Hazard analysis.doc

4.5.0 HAZARD ANALYSIS

H - # ACTIVITY HAZARD / THREAT EVENT / CONSEQUENCE CONTROL MEASURES

H1 – HYDROCARBONS

1 Working near a live facility Excavation with mechanical diggers Bull doing / Griding Crossing pipe lines by heavy equipments.

Hydrocarbon under pressure (crude oil, gas, LPG condensate) due to:

- Rupture of pipeline and loss of containment due to defective assembly, process failure, excessive process stress, inadequate protection.

Injury / fatality due to:

- Fire & Explosion- Poisoning / Fatalities- Environmental damage- Asphyxiation

- Permit to work with excavation certificate

- Hand digging- Use of metal detectors and digging

trial pits where drawings are not available.

- Gas test before any hot work in the vicinity.

- Keep vehicle exhausts away from excavation.

- No ignition sources at site.

H2 – TOXIC SUBSTANCES

1 Working near live facility Excavation with mechanical diggers Bull Dozing / grading Crossing pipe lines by heavy equipments.

- Toxic substances (Hydrogen sulfide, sulpherdioxide, carbon monoxide, exhaust gases / smoke).

- Poisoning / fatalities- Asphyxiation- Oxygen deficiency- Environmental damage.

- H2S entry permit- H2S monitors- Gas testing at the required

frequency- Training & instructions- Close supervision.

H3 - HIGH PRESSURE LIQUID OR GASES

1 Working near a live facility Excavation with mechanical diggers Bull dozing / grading Crossing pipe lines by heavy equipments.

- High-pressure liquids or gas (injection water, steam compressed air, nitrogen, acetylene, oxygen).

- Fatalities or bodily injuries, local damages.

- Follow procedures (work practice) supervision,

- Maintenance of machines and accessories

- Training & instruction.

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H4 – SPRAY PAINTING

1 Painting (Spray) and Paint storage - Fire & explosion in presence of ignition source.

- Inhalation of toxic fumes and skin contact of solvents.

- Defective equipments (spray gun high pr. Hose, spray pump, compressor).

- Heights

- Confined Space

- Injuries

- Poisoning, lung disorders, skin diseases.

- Body injuries.

- Hearing impairment

- Fall injury

- Poisoning due to inhalation of toxic gas.

- Asphyxiation

- Proper ventilation- No ignition source in the area.

- Ventilation

- Use of adequate PPEs (facemask, fire resistant coveralls, eye protective goggles, hand gloves).

- Use well-maintained equipments.- Daily inspection before use

- Use earplug while cleaning the job with compressed air.

- Use scaffolding or elevated platform erected as per procedure and certified by competent persons.

- Use safety harness wherever platform or ladder is inadequate or inconvenient or where work is required only for a short while.

- Ventilation- Air circulation.

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H5 – BLASTING (ABRASIVE)

1 Blasting (grit) - Defective equipments, hoses, nozzle valves, compressor)

- Flying metal fragments- Presence of hydrocarbon source

- Noise

- High pressure air

- Heat stress

- Dust containing silica or metallic slag

- Blasting grit

- Hit injuries due to breakage of hose etc.,

- Body and eye injuries- Fire and explosion

- Hearing impairment

- Injury

- Heat ailments

- Lung disorders- Environmental damage

- Use only well-maintained equipments- Daily checking of all equipment- Employ only competent operator- Wear essential PPEs by all persons

engaged in the work.- Keep minimum persons in the

hazardous zone.- Provide / barricade /screen and caution

tape and warning signals or boards for the basting area

- Keep the area far away from live zone- Gas testing frequently- PTW for hot work in place.

- Use earplug / muff.

- Use compressed air hose of adequate strength and in good repair.

- Daily check up for hose damages.

- Provide large quantity of water- Give access to shady shelter for

intermittent rest.

- Use dust mask to cover the mouth also.- Disposal of the basted grits

accumulation as per Waste Management Procedure.

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H6 – AIR COMPRESSOR

1 Use of air compressors - Pressure control switch not in place or defective

- High temperature limiting switch not in place / defective.

- Safety valve not set.

- Defective hose / fittings

- Non use of PPE

- Noise

- Filling of fuel

- Fatality / Injury

- Fatality / Injury

- Fatality / Injury

- Fatality / Injury

- Fatality / Injury

- Hearing loss.

