CARRYING OUT STEEL STOPPLE OPERATIONS Safeguard Safe Work Method Statement
Document: APAND00015 Version: 0.01 Date: 27/03/2013 Review by: 31/03/2014 Page 1 of 14 pages
SAFE WORK METHOD STATEMENT - CARRYING OUT STEEL STOPPLE OPERATIONS
HSE NET NAT SWMS APAND00015
Principal Contractor (PC)
APT AM Holdings Pty. Ltd.
[ABN] 95124754383
APA Group Level 19, HSBC Building 580 George Street Sydney NSW 2000
State Representative :
Subcontractor
Person responsible for reviewing &
approving the SWMS
John Ferguson Group Executive Networks Phone 02 9693 0057
Signature and Date Sign: Refer to Approval Sign off Sheet APADN00020 Date: 28/3/2013
Date SWMS provided to PC
27/3/2013 Provided to: Robin Gray Manager Systems Operations Phone 08 8159 1656
Work Description
SAFE WORK METHOD STATEMENT ACTIVITY
Connecting onto live gas mains Carrying out Steel Stopple Operations
Project Reference
Steel Hot Tap And Stopple Activities
Work Location /Address
Not applicable
Person Responsible for ensuring
compliance with SWMS on site
As identified on the APA JHEA (APA NAT-00026)
The following personnel who have
consulted and assisted in the
development of this
Billy McNeil, Ross Darrigan, Anthony Cronin. Jason Riddell Review date for this
SWMS March 2014
CARRYING OUT STEEL STOPPLE OPERATIONS Safeguard Safe Work Method Statement
Document: APAND00015 Version: 0.01 Date: 27/03/2013 Review by: 31/03/2014 Page 2 of 14 pages
PERSONNEL SITE CONTENT
Required Supervision As identified on the APA JHEA(APA NAT-00026)
Permit to Work & other Approval Requirements
Required Qualifications
TDW Competency
Plant, Equipment, Materials
Required Training
APA induction Card or Short term induction
Construction Industry General Induction
Workplace Specific Induction (if required)
Induction in to this SWMS
Induction to APA Pre Start HSE Check/Plan
Hazardous Substances
Ref MSDS Register on Crew Truck
Personal Protective Equipment (PPE)
High Visibility Clothing – Day and Night MANDATORY
Safety Gloves (as required)
Safety Glasses Clear and Sunglasses(as required)
Hearing Protection – Earmuffs / Earplugs (as required)
Safety Boots - Steel Cap MANDATORY
Protective Clothing – Must meet and be used as
Emergency Procedures and
Equipment
Seat Belts
Flashing lights
Reversing warning
First Aid Kit (on site)
SWMS
CARRYING OUT STEEL STOPPLE OPERATIONS Safeguard Safe Work Method Statement
Document: APAND00015 Version: 0.01 Date: 27/03/2013 Review by: 31/03/2014 Page 3 of 14 pages
per APA Operations Field Book Procedure 5206
Safety Helmet (as required)
Sun Lotion (as required)
Sun Hat (as required)
REFERENCES ASSOCIATED DOCUMENTS
[List as required. May include Legislation, Australian Standards, MSDS, Codes of Practice, etc.]
Work Health & Safety Act 2011
Work Health & Safety Regulations 2011
Work Health & Safety Act 2012 SA
Work Health & Safety Regulations 2012 SA
Work Health & Safety Plant Code of Practice
Work Health & Safety Risk Management Code of Practice
Work Health & Safety Noise Code of Practice
AS 1742.3:2009
[List as required. May include work instructions, APA Operating Manuals, inspection procedures, maintenance instructions]
APA Pre Start HSE Check/Plan
APA traffic management check/plan Book
APA Operations Field Book
Safeguard
CARRYING OUT STEEL STOPPLE OPERATIONS Safeguard Safe Work Method Statement
Document: APAND00015 Version: 0.01 Date: 27/03/2013 Review by: 31/03/2014 Page 4 of 14 pages
Step No.
What are the tasks involved?
in order of job sequence
Hazards/risks What can happen and how can it happen?
