Transcript WE i engineering

Systematical follow-up of WE in new
building and modifications
(Norwegian Oil and Gas)
NORSOK S-002
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Agenda
• Norwegian O&G regulation (see separate presentation)
• Requirements for WE analyses in Norsok S-002
• Systematical follow-up of WE in projects
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Working environmental program
Activity plan
Examples of studies
• Who to implement the NORSOK WE requirement in your project –
when and where:
– Knowledge requirements
– Involvment of other disiplines
– Worker involvment
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Your (the projects) WE philosopy
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Comment No 1: Chapter 2, Page
Nosok s-002 is described to constitute of only prescriptive requirements.
5, last paragraph
The standards constitute both prescriptive and goal-oriented requirements. The
document fails in describing how the projects shall address and implements the
goal oriented requirements in the projects.
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The activities described in Norsok s-002 is described in chapter 3 (and
the following chapters) as list of activities.
Comment No 2: Chapter 3, Page 6
The systematically follow-up of WE according to PSA and NORSOK
requirements require an interaction between the activities – they are not a list
of proceeding activities.
Systematic management and follow-up of
working environment in design and
new-building
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WE program
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Procedures and work instructions
Competence
Document list
Verification plan
Decomposition of requirements
WE design basis
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Acceptance criteria
WEAL
Manning and organization
Experience transfer
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WE analyses
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Follow-up / Verification of design
requirements
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Working environment design reviews
Working environment inspections
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Comment No 3: Competence
The NORSOK standard require the WE competence and resources to be
stated in an early stage.
Resources allocated to a typical development project (FEED and detailed engineering):
WE resources design team
Technical working environment, ergonomics (full time)
Human Factors (full time)
Acoustics ( full time)
+ other specialists
Company
Technical working environment (full time)
Human Factors (full time)
Acoustics (part time)
Ergonomist (part time)
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NORSOK S-002 gives an example of WE analyses and when they preferable
should be conducted in a normal project
A so-called ”fast track” project might impose special issues – this is not
considerate in the document.
The interaction between the activities are not considered.
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Managing and follow-up of WE in design and new-buildings are a continues
process that could not be reduced to single work shop activities.
The analyses and activities listed needs carefully planning, information gathering,
expert analyses, discussions and interactions with all parties (designer, worker
representatives, discipline leaders, Company, PSA etc.). The suggested work
shops are to be regarded as verification activities – not as the main activity.
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Work shops are described as the major way of working.
Managing and follow-up of WE in design and new-buildings are a
continues process that could not be reduced to single work shop
activities.
The analyses and activities listed needs carefully planning,
information gathering, expert analyses, discussions and
interactions with all parties (designer, worker representatives,
discipline leaders, Company, PSA etc.). The suggested work
shops are to be regarded as verification activities – not as the
main activity.
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Working Environment Programme
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Working Environment
Programme
• A WE programme shall be established for
every project phase.
• The WE programme may be a separate
document or integrated into the project’s
HSE programme, and shall be linked to
the project execution plan.
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Working Environment
Programme
• The WE programme shall
– define the project’s WE objectives
– define risk acceptance criteria for
occupational safety, human error and health
risks
– State references to applicable WE
requirements and procedures
– describe means of ensuring the statutory
worker participation in the design process
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Working Environment
Programme
• The WE programme shall include an activity plan
stipulating the responsibilities, schedule and deliverables
for the various activities to manage WE in the design
process.
• In particular, the WE analyses shall be planned with due
consideration of the needs for timely input to design and
procurement, and needs for verification and
documentation.
• The WE activity plan shall be maintained to provide
status regarding execution and documentation of the
various WE management activities.
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Working Environment
Programme
• Deviations from WE requirements shall be subject
to the project’s nonconformity procedures.
• A follow-up system shall be established that
enables proper documentation, handling, followup and closeout of agreed actions and
recommendations from the various WE studies
and analysis in the project. The WE follow-up
system shall be integrated in the overall HSE
management system in the project.
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Working Environment
Programme
• To document status regarding
implementation of WE requirements,
Working Environment Area Charts
(WEAC’s) shall be issued at predefined
project milestones
• In principle, a WEAC shall be prepared for
each room and area on the installation.
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WE activity plan
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Working Environment
Activity Plan
• This Working Environment Activity Plan (WE
Activity Plan) provides information on WE
activities and documentation to be performed or
issued by xxx during execution of xxx EPCH
Project.
• This activity plan supports project /1/ Working
Environment Program, doc. no. xxx and is
established for survey and status reporting
between Company and Contractor throughout
Project
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Working Environment
Activity Plan
• The plan contains planning and status
information provided in the following tables:
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Table 1: WE documentation and analyses
Table 2: WE Area design reviews
Table 3: Specific WE reviews and analyses
Table 4: Human Factor activities and analysis
Table 5: WE Packages Follow-Up
Table 6: Familiarisation of WE Design Basis
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Working Environment
Activity Plan
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WE Program WE Activity Plan
WE Design Specification
HSE Check List for Equipment
and Packages
Working Environment Area Limits
(WEALs)
HSE Data Sheets
Chemical Health Risk Assessment
(CHRA)
Weather Protection Study Report
Constructability Analysis WEIA
report
Working Environment Area Charts
(WEACs)
Working Environment Summary
Report
Illumination Layout Report
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Coarse Noise Control Report
Noise Prediction Report
Sound Absorption Requirements
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HUMAN FACTORS:See Table 4
below
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CLIENT DOCUMENTS:
Organisation and Manning Study
including Psychosocial Analysis
Psychosocial Preconditions report,
(Demand Resource Analysis
(DRA)
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Working Environment
Activity Plan HF
• Rapporter
• CCR Specification
• Functional Analysis of CCR &
Collaboration Room
• Task & Error Analysis of CCR
& Collaboration room
operations
• Workload Analysis of CCR &
Collaboration room operations
• Communication Analysis of
CCR & Collaboration Room
• Situation Analysis of xxx SAS
& safety system interfaces
• Human Factors Analysis
Report (Summary report)
• ACTIVITIES
• HF related to integrated
operations
• HF related to SAS design &
development
• HF Group meetings
• Verification & Validation
activates for Control Centre
• Miscel. meeting/input
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Activity Plan
3D layout Review
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DECK (Utility, Process, Riser &
Flare modules);
Coarse Layout and WE Design
Review
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UTILITY MODULE;
Detailed Layout & WE Design
Review
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PROCESS MODULE;
Detailed Layout & WE Design
Review
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RISER MODULE;
Detailed Layout & WE Design
Review –
FLARE
Detailed Layout & WE Design
Review
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• WORKSHOPS;
• Detailed Layout & WE Design
Review
• LABORATORY
• Detailed Layout & WE Design
Review
• HULL:
• HULL Coarse Layout & WE
Design Review –
• Detailed Layout & WE Design
Review -
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Activity Plan
Specific analysis and reviews
• Coarse Chemical Health Risk
Assessment (Coarse CHRA)
of DECK and HULL
• WE Design Review;WIND AND
• Detailed Chemical HRA;
CHEMICAL SAMPLING
ARRANGEMENTS
• WE Design Review;ACCESS
TO EQUIPMENT, VALVES AND
INSTRUMENTS
• Detailed Chemical HRA;MEG
& TEG SYSTEMS
• WE Design Review;ACCESS
TO FLOODLIGHTS, LIGHT
FIXTURES, F&G, TELECOM
• Detailed Chemical HRA;
PIGGING OPERATIONS
• Detailed Chemical HRA;
CHEMICAL INJECTION
SYSTEMS
WEATHER PROTECTION
• ERGONOMIC ANALYSIS OF
MAJOR MANUAL WORK
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WE Package Follow-Up
BE: Bid Evaluation
DR: Design Review
PI/SI: Package/Site Inspection
Noise: Includes noise activity
• ER252 GAS COMPRESSORS(CENTRIFUGAL) – High priority
•BE DR PI Noise
•ER254 PROCESS & UTILITY PUMP – Medium priority
•BE Noise
•ER255 EMERGENCY & ESSENTIAL DIESEL GENERATOR – High priority
•BE DR PI Noise
•ER256 NITROGEN COMPRESSOR, AIR COMPRESSORS – Medium priority
•BE Noise
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Document Title: HSE Check List for Packages and Equipment
(NORSOK S-002, S-003 & S-005
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INTRODUCTION
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ABBREVIATIONS
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SURVEY OF EQUIPMENT AND HAZARDS
3.1 Checklist 1 - LISTING OF EQUIPMENT
3.2 Checklist 2 – GENERAL - SUMMARY OF HAZARDS AND RISKS
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ENVIRONMENTAL CARE (EC)
4.1 Checklist 3 – PLANNED EMISSIONS AND DISCHARGES (NORSOK S-003)
4.2 Checklist 4 – EXPECTED WASTE GENERATION (NORSOK S-003)
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WORKING ENVIRONMENT (WE)
5.1 WE Checklists
5.2 Checklist 5 - WE DOCUMENTATION RESPONSIBILITIES (TYPICAL)
5.3 Checklist 6 - HAZARD IDENTIFICATION AND JOB HAZARD ANALYSIS (JHA)
5.4 Checklist 7 - WE RISK ASSESSMENT (S-005 Annex E)
5.5 Checklist 8 - CHEMICAL INVENTORY (S-005 Annex F)
5.6 Checklist 9 - WE DESIGN REVIEW (S-005 Annex G)
5.7 Checklist 10: RISK ASSESSMENT FOR HEADROOM 1900-2100 MM AND
ACCESS WAY WIDTH 500-600 MM (ISO 14122-2)
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REFERENCES
ATTACHMENT 1: WE DESIGN BASIS (HIERARCHIC LISTING)
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WEATHER PROTECTION STUDY
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TABLE OF CONTENTS
1.