- Fire explosion and oil spilling

- Precut off switches properly set.

- Temp. Control device properly set.

- Safety valve properly calibrated

- Check and replace hose & fittings

- Use proper PPEs

- Use ear plug/muff appropriately.- Training and instructions

- Stop the engine before filling of fuel- Provide earthing.

H7 – ENGINE GENERATOR SET

1 Engine Generator Set - Improper earthing- Improper insulation- Faulty appliances/control system.- Poor exhaust- Poor ventilation- Hydrocarbons

- Oil leakage- Toxic gases.

- Electric Shock- Electric Shock- Fire / explosion

- Asphyxiation- Fire & explosion

- Fire & explosion- Poisoning

- Proper earthing- Adequate insulation- Proper preventive maintenance - Ventilation

- Periodical gas testing of the premises

- Prevent leakages- Gas testing & monitoring.

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H8 – ARC WELDING

1 Arc welding & welding in the site near live hydrocarbon facilities.

- Radiation harmful to naked eyes.

- Splinters / Slag.- Harmful fumes- Dislocation / fall of job piece due to

faulty clamping- Electricity due to :

Loose connections / loss of insulation.

- Presence of flammable gases- Poor ventilation.

- Welder’s cataract

- Burn injury- Lung ailments- Dermatitis- Hit injury / crush injury- Electric shock- Fire / explosion

- Use welding shield / goggles- Carry out the welding where there is no

winds.- Provide wind screens- Fire proof apron/gloves/screen

- Ventilation (local exhaust, if possible)- Fire watch- Proper clamping system- Proper maintenance of the plant, use

shockproof boots and hand gloves.- Provide earthing to the plant.- Gas testing periodically, use fire

extinguisher (DCP/CO2)- Adequate ventilation.- Training & instructions.

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H9 – GAS WELDING

1 Gas welding / cutting / heating - Working without PPEs- Backfiring

- Heat- Splashing / Splinters

- Gas leakage- Valve leakage

- Wrong position of cylinders

- Presence of flammable gases

- Wind

- Fatality / burn injury, fire / explosion

- Burns- Burns

- Fire & explosion

- Gas leakage due to fall of cylinder and damage of valve.

- Fire & explosion

- Spreading of flame

- Work only after wearing PPEs- Fit flash back arrester on both cylinder

outlets.

- Use face shield and fireproof gloves- Use face shield and fireproof gloves

- Daily check up before start of work

- Keep cylinders in trolleys or chain to some fire structure to prevent fall.

- Gas testing before start of work - Employ competent and trained welder.

- Provide windshield.

H10 – PORTABLE HAND TOOLS

1 Working with portable hand tools - Defective / damaged tools and tools without protection handle

- Improper handling- Improper storage- Misuse / abuse

- Accident and bodily injuries

- Property damages

- Replace defective / damaged tools- Use tools only with protective handle.- Training & Inspection- Keep only in toolboxes.- Training & instruction to use right tools

for the right job.

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H11 – PORTABLE ELECTRIC TOOLS

1 Working with electrical portable tools

- Damaged cable- Defective tool- Loose components (wheel, switch

etc.)- Electrical system / Hubara station

tripping- Excess pressure on tool- Improper handling- Non use of PPE

- Electric shock- Spark / shock- Hit injury- Accident and injury- Bodily injury- Shock / eye and bodily injuries

- Daily check up before start.- Use of ELCBs to step down to 110V- Replace defective tools- Proper maintenance- Tagging of all electrical tools- Training on proper use & care- Inspection and corrective action to

follow correct handling procedure.- Use adequate PPEs (Face shield /

goggles and gloves).

H12 – BENCH GRINDING

1 Bench grinding, grinding and wheel replacing

- Grinding without goggle- Absence of tool rest- More gap between the wheel and

tool rest.- Improper / wrong size grinding- Excess pr. On wheel.- Flammable gas in the vicinity - Breakage of wheel- Changing the disc on electric

grinders while still plugged in.

- Bodily injury- Accident / Injury- Accident / Injury

- Accident / Injury- Accident / Injury- Fire- Hit injury- Damage, hands, finger injury.

