Fmc close out repot hse dept. rev.000

CLOSE OUT REPORT

HSE DEPARTMENT

Period : JUNE 2013 – OCTOBER 2013

1st ARTICLE – SUB SEA MANIFOLD PROJECT

PT GUNANUSA UTAMA

FABRICATORS

HSE CLOSE OUT REPORT 2013

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CONTENT 1. INTRODUCTION ................................................................................................. 3

1.1 PURPOSE ..................................................................................................... 3 1.2 SCOPE .......................................................................................................... 3

2. HSE MANAGEMENT SYSTEM ............................................................................. 3 3. HSE POLICY 2013 ............................................................................................... 5 4. PROJECT HSE OBJECTIVE 2013 ........................................................................... 5

4.1 SAFETY OBJECTIVES ..................................................................................... 5 4.2 OCCUPATION HEALTH OBJECTIVES............................................................... 5 4.3 ENVIRONMENTAL OBJECTIVES ..................................................................... 5

5. PROJECT HSE ACHIEVEMENT 2013 ..................................................................... 6 5.1 SAFETY OBJECTIVES ..................................................................................... 6

5.2 OCCUPATION HEALTH OBJECTIVES............................................................... 7 6. HSE ORGANIZATION CHART .............................................................................. 8 7. HSE PERFORMANCE STATISTIC .......................................................................... 8

7.1 MAN HOURS EXPOSURE .............................................................................. 8 7.2 FATALITY (FAT)........................................................................................... 10 7.3 LOSS TIME INJURY (LTI) .............................................................................. 10 7.4 MEDICAL TREATMENT CASE (MTC) ............................................................ 10 7.5 FIRST AID CASES (FAC) ............................................................................... 10 7.6 DAY LOSS ................................................................................................... 10 7.7 NEAR MISS INCIDENT (NMI) ....................................................................... 11 7.8 MEDICAL RECORDS .................................................................................... 11 7.9 HAZARD IDENTIFICATION AND RISK ASSESSMENT (HIRA) .......................... 11

7.10 MANAGEMENT QHSE WALKTHROUGH RECORDS .................................... 11 8. AREA OF CONCERN AND FOLLOW UP FOR CORRECTIVE ACTION ..................... 11

8.1 AREA OF CONCERN .................................................................................... 11 8.2 FOLLOW UP FO FOR CORRECTIVE ACTION OF CONCERN AREA ................... 12

9. SUMMARY OF HSE PROGRAM IMPLEMENTATION ........................................... 13 9.1 INDUCTION AND TRAINING........................................................................ 13


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9.2 JOB RISK ASSESSMENT ............................................................................... 14 9.3 HSE AUDITS ................................................................................................ 14 9.4 HSE TRACKING RECORDS............................................................................ 14 9.5 HSE INSPECTION PROGRAM ....................................................................... 14 9.6 HSE COMMUNICATION PROGRAM ............................................................ 15 9.7 HEALTH AND HYGIENE ............................................................................... 16 9.8 ENVIRONMENTAL IMPROVEMENT ............................................................. 16

9.9 HSE PROCEDURE DEVELOPED ..................................................................... 17 9.10 HSE REPORTING SYSTEM ......................................................................... 17

ATTACHMENT 1 HSE POLICY

ATTACHMENT 2 YARD HSE ORGANIZATION CHART

ATTACHMENT 3 SUMMARY WORK PERMITS YARD ACTIVITY

ATTACHMENT 4 JRA RECORDS

ATTACHMENT 5 MANAGEMENT WALKTHROUGH

ATTACHMENT 6 HSE MASTER DOCUMENT REGISTERS

ATTACHMENT 7 LOAD OUT PICTURE

ATTACHMENT 8 INSPECTION REPORT


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1. INTRODUCTION

PT. Gunanusa Utama Fabricators HSE dossier is provided as Close Out Report for measurement of the HSE Management System include HSE Program implementation of FMC Technologies has been awarded 1st article Project for PT Gunanusa Utama Fabricators yard Grenyang – Serang Banten.

1.1 PURPOSE

The purpose of this dossier is to report the commitment of PT Gunanusa Utama Fabricator management on managing the implementation of their HSE policy and other HSE issue raised during the execution of Project since the Project activities started until the end of project include the achievement of Project HSE Objectives.

1.2 SCOPE

This HSE Close Out Report (Dossier) is covered the implementation all HSE activities during engineering, procurement, fabrication and assembly, materials management, Load out and pre commissioning PTG has completed successfully all fabrications and SDSS Pipe, Structural Steel, SS Tube load out (October 24th, 2013).

2. HSE MANAGEMENT SYSTEM

HSE Management System developed based on the integrated of HSE Management System : - OHSAS 18001:2007 (HSE Management System) - ISO 14001:2004 (Environmental Management System) - SMK3 PP No. 5/2012 (OHS Management System of Indonesia) - ISO 9001:2008 (Quality Management System)

And also to meet and comply of others requirement both International and National statutory regulations, Industrial Standard Code Practices and client requirement.

The Elements of HSE Management System consist of :

- Leadership & commitment - Policy & strategic objective - Organization, responsibility, resources standards and documentation - Hazards and effect management - Planning and procedures - Implementation & performance monitoring - Audit & review


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Key Elements Integrated HSE Management System


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3. HSE POLICY 2013

This policy statement has been produced in pursuance of CTR statutory and contractual obligations and is designed to promote high standards of Occupational Health and Safety for duration of the Yard & Site Construction. (see the attachment 1)

4. PROJECT HSE OBJECTIVE 2013

The HSE Objective of CTR stipulated for the year 2013 is to improve the behavior of all employees to become habitual by providing more knowledge in understanding the safety aspect of a project as such to prevent the occurrence of accidents. This objectives shall be achieved by maintaining the following targets.(Attachment 2)

4.1 SAFETY OBJECTIVES

4.1.1 Safety Objective # 1 - HUMAN DIMENSION • No fatality, • No major accident (including lifting and transport), • No major fire, • No explosion.

4.1.2 Safety Objective # 2 TRIR – Total Recordable Injury Rate < 1.06,

4.1.3 Safety Objective # 3 LTIF – Lost Time Injury Frequency < 0.28,

4.1.4 Safety Objectives # 4 – HSE Management System and Performance Management • Develop HSE Management System, • Socialization Key Performance Indicator to workforces, • Control of Key Performance Indicator

4.1.5 Safety Objectives # 5 – SAFETY BEHAVIOR

4.2 OCCUPATION HEALTH OBJECTIVES

1. Ensure availability of emergency equipments and maintain medicine stock 2. Reduce occupation illness and sickness 3. Continue improve the implementation of industrial hygiene

4.3 ENVIRONMENTAL OBJECTIVES

1. Improve employees environmental awareness by conduct regular training, displayed label, MSDS hazardous sign.

2. Minimize dust exposure during abrasive blasting and minimize oil spills 3. Improve waste management by waste segregation, storage and regular transportation


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5. PROJECT HSE ACHIEVEMENT 2013

5.1 SAFETY OBJECTIVES

5.1.1 General Safety Objective # 1 HUMAN DIMENSION

Total man-hours achievement of FMC Project since period June 2013 up to October 2013 are 13.244 (COD: 16 October 2013) which :

- no fatality, - no major accident, - no major fire and - no explosion was occurred

Therefore, General Safety Objective # 1 –

5.1.2 Safety Objective # 2

HUMAN DIMENSION is achieved.

During execution of FMC Project period June 2013 up to October 2013, the following HSE performance with total cumulative man hours achieved there were some 13.244 at yard as of closed date October 16 June, 2013 some accident has occurred as follows.

a. TRIR (Total Recordable Injury Rate)

During execution of FMC Project period June 2013 up to October 2013, Total FAT (Fatality) = 0, LTI (Lost Time Accidents) = 0, RWDC (Restricted Work Day Case) = 0, MTC (Medical Treatment Case) = 0. There for base on formula ANSI version below : TRIR =

(FAT+RWDC+MTC+LTI) * 1.000.000 Man Hours

TRIR =

TRIR = 0,00

(0+0+0+0) * 1.000.000 13.244

Comparing objective TRIR value shall be < 2, 00. it means TRIR archived (0,00 < 2,00)

b. LTIF (Lost Time Injury Frequency)

During execution of FMC Project period June 2013 up to October 2013, Total FAT (Fatality) = 0, LTI (Lost Time Accidents) = 0 LTIF =

(FAT+LTI) * 1.000.000 Man Hours


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LTIF =

LTIF = 0

(0+0) * 1.000.000 13.244

Comparing objective LTIF value shall be < 0, 75. it means LTIF archived (0 < 0, 75) Therefore, Safety Objective # 2 –

5.1.3 Safety Objective # 3

TRIR = 0,00 and LTIF = 0 are achieved

During the implementation of fabrication period 2013, there was a significant improvement of safety behavior by proactive all employees and subcontractors on HSE program throughout: 1. Participate regularly on meeting program such as Toolbox Meeting in daily basis, mass

meeting in weekly basis, HSE weekly and monthly meeting with client and monthly Safety Committee meeting

2. Implementation housekeeping (5S) program 3. Discipline on wearing PPE and unsafe practices has been reduced due to the

implementation of violation card system 4. Conduct HSE inspection and internal & external audit in regular basis 5. Implementation safety communication such as safety poster/banner, barricade, HSE

notice board, etc. 6. Management Communication such as management visit / management walkthrough. At meanwhile, HSE has been recognized for the implementation of HSE Management System by external audit as below: 1. We successfully in audit surveillance certified by SICS (Sucofindo International

Certification Service) on OHSAS 18001:2007 (HSE Management System), ISO 14001:2004 (Environmental Management System)

2. SMK3 (PERMENAKER No. 5 / 1996 and PP No. 50 / 2012) scored 92 (gold flag) and certificate will issue on March 2009.

3. We certified by LRQA (Lloyd Register Quality Assurance) on ISO 9001:2008 on Quality Management System.

4. We conduct internal HSE audit which held by internal auditor. It makes increase HSE performance.

5. Our corporate HSE manager has been selected as a Chairman of National of Safety Committee and has been selected as a Chairman of Provincial Banten Safety Committee by Banten Governor.

Therefore, Safety Objective # 3 –

Safety Behavior is achieved

5.2 OCCUPATION HEALTH OBJECTIVES


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During the project execution contractor has provided adequate of the availability of medicine stock to cover employee and medical check up are completed performed to all employee improved to the project.

1. Ensure availability of emergency equipments and maintain medicine stock

Emergency equipments and maintenance facilities has been improve such as New Clinic building complete with ambulance and clinic facilities and ERT Room building complete with emergency equipment, etc and also we maintain medicine stock in regular basis. All documents are recorded and reported to involved parties. Conduct drill regularly in monthly basis.

2. Reduce occupation illness and sickness

Based on the clinic statistic reported, there was no occupation illness and sickness occurred.

3. Continue improve the implementation of industrial hygiene

The implementation of industrial hygiene program is we conducted regularly such as inspection on canteen, noise level check, emission, illumination, UV Light, radiation, etc. All documents are recorded and reported to involved parties.

We achieved Occupational Health objectives

6. HSE ORGANIZATION CHART

See attachment 3 – Yard HSE Organization Chart

7. HSE PERFORMANCE STATISTIC

7.1 MAN HOURS EXPOSURE

Since FMC Project started from October June 2013 up to October 2013 total cumulative man hours achieved are 13.244 .


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SUMMARY OF HSE PERFORMANCE STATISTIC 1st article Project

PERIOD : June 2013 – October 2013

DescriptionPerformance

StatisticRemarks

WORKED HOURS1 Total Man Power 202 Total Man Hours 13244

INCIDENT1 Fatality Accident 0 No fatality2 Lost Time Injury (Company) 0 No Lost Time Injury3 Lost Time Injury(Contractor) 04 Day Lost 0 No Lost Day5 Restricted Workday Case 06 Medical Treatment Case 0 No Restricted Work Case7 High Potential (HiPo) Incident 0 No High Potential8 First Aid Case (FAC) 09 Occupational Illness 0 No Occupational Illness

10 Material / Production Loss 0 No Material / Production Loss11 Pollution / Spill 012 Fire (not HPI) 013 Damage (not HPI) 014 Incident (Near Miss / NC) 015 RTA / Incidents 016 Security 017 External RTA / Road Incidents 018 External (Social) 019 Vehicles Incident 0 No Vehicle Incident20 Root Cause Analysis 0

HSE ACTIVITIES1 Safety Tool Box Meeting (Event) 242 Safety Induction (No. of Persons) 203 HSE Walkabout 84 HSE Inspections 75 SubContractors HSE Audits 56 Medical Check up 207 HSE Document Preparation 88 Safety Weekly Meeting 159 Safety Monthly Meeting 1

10 Weekly Construction Meeting 5D TRIR 1,10E LTIF 0,26

No

A

B

C


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7.2 FATALITY (FAT)

Since project activities started until the end project there was No Fatality case occurred.

7.3 LOSS TIME INJURY (LTI)

Since project activities started until the end project there was No Lost Time Injury case occurred.

7.4 MEDICAL TREATMENT CASE (MTC)

Total First Aid cases occurred on June 2013 up to October 2013, there were 6 cases that occurred at Yard activities. All corrective action as required by Client has been done.

7.5 FIRST AID CASES (FAC)

Total First Aid cases occurred since June 2013 up to October 2013, there were 6 cases that occurred at Yard activities. All corrective action as required by Client has been done.

7.6 DAY LOSS

During the yard activity performed until the end of the construction project there was no Day Loss occurred.

June July August September October

Year 2013

TRIR 1.10 1.10 1.10 1.10 1.10

LTIF 0.26 0.26 0.26 0.26 0.26

0.00

0.20

0.40

0.60

0.80

1.00

1.20

HSE Objective & HSE AchievementPeriod : June 2013 - October 20132


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7.7 NEAR MISS INCIDENT (NMI)

Total Near miss cases occurred since June 2013 up to October 2013, there were 2 cases. All corrective action as required by Client has been done (See attachment 12 – HSE Event Log Accident/Incident register)

7.8 MEDICAL RECORDS

Since the starting of the project on June 2013 up to October 2013, the total clinic visitor were 20 Reported. (See attachment 9 – Summary Medical Record as Yard Clinic Visitor)

7.9 HAZARD IDENTIFICATION AND RISK ASSESSMENT (HIRA)

PT. Gunanusa has applied hazard identification and risk assessment with JRA & weekly Management walkthrough. All finding of both program had been closed and corrective action taken.

7.10 MANAGEMENT QHSE WALKTHROUGH RECORDS

Total management QHSE walkthrough issued from contractor and company during 2013 up to October 2013. All of management QHSE walkthrough had been corrected and closed out (See attachment 10 - Safety Management QHSE Walkthrough Finding & Close Summary Number)

8. AREA OF CONCERN AND FOLLOW UP FOR CORRECTIVE ACTION

8.1 AREA OF CONCERN

Referring to the HSE tracking record there were a lot of HSE issued identified from event log record, issued include findings and comments by Contractor and Client representative during HSE regular inspection. The finding areas of concerns that need to be improved were as follow:

a. Unsafe work practice & poor safety behavior b. Lack of PPE/ Fail to wear PPE c. Poor of Housekeeping d. Lack & unsafe equipment operation e. Improper electrical equipment /tools


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8.2 FOLLOW UP FO FOR CORRECTIVE ACTION OF CONCERN AREA

Almost all event log, SHOC Card, and Violation card reported have been corrected and follow up.

Corrective Action & Follow-Up area of concern were as follow:

1. Unsafe work practice and poor safety behavior

Finding: Not followed the correct Standard Operational Procedure (SOP) The used of equipment and tools with the wrong method

Action taken: o Conducted safety behavior training. o Highlight at tool box talk related unsafe work practice by daily basis. o Conducted on the job training such as: Safe to use grinding machine, safe to use

body harness, safe to use cutting torch. o Socializing the slogan” Safety is everybody business “, therefore everybody could

have contribution encourage them to control each other’s and immediately reported by use SHOC card or correct the unsafe practices before incident occurred.

2. Lack of PPE / Fail to wear PPE

Finding: Undisciplined used of safety glasses although already supplied. The used improper of Safety shoes The used incorrect PPE for specific work such as working at height

Action taken: o Supply standard PPE as requirement such as : Safety Helmet, safety glasses,

dust mask, earplug, full body harness, Safety shoes. o Maintain PPE minimum stock and report the PPE stock by weekly basis. o Performed PPE inspection at entrance gate prior starting the work by daily basis. o Law enforcement wears PPE at work place. o Issue violation card

3. Poor Housekeeping

Finding: The storage of material in the wrong position and subtract to the way The poor condition of work area waste management The spread of welding rod

Action taken:


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o Assign cleaning team who placed at every work place o Perform daily housekeeping lead by supervisor after finish work o Highlight at Tool Box Talk related this topic by daily basis o Provide adequate fire protection equipment, to cover hazardous area when

welding, cutting, grinding and sand blasting work performed

4. Lack and Unsafe Equipment Operation

Finding: Used homemade tools that unsafe Lack of inspection to all equipment and tool

Action taken : o Removed unsafe equipment and tools from work place o Performed all equipments regularly

5. Improper Electrical Equipment/Tools

Finding: Improper connection cable for electrical Lack of inspection of electrical equipment Action taken: o Performed electrical equipment inspection regularly o Conducted basic electrical training

9. SUMMARY OF HSE PROGRAM IMPLEMENTATION

9.1 INDUCTION AND TRAINING

9.1.1 Induction HSE induction has conducted for all new hire including Visitor. In HSE induction all new hire were given information regarding safety rules and knowledge of HSE matters. During period June 2013 to October 2013, PTG HSE dept has been conducted induction for PTG & subcontractor and visitors.