Raw Risk Controls to be implemented to reduce risks What will be done to ensure zero harm?
Residual Risk
Person responsible Who will make sure
it happens?
Break the job down into steps. Each step should accomplish some major task and be in a logical sequence
Specify the potential hazards associated with each step and risks to health, safety and the environment. Examine each to find possibilities that could lead to an incident.
Assess the raw risk without controls
Describe the measures to be implemented to eliminate or control the risks. Describe how these measures are to be implemented, monitored and reviewed.
Assess the residual risk with controls
Specify Person(s) Responsible
1. Check Design
Fitting failure due to incorrect fittings ordered and non-compliance to Australian Standard
Possible injuries from site selection due to deep excavation, wet areas.
Failure to have design checked and approved
Incomplete job packs
High
Design checklist to be approved by the Delegation of Authority (DOA)
Completed work pack signed by Delegation of Authority (DOA) prior to issue
Check location design for suitability.
All selected fittings to comply with Australian Standards
Moderate
Project Manager
Engineer
Site responsible supervisor
2.
Check Materials / Fittings
Failure of fittings due to incorrect pressure class.
Injuries from uncontrolled release of gas due to faulty fittings.
Inability to plug fittings due to damage caused prior to or during fitment.
Maximum Allowable Operating Pressure (MAOP) resulting in possible down rating of pipeline
Incorrect carbon content in
High
Confirm Maximum Allowable Operating Pressure (MAOP) of main / service
All materials to comply with Australian Standards
Visual inspection of fittings to ensure compliance to engineering design
Check all supplied materials for mechanical operation fit for task
Identification check of fitting number
Moderate
Project Manager
Engineer
Site responsible supervisor
CARRYING OUT STEEL STOPPLE OPERATIONS Safeguard Safe Work Method Statement
Document: APAND00015 Version: 0.01 Date: 27/03/2013 Review by: 31/03/2014 Page 5 of 14 pages
fittings
Incorrect quantity of fittings for task
Incorrect stopple cups range selection
Missing fitting certification
against supplied certification and APA requirements
Check fitting certification meets engineering design specification
Check quantity supplied meets order requirements
3. Site Set Up
Trips and falls during site walk due to uneven ground or items lying around.
Traffic Incident. Injuries to pedestrians / others.
Environmental impact – failure or leak while setting down equipment and or product.
Stopple plant set down areas not suitable for task
Inadequate area footprint to complete stopple task
High
Ensure a complete work pack is signed off and issued prior to site mobilization
Tool Box Meeting. (Identify site specific risks).
Pre-start and JHA completed
Ensure the fittings supplied are as specified
Keep site tidy and maintain good housekeeping.
Traffic management plan comply with Manual Uniform Traffic Control Device (MUTCD)
Implement sediments controls measures as per APA procedures.
Set down area to be pre-identified and managed by Traffic Controllers (TCs) / site foreman.
Ensure spill kits are available on site.
Moderate
Site responsible supervisor
All Team members
CARRYING OUT STEEL STOPPLE OPERATIONS Safeguard Safe Work Method Statement
Document: APAND00015 Version: 0.01 Date: 27/03/2013 Review by: 31/03/2014 Page 6 of 14 pages
Ensure adherence to approved applicable APA SWMS
4. Excavate site.
Trench collapsing
Damage to pipe or coating
High
Refer SWMS for Excavating and working in a trench greater than 1.5m
Refer to SWMS for Steel Main Laying
Ensure compliance with APA permitting procedures
Ensure adherence to approved applicable APA SWMS
Moderate
Site responsible supervisor
All Team members
5. Weld Fittings on to Main
Possible eye injuries due to weld flash.
Possible injuries from grinding slag.
Burns from welding.
Burn through of pipe during welding causing uncontrolled gas escape / fire.
Failure of welds causing uncontrolled gas escape / fire
Fire caused by grinding / pre heat.
Injuries from mechanical failure of equipment.
Hearing damage from excessive noise.
Heat stress.
Electrocution from contact with metal pipe during electrical storm
High
Use welding screens to protect public and other workers from flash.
