1. Safety Talk 13

2. Safety Talk 13 / 2 Entry into a confined space is a hazardous activity in the oil and gas business. Entry permit systems have been in place for years but fatal accidents continue to happen. An entry permit, by itself, does not make entry safe. Briefings and discussions like this are essential: To maintain awareness To learn the lessons from past accidents To add local knowledge to the Company’s procedures Workplace safety depends on people factors ! Why discuss entry ?

3. Safety Talk 13 / 3 A confined space is any space with limited access and escape, where flammable or toxic vapours could collect, or where the oxygen content could be reduced What is a confined space ? Some spaces are obviously confined eg. process vessel Others are less obvious eg. open-topped / floating roof tank, pit, sump, excavation > 1.5 m. deep Other specific locations may be designated as confined spaces by site management Note that ‘entry’ includes putting your head inside an enclosed space eg. for visual inspection Can you add to the list ?

4. Safety Talk 13 / 4 Risks of entry Failure to identify confined space Failure to isolate the vessel Failure to isolate internal appliances eg. mixers Exposure to explosive, toxic or asphyxiating atmosphere Exposure to hazardous materials Risks associated with work in a confined space eg. fumes Inability to exit quickly in emergency Risk from activities outside the vessel

5. Safety Talk 13 / 5 Risk assessment Plan and think through the work in advance, involving all the relevant people including specialists (Ops, Maintenance, HSE) Is entry essential, or can the work eg. inspection be done from outside ? All practical means must be employed to make the vessel safe from the outside before entry is permitted The entry permit system is then used to control entry

6. Safety Talk 13 / 6 What is an entry permit ? An entry permit is a ‘contract’ between the operating authority and the performing authority, covering: Responsibility for all aspects of the entry Definition of the vessel, location, and permit validity Isolation, and preparation of vessel and workplace (Gas) test results Remaining hazards and precautions including monitoring Completion and withdrawal of permit Distribution of permit copies ensures all interested parties are informed Safety Talk 8A / 6

7. Safety Talk 13 / 7 Working in a confined space An entry permit is not a permit to carry out work Additional cold, hot, electrical permits are required as appropriate, cross referenced to the entry permit Each work permit must cover the additional hazards of working in a confined space

8. Safety Talk 13 / 8 Shut down and removal of oil and gas hazards by depressuring, draining etc. Positive isolation* by disconnection or blanking as near to vessel as practical Valve(s) isolation is not adequate Isolation of heating coils and driven internal appliances * If positive isolation is impractical, entry is prohibited without special dispensation from senior management Decommissioning / isolation

9. Safety Talk 13 / 9 Preparation of worksite Warning notices posted and vessel clearly marked for entry Good access and escape provided Separate access ways for services, hoses, cables etc All means employed to make vessel safe from the outside before entry permitted Remove surrounding (<15m) hazards eg. seal drains Vessel purged and ventilated

10. Safety Talk 13 / 10 Gas testing to be carried out, by competent person, for oxygen, flammable and toxic gas (in that order) Test equipment of suitable design, regularly inspected, tested / calibrated and maintained Limitations of equipment and test method recognised High risk areas identified and checked Tested from outside initially, and then inside Gas testing

11. Safety Talk 13 / 11 Conditions required: Gas test results: –Oxygen 20.8% (as atmospheric air) –Flammable gas less than 1% LEL –Toxic gas less than 10% OEL (8 hours exposure) All traces of oil, sludge, scale etc removed Conditions not expected to change Adequate ventilation to maintain atmosphere Entry without Breathing Apparatus (BA) If not met, further risk assessment must be done

12. Safety Talk 13 / 12 Entry with suitable BA Guidelines: –Oxygen 19.5% to 23.5% volume –Flammable gas < 10% LEL (entry), 20% LEL (exit) –Toxic gas < STEL (15 mins exposure) BA wearers must have been specifically trained and accredited Outside the above limits the atmosphere inside the vessel must be considered life threatening

13. Safety Talk 13 / 13 Life threatening atmospheres An entry permit must not be issued to enter a life threatening atmosphere Entry under inert gas eg. catalyst removal under nitrogen: Only specialist contractors will enter and work in inert atmospheres, with authorisation from senior site management

14. Safety Talk 13 / 14 Summary of gas test levels OXYGENFLAMMABLETOXIC Without Breathing 20.8%<1% LEL<10% OEL Apparatus (BA) With BA subject 19.5 - 23.5% 10% LEL to enter <STEL to risk assessment20% LEL exit Unsafe 20% LEL>STEL or >23.5% OEL (Occupational exposure limit – for 8 hours exposure) STEL (Short term exposure limit – for 15 minutes exposure)

15. Safety Talk 13 / 15 Coordination and segregation of work to prevent dangerous interactions, particularly for complex work Restrictions on work to be carried out externally and internally Adequate internal lighting suitable for zone 1, and where possible < 25 volts PPE to be worn Precautions against remaining hazards

