Hazard Identification, Risk Assessment & Safe Working Procedure for Installing Containment, Cable, Glanding, Terminating, Testing, Instrumentation & Tubing 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 Paul Bunyan 24/04/2014 19/04/2015 Steve Tossell 24/04/2014 19/04/2015 Approved By: Print Name Signature Date Approved Richard Jenkins 24/04/2014 C&P Engineering Services Ltd Ref. 13.2.9 Rev. 1 24/04/2014 Page 1 of 20
Hazard Identification C&P ENGINEERING SERVICES LTD 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. 13.2.9 Rev. 1 24/04/2014 Page 2 of 20
Risk Assessment Task: - Installation of Containment, Cabling, Glanding, Terminating, Testing,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, 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). HAZARDS L C HR WHO MAY BE HARMED 1. Airborne Dust - Some plants may expose employees to windborne dust. 5 3 15 C&P 2.Access and Egress on site 5 5 25 C&P CONTROL MEASURES TO REDUCE THE RISK TO AS LOW AS IS REASONABLY PRACTICABLE 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 working at height section. For working at height hazard controls please refer to C&P document reference 2.14.1 Working at Height Policy. L C RR 1 3 3 C&P Engineering Services Ltd Ref. 13.2.9 Rev. 1 24/04/2014 Page 3 of 20
HAZARDS L C HR WHO MAY BE HARMED 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 4.Working in Confined Spaces 5 5 25 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. 4 5 20 C&P 5 5 25 C&P CONTROL MEASURES TO REDUCE THE RISK TO AS LOW AS IS REASONABLY PRACTICABLE 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. For safe isolation please refer to C&P document reference 13.1.3 Safe Isolation Procedure for DEAD working on LV and ELV. L C RR 1 3 3 2 5 10 C&P Engineering Services Ltd Ref. 13.2.9 Rev. 1 24/04/2014 Page 4 of 20
HAZARDS L C HR WHO MAY BE HARMED 7.Objects falling from Height 5 5 25 C&P 8.Falling from Height (Working at Height) 5 5 25 C&P CONTROL MEASURES TO REDUCE THE RISK TO AS LOW AS IS REASONABLY PRACTICABLE 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. 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, L C RR 2 5 10 2 5 10 C&P Engineering Services Ltd Ref. 13.2.9 Rev. 1 24/04/2014 Page 5 of 20
HAZARDS L C HR WHO MAY BE HARMED 9.Gas / Oxygen Depletion 5 5 25 C&P 10.Hot Surfaces 3 3 9 C&P 11.Slips, Trips and Falls due to poor housekeeping 5 5 25 C&P 12.Manual Handling carrying of equipment ladders, tools etc. 3 3 9 C&P CONTROL MEASURES TO REDUCE THE RISK TO AS LOW AS IS REASONABLY PRACTICABLE 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. L C RR Hot pipe work lagged/insulated. Signage. 1 2 2 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. 1 3 3 C&P Engineering Services Ltd Ref. 13.2.9 Rev. 1 24/04/2014 Page 6 of 20
HAZARDS L C HR WHO MAY BE HARMED 13.Moving Machinery / Entanglement / Trapping points - controlled by Client 5 5 25 C&P 14.Noise 5 3 15 C&P 15.Operating/driving MEWPS on site 5 5 25 C&P CONTROL MEASURES TO REDUCE THE RISK TO AS LOW AS IS REASONABLY PRACTICABLE 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 L C RR 1 3 3 C&P Engineering Services Ltd Ref. 13.2.9 Rev. 1 24/04/2014 Page 7 of 20
HAZARDS L C HR WHO MAY BE HARMED 16.Lighting 5 5 25 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 3 5 15 C&P 5 5 25 C&P, other road users CONTROL MEASURES TO REDUCE THE RISK TO AS LOW AS IS REASONABLY PRACTICABLE 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. L C RR 2 5 10 C&P Engineering Services Ltd Ref. 13.2.9 Rev. 1 24/04/2014 Page 8 of 20
HAZARDS L C HR WHO MAY BE HARMED 19. Legionella 2 5 10 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. 5 4 20 C&P 21.Fire- flammable atmospheres, sources of ignition 3 5 15 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. 5 5 25 C&P CONTROL MEASURES TO REDUCE THE RISK TO AS LOW AS IS REASONABLY PRACTICABLE 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. L C RR 2 4 8 C&P Engineering Services Ltd Ref. 13.2.9 Rev. 1 24/04/2014 Page 9 of 20
HAZARDS L C HR WHO MAY BE HARMED CONTROL MEASURES TO REDUCE THE RISK TO AS LOW AS IS REASONABLY PRACTICABLE L C RR 23. Environment - waste disposal 3 4 12 Environment Responsibly dispose of all generated waste by using client s on site recycling facilities. 24. Impulse Lines /Pneumatics/Hydraulics- high pressure, corrosive chemicals 5 5 25 C&P 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 3 3 25.Process Piping In-line instruments, high pressure, corrosive chemicals 5 5 25 C&P 26.Hot Surfaces 5 3 15 C&P Where instruments are mounted in process lines i.e. in-line the process linemust 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. Hot pipe work lagged/insulated. Signage. If working on high temperature instrumentation, allow C&P Engineering Services Ltd Ref. 13.2.9 Rev. 1 24/04/2014 Page 10 of 20
HAZARDS L C HR WHO MAY BE HARMED CONTROL MEASURES TO REDUCE THE RISK TO AS LOW AS IS REASONABLY PRACTICABLE cooling if possible and wear protective gloves. L C RR C&P Engineering Services Ltd Ref. 13.2.9 Rev. 1 24/04/2014 Page 11 of 20
