Health Safety Environment Community

Hazard Assessment for (Unit 251 17th Steam Reformer)

Hazard Assessment Workshop for: (Unit251, 17th Steam Reformer)

Principal Contractor: Kentz (Pty) Ltd
Project Number: SC 3062 Date: 11/23/2010 Location: Unit 251

Context: Hydrostatic Pressure Testing of the Pipe / Lines on the OBL (Unit 251)

Objectives: To ensure all Hydrostatic Pressure Testing is carried out safely.

Workshop Facilitator: Recorded by:

Key Success Factors: No harm to any personnel, damage to equipment or property.

Stakeholders:

AA-W-QR 2602 (EN) Vol 1

 Health Safety Environment Community
Hazard Assessment for (Unit 251 17th Steam Reformer)

Workshop Participant's:
Name Company Position Phone Number
Attendees:

Apologies:
 Hazard Assessment for Unit 251 (17th Steam Reformer) AA-W-QR 2602 (EN) Vol 1

Item Task or Activity Hazard Possible Initial Risk Proposed Control Measure Revised Action Completed
(Potential danger) Consequence Score Risk
Likely to happen Score

Consequence
Likelihood
Risk Rating

Consequence
Likelihood
Risk Rating
By Date By Date

1,1 Preparation of Documentation incomplete. Time delay. Wrong All documentation must go via the Document Controller. Document 6.2 23/11/2010 6.2 23/11/2010
pressure test Documentation has the wrong lines identified. Wrong Controller must transmit all documentation via a transmittel document. & &
information on it. Incompetent document information resulting Document Controller must ensure the correct document is transmitted Artisan Artisan
receiver and does not understand the in incorrect pressures to the correct person. The recipient of the cdocument must ensure all
content of the document. Wrong system / used during pressure information on the transmitted document is correct and all information
line identified. System / line not marked / testing. is understood. If the recipient does not understand all the information,
tagged. Incorrect pressure used to test he must contact the Supervisor and get clarification on the content.
the line. No work permit received / issued The system / line must be identified prior to any pressure testing being
for the pressure test. EMS not notified if done. The system / line must be marked / tagged to identify it. No
fire water is to be used. Using personnel pressure testing to be carried out until conformation has been received
that were not involved in the debfiefing. re the line to be tested. Before any pressure testing can be performed,
Task executor not available. a competent permit recipient must sign for the permit. EMS must be
3 4 12 notified 24 hours prior to any pressure testing being done where fire 1 2 2
water is to be used. Only personnel that were in on the debriefing will
to be involved with the pressure testing activities. Task executor to be
present at all times during the pressure testing.

1,2 Preparation of the Unauthorised entry / uninformed persons Fatal, temporary / The entire area around the pressure test area must be barricaded with 6.2 23/11/2010 6.2 23/11/2010
pressure test site in the area. No proper emergency egress permanent yellow and black flags meaning, ABSOLUTELY NO ENTRY. This & &
established. The entire test area not disablement, leagal barricading must be a minimum of a 10m. radius around the test area. Artisan Artisan
barricaded. No boards warning the liabilities. At identified places, standby personnel must be positioned to keep
people of pressure testing put up. unauthorised people out of the testing area. Boards must be put up
stating PRESSURE TESTING IN PROGRESS - KEEP OUT.
3 4 12 1 2 2
 Hazard Assessment for Unit 251 (17th Steam Reformer) AA-W-QR 2602 (EN) Vol 1

Item Task or Activity Hazard Possible Initial Risk Proposed Control Measure Revised Action Completed
(Potential danger) Consequence Score Risk
Likely to happen Score