Ensure adherence to approved applicable APA SWMS
Provision and use of Personal Protective Equipment - Ref Protective Clothing – Must meet and be used as per APA Operations Field Book Procedure 5206.
Use qualified welders and procedures.
Carry out lamination and thickness checks on main as specified by project engineer.
Use qualified welders and procedures. Carry out non-destructive testing of welds as per engineering specification.
Ensure compliance with APA permitting procedures
Have frequent breaks. Drink plenty of water. Provide shade (tarps).
Moderate
Site responsible supervisor
All Team members
Weld supervisor
CARRYING OUT STEEL STOPPLE OPERATIONS Safeguard Safe Work Method Statement
Document: APAND00015 Version: 0.01 Date: 27/03/2013 Review by: 31/03/2014 Page 7 of 14 pages
/stray currents.
Damage to exposed pipe during lifting operation.
Do not carry out welding operations during storms. Check weather reports.
Ensure Earthing leads attached to main. Use neon detector to check for stray current.
Have suitable repair fittings on site to suit Maximum Allowable Operating Pressure (MAOP) and size of pipe if specified.
6.
Test Fittings / Valves / By -passes
Injuries from sudden escape of pressure due to fitting failure.
Incorrect testing pressures.
Failure to comply with testing procedures/specifications.
Failure of test equipment.
Failure of pipe or fittings during test operations.
High
Visual inspection of fittings. Ensure all equipment and fittings to be used are suitable for test pressure.
Pressure test fittings and equipment prior to drilling. Refer to AS2885.2 Welding Standard; Section 13.14. Test Pressure must be minimum of 100kPa less than the pipeline operating pressure.
Use hydro test in preference to air test where possible or as specified by the project engineer.
Dewatering or depressurizing air/gas from tested section of mains should be undertaken with extreme caution refer to AS2885.5 Field Pressure Testing
Consider use of whip checks on flexible test equipment to prevent injury.
Use appropriate signage to warn others of pressure test.
Moderate
Site responsible supervisor
All Team members
Weld supervisor
CARRYING OUT STEEL STOPPLE OPERATIONS Safeguard Safe Work Method Statement
Document: APAND00015 Version: 0.01 Date: 27/03/2013 Review by: 31/03/2014 Page 8 of 14 pages
7. Drill Fittings
Injuries from uncontrolled escape of gas that may cause fire or explosion.
Fitting / valve failure due to incorrect drill size resulting in pipe damage/ leak that may cause fire or explosion.
Commissioning prior to pre-commission checklist being approved.
Loss of coupon could damage downstream equipment.
Injuries due to failure of mechanical or hydraulic/pneumatic equipment.
Environmental spills.
Hearing damage due to excessive noise.
Injuries from lifting equipment. (craning loads)
Possible fall during drilling operation.
High
Pressure test fittings and equipment prior to drilling. Refer to AS2885.2 Welding Standard; Section 13.14. Test Pressure must be minimum of 100kPa less than the pipeline operating pressure.
Check and confirm correct drill and pilot size selected. Use measurement cards. (Refer T.D.W. training manuals)
Ensure coupon catcher operating correctly.
Visual inspection of drilling equipment.
Check / maintain equipment.
Visual inspection of hydraulic / pneumatic hoses and couplings.
Provision and use of Personal Protective Equipment - Ref Protective Clothing – Must meet and be used as per APA Operations Field Book Procedure 5206.
Ensure adherence to approved applicable APA SWMS
Ensure spill kit on site.
Visual inspection of lifting equipment for damage.
Use drill platform or other appropriate controls.
Moderate
Site responsible supervisor
All Team members
Weld supervisor
CARRYING OUT STEEL STOPPLE OPERATIONS Safeguard Safe Work Method Statement
Document: APAND00015 Version: 0.01 Date: 27/03/2013 Review by: 31/03/2014 Page 9 of 14 pages
8. Stopple Main, Tie in /
Cut and cap
Injuries due to sealing element / mechanical equipment failure causing uncontrolled escape of gas that may cause fire or explosion.
