13.2.17 RA SWP For Installing Containment Cable Glanding Terminating Testing Tubing Instrumentation at DCL

C&P ENGINEERING SERVICES LTD
INSTRUMENTATION & ELECTRICAL ENGINEERS

Gorseinon Road, Gorseinon, Swansea, SA4 9GE
Telephone: 01792 897002  Fax: 01792 895193  Email: info@cpengineering.co.uk
www.cpengineering.co.uk
Hazard Identification, Risk Assessment & Safe Working

Procedure for “Installing Containment, Cable, Glanding,
Terminating, Testing, Instrumentation & Tubing”
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
Paul Bunyan 24/04/2014 19/04/2015
Steve Tossell 24/04/2014 19/04/2015
Approved By:
Print Name Signature Date Approved
Richard Jenkins 24/04/2014
C&P Engineering Services Ltd Ref. 13.2.9 Rev. 1 24/04/2014 Page 1 of 19

Hazard Identification
Physical Hazards Y Physical Hazards (Continued) Y Fire Hazards Y

Airborne Dust / Fumes  Explosive Materials
Access / Egress  Flammable / Combustible Materials
Adverse Weather Conditions  Flammable Atmospheres 
Aggression/Violence Pyrophoric Material
Bullying Sources of Ignition
Collapse of Equipment / Materials Static Electricity
Confined Space Entry 
Crane Movements / Lifting 
Display Screen Equipment
Drowning
Electricity - Electric Shock / Burns 
Entanglement 
Equipment / Materials  Other Hazards – Specify Below Vulnerable Groups
Falling Objects / Materials from Height  Environment - Waste Disposal 
Falls from Height (Working at Height)  Process Pipework  Expectant and Nursing Mothers
Gas Cylinders Impulse Lines / Tubing  Lone Workers 
Gasses  Young Persons 
High Pressures 
High Ambient Temperature
Hot Surfaces 
Housekeeping / Slips, Trips & Falls 
Low Ambient Temperature
Manual Handling / Ergonomic  Biological Hazards
Moving Equipment/Machinery  Blood Borne Pathogens / Body Fluids
Noise  Hygiene/Welfare
Operating / Driving MEWP’s  Legionella 
Oxygen Depletion / Enrichment  Leptospirosis (Weils Disease)
Pneumatics / Hydraulics 
Poor Lighting 
Radiation
Sharp Objects Chemical Hazards
Stress Asbestos
Struck By / Against Corrosive Chemicals 
Trapping Points  Harmful Chemicals 
Underground Services Irritant Chemicals 
Uneven Work Surfaces Odorous/Noxious Chemicals
Use of Hand Tools / Power Tools  Toxic Chemicals 
Vehicles / Transport 
Vibration

Risk Assessment
Task: - “Installation of Containment, Cabling, Glanding, Terminating, Testing, Instruments and Instrument Tubing”
The following risk assessment has been completed to ensure adequate controls are in place to eliminate or reduce the risk to as low as is reasonably practicable.
In considering who may be harmed we have included C&P Employees, but for each task, depending on where it takes place, then further consideration should be
given to others who may be affected by our activities e.g. other contractors.
L = Likelihood HR = Hazard Rating (with NO controls in place).

C = Consequence RR = Risk Rating (with controls in Place).
HAZARDS L C HR WHO MAY CONTROL MEASURES TO REDUCE THE RISK TO L C RR

BE HARMED AS LOW AS IS REASONABLY PRACTICABLE
1. Airborne Dust - Some plants may expose 5 3 15 C&P Safety glasses to be worn on site at all times. Safety 1 3 3
employees to windborne dust. Employees goggles must be worn in designated red and white
striped areas.
2. Access and Egress on site 5 5 25 C&P All areas of plant require a comprehensive Permit to 1 5 5
Employees work form for all jobs undertaken on DCL site except
when working within office buildings. When working
within office buildings a “Job Card” may be issued by
the permit issuer/custodian of the building in place of a
Permit to work.
Access and egress to each working area will be by
roadways, fixed walkways and platforms at each
process plant area. Access and egress to the individual
working areas will be from the platform or will be by one
of the safe working at height methods described in the
working at height section. 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, water proof exterior clothing. Ability to postpone
storm etc. This is particularly important when working jobs in extreme weather conditions i.e. high winds,
at height, using ladders, accessing/egressing steps torrential rain when working at height
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 (client 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 MEWP’s. 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 requires a “step up” of a 2 5 10
Employees 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 work areas are at height and close to platform
edges then scaffolding should be requested. The
scaffolding 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
duration and the height to work at is relatively low,