INTRODUCTION
1.1.
Purpose
1.2.
Scope
1.3.
Conditions
2.
ABBREVIATIONS AND DEFINITIONS
2.1.
Abbreviations
3.
WIND CHILL REQUIREMENTS
3.1.
Gjøa Working Environment Program
3.2.
Petroleum Safety Authorities (PSA) requirements
3.3.
STATOIL requirements
3.4.
NORSOK S-002 requirements
4.
WIND CHILL CALCULATIONS
5.
WEATHER PROTECTION EVALUATIONS
5.1.
Wind chill effects on personnel
5.2.
Evaluations of need for wind protection
6.
CONCLUSION AND RECOMMENDATIONS
6.1.
Recommendations
7.
REFERENCES
8.
ATTACHMENT 1: WIND CHILL CALCULATIONS
9.
ATTACHMENT 2: WIND PROTECTION WALLS (MARKED UP PLOT PLANS)
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WEATHER PROTECTION STUDY
• Wind Chill Index (WCI) has been calculated and
evaluated for typical work places on Topsides by a
methodology advised in NORSOK S-002.
• First local wind velocities have been calculated using
Computational Fluid Dynacics (CFD) code FLUENT on a
platform 3D-model inclusive first proposal for wind walls.
• Then the results of the wind calculations have been
combined with Gjøa field temperature data.
• The Wind Chill Index average is calculated for a year
and for the seven coldest months. See Attachment 1.
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WEATHER PROTECTION STUDY
• Based upon the WCI calculations and operational work tasks
evaluations in this report, 3 m high (40 % porosity) wind walls should
be included in the following areas. See marked-up plot plans in
Attachment 2.
• Lower Deck : Wind walls to be included on North and South at
periphery of central part of platform
• Tween Deck: Wind protection not required
• Main Deck : Wind walls to be included in central process module
North and South at platform periphery and for pig launcher area at
South/East
• Upper Deck : Wind walls to be included on all periphery of the area.
• Staircases : Wind walls to be included for all open staircases at
periphery of platform.
• At a later phase in the Project the WCI calculations should be
updated to include of the modified wind walls proposed in this report
and the wind walls arrangement re-evaluated.
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WEATHER PROTECTION STUDY
Calc.point
Area
WCI > 1000 W/m
[% in time]
2
Dominating wind direction
giving contribution to WCI >
2
1000 W/m
Annual
January
0.9
3.2
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SE, SW
main_wci4
0.5
0.5
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main_wci5
6.7
20.5
SW, S
S, SW
main_wci3
Separator area
Annual
January
main_wci6
MEG regeneration
2.3
8.9
SW, S
SW, S
main_wci7
Export
compr.scrubber
0.3
0.3
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-
main_wci8
Recompr.
scrubber
0.2
0.7
-
-
main_wci9
Fuel gas area
0.7
2.3
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SE
main_wci10
Flare area
2.3
5.6
SE
SE, N
main_wci11
Pig area
4.4
8.5
NE, SE
SE, NE, N
suction
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WEATHER PROTECTION STUDY
Figure 6-5: WCI at Main Deck with wind velocity 7.5 m/s from south, ambient
temperature 2.5°C at 1.5m above deck. Colour scale: 1200<WCI<400 W/m2
(Blue is cold and red is warm)
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Noise study report
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1.
