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Process Flare system along with piping, knockout vessels & pumps.
Location Plant
Area Flare System
Process is Routine / Non-Routine
Frequency of process Daily
Process duration 24 Hrs
No. of personnel working 01
Process is Supervised / Not Supervised
Equipment to be work on Valves, vessel, pump (positive displacement pump)
Tools/Equipment to be work with Wheel keys.
Non-recoverable un-burnt gases as a result of abnormalities in operation are collected and burnt off through flare stack
in the form flare. A pilot burner (on natural gas/ refinery gas) remains in operation to burn gases in case of emergency at
the plant.
Overall Observations:
Knock out vessels are provided to drain any liquid to flare stack. Water seal is provided at bottom of Flare Stack to absorb
any liquid and flash back from stack-top.
Page 1 of 20
Health & Safety Hazard Identification/ Risk assessment/ Operational Plan
HSEQ-F-02 Rev: 04; Date: 29.03.2006
RESIDUAL
BASE RISK
O PER ATI O N S RISK
HAZARD IDENTIFICATION ASSESSMEN
PLAN ASSESSMEN
T
T
Responsibility
(b+c)
(b+c)
Consequen Consequen
ces ces
Likelihood (a)
Likelihood (a)
Facility/ Assets (c)
*
Health/ life (b)
=a
Hazards
Control Ensured/
Ye s
No
Observation
Overall Risk
Overall Risk
Ref. Document
( F l a r e To w e r )
Page 2 of 20
Health & Safety Hazard Identification/ Risk assessment/ Operational Plan
HSEQ-F-02 Rev: 04; Date: 29.03.2006
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O PER ATI O N S RISK
HAZARD IDENTIFICATION ASSESSMEN
PLAN ASSESSMEN
T
T
Responsibility
*
*
Consequen Consequen
=a
=a
ces ces
Likelihood (a)
Likelihood (a)
(c)Facility/ Assets
(b+c)Overall Risk
(c)Facility/ Assets
(b+c)Overall Risk
Health/ life (b)
PROD.M/
As the chances of fire are high The area is open from all sides. Flare All
f) Emergency exits - 3 5 1 18 2 5 1 12
in flare, exits are necessary stack is located in an isolated area. Employee
s.
7.
Mechanical
PROD.M/
a) Body contact with Proper designing of the area is
- May lead to injuries 3 5 2 21 project & 2 5 2 14
sharp edges ensured during erection.
Construct
d) Unguarded machines -
e) Breaking - Abnormal rise in flare lines 3 5 5 30 Visual checks. Routine Maintenance. Engineeri 2 5 5 20
pressure may lead to HS hazard Inspection Manual. Maintenance Plan. ng/
PRL-SOPM-01. PROD.M/
Inspection
Engineer.
Page 3 of 20
Health & Safety Hazard Identification/ Risk assessment/ Operational Plan
HSEQ-F-02 Rev: 04; Date: 29.03.2006
RESIDUAL
BASE RISK
O PER ATI O N S RISK
HAZARD IDENTIFICATION ASSESSMEN
PLAN ASSESSMEN
T
T
Responsibility
*
*
Consequen Consequen
=a
=a
ces ces
Likelihood (a)
Likelihood (a)
(c)Facility/ Assets
(b+c)Overall Risk
(c)Facility/ Assets
(b+c)Overall Risk
Health/ life (b)
PROD.M/
Proper house keeping is maintained. Walkthrou
a) Foreign object on a
17. - May lead to trip hazard 3 4 2 18 HSE Regulations. PRL-SOPM-01. gh 2 4 2 12
walking surface
Walkthrough Inspection. Inspection
Team.
