Hazard Identification & Task Risk Assessment

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Document No.: PRO/SFTY/018 Issue Date: August 18, 2007 Page 1 of 38 DOCUMENT CONTROL Revision Record Revision No. Revision Date

Section / Page Description & Reason for amendment

1 Dec. 05,

2005

Various To bring in line with CoW Standard, revised PTW procedure, and in response to various audits recommendations & feedbacks. Also the risk evaluation criteria have been modified to 5 x 5 matrix.

2 August 18, 2007

Various To clarify sections relating to Roles,

Responsibilities, Accountabilities and Competencies to further align with the CoW Standard and to incorporate the Group HITRA Draft Guidelines.

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Document No.: PRO/SFTY/018 Issue Date: August 18, 2007 Page 2 of 38 TABLE OF CONTENTS

1.0 INTRODUCTION ... 3

2.0 PURPOSE AND SCOPE ... 3

3.0 LINKAGE WITH OTHER PROCEDURES AND STANDARDS ... 3

4.0 DEFINITIONS ... 4

5.0 ROLES AND RESPONSIBILITIES ... 5

6.0 TRAINING AND COMPETENCY ... 7

7.0 HITRA PROCESS OVERVIEW ... 9

8.0 PROCEDURE ... 10

8.1 WORK REQUEST... 11

8.2 CHECK TASK CATEGORY... 11

8.3 PERFORM LEVEL-1TRA... 11

8.4 DEFINE TASK PARAMETERS... 12

8.5 PERFORM LEVEL-2TRA... 12

8.6 FORM TRATEAM... 12

8.7 BREAK DOWN OF TASK INTO ACTIVITIES... 14

8.8 IDENTIFY HAZARDS... 14

8.9 IDENTIFY HAZARD EFFECTS (CONSEQUENCES) ... 14

8.10 DEFINE RISK RATING... 15

8.11 IDENTIFY CONTROLS... 18

8.12 CONTROLS ADEQUATE... 21

8.13 RESIDUAL RISK ACCEPTABLE... 22

8.14 AGREEMENT ON RISKS AND CONTROLS... 22

8.15 DOCUMENT AND RECORD... 22

8.16 REVIEW OF TRA... 23

8.17 COMMUNICATION... 23

8.18 IMPLEMENT CONTROLS... 22

8.19 CARRY OUT THE TASK... 24

8.20 MONITOR FOR CONDITION CHANGE... 24

8.21 RECORD LESSONS LEARNED... 24

APPENDIX 1 - TASK RISK ASSESSMENT FLOWCHART ... 25

APPENDIX 2 - TASK CATEGORIZATION CHART ... 25

APPENDIX 3 - HAZARD CHECKLIST ... 27

APPENDIX 4 - RISK ASSESSMENT SAMPLE ... 32

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Document No.: PRO/SFTY/018 Issue Date: August 18, 2007 Page 3 of 38 1.0 INTRODUCTION

Pre-job risk assessment is a key element of the BP Group Standard for the Control of Work (Element 5 – Assess and manage the risks), the BP Golden Rules of Safety (Getting the Basics Right) as well as the Getting HSE Right Management Framework (Element 2 – Risk Assessment and Management).

The identification and control of risk is an essential pre-requisite to ensure safe execution of work activity and secure compliance with the requirements of health and safety legislation. The process comprises the following three basic stages:

• hazard identification – identifying hazards which could cause harm. • risk assessment – assessing the risk that may arise from hazards. • risk control – deciding on suitable measures to eliminate or control risk. The Control of Work Group Standard states that:

“Tasks shall not be conducted without being risk assessed.”

This document is intended to provide the information and guidance to develop the systems necessary to effectively identify the hazards and manage the risks associated with work activities.

2.0 PURPOSE AND SCOPE

The purpose of this procedure is to provide guidelines to the user of Hazard Identification and Task Risk Assessment (HITRA) within Pakistan Performance Unit Operations. The procedure shall be used to identify the potential hazards, assess the risks involved and identify the controls and precautions necessary to reduce the risk to ‘as low as reasonable practicable (ALARP)’ level before undertaking the work safely.

This procedure shall apply to all operations of BP Pakistan, and also to its contractors and sub-contractors where procedure does not exist. This procedure shall be used for Level 1 and Level 2 tasks to mitigate potential hazards by assessing the risks involved in carrying out the task and providing controls to reasonably practicable level.

3.0 LINKAGE WITH OTHER PROCEDURES AND STANDARDS

This procedure has linkages with the following procedures, rules, standards and regulations.

a) BP Group Standard for the Control of Work (Element – 5) b) BP Getting HSE Right Management Framework (Element – 2) c) BP Golden Rules of Safety (Getting the Basics Right)

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Document No.: PRO/SFTY/018 Issue Date: August 18, 2007 Page 4 of 38 4.0 TERMINOLOGY

Hazard The potential or condition to cause harm, including ill health and injury, damage to property, plant, products or the environment, production losses or increased liabilities.

Hazard Effect

[Consequence] The harm or consequence which takes place due to the realization of the hazard.

Probability Likelihood of an event occurring, and resulting in specified Hazard Effect or consequence.

Risk The likelihood that a specified undesired event will occur due to the realization of a hazard by, or during, work activities or by the products and services created by work activities. Risk is the combination of the Hazard Effect (Consequence) and Probability (likelihood of its occurrence).Risk = Hazard Effect (Consequence) x Probability (Likelihood of Occurrence).

Control Control is the reduction in the level of risk by applying suitable safety measures.

ALARP To reduce a risk to a level, which is "as low as reasonably practicable" and involves balancing reduction in risk against the time, trouble, difficulty, and the cost of achieving it.

Competency The system to provide the information, instruction, training, and supporting communication's effort needed to meet the task needs.

Planning Is used to describe the process by which the objectives and methods of implementing the health and safety policy are decided. It is concerned of allocating resources to achieve objectives and decide priorities. It ranges from general topics dealing with the direction of the whole organization to detailed issues concerned with standards setting and the control of specific risks.

Measuring The collection of information about the implementation and effectiveness of plans and standards. This involves a variety of checking or ‘monitoring’ activities.

Task Risk

Assessment Also known as JSA (Job Safety Analysis) or JHA (Job Hazard Analysis). It is an organized and systematic effort to identify and analyze the significance of potential hazards of each manageable task associated with the materials, equipment, instrumentation, utilities, human actions (routine and non-routine), and external factors that might impact the process. (This is done by breaking the activity into manageable tasks) and then to identify suitable controls to ensure risks are reduced to an acceptable level and document risk assessment results.

Residual Risk The Risk remaining after applying Control measures, and carrying out a

re-assessment of HE rating and Probability.

Auditing The structured process of collecting independent information on the efficiency, effectiveness and reliability of the total safety management system and drawing up plans for corrective action.

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Document No.: PRO/SFTY/018 Issue Date: August 18, 2007 Page 5 of 38 5.0 ROLES AND RESPONSIBILITIES

The roles and associated responsibilities required to successfully deliver the HITRA process are described below. The roles and responsibilities described under each job title must be assigned to suitably competent, trained, knowledgeable and authoritative personnel for the HITRA process to work successfully. The necessary trainings and competencies required to effectively fulfil these roles and responsibilities are elaborated in Section 6.0 of this procedure.

5.1 Single Point Accountable Person(s) – (SPA)

Operations Manager shall be the SPA for all field operations whereas the Support Services Team Leader shall be the SPA for the Karachi and Islamabad Offices.

The SPA person shall be responsible for giving assurance to BPP Management that the correct procedure is being followed. He is the operational custodian of the HITRA procedure and is responsible for its up gradation, training and operation. He is the principal resource to provide support and advice on HITRA procedure and its implementation.

He will be responsible for:

• Ensuring that a Risk Assessment process is in place and is being followed consistently at the site / premises.

• Reviewing and auditing the risk assessment process to ensure that the standard of risk assessments is maintained and areas of improvement are identified and implemented.

• Approve any reviews / updates / revisions in the HITRA procedure in the light of experience gained and lessons learned.

• Ensuring a process is in place to manage the appointment of competent persons to act as Authorising Signatories for Level 1 and Level 2 Risk Assessments. • Ensuring a process is in place to manage the appointment of competent persons

to act as Level 1 Risk Assessment Completers.

• Ensuring a process is in place to manage the appointment of competent persons to act as Level 2 Risk Assessment Team Leaders.

• Assisting and advising all users of the HITRA procedure in its correct interpretation and implementation and maintenance of the HITRA system.

5.2 Level – 1 HITRA Completer

This role is performed by those carrying out the work activity or Performing Authorities. The main responsibilities for this role are:

• Complete Level 1 Risk Assessments where required.

• Ensure that adequate consultation has taken place (typically with the Area Authority and/or Permit Issuer).

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Document No.: PRO/SFTY/018 Issue Date: August 18, 2007 Page 6 of 38 • Ensure that appropriate authorisation has been obtained prior to the

commencement of work. 5.3 Level – 2 HITRA Team Leader

This role is normally performed by a person belonging to the Performing Team and being in a senior supervisory position with appropriate training and certification of the HITRA process as well as sufficient experience in the task to be performed. The main responsibilities for the Level - 2 HITRA Team Leader are:

• Lead the Team responsible in performing a Level 2 HITRA to the process described in this document. Refer to Section 7.0.

• Ensure the team understands the assessment process and what it is trying to achieve.

• Take responsibility for maintaining the quality of the Risk Assessment and ensure that the assessment team includes personnel with all the necessary knowledge and competence for the task involved.

• Ensure the Risk Assessment includes a worksite visit.

• Ensure that all members of the Risk Assessment team have a full opportunity to contribute and that the details of the assessment are agreed by all team members.

• Ensure that the details of the assessment are accurately recorded. 5.4 Level – 2 HITRA Team Member

Level – 2 HITRA Team Members include representatives from the Performing Team as well as any additional members who can contribute to the Risk Assessment Process by virtue of their specialized knowledge and skills or relevant prior work experience. The responsibilities of the individual team members are to:

• Actively participate in the Risk Assessment process.

• Help identify hazards and control measures to remove or reduce the likelihood of an incident/accident happening.

• Ensure they agree with the overall Risk Assessment before approval and that risks have been reduced as low as reasonably practicable.

5.5 People Carrying out the Work

The responsibilities of the people carrying out the work are to:

• Understand the hazards and control measures associated with the task. • Participate and contribute in the pre-job toolbox talk / safety meeting. • Actively monitor the worksite and surroundings for change.

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Document No.: PRO/SFTY/018 Issue Date: August 18, 2007 Page 7 of 38 • Stop the job if they identify a hazard not recorded on the Risk Assessment and

Permit to Work or Procedure.

• Carry out work as defined in the Risk Assessment and Permit to Work or Procedure.

5.5 HITRA Authorizing Signatories

The SPA Person (or delegated nominee) will appoint personnel competent to authorize completed Level 1 and Level 2 Risk Assessments. For Work Control Activities, this role would normally be performed by the Permit Issuer. For non Work Control Activities, this role would be performed by the Area Authority or his representative.

A person authorising a Level 1 Risk Assessment will:

• Decide whether the risks can be controlled adequately by the proposed means, taking into account the controls required by any relevant local procedure and the competence of the person in charge.

• Initiate the need to complete a Level 2 Risk Assessment if they are not completely assured that the risks will be adequately controlled and believes a more rigorous risk assessment is required.

A person authorising a Level 2 Risk Assessment will: • Accept the level of residual risk.

• Confirm that the risk assessment was carried out by a team with the appropriate level of expertise.

• Confirm that the risk assessment team has taken appropriate guidance on health, safety and environmental legislation and consequent limits on operation (e.g., environmental consents).

6.0 TRAINING AND COMPETENCY

6.1 Training

HITRA methodologies are not complex, but they do rely on wide work-related underpinning knowledge and experience. This includes experience of:

• relevant hazards • realistic consequences

• good quality and effective controls

All personnel involved in the HITRA process should undertake the following basic training:

• definitions – hazard, risk, consequences, likelihood, controls, hierarchy of controls, risk matrix

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Document No.: PRO/SFTY/018 Issue Date: August 18, 2007 Page 8 of 38 • when to conduct Level 1 and 2 Risk Assessments

• other types of Risk Assessment – generic, JSA, quantified, major hazard, environmental, etc

• Risk Assessment tools – e.g. checklists

• expectations of Team members - need to contribute personal experience, reach agreement or record divergent views

• responsibilities after TRA is completed – at task location, identifying changes, etc Before selection for training, Level 2 HITRA Team Leaders should be able to demonstrate wide knowledge of the work environment and relevant tasks. Although checklists and other generic tools are available, the Team Leader has to use these with informed judgement.

6.2 Proven Competency / Certification

All personnel involved in the use of the HITRA process or procedures shall be trained and / or assessed as competent to the appropriate level as elaborated in the following training grid.

Role 1-day Awareness Training 2-day Training + Certification

Level 1 HITRA

Completer Yes No

Level 2 HITRA Team

Leader No Yes

Level 2 HITRA Team

Member Yes No

HITRA Authorizing

Signatories No Yes

The required competency of all relevant personnel should be confirmed during the planning process for a particular task. The SPA Person (or delegated nominee) should ensure that new personnel have the required competencies properly certified from acceptable source or third parties.

Having undergone the appropriate training and having been assessed competent to carry out the relevant duties, Authorised Signatories and Level 2 Risk Assessment Team Leaders can only take on these roles when they have been duly certified and authorised.

6.3 Records

Records of attendance and competency should be filed for future reference/verification.

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Document No.: PRO/SFTY/018 Issue Date: August 18, 2007 Page 9 of 38 6.4 Reassessment and Refresher Training

For those considered experienced, re-assessment of competence should occur at a frequency of not more than 2 years. If someone is absent from an operational role in the HITRA system for more than 12 months, they should undergo both refresher training and competence reassessment.

