... 56 2.10.7 MINIMISING THE RISK ........................................................................................................... 57 2.10.8 CLOSING THE RISK ASSESSMENT LOOP ............................................................................. 57 2.10.9 IMPLEMENTATION OF TRA RECOMMENDATIONS ............................................................ 57 2.11 AREA AUTHORITIES ...................................................................................................................... 71 2.11.1 INTRODUCTION ...................................................................................................................... 71 2.11.2 INDUSTRIAL AREA .................................................................................................................. 71 2.11.3 RESTRICTED/ NON-INDUSTRIAL AREAS.............................................................................. 71 2.11.4 NON-INDUSTRIAL AREA ROUTINE WORK ........................................................................... 71 2.11.5 PERMIT WORK ......................................................................................................................... 71 2.11.6 TYPES OF PERMITS ................................................................................................................ 72 2.11.7 NOMINATED AREA AUTHORITIES ........................................................................................ 72 2.11.8 RESPONSIBILITIES OF AREA AUTHORITIES ....................................................................... 73 2.11.9 JOB OFFICERS ........................................................................................................................ 73 2.11.10 PERFORMING AUTHORITY.................................................................................................... 73 2.11.11 PROCEDURE FOR ISSUE OF PERMITS (NON-INDUSTRIAL)............................................. 73 2.12 MANAGEMENT OF CHANGE ........................................................................................................ 77 2.12.1 PLANT MODIFICATIONS AND PROJECTS ........................................................................... 77 2.12.2 ORGANISATIONAL CHANGES................................................................................................ 78
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2 SAFETY MANAGEMENT 2.1 UNITED ARAB EMIRATES LEGISLATION 2.1.1 INTRODUCTION United Arab Emirates legislation in regard to matters of safety was first introduced in 1980 with the publication of Federal Law No.8 regulating labour relations. This was followed in 1982 by the issue of Ministerial Decision No.32 on The Determination of Preventative Methods and Measures for the Protection of Labour from Risks at Work.
2.1.2 FEDERAL LAW NO.8, YEAR 1980 (AS AMENDED 1986) Within Part V of this Law, Industrial Safety, Preventative Measures, Health and Social Cases for Workers are addressed in general terms indicating the provisions required by both employer and employee. The employers duties include, but are not limited to: Provision of preventive equipment to give protection against accidents, occupational diseases, fire hazards, and hazards from the use of equipment. · · · · · · · ·
Display of instructions to prevent fire, and to protect against work hazards. Provision of first aid boxes. Ensure ventilation and cleanliness, with provision of adequate lighting, drinking water and toilets. Periodic medical examination of workers, and provision of medical care facilities. Provisions of details relating to workplace hazards. Prohibit the use of alcoholic beverages at work. Disciplinary code for contravening safety provisions. Remote area provisions.
Employees duties include, but are not limited to: · ·
Use and maintenance of protective equipment supplied. Compliance with instructions given to protect against hazards.
Provision is also made within Law No.8 (1978), for additional safety related matters, namely, Accident Compensation, Accident Reporting, Workplace Inspections, and it defines Occupational Diseases and Disability Compensation Assessments.
2.1.3 MINISTERIAL DECISION NO.32 OF 1982 This Decision defines in more detail the provisions of Law No.8 (1980), giving specific requirements for working conditions, fire precautions, hazard protection, safety of Doc. Number
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machines, provision of safety instructions and their compliance, safety provisions for steam boilers, protective clothing, hazardous materials, construction safety, health and safety inspections and audits, accident reporting, and industrial security. Details are also provided as to:· · · ·
Lighting Levels. Maximum Permissible Airborne Concentrations of Hazardous Substances. First Aid Box Contents. Accident Notification Requirements.
2.1.4 ADDITIONAL MEASURES Ministerial Decision No.32 (1982) enables the imposition of additional measures and alterations to that Decision, as and when required, by the Under-secretary of the Ministry of Labour and Social Affairs. Ministerial Decision No 467 (2005) relates to the control of work carried out "under the sun" and in "exposed work sites (open air)" during the months of July and August. Refer to Chapter 3, Section 14.
2.1.5 ARABIC AUTHORITATIVE VERSION It should be noted that both the above pieces of legislation were originally published in Arabic, and although official translations into English are available, the Arabic version shall be regarded as authoritative. References Federal Law No.8, Year 1980 (As Amended 1986) Ministerial Decision No.32 Of 1982 Ministerial Decision No 467 (2005) ADNOC_COPV1-01 HSE Administration Systems
2.2 ADGAS HSE POLICY STATEMENT
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2.3 RESPONSIBILITIES 2.3.1 INTRODUCTION The responsibilities and arrangements that follow from the HSEM Policy Statement are detailed in the following pages and are illustrated Figure 2-1.
2.3.2 GENERAL MANAGER The General Manager has the following responsibilities as custodian of the company's assets: · · ·
To define the Company's HSEM Policy. To ensure that appropriate arrangements exist, and are in place, regarding the fulfilment of that policy. To delegate the implementation of that policy, ensuring that the Plant Manager fully understands the requirements of the policy and its implications. Further Information ADNOC_COPV1-01 HSE Administration Systems. Section 4.5
2.3.3 PLANT MANAGER The Plant Manager (PM) has prime accountability to the General Manager for the implementation of the ADGAS HSEM Policy on Das Island. This places the following responsibilities for ensuring the safe and proper care of the Das Island facilities on the Plant Manager: · · · · · ·
Ensure that the policy and its interpretation are understood by Departmental Managers and other plant personnel. Ensure that arrangements to fulfil the policy are in place and that they are reviewed from time to time to ensure their adequacy. Ensure that safety performance is effectively monitored and that remedial action is taken to maintain a high standard. Review and authorise proposals concerning contingency planning and emergency procedures. Ensure interchange of ideas and good communications by establishing and chairing the Management Safety Committee. Ensure that the arrangements are, where appropriate, integrated with ADMA-OPCO arrangements.
2.3.4 DIVISIONAL AND DEPARTMENTAL MANAGERS Divisional and Departmental Managers are responsible for ensuring the application of the HSEM Policy as directed by the PM. Doc. Number
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This responsibility includes the following: · · · · · ·
Ensure that Superintendents and Supervisors are fully conversant with the HSE Manual and the arrangements affecting their particular areas. Ensure that Task Risk Assessment is carried out on all new or unusual tasks to ensure a safe work method. Formulate, and recommend to the Plant Manager, methods to ensure correct application of the policy and subsequently implement and operate these methods within their Division/Department. Ensure that adequate monitoring of worksite safety practices is carried out. Attend the Management Safety Committee Meeting to ensure an interchange of information both inter and intra Departmental. Ensure the promotion of safety awareness within his Division/Department.
2.3.5 MANAGER HEALTH, SAFETY AND ENVIRONMENT The Manager Health, Safety and Environment is responsible for advising the PM on the day to day implementation of the Health, Safety and Environment Management Policy. This responsibility includes the following: · · · · · · · · ·
Act as Health, Safety and Environment Co-ordinator and has specific responsibility to control the Health, Safety and Environment Programme. Ensure that Management is kept fully informed of the latest requirements, both statutory and in terms of good working practice, for occupational safety, health and environment. Ensure that all accidents and incidents are investigated and remedial measures are implemented. Act as a co-ordinator to develop and administer the overall emergency plan. Ensure that written guidance material in the form of Health, Safety and Environment instructions, operating and emergency procedures are maintained up to date and complete. Attend various Safety Committees to ensure sufficient and suitable interchange of information on safety, health, environment and fire protection matters, both within the Company and within the ADNOC group. Implement the Company policy on safety, fire and emergency training. Ensure that technical input is provided for modification/reviews and additional or improved safety or fire detection/protection systems. Act as the focal point for the implementation of Safety Audits, Inspections, and other special studies.
2.3.6 SUPERINTENDENTS/SUPERVISORS Superintendents and supervisors are responsible for ensuring the application of the arrangements for individual job/tasks and day-to-day work activities. Doc. Number
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This responsibility includes the following: · · · · · · ·
Ensure that safe systems of work under their jurisdiction are prepared and implemented. Ensure that a Task Risk Assessment is carried out on all new or unusual tasks to ensure a safe work method. Ensure that all employees and contractors comply with all physical and procedural arrangements associated with their work activities. Monitor work activities, reporting to Senior Management potential hazards, unsafe practices and accidents/incidents. Formulate, and recommend to Senior Management, improved methods of work to promote safe operation. Attend appropriate Safety Committees to ensure interchange of information between employees and Management. Ensure that employees for whom they are responsible read the following as appropriate: o Safety Instructions o HSE Manual. o Operating Procedures. o Standing Instructions. o Emergency Plans and Procedures
2.3.7 EMPLOYEES All personnel have the following responsibilities:· · · · · · ·
To take due care in the performance of their duties to prevent personal injury to themselves and their fellow workers and damage to property. To be diligent in identifying potential hazards and taking the appropriate actions to mitigate their effects. To report all unsafe conditions and accidents/incidents to their supervisor. To wear or make use of protective clothing and equipment as directed by their Supervisor. To take good care of Personnel Protective Equipment (PPE) and avoid its abuse. To comply with the Company's Safety Instructions, HSE Manual, Operating Procedures, Standing Instructions, Emergency Plans and Procedures. To read the following as appropriate: o Safety Instructions. o HSE Manual. o Operating Procedures. o Standing Instructions. o Emergency Plans and Procedures.
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2.3.8 CONTRACT EMPLOYEES 2.3.8.1 CONTRACT WORKFORCE Additionally, all contractor's employees have the following responsibilities: · · · · · · ·
To take due care in the performance of their duties to prevent personal injury to themselves and their fellow workers and damage to Company's property. To be diligent in identifying potential hazards and taking the appropriate actions to mitigate their effects. To report all unsafe conditions and accidents/incidents to their supervisor. To wear or make use of protective clothing and equipment as directed by their Supervisor. To take good care of Personnel Protective Equipment and avoid its abuse. To comply with their own company's and ADGAS Safety Instructions, HSE Manual, Operating Procedures, Standing Instructions, Emergency Plans and Procedures. To read the following ADGAS and contractor documents as appropriate: o Safety Instructions. o HSE Manual. o Operating Procedures. o Standing Instructions. o Emergency Plans and Procedures
2.3.8.2 CONTRACTOR MANAGEMENT All Contractors supplying labour for employment on ADGAS facilities will present their Health and Safety Policy with its particular arrangements to ADGAS Management to ensure compliance with the HSEMS Policy. In addition the Contractor shall ensure the following: · · ·
Adherence to ADGAS Safety Instructions and the safety precautions and procedures outlined in the HSE Manual. That the personnel supplied have received adequate training for the job function allocated and that all employees have received the appropriate safety training. That suitable provision for personal protective clothing and equipment has been made.
2.3.8.3 SAFETY OFFICERS Contractors are to provide a Safety Officer for their work, to ensure the implementation of high standards of safety that meet the requirements of ADGAS and this manual. Designated Safety Officers must be qualified to a standard acceptable to the MHSE.
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The contractors managers and supervisors have the responsibility to ensure that ADGAS and their own safety policies are followed and that their Safety Officer(s) and employees fulfil their responsibilities.
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HSE POLICY
ORGANISATION/ ACCOUNTABILITY
ARRANGEMENTS
GENERAL MANAGER Defines Policy and delegates
SAFETY COMMITTEES
SAFETY, FIRE AND EMERGENCY TRAINING POLICY
EMERGENCY PROCEDURES AND CONTINGENCY PLANS
WORK ACTIVITY
PLANT MODIFICATION/PROJECTS
QUALITY ASSURANCE
MEETINGS
PLANT MANAGER Site implementation of policy
MANAGEMENT
SAFETY TRAINING MANUAL
EMERGENCY COMMITTEE
HSE MANUAL AND OPERATING PROCEDURES
DEFINITION OF REQUIREMENTS SPECIFICATIONS/MODIFICATIONS
QUALITY CONTROL/ INSPECTION
Health, Safety and Environment Department
HSE MANAGER Day to day implementation of policy
HSE COMMITTEES
SAFETY TRAINING COURSES
EMERGENCY PROCEDURES MANUAL
STANDING INSTRUCTIONS
CODES, STANDARDS AND APPROVALS
SAFETY AUDIT
Task Risk Assessment
DIVISIONAL/DEPT MANAGER Implementation of policy
PROJECTS
FIRE TRAINING COURSES
CONTRACTORS RESPONSIBILITIES
SAFETY REVIEW HAZOP/HAZAN
SAFETY INSPECTION
Work Site (Tool Box) Safety Meeting
SUPERVISOR Implementation of policy for work group
ADMA-OPCO
B.A. COURSES
COMMISSIONING/ ACCEPTANCE
EMPLOYEES AND CONTRACTORS Their safety and those they work with
Special Projects Meetings
INTRODUCTION INTO COMPANY RECORDS AND PROCEDURES
HAZARDOUS AREA CLASSIFICATION COMMITTEE
Figure 2-1: Policy Implementation Flowchart
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2.4 SAFETY COMMITTEES 2.4.1 INTRODUCTION 2.4.1.1 GENERAL ADGAS is committed to ensuring a safe and healthy working environment for all personnel in its offices and worksites. ADGAS believes that all work-related injuries, diseases and property losses are preventable, and that safety is good business. ADGAS considers that there is no more important factor in the undertaking of anyone's job than the prevention of injury or ill-health The main purpose of safety committees and meetings is to stimulate effective two-way communication between management and personnel regarding occupational health, safety and welfare matters. Safety committees should effectively contribute to full employee participation in the implementation of the safety programme, thereby enhancing its effectiveness. In addition, safety committees should serve as advisory bodies to management. The ADGAS hierarchy of safety committees and meetings is illustrated graphically in Figure 2-1. 2.4.1.2 OBJECTIVES The ADGAS objectives in the fulfilment of this policy are: · · · · · · · · · · ·
To be an industry leader in occupational health and safety. To give occupational health and safety considerations equal status with other primary business objectives To provide facilities designed to minimise risk and to develop safe working practices to ensure that hazards to personnel are minimised To minimise any adverse impact of its activities on the environment To ensure that no work starts without confirmation that essential safety systems are in place, and that if safety would be compromised, operations are to be suspended To audit and continually improve occupational health and safety standards and procedures To staff its activities with competent, adequately trained personnel To have all personnel recognise their responsibility to identify and eliminate hazards and to prevent injury to themselves and others To promote a pro-active approach to health and safety and encourage all personnel to participate actively in development of its occupational health and safety programs To provide appropriate levels of health care and rehabilitation for all personnel To share occupational health and safety experience with all personnel and relevant organisations Doc. Number
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To ensure that its contractors and other third parties clearly understand and adhere to the ADGAS HSEM Policy.
2.4.1.3 MEETING FORMAT All formal safety meetings should have the aim of being productive and incorporate the features of: · · · · · · · ·
Following an agenda which has been well published beforehand so that meeting participants have time to formulate ideas for constructive input at the meeting. Effective leadership which gives all present an opportunity to express their views, encourages participation and keeps discussion focused on the current topic without wandering. Elimination of distractions as much as possible. Keeping to a timetable while fully using the time allotted for the meeting. Good recording of minutes which catch the essence of the meeting discussion and in particular the decisions, resolutions and group views. Aiming for consensus on group decisions and recommendations. Using minutes from previous meetings as a stepping stone to the achievement of safety goals. Being in touch with, and forming a part of, the plant and the company safety objectives and programmes.
2.4.2 HSE WORKPLACE COMMITTEE MEETINGS 2.4.2.1 INTRODUCTION Responsibilities for HSE matters are defined in the Company’s HSE Management System Manual and in the HSE Manual. Line Management has particular responsibility for operational safety and for handling any HSE hazards, problems or issues that might arise. HSE Department is available to provide advice on these matters to both management and employees. 2.4.2.2 OBJECTIVE To provide a formal forum for consultation and participation between Management and Company personnel on HSE Protection matters. Specifically to reduce accidents and incidents by promoting awareness; positive attitudes; health, safe and environmentally acceptable systems of working and identification and rectification of perceived hazards. Note All Chairmen of HSE Workplace Committees are advised to ensure that meetings should not exceed one hour.
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2.4.2.3 TIER SYSTEM There are three tiers of formal consultation operating within ADGAS on HSE matters, These tiers are structured to allow workplace HSE Workplace Committees to monitor the effectiveness of the arrangements in operation within their areas with management and to promote improvements. A Central HSE Committee is available for referral if problems cannot be resolved at the Workplace Committee. This Central Committee also encourages and supervises the activities of the Workplace Committees in accident/incident prevention and in maintaining a health place of work. The Central Committee reviews substantive changes to the HSE Manual before issue as well as passing concerns on HSE Policy to Executive Meeting. The Executive HSE Committee discusses policy and strategy matters and monitors the overall functioning of these arrangements. 2.4.2.4 REPRESENTATION EXECUTIVE HSE COMMITTEE Production Manager (Chairman) Personnel & Training Manager Integrity & Quality Manager Manager Health, Safety and Environment (Secretary) CENTRAL HSE COMMITTEE Integrity & Quality Manager (Chairman) Head of Operations Head of Operations Support Head of Maintenance Head of General & Technical Services Head of Overhaul and Planning. Head of Product & Quality Head of Corrosion & Inspection Personnel & Training Manager Senior Process Engineer Senior Health, Safety and Environment Engineer Manager Health, Safety and Environment Engineering Division Manager Head of Material Operations Senior Operational Safety Engineer (Secretary) OPERATIONS HSE WORKPLACE COMMITTEE Head of Operations Support (Chairman) Head of Operations Doc. Number
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Shift Superintendent Area Controllers Area Team Leaders Senior Process Engineer Safety Representatives – (2 or 3) Representative from HSE Department This is the representation for the Operations Areas. Other Workplace Committees (Maintenance, Product & Quality (Lab), General & Technical Services, etc…, will have different representation.). 2.4.2.5 FREQUENCY OF MEETINGS Executive HSE Committee These are held bi-annually in the Management Conference Room. Central HSE Committee These are held quarterly at dates to be agreed at the end of each calendar year, for the next year. Workplace HSE Committee These are held once every 2 months on dates to optimise, so far as possible, attendance by all participants. The Workplace HSE Meetings will be held in locations convenient for the ease of access for the shift representatives at the meeting each. Note Workplace Committee Chairman must ensure the attendance of the Contractor(s) Representative(s) at each committee. 2.4.2.6 SPECIAL MEETINGS Where there is an important issue, or the occurrence of a serious accident or incident requiring consultation with Company personnel, the Chairman of each Committee may call a special meeting. For Overhaul and Major Projects Safety Committees will stay as they are. ( No change in the present practice) 2.4.2.7 QUORUM The Quorum shall be at least five Committee members for the Executive Committee.
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The Quorum for a Workplace Committee meeting shall be the Area Head/Superintendent, two Safety representatives, a representative from HSE Department, Shift superintendent and one nominated members of day staff. The Contractors Committee does not have a specified quorum for contractors due to variability of the number of contractor companies on site. The three ADGAS members specified above or their replacement must be in attendance. 2.4.2.8 AGENDA Items for the Executive, Central and Contractor HSE Committee Meeting Agendas must be submitted to the secretary three weeks prior to the meeting. Items arising within the three-week period may be discussed. Copies of the Agendas will be submitted to Committee members seven days before the meeting. Items for the Workplace HSE Committee Meeting Agenda should be submitted to the secretary at least two days before the meeting. Where an item on the agendas requires the presence of a Departmental Head or any other specialist member, he shall be invited to attend to report on the relevant item. Normally matters should be fully discussed at the Workplace and Central Committees prior to being submitted as agenda items for the Executive Meeting. 2.4.2.9 COMMITTEE ACTIVITIES As a routine, each Committee should discuss relevant Health, Safety and Environment (HSE) topics. Matters for discussion should be passed through the three levels i.e. Workplace, Central, then Executive Committees. Only in exceptional circumstances should any of the levels be bypassed 2.4.2.10 MINUTES OF MEETINGS HSE Division shall provide a Secretary for the Executive and the Central Committees who shall produce minutes of each meeting. One copy of the minutes of the Executive and Central Committee’s Meetings shall be sent to members of the Committee and to each Safety representative. A nominated member of the day staff from the Workplace Area shall be appointed as Secretary for the Workplace Committee and shall produce minutes of each meeting.Copies of the minutes of Workplace Meetings shall be copied to each member of the Committee and to the Area Notice Boards and to HSE Department if they are not present on the Committee Personnel assigned actions in the minutes not in attendance at the meeting should be given details by the secretary of the meeting and a timescale for response agreed. This should be included in the minutes. All actionees should receive copies of the minutes. Progress on actions should be followed up under “Matters Arising” at the next meeting. Items with protracted completion periods should be listed in an updated attachment to Doc. Number
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the meting minutes and discussed at the appropriate future meeting. References should be in the following format: Date raised/minute number/completion date/person responsible e.g. 17.07.99/2.11/1q92/HSE. Feedback to persons raising items is through the minutes of the meeting and their Safety representatives. 2.4.2.11 LINES OF COMMUNICATION Should an employee observe a situation which he believes unsafe, or wishes to request information concerning HSE matters, the first action is to raise it with his immediate supervisor. Should the outcome of this approach be unsatisfactory to the employee he may request the Safety representative for the Workplace to raise the point with the Line Supervisor. If no acceptable action follows this approach then the Safety representative and Line Supervisor should contact HSE Department for advice. 2.4.2.12 FUNCTIONS OF SAFETY REPRESENTATIVE A Safety Representative shall represent all employees in his work area. In case of his absence another Safety Representative may by mutual consent, assume his responsibilities. A Safety Representative is an official position recognised by ADGAS Management as an important member of the HSE structure. He is an integral member of a work team at the operator or technician level and as such will be the recognised point of contact for this colleagues to raise and discuss HSE issues. He will help to communicate the output of the HSE Committee structure to and from his colleagues. When a Safety Representative is asked to investigate a potential hazard or inspect a work area or the scene of an accident, or to take part in a Board of Enquiry his line Supervisor will normally grant the necessary time off the job. In normal circumstances only Safety Representative with responsibility for the area in question will be involved in inspections and investigations. A HSE Comments book shall be provided in each area for logging of any HSE related hazards or defects. The HSE comments book will be reviewed at the Workplace Committee. The Safety Representative will inform himself of the position of all outstanding items prior to each workplace HSE Protection Committee Meeting. Any outstanding actions will be discussed at the Workplace HSE Protection Committee Meeting. Doc. Number
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2.4.2.13 COMPOSITION OF WORKPLACE COMMITTEES Operations Workplace Committee · · · · · · · · · ·
Head of Operations (HO) - Chairman Area Coordinator (U) Area Coordinator (P) Shift Superintendent Area Team Leader (U) Area Team Leader (P) Process Operator, Trains 1, 2 & 3 Utilities Operator, Trains 1, 2 & 3 UAE Assignee Representative from HSED
Alternative Secretary Alternative Secretary
General & Technical Services HSE Committee · · · · ·
· · ·
Head of General & Technical Services (Chairman) Instrument Electrical Supervisor Mechanical Supervisor Fabrication Supervisor Senior. Engineer (General Services) + o Rigging/scaffolding Supervisor o Civil Supervisor o Painting Supvr. o Insulation Supervisor Safety Representatives (2) Representative from HSE Department Representative(s) from Contractors
Maintenance HSE Committee · · · · · · ·
Head of Maintenance (Chairman) Electrical Section Engineer or Supervisor Instrument Section Engineer or Supervisor Mechanical Section Engineer or Supervisor Safety Representatives (3 or 4) Representative from HSE Department Representative(s) from Contractors
Product & Quality HSE Committee · · ·
Head of Product & Quality (Chairman) Chief Chemist Member of Laboratory Staff Doc. Number
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Safety Representative Representative from HSE Department Representative(s) from Contractors
Materials HSE Committee · · · · · ·
Head of Materials Operations Senior Stores Supervisor Store Keeper Safety Representatives (2) Representative from HSE Department Representative(s) from Contractors
Personnel & Training HSE Committee · · · · · · · · ·
Personnel & Training Manager English Language Instructor Head of Training (Das) Training Coordinator Senior Personnel Officer (Das) Personnel Officer (Das) Senior Accommodation Officer Representative from HSE Department Representative(s) from Contractors
Other personnel may be asked to attend where appropriate. The meetings should be convened in sufficient time to allow comments and business to be forwarded as necessary to the Central Committee for discussion at its quarterly meeting. The convening and administration of the Workplace Committee meetings shall be the responsibility of the person from the area nominated by the Chairman of the Committee.
2.4.3 ADGAS PROJECTS SAFETY COMMITTEE OBJECTIVES The objective of the Projects Safety Committee is to provide a forum for effective communication on occupational health, safety and welfare and fire protection/prevention for projects being carried out on Das either managed directly by ADGAS or by others on behalf of ADGAS. REPRESENTATION: · ·
Head of projects Health, Safety and Environment Manager Doc. Number
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Senior Health, Safety & Env. Engr.(P) (Secretary) Senior Project Representative] Each Project Senior Project Safety Officer ] Senior Contractor Safety Officer Project Liaison Officer
TERMS OF REFERENCE The Committee will normally meet on the third Sunday of every other month at 10:00 hours at a nominated venue when required when projects are being executed. The frequency of meetings may be increased from time to time, to suit high levels of contract work. The topics for discussion at the meting will be of a general policy nature and not individual project activities. The Committee will, in particular, deal with safety matters within one project group affecting other groups on the island including ADGAS and ADMA-OPCO. Items discussed at this Committee may be referred to the appropriate Management Safety Committees or actioned directly. All other functions of the Committee are covered in the preceding sections.
2.4.4 ADNOC SAFE PRACTICE COMMITTEE OBJECTIVE The objective of the ADNOC Processing Directorate Safe Practice Committee is to provide a forum for discussing all aspects of occupational health, safety, and welfare and fire protection/prevention within the group of joint venture companies. REPRESENTATION Representatives at Safety Superintendent level from the following companies: · · · · ·
ADNOC (PD) (Various Centres) GASCO ADGAS FERTIL ADMA-OPCO
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These are prescribed by ADNOC Processing Directorate, but it is understood that the Committee is to assist the respective Senior Management by considering the following:Planning and co-ordinating the development of common operating safety practices. Execution of joint safety campaigns.
2.4.5 ADMA-OPCO SAFETY COMMITTEE OBJECTIVE To facilitate the flow of safety information between ADGAS and ADMA-OPCO a representative of the ADGAS HSED attends the above Committee. REPRESENTATION The representative is the MHSE. TERMS OF REFERENCE The terms of reference, objectives and membership of the Committee are as prescribed by ADMA-OPCO.
2.4.6 EMERGENCY COMMITTEE OBJECTIVE To act as a focal point for the co-ordination and implementation of emergency procedures and contingency plans as laid out in the HSEM Policy. REPRESENTATION ADGAS · Operations Manager (Chairman, alternately) · Manager Health, Safety & Environment · Senior Health, Safety and Environment Engineer (Secretary, alternately) ADMA-OPCO · · · ·
Head of Das Operations (Chairman, alternately) The Supdt. Fire & Rescue Services or his deputy Senior Safety Engineer (Das) (Secretary) Other disciplines to be invited depending on the topics under discussion.
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The Committee should meet on a quarterly basis or more frequently dependent on the matters under consideration The Committee will provide an interface between all interested parties and will develop a consensus approach to emergency procedures and contingency plans within the HSEM Policy. In particular the Committee will consider, but not be limited to, the following: · · · · · ·
·
Overall emergency organisation within ADGAS and interrelationship with ADMAOPCO. The preparation of, or modification to, Emergency Procedures and Contingency Plans. Prior to forwarding such procedures to Management for approval, the Committee shall review and approve all joint new and modified procedures. Critically consider the effect on joint ADMA-OPCO and ADGAS emergency procedures of plant facilities and, if deemed necessary, recommend HAZAN studies be carried out. Monitor the various Safety Committees to ensure that the views of various personnel on emergency procedures are being noted. To note all comments and recommendations from planned general inspections and plant audits which might affect emergency procedures and ensure arrangements are modified accordingly including the effects this may have on the services supplied by ADMA-OPCO. Review Emergency Evacuation Procedures with regard to the marine capability to evacuate Das Island within the planned period and account for varying population levels subject to construction activities.
2.4.7 HAZARDOUS AREA CLASSIFICATION COMMITTEE OBJECTIVE The objective of the Committee is to ensure that appropriate hazardous area classification techniques are applied to ADGAS facilities. REPRESENTATION · · · · · ·
Manager Health, Safety and Environment (Chairman). Senior Electrical Engineer . Senior Instrument Engineer. Operations Co-ordinator. Senior Development Engineer (E&I) Secretary nominated by Manager Health, Safety and Environment.
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The Committee shall meet as necessary to review changes to the hazardous area classification drawings brought about as a result of modifications, process changes, installation of new plant, etc
2.4.8 MAJOR OVERHAUL SAFETY COMMITTEE OBJECTIVES The objective of the Committee is to provide a forum for effective communication on occupational health, safety and environment for major overhaul of the LNG Plant REPRESENTATION · · · · ·
Health, Safety and Environment Manager (Chairman) Head of Overhaul and Planning Senior Health, Safety and Environment Engineer (Secretary) Contractor Overhaul Manager Contractor HSE Manager/ Safety Engineer
2.5 MEETINGS 2.5.1 WORKPLACE HSE TALK MEETINGS These meetings shall be held by the supervisor with his work group usually once per month or more often if required. It covers selected safety topics, new work plans, significant accidents and other useful items of safety and occupational health. Safety topic materials and training videos are available from the HSEE (Trng) as well as assistance in preparing talks on safety subjects.
2.5.2 SAFETY PROJECTS MEETINGS These are found necessary when substantial work projects of non-routine nature are to be introduced. These serve to inform incoming project teams of current safety requirements and restraints and establish good understanding and lines of communication with plant operations personnel.
2.5.3 TASK RISK ASSESSMENT MEETINGS Task Risk Assessment meetings are held with all participants in selected new nonroutine or other hazardous activities for the purpose of examining the job in detail, identifying likely hazards and incorporating preventative safeguards into the job process. (See Section 9 of this Chapter)
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OBJECTIVE Interchange of information between members of the HSED. REPRESENTATION All senior members of staff in the HSED present on Das Island will attend. The MHSE or his Deputy shall chair the meeting. TERMS OF REFERENCE The meeting will be held bi-monthly. The meeting is a forum for members of the Health, Safety and Environment Department to discuss department matters, exchange ideas and review various strategies to progress the aims of high standards of occupational health and safety for all personnel. Other areas for considerations may include: · · ·
Training and continuing education for Health, Safety and Environment personnel. Safety performance in ADGAS contract work and other associated contracts. Skills and induction training programme.
2.6 EMPLOYEE INVOLVEMENT 2.6.1 NEAR MISS REPORTING AND HSE SUGGESTION SCHEME All ADGAS personnel are encouraged to report near misses and propose HSE suggestions. All reports and proposals are scrutinised by the HSE Initiative Committee on a regular basis where rewards are made. Further Information ADNOC-COPV4-01: FRAMEWORK OF OCCUPATIONAL SAFETY RISK MANAGEMENT
2.6.2 HSE QUIZ All ADGAS personnel can take part in the monthly HSE quiz. The quiz focusses on relevant and current HSE issues and requirements. Winning entrants are rewarded with prizes such as mobile phones.
2.6.3 HSE MAN OF THE MONTH This is awarded to the person who has taken an action which had a positive HSE impact on the plant operation or plant personnel. The HSE Initiative Committee evaluates the candidates and decides who receives awards. Doc. Number
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2.6.4 SPOTLIGHT ON HSE / HSE FLASH These bulletins provide a rapid and succinct medium for publicising HSE incidents/issues and dissemination of lessons learned. They are produced by the HSED on a regular basis in response to current HSE issues. Further Information ADNOC-COPV1-01: HSE ADMINISTRATION
2.6.5 WORKPLACE HSE COMMITTEES Provide a formal forum for consultation and participation between Management and Company personnel on HSE protection matters. Specifically to reduce accidents and incidents by; promoting awareness; positive attitudes; health, safe and environmentally acceptable systems of working; and identification and rectification of perceived hazards. (Refer to Section 4.4)
2.6.6 TOOL BOX TALKS The Tool Box Talk (HSE talk) subject addresses the hazards of the work being performed. Control measures to minimise risk as identified in the Task Risk Assessment must be communicated to all employees on site in order for ensuring safety at the work site. These measures must be communicated to employees in the form of job specific tool box talk (HSE talk) prior to commencement of the work being performed.
2.6.7 ADVANCED SAFETY AUDITS All ADGAS Departments and Divisions are encouraged to carry out Advanced Safety Audits. Departments and Divisions whose Auditors carry out prescribed numbers are eligible for receiving rewards in line with the HSED Guidelines.
2.7 PLANNED INSPECTIONS 2.7.1 INTRODUCTION Inspection is one of the best tools available to identify hazards and assess their risks before accidents and other losses occur. A well managed inspection programme helps to identify potential hazards not anticipated during design, equipment deficiencies due to normal wear and tear or abuse, employees unsafe acts, inadequacies in remedial action taken earlier for a specific problem and effect of cumulative changes in people, equipment and material. Planned inspection involves the systematic examination of the production units, equipment, tools, materials and their use by the employees. These inspections are a basic and important element of the loss prevention programme.
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Further Information ADNOC-COPV1-01: HSE ADMINISTRATION SYSTEMS. Section 9.3
2.7.2 TYPE OF INSPECTION PLANNED GENERAL INSPECTIONS Planned General inspections are the Supervisor's self inspection of their work areas (or other areas within same division on mutual exchange basis). These inspections shall be carried out by line supervisors for their area as they have the primary interest in and responsibility for efficient and safe operation and they have better working knowledge of the jobs and the people doing them. A flow chart for Planned General Inspection is given in Figure 2-2: Planned General Inspections. MANAGEMENT SAFETY TOURS Management Safety Tours are neither Planned Inspections nor Plant Audits and are meant to visibly show the interest of upper/middle level managers towards safety and health/loss control. These are not comprehensive inspections, rather they are a "walk through" of an area to observe critical safety and health items. Details regarding these tours have been issued separately to relevant managers.
2.7.3 INSPECTION RESPONSIBILITY Managers/superintendents shall assign inspection responsibility for each area/facility or office to the concerned supervisor by job title. It shall be the responsibility of the line supervisors to inspect the area/facility or office that falls within the area of their responsibility. Occasionally supervisors from one area should be assigned to inspect other areas within the same division on a mutually agreed exchange basis. FREQUENCY OF INSPECTION Planned General Inspection of units and facilities shall be done once in every 2 months while the frequency of inspection for offices shall be 3 months. INSPECTION CHECK LIST The individual or the team shall plan the inspection in advance and determine what to look at and what to look for. Check lists providing details on items that need to be looked at and condition/practices which need to be looked for shall be made for each area and used during inspection.
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Once made the check list needs only to be kept up-to-date as things change and experience dictates. This check list shall be updated by line supervisors on an annual basis and forwarded to MHSE for records. Personnel using the check list shall guard against relying only on the check list. It is to be used as a guide and not regarded as a comprehensive list of every conceivable substandard practice/condition.
2.7.4 HAZARD CLASSIFICATION Hazard classification is the technique used to describe the loss potential of a condition or practice observed during the inspection. The most apparent benefit of hazard classification is the establishment of priorities for remedial action. Hazards can be classified as follows: Class '1' Hazard A condition or practice likely to cause permanent disability, loss of life or body part, and/or extensive loss of structure, equipment or material. Example 1. operation.
A barrier guard missing on a large press brake for a metal shearing
Example 2. A maintenance worker observed servicing a large sump pump in an unventilated deep pit, with the gasoline motor running. Class '2' Hazard A condition or practice likely to cause serious injury or illness, resulting in temporary disability or property damage that is disruptive but not extensive. Example 1.
Slippery oil condition observed in main aisle way.
Example 2.
Broken tread at bottom of office stairs.
Class '3' Hazard A condition or practice likely to cause minor, non-disabling injury or illness, or nondisruptive property damage. Example 1.
A carpenter observed handling rough timber without gloves.
Example 2.
A strong rancid odour from cutting oil circulating in the bed of a large lathe.
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2.7.5 INSPECTION REPORT 2.7.5.1 GENERAL The Inspection Report shall provide the following information; · · · · · ·
Identification of the item or area inspected List of substandard practices and conditions observed Classification of the degree of hazard Immediate remedial action taken, if any Recommendations for permanent action to eliminate the basic or real causes of the sub-standard condition/act Assignment of responsibility and schedule for completion of the recommended action.
Good conditions and practices noted during inspection shall be commended separately and attached to the report. 2.7.5.2 PLANNED GENERAL INSPECTION (PGI) The report for PGI shall be prepared by the concerned supervisor conducting the inspection using the form shown in Figure 2-3: Inspection Report. The supervisor shall complete all the columns of the report except columns 3, 11 and 12 titled "Quality Score", "Action By" and "Target Dates" respectively. Column 13 titled "Remarks" shall be used to highlight items carried over from earlier inspection reports, recurring substandard conditions or acts and any problems or delays in implementation of remedial actions. The supervisor shall forward the report to his Division/Department Head within 48 hours of inspection. The Division/Department Head shall review/approve the report, assign responsibility and schedule for completion of remedial actions (columns 11 and 12) and sign the report before distributing it within 24 hours of receipt to MHSE and all personnel listed in Column 11. 2.7.5.3 REMEDIAL ACTION Action required to rectify certain substandard conditions or acts may consist only of a verbal request. The concerned supervisor shall initiate the verbal request during or soon after the inspection and record it in the report. Remedial action that cannot be implemented by verbal request shall be developed for other substandard conditions or acts noted during inspection and recorded in the report under column 10. 2.7.5.4 SCHEDULE OF IMPLEMENTATION The priority of implementation of the action shall depend on the combination of the potential severity of loss (as determined by hazard classification of 1, 2 and 3) and the probability of a loss occurring from the exposure or hazard (i.e. high, medium or low). Doc. Number
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For example a class 2 hazard with a high probability of loss occurrence shall be given a higher priority for rectification than a class 1 hazard with a low probability of loss occurrence. Remedial actions requiring plant modification or project of capital nature shall be implemented as quickly as possible within the constraints of the existing procedure for plant modification and capital projects. All other actions shall be completed within a period of 1 week to 4 weeks depending on the combination of potential severity and probability of loss occurrence. 2.7.5.5 FOLLOW-UP Remedial actions arising out of an inspection shall be entered into the SAP System. It should be understood that all actions will not be related to Mechanical Maintenance and some might require procedural changes, capital expenditure, engineering control, etc. The use of SAP System is recommended for the convenience of keeping a track of all remedial actions through a single report. At the end of each month a summary of all actions completed during the month and the status/cause of delay of remaining jobs shall be produced and copied to MHSE for review. Jobs once reported as complete will not be reflected in subsequent reports. It shall be the responsibility of the person whose name appears in Column 11 of the report to ensure that the action is completed as per the target date mentioned in Column 12. MHSE shall report the status of all actions pertaining to Class 1 & 2 hazards that have been delayed in the first weekly PM meeting of the month. MHSE and the concerned Division/Department Head shall review the remedial action after its implementation as and when deemed appropriate to confirm that it provides adequate control of the risk and has no undesired side effect.
2.7.6 REPORT ANALYSIS AND RECORDS STL (Tech and Training) shall be responsible for the following: · · · ·
Maintain a central file for all inspection and follow-up reports. Prepare a quarterly report highlighting percentage of inspections completed versus planned for all areas/facilities for management review. Determine the quality of inspection reports using the Inspection Report Analysis sheet shown in Figure 2-4. Compile quality score on a quarterly basis for management review. Analyse all inspection reports to identify repetitive substandard conditions and their basic causes on a half yearly basis using the Analysis Sheet for management review.
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Every Two Months
DEVELOPMENT CHECK LIST 48 hrs LOCALISED INSPECTION REPORT
Area/ Exchange Supervisors
COMPLETE REPORT
1. ACTIONEES 2. MHSE
QUARTERLY REPORT MHSE
Dept. Head
Inspection Report
DEPARTMENT HEAD FOLLOW UP REPORT
STL (Tec & Trg)
Review Action PM MEETING, 1ST WEEK OF MONTH
CENTRAL FILE
QUARTERLY FILE
QUALITY
ANALYSIS
Figure 2-2: Planned General Inspections
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Figure 2-3: Inspection Report
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Figure 2-4: Inspection Analysis
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2.8 QUALITY ASSURANCE 2.8.1 MAINTENANCE OF QUALITY The maintenance of Quality is an essential aspect of the HSE Management Policy to ensure high standards of engineering and operational practice to plant and personnel safety. Quality assurance is a built-in responsibility of all employees. In addition to this responsibility, the MHSE through a programme of monitoring and compliance with appropriate ADGAS procedures will ensure these aims are met and that in particular, the following areas are given consideration: · · · ·
The selection of new equipment is correct, taking into account safety, application, reliability, operability and maintainability. That operational, safety and engineering procedures are adhered to, and monitored to ensure their adequacy during changing plant circumstances. A formal training policy is administered to promote sufficient and suitable job skills amongst personnel. The various audit functions are carried out professionally and their recommendations are followed up. Working groups responsible for such auditing functions are, Health, Safety and Environment Division, Corrosion and Inspection Department and the Laboratory. Further Information ADNOC-COPV1-01: HSE ADMINISTRATION SYSTEMS. Section 9.2 HSE Audit
2.8.2 QUALITY CONTROL AND INSPECTION To maintain a high level of safety on the site, inspection is carried out on all aspects of plant and equipment. The Corrosion and Inspection Department of Engineering and Technical Services Division ensures the following: · · · · ·
That statutory requirements are met. Where no local statutes apply, accepted International Standards and Codes of Practice are used. That all appropriate design requirements are incorporated. That all relevant certification is prepared and catalogued. That all installation procedures, e.g. welding, are carried out to the appropriate standards. That equipment is inspected to ensure that it remains fit for purpose.
2.8.3 SAFETY AUDITS A Safety Audit subjects all areas of ADGAS activities to a systematic critical examination with the object of minimising loss. Doc. Number
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A Safety Audit is to be carried out on ADGAS facilities, Das Island, at least once every five years. Such an audit has five main elements as follows: · · · · ·
Identification of possible loss producing situations. Assessment of potential losses associated with these risks. Selection of measures to minimise losses. Implementation of these measures within the Company. Monitoring of the changes.
The audit shall be carried out by a professional external audit team. The results are presented in a formal report for issue to the General Manager. In addition to the above, regular Risk Management Surveys of the ADGAS facilities are carried out by a Consultant at the request of ADNOC, Insurance Department. The Health, Safety and Environment Manager or his Deputy acts as co-ordinator for all plant surveys. Furthermore, an assessment is carried out bi-annually for insurance purposes, at the request of ADNOC.
2.9 DIVISIONAL STANDING INSTRUCTIONS 2.9.1 OBJECTIVE To convey to relevant personnel a particular Divisional requirement in the performance of their duties.
2.9.2 PREPARATION Standing Instructions (SI) are prepared by each Division and are endorsed by the Divisional Manager. They cover a variety of specific items, many of which are safety oriented. These documents are published internally within Divisions. In the event an SI being of general application, amendments will be made as required in other concerned manuals such as the HSE Manual.
2.9.3 DIVISIONS Standing Instructions are produced by the following:Production Division (Operations & Maintenance) Integrity & Quality Division Doc. Number
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Engineering Division
2.9.4 RESPONSIBILITY Divisional Managers are responsible for sending revisions to all manual holders. Note A Standing Instruction is a procedure, which is prepared by concerned division and cover a variety of specific items related mostly to HSE. It should not be anomalous or contradictory to any other ADGAS documents, it should be written in the imperative sense, in the simplest English language and should be available for all concerned personnel.
2.10 TASK RISK ASSESSMENT 2.10.1 INTRODUCTION All activities or tasks undertaken in our organisation represent a potential risk to many aspects of the business and in particular to health, safety and environment. It is recognised that in undertaking an industrial activity risk can never be eliminated, however, we must always mange risk to a level that is as low as reasonably practicable. In other words, we must reduce the risk to a level that is acceptable. The Company uses many techniques to analyse risk at various levels. In this section the tools are provided to allow structured analysis of risk and allow methods to be put in place to ensure minimisation of the risk. Further Information ADNOC_COPV4-01 FRAMEWORK OF OCCUPATIONAL SAFETY RISK MANAGEMENT. Section 3
2.10.2 WHAT SHOULD BE RISK ASSESSED? In theory all tasks undertaken on a day to day basis requires risk assessment however many of these tasks are of such low risk that there is no need to document how the risk is controlled. In ADGAS maintenance and other activities are controlled by the permit to work system and other risks by procedures and standing instructions. In producing a permit, a procedure or a S.I. the author is going through the thought process of a risk assessment in developing the controls. The tools provided in this section allow a structured approach to be taken to risk assessment that will document the thought process involved in controlling a particular risk. Whilst task risk assessment can be utilised for all tasks only the tasks perceived to be high-risk by management or employees need be tasks risk assessed. Examples of tasks that are likely to require risk assessment are: -
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Use of cranes lifting over live lines/plant. Working over water. Work on live flare systems. Activities that have been known to cause serious accidents/incidents. Tasks with high hazard potential to people, assets, environment or reputation. (listing of these activities can be found in Chapter 2 Section 2.9.1 of ADGAS Safety Case document which is available in the Public folder “All Public Folders/ HSEMS Supporting Documents/ ADGAS Safety Case”
However assessments should not only be restricted to the above list, experience and judgement should be utilised to decide if a task needs to be risk assessed.
2.10.3 WHAT IS RISK? Risk is defined as the product of the measure of the likelihood of occurrence of an undesired event and the potential adverse consequences which this event may have on: · · · ·
People – injury or harm to physical or psychological health. Assets (or revenue)– damage to property (assets) or loss of production. Environment – water, air, soil, animals, plants and social. Reputation – employees and third parties.
Risk can be measured in strict mathematical terms, however, for the purpose of tasks risk assessment the assessment will be entirely qualitative, utilising the qualitative risk matrix in Figure 2-5. The assessment will require experience and judgement.
2.10.4 TASK RISK ASSESSMENT TEAM The task risk assessment is the type of assessment that requires to utilise the knowledge and experience of a small multi-disciplinary team. A small competent team will produce much more useful and realistic tasks risk assessment than a large team of people who only partly understand the work to be undertaken. The suggested optimum size for such a team is around four typically consisting of: · · · ·
HSED Member Production Div. Member Engineering Div. Member Job Officer ( person who will lead the work)
The actual team members will depend on the work to be assessed, for example if the work was in the laboratory then a member of Engineering Division will be more appropriate than a Production Division member. An HSED member will always be present to guide HSE input and further technical expertise can be co-opted to the team as required.
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If additional support is required from Das Fire Rescue Team, then the Job Officer must ensure that Fire Rescue Team member is present during the Task Risk Assessment.
2.10.5 CONDUCTING THE RISK ASSESSMENT The first step is for the full assessment team to visit the proposed worksite and to be briefed by the job officer on how the work will be carried out. Any procedures or documentation should also be available for review. The idea of the site visit is for the team to gather information and get a full picture of how the work will be carried out and an indication of the hazards present, and the hazards to the process plant that may arise whilst the task is being carried out. As an aid-memoire the hazard checklists in Error! Reference source not found. can be utilised at this stage to help identify potential hazards. On completion of the site visit, the task risk assessment team can conduct the remainder of the assessment primarily in an office-based environment. The procedure, work plan or method statement should be reviewed by the team and the HSE Task Risk Assessment Form in Error! Reference source not found. completed by: · · · ·
·
Listing each activity in the activity column. Listing the associated hazards identified from site visit or discussions that are associated with each activity. List the relevant associated effects (or “type of harm”) associated with each hazard. The team should then utilise the qualitative risk matrix and using their combined experience and judgement to rate the severity (guidance for levels of severity are given in Figure 2-5) of each effect on the Scale 1 to 5 (Negligible to Catastrophic). The probability should also be rated on the Scale A to E. The risk can then be stated as the product of probability and severity e.g. A.5. which from the qualitative risk matrix can be seen to fall in the medium risk (M) region.
2.10.6 THE QUALITATIVE RISK MATRIX The qualitative risk matrix can be used for many applications e.g. accident/incident investigation categorisation and in this case for pre-work risk assessment. As described above the task risk assessment team will have assessed the probability and severity of the various activities in the task being studied. This will result in the risk falling into one of three categories which require to be treated in deferent ways, i.e.: 2.10.6.1 HIGH RISK This is intolerable and work should not be undertaken unless steps can be taken to minimise risk and move it into the medium or low risk category. 2.10.6.2 MEDIUM RISK In this area the risk can be tolerable provided every effort is made to minimise the risk to as low as reasonably practicable (ALARP) by putting minimisation measures in place. Doc. Number
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2.10.6.3 LOW RISK This is considered an acceptable level of risk for industry.
2.10.7 MINIMISING THE RISK On completion of the evaluation of the initial risk level at either high or medium the team should now develop ideas or measures that will reduce the risk to as low as reasonably practicable. The “risk reduction measures” will normally be extra controls that will be put in place to result in risk reduction. The team should then assess the final risk on implementation of the risk reduction measures to either medium (ALARP) or to low and then slate final assessment as either acceptable or not acceptable.
2.10.8 CLOSING THE RISK ASSESSMENT LOOP The risk assessment should be given a unique reference number from the HSED – Index of Risk Assessments, controlled by the SOSE. Copies of the completed form should be sent to all Team members and a copy to the SOSE for central filing. The completed risk assessment forms should be used to incorporate the risk reduction measures into the procedures or other methods of work control. Any lessons learnt from the implemented control measures should be passed to the SOSE for future reference.
2.10.9 IMPLEMENTATION OF TRA RECOMMENDATIONS Control measures to minimise risk as identified in the TRA must be communicated to all employees on site in order for ensuring safety at the work site. These measures must be communicated to employees in the form of job specific tool box talk (HSE talk) prior to commencement of the work being performed. The Tool Box Talk (HSE talk) subject must address the hazards of the work being performed. Should conditions on the work site change which introduces new hazards that are not addressed in the Task Risk Assessment (TRA) then work should be suspended and the Safety Engineer informed. Safety Engineer and Job Officer will then discuss and decide the need for a further TRA and if required then Job Officer should reconvene the new TRA. Worked Example For guidance and as a point of illustration see Figure 2-7 and Figure 2-8 for completed risk assessment form.
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Chapter No. 02 PROBABILITY
A
SEVERITY
PEOPLE
ASSETS
ENVIRONMENT
REPUTATION
5. Catastrophic
Multiple fatalities or permanent total disabilities
Extensive damage
Massive effect
International impact
4. Severe
Single fatality or permanent total disability
Major damage
Major effect
National impact
3. Critical
Major injury or helath effects
Local damage
Localised effect
Considerable impact
2. Marginal
Minor injury or health effects
Minor damage
Minor effect
Minor impact
1. Negligible
Slight injury or health effects
Slight damage
Slight effect
Slight impact
B
Has occurred in world-wide industry but not in ADNOC
Has occurred in other ADNOC Group Company
C
D
E
Has occurred in specific ADNOC Group Company
Happens several times a year in specific ADNOC Group Company
Happens several times per year in same location or operation
HIGH RISK MEDIUM RISK (ALARP)
LOW RISK
Figure 2-5: Qualitative Risk Matrix Detailed breakdown of consequences for the Health Risk Management Categories Table 2-1: People Severity 5
Description Multiple fatalities - from an accident or occupational illness (poisoning, cancer).
4
Single fatality or permanent total disability - from an accident or occupational illness (poisoning, cancer).
3
Major injury or health effects (including Permanent Disability) – Affecting work performance in the longer term, e.g. prolonged absence from work. Irreversible health damage without loss of life, e.g. noise induced hearing loss, chronic back injuries.
2
Minor injury or health effects –Affecting work performance, e.g. restriction to activities (restricted work case –RWC) or need to take a time off work to recover (lost time incident – LTI). Limited, reversible health effects, e.g. skin irritation, food poisoning. Slight injury or health effects (incl. first aid case –FAC and medical treatment case –MTC). Not affecting work performance or causing disability.
1
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Table 2-2: Assets Severity 5 4 3 2 1
Description Extensive damage - Substantial or total loss of operation (costs in excess of US$10,000,000).* Major - Partial operation loss (2 weeks shutdown, costs up to US$10,000,000).* Local damage - Partial shutdown (can be restarted but costs up to US$500,000).* Minor damage - Brief disruption (costs less than US$100,000).* Slight damage - No disruption to operation (costs less than US$10,000)*.
These losses in US$ are meant as guidance only. Individual ADNOC Group Company may use more appropriate figures provided they are within the above quoted limits. Table 2-3: Environment Severity 5
4
.3
2
1
Description Massive effect - Persistent severe environmental damage or severe nuisance extending over a large area. In terms of commercial or recreational use or nature conservation, a major economic loss for the company. Constant, high exceedance of statutory or prescribed limits. Major effect - Severe environmental damage. The company is required to take extensive measures to restore polluted or damaged environment to its original state. Extended exceedance of statutory or prescribed limits. Localised effect - Limited loss of discharges of known toxicity. Repeated exceedance of statutory or prescribed limit. Affecting neighbourhood Spontaneous recovery of limited damage within one year. Minor effect - Contamination. Damage sufficiently large to attack the environment. Single exceedance of statutory or prescribed criterion. Single complaint. No permanent effect on the environment. Slight effect - Local environmental damage. Within the fence and within systems. Negligible financial consequences.
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Table 2-4: Reputation Severity 5
4
3
·.2
1
Description International impact - International public attention. Extensive adverse attention in international media. National/ international policies with potentially severe impact on access to new areas, grants of licenses and/ or tax legislation. National impact - National public concern. Extensive adverse attention in the national media. Regional/national policies with potentially restrictive measures and/ or impact on grant of licences. Mobilisation of action group. Considerable impact - Regional public concern. Extensive adverse attention in local media. Slight national media and/ or local/ regional political attention. Adverse stance of local government and/ or action groups. Limited impact - Some local public concern. Some local media and/or political attention with potentially adverse aspects for company operations Slight impact - Public awareness may exist, but there is no public concern
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Table 2-5: Hazards associated with plant and equipment (including non-powered plant and hand tools) CATEGORY Mechanical
TYPE OF HARM Trapping (crushing, drawing in and shearing injuries)
Impact (includes puncture)
Contact (Cutting, friction or abrasion)
Entanglement (rotating parts)
Ejection (of work piece or part of tool)
EXAMPLES OF HAZARD Two moving parts or one moving part and a fixed surface Conveyor belt and drive Vee belt and pulley Power press "in-running nips" Mangle Guillotine Scissors Stapler Using hammer Something that may strike or stab someone or can be struck against Moving vehicle Robot arm Sewing machine Drill Hypodermic needle Pendulum Crane hook Something sharp or with a rough surface Knife, chisel, saw, etc. Blender blade Circular saw blade Sanding belt Abrasive wheel Hover mower blade Drill chuck and bit Power take off shaft Pipe threading machine Abrasive wheel Cartridge tool Thicknessing machine Using hammer and chisel Abrasive wheel
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TYPE OF HARM Shock/burn/fire/explosion
EXAMPLES OF HAZARD Electricity above 240v Electricity - 240v Electricity- 110vCTE Extra low volt electricity Ignition sources Static Batteries Pressure Release of energy Compressed air (Explosion/injection/implosion Compressed gas ) Steam boiler Vacuum Hydraulic system Stored energy Flying/Failing materials Springs under tension Springs under compression Hoist platform/lift cage Conveyor tension weight Raised tipper lorry body Counterweight Load carried by crane Thermal Burns/fires/scalds/frostbite Hot surface Using blow lamp Welding flame/arc Refrigerant Steam Radiation Ionising Burns, cancer X Rays radiation a orb Radiation Neutrons Non ionising Burns Micro wave radiation Radio frequency Laser Ultra violet lnfra red Noise Hearing loss, tinnitus, etc. Noise > 85 dB(A)L EP,d Vibration Vibration white finger, whole Pneumatic drill body effects Operation of plant Stability Crushing Inadequate crane base Fork lift truck on slope Machine not bolted down Mobile Scaffold too high Scaffold not tied Overload/defectiv Crushing Crane overload e due to Chain sling mechanical failure Eye bolt overload Scaffold overload Hopper overfill Doc. Number
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Table 2-6: Hazards associated with materials and substances CATEGORY FIRE/EXPLOSIO N Combustion
TYPE OF HARM Burns
Increased Combustion Flammable substance (inc. Highly and Extremely Flammable) See also explosive below
Burns
Oxidising substance
Burns
Dust explosions
Burns
Burns
EXAMPLES OF HAZARD Timber stack Coal store Paper store Grease Magnesium Straw Plastic foam Oxygen enrichment Petrol Propane gas Methane Carbon Monoxide Methanol Paraffin Acetone Toluene Organic peroxide Potassium permanganate Nitric acid Explosive material Fireworks Proprietary explosives Detonators Some oxidising agents Highly flammable gas in confined space Coal dust Wood dust Aluminium powder Flour
Table 2-7: Health Hazards CATEGORY HEALTH HAZARDS Corrosive/irritatin g materials Particles
TYPE OF HARM Skin effects
EXAMPLES OF HAZARD Sulphuric acid Caustic soda Man made mineral fibre
Lung effects
Asbestos fibres
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Fumes
TYPE OF HARM
Acute and chronic effects on health (Local and systemic effects) Acute and chronic effects on health
Vapours
Gases
Acute and chronic effects on health
Mists
Acute and chronic effects on health
Asphyxiants
Acute and chronic effects on health
Health hazards by Burns to upper alimentary ingestion tract Poisoning
Hazards by contact
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Chapter No. 02 EXAMPLES OF HAZARD Silica dust Dust mite faeces Pigeon droppings Coal dust Grain dust Wood dust Lead fume Rubber fume Asphalt fumes Acetone 1,1 1-Trichloroethane Dichloromethane Benzene Lsocyanates Carbon monoxide Hydrogen sulphide Carbon disulphide Sulphur dioxide Oil mist Printing ink mist Water – legionelia Nitrogen Carbon dioxide Argon Toxic, harmful, corrosive and irritant liquids All harmful aerosols Polluted water Contaminated food and drink Swarf Rough timber Concrete blocks Molten metal Frozen food
Cuts, abrasions
Burns, Frostbite
Table 2-8: Hazards associated with the place of work CATEGORY Pedestrian Access
TYPE OF HARM Tripping, slipping
EXAMPLES OF HAZARD Damaged floors Trailing cables Oil spills Water on floors
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TYPE OF HARM
Work at heights
Falls
Obstructions
Striking against
Stacking/Storing
Failing materials
Work over/near liquids, dusts, grain, etc.
Fall into substances, drowning, poisoning, suffocation, etc.
Emergencies
Trapping in fire
Issue 02, Rev 05
Chapter No. 02 EXAMPLES OF HAZARD Debris Wet grass Sloping surface Uneven steps Changes in floor level Fragile roof Edge of roof Edge of mezzanine floor Work on ladder Erecting scaffold Hole in floor Low headroom Sharp projections High stacks Insecure stacks Inadequate racking Stacking at heights Grain silo Tank Reservoir Sump Work over river Work near canal Locked exits Obstructed egresses Long exit route
Table 2-9: Hazards associated with the working environment CATEGORY Light (NB: Also increases risk of contact with other hazards)
TYPE OF HARM Eye strain, arc eye and cataracts
Temperature
Heat stress, hypothermia Heat stress, sunburn, melanoma, hypothermia, etc.
Confined spaces
Asphyxiation, explosion,
EXAMPLES OF HAZARD Glare Poor lighting Stroboscopic effect Arc welding Molten metal Work in furnace Cold room Outdoor work Hot weather Cold weather Wind chill factor Work in rain, snow, etc. Work in tank
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Ventilation
TYPE OF HARM poisoning, etc.
"Sick Building Syndrome", nausea, tiredness, etc.
Issue 02, Rev 05
Chapter No. 02 EXAMPLES OF HAZARD Chimney Pit Basement Unventilated room Vessel Silo Fumes Odours Tobacco smoke
Table 2-10: Hazards associated with methods of work CATEGORY Manual handling
TYPE OF HARM Back injury, hernia, etc.
Repetitive movements
Work related upper limb disorders
Posture
Work related upper limb disorders, stress, etc.
EXAMPLES OF HAZARD Lifting Lowering Carrying Pushing Pulling Hot / Cold loads Roughloads Live loads - animal/person Keyboard work Using screwdriver Using hammer and chisel Bricklaying Plucking chickens Production line tasks Seated work Work above head height Work at floor level
Table 2-11: Hazards associated with work organisation CATEGORY Contractors
TYPE OF HARM Injuries and ill health to employees by contractors work Injuries and ill health to contractors' employees by work in premises.
EXAMPLES OF HAZARD Work above employees Use of harmful substances Contractors' welding Process fumes Services (e.g. underground electricity cables) Stored hazardous materials
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SAFETY MANAGEMENT CATEGORY Organisation of work
Work in public areas
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TYPE OF HARM Injuries to employees
EXAMPLES OF HAZARD Monotonous work Stress Too much work Lack of control of job Work too demanding Injuries and ill health of public Trailing cables Traffic/plant movement Obstruction to blind person Obstruction to prams, etc. Work above public Table 2-12: Other types of hazard
CATEGORY Attack by animals
TYPE OF HARM Bite, sting, crushing, etc.
Attack by people
Injury, illness, post trauma stress disorder
Natural hazards
Various injuries, illnesses
EXAMPLES OF HAZARD Bees Dog Bull Fleas Snake Criminal attack Angry customer Angry student Drunken person Drug abuser Mentally ill person Lightning Flash flood
Table 2-13: Hazards to Process Plant CATEGORY Vibration
TYPE OF HARM Plant trip
Dropped objects
Plant damage
Fire
Plant damage Production loss
EXAMPLES OF HAZARD Jack hammers Mobile cranes and equipment Portable motors and generators Cranes and lifting equipment Overhead work Scaffolding Hot work Cutting and welding Vehicle entry
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Figure 2-6: HSE Task Risk Assessment Form
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Figure 2-7: Example of Completed HSE Task Risk Assessment (i)
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Figure 2-8: Example of Completed HSE Task Risk Assessment (ii)
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2.11 AREA AUTHORITIES 2.11.1 INTRODUCTION To ensure that all locations and personnel in work areas have a clearly and defined personal responsibility for safety matters, a system of Area Authorities is in place in ADGAS, and is divided into two main areas, Industrial and Non-Industrial.
2.11.2 INDUSTRIAL AREA This area covers the LNG Plant, Storage and associated facilities. Within this area, the nominated Area Authorities have detailed responsibilities under the Permit To Work System.
2.11.3 RESTRICTED/ NON-INDUSTRIAL AREAS Industrial areas are divided into Restricted & Non Restricted Areas as shown in the Drawing No. 33-AOZ-03735 Rev 8. There are four (4) areas that are considered nonrestricted areas in the industrial areas. They are QMB, CCB, 501/502 Laydown Area and Train 3 Construction Jetty, as shown in Drawing No 33-AOZ-03735 Rev 8. Further Information OD Permit-To-Work Manual: Chapter 5
2.11.4 NON-INDUSTRIAL AREA ROUTINE WORK In general, routine work operations performed outside of the Industrial Area do not need a Permit-to-Work System, such as:Workshops: Excluding any modifications/construction work on the Workshop itself. General Maintenance of Buildings and Offices: To carry out light maintenance of the building, such as cleaning, painting, plumbing, bulbs and tube lights replacement, fixing of cupboards shelving etc. Cleaning/ replacement of HVAC window units, alarm testing and floor tile replacement. ADGAS Stores Areas: Excluding any modifications/construction work.
2.11.5 PERMIT WORK There are certain classes of work, normally of a routine nature, for which a standard written authorisation, to initiate such work, is essential to ensure the safe conduct of working. The following are operations that do require a Permit-to-Work. Doc. Number
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Welding/gas cutting torches. Excavation/Trenching. Confined Space Entry. Working on elevated places (roofs, walls etc.). Cable laying/Electrical Isolation. Service piping modifications.
2.11.6 TYPES OF PERMITS Standard documentation for the above work can be in the form of:· ·
A Long Term Permit or, A Non-Industrial Area Permit.
2.11.7 NOMINATED AREA AUTHORITIES Table 2-14: Area Authorities Plant (Industrial) Area Plant (Industrial) LNG Plant Process Area. Utilities Area. Installations Area. 501/ 502 Laydown Area QMB Train 3 Construction Jetty CCB
Title HSO OC(P) OC(U) OC(S) HTAP LME(M) HTAP HSO
Table 2-15: Outside Plant (Non Industrial) Product & Quality (Lab) OMA Building Safety Building ADGAS Office Building Materials Stores Central Workshop Training Office & Workshop Al-Jimi Village Project Building Contractors Yards
HPQ SSSE(P) SSSE(P) SPO (Das) HMO MGTS T&DC SAO SSSE(P) (old E&TSD Building) MGTS
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2.11.8 RESPONSIBILITIES OF AREA AUTHORITIES The general responsibilities for Area Authorities (Non-Industrial Areas) are:· · · · · ·
To ensure that no work in their area of responsibilities proceeds without their knowledge and clearance. To act as a focal point for safety matters in their area and initial contact for contractors working in their area of responsibility. To initiate the Non-Industrial Area Permit, Figure 2-9, if required for work to commence in their area of responsibility To highlight all hazards in the work area covered by the permit. To ensure that employees and contractors working in their area have received a safety induction (Random checks shall be carried out for currency of induction card which for contractors is valid for three years only). Exclusively for QMB, CCB, 501/502 Laydown and Train 3 Construction Jetty areas, Non Industrial permit applies, however Area Authority must ensure that Shift Superintendent countersigns the Non-Industrial Permit prior to performing any Naked Flame job. Note Any person leaving ADGAS for a period exceeding six months will require Safety Induction on his return to the ADGAS facilities.
2.11.9 JOB OFFICERS All ADGAS Job Officers with responsibility for contractors, must ensure that the NonIndustrial Area Permit is completed and signed by all parties before commencement of work. Also, that the Performing Authority is fully aware of the scope of work and any associated hazards.
2.11.10
PERFORMING AUTHORITY
In the Non-Industrial Area, the Performing Authority shall be the person nominated by the ADGAS Job Officer.
2.11.11
PROCEDURE FOR ISSUE OF PERMITS (NON-INDUSTRIAL)
The procedure for the permit issue, to the completion of work, is as follows: · · ·
The Job Officer, initiating the Permit Application, fills in Section ‘A’ and passes it to the Area Authority. After being informed by the Job Officer of the scope of work to be performed, the Area Authority will complete Section ‘B’ of the permit, indicating any hazards in the area covered by the permit. Section ‘C’ will be completed by the Job Officer after being informed of any job hazards and means of control.
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The Performing Authority will complete Section ‘D’ after being informed of the full scope of work and any hazards in the area of work.
Before the work is commenced, the Performing Authority shall ensure that all personnel carrying out the work are aware of the exact identity, nature, extent of the job, hazards involved and means of control · · · · ·
Section ‘E’ will be completed by the Performing Authority, accepted by the Area Authority and the Job Officer will then sign off the work on the white copy along with the pink copy. The white copy is retained by the Job Officer, and completed at the end of the job for reference only. The yellow copy is retained by the Performing Authority and displayed on the work site until the job is completed. The green copy is forwarded to the SOSE for reference and scrutiny. The pink copy remains with the Area Authority, to be completed when the job has finished and the area is accepted. This copy is then signed off along with the white copy. Further Information OD Permit to Work Manual Chapter 3.14
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Chapter No. 02
NON-INDUSTRIAL AREA PERMIT A.
Job Officer Serial Name:__________________________________ No.____________ Location of WorkSite: Date: ______________________________ ________________ Description of Work: _____________________________________________________ Tools & Equipment to be Used: ____________________________________________
B.
AREA AUTHORITY :- I confirm that I have discussed the Scope of Work with the Officer who has been Job advised of the following hazards and means of control: Hazard Means of Control
Name: _____________Signature: _____________ Designation: _________Date: ______ C.
JOB OFFICER:- I confirm that I have discussed the Scope of Work with the Authority and have Area been informed of the hazards and the means of control as Section listed in ‘B’. Name: _____________Signature: _____________ Designation: _________Date: ______
D.
PERFORMING AUTHORITY : I confirm that I am aware of the Scope of Work and been advised on the hazards haveas listed in Section ‘B’ and will inform my workforce the job, hazards of and means of control. Name: _____________Signature: _____________ Designation: _________Date: ______
E.
Time: _________ Signature: W ORK COMPLETED: Date: __________ ____________ Performing Name: Authority: ______________________________________ Work & Area Area AuthorityDate:______Signature:________ Accepted: Name:_____ _____ Signature: ____________ Job Officer: Date: ______ Name:_____________
Distribution:
White copy – Job Officer, Yellow copy – Performing Authority
Green copy – SHSEE, Pink copy – Area Authority
Figure 2-9: Non-Industrial Area Permit
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M.P. 3 M.P. 2 M.P. 4
M.P. 1
M.P. 5 M.P. 6
M.P. 7
SAFETY DEPT
M.P. 8
AL-JIMI VILLAGE A MESS OASIS CLUB B & C MESS
AL JAZERA CLUB
MARSHALLING POINTS - INDUSTRIAL AREA MARSHALLING POINTS - NON-INDUSTRIAL AREA INDUSTRIAL AREA
Figure 2-10: MAP OF INDUSTRIAL / NON-INDUSTRIAL AREA
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2.12 MANAGEMENT OF CHANGE 2.12.1 PLANT MODIFICATIONS AND PROJECTS 2.12.1.1 INTRODUCTION Procedures for modifications to the plant and the design, construction and commissioning of new facilities are required to ensure that appropriate engineering and HSE controls are implemented. The procedures detail all items required from initiation through to physical completion, commissioning and post commissioning evaluation. Further Information ADNOC GROUP GUIDELINE HSEM S5.5 Management of Change 2.12.1.2 OBJECTIVE To ensure that in the design, construction and commissioning of new facilities, or modification to existing facilities, due attention is paid to the safety of personnel and plant as stated in the Health, Safety and Environment Management Policy. The means to achieve this are firstly, by correct specification and utilisation of appropriate Codes and Standards in order to obtain the relevant approvals and secondly, the rigorous application of safety review techniques at all stages. All documentation relating to any modification shall be logged and maintained within the Company records for future retrieval if required.(held by Engineering Division). 2.12.1.3 DETAILED PROCEDURES The procedures for work involving modifications and new construction is detailed in ETSD SI, D-1. Modification Procedures. 2.12.1.4 SCOPE OF THE MODIFICATIONS PROCEDURE Consideration for applying the Modifications Procedure must be considered for the following changes: ·
· · · ·
Operating conditions including; o routes o materials o system parameters o isolations o relief arrangements o line specifications Operating parameters Control logic Trip systems New Construction Doc. Number
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Minor changes Temporary changes Intermittent Plant Changes Plant documentation of the Engineering Division including: o Standing Instructions o Procedures o Plant Manuals
2.12.1.5 JOINT INTERFACE MODIFICATION BETWEEN ADMA-OPCO & ADGAS All modifications / studies on interface systems affecting joining systems between the two companies must be mutually agreed before implementation. Any development process of any changes of the following systems should be done with the involvement of ADMA OPCO Technical Support. · · · · · · · · · · · · · · · · · · ·
LNG/ ADMA OPCO manifold location West of 7th Street (includes Feed Gas Inlet line – atmos., 35#, 75#, 230# and 780 – HP). 6” Pentane Spiking line West of Tank D 15. Oily water line from discharge separators (includes oily water from 21-C-1/C-2/C-3) Sulphur Product Steam and Condensate line (ADGAS OBL) Fuel Gas line to ADMA Power station (includes 11KV Switch Room) 30” Firewater Backup line (33-MOV-196) Potable water supply line (to ADGAS) BFW make-up to ADMA utilities. Knockout drums for onshore flares (includes HP relief header in North foreshore area) 60” Manifold at Plant 26 (Booster Compressors suction header) Nitrogen Supply line. Stripping (Sweet Gas Supply to Strippers) gas lines. Cooling Water supply (includes the header supplying to fire main) Ground and Elevated Flares Plant 26 pipelines to LNG Manifold 30” MGL valve pit near LNG/ LPG Tank Farm Area ADMA-OPCO Blow Case No. 6 (located at the junction of Road 6 and 6th Street) Feed Gas Compressors (Trains 1 & 2) relief line to HP Relief Header Oily water line from Booster Compressors to BQ.
2.12.2 ORGANISATIONAL CHANGES 2.12.2.1 INTRODUCTION Organisational change is a normal and inevitable part of ADGAS's business, however, such changes, if poorly managed, can lead to unwanted consequences such as accidents and plant failures. Organisations associated with major accident hazards, such as ADGAS, have the potential for disastrous consequences and high costs in terms
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of lives and money, and therefore all organisational changes require to be carefully managed. 2.12.2.2 OBJECTIVES The objective of this guidance is to ensure that organisational changes are analysed and controlled as thoroughly as plant modifications. Also, organisational change may lead to opportunities to improve HSE standards, for example through the reappraisal of safeguards or clarification of personal accountabilities. 2.12.2.3 SCOPE OF ORGANISATIONAL CHANGES Organisational changes which may need to be managed include changes to: · · · · · · · · ·
Roles and responsibilities Organisational structure Staffing levels Shift rotas Key personnel Communication systems or reporting relationships Personnel resources Management systems Availability of specialist expertise (for design, engineering support, procurement etc.).
2.12.2.4 CONTROLS The UK Health and Safety Executive (http://www.hse.gov.uk/) provide guidance on how to manage organisational changes. Further Information Chemical Information Sheet No CHIS7: Organisational Change and Major Accident Hazards Contract Research Report 348/2001: Assessing the safety of staffing arrangements for process operations in the chemical and allied industries The HSED will provide guidance and support to Departments who are implementing organisational changes.