9.1.2 Training In order to comply the Contractor and client requirement those are project employees are participating. During period June 2013 to October 2013, PTG HSE dept has been conducted training as per training matrix, training syllabus, training schedule and training need analysis. PTG has provided two training room which 20 seat capacity and equipped by computer and LCD projector and audio. (See Attachment 7 – HSE Training Record)


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PTG also have conducted some safety training with Topic: 1. Acceptance Scaffolding 2. HSE Awareness 3. Lifting and rigging practice 4. Job Risk Assessment 5. Radiography 6. Accident Incident investigation 7. First aid & CPR HSE passport has been implemented and recognized the workers who attended and participated the training. Also the attendances were given a certificate

9.2 JOB RISK ASSESSMENT

PTG – FMC for 1st Articles Project. HSE Department has proposed HIRADC/JRA issued at yard as required by client prior to commencement of specific work since All JRA has socialized to all workers prior execute the job. (See attachment 9 – Job Risk Analysis Record)

9.3 HSE AUDITS

HSE Audit is determined as follow: 1. HSE Internal Audit 2. Internal audit integration Quality and HSE 3. HSE external by Third Party 5. HSE Audit for Subcontractor PTG was performed HSE Audit for all Sub contractor prior commencement the work. The external Audit from Sucofindo for SMK3, OHSAS 18001, ISO 14001 also to be held during execution project. PTG has awarded SMK3, OHSAS 18001, ISO 14001 certification.

9.4 HSE TRACKING RECORDS

HSE Dept has established a system for tracking the status finding of: • HSE Join inspection (QHSE Management Walkthrough) • Equipment Inspection • HSE Audit

9.5 HSE INSPECTION PROGRAM

9.5.1 Join Inspection

FMC and PTG joint inspection on PTG operations and facilities was conducted regularly since June 2013 to October 2013. The corrective actions/follow up status is submitted to FMC regularly in weekly basis. The participants were FMC Project Management Team and PTG Project Management and conducted HSE management review meeting after yard walk around. (See Attachment 10 – QHSE Management Walkthrough)


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9.5.2 Equipments, Tools Inspection To ensure all equipment & tools is used in safe and proper condition therefore the inspection has to perform regularly. The equipment & tools inspection is performed by Safety inspector and yard facility inspector as per schedule, the inspection including: 1. Lifting gears applied as color code. 2. Heavy vehicles such as : Cranes, Loaders, forklift, trailer, excavator 3. Electrical equipments such as : Generator set, 4. Powered tools and hand tools 5. Scaffolding and accessories 6. Equipment such as : Compressor, Air receiver tank 7. Light vehicles 8. Firefighting equipment 9. Gas cylinders and accessories 10. Welding equipment and accessories 11. Over Head Crane 12. Radiography equipments

9.6 HSE COMMUNICATION PROGRAM

9.6.1 Pre Start Job Meeting

Pre start job meeting was conducted by Safety personnel, Supervisors at yard with the workers in daily basis of each working shift before start work and the foreman have to fill the Pre job check list.

9.6.2 Tool Box Meeting

Toolbox meeting are conducted by PTG Safety and Supervisors in daily basis. The agenda was to review the incidents, Near miss cases occurred in the previous week and other safety issued if any. The main topic is generally decided in the weekly Safety Coordination Meeting with sub contractors based on the priority of the most critical and significant incident and/ or Near miss of the week.

9.6.3 Safety Coordination Meeting

This meeting is conducted by PTG in weekly basis attended by AGJV and PTG, in addition to the discussion of important safety issues, the topics of toolbox meeting in the coming weekly are decided also in this meeting.

9.6.4 Project Management Review Meeting


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Project Management Review Meeting was conducted by PTG Management in monthly basis and attended by PTG Top Management, Yard Manager, Yard Construction Manager, Corp HSE Manager or Project HSE Manager.

9.6.5 HSE Internal Meeting

HSE Internal Meeting was conducted by PTG corp HSE Manager in weekly basis and attended by All HSE personnel (Safety and Medic).

9.7 HEALTH AND HYGIENE

Health and hygiene matters is maintained and inspected by Medical doctor and Environmental officer with concern: 1. Aqua Maker for drinking water and supply all employee at the Yard. 2. To ensure the process of aqua maker meet the health and hygiene standard, the water

has been sent to third party laboratory for examination every month. 3. Canteen and kitchen. 4. The inspection is performed by PTG Doctor ,PTG GA Officer and Environmental Officer

by monthly basis

9.8 ENVIRONMENTAL IMPROVEMENT

All environmental matters have been improved with concern: 1. Noise mapping

Noise mapping have available as per the result of noise measurement at work place area.

2. Oil Spill Management Provide Secondary containment, Oil Absorbent and drip pan to prevent oil spill from generator set or compressor felt to the ground directly.

3. Hazardous material handling Give labeling at chemical containers, drums and cans to identify the potential hazard, provide MSDS box at each work shop and has socialized to workers.

4. Water spraying Water spraying used water tank was performed to prevent dust pollution impact when dry season coming at yard.

5. Environmental Awareness PTG has conducted environmental awareness, hazardous handling material, and Audit ISO version 14001 to increase the employee’s environmental awareness. A PTG employee also has attended external training and seminar such as: Oil Spill Management, Seminar of new environmental regulation of Banten Government.

6. Yard Facility Improvement PTG has improved yard facility such as: Upgrading Jetty 1, add new Office building, new access road, Parking area, boundary, new water drainage, TSA Chamber, RT Chamber, New clinic building, New temporary waste disposal building.


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9.9 HSE PROCEDURE DEVELOPED

PTG has improved and issued some HSE procedure and has approved by AGJV such as HSE Manual. (See attachment 11 – HSE Master Document Register)

9.10 HSE REPORTING SYSTEM

PTG have been implemented HSE Reporting System as required in Daily basis, Weekly basis and Monthly Basis. The Reporting System that issued to PTG and AGJV as a followed: HSE Performance Statistic input report include HSE Training record, HSE Inspection record,

Medical record, PPE stock, reported in Weekly basis. Environmental Report (included waste management, Oil spill management, and other

environmental matters) reported in Monthly basis.


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ATTACHMENT 1

HSE POLICY


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ATTACHMENT 2

YARD HSE ORGANIZATION

CHART


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ATTACHMENT 3

SUMMARY WORK PERMIT

Page 1

Cut Of Date : 24 October 2013

Date Time REQUESTER Spv./FM COORD. SAFETY

1 HPP/HSE/IX/FMC/13/01 High Pressure Potential

Workshop 1 Pre-Hydrotest for piping 24-Sep-13 24-Sep-13 07:30 - 17:00 25-Sep-13 25-Sep-13 CLOSED Donny N. Andy Siswadi


Workshop 1 Hyfrojetting 100 bar 25-Sep-13 25-Sep-13 13:30 - 17:00 26-Sep-13 26-Sep-13 CLOSED Donny N. Donny N. Siswadi


Workshop 1 Hyfrojetting 100 bar 26-Sep-13 26-Sep-13 12:00 - 17:00 27-Sep-13 27-Sep-13 CLOSED Donny N. Donny N. Sobari


Workshop 1 Hydrotest 1,000 Psi, During 8 hours

31-Sep-2013 31-Sep-2013 11:00 - 17:00 31-Sep-2013 31-Sep-2013 CLOSED Donny N. Donny N. Sobari

5 HPP/HSE/X/FMC/13/05 High Pressure Potential

Workshop 1 Hydrotest 1,000 Psi, 1-Oct-13 1-Oct-13 07:30 - 17:00 2-Oct-13 2-Oct-13 CLOSED Donny N. Donny N. Sobari


Workshop 1 Hydrotest 1,000 Psi, 2-Oct-13 2-Oct-13 07:30 - 17:00 3-Oct-13 3-Oct-13 CLOSED Donny N. Donny N. Sobari


Workshop 1 Flushing 3-Oct-13 3-Oct-13 07:30 - 17:00 4-Oct-13 4-Oct-13 CLOSED Donny N. Donny N. Sobari

