Ships in Service Training Material A-M CHAUVEL Risk Assessment Case Study Product Tanker.
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Transcript of Ships in Service Training Material A-M CHAUVEL Risk Assessment Case Study Product Tanker.
Ships in Service Training Material A-M CHAUVEL
Risk Assessment
Case StudyProduct Tanker
Ships in Service Training Material A-M CHAUVEL
Problem Definition (STEP #1)Product Ship Conversion to Carry Benzene
Discussion
As a special project, a tanker company was requested to modify an existing product tanker to routinely carry benzene as a cargo from a refinery in Puget Sound, WA, to the Gulf Coast of the United States.
As a part of this process to convert the tanker and modify operating procedures, a risk assessment was warranted to determine what safety modifications needed to be made tocurrent operating practices to protect vessel personnel.
Ships in Service Training Material A-M CHAUVEL
Problem Definition (STEP #1)Product Ship Conversion to Carry Benzene
Where will this operation take place? and which geographic areas need to be examined?
From Puget Sound, WA, to the Gulf Coast of the United States.
Ships in Service Training Material A-M CHAUVEL
Problem Definition (STEP #1)Product Ship Conversion to Carry Benzene
Which operations are going to be considered in this assessment?
Loading Operations Transit Operations Discharging Operations Tank Cleaning Operations Spill Response Operations
Ships in Service Training Material A-M CHAUVEL
Problem Definition (STEP #1)Product Ship Conversion to Carry Benzene
What safety and other concerns are to be addressed?
Personnel safety Vessel / physical plant safety Environment Regulatory compliance
This risk assessment focuses on personnel safety during: loading, transit, discharging, and tank cleaning operations.
Ships in Service Training Material A-M CHAUVEL
Selection of Experts (STEP #2)Product Ship Conversion to Carry Benzene
The tanker operator gathered: two senior captains, the operations manager, three senior engineers, the Environmental Health & Safety (EH&S) manager, and a senior EH&S advisor.
Ships in Service Training Material A-M CHAUVEL
Hazard & Potential Accident Identification (STEP #3)Product Ship Conversion to Carry Benzene
This is a key step in the process.It can be done offline by a knowledgeable individual (s) and then verified and corrected by the group of experts.
Doing this ahead of time can make the risk assessment process much easier.
Ships in Service Training Material A-M CHAUVEL
Hazard & Potential Accident Identification (STEP #3a)Product Ship Conversion to Carry Benzene
CargoOrders
LoadingCargo
Transport& StorageActivities
CargoDischarge
TankCleaning
Establishing Flow Chart of operations
Ships in Service Training Material A-M CHAUVEL
Hazard & Potential Accident Identification (STEP #3b)
Cargo Orders:
1. Load cargo into tanks 4 port and starboard
Establishing Flow Chart of operations
Ships in Service Training Material A-M CHAUVEL
Hazard & Potential Accident Identification (STEP #3b)
Loading Cargo:
1. Vessel tied up2. Notifications signs placed on deck3. Cargo tanks inerted to 8% O²4. Cargo tanks at normal IG pressure5. Make Chicks an arm connections6. Start pump room ventilation7. Shore side provides physical properties8. Close accommodation doors9. Seal pump room sea valves
Establishing Flow Chart of operations
Ships in Service Training Material A-M CHAUVEL
Hazard & Potential Accident Identification (STEP #3b)
Loading Cargo:
10. Make log entries11. Place house ventilation on recirculation12. Connect vessel to shore side vapor recovery13. Open shore side manifold valves14. Make shore side notifications15. Monitor and record ullages16. Conduct leak checks17. Monitor cargo pressures18. Record tank temperatures and gravity
Establishing Flow Chart of operations
Ships in Service Training Material A-M CHAUVEL
Hazard & Potential Accident Identification (STEP #3b)
Loading Cargo:
19. Perform controlled venting20. Conduct vessel stress checks21. Close isolation valves22. Conduct radio check23. Shore side stops transfer24. Close shore side manifolds25. Obtain sample26. Conduct final gauging27. Close ullage caps
Establishing Flow Chart of operations
Ships in Service Training Material A-M CHAUVEL
Hazard & Potential Accident Identification (STEP #3b)Product Ship Conversion to Carry Benzene
Loading Cargo:
28. Disconnect Chicksan arms29. Reinstall manifold blanks30. Dispose of all NLS waste
Ships in Service Training Material A-M CHAUVEL
Hazard & Potential Accident Identification (STEP #3b)
Voyage Activities:
1. Open house ventilation2. Start IG blower3. Vent tanks
Establishing Flow Chart of operations
Ships in Service Training Material A-M CHAUVEL
Hazard & Potential Accident Identification (STEP #3b)
Cargo Discharge:
