Tier: GL Doc Type: Form
Sub Element / Function: Risks and Impacts
Document Number: HSES-FM-ORA-212
Revision: A
Effective Date: 03-Feb-2021
Risk Assessment Form
Operational Risk Assessment (ORA), Risk Assessment (RA)
Last 4 Revisions
Rev. RDR Amendment Detail Reviewer Approver Effective Date
New Template
B K. Lant D. Kaminski 8-Nov-2022
Initial Release / Reviewed by ALS West Supervisor team April
A 2019 K. Lant D. Kaminski 11-Sep-2019
Copyright 2017- 2022 Baker Hughes Company. All rights reserved. The information contained in this document is company confidential
and proprietary property of Baker Hughes and its affiliates. It is to be used only for the benefit of Baker Hughes and may not be
distributed, transmitted, reproduced, altered, or used for any other purpose without the express written consent of Baker Hughes.
Uncontrolled when printed or transmitted electronically Baker Hughes – Company Confidential
_x000D_ Baker Hughes Confidential
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Operations Risk Assessment (ORA) HSES-FM-ORA-212
Effective Date: 08-Nov-2022 HSE-GLB-En-101697
Product Line : Cementing Services
Activity / Service Type : Cement Job Operation ( MIXING & PUMPING CEMENT SLURRY )
Required PPE:
(Personal Protective
Equipment) Hard hat, Impact Gloves, Safety Shoes, Safety Glasses, Googles And Hearing prot
Location :
Crew Members :
RL1 - Immediately Dangerous to Life or Health (IDLH), life critical, major environmental impact, process safety, major
injury, explosion, dropped object, loss of well control, loss of primary containment, major property damage greater than
$250,000 or a reliability and service delivery incident classified as High Impact.
RL2 - All remaining HSE risk not listed in RL1 and service delivery impacts can be viewed in the Reliability Assurance
NOTE: Risk Levels identified as "RL1" require a Stop Work until controls are in place to reduce the risk or impact. For "RL2"
Risk Levels, if controls cannot be implemented, the team must Stop Work and evaluate and implement new controls
Uncontrolle
Sequence of Job Controlled
Potential Hazards Control Measures d RISK
Steps RISK LEVEL
LEVEL
Pre Job safety Meeting Miscommunication. Prepare the JSA at work site with all involved crew.
Crew unaware about the task and Discuss the JSA and Work instruction with crew and
individual responsibilities. ensure a Cold Work Permit is issued for the cementing
job.
Ensure crew understand the task, individual
responsibilities. RL2 HSE Mitigated
Ensure crew aware about the hazards involved in the
task and the control measures.
Start the rig Bulk air Insufficient air for the operation. Rig mechanic to start the rig air compressor and
compressor and the Improper flow of cement leads to regulate the air to the cement silo to 60PSI.
regulate the system the cement line block. Use of appropriate hearing protection while working
with 60 PSI pressure High Noise. near air compressor. RL2 HSE Mitigated
Ensure all gauges are properly calibrated and working
good.
Fluff the silo 15 min Improper flow of cement or hard Ensure that the transfer facilities from the ‘P’-tanks to
prior to transfer the cement the cement unit are operating correctly with no
cement moisture in lines.
Ensure P-tanks have been fluffed with clear air prior to RL2 HSE Mitigated
transferring.
Check and verify the Improper line up. STOP , Make sure all valves are operated from the
cement transfer line up Visual damage in cement hoses remote valve control panels, 1 at the cement unit and
from cement silo to the connected to the unit. 1 in the cement silo room (either 1 can be used, but
unit including vent lines. ensure that valves are in closed position on the panel
not being used before using the chosen panel.
Rig Barge engineer to ensure that all the line up are
done correctly.
Open all line valves between the cement silos and the
T-Piece. Check with cementer that all the valves in RL2 HSE Mitigated
batch mixer unit is kept in open position (if using Batch
Mixer).
Page 2 of 6_x000D_ Baker Hughes Confidential
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Operations Risk Assessment (ORA) HSES-FM-ORA-212
Effective Date: 08-Nov-2022 HSE-GLB-En-101697
Rig up high / Low Motion - Struck by iron or Ensure FSR are properly restrained as per
pressure lines hammer, back strains, slips, trips, manufacturer manual. Use proper hand and body
falls, pinch points. placement while lifting and moving iron into position,
proper lifting techniques, use mechanical lifting
Temperature - Extreme heat or devices, proper PPE.
cold. Hydration, buddy system, use fans, stay in the shade.
Take breaks and/or alternate personnel on task.
Ergonomics - Repetitive motion, STOP and Visual check the cement supply hose and
fatigue, posture. make sure proper type of hoses is used ( bulk hose ) , RL2 HSE Mitigated
Ensure hoses are in good condition , laid out the hose
and avoid loop.
Review Standard Job not pumped according to Read the entire procedure prior to commencing any
OPS-GLB-EN-PP_100032 Baker Hughes standards, Field work. Ask the District or Project Engineer, if any clarity
2.4.6 Job Execution for Specialist not have access to is required. Read the MSDS for each additive and
Offshore Cementing Standards. ensure correct PPE is available and used.