- Use Proper PPEs- Mount the tool rest on both sides- Replace the wheel. Gap more than

3mm is unsafe. - Use grinding wheel of correct size- Training & instruction- Gas testing before work starts- Proper tightening of wheel- Use of correct size spacer washers- Unplug the grinder when changing

discs.

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H13 – MATERIAL HANDLING (MANUAL)

1 Material Handling (manual) - Non-use of PPEs (helmet, gloves, shoes etc.,)

- Wrong identification of material

- Inadequate manpower

- Lack of co-ordination in-group effort.

- Wrong body posture- Lifting error- Bur / sharp edges / corners /

projecting parts / protruding nails

- Fall of materials

- Accident / injury

- Property damage & personal injury

- Back pain, sprain etc.,- Property damage

- Accident / injury- Back pain, sprain etc.,- Property damage

- Do

- Accident / injury- Back pain, sprain etc.,- Property damage

- Use adequate PPEs

- Correct labeling and proper identification

- Provide adequate manpower for the lifting of heavy load

- Training & instructions

- Training & instruction

- Use hand gloves

- Use proper lifting devices for good grip

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H14 – MATERIAL HANDLING (MECHANICAL)

1 Material Handling (mechanical) forklift, hiab, crane

- Lack of knowledge- Defective equipment

- Defective lifting jacks

- Overloading

- Untrained operator

- Accident / Injury- Material loss / injury

- Do

- Tilting of jacks / boom

- Injury due to accident ad property damage

- Only competent Operator shall be provided for lifting operations.

- Periodic inspection by third party.

- Equipment as well as lifting jacks to be certified by competent persons before deployment.

- No overloading allowed. Follow procedures

- Training and assistance of banksmen / rigger.

H15 – WORKING UNDER CRANE / LIFTING EQUIPMENTS / LIFTING OF THE PUMP

1 Working under crane / lifting equipment’s

- Working without PPE

- Failure of slings

- Improper handling- Overloading- Defective equipment

- Lack of awareness

- Fatality / injury- Material damage

- Fatality / injury due to fall of load

- Fatality / injury- Material damage- Fatality / injury- Material damage

- Fatality / injury- Material damage

- Use required PPEs (helmet, shoes, goggles, etc.)

- Use only certified slings as per colour coding.

- No person to stand under lifting load

- Follow safe procedures

- Only approved equipment to be used

- Training to Operator and providing banksman / rigger.

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H16 – LOADING / UNLOADING TRUCK / TRAILER

1 Loading and unloading of materials on trucks / trailers

Use of chain binder

- Loading material due to fall - Defective equipment.

- Overloading

- Defective chain binder

- Use of extra leverage for tightening

- Over tightness

- Height of the load

- Accident / Injury, damage of materials damage to equipments.

- Accident / injury, damage of materials damage to equipments.

- Accident / injury to persons due to fall

- Damage to materials

- Do

- Accident / injury to persons

- Injury due to falls.

- Follow lifting procedure- Use correct equipments & Lifting

tackles- Proper supervision

- Use certified chain binders

- No extra long pipe used for extra coverage (not more than 76mm long).

- Do not overtight

- Stand on ground while fixing and tightening chain binders.

H17 –TRUCK MOUNTED CRANE

1 Crane positioning - Outriggers on soft ground / loose soil - Tilting of crane - Outrigger base plates to rest on firm ground or on timber blocks / steel plates.

2

3

Operation of PTO

Extending outriggers

- Operating levers not in neutral position

- Outriggers not extended fully

- Outriggers not locked

- Crane will start operating immediately on engagement of PTO

- Tilting of the crane

- Retracting of outrigger and tilting of the crane

- Make sure control levers are all in neutral position

- Extend outriggers fully

- Lock the outrigger beam.

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4 Loading operation - Side loading / dragging of load

- Overload

- Swinging the load

- Abrupt operation of control levers

- Keeping the load in the elevated position

- Persons standing below the lifting load.

- Traveling with load

- Tilting of the crane due to uneven load.

- Damage to crane and loss of materials.

- Un-stability and tilting of crane

- Jerking, fall of load, hitting person

- Fall of load due to mechanical failures.

- Fall of load causing human injuries.

- Fall of load & tilting of crane

- Lifting only vertically- No dragging of load

- No overload

- No swinging of load

- Operate the levers slowly and smoothly.

- Do not keep the load in the elevated position.

