DODSAL ENGINEERING & CONSTRUCTION PTE LTD

TASK RISK ASSESSMENT WORKSHEET Attachment to Doc.No: TRA - 63

TASK DESCRIPTION Pressure hydro Testing of A/G Piping SUBCONTRACTOR Dodsal Engg. & Const. Pte
Ltd.

TRA TEAM MEMBERS Page 1 of 3 DATE: 20.02.2012

STEP DESCRIPTION OF HAZARD CONSEQUENCES CONTROLS BASELINE ADDITIONAL RESP. RESIDUAL

NO. TASK STEP PEOPLE, ENVIRONMENT, PREVENT, DETECT, CONTROL, MITIGATE RISK CONTROL PARTY RISK
ASSETS, REPUTATION MEASURES /
S P R ACTIONS S P R

 Obtain an appropriate work 4 3 12  Close 3 2 6

01 Hydro testing  Slips  Injury permit from SECL & conduct supervisionl.
 Strains & Sprains  Fatality TBT before commencement of
Water filling for  Manual handling.  Pinch point work  Emergency
Hydrotest  Falling object.  Damage to  Personnel must be undergone Arrangements’
 Trip hazard. existing facilities of Work At Height Training from like First Aid
Pressurization  Slippery surface Takreer/ own SECL Box, First Aider
 Fall from Height properties  Secure all tools & equipment must be
Draining  Hose handling when working elevated height available at
 Trapped air during  Secure all loose objects site.
Housekeeping filling of test  Compressors to be inspected
medium from SECL prior to use.  Ensure

Samsung Electrical supervisor

 High pressure  Hoses and fittings of walkways are
release appropriate pressure rating free from
 Damage to  Use Whip arrestor and safety obstacles
associated pins. Correct lifting
equipments/pipe  Inspection of the hoses and techniques to
lines /valves fittings before use . be used
 Filling and disposal  Area around the pressure test  Proper Earthing
of Test Medium shall be suitably barricaded of equipment
 Failure of system and signs posted to prevent  Electrical
 Over Pressure access to unauthorized equipment to
 Failure of gauges persons be inspected
 Damage of system  Authorized personnel only at by Electrical
 worksite. dept. prior to
 Calibrated gauges shall be use
installed to monitor the  Avoid water
pressure / temp (As per the spillage.
approved procedure).  Ensure spilled
 Pressure test shall be carried water drained
out as per the procedure properly.
approved by Samsung

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DODSAL ENGINEERING & CONSTRUCTION PTE LTD

 Air vents shall be opened at Close

the start of the filling to Supervision.
ensure complete air discharge
prior to testing. Emergency
 Pressurizing/depressurizing Arrangements’
shall be performed gradually like First Aid
at a moderate and constant Box, First Aider
rate, as per the test must be
procedure. available at site.
 During pressurizing,
connections/joints shall be  All in line
periodically inspected for valves shall be
leaks. in fully open
 Never strike or subject the condition
testing component to any during pressure
shock during a full over test.

Samsung Electrical supervisor

pressure test.  Apply proper
 Never approach a test manual
component subject to handling
maximum test pressure until techniques
a safe period of time has
elapsed
 Ensure that the blanking off
devices (screwed plugs &
connections) are made of
correct material with strong
screw threads.
 Pressure retaining threads
and tapping should be
inspected for wear and
corrosion using calibrated
thread gauges.
 Ensure that all
linked/networked pipes are
free from pressure and
isolated.
 Suitable pressure rated blinds
shall be used to withstand
test pressure.
 Proper arrangement for filling
the test medium.

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 DODSAL ENGINEERING & CONSTRUCTION PTE LTD

 Proper arrangement for

containment and disposal of
test water after the Job.
 Ensure that the vent & drains
are opened at the same time.
 Avoid draining to open drain.
 Area to be cleaned for dirt
and waste materials.

02 PNEUMATIC  Possible release of  Explosion  Method statement to be 4 4 16  Close 3 3 9

PRESSURE Stored energy  Injury explained to all employees Supervision
TESTING  Brittle fracture of and it must be made available  Testing to be
metal due to low  Sharp edges at the site during the carried out in
temperature of  Pinch point activities part of line
metal  High Noise  Job specific TRA to be made isolated by
 Failure of system  Slipping/Tripping available at the site & control using adequate
 Over Pressure measures to be capacity of
 Failure of gauges,  Damage to communicated to all flanges & blind
Pressure relief existing facilities of personnel involved in the job to withstand
valves Takreer/ own through Tool Box Talk Meeting the test
 Damage of system properties  All necessary documents shall pressure
 Safe distance from  Heat stress attach with the work permit  Ensure that all
dangerous  and made available at the personnel are
pressurized work site aware of the
equipment not  Site Mandatory PPE like hazards and
identified Helmet, goggles, gloves, ear takes
 Lack of protection to be used by all appropriate
Communication employees precautions
/Languages/  All barricading shall be as per  All personnel
Translators the Safety Distance exclusion working for
 Lack of PWHT/NDT zone Ensure that sufficient testing shall
inspection accessibility, proper wear high
 No interpreters barricading is done in the visibility jackets
were used to work area all the time
translate hazards  Place the compressor station  Barricading
 Hazards were not and gauge manifold away shall be yellow
mentioned in the from the testing location. black warning
TRA/ Method  Ensure that compressor tape
statements station is technically inspected 
were mentioned and approved from SECL
 Lack of warning
signs for testing
 Unauthorized
personnel Page 3 of 6
 DODSAL ENGINEERING & CONSTRUCTION PTE LTD

