C&P ENGINEERING SERVICES LTD. Hazard Identification, Risk Assessment & Safe Working Procedure for Installation of Unistrut, Ladder Rack and Cable Tray

Transcription

1 Hazard Identification, Risk Assessment & Safe Working Procedure for Installation of Unistrut, Ladder Rack and Cable Tray Project Title: Site Address: Client: PO Number: Work Location: Cardiff Road, Barry, South Glamorgan, CF63 2YL Dow Corning Ltd Assessed By: Print Name Signature Date Assessed Assessment Review Date Richard Jenkins 18/02/ /02/2015 Steve Tossell 18/02/ /02/2015 Approved By: Print Name Signature Date Approved Paul Bunyan C&P Engineering Services Ltd Ref Rev Page 1 of 15

2 Hazard Identification Physical Hazards Y Physical Hazards (Continued) Y Fire Hazards Y Airborne Dust / Fumes Explosive Materials Access / Egress Flammable / Combustible Materials Adverse Weather Conditions Flammable Atmospheres Aggression/Violence Pyrophoric Material Bullying Sources of Ignition Collapse of Equipment / Materials Static Electricity Confined Space Entry Crane Movements / Lifting Display Screen Equipment Drowning Electricity - Electric Shock / Burns Entanglement Equipment / Materials Other Hazards Specify Below Vulnerable Groups Falling Objects / Materials from Height Environment - Waste Disposal Falls from Height (Working at Height) Process Pipework Expectant and Nursing Mothers Gas Cylinders Impulse Lines / Tubing Lone Workers Gasses Young Persons High Pressures High Ambient Temperature Hot Surfaces Housekeeping / Slips, Trips& Falls Low Ambient Temperature Manual Handling / Ergonomic Biological Hazards Moving Equipment/Machinery Blood Borne Pathogens / Body Fluids Noise Hygiene/Welfare Operating / Driving MEWP s Legionella Oxygen Depletion / Enrichment Leptospirosis (Weils Disease) Pneumatics / Hydraulics Poor Lighting Radiation Sharp Objects Chemical Hazards Stress Asbestos Struck By / Against Corrosive Chemicals Trapping Points Harmful Chemicals Underground Services Irritant Chemicals Uneven Work Surfaces Odorous/Noxious Chemicals Use of Hand Tools / Power Tools Toxic Chemicals Vehicles/Transport Vibration C&P Engineering Services Ltd Ref Rev Page 2 of 15

3 Risk Assessment Task: - Installation of Unistrut, Ladder Racks & Cable Trays 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, 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 C = Consequence HR = Hazard Rating (with NO controls in place). RR = Risk Rating (with controls in Place). 1. Airborne Dust - Some plants may expose employees to windborne dust C&P 2.Access and Egress on site C&P Safety glasses to be worn on site at all times. Safety goggles must be worn in designated red and white striped areas. All areas of plant require a comprehensive Permit to work form for all jobs undertaken on DCL site except when working within office buildings. When working within office buildings a Job Card may be issued by the permit issuer/custodian of the building in place of a Permit to work. Access and egress to each working area will be by roadways, fixed walkways and platforms at each process plant area. Access and egress to the individual working areas will be from the platform or will be by one of the safe working at height methods described in the C&P Engineering Services Ltd Ref Rev Page 3 of 15

4 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 C&P 4.Working in Confined Spaces C&P 5.Overhead Crane Movements causing struck by injuries. (Linked with working at height) 6.Electricity - Contact with live electrical components causing electrical shock, burns or electrocution C&P C&P working at height section. For working at height hazard controls please refer to C&P document reference Working at Height Policy. PPE in the form of warm clothing, good quality safety boots, water proof exterior clothing. Ability to postpone jobs in extreme weather conditions i.e. high winds, torrential rain when working at height 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. Where overhead cranes move overhead, either isolate cranes (client to isolate or with their permission) or bellman required to alert employees to stop work and move away from area. Only qualified and competent persons to work on electrical equipment. All work on electrical equipment only to be carried out following isolation. C&P are competent to undertake the isolations. This must either be done at the local substation or at the fuse board C&P Engineering Services Ltd Ref Rev Page 4 of 15