7.0 HITRAPROCESS OVERVIEW

The BP Golden Rules – Getting the Basics Right and the Control of Work Group Standard, Element – 5 require application of the risk assessment principles. The three key steps in risk assessment are:

1. Identify the hazards.

2. Evaluate the hazards - decide who or what might be harmed and how.

3. Mitigate the hazards - assess the risks against a standard/benchmark and decide whether the hazard can be removed, substituted or controlled.

Task Risk Assessment is a tool for reducing the probability and consequence of accidents at work. Therefore, all work/tasks should be analyzed to identify the hazards present, assess the risks involved, and identify the controls necessary to undertake the work safely.

The number and varieties of tasks carried out within BP are very large and there is a correspondingly wide range of risks involved. This means that, for practical reasons, the extent of assessment of any particular case has to be balanced against the type of risk so that the greatest effort is focused in the areas of most severe risk. Consequently, the TRA has been divided into two levels i.e. Level –1 and Level –2. 7.1 Level-1

Level 1 is a broad overview of the task by a competent person(s) – typically the Performing Authority – to identify all significant hazards involved and appropriate controls which are required to let the job to proceed.

A Level-1 Task Risk Assessment involves a review of the task by the performing person in consultation with his Team Leader, Superintendent or Supervisor or Area Authority to identify the hazards associated with the task and appropriate control measures required for managing these hazards. The Team Leader, Superintendent or Supervisor must decide whether the risks can be controlled adequately by the proposed means, taking into account the controls required by any relevant procedure and the competence of the person-in-charge. Once the task is identified as low risk, it shall be forwarded for approval to proceed. If the Team Leader, Superintendent or Supervisor is not completely assured that the risks will be adequately controlled by proposed means and are medium or high risks, he shall ask for level-2 task risk assessment.

Level 1 TRA must be carried out for the following: (a) All new activities.

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Document No.: PRO/SFTY/018 Issue Date: August 18, 2007 Page 10 of 38 (b) All jobs at planning and design stage.

(c) Repeated activities, if condition is changed. (d) Annual review of TRAs for repeated activities.

A new risk assessment will not be required for every task. Where a task has previously been assessed and/or is covered by a procedure, it may not need a new risk assessment. Where this is the case, the previous assessment or procedure should be reviewed to ensure that the hazards and controls are still relevant and that any site or job specific controls are identified. If condition is changed or an incident occurs while the procedure or previously assessed TRA is in use, the whole

procedure, including the risk assessment, must be reviewed before it is re-issued. For low risk tasks performed by competent people, no formal recorded risk assessment is required as it is covered by the individual’s competency and skill. 7.2 Level- 2

Level 2 is a more structured semi-quantitative assessment which is required when competent person judges that there are greater hazards or complexities associated with the task which require more rigorous assessment. A Level 2 TRA is carried out by a team.

The following are considered high-risk activities that require level 2 TRA, written procedures, and Permit to Work (PTW) as well:

a) Confined Space Entry including vessel / tank cleaning, sandblasting or de-sludging.

b) Trench Excavation or pit more than 4 feet deep or other ground penetration such as piling.

c) Working at height, including erection of scaffolding or structures, where serious injury is likely in case of a fall (2m is normally taken as the guide height, where the fall would be onto flat ground, but lower heights will be relevant where a fall would be onto other surfaces)

d) Hot work in Hazardous Areas.

e) Failure to meet minimum isolations requirement.

f) Complex and complicated lifting operations involving multiple suspensions or lifting over live plant.

g) High potential source of ignition.

h) Any activities involving potential exposure to H2S.

i) Where multiple protective devices are removed or inhibited from a system. j) Simultaneous operations like well operation adjacent to operating plant. k) Mud plugging and hot tapping for tanks or main oil & gas lines.

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Document No.: PRO/SFTY/018 Issue Date: August 18, 2007 Page 11 of 38 m) Waste Management (Handling and disposal of NORM wastes, asbestos etc). n) Road transportation of crude oil / condensate.

o) Any other activities where risk assessment is medium and high. 8.0 HITRAPROCEDURE

The first part of the procedure is to establish what it will involve, once the task is identified. The initial appraisal should identify the need of special safety assessment and identify at the outset, if it is obvious that the task cannot be carried out safely. If the hazards are not reconciled at this stage, the task should be rejected or redefined. The Task Risk Assessment procedure is shown in the flow chart (Appendix-1) and following sections give guideline to each stage of the process.

8.1 Work Request

Work request can be in the form of written or verbal request to carry out any work. The originator of the work request can be from any department of Pakistan PU. 8.2 Check Task Category

Once the parameters of a task are defined, the task should be categorized in either Level 1 or Level 2 as defined in section 7.0. (See also Appendix-2 – Task Categorization Chart).

8.3 Perform Level-1 TRA

A Level 1 TRA involves a review of the task by the performing person in consultation with another authorised and competent person – this would typically be the Area Authority and/or Line Supervisor. The review purpose is to identify and agree the hazards associated with the task and appropriate control measures required for managing these hazards. The Authorised Signatory must decide whether the risks can be controlled adequately by the proposed means, taking into account the requirements of any relevant procedure and the competence of the performing person. The Level 1 TRA will need to be recorded. Typically, for work being controlled using a permit, the Level 1 TRA will be incorporated directly into the permit document. Otherwise, a suitable record of the task, identified hazards, controls, authorisation, etc. should be completed.

When the task is considered to have an acceptably low risk, it shall be approved to proceed using the agreed controls. However, if the Authorised Signatory is not completely assured that the risks will be adequately controlled by the proposed means, they shall ask for a more detailed, Level 2 Task Risk Assessment to be carried out.

A new risk assessment will not necessarily be required for every task, as routine tasks could be covered by a generic risk assessment or a procedure (as long as that procedure is based on a documented risk assessment). Also a non-routine task may have previously been assessed. For such tasks, the previous assessment may be reviewed to ensure that the hazards and controls are still relevant and that any

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Document No.: PRO/SFTY/018 Issue Date: August 18, 2007 Page 12 of 38 necessary location-specific and time-specific controls are included. If conditions have changed, the RA should be reviewed and revised before it is re-used.

The Team Leader, Superintendent or Supervisor must decide whether the risks can be controlled adequately by the proposed means, taking into account the controls required by any relevant local procedure and the competence of the person in charge.

If the Team Leader, Superintendent or Supervisor is not completely assured that the risks will be controlled adequately by these measures and feels a more rigorous assessment is required, then he must inform the performing person of the work and request a Level 2 Assessment.

8.4 Define Task Parameters

When a work request is received, the task parameters should be defined clearly to determine exactly what the task would involve. This is the responsibility of the site supervisor i.e. the person responsible for seeing that work is carried out. In case of tasks at design stage, Project Team Leader / Project Engineer / MOC coordinator is responsible.

Following are to be considered while defining the parameters of a task:

• The need for any special safety studies or assessments (e.g. manual handling). • If the hazards cannot be reconciled and it is obvious that carrying out of task is

unsafe, it should be immediately discarded or redefined.