Page 4 of 20
Health & Safety Hazard Identification/ Risk assessment/ Operational Plan
HSEQ-F-02 Rev: 04; Date: 29.03.2006
RESIDUAL
BASE RISK
O PER ATI O N S RISK
HAZARD IDENTIFICATION ASSESSMEN
PLAN ASSESSMEN
T
T
Responsibility
*
*
Consequen Consequen
=a
=a
ces ces
Likelihood (a)
Likelihood (a)
(c)Facility/ Assets
(b+c)Overall Risk
(c)Facility/ Assets
(b+c)Overall Risk
Health/ life (b)
PROD.M/
b) Design flaw on a Proper design consideration is done
- May lead to trip hazard 3 4 2 18 Engineeri 2 4 2 12
walking surface during all plant changes.
ng
PROD.M/
Proper house keeping is maintained.
Walkthrou
The area is concrete. HSE Regulations.
c) Slippery surface - Is a fall hazards 3 4 2 18 gh 2 4 2 12
PRL-SOPM-01. Walkthrough
Inspection
Inspection.
Team.
PROD.M/
Engineeri
Holes covered with sheet, no open ng/
Drains on the floor are a
d) Hole on the floor - 3 4 2 18 holes allowed in the area. Walkthrough Walkthrou 2 4 2 12
potential fall hazard
Inspection. gh
Inspection
Team.
e) Missing - Ladders are used to climb on 3 5 1 18 Properly designed ladders are used, PROD.M/ 2 5 1 12
stair/ladders/plank the flare stack for various jobs inspection done. Inspection Manual. Engineeri
Routine Maintenance. Permit to Work ng/
System. Walkthrough Inspection. Inspection
Engineer./
Walkthrou
gh
Inspection
Team.
Page 5 of 20
Health & Safety Hazard Identification/ Risk assessment/ Operational Plan
HSEQ-F-02 Rev: 04; Date: 29.03.2006
RESIDUAL
BASE RISK
O PER ATI O N S RISK
HAZARD IDENTIFICATION ASSESSMEN
PLAN ASSESSMEN
T
T
Responsibility
*
*
Consequen Consequen
=a
=a
ces ces
Likelihood (a)
Likelihood (a)
(c)Facility/ Assets
(b+c)Overall Risk
(c)Facility/ Assets
(b+c)Overall Risk
Health/ life (b)
Engineeri
f) Inadequate
Employees are trained. PRL-SOPM-01. ng/
maintenance of Ladders are used to climb on
- 3 5 2 21 also platforms are inspected. PROD.M/ 2 5 2 14
platforms/walkways at the flare stack for various jobs
Inspection Manual. Inspection
height
Engineer.
Impact and acceleration
b) Heat convection i-e The height of the flare stack is kept PROD.M/
The temperature of the flare
transfer of heat by - 3 4 2 18 high so as to avoid exposure. No one is Engineeri 2 4 2 12
gases is very high
way of gases allowed to go at top. ng.
c) Excessive exposure to - The temperature of the vicinity
sun in extreme climate is less than the temperature of
the flare.
Page 6 of 20
Health & Safety Hazard Identification/ Risk assessment/ Operational Plan
HSEQ-F-02 Rev: 04; Date: 29.03.2006
RESIDUAL
BASE RISK
O PER ATI O N S RISK
HAZARD IDENTIFICATION ASSESSMEN
PLAN ASSESSMEN
T
T
Responsibility
*
*
Consequen Consequen
=a
=a
ces ces
Likelihood (a)
Likelihood (a)
(c)Facility/ Assets
(b+c)Overall Risk
(c)Facility/ Assets
(b+c)Overall Risk
Health/ life (b)
PROD.M/
d) Body contact with hot All
- May lead to injuries. 3 4 2 18 PPEs are used. Operators trained. 2 4 2 12
object/gases/ machine Concerne
and temperature
d.
29.