- Do not allow any person to be under the load.

- Do not travel with lifting load.H 18 – WORKING AT HEIGHT

1 Working at height - Defective scaffolding

- Improper use of scaffolding

Substandard materials Faulty erection Defective access device Overload

- Vertigo while working at heights.

- Fall injury / fatality

- Dizziness and fall injury / fatality

- Construction of scaffolding only by experienced persons under the supervision of a competent person.

- Daily inspection and certification by a competent person

- Site supervision to prevent overload.

- Confirm non-attack of vertigo in the past before allowing to work at heights.

- Accompany the workers for the 1st time to check up and ensure that he does not suffer from vertigo.

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Working at height (Contd..) - Lack of platform

- Inadequate area on the platform - Defective platform

- Defective / unguarded, ladder or stairs

- Faulty mounting of the ladder

- Leaning / overstitching at height to reach the pipe / bolt / instrument ahead.

- Injury by trip / slip and fall




- Fall injury

- Provide elevated working platform for all activities at heights more than 1.5m or construct scaffolding.

- Platform to be of sufficient area for optimum movements of the worker

- Use ladder as per specification.

- Provide ladder on firm footing at appropriate inclination and fasten on top.

- Training and instructions- Close supervision- Provide safety harness if platform or

ladder has no safe access to such job - Do not work on ladders.

H19 – WORKING IN CONFINED SPACE

1 Working in confined space (tanks, vessels, deep excavation etc.,)

- Hydrocarbons

- Toxic gases

- Oxygen deficiency

- Inadequate access to outside

- Lack of communication

- Fire, explosion

- Poisoning

- Asphyxiation

- Inability to escape

- Inability to contact the stand by man

- Frequent gas testing- No ignition source- Frequent gas testing

- Frequent gas testing- Circulation of air- Ensure emergency access and rescue

plans before entry

- Maintain uninterrupted contact with the workers by the standby person.

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Working in confirmed space (tanks, vessels, deep excavation etc.,)

Contd…

- Tools striking due to congested work

- Closure of access due to miscalculation and trapping of persons in.

- Heat stress due to working in hot climate or doing hot work

- Tool injuries

- Injury / fatality

- Heat ailments (heat exhaustion, heat stroke etc.,)

- Keep only minimum number of persons for work to avoid congestion

- Supervisor and standby man to ensure record of all persons working in confined space.

- Provide access to shade at intervals- Provide adequate cold water- Ensure adequate ventilation.

H20 – HYDROTESTING

1 - Pumping Operation

- Breaking or tightening flange bolt on pr. Lines

- Disposal of hydro-tested water

- High pressure water

- Hydrocarbons

- High pressure water in the pressure lines, hose etc.

- Fall from heights- Chemicals / pollutants in water due

to adding of chemicals / using production water

- Oxygen deficiency

- Bodily injury / fatality due to failure of pressurized system

- Fire & explosion

- Injury due to bursting of the flange coupling.

- Fall injury

- Environment pollution

- Check pr. Relief valve- Calibrate pr. Gauge- Monitor pr. Rise

- Tightening / loosing only after depressurising the pressure lines.

- Barricading the pressurized system to prevent entry to other workers.

- Permit to work and hot work certificate- All precautions for working at heights- Draining and conveying the entire

quantity of water through flexible hose upto the disposal point.

- Circulation of air, after gas testing, if required.

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- Cleaning the inside of the tank

- Asphyxiation


H21 – RADIOGRAPHY

1 Radiography

NDT (MT / PT)

- Ionising radiation to persons working nearby.

- Inhaling, touching the consumables with bare hands.

- Fatality- Poisoning- Environmental damage

- Irritation, poisoning

- Competent radiographer- Adequate PPEs- Barriers and warning devices to restrict

entry of other persons within the hazardous area

- Checking of gamma ray radiation with dosimeter and monitoring.

- No travel in the same compartment where the source is kept while transportation.

- Loading, unloading, parking and transporting must be well planned so as to minimise risk of exposure to personnel.

- Use proper PPE.

H22 – SCAFFOLDING

1 Scaffolding erection - Improper manual handling: fall of scaffolding materials hitting Defective lifting equipment /

improper use.

- Personal injuries

- Material damage

- Train on proper manual lifting procedures.

- Use only tested and certified equipment and lifting tackles.