8 LIFT/HSE/X/FMC/13/01 LIFTING Workshop 5 Lift for test manifold 4-Oct-13 4-Oct-13 07:30 - 17:00 4-Oct-13 4-Oct-13 CLOSED Donny N. Donny N. Sobari

9 LIFT/HSE/X/FMC/13/02 LIFTING Workshop 1 Load out manifold 24-Oct-13 24-Oct-13 10:00 - 12:00 24-Oct-13 24-Oct-13 CLOSED M. Zen Ardan Sobari

Prepared by,

Fitri IfonyHSE Engineer

1st Articles Project

WORK PERMIT REGISTER OVERALL

Period : September 2013 - October 2013

EXECUTION

NO. WORK PERMIT NUMBER

ACTIVITY LOCATION

PERSONNEL IN CHARGE

REMARKSDESCRIPTION OF WORKWork

Planned to start

Actual start

Valid Finish STATUS

PT. GUNANUSA UTAMA FABRICATORSPT. GUNANUSA UTAMA FABRICATORSPT. GUNANUSA UTAMA FABRICATORS


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ATTACHMENT 4

JRA RECORD

TRA Ref :Revision :

Date :Leader : M. Natsir

Description of the job :

Risks & Possible Accidents Scenario P HE IR P HE IR

1 Work on construction Yard 1.1Unfamiliar with the construction work activity, uncontrolled activities

Contact with hot metal particles, under load swinging by crane, use of tools improperly, etc.

4 3 12 1.1.1 2 3 6 Medium HR

1.1.2 Doctor of PTG

1.1.3 HR & HSE1.1.4 HR

1.1.5 Warehouse

1.1.6 Yard Manager

1.1.7 Warehouse

1.1.8 Supervisor

1.1.9 Doctor of PTG

1.1.10

1.2 Poor response for emergency case Mass panic, late evacuation 1.2.1 HSE

1.2.2 HSE1.2.3 HSE

2 Traffic Management 2.1 Vehicle movements Struck by vehicles, collision 4 3 12 2.1.1 2 3 6 Yard Manager

2.1.2 Yard Manager

2.1.3 Supervisor

2.1.4 Supervisor2.1.5 Yard Manager2.1.6 Yard Manager2.1.7 Yard Manager2.1.8 Yard Manager

2.2 Lack of information Collision 2.2.1 HSE

Ensure all working personnel are qualified and familiar with the construction activity

Ensure all working personnel have passed the medical examination prior to first day of workAll working personnel must complete safety inductionAppropriate trainings are conducted for all working personnelMandatory PPE (hard hat, eyewear, footwear, long sleeves shirt) must be worn when entering the construction YardAdditional PPE is selected and worn as per activity to be performed

No private or motorbike car allowed to go to siteProvide car parking away from siteControl the gateway from entry and exit vehicleApply speed limit at Yard (15 km/hours)

Place standard road signs in place where appropriate and visible

Clear the road access from any obstruction such as material storage to minimise reversing

Residual Risk

Responsible Person for Checking

Implementation

Toolbox Meeting is conducted regularly at the first shift and prior to commencing critical work Personnel who are going to do critical task such as scaffolder for work at height shall pass appropriate medical check conducted regularly

Emergency drill conducted regularly

Provide separate entry and exit gateways for pedestrians and vehicles

Risk CategoryAdditional Risks Reduction Measures

Acceptable Risk

Hazards

Permit to work established for critical tasks namely confined space entry, heavy lifting, radiography test, hydrotest, leak test, pressure test, excavation, working at height, energi isolationEnsure the lighting is adequate for work at night

Establish the emergency preparedness and response system

Designated Muster Points for evacuation are established

Ensure that drivers driving out onto public roads can see both ways along the footways before they move onto it

GENERIC HAZARD IDENTIFICATION & RISK ASSESSMENT (HIRA)FOR FMC SUBSEA FABRICATION

Location: Construction Yard, CilegonTRA-Yard-2013-001010-Jan-12

Install barrier between the road access and fabrication area

JRA Team :General Fabrication & Erection

TaskHazards - Risks & Possible Accidents Scenario

PT. Gunanusa Utama Fabricators

TRA Ref :Revision :




Residual Risk


Implementation


Acceptable Risk

Hazards






3 Using vehicles and mobile plant 3.1 Poor vehicles, mobile plant Failure vehicles, mobile plant 4 3 12 3.1.1 2 3 6 Medium Yard Manager

3.1.2 Supervisor3.1.3 Supervisor3.1.4 Supervisor

3.1.5 Supervisor

3.1.6 Supervisor3.1.7 Supervisor

3.2 Unsafe driving Collision 3.2.1 Supervisor

3.2.2 Driver/Operator

3.2.3 Supervisor

3.2.4 Supervisor



3.2.7 Yard Manager

3.2.8 Driver/Operator3.2.9 Driver/Operator3.2.10 Signalman

4 Material delivery 4.1 Poor loads arrangement Material fall from vehicles, injured person 4 3 12 4.1.1 2 3 6 Medium Supervisor

4.1.2 Supervisor

4.1.3 Supervisor

4.1.4 Supervisor

4.1.5 Supervisor

Select suitable vehicles or mobile plant for purpose

The vehicles have adequate visibility for driver/operatorVisibility aids such as mirror and CCTV providedEffective braking system and steering provided and functionHeadlights, horn, windscreen wiper and warning devices such as reversing alarm and sign lamp provided and functionSeat belt provided and functionInspection and maintenance conducted regularlyDriver/operator are competent person (trained and certified) as per class of machineDriver/operator conduct inspection of vehicle prior to use (daily basis)Driver/operator are in fit condition to work and medical examination will be check prior to commencing critical workDriver/operator are fully understand the operating procedure of the vehicleDriver/operator respect to speed limitsPark vehicle on flat ground with engine switched off, handbrake applied and use wheel chock if necessaryProvide designated turning areas if applicable to minimise vehicle reversingCheck the condition behind vehicle prior to reversingUse signalman to guide vehicles for reverse movementSignalman in safe position during reversing vehicles

Load platform, bodywork and anchorage points are appropriate for for the loadPut the material as per maximum load capacity of vehicleLoad placed on the center of gravity of load platform if applicable to keep the stability of vehicleThe larger and heavier load placed at the bottomWhen a load is stacked, the lower packages should be strong enough to support the others when the vehicle is braking, cornering or accelerating

TRA Ref :Revision :




Residual Risk


Implementation


Acceptable Risk

Hazards






4.1.6 Supervisor

4.1.7 Supervisor

4.2 Poor load restraint Material fall from vehicles, injured person 4.2.1 Supervisor


4.2.4 Supervisor

4.2.5 Supervisor

4.2.6 Supervisor

4.2.7 Supervisor

4.2.8 Supervisor


4.2.11 Supervisor

4.2.12 Supervisor4.2.13 Personnel

5 Loading and unloading materials 5.1 Crowded area Collision, turning vehicle 4 3 12 5.1.2 2 3 6 Medium Supervisor

5.1.3 Supervisor5.1.4 Driver/Operator5.1.5 Driver/Operator

5.1.6 Supervisor

5.2 Personnel move up and down the load platform Fall from height 5.2.1 Supervisor

5.2.2 Supervisor

Positioning vehicle so that it does not effect to vehicle stabilityApply braking system during loading and unloadingUse wheel choke if necessaryDetermine the exclusion zone during loading unloading activity and place barricade surround itSuitable means of access used to move up and down to load platform

The angle of lashing not exceed 60 degree from horizontal positionAt least one lashing every 1.5m along the length of the loadLashings must be protected against abrasion and or cutting by the use of corner protectors or protective sleevesSuitable dunnage as additional equipment to restraint loadBeware of crushing when opening the tie of load

Load and unload vehicle on level ground away from passing traffic, overhead hazards.

The load should be arranged so that it does not obstruct the driver’s field of vision including rear view through the driving mirrorsAppropriate securing equipments such as clamps, special bolts, steel wire ropes, chains, webbing harnesses, sheets, nets, ropes and shoring barsare available on vehicleThe securing equipment regularly inspected for wear or damageNo misuse for securing equipmentThe steel wire rope or other equipment should have safe working loadThe load must be packed tightly before applying the restraintsThe load must be checked for security and the lashings tested for adequate tensionCheck that cargo doors are locked and that locking mechanisms are in good condition.Lashings must be properly tensioned at all times using a tensioning device specified by the manufacturer of the lashing.

The access facilitates three points contact

The weight of heavy loads of small dimensions should be distributed across the vehicle platform by the use of load spreading devices. (e.g.. pallets, large wooden board etc.)

