RISK ASSESSMENT

Doc No: MAC-MEP-MS-032

RA DESCRIPTION WELDING & RADIOGRAPHY TEST OF CHILLED WATER PIPES.

PROJECT DUCAB- HV & EHV FACILITIES, DUBAI
CONTRACTOR KHANSAHEB CIVIL ENGINEERING L.L.C.
LOCATION JEBEL ALI,DUBAI DATE:
RISK ASSESSMENT TEAM SITE REPRESENTATION
NAME DESIGNATION SIGNATURE NAME DESIGNATION SIGNATURE

SAED DIRAR PROJECT MANAGER GHOSH MRINMOY DUCT C/HAND

VENKATESH BABU MECH.ENGINEER(HVAC) LAZARO LOPEZ RANIDO PF./C/HAND

MUAYYAD A.(MOHD.ALI) MECH.ENGINEER(HVAC)

DESIGNATION INITIALS & SURNAME APPROVED COMMENTS

PROJECT DIRECTOR BRETT PLUMBRIDGE YES NO
PROJECT MANAGER SAED DIRAR YES NO
CLIENT / CONSULTANT REP. KANNAN VENKATESAN A.R.E. YES NO

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REQUIRED AND EXISTING CONTROL AVAILABLE ADEQUATE ATTACH TO RA DOCUMENT

MEASURES YES NO YES NO REMARKS
METHOD STATEMENT STEPS OF THE TASK X X
PROCEDURES (SWP, WI, VENDOR SPECS.) X
SPECIAL PERMITS REQUIRED X Hot work
EQUIPMENT / TOOLS REGISTERS AVAILABLE X Crane, lifting equipment
TRAINING REQUIRED X
COMPETENCY CERTIFICATES REQUIRED X Crane operator, welder

SEVERITY CONSEQUENCE RATING SEVERITY OUTCOME

CATASTROPHIC 5 4 3 2 1 1 FATALITY / DI
CRITICAL 10 8 6 4 2 2 MAJOR INJURY / ILLNESS
SERIOUS 15 12 9 6 3 3 SERIOUS INJURY / ILLNESS
MEDIUM 20 16 12 8 4 4 MINOR INJURY / ILLNESS
MINIMAL 25 20 15 10 5 5 NONE OR SMALL FA

5 4 3 2 1
LIKELYHOOD
VERY ALMOST
UNLIKELY LIKELY VERY LIKELY
UNLIKELY CERTAIN

RISK RANKING (RR) / PRIORITY FACTOR RATING

SCORE 1-2 POTENTIALLY CATASTROPHIC / ACTION NEEDED IMMEDIATELY H+
SCORE 3 -6 POTENTIALLY MAJOR / ACTION TO BE TAKEN WITHIN 12 HRS H
SCORE 7 - 10 POTENTIALLY SERIOUS / ACTION TO BE TAKEN WITHIN 48 HRS M
SCORE 11 - 25 POTENTIALLY MINOR / ACTION TO BE TAKEN WITHIN 7 DAYS L

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POSSIBLE CAUSES OF LOSS PRODUCING EVENTS OR HAZARDS

1. ADVERSE ENVIRONMENT 7. FALLING OBJECTS
NOISE BAD SLINGING AND LOADING YES
LIGHTING LOOSE MATERIALS AND EQUIPMENT
RESTRICTED ACCESS LOAD SECURITY
HEAT, COLD 8. HEALTH HAZARDS
COMMUNICATION YES BAD SANITATION
2. MOVING MACHINERY DUST, FUMES YES
NIP POINTS OCCUPATIONAL DISEASE
REVOLVING PARTS RADIATION YES
INTERLOCKS AND VALVES 9. FIRE
CUTTING ACTION COMBUSTIBLE MATERIALS YES
LACK OF CLEARANCE FUELS AND OILS
MISLEADING APPEARANCE OF QUALITY NO WELDING, CUTTING YES
3. SLIPPING AND FALLING OVERHEAD MACHINES
FLOOR CONDITIONS YES ELECTRICAL INSTALLATIONS
FALLING FROM A HEIGHT YES 10. SUDDEN RELEASE OF MATERIALS
EXCAVATIONS WATER TANKS
SCAFFOLDING AND LADDERS YES DAMS
PLATFORMS PRESSURE
FALLING FROM VEHICLES FLYING OBJECTS YES
4. ELECTRICITY 11. HAZARDOUS CHEMICALS
ISOLATION OILS, LUBRICANTS, FUELS
DAMAGED CABLES YES ACIDS
POWER FAILURE ALKALIS
FLAME PROOFING HEAVY METALS
FAILED TRIPS YES SOLVENTS
5. EXPLOSIONS 12. FALLS OF GROUND
DETONATORS AND EXPLOSIVES UNDERCUTTING
LIGHT ALLOYS SHORING AND BRACING
VEHICLE TIRES DETERIORATED CONSTRUCTION
FUEL TANKS 13. STRESS
GAS BOTTLES, BULLETS MATERIALS HANDLING YES
FIRE EXTINGUISHERS YES HIGH WORKLOADS
BOILERS AND PRESSURE VESSELS HEAT STRESS
6. MOVING VEHICLES METAL STRESS YES
PEDESTRIANS YES 14. PRESSURE SYSTEM
INSECURE LOADS YES AIR, WATER, PIPES
DRIVER PROTECTION AND COMPETENCE YES HYDRAULIC SYSTEM
PASSENGER PROTECTION GAS BOTTLES YES
ROAD CONDITIONS AIR RECEIVERS
VISIBILITY BOILERS
BAD MAINTENANCE, MECHANICAL YES 15. TEMPERATURE
TRAFFIC CONTROL YES HOT
COLD