Pressure
a) Boiler - -
Heat
b) Furnaces - -
PROD.M/
The blockage in the system may
c) Pressure vessels - 3 5 5 30 Visual checks. Maintenance Plan. Engineeri 2 5 5 20
pressurize the system.
ng.
d) Design construction - May lead to release of gases 3 5 4 27 The plant is properly designed, all new PROD.M/ 2 5 4 18
and installation errors resulting in fire/ HSE hazards installation done as per plant change Engineeri
procedure. ng/ TEP
Page 7 of 20
Health & Safety Hazard Identification/ Risk assessment/ Operational Plan
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O PER ATI O N S RISK
HAZARD IDENTIFICATION ASSESSMEN
PLAN ASSESSMEN
T
T
Responsibility
*
*
Consequen Consequen
=a
=a
ces ces
Likelihood (a)
Likelihood (a)
(c)Facility/ Assets
(b+c)Overall Risk
(c)Facility/ Assets
(b+c)Overall Risk
Health/ life (b)
f) Water hammering - -
Page 8 of 20
Health & Safety Hazard Identification/ Risk assessment/ Operational Plan
HSEQ-F-02 Rev: 04; Date: 29.03.2006
RESIDUAL
BASE RISK
O PER ATI O N S RISK
HAZARD IDENTIFICATION ASSESSMEN
PLAN ASSESSMEN
T
T
Responsibility
*
*
Consequen Consequen
=a
=a
ces ces
Likelihood (a)
Likelihood (a)
(c)Facility/ Assets
(b+c)Overall Risk
(c)Facility/ Assets
(b+c)Overall Risk
Health/ life (b)
PROD.M/
Engineeri
ng/
All the lines are properly supported. Inspection
k) Vibration - May cause leakages 3 3 5 24 Inspection Manual. Routine Engineer./ 2 3 5 16
Maintenance. Walkthrough Inspection. Walkthrou
gh
Inspection
Team.
PROD.M/
Engineeri
ng/
Proper supports provided. Inspection Inspection
m) Inadequate support of May cause leakages as a result
- 3 5 4 27 Manual. Routine Maintenance. Engineer./ 2 5 4 18
pressure pipelines of sacking
Walkthrough Inspection. Walkthrou
gh
Inspection
Team.
Elect
Engineer./
Properly insulated wires are used. PROD.M/
Could lead to electric shock to
42. a) Non-insulated wire - 3 5 2 21 Maintenance Manual. Walkthrough Walkthrou 2 5 2 14
worker
Inspection. gh
Inspection
Team.
Page 9 of 20
Health & Safety Hazard Identification/ Risk assessment/ Operational Plan
HSEQ-F-02 Rev: 04; Date: 29.03.2006
RESIDUAL
BASE RISK
O PER ATI O N S RISK
HAZARD IDENTIFICATION ASSESSMEN
PLAN ASSESSMEN
T
T
Responsibility
*
*
Consequen Consequen
=a
=a
ces ces
Likelihood (a)
Likelihood (a)
(c)Facility/ Assets
(b+c)Overall Risk
(c)Facility/ Assets
(b+c)Overall Risk
Health/ life (b)
El PROD.M/
Elect
ec All deteriorated wires are removed Engineer./
No deterioration of wire found
t b) Deteriorated wire -
in the area.
3 5 4 27 promptly replaced. Maintenance Walkthrou 2 5 4 18
Manual. Walkthrough Inspection. gh
r Inspection
ca Team.
l PROD.M/
Elect
Proper earthing is now in place. Engineer./
c) Absence/inadequate
- Could lead to fire hazards 3 5 5 30 Maintenance Manual. Walkthrough Walkthrou 2 5 5 20
earthing
Inspection. gh
Inspection
Team.
Permit to Work System in Place. Also
d) Working with electrical
welder is provided with shock resistant Engineeri
equipment of damped - Could electrocute the worker 3 5 2 21 2 5 2 14
shoes. HSE Regulations. PRL-SOPM- ng
floor
01.
Elect
e) Static electricity
Engineer./
discharge (rubbing of
Proper earthing in place. Maintenance Walkthrou
non conductive - Could lead to spark 3 4 4 24 2 4 4 16
Manual. Walkthrough Inspection. gh
material over
Inspection
stationary surface)
Team.
f) Friction between - Could lead to development of 3 3 3 18 PRL-SOPM-01. Maintenance Manual. PROD.M/ 2 3 3 12
flowing liquid and solid static charge Elect
surface) use of Engineer.