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5.3 Load positioning, unstable Material fall 5.3.1 Supervisor5.3.2 Supervisor

5.3.3 Supervisor

5.3.4 Supervisor5.3.5 Supervisor5.3.6 Supervisor5.3.7 Personnel

6 Lifting operations by crane 6.1 Failure of crane/lifting gears Fatality, Property Damage 4 4 16 6.1.1 4 3 12 Medium Supervisor6.1.2 Supervisor6.1.3 Rigger

6.1.4 Rigger

6.1.5 Rigger


6.2 Load fall down / drop object Property damage, Fatality, Injured person

6.2.1 Supervisor

6.2.2 Rigger6.2.3 Rigger6.2.4 Supervisor

6.3 Pinch point Personal injury 6.3.1 Rigger6.3.2 Supervisor

7 Using lifting gears 7.1 Poor lifting gear condition Failure lifting gear when in use 4 3 12 7.1.1 3 2 6 Medium Supervisor

Inappropriate lifting gears to 7.1.2 Supervisor

7.1.3 Supervisor

7.1.4 SupervisorEnsure that working load limit statement is stamped from manufacture

Ensure that safety signal work properly

Use tag line to control movement of lifted objectNo body under the load during liftingOnly competent & experience personnel who operate the crane

Pinch bar to be used to remove plate clamp on the groundWorkers to wear rigger gloves for protection

Conduct inspection regularly to ensure that lifting gears are in good conditionFind out the purpose of use for each lifting gears

Find out the correct way of each lifting gears

Crane to be checked prior to use by the operatorVisual inspection for sling & shackle to be done prior to useControl/check and make sure that the weight of the material is not over the SWL of crane & lifting gears

Nobody under the load during lifting

Only competent & experience personnel who operate the craneNo lifting activity during bad environment such as raining and darkClear access of over head crane at workshop

No roll off load out of vehicleNo load tied on an object to drag it off by moving the vehicleBeware of crushing when opening the tie of load

Use certified crane & lifting gears

Use appropriate means of unloading if the loads become unstable during transportExtended exclusion zone during such unloading activity

Check the load from movement prior to unloadingKeep the load on the position until unloading starts

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7.2 Incorrect sling configuration Load fall down 7.2.1 Supervisor

7.2.2 Supervisor

7.2.3 Supervisor

7.2.4 Rigger

7.2.5 Supervisor

7.2.6 Supervisor

7.2.7 Rigger

7.2.8 Rigger

7.2.9 Supervisor

7.2.10 Supervisor

7.2.11 Supervisor

7.2.12 Supervisor

7.2.13 Rigger

7.2.14 Rigger

8 Using lever hoist 8.1 Poor lever hoist Failure lever hoist when in use 4 3 12 8.1.1 3 2 6 Medium Supervisor

8.1.2 Supervisor

8.2 Poor application Chain break, shock pressure, object fall 8.2.1 Supervisor

8.2.2 User

Do not overload or perform excessive fixed dragging

Check the position of holder pawl

Understand the effect of sling angle on sling load or pull angle on beam loadEnsure the riggers are able to tie basic knots and hitchesWith two or more slings on hook, use shackle as supporting to sling balance

Use tag line for control, attached to the load

Consider the best method of slinging relative to weight, shape, center of gravity, lifting points and load stability

Ensure the load is secured

Avoid sharp bends, pinching and kinks in rigging equipment

Never wrap wire rope sling completely around a hook

Avoid bending the eye section of wire rope sling around corner or near any attached fitting

Block loose loads before unhooking

Stay back when slings are pulled out under the loads

Do not use deformed hook

Conduct check prior to use

Never wrap the crane hoist rope around the load

Never point-load a hook unless it is designed and rated for such use

Make sure the load is balanced in the hook

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8.2.3 User

8.2.4 User8.2.5 User8.2.6 User8.2.7 User

8.2.8 User

9 Using chain hoist 9.1 Poor chain hoist Failure chain hoist when in use 4 3 12 9.1.1 3 2 6 Medium Supervisor

9.1.2 Supervisor

9.2 Poor application Overload, load fall, chain break 9.2.1 Supervisor

9.2.2 User

9.2.3 User

9.2.4 User

9.2.5 User

9.2.6 User

9.2.7 User

9.2.8 User

10 Material handling and stacking by forklift truck 10.1 Wrong operation Material falling, forklift over

turn 4 3 12 10.1.1 2 3 6 Medium Supervisor

10.1.2 Operator

10.1.3 Supervisor

Keep the object into the saddle of hook

Do not unwind or wind the loadAvoid using two blocks for suspending a loadKeep the improper lever hoist in the storage

Conduct check prior to use

Do not use deformed hook

Do not overload the chain hoist

Keep the chain alignment with both of hooks

Do not step in under the load

Keep the chain alignment with both of hooks

Ensure the chain is free from kink or twist

Stop pulling when the load is 10 cm above the floor, check for break action

Do not get the load dragged against floor

Avoid using two blocks for suspending a load

Do not turn around the chain block as loaded

Do not pull up too far or pull down slamming fast

Suitable attachment i.e. fork extension or barrel clamp as per manufacturer instruction

Forklift completed with load backrest, overhead guard, audible warning and lightOperator restraint (seat belt) worn all the times

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10.1.4 Supervisor

10.1.5 Supervisor

10.1.6 Operator10.1.7 Operator10.1.8 Operator

10.1.9 Operator

10.1.10 Operator

10.1.11 Operator

10.2 Unstable forklift position Material falling, forklift over turn 10.2.1 Operator

10.2.2 Operator10.2.3 Operator

11 Manual Handling 11.1 Wrong position Back Injury 4 2 8 11.1.1 2 2 4 Low Supervisor

11.1.2 Supervisor

11.1.3 Supervisor

11.1.4 Worker

11.1.5 Worker11.1.6 Worker11.1.7 Worker11.1.8 Worker11.1.9 Worker

12 Material storage at yard 12.1 Flammable liquid (fuel, oil) Fire, explosion 4 3 12 12.1.1 2 3 6 Medium Supervisor

12.1.2 SupervisorPlace the tanks into secured designated area that away from construction area

Try to avoid heavy lifting especially repetitive lifting over a long Pay attention for moving heavy objects, awkward load shapes,

strenuous pushing and pulling, stacking above shoulder height, uncomfortable working positions, repetitive work (eg packing) and use of excessive forceUse hand handle to lift the load if applicableEnsure no obstruction of sight when handlingAvoid lifting carrying object with awkward positionDo not lift a load not exceed 20 kgApply good handling technique for lifting equipment

Keep the flammable liquid in the appropriate tanks

Avoid violent braking or sudden change of directionWhere possible, travel with the fork arms lowered to within 150 mm (6’’) of level ground and mast tilted slightly backWhen loaded, travel down or up slopes with the fork arms facing uphillBefore raising a load ensure there is sufficient clearance overhead to do so and that objects which could fall and injure people nearby will not be dislodgedBefore the mast/boom is raised/lowered or extended, the truck should be stationary with the parking/handbrake applied and transmission disengaged before the hydraulics are used.No stacking or destacking allowed on incline positionAdjust the fork spread to suit the load

Avoid the need to move loads manually

Fully utilise mechanical handling devices, eg lift trucks, pallet trucks, trolleys

The rate capacity marked on attachmentNobody allowed to be lifted by forklift truck unless using certified safe working platformLower the fork on the ground when parkingNo over reach or over load when loading

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12.1.3 Supervisor12.1.4 Supervisor12.1.5 Supervisor12.1.6 Supervisor

12.1.7 Supervisor

12.2 Compressed gas cylinder Gas leak, fire, explosion 12.2.1 Supervisor12.2.2 Supervisor12.2.3 Supervisor12.2.4 Supervisor

12.2.5 Supervisor

12.3 Tubular steel (pipe, scaffolding pipe) Rolling pipe, material damage 12.3.1 Supervisor


12.4 Non tubular steel (beam, channel)

Stacked material collapse, material damage 12.4.1 Supervisor


12.5 Garnet mesh Dust 12.5.1 Supervisor12.5.2 Supervisor

12.6 Paint and solvent Fire, explosion 12.6.1 Supervisor12.6.2 Supervisor12.6.3 Supervisor12.6.4 Supervisor12.6.5 Supervisor12.6.6 Supervisor

13 Electricity 13.1Contact with live equipment, poor installation, faulty equipment, source of ignition

Electric shock, burns, electric arc, fire and explosion 4 3 12 13.1.1 2 3 6 Medium Supervisor

13.1.2 Supervisor

Personnel wear appropriate masker when work in the room

Ensure the electrical installation is safe as per suitable standard

Sort the position orderly and tidyKeep the garnet in the bag prior to usePut the bag on pallet to make it tidy and orderlyKeep the material in designated roomEnsure the room is well ventilatedNo smoking area applied for the room

