Asset Integrity – Condition Reporting

Toolbox talk 1: Supervisor’s instructions

This toolbox talk is designed to:

• Help your team to identify potential or emerging problems in the condition of the plant and equipment

• Encourage your team to report equipment and plant in poor condition

• Ensure it is being appropriately dealt with

Carry out this toolbox talk before commencing a new task/job looking at condition.

Supervisors should also check to see if additional information and training is available from the local management team.

It is best to complete this talk in small groups – maximum ten people.

1) Give a copy of the photos on the Group sheet to your group.

2) Ask them to discuss the images and ask them if they have seen similar conditions on their site (five mins).

3) To support the discussion, describe the issues and their implications (see information below).

4) Ask what the team should do if they see any of these conditions or other examples of poor condition in the future (first step would be to report them to their supervisor).

5) Ask what other conditions they have seen that are not shown in the examples.

ASSET INTEGRITY

MAJOR HAZARDS AWARENESS

If you identify any specific gaps in knowledge or practice and for guidance on how to manage these, please contact Richard Carroll, Group Technical Authority for Corrosion and Materials – richard.carroll@bg-group.com

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AnswersToolbox talk 1: Supervisor’s instructions

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Cracked fitting?

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Misaligned flange

3

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? Corroded bolts Submerged pipe

1Significantly corroded bolts requiring replacement. Smaller diameter bolts are more likely to fail earlier through

corrosion than larger diameter bolts. It is important to identify corroding bolts (especially those hidden from normal view) so that their condition can be assessed, and appropriate and timely actions taken.

2Submerged Pipe. During construction, materials and equipment stored on site prior to installation must be preserved.

In this case, pipes should be securely sealed/ capped to prevent entry of water, sand or other foreign materials.

3Flange not made up properly. This may be due to problems such as misalignment, uneven tightening of bolts or bolts corroded

may detract from the flange. Whatever the cause this flanged joint is weaker than intended and may give rise to a leak; potentially leading to a fire or explosion.

4This fitting has a crack in it, possibly dropped or could be fatigue. Any fitting or other component that has a defect (such

as a crack, worn threads or poor finish) should be put aside and disposed of. Procedures for fitting new components or spares or the re-use of fittings, materials or bolts must be followed exactly.

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MAJOR HAZARDS AWARENESS