Hydrotest Risk Assessment new

Risk Assessment Tables (Guidance for assessing risk)

Risk Tolerability/Acceptance Tolerability/Acceptance Table Risk Rating & Rating Number

Likelihood of Occurrence Regular occurrence within the area of operations to which it refers, with the possibility of being realised once per day/shift. High Likelihood Moderate Likelihood Occasional occurrence with the possibility of being realised once per job/project/contract/month. #nlikely to occur but known to ha"e occurred in the rele"ant industry/operation/type industry/operation/type of work it refers to. Lo" Likelihood $e%erity in'ury( High $e%erity Moderate $e%erity Lo" $e%erity

&ajor !njury/'isablement/atality !njury/'isablement/atality (e.g. amputation, major fracture, poisoning, multiple injuries, occupational cancer or other se"ere life shortening diseases, acute fatal diseases). ost *ime !njury (off work for more than + working days)(lacerations, days)(lacerations, burns, concussions, serious sprains, minor fractures, deafness, dermatitis, asthma, work related upper limb disorders, ill health leading to permanent minor disability). irst id !njury, &edical id *reatment *reatment !njury (return to work after loss of 0 shifts/working days)(e.g. superficial injuries, minor cuts/bruises, eye irritation, headaches, temporary discomfort.

 !ntolerable Risk

ork shall not be started or continued until the risk has been reduced. !f it is not possible to reduce the risk e"en with unlimited resources, work shall remain prohibited.

# $ubstantial Risk

ork shall not be started until the risk has been reduced. reduced. $onsiderable d erable resource resourcess may be re%uired re%uired to do this. here here the risk in"ol"es " es work in progress, urgent action shall shall be taken.

) Moderate Risk

$e%erity property/e*uipment( 1roperty/2%uipment 1roperty/2%uipment 'amage costs e-ceeding 345,555. High $e%erity Moderate $e%erity Lo" $e%erity

1roperty/2%uipment 1roperty/2%uipment 'amage costs (direct and indirect) between 345,555 and 34,555. 1roperty/2%uipment 1roperty/2%uipment 'amage costs (direct and indirect) not e-ceeding 34,555.

+ Tolerable Risk

, Lo" Risk

$e%erity en%ironmental( High $e%erity Moderate $e%erity Lo" $e%erity

Remedial Action and Timescale Timescale

ork may proceed but efforts should be made to reduce the risk below below this le"el. *he resources/costs re%uired for pre"ention should be carefully measured measured and limited. limited. Risk reduction measures and remedial action shall be implemented as soon as practicable and within one month as a ma-imum. here the moderate risk (le"el +) in"ol"es high se"erity conse%uen conse%uences, ces, further further assessmen assessmentt may be necessar necessaryy to establish establish the likelihood likelihood more precisely and determine the need for impro"ed control measures. 6o additional costs are re%uired. $onsideration may be gi"en to more cost effecti"e remedial actions or impro"eme impro"ements nts that in"ol"e no additional resources/cost burden. &onitoring is re%uired to ensure that controls are maintained and in place. Risk cceptable. 6o action re%uired. 'ocument findings.

2n"ironmental 2n"ironmental damage is catastrophic and/or in"ol"es prosecution, prosecution, se"ere damage to company image and substantial costs. 2n"ironmental 2n"ironmental damage e-ternal to local area and/or damage to company image and profits. 2n"ironmental damage is local and has minimal e-ternal impact.

Risk Rating & Rating Number Table High High Like Likelih lihoo ood d Mode Modera rate te Lik Likel elih ihoo ood d

Lo" Lo" Likel Likelih ihoo ood d

High $e%erity

 !ntolerable risk

# 9ubstantial risk

) &oderate risk

Mode Modera ratte $e%eri %eritty

# 9ubstantial risk

) &oderate risk

+ *olerable risk

) &oderate risk

+ *olerable risk

, ow risk

Lo" $e%erity

Notes- or each ha7ard8 ha7ard8  ,( 2stimate ,( 2stimate ikelihood of Occurrence. +( 2stimate +( 2stimate 9e"erity of potential injury, property damage or en"ironmental damage. )( $ombine )( $ombine estimates to allocate !nitial Risk Rating. #( ssess #( ssess Risk *olerability or cceptance. ( !ntroduce ( !ntroduce $ontrol &easures to reduce risk. .( Reassess .( Reassess re"ised estimates of ikelihood and 9e"erity after controls implemented and allocate new risk rating. ( Reassess ( Reassess Risk *olerability and if acceptable, enter Residual Risk Rating and associated ikelihood and 9e"erity le"els. !f not repeat stages 4:.