Injuries from hydraulic / pneumatic hose failure.
Environmental spills
Hearing damage.
Supply loss
Injuries from cutting pipe. Sharp metal edges.
Burn from flaring gas
High
Ensure correct sealing elements are used, and that they are in good condition. Check elements are within use by date. (Refer to T.D.W. Training manuals.)
Ensure the second block between cut end and stopple sealing element is in place or as specified by the project engineer.
Have fire extinguishers located in an appropriate location.
Ensure all plant and equipment is well maintained/ calibrated and is fit for purpose.
Provision and use of Personal Protective Equipment - Ref Protective Clothing – Must meet and be used as per APA Operations Field Book Procedure 5206.
Ensure adherence to approved applicable APA SWMS
Support pipe with stands, jacks, slings. Discuss with staff and make them aware of possible movement.
Ensure non routine is followed to prevent loss of supply.
Moderate
Site responsible supervisor
All Team members
Weld supervisor
9. Purge main / by pass Failure on high pressure bypass
Burn while purging gas High
Refer to SWMS on Direct and Indirect Purging
Adherence to procedures as specified by the project engineer.
Moderate
Site responsible supervisor
All Team members
CARRYING OUT STEEL STOPPLE OPERATIONS Safeguard Safe Work Method Statement
Document: APAND00015 Version: 0.01 Date: 27/03/2013 Review by: 31/03/2014 Page 10 of 14 pages
Prior preparation of by-pass hoses (test)
Provision and use of Personal Protective Equipment - Ref Protective Clothing – Must meet and be used as per APA Operations Field Book Procedure 5206
Adherence to Emergency Services fire danger rating (FDR) and if required get permits.
10. Commissioning
Failure and gas escape, failure of golden weld
Failure of equalization of mains pressure
Failure to bring the main back to operating pressure
Loss of supply
Failure during decommissioning of by-pass hoses / fittings
High
Pre-commissioning checklist is to be approved, signed and sighted and on site prior to commissioning.
Adherence to general procedures as specified by the project engineer.
Provision and use of Personal Protective Equipment - Ref Protective Clothing – Must meet and be used as per APA Operations Field Book Procedure 5206
Moderate
Project manager
Site responsible supervisor
All Team members
11. Install completion plugs
/ fittings
Injuries from uncontrolled release of gas due to failure of plug to seat / seal correctly.
Injuries from mechanical failure of plug or plugging equipment.
Damage to existing infrastructure
Incorrect installation / failure of fitting
Loss of plug off the plugging
High
Visual inspection of plug, ensure all mechanical components of plug are operating correctly. Check seal for damage. Refer to T.D.W. procedure manuals
Ensure correct pressure rating of stopple plugging equipment.
Ensure adherence to approved applicable APA SWMS
Adherence to general procedures as specified by the project engineer.
Moderate
Site responsible supervisor
All Team members
CARRYING OUT STEEL STOPPLE OPERATIONS Safeguard Safe Work Method Statement
Document: APAND00015 Version: 0.01 Date: 27/03/2013 Review by: 31/03/2014 Page 11 of 14 pages
equipment
Failure to follow pre-determine measurements recorded on measurement card
Stopple measurement card to be located in a safe accessible place.
12. Mummify fittings / pipe /
valves
Possible future failure of asset due to corrosion, causing uncontrolled escape of gas.
Possible fires from use of gas torch to heat shrink sleeves where applicable.
Moderate
Use approved wrapping materials.
Follow A.P.A. procedures. Use Holiday detector to confirm wrapping done correctly.
Remove all flammable materials from site.
Check gas torch and gas bottle for leaks. Confirm bottle is in test.
Minor
Site responsible supervisor
All Team members
13. Backfill of Excavation
Non-compliance to SWMS for Excavating and Working in a Trench Greater than 1.5m
High Ensure adherence to approved
applicable APA SWMS Moderate
Site responsible supervisor
All Team members
14.
Deviation from this Safe Work Method Statement
Miscommunication by all parties onsite.
High
STOP all work activities
Ensure task and equipment is made safe
Hold a tool box meeting and record and adjust
Complete JSA for variations from work method – obtain approval from site representative.