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 5 10 15 20 25 Probable 4 8 12 16 20 Likely 3 6 9 12 15 Possible 2 4 6 8 10 Unlikely 1 2 3 4 5 Acceptable (1-5) No further action but ensure controls are maintained Adequate (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 the Cable Installation, Glanding, Terminating, Testing, Tubing and Instrumentation 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 adequate (yellow section 6-15) but improvements should be made to reduce the overall risk down to acceptable (green section 1-5). 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 work on this contractmust have been taken through this SWP and must sign the register (on the last page of this document) to demonstrate that they understand the controls and how they are to be applied. They must be competent and have the relevant certification for the equipment they are working on and for operation of the MEWP. PPE Requirements The individuals on this contract are required to wear at all times:- Safety Footwear with minimum 200Joules toe cap. The ankles must be protected. General Proban treated overalls or Proban treated trousers & jacket. General purpose gloves or Kevlar gloves over surgical nitrile gloves (depending on the task). Safety helmet centurion or equivalent. No requirement for safety helmet in office buildings. Safety glasses to be worn or safety over-glasses to be worn if wearing your own prescription glasses. No requirement for safety glasses or safety over-glasses in office buildings. High visibility waistcoat.no requirement for high visibility waistcoat in office buildings. Ear defenders when working in areas which require mandatory hearing protection. In addition to the above goggles may be required in plant areas instead of safety glasses and Kevlar gloves used when using open blade knives, harnesses will be used when working from a MEWP basket. Some process areas may require chemical suits and this will be stipulated on the permit to work. C&P Engineering Services Ltd Ref. 13.2.9 Rev. 1 24/04/2014 Page 12 of 20
NOTE: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. A clip off point must be checked or tested to ensure it is suitable to attach to. A hand rail is not suitable or designed to be used as a point to attach the harness. Plant Status In almost all cases electrical isolation will be required for the equipment that is to be worked on. When carrying out Inspection & Testing of circuits somelive tests are required. This live working is to be carried out as per C&P document reference 13.1.4 Live Working Procedure on Low Voltages (up to 1000V). Permits, Certificates or Registers A general permit to work is required for all work locations and access onto process plant. Isolations will be recorded on this permit. A separate hot work permit is required for battery operated equipment or any specific hot work. Access and Egress Before accessing any part of a plant then an authorisation to work permit will be obtained from the permit issuing office for that particular area. Access and egress will be by recognised walkways, pavements, road crossings, working and process platforms. Access to areas where there is a risk of falling to danger will be by additional access equipment such as scaffolding, MEWP, fixed or secured and supported ladders. Procedure 1. Contact the site area in advance and agree that access to the specific area is acceptable. 2. 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 the PPE is in good condition and affords adequate protection. 3. Report to the permit office before accessing site. Obtain a permit to work form and comply with all requirements stated and explained verbally by the issuer. Additional PPE stated must be worn. Agree access and egress routes. Any Isolation of electrical circuits, need to be agreed with the permit issuing office. 4. Undertake the appropriate isolation in the electrical substation or at the appropriate fuse or electrical control panel. Ensure that the personal locks are attached and the keys are retained by the working party member. 5. Where the inspection revealed working at height is a risk, then the appropriate control(s) must be adopted. We must follow the hierarchy of working at height and aim to prevent the fall in the first place i.e. permanent platform, scaffold, MEWP, stepladder with handrails on top step, harnesses 6. Scaffolding requirements must be agreed with permit issuing office and their approved scaffolding sub contractor. If a MEWP is required then this must be pre-booked in advance. 7. Where electrical installations are at height and close to platform edges i.e. Process areas, then consideration, as a first option, should be given to erecting scaffolding extensions to the handrails to prevent falls from height, or where this is impracticable, then full body fall arrest harnesses should be worn if working from stepladders near to the platform edge (this does not prevent the fall but C&P Engineering Services Ltd Ref. 13.2.9 Rev. 1 24/04/2014 Page 13 of 20
prevents a person falling to danger and therefore limits the consequences of the injury) bearing in mind any structures that may be below the working platform and interfere with the fall. Fall arrest harnesses should be regarded as the last resort but can and should be worn in conjunction with certain controls for working at height. Lightweight detachable stepladders with handrails and gate all around the top working platform should be used if available. Approved/certified clip off points should be used to attach the harness. Handrails are not designed for attaching a harness. 8. Park vehicle in recognised parking areas for equipment off loading. Manually handle equipment to the location using the kinetic manual handling techniques supplied in safety contact and training course. Where heavy or awkward items need to be carried then a separate manual handling risk assessment is required for the particular location. 9. Collect MEWP if required for access from MEWP parking location. Full Body Harnesses will be worn and attached by all operatives as soon as they enter the MEWP basket. This applies to driving the MEWP to the location of work. One operative is to drive MEWP on roadways to the location. Use the C&P vehicle as escort using hazard warning lights to warn other road users. A fall restraint lanyard must be used and not fall arrest. 10. Create appropriate road control if MEWP is needed to be parked on the road way road control will be appropriate to the risk and extent of use of the road. As a minimum the MEWP will be coned off and bunting placed between cones. This could be increased if necessary to traffic light controls or road closure if agreed with site. 11. Place bunting at ground level to demarcate exclusion zone below location of work when working at height. This will be a minimum of 10m diameter but will be greater in most circumstances using the structures in the area. 12. Equipment transported in the MEWP basket will be secured in the basket until it is to be fitted. This will include tools and fittings. Containment 1. 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. 2. 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. 3. 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. 4. Cut steel banding wire once the bundles of cable trays have been positioned on site. Stand clear as sections may spring open. 5. 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. C&P Engineering Services Ltd Ref. 13.2.9 Rev. 1 24/04/2014 Page 14 of 20
6. When joining cable trays together four sets of bolts are required each side to secure them together. 7. All ladder racks and cable trays with return lips should be installed with return lip outermost. 8. 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. 9. 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. 10. 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. 11. 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. 12. 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. 13. 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. Cable Installation, Glanding, Terminating & Testing 1. Install power supply cable as per specification. 2. Gland cable both ends, insulation resistance test using equipment with valid calibration certificate. Check cable and terminate at both ends. 3. Dead tests on electrical circuits to be carried out by competent person using valid calibrated test equipment and results recorded. 4. The electrical isolations will be removed and power restored to the electrical section that had previously been isolated. 5. Live tests on electrical circuits to be carried out by competent person using valid calibrated test equipment and recorded. 6. Once the work is completed all tools, equipment, waste fittings and cut offs from cable must be removed from the site or disposed of in identified on site recycling services. 7. The MEWP will be returned to the MEWP parking area and off hire arranged. C&P Engineering Services Ltd Ref. 13.2.9 Rev. 1 24/04/2014 Page 15 of 20
8. The permit to workwill be cancelled. 9. Electricaltest certificate is to be completed if required. The top copy of the certificate is to be given to the customer and the yellow copy is to be returned to Paul Bunyan at Gorseinon Head Office. Instrumentation & Tubing Instrument Installation 1. Report to the permit office before accessing process plant areas. Obtain a site permit to work and comply with all requirements stated and explained verbally by the issuer. Additional PPE stated as well as mandatoryppe must be worn. Agree access and egress routes. Agree any isolation required before commencing work. 2. Where process plant isolations are required, obtain an isolation permit from the site personnel on completion of the relevant isolation, confirming that the correct isolation has been made. 3. If a local isolation is adequate, obtain permission from site personnel prior to carrying out the isolation. 