Professional Documents
Culture Documents
S-005
Rev. 1, March 1999
Provided by Standard Online AS for Universitetsbiblioteket i Stavanger 2014-05-16
This NORSOK standard is developed by NTS with broad industry participation. Please note that
whilst every effort has been made to ensure the accuracy of this standard, neither OLF nor TBL or
any of their members will assume liability for any use thereof. NTS is responsible for the
administration and publication of this standard.
Telephone: + 47 22 59 01 00 Fax: + 47 22 59 01 29
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Machinery - Working Environment Analyses and Documentation S-005
Rev. 1, March 1999
CONTENTS
FOREWORD 3
1 SCOPE 4
2 NORMATIVE REFERENCES 4
3 DEFINITIONS AND ABBREVIATIONS 4
3.1 Definitions 4
3.2 Abbreviations 5
FOREWORD
NORSOK (The competitive standing of the Norwegian offshore sector) is the industry
initiative to add value, reduce cost and lead time and eliminate unnecessary activities in
offshore field developments and operations.
The NORSOK standards are developed by the Norwegian petroleum industry as a part of the
NORSOK initiative and supported by OLF (The Norwegian Oil Industry Association) and
TBL (Federation of Norwegian Engineering Industries). NORSOK standards are administered
and issued by NTS (Norwegian Technology Standards Institution).
1 SCOPE
This NORSOK standard addresses methods for working environment analyses and
documentation of machinery according to machinery regulations and the normative references.
The methods may also be used for other technical products having similar hazards.
The scope and objectives of this standard are elaborated in Annex A1.
2 NORMATIVE REFERENCES
NS-EN 292 Part 1 Safety of machinery - Basic concepts, general principles for design - Part 1:
Basic terminology, methodology
NS-EN 292 Part 2 Safety of machinery - Basic concepts, general principles for design Part 2:
Technical principles and specifications (as amended)
NS-EN 1050 Safety of machinery - Principles for risk assessment
NORSOK S-002 Working Environment
3.1 Definitions
etc., joined together for a specific application, in particular for the processing, treatment,
moving or packaging of a material.
- An assembly of machines which in order to achieve the same end, are arranged and
controlled so that they function as an integral whole.
- Interchangeable equipment modifying the function of a machine.
Safety data sheet: Documentation of the safety, health and environment hazards of a
Shall: Verbal form used to indicate requirements strictly to be followed in order to conform to
the standard and from which no deviation is permitted, unless accepted by all involved parties.
Should: Verbal form used to indicate that among several possibilities one is recommended as
particularly suitable, without mentioning or excluding others, or that a certain course of action
is preferred but not necessarily required.
Sub-assembly: A machine that cannot function independently, and that is intended for
incorporation into machinery.
3.2 Abbreviations
PO Purchase Order
WE Working environment
4 RESPONSIBILITIES
The following responsibilities apply with respect to execution of analyses and delivery of
working environment (WE) documentation for machinery:
4.1 Contractors
The responsibilities of a company working for Client according to contract are described
below. Various contract strategies may apply, including engineering, procurement,
construction, installation, and/or commissioning. Typical deliveries from principal contractors
are offshore platforms, pipelines, and sub-sea installations. A principal contractor may use
various sub-contractors. Typical deliveries from sub-contractors are living quarters, drilling
modules, and process modules.
For each subject machinery within Contractors scope of work, the Contractor shall ensure
that the boundaries of machinery and sub-assemblies and the responsibilities for issue of
statutory declarations and indicators (e.g. instructions, CE-marking) are defined. Further, the
Contractor shall ensure that the requirements for WE documentation are determined and
specified in sub-contract and/or Purchase Orders (POs); cf. clause 5.
4.2 Suppliers
Supplier of machinery is responsible for the safety of the machine and for providing the
Declaration of Conformity and the Instructions issued according to machinery regulations;
cf. clause 5.1. Further, the Supplier shall ensure that the necessary WE analyses of subject
machinery are executed and documented.
As specified in sub-contract or PO, the Supplier shall compile and provide the required
technical WE documentation; cf. clause 5.
Supplier of sub-assembly is responsible for the safety of the sub-assembly and for providing
the Declaration of Incorporation issued according to machinery regulations.