Keep the paint into designated drum or container prior to useProvide designated waste bins for contaminated material of paints

Personnel working on electrical equipment or system are competent person

Use lifting lugs to lift the basket otherwise use forklift truck Keep the basket in safe clear distance from hot work activity otherwise protect it by fire blanket

Put the pipes on appropriate support placed on the level ground

Put scaffolding pipe on designated rackUse appropriate stopper under stacked pipesUse appropriate clamp to lock pipe movementsPlace barricade or other barrier surround the stacked pipes

Put the material on appropriate support placed on level ground

Put small size materials on pallet

Provide adequate suitable fire extinguishers in the storage areaOnly authorised person could enter the storage areaPlace appropriate warning sign Maintain the drainage of spillageUse small locked drum or container and put it away from hot work activity when it is in use on construction or maintenance activity Put the cylinder in upright position all the times Keep the cylinder in appropriate basketEnsure the basket in stable position

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13.1.3 Supervisor13.1.4 Supervisor13.1.5 Supervisor13.1.6 Supervisor13.1.7 Supervisor

13.1.8 Supervisor


13.1.12 Supervisor

13.1.13 Supervisor13.1.14 User

13.1.15 Supervisor

14 Using powered equipment 14.1 Use improper equipment Electrocute, electric shock 4 3 12 14.1.1 2 3 6 Medium Supervisor

14.1.2 Supervisor

14.1.3 Supervisor

14.1.4 Supervisor

14.2 Unsafe electrical supply Overheating, source of ignition

14.2.1 Supervisor

14.2.2 Supervisor

14.2.3 SupervisorUse Residual Current Devices (RCD) on electrical supply with tripping current < 30 mA

Position any trailing wires so that it avoid trip hazard or get damaged

Use suitable equipment for working environmentUse wireless equipment to eliminate electrical risk if applicableUse adequate insulated equipment

Check that the electrical equipment is suitable for electrical supply

Check the equipment is in good condition

Check the plug is in good condition and is properly secured with no internal wire visibleCheck the electrical cable is not damaged, not repaired with insulating tape or unsuitable connector

Check the electrical supply is safe to use

Provide adequate socket outlet to prevent overloading socket

Provide clearly marked switch on equipmentFor earthing cable, the end of cable firmly clamped to stop wire pulling out of the terminal

No work on live equipment or installation unless permit to work has been approved

Use proper connector to joint the length of cableProtect light bulb or other equipment that could be easily damaged Limit the supply voltage to the lowest neededEnsure the main switchboard, socket outlet or equipment are equipped with RCD that have rated current tripping not more than 30 mARegular inspection and maintenance conductedPre-use check conducted by user

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15 Working on live equipment 15.1 Unplanned work

Contact with energy (electricity, mechanical, rotating equipment, stored energy, pressure)

4 4 16 15.1.1 3 2 6 Medium Supervisor

15.1.2 Supervisor

15.1.3 Supervisor

15.1.4 Supervisor

15.1.5 Supervisor

15.1.6 Supervisor

15.1.7 Supervisor

15.1.8 Supervisor

15.1.9 Supervisor

15.1.10 Supervisor

15.1.11 Supervisor

15.1.12 Supervisor

15.1.13 Supervisor

15.1.14 Supervisor

15.1.15 Supervisor

15.1.16 Supervisor

15.1.17 Supervisor

15.1.18 Supervisor

If a plug has been withdrawn, ensure that it can not be reconnected

If a fuse has been removed, ensure that it can not be reinserted

Post notice to let everyone knows that work is being done

Completed the notice with name of person working and contact number

Test the isolated equipment to ensure the power is off

Provide appropriate protective equipment

Isolate the lived equipment or relevant part with it

Ensure the means of disconnection is secured by safety lock having unique key

Identify the circuit or equipment to be worked

Know the drawing of electrical system for details information and work to be donePlan and manage the work

Specify correct system of work and its procedures

Only trained person can do this job and specify level of supervision

Propose appropriate work permit prior to work

Use earthing devices if necessary

Ensure the equipments have adequate working space, access and lighting

Provide appropriate information, tools and instrument

Disconnect the equipment from any source of electrical energy

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15.1.19 Supervisor

15.1.20 Supervisor

15.1.21 Supervisor

16 Using hand tools 16.1 Flying debris, broken handle when using cold chisel Injury 3 2 6 16.1.1 3 1 4 Low Supervisor

16.1.2 User16.1.3 User

16.2 Flying head, broken handle when using hammer Injury 16.2.1 User

16.2.2 User

16.2.3 User

16.2.4 User

17 Using pneumatic tools (blasting, painting, chipping) 17.1 High pressure Personal injury 4 2 8 17.1.1 2 2 4 Low Supervisor

17.1.2 User17.1.3 User17.1.4 User17.1.5 User17.1.6 User17.1.7 User17.1.8 Supervisor17.1.9 User

18 Cutting by torch 18.1 Sparks, spatter Fire, burn, explosion 4 4 16 18.1.1 3 2 6 Medium Supervisor

18.1.2 User

18.1.3 Supervisor

Apply a permit to work after all precautions have been taken, especially for high-voltage systemRemove all safety lock used for securing equipment when work has finished

Close work permit when work has finished

Disconnected the power when replacing anythingConduct inspection regularly

Replace damaged handle or stemHit the target with head of sledgehammer to avoid weakening the stem and flying headAs with any striking or struck tool, use eye protection when using sledgehammer

Used to cut or shape soft metals as well as concrete and brick

Avoid using the chisel with mushroom head, it should be ground offUse hand gloves and eye protection when using chisel

Ensure that head is secure and tight prior to using it

Proper PPE to be use while working with pneumatic tools.

Flash back arrestor/check valve is installed on both cutting torch & regulatorSecured the connection between hose to cylinders & hose to cutting torch by proper mechanical clampsOxygen & LPG cylinder stored on the rack

Only trained person allowed to operate pneumatic tools

Marked capacity of power tools is readibleKeep all tools in good condition with regular maintenanceUse the right tool for the jobExamine each tool from damage before useOperate according to the manufacturer's instructions

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18.1.4 User

18.1.5 User

18.1.6 User18.1.7 User

19 Compressed gas handling 19.1 Flammable gas, oxydizing gas, toxic gas, akwark shape

Fire, Explosion, Personal Injury 5 3 15 19.1.1 2 2 4 Low Supervisor

19.1.2 User

19.1.3 User

19.1.4 User

19.1.5 User

19.1.6 User

19.1.7 User

19.1.8 Supervisor

19.1.9 User

19.1.10 User

20 Grinding/ Cutting by grinding machine 20.1 Electricity Electric shock 4 3 12 20.1.1 2 3 6 Medium Supervisor

20.1.2 Supervisor Electrician20.1.3 User20.1.4 User

20.1.5 User

20.1.6 Supervisor20.1.7 User20.1.8 User

20.1.9 Supervisor Electrician

20.1.10 User

20.1.11 User20.1.12 Supervisor

Good electrical cable insulation and groundingThe electrical cable has been tested & tagged

Only trained person that allowed to operate powered tools

Keep all tools in good condition with regular maintenanceExamine each tool from damage before use

Always turn the gas supply off at the cylinder when the gas is not in use

Operate according to the manufacturer's instructionsMandatory PPE + faceshield to be use while working with powered tools.

Put cylinders in the appropriate rack/ basket

Regularly check all connections from fault and leaksAvoid taking gas cylinder in to poorly ventilated rooms or confined spacesStore gas cylinders outside whenever possible or in a well ventilated placeNever allow oil or grease to come into contact with cylinder fittingsCylinder containing flammable gases, must not be stored in close proximity to open flames

Conduct test to check gas leak by soapy water Remove flammable materials from work area otherwise protect it by fire blanketProvide fire extinguisher and watchman to be stand byUse appropriate PPE (faceshield and glove)

Use hand glove for protectionTo ensure that all electrical cables & equipments are installed by designated trained electricianTurn off/unplugged the power of grinding machines during replacement the discEnsure cable insulation in good conditionProvide ELCB

Cylinders shall be stored protected from direct sunraysTo protect the valve during transportation, the cover cap should be screwed on hand tight and remain on until the cylinder is in place Cylinders should never be rolled or dragged when removing