ladders can be secured or footed and supported.
When working from stepladders near to platform edges
and there has been NO scaffolding erected, then full
body fall arrest harnesses should be worn. Full body fall
arrest harnesses are a last resort and should be worn in
conjunction with other controls for working at height.
9. Gas / Oxygen Depletion 5 5 25 C&P Individual gas monitors and procedures for evacuation 1 5 5
Employees from Process Areas. Regular Operational checks for
gas leaks by trained and competent operators. Regular
Planned Maintenance checks and repairs by client.
Site Inductions.
10. Hot Surfaces 3 3 9 C&P Hot pipe work lagged/insulated. Signage. 1 2 2
Employees
11. 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.
12. Manual Handling – carrying of equipment 3 3 9 C&P Hand tools are relatively lightweight (tools to be carried 1 3 3
ladders, tools etc. Employees in single tool box). All Manual Handling tasks are
individually Risk Assessed. Individuals trained in
Manual Handling techniques. Large and awkward cable
tray or ladder rack to be handled/carried by two
operatives. Avoid Manual Handling where possible.


13. 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.
14. Noise 5 3 15 C&P Certain areas of plant will require mandatory Hearing 1 3 3
Employees Protection in the form of Ear Defenders.
Ear defenders to be worn prior to and during time spent
in these areas.
Signage.
15. Operating/driving MEWPS on site 5 5 25 C&P Trained and competent operators holding certificate for 1 5 5
Employees driving and operating MEWPS.
Equipment to be fully maintained and inspected.
Driver to use harness at all times when driving on site
or when working from MEWP basket at height.
When stationary prior to work commencing outriggers
must be fully deployed on solid, level ground. If ground
is soft or uneven, boards are to be placed under
outrigger legs.
Whilst working at height, operator is to control
movement of basket from the basket and not the floor.
Operators working from basket not to over-reach or
lean out of basket.
Under no circumstance are operators to exit the MEWP
basket as a means of access to a place above ground
level (except in an emergency). All loose equipment
placed in the basket for use will be secured to ensure


they cannot fall. The area around the base of a MEWP
will be bunted and have cones to prevent collision from
other vehicles and road users and also to prevent
persons working or walking underneath.
16. Lighting 5 5 25 C&P Good plant lighting. Where plant lighting is poor, obtain 1 5 5
Employees temporary lighting.
If working in potentially explosive atmosphere, torch or
headlamp may be used providing they are certified to
be used in explosive atmospheres. Permission to be
granted by Client personnel and hot work permit may
also be required.
17. Use of hand tools and power tools / 3 5 15 C&P Drills and other power tools will be battery operated. 1 5 5
Entanglement / Trapping points Employees Where this is not reasonably practicable then low
voltage mains will be required (110v workshop only)
See electrical controls above. PAT testing of mains
operated tools. Secure cables.
No loose clothing or jewellery near to rotating chuck.
All hand tools to be clean and in good working order,
and checked daily.
18. Vehicles and Transport – travel to site and use 5 5 25 C&P Use of company vehicles. Fully maintained vehicles 2 5 10
on site internal roads Employees, with current MOT and insurance. Competent drivers
other road holding appropriate licence for the vehicle. Vehicle pre-
users flight checks. All tools stored safely in vehicle.
Restricted access to site – only authorised vehicles.
Road signs, road traffic standards, high way code.
Pedestrian crossings.
Park in designated parking areas only.


