tra for storage tank erection

8/11/2019 TRA for Storage Tank Erection

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TASK RISK ASSESSMENT

Sulphur Tank Construction Using Hydraulic Tank Jacking Equipment Page 1 of 34

GeneralFacility Information:

Company: Dolphin Energy Limited Qatar Operation

Location: Ras Laffan Gas Plant, QatarUnit: Fire Zone:FZ02 Unit:144 Tag #: 144-OT-1001 Name:Construction of Liquid Sulphur Storage Tank

Project ID: DEL QOP

Study Duration:

Start: 6/13/2011

End: 6/13/2011

Methodology:

Type: Task Risk Assessmentas per QOP OMS Procedure QQH-GEN-0000-FRP-00025

GENERAL:The new Sulphur Tank will be constructed using two construction methods; (1) conventional tank construction for Tank shell co urse 5 and 6, and a temporary roofdome structure (2) using a Hydraulic Tank Jacking Equipment to install Tank shell course 1, 2, 3 and 4. This TRA will cover both construction methodologies.

CONDITIONS:1. Tank foundation, bottom and annular plate installation is completed with all NDT and radiography completed.2. All pre-fabricated parts required for the construction of the tank is shipped from the DOPET yard in DELWA to the construction site in the Dolphin Facility.3. All fabricated parts shall be identified with Tank No, Part No, Item No and Drawing No.4. All pre-fabricated items are properly supported and packed for transport from the DOPET yard in DELWA to the construction site in the Dolphin Facility.5. All Hydraulic Tank Jacking equipment shall have valid 3

rdParty Inspection Certificates.

6. All other lifting equipment used during the course of work shall have valid 3rd

Party Inspection Certificates (expect field welded lugs which will be inspected bycompetent welding inspector from DOPET or PMT).7. All tank construction work shall comply with the Dolphin PTW and Safe Work System.8. Four (4) Naked Flame Permits are allowed during the construction of the Tank; when additional Naked Flame Permits are required then the requirement shall bere-assessed by QOP ( Based on the quantum of work permitted without causing distortion due to welding).9. QOP approved Rescue Plan in place.10. During the lifting process all required guy wires (4) shall be in place to maintain tank stability.

11. Guy wires shall be installed and the roof will have four (4) open areas (no plate installed) to prevent movement or lifting of the tank during high winds and forventilation.12. Maximum number of personnel allowed inside during lifting of tank shell using hydraulic jacks is 6 people (two hydraulic jack operators, two helpers, and twosafety watch).13. Maximum number of personnel allowed inside the tank area during welding of shell course 5 and 6, and roof structure is 1414. Maximum number of personnel allowed inside the tank area during welding of shell course 4, 3, 2 and 1 is 10 subject to work conditions.15. Maximum number of personnel allowed inside the tank area during vacuum box testing of bottom plate welds is 4.16. No lifting activities (crane operation) if wind speed is above 20 knots as per Dolphin standard.


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ASSUMPTIONS:1. All items that are required for tank construction and pre-fabricated in DOPET and Vendor workshops have passed the required inspections as stipulated in the ITP2. All dimensional measurements of tank ancillary equipment have been pre-checked and conform to the Company approved drawings and are within the allowableolerances3. Tank is constructed in accordance with API 650 Standard4. All personnel assigned to operate the Hydraulic Tank Jacking Equipment are competent5. Construction of the roof dome temporary structure requires mobile scaffolding6. Welding of the horizontal and vertical seams and seal welding of the roof plates requires mobile scaffolding7. Temporary structure required to support the crown plate, roof frame and roof petals during construction of the roof dome.

STEPS OF THE WORK METHOD STATEMENT:

1. Receiving Material on Site2. Conventional Construction of Tank Shell Course 5 and 63. Construction of Curb Angle4. Construction of roof dome temporary structure

5. Installation of Hydraulic Tank Jacking Equipment6. Construction of Tank Shell Course 1, 2, 3, and 47. Installation of Tank staircase, roof walkway and steam coils8. Vacuum Box Testing9. Hydrostatic Testing10. Painting


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Team MembersFirst Name Last Name Title Company

Narendran CK Project HSE Manager DOPET

Veeraraghavan N HSE Officer DOPET

Srinivasa Rao Sr. Project Engineer DOPET

Sunil Palmal Tank Supervisor DOPET

Jeeri Reddy Tank Engineer DEL

Nitin Reddy Mech Supervisor DEL

Ramadhan Al Bulshi HSE Officer DEL

Reginald Simons Project Specialist DEL

Shaji Kumar Field HSE Coordinator DEL

Neil Cooper ERT Chief DEL

Malik Al Bushi Sr. HSE Officer DEL


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SessionsDate Duration Description Leader Scribe Comment