conducting ladders
Page 10 of 20
Health & Safety Hazard Identification/ Risk assessment/ Operational Plan
HSEQ-F-02 Rev: 04; Date: 29.03.2006
RESIDUAL
BASE RISK
O PER ATI O N S RISK
HAZARD IDENTIFICATION ASSESSMEN
PLAN ASSESSMEN
T
T
Responsibility
*
*
Consequen Consequen
=a
=a
ces ces
Likelihood (a)
Likelihood (a)
(c)Facility/ Assets
(b+c)Overall Risk
(c)Facility/ Assets
(b+c)Overall Risk
Health/ life (b)
g) Absence of PROD.M/
explosion/fire proof - Is a potential fire hazard 3 5 4 27 Maintenance Manual. Elect 2 5 4 18
devices Engineer.
PROD.M/
May occur during maintenance / Permit to Work System in place. HSE
h) Electrical hot work - 3 4 4 24 Engineeri 2 4 4 16
shut down. Regulations.
ng
i) Absence/inadequate All
Proper PPEs are used. PRL-SOPM-01.
PPE during electrical - Could result in human injury 3 5 1 18 Employee 2 5 1 12
HSE Regulations.
work s
j) Conductor carrying
All conductors are insulated and
current in close Elect
- Could lead to fire 3 5 4 27 explosion proof. Maintenance Manual. 2 5 4 18
proximity of flammable Engineer.
Area classification.
gases
k) Load factor balance
including at the time of
- -
infrastructure
development
PROD.M/
Elect
l) Absence/inadequate
All electrical equipments and Engineer./
identification of All equipments/ switches are marked.
- installations need to be properly 3 2 4 18 Walkthrou 2 2 4 12
switches, breaker, Walkthrough Inspection.
marked/identified gh
distribution boards
Inspection
Team.
Page 11 of 20
Health & Safety Hazard Identification/ Risk assessment/ Operational Plan
HSEQ-F-02 Rev: 04; Date: 29.03.2006
RESIDUAL
BASE RISK
O PER ATI O N S RISK
HAZARD IDENTIFICATION ASSESSMEN
PLAN ASSESSMEN
T
T
Responsibility
*
*
Consequen Consequen
=a
=a
ces ces
Likelihood (a)
Likelihood (a)
(c)Facility/ Assets
(b+c)Overall Risk
(c)Facility/ Assets
(b+c)Overall Risk
Health/ life (b)
54. PROD.M/
Permit to Works System. HSE All
a) Hot work - Could lead to fire 3 5 5 30 2 5 5 20
Regulations. Emergency Plan. Concerne
d.
The flare burns the gases in
Water seal is provided to avoid PROD.M/
open atmosphere at sufficient
backfire / back flow of gases. Process All
b) Open fire - height; misoperation may lead 3 5 5 30 2 5 5 20
is controlled round the clock. PRL- Concerne
to release of a fireball.
SOPM-01. Emergency Plan. d.
PROD.M/
All vehicles are provided with spark
c) Vehicle movement Sparks from the exhaust can All
- 3 5 4 27 arrestors. HSE Regulations. PRL- 2 5 4 18
near flammable gases lead to fire Concerne
SOPM-01.
d.
PROD.M/
Smoking is not allowed in danger area. All
d) Smoking - Could lead to fire 3 5 4 27 2 5 4 18
PRL-SOPM-01. HSE Regulations. Concerne
d.
PROD.M/
Batteries of the mobiles are not Mobile phones are not allowed inside
e) Use of mobiles near All
- intrinsically safe for operation in 3 5 4 27 danger area. PRL-SOPM-01. HSE 2 5 4 18
flammable gases Concerne
hazardous area. Regulations.
d.
f) Weeds growth - Weed growth occurs around 3 5 4 27 The area is cleaned periodically. PROD.M/ 2 5 4 18
flare stack. May lead to fire Walkthrough Inspection. Civil/
hazard in case liquid fall from Walkthrou
flare stack. gh
Inspection
Team.