Authorised by competent person, supervisor or HSE Advisor
Sign off on changes prior to the recommencement of work.
Adequately trained to complete JSA.
Moderate
Site responsible supervisor
All Team members
CARRYING OUT STEEL STOPPLE OPERATIONS Safeguard Safe Work Method Statement
Document: APAND00015 Version: 0.01 Date: 27/03/2013 Review by: 31/03/2014 Page 12 of 14 pages
CARRYING OUT STEEL STOPPLE OPERATIONS Safeguard Safe Work Method Statement
Document: APAND00015 Version: 0.01 Date: 27/03/2013 Review by: 31/03/2014 Page 13 of 14 pages
Declaration by contractors and workers - I have been given the opportunity to comment on the content of this SWMS. - I have read and understand how I am to carry out the activities listed in this SWMS. - I have been supplied with the personal protective equipment identified on this SWMS and I have been given training in the safe use of this equipment. - I have read and understand the requirements set out in the material safety data sheets for the hazardous substances identified in this SWMS
Consultation & Review Sign Off Analysis of Training / Skills or Competencies Required
Training / Skill / Competency Required to Complete the Work Safely
Gen
eral
Ind
ust
ry
Ind
uct
ion
Pro
ject
Sp
ecif
ic
Ind
uct
ion
[ Li
st o
ther
s]
A = All employees are required to hold. % of personnel required to hold
A A
Number of personnel required to hold
Name Position Signature Date Training / Skill / Competency held by employee – tick () – evidence must
be available
CARRYING OUT STEEL STOPPLE OPERATIONS Safeguard Safe Work Method Statement
Document: APAND00015 Version: 0.01 Date: 27/03/2013 Review by: 31/03/2014 Page 14 of 14 pages
Risk Assessment CONSEQUENCE
RISK RANKING ACTION REQUIRED
Negligible Work can proceed once risk controls identified and implemented
Minor Work can proceed once risk controls
identified and implemented
Moderate Work can proceed once supervisor has confirmed process has been
adequately followed and risk controls identified and implemented
High Reduce risk to at least moderate or to ALARP through additional controls.
Activity must not commence without Management approval
Extreme Activity must not commence.
Reduce risk to at least moderate or to ALARP through additional controls.
HSE First aid treatment only with the ability to return to work immediately
External medical treatment but excluding hospitalisation with the ability to return to work the next work day
Injury or illness requiring hospitalisation and resulting in the inability to return to work the next day (LTI
Permanent partial disability
Fatality OR permanent total disability
Multiple fatalities
Environment Limited impairment to minimal area of low significance
Short-term (<12 months) temporary impairment to the biological or physical environment of a very localised area (<0.1ha)
Prolonged (<5 years) reversible impairment to the biological or physical environment of a localised area (<1ha) which is easily rectified and which does not affect ecosystem function
Uncontrolled off-site release or event. Reversible prolonged impairment to the environment but which does not affect ecosystem function
An uncontrolled off-site release or event in wide area resulting in reversible long-term environmental impairment of ecosystem function
Uncontained, long-term serious environmental degradation OR permanent impairment to ecosystem function or habitat
LIK
ELIH
OO
D
Probability Historical Descriptor LEVEL 1 LEVEL 2 LEVEL 3 LEVEL 4 LEVEL 5 LEVEL 6 At least once per
year Is expected to occur in
most circumstances Frequent Minor Moderate High Extreme Extreme Extreme
At least once every 1 to 5 years
Expected to occur infrequently
Likely Minor Moderate High High Extreme Extreme
At least once every 5 to 10 years
May occur occasionally
Occasional Minor Minor Moderate High High Extreme
At least once every 10 to 50 years
Might occur at some time
Possible Negligible Minor Moderate High High High
At least once every 50 to 100 years
Could occur at some time but not
considered likely Unlikely Negligible
Minor
Moderate Moderate High High
Less than once every 100 years
Conceivable but only in exceptional circumstances
Improbable Negligible Negligible Minor Moderate Moderate High