Hazard Identification, Risk Assessment & Safe Working Procedure for Installation of Instruments and Instrument Tubing

Project Title:
Site Address: / Cardiff Road, Barry, South Glamorgan, CF63 2YL
Client: / Dow Corning Ltd
PO Number:
Work Location:

Assessed By:

Print Name / Signature / Date Assessed / Assessment Review Date
Paul Bunyan / / 18/02/2014 / 17/02/2015

Approved By:

Print Name / Signature / Date Approved
Richard Jenkins /
Steve Tossell /
Physical Hazards / Y / Physical Hazards (Continued) / Y / Fire Hazards / Y
Airborne Dust / Fumes / ü / Explosive Materials
Access / Egress / ü / Flammable / Combustible Materials
Adverse Weather Conditions / ü / Flammable Atmospheres / ü
Aggression/Violence / Pyrophoric Material
Bullying / Sources of Ignition
Collapse of Equipment / Materials / Static Electricity
Confined Space Entry / ü
Crane Movements / Lifting / ü
Display Screen Equipment
Drowning
Electricity - Electric Shock / Burns / ü
Entanglement / ü
Equipment / Materials / ü / Other Hazards – Specify Below / Vulnerable Groups
Falling Objects / Materials from Height / ü / Environment - Waste Disposal / ü
Falls from Height (Working at Height) / ü / Process Pipework / ü / Expectant and Nursing Mothers
Gas Cylinders / Impulse Lines / Tubing / ü / Lone Workers / ü
Gasses / ü / Young Persons
High Pressures / ü
High Ambient Temperature
Hot Surfaces / ü
Housekeeping / Slips, Trips & Falls / ü
Low Ambient Temperature
Manual Handling / Ergonomic / ü / Biological Hazards
Moving Equipment/Machinery / ü / Blood Borne Pathogens / Body Fluids
Noise / ü / Hygiene/Welfare
Operating / Driving MEWP’s / ü / Legionella / ü
Oxygen Depletion / Enrichment / ü / Leptospirosis (Weils Disease)
Pneumatics / Hydraulics / ü
Poor Lighting / ü
Radiation
Sharp Objects / Chemical Hazards
Stress / Asbestos
Struck By / Against / Corrosive Chemicals / ü
Trapping Points / ü / Harmful Chemicals / ü
Underground Services / Irritant Chemicals / ü
Uneven Work Surfaces / Odorous/Noxious Chemicals
Use of Hand Tools / Power Tools / ü / Toxic Chemicals / ü
Vehicles / Transport / ü
Vibration

Hazard Identification

C&P Engineering Services Ltd / Ref. 13.2.11 / Rev. 1 / 31.07.12 / Page 12 of 16

Risk Assessment

Task: - “Installation of Instruments and Instrument Tubing”

The following risk assessment has been completed to ensure adequate controls are in place to eliminate or reduce the risk to as low as is reasonably practicable. In considering who may be harmed we have included C&P Employees, but for each task, depending on where it takes place, then further consideration should be given to others who may be affected by our activities e.g. other contractors.

L = Likelihood HR = Hazard Rating (with NO controls in place).

C = Consequence RR = Risk Rating (with controls in Place).