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CHAPTER 3 CONTENTS 3
GENERAL AND PERSONAL SAFETY ................................................................................................. 83 3.1 SAFETY INDUCTION ...................................................................................................................... 83 3.1.1 ATTENDANCE ............................................................................................................................... 83 3.1.2 CATEGORIES ................................................................................................................................ 83 3.1.3 RECORDS ...................................................................................................................................... 83 3.1.4 SAFETY TRAINING MANUAL ...................................................................................................... 83 3.1.5 JOB OFFICERS RESPONSIBILITY .............................................................................................. 84 3.2 VISITORS .......................................................................................................................................... 84 3.2.1 DEFINITION.................................................................................................................................. 84 3.2.2 ROLE OF THE GUIDE/HOST....................................................................................................... 84 3.2.3 COMPLIANCE ............................................................................................................................... 84 3.2.4 VALID PASSES .............................................................................................................................. 84 3.2.5 PERMISSION ................................................................................................................................. 85 3.2.6 NATIONAL DRESS ........................................................................................................................ 85 3.2.7 VISITOR REGULATION CHECKLIST .......................................................................................... 85 3.3 RESTRICTED AREAS ...................................................................................................................... 86 3.3.1 GENERAL ...................................................................................................................................... 86 3.3.2 DAS ISLAND .................................................................................................................................. 86 3.3.3 CONSTRUCTION SITES ............................................................................................................... 86 3.3.4 INDUSTRIAL AREAS ..................................................................................................................... 86 3.4 HAZARDOUS AREAS AND ZONES ............................................................................................... 86 3.4.1 INTRODUCTION ........................................................................................................................... 86 3.4.2 HAZARDOUS ZONES .................................................................................................................... 87 3.4.3 VERTICAL/HORIZONTAL BOUNDARIES ................................................................................... 87 3.4.4 HAZARDOUS ZONE DRAWINGS ................................................................................................. 87 3.4.5 RESPONSIBILITY .......................................................................................................................... 88 3.4.6 IGNITION SOURCES .................................................................................................................... 89 3.4.7 BATTERY EQUIPMENT, MATCHES AND LIGHTERS ................................................................ 89 3.4.8 SMOKING ...................................................................................................................................... 90 3.5 HOUSEKEEPING .............................................................................................................................. 90 3.5.1 GENERAL ...................................................................................................................................... 90 3.5.2 HOUSEKEEPING COMPETITION ............................................................................................... 91 3.6 WASTE MANAGEMENT ................................................................................................................. 91 3.6.1 GENERAL ...................................................................................................................................... 91 3.6.2 WASTE IDENTIFICATION AND CLASSIFICATION ................................................................... 93 3.6.3 WASTE SEGREGATION AND COLLECTION .............................................................................. 94 3.6.4 RESPONSIBILITIES ...................................................................................................................... 95 3.6.5 RECORDS ...................................................................................................................................... 95 3.7 PERSONAL SAFETY ........................................................................................................................ 95 3.7.1 GENERAL SAFETY RULES ........................................................................................................... 95 3.7.2 ALCOHOL AND DRUGS ............................................................................................................... 95 3.7.3 FINGER RINGS, NECK CHAINS AND BRACELETS ................................................................... 96 3.8 SAFETY SIGNS AND BARRIERS ................................................................................................... 96 3.8.1 INTRODUCTION ........................................................................................................................... 96 3.8.2 ROLE OF SAFETY SIGNS ............................................................................................................. 96 3.8.3 DEFINITIONS ................................................................................................................................ 96 3.8.4 CLASSIFICATION ......................................................................................................................... 97 3.8.5 COLOURS ...................................................................................................................................... 97 3.8.6 VISIBILITY ..................................................................................................................................... 97 Doc. 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3.8.7 GENERAL ...................................................................................................................................... 98 3.8.8 PORTABLE SIGNS ........................................................................................................................ 98 3.8.9 ROAD TRAFFIC SIGNS ................................................................................................................ 99 3.8.10 BARRIERS ................................................................................................................................. 99 3.9 PERSONAL PROTECTIVE EQUIPMENT ..................................................................................... 100 3.9.1 INTRODUCTION ......................................................................................................................... 100 3.9.2 MINIMUM SAFETY WEAR ......................................................................................................... 100 3.9.3 HAZARDS .................................................................................................................................... 101 3.9.4 HEARING PROTECTION ............................................................................................................ 101 3.9.5 HEAD PROTECTION .................................................................................................................. 102 3.9.6 FOOT PROTECTION .................................................................................................................. 103 3.9.7 EYE AND FACE PROTECTION .................................................................................................. 104 3.9.8 OPTICAL FILTERS...................................................................................................................... 105 3.9.9 HAND PROTECTION .................................................................................................................. 105 3.9.10 VISORS/FACE SHIELDS ........................................................................................................ 106 3.9.11 BODY PROTECTION .............................................................................................................. 106 3.9.12 RESPIRATORY PROTECTIVE EQUIPMENT ........................................................................ 107 3.10 MANUAL HANDLING ................................................................................................................... 111 3.10.1 INTRODUCTION .................................................................................................................... 111 3.10.2 RISK IDENTIFICATION ......................................................................................................... 111 3.10.3 RISK FACTORS ....................................................................................................................... 112 3.10.4 SAFE MANUAL HANDLING .................................................................................................. 113 3.10.5 TRAINING ............................................................................................................................... 117 3.10.6 SUPERVISION ........................................................................................................................ 117 3.10.7 PROTECTIVE CLOTHING ..................................................................................................... 117 3.10.8 RISK CONTROL ...................................................................................................................... 117 3.10.9 RISK CONTROL OPTIONS..................................................................................................... 118 3.11 HEARING CONSERVATION ......................................................................................................... 118 3.11.1 INTRODUCTION .................................................................................................................... 118 3.11.2 DEFINITIONS ......................................................................................................................... 119 3.11.3 HEARING CONSERVATION PROGRAMME ......................................................................... 119 3.11.4 NOISE ASSESSMENT ............................................................................................................. 120 3.11.5 HEARING CONSERVATION METHODS ............................................................................... 121 3.11.6 NON-HAZARDOUS NOISE .................................................................................................... 122 3.11.7 NOISE PROBLEM INDICATORS ........................................................................................... 122 3.12 EYE SAFETY PROGRAMME ........................................................................................................ 123 3.12.1 PURPOSE................................................................................................................................ 123 3.12.2 OBJECTIVES........................................................................................................................... 123 3.12.3 SPECIFIC REQUIREMENTS.................................................................................................. 123 3.12.4 EYE TESTING ......................................................................................................................... 124 3.12.5 PRESCRIPTION GLASSES ..................................................................................................... 124 3.12.6 CONTACT LENSES ................................................................................................................. 124 3.12.7 SAFETY SPECTACLES/ EYESHIELDS/ OVERSPECS........................................................... 124 3.13 VEHICLES AND BICYCLES .......................................................................................................... 125 3.13.1 INTRODUCTION .................................................................................................................... 125 3.13.2 GENERAL PRECAUTIONS .................................................................................................... 126 3.13.3 REVERSING ............................................................................................................................ 126 3.13.4 PASSENGER SAFETY ............................................................................................................. 126 3.13.5 PASSENGER LOAD LIMITS ................................................................................................... 127 3.13.6 SPEED LIMITS........................................................................................................................ 127 3.13.7 ROAD LIMITS ......................................................................................................................... 127 3.13.8 ROAD CLOSURES (TOTAL/PARTIAL) .................................................................................. 127 3.13.9 ROAD MOVEMENT OF WIDE IRREGULAR LOADS ........................................................... 128 Doc. 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3.13.10 DRIVER TRAINING ................................................................................................................ 128 3.13.11 LOADING/UNLOADING ........................................................................................................ 128 3.13.12 PROJECTING or WIDE LOADS ............................................................................................. 128 3.13.13 TOWING .................................................................................................................................. 128 3.13.14 MAINTENANCE ...................................................................................................................... 129 3.13.15 BICYCLES ............................................................................................................................... 129 3.14 HEAT DISORDERS ......................................................................................................................... 129 3.14.1 INTRODUCTION .................................................................................................................... 129 3.14.2 BODY HEAT RESPONSES ...................................................................................................... 130 3.14.3 ACCLIMATISATION ............................................................................................................... 130 3.14.4 BODY TEMPERATURE .......................................................................................................... 130 3.14.5 HEAT EXHAUSTION .............................................................................................................. 131 3.14.6 HEAT STROKE........................................................................................................................ 131 3.14.7 TEMPERATURE LIMITATIONS ............................................................................................. 132 3.15 SAFE ACCESS AND WORK PLACES ........................................................................................... 133 3.15.1 INTRODUCTION .................................................................................................................... 133 3.15.2 ENTRANCE AND EXIT ........................................................................................................... 133 3.15.3 RESTRICTED AREAS ............................................................................................................. 133 3.15.4 TEMPORARY ACCESS ........................................................................................................... 134 3.15.5 ACCESS TO ELEVATED AREAS ............................................................................................ 134 3.15.6 ESCAPE ROUTES ................................................................................................................... 134 3.15.7 SAFE WORK PLACES ............................................................................................................ 135 3.16 OFFICE SAFETY ............................................................................................................................. 137 3.16.1 FIRE ........................................................................................................................................ 137 3.16.2 TRIPS and FALLS.................................................................................................................... 137 3.16.3 LIFTING .................................................................................................................................. 138 3.16.4 HAZARDOUS SUBSTANCES.................................................................................................. 138 3.16.5 ELECTRICAL HAZARDS ........................................................................................................ 138 3.16.6 WORKSTATION ...................................................................................................................... 138 3.16.7 BREAKS ................................................................................................................................... 140 3.16.8 FIRST AID ............................................................................................................................... 141
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3 GENERAL AND PERSONAL SAFETY 3.1 SAFETY INDUCTION 3.1.1 ATTENDANCE All personnel regardless of employer or grade shall have attended an ADGAS safety induction (A) course before working for ADGAS on Das Island. Until such induction is completed the personnel are to be regarded as visitors and treated accordingly.
3.1.2 CATEGORIES The following categories of Safety Induction Courses are available. · ·
·
Senior staff (English Language) o ADGAS o Contractor Breathing Apparatus and Resuscitation o Junior staff o English o Arabic o Hindi o Urdu o Malayalam Visitor briefing
3.1.3 RECORDS Records are kept of all personnel inductions and an attendance card issued to the attendee. The number of the induction card is referenced to personal possum card numbers. Job Officers can check attendees records by advising HSED of possum numbers.
3.1.4 SAFETY TRAINING MANUAL Full details of the course content for inductions is contained in the Safety Training Manual · · ·
The Safety Training Manual specifies the minimum safety training requirements for various categories of Company and Contract personnel. Initial and Refresher training are essential to ensure that all personnel are adequately trained to carry out their appointed tasks safely. The Safety Training Manual is a guide for line managers to identify the training needs of their subordinates to fulfil their obligations under the Health, Safety and Environment training policy. Doc. Number
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3.1.5 JOB OFFICERS RESPONSIBILITY Job Officers are responsible for arranging safety inductions for all personnel under their control. The Health, Safety and Environment Engineer (Training) shall be advised, wherever possible, at least 48 hours prior to the induction Further Information ADNOC-COPV4-01: FRAMEWORK OF OCCUPATIONAL SAFETY RISK MANAGEMENT. Section 8. TRAINING AND COMPETENCY
3.2 VISITORS 3.2.1 DEFINITION A visitor is a person who is not normally a resident of Das Island and who will be accompanied throughout their visit to the Plant by a member of ADGAS staff who will be responsible to the Plant Manager for the visitor's safety and conduct.
3.2.2 ROLE OF THE GUIDE/HOST The person designated to accompany the visitor(s) should ensure that the visitor are provided with helmet, ear protection, eye protection, self rescue respirator and check list (Refer to Error! Reference source not found.). the contents of the check list should be explained to the visitor(s) with particular emphasis given to: · · · ·
No matches/lighters to be carried. No calculator, telephones, bleepers which are Non- Intrinsically safe Use of Self Rescue Respirator Action if alarm sounds.
3.2.3 COMPLIANCE All personnel proceeding to Das Island shall comply with the Health, Safety and Environment Manual as well as any other requirements stipulated by the respective divisional or departmental manager.
3.2.4 VALID PASSES All visitors shall be in possession of a valid security card to the installation issued by the Oil Installation Security Department and Area Access Pass (Possum Cards) as appropriate for their visit. The areas to be visited shall be indicated on the card.
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3.2.5 PERMISSION The person responsible for visitor proceeding to Das Island shall ensure that the relevant Divisional/Departmental heads permission, as appropriate, is obtained at least twentyfour hours prior to the person(s) entering a restricted area.
3.2.6 NATIONAL DRESS Guides/Hosts are to ensure that visitors in National Dress are not placed in a position where the lack of Personal Protective Equipment would put them at risk. When entering the Industrial Area, visitors must stay in the bus/ car. If they wish to enter into the Plant area, then they must comply with the minimum requirements as per Chapter 3-9 “Minimum Safety Wear”.
3.2.7 VISITOR REGULATION CHECKLIST THE FOLLOWING REGULATIONS ARE MANDATORY ON ENTRY TO THE ADGAS FACILITIES. · · · · · · ·
All personnel require an Area Access Pass (Possum Card) and a Security Pass to enter the Industrial Area. Smoking is not permitted in any Industrial Area except where valid Smoking Permits are displayed. Matches and lighters must NOT be carried by any person. Safety Helmets and Safety Glasses will be worn in the designated areas. Self Rescue Respirator is issued and must be kept close at hand at all times. Ear plugs or ear muffs are issued and shall be worn in the designated hearing protection areas. Visitors will be accompanied by an ADGAS employee at all times. The Shift Superintendent should be informed of the visit when the visit is about to start. On a fire or gas outbreak, the alarm siren will be sounded and the staff member will direct you across wind to safety. When the alarm sounds, use your respirator immediately.
Note These sirens are tested at 07.30 (ADMA) 07.35 hours (ADGAS) and 07.40 hours (ADGAS Tank Farm) on Thursdays when no action is required of the visitor. Only personnel authorised by the Ministry of Petroleum Security Branch may use a camera, and only then when accompanied by a Police Officer and having obtained the necessary ADGAS permit. Evidence of identity may be requested at any time by a member of staff and it should be noted that entry to the Jetty Area is forbidden without the clearance of the Storage & Export Superintendent.
Caution The emergency telephone number for the lng Control Room is 62222
Warning Non-intrinsically safe pagers, Mobile telephones, Computers, Calculators and other non approved electronic equipment shall not be taken into the lng Plant
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3.3 RESTRICTED AREAS 3.3.1 GENERAL These are areas where only authorised personnel are permitted to enter because of the requirement for special precautions due to the high risks presented by an explosive atmosphere, toxic or hazardous substances, e.g. H2S, radioactivity, etc.
3.3.2 DAS ISLAND ·
· · · · ·
The Restricted Areas on Das Island are those areas where hydrocarbons are processed, stored or loaded, offshore flares and central manifold platform. It includes that part of the water surface bounded by an imaginary line not less than 100 metres from a berthed tanker and from any tanker moving within the Port limits. The management of both ADGAS and ADMA-OPCO exercise strict control over all movements and operations in those Restricted Areas for which they are respectively responsible. Within the Restricted Areas the majority of work is not permitted unless authorised by the issue of a Work Permit. Outside the Restricted Areas all work involving excavations, valve pits, sewage systems, domestic gas supplies and major modifications to buildings is also covered by Work Permits. Restricted Areas shall only be entered or left by recognised routes according to local restriction area notice. No unauthorised or non-operational craft may enter a Marine Restricted Area without permission.
3.3.3 CONSTRUCTION SITES Any ADGAS area that is designated a construction site is subject to the same restrictions and regulations in force in that area. Dispensations for specific types of work shall be authorised by the PM after consultation with concerned managers and MHSE.
3.3.4 INDUSTRIAL AREAS That part of Das Island for which a valid area access pass (Possum Card) is required for entry. The ADGAS Industrial area is that part of Das Island containing the ADGAS Plant, Storage and other facilities. The other three industrial areas on Das Island are Airport, Harbour and ADMA-OPCO. Drawings : A-33-AOZ-0-3735-0001-8 & A-100A1Z-0-10034-0001-0
3.4 HAZARDOUS AREAS AND ZONES 3.4.1 INTRODUCTION A further division within the restricted area is the classification of the plant into hazardous areas zones, in which there is a known risk that a flammable atmosphere may occur, and Doc. Number
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into non-hazardous areas in which such a risk is non-existent or may be neglected. This provides the basis for the selection and protection of electrical and instrument equipment appropriate to the defined areas, and for the safe positioning of other potential or actual sources of ignition (e.g. fired heaters).
3.4.2 HAZARDOUS ZONES A hazardous zone is defined by the distance in any direction from the source of potential release to a point where the ignition potential of the flammable atmosphere created would have dropped to below the lower flammable limit. The classifications are: Zone 0 Areas where the explosive atmospheres are continually present for long periods, i.e. vapour space of a storage tank for flammable liquids. Zone 1 Areas where the explosive atmospheres are likely to occur during normal plant operations, i.e. leakages from pump shafts, control valves, automatic instrument gas vents, sump vents, etc. Zone 2 Areas where explosive atmospheres are not likely to occur except during abnormal circumstances and when it does occur is of short duration, i.e. flange joints, gauge glasses, etc. Non Hazardous Areas These contain no source of flammable materials.
3.4.3 VERTICAL/HORIZONTAL BOUNDARIES It should be remembered that hazardous zones extend horizontally and vertically over the source of the dangerous atmosphere and in some cases overlapping of different zones may exist.
3.4.4 HAZARDOUS ZONE DRAWINGS Hazardous zone drawings are prepared for all ADGAS facilities in general accordance with BS EN 60079-14:2003, BS EN 60079-25:2004 and BP RP 44-6. The application of these codes of practice refers to normal operating conditions and does not cater for catastrophic situations, e.g. rupture of a process vessel or large pipeline.
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Further Information BS EN 60079-14:2003: Electrical apparatus for explosive gas atmospheres. Electrical installations in hazardous areas (other than mines) BS EN 60079-25:2004: Electrical apparatus for explosive gas atmospheres. Intrinsically safe systems BP RP 44-6 Copies of the hazardous zone drawings are enclosed as Appendices 1 to 14 at the end of the Manual as follows: Appendix 3-4-1 1 of 6) Appendix 3-4-2 2 of 6) Appendix 3-4-3 3 of 6) Appendix 3-4-4 4 of 6) Appendix 3-4-5 5 of 6) Appendix 3-4-6 6 of 6) Appendix 3-4-7 DOP-P7851) Appendix 3-4-8 016) Appendix 3-4-9 017) Appendix 3-4-10 Appendix 3-4-11 Appendix 3-4-12 0001-1) Appendix 3-4-13 0001-2) Appendix 3-4-14 0002)
Process & Utilities Area
(Drg. No.33-AOZ-0-3785
Blowdown & Flare Area
(Drg. No.33-AOZ-0-3785
LNG/LPG Storage Tanks (Old)
(Drg No. 33-AOZ-0-3785
LNG/LPG Storage Tanks (New)
(Drg. No.33-AOZ-0-3785
Jetty Walkway & Head (LNG/LPG)
(Drg. No.33-AOZ-0-3785
Booster Compressor/QMB
(Drg. No.33-AOZ-0-3785
New Seawater Intake
(Drg. No.C42/43-30-
Composite Area 6, Trains 1 & 2, Plant
(Drg. No. RMP-7-EP-0-
Composite Area 6, Trains 1 & 2, Elevation (Drg. No. RMP-7-EP-0Sulphur OBL Facilities Sulphur Berth Third LNG Train - Plan
(Drg. No. EB-A-42004) (Drg. No. EB-A-42005) (Drg. No. 100-AOP-3-
Third LNG Train - Elevation
(Drg. No. 100-AOP-3-
BOG Compressor Area.
(Drg. No. 100-AIP-3-
3.4.5 RESPONSIBILITY The responsibility for area classification rests with the Hazardous Area Classification Committee chaired by MHSE or his Deputy. The committee shall submit any recommendations for changes to the Plant Manager. The composition and terms of reference of this committee can be found in Section 2.4 of this manual. It is important that, when considering modifications to process equipment or operating procedures, the requirements of area classification are considered and reviewed by the Doc. Number
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committee responsible for area classification. Where changes are necessary, it is essential that they be recorded, and any re-classification implemented immediately by updating of drawings. A similar review shall be carried out periodically to ascertain whether the area classification is being affected by deterioration in the performance of process equipment, or by any other changed circumstances. Further Information Model Code of Safe Practice for the Petroleum Industry. Part 15: Area Classification Code for Installations Handling Flammable Fluids 3rd ed., July 2005. ISBN 0 85293 418 1 BP RP 44-6 :Area Classification BS EN 60079-14:2003: Code of Practice for the Selection, Installation and Maintenance of Electrical Apparatus for Use in Potentially Explosive Atmospheres BS EN 60079-25:2004: Electrical Apparatus for potentially explosive atmospheres
3.4.6 IGNITION SOURCES Within Restricted Areas no ignition source may be introduced without an authorised Hot Work or Naked Flame Permit. Examples of local ignition sources that are capable of igniting flammable substances are: · · · · · · · · · · ·
All naked flames, fires, exposed incandescent material including pyrophoric deposits, electric arcs and sparks. Electric and gas welding torches. Grit and shot blasting apparatus. Power operated grinders and cutting machines. Electrical equipment of normal industrial type, i.e. that which is not flame proof, intrinsically safe or approved. Power operated ferrous tools in contact with dry concrete, stone or masonry. Internal combustion engines. Diesel engines that are not provided with approved inlet and exhaust systems and ancillary electrical equipment. Any machine capable of producing a local source of ignition. All instruments embodying the use of electricity either in the driving, indicating or recording mechanism that are not flame-proof, intrinsically safe or approved. Static electricity
3.4.7 BATTERY EQUIPMENT, MATCHES AND LIGHTERS The carrying of matches, safety or otherwise, lighters, non-approved electric torches and other battery operated equipment (i.e. not flame proof or intrinsically safe) such as portable transistor radios, tape recorders, portable telephones or Etisalat commercial
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pagers is strictly forbidden in Hazardous Areas. Special matches or igniters for particular purposes may be used but only by nominated persons under the Permit to Work System. Batteries themselves are to be considered "battery operated equipment". Batteries will only be changed in a pressurised/safe area. A Hot Work Permit shall be obtained to carry out any work requiring the use of nonapproved battery operated equipment.
3.4.8 SMOKING Smoking is forbidden in any Restricted Area except in specially selected places referred to as "designated smoking areas" in which a valid Smoking Permit is displayed. In places where smoking is permitted, matches or other means of ignition and incombustible receptacles for spent matches shall be provided. "No Smoking" notices are prominently displayed at entrances to all Restricted Areas and at all exits from places where smoking is permitted. Smoking is prohibited on all chartered flights to and from Das Island.
3.5 HOUSEKEEPING 3.5.1 GENERAL All plant and areas under the authority of ADGAS will maintain the highest possible standard of housekeeping. High standards contribute to safe working conditions, where as poor housekeeping is one of the major causes of accidents and incidents. The work place should be tidy before beginning a task, at the end of shifts and on completion of the task. This should be specified on the Work Permit and should not be signed off until the area is clear of all work materials. Floors will be kept free from oil, grease and other slippery substances and kept clean at all times. Staircases, gangways, passages and doorways shall be kept clear of obstructions. All handrails, safety railings and netting should be kept in good repair. Toe boards shall be fitted to all overhead platforms, gangways, scaffolding and work places, etc. to prevent articles from falling or rolling off. Suitable receptacles should be provided for the collection of solid and liquid waste materials and marked as such, e.g. waste oil. These should be emptied at regular intervals. Doc. Number
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Any unnecessary materials or liquids shall not be permitted to accumulate in areas or stores. Unnecessary tools and equipment should be removed from work sites and returned to stores. Solvents, paints, flammable liquids, chemicals and explosives are to be stored in locked containers or stores used solely for the purpose. The containers or stores are to be located outside of workshop, portacabin and working areas. Fire or emergency equipment should never be obstructed by stacking objects around or in front of them. Hoses, wires, ropes and electric cables should never be left over walkways where people could trip over them. Electric/welding cables should be kept out of water. Fire doors should never be obstructed by cables or propped open by fire extinguishers. Guards, rails and gratings should never be removed before first erecting barriers and warning notices. Concentrations of dust should not be allowed to build up on structures, shelves, ledges etc. in stores or other buildings.
3.5.2 HOUSEKEEPING COMPETITION A housekeeping promotion programme involving quarterly inspections is carried out in the following areas. · · · · · · · ·
CWS QMB Utilities & NSI Materials Stores LNG/LPG Jetties and Tank Farm Train 1 and Plants 18 & 19 Train 2 and Plant 26 Train 3
A standard checklist is used by the HSED to assess each area and quarterly and annual winners are selected.
3.6 WASTE MANAGEMENT 3.6.1 GENERAL A waste is material which is discarded or intended to be discarded.
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The management of waste calls for a great degree of supervision to minimise it from ADGAS operations. Principally a common methodology for a waste management programme covers, elimination, source reduction, recycling / revovery, reuse, treatment and disposal. This is generally known as the waste hierarchy and is shown in Figure 3-1. 3.6.1.1 THE STEPS IN THE WASTE HIERARCHY The Waste Hierarchy Eliminate
Best Environmental Option
Reduce Re-use Recycle Energy Recovery Worst Environmental Option Disposal Figure 3-1: The Steps in the Waste Hierarchy Eliminate Not creating waste for disposal by adhering to the following hierarchy; consumption avoidance, product and packaging re-use, and organic and non-organic material recycling and composting (in that order of priority). Reduce Applying the principle of 'true cost', shows that it is far more time and cost effective to tackle the causes of waste rather than treat the waste once it has been produced. Reducing waste can be achieved through a combination of monitoring and analysing systems and processes. This is where staff can make an invaluable contribution in identifying improvements. Re-use Imagination and innovation is required, remember not to be restricted to the continuous re-use of a material for its original purpose. For example, much ingenuity has been seen Doc. Number
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in the re-use of materials for packaging, using shredded paper and cardboard as a packaging material is one such example, thus extending the useful life of the paper/cardboard and reducing the cost of buying in specific packaging materials. Repair or upgradability may also be a consideration when deciding whether an item has re-use potential. Recycle Recycling involves the recovery of materials for use in another product. The process of recycling includes the segregation and collection of waste, as well as the physical recycling itself. The term also encompasses composting and waste exchange. Items or materials must be considered discarded and available for disposal in order to be recycled, therefore the item or material is legally classified as waste. Recycling can be conducted in-house or through a direct relationship with a re-processor. Recover Energy Energy can also be recovered from waste by using it as a fuel; the viability of this option is often dependent on the materials calorific value. The energy is usually recovered in the form of heat but can include electricity and biogas generation. This also reduces its volume and weight for disposal. Disposal Disposal generally either involves containment, generally through landfill, or destruction, normally through incineration. Incineration reduces the waste to approximately a third of its original mass. Disposal in these ways is considered the least sustainable option, maximising resource recovery in all the ways outlined reduces the demand for raw materials, thus lessening the impacts on the environment whilst providing an economic incentive to re-use and recycle "waste". Further Information Hazardous Substance Manual. Waste Disposal Manual. OD SI W-08, Disposal of dangerous materials. ADNOC-COPV2-05: Waste Management
3.6.2 WASTE IDENTIFICATION AND CLASSIFICATION Wastes are classified as either Hazardous or Non-Hazardous in the form of solid, semisolid, liquid and gaseous. Wastes produced in ADGAS operation are identified and listed in the Waste Disposal Manual with ID No. against each waste. The data sheet for the respective waste will describe identification, waste name, classification, source, main chemical constituents, chemical formula, description , estimated discharge rate, hazards, procedure for disposal, documentation requirements and any other additional information.
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3.6.3 WASTE SEGREGATION AND COLLECTION 3.6.3.1 NON-HAZARDOUS WASTE DISPOSAL PRACTICE In ADGAS labelled and colour coded drums are placed in strategic locations to collect different types of routinely produced non-hazardous waste. Office cleaners assigned to a department pick up the waste from each office and deposit it in the labelled drums. The labelled drums are emptied out by the Das Island Services Department when they are full. The responsibility lies with the generator of the waste to ensure that all such wastes are deposited in the correct drum as per the following colour codes:Waste Type Scrap metal (any metal or metal object) Glass (Bottles, broken window, glass electrical fittings and non contaminated laboratory glass) Waste paper (clean grease free paper, cardboard, photocopy paper, old books and files) Scrap plastic (Mineral water/ drink bottles, plastic sheet, plastic packaging material/ file folder etc. Other Waste (Dirty paper, contaminated food wrapper, wax paper oily rags, wood cuttings, paper towels etc.)
Drum Colour Red Green White Blue Cream
The waste is collected, volume reduced and sent to vendor for recycling and disposal of other waste by incineration. 3.6.3.2 HAZARDOUS WASTE DISPOSAL PRACTICE Recyclable hazardous waste are primarily the lubricating oil, printer cartridge, liquid chemical samples etc. The waste generator shall collect liquid hazardous waste in good steel/plastic drums with bungs only .DO NOT USE DEFORMED OR LEAKING DRUMS. Ensure no leakage occurs. Printer cartridges shall be collected in double polythene bags. Label the description of the waste on the receptacles as described in ADGAS Waste Disposal Manual, section 5. Disposal of the waste shall be initiated through waste disposal form and sent to HSED for approval and documentation. After receiving the feedback from HSED, the generator will arrange for its disposal as per the procedure outlined in the ADGAS Waste Disposal Manual. Non recyclable hazardous wastes are those other than the above and listed in section 5 of the ADGAS Waste Disposal Manual. This will generally require the waste to be properly segregated, labelled, packed and transported to ADNOC – Ruwais site. Doc. Number
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3.6.4 RESPONSIBILITIES For a complete description of responsibilities, refer to section, “Disposal To Places Other Than Das Island of ADGAS WASTE DISPOSAL MANUAL”.
3.6.5 RECORDS A Waste Disposal Form must be produced for all types of Waste, by the generator and approved by HSED. Record of Waste disposal will be maintained by the waste generator and HSED. The minimum required procedure has been outlined in the ADGAS Waste Disposal Manual. Further Information ADGAS Waste Disposal Manual.
3.7 PERSONAL SAFETY 3.7.1 GENERAL SAFETY RULES The following are some important General Safety Rules that shall be observed at all times by all persons: · · · · · · · · · · ·
Do not smoke in the Plant area except where a valid Smoking Permit is displayed. Do not carry matches/lighters within the Plant area. Report all accidents/hazardous conditions to your Supervisor immediately, regardless of how minor it appears. Get first aid promptly, if injured. Obey all rules, procedures, signs and instructions. Always carry your Self Rescue Respirator and wear hard hat, approved eye protection, safety shoes and ear muffs while in the plant. Keep them in good condition. Do not do any work in the Plant area without obtaining a Work Permit from the Area Authority. Be familiar with the Emergency Procedures. Always be aware of the wind direction. Ensure Good Housekeeping. Always keep your work area clean and orderly. Use, operate, repair or adjust equipment only when authorised. Use the right tool/equipment for the job. Use them correctly. Ensure adequate liquid intake during the working days in summer.
DO NOT TAKE CHANCES, IF IN DOUBT, PLEASE ASK
3.7.2 ALCOHOL AND DRUGS Alcoholic drinks are not allowed on Das Island except where specifically authorised by MDI(S) and PM. Doc. Number
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Drugs, other than those specifically required for medical use, are prohibited. Personnel travelling to Das Island carrying prescribed medication shall report the fact to the HMSD on arrival.
3.7.3 FINGER RINGS, NECK CHAINS AND BRACELETS Caution The wearing of finger rings, neck chains and bracelets can create a potentially serious hazard. The possibility of these articles being caught on moving or static equipment and their electrical conductivity leaves the wearer susceptible to shock, burns and severe hand and other injuries.
3.8 SAFETY SIGNS AND BARRIERS 3.8.1 INTRODUCTION As in other industrial work environments, safety signs play an important role in safety on Das Island. There exists a wide variety of types, shapes, colours, sizes and legends. This section breaks down to basics the principles involved in designs for different purposes and assists with improvement in recognition and understanding in this field.
3.8.2 ROLE OF SAFETY SIGNS In general, safety signs are used for the purposes of: · · · · · ·
preventing accidents identifying health hazards giving locations for safety and emergency equipment giving guidance and instruction in emergency procedures assisting in movement of personnel in emergencies drawing attention to objects and situations involving health, safety and environmental issues. Note Safety signs do not replace, but supplement proper accident prevention measures. To ensure full benefit, the function and meanings of safety signs should be included in basic induction and safety training.
3.8.3 DEFINITIONS 3.8.3.1 SAFETY SIGN Gives a particular safety message to those who may be exposed to hazards in an industrial environment. Doc. Number
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The message is obtained from: · · ·
A combination of geometric form, a safety colour and a safety symbol. A combination of text and safety colour A combination of all the above.
3.8.3.2 SUPPLEMENTARY SIGN A sign with text only used in conjunction with a symbolic sign
3.8.4 CLASSIFICATION Safety signs may be classified as: · · ·
Regulatory signs - mandatory or prohibitive instructions Caution (warning) signs - potential hazards, advisory Emergency information signs - first aid, exits, etc.
Combinations of shape, symbol, colours and text are employed to convey the sign's message.
3.8.5 COLOURS · · ·
Regulatory Signs: o Prohibition: o Mandatory: Caution/Warning Signs: Emergency information signs:
RED AND WHITE BLUE YELLOW GREEN
The colour of the text lettering on a sign may be either black or white only, depending on the base colour of that sign.
3.8.6 VISIBILITY The size and proportions of a sign are determined by the location, viewing distance, type of hazard and the type of symbol or legend it contains. Signs are generally placed slightly above eye level, but in some situations other levels may be more suitable. Signs should contrast with their background environment colour whenever possible. Locations should avoid the possibility of screening or obstruction, e.g. stacked materials, trees, bushes etc. Illumination of signs is especially important in the plant. The possibility of poor visibility or lighting failure is inherent.
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On the plant three types of illumination are employed: · · ·
Reflective glows when light is directed towards the sign. Photoluminescent stores light energy and glows for a period in darkness Self Illuminating uses energy independent of power supplies and is usually low energy radiation source powered.
3.8.7 GENERAL Care must be taken that a sign does not create a visual or physical hazard in itself. If the reason or purpose for the sign is eliminated the sign must be removed. Redundant signs left in position after their purpose is no longer relevant may induce a disregard for all signs on the facility. Prohibition, danger, obligation and warning signs should be sited in relation to the hazards to allow ample time after first viewing the sign to heed the warning. Signs must not be placed on moveable objects such as doors, racks, etc. Subsequent movement of the object may render the sign void or conceal it. A large number of different signs in a particular area may create confusion and lessen visual impact. Care must be exercised to ensure that the messages from the most important signs are not compromised Deterioration of signs must be monitored with the sign maintained or replaced as required to retain legibility or visibility. The placement of a new sign or change of location warrants the reasons for the change explained. Symbolic (pictorial) signs are widely used due to the ease and speed of message recognition and international acceptability. On ADGAS facilities and sites the Arabic and English languages are used for all text and legends on safety signs.
3.8.8 PORTABLE SIGNS Along with the permanent signs found in fixed locations on the plant there is a need for moveable signs. Some work activities on the plant are of a temporary, non-routine and often hazardous nature and may obstruct, interfere with, or create hazards for routine activities. Examples are: · · ·
Radiography Hot work Abrasive blasting Doc. Number
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Overhead work Excavation
Characteristics of a good portable sign are: · · · ·
lightweight, non-corrosive fibreglass material incorporation of the standard layout, wording and colours to identify it as a "Danger" or a "Caution" provision of a plain panel of sufficient area for the hand lettering of the appropriate safety message with a felt marker holes and/or hooks suitable for secure fastening to rope barriers or standard handrails.
Typically the hand written message on the portable temporary sign will state: · · · ·
the type of work in progress, e.g. abrasive blasting the type or hazard involved (eye injuries) the protection or hazard avoidance required (full eye protection) the serial number of the work permit current for the job
This sign may be supplemented by standard safety signs at the site to reinforce the message.
3.8.9 ROAD TRAFFIC SIGNS All road traffic signs on Das Island conform to the requirements of United Arab Emirates legislation.
3.8.10 BARRIERS Barriers, either structural, roped or flagged may be employed to warn personnel and limit access to the job site, together with appropriate signs at all approaches to the risk area. Barriers are a safety precaution specified on a work permit. Barriers must not obstruct established escape routes. Persons may only bypass a barrier if they are authorised to do so or the conditions on the displayed sign permit it. Further Information BS 5378, Safety Signs and Colours
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3.9 PERSONAL PROTECTIVE EQUIPMENT 3.9.1 INTRODUCTION Personal protective equipment (PPE) must not be regarded as a substitute for safe working practices, but as an extra protective barrier to prevent injury. In every work situation, some form of PPE is necessary. The Permit to Work for any task must specify the PPE requirements that are not part of the minimum standard for the operational area and should re-emphasise the minimum standards where they might be overlooked. Where particular forms of PPE are mandatory for everyone entering a particular operational area, whether on a permanent or a temporary basis, boundary marking must be provided and appropriate mandatory safety signs must be displayed. Further Information Chapter 3 Section 8 ADNOC-COPV4-04: PERSONAL PROTECTIVE EQUIPMENT
3.9.2 MINIMUM SAFETY WEAR The wearing of protective clothing in the ADGAS Industrial area is mandatory. The minimum PPE required is as follows: · · · · · ·
Safety Helmet Safety boots/shoes Trousers and short sleeved shirt or short sleeved coveralls Self Rescue Respirator Ear protection. Eye protection.
Coveralls and PPE are provided by the Company at no cost to the employee. Contractors must be in possession of all necessary PPE prior to entry into the plant area. Industrial clothing should always be in good repair, close fitting and secured, especially when around moving machinery. Note The need for PPE and clothing above and beyond this minimum requirement must be identified in the development of a Task Risk Assessment for nonroutine or high risk category jobs. Details of protective wear, in addition to the minimum plant requirements, must be noted on work permit forms and checklists.
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3.9.3 HAZARDS The nature of safety hazards in the workplace may be identified as one or a combination of: · · · ·
·
Direct contact, projectile, sharp or abrasive Moving machinery Biological, bacterial, parasitic, fungal Chemical o irritant o carcinogenic o system poison o sensitiser Physical o noise o radiation o extreme temperatures o vibration
In identifying the need for and the appropriate type of personal protective wear, the following aspects should be considered. What form is the hazard in ? ·
Gas, vapour, mist, dust, fume, liquid, solid, temperature, pressure
How will the hazard act on the person ? ·
Inhalation, skin, hearing, eyes, whole or specific part of body, ingestion
What type of effect does exposure to the hazard cause ?
3.9.4 HEARING PROTECTION Short periods of exposure to excessive noise levels can produce hearing loss that initially may be reversible. Permanent damage occurs however, when exposure to excessive noise continues over a longer time. Noise elimination or attenuation at its source are the most satisfactory methods of hearing protection. Where such measures are not practical, personal hearing protection is required. All persons in designated noise areas must wear hearing protection to the appropriate standards. Common types of hearing protection available include: Doc. Number
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Disposable (mouldable) earplugs Re-usable earplugs Ear muffs of various types and ratings Combination of plugs and ear muffs
Disposable earplugs are found in dispensers located in strategic locations around the plant. Both the head fitting and helmet attachment types of earmuffs are drawn from stores. Full details of the problems of, and protection against, noise are found elsewhere in this manual. Further Information 3.11 HEARING CONSERVATION
3.9.5 HEAD PROTECTION The head, or more specifically the brain, is the part of the body most susceptible to disabling injury from an impact. Safety helmets are intended to protect the person against impact and penetration damage and are so designed that they will not fracture when struck, or transfer the force of the blow to the wearer’s skull below the point of impact The wearing of a safety helmet is mandatory outdoors in the designated plant areas. Note All safety helmets must comply to Standards and must be clearly marked with the year and quarter of manufacture. Further Information BS EN 397:1995: Specification for industrial safety helmets Warning Helmet shells made of metal or electrically conductive material are prohibited on the plant 3.9.5.1 ACCESSORIES · · · ·
Chin strap of fabric, leather or plastic covered elastic Visors and face shields Sweatbands Earmuffs
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Note Chin straps should be worn by all personnel in high winds Caution Any unauthorised alterations to helmets including drilling of holes or painting will compromise the protection of the helmet and are not permitted. 3.9.5.2 MAINTENANCE · · ·
Helmets must be regularly cleaned using warm water and soap solution All components must be inspected visually on a weekly basis for signs of dents, cracks, penetration or rough treatment Helmets showing signs of damage or deterioration must be immediately withdrawn from service and destroyed. Note Complaints of discomfort may be attributed to fit characteristics and be due to too rigid suspension components or poorly adjusted suspension.
3.9.5.3 PRECAUTIONS The following precautions must be observed: · · · ·
If the safety helmet has been subjected to a heavy blow, it must be replaced immediately even though there may be no visible damage The shell or suspension must never be altered or modified Wearers must not carry or transport anything inside the helmet Helmets must not be dropped, thrown or used as supports, or subjected to any other form of abuse.
All safety helmets are susceptible to damage from: · · ·
Ultraviolet light (sunlight) Temperature extremes Chemical degradation
Suspension systems must be inspected regularly as perspiration, hair oils and normal wear can affect their integrity.
3.9.6 FOOT PROTECTION Protective footwear must provide protection against hazards ranging from dermatitis to crushing injuries. The possibility in the work place exists for exposure to: ·
Chemicals Doc. Number
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Extremes of cold or heat Slippery or abrasive surfaces Punctures from nails or other sharp objects Heavy dropped objects Crushing Electrical hazards
In use, no electrically insulating element should be introduced between the shoe sole and the wearer's foot. Cotton socks are generally suitable in preventing a build-up of static electricity on the person's body. Special footwear, may be required for certain tasks or occupations such as "Trainer" type safety shoes for riggers/scaffolders. These give a better "feel" on rigging and scaffolding tasks with a consequent increase in safety. Safety footwear meeting BS EN ISO 20345:2004 is to be worn by all personnel, except visitors, who will be assessed for their specific requirements in the ADGAS Industrial area. Further Information BS EN ISO 20345:2004: Personal protective equipment. Safety footwear
3.9.7 EYE AND FACE PROTECTION The list of equipment for the protection of the eyes and face can be divided into: · · · ·
Spectacles Goggles Visors/face shields Hoods
Eye and face protection is designed to protect the wearer from hazards such as impact, chemical splashes, gases and vapours, foreign bodies and ultraviolet and infrared radiation. Damage to sight can be caused by injury: · · ·
To the surface of the eye Within the lenses At the retina
Damage to the eye may result in permanent scarring of the surface of the eye with resultant long term sight defects.
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Personnel working in areas of abrasive grinding, scaling and blasting are at risk. Contact lenses are not protective but may be worn in combination with approved eye protection. The wearer must be made aware that the contact lenses may be lost during emergency irrigation of the eye or damaged by chemical contact. Accidental displacement can also cause temporary loss of vision. Where there is a significant risk of splashing hazardous substances a visor in addition to goggles is recommended in order to provide full face protection. For personnel with sight defects, safety glasses with prescription lenses are available and can be worn instead of plain safety glasses. Goggles must be worn over non-safety prescription glasses in risk areas. Further Information BS EN 166:2002): Personal eye protection. Specifications Chapter 3.12 EYE SAFETY PROGRAMME
3.9.8 OPTICAL FILTERS Optical filters for spectacles, sunglasses, goggles and welding shields are designed to reduce radiation intensity to a safe level and prevent eye damage. They may attenuate all wavelengths or bands of wavelengths or have specific properties related to a particular radiation risk. Caution The safe level of intensity varies with wavelength. The optical properties of the filters differ and it is essential that the correct filters are used during welding or with other high intensity radiation sources. Welding glasses or lenses protect the eyes from visible or infrared radiation as well as invisible ultraviolet. Replaceable clear glass or polycarbonate covers must be used to protect the optical filters from damage due to impact, molten metal, fume.
3.9.9 HAND PROTECTION Gloves must be used in risk areas to protect the hands against chemical, physical and biological hazards. There is no glove that suits every purpose, and a glove should be selected by referring to the manufacturer's recommendations. Process operators, and maintenance personnel are encouraged to carry gloves at all times to cater for emergency use. Most gloves do not provide total protection during immersion in some chemical solutions. Gloves of impervious synthetic materials (e.g. PVC/Neoprene) or leather gloves or gauntlets must be worn according to the type of exposure. In general PVC/Neoprene Doc. Number
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gloves are suitable for oil/chemical handling and leather generally for dry handling. Special gloves are available (nitrile) for handling solvents. Hands and arms should be thoroughly washed after the gloves/gauntlets are removed at the end of the working period or before meals.
3.9.10 VISORS/FACE SHIELDS The full-face welding helmet is recommended for arc welding operations. Whilst the flipfront helmet gives clear glass protection for chipping, etc., the operator must always wear regulation safety spectacles for full-time eye protection when the helmet is up. Visors fitted to head harness or safety helmets should be the lift-up type for intermittent use. Goggles must also be worn with them when the possibility of face splashes under the visor exists. A combination of goggles plus face shield may also be needed for chemicals very hazardous to the eyes. Visors are generally resistant to fogging and where necessary can be worn together with prescription spectacles.
3.9.11 BODY PROTECTION 3.9.11.1 CHEMICAL PROTECTIVE CLOTHING The purpose of chemical protective clothing is to prevent chemical contact with the skin. No material is totally impermeable to all chemicals and all commonly used materials have protection limitations. Manufacturer's recommendations and relevant standards should be consulted for the right protection in each case. Full protective suits fabricated from PVC are available to protect against toxic vapours, liquids and, when supplemented by a cryogenic suit, low temperature liquids. These suits should always be worn in conjunction with suitable gloves and footwear. Aluminised close proximity suits are available for when personnel might be exposed to flames or where a flash fire might occur. 3.9.11.2 HOT WORKING ENVIRONMENTS Clothing reduces the heat transfer between the wearer and the environment. In hot environments the clothing should be light and well ventilated. Clothing restricts the body's ability to remove heat through evaporation and perspiration and forced ventilation of clothing may be necessary for prolonged work at high temperatures.
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The wearing of chemical protective clothing to prevent exposure to toxic chemicals also presents an additional barrier to perspiration, thereby significantly increasing the potential for heat stress. Further Information 3.14 HEAT DISORDERS 3.9.11.3 CLOTHING STATIC ELECTRICITY Natural fibres have better capacity to dissipate static electrical charges than synthetic fibres due to their greater ability to absorb moisture. A hazardous discharge could occur if synthetic fibre clothing is removed in a potentially hazardous gas atmosphere.
3.9.12 RESPIRATORY PROTECTIVE EQUIPMENT 3.9.12.1 INTRODUCTION The use of respirators, where an inhalation hazard exists, is mandatory when it is necessary: · · · · ·
To reduce the level of exposure until engineering controls are installed To supplement engineering controls and work practices which have failed to reduce the hazard to an acceptable level During short term activity such as maintenance and inspections when engineering control is not feasible During emergencies When measures and procedures necessary to control the exposure do not exist
Air supplied respiratory protection (BA) must be used when the oxygen level in the working atmosphere is below 20% Respiratory protection equipment is provided both for use in an emergency and for maintenance operations where there is the potential for the release of toxic materials or where low oxygen levels may be encountered. Resuscitation equipment is available throughout the facilities and also carried in emergency vehicles. 3.9.12.2 FACIAL HAIR POLICY FOR WEARERS OF BREATHING APPARATUS Breathing Apparatus is designed to provide an effective seal between the face mask and the Wearers face when the person is clean shaven. Any person with heavy facial hair will be unable to obtain a satisfactory face seal. A poor face seal can result in injury or potentially asphyxiation of the wearer due to lack of air supply or ingress of toxic gases in a hazardous environment. Doc. Number
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ADGAS policy regarding employees who may be required to wear B.A. and who work on the plant or other hazardous areas falls into two distinct categories depending on the reason for wearing of B.A. 1. 2.
B.A. for escape from a hazardous area. B.A. worn as part of a procedure (e.g. emergency response, search and rescue, fire fighting, vessel entry, toxic gas sampling etc.).
Persons who are likely to be involved in ‘1’ above, escape from a hazardous area, can have facial hair however, the hair must be trimmed to a level which will allow a reasonably good sealing of the B.A. Mask (5 to 10 minutes for escape). All such employees are responsible for ensuring that their beards are kept trim. Persons who, as part of their job, are likely to be involved in ‘2’ above, B.A. worn as part of a procedure, must be clean shaven to enable them to utilise the B.A. Set safely and perform the operation successfully. Immediate Line Supervisors are responsible to ensure that those people with facial hair are not permitted to carry out activities involving the wearing of B.A. as part of a procedure. 3.9.12.3 HEALTH ASPECTS There are a number of physiological and psychological conditions that may interfere with safe and effective respirator use. These include: · · · · · ·
Impaired function of heart, blood vessels or lungs Thermal stress Diminished sense Skin reactions Anxiety Claustrophobia
If users are known to have any of the above problems, medical clearance is required. Before being assigned to tasks requiring respirators or BA, the user must also be observed during a trial period to evaluate potential physiological and psychological problems. The type of respirator must be worn during the trial for at least 30 minutes during which the person will engage in an exercise similar to the actual working situation before being exposed to risk. This test is normally carried out as part of the Breathing Apparatus Course and Refresher Training conducted by the HSED. 3.9.12.4 FILTERING RESPIRATORY PROTECTION NON-POWERED AIR PURIFYING SYSTEMS Disposable filtering face piece - are used for a day or task then discarded. Doc. Number
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Half-mask or full face piece air purifying - uses a screw-in renewable cartridge. No absorbent cartridge will remove all gaseous contaminants, therefore the type of absorbent must be carefully selected according to the hazards. Cartridges must only be used for gases and vapour listed on the label. Caution Respirable dust particles, which actually penetrate into the lungs are usually not visible to the naked eye. Combination vapour cartridge and filter type are used against gaseous and particulate contaminations and have a combination of cartridge and dust filter. 3.9.12.5 EMERGENCY BREATHING EQUIPMENT SELF RESCUE RESPIRATOR · ·
All personnel working or visiting the ADGAS Facilities are issued with a Self Rescue Respirator for protection against hydrogen sulphide if there is a gas release. The respirator is to be carried at all times when working or visiting ADGAS facilities.
DRAEGER S.A.V.E.R. BREATHING APPARATUS (ESCAPE SETS) The SAVER Set is provided at particular locations throughout the Plant to enable a man to escape from a work area if there is gas release. The wearer breathes from a high pressure air cylinder via a reducing valve and demand valve controlling the air supply to the face piece. The exhaled air passes from the face piece through a non-return valve to the atmosphere. · · ·
The nominal duration of the set is ten minutes. The locations of all sets are indicated on Safety Equipment Layout Drawings at Section 1.4 in the Emergency Plans and Procedures Manual. The SAVER Set is not to be used for normal BA work or rescue operations.
SABRE CEN-PAQ BREATHING APPARATUS · A limited supply of CEN-PAQ, of fifteen minutes duration, is kept in the Laboratory for the exclusive use of Laboratory Staff. · The CEN-PAQ Set is not to be used for normal BA work. FIREFIGHTER COMPRESSED AIR BREATHING APPARATUS (CABA) The Firefighter CABA sets are strategically located throughout the ADGAS Industrial Area for use by Operations and other designated personnel if there is an emergency (see Emergency Plans and Procedures Manual).
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These sets are for emergency use only. Firefighter BA Sets required for normal maintenance duties will be obtained from Safety Division through the normal laid down procedures. The Firefighter CABA is a positive pressure self contained open circuit type of breathing apparatus in which the wearer exhales direct to the atmosphere. A single cylinder is mounted on the lightweight back plate together with a main reducing valve and pressure outlets. A warning whistle is fitted to indicate approaching exhaustion of the cylinder. (This may not be audible in the plant and a constant visual check must be maintained). A nominal working duration of twenty minutes can be expected dependent on the individual and the amount of work undertaken. 3.9.12.6 MAINTENANCE BREATHING EQUIPMENT COMPRESSED AIRLINE BREATHING APPARATUS (HOSE REEL AND TROLLEY) The airline breathing apparatus is for use by Control Room personnel of the Operations Division and Maintenance personnel when working in an area where the potential for a gas leak is present or when working in enclosed environments where there may be low oxygen content, e.g. vessels subsequent to purging. Air is supplied to the user through the axis of the reel from compressed air cylinders mounted beneath the reel. The air supplied from the reel is used by one (or two) person(s) wearing a positive pressure demand valve and face mask. To provide appropriate back-up, if there is isolation from the source of air due to severance or inaccessible kinking of the hose, self-contained breathing apparatus with a suitably trained stand-by man shall also be available. FIREFIGHTER COMPRESSED AIR BREATHING APPARATUS (CABA) In certain circumstances where it is not possible to safely use a Trolley Set, the Firefighter set may be used for personnel protection. 3.9.12.7 RESUSCITATION EQUIPMENT The resuscitation equipment used by ADGAS is the MicroVent. Sets of this equipment are available in Emergency Vehicles and at various locations throughout the Trains. The MicroVent is a pneumatically powered, time/ volume resuscitator with an additional Manual Trigger for use in conjunction with external cardiac massage. The automatic cycling is used for longer term ventilatory support or patient transport. 3.9.12.8 TRAINING Appropriate training in the use of the above equipment is provided periodically by the HSED Training Section. Doc. Number
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3.9.12.9 LAST DEFENCE Personal protective equipment is the last line of defence after all other means of protection have been instituted. Its effectiveness is crucial to the health of personnel. Further Information HSED Breathing Apparatus Manual.
3.10 MANUAL HANDLING 3.10.1 INTRODUCTION Manual handling is a process where the person is the prime source of power in moving materials and equipment. It includes lifting, putting, pulling, pushing, carrying or moving. Accident data has revealed that more than one third of all work place injuries, some serious and disabling, are the direct result of manual handling. Typically, these injuries are to the back and the neck. The objective of this section is to provide practical advice relating to the identification, assessment and control of risks in manual handling activities on ADGAS facilities.
3.10.2 RISK IDENTIFICATION Any manual handling likely to be a risk to health and safety must be examined and assessed. The assessment must be done in consultation with personnel involved in the manual handling and take into account: · · · · · · · · · · · · ·
The force applied and movements involved The range of weights handled The duration and frequency of movements The time and distance over which an object is handled The availability of mechanical aids The layout and condition of the workplace environment The work organisation The postural requirements imposed by the manual handling The analysis of relevant injury statistics The age of the personnel The skill, strength and experience of the personnel The nature of the object/material being handled Any other relevant factors
Figure 3-2 provides guidance on what an average person may be expected to lift.
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Caution This is only guidance and the weights shown must not be regarded as "safe" for all personnel.
Figure 3-2: Guidance on Safe Weights
3.10.3 RISK FACTORS 3.10.3.1 DURATION AND FREQUENCY The risk of injury rises with the increased frequency, repetition and duration of manual handling activity by any one person. These risks are not restricted to lifting or lowering of loads. Pushing, pulling, carrying and holding of loads can also have potential for injury. The same manual handling task repeated over long periods may induce feelings of monotony and boredom. The reduction of alertness may have important safety consequences. A person's ability to continue prolonged exertion depends upon energy reserves, physical fitness, relative work load and the physical activity required for the task. Manual handling operations involving the use of hands only can quickly cause muscle fatigue when overloaded. 3.10.3.2 DISTANCES MOVED Distances over which loads are manually moved must be as short as possible to decrease the injury risks, if the load is located: · ·
Above the person's shoulder height Below mid-thigh height Doc. Number
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At an extended reach
Injury potential is also aggravated if the load: · · ·
Requires manoeuvring to be placed accurately into position Requires twisting of the back Requires sideways bending of the back
3.10.3.3 WEIGHT In seated work it is advisable not to lift loads more than 4.5kg. The risks of back injury increase significantly lifting weights above 20kg. In a work situation loads above 55kg should not be lifted manually. Mechanical assistance and/or team lifting arrangements must be provided to reduce the risk of injury Attempting to lift an object of unknown weight is to risk accident or injury. With unfamiliar loads an idea of weight must be gained to ensure it is within the lifter's capabilities under the prevailing conditions. Large or awkward loads require special care whereas a handy compact load, e.g. toolbox with handle, is relatively safe to lift. Weight assessment can be gained by one or more of these methods: · · · · ·
Move the object around on the ground Try lifting one side (half the weight) Read the labels and markings Open the container or read contents. It could be toilet rolls or large bolts. Ask a knowledgeable person
If after assessment, the weight appears close to the person's limits, team help or use of mechanical aids, e.g. crane or chain block, should be employed. Caution Serious injuries have resulted from a heavy weight, thought to be lighter, being pulled from a higher level, with the person being unable to control its fall. A short time taken before the lift to make an assessment of all factors and take appropriate actions will contribute to prevention of most manual handling accidents.
3.10.4 SAFE MANUAL HANDLING Before starting any handling procedure, assess the situation by sizing up the load, and: ·
Position the body correctly before starting Doc. Number
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Use the legs to raise and lower loads Use the legs to provide momentum for horizontal movement when pushing or pulling. Use body weight together with the above actions to counter loss of balance and to assist in moving loads
3.10.4.1 POSITION OF THE FEET When lifting objects the following should be observed. · · · · · · ·
Feet placed comfortably apart, one foot forward, one foot back. This position helps to maintain balance. When lifting, the feet should if possible be placed around the load. If not possible then the feet should be placed close to the load. When neither method is possible, the load is moved to a suitable position clear of obstruction before lifting, or lifted with mechanical assistance. When lowering the load, this should, if possible, be done between the feet Where forward movement is anticipated, the front foot is placed beside the load pointing in the direction of movement. When moving backwards, one foot is placed backwards to receive the combined weight of load and body. Most of the weight should be on this foot before any pivoting movement is made All handling movements are carried out smoothly and rhythmically.
Having the legs naturally apart during lifting improves stability, and does not necessarily increase the risk of hernia. 3.10.4.2 KNEES AND BACK The knees should be bent before the hands are lowered to lift or set down loads. When loads must be raised above waist level, the knees should first be bent, then straightened, to give momentum to the upward movement. When a load is taken from the shelf, or received from another person, the knees must be bent so that the force of the load can be absorbed. If the knee is bent acutely the mechanical efficiency of the leg muscles is lessened. Bending of knees is greatest when loads are taken up from the floor. When the load is on the floor, loads must be limited. In a typical lifting posture, with the knees and hips bent, the lumbar spinal curve should be flattened resulting in a straight back but not necessarily a vertical back.
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When only one hand can be used for lifting, overloading the back muscles can be reduced by placing the other hand on the knee or against a firm support. Lifting and carrying heavy loads with one hand must be avoided. 3.10.4.3 ARMS AND HAND GRIP During lifting the arms should be kept close to the body and: · · · · · · · · · ·
The hands must if possible hang between the thighs when lifting or lowering a load The load is carried close to the body with elbows by the sides Wide loads may be held obliquely or vertically provided that the load does not obscure vision Loads should not be held out from the body when they are being raised, lowered or supported. The arms must act as links, not sources of power, i.e. the muscles of the legs and buttocks are used to move the load In lifting, the hand on the same side of the body as the forward foot should grasp the side of the load further from the body When carrying, the hand supporting the far side of the load pulls the load to the body In all handling procedures a secure grasp should be used to keep control of the load The load must be grasped with the whole length of the fingers and palm of the hand, not just the finger tips In continuous carrying of light loads by only one hand the hand used should be alternated.
3.10.4.4 HEAD POSITION During lifting keep the head erect and: · · · ·
Raise the head just before the lift thus automatically assisting in keeping a straight back during the lift Keep a straight back to ensure that uniform pressure is applied to discs between the spinal bones Avoid turning the head causing the spine to rotate. This must be avoided If it is necessary to look around, the body must be turned by pivoting on the feet.
3.10.4.5 BODY MASS Body mass used as a source of momentum acts with the muscles to set loads in motion and to propel moving loads. When setting loads in motion, jerky actions must be avoided by applying force slowly to the load through the shoulders, arms and hands. Never flex the back whilst carrying the load as shown in Figure 3-3. Doc. Number
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Figure 3-3: Safe Handling Body mass may be used as a counter balance in handling procedures. Note Situations are rare when all procedures and precautions can be adhered to at the same time. In all cases when lifting procedures must be compromised due to circumstances, the load limit must be reduced accordingly. Refer to Figure 3-4.
Figure 3-4: Handling Techniques
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3.10.5 TRAINING All personnel must be advised of the risks arising from incorrect handling and instructed in recommended methods of manual handling and the use of mechanical handling equipment appropriate to the work sites. The training must be at a level giving all personnel a thorough understanding of the recommended techniques and ensuring they will be used in all phases of the work. Caution No person SHALL be required to undertake manual handling beyond their physical capacity, training and experience.
3.10.6 SUPERVISION Supervisors must be prepared to set a good example and be able to demonstrate the correct methods of manual handling. Supervisors are responsible for: · · · · · · · · ·
Ensuring jobs involving physical effort are correctly planned and carried out. Recognising handling hazards and initiating corrective methods. Encouraging reports and suggestions. Ensuring that all personnel receive adequate instructions in the skill of manual handling. Providing follow-up instructions. Ensuring there is adequate space for manual handling. Arranging adequate rest periods or rotation of duties if relief is not afforded by the nature of the work cycle. Investigating all accidents and incidents caused by manual handling Arranging correction of potential injury causes.
3.10.7 PROTECTIVE CLOTHING Close fitting overalls in good repair are recommended work wear, and in addition aprons when the load is wet, dirty or greasy, as there is a tendency for loads to be held away from the body to protect clothing, thereby increasing risk of injury. The correct type of protective gloves must be worn if there is a possibility of materials injuring the hands.
3.10.8 RISK CONTROL Risk control is the process of eliminating or reducing identified and assessed risk factors. Risk control can be best accomplished by a combination of:
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Job redesign Mechanical handling Training
3.10.8.1 JOB REDESIGN · · · · · · ·
Modifying the object - to a different size, shape or weight Modifying the workplace layout - so that arrangements of plant equipment reduces risk Rearrange materials flow - to improve positioning and timing of materials movement Different actions - in modifying the means of doing the job with or without workplace changes Mechanical assistance - used to reduce risk Team lifting - can share lifting loads Eliminating the job, e.g. sacks changed to bulk handling
3.10.8.2 MECHANICAL HANDLING EQUIPMENT Use to replace manual handling and reduce the forces required. 3.10.8.3 TRAINING Giving particular instruction, training and education to reduce risks at work.
3.10.9 RISK CONTROL OPTIONS Success in reducing manual handling injuries is usually achieved by applying the most effective combination of control options to each risk factor:
3.11 HEARING CONSERVATION 3.11.1 INTRODUCTION Constant daily exposure to high noise levels causes irreversible damage to delicate hair cells within the inner ear of the exposed person. These cells convert the mechanical energy of sound waves into electrical impulses that are transmitted to the brain, classified and perceived as sounds. Permanent damage to the hair cells therefore causes permanent loss of hearing. Noise induced hearing loss progressively affects perception of the sound frequencies in the speech range. This progress is gradual and without regular monitoring the decrease in hearing levels may not be noticed until the affected person is suffering a severe chronic social disability, finding it difficult to understand spoken communication. The ADGAS Hearing Conservation Program has been designed to prevent industrial deafness in its employees on Company worksites.
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The responsibilities for noise reduction and hearing conservation extends back to the designers, the manufacturers, suppliers, installers and ultimately the users of noisy plant and equipment. Further Information ADNOC-COPV3-10: NOISE CONTROL AND HEARING CONSERVATION
3.11.2 DEFINITIONS Action Level - the level of noise above which steps must be taken to reduce that level or impose other protection strategies. The ADGAS level is 85dB(A) dB(A) - units of measurement of sound pressure level expressed in decibels in the A weighted scale (audible frequencies) dB(Lin) - units of measurement of sound pressure level expressed in decibels in the 'linear' or unweighted scale. Noise Exposure - (LAeq. 8h) is the equivalent continuous A-weighted sound pressure level a person would be exposed to during a representative working day of 8 hours. Steady State Noise - noise with small fluctuations of level not exceeding a range of 8dB(A). Intermittent Noise - noise that fluctuates more than 8dB(A) in sound pressure level. Broad Band Noise - noise without significant tonal components with continuous frequency distributions in the audible frequency range. Narrow Band Noise - noise whose energy is concentrated in a small portion of audible frequencies. Meters and Measuring Instruments - these include the integrating sound level meter, noise dosimeter, sound level meter and other analysers and tape records. Hearing Protection Device - A personal protection device worn to reduce the effects of noise on the auditory system of the wearer.
3.11.3 HEARING CONSERVATION PROGRAMME The ADGAS program for hearing conservation comprises of the following: ·
Noise surveys conducted throughout the plant to identify the noise hazardous areas and the sound pressure levels within them.
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In practice, noise hazard areas are identified on drawings before plant construction and signs are in place when the new plant is first occupied and the equipment commissioned. Periodical noise surveys are an ongoing requirement. Engineering investigations are undertaken in each noise hazard area to determine: o whether the noise hazard can be eliminated o whether the noise hazard can be reduced o whether the noise hazard can be isolated from employees
All the above are assessed within the physical, logistical and financial constraints of the company's operations. · · ·
Noise hazard areas still remaining are all identified and warning signs erected. Educational programs are designed and run, highlighting the effects of noise and means required to minimise exposure. This education is ongoing. When engineering and administrative measures do not satisfactorily reduce noise levels to below 85dB(A), hearing protection devices are required to be used by all likely exposed personnel in all designated noise risk areas.
An additional feature of the Company program is audiometric testing of employees before employment. Further audiometric testing is carried out as part of the periodic medical examinations at Das Island Hospital. Audiometric hearing tests are designed to provide early warning for potential victims of hearing loss and assist in highlighting areas where hearing conservation measures may not be effective.
3.11.4 NOISE ASSESSMENT Noise in all areas of the plant is assessed on a frequency dictated by relevant standards, whenever a change has occurred affecting noise levels and every five years. 3.11.4.1 INITIAL ASSESSMENT A walk-through survey identifies those areas on the plant of potential noise hazard risk requiring more detailed information or a survey. 3.11.4.2 NOISE SURVEY This is conducted in areas suspected of containing a noise hazard, by appropriately trained and certified personnel. A noise survey is conducted for the following purposes: ·
Identifying noise hazard areas and the drawing of 85dB(A) contours for hazard warning sign placement.
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Determining attenuation (noise reduction) requirements for personal hearing devices and checking the suitability of those supplied. Assessment of employee exposure to noise using the standard LAeq. 8h = 85dB(A) as the standard. Compliance testing of newly installed or modified plant and equipment and assessment of its effects on employees.
Results of noise surveys must be recorded on an approved form and the values transferred to a contoured floor plan of the subject area.
3.11.5 HEARING CONSERVATION METHODS 3.11.5.1 CONTROL OF EXPOSURE TIME If engineering noise control measures are unavailable or inadequate, the option of job design change is considered. Line management is responsible for assessing all noise exposed jobs and reducing employees exposure time where practicable. Job design changes and personnel rotation out of hazard areas are options. 3.11.5.2 PERSONAL HEARING PROTECTION Wearing of approved hearing protection is compulsory for all plant noise areas known to be within the 85dB(A) contours and where hearing protection signs are displayed. Hearing protectors must be readily available and comply with relevant standard: BS EN 352-1:2002 Attenuate the loudest noise received by the wearer to preferably below 85dB(A) as calculated using approved methods. Further steps are necessary if the attenuation of available ear protectors is calculated as not providing reduction to less than 85dB(A). These steps are required by the line supervisor · · · ·
Limit personnel access time in the area so that the noise exposure standard is not exceeded. Impress on employees the need for double protection, i.e. ear plugs plus ear muffs. Seek assistance in sourcing ear protectors which by calculation do comply. Expedite a noise reduction program.
Supervisors must also ensure that all employees in designated high noise areas are aware of the full range of hearing protectors and are able to correctly fit, store and
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maintain each type. The supervisor must also closely supervise and reinforce mandatory hearing protection requirements. Information on the design, wearer information, performance and procedures relative to hearing protectors (ear muffs) can be found on relevant supplier literature and in the British Standards. Further Information BS EN 352-1:2002: Hearing protectors. Safety requirements and testing. Earmuffs All personnel likely to be exposed to noise in workshops and in the use of power tools, must carry their own pair of earmuffs of approved and suitable type. Ear plugs are suitable for intermittent, short term protection only. Long term presence in these designated areas requires the wearing of appropriately rated ear muffs, whilst for long term exposure in high noise areas the double protection of ear muffs and ear plugs worn together shall be used. The use of some power tools also generates high noise levels, in particular the larger right angle disc grinders, and double protection is also required for users of these tools. Caution The claimed attenuation value for any hearing protection device may be compromised if: · The size and type is inappropriate for the area · The fit and adjustment of the device is incorrect · The unit is old, poorly maintained or broken · The fit is impaired by spectacles, clothing, etc. Further Information 3.9.4 HEARING PROTECTION
3.11.6 NON-HAZARDOUS NOISE Noise in some areas of the plant may be below the level of hearing loss risk, but may cause other problems. Noise that may interrupt verbal communication or create distraction also needs to be monitored and controlled.
3.11.7 NOISE PROBLEM INDICATORS Noise may occur in non routine activity or in the use of newly installed machinery, e.g. portable diesel power packs, which have not been assessed or identified in previous routine surveys.
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A noise problem exists if: · · ·
Voices have to be raised in speech communications in the affected area at a range of one metre or less. There is a residual ringing in the ears or difficulty in hearing normal sounds experienced after exposure (threshold shift). There is a prevalence of hearing problems amongst employees.
3.12 EYE SAFETY PROGRAMME 3.12.1 PURPOSE To define the appropriate standards of mandatory eye protection for personnel working on ADGAS facilities. Further Information ADNOC-COPV4-04: PERSONAL PROTECTIVE EQUIPMENT. Section 3.2 Eye Protection
3.12.2 OBJECTIVES · · ·
To prevent injury to eyes of employees, contractors and third parties while working on ADGAS facilities. To identify and eliminate potential eye injury hazards. Where it is not possible to eliminate hazards, work practices and personal protective equipment are to be used to minimise the risk. To ensure that all employees, contractors and third parties know, understand and comply with the requirements of this policy, and their duty of care regarding their own safety , and that of others.
3.12.3 SPECIFIC REQUIREMENTS To achieve these objectives, the following specific requirements must be complied with: · · ·
Prior to the commencement of any work activity, the hazards that may lead to eye injury are to be identified and where possible eliminated Where hazards cannot be removed, appropriate protection will be used. Evidence is required that eye safety has been considered in all jobs by Task Risk Assessment or other appropriate means.
It is recognised that at times temporary removal of eye protection may be necessary for cleaning and de-fogging or for close inspection when it is not hazardous. In these cases common sense should ensure that the eye protection is removed away from potential hazards and replaced as soon as possible. Doc. Number
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If a situation arises where the actual wearing of eye protection is thought to be potentially hazardous, the relevant supervisor will convene a Task Risk Assessment, to determine the safest way to perform the job. Note 'Appropriate' eye protection indicates a need for the best protection for the job, which may be safety spectacles (with side shields) minimum protection, safety goggles, a face shield, or any combination of these.
3.12.4 EYE TESTING All employees will have a pre-employment eye test according to the ADGAS Preemployment Health Assessment Policy.
3.12.5 PRESCRIPTION GLASSES Where prescription glasses are worn and an employee is required to work in the ADGAS Industrial Area, the company will provide one pair of glasses conforming with British Standard 2092. The glasses will be replaced by ADGAS when visual ability changes, or when glasses are accidentally damaged. Prescription safety glasses are not provided for personnel employed solely outside the plant unless they are also required to work in the Industrial area.
3.12.6 CONTACT LENSES Although not recommended, there is no barrier to wearing contact lenses on the plant providing the appropriate level of eye protection is also worn according to this policy. Further Information BS 7028:1999 - Selection, use and maintenance of eye protection for industrial and other uses.
3.12.7 SAFETY SPECTACLES/ EYESHIELDS/ OVERSPECS 3.12.7.1 INTRODUCTION The safety spectacles/ eyeshields have been reviewed and additional types have been added to the range. The following types are available on stores requisition. · ·
Clear for general use, and to be worn in areas of reduced lighting. Tinted for general use, particularly in areas of intense radiation (sunlight) and excessive glare. Doc. Number
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(clear/tinted) for general use, worn over non-safety prescription to be worn in the immediate areas of welding.
3.12.7.2 CONDITIONS · ·
·
Supervisory staff must ensure that eye protection is worn at all times, within the ADGAS Industrial Area, by their workforce. Spectacles may only be adequate for relatively low energy projectiles e.g. metal swarf. Whenever there is a risk of high speed solid projectiles, an exposure to dust or splashing of toxic/ corrosive substances, then goggles or face shields should be worn. Tinted spectacles/ eyeshields must not be worn in any area, that has subdued lighting i.e. within the LNG Trains.
3.12.7.3 CARE AND MAINTENANCE · · · ·
Ensure adequate fitting of the spectacles/ eyeshields to the face by altering the length of the side frame to fit snugly over the ears, if applicable, and adjust the angle of the side frame/ main body for a comfortable fit, wherever possible. Employees must take all reasonable steps to ensure that the safety spectacles/ eyeshields supplied are correctly used and maintained in a clean condition. Cleaning can be carried out by the use of lens cleaner and tissue or if there is heavy contamination, washing in a mild soap solution. Strong detergents should be avoided. Lenses that are heavily scratched, pitted or show other signs of damage should be replaced as they will impair vision, and the impact resistance may be reduced.
Prompt Reporting of Loss or Damage will Aid in a Speedy Replacement.
3.13 VEHICLES AND BICYCLES 3.13.1 INTRODUCTION Road traffic on Das Island is governed by the Abu Dhabi Traffic Laws and nothing in this Section of the HSE Manual will supersede or be interpreted to supersede relevant items within these laws. All drivers must be in possession of a current driving licence issued by the Police Department of Abu Dhabi, and be fully conversant with and comply with all requirements of local traffic regulations. Along with the above, drivers and other vehicle users must comply with the requirements laid down in this Section to ensure the safety of personnel.
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The term "vehicle", as used within this Section, includes all motorised vehicles and pedal cycles. Further Information ADNOC-COPV4-06: ESSENTIAL FEATURES OF ROAD TRANSPORT OPERATIONS, RISK ASSESSMENT AND CONTROL
3.13.2 GENERAL PRECAUTIONS Drivers and passengers should never mount, or dismount from a moving vehicle or jump from a high cab instead of using the steps. Neither should they (because they intend to be away for a short time) leave the vehicle with the engine running. An unattended vehicle should have the engine switched off, the gears in neutral and the hand brake on. As an added precaution on sloping ground the wheels should be chocked. Tipping bodies should always be lowered whenever the Operator leaves the machine. Drivers and front seat passengers must wear seat belts, as required by the Abu Dhabi Traffic Law.
3.13.3 REVERSING Large vehicles should not be reversed without the help of a banksman. If a banksman is unavailable, then the driver must ensure before moving that no-one is in a position of danger. Audible warning systems should be installed where possible.
3.13.4 PASSENGER SAFETY Suitable arrangements must be made for the transport of personnel through the facilities. The number of passengers carried in company vehicles must be strictly limited to the figures quoted in the Passenger Load Limits following. In the case of a vehicle provided with only one seat, e.g. tractor, dumper, etc., then passengers are strictly forbidden. Certain vehicles may be used to transport personnel that are not specifically designed to carry personnel. To ensure the safety of personnel in such vehicles the following must be complied with:Permanent or temporary seating shall be fitted to all vehicles. If temporary, adequate means of securing must be fitted. All flat beds and trailers transporting passengers shall be approved by ADMA-OPCO Transport Engineer and MHSE.
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3.13.5 PASSENGER LOAD LIMITS 3.13.5.1 CARS Driver and up to four passengers with one passenger only in front passenger seat. 3.13.5.2 LIGHT DUTY (SHORT WHEEL BASE) PICK-UP Driver and one passenger only in front, and, where seats are provided, up to six passengers in the rear. 3.13.5.3 HEAVY DUTY (LONG WHEEL BASE) PICK-UP Driver and one passenger only in front, and, where seats are provided, up to six passengers in the rear. 3.13.5.4 LORRY Driver and one passenger only in front, and, where seats are provided, up to eighteen passengers in the rear.
3.13.6 SPEED LIMITS The speed limit for all vehicles between Marshalling Points 1 and 5 is 25 kph. On other roads the speed limit is 45 kph.
3.13.7 ROAD LIMITS All five bridges on Das Island are constructed for a single maximum axle load of 20 tonnes, and the four height restrictions are set at 5.20m. The routing of heavy load vehicles from site to the harbour must be approved by ADMA-OPCO. If construction work on roads is required for piping, culverts, cables, etc., there must always be left open for vehicular traffic at least a 3m wide unrestricted road width. Measures are to be provided for traffic lights or a flag man. A complete blockage of roads is not acceptable.
3.13.8 ROAD CLOSURES (TOTAL/PARTIAL) Any road normally open to traffic within the areas operated by ADMA-OPCO, that is to be fully or partially closed, requires notification to ADMA OPCO in order to Obtain ADMA’s approval through ADGAS HSE . Total/ Partial road closures within the ADGAS operated areas must be requested through HSED and HO. The above permits/ requests must be completed in sufficient time to comply with the mandatory requirement of 72 hours notification to the Police and the Emergency Services.
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3.13.9 ROAD MOVEMENT OF WIDE IRREGULAR LOADS Whenever a wide/ irregular load is to be moved which is liable to obstruct normal traffic due to its shape, length or speed, a permit (Road Movement of Irregular Loads/ Equipment) is required within the ADMA-OPCO operated areas. Notification of movement must be submitted to HSED for roads within the ADGAS areas. Submission of the permit/ notice for the above must be in time to comply with the mandatory 72 hours notification. If trailers are used then they must have an integrated braking system with the towing unit.
3.13.10
DRIVER TRAINING
Specialised vehicles such as tractors, forklifts, cranes, etc. may only be driven by persons who have been appropriately trained and who have passed a competence test to drive the particular vehicle. ADMA-OPCO is responsible, on request, for arranging the testing of drivers of such vehicles.
3.13.11
LOADING/UNLOADING
Vehicles must not be overloaded and the loads must be evenly distributed, secured and not projecting beyond the sides of the vehicle wherever possible. When vehicles are to be loaded by means of some other machine, the driver should leave the cab before loading commences. It is the responsibility of the user Department to ensure safe loads according to the vehicle capacity, and to secure all loads adequately.
3.13.12
PROJECTING OR WIDE LOADS
If some degree of projection is unavoidable, it should be properly marked in a manner that makes the projection clear to other road users. At the discretion of MHSE a warning vehicle may be required to accompany and or direct the abnormal load within the ADGAS Industrial Area.
3.13.13
TOWING
The towing vehicle and trailer, compressor, etc. must be matched to ensure the combination is capable of negotiating inclines, bends, etc. Brakes on the trailer unit should be operable from the towing unit.
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Any connections between the trailer and the towing unit must be securely fixed using the correct towing pin and the trailer parking brakes applied before disconnection from the towing vehicle. Suitable wheel chocks should be provided when parking on an incline.
3.13.14
MAINTENANCE
Company owned motor vehicles and those permitted to be used for Company projects must be maintained in an efficient and safe condition. Vehicles must be taken to the ADMA-OPCO Garage for servicing on the day specified. Any defects must also be reported so that repairs can be effected. No driver may attempt to carry out his own repairs to the vehicle or engine. Each vehicle must have a current registration document that is to be kept in the vehicle and display a rear number plate sticker. Additionally, police permission to use the vehicle must be kept in the vehicle. The maintenance of current documents is the responsibility of ADMA-OPCO Transport Section.
3.13.15
BICYCLES
Bicycles must be maintained in a good and safe condition and not used during the hours of darkness unless they have a white light showing to the front and a red light showing to the rear. Bicycles are not allowed in certain areas as indicated by notices in the ADGAS Industrial Areas. All bicycles and riders must be licensed by the Das Island Police. Brakes, both front and rear, shall be regularly checked for effective operation.
3.14 HEAT DISORDERS 3.14.1 INTRODUCTION Ideally man's thermal environment should maintain the body temperature at about 36.8°C or, if under thermal stress, some value normally within the range of 36.5-39°C. The thermal environment has a pronounced effect on personal comfort. Marked deviations can cause adverse effects including fatigue, irritability, reduced concentration, heat cramps due to salt loss, fainting, heat exhaustion and heat stroke. These in turn affect productivity, increase error and accidents and, of course, an individual's health. In addition to presenting information on the body's response to high temperature, sensible precautions are suggested here for reducing the effects of working in a hot environment.
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Further Information ADNOC-COPV3-08: GUIDELINE ON OCCUPATIONAL HEALTH RISK ASSESSMENT( OHRA)
3.14.2 BODY HEAT RESPONSES When the body senses increased skin temperature, peripheral blood vessels dilate and pulse rate increases resulting in a greater flow of blood to the surface of the body. This increases the potential for heat transfer from the body core to the skin and surroundings. Sweating increases heat loss due to latent heat of evaporation of sweat. In very hot climates sweating offers the greatest potential for regulating body temperature.
3.14.3 ACCLIMATISATION On going from a cool to a predominantly warmer climate it is necessary to allow the body to acclimatise by increasing the body's ability to replenish lost fluids and sweat capacity while decreasing salt losses in sweat. It takes about three days to get to 60% sweat capacity and ten days for complete acclimatisation. This increased sweat capacity is lost after a few days in a cooler environment.
3.14.4 BODY TEMPERATURE In the thermal environment and general working conditions on Das the following factors are most important in the regulation of body temperature: 3.14.4.1 AIR VELOCITY Heat will be removed from the body by convection when an air current passes over it unless the air temperature is higher than the temperature of the skin. Air movement will also affect the rate of evaporation of moisture (sweating) from the skin unless the air is 100% saturated or it's vapour pressure is greater than that on the surface of the skin. It is therefore beneficial to maintain air movement in areas of high ambient temperature, particularly in enclosed spaces. 3.14.4.2 HUMIDITY As indicated above, the evaporation of moisture (sweat) plays a major role in dissipating body heat and thus the temperature and humidity of the air are important. The higher the humidity the more difficult it is for the sweat to evaporate; hence the effect of heat on the body is greater.
