3B Risk Assesment VJ3100-003-A-4052 - F1 - 0001

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Subcontractor’s Name : Nasser S. Al-Hajri Corporation
Subcontractor No. : 0-6798-Z-3100-003
Project Name : KNPC Clean Fuels Project
Subcontractor Work Package : General Construction Works
: Risk Assessment for Thermal Spray Aluminium (TSA) Coatings by

Document Title
Flame & Arc Spray Process at 3B Workshop
Subcontractor’s Doc. No. : VJ3100-003-A-4052
KNPC CLEAN FUELS PROJECT
Subcontractor
ISSUE PURPOSE: FA FR FI √ FC AB
c
Approval or review hereunder shall not be construed to relieve Vendor / Subcontractor
a the Contract.
of his responsibilities and liability under
n CTR DEPT. /
Contractor Review Result SIGNATURE
p
1. Approved o / No Comments
2. Approved s / Reviewed - Minor
Comments
PNT/ I.P. Gautam
i HSE/ A. Mesquita
3. Rejected - Comments as Noted
t DHT/ A. Esguerra
4. Rejected
i
5. Not Reviewed
o
JOB. NO. n 0-6798-2
COMPANY t REV
DOC.no. P6011MAA.000-51H.1134
h
Conctractor
V plus Purchaser Code (V/J/G/S) & Subcontract No. - SERIAL no.
e F1
DOC.no. VJ3100-003-A-4052
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D R A h
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Kuwait National Petroleum Company (K.S.C) VJ3100-003-A-4052
Clean Fuels Project (CFP) Rev: F1
KNPC Contract No. CFP/EPC/0054-MAA Page 2 of 12
Contractor Job No. 0-6798-20-0000 P6011MAA.000-51H.1134
NASSER S.AL-HAJRI CORP.

KNPC-CLEAN FUELS PROJECT
RISK ASSESSMENT FOR THERMAL SPRAY ALUMINIUM (TSA)

COATINGS BY FLAME & ARC SPRAY PROCESS AT 3B WORKSHOP
Operation Center JOB CODE 0-6798-20-0000
Operation Center Doc No. VJ3100-003-A-4052
F1 12-Mar-2016 Issued for Final Bibin Mohan Michael O Bailli PV Santhosh
O2 10-Mar-2016 Issued for JGSK Comments Bibin Mohan Michael O Bailli PV Santhosh
O1 09-Mar-2016 Issued for JGSK Comments Bibin Mohan Michael O Bailli PV Santhosh
Rev. No Date Description Orig. by Checked by Approved by
Kuwait National Petroleum Company (K.S.C.)

Clean Fuels Project (CFP)
Kuwait
JGC Corporation / GS Engineering & Construction / SK Engineering & Construction
CONTRACT NO. DOCUMENT NO: REV.
0-6798-Z-3100-003 VJ3100-003-A-4052 F1
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Record of Revisions
Rev no Date Description
O1 09-Mar-2016 Issued for JGSK Comments
O2 10-Mar-2016 Issued for JGSK Comments
F1 12-Mar-2016 Issued for Final
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RISK ASSESSMENT FOR THERMAL SPRAY ALUMINIUM (TSA) COATINGS BY FLAME & ARC SPRAY PROCESS AT 3B WORKSHOP
Location CLEAN FUELS PROJECT-MAA Ref. No. : 0-6798-Z-3100-003
Department / Division PAINTING Date: : 13-Mar-2016
Area/ unit MAA Green Field / 3B Workshop Review date: : 12-Sep-2016
Description of Activity THERMAL SPRAY ALUMINIUM COATINGS WORKS (SHOP WORKS)
Estimated No. of Persons Likely Personnel involved: 15 Nos. Contractors: NASSER S.AL-HAJRI CORP.
to be exposed: &
No Hazards Likelihood Severity Risk Control in place Likelihood Severity Risk
1 Non-compliance of  Approved Work Method Statements should be

KNPC procedures 3 2 Caution made available. 1 2 Care
 Project specified proper PPE shall be worn.
 TBT & STARRT shall be conducted prior to the start
of work.
 All person need to undergo safety orientation
induction.
2 Personal injuries  Ensure correct tools are used for each activity.
2 3 Caution  Project specified proper personal protective 1 2 Care
equipment shall be used.
 Strict supervision must be there during all the
activities.
3 Yard floor cleaning by  Do not broom the sealer dust in the manner of dust
broom 2 3 Caution fly out, if need sprinkle water to prevent dust fly out. 1 2 Care
 Inhaling TSA dust  Collect the dust and dispose into hazardous waste
storage.
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4 Yard floor cleaning by  Do not broom the sealer dust in the manner of dust
broom 2 3 Caution fly out, if need sprinkle water to prevent dust fly out. 1 2 Care
 Collect the dust and dispose into hazardous waste
 Inhaling TSA dust storage.
 Eye Contact  Eye wash station to be located at the working area.
5 Material Lifting,  Proper PTW shall be obtained prior to the start of