As specified in PO, the Supplier shall provide the documentation necessary to demonstrate
conformity with machinery regulations, normative standards, and other WE requirements.
5.1 General
As stipulated in the Machinery regulations, subject machinery shall bear CE marking and the
following documentation shall be provided:
Declaration of Conformity.
Instructions for safe use, etc. Instructions for regular use and maintenance by operators
shall be in the Norwegian language.
A method for risk assessments during design of machinery, based on the principles of NS-EN
292-1 and NS-EN 1050, is described in more detail in clause 6 of this standard.
The risk assessments of machinery shall be documented in risk assessment reports, providing
information about any:
dangerous manual tasks / interactions; cf. clause 6.5
hazards and hazardous situations / events; cf. clause 6.6
risk estimates; cf. clause 6.7
safety measures in design and/or operations; cf. clause 6.7
In addition to the risk assessment method described in clause 6, there may be needs for special
methods to analyse hazards and estimate risks of complex and/or safety critical machinery.
Methods outlined in NS-EN 1050 and NORSOK S-002 are referred to, e.g.:
Failure Mode and Effects Analysis (FMEA) or Fault Tree Analysis (FTA), to document
reliability of control and safety systems; cf. NS-EN 1050 Annex B;
Ergonomic job / task analysis, to document risks of muscle-skeletal injuries; cf. NORSOK
S-002 clause 4.9.4 and Annex I.
Crisis Intervention in Offshore Production (CRIOP) analysis, to document man-machine
interface of control rooms; cf. NORSOK S-002 clause 4.9.5 and Annex I;
Chemical handling analysis, to document risks of exposure to hazardous chemicals; cf.
NORSOK S-002 clause 4.9.6 and Annex I.
Design reviews are required to verify conformity with the specific WE requirements
To provide input to the design, a first design review should be performed as part of early
engineering, and this checklist should at least be updated prior to construction.
The personnel/team performing WE design reviews shall have adequate working environment
qualifications, and shall be familiar with operation and maintenance activities associated with
the machinery.
All chemical substances and preparations that are contained within machinery boundaries
and/or are planned to be used in connection the machinery shall be identified and documented
in an inventory. Typical chemicals to be included are lube oils, grease, and preservation
chemicals. Information regarding intended use, location and quantities shall be listed, along
with reference to the safety data sheet. Also, the potential for personnel exposure, as identified
in risk assessments or WE design reviews, shall be documented.
Chemicals that follow the installation offshore or are included in instructions for operation
and maintenance shall be documented on safety data sheets; cf. NORSOK S-002 clause 5.4.2.
The safety data sheets shall be in the Norwegian language and approved through the
Norwegian Oil Industry Associations quality assurance scheme for such data sheets.
For all potentially noisy machinery, noise data sheets with Company specified data (noise
level limits) are included in the inquiries; cf. NORSOK S-002 clause 4.8.2. A typical noise
data sheet is included in NORSOK S-002 Annex H.
During engineering, the noise data sheet for subject machinery shall be completed with all the
information required:
Equipment design data;
Guaranteed Supplier data (noise levels), in the same format as the Company specified
data;
Method for planned noise level test during fabrication (see below);
Description of all noise control measures that have been implemented in order to achieve a
low noise design and meet the specified data. The recommended practice for the design of
low noise machinery and equipment in standard ISO 11688 is referred to.
It should be stated whether the specified / guaranteed noise data applies to the complete
machinery or to specific components or sub-assemblies.
During fabrication, measurements to verify the guaranteed noise levels are required, unless
data from previous tests on standard machinery can be accepted. The verification
measurements shall be performed according to a documented test procedure, and should be
executed or witnessed by a qualified noise control engineer. Recommended methods for noise
level tests are described in Annex B1. The measurement results, incl. correction for
measurement uncertainty, shall be documented in the noise data sheet.
Maximum limits for continuous whole body vibration from machinery are given in NORSOK
S-002 Annex E. The limits cover the range 1 - 80 Hz.
When input data for structural vibration analysis are required, the following vibration data
shall be provided:
Frequency of revolution (rpm).
Unbalance force and direction (N).
Weight of rotor (kg).