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2

Scaffolding erection (Contd..)

Working on scaffolding

- Faulty erection.

- Defective scaffolding

- Improper use

- Faulty access to platform- Inadequate size of platform

- Overloading

- Faulty / unguarded access ladder / stairs

- Vertigo

- Collapse of scaffolding and fall of persons.

- Injury due to fall

- Fall injury

- Fall injury- Fall injury

- Fall injury

- Fall injury

- Fall injury

- Erection only by experienced persons under supervision of a competent person.

- Daily inspection and certification by competent person

- PTW in place- Daily inspection and certification by

competent person.

- Training and supervision

- Provide access as per specification- Adequate size as per job requirement.

- No overloading permitted. Only minimum number of persons allowed to work at a time.

- Ladder / stirs as per specification

- Supervisor to confirm that persons working are not having previous attach of vertigo.

- Test for the first time whether the person exhibits vertigo symptoms while working at heights.

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3

Working on scaffolding (contd..)

Dismantling of scaffolding

- Presence of hydrocarbons, toxic gases etc.,

- Heat stress

- Fall of persons

- Fall of scaffolding materials

- Fall of hand tools (hammer)

- Fatality- Poisoning- Fire & explosion

- Heat ailments like exhaustion, heat stroke

- Fatality / injury

- Fatality / injury

- Injury

- Gas testing frequently as specified in the permit

- Provide access to shade- Provide adequate cold water for

drinking

- Follow dismantling procedures

- Do not allow persons to be under the scaffolding structure

- Use PPEs (Helmet, safety shoe, hand gloves and eye protective glasses)

- Keep tools in proper holder.

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H23 – GAS CYLINDERS

1 Loading / Unloading / Transporting gas cylinders:OxygenAcetyleneArgonNitrogenLPG

- Cylinders kept horizontal

- Cylinders with no valve cap

- Valve leakage

- Fire and explosion property damage

- Gas leakage due to valve damage

- Fire & Explosion

- Keep cylinder (charged) only vertically and tie with chain to a fixed structure

- Keep in specially fabricated cage to prevent fall

- Keep valve cap in position during transportation

- Different types of gas cylinders not to be loaded in the same vehicle at a time.

- Only authorized vehicle and specially trained driver shall be engaged in gas cylinder transportation.

- Details of the load shall be entered in the Journey plan.

- Do not use leaking cylinder- Keep upright and locked.

H24 – HEAT STRESS

1 Working in hot environment - Hot sun- Hot work such as welding,

cutting, heating, cooking etc.

- Heat stress due to failure of thermo-regulatory system of the body; dehydration due to excess loss of body fluids.

- Heat ailments such as heat exhaustion heat cramps and heatstroke.

- Drinking plenty of cold water- Intermittent rest under shades. Eating

more of vegetables and fruits items. - Appropriate PPEs to protect body

against direct exposure to heat or hot sun.

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H25 – DUST

1 Working in dust - Inhalation and striking the eye- Lung disorders (silicosis) and eye

injury

- Sprinkle water to suppress dust generation.

- Use PPE (dust mask and protective spectacles / goggles).

H26 – NATURAL CALAMITIES

1 Working during natural calamities - Flood

- Fog- Rain

- Storm / wind

- Drowning and washing away in flood water

- Injury / fatality due to hitting or vehicle accident

- Injuries due to collapse of buildings

- Do not go into flood- No driving of vehicles in fast flowing

water- Ascertain the depth of water and the

firmness of the road surface- Keep on elevated terrain till flood

subsides

- Vehicle / equipment movements only in clear vision

- Drive slowly with head lights and wipers on

- Sufficient anchoring of residential / office cabins.

- Outside doors fitted with auto-hinges.

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H27 – DRIVING / OPERATION OF VEHICLES & EQUIPMENTS

1

2

Driving / operating vehicles / equipments

Driving on graded roads

- Lack of knowledge and skill- Untrained drivers / operators- Defective vehicles / equipments- Over speed / overload

- Rain

- Loose surface, erosion, pot holes

- Dust

- Fatality / injury- Loss of property / material- Damage of equipments

- Vehicle swept away in heavy floods- Diving in mud

- Injuries / fatalities due to accidents

- Loose surface, erection, pot holes

- Only authorized persons to be deployed for driving / equipment operation.

