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Health & Safety Hazard Identification/ Risk assessment/ Operational Plan

HSEQ-F-02 Rev: 04; Date: 29.03.2006

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.

Brief description of process:

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)

Facility/ Assets (c)


*

*
Health/ life (b)

Health/ life (b)


=a

=a
Hazards
Control Ensured/
Ye s
No

Observation

Overall Risk

Overall Risk
Ref. Document
( F l a r e To w e r )

The posture may become PROD.M/


The workers are trained and
a) Inappropriate posture  - inappropriate while doing 3 4 2 18 Engineeri 2 4 2 12
experienced. PRL-SOPM-01
maintenance jobs ng.
PROD.M/
As the flare stack is very high,
Proper designing of the stack is done. Engineeri
various jobs are to be performed
Monkey ladders are provided with age ng/
b) Workplace design  - at height, which may lead to fall 3 5 3 24 2 5 3 16
and platforms all made of MS. Routine Instrumen
Physical

hazards, along with work on


Maintenance. Inspection Manual. t
pipe lines & pumps
Engineer.
1. Proper PPE’s are used. The flare
PROD.M/
During maintenance jobs/ system has been modified for safe
c) Handling hazards  - 3 4 4 24 Engineeri 2 4 4 16
startup when the flare is lit up operation, now pilot system is used for
ng
startup.
PPEs are essential. PRL-SOPM-01.
d) Absence of foot/ head All
 - May lead to physical injuries 3 4 2 18 Maintenance Manual. HSE 2 4 2 12
protection, other PPEs employees
Regulations.
Workers are trained. Proper
May lead to back-aches and All
supervision.. Also carrying of load with
e) Overload lifting  - other injuries, especially if 3 4 4 24 Employee 2 4 4 16
climbing on monkey ladder is not
carrying load to the platform s
allowed. HSE Regulations.

Page 2 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)

Health/ life (b)


Hazards
Control Ensured/
Ye s
No
Observation Ref. Document
( F l a r e To w e r )

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

Excessive forces on the shaft of PROD.M/


Maintenance Plan. Routine
b) Shearing hazard  - the FKO pump can shear it 3 4 3 21 Engineeri 2 4 3 14
Maintenance.
down. ng
Engineeri
ng/
Visual checks. Routine Maintenance.
c) Puncturing/ leakage  - May lead to fire/ HSE hazards 3 4 4 24 PROD.M/ 2 4 4 16
Inspection Manual. Maintenance Plan.
Inspection
Engineer.

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)

Health/ life (b)


Hazards
Control Ensured/
Ye s
No
Observation Ref. Document
( F l a r e To w e r )

Workers are trained. PPEs are


Liquid may splash if the pumps PROD.M/
f) Chemical and hot provided to the employees. Routine
 - are operated without opening 3 5 2 21 Engineeri 2 5 2 14
metal splashes Maintenance. PRL-SOPM-01. HSE
discharge valves ng.
Regulations.
g) Machine malfunction Shut down procedure in place. PROD.M/
May lead to excessive flaring
[mechanical/ electrical  - 3 4 3 21 Standby to the equipments are Engineeri 2 4 3 14
and probable fire
failure] available. PRL-SOPM-01 ng
PROD.M/
Engineeri
PRL-SOPM-01. Good house keeping
ng/
h) Falling objects on a May lead to stopage of knock ensured. Routine Maintenance. HSE
 - 3 4 3 21 Walkthrou 2 4 3 14
moving machine out pumps. Regulations. Permit to Work System.
gh
Walkthrough Inspection.
Inspection
Team.
Appropriate lock out and tag out is PROD.M/
i) Absence of lockout & May lead to abnormalities in done during maintenance. Permit to All
 - 3 5 4 27 2 5 4 18
tag out flare/ operational disorder Works System. PRL-SOPM-01. HSE Section
Regulations. Heads

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)

Health/ life (b)


Hazards
Control Ensured/
Ye s
No
Observation Ref. Document
( F l a r e To w e r )
Falling

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)

Health/ life (b)


Hazards
Control Ensured/
Ye s
No
Observation Ref. Document
( F l a r e To w e r )

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

Whenever work is performed the area PROD.M/


a) Falling objects from May lead to serious injury to
 - 3 5 1 18 is cordoned off. Permit to Works Engineeri 2 5 1 12
height employee
System. HSE Regulations. ng.
23.

Movement of these vehicles Clearance height of flare line is PROD.M/


b) Movement of
 - could damage the flare line, 3 5 3 24 marked. Permit to Work System in Engineeri 2 5 3 16
lifters/cranes/vehicles
especially on road # 10 place. HSE Regulations. ng.

25. The temperature of the flare PROD.M/


a) Heat conduction i-e
Operators are trained. PPEs are used.
heat transfer through  - gases is very high during 3 4 2 18 Engineeri 2 4 2 12
HSE Regulations. PRL-SOPM-01.
mechanical contact abnormal condition. ng.

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)

Health/ life (b)


Hazards
Control Ensured/
Ye s
No
Observation Ref. Document
( F l a r e To w e r )

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
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)

Health/ life (b)


Hazards
Control Ensured/
Ye s
No
Observation Ref. Document
( F l a r e To w e r )

e) Poor or insufficient May result in misoperation


 - 3 5 5 30 Proper training given. PROD.M. 2 5 5 20
training of operator resulting into fire

f) Water hammering -  -

g) Mechanical May lead to abnormalities in


 - 3 5 4 27 PRL-SOPM-01. Shutdown procedure. PROD.M 2 5 4 18
breakdown or failure flare/ operation

h) Failure or blockage of May lead to abnormalities in


control and/or safety  - flare/ operation/ release of 3 5 4 27 PRL-SOPM-01. Maintenance Manual. PROD.M 2 5 4 18
device gases into the flare system
PROD.M/
i) Absence or insufficient
Engineeri
inspections/ May lead to release of gases/ Maintenance plans intact Routine
 - 3 5 4 27 ng/ 2 5 4 18
monitoring/preventive fire Maintenance. Inspection Manual.
Inspection
maintenance
Engineer.
j) Leak, pulsation  - May lead to release of gases/ 3 5 4 27 Routine Maintenance. PROD.M/ 2 5 4 18
fire Engineeri
ng.

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)

Health/ life (b)


Hazards
Control Ensured/
Ye s
No
Observation Ref. Document
( F l a r e To w e r )

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.

l) Release of high Leakage from flare line can


 - 3 5 4 27 Monitoring done round the clock. PROD.M 2 5 4 18
pressure gases result in release of gases/ fire

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)

Health/ life (b)


Hazards
Control Ensured/
Ye s
No
Observation Ref. Document
( F l a r e To w e r )

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)

Health/ life (b)


Hazards
Control Ensured/
Ye s
No
Observation Ref. Document
( F l a r e To w e r )

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)

Health/ life (b)


Hazards
Control Ensured/
Ye s
No
Observation Ref. Document
( F l a r e To w e r )
Fire

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)

Health/ life (b)


Hazards
Control Ensured/
Ye s
No
Observation Ref. Document
( F l a r e To w e r )

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)

Health/ life (b)


Hazards
Control Ensured/
Ye s
No
Observation Ref. Document
( F l a r e To w e r )

PRL-SOPM-01. Seal adjustment.


May take place in case of back
l) Explosion  - 3 5 5 30 Emergency Plan. s/o as per routine PROD.M 2 5 5 20
flash
plan.

No fire arms except security


Gun fire sparks could lead to PROD.M/
m) Use of fire arms  - 3 5 4 27 personnel. Security manual 2 5 4 18
fire MS&A
Emergency Plan.

Proper security arrangements are


PROD.M/
n) Terrorist attack  - Chances are very high 3 5 4 27 made. Security manual. Emergency 2 5 4 18
MS&A
Plan.