19. Legionella 2 5 10 C&P Client to provide information on potential Legionella 1 5 5

Employees presence by providing COSHH risk assessments.
Wearing of RPE.
20. Contact with Dow Corning Chemicals on site 5 4 20 C&P Comprehensive Permit to work form required for all jobs 2 4 8
Different Process areas manufacture and use Employees undertaken on DCL site except when working within
different types of chemicals i.e. toxic, corrosive, office buildings. When working within office buildings a
harmful etc. “Job Card” may be issued by the permit
issuer/custodian of the building in place of a Permit to
work.
Dow Corning to provide details of hazards and
precautions necessary for each process area including
COSHH risk assessments.
21. Fire- flammable atmospheres, sources of ignition 3 5 15 C&P No sources of ignition to be used or taken on to plant 1 5 5
Employees areas without a valid Work Permit for the task
Some situations may require minor hot work but it is
very unlikely. Agree any hot work necessary with client
– agree permit required for hot work.
Fire extinguishers and fire watchmen at area of hot
work. Trained competent operators.
Familiarisation with Plant specific Emergency
Procedures and assembly points.
22. Lone Workers - Lone Workers, if injured, are 5 5 25 C&P Trained and competent persons. Contact Protocol with 1 5 5
more likely to go undetected and could exacerbate Employees C&P supervisor. Individual radio. Plant Alarms.
the seriousness of the injury due to delays in rescue Emergency assembly points.
and treatment.
C&P lone worker policy.


23. Environment - waste disposal 3 4 12 Environment Responsibly dispose of all generated waste by using 1 3 3
client’s on site recycling facilities.
24. Impulse Lines / Pneumatics / Hydraulics- high 5 5 25 C&P Where instruments involve impulse lines / pneumatics /
pressure, corrosive chemicals Employees 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)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.
25. Process Piping – In-line instruments, high 5 5 25 C&P Where instruments are mounted in process lines i.e.
pressure, corrosive chemicals Employees “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.
26. Hot Surfaces 5 3 15 C&P Hot pipe work lagged/insulated. Signage.
Employees
If working on high temperature instrumentation, allow
cooling if possible and wear protective gloves.

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
Acceptable (1-5) No further action but ensure controls are maintained

Adequate (6-15) Look to improve at next review
Unacceptable (16-25) Stop activity and make immediate improvements
Safe Working Procedure

Final Risk Rating
The risk rating for the activity of the “Cable Installation, Glanding, Terminating, Testing, Tubing and
Instrumentation” 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 adequate (yellow section 6-15) but
improvements should be made to reduce the overall risk down to acceptable (green section 1 - 5). This Risk
assessment needs to be reviewed in the next 12 months (see review date).
Persons and Competency
All the C&P Engineering employees who work on this contract must have been taken through this SWP and
must sign the register (on the last page of this document) to demonstrate that they understand the controls
and how they are to be applied. They must be competent and have the relevant certification for the
equipment they are working on and for operation of the MEWP.
PPE Requirements
The individuals on this contract are required to wear at all times:-

Safety Footwear with minimum 200 Joules toe cap. The ankles must be protected.
General Proban treated overalls or Proban treated trousers & jacket.
General purpose gloves or Kevlar gloves over surgical nitrile gloves (depending on the task).
Safety helmet – centurion or equivalent. No requirement for safety helmet in office buildings.
Safety glasses to be worn or safety over-glasses to be worn if wearing your own prescription glasses. No
requirement for safety glasses or safety over-glasses in office buildings.
High visibility waistcoat. No requirement for high visibility waistcoat in office buildings.
Ear defenders when working in areas which require mandatory hearing protection.
In addition to the above goggles may be required in plant areas instead of safety glasses and Kevlar gloves
used when using open blade knives, harnesses will be used when working from a MEWP basket. Some
process areas may require chemical suits and this will be stipulated on the permit to work.