5 7.Objects falling from Height C&P 8.Falling from Height (Working at Height) C&P For safe isolation please refer to C&P document reference Safe Isolation Procedure for DEAD working on LV and ELV. 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. Where overhead cranes move overhead, either isolate cranes (plant to isolate or with their permission) or bellman required to alert to stop work and move away from area. Where access to work area 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 work areas are at height and close to platform edges then scaffolding should be requested. The scaffolding should be erected by recognised Scaffolding Company C&P Engineering Services Ltd Ref Rev Page 5 of 15

6 9.Gas / Oxygen Depletion C&P 10.Hot Surfaces C&P 11.Slips, Trips and Falls due to poor housekeeping C&P 12.Manual Handling carrying of equipment ladders, tools etc C&P 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 erected, 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. 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. Hot pipe work lagged/insulated. Signage 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. Hand tools are relatively lightweight (tools to be carried in single tool box). All Manual Handling tasks are individually Risk Assessed. Individuals trained in Manual Handling techniques. Large and awkward cable tray or ladder rack to be handled/carried by two operatives. Avoid Manual Handling where possible C&P Engineering Services Ltd Ref Rev Page 6 of 15

7 13.Moving Machinery / Entanglement / Trapping points - controlled by Client C&P 14.Noise C&P 15.Operating/driving MEWPS on site C&P 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. 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. 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 C&P Engineering Services Ltd Ref Rev Page 7 of 15

8 16.Lighting C&P 17.Use of hand tools and power tools/ Entanglement / Trapping points 18. Vehicles and Transport travel to site and use on site internal roads C&P C&P, other road users 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. Good plant lighting. Where plant lighting is poor, obtain temporary lighting. 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. Drills and other power tools will be battery operated. Where this is not reasonably practicable then low voltage mains will be required (110v workshop only)see electrical controls above. PAT testing of mains operated tools. Secure cables. No loose clothing or jewellery near to rotating chuck. All hand tools to be clean and in good working order, and checked daily. Use of company vehicles. Fully maintained vehicles with current MOT and insurance. Competent drivers holding appropriate licence for the vehicle. Vehicle preflight checks. All 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 C&P Engineering Services Ltd Ref Rev Page 8 of 15

9 19. Legionella C&P 20.Contact with Dow Corning Chemicals on site Different Process areas manufacture and use different types of chemicals i.e. toxic, corrosive, harmful etc C&P 21.Fire- flammable atmospheres, sources of ignition C&P 22.Lone Workers - 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 C&P Client to provide information on potential Legionella presence by providing COSHH risk assessments. Wearing of RPE. Comprehensive Permit to work form required for all jobs undertaken on DCL site except when working within office buildings. When working within office buildings a Job Card may be issued by the permit issuer/custodian of the building in place of a Permit to work. Dow Corning to provide details of hazards and precautions necessary for each process area including COSHH risk assessments. 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. Trained and competent persons. Contact Protocol with C&P supervisor. Individual radio. Plant Alarms. Emergency assembly points. C&P lone worker policy C&P Engineering Services Ltd Ref Rev Page 9 of 15

10 23. Environment - waste disposal Environment Responsibly dispose of all generated waste by using client s on site recycling facilities C&P Engineering Services Ltd Ref Rev Page 10 of 15