16. Safety Talk 13 / 16 Entry permit form fully completed and issued by operating authority to performing authority Permit distribution ensures that the required information is formally communicated to all interested parties Original to the performing authority, to be posted at the entrance to the vessel Copies to –Control room or other operating centre –Operations supervisor –HSE dept –Others as decided by site management Entry permit issue and distribution

17. Safety Talk 13 / 17 Entry Tags Tags are used to: Reinforce the entry permit Warn that hazardous conditions exists – see entry permit Prohibit entry

18. Safety Talk 13 / 18 PERFORMING AUTHORITY Supervisor visits worksite Holds a ‘toolbox talk’ with those who will carry out the work Additional briefing for contractors and subcontractors Explains scope, restrictions, timescale, precautions, first aid and emergency procedures Considers factors relating to the specific day Gives clearance signature to enter Is present when entry first made OPERATING AUTHORITY Supervisor visits worksite Commencement of entry

19. Safety Talk 13 / 19 Repeat gas tests or continuous gas monitoring Position Vessel Entry Standby’s immediately outside the confined space – at least one with SCBA if worn for entry Control over routine access / exit should be maintained If conditions change, in an emergency, and if the general alarm sounds, persons must be able to exit quickly Monitoring EVERYONE has a duty of care to those inside the vessel ANYONE can and must raise the alarm to evacuate the vessel if they detect a hazard to the people inside

20. Safety Talk 13 / 20 Vessel Entry Standby duties Remain on duty until relieved Maintain an accurate count of all persons in the vessel Maintain effective contact with the persons inside the vessel Use a life-line where appropriate Monitor activities to confirm that it remains safe for people to remain inside Order evacuation if conditions change to endanger people inside Summon rescue services in an emergency Do not enter

21. Safety Talk 13 / 21 Emergency action and rescue Entry must cease if the emergency siren sounds First action is to raise the alarm and summon the emergency services Only specially selected, fit, trained rescuers can attempt rescue. Untrained persons MUST NOT ATTEMPT RESCUE Self contained breathing apparatus (SCBA) must be used If work or entry is stopped for safety reasons,it must not be restarted until all tests and checks are repeated and written authorisation given

22. Safety Talk 13 / 22 Validity rules will be set by site management according to the risks involved and the working / shift system Entry permits should not be valid for more than 1 work period or day All ‘live’ entry permits must be formally handed over at working / shift changeovers, together with a status update Permit validity

23. Safety Talk 13 / 23 Completion of entry Performing authority signs and returns the original entry permit to the operating authority Operating authority inspects the vessel and, if satisfied, withdraws the permit The original permit form should be filed for future reference All copies should be filed or destroyed to ensure that only valid permits are ‘live’ in the workplace

24. Safety Talk 13 / 24 Entry which cannot be carried out in accordance with the entry permit system: –where gas test criteria cannot be achieved –where disconnection or spading is impractical –other entry permit rules cannot be met Involves more detailed planning and control procedures outside the scope of this safety talk Requires authorisation by a senior manager Higher risk work

25. Safety Talk 13 / 25 Wrong equipment A contractor entered the cage of the wrong air cooler, through a trap door locked with a padlock and key. Unfortunately the padlock was in a bad condition so he cut it off. Luckily the fan was not started while he was inside.

26. Safety Talk 13 / 26 Electrical isolation must be positive lock-out / tag out Each vessel should have an isolation list There is no substitute for walking around a vessel, physically checking each connection, and verifying positive isolation ‘Mixed up’ A worker cleaning the inside of a vessel was killed when the (wrong) mixer was inadvertantly started.

27. Safety Talk 13 / 27 ‘Boxed in’ Workers cleaning trays in a column were working from the bottom to the top. Others ‘boxing up’ man ways were working top to bottom simultaneously to save time. Luckily frantic banging raised the alarm, and the cleaners were released.

28. Safety Talk 13 / 28 If the mate had called for help he may have saved the worker’s life as well as his own Attempted rescue A worker collapsed inside a vessel. His mate attempted to rescue him, without raising the alarm, but was also overcome. They were both found dead some time later.

29. Safety Talk 13 / 29 ‘Putting your head in’ An operator put his head into the tank opening of a barge to check the oil level. He was overcome and fell inside the tank and was killed. A maintenance foreman put his head inside a manhole on a nitrogen purged vessel to check details of internal fittings. He was found collapsed (dead) over the manhole.

30. Safety Talk 13 / 30 ‘Putting your head in’ again A welder was repairing cracks in the man way of a tank that had been nitrogen purged. Work was not possible with the manhole cover in place. He dropped a torch tip into the tank, looked inside for it, collapsed, fell in and died.

31. Safety Talk 13 / 31 Enhanced combustibility A fire broke out inside a Hortonsphere when tarpaulins and scaffolding boards caught fire as a result of enhanced combustibility due to oxygen leaking from cutting equipment (1 man killed).