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3.14.5 HEAT EXHAUSTION Heat exhaustion is associated with a depletion of both salt and minerals. The concentration of body fluids is not altered greatly, but there is a drop in blood volume that causes the symptoms. Symptoms over a period of a few days the person complains of weakness, fatigue and headache with perhaps vomiting. Treatment consists of removing the patient to a cool place, rest in bed and replacement of salt and water, normally orally. Only in severe cases is intravenous supplement necessary.
3.14.6 HEAT STROKE Heat stroke indicates the failure of the thermoregulatory mechanism and consequent increasing of body temperature. When the body temperature reaches 40.6oC the person will fall unconscious. Onset is abrupt. If a person has heat-stroke, he must be rapidly cooled, by whatever means are available, to reduce his temperature. Treatment may be required for as long as a week before sweating returns and the patient is able to regulate his temperature unaided. The differences between the two heat disorders are illustrated in Figure 3-5: Signs and Symptoms of heat exhaustion include: · · · · · · · · ·
Signs of heat stroke include: ·
Cool, clammy, pale skin Sweating Dry mouth Fatigue, weakness Dizziness Headache Nausea, sometimes vomiting Muscle cramps Weak and rapid pulse
· · · · · · ·
Very high temperature (104 degrees F or higher) Hot, dry, red skin No sweating Deep breathing and fast pulse - then shallow breathing and weak pulse Dilated pupils Confusion, delirium, hallucinations Convulsions Loss of consciousness
Figure 3-5: HEAT EXHAUSTION, HEAT STROKE
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3.14.7 TEMPERATURE LIMITATIONS Ministerial Decision No 467 (2005) ADGAS and ADGAS contractors are required to set a roster specifying the daily working hours for all labourers working under the sun or in exposed work sites during the months of July and August. The roster must be displayed in a prominent place, and must be in Arabic and other languages understood by the labourers. American industrial hygienists recommend to use Wet Bulb Globe Temperature Index (WBGTI) to establish exposure limit values for work in hot environment. This index sets the duration of work and rest periods so as to ensure that the core body temperature does not rise above 38°C WBGTI is calculated as follows: (i)
Outdoors when solar radiation is present.
WBGTI (ii)
=
0.7 WBT + 0.2 BGT + 0.1 DBT
Indoors or outdoors when solar radiation is not present.
WBGTI
=
Where
WBGTI WBT BGT DBT
0.7 WBT + 0.3 BGT = = = =
Wet Bulb Globe Temperature Index in °C Wet Bulb Temperature in °C Black Globe Temperature in °C Dry Bulb Temperature in °C
Recommended work/rest duration for various type of activities and corresponding WBGTI is given below: Work/rest Continuous work 75% work - 25% rest 50% work - 50% rest 25% work - 75% rest
Workload Medium 26.7 28.0 29.4 31.1
Light 30.0 30.6 31.4 32.2
Heavy 25.0 25.9 27.9 30.0
The duration of each work/rest cycle should be one hour, i.e.: 45 minutes work - 15 minutes rest, 30 minutes work - 15 minutes rest etc. The above values are recommended when temperature conditions at the resting place differ little from those at work place. If the resting place temperature is equal to or less than 24°C WBGT, the rest periods may be shortened by 25%. Doc. Number
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The limit values in table above shall not be exceeded.
3.15 SAFE ACCESS AND WORK PLACES 3.15.1 INTRODUCTION Plant layout and building designs are such that safe entrance and exits are provided to all normal/regular work locations. Emergency escape routes are also provided in most areas to afford a secondary route of escape. The purpose of this section is to detail the minimum acceptable criteria for safe means of access and workplace safety.
3.15.2 ENTRANCE AND EXIT 3.15.2.1 GENERAL All normal routes of entrance to and exit from and within work places must be sized to accommodate the anticipated normal traffic, in both directions, for that route. As a minimum, all normal means of access must have a width of 1 metre and a clearance height of 2.2 metres. Access routes should be defined where possible within Plant and Workshop areas by yellow markings delineating the width and direction of the route. Adequate lighting shall be provided on all entrance and exit routes. Surfaces of routes shall provide firm footing without trip hazards and be non-slip. Constructions and equipment must not protrude into the designated route. No "dead end" access routes are to exceed 10 metres in length. Where possible, secondary means of access should be provided to work areas. Any routes requiring to cross pipes, etc., shall be provided with ramps or steps of suitable width and inclination.
3.15.3 RESTRICTED AREAS Restricted Areas are defined as those in which ADGAS exercises control over movement and operations. The Restricted Area shall be entered or left only by the recognised routes.
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3.15.4 TEMPORARY ACCESS Where normal routes of access are obstructed due to operational or maintenance requirements, alternative routes shall be established and clearly signed. Temporary accesses are not required to conform to the minimum criteria given, but shall be free of protrusions and trip hazards. Any restrictions in height or width on temporary walkways less than the normal minimum criteria, are to be clearly marked with yellow and black diagonal stripes.
3.15.5 ACCESS TO ELEVATED AREAS The following criteria apply to all work places that are 2m or more above grade. Wherever possible access should be by stairways complete with handrails. Ladders in excess of 2.5 metres must be provided with a safety cage from 2.5 metres above grade to the ladder top. Landings are to be provided at 6 metre intervals for extended height accesses. Safety bars or gates are to be provided at ladder tops. Ladder hand rails are to extend 1 metre above the platform, etc., level. Where ladder access movements are minimal or the fitting of safety cages is not operationally feasible, provision must be made for the use of safety belts/harnesses and lines, ideally of the permanently engaged type. All accesses that have a vertical drop of more than 2m on either or both sides, shall be provided with handrails.
3.15.6 ESCAPE ROUTES 3.15.6.1 GENERAL Emergency escape routes shall be provided from work areas, each route being clearly defined. A normal access route can be designated an escape route provided the minimum requirements designated below are met. Lighting on emergency escape routes is to be provided with battery backup to ensure visibility if there is power failure. Routing of emergency escape routes must take into consideration the inherent hazards of the work place and where possible, minimise them by physical separation or by shielding. Doc. Number
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3.15.6.2 BUILDINGS Escape routes within buildings are to take the minimum practicable route to an external door. Where dead ends or excessively long routes exist, provision shall be made for emergency escape doors, each fitted with panic bar or break-glass bolts. All doors on escape routes are to open in the direction of escape. 3.15.6.3 ESCAPE ROUTE SIGNS AND MARKINGS The directions of emergency escape routes are to be clearly defined by white arrows on a green background. At the beginning of the escape route and at subsequent junctions, the direction arrows are to be supplemented by a sign with the wording "Escape Route" in white on a green background in Arabic and English. Exits from buildings are to be indicated by self illuminated or photoluminescent signs above the door indicating "Exit" or "Emergency Exit" - again, white lettering on a green background in Arabic and English.
3.15.7 SAFE WORK PLACES 3.15.7.1 GENERAL Design and layout of plant, equipment and facilities are to ensure, where practicable, that all hazards are minimised. Procedures for routine and specific work requirements shall reflect safe and accepted work practices. Housekeeping within work areas shall be maintained at a high standard. Employees shall ensure familiarity with workplaces, especially escape routes and emergency equipment locations. 3.15.7.2 PLANT AND WORKSHOPS All access and escape routes must be maintained free of obstructions. Hand tools and portable equipment are to be maintained in good condition with repairs only being undertaken by competent persons. All tools and portable equipment are to be returned to their proper place of storage after use.
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Electrical leads and cables are to be utilised with approved connectors only. Temporary repairs to cables are not permissible. Waste and rubbish shall be deposited in approved containers as soon as practicable and not allowed to accumulate. 3.15.7.3 CONTROL ROOMS AND SUBSTATIONS All panel doors shall be secured except during maintenance. Control stations are to be maintained free of obstructions and desk top surface controls are to remain unobscured. Where computer type floor or floor panels are used, panels are to be secured and level. If any panels are removed for access, the opening shall be barriered. 3.15.7.4 OFFICES The following items are the responsibility of all employees: Do not allow electrical leads to trail where someone may trip over them. Frayed or damaged leads are to be replaced immediately by a competent person. Keep gangways and passages clear - do not leave drawers of desks and filing cabinets open. Never overload shelves and always use step ladders to reach shelves out of your reach. 3.15.7.5 TANK ROOFS All work on tank roofs shall be covered by a valid permit. Unsafe tank roofs shall be so marked with a notice at the top of the tank stairs or ladder, where a barrier prohibiting access shall be placed. Access onto floating tank roofs requires an Entry Permit See Chapter 9 3.15.7.6 FRAGILE ROOFS Buildings having asbestos or similar fragile roofing materials shall be marked by a notice giving warning of this. Any work undertaken on fragile roofs shall use roofing boards or if necessary, proper scaffolding or walkways. Stepping onto the roof is prohibited. If no safety barriers are provided, safety belts/harnesses with life lines attached to suitable anchor points shall be used. Doc. Number
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If ladders are used for roof access, their construction and use shall comply with the requirements detailed in Section 9-3 Scaffolding and Ladders. Further Information Chapter 9.7 WORK OVER WATER Chapter 9.8 WORK ON ROOFS Chapter 9.9 WORK AT HEIGHT
3.16 OFFICE SAFETY 3.16.1 FIRE 3.16.1.1 EVACUATION OF ADGAS MAIN OFFICE BUILDING (DAS) On the sounding of the local Fire Alarm, personnel SHALL take the following actions: · · · · · · ·
Leave their place of work or office. Shut, but do not lock, doors. If safe to do so, attack fire with available fire extinguisher. Call Fire Service, 63333 from safe area. Evacuate the building through the nearest fire exit. Assemble at either Marshalling Points (North or South side) Await further instructions.
3.16.2 TRIPS AND FALLS Watch out for falls. You can fall while walking, climbing stairs or even leaning back in chairs. You can trip on telephone and electric cords, open drawers and misplaced boxes or furniture. It’s easy to slip on a spot of spilled coffee on a polished floor. To prevent these common office accidents: · · · · · · · · ·
Keep your office tidy, with boxes and furniture in their proper places Don't leave the bottom drawers of desks and filing cabinets open. Open one drawer at a time, and close the drawers slowly and carefully Clean up any spills immediately and use a suitable cleaning agent if spills are greasy Report worn or loose tiles and carpets immediately Use warning signs and arrange alternative routes when floors are wet Make sure cables don't cross pedestrian routes, secure them to the floor, or use cable covers where appropriate Keep mats securely fixed to the floor surface and make sure they don't have any curling edges Do not allow rubbish to build up; clean up and keep work areas free of obstructions Ensure pedestrian routes are free of obstacles left in the way and protruding obstacles Doc. Number
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If you cannot safely reach items on high shelves, re-organise your arrangements. If this is not practicable use a step-up or step ladder Be wary of top-heavy drawers can cause a filing cabinet to topple over Drawers can also pinch fingers if slammed shut
3.16.3 LIFTING Avoid lifting any heavy or awkward items · · · · ·
Use a trolley when possible Break down large or heavy loads Seek help if necessary Check your route is clear Take extra care with awkward tasks such as emptying a car boot
· · · · · · · ·
Stand close to the item with feet apart Bend your knees, not your back Grip the item firmly Lift with your legs Bend your knees to lower the load Don’t trap your fingers and toes Put it down first, then slide it into place Don’t over-reach or stretch
3.16.4 HAZARDOUS SUBSTANCES Exposure of personnel to hazardous substances in office environments is minimal. Nevertheless, some hazardous substances such as cleaning materials and copying materials may be present in small quantities. Office personnel should avoid contact with such substances, however, if they must be handled reference should be made to Hazardous Substances Manual, and the controls in the MSDS's should be applied.
3.16.5 ELECTRICAL HAZARDS · · · ·
Guard against electric shock by making sure equipment is properly connected using three-pronged plugs Check cables regularly and replace frayed or improper wiring Never tamper with electrical plugs to make them fit the wrong type of socket Keep coffee and other liquids away from your electrical equipment.
3.16.6 WORKSTATION Setting up your workstation correctly will reduce most of the causes of pain and discomfort from sitting at a computer. Approach this from the point of view that your current setup is, obviously, what you thought was OK, but now the idea is to change it. Doc. Number
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The correct setup might not feel right straight away, and changing ingrained habits may take a prolonged effort. First, adjust your chair height so that when you put your fingers on the middle row of the keyboard your forearms and hands are horizontal, with your elbows vertically under your shoulders and no angle at the wrist. Often it helps to get a colleague to look from the side, as it can be hard to judge for your self. Many people have their chair too high so adjust your chair to this height now. If the undersides of your thighs are now compressed, you need either a footrest or a lower desk. Most desks are a standard height of around 2'6" (710 mm) so a large proportion of people will benefit from a footrest Adjust the height of the monitor so that you are looking horizontally, not down at it. Generally this means having the top of the visible area at eye height, when you are sitting upright. Many people have their monitor too low, but you can raise the monitor on anything suitable that you have to hand, it doesn't need to be an adjustable monitor arm. Adjust the angle of the backrest, and/or the length of the bottom-cushion, so that your back is supported in your work position, and the bottom-cushion is not too long for you. If you can't sit fully back and upright without the back of your knees hooking the front of the seat, you need a different chair with a shorter bottom-cushion. Adjust the backrest height so that it supports the lower back Sit very upright. If the shape of the backrest does not fit fully into the small of your back, you would probably benefit from adding a back support. Move your chair so that when typing your elbows are vertically under your shoulders. If you cannot get close to the desk because the chair armrests hit the edge of the desk, either change the chair or remove them. Fixed-height armrests are generally too low, encouraging you to slump down to them. Adjustable-height armrests are usually shorter and will let you get close enough to your desk while offering valuable support taking some of the weight of your arms off your shoulder and neck muscles. Short but fixed armrests can be raised by wrapping foam round them, or adding a layer of foam and wrapping fabric round. Don't be surprised if you need to add up to three inches of height in order to have elbow support when sitting upright. Check the distance of the monitor. For most people to view the screen comfortably it should be about 22-26" (55 - 65 cm) away, so that your eye focus muscles do not have to work too hard. If you are sitting much closer than this, consider if there is a problem with your eyesight, the screen quality or settings, or the desk depth. Usable desk depth can often be increased by pulling the desk away from the wall and allowing the monitor to overhang at the back. Check the side-to-side position of the monitor - it should be directly in front of you. Don't put the monitor in the corner - either it will be hard to get close enough to the keyboard, or you will be twisted and your back and neck may develop problems. Doc. Number
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Sit close to the desk and don't put things between you and the keyboard except a gel wrist rest - your elbows need to be vertically under your shoulders. Don't automatically deploy the keyboard's rear feet - you only need them if your elbows are below desk height. If you rest your wrists on the table when you type you should use a wrist rest. Position and use the mouse as close to you as you can. Aim to have your elbow vertically under your shoulder, and right by your side or on the armrest. If your mouse tends to stray away from you during the day, try making your mouse mat smaller (most can be cut easily) and sticking it down in the correct position with doublesided tape or blu-tak. If possible, or at all costs if you develop any sensation in your mouse-side shoulder, use a narrow (84-key) keyboard so that you can have your mouse closer. If you often refer to documents whilst typing use a document holder. This should be positioned at the same height and distance as your monitor. If you look at the documents more than the screen put the document holder directly in front of you and the monitor to the side. Eliminate any glare or reflections on your monitor. Try closing blinds and changing the position of the workstation so that the monitor is at right-angles to the window. Turn off overhead lights unless you really need them, using a tall desk lamp for reading. You can reduce reflections from overhead lights by raising your monitor then tilting it down to make the screen vertical. Position any additional equipment e.g. phones, paper trays, reference material in accessible places. Try to avoid reaching and twisting. Investigate storage facilities and desktop accessories to help you organise your workstation better.
3.16.7 BREAKS The timing of breaks is more important than length of the breaks. Take short, frequent breaks before you become tired. A 2-3 minute break after 30 minutes of screen and keyboard work is more refreshing than a 15 minute break after 2 hours. Taking a break need not mean going for a cup of coffee. Simply changing activities is a useful type of break. Alternate between screen and non-screen based tasks throughout the day. Make sure the change of activity uses different muscles and tendons to your computer work. Take short pauses from your work to stretch your arms and legs. Use your formal breaks to get away from your keyboard and screen. Help to relax your eyes by finding somewhere that allows you to look at a distant object.
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3.16.8 FIRST AID A small cut, seemingly a minor graze which causes no pain, can quite easily turn septic which in turn can lead to blood poisoning. All this may happen because a simple antiseptic cover was not applied at the time of injury. Know who your first aiders are and where first aid equipment is located. Further Information ADNOC-COPV3-03: OCCUPATIONAL HEALTH RISK MANAGEMENT GENERAL. Section 8.4 Facilities and Personnel for Medical Emergency Response
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CHAPTER 4 CONTENTS 4
HAZARDOUS SUBSTANCES ............................................................................................................... 145 4.1 INTRODUCTION ............................................................................................................................ 145 4.1.1 GENERAL .................................................................................................................................... 145 4.1.2 NEW CHEMICAL APPROVAL PROCEDURE ........................................................................... 145 4.2 HAZARDOUS SUBSTANCE CONTROL ...................................................................................... 148 4.2.1 ELIMINATION ............................................................................................................................. 148 4.2.2 SUBSTITUTION OF LESS HAZARDOUS MATERIAL ............................................................... 148 4.2.3 ENCLOSURE OF THE HARMFUL PROCESS ........................................................................... 148 4.2.4 ISOLATION OF THE HARMFUL PROCESS .............................................................................. 148 4.2.5 LOCAL EXHAUST VENTILATION ............................................................................................. 148 4.2.6 GENERAL VENTILATION........................................................................................................... 148 4.2.7 WET METHODS .......................................................................................................................... 149 4.2.8 PERSONAL PROTECTIVE EQUIPMENT .................................................................................. 149 4.2.9 PERSONAL HYGIENE ................................................................................................................ 149 4.2.10 EDUCATION ........................................................................................................................... 150 4.2.11 HOUSEKEEPING AND MAINTENANCE .............................................................................. 150 4.2.12 WARNINGS AND PUBLICITY ................................................................................................ 150 4.3 RESTRICTED MATERIALS ........................................................................................................... 150 4.3.1 ASBESTOS ................................................................................................................................... 150 4.3.2 OZONE DEPLETING SUBSTANCES .......................................................................................... 151 4.3.3 POLY CHLORINATED BIPHENYLS (PCBS) ............................................................................. 151 4.4 RISK AND CONTROLS .................................................................................................................. 152 4.4.1 INTRODUCTION ......................................................................................................................... 152 4.4.2 DEFINITIONS .............................................................................................................................. 152 4.4.3 RESTRICTIONS ........................................................................................................................... 153 4.4.4 FLAMMABILITY .......................................................................................................................... 153 4.4.5 HEALTH HAZARDS .................................................................................................................... 154 4.5 CHEMICAL HANDLING ................................................................................................................ 155 4.5.1 GENERAL SAFETY...................................................................................................................... 155 4.5.2 FLAMMABLE LIQUIDS .............................................................................................................. 156 4.5.3 UNSTABLE MATERIALS ............................................................................................................. 157 4.5.4 REACTIVE MATERIAL................................................................................................................ 157 4.5.5 INCOMPATIBILITIES ................................................................................................................. 157 4.6 WORK WITH HARMFUL CONTACTS ......................................................................................... 158 4.6.1 INTRODUCTION ......................................................................................................................... 158 4.6.2 SYNTHETIC MINERAL FIBRES ................................................................................................. 159 4.6.3 ASBESTOS ................................................................................................................................... 159 4.6.4 QMB and CWS AREAS ................................................................................................................ 162 4.6.5 ASBESTOS WASTE DISPOSAL ................................................................................................... 163 4.6.6 LAGGING AND OTHER FIBROUS INSULATION ..................................................................... 163 4.6.7 STORES PROCEDURES ............................................................................................................. 163 4.6.8 CHEMICAL CLEANING .............................................................................................................. 164 4.7 LABELLING HAZARDOUS SUBSTANCES ................................................................................ 166 4.7.1 INTRODUCTION ......................................................................................................................... 166 4.7.2 ARABIC WARNING ..................................................................................................................... 166 4.7.3 CLASSES ...................................................................................................................................... 166 4.7.4 SUB-DIVISIONS .......................................................................................................................... 166 4.7.5 LABELLING REQUIREMENTS................................................................................................... 166 Doc. 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4.7.6 NON HAZARDOUS SUBSTANCES ............................................................................................. 168 4.7.7 CLASS LABELS/HAZARD DIAMONDS ...................................................................................... 168 4.7.8 RISK PHRASES ............................................................................................................................ 168 4.7.9 SAFETY PHRASES ...................................................................................................................... 169 4.7.10 UN NUMBERS ........................................................................................................................ 169 4.7.11 NFPA SYSTEM ........................................................................................................................ 169 4.7.12 GENERAL SAFETY ................................................................................................................. 169 4.7.13 INFORMATION....................................................................................................................... 169 4.7.14 RESPONSIBILITIES ................................................................................................................ 170 4.8 COMPRESSED GASES ................................................................................................................... 170 4.8.1 INTRODUCTION ......................................................................................................................... 170 4.8.2 HAZARD CLASSIFICATION ....................................................................................................... 170 4.8.3 PROPERTIES OF GASES ............................................................................................................ 171 4.8.4 OXYGEN ...................................................................................................................................... 173 4.8.5 LIQUIFIABLE GASES ................................................................................................................. 175 4.8.6 SAFE STORAGE .......................................................................................................................... 177 4.8.7 SAFE HANDLING........................................................................................................................ 177 4.8.8 LEAK TESTING ........................................................................................................................... 177 4.8.9 CARE OF CYLINDERS ................................................................................................................ 178 4.8.10 EMERGENCY SITUATIONS ................................................................................................... 178 4.9 OTHER DANGEROUS SUBSTANCES.......................................................................................... 180 4.9.1 INTRODUCTION ......................................................................................................................... 180 4.9.2 METHANOL ................................................................................................................................. 180 4.9.3 CAUSTICS AND ACIDS .............................................................................................................. 181 4.9.4 AMMONIA ................................................................................................................................... 182 4.9.5 CAUSTIC SODA .......................................................................................................................... 182 4.9.6 MIXED LIGHT HYDROCARBONS ............................................................................................. 183 4.9.7 CARBON DIOXIDE AND NITROGEN ........................................................................................ 183 4.9.8 ACETYLENE ................................................................................................................................ 183 4.9.9 MERCURY ................................................................................................................................... 183 4.9.10 MERCURY RECOVERY UNITS .............................................................................................. 184 4.9.11 PYROPHORIC MATERIAL HANDLING STORAGE AND DISPOSAL PROCEDURE ......... 185 4.10 RADIOACTIVE SOURCES ............................................................................................................ 187 4.10.1 INTRODUCTION .................................................................................................................... 187 4.10.2 DEFINITIONS ......................................................................................................................... 187 4.10.3 PERSONAL MONITORING .................................................................................................... 189 4.10.4 INDIVIDUAL RESPONSIBILITY ............................................................................................ 189 4.10.5 EMERGENCY EXPOSURE ..................................................................................................... 190 4.10.6 WORK PERMIT REQUIREMENTS ........................................................................................ 190 4.10.7 RADIOGRAPHY ...................................................................................................................... 190 4.10.8 CONTROL OF RADIOACTIVE SOURCES ............................................................................ 190 4.10.9 NUCLEONIC SOURCES ......................................................................................................... 193 4.10.10 SITE RADIOGRAPHY ............................................................................................................. 195 4.10.11 OTHER APPLICATIONS ........................................................................................................ 196 4.10.12 MONITORING......................................................................................................................... 196 4.10.13 RADIOACTIVE EMERGENCY ............................................................................................... 197 4.10.14 TRANSPORT ........................................................................................................................... 197 4.10.15 DEFINITIONS OF RADIOLOGICAL TERMS ........................................................................ 199 4.10.16 DOSE LIMITS.......................................................................................................................... 201 4.10.17 APPOINTED RADIATION PROTECTION SUPERVISORS ................................................... 205 4.11 PLANT PRODUCT HAZARDS....................................................................................................... 205 4.11.1 INTRODUCTION .................................................................................................................... 205 Doc. 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4.11.2 CRYOGENIC MATERIALS ..................................................................................................... 206 4.11.3 CRYOGENIC SPILLS/FLARES ............................................................................................... 208 4.11.4 EQUIPMENT FOR CRYOGENIC SERVICE .......................................................................... 210 4.11.5 PENTANE ................................................................................................................................ 210 4.11.6 HYDROGEN SULPHIDE (H2S) ............................................................................................. 210 4.11.7 SULPHUR ............................................................................................................................... 212 4.12 HAZARDOUS SUBSTANCES DISPOSAL .................................................................................... 214 4.12.1 GENERAL ................................................................................................................................ 214 4.12.2 OUTSIDE AGENCIES ............................................................................................................. 214
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4 HAZARDOUS SUBSTANCES 4.1 INTRODUCTION 4.1.1 GENERAL Exposure of personnel to hazardous substances must be kept to levels as low as reasonably achievable, and in all cases, below levels set by regulations and relevant U.A.E and/or international exposure standards. Exposure and/or environmental control measures are evaluated and implemented in the following order of preference: · · · · ·
Elimination of the need for the hazardous substance Substitution with a less hazardous substance Engineering measures, such as enclosure and/or ventilation Administrative measures such as restricting access/exposure via job rotation. Use of personal protective equipment.
Exposure of personnel to hazardous substances on Das Island should be minimal, but for certain non-routine operations importation and use may be unavoidable. Note The use of special personal protective equipment to control exposure must be restricted to short term, non-routine work, or for emergency situations. Further Information ADNOC-COPV3-04: OCCUPATIONAL HEALTH RISK MANAGEMENT CHEMICAL & BIOLOGICAL AGENTS
4.1.2 NEW CHEMICAL APPROVAL PROCEDURE Divisional Managers /Departmental Heads are responsible for informing the HSED when new chemicals are about to be introduced. A memorandum following the format shown in Figure 4-2: New Chemical Request Form (NCRF), Introduction Of New Chemical should be sent to MHSE with attached Material Safety Data Sheet. HSED will review and inform approval or rejection to the initiator. Once the chemical is approved, the old chemical will be taken out from the inventory list after 6 months. Chemical brought for trial purpose shall follow MSDS of the manufacturer. The approved chemical will then be included in the Hazardous Substance Manual.
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Roadmap to new chemical approval procedure is shown in Figure 4-1: New Chemical Approval Procedure.
NEW CHEMICAL APPROVAL PROCEDURE User’s User’s dpt. dpt. Procure Procure MSDS MSDS
Send Send request request to to HSED HSED with with MSDS MSDS and and aa brief brief justification justification in in the the prescribed prescribed format format HSED HSED will will review review on on HSE HSE issues issues and and Feedback Feedback within within 22weeks weeks in in writting writting
MSDS MSDS Alternate Alternate chemicals chemicals
Inform Inform Materials Materials Dpt.to Dpt.to look look for for alternative alternative
Not Not Acceptable Acceptable
Acceptable Acceptable
User’s User’s Dpt. Dpt. will will advice advice Materials Materials Dpt. Dpt. To To procure procure for for field field trial trial
ALL CHEMICALS INTENDED FOR USE IN DAS ISLAND MUST HAVE THE MATERIAL SAFETY DATA SHEET AND BE REVIEWED BY HSED BEFORE PROCUREMENT.
User User Dpt. Dpt. To To carry carryout out field field trial trial and and feed feed back back to to HSED HSED of of the the result. result.
Look Look for for other other users users for for reference reference
HSED HSED formally formallyendorses endorses ifif the the feedback feedback from from the the trial trial is is successful. successful. User’s User’s dpt. dpt. will will advise advise Materials Materials dpt. dpt. to to Include Include in in the the materials materials register. register.
Figure 4-1: New Chemical Approval Procedure Further Information Hazardous Substances Manual Full details on all approved hazardous substances are contained in the ADGAS Hazardous Substances Manual. Any chemical missing from the list may please be intimated to HSED.
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To be completed by New Chemical Initiator From:
……………………………………
Date:
……………………………………
1. 2. 3. 4. 5. 6. 7. 8.
9. 10. 11.
To: HSED: (Strike out as applicable)
Name of Chemical: ……………………………………………………………………………… Supplier: …………………………………………………………………………………………. Anticipated use t/annum: ……………………………………………………………….……….. Type of container :……………………………………………………………………………..… What will chemical be used for? ……………………………………………………………...… New/ Replacement chemical? (Strike out as applicable) Store ID Number of old chemical (where applicable) ………………………………………….. Is this chemical really required? Please supply answers to the following questions as attachment to this form: 8 (a) If a replacement chemical, what is it’s advantage over existing chemical? 8 (b) What benefits does the chemical give over not using it? 8 (c) Is the chemical effective? Please supply supporting evidence from field trial. 8 (d) Is the chemical economically justified? Please give details of alternatives, including no use. Where will chemical finish up? Air ……………..% Water …………….% Oil …………….% Please attach completed MSDS (yes/no) (Strike out as appropriate) Please supply plan for monitoring effectiveness of chemical during use.
Signed:
……………………………………………….
Telephone Number: …………………
To be completed by HSED The chemical is approved/ rejected ((Strike out as appropriate) Signed
………………………………………….(HSED) (Strike out as appropriate)
Date:…………………………..
NB: If the replacement chemical is approved, the old chemical will be taken out of inventory list after 6 months. Figure 4-2: New Chemical Request Form (NCRF)
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4.2 HAZARDOUS SUBSTANCE CONTROL 4.2.1 ELIMINATION Division/Department Managers shall make every effort to control and minimise the effects of hazardous substances in their areas. If the substance cannot be eliminated then the methods of control are listed below in order of preference.
4.2.2 SUBSTITUTION OF LESS HAZARDOUS MATERIAL This is the most effective method of dealing with a hazardous substance hazard. The hazardous substance is removed and another substance that will do the job, but which does not produce toxic effects, is substituted.
4.2.3 ENCLOSURE OF THE HARMFUL PROCESS This is the method adopted in most chemical manufacturing where the product or intermediates are toxic. Enclosure with automatic operation further reduces the risk of exposure of employees.
4.2.4 ISOLATION OF THE HARMFUL PROCESS This is a useful method for dealing with a hazard in a workshop where most of the work is hazard free. The particular process that is dangerous can be segregated and special precautions can be taken in this area. The people who work in this area may also require special protection.
4.2.5 LOCAL EXHAUST VENTILATION This is the standard way of dealing with dusts, vapours and fumes arising from a point source, for example in grinding, cutting, welding and burning. The harmful substances should be extracted at source so that they do not enter the general atmosphere. The direction of the ventilation should be away from the breathing zone of any potentially exposed workers. The velocity of air that is needed for the purpose must be adequate and orifice sizes and the extractor fans capacity to shift air must be specified exactly.
4.2.6 GENERAL VENTILATION The main problem with this method is that it is only effective against low concentrations of hazardous substances. General ventilation can only be used effectively and safely if the following criteria are satisfied: ·
The quantity of the contaminant is not too great.
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People must be far enough away from the contaminant for general ventilation to dilute the contaminant to levels below the control limit or the contaminant must be evolved in levels below the control limit. The contaminant must be of low toxicity. The release of the contaminant must be uniform and without sudden peaks.
4.2.7 WET METHODS These are used for dust suppression. A fine spray of water can often be utilised to minimise dust. Powders which give rise to dust when dry will give little or no dust when wetted.
4.2.8 PERSONAL PROTECTIVE EQUIPMENT These devices, such as dust masks, ear defenders and gloves are the last line of defence and should not be resorted to unless all other methods have been exhausted. There are certain criteria that can be applied to the use of personal protection, i.e. when the effect of not using the personal protection provided is: · · ·
immediate painful or disabling certain.
Personal protection shall be worn. As these criteria are removed, so the likelihood of personal protection being worn reduces, particularly if the apparel is uncomfortable.
4.2.9 PERSONAL HYGIENE Washing with soap and water can make a great deal of difference to whether a person develops skin trouble or not, for example, the person who washes seldom, who wears clothing saturated or heavily contaminated with work-soiling and who is generally dirty in his habits, thus increasing the risk of infection, will be at much greater risk than the fastidious person who takes a pride in his appearance. Cutting oils, (oil-water emulsions), which are used to cool the cutting areas of machine tools needed in metal cutting, are a source of potential skin hazards that may vary from irritation and oil acne to, in a few instances, cancer. In general, the people who suffer problems arising from cutting oils use poor work methods, allowing oil to spray around needlessly and are often not scrupulous about the cleanliness of their skin, their clothes or the workplace. Barrier creams are sometimes presented as a panacea for all skin troubles in industry. Far from being so, these creams
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may easily detract from the real needs of the situation, which are to keep the offending substances and the skin apart. Substitution, enclosure, better work methods, waterproof aprons and personal hygiene are all more important and effective ways of tackling the problem.
4.2.10 EDUCATION In general the best protection that any person can have against any hazard is a knowledge of that hazard. Employees should know, for example, how a substance can or could harm them, what they can do to prevent trouble, what has been done in design and engineering of plant and equipment to make the work safe and the various rules that have to be followed.
4.2.11 HOUSEKEEPING AND MAINTENANCE Tidiness, (good housekeeping), plays an important role in the prevention of hazards at work. No installation or plant that looks a mess can possibly be as safe as one that is free from spillages, accumulated dust and dirt and which is generally clean and tidy.
4.2.12 WARNINGS AND PUBLICITY These are effective as reminders and as stimulators of awareness provided that training has previously been carried out. Alone, they are at very best a very poor way of trying to deal with any problem and at worst they can be an evasion of a real control plan to deal with hazards. Further Information Substances Hazardous to Health - Croner ADGAS Hazardous Substances Manual
4.3 RESTRICTED MATERIALS 4.3.1 ASBESTOS Medical evidence has firmly established that exposure to inhalation of asbestos fibre can lead to fatal illness in humans. The only asbestos based products currently authorised for use within ADGAS are: · ·
Spiral wound asbestos fibre (SWAF) and compressed asbestos fibre (CAF) gaskets within existing facilities, where it can be demonstrated that use of alternative materials may increase the risk of plant failure and accident. Some brake linings.
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Further Information Chapter 4 Section 6 Work with Harmful Contacts
4.3.2 OZONE DEPLETING SUBSTANCES Ozone Depleting Substances (ODS), mainly halons and chlorofluorocarbons (CFCs), are used on Das Island. The increasing scientific evidence that halons and CFCs are damaging the earth's ozone layer has prompted a global review of the use of these substances. As an interim measure, fixed flooding fire fighting systems still use halon where it can be shown to be "essential". this is defined as providing protection from risk of: · · ·
Loss of life or traumatic injury Acute or chronic illness (effects of alternative agents) Damage to the environment (due to major catastrophe)
Other applications where CFCs and halons are used will come under the ADGAS policy of elimination of these agents and replacement with suitable substitutes as soon as these become available. Applicants and systems affected are: · · · · · · ·
Portable fire extinguishers Fixed or flooding fire fighting systems Aerosol propellants (CFCs) Laboratory chemicals Foam insulation blowing agents Refrigeration systems Cleaning applications
4.3.3 POLY CHLORINATED BIPHENYLS (PCBS) These chlorinated hydrocarbons are extremely stable, non-flammable, non-explosive and oxidation resistant liquids. Such properties make them very attractive for use in electrical heat transfer and insulation equipment, as well as other systems such as hydraulics and vacuum pumps. Upon proof that the substance was carcinogenic manufacture ceased. As a result of the systematic substitution of PCBs throughout industry, ADGAS has already initiated PCB phase out programme for the transformers.
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Further Information United Nations, Recommendations on the Transport of Dangerous Goods. Seventh Revised Edition 1991. International Maritime Organisation. International Maritime Dangerous Goods Codes. International Air Transport Association. (IATA) Dangerous Goods Regulations 1992. US EPA guidelines.
4.4 RISK AND CONTROLS 4.4.1 INTRODUCTION Chemical hazards are found in many areas on Das Island. Chemicals with hazardous qualities are used in the production processes and in construction and maintenance at various locations. The range of hazardous chemicals includes additives, reagents, byproducts, wastes and those used in construction and maintenance processes such as lubricants, sealants, cleaners, protective coating, building/ insulation materials, welding/soldering/bonding consumables, pesticides, etc. Products that are purchased and brought to Das Island need to be carefully controlled.
4.4.2 DEFINITIONS Hazardous Substance. This term is used to denote any of the following: · · ·
Chemicals - elements and compounds or formulated mixtures of those in gaseous, liquid or solid state, packaged or in bulk. Explosives Radioactive substances
Hazardous substances can be classified by the effects they produce: · · · · · · · · ·
Acute lethal effects Non lethal reversible effects Severe effects after prolonged exposure Irritancy affecting the skin and lungs Sensitisation causing long term allergic reactions. Carcinogenic, which may induce or increase the frequency of cancer Teratogenic, which is having a damaging effect on the embryo Mutagenic, which is alteration of the genetic programme of a person. Corrosive, that is capable of tissue damage by corrosion or burning.
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4.4.3 RESTRICTIONS Unnecessary procurement, storage and handling of hazardous substances must be avoided or eliminated. A hazardous substance must not be introduced to an ADGAS workplace unless: · · ·
Its use, presence or production is essential and there is no alternative product or process available that is less hazardous but otherwise equivalent. An approved Material Safety Data Sheet (MSDS) is available to those handling or using the material, before exposure. All statutory and ADGAS requirements can be met for: o safe handling and health protection o packaging o labelling o transport o storage o emergency procedures o waste disposal and environmental protection
In particular, those directly handling possibly hazardous substances must not do so until they have satisfied themselves that they have identified the material, and if it is classified as hazardous, they have established the practices to be adopted.
4.4.4 FLAMMABILITY An understanding of the following terms is important in the LNG industry: Flash point - is the lowest temperature at which vapour is given off from a material in sufficient quantities that mixed with air will ignite in the presence of a flame or other direct ignition source but will not sustain combustion. Flammable - having a closed cup flash point below 37.8°C . Combustible - will continue to burn in air after the heat source has been removed Non Combustible - combustion ceases when the heat source is removed Explosive Clouds/Mists - finely dispersed particles or droplets in air creating conditions for an explosion. Auto-ignition Temperature - is the lowest temperature at which a substance will ignite and sustain combustion when mixed with air without the presence of a spark or flame.
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Explosive Limits - or flammable limit, relates to the range in which a mixture of vapour (gas, mist or powder) with air can burn on ignition. Gas and vapour concentrations are given in percent by volume in air and powdered substances in grams per cubic metre. Lower Explosive Limit (LEL). The minimum percentage of a vapour which in air will support ignition. Lower percentages will not ignite. Upper Explosive Limit (UEL): The maximum percentage of a vapour which in air will support ignition. Higher percentages will not ignite.
4.4.5 HEALTH HAZARDS The form of exposure to harmful substances can be categorised in several ways depending on the means of contact, i.e. skin contact, inhalation, etc. The effects of the substance can be categorised in varying degrees of either irritation to the body or toxicity (poisoning). 4.4.5.1 INHALATION Irritation can range upwards from mild discomfort to laboured breathing and fluid in the lungs. Toxic effects are measured on the LC 50 scale (lethal concentration), based on animal experiments. The level of toxicity is given in parts per million (PPM) concentration in air ranging from 10,000ppm and above as non toxic, with up to 100ppm as highly toxic. The lower figure represents the more dangerous level of toxicity. Asphyxiation, caused by lack of oxygen and high background concentrations of inert gases (CO2 and N2) can cause suffocation due to impaired respiration. The minimal oxygen content in breathing air is 18% by volume at normal pressure. Sensitisation may be caused in certain persons by repeated exposure causing an allergic type asthmatic bronchitis. 4.4.5.2 SKIN Irritation degrees range from minor discomfort up to blistering or full depth skin loss as when in contact with strong acids and alkalis. Dermatitis may result from defatting of the skin from contact with organic solvents. Repeated contact may also cause allergic skin reactions. Toxic effects result from a substance being absorbed through the skin. Degrees of toxicity are based on the LD 50 scale (lethal dose) given as mg/kg of body weight. Toxicity ranges from 350mg/kg which is slightly toxic up to 50mg/kg or less in the highest range of toxicity. Doc. Number
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4.4.5.3 EYES Irritation from contact with chemicals can range from mild discomfort up to permanent eye damage and loss of sight as with the effect of concentrated acid or alkali. 4.4.5.4 INGESTION This is an unlikely route for the entry of occupational chemicals. Ingestion can occur however, in small and significant quantities by means of poor hygiene with meals, smoking, or from airborne particles swallowed and accumulating in the body. Irritation can range from minor discomfort up to severe tissue loss and scarring in the mouth, throat and stomach caused by swallowing strong acid or alkali. Toxic effects of various substances ingested are measured on the LD (Lethal dose) scale and given as mg/kg of body weight. Degrees of toxicity range from slight toxicity at 500mg/kg and above, up to highly toxic at 50mg/kg or less. The preceding information is based on the more acute forms of response to irritants or toxic agents. Long term effects are a separate study, but may result from exposure to common agents including dusts, welding, soldering and cutting fumes, smoke, solvents, paint polymers and cleaning agents and others.
4.5 CHEMICAL HANDLING 4.5.1 GENERAL SAFETY 4.5.1.1 HAZARD INFORMATION The MSDS (Material Safety Data Sheet) is the guide to handling and disposal of each chemical in the workplace. Before attempting to work with any chemical, the relevant MSDS must be read and the procedures and precautions given must be taken into account. A Task Risk Assessment may have to be prepared. Further Information Chapter 2.10 Task Risk Assessment 4.5.1.2 SAFETY WEAR Dangerous chemicals and strong acids and alkalis may only be handled by persons properly protected by appropriate selection of the following safety apparel: · · ·
Eye goggles and face visor Rubber/PVC gloves Rubber/PVC footwear Doc. Number
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Rubber/PVC apron Overalls or chemical suit Appropriate breathing apparatus
MSDS or assessment reports will specify the personal protective equipment required. The MSDS gives general information whilst the assessment report is specific to the job task. 4.5.1.3 EMERGENCY EQUIPMENT Eyewash stations and emergency showers must be located close to chemical handling areas. Should contamination occur, the person either irrigates the eyes for 15 minutes or uses the shower and removes contaminated clothing whilst in the shower as required. Persons must ensure they are familiar with all safety and emergency equipment and check that it is immediately available: · · · · · ·
Learn the hazards of each chemical before working with it. Clean up and/or neutralise any spilt chemicals. Pack leaking containers in another outer leak proof container, suitably identified as a damaged container, with appropriate hazard labels and return to stores for disposal. Ensure appropriate neutralising chemicals, hoses and containers are on hand to deal with spills. Do not allow personnel to work alone or unaided with dangerous chemicals. Supervision is required. Avoid weather conditions which may cause spilling, spraying or dusting. Caution Larger hazardous chemical jobs involving pumping acids, etc. Will require the use of a Task Risk Assessment and a work permit.
4.5.2 FLAMMABLE LIQUIDS Storage of flammable liquids, e.g. oils, solvents, paints, etc. is restricted to designated areas. These areas have the appropriate signs and barriers, good ventilation and appropriate portable and fixed fire fighting equipment. Flammable liquids may be kept outside of main storage areas in quantities up to 8 litres only. Larger quantities must be returned to protected storage after use. Container type will depend on the volatility and the flash point of the liquid, highly flammable products, e.g. solvents, must be in portable safety containers with spring closure, flame traps and stout construction. Red is the approved signal colour. Storing drums of solvents, lubricants and similar products in pump and generator spaces, turbine rooms or switch rooms is prohibited. Doc. Number
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4.5.3 UNSTABLE MATERIALS A material that will vigorously polymerise, decompose or condense or become self reactive and undergo other violent chemical changes is known as an unstable chemical or compound.
4.5.4 REACTIVE MATERIAL A material is termed reactive when it can enter into a chemical reaction with other stable or unstable materials. Water is included if in the resultant reaction energy is released. Reactions of some chemicals or products with common materials may release energy in a violent manner. The range of materials commonly found in LNG operations that can be considered in the list of reactive materials in particular combinations are: · · · · · · · · ·
Water or water vapour Air Metals Rubber Plastics Oxidants Reducing agents Acids Alkalis
4.5.5 INCOMPATIBILITIES The physical characteristics and behaviour of some chemicals may change when in contact with other materials and create potential hazards of : · · · ·
Hazardous reaction products, e.g. flammable or toxic gases Fire or explosion (including violent reactions) Loss of protection Hazardous polymerisation
Incompatibilities exist in the transport and storage of flammable liquids in use in the hydrocarbons industry. Flammable liquids must be segregated from: · · · ·
Flammable, compressed gases Substances liable to spontaneous combustion (Class 4.2) Oxidising substances (Class 5.1 and 5.2) Radioactive substances (Class 7)
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General incompatibilities are shown in Table 4-1: INCOMPATIBILITIES OF SUBSTANCES. CLASS
INCOMPATIBLES
Flammable Solids
2.1, 4.2, 5.7
Substances Liable to Spontaneous Combustion Dangerous when wet
2, 3, 4.1, 5, 7
Oxidising Agents
2.1, 2.3, 3, 4, 5.2, 7, 8
Organic Peroxides
2, 3, 4, 5.1, 7, 8
Poisons - (combustible)
5
Poisons - (cyanides)
8
Poisons - (general)
Foodstuffs
Radioactive Substances
2.1, 3, 4, 5, 8,
Corrosives
4.3, 5, 6, 7
2.1, 5, 7, 8
Table 4-1: INCOMPATIBILITIES OF SUBSTANCES Caution Supervisors are to ensure that all users of each chemical substance have been made aware of the appropriate incompatible chemicals with that substance from the Materials Safety Data Sheet.
4.6 WORK WITH HARMFUL CONTACTS 4.6.1 INTRODUCTION Some of the materials encountered in work processes may involve exposure of personnel to potential short term or long term health effects. Synthetic Mineral Fibres (SMF) are found as fibrous insulating material in the industry as a substitute for asbestos. Chemical cleaning procedures pose special risks and require a knowledge of the preventive measures required to reduce contact hazards to a safe level.
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4.6.2 SYNTHETIC MINERAL FIBRES Many asbestos substitutes are based on SMF of various types such as glass fibre, rock wool, slag wool and refractory ceramic fibres. These are found in many applications within ADGAS, mainly in tapes, lagging, gaskets and other insulating applications. In general, SMF are less hazardous than asbestos, but there is still some potential for harm if dust is produced during handling. Safe handling of SMF products therefore, requires precautions that are similar to those used for asbestos, although less stringent. SMF Handling Procedure General safety requirements in the handling and use of SMF include: · · · ·
Selection of those products packaged and/or treated to reduce the generation of dust. Procurement of the material pre-cut as far as practicable to reduce on-site work. The use of manually operated tools for on-site cutting or shaping. Ensuring that the material is clearly labelled with the product identification and contents, directions for use and precautions. Note Special protective procedures will be required only if the SMF is likely be disturbed and if significant amounts of free fibre may be generated. For larger long term work, preparation of a Task Risk Assessment and a work permit are required.
Large scale disturbance or working of SMF involving exposure to fibrous dust requires the operators to: · · · · ·
Wear an appropriate particle respirator, dust goggles, gloves and one piece hooded disposable overalls. Damp or wet down materials wherever possible Clean up Synthetic Mineral Fibre (SMF) waste immediately. If dust is present, use vacuum or wet methods. Securely package or label surplus SMF for future storage and use if required. Package and label waste SMF to be disposed of according to the environmental procedures.
4.6.3 ASBESTOS Company policy is to avoid the use of asbestos wherever possible. There are some applications however, where non asbestos substitutes are less than satisfactory or unsafe and white asbestos may still be found in the form of: ·
CAF gaskets (compressed asbestos fibre) Doc. Number
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SWAF gaskets (spiral wound asbestos fibre) Asbestos based packings for valves and pumps. Asbestos woven tape for high pressure vessels (boiler steam drum). Some brake linings Boiler FD air dust bellows.
Because of crystalline structure, asbestos splits to produce fine fibres which can remain suspended in the air for considerable periods. When inhaled, fine asbestos fibres are capable of being deposited in the deepest regions of the lung, where they may cause diseases such as asbestosis and mesothelioma, both forms of lung cancer. To control exposure of airborne asbestos fibres, whenever work with asbestos is conducted, practicable measures wherever applicable should be undertaken as follows:· · · · ·
Adherence to working methods which minimise breakage, abrasion, machining, cutting that might generate dust. Suppression of dust by keeping the material wet, where appropriate. Temporary segregation – avoid asbestos work and other activities in the same place. Keeping work areas clean by removing debris offcuts promptly. “Permit to Work” system.
The controlled wet stripping technique could be an effective method in minimising dust release. Asbestos Handling Procedure Procedures for Removal of CAF/ SWAF with Gaskets and Packing Material Obtain the required replacements from the store. Ensure they are correctly packaged in polyethylene bags and labeled. Prior to breaking the line flanges, ensure that any residual line pressure is vented away from the system. Loosen bolts of the flange or spade in the respective line. Wear PVC/ Neoprene long sleeve gloves and disposable half face piece valved mask “JSP make FFP3/SL”, NPF 50 prior to starting the job. Do not use electric or air powered tools for removal of stuck gasket material. Wet the gasket surface by spraying with water using the garden spray pot. Spread a polyethylene drop sheet underneath to collect all pieces dropped on floor. Remove slowly the old gasket or packing, place it directly into a specific “Asbestos disposal bag” with “Asbestos Warning Label”. Seal the bag and place it directly into the Doc. Number
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dedicated “Asbestos only container”. Avoid breaking the gasket and packing material into small pieces. If all or part of the gasket sticks to the face, wet it with water. Manually scrape and wire brush the remnants. Re-wet as often as necessary to prevent dust formation. Fold the drop sheet and dispose it in the “Asbestos Disposal Bag”. Wash hands and face with soap and water thoroughly to remove any residual contamination. Maintenance Procedure with asbestos lagging and Other Asbestos Reinforced Calcium Silicate Insulation (Friable Asbestos) Contractor employees engaged in asbestos related work must be assessed for competency by ADGAS Job Officer, in safe handling, working and disposal of asbestos containing material, according to this procedure. Wear disposable zipped up boiler suit and disposable half face piece valved mask “JSP make FFP3/SL”, NPF 50. Put tools and wet cleaning rag and water spray inside plastic glove bag for asbestos. In absence of plastic glove bag, use disposable gloves. Sprinkle water using the garden spray pot on the surface of the insulation. Areas where insulation is required to be removed wrap the plastic glove bag around the area of the pipe and seal it with masking tape. Put a plastic drop sheet underneath the area where the insulation will be removed. While removing the insulation sprinkle water intermittently to keep the surface always wet and avoid dispersing of the friable fibers. Once all insulation removed and collected in glove bag, clean the pipe surface with wet rag to remove any remnant particles/ fibers from the surface; and then gradually remove glove bag from the pipe. Fold and dispose the “Asbestos glove bags” in the “Asbestos Disposal Bag”. Seal the bag and place it directly into the dedicated “Asbestos only container”.
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Note Where insulation dismantling work is more than the area covered by glove bag, use a plastic sheet underneath and wet area thoroughly and use trolley mounted full mask breathing apparatus. Area must be barricade at least 5 meter around job to minimize exposure of other personnel working in the area, and displayed with standardized warning sign. Do not use electric or air powered tools for removal of insulation material. During tea and lunch breaks, remove used PPE and dispose inside the “Asbestos Disposal Bag”. Always remove the disposable coverall first and then remove the half piece face mask. Wash hands and face with soap and water thoroughly to remove any residual contamination.
4.6.4 QMB AND CWS AREAS Cutting and finishing CAF, SWAF and Asbestos packing material must be carried out in well ventilated and isolated area which should be permanently assigned for this job. Instruction “Asbestos material-Keep Away’ should be displayed in the same area. Do not use electric or air powered tools. Before the activity starts, the employee must wear a disposable zipped up boiler suit and disposable half face piece valved mask “JSP make FFP3/SL”, NPF 50. Put a plastic drop sheet in the area of gasket cutting/ packing material finishing. After the activity is over wipe off the contaminated tools with moist cloth and discard it along with the remnants and the PPE outfit in the provided Asbestos disposal bag. Roll up plastic sheet and put if in the asbestos disposal bag. Tie the bag properly to avoid any spill. Always remove the disposable coverall first and then remove the half piece face mask. Put the filled Asbestos only bag in the provided Asbestos container in the respective areas. No other waste to be dumped in the asbestos only container. Seal the container once it is full. Wash thoroughly face, hands and other exposed parts of the body with soap and water. A waste disposal form must be filled and authorized by HSED prior to disposal from the area.
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4.6.5 ASBESTOS WASTE DISPOSAL The containers having asbestos waste shall be stored in a secure barricaded area. An instruction board “Asbestos Material Keep Away” should be displayed in Arabic, English, Hindi, Urdu & Malayalam. The quantity of asbestos waste shall be recorded by the concerned supervisor. When the asbestos containers are full, they should be properly sealed. A Waste Disposal Form must be filled by the responsible supervisor and authorised by HSED prior to dispatch of the containers to Ruwais for disposal. Note In case the half-valved face piece mask is out of stock in the store, the person engaged in Asbestos Handling Materials must wear a disposable dust mask. Wear personal protective clothing as specified by the perceived risk of contamination and inhalation in the job. Note Bags for asbestos waste must be of double wall heavy duty plastic with legible asbestos warning labels.
4.6.6 LAGGING AND OTHER FIBROUS INSULATION The removal or installation of large quantities of lagging or insulation containing asbestos or SMF fibres must be performed by a contractor familiar with this type of work. Removal and replacement of lagging and cladding from valves, flanges and small items of equipment, will require the following precautions: · · ·
Wear disposable overalls and an appropriate respirator. Use a plastic drop sheet to catch loose material. Fold and dispose of it according to current regulations. Maintain the material in a wet condition during the work if possible.
4.6.7 STORES PROCEDURES The day to day management of stock items of gaskets and packings involves the following precautions and procedures: ·
All bins and racks containing asbestos items must be clearly labelled with black letters on a pink background (the colour pink identifies asbestos materials within ADGAS)
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SWAF and CAF gaskets are stored in labelled plastic bags in the prescribed height in the rack Asbestos packings in the storage bins must be in the required labelled plastic bags. Handling asbestos items is kept to a minimum and issue of gaskets is in multiples of 3, 5 or 10 depending on size Any opening of sealed bags must be performed so that dust is contained in the bag.
No specific personal protective wear is required for these routine activities in the store. Major movements of the store asbestos inventory or major housekeeping activities will require the use of full personal protective wear and isolation of the area with signs and barriers. All waste in sealed, labelled plastic bags is to be disposed of in the prescribed manner.
4.6.8 CHEMICAL CLEANING 4.6.8.1 INTRODUCTION Cleaning methods that may involve the use of chemicals are: · · · · ·
Removal of scale produced by corrosion on metal surfaces Removal of by-products from process systems Removal of inorganic salts from water heat transfer surfaces Removal of oil and grease from mechanical equipment Rust conversion
Chemical agents used are normally acid or alkaline solutions containing corrosion inhibitors, or they may be organic solvents. As these chemicals may be used at elevated temperatures, additional hazards may be associated with their use. Risks associated with the use of chemicals and solvents for cleaning purposes include: · · · · · ·
Eye and skin injuries as a result of contact with the cleaning agent. Health effects of the respiratory system due to the inhalation of chemical agents. Narcosis (dizziness) from inhalation of solvent fumes which may result in lack of control in work tasks and risk of disease. Metal corrosion leading to the weakening of associated equipment that can arise from the wrong choice of cleaning agents, inadequate inhibition of cleaning solutions or use of excessive temperatures. Generation of flammable and/or toxic gases that may arise from the chemical process or the reactions involved. Environmental pollution as a result of spilt or incorrect disposal of cleaning agents.
Chemical cleaning of large items of fixed equipment may involve the problems of: Doc. Number
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Damage to associated equipment. Spillage and run-off causing environmental pollution.
4.6.8.2 WORK PERMITS For chemical cleaning with hazardous agents, the use of high pressure, or risk to plant and personnel, a work permit is required detailing all safety requirements and procedures. Use of flammable chemicals is to be avoided with substitution by water soluble agents wherever possible. Any flammable vapours produced by cleaning must be treated in the same way as other flammable emissions on the plant. Work permits must specify all personal protective wear according to the risk. Reference to the MSDS for the cleaning agent and process will suggest the correct type to wear which may include as required: · · · · · ·
Breathing mask or other respiratory protection Face shield and chemical goggles Chemical resistant gloves Chemical work suit, apron or appropriate barrier Chemical resistant safety approved footwear Standard safety helmet if compatible with other headgear Note The appropriate use of the above safety wear will be determined using a Task Risk Assessment with the MSDS as a guide.
Included in the safety precautions are the provision of emergency shower and eye wash facilities and agreed emergency procedures. 4.6.8.3 CHEMICAL AGENTS AND EQUIPMENT Chemical containers must be safely transported, segregated, stored and used accordance with the MSDS. Containers must be labelled according to the nature of the chemical under the chemicals regulations. All pumping and dispensing equipment must be inspected and maintained in serviceable condition. Quick release fittings shall be secured with safety clips and all necessary steps taken to avoid over pressuring systems.
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4.7 LABELLING HAZARDOUS SUBSTANCES 4.7.1 INTRODUCTION Correct labelling of all dangerous goods and containers is required to facilitate their identification and hazards associated with their transport, handling, storage and use, so as to reduce the risk to personnel and property. Suppliers of chemicals and chemically formulated materials to ADGAS are required to supply all necessary information on the relevant MSDS and label all materials and containers according to legislative requirements.
4.7.2 ARABIC WARNING Any door or hatch giving access to any place at which radioactive, corrosive, toxic or explosive substances are stored shall bear on the outside the word "DANGER" in red Arabic and English capital letters at least 50 mm high with an adequate description or indication of the substances in question. This is to be in addition to any other required signage.
4.7.3 CLASSES Dangerous goods are each assigned to a class representing their major hazard under transport, storage and handling conditions. Some materials may also bear a subsidiary risk label if warranted by the hazards they represent. Subsidiary risk labels do not carry the class number.
4.7.4 SUB-DIVISIONS In addition to the allotted class number given each substance, e.g. No. 2 - Gases, 3 Flammable liquids, the class may be subdivided relative to the type and degree of hazard. Class 6- Poisonous Substances is sub-divided into, 6.1 Toxic Substances and 6.2 Infectious. Refer to Table 4-2.
4.7.5 LABELLING REQUIREMENTS Hazardous substances labelling must give the following information: · · · · · · · ·
Full chemical name (if a pure chemical) Full proprietary name Active ingredients and/or major components Appropriate poison label if required Appropriate hazard label if required UN number First aid advice Name, address and telephone number of manufacturer or supplier Doc. Number
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Further Information IATA Dangerous Goods Regulations (air transport) International Maritime Dangerous Goods (IMDG) code These authorities are most commonly referred to for air and sea shipment of materials to Das Island. Refer to Table 4-2.
Class 1
Classes Explosives
Class 2
Gases: compressed, liquefied or dissolved under pressure
Class 3
Flammable liquids
Class 4
Flammable substances other than those of classes 1.2.3 and 5.2
Class 5
Oxidising substances
Class 6
Poisonous (toxic) or infectious substances Radioactive substances
Class 7
Class 8 Class 9
Corrosive substances Miscellaneous dangerous substances
Subdivisions Divisions 1.1 to 1.5 in accordance with the nature of the hazard. 2.1. Flammable gases 2.2. Non-Flammable gases 2.3. Poisonous (toxic)gases 3.1. Liquids with a flashpoint below 23oC (closed cup test)(highly flammable) 3.2. Liquids with a flash point of 230C or more up to and including 610C 4.1. Flammable solids 4.2. Substances liable to spontaneous combustion 4.3. Substances which, on contact with water, emit flammable gases 5.1. Oxidising agents (oxidising substances other than organic peroxides) 5.2. Organic peroxides 6.1. Toxic substances 6.2. Infectious substances Category 1 Categories in White accordance with the Category II level of radiation Yellow emitted from the Category III container Yellow No subdivision of class No subdivision of class
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Table 4-2: Classification System.
4.7.6 NON HAZARDOUS SUBSTANCES Non-hazardous substances are those not classified as dangerous goods under United Nations classification system. Labels on all containers, packets, tins and the like for non-hazardous substances must show: · · · ·
Full chemical name (if a pure chemical) Full proprietary name Active ingredients and/or major components Name, address and telephone number of manufacturer and/or supplier
4.7.7 CLASS LABELS/HAZARD DIAMONDS Class labels (hazard diamonds) found on containers of hazardous substances may be either stick on metal plates or stencilled or printed on the container. Sizing of class labels is according to the volume and mass of the container. Each class may be identified by its label colour: CLASS Class 1 Explosives Class 2 Gases Class 3 Flammable liquids Class 4 Flammable solids Class 5 Oxidising agents Class 6 Poisonous or infectious Class 7 Radioactive Class 8 Corrosive
LABEL COLOUR orange red, green or white red red, white or blue yellow white yellow or white black and white
Table 4-3: Label Colours
4.7.8 RISK PHRASES Risk phrases (R-phrases) convey a general description of the risk relative to the material, to supplement the class labels. The R system runs from R1 to R43, examples are R1-'explosive when dry' and R11'highly flammable'.
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When the R numbers are combined, this indicates a combination of two hazards from the material, e.g. R15/29 - contact with water liberates toxic, highly flammable gas.
4.7.9 SAFETY PHRASES Safety phrases (S-phrases) provide information on safe storage, handling and personal protection. The S system runs from S1 to S49. Examples are: S15 - 'keep away from heat' and S37 - 'wear suitable gloves'
4.7.10 UN NUMBERS The UN (United Nations) Substance Identification Numbers are used in conjunction with other systems of labelling on packages and in particular on shipping manifests for transport to the Island. Comprising a series of four-digit numbers, each number represents a substance, or class of substances with like characteristics. They are primarily intended to facilitate the identification of substances without the need for a knowledge of the language in which the chemical name of the substance is printed. Their use has also proved to be of great value for emergency services and the correct relaying of long or complex substance names, thus allowing error-free identification.
4.7.11 NFPA SYSTEM This system was developed by the National Fire Protection Association (NFPA) in the United States of America. The unique coded NFPA diamond symbol gives a quick visual indication of the degree of hazard associated with that substance in the field of health, flammability and reactivity.
4.7.12 GENERAL SAFETY All decanted hazardous substances must be fully labelled according to the regulations in the same way as the parent package. All containers of hazardous materials must remain labelled until cleaned and free of the substance that they contained. If the contents of a container cannot be positively identified, the contents must be safely packaged, labelled 'CAUTION: DO NOT USE-UNKNOWN SUBSTANCE', shipped and disposed of in a safe manner.
4.7.13 INFORMATION On Das island information on any hazardous chemical may be found by reference to: Doc. Number
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Hazardous Substances Manual. MSDS (Materials Safety Data Sheet) provided by the manufacturer/supplier of a substance. Placards on larger containers showing the nature and hazards associated with a particular chemical Identification of hazardous products in pipes and vessel by labels and colour coding.
4.7.14 RESPONSIBILITIES 4.7.14.1 NEW CHEMICALS It is the responsibility of the relevant Divisional/Departmental Manager to ensure that no new chemicals are used without the accompanying MSDS being available in the Hazardous Substance Manual. 4.7.14.2 TRAINING All users through training must understand how to access MSDS in the Hazardous Substance Manual and be able to apply the information in terms of the health and safety effects, precautions/protective measures and application of these measures appropriate to the hazard. 4.7.14.3 COMMUNICATION Each Supervisor and Manager must ensure that sufficient people know how to access the information, apply it and pass it on to users in a usable form.
4.8 COMPRESSED GASES 4.8.1 INTRODUCTION Compressed gases on Das Island are used in a variety of work applications. This section deals with the portable, refillable type of cylinders used for welding and cutting, inerting, fuel and some special purposes.
4.8.2 HAZARD CLASSIFICATION 4.8.2.1 DANGEROUS GOODS All compressed or liquefied gases are classified dangerous goods. There are nine classes of dangerous goods in all including Class 6 poisonous, Class 8 corrosive, etc. A class diamond (label) is used on all dangerous goods packages to indicate the class to which it belongs. (Refer Section 4.7 - Labelling Hazardous Substances.
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All gases are Class 2 and a major hazard is the pressure under which gases are stored. Class 2 is divided into three sub classes to indicate the chemical hazard: 2.1 2.2 2.3
Flammable Gas (red diamond) Non-flammable gas (green diamond) Poisonous (white diamond)
4.8.2.2 SUBSIDIARY RISK Some dangerous goods have hazards in more than one category. These are given a second class or 'subsidiary risk' and are labelled with a second diamond. Oxygen is an exception, having a single 'oxidising gas' yellow diamond. Some typical gases with subsidiary risk are: Carbon monoxide (2.1, 2.3) Chlorine (2.3, 5.1) Hydrogen chloride (2.3, 8) Liquid oxygen (2.2, 5.1)
-
red, white diamonds white, yellow diamonds white/black diamonds green, yellow diamonds
Exceptions are: Compressed oxygen (2.2, 5.1) Compressed nitrous oxide (2.2, 5.1) -
yellow diamond only yellow diamond only.
4.8.3 PROPERTIES OF GASES 4.8.3.1 PRESSURE Non Liquifiable gas can only be stored under pressure, which can result in two major hazards: · ·
Over pressure - leading to rupture of the container with the resultant shock wave and fragmentation damage. Leaking into the atmosphere - creating a hazard dependent on the sub-class of the gas involved.
Over pressure precautions are: · · · ·
Check that gas pressure will not exceed the pressure rating of the equipment. Do not tamper with pressure safety devices Do not weaken containers through damage - ensure they are secured in vertical position, etc. Shield cylinders from the heat of the sun and flares (the surface temperature of gas cylinders should never exceed 45°C
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Leaking precautions are: · · ·
Use care and cleanliness in connections and valve operation Check for leaks regularly Use/store/transport in well ventilated conditions preventing build-up and concentration
4.8.3.2 FLAMMABILITY (CLASS 2.1) Gases such as acetylene, propane and hydrogen, when mixed with air or oxygen can explode violently in the presence of an ignition source. Explosions, depending on size, can lead to serious damage and injury. The flammable range of different gases varies and is defined by the Lower Explosive Limit (LEL) below which concentration in air an explosion cannot occur due to lack of fuel and the Upper Explosive Limit (UEL) above which an explosion cannot occur due to lack of oxygen. The precautions to be taken with flammable gases, in addition to those precautions of pressure are: · · · ·
Avoid sources of ignition Avoid mixtures of flammable gas and air/oxygen/oxidising agents Segregate flammable gases from oxidising gases, flammable/ combustible materials. Have fire fighting equipment on hand
4.8.3.3 TOXICITY (CLASS 2.3) Poison gases react adversely on human beings. They usually enter through the lungs but some may also be absorbed through the skin. These effects may be quick or delayed. They are termed acute if they kill in minutes or days. Their effects may also be long term and be termed chronic. Survivors may be left with lingering disability. Some toxic gases may also be carcinogenic. The ways by which gases poison humans are varied. One group of poisons are simply irritants, i.e. the acid gases such as sulphur dioxide, hydrogen chloride and others, and the caustic gases, e.g. ammonia. Irritant gases can be quite deadly but do have the virtue of making their presence felt. Other poisons are more insidious. The common measure of toxicity is the Threshold Limit Value Time Weighted Average or TLV (TWA) for short. This is the concentration in parts per million (ppm) to which you may be exposed eight hours a day, five days a week without harm. As a general rule, any gas with a TLV (TWA) of less than 100 ppm is classed 2.3 (white diamond). Another measure of toxicity is the Short Term Exposure Limit (STEL) which is the concentration (ppm) which will not harm you with a 15 minute exposure.
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Peak limitation values are also quoted for some substances where short term (i.e. a few minutes) exposure may cause intolerable irritation, chronic tissue damage or narcosis leading to accidents. Yet another is the Immediate Danger to Life and Health (IDLH) which is the concentration (ppm) which will permanently disable in 30 minutes. An example is carbon monoxide which has a TLV of 50, a STEL of 400 and an IDLH of 1500.
4.8.4 OXYGEN 4.8.4.1 OXYGEN DEFICIENT ATMOSPHERE While only some gases are poisonous, only oxygen is positively beneficial (and even then only at 21% in a breathing atmosphere) Any gas entering the atmosphere can create a hazard if it lowers the oxygen content to 18%. Any gas at about 17% concentration in the atmosphere will displace oxygen to this hazardous level. Gases which create a hazard simply by displacing oxygen are termed simple asphyxiants. Asphyxiation can cause death in seconds if the oxygen content is zero, or in minutes if it is less than 8%. All simple asphyxiants are Class 2.2 with no subsidiary risk. Common asphyxiant gases are nitrogen, argon, carbon dioxide and some refrigerant gases. The hazard is increased because there is no warning (no smell, no flames). The victim is unaware of anything wrong and rescuers are often trapped (and become victims) in oxygen deficient atmospheres. The universal precautions of leak avoidance and ventilation apply. There is however a further precaution which is "beware of confined spaces". The two significant asphyxiant gases found in quantity on Das Island are nitrogen used in purging and carbon dioxide in fire fighting systems. Further Information Chapter 7 Confined Space Entry
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4.8.4.2 OXYGEN ENRICHED ATMOSPHERE An oxygen content above 23% (i.e. 2% additional oxygen) will increase the flammability of any fuels in the atmosphere, even those that would not normally burn in air. A particular hazard is oxygen saturated clothing. This will burn vigorously if ignited. A grinding spark, which would normally just scorch cotton overalls, will cause them to ignite in an oxygen enriched atmosphere with serious to fatal consequences for the wearer. Warning Never attempt to blow dust etc. off work clothing with the oxygen stream from a welding or cutting torch. Again the precautions of leak avoidance and ventilation apply. Additionally: · ·
Follow the rules in 7 CONFINED SPACE ENTRY. Never use oxygen as a substitute for compressed air for any purpose.
4.8.4.3 OXYGEN NON COMPATIBILITY Flammable gases and other fuels will burn because they react with oxygen. Burning is rapid oxidation. An important property of oxygen is that it is very reactive. Almost everything will oxidise if enough heat and energy (i.e. pressure) are applied. These conditions can be achieved by rapid pressurisation of closed oxygen systems. Oxygen systems made up of oxygen compatible components may be contaminated with non compatible materials. Oil is one, but any contamination, e.g. dust, grit, swarf and lint will be non compatible. They will either burn readily or provide a source of ignition for compatible components. Once a fire starts, the abundance of oxygen will fan it into a major burn-out with risk of burn injury and property damage. Caution · Keep oxygen systems clean. · Never use lubricants or sealants. · Use only equipment designed for oxygen. · Open valves slowly, 'cracking' first to pressure up.
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4.8.5 LIQUIFIABLE GASES All gases are stored under pressure, but some gases are liquefied at storage pressure and ambient temperature. This increases the gas contents of the cylinder, but creates some new hazards. The common liquifiable gases are carbon dioxide, LPG, nitrous oxide and refrigerants. The hazards with liquefied fuel gases are: · · · · ·
Depending on the orientation of the cylinder, liquid may come out of the cylinder valve and into the user system. This will give a higher than expected flowrate (an LPG torch could act as a flame thrower). Similarly liquid leaks have a much greater effect on the working atmosphere contamination level than dry gas leaks. If the safety device of the cylinder is submerged in the liquid phase of the contents, its operation will not lower the pressure as quickly as with gas venting. This may lead to over pressure and rupture in a fire. Venting liquid flashes to cold gas and liquid which may cause cold burns. If cool liquid is trapped in a system and subsequently warmed up, the pressure may rise to exceed the bursting pressure of that system.
The precautions to be followed are: · · · ·
Only use cylinders in the upright position. Only store and transport cylinders in the upright position. Wear gloves when handling any liquefied gas, consider further protection, e.g. eye and face protection. If a liquid leak cannot be stopped, move the cylinder to convert it to a gas leak.
4.8.5.1 GAS NAME IDENTIFICATION The gas name label is the primary identification of any cylinder contents and is usually located on the shoulder of the cylinder. This identifies the product by its correct technical name and classification. On some cylinders the gas name is labelled or stencilled on the body of the cylinder. 4.8.5.2 UNITED NATIONS NUMBER (UN NO.) The number may appear near the gas name on cylinders, either on the label or as stencil. 4.8.5.3 COLOUR CODE Table 4-4 shows typical cylinder colours and characteristics for gases in common used on Das Island GAS
CHARACTERISTICS
CYLINDER
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Oxygen (O2)
Nitrogen (N2)
Argon (Ar)
Acetylene (C2 H2)
Propane (C3H8)
Hydrogen (H2)
Air Carbon Dioxide (CO2)
No smell. Non-toxic. Will not burn but supports and accelerates combustion. Materials not normally considered combustible may be ignited by sparks in oxygen rich atmosphere. No smell. Does not burn. Inert except at high temperatures. Nontoxic but does not support life so could cause asphyxiation in high concentrations. No smell. Heavier than air. Does not burn. Inert. Will cause asphyxiation in absence of sufficient oxygen to support life. Distinctive garlic-like smell. Fire and explosion hazards are similar to those for propane. However, it is lighter than air and less likely to collect in ducts and drains. Distinctive fish-like smell. Will ignite and burn instantly from a spark or piece of hot metal. Is heavier than air and will collect in ducts, drains, etc. No smell. Non-toxic. Much lighter than air. Will collect at the highest point in any enclosed space unless ventilated there. Fire hazard. No smell, Non-toxic. Essential for life No smell. Heavier than air. Does not burn. Will cause asphyxiation in absence of sufficient oxygen to support life
Neck Bands
Black
French Grey
Black
Peacock Blue
Black
Maroon
Signal Red bearing words "Propane and "Highly flammable"
Signal Red
French Grey Black
White
Table 4-4: Gas Characteristics/Cylinder Colours Caution If the contents of a gas cylinder cannot be positively identified, the cylinder should not be used. It must be identified with a tag, manifested as dangerous Doc. Number
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goods and returned to the gas agent onshore. Never use an unidentified cylinder and always assume the worst, i.e. It is flammable and poisonous.
4.8.6 SAFE STORAGE Storage Design Gas cylinder stores must be: · · · · · · · · · · · ·
Constructed of fire rated materials and have firm level floors. Away from escape routes and emergency equipment. Well ventilated and preferably provided with basic weather protection. Free from fire risk. Away from sources of artificial heat and ignition. Free from contamination (dust, fumes, spray or chemicals). Designated and marked as a 'no hot work' area. Clearly marked as a gas store with appropriate hazard diamond signs, e.g. flammable, poison, corrosive, etc. Kept clean and with clear access restricted to authorised personnel. Provided with appropriate safety/emergency equipment and fire and gas detection/protection systems. Provided with sign "DANGER" in red Arabic and English letters at least 50mm high with an adequate description of the substances. Provided with appropriate racks or chains to secure cylinders.
4.8.7 SAFE HANDLING Personnel who regularly move and use gas cylinders must follow the precautions for this work: · · · ·
Wear personal protective wear free of grease, oil and grit including gloves, and eye protection along with minimum worksite safety wear requirements. Use recommended mechanical handling aids, e.g. quads, racks, trolleys, etc. and secure cylinders at all times. Follow the approved manual handling procedures and techniques to prevent back injury. Make sure valve caps, plugs and other devices are fitted when provided.
4.8.8 LEAK TESTING In the case of an oxy/acetylene torch assembly a simple leak test of the complete system is recommended: · ·
'Crack' the cylinder valve to remove dirt Attach and tighten the regulator, hose and equipment Doc. Number
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Shut off the control valve on the blowpipe Slowly open cylinder valve, then screw in regulator control knob to pressurise the system Close the cylinder valves and watch the regulator pressure gauges.
If pressure is retained there is no leak in the system. If pressure drops, a leak is present and should be located with the leak detection solution then de pressurised and repaired. Further leak testing using leak detection solution will include: · · ·
Cylinder valve gland. Cylinder safety device. Cylinder neck thread.
4.8.9 CARE OF CYLINDERS · · · · · · · · · · · · ·
Do not drop cylinders from a height or allow them to fall over. Secure cylinders against falling while in use, storage or transport. Do not allow naked flames to impinge on cylinders. Do not allow any form of heating which would raise the temperature of the cylinder above 45°C. Do not use cylinders as rollers or supports. Protect cylinders from impact damage from passing vehicles or crane loads. Protect cylinders from paint spray, acids, alkalis and prolonged water contact. Ensure no electrical power can flow through a cylinder, e.g. arc welders. Do not attempt to repair cylinder valves. Keep cylinders and in particular the valves, clean and oil free. Do not use cylinders with dirty valves Do not attempt to clean valves other than 'cracking' before fitting regulators Close cylinder valves when the cylinder is not in use and especially when the cylinder is empty Note Discharged cylinders must be tagged and/or prominently marked "MT" and stored in a separate dedicated area for return to the supplier.
4.8.10 EMERGENCY SITUATIONS 4.8.10.1 GENERAL Emergencies involving compressed gases are unlikely provided the recommendations are followed for their correct storage, handling and use. When major hazards do arise they are usually due to:
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Fire threatening the cylinder. Compressed gas cylinders if in contact with excessive heat for prolonged periods may rupture or explode. Flammable gas leak. All flammable gases will form explosive mixtures with air. When ignited, significant explosive energy can be released from flammable gas/air mixtures. Toxic gas leak. Non-flammable compressed (inert) gas leak. This is usually considered to be harmless, however, if in a confined or poorly ventilated space, asphyxiation and death of unprotected personnel can occur.
4.8.10.2 FIRE EMERGENCIES General procedures and precautions are: · ·
· ·
Isolate supplies so they do not flow into the affected area. Safely release gas pressure in affected pipelines and equipment. Ventilate the area to prevent explosive atmosphere build-up, i.e. keep it below the lower explosive limit (LEL). When fire threatens compressed gas cylinders there is a risk of rupture/explosion of cylinders subject to prolonged heating. These should be moved to a protected safe place before they become too hot or if this is not possible, cooled with a fire hose at a safe distance. Any cylinder that has been involved in a fire must be segregated and clearly marked as such and the supplier must be notified accordingly to prevent hazards to people who refill cylinders. Visibility of flames. Not all fuel gases burn with a clearly identifiable flame. Burning hydrogen for example is very difficult to see Warning With a burning flammable gas leak isolate the gas supply, if this is not possible, do not extinguish the flame. Ensure the flammable gas burns in a controlled manner, does not ignite anything else and does not impinge on any pressurised gas containers, equipment or pipelines. keep surrounding area cool by spraying with water from a protected safe distance.