11 Risk Matrix First Aid Injury no disruption of activity Minor Injury (preventing activity for one day) Suffering (preventing activity for 3 days or longer Major injury Fatal Certain Probable Likely Possible Unlikely Acceptable Adequate (1-5) No further action but ensure controls are maintained (6-15) Look to improve at next review Unacceptable (16-25) Stop activity and make immediate improvements Safe Working Procedure Final Risk Rating The risk rating for the activity of Installation of Unistrut, Cable Tray and Ladder Rack has a final risk rating of 10, if all the controls are applied at all times. Failure to implement the controls will lead to a higher risk of injury. The level of 10 is tolerable (yellow section 10-15) but improvements should be made to reduce the overall risk down to acceptable (Green section 1-4). This Risk assessment needs to be reviewed in the next 12 months (see review date). Persons and Competency All the C&P Engineering employees who install unistrut, cable trays and ladder racks must have been taken through this SWP and must sign the register to demonstrate that they understand the controls and how they are to be applied. Supervisor to plan the job by visiting site beforehand and calculating the size of cable trays and unistruts required so where reasonably practicable they can be cut to size and shape in the workshop before being taken to site. Planning of job is critical. PPE Requirements Safety Footwear with minimum 200 Joules toe cap. The ankles must be protected. General Proban treated overalls General purpose gloves over surgical nitrile gloves (depending on the task). Safety helmet centurion or equivalent C&P Engineering Services Ltd Ref Rev Page 11 of 15

12 Safety glasses or safety over-glasses to be worn if wearing their own prescription glasses. Goggles are mandatory in chemical splash areas. Ear Defenders are mandatory in certain process areas. High visibility waistcoat. Additional PPE dependent on local conditions. Plant Status Depending on where the job is being carried out, plant will quite likely be working. Electrical isolations may be required for installation of cable trays/ladder racks if live electrical cables present could be affected by the installation. These should be isolated and moved to an alternative position. Permits, Certificates or Registers A general permit to work is required for all work locations and access onto process plant. Any isolation will be recorded on this permit. A separate hot work permit is required for battery operated equipment. Access and Egress Before accessing any part of a process plant then an authorisation from the Client will be required and their permit to work procedure will be followed. Access and egress will be by recognised walkways, pavements, road crossings, stairways. Procedure 1. Wear the PPE that is required for the particular process area that you will be working in. N.B. There is minimum requirement as highlighted in the PPE section above for all areas. Ensure that PPE is in good condition and affords adequate protection. 2. Report to the permit office before accessing site. Obtain a Client permit to work and comply with all requirements stated and explained verbally by the issuer. Additional PPE stated must be worn. Agree access and egress routes. 3. Travel to the building/site area by company vehicle if necessary and park appropriately. 4. Where cable trays/ladder racks are delivered in bundles of six trays (3 metres long) by lorry, then arrangements must be made prior for off-loading. A HIAB or Fork Lift Truck may be required to offload. Ensure Lifting Plan and a competent person in charge of lifting operation has organised the lift. Ensure sufficient space created to off-load in a suitable accessible position as near to the site of work as possible. 5. Where a HIAB is used then a lifting Plan must be created prior to commencement of job. Driver/operator to be fully trained and competent in HIAB lifting operation. 6. Where a mobile crane is required to off-load ladder racks/cable trays at height then the load must be secured. Area around crane to be cordoned off. A banksman will ensure that all persons are clear during crane lift and that all other persons are aware of the lifting activity. Only a competent person trained in slinging techniques to attach lifting slings. Lifting equipment must be to the approved standard with certification of testing and thorough examination. Lifting Plan required for Mobile Crane and a competent person in charge of Lifting operation. C&P Engineering Services Ltd Ref Rev Page 12 of 15

