The process of completing a risk assessment. Understanding the difference between probability & severity, and techniques for risk mitigation.
Engineered touchpoint access, though essential for maintaining pipeline integrity, presents inherent risks that must be carefully identified and mitigated to ensure personnel safety, protection of the environment, and operational efficiency. In this section, we delve into the various risks associated with engineered line lifting of in-service piping, methods for grading the severity of each risk and explore strategies for effectively mitigating these risks.
5.1 Risk Identification
The first step is risk identification. Before embarking on any line lifting operation, it's crucial to discuss each step of the process to identify all the potential risks and hazards of the job, and their associated consequences. This can include the following:
5.1.1 Equipment and Structural Integrity Risks:
Overloading of Ovolifts pipe rack jacks leading to structural failure.
Excessive bending or deformation of the pipeline during lifting.
Damage to pipeline coatings or protective layers.
Damage to connecting equipment during lifting
5.1.2 Environmental Risks:
Spills or leaks (loss of containment).
Disturbance of surrounding habitats or ecosystems during lifting operations.
Potential for contamination of soil or water sources in the vicinity.
5.1.3 Injury to personnel:
Slips, trips, and falls during lifting activities.
Manual handling of heavy equipment.
Pinch points between moving components and equipment.
Dropped objects when working at heights such as in a pipe rack.
Loss of containment. Personnel exposure to hazardous materials or substances within the pipeline.
5.1.4 Operational Risks:
Delays or disruptions to regular operations caused by unforeseen issues during lifting.
Equipment downtime or breakdowns impacting project timelines and budgets.
Inadequate planning leading to inefficiencies in lifting procedures.
5.2 Risk Severity
Severity, in this context, refers to the potential consequences or impact of a risk event. It is often quantified in terms of the magnitude of harm or damage (consequence) that could occur if the risk were to materialize (probability). Understanding risk severity involves evaluating both the probability of occurrence and the potential consequences, as risk severity is typically calculated as the product of these two factors.
5.2.1 Probability of Occurrence
The Probability (P) of a risk event refers to the likelihood or chance that it will occur during the lifting operation. Assessing probability involves considering various factors such as the complexity of the lifting task, the competency of personnel involved, the condition of the pipeline prior to lifting or the uncertainty thereof and external factors like environmental conditions.
By evaluating these factors, we can more accurately determine the likelihood of specific risk events and prioritize their mitigation efforts accordingly.
P- Probability
Value | Event Probability | Likelihood of the event happening |
5 | High - Almost certain to happen | Common or repeating occurrence |
4 | Significant - Likely to happen | Known to occur or ‘has happened before’ |
3 | Medium - Possible to happen | Could occur or has ‘potential to happen’ |
2 | Remote - Unlikely to happen | Not likely to occur in system life cycle, but it is still remotely possible to happen |
1 | Improbable - Rare- Acceptable | Practically impossible, so unlikely to occur it can be assumed it may never happen |
5.2.2 Consequences or Impact
Consequence (C), on the other hand, describes the potential outcomes or effects of a risk event. This includes both the immediate impacts, such as injuries, damage to equipment, or environmental contamination, as well as long-term consequences like financial losses, reputational damage, and regulatory penalties. Understanding the potential consequences allows organizations to gauge the severity of a risk event and allocate resources to mitigate or prevent its occurrence.
C - Consequence
Value | Severity | Personal Injury (PI) | Environmental (E) | Financial (F) |
5 | Catastrophic | Fatalities, permanent/ partial disability, serious or long term effect | Massive effect- immediate severe/ long term harm to environment | Extensive damage, project/ plant halted indefinitely, >$200,000 in costs and consequential losses |
4 | Major | Major injury, LTA affecting work performance, restricted duties etc | Major effect, will require extensive external assistance/ expertise to control | Major effect on work schedule/ total shutdown of production, damage and losses $50,000 to $200,000 |
3 | Moderate | Minor injury, recordable MTC | Localized impact of known toxicity, repeated breach of prescribed limits | Noticeable effect on work schedule, partial shutdown, asset damage/ consequential loss $20,000 to $50,000 |
2 | Minor | First aid, slight injury not affecting work performance | Minor impact- immediate containment/ control, single breach of limits | Brief disruption, minimal effect on schedule, asset damage/ consequential loss $1,000 to $20,000 |
1 | Insignificant | Minimal risk of any injury | Zero impact, contained within existing systems and controls (in-house) | No effect on plant/ schedule, asset damage/ consequential loss less than $1,000 |
5.2.3 Calculating Risk Severity
Risk Severity (S) is commonly expressed as the product of probability and consequence. This quantitative approach provides a systematic way to prioritize risks based on their potential impact. By assigning numerical values to probability and consequences (e.g. on a scale of 1 to 5), organizations can calculate the risk severity using the following formula:
(R) Risk Severity = (P) Probability x (C) Consequence
By multiplying the probability and consequences scores, organizations obtain a numerical value that represents the overall severity of the risk. This value serves as a basis for prioritizing risk management efforts, with higher severity risks warranting more attention and resources to mitigate or eliminate them.