 Vehicular  Testing supervisor shall  AIR LEAK

movements ensure the pipes are PWHT TESTING IN
 Insufficient and NDT tested PROGRESS,
accessibility  Place sufficient number of fire KEEP AWAY
 Poor lighting extinguishers near by the sign boards
 Defected tackles compressor station shall be posted
Modified/Home  Testing supervisor shall be  Ensure all are
made tools available in the compressor provided with
 Hose clamps station during the testing water bottles
used/not crimping  Do not allow any unauthorized and all are
fittings personnel entry inside the having it while
 Compressed air barricading working
 Manual handling  Ensure trained and  Remove all
 Damaged experienced operator defected,
equipment assigned for the job modified/modifi
 Dropping pressure  Ensure all tools and tackles ed tools from
gauges are inspected and approved site

Site SAMSUNG Supervisor

 Very heavy flanges by SECL .  Adequate dust
 Sharp edged tools  Ensure all hose connections protection shall
 Defected/Modified are in good condition be worn by the
tools  Whip arrestors shall be fitted operator
 Accumulation of between the compressor and  Care shall be
debris hose connection taken to avoid
 Awful Impression  Protection pins shall be fitted personnel
 Tripping hazards in all hose to hose injuries
 Bolt tightening connections  Ensure all hand
 Personnel  Ensure the Pressure Relief tools are in
entry/control valves are properly calibrated good condition
 Poor lighting which is set for 110% of Test  Disseminate
visibility pressure.Tested and certified the points of
 Personnel entry – manifold (Tested 1.5times emergency
no barricading than the required Test response
 No safe distance pressure)to be used measures
 Faulty gauges  All pressure gauges shall be during Tool Box
 Faulty couplings calibrated & checked by the Talk meeting
 Leaking couplings testing supervisor prior to the  is available at
 Unawareness of testing for it’s proper site and all
emergency operation & Test gauge range employees are
response measures shall be selected to ensure drinking water
 Filling and disposal that the test pressure falls periodically
of Test Medium between 30 to 80% of test  No vehicular
pressure movement is
 Use ear protection during allowed in the
cleaning area
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 DODSAL ENGINEERING & CONSTRUCTION PTE LTD

 Ensure dead man switch is  Ensure that all

fitted in the end of hose proper PPE
 Ensure all are using necessary while entering
PPE’s while working with hand the
tools area,hearing
 Inform all information about protection
the initial pressurization to  Ensure no
the area authority modified tools
 Care must be exercised to are available at
prevent exceed the specified the site
test pressure by morethan  At elevated
10%. height
 Do preliminary check at Recommended
0.71kg/cm2,Rectify all leaks for 84” dia
prior to start the pipes shall be
pressurization, gradually tested to 100%
increase pressure in steps to NDT
full test pressure  Emergency
 Bolt shall not be tightened contact
while system being tested are numbers shall
pressurized above 2.1 kg/cm2 be available
 Ensure no personnel entry with all crew
inside the barricades during members
air leak testing  Ensure plenty
 At elevated placed above of cool drinking
54” dia pipes must be water
passed 100% NDT test
,any deficit likely to result
in catastrophic event

Remarks :

Reviewed By: Name: Approved By: Name: Approved By: Name:

Sub Contractor Sub Contractor SECL
Sign: Sign: Sign:

Date: Date: Date:

S: Severity, P: Probability, R: Risk

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 DODSAL ENGINEERING & CONSTRUCTION PTE LTD

Risk Factor Matrix

Probability Methodology
Probability Risk Priority
4 – Probable / Likely to occur immediately or shortly 1. Identify Hazards
3 – Reasonably probable – Probably will occur in time 4 3 2 1 8-16 High Risk 2. List Hazard Events
S
2 – Remote – May occur in time 3. Calculate risk factor with initial risk rating
e 4 16 12 8 4 5-7 Medium Risk
1 – Extremely remote – Unlikely to occur 4. Detail controls and mitigation plan
v
5. Calculate residual risk factor with final risk rating
e 3 12 9 6 3 1-4 Low Risk 6. Enter risk priority
r
7. Evaluate acceptability of risk
I 2 8 6 4 2
t
y 1 4 3 2 1

Severity
4 – Catastrophic – Imminent danger exists, hazard capable of causing death or illness at wide scale
3 – Critical – Hazard can result in serious illness, severe injury, property and equipment damage
2 – Marginal – Hazard can cause illness, injury or equipment damage but the damage is not expected to be serious
1 – Negligible – Hazard will not result in serious injury or illness, remote possibility of damage beyond minor first-aid case.

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