1. 6/13/2011 1.50 Reginald Simons Reginald Simons


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Attendance

Team Members

Sessions

1. 6/13/2011

HoursNarendran Present 1.5

Veeraraghavan Present 1.5

Srinivasa Present 1.5

Sunil Present 1.5

Jeeri Present 1.5

Nitin Present 1.5

Ramadhan Present 1.5

Reginald Present 1.5

Shaji Present 1.5

Neil Present 1.5

Malik Present 1.5


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DrawingsDrawing / Procedure Title File Path


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Revalidation HistoryStart Date End Date Comments

6/13/2011 6/13/2011


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SystemSystem / Main Activity Drawings Comment

1. Sulphur Tank Construction using Hydraulic Tank Jacking Equipment


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SubsystemsRig Activity: 1. Sulphur Tank Construction using Hydraulic Tank Jacking Equipment

Subsystem / Job Step Activities Design Conditions/Parameters Drawings Comment

1. Receiving Material on Site

2. Conventional Construction of Tank Shell Course 5 and 6

3. Construction of Curb Angle

4. Construction of roof dome temporary structure

5. Installation & Testing of Hydraulic Tank Jacking Equipment

6. Construction of Tank Shell Course 1, 2, 3, and 4

7. Installation of Tank staircase, roof walkway and steam coils

8. Vacuum Box Testing of Bottom & roof plate welds

9. Hydrostatic Testing

10. Blasting & Painting


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WorksheetSystem / Main Activity: 1. Sulphur Tank Construction using Hydraulic Tank Jacking Equipment

Subsystem / Job Step: 1. Receiving Material on Site Drawings:

Activities: Equipment ID:

Design Conditions/Parameters:

Hazards/Safety Issue or concerns Consequences S SafeguardsRisk Matrix

Recommendations ResponsibilityL RR

1. Vehicle movement 1. Property damage Moderate 1. Competent driver Remote B (8)

2. Banks man

3. Pre-start route survey

4. TBT

2. Personal injury Minor 1. Competent driver Remote A (1)

2. Banks man

3. TBT

2. Dropped objects 1. Property damage Minor 1. Competent driver Remote A (1)

2. Load is properly secured3. TBT


2. Load is properly secured

3. TBT

3. Crane failure (with load) 1. Property damage Moderate 1. Certified equipment Remote B (8) 1. Ensure no personnel undersuspended load.

Sunil Palmal

2. Crane inspection

3. Adequate tag line

4. Competent personnel

5. Crane SWL should be checkbefore lifting

2. Personal injury Major 1. Certified equipment Remote B (16)

2. Swinging zone shall beBarricaded




4. Oil spills (hydraulic oil from crane) 1. Environmental impact Minor 1. Certified equipment Remote A (1)

2. Crane inspection

3. Competent


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System / Main Activity: 1. Sulphur Tank Construction using Hydraulic Tank Jacking Equipment

Subsystem / Job Step: 1. Receiving Material on Site Drawings:



Hazards/Safety Issue or concerns Consequences S Safeguards Risk Matrix Recommendations ResponsibilityL RR

operator/personnel

5. Heat Stress 1. Personal injury Moderate 1. DEL heat stressmanagement program

Remote B (8) 2. Suffient water shall be in place inrest shelter

Veeraraghavan N

2. Rest shelter

3. Work rotation

6. Manual handling (shifting heavyequipment)

1. Personal injury Minor 1. Trained personnel in manualhandling technique

Remote A (1)

2. TBT

3. Supervision

7. Slip, trip and falls 1. Personal injury Minor 1. Good housekeeping to bemaintained

Remote A (1)

2. Warning signage3. Proper cable & hoses

management


Subsystem / Job Step: 2. Conventional Construction of Tank Shell Course 5 and 6 Drawings:





1. Caught in between equipment andpinch points

1. Personal injury Minor 1. PPE Remote A (1)


3. Barricade with properwarning signage


Sunil Palmal

2. Crane inspection






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Hazards/Safety Issue or concerns Consequences S Safeguards Risk Matrix Recommendations ResponsibilityL RR







3. TBT



3. TBT

4. Electric shock 1. Personal injury Moderate 1. Certified & DEL inspectedElectrical equipment

Remote B (8)

2. Regular inspection bycompetent person

3. Proper earthing

4. Proper cable & hosesmanagement

5. Fire 1. Property damage Minor 1. Fire watcher Remote A (1)

2. Firefighting equipment

3. Habitat with fire blanket

4. Gas monitor

2. Personal injury Moderate 1. Firefighting equipment Remote B (8)

2. TBT

3. Approved PPE

6. Flying objects (due to grinding) 1. Personal injury Moderate 1. Approved PPE Remote B (8)

2. TBT


4. Approved & Certifiedequipment


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Veeraraghavan N

2. Rest shelter

3. Work rotation

8. Inhalation of fumes (welding) 1. Personal injury Minor 1. Adequate ventilation Remote A (1) 3. 3M face Mask should be kept at site Veeraraghavan N