S - Severity
1-5 = Acceptable Severity | 5-10 = Low Severity | 10-15 = Moderate Severity | 15- 20 = High Severity | 20- 25 = Critical Severity |
Proceed with caution | STOP - Address onsite via controls - involve Client Supervision etc. | STOP - Must be referred to Project Supervisor / Engineer | STOP! Consider ‘Do Nothing Option’ | STOP! Consider ‘Do Nothing Option’ |
5.2.4 Importance of Risk Severity Assessment:
Assessing risk severity enables organizations to make informed decisions regarding risk management strategies. By prioritizing risks based on their severity, organizations can allocate resources effectively, implement targeted mitigation measures, and focus on addressing the most significant threats to safety, operational integrity, and environmental protection. Moreover, understanding risk severity facilitates communication and collaboration among stakeholders, ensuring that everyone involved in the lifting operation is aware of the potential risks and their implications.
In conclusion, risk severity assessment is a critical aspect of engineered touchpoint access, allowing organizations to prioritize risks based on their potential impact and allocate resources to mitigate them effectively. By evaluating both the probability of occurrence and the consequences of risk events, organizations can make informed decisions to safeguard personnel, protect assets, and ensure the successful execution of lifting operations.
5.3 Risk Mitigation
To effectively manage the risks associated with line lifting on in-service piping, a proactive approach that integrates safety measures, robust planning, and adherence to industry best practices is essential. Here are some key strategies for mitigating risks:
5.3.1 Engineering:
A Pipe Stress Analysis is a very effective method of ensuring pipeline integrity when the pipe is lifted. It allows one to model the piping geometry using actual operating conditions to evaluate various lift heights (deflections) and the impact this has on pipe stress.
A Lift Plan follows from a stress analysis and it’s essential for calculating lifting loads are within limits of the pipe rack jacks. A Lift Plan also documents the jack configurations and bending moment calculations of the lifting equipment to ensure these are within safe limits.
Lastly is a Method Statement that provides a step by step procedure for handling and operating the pipe rack jacks to both lift and lower the piping that conforms to both the Lift Plan and Pipe Stress Analysis.
5.3.2 Training and Education:
Provide training for personnel involved in line lifting operations, emphasizing safety protocols, equipment handling, and emergency procedures. This ensures personnel are competent to both handle and operate Ovolifts equipment, and also ensures they understand how to read and interpret a Method Statement.
5.3.3 Equipment Inspection and Maintenance:
All lifting equipment must be visually inspected for signs of wear, damage or malfunction prior to mobilization. For longer duration projects the visual inspection intervals should be on a weekly basis.
All hydraulic equipment must be pressure tested to the rated pressure of each component prior to mobilization and at least once per month during projects.
Ovolifts pipe rack jacks are load tested at 2x their rated capacity on a yearly basis to ensure their reliability during lifting operations.
5.3.4 Personal Protective Equipment (PPE)
All persons on site must have basic PPE (hard hat, safety glasses, FR coveralls, gloves and hearing protection). Basic PPE is sufficient for handling and assembling Ovolifts pipe rack jacks but additional PPE should be considered during lifting operations which can include a supplied air respirators with a full facepiece to provide fresh air in the event of a release of product.
5.3.5 Non-Destructive Testing (NDT)
A comprehensive risk mitigation strategy for pipe lifting devices includes conducting thorough inspections before the lift, especially on older piping where the remaining wall thickness is a concern. NDT testing is a helpful tool that’s used to assess the pipe’s condition to provide a level of confidence that it can safely undergo lifting without the risk of opening a leak at the pipe touchpoint. Additionally, in cases where there is significant wall loss, these NDT measurements can be used in the Pipe Stress Analysis for a more accurate calculation of pipe stresses during lifting.
5.3.6 Inspection and Safety:
Inspection crews equipped with gas sniffing devices can detect potential leaks during lifting operations. After identifying the services of all piping to be lifted, these teams continuously monitor the area for any release of these hazardous products, especially during the critical breakaway lift, where even small leaks can pose significant safety risks.
