SINGAPORE QI 19 Page 1 of 5 RISK ASSESSMENT Ships Name Ships No Work Activity Activity / Operation Analyse/review/Assess WHAT IF? MAIN AIR COMPRESSOR OVERHAUL Possible Consequence / Hazard / Impact Monitor / Review (Who Responsible /Next Review / By Whom) Controls Required Decision Implement RISK LEVEL Likelihood Frequency L Rare Once in 20 years 1 Unlikely Once in 5 years 2 Likely Once per year 3 Imminent Once in six months 4 Certain Once per month 5 Extent of consequences Degree of Impact (D) Minor 1 Medium 2 Major 3 Severe 4 Catastrophic 5 Additional controls required for Risk Level > 10 No Activity/ Operation Hazard/ Impact Existing Control / Safeguards 1 Main air compressor availability for service 1. Skill & knowledge for, maintenance and troubleshooting 2. Monitoring automatic & manual 3. Safe maintenance, start, run and stop practice for equipment 4. Planned maintenance system a. Time based b. Condition based 5. Approved quality & quantity of spares in inventory 6. Good lubrication 7. Control air usage and leakage to Likelihood L Degree of Impact D Risk Level R=LxD 2 Additional Controls Required Y/N
SINGAPORE QI 19 Page 2 of 5 reduce running hours 2 Maintenance of main air compressor, motor & control gear 5. Hot surface 6. Hazardous substance (lube oil)-skin rashes and slippery 7. Slips and trips 8. Compressed air 9. Noise 10. Rotating parts 11. Falling objects 12. Manual lifting of heavy object 13. Electrical shock 14. Electrical fire 1. Tool box meeting to be done, tasks, procedures and hazards considered and explained 2. Reference material: History, Instruction manual, tools, spares and technical data available 3. Fuses removed from compressor starter panel. 4. Compressor cooled down 5. Compressor discharge valve closed. 6. Lock out/ tag out procedures to be implemented. 7. Isolation certificate SCL8 completed 8. Warning signs to be displayed in ECR and at compressor starting switch. 9. Work personnel in boiler suit with 10. Safe handling of used & new lube oil. 11. Clean floor plates and work area 12. Lifting appliances in good condition and correct SWL for the load 13. Correct size, material, quality and quantity of spares available for the task. 14. Portable electrical equipment, hand lamps in good condition.
SINGAPORE QI 19 Page 3 of 5 3 Starting an air compressor after overhaul 5. Slips and trips 6. Compressed air 7. Noise 8. Rotating parts 9. Electrical shock 10. Electrical fire 1. Work personnel in boiler suit with 2. Clean floor plates and work area 3. Inspect for tightness of bolts for compressor, accessories and electrical equipment. 4. Electrical equipment & connections checked for tightness, correct direction of rotation and start, stop and cutout. 5. Electric motor casing & control box grounded & confirmed. 6. Cooling water flow 7. Rotating parts guard plate in place 8. HP and LP valves installed in correct air flow direction 9. Safety cutout, auto start & stop switch, LP, HP safety valves, Non return valve and water jacket safety device in good working condition 10. Initially compressor turned manually 11. Lube oil level 12. Open compressor discharge valve and filling valve to the air bottle, before starting. 13. After starting confirm lube oil & air pressure/flow, starting and running amps and abnormal sound. 14. Prepare to stop immediately if abnormal condition encountered.
SINGAPORE QI 19 Page 4 of 5 4 Air compressor under (running ) 5. Hot surface 6. Hazardous substance (lube oil)-skin rashes and slippery 7. Slips and trips 8. Compressed air 9. Noise 10. Rotating parts 11. Falling objects 12. Manual lifting of heavy object 13. Electrical shock 14. Electrical fire 1. Work personnel in boiler suit with 2. Clean floor plates and work area 3. Inspect for leaks-water, oil & air. 4. Inspect for normal readings for flow, pressure, temperature and amps checked. 5. Drainage of condensed moisture. 6. Rotating parts guard plate in place 7. Lube oil level and consumption 8. Auto start & stop of compressor 9. Listen to the mechanical sound from HP,LP valves and crankcase for abnormality 10. Check for overheating of compressor, motor and electrical control gear. 11. Prepare to stop under abnormal condition Additional Control Measures Activity No Further action if necessary (Additional Controls) Responsible Remedial action due Date Completed 1 Take 5 will be followed strictly at all stages of the work. In tool box meeting following points will be discussed in detail a) Hazards involved and all necessary safety precautions to be taken. b) Procedure given in the manual to be strictly followed. c) Importance of wearing proper d) Company s safety guidelines to be followed. Chief engineer
SINGAPORE QI 19 Page 5 of 5 2 If there is any forecast of bad weather etc compressor will be boxed back as quickly as possible taking all safety precautions. 3 ETA of the vessel arriving at next port or TSS areas, prevailing weather conditions, weather forecast for the planned duration of overhaul to be assessed prior proceeding on to the job Chief Engineer Master Chief Officer/Chief Engineer s Signature / Name / Date Master s Signature / Name / Date