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KUWAIT NATIONAL PETROLEUM COMPANY

COLD HOT ENTRY


MASTER COPY
Location MAA MAB SHU LM OTHER Reference Number MAA-OA8-U63-WPRA -
Department / Division Operations Date 17/04/2017
Area / Unit Area -8, Unit -63, LAGOON Review Date
Description of Activity DEWATERING, DESLUDGING, SCAFFOLDING ERECTION/DISMANTLING AND INSPECTION
Estimated Number of Persons likely to be
exposed
Mitigation (Precaution taken) Residual
No Hazard Likelihood Severity Risk Likelihood Severity
Consider KNPC Standards/Codes/Practices. Risk
1 Hazards from the 3 3 Alert Lagoon shall be positively isolated from all sources 2 2 Care
connected equipment as per the approved blind list.
Blinding shall be done as per the approved blind list
Failure of blinds using standard rated blinds.
Physically verify that all blinds are present.
A copy of the blind list shall be kept at job location.
2 Dewatering the Lagoon 3 3 Alert Gas testing to be done in the whole area in the 2 2 Care
presence of operation, safety & maintenance before
Exposure to toxic and start of job and all reading shall be within
permissible limits as per the HOT work permit
flammable gases
requirements.
Fire Hazard Required HOT work permits shall be obtained
Drowning before starting the job.
Whipping of temporary Air pockets in the pump shall be removed as per
hoses and its standard operating procedure,
connections. Discharge pressure of the pump shall be monitored
by pressure gauge. It shall have calibration date.
All flange connection between temporary hoses &
pipes shall be tightened well with the appropriate
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gaskets and bolts. They shall be checked for any
possible leaks by soap solution. Bonding between
the hose flanges shall be ensured.
The electrical pump shall be of flame proof /
intrinsically safe type. The integrity of the flame
proof shall be checked by a competent electrical
person.
Proper bonding and grounding to be ensured by the
competent person to prevent the static sparks while
pump is using in transferring operations.
Generator shall be kept 15 meters away from the
lagoon.
Ensure to remove all the combustible materials from
the pump proximity area (min 15m distance)
The pump should have a valid safety certificate.
Temporary hose / piping connection authorization
shall be obtained for using temporary connections.
All temporary hoses and its connections shall be
anchored well with a permanent structure.
Hoses shall have valid pressure certificate.
Max. Discharge pressure of the Centrifugal pump-
4.71 Bar
Size of the hoses- 4/6 Inch
Pressure rating of the hose 17 Bar
Area shall be monitored continuously by continuous
gas monitor ( Check LEL, H2S, CO and O2)
Use only non-sparking tools.
Ensure to use the life vest
The level of liquid in both the lagoons shall be
closely monitored by Supervisor.
3 Removal of loose sludge 3 3 Alert Vacuum tanker shall be used to remove the loose 2 2 Care
from the Lagoon by using sludge from the lagoon.
Vacuum Tanker Gas test shall be ensured by the authorized gas tester

