07A Risk Analysis EU Machinery Directive CE

RISK ANALYSIS
ACCORDING TO EU MACHINERY DIRECTIVE CE/2006/43
Project
10892 - HARLINGEN
Document n 10892EA00400
Table of Content
1 - General part 2 - List of specific parts 3 - Risk Interfaces 4 - EC certificates 5 - List of norms applied
p2 p5 p 43 p 44 p 45
Date Written by :
02/03/2011 IS
Revision Checked by : AB GL
0 first edition Approved by : PMi
1- General part CE MARKING - RISK ANALYSIS ACCORDING TO EU MACHINERY DIRECTIVE CE/2006/42 ORIGIN AND KIND OF RISKS
1.1 GENERAL REMARKS
1.1.1 Definitions 1.1.2 Principles of safety integration
POTENTIAL CONSEQUENCES
REMEDIES AND REFERENCES
Personal and mechanical damages due to uncorrect design All equipment with moving part (fans, pumps, motors, conveyors, mixers ) and/or abnormal use Actuators, dampers, valves, instruments Access to instruments, actuators, equipment
- Lay-out reviews for circulation inside the plant, access to instruments, actuators, equipment ...HAZOP studies - Equipment CE marking by sub-supplier + Machines Directive - Operating & maintenance instructions in dutch language for each equipment - Marking, labelling - Training Yearly audit by Bureau Veritas of LAB SA for design and studies and control of subsuppliers. Quality certificate ISO 9001 ver. S2000. Steel structure calculations done by specialized companies + material products for steel (origin from European Community) Safety data sheet Training Marking & labelling HAZOP studies Level indicator & alarm Filter Safety valve on silo Activated carbon NORIT GL50 or SGL CARBON LINK (see safety datasheet in asbuilt documentation (DOE) section A 01 "safety") Level indicator & alarm Filter Safety valve on silo ATEX classification Safety data sheet Training Marking & labelling Safety valves PED certificates for economizer, hot water piping, SCR steam heater Packed in closed containers Safety datasheet Maintenance instructions Retention tank Detector, alarms, safety valves, explosion disc Safety datasheet Retention under tank and pumps and unloading area negative pressure; tightness requirements in technical specifications to sub-suppliers negative pressure; tightness requirements in technical specifications to sub-suppliers Level indicator & alarms Filter Electrical tracing -For the record - Under OMRIN responsability -For the record - Under OMRIN responsability Asbestos or carcinogen ceramic fibers not allowed Special precaution in case of welding. By the client Special care for internal lighting during inspection Carcinogen ceramic fiber not allowed, refer to Technical Specification Protected by cladding
1.1.3 Materials and products
General design Steel structure and equipment in steel material All products (liquids, solids) for operation of the plant: loading/unloading, use ) Corrosion
Personal damage
Sodium bicarbonate
Personal damage
Activated Carbon
Personal damage, explosion
Glycol Hot water & steam Lubricants/oil/grease Oil for HV transformer + oil for silo extraction system Ammonia Flue gas Dust Residue Nitrogen for inertisation of silos and fabric filter Gas for analyser Gaskets, sealing devices Expansion joints, plastic, polymer material for valves Heat insulation
1.1.4 Lighting
Personal damage Personal damage Personal damage Personal damage, flamable Personal damage, environment damage Personal damage & corrosion Personal damage & corrosion Personal damage & corrosion
flamable Personnal damage
Not applicable - OMRIN scope - No special LAB requirements

1.1.5 Design of machinery to facilitate its handling
General maintenance of the plant
Personal injuries
General handling/lifting of equipment > 20 kg (contract) Fan dismantling Catalyst handling

1.1.6 Ergonomics
Equipment damage + personal injuries Equipment damage + personal injuries Equipment damage + personal injuries
Refer to general instructions in maintenance manual: helmet + gloves + safety shoes are mandatory - Special clothes protection for operation inside specific equipment (silos, ) Lifting lugs required in Technical Specification Hinged man hole Tests/inspections of lifting beams Marking of lifting beams Special access, beam and procedure, refer to training Special access, beam and procedure, refer to training Access review on layout done with OMRIN Fulfillment of contract (European Norms EN 389, 547-1, 614-1, 894-1 + Dutch laws) for space around equipment, height for access, staircases . Thermal emission data supplied to OMRIN for design of the ventilation unit Global acoustic calculation for building definition by OMRIN Minimum diameter for manholes 800mm + mounted on specific hinges when > 20kg Integration in a new OMRIN control room Control System screen views approval by OMRIN
All equipment
Manholes Control room

1.1.7 Operating positions
Personal damage Ammonia injection : chemical risks Specific rooms (limestone room, analysers room)
1.1.8 Seating
Personal damage & corrosion
Escape routes discussed/agreed with OMRIN + local fire people Refer to above for alarms; Special dedicated devices as showers, eyes cleaning Individual personal protection equipments required OMRIN scope
Not applicable for onsite equipment 1.2 CONTROL SYSTEMS

1.2.1 Safety and reliability of control systems
PCS system requested by OMRIN : low availability and/or failure in operation Sensitive operating measurements (temperature, pressure ) Instruments, valves, electrical cabinet damage due to environment
1.2.2 Control devices
Abnormal operation of the plant + high number of stops Damage of instruments + stop of the plant Damage of equipment Damage of equipment + risks for operators Damage of equipment + risks for operators
Availability guarantee by siemens / OMRIN Installation of 3 instruments + operation on 2/3 according to SIL study Specific protection class (IP54, IP55, IP65, ATEX) for instance depending on location/utilisation Process risk analysis + LAB functional analysis Local maintenance switches of the equipment with moving parts Co-ordination with boiler (pre-ventilation sequences ), see interfaces in chapter 3 Emergency devices (safety positions for fans, fabric fitler bypass, SCR bypass, safety valves ) / Operating manual
Programming of PCS + start-up/stop conditions

1.2.3 Starting
Start of each individual equipment Start of the plant through sequences / Error in programming
1.2.4 Stopping
Automatic stop of the plant (sequences) - Risk of damage of the plant
Damage of equipment + operators risks
1/3
10892EA00400-0
ORIGIN AND KIND OF RISKS

Emergency stop of the plant Safety position of individual equipment during long stops Stoppage for maintenance or dismantling
1.2.5 Selection of control or operating modes
Damage of equipment Equipment damage + personal injuries

Definition and installation of local maintenance switches by electrical lot (ammonia, ID fan, heat recovery pumps) Sub-supplier operating manuals Electrical consignation on the MCC by the autorized operator and special procedure ID Fan rotation by natural draft avoided by mechanical design (refer to training) Watch tours + cold/hot tests commissioning Sensitive equipment on emergency diesel ID Fan with emergency motor to maintain negative pressure in the flue gas cleaning + automatic start "Live" black-out tests during commissioning
Automatic control / operation of the plant

1.2.6 Failure of the power supply
Damage of the plant and of equipment
Power black-out
Damage of equipment
1.3 PROTECTION AGAINST MECHANICAL HAZARDS

1.3.1 Risk of loss of stability
Breakdown due to bad installation
Damage of equipment + risk for operators
Refer to risk analysis, maintenance and operating manual of elements by suppliers Integration of equipment in Steel structure Steel structure calculations done by a specialized company according to dutch norms
1.3.2 Risk of break-up during operation
Breakdown following operation
Damage of equipment + stop of the plant
Mechanical calculation notes for vessels, piping. including stress analysis Expansion joint for thermal displacements avoiding unacceptable stress Installation of anti-whip cable on nitrogen flexibles Quality Control during fabrication and erection, for material, thickness, welding... Operating manual + maintenance manual Cleaning of the plant and general plant instructions by OMRIN Specific retentions Hand rail, foot plates on structure Hinged doors on the top of access ladders. Internal vessels device in case of internal inspection or maintenance No quick and easy release devices for vessels door opening; only bolting, requiring tools
1.3.3 Risks due to falling or ejected objects
Falling of objects
Damage of equipment + risk for operators
Ejected objects: not applicable

1.3.4 Risks due to surfaces, edges or angles
Edges and angles Height / Header

1.3.5 Risks related to combined machinery
Risk for operators Risk for operators
Design + inspections Grinding of edges and angles if risk of injury Fulfillment of contract (2.3 m. minimum) Helmet mandatory
Not applicable
1.3.6 Risks related to variations in operating conditions
Stop of the plant

1.3.7 Risks related to moving parts
Damage of equipment + loss of operation
Large operating range according to the contract Automatic control of process parameters, alarm and automatic actions in case of emergency or running out of the designed operating range Protection for moving parts (fans, pumps ) CE marking and corresponding devices by sub-suppliers (as for pumps, fan, dampers, screws ) Mechanical locking of the flue gas dampers
Rotating machines, electrical motors, fans and pumps automatic valves and dampers, actuators Rappers and vibrators
1.3.8 Choice of protection agains risks arising from moving parts
Risk for operators Personal injuries
See 1.3.7
1.3.9 Risks of uncontrolled movements
Abnormal stop 1.4 REQUIRED CHARACTERISTICS OF GUARDS AND PROTECTIVE DEVICES

1.4.1 General requirements
Damage of equipment
Safety positions of valves/dampers and air buffer tanks in case of loss of power and loss of instrument air. Refer to 1.2.4 stoppage for maintenance or dismantling
Design & installation of protective devices by OMRIN
Process risks definition in risk analysis, maintenance and operating manuals, refer to 1.3.7 Vessels and ducts are calculated according to normal and exceptionnal pressure and temperature conditions. Piping support are calculated according to weight and flexibility if relevant Pressure vessels are designed and made according to PED, safety valves are installed accordingly Pumps are designed and tested according to official rules and standards. Volumetric pumps are equiped with discharge valves (NH3) connected to the suction side Equipments are attached to steel structure or concrete plinths with bolts, anchorages... Procedures / operating manual
1.4.2 Special requirements for guards
Refer to equipment documents provided by supplier and operating manual

1.4.3 Special requirements for protective devices
Refer to equipment documents provided by supplier and operating manual 1.5 RISKS DUE TO OTHER HAZARDS
1.5.1 Electricity supply
Procedures / operating manual
High voltage, transfo, electrical cabinets

1.5.2 Static electricity
Damage of equipment
Directive CE/73/23 in LAB contract to sub-suppliers (calculation of cables ) Automatic grounding device definition of isolation class IP Electrical continuity for ducts Earthing of consumers and steel structure and pneumatic transport pipe ESP specific earthing for high voltage unit
Earthing system
1.5.3 Energy supply other than electricity
pneumatic system under pressure hydraulic system under pressure

1.5.4 Assembly errors
Personal injuries Personal injuries
discharge of air tank before intervention on equipment refer to supplier operating and maintenance manual refer to maintenance manual for handling beam assembly : end stop must be mounted at the extremity of the handling beam Insulation, personnel protection No possibility of entrance in the vessels without voluntary action. Heat insulation is only removable by unscrewing the cladding. Thermal swhitches in case of too high temperature on electrical heaters or heat tracing All materials are conformed to standards DIN No dead-end area in the plant Silos and fabric filter hoppers are equipped with nitrogen injection (nitrogen released on temperature alarm) Hot works permit for all works with hotspots close to flamable products + marking of the area Procedures / operating & maintenance manuals
handling of catalyst modules with handling beam : end stop not mounted on personal injuries / material damage handling beam
1.5.5 Extreme temperatures
Thermal equipment (ducts, piping, heat exchangers )
Damage of equipment / damage of downstream equipment / damage of steel structure / personal damage Damage on equipment Personal injuries Personal injuries Damage / Personal injuries Personal injuries
Material resistance
1.5.6 Fire
Design of the plant / lay-out Activated carbon storage, spent sorbent storage and fabric filter hoppers Erection / maintenance Checking of electrical tracing
2/3
10892EA00400-0
ORIGIN AND KIND OF RISKS