32. Safety Talk 13 / 32 Pride comes before a fall Attempting to unplug a tank pump suction, a contractor entered the tank through a small opening, wearing only a cannister respirator. There was no entry permit and he was instructed not to go in. He would not come out even when felt dizzy. He was killed by benzene vapours.

33. Safety Talk 13 / 33 The permit system should tell us all the work and entry that is happening at any point in time Large / complex jobs and or worksites have to be broken down into manageable parts When preparing for hot work, ‘vapour – free’ does not mean ‘gas free’ Dangerous interactions A contractor was carrying out hot work on an overheads line resulting in an internal fire – fuel was probably gas oil distilled over during steaming out. The fumes migrated to the column overcoming unprotected workers carrying out familiarisation training (2 deaths).

34. Safety Talk 13 / 34 ‘I thought’ (that I knew better) Another (forbidden) rescue attempt An employee was cleaning the inside of a storage tank. Instructed to use a steam cleaner but used solvent because he thought it would be quicker. He was working unsupervised. He knocked over a container of solvent and was overcome by vapours. A second person, who entered the tank without breathing apparatus, was also overcome

35. Safety Talk 13 / 35 Competency, training and awareness Workplace safety depends on: Awareness, communications, training and supervision Care and competence of those responsible for the work Competencies should be Defined in terms of skills and experience required Training and experience given Confirmed by formal testing and accreditation eg. operating and performing authorities, gas testers, vessel guards Workplace safety depends on PEOPLE

36. Safety Talk 13 / 36 Contractors Contractors should receive training in the work permit system as part of their induction Contractors workers may also require: Specialist training eg. in wearing / using breathing apparatus Medical examinations to confirm physical fitness

37. Safety Talk 13 / 37 Summary Entry is one of the higher risk activities carried out in our refineries We have pointed out the risks, and the controls that are available in the permit system The permit system is one of the critical controls used to establish and maintain a safe workplace An entry permit: –is a contract between the Operator and the Performer –defines responsibilities, scope and timing of work –raises awareness and provides a useful checklist / aide memoire A permit alone can never make entry safe Only the care and competence of those who operate the system can do that

38. Safety Talk 13 / 38 1.Managing risk involves (4 steps) 2.Name 4 inherent hazards of entry 3.Is valve isolation adequate for entry ? 4.What important roles does the (operating) supervisor play ? (4) 5.What important roles does the (performing) supervisor play ? (4) 6.What important roles does the standby person outside a vessel play ? (4) 7.What should you do if you discover a hazard that compromises the safety of entry ? (2) 8.What should you do if you discover a person in difficulty in a confined space ? 9.What checks would you make if asked to enter a vessel ? 10.How can we generate interest and maintain awareness of everyday safety issues ? (any ideas would be welcome) Optional quiz

39. Safety Talk 13 / 39 Work permit process / responsibilities 1 Before work starts Permit required (Yes, no, type)Application for a Work Permit: Define work scope Identification of the hazards of performing the work Joint planning of work with the Area Authority Decisions on isolation Decommissioning Joint planning of work with the Performing Authority Coordination with other work Identify hazards associated with facility operations Raise and complete the appropriate permit form(s) Receive Work Order A P P E N D I X 1 OPERATING AUTHORITY PERFORMING AUTHORITY

40. Safety Talk 13 / 40 Preparation of worksite environmentPreparation of worksite for the work to be done Review permit (Hot, Entry and Contractors) and accept Issue permit Review the completed permit form and authorise Specifying precautions Interpretation of gas results and decision on proceeding Arranging for gas testing (by accredited gas tester) Carry out isolationPreparation of equipment A P P E N D I X 1 OPERATING AUTHORITYPERFORMING AUTHORITY Work permit process / responsibilities 2

41. Safety Talk 13 / 41 Permit distribution Post original permit at worksite Commencement of work Final inspection Post copy of permit at reporting point Tool box talk for work teamBrief operating personnel A P P E N D I X 1 OPERATING AUTHORITYPERFORMING AUTHORITY Work permit process / responsibilities 3

42. Safety Talk 13 / 42 Performing work Complying with restrictions Implementing precautions Monitoring the work related hazards Restart workReissue permit Withdraw permit Commencement of work Monitoring eg. gas monitoring Entry Guard, Fire Watch Monitoring of workplace operating hazards Emergency and Rescue Suspension of work, uncompleted or interrupted work A P P E N D I X 1 OPERATING AUTHORITYPERFORMING AUTHORITY Work permit process / responsibilities 4

43. Safety Talk 13 / 43 Completion of work Sign off permit Withdrawal of Permit Completion of work Handover at shift and personnel changes Stopping work if conditions change making work unsafe Clear workplace of tools, equipment, materials & workers Hand back the equipment in a safe condition to be recommissioned Inspection of completed work A P P E N D I X 1 OPERATING AUTHORITYPERFORMING AUTHORITY Work permit process / responsibilities 5