handling and 2 3 Caution work. 1 2 Care
Transportation  Prior to lifting operation consider the wind speed
and climatic conditions.
 Falling of Load  Keep the boom down, fasten the load and clear
 Hit by the load from the area.
 Pinch points shall be considered and hands shall
 Pinch points
not be placed in the ‘Line of Fire’ between
 Fire unsecured items or under loads being raised or
landed.
 Tag lines shall be used to assist the positioning of
loads.
 Crane or forklift operators shall retain final authority
over decision to commence the lift or movement.
 Slings shall be inspected and colour coded prior to
use.
 Crane and the Forklift shall have a valid KNPC
Safety Certificate.
 All pipe loads on forklift shall be secured by means
of ratchet strapping, or in the event of small
component or fittings placed in crates or secured to
pallets in good order.
 Lifts shall be within capacity of lifting equipment.
 Operators shall be qualified and approved &
holding a valid 3rd party certificate.
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 Operators shall carry out a daily inspection on their

assigned equipment and should maintain a
checklist.
 Loads shall not be left unattended or in an elevated
position when operators are not within crane cab or
forklift seat.
 Lifting area shall be barricaded Lifting in Progress
Signage shall be available.
 Flame proof wirings provided to avoid spark
creation.
6 Loading on TSA Wire  Report problems immediately.

in Trally 2 3 Caution  Wear safety shoe & safety helmet while handling. 1 2 Care
 Material fall due to  Certified and inspected tools and equipment’s shall
trally or hooks be used.
failure
7 Cleaning by  Wear cartridges type nose mask and goggle.

compressed air 2 3 Caution  Provide eye wash can. 1 2 Care
 Inhaling Dust  Skilled operator are required.
 Eye contact  Proper PPE should be used.
 Skin irritation  Medical fit test prior to commencing blast / paint
work for blaster and painter.
8 Abrasive Blasting  Area shall be barricaded and adequate signage

Surface Preparation 2 3 Caution shall be provided. 1 2 Care
 All equipment, compressors shall be inspected and
 Inhaling Dust defective equipment shall be replaced.
 Eye injury due to  Wear suitable coveralls and gloves as
dust particles recommended by the Vendor MSDS.
 Fire  Proper eye protection shall be worn to prevent dust
particle injury.
 Noise hazard
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 Blast Technicians shall wear the correct and

appropriate Air Fed Hood.
 All are materials shall be kept in a barricaded
location at site.
 Periodically maintained and approved fire
extinguisher shall be available at site.
 Operators shall visually check the blast / air hoods
prior to use for any damage.
 Check all the hose connections and the hoses for
any leaks and damage.
 Ensure the position of the blast nozzle is always
facing the blasting surface and should be away
from the body all times.
 Air Supplied Filler shall be free from dust, oil
vapors& moistures.
 Nozzle gun shall be equipped with dead man
handle.
9 Application on  Proper PPE as per MSDS should be used, skilled

ARC/Flame spray gun 2 3 Caution operators are required. 1 2 Care
& Airless painting gun  Static electricity awareness given to applicators.
for spraying Antistatic shoes provided.
components  Wear mask, goggle, sleeves and hand gloves etc.
as recommended in the MSDS.
 Electric shock  Any modification to electrical component or
installation shall be carried out by competent
 Skin Allergy
authorized personnel only.
 Inhalation of dust
 Surface Preparation Technicians shall wear the
 Inhalation of smoke correct and appropriate PPE.
 Slip, trip & falls  Periodically maintained and approved fire
 Fire extinguishers shall be made available.
 Inhalation of paint  Proper housekeeping should be maintained.
particles  Check air hose tightness.
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 Yard should be closed while in use. Hot works not

allowed in surrounding area. Collecting abrasive
should be provided at the floor for collect the
spillage. Cell phone usage not allowed in
application area. Fire extinguisher provided. Follow
procedure Handling & storage of flammable solids,
liquids, Aluminum Wire and gases.
 Awareness given to shop floor operators for spark
prevention. Work permit system followed for
service providers. Awareness given for not to
operate any electronic measuring meter inside the
Yard for fire prevention due to spark.
extinguisher shall be available at site.
 Change the operator frequently.
 High Pressure and Hydraulic hoses shall be daily
checked for cracks, bubbles, defective connectors
etc. All opened paint or chemical containers shall
be placed in drip trays.
 Spill containment equipment shall be available at
the paint spray/mixing areas.
 MSDS shall be made available at site
10 Maintenance of  Check the diagram of the spools. Check incoming

Identification tag in 2 3 Caution spools / outgoing spools and tag it properly & record 1 2 Care
the spools during in the log book.
 Follow spool handling procedure during and after
TSA
painting.
 Wrong identification
11 Protection if weld
joints during TSA 2 3 Caution  Use proper masking tape to protect Welding joints. 1 2 Care
 Affect quality of TSA
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12 Waste Handling  MSDS and Hazchem Signage shall be prominently

2 3 Caution displayed at all times. 1 2 Care
 Fire  Spill kit shall be provided at work location.
 Flammable products shall be stored separately with
adequate signage.
extinguisher shall be made available.
 Observe and position all safety labels on packaging
to be easily recognized.
 Packaging and cans shall be completely empty
prior to crