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Report : EP200907328245
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HAZID AND RISK ASSESSMENT REPORT FOR THE USE OF ALLOY SCAFFOLDING ON
OFFSHORE FACILITIES
Page i
Distribution List
Name
EP200907328245
Reference
July 2009
Page ii
HAZID AND RISK ASSESSMENT REPORT FOR THE USE OF ALLOY SCAFFOLDING
ON OFFSHORE FACILITIES
Accepted by;
Signed :
Signed :
Reviewed by;
Alan Sherriff (EPE-P-ED)
Philip Brunton (EPE-S-HU)
July 2009
EP200907328245
HAZID AND RISK ASSESSMENT REPORT FOR THE USE OF ALLOY SCAFFOLDING ON
Page iii
OFFSHORE FACILITIES
Contents
BACKGROUND............................................................................................................. 4
PURPOSE OF HAZID AND RISK ASSESSMENT ....................................................... 5
KEY FINDINGS AND CONCLUSIONS ......................................................................... 5
ACTION CLOSE-OUT ................................................................................................... 5
ATTACHMENTS............................................................................................................ 6
APPENDIX 1 WORKSHEETS
EP200907328245
July 2009
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HAZID AND RISK ASSESSMENT REPORT FOR THE USE OF ALLOY SCAFFOLDING
ON OFFSHORE FACILITIES
BACKGROUND
A Lean/Kaizen event was held on Brent Charlie during September 2008 which
established a number of improvement opportunites to improve HSE risk exposure
and efficiency of platform scaffolding operations. In summary these opportunities
included better planning, reduced manual handling and transportation wastes due to
more strategic storage of materials and also the use of alloy scaffold materials.
Brent Charlie had previously been testing an alloy system scaffold however the
Kaizen event established this was not fot for purpose due to its fixed dimensions and
as a result the use alloy scaffold tube was identified and developed as an opportunity.
Susequent performance tracking and analysis has demonstrated the improvements
on Brent Charlie have reduce carrying of materials by 50% and the overall task time
per m3 of scaffold has reduced by 32%.
July 2009
EP200907328245
HAZID AND RISK ASSESSMENT REPORT FOR THE USE OF ALLOY SCAFFOLDING ON
Page 5
OFFSHORE FACILITIES
Role
Chris Wilson
Chris Grant
Scott Fraser
Andy Fairnie
Roger Esson
Hamid Iravani
Corrosion Engineer
Keith Greenwood
ACTION CLOSE-OUT
The following actions were raised during the HAZID and risk assessment session.
Responsibility for the close-out of the actions rests with Roger Esson, SORT4
Delivery Manager with Chris Grant, Field Productivity Team acting as close-out coordinator. Unless otherwise agreed with the co-ordinator, all actions should be
st
targeted for completion by 1 September 2009.
EP200907328245
July 2009
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HAZID AND RISK ASSESSMENT REPORT FOR THE USE OF ALLOY SCAFFOLDING
ON OFFSHORE FACILITIES
ATTACHMENTS
Presentation prepared by SORT4 addressing concerns raised about the use of
aluminuium alloy scaffolding systems in an offshore environment.
Scaffold Alum
Alloy.ppt (Compr...
July 2009
EP200907328245
HAZID AND RISK ASSESSMENT REPORT FOR THE USE OF ALLOY SCAFFOLDING ON
Page 7
OFFSHORE FACILITIES
APPENDIX 1
EP200907328245
July 2009
Page 8 HAZID AND RISK ASSESSMENT REPORT FOR THE USE OF ALLOY SCAFFOLDING ON OFFSHORE FACILITIES
HAZARD
Incendive sparking
Incendive sparking is
initiated by an exothermic
reduction of iron oxide (in the
form of rust) by aluminium
particles. Three basic
mechanisms produce the
pre-requisite conditions for
incendive sparking. The first
is single impact sparking and
requires relatively high
energy (minimum 300
Joules). Subsequent impact
sparking may occur from
striking a previously
deposited aluminium smear
resulting from an earlier
impact of an aluminium
object on a rusted steel
surface. This mechanism is
the most probable as it
requires much lower impact
energies (1-5 Joules) to
initiate the spark. The third
mechanism is friction
sparking. This type of
sparking is most unlikely to
occur as the temperature
caused by sparking are
July 2009
POTENTIAL
CONSEQUENCES
Ignition risk in
flammable gas
environment
Ignition of other
flammable materials
e.g. oily rags.