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20.1.13 User20.1.1420.1.15

20.2 Flying small particles from the activity Eye injury 20.2.1 User

20.2.2 Supervisor

20.2.3 User

20.3 Grinding disc broken Injured personnel 20.3.1 User

20.3.2 User

20.3.3 User

20.4 Sparks come to flammable material Fire, burn 20.4.1 User

20.4.2 User

21 Welding, Gouging 21.1 Electricity Electric shock 5 3 15 21.1.1 5 2 10 Medium Supervisor21.1.2 Welder21.1.3 Welder

21.1.4 Welder

21.1.5 Welder

21.2 UV-IR-Light radiation Eyes and skin irritation 21.2.1 Welder21.2.2 Welder21.2.3 Welder

21.3 Fumes and gas Ill-health 21.3.1 Supervisor

21.3.2 Welder

Always be sure the work cable makes a good connectionsConnection shall be close as possible from the welding pointBe certain of a good electrical grounding

Use only approved grinding machine that has passed the inspection

Inspect equipment prior to useUse approved grinding disc onlyGrinding machine is equipped with dead man switch

Make sure grinding machine rotation speed (RPM) less than grinding disc allowable rotationProper replacing/installing/tightening grinding disk

Remove flammable materials from the area otherwise protect the materials by fire blanket. Keep the safe distance from the flammable material and grinding activityProvide portable fire extinguisher

Weld within a ventilated areaProvide blower when welding in confined space or where there is a risk that the concentration of fumes and gases could be too high, welder must wear individual breathing protection

Maintain the electrode holder, work clamp, welding cable and welding machine in good condition When working at height use full body harness to avoid falling down in case of electric shock

Use a shield with proper filterand cover platesUse suitable cloathing made from durable flame resistant materialProtect others by installing an appropriate screening

Use proper PPE for grinding activity: safety glass, face shield

Limitation access to the work areaUse spark shield during grinding activities for protection to other workers/visitors

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21.4 Sparks, spatter Fire and Burns 21.4.1 Supervisor21.4.2 Welder21.4.3 Welder

21.4.4 Welder

21.4.5 Welder

21.5 Noise Ill-Health (deft) 21.5.1 Supervisor21.5.2 Welder21.5.3 Welder21.5.4 Welder

21.5.5 Welder

22 Work in the extreme environment 22.1 Poor lighting Visual fatigue 3 3 9 22.1.1 3 2 6 Medium Supervisor


22.1.5 Supervisor

22.2 Exposure of dust, fume or gas Ill-health 22.2.1 Supervisor

22.2.2 Supervisor

22.2.3 Supervisor

22.2.4 Supervisor

22.3 Noise from machine operation, gouging activity Ill-health (deft) 22.3.1 Supervisor

22.3.2 Supervisor

22.3.3 Supervisor

22.3.4 Supervisor

22.3.5 Supervisor

Conduct inspection for the luminance

Provide proper respiratory protective equipment for employees

Inform all employee the need of using respiratory protective equipment in some certain workplaces

Look after the respiratory protective equipment given

Conduct inspection for using of respiratory protective equipment

Provide proper hearing protection for employees

Monitor the sound level at workplace

Inform all employee the need of using hearing protection in some certain workplace

Look after the hearing protection given

Make sure that sufficient fire extinguisher is availableWelding shields or barriers shall be used to protect workers from flashUse appropriate PPE for welding (appron, welding hand glove)

Use individual ear protectorInstall noise absorberScreen off noisy work areaUse quiter tools for grinding and removing slagUsing a suitable welding process and welding technique can minimise grinding and slag removal

Conduct inspection for using of hearing protection

Provide good light including natural light and avoid glare

Provide a good level of local lighting in place where necessaryProvide suitable form of lightingProvide special fittings for flammable and explosive atmosphere

Remove flammable material in the risk zoneScreen off the area

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23 Working at height 23.1Improper access, work area is not safe to prevent people from falling

Personnel falling, drop object 4 4 16 23.1.1 3 2 6 Medium Supervisor

23.1.2 Supervisor

23.1.3 Supervisor

23.1.4 Supervisor

23.1.5 Supervisor

23.1.6 Supervisor

23.1.7 Supervisor

23.1.8 Supervisor

23.1.9 Supervisor

23.1.10 Supervisor

23.1.11 Supervisor

24 Erecting and Dismantling scaffolding 24.1 Working at height, personnel

falling Injured person, Fatality 4 4 16 24.1.1 3 2 6 Medium Scaffolder

24.2 Scaffolding collapse Injured person, Fatality 24.2.1 Supervisor

24.2.2 Supervisor

24.2.3 Supervisor

24.2.4 Inspector

24.2.5 Supervisor

24.2.6 Supervisor

24.2.7 Supervisor

Avoid working at height

In existing place, provide appropriate permanent access and edge protection Provide work equipment with collective fall protection that protect all those at risk (scaffolding, MEWP)

Wear safety harness and hand gloves during erecting or dismantling scaffolding

Provide work equipment with collective fall protection that protect the individual (fall restrain system)Minimize distance and consequences of fall and protect all those at risk (nets, soft landing systemsMinimize distance and consequences of fall and protect the individual (fall arrest system, rope access)

Closure or segregate area from unauthorized people

Keep materials into the box or secure it

Use rope and pulley to move material up and down

Provide working at height awareness training

Only certified and competent scaffolder allowed to erecting or dismantling scaffolding Conduct inspection regularly (weekly basis)To use approved material scaffolding (tubing, wood plank and clamp)Applied tagging systemNo modification allowed without authorization from supervisors/inspector concernedInspector shall recertified acceptance of the scaffold after modification (if any)Scaffolding shall be connected to the permanent structure to prevent collapse

Use podium steps or ladders for light duty

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24.2.8 Supervisor

24.2.9 Supervisor

24.2.10 Supervisor

24.2.11 Supervisor

24.3 Material/tools dropped from height Injured person 24.3.1 Scaffolder

24.3.2 Scaffolder

25 Working on scaffolding 25.1 Personnel falling from height Injured person 4 4 16 25.1.1 3 2 6 Medium User

25.1.2 User

25.1.3 User

25.1.4 User

25.1.5 User

25.1.6 User

25.1.7 User

25.1.8 User

26 Wearing safety harness 26.1 Use improper safety harness Injured person 4 4 16 26.1.1 2 2 4 Low User

26.1.2 User

26.1.3 User

Check the tag of scaffolding prior to use

No one allowed to make a modification of scafffolding

Keep materials into the box or secure it

Use rope and pulley to move material up and down

Conduct visual check prior to use

Ensure the hook still function properly

Scaffolder must wear safety harness with double lanyard completed with shock absorber

Provide extra support as necessary

Stabilize by bracing & tightening to permanent structure

Design duty rating to the scaffolding

Contact scaffolder to repair or make modification of scaffolding

Do not climb on or lean over handrail, work on platform only otherwise provide fall arrest system

Do not overload the scaffolding, use scaffold as its duty rating

To ensure all tools and materials must be tied off and all small materials shall be stored in the basket and no dropping down any materials from high level Barricading system to be applied during erecting and dismantling scaffolding

Scaffolding must be based on firm, level foundation and avoid soft ground

Minimize storage material on work platform

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26.2 Hook not anchored Personnel falling 26.2.1 User

26.2.2 User

26.3 Incorrect method of using safety harness Personnel falling 26.3.1 User

27 Using ladder 27.1 Unstable or potential to slip position Personnel falling 4 4 16 27.1.1 3 2 6 Medium User

27.1.2 User

27.1.3 User

27.1.4 User

27.1.5 User

27.2 Insecure hand, feet and body position Personnel falling 27.2.1 User

27.2.2 User

27.2.3 User

28 Working above water 28.1 Lack of awareness People drowning 4 4 16 28.1.1 3 2 6 Medium Supervisor

28.1.2 Supervisor

28.1.3 Supervisor

28.1.4 Supervisor

28.1.5 Supervisor

28.1.6 SupervisorProvide buoyancy aids

Provide safe system of work

Worker must be properly trained

Provide suitable emergency equipment

Conduct visual and functional inspection

Keep lanyard being connected to safe anchor points

Keep lanyard as high as possible and away from the edge if possible

Remove snap hooks one by one to move around

Maintain three point of contacts

Do not overreach

Do not use top, second or three rung

Put ladder on level stable surface

Secure ladder position – hold it or tie it off at top

Use rule of thumb “one out for every four up” to get the correct angle

Used for light duty & short-duration work

Provide barrier as guard rail to stop people falling

Provide life jacket (with auto-inflating)

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28.1.7 Working personnel

29 Working with hazardous substances 29.1

Working with chemicals or products contain chemicals/ Activities generate fumes, dust, mists, vapors

Burn, asphyxiation, ill-health 3 3 9 29.1.1 2 2 4 Low Supervisor

29.1.2 Supervisor

29.1.3 User

29.1.4 Supervisor

29.1.5 Supervisor

29.1.6 Supervisor

29.1.7 Supervisor

30 Blasting/Painting 30.1 Dust Exposure Ill-Health 4 3 12 30.1.1 2 2 4 Low Worker30.2 Noise Ill-Health 30.2.1 Worker30.3 Broken Hose Personal Injury 30.3.1 Worker30.4 Hose realese from extension Personal Injury 30.4.1 Worker30.5 Expose by sand stain Personal Injury 30.5.1 Worker30.6 Eye Irritation Ill-Health 30.6.1 Worker