HAZARDS /

L

/

C

/

HR

/ WHO MAY BE HARMED / CONTROL MEASURES TO REDUCE THE RISK TO AS LOW AS IS REASONABLY PRACTICABLE / L / C / RR /
1. Airborne Dust - Some plants may expose technicians to windborne dust. / 5 / 3 / 15 / C&P Employees / Safety glasses or goggles to be worn at all times. / 1 / 3 / 3
2. Access and Egress on site / 5 / 5 / 25 / C&P Employees / Site Induction prior to job commencement. Authorisation to Work (permit) from client. Access and egress to each work area will be by roadways, fixed walkways and platforms at each process plant area. Access to some instruments may require working at height.
For working at height hazard controls please refer to C&P document reference 2.14.1 Working at Height Policy. / 1 / 5 / 5
3. Adverse Weather Conditions. Extremes of weather such as ice, snow, heavy rain, lightning storm etc. This is particularly important when working at height, using ladders, accessing/egressing steps and plant, driving on site. / 5 / 3 / 15 / C&P Employees / PPE in the form of warm clothing, good quality safety boots, waterproof exterior clothing. Ability to postpone jobs in extreme weather conditions i.e. high winds, torrential rain when working at height / 1 / 3 / 3
4. Working in Confined Spaces / 5 / 5 / 25 / C&P Employees / Site Induction. Site Authorisation to Work Permit. Confined Spaces permit. C&P watchman. Emergency rescue plan in place. RPE available and to be worn depending on ‘confined space’. Resuscitation equipment on standby. Specific tools required (discuss with Plant personnel).
Only trained and certified C&P operatives to enter confined spaces. / 2 / 5 / 10
5. Overhead Crane Movements causing struck by injuries. (Linked with working at height) / 4 / 5 / 20 / C&P Employees / Where overhead cranes move overhead, either isolate cranes (plant to isolate or with their permission) or bellman required to alert Employees to stop work and move away from area. / 1 / 5 / 5
6. Electricity - Contact with ‘live’ electrical components causing electrical shock, burns or electrocution. / 5 / 5 / 25 / C&P Employees / Only qualified and competent persons to work on electrical equipment.
All work on electrical equipment only to be carried out following isolation.
C&P Employees are competent to undertake the isolations. This must either be done at the local sub-station or at the fuse board.
For safe isolation please refer to C&P document reference 13.1.3 Safe Isolation Procedure for DEAD working on LV and ELV. / 1 / 5 / 5
7. Objects falling from Height / 5 / 5 / 25 / C&P Employees / Permanent metal toe boards on process plant working platforms and on MEWP’s. Good housekeeping across whole plant. When working at height area below to be cordoned off by use of bunting and signage to at least 10 metres. Items secured when being transported in a MEWP basket.
Discussion to take place at Induction to prevent other workers/contractors working immediately above Employees.
Where overhead cranes move overhead, either isolate cranes (plant to isolate or with their permission) or bellman required to alert Employees to stop work and move away from area. / 2 / 5 / 10
8. Falling from Height (Working at Height) / 5 / 5 / 25 / C&P Employees / Where access to work area only requires a “step up” of a few centimetres then this can be achieved on most levels. Where the need to work at height exposes the individual to a fall to danger then additional controls will need to be in place. These will involve scaffolding platforms. MEWP to be supplied and maintained to a high standard. Trained and certificated C&P operatives to operate the MEWP.
Where Instruments are at height and close to platform edges then scaffold extensions should be requested. The scaffold extensions should be erected by recognised Scaffolding Company.
Stepladders with handrails and Fibre glass ladders can be used in many locations where the work is of short duration and the height to work at is relatively low, ladders can be secured or footed and supported.
When working from stepladders near to platform edges and there has been NO scaffolding extensions attached to the handrail then full body fall arrest harnesses should be worn. Full body fall arrest harnesses are a last resort and should be worn in conjunction with other controls for working at height. / 2 / 5 / 10
9. Gas / Oxygen Depletion / 5 / 5 / 25 / C&P Employees / Individual gas monitors and procedures for evacuation from Process Areas. Regular Operational checks for gas leaks by trained and competent operators. Regular Planned Maintenance checks and repairs by client.
Site Inductions. / 1 / 5 / 5
10.Impulse Lines / Pneumatics / Hydraulics- high pressure, corrosive chemicals / 5 / 5 / 25 / C&P Employees / Where instruments involve impulse lines / pneumatics / hydraulics, they MUST be isolated prior to work commencement. Ensure isolation valves at tapping points are closed, isolate impulse lines at instrument manifold (if differential pressure ensure equalising valve is only opened AFTER closing high pressure and low pressure isolation valves and prior to opening drain valves/bleed screws. Be careful to open drain valves/bleed screws very slowly in the first instance and wear goggles and appropriate gloves whilst doing so)Do NOT assume impulse lines / pneumatics / hydraulics have been isolated – physically check i.e. tapping point isolation valves are closed, instrument manifold valves are closed, drain valves/bleed screws are open - open drain valves/bleed screws very slowly. / 1 / 5 / 5
11. Process Piping – In-line instruments, high pressure, corrosive chemicals / 5 / 5 / 25 / C&P Employees / Where instruments are mounted in process lines i.e. “in-line” the process line MUST be isolated and flushed out / cleaned / purged / spaded off (by client). C&P employees to discuss this with the client to make sure all precautions have been taken and Work Permit to include these precautions prior to work commencement. / 1 / 5 / 5
12. Hot Surfaces / 5 / 3 / 15 / C&P Employees / Hot pipe work lagged/insulated. Signage.
If working on high temperature instrumentation, allow cooling if possible and wear protective gloves. / 1 / 3 / 2
13. Slips, Trips and Falls due to poor housekeeping / 5 / 5 / 25 / C&P Employees / Good housekeeping practices across site by the client provides for a safe place of work. Clear concrete pathways, roadways and signage. Painted walkways. Good safety footwear. Audits by Plant personnel. C&P standards in housekeeping, safety contacts provided and more specific training. Removal of all waste. / 1 / 5 / 5
14. Manual Handling – carrying of equipment ladders, tools etc. / 3 / 3 / 9 / C&P Employees / Calibration instruments and hand tools are relatively lightweight (tools to be carried in single tool box). Removal of some Control Valves may be heavy. Individuals trained in Manual Handling techniques. Help required from Plant personnel or second C&P Calibration technician. Avoid Manual Handling where possible. / 1 / 3 / 3
15. Moving Machinery / Entanglement / Trapping points - controlled by Client / 5 / 5 / 25 / C&P Employees / Variety of operating machinery could be present in process areas. All moving parts to be guarded. No access beyond any guard or barrier protecting machinery. Permit to work in all plants. / 1 / 5 / 5
16. Noise / 5 / 3 / 15 / C&P Employees / Certain areas of plant will require mandatory Hearing Protection in the form of Ear Defenders.
Ear defenders to be worn prior to and during time spent in these areas.
Signage. / 1 / 3 / 3
17. Operating/driving MEWPS on site / 5 / 5 / 25 / C&P Employees / Trained and competent operators holding certificate for Driving and operating MEWPS.
Equipment to be fully maintained and inspected.
Driver to use harness at all times when driving on site or when working from MEWP basket at height.
When stationary prior to work commencing outriggers must be fully deployed on solid, level ground. If ground is soft or uneven, boards are to be placed under outrigger legs.
Whilst working at height, operator is to control movement of basket from the basket and not the floor.
Operators working from basket not to over-reach or lean out of basket.
Under no circumstance are operators to exit the MEWP basket as a means of access to a place above ground level (except in an emergency). All loose equipment placed in the basket for use will be secured to ensure they cannot fall. The area around the base of a MEWP will be bunted and have cones to prevent collision from other vehicles and road users and also to prevent persons working or walking underneath. / 1 / 5 / 5
18. Lighting / 5 / 5 / 25 / C&P Employees / Good plant lighting. Where plant lighting is poor, obtain temporary lighting, torch or head lamp may be used in non-hazardous areas (non-explosive atmosphere check with client personnel).
If working in potentially explosive atmosphere, torch or headlamp may be used providing they are certified to be used in explosive atmospheres. Permission to be granted by Client personnel and hot work permit may also be required. / 1 / 5 / 5
19. Use of hand tools and power tools / Entanglement / Trapping points – most calibration tools are not powered but there may be a requirement to use powered tools in the workshop or laboratory. / 3 / 5 / 15 / C&P Employees / Drills and other power tools will be battery operated. Where this is not reasonably practicable then low voltage mains will be required (110v). See electrical controls above. PAT testing of mains operated tools. Secure cables. Non-Adjustable Spanners required in some plants (check at Induction).
No loose clothing or jewellery near to rotating chuck.
All hand tools to be clean and in good working order. / 1 / 5 / 5
20. Vehicles and Transport – travel to site and use on site internal roads / 5 / 5 / 25 / C&P Employees, other road users / Use of company vehicles. Fully maintained vehicles with current MOT and insurance. Competent drivers holding appropriate licence for the vehicle. Vehicle pre-flight checks. All calibration equipment and tools stored safely in vehicle.
Restricted access to site – only authorised vehicles. Road signs, road traffic standards, high way code. Pedestrian crossings.
Park in designated parking areas only. / 2 / 5 /