INTRODUCTION
1.1.
Purpose
1.2.
Scope
1.3.
Conditions
2.
ABBREVIATIONS AND DEFINITIONS
2.1.
Abbreviations
2.2.
Definitions
3.
NOISE EVALUATIONS
3.1.
Noise Strategy
3.2.
Design Criteria
3.3.
Equipment Noise Control
3.4.
Other Noise Control Measures
3.5.
Living Quarter
3.6.
Hull Areas
4.
ESTIMATES OF AREA NOISE LEVELS
5.
DEVIATIONS / TECHNICAL CLARIFICATIONS
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CONCLUSION AND RECOMMENDATIONS
6.1.
Conclusion
6.2.
Recommendations
7.
REFERENCES
ATTACHMENT 1 – AREA NOISE AND VIBRATION LIMITS
ATTACHMENT 2 – ESTIMATED AREA NOISE LEVELS
ATTACHMENT 3 – SOME ACOUSTIC TERMS
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Noise study report
• Noise Strategy
– The Installation shall have an acceptable noise level within the
authority requirements. This implies that as-built measurements,
performed under platform design conditions, shall demonstrate
that personnel noise exposure requirements are within statutory
requirements given in PSA/SFT/NSHD – The Facilities
Regulations, § 22, and that area noise levels as a minimum are
within the limits as given in NORSOK S-002, rev. 04. For
process and utility areas shall 85 dBA apply as noise limit, and
an internal deviation request is needed if increased up to 90
dBA.
– Use of ALARP-principle. Where relevant, the selection of low
noise equipment shall be proritized utilizing the ALARP-principle.
09.02.2007
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Noise study report
– Project noise control activities shall be in accordance with
NORSOK S-002. Noise control is a multi-discipline activity with
line responsibility and shall be performed in accordance with
Annex H of NORSOK S-002, rev. 04. Noise control engineer(s)
shall be part of the project organisation throughout the project.
Noise control shall be included in all project phases, including
engineering, fabrication, commissioning and start-up of
production. Relevant design changes shall be checked with
respect to possible noise impact. The status for the noise control
activities shall be included in HSE meetings.
– Personnel noise exposure evaluations to be performed
Personnel noise exposure evaluations shall be performed as a
parallel activity to the work to fulfil area noise requirements. The
calculations shall be updated as a part of the noise predictions.
Company will provide relevant personnel matrix as basis for
noise exposure evaluations.
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Noise study report
– Procurement of packages shall be followed-up. Requirements to
equipment noise control and noise limits shall be included in
inquiry and Purchase Order documentation. All main equipment
shall be followed up including witnessing the performance of
noise test as part of Factory Acceptance Test. A cost-effective
equipment noise control design shall be aimed for.
09.02.2007
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Noise study report
Lp =
average sound pressure level in dB (ref. 20  Pa) at one meter distance,
free-field conditions over a reflecting plane
Lw =
sound power level in dB (ref. 1 pico W)
Table 3.1
Equipment Noise Level Limits – Long Lead Tagged Equipment
Package
Top Tag no
Description
ER 252
GAS
COMPRESSORS
23KZ001
1 and 2
23KZ004
LP/3 stage Compression Package
23CS050
3 stage/LP Compressor Lube Oil Console
09.02.2007
st
nd
stage Compressor Package
rd
rd
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Sound Limit, dBA
Lw = 100
Lp = 80
Lw = 100
Lp = 80
Lw = 95
Lp = 77
Noise study report
Table 3.2
Actual Equipment Noise Control Measures – Long Lead Tagged Equipment
Possible noise control measures
Package
Top Tag no
Description
ER 252
GAS
COMPRESSORS
23KZ001
1 and 2 stage Compressor
Package
23KZ004
LP/3 stage Compression Package
23CS050
3 stage/LP Compressor Lube Oil
Console
Low noise motors
27KZ001
Export Compressor Skid
Complete acoustic enclosure, skid on
vibration isolators
27XX060
Export Compressor Air Intake and
Ventilation System
Silencers. Acoustic duct lagging.
