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Thursday, December 31, 2020

Flare Maintenance Job Safety Analysis

Activities, Potential Hazards and Control Measures

1. Set up the crane for assembly of the crane used for flare tip removal. 

Potential Hazard

  • Drop of Crane’s heavy & Long legs on the person during crane setting up.
  • damaging of nearby machinery or components while crane set up due to drop of Crane’s heavy & Long legs.
  • Accidently loss of hydraulic pressure mechanism would cause uncontrolled dropping of the parts being lifted crushing co-worker or damaging other components of adjacent property or machinery.
  • The default type of pin or one missing a retainer could become the root cause of the crane to collapse under lifting stress.
  • Un-Standardized and bad welding work or insufficient alterations could cause the crane to collapse under lifting stress.
  • Crane wheels may sink in the soft ground causing the crane to tip over while lifting component.

Control/Mitigation Measures

  • Set up a crane in an open area away from other machines, components or other workers
  • Move crane slowly and carefully avoiding speed, quick cornering and rough floors which could cause latch pins to come off legs causing legs to fall free of the crane.
  • Tighten, repair or replace leaking component.
  • Replace pins with only Original Equipment Manufacturer (OEM) pins and retainers, never use ordinary bolts.
  • Crane may have to be re-examined and approved by Manufacturers Representative (MR) before use.
  • Portable Engine Cranes (PEC) are best to be used on smooth concrete floors.
  • Never use a crane on a slope ground level.

2. Removal of Nut & Bolts 

Potential Hazard

  • Unknown conditions of the bolts & gaskets.
  • Failure of bolts during removal operation on the adjacent bolt
  • Improper tools.
  • Falling material or tools.
  • Gas/fluid/vapour leak
  • Control/Mitigation Measures
  • Check the bolt nut condition before operation.
  • Experienced person allowed for the task.
  • Proper tools should be used.
  • PREPARATION/REINSTATEMENT CERTIFICATE 
  • secure and toe the materials from falling.
  • Keep the portable gas monitors & toxic clip.
  • The area should be barricaded and warning signs should be displayed before starting the work.

3. Manual Spading 

Potential Hazard

  • Isolation valve passing
  • Spark generation/fire
  • Exposure to toxic vapour
  • Splash of hazardous fluid
  • Leak/spill
  • Improper tools
  • Fall, stripping or caught in-between (in case of spading in height)
  • Miss communication
  • Falling men /material
  • Muscles collapse

Control/Mitigation Measures

  • Confirm Isolation Valve Integrity (IVI) by opening lightly the nearest vent/drain point.
  • Isolation must be done as per QP isolation procedure.
  • Isolations done by authorized person only Confirm the equipment before isolation
  • Ensure that all lines are drained and de-pressured before disconnections/opening is performed.
  • Always use personal gas monitors while performing spading activity.
  • Use non-spark tools & brass hammer in a hazardous location
  • Check the work area is free from the toxic vapour.
  • Marginally open one bolt/stud to confirm no pressure. Use airline unit if needed. Splash of Hazardous Fluid/substance.
  • Use safety goggles.
  • Loosen the bolts/studs slowly to ensure Leak / Spill
  • Use the correct type of tools to open & hold the flange.
  • Install the spade properly.
  • Ensure the flanges are tightened securely.
  • Ensure the erection of certified scaffolding done by certified inspectors.
  • Use approved safety harness/lanyard.
  • Supervision to be at the work front at all times by performing party to ensure that the workforce has a good understanding of the task and communication should be good and working to the approved JHA and Permit Requirements.
  • Secure all loose materials or remove any loose materials from the top of the scaffolding platform.
  • Use manual lifting procedure to avoid muscle collapse.