Page 1 of 6

Risk Assessment Form Base/Area/Dept/Project: Dubai/MEAP/Operations/Azeri Baku Pipelines Project Activity/Operation/Job: Pre-coissionin!/"ydrotestin!/MEPP# Task/Job Steps

Hazard ;a7ard 'escription and 2ffect for each *ask. 6ote8 dditional ha7ards may arise from interaction with other work.

Initial Risk 1ersonnel / 2%uipment / 2n"ironment at Risk

Assessed by: Date: Controls

Residual Risk

;a7ard ikelihood of Risk ist and describe fully all $ontrols Re%uired. $rossrefers ;a7ard ikelihood of Risk 9e"erity Occurrence Rating to any other rele"ant assessment (112, $O9;;, &anual 9e"erity Occurrence Rating 6o. 6o. ;andling, O2R etc).

Prepare detailed test procedure

$oinate %ron! test pressure Over pressure syste

Daa!e to client syste

Mod

Mod

&

Procedure/job card %ill be prepared' c(ecked and approved by & separate BJ ) client personnel*

Mod

+o%

,


$oinate %ron! test liits Over pressure syste


Mod

Mod

&


Mod

+o%

,


ailure to identi.y $01s and valves Daa!e to to be ec(anically opened %it(in client syste t(e test liits 2rapped pressure in syste

Mod

Mod

&


Mod

+o%

,

Prepare syste .or .loodin!

ailure o. perit to %ork syste On!oin! con.lictin! %ork on t(e sae syste

Personal injury and BJ e3uipent daa!e

Mod

Mod

&

Perit to %ork syste is ad(ered to ri!idly and s(ortcoin!s/potential con.licts reported to P24 o..ice iediately*

Mod

+o%

,


i! up all .loodin! e3uipent Muscle / back strain .ro ovin! (eavy e3uipent

Personal injury

Mod

Mod

&

ollo% all !uidelines laid out durin! +o% sa.ety induction and BJ "#E anual* Personnel trained in anual (andlin! tec(ni3ues* 5tes over 67 8!s to be li.ted by , or ore people*

+o%

9


5nstall incorrectly rated teporary (ose / blinds / spades Overpressure o. teporary e3uipent

BJ e3uipent daa!e

Mod

Mod

&

Ad(ere at all ties to procedure' all teporary e3uipent to be certi.ied and pre-tested*

Mod

+o%

,


se o. (and 2ools 2rapped / cut injured body parts

Personnel injury Mod

Mod

&

ollo% all !uide lines laid out durin! sa.ety induction and BJ "#E anual

Mod

+o%

,


4orkin! at (ei!(t all .ro (i!( levels

Personnel injury "i!(

Mod

6

On ly use appro ved sca..o ldin!' %ear correct (arness above , .ro .loor*

Mod

+o%

,

Risk Assessment Form Base/Area/Dept/Project: Dubai/MEAP/Operations/Azeri Baku Pipelines Project Activity/Operation/Job: Pre-coissionin!/"ydrotestin!/MEPP# Task/Job Steps



Assessed by: Date: Controls

Residual Risk

;a7ard ikelihood of Risk ist and describe fully all $ontrols Re%uired. $rossrefers ;a7ard ikelihood of Risk 9e"erity Occurrence Rating to any other rele"ant assessment (112, $O9;;, &anual 9e"erity Occurrence Rating 6o. 6o. ;andling, O2R etc).


$oinate %ron! test pressure Over pressure syste


Mod

Mod

&


Mod

+o%

,


$oinate %ron! test liits Over pressure syste


Mod

Mod

&


Mod

+o%

,


ailure to identi.y $01s and valves Daa!e to to be ec(anically opened %it(in client syste t(e test liits 2rapped pressure in syste

Mod

Mod

&


Mod

+o%

,



Personal injury and BJ e3uipent daa!e

Mod

Mod

&


Mod

+o%

,


i! up all .loodin! e3uipent Muscle / back strain .ro ovin! (eavy e3uipent

Personal injury

Mod

Mod

&

ollo% all !uidelines laid out durin! +o% sa.ety induction and BJ "#E anual* Personnel trained in anual (andlin! tec(ni3ues* 5tes over 67 8!s to be li.ted by , or ore people*

+o%

9


5nstall incorrectly rated teporary (ose / blinds / spades Overpressure o. teporary e3uipent

BJ e3uipent daa!e

Mod

Mod

&

Ad(ere at all ties to procedure' all teporary e3uipent to be certi.ied and pre-tested*

Mod

+o%

,


se o. (and 2ools 2rapped / cut injured body parts


Mod

&

ollo% all !uide lines laid out durin! sa.ety induction and BJ "#E anual

Mod

+o%

,




Mod

6


Approved by ;$ae<: #i!nature:

Task/Job Steps

Approved by ;2itle<: Date:



;a7ard ikelihood of 9e"erity Occurrence

Mod

+o%

,

Pa!e , o. =

Controls

Risk ist and describe fully all $ontrols Re%uired. $rossrefers Rating to any other rele"ant assessment (112, $O9;;, &anual 6o. ;andling, O2R etc).

