Project Title:
Site Address: Cardiff Road, Barry, South Glamorgan, CF63 2YL
Client: Dow Corning Ltd
PO Number:
Work Location:
Assessed By:
Assessment
Print Name Signature Date Assessed
Review Date
Approved By:
Richard Jenkins
Steve Tossell
Hazard Identification
Risk Assessment
1. Airborne Dust - Some plants may expose 5 3 15 C&P Safety glasses or goggles to be worn at all times. 1 3 3
technicians to windborne dust. Employees
2.Access and Egress on site 5 5 25 C&P Site Induction prior to job commencement. 1 5 5
Employees Authorisation to Work (permit) from client. Access and
egress to each work area will be by roadways, fixed
walkways and platforms at each process plant area.
Access to some instruments may require working at
height.
For working at height hazard controls please refer to
C&P document reference 2.14.1 Working at Height
Policy.
3.Adverse Weather Conditions. Extremes of 5 3 15 C&P PPE in the form of warm clothing, good quality safety 1 3 3
weather such as ice, snow, heavy rain, lightning Employees boots, waterproof exterior clothing. Ability to postpone
storm etc. This is particularly important when jobs in extreme weather conditions i.e. high winds,
working at height, using ladders, torrential rain when working at height
accessing/egressing steps and plant, driving on site.
4.Working in Confined Spaces 5 5 25 C&P Site Induction. Site Authorisation to Work Permit. 2 5 10
Employees Confined Spaces permit. C&P watchman. Emergency
rescue plan in place. RPE available and to be worn
depending on confined space. Resuscitation
equipment on standby. Specific tools required (discuss
with Plant personnel).
Only trained and certified C&P operatives to enter
confined spaces.
5.Overhead Crane Movements causing struck by 4 5 20 C&P Where overhead cranes move overhead, either isolate 1 5 5
injuries. (Linked with working at height) Employees cranes (plant to isolate or with their permission) or
bellman required to alert Employees to stop work and
move away from area.
6.Electricity - Contact with live electrical 5 5 25 C&P Only qualified and competent persons to work on 1 5 5
components causing electrical shock, burns or Employees electrical equipment.
electrocution.
All work on electrical equipment only to be carried out
following isolation.
C&P Employees are competent to undertake the
isolations. This must either be done at the local sub-
station or at the fuse board.
For safe isolation please refer to C&P document
reference 13.1.3 Safe Isolation Procedure for DEAD
working on LV and ELV.
7.Objects falling from Height 5 5 25 C&P Permanent metal toe boards on process plant working 2 5 10
Employees platforms and on MEWPs. Good housekeeping across
whole plant. When working at height area below to be
cordoned off by use of bunting and signage to at least
10 metres. Items secured when being transported in a
MEWP basket.
Discussion to take place at Induction to prevent other
workers/contractors working immediately above
Employees.
Where overhead cranes move overhead, either isolate
cranes (plant to isolate or with their permission) or
bellman required to alert Employees to stop work and
move away from area.
8.Falling from Height (Working at Height) 5 5 25 C&P Where access to work area only requires a step up of 2 5 10
Employees a few centimetres then this can be achieved on most
levels. Where the need to work at height exposes the
individual to a fall to danger then additional controls will
need to be in place. These will involve scaffolding
platforms. MEWP to be supplied and maintained to a
high standard. Trained and certificated C&P operatives
to operate the MEWP.
Where Instruments are at height and close to platform
edges then scaffold extensions should be requested.
The scaffold extensions should be erected by
recognised Scaffolding Company.
Stepladders with handrails and Fibre glass ladders can
be used in many locations where the work is of short
11.Process Piping In-line instruments, high 5 5 25 C&P Where instruments are mounted in process lines i.e. 1 5 5
pressure, corrosive chemicals Employees in-line the process lineMUST be isolated and flushed
out / cleaned / purged / spaded off (by client). C&P
employees to discuss this with the client to make sure
all precautions have been taken and Work Permit to
include these precautions prior to work
commencement.
12.Hot Surfaces 5 3 15 C&P Hot pipe work lagged/insulated. Signage. 1 3 2
Employees
If working on high temperature instrumentation, allow
cooling if possible and wear protective gloves.
13.Slips, Trips and Falls due to poor housekeeping 5 5 25 C&P Good housekeeping practices across site by the client 1 5 5
Employees provides for a safe place of work. Clear concrete
pathways, roadways and signage. Painted walkways.
Good safety footwear. Audits by Plant personnel. C&P
standards in housekeeping, safety contacts provided
and more specific training. Removal of all waste.
14.Manual Handling carrying of equipment 3 3 9 C&P Calibration instruments and hand tools are relatively 1 3 3
ladders, tools etc. Employees lightweight (tools to be carried in single tool box).