- Training / refresher training to drivers / operators

- Use of approved vehicles / equipments - Inspection & supervision- Provide banksmen as appropriate.

- Not to drive in bad weather

- Use tyres with a minimum of 2 mm tread.

- Drive with dipped head lights and high intensity lights on.

- Observe dust code- No overtaking- Head lights on- Dead slow- Defensive driving- If no front vision, stop and keep off the

road.

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- Use of approved equipments competent and trained operator

- PTW safety measures in place.


3

4

Loading transportation and unloading of soil.

Operation of crane / hiab

- Hydro carbons / gases / electricity due to hitting pipe lines

- Dust

- Hydrocarbons / gases, electricity due to hitting on live facilities nearby, by accidents or mechanical defects

- Fatality / injury due to fire & explosion, poisoning or electric shock.

- Eye injuries (striking), lung disorders (inhalation).

- Facilities / injuries due to fire & explosion, poisoning or electric shock.

- Use only approved vehicles- Competent and trained drivers- Providing banksmen.- Restrict the vehicle movements only on

graded path.

- Sprinkle water to suppress dust- Use dust mask- Use only approved equipments- Employ competent and trained

operators- Provide banksmen / riggers- PTW in place.

H28 – VEHICLE PARKING

1 Vehicle parking - Improper parking- Uneven surface- Defective hand brake- Absence of wheel chock- Non / partial application of hand

brake

- Rolling of vehicle resulting fatality / injury

- Damage to vehicle / properties / live facilities nearby

- Follow parking procedure- Level ground for parking- Hand brake proper- Wheel chocks in position- Gear engagement

H29 – STAY IN CAMPS

1 Staying in residential camps - Biological hazards (Malarial mosquitoes, contaminated water / food stuff, unhygienic living

- Infectious diseases, fatalities, ill health

- Environmental damages

- Prompt disposal of wastes, concealment of drainage

- Use of insecticides

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conditions, poor ventilation. - Ventilation in living accommodation.


Staying in residential camps (Contd..)

- Straying of live stock Camels Fox Rabbits Deer etc.,

- Fire

- Electric shock

- Death / injury to live stock

- Infections to live stock from food wastage

- Fatality / injury to persons due to vehicle accidents while trying to save the live stock.

- Environmental damages

- Injury / fatality - Property loss

- Injury / fatality

- Fencing around residential camps with camel grid t the entrance.

- Keeping food wastes in garbage bags / closed buckets and prompt disposal to the food waste dump yard as per waste management manual.

- Dead slow driving in camp premises.- Extremely cautious against crossing of

stray animals. - Do not cause harm to any live stock.- Observe warning signals on roads

against stray animals.

- No open flames inside portacabins.- Isolation valve on cooking gas

cylinders.- Use of only three pin plugs.

H30 – CABLE LAYING

1 Laying out electrical cables - Cable not discharged after insulation resistance checks.

- Faulty manual lifting

- Fatality / severe injury due to electric shock.

- Bodily injury

- Cable shall be discharged after insulation resistance checks.

- Adopt proper manual lifting procedure.

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- Use adequate PPEs.


Laying out electrical cables (Contd.)

- Faulty equipment / incorrect operation.

- Defective drum jack leading to fall of drum.

- Fall of persons in the cable trench

- Trapping of fingers between cable and rollers.

- Human injury

- Human injury

- Human injury

- Human injury

- Use only certified equipments - Employ competent operators

- Use correct jack and place it over firm, level ground.

- Keep excavated soil at least 1m away from the edge of the trench.

- Keep away from the extreme edge while walking along the banks.

- Keep fingers away from nip points - Use hand gloves.

H31 – TIE-INS TO ELECTRICAL SYSTEM

1 - Tie-ins to electrical systems - Electric Shock - Fatality / injury - Barriers and red / green flags to indicate safe working area.

H32 – ACTIVITIES IN SWITCH YARD

1 - Working in the switch yard- Isolation of equipments- Tie-ins to electrical systems

- Electric Shock - Water coming in contact with live

points.

- Fatality / injury - PTW with isolation permit in place. - Electrical isolation by competent

person under close supervision.- Keep water away from electrical

equipments or live points- Barriers and red/green flags to indicate

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safe working area.

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Documents

Hazard analysis.doc