In addition, having safety crews on standby such as fire response is essential to respond immediately in case of an emergency. This combination of inspection and safety crews ensures that any issues can be quickly addressed, reducing the risk of accidents.
5.3.7 Procedures - Stress Free Lift
In situations where the calculated pipe stress for a given lift height exceeds allowable limits according to certain piping codes, a technique known as a "stress-free lift" can be employed. Rather than lifting the pipe at a single point, which is typically at the support needing repair, two adjacent lift points are used.
By carefully selecting the placement of these points and lifting them to prescribed heights, the required clearance at the target support is still achieved without imposing additional stress on that location, ensuring the integrity of the pipe during the lift.
5.3.8 Procedures - Remote Breakaway Lifts
In some cases significant wall loss at the pipe touchpoint may result in exposing or creating a leak during the lifting event when the pipe lifts away from the support. When taking the line out of service is not an option, in-service lifting becomes necessary, but it must be done with strict safety protocols. The most critical stage is the breakaway lift, where the pipe first separates from the support. This step should be performed remotely to keep personnel at a safe distance. Once the area is deemed safe, crews can proceed with lifting to the required height that allows crews to complete their inspection and repairs.
5.3.9 Procedures - Jiffy Clamps Pre-fitted
As a final safety measure it is possible to have a jiffy clamp or other band clamp pre-fitted to the pipe adjacent to the touchpoint such that in the event of a leak it can quickly be slipped into place and secured to contain the leak. This is an acceptable method of containment for certain types of products so it is important to be aware of the service in each line being lifted prior to lifting.
5.4 Emergency Response Planning
A critical component of Ovolifts' methodology is consulting with the contractor or operator on the implementation of robust emergency response measures to safeguard personnel, equipment, and facilities during lifting operations.
5.4.1 Emergency Response Preparation
Portable water cannons can be strategically deployed near touchpoints to provide rapid and targeted responses in the event of a leak or fire. These cannons are connected to nearby fire hydrants via fire hoses, ensuring immediate access to a high-pressure water supply. Each lifting operation is closely monitored by a representative familiar with the contents of the pipelines being lifted, ensuring real-time decision-making tailored to the specific circumstances of the operation.
5.4.2 Operational Oversight and Communication
The on-site operator maintains constant communication with the operations team via radio and oversees the lifting process. In case of an emergency, such as a leak, the operator is responsible for activating water cannons and coordinating an isolation or emergency shutdown if necessary. This centralized control ensures quick, effective responses to mitigate risks.
5.4.3 Risk Assessment and Response
The presence of knowledgeable personnel allows for the immediate evaluation of potential leaks, the identification of associated risks, and the determination of appropriate responses. For example, a minor leak in a cooling water line may pose minimal risk, whereas a hydrocarbon leak could present significant hazards requiring more extensive emergency measures.
5.4.4 Personnel Safety
All personnel involved in lifting operations are equipped with 5-minute escape packs containing full-face respirators that provide a fresh air supply, enabling safe evacuation in the event of a hazardous leak. Leak sealing teams are stationed nearby with respirators connected to larger air supplies, allowing them to re-enter the affected area and perform leak containment using pre-fabricated mechanical enclosures.
5.4.5 Leak Containment
Leak sealing methods include the use of clamps designed to the exact specifications of the affected piping. These clamps are bolted into place and injected with a sealant, effectively closing gaps without necessitating a shutdown. This approach ensures operational continuity while addressing leaks in a timely and controlled manner.
5.4.6 Mitigating Operational Risks
To further mitigate risks, the locations of all isolation valves are identified and confirmed to be accessible before lifting operations commence, allowing for rapid isolation of affected lines if required. For situations where isolation is not possible, a controlled shutdown plan is developed and ready for implementation.
5.4.7 Strategic Considerations for Live Line Lifting
While the potential for loss-of-containment during live lifting is a valid concern, addressing compromised touchpoints under controlled conditions with a well-prepared response team and resources on-site is a more effective strategy than postponing maintenance. Pipelines prone to leaks during lifting operations are likely already at risk of failure under normal conditions, underscoring the importance of proactive intervention.
5.4.8 Economic and Operational Context
Many aging facilities schedule turnarounds every two to four years, leaving limited opportunities to address widespread touchpoint corrosion. Extending turnarounds or replacing entire pipelines introduces significant economic and operational pressures. Consequently, employing safe and controlled live lifting practices becomes a cost-effective and efficient method to address critical maintenance needs while minimizing production losses.
By adhering to these methodologies and incorporating comprehensive safety and emergency response measures, Ovolifts ensures the integrity of pipeline systems while balancing operational efficiency and risk mitigation across diverse projects.
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