NOTE: When working from stepladders near to platform edges and there has been NO scaffolding
extensions attached to the handrail then full body fall arrest harnesses should be worn. Full body fall
arrest harnesses are a last resort and should be worn in conjunction with other controls for working at height.
A clip off point must be checked or tested to ensure it is suitable to attach to. A hand rail is not suitable or
designed to be used as a point to attach the harness.
Plant Status
In almost all cases electrical isolation will be required for the equipment that is to be worked on.
When carrying out “Inspection & Testing” of circuits some LIVE tests are required. This live working is to be
carried out as per C&P document reference 13.1.4 Live Working Procedure on Low Voltages (up to
1000V).
Permits, Certificates or Registers
A general permit to work is required for all work locations and access onto process plant. Isolations will be
recorded on this permit. A separate hot work permit is required for battery operated equipment or any
specific hot work.
Access and Egress
Before accessing any part of a plant then an authorisation to work permit will be obtained from the permit
issuing office for that particular area. Access and egress will be by recognised walkways, pavements, road
crossings, working and process platforms. Access to areas where there is a risk of falling to danger will be
by additional access equipment such as scaffolding, MEWP, fixed or secured and supported ladders.
Procedure
1. Contact the site area in advance and agree that access to the specific area is acceptable.
2. 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 the PPE
is in good condition and affords adequate protection.
3. Report to the permit office before accessing site. Obtain a permit to work form and comply with all
requirements stated and explained verbally by the issuer. Additional PPE stated must be worn.
Agree access and egress routes. Any Isolation of electrical circuits, need to be agreed with the
permit issuing office.
4. Undertake the appropriate isolation in the electrical substation or at the appropriate fuse or electrical
control panel. Ensure that the personal locks are attached and the keys are retained by the working
party member.
5. Where the inspection revealed working at height is a risk, then the appropriate control(s) must be
adopted. We must follow the hierarchy of working at height and aim to prevent the fall in the first
place i.e. permanent platform, scaffold, MEWP, stepladder with handrails on top step, harnesses
6. Scaffolding requirements must be agreed with permit issuing office and their approved scaffolding
sub contractor. If a MEWP is required then this must be pre-booked in advance.
7. Where electrical installations are at height and close to platform edges i.e. Process areas, then
consideration, as a first option, should be given to erecting scaffolding extensions to the handrails to
prevent falls from height, or where this is impracticable, then full body fall arrest harnesses should be
worn if working from stepladders near to the platform edge (this does not prevent the fall but

prevents a person falling to danger and therefore limits the consequences of the injury) bearing in
mind any structures that may be below the working platform and interfere with the fall. Fall arrest
harnesses should be regarded as the last resort but can and should be worn in conjunction with
certain controls for working at height. Lightweight detachable stepladders with handrails and gate all
around the top working platform should be used if available. Approved/certified clip off points should
be used to attach the harness. Handrails are not designed for attaching a harness.
8. Park vehicle in recognised parking areas for equipment “off loading”. Manually handle equipment to
the location using the kinetic manual handling techniques supplied in safety contact and training
course. Where heavy or awkward items need to be carried then a separate manual handling risk
assessment is required for the particular location.
9. Collect MEWP if required for access from MEWP parking location. Full Body Harnesses will be worn
and attached by all operatives as soon as they enter the MEWP basket. This applies to driving the
MEWP to the location of work. One operative is to drive MEWP on roadways to the location. Use
the C&P vehicle as escort using hazard warning lights to warn other road users. A fall restraint
lanyard must be used and not fall arrest.
10. Create appropriate road control if MEWP is needed to be parked on the road way – road control will
be appropriate to the risk and extent of use of the road. As a minimum the MEWP will be coned off
and bunting placed between cones. This could be increased if necessary to traffic light controls or
road closure if agreed with site.
11. Place bunting at ground level to demarcate exclusion zone below location of work when working at
height. This will be a minimum of 10m diameter but will be greater in most circumstances using the
structures in the area.
12. Equipment transported in the MEWP basket will be secured in the basket until it is to be fitted. This
will include tools and fittings.
Containment
1. Where cable trays/ladder racks are delivered in bundles of six trays (3 metres long) by 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.
2. 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.
3. Where a mobile crane is required to off-load ladder racks/cable trays at height then the load must be
secured. Area around crane to be cordoned off. A banks man 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.
4. Cut steel banding wire once the bundles of cable trays have been positioned on site. Stand clear as
sections may spring open.
5. Two men to carry individual ladder racks into position. Where 3 metre smaller cable trays or flat
plates are being used then two men are still required to carry cable trays especially if carrying them
up stairways etc. Where cable trays have been purposely cut to size and are of short length then this
can be done by one person.