CONTROLS
RISK ASSESSMENT
ACTION
ACTION 1 Communicate
requirement for Cat 2 Hot
Work WCC for alloy
scaffold use in Zone 1
areas.
EP200907328245
HAZID AND RISK ASSESSMENT REPORT FOR THE USE OF ALLOY SCAFFOLDING ON OFFSHORE FACILITIES
HAZARD
POTENTIAL
CONSEQUENCES
CONTROLS
Page 9
RISK ASSESSMENT
ACTION
Degradation of
material leading failure
which could lead to
possible collapse of
scaffolding
Incorporate guidance in to
SORT4 procedures on
how to identify corroded
alloy tubes that need to be
taken out of service.
ACTION Roger Esson
EP200907328245
Failure of scaffold
structure with potential
injury to personnel
and damage to
July 2009
Incorporate guidance in to
SORT4 procedures to
ensure tube materials are
not mixed
Page 10 HAZID AND RISK ASSESSMENT REPORT FOR THE USE OF ALLOY SCAFFOLDING ON OFFSHORE FACILITIES
HAZARD
tubing)
POTENTIAL
CONSEQUENCES
equipment
CONTROLS
ladder beams are used, Scaffold
Design Engineer sign off is
required. This applies to scaffold
structures used as lifting frames.
RISK ASSESSMENT
low.
ACTION
Failure of scaffold
structure with potential
injury to personnel and
damage to equipment
Confirm Alloy/Steel
corrosion is not an issue
with the controls in place
via Draugen experience.
ACTION Andy Fairnie
Incorporate guidance in to
SORT4 procedures to
monitor any corrosion at
tube/fitting interface as
part of inspections. This
should continue until we
can assure ourselves this
is not an issue.
ACTION Roger Esson
Communication, familiarisation
and understanding of the new
system.
Incorprate in to SORT4
Q&A engagement pack
ACTION Roger Esson
July 2009
EP200907328245
Review locations of
scaffold storage racks to
ensure proximity to
HAZID AND RISK ASSESSMENT REPORT FOR THE USE OF ALLOY SCAFFOLDING ON OFFSHORE FACILITIES
HAZARD
POTENTIAL
CONSEQUENCES
CONTROLS
steel scaffold bays. This means
the number of materials is the
same, therefore no extra manual
handling.
Page 11
RISK ASSESSMENT
overall task time reduced by
30% through the use of alloy
tube and strategic storage
locations.
Alloy tube 30% of steel weight.
ACTION
worksite.
Incorporate alloy bay size
guidance in to SORT4
procedures and
commincate requiremts
with offshore scaffolder
staff
ACTION Roger Esson
Injury to personnel
caused by carrying too
many tubes (which are
much lighter than
steel)
Introducing guidance/caps on
number of tubes to be carried.
EP200907328245
Failure of scaffold
structure with potential
injury to personnel
July 2009
Incorporate guidance in to
SORT4 procedures on
how to identify corroded
Page 12 HAZID AND RISK ASSESSMENT REPORT FOR THE USE OF ALLOY SCAFFOLDING ON OFFSHORE FACILITIES
HAZARD
POTENTIAL
CONSEQUENCES
and damage to
equipment
CONTROLS
is generally better than Carbon
Steel
RISK ASSESSMENT
routine inspections before it
becomes critical
Failure of scaffold
structure with potential
injury to personnel and
damage to equipment
Failure of scaffold
structure with potential
injury to personnel and
damage to equipment
ACTION
alloy tubes that need to be
taken out of service.
ACTION Roger Esson
None required.
Incorporate guidance in to
SORT4 procedures on
how to identify corroded
alloy tubes that need to be
taken out of service.
July 2009
Failure of scaffold
structure with potential
injury to personnel
EP200907328245
None required.
HAZID AND RISK ASSESSMENT REPORT FOR THE USE OF ALLOY SCAFFOLDING ON OFFSHORE FACILITIES
HAZARD
POTENTIAL
CONSEQUENCES
and damage to
equipment
CONTROLS
EP200907328245
RISK ASSESSMENT
blasting.
July 2009
Page 13
ACTION
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July 2009
EP200907328245