• What personal competency requirements are needed of those who will assess the risks and perform the task

• What types of equipment are needed? 8.5 Perform Level-2 TRA

The objective of the Level 2 TRA is to:

• assemble a team of persons with intimate knowledge and expertise of the task (including knowledge of the task location)

• examine all the hazards associated with the task in a structured way

• devise a set of controls which will ensure an acceptable level of risk is achieved • use external experts (e.g. specialist vendors) where necessary

In case of larger tasks, turnarounds or projects, early work should be undertaken to identify potential tasks requiring Level 2 assessments in order to allow adequate time for the TRA to be planned and completed.

A Level-2 assessment must be carried out by a Team and can be done at any stage in the process. It shall be carried out, when it is believed that significant risks exist and such risk can not be adequately controlled without more rigorous assessment

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Document No.: PRO/SFTY/018 Issue Date: August 18, 2007 Page 13 of 38 and the application of additional controls. Level-2 TRA is mandatory for activities defined in section 7.2

8.6 Form TRA Team

Job performing Team Leader or his nominee shall nominate TRA team and the leader of the team – a BPP trained, certified competent and authorized person. This team shall have a minimum of three members. Team members must be familiar with the TRA process and have intimate knowledge of the work activities and environment and the tools and equipment to be used to make informed judgments of the risks involved and measures to mitigate them.

Depending on the complexity and size of the Task involved, a team might include the following people, in addition to the leader:

• A Representative or supervisor of the contractor carrying out the job • Technician(s)

• Delivery / Service Team Engineer(s) • HSE representative

• Other members of the workforce or persons external to the site who may have specialist knowledge or experience which could help with the Assessment. This requires knowledge and experience of the area, plant, equipment or system to be worked on and awareness of the hazards involved and the potential consequences, and knowledge of company’s HSE procedures. The team shall have personnel who:

• Are responsible for the task.

• Are competent to conduct TRAs and have the ability to facilitate the process. • Have sufficient knowledge, expertise and understanding of hazards.

• Will be involved in carrying out the task.

The team shall discuss and carry out preparatory work, job plan review to ensure that the team members have sufficient background information on which to base their judgment. The team member shall visit the work site to see the physical layout of the area and current site conditions. Particular attention shall be given to other plants or equipment in the area. It shall also be noticed that other adjacent activities are not planned to take place at the same time as the task to be performed as they could impact the TRA.

The team leader shall make arrangements for the team to work as a group and shall ensure that there is adequate space for examination of drawings and that sufficient time is allocated to reach a rational decision.

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Document No.: PRO/SFTY/018 Issue Date: August 18, 2007 Page 14 of 38 All Risk Assessment teams must include at least one representative from the workforce assigned to carry out the task being assessed. Where more than one team

is assigned to carry out the work, a representative from each should be included. 8.7 Break Down of Task into Activities

Once the team is prepared to proceed for actual risk assessment, they shall break down the task into individual activities, if a task consists of more than one activity. This will allow the team to identify the hazards of individual activity instead of the whole task. The task shall comprise of distinct activities neither having unnecessary large number of activities to make the TRA process complex, nor too general so the activities containing potential hazards are omitted or overlooked.

(For instance, isolation process may be either electrical/control/mechanical/ or process. Each isolation process may encounter different type of hazard, and may be conducted by different work disciplines).

8.8 Identify Hazards

The team shall list down all significant hazards in a particular activity and then review them to determine what foreseeable effects they could cause if not eliminated or controlled. This should be done by way of full group discussion under the direction of the TRA team leader to ensure that all members are given adequate opportunity to express their views. To identify the hazard, following aspects of the task should be considered as minimum:

• Characteristics of the plant and systems directly involved, e.g. pressure, noise, temperature, voltage, H2S, toxic chemicals, foam, sand, wax, sludge, scale, etc. • Sensitivity of the location, within the site / installation caused by proximity to

other HSE critical plant or systems, e.g. HVAC intakes, flare header, separator, risers, ESDVs, escape routes, fire pumps, or large process inventories such as pipelines, vessels or tanks, etc.

• Possibilities of interaction, between simultaneous activities within the task itself, or any other, unrelated task taking place nearby which require close coordination in term of cooperate emergency response procedures.

• Consider the hazard effects of, and actions to be taken in the event of an emergency. Refer to the BP Group Standard for the Control of Work (Element 5). The team shall note down all the hazards identified for each activity so the consequences can be identified.

A generic hazards checklist is provided as a guide in Appendix 3. 8.9 Identify Hazard Effects (Consequences)

Once all the hazards associated with the task are established, the consequences or hazard effects caused by each hazard (i.e. harm which could possibly occur) and people who may be affected need to be identified and considered as well as those directly involved in the task. The effects or consequences of each hazard, which may

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Document No.: PRO/SFTY/018 Issue Date: August 18, 2007 Page 15 of 38 be more than one, shall be identified and recorded in TRA form (See Appendix 5). While writing Hazard Effects, care should be taken to be as specific as possible, i.e. one should avoid expressions such as ‘personal injury’ in the Hazard Effect’s column. 8.10 Define Risk Rating

Risk rating is a means whereby the risks associated with a particular task can be expressed as a value and so judged whether to be within acceptable limits. The risk created by each hazard on list should be evaluated according to:

• The worst, reasonably credible severity of the hazard effects, should anything go wrong, based on (What if? Then), i.e., how severe the consequences could be, realistically. (Almost all hazards could result in death but most realistic outcome should be considered. For example, it is remotely possible that someone falling off a chair in an office may be killed, but the most probable result is bruising or a fractured bone). See Table 8.10.1.

• The probability of the hazard being realized and resulting in the specified hazard effect. See Table 8.10.2.

It is important to consider property damage and environmental impact and not just personal injury. The matrix method of making these evaluations helps to focus attention on the most serious risks. For the purposes of consistency this matrix should be used when assessing risk.

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Document No.: PRO/SFTY/018 Issue Date: August 18, 2007 Page 16 of 38 8.10.1 Hazard Effect Rating (HE) or Severity

HAZARD EFFECT RATING

PEOPLE FACILITIES LOST

PRODUCTION ENVIRONMENT VERY HIGH MULTIPLE FATALITIES MAJOR DAMAGE LOSS > $ 10 MILLION MAJOR DAMAGE LOSS > $ 10 MILLION TOTAL LOSS OF PRIMARY CONTAINMENT. SPILL OF MORE THAN 100 BBLS. HIGH FATAL INJURY PERMANENT DISABILITY SIGNIFICANT DAMAGE LOSS $ 01 MILLION TO $10 MILLION SIGNIFICANT DAMAGE LOSS $ 01 MILLION TO $10 MILLION SIGNIFICANT LOSS OF PRIMARY CONTAINMENT. SPILL UP TO 100 BBLS. MEDIUM LOST TIME HOSPITALIZATION TEMPORARY DISABILITY MODERATE DAMAGE LOSS $100K TO $ 01 MILLION MODERATE DAMAGE LOSS $100K TO $ 01 MILLION SIGNIFICANT LOSS OF PRIMARY CONTAINMENT. SPILL > 10 BBLS. LOW NO LOST TIME NO HOSPITALIZATION FIRST AID MINOR DAMAGE LOSS $10K TO $ 100K MINOR DAMAGE LOSS $10K TO $ 100K MINOR LOSS OF PRIMARY CONTAINMENT. SPILL < 10 BBLS. VERY

LOW SIMPLE FIRST AID LOSS <$10K LOSS <$10K

SLIGHT LOSS OF PRIMARY CONTAINMENT. SPILL < 1 BBL.