Total weigth of machinery, including frame (kg).
For vibration isolated machinery the following data shall also be provided:
The degree of vibration isolation obtained will depend on the stiffness of the deck. If a
specific value for vibration isolation insertion loss is required, the Supplier shall specify a
minimum stiffness value for the deck at the support positions in N/m.
If required, input data for analysis of structureborne noise from the machinery shall be
provided. The data shall be given as vibration levels at the supports. Recommended methods
6 RISK ASSESSMENT
The main steps of a generally applicable method for risk assessments of machinery are shown
in Figure 1. The steps are discussed in more detail in clauses 6.2 - 6.7 below. Basic concepts
regarding this method to remove hazards of machinery are elaborated in Annex A3.
The process shall be documented; a typical form for documentation of the assessment is
included in Annex E.
The purpose of the risk assessment is to ensure timely implementation of necessary safety
measures. It is essential to perform an initial / coarse examination of hazards and assessment
before layout freeze and placement of major purchase orders (POs) for sub-deliveries.
Responsibilities and limits should be determined before start of detailed engineering. The
other steps should be initiated during early engineering, and should be performed and updated
in more detail as the design develops and when modifications are required.
Requirements for risk assessments as part of the aggregated working environment (WE)
documentation shall be specified in the PO. A risk assessment performed for a previous
delivery can be accepted, provided that the assessement meets the requirements in this
standard and that the machinery design and operational modes are unchanged. Previously
performed risk assessments shall be documented, together with an evaluation of the adequacy
of this assessment for the recent application.
Extent and level of detail of the risk assessment, as well as needs for updates as the design
develops should be adapted to the category and complexity of the machinery / equipment,
manual tasks, and hazards involved.
Each machinery on the installation shall be subject to the risk assessment process, and for
each machinery, the party responsible for executing and documenting the risk assessment shall
be identified and documented; cf. clause 5.1 and Annex C. To achieve this, the boundaries
between the various assembled machines, individual machines, and sub-assemblies must be
identified. In particular, it is imperative to sort out interface issues and determine
responsibilities with regard to an assembly of machines.
An assembly of machines may comprise individual machines and sub-assemblies which
have to be assessed and documented both as part of the assembled unit and separately,
typically when the machine / sub-assembly seen in isolation represents particular hazards,
or when the design of the individual machine / sub-assembly is critical to the safety of the
assembled unit.
The principal Contractor shall initiate this activity, and shall ensure that allocation of
responsibilities are agreed by Suppliers and/or sub-contractors for all the various machinery
within his scope of work. Each Supplier has to evaluate to what extent his delivery is made up
of machinery / sub-assemblies from sub-suppliers, and determine the corresponding risk
assessment responsibilities.
The use, space and life time limitations of each subject machinery shall be identified in detail,
and any interface issues resolved, prior to commencing the risk assessment. As relevant, the
following information shall be collected and documented for the risk assessment:
A. Description of the machinery (drawings, etc.).
B. Definition and description of interfaces concerning physical arrangements, control system,
power supply, and space requirements; e.g., by reviewing lay-out / arrangement drawings,
process and instrument diagram (P&ID), electrical and instrument diagrams.
C. Assumptions about installation arrangements and ambient conditions (indoor / outdoor
climate, lighting, noise, vibration, etc.).
D. Machinery life time, e.g., mean time to change of components, sub-assemblies, etc.
E. Assumptions about the user (qualifications, etc.)
F. Accident and health impairment statistics for subject or similar machinery.
To execute the risk assessment, a qualified assessment team shall be organised. The Supplier
shall ensure that personnel representing the following competence participates on the team:
personnel familiar with operation and maintenance of the machinery;
relevant engineering disciplines (e.g., layout, mechanical, instrument, electrical);
working environment specialist with adequate qualifications (e.g. in ergonomics and/or
industrial hygiene), the manual tasks and hazards taken into consideration.
Operations and maintenance personnel from the Clients organisation should be invited to
participate.
Manual tasks and interactions where personnel may be present inside the danger zone of the
machinery shall be identified and used as a basis for risk estimation and evaluation.
