Risk Assessment Matrix. By: Brent McCarty and Ricky Lautzenheiser

Transcription

1 Risk Assessment Matrix By: Brent McCarty and Ricky Lautzenheiser

2 Introductions/Credentials Ricky Lautzenheiser Marathon Electrician 16 years Rewind Electrician 6 years Navy Nuclear Electrician 6 years Brent McCarty Safety Professional 5+ Years CSP DOT Coordinator Volunteer Firefighter Worked as a Shift Supervisor

3 Objective During this training we will cover: RAMSCORE Expectations Invasive Work Scenarios

4 Background The Risk Assessment Matrix (RAM) Is a Hazard Assessment tool designed to help mitigate risks while preparing and performing maintenance on equipment. It answers the questions: What is the proper PPE? What mitigation steps are required? What are the Hazard? It Bridges Hazard assessment gaps by taking the Guess Work out.

5 The Why Behind It Workforce Turn-over Younger Work Force Less Experience Variances in Experience Increase in Hazard Recognition related incidents and near misses. Gaps identified in Permit Writers Hazard acceptance levels. Performing work with multiple crafts with varying work experience.

6 The Why Behind It Experiment Volunteer with NO Oil and Gas Experience Minimal Safety Experience What are the Top 3 Hazards in your Industry? What are the Top 3 Hazards in our Industry?

7 Expectations Past: I THINK WE USED TO I M PRETTY SURE THAT COULD BE RIGHT Future: Utilize RAMSCORE Refer to the Safe Work Practices Review the Training Lesson Plans Ask a Crew Member/Supervisor/Safety Professional STOP!

8 Invasive Work What is Invasive Work? Invasive work is any work that results in exposure to the internals of a vessel, pump, exchanger or any piece of refinery equipment. What is inside the pipe!

9 Who needs a RAM Score? The RAM Score must be done before any invasive work is performed (Operations or Maintenance) Example: Removing a bull-plug Pulling a filter that is plugged Breaking a Flange Pulling a Motor The RAM Score is conducted during Equipment Preparation as well as during Maintenance.

10 Safe Equipment Preparation Steps Isolate equipment from the process RAM before pulling bull-plugs / connecting gauges and tubing Verify isolation valves are holding Decon equipment to safe location Energy Isolation of equipment Gas Test equipment RAM equipment for maintenance Issue Permit for equipment

11 Risk Assessment Matrix Value Exposure Concern 1 IDLH Atmosphere 1 Material Above Auto Ignition 2 Corrosives Acid/Caustic 2 Over PEL, STEL or 1-10% of LEL 3 Hot Service Above 140 F 10 Other Material ORD Technician Level Invasive Work Risk Assessment Matrix Value Exposure Volume 1 Live Equipment 1 Large Volume Value Exposure Impact 1 Large Impact 2 Medium Impact 2 Medium 3 Small Impact Volume 3 Small Volume 4 Low Impact 4 Low Potential 5 No Impact 6 Bleeder Volume

12 Risk Assessment Matrix Volunteer s What Industry are you in? What is your Top Exposure Concern?

13 Exposure Concerns 6 Categories IDLH Atmosphere: Immediately Dangerous to Life and Health concentration Materials Above Auto Ignition: Equipment or piping that contains materials that will auto-ignite upon contact with atmosphere Corrosives : Equipment or piping systems that contain material with any caustic, acid or KOH mixture Over PEL, STEL or 1-10% LEL: equipment or piping systems that contain material that is above the permissible exposure limit, short term exposure limit or between 1% and 10% of the LEL limit Hot Service Above 140 F: equipment of piping systems that contain material that is above 140 degrees F. Other Material: utilities such as air and water that are low temperature and low pressure or any steam that does not meet any of the exposure concerns listed above.

14 Exposure Volume 6 Categories Live Equipment: Any equipment or piping circuit that is still in service or not completely isolated. Large Volume: Towers, Vessels, Receivers and Large Bore piping circuits Medium Volume: Knock-out drums, Pumps, Compressors and Piping systems Small Volume: Transmitter impulse lines, Sight glass assemblies, Sample stations and Small bore piping Low Potential: All volumes that have been quantifiably decontaminated or live equipment that is in operations exclusive control Bleeder Volume: Volume contained between a standard isolated bleeder of less than 1 and its plug or cap

15 Exposure Impact 5 Categories Large Impact: Could have off-site impact Medium Impact: Could have a refinery wide impact Small Impact: Could have an impact contained to the local unit Low impact: Could have a localized impact at the Invasive work site No impact: No negative impact to the invasive work site