Showers, fire extinguishers in OMRIN scope
1.5.7 Explosion

Safety datasheet and lay out transmitted by LAB (for dangerous product identification and location)
Activated carbon
1.5.8 Noise
Damage / Personal injuries
Refer to ATEX study Max. 80 dB(A) at 1 m. for each single equipment Grinders (90dB(A)) in specific room Protective devices for some specific equipment (ID fan motors ) Process silencer downstream the ID fan OMRIN contractual requirements to all sub-suppliers LAB contractual requirement to all sub-suppliers to avoid any resonance mode Specific vibration controls for ID fan equipment complies with EMC (European Electro Magnetic compatibility)
All equipment Outside noise generated by the plant (stack)

1.5.9 Vibrations
Personal injuries
All equipment Fans

1.5.10 Radiation
Equipment damage + personal injuries Equipment damage interferences between equipment, equipment damage or malfunction
presence of electromagnetism, no ionizing sources, no X-ray

1.5.11 External radiation
Not applicable
1.5.12 Laser radiation
Not applicable
1.5.13 Emissions of hazardous materials and substances
All equipment
Equipment damage + personal injuries
Flue gas cleaning line is underpressure Watch tours (check for leaks) Concrete basin for ammonia solution Watch tours (check for leaks) Drains connected to gutters/pit - instruments drains plug when dangerous Special procedure for heavy maintenance by OMRIN (works permit) Handrails + safety ladders for steel structure - anti-slip gratings installation of adequate grating when opening manholes (ESP / fabric filter) or intervention on residue equipment : installation of chequered plates on the grating below the equipment Design with fixed access to all instruments/equipment (approved by OMRIN during lay-out meetings) Use of scaffoldings during long stops for internal inspection or external access
Reagent injection (activated carbon, bicarbonate), ammonia injection and residue conveying Drains
1.5.14 Risk of being trapped in a machine
Personal injuries Personal injuries Personal injuries and death
Heavy equipment
1.5.15 Risk of slipping, tripping or falling
Steel structure
Personal injuries
Instrument/equipment All heavy and big equipment

1.5.16 Lightning
Personal injuries Personal injuries
Not applicable (OMRIN scope) Lightning during erection 1.6 MAINTENANCE

1.6.1 Machinery maintenance (except equipment internal inspection)
Personal injuries and death
Earthing in operation at end of civil works Complete earthing system for equipment, steel structure and pipes of pneumatic transport Checking of weather conditions by site manager
Plant All equipment

1.6.2 Access to operating positions and servicing points
Equipment damage / breaking
Preventive maintenance list Greasing points are accessible, with extension if necessary Maintenance manual for each equipment and for the entire FGT Access to instruments/equipment Isolation of each equipment for maintenance from electrical room or local maintenance switch, with dedicated instructions for electrical locking Screen views in control room with relevant parameters Local indicator to be checked during watch tour Access to manual valves or dampers and to instruments Equipment are designed to avoid internal maintenance (slopes, flush weld) and when necessary rappers are installed Equipment internal is only accessible during plant stoppage Procedure for works in confined spaces
Design
1.6.3 Isolation of energy sources
Help for operators
All equipment
1.6.4 Operator intervention
Plant
1.6.5 Cleaning of internal parts
Plant
1.7 INFORMATION : the LAB flue gas treatment and its equipments are partly completed machinery within the meaning of the machinery directive CE/2006/42. As such, the marking is not required, the following have to be supplied : - the assembling instructions described in appendix VI, if required - the instruction manual in accordance with appendix I, 1,7,4 - the declaration of incorporation of partly completed machinery in accordance with appendix II, part 1 B
1.7.1 Information and warnings on the machinery
All equipment
Mistakes resulting in equipment damages and personal injuries
Specific instructions / warnings on sensitive equipment : - sound and light for ammonia - marking during handling and maintenance operation Labelling of each equipment Marking with colour code of pipes / channels Training of operators by LAB Position of local maintenance switches (emergency stops) by OMRIN Alarms & horns for ammonia Nitrogen injection in activated carbon CE marking Sub-suppliers plates Marking / labelling : - KKS tags - ATEX specific marking - High voltage specific marking - For the running beams, the checking is realized by approved certification body during acceptance tests for the related lifting devices Operating and maintenance instructions CE conformity certificate (integration) Risk analysis according to EU Machinery Directive 2006_42 LAB as-built documentation including drawings, PID, data sheets, test reports, structure and PED calculation notes, training manual, operating manual with watch tour lists, trouble shouting analysis, process parameters for control and alarms, maintenance documentation, spare parts list, safety data-sheets Risk analysis and HAZOP with OMRIN Integration of LAB's information in OMRIN documents
1.7.2 Warning of residual risks
Plant
1.7.3 Marking of machinery
All equipment
Flue gas cleaning

1.7.4 Instructions
Plant
3/3
10892EA00400-0
ch in ec te ki rv ng en tio vi si n t in m si ou de nt in eq g ui /d pm is en m an t Se O tli th e n al e g rs s do a o m cu na an m ly u 01 en sis fac "S tati in ture A on as r FE ( -b ri TY DO uil sk ce " a E ) t rt nd se ifi c ca A tio te 03 n s" "E A C su pp lie d by :
al so as ma -b in u te (D ilt d nan O oc ce E) u re me ma fe n nu re ta a nc tio l e n :
ESP
Checking visit of the ESP
10892SA11101
ELEX
10892NA11101-102-111-123-151ELEX 141
X X X
10892SA14001 LAB 10892NA14001 10892NA25110-111 10892NA25111 10892NA25411 LAB GEA ROSINK ROSINK BASF
LAB-LOOP
Mounting/Dismantling reagent injection lances LAB-LOOP cleaning
Fabric filter
Bag replacement
Gas Heat exchanger

Intervention or check inside heat exchanger
X
10892NA30201 10892NA30202
DeNOx reactor
Intervention inside the DeNOx reactor for cleaning or sampling Catalyst replacement
X X
10892NA31111-112-114-115-116 POLLRICH
IDfan
Checking visit of fans Mounting / dismantling of fan driving wheel and motor
X X
10892NA32101 AD INGENIERIE
Silencer
Mounting / Dismantling of the silencer
X X
10892NA35121 STEELCON
FG duct
Flue gas ducts checking
Stack
Stack checking
X
10892NA14400 10892NA31112-212 10892NA31315 10892NA31311-31210892NA40721 JEANNOT POLLRICH JEANNOT REITZ
Fans (preheating / sealing air / activated carbon injection) and battery

Removal / replacement of fan motor/wheel or battery Cheking visit of the fabric filter and DeNOx preheating and sealing system and of activated carbon injection systems
X X
10892NA23111 10892NA23112 ESSCANO
Dampers
Handling of a damper
X
10892NA17201 10892NA17202 10892NA40401 WAM
Reagents silo
Activated carbon or Bicarbonate Unloading Changing bag filter on silo Silo inspection
X X X
10892QA40114 PCVS PCVS
NH4OH installation
Checking visit of ammonia installation NH4OH Unloading NH4OH tank draining Tank inspection
X X X X
10892SA17201 MORILLON 10892NA17303-304-305-306 10892NA17201-17202-40401 MORILLON WAM
Residue silo
Residue loading Changing bag filter on silo Residue silo inspection
X X X
10892SA40520 SODIMATE 10892NA40520-521-522-523-524- SODIMATE 531-532-533 10892NA40401 WAM
Reagent dosing system

Checking visit of the reagent dosing system Remove / replace of the system motor-screw
X X
10892SA40811 GTS 10892NA40812-814-815-816 GTS
Grinders and injection fans

Watching visit of the grinders Cleaning of grinder chamber and injection fan Removal / replacement of fan or grinder motor/wheel/selector
X X X
10892NA26411-412 10892NA26512-513-514 KSB SALMSON
Water pumps (boosters / circulation)

Watching visit of different pumps Mounting/Dismantling of pumps with their motors
X X
10892NA26401-412 10892NA26211-212-213 KSB LEWA
NH4OH pumps
Checking visit of the unloading/injection pumps Removal/replacement of the ammonia motor/pump
X X X
10892QA27550-560 SNZ 10892NA25611 SNZ GEA
NH4OH injection
Checking visit of the ammonia injection
Hot piping
Mounting/Dismantling hot piping
X
10892SA17201 STAG ELEX 10892NA11121-122-123 10892NA17601-602-603-604-606- STAG STAG 607-619-620-631-632-633
Residue Mechanical transports

Checking visit of the mechanical transport equipment Mounting / dismantling of the mechanical transport equipment
X X
10892NA17601-602-605-609-673 STAG
Residue Pneumatic transport

Inspection of pneumatic transport equipment
X
10892NA29111-113-114-115-116- WIKA 10892NA29151 KHRONE 10892NA29130-131-132 ENDRESS HAUSER
Instrument
Checking visit of the instruments
X
10892NA28450-451-460 to 467 10892NA28470-480-490 10892NA26516 AVS SALMSON TRACE TEC STAG ELEX
Valve & components

Checking visit of the valves and accessories
X
10892NA24311-312 10892NA17612 10892NA11312
Electrical tracing & insulation

Checking visit of an equipment equipped with electrical tracing Removal of insulation for equipment inspection
X X
1/1
se e
in
su pp lie d
2- Specific parts
10892EA00400-0
by
TASK Nr
Checking visit of the ESP
MLS : during operation
Frequency : Daily
OPERATION N Identification
The ESP is used to separate the main part of dust from the flue gas The intervention consists in checking the good functioning of the ESP COMPONENT OF THE RISK dangerous event, hazardous Hazard situation possible damage Rotation of the fan axis ESP roof Contact with the rotating Working nearby the part. rotating part Injury Working nearby electrical circuit Contact with conductor under voltage. Electrical shock
PREVENTIVE MEASURE P S Initial On what component we have to act Means P S residual
Visual and audio check of the ESP during operation high voltage
Make sure that protections supplied by the manufacturer are Removal of the installed before intervention dangerous phenomenon Trapdoors closed. : obstacle / rotating parts Follow the instructions of the O&M manual (Lab & manufacturer) Removal of the Follow the instructions of the O&M manual (Lab & dangerous phenomenon manufacturer) Insulation of the system. Removal of the Follow the instructions of the O&M manual (Lab & dangerous phenomenon manufacturer) S= maximal severity of Means the possible damage 1 : Insignificant 2 : Limited 3 : Serious 4 : Fatal
Noise MLS : Machine life step Installation : During operation Maintenance Mounting/Dismantling
Working nearby the auditory risks noise source Frequency of the task
P= probability of occurrence A : Unlikely B : Uncommon C : Casual D : highly
Continuous Daily Weekly Monthly Annual Exceptional
Arrangement taken in order to solve or reduce to the maximum the problem caused by the risk
See also supplier risk analysis and maintenance manual in ELEX as built documentation references 10892SA11101 10892NA11101-102-111-123-151-141
Specific part : ESP - 1 / 1
10892EA00400-0
TASK Nr
Mounting/Dismantling reagent injection lances
MLS : mounting/dismantling
Frequency : Annual
The reagent injection lances are designed to inject reagents (activated carbon and bicarbonate) from pneumatic transport in the LAB-LOOP The intervention consists in disconnecting the piping with the lances COMPONENT OF THE RISK PREVENTIVE MEASURE P S hazardous dangerous event, On what component Means Hazard Initial situation possible damage we have to act Leak of reagent Hot temperature of the lances Working nearby the reagent injection Working nearby the reagent injection Contact with the reagent : corrosive effect Contact the hot lances C 3 Installation of means to avoid damages C 3 Wear PPE. Follow the instructions of the O&M manual (Lab & manufacturer)
rsidual A 1
Connection / disconnection of the hose
Handling the pipe with the lance
Suspended equipment
Presence under the load
Fall of the load : injury
Certified handling/lifting equipments. Removal of the Handling by authorized operators. dangerous phenomenon: Marking area and banning access under the load. Make sure nobody is Follow the instructions of the O&M manual (LAB & present under the load manufacturer) S= maximal severity of the possible damage 1 : Insignificant 2 : Limited 3 : Serious 4 : Fatal Means
MLS : Machine life step Installation : During operation Maintenance Mounting/Dismantling
Frequency of the task Continuous Daily Weekly Monthly Annual Exceptional
Specific part : LABLOOP - 1 / 2
10892EA00400-0
TASK Nr
LAB-LOOP cleaning
MLS : maintenance
Frequency : Annual
The LAB-LOOP is designed to ensure contact between flue gas and reagentsinjected The intervention consists in cleaning the LAB-LOOP by opening the manhole at the bottom OPERATION N Identification Hazard COMPONENT OF THE RISK hazardous situation Working nearby reagent deposits dangerous event, possible damage Contact with the reagent : corrosive effect P S Initial C 3 On what component we have to act PREVENTIVE MEASURE P Means S rsidual A 1
Contact with reagent 1 Visual inpection inside of the LAB-LOOP
Removal of the Wear PPE : goggles / gloves / boots / mask / safety helmet dangerous phenomenon Respect of procedures before intervention : Intervention of minimum two persons entiltled and wear PPE Removal of the dangerous phenomenon Check of IDfan stop, equipment correct venting and equipment inside temperature before manhole opening Removal of the Wear PPE : goggles / gloves / boots / mask / safety helmet dangerous phenomenon Respect of procedures before intervention : Intervention of minimum two persons entiltled and wear PPE Removal of the dangerous phenomenon Check of IDfan stop, equipment correct venting and equipment inside temperature before manhole opening Removal of the Respect of procedures (in particular for scaffolding) dangerous phenomenon wear PPE Removal of the Wear PPE : goggles / gloves / boots / mask / safety helmet dangerous phenomenon Respect of procedures before intervention : Intervention of minimum two persons entiltled and wear PPE Removal of the dangerous phenomenon Check of IDfan stop, equipment correct venting and equipment inside temperature before manhole opening S= maximal severity of Means the possible damage 1 : Insignificant 2 : Limited 3 : Serious 4 : Fatal
Hot temperature of the LAB-LOOP
Work in an equipment where Contact the hot gas are usually at equipment 200C Working nearby reagent deposits Contact with the reagent : corrosive effect
Contact with reagent 2 Cleaning of the bottom of the LAB-LOOP
Hot temperature of the LAB-LOOP Baffles are located overhead in the LABLOOP
Work in an equipment where Contact the hot gas are usually at equipment 200C Overhead job Working nearby reagent deposits People falling : injury / death of the people Contact with the reagent : corrosive effect
Cleaning of the baffles Contact with reagent plates in the LAB-LOOP Hot temperature of the LAB-LOOP MLS : Machine life step
Work in an equipment where Contact the hot gas are usually at equipment 200C
Installation : During operation Maintenance Mounting/Dismantling
Specific part : LABLOOP - 2 / 2
10892EA00400-0
TASK Nr
Bag replacement
MLS : maintenance
Frequency : Exceptional
The fabric filter is used to capture dusts contained in the flue gas and is the place of chemical reaction with reagents injected in the LAB-LOOP OPERATION N Identification This intervention consists in replacing one of the bags in one fabric filter cell Hazard See risk analysis for overhead crane utilisation Intervention on hopper MLS : maintenance Frequency : Annual COMPONENT OF THE RISK hazardous situation dangerous event, possible damage P S Initial On what component we have to act PREVENTIVE MEASURE Means P S residual
TASK Nr
The fabric filter is used to capture dusts contained in the flue gas and is the place of chemical reaction with reagents injected in the LAB-LOOP This intervention consists in opening the hopper manhole OPERATION N 1 Identification Manholes opening on hoppers MLS : Machine life step Installation : During operation Maintenance Mounting/Dismantling Hazard Residue spillage COMPONENT OF THE RISK hazardous dangerous event, situation possible damage Work below the platform at Contact with hot residue hopper level P S Initial C 3 On what component we have to act PREVENTIVE MEASURE Means P S residual A 1
Removal of the When opening the manhole on hopper, installation of dangerous phenomenon chequered plates on the grating below the manhole S= maximal severity of the possible damage 1 : Insignificant 2 : Limited 3 : Serious 4 : Fatal Means
See also supplier risk analysis and maintenance manual in LAB as built documentation references 10892SA14001 10892NA14001
Specific part : Fabric filter - 1 / 1
10892EA00400-0
TASK Nr
OPERATION N 1 Identification Removal of insulation
Intervention or check inside heat MLS : maintenance Frequency : Annual exchanger The gas/gas and steam/gas heat exchangers is used to heat flue gas before entering the catalyst The condensate water/gas heat exchanger is used to transfer heat recovered from flue gas PREVENTIVE MEASURE COMPONENT OF THE RISK hazardous dangerous event, On what component we P S Hazard Means Initial situation possible damage have to act Presence of Breathing of these Chemical risk Removal of the dangerous mineral fiber in mineral fibers in C 2 Wear PPE : goggles / gloves / boots / mask / safety helmet Breathing problems phenomenon suspension suspension Slide. Fall Injury C 3 Removal of the dangerous phenomenon Intervention by authorized operators. Wear PPE (goggles / gloves / boots / mask / safety helmet and body harness) Respect the specific procedures of work in confined area (ventilation, atmosphere control, temperature). Follow the instructions of the O&M manual (Lab & manufacturer). Check of IDfan stop, equipment correct venting and equipment inside temperature before opening manhole
P S residual A 1
Presence into the Heat exchanger
contact with dusts Work in an Hot equipment due equipment where to gas circulating gas are usually at inside 200C Doors and access handling Access inside the exchanger hoppers Opening of the internal manhole intervention in a dead-end area
breathing problems
Removal of the dangerous phenomenon
Intervention in the exchanger
Contact with hot equipment and hot gas Uncorrect handling Operator falling Manhole closing, person enclosed isnide the heat exchanger
Removal of the dangerous phenomenon Removal of the dangerous phenomenon
Doors with hinges easily handling fastener hook for harness Intervention by authorized operators. Respect the specific procedures of work in confined area (ventilation, atmosphere control, temperature). Follow the instructions of the O&M manual (Lab & manufacturer).
S= maximal severity of the Means possible damage 1 : Insignificant 2 : Limited 3 : Serious 4 : Fatal
See also supplier risk analysis and maintenance manual in GEA ROSINK ROSINK as built documentation references 10892NA25110-111 10892NA25111 10892NA25411
Specific part : Gas heat Exchanger - 1 / 1
10892EA00400-0
TASK Nr
Intervention in the reactor
Intervention inside the SCR reactor MLS : maintenance Frequency : annual for cleaning or sampling The SCR reactor is composed of modules of catalysts to treat chemical pollutants The intervention consists in cleaning the top of the modules or taking the catalyst samples COMPONENT OF THE RISK PREVENTIVE MEASURE hazardous dangerous event, On what component P S Means Hazard Initial situation possible damage we have to act Temperature control. Specific tools needed to open the manholes. Wear PPE. Work in a Isolation of NH4OH pumps. Hot equipment because equipment Intervention by two authorized operators. Contact with hot Removal of the C 3 where 250C of hot gases passing equipments : burning. dangerous phenomenon Stop the ID fan during intervention. gases have through the reactor Stop the steam circulation in the steam/gas heat exchanger circulated Respect the specific procedures of work in confined area (ventilation, atmosphere control). Follow the instructions of the O&M manual (Lab & manufacturer). Chemical products and work nearby the catalyst dust on catalyst modules modules Doors and Access to the top of the access hopper handling Contact with chemical product and dusts : chemical injury, breathing problem Uncorrect handling. Operator falling C 2 Removal of the Wear PPE (goggles / gloves / boots / dust mask / safety helmet) dangerous phenomenon Follow the instructions of the O&M manual (Lab & manufacturer). Doors easy to handle. Harness hook. Removal of the dangerous phenomenon Specific tools needed to open the manholes. Follow the instructions of the O&M manual (Lab & manufacturer). S= maximal severity of Means the possible damage 1 : Insignificant 2 : Limited 3 : Serious 4 : Fatal
P S residual
Specific part : SCR reactor - 1 / 2
10892EA00400-0
TASK Nr
OPERATION N Identification Mounting and dismantling of SCR reactor doors / catalyst modules
Catalyst replacement MLS : maintenance Frequency : exceptional The SCR reactor is composed of modules of catalysts to treat chemical pollutants This intervention consists in replacing the catalysts modules COMPONENT OF THE RISK PREVENTIVE MEASURE hazardous dangerous event, On what component P S Hazard Means Initial situation possible damage we have to act Certified handling/lifting equipments. Removal of the Intervention by authorized operators. dangerous part : Presence Falling down of the load Area marking and banning access under the load Suspended load B 4 Make sure nobody is under the load Crushing of operator Follow the instructions of O&M manual (Lab & manufacturer). present under the load Wear PPE Hot equipements because of circulating flue gas Presence in the reactor Working in a Contact with hot duct where hot equipments and hot gases are gases circulating presence of dusts Sliding, falling : Injury P= probability of occurrence A : Unlikely B : Uncommon C : Casual D : highly Respect of the specific procedures of work in confined area (ventilation, atmosphere control). Removal of the Verification of the equipment correct ventilation and of the dangerous phenomenon temperature in the equipment before opening the manhole. Follow the instructions of the O&M manual (Lab & manufacturer) S= maximal severity of the possible damage 1 : Insignificant 2 : Limited 3 : Serious 4 : Fatal Means
P S residual
Intervention in the SCR reactor to replace the catalyst
See also supplier risk analysis in BASF as built documentation reference 10892NA30201 10892NA30202
Specific part : SCR reactor - 2 / 2
10892EA00400-0
TASK Nr
Checking visit of fans
Frequency : Daily
The ID fan is used to drive the flue gas from the silencer to the stack. The preheating fan is used to preheat the SCR reactor. The intervention consists in checking the good functioning of the fans COMPONENT OF THE RISK hazardous dangerous event, Hazard situation possible damage Contact with the rotating Working nearby the part. rotating part Injury Contact with conductor under voltage. Electrical shock
PREVENTIVE MEASURE P S Initial On what component we have to act Means P S residual
Rotation of the fan axis Check of the fan during operation : visual checking, audio Working nearby checking and vibration Conductor under voltage electrical circuit measurements Noise, heat
Make sure that protector supplied by the manufacturer are installed before Removal of the intervention dangerous phenomenon Trapdoors closed. : obstacle / rotating parts Follow the instructions of the O&M manual (Lab & manufacturer) Removal of the No bare conductor under voltage dangerous phenomenon Follow the instructions of the O&M manual (Lab & manufacturer) Insulation of the system. Removal of the Wear of PPE (ear plugs or other hearing protection) dangerous phenomenon Follow the instructions of the O&M manual (Lab & manufacturer) 1 : Insignificant 2 : Limited 3 : Serious 4 : Fatal