4. Erection & modification of scaffolding for flare tip 

Potential Hazard

  • Critical damage to onsite detectors /switches/transmitters etc. mechanism.
  • Fall of objects / Tools.
  • Accidental Fall of Person.
  • Unstable Scaffold.
  • Weak Scaffold.
  • Damaged Scaffold
  • Modified Scaffold
  • Improperly Supported Scaffold.
  • Incomplete Scaffold

Control/Mitigation Measures

  • Take great care during erection and override it if required. 
  • Provision of guardrail & toe board installations to stop falling of tools /objects.
  • Don’t keep the unwanted materials/objects/substances on the scaffold platform.
  • Hand tools must be tied and secured with a permanent structure or person.
  • The Scaffolders must use Safety Harness to prevent accidental fall.
  • The scaffold must be observed, inspected, certified & tagged by the authorized and competent person confirming its suitability and stability.
  • The purpose of the scaffold tag is to indicate the maximum load capacity that it can bear.
  • Inspection of the scaffolding shall be done by a qualified scaffolding inspector.
  • The scaffolding inspection is to be conducted at least weekly for any destruction/damage due to extreme weather condition for example heavy rain, high wind etc. or other unsafe conditions.
  • No one else is allowed to make any alteration in the scaffolding without the approval of scaffolding inspector/or any other responsible person.
  • In case of any additional alterations in the scaffold, it has to be re-inspected, observed & certified.
  • Make sure that the Scaffold is securely supported on a rigid ground and not on any unsafe ground conditions such as process piping/vessel or equipment.
  • Do not use the scaffold if green Tag is missing or outdated.
  • Do not use if the scaffold structure if the red tag is available.

5. Removal & Re-fixing of Flare tip using man basket

Potential Hazard

  • Work at height on man baskets
  • Uncertified man basket
  • Collisions/failure of equipment
  • High Wind
  • Fall of Objects/ Swinging
  • Overloading
  • Load failure
  • Manual handling
  • The collapse of the Crane & Load
  • Injury to Workers
  • Damage to the Load

Control/Mitigation Measures

  • use the approved and certified full body harness if the man working at height
  • Use tag lines to control the unwanted movement of the man basket.
  • use approved and certified Man basket.
  • A safe distance from overhead facilities (Power Cables/Pipe) and fixtures on both sides
  • Lifting plan to be completed and work according to the lifting plan
  • Confirm the signals between crane Operator & Banks man. Only trained Banks man to give the signal.
  • Do not carry out lifting activity during high wind conditions (25 knots above)
  • Good communication between rigger and crane operator. (Visual Contact/Radio communication). 
  • Follow QP lifting procedures.
  • Secured and fixed to the hook. 
  • The clip on the hook for safety purpose must be correctly and accurately closed.
  • Ensure Lift within SWL
  • Use tag lines to control the lifting load
  • Perform the activity according to the critical lifting plan
  • Supports to which lifting gears are attached shall be strong enough to withstand the lifting load.
  • Do not leave the load suspended
  • Ensure the load safety before lifting and never overload more than the capacity of the crane, pallet, container, slings /chain/ropes or tackles etc.
  • Outriggers of the crane shall be on firm and level surface, supported on spread weight and ground conditions to be suitable for lifting load
  • Use good manual lifting technique
  • Confirm & communicate manual lifting if to or more people are involved in   manual lifting
  • The competent crane operator and riggers approved in QP.
  • Use only certified lifting tackles for lifting approved in QP 
  • Inspect all lifting tackles before the start.
  • Confirm the stability of the crane at the worksite.
  • Conduct a safety check of the crane before start lifting.
  • Conduct the load test in case the crane is assembled at the workplace.
  • Inspect third party certificates of all personnel before the job.
  • Banks man to guide all crane movement in the plant area.
  • Never stand/walk on/under lifting load
  • Barricade the lifting area/ swing radius and place safety caution, boards
  • Verify the workforce is properly well trained for heavy lifting operations and non-essential person leave the area before lifting operations starts.
  • Double-check the suitability of lifting tackles & crane for the loads to be handled.
  • Check the Lifting Tools; Tackles & Crane have fitness validity, certificate and colour coding as per QP.
  • Ensure the area is free from obstacles for crane operations and the ground is properly compacted.
  • Always make sure that the load is secured properly for safe lifting.
  • Double-check and inspect the various components such as the slings, chain, ropes, eye bolt, pallet, container are not damaged and in a safe condition for lifting the load.
  • Lift the load slowly & check the slings/ropes/chains are not twisted keeping the load in a central position.
  • Utilize the rope for guiding the load if needed.
  • Utilize the rubber pads to check the abrasion from slings.