16 Using RAM Score for Mitigation Example: Job has an. Exposure Concern = 1 Exposure Volume = 3 Exposure Value = 4 RAM Score = 1 x 3 x 4 = 12 So, Level 1 Mitigation is needed

17 Level 1 Mitigation Inhalation Hazard Mitigation Breathing Air Level 1 Mitigations Corrosive Material Hazard Mitigation Chemical Resistant Suit (Refer to the ORD PPE Selection Guide) Face Shield & Goggles Material Above Auto-Ignition Temperature Verify isolations and cool down below Auto-Ignition Temperature before doing invasive work Fire or Hot Oil Hazard Mitigation Bunker Gear Heat Resistant Protective Clothing (Refer to the ORD PPE Matrix Miscellaneous Mitigations (Can be used with any of the above Mitigations) Bleeder Cleaner Tool Face Shield, Goggles and Protective Clothing (Refer to the ORD PPE Matrix

18 Level 2 Mitigation Level 2 Mitigations Inhalation Hazard Mitigation Eductor to dilute and/or move toxic emissions from the work area. Air Purifying Respirator (Refer to the ORD PPE Matrix) Route Potential Source to Safe Location using tubing or pipe. Corrosive Material Hazard Mitigation Chemical Resistant Suit (Refer to the ORD PPE Matrix) Face Shield & Goggles Hot Service (Above 140 Degree F)Mitigation Route Potential Source to Safe Location using tubing or pipe. Heat resistant Protective Clothing (Refer to the ORD PPE Matrix Miscellaneous Mitigations (Can be used with any of the above Mitigations) Bleeder Cleaner Tool Face Shield, Goggles and Protective Clothing (Refer to the ORD PPE Matrix

19 Level 3 Mitigation Class D PPE Standard work practices Class D (Basic Level) PPE Includes: FR Clothing Cut Level 3 Gloves Safety Glasses Hardhat Safety Toed Footwear Ear Plugs H2S PAM

20 Practice Exercises RAM Score Practice Do We Have Anymore Volunteers?

21 Scenario #1 Details: 1. You will be performing invasive work on a Caustic Treater Pump. 2. You are tasked with decontamination of the pump in preparation for maintenance. 3. The equipment can be successfully isolated from the process and is not Live Equipment. Brent 2 X 2 X 3 = 12 Level 1 Mitigation Ricky 4. WHAT IS YOUR RAMSCORE? 2 X 2 X 4 = 16 Level 2 Mitigation

22 Scenario #1 Level 1 Mitigation Level 2 Mitigation

23 Scenario #2 Details: 1. You will be performing invasive work on a leaking sample station. 2. You are tasked with replacing 2 ft. of tubing on the sample station. 3. The equipment can be successfully isolated from the process and is not Live Equipment. 4. There is residual product in the tubing resulting in a 4% LEL on your 4 gas meter. Brent 2 X 3 X 4 = 24 Level 2 Mitigation Ricky 2 X 3 X 5 = 30 Level 2 Mitigation 5. WHAT IS YOUR RAMSCORE?

24 Scenario #2 Level 2 Mitigation

25 Scenario #3 Details: 1. You will be performing invasive work on a leaking sample station. 2. You are tasked with replacing 2 ft. of tubing on the sample station. 3. The equipment can be successfully isolated from the process and is not Live Equipment. 4. There is residual product in the tubing resulting in a 92% LEL on your 4 gas meter. Brent Not performing any work >10% LEL Ricky Just wait for Safety to go home! 5. WHAT IS YOUR RAMSCORE?

26 Scenario #4 Details: 1. You will be performing invasive work on a Slurry Pump. 2. You are tasked with pulling the strainer, cleaning it, and re-installing it. 3. The equipment can be successfully isolated from the process and is not Live Equipment. 4. The Slurry is sitting at roughly 300 deg. Brent 3 X 2 X 3 = 18 Level 2 Mitigation Ricky 3 X 1 X 3 = 9 Level 1 Mitigation 5. WHAT IS YOUR RAMSCORE?

27 Scenario #4 Level 1 Mitigation Level 2 Mitigation

28 Questions?

29 Extras How Many Mitigation Levels are there? What is the trigger for a RAMSCORE? What Mitigation Level is the least stringent? What % LEL is the cutoff for work? What is considered Hot Service? How Long has Ricky worked for Marathon? Who is a better presenter Ricky or Brent?