CRITICAL TASK RISK ASSESSMENT APPENDIX – H

Part-A
COLD 􀂅 HOT 􀂅 ENTRY 􀂅
KNPC Site: MAA 􀂅 MAB 􀂅 LM 􀂅 OTHERS 􀂅 Ref. No: MAA-OA5-U64-CTRA-19-TM-24 Date: 30-06-2019

Location: AREA -05,UNIT -64, TK 64-003 Dept. / Div. OPERATION

Description of activity: Scaffolding Erection, Dismantling & Inspection - inside & outside the tank Area / Unit: 5 / 64
Note: The tank is positively isolated, opened and cleaned prior to this risk assessment.

Estimated No. Of Persons Likely to be exposed: Operation: 2 / Maintenance : 20

Hazard Initial Residu Responsible
{Location specific hazards, Existing controls Risk al Risk Person
Configuration specific Additional Controls (Who is responsible to
implement the control
hazards (in case of CSE) & L S R L S R Measure identified?)
Other hazards}

Scaffolding Erection,
Modification &
Dismantling:
 Exposure to Toxic
(H2S) & Flammable
gases
 Fall of materials from
height
 Fall of personnel from
height
 Collapsing of Scaffold
 Required work permits shall be obtained before starting D 5 H  Scaffolding works shall be B 3 L  Issuer
the job. executed by KNPC approved  Executor
 Authorized gas tester shall carry out the gas test around scaffold supervisor only.  Authorized gas
the job (15m) to ensure the 100% gas free before start of  Only trained and certified tester
the job. Scaffolders shall be engaged
 The area shall be barricaded for unauthorized entry into for the erection/dismantling of
the scaffold erection/dismantling area. the scaffold
 No other parallel work shall be allowed in the area below  Condition of scaffold materials
the scaffold erection/dismantling activity. shall be checked prior to use.
 Use buckets with rope for loose nuts, bolts and other  A RED tag shall be provided
materials. while erecting / dismantling
 Ensure to use the non-sparking tools if it is require. the scaffold.

TK-64-003 CTRA-Scaffolding Erection, Dismantling & Inspection – inside & outside the tank
  Personnel carrying out scaffold erection/ dismantling  Ensure GREEN tag on the
and working on scaffold shall wear full body safety scaffold before using it.
harness with double lanyard and it shall be attached to  Alteration/Modification of the
either a vertical lifeline, horizontal lifeline, or stable scaffold shall be carried out by
scaffold structure member. competent personnel and shall
 Number of personnel and other materials on the be recertified after completion.
scaffolding shall be restricted as per scaffolding load  Scaffold exceeding a) 38
bearing capacity. Meters b) requiring special
 After completion of erection of the scaffold, the same application, shall be designed
shall be inspected and GREEN tagged. by a KNPC approved qualified
 Scaffold shall be inspected as per KNPC approved engineer only.
checklist and certified by competent personnel in every  While utilizing portable
7 days. ladders three-point contact
 Scaffolders and Scaffolding supervisors shall audit on shall be maintained at all
each shift of scaffolding use in order to ensure the times.
integrity of scaffold and ensure on gaps between planks.  Dismantled/ any materials
 All openings on the scaffolding platforms shall be shall be lowered to the ground
protected with guard rail system (Top guardrail, midrail, and not stored on the scaffold
Toe boards) as per KNPC standard. platform
 Dismantling shall be start from top to bottom in orderly  To ensure adequate
fashion. illumination, light intensity
 Ensure the Sufficient illumination (300 Lux) around the shall be measured by work
working area. permit executor, using Lux
 Workers shall be mindful about the presence of the meter.
materials lying on the ground to avoid tripping.  Precautions should ensure the
 The electrical cables shall be laid properly to prevent lighting used do not create
tripping. additional hazards.
 Proper housekeeping shall be maintained at all times in
the work area.
TK-64-003 CTRA-Scaffolding Erection, Dismantling & Inspection – inside & outside the tank
  Use suitable PPE as mentioned in work permit at all
times in the work area.
 Provide sufficient cold water and rest work cycle for the
workers.
 Wear H2S monitor with valid calibration.
 Other precautions outlined in KNPC SWP of Scaffolds,
Ladders & Work at heights (HSE-TSSA-06-2015) and
SWP Checklist to be followed.
Confined Space Entry:  Ensure tank is positively isolated from all sources as D 5 H  Physical verification that all B 3 L  Issuer
per the approved blind list. blinds are present shall be  Executor
 Failure of positive  Ensure Blinding is done as per the approved blind list ensured by issuer and  Authorized Gas
isolations/blinds using standard rated blinds. executor. Tester
 Restricted entry/exit  Ensure copy of the blind list is available at job location.  Work inside the tank shall be  Confined Space
 Oxygen deficiency
 Tank shall be made gas free by using the exhaust fan carried out only under direct Attendant
 Exposure to toxic and
and temporarily stop the ventilation 15 min before the supervision.
flammable gases
 Fire hazard gas test.  Ensure the validity of confined
 Static electricity  Authorized Gas tester shall carry out gas test (LEL, space entrant and attendant
 Poor illumination H2S, CO and O2). If the gas test results are okay, card for the personnel
 CO from engine permit the activity by issuing necessary permit & involving in this activity.
exhaust authorizations.  Precautions should ensure the
 Slip, Trip & Falls  Display Entry Authorization with associated work lighting used inside the
permits, attendance sheet, blind list, CTRA and rescue confined space do not create
(Note: If Scaffolding to pre-plan at the tank man way. additional hazards. Also
be erected inside the
 Only trained and certified personnel shall be engaged lighting used should be
tank, follow the positioned to enable the
for the job and having a valid entrant card before
Mitigation for Confined attendant to see clearly the
entering into the Confined Space.
Space Entry)
 A trained and certified confined space attendant shall entrants working in confined
be made available who remains outside the tank. space.
 Inform EDC and Rescue team.
TK-64-003 CTRA-Scaffolding Erection, Dismantling & Inspection – inside & outside the tank
  Head count for the personnel inside the tank shall be  Ensure rescue pre-plan is
maintained by the attendant. available at the site.
 Confined space sign board shall be readily available at  Fire extinguishers shall be kept
site, display green “ENTRY ALLOWED” sign at ready at site to take care of any
authorised entry point(s) while attendant is present. emergency at the site.
Display red “NO ENTRY” signs or Cross Barricade at
man ways not approved for entry during break times or
when the attendant is away.
 In confined space, if the attendant cannot directly and
effectively communicate visually or by voice with the
entrants, effective means of communication (e.g.
Whistle etc.) or intermediate person shall be available.
 For confined space with multiple manholes (entry
points), entry shall be restricted by providing cautions
board or warning tape (cross barricade) or controlled by
having additional attendant(s) with proper
communication among the attendant.
 Dedicated tank man way shall be used for personnel
entry only and not to be used for other purpose.
 Ensure proper ventilation arrangements by means of
exhaust fans prior to entry inside and it shall be
properly grounded (earthed) to dissipate any static
charges.
 Personnel shall wear personal H2S monitor with valid
calibration sticker.
 The equipment should be located in a well-ventilated
area that is free from contaminants such as harmful
fumes, engine exhaust.
 Provide sufficient cold water and rest work cycle.