1. Vessel tied up2. Pump room sea valves pressure tested3. Cargo tanks at pressure4. Cargo tanks inerter5. Make Chicksan arm connections6. Restrict access to deck7. Turn on pump room ventilation8. Seal pump room sea valves and record9. Close all accommodation doors10. Open cargo tank to manifold
Establishing Flow Chart of operations
Ships in Service Training Material A-M CHAUVEL
Cargo Discharge:
11. IG system running on recirculation12. Shore side communication13. Check for leaks14. Draw line sample15. Verify ullage16. Increase rate17. Record cargo temperature18. Monitor cargo tank pressures19. Check pump room for leaks20. Monitor pump room LEL
Establishing Flow Chart of operations
Hazard & Potential Accident Identification (STEP #3b)
Ships in Service Training Material A-M CHAUVEL
Product Ship Conversion to Carry BenzeneCargo Discharge:
21. Record cargo temperature last 30 min22. Strip cargo tanks23. Perform cargo checks24. Strip lines ashore25. Stop cargo pumps26. Close ship’s manifold valves27. Drain Chicksan arms28. Reinstall manifold blanks29. Clean up leaks or drips30. Dispose of all NLS waste
Hazard & Potential Accident Identification (STEP #3b)
Ships in Service Training Material A-M CHAUVEL
Tank Cleaning:
1. Put house on recirculation2. Restrict deck activities3. Notify engine room4. Close all accommodation doors5. Open purge pipes6. Start IGS system7. Initiate gas testing8. Put IGS on recirculation
Establishing Flow Chart of operations
Hazard & Potential Accident Identification (STEP #3b)
Ships in Service Training Material A-M CHAUVEL
Tank Cleaning:
9. Connect hoses to hydrants10. Check electrical conductivity of hoses11. Open Butterworth plates12. Lower hoses into tanks13. Restart IGS into tanks14. Water wash tanks15. Strip tanks of water16. Test tank atmosphere
Establishing Flow Chart of operations
Hazard & Potential Accident Identification (STEP #3b)
Ships in Service Training Material A-M CHAUVEL
Hazards & Potential Accident Identificationfor each phase of the operation (STEP #3c)
Product Ship Conversion to Carry Benzene
Cargo Orders – Hazards:
1. No MSDS2. Not enough planning time
Ships in Service Training Material A-M CHAUVEL
Hazards & Potential Accident Identificationfor each phase of the operation (STEP #3c)
Product Ship Conversion to Carry Benzene
Loading Cargo – Hazards:
1. New Crew2. Unauthorized personnel on deck3. Inspector not benzene certified4. Sampling exposure5. Engine room exposure due to vent system6. Incorrect air monitoring7. Benzene waste not properly stored
Ships in Service Training Material A-M CHAUVEL
Hazards & Potential Accident Identificationfor each phase of the operation (STEP #3c)
Product Ship Conversion to Carry Benzene
Loading Cargo – Hazards:
8. Open accommodation doors 9. Crew not wearing proper PPE10. Deck spill11. Pump room spill12. Warning signs not posted13. Benzene splashing on person
Ships in Service Training Material A-M CHAUVEL
Hazards & Potential Accident Identificationfor each phase of the operation (STEP #3c)
Product Ship Conversion to Carry Benzene
Voyage Activities – Hazards:
1. Venting exposures on deck2. Unauthorized personnel on deck3. House ventilation not on recirculation while venting
Ships in Service Training Material A-M CHAUVEL
Hazards & Potential Accident Identificationfor each phase of the operation (STEP #3c)
Product Ship Conversion to Carry Benzene
Cargo Discharge – Hazards:
1. Unauthorized personnel on deck2. Sampling mishap3. Personnel exposure4. Spill on deck5. Pump room spill6. Improper air monitoring7. Inspector not benzene qualified
Ships in Service Training Material A-M CHAUVEL
Hazards & Potential Accident Identificationfor each phase of the operation (STEP #3c)
Product Ship Conversion to Carry Benzene
Cargo Discharge – Hazards:
8. Draining of benzene from Chicks an arms onto deck 9. Warning signs not posted10. Piping leak11. Benzene waste not stored properly12. Crew not wearing proper PPE13. House ventilation not on recirculation while venting
Ships in Service Training Material A-M CHAUVEL
Hazards & Potential Accident Identificationfor each phase of the operation (STEP #3c)
Product Ship Conversion to Carry Benzene
Tank Cleaning – Hazards:
1. Unauthorized personnel on deck2. House ventilation not on recirculation while venting3. Personnel exposure4. Spill on deck5. Benzene / water disposed of improperly6. Improper air monitoring
Ships in Service Training Material A-M CHAUVEL
Hazards & Potential Accident Identificationfor each phase of the operation (STEP #3c)
Product Ship Conversion to Carry Benzene
Tank Cleaning – Hazards:
7. Engine room pulls in benzene vapors 8. Draining of benzene from Chicks an arms onto deck 9. Warning signs not posted10. Piping leak11. Benzene waste not improperly stored12. Crew not wearing proper PPE
Ships in Service Training Material A-M CHAUVEL
Consolidate list of Hazards &Potential Accidents (STEP #3d)Product Ship Conversion to Carry Benzene
The tanker operator narrowed the comprehensive list of hazards and potential accidents that was created in step #3c down to a list of seven.