30.6.2 Supervisor

30.7 Contamination air in blasting hood 30.7.1 Supervisor

30.8 Chemical fire 30.8.1 Supervisor30.8.2 Supervisor

30.8.3 Supervisor

30.8.4 Supervisor

Arising alarm if anyone has fallen eg. using whistle and light

Use suitable maskerUse Ear ProtectionCheck the hose condition must be good before start to workEvery connection secured with anti whipUse long forearm uniform

Proper paint storage No smoking sign and MSDS shall be provided at paint storage and painting area. Risk and hazard of painting shall be socialized to crew based on MSDS recommendation

Ensure control equipments are in place and properly function eg local exhaust ventilationProvide emergency equipment such as eye wash near the workplaceProvide suitable hygiene facilities for decontaminating skin and facilities for cleaning personal protective equipment.Provide suitable means for disposal of the substance and contaminated materials only

Use safety glass Provide eye washChange the filter breathing carbon periodically (consult to manufacture instruction)Prohibited to smoking in painting area

Checking information that came with the product, eg a safety data sheet

User are trained to understand the information such as the symbols and hazardsWear appropriate PPE recommended by the safety data sheet

TRA Ref :Revision :




Residual Risk


Implementation


Acceptable Risk

Hazards






31 Confined Space Entry 31.1Existing of toxic gas, lack of oxygen, flammable and toxic residue

Toxicity, Asphyxiation, Fatality 4 4 16 31.1.1 3 2 6 Medium Supervisor

31.1.2 Supervisor31.1.3 Supervisor31.1.4 Supervisor31.1.5 Supervisor31.1.6 Supervisor31.1.7 Supervisor31.1.8 Supervisor31.1.9 Supervisor31.1.10 Supervisor

31.1.11 Supervisor


31.1.16 Doctor of PTG

32 Excavation 32.1 Live underground services Electric shock, explosion 4 3 12 32.1.1 3 2 6 Medium Supervisor

32.1.2 Supervisor

32.1.3 Supervisor

32.1.4 Supervisor

32.1.5 Supervisor

32.1.6 Supervisor

32.1.7 Supervisor

32.1.8 Supervisor

Trolley for rescue person must be available at the main holeMedical examination by doctor or paramedic prior to entering the confined space

Certified gas tester to performed gas testCheck gas content periodically with calibrated gas detectorControl ventilation systemCheck electric cable insulation systemProvide DC lighting or pneumatic lampPermanently stand by man on the man hole (Attendance) and he must be identified by hand armProvide breathing apparatus if necessaryProvide board for registering time in and out of entering person Provide rescue kits

Issued appropriate Permit to Work prior to work

Communicate permit to all affected personnel and postedAll person involved are competent to do the workAll source of energy affecting the space have been isolatedConduct gas test before entering confined space

Pinpoint any buried services by means of locating device to determine the possible locationOnly a well-trained or experienced person can use locating device

Get written confirmation of disconnection from the owner operation areaMake digging alongside or above the buried service by hand tools first i.e. spade, shovel

Use insulated hand tools for digging nearby the power line cable

Do not use buried service as hand or foot hold to climb out of the excavation

Provide accurate, clear, readable plans showing the locations of buried serviceAny doubt about identification of buried service, cables and pipes should be treated as if it were electricity cable and gas pipe until proved otherwise

TRA Ref :Revision :




Residual Risk


Implementation


Acceptable Risk

Hazards






32.1.9 Supervisor

32.1.10 Supervisor

32.1.11 Supervisor

33 Radiography 33.1 Using isotop Ionizing, Ill- health 4 4 16 33.1.1 3 2 6 Medium Supervisor

33.1.2 Supervisor33.1.3 Authorized Person33.1.4 Authorized Person

33.1.5 Authorized Person


33.1.8 Supervisor

Noted :P : ProbabilityHE : Hazard EfectIR : Individual Risk

Avoid large piece of rock or hard core for backfilling

The backfilling should be suitably compacted, use suitable support to the buried service if necessary

After backfilling, place sign indicating the presence of buried service

Provide rotary light when operation during night time

Issued Permit to Work

Keep the source into the locked isotop camera and put it into the appropriate designated pit (bunker) when not in useOnly appropriate person that handle the cameraCheck the source of isotope regularlyCheck periodically validity of ID card protectionCheck radiography exposure use survey meter before conduct radiography activityWarning sign and barricade to be installed


22

ATTACHMENT 5

MANAGEMENT WALTHROUGH

Gunanusa Yard, Cilegon PT. GUNANUSA UTAMA FABRICATORS

Telp. : +62254-500088 Fax. : +62254-500091

WEEKLY HSE WALKABOUT PROJECT: Subsea Manifold WALKABOUT NO.: 02 DATE/TIME: 18 July 2013 / 09.00 am

Attendees: FMC – Tey Arn Soon; Hadi Purwanto PTG – Iman Triwahyudi; Andi S.H; Wahyu Ardi; M. Natsir; Sabrawi;

NO LOCATION DATE OF FINDING FINDING RECOMMENDATION ACTION BY TARGET

DATE REMARKS

1 Subsea Manifold Fabrication Workshop No. 2

18 July 2013

Sulaiman Sarman 19 July 2013 Closed

Welding cable: • Should placed neatly (S-Shape)

• Hanger the provide


18 July 2013

Data Kususma 19 July 2013 Closed

Drilling Workbench: • At first, it was placed at unstable place

• Moved to above

ground and now

(stacked beam), stopped work by Mr. Tey.

welded to beam to have better stability.


18 July 2013

Herry Budiman 19 July 2013 Closed

Lighting: • Lack of lighting • Broken Lamp

• Lighting is

completed to repair


18 July 2013

Ondo Nababan 19 July 2013 Closed

Hose: • At first placed at passage way

• Moved to storage

area to prevent blockage


18 July 2013

Data Kusuma 19 July 2013 Closed Pallet: • Found have lost partial legs, unstable condition

• Discarded, then replace with the new one


18 July 2013

Siswanto 19 July 2013 Closed

High Pressure: • High Pressure without completed with antiwipe

• Has completed with antiwipe

Prepared by: Verified by: Acknowledgement by: Witness by:

Alnidi S. Bratanegara M. Natsir Iman Triwahyudi Corporate HSE Secretary

Tey Arn Soon Corporate HSE Manager Project Manager Asst. Fabrication Manager


23

ATTACHMENT 6

HSE MASTER DOCUMENT

REGISTER (MDR)

Date : 22-May-2013

No. Title of Documents Document No. Rev. Status Reviewed Date

1 HSE Management PlanID-GNU-FMC-47688727-

HSE-0001A IFC 22-May-13

2Personal Protective Equipment (PPE) Inspection, Controling Program and Distributuion System Procedure

ID-GNU-FMC-47688727-HSE-0002

A IFC 22-May-13

3Hazard Identification and Risk Assessment

ID-GNU-FMC-47688727-HSE-0003

A IFC 22-May-13

4 Generic Risk AssessmentID-GNU-FMC-47688727-


5 Lifting and Rigging ProcedureID-GNU-FMC-47688727-


6 Confined Space Entry ProcedureID-GNU-FMC-47688727-


7 Lifting and Rigging With CategoriesID-GNU-FMC-47688727-


8 Permit to Work ProcedureID-GNU-FMC-47688727-


LIST OF FMC HSE PROCEDURES

PT. GUNANUSA UTAMA FABRICATORS

Prepared by:

Alnidi Safarach Bratanegara

Corporate HSE Secretary

Acknowledge by:

M. Natsir

Coprporate HSE Manager


24

ATTACHMENT 7

LOAD OUT PICTURE

LOAD OUTSub Sea Manifold Picture


25

ATTACHMENT 8

INSPECTION REPORT

Inspection Report 1-2

SUBSEA MANIFOLD PROJECT

INSPECTION REPORT

: 2 UnitTruck Trailler : 6 Unit

Stand by Welding Rectifier (Cable Power not yet Connected)

Stand by Welding Rectifier (Ready for used)

Inspection – Welding Rectifier Green Tag Inspection Welding Rectifier

Inspection Report 2-2

Calibration date welding rectifier Inspection – Distribution Panel

Inspection – Distribution Panel Green Tag Inspection Distribution Panel

Inspection – Extension Panel Inspection – Extension Panel

Education

Fmc close out repot hse dept. rev.000