A step-by-step breakdown of the tasks / activities to a sufficient level of detail shall be carried
out and documented in the risk assessment form; cf. Annex E (column 2). The break down
shall cover all operational modes and foreseeable uses, including:
normal operation, incl. start up and shut down;
cleaning;
inspection, incl. fault diagnosis;
maintenance, incl. repair and material handling.
The requirements for analysis of workplaces and tasks stipulated in NORSOK S-002 clause
4.9 are referred to.
Hazards and hazardous situations / events associated with the various operational modes of
the machinery shall be identified, incl. both hazards resulting in injuries as well as work
related diseases.
For an initial risk assessment, typical hazards and hazardous situations to consider for risk
assessment are listed in Annex D. For more detailed assessments, the description and
examples of hazards and hazardous situations / events in NS-EN 292-1 clause 4 and NS-EN
1050 Annex A are referred to.
A description of each actual hazard and why a hazardous situation may arise shall be
documented in the risk assessment form; cf. Annex E (column 3).
Estimation of the risk from occupational accidents and/or lasting exposures serves as a basis
for identifying needs of remedial actions, incl. safety measures / safeguarding in design. The
risks are estimated and characterised by the assessment team, using professional judgement
and any applicable rating criteria for the elements of risk. In the estimation, existing design
safety measures shall be considered, but not operational measures such as the use of personal
protective equipment.
Frequency
1 time per 100 1 time per 10 1 time per 10 times per
Consequence years or less years year year or more
(1) (2) (3) (4)
First-aid (1) Low Low Medium High
injury
Lost time (2) Low Medium High High
injury
Permanent (3) Medium High High High
disability
Fatality (4) High High High High
For hazards where exposures can result in work-related diseases (e.g. ergonomics, materials
and substances), rating criteria for use in a risk matrix have not been established and the
judgement of the assessment team is referred to for risk characterisation. The exposure risk
shall be estimated (as High, Medium or Low) and documented; cf. Annex E (column 6).
In case the Supplier has data related to the personnels overall exposures during a work
shift, he shall perform detailed ergonomic and/or chemical handling analyses as specified
in NORSOK S-002 clause 4.9. Otherwise, he shall state the need for such analyses to his
customer.
Risk evaluation shall be carried out as outlined in Figure 2, to determine if risk reduction is
required or whether safety has been achieved. High residual risks are not acceptable. Within
the Medium risk range, safety measures shall be implemented to lower the risk as far as
reasonably practicable (the ALARP principle).
Safety measures shall be identified by considering the strategy for selection of safety measures
according to NS-EN 292; cf. Annex A3. Changes in layout, selection of safe sub-assemblies
and components, and safeguarding shall be considered as applicable, and the result of such
evaluations shall be followed-up in design and procurement.
If additional hazards are created when new safety measures are applied, they shall be added to
the list of hazards, and the risk shall be estimated and evaluated.
Risk assessment
steps 1-3
Identify hazards
for each manual task
new
(step 4)
hazards?
No
Yes Risk reduction by design
change possible? Document
No in
Risk reduction by
Yes Risk
safeguarding possible?
Assessment
No
Risk reduction by user Form
Yes precautions possible ?
(cf. Annex E)
No
No Residual risk Yes
acceptable ?
This NORSOK standard describes rational methods for necessary working environment (WE)
analyses of machinery design (i.e. risk assessments and design reviews) and documentation of
conformity with WE requirements applicable to offshore machinery. The described allocation
of responsibilities, review and assessment processes, and formats of documentation addresses
the basic regulatory requirements, normative standards, and expectations of major Clients in
the offshore industry.
Suppliers (i.e. manufacturers and/or vendors) of offshore machinery, sub-assemblies and other
technical products are the primary users of the methods of the standard. The purpose is to
assist the Suppliers in meeting regulatory and contractual requirements for WE analyses and
documentation during design, and to ensure quality and consistency of the WE documentation
aggregated in the as-built documentation handed over to Client.
By proper implementation of the standard and incorporation of the safety measures identified
by the risk assessment, the Supplier will meet the offshore industrys expectations for:
Integration of safety into design of subject machinery; cf. the essential health and safety
requirements in Machinery regulations 7 and Annex I, and WE requirements in other
relevant regulations, standards and codes.