2. Approved PPE

3. Proper positioning bycompetent person

9. Manual handling (shifting heavyequipment)


Remote A (1)

2. TBT

3. Supervision10. Slip, trip and falls 1. Personal injury Minor 1. Good housekeeping to be

maintainedRemote A (1)

2. Warning signage


11. Oil spills (Diesel from Gen set) 1. Environmental impact Minor 1. Certified equipment Remote A (1)

2. Crane inspection

3. Competentoperator/personnel

12. Radiography 1. Personal injury Minor 1. Competent personnel Remote A (1)

2. Radiography shall be done innormal off hours


13. Working at height 1. Personal injury Minor 1. Fall protection with 100 % tieoff

Remote A (1)

2. TBT

3. Supervision




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2. Banks man


4. TBT


2. Banks man

3. TBT


Subsystem / Job Step: 3. Construction of Curb Angle Drawings:









2. Chemical exposure 1. Personal injury Minor 1. Approved PPE Remote A (1)


3. MSDS

4. TBT


Sunil Palmal

2. Crane inspection3. Adequate tag line







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3. TBT



3. TBT


Remote B (8)


3. Proper earthing





4. Gas monitor


2. TBT

3. Approved PPE

7. Flying objects (due to grinding) 1. Personal injury Moderate 1. Approved PPE Remote B (8)2. TBT





Veeraraghavan N

2. Rest shelter


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3. Work rotation


2. Approved PPE


10. Manual handling (shifting tools &Tackles)


Remote A (1)

2. TBT

3. Supervision


Remote A (1)


management


2. Crane inspection





14. Working at height 1. Personal injury Minor 1. Fall protection with 100 % tie

off

Remote A (1)

2. TBT

3. Supervision



2. Banks man


4. TBT


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2. Banks man

3. TBT


Subsystem / Job Step: 4. Construction of roof dome temporary structure Drawings:





1. Caught in between equipment andpinch points 1. Personal injury Minor 1. PPE Remote A (1)2. Competent personnel



Sunil Palmal

2. Crane inspection











3. TBT



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3. TBT


Remote B (8)


3. Proper earthing




3. Habitat with fire blanket4. Gas monitor


2. TBT

3. Approved PPE


2. TBT





Veeraraghavan N

2. Rest shelter

3. Work rotation


2. Approved PPE




Remote A (1)

2. TBT


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3. Supervision


Remote A (1)

2. Warning signage



2. Crane inspection


12. Vehicle movement (Crane & Flat bed) 1. Property damage Moderate 1. Competent driver Remote B (8)

2. Banks man3. Pre-start route survey

4. TBT


2. Banks man

3. TBT


Remote A (1)

2. TBT

3. Supervision


System / Main Activity: 1. Sulphur Tank Construction using Hydraulic Tank Jacking EquipmentSubsystem / Job Step: 5. Installation & Testing of Hydraulic Tank Jacking Equipment Drawings:









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Subsystem / Job Step: 5. Installation & Testing of Hydraulic Tank Jacking Equipment Drawings:





3. Approved PPE



Veeraraghavan N

2. Rest shelter

3. Work rotation


2. Approved PPE




Remote A (1)

2. TBT3. Supervision

10. Oil spills (hydraulic oil) 1. Environmental impact Minor 1. Certified equipment Remote A (1)

2. Crane inspection



Remote A (1)

2. Warning signage



2. Banks man


4. TBT


2. Banks man

3. TBT



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Subsystem / Job Step: 6. Construction of Tank Shell Course 1, 2, 3, and 4 Drawings:











3. MSDS

4. TBT



3. TBT



3. TBT


Remote B (8)


3. Proper earthing


5. Failure of hydraulic jack(s) 1. Property damage Major 1. Anti fall (Mechanical) lockingsystem equipped with thelifting jacks

Remote B (16)

2. Load is Guided by a trestle

(columns) which lowers theload slowly.