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Exposure to toxic and from the bottom of the lagoon (suction point) to the
flammable gases vacuum tanker (vacuum point) prior to use the
vacuum tanker. If the gas test results are within the
Static electricity
acceptable limit, Work permit shall be issued to
CO from engine remove the sludge by using the Vacuum tanker.
exhaust Continuous gas monitoring (LEL, H2S, CO and O2)
shall be ensured and wok must be stopped if the gas
levels exceed the acceptable limits as mentioned in
the work permit.
Vacuum tanker shall be located far away from the
ignition sources.
The end fittings of the suction hose of the vacuum
truck shall not have any metallic components that
can produce a spark.
Proper grounding and bonding shall be ensured
during the transfer.
Safe Operation of Vacuum Tanker HSE-TSSA-04-
2024 shall be followed for the additional guideline
related to the safe use of Vacuum Tanker.
Stop all the hot work in 15m radius including use of
battery operated instruments and vehicle/ equipment
use. All precautions pertaining to the safe use of
Vacuum tanker as mentioned in KNPC SWP shall be
followed.
Once all the loose sludge has been removed and
only heavy sludge is left out then the man entry
shall be allowed to remove the heavy sludge from
the lagoon.
Perform regular housekeeping at the end of the job
on daily basis.
Sludge shall be disposed as per the KNPC Waste
management system.
Personnel shall wear personal H2S monitor.
First aid fire fighting equipment shall be kept ready
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at site to take care of any emergency like fire due to
the presence of pyrophoric material.
Keep all access clear; ensure workers can escape
easily in case of emergency.
4 Man entry into the 3 3 Alert Ensure Lagoon is positively isolated as per the 2 2 Care
Lagoon to remove the approved BLIND LIST.
heavy sludge and Hydro Lagoon shall be made gas free and KNPC Safety
jet cleaning. along with operation and maintenance shall ensure
the gas testing prior to the first entry into the lagoon
and commencing any activities inside the lagoon. If
Oxygen Deficiency
gas test results are okay, permit the activity by
Exposure to toxic and issuing necessary permit/authorizations.
flammable gases Ensure Continuous ventilation of lagoon is arranged
Pathogens through Exhaust Fan connecting with flexible
ducting hose.
Pyrophoric ignition
Mechanical ventilation equipment shall be properly
Accidental fall when grounded (earthed) to dissipate any static charges.
ascending / descending Cleaning of lagoon should be carried out only under
ladders. direct supervision.
Fall of lifting materials Supervisor shall ensure the appropriate sign boards
Tilting of Crane (Entry/No Entry) available at the site.
All Confined space entry requirements as mentioned
Static electricity
in KNPC SWP (HSE-TASA-04-SP-2007) shall be
Potential injuries to all followed.
exposed body parts by Airline breathing apparatus set shall be used for the
high pressure water first entry. Similarly keep a SCBA set as a standby
near the entry point.
Ensure to give the frequent break and exposure to
fresh air atmosphere to the workers.
Personnel entering should be equipped with gum
boot, rubber gloves, protective suit (PVC rain coat),
Mask / respirator and personal H2S monitor.
Ensure to follow the basic personal hygiene habits.
Provide certified CSE attendant.
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Entrant shall be certified.
Each authorized entrant shall use a full body
harness, with a retrieval line attached to a fixed
anchor point outside the lagoon to enable the rescue
in case of any emergency.
Always maintain a 3-point (two hands and a foot, or
two feet and a hand) contact on the ladder when
climbing. Keep your body near the middle of the
step and always face the ladder while climbing.
Ladder must be free of any slippery material on the
rungs, steps or feet.
The proper angle for setting up a ladder is to place
its base a quarter of the working length of the ladder
from the wall or other vertical surface (75 Deg).
An extension or straight ladder used to access an
elevated surface must extend at least 3 feet above
the point of support
Use a ladder only on a stable and level surface,
unless it has been secured (top or bottom) to prevent
displacement.
Ensured Ladder not to be used to support near or on
energized electrical equipment.
Always inspect the ladder prior to using it. If the
ladder is damaged, it must be removed from service
and tagged until repaired or discarded.
Do not exceed the maximum load rating of a ladder.
Crane shall be used to mobilize the Tray into the
Lagoon to fill the heavy sludge into it.
Rigging plan shall be made available at site.
All heavy lifting equipment should have necessary
third party inspection certificate.
Necessary lifting device / tools to be used and
ensure validity of applicable certificates.

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Ensure lifting appliance is not used beyond its safe
working load.
Soil or floor condition shall be taken into account
while positioning the crane.
Work should be carried out by the qualified
personnel only.
Drop area shall be barricaded; guide rope shall be
used to prevent swing of the lifting materials.
Ensure that, during the course of lifting, no
personnel shall stand over or under the suspended
load.
Provision of water filled in the drum shall be
ensured as standby for wetting the solid sludge in
order to avoid the pyrophoric material exposure, if
any.
Sludge shall be disposed as per the KNPC Waste
management system.

After removal of heavy sludge from the Lagoon, hydro


jetting shall be carried out for internal cleaning.