Consequence
Likelihood
Risk Rating

Consequence
Likelihood
Risk Rating
By Date By Date

1,3 Preparation of test Test equipment not calibrated, certified Fatal, temporary / All pressure testing equipment must be calibrated, certified and on 6.2 23/11/2010 6.2 23/11/2010
equipment and on record. Gauges not calibrated permanent record. All gauges must be tested, calibrated and certified a SANAS & &
and certified, within three months by a disablement, leagal accredited institution. All gauges, Bourdon Tube and electronic Liquid Artisan Artisan
South African National Accreditation liabilities. Crystal Display (LCD) must have the latest calibration stickers on them
Systems (SANAS) accredited institution and they must be within 3 months. All systems to be pressure tested
and on record. No calibration stickers on must have a gauge at the end of the system to ensure the gauge on
gauges. No gauge positioned at the the pump and the one at the end correspond taking into consideration
furthest end of the line to be tested. the head height. Should there be a discrepancy in reading, the gauges
Electrical high pressure pumps not must be removed and sent for re-calibration. Bursting pressures on
calibrated and on record. Bursting system / lines must be known. Hand pressure pumps must be
pressure of system / lines not known. calibrated, certified and on record. Water temperature must be
Hand pressure pumps not calibrated. between 16 and 22 degrees celcius before any pressure testing may
Water temperature not between 16 and take place. All personnel involved with pressure testing must be well
22 degrees celcius. Incompetent person / informed of all activities and the Supervisor must be declared
people conducting the hydrostatic 3 4 12 competent for the job. All gauges must be sealed with wire and a lead 1 2 2
pressure testing. Pressure gauges not seal. All gauges must be in Kpa.
sealed with wire and a lead seal. Gauges
are in Bar or Mpa.
 Hazard Assessment for Unit 251 (17th Steam Reformer) AA-W-QR 2602 (EN) Vol 1

Item Task or Activity Hazard Possible Initial Risk Proposed Control Measure Revised Action Completed
(Potential danger) Consequence Score Risk
Likely to happen Score

Consequence
Likelihood
Risk Rating

Consequence
Likelihood
Risk Rating
By Date By Date

1,4 Filling of the system to Filling the system at the highest point. Property damage, When there is the slightest of incline in the system, the system must 6.2 23/11/2010 6.2 23/11/2010
be pressure tested. Not opening vents whilst filling the fatility be filled at the lowest point and be vented at intervals all the way to & &
system. Filling the system too fast the highest point. If the system is horizontal, the vents / valves situated Artisan Artisan
causing water hammer. Filling the at intervals must be opened to vent all the air out of the system. Whilst
system with contaminated water, water is issuing out at low pressure, the flange bolts must be pulled up.
depending on the material. Not having The system must be vented at regular intervals to ensure no air is
people walk the length of the system to trapped in the system. The system must be filled slowly to ensure no
be pressure tested whilst filling to identify frothing of the water which entraps air bubbles. The water must be
leaks. Not entirly filling the system, clear of impurities which may also entrap air bubbles. Have people
leaving an air pockets. Over pressurizing walk the length of the system to ensure no visible leaks are detected.
the system. Process Intergration The system must be filled completely and must be purged a couple of
(Skoffies) and EMS not informed of the times to ensure all entrapped air is expelled. Extra care must be taken
use of fire water, no fire water permit. when filling the system with fire water as the pressure is 1280KpA,
Structure not designed to carry the mass 12,8 bar. Process Intergration must be informed of all fire water usage
of the system plus water. Freezing of the 3 4 12 and a permit is necessary. No perssure testing may take place on 1 2 2
water during winter months. Filling the temporary structures. Supervisors to ensure all water stays liquified but
system and leaving it to stand over night. above 16 degrees celcius. No system may be filled with the testing
Blanks / bolts on flanges can not medium and left overnight. Ensure all blanks / bolts on the system can
withstand the internal pressure of the withstand the internal test pressure
test.