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HAZARD & RISK IDENTIFICATION

RATING
NO HAZARDS IDENTIFIED WHO CAN BE HARMED (RISK ID) PREVENTATIVE CONTROL MEASURES
(Who, What, How, Why, Where, When) (Eliminate, Reduce, Isolate, Control, PPE, Discipline)
L S R H S E

1 3 4 H S Lifting materials (Pipe, ducts, Personal Injury, property damage, Regulations require employers to avoid the need to carry
tools, equipment) Persons may cause long and or out manual handling which creates a risk of injury.
manual handling short term injury to themselves Where avoidance is not reasonably practicable
employers have to make an assessment, reduce the risk
of injury as far as reasonably practicable and provide
information about the weight of loads.

Choose person who is capable of manually handling the

pipe, do the proper technique, ( stable foot position
shoulder width apart, bend knee, get a good grip of the
load, lift it closer to trunk/body, lift it with leg, and move
moderately, never twist body once load is lifted, always
ask for help.

2 3 4 H S Transportation of materials Personal Injury, Property damage, Ensure the transport vehicle is in sound condition.
(pipe) Road/vehicular accident Ensure driver has valid driving license
Follow traffic rules & regulations
Ensure material is placed tightly and secured with
proper belts & wedges
Store material in designated area and stack properly
Proper manual handling method.

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3 3 4 H S Lifting operation Off loading of
unit (crane / forklift)
4 3 4 H S Use of drill machine, grinding
machine (inproper use)
Support installation
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Serious injury, Property damage,
death, Overturn of equipment,
colapse of crane, crushing with
falling load(pipe)
Personal injury, property damage
Fire, electric shock, trip, burn
Resposible engineer/supervisor must ensure that all
crane , forklift and all lifting equipment/tackle were
inspected and in good condition with a valid test
certificate from registered 3rd party cetifying company.
Supervisor, operators, slinger / signaler must be
certified competent by an external 3rd party certifying
company.
Riggers will wear neon vests and bright orange hard
hats.
Ensure crane are stable(level ground, fully extend
outrig, enough clearance)
Ensure enough clearance and area is not restricted for
forklift manouver.
Ensure supervision is present all the time during the
operation.
Electrical power operated tools shall be of the
approved double-insulated type or grounded.
The use of electric cords for hoisting or lowering tools
shall not be permitted.
Inspect all tool before using.
Use eye protection, (gogles, facesheild), dust mask,
hand gloves.
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5 3 4 H S Use of scaffold, Personal injury, property damage, Use only scaffold that is built, inspected, taged and will
overhead/vertical/risers Fall of person / material, collapse or be modified only by competent scafolder,
installation overturning of scaffold, struck by Ensure that brakes are engaged.
falling materials. No material and person in the scaffold when moving
scaffold.
Do not throw materials, Use ropes to handle them
safely
Ensure complete platforms with safety handrails, guard
rails toe boards & access ladders.

6 3 3 M S Use of ladder Fall from ladder, slip of ladder,
object dropped from user.
Radiography Test of chilled
7 4 4 H S Water pipes. Personal injury, property damage
Persons may cause long and or
short term injury to themselves
cause by Radiation
Ladders must be checked/inspected before use
Correct length must observed.
Ground base must be firm and level
A ratio of 1:4 base to height must be observed
Avoid over reaching
None slip base must be used and tie ladder on top.
While using A type step ladder unsure the ladder
having proper rubber footing and locked cross arm
2m above Astepladder are prohibited at site.
.
Ensure working area 15m radius Barricated with
warning tape
Ensure sufficient lighting and ventallation is provided.
Ensure good communication and assign a watcher.
Authorized/ Engineer approved 3rd party should carry
out Radiography test.
Prior starting they should submit the specific Risk and
control measure and it should be approved by Engineer.

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Obtain Hot Work Permit from contractor.

8 3 4 H S Use of welding machine, (fire, Serious Injuries. Ensure welding machine and all welding tool and
explosion) Damage to property. accessories are inspected before use.
Electric shock All welding cables shall be of the completely insulated,
Burn flexible type, capable of handling the maximum current
requirements of the work in progress.
When electrode holders are to be left unattended, the
electrodes shall be removed and protected or machine
switched off.
When the arc welder leave his work for any appreciable
length of time, or when the arc welding or cutting
machine is to be moved, the power supply shall be
switched off.
Pipelines containing gases or flammable liquids or
conduits containing electrical circuits, shall not be used
as a ground return.
All arc welding operations shall be shielded by non-
combustible or flameproof screens, which will protect
employees and other persons working in the vicinity from
the direct rays of the arc.
No welding shall be done where the application of
flammable paints or the presence of other flammable
compounds or heavy dust concentrations create a
hazard.
Suitable fire extinguisher equipment shall be
immediately available in the work area and shall be
maintained in a state of readiness for instant use.
Engage only competent welder and helper for the
welding job and supervision must present all time .
Obtained hot work permit if applicable.

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9 3 3 M H S
Use of solvent, adhesive
cleaners (insulation)
Fire, Explosion
Personal injury, irritation, alergic
reaction.
Ensure that proper handling, use and dispossal of
solvent / adhesive are adhere, based on MSDS (Material
Safety Data Sheet) and ensure that hadler are informed,
trained and instructed
Keep away the material from any kind of fire source
Application of solvent / adhesive should be supervised
closely
Keep fire extinguisher at site.
Use appropriate PPE ( hand gloves , mask) as
suggested in MSDS

10 2 3 M H S Use of Fiber glass insulation Personal injury, irritation alergic Minimised working time / exposure with fiber glass
reaction, ionhallation of fiber glass insulation by proper planning of work.
Avoid breathing of fiberglass dust , use specified dust
mask by manufacturer, MSDS
Ensure proper stacking of fiber materials and only the
required amount / volume should be brought to site.
Avoid contact with the skin or eye, wear long sleeved,
loose-fitting clothing, gloves and eye protection
Ensure to engage only competent person (trained,
instructed and experienced).

11 3 4 H S Hydro (pressure) testing Personal injury, property damage Competent personnel supervised by qualified and
(bursting of pipe / hose / joints etc.) experienced supervisor shall only carry out testing.
Ensure that testing procedures are strickly follow.
Barricade and caution signs must be placed at the
appropriate and critical area.
Only calibrated and inpected gauges shall be used.
Do not over pressure the pipe follow only
required/recommended pressure.
Conduct tool box talk before carrying out testing.

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12 4 2 M S Emergency Injuries In case of emergency injured personnel will be

Death. removed from site to first aid room, they will then be
taken to hospital, an injury will be stabilized on site and
shuold not moved until ambulance arrives.
Emergency evacuation system should be brief to
workers.

13 3 3 M S Poor Supervision Death. Constant adequate supervision will be required in the

Injuries. installation of chilled water pipe activities. Supervisor will
Time loss. receive related risk and hazard analysis prior to
commencing operations.

14 3 3 M S E Excess and waste materials Personal injury, damage to Maintain house keeping at all times. Waste materials to
Tripping/Slipping Fire hazard property. be disposed off immediately or upon completion of the
activities.

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SAFE WORK PROCEDURE

NO ACTIVITIES CONTROLS

1 Obtain drawings of the works that needs to be done. Ensure safety measures have been incorporated within the drawings as far as
practically possible.

2 Training Train worker of proper manual handling and proper handling of solvent cement.

3 Assigned workers, assemble all equipment necessary to carry Conduct TOOL BOX TALK before start of work.
the task.

4 Proceed with installation works until works are finished. Any deviation or other safety concern that will come up, must be brought to the
attention of safety personnel/officer on the site.

5 Day end cleanup and housekeeping The area must be made safe at the end of each shift ensuring adequate barricades are
in place preventing unauthorized entrance of persons in the areas that may pose a risk.
Stack all equipment and materials in a safe manner at all times and clean the area to
eliminate tripping hazards.

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RISK ASSESSMENT COMMUNICATIONS FORM.

I, THE UNDERSIGNED HEREBY ACKNOWLEDGE THAT THIS RISK ASSESSMENT(Welding and Radiography test of Chilled Water pipe) HAS BEEN
DISCUSSED WITH ME AND THAT I UNDERSTAND THE CONTENTS AND THE RISKS INVOLVED IN THE TASK TO BE PERFORMED. I HAVE ALSO
BEEN INSTRUCTED ON THE SAFE METHODS TO PERFORM THIS TASK.
NAME TG. NO TRADE SIGNATURE NAME TG. NO TRADE SIGNATURE

DASAN BARBARAMMA 55944 WELDER

SARFRAZ AHMED 28721 WELDER

SHAMBHU KADRIYA 40554 WELDER

BIJIN ELIAS 47770 WELDER

MIR HAIDER ALI 40539 WELDER

SURESH KUMAR
35848 PIPEFITTER
GOPALAKRISHNANNAIR

SUSOBHKUMAR 35931 PIPEFITTER

SHANMUGHAN K. 49296 PIPEFITTER

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