In doing so, the operator remained focused on personnel safety.
Ships in Service Training Material A-M CHAUVEL
Consolidate list of Hazards &Potential Accidents (STEP #3d)Product Ship Conversion to Carry Benzene
Personnel Exposure – Hazards:
1. Vapors entering house, engine room, and lingering on deck2. Liquid cargo spills3. Waste mishandling4. Inspector not benzene qualified5. New crew6. Improper clean up of residual cargo / spill7. Improper sampling
Ships in Service Training Material A-M CHAUVEL
Assign Frequency Ratings, Consequence Ratings & Risk Priorities ( Steps 4,5 & 6 )
Product Ship Conversion to Carry Benzene
Utilizing the scales in Steps #4 and #5 and the matrix in step #6, the following chart was developed
Ships in Service Training Material A-M CHAUVEL
Vapors entering house , engine room, andlingering on deck
Liquid cargo spills
Waste mishandling
Inspector not benzene qualify
New crew
Improper clean up of residual cargo/spill
Improper sampling
Hazard :Personnel Exposure
to Benzene
FrequencyRating
ConsequenceRating
RiskPriorityScore
Assign Frequency Ratings, Consequence Ratings & Risk Priorities ( Steps 4,5 & 6 )
Product Ship Conversion to Carry Benzene
H
M
M
L
VH
VH
H
3
2
2
2
5
5
5
3
4
3
2
4
4
2
Ships in Service Training Material A-M CHAUVEL
Assign Frequency Ratings, Consequence Ratings & Risk Priorities ( Steps 4,5 & 6 )
Product Ship Conversion to Carry Benzene
This is a subjective process.
To determine which of two hazards having the same risk priority score was more significant than the other, the group turned to the frequency and consequence ratings and ranked each hazard appropriately.
Ships in Service Training Material A-M CHAUVEL
New crew
Improper clean up of residual cargo/spill
Improper sampling
Vapors entering house engine room, andlingering on deck
Liquid cargo spills
Waste mishandling
Inspector not benzene qualify
Hazard :Personnel Exposure
to Benzene
FrequencyRating
ConsequenceRating
RiskPriorityScore
Assign Frequency Ratings, Consequence Ratings & Risk Priorities ( Steps 4,5 & 6 )
Product Ship Conversion to Carry Benzene
4
4
3
3
4
3
2
VH
VH
H
H
M
M
L
5
5
5
3
2
2
2
Ships in Service Training Material A-M CHAUVEL
Assign Frequency Ratings, ConsequenceRatings & Risk Priorities ( Steps 4,5 & 6 )
Product Ship Conversion to Carry Benzene
Other factors, such as: the potential for more than one person to be exposed or an additional environmental problem, can be used to distinguish between two hazards having the same risk priority score. It’s all up to the risk assessment team.
Review your results for consistency.
Ships in Service Training Material A-M CHAUVEL
Development of Countermeasures (STEP #7)
Product Ship Conversion to Carry Benzene
The causal chain shown in this step applies only to personnel exposure to benzene due to improper sampling. Similar causal chains were created by the assessment team for the remaining six hazards that were analyzed.
