Presentation Transcript

1. MDPI/GOODWILL OIL AND GAS TRAINING
2. Why discuss hot work ? Hot work is a hazardous activity in the oil and gas business. Companies has had a hot work permit system in place for years but fires, explosions and near misses continue to happen. MDPI/GOODWILL OIL AND GAS TRAINING
3. What is hot work ? Hot work isan activitythat uses or produces a source of ignition Welding, cutting, grinding Tools that produce sparks/heat Sand or grit blasting Heat treatment and stress relieving Opening up of electrical equipment Petrol or diesel engine Presence of pyrophoric substance Other types of work specified by site management MDPI/GOODWILL OIL AND GAS TRAINING
4. Risks of hot work in hazardous areas Facility areas are classified as hazardous if flammable vapour is likely to be present Toxic substances may also be present The simultaneous presence of flammable vapour and an ignition source MAIN RISK So a system is needed to control the presence of ignition sources in hazardous areas –the hot work permit system MDPI/GOODWILL OIL AND GAS TRAINING
5. Managing hot work Plan and think through the work in advance, involving all the relevant people including specialists Identify and assess the risks using the site risk assessment procedure Apply the appropriate controls to the extent warranted by the risks– can a safer (cold) method or location be used ? – apply the hot work permit system, communicating the requirements to all concerned – train and brief those involved including contractors MDPI/GOODWILL OIL AND GAS TRAINING
6. What is a hot work permit ? The Area Authority issues the permitto the Performing Authority givingpermission to carry out the hot work The Performing Authority confirms by signature that restrictions and precautions are understood, and will be followed by all those involved Distribution of permit copies ensures all interested parties are informed A hot work permit is a signed ‘contract’ to carry out hot work safely, between: The Area Authority who ‘owns’ the facility The Performing Authority who will carry out the work 1 2 3 MDPI/GOODWILL OIL AND GAS TRAINING
7. What does the hot work permit cover ? Authority for all aspects of the work Precise description of the work, the equipment, the location, and the validity period Steps required to isolate equipment, and to prepare the work site and make it safe Test results confirming the work area is free from unacceptable risks Description of all remaining hazards and the required precautions and controls including monitoring Completion of work Acceptance of equipments and withdrawal of permit MDPI/GOODWILL OIL AND GAS TRAINING
8. Preparation of worksite Access and egress Work area marked off and protected Removal of oil and gas hazards, depressuring, draining etc. Equipment isolation Cover drains and isolate sources of vapour within 15m Remove combustible materials eg. dry grass Clean work-piece MDPI/GOODWILL OIL AND GAS TRAINING
9. Mechanical isolation of equipment For hot work positive isolation is required – physical disconnection – insertion of a blind/spade of the appropriate (pressure) rating Valve(s) isolation is not adequate* For complex jobs, an isolation list is needed The extent of the isolation must match the risk associated with the isolation failing * If positive isolation is impractical, the work becomes ‘high risk’, requiring higher level authorization MDPI/GOODWILL OIL AND GAS TRAINING
10. Gas Testing Performed by competent person High risk areas identified and checkedeg. low points Limitations of equipment/test methodrecognised 1% LEL* is maximum allowed for hot work All traces of oil, sludge, scale and otherflammable materials must be removed beforedeclaring ‘gas free’ If appropriate, test for toxic gas *If <1% LEL is impractical to achieve, the work becomes high risk’, requiring higher level authorisation MDPI/GOODWILL OIL AND GAS TRAINING
11. Accredited gas tester A gas tester should be trained and accredited in the following: Calibration and use of gas testing equipment The limitations of testing equipment and test methods The ability to understand and interpret results Have practical facility experience (preferably) or training Be formally tested and exceed pass mark Be retrained/retested every 2 years Gas testing and work permit procedures: – oxygen – flammable gas – toxic gases MDPI/GOODWILL OIL AND GAS TRAINING Safety Talk 7 / 11
12. Precautions against remaining hazards Restrictions on tools, equipment and methods to be used Beware of hidden pockets of hydrocarbonseg. linings Precautions for interactions with other work PPE to be worn Safe location of equipment eg. welding machine Welding return to be connected to work piece Standby fire equipment Hazard monitoring requirements MDPI/GOODWILL OIL AND GAS TRAINING
13. Monitoring Repeat gas tests or continuous gas monitoring Fire watch Hot work TO STOP immediately if general alarm sounds Everyone has a duty of care to consider the effect of any changes that could impact the work being undertaken Anyone can and should stop the job if he orshe detects a hazard that compromises safety MDPI/GOODWILL OIL AND GAS TRAINING
14. Fire Watch responsibilities Stop unauthorized entry into work area Provide and inspect fire fighting equipment Monitor for the presence of combustible gas Remain alert – for flammable substances – to raise the alarm – to shut down equipment eg. welding machine Wet down the work area and quench sparks Stop the job if conditions become unsafe MDPI/GOODWILL OIL AND GAS TRAINING
15. Issue and distribution of permits Hot work permit form satisfactorily completed and issued by Operating Authority to Performing Authority Permit distribution ensures that the required information is formally communicated to all interested parties Original to the Performing Authority for the person in charge at the worksite Copies to – Control room or other operating centre – HSE dept – others as decided by site management MDPI/GOODWILL OIL AND GAS TRAINING