4.8.10.3 GAS LEAKS In general, gas leaks are dealt with by: · · · · ·
Establishing the name and type of gas involved. Isolating the cylinder valve. Evacuating the area if necessary. Instituting fire prevention measures if appropriate. Ventilating if possible and moving faulty cylinders to an open area.
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Note Dirt ingress in cylinder valves is a common cause of leakage. In this case 'crack' the cylinder valve to open air wearing hearing and eye protection. This should be a standard procedure before fitting regulators together with examination for oil or other contamination in the area of connection.
4.9 OTHER DANGEROUS SUBSTANCES 4.9.1 INTRODUCTION This heading covers a wide variety of chemical products; some of the more potential dangers to personnel are covered in the following paragraphs. Normally, those used in specific process will be delivered in highly concentrated form. It is therefore necessary that their toxic and other properties should be known and understood before the materials are used. These are detailed on the MSDS which are available for all chemicals used in ADGAS in the Hazardous Substances Manual.
4.9.2 METHANOL Methanol is a poison with a vapour toxicity comparable with that of many common solvents. It burns with a colourless flame. Prolonged exposure to methanol at relatively low concentrations (200ppm) can have some physiological effects. Blindness can occur from severe exposure and very large doses can be lethal. Methanol is toxic to humans through ingestion, inhalation or skin absorption and harmful on repeated skin contact. Methanol shall not be dumped into the sea. Special emphasis is placed on the requirements involving the use of personal protective equipment while handling Methanol and Methanol inhibitor. Personnel assigned to this handling operation shall wear chemical goggles, chemical gloves and full chemical protective suits. Eye wash and emergency shower station shall be in the immediate vicinity of the Methanol handling areas. Self Contained Breathing Apparatus shall be readily available for use should vapour escape into the atmosphere during this operation. Entry to a Methanol tank, vessel or pipeline shall be governed by the conditions and precautions as stated in the MSDS. Entry to a tank or vessel is permitted only when covered by a valid Entry Permit. The areas of Methanol handling, tanks, pipelines, vessels and heat exchangers shall be free from any source of ignition including any mechanical equipment used during this operation that may cause any spark. Doc. Number
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Methanol shall only be allowed to enter the pipelines, vessels or heat exchangers that have been purged with nitrogen and the oxygen content has been reduced to below 2%. Dry powder fire extinguishers shall be placed at the Methanol tanks, pipelines and vessels. Fire hoses shall be readily available and stand-by watch shall be provided during this operation. Electrical earthing/bonding shall be provided to all Methanol associated tanks, equipment and piping. Self-Contained Breathing Apparatus shall be used when cleaning up spills of Methanol to avoid inhalation of vapours emitted. An absorbent shall be readily available for use should a spill occur. Personnel shall make every effort possible to prevent Methanol from entering the sea.
4.9.3 CAUSTICS AND ACIDS Caustics, hydrochloric and other acids used for acidising are dangerous in that they can destroy normal clothing fabric and rapidly affect the skin, causing severe burns. Breathing of the acid fumes should be avoided as they are asphyxiants, and even in small quantities can be injurious to the membrane of the nose. When diluting always add acid to water, and not the reverse. Personnel handling acids should be equipped with protective clothing, including hoods, PVC/Neoprene gloves and rubber boots. All chemicals shall be clearly marked and labelled (preferably on two sides) with the contents, nature of associated hazards and recommended means of safe handling. During acidising operations no person other than the crew directly employed should be allowed nearby. A quantity of lime should be made available and utilised to neutralise any acid spilled. Pumps, lines, tanks, etc., through which acid and caustic substances are handled should be thoroughly washed out with water upon completion of the operations. A check valve should normally be installed in the treatment lines as close to the work as practicable. All pressure lines and related connections shall be pressure tested before operations commence.
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Acid carboys shall be stored in single tiers. They shall not be lifted by the neck of the carboy. Spilt acid shall be neutralised under supervision or washed away with water from a safe distance. Discharge should be by pouring, mechanical siphoning, pumping or by means of an approved discharge device. Galvanised iron drums shall not be used for the storage or transport of acid solutions. Overhead acid tanks shall have adequate overflow pipes to a safe location, where any spillage may drain away. The area below the tanks should be bunded. Closed tanks shall be provided with air vents which cannot be shut off. Drums or carboys of acid shall not be discharged by the application of any gas pressure to the container. If there is an accident with acid, first-aid treatment should be carried out immediately according to the instructions, which should always be contained in each adjacent first-aid kit.
4.9.4 AMMONIA Ammonia is usually stored as an anhydrous liquid under pressure in cylinders from which it can be released either as a liquid or as a gas. It is also supplied as an aqueous solution in various concentrations. The gas is colourless and has pungent easily detectable odour even in low concentrations. Its density relative to air is 0.771, and it will rapidly disperse in open locations. The flammable range is from 16% - 25% by volume in air with an auto-ignition temperature of 650°C. It is extremely irritating to the eyes, nose throat and lungs and all moist parts of the body. The TLV is 25ppm. Whenever ammonia is used in quantity, protective equipment should be readily available. Air line masks or self-contained breathing apparatus should be used for all concentrations of ammonia. Severe skin irritation will result from prolonged work in a contaminated area unless full body protection or a chemical suit is also worn. Since ammonia is extremely soluble in water, water fog or spray can be used to good effect as a dispersant where large leakages occur.
4.9.5 CAUSTIC SODA Caustic Soda is a water soluble alkali used in the treatment of hydrocarbon products for the removal of undesirable sulphur products. It is mainly supplied as a solution in special containers.
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It is non-flammable, but spent caustic soda may contain entrained hydrocarbons, and should not be exposed to an ignition source. Caustic soda is highly toxic, as an irritant or if ingested. the chemical acts quickly upon tissue causing burns and deep ulceration. In the handling of small quantities of caustic soda solution, in addition to normal work clothing e.g. overalls, chemical goggles, PVC gloves and rubber footwear shall be used. When making up large quantities of solution from solid drummed caustic soda full PVC protective clothing shall be worn including full face protection.
4.9.6 MIXED LIGHT HYDROCARBONS As well as being highly flammable the vapours from petroleum are toxic and, if inhaled in sufficient concentration will ultimately result in death. They vary considerably because of the large variety of component substances present in crude oil and refined products, but with the exception of certain aromatic compounds, may be considered as similar in having the same harmful effects. Comparatively small quantities cause symptoms of dizziness with headache and irritation of the eyes. These effects can occur well below the limits of flammability. The TLV for petroleum vapour is not uniform because the constituents can vary in their proportions but a figure of 500 ppm is generally accepted. It should not be necessary to expose personnel to concentrations above the TLV but for short periods, e.g. to shut off an escape of gas/vapour from a leaking flange or pump, an air line mask or self-contained breathing apparatus shall be worn.
4.9.7 CARBON DIOXIDE AND NITROGEN Although not toxic, both are asphyxiants and in sufficient concentration will quickly produce unconsciousness from lack of oxygen. They are particularly hazardous in that they have no smell and there are no physical symptoms preceding unconsciousness.
4.9.8 ACETYLENE Acetylene has a distinctive garlic-like smell. It will ignite and burn instantly from a spark or piece of hot metal. Lighter than air, acetylene will collect in roof spaces and confined spaces such as vessels. To prevent the build-up of acetylene becoming an explosion hazard, constant and thorough ventilation is necessary.
4.9.9 MERCURY Mercury is highly toxic and shall be handled with care. Precautions shall be taken to prevent contact with the skin. Gloves shall be worn when handling. Doc. Number
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Exposure to mercury vapour for short periods requires only removal from exposure to rectify but if mercury is swallowed, medical attention should be sought. Mercury is volatile at room temperature and dangerously high concentrations can build up in a non-ventilated area (TLV 0.0005ppm).
4.9.10 MERCURY RECOVERY UNITS 4.9.10.1 INTRODUCTION Trains 1 and 2 have both been provided with Mercury Recovery Units (MRU). Each MRU consists of 2 vessels, one for treating the vapour stream and the other for treating the liquid condensate stream. The vapour treating vessel 3-C-150/250 contains a single bed of 10.2 Tons of Chemivron (HGR) granulated sulphur impregnated activated carbon. The liquid condensate treating vessel 3-c-151/251 contains a single bed of 3.6 Tons of PROCATALYSE CMG 273 granulated alumina impregnated with copper sulphide. Each mercury guard vessel is followed by a dust filter to remove any particulate matter escaping from the vessel. The mercury guard beds are of a non-regenerative type and are expected to be disposed of after 3 to 6 years of continuous service. Train 3 has a gas bed of 18 tons of Chemivron (HGR). 4.9.10.2 HANDLING OF FRESH MERCURY GUARD MATERIALS Absorbent materials must be handled with care to avoid formation of dust. Persons involved in handling of the absorbent materials must be suitably attired with protective clothing consisting of : · · · · ·
Long Sleeved Boiler Suit Rubber Gloves Goggles Filter type face mask
Dust contact with the eyes must be avoided and a supply of water or drench shower must be available at all times at the work place. 4.9.10.3 HANDLING OF SPENT MERCURY GUARD MATERIALS Mercury contaminated absorbents must be handled with extreme care. Full protective clothing must be worn when removing and handling the spent absorbents. Protective clothing shall consist of : Doc. Number
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A long sleeved boiler suit Rubber gloves Long Rubber Boots Goggles Filter type face mask (for correct type, contact HSED) Face mask with air supply if person has to enter vessel.
A supply of water or drench shower must be available at all times at the work place. For handling and disposal procedure. See HSED Waste Disposal Manual. 4.9.10.4 WRITTEN PROCEDURES/TASK RISK ASSESSMENT All aspects of work shall be covered by a Task Risk Assessment that should include: · · ·
Containment of contamination as near as possible to its site of production. Limiting the possibility of ingestion or inhalation Controlling and restricting direct exposure of workers
4.9.11 PYROPHORIC MATERIAL HANDLING STORAGE AND DISPOSAL PROCEDURE 4.9.11.1 DEFINITION Pyrophoric material is a complex ferrite type compound and is formed when iron scale or corrosion debris combines with sulphur compounds, (in particular H2S), often with organic materials. This compound is stable when kept wet. On drying, it will combine vigorously with the oxygen in air producing considerable heat reaction, which will result in spontaneous ignition. The reaction takes place below about 45oC and hence the hazards arising from the use and handling of such materials involve fire, either from direct contact with the pyrophoric material or as a result of secondary fires following ignition. Oxidisation of the pyrophoric will, in any case cause sufficient temperature rise to ignite a flammable vapour/air mixture in its vicinity. 4.9.11.2 CONTROL MEASURES Before opening any equipment on the LNG plant the possibility of pyrophoric material presence must be assessed and precaution taken as follows; · ·
The sludge 1 deposits must be wetted down with water and, when removed from plant equipment must be kept wet. The material must be immediately put into empty dedicated drums, they must contain at least 15 cm of water in the bottom and all times the contents must maintain a 15 cm level of water above the level of pyrophoric material.
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The metal drums should be black with the identification "pyrophoric material" Stencilled in white. If possible drums should be used on a "once only" basis. All Supervisors must ensure that no pyrophoric material is spilled on platforms walkways, into drains etc. If this occurs the spillage must be kept damp and cleaned up immediately. Drains and sewers must be adequately covered to prevent any material failing into them. The drums must be immediately removed from the site and to be temporarily stored in the waste disposal area (plant 19). They must not be allowed to dry out within process area. In no circumstances will pyrophoric material be allowed to remain on or about the job-site. Once in Plant 19, pyrophoric drums shall be unloaded and spreaded evenly on the ground. The waste should be kept moist for 30 days. Level the date of waste dump. Every forthright the waste should be mixed and re-spreaded. After 30 days, collect the weathered waste in the metal drums. Cover the waste with sand/earth material. Seal and level as "PYROPHORIC" hazardous waste. Fill waste disposal form and inform ADGAS civil when the waste drums are sealed and labelled. Civil will arrange to pick up and organise with store for onward dispatch to Ruwais. All pallets used to transport the drums must be cleaned and removed from storage area. If a vehicle, skip, or containers is used for disposal of pyrophoric material, all parts, which may have been in contact with the material must be thoroughly hosed down with water before it leaves the disposal area. If this is not done, there is a very high risk of the vehicle catching fire. Further Information Operations- Standing Instructions C-14 (Potential sources of Pyrophoric Material) Note Pyrophoric sludge MUST be carefully segregated from other materials being stored in the dedicated area (Plant 19).
4.9.11.3 PERSONNEL PROTECTION To prevent contamination of personal clothing with pyrophoric material disposable masks and overalls, gloves of PVC material and boots should be worn by personnel employees during its removal. Anyone handling pyrophoric material which could result in airborne dust must wear goggles for eye protection. All disposable overalls etc., must be dumped with the pyrophoric material into the same dedicated area. The PVC gloves and boots must be washed with water to remove any adhering pyrophoric material at the end of each work period.
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4.9.11.4 TRAINING Supervisors must ensure that all persons who are engaged on operations involving pyrophoric material are properly instructed on, and constantly reminded of the dangers related to the job and the proper precautions which must be taken to minimize the risk. · · · ·
Wash skin/eye with large amounts of water (emergency showers), continuously for at least 15 minutes. Remove contaminated clothing whilst in the shower. If swallowed, wash mouth, drink plenty of water. Do not induce vomiting, summon medical assistance.
4.10 RADIOACTIVE SOURCES 4.10.1 INTRODUCTION Sources of ionising radiation are employed for several purposes within the ADGAS Industrial Area. These are: · · · ·
Sealed sources of radioactive material used in Nucleonic instruments, installed on Plant for Process Control, e.g. level measurement. Temporary use of sealed sources by the C&ID or by Contractors for checking the quality of welds by radiographic methods (NDT). X-ray generator for radiography. Use of sealed sources in the Nucleonic Analyser, for alloy identification.
The potential for personal injury resulting from excessive doses of ionising radiation is well known, but as radiation is not detected by any of the human senses, controls are necessarily rigidly enforced by strict safety procedures and practices. Further Information ADNOC-COPV3-09 (GUIDELINES): Ionising Radiation
4.10.2 DEFINITIONS 4.10.2.1 EMPLOYER The PMshall be regarded as the agent of the Employer on the site and all formal communications with external bodies, i.e. Government Departments or other companies, must be channelled via the PROM. For administration of radiological matters, the PROM's nominees are the HC&I/DHC&I for all NDT operations and the SIE/LIE’s for all Nucleonic Instrument equipment and procedures. 4.10.2.2 RADIATION PROTECTION SUPERVISORS (RPS) Radiation Protection Supervisors are nominated by the HC&I for their departmental operations. The SIE and LIE are nominated as RPS’s for PROM&ED. The personnel Doc. Number
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nominated as RPS’s are appointed in writing by the Plant Manager. See Appendix 4-106. The RPS should be directly involved with the work with ionising radiations and employ such supervision that will ensure that the work is done in accordance with the written procedures and practices. No person should be appointed as an RPS unless they: Know and understand the requirements of the regulations, written procedures and practices. Understands the necessary precautions to be taken in the work which is being done and the extent to which these precautions will restrict exposures. 4.10.2.3 RADIATION PROTECTION ADVISOR (RPA) In the event of an incident involving radioactive isotopes, the use of a normal Radiation Protection Advisor should be used to provide advice on a call off basis. A contact for this type of service is:Synetix Services, Tracerco, P.O.Box 1 R2 Building, Belasis Avenue, Billingham Cleveland, England. Telephone: 0044 1642 522350 Fax: 0044 1642 522991 4.10.2.4 CLASSIFIED WORKERS Any person who is (or is liable to be) employed for any part of their time in an area designated as a radiation controlled area and authorised under a written system of work, will be a "Classified Worker" 4.10.2.5 MONITORED PERSONNEL All authorised personnel who come into contact, with Nucleonic devices and operate under a written system of work which includes monitoring their exposure by an acceptable method, will be "Monitored Personnel" only. Note Contractors shall ensure ADGAS that all designated "Classified Workers" meet the requirements of the mandatory regulations. ADGAS personnel who perform the functions of a "Classified Worker" will be so certified. Doc. Number
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Further Information Chapter 4.10.2 DEFINITIONS for additional definitions
4.10.3 PERSONAL MONITORING 4.10.3.1 THERMOLUMINESCENT DOSEMETER (TLD) It is mandatory that all classified personnel and authorised monitored personnel are issued with monitoring badges (TLDs) and that they are worn at all times when working with radiation. Any lost, damaged or accidentally exposed badge must be reported immediately and a replacement obtained before work in continued. 4.10.3.2 DOSIMETRY Monitoring badges (TLDs) are normally issued to be worn over a four week period and then assessed by an Approved Dosimetry Service e.g. The National Radiological Protection Board (NRPB) in the UK, where the radiation dose records are kept. Copies of the TLD assessments will be retained by the Contractor. 4.10.3.3 TRANSFER RECORDS It is the responsibility of the contractor to comply with all regulations pertaining to transfer records of Classified Workers. 4.10.3.4 HIGH EXPOSURE If at any time it appears that a person has received a radiation dose greater than 15 mSv (three tenths of permitted dose), the HC&I/DHC&I or the SIE/LIEs will; · ·
Contact the MHSE who will then notify the PMand Head of Medical Services Das (HMSD). Initiate an investigation into the circumstances leading to the exposure and report their findings to the MHSE, who will ensure that the principle of individual responsibility has been complied with by all involved personnel. The final report will be submitted to the PROM.
4.10.3.5 MEDICAL SURVEILLANCE All medical arrangements required for Contractor Classified Workers, and the keeping of their Health Records, is the responsibility of the Contractor.
4.10.4 INDIVIDUAL RESPONSIBILITY It is the individual's responsibility to ensure, so far as is reasonably practicable, that exposure to ionising radiation shall not be greater than is necessary for the purpose of his work. Dose rates shall be maintained below the value given Section 4.10.16. Doc. Number
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4.10.5 EMERGENCY EXPOSURE Personnel involved in an emergency exposure to radiation will undergo a medical examination and monitoring.
4.10.6 WORK PERMIT REQUIREMENTS All use of portable radioactive sources for radiography will require the coverage of a Hot Work Permit and be conducted by approved Classified Workers. All work will be conducted by a minimum of a two man team, never by a single person. The prepared Safety Checklist for Radiography, Figure 4-3, is attached to the White copy of the permit. This gives details of the isotope and the safety requirements prior to commencing work. The ADGAS NDT Specialist, carrying out the work, will then tick the boxes according to the needs of the job. The HSED will then sign the checklist after checking that all the requirements have been met.
4.10.7 RADIOGRAPHY Radiography can isolate substantial work areas and for this reason is usually restricted to the hours with the minimum of personnel activity. No other work permits may be issued or remain current for the area designated. The approved radiation symbol is to appear on all packages and storage containers and on barrier signs around the radiation work areas. 4.10.7.1 SAFETY PROCEDURES With the work place and affected area identified, the checklist must be rigorously applied. Along with the items in the checklist the following actions are required. · · · · ·
Good liaison and communications should be established in case field personnel need to access past the barriers. All radioactive sources are to be stored within locked shields when not in use. If there is a plant emergency, the radiation source is returned immediately to its safe storage. All sources of ionising radiation shall, where reasonably practicable, be adequately shielded.(Collimated) Radioactive sources must only be manipulated by remote handling equipment.
4.10.8 CONTROL OF RADIOACTIVE SOURCES 4.10.8.1 MAXIMUM HOLDINGS The maximum quantity of sealed sources of Iridium 192 for radiography purposes on Das Island at any one time shall not exceed 3.7 TBq (Terabecquerels) (100 Curies) Doc. Number
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The size of any single Iridium 192 source shall not exceed 1.1 TBq (30 curies). Total holdings of Caesium 137 and Cobalt 60 sources shall not exceed 111GBq (Gigabecquerels) (3 Curies). 4.10.8.2 NOTIFICATION OF IMPORT TO DAS ISLAND The HC&I and the SIE/LIE shall ensure that the following information is submitted to the ADMA-OPCO Safety and Environmental Protection Department (SEPD – Das) and copied to the MHSE at the time of mobilisation and that the radioactive sources are within the agreed limitation set by ADMA-OPCO. · · · · ·
Completed Radioactive Isotope Movement Form. Decay Table (Iridium Sources) Radioactive Source Test Report. Radioactive Material Package Certificate. Civil Defence Valid Registration Certificate.
Prior notification of disposal shall also be given to the ADMA-OPCO SEPD and copied to the MHSE. (See appendix 4-10-5). 4.10.8.3 MASTER REGISTERS It is the responsibility of the HC&I to maintain an up-to-date Register of sealed sources, for general NDT, and the same applied to the SIE/LIE for Nucleonic Sources. Each specific source shall be identified by its serial number. Copies of all certificates and decay charts (where applicable) shall be copied to the MHSE, this also applies to Contractors carrying out radiography work. 4.10.8.4 STORAGE OF RADIOACTIVE SOURCES There are two main stores for radioactive isotopes within the ADGAS Industrial Area. 502 Laydown Area The storage area consists of two stores, one for Nucleonic sources under the control of the SIE/LIEs and one for general NDT sources controlled by the HC&I. Train 3 Area This store area is used for general operational NDT sources for ADGAS and for all ADGAS subcontractors sources and is under the control of the HC&I. When not installed on the plant, in use, or in transit, all radioactive sources shall be housed in adequately shielded containers within the radioactive source stores. Doc. Number
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Every container shall be marked with a warning notice and shall specify the identification number of the source, the isotope and strength. The stores shall be reserved exclusively for the storage of sealed radioactive sources and, in particular, no flammable material will be located in the store area. The stores shall be kept locked and the keys shall be under the control of the HC&I and SIE/LIE’s for their respective store areas, allowing access to authorised personnel only. The function may be carried out by the departmental RPS. The maximum reading at the outside of the radiation stores must not exceed 2.5 mSv/hr (0.25 mrem/hr) at any place around the perimeter. Suitable signs must be displayed on the outside of the stores advising of the nature of the hazard presented by the contents and also information must be displayed regarding RPS and emergency contact numbers. A radiation Dose Rate Meter or monitor should always be used when approaching or entering the isotope stores to remove or replace an isotope or when checking the contents. Note All notices shall be in Arabic and English 4.10.8.5 ISOTOPE MOVEMENT REGISTER When an isotope is removed from, or returned to any radiation store, the details must be entered into the source Movement Register together with the signature of the authorised person in charge of the movement. This also applies to any Nucleonic source that may be placed in the pit for long term storage or on a temporary base, having been removed from the Plant. 4.10.8.6 LOCATION OF RADIOACTIVE SOURCES General NDT isotopes will always be placed in the radioactive source stores when not in use. The location of all nucleonic sources is listed in Figure 4-4. It shall be the responsibility of the SIE/LIE to advise the MHSE of any changes to the location list so that amendments may be notified to all Manual holders.
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4.10.9 NUCLEONIC SOURCES 4.10.9.1 DESIGN REQUIREMENTS Each installation shall be such that the dose rates on any external surface of the instrument or plant on which it is installed shall not exceed 7.5 mSv/hr ( 0.75 mR/hr). To ensure that this is achieved, each radioactive source shall be securely housed in a shielded container of sufficient size to ensure that radiation dose rates on all accessible surfaces are below 7.5 mSv/hr. If this is not possible, extra guards must be positioned and fixed securely in place to ensure that the dose rate at the guard is less than 7.5 mSv/hr. Additionally, radiation dose rates on all surfaces of the vessel or item to which the installation is fixed should be less than 7.5 mSv/hr, even when empty. If not, then additional guards must be positioned and fixed securely in place and the dose rate at the guard must not exceed 7.5 mSv/hr. The immediate source container shall be painted yellow and bear the international radiation symbol (black trefoil on a yellow background). The shielded source container shall provide protection of the source against damage and collimate the useful beam to the minimum dimensions necessary for efficient operation of the installed instrument. The shielded source container shall be fitted with a shutter that shall be capable of being locked in the closed position, to attenuate the useful beam such that any residual dose rate accessible to personnel does not exceed 7.5 mSv/hr. Clear notices should be fixed to the container to indicate whether the shutter is in the open or closed position. The source holder shall be locked into the shielded source container and the keys controlled by the OSS. 4.10.9.2 WARNING NOTICES Fixed to the shielded source container or immediately adjacent to it there must be a notice that bears the radiation symbol. The notice must also indicate the presence of a radioactive source and give the following information: "Make no adjustment to the installation without clearance from SIE/LIE. In the event of any unusual occurrence involving the source the OSS must be contacted immediately" In cases where a source is installed on or inside a process vessel having manhole access, then additional notices of a similar type must be fitted to each manhole. These should bear the additional instruction: Doc. Number
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"Contact the SIE/LIE before entering vessel" Note Warning notices shall be in Arabic and English. 4.10.9.3 INSTALLATION A suitable area around the Plant on which an instrument is to be installed shall be isolated by temporary barriers at which the dose rate will not exceed 7.5 mSv/hr. Installation shall be carried out by Authorised Persons from the Instrument Section. A calibrated Radiation Dose Rate Meter must be used during the installation process. 4.10.9.4 SUPERVISION The RPS shall be responsible for ensuring that the shutter is locked in the closed position. The keys will be under the control of the OSS. 4.10.9.5 MAINTENANCE Access to installed equipment will require a Hot Work Permit issued by the OSS and countersigned by the RPS. The RPS shall issue specific instructions on precautions to be taken before dismantling or removing a shielded container from it's normally installed position. 4.10.9.6 ACCESS No person shall be permitted to enter a vessel or have access to any vessel, pipe, or other part of the Plant on which a sealed source is installed without clearance from the RPS. Further Information Operations Department Permit to Work Manuals. Sections 6.13 and 10.47 4.10.9.7 LEAKAGE TESTING A test for leakage of radioactive substances shall be organised by an RPS, who shall arrange for swabs to be taken and assayed by a qualified person at least once in every period of twenty-six months of: · ·
Every immediate container or bonding which forms part of a sealed source, OR Every container in which a sealed source is permanently installed but which does not form part of a sealed source according to the relevant British Standard Doc. Number
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Further Information BS 5288 : 1976: Specification. Sealed radioactive sources. Section D21 Each leakage test shall be indicated by the request of the RPS from the Department responsible for the use and control of the source. The result of each test shall be entered into a Master Register. A satisfactory result will be recorded if the activity measured on the swab is less than 185 Becquerels (5 nanocuries) If any leakage is observed above this level, the RPS will arrange for its safe disposal and replacement.
4.10.10
SITE RADIOGRAPHY
The requirements relating to site radiography are as follows: 4.10.10.1
PRIOR TO EXPOSURE
The Controlled Area, within which the radiography takes place, shall be segregated by means of a barrier at such a position to prevent access by other than classified persons associated with the radiography work. The instantaneous dose rate shall not exceed 7.5 mSv/hr at the barrier. No classified personnel should be within the Controlled Area during radiographic exposure. When this cannot be avoided for the purpose of commencing or terminating an exposure, a person entering should not be exposed to an instantaneous dose rate more than 2 µSv/hr(200 mR/hr). Local shielding of sources, including collimators, should be used where possible to reduce dose rate and size of controlled area. Warning signs should be clear, unambiguous and carefully situated so that any person within or approaching an area is made aware of the presence of radiation. Further Information Chapter 3 Section 8 Safety Signs and Barriers. 4.10.10.2
DURING EXPOSURE
Once the exposure has commenced no alterations shall be made to the radiographic setup until the exposure has terminated. Doc. Number
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AFTER EXPOSURE
After every exposure using sealed sources, a check using a monitoring instrument should be made to ensure that the source has properly retracted into its shield or container. Sources must never be handled with the bare hands; handling tools must always be used. Lead shot and sheet for shielding purposes shall be readily available for use in an emergency. X-ray equipment shall be provided with effective means of isolation to prevent unauthorised use. Source containers shall have a lock to prevent unintended or unauthorised exposure. The lock should be such that if defective it does not prevent retraction of the source and the act of unlocking does not give rise to an immediate exposure of the source. Every exposure container used with radiography shall comply with BS 5650:1978, ISO 3999-1977: Specification for apparatus for gamma radiography (for remote exposure units only) and the position of the shutter, whether open or shut, shall be clearly indicated.
4.10.11
OTHER APPLICATIONS
Any work with sources of ionising radiation not covered by these instructions shall be carried out only with the approval of the MHSE
4.10.12
MONITORING
4.10.12.1
GENERAL
The RPS shall ensure that adequate and appropriate monitoring equipment is available to assess the radiological safety of all applications of sources of ionising radiation in progress at any time on the Site. 4.10.12.2
MAINTENANCE AND CHECKING
The RPS of the Department concerned shall ensure that each Radiation Dose Rate Meter is maintained in good working order and is calibrated by a qualified person according to the following:· ·
Once in every period of 14 months, and After any repair.
The calibration report shall be retained by the RPS with a copy to the MHSE.
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HAZARDOUS SUBSTANCES
Chapter No. 04
4.10.13
RADIOACTIVE EMERGENCY
4.10.13.1
OCCURRENCE CONSTITUTING AN EMERGENCY
Any suspected loss of, breakage of, or damage to any sealed source of radioactive material or to the shielding of any source or any circumstance which may result in these occurrences (e.g. fire on the plant) shall be regarded as an emergency. Further Information Emergency Plans and Procedures Manual Section "Loss of Radioactive Source".
4.10.14
TRANSPORT
4.10.14.1
INTRODUCTION
All regulations governing the transport of radioactive materials, nationally or internationally, are based on the International Atomic Energy Agency's "Regulations for the Safe Transport of Radioactive Materials". International organisations involved in moving radioactive materials have produced their own Regulations and Codes, specific to their own mode of transport, embodying the principles of the IAEA Regulations and the two of particular relevance to movements to and from Das Island are:The International Maritime Dangerous Goods Code - produced by the InterGovernmental Maritime Consultative Organisation. The Dangerous Goods Regulations - produced by the International Air Transport Authority. Both are updated and re-issued regularly. They are both designed to ensure that no hazard arises to personnel, passengers or persons handling the packages and, to this end, sufficient information must be given to the carrier to enable him to make suitable arrangements for transport. The materials must be correctly packed and warning notices should be fixed to the packages. Further Information International Atomic Energy Agency's "Regulations for the Safe Transport of Radioactive Materials". The International Maritime Dangerous Goods Code The Dangerous Goods Regulations 4.10.14.2
DESPATCH OF RADIOACTIVE MATERIALS
All arrangements for receipt and despatch of radioactive materials are made by the ADGAS Transit Store, Abu Dhabi and the Materials Store, Das Island. Doc. Number
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To enable them to comply with the Regulations they must be given the correct information to pass on to the carrier and the containers of radioactive material must be of the correct type and correctly labelled. 4.10.14.3
INFORMATION REQUIRED
The information is in the form of a Shippers Declaration for Dangerous Goods. Details of the Shipper, Consignee, airport of departure and destination and whether the material may be carried by passenger and cargo aircraft must be completed. Additional information and documentation must be supplied as follows: ·
·
·
· ·
A description of the material. For sealed sources this will normally be a statement, "Radioactive Material", and the type of isotope, together with its composition, i.e. "Iridium 192", (or Caesium 137) "Metal, Solid", "Not Otherwise Specified" (abbreviated to N.O.S.). If the isotope has undergone the rigorous testing for it to be classed as "Special Form" material, a statement to this effect and a copy of the special form certificate. Larger quantities of special form material (A1 limit) may normally be carried than of non-special form materials (A2 limit), e.g. for Caesium 137, 30 curies and 20 curies respectively, although 20 curies of either form of Iridium 192, when carried in type 'A' containers. If it is desired to carry greater quantities of material than those mentioned above, then type 'B' containers must be used. The limit then becomes the limit detailed in the type 'B' container certificate, issued by an approved Government Department. One copy of this certificate must accompany the Shippers certificate. For 'A' type containers, i.e. those carrying up to the A1 or A2 limits, no certificate is necessary since the testing has been carried out by the owner of the container, rather than a Government Department, although the container must be legibly marked 'A' type container. The dimensions of the package must also be given on the Shipper Declaration for Dangerous Goods. Details of the Transport Index (abbreviated to T.I.) of the package and type of warning label used must also be given on the Shipper's Declaration for Dangerous Goods (see Section below).
4.10.14.4
LABELLING OF CONTAINERS
The objective of the labels used on radioactive containers is to give immediate information to any person concerned, that: · · · ·
The material is radioactive. The type of isotope enclosed. The quantity of radioactive material. The radiation dose rate from the container. Doc. Number
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Special labels are therefore used, all carrying the International Trefoil Symbol and the word "Radioactive". Space is provided to write in the isotope and quantity of radioactive materials in the container. Two labels must be used, fixed to the top and side of the container. Information on dose rate at the surface of the container is given by using a particular type of label and information on dose rate at a distance is given by writing on the Transport Index of the container (i.e. the maximum dose rate measured, in mSv/hr (milliRad per hour), at one metre from the surface of the container). For the isotopes used on site (non fissile isotopes) one of three types of label will be appropriate. Use: · · ·
A white label when surface dose is less than 5 mSv/hr (0.5 mRad/hour). A yellow II label when both surface dose rate is within the range 5 to 500 mSv/hr (0.530 mRad/hr) and the Transport Index is less than 1. A yellow III label when either the surface dose rate is greater than 500 mSv/hr (50 mRad/hr) or the Transport Index is greater than 1. Note Package surface dose rates may not exceed 2 µSv/hr (200 mRad/hr) or the transport index exceed 10, unless the consignee has sole use of the transport medium, i.e. the material goes as a "Full Load".
4.10.14.5
DESPATCH REQUEST
A completed despatch request form in duplicate must be sent to the Transit or Materials Store with the isotope information. 4.10.14.6
CONFIRMATION OF DESPATCH
Following despatch of the radioactive materials the Transit or Materials Store shall send a copy of the dispatch request to the MHSE. 4.10.14.7
PRIOR NOTIFICATION
Before any radioactive material is imported to/from Das Island, notice must be given to the ADMA-OPCO Senior Safety Engineer (SSE) Das. 4.10.14.8
NOTIFICATION OF RECEIPT/ DISPATCH
Notification of receipt/ dispatch of radioactive materials on Das Island must be given by the relevant department to the ADMA-OPCO SSE(Das) and copied to the MHSE using the Radioactive Isotope Movement Form, Figure 4-5.
4.10.15
DEFINITIONS OF RADIOLOGICAL TERMS
RADIOACTIVE SUBSTANCE Means any substance having an activity concentration of more that 100 Bqg-1 and any other substance that contains one or more radionuclides whose activity cannot be Doc. Number
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disregarded for the purposes of radiation protection, and the term includes a radioactive substance in the form of a sealed source. IONISING RADIATION Means electromagnetic radiation (that is to say, X-rays and gamma rays) or corpuscular radiation (that is to say, alpha particles, beta particles, electrons, positrons, neutrons, or heavy particles) being electromagnetic radiation or corpuscular radiation capable of producing ions and emitted from a radioactive substance or from a machine or apparatus that is intended to produce ionising radiation or from a machine or apparatus in which charged particles are accelerated by a voltage of not less than five kilovolts. USEFUL BEAM Means, in the case of X-rays, that part of the radiation from a X-ray tube that passes through the aperture, cone or other device for collimating the X-ray beam, and, in other cases, any ionising radiation from a sealed source that can be employed for the purpose for which the sealed source is used. CONTROLLED AREA Means a part of premises in which any person is exposed to a radiation dose rate which when averaged over any one minute exceeds or is liable to exceed 7.5 mSv/hr. ADEQUATE SHIELDING Means shielding or a demarcating barrier outside which the radiation dose rate averaged over any one minute does not exceed 7.5 mSv/hr. RADIATION PROTECTION SUPERVISOR Means a person appointed in writing by the Plant Manager to exercise special supervision with regard to the control and use of sources of ionising radiation and to assist in the implementation of these instructions. CLASSIFIED PERSON Means a person who is (or is liable to be) employed for any part of his time in a controlled area in work involving operations with sealed sources and has been designated by an appointed doctor. MONITORED PERSON Means a person who is involved with radioactive sources, but is not a "Classified Person". GRAY (GY) Is defined as the unit of absorbed dose equal to 1 joule/ kilogram (J/Kg) in any medium. (original unit was the rad. 1 Gy = 100 rads).
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SIEVERT (SV) Is the dose equivalent, and is obtained when the absorbed dose (Gy) is multiplied by the appropriate quality factor. (original unit was the rem. 1 Sv = 100 rems). BECQUEREL(Bq) The activity of radiation that undergoes one disintegration per second. (original unit was the curie. 1Ci = 37 gigabequerels (Gbq)
4.10.16
DOSE LIMITS
DOSE LIMITS FOR THE WHOLE BODY The dose limit for the whole body resulting from exposure to the whole or part of the body, being the sum of the following dose quantities resulting from exposure to ionising radiation, namely the effective dose equivalent from external radiation and the committed effective dose equivalent from that year's intake of radionuclides, shall in any calendar year be: · For radiographers aged 18 years or over 50 mSv · For trainees aged under 18 years 15 mSv · For all other personnel 5 mSv DOSE LIMITS FOR INDIVIDUAL ORGANS AND TISSUES Without prejudice to Part 1 of this schedule, the dose limit for individual organs or tissues, being the sum of the following dose quantities resulting from exposure to ionising radiation, namely the dose equivalent from external radiation, the dose equivalent from contamination and the committed dose equivalent from that year's intake of radionuclides averaged throughout any individual organ or tissue (other than the lens of the eye) or any body extremity or over any area of skin, shall in any calendar year be: · For radiographers aged 18 years or over 500 mSv · For trainees aged under 18 years 150 mSv · For all other personnel 50 mSv In assessing the dose quantity to skin whether from contamination or external radiation, the area of skin over which the dose quantity is averaged shall be appropriate to the circumstances but in any event shall not exceed 100 cm2. DOSE LIMITS FOR THE LENS OF THE EYE The dose limit for the lens of the eye resulting from exposure to ionising radiation being the average dose equivalent from external and internal radiation delivered between 2.5mm and 3.5mm behind the surface of the eye, shall in any calendar year be: · For radiographers aged 18 years or over 150 mSv · For trainees aged under 18 years 45 mSv · For all other personnel 15 mSv
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Details of Isotope
Type..........................................................................Type of Emission................................................ Strength on manufacture...........Ci...............................Date...................... Present Strength.......................Ci...............................Date...................... Decay Rate..............................Days/Years.................Collimated/uncollimated 2. Safety Requirements
Yes
No
a) Erect Safety Barriers. b) Place Trefoils (Radiation Warning Signs). c) Place Warning Lights (in low light areas). d) Inform Plant/Workshops personnel that work with isotopes is imminent. e) Check locker rooms, toilets, showers and offices in sterile area. Evacuate personnel and lock or wire shut all doors in sterile area. f) All "Classified Persons" equipped with TLD's. g) Calibrated Dose Rate Meter on Site. h) Adequate shielding in place. i) Safe Working platform with safe means of access. 3.
Health, Safety and Environment Division.
I have checked the area in which Radiography will take place and am satisfied that all the requirements have been met. Name............................................................ Name............................................................ Name............................................................ Name............................................................
Time ....................... Time........................ Time ....................... Time .......................
Date....................................... Date....................................... Date....................................... Date.......................................
(This document must be attached to a Hot-Work Permit and the relevant requirements must be met before any Radioactive Isotope is exposed in the Plant or Workshops). Figure 4-3: Radiation Safety Checklist
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TRAIN I SOURCE(S)
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SERIAL NO.
Hot Carbonate Absorber 2-C-103 11 x 0.5mCi Cs137 M5917, M5921, M5922, 5923 M5924, M5925, M5928, M5930 M5932, M5936, M5938. Hot Carbonate Absorber LLA 2-C-103
20mCi Cs137
Hot Carbonate Flash Drum 2-C-108 260mCi Cs137 255mCi Cs137 M5940 (Lower) Amine Absorber 2-C-109 1Ci Cs137
M5761
0975 GM (Upper)
N1314
Amine Flash Drum 2-C-111 16mCi Cs137 16mCi Cs137 0123GM
0122GM
TRAIN II Hot Carbonate Absorber 2-C-203 11 x 0.5Ci Cs137 M5915, M5916, M5918 M5919, M5920, M5929 M5931, M5933, M5934 M5935, M5936 Hot Carbonate Absorber LLA 2-C-203
20mCi Cs137
Hot Carbonate Flash Drum 2-C-208 250mCi Cs137 269mCi Cs137 M5943 (Lower) Amine Absorber 2-C-209 1Ci Cs137
M5946
0976 GM (Upper)
N1344
Amine Flash Drum 2-C-211 16mCi Cs137 16mCi Cs137 M5979
M5963
Plant 27 LPG Flare Line 18-LSH-37 3mCi CS 137
4222 GF
LNG Flare Line 18-LSH-35 5mCi Cs137
4135 GF
LNG Flare Line 18-LSH-36 5mCi CS137
3900 GF
Train III Sour Gas Flare Blowdown Drum Exit Line
3mCi Cs137
8127 GF
502 LAYDOWN AREA NUCLEONIC STORE Calibration Source Isotope storage pit
3mCi Cs137 22mCi Cs137
0646 GM 4681 GF
Figure 4-4: RADIOACTIVE SOURCE LOCATION LIST Doc. Number
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To
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From
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Date: August 2006
HAZARDOUS SUBSTANCES
Chapter No. 04
Senior Safety Engineer (Das)
Date Ref.
:
:
Mobilisation/ Demobilisation of Radioactive Isotope(s)
A. The under mentioned Radioactive Isotope (s) have arrived on Das Island. Decay chart attached for your reference.
Isotope No.
Isotope Activity Upon Arrival
Storage Pit
B. The under mentioned Radioactive Isotope (s) have been removed from Das Island.
Isotope No.
Destination
Name : ................................................ .........................................................
Company :
Signature : ......................................... ..........................................................
Position :
Note: This form must be completed on the day an Isotope is brought into Das or the day it is taken off.
Figure 4-5: RADIOACTIVE ISOTOPE MOVEMENT FORM
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4.10.17
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APPOINTED RADIATION PROTECTION SUPERVISORS
The following personnel have been nominated and appointed as Radiation Protection Supervisors for ADGAS. No person shall be nominated unless they have received such information instruction and training that will enable them to conduct the work, within the ADGAS Controlled Areas, and is in compliance with their Departmental systems of work for radioactive isotopes and also with this Chapter of the HSEM.
Nominated Personnel a)
Corrosion and Inspection Department Steve Bishop John Den Heyer
b)
PIE NDT Specialist
-
Maint – Instrument Section Raweh Ali Saleh Ali Mohamed Ismail -
LIE LIE
MOH’D SAQER A. AL SHEHHI PRODUCTION MANAGER
Figure 4-6: RADIOACTIVE PROTECTION SUPERVISORS
4.11 PLANT PRODUCT HAZARDS 4.11.1 INTRODUCTION The ADGAS Liquefied Natural Gas (LNG) Plant produces the following end products for export:- Liquefied Natural Gas (LNG) (methane/ethane), Liquefied Petroleum Gas (LPG) (propane/butane), pentane and sulphur. LNG and LPG are cryogenic materials in that they are produced, handled and stored at below 0°C.
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It should also be noted that a further cryogenic material utilised on the Plant, and for which similar precautions should be taken, is nitrogen.
4.11.2 CRYOGENIC MATERIALS 4.11.2.1 BURNS AND FROSTBITE Exposure of the skin to low temperature can produce effects similar to a burn. These will vary in severity with the temperature and the time of exposure. Insufficiently protected parts of the body coming into contact with very cold uninsulated pipes or vessels may become stuck fast due to the freezing of available moisture, resulting in flesh being torn on removal. Prolonged exposure to cold can result in frostbite. There may well be insufficient warning by local pain whilst the freezing action is taking place. Cryogenic liquids and vapour can damage the eyes. Although prolonged direct inhalation of cold vapour or gas can damage the lungs, exposure to the rising visible cloud of gas/water vapour associated with discharges of cryogenic fluids has been found to be non-hazardous. The low viscosity of cryogenic fluids means that they will penetrate woven or other porous clothing materials much faster than, for example, water would. 4.11.2.2 OXYGEN DEFICIENCY All the liquefied gases processed on the plant are asphyxiants. In sudden and acute asphyxia, such as that from inhalation of a gas containing practically no oxygen, unconsciousness is rapid. Immediate remedial action should be undertaken as the casualty may suffer permanent brain damage unless treated within three minutes, and may die if treatment is delayed longer. Oxygen deficient atmospheres may occur during venting and purging operations and appropriate precautions should be taken. 4.11.2.3 TOXICITY The liquefied gases processed on the plant, when free of hydrogen sulphide, may be considered non-toxic. Abnormally prolonged exposure to high concentrations may cause some nausea, drowsiness or dizziness. Removal from exposure usually causes the symptoms to disappear quickly. 4.11.2.4 COLD EXPOSURE Hypothermia occurs due to the body being unable to maintain its normal temperature, even at temperatures up to 10°C. Individuals not suitably protected against low ambient Doc. Number
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temperatures may be adversely affected so far as their reactions and capabilities are concerned. Personnel should be protected against low ambient temperatures that may occur for example on entering cold tanks or vessels. Personnel apparently suffering from the effects of hypothermia should be removed from the cold area to a warm environment. 4.11.2.5 FIRST AID On exposure to a cryogenic material, immediate first aid involves flushing the affected areas of skin with large quantities of fresh water. Where practicable the patient should be moved to the emergency shower and drenched. The casualty should then receive immediate medical attention and be transported to hospital without delay. In the event of a person collapsing due to oxygen deficiency, rescue personnel should ensure that they are adequately equipped with breathing apparatus before attempting to remove anybody overcome in an oxygen deficient atmosphere. The casualty should be removed immediately to a normal atmosphere. It is vitally important to start artificial respiration at the first opportunity, if the casualty is not breathing 4.11.2.6 PROTECTIVE CLOTHING Under normal operating conditions, individual protective clothes, gloves and especially visors, should be worn when handling cryogenic fluids. Protective clothing for handling low temperature liquefied gases serves mainly to protect against frost burns. Non-absorbent gloves should always be worn when handling anything that is or may have been in contact with cold liquids or vapours. If severe spraying or splashing is likely to occur, eyes should be protected with a face shield or goggles. Full body protection is also available through the wearing of a cryogenic suit. Further Information 3.9 PERSONAL PROTECTIVE EQUIPMENT 4.11.2.7 OVER PRESSURISATION All systems used for processing cryogenic liquids have the potential to be over pressurised in adverse operating circumstances. Suitable relief systems sized and installed to appropriate industry codes and standards must always be provided.
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4.11.3 CRYOGENIC SPILLS/FLARES 4.11.3.1 SPILLAGE CHARACTERISTICS When a cryogenic spillage occurs, a white visible cloud develops due to the condensation of water vapour in the atmosphere. It should not be confused with the dangerous cloud where the gas content lies within its flammable range. Tests have shown that the flammable cloud is located inside the visible cloud when the relative humidity level of the air exceeds 40%. The initial volume of the cloud will be greatest at the beginning of the spill, due to the initial flash off of vapour. The eventual size of the cloud depends on the wetted surface area and on the nature of the ground once conditions have stabilised and a steady-state is reached. There are various differences in the behaviour of LNG in comparison with LPG when spilled. LNG has an initial high rate of evaporation, the cloud moving downwind until its temperature is sufficiently raised for the gas to disperse upward. LPG, being heavier than air and with a smaller temperature differential between the liquid temperature and ambient, boils off more slowly and follows ground contours downwind. LPG will therefore tend to collect in depressions and trenches. 4.11.3.2 SPILLAGE CONTROL A distinction should be made between the large spills of cryogenic fluid associated with tank incidents and the small spills associated with seal/flange leakages which essentially behave as gas leaks, since the cryogenic fluid vaporises rapidly and completely on emission 4.11.3.3 PLANT (T1/T2 UTILITIES) Facilities on the LNG Plant are provided to assist in the control of large spills by the provision of water curtains and foam units. Further Information Emergency Plans and Procedures Manual: Chapter 3 4.11.3.4 NEW TANK FARM/TRAIN 3 Spillage of LNG/LPG in the New Tank Farm and Train 3 is controlled by the drainage and flow of the liquid hydrocarbons to Impounding Basins. There are two cases to consider; spillage of LNG and spillage of LPG: 4.11.3.5 SPILLAGE OF LNG ·
Vapour dispersion and fire control of LNG collected in Impounding Basins can be achieved rapidly using expansion foam. o For vapour dispersion control, the expansion foam increases the evaporation rate by warming the vapours of LNG so that they are less dense than air and, therefore, disperse vertically rather than horizontally. Doc. Number
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o For fire control of ignited LNG, the expansion foam blanket reduces the boil-off rate and subsequent flame size by shielding the LNG from the fire, thereby reducing or essentially eliminating radiation feedback from the fire. Caution It is advisable to allow a foam-controlled LNG fire to burn rather than extinguish it using dry powder. 4.11.3.6 SPILLAGE OF LPG ·
Owing to the heavier than air characteristic of LPG, vapour dispersion of an LPG spill in an Impounding Basin cannot be achieved using expansion foam.
In fact, the use of expansion foam increases the boil-off rate with an increase in the hazards associated with a vapour cloud. ·
For fire control of ignited LPG, the high-expansion foam blanket shields the liquid fuel source from the radiation of the fire, thereby controlling the evaporation rate and size of fire. Caution It is advisable to allow a foam-controlled LPG fire to burn rather than extinguish it
4.11.3.7 FIRE CONTROL If there is a fire involving cryogenic material two basic cases should be considered: · ·
Small Area Fires of between 5m2 and 10m2 can be extinguished directly with dry powder. Care however must be taken not to extinguish a three dimensional (gas leak) fire until the fuel source is isolated. Large Area Fires generate intense heat radiation and require large quantities of dry powder and it is more usual to apply foam of an expansion ratio of at least 1:150.
This will reduce the flame height allowing consequent extinction with less dry powder. However, under certain circumstances the controlled burning of the flammable vapours on top of the foam blanket is preferable to extinguishing the fire with dry powder completely. This prevents possible uncontrolled re-ignition of the gas cloud with potentially more disastrous results. Under these conditions, the cooling effects of water can be used to effectively screen and protect adjacent facilities from the thermal radiation generated by the fire. It must be emphasised that water must not be directed onto the area involving the fire. Doc. Number
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4.11.4 EQUIPMENT FOR CRYOGENIC SERVICE Materials incorporated in a correctly designed cryogenic plant are suitable for the lowest temperatures to be expected in actual operation, and foreseeable conditions arising from maloperation. It is essential that the limiting temperature conditions applying to items of equipment or systems are clearly defined and that the plant is at all times operated within these limits. When replacement parts for cryogenic plant are procured, it is essential that the original design criteria are maintained.
4.11.5 PENTANE Pentane is a colourless extremely flammable liquid with a pleasant odour when pure and an offensive odour when contaminated with mercaptans and/or hydrogen sulphide. Its vapour is heavier than air and vapour/air mixtures may be explosive. 4.11.5.1 TOXICITY Pure Pentane is of low toxicity being a mild irritant but is narcotic if the vapour is inhaled at high dosage. Sour Pentane produced by ADGAS contains sulphur compounds. 4.11.5.2 FIRE CONTROL Spillages of Pentane which ignite can be extinguished using low expansion foam fire fighting equipment or dry powder extinguishers. 4.11.5.3 PROTECTIVE CLOTHING Further Information Chapter 3 Section 7
4.11.6 HYDROGEN SULPHIDE (H2S) 4.11.6.1 GENERAL The feed gas provided to ADGAS contains a proportion of hydrogen sulphide gas (H2S) It's properties can be summarised as follows: · · · · · ·
Highly toxic. Colourless. Heavier than air, hence tends to settle in low-lying areas. Readily dispersed by wind or air currents Has characteristic smell of rotten eggs at low concentration; at higher concentrations the sensitivity to smell disappears. Flammable. (LEL 4.3% UEL 46% AUTO IGN 260°c)
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Warning Do not depend on your sense of smell to detect hydrogen sulphide. 4.11.6.2 TRAINING All persons working or visiting the ADGAS facilities must be made aware of the dangers of hydrogen sulphide, made familiar with evacuation procedures and in the use of the Self Rescue Respirator. This information is normally given at an induction course provided by the HSED. No one, with the exception of accompanied visitors, are allowed on the facilities without an induction. Advanced training on the properties and safety precautions relating to hydrogen sulphide is provided to other Departments by the HSED, as required. 4.11.6.3 TOXICITY Table 4-5 indicates the toxic effects of H2S at various concentrations. Concentration 0.13 ppm 4.60 ppm 10 ppm 27 ppm 100 ppm 200 ppm 500 - 700 ppm 700 - 1000 ppm 1000 - 2000 ppm
Effect Minimal perceptible odour. Easily detectable odour. Slight eye irritation. Strong, unpleasant odour, but not intolerable. Coughing, eye irritation, loss of sense of smell. Marked eye inflammation. Respiratory tract irritation after one hour exposure. Loss of consciousness and possibly death in 30 minutes to one hour. Rapid unconsciousness, stopping of respiration and death. Unconsciousness at once with rapid stopping of respiration. Death may occur even if individual is removed to fresh air at once. Table 4-5: H2S Toxicity
4.11.6.4 SAFETY PRECAUTIONS In the event of a hydrogen sulphide leak on the plant procedures are laid down in the Emergency Plans and Procedures Manual. It is important that all personnel retain their Self Rescue Respirator on their person whilst in the ADGAS industrial area.
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4.11.6.5 SPECIFIC PRECAUTIONS Working in an actual or potential hydrogen sulphide environment requires accurate planning and preparation. ·
The proposed method of work is to be reviewed by the Area Authority and SHSEE(Ops) (a Task Risk Assessment should be carried out) and attached to the appropriately completed work permit.
Note: Provision of BA standby is essential. 4.11.6.6 PORTABLE H2S DETECTORS LEAD ACETATE CASSETTES Operations Division personnel carry lead acetate cassette detectors which will give an indication of the concentration when in the presence of hydrogen sulphide. DRAEGER SULFIWARN Sulfiwarn hydrogen sulphide detectors are held by the HSED. These may be used for monitoring the hydrogen sulphide content of the ambient air in work areas. An alarm threshold is set on the device which, when exceeded, provides an audible and visual alarm. 4.11.6.7 FIXED H2S DETECTORS Fixed hydrogen sulphide detectors have been strategically located throughout the LNG facility to monitor the area on a continuous basis. The alarm control panel for these detectors is located in the Control Room. An audio/visual alarm is sounded when the hydrogen sulphide concentration reaches 10 parts per million. Further Information Dangerous Properties of Industrial Materials, Sax. Substances Hazardous to Health, Croner.
4.11.7 SULPHUR 4.11.7.1 PHYSICAL PROPERTIES AND HAZARDS Sulphur remains solid as yellow crystals or powder up to its melting point of 119oC (248oF). Auto-ignition occurs at 288oC (450oF) but in a dust cloud auto-ignition could occur at a temperature as low as 190oC (375oF). Sulphur is easily ignitable and combustible. Burning sulphur produces highly toxic sulphur dioxide gas which has a threshold limit value (TLV) of 2 ppm. The IDLH concentration for SO2 is 100 ppm. The main hazards from liquid sulphur are release of dissolved H2S (upto 15 ppm H2S in Doc. Number
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Sulphur) in the ullage space of the tank. Severe burns on contact due to the high temperature of the liquid sulphur which is kept at approximately 140oC and sulphur dioxide release in the event of the sulphur catching fire. Hydrogen sulphide (H2S) is a hazardous gas. The gas is colourless and even at low concentrations of 0.13 ppm has the distinct smell of rotten eggs. Concentrations of 100 ppm will cause loss of smell and above 500 ppm will rapidly cause unconsciousness and death. The gas is explosive between 4 to 44 vol % in air. While the liquid sulphur is stored at a constant temperature with no agitation, very little hydrogen sulphide is released. High and dangerous concentrations of H2S may be evolved, even several days after sulphur production, by either or both of the following: · ·
A drop in temperature Agitation of liquid sulphur.
Tests have shown that tankers filled to within 1 to 2 % of full capacity and carrying liquid sulphur with an H2S concentration of more than 15 ppm would be capable of evolving sufficient H2S to reach the lower explosive limit within 7 to 8 hours of transport. 4.11.7.2 HANDLING LIQUID SULPHUR The continuous threat of the presence of explosive and toxic H2S, the severity of liquid sulphur burns and the dangers posed by the ignition of sulphur demand the use of welltrained and experienced personnel. The following precautions shall be observed: · · · · · · · ·
No sparks, open flames or welding shall be permitted in the handling area without a permit to work. Operators shall wear a helmet, face shield, long-sleeved overalls, heat-resistant gauntlet and safety boots. Liquid sulphur piping and associated steam piping shall be insulated to eliminate contact burns. All liquid sulphur handling operations shall be supervised. Supervisory staff and operators shall be aware of emergency procedures to be taken in event of H2S release or liquid sulphur fire. In the event of H2S release or fire, emergency shutdown of the loading/ unloading operations shall be initiated. Spot checks on loaded tankers entering or leaving Das should be carried out by the Health, Safety and Environment Division. Respiratory protection equipment shall be worn during all manual venting operations.
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4.11.7.3 BURNS FROM LIQUID SULPHUR Should any person come into contact with the hot sulphur the area should be flushed with running water for at least 15 minutes and no attempt should be made to remove it. Skin or clothing burned by liquid sulphur is usually covered with a thin hard coat of solidified sulphur, and this should be covered with a clear dry dressing with no attempt made either to remove clothing or the offending sulphur. The patient should be treated for shock if necessary and medical attention sought immediately. Further Information Hazardous Substances Manual - Product Health & Safety Data sheet on Sulphur (Liquid).
4.12 HAZARDOUS SUBSTANCES DISPOSAL 4.12.1 GENERAL MSDS included in the Hazardous Substance Manual, will indicate, when applicable, the required methods of disposal together with any special precautions required during transportation from site and during final disposal. The disposal of all flammable, corrosive or toxic substances from the LNG Plant is covered by GOP 4.2/4.3/4.4: Disposal of Dangerous Material, requiring the Head of Process to be informed before removal from site of all such materials.
4.12.2 OUTSIDE AGENCIES Where outside agencies, including ADMA-OPCO, are employed for the disposal of hazardous substances, HSED will ensure the methods and precautions used for the disposal of a specific substance meet the required standard, as described in the Waste Disposal Manual before endorsement of the Waste Disposal Form. Further Information ADNOC-COPV2-05: Waste Management ADGAS Waste Disposal Manual ADGAS Hazardous Substance Manual.
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CHAPTER 5 CONTENTS 5
PERMIT TO WORK SYSTEM ............................................................................................................. 216 5.1 INTRODUCTION ............................................................................................................................ 216 5.2 GENERAL RESPONSIBILITIES .................................................................................................... 216 5.2.1 MANAGEMENT ........................................................................................................................... 216 5.2.2 SUPERVISORS ............................................................................................................................ 216 5.2.3 CONTRACTORS .......................................................................................................................... 217 5.3 PERMIT AUTHORITIES................................................................................................................. 217 5.3.1 AREA AUTHORITY...................................................................................................................... 217 5.3.2 AREA AUTHORITIES (NON-INDUSTRIAL)............................................................................... 217 5.3.3 AREA OPERATOR ....................................................................................................................... 217 5.3.4 AUTHORISED ELECTRICAL PERSON ...................................................................................... 217 5.3.5 AUTHORISED GAS TESTER ...................................................................................................... 217 5.3.6 ISSUING AUTHORITY ................................................................................................................ 218 5.3.7 JOB OFFICERS ........................................................................................................................... 218 5.3.8 OPERATIONS AUTHORISED PERSON ..................................................................................... 218 5.3.9 PERFORMING AUTHORITY ...................................................................................................... 218 5.4 WHEN IS A PERMIT REQUIRED .................................................................................................. 218 5.5 PERMIT SUBMISSION ................................................................................................................... 219 5.6 TYPES OF PERMIT ......................................................................................................................... 219 5.6.1 COLD WORK PERMIT ................................................................................................................ 219 5.6.2 HOT WORK PERMIT .................................................................................................................. 219 5.6.3 NAKED FLAME PERMIT ............................................................................................................ 219 5.6.4 VEHICLE ENTRY PERMIT ......................................................................................................... 220 5.6.5 REMOVAL PERMIT .................................................................................................................... 220 5.6.6 BREACH OF BUND PERMIT ..................................................................................................... 220 5.6.7 SMOKING PERMIT ..................................................................................................................... 220 5.6.8 INSTRUMENT ROUTINE PERMITS ........................................................................................... 220 5.6.9 NON-INDUSTRIAL AREA PERMIT ............................................................................................ 221 5.6.10 CONFINED SPACE ENTRY CERTIFICATE .......................................................................... 221 5.6.11 EXCAVATION WORK REQUEST ........................................................................................... 221 5.6.12 DATA HIWAY ACCESS REQUEST ......................................................................................... 221 5.7 PERMIT GAS TESTING.................................................................................................................. 222 5.7.1 CONFINED SPACES ................................................................................................................... 222 5.7.2 OPEN SPACES (I.E. OTHER THAN CONFINED SPACES) ...................................................... 222 5.7.3 CALIBRATION ............................................................................................................................. 222 5.8 TRAINING ....................................................................................................................................... 223 5.9 AUDITING OF THE PERMIT TO WORK SYSTEM...................................................................... 223 5.9.1 DAILY MONITORING ................................................................................................................. 223 5.9.2 MONTHLY AUDIT ....................................................................................................................... 223 5.9.3 ANNUAL AUDIT REVIEW .......................................................................................................... 223 5.9.4 EXTERNAL AUDIT REVIEW ...................................................................................................... 224
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5 PERMIT TO WORK SYSTEM 5.1 INTRODUCTION This chapter gives a general overview of the ADGAS Permit to Work System. For authoritative and detailed information on the complete system the Operations Division Permit to Work Manual should be consulted. A permit to work procedure is a formal written procedure used to control particular types of work that are potentially hazardous. Essential features of a permit to work system are: · · ·
Clear definitions stating who may authorise particular jobs, who is responsible for specifying the necessary precautions and who may accept the precautions to be undertaken during the work. Training and instruction in the issue and use of permits. Effective monitoring to ensure that the system works as intended.
A permit to work is not permission to carry out a dangerous job, but is an essential part of a procedure that provides instructions on how a potentially dangerous job can be carried out safely. The issue of a permit does not, by itself, make a job safe. This can only be achieved by those preparing and those carrying out the work. The permit is a written document that authorises certain people to carry out specific work, at a certain time, and measures needed to complete the job safely. Further Information ADGAS OPERATIONS DEPARTMENT: Permit to Work Manual ADNOC-COPV4-05: NON-ROUTINE OPERATIONS
5.2 GENERAL RESPONSIBILITIES 5.2.1 MANAGEMENT It is the responsibility of Management to ensure that: · · · ·
An appropriate permit to work procedure is written and implemented. Satisfactory arrangements, including training, exist for implementing the procedure on a day to day basis and that these arrangements include contractor personnel. Operation of the procedure is monitored to ensure it is being correctly applied. Procedures are reviewed regularly and amended as necessary.
5.2.2 SUPERVISORS Supervisory staff, whether ADGAS or Contractor, should ensure that: Doc. Number
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They are fully conversant with the ADGAS permit to work procedure. No work under their supervision shall start until a permit has been raised and appropriate authorisation obtained. Conditions and precautions of any particular permit are understood by their workforce and strictly followed. Contractors are told of, and understand, the specific permit to work procedures that apply on the ADGAS Facilities. When the job has been completed, the permit is signed off.
5.2.3 CONTRACTORS Certain contractors working on the ADGAS Facilities may be appointed as permit signatories. This will be at the sole discretion of Management. Before acceptance as signatories, contractors so nominated, will be required to demonstrate detailed knowledge and understanding of the Permit System.
5.3 PERMIT AUTHORITIES 5.3.1 AREA AUTHORITY The Area Authority is a member of the Operations Division who has been given the authority by the Production Manager for the operation of the ADGAS Permit to Work System within his area.
5.3.2 AREA AUTHORITIES (NON-INDUSTRIAL) Any additional area (Non-Industrial) nominated as an authorised area (even a temporary site) due to work being carried out by ADGAS must have an Area Authority, nominated by the functional Divisional Manager and agreed by HSED. Refer to 2.11 AREA AUTHORITIES.
5.3.3 AREA OPERATOR The Area Operator signs all Work Permits (new and renewed) before work may start in his area.
5.3.4 AUTHORISED ELECTRICAL PERSON An Authorised Electrical Person is authorised by the Senior Electrical Engineer to carry out electrical isolation and de-isolation of equipment required for Work Permits. (High Voltage Switching requires special Authorisation).
5.3.5 AUTHORISED GAS TESTER An Authorised Gas Tester is a member of the Operations Division or a Laboratory Technician who is authorised to carry out gas tests required for Work Permits. A monthly update register of Authorised Gas Testers will be issued along with the list of authorised permit signatories. Doc. Number
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5.3.6 ISSUING AUTHORITY An Issuing Authority is a member of the Operations Division who has been given the authority by the Production Manager to issue Work Permits.
5.3.7 JOB OFFICERS All ADGAS Job Officers with responsibility for contractors must ensure that the Non Industrial Area Permit is completed and signed by all parties before commencement of work. Also, that the Performing Authority is fully aware of the scope of work and any associated hazards.
5.3.8 OPERATIONS AUTHORISED PERSON An Operations Authorised Person is a member of the Operations Division who has been given the authority by the Production Manager to carry out key isolations, fill in specific parts of the Work Permit and to certify site preparation prior to issue of the Work Permits.
5.3.9 PERFORMING AUTHORITY A Performing Authority is an ADGAS Engineer, Supervisor or Technician who has been given the authority by the Production Manager to accept Work Permits and carry out specific maintenance work on the LNG Plant. In the Non-Industrial Area, the Performing Authority shall be the person nominated by the ADGAS Job Officer.
5.4 WHEN IS A PERMIT REQUIRED A permit is required for any work carried out within the ADGAS Restricted Areas as defined by drawing 33-AOZ-0-3735 "ADGAS Industrial Area Designation and Marshalling Points". A copy of this drawing is contained in the Emergency Plans and Procedures Manual. There are certain classes of work in the ADGAS Industrial Area, of a relatively low risk nature, where only permission of the Area Team Leader (Process, Utilities, Storex) is required. The following are examples of work that may be carried out with the permission of the ATL(P), ATL(U), ATL(S) without a Work Permit: · · · · · · ·
Routine work in offices, control rooms and amenities building. Domestic Type Electrical work in Offices and Control Rooms. Visual inspection of plant and equipment (excluding confined space entry). Routine housekeeping and cleaning of the plant areas. Work on domestic type plumbing and toilets in Offices and Control Rooms. Decorating and painting in Offices and Control Rooms. Implementing DCS changes. Doc. Number
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Routine sampling by Laboratory Technicians.
5.5 PERMIT SUBMISSION Work Permits and Confined Space Entry Permits must be submitted by the Performing Authority to the Area Controller (AC / OSS) a minimum of 48 hours before the work is planned to start due to the time needed to adequately prepare the necessary equipment and work area. The Work Permits submitted will be checked by the Area Controller (AC / OSS) to ensure that: · · · · ·
A Work Permit is required for the work (may be Non-Permit Work). The equipment may be released without affecting plant production. The Permit Application part of the Work Permit form has been filled correctly. The person applying for the Work Permit is an approved Performing Authority. The correct category of Work Permit is being applied for.
5.6 TYPES OF PERMIT The Area Controller will confirm that the appropriate type of permit is being applied for.
5.6.1 COLD WORK PERMIT A Cold Work Permit is mandatory for any work (except routine) that does not include the use of a source of ignition. This includes the use of hand tools (spanners, screwdrivers, hammers, picks and shovels etc.) in such a way so as not to generate sparks. Note Air driven spanners/pneumatic tools must be considered as a source of ignition and require a Hot Work Permit.
5.6.2 HOT WORK PERMIT A Hot Work Permit is mandatory for any work involving the use of a source of ignition (other than Naked Flames which require a Naked Flame Permit) capable of igniting flammable gases, volatile liquids or other materials.
5.6.3 NAKED FLAME PERMIT A Naked Flame Work Permit is required for the use of a flame or other high energy source of ignition which is almost certain to ignite a flammable mixture. Such equipment is potentially extremely hazardous and must only be used when no other means are feasible.
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5.6.4 VEHICLE ENTRY PERMIT A Vehicle Entry Permit is required for any diesel vehicles or crane to pass the LNG complex barriers and enter plant roads, streets and bunds.
5.6.5 REMOVAL PERMIT Whenever equipment is to be removed from the LNG Plant Site to the Central Workshops, suitable precautions must be taken to ensure that, wherever possible, no hazards exist from the presence of hydrocarbons, toxic, corrosive or pyrophoric materials. All such items of equipment should be decontaminated by steam/water washing/nitrogen purging/weathering as appropriate and then tested. There are two types of Removal Permit, a Removal Permit (Blue), which certifies that the equipment has been cleared of hazardous materials, and a Removal Permit (Red), for equipment that cannot be cleared until dismantled in the workshop. Further Information GOP 4.1: Potential Sources of Pyrophoric Material PMED SI I-06
5.6.6 BREACH OF BUND PERMIT A tank bund should not be opened without the authorisation of the PMand then, only after an appropriate Breach Of Bund Permit, has been issued by the PROM.
5.6.7 SMOKING PERMIT Smoking is forbidden on the ADGAS LNG complex except in designated smoking areas in which a valid Smoking Permit is displayed. These areas are situated in the CCB, QMB, Train 1/2 Amenity Building, Train 3 Amenity Building and Storex Control Room. A Smoking Permit is issued annually by the PMand I&QM. Warning Any person found smoking in a restricted area outside the limits indicated on the Smoking Permit will be dismissed. In places where smoking is permitted, HSED Approved means of ignition and incombustible receptacles for spent cigarettes are provided and must be used.
5.6.8 INSTRUMENT ROUTINE PERMITS Instrument planned routine maintenance work may be authorised by completion and issue of an Instrument Routine Permit. This allows for up to 6 routine tests to be carried out on one Work Permit, Hot or Cold as appropriate.
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5.6.9 NON-INDUSTRIAL AREA PERMIT The Non-Industrial Area Permit system specifies the work to be done and precautions to be taken when working outside of the ADGAS Industrial Area. The ADGAS Permit to Work System does not apply to large projects outside of the Industrial Area. Such projects will be covered by the Contractors Safe Systems of Work and Permit to Work scheme after acceptance by HSED. Its main purpose is to control certain types of work that are identified as potentially hazardous.
5.6.10 CONFINED SPACE ENTRY CERTIFICATE A Confined Space Entry Certificate is mandatory for any person to enter or partially enter any confined space. A confined space is generally defined as a space or volume, capable of being entered by a person, which: · · · ·
Is not intended as a regular workplace. Has a restricted means of access and exit. Has inadequate ventilation. Has an atmosphere that was either contaminated or was Oxygen deficient. Note A Confined Space Entry Certificate is not a Work Permit, it covers ENTRY and VISUAL INSPECTION only. Any other work or equipment must be covered by an appropriate Naked Flame, Hot Work or Cold Work Permit
5.6.11 EXCAVATION WORK REQUEST An Excavation Work Request is mandatory for all excavation work, the driving of stakes into the ground and the movement of heavy cranes and equipment off designated roads or streets. Caution An Excavation Work Request is not a Work Permit and it must be accompanied by the appropriate Hot or Cold Work Permit and a Confined Space Entry Permit if the excavation is deeper than 1.3 metres.
5.6.12 DATA HIWAY ACCESS REQUEST A Data Hiway Access Request is mandatory for access to Data Hiways. Data Hiways contain live DCS cables which are critical for the control and safe operation of the LNG plant. Caution A Data Hiway Access Request is not a Permit to Work.
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5.7 PERMIT GAS TESTING Any gas testing specified by the Issuing Authority must be carried out by an Authorised Gas Tester. An up to date list of Authorised Gas Testers is kept in the Permit Office. Further Information Authorised Gas Tester Certification Procedure
5.7.1 CONFINED SPACES Gas testing for Confined Space Entry must be carried out by Authorised Laboratory Personnel until the results obtained are satisfactory, after which, the gas testing may be done by an Authorised Gas Tester. The following regulations are applicable to gas-testing: · · ·
The initial tests for flammable and toxic gases, and oxygen deficiency will be made from outside the confined space using a long probe. If these initial tests indicate a concentration that is above the permissible levels, then further gas freeing procedures and tests will be necessary until the gas concentration is within the permissible limits for the work involved. If it is necessary for the Gas Tester to enter the confined space to make further tests, full protective equipment including air-line or self contained breathing apparatus and life line must then be worn and entry must be controlled through the SHSEE(Ops) and authorised by PROM.
5.7.2 OPEN SPACES (I.E. OTHER THAN CONFINED SPACES) The gas testing of general open spaces for combustible and toxic gases and oxygen deficiency will be carried out by the OSS, Charge Engineer, ISS or other authorised OD personnel. All combustible and toxic gas tests must be carried out by a person who has been certified competent by HSED. A register of all authorised Gas Testers will be maintained by Training Department and copied to OD and HSED.
5.7.3 CALIBRATION Combustible gas testing equipment shall be tested for accuracy according to the manufacturer's instructions. Calibration and maintenance of gas testing equipment shall be carried out on a regular basis, or as required to ensure accuracy, by Instrument Section. Dates of calibration and re-calibration shall be displayed on the equipment. Further Information 7.4.6 GAS TESTING Doc. Number
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5.8 TRAINING Performing Authorities, Issuing Authorities and Operations Authorised Persosn for Work Permits, must attend and pass HSED Permit to Work Training Couse and Test. An Authorised Gas Tester is a person who has attended the Work Permit Gas Testing Training Course and has been passed as competent in the use of the test equipment by HSED.
5.9 AUDITING OF THE PERMIT TO WORK SYSTEM 5.9.1 DAILY MONITORING The copy of all new Work Permits issued should be checked daily by HSED at the CCB Permit Office. A random selection of three Work Permits should be checked thoroughly by a member of HSED for correct form completion, worksite preparation and compliance with the specified precautions. A Daily Monitoring Check List, see Appendix 10.46, should be used for each Work Permit checked. Any non-conformance highlighted by the daily monitoring should be noted on a Permit Non-Compliance Report, that should then be sent to HOS who should take the necessary corrective action.
5.9.2 MONTHLY AUDIT A monthly audit should be carried out by HO/HOS. For this monthly audit, two signed off Originals/Copies of each type of Work Permit should be taken at random from HSED archive for each of the Process, Utilities and Storex areas and checked systematically using the Monthly Audit Checklist. A copy of the completed Monthly Audit Checklist should be sent to Area Authority who should take the necessary corrective action and to HSED for information.
5.9.3 ANNUAL AUDIT REVIEW An annual review of the Permit to Work System should be carried out by an audit team consisting of members of HSED, Operations Department and Maintenance Department, and chaired by I&QM. The scope of the annual audit should be drawn up by the chairman of the audit team and agreed with the Production Manager beforehand. Appendix 10.50, Permit to Work System Checklist, shows the Permit to Work checklist that is designed to test integrity of a Permit to Work System.
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An Annual Audit Review Report should be written and include all the findings of the audit team, together with any recommendations for changes to the Permit to Work System.
5.9.4 EXTERNAL AUDIT REVIEW An external audit review of the Permit to Work System should be carried out by an approved external body and must be conducted every two years. This audit should be initiated by the PROM. The external auditors should provide a scope and programme for the audit review to ADGAS. On completion of the audit a review report should be written that includes all the findings of this audit, together with any recommendations for change to the Permit to Work System.