27CS050
Export Compressor Lube Oil
Console
Low noise motors
27CT011
Hydarulic Start Unit Export
Compressor
41HW300
Export Compressor Waste Heat
Recovery Unit and Exhaust
Assembly
09.02.2007
nd
st
rd
rd
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Complete acoustic enclosure, skid on
vibration isolators
Complete acoustic enclosure, skid on
vibration isolators
Silencers. Acoustic duct lagging.
Noise study report
Attachment 1: Area Noise and Vibration Limits Applying to Gjøa Semi
Area ID.
Area Type 5)
Noise Level in dBA
Project Total
Limit 3)
HVAC Limit
Vibration
Level
Category,
NORSOK S002 4)
Q114-04
Emergency generator
room
110
80 1)
3
Q114-05
Dehumidification unit
85
70 1)
3
Q114-06
Maintenance route N/S
80
70 1)
-
Q121-01
Air compressor room
85
70 1)
3
Q122-01
Maintenance route E/W
80
70 1)
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Q122-02
Goods lift (all levels)
80
70 1)
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Q122-03
Hot water heater area
85
70 1)
3
Q122-04
Air lock
80
70 1)
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09.02.2007
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Comments
Total limit is 85 dBA
when equipmnet is not
running.
Noise study report
Attachment 2: Estimated Area Noise Levels – Normal Platform Operating Conditions
Area ID.
Area Type 1)
TOTAL NOISE LEVEL IN dBA
LIMIT 2)
ESTIMATED
Q114-04
Emergency generator
room
85 / 110
65 - 70
Q114-05
Dehumidification unit
85
70 - 75
Q114-06
Maintenance route N/S
80
70 - 75
Q121-01
Air compressor room
85
85
Q122-01
Maintenance route E/W
80
75 - 80
Q122-02
Goods lift (all levels)
80
< 80
Q122-03
Hot water heater area
85
80 - 85
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Comments
105 – 110 when Emergency
Generator is in operation.
Noise level depending of lift type
Human Factors reports
• CCR Specification
• This report identified the functional design requirements
and concept for the xx Control Suite (Central Control
Room and adjacent areas) and shall provide the basis
for detailed design phase work. The requirements in this
document and the requirements given in the law, the
applicable regulations, recognised standards and other
project requirements together forms the xx CCR
requirements.
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Human Factors reports
• Situational Analysis of xxx CCR
• As xxx was to be closely based on yyy it was
important to gather operational feedback on how
well yyy is functioning in practice. The purpose of
this Situational Analysis was to document how the
CCR design on yyy is functioning and to ensure that
any features working well are reused on xx whilst
any that are not are improved in the xx design.
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Human Factors reports
• Functional Analysis of CCR
• The purpose of this document was to identify all the main
functions that the xxx control room is responsible for. The
main aim of the analysis during the FEED phase was to provide
input for the layout of the Central Control Room (CCR) and
surrounding area by clarifying the functions that they will be
involved in and ensuring that the goals and requirements for
these are accounted for in the layout
• The main focus for this report was Functional Analysis.
Functional Allocation was not conducted at this stage of the
design but shall be done early in Detailed Engineering.
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Human Factors reports
• Communication Analysis of CCR
• The purpose of this document was to identify the
main communication links for the xxx Central
Control Room.
• The analysis considered communication needs for
the main parties within the control room, those in
communication with the control room and the
frequency and the importance of the communication.
Both normal and emergency situations were
analysed.
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Human Factors reports
• Task Listing for CCR
• The purpose of this document was to list the main
tasks to be performed in the xxx CCR, to provide
information for the FEED Phase deliverables.
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Human Factors reports
• CRIOP 1 of CCR
• The purpose of the CRIOP process was to verify and validate the
design of the xxx CCR after the FEED phase work was in
accordance with a set of Human Factors requirements given in the
CRIOP checklists and also to ensure it meets best practice and
complies with project and agreed requirements (international,
national and regulatory). This work is seen as a part of requirements
in ISO 11064 Part 1 Ergonomic Design of Control Centres Scope.
• The analysis concentrated on the CCRs Layout and Work
Environment, as these are the main FEED deliverables. In addition
parts of the checklists for Control and Safety Systems that are
relevant for FEED Phase deliverables have also been applied.
Arbeidsmiljø i prosjekt HTS 15.03.2010 – Generell Yrkeshygiene – EVU - NTNU