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)

Health/ life (b)


Hazards
Control Ensured/
Ye s
No
Observation Ref. Document
( F l a r e To w e r )
Toxic Substances and Explosive

Knock out drums have storage


c) Storage and handling  - 3 4 3 21 Routine draining jobs carried out. PROD.M 2 4 3 14
of toxic gases

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)

Health/ life (b)


Hazards
Control Ensured/
Ye s
No
Observation Ref. Document
( F l a r e To w e r )

Cleaning nuts and bolts during PROD.M/


Only kerosene used during
h) Cleaning metal parts  - maintenance activity can lead to 3 5 3 24 Engineeri 2 5 3 16
maintenance work
fire ng
Permit to Works System. All vehicles
i) I/C engines (fork
Spark from the exhaust may operating in the area are equipped
lifters, lift trucks,  - 3 5 5 30 PROD.M. 2 5 5 20
lead to fire/ explosion with spark arrestors. HSE Regulations.
vehicles)
PRL-SOPM-01.
PROD.M/
Elect
Engineer./
Airborne toxic /flammable Earthing in place. Maintenance
j) Static electricity  - 3 5 4 27 Walkthrou 2 5 4 18
substance can cause explosion Manual. Walkthrough Inspection.
gh
Inspection
Team.
79.
Radiation

Ionized Radiation:

May expose the worker/ 3 5 1 18 Whenever radiography is required it is PROD.M/ 2 5 1


a) Radiography  - employees to radiations done through contractor. The area is Inspection 12
properly cordoned off through warning Engineer.
tapes. Permit to Work System is
b) Storage of radioactive  - followed religiously. Radiation
material monitoring device is used.

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)

Health/ life (b)


Hazards
Control Ensured/
Ye s
No
Observation Ref. Document
( F l a r e To w e r )

c) Absence or
inadequacy of
monitoring devices  -
(film badges, pocket
chambers, film rings).

Non-ionized Radiation:

d) Visible radiation (light


source that can cause  - High flames on release of gases 3 4 2 18 PRL-SOPM-01. PROD.M. 2 4 2 12
distraction),
e) UV radiation (sun,
LASER, welding arcs,
UV lamps, high
temperature - 
processes such as
production of glass or
steel.)
f) Electromagnetic
radiation generated - 
from power lines.

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)

Health/ life (b)


Hazards
Control Ensured/
Ye s
No
Observation Ref. Document
( F l a r e To w e r )
Noise & Vibration

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)

Health/ life (b)


Hazards
Control Ensured/
Ye s
No
Observation Ref. Document
( F l a r e To w e r )

May be used during PROD.M/


Permit to Works System. PPEs given.
g) Use of power tools  - maintenance activity leading to 3 4 4 24 Engineeri 2 4 4 16
PRL-SOPM-01. HSE Regulations.
health amages ng

h) Mechanical work/
installation

Flare stack height may lead to


Flare stack is properly supported with PROD.M/
Any shear hazard/ material failure of
97.  - 3 4 5 27 Guy Wires. Proper designing done. Engineeri 2 4 5 18
oth the stack. Especially due to the
Routine Maintenance. ng.
er high wind velocity in the area.

Page 19 of 20
Health & Safety Hazard Identification/ Risk assessment/ Operational Plan
HSEQ-F-02 Rev: 04; Date: 29.03.2006

ENGINEERING CONTROLS ENSURED


Controls Observation
Y N N/A

1. Operational procedures  - - SOP for Flare Light –up and flare operation to be developed.

2. Trained personnel  - - Personnel are adequately trained.

3. Process Monitoring  - - Physical monitoring of flare is done.

4. Monitoring equipment  - - Physical monitoring of Flare is done.

5. Identification  - - Identification in place.


Overall, gloves, safety shoes, safety belt in case of climbing for maintenance
6. Personal Protective Equipment  - -
purpose.
7. Fire Fighting  - - DCP, Fire Hydrant, Fire Water Line.

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

Date: 11-10-2007 Date: 11-10-2007

Page 20 of 20