Operations It is critical to the performance of cement
slurries, spacer systems and other associated fluids RL2 HSE &
Eliminated
that they are mixed accurately according to the given Quality
design and procedures.
OPS-GLB-EN-PP_100032.pdf
Inspecting the cement Incomplete inspection of cement A copy of the specific check sheet for the cement unit
unit unit, Reduces the reliability of the onboard will be completed at the work area this will
equipment. be required for each job. Each item that is marked
unsatisfactory will be repaired before mixing and
pumping cement. If repairs cannot be completed
before the next job, contact your supervisor and AMO
to mitigate the risk involved.
Form 1013 Seahawk Check List RL2 Quality Mitigated
Form 1001 35-8-5 Check List
Form 1004 348 SCM 348
Mixing fluids in rigs mud Contaminations of fluids Create a plan with those in charge of the pit system,
pits. OPS-GLB-EN- Loss of fluids due incorrect valve the mud company or rig crew, for cleaning the pit used
PP_100032 2.4.6 Job line up for the Baker Hughes fluid
Execution for Offshore Mixing water becoming heated. Remove all mud residue from the pit and the lines
Cementing Incorrect volume used/mixed feeding it. Contact the responsible technical
Operations Poor communications. representative for further assistance with planning.
Skin or eye irritation, burns or Always ensure pits are thoroughly flushed with fresh
poisoning. water before preparing cement-slurry mix fluid.
Wrong body posture resulting in Verify the volume in pit after mixing, use rig marking
spine injuries. system to mark the level.
Personnel injuries due to slips , Ensure the valves to adjacent pits are sealed
trips or falls. correctly, place Lock-Out/Tag-Out signs on the valves RL2 Quality Mitigated
to prevent opening the wrong mud or chemical-pit
tank.
Be aware of fluids heated by adjacent active pit
Verify volume used after job.
Ensure using relevant PPE as per MSDS.
Prime pumps and Prime cement unit as per the Cementing Seahawk
mixing system. Skid Operating Manual, version 1.1 RL2 Quality Eliminated
Page 3 of 6_x000D_ Baker Hughes Confidential
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Operations Risk Assessment (ORA) HSES-FM-ORA-212
Effective Date: 08-Nov-2022 HSE-GLB-En-101697
Pressure Test All Pressure - High Pressure on all STOP And Ensure PTW is issued and revised with ORA
Lines lines being tested, possible over and STP form.
pressure. Certified and properly calibrated PRVs.
Cementer to have valid FSR Training certificate.
Possible lines/connections burst. Ensure proper valve alignment prior to testing lines.
Set over-pressure shutdowns on cement unit.
Set Pressure Relief Valves (PRVs) to not exceed MAWP.
Stay clear of all pressurized lines. No hammering on
lines under pressure. Make sure Pressure is zero
confirmed by the gauge and keep the valve open
before hammering any line. RL1 HSE Mitigated
Verify on chart recorder and gauge that pressure is at
ZERO psi prior to testing.
Barricade area and make announcement of high
pressure testing.
Batch Mode. Incorrect cement slurry density Achieve the designed slurry density in batch mode
ACC not programed with correct before mixing downhole on the fly.
values. Review program settings and check against the Lab
Cement on skin, face and in eyes. Report (yield, mixing fluid, density) check DCV it should
High noise level from cement unit open to 45% in batch mode.
engines and hydraulic system. Verify density with pressure mud scales only, use mud
scales as per manufactures user manual.
Check calibration on pressurized mud scales before
the job with bottle water. RL2 HSE &
Eliminated
Quality
Personnel weighing cement will wear facesheild,
goggles, and rubber gloves.
Proper hearing protection is to be worn while in high
noise level area.
Transfer the cement Miscommunication. STOP and Ensure the cementer had good
from rig Silo to Poor cement delivery. communication with Barge Engineer through out the
concerned unit. Excess delivery of cement from silo cement transfer. Open the purge air valve to clear any
to concerned unit. residue cement from the line and to establish a vent
Cement block inside the line. from the unit.
High Noise Once a good vent has been establishes from the unit
Respiratory Hazard. and line confirmed clear of any obstruction, stop purge
air and await further instruction.
Barge Engineer to monitor the cement silo weight
indicator to maintain a consistent reading
predetermined by the cementer.
Do not operate any valve with out prior permission or RL2 HSE &
proper communication with Barge Engineer and Quality
Mitigated
cementer.
Use appropriate hearing protection.
Use respiratory protection as per MSDS.
Ensure the MSDS is available in cement unit.
Page 4 of 6_x000D_ Baker Hughes Confidential
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Operations Risk Assessment (ORA) HSES-FM-ORA-212
Effective Date: 08-Nov-2022 HSE-GLB-En-101697
Mixing and pumping Incorrect cement slurry density If slurry density is below design, check surge tank level
cement slurry on the ACC not programed with correct and pressure, adjust pump rate if surge tank level is
fly. OPS-GLB-EN- values. low. If surge tank pressure is low check rig air supply.