4. Follow C&P manual handling guidelines when taking instruments to the work site. 5. 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) 6. 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. 7. 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. 8. If working on high temperature instrumentation, allow cooling if possible and wear protective gloves. 9. Remove the instrument concerned, and if being replaced, install new instrument in its place. 10. Discuss with the permit issuer when the works are complete and following the above procedure in reverse if reinstating the lines. Ensure any spades or line breaks are reinstated by the client or their representative, including any isolations made by them. 11. If the installation is new, then install the instrument where identified utilising the supplied brackets and fixing bolts. Follow the manufacturers recommended procedures for installation. 12. If required, mount enclosure boxes or instrument stands, prior to taking the instrument to the work site. 13. If large valves require installation, then ensure qualified personnel are present, such as the client s mechanical team to assist with lifting the item, and bolting into position. C&P Engineering Services Ltd Ref. 13.2.9 Rev. 1 24/04/2014 Page 16 of 20
Tubing Installation. 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 tubing or containmentto support tubing is delivered in bundlesby lorry, then arrangements must be made prior for off-loading. A HIAB or Fork Lift Truck may be required to off-load. 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 tubing at height, then the load must be secured. Area around crane to be cordoned off. A banks man 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. 7. Cut banding strap once the bundles have been positioned on site. Stand clear as sections may spring open. 8. Two men to carry individual bundles into position. Where 3 metre smaller lengths are being used, then two men are still required to bundles especially if carrying them up stairways etc. Where tubing has been purposely cut to size or are of short lengths, then this can be done by one person. 9. If tubing is required to be positioned vertically and are 6 metres in length, then they should be handled by two persons. Scaffolding should be erected at specific heights to allow easy handling of the lengths. Where it is too difficult to erect scaffolding then one man should be positioned at height and the other below to assist with the installation. Where anyone needs to lean over to manipulate them into position then they must wear a fall arrest harness. 10. The tubing could be temporarily tied in position whilst the permanent brackets to support the tubeis installed. Where no permanent brackets are in situ, then these need to be installed or welded in place, preferably before the support trays/unistruts are fitted. In some areas where it is difficult to attach permanent support brackets then pipe clamps can be used to clamp unistruts to fixed hand railings with client s permission, ready to support the tubing. The appropriate clamps can then be fitted to the support work ready for the tubes. 11. Tubing 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. 12. Install appropriate clamps onto the supports and install tubing accordingly. 13. If it requires bending or setting, ensure the bender is in good working order, prior to use. C&P Engineering Services Ltd Ref. 13.2.9 Rev. 1 24/04/2014 Page 17 of 20
14. Carry out appropriate flushing or pressure testing of the tubes, if identified within the specification. 15. If tubing is required to tap in points, ensure the isolation process stated above is followed prior to installation. 16. If a new line has been installed, ensure the correct tap in point is identified prior to installation. 17. If instrument air/nitrogen is required to the item, gain permission from the permit issuer prior to any supply being turned on. 18. On completion of the job all waste material to be removed from site and re-used or disposed of responsibly. 19. When installation is complete, ensure the permit is cancelled. C&P Engineering Services Ltd Ref. 13.2.9 Rev. 1 24/04/2014 Page 18 of 20
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 are sounded. 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 area accordingly. Raising the Alarm Telephone 3333 Use your radio Channel 15/16 call sign DC control In the event where neither of the above options are possible then use safety shower or eyewash point on plant as these will activate the alarm in DC control Use break glass point within building for local alarm 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. 13.2.9 Rev. 1 24/04/2014 Page 19 of 20
Hazard Identification, Risk Assessment & Safe Working Procedure for Cable Installation, Glanding, Terminating & Testing 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, EMAIL, POST OR HAND) ** C&P Engineering Services Ltd Ref. 13.2.9 Rev. 1 24/04/2014 Page 20 of 20