Page 12 of 20
Health & Safety Hazard Identification/ Risk assessment/ Operational Plan
HSEQ-F-02 Rev: 04; Date: 29.03.2006
RESIDUAL
BASE RISK
O PER ATI O N S RISK
HAZARD IDENTIFICATION ASSESSMEN
PLAN ASSESSMEN
T
T
Responsibility
*
*
Consequen Consequen
=a
=a
ces ces
Likelihood (a)
Likelihood (a)
(c)Facility/ Assets
(b+c)Overall Risk
(c)Facility/ Assets
(b+c)Overall Risk
Health/ life (b)
PROD.M/
Elect
Engineer./
Sparks due to static charge Proper earthing in place. Walkthrough
g) Static charge - 3 5 4 27 Walkthrou 2 5 4 18
could cause fire Inspection.
gh
Inspection
Team.
PROD.M/
Elect
Engineer./
No open wiring allowed Maintenance
h) Open wiring - Could lead to fire 3 5 4 27 Walkthrou 2 5 4 18
Manual. Walkthrough Inspection.
gh
Inspection
Team.
PROD.M/
Maintenance Plan. Maintenance
i) Oil spillage - May result in fire. 3 5 5 30 Elect 2 5 5 20
Manual. Emergency Plan.
Engineer.
Elect
Any leakage could lead to fire
j) Leakage - 3 5 5 30 Maintenance Plan. Visual monitoring Engineer. 2 5 5 20
hazards
/ PROD.M
k) Lightning - Could lead to fire 3 5 5 30 Proper earthing ensured. Maintenance PROD.M/ 2 5 5 20
Manual. Walkthrough Inspection. Elect
Engineer./
Walkthrou
gh
Inspection
Team.
Page 13 of 20
Health & Safety Hazard Identification/ Risk assessment/ Operational Plan
HSEQ-F-02 Rev: 04; Date: 29.03.2006
RESIDUAL
BASE RISK
O PER ATI O N S RISK
HAZARD IDENTIFICATION ASSESSMEN
PLAN ASSESSMEN
T
T
Responsibility
*
*
Consequen Consequen
=a
=a
ces ces
Likelihood (a)
Likelihood (a)
(c)Facility/ Assets
(b+c)Overall Risk
(c)Facility/ Assets
(b+c)Overall Risk
Health/ life (b)
o) Improper storage of
- Could lead to fire 3 5 4 27 Storage not allowed PROD.M 2 5 4 18
flammable materials
69. PROD.M/
Engineeri
a) Presence of airborne Toxic gases are present in the Toxic gases are burnt at sufficient feet
- 3 4 3 21 ng/ 2 4 3 14
toxic substances flare system.. height. Visual checks.
Inspection
Engineer
b) Spills from container - Flare system has toxic gases 3 4 4 24 Visual checks. Maintenance Plan. PROD.M/ 2 4 4 16
or damage to a pipe Inspection Manual. Engineeri
carrying toxic liquid ng/
Inspection
Engineer.
Page 14 of 20
Health & Safety Hazard Identification/ Risk assessment/ Operational Plan
HSEQ-F-02 Rev: 04; Date: 29.03.2006
RESIDUAL
BASE RISK
O PER ATI O N S RISK
HAZARD IDENTIFICATION ASSESSMEN
PLAN ASSESSMEN
T
T
Responsibility
*
*
Consequen Consequen
=a
=a
ces ces
Likelihood (a)
Likelihood (a)
(c)Facility/ Assets
(b+c)Overall Risk
(c)Facility/ Assets
(b+c)Overall Risk
Health/ life (b)
d) Leakage of oxygen
diluting gases (N2, PROD.M/
CO2, ethane, Visual checks. Maintenance Plan. Engineeri
hydrogen, methane) Any leakage from flare line will
- 3 4 3 21 Inspection Manual. Routine ng/ 2 4 3 14
or anesthetics result in O2 diluting gases.