HAZARD EFFE

CT

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Document No.: PRO/SFTY/018 Issue Date: August 18, 2007 Page 17 of 38 8.10.2 Probability

Likelihood of event occurring and resulting in the specified Hazard Effect P Rating Probability of occurrence more than once per month

(Has happened more than once in BPP)

Every Time Very High (VH) Probability of occurrence more than once per quarter but

less than once per month (Has happened once in BPP)

Nearly Every Time High (H)

Probability of occurrence once in six months but less than once per quarter

(Has happened more than once in BP / industry)

Often Medium (M)

Probability of occurrence once in a year but less than once in six months

(Has happened once in BP / industry)

Sometimes Low (L)

Probability of occurrence more than once in a year (Not known in BP / Industry)

Hardly Ever Very Low (VL)

Risk (R) is derived from matrices showing Hazard Effect (HE) and Probability (P). These matrix values are presented to allow a semi-quantitative derivation of Risk to provide consistent application of policies regarding the acceptability of risks – Refer to Table 8.10.3.

8.10.3 Risk Matrix

HAZARD EFFECT SEVERITY

VL L M H VH VH 11 20 21 22 25 H 6 12 18 19 24 M 5 8 13 17 23 L 4 7 9 14 16 PROBABILI TY VL 1 2 3 10 15

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Document No.: PRO/SFTY/018 Issue Date: August 18, 2007 Page 18 of 38 8.10.4 Evaluation and Prioritization of Risk

RISK FACTOR CONTROL ACTIONS

21 - 25

Immediate Action. Task must not proceed due to serious loss potential.

Task should be re-defined or, further control measures put in place to reduce risk, these controls again must be subject to a full assessment and accepted before the task may commence.

16 - 20

Task may only proceed following direct authorisation from OM / area authority following consultation with any specialist personnel and full assessment team.

Wherever possible the task should be re-defined to take account of the hazards involved or, the risk should be reduced further prior to the task commencing.

11 - 15

The task may proceed, however only under strict supervision and monitoring. The team must revisit all areas of the assessment to see if risks may be reduced further before the task is allowed to proceed.

6 - 10 Implement Controls to reduce risk to lowest level reasonably practicable.

3 - 5 Acceptable measures, however review to see if risk can be reduced still

further.

1 – 2

Acceptable level of risk no need to consider further measures. Review to ensure that level of risk does not increase.

Once the risk rating has been determined, the next stage is to identify the controls that are required to reduce /control the risk.

8.11 Identify Controls

8.11.1 Specification of Control Measures

In identifying controls consideration must be given to the following: • The task.

• The people involved.

• The tools, equipment, PPE and materials to be used. • The working environment.

The team must work systematically through the list of hazards to specify all the methods needed to control each of their associated risks. Existing controls must be recorded, as well as any additional ones that the team considers necessary to achieve an acceptable level of overall control. The risk rating scale should be used as a guide for this purpose. A Hierarchy of Control (Table 8.11.2) may be used together with the Typical Control Examples as a guide in order that a full range of controls is considered and that emphasis is placed upon controls at source. Wherever possible, measures higher in the hierarchy should be used, providing that they are reasonably

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Document No.: PRO/SFTY/018 Issue Date: August 18, 2007 Page 19 of 38 practicable. When the control actions have been identified the Evaluation and Prioritization Matrix (Table 8.10.4) should again be used to establish the level of residual risk once these controls are in place.

A combination of measures will usually be necessary in order to reduce the level of risk to that which is considered as low as reasonably practical.

8.11.2 Hierarchy of Control

BASIS OF CONTROL EXAMPLES

Prohibit No smoking

No stacking over specified height No unauthorized personnel

Substitute Solvent based paint with water based paint Electric hand tools with pneumatic tools

Segregate Barrier

Guard

Separate storage areas

Physical isolations (Spade, Lock-off)

Change Process Automated Semi-automatic

Enclosure Top of containers

Noise enclosures of turbines/pumps

Reduced Exposure Times Job rotation Breaks

Dilution Dispense dilute chemical

Increase airflow / ventilation through work area

Extraction Welding

Grinding

Knowledge Training

Competency

Personal Protective Equipment Gloves Goggles Boots Respirators

Note: It is important not to write any of the basis of control (e.g. ‘Prohibit’) under ‘Control’ in the TRA form. Full details should be inscribed, e.g. ‘No unauthorized personnel’.

An illustrative graphic reproduced from the UK Offshore Industry – Step Change in Safety guidance for Task Risk Assessment is shown below. It must be emphasized that when identifying control measures, one must always start from the first or lowest step.

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Document No.: PRO/SFTY/018 Issue Date: August 18, 2007 Page 21 of 38 Typical control measures can be classified as follows:

Controls Typical Examples

Human Ensure competency of personnel

Use of independent specialist personnel Regular or constant monitoring of the task Clear instructions and warnings to workforce

Clear definition of roles and responsibilities during the task Adequate supervision

Conduct Tool Box Talk (TBT)

Physical Removal of pipe work

Insert spade or blank flange Lock off valve

Place mechanical barrier Use locked enclosure

Keep people at a distance (warning tape) Eliminate or substitute toxic substances Substitute noisy machinery

Use mechanical handling equipment, etc.

Procedural Test for pressure build-up or leaks

Test for flammable gas

Procedure for control of simultaneous or adjacent work Prohibition of hot work

Equipment locked-out/tagged-out. Scafftag procedure.

Time

(no change in

consequence, risk reduced by limiting exposure)

Limit duration of the task

Use time-saving measures such as hot bolting, good work-site preparation and planning for movement of materials, tools, etc. Rotational work and applying interim break time.

Contingency / Control / Mitigation:

(no change in likelihood, but consequences are reduced when the hazard is realized)

Emergency shutdown, deluge and blow down systems, reduction of inventory, etc.

Temporary refuge, emergency response system, water curtain, provision of PPE, rescue equipment, etc.

The team should specify controls in all these categories, to the extent that they are appropriate. Particular emphasis, though, must be placed on physical or procedural controls that prevent or reduce risk by reducing the probability of occurrence or the severity of consequences as well as on task-specific contingency/emergency arrangements to control or mitigate the consequences if anything does go wrong. 8.12 Controls Adequate

Once all the controls are identified to reduce the risk, the following questions should be asked:

• Have all the necessary controls measures been fully / effectively identified? • Are any additional competencies required to complete the task?

