RISK ASSESSMENT AND ANALYSIS

RA Number : 003/Hydrotest/Rev-00 Department / Area: HSE

WORKPLACE / TASK / ACTIVITY / PROCESS NAME
RA TEAM ( Names ): Date: 27-Apr-2023
1. Syed - Site Engineer (Mechanical) Next Review Date: 30-Jul-2023
2. Noorullah - QC Engineer

3. Mashooq - Safety Lead Officer

Hydrotest Approved by Manager / Supervisor: Vashid Poolat

Signature:
HAZARD IDENTIFICATION CONTROL RISK ASSESSMENT RISK REDUCTION PLAN

Consequen

Consequen
Risk Rating

Risk Rating
Follow up by Controls

Likelihood

Likelihood
Workplace/Activity/ Risk Issue Posible Incident [ What
Item Improve existing controls / whom implement
Process / Hazards can go wrong ] (Accident/ill health Existing Controls

ce

ce
# Implement new controls ( name )& by ed ( yes/
Equipment/Material to persons, fire or property loss)
when (date) no )
Violation of Site Procedure that
Working without obtaining lead to accident due to insufficient Risk Assessment Mechanical yes
Obtained the required work permit for the job prior to start. 4 2 8 4 1 4
work permit information, lack of orientation and discussed to workers
communication

Prior to start of any

activity, must ensure
Violation of Site Procedure that All personnel should be certified for this activity and must
necessary clearance is
lead to accident due to insufficient pocess valid access (entry - exit). Mechanical yes
Unauthorized work force 4 2 8 obtained such as Proper 4 1 4
information, lack of orientation and All work should be carried out by MGC supervisor under client
Work Permit , Access
communication supervision
Permits etc., must be
availed.
General Work
1
Preparation
All Equipment and tools must be inspected and 3rd party
Usage of improper Damaged to Properties and lead certified (as required) Impelementation of JV Mechanical yes
4 3 12 4 1 4
equipment/Tools to personal, major injury Only approved equipment and competent operator will be procedure.
allowed to transport materials.

Vehicle Collision to workers and

other heavy equipment, Fumes The defined work and temporary parking area and clearing from
Heavy Equipment Flagman or pointman & Mechanical yes
emitted and dust generations - obstruction prior to execution of activity.Checking of fuel 4 3 12 4 1 4
movement speed limit sign available
Major Injury and harmful to human injection system,low speed & Suppression of dust by water
respiratory system
Tool Box Talk was given Mechanical yes
Weather Condition Cold, Flu, Hyperthemia Frequent Rest and Rotation of Work 3 3 9 3 1 3
to workers

Employee should adopt correct lifting techniques get help if

required.
Remove obstacles before moving.
Mobilization of hand Personal protective Equipment (E.g, Gloves, foot protection, Tool box talk and
Musculoskeletal disorder, Sprains, Mechanical yes
2 tools and gauges Manual handling injuries
strains, Muscular injuries etc.
non-slip footwear etc) must be worn. 3 3 9 awareness training, 3 1 3
(Manual Handling) Ensure appropriate rest breaks, job rotation and training are Safety Orientation
involved.
Pre use inspection of power tools.
Check for monthly inspection color coding prior to mobilize.
All electrical tools must be inspected by competent person

Reversible injury or moderate Prior to mobilize workforce ensure proper training completed as Ensure competence of
Mobilization of work Incompetent work force to Mechanical yes
3
force the task
damage or impairment – Typically required by the JV 3 3 9 people conducting the 3 1 3
a lost time injury. task.
 Control and properly monitor the pressure using calibrated
Manifold, Pressure Gauges, and Pressure Safety Valves.
Ensure continues monitoring of pressure gauge and personnel
shall not approach the system under high Pressure.
Calibrated pressure gauges and Pressure safety valves only
Reversible injury or moderate
shall be used.
damage or impairment
Holding and pressure Hydro testing crew should not stay in the direction of the blind Work supervisor has to Mechanical yes
4
releasing
Over Pressure to one or more persons.
flanges to prevent injury
3 3 9 ensure the requirements
3 1 3
Typically a lost time or restricted
An air compressor shall always be inspected and under the
work injury
supervision of a competent person. It should always be situated
in such a place so as to have adequate ventilation.
All high-pressure equipment shall be earthed before work starts
and during operation, to prevent the development of
electrostatic charges between the lance and the workplace

Hydro test area shall be barricaded and provide warning boards

to prevent personnel entry.

Ensure all bolts are tightened and complete torques as per

required procedure.

Rating of fittings, pressure gauges, vent valves, gasket shall be

suitable for the test pressure.
Reversible injury or moderate
Breaking /failure of line, damage or impairment Flanges and blinds plates shall be per the line class.
Hydro test of 700mm Work supervisor has to Mechanical yes
5
dia pipes
gasket, flanges, and to one or more persons. 3 3 9 ensure the requirements
3 1 3
gauges Typically a lost time or restricted Pressure system shall be applied to piping system and to
work injury equipment as designated in test flow diagram. The test pressure
shall be as specified on the project line test procedure.

During the application of hydro test, an inspection shall be

made, in a safe manner, of all joints and connection for leaks
within the piping system being tested.

All personnel shall ensure that all hoses have been routed in a
safe manner

Reversible injury or moderate Ensure air vent is provided.

Air entrapment inside the Work supervisor has to Mechanical yes
pipe
damage or impairment – Typically a Ensure to Secure the joints with safety devices (whip lash arrester and
ensure the requirements
3 1 3
lost time injury. safety pins).
Reversible injuries requiring
treatment but does not lead to Bolting shall never be conducted while pipeline under pressure.
Injuries from Tightening of 6 Work supervisor has to Mechanical yes 2 1 2
nut(Bolting and unbolting)
restricted duties. Check monthly inspection color coding for the tools 2 3
Typically a medical treatment Use proper PPE’s to avoid minor injuries (Hand Gloves, safety Shoes) ensure the requirements

1. Pressure should be raised gradually under control to allow time for

pipe to strain and time for personnel to check for leaks.
Inadvertently/suddenly 2. There shall be at least two pressure gauges, one at lowest point
increase of pressure due to Irreversible health effects or disabling and another at the highest point in the system. Work supervisor has to Mechanical yes
underrated or non-calibrated illness to a person 3. Hydro testing crew should not stay in the direction of the blind ensure the requirements
3 1 3
pressure gauges flanges to prevent injury in case of flange rapture.
4. All hoses/ piping/ gasket and connector/ clamps shall be of
adequate rating to withstand pressure.
 HIGH Risk Medium Risk Low Risk

1-5
(Accept
15 - 25 (Stop operation till reduce risk to be tolerable risk 6-14 (cotnrol measure required able
with
PPE)

S 5 4 3 2 1
5 25 20 15 10 5
4 20 16 12 8 4
3 15 12 9 6 3
2 10 8 6 4 2
1 5 4 3 2 1