6. When joining cable trays together four sets of bolts are required each side to secure them together.
7. All ladder racks and cable trays with return lips should be installed with return lip outermost.
8. If ladder racks are required to be positioned vertically and are of greater length than one piece (>3
metres) then they should be bolted together before lifting into position. Scaffolding should be erected
at specific heights to allow easy handling of the length of trays. Where it is too difficult to erect
scaffolding then two men should be positioned at height to help pull the trays into position using
ropes tied to the cable trays whilst two men at ground level should help manipulate the trays and
prevent them from swinging. Where anyone needs to lean over to manipulate the trays into position
then they must wear a fall arrest harness, either over fixed hand railing, scaffold hand railing or
MEWP hand railing.
9. The ladder racks /trays should be temporarily tied in position whilst the racks are bolted to
permanent brackets to support the cable trays/ladder racks. Where no permanent brackets are in
situ, then these need to be manufactured and welded in place, preferably before the cable trays are
fitted. In some areas where it is difficult to attach permanent support brackets then pipe clamps can
be used to clamp the unistruts to fixed hand railings with client’s permission.
10. Small cable trays 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.
11. Where cable trays need to be fitted to walls or other permanent structures then rather than be bolted
directly to the wall they must be attached to unistrut. This will enable easy access for cable
installation at a later stage. The unistruts should be cut to length and mounted in positions by drilling
holes in the structure and fitting with anchor bolts.
12. The cable trays/ladder racks must then be bolted to the unistruts. All drilling to use low voltage or
battery operated drills. Check to make sure that any holes to be drilled do not contact any electrical
cables.
13. The distance between Unistruts should be determined bearing in mind the width of the cable trays
(150m – 600mms wide) and/or the alarm or signal boxes to be fitted.
Cable Installation, Glanding, Terminating & Testing
1. Install power supply cable as per specification.
2. Gland cable both ends, insulation resistance test using equipment with valid calibration certificate.
Check cable and terminate at both ends.
3. Dead tests on electrical circuits to be carried out by competent person using valid calibrated test
equipment and results recorded.
4. The electrical isolations will be removed and power restored to the electrical section that had
previously been isolated.
5. Live tests on electrical circuits to be carried out by competent person using valid calibrated test
equipment and recorded.
6. Once the work is completed all tools, equipment, waste fittings and cut offs from cable must be
removed from the site or disposed of in identified on site recycling services.
7. The MEWP will be returned to the MEWP parking area and off hire arranged.

8. The permit to work will be cancelled.
9. Electrical test certificate is to be completed if required. The top copy of the certificate is to be given to
the customer and the yellow copy is to be returned to Paul Bunyan at Gorseinon Head Office.
Instrumentation & Tubing
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 mandatory PPE 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 client’s
mechanical team to assist with lifting the item, and bolting into position.

Tubing Installation.
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 containment to support tubing is delivered in bundles by 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 banks man 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 tube is
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 client’s 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.
19. When installation is complete, ensure the permit is cancelled.

Emergency Procedures – Telephone 3333 Internally
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 are sounded. 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 area accordingly.
Raising the Alarm

Telephone 3333
Use your radio – Channel 15/16 call sign “DC control”
In the event where neither of the above options are possible then use safety shower or eyewash point on
plant as these will activate the alarm in DC control
Use break glass point within building for local alarm
Dow Corning Alarm Signals
Klaxon 3 seconds on 3 seconds off – Major Incident

All personnel to report to their nearest muster point indoors immediately. Swipe badge on Muster Reader.
Fire Alarm Bells

All personnel to report to their nearest fire assembly point outside immediately.
Blue Flashing Light - Outside a Building

No personnel to enter the building until advised by a DCL member.
Audible Alarm and Red Flashing Light on Process Plant

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 “Cable
Installation, Glanding, Terminating & Testing”
The above document has been read and explained to me by my supervisor.

I the undersigned understand the controls and how they are to be applied.
Print Name Signature Date
The following comments/queries were raised and discussed with my supervisor (Please
insert below any concerns, comments or views which may identify additional problems):
** THIS PAGE IS TO BE SIGNED, DATED, DETACHED AND RETURNED TO GORSEINON HEAD

OFFICE A.S.A.P. (VIA FAX, EMAIL, POST OR HAND) **

13.2.17 RA SWP For Installing Containment Cable Glanding Terminating Testing Tubing Instrumentation at DCL

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13.2.17 RA SWP For Installing Containment Cable Glanding Terminating Testing Tubing Instrumentation at DCL

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C&P ENGINEERING SERVICES LTD

INSTRUMENTATION & ELECTRICAL ENGINEERS

Hazard Identification, Risk Assessment & Safe Working

Paul Bunyan 24/04/2014 19/04/2015

Steve Tossell 24/04/2014 19/04/2015

Print Name Signature Date Approved

Richard Jenkins 24/04/2014

C&P Engineering Services Ltd Ref. 13.2.9 Rev. 1 24/04/2014 Page 1 of 19

Physical Hazards Y Physical Hazards (Continued) Y Fire Hazards Y

C&P Engineering Services Ltd Ref. 13.2.9 Rev. 1 24/04/2014 Page 2 of 19

L = Likelihood HR = Hazard Rating (with NO controls in place).

