Revamps 2024 Issue

Existing philosophy of installation at site

Internal vendor

Figure 1 Cartridge tray installation requiring crane support

through column flanges after erection of the column in a vertical configuration. HSE on-site: HSE management plays a critical role in ensur - ing the well-being of personnel in the oil and gas sector. This importance is heightened during the refinery construction phase, where workers face a range of challenges and poten - tial risks. Some of these key aspects include: a) Safety measures: Proper safety protocols are crucial to prevent falls and accidents during work at height. b) Confined spaces: A confined space encompasses various enclosed areas, including columns, vessels, tanks, contain - ers, pits, bunds, chambers, and cellars. These spaces create conditions that are prone to risk of accidents, harm, or injury. c) Work-at-height and permit requirement: When work - places are elevated at more than two metres (approxi - mately 6.5 ft), a work-at-height permit becomes necessary. This applies to tasks involving ladders, scaffolds, mobile elevated work platforms (MEWPs), or any work performed above ground level. d) Emergency action: Emergency procedures are essential due to the presence (or foreseeable presence) of: • Flammable or explosive atmospheres • Harmful gases, fumes, or vapours • Free-flowing solids or rising liquid levels • Excessively high temperatures • The lack (or foreseeable lack) of oxygen. Vigilance, training, and adherence to safety protocols are paramount to safeguard workers and mitigate risks in these challenging environments. e) HSE challenges with cartridge tray installation: Installing cartridge trays is inherently challenging. Cranes with extended arms are employed to lift the cartridge trays to ele - vated heights above the column flanges (see Figure 1 ). Workers must stand on temporary scaffolding platforms to guide the bundles into the column. These makeshift plat - forms must adhere to HSE standards, with proper checks to ensure personnel safety. Despite safety precautions, scaf - foldings remain susceptible to failures and accidents. The suspended load of trays hanging from the crane poses a risk

Figure 2 Column mismatches occurring between tray vendor and actual installer concerning cartridge trays

to workers below. Workers wear personal protective equip - ment (PPE) and safety harnesses while working at height. Crane selection has to be based on the loading requirements specified in the load chart to ensure safe operation. The challenge amplifies when either column or cartridge tray bundles are fabricated outside the respective tolerance range, which makes trays oversized or undersized compared to the column shell. If the tray bundle becomes stuck inside the column due to size discrepancies, in-situ modifications to either the column or trays are necessary. These modifica - tions transform an already high-risk installation practice into a cumbersome and hazardous task. When modifications are necessary inside the column, a worker must be lowered down into the erected column using a crane or other means. Their objective is to grind off excessive material inside the shell (typically welding beads that escaped the ground flushing operation in workshops). Unfortunately, this activity can expose workers to toxic fumes and fine metal dust within the confined space, posing a significant health hazard. Moreover, the position of work - ers at such elevated heights creates an additional safety risk. Ensuring their safety during these critical tasks is paramount. Measures to be taken during different project phases for smooth cartridge tray installation a) Column configuration: Finalising the column configuration is the first and most critical step for columns

Revamps 2024