Residual Risk ;a7ard ikelihood of 9e"erity Occurrence

Risk Rating 6o.

lood syste

Drainin! %ater #oakin! adjacent %orkin! personnel

Personnel injury

+o%

Mod

,

4 (en drainin! %ater %arn as any people as possible and onitor t(e draina!e pat( o. t(e %ater* >over all electrical e3uipent*

+o%

+o%

9

lood syste

#plas(ed by (i!( velocity %ater Eye injury


+o%

&

se o. correct PPE adv ised durin! induction and in "#E anual*

+o%

+o%

9

Prepare .or (ydrotest



Mod

6


Mod

+o%

,



E3uipent and plant daa!e

"i!(

Mod

6


Mod

+o%

,


i! up all "ydrotestin! e3uipent Muscle / back /strain .ro ovin! (eavy e3uipent


Mod

&

o llo% all !uidelines la id out durin! sa.ety induction and BJ "#E anual

+o%

+o%

9


5nstall incorrectly rated teporary pipe%ork / (oses / blinds / spades Overpressure o. teporary e3uipent se o. (and 2ools 2rapped injured body parts

BJ e3uipent and personnel injury

Mod

"i!(

6

Ad(ere at all ties to procedure* All Mod teporary e3uipent to be pre-tested prior to (ook up to clients syste*

+o%

,


Mod

&


Mod

+o%

,


"ydrotest syste

Over pressurise syste >lient syste >ritical .ailure / rupture o. pipe%ork

"i!(

Mod

6

tilise syste over pressure protection device .itted upstrea o. test !au!e on (ydrotest injection ani.old*

Mod

+o%

,

"ydrotest syste

$on testin! personnel %orkin! on systes under pressure >ritical .ailure

"i!(

Mod

6

Mod

+o%

,

Depressurise / drain

2rapped Pressure in syste


Mod

&

ollo% all !uidelines on Perit to %ork* Ad(ere to barriers / si!ns recoended in procedure* $o unaut(orised personnel in test area* ollo% all !uidelines on Perit to

Mod

+o%

,

All personnel in test area

Task/Job Steps




Controls



Risk Rating 6o.

lood syste


Personnel injury

+o%

Mod

,


+o%

+o%

9

lood syste

#plas(ed by (i!( velocity %ater Eye injury


+o%

&

se o. correct PPE adv ised durin! induction and in "#E anual*

+o%

+o%

9




Mod

6


Mod

+o%

,



E3uipent and plant daa!e

"i!(

Mod

6


Mod

+o%

,


i! up all "ydrotestin! e3uipent Muscle / back /strain .ro ovin! (eavy e3uipent


Mod

&


+o%

+o%

9


5nstall incorrectly rated teporary pipe%ork / (oses / blinds / spades Overpressure o. teporary e3uipent se o. (and 2ools 2rapped injured body parts

BJ e3uipent and personnel injury

Mod

"i!(

6

Ad(ere at all ties to procedure* All Mod teporary e3uipent to be pre-tested prior to (ook up to clients syste*

+o%

,


Mod

&


Mod

+o%

,


"ydrotest syste

Over pressurise syste >lient syste >ritical .ailure / rupture o. pipe%ork

"i!(

Mod

6

tilise syste over pressure protection device .itted upstrea o. test !au!e on (ydrotest injection ani.old*

Mod

+o%

,

"ydrotest syste

$on testin! personnel %orkin! on systes under pressure >ritical .ailure

"i!(

Mod

6

Mod

+o%

,

Depressurise / drain

2rapped Pressure in syste


Mod

&

ollo% all !uidelines on Perit to %ork* Ad(ere to barriers / si!ns recoended in procedure* $o unaut(orised personnel in test area* ollo% all !uidelines on Perit to

Mod

+o%

,

All personnel in test area


Task/Job Steps





Pa!e & o. =

Controls



Risk Rating 6o.