HAZARDS L C HR WHO MAY CONTROL MEASURES TO REDUCE THE RISK TO L C RR

C&P Engineering Services Ltd Ref. 13.2.9 Rev. 1 24/04/2014 Page 3 of 19

HAZARDS L C HR WHO MAY CONTROL MEASURES TO REDUCE THE RISK TO L C RR

C&P Engineering Services Ltd Ref. 13.2.9 Rev. 1 24/04/2014 Page 4 of 19

HAZARDS L C HR WHO MAY CONTROL MEASURES TO REDUCE THE RISK TO L C RR

C&P Engineering Services Ltd Ref. 13.2.9 Rev. 1 24/04/2014 Page 5 of 19

HAZARDS L C HR WHO MAY CONTROL MEASURES TO REDUCE THE RISK TO L C RR

C&P Engineering Services Ltd Ref. 13.2.9 Rev. 1 24/04/2014 Page 6 of 19

HAZARDS L C HR WHO MAY CONTROL MEASURES TO REDUCE THE RISK TO L C RR

C&P Engineering Services Ltd Ref. 13.2.9 Rev. 1 24/04/2014 Page 7 of 19

HAZARDS L C HR WHO MAY CONTROL MEASURES TO REDUCE THE RISK TO L C RR

C&P Engineering Services Ltd Ref. 13.2.9 Rev. 1 24/04/2014 Page 8 of 19

HAZARDS L C HR WHO MAY CONTROL MEASURES TO REDUCE THE RISK TO L C RR

19. Legionella 2 5 10 C&P Client to provide information on potential Legionella 1 5 5

C&P Engineering Services Ltd Ref. 13.2.9 Rev. 1 24/04/2014 Page 9 of 19

HAZARDS L C HR WHO MAY CONTROL MEASURES TO REDUCE THE RISK TO L C RR

C&P Engineering Services Ltd Ref. 13.2.9 Rev. 1 24/04/2014 Page 10 of 19

Acceptable (1-5) No further action but ensure controls are maintained

Safe Working Procedure

Persons and Competency

The individuals on this contract are required to wear at all times:-

C&P Engineering Services Ltd Ref. 13.2.9 Rev. 1 24/04/2014 Page 11 of 19

Permits, Certificates or Registers

Access and Egress

C&P Engineering Services Ltd Ref. 13.2.9 Rev. 1 24/04/2014 Page 12 of 19

C&P Engineering Services Ltd Ref. 13.2.9 Rev. 1 24/04/2014 Page 13 of 19

Cable Installation, Glanding, Terminating & Testing

1. Install power supply cable as per specification.

C&P Engineering Services Ltd Ref. 13.2.9 Rev. 1 24/04/2014 Page 14 of 19

8. The permit to work will be cancelled.

Instrumentation & Tubing

C&P Engineering Services Ltd Ref. 13.2.9 Rev. 1 24/04/2014 Page 15 of 19

C&P Engineering Services Ltd Ref. 13.2.9 Rev. 1 24/04/2014 Page 16 of 19

19. When installation is complete, ensure the permit is cancelled.

C&P Engineering Services Ltd Ref. 13.2.9 Rev. 1 24/04/2014 Page 17 of 19

Emergency Procedures – Telephone 3333 Internally

Raising the Alarm

Dow Corning Alarm Signals

Klaxon 3 seconds on 3 seconds off – Major Incident

Fire Alarm Bells

Blue Flashing Light - Outside a Building

Audible Alarm and Red Flashing Light on Process Plant

C&P Engineering Services Ltd Ref. 13.2.9 Rev. 1 24/04/2014 Page 18 of 19

The above document has been read and explained to me by my supervisor.

Print Name Signature Date

** THIS PAGE IS TO BE SIGNED, DATED, DETACHED AND RETURNED TO GORSEINON HEAD

C&P Engineering Services Ltd Ref. 13.2.9 Rev. 1 24/04/2014 Page 19 of 19

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