13 7. Cut steel banding wire once the bundles of cable trays have been positioned on site. Stand clear as sections may spring open. 8. Two men to carry individual ladder racks into position. Where 3 metre smaller cable trays or flat plates are being used then two men are still required to carry cable trays especially if carrying them up stairways etc. Where cable trays have been purposely cut to size and are of short length then this can be done by one person. 9. When joining cable trays together four sets of bolts are required each side to secure them together. 10. All ladder racks and cable trays with return lips should be installed with return lip outermost. 11. If ladder racks are required to be positioned vertically and are of greater length than one piece (>3 metres) then they should be bolted together before lifting into position. Scaffolding should be erected at specific heights to allow easy handling of the length of trays. Where it is too difficult to erect scaffolding then two men should be positioned at height to help pull the trays into position using ropes tied to the cable trays whilst two men at ground level should help manipulate the trays and prevent them from swinging. Where anyone needs to lean over to manipulate the trays into position then they must wear a fall arrest harness, either over fixed hand railing, scaffold hand railing or MEWP hand railing. 12. The ladder racks /trays should be temporarily tied in position whilst the racks are bolted to permanent brackets to support the cable trays/ladder racks. Where no permanent brackets are in situ, then these need to be manufactured and welded in place, preferably before the cable trays are fitted. In some areas where it is difficult to attach permanent support brackets then pipe clamps can be used to clamp the unistruts to fixed hand railings with client s permission. 13. Small cable trays can be fitted from a stepladder providing the top of the ladder has handrails fitted. The step ladder must be erected on level, stable ground. If at height and close to a platform edge then a fall arrest harness must be worn. Scaffolding may also be erected on top of the handrail as an extension. 14. Where cable trays need to be fitted to walls or other permanent structures then rather than be bolted directly to the wall they must be attached to unistrut. This will enable easy access for cable installation at a later stage. The unistruts should be cut to length and mounted in positions by drilling holes in the structure and fitting with anchor bolts. 15. The cable trays/ladder racks must then be bolted to the unistruts. All drilling to use low voltage or battery operated drills. Check to make sure that any holes to be drilled do not contact any electrical cables. 16. The distance between Unistruts should be determined bearing in mind the width of the cable trays (150m 600mms wide) and/or the alarm or signal boxes to be fitted. 17. On completion of the job all waste material to be removed from site and re-used or disposed of responsibly. 18. The permit to work will be cancelled. C&P Engineering Services Ltd Ref Rev Page 13 of 15

14 Emergency Procedures Telephone 3333 Internally In the event of an emergency and depending on the site and access to such, the emergency services should be called using the internal emergency number. Raising the alarm is our first priority. All C&P employees must report to their appropriate place of safety, if the alarms aresounded. You must stay at this location and report to the Client representative. Follow the directions of the Client personnel in charge at the muster point. Lifting an eye wash station or stepping on a safety shower will raise alarm to DC Control, who will send assistance to the areaaccordingly. Dow Corning Alarm Signals Klaxon 3 seconds on 3 seconds off Major Incident All personnel to report to their nearest muster point indoors immediately. Swipe badge on Muster Reader. Fire Alarm Bells All personnel to report to their nearest fire assembly point outside immediately. Blue Flashing Light -Outside a Building No personnel to enter the building until advised by a DCL member. Audible Alarm and Red Flashing Light on Process Plant All personnel to make their work area safe and leave the area. No return until advised by a DCL Member. Note: If the last page of this document is not attached do not worry as it does not contain any relevant information regarding the SWP. The last page is a register of signatories and is intended to be detached and returned to Gorseinon head office for filing. C&P Engineering Services Ltd Ref Rev Page 14 of 15

15 Hazard Identification, Risk Assessment & Safe Working Procedure for Instrument Calibration on Client s Site in Situ (and at Client s Workshop). The above document has been read and explained to me by my supervisor. I the undersigned understand the controls and how they are to be applied. Print Name Signature Date The following comments/queries were raised and discussed with my supervisor (Please insert below any concerns, comments or views which may identify additional problems): ** THIS PAGE IS TO BE SIGNED, DATED, DETACHED AND RETURNED TO GORSEINON HEAD OFFICE A.S.A.P. (VIA FAX, , POST OR HAND) ** C&P Engineering Services Ltd Ref Rev Page 15 of 15