3. Certified equipment

4. Regular inspection of TankJacking equipments bycompetent person


2. Personal injury Major 1. Anti fall (Mechanical) locking Remote B (16)


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Recommendations ResponsibilityL RRsystem equipped with thelifting jacks

2. Load is Guided by a trestle(columns) which lowers theload slowly.

3. Certified equipment

4. Regular inspection of Jackingequipments by competentperson



2. Firefighting equipment3. Habitat with fire blanket

4. Gas monitor


2. TBT

3. Approved PPE


2. TBT



8. Flying objects (due to release of storedenergy)

1. Personal injury Moderate 1. Approved PPE Remote B (8)

2. TBT3. Competent personnel




Veeraraghavan N

2. Rest shelter

3. Work rotation


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Hazards/Safety Issue or concerns Consequences S Safeguards

Risk Matrix



2. Approved PPE


11. Manual handling (shifting Tools &ackles)


Remote A (1)

2. TBT

3. Supervision

12. Oil spills (diesel fuel) 1. Environmental impact Minor 1. Certified equipment Remote A (1)

2. Inspection

3. Competent

operator/personnel13. Oil spills (hydraulic oil) 1. Environmental impact Minor 1. Certified equipment Remote A (1)

2. Crane & Hydraulic pumpinspection






Remote A (1)


management

16. Vehicle movement (crane & flat bed) 1. Property damage Moderate 1. Competent driver Remote B (8)

2. Banks man


4. TBT



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Subsystem / Job Step: 7. Installation of Tank staircase, roof walkway and steam coils Drawings:




Risk Matrix







3. TBT



3. TBT

5. Electric shock 1. Personal injury Moderate 1. Certified & DEL inspected

Electrical equipment

Remote B (8)


3. Proper earthing





4. Gas monitor


2. TBT

3. Approved PPE7. Flying objects (due to grinding) 1. Personal injury Moderate 1. Approved PPE Remote B (8)

2. TBT





Veeraraghavan N


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Risk Matrix


2. Rest shelter

3. Work rotation


2. Approved PPE


10. Manual handling (shifting of tools &Tackles)


Remote A (1)

2. TBT

3. Supervision


2. Inspection



Remote A (1)

2. Warning signage


13. Vehicle movement (crane & flat bed) 1. Property damage Moderate 1. Competent driver Remote B (8)

2. Banks man


4. TBT


2. Banks man

3. TBT


Remote A (1)

2. TBT

3. Supervision



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Risk Matrix



2. Banks man


4. TBT


2. Banks man

3. TBT


Subsystem / Job Step: 8. Vacuum Box Testing of Bottom & roof plate welds Drawings:









2. Confined space 1. Personal injury Moderate 1. Approved rescue plan Remote B (8)

2. DEL Confined space entryprocedure

3. Hole watch

4. TBT




3. TBT



3. TBT


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Subsystem / Job Step: 9. Hydrostatic Testing Drawings:




Risk Matrix


3. Proper earthing



2. Inspection




Veeraraghavan N

2. Rest shelter

3. Work rotation

5. Slip, trip and falls 1. Personal injury Minor 1. Good housekeeping to bemaintained Remote A (1)

2. Warning signage



Remote A (1)

2. TBT

3. Supervision


7. Flooding 1. Property damage Major 1. Proper tank Inspectionhroughout construction

Remote B (16)

2. Compliance with QA/QCProcedures

3. Tank is constructed inaccordance with API 650

2. Personal injury Moderate 1. Proper tank Inspectionhroughout construction

Remote B (8)

2. Compliance with QA/QCProcedures

3. Tank is constructed inaccordance with API 650


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Subsystem / Job Step: 10. Blasting & Painting Drawings:







3. MSDS

4. TBT



3. TBT



3. TBT

3. Flying objects (due to release of storedenergy)

1. Personal injury Moderate 1. Approved PPE Remote B (8)

2. TBT





Veeraraghavan N

2. Rest shelter

3. Work rotation


2. Inspection

3. Competent

operator/personnel6. Slip, trip and falls 1. Personal injury Minor 1. Good housekeeping to be

maintainedRemote A (1)

2. Warning signage



2. Banks man


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Subsystem / Job Step: 10. Blasting & Painting Drawings:




Risk Matrix





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RecommendationsRecommendations Place(s) Used Responsibility Comment Signature

1. Ensure no personnel under suspended load. Hazards: 1.1.3, 1.2.2, 1.3.3, 1.4.2,1.7.3

Sunil Palmal

2. Suffient water shall be in place in rest shelter Hazards: 1.1.5, 1.2.7, 1.3.8, 1.4.7,1.5.7, 1.6.9, 1.7.8, 1.8.5, 1.9.4,1.10.4

Veeraraghavan N

3. 3M face Mask should be kept at site Hazards: 1.2.8, 1.3.9, 1.4.8, 1.5.8,1.6.10, 1.7.9, 1.10.11

Veeraraghavan N

4. Ensure that a proper habitat is in place to prevent therelease of grit to atmosphere

Hazards: 1.10.10 Sunil Palmal

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