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CHAPTER 6 CONTENTS 6
HOT AND NAKED FLAME WORK .................................................................................................... 227 6.1 INTRODUCTION ............................................................................................................................ 227 6.1.1 DEFINITION................................................................................................................................ 227 6.1.2 LIMITATIONS .............................................................................................................................. 227 6.2 PRELIMINARY CONSIDERATIONS ............................................................................................ 227 6.2.1 GENERAL .................................................................................................................................... 227 6.2.2 PERMIT REQUIRED ................................................................................................................... 228 6.2.3 SUPERVISOR'S DISCRETION .................................................................................................... 228 6.2.4 ZONING OF HAZARDOUS RISK AREAS ................................................................................... 229 6.3 WELDING, CUTTING, BURNING, BRAZING AND SOLDERING ............................................ 229 6.3.1 GENERAL PRECAUTIONS ......................................................................................................... 229 6.3.2 FUME RISKS IN WELDING ........................................................................................................ 231 6.4 GAS WELDING AND CUTTING ................................................................................................... 232 6.4.1 CYLINDER FITTINGS ................................................................................................................. 232 6.4.2 VENTILATION DURING GAS WELDING .................................................................................. 233 6.4.3 REPAIRS TO SMALL CONTAINERS .......................................................................................... 234 6.4.4 CYLINDER CARE ........................................................................................................................ 234 6.5 ELECTRIC ARC WELDING AND CUTTING ............................................................................... 235 6.5.1 INJURIOUS EFFECTS OF ARC RADIATION ............................................................................ 235 6.5.2 ELECTRICAL SUPPLY AND CONNECTIONS ........................................................................... 235 6.5.3 WELDING LEADS ....................................................................................................................... 235 6.5.4 EARTHING AND BONDING ....................................................................................................... 236 6.5.5 STRAY CURRENTS ...................................................................................................................... 236 6.5.6 ELECTRODE HOLDERS ............................................................................................................ 237 6.5.7 ENGINE DRIVEN WELDING MACHINES ................................................................................. 237 6.6 PLASMA CUTTING SYSTEM ....................................................................................................... 237 6.6.1 INTRODUCTION ......................................................................................................................... 237 6.6.2 ELECTRICAL SUPPLY AND CONNECTION ............................................................................. 237 6.6.3 SAFETY PRECAUTIONS ............................................................................................................. 237 6.7 BLAST CLEANING AND PAINTING............................................................................................ 238 6.7.1 DEFINITIONS .............................................................................................................................. 238 6.7.2 RESPONSIBILITY ........................................................................................................................ 238 6.7.3 WORK AREA PROTECTION ....................................................................................................... 239 6.7.4 PPE .............................................................................................................................................. 240 6.7.5 EQUIPMENT SAFEGUARDS ..................................................................................................... 240 6.7.6 ENCLOSED SPACE WORKING.................................................................................................. 241 6.7.7 EQUIPMENT MAINTENANCE ................................................................................................... 242 6.8 PORTABLE TOOL IGNITION RISKS ............................................................................................ 242 6.8.1 INTRODUCTION ......................................................................................................................... 242 6.8.2 ELECTRIC POWER TOOLS ........................................................................................................ 242 6.8.3 PNEUMATIC POWER TOOLS .................................................................................................... 243 6.8.4 REDUCED SPARKING TOOLS .................................................................................................. 244 6.8.5 STEEL HAND TOOLS ................................................................................................................. 244 6.9 STATIC ELECTRICITY .................................................................................................................. 245 6.9.1 INTRODUCTION ......................................................................................................................... 245 6.9.2 ABRASIVE BLASTING ................................................................................................................. 245 6.9.3 SPRAY PAINTING ....................................................................................................................... 246 6.9.4 ENGINE REFUELLING .............................................................................................................. 246 Doc. 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6.9.5 MECHANICAL SOURCES........................................................................................................... 246 6.9.6 NEEDLE GUNS AND DESCALING ............................................................................................ 246 6.9.7 STATIC ELECTRICITY ON PERSONNEL .................................................................................. 246 6.10 PORTABLE GAS DETECTORS ..................................................................................................... 248 6.10.1 INTRODUCTION .................................................................................................................... 248 6.10.2 WHEN TO TEST ...................................................................................................................... 248 6.10.3 TEST RESULT CRITERIA ....................................................................................................... 248 6.10.4 USING GAS DETECTORS ...................................................................................................... 248 6.10.5 WORK EXAMPLES ................................................................................................................. 249 6.10.6 EXPLOSIVE LIMITS FOR PLANT GASES ............................................................................. 250 6.10.7 CURRENT DETECTORS ........................................................................................................ 250 6.10.8 "Crowcon" Triple, Type 84 TR Portable Gas Detector ........................................................... 251 6.10.9 SIEGER 1601 PORTABLE HYDROCARBON CONTINUOUS GAS MONITOR ('DALEK' TYPE) 253 6.10.10 "DRAEGER" GAS DETECTOR............................................................................................... 254 6.10.11 MSA "TANKSCOPE" ............................................................................................................... 255 6.10.12 DELMAR MINI-CHECK H2S DETECTOR ............................................................................ 257 6.10.13 OLDHAM (BM 22 PLUS BEACON) ....................................................................................... 258
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6 HOT AND NAKED FLAME WORK 6.1 INTRODUCTION 6.1.1 DEFINITION Hot Work and Naked Flame practices are any work on the plant that will or could create a spark or flame or generate surface temperatures likely to ignite combustible gases or vapours or which are deemed to be of such a hazardous nature that it requires coverage by a Hot Work or Naked Flame Permit. Further Information ADGAS OPERATIONS DEPARTMENT: Permit to Work Manual ADNOC-COPV4-05: Non-Routine Operations
6.1.2 LIMITATIONS The amount of simultaneous hot and naked flame work, e.g. welding, cutting and grinding on the plant must be limited to retain control. Jobs should be fabricated, repaired or modified in the welding workshop if at all possible. Cold cutting should always be used in preference to flame cutting as it is the safer alternative.
6.2 PRELIMINARY CONSIDERATIONS 6.2.1 GENERAL Observe any colour coding or other indicators on vessels, lines and valves for their combustion potential and adjust safe working procedures and precautions accordingly. Identify other possible work hazards, e.g. any other combustibles, hazardous materials, effects of heat, fire and gas detection, rigging considerations, etc. Restrict ignition sources wherever possible and satisfy the following questions: · · · · ·
Can the work piece be prefabricated elsewhere and brought to the site as a bolt up cold work operation? Can the hot work or the naked flame be eliminated by selecting alternative safe methods, e.g. cold cutting, air-hydraulic tools or hand tools? Can the work be moved out of the hazard area? Can the design be modified to avoid or minimise hot work or the naked flame e.g. drilling, bolting or clamping? Can the worksite be shielded from potentially flammable gas or vapour sources?. Doc. Number
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Are the risks associated with the hot work or naked flame justified ?
If the use of hot work or naked flame methods on site is unavoidable, establish a safe hot work/naked flame area to meet all local safety requirements. Set up surveillance and emergency procedures. Designate personnel responsibilities for area authority, fire guard, etc. and ensure they are adequately trained in emergency procedures. Ensure that the appropriate fire fighting equipment is on site and operative/pressured. Establish emergency communications and alarm procedures and emergency shutdown procedures of equipment. Ensure effective communications with the control room and other designated authorities. Prepare the hot work or naked flame permit. Hold a preliminary briefing, conduct and record a Task Risk Assessment as appropriate, inspect the worksite and have gas testing performed as per the work permit requirements. Further Information 2.10 Task Risk Assessment Consider that your work may be in conflict with other activities, e.g. gas release, and that any changes in the scope of the work or site conditions may require re-permitting.
6.2.2 PERMIT REQUIRED Site preparation, the gathering of tools, etc. can proceed provided that no electric, gas, or other power systems are energised. Work activities may NOT commence until the relevant fully endorsed work permit is at the worksite. Further Information 5 PERMIT TO WORK SYSTEM
6.2.3 SUPERVISOR'S DISCRETION Adherence to the safe working guidelines will contribute to the desired state of the workplace. Supervisors however, must continue to exercise their judgement when considering the approval of welding, gas cutting or grinding in hazardous areas. The safe working standards may be extended but not diminished to suit a given work situation.
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6.2.4 ZONING OF HAZARDOUS RISK AREAS In planning hot work in or near hazardous areas, first refer to the hazard zone classification for the proposed job site, and establish the appropriate protective measures. Further Information Chapter 3.4 HAZARDOUS AREAS AND ZONES
6.3 WELDING, CUTTING, BURNING, BRAZING AND SOLDERING 6.3.1 GENERAL PRECAUTIONS 6.3.1.1 INTRODUCTION All welding, cutting, burning, brazing and soldering work must be conducted under the conditions of the Permit System and the conditions of such work permits must be strictly followed. All tanks, vessels and equipment on which welding, cutting, burning, brazing or soldering work is done, and any area in which the work is carried out, must be free from flammable gases and vapours, and no oil or sludge must be present. A naked flame permit shall be completed according to these regulations before any naked flame can be used. Gas and electric welding are safe operations when carried out under correct conditions of work, but it must be stressed that equipment is to be properly maintained and well located with proper lighting. In addition, good ventilation and a tidy work area are important factors in safe working. Precautions concerning ventilation shall be taken when vessels and tanks are being welded or burned on the outside and where there is a danger of toxic or flammable gases collecting on the inside. In no circumstances shall compressed oxygen be used for ventilation or to blow through acetylene hoses. Explosions can occur when acetylene gas is present in air in any proportion between 2.5% and 80% volume. In all welding or burning operations, consideration shall be given to the space between double plates or wear plates where flammable material may be found. Inspection by the Area Authority will be necessary to decide on the precautions to be taken. Before cutting the bottom plates of any tank, test holes shall first be drilled and gas tests taken to ensure that conditions are safe under the tank floor. Old barrels or drums shall NOT be used to support work in welding operations in view of the explosion risk in the event of accidental flame impingement on such receptacles. Doc. Number
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(This is apart from the instability of the drums which are not designed for such a purpose). Welding, burning or hot tapping shall NOT be carried out on "live" lines except by special permission of the PROM. Welding or burning shall NOT be permitted on pipelines where mechanical seal plugs are necessary unless the isolation is approved and the site fit for Naked Flame Work. Ignition of oxy/acetylene or propane flames shall only be made using the "Gas Lighters" that are supplied for this purpose. 6.3.1.2 PROTECTIVE CLOTHING All welding, cutting, chipping and grinding operations shall be carried out using goggles, screens, helmets and protective clothing according the approved British Standards specification. Persons who may be exposed to the radiations and flash from this type of work shall also be protected. Gloves or gauntlets made of leather or some other incombustible material are required for shielding the hands and arms from the radiation of the arc and from sparks. Sleeves of similar material shall be used along with gloves if gauntlets are not worn. Leather gloves and gauntlets give little insulation against electrical hazards. Further Information Chapter 3.9 PERSONAL PROTECTIVE EQUIPMENT 6.3.1.3 HOT METAL The necessity for protective clothing against sparks and pieces of hot metal depends very much upon the position of the arc in reference to the welder's body. For some classes of welding, e.g. where the welder is standing at a bench, the head screen and gauntlets may well provide sufficient protection. A thick apron of leather or other suitable material may be needed if the welder is sitting at his work position where molten metal may fall upon his thighs and legs. If the arc is above the level of his shoulders, complete protection for the head, arms, and upper part of the body is necessary. 6.3.1.4 CHIPPING OF SLAG A common cause of eye injury is the chipping away of slag that covers the weld when coated electrodes are used. In these circumstances a helmet with a double screen should be used; one screen consists of a clear safety glass window while the other contains a glass that absorbs arc radiation. Doc. Number
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The screens can be simply adjusted to bring either or both screens into use. Alternatively, safety clear glass goggles may be worn in conjunction with the use of a hand screen.
6.3.2 FUME RISKS IN WELDING Toxic gases and fumes can be produced in welding operations and create serious hazards. The following methods of production of such gases should be noted. 6.3.2.1 NITROUS FUMES AND CARBON MONOXIDE Nitrous fumes may be produced if the oxy-acetylene flame is permitted to impinge on a large mass of metal for long periods during gas welding. A deficiency of air during such work may also produce carbon monoxide. 6.3.2.2 ACTION OF THE HEAT SOURCE ON THE BASE MATERIALS/WELDING RODS The arc welding of iron or steel is accompanied by the evolution of considerable quantities of fumes consisting of very fine particles of iron oxide. The welding of brass, bronze and manganese steel requires the provision of adequate ventilation or the wearing of suitable apparatus to give effective nasal-oral protection. 6.3.2.3 ACTION OF HEAT SOURCE ON COATINGS Harmful fumes may be produced by the action of the arc or flame on certain paints and protective coatings on the metal being welded. The welding and cutting of coated materials shall only be carried out when adequate means for removing the fumes are provided or adequate respiratory devices are available. Lead based paints and turn-plating emit harmful lead fumes when welded or cut. Inhalation of the fumes produced during the welding and cutting of zinc galvanised metal may result in an attack of metal fume fever which is characterised by a raised temperature, aching muscles, shivering and sweating. These symptoms develop in a few hours after exposure to the fumes and disappear after a period of about 24 hours. The welding of greasy material can produce unpleasant fumes and accordingly such materials shall be degreased before welding. Parts that have been degreased shall be dry before welding. In cases where galvanised, painted, lead or cadmium coated materials are used, air-line masks shall be worn. 6.3.2.4 HARDENED DEPOSITS Where hardened deposits are found on the equipment, welding or cutting shall NOT be started until the general nature of the deposits are established. Effective protective Doc. Number
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measures shall be taken when dangerous fumes are likely to be evolved during cutting or welding 6.3.2.5 PREVENTION OF FIRE AND EXPLOSIONS A welder and any helper shall always be alert to the dangers of fire and explosion. Welding or cutting shall NOT be carried out within the Restricted Area without a Naked Flame Permit, and the conditions laid down on that permit shall be strictly observed. Welding booths and screens shall be of a fire resistant construction and the interior surfaces shall be such as to minimise the reflection of dangerous rays. There shall be ample means for through ventilation. Work shall be screened to prevent sparks from flying outside the immediate welding area, and all combustible material shall be removed if there is danger of ignition. When working at a height, precautions shall be taken to prevent welding rods and spent stands from falling. Non-combustible screens shall surround the work area to prevent scatter of sparks and hot metal. Particular attention shall be given to the area immediately below the welding area. In all welding operations portable fire extinguishers shall be in close proximity of the work area. Welders shall NEVER coil hoses around their body when welding. The blow-pipe from any oxygen, propane or acetylene cylinder when alight shall NOT be hung on the cylinder or regulator. Caution Blow-pipe and hoses shall NOT be left in vessels or enclosed spaces when they are not in use, for example, during a lunch break, or over-night. A very small leak over such a period of any gas, particularly acetylene, from a torch can make the atmosphere in the vessel dangerous. Where this cannot be done, the oxygen and acetylene connections shall be disconnected at the cylinders situated outside the vessel. Merely closing the valve is not a disconnection.
6.4 GAS WELDING AND CUTTING 6.4.1 CYLINDER FITTINGS Fittings or equipment containing above 90% copper (except burner tip) shall NOT be used with acetylene, as copper in contact with acetylene is liable to form the dangerously explosive compound, Copper Acetylide.
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The use of lead washers or any kind of packing whatsoever in the valve joints is strictly forbidden. Packing, particularly lead or copper, tends to get forced into the orifice causing a blockage; its subsequent extraction is attended by grave risk. Cylinders containing faulty valve joints, immovable valve spindles, or valve leakage shall be returned immediately to Stores with a note stating the cylinder number, nature of the fault and whether or not the cylinder is charged. Under no circumstances shall the user of the cylinder attempt any repair whatsoever. Only standard valve keys shall be used. Cylinder valves shall always be opened SLOWLY by gently tapping the key. Cylinder valves shall always be closed when the cylinders are empty or not in use. Keys with long leverage shall never be used to force a valve to close. If the valve leaks when closed, it is usually due to grit and this can often be removed by opening the valve slowly and closing it sharply. Only standard automatic pressure regulators and pressure gauges shall be fitted to both oxygen and acetylene cylinders when in use. The adjustable screw on the regulator must always be released before the cylinder is opened. The cylinder valve must be closed before the regulator is removed. Only high pressure blow-pipes shall be used with high pressure equipment. All blowpipes shall be dismantled and cleaned internally at regular intervals. Only the manufacturer's recommended tip cleaner, and not a hard metal reamer, shall be used for cleaning or altering the blowpipe tip, but accumulated slag shall be frequently removed during operation. The blowpipe tip shall NOT be dipped into the molten metal or otherwise blocked up. Blowpipes shall be connected to the oxygen and acetylene supply by stout canvas reinforced rubber hose firmly attached. Red hose being used for acetylene and other flammable gases, and the hose for oxygen coloured blue. Hoses must be examined periodically and damaged hose must NOT be used. The supply of both gases shall be shut off before changing the blowpipe or a cylinder Note New oxygen and acetylene hoses are frequently coated with French chalk during storage. Hoses shall be blown through with air before being connected to cylinders and blowpipes to prevent clogging of equipment.
6.4.2 VENTILATION DURING GAS WELDING The application of an oxy-acetylene flame to sheet metal coated with metallic lead, zinc, lead paints or other injurious substances may give rise to highly toxic vapours, particularly in cutting work where an excess of oxygen is required. For such work, a suitable breathing apparatus (NOT CANISTER RESPIRATOR) shall be worn. Doc. Number
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6.4.3 REPAIRS TO SMALL CONTAINERS These repairs include the welding, brazing, soldering or cutting of drums or containers (e.g. 40 gall. drums, petrol tanks of vehicles) which have contained petroleum products or other flammable or combustible materials. Before any work mentioned above is carried out, the drum or container, after removal of the filler caps and draining, shall be thoroughly steamed out or submerged in boiling water and kept at the boiling point for at least one hour. After the steaming or boiling process, compressed air (ensuring that the air has a free exit to prevent build-up of pressure) shall be blown through the drum or container until the vapours are removed. Before carrying out the work, the drum or containers must be certified "Gas Free" and the appropriate Naked Flame Permit completed. When burning or welding is in progress on a small vessel, unburnt gases can collect inside and an explosive mixture can be formed. Compressed air or steam shall be passed through the vessel, care being taken to ensure free and adequate exit for the air or steam. Compressed oxygen must NOT be used for purging. The following methods are considered inadequate in preparing vessels for repair purposes: · · ·
Washing out with hot or cold water or allowing water to run through. Purging with compressed air. Cleaning by means of solvents such as trichloroethylene (Genklene).
All vessels sent to the Workshops for repair shall be certified free of gas and corrosive chemicals with a Blue Label or carry a Red label warning of possible contamination. Further Information GOP4.1.
6.4.4 CYLINDER CARE Further Information Chapter 4.8 COMPRESSED GASES
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6.5 ELECTRIC ARC WELDING AND CUTTING 6.5.1 INJURIOUS EFFECTS OF ARC RADIATION The injurious effects of the radiation from a welding arc on the eyes and skin are similar whether direct or alternating current is employed. The effect of looking at an unscreened arc, even at a considerable distance and for a few seconds only, can cause a temporary eye injury that, however, does not become apparent until some four to eight hours later. It is therefore necessary for the welder and any helper to protect their eyes with the screens, goggles or spectacles provided. The work shall also be effectively screened from other workers nearby.
6.5.2 ELECTRICAL SUPPLY AND CONNECTIONS All welding sets, cables, connectors and terminations shall be maintained in good condition. Electrical supply and earthing connections to welding transformers and generator sets shall be made and maintained (and condemned where required) by the Electrical Section. Inspection of all trailing leads from machine to "work piece" shall be carried out regularly by the Fabrication Supervisor. All supplies for welding equipment shall be made with approved cables and approved plug boxes, and shall be controlled from a circuit that includes protection sensitive to earth fault currents. Where stationary transformers or generator sets are being used, a suitable switch shall be mounted adjacent to the equipment so that it can be isolated from supply.
6.5.3 WELDING LEADS Portable transformers or generator sets having trailing leads shall be provided with interlocked fused switch sockets and plugs, thus protecting both trailing cable and equipment. All welding leads and returns shall consist of flexible tough rubber covered cables connected where necessary by approved cable couplers. All leads shall be properly terminated, and lead cable couplers and terminations shall be of adequate current carrying capacity. To avoid long lengths of power cables, the machine shall be sited as close as possible to the power supply points
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A welding return lead shall be provided from the neutral terminal of each phase of an AC welding transformer or the negative terminal of a DC generator to the "work piece". This lead is required in addition to the earth bonding. The connections at the "work piece" shall be made by firmly bolting or clamping as near as possible to the point at which welding is to take place. Where more than one operator is working from the same welding machine, the polarity of each welding lead and welding return shall be the same. When two or more leads are being used in a confined area, the corresponding leads must be paired and, as far as possible, the crossing of pairs with one another or with any single lead shall be avoided. In instances where welding leads trail near tanks or sumps that may contain hydrocarbons, additional lengths of cable shall be added to the circuit to circumvent the danger area.
6.5.4 EARTHING AND BONDING For all AC welding transformers, the transformer low voltage winding shall NOT be earthed, but the transformer case shall be effectively bonded to an earthing system adjacent to the equipment. For all AC driven DC welding generators earth connectings shall be applied to either pole of the DC welding output. The machine frame shall be effectively bonded to earth. In both the above cases the "Work Piece" shall be bonded to earth by means of a heavy section conductor having suitable clamped or bolted connections. For engine driven DC welding generators earth connections shall NOT be applied to the generator output terminals. Under no circumstances shall pipeline or structures be used for earthing purposes. Before electric welding commences the Electrical Section shall ensure that adjacent cathodic protection systems are not affected.
6.5.5 STRAY CURRENTS In all cases where butt welding of two items (e.g. butt ends of pipe) is required and neither item is permanently attached to any structure, both items must be connected to the welding return. Bonding shall be effected by the use of mechanical clamps or securely attached clips. This requirement is necessary to prevent stray electric currents causing sparks at a distance from the welding point where there may be flammable atmospheres. Doc. Number
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6.5.6 ELECTRODE HOLDERS Electrode holders shall be provided with a handle of tough insulating non-ignitable material with a guard disc of similar material between the hand of the operator and the projecting line portion. An electrode holder when not in use, shall be placed on insulating supports.
6.5.7 ENGINE DRIVEN WELDING MACHINES Engine driven welding machines must not be refuelled whilst in operation. A Hot Work Permit must be in force where applicable (i.e. within Restricted Area).
6.6 PLASMA CUTTING SYSTEM 6.6.1 INTRODUCTION Plasma is a gas that has been heated to an extremely high temperature and ionized so that the gas becomes electrically conductive. The plasma cutting process uses this plasma to transfer an electric arc to the workpiece. The metal to be cut is melted by the heat of the arc and then blown away by a secondary gas.
6.6.2 ELECTRICAL SUPPLY AND CONNECTION To avoid over heating of the cables and the generator, the overload switch should be maintained properly to trip the generator. Special care should be taken to ensure that electrical cables and cooling hose are not damaged by constant movement. The plasma cutting nozzle can be susceptible to mechanical damage and should be protected or stored carefully when not in use.
6.6.3 SAFETY PRECAUTIONS Ventilation must be adequate to remove the smoke during cutting. Vapours of chlorinated solvents can form the toxic gas phosgene. All solvents, degreasers and potential sources of these vapours must be removed from the cutting area. Keep all fumes and gases away from breathing area. To avoid eye injuries use welding shield with number 10 lens or darker. Doc. Number
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Wear proper protective clothing. Install and maintain equipment according to National Electrical Code® 2005 Edition (NFPA 70). Proper grounding procedures must be adhered to when using plasma cutting equipment to avoid electrical shock. DO NOT contact electrically live parts. Replace any cracked or damaged insulating parts, including torch bodies and hoses. Turn off primary power before working on torch parts, including changing cups and tips. Remove combustibles from working area before start of the work and provide a fire watch. Operators and others in the near vicinity should use hearing protection. Plasma cutting produces 90 dB(A) when cutting 20 mm thick material. Further Information National Electrical Code® 2005 Edition (NFPA 70)
6.7 BLAST CLEANING AND PAINTING 6.7.1 DEFINITIONS BLAST CLEANING consists of particles of sand, powdered quartz, chilled-iron globules, emery or other hard granular material blown by a jet of compressed air, water or steam against a surface with the intention of removing scale, rust or old surface coatings before painting or coating. PAINTING as covered in this section consists of the application of a protective coating material using a spray by compressed air or hydraulic atomisation (airless), or using other more conventional methods of application such as brushes, rollers, sponges, etc.
6.7.2 RESPONSIBILITY Although blasting and painting requirements are generally undertaken by contractors, there may be occasions when these activities are undertaken by ADGAS staff. In either case the following responsibilities are applicable: ·
Personnel must be trained and qualified to undertake the required work. Doc. Number
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All required equipment must be safe and well maintained. Personnel must be aware of any specific safety requirements and information that may affect the working conditions or procedures. All work must be carried out under the Work Permit procedures. A Hot Work Permit is required for any blast cleaning operation. Because of the possibility of inhalation of dust and fumes, it is recommended that any personnel involved in blast cleaning and paint spraying are subject to regular lung function examinations. Before commencement of any grit blasting, the area shall be inspected by OD to ensure permit compliance. Daily inspections and permit revalidation are also required. Further Information PMED SI H-10 - 01, Dry Grit Blasting on LNG Plant.
6.7.3 WORK AREA PROTECTION All necessary protection of the work area shall be provided to ensure the work can be performed in a safe manner, to both personnel and installed equipment. Warning signs indicating that blast cleaning or painting is being carried out in a specific area shall be provided in conspicuous places on the periphery of that area. Markers, ropes or barricades shall be erected to prevent easy access to the work area by unauthorised personnel. Protective materials such as tarpaulins, plastic sheeting, etc., shall be provided around the work area to provide protection to personnel and equipment outside the work area, and to retain grit within the screened area. Protective coverings or masking shall be provided to protect instruments, instruments lines, gauges, valves, etc., which are not to be blasted or painted. These coverings will be so constructed, and be of the correct materials, to with stand the mechanical and chemical effects of blasting and painting. Tarpaulins, plastic sheets etc. must not come into contact with hot surfaces (steam pipes etc.) or potential hot surfaces. Electrical cables and air lines used in carrying out blasting and painting operations will be so protected that they will not be damaged by the work in hand or by work in other areas. Housekeeping is essential with blasting and painting areas, with excessive debris, spent abrasive and expended paint containers being removed as soon as reasonably practicable, with the site being thoroughly cleaned after each work period. Doc. Number
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6.7.4 PPE Due to the hazardous nature of blast cleaning and painting, the following additional personal protective equipment shall be provided and used when undertaking these activities. 6.7.4.1 BLAST CLEANING Personnel shall wear long trousers and long sleeved shirts, with a heavy duty protective coat or oversuit. Heavy duty leather gloves shall be worn, together with a protective hood that may be provided with air cooling facilities. Full face shields will be worn. Dust filter masks will be used when dry blasting is undertaken. Hearing protection of an approved type will be worn as necessary. 6.7.4.2 PAINTING Dust filter masks will be used during paint application by spray. Safety glasses or goggles of an approved type will be worn during all spray paint operations. Long sleeved shirts and long trousers will be worn during all paint operations.
6.7.5 EQUIPMENT SAFEGUARDS Static electricity can be generated in the hoses and nozzles of blast cleaning and spray painting equipment, especially in airless spray equipment. All discharge nozzles and hoses shall be properly earthed to minimise static electricity build up. Earthing shall be ensured by either using hose that is constructed to include an earthing conductor, or by the attachment of a properly earthed static cable to the nozzle or spray gun, and earthing the object being cleaned or sprayed. 6.7.5.1 DISPENSER REFILLING The method of containing, dispensing and refilling both blast cleaning abrasives and paint will vary dependent on manufacturer and type being used but the following precautions will generally apply:
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Ensure all pressure is vented slowly from any material container or supply hose before opening container. Do not re-apply pressure to the nozzle until it is manned. Do not overfill dispenser, and ensure that all covers/lids are properly secured and are air tight at operating pressures.
6.7.5.2 AIR COMPRESSORS Most blast cleaning and spray painting requires air to perform the desired work, and therefore the safety considerations are important. The air compressor shall be located as near as practicable to the work site, with adequate access for inspections, maintenance and refuelling. Compressors shall have a fire guard, with suitable equipment, positioned adjacent to them whilst running. Location of compressors shall not cause interference with other work areas, and shall not block or constrict access or escape routes. Trailer compressors shall have provision to prevent movement of the trailer during operation, i.e. wheel chocks, support stands, etc. Operation of the air compressors shall be strictly according to the manufacturer's instruction. Engine packages are to conform to Section 13 of this Chapter "Diesel Engine Units". 6.7.5.3 WET GRIT BLASTING In addition to the general precautions, given above, for dry blast cleaning, the following specific requirements apply to wet grit blasting: · · ·
Wet Grit Blasting equipment shall be so designed to ensure grit is mixed with water before leaving nozzle. Only inhibited water shall be used for wet grit blasting and any subsequent washing down operations. The wet grit blasting equipment shall include an automatic cut out, ensuring a fail safe condition if a pressure drop occurs in the inhibited water supply.
6.7.6 ENCLOSED SPACE WORKING Where practicable, at least two possible exits should be established from an enclosed space, each well marked and kept clear of obstructions at all times.
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Effective ventilation and exhaust of the space must be established before commencement of work, with gas tests having been carried out to verify suitability of enclosed atmosphere. In enclosures where the possibility of toxic or flammable gas releases exists, appropriate emergency escape breathing apparatus sets shall be provided. Evacuation plans must be prepared by the Contractor and approved by HSED prior to commencement of work. It is the responsibility of the Contractor to ensure that all equipment is maintained according to manufacturers instructions/accepted codes of practice. Where possible, maintenance shall be carried out off work site. All equipment must be cleaned immediately after use to ensure no blocking or clogging will occur. Compliance with the conditions of the Permit System is mandatory.
6.7.7 EQUIPMENT MAINTENANCE When using solvents and/or flammable liquids for cleaning purposes, utmost care must be taken that no sources of ignition exist nearby, that ventilation is adequate, that all flammable liquid containers are properly sealed and returned to suitable storage, and that used fluids are disposed of in a safe manner. Brushes, rollers, etc., are not to be left soaking in cleaning fluids.
6.8 PORTABLE TOOL IGNITION RISKS 6.8.1 INTRODUCTION Because of the portable nature of hand and smaller power tools, some of which are ignition sources and capable of igniting hydrocarbons gases, strict controls on their use in the plant is necessary. As a general rule the common electric hand tools in general use are not permitted in classified hazard areas. Air powered tools are the intrinsically safe alternative and should be used wherever practicable.
6.8.2 ELECTRIC POWER TOOLS Electric power tools may be used in the plant in non-hazard areas or in special cases under a hot work permit when no safe alternative exists.
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There is an added and inherent risk in the deteriorating condition of these tools through use, abuse or lack of maintenance. All electric powered hand tools and extension leads used in the plant must be inspected initially and thereafter at specified frequency by an authorised person. Tools that are suspected of being defective in any way must not be used until the defect has been corrected and the tool is reissued as safe. A defective tool must be tagged with the standard out of service tag and delivered immediately to the electrical repair workshop for attention. It is the responsibility of the user to make frequent inspections of electrical tools and to return suspect tools for test and repair after tagging them out of service. Additional temporary or local electric systems must be installed under the Permit System and with the authority and supervision of the Electrical Section. No connection may be made to any electrical power until the equipment is inspected and approved by the Electrical Section. When an electrical supply is no longer required, the user will inform the Electrical Section. Disconnection can then be made and the covering work permit signed off where applicable. All electrical tools and portable equipment must have screened supply cables. Flexible electric supply cables (wandering leads) must not pass through a classified gas hazard area. In any instance when determining the ignition risk area of electric tools for permit purposes, the length of the supply cable back to the supply outlet must be included. Full length continuous cable from outlet to tool is a safety requirement. Note All power tools used in confined spaces are required to be fitted with 'dead man' on/off switches.
6.8.3 PNEUMATIC POWER TOOLS Hand operated power tools should whenever possible be air driven. Where appropriate air driven tools are unobtainable, the use of portable electric hand tools may be permitted, providing that these comply with hazardous areas regulations under the hot work permit system. Only air driven power tools of an approved type may be used in gas hazard areas as a general rule.
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Note A pneumatic tool may be classified as an ignition source by virtue of its application that may result in spark generation or static electricity, e.g. needle guns. Air driven power tools may only be used after all the required permits to carry out the work are duly authorised. Compressed air driven lamps of an approved type and associated with other work may be used within classified hazardous areas. The voltage generated by such lamps shall not be higher than 24 volts.
6.8.4 REDUCED SPARKING TOOLS The use of special 'non-sparking' tools is not recommended for use in the plant. If used, with no alternative, their condition should be checked and the user made aware that they are not a complete safeguard against ignition and represent risks to the user. Non, or reduced-sparking hand tools, normally non-ferrous in design, suffer from a number of deficiencies: · · ·
They can produce sparks even when in first class condition. As they are made of softer materials, particles of steel and other materials can become imbedded in them and in this condition can produce higher energy sparks than the normal steel tools. Because of their poor mechanical properties they have contributed to hazards of a different kind, e.g. personal injury.
6.8.5 STEEL HAND TOOLS There is ample evidence to show that the impact of steel on steel while using hand tools will not produce sparks of sufficient energy to ignite hydrocarbon/air mixtures under normal conditions. However, ignition is possible in hydrogen/air mixtures and in atmospheres of enriched oxygen. However, intrinsically safe power driven tools (e.g. grinders or drills) may produce high energy sparks which are capable of igniting gas/air mixtures. The impact of steel tools on rust or finely divided metal such as aluminium, can produce incendiary sparks. Therefore, where sparking could present a hazard, the effects of accidental impacts such as dropping tools should be avoided and restraining lanyards may be effective. Safety in this regard may be enhanced by covering areas of equipment with soft impact absorbing material around and below the job. Doc. Number
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6.9 STATIC ELECTRICITY 6.9.1 INTRODUCTION Static electricity is one of the most difficult ignition hazards to control. There are few operations in which it is not present to some degree and it is more serious when humidity is low. Static electricity is generated in several ways; by friction, by making and breaking of physical contact between two masses and by the passage of solids, liquids or gases at high velocity through pipework or apertures. The control of static electricity charges in electrically conductive materials is made easier by providing the correct grounding and ensuring that bonding procedures are followed. Control of this problem on non-conductors such as plastic pipe, requires special procedures as the object cannot be grounded in the normal manner. More obvious hot work such as welding is covered as a matter of course under the hot work permit system and receives the full impact of the precautionary measures designed to prevent ignition. Ignition caused by procedures normally considered safe, as in sampling and decanting, needs special attention due to the possibility of static discharge. The rate of static charge generation in fluid flow is relative to: · · · ·
Rate of flow (velocity). Conductivity of the two materials. Amount of turbulence and splashing. Surface area of the interface.
The presence of impurities in material flows, such as water droplets or solids, also greatly increases the rate of static electricity generation. Equipment must always be grounded to prevent static charge build-up, therefore dipping tanks immediately after transfer is not recommended.
6.9.2 ABRASIVE BLASTING Abrasive blasting generates high static charges. Sparks jump from the hose to ground and for this reason the hose should always be grounded. Nozzles must be bonded to the work piece or via the hose to the process structure. Nozzle and hose electrical continuity must be checked before use and verified at regular, frequent intervals. Wet blasting using the addition of water to the abrasive blast effectively 'grounds' the equipment continuously due to the electrically conductive properties of water.
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6.9.3 SPRAY PAINTING The high velocity of material through the spray nozzle can generate static charge. The spray hose must contain an integral earthing wire connecting gun and pressure source, which is in turn earthed to the structure. A spark at an otherwise unprotected paint gun could cause the atomising paint mixture to ignite. Electrical continuity tests of these components must be checked before start-up and at regular intervals.
6.9.4 ENGINE REFUELLING Portable diesel powered equipment is fuelled by extension type hoses. The flash point of diesel fuel is normally above the range of temperatures conducive to spark ignition, but unusual conditions such as heating or contamination may create an ignition risk. The full sequence for earthing and other precautions must therefore be followed in all refuelling operations within the plant hazardous areas.
6.9.5 MECHANICAL SOURCES Flexible transmission drive belts have been identified as a source of static electricity. Although not in wide use in gas hazard areas the general precautions in practice include the fitting of anti-static type belts where possible to reduce this hazard. Although not relative to static charge hazards, the effect of slipping drive belts is to generate heat and even start fires if correct belt tension and condition are not regularly maintained.
6.9.6 NEEDLE GUNS AND DESCALING These operations are treated in a similar way to abrasive blasting due to the close similarity of their risks and precautions. Only phosphor bronze needles are approved for work on the plant. In critical gas hazard areas needle guns may have to be converted to hand scraping as a means of eliminating the ignition risk. Additional to recommended minimum safety wear requirements the use of approved hearing and eye protection is mandatory in these job operations.
6.9.7 STATIC ELECTRICITY ON PERSONNEL The volume resistivity of the human body is low enough for it to act as a conductor. If a person insulated from earth becomes charged, he can give rise to sparks that may be of sufficient energy to ignite a flammable gas-air mixture or to cause electric shocks to himself or others.
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The person may be insulated because he is standing on an insulating floor or is wearing insulating footwear. The person's body can be charged by contact electrification, induction or charge sharing. Examples of charge generating mechanism include: · · ·
Walking on an insulating floor, for example a carpet made of high resistivity material, or polyurethane foam insulation used in annular space of propane/butane tanks. Removal of an outer garment, especially if manufactured from low conductivity synthetic material. Pouring of a liquid or a powder from a container held by a person.
A fire hazard is created when the charge is retained in the presence of a flammable gasair mixture. In such situations the precautions set out below must be taken. A conductive path must be provided by the person and earth. This can be most easily achieved by the use of conductive footwear and/or the provision of conductive flooring. Leather-soled footwear is usually sufficiently conductive although it may fail under very dry conditions. Alternatively, anti-static footwear should be worn, but it should be appreciated that these could be ineffective if the wearer were walking on a low conductivity material such as polyurethane foam used as insulation. Under normal circumstances earth, sand, concrete or tarmac surfaces are sufficiently conductive to dissipate charge from personnel, although this may not be the case under very dry conditions. Caution In general, although man-made fibres are more prone to static charging effects, clothing made from any material can be worn provided that the wearer is earthed as described above. However, clothing or any material must not be removed in an area where a flammable gas-air mixture is present, since the action can create sparks. Further Information IP Model Code of Practice, Part 1 Electrical Safety Code 7th edition, August 2003. Loss Prevention in the process Industries, F. Lees.
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6.10 PORTABLE GAS DETECTORS 6.10.1 INTRODUCTION While the operation of a portable gas detector is not usually defined as hot work, the use of these instruments is inseparable from the safe conduct of any kind of hot work or naked flame in the plant. Prior testing and monitoring for explosive atmospheres is accepted as normal mandatory action where major ignition source jobs such as welding are undertaken in hazardous areas. Work operations involving the potential for a random spark, may be overlooked as being of minor risk, but do however, require the full use of gas testing and monitoring procedures. Gas testing for hot or naked flame work, vessel entry and other critical operations may only be performed by trained and authorised personnel (Authorised Gas Testers). Authorised Gas Tester personnel are authorised by the Operations Manager after successful completion of a two part gas detector training course conducted the OD and the HSED.
6.10.2 WHEN TO TEST A gas test must be performed before commencing any hot or naked flame or confined space entry work and periodically or continuously during any potential spark or flame producing operation.
6.10.3 TEST RESULT CRITERIA When gas tests are conducted to conform to permit requirements, only zero readings for toxic and flammable gases and 20% for oxygen will be acceptable. Further Information OD SI W-12, Minimum O2 level for entry
6.10.4 USING GAS DETECTORS 6.10.4.1 OPERATING PROCEDURES Understand how the unit works, its use and limitations Ensure that the unit has been calibrated within the specified service period by referencing the attached calibration label. Ensure that equipment is in sound mechanical condition and check the calibration of the unit before use or when its accuracy is in doubt.
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If an extension tube is to be used, allow enough time for the mixture to reach the cell. Begin aspirating as the mixture to be tested is approached, not after the probe or tester is inserted in the mixture. Observe the meter and alarm at all times. Ensure that check valves are in place on the inlet and outlet of the bulb in the correct flow direction on manually aspirated models, or sample gas may not reach the cell. 6.10.4.2 UNSAFE AND IMPROPER PROCEDURES: · · · · · ·
Contamination or damage to the cell caused by immersing the probe or detector in liquids. Dropping or knocking the instrument Using for prolonged periods in high gas concentrations, as the filament may be damaged or burnt out. Forcing the mixture through the detector. The sample must be at atmospheric pressure and aspirated (drawn) through the detector. Using with raw oxygen, acetylene or hydrogen, as the instrument may ignite the gas. Reliance on the gas detector to measure the exact percentage of gas present, i.e. if flammable gas is present, hot work and naked flame is not permitted in the area.
6.10.5 WORK EXAMPLES Examples of work involving the potential for sparking include: · · ·
Opening electrical junction boxes. Using equipment that is not intrinsically safe (Non-IS) for use in gas atmospheres. Using impact type tools.
A gas test of the immediate area of the worksite must be performed. Particular attention must be paid to flanges, seals, vents, high and low points, valve packings and areas where pockets of gas may collect. Examples of work generating spark or flame include: · · ·
Welding. Grinding. Heating or oxy-acetylene cutting. Further Information Full details of the requirements for gas testing are contained in the OD Work Permit Manual.
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6.10.6 EXPLOSIVE LIMITS FOR PLANT GASES GAS
LEL
UEL
Methane
5.3
13.3
Ethane
3.2
12.5
Propane
2.3
7.3
Butane
1.8
8.4
Hydrogen Sulphide
4.3
46.0
Pentane
1.4
7.8
Table 6-1: UEL/LEL of Plant Gases Note A reading of 2% LEL on the gas detector dial in an atmosphere of pentane indicates that the actual concentration in the area is 2% of 1.4 = 0.028%
6.10.7 CURRENT DETECTORS The following equipment is available for use on the LNG facility:Crowcon Triple, Type 84 TR. Suitable for measurement of gases in AIR mixtures only. Can be used to detect flammable, toxic and oxygen concentrations in air. Refer to Para 6.10.8 Seiger 1601 (Dalek) Suitable for measurement of concentrations of hydrocarbon gases in AIR mixtures only. Is used as a continuous gas monitor in association with "Hot Work" and "Naked Flame" work. Refer to Para 6.10.9 Draeger Gas Detector Suitable for measurement of gases in AIR mixtures only. Can be used for spot checks where approximate quantities are acceptable. Refer to Para 6.10.10
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MSA "Tankscope" Suitable for measurement of gases in inert, (Nitrogen), atmospheres. Can be used to detect hydrocarbons in vessels or pipelines purged with N2 Refer to Para 6.10.11 The Delmar Lead Acetate Cassette This is a cassette measuring device for individual assessment of H2S levels. Refer to Para 6.10.12 OLDHAM (BM 22 Plus Beacon) It can be used to detect the presence of four gases simultaneously in the air by means of measuring all specific to each of the gases to be detected. These can be explosive or toxic gases or oxygen. Refer to Para 6.10.13
6.10.8 "CROWCON" TRIPLE, TYPE 84 TR PORTABLE GAS DETECTOR 6.10.8.1 INTRODUCTION The Triple 84 TR is a free standing, self powered, portable gas detector for hydrocarbons, hydrogen sulphide and oxygen. The sensors used are pellistors for flammable gases and electrochemical cells for H2S and O2 All alarms are indicated by a penetrating audible alarm and flashing lamps. Alarms are set at 20% LEL for flammables, 10 ppm for H2S, 19% for O2 deficiency and 24% for O2 enrichment. The unit is powered by a detachable nickel cadmium battery pack. Batteries can either be charged in situ via the charging socket under the door on the top of the instrument, or they can be charged separately from the instrument. CAUTION: The Crowcon Triple flammable sensor is calibrated specifically for methane, and although it will respond to nearly all other flammable gases, it may give higher or lower readings with these other gases. 6.10.8.2 LIMITATIONS OF USE This unit will not detect the presence of flammable gases in inert atmospheres, or of combustible mists such as lubricating oil. Doc. Number
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The instrument may be unsafe in atmospheres enriched with pure oxygen and is unsuitable for use in hydrogen measurement. It is recommended that batteries are kept on charge when not in use. 6.10.8.3 CHARGING THE BATTERY When the mains lead is plugged into a line socket and the battery lead plugged into the instrument, the red lamp on the charger will glow. The instrument must be switched "Off" to enable the battery to be charged. If the red lamp on the battery charger does not glow, the unit is not charging and charger and instrument must be returned to PMED, (Instruments), for examination. A completely flat battery will take approximately 16 hours to charge. Partially discharged batteries will require re-charging for a period of time equating to the period of time for which the instrument has been used. (i.e. 2 hours usage would require 2 hours of recharging). 6.10.8.4 OPERATING THE INSTRUMENT Check calibration is in-date. Check that aspirator and associated hose are in good condition. Turn operating switch to "Test". The audible alarm will sound, the three red lights will flash rapidly and the green light will flash at 10 second intervals. The digital read-out should indicate around "50". If the read-out indicates less than "40" the battery should be re-charged or changed for a fully charged one. Turn operating switch clockwise to next position, (EXP). It is now possible to silence the alarms by pressing the "Reset" button. The instrument is now operational. Every 10 seconds the instrument will emit an audible click and the green lamp will flash; this indicates that all circuitry is functioning normally. Allow instrument to operate in fresh air for approximately 1 minute to purge the detecting chambers When utilising the extension hose ensure that hose tip is not inserted into liquid residues. To measure gas concentrations turn selector switch to required position, e.g. EXP, (Flammable gas), TOX, (H2S) or Ox (O2). Digital read-out will indicate percentage of LEL when switch is in "EXP" position.
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Digital read-out will indicate PPM when switch is in "TOX" position. Digital read-out will indicate percentage of oxygen present when switch is in "Ox" position. When alternating modes, i.e. when changing from sampling flammable gases to sampling toxic gas, it will be necessary to allow the instrument to purge for approximately 1 minute in fresh air prior to the change. Prior to returning the unit to storage/recharging, allow it to purge in fresh air for at least 1 minute before switching off. 6.10.8.5 FLAT BATTERY ALARM If, whilst the unit is in use, the battery voltage falls below the operating requirement, an audible warning will be sounded. This is a steady continuous note quite distinct from the warbling alarm note. At the same time the intermittent audible click and flashing green light, indicating normal operation, will cease.
6.10.9 SIEGER 1601 PORTABLE HYDROCARBON CONTINUOUS GAS MONITOR ('DALEK' TYPE) 6.10.9.1 INTRODUCTION In order to be of any use, a monitor must be placed up-wind of the persons or equipment to be protected and is only as good as the person watching it for signals. Although it has an audible alarm, this may not be heard on the LNG Plant due to the high noise levels. 6.10.9.2 SIGNALS The Sieger 1601 ('Dalek' type) is capable of giving two distinct Audio/Visual signals as follows:Intermittent 'Bleeper' Note and Flashing Light This is the gas alarm signal indicating that gas is present at or above 25% of the lower explosive limit of the gas picked up by the sensor. The exact percentage will be shown on the scale. ACTION; Immediately stop all Naked Flame and Hot-Work in area Evacuate persons in immediate vicinity Use breathing apparatus if necessary Inform Central Control Building as soon as possible Operations personnel should endeavour to stop leak. Doc. Number
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Constant Note With Light On (but Not Flashing) This is the low battery charge signal ACTION Switch the instrument off and obtain a replacement. Naked Flame-Work or Hot-Work on a permit requiring a gas monitor should be discontinued until a replacement is in operation. 6.10.9.3 BATTERY CHANGING Battery changing is carried out by the Electrical Section. A 12-hour or a 24-hour battery may be fitted. 6.10.9.4 ADDITIONAL FACILITY The Sieger 1601 may be used with the sensor attached to the instrument or placed on a 60-foot extended lead when required Appendix 6-10-2
6.10.10
"DRAEGER" GAS DETECTOR
6.10.10.1
INTRODUCTION
The Draeger Gas Detector is a standard volume bellows pump (100cc) into which a detector tube is tightly fitted. These tubes are sealed until required when both ends are broken off before insertion in the pump. Tubes are available for specific toxic gases and are reasonably accurate. Aspirate only the number of times stated on the tube packet and interpret the results as directed. 6.10.10.2
OPERATING INSTRUCTIONS
Test the pump before use by compressing fully and sealing the inlet. The pump should not expand. Ensure correct tubes are selected for specific gas. Ensure that the tube is fitted the right way, with the arrow pointing towards the pump. The chain must be fully extended between aspirations. Replacement tubes are supplied by the Chief Chemist.
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MSA "TANKSCOPE"
6.10.11.1
GENERAL DESCRIPTION
Issue 02, Rev 05 Date: August 2006 Chapter No. 06
The MSA Tankscope is intended primarily for the measurement of hydrocarbon gas concentrations in vessels or lines which contain inert gas The instrument is scaled 0-20% gas and the standard calibration gas mixtures are composed of butane in inert gas. The inert gas used for calibration purposes is a mixture containing 85% vol. nitrogen and 15% vol. carbon dioxide. The MSA Tankscope determines hydrocarbon concentrations by measuring the rate of heat loss from a heated filament to the surrounding gas mixture. The rate of heat loss depends on the heat transport characteristics of the gas mixture. Given a relatively constant quality of background gas, the heat transport characteristics of the mixture depend on the hydrocarbon concentration. The gas sample is drawn through the instrument by means of a rubber aspirator bulb fitted with double acting check valves. Measurement of hydrocarbon gas concentrations is made over the full range of the instrument without dilution of the sample. Two identical heated filaments are employed in a Wheatstone bridge measuring circuit in the MSA Tankscope. Initially both filaments are exposed to air that is free from hydrocarbons and the instrument circuit is balanced, i.e. zeroed. One filament is then exposed to the gas sample which causes a change of balance between the filaments. The out-of-balance change in the Wheatstone bridge is indicated as a gas concentration The dual filament arrangement has the advantage of providing a fully balanced bridge, thus compensating for battery voltage drift. Separate controls are provided for adjusting circuit voltage and zero. Experimental investigations have shown that the heat transport properties of inert gas and air are virtually identical. This fact allows the MSA Tankscope to be zeroed on air and used to measure hydrocarbon gas concentrations in inert gas. If a MSA Tankscope should be re-calibrated for other gaseous mixtures, the heat transport properties of air and the background gas may not coincide. In this case it would be necessary to zero the instrument using the appropriate background gas. 6.10.11.2
LIMITATION OF USE
The MSA Tankscope is limited to measuring gas concentrations in mixtures for which the instrument has been calibrated and which remain gaseous at the temperature of the instrument. Doc. Number
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Any atmosphere that is at a temperature substantially higher than that of the MSA Tankscope may contain components that will condense in the instrument. In such a situation the instrument reading would not provide an accurate measurement of the original gas sample. The sampling lines and the MSA Tankscope could be heated to prevent condensation, but in no circumstances should they be heated to a temperature more than 65°C. The MSA Tankscope will not detect the presence of liquid mists, such as the lubricating oil mists which are present in gear boxes and engine crankcases. 6.10.11.3
OPERATING INSTRUCTIONS
The measuring circuit is a balanced Wheatstone bridge. Three major steps must be taken before samples are drawn into the instrument for analysis: · · ·
The detector chamber must be swept free of hydrocarbon gases and filled with inert gas or air. Batteries must be turned ON, and the proper voltage applied to the bridge. The bridge must be balanced to zero deflection on the meter with inert gas or fresh air in the open chamber. Note The MSA Tankscope is sensitive to tilt. It is important therefore that the instrument should be kept in a normal upright position at all times during its operation. Failure to observe this precaution may lead to significant errors in instrument readings.
The following steps must be followed carefully for proper results: · ·
Check calibration, etc. Attach the sampling line to the inlet of the instrument and the aspirator bulb to the outlet. Check the air tightness of the system by pinching a bight on the sampling line and squeezing the aspirator bulb. The aspirator bulb should not expand as long as the sampling line is pinched. If the bulb expands, re-check the connections and the non-return valves on the aspirator bulb.
Place sample line in fresh air. Turn selector switch to "Check". This places the meter across the active filament where it will indicate the voltage across the filament. Pull straight up on the switch. This operation closes the battery circuit and the meter pointer will now be seen to move on the scale towards the "Check" point.
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The air is drawn through the Tankscope by alternately squeezing the rubber aspirator bulb and allowing it to expand completely. Eight to ten squeezes of the aspirator bulb are sufficient to flush the chamber. If a sampling line is used, approximately two additional squeezes will be required for each 3 m of line. Adjust the meter pointer to "Check". To accomplish this turn the volt adjust knob in the direction the meter pointer must move to come to "Check". This establishes the proper operating voltage to the bridge. Turn the Selector switch to "Gas". Adjust the meter pointer to "Zero". For ordinary usage the MSA Tankscope will be fitted with a sampling line attached to the inlet connection. Place the end of the sampling line at the point where the sample is to be taken, ensuring that the sample line is not in any liquid. Aspirate the sample through the instrument. The aspirator bulb should be operated until the meter pointer comes to rest on the scale (with a 1.5m sampling line and probe, the meter pointer should rise on the scale within fifteen squeezes of the bulb. If it does not move in this time, the sample may be considered gas free). Stop aspiration and note final reading attained. It is important that the reading should be taken with zero flow through the instrument and with the gas at normal atmospheric pressure. During aspiration the needle will come to a steady reading. When aspiration stops, the reading will change by a small amount. In general the reading will decrease slightly but in some instruments a slight increase may be observed. The "No-flow" reading is correct. Relatively small deviation from normal atmospheric pressure in the instrument produces significant differences in the indicated gas concentration. If a space which is under elevated or reduced pressure is sampled, it is important to detach the sampling line from the MSA Tankscope when aspiration is stopped. This allows the instrument to attain atmospheric pressure before the reading is noted. After each reading flush the sampling line and instrument with fresh air.
6.10.12
DELMAR MINI-CHECK H2S DETECTOR
6.10.12.1
OPERATION
Turn winding knob counter clockwise, as the arrows indicate, to expose a fresh, unexposed portion of the chemically impregnated tape at the exposure port.
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Breathe several times into the exposure port to slightly moisten the tape. Never place even a drop of water directly on the tape, as wet tape will break very easily. Place Mini-Check in area, so that exposure port is exposed to the atmosphere to be checked for H2S. Avoid moving air streams, as they will likely cause a higher reading than the actual H2S level of the atmosphere. After approximately three minutes, compare the tape colour at the exposure port to the colour standards to determine the approximate H2S level. To conserve the tape, do not rotate the knob until you are ready to take another reading. The unique design of the Min-Check does permit a comparison of several successive readings. After approximately 1000 uses, the chemically impregnated tape can be replaced with a fresh roll. Also, should the tape break (probably due to excessive moisture on the tape), it can be repaired. To replace or repair the tape, remove the two screws and the mini-check top cover. This will expose the tape so that a piece of scotch tape can be used for repair of for replacement with a fresh roll. Note Always wash hands after handling the chemically impregnated tape.
6.10.13
OLDHAM (BM 22 PLUS BEACON)
6.10.13.1
INTRODUCTION
The BM22 plus Beacon is a portable gas detector. It can be used to detect the presence of four gases simultaneously in the air by means of measuring cells specific to each of the gases to be detected. These can be explosive or toxic gases or oxygen. The BM 22 PLUS must be placed in the vertical position with the battery unit as the base. Depending on the " of gas to be detected or which may be present, the appliance must be placed: On the ground, for the detection of heavy gases (H2S, CO), At mid height (about 1 metre above the ground) or at the outlet of a ventilation port for the general detection of a maximum number of gases or for oxygen monitoring). The gas content measured by each of the cells in service can be viewed on the alphanumeric display panel. This display panel is divided into four separate areas
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(quadrants), each one corresponding to a specific cell or channel. A maximum of four measurements can be displayed simultaneously. Example: The values representing the concentration of methane gas (0% LEL CH4), of CO (10 ppm CO), of NO2 (0.0 ppm N02) and oxygen (20.9% O2) are clearly displayed. 0 LEL 0.0 ppm
10 ppm 20.9
0 CH4 0.0 NO2
10 CO 20.9 O2
Example of alternating display (measurement - -type of gas) illustrating the sequence of data displayed after reading. 6.10.13.2
STARTING UP
When the appliance is started up, you have the choice between the following three procedures: 1. 2. 3.
The standard procedure adopted in most cases, A procedure allowing the reference explosive gas to be selected, which is useful when checking for a specific gas (town -as. methane, etc.) A procedure known as "auto-adjustment" which allows the automatic adjustment of the zero of explosimetric cells or toxic gas metering cells as well as the setting of the oxygen cell to 20.9%. This procedure must be regularly carried out.
6.10.13.3
SHUTTING DOWN
The appliance is shut down by holding down the "ON/OFF" key for three seconds 6.10.13.4
LIGHTING OF DISPLAY PANEL
It can be made easier to read measurements in dimly lit conditions by pressing the "Lighting" key. This operates a back-lighting device which lights up the data on the display panel. This lighting is automatically stitched off after 15 seconds The lighting section can be used in hazardous environments, i.e. environments containing explosive gases: the BM 22 PLUS beacon complies with intrinsic safety requirements,
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SCROLLING THROUGH PARAMETERS STORED IN MEMORY
During normal operation of the appliance, you can consult data sequences regarding, on the one hand, gas measurements and, on the other hand, specific data internal to the appliance (battery voltage, date and time). These displays are selected by pressing the "Up" arrow key the required number of times the data memorized by the appliance are then displayed. Starting from the display of instantaneous measurements and in maximum configuration, the data displayed concerns: 6.10.13.6
ALARMS
The alarms given are of the visual type (indicator lights and display panel) and the audio type GAS ALARMS Depending on the programming and the type of gas “Gas alarms’’ may be triggered when the following values are exceeded : · · · · ·
Instantaneous (on all four channels) Minimum (applicable on the Oxygen metering channel only) Maximum (on all four channels) Short Term Exposure Limit (STEL) corresponding to a sliding mean over 15 minites on each channel equipped with a toxic gas metering cell Time limit Value (TLV) corresponding to a sliding mean over 8 hours on each channel equipped with a toxic gas metering cell.
LEL ALARM (explosimetric) Proceed with caution (presence of explosive gases) Press ‘’ENTER’’ in order to: Try to acknowledge the audio alarm (Acknowledgement is possible if the measurement is less then 10% LEL) and reactivate the display OXYGEN ALARM The oxygen measurement must be between the two oxygen thresholds: excess oxygen and insufficient oxygen. The alarm is triggered as soon as the measurement fails to fall within the ‘’High alarm/Low alarm’’ window Leave the area as quickly as possible. Excessive oxygen content and insufficient oxygen content are both hazardous. Press ‘’ENTER’’ to acknowledge the audio alarm and reactivate the display. Doc. Number
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TOXIC GAS ALARM A ‘’toxic gas’’ alarm can be triggered by three types of measurement. · · ·
Measurement exceeding the maximum authorized instantaneous value Measurement exceeding the authorized Time Limit Value (TLV) Measurement exceeding the authorized Short Term Exposure Limit ‘’ALARM’’ when the permitted maximum instantaneous value has been exceeded. The measurement is frozen so that the user can read off the maximum value recorded.
FAULT ALARMS Faults Alarms can be divided into two groups: 1 Faults regarding cells (outside range, worn cell, request for calibration on occurrence of major deviation during auto-adjustment): these faults lead to the generation of individual messages displayed on the relevant quadrant of the display panel and the triggering of a cyclic visual and audio alarm. 2 Fault regarding the appliance itself (Flat batteries or electronic fault): The corresponding fault message appears on the display panel. This message takes priority over all other messages concerning the cells ACKNOWLEDGING ALARMS Gas Alarm This does not cancel the gas alarm but only the rapid audio signal. When the tactile ‘’ENTER/Buzzer’’ area has been pressed. The rapid audio alarm is deactivated but the corresponding alarm indicator light continues to flash until the measurement falls to bellow the programmed alarm threshold. As soon as the measurement on the relevant channel returns to within the limits defined by the alarm thresholds . This is applicable for instantaneous alarms as well as for mean exposure values (TLV) or limit exposure values (STEL) . Fault alarms This happens automatically as soon as the measurement on the relevant channel returns to within the limits defined by the alarm thresholds. This is applicable for instantaneous alarms as well as for mean exposure values (TLV) or limit exposure values (STEL). Further Information OLDHAM (BM 22 PLUS BEACON) Operating and Maintenance Manual.
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INTRINSICALLY SAFE EQUIPMENT
INTRODUCTION The term 'Intrinsically Safe' (IS) as used in the petroleum industry generally refers to tools, instruments or equipment which due to the design and use, are incapable of generating heat, sparks or flame sufficient to ignite any of the flammable or explosive atmospheres likely to be encountered on hydrocarbon facilities. In electrical terms 'Intrinsically Safe' refers to a circuit under test conditions in which any spark or thermal condition (in both normal and fault conditions) is incapable of igniting a specific explosive atmosphere. 'Non Intrinsically Safe' (Non-IS) is the term used when the possibility for ignition exists, either in the design or in the operation of the unit. Further Information BS EN 50020, 2002: Electrical apparatus for potentially explosive atmospheres. Intrinsic safety 'i' RESTRICTED ITEMS Many of the common portable items such as hand torches, telephones, pagers and electrical or electronic instruments and larger moveable equipment are in the restricted range due to their potential as ignition sources. Whenever possible, the use of Non-IS equipment is to be avoided. The recommended course of action, assuming their intended use in the plant is essential, is to select the intrinsically safe model, of which there are many available. Failing this, the equipment and operating procedures must be introduced under the full control of the Permit System for Non-IS equipment in the plant. Restricted items include: · · · · · · · · · · ·
Cameras with batteries. Flash guns and non-approved lighting. Temporary electrical power distribution systems. Portable electric power tools. Non -approved radios and transceivers. Portable telephones. Pagers. Soldering and heat guns. Electrical stress-relieving or preheating equipment associated with welding. Electrode hot boxes Electronic measuring devices. Doc. Number
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Calculators. Computers. All other under the Non-IS definition.
EXEMPTIONS All items put forward for exemption must have the appropriate gas rating nameplate attached and be subject to the electrical inspection and maintenance procedures as outlined in this manual. Further Information Chapter 6.8 PORTABLE TOOL IGNITION RISKS 6.10.13.8
PRE AND POST HEATING EQUIPMENT
INTRODUCTION As a concurrent operation with some of the more major welding jobs, the use of electric heating coils creates a longer term ignition hazard due to the considerable time duration of these operations. Hazards include the potential for sparking and the elevated surface temperatures of the coils being sufficient to initiate fire or explosion. SAFETY PROCEDURES Operating safety procedures include: · · · · · ·
Power supply located in a safe area. Control panels are located away from potential gas hazard areas. Continuous surveillance and gas monitoring by qualified personnel whilst power is on and until all surface temperatures have fallen below 200°C in the cooling cycle. Heating coils to be clear of all flammable and combustible materials. The total area including the power supply, controls, cabling and worksite be a designated Hot Work area for work permit purposes. The Hot Work Permit System procedures to be applied in full as appropriate to the area of operations.
6.10.13.9
DIESEL ENGINE UNITS
INTRODUCTION The use of diesel engines in Zone 2 Hazardous Areas is to be avoided as far as possible. This section outlines the general design requirements for the protection of permanently installed diesel engines and diesel engines driving mobile equipment when their use in Zone 2 Hazardous Areas is unavoidable.
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These requirements have been drawn up primarily for naturally aspirated, water cooled, diesel fuelled, compression ignition engines. They shall also apply to turbo charged, super charged, air cooled or dual fuelled compression ignition engines, unless other wise specified by ADGAS, although it should be noted that such engines have relatively higher exhaust and surface temperatures and compliance with this section will be more onerous. Spark ignition engines are specifically excluded. GENERAL The requirements outlined in this section are generally according to OCMA publication No.MEC-1 1977. Also refer to GS 134-8 REQUIREMENTS FOR THE PROTECTION OF DIESEL ENGINES OPERATING IN ZONE 2 HAZARDOUS AREAS Where reference is made to approved equipment or to a test by a responsible authority, this refers to acceptance or test by ADMA-OPCO Municipal Maintenance Department, Transport Section. The contractor or main equipment supplier shall be responsible for the design, and provide evidence of the satisfactory functioning, of all the equipment fitted to the diesel engine. In particular, he shall be responsible for ensuring that all protection equipment is correctly sized and installed and carries the correct certification as required herein. Further Information OCMA No.MEC-1 1977. GS 134-8 REQUIREMENTS FOR THE PROTECTION OF DIESEL ENGINES OPERATING IN ZONE 2 HAZARDOUS AREAS PRIMARY IGNITION HAZARDS These ignition hazards can exist when the engine is started or running normally: · · · · · ·
Engine surface and exhaust gas temperatures. Discharge of sparks from exhaust system. Overspeeding of engine. Discharging of sparks from electrical equipment. Static electricity discharge. Flame transmission through decompression ports.
SECONDARY IGNITION HAZARDS Additional ignition hazards that may be expected to occur as a result of engine malfunction or equipment failure are: Doc. Number
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Explosion in crank-case. Reverse running of the engine.
PRIMARY HAZARD DESIGN REQUIREMENTS Excessive temperature. The temperature of the exhaust discharge gases and the exposed surface temperature of any part of a diesel engine operating in a hazardous area, including exhaust piping and manifold, shall in no circumstances exceed 250°C when providing the maximum power requirements imposed by the driven equipment. Water-jacked exhaust systems are the preferred method of meeting the above surface temperature requirements. Engine radiators or, where applicable, heat exchangers shall be suitably sized to accept the additional heat load. Discharge of Exhaust Sparks/Flames A spark arrestor, preferably of the cyclone type, shall be fitted to the discharge end of the exhaust system. Spark arrestors shall be provided in corrosion resistant materials, suitable for the Das Island environment and robustly constructed. All flame arrestors shall be provided with appropriate certification. Overspeeding Due to Gas or Vapour An automatically operated valve shall be installed in the air intake system so designed to shut when the engine speed rises above a set limit. This limit must not exceed the safe limits for the engine or driven equipment. The valve and its control system shall be of proven design and shall close sufficiently tightly to ensure that closure stops the engine whether running on normal fuel or induced vapour. Acceptable makes of such equipment are: Chalwin, Mitcham, Weston and Harmo. Discharge of Electrical Sparks The starter system shall be of non-sparking type or of the following non electrical types: · · · ·
Pneumatic Hydraulic Spring recoil Inertia
All other electrical equipment shall be of the non-sparking type. Electrical equipment shall be effectively earthed and bonded to the main engine frame. Doc. Number
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Any electrical equipment that does not meet the above standard may be acceptable if: A lockable switch is provided to prevent it's use in a hazardous area and this is coupled with a satisfactory control system, or A slave battery system is used and the diesel engine is started outside the hazardous area and the connection is made through a heavy duty approved socket. Static Electricity Discharge All driven belts shall be manufactured from anti-static fire resistant material according to BS 2050: Specification for electrical resistance of conducting and antistatic products made from flexible polymeric material (obsolete). Currently there is no direct equivalent but refer to BS 3790 (http://www.bsonline.bsi-global.com/search/). Further Information BS 3790: 2006: Specification for belt drives. Endless wedge belts, endless Vbelts, banded wedge belts, banded V-belts and their corresponding pulleys At this time they will be issued a certificate of suitability for use in Zone 2 Area that is to be retained with the engine at all times. All engines used in the ADGAS hazardous area will re-certified at least annually. Transmission Ports Decompression ports shall not be provided. SECONDARY IGNITION HAZARD REQUIREMENTS Crankcase Explosion It is desirable that engines having a crankcase volume of over 0.5m3 be provided with a relief device. Relief device valves or breathers on engines shall be fitted with flame traps or, alternatively, discharge into the induction system downstream of the flame trap and upstream of the shutoff valve. Dipsticks should be of screw in type.. Note This is not applicable to ADGAS since the Company has no equipment of this size. It may however apply to contractors in the ADGAS hazardous area. Reverse Running Doc. Number
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The fuel injection pump and governor, where fitted, shall be so designed that reverse running of the engine is not possible. APPROVAL AND MARKING Approval All engines to be used in the ADGAS hazardous area shall be tested and approved by ADMA-OPCO Municipal Maintenance Department, Transport Section. Marking Engines certified by ADMA-OPCO will be marked with a green square, bearing the date of the certification. Each certificate is valid for one calendar year. Further Information BP Engineering, GS-134-8: Requirements for the protection of diesel engines operating in Zone 2 hazardous areas BS 2050 (obsolete). Currently there is no direct equivalent but refer to: BS 3790: 2006: Specification for belt drives. Endless wedge belts, endless Vbelts, banded wedge belts, banded V-belts and their corresponding pulleys BS 4056 (obsolete). Currently there is no direct equivalent but refer to: BS 229: 1957: Specification. Flameproof enclosure of electrical apparatus BS 1259: 1958: Intrinsically safe electrical apparatus and circuits for use in explosive atmospheres IEC 60079-4. 6.10.13.10
HOT TAPPING
INTRODUCTION The term "Hot Tapping" refers to a method of making a connection into a pipeline, vessel or tank while it is in service. This section is concerned with safety aspects of this specialised operation in which a valved stub piece is welded to a pipeline, vessel or tank and the connection is made by trepanning a hole using a specialised cutting machine. This operation calls for a high degree of expertise and experience and shall be carried out only by a competent person . It should only be undertaken in very special circumstances and only after all other means of making a connection have been considered. It is intended for those situations where it is extremely difficult to isolate, clean and gas free the equipment, e.g. on very long lines. Authorisation for this operation to be carried out must be obtained from the PMin consultation with the MHSE.(Refer to Figure 6-1) Before undertaking a modification involving a hot tap, the Check Out Certificate shown in Figure 6-2 will be completed by the Area and Performing Authorities.
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REQUIRED CONDITIONS Before welding commences it must be established that the equipment or pipeline, etc., has sufficient thickness and strength. In any event the metal thickness shall not be less than 5mm and the material must be free from laminations, cracks, or other injurious defects. In some cases the equipment may require strengthening to take the new connection. Where possible system pressures shall be reduced to the lowest safe level. The atmosphere around the equipment must be checked to ensure that it is gas free and that the area is free from combustible material. As guide, the atmosphere up to a height of 2m above ground level or above the point at which welding is to take place, whichever is the greater, and within 15m radius at all levels up to this height, shall remain free at all times from dangerous concentrations of gas or vapour. In this connection wind direction shall be taken into account. The ground within 15m of the welding shall be free from any flammable liquids or other combustible material or open drains. Continuous combustible gas monitoring is required. When welding on underground pipelines, an excavation of adequate size, with suitable shoring and ladder access, and a secondary means of escape, shall be provided. Advice shall be sought from the HSED. The excavation or pit shall be adequately vented and gas tested before entry and monitored throughout the operation. An entry permit will be required if the excavation is deeper than 1.3m. The temperature and pressure inside the equipment to which such welding operations may be carried out are governed by the reduced strength zone during the welding operations and the measured wall thickness. These factors must be determined in each case to ensure that at all times during the welding operation sufficient thickness of metal in the area remains unaffected to contain the internal pressure. As a guide the pressure and temperature in the system should, where practicable be kept below 3.3 barg and 120°C. This operation shall not be carried out where the internal pressure is less than atmospheric or the temperature less than 0°C. Hot tapping operations shall never be carried out on equipment that contains: · · · ·
Any flammable mixture of gases or vapour. Oxygen enriched atmospheres in the presence of hydrocarbons or other flammable materials. Compressed air in the presence of hydrocarbons or other flammable materials, such as lubricating oil carryover from an air compressor. Caustic Soda or Elemental Sulphur Doc. Number
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Hot tapping shall not be carried out on any equipment where effective control over its contents cannot be exercised and such lack of control could make the operation dangerous, for example, any part of flare line system.
Welding on pressure vessels, pipelines, or equipment in service shall not be allowed in circumstances where the materials of construction are such that post-weld heat treatment is necessary. Hot tapping shall not be carried out on lines or equipment lined with special materials. Welding procedures are most important and must be established and approved by the HCI and E&TSM prior to commencing any hot tapping operation. Paint or other contaminants shall be removed from the surface of equipment before welding. Drains near the welding operations must be effectively sealed. Flow in the line shall be established before naked flame work commences and maintained at least until after welding is completed and the metal has been cooled to the temperature of the flowing liquid. All connections must be fitted with a block valve, the material of construction, flange rating, jointing and gland packing of which shall be suitable for the equipment design and operating conditions. The connection, valve and valve seat shall be strength tested according to the code requirements to prove the fitting welds and valve flange gaskets and the valve seat, wherever possible use of specially manufactured fittings and valves will be made. Before commencing cutting operations, the machine flange gasket and spindle stuffing box gland shall be tested to prove they are leak tight under the operating conditions. Attention is drawn to the need to establish that the strength of the section of the equipment to which the connection is to be welded is adequate to withstand the external pressure loading before applying a strength test. Because of the heavy weight of valves and drilling equipment used in these operations, it is preferable to mount them vertically. Where the connection cannot be made vertically, the engineering design shall take into account the weight of the valve and drilling machine. In all cases the connection shall be suitably supported. Before hot tapping is commenced, the cutter and its pilot bit shall be inspected to ensure that it is in a satisfactory condition and the coupon recovery attachment is fitted correctly. Care shall be taken in the design and selection of the branch connection. It shall be long enough to accommodate the cutter and pilot and be designed to the appropriate code. Further Information BS 6990: 1989 : Code of practice of welding on steel pipes containing process Doc. Number
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fluid or their residuals ABU DHABI GAS LIQUEFACTION COMPANY LIMITED APPLICATION FOR AUTHORISATION OF A HOT TAPPING OPERATION To : Plant Manager From : Operations Manager 1. on
Date:
Permission is requested to undertake a Hot Tapping Operation on:(Name and reference number of pipe/vessel:...................................... Location:........................ / / ) The check list overleaf shows that the operation is technically feasible on this pipe/vessel. The permits for the two distinct phases of the operation will only be issued by my Division
when:(a) The requirements of the permit and the associated phase on the checklist have been met and the list contains the required signatures. (b)
They are countersigned at the level of management required.
(c) The work from the previous phase (where there is one) is complete and the associated permit has been cancelled. Signed: (Operations Manager) 2.
This application is rejected (cross out if not applicable). Signed: (Plant Manager)
This application for authorisation of Hot Tapping is granted. (Subject to the requirements outlined in (1) above being fulfilled and full consideration being given to the conditions laid down in the ADGAS Safety Manual, Section 6.14) (Cross out if not applicable).
Signed: (Plant Manager)
Figure 6-1: APPLICATION FOR AUTHORISATION OF A HOT TAPPING OPERATION
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Chapter No. 06
PART - 3: CUTTING COUPON WITH HOT TAP MACHINE Signature
1.
Obtain Permit from SME
2.
Final check that block valve on stub piece is in open position.
3.
Wind cutting head of Hot Tap Machine down to measurement. 12 in Part 2
4.
Start machine and engage automatic feed. When the machine slows down this is the signal that the cutter has reached the pipe. Stop machine and check measurement. 13 in Part 2. Restart machine.
5.
Continue cutting with that automatic feed engaged. When the machine speeds up again this is the signal that your cutter has removed the coupon. Stop machine and check measurement. 14 in Part 2.
Date
Workshop Supervisor
Date
Workshop Supervisor
PART - 4: REMOVAL OF COUPON AND HOT TAP MACHINE Signature
1.
Reverse direction rotation of machine and wind cutter back until the measurement corresponds to No. 11 Part 2.
2.
Close block valve slowly until it starts to seat, back off slightly and open bleeder valve to blow chips out of seat.
3.
Close block valve and bleeder valve.
4.
After 5 minutes open bleeder valve to make sure block valve is holding.
5.
Remove machine from stub
6.
Remove cut out coupon from drill and retain coupon for CID.
7.
Fit blank to block valve.
8.
Sign permit as completed and hand back to SME.
Figure 6-2: Hot Tap Check Out Certificate Doc. Number
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CONFINED SPACE ENTRY
Chapter No. 07
CHAPTER 7 CONTENTS 7
CONFINED SPACE ENTRY ................................................................................................................. 273 7.1 INTRODUCTION ............................................................................................................................ 273 7.1.1 DESCRIPTION ............................................................................................................................ 273 7.1.2 MANDATORY ENTRY PERMIT .................................................................................................. 273 7.1.3 DEFINITION................................................................................................................................ 273 7.2 RISK ASSESSMENT ....................................................................................................................... 274 7.2.1 HAZARD CATEGORIES .............................................................................................................. 274 7.2.2 OXYGEN DEFICIENCY .............................................................................................................. 274 7.2.3 EXPLOSION OR FIRE................................................................................................................. 274 7.2.4 TOXIC CONTAMINATION .......................................................................................................... 275 7.2.5 PHYSICAL HAZARDS/ AGENTS ................................................................................................. 275 7.2.6 CONCURRENT WORK................................................................................................................ 276 7.3 ISOLATION AND GAS FREEING ................................................................................................. 276 7.3.1 INITIAL GAS TEST ...................................................................................................................... 276 7.3.2 RADIOACTIVE DEVICES ........................................................................................................... 276 7.4 SAFE WORKING ENVIRONMENT............................................................................................... 277 7.4.1 CLEANING .................................................................................................................................. 277 7.4.2 FLUSHING .................................................................................................................................. 277 7.4.3 STUBBORN DEPOSITS ............................................................................................................... 277 7.4.4 PURGING .................................................................................................................................... 277 7.4.5 VENTILATION ............................................................................................................................. 278 7.4.6 GAS TESTING .............................................................................................................................. 279 7.4.7 GAS CONCENTRATIONS ........................................................................................................... 279 7.4.8 GAS SAMPLING .......................................................................................................................... 280 7.4.9 CARBON DIOXIDE (CO2) RELEASE IN CONFINED SPACES ................................................ 280 7.5 ENTRY REQUIREMENTS.............................................................................................................. 281 7.5.1 AUTHORITY ................................................................................................................................ 281 7.5.2 RESCUE PLANS .......................................................................................................................... 282 7.5.3 COMMUNICATIONS................................................................................................................... 282 7.5.4 SAFE WORKING GUIDELINES ................................................................................................. 282 7.5.5 ACCESS........................................................................................................................................ 283 7.5.6 NON GAS-FREE ENTRY ............................................................................................................. 283 7.5.7 STANDBY PERSONNEL .............................................................................................................. 284 7.6 PROTECTIVE AND RESCUE EQUIPMENT ................................................................................. 286 7.6.1 BREATHING APPARATUS ......................................................................................................... 286 7.6.2 SAFETY BELTS AND LINES ....................................................................................................... 287 7.6.3 PPE .............................................................................................................................................. 287 7.7 CANCELLATION OF PERMIT ...................................................................................................... 287 7.8 HOT AND NAKED FLAME WORK HAZARDS ........................................................................... 287 7.8.1 ELECTRICALLY DRIVEN EQUIPMENT .................................................................................... 287 7.8.2 ELECTRICAL EQUIPMENT INSIDE VESSELS ......................................................................... 287 7.8.3 LIGHTING OF CONFINED SPACES ......................................................................................... 288 7.8.4 HOT WORK/NAKED FLAME...................................................................................................... 290 7.8.5 CONTROL OF FUMES ............................................................................................................... 291 7.8.6 GAS EXPOSURE HAZARDS ....................................................................................................... 291 7.8.7 PHYSIOLOGICAL EFFECTS OF GASES ................................................................................... 292
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Chapter No. 07
7 CONFINED SPACE ENTRY 7.1 INTRODUCTION 7.1.1 DESCRIPTION Work in a vessel or other confined space involves particular health and safety considerations. Key concerns are the potential presence of toxic vapours, explosive atmospheres or oxygen deficiency. Other harmful agents such as noise and heat are also potential health hazards. The following guidelines represent the minimum precautions to be taken to ensure the safety and protection of personnel entering vessels, tanks or other confined spaces on the ADGAS plant. They do not supersede the requirements of statutory or other ADNOC or ADGAS regulations that must be observed. Further Information ADNOC COP V4-05, NON-ROUTINE OPERATIONS. SECTION 3 ENTRY INTO CONFINED SPACES ADGAS PTW Manual. SECTION 5.8 Once the decision is made by a responsible authority that the entry is necessary, positive actions must be taken to eliminate the atmospheric hazards and also physical hazards such as moving equipment and also other work activities that may affect the vessel entry work site. Whilst the isolation of electrical and mechanical hazards is always possible, in cases where it has not been possible to completely remove the chemical hazard the entry procedures for Non Gas Free Entry must be followed. (Refer to Section 7.5.6).