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Document No.: PRO/SFTY/018 Issue Date: August 18, 2007 Page 22 of 38 When all the controls of task are identified, the risk evaluation matrix should be revisited to establish the level of residual risk once these controls are in place.

8.13 Acceptable Residual Risk

An assessment of the residual risk should be made for each of the hazards assuming that all control measures are in place. If the residual risk is unacceptable, the hierarchy of controls should be used again, with emphasis on lateral thinking to identify possible further controls at the lower end of the hierarchy. If any control measures are identified and judged to be practicable to implement (and thereby reduce the residual risk to an acceptable level) this additional data should be recorded. If further control measures cannot reduce the risk to an acceptable level, the TRA Team must not authorise the task and shall refer back to the work requester.

As a final check, the team should ask itself the following questions about the proposed Task:

• Have all relevant legislative requirements been met? • Have all the necessary control measures been identified? • Is the degree of supervision adequate? Is a dedicated charge

hand/supervisor/BPP authorized person required?

• Is there a need for engineering change to eliminate or reduce the Risk? • Is there a need for shutdown of process plant?

• Is the Residual Risk rating acceptable?

• Does a plan exist to implement any outstanding Control Measures before the Task is begun?

8.14 Agreement on Risks and Controls

It is essential that agreement on risks and controls is unanimous of the whole team and the residual risk is acceptable and ALARP. The HITRA Team should document their assessment, including all the identified control measures which should be in place for the defined task. A consideration for the acceptability of risk is that the greater the perceived number risk for any particular hazard, the greater the number and quality of independent controls.

8.15 Document and Record

The team shall record their finding on standard attached TRA format (Appendix 5), which covers the following:

• Date of TRA • Reviewed by and date

• Task Title • Controls (identified by Team)

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Document No.: PRO/SFTY/018 Issue Date: August 18, 2007 Page 23 of 38

• Distinct activities

• Hazard identified

• Hazard Effects

• Risk Evaluation (HE, P,R)

• Residual Risk (HE rating, P, R) • ALARP (Y/N)

• Emergency Provision required

• Name, P. No. and signature of Team members / leader

8.16 Review of TRA

A Review of TRA should be done:

a) If and when Conditions of working environment change.

b) When a previously completed TRA is being used in a different job or activity. c) Before starting or proceeding with the activity, by BPP authorized personnel

along with those involved in the activity i.e. through a Toolbox or Safety meeting.

Risk assessments must be carefully carried out/reviewed when a change is to be implemented. Incidents have often occurred where all impacts of ‘small’ or ‘creeping’ changes were not fully assessed and understood.

8.17 Communication

The success of TRA will depend on how effectively it has been communicated. The value of the risk assessment will be wasted if the people executing the job are not fully aware of, or do not thoroughly understand, the hazards and the precautions put in place. The TRA team shall distribute the copies to all concerned to give understanding of:

• Details of the activities involved in carrying out the job. • Potential hazards identified for each stage of the task.

• Control measures in place or to be put in place to mitigate the hazards. • Individual actions and responsibilities at various stages of the task.

An opportunity shall be provided to all involved in the task to identify further hazards and control measures, which might have been overlooked in the initial assessment. If such improvements are identified, this should be fed back to the TRA Team Leader. 8.18 Implement Controls

There are two types of control measures that will be identified from either Level 1 or Level 2 TRA process:

• Prerequisite controls: Controls that must be in place prior to the job execution. These may, or may not, include a Permit to Work and associated documentation • Supplementary controls: Controls that have to be applied during the job.

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Document No.: PRO/SFTY/018 Issue Date: August 18, 2007 Page 24 of 38 Before the task is authorised to start the person controlling the work activity must satisfy himself that:

• all the prerequisite controls are in place

• the persons allocated to perform the task, are competent to initiate and manage the required supplementary controls

• the output from the risk assessment has been”…communicated in writing and signed off by all involved in the task….” (this is a requirement of the Control of Work Group Standard)

8.19 Carry out the Task

Once all involved in the task are satisfied that all the prerequisite controls are in place and supplementary controls will be put in place during the job, using company control documents e.g. PTW/Certificates, thereafter they can carry out the task. Even when the task has been duly authorised, each person involved should be satisfied that all the defined controls are in place and are effective. If they have any doubts or concerns, the culture should be such that they feel able to voice these, by not starting or stopping the task if necessary.

8.20 Monitor for Condition Change

By monitoring on an ongoing basis, the team should always be aware of any changes in personnel, conditions at the work site, or if the TRA is found to be incomplete or incorrect. If it becomes necessary, they should re-assess the task and if in any doubt, STOP THE JOB.

8.21 Record Lessons Learned

On completion of work it is important that any lessons learned are captured and incorporated into the process. This may be in the form of changes / revisions to: • links between a procedure used and the underpinning TRA

• TRA records

• the TRA process, including team composition

In the event of an accident, incident, or near miss taking place, it is critical that the TRA is reviewed. Three types of error may have contributed to the accident, each of which requires different remedial actions:

• hazard not identified during TRA

• hazard identified, but specified controls were ineffective

• hazard and controls identified, but controls not implemented as defined in TRA Lessons learned are communicated to all concerned through existing methods such as meetings, circulars, training, toolbox talks, etc.

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APPENDIX 1-TASK RISK ASSESSMENT FLOWCHART

LEVEL-2 (MANDATORY)

*

* IN CASE OF LEVEL 2 TRA.

WORK REQUEST CHECK TASK CATEGORY MANDATORY? PERFORM LEVEL-1 TRA DEFINE TASK PARAMETER LEVEL-2 TRA

FORM TRA TEAM

BREAK DOWNACTIVITIES

IDENTIFY HAZARDS for each activity

FIND ASSOCIATED HAZARDS for each

activity

IDENTIFY CONSEQUENCES for each activity

DEFINE RISK RATINGS

IDENTIFY CONTROLS

RESIDUAL RISK ACCEPTABLE?

CONTROLS ADEQUATE?