10

21. Legionella / 2 / 5 / 10 / C&P Employees / Depending on site location of instruments to be calibrated. Client to provide information on potential Legionella presence by providing COSHH risk assessments. Wearing of RPE. / 1 / 5 / 5
22. Contact with Chemicals on site - Different Process areas manufacture and use different types of chemicals i.e. toxic, corrosive, harmful etc. / 5 / 4 / 15 / C&P Employees / Comprehensive Permit to work form required for all jobs undertaken on chemical sites. Client to provide details of hazards and precautions necessary for each process area including COSHH risk assessments.PPE in the form of chemical gloves to be worn on some sites. / 1 / 4 / 4
23. Fire- flammable atmospheres, sources of ignition / 3 / 5 / 15 / C&P Employees / No sources of ignition to be used or taken on to plant areas without a valid Work Permit for the task
Some situations may require minor hot work but it is very unlikely. Agree any hot work necessary with client – agree permit required for hot work.
Fire extinguishers and fire watchmen at area of hot work. Trained competent operators.
Familiarisation with Plant specific Emergency Procedures and assembly points. / 1 / 5 / 5
24. Lone Workers - Many of the Routine Operational checks are required to be completed by one person. Lone Workers, if injured, are more likely to go undetected and could exacerbate the seriousness of the injury due to delays in rescue and treatment. / 5 / 5 / 25 / C&P Employees / Trained and competent operators. Personal radio or mobile phone (if working in potentially explosive atmosphere equipment MUST be certified). Personal gas monitor in some plants. Plant alarms. Call stations.
C&P lone worker policy and established protocol to call in to supervisor at regular intervals. / 1 / 5 / 5
25. Environment - waste disposal / 2 / 4 / 8 / Environment / Responsibly dispose of all generated waste by using client’s on site recycling facilities. / 1 / 2 / 2
C&P Engineering Services Ltd / Ref. 13.2.11 / Rev. 1 / 31.07.12 / Page 12 of 16