Description of the methods chosen to remove the hazards of subject machinery; cf.
requirements for technical documentation to the Declaration of Conformity in Machinery
regulations 9.2 and Annex V.
Documentation of WE analyses, noise and vibration control, and hazardous chemicals for
subject machinery; cf. NORSOK S-002.
Machinery delivered for use on offshore installations shall comply with the requirements
stipulated in the Machinery regulations; i.e. Norwegian Labour Inspection order no.522,
equivalent to EU directive 89/392/EEC (as amended). This implies that the machinery shall be
designed and constructed according to the principles of safety integration, in compliance with
the essential health and safety requirements (i.e. WE requirements) applicable to subject
machinery. Applicable WE requirements shall be identified based on assessment of the
hazards associated with the machinery.
The breakdown of the WE requirement and analysis / verification methods are outlined in
Figure A1 below.
Also, machinery shall be provided with statutory indicators, incl. Instructions with
information necessary for safe use, maintenance, etc.; cf. Machinery regulations Annex I,
no.1.7.4.
Functional Specific
WE requirements WE requirements
Design of machinery
Specific Identified
Risk Assessment Design Review of
requirement non-
of design vs. design vs. specific
for safety conformities
functional WE WE requirements
measures
requirements
The preferred method for removing hazards associated with machinery is an iterative process
of risk assessments to examine the hazards, followed, when necessary, by specification of
safety measures to eliminate or reduce the risk; cf. NS-EN 292-1 clause 6, NS-EN 1050, and
clauses 5.2 and 6 of this standard. To verify conformity with specific WE requirements, a
design review is also required; cf. ISO 9001, and clause 5.3 and Annex G of this standard.
Risk is a function of the severity of the possible injury or damage to health and the probability
of occurrence of that harm, as determined by the frequency and duration of exposure, the
probability of occurrence of the hazardous situation, and the possibility to avoid or limit the
harm; cf. NS-EN 1050. Risk assessments includes risk analysis (i.e. determination of the
limits of the machinery, hazard identification, and risk estimation of hazardous situations) and
risk evaluation to determine if risk reduction is required or whether safety has been achieved.
Risk assessments to specify appropriate safety measures are applicable to hazards resulting in
both occupational injuries as well as work related diseases.
The strategy and priorities for selecting safety measures are stipulated in NS-EN 292-1 clause
5 and further specified in NS-EN 292-2:
1. Risk reduction by design, i.e. removal of the hazard or limitation of the risk; cf. NS-EN
292-2 clause 3.
2. Safeguarding against hazards by design, i.e. establishment of barriers between the hazard
and the person, thereby preventing the person to get in contact with the danger zone; cf.
NS-EN 292-2 clause 4.
3. Informing and warning users about residual risks, e.g. information concerning safe work
methods, personal protective equipment, work permits; cf. NS-EN 292-2 clause 5.
4. Additional precautions shall also be considered, including emergency stops, escape
possibilities, isolation, safe access, etc; cf. NS-EN 292-2 clause 6.
According to the statutory principles of safety integration, lower priority safety measures shall
not be selected before all possible measures of higher priority have been evaluated and, if
feasible, have been implemented.
For measurements of free field sound pressure levels at specified positions, the standards in
the NS-EN ISO 11200 series should be used. Alternatively, specific product standards based
on these main standards may be used. When the machine is installed in a room, the noise level
Concerning measurements of sound pressure level at operators position, e.g. inside a crane
cabin, standardised methods are preferred. However, specific written procedures may be used.
For sound power measurements, standards in the NS-EN ISO 3740 series or NS-EN ISO 9614
series should be used. Alternatively, specific product standards based on these main standards
may be used. Standards with engineering grade of accuracy, NS-EN ISO 3744 or NS-EN ISO
9614-2, are recommended.
The condition for verification of the guaranteed noise level (Lg) is:
Lg L + K
where L is the measured value in dB(A) and K is the measurement uncertainty; cf. NS-EN ISO
4871. The sum of L + K shall be presented in the noise data sheet.
The uncertainty value K depends on the grade of accuracy for the measurement method. The
K-value is to be specified from the supplier, and is his responsibility. However, the following
values may be used as typical values :
Vibration from the machinery supports will allways be transmitted to adjacent areas and
radiate noise, i.e. structureborne noise. In work areas, structureborne noise may usually be
neglected compared to air transmitted noise. There are exceptions, however, and especially in
living quarters and control rooms the structure borne noise level should be evaluated.