syste

uture release o. pressurised .luid critical .ailure

%ork* Ad(ere to barriers / si!ns recoended in procedure*

Depressurise / drain syste


Personnel injury

+o%

Mod

,


+o%

+o%

9

e-instate syste

De-ri! o. "ydrotestin! e3uipent Muscle / back / strain .ro ovin! (eavy e3uipent


Mod

&


+o%

+o%

9


se o. (and 2ools 2rapped injured body parts

Personnel 5njury Mod

Mod

&


Mod

+o%

,


4 ork in! at (ei!(t all .ro (i!( levels

Personnel 5njury "i!(

Mod

6


Mod

+o%

,


5nstall e3uipent incorrectly uture .ailure o. process syste

>lient syste

"i!(

Mod

6

>opletion o. einstateent >(eck s(eet by BJ and client*

Mod

+o%

,


se o. (ydraulic bolt tensionin! and Personnel injury Mod tor3uin! e3uipent Muscle / back / strain .ro ovin! (eavy e3uipent

Mod

&

2rained and 3ua li. ie d personnel on Mod site to carry out bolt tensionin! %orks* Assistance !iven %(en (andlin! (eavy objects* 2%o an li.tin!*

+o%

,


se o. (ydraulic bolt tensionin! and >lient syste e3uipent 5ncorrect tensionin!' loose bolts

Mod

6

Bolt tensionin! procedures .ollo%ed' Mod .ully trained personnel to carry out t(e bolt tensionin! operations*

+o%

,

"i!(

Task/Job Steps




Controls

Residual Risk



Risk Rating 6o.

syste

uture release o. pressurised .luid critical .ailure

Depressurise / drain syste


Personnel injury

+o%

Mod

,


+o%

+o%

9


De-ri! o. "ydrotestin! e3uipent Muscle / back / strain .ro ovin! (eavy e3uipent


Mod

&


+o%

+o%

9


se o. (and 2ools 2rapped injured body parts

Personnel 5njury Mod

Mod

&


Mod

+o%

,


4 ork in! at (ei!(t all .ro (i!( levels

Personnel 5njury "i!(

Mod

6


Mod

+o%

,


5nstall e3uipent incorrectly uture .ailure o. process syste

>lient syste

"i!(

Mod

6

>opletion o. einstateent >(eck s(eet by BJ and client*

Mod

+o%

,


se o. (ydraulic bolt tensionin! and Personnel injury Mod tor3uin! e3uipent Muscle / back / strain .ro ovin! (eavy e3uipent

Mod

&

2rained and 3ua li. ie d personnel on Mod site to carry out bolt tensionin! %orks* Assistance !iven %(en (andlin! (eavy objects* 2%o an li.tin!*

+o%

,


se o. (ydraulic bolt tensionin! and >lient syste e3uipent 5ncorrect tensionin!' loose bolts

Mod

6

Bolt tensionin! procedures .ollo%ed' Mod .ully trained personnel to carry out t(e bolt tensionin! operations*

+o%

,


%ork* Ad(ere to barriers / si!ns recoended in procedure*

"i!(


Pa!e 6 o. =

Risk Assessment 0 1ob $ite Re%ie" 2orm 1age 6o8 Assessment No-

4

1ob No/3ro'ect No-

4ork $copeLocationNote- !f 1rocedure $hange $ontrol pro"isions apply during the job this form shall be used for the re%uired assessment re"iew.

Ha5ards / Risks on 6eneral Risk Assessment "hich are not applicable for this 4ork $cope(!dentify by no. and description).

#se continuation sheet if out of space.

Ha5ards / Risks "hich ha%e not been identified in 6eneral Risk Assessments "hich are applicable for this 4ork $cope - (
Risk Assessment 0 1ob $ite Re%ie" 2orm 1age 6o8 Assessment No-

4

1ob No/3ro'ect No-





7ontrol Measures to be utilised to minimise these additional Ha5ards / Risks(ull 'escription of $ontrol &easures to be implemented).


! confirm that ! ha"e read the General Risk ssessment pro"ided for this ork 9cope and ha"e sur"eyed the work site, where the additional risks ha"e been identified. *hey are listed abo"e and control measures suggested.

1ob $ite Re%ie" 3erformed by-

8ate-

! confirm that ! ha"e read and understood both the General Risk ssessment and this =ob 9ite ssessment Re"iew, which are pro"ided for this ork 9cope. (*o be signed by all personnel in"ol"ed in this ork 9cope i.e. all <= and $lient/*hird 1arty as appropriate). (#se re"erse if not enough space below for signatures).

Name 3rinted(

$ignature

Name 3rinted(

$ignature

Risk Assessment 0 1ob $ite Re%ie" 2orm 7ontinuation $heet Assessment No-

1age 6o8

>

1ob No/3ro'ect No-





7ontrol Measures to be utilised to minimise these additional Ha5ards / Risks(ull 'escription of $ontrol &easures to be implemented).


Hydrotest Risk Assessment new

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