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.

Download File

Flare Maintenance Job Safety Analysis