The input data for analysis of structureborne noise from machinery shall be given as vibration
level at the supports.
For vibration isolated machinery the vibration shall be measured on the top of the vibration
For a machine that is fastened directly to the deck, the vibration level at the support points
will depend on the stiffness and other details of the deck and support points. Vibration shall
be measured at the carrying frames as near as possible to the machine support points. The
mean value of vibration on the supports shall be given, as specified above. These data are only
valuable if the details of the deck, frames and supports, in which the measurements are taken,
are described in detail.
1
The examples of hazards etc. in NS-EN 1050 Annex A also includes cross-references to the essential health and
safety requirements in Machinery regulations in Machinery regulations Annex I (i.e. NS-EN 292-2/A1 Annex A),
and to clauses in NS-EN 292-1 and NS-EN 292-2.
Mechanical [4.2]
! crushing
! shearing / cutting / stabbing / puncture
! entanglement / drawing-in / trapping
! impacts
! friction / abrasion
! high pressure fluid ejection
! falling / ejected objects
! slipping / tripping / falling persons
! loss of stability / overturning
Electrical [4.3]
Thermal [4.4]
! hot surfaces (contact)
! flames / explosions (contact)
! heat sources (radiation)
! cold stress (outdoor work)
Noise [4.5]
! excessive noise (dangerous to hearing)
Vibration [4.6]
! excessive whole-body vibration
! excessive hand-arm vibration
Radiation [4.7]
! low frequency electromagnetic fields
! radio frequencies / micro-waves
! infra-red / visible / ultra-violet light
! lasers
! ionizing X-rays, -rays, ion beams, etc.
Ergonomics* [4.9]
! monotonous / excessive muscular load
! work in fixed / static postures
! work in kneeling / squatting / lying positions
! work with hand above shoulder / below knees
! continuous asymmetric load on body
* Hazards from neglecting ergonomic principles in design
NO. DANGEROUS MANUAL HAZARDS / HAZARDOUS RISK* SAFETY MEASURES / OPERATIONAL RESIDUAL STATUS
TASKS / INTERACTIONS SITUATIONS AND EVENTS SAFEGUARDING PRECAUTIONS RISK*
IN DESIGN BY USER
C F R C F R
1 Operation
.
.
2 Cleaning
.
.
3 Inspection
.
.
4 Maintenance
.
.
5 Other operational modes
.
* Risk estimation according to clause 6.7: C = Consequence (1-4) / F = Frequency (1-4) / R = Risk (H=high, M=medium, L=low)
Product name Intended use Location (tag no.) Safety Data Sheet Potential for hazardous
Quantity (Doc. ID No.) exposures; cf. risk assessment
1. REQUIREMENT
A short description of the requirement, with actual dimensions where applicable.
3. REFERENCES
Reference to the standard or code where the requirement is stipulated.
NORSOK C-002 Architectural components and equipment NS-EN 292 Safety of machinery Basic concepts, general principles for
design (Parts 1 - 2)
NORSOK S-DP-001 Design principles Technical safety NS-EN 349 Safety of machinery Minimum gaps to avoid crushing of
parts of the human body
NORSOK S-002 Working Environment NS-EN 626 Safety of machinery Reduction of risks to health from
hazardous substances (Part 1)
NORSOK S-DP-003 Design principles Environmental care prEN 12437 Safety of machinery Permanent means of access to
machinery and industrial plants (Parts 1 - 4)
4. STATUS
Indication of machinery status and result of review.
OK : Fully in compliance with the referred standard or code.
AR : Action required.
NCP : Non-conformity, action pending.
NCA : Non-conformity, action approved.
NA : Requirement not applicable for the specific delivery.
4. COMMENTS
All actions necessary to meet requirements stipulated in regulations, standards and codes should be noted.
Status indications AR, NCP and NCA shall be followed by a comment.
PROJECT :
PACKAGE :
MODULE / AREA :
REV. :
DATE :
SIGN. :
GENERAL
COMMENTS :