Working nearby the auditory and burning noise source risks A : Unlikely B : Uncommon C : Casual D : highly
Continuous Daily Weekly Monthly Annual Exceptional
Specific part : IDfan - 1 / 2
10892EA00400-0
TASK Nr
Mounting / dismantling of fan driving wheel MLS : maintenance and motor The ID fan is used to drive the flue gas from the silencer to the stack. The preheating fan is used to preheat the SCR reactor. The intervention consists in removing then replacing the fans
OPERATION N Identification Hazard
COMPONENT OF THE RISK hazardous situation dangerous event, possible damage P S Initial On what component we have to act
PREVENTIVE MEASURE P Means S residual
Rotation of the fan axis 1 Connection / disconnection of the fan motor Rotation of the fan axis by natural draught
Contact with the rotating Working nearby the part. rotating part Injury
Disconnecting switch with padlock in general low voltage panels or local Removal of the panel dangerous part : Manufacturer protection. electrical isolation of the Coupling replacement ensured by authorized operators. motor Follow the instructions of the O&M manual (Lab & manufacturer) This operation can only be done at complete stop of the wheel and with Removal of the security signalling of the danger dangerous phenomenon If the Idfan motor running feedback is not obtained, the upstream dampers can be manually closed to avoid rotation of the wheel by natural draught Removal of the dangerous part : Make sure nobody is present under the load Certified handling/lifting equipments. Intervention by authorized operators. Area marking and banning access under the load. Follow the instructions of O&M manual (Lab & manufacturer). Wear PPE
The operators are handling parts of fan (cleaning, lubricating, driving wheel replacement)
Part of the fan suspended
Presence under the Fall of the load. load Crushing of operator
Rotation of the fan axis by natural draught
This operation can only be done at complete stop of the wheel and with Removal the dangerous security signalling of the danger phenomenon If the Idfan motor running feedback is not obtained, the upstream dampers can be manually closed to avoid rotation of the wheel by natural draught S= maximal severity of the possible damage 1 : Insignificant 2 : Limited 3 : Serious 4 : Fatal Means
MLS : Machine life step Installation : During operation Maintenance Mounting/Dismantling Continuous Daily Weekly Monthly Annual Exceptional
Frequency of the task
See also supplier risk analysis and maintenance manual in POLLRICH as built documentation references 10892NA31111-112-114-115-116
Specific part : IDfan - 2 / 2
10892EA00400-0
TASK Nr
Mounting / Dismantling of the silencer
MLS : maintenance
The intervention consists in removing and then replacing the silencer (no possibility to remove the baffles without removing the whole silencer) OPERATION N Identification The operators are handling the silencer : baffles cleaning or replacement requires to lift down to the ground the complete silencer MLS : Machine life step Installation : During operation Maintenance Mounting/Dismantling Hazard COMPONENT OF THE RISK hazardous situation dangerous event, possible damage P S Initial On what component we have to act PREVENTIVE MEASURE P Means Certified Handling/lifting equipments. Intervention by authorized operators. Area marking and banning access under the load Follow the instructions of the O&M manual (Lab & manufacturer). Wear PPE and body harness. Means S residual
Silencer suspended
Presence Fall of the load. under the load Crushing of operator
Removal of the dangerous part : Make sure nobody is present under the load S= maximal severity of the possible damage 1 : Insignificant 2 : Limited 3 : Serious 4 : Fatal
P= probability of occurrence
A : Unlikely B : Uncommon C : Casual D : highly
See also supplier risk analysis and maintenance manual in AD INGENIERIE as built documentation references 10892NA32101
Specific part : Silencer - 1 / 1
10892EA00400-0
TASK Nr
Flue gas ducts checking
MLS : maintenance
Frequency : Annual
Flue gas ducts are used in the whole installation to transport flue gas from an equipment to another COMPONENT OF THE RISK P S hazardous dangerous event, On what component Hazard Initial situation possible damage we have to act
Visual verification of the Presence in the duct ducts good conditions
Slide. Fall. Injury. Presence of Chemical risks untreated flue (Breathing problems). gas
Intervention by two authorized operators. Venting flue gas with air before any intervention. Flue gas treatment stopped and cooled (ID fan stopped). Adequate scaffolding. Prohibition on being in the duct during the handling of Removal of the dampers. dangerous phenomenon Dampers mechanically blocked Wear PPE and body harness, check of temperature Respect the specific procedures of work in confined area (ventilation, atmosphere control). Follow the instructions of the O&M manual (Lab & manufacturer) S= maximal severity of the possible damage 1 : Insignificant 2 : Limited 3 : Serious 4 : Fatal Means
Specific part : FG duct - 1 / 1
10892EA00400-0
TASK Nr
Stack checking
MLS : maintenance
The outside stack evacuate the clean flue gas COMPONENT OF THE RISK Hazard hazardous situation dangerous event, possible damage P S Initial On what component we have to act
Visual verification of the Presence in the duct ducts good conditions
Slide. Fall. Injury. Presence of Chemical risks untreated flue (Breathing problems). gas
Intervention by two authorized operators. Venting flue gas with air before any intervention. Flue gas treatment stopped and cooled (ID fan stopped). Removal of the Adequate scaffolding. dangerous phenomenon Prohibition on being in the duct during the handling of dampers. Wear PPE and body h S= maximal severity of the possible damage 1 : Insignificant 2 : Limited 3 : Serious 4 : Fatal Means
See also supplier risk analysis and maintenance manual in STEELCON as built documentation references 10892NA35121
Specific part : stack - 1 / 1
10892EA00400-0
TASK Nr
Removal / replacement of fan motor/wheel or battery
MLS : maintenance
Electrical connection / disconnection of fan motor or battery
Fabric filter preheating is ensured by preheating battery and fan DeNOx and fabric filter sealing air injection are ensured by sealing air batteries and fans Activated carbon transport is ensured by air transport fan This intervention consists in removing and replacing part of fan or battery COMPONENT OF THE RISK PREVENTIVE MEASURE hazardous dangerous event, On what component P S Means Hazard Initial situation possible damage we have to act Removal of the Work nearby dangerous phenomenon: Disconnecting switch with padlock in general low voltage Contact with rotating part B 3 Rotation of the fan shaft rotating electrical motor locked panels or local panel of the fan - Injury equipment out Work on the fan Contact with conductor Conductor under electric under voltage - electrical or battery potential shock electrical part Removal of the dangerous phenomenon: Disconnecting switch with padlock in general low voltage electrical motor and panels or local panel battery locked out Adequate lifting device Removal of the (Overhead crane foreseen for equipment handling) dangerous phenomenon C 4 Make sure nobody is present under the load S= maximal severity of the possible damage 1 : Insignificant 2 : Limited 3 : Serious 4 : Fatal Handling by trained people Area marking and forbidden access under the load Means
P S residual A 1
One or more operators lift and handle part of the fan or battery
Part of fan or battery overhanging
Presence under Falling down of the load the load Crushing of operator
Specific part : fans & battery - 1 / 2
10892EA00400-0
TASK Nr
Cheking visit of the fabric filter and DeNOx preheating and sealing system and of activated carbon injection systems
Frequency : Daily
Fabric filter preheating is ensured by preheating battery and fans DeNOx and fabric filter sealing air injection are ensured by sealing air batteries and fans Activated carbon transport is ensured by air transport fan This intervention consists in checking the correct functioning of the fans OPERATION N Identification Hazard COMPONENT OF THE RISK dangerous event, hazardous possible damage situation Work nearby rotating equipment PREVENTIVE MEASURE P S Initial 3 On what component we have to act Means P S residual A 1
Rotation of the fan shaft 1 Visual and audio check of the functioning
Contact with rotating part B of the fan - Injury
Make sure that protector supplied by the manufacturer are Removal of the installed before intervention dangerous phenomenon: obstacle / rotating parts Trap doors closed Removal of the No barre conductor under voltage dangerous phenomenon S= maximal severity of the possible damage 1 : Insignificant 2 : Limited 3 : Serious 4 : Fatal Means
Contact with conductor Conductor under electric Work nearby under voltage - electrical potential electric cirucit shock Frequency of the task Continuous Daily Weekly Monthly Annual Exceptional
See also supplier risk analysis and maintenance manual in JEANNOT POLLRICH JEANNOT REITZ as built documentation references 10892NA14400 10892NA31112-212 10892NA31315 10892NA31311-312-10892NA40721
Specific part : fans & battery - 2 / 2
10892EA00400-0
TASK Nr
Handling of a damper MLS : maintenance Dampers, by isolation of ducts, allow partial FGT bypass this intervention consists in removing/replacing one damper OPERATION COMPONENT OF THE RISK hazardous dangerous event, situation possible damage Fall of the operator. Injury. Presence of chemical substance P S Initial
PREVENTIVE MEASURE On what component we have to act Means P S residual
Identification
Hazard
Visual verification of the Uncontrolled movement Checking of the damper during operation of the damper damper position
Handling of the damper
Hot equipements because of circulating Hot equipment flue gas
Contact with hot equipments and hot gases
Part of the damper suspended
Presence under the Falling down of the load load Crushing of operator
Proximity with the air Quick release of air hose whiping : tanks : pressurized tank from tank or hose operator injury
prohibition on being in the duct during the handling of the damper. Intervention by two authorized operators. Wear PPE. Removal of the Follow the instructions of the O&M manual (Lab & manufacturer) dangerous phenomenon Presence of limit switch (open/closed). Damper machanically locked Follow the instructions of the O&M manual (Lab & manufacturer) Stop of the IDFan Removal of the Wear PPE dangerous phenomenon Wait for complete cooling (transmitted temperature measurement) Follow the instructions of the O&M manual (Lab & manufacturer) Removal of the Certified handling/lifting equipments. dangerous Handling by authorized operators. phenomenon: Marking area and banning access under the load Make sure nobody is Follow the instructions of the O&M manual (Lab & manufacturer) present under the load CE certificate by the supplier. Pressure Equipment Directive (PED) standardized. Removal the dangerous Wear PPE. phenomenon Air tank discharge before maintenance Follow the instructions of the O&M manual (Lab & manufacturer) S= maximal severity of Means the possible damage 1 : Insignificant 2 : Limited 3 : Serious 4 : Fatal
See also supplier risk analysis and maintenance manual in ESSCANO as built documentation references 10892NA23111 10892NA23112
Specific part : Dampers - 1 / 1
10892EA00400-0
TASK Nr
OPERATION
Identification
Activated carbon or Bicarbonate MLS : during operation Frequency : Weekly Unloading Activated carbon and sodium bicarbonate are stored in a silo This intervention consist in unloading reagent from the delivery truck to the silo COMPONENT OF THE RISK P S On what hazardous dangerous event, Hazard component we Initial situation possible damage have to act Explosion of the silo. Explosion of the truck. Injury of operators
PREVENTIVE MEASURE P Means S
residual
Unloading operation by the truck
Auto inflammation Working nearby and explosion of the activated activated carbon carbon silo
Silo overflowing
Working nearby the activated carbon silo
Excessive pressure in the silo
Avoid the sparks caused by static electricity loads. Earthing of the truck. Respect the product used (Activated carbon) and ban all other products. Keep the installation clean. Automatic silo inerting when hot temperatures are detected. Follow the instructions of the O&M manual (Lab & manufacturer) Redundancy of security equipements for high level. Presence of safety valves (pressure/depression) on the roof. Indication on the local panel of high level reached + shut off valve An alarm is set off when silo high level is reached. Follow the instructions of the O&M manual (Lab & manufacturer)
Operations on the Static electricity reagent silos generated
Working on one reagent silo
Electrical shock
Earthing of the metallic silos and pipes
S= maximal Means severity of the possible damage 1 : Insignificant 2 : Limited 3 : Serious 4 : Fatal Arrangement taken in order to solve or reduce to the maximum the problem caused by the risk
Specific part : reagent silo - 1 / 2
10892EA00400-0
TASK Nr
Changing bag filter on silo
MLS : Mounting /dismantling
Frequency : Annual
OPERATION
Identification
Activated carbon and sodium bicarbonate are stored in a silo and silos are equipped with filter to allow air evacuation without dust emission This intervention consists in changing the filter COMPONENT OF THE RISK PREVENTIVE MEASURE P S On what hazardous dangerous event, Hazard component we Means Initial situation possible damage have to act Presence of a handrail around the top of the silo. Certified handling/lifting equipments. Handling by authorized operators. Marking area and banning access under the load. Follow the instructions of the O&M manual (Lab & manufacturer)
residual
Replacement of the silos bag filter
Parts of the filter removed by the operators
Presence nearby Fall of object the bottom of the Injury silo MLS : maintenance
TASK Nr
Silo inspection
Frequency : Exceptionnal
Activated carbon and sodium bicarbonate are stored in a silo This intervention consist in internal inspection of the silo COMPONENT OF THE RISK Hazard hazardous situation dangerous event, possible damage P S Initial On what component we have to act
PREVENTIVE MEASURE P Means Intervention by two authorized operators. Complete emptying of the silo before any intervention Venting with air before any intervention. Adequate scaffolding. Nitrogen injection in Activated carbon silo mechanically locked Wear PPE and body harness, check of temperature Respect the specific procedures of work in confined area (ventilation, atmosphere control). Follow the instructions of the O&M manual (Lab & manufacturer) S residual