7.1.2 MANDATORY ENTRY PERMIT An Entry Permit is mandatory for a person to enter or partially enter a confined space on the LNG facilities. There are no exceptions to this requirement. An Entry Permit is not a permit to work and appropriate permits will be issued to cover any work activity after entry.
7.1.3 DEFINITION In general terms applicable to the LNG plant a confined space is defined as a space of any volume which: Doc. Number
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Is not intended as a regular workspace Has restricted means of entry and exit May have inadequate ventilation and/or an atmosphere that is either contaminated or oxygen deficient
On the LNG facilities the term includes, but is not restricted to, tanks, bunds, vessels, floating roof spaces, towers, sewers, sumps, pits, piping, ductwork, flues or to any other excavation more than 1.3m deep.
7.2 RISK ASSESSMENT A Risk Assessment must be carried out in accordance with Chapter 2.9 prior to entering the confined space. All information regarding the confined space should be considered during the Risk Assessment, such as engineering drawings, working plans, and data on relevant soil or geological conditions. Further Information ADNOC COP V4-05, NON-ROUTINE OPERATIONS. SECTIONS 2 and 3.3
7.2.1 HAZARD CATEGORIES The range of hazards likely to be encountered with work in confined spaces includes: · · · ·
oxygen deficiency explosion or fire toxic vapours and atmospheric contaminants physical hazards and agencies
7.2.2 OXYGEN DEFICIENCY Lack of oxygen can be created by: · · · · ·
displacement of air by other gases which may be toxic, combustible or inert internal corrosion of surfaces fire or other combustion wet charcoal effects of the work progress, e.g. welding and cutting, painting, sprays, etc. Caution All confined spaces are deemed to be oxygen deficient if the oxygen concentration is measured as below 20% at any point.
7.2.3 EXPLOSION OR FIRE As with other types of fires, the essential elements required to support combustion are: Doc. Number
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oxygen (air) fuel (flammable gas, vapour, dusts, sludges, etc.) heat (welding, grinding, static electricity or Non-IS equipment)
7.2.4 TOXIC CONTAMINATION This may exist in the atmosphere in the ambient state, be created by the work procedure or be introduced. Sources of toxic gases and vapours include: · · · · · ·
residue in the vessel or space left by incomplete cleaning or preparation, or materials trapped in surface scale or sludge results of failure to properly isolate the space from the normal process connections contamination by engine exhaust gases or other pollutants through an entry point substances used for cleaning H2S residual inert gas remaining due to incomplete air purging and ventilation
The physiological effects of some of these atmospheric contaminants need to be known by all personnel involved in confined space entry.
7.2.5 PHYSICAL HAZARDS/ AGENTS The potential for physical injury is often exacerbated in confined spaces. Mechanical agitators and other powered equipment are cases where correct isolation procedures must be rigidly followed. Further Information Chapter 9.1 ELECTRICAL Other physical agents may be present depending on the nature of the work and these may include: · · · · · · · ·
ultraviolet radiation from arc welding infra-red and heat from hot work environmental heat from the job or local conditions risk of falling from ladders, staging or scaffolding within or on the access to large vessels excessive noise either location or job-created effects of blowers or eductors general hazards from abrasive blasting, chipping, grinding or high pressure cleaning electric shock from welding, lighting or other power sources Doc. Number
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7.2.6 CONCURRENT WORK As an essential element in planning vessel entry work, the effect of other concurrent local work activities must be considered. Due to the vulnerability of workers in enclosed spaces, the following other external activities must be taken into account as adding to the job risk inventory: · · · · · ·
hot work abrasive blasting hydrocarbon release blast cleaning spray painting other activity likely to cause plant change of conditions Caution The responsible supervisor must be aware of the potential for psychological stress on unseasoned workers in difficult confined space operations. The combined effect of heat, wearing of confining clothing and breathing apparatus may lead to distress.
7.3 ISOLATION AND GAS FREEING Isolation and gas freeing of items of plant equipment will be achieved according to the requirements set out in Section 8.2 and in the Operations Division Maintenance Preparation Procedures and Blank Schedules.
7.3.1 INITIAL GAS TEST The initial gas test must be conducted by an Authorised Gas Tester from the Laboratory before entry.
7.3.2 RADIOACTIVE DEVICES Isolation of vessels fitted with radioactive devices is not complete until the isotopes have been removed by competent and classified personnel to the isotope storage room located off-site. Further Information Chapter 08.2 TANKS AND VESSELS ADGAS Permit to Work Manual
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7.4 SAFE WORKING ENVIRONMENT 7.4.1 CLEANING All materials, solid, liquid or gas, seen as likely hazards to persons inside a confined space must be removed. This may present difficulties as the potentially dangerous material may be trapped in sludge, scale or other deposits, or behind loose linings. Similarly such material may lodge in joints in vessels or in bends of connecting pipes or other places where removal is difficult. Special care should therefore be taken in cleaning processes and methods should be adapted to meet each set of circumstances. Cleaning may have to be repeated to ensure that all potentially dangerous materials have been removed.
7.4.2 FLUSHING The vessel may require flushing out with potable water several times. When required the vessel should be water-filled and flushed while still closed, allowing hydrocarbons to be displaced through vent lines. Caution Due to the weight factor, care should be taken to ensure that vessels and supports will not be over stressed if filling with water. Also adequate venting must be provided while draining to prevent damage to the vessel due to formation of a vacuum.
7.4.3 STUBBORN DEPOSITS Any vessel residue should be flushed out with a water hose. Failing this, a high pressure water jet may be employed. Heavy or stubborn deposits may require the entry of personnel to shovel the mixture and dispose of it through manways.
7.4.4 PURGING The vessel must be purged until the lowest safe gas concentrations are attained and are able to be sustained. 7.4.4.1 PROCEDURE Attach air mover to open manhole Open vessel vents to atmosphere Start the air purge and gas test the vessel atmosphere at the vent at 30 minute intervals. Special care should be taken to ensure that the venting of the vessel will not create hazards that could affect adjacent work.
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Caution Ventilation and purging equipment must be electrically grounded to the vessel's structure to negate static charge effects. As the vessel may not have been cleared for free entry, more care and special procedures must be followed in this operation.
7.4.5 VENTILATION 7.4.5.1 REQUIREMENTS When persons entering a confined space will work without breathing apparatus the confined space must be ventilated with fresh clean air by natural, forced or mechanical means to establish and maintain a safe working atmosphere. This ventilation must be continued throughout the period of occupancy as a safeguard against the unexpected release of contaminants into the work space and replenish the oxygen consumed by the occupants of the vessel. 7.4.5.2 NATURAL DRAUGHT All access points must be open to ensure the maximum flow of air through the confined space. Where there is only one manhole, it will be necessary to remove pipe spools or flanged covers to establish adequate draught and replenishment of fresh air. When natural ventilation is found to be inadequate, forced or mechanical ventilation must be provided. 7.4.5.3 FORCED VENTILATION Fresh, certified quality air may be introduced through a hose with its outlet inside the confined space at a point as remote as possible from the access manway. A positive air flow is established with its exhaust at the manway. Air flow must be maintained for the full period in which a person not equipped with BA or a positive supplied air respirator is likely to be in the confined space. The air supply must be regulated or throttled to the optimum flow and pressure setting and the supply valve tagged for safety reasons. Air must be sourced from a safe area with regard for the possibility of recirculation. 7.4.5.4 MECHANICAL VENTILATION The two major systems for mechanical ventilation are the electrical or air powered fan or compressed air venturi eductor. Due to inherent ignition hazard in the electric fan, airpowered units are favoured in hydrocarbon service areas. The following precautions in use must be observed: Doc. Number
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Controls for the ventilating equipment must be accessible outside the confined space. Controls for electric or pneumatic ventilation equipment must be clearly identified and tagged to prevent accidental shut-off. All equipment must be certified suitable for use in hazardous locations. While ventilating, exhaust from the confined space must be directed away from other personnel and equipment. When the job is likely to generate smoke or fumes, the ventilation should be arranged to extract these contaminants at their source. Flexible convoluted large bore hose or trunking is appropriate.
Air operated eductors and exhaust fans utilise the principle of exhausting air from the vessel at an opening, creating a low pressure within the vessel that causes external air to flow in through all other openings. Careful selection of the eductor position and other inlet openings is necessary to obtain the most complete and efficient air exchange from the vessel, thereby avoiding the problem of dead zones of contamination. Eductors are most effective when assisting natural flow created by heat convection or wind effects. Caution Air-operated venturi eductors may be a source of static electric generation and must be earthed or bonded to the structure.
7.4.6 GAS TESTING The maximum concentrations of contaminants and the quality of the air in confined spaces must be assessed and compared with the allowable values shown in the table below. The terms used are: 7.4.6.1 FREE ENTRY Conditions favourable to the entry and work in a confined space without the need for personal breathing equipment. 7.4.6.2 RESTRICTED ENTRY Entry permission is given only to persons wearing approved supplied-air or selfcontained breathing equipment.
7.4.7 GAS CONCENTRATIONS Gas concentrations for entry are tabulated below.
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Free Entry
Restricted Entry 1400 PPM Max. (10% of LEL)
Hydrocarbons
50 PPM max.
Oxygen (O2)
20 to 23.5%
Below 20%
Hydrogen Sulphide (H2S)
10 PPM max.
200 PPM max.
Carbon Monoxide(CO)
10 PPM max.
500 PPM max.
Carbon Dioxide(CO2)
0.5% max. (5000 PPM max.)
15% max. (150,000 PPM Max.)
Table 7-1: ALLOWABLE GAS CONCENTRATIONS
7.4.8 GAS SAMPLING Testing must be representative of the entire space. Sampling of the interior is conducted from the outside by means of aspiration through tubing extension of the portable gas detector. If the space has been under ventilation a period of 30 minutes must elapse after ventilation is switched off before entry. If representative samples cannot be taken from outside the vessel, entry wearing BA may be necessary to conduct thorough tests and verify the safety of the atmosphere for work. Caution There must be no doubts as to the composition and quality of the atmosphere contained in the confined space. The time at which the tests were conducted and the highest risk readings obtained must be recorded on the work permit.
7.4.9 CARBON DIOXIDE (CO2) RELEASE IN CONFINED SPACES The discharge of carbon dioxide in fire extinguishing concentration creates serious hazards to personnel, such as suffocation and reduced visibility during and after the discharge period. Suitable safeguards i.e. audible and visual warnings are provided to prevent entry into such atmospheres. In the event of CO2 discharge into a confined space, i.e. outstations, BMS equipment rooms, LG5 and ADGAS/ADMA Gas Turbine compartments.
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Personnel must not enter area until it has been checked for 21% oxygen and thoroughly ventilated to disperse possible pockets of CO2. Clearance to enter building must be given by competent person, OSS, USCE, Lab Tech or Safety Engineer. Further Information Chapter 8 PIPELINES, TANKS AND VESSELS
7.5 ENTRY REQUIREMENTS 7.5.1 AUTHORITY Responsible supervisors are accountable for determining vessel isolations, monitoring and emergency rescue plans before submission of entry permits for approval. The Vessel Entry Checklist is to be used to indicate the requirements specific to the job. The Task Risk Assessment conducted for the job will provide a set of safety precautions and develop procedures to control hazards and prevent accidents. 7.5.1.1 BLANKING/DISCONNECTION For the purpose of man-entry, isolation must be by means of blanking or disconnection. There are certain exception in the Utilities Area, but in each of these cases, the Utilities Superintendent must first be advised before entry is effected. 7.5.1.2 PERSONNEL Before entering the vessel, all personnel involved will be instructed in: · · · · · · · · ·
the scope of the work potential hazards the duties of all personnel the safety requirements applicable to the job personnel and worksite precautions applicable to the work the correct use of breathing apparatus for work and/or rescue the correct use of gas testing and monitoring equipment emergency response and rescue procedures agreed communications procedures
Because self-rescue may be difficult under certain extreme conditions, the selection of workers should be geared towards those physically and psychologically equipped to work in a cramped space. The number of personnel will be limited to that necessary for completion of the work scope. People entering the space must be competent in performing the tasks assigned to them and have a good knowledge in the use of the tools and protective equipment. Doc. Number
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Standby personnel must be trained and competent in emergency rescue techniques, breathing apparatus and emergency rescue equipment in use. They will normally be ADGAS Safety Assistants.
7.5.2 RESCUE PLANS The availability of the number of trained and suitable personnel and protective equipment, protective clothing and rescue equipment must be established. The safety equipment must be in sufficient supply and available to all personnel likely to enter the confined space for work and for rescue purposes. The planning for possible emergency rescue must take into account the factors of: · · · · · ·
the shape and size of the confined space the nature of the task to be performed any obstacles within the space and the feasibility of their removal the means of entry and exit the maximum number of persons occupying the space the number of persons necessary outside the vessel space required to maintain work equipment used, to ensure communication with and observation of personnel in this space and to initiate rescue procedures if necessary.
7.5.3 COMMUNICATIONS Adequate means of communication with and between people inside the space and standby personnel and between the standby personnel and the control room are essential. Hand held radios will be used to raise the alarm or summon assistance. These must be tested before entry.
7.5.4 SAFE WORKING GUIDELINES The following safe working guidelines must be observed: · · · ·
·
Work required in the confined space must be carefully planned and clearly defined so that potential hazards are identified. The use of Task Risk Assessment is recommended. Diagrams or drawings of vessel internals should be used to familiarise personnel before entry. The confined space must be isolated from associated processes or equipment. Chemical and physical agents and oxygen levels must be measured before entry and compared with existing standards to judge the need to employ ventilation or personal protection. During the period of occupation, environmental measurements must be taken either continuously or at predetermined frequency. All tasks to be performed must be evaluated, particularly those possibly creating changes of conditions within the space. Doc. Number
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Safe and adequate lighting must be provided to illuminate the worksite. The men entering must be briefed on the effects of claustrophobia and disorientation. Periods of work in the confined space should be minimised. Breathing air intakes must be established as safe and monitored for any changing conditions, e.g. engine exhaust contamination. A dedicated spotter/attendant must be posted at the entry at all times whilst there are personnel within Personnel for vessel work should be selected on the basis of previous training and experience and be both physically and mentally fit. Due regard should be given to size/weight of the person. Warning Blow-pipe and hoses of welding equipment shall NOT be left in vessels or enclosed spaces when they are not in use, for example, after use, during a lunch break, or over-night. A very small leak over such a period of any gas, particularly acetylene, from a torch can make the atmosphere in the vessel dangerous. Where this cannot be done, the oxygen and acetylene connections shall be disconnected at the cylinders situated outside the vessel. Merely closing the valve is not a disconnection.
7.5.5 ACCESS Access openings into the confined space must permit rescue of all personnel who enter the confined space Access ways in and out of and surrounding the vessel must be kept clear of obstructions at all times It may be necessary to provide scaffold platforms and stairs or ladders at the manways levels to gain safe convenient access for work and for rescue purposes Signs and barriers shall be erected at all access points to restrict entry of those not engaged in the work
7.5.6 NON GAS-FREE ENTRY 7.5.6.1 GENERAL Circumstances may dictate the need for personnel entry before the vessel or spaces have been confirmed and certified safe. Examples are: · ·
the need to test the interior in remote pockets inaccessible from the outside. When residues in the vessel require manual removal and continue to generate vapour or gas. Doc. Number
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rescue of personnel in emergency situations.
Strict control of these situations is essential and only after all preparatory work such as isolations, purging and ventilation, etc. has been effected. After all reasonably practicable steps have failed to establish the atmosphere as gas free, the decision may be taken to authorise the non gas free entry. 7.5.6.2 SAFE WORKING PROCEDURE The Work Permit must specify all precautions necessary: · · · · · · · ·
The degree of risk must be assessed by use of Gas Detectors. Test results to be entered on the Work Permit. The person who enters must be equipped with and trained in the use of airline or self contained BA, belt and lifeline and suitable protective wear and lighting. Standby personnel to maintain communication with and tend the lifeline for the entry persons. Inert body retrieval must be understood by the standby crew with prearranged procedures rehearsed for use in an emergency. HSED advice and assistance may be employed before the work starts and during the entry period. Continuous gas monitoring must be maintained. Routine conflicting activities in the vicinity should be evaluated and suspended if necessary. The PMshall approve the entry.
7.5.6.3 STAFF For safety, rescue and communication purposes, at least two persons (BA Team) must be in attendance at all times at the opening closest to any personnel in the confined space. Standby personnel will not leave their station unattended. If the standby person must leave, either a relief person will be provided or work will cease in that section of that confined space and workers will exit the space. Under some circumstances more than one standby team may be necessary. This will depend on the number of people entering the space, the work being performed or the requirements for emergency rescue.
7.5.7 STANDBY PERSONNEL 7.5.7.1 NORMAL DUTIES The main responsibilities of standby personnel are listed below: Doc. Number
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Check the standby BA equipment. Leave the standby set near the point of entry in a secure, accessible position. Ensure that a fully authorised Entry Permit is displayed at the entry point. Check the condition and status of any safety equipment being worn by anyone entering the space. Maintain communication with those entering the space and be aware of the location of fire and safety equipment and the plant call points nearby. Be alert for any deteriorating conditions, internally or externally and advise those inside to evacuate the space until conditions have improved. Alert the Operator or his supervisor of any impending problems. If an airline BA system is being used, monitor air supplies and regulators and ensure that the air hose does not become kinked or tangled. Evacuate personnel if the air pressure varies beyond safe limits. Stay in attendance at all times unless relieved. If it is necessary to leave, make sure that everyone exits the confined space first. Maintain competence in the use of rescue equipment and breathing apparatus and be familiar with all emergency procedures. Hold the free end of tag lines when in use.
7.5.7.2 RESPONSE TO PLANT EMERGENCY Have everyone inside the space exit immediately and follow the emergency procedures. Note All equipment in use is to be left in a safe condition. Take steps to minimise any danger to the occupants in the confined space while they exit. In the event of evacuation notify the Marshaller that all people have exited the confined space after they have been checked off. Note Should an emergency develop on the plant, all permits are automatically cancelled. Following an emergency it will be necessary to re-certify confined spaces before permitting re-entry. 7.5.7.3 RESPONSE TO INTERNAL EMERGENCY One BA team member shall seek help immediately by notifying the Control Room of emergency details and alerting personnel nearby. The Control Room will mobilise emergency services and personnel.
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Other BA team member shall don breathing apparatus, safely belt and lifeline and then enter with caution, assessing the risk and responding to the situation. Other BA team member monitors activity from entrance. In some cases because of the small size of the manway, it may only be possible to wear the mask. The cylinder must be inserted through the manway first, then climb in wearing the face piece. Sufficient care must be exercised to ensure the operator does not lose control of the cylinder before donning it again. Personnel responding to the call must take extra BA sets with them and organise for required rescue equipment to be brought to the location. Depending on the circumstances the leader may take control with appointment of a BA Controller and other requirements.
7.6 PROTECTIVE AND RESCUE EQUIPMENT 7.6.1 BREATHING APPARATUS Appropriate personal protective equipment, particularly respiratory protection, must be utilised when confined space atmospheres cannot be guaranteed to be hazard free. Self contained breathing apparatus must be worn when entering a confined space if: · · ·
tests specified on the permit indicate a hazardous environment due to the presence of gases or oxygen deficiency. the potential exists for release of gas or vapour, e.g. from sludge remaining in a confined space. entry is required for further testing of the atmosphere. Caution Entry with BA must not be permitted if the LEL reading is above 10%.
Before entry, a BA set for each person must be made available at the nearest entry point in excess of sets being used during the job or entry conditions. The BA sets must be tested when delivered and before entry. The following precautions must also be followed: · ·
entry with BA may only be made by currently trained and competent BA wearers. a dedicated standby person is present at all times at the vessel entry point. He must be trained and competent in the use and the control of BA equipment.
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7.6.2 SAFETY BELTS AND LINES Safety harness and lifelines must be kept available in close proximity to any confined space being entered for use in rescue operations. The type of safety harness should be selected to provide rapid and positive retrieval of the wearer under all circumstances without injury. The activity of the wearer should not be unnecessarily impeded or introduce a personal risk by wearing belt and line.
7.6.3 PPE Ear protection, helmet, face shield, goggles, gloves, etc. must be worn as determined by the job to be performed. Special considerations for vessel entry personal wear include: · · ·
Small, loose items of safety wear or the contents of pockets should be removed from the person or left outside due to the possibility of dropping inside vessels or confirmed spaces. Clothing should be adequate for the task and allow free movement while not being too loose or have loops, belts, etc. which may snag on vessel internals. Gloves should be worn for protection against injury on sharp or serrated surfaces.
7.7 CANCELLATION OF PERMIT The Permit must be properly cancelled when operations to which they refer have been completed. They shall be returned to the Area Authority by the person to whom they were issued, who shall sign the declaration that all personnel and equipment, (including surplus and waste materials), have been removed from the plant. The Area Authority shall first check that completion of work is satisfactory before signing for acceptance of the plant for operation.
7.8 HOT AND NAKED FLAME WORK HAZARDS 7.8.1 ELECTRICALLY DRIVEN EQUIPMENT Electrically driven drills, saws, etc. must only be used in approved safe areas. Air driven tools are preferably used in hazardous areas and in vessel entry work.
7.8.2 ELECTRICAL EQUIPMENT INSIDE VESSELS If electrical equipment must be used a hot work permit is required and the following precautions should be taken: Doc. Number
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Portable tools feature a 'dead man' switch. All extension leads to be of the heavy duty type with mechanical connecting flameproof fittings up to the vessel manway. Earth fault relay (EFR) to be tested and located outside of the vessel manway, if not fitted elsewhere in the circuit. Wherever possible, all leads must enter the vessel through a nozzle or opening other than the access manway. Leads entering nozzles are to be encased in a flexible hose for approximately 2m where the lead goes through the nozzle. All electrical equipment and leads are to be checked by an electrician before use. All welding leads to be checked for cracks, cuts and breaks in insulation and if any doubt exists to be checked by the authorised person and faults rectified. Isolation switches for all equipment readily available to the outside fireguard or standby person.
7.8.3 LIGHTING OF CONFINED SPACES Where it is necessary to introduce temporary artificial lighting into a tank, vessel or other confined space, the following regulations apply: 7.8.3.1 DEFINITION VESSEL DECLARED "GAS FREE" A "Gas Free" vessel or Confined Space is one that has been so prepared by venting, air purging, flooding or steaming that it presents no risk to personnel from flammable or toxic gas, or oxygen deficiency. Referred to as "Free Entry" for personnel. Illumination may be provided by any of the means detailed in the previous part. In addition Zone 2 certified, fixed lighting fittings operating at a maximum voltage of 110 volt AC (55 volt to earth) may be installed, provided these are of an approved type and are rigidly affixed to internal structures and, therefore, not moveable whilst in use. Normal industrial standard lighting fittings shall NOT be used in any vessel that could, before being prepared for entry, have contained an explosive atmosphere or flammable substance. Whenever temporary lighting, fixed or hand-held, is to be used within a vessel, the Work Permit must clearly state the specific type of lighting equipment that may be used. At all times extreme care must be exercised by personnel working around and within a vessel in which temporary lighting is in use to avoid damage to cables, air hoses or lamps. Any damage or failure must be immediately reported to a member of the Electrical Section, who must withdraw the damaged or faulty item from use.
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Repairs or revamping of lighting equipment must be carried out only by an authorised member of the Electrical Section. At no time must repairs, or similar adjustments, to lighting equipment be carried out within a vessel by any person and any repositioning of fixed lighting must be carried out only after the power supply has been isolated. Supply and distribution cables for temporary lighting facilities must, at all times, be securely supported above ground level to minimise the risk of damage and consequent danger to plant and personnel. 7.8.3.2 VESSEL NOT DECLARED "GAS FREE" SOUR SERVICE There are three risks: · · ·
Ignition of ferrous sulphide due to drying by air or direct heating. Ignition of a hydrocarbon/air mixture within its flammable range. The toxic risk from H2S or SO2 where there is a possibility of pyrophoric ignition (vessel not wetted internally).
WARNING: ENTRY IS NOT PERMITTED. Battery Operated, certified safe hand lamps may be used from the manway only. Alternatively, reflected light from an acceptable external source may be used. 7.8.3.3 VESSEL NOT DECLARED "GAS FREE" SWEET SERVICE The risk here is from a hydrocarbon/air mixture within its flammable range. No person shall enter a vessel or confined space where the hydrocarbon/air mixture exceeds 10% LEL. Every effort shall be made to gas free the vessel before introducing personnel or lighting. Where this is impracticable because of the condition of the vessel or confined space, the following regulations apply: · · ·
Breathing apparatus and lifelines must be used. Forced or induced draught shall be used to assist in dilution of the confined space atmosphere. Only the following types of lighting shall be used: o Flame proof (Zone 1 certified) hand lamps operating at maximum voltage of 25 volt AC (12.5 volt to earth) supplied from a certified, flameproof, isolating transformer situated outside the vessel. o Compressed air turbine, certified flameproof lamps. o Battery powered lamps of a type certified as safe by the SIE for use in the appropriate environment.
Referred to as "Restricted Entry" for personnel. Doc. Number
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Further Information Chapter 7.5: Entry Requirements
7.8.4 HOT WORK/NAKED FLAME Caution must be exercised at any time hot work or naked flame is required in a confined space as the work process itself may render the atmosphere hazardous even though initial tests were satisfactory. The safety requirements and precautions pertaining to each Entry Permit must be carefully analysed taking into account the type of work involved. A Hot Work or Naked Flame Permit will be required in addition to the Entry Permit. In addition to the normal precautions associated with vessel entry and hot work/naked flame the following conditions also apply: · · · · · · ·
The concentrations of flammable gases or vapours in the atmosphere must be verified as sustainable below 1% LEL. Continuous gas monitoring must be employed. The flammability and thermal decomposition products of coatings in the work area must be identified with suitable respiratory equipment worn if considered hazardous. All liquid and solid residues must be removed which may contribute to the release of flammable vapours or gases thereby raising the concentration above the 1% LEL limit. All potential flammable vapour/liquid traps must be tested hydrocarbon free and covered with a fire blanket. Where arc welding is suspended for crew breaks or at end of shift, the power source to the equipment must be switched off. All electrodes must be removed from holders and placed so that accidental arcing or contact cannot occur. When oxy acetylene cutting, heating or welding is suspended for crew or at end of shift, the torch and cylinder valves must be closed. The torch and hose are then removed from the confined space and de pressurised.
Note: No compressed gas cylinders or associated manifolds other than those used for breathing apparatus may be located inside the confined space. Further Information Chapter 6 HOT and NAKED FLAME WORK
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7.8.5 CONTROL OF FUMES During hot work in confined spaces, vessels should be continuously ventilated and fumes extracted by mechanical means. Tests should be conducted at frequent intervals to ensure that toxic, corrosive or irritant components do not accumulate during the hot work. All extraction must exhaust into areas where adjacent personnel are not affected and where contaminants can not be recirculated into the original confined space. In planning hot work or naked flame the rate of air flow calculated must take into account the rate of change required to exhaust the fumes, provided cooling and maintain good quality breathing air. This will be many times the requirement for simple vessel entry or cold work.
7.8.6 GAS EXPOSURE HAZARDS The three most important toxic conditions found in vessel entry work relate to the presence of carbon monoxide (CO), hydrogen sulphide (H2S) in varying concentrations and the lack of oxygen (O2) which is essential to support life. Both CO and H2S may be found in vessels as a result of chemical reactions. Inhalation of CO or H2S or exposure to atmospheres lacking in oxygen can lead to death. Equipment required to conduct accurate testing by the AGT for dangerous gases and ensuring air quality must also be available and used whenever atmospheric conditions are suspect. Further Information Chapter 0CONTENTS and REVISION At low concentrations hydrogen sulphide smells like rotten eggs, but at high concentrations (100 PPM or more) it cannot be smelt, because one's sense of smell is lost. This creates a dangerous situation when a person's senses may not be relied upon as a danger warning. The physiological effects of the three gases are tabled in Table 7-4: . Caution The gas nitrogen is a major component of normal air. It is used in pure form however, for process purging. The inhalation of pure nitrogen when a person's head is immersed in the gas will bring about instant collapse and death if not rescued and resuscitated. Doc. Number
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Further Information ADGAS OPERATIONS DEPARTMENT PTW Manual Section 6.13 Gas Tests
7.8.7 PHYSIOLOGICAL EFFECTS OF GASES Oxygen (O2) Deficiency Vol. %
Effect
20.9 17.5
Normal air supply Atmosphere can be breathed and work done without ill effect for several hours Work difficult; considerably increased rate of breathing; lips blue; nausea and headache Loss of consciousness on exertion Unconsciousness and death if adequate supply not quickly restored
13.0 7 to 11 Below 6
Table 7-2: Physiological Effects of Oxygen Deficiency
Carbon Monoxide (CO) Conc. (PPM) 50 or more 200 400 1000 to 2000 2000 to 2500
Effect Produce symptoms of poisoning if breathed for a sufficiently long time Mild symptoms (slight headache, discomfort) within several hours Headache and discomfort within 2 or 3 hrs Slight palpitation of the heart in 30 minutes. A tendency to stagger in 1 ½ hours: confusion, headache and nausea in two hours Unconsciousness in about 30 minutes
Table 7-3: Physiological Effects of Carbon Monoxide
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Hydrogen Sulphide (H2S) Conc. (PPM) 10 70 to 150 170 to 300 400 to 700 700 and above
Effect TLV for prolonged exposure (Threshold Limit value) Slight symptoms after several hours exposure. Irritates the eyes Maximum concentration for 1 hour without serious effects Dangerous after exposure of 1 1/2 hours Fatal in 30 minutes
Table 7-4: Physiologiocal Effects of Hydrogen Sulphide
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CHAPTER 8 CONTENTS 8
PIPELINES, TANKS AND VESSELS ................................................................................................... 295 8.1 PIPELINES ....................................................................................................................................... 295 8.1.1 OPERATIONAL REQUIREMENTS ............................................................................................. 295 8.1.2 DRAINING AND VENTING LINES ............................................................................................. 297 8.1.3 ISOLATION .................................................................................................................................. 297 8.1.4 LINE CLEARANCE ...................................................................................................................... 298 8.1.5 REPAIR OR MODIFICATION ..................................................................................................... 300 8.1.6 REPAIR OF NON GAS FREE PIPELINES .................................................................................. 300 8.1.7 PIPELINES PRESSURE STRENGTH TESTING ......................................................................... 301 8.2 TANKS AND VESSELS .................................................................................................................. 304 8.2.1 MANDATORY ENTRY PERMIT .................................................................................................. 304 8.2.2 OPERATIONAL REQUIREMENTS ............................................................................................. 305 8.2.3 ISOLATION .................................................................................................................................. 307 8.2.4 GAS FREEING ............................................................................................................................. 308 8.2.5 ISOLATION BY SPADING ........................................................................................................... 310 8.3 SAFETY VALVES ........................................................................................................................... 312 8.3.1 SAFETY RELIEF VALVES ........................................................................................................... 312 8.3.2 REMOVAL OF SAFETY VALVES ................................................................................................ 312
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8 PIPELINES, TANKS AND VESSELS 8.1 PIPELINES 8.1.1 OPERATIONAL REQUIREMENTS 8.1.1.1 BOXING-IN OF PIPELINES A section of a pipeline containing liquid shall not be boxed in without first making arrangements to allow it to breathe through an open vent or suitably sited pressure relief valve. High pressure can develop very quickly through expansion of the liquid in the pipe under the heat of the sun. In this respect it should be remembered that a non-return valve can act as a shut valve if the liquid downstream of its discharge connection expands. 8.1.1.2 STABILITY OF PIPELINES Pipelines shall be regularly inspected by the Operating Authority to ensure that pipework is adequately supported. This is particularly important where pipework is subjected to vibration. Any unusual or excessive vibration of a pipeline system shall be reported to the Operating Authority immediately. Stays, guy wires or tackle of any description shall not be attached to any pipeline or pipe support. 8.1.1.3 PIPEWORK CROSSINGS - MEANS OF ACCESS Where possible pipe work should be routed so that it does not cross footpaths or access platforms, etc. However should this be unavoidable, then adequate crossing facilities must be provided. Overhead pipework shall be at least 2 metres above floor level at working platforms and walkways. Where this is impossible, black and yellow diagonal banding shall be applied to the pipework, denoting the hazard. Further Information EEMUA 105:02 Factory Stairways, Ladders and Handrails 8.1.1.4 PIPEWORK PASSING THROUGH BUNDS The annular space between the pipe and its protecting sleeves must be completely packed with non-combustible material to ensure that, if there is of a spillage, no oil leaks through the bund or firebreak. 8.1.1.5 COMMISSIONING STEAM LINES Steam lines must be thoroughly warmed before commissioning. Drains and steam traps shall be allowed to blow until all slugs of condensate are cleared.
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Where steam lines are to be vented adjacent to roads, and clouds of steam may obscure the road visibility, the venting of steam must be led away by steam hoses or other pipes, or alternatively the road closed. 8.1.1.6 SUMPS, HOLES AND EXCAVATIONS Sumps, holes and excavations can be dangerous gas traps. Unless a gas test has shown the absence of toxic or flammable gas and the presence of sufficient oxygen, each man entering such traps to investigate or repair leakage must wear breathing apparatus, a safety belt and a life line. Each life line shall have attendants whose sole duty is to stand by to raise the alarm and to help pull out any man who has become affected. Each attendant must also be provided with breathing apparatus ready for immediate use. An entry permit will be required if below 1.3m. Further Information Chapter 5 PERMIT TO WORK SYSTEM Chapter 7 CONFINED SPACE ENTRY 8.1.1.7 DANGER FROM STATIC ELECTRICITY Steam or hydrocarbon liquids spraying under pressure from a break in a line, from parted flanges or similar orifice can generate an electro-static charge capable of accumulating to a dangerous level upon any conductor not connected to earth (i.e. a man wearing ordinary rubber boots). Immediate action shall be taken to repair leaks of this nature. Further Information Chapter 6.9STATIC ELECTRICITY BS 5958: Part 1: 1991 Code of practice for Control of undesirable static electricity: Part 1. General considerations 8.1.1.8 OIL AND GAS LEAKAGES In the event there is a large leakage of oil or gas the affected area shall be immediately sealed off and all ignition sources extinguished and excluded. The appropriate LNG Plant Emergency Procedure must be instituted immediately. 8.1.1.9 DANGER FROM HOT OIL/WATER MIXTURES The consequences of admitting hot oil to a line containing water or passing cold oil through such a line into a hot vessel can be disastrous. Where a line has been steamed out or flushed with water, it must be thoroughly drained before oil is admitted.
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8.1.2 DRAINING AND VENTING LINES 8.1.2.1 DRAINING OF HYDROCARBON LIQUID LINES Before a hydrocarbon liquid line is isolated for repair or maintenance, it is essential that it is completely drained. Lines shall be depressured to a vessel and then drained as far as possible through fitted drain points. Facilities must be provided for controlling releases and containing any liquid spillages. The utmost care must be taken to limit the release of flammable or toxic vapours to atmosphere; it is essential that this operation is adequately supervised. The area downwind of the release that may include a combustible atmosphere must be clear of all sources of ignition. Personnel working downwind must receive adequate warning by the Operating Authority if there is a possibility of an escape of toxic or combustible gas. 8.1.2.2 VENTING GAS LINES Pipelines containing gas shall be depressured to atmosphere, as far as possible through process flare systems. Gas may only be vented direct to atmosphere when it is absolutely necessary and then only under strictly controlled conditions. The area must be adequately fenced off and warning notices posted of the possibility of toxic or flammable atmospheres being present. A Fireguard will standby whilst joints are being broken and will remain on site until gas tests prove that all gas has dispersed. All work and vehicle movements in the area will be strictly controlled. Persons engaged in maintenance work at the site will wear self contained BA sets or air line breathing apparatus. 8.1.2.3 DRAINAGE OF CORROSIVE OR TOXIC CHEMICALS When lines containing corrosive or toxic chemicals are to be entered, provision must be made for draining the line contents to a suitable container or drain. Neutralisation or water dilution may be necessary and advice shall be sought from HSED. Adequate protective clothing and/or equipment shall be worn.
8.1.3 ISOLATION 8.1.3.1 WORK PERMITS Before the isolation of any pipeline can commence, a Cold Work Permit must be issued by the Area Authority. This permit must detail the conditions of work which will enable the work to be carried out safely.
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8.1.3.2 ISOLATION OF HYDROCARBON OR CHEMICAL LINES Isolation of lines containing hydrocarbons or chemicals shall be effected by one or a combination of the following methods: · · ·
By removing a valve or spool piece and by sealing off the live section with a standard blank flange. By inserting a company approved spade between mating flanges. By closing both valves and opening the bleed valve when ever double block and bleed facility is available.
Note: Isolation by blanking or removing a section of line is mandatory when men have to enter vessels connected to these lines In the above cases, bonding straps shall be used. Further Information HSE OIAC The Safe Isolation of Plant and Equipment 1997: ISBN 0 7176 0871 9 8.1.3.3 ISOLATION OF STEAM LINES The isolation of steam lines may be effected by locking isolating valves in the shut position, provided that an adequate number of drain valves in the isolated section are kept fully open. If it is evident that steam leakage past the valves is excessive, then blank isolation shall be used. Note: Isolation by blanking or by removing a section of line is mandatory when men have to enter vessels connected to these lines. 8.1.3.4 ISOLATION OF AIR AND WATER LINES Air and water lines may be isolated by locking the isolating valves in the shut position. If there is a tie-in to a hydrocarbon system, then isolation shall be by spading or disconnection. Note Isolation by blanking or by removing a section of line is mandatory when men have to enter vessels connected to these lines
8.1.4 LINE CLEARANCE As the configuration of pipework and work content will vary with each job, it is not feasible to establish a common safety procedure. Supervisors shall note carefully sections of lines which form natural traps for hydrocarbon liquid or gas, e.g. loops, by-passes, drain points and changes in elevation. Doc. Number
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Methods of removing oil from the line will depend upon the shape of the line and the type of hydrocarbon. The following points shall be noted: · · · ·
Where the line is relatively short and connections are available, draining followed by steaming to a gas free condition is an ideal procedure. For lines of 150mm diameter and less, water flushing at high velocity is an effective method of purging oil of low viscosities (e.g. Pentane). Air blowing is not permitted to clear hydrocarbon lines because of the possibility of an air/hydrocarbon gas explosion. Air may be used to blow out the contents of a strong sulphuric acid line to a safe place. The residual air pressure must be reduced gradually.
Subsequent water washing may be necessary for complete removal of acid. Protective clothing including chemical suits, boots and goggles shall be worn during this operation. 8.1.4.1 LONG SECTION OF PIPELINES If it is necessary to cut into a long section of pipeline that cannot readily be made gas free, then the regulations given in the following parts of this section are to be observed: · · ·
Hot tapping techniques. (refer Chapter 6-14) Cutting of Pipelines. Repair/Modification of non gas-free pipelines.
8.1.4.2 PYROPHORIC SCALE In lines that carry gas or oils which contain hydrogen sulphide there is a possibility that pyrophoric scale may have been formed. When these lines are opened, the exposed parts must be kept wet with water or blanketed with steam to render harmless any pyrophoric scale that may be present. Pipelines that may contain pyrophoric scale shall never be left open without ensuring that any deposits are kept well wetted. Scale removed from these lines shall be placed in a drum and covered with water. Advice on the disposal of the scale shall be sought from the HSED. Lines that have been used on sour-gas duty shall not be opened in more than one place at a time unless the pyrophoric scale has been rendered harmless. Otherwise, currents of air could ignite the scale. Further Information Chapter 4.9.11 PYROPHORIC MATERIAL HANDLING STORAGE AND DISPOSAL PROCEDURE Cheresources.com: Pyrophoric Iron Fires Doc. Number
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8.1.5 REPAIR OR MODIFICATION 8.1.5.1 CERTIFICATES Before any work is carried out on a pipeline, the necessary work permit(s) must be issued by the Area Authority. 8.1.5.2 CATHODICALLY PROTECTED PIPELINES When any maintenance work is to be carried out on pipelines that are cathodically protected, then the regulations given in Chapter 9.1, Electrical are to be followed. 8.1.5.3 HOT TAPPING TECHNIQUES The term "Hot Tapping" refers to a method of making a connection into a pipeline, vessel or tank while in service. The procedures and requirements for hot tapping are presented in Chapter 6.14, Hot Tapping. Further Information Chapter 6.10.13.10 HOT TAPPING EEMUA: Guide for Hot Tapping on Piping and other Equipment 8.1.5.4 CUTTING OF PIPELINES Cold cutting techniques must be used if full bore access is required into pipelines that have contained flammable materials. Cold cutting must be carried out using properly designed and manufactured mechanical air-operated or manual pipe cutters. During the cutting operation heat is generated and suitable lubricants and coolants must be used to dissipate this heat. 8.1.5.5 ABRASIVE WHEEL CUTTERS Abrasive wheel cutters shall not be used for cold cutting of pipelines. There is a risk external to the line from low energy sparks which could ignite carbonaceous material, but there is greater risk internal to the line as the cutter penetrates the wall. The internal wall of the pipe becomes very hot and high energy sparks are projected into the pipe. A further hazard is the tendency of these brittle cutting wheels to shatter if improperly used.
8.1.6 REPAIR OF NON GAS FREE PIPELINES The application of heat, as by welding, to any part of a line that has not been gas freed is potentially very dangerous. Therefore, whenever such mechanical work is required on pipelines, the procedures and cautionary instructions given in these regulations must be adopted to ensure that all work is carried out and completed under the safest possible conditions.
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Further Information HSE OIAC The Safe Isolation of Plant and Equipment 1997: ISBN 0 7176 0871 9 8.1.6.1 PREPARATORY ARRANGEMENTS The Area and Performing Authorities or their deputies shall visit the site and discuss the method and timing of the work. At the meeting it must also be determined whether the work can be completed by removal to offsite facilities for Naked Flame, Hot Work or Cold Work techniques. If the aforementioned methods are not practicable, Naked Flame or Hot Work may be permitted with the use of mechanical seal plugs, but only after authorisation from the Plant Manager in consultation with the MHSE. Further Information PM&ED Standing Instructions H4-6 Use Of Mechanical Seal Plugs. Having agreed a work programme, the necessary work permits must be prepared before work can be started. 8.1.6.2 LINE ISOLATION Since mechanical plugs are not designed to hold pressure, a secondary atmospheric vent, preferably of full line diameter, must always be provided on the system. Further Information CHAPTER 8.1.3 ISOLATION
8.1.7 PIPELINES PRESSURE STRENGTH TESTING 8.1.7.1 HYDRAULIC TESTING GENERAL The practice of hydraulic testing has long been accepted as an essentially safe method of conducting a strength test on fabricated piping systems, a fact proven by the amount of such testing in the oil industry alone, and the infrequency of accidents directly related to it. Further Information HSE GS4 Safety in Pressure Testing 1992: ISBN 0 7176 0811 5 ASME B31 Code for Pressure Piping The intrinsic safety of hydraulic testing lies in the incompressibility of the medium. This may seem an obvious statement, but the lack of appreciation of the difference between testing with liquid and testing with gas for strength proof purposes is surprising. Simply if a system is completely filled with liquid, then the injection of a very small additional volume may produce a considerable pressure; should failure occur, then the pressure will be released comparatively harmlessly on the emission of that small volume. To Doc. Number
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induce an equivalent pressure in the system filled with gas might necessitate the air being compressed to many times its own volume; in this case, the release of stored energy upon a failure can give rise to catastrophic effects akin to those of explosion. When conducting hydraulic strength tests, the following safety factors must be borne in mind: Supporting structures and their foundations must be checked to ensure their ability to support the combined weight of the equipment and the fluid required to fill it. Note Testing fluid is nearly always water which is approximately twice as heavy as the hydrocarbon for which the vessel may be designed. · ·
· ·
· ·
·
· · ·
Temporary closure, such as blind flanges, and spades, must be checked, together with their fastenings, to ensure their adequacy to withstand the test pressure involved. Screwed plugs shall be removed for examination to ascertain that: o They are of the specified type and material. o The threads are properly cut and in good condition. o An adequate length of thread is entered into the socket. Pressure indicating devices must be properly connected, accurately calibrated, and of a range suited to the test pressure involved. Adequate vents must be provided at high points and blind ends to ensure that no air is entrapped during the filling process. Indication that air is trapped is invariably given by the behaviour of the pumps and difficulty in attaining pressure. Such a situation Must be Rectified Immediately. Pressure must be raised gradually. Attempts to correct leaks must be made judiciously, and normally it will be necessary to relieve the pressure. If the application of reasonable force proves insufficient, the cause of the leak must be investigated. Particular care must be exercised when attempting to rectify leaks at screwed plugs and connections. Care must be taken to avoid the consequences of a pressure rise due to thermal expansion of the test medium. If no automatic relief is provided, then the filled system, when closed, whether under pressure or not, must be kept under close surveillance. When emptying the system, adequate venting must be provided to preclude the drawing of vacuum in any part of it. In determining test pressures, where a system contains flanges and other fittings, the test pressure must not exceed the test pressure applicable to the lowest rated component in the assembly. When pipework is being pressure tested to pressures upto and including 20 barg, barriers shall be placed at 15 metres. For test pressures above 20 barg, barriers Doc. Number
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shall be placed at 20 metres. No personnel, except the inspector and test personnel shall enter these barriers. Performing Authorities will ensure that barriers and warning notices are sited, wherever practicable, at the above indicated distances prior to commencing tests.
8.1.7.2 TEST FLUIDS Water is the medium used for hydraulic testing of carbon and ferritic steels. Austinitic stainless steel requires water having a chloride content less than 30 parts per million (ppm). 8.1.7.3 PRESSURE TESTING PROCEDURES (STAINLESS STEEL PIPEWORK) Stainless Steel pipework that has been repaired, reworked or had new components fitted shall be pressure tested according to the following procedures. 8.1.7.4 TYPE 321 MATERIAL Type 321 material, used in sour gas service on Plant 1 and 2 of both Trains, shall be tested in accordance with the following procedures Pressure Testing of Type 321 Material
(Non-cryogenic service)
The test fluid shall be either water or light distillate (diesel fuel). 8.1.7.5 WATER AS THE TEST FLUID Pipework that has been removed from the LNG Plant and taken to the Workshops for repair or renewal will be tested with water, subject to the pipework being flanged or capped at its extremities such that it can be pressurised. Before testing, the pipework shall be thoroughly flushed internally with water which has a chloride content of less than 30ppm and which also contains soda ash or similar agent sufficient to neutralise the sulphide films and/or other acid compounds. Following the procedures above, the pipework shall be flushed a second time with de mineralised water. Following this flushing, the pipe work shall be filled with demineralised water and pressure tested to a pressure of 1.5 times design pressure. All air shall be vented from the pipework prior to pressure being applied. The test pressure shall be maintained for a time sufficient to permit a full visual inspection of all welds or for 20 minutes, whichever is the greater. The test pressure shall be released slowly and the fluid discharged. Doc. Number
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The pipework shall be thoroughly drained and dried internally as far as it is practicable. The weld repairs shall not be painted until after satisfactory completion of the test procedure. All practical steps shall be taken to prevent atmospheric contamination of the weld at all stages between welding, NDT, PWHT and final hydraulic test. A record shall be kept of the pipe, the test fluid, the test pressure and the signature of the person witnessing and passing the test. 8.1.7.6 TYPE 304/316 USED IN CRYOGENIC SERVICE Type 304 or 316 used in cryogenic service at temperatures of 0°C down to minus 160°C is generally only tested in accordance with pneumatic pressure testing. 8.1.7.7 PNEUMATIC PRESSURE TESTING Pneumatic pressure testing of closed equipment and pipework is potentially hazardous because of the large amount of stored pressure energy in the system. Consequently, this form of testing is only resorted to where hydraulic testing is inappropriate and then only with prior approval from PS or US. When pipework is being pressure tested to pressures up to and including 20barg, personnel except the inspector and test personnel shall not approach within 15m of the piping system. The approach limit shall be increased to 20m for test pressures above 20 barg. Barriers shall be placed at the above limits. Nitrogen is the normal medium used for pneumatic tests in the LNG plant, but the use of air may be sanctioned by PMin special cases. Except where PMgrants special permission to use another procedure, only Operations Division Procedures G.O.P. No.4 shall be used. Further Information Operations Division Procedures G.O.P. No.4
8.2 TANKS AND VESSELS 8.2.1 MANDATORY ENTRY PERMIT An Entry Permit is mandatory for a person to enter or partially enter a confined space on the LNG facilities. This includes the trash and outfall pits, Train 3 Cooling Water Inlet Manifold Pit and CW/FW pump discharge pit.
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Warning There are no exceptions to this requirement. An Entry Permit is not a permit to work and appropriate permits will be issued to cover any work activity after entry.
8.2.2 OPERATIONAL REQUIREMENTS 8.2.2.1 BUNDS Tank bunds and retaining walls shall be maintained in good condition. Vegetation inside bunds must be kept to a minimum. Where pipework passes through bund walls, the sleeve seals must be routinely checked. A tank bund may not be opened without the authorisation of the PMand then only after an appropriate work permit has been issued by the PROM. This permit shall specify the method of opening, the machines or tools to be used and any precautions to be taken to guard against damage to buried cables, etc. Where the tank contains a product, temporary facilities must be provided for closing the bund at short notice. Water collecting sumps are located in the tank bunds and should be emptied frequently when there has been rain. This is particularly important in the case of tanks in cryogenic service. All approaches to tanks must be adequately lighted. There shall be sufficient steps over bund walls and adequate access to tank valves. Further Information ADGAS PTW Manual Section 5.13 8.2.2.2 HAND-RAILS, STAIRS AND LADDERS These shall be kept in good condition and any defects reported. 8.2.2.3 RELIEVING DEVICES All tanks and vessels must be protected by atmospheric vents or pressure/vacuum relieving devices according to duty, and maintained in good working condition by regular inspection. The fitting of an intervening stop valve, for maintenance purposes, either between a pressure vessel and it's relief valve or on the downstream side should only be resorted to after careful consideration of the possibilities of mal-operation of the stop valve. Written agreement of the PMand the HCI/SPIE is required for this operation and further permission of statutory or insurance bodies may also be required. Doc. Number
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Stop valves must be locked either in the open or shut position by authorised persons in OD. During the exceptional period that a tank or vessel is operated without a relief valve, an operator must remain at the control point to observe that the internal pressure does not exceed the vessel's set working pressure. Note This procedure shall only be authorised by PROM If the operating conditions on a vessel or system protected by a relief valve are changed, then the HCI/SPIE must be notified so that the relieving capacity of the valve may be recalculated. This would also involve the application of the Modification Procedure. Where goose-necked, mushroom or similar type vents are fitted, the gauze screen must be regularly inspected to ensure that it is in good condition and free from blockage. Further Information EEMUA: 184:96. Guide to the Isolation of Pressure Relieving Devices 8.2.2.4 DIP HOLES The covers of tank dip holes, sampling hatches and manholes must be kept closed when not required to be open for operating purposes. 8.2.2.5 MANHOLES Manholes used as means of entry for a tank or vessel shall not be less than 460mm long and 410mm wide, or if circular, not less than 460mm diameter. Safe access and means of entry and exit shall be provided at all manholes. 8.2.2.6 ACCESS TO TANK ROOFS As the condition of a tank roof may be unknown, access onto the roof shall only be authorised under an Entry Permit. The conditions for safe access must include the wearing of a safety belt and lifeline with two persons on standby for each man. For a floating roof tank, e.g. pentane, when it is not at rim level then breathing apparatus must be worn.
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8.2.2.7 FILLING AND DRAINING VALVES Valves on tanks and vessels shall be conveniently positioned so as to be easily accessible for operation. Rising spindles and valve wheels should not present a safety hazard. 8.2.2.8 SUMPS AND PITS All sumps and pits shall be provided with handrails to a height of 1m or be completely covered by an approved flooring.
8.2.3 ISOLATION 8.2.3.1 GENERAL METHODS OF ISOLATION Isolation shall be by one of the following methods: · ·
·
By removing a valve or section from each connecting line and its junction with the tank or vessel as near to the shell as possible and by sealing off the disconnected line with a standard blank flange. By insertion of standard blank flanges as close to the tank or vessel as possible. For this purpose, spectacle blanks of appropriate pressure rating shall be used. Care must be taken to ensure that pockets of liquid hydrocarbons are not trapped between blanks and closed valves. Sumps may be isolated by expandable rubber plugs. If this method is used, care shall be taken to ensure that the bore of the pipe is smooth and round. These expandable rubber plugs must not be used where there is any possible build up of pressure in the line. Caution Valve closure as the only means of isolation shall only be approved by PMafter consultation with MHSE. Further Information HSE OIAC The Safe Isolation of Plant and Equipment 1997: ISBN 0 7176 0871 9
8.2.3.2 PRECAUTIONS TO BE TAKEN WHEN ISOLATING When opening manholes or breaking lines on any tank or vessel in sour gas service, the possibility of internal pyrophoric scale being present must be considered. Steam and water hoses must be immediately available to damp down any pyrophoric material. Great care should be taken in the case of vessels and equipment which have contained raw gas because the corrosive sulphur compounds present in this material may form an easily oxidisable scale that is pyrophoric.
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In opening manholes or breaking lines where there is a possibility of the evolution of H2S rich gas, compressed air breathing apparatus must be worn. It is also required to ensure the area around the manhole or the line is properly cordoned off. The operation of breaking into lines to swing blanks or to remove distance pieces is one that can be hazardous. Before permission is granted to do this work by Cold Permit, the OD must be satisfied that all possible means have been taken to remove pressure from the lines. Any possibility of liquid being left in the butt end of lines or valves must be pointed out to the Performing Authority and referred to on the Cold Work Permit. The Cold Work Permit must also specify which blanks are to be swung, bearing in mind that drain lines may be required to be left open. 8.2.3.3 ISOLATION OF VESSELS FITTED WITH ISOTOPES Some vessels are equipped with Radioactive Isotopes. Isolation of these vessels is not complete until the source is isolated in its shielded container. It is not required to remove the isotope from the vessel unless there is a great chance of accidental damage of the source container during the normal job on that vessel. In this last case, the source should be isolated, locked in the source container and the whole thing removed by a competent and classified person, from the vessel into the isotope Storage Room offsite. Further Information ADGAS PTW Manual Section 10.47 8.2.3.4 ISOLATION OF ACID TANKS AND VESSELS Spectacle blanks shall not be used in the isolation of acid tanks. The only approved method is by removal of spool pieces with subsequent sealing of disconnected lines with solid blank flanges. Any remaining acid sludge shall be completely neutralised and drained. The tank or vessel shall be washed down with water before personnel are allowed to enter without protective clothing.
8.2.4 GAS FREEING Following the isolation of a tank or vessel it must not be entered unless an Entry Permit has been issued by OD who will specify the conditions of the entry and who will certify it as safe for entry without breathing apparatus only after it has been satisfactorily gasfreed. Further Information Guidance Note CS15 HSE Books 1985 (rev 1997) Cleaning and gas-freeing of tanks containing flammable residues. ISBN 0 7176 1365 8 Tank cleaning safety code (Model code of safe practice in the petroleum industry, Part 16) Institute of Petroleum 1996 (2nd ed) ISBN 0 4719 7096 4 Doc. Number
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The following methods of removing dangerous vapour, flammable gas or liquids may be used either singly or in combination. 8.2.4.1 VENTILATION BY FORCED OR NATURAL DRAUGHT This method shall only be employed on oil or gas vessels where steaming, flooding or inerting is impracticable. When a decision is made to employ this technique, every effort must be made to pump out as much hydrocarbon liquid and sludge as possible before opening the tank or vessel. Whenever possible, forced ventilation should be used so that flammable vapour may be cleared in the shortest possible time. All electrical equipment shall be of flameproof construction. Air movers should be fitted at the tank or vessel top to pull air in at a low level through a shell manhole and discharge gas at a high level. Care should be taken when using natural draught ventilation during periods of calm weather because vapour released from tanks can travel considerable distances without being dispersed. Vapour issuing from shell manholes can give rise to a dangerous concentration in a bunded or confined area. Under such conditions no ignition sources may be allowed. With tanks or vessels which have contained sour gas or liquid, provision shall be made for continuous wetting of the internal surfaces by means of water fog nozzle(s) inserted into the roof opening. The water fog nozzle(s) shall be turned on first and the air movers started immediately afterwards. A shell manhole should be opened after approximately five minutes operation when the internals are thoroughly wet. With the air movers still in operation, the fog nozzle shall be removed and loose scale dislodged with high pressure water streams. The water nozzle must be earthed. 8.2.4.2 STEAMING This method can be used in the case of process vessels, small storage tanks and medium sized insulated tanks. It is essential that following a period of closed steaming, adequate provision is made to prevent damage due to a vacuum being drawn by condensation of steam. In large tanks the rate of condensation of steam is such that adequate purging is not possible. Where residual material is left on the tank or vessel surface after prolonged steaming, such residual material could still evolve vapour on application of heat, e.g. burning or welding. In such cases cold cutting may be employed or the internal surface kept thoroughly wet during the heating operation.
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All temporary steam hoses shall be earth bonded. 8.2.4.3 WATER FLOODING Before a tank or vessel is flooded with water, it must be ascertained that it and its foundations are capable of sustaining the weight. To avoid a build up of a static charge when this method is used, water should preferably be added from the base of the tank or vessel. If a hose pipe is used, the velocity should be kept low until the end is submerged, and the nozzle should be electrically earthed. Flooding with water should not be considered reliable for the removal of all petroleum vapour, liquid or solid residues. If any Naked Flame or Hot Work is to be done on the outside of tanks which have been water flooded, the internal surfaces must be kept wet with water. 8.2.4.4 INERTING This method is to be used when it is impossible to displace flammable gases or liquids because of the effect of steam, water or air on the contents of tanks. There is a danger in this method that if air later displaces the inert gas, any pyrophoric scale deposits that are present may burst into flame. The internal surfaces shall therefore be thoroughly wetted as described in "Ventilation by forced or natural draught". The atmosphere of the tank or vessel will not be suitable to breathe after Inerting; therefore, the inert gas shall be swept out with air and a test for sufficiency of oxygen carried out before anyone may enter without wearing breathing apparatus (See Chapter 6.10 Portable Gas Detectors). Adequate sized openings must be made in the top and bottom of the tank or vessel. 8.2.4.5 WORKING IN INERT ATMOSPHERES Entry into a tank or vessel containing an inert atmosphere will only be allowed under exceptional circumstances. In such a case the requirements for Restricted Entry are to be followed. Further Information Chapter 7.5 ENTRY REQUIREMENTS API STD 2217A: Guidelines for Safe Work in Inert Confined Spaces in the Petroleum and Petrochemical Industries
8.2.5 ISOLATION BY SPADING 8.2.5.1 INTRODUCTION Spading is a method of providing physical isolation of a pipeline, vessel or an item of process equipment, by the insertion at a suitable flange point of a blind rated for the duty. Doc. Number
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Properly installed, a spade will provide isolation from any contained pressure, fluid or flammable/toxic gases. When isolations are accomplished by the provision of a blind flange on a single flange, the operation is termed blanking and is not covered by this section. Further Information HSE OIAC The Safe Isolation of Plant and Equipment 1997: ISBN 0 7176 0871 9 8.2.5.2 APPLICATION Spading is generally considered as a temporary method of obtaining system/equipment isolation for operational purposes but may also be required for test or other purposes. Spading can be used to: · · · ·
Permit isolation of major items of equipment or group of items for gas freeing, making safe and under special conditions, testing. A group of items containing no block valves in the interconnecting pipework may be considered as one item of equipment. Isolate a section of plant for overhaul. Isolate utility services, e.g. fuel gas, fuel oil, steam, etc., to individual fired heaters. Prevent contamination of utility supplies, e.g. steam, water, air and nitrogen where permanently connected to a process unit.
8.2.5.3 DESIGN Design of flanges are to be according to BP Engineering Code of Practice CP-12, as detailed on drawings S-0755M and S-0756M. Spades shall be full flat faced on both sides, the faces being parallel to each other and free of distortion and weld splatter. Gasket contact surfaces shall be concentrically machined about the pipeline centreline. 8.2.5.4 USE AND PRECAUTIONS The use of spades and blinds are to contain enclosed fluids and gases, and generally are designed to contain maximum operating pressures only. Blinds or spades inserted for pressure test purposes must be rated for the required pressures. It is the responsibility of the Performing Authority to ensure that all blanks inserted for isolation conform to the correct specification, i.e. thickness and material.
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Thin blinds can be deformed due to differential pressure, therefore, they should be used with caution, and then only in special cases after the approval from the PROM. Any changes of spade orientation i.e. open to shut, or vice-versa, must be noted on the blind list at the time the change takes place. Note This is especially important during shutdowns or overhauls Arrangements shall be provided to enable a section of line containing a spade to be checked as free from pressure before spade insertion or removal. If during maintenance, pump suction or discharge valves are found to be passing, spades must be inserted in the suction and discharge lines before the pump casing is removed. Pumps on H2S, acid or chemical duty will not be opened for maintenance without spade isolation of suction and discharge lines - valve isolation is not sufficient. Spades will be fitted to any hydrocarbon duty pumps that are to remain open at the end of the normal working day.
8.3 SAFETY VALVES 8.3.1 SAFETY RELIEF VALVES The fitting of an intervening stop valve between a vessel and its relief valve or protecting device, or on the downstream side of a relief valve or protecting device shall only be resorted to after careful consideration of the possibilities of mal-operation of the stop valves. When it is desired to fit such a stop valve, the Modification Procedure must be followed. Where stop valves are so fitted, they must be arranged so that they can be locked in the open or closed position. Permission must be obtained from the OD before any lock is removed and the stop valve operated. The keys for the locks of any stop valves on the upstream or downstream side of relief valves will be held in the custody of the OD.
8.3.2 REMOVAL OF SAFETY VALVES If it is necessary to remove or isolate a safety valve from any pressure vessel in service, the Modification Procedure must followed. During the period that a vessel is operated without a relief valve, a member of the OD must remain at the control point of the vessel to observe the pressure on a freshly calibrated gauge and ensure that the vessel does not exceed its set working pressure. Doc. Number
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When the safety valve is refitted, the stop valves must be locked in the open position before the services of the special operator are discontinued. Further Information Chapter 2.12.1 PLANT MODIFICATIONS AND PROJECTS EEMUA: 184:96 Guide to the Isolation of Pressure Relieving Devices
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CHAPTER 9 CONTENTS 9
MAINTENANCE SAFETY .................................................................................................................... 317 9.1 ELECTRICAL .................................................................................................................................. 317 9.1.1 INTRODUCTION ......................................................................................................................... 317 9.1.2 DEFINITIONS .............................................................................................................................. 317 9.1.3 EQUIPMENT FOR CLASSIFIED HAZARDOUS AREAS ........................................................... 318 9.1.4 ELECTRICAL PERMIT SYSTEM ................................................................................................ 318 9.1.5 ELECTRICAL ISOLATION PROCEDURE ................................................................................. 319 9.1.6 ELECTRICAL ISOLATION CERTIFICATE/DANGER NOTICE CARD ..................................... 319 9.1.7 PROCEDURE .............................................................................................................................. 320 9.1.8 REPORTING OF FAULTS ........................................................................................................... 321 9.1.9 STATUTORY POSTERS ............................................................................................................... 321 9.1.10 WORK NEAR CABLES AND WIRING .................................................................................... 321 9.1.11 CABLE MARKERS .................................................................................................................. 321 9.1.12 CABLE DUCTS/CABLE TRAYS .............................................................................................. 321 9.1.13 CUTTING OF CABLES ........................................................................................................... 322 9.1.14 TEMPORARY INSTALLATIONS ............................................................................................. 322 9.1.15 INSTRUMENT CIRCUITS ....................................................................................................... 322 9.1.16 PORTABLE HAND LAMPS (BATTERY)................................................................................. 322 9.1.17 PORTABLE EQUIPMENT ...................................................................................................... 322 9.1.18 LIGHTING IN CONFINED SPACES ...................................................................................... 323 9.1.19 SUBSTATIONS AND SWITCHGEAR ...................................................................................... 323 9.1.20 EARTH CONNECTIONS ......................................................................................................... 323 9.1.21 PORTABLE LADDERS ........................................................................................................... 323 9.1.22 DEMOLITION ......................................................................................................................... 324 9.1.23 ELEVATED WORK ................................................................................................................. 324 9.1.24 CLOTHING ON EQUIPMENT ............................................................................................... 324 9.1.25 WASHING DOWN EQUIPMENT ........................................................................................... 324 9.1.26 CATHODIC PROTECTION .................................................................................................... 324 9.1.27 FIRE FIGHTING EQUIPMENT ............................................................................................. 325 9.1.28 TREATMENT FOR ELECTRICAL SHOCK ............................................................................ 326 9.2 LIFTING APPLIANCES AND EQUIPMENT ................................................................................. 332 9.2.1 INTRODUCTION ......................................................................................................................... 332 9.2.2 LIFTING APPLIANCES ............................................................................................................... 332 9.2.3 LIFTING EQUIPMENT ............................................................................................................... 336 9.3 SCAFFOLDING AND LADDERS .................................................................................................. 342 9.3.1 INTRODUCTION ......................................................................................................................... 342 9.3.2 DEFINITIONS .............................................................................................................................. 343 9.3.3 EFFECTS ON AREAS .................................................................................................................. 344 9.3.4 ALUMINIUM SCAFFOLDING .................................................................................................... 344 9.3.5 SCAFFOLDING IN TRAIN 3 ....................................................................................................... 345 9.3.6 MATERIAL SPECIFICATIONS ................................................................................................... 345 9.3.7 MISUSE OF BOARDS ................................................................................................................. 346 9.3.8 SCAFFOLDING ADJACENT IGNITION SOURCES .................................................................. 346 9.3.9 INDEPENDENT SCAFFOLDS .................................................................................................... 347 9.3.10 INDEPENDENT TIED SCAFFOLDS...................................................................................... 347 9.3.11 MOBILE ACCESS TOWERS ................................................................................................... 351 9.3.12 LADDERS ................................................................................................................................ 353 9.3.13 SPECIALISED TEMPORARY STRUCTURES ........................................................................ 355 Doc. 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9.4 MACHINERY SAFEGUARDS ....................................................................................................... 357 9.4.1 INTRODUCTION ......................................................................................................................... 357 9.4.2 DANGERS .................................................................................................................................... 357 9.4.3 PRINCIPLES OF SAFEGUARDING ........................................................................................... 357 9.4.4 GENERAL PROVISIONS ............................................................................................................. 358 9.4.5 CONSTRUCTION OF SAFEGUARDS ........................................................................................ 358 9.4.6 CHOICE OF MACHINE GUARDS ............................................................................................. 359 9.4.7 REMOVAL OF GUARDS ............................................................................................................. 359 9.4.8 ISOLATION OF MACHINERY .................................................................................................... 359 9.4.9 STARTING UP MACHINERY ...................................................................................................... 360 9.4.10 CLOTHING AND CLEANLINESS........................................................................................... 360 9.4.11 LUBRICATION ........................................................................................................................ 360 9.4.12 TRIPS AND GOVERNORS ...................................................................................................... 360 9.4.13 DRAINING AND VENTING PUMPS ...................................................................................... 361 9.4.14 WARMING THROUGH PUMPS ............................................................................................. 361 9.4.15 LIGHTING AT MACHINES..................................................................................................... 361 9.4.16 DIESEL ENGINES................................................................................................................... 361 9.4.17 STEAM TURBINES ................................................................................................................. 361 9.4.18 EYE PROTECTION ................................................................................................................. 362 9.4.19 MACHINE OPERATOR TRAINING........................................................................................ 362 9.4.20 GRINDING MACHINES/ ABRASIVE WHEELS ..................................................................... 364 9.4.21 PORTABLE GRINDERS AND ABRASIVE CUTTERS ............................................................ 365 9.5 EXCAVATIONS .............................................................................................................................. 365 9.5.1 INTRODUCTION ......................................................................................................................... 365 9.5.2 PERMITS...................................................................................................................................... 365 9.5.3 UNIDENTIFIED BURIED CABLES AND PIPELINES ............................................................... 365 9.5.4 EXCAVATION EDGES ................................................................................................................ 365 9.5.5 MEANS OF EGRESS FROM TRENCH EXCAVATIONS ............................................................ 366 9.5.6 BARRIERS AND LIGHTING........................................................................................................ 366 9.5.7 SHORING ..................................................................................................................................... 366 9.6 DIVING OPERATIONS................................................................................................................... 367 9.6.1 INTRODUCTION ......................................................................................................................... 367 9.6.2 DIVING CONTRACTORS ............................................................................................................ 368 9.6.3 DIVING SUPERVISORS .............................................................................................................. 368 9.6.4 PLANT AND EQUIPMENT ......................................................................................................... 368 9.6.5 EMERGENCY INSTRUCTIONS .................................................................................................. 368 9.6.6 DIVING IN CONFINED SPACES................................................................................................ 369 9.7 WORK OVER WATER.................................................................................................................... 369 9.7.1 INTRODUCTION ......................................................................................................................... 369 9.7.2 HAZARDS .................................................................................................................................... 369 9.7.3 GENERAL PRECAUTIONS ......................................................................................................... 370 9.7.4 SAFETY NETS .............................................................................................................................. 370 9.7.5 SAFETY BELTS AND HARNESSES............................................................................................. 371 9.7.6 FALL ARREST DEVICES ............................................................................................................ 373 9.7.7 USE OF FALL ARREST DEVICES .............................................................................................. 374 9.7.8 CARE OF BELTS AND HARNESSES .......................................................................................... 375 9.7.9 WORK SITE REQUIREMENTS ................................................................................................... 375 9.7.10 PERSONAL PROTECTIVE EQUIPMENT .............................................................................. 376 9.7.11 RESCUE EQUIPMENT ........................................................................................................... 376 9.8 WORK ON ROOFS .......................................................................................................................... 378 9.8.1 INTRODUCTION ......................................................................................................................... 378 9.8.2 PLANNING .................................................................................................................................. 378 Doc. 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9.8.3 SAFE ACCESS ............................................................................................................................. 379 9.8.4 SAFE PLACE TO WORK ............................................................................................................. 379 9.8.5 Flat roofs ...................................................................................................................................... 380 9.8.6 Non-fragile sloping roofs ............................................................................................................. 381 9.8.7 Non fragile roofs .......................................................................................................................... 382 9.8.8 FRAGILE ROOFS ........................................................................................................................ 382 9.8.9 FRAGILE ROOF REGISTER ....................................................................................................... 383 9.8.10 SAFETY HARNESSES AND NETS .......................................................................................... 383 9.8.11 PROTECTION OF OTHER PERSONNEL .............................................................................. 384 9.9 WORK AT HEIGHT ........................................................................................................................ 384 9.9.1 INTRODUCTION ......................................................................................................................... 384 9.9.2 GENERAL .................................................................................................................................... 385 9.9.3 WORK OVERHEAD ..................................................................................................................... 385 9.9.4 MAN CAGE/WORK BASKET ...................................................................................................... 385 9.9.5 SKY CLIMBER ............................................................................................................................. 386 9.9.6 ABSEILING .................................................................................................................................. 386
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9 MAINTENANCE SAFETY 9.1 ELECTRICAL 9.1.1 INTRODUCTION The stopping and starting of motors and the switching On and Off of lights, heaters, fans and other such electrical equipment is normally carried out by the user. All other operations affecting electrical equipment may only be carried out by a person holding the appropriate certificate of authorisation.
9.1.2 DEFINITIONS 9.1.2.1 EXPLOSION PROOF/FLAMEPROOF An explosion proof/flameproof enclosure for electrical apparatus is one that will withstand, without damage, any explosion of the prescribed flammable gas or vapour that may occur within it under practical conditions of operation within the rating of the apparatus and the fault level of the electrical system (and recognised overloads, if any, associated therewith) and will prevent the transmission of flame such as will ignite the prescribed flammable gas or vapour which may be present in the surrounding atmosphere. 9.1.2.2 INTRINSICALLY SAFE The term 'Intrinsically Safe' as used in the petroleum industry generally refers to tools, instruments or equipment which due to the design and use, are incapable of generating heat, sparks or flame sufficient to ignite any of the flammable or explosive atmospheres likely to be encountered on hydrocarbon facilities. In electrical terms 'Intrinsically Safe' refers to a circuit under test conditions in which any spark or thermal condition (in both normal and fault conditions) is incapable of igniting a specific explosive atmosphere. Intrinsically safe apparatus denotes that it is so constructed that when installed and operated under conditions specified by the certifying authority any electrical sparking that may occur in normal working, either in the apparatus or in the circuit associated therewith, is incapable of causing an ignition of the prescribed flammable gas or vapour. Further Information Chapter 6.10.13.7 INTRINSICALLY SAFE EQUIPMENT
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9.1.2.3 APPROVED APPARATUS Apparatus other than flameproof, explosion proof, or intrinsically safe that has been submitted to the appropriate authority for examination and test, and in respect of which a certificate has been issued approving its use in prescribed applications. Note No work shall be carried out on any such apparatus or wiring, nor shall the flameproof enclosure of any apparatus be opened unless all electrical supplies have been isolated from the apparatus and wiring. All such apparatus and wiring shall be inspected and maintained so as to retain the characteristics upon which the design depends to secure flameproof or intrinsic safety and to comply with the conditions of certification. Before any such apparatus or wiring is put into use either originally or after repair, adjustment or removal, it shall be thoroughly examined and where necessary tested. All circuits associated with flameproof equipment or wiring shall be controlled automatically so as to prevent damage to the apparatus or wiring by reason of overload or short circuit or leakage of current to earth.
9.1.3 EQUIPMENT FOR CLASSIFIED HAZARDOUS AREAS All equipment in Classified Hazardous Areas must conform to: · · ·
BS EN60079-14:2003: Electrical apparatus for explosive gas atmospheres. Electrical installations in hazardous areas (other than mines) BS EN60079-25:2004: Electrical apparatus for explosive gas atmospheres. Intrinsically safe systems BP RP 44-6
A Non-Hazardous Area is considered as an area no part of which is classified as a Hazardous Zone. Normal industrial equipment is permitted but permission must be obtained on a Work Permit for its use inside the Restricted Area Further Information Chapter 5 PERMIT TO WORK SYSTEM Chapter 3.4 HAZARDOUS AREAS AND ZONES
9.1.4 ELECTRICAL PERMIT SYSTEM The following types of permits are issued to cover work on electrical apparatus or to enter sub-stations: ·
Figure 9-1: Electrical Isolation Certificate/Danger Notice Doc. Number
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Figure 9-2: Permit to Work on Apparatus Figure 9-3: Permit to Enter Sub Station Figure 9-4: Sanctions For Testing Of Electrical Apparatus Figure 9-5: Temporary Supply Certificate For Change Of Use Hot, Cold, Entry Permits. (Refer to Chapter 5 PERMIT TO WORK SYSTEM) Excavation Work Request. (Refer to Chapter 5 PERMIT TO WORK SYSTEM)
Before mechanical inspection and/or cleaning work on any plant or equipment directly connected to an electrical power supply exceeding 250 volts is carried out, the Area Authority must obtain confirmation from the Electrical Section that it may proceed. Within the terms of any such sanction the Electrical Section will issue an "Electrical Isolation Certificate/Danger Notice" to the Area Authority. Work must NOT be carried out on such "live" apparatus until an Electrical Isolation Certificate/Danger Notice is noted on the Work Permit and the Work Permit issued by the Area Authority to the person carrying out the work. The permit must be retained until the work is completed or stopped by an authorised person. Before an Electrical Isolation Certificate/Danger Notice is issued covering work on any plant or equipment connected to an electrical power supply (e.g. motor driven pumps, electrically traced lines etc.), electrical isolation must be arranged by the Operating Authority with an authorised person in the Electrical Section. This authorisation will also be recorded on the respective Hot, Cold/Entry Permit. At the discretion of the "Authorised Person", routine maintenance operations on circuits operating at voltages not exceeding 240 volts, e.g. lamp changing, may be carried out under a Special Standing Instruction without a specific written Electrical Work Permit.
9.1.5 ELECTRICAL ISOLATION PROCEDURE 9.1.5.1 PURPOSE To establish a uniform procedure for the isolation of electrical circuits, and to prevent those electrical circuits from being accidentally or inadvertently energised while work is being performed on electrical equipment or on equipment which is electrically driven.
9.1.6 ELECTRICAL ISOLATION CERTIFICATE/DANGER NOTICE CARD A "Electrical Isolation Certificate/Danger Notice" must be attached to the switch directly controlling the isolation of the section to be worked upon by a member of the Electrical Section. Certification of the Work Permit that the work on the apparatus is complete and is safe to energise must be obtained before a Electrical Isolation Certificate/Danger Notice Card is removed by either:
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An Authorised person in the Electrical Section. The person who affixed the Danger Notice.
9.1.7 PROCEDURE Upon receipt of a request for a permit to work the Area Authority must decide if any electrical isolation is necessary. If electrical isolation is required then the Area Authority must initiate this by completing Section 'A' of the Electrical Isolation Certificate/Danger Notice. He must contact the Electrical Section authorised person who is to effect the isolation. The authorised person will complete Section 'B' of the certificate. He will remove the Section 'B' tear-off portion. This he will affix at the point of isolation. The authorised person will then perform the isolation as appropriate to the equipment. He will ensure the isolation is locked off using a padlock unique to that isolation. He will then place the padlock key in a lock-out box in the Control Room. The lock out box will then be secured using the multi-lock hasp. Padlocks will be applied to the hasp by the following: · · ·
The Operating Authority who is to issue the permit. The Electrical Section authorised person. The Performing Authority who is to take receipt of the permit. Caution WHERE MORE THAN ONE WORK PERMIT IS ASSOCIATED WITH THE ISOLATION, EACH PERFORMING AUTHORITY WILL APPLY A PADLOCK TO THE MULTI-LOCK HASP
The isolation certificate number and the lock out box number should be entered on the associated work permit(s). Similarly the permit number(s) should be shown on Section 'A' of the Electrical Isolation Certificate/Danger Notice. Only at this stage can the Work Permit be issued. On completion of the work, a Performing Authority must sign off the work completed section of his permit, and remove his padlock from the lock out box hasp.