Hydro jetting shall be carried out for lagoon internal


after the removal of all the sludges from Lagoon.
Care shall be taken to carry out hydro jetting after
gas freeing to avoid static charge generation.
Hydro jetting machine should have the valid safety
certified and qualified personnel shall execute the
job.
Ensure to use the gum boot, protective suit (rain
suit) and clear face shield.
The water used inside the lagoon for washing
purpose shall be removed once again by vacuum
tanker.
Hot Work permit shall be issued to use the Vacuum
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tanker if gas test results are within the acceptable
hot work permit limits.
Safe Operation of Vacuum Tanker HSE-TSSA-04-
2024 shall be followed for the additional guideline
related to the safe use of Vacuum Tanker.
Machine attendant shall be available at the hydro
blast machine.
Hoses shall be inspected before each job.
5 Scaffolding Erection and 3 3 Alert Ensure lagoon is positively isolated as per the 2 2 Care
Dismantling: approved BLIND LIST.
Carry out Gas test. If gas test results are okay as per
Exposure to toxic and the permit requirement, permit the activity by
flammable gases appropriate work permit/authorization.
Fall of personnel from Ensure Continuous ventilation of lagoon is arranged
height through Exhaust Fan connecting with flexible
ducting hose.
Fall of material from
Only trained and certified Scaffolders shall be
height engaged for the erection/dismantling of the scaffold.
Condition of scaffold materials shall be checked
prior to use.
Scaffold must be secured to prevent it from tipping
by means of tying the scaffolding to an adjacent
structure, using guy wires, or increasing the base
width and bracing.
Base plate and sole plate shall be placed at dry and
firm ground. Slippery/unstable ground shall be
avoided.
There shall not be any gaps existing on the working
platform.
Scaffolding shall have the top rail, mid rail and toe
guard as per the KNPC procedural requirement.
The area shall be barricaded for unauthorized entry
into the scaffold erection/dismantling area.
Use buckets with rope for loose nuts, bolts and other
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materials.
Personnel shall wear Personal H2S Monitor.
Personnel carrying out scaffold erection/dismantling
shall wear full body safety harness with double
lanyard and shall be latched while working at
height.
A RED tag shall be provided while erecting /
dismantling the scaffold.
After completion of erection of the scaffold, the
same shall be inspected and tagged. Ensure GREEN
tag on the scaffold before using it.
Scaffold shall be inspected as per KNPC approved
checklist and certified by competent personnel in
every 7 days.
Alteration/Modification of the scaffold shall be
carried out by competent personnel and shall be
recertified after completion.
Follow standard confined space precautions inside
the lagoon.
6 Hazards in Using BA sets 4 4 Alarm Airline respirator connected to the breathing 2 2 Care
compressor shall be used to prevent the inhalation of
toxic/flammable gases.
Breathing air compressor used during the operation
shall have lab test documents mentioning its
suitability for usage.
BA users shall be trained, certified and medically fit.
Wear airline mask with escape cylinder or SCBA for
IDLH (Immediate Dangerous to Life and Health)
situations.
Limit the personnel wearing BA to minimum (two).
All others shall be safe distance away with clear
escape path.

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7 Difficulty in 3 3 Alert Keep access clear; ensure workers can escape easily 2 2 Care
access/Escape. in case of emergency.
Workers shall be mindful about the presence of the
hoses/other materials lying on the ground to avoid
tripping.
Hoses/other materials shall be arranged in a manner
that does not block access/Escape.
Perform regular housekeeping at the end of the job
to avoid slip, trip/fall injury.
Train the workers for the emergency evacuation and
Practice emergency escape in advance.
8 Poor hazard 3 3 Alert Conduct Safety talk before starting the job. 2 2 Care
communication Explain above precautions in language craftsman
can understand.
Explain precautions in work permit, associated
permits & authorisations.
Verify they have understood properly.
For any other activity (not mentioned above), separate risk assessment will be done based on the
nature of the activity.
Specific prevention and protection measures
Work Permit System, Risk Assessment HSE-TSSA-06-2029 and all related procedure shall be
KNPC references:
followed.
Keep blind list, risk assessment, and work permits at site.
Key: ALARM Serious or major harm will probably occur ALERT Moderate harm probable, major harm unlikely to occur
CAUTION Minor harm probable, major harm unlikely to occur CARE Minor harm possible, major harm very unlikely to occur

Operations Maint/Constr. Engr. Maint/Constr. Safety Engr.


Section Head Safety Engr. (KNPC) Others
Controller (KNPC) Engr.(Contractor) Contractor

Signature

Name

Empl #

Note :-1. Master Copy(original) shall be retained in file for record and future reference.
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2. Photocopy shall be attached with work permit.
3. Ref. No. guidance:- Example LOCATION-DEPT./DIV.RISK ANALYSIS-YEAR-SERIAL NO.eg.1. MAA-XXXXRA-05-1001,2.PRJ-XXXRA-05-1001.
4. If same Risk assessment is being used again,it must be reviewed to check relevancy.

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