6. Sweep Blasting for inspection 

Potential Hazard

  • Severe exposure of Dust, Noise & Injury to Workforce.
  • Lack of Communication
  • Fire & Explosion
  • Continuous flow
  • Damage hose
  • Improper connection
  • Control/Mitigation Measures
  • Ensure workers involved in sweep blasting are wearing required PPE.
  • Short-term entry into the exclusion zone is acceptable if necessary respiratory protection and hearing protection is worn
  • Act as a safety observer for the blasting operator and to assist in an emergency.
  • Good communication between workers
  • Enclose the grit blasting the area with tarpaulin and post warning notice.
  • Keep a fire extinguisher 
  • Make sure that the blast gun is fitted with Emergency Release Handle and it is fully functional.
  • Ensure a continuous supply of breathing air to the blast hood.
  • Never leave the grit blast equipment un-attended with air supply on.
  • The blasting operator shall have direct control of the flow of abrasive material/substances through the nozzle. A positive, fast-acting emergency cut-off device (dead man control) shall be adjusted at the nozzle end of the abrasive blasting hose to automatically cut off the flow of abrasive material/substances from the blast pot if the person operating the nozzle becomes unable to control the flow of abrasive material/substances through the nozzle.
  • The startup, maintain and shut down the supply of compressed air or blasting media to the blasting operator as required.
  • Where respiratory protection is needed, a dedicated supply of breathing air shall be provided for the operator/workforce.
  • Flow control using a manually operated ball valve is not acceptable as an emergency cut-off device

7. Inspection of the flare tip

Potential Hazard

  • Fall, slip, trip
  • Improper barricade
  • Exposure to chemicals/gases
  • Poor visibility
  • Dust

Control/Mitigation Measures

  • Ensure that area is free from materials to avoid slip, trip or fall
  • Barricade the area properly and post warning signage.
  • Check the work area is free from the toxic vapour
  • use 24volt lighting for poor visibility
  • Proper cartridge mask should be used 

8. In the event of emergency alarm

Potential Hazard

  • Panic 
  • Unfamiliar with an emergency alarm
  • Slips trips and falls.
  • Lack of knowledge of the emergency procedure.
  • Control/Mitigation Measures
  • In the event of plant alarm or gas detector alarming following actions are to be taken
  • Immediate STOP/suspend all activities.
  • Do not run-in case of emergency to avoid to trip, slip, fall
  • Familiarized of emergency evacuation procedures.
  • Drivers stop vehicles and switch off the engine and other equipment also should be switched off
  • All personnel should proceed to the nearest muster point
  • Wait at the muster point for further instruction

9. Housekeeping

Potential Hazard

  • Slips trips and falls 
  • Scattered materials

Control/Mitigation Measures

  • Regular housekeeping at the site shall be performed. 
  • Ensure proper wind-up & housekeeping at the worksite.
  • Adequate and correct stacking of materials.
  • Regular inspection and immediate corrective action. Keep always clear of obstruction.
  • Regular clearing of worksite shall be implemented.
  • Access & Walking ways or Working Places Always Clear.

10. Manual handling

Potential Hazard

  • Hand injury
  • Back injury

Control/Mitigation Measures

  • Use proper PPE
  • Follow the ergonomics and ensure good supervision by the responsible person.
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