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When all Performing Authority padlocks have been removed, and all associated permits are signed off, the Operating Authority will initiate the request for re-energisation of the equipment. The Operating Authority will sign Section 'C' of the Electrical Isolation Certificate/Danger Notice. The authorised person will sign, date, and time Section 'C', and retain the whole left hand section after it has been signed off. Both the Operating Authority and authorised person padlocks can now be removed from the lock out box hasp, and the isolation padlock key retrieved. The authorised person can then re-energise the equipment, and replace the isolation padlock key in it's storage cabinet.
9.1.8 REPORTING OF FAULTS All electrical faults and breakdowns must be reported immediately to the Electrical Engineer/Supervisor or Shift Superintendent.
9.1.9 STATUTORY POSTERS Instructions for the treatment of persons suffering from electric shock shall be posted in all premises where electricity is used at over 250 volts D.C. or 100 volts A.C.
9.1.10 WORK NEAR CABLES AND WIRING If work is planned on buildings, plant or overhead cranes, etc. where damage may be caused to wiring or where there may be danger from exposed wires, the persons responsible for the work must contact the SEE to ensure that any danger or damage is avoided.
9.1.11 CABLE MARKERS Cable markers must NOT be moved except under the authority of SEE or his Deputy.
9.1.12 CABLE DUCTS/CABLE TRAYS Vehicles may not be driven on to cable ducts or slabs except those ducts designed as part of a road system. Discarded materials must not be placed or left on cable trays and lifting appliances must not be attached to these trays.
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9.1.13 CUTTING OF CABLES Before any cable is cut, except immediately adjacent to a terminating box where it is possible to trace a cable back to the earthing bond, the SEE and the Area Authority must be satisfied that the cable has been made dead and earthed, and see an iron spike driven into the cores of the cable at the point where the cable is to be cut using an approved cable spiking gun
9.1.14 TEMPORARY INSTALLATIONS Temporary installation work should be avoided as far as possible and will conform with the BP-RP 12-19 Electrical System and Installation - Construction Site Power. Where work of a temporary nature is unavoidable, it must not remain as a temporary installation after a period of three months. If, at the end of that time, an installation is still required, it must be made a permanent installation complying with all general regulations. Further Information BP-RP 12-19 Electrical System and Installation - Construction Site Power
9.1.15 INSTRUMENT CIRCUITS The SEE is responsible for the safe operation and maintenance of all 110 volt circuits associated with instrumentation and will, as necessary, carry out repairs to individual items of equipment in this category.
9.1.16 PORTABLE HAND LAMPS (BATTERY) Only the approved portable battery hand lamps supplied by the Company may be used in Restricted Areas. All hand lamps will be checked, sealed and numbered by the Electrical Section before being issued. Battery replacement or repairs will only be carried out by the Electrical Section and NOT by the user. This will ensure that certification of approval for use in a Restricted Area is maintained.
9.1.17 PORTABLE EQUIPMENT In order to minimise the effects of electrical shock the power requirements for apparatus used in the ADGAS areas are listed below and shall not exceed Industrial Area Hand lamps - 25 volts (12.5 volts to earth). Hand held portable tools must be of a type designed to operate at a voltage not greater than 110 volts and the supply to such appliance shall not be more than 55 volts above earth potential. Non-Industrial Area: In addition to the 110 volts supply equipment power hand tools, hand lamps and extension leads of 230 volt mains supply, through a 30mA residual current device (RCD) may also be used. Portable power tools must not be used if any defect is suspected or any damage apparent. Care must be taken to avoid damage to flexible cables. Kinking and the formation of knots can cause serious damage which may not be apparent on the Doc. Number
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outside. Crushing and damage to the outer sheath should be treated as damage necessitating repair.
9.1.18 LIGHTING IN CONFINED SPACES Further Information Chapter 7.8.3 LIGHTING OF CONFINED SPACES
9.1.19 SUBSTATIONS AND SWITCHGEAR Only an authorised person, competent person, or persons under his direct and continuous supervision shall enter any enclosure containing high voltage equipment where it is possible, under any circumstances, to come into contact with live high voltage conductors. Enclosures containing live high voltage apparatus must be kept locked and keys must only be in the possession of persons authorised to enter such enclosures. Substations, switch houses, transformer houses and bays must never be used as subsidiary store rooms. The switchgear and floors of these buildings must be kept clear of all materials and obstructions. Switchgear installed in pump houses and on various plants must be kept clear of all obstructions, and materials shall NOT be stored behind or on top of such switchgear. An area is to be marked off around all switchboards at a distance of 1m from the equipment, and this area must be kept clear of all obstructions. All spare entries to metal switches, fuse gear or other equipment must be plugged or blanked off. All covers, cover bolts and nuts must be fixed in position and tight.
9.1.20 EARTH CONNECTIONS All earth connections on tanks, poles, process plant and buildings are to be tested annually for resistance to earth by a member of the Electrical Section and a record of these tests must be maintained.
9.1.21 PORTABLE LADDERS Where there is any possibility of a ladder coming in contact with bare electrical conductors, wooden or glass fibre ladders without any metal reinforcement must be used.
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9.1.22 DEMOLITION Before demolition work is begun on plant or buildings, the electrical wiring of the system, especially lighting wiring, must be disconnected from the power supply by the Electrical Section and an Electrical Isolation Certificate issued. The responsibility for ensuring that the Electrical Section disconnects power rests with the person in-charge of the demolition work.
9.1.23 ELEVATED WORK A safe means of access must be provided for personnel engaged in lamp replacement, maintenance work, etc., on overhead masts and high exposed positions. In many cases (e.g. work on masts) safety harnesses must be worn.
9.1.24 CLOTHING ON EQUIPMENT Placing or hanging clothes or other materials on electrical equipment is forbidden.
9.1.25 WASHING DOWN EQUIPMENT The use of water for washing down equipment in the vicinity of electrical apparatus is forbidden.
9.1.26 CATHODIC PROTECTION 9.1.26.1 GENERAL Cathodic protection which is used to prevent corrosion of tanks, pipelines, jetties and offshore structures introduces some risk of incendive sparking when this method of protection is used in hazardous areas. Protection may be provided by the current generated either by an external transformer/rectifier system or by sacrificial anodes. To confine the flow of direct current to the structure being protected, insulating flanges are installed at each end and at certain intermediate points in the system. Incendive sparks can be produced if joints or connections in the system are broken or when insulators are short circuited. 9.1.26.2 MAINTENANCE WORK When maintenance work or any other work is required on cathodically protected pipelines or tankage or equipment, the system must first be made safe against any possible arcing by: ·
Switching off the associated rectifier(s) and/or; Doc. Number
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clamping a heavy copper bonding wire not less than 70 sq.mm to each side of the intended break.
Alternatively depending on the work to be done, the transformers associated with the Cathodic Protection Beds in the vicinity can be switched off. C&ID must be consulted. They will advise, using their “Guideline for CP System Isolation” document, which transformers must be isolated for work to continue safely. These switching and bonding operations will be the responsibility of an Electrical Engineer nominated by SEE and the work permit will indicate that this work has been carried out. An up-to-date plan showing the systems protected by impressed currents must always be maintained by SEE. 9.1.26.3 INSULATING FLANGES Insulating flanges must be kept clean and protected against accidental short circuit. Insulating flanges must be tested at least once in every year to ensure that the insulation resistance is not less than 10,000 ohms.
9.1.27 FIRE FIGHTING EQUIPMENT Foam, water or steam used for fire fighting must not be allowed to contact live electrical equipment. CO2, BCF or dry powder extinguishers shall be used on fires involving electrical equipment. Use water, foam or steam only when certain that the electrical supply has been cut off. Further Information ADGAS General Rules Relating to the Control and Safe Operation and Maintenance of Electrical Apparatus
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9.1.28 TREATMENT FOR ELECTRICAL SHOCK
TREATMENT FOR ELECTRICAL SHOCK
FREE FROM CONTACT
Switch off the power immediately, or send someone to do so. If the power cannot be switched off at once, attempt to remove the person, but do not touch him with bare hands. Preferably use rubber gloves, or if these are not available, use a loop of rope, coat or stick to drag the person free. Whatever is used must be dry and non-conducting.
AFTER RELEASE
Lay the patient down on a dry surface, if possible, and if no sign of breathing can be observed, immediately proceed to promote artificial resuscitation (mouth-to-mouth or mechanical resuscitator) and send for medical aid. Check that heart is beating, if not commence external cardiac massage.
STIMULANTS/HOT DRINKS
Stimulants must not be administered unless recommended by a doctor. Hot drinks must never be given unless the patient is fully conscious.
KEEP THE PATIENT WARM
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Figure 9-1: Electrical Isolation Certificate/Danger Notice
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Figure 9-2: Permit to Work on Apparatus
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Figure 9-3: Permit to Enter Sub Station
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Figure 9-4: Sanctions For Testing Of Electrical Apparatus
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ABU DHABI GAS LIQUEFACTION CO. LTD. (ADGAS) No. ………….
ELECTRICAL SECTION OVERHAUL ENERGISATION NOTICE 1. THIS NOTICE REFERS ONLY TO THE CIRCUIT/ EQUIPMENT:No.
Title
Plant
2. OVERALL CONTROLLING DANGER NOTICE:-
Train
No.
3. PURPOSE OF INTERIM ENERGISATION:-
4. MODIFICATIONS TO NORMAL CONFIGURATION. MAIN OR CONTROL CIRCUITRY ETC.:-
SIGNED
DESIGNATION
TIME
DATE
RETURN TO NORMAL PERMIT CONTROL 5. ALL MODIFICATIONS AS DETAILED IN 4. HAVE BEEN REMOVED. THE CIRCUIT/ EQUIPMENT IS RETURNED TO ITS ORIGINAL STATE AND IN NOW RE-ISOLATED UNDER DANGER NOTICE. No. SIGNED
DESIGNATION
TIME
DATE
Figure 9-5: Temporary Supply Certificate For Change Of Use
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9.2 LIFTING APPLIANCES AND EQUIPMENT 9.2.1 INTRODUCTION Lifting operations involving lifting appliances and lifting equipment are used frequently within the LNG Plant to effect maintenance requirements, operating requirements, corrective actions, modifications and scheduled plant shutdowns or overhauls. To this end it is essential that the requirements of this section on the operation, condition and storage of the lifting appliances and lifting equipment are strictly followed by responsible parties of the Company and Contractors.
9.2.2 LIFTING APPLIANCES 9.2.2.1 DEFINITION Lifting Appliance means any crane, grab, sheer legs, excavator, piling frame drag-line, pulley block, gin wheel, chain hoist, davit, pull-lift or other lifting device, including a fork lift truck. 9.2.2.2 CONSTRUCTION AND USE All parts and working equipment on lifting appliances, both fixed and movable, must be of good construction, sound material and free from patent defect. They must be properly maintained and examined by a competent person at least every fourteen months in accordance with accepted codes of practice. A register shall be maintained of all items classed as lifting appliances and details of examinations shall be entered in a register. Every lifting appliance, as far as the construction permits, must be inspected at least once in every week by the operator, if competent for the purpose, or other competent person. A log of each inspection shall be carried on every crane and be available for inspection by HSED, or other authorised party. In addition to inspections and examinations every lifting appliance must be tested at least once in four years or following substantial repair or alteration. The test shall be carried out under the direction of a competent person who will decide on the test weight to be lifted. The test weight shall be a minimum of 25% over the safe working load (SWL) of the appliance. A test certificate in respect of each test shall be issued by the competent person making the test. A copy of the test certificate shall be retained with the lifting appliance.
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9.2.2.3 ISSUE New lifting appliances shall not be brought into use initially unless accompanied by the manufacturers test certificate. Every such appliance shall also be subject to inspection by a competent person with details of inspection being recorded in the register. 9.2.2.4 OVERLOADING OF LIFTING APPLIANCES A lifting appliance shall not be loaded beyond the safe working load marked on it, except for the purpose of proof testing by an authorised person. Where a lifting appliance is fitted with a safe working load indicator or alarm, this shall not be disconnected at any time when the appliance is in service. 9.2.2.5 TANDEM LIFTS Where by the nature of the load being lifted, a tandem lift is necessary, prior approval shall be sought from the PM& EM. The operation will require careful planning and an assessment of the share of the load which is to be carried by each crane. A competent person shall be specifically appointed to supervise the operation and shall ensure that the signals to the crane drivers are clear and well rehearsed. A Task Risk Assessment may need to be considered for involved lifts. In all lifting operations, rigging supervisors and crane operators must know the weight of the load to be lifted. If this information is not available, competent advice shall be sought. 9.2.2.6 QUALIFICATIONS OF CRANE OPERATORS Cranes shall be operated only by trained crane operators who are in possession of a valid U.A.E. Crane Operators Licence. No person under 21 years of age shall operate a crane or give signals to the operator. Crane operators must be physically fit with good hearing and eyesight, corrected by spectacles if necessary. 9.2.2.7 MOBILE CRANES Mobile cranes shall not travel within the Restricted Area unless accompanied by a Banksman whose duty is to guide the crane underneath overhead piperacks, up or down inclines, through sharp turns or within congested areas. When a mobile crane fitted with outriggers is used, the outriggers shall be fully extended and jacked down on even firm ground, using a spread support where necessary.
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On all multi boom length/jib angle cranes, the operator shall have at his disposal, in the cabin a chart and automatic device indicating the safe working load of the crane in all acceptable positions. No crane shall leave the recognised roads on Das Island without an authorised Vehicle Movement Permit . No person(s) shall be carried on the platform of a mobile crane unless there is securely affixed to the platform a proper seat. Pre-use inspection checklists are to be completed according to current instructions. 9.2.2.8 CRAWLER MOUNTED CRANES Crawler mounted cranes shall not travel within the Restricted Area or on the roads of Das Island unless accompanied by a Banksman, whose duty is to direct the operator and other road users. When travelling on the asphalt roads of Das Island, the road surface shall be protected by "Tracked Vehicle Travelling Mats" (Conveyor belt material is ideal). During the summer months vehicles of this type shall only be moved between 02.00 05.00 hours when road surfaces are at their hardest. If there is any damage to the road surface then the contractor in question is responsible for the reinstatement of the damaged surface to a standard acceptable to ADGAS. 9.2.2.9 PEDESTRIAN OPERATED OVERHEAD CRANES Only authorised persons who are experienced and trained shall operate these cranes. A minimum of two experienced personnel are required during the operation of these cranes, one person to operate the crane the other to act as banksman. It is essential that a clear path be kept at all times over the full length of the floor for personnel operating the crane controls. Lines indicating the width of the path should be painted on the floor as well as notices indicating that the path shall be kept clear. The pendant control on such cranes shall be adequately supported so as no undue strain or weight is taken on the electrical power line. Crane hoist and travel controls are to be clearly marked and legible. Pre-use inspection check lists are to be completed in accordance with current instructions.
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9.2.2.10 WORK ON OR NEAR OVERHEAD GANTRY CRANES Work that necessitates the presence of men on or near electrically driven overhead gantry cranes or crane tracks shall not be started until the crane has been rendered inoperable by the removal of the fuses by an Authorised Electrical Engineer. In addition the crane power supply switch shall be padlocked in the Off position. 9.2.2.11 USE OF CRANES The hoisting mechanism of a crane shall not be used for any purpose other than lifting a load vertically except in the case of a crane fitted with a manufacturer approved dragline. Transportation of suspended loads by mobile cranes shall only be undertaken where all other methods are impracticable. No person shall enter the cabin or otherwise distract the operator of a crane during a lifting operation. Only the appointed banksman shall give signals to the crane operator. Note Before the commencement of a lift in excess of one tonne in the ADGAS Restricted Area, the site shall be inspected and approval given by the Area Authority While in transit all telescopic boom cranes shall have boom sections fully retracted, the jib in a near horizontal position and hook block firmly secured to prevent swinging. Pipeline and supports of equipment shall not be used to tie down crane jibs. 9.2.2.12 SECURING OF LOADS Every part of a load shall be securely suspended or supported to prevent danger from slipping or displacement. When possible the lifting of a load shall be halted after the load has been raised a few inches, the security of the slinging attachment shall then be checked before proceeding with the operation. 9.2.2.13 GIN POLES AND DERRICKS Gin poles shall be adequately constructed of steel with attachments at the head for suspending the load and guying, and be fitted with proper base plates. Guys for gin poles shall be attached to "Dead man" earth screws or substantial steel structure. They shall not be attached to vessels, pipelines or pipeline supports.
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An excavation permit must be obtained before driving stakes, etc., into the ground for gin poles. 9.2.2.14 INDUSTRIAL POWER TRUCKS/FORK LIFT TRUCKS Industrial power trucks or fork lift trucks shall not be used to lift a load greater than the maximum safe working load permitted for the truck. Industrial power and fork lift trucks shall be fitted with cabin front protection (e.g., mesh/plexiglass) to ensure safety of the operator. Only secure loads shall be moved, and the forks shall be in a low position when in transit. Passengers are forbidden to ride on fork lift trucks.
9.2.3 LIFTING EQUIPMENT 9.2.3.1 DEFINITION Lifting equipment or equipment means any chain sling, rope sling or similar equipment, a ring, link, hook, plate clamp, shackle, swivel, eyebolt or any part thereof used in conjunction with a lifting appliance. 9.2.3.2 CONSTRUCTION AND USE No lifting equipment shall be used unless it is of good construction, sound material, adequate strength and free from patent defect. Lifting equipment shall be inspected by a competent person at least once every six months. Every item of lifting equipment must be clearly die-stamped with a Works Identification Number and its Safe Working Load (SWL). Where lifting equipment fails a test or is visibly defective, it shall be destroyed and deleted from the register. Lifting equipment shall not be issued unless there is in existence a valid test certificate in respect of that item. 9.2.3.3 STORAGE Adequate storage shall be provided for slings and ropes when not in use. Storage will be under cover and well ventilated. It will include racks so that air can circulate naturally around slings. Ropes and slings shall not be stored on the floor. Items shall be examined by a competent person before they are issued from the Stores, Doc. Number
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9.2.3.4 WIRE ROPE Wire ropes or wire slings shall not be used in raising or lowering or as a means of suspension if in any length of ten diameters the total number of visible broken wires exceed 5% of the total number of wires in the rope. 9.2.3.5 LASHING WIRE Flexible steel lashing wires of 6mm diameter are designed for lashing ladders, etc., and shall not be used for suspended loads. 9.2.3.6 SLINGING OF LOADS Care shall be taken by the use of wood or similar packing piece to ensure that the sling is not bent over a small curvature or sharp edge since this may damage the sling. The weight being lifted plus the weight of the tackle shall be known before starting a lift. Information indicating the safe working loads of chains, ropes or lifting tackle in use, and, in the case of a multiple sling, the safe working load at different angles of the legs, shall be issued to all personnel involved in this type of work. 9.2.3.7 FIBRE ROPE SLINGS Fibre rope slings shall not be used for lifting or lowering if the rope is badly chaffed externally or worn internally, or where the fibres have noticeably deteriorated to a marked degree. When not in use, natural fibre rope slings shall be hung up where they can dry naturally in a free circulation of air. 9.2.3.8 DAVITS Davits shall be inspected by a competent person from CID once in every three year and before usage. When suspending floating heads, manhole doors and similar pieces of equipment from davits, it is important to ensure that the suspension bolts are not bent or distorted. 9.2.3.9 YARN ROPES All ropes shall be checked for signs of damage and replaced if faulty. Knotting and splicing of rope shall only be undertaken by a competent person. In use, care should be taken to avoid damage to the rope by use of suitable packing and by avoiding contact with sharp or abrasive objects. Doc. Number
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Ropes shall be stored in thoroughly ventilated areas, preferably tied in loose coils and hung. Where natural ropes are liable to come into contact with chemicals, acid scale or sludge that is detrimental to the fibres, then suitable man made fibre or wire ropes shall be used. 9.2.3.10 CHAINS Chains should be checked on each occasion before use for distortion of links, rings or hooks, and cuts in links. Chain repairs should only be carried out where there is a proper heat treatment facility available. A chain should never be: · · · ·
Hammered to straighten a link. Joined by a bolt and nut. Shortened by twisting or knotting. Subjected to strain if it is in a kinked or twisted position, or if the links do not move freely.
9.2.3.11 FLAT BELT SLINGS Belts made from woven material shall comply with BS 3481: Flat lifting slings. Specification for flat woven webbing slings made of man-made fibre for general service, or a recognised alternative standard approved by MHSE and should only be used if there is no satisfactory alternative. They should be discarded after each job or, if not, they should be regularly checked for cuts, excessive wear or fraying. Blisters in the covering of wire mesh types are a sure indication that the mesh has been broken underneath. In use, flat belt slings should be protected from sharp-edged loads by sacking or similar padding. It is most important that all lifts should take place vertically, since any side-pull tends to overload the edge of the belt and risks tearing it; it also tends to move the belt inwards over possible rough edges and risks cutting. 9.2.3.12 SHACKLES Shackles are widely used for making connections in slinging. They shall be tested, certificated and identified. The SWL shall also be stamped on them and they shall be recorded in the register. The shackle pin is a separate part of the shackle but belongs to it. Only the correct pin shall be used.
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9.2.3.13 HOOKS Every hook used for raising or lowering, or as a means of suspension, shall comply with BS EN1677-5: 2001 or a recognised alternative standard approved by MHSE It shall be provided with an efficient device to prevent the displacement of the sling or load from the hook. A load can become displaced by an unlatched hook falling back after it has been set through an eye or hole in the load to be lifted, or, particularly in the case of multi-leg slings, when the load is at rest. Loads can also become displaced if the point of the hook catches against an obstacle during the lift. Further Information BS EN1677-5: 2001: Components for slings. Safety. Forged steel lifting hooks with latch. Grade 4 9.2.3.14 EYE BOLTS The construction, fitting and use of eyebolts shall comply with a recognised standard approved by MHSE such as BS 4278:1984: Specification for eyebolts for lifting purposes. It is essential for safe lifting that eyebolts should be screwed only into tapped holes with which they are compatible. To avoid mismatching both eyebolts and tapped holes should be identified and clearly marked with diameter and thread form. Eyebolts are made to screw into or through a load and may be plain or have collars. The plain eyebolt is good for vertical loading but if loaded at any angle the load it can carry is considerably reduced. Even when a collared eyebolt is used the safe working load is reduced with angular loading. When installed the collar shall be at right angles to the hole and should be in full contact with the surface, and be properly tightened. The load should always be applied in the plane of the eye, never in any other direction. If necessary, washers or shims should be inserted below the collar to ensure that the eye is correctly aligned when tight. Eyebolts should not be permanently secured in place, e.g. by spot welding. In common with other general purpose lifting equipment, all eyebolts should be kept in a suitable store under the charge of a responsible person. They should be inspected for damaged threads or other defects before and after use. Further Information BS 4278:1984: Specification for eyebolts for lifting purposes
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9.2.3.15 CHAIN HOISTS The general rules relating to slings and lifting equipment apply to chain hoists, in addition, attention is drawn to the following: The correct size of chain hoist for the load to be lifted shall be used; only one man shall operate the hoist and he should be able to operate it with ease, other-wise a larger capacity hoist should be used. Loads shall not be left suspended for any length of time without securing the pull chain to avoid the load dropping. The load chain shall not be run out to the point where the load is entirely dependent on the bolt holding the dead end of the chain. The load chain shall never be used to encircle the load; a sling should be used. A load shall never be lifted with the tip of a hook. 9.2.3.16 SPREADER BEAMS/EQUALISER BEAMS Spreader beams should be used to support long or wide loads. They eliminate the hazard of a load tipping as well as wide sling angles and any tendency of the sling to crush the load. Spreader beams should be used where eyebolts are in use, in which case only vertical lifts should be made. They should be used where it is necessary to distribute the loading to avoid excessive stresses in the object being lifted. Equaliser beams should be used to equalise the load in sling legs and keep equal loads when making multiple lifts. Both types of beam are manufactured to suit a specific purpose and care should be taken to ensure that the correct beam is used. The capacity of a beam with multiple attachments depends on the distance between attachment points. If the distance between attachment points is doubled the capacity of the beam is halved. 9.2.3.17 PADEYES Padeyes are designed specifically to suit the package weight and centre of gravity of the item to be lifted. They are constructed and fixed by welding to the load in order to lift with minimum additional stress being placed on the load.
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Accuracy of the design criteria is of paramount importance to ensure that the strength, size and location of the padeyes are correct. The following criteria form the main aspects of the padeye design: The theoretical centre of gravity in relation to the geometry of the structure to be lifted. The design package weight shall be distributed such that 75% is transferred to any diagonal pair of slings in the case of a four point lift. The distribution of the load to the padeyes is proportional to the distance from the design centre. Construction of the padeyes shall be in strict accordance with the calculated design criteria. Note Following welding of pad-eyes to the load as a minimum NDT such as MPI must be carried out in consultation with CI&D 9.2.3.18 COLOUR CODING OF LIFTING EQUIPMENT To ensure that all the lifting equipment used by ADGAS and ADMA-OPCO has been systematically examined and certified for use by the CI&D, a colour coding system is to be used by the Central Workshop Rigging Section. See Figure 9-6: Colour Coding for Items on a 6 Month Cycle. 9.2.3.19 RESPONSIBILITY The HOW is responsible for providing the Health Safety & Environment Manager with details of changes to the colour code for publication as a revision to the manual. Note DEFINITION For the purpose of this instruction, lifting equipment is defined as all lifting equipment of a mobile nature under the general control of the Central Work Shop Rigging Section. It does not include site cranage, fixed runway beams, etc.
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ITEMS CERTIFIED FOR A SIX MONTH SERVICE PERIOD (inspected on a seven month cycle) WILL BE COLOUR CODED as follows: YEAR 2006 2007 2008 2009 2010
JAN BL OR GR WH BL OR GR WH BL OR
FEB
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MONTH JUN JUL OR OR GR WH WH BL OR OR GR WH WH BL OR OR GR
AUG
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Figure 9-6: Colour Coding for Items on a 6 Month Cycle ITEMS CERTIFIED FOR A TWELVE MONTH SERVICE PERIOD (inspection on a thirteen month cycle) WILL BE COLOUR CODED as follows: YEAR 2006 2007 2008 2009 2010
JAN BK Y Y BK BK Y Y BK BK Y
MONTH JUN JUL
FEB
MAR
APR
MAY
AUG
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Figure 9-7: Colour Coding for Items on Annual Cycle Users of lifting tackle will be notified of the colour system for 2011 to 2015 during the 4th quarter of 2010 by way of a revision to this page of the Health, Safety and Environment Manual.
9.3 SCAFFOLDING AND LADDERS 9.3.1 INTRODUCTION Where work is required to be performed at heights which cannot be reached from the ground, means must be provided to raise the worker to a suitable working level and a Doc. Number
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temporary platform must be built from which the job can be completed safely. It is vital that all scaffolding working platforms be properly constructed, provide adequate space and comply with statutory requirements. In the absence of definitive U.A.E. legislation in this area reference has been made to British Standards throughout this section.
9.3.2 DEFINITIONS 9.3.2.1 SCAFFOLDING Scaffolding is defined as a temporary structure on which persons may work. It also provides support for the materials used in construction, maintenance, repair and demolition work and can be used to obtain temporary access to certain areas or equipment. 9.3.2.2 STANDARDS Scaffolding shall be constructed to the following standards: · ·
BS EN 12811-1:2003 Temporary works equipment. Scaffolds. Performance requirements and general design and BS 5974: 1990 Code of Practice for "Temporarily Installed Suspended Scaffolding and Access Equipment".
Equivalent or recognised codes approved by MHSE may also be acceptable. Further Information BS EN 12811-1:2003 Temporary works equipment. Scaffolds. Performance requirements and general design BS 5974: 1990 Code of Practice for "Temporarily Installed Suspended Scaffolding and Access Equipment". 9.3.2.3 SCAFFOLDING SUPERVISOR This shall be an Engineer, Supervisor or a Foreman who has the practical and theoretical knowledge and who knows the purpose of the scaffolding and how it should be constructed to carry the load to be placed on it. This would normally be an ADGAS or Contractor, Rigging/Scaffolding Supervisor. 9.3.2.4 SCAFFOLDING INSPECTOR This shall be a Scaffolding Supervisor who was not involved in the erection or alteration of the scaffold construction he is inspecting. This would normally be an ADGAS Rigging/Scaffolding Supervisor.
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9.3.2.5 SCAFFOLD CONSTRUCTION All scaffolding shall only be erected, altered or dismantled by competent and experienced workers under the immediate supervision of a Scaffolding Supervisor. 9.3.2.6 SCAFFOLD INSPECTION All scaffolding shall be inspected: · · ·
Prior to handover to the user, At least once each quarter during use and Following inclement weather conditions liable to adversely effect the integrity of the structure,
by a Scaffolding Inspector. A record of inspections of every scaffold construction shall be maintained by the Rigging Section.
9.3.3 EFFECTS ON AREAS As a non-routine work operation, usually of a temporary nature, the erection of scaffolding on a process area may have various undesirable effects. Some of these effects are: · · · ·
Restriction of free movement of personnel on escape routes. Restriction of access to process controls including valves, sight glasses and other operator control points. Blocking of free access to fire and safety points such as manual call points, fire extinguisher stations, hose reels and emergency showers and others. Inhibition of, or interference with, the process fire and gas detection and protection systems.
The relevant area supervisor must be involved in the planning and setting of the scaffold so that it has of minimum impact on the safety of the plant and its operation.
9.3.4 ALUMINIUM SCAFFOLDING The use of aluminium scaffold materials is widespread and usually acceptable in the construction industry. However, aluminium scaffolding and fittings are not acceptable for use within the Industrial Area. Use of aluminium scaffold tubing has the potential to create the problems of: ·
Generation of incendiary sparks when aluminium is impacted on oxidised surfaces, e.g. rust. Doc. Number
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Low heat strength with possible melting or burning in situations of excessive heat or fire.
9.3.5 SCAFFOLDING IN TRAIN 3 The location and type of scaffold erected in an area serviced by a deluge system such as is found in areas of Train 3 can have radical effects on the designed coverage and water volume in that area. Such interference to spray patterns in the case of a process fire could lead to catastrophic process vessel failure. The major problem created by scaffolding is in the blanking effect of the scaffold boards, stairs and staging. Control measures in this case include: · · · ·
prior planning for location and scaffold design that will minimise the blanking effect on established spray patterns. open mesh type approved scaffold planks and stair treads, if appropriate. minimising the life span of the scaffold by promptly removing on the completion of the job. when an extended period of installation is unavoidable, removal of planks and flooring will alleviate the blanking effect. Caution Danger signs, barriers and appropriate prohibition scafftags must clearly indicate that the scaffold is unserviceable during the period the decking is removed
In the unavoidable situation of extended term installations, the possibility of extending the length of the spray nozzle branches through the scaffolding to clear the areas of deluge coverage together with the possibility of compensating spray angles may be contemplated. This alternative must be assessed by the relevant qualified authorities and the original design configuration restored promptly on removal of the scaffold.
9.3.6 MATERIAL SPECIFICATIONS 9.3.6.1 GENERAL Every scaffold shall be of suitable and sound material and of adequate strength for the purpose for which it is built. Wooden standards and ledgers shall not be used. All scaffolding components shall be examined by a competent person before issuing for use. 9.3.6.2 TUBES AND FITTINGS All tubes, couplers and fittings, when new, must be at least up to the standard and type described in BS 1139. Tube ends must be square with the axis and cut cleanly. Used tubes must be free form cracks, splits and excessive corrosion and be straight. All Doc. Number
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couplers and fittings shall be free from distortion and shall be maintained in an oiled condition. Bolts with worn or damaged threads shall be replaced. Further Information BS 1139: Metal Scaffolding 9.3.6.3 BOARDS Boards for use in platforms shall be unpainted to facilitate identification of defects, and shall be fire retardant or sprayed with a fire retardant chemical approved by the MHSE before assembly into the scaffolding. Face knots shall not exceed 150mm in total when summed across the width of both faces, with the width of a single knot not exceeding 75mm. Edge knots generally shall not exceed 28mm. Where an edge knot also appears on the face, it is summed in with the total of the face knots. Generally there shall be a clear distance between knots or knot groups of not less than 150mm. The twist in a 3.9m board shall not exceed 12mm over the full length. Standard boards are nominal 225mm wide x 38mm thick. Other board thicknesses of 50mm and 63mm are available. Further Information BS 2482: 1981. Standard Boards
9.3.7 MISUSE OF BOARDS Scaffolding boards must not be used for any other purpose than scaffold platforms. Their use as ramps on roadways for hoses and cables is a dangerous practice that weakens the board internally and may cause a serious accident if the board is subsequently used in a platform. If non-serviceable boards are to be used for these purposes they must be painted on both sides. Caution The use of serviceable scaffold boards other than for scaffolding will be regarded as a serious safety breach.
9.3.8 SCAFFOLDING ADJACENT IGNITION SOURCES Owing to the effects of radiant heat on scaffold boards care must be taken when erecting scaffold platforms adjacent to process heat sources. Doc. Number
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The checklist shown in Figure 9-8: Scaffolding Adjacent Ignition Source Checklist is to be completed jointly by the plant operator and performing authority and attached to the field white copy of the permit.
9.3.9 INDEPENDENT SCAFFOLDS This scaffold construction is free standing and is completely independent of the structure being worked upon. When used, the scaffold must be adequately guyed and tensioned. Frequent checks, particularly during high winds, must be made on the tensioning system to ensure integrity of the scaffold.
9.3.10 INDEPENDENT TIED SCAFFOLDS 9.3.10.1 GENERAL This type of scaffold is not completely independent of the building or structure. The scaffold structure carries its own weight and all applied loads- men, materials and wind loads - placed upon it down to the ground, but it must be tied to the building or structure to obtain stability and prevent possible movement. 9.3.10.2 BASE A good base is essential. Standards shall be supported on base plates. Where necessary, ground shall be levelled and rammed to provide a firm surface. Timber sole plates, at least 219mm wide and 35mm thick, shall be laid to support the base plates for standards. The sole plate area must not be less than 300cm2, or 500cm2 for soft ground. Wherever possible, a sole plate should support at least two standards. This will ensure that the load carried by each standard is distributed over a fairly large area to prevent the standard from sinking into the ground, so disturbing the balance of the scaffold. Bricks, broken paving stones and similar loose materials are dangerous and shall not be used as supports for standards as they can easily shatter or become displaced. 9.3.10.3 STANDARDS Standards must be vertical and this must be ascertained with a spirit level. Any joints necessary in standards to reach the required height shall be staggered and occur near ledgers. Joints in adjacent standards shall not occur in the same lift. 9.3.10.4 LEDGERS The standards in each row are kept equidistant and strengthened by ledgers fixed horizontally on the inside of standards with right angle couplers.
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Joints in ledgers shall also be staggered, i.e. joints in adjacent ledgers shall not occur in the same bay. These joints should preferably be made using sleeve couplers and be at not more than one-third of the distance between two standards. 9.3.10.5 TRANSOMS Transoms, keeping the inner and outer rows of standards apart, are set on top of ledgers and at right angles to them and to the building or structure. Horizontal distance between transoms at working platform level is determined by the thickness of the boards to be used. For 38mm boards, transoms must be spaced so that no board overhangs by more than 150mm or less than 50mm. Transoms shall be fixed to ledgers or standards with right angle or putlog coupler. Where transoms are not required to support boards, a transom must occur within 300mm of each pair of standards. Where a scaffold structure exceeds 50m in height, the transom adjacent to the standard on an unboarded lift shall be secured to the ledger or standard by couplers capable of sustaining a safe working load of at least 5KN. Ledgers and transoms shall not protrude more than is necessary beyond the general outline of the scaffold. At lower levels, such protrusions are a danger to pedestrians or passing vehicles and it is good practice to use safety caps on the open ends; at higher levels, these protrusions can easily be struck by crane-handled loads or dislodge materials hoisted by gin wheels, etc. 9.3.10.6 BRACING Bracing is essential to stiffen the structure. Use right angle couplers wherever possible; failing that swivel couplers. Bracing takes two forms: · ·
Ledger bracing. This runs diagonally from ledger to ledger or standard to standard at alternate pairs of inner and outer standards. Diagonal braces may all run parallel or rise in zig-zag fashion. Care is necessary to ensure correct seating of toe-boards. Facade bracing. This usually runs across the face of the scaffold to its full height at an angle of approximately 45° to the horizontal at 30m intervals. The brace should cross standards at, or near, ledger positions.
Alternatively, this bracing can extend to the full height of the scaffold in zig-zag fashion across the first and last bays and at 30m intervals between. Joints in braces shall be made with sleeve or parallel couplers. As a general rule, ledger bracing shall not be removed to make way for men or materials. If this does become necessary, individual braces, within one lift, may be removed to allow passage of material. Braces must then be replaced. Doc. Number
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9.3.10.7 TIES The spacing of lines of ties shall not exceed 8.5m horizontally or vertically and shall be evenly distributed over the scaffold surface. 9.3.10.8 WORKING PLATFORMS All boards that make up a working platform shall rest squarely and evenly on correctly spaced transoms. Each board must have at least three supports unless its thickness or span is sufficient to prevent sagging under load. In practice a 3.9m x 38mm board will be supported at approximately 1.2m intervals with a maximum permissible span of 1.5m. Nominal Thickness mm 38 50 63
Maximum Span m 1.5 2.6 3.25
Minimum Overhang mm 50 50 50
Maximum Overhang mm 150 200 250
Table 9-1: Maximum Span Scaffold Boards Where boards need to butt, transoms must be doubled and spaced to ensure that board overhang falls within the permissible range. Too much overhang will cause a board to tip if someone steps on the end; too little will make it unsafe, i.e. a small movement may allow the board to drop through. No board shall overhang its support by more than four times its thickness, i.e. 150mm when using boards of 38mm. No board, of whatever thickness, shall be allowed to overhang less than 50mm. The surface of the working platform should be even to reduce tripping hazards. All boards shall lie closely together along their length. If, for any reason, a platform has to be completed with short boards, they must be battened together to prevent any one board from tipping. Every precaution must be taken to prevent boards from lifting in high winds by using straps or purpose made metal clamps. Probably the simplest method is to use straps at the ends of each run, anchored to the transom with wire or hook bolts.
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9.3.10.9 PLATFORM WIDTH Platforms must always be wide enough to permit freedom of movement and, as necessary, to accommodate storage of such materials as are necessary.
Duty Inspection Light Duty General Purpose Heavy Duty
Distributed Load KN/m2 0.75 1.5
Maximum Number Platforms 1 2
2.0 2.5
Common Width
Maximum Bay Length
3 boards 4 boards
2.7m 2.4m
2
4/5 boards
2.1m
2
4/5 boards
2.0m
Table 9-2: Working Scaffolds of Tube and Couplers Platform widths of independently tied scaffolds in general terms are: · · ·
boards (600mm) - used only as footing. boards (800mm) - as footing and materials. (Figures in brackets are minimum permitted width). Further Information BS EN 12811-1:2003: Temporary works equipment. Scaffolds. Performance requirements and general design
Wherever materials need to be deposited, a clearway of 430mm must always be maintained. The space between the edge of the platform and the face of the building or structure must always be as small as possible. 9.3.10.10
TOEBOARDS AND GUARDRAILS
Guardrails and toeboards are required at the sides and ends of all working platforms from which men or materials can fall more than 2m. Toeboards and guardrails shall be fitted to the inside of standards to prevent outward movement. Toeboards must rise at least 150mm above the working platform. Guardrails must be not less than 915mm nor more than 1150mm above the working platform. The distance between the top of the toeboards and the underside of the guardrails must not be more than 765mm. Where materials need to be stored on the working platform, additional boards may be necessary to stop materials falling. Alternatively, wire mesh frames may be suspended from guardrail to toeboard to effect complete closure.
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If guardrails and toeboards are removed to permit passage of men and materials, they must be replaced as soon as possible. 9.3.10.11
MOVING THE WORKING PLATFORM
Careful attention must be given to moving all boards from lift to lift, otherwise a well designed and prepared deck progressively becomes an incomplete and unsafe platform. 9.3.10.12
MEANS OF ACCESS
Ladders provided for access purposes must be supported by the stiles resting on a firm, even base. The stiles shall be securely lashed or fixed with a ladder clamp to a ledger or transom near the top to prevent slipping either sideways or outward. Ladders must be set at a working angle of 75° to the horizontal, i.e. 1m out for every 4m in height, and extend at least 1m, (5 rungs), above platform level to provide adequate handhold at the stepping off point. Ladders required to rise more than 9m of vertical height shall have an intermediate landing place provided. Stairs must be provided with handrails and, where persons can fall more than 2m, there must be guardrails, fitted at a height of between 900mm and 1m above the centre of each step. A lower guardrail, 450mm above the centre is advisable since toeboards cannot be fitted. Handrails shall be continued beyond the end of the stairs if additional handhold is necessary. Stairways must be kept free of obstruction, materials and rubbish, and if they become slippery shall be cleaned or sanded as quickly as possible.
9.3.11 MOBILE ACCESS TOWERS Mobile scaffolds take the form of towers made of normal steel tube and fittings and mounted on wheels, with one working platform, the dimensions of which are normally equal to, or less than, the corresponding base dimensions. 9.3.11.1 STRUCTURE Dimensions will vary according to need, but the corner standards shall never be less than 1.2m apart. On larger types of rectangular shapes an additional standard may well be advisable in the centre of each of the larger sides. Where joints become necessary in standards, they shall be made with sleeve or parallel couplers. Wheels, or castors, not less than 125mm in diameter and fitted with brakes which cannot accidentally be released, must be locked into the base of the standards. Wheels or castors shall be marked with safe working load. Ledgers and transoms, at right angles to the standards, shall commence approximately 150mm from the bottom to provide a firm base clear of the wheels. Lifts shall not exceed 2.5m.
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Bracing is in two forms: · ·
Plan bracing, i.e. diagonal at base, working platform and alternative lifts. Diagonal bracing at approximately 45° to the horizontal in zig-zag position to full height of the structure on all four sides.
9.3.11.2 HEIGHT LIMITATIONS The height to base ratio is based on the shortest base length. Height is measured from ground to level of working platform and does not include guardrails. Height to base ratios shall not be greater than the following: · ·
Mobile internal tower 3.5: 1 Mobile external tower 3.0: 1
The recommended maximum height for mobile scaffolds is 9.5m except that this may be increased to 12m where the scaffold is tied-in to a structure whilst in use. 9.3.11.3 WORKING PLATFORM The working platform shall be fully and closely boarded using boards with 38mm thickness. Transoms shall be spaced at not more than 1.5m intervals. Distributed load on the platform of a light duty platform shall not exceed 1.5 KN/m2. 9.3.11.4 GUARDRAILS AND TOEBOARDS Guardrails and toeboards will be necessary on all four sides. Toeboards must rise at least 150mm above platform level. Guardrails must be between 900mm and 1m above platform with the distance between the top of the toeboard and the guardrail not exceeding 750mm. 9.3.11.5 ACCESS A ladder for access purposes can be lashed vertically to one of the narrow sides, the foot resting on an additional transom. The ladder must extend at least 1m above platform level to provide hand-hold at the stepping-off point. 9.3.11.6 IN USE Mobile scaffolds shall only be used on ground which is firm and level. Moving the structure shall only be effected by pulling or pushing at the base. Working platform shall be clear of men and materials when the scaffold is being moved.
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Wheels shall be turned outwards to provide maximum base dimensions and wheel brakes must be "on" and locked when the scaffold is in use. Further Information Chapter 9.8 WORK ON ROOFS Chapter 9.9 WORK AT HEIGHT
9.3.12 LADDERS 9.3.12.1 INTRODUCTION Ladder misuse is the cause of many accidents and these could be obviated by more frequent inspection of the ladder before use and correct placing during use. A ladder shall be used as a working place only after careful consideration that it is suitable for the purpose. All ladders shall be soundly constructed of timber, steel or aluminium and shall be of a proprietary manufacture complying with the relevant British Standard. 9.3.12.2 PORTABLE LADDERS Ladders shall be erected on a firm level base and the ladder supported by the stiles only. On sloping or uneven surfaces an adjustable safety foot can be used to ensure equal support. Loose packing shall not be used. The use of non-slip pads, caps or sleeves is recommended, especially on slippery floor surfaces. The head of the ladder should rest on a firm, solid surface. A ladder stay can be used where the support may be otherwise unsuitable, i.e. at a plastic gutter. The correct slope for a ladder is an angle of about 75° to the horizontal, i.e. one metre out for every four metres in height. Where possible, ladders must be secured near the top to prevent the base from slipping outwards and the top from slipping sideways. This is normally achieved by lashing or clamping each stile to a convenient secure anchorage. In certain cases, the use of spreader arms attached to the top of the ladder may satisfy this requirement to secure, but it must first be established that the ladder, so fitted, cannot slip in the circumstances in which it is to be used. Where a ladder cannot be secured at the top, it must be secured near its base by means of guy ropes secured between stiles and stakes embedded into the ground or to other suitable anchorages. If possible the feet of the ladder should be heeled in. If no other means of securing the ladder can be used, then someone must hold it at the base whilst it is in use. This is only effective with comparatively short ladders.
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In use, a ladder shall be placed so that there is space behind each rung for proper foothold. Rungs should be clear of grease, oil or other slippery substances. Only one person is permitted on a ladder at any one time. 9.3.12.3 TIMBER LADDERS Damage to timber ladders may be caused without leaving any visible sign of that damage. Great care must be exercised in handling timber ladders to ensure that they are not overloaded or dropped from a height. Correct storage is necessary so that the ladders do not warp or the rungs become loose. Ladders shall be erected with the wire tie rods beneath the rungs, and wire stile reinforcement on the underside of the stile. Timber ladders must not be painted as the paint may disguise defects. Coating with a preservative and clear varnish is permissible. All ladders must be inspected by a competent person before issue and after use, and additionally, inspections are to be conducted at least every six months in January and July of each year to ensure all are serviceable. Inspection shall include the following items: · · · ·
Timber ladders for splits or cracks, splintering, warping or bruising. Metal ladders for mechanical damage. Rungs for signs of undue wear or movement. No rungs shall be missing. Wedges and tie-rods for tightness. Metal reinforcement to stiles for correct position and wear. Feet for splitting and fraying. Timber/plastic inserts to metal ladders for wear and correct position.
9.3.12.4 METAL LADDERS Metal ladders and timber ladders with metal stile reinforcement shall not be used where any electrical hazard exists. 9.3.12.5 ALUMINIUM LADDERS Aluminium ladders can produce a spark via a thermic reaction when impacted onto an oxidised surface eg. rust. They should not be used in areas where there is a possibility of an ignition. Aluminium ladders shall not be used inside the Industrial Area. 9.3.12.6 SUSPENDED LADDERS When ladders are suspended they shall be lashed or clamped at top and bottom so that they are equally supported on each stile. Long ladders will need additional ties in the length to prevent movement. Doc. Number
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9.3.12.7 LADDER TOWERS Ladders used for gaining access will normally be timber pole ladders and should be erected in parallel rather than zig-zag pattern where more than one ladder is used. 9.3.12.8 ACCESS TO AND FROM LADDERS All ladders must extend at least 1m above any landing place, or beyond the highest rung from which a man may be working, to ensure adequate handhold. If this is not possible then a nearby adequate handhold must be provided. Suitable access to a working place must be provided at the stepping off point. Persons must not be required to climb over or under guardrails or over toeboards, gaps in guardrails and toeboards must, however, be kept as small as possible. Landing places shall be provided at intervals not exceeding 9m and these must be provided with correctly fitted toeboards and guardrails. Where ladders pass through platforms, the openings must be no longer than is reasonably practicable and no more than 500mm wide, leaving sufficient platform width for access.
9.3.13 SPECIALISED TEMPORARY STRUCTURES Specialised scaffolding and power or manually operated working cradles must be erected/rigged under the direct supervision of a competent and suitably experienced person and must conform to the relevant standard. Further Information Construction Safety Manual: Building Advisory Service. BS 1129:1990 Portable Timber Ladders. BS 2037:1994 Portable Aluminium Ladders. BS 2482:1981 Timber Scaffold Boards. BS EN 12811-1:2003 Temporary works equipment. Scaffolds. Performance requirements and general design BS 5974:1990 Code of Practice for temporarily Installed Suspended Scaffolding and Access Equipment
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SCAFFOLDING CHECKLIST For use with scaffold work permits where the scaffold will be adjacent to hot surface lines or vessels (Even if they are not in service at the time) 1. Identify possible heat source.
Yes
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steam lines
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hot oil lines
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exhaust pipes
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heat stress relief work
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heat exchangers
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other
No
2. Check insulation of hot service lines. -
is the scaffold required to gain access to remove insulation
-
will this expose the scaffold to higher temperature
are the scaffold boards at a safe distance from the hot service line. 3. Should the boards be removed when not in use ? 4. Is a fire blanket required ?
INITIAL : 1.
Performing Authority
________________ Date:
2.
/
/
Plant Operator
____________ Date:
/
/
Figure 9-8: Scaffolding Adjacent Ignition Source Checklist
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9.4 MACHINERY SAFEGUARDS 9.4.1 INTRODUCTION The absence of any injury from operating machinery without the necessary safeguards over a period of time does not mean that the moving parts are not dangerous. Although good supervision, co-operation, training and constant attention by the operator have an important part to play, there is no substitute for proper safeguarding measures and their maintenance. The basic principle is that unless a danger point or area is safe because of its position, the machinery should be provided with an appropriate safeguard that eliminates or reduces danger before access to the dangerous point or area can be achieved. The general requirements for safeguarding machinery are presented below. Further Information PD 5304:2000 Safe use of machinery
9.4.2 DANGERS A person may be injured at machinery as a result of: · · · ·
Coming into contact with a moving part, or being trapped between the machinery and any fixed structure. Being struck by, or becoming entangled in or by any material in motion in the machinery. Being struck by parts of the machinery ejected from it. Being struck by material ejected from the machinery.
These may be regarded as mechanical hazards. Some machinery may also present non mechanical hazards in which the dangers are less obvious or tangible, e.g. electric shock, toxic vapour production, airborne contaminants, ionising radiation, noise. These areas are dealt with elsewhere in this Manual.
9.4.3 PRINCIPLES OF SAFEGUARDING Wherever practicable, dangerous parts should be eliminated or effectively enclosed in the initial design of the machinery. If this cannot be achieved, safeguards should be incorporated. Provision should be made to facilitate the fitting of alternative types of safeguards on machinery where it is known that this will be necessary because the work done on it will vary.
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Where a movable guard or cover is used as a safeguard it should be interlocked to the drive. Machinery should be isolated from the power source during maintenance. Lubrication and routine maintenance facilities should be located outside the dangerous area. Suitable illumination should be provided at all dangerous areas. Every mechanism and control forming part of a safeguard should, as far as practicable, be of fail safe design.
9.4.4 GENERAL PROVISIONS It is the duty of all employees supervising the operation of machines to be vigilant to check all dangerous operating practices being performed by persons under their control, and to encourage the practice of all reasonable safety precautions, such as the use of suitable push sticks and holders for the work, and the use and maintenance in proper adjustment of all safety guards. Sufficient clear and unobstructed space shall be maintained at every machine while in operation to enable the work to be undertaken without unnecessary risk. The floor surrounding every machine shall be maintained in good and level condition, and as far as practicable be free of machine cuttings or other loose material and shall not be allowed to become slippery. When doubt exists as to the regulations laid down for various machines then the MHSE should be consulted. Aisles shall be kept clear of materials. Floors should be swept at regular intervals and all scrap and cuttings removed. Oil spillages should be immediately cleaned up. Where dangerous or objectionable dust, fumes or flammable swarf is produced by the operation of the machine, specific provision should be made for the control and effective removal of such substances in such a way as to avoid danger to the operator and machine. This may involve the provision of effective exhaust appliances over the machine.
9.4.5 CONSTRUCTION OF SAFEGUARDS All safeguards should be of sound design and adequate strength. Guards should be made of appropriate material for the potential danger; the shatter resistant properties of the materials may need to be considered. Doc. Number
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Whatever safeguard is used should not itself present a hazard such as trapping or shear points, splinters, rough or sharp edges or any other source likely to cause injury. Fixed guards should be secured with fastenings that require the use of a tool.
9.4.6 CHOICE OF MACHINE GUARDS The general principles regarding choice of type of guard are: · · ·
Fixed guards must be installed in every practical case. Where a fixed guard is impossible, an inter-locking guard should be fitted where practical. Where neither a fixed guard nor an inter-locking guard is practical, an automatic guard should be used as the second alternative.
9.4.7 REMOVAL OF GUARDS No person is allowed to remove a recognised machine or shafting guard without written authority or sanctioned work permit, and the guard must be replaced before the machine is restarted.
9.4.8 ISOLATION OF MACHINERY A Work Permit must be obtained giving detailed conditions and precautions to be taken in the isolation procedure of process machinery or equipment. Adjustment, repairs or cleaning operations that may be a possible source of danger must not be carried out until the machine is isolated from any source of power. Electrical power must be locked off at the switch gear of any machine by an authorised person in the Electrical Section. The person making the isolation must attach a Danger Notice Card to the switch at the time of isolation. Isolation of compressors may be made using two valves and a bleeder provided that both valves are locked shut and the bleeder is checked as open and clear (double block and bleed). Where work upon pumps, compressors, etc., cannot be completed within a normal working day, isolation shall be effected by removing spool pieces and blanking off the live lines.
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When pressure gauges are to be removed from running machinery, the gauge and associated pipework must first be correctly vented. Pressure gauge pipework shall be plugged off immediately after a gauge is removed. The machine must be isolated so that no liquid or gas can enter the machine or equipment concerned if opening up of a section to atmosphere is necessary. Further Information BS 1506:1986. Standard blanks Chapter 5 PERMIT TO WORK SYSTEM
9.4.9 STARTING UP MACHINERY Before starting up any machinery, care shall be taken that no apparatus, tools, rags, etc. are in a position to foul a moving part, and that no person is in a position of danger. No person may enter a machinery space within which he may be trapped without an Entry Permit that specifies isolation of power from the driver. Every machine must be provided with efficient starting and stopping appliances so situated as to be conveniently controlled by the machine operator.
9.4.10 CLOTHING AND CLEANLINESS Machine operators must not wear loose clothing, which would be liable to catch in moving parts. The area and floors surrounding every machine must be maintained free from loose material and kept dry and free from oil or chemical spillages.
9.4.11 LUBRICATION Lubrication of moving parts of a machine may only be carried out where it is unnecessary to remove guards. Lubricating oil bottles and grease lubricators shall be checked frequently and any abnormal usage of lubrication reported immediately.
9.4.12 TRIPS AND GOVERNORS Machines fitted with overspeed and other trips shall not be operated unless these are in full working order. No attempt shall be made to render trips and governors inoperable. Trip Testing is to be carried out: · ·
In accordance with statutory requirements, e.g. limit devices on passenger carrying hoists. Whenever a machine is shut down. Doc. Number
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At periodic intervals which experience has shown to be appropriate for the type of limiting device on the particular machine concerned.
9.4.13 DRAINING AND VENTING PUMPS The greatest care must be exercised when draining pumps for maintenance work. Draining shall be carried out slowly, and oil spillage kept to a minimum at the pump surroundings to avoid slipping hazards. Drain and vent line connections to pumps and compressors shall be adequately secured according to BP Engineering Practice. Steam hoses and/or portable fire equipment shall be readily available during the draining or venting of pumps and compressors on light hydrocarbon duty. When gas or liquid is to be released to atmosphere, it shall be done only after it has been established that there are no ignition sources nearby.
9.4.14 WARMING THROUGH PUMPS Pumps on hot oil duty after being returned to service following maintenance work, shall be warmed through slowly. Where warming-through lines are fitted, they shall always be used.
9.4.15 LIGHTING AT MACHINES Where shop lighting is inadequate to permit work at machines to be carried out safely, additional illumination shall be provided.
9.4.16 DIESEL ENGINES Diesel driven equipment must have the diesel drive immobilised by some positive method that will prevent it being started when work is carried out involving the driven part. The use of mobile diesel engines in Zone 1 or Zone 2 areas shall be made subject to a Hot Work Permit Further Information Chapter 6.10.13.9 DIESEL ENGINE UNITS
9.4.17 STEAM TURBINES Whenever steam turbines, which exhaust to a low pressure (LP) steam main, are taken out of service for maintenance work, the high pressure (HP) steam supply must always be valve isolated before the LP steam valve is closed. Steam valves must be locked closed and drains and vents open while the machine is off line. Whenever preparations are being made for the starting of a steam turbine, the HP and LP steam lines shall be drained of condensate and the LP steam valve opened slowly to Doc. Number
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warm the turbine casing through to open drains. The exhaust valve must be fully open before any attempt is made to open the HP steam supply valve. Note An instruction to this effect must be prominently displayed in all areas where steam turbines are sited Overspeed trip mechanisms shall be checked, as far as is practicable, for mechanical operation before running a turbine at, or near, its overspeed trip setting. The speed shall be checked with a rotational speed indicating instrument. Reed/Vibrational type tachometers are not acceptable for the setting up of overspeed trips. During all overspeed trip tests, a member of the OD will stand-by, and operate the main steam inlet valve.
9.4.18 EYE PROTECTION Adequate eye protection is to be worn when: · · · · · · ·
Welding or cutting of metals by means of an electrical, oxygen-acetylene or similar process. Grinding, using either a pedestal or portable grinder. The following processes when carried out by means of hand tools or other portable tools: Fettling of metal castings involving the removal of metal. Cutting out or cutting off (not including drilling or punching back) cold rivets or bolts from boilers or other plant. Chipping or scaling of boilers, vessels, etc. Breaking or dressing of stone, concrete or slag. Further Information Chapter 3.12 EYE SAFETY PROGRAMME
9.4.19 MACHINE OPERATOR TRAINING No person may be employed at a machine unless he has been sufficiently trained to work that class of machine, or unless he works under the supervision of a person who has a thorough knowledge of the working of the machine and of the dangers associated with the machine and of the precautions to be observed. Every person being trained to work a machine must be fully and carefully instructed as to the dangers associated with such a machine and the precautions to be observed. 9.4.19.1 CIRCULAR SAWS The blade of a sawing machine shall not be cleaned by hand while the blade is in motion. Doc. Number
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The blade of a circular saw shall be fenced as follows: · · ·
The part of the saw blade that is below the table shall be guarded to the greatest extent possible. The sawing machine shall be provided with a riving knife, securely fixed below the machine table, behind and in direct line with the saw blade and have a smooth surface, be strong, rigid and easily adjustable. The part of the saw blade above the machine table shall be guarded with a strong and easily adjustable guard, to extend from the top of the riving knife to a point above the top surface of the material being cut, which is as close as practicable to that surface. The guard shall have a flange of adequate depth on each side of the saw blade and be kept so that the flanges extend beyond the roots of the teeth of the saw blade.
A suitable push stick shall be provided and kept available for use at every circular sawing machine fed by hand. A person shall not stand at the delivery end of a machine to remove material whilst the saw is in operation. 9.4.19.2 PLANING MACHINES Planing machines that are not mechanically fed shall be provided with a bridge guard with a length not less than the full length of the cutter block and a width not less than the diameter of the cutter block and be so constructed as to be easily adjusted. 9.4.19.3 MACHINE TOOLS Machine tools shall only be operated by authorised and suitably trained persons. Protective clothing, particularly eye protection shall be worn as appropriate to the job and machinery in use. Machine safety guards shall be in position. Machines used in a workshop, such as wood working equipment, lathes, boring, grooving, mortising, milling machines, power presses, circular band saws, etc., are governed by special regulations regarding the operation of the machines in the Standing Instructions of the appropriate Division. In the majority of cases the regulations require the following: · ·
Trays with adequate drainage to reservoirs should be arranged beneath hydraulic units, coolant pumps, or any similar unit which can leak oil and cutting fluids to the floors. Safe means of removing swarf or trade waste, such as a brush, is to be provided to clear the operating area. On no account will compressed air or bare hands be used.
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The cutters of every machine tool shall be enclosed by a guard or guards as far as practicable, having regard to the work being done. All guards shall be of sound construction. Guards shall be correctly positioned whenever a machine is operated. On no account should guards be adjusted whilst the cutting tool is in motion. Every machine tool shall be provided with an efficient device for starting and stopping the machine and be in such a position as to be readily and conveniently operated by the operator. Every part of the machine tool shall be of sound construction, sound material and properly maintained. Every machine tool other than those held by hand, shall be securely fixed to a foundation.
9.4.20 GRINDING MACHINES/ ABRASIVE WHEELS 9.4.20.1 SAFETY PRINCIPLES The main principles of safe use of grinding machines and abrasive wheels are as follows: · · · · · · ·
Abrasive wheels must be maintained properly by trained persons. A register of such competent persons is held by the Head of Workshops. Every abrasive wheel more than of 55mm diameter shall have the maximum permissible speed marked on the wheel. Maximum speeds of small wheels will be stated on a notice attached to the machine. The maximum permissible speed of an abrasive wheel must not be exceeded under any circumstances. No spindle shall be operated at a speed in excess of the maximum permissible speed of the wheel. The maximum working speed of spindles on grinding machines must be marked on the spindle. A guard shall be provided to enclose the wheel to the greatest possible extent, the opening being as small as possible consistent with the nature of the work. Eye protection in the form of goggles and/or shields must be used when working with grinding machines and abrasive wheels.
9.4.20.2 GENERAL RULES · ·
· ·
Trained persons only shall be allowed to use grinding machines and abrasive wheels. Before starting a machine: o Brush and inspect the wheel for defects. o Check position of safety guards. o Check wheel has correct speed rating. On starting the machine stand aside until wheel reaches its normal running speed, thereafter check for wobbling and vibration. Apply the workpiece slowly and do not use excessive pressure. Doc. Number
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Keep the workpiece properly secured and use a holder for small pieces. Keep the workpiece rest adjusted as closely as practicable to the wheel. Do not strike the wheel or use the side of the wheel for grinding unless it is so designed. Switch off machine and wait for wheel to stop before making adjustments.
9.4.21 PORTABLE GRINDERS AND ABRASIVE CUTTERS All persons handling or using this equipment must be familiar with the hazards involved. Sufficient heat may be generated by the operation - in the form of sparks or by friction to ignite a flammable mixture; heavy hydrocarbons can also be vaporised by the heat of grinding. A Hot Work Permit shall be obtained before using grinders or abrasive cutters in hazardous areas, or on equipment that is not completely free of oily residue. The permit shall state the conditions for carrying out the operation safely.
9.5 EXCAVATIONS 9.5.1 INTRODUCTION Excavations are inherently dangerous because of a number of factors such as: · · ·
Possible contact with, or damage to, underground cables/services. Possible collapse of the excavation walls. Personnel falling into the excavation.
It is, therefore, essential to check services in an excavation area and to provide safeguards for personnel who have to work in and around the excavation.
9.5.2 PERMITS All excavations shall be carried out according to the work permit procedures detailed in Chapter 5 Permit Systems.
9.5.3 UNIDENTIFIED BURIED CABLES AND PIPELINES If any buried cables, pipelines or structures are unexpectedly encountered during excavation, work shall cease immediately and shall be reported to the Area Authority. Work shall not recommence until clearance is obtained from the Area Authority.
9.5.4 EXCAVATION EDGES No load, plant or equipment shall be placed, or moved, near the edge of any excavation where it is likely to cause the collapse of the side of the excavation.
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Similarly, scaffold structures shall not be constructed adjacent to excavations where the danger of excavation collapse may result. Whenever possible scaffold structures near, but not constituting a danger to the excavation, should be supported on large foot plates or boards. Employees shall be protected from excavated or other materials or equipment that could pose a hazard by falling or rolling into excavations. Protection shall be provided by placing and keeping such materials or equipment at least 1 metre from the edge of excavations, or by the use of retaining devices that are sufficient to prevent materials or equipment from falling or rolling into excavations, or by a combination of both if necessary.
9.5.5 MEANS OF EGRESS FROM TRENCH EXCAVATIONS A stairway, ladder, ramp or other safe means of egress shall be located in trench excavations that are 1.3 metres or more in depth so as to require no more that 7.62 metres of lateral travel for employees.
9.5.6 BARRIERS AND LIGHTING Excavations in which persons are working and into which a person is liable to fall shall be suitably covered or protected by a barrier. No work shall be carried out from the edge of the excavation to the barrier boundary. During darkness, such fences, covers or barricades shall be clearly illuminated to prevent accidents. This also applies to open manholes or drains, removed covers in cable trenches, etc. The person in charge of the work will be responsible for the erection of any barricades, roping off and provision of yellow warning lamps. Excavations and barriers, or the traffic associated with their construction, which will affect roads and other means of access shall be reported to the HSED by the Performing Authority, before work commencement. Appropriate precautions such as temporary controlled drainage, suction pumps, or other suitable means shall be taken to protect the excavation from water/rain ingress.
9.5.7 SHORING Generally, shoring of all excavations 1.3m, or less in depth will be at the discretion of the performing authority. However, each excavation should be considered separately for particular precautions or exemptions. All excavations more than 1.3m deep will be shored unless prior exemption is approved by Snr. Safety Engineer – ADGAS, Lead Construction Engineer and SE-GS. It will be the responsibility of the Performing Authority to obtain said approval. Doc. Number
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Factors for consideration should include the width and length of the excavation, soil condition-sandy, clay, compacted, wet or dry. Whether the sides are battered or can be battered, location of spoil to the edge, loading from other sources, services in the immediate area and in particular the work to be carried out in the excavation. When these factors have been considered, a decision can be made on the extent of shoring if required, or other safety considerations. Shoring designs must take into account the composition of the soil, its water content, depth of the excavation and the intended work activity. All shoring shall extend at least 300mm above the top of the excavation, and in the case of wide excavations horizontal and diagonal bracing maybe required. Shoring will be subject to daily inspection in excavations where men are to work. The inspection shall be carried out by the Performing Authority before commencement of work and the permit endorsed with his findings. Shoring structure must not be altered or removed except under the direction of the Performing Authority. Caution Excavations shall be kept clear from toxic and explosive gases. These may be natural gases like methane and sulphur dioxide, exhaust gases from nearby engines or leaks from nearby pipes or installations. These can seep through the soil and accumulate at the bottom of an excavation below ground level.
9.6 DIVING OPERATIONS 9.6.1 INTRODUCTION Diving activities considered to be covered by this section are those associated with the installation, maintenance or removal of any subsea equipment or structure that necessitates the use of compressed air breathing apparatus either surface supplied or self contained. Installations subject to these rules include but are not limited to: · · ·
Sub-sea Pipelines and Risers. Sea Water Intakes and Facilities. Jetty structures.
It should be noted that all diving activities beyond the shoreline of Das Island, including those associated with ADGAS facilities, come under the responsibility and supervision of Doc. Number
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ADMA-OPCO, and therefore reference must be made to ADMA-OPCO Diving Regulations in these cases. The rules given below will apply in all other cases. All diving operations will generally be required to comply with the, or equivalent. Further Information The Diving at Work Regulations 1997 Approved Code of Practice and Guidance - L103 ADNOC COP V4-09: Diving Operations. Risk Assessment and Control.
9.6.2 DIVING CONTRACTORS It is anticipated that most diving operations shall be undertaken by an approved Contractor. The Diving Contractor must issue diving rules and has the duty to ensure they are followed. Contractors must appoint, in writing, sufficient diving supervisors to ensure direct and effective control of diving operations at all times. A diving operations log book that shall record all diving activities and incidents must be provided by the Contractor.
9.6.3 DIVING SUPERVISORS A diving supervisor has overall responsibility for all diving activities, including the determination that the operations are carried out from a suitable safe place by an appropriately qualified Diving Team with all plant, equipment and facilities for the safe conduct of these operations.
9.6.4 PLANT AND EQUIPMENT A high standard of plant and equipment selection and maintenance is vital to reduce risks to a minimum, and care shall be taken to ensure that intakes of air compressor are situated well clear of areas where dangerous gases or fumes might occur.
9.6.5 EMERGENCY INSTRUCTIONS As part of the planning for the diving operations Emergency Instructions for evacuation of the diving site in the event of plant alarms are to be produced jointly by the Diving Supervisor and SHSEE.
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9.6.6 DIVING IN CONFINED SPACES An underwater confined space may be regarded as any underwater situation in which there is an "overhead environment" obstructing direct vertical access to the open water surface. Underwater confined spaces also may exhibit the characteristics of other confined spaces, such as tanks and vessels, where there are a limited number or size of openings for entry and exit. The following examples are typical underwater confined space diving situations: · · · ·
Sewer line installation, repair and maintenance Sea Water Intakes repair, maintenance, and debris removal Underwater construction activities which involve an overhead environment with limited direct access to the water’s surface Recovery and rescue operations (which can be necessary in the above situations)
Diving in confined or restricted spaces is a hazardous activity and should only be carried out when all alternatives have been considered. Only Diving Contractors specialised and experienced in this type of work should be employed. The work must be carried out in complete compliance with the Work Permit Procedure for confined space entry, and the following considerations must be taken into account: · · · · ·
A Task Risk Assessment must be carried out A dive plan must be prepared Tether and tend all divers in the water Communication and retrieval systems suitable for the conditions that can be operated from the surface Emergency plans
9.7 WORK OVER WATER 9.7.1 INTRODUCTION Working over, on or near water has the ever-present risk of persons falling into the water. General guidance only is given in the following paragraphs on the most obvious hazards. Detailed safe working procedures from a Task Risk Assessment shall be developed for each individual project by the Job Officer and SHSEE(Ops) in the light of prevailing conditions.
9.7.2 HAZARDS Any workplace over, on or near water presents a danger that persons might slip, fall or be swept off their feet by a rapid rise of tide, strong current, or swell. Whether or not a person is injured by a fall, there is an immediate risk of drowning and/or being carried away by the current. Doc. Number
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Considerable effort must be made, firstly to prevent persons from tripping, falling or being swept into the water and secondly, if the worst does happen, to ensure that they are rescued in the shortest possible time before they can come to any further harm.
9.7.3 GENERAL PRECAUTIONS 9.7.3.1 PLATFORMS, GANGWAYS, ETC. Platforms and gangways must be of the correct width and equipped with guard-rails and toeboards. At all edges from which a person might fall into the water, secure barriers or fences are required. Barges, pontoons, etc. used as working platforms, must be properly constructed and sufficiently stable to avoid tipping. Special attention must therefore be paid to good anchorage and ballasting, point loads near the edge should be avoided and due account should be taken of the variation of load at the different radii of crane jibs. 9.7.3.2 LADDERS Ladders must be sound, of sufficient length and strength and be securely lashed to prevent slipping. Where ladders are permanently fitted to plant over water, they should be fitted with safety hoops
9.7.4 SAFETY NETS 9.7.4.1 GENERAL Safety nets shall be used wherever practicable. Safety nets should be properly secured and slung sufficiently far above high water level for anyone caught in them to remain clear. Manufacturers should be consulted on what type of net best suits the kind of work to be carried out and the prevailing conditions. Safety nets should be erected as close to the working level as possible and, if on the outside of a structure, should be higher at the outer edges than at the inner. 9.7.4.2 TYPE AND STRENGTH Personnel nets are usually constructed in a 100mm mesh - and the size of cord from which they are made is determined by the distance below working level at which they are to be suspended. Every effort should be made to keep this distance to a minimum. Nets can be made from both natural and man-made fibres. Natural fibres should be rotproofed. Whereas all must have minimum breaking strengths each have varying characteristics in relation to their resistance to abrasion, overloading, mildew and chemical attack.
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9.7.4.3 STORAGE When nets are stored they should be protected from damp and heat and it is well to hang them on wooden pegs or galvanised hooks so that air can circulate through them. Wet nets should be dried naturally. If nets need to be placed on the floor they should be stacked on timber and kept clear of the ground.
9.7.5 SAFETY BELTS AND HARNESSES 9.7.5.1 USE OF HARNESSES AND BELTS The main reason for the use of safety belts and harnesses is to limit the distance of any fall and thereby minimise the risk of injury. Safety belts and harnesses provide valuable protection, but they are not a substitute for effective fall prevention measures. It should be clearly understood that, where practicable, proper working platforms, with guard-rails and toeboards, must be provided. Note Where the provision of working platforms, or the use of safety nets, is impracticable, safety harnesses or belts shall be provided and used. In choosing a belt or harness for a particular application care should be taken to ensure that it will give the user, as far as is compatible with safety, maximum comfort, freedom of movement and if there is a fall every possible protection to the body from the shock of sudden arrest. Proper fitting and adjustment are essential to achieve these aims. A full harness gives greater protection than a safety belt if there is a fall and is therefore preferable. 9.7.5.2 TYPES OF BELTS AND HARNESSES BS 1397 Specifications for industrial safety belts, harnesses and safety lanyards, gives guidance on the choice of a suitable belt or harness but in view of the wide variations in conditions of use it does not attempt to standardise the design of any specific type or to prescribe which type should be used in any particular industry. The general purpose harness incorporating shoulder and crutch straps and fitted with fall arrest device shall be the only type to be used on ADGAS sites.
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Figure 9-9: General Purpose Safety Harness Further Information BS 1397: Specification for industrial safety belts, harnesses and safety lanyards 9.7.5.3 FIXING POINT It is of the utmost importance that, whenever a harness is provided there is also an effective means of fixing it to the structure at all times the protection is required. It is also vital that the fixing point is strong enough to withstand the snatch load of a fall. The distance of fall should be as small as is possible and should not exceed the dimensions specified above. To that end the belt or harness should be fixed to the structure, or fixing point as high as practicable above the working position. It is vital that the harness and the attendant line are not damaged during use. The practice of fastening the line around small sectioned structural steel or other sharp objects and hooking the karabiner back on to the line may cause failure. As an alternative it is recommended that a tested loop of at least 8mm diameter steel wire rope with properly made eyes, be used. Refer to Figure 9-10: Method of attaching line to small sectioned steel. The wire loop should be wrapped around the steel and the harness line attached to the loop, maintaining the maximum falling distances previously outlined. An alternative anchorage may be provided by use of special proprietary hooks that are available with openings to accommodate metal sections up to 50mm.
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Figure 9-10: Method of attaching line to small sectioned steel
9.7.6 FALL ARREST DEVICES 9.7.6.1 GENERAL These mechanical devices, when used in conjunction with a harness, permit greater freedom of movement. The devices have two main features: · ·
They extend the area over which the user may work safely. If there is a fall, they restrict the drop, thereby reducing the load imposed upon the body on sudden arrest.
Types BS EN 353-1:1993 Personal protective equipment against falls from a height. Specification for guided type fall arresters on a rigid anchorage line Type 1 A device that runs on a fixed anchorage, line or rail, the safety belt or harness being attached to the device. BS EN 353-2:1993 Personal protective equipment against falls from a height. Specification for guided type fall arresters on a flexible anchorage line Doc. Number
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Type 2 A device through which an extendable line passes or unreels from, the user being connected to the end of the anchorage line, the device itself being attached to a fixed anchorage point. See Figure 3 below page. Note The Type 2 is the only type to be used on ADGAS sites
Figure 9-11: Inertia Reel Further Information BS EN 353-1:1993 Personal protective equipment against falls from a height. Specification for guided type fall arresters on a rigid anchorage line BS EN 353-2:1993 Personal protective equipment against falls from a height. Specification for guided type fall arresters on a flexible anchorage line
9.7.7 USE OF FALL ARREST DEVICES The following precautions shall be observed when using fall arrest devices: · ·
The correct type rail or cable for the device shall be used for the anchorage line. The attachment point and attachment structures shall be adequate to hold the user if there is a fall.
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Before each occasion of use the end of the anchorage line should be jerked to simulate a fall, this will lock the device. Should the device not lock it must be immediately withdrawn from service for investigation. Instructions on safe use, which must be provided by manufacturers, shall be given to users. Regular inspection and maintenance of the equipment shall be carried out according to the manufacturer's instructions. Equipment must be stored safely according to the manufacturer's instructions. In the event that the device is subjected to shock loading, action must be taken according to the manufacturer's instruction. Usually the device must be returned to the manufacturer for inspection and overhaul.
9.7.8 CARE OF BELTS AND HARNESSES 9.7.8.1 EXAMINATION AND INSPECTION All belts and harnesses shall be thoroughly examined by a competent person at least every three months. Leather and webbing shall be inspected for cuts, cracks, abrasions or tears and any signs of undue stretching. Snap hooks shall be examined for signs of damage, distortion or faulty springs. The tongues of buckles shall be examined where they fit to the shoulders. Stitching threads should not be cut or worn. A record of examinations shall be maintained. The wearer should make a visual inspection at least daily before use. 9.7.8.2 STORAGE Belts and harnesses shall be stored in a cool, dry well-ventilated place away from direct sunlight and free from contact with anything that could cause damage.
9.7.9 WORK SITE REQUIREMENTS 9.7.9.1 SITE TIDINESS Site tidiness is of special importance in minimising tripping hazards. Tools, ropes and other materials not in use should be cleaned up promptly. Materials awaiting use should be stacked compactly and particularly on pontoons, not piled too high. Slippery surfaces are extremely dangerous and should be treated immediately. Seaweed, sea-slime and bird droppings should be cleaned off. Oily or greasy surfaces should be gritted. 9.7.9.2 ILLUMINATION Illumination is essential for night work and at all times in shafts, dark corners and stairways. An even spread of light is required to avoid deceptive shadows and glare. The area floodlit should always include the immediate water surface; spotlights, on swivels should be fixed at strategic points to assist in locating a person in the water. Doc. Number
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9.7.9.3 FIRST AID EQUIPMENT A suitable stretcher and resuscitation equipment, of the portable type, should be readily accessible to the main working area over water and to normal landing places.