Removal of some Control Valves may be heavy.
Individuals trained in Manual Handling techniques. Help
required from Plant personnel or second C&P
Calibration technician. Avoid Manual Handling where
possible.
15.Moving Machinery / Entanglement / Trapping 5 5 25 C&P Variety of operating machinery could be present in 1 5 5
points - controlled by Client Employees process areas. All moving parts to be guarded. No
access beyond any guard or barrier protecting
machinery. Permit to work in all plants.
Risk Matrix
First Aid Injury Minor Injury Suffering Major injury Fatal
no disruption (preventing (preventing
of activity activity for one activity for 3
day) days or longer
Certain 5 10 15 20 25
Probable 4 8 12 16 20
Likely 3 6 9 12 15
Possible 2 4 6 8 10
Unlikely 1 2 3 4 5
The risk rating for the activity of Instrumentation & Tubing has a final Risk rating of 10, if all the controls
are applied at all times. Failure to implement the controls will lead to a higher risk of injury. The level of 10 is
tolerable (yellow section 10-15) but improvements should be made to reduce the overall risk down to
acceptable (Green section 1 - 4). This Risk assessment needs to be reviewed in the next 12 months (see
review date).
All the C&P Engineering employees who install piping and containment must have been taken through this
SWP and must sign the register to demonstrate that they understand the controls and how they are to be
applied.
Supervisor to plan the job by visiting site beforehand and calculating the piping routes
PPE Requirements
Safety Footwear with minimum 200 Joules toe cap. The ankles must be protected.
General Proban treated overalls
General purpose gloves over surgical nitrile gloves (depending on the task).
Safety helmet centurion or equivalent
Safety glasses or safety over-glasses to be worn if wearing their own prescription glasses.
Goggles are mandatory in chemical splash areas.
Ear Defenders are mandatory in certain process areas.
High visibility waistcoat.
Additional PPE dependent on local conditions.
Plant Status
Depending on where the job is being carried out, plant will quite likely be working. Mechanical and electrical
isolations may be required for installation of piping and instrumentation. All systems to be worked on should
be isolated and tagged locked out accordingly in line with site procedures. No C&P personnel to break into
existing lines and all first breaks to be carried out by the client where required.
A general permit to work is required for all work locations and access onto process plant. Any isolation will
be recorded on this permit. A separate hot work permit is required for battery operated equipment.
Before accessing any part of a process plant then an authorisation from the client will be required and their
permit to work procedure will be followed. Access and egress will be by recognised walkways, pavements,
road crossings, stairways.
Instrument Installation
1. Report to the permit office before accessing process plant areas. Obtain a site permit to work and
comply with all requirements stated and explained verbally by the issuer. Additional PPE stated as
well as mandatoryPPE must be worn. Agree access and egress routes. Agree any isolation required
before commencing work.
2. Where process plant isolations are required, obtain an isolation permit from the site personnel on
completion of the relevant isolation, confirming that the correct isolation has been made.
3. If a local isolation is adequate, obtain permission from site personnel prior to carrying out the
isolation.
4. Follow C&P manual handling guidelines when taking instruments to the work site.
5. Where instruments involve impulse lines / pneumatics / hydraulics, they MUST be isolated prior to
work commencement. Ensure isolation valves at tapping points are closed, isolate impulse lines at
instrument manifold (if differential pressure ensure equalising valve is only opened AFTER closing
high pressure and low pressure isolation valves and prior to opening drain valves/bleed screws. Be
careful to open drain valves/bleed screws very slowly in the first instance and wear goggles and
appropriate gloves whilst doing so)
6. Do NOT assume impulse lines / pneumatics / hydraulics have been isolated physically check i.e.
tapping point isolation valves are closed, instrument manifold valves are closed, drain valves/bleed
screws are open - open drain valves/bleed screws very slowly.
7. Where instruments are mounted in process lines i.e. in-line the process line MUST be isolated and
flushed out / cleaned / purged / spaded off (by client). C&P employees to discuss this with the client
to make sure all precautions have been taken and work permit to include these precautions prior to
work commencement.
8. If working on high temperature instrumentation, allow cooling if possible and wear protective gloves.
9. Remove the instrument concerned, and if being replaced, install new instrument in its place.
10. Discuss with the permit issuer when the works are complete and following the above procedure in
reverse if reinstating the lines. Ensure any spades or line breaks are reinstated by the client or their
representative, including any isolations made by them.
11. If the installation is new, then install the instrument where identified utilising the supplied brackets
and fixing bolts. Follow the manufacturers recommended procedures for installation.
12. If required, mount enclosure boxes or instrument stands, prior to taking the instrument to the work
site.