Internal inspection Presence in the of the silos silo
Slide. Fall. Presence of gas
Injury. (Breathing problems).
S= maximal Means severity of the possible damage 1 : Insignificant 2 : Limited 3 : Serious 4 : Fatal
See also supplier risk analysis and maintenance manual in WAM as built documentation references 10892NA17201 10892NA17202 10892NA40401
Specific part : reagent silo - 2 / 2
10892EA00400-0
TASK Nr
OPERATION
Checking visit of ammonia MLS : during operation installation Ammonia solution 24,5% is stored in a tank Ammonia is injection in the DeNOX reactor COMPONENT OF THE RISK P Hazard hazardous situation dangerous event, possible damage
Frequency : Daily
PREVENTIVE MEASURE S On what component we have to act Means P S
Identification
Initial
residual
Spatter of ammonia Visual checking of Risk of ammonia Working nearby chemical injury the installation leakage on the line the ammonia line Operator breathing problem NH4OH Unloading
Welded inox pipes, flanges only on pump and injection connection with detection and alarm, the pipe routing is agreed with OMRIN. Ammonia resistant gaskets Wear of PPE
TASK Nr
Frequency : Weekly
OPERATION
Ammonia solution 24,5% is stored in a tank Ammonia is unloaded from a truck. COMPONENT OF THE RISK P S On what component we have to act hazardous situation dangerous event, possible damage
PREVENTIVE MEASURE P Means Leakage detection with horn Automatic spraying Drips collection in a retention safety shower and eye rinsing nearby the unloading area indication on connecting pipe Wear of PPE Redundancy of security equipements for high level Indication on the local panel of high level reached and sequence stopped Leakage detection with horn Automatic spraying Drips collection in a retention safety shower and eye rinsing nearby the unloading area Wear of PPE Follow the instructions of the O&M manual S
Identification
Hazard
Initial
residual
Risk of ammonia spillage or hose connection uncorrect or broken 1 Unloading operation by the truck Tank overflowing
Spatter of ammonia Working nearby chemical injury the ammonia tank Operator breathing problem
S= maximal severity of Means the possible damage 1 : Insignificant 2 : Limited 3 : Serious 4 : Fatal
Specific part : NH4OH installation - 1 / 3
10892EA00400-0
TASK Nr
NH4OH tank draining
Frequency : exceptional
OPERATION
Ammonia solution 24,5% is stored in a tank and is unloaded by a truck. Ammonia can be discharged from the tank to a truck COMPONENT OF THE RISK P Hazard hazardous situation dangerous event, possible damage
PREVENTIVE MEASURE S On what component we have to act Means Leakage detection with horn Automatic spraying Drips collection in a retention safety shower and eye rinsing nearby the unloading area Wear of PPE P S
Identification
Initial
residual
Tank draining to a risk of ammonia truck spillage
TASK Nr
OPERATION
retention emptying under NH4OH MLS : during operation tank Any ammonia leakage is collected in a pit This intervention consists in operating in this pit COMPONENT OF THE RISK P Hazard hazardous situation dangerous event, possible damage Slipping in the retention Spatter of ammonia chemical injury Operator breathing problem P= probability of occurrence A : Unlikely B : Uncommon C : Casual D : highly
PREVENTIVE MEASURE S On what component we have to act Means Leakage detection with horn safety shower and eye rinsing in the retention and outside of the retention Wear of PPE Follow the instructions of the O&M manual P S
Identification
Initial
residual
Retention drainage
Presence of ammonia
working nearby ammonia
10892EA00400-0
TASK Nr
Tank inspection
MLS : maintenance
Frequency : Exceptionnal
Ammonia solution 24,5% is stored in a tank This intervention consist in internal inspection of the tank COMPONENT OF THE RISK Hazard hazardous situation dangerous event, possible damage P S Initial On what component we have to act
PREVENTIVE MEASURE P Means Intervention by two authorized operators. Draining of the tank before any intervention Venting with air before any intervention. Adequate scaffolding. Wear PPE and body harness, check of temperature Respect the specific procedures of work in confined area (ventilation, atmosphere control). Follow the instructions of the O&M manual (Lab & manufacturer) S residual
Internal inspection Presence in the of the tank tank
Slide. Fall. Presence of ammonia
Chemical injury, operator breathing problems.
10892EA00400-0
TASK Nr
Residue loading
Frequency : Daily
OPERATION
Residue are stored in a silo (one for ashes and one for spent sorbent) This intervention consists in loading residue in a truck COMPONENT OF THE RISK P Hazard hazardous situation Working nearby the residue silo dangerous event, possible damage
PREVENTIVE MEASURE S On what component we have to act Removal of the dangerous phenomenon Means P S
Identification
Initial
residual
Loading operation in Truck overflowing the truck
Truck overflowing
Indication on the local panel of high level reached and valve shut off An alarm is set off when truck high level is reached.
TASK Nr
Changing bag filter on silo
MLS : Mounting /dismantling
Frequency : Annual
OPERATION
Identification
Residue are stored in a silo (one for ashes and one for spent sorbent) and are equipped with filter to allow air evacuation without dust emission This intervention consists in changing the filter COMPONENT OF THE RISK PREVENTIVE MEASURE P S On what hazardous dangerous event, component we Means Hazard Initial situation possible damage have to act Presence of a handrail around the top of the silo. Certified handling/lifting equipments. Handling by authorized operators. Marking area and banning access under the load. Follow the instructions of the O&M manual (Lab & manufacturer) Means
residual
Parts of the filter Replacement of the removed by the silos bag filter operators
Presence nearby Fall of object. the bottom of the Injury silo
Removal of the dangerous phenomenon S= maximal severity of the possible damage 1 : Insignificant 2 : Limited 3 : Serious 4 : Fatal
Specific part : residue silo - 1 / 2
10892EA00400-0
TASK Nr
Residue silo inspection
MLS : maintenance
Frequency : Annual
Residue are stored in a silo (one for ashes and one for spent sorbent) This intervention consists in internal inspection of the silos that could be necessary for maintenance of the extraction system OPERATION COMPONENT OF THE RISK PREVENTIVE MEASURE On what P S P S hazardous dangerous event, N Identification Hazard component we Means Initial residual situation possible damage have to act Intervention by two authorized operators. Emptying of the silo before any intervention Preliminary check from the roof manhole that the silo is empty Venting with air before any intervention. Injury. Nitrogen injection in spent sorbent silo mechanically locked Slide. Chemical risks Internal inspection Pneumatic transport stopped Presence in the silo, Fall. (Breathing Removal of the of the silos Adequate scaffolding. 1 contact with the Presence of problems). C 3 dangerous A 2 maintenance Prohibition on being in the silo during the operation of the extraction residues residues Work in equipment phenomenon operation in the silo system where residue are Extraction system mechanically locked usually at 80C Wear PPE and body harness, check of temperature Respect the specific procedures of work in confined area (ventilation, atmosphere control). Follow the instructions of the O&M manual (Lab & manufacturer) S= maximal MLS : Machine life step Frequency of the task P= probability of occurrence Means severity of the possible damage Installation : Continuous 1 : Insignificant During operation A : Unlikely Daily 2 : Limited Maintenance B : Uncommon Weekly Arrangement taken in order to solve or reduce to the maximum the problem caused by 3 : Serious Mounting/Dismantling C : Casual Monthly the risk 4 : Fatal D : highly Annual Exceptional See also supplier risk analysis and maintenance manual in MORILLON WAM as built documentation references 10892SA17201 10892NA17303-304-305-306 10892NA17201-17202-40401
Specific part : residue silo - 2 / 2
10892EA00400-0
TASK Nr
Checking visit of the reagent dosing system
Frequency : Daily
OPERATION
The reagent dosing system transports activated carbon and bicar in each injection line the intervention consists in checking nearby the dosing system its good functioning COMPONENT OF THE RISK P S Hazard hazardous situation Work nearby rotating part of the dosing system work nearby electric circuit dangerous event, possible damage Contact with rotating part of the dosing system - Injury Contact with conductor under voltage - electric shock Initial On what component we have to act
Identification
residual
Visual and hearing check of the screw functioning
Rotating part of the dosing system Conductor under voltage
Make sure that protector supplied by the Removal of the dangerous phenomenon manufacturer are installed before : obstacle / rotating parts intervention Removal of the No bare conductor under voltage dangerous phenomenon S= maximal severity of the possible damage 1 : Insignificant 2 : Limited 3 : Serious 4 : Fatal Means
Specific part : Reagent dosing system - 1 / 2
10892EA00400-0
TASK Nr
Remove / replace of the system motor-screw
MLS : maintenance
OPERATION
The reagent dosing system transports activated carbon and bicar in each injection line the intervention consists in removing and then replacing an equipment motor COMPONENT OF THE RISK P S Hazard hazardous situation dangerous event, possible damage Initial On what component we have to act Removal of the dangerous phenomenon: electrical motor locked out Removal of the dangerous phenomenon: electrical motor locked out Installation of means to avoid damages reagent projection A 2
Identification
residual
Electrical connection / disconnection of screw motor
Rotation of the equipment axis
Contact with rotating Work nearby rotating part of part of the equipment the screw Injury work nearby electric circuit Contact with conductor under voltage - electric shock
Disconnecting switch with padlock in general low voltage panels or local panel Disconnecting switch with padlock in general low voltage panels or local panel Wear PPE : goggles / gloves / boots / mask
Conductor under voltage
operator(s) work under silo
Reagent leakage from the silo cone
Work nearby activated carbon circuit
Removal of the Close manual isolating gate valve under dangerous phenomenon silo and evacuate downstream circuit P= probability of occurrence S= maximal severity of the possible damage 1 : Insignificant 2 : Limited 3 : Serious 4 : Fatal Means
See also supplier risk analysis and maintenance manual in SODIMATE
WAM as built documentation references 10892SA40520 10892NA40520-521-522-523-524-531-532-533 10892NA40401
Specific part : Reagent dosing system - 2 / 2
10892EA00400-0
TASK Nr
Watching visit of the grinders
Frequency : Daily
The bicarbonate grinders mill the bicarbonate and the fan transports it in each injection line The intervention consists in checking the good functioning of the grinder and the fan OPERATION N Identification Hazard Rotation of the grinder and fan COMPONENT OF THE RISK hazardous dangerous event, situation possible damage Work nearby rotating equipment Contact with rotating part of the fan - Injury PREVENTIVE MEASURE P S Initial B 3 On what component we have to act Means P S residual A 1
Make sure that protections supplied by the manufacturer Removal of the are installed before intervention dangerous phenomenon: Follow the instructions of O&M manual (Lab & obstacle / rotating parts manufacturer). Removal of the No bare conductor under voltage dangerous phenomenon Installation of means to avoid damages Wear PPE Follow the instructions of the O&M manual (Lab & manufacturer)
Contact with conductor Visual and hearing check Conductor under electric Work nearby under voltage - electrical of the functioning potential electric cirucit shock Noise, heat Working nearby the noise source auditory and burning risks
TASK Nr
Cleaning of grinder chamber and injection fan
MLS : maintenance
Frequency : Monthly
The bicarbonate grinders mill the bicarbonate and the fan transports it in each injection line The intervention consists in cleaning the grinder and the injection fan COMPONENT OF THE RISK dangerous event, hazardous P S On what component we Hazard Initial possible damage have to act situation
PREVENTIVE MEASURE Means Protection by safety locking device, the key is released when the grinder motor is stopped, the drive cannot be switched on as long as the mill housing is not completely closed. Disconnecting switch with padlock in general low voltage panels or local panel Follow the instructions of O&M manual (Lab & manufacturer). Means P S residual
The operators are cleaning inside the grinder chamber and inside the fan housing
Rotation of the wheels
Working nearby the wheel
Contact with the rotating wheel
Removal the dangerous phenomenon
S= maximal severity of the possible damage 1 : Insignificant 2 : Limited 3 : Serious 4 : Fatal
Specific part : Grinders and injection fans - 1 / 2
10892EA00400-0
TASK Nr
Removal / replacement of fan or grinder motor/wheel/selector
MLS : maintenance
The bicarbonate grinders mill the bicarbonate and the fan transports it in each injection line This intervention consists in removing and replacing part of fan or grinder OPERATION N Identification Hazard COMPONENT OF THE RISK hazardous dangerous event, situation possible damage Work nearby rotating equipment PREVENTIVE MEASURE P S Initial On what component we have to act Removal of the dangerous phenomenon: electrical motor locked out Means Protection by safety locking device, the key is released when the grinder motor is stopped, the drive cannot be switched on as long as the mill housing is not completely closed Disconnecting switch with padlock in general low voltage panels or local panel P S residual
Rotation of the fan or grinder shaft 1 Electrical connection / disconnection of fan or grinder motor
Contact with rotating part of the fan - Injury
Work on the Conductor under electric fan or battery potential electrical part
Contact with conductor under voltage - electrical shock
Removal of the dangerous phenomenon: Disconnecting switch with padlock in general low voltage electrical motor and panels or local panel battery locked out Removal of the Adequate lifting device dangerous phenomenon Handling by trained people Make sure nobody is present under the load Area marking and forbidden access under the load S= maximal severity of Means the possible damage 1 : Insignificant 2 : Limited 3 : Serious 4 : Fatal
