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


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.



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.



Which operations are going to be considered in this assessment?

Loading Operations Transit Operations Discharging Operations Tank Cleaning Operations Spill Response Operations



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.


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.


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.


Hazard & Potential Accident Identification (STEP #3a)Product Ship Conversion to Carry Benzene

CargoOrders

LoadingCargo

Transport& StorageActivities

CargoDischarge

TankCleaning

Establishing Flow Chart of operations


Hazard & Potential Accident Identification (STEP #3b)

Cargo Orders:

1. Load cargo into tanks 4 port and starboard




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




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




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



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



Voyage Activities:

1. Open house ventilation2. Start IG blower3. Vent tanks




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



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




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



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




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




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




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




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




Voyage Activities – Hazards:

1. Venting exposures on deck2. Unauthorized personnel on deck3. House ventilation not on recirculation while venting




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




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




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




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


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.


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


Assign Frequency Ratings, Consequence Ratings & Risk Priorities ( Steps 4,5 & 6 )


Utilizing the scales in Steps #4 and #5 and the matrix in step #6, the following chart was developed


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



H

M

M

L

VH

VH

H

3

2

2

2

5

5

5

3

4

3

2

4

4

2




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.


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



4

4

3

3

4

3

2

VH

VH

H

H

M

M

L

5

5

5

3

2

2

2


Assign Frequency Ratings, ConsequenceRatings & Risk Priorities ( Steps 4,5 & 6 )


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.


Development of Countermeasures (STEP #7)


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




Intervene before the INCIDENT.Sampling training.Modify sampling procedure.New sampling system.


Inadequate


Impropersampling

Reportableexposure

Employeerequires






Intervene before the ACCIDENT.Hazardous materials training.New hazardous materials handling procedure.Upgrade PPE.


Inadequate


Impropersampling

Reportableexposure

Employeerequires






Intervene before the CONSEQUENCE.Refresh medical notification.Notify medical department;Upgrade PPE.


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



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.



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.


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 -


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


ProposedCountermeasure

EstimateEffectiveness

CostEstimates

OverallScore

FocusHazard ÷ =

Decision : Choose the countermeasures with the highest Benefit-cost rations

123456

123456

A-

B-


Documents

Ships in Service Training Material A-M CHAUVEL Risk Assessment Case Study Product Tanker