AGREEMENT ON RISKS & CONTROLS

DOCUMENT & RECORD APPROVAL TO PROCEED

TRA COPIES TO ALL INVOLVED IMPLEMENT CONTROLS CARRY OUT TASK MONITOR FOR CONDITION CHANGE STOP RE-ASSESS IF REQUIRED RECORD LESSONS LEARNED YES YES NO NO NO IF CONDITIONS CHANGE YES HIGH OR MEDIUM RISK LOW RISK LEVEL-1

a) All new activities

b) All jobs at planning and design stage c) Repeated activities, if condition is changed d) Annual review for repeated activities

LEVEL-2 (MANDATORY)

a) Confined Space Entry (including vessel cleaning)

b) Excavations greater than 4 feet deep c) Working at heights > 6 feet (including erection of structures for this work) d) Hot Work in Hazardous Areas e) Failure to meet minimum isolation requirements

f) Complex lifting operations involving multiple suspensions or lifting near live plant g) Any activity with potential H2S exposure h) Where multiple protective devices are removed or inhibited from a system i) Simultaneous operations j) Mud plugging and Hot tapping

k) Deviation from an existing policy, procedure, or practice

l) Mandatory for activities where risk assessment is medium or high

8.1 8.2 8.3 8.4 8.5 8.6 8.7 8.8 8.9 8.8 8.10 8.11 8.12 8.13 8.14 8.15 8.16 8.17 8.18 8.19 8.20 8.21 m) Well intervention

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APPENDIX 2-TASK CATEGORIZATION CHART

YES

¾ Confined Space Entry including vessel/tanks, cleaning,

sandblasting or de-sludging

¾ Hot work in Hazardous areas

¾ Working at Heights more than 6 feet

→ → →

¾ Narrow excavation or pit →

¾ Trench Excavation or pit more than 4 feet deep. →

¾ Erecting of scaffold or structure at height in excess of 6 feet →

¾ Using high potential sources of ignition inside tank bund wall area,

for gas blowout / flare lines, or for oil & gas well casing repair.

→

¾ Failure to meet minimum positive isolations requirement. →

¾ Complex and complicated lifting operations involving multiple

suspensions or lifting over live plant, near overhead pipelines or power-lines.

→

¾ Multiple protective/safety devices are removed or inhibited from a

system

→

¾ Any activities involving uncontrolled potential exposure to H2S →

¾ Simultaneous operations like well operation adjacent to operating

plant

→

¾ Mud plugging and hot tapping for tanks or main oil & gas lines. →

¾ Deviation from an existing procedure or practice →

¾ Any other activities where risk assessment is medium and high →

LEVEL 2 - TRA & PTW SYSTEM IS MANDATORY

¾ All new activities →

¾ All jobs at planning and design stage →

¾ Repeated activities, if condition is changed →

¾ Annual review of TRAs for repeated activities →

LEVEL 1 - TRA & PTW SYSTEM MAY OR MAY NOT BE REQUIRED

Go down the list until you can answer YES, then follow the arrow to determine the TRA Level required

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APPENDIX 3-HAZARD CHECKLIST

A- Hazards associated with plant and equipment

Category Examples of Hazards Hazard Effects

Two moving parts, one moving part and a fixed surface

Conveyor belt and drive V belt and pulley

Power press "In running nips" Mangle Guillotine Scissors Stapler Using hammer Trapping (crushing, pressing, drawing in and shearing injuries)

Something that may strike or stab someone or can be struck against

Moving vehicle Drill Sewing machine Hypodermic needle Pendulum Crane hook Impact (includes puncture)

Something sharp or with a rough surface Knife, chisel, saw, etc.

Fan blade

Circular saw blade Sanding belt Abrasive wheel Hover mower blade

Contact (Cutting, friction or abrasion)

Drill chuck and bit Power take off shaft Pipe threading machine Abrasive wheel

Entanglement (rotating parts) Mechanical

Cartridge tool

Using hammer and chisel Abrasive wheel

Ejection (of work piece or part of tool) Electrical Electricity above 240v

Electricity 240v Electricity 110v

Extra low volt electricity Static

Batteries

Shock/burn/fire/ Explosion

Ignition sources

Pressure Compressed air

Compressed gas Steam Vacuum Hydraulic system Release of energy (Explosion/injection/ implosion)

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Stored energy Springs under tension Springs under compression Hoist platform cage

Conveyor tension weight Raised tipper lorry body Counterweight

Load carried by crane

Flying/Falling materials

Thermal Hot surface

Using blow lamp Welding flame/arc Refrigerant Steam Burns/fires/scalds/ frostbite Radiation Ionizing radiation X Rays α or β radiation Neutrons Burns, cancer Non ionizing radiation Micro wave Radio frequency Laser Ultra violet Infra red Burns

Noise Noise > 85 dB(A) Hearing loss, tinnitus,

etc.

Vibration Pneumatic drill

Operation of plant Using Jackhammer

Vibration white finger, whole body effects

Stability Inadequate crane base

Fork lift truck on slope Machine not bolted down Mobile scaffold too high Scaffold not tied

Crushing Overload/ Defective due to mechanical failure Crane overload Chain sling Eye bolt overload Scaffold overload Hopper overload

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Document No.: PRO/SFTY/018 Issue Date: August 18, 2007 Page 29 of 38 B - Hazards associated with materials and substances

FIRE/EXPLOSION Combustion Timber stack Paper sore Grease Plastic foam Burns

Increased Combustion Oxygen enrichment Burns

Flammable substances (inc. Highly and Extremely Flammable)

See also explosive below Petrol Propane gas Crude oil Methane LPG LNG Hydrogen Carbon Monoxide Burns

Oxidizing substance Organic peroxide

Potassium permanganate Nitric acid

Explosive material Detonators

Some oxidizing agents

Highly flammable gas in confined space

Burns

Dust explosions Wood dust

Sulfur dust Coal dust Flour Aluminum powder Burns HEALTH HAZARDS Corrosive/Irritating materials Sulfuric acid Caustic soda Ammonia Skin effects

Particles Asbestos fibers

Silica dust Wood dust Iron dust Lung effects Vapors Benzene Toluene Acetone Some solvents

Acute and chronic effects on health

Fumes Lead fume

Rubber fume Asphalt fume

Acute and chronic effects on health (local and systemic effects)

Gases Carbon Monoxide

Hydrogen Sulfide Sulfur dioxide

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Mists Oil mist

Printing ink mist Detergents Aerosols

Asphyxiants Nitrogen Carbon dioxide Argon

Acute and chronic effects on health Toxic, harmful, corrosive and irritant

liquids

Burns to upper alimentary tract Health hazard by

ingestion

All harmful aerosols Polluted water

Contaminated food and drink

Poisoning Sward Rough timber Concrete blocks Cuts, abrasions Hazards by contact Molten metal Frozen food Burns, Frostbite ENVIRONMENTAL HAZARDS Hazardous waste storage and disposal

Crude/Condensate transportation Storage of hazardous

sludge/material in pits

NORM waste (scales, sludge)

Groundwater / Soil pollution

C- Hazards associated with the place of work

Pedestrian Access Damaged floors Trailing cables Oil spills Water on floors Debris Wet grass Sloping surface Uneven steps

Changes in floor levels

Tripping, slipping

Work at heights Fragile roof Edge of roof Work on ladder Erecting scaffold Hole in floor

Falls

Obstructions Low headroom

Sharp projections

Striking against

Stacking/Storing High stacks

Insecure stacks Inadequate racking Stacking at heights

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Document No.: PRO/SFTY/018 Issue Date: August 18, 2007 Page 31 of 38 Work over/near

liquids, dusts, etc.

Tank Reservoir Sump Sewer

Work over water

Fall into a substances, drowning, poisoning, suffocation, etc.

Emergencies Locked exits

Obstructed egress Long exit route

Trapping in fire

D. Hazards associated with methods of work

Category Example of Hazard Hazard Effects

Manual handling Lifting Lowering Carrying Pushing Pulling

Hot / Cold loads Rough loads

Live loads – persons

Back injury, hernia, etc.