9.7.10 PERSONAL PROTECTIVE EQUIPMENT 9.7.10.1 SAFETY HELMETS Safety helmets should be worn at all times, since anyone struck on the head and then falling into water is at special risk. Chin straps should be considered for scaffolding work or other tasks requiring bending or awkward body positions. 9.7.10.2 FOOTWEAR Types with non-slip soles should be worn. The "Trainer" type of safety shoe is recommended for riggers and scaffolders. 9.7.10.3 BUOYANCY AIDS Some form of buoyancy aid must be worn as standard practice. A wide range of life jackets is available and, pending introduction of a local standard, selection should be made from those conforming to relevant British Standards. Further Information BS EN 396:1994: Lifejackets and personal buoyancy aids. Lifejacket 150 Life jackets must be suitable both for the work and the hazards and they should: · · · · · · ·
Provide sufficient freedom of movement for persons to be willing to wear and work in them. have sufficient buoyancy to bring persons to the surface and keep them afloat, face up. be easily secured to the body. be readily visible. be capable of withstanding hard treatment. require minimum maintenance. not be prone to snagging under water.
9.7.11 RESCUE EQUIPMENT 9.7.11.1 LIFEBUOYS AND RESCUE LINES Lifebuoys, or rescue lines, should be set at intervals along the workings. Lifebuoys, which are normally 765mm outside diameter, should be fitted with a 30m buoyant lifeline, knotted at every 3m to assist handhold, i.e. long enough to allow for the state of the tide, height of working place above water, or for the person being carried Doc. Number
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downstream by a current. They may be constructed of either cork with canvas covering, or of polyurethane foam with a rigid PVC cover. If night work is carried out self-ignition lights should be fitted. Lifebuoys or rescue lines should be thrown as near as possible to a person in the water and if any tide is running they should be thrown on the upstream side. Daily checks should be made to ensure that lifebuoys and rescue lines are still in their proper place and that no repair work is required as a result of vandalism or other interference. 9.7.11.2 STANDBY BOAT The rescue boat, if required, should be properly made and of sufficient length and beam to afford reasonable stability. Inflatable craft are preferred since they provide a better chance of getting a person aboard without injury. Engines of rescue craft, when not patrolling should be run several times a day to ensure full efficiency. Propeller blades shall be adequately guarded. All rescue boats should carry three oars or paddles to cater for losing one overboard. Rowlocks should be removable and on retaining lines so that they can hang from the side without being lost. The boat should be fitted with grab lines and carry at least one approved life buoy. Boathook, baler, anchor and line should be standard equipment. Two-way communication between boat and work site shall always be provided. If night work is to take place, a powerful spotlight should be fitted. Rescue boats should be manned continuously and on patrol whilst work is in progress by experienced boatmen who are qualified First Aiders. There shall be a minimum two persons to a boat so that one is free to attend to the person in the water. Boatmen should always wear suitable buoyancy aids. Whether first aid treatment can be given on the rescue boat, will depend on its size and the state of the rescued person. Boats should at least carry sterile wound dressings and some bandages, a sucker for clearing a person's airway, and blankets. All first-aid equipment on board should have waterproof protection. It is essential that: · · ·
the number of persons at work is periodically checked to ensure that no one is missing. operatives work in pairs so that there is always one to raise the alarm. each person is trained in what to do if there is an emergency. Doc. Number
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Further Information BS EN 354:2002 Personal protective equipment against falls from a height. Lanyards BS EN 361:2002 Personal protective equipment against falls from a height. Full body harnesses BS EN 362:2004 Personal protective equipment against falls from a height. Connectors BS EN 363:2002 Personal protective equipment against falls from a height. Fall arrest systems BS EN 365:2004 Personal protective equipment against falls from a height. General requirements for instructions for use, maintenance, periodic examination, repair, marking and packaging BS EN 1263-1:1997 Safety nets. Safety requirements, test methods BS 4211:2005 Specification for permanently fixed ladders BS EN 1263-1:2002 Safety nets. Safety requirements, test methods BS EN 396:1994 and BS EN 396:1994 Life jackets BS 5062 Part 1:1985 Self locking safety anchorages for industrial use Construction Safety, Construction Employers Federation.
9.8 WORK ON ROOFS 9.8.1 INTRODUCTION Work on roofs is a hazardous task and has resulted in a significant number of injuries. Most of these accidents could have been prevented by the identification of hazards and by the provision and proper use of readily available equipment.
9.8.2 PLANNING As a high risk activity it is important that any roof work operation is pre-planned. As falls are the major cause of accidents precautions must be taken either to prevent a person from falling or if that is not practicable, to prevent the fall from leading to serious injury. The particular hazards of each job and the best means of overcoming them must be considered so that a safe method of work can be established. Note With complex jobs it may be appropriate for a detailed Task Risk Assessment to be prepared The system of work should take into account not only persons involved in the work but others who might be affected such as personnel normally working in, or passing through the area. Roof work includes not only its original construction but also its maintenance, such as replacing sheets or guttering and gutter cleaning. Doc. Number
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Note Maintenance is often carried out by persons with little experience in roof work which makes it all the more important for a safe system of work to be established and followed
9.8.3 SAFE ACCESS Suitable equipment must be provided to give safe access to the roof, for example: 9.8.3.1 LADDERS Ladders should be placed at an angle of about 75° to the horizontal, i.e. about 1m out for every 4m in height. They must be long enough for the job, extending to a height of at least 1m above the landing place unless there is an alternative handhold. A ladder should be secured as near as practicable to its upper resting place or where this is not possible at or near its base. Care must be taken that the support for the top of a ladder is strong enough to withstand the thrust imposed. Refer to Section 9.8.3.1 9.8.3.2 TOWER SCAFFOLDS The height of a tower's working platform in relation to the width at the base is critical. Requirements for towers constructed from tube and fittings are given in Section 9.3.11. For proprietary towers the manufacturer's instructions must be strictly followed. Mobile towers must have wheels which are positively secured to the uprights and each wheel should have a locking device to be applied when the tower is stationary. Towers should be moved only by pushing or pulling at the base and never when any person is on the scaffold. 9.8.3.3 INDEPENDENT SCAFFOLDS In addition to providing access and a working platform around the edge of a roof, scaffolding may also be used to prevent falls of persons and materials from the edge of a roof and to provide a storage area for materials. 9.8.3.4 MOBILE WORK PLATFORMS Mobile work platforms may be useful for work of short duration such as inspection where the expense and risks involved in erecting scaffolding might not be warranted. Power operated mast work platforms (cherry pickers) may be suitable for some operations such as the fixing of vertical cladding sheets or remote roof inspections.
9.8.4 SAFE PLACE TO WORK Appropriate precautions against falls will be determined by the type of roof and the nature of the work to be carried out. Doc. Number
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9.8.5 FLAT ROOFS Where a roof is not more than 5m above ground level scaffold tube uprights spaced at above 3m centres are pitched from the ground level, suitably propped by raking tubes and braced by a longitudinal diagonal tube in every fifth bay. Guard rails and toe boards are fixed to the uprights. Refer to Figure 9-12: Flat Roof Edge Protection. Roofs with a pitch of less than 10° may be considered to be flat. Toeboards at least 150mm high and guardrails not more than 765mm above the top of toeboards and 910mm to 1.15m above roof levels are required at any point where a person could fall more than 2m. Where it is necessary for a person to kneel or crouch near the edge of roof an intermediate guardrail should be provided unless other precautions such as the use of a safety harness are taken. On a large roof where work does not have to be carried out at or near the edge a simple barrier consisting of crossed scaffold tubes supporting a tubing guardrail may be used to limit the extent of the working area. Such barriers should be positioned at least 2m from the edge and work should be closely supervised to ensure that persons do not go outside the designated area
Figure 9-12: Flat Roof Edge Protection
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9.8.6 NON-FRAGILE SLOPING ROOFS On sloping roofs, unless suitable precautions are taken there are dangers of persons falling from the perimeter edge - either whilst working there or due to slipping down the roof - and of falling through the roof at the working edge. Protection can be provided by: 9.8.6.1 BARRIERS AND PLATFORMS A typical method of providing barriers or platforms to prevent falls from the eaves of a roof are the provision of a scaffold barrier at least 900mm above the roof and not more than 700mm above the scaffold board catch barrier The catch barrier should protrude at least 430mm above the roof. The barrier must be high and strong enough to stop a person who is rolling or sliding down the roof slope. Platforms must be so positioned that they will stop a fall from the roof. An intermediate guardrail, or other barrier will be needed where persons need to kneel or crouch near the edge. The need for a barrier at the gable edge must also be considered. 9.8.6.2 ROOF LADDERS On most sloping roofs, suitable roof ladders or crawling boards are essential. For minor maintenance work or inspection where work is of short duration and edge protection is not provided roof ladders should always be used. Roof ladders or crawling boards should be purpose made for the job and should be strong enough to support persons when spanning across the supports for the roof covering and be secured or so positioned as to prevent movement. A suitable type with sockets and locking bars at the joints, is illustrated in Figure 9-13.
Figure 9-13: Roof Ladder With Sockets And Locking Bars The anchorage at the top of the ladder should not rely on the ridge capping which may break away from the ridge. The anchorage should, wherever possible, bear on the Doc. Number
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opposite slope by means of a properly designed and manufactured ridge iron or be secured by other means such as a rope tied to a strong point. Caution Eaves gutters should never be used as a footing or to support a roof ladder as they are seldom strong enough 9.8.6.3 WORKING PLATFORMS In some cases a working platform fitted with guardrails and toeboards situated on the roof may be used as an alternative to a barrier or platform at the roof edge. This applies particularly where the steepness of the slope or the type of surface could give rise to an insecure foothold.
9.8.7 NON FRAGILE ROOFS A significant number of accidents occur during the fixing of non-fragile industrial roof sheeting. Where the continuous use of safety nets is not practicable steps must be taken to minimise the risk of falls by planning a system of work that avoids the need to lean or step out over an unprotected area. This may entail the provision of a suitable working platform on the purlins and/or the use of safety harnesses attached to suitable anchorages for certain stages of the operation. Lightweight stagings can be used to provide protection at the leading edge while work is done on the decked area. They can also be used to help prevent the need to lean or step out over an unprotected area. Care must be taken in the positioning of stagings so that they do not dangerously overhang their supports. Consideration must also be given to the means of moving stagings as the work progresses. Where stagings are used as a walkway or as a working platform, guardrails and toeboards must be fixed at the edge away from the roof decking, stagings should also be secured against the risk of tipping if a person leans on the guardrail. Working platforms must be at least 600mm wide, i.e. two stagings. Non-fragile roofs often contain fragile components such as rooflights and these should be covered or protected by suitable barriers during cladding operations.
9.8.8 FRAGILE ROOFS 9.8.8.1 PRECAUTIONS Before any roof is used as a means of access or as a place of work during any operations whether construction, repair, maintenance or demolition it is essential to identify parts covered with fragile materials and decide on the precautions to be taken.
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The appearance of some roof coverings is misleading and can give a false sense of security to those who are working on or passing across them. Although such coverings may be capable of carrying a significant distributed load and appear solid, they will not in fact carry a concentrated load such as that applied by the heel of a person walking or by a person stumbling and falling. For example asbestos and non-asbestos cement sheeting unless reinforced and/or of sufficient thickness is liable to shatter without warning under a person's weight. Any sheeting may become more brittle with age, chemical or environmental attack and even corrugated steel sheets will become "fragile" due to rust. There is a mistaken belief that, on a fragile roof, it is safe to walk along the line of roof bolts above the purlins, in reality this is like walking a tightrope and one false step or loss of balance can lead to disaster. Problems can also arise where a non-fragile roof has been repaired with fragile materials which may not easily be recognised under a paint or other surface coating. Plastic rooflights may similarly be disguised by age or paint and it is important that these points are borne in mind by persons carrying out roof surveys. Note On roofs covered by fragile materials roof ladders or crawling boards must be used 9.8.8.2 ROOF LADDERS/CRAWLING BOARDS The number of boards or ladders required will depend on the nature of the work, the type of roof and the access to it, and the number of persons carrying out the work. A person must never have to step on to a fragile roof to move a board or ladder. An absolute minimum of two boards or ladders should be provided, but more will normally be required. Scaffold boards are sometimes used as crawling boards, but they are liable to rock if laid along roof corrugations or on projecting bolts and they are normally only 225mm wide. If scaffold boards are used there must be a sufficient number to provide safe access and they should be secured against movement. Purpose made stagings or roof ladders are therefore preferred. Where access is needed on a regular basis the installation of a permanent means of protection should be considered.
9.8.9 FRAGILE ROOF REGISTER Area Authorities are to keep a register of the fragile roofs under their control and are to be prepared to brief any Performing Authority who may have to work on them.
9.8.10 SAFETY HARNESSES AND NETS The aim must always be to provide a safe place of work but in roof work this may not always be practical. In such cases the use of safety harnesses and fall arrest device may be appropriate provided suitable anchorage points capable of withstanding any anticipated shock load are available. Similarly safety nets can provide a potential Doc. Number
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solution to many of the problems. The advice of manufacturers should be sought on the suitability of any particular net for the purpose for which it is to be used. Refer to Chapter 9.7.6 FALL ARREST DEVICES.
9.8.11 PROTECTION OF OTHER PERSONNEL Other personnel must be protected from the hazards of any falling material during roof work operations. This may entail the provision of guards and other similar precautions. It may also be necessary to lay sheeting or boarding to prevent material falling through gaps in a working platform or between the working platform and the building. Barriers at ground level may also be necessary. Waste material shall be lowered in skips or baskets or disposed of through enclosed debris chutes. The practice of throwing such material from the roof or scaffold shall be strictly prohibited.
9.9 WORK AT HEIGHT 9.9.1 INTRODUCTION Work of a non-routine nature at heights of 2m above grade e.g. cleaning, painting, construction, inspections, etc. may introduce hazards to both the work group and others nearby. Work at height by definition entails some potential hazards for those involved due to the height above grade whilst it also carries a potential risk for those directly below the worksite. Work at height is treated in two broad categories: · ·
Where personnel are on scaffold platforms, other temporary staging or elevating lifts. Where personnel are suspended by crane or other hoist working from a man cage, also known as a work basket.
Caution Where the task / work activity requires the employee working on platform to lean over the barrier, he is required to wear the proper harness.
Further Information Operations Standing Instructions C-47: Suspension of Work During Periods of Strong Wind BS 8454:2006: Code of practice for the delivery of training and education for work at height and rescue Doc. Number
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9.9.2 GENERAL 9.9.2.1 PERSONAL PROTECTION Working at height outside fully approved scaffolded areas or access ways at heights above 2m requires a safety net or approved form of body restraint to prevent or arrest a fall. Elevation of personnel by boom lift, scissors lift, etc. may also require the use of a safety harness and inertia reel. An approved safety harness worn together with an inertia reel restraint is the minimum safety requirement. Lifelines can restrict mobility of a worker at times and the temptation may be present, even in hazardous conditions, to disregard this important safety requirement. Personnel in these situations are required to wear a harness and reel at all times and clip on for the maximum part of the job time. Head protection is mandatory as a minimum workwear requirement. The fitting of a chin strap to the helmet for use at all times aloft and especially in windy conditions is required. This will prevent the loss of the helmet or the possible risk of its striking another person if dislodged.
9.9.3 WORK OVERHEAD Securing tools and materials at height with the use of lanyards and tie-downs helps to prevent objects falling. Loose materials should always be removed or secured at the end of work. Round or cylindrical objects are particularly prone to rolling off staging and as such require special attention. Sparks and hot slag need to be contained during hot work. Additional precautions in the form of nets or tarpaulins to protect those below the job site shall be provided where appropriate. Caution Where any doubt remains whether material can fall on to personnel access areas below, those areas must be flagged off or barricaded and prominently marked with the appropriate danger signs.
9.9.4 MAN CAGE/WORK BASKET For short term elevation to otherwise inaccessible points use of the crane man cage is a safe method. General conditions for safe working include: Doc. Number
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Banksman with radio in the basket who is in communication with the crane operator. The work basket in view of the crane operator at all times. Crane operator stays at the controls throughout the operations. A minimum of two persons in the basket whilst aloft. Personal protective wear for all occupants appropriate to the work in progress. The work basket to be in current serviceable condition, certified and inspected according to the controlling regulations. The basket must not be loaded beyond its rated and marked weight capacity. Safety harness must be worn by occupants with lifelines to a fast point. The approved man basket is dedicated to the task of carrying workers and their equipment to otherwise inaccessible locations by crane. The man basket must not be used for any other purpose and conversely no substitute is permitted in the form of skips or bins that are not authorised for this purpose. Wind velocity may impose limitations on use of the man cage. All safety considerations must be considered including wind speed, location of lift, nature of work, etc.
These conditions may only be varied by the R&SS after consultation with SOSE. Direction to crane operators should be given by certified banksmen, however approval may be given by I&QM to waive the requirement for the continuing presence of a banksman in the man cage when the work is long term, routine, in favourable conditions and in sight of the crane operator. A designated radio operator in the man cage however, will maintain communications with the crane operator.
9.9.5 SKY CLIMBER The Sky Climber is an elevating work platform which ascends on two wire ropes by means of air operated winches. When required on Plant, R&SS shall visit the site to determine if the Sky Climber is suitable for the task in hand. R&SS will also supervise installation before use and brief users on the safety requirements of the equipment.
9.9.6 ABSEILING Abseiling is a commonly used technique for mountaineering descent using a double rope system. Increasingly the technique has been adopted in the offshore oil/gas industry for the inspection and maintenance of platforms and high structures. It is not commonly used in ADGAS, but when it is used, the activity is classed as a risk and must be managed by application of HSE standards and practices. Prior to performing such a task, the following safety instructions must be strictly followed:Kick off meetings must be held with all Abseiling contractors/employees prior to the work. Doc. Number
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Task risk assessment requirements should be performed as per Chapter 2 Section 9. As a minimum requirement the following points must be addressed:· · · · · · · · · · · · · · · ·
Joint site inspection must take place during which C&ID/GSD will identify all safe Abseiling anchor points and C&ID to confirm all such points are sound and non corroded. All Abseiling equipment certification must be checked and confirmed valid and unexpired. Where doubt exists ADGAS Rigging Section may consider testing. Site visits to demonstrate equipment use must be done. Assessment of exclusion zones at grade level must be made to ensure no personnel enter the restricted area during Abseiling activities. An appointed safety standby will be present with a radio at all times during work activities. Role of the Safety standby will be clearly communicated to all involved in the work. An alternative system of communication will be established in case of radio failure. The effect of wind speed must be considered. In the event of wind speeds above 20 knots all work must cease. In the event of a rising wind speed the operations Shift Superintendent must be informed by the Central Control Building staff. The duty OSS will advise the Abseiling crew and decide a safe course of action. In the event of unusual flaring or high SO2 atmospheric conditions all Abseiling must stop and Abseilers must return to ground level. Working hours and rest breaks must be discussed and agreed taking due consideration of ambient temperatures and relative humidity conditions. Operations must identify any potential risk areas (flange leaks/valve gland leaks etc.) If the Abseiling work is extensive a formal work method statement must be issued for ADGAS review and agreement prior to the work commencing. Manpower histograms must be identified and agreed. If during Abseiling activities, the No. of abseilers is extensive, HSED must conduct risk assessment and conduct emergency drills.
All Abseiling work in the ADGAS LNG Plant will be subject to Permit to Work conditions and issue of a cold work permit. Further Information Chapter 2.10Task Risk Assessment
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ACCIDENT INVESTIGATIONS
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CHAPTER 10 CONTENTS 10
ACCIDENT INVESTIGATIONS........................................................................................................... 389 10.1 INTRODUCTION ............................................................................................................................ 389 10.2 DEFINITIONS ................................................................................................................................. 389 10.3 REPORTING .................................................................................................................................... 390 10.4 INITIATING AUTHORITY............................................................................................................. 391 10.5 MANAGEMENT ROLE .................................................................................................................. 391 10.6 HSED ROLE ..................................................................................................................................... 392 10.7 FOLLOW-UP PROCEDURE ........................................................................................................... 392 10.7.1 RESPONSIBILITY OF MHSE ................................................................................................. 392 10.8 STATUTORY REQUIREMENTS- REPORTABLE ACCIDENTS ................................................ 393 10.9 NOTIFICATION TO OTHER AUTHORITIES ............................................................................... 393 10.10 IN-HOUSE NOTIFICATION ...................................................................................................... 394 10.11 MOTOR VEHICLE ACCIDENTS .............................................................................................. 394 10.11.1 REPORTING OF MOTOR VEHICLE ACCIDENTS ............................................................... 394 10.11.2 INVESTIGATION OF MOTOR VEHICLE ACCIDENTS ........................................................ 395 10.11.3 REMOVING VEHICLE FROM SITE....................................................................................... 395 10.12 BOARDS OF ENQUIRY ............................................................................................................. 395 10.13 INSURANCE REPORTING ........................................................................................................ 396 10.14 NEAR-MISS (INCIDENT) REPORTING ................................................................................... 396 10.15 REPORTING OF SERIOUS HSE INCIDENTS TO ADNOC ..................................................... 397 10.15.1 GUIDELINES .......................................................................................................................... 397 10.15.2 CLASSES OF SERIOUS REPORTABLE INCIDENTS ............................................................ 397 10.15.3 REPORTING ARRANGEMENTS ............................................................................................ 399 10.15.4 RESPONSIBILITY FOR REPORTING INCIDENTS ............................................................... 400
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10 ACCIDENT INVESTIGATIONS 10.1 INTRODUCTION Accidents and incidents are usually caused by a combination of substandard acts and substandard conditions (previously known as unsafe acts and unsafe conditions). These substandard acts/conditions are the "symptoms" or immediate causes of the accidents and incidents. Behind the "symptoms" are the real causes or basic causes which need to be identified to permit meaningful management control to avoid recurrence of the event. The main objective of an investigation is to determine the immediate and real causes and recommend remedial actions, rather than to apportion blame on an individual or group of individuals. Further Information ADNOC-COPV1-01: HSE ADMINISTRATION SYSTEMS. Section 7.3 Work related injuries & illnesses ADNOC-COPV1-03: Determining Reportability of Occupational Injuries and Illnesses ADNOC-COPV1-07: Directions for Preparing the Annual HSE Letter ADNOC-COPV1-08: Reporting of Serious HSE Incidents
10.2 DEFINITIONS · · · ·
Accident/Incident - An undesired event that results in harm to people, damage to property and/or Environment, loss of product or loss of containment. Accidents result from contact with a substance or source of energy above the threshold limit of the body or structure. Major accident - fatality, lost-time injury, fire or explosion, high potential chemical spill, undesired process loss, and property loss exceeding US$ 50,000. Near Miss - An undesired event which, under slightly different circumstances, could have resulted in harm to people, damage to property and/or Environment, loss of product or loss of containment.
A Near-Miss s also commonly known as a Near-Accident. · · · ·
High potential Near miss – Near miss having the potential of causing major accident under slightly different circumstances. Injury - Harm to people resulting from an accident. Motor Vehicle Accident - An accident associated with motor vehicles. Lost-Time Injury - An injury which disables a person from working on one or more days following the day of the accident.
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Minor Injury - An injury which does not disable the person from working beyond the day of the accident.
This is also referred to as a Non Lost-Time Injury. ·
Occupational Disease - An illness/disease resulting from an exposure during the course of work.
10.3 REPORTING All accidents and incidents (hereafter referred to as events) shall be immediately reported to the responsible supervisor who will take the following actions as appropriate: · · · · ·
·
Arrange medical attention for the injured. Make conditions safe. Report the event to his Section Head and CCB. Central Control will notify duty HSE. Central Control will also notify DIFS in case of fire or explosion, major oil/gas spills or serious injury (see Fig. 10-15). Any fires (fire, flame, smouldering, burning etc.) must be reported immediately to Das police, this will be done through HSE who will contact Personnel Officer (Relations) who in turn will report to the police (see Fig. 10-15). All accidents & incidents including fires, injuries, and environmental damage or asset damage will be investigated by ADGAS through the Accident & Incident reporting procedure to allow lessons to be learned and improvements to be made. Only cases of suspected criminal damage will be handed to the police for investigation. The Police and State Security will be kept informed of the outcome of any ADGAS investigation into Reportable Accidents (see Chapter 10, Section 8). Complete Section A of Das Hospital Medical Examination Form for presentation to the Das Island Medical Service by the injured person. (In case of serious injury, priority shall be given in transporting injured person to hospital and documentation should be initiated later).
Brief details of any event aboard a ship shall also be immediately communicated by PM/HO or their deputies via telephone to the Senior Marine Superintendent, Commercial Division, Shipping and Marine Department, Abu Dhabi. This information shall be confirmed by MHSE in writing within 24 hours of the event. All accidents occurring in ADGAS non industrial areas, must be reported following the reporting procedure chart in fig. 10-17. Accidents and incidents occurring in project sites should be reported and an accident/incident form should be completed.
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10.4 INITIATING AUTHORITY For all events, excepting those that result in injury only, the Authority responsible for the area where the event occurred, or the Projects Liaison Superintendent, shall report to the scene of the event for investigation and shall initiate the accident/incident investigation report. See Accident Report and Completion Guidelines in Figure 10-1/2/3/4. Area Authorities are detailed in Chapter 2.11. For events that result in injury only, the supervisor of the injured shall be responsible for reporting to the scene of the accident for investigation and initiating of the report. The Duty SOSE/OSC shall assist the responsible authority initiate the investigation of the event without delay upon receipt of the information from the CCB.
10.5 MANAGEMENT ROLE Division/Department Head upon receiving a copy of partly filled Accident/Incident Investigation Report from the authority responsible for the area where the event occurred shall immediately visit the site of the event for at-the-scene investigation. Division/Department Heads shall be involved in at-the-scene investigation of the following events as a minimum: · · · · · ·
Fatality. Lost-time injuries. Fires and explosion. High potential chemical spills. High loss potential incidents. Property loss exceeding US$ 50,000/-
Sections A to F of the report shall be completed and signed before the end of shift/work day. If necessary the concerned person shall stay on after the shift change to complete the report. It shall be submitted to the concerned Division/Department Head as per the following guide lines: · · ·
Before the end of the day for events occurring two hours prior to work completion. No later than 10:00 hours on the next working day for events occurring within two hours of work completion. Upon receipt of the report, Division/Department Heads shall inform the PM of all the events except non lost-time injuries.
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The Division/Department Head shall investigate the event and complete and sign Section G of the report before the end of the normal working day on which the report was received and forward it immediately to MHSE.
10.6 HSED ROLE The SOSE/OSE, after completing Sections H to L shall submit a copy of the report or its brief summary to MHSE not later than 09.00 hours on the normal working day following receipt of the report. The investigation shall be completed as soon as possible considering the need of supporting documents, statements from witnesses and operational requirement of the LNG Plant/Equipment. The result of investigation shall be submitted to MHSE within two days for all injuries and within three days for all other events. Sections M and N are completed by the MHSE when notifications have been sent to all authorities, and forwards the report it to the PM. This is to be completed within three days for injuries and four day for other events. Note If the form can not be completed within the 2 days it still moves onward and a separate investigation is carried out. Reference on the Accident/Incident form is made to the follow up report in preparation The PM shall nominate responsibility for implementation of the recommendations by completing Section P of the report and return to MHSE within one day of its receipt. MHSE upon receipt of completed report from PM, initiates the procedure for accident/incident follow up.
10.7 FOLLOW-UP PROCEDURE 10.7.1 RESPONSIBILITY OF MHSE After PM has assigned the responsibility of implementation of remedial actions to various division department heads in Section P of the report, it will be forwarded to MHSE for distribution and follow-up. Responsibilities of MHSE are as follows: Distribute copies of accident/incident investigation report to designated departments/divisions within 48 hours upon receipt of report from PM. Maintain a record of all corrective actions, divisions/departments responsible for implementation, completion target dates and status for effective follow-up. Doc. Number
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Advise Management on the status of remedial actions on a monthly basis via the PM's weekly meeting on 1st Thursday of every month. Retain status and completion reports with the investigation report. Responsibility of Division/Department Heads The concerned division/department heads upon receipt of a copy of the report from MHSE will initiate necessary action to implement the recommendations as per the completion target dates. Should any delay in meeting the schedule be foreseen, MHSE shall be notified immediately in writing as to the reason for the delay and expected date of completion. The division/department heads will advise MHSE of the status of actions on a monthly basis in writing by the last working day of the month. Upon completion, the division/department heads shall inform MHSE in writing certifying that the corrective action has been completed.
10.8 STATUTORY REQUIREMENTS- REPORTABLE ACCIDENTS Certain types of Accidents shall be reported to the appropriate Government Departments according to Abu Dhabi legislation. Types of accidents requiring reporting, the reporting procedure and the person responsible for notification are shown in Table 10-6: Statutory Notification Requirements and the prescribed forms are shown in Figure 10-5 to Figure 10-8. The reporting to the authorities will be coordinated by ADGAS MHSE and reporting will be in writing at the earliest opportunity or within 24 hours of the accident occurring. Where an accident occurs outside the LNG Facilities but in an area of ADGAS responsibility, i.e. fenced Project Worksites, the Projects Liaison Superintendent or the Area Authority shall be responsible for ensuring that the Statutory Notification Requirements are complied with by the Company involved in the accident.
10.9 NOTIFICATION TO OTHER AUTHORITIES There is no statutory obligation to report accidents of any type to the police or state security representative. However in the interest of good relations and effective communication the following will apply: Any accident reported to the Supreme Petroleum Council or Ministry of Labour & Social Affairs will also be reported to the Police and State Security representatives on Das Island by a letter in the format shown in Figure 10-9. The letter will be prepared by MHSE and signed by the PM. Doc. Number
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Any fire that occurs in any area managed by ADGAS will be reported to the Police immediately. This will be done by PO(R) who will be informed by duty OSE who will have been called by OSS on discovery of the fire. The responsibility for investigating all accidents (including fires) will rest with ADGAS through the accident and incident reporting procedure. Only cases of suspected criminal damage will be handed to the police for investigation. The Police and State Security will be kept informed of the outcome of any ADGAS investigation into reportable accidents.
10.10 IN-HOUSE NOTIFICATION A brief statement of the facts, as available following an initial investigation, and of precautions to be taken to avoid similar events from occurring elsewhere, will be circulated by MHSE to all Superintendents and above for all major accidents and high potential incidents by next working day after the event. The "Major Accident/Incident Announcement" form shown in Figure 10-10 shall be used for this purpose. Supplementary announcements should be made by MHSE as other data is confirmed or cause(s) determined related to the event.
10.11 MOTOR VEHICLE ACCIDENTS 10.11.1
REPORTING OF MOTOR VEHICLE ACCIDENTS
10.11.1.1
ACCIDENT ON ADGAS PROPERTY RESULTING IN PERSONNEL INJURY
The driver of the vehicle (or a witness to the accident if the driver is badly injured) shall inform Train Shift Supervisor in Central Control Building on Telephone 62222 (see Fig. 10-16). The Train Shift Supervisor will do the following: · · · ·
Arrange medical assistance. Inform driver's supervisor. Inform duty HSE. Inform DAS Police.
10.11.1.2
ACCIDENT ON ADGAS PROPERTY WITHOUT INJURY
The driver of the vehicle shall take the following action: ·
Inform Central Control Room Telephone 62222 (See Fig. 10-16). Doc. Number
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Inform his supervisor. Inform DAS Police. Inform duty HSE.
Accidents outside ADGAS Facilities ADGAS driver involved in traffic accidents outside ADGAS facility shall do the following: · · · ·
Inform ADMA-OPCO Emergency Services Control Room (Tel: 63400/63228). Ask for medical help in case of injury. Inform ADGAS Duty HSE. Inform his supervisor. Inform DAS Police.
10.11.2
INVESTIGATION OF MOTOR VEHICLE ACCIDENTS
All motor vehicle accident investigation reports shall be initiated by the Section Head of the driver on the Accident/Incident Investigation Report. Section A to F of the report shall be completed before the end of shift/work day and submitted to concerned Division/Department head to complete Section G as per following guidelines: · ·
Before the end of the day for accidents occurring two hours before work ceases. No later than 10:00 hours on the next working day for accidents occurring in the last two hours of work.
In the case when more than one driver is involved in the accident, the report shall be initiated by HSED and Section A to H shall be filled by the duty HSE.
10.11.3
REMOVING VEHICLE FROM SITE
Vehicle(s) involved in an accident shall not be removed from their exact position unless authorised by police. In exceptional circumstances the vehicle should be moved, if leaving the vehicle on site will create additional hazards and it is considered essential to remove the same for the safety of plant and personnel.
10.12 BOARDS OF ENQUIRY All major accidents and high loss potential incidents shall, at the discretion of the PM or GM, be investigated by a Board of Enquiry, using ADGAS RCA procedures and RCA Workflow Diagram (Accident/ Incident Investigation). Figure 10-14. Terms of Reference for the Boards of Enquiry are shown in Figure 10-11 . After a major accident the scene should, as far as safety will allow, be left untouched pending an enquiry. In all major accidents, SOSE/OSE shall take statements from all Doc. Number
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witnesses and interested parties and obtain if possible whatever photographs are necessary to assist in the investigation. These statements may also be required to assist the Board of Enquiry if constituted for the event.
10.13 INSURANCE REPORTING For those accidents wherein an insurance claim may be filed, the PM, in consultation with the MHSE, shall submit to the ADGAS Insurance Co-ordinator a report within two days of the accident. The report shall include the time and date of the accident, the location, nature of loss or damage and circumstances of the event.
10.14 NEAR-MISS REPORTING A Near-Miss is an event which under slightly different circumstances could have resulted in an actual loss occurring. The potential loss could have resulted in harm to people, an undesired process loss or damage to the environment. In order to learn from these events it is important that they are always noted and reported. Learning from Near-Miss will help us prevent more serious accidents. To help reduce and eventually eliminate accidents, a Near-Miss Reporting Procedure has been introduced throughout ADGAS. When a Near-Miss has been witnessed, or someone has been involved in one, regardless of how minor it appears, a Near-Miss Report Form (Refer to Figure 10-12) must be completed, and placed in the Near-Miss Report boxes at selected points in ADGAS. The forms are designed so that identification of the originator is not required. The Near-Miss must be reported verbally to the Supervisor who will investigate and initiate any temporary corrective action, where applicable. The verbal report is essential in order to ensure that the incident can be rectified before an accident occurs, if required the supervisor should initiate corrective action by the SAP system. The Near-Miss Report will be entered onto the Action Tracking sheet for discussion at the Central HSE Sub Committee meeting and actions allocated, where required. Immediate actions taken at the time will also be logged on the sheet. The originator should be notified, by his Supervisor, of the recommendations and actions taken, when available. The identification number on the Near-Miss Reporting Form will be entered into the monthly draw, held by the HSED, and the winning numbers selected, will be displayed on the Safety and Health Bulletin Boards. Doc. Number
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10.15 REPORTING OF SERIOUS HSE INCIDENTS TO ADNOC 10.15.1
GUIDELINES
‘The Guidelines’ require ‘serious’ HSE Incidents to be reported to ADNOC in the most timely manner possible following the incident. For the purpose of ‘the Guidelines’, definitions of HSE incidents are taken from the ADNOC HSE Risk Management Guidelines. Incident is defined as: ‘an event or chain of events which has caused, or could have caused injury, illness, and/or damage (loss) to assets, the environment, company reputation or third parties’. ‘Serious’ incident is a generic category which has been chosen to include catastrophic, severe and critical incidents. These are defined in summary form in Table 10-1. Severity
Catastrophic
Severe Critical
People
Assets
Multiple fatalities or permanent total disabilities Single fatality or permanent total disability Major injury or health effects
Environment
Reputation
Extensive damage
Massive effect
International Impact
Major damage
Major effect
National Impact
Local damage
Localised effect
Considerable Impact
Table 10-1: Reporting Guidelines It will be noted that the ADNOC definition of ‘incident’ includes events which cause or could have caused injury, illness etc. It follows therefore that any event which could have resulted in either catastrophic, severe or critical consequences should also be reported in accordance with these guidelines. These events are often referred to as ‘High Potential Near Misses’. Less serious incidents e.g. a Lost Time Injury where the person does not have ‘severe’ or ‘critical’ injuries shall not be reported to ADNOC immediately. This type of incident will be reported as part of the requirement to submit safety and environmental data periodically. The requirement will be defined in the ‘Guidelines on the periodic reporting of HSE data and statistics from Group Companies to ADNOC’.
10.15.2
CLASSES OF SERIOUS REPORTABLE INCIDENTS
More detailed definitions of catastrophic, severe and critical incidents (generically classed as ‘serious’ incidents for the purposes of ‘the Guidelines’) are given below. They have been taken directly from the ADNOC HSE Risk Management Guidelines.
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Table 10-2: People: Severity Catastrophic Severe Critical
Description Multiple fatalities or permanent total disabilities – from an accident or occupational illness (poisoning, cancer) Single fatality or permanent total disability – from an accident or occupational illness (poisoning, cancer) Major injury or health effects (including permanent disability) – Affecting work performance in the longer term, e.g. prolonged absence from work. Irreversible health damage without loss of life, e.g. noise induced hearing loss, chronic back injuries
Table 10-3: Assets: Severity Catastrophic Severe Critical
Description Extensive damage – Substantial or total loss of operation (costs in excess of US$ 10,000,000). Major – Partial operation loss (2 weeks shutdown, costs up to US$ 10,000,000). Local damage – Partial shutdown (can be restarted but costs up to US$ 500,000).
Table 10-4: Environment: Severity Catastrophic
Severe
Critical
Description Massive effect – Persistent severe environmental damage or severe nuisance extending over a large area. In terms of commercial or recreational use or nature conservation, a major economic loss for the company. Constant, high exceedance of statutory or prescribed limits Major effect – Severe environmental damage. The company is required to take extensive measures to restore polluted or damaged environment to its original state. Extended exceedance of statutory or prescribed limits Localised effect – Limited loss of discharges of known toxicity. Repeated exceedance of statutory or prescribed limit. Affecting neighbourhood. Spontaneous recovery of limited damage within one year.
Table 10-5: Reputation: Severity
Description
Catastrophic
International impact – International public attention. Extensive adverse attention in international media. National/international policies with potentially severe impact on access to new areas, grants of licenses and/or tax legislation. National impact – National public concern. Extensive adverse attention in the national media. Regional/national policies with potentially restrictive measures and/or impact on grant of licenses. Mobilisation of action group. Considerable impact – Regional public concern. Extensive adverse attention in local media. Slight national media and/or local/regional political attention. Adverse stance of local government and/or action groups.
Severe
Critical
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Issue 02, Rev 05 Date: August 2006 Chapter No. 10
Note Reputation also accounts for the liabilities arising from injuries and property damage to third parties including the cross liabilities that may arise between the interdependent ADNOC Group Companies.
10.15.3
REPORTING ARRANGEMENTS
Catastrophic, Severe and Critical Incidents must be reported to ADNOC as soon as possible after they occur. The objective should be to provide ADNOC with a report within twenty-four hours of the incident occurring. It is acknowledged that in some cases, particularly with respect to ‘High Potential Near Misses’, this may prove to be difficult. The objective in this case must be to report in the most timely manner possible. As a minimum in all cases, the ‘ADNOC Initial Incident Notification Form’, shown as Attachment 1 of ADNOC-COPV1-08: Reporting of Serious HSE Incidents, must be completed and faxed to the ADNOC Control Room on Fax No. 6673766. The ADNOC Control Room is manned 24 hours/day, 7 days/week. The ADNOC Control Room Supervisor shall contact the relevant Duty Manager(s) from the concerned Directorate(s) and provide them with a copy(s) of the ‘ADNOC Initial Incident Notification Form’. ADNOC Duty Managers shall follow up the incident in accordance with their procedures and notify ADNOC senior management accordingly. Based on the gravity of the incident, the Senior Management of each respective Business line Directorate will then inform the CEO. The ADNOC Control Room Supervisor shall also, in all cases, provide the ADNOC EH&S Division Manager with a copy of the ‘ADNOC Initial Incident Notification Form’. Note Relevant ADNOC Directorates are as follows: Exploration & Production: Gas Processing Div. GASCO; ADGAS; ATHEER Offshore Div. ADMA-OPCO; ZADCO; ADNOC; TOTAL-ABK; BUNDUQ Onshore Div. ADCO; NDC Marketing & Refining: ADNOC-FOD; TAKREER; NGSCO; ADNATCO Chemicals Directorate: BOROUGE; FERTIL Shared Services Directorate: NMS; ADDCAP; ADDPOC; NPCC
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RESPONSIBILITY FOR REPORTING INCIDENTS
All incidents shall be reported by the Group Company which has overall control of the site or operation where the incident has occurred. This includes incidents which result in injuries to employees, contractors, visitors or employees of other Group Companies. Where an incident in one Group Company impacts on another Group Company, the Group Company having control of the site where the incident was initiated shall report the incident. Where one Group Company is providing a service to another Group Company, the Group Company in overall control shall report the incident. For example, if an incident occurs on an NDC rig while it is working for ADCO, ADCO must report the incident.
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Figure 10-1: Investigation Report (1st page)
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Figure 10-2: Investigation Report (2nd page)
Figure 10-3: Investigation Report (3rd page)
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Figure 10-4: Investigation Report (4th page)
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TYPE OF ACCIDENT
STATUTORY NOTIFICATION TO
Fire and Explosion in Process Plant Major Spillage of Oil or Gas from Process Plant Fire, irrespective of location.
Fatality
Injury resulting in 3 or more days lost-time Injuries resulting in less that 3 days lost-time, non lost time injuries and occupational disease.
REPORT PREPARED BY
REPORT APPROVED BY
SPC Via LA, Head Office, Abu Dhabi
MHSE
PM
SPC via LA, Head Office, Abu Dhabi
MHSE
MOLSA via LA, Head Office Abu Dhabi MOLSA (Das Island) via P&TM copied to LA, Head Office, Abu Dhabi MOLSA (Das Island) via P&TM copied to LA, Head Office, Abu Dhabi MOLSA (Das Island) via P&TM copied to LA, Head Office, Abu Dhabi
PM
Issue 02, Rev 05 Date: August 2006 Chapter No. 10
NOTIFICATION REQUIREMENT S Initial report by fastest means of communication; Detailed report within 15 days. Initial report by fastest means of communication; Detailed report within 15 days. By fastest means of communication
REPORT FORMAT REF
Figure 10-5 Figure 10-6 Figure 10-5 Figure 10-6 Figure 10-7
MHSE
PM
MHSE
PM
By fastest means of communication
Figure 10-7
MHSE
PM
Within 24 hours
Figure 10-7
PM
Quarterly return within 15 days of the end of the quarter.
Figure 10-8
MHSE
Table 10-6: Statutory Notification Requirements
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Chapter No. 10
TELEX FROM PM TO GM
"URGENT"
TO Via c.c.
: : :
FROM :
Legal Advisor - ADGAS - Abu Dhabi. GM - ADGAS - Abu Dhabi HRRD - ADGAS - Abu Dhabi PM - ADGAS - Das Island
SUBJECT :
Date and Time of Accident : Location of Accident
:
Brief Details:
INJURED
:
DAMAGE
:
Figure 10-5: TELEX FROM PM TO GM
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Chapter No. 10
TYPED REPORT FROM MHSE, APPROVED BY PM TO GM AND L.A. WRITTEN NOTIFICATION (WITHIN 15 DAYS) OF ACCIDENT TO SUPREME PETROLEUM COUNCIL (Law 8 of 1980, "Conservation of Petroleum Resources", Article 50) In accordance with the above legislation the final report of the following accident is hereby attached for forwarding to the Supreme Petroleum Council. ACCIDENT INVESTIGATION REPORT TITLE 1.
Synopsis.
2.
Details of how accident occurred.
3.
Reporting of accident.
4.
Conclusions.
5.
Recommendations to prevent recurrence.
6
Attachments. Reported By : Manager Health Safety and Environment
Approved By : Production Manager
Figure 10-6: TYPED REPORT FROM MHSE
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ACCIDENT INVESTIGATIONS
Chapter No. 10
ABU DHABI GAS LIQUEFACTION COMPANY LIMITED LNG PLANT, DAS ISLAND NOTIFICATION OF ACCIDENT TO MINISTRY OF LABOUR AND SOCIAL AFFAIRS In accordance with Article (28) of Ministerial Decision No.(32) of 1982. 1.
Type of Activity
:
2.
Date of Accident
3.
Full Description of Accident
4.
Details of Injured Person;
: :
Name
:
Company No.
:
Age
:
Address
:
Grade/Salary range
:
Date of Appointment
5.
:
Injuries Sustained
:
Period of Disablement from Normal Duties
:
Damage caused by Fire or Explosion :
PRODUCTION MANAGER Date:
Figure 10-7: NOTIFICATION OF ACCIDENT
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TO Through
: :
Ministry of Labour and Social Affairs Personnel and Training Manager
c.c.
:
Legal Advisor, ADGAS, Abu Dhabi.
Subject
:
NOTIFIABLE INJURIES/OCCUPATIONAL ILLNESS DURING THE PERIOD TO ( QTR 200 )
Details of notifiable injuries and illness for Qtr 200 in compliance with Article 26 of Ministerial Decision No.32 of 1982 is tabulated below:Name
Employer
Date of Injury/ Disease
Description
Report Prepared by ___________________ MHSE
_________________ Date
Approved by
_________________ Date
____________________ PM
Figure 10-8: Summary of Notifiable Injuries and Illnesses
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Chapter No. 10
ABU DHABI GAS LIQUEFACTION COMPANY LIMITED LNG PLANT - DAS ISLAND
INFORMATION TO BE PASSED TO BOTH OFFICER I/C POLICE AND STATE SECURITY CONCERNING ACCIDENT ON LNG SITE
Date
:
Time
:
Location
:
Injuries
:
Damage
:
Details
:
PRODUCTION MANAGER
Date:
Figure 10-9: State Security Report
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MAJOR ACCIDENT/INCIDENT ANNOUNCEMENT Event o•
Personal Injury
o•
Incident
o• Other (Specify)
o•
Process Loss
o•
Property Damage
Location Date:________________
Division/ Dept:____________________
Apparent nature and extent of injury, damage, process loss or potential loss
Details available at present. (Description of Accident/ Incident)
Cause Apparent at this time.
Dist.: All Division Managers/Department Heads. Report Prepared by ____________________ _________________ MHSE Date Approved by ____________________ _________________ PM Date Figure 10-10: Major Accident/Incident Announcement
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TERMS OF REFERENCE FOR BOARDS OF ENQUIRY INTRODUCTION Any major accident or High Potential Loss incident that occur within the sphere of operations of ADGAS, involving company or contractor's personnel or property shall, at the discretion of PM or GM be investigated by a Board of Enquiry. CONSTITUTION The Chairman will be independent and the members shall have no direct involvement with the event. The members should be appointed by PM in consultation with the chairman of the Board of Enquiry and shall be sufficiently qualified and experienced to meaningfully conduct and complete the enquiry. It is advisable that in team selection the following are considered as well: Manager HSE or his nominee shall not be member of the Board but only act as a technical advisor. A facilitator, skilled in conducting Root Cause analysis (RCA) and will normally be part of the team. A member from HR Division should be nominated as part of the BOE team. DUTIES The task of the Board of enquiry is to follow a structured procedure (using ADGAS RCA procedure) to expose the root cause(s) of the incident and recommend appropriate actions in order to avoid recurrence. It is the duty of the Board of Enquiry to establish all the relevant facts. This may require laboratory/metallurgical tests, questioning of witnesses, etc. The Board Members shall have the right to examine all the relevant evidence including operational and maintenance records, work permits etc., and interview any person considered appropriate. Based on available evidence the Board of Enquiry shall report as accurately as possible the precise course of event before, during and after the event. The Board of Enquiry should determine the immediate causes and basic causes of the event. The Board of Enquiry shall recommend actions needed to avoid a recurrence of the event. The Board of Enquiry shall submit its findings as a single comprehensive report with appropriate attachments to the PM/ GM within ten days of the occurrence of the events. REPORT FORMAT The Board of Enquiry shall submit its report in three distinct and separate sections: Findings This consists of a narrative in chronological order of the facts established by the Board as a result of their enquiry. This section should be supported by appropriate drawings, photographs, laboratory analysis, flow diagrams, work permits, log books, etc., as applicable. Causes and Recommendations
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This consists of the Board's opinion as to the causes of the accident/incident and recommendations to prevent recurrence. The recommendations must be converted into an action plan. Statements This consists of statements made by witnesses and other persons who gave evidence to the Board.
DISTRIBUTION Only Five copies of the full report shall be prepared and distributed to the following persons: The General Manager. The Deputy General Manager The Plant Manager. Health, Safety and Environment Manager. Copies of the report shall be distributed to other persons and third parties only after approval by the General Manager and Production Manager. ASSIGNMENT OF ACTION PM consultation with GM upon receipt of the report shall review and approve the recommendations and action plans and if necessary changes of responsibilities/ target dates where considered appropriate be advised. The action plan will be forwarded to HSED for inclusion in the Action Tracking System.
Figure 10-11: Terms Of Reference For Boards Of Enquiry
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Figure 10-12: Near Miss Report Form
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FAX MESSAGE TO ADNOC CONTROL ROOM - FAX NUMBER: 02-6673766 ADNOC Control Room Supervisor to Notify ADNOC Duty Managers in the following Directorate(s) and ADNOC EH&S Division Manager E&P ‡ Marketing & Refining ‡ Chemicals ‡ Shared Services ‡ Others: ………………………………………… Date: Group Company/Site/Location:
Time of Incident:
Type of Incident:
Casualty(ies) Details: Name(s): Nationality(ies): Employer(s): Job Title(s): Status: Incident Description:
Nature and extent of losses:
Status at present and apparent cause (if known):
From: Signature: Name: Position:
Group Company:
Figure 10-13: INITIAL NOTIFICATION TO ADNOC – SERIOUS HSE INCIDENTS
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Date: August 2006
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Chapter No. 10
RCA Workflow Diagram Accident/ Incident Investigations
Employee Initiates Yellow Form
-
Head of Department / Div. Manger Comments
HSED review and investigate
IQM comments. Consult H&PR of required on integrity and reliability
PROM Remarks
What Happened Where Happened When Happened Who was there Losses Decide of Maxi or Mini RCA required
Technical Report Required
To RCA Flow Diagram
Assign Responsible
Figure 10-14: RCA Workflow Diagram
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Figure 10-15
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Figure 10-16
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Figure 10-17
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LABORATORY SAFETY
Chapter No. 11
CHAPTER 11 CONTENTS 11
LABORATORY SAFETY ...................................................................................................................... 421 11.1 INTRODUCTION ............................................................................................................................ 421 11.2 GENERAL SAFETY ........................................................................................................................ 421 11.3 GLASSWARE .................................................................................................................................. 422 11.4 SAFETY EQUIPMENT AND PPE .................................................................................................. 423 11.5 NAKED LIGHTS ............................................................................................................................. 424 11.6 SMOKING, FOOD AND DRINK .................................................................................................... 424 11.7 CHEMICAL USE ............................................................................................................................. 424 11.7.1 HANDLING OF CHEMICALS ................................................................................................ 424 11.7.2 FLAMMABLE AND EXPLOSIVE CHEMICALS ..................................................................... 425 11.7.3 CORROSIVE CHEMICALS ..................................................................................................... 425 11.7.4 TOXIC SUBSTANCES ............................................................................................................. 425 11.7.5 FUME CUPBOARDS .............................................................................................................. 426 11.8 LABELLING .................................................................................................................................... 426 11.9 ULTRA VIOLET (UV) RADIATION .............................................................................................. 427 11.10 SAMPLE DESPATCH ................................................................................................................. 427 11.11 WASTE DISPOSAL .................................................................................................................... 427 11.12 GAS CYLINDERS ....................................................................................................................... 428 11.13 ELECTRICITY ............................................................................................................................ 429 11.13.1 ELECTRICAL APPARATUS.................................................................................................... 429 11.13.2 STATIC ELECTRICITY ........................................................................................................... 429 11.14 FIRST AID ................................................................................................................................... 430 11.15 CRYOGENIC MATERIALS ....................................................................................................... 430 11.16 MERCURY .................................................................................................................................. 430
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LABORATORY SAFETY
Chapter No. 11
11 LABORATORY SAFETY 11.1 INTRODUCTION This section covers the specific safety requirements for laboratories and laboratory sampling operations and includes hazards and precautions such as toxic/hazardous substances, disposal of waste and use of compressed gases. These procedures shall be read and complied with by all personnel working in or visiting ADGAS Laboratories.
11.2 GENERAL SAFETY The main factors which contribute to a high standard of safety in laboratories are as follows: · · · ·
Adherence to laid down experimental procedures. High standards of housekeeping. Use of protective equipment provided. High standard of equipment maintenance and the use of equipment in good condition.
Apart from the dangers associated with toxic chemicals many common laboratory chemicals carry with them the risk of fire or explosion due to either their flammability or their unstable and highly reactive nature. A laboratory with a heavily polluted atmosphere indicates faults which if not rectified could cause a toxic or flammable atmosphere. These may be produced by one or a combination of the following: · · · ·
Poor ventilation. Poor fume extraction from fume cupboards. Spillage of chemicals. Badly designed experimental procedures.
Whenever a test is in progress a qualified competent person shall always be present. Laboratory users shall ensure that any equipment they have used is left in a safe condition. All personnel working within a laboratory shall make themselves familiar with the siting of the fire fighting and other safety and emergency equipment. Doc. Number
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The senior person in charge shall ensure that the laboratory is left in a safe condition at the end of the working day or at shift change. All flexible tubing should be inspected before use to ensure that it is in good condition. Protective clothing issued, either laboratory coats or overalls, shall be worn at all times. Coats should be buttoned to ensure that loose flapping clothing does not catch in machinery or knock over glassware. Gas cylinders when not in use shall be turned off at the cylinder valve. Cylinders should be securely stored in racks with safety chains or bench straps. Work benches should be kept tidy, free of unwanted apparatus and chemicals and the work areas free of obstructions. All electrical apparatus should be inspected for worn cables, damaged plugs, deficient earthing, etc. Defective equipment should be withdrawn and any repairs effected by a competent person from the Electrical Section. Do not pipette by mouth any volatile, toxic or corrosive liquids. Use a safety device such as a pi-pump pipette or a Griffin pipette filler, auto pipette, etc. Rubber tubing connecting apparatus should be secured by metal clips and not twisted wire. Wire is unsatisfactory since there is invariably a point of weakness at the base of the twist and an additional hazard is introduced by the twisted end having sharp points. Samples of oil/chemicals shall not be stored in the offices, mess rooms or in any area where there are naked lights or where smoking is permitted. Thermometers that are broken should only be disposed of after the mercury has been removed in a safe manner.
11.3 GLASSWARE All glassware should be inspected before use especially those items or apparatus subjected to vacuum or high temperature. Damaged equipment should be sent for repair or discarded. Glass vessels containing liquid reagents should be kept out direct sunlight; this will prevent any lens effect taking place and creating an additional fire hazard. Glass Winchesters should be treated with care as often the walls are thin. Winchesters should never be lifted by the neck as the weight of the contents may be sufficient to shatter the bottle. Doc. Number
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Winchesters of corrosive liquids should only be transported in the special carriers provided. One of the most common causes of accidents within a laboratory is the careless handling of glass tubing and apparatus. Although ground glass joints are almost universally used, the insertion of glass tubing into cork or rubber bungs still causes accidents. The following points should reduce such accidents: · · · ·
Glass tubing after being cut should be rounded off in a flame. A lubricant such as glycerine or Teepol should be used to ease the insertion of the glass tubing into a cork bung. When inserting the tubing, hold the glass in a sufficient thickness of cloth or gloves. If force is required then hole is too small. Long lengths of glass tubing should be carried vertically.
Broken glass should be cleared up immediately and disposed of in a safe manner, ensuring that there will be no hazard to persons clearing away waste materials. Spillages shall be cleared up immediately. Acid or alkalis may require neutralisation or dilution before disposal is safe.
11.4 SAFETY EQUIPMENT AND PPE All personnel must know the location of fire extinguishers, control valves and electrical isolating switches. All personnel shall be instructed in the use of portable fire fighting equipment. Protective clothing must be worn when handling hazardous materials. Armoured glass safety spectacles are provided and must be worn by all personnel working or visiting in the Laboratory. Safety spectacles and goggles provide protection against unexpected dangers. With work involving a known potential hazard, use additional protection such as a full face visor. See also Section 3-9, Personal Protective Equipment and the Hazardous Substances Manual.
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11.5 NAKED LIGHTS Naked lights such as a gas burners, non flameproof electrical equipment, etc., should only be used in rooms or locations agreed by the HSED. Flammable liquids shall not be stored in such areas where naked lights are allowed. All necessary ignition sources, e.g. Bunsen burners, heaters, etc., should be turned off when not in use.
11.6 SMOKING, FOOD AND DRINK Smoking is not permitted in the laboratory or laboratory storerooms. Food shall not be consumed in laboratory working areas Laboratory apparatus shall not be used instead of cups or glasses and vice versa.
11.7 CHEMICAL USE 11.7.1 HANDLING OF CHEMICALS Most chemicals are potentially harmful and should be handled with caution. It is a requirement of recognised international standards such as the UK Health and Safety at Work Act, 1974 that manufactures/suppliers of potentially harmful materials shall supply their customers with relevant health and safety information. Should this information not be supplied with the materials, manufacturers will provide it on request. Before a new or unknown chemical is used within the laboratory all relevant information shall be obtained by the Lab Superintendent. Copies of the data shall be forwarded to the HSED in accordance with Section 11.4, who will be responsible for updating the Hazardous Substances Manual. Chemicals shall be transported, stored and used according to the manufacturer's instructions, company safety regulations and codes of practice such as those issued by the UK Health and Safety Executive. Glass bottles, whatever their contents, should be transported in a safe manner using the carriers provided. Extreme care shall be exercised when decanting liquids, for example when filling reagent bottles from a full Winchester. It is highly dangerous when pouring from a large container to rest it so that the whole weight is on the receiver. A variety of suitable liquid transfer equipment is available from various laboratory suppliers and these should be used as they provide a safe, efficient and speedy method of transferring liquids. All transfers where practicable should take place on spillage trays.
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11.7.2 FLAMMABLE AND EXPLOSIVE CHEMICALS Flammable explosive chemicals shall not be stored in the vicinity of naked lights. They will be stored only in specifically designated areas of storeroom/cupboards. Mechanical stirring of flammable materials should only be carried out using either compressed air or explosion proof electrical equipment. Such operations should be carried out in a fume cupboard. The maximum quantity of highly flammable materials held in the laboratory should be the minimum amount required to ensure the continuance of the work in hand. Storage of explosion and flammable compounds should comply with a recognised standard, approved by MHSE such as the UK Highly Flammable Liquids & Liquefied Petroleum Gas Regulations. Within the laboratory these compounds should not be placed on window sills or shelves above shoulder level. Safety containers should be used for the transfer and conveyance of highly flammable liquids. Strong oxidising chemicals shall not be stored with flammable substances or materials. Organic chemicals which can form peroxides should be stored in a darkened area. Inter-reacting chemicals shall be adequately isolated from one another in storage. Non-explosive proof refrigerators are unsuitable for storing substances that may lead to flammable/explosive gas/vapour and should be labelled as such. Any items stored in a refrigerator should be clearly labelled and be recorded in a log book. Refrigerators should be clearly labelled "Chemicals only - no Food".
11.7.3 CORROSIVE CHEMICALS Large containers of these chemicals (acids and alkalis) shall be transported in suitable carriers. When handling these liquids in bulk, full chemical protective clothing shall be worn. Concentrated acids should not be used or stored in the vicinity of flammable material.
11.7.4 TOXIC SUBSTANCES Toxic substances may enter the body by inhalation, ingestion or by absorption through the skin. Extreme care shall be exercised when handling these substances and the appropriate protective clothing/equipment shall be worn. Doc. Number
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LABORATORY SAFETY
Chapter No. 11
Toxic substances shall be stored in clearly labelled containers. Any poisonous substances shall be stored in a properly labelled container. The container shall be replaced in its proper position immediately after use. All recognised poisonous substances shall be stored in a Poisons Cupboard that shall be kept locked, the key being under the control of the person in charge of the laboratory. Note A Poisons register shall be kept containing details of all poisons and amounts stored.
11.7.5 FUME CUPBOARDS Any operations involving harmful or dangerous gases or fumes shall be carried out in a fume cupboard. Only fume cupboards equipped with flameproof motors shall be used when flammable gases are being vented, cooled, etc Before any work is carried out in a fume cupboard it shall be ascertained that the ventilation is adequate. The effluent from the fume cupboard should be directed to a safe place where dispersion is assured.
11.8 LABELLING All containers, bottles, jars, etc., used in the laboratory and in particular those containing highly toxic, corrosive or reactive substances shall be clearly labelled with the name of the contents. All substances shall be stored in properly designed and approved containers, bottles, etc., suited to the nature of the substance and hazards involved and never in any container that may suggest that the contents are a foodstuff or other domestic product. Substances, liquids, etc., that cannot be positively identified should be set aside and labelled as "UNKNOWN LIQUID OR SUBSTANCE", carefully packed and the Safety and Loss Prevention Department notified. Wash bottles that contain a liquid other than water should be clearly labelled as to its contents. Highly poisonous, corrosive or reactive substances should have this indicated in red.
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11.9 ULTRA VIOLET (UV) RADIATION UV radiation readily causes conjunctivitis and in extreme cases causes irreparable damage to the retina. UV sources should always be properly shielded and eye protection worn by all personnel working in the vicinity.
11.10 SAMPLE DESPATCH Flammable liquids and other reactive materials require special packaging and labelling to conform with a recognised standard, approved by MHSE such as the Dangerous Substances (Classification, Packing and Labelling) Regulations 1996, and IATA Regulations, etc. A record of all samples despatched from the laboratory shall be meticulously logged.
11.11 WASTE DISPOSAL The attention of all personnel is drawn to the fact that the disposal of waste shall be carried out in a responsible manner. National, Gulf and International protocols and legislation are in force to protect the environment. Special bins or drums shall be provided for the disposal of waste material. Broken glassware should be segregated from other waste, e.g. paper, rags, etc., Separate drums shall be provided to store chlorinated and non chlorinated waste solvents. All containers, even when empty, if they have contained flammable materials, shall be stored and treated as if they were full containers. Empty containers for disposal shall be rendered safe by thorough washing and gas freeing. It shall be borne in mind that other persons who finally dispose of the waste material can be exposed to hazard should not enough care be exercised in the original disposal of waste into segregated containers. Care shall be taken in the disposal of any materials that can spontaneously ignite or give off excessive heat when in contact with water. Disposal procedures will normally be specified in the relevant Material Safety Data Sheet in the Hazardous Substances Manual.
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11.12 GAS CYLINDERS Gas cylinders or compressed air shall not be connected directly to any glass apparatus, a safety bottle shall be used. Always open the cylinder slowly and release a little gas before connecting the apparatus. Wherever possible gas cylinders should be kept outside and the gas piped into the laboratory. Cylinders should be secured in racks and out of the direct rays of the sun. The direct heating of gas cylinders to increase the evaporation rate is not allowed. Gas cylinders are marked with a specification colour code and these colours should be checked against the contents before use. On British cylinders, red is used to indicate flammability and yellow to indicate toxicity. Compressed gas cylinders shall be handled with care, they shall not be dropped or allowed to strike against each other. Safety devices where fitted shall not be tampered with. Cylinder valves shall always be closed even when the cylinder is empty. Ensure that the mating surfaces of the cylinder and the required pressure regulator are clean and in good condition before being attached. Ensure that the thread connections on cylinder regulators correspond to those on the cylinder outlet as threads vary for different gas cylinders. Regulators provided for a particular gas shall not be used on cylinders containing any other gas. Only the standard valve keys as provided by the manufacturer shall be used. Valve keys that have been adapted to provide extra leverage should never be used to force a valve open or shut. The cylinder valve shall always be opened slowly and by gently tapping the key. Cylinders with faulty valve joints, immovable valve spindles or valve leakage shall be returned to stores stating clearly the nature of the fault and whether the cylinder is empty or is still charged. Under no circumstances shall the user attempt any repairs whatsoever. Should the cylinder valve leak slightly when closed it is usually due to grit on the seat; this can often be removed by opening the valve slowly and closing it sharply.
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Cylinders should be protected against excessive rise in temperature and extremes of temperature. Cylinders of compressed gas should not be stored near highly flammable materials. Every possible precaution should be taken to prevent oil and grease coming into contact with cylinder valves or regulators. Warning OILS AND GREASES ARE SPONTANEOUSLY COMBUSTIBLE IN THE PRESENCE OF OXYGEN UNDER PRESSURE Further Information Chapter 4.8 COMPRESSED GASES
11.13 ELECTRICITY 11.13.1
ELECTRICAL APPARATUS
All electrical apparatus shall be serviced as per laid down schedules by a competent electrician and maintained in good order. Laboratory personnel shall not undertake any electrical repairs or alterations to equipment or permanent electrical wiring. All electrical apparatus, plugs, leads, etc., should be kept clean and dry. If any part should become wet immediately switch off the power, disconnect the plug and dry thoroughly. If in doubt seek advice from the Electrical Section. Warning Never touch electrical equipment with wet hands. Tangles of wires and undue lengths of cables on work benches should be avoided. Further Information Section 9.1 ELECTRICAL
11.13.2
STATIC ELECTRICITY
Organic solvents and solids (powder) often develop high electrical charges when being poured from containers and particularly so when constructed from polythene. Whenever possible metal drums and gas cylinders should be earthed to prevent sparks through static electricity that would cause an explosion. The receiver should also be earthed. Earthing shall be checked by a competent electrician.
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Further Information Section 6-9 Static Electricity
11.14 FIRST AID All injuries shall be reported as laid down in Chapter 10 of this Manual. A reference list of toxic substances, medical symptoms and first aid treatment shall be readily available in the laboratory. The Medical Services Department of ADMA-OPCO and HSED shall be informed of any extremely toxic substances being used which may require them to hold recognised antidotes. The handling of chemicals can give rise to skin irritation, and any such case noticed shall be reported at once to the Senior Laboratory Staff.
11.15 CRYOGENIC MATERIALS Cryogenic materials such as liquid nitrogen or solid carbon dioxide are extremely cold. Cryogenic liquids and their cold boil-off vapours can rapidly freeze human tissue and cause many common materials such as carbon steel, plastic and rubber to become brittle or even fracture under stress. Accidental contact of liquid or cold gas with the eyes or skin may cause severe frostbite. Always handle cryogenic liquids carefully. Safety spectacles, gloves and other personal protective equipment shall be worn at all times when transferring liquid nitrogen to or from glass vacuum flasks, which occasionally fail in service. Stand clear of boiling or splashing liquid and its vapours.
11.16 MERCURY Mercury is highly toxic and shall be handled with care. Precautions shall be taken to prevent contact with the skin. Suitable gloves shall be worn when handling. Exposure to mercury vapour for short periods requires only removal from exposure to rectify but, if mercury is swallowed, medical attention shall be sought. Mercury vapour is volatile at room temperature and dangerously high concentrations can build up in a non-ventilated room (TLV 0.0005 ppm). Its use should be limited and equipment shall be designed to contain spillages through breakage or malfunction. Mercury manometers should be fitted with an effective mercury trap.
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If, in spite of precautions, mercury is spilled, it shall be removed immediately using suitable suction equipment. Any inaccessible residues in floor cracks should be treated with lime-sulphur paste or zinc dust to render harmless. Further Information ADGAS Hazardous Substances Manual
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Issue 02, Rev 05 Date: August 2006
OFF THE JOB SAFETY
Chapter No. 12
CHAPTER 12 CONTENTS 12
OFF THE JOB SAFETY ......................................................................................................................... 433 12.1 FIRE PRECAUTIONS IN ACCOMMODATION UNITS ON DAS ISLAND ................................ 433 12.1.1 FIRE PREVENTION ................................................................................................................ 433 12.1.2 FIRE ACTIONS ....................................................................................................................... 433 12.2 FIRE PRECAUTIONS AT HOME ................................................................................................... 434 12.2.1 FIRE PREVENTION ................................................................................................................ 434 12.2.2 FIRE ACTIONS ....................................................................................................................... 434 12.3 SAFETY IN THE HOME ................................................................................................................. 436 12.3.1 KITCHEN ................................................................................................................................ 436 12.3.2 BATHROOM ............................................................................................................................ 436 12.3.3 ELECTRICAL SAFETY ........................................................................................................... 437 12.4 SPORT AND RECREATION........................................................................................................... 437 12.5 DRIVING ......................................................................................................................................... 437
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12 OFF THE JOB SAFETY 12.1 FIRE PRECAUTIONS IN ACCOMMODATION UNITS ON DAS ISLAND 12.1.1 FIRE PREVENTION · · · · · ·
Never bring any highly flammable materials such as gasoline into your accommodation unit Always douse cigarette and cigar butts with water before putting them in the bin Never smoke in bed Never overload electrical outlets and extension cords Report any damaged electrical wires and cords to Camp Maintenance Make sure that you know where your marshalling point is, and your nearest fire alarm and fire extinguisher
12.1.2 FIRE ACTIONS 12.1.2.1 INITIAL FIRE ACTION If you discover a fire in your room take the following action: · · · · · · ·
Sound the nearest fire alarm and if practicable dial 62222 If safe to do so, attack fire with available fire extinguisher Shut, but do not lock, doors If safe to do so, attack fire with available fire extinguisher Evacuate your area to the nearest Marshalling Point Make yourself known to the emergency services and inform them of the location of the fire Await further instructions
12.1.2.2 IF YOU HEAR THE FIRE ALARM On the sounding of the local Fire Alarm residents SHALL take the following actions: · · · · · · ·
Leave their room Shut, but do not lock, doors Leave their place of work or room Shut, but do not lock, doors If safe to do so, attack fire with available fire extinguisher Evacuate your area to the nearest Marshalling Point Await further instructions
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12.2 FIRE PRECAUTIONS AT HOME 12.2.1 FIRE PREVENTION · · · · · · · · ·
Make sure that flammable items are kept in their original containers in a locked storage area separate from the home? Avoid bring any highly flammable materials such as gasoline into your home Always douse cigarette and cigar butts with water before putting them in the bin Never smoke in bed Never overload electrical outlets and extension cords Regularly check all wires and cords for damage Regularly use the “test button” on any smoke alarms to ensure that they are working and so that everyone will recognise the sound of the alarm Ensure that family members with special needs, such as ill or frail family members or small children, have arrangements to help them get out safely Ensure that family members know to get out first if there is a fire, and then call for help once safely outside
12.2.2 FIRE ACTIONS 12.2.2.1 INITIAL FIRE ACTION If you discover a fire in your apartment · · · · · · ·
Tell everyone in your apartment to leave If the fire is small and contained, and you are trained in the use of fire extinguishers, use a suitable fire extinguisher or fire blanket to attack the fire. If in doubt - get out Then close all doors behind you Sound the nearest fire alarm and shout fire Leave the building using the nearest stairway When you are safe phone the Fire Brigade on --------If practical, someone should meet the Fire Brigade at the front entrance and tell them where the fire is
12.2.2.2 IF YOU HEAR THE BUILDING FIRE ALARM · · · · ·
Make sure everyone in your apartment is awake and aware of the alarm Normally the best course of action is to leave the building as soon as possible In some cases you may not be able to leave and you may have to stay in your apartment In either case you must act quickly No matter what your decision you must protect yourself from the smoke
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If you decide to leave the building · Check the door to your apartment. If smoke is entering from around the door, do not open it, but protect yourself from smoke inside your apartment as described later · If there is no smoke, brace yourself and open the door a little · If you see smoke or feel heat, close the door quickly and protect yourself · If the corridor is clear, take your keys, lock your door, and go to the nearest stairway · DO NOT USE THE LIFTS · Open the nearest escape stairway door carefully · If there is no smoke, use the stairway to leave the building · If there is smoke, do not enter. Close the door. Go to another stairway and open the door carefully · If there is no smoke here, use this stairway to leave the building · If there is smoke, do not enter. If there are other stairways, try them. If there are not, return to your apartment and protect yourself from smoke · If you can't use any stairway, return to your apartment if you can, or go into any corridor and bang on apartment doors until you find a place to take shelter. · Never go to the roof · Remember, wherever you are, if there is smoke, crawl low under it. The air is cleaner near the floor If you remain in your apartment · You must protect yourself from smoke. Stay in your apartment until you are rescued or until you are told to leave. This may take a long time. Do not try to leave your apartment a long time after the alarm has sounded. The longer you wait, the more risk there is that heavy smoke will have spread into stairways and corridors. Your chances of survival are less. · Keep smoke from entering your apartment. Use duct tape to seal cracks around the door and place wet towels at the bottom. Seal vents and air conditioning ducts the same way. If smoke enters your apartment · Telephone the Fire Brigade and tell them where you are and then move to the balcony and close the doors behind you · If you don't have a balcony, go to the most smoke-free room, close the door and seal it with any available tape and towels. Open the window for fresh air · Show your rescuers where you are by hanging a sheet from the window or balcony · Keep low to the floor where the air is cleaner · Listen for instructions from authorities
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12.3 SAFETY IN THE HOME 12.3.1 KITCHEN · · · · · · · · · · · · · · · · ·
Store harmful products in their original containers and away from food Do not transfer poisonous or caustic products to drinking glasses, pop bottles, or other food containers If you have small children install store medicines and other potential or harmful substances in secure places where they cannot reach or install child safety locks on accessible cabinets Store knives and other sharp objects out of the reach of children Make sure that all dangerous products, including medication, cleaning products and chemicals have child-resistant caps Read and follow the use and storage directions before using cleaning products Wear gloves when using harsh products such as bleach Do not mix products together to avoid dangerous reactions Put away products after use and wipe up spills immediately Keep kitchen walkways clear of clutter Make sure the bin is covered with a lid Do not leave oils and fats unattended when in use for cooking Keep things that can burn, such as dishtowels, paper or plastic bags, and curtains at least three feet away from the stove or burners Turn pan handles always inward while cooking Keep hot items, such as beverages and cooking trays, away from the edge of work tops and out of children’s reach
12.3.2 BATHROOM · · · · · · · ·
Use a non-slip mat or install adhesive safety strips in baths and showers Keep the bathroom floor clean and promptly wipe up all spills. If you use a bath mat on the floor, choose one that has a non-skid bottom Use nightlights to help light hallways and bathrooms during night-time hours Never leave children unattended in the bath or near standing water. Always stay within touch supervision of young children – within an arm’s reach -during bath time. Never leave them unattended, even for a short while. to answer the telephone or door Make sure electrical appliances, cords and fixtures in your bathroom are suitable for the location and are properly installed Never use electrical appliances such as hair dryers, curling irons, and razors whilst in the bath or shower. Keep them away from water and unplugged and stored when not in use.
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12.3.3 ELECTRICAL SAFETY · · · · · · · · ·
Make sure that all electrical equipment is fitted with correct type of plug for the sockets in your home Never overload sockets. One socket per appliance is good practice Only use the safe light bulb wattage for each light fixture Never tamper with electrical plugs to make them fit the wrong type of socket Keep electrical leads away from walking routes Ensure that all electrical leads are in good condition and not knotted or coiled or run under furniture or rugs If fuses are used, ensure they are the correct size for the circuits they protect Ensure that all power tools are earthed or marked to indicate that they are double insulated
12.4 SPORT AND RECREATION Many injuries are caused because people are not fit enough to carry out strenuous activities such as running or squash, or that they do not adequately warm up before starting the activity. Always stretch and warm up before commencing any strenuous activity. If you go out jogging at night always wear bright clothing with reflective tape to ensure that drivers can see you clearly. Always run on the left side of roads facing the oncoming traffic. Never go swimming alone. Closely monitor all children near swimming pools and open water, particularly those who cannot swim. Carefully plan all desert trips ensuring adequate supplies of food, water, fuel, spares, firts aid kit and maps. Always let someone responsible what your plans are, and when you intend to return. Protect yourself, and in particular your children, from the harmful effects of the sun by the use of sunscreen, sunglasses and hats. In summer always make sure that you have plenty of water to drink. Prolonged exposure can lead to heat stroke or exhaustion. Be aware of changes in peoples skin colour and attitude. Sufferers may become red faced with hot dry skin and complain of headaches and dizziness.
12.5 DRIVING Driving is one of the most hazardous off the job activities undertaken. When you are driving you are responsible for the safety of everybody in the vehicle including you and your family. ·
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Issue 02, Rev 05 Date: August 2006 Chapter No. 12
Ensure that your vehicle and its equipment is maintained in good condition Use the seat belts provided with the car Children should not ride in the front seat. Make sure that they are secure in the rear seats Always drive within posted speed limits and obey highway instructions Avoid using your mobile phone whilst driving. If necessary, stop and pull over At filling stations, turn off the engine, do not use your mobile, and if self service keep hold of the filling nozzle throughout the refuelling operation
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Issue 02, Rev 05 Date: August 2006
MANAGEMENT OF HSE IN PROJECTS
Chapter No. 13
CHAPTER 13 CONTENTS 13
MANAGEMENT OF HSE IN PROJECTS ........................................................................................... 440 13.1 13.2 13.3
INTRODUCTION ............................................................................................................................ 440 SCOPE .............................................................................................................................................. 440 GUIDANCE ..................................................................................................................................... 440
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MANAGEMENT OF HSE IN PROJECTS
Chapter No. 13
13 MANAGEMENT OF HSE IN PROJECTS 13.1 INTRODUCTION This Section provides a summary of the HSE issues which need to be taken into account and managed during the project phase of an ADGAS asset, and provides links to the standards and processes that should be complied with or referred to. The objectives are to safeguard the well-being of our employees, contractors and community and protect the environment throughout the design, construction and operation of ADGAS projects.
13.2 SCOPE This Section addresses the lifecycle of an asset from appraisal to operation and maintenance, and should be applied to all projects.
13.3 GUIDANCE Projects vary in size, complexity and associated HSE Risks therefore a project specific set of HSE Requirements shall be established for every ADGAS Project and Major Plant Modification. The Project HSE Requirements CHECKLIST (Tables 13.1-5) provides a systematic approach for identifying the requirements, assigning responsibilities and giving necessary guidance, references and procedures. The CHECKLIST shall be initiated by ADGAS Project Managers in coordination with HSED during the conceptual phase. The requirements shall be revisited and updated if necessary at the end of every consecutive project phase. For detailed information on how to prepare and use the CHECKLIST, refer to I&Q Division PROJECT HSE REQUIREMENTS CHECKLIST & GUIDLINE document.
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Table 13.1 - Guideline for Project HSE Activities
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Table 13.2 - Guideline Check List of HSE Deliverables
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Table 13.3 - Guideline Check List of HSE Deliverables
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Chapter No. 13
Table 13.5 – Project HSE Codes, Guidelines & Procedures
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