1,5 Pressurizing the System brought onto pressure too Fatal, temporary / System must be brought onto pressure at 15 minute incremental 6.2 23/11/2010 6.2 23/11/2010
system quickly. Whole system not checked for permanent steps. System can be brought onto half the working pressure first and & &
leaks or bulging during pressurization. disablement, legal kept there for 15 minutes whilst the whole line is inspected. Thereafter Artisan Artisan
Over pressurization of the system. Not liabilities. the pressure can be taken onto the working pressure of the system
manufactured / tested under supervision and held there for 15 minutes. The pressure can then be increased to
of an AIA 1,25 times of the working pressure and held for 15 minutes. Thereafter
to 1,5 times the working pressure and held for a minimum of 10
minutes. During the wholes pressurization activity, people must walk
the length of the system to check for leaks or abnormal bulging of the
system. All gauges must be checked to make sure there is no
4 5 20 pressure drop on any of the gauges. Should there be a pressure drop 1 2 2
and a leak detected, the whloe system must be depressurized, the
bolts pulled up with a slogger then the whole prosess repeats itself.
The system must only be pressurized to one and a half times the
normal working pressure and no more.
 Hazard Assessment for Unit 251 (17th Steam Reformer) AA-W-QR 2602 (EN) Vol 1

Item Task or Activity Hazard Possible Initial Risk Proposed Control Measure Revised Action Completed
(Potential danger) Consequence Score Risk
Likely to happen Score

Consequence
Likelihood
Risk Rating

Consequence
Likelihood
Risk Rating
By Date By Date

1,6 Depressurizing the System not depressurized at the furthest Fatal, temporary / The depressurizing of the system must always be started at the 6.2 23/11/2010 6.2 23/11/2010
system point. Vents / valves opened too fast permanent furthest point from the pressure pump. The vents / valves must be & &
causing hammering in the system. All disablement, leagal opened slowly to avoid hammering in the system which is detremental Artisan Artisan
gauges not returning to zero. All findings liabilities. for the metal. All gauges must return to zero before any flanges are
and meassurements not recorded. loosened. All the findings must be recorded by the responsible people.
3 4 12 1 2 2

1,7 Draining the system Draining the system onto the ground, no Leagal liabilities. Fire water must be channeled into the oily water sewers and raw water 6.2 23/11/2010 6.2 23/11/2010
channeling the water to the sewers. into the storm water sewers. Ensure sufficient venting in the system to & &
Partial vacuum caused when emptying allow all the water to drain out. Involve the Production to ensure the Artisan Artisan
the system due to vents not opened. correct place to drain the water.
Area not identified to drain the water.
3 4 12 1 2 2

1,8 3 4 12 1 2 2 6.2 23/11/2010 6.2 23/11/2010

& &
Artisan Artisan
 Hazard Assessment for Unit 251 (17th Steam Reformer) AA-W-QR 2602 (EN) Vol 1

Item Task or Activity Hazard Possible Initial Risk Proposed Control Measure Revised Action Completed
(Potential danger) Consequence Score Risk
Likely to happen Score

Consequence
Likelihood
Risk Rating

Consequence
Likelihood
Risk Rating
By Date By Date

1,9 3 4 12 1 2 2
2,0 3 4 12 1 2 2
2.1 3 4 12 1 2 2
2.2 3 4 12 1 2 2
2.3 3 4 12 1 2 2
2.4 3 4 12 1 2 2
2.5 3 4 12 1 2 2
2.6 3 4 12 1 2 2
2.7 3 4 12 1 2 2
2.8 3 4 12 1 2 2
2.9 3 4 12 1 2 2
3 3 4 12 1 2 2
3.1 3 4 12 1 2 2
3.2 3 4 12 1 2 2
3.3 3 4 12 1 2 2
3.4 3 4 12 1 2 2
3.5 3 4 12 1 2 2
3.6 3 4 12 1 2 2
3.7 3 4 12 1 2 2
3.8 3 4 12 1 2 2
3.9 3 4 12 1 2 2
4 3 4 12 1 2 2
4.1 3 4 12 1 2 2
Failure to follow any of the preceding safety instructions or those that follow within this manual, could result in serious injuries or death.
 Health Safety Environment Community
Hazard Assessment for (Unit 251 17th Steam Reformer)