Maintenance. Inspection
( acetone, methyl ethyl Engineer.
ketone, acetylene,
ether, chloroform)
e) Lack of ventilation in
Could lead to the accumulation
rooms containing toxic - 3 4 3 21 The area is open from all sides. PROD.M. 2 4 3 14
of toxic gases.
substances,
PROD.M/
Elect
f) Un-insulated source All conductors are insulated. Engineer./
carrying current - Could lead to explosion 3 5 4 27 Maintenance Manual. Walkthrough Walkthrou 2 5 4 18
/charge /spark Inspection. gh
Inspection
Team.
g) Oil burners - Not used here
Page 15 of 20
Health & Safety Hazard Identification/ Risk assessment/ Operational Plan
HSEQ-F-02 Rev: 04; Date: 29.03.2006
RESIDUAL
BASE RISK
O PER ATI O N S RISK
HAZARD IDENTIFICATION ASSESSMEN
PLAN ASSESSMEN
T
T
Responsibility
*
*
Consequen Consequen
=a
=a
ces ces
Likelihood (a)
Likelihood (a)
(c)Facility/ Assets
(b+c)Overall Risk
(c)Facility/ Assets
(b+c)Overall Risk
Health/ life (b)
Ionized Radiation:
Page 16 of 20
Health & Safety Hazard Identification/ Risk assessment/ Operational Plan
HSEQ-F-02 Rev: 04; Date: 29.03.2006
RESIDUAL
BASE RISK
O PER ATI O N S RISK
HAZARD IDENTIFICATION ASSESSMEN
PLAN ASSESSMEN
T
T
Responsibility
*
*
Consequen Consequen
=a
=a
ces ces
Likelihood (a)
Likelihood (a)
(c)Facility/ Assets
(b+c)Overall Risk
(c)Facility/ Assets
(b+c)Overall Risk
Health/ life (b)
c) Absence or
inadequacy of
monitoring devices -
(film badges, pocket
chambers, film rings).
Non-ionized Radiation:
87. Noise:
Page 17 of 20
Health & Safety Hazard Identification/ Risk assessment/ Operational Plan
HSEQ-F-02 Rev: 04; Date: 29.03.2006
RESIDUAL
BASE RISK
O PER ATI O N S RISK
HAZARD IDENTIFICATION ASSESSMEN
PLAN ASSESSMEN
T
T
Responsibility
*
*
Consequen Consequen
=a
=a
ces ces
Likelihood (a)
Likelihood (a)
(c)Facility/ Assets
(b+c)Overall Risk
(c)Facility/ Assets
(b+c)Overall Risk
Health/ life (b)
a) Exposure to noise
levels greater than 90
-
dBA for more than 8
hours TWA.
b) Continuous exposure
- -
of 115dBA or higher
c) Impulse exposure of
- -
140 dBA.
d) Pump rooms - -
e) Generator rooms - -
PROD.M/
Permit to Works System. PPEs are
f) Maintenance works/ All
- May lead to health hazard. 3 4 2 18 worn by employees. HSE Regulations. 2 4 2 12
activity Concerne
PRL-SOPM-01.
d.
Vibration:
Page 18 of 20
Health & Safety Hazard Identification/ Risk assessment/ Operational Plan
HSEQ-F-02 Rev: 04; Date: 29.03.2006
RESIDUAL
BASE RISK
O PER ATI O N S RISK
HAZARD IDENTIFICATION ASSESSMEN
PLAN ASSESSMEN
T
T
Responsibility
*
*
Consequen Consequen
=a
=a
ces ces
Likelihood (a)
Likelihood (a)
(c)Facility/ Assets
(b+c)Overall Risk
(c)Facility/ Assets
(b+c)Overall Risk
Health/ life (b)
h) Mechanical work/
installation
Page 19 of 20
Health & Safety Hazard Identification/ Risk assessment/ Operational Plan
HSEQ-F-02 Rev: 04; Date: 29.03.2006
1. Operational procedures - - SOP for Flare Light –up and flare operation to be developed.
8. Containment - -
9 Any other
HSE advises the employees on all matters pertaining to Health, Safety, Environment and Quality.
Training is done through HR.
Maintenance and tank repair plans are based on Inspection Reports
Approved by Management
Representative:
Assessed by: Mr. Sakhawat Ali & Mr. Akbar Musharraf
M Naman Shah
Page 20 of 20