13. If large valves require installation, then ensure qualified personnel are present such as the clients
mechanical team to assist with lifting the item, and bolting into position.
14. If the installed item requires any instrument tubing, then the following procedures need to be followed.
1. Wear the PPE that is required for the particular process area that you will be working in. N.B. There
is minimum requirement as highlighted in the PPE section above for all areas. Ensure that PPE is in
good condition and affords adequate protection.
2. Report to the permit office before accessing site. Obtain a client permit to work and comply with all
requirements stated and explained verbally by the issuer. Additional PPE stated must be worn.
Agree access and egress routes.
3. Travel to the building/site area by company vehicle if necessary and park appropriately.
4. Where tubing or containmentto support tubing is delivered in bundlesby lorry, then arrangements
must be made prior for off-loading. A HIAB or Fork Lift Truck may be required to off-load. Ensure
lifting plan and a competent person in charge of lifting operation has organised the lift. Ensure
sufficient space created to off-load in a suitable accessible position as near to the site of work as
possible.
5. Where a HIAB is used then a lifting Plan must be created prior to commencement of job.
Driver/operator to be fully trained and competent in HIAB lifting operation.
6. Where a mobile crane is required to off-load tubing at height, then the load must be secured. Area
around crane to be cordoned off. A banksman will ensure that all persons are clear during crane lift
and that all other persons are aware of the lifting activity. Only a competent person trained in slinging
techniques to attach lifting slings. Lifting equipment must be to the approved standard with
certification of testing and thorough examination. Lifting plan required for mobile crane and a
competent person in charge of Lifting operation.
7. Cut banding strap once the bundles have been positioned on site. Stand clear as sections may
spring open.
8. Two men to carry individual bundles into position. Where 3 metre smaller lengths are being used,
then two men are still required to bundles especially if carrying them up stairways etc. Where tubing
has been purposely cut to size or are of short lengths, then this can be done by one person.
9. If tubing is required to be positioned vertically and are 6 metres in length, then they should be
handled by two persons. Scaffolding should be erected at specific heights to allow easy handling of
the lengths. Where it is too difficult to erect scaffolding then one man should be positioned at height
and the other below to assist with the installation. Where anyone needs to lean over to manipulate
them into position then they must wear a fall arrest harness.
10. The tubing could be temporarily tied in position whilst the permanent brackets to support the tubeis
installed. Where no permanent brackets are in situ, then these need to be installed or welded in
place, preferably before the support trays/unistruts are fitted. In some areas where it is difficult to
attach permanent support brackets then pipe clamps can be used to clamp unistruts to fixed hand
railings with clients permission, ready to support the tubing. The appropriate clamps can then be
fitted to the support work ready for the tubes.
11. Tubing can be fitted from a stepladder providing the top of the ladder has handrails fitted. The step
ladder must be erected on level, stable ground. If at height and close to a platform edge then a fall
arrest harness must be worn. Scaffolding may also be erected on top of the handrail as an
extension.
12. Install appropriate clamps onto the supports and install tubing accordingly.
13. If it requires bending or setting, ensure the bender is in good working order, prior to use.
14. Carry out appropriate flushing or pressure testing of the tubes, if identified within the specification.
15. If tubing is required to tap in points, ensure the isolation process stated above is followed prior to
installation.
16. If a new line has been installed, ensure the correct tap in point is identified prior to installation.
17. If instrument air/nitrogen is required to the item, gain permission from the permit issuer prior to any
supply being turned on.
18. On completion of the job all waste material to be removed from site and re-used or disposed of
responsibly.
In the event of an emergency and depending on the site and access to such, the emergency services should
be called using the internal emergency number. Raising the alarm is our first priority. All C&P employees
must report to their appropriate place of safety, if the alarms aresounded. You must stay at this location and
report to the Client representative. Follow the directions of the Client personnel in charge at the muster point.
Lifting an eye wash station or stepping on a safety shower will raise alarm to DC Control, who will send
assistance to the areaaccordingly.
All personnel to report to their nearest muster point indoors immediately. Swipe badge on Muster Reader.
All personnel to report to their nearest fire assembly point outside immediately.
All personnel to make their work area safe and leave the area. No return until advised by a DCL Member.
Note: If the last page of this document is not attached do not worry as it does not contain any
relevant information regarding the SWP. The last page is a register of signatories and is intended to
be detached and returned to Gorseinon head office for filing.
Hazard Identification, Risk Assessment & Safe Working Procedure for Instrument
Calibration on Clients Site in Situ (and at Clients Workshop).
The following comments/queries were raised and discussed with my supervisor (Please
insert below any concerns, comments or views which may identify additional problems):