Repetitive movements

Keyboard work Using screwdriver

Using hammer and chisel Bricklaying

Work related upper limb disorders

Posture Seated work

Work above head height Work at floor level

Work related upper limb disorders, stress, etc.

E. Hazards associated with the working environment

Light (NB: Also increases risk of contact other hazards) Glare Poor lighting Stroboscopic effect Arc welding Molten metal

Eye strain, arc eye and cataracts Work in furnace Cold room Heat stress, hypothermia Temperature Outdoor work Hot weather Cold weather Wind chill factor

Work in rain, snow, etc.

Heat stress, sunburn, melanoma,

hypothermia, etc.

Confined spaces Work in tank Chimney, stack Pit Basement Unventilated room Vessel Excavation Asphyxiation, explosion, poisoning, claustrophobia, etc.

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Document No.: PRO/SFTY/018 Issue Date: August 18, 2007 Page 32 of 38 Ventilation Fumes Odors Tobacco smoke “Sick Building Syndrome”, nausea, tiredness, etc. F. Hazards associated with work organization

Work above employees Use of harmful substances Contractors’ welding

Injuries and ill health to employees by contractors work Contractors

Process fumes

Services (e.g. underground electricity cables)

Stored hazardous materials

Injuries and ill health to contractors’

employees by work in premises

Organization of work Monotonous work Stress

Too much work Lack of control of job Work too demanding

Injuries to employees

Work in public area Trailing cables

Traffic/ Plant / Rig movement Work above public

Drilling near dwelling area

Injuries and ill health of public

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APPENDIX 4-RISK ASSESSMENT SAMPLES

Confined Spaces Description of Task

This general assessment and arrangements covers the general principles for work within confined spaces in the work of cleaning or de-sludging of crude oil/slop oil vessels/tanks by an organization’s employees or contractor’s.

A confined space is defined as any place, including any chamber, tank, silo, pit, sewer, flue, well, or other similar space in which, by virtue of its enclosed nature, there arises a reasonably foreseeable specified risk. As a consequence it is likely that the confined space will have restricted natural ventilation, will have limited means of access and egress and would not be intended for the continual occupancy by persons at work.

Persons at Risk

Personnel carrying out cleaning work in confined spaces are especially at risk. In the event of fires or explosions occurring as a result of work in confined space, all persons inside the tank and others outside may be at risk.

Hazards

Hazards associated with confined spaces fall into two categories.

1. Hazards associated with conditions which exist in the confined space before work take place, for example lack of oxygen, presence of pyrophoric iron sulfide scales on the inside shell, presence of sludge, and hydrogen sulfide gas.

2. Hazards which can be introduced into the confined space by the work to be carried out, and by the equipment/tools and materials to be used, for example using sparking tools, electrical or pneumatic tools, artificial lighting, using cleaning detergents, etc. The significant hazards associated with confined spaces are:

• Atmospheric hazards • Oxygen depletion

• Toxic gases (H2S for example)

• Simple suffocating hydrocarbon vapors

• Flammable liquids/sludge/vapors/mists/gases • Pyrophoric iron sulfide

• Electrical equipment • Hand tools

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Document No.: PRO/SFTY/018 Issue Date: August 18, 2007 Page 34 of 38 • Obstructions/barriers

• Limited access/egress

• Connected pipe-works/valves/pumps/stirrers/heaters • Water and other liquids

• Heat

• Scaffold/ladder/staging • Noise/humidity

• Environment pollution • Poor lighting

• Difficulty of rescue and emergency control • Biological hazards

• Panic/claustrophobia/stress

Entry into confined space is a high-risk activity. A specified task risk assessment, job plan and written procedures will be required. PTWS and relevant Certificates (e.g. Isolation and Entry Certificates) is mandatory requirement in each work.

The following arrangements are an indication of the measures to be considered to eliminate or reduce the risk of the hazards to an acceptable level and ALARP. The Team Leader must ensure that the equipment, facilities, and working practices are maintained to these standards by arranging inspections either personally or by a competent Superintendent or Supervisor.

Arrangements

Planning and Organization

Before any operation commences, the Team Leader must establish if work in confined space is to be carried out and if so, must arrange for information from operation manuals, P&ID’s, site visit, risk assessments, sampling, equipment, working procedures, training, etc. to be provided, taking into account the hazards likely to be encountered.

Training and Instruction

Training will be provided through HSE department for all personnel required to carry out testing and monitoring of atmospheres and for operatives required to use breathing apparatus, rescue and permit procedures and any other equipment or procedures necessary. Toolbox Talk (TBT) will be given to personnel before commencing the work.

Management Control Competent Persons

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Document No.: PRO/SFTY/018 Issue Date: August 18, 2007 Page 35 of 38 The Superintendent / Supervisor will ensure that:

• Necessary equipment is available on site in accordance with planned procedures before any person is required to enter the confined space.

• The planned procedures, including any permit to work systems, are carried out as planned and that only authorized persons are permitted to enter the confined space • A person is stationed outside the confined space at all times that work is taking place

inside.

Care of Equipment and Arrangement of PPE

The Superintendent / Supervisor will ensure that suitable storage facilities are provided for monitoring equipment and PPE.

• All equipment used for confined space work will be inspected by the user on each occasion, a thorough examination must be carried out every month by the supervisor and a record made of the examination. A more frequent examination may be required depending on the circumstances of the specific method statement.

• All safety equipment must be regularly maintained and record in accordance with defined procedures. Any defects in equipment must be attended to immediately. Procedures for Serious and Imminent Danger

Rescue procedures for workers in a confined space must be defined in method statement, and rescue must be carried out by well-trained rescue team.

Monitoring and Review Inspections

An inspection of the work and precautions must be made by the Superintendent / Supervisor at least once every day that work continues in confined space.

The Team Leader will carry out random inspections of confined space work. Risk Assessment Review

This risk assessment and arrangements will be reviewed at intervals of one year at which any specific risk assessments and method statement will also be reviewed. A review will also take place after any reported complaint, incident or accident, or when there is a change in the activity.

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APPENDIX – 5

T

ASK

R

ISK

A

SSESSMENT

F

ORM DATE:

TASK TITLE

:

ACTIVITY: LOCATION:

DESCRIPTION

S/No: HAZARD HAZARD EFFECT RISK EVALUATION

(Refer to Evaluation Form) CONTROLS ACTIONS TO BE TAKEN RESIDUAL RISK

ALARP

HE P R DESCRIBE

ACTION MANPOWER HE P R

Y/N

EMERGENCY PROVISION REQUIRED: GENERAL COMMENTS:

RISK ASSESSMENT APPROVAL

I am satisfied that the safeguards put in place will reduce the level of risk to an acceptable level and the task/action is permitted to proceed.

Risk Assessment Team

Leader………...…Date………Time………

NAMES OF TEAM MEMBERS SIGNATURE

Authorizing

Signatory………Date………Time…………..

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