Figure 6 Countermeasures and the Causal Chain Example
Inadequate
TrainingProceduresEquipment(PPE)
Impropersampling
Reportableexposure
Employeerequires
medical testing& surveillance
Cause Incident Accident Consequences
Ships in Service Training Material A-M CHAUVEL
Development of Countermeasures (STEP #7)
Product Ship Conversion to Carry Benzene
Intervene before the INCIDENT.Sampling training.Modify sampling procedure.New sampling system.
Figure 6 Countermeasures and the Causal Chain Example
Inadequate
TrainingProceduresEquipment(PPE)
Impropersampling
Reportableexposure
Employeerequires
medical testing& surveillance
Cause Incident Accident Consequences
Ships in Service Training Material A-M CHAUVEL
Development of Countermeasures (STEP #7)
Product Ship Conversion to Carry Benzene
Intervene before the ACCIDENT.Hazardous materials training.New hazardous materials handling procedure.Upgrade PPE.
Figure 6 Countermeasures and the Causal Chain Example
Inadequate
TrainingProceduresEquipment(PPE)
Impropersampling
Reportableexposure
Employeerequires
medical testing& surveillance
Cause Incident Accident Consequences
Ships in Service Training Material A-M CHAUVEL
Development of Countermeasures (STEP #7)
Product Ship Conversion to Carry Benzene
Intervene before the CONSEQUENCE.Refresh medical notification.Notify medical department;Upgrade PPE.
Ships in Service Training Material A-M CHAUVEL
Countermeasures (Step #7)
Estimate ofEffectiveness
(Step #8)
Cost Estimate (Step #9)
Benefit- Cost Ratio
2
2
1
1
1
3
3
Analyzing Benefit-Cost (Steps 8,9 & 10) Product Ship Conversion to Carry Benzene
=÷
Sampling training
Hazmat Training
Modify samplingprocedure
Refresh medicalnotification
Notify medical depart.for testing
New sampling system
Upgrade PPE
1.5
1.5
3.0
;2.0
2.0
1.3
1.3
3
3
3
2
2
4
4
Ships in Service Training Material A-M CHAUVEL
Analyzing Benefit-Cost (Steps 8,9 & 10) Product Ship Conversion to Carry Benzene
Conclusion:
This case study is not fictitious.
It was actually conducted and the results were used. All of the countermeasures listed at the end of step #7 were implemented.
Many of these countermeasures addressed more than one of the hazards or potential accidents that were identified in step #3.
Ships in Service Training Material A-M CHAUVEL
Analyzing Benefit-Cost (Steps 8,9 & 10) Product Ship Conversion to Carry Benzene
Conclusion:
The risk assessment team, including all vessel personnel involved, were very satisfied that the process provided them with a comprehensive review and felt prepared to carry the new cargo.
The training techniques developed as a result of this process served to refresh vessel personnel each time a benzene cargo was carried.
The cargo was carried without incident until sale of the vessel.
Ships in Service Training Material A-M CHAUVEL
Source
U.S. Coast GuardHuman Element and Ship Design DivisionCommandant (G-MSE-1)U.S. Coast Guard Headquarters2100 Second Street, S.W.Washington, D.C. 20593(202) [email protected]://www.uscg.mil/hq/g-m/nmc/ptp/index.htm
Company Name :Vessel Name :Phase of operation assessed
Participant Name, Function/Title/Organization :
FrequencyRating
Hazarddescription
ImpactRating
RelativeRisk Score
A -
B -
Step1
Step2
Step4
Step3
Step5
Step6
Marine Risk Assessment Worksheet
Company Name :Vessel Name :Phase of operation assessed
Participant Name, Function/Title/Organization :
FrequencyRating
Hazarddescription
ImpactRating
RelativeRisk Score
A -
B -
Marine Risk Assessment Worksheet
ProposedCountermeasure
EstimateEffectiveness
CostEstimates
OverallScore
FocusHazard ÷ =
From Step 10 Decision : Choose the countermeasures with the highest Benefit-cost rations
123456
123456
A-
B-
Step8
Step9
Step10
Step7
Marine Risk Assessment Worksheet
ProposedCountermeasure
EstimateEffectiveness
CostEstimates
OverallScore
FocusHazard ÷ =
Decision : Choose the countermeasures with the highest Benefit-cost rations
123456
123456
A-
B-
Marine Risk Assessment Worksheet