One or more operators lift and handle part of the fan or grinder
Part of fan or grinder overhanging
Presence Falling down of the load under the load Crushing of operator
See also supplier risk analysis and maintenance manual in GTS as built documentation references 10892SA40811 10892NA40812-814-815-816
Specific part : Grinders and injection fans - 2 / 2
10892EA00400-0
TASK Nr
Watching visit of different pumps
Frequency : daily
Circulation pumps ensure condensate water circulation in the heat recovery primary loop Booster pumps ensure condensate water pressure in the heat recovery primary loop The intervention consists in checking the good functioning of the pumps COMPONENT OF THE RISK hazardous dangerous event, On what component P S Hazard Initial situation possible damage we have to act Working Contact with the moving Removal of the nearby the Rotation of the pump axis part of the pump. B 3 dangerous phenomenon: moving part of Injury obstacle / rotating parts the pump Working Contact with a conductor Conductor under voltage nearby under voltage electrical circuit Electrical shock Working nearby the process fluid circuit spatter of process fluid B 4
PREVENTIVE MEASURE Means P S rsidual 1
Visual and audio checking of the pump during operation
Process fluid leakage
Frequency of the task Continuous Daily Weekly Monthly Annual
Follow the instructions of the O&M manual (Lab & manufacturer). A Protectors provided by the manufacturer. CE certificate provided by the manufacturer Disconnecting switch with padlock in general low Removal of the voltage panels or local panel. A dangerous phenomenon Follow the instructions of the O&M manual (Lab & manufacturer) Wearing of the PPE. Removal of the Follow the instructions of the O&M manual (Lab B dangerous phenomenon & manufacturer) Material of gasket compatible with ammonia S= maximal severity of Means the possible damage 1 : Insignificant 2 : Limited Arrangement taken in order to solve or reduce to the 3 : Serious maximum the problem caused by the risk 4 : Fatal
Specific part : Water pumps - 1 / 2
10892EA00400-0
TASK Nr
OPERATION N Identification Connection / disconnection of the motor
Connection / disconnection of the pump
Mounting/Dismantling of pumps with MLS : maintenance Frequency : Exceptional their motors Circulation pumps ensure condensate water circulation in the heat recovery primary loop Booster pumps ensure condensate water pressure in the heat recovery primary loop This intervention consists in removing then replacing the motor or the pump COMPONENT OF THE RISK PREVENTIVE MEASURE hazardous dangerous event, On what component P S Means Hazard Initial situation possible damage we have to act Disconnecting switch with padlock in general low Removal of the voltage panels or local panel Working Contact with the moving dangerous phenomenon: Manufacturer protection Rotation of the motor axis nearby the part of the motor. B 3 electrical motor locked Follow the instructions of the O&M manual (Lab Injury moving part out & manufacturer) Removal of the Disconnecting switch with padlock in general low Working Contact with a conductor dangerous phenomenon: voltage panels or local panel Conductor under voltage nearby the under voltage. B 4 electrical motor locked Follow the instructions of the O&M manual (Lab electrical part Electric shock out & manufacturer) Wear PPE. Installation of means to Follow the instructions of the O&M manual (Lab avoid damages & manufacturer) Working Contact with the hot Leak of process fluid nearby the Removal of the condensate water C 3 Before dismantling, bleeding and drainage of the (fluid under pressure) process fluid dangerous phenomenon: Injury hot water circuit circuit pump draining before Follow the instructions of the O&M manual (Lab disconnection, wait for & manufacturer) circulation pump cooling Certified handling/lifting equipments. Handling by authorized operators. Marking area and banning access under the load. Follow the instructions of the O&M manual (LAB & manufacturer) Means
P S rsidual
Handling
Suspended machine
Presence Fall of the load. under the load Crushing of operators
Removal of the dangerous phenomenon: Make sure nobody is present under the load S= maximal severity of the possible damage 1 : Insignificant 2 : Limited 3 : Serious 4 : Fatal
See also supplier risk analysis and maintenance manual in KSB SALMSON as built documentation references 10892NA26411-412 10892NA26512-513-514
Specific part : Water pumps - 2 / 2
10892EA00400-0
TASK Nr
Checking visit of the unloading/injection pumps
Frequency : Daily
The unloading pump feed the storage tank from the truck The injection pump feed upstream SCR with ammonia the intervention consists in checking the good functioning of the ammonia pumps COMPONENT OF THE RISK hazardous dangerous event, P S On what component we Hazard Initial situation possible damage have to act Rotation of the pump axis Working nearby Contact with the moving the moving part part of the pump. of the pump Injury Contact with a conductor Working nearby under voltage electrical circuit Electrical shock Working nearby the ammonia circuit Spatter of ammonia injury with caustic etching B 3
PREVENTIVE MEASURE Means P S rsidual A 1
Removal of the Make sure that protector supplied by the dangerous phenomenon: manufacturer are installed before intervention obstacle / rotating parts Removal of the dangerous part Installation of means to avoid damages Removal of the dangerous part S= maximal severity of the possible damage 1 : Insignificant 2 : Limited 3 : Serious 4 : Fatal
Visual and audio checking of the pump during operation
No bare conductor under voltage Wear PPE :goggles / gloves / respirator Safety shower / eye rinsing nearby Leakage detection with horn Ammonia detection alarm Means
B B
1 1
Ammonia leakage
Specific part : NH4OH pumps - 1 / 2
10892EA00400-0
TASK Nr
Removal/replacement of the ammonia MLS : maintenance motor/pump The unloading pump feed the storage tank from the truck The injection pump feed upstream SCR with ammonia The intervention consists in removing then replacing the motor or the pump COMPONENT OF THE RISK hazardous dangerous event, P S Hazard Initial situation possible damage Rotation of the pump axis Work nearby rotating part Contact with the rotating part. Injury B 3
PREVENTIVE MEASURE On what component we have to act Removal of the dangerous part : electrical isolation of the motor Removal of the dangerous part : electrical isolation of the motor Installation of means to avoid damages Means Disconnecting switch with padlock in general low voltage panels or local panel P S rsidual A 1
Electrical connection / disconnection of pump motor
Contact with conductor Work nearby under voltage. electrical circuit Electrical shock
Disconnecting switch with padlock in general low voltage panels or local panel Wear PPE :goggles / gloves / respirator Safety shower / eye rinsing nearby Leakage detection with horn
Connection / disconnection of ammonia pump from fluid circuit
Ammonia solution 24,5% leakage
Work nearby Ammonia splashing ammonia circuit chemical injury
Removal of the Before dismantling, connection with the water dangerous phenomenon: network, rinsing of the pump with waste water rinsing of the pump sending to the sewer before intervention Leakage detection with horn Removal of the safety shower and eye rinsing in the retention dangerous phenomenon Wear of PPE Follow the instructions of the O&M manual S= maximal severity of the possible damage 1 : Insignificant 2 : Limited 3 : Serious 4 : Fatal Means
Intervention in the retention
Presence of ammonia
working nearby Slipping or operator ammonia breathing problem
See also supplier risk analysis and maintenance manual in KSB LEWA as built documentation references 10892NA26401-412 10892NA26211-212-213
Specific part : NH4OH pumps - 2 / 2
10892EA00400-0
TASK Nr
Checking visit of the ammonia MLS : During operation Frequency : Daily injection The ammonia injection system is used to inject the chemical upstream SCR reactor This intervention consists in checking the ammonia injection during operation PREVENTIVE MEASURE COMPONENT OF THE RISK P S hazardous dangerous event, On what component Hazard Means Initial situation possible damage we have to act Wear PPE. Ammonia detectors. Ducts in stainless steel. Remove the dangerous No flanges or flanges protected. Security shower. phenomenon Ammonia resistant gaskets. Follow the instructions of the O&M manual (Lab & manufacturer). S= maximal severity of Means the possible damage 1 : Insignificant 2 : Limited 3 : Serious 4 : Fatal
residual
Checking visit of ammonia injection
Leak of ammonia
Presence of operators nearby the injection system
Contact with ammonia : B chemical injury
Specific part : NH4OH injection - 1 / 2
10892EA00400-0
TASK Nr
disassembly of the ammonia lances
MLS : During operation
Frequency : Annual
The ammonia injection system is used to inject the chemical upstream SCR reactor This intervention consists in checking the ammonia injection during operation COMPONENT OF THE RISK P S hazardous dangerous event, On what component Hazard Initial situation possible damage we have to act
Checking visit of ammonia injection
Leak of ammonia
Presence of operators nearby the injection system
Contact with ammonia : B chemical injury
Wear PPE. Ammonia detectors. Ducts in stainless steel. Remove the dangerous No flanges or flanges protected. Security eye rinsing phenomenon Ammonia resistant gaskets. Follow the instructions of the O&M manual (Lab & manufacturer). S= maximal severity of Means the possible damage 1 : Insignificant 2 : Limited 3 : Serious 4 : Fatal
Specific part : NH4OH injection - 2 / 2
10892EA00400-0
TASK Nr
Mounting/Dismantling hot piping
MLS : mounting/dismantling
Hot piping is present at the heat recovery system The intervention consists in disconnecting piping COMPONENT OF THE RISK Hazard hazardous situation dangerous event, possible damage P S Initial On what component we have to act Installation of means to avoid damages
PREVENTIVE MEASURE P Means Wear PPE. Follow the instructions of the O&M manual (Lab & manufacturer) B 1 S rsidual
Connection / Leak of process fluid disconnection of the pipe
Working nearby the process fluid circuit
Contact with the hot condensate water Injury
Before dismantling, drainage of the hot Removal of the dangerous phenomenon: water circuit pipe draining before disconnection, wait for Follow the instructions of the O&M manual (Lab & manufacturer) pipe cooling Certified handling/lifting equipments. Handling by authorized operators. Removal of the dangerous phenomenon: Marking area and banning access under the load. Make sure nobody is present under the load Follow the instructions of the O&M manual (LAB & manufacturer) S= maximal severity of the possible damage 1 : Insignificant 2 : Limited 3 : Serious 4 : Fatal Means
Handling
Suspended equipment
Presence Fall of the load. under the load Crushing of operators
See also supplier risk analysis and maintenance manual in SNZ GEA as built documentation references 10892QA27550-560 10892NA25611
Specific part : Hot piping - 1 / 1
10892EA00400-0
TASK Nr
Checking visit of the mechanical transport equipment
Frequency : Daily
Fly ash transport : screw conveyor under ESP/ lump breaker Spent sorbent transport : screw conveyors under fabric filter The intervention consists in checking the good functioning of the mechanical transport equipment OPERATION N Identification Hazard COMPONENT OF THE RISK hazardous dangerous event, situation possible damage Working Contact with the moving nearby the moving part of part. Injury the screw conveyor Contact with a conductor Working under voltage nearby an electrical circuit Electrical shock Working nearby the circuit of chemicals substance PREVENTIVE MEASURE P S Initial On what component we Means have to act Make sure that protector supplied by the manufacturer are Removal of the installed before intervention dangerous phenomenon : Special tool needed to open the trapdoor. obstacle / rotating parts Follow the instructions of the O&M manual (Lab & manufacturer) No bare conductor under voltage. Removal of the dangerous phenomenon Follow the instructions of the O&M manual (Lab & manufacturer) P S residual
Visual and auditory checking of the mechanical transport equipment during operation
Rotation of the screw axis
Leakage checking
Leak of chemical substance
Contact with the chemical substance : injury
Removal of the Wear PPE. dangerous phenomenon Follow the instructions of the O&M manual (Lab & manufacturer) S= maximal severity of the possible damage 1 : Insignificant 2 : Limited 3 : Serious 4 : Fatal
Means
Specific part : Residue mechanical transport - 1 / 2
10892EA00400-0
TASK Nr
Mounting / dismantling of the mechanical transport equipment
MLS : maintenance
Frequency : Annual
Fly ash transport : screw conveyor under ESP/ lump breaker / rotary valve before big bag Spent sorbent transport : screw conveyor under fabric filter The intervention consists in removing one component (motor, sealing, stuffing box,...) OPERATION N Identification Hazard COMPONENT OF THE RISK hazardous situation dangerous event, possible damage P S Initial On what component we have to act PREVENTIVE MEASURE P Means S residual
Handling of the mechanical transport equipment
Part of the equipment suspended
Presence Fall of the load under the load Crushing of the operator
Removal of the dangerous phenomenon: Make sure nobody is present under the load
Certified handling/lifting equipments. Handling by authorized operators. Area marking and banning access under the load Wear PPE. Follow the instructions of the O&M manual (Lab and manufacturer)
Spillage of residue 2 Handling of the mechanical transport equipment Conductor under voltage
Working nearby the circuit of chemicals substance Working nearby the electrical part
Contact with chemical substances
Wear PPE. Removal of the Special tool needed to open the trapdoor. dangerous phenomenon Follow the instructions of the O&M manual (Lab & manufacturer)
Contact with a conductor under voltage Electrical shock
Disconnecting switch with padlock in general low voltage panels Removal of the or local panel. dangerous phenomenon Follow the instructions of the O&M manual (Lab & manufacturer) S= maximal severity of the possible damage 1 : Insignificant 2 : Limited 3 : Serious 4 : Fatal
Means
See also supplier risk analysis and maintenance manual in ELEX STAG STAG as built documentation references 10892SA17201 10892NA11121-122-123 10892NA17601-602-603-604-606-607-619-620-631-632-633
Specific part : Residue mechanical transport - 2 / 2
10892EA00400-0
TASK Nr
Inspection of pneumatic transport equipment
MLS : maintenance
Frequency : Annual
Fly ash pneumatic transport from ESP to storage silo Spent sorbent pneumatic transport from fabric filter to storage silo The intervention consist in checking the inside of the equipments COMPONENT OF THE RISK dangerous event, Hazard hazardous situation possible damage Working nearby the pressurized vessel Working nearby the conveying equipment quick depressurization of the equipment - injury Contact with chemical substances
PREVENTIVE MEASURE P S Initial B 3 On what component we have to act Removal of the dangerous phenomenon Removal of the dangerous phenomenon S= maximal severity of the possible damage 1 : Insignificant 2 : Limited 3 : Serious 4 : Fatal Means Check local pressure measurement and deaerate the vessel Follow the instructions of the O&M manual (Lab and manufacturer) Wear PPE Follow the instructions of the O&M manual Means P S residual A 1
Equipment under Opening of the conveying pressure vessel and conveying lines Spillage of residue MLS : Machine life step
See also supplier risk analysis and maintenance manual in STAG as built documentation references 10892NA17601-602-605-609-673
Specific part : Residue pneumatic transport - 1 / 1
10892EA00400-0
TASK Nr
Checking visit of the instruments DESCRIPTION OF THE EQUIPMENT
Frequency : Daily
Instruments are composed of pressure, temperature et other variables detectors. OPERATION N Identification Hazard COMPONENT OF THE RISK hazardous situation dangerous event, possible damage P S Initial On what component we have to act PREVENTIVE MEASURE P Means S residual
Checking visit of the instruments
under voltage or hot instrument
Contact with Injury : electrical shock; an instrument burning.
Intervention only by authorized people Wear PPE. Remove the dangerous Follow the instructions of the O&M manual (Lab & manufacturer). phenomenon Earthing. Electrical isolation. S= maximal severity of Means the possible damage 1 : Insignificant 2 : Limited 3 : Serious 4 : Fatal
See also supplier risk analysis and maintenance manual in
WIKA KHRONE ENDRESS HAUSER as built documentation references 10892NA29111-113-114-115-116-10892NA29151 10892NA29130-131-132
Specific part : Instruments - 1 / 1
10892EA00400-0
TASK Nr
Checking visit of the valves and MLS : During operation Frequency : Daily accessories DESCRIPTION OF THE EQUIPMENT Valves and accessories are present in the whole installation and are used to allow, or not, fluids circulation in the pipes or ducts. COMPONENT OF THE RISK PREVENTIVE MEASURE P S hazardous dangerous event, On what component Hazard Means Initial situation possible damage we have to act Wear PPE. Suitable material for accessories Remove the dangerous Follow the instructions of the O&M manual (Lab & phenomenon manufacturer). Ducts and pipes can be drained by gravity flowing Wear PPE. Remove the dangerous Follow the instructions of the O&M manual (Lab & phenomenon manufacturer). Wait for accessory cooling before intervention No bare conductor under voltage Removal of the Follow the instructions of the O&M manual (Lab & dangerous phenomenon manufacturer). S= maximal severity of the possible damage 1 : Insignificant 2 : Limited 3 : Serious 4 : Fatal Means
residual
Leak of a chemical products Checking visit of the accessories Working nearby the accessory, contact with it
Chemical injury
Hot accessory
Injury : burning
Conductor under electric potential MLS : Machine life step Installation : During operation Maintenance Mounting/Dismantling Frequency of the task Continuous Daily Weekly Monthly Annual Exceptional
Contact with conductor under voltage - electrical shock
See also supplier risk analysis and maintenance manual in
AVS SALMSON as built documentation references 10892NA28450-451-460 to 467 10892NA28470-480-490 10892NA26516
Specific part : Valve & components - 1 / 1
10892EA00400-0
TASK Nr
Checking visit of an equipment equipped with MLS : During operation electrical tracing Electrical tracing is used on residue silos and residue transport equipment Intervention on an equipment equipped with electrical tracing COMPONENT OF THE RISK P S dangerous event, Hazard hazardous situation Initial possible damage
Frequency : Annual
PREVENTIVE MEASURE On what component we have to act Remove the dangerous phenomenon P Means Marking of heat traced area Wear PPE Follow the instructions of the O&M manual (Lab & manufacturer). S residual
Checking visit of the residue silos, mechanical transport under ESP or under fabric filter, pneumatic transport
Hot electrical tracing Work nearby electric circuit Conductor under electric potential Removal of insulation for equipment inspection
Injury : burning Contact with conductor under voltage - electrical shock
Removal of the No barre conductor under voltage dangerous phenomenon Frequency : Annual
TASK Nr
Electrical tracing is used on residue silos and residue transport equipment Intervention on an equipment equipped with electrical tracing COMPONENT OF THE RISK Hazard Presence of mineral fibers in suspension hazardous situation dangerous event, possible damage P S Initial C 2 On what component we have to act
PREVENTIVE MEASURE P Means S residual A 1
Removal of insulation MLS : Machine life step
Breathing of these mineral Breathing problems fibers in suspension Skin irritation
Removal of the Wear PPE : goggles / gloves / boots / dangerous phenomenon mask / safety helmet S= maximal severity of the possible damage 1 : Insignificant 2 : Limited 3 : Serious 4 : Fatal Means
See also supplier risk analysis and maintenance manual in TRACE TEC STAG ELEX as built documentation references 10892NA24311-312 10892NA17612 10892NA11312
Specific part : electrical tracing & insulation - 1 / 1
10892EA00400-0
3- RISK INTERFACES OPERATION N 1 2 Identification Plant cleaning Handling/lifting with the overhead crane of the plant Handling with truck and load on the ground Noise (addition / reverberation) Hazard Cleaning nearby equipment Fall of the load Circulation nearby equipment Circulation of a load on the ground Increase of noise COMPONENT OF THE RISK hazardous situation Damage on equipment People under the load Fall on equipment Collision with equipment Overload on the concrete Working in the area concerned dangerous event, possible damage People injury Material damage People injury Material damage People injury / material damage Damage on civil work People hearing damage P S On what component we have to act Remove the dangerous phenomenon Remove the dangerous phenomenon Remove the dangerous phenomenon Remove the dangerous phenomenon Remove the dangerous phenomenon Remove the dangerous phenomenon Means Follow the procedures and the O&M manual Follow the procedures and the O&M manual Overhead running by authorized people Wear PPE Follow the procedures and the concerned O&M manuals Circulation ways defined by OMRIN Definition of the concrete by OMRIN with LAB load information Global acoustic study by OMRIN including LAB information Initial B B B B B B B 4 3 4 3 4 3 2 PREVENTIVE MEASURE P S residual (*) A A A A A A A 1 1 1 1 1 1 1
Temperature / ventilation
Ventilation default
Temperature increase People discomfort Possible presence of chemical products
Remove the dangerous phenomenon
Follow the procedures and the O&M manuals Global thermal study by OMRIN including LAB information
Stop of the Idfan
Idfan stop and fluegas pressure back into boiler pressure back via DeNOx air inlet or fresh air intake Piping breakdown Process fluid leakage
Presence of people People injury
Emergency motor installed on IDfan to maintain the flue gas line under pressure General safety procedure under OMRIN responsability Acceptable stress on flanges indicated by LAB Firm plate on heat exchanger DESP classification - Drainage by a truck equipped with a pump : tank drainage procedure to study with OMRIN to define the means for protection - The floor marking of the danger area is recommended - Leakage detection with flashing light and horn visible before being in the ammonia area (position approved by OMRIN) - Three detections in the area (retention, tank roof and truck unloading) - Two safety showers with eye rinsing : one in the retention, one in unloading area - For maintenance intervention on the pumps, wearing a mask is strongly recommended The valve to sewer is closed when ammonia is detected The doubling of the valve is strongly recommended Access restriction and electrical locking management by OMRIN
Water/water heat exchanger
Presence of people People injury
Presence of NH4OH in the retention under the tank
Retention full of ammonia drainage of ammonia in the Presence of people People injury retention
Valve under retention is opened 9 Automatism, Electricity and Instrumentation Control system MLS : Machine life step Installation : During operation Maintenance Mounting/Dismantling Continuous Daily Weekly Monthly Annual Exceptional Access to electrical equipment, intervention on equipment
The ammonia is evacuated to the sewer
Environment damage
remove the dangerous phenomenon
Presence of people Electrical shock
remove the dangerous phenomenon
10
People injury Uncorrect functioning of the Presence of people equipment damage safety Frequency of the task
Remove the dangerous phenomenon S= maximal severity of the possible damage 1 : Insignificant 2 : Limited 3 : Serious 4 : Fatal
Commisioning synchronisation by OMRIN with LAB commisioning documents Means
Part 3-Risk interfaces - 1 / 3
10892EA00400-0
(*) : Residual probability and damage severity to be evaluated by OMRIN
10892EA00400-0
See also Interfaces in HAZOP report dated 12/02/08 action 3 : boiler flue gas action 7 : steam supply action 8 : steam supply action 9 : steam supply action 12 : operation of Idfan action 13 : Trudel motor action 14 : flue gas analyser action 18 : condensate from/to water - water HE action 21 : condensate to LAB buffer tank action 37 : motor primary air fan pressure control failure no steam supply no steam supply malfunctioning of temperature control, open failure of control valve failure of IDFan or Idfan drive or related components main motor failure not correct functioning of the analyser stop of condensate pumps or open bypass or blockage level control failure failure of motor or related motor
10892EA00400-0
4- EC CERTIFICATES Please refer to as-built documentation (DOE) section A 03 "EC conformity"
Part : 4-EC Certificates - 1 / 1
10892EA00400-0
5 - LIST OF NORMS APPLIED REFERENCE DESCRIPTION NEN standards and guidelines Relating to the inspection of works, in the currently valid version. Guidelines for energy delivery to the public grid. Guidelines Commissie preventie van rampen door gevaarlijke stoffen. Committee on prevention of disasters caused by dangerous substances ARBO guidelines. Stoomwezen/ PED. Besluit verbranding afvalstoffen Bva. Bva waste incineration decisions The applicable Netherlands Standards Specification (NEN) and publications of Nederlands Normalisatie Instituut (NEN), VDEN, KEMA, Dte, EnergieNed. Dutch Practical Guidelines (NPR). The applicable International Standards (ISO), in particular for unit of measures, mechanical accessories and assemblies, bolts and nuts, the ISO system of units shall be used. The applicable standards of the European Committee for Electro technical Standardisation (CENELEC). The codes and regulations of the Netherlands Directorate General of Labour. European Electro Magnetic Compatibility (EMC) regulations as applicable. EN Standards Guideline: Tolerances for steel structures regarding architectural aspects and strength, stiffness and stability. (Report BI-84-3) Published by the Staalbouwkundig Genootschap; Dutch Practical Guidelines (NPR) for the design of connections (Report BI-85-7) Published by the Staalbouwkundig Genootschap; Guidelines for design calculations for and detailing bolted angle connections Published by the Staalbouwkundig Genootschap; Bouwbesluit of 2003 Building regulation The local authority building regulations relating to the construction site Guidelines for design calculations for stiffened and unstiffened plate arrays subjected to distributed loads Report BI 80-50. Published by the Staalbouwkundig Genootschap EU Machinery directive CE/2006/42 DIN 45641 and DIN 45645 Sound insulation design DIN 52612 thermal conductivity determination for flat products DIN 52613 thermal conductivity for cylindrical products EN 287 welders Qualification EN ISO 389 Acoustics -- Reference zero for the calibration of audiometric equipment Safety of machinery, human body measurements Part 1 : Opening - Part 2 : orifices - Part 3 : anthropometric data EN 547 - 1 to 3 Safety of machinery - Ergonomic design principles - Part 1 : Terminology and design principles - Part 2 : Interaction between machinery design and work tasks EN 614 - 1 & 2 Safety of machinery Ergonomics requirements for the design of displays and control actuators Part 1 : interactions - Part 2: Displays - Part 3 : control actuators EN 894 - 1 to 3 ISO 10816 Vibration of mechanical equipment ISO 2373 low voltage motor - mechanical vibration ISO 5167 / 5168 orifices plates and nozzles calcualtion ISO 5210 / 5211 driving elements for electrical actuators ISO 8501 Paint system - sand blasting NEN 1008 thickness of the galvanized layer on the trays and vertical runs NEN 1010 electrical equipment protection type NEN 1010 types of protection NEN 1010 choice of cable cross sectional areas NEN 1010 and NEN 3140 prevention shock currents from both direct and indirect contact NEN 1041 definition of safe working class for safe working in high voltage areas with explosion mixtures. NEN 1041 definition of sealing for cable penetrations in the walls, ceilings and floors so that they are fireproof NEN 1041 and NEN 3840 for safe working in high voltage areas
Part : 5-List of norms - 1 / 2
10892EA00400-0
REFERENCE NEN 1041 and NEN 3840 NEN 1275 NEN 2062 and NEN 2063 NEN 2446 NEN 3125 NEN 3173 NEN 3173 NEN 3184 NEN 3621 NEN 6064 NEN 6065 NEN 6700 NEN 6720 VB NEN-EN-ISO 14122 part 2, 3 and 4. NEN-ENV 1090-1:1997
DESCRIPTION Protective earthing measures and protection against contact Galvanization Arc welding cable identification necessary explosion proof design for installation of electrical equipment in explosion- proof areas standards NEN-EN-IEC 60034 low- voltage motors noise limit values converter transformers design cable design bare insulation products non combustible Insulation : For products dressed with aluminium foil the flame spread shall be class 1 Technical bases for the design and calculations of building structures TGB 1990 beton technical requirements Safety of machinery : working platform and access / stairs, stepladder and guard-rails / fixed ladders Execution of steel structures - Part 1: General rules and rules for buildings
Part : 5-List of norms - 2 / 2
10892EA00400-0

07A Risk Analysis EU Machinery Directive CE

Uploaded by

Document Information

Original Description:

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

07A Risk Analysis EU Machinery Directive CE

Uploaded by

Copyright:

Available Formats

RISK ANALYSIS

ACCORDING TO EU MACHINERY DIRECTIVE CE/2006/43

0 first edition Approved by : PMi

REMEDIES AND REFERENCES

1.1.3 Materials and products

Personal damage, explosion

flamable Personnal damage

Not applicable - OMRIN scope - No special LAB requirements

General maintenance of the plant

General handling/lifting of equipment > 20 kg (contract) Fan dismantling Catalyst handling

Manholes Control room

Personal damage & corrosion

Not applicable for onsite equipment 1.2 CONTROL SYSTEMS

Programming of PCS + start-up/stop conditions

Automatic stop of the plant (sequences) - Risk of damage of the plant

Damage of equipment + operators risks

ORIGIN AND KIND OF RISKS

REMEDIES AND REFERENCES

Automatic control / operation of the plant

Damage of the plant and of equipment

1.3 PROTECTION AGAINST MECHANICAL HAZARDS

Breakdown due to bad installation

Damage of equipment + risk for operators

1.3.2 Risk of break-up during operation

Breakdown following operation

Damage of equipment + stop of the plant

1.3.3 Risks due to falling or ejected objects

Damage of equipment + risk for operators

Ejected objects: not applicable

Edges and angles Height / Header

Risk for operators Risk for operators

Stop of the plant

Damage of equipment + loss of operation

Risk for operators Personal injuries

Abnormal stop 1.4 REQUIRED CHARACTERISTICS OF GUARDS AND PROTECTIVE DEVICES

Design & installation of protective devices by OMRIN

1.4.2 Special requirements for guards

Refer to equipment documents provided by supplier and operating manual

Procedures / operating manual

High voltage, transfo, electrical cabinets

pneumatic system under pressure hydraulic system under pressure

Personal injuries Personal injuries

Thermal equipment (ducts, piping, heat exchangers )

ORIGIN AND KIND OF RISKS

REMEDIES AND REFERENCES

Damage / Personal injuries

All equipment Outside noise generated by the plant (stack)

All equipment Fans

presence of electromagnetism, no ionizing sources, no X-ray

Equipment damage + personal injuries

Personal injuries Personal injuries Personal injuries and death

Instrument/equipment All heavy and big equipment

Personal injuries Personal injuries

Not applicable (OMRIN scope) Lightning during erection 1.6 MAINTENANCE

Personal injuries and death

Plant All equipment

Equipment damage / breaking

Help for operators

Mistakes resulting in equipment damages and personal injuries

1.7.2 Warning of residual risks

Mistakes resulting in equipment damages and personal injuries

Mistakes resulting in equipment damages and personal injuries

Flue gas cleaning