16. Commencement of work PERFORMING AUTHORITY Supervisor visits worksite OPERATING AUTHORITY Supervisor visits worksite Holds a ‘toolbox talk’ with those who will carry outthe work Explains scope, restrictions, timescale, precautions, first aid and emergency procedures Additional briefingfor contractors and subcontractors Considers factors relatingto the specific day Gives clearance signatureto start work Is present when work commences MDPI/GOODWILL OIL AND GAS TRAINING
17. Permit validity Validity rules will be set by site management according to the risks involved and the working/shift system Hot work permits should not normally be valid for more than 1 work period/day All ‘live’ work permits must be formally handed over at work/shift changeovers, together with a status update MDPI/GOODWILL OIL AND GAS TRAINING
18. Completion of work Perfoming Authority signs off and returns original hot work permit to Operating Authority Operating Authority inspects the worksite for safe takeover – confirms that workers are clear of the area and their equipment has been removed – area is restored to its original condition Operating Authority accepts the completed work and withdraws all permits – original should be filed – all permit copies should be filed or destroyed MDPI/GOODWILL OIL AND GAS TRAINING
19. Hot work inside a confined space Particular precautions: Gas cylinders and welding machines to be located outside Gas supplies to be isolated outside during work breaks Electrode holders to be de-energised during work break Insulating mats required for AC weldingover 50 volts Ventilation should be adequate to remove fumes This involves the combined risks of entry and hot work which require an entry permit and a hot work permit MDPI/GOODWILL OIL AND GAS TRAINING
20. Higher risk work Work which cannot be carried out in accordance with the hot work permit system: – where <1% LEL cannot be achieved – where disconnection or spading is impractical – other work categories specified by management – in a Zone 0 or Zone 1 Hazardous Area Requires authorisation by a senior manager Involves more detailed planning and control procedures outside the scope of this safety talk MDPI/GOODWILL OIL AND GAS TRAINING
21. Awareness, competency and supervision Workplace safety depends on: Awareness of the risks Communications & training Strict supervision Adherence to theprescribed conditions Care and competence Competencies should be defined, training given, and people tested and accredited: Operating and performing authorities Gas testers Users Contractors should receive training in the work permit system as part of their induction A work permit, by itself, does not make a job safe MDPI/GOODWILL OIL AND GAS TRAINING
22. Wrong equipment The permit must clearly describe the specific work to be carried out, on a specific piece of equipment, including the exact location. If there is any chance of confusion, draw a diagram and tag the equipment A welder cut into a live line resulting in a fire. Luckily no-one was burned. The line identification was poor and the line had not been ‘walked’, or otherwise clearly identified. A sandblaster connected his air supplied dust mask to a nitrogen point. He lost consciousness but was rescued and suffered no ill effects. This is an example of lessons not being learned – the same thing has been reported before, with the same recommendations for unique couplings and identification MDPI/GOODWILL OIL AND GAS TRAINING
23. ‘Old Permits’ Permits must be signed off and all copies withdrawn or destroyed, when a job is finished. There must be no confusion as to whether a permit is valid. Several incidents have happened where an ‘old’ permit was thought to be valid, and equipment that had been recommissioned, and was standing ready to run, was worked on in error. MDPI/GOODWILL OIL AND GAS TRAINING
24. Inadequate isolation The gas free testing procedure should have specifically included the connecting piping, particularly dead legs and low points. Isolation should have been closer to the work. A flash fire occuredduring hot work, injuring9 people, 1 seriously. Three vessels were isolated as a single unit and blinds located conveniently butaway from one ofthe vessels. MDPI/GOODWILL OIL AND GAS TRAINING
25. A last cigarette A worker cleaning a tank lit a cigarette causing a fire from which he died. MDPI/GOODWILL OIL AND GAS TRAINING
26. Enhanced combustibility A fire broke out inside a Hortonsphere when tarpaulins and scaffolding materials caught fire as a result of combustibility due to oxygen leaking from cutting equipment. MDPI/GOODWILL OIL AND GAS TRAINING
27. Unexpected flammable atmosphere An explosion in a floating roof tank with its roof grounded propelled two workers off the tank roof, 140 feet through the air to the ground. 1 worker actually survived – his fall being broken by electric cables! MDPI/GOODWILL OIL AND GAS TRAINING
28. Hot Work summary Hot work is one of the higher risk activities carried out in the oil industry. We have discussed the risks, and the controls that are available, in particular the hot work permit system Line management use the risk management process to identify and assess the risks The appropriate controls must be applied to the extent required by the risk ALL non-routine work entails risk and has to be controlled. MDPI/GOODWILL OIL AND GAS TRAINING
29. Optional Quiz 1. Name 4 inherent hazards of hot work 2.Is valve isolation adequate for hot work, entry, neither, both ? 3. What important roles does the (operating) supervisor play ? (4) 4. What important roles does the (performing) supervisor play ? (4) 5. What important roles does the standby person outside a vessel play ? (4) 6. What should you do if you discover a hazard that compromises the safety of hot work, entry ? (2) What should you do if you discover a person in difficulty in a confined space ? MDPI/GOODWILL OIL AND GAS TRAINING