TK-64-003 CTRA-Scaffolding Erection, Dismantling & Inspection – inside & outside the tank
  Sufficient illumination (300 Lux) shall be ensured
inside the confined space, both prior to entry and
during the work.
Electrical hazard due to  Source of electricity shall be isolated by following lock C 4 M  Executor shall ensure the B 3 L  Executor
electrical equipment. out tag out system. proper inspection of all tools &
 Electrocution  All electrical fittings shall meet the electrical area equipment before use.
 Burn injury classification.  Ensure proper functioning of
 Proper earthing shall be ensured. ELCB (30 mA only).
 All electrical power supply shall be connected through  Use of any electrical
ELCB with a rating of 30mA only. equipment above 24V shall
 Ensure to use the 24V explosion proof hand lamp inside have earth leakage tripping
the tank. device. Electrical fittings
 Electrical wiring shall be without any defect and it shall exceeding 24V and
be reinforced type. connections inside confined
 Electrical cables shall not be laid along the wet areas. space (including ELCB) shall
 Don’t use cable with multiple and loose joints. be inspected and approved by
 Use appropriate PPE (rubber gloves) to protect from KNPC Electrical Maintenance
electrical shock before starting the job.
Emergency equipment  Materials shall be laid in a manner that does not block C 4 M  Equipment / Scaffold / B 3 L  Executor
obstruction the emergency routes /equipment. Materials must not obstruct
access to any emergency / fire
fighting equipment.
Poor hazard  Conduct Safety talk before starting the job. C 4 M  Executor shall verify that the B 3 L  Executor
communication  Explain precautions in confined space entry workers have understood all
authorization and associated permits through the the precautions properly.
language that the craftsman can understand to ensure
workers can escape easily in case of emergency.

TK-64-003 CTRA-Scaffolding Erection, Dismantling & Inspection – inside & outside the tank
  Keep access clear; ensure workers can escape easily in
case of emergency (Follow the wind sock direction
(cross or upwind) to reach the nearest transfer point).
We agree with the residual risk levels and control measures required to perform the tasks based on the identified hazards. We confirm that we,
the members of this CTRA team have visited the job site to identify and document all the hazards associated with the activity.
CTRA member name / Designation Signature CTRA member name / Designation Signature
Section Head Safety Engineer (cont.)

Operation controller Maint / Constr.Engr (Cont.)

Maint / Constr.Engr (KNPC) Others

Safety Engineer (KNPC)

TK-64-003 CTRA-Scaffolding Erection, Dismantling & Inspection – inside & outside the tank