PP_100032 2.4.6 Job Poor cement delivery to Surge Review ACC programed values before starting the
Execution for Offshore Tank, TEM packing off. job. Poor cement delivery from rig, decrease pump
Cementing Erratic slurry density. rate until rig can sort out their issues.
Operations Low Slurry pump pressure. Seahawk manual control valve will be kept
Changes in pump pressure or 100% in the open position to prevent the decrease in
pump rate during job. bulk cement flow to the TEM, the manual bulk cement
valve will not be used to meter bulk cement to the
TEM. Verify slurry density using
pressurized mud scale, mud scales will be used
according to the manufacture user manual, Field
Specialist will verify slurry density and that pressurized
mud scale are used correctly. To reduce RL1 Quality Mitigated
the risk of the TEM packing off monitor any changes in
the DCV position and decrease in slurry pump
pressure. Monitor pump pressure during job, record
any changes, record time, and volumes.
Cementing Seahawk Skid Operating Manual,
version 1.1
Mixing & Pumping Not recording density from batch Check the density of each slurry with a pressurized
cement from batch mixer mixer, spike in density on Job mud balance at the beginning, middle and end of the
Master chart. mixing process, as a minimum. On Seahawk units the
cement slurry will be pump through the Mass Flow
Over weighted the slurry Meter, to record density from batch mixer. Discharge
hoses from batch mixer to cement unit will be primed
with cement prior to pumping.
While stop mixing to check the density weight , make
sure the cement supply line is flushed before closing
the air valve and the batch mixer valve ( DO NOT
CLOSE THE VALVE BEFORE INFORMING BARGE
ENGINEER )
Consider the dry cement volume inside supply line in
your slurry calculation.
If you reached the desired density and you still have RL1 Quality Eliminated
dry cement in the supply line. DO NOT CLOSE the batch
mixer valve without informing the Barge engineer .
communicate with him and let the bulk system
completely CLOSED then you can flush the line after
the job and during washing equipment operations
Page 5 of 6_x000D_ Baker Hughes Confidential
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Operations Risk Assessment (ORA) HSES-FM-ORA-212
Effective Date: 08-Nov-2022 HSE-GLB-En-101697
Displacing Cement. OPS- Loss of returns, data not recorded, Monitor the returns and relay the information to the
GLB-EN-PP_100032 incorrect volumes pumped, rig Field Specialist during the operation.
2.4.6 Job Execution for displacement incorrect, Float Use Job-Master to record all major job
Offshore Cementing equipment not holding. Foreman events on the treatment report and graphs.
Operations not kept updated on volumes The pump-barrel counters
pumped. Plug not bumped. may not accurately reflect the exact volume of fluid
pumped. When displacing, always determine the fluid
volumes from the cement unit inventory, or
displacement, tanks.
Alert the customer to significant changes in pressure,
rate, or density and indicate when changing from
slurry to slurry.
When using the rig pumps for displacement,
the Field Specialist must be on the rig floor to monitor
the displacement and witness the landing or bumping
of the top plug. RL1 Quality Mitigated
Once the top plug has
bumped or displacement has ended, check for
backflow of displacement fluid to ensure floats are
holding.
Monitor the volume returned. Discuss with
company representative a plan to pump the backflow
volume into the casing and the amount of pressure to
trap in the casing.
Take into account the calculated
differential pressures and the shoe-track volume or
wait until the cement has taken an initial set before
rechecking the backflow and rigging-down the cement
head.
Batch mixing cement- Trapped pressure presenting risk Bulk supply lines to be cleared utilizing procedure
Blockage in Bulk supply of sudden release and in turn outlined in Doc. Procedure for clearing blocked bulk
line. uncontrolled hose movement and cement lines offshore. Correct PPE to be utilized
discharge of cement. Personal including goggles and face mask. Lines need to be
Injury and property damage. methodically checked for trapped pressure. whip
Pressure up the cement delivery checks to be utilized as per procedure. Restriction of
line due to pumping air against personnel movement in designated work area.
closed valve on batch mixer Isolation of potential energy sources.
STOP , keep clear and constant communication with
Barge Engineer
NEVER close the cement delivery line on the batch
mixer before informing the Barge Engineer. Verify with RL1 HSE Mitigated
the Barge Engineer to make sure that the bulk system
is closed completely ( dry cement and air supply lines)
Over board vent remained open at all times.
Clearing Operations Unintended pressurization of Never close the cement delivery line on the batch
system during line clearing mixer before informing the Barge Engineer. Verify with
operations the Barge Engineer to make sure that the bulk system
is closed completely ( dry cement and air supply lines)
RL1 HSE Mitigated
Over board vent remained open at all times
Manual handling Manual handling risk. Correct manual lifting procedure when handling hoses.
Ensure safe practices when ascending and descending
batch mixer. No handling of loads over 25 KG without
supervisor approval and a lifting plan for mechanical
lifting. RL1 HSE Mitigated
STOP ! Don't climp the batch mixer ladder caring load
in hands
Page 6 of 6_x000D_ Baker Hughes Confidential
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