RISK MATRIX

Consequences [C]
Risk Matrix (Where an event has more than one “loss type”, choose the “consequence” with the highest rating)
Loss Type 1 2 3 4 5
(Additional ‘loss types’ may exist for an event; identify & rate
accordingly) None Negligeable Minor Serious Very serious
No injury or damage to health. Slight to minor injury or health effect ( Major Injury or health effects (including 1 to 3 Fatalities or Permanent Total Multiple fatalities.
including First Aid Case, Medical Treatment Permanent Partial Disability and Occupationnal Disability.
Harm to People (Health and Safety) Case, Lost Time Injury and occupational Illness). From Accident or occupational illness
illness.) Affecting work performance in the longer term, From an accident or occupational (e.g chemical asphyxiation or cancer -
such as prolonged absence from work. illness. Large exposed population).
May affect work performance, such as Irreversible health damage without loss of life, Irreversible health damage with
restriction to activities (Restricted work case or e.g noise induced hearing loss, chronic back serious disability or death, e.g
occupational illness) or a need to take a few injuries, sensitisation, hand/arm vibration corrosive burns, heat stroke, cancer
days to fully recover (Lost work days). syndrome, repetitive strain injury. (small exposed population)
Minor Health effects, which are reversible, e.g
skin irritation, food poisoning.
Zero Effect. No environmental damage. Slight Effect. Minor Effect. Major Effect. Massive Effect.
No financial consequences. Sufficiently large contamination or discharge to Severe environmental damage. The Persistent severe environmental damage
Harm to the Environment Slight environmental damage within the fence damage or attack the environment, but no company is required to take or severe nuisance extending over a
and within systems. lasting effect. extensive measure to restore the large area. Loss of commercial, or
Negligeable financial consequences. Single breach of statutory or prescribed limit, damage environment. recreational use or nature conservany
or single complaint. Extended breaches of statutory or resulting in major financial consequence
prescribed limits or widespread for the company.
nuisance. Ongoing breaches well above statutory
or prescribed limits.
Zero Effect. Slight impact. Limited Impact: Considerable to National Impact. International Impact.
No public awareness Some local public concern. Some local media National public concern. Extensive International public attention. Extensive
Impact on repuration
Public awareness may exist, but there is no and/or local political attention with potentially adverse attention in the national adverse attention in international media.
public concern. adverse aspects for company operations. media. Effect on Regional/national National/International policies with
policies with potentially restrictive potential severe impact on access to
measures and/or impact on grant of new areas, grants of licences and/or tax
licence. Mobilisation of action groups. legislation.

Zero Damage. Slight Damage Minor Damage Major Damage. Serious to Extensive Damage.
Asset Damage and business losses No disruption of operations. Brief disruption of operations Partial shutdown Partial operation loss to Substantial or
total loss of operation .

Frequency /
Likelihood /
Probability [L]
Risk Rating
Incidents occur repeatedly during the
4 operational life of the process or facility or
activity.
Incidents occur repeatedly at construction
Likely sites. 4 (L) 8 (M) 12 (M) 16 (H) 20 (H)
3 Incidents occur more than once during the
operational life of the process or facility or
activity.
Incidents occur frequently at construction sites.
Frequent 3 (L) 6 (L) 9 (M) 12 (H) 15 (H)
2 Incidents occur not more than once during the
operational life of the process or facility or
activity.
Incidents occur occasionally at construction
sites.
Probable 2 (L) 4 (L) 6 (M) 8 (M) 10 (H)
1 Incidents do not occur during the lifetime of the
unit or facility or activity.
Incidents occur seldom at construction sites.
Seldom 1 (L) 2 (L) 3 (L) 4 (L) 5 (M)
0 Similar incidents are not known to have
occured anywhere before.
Improbable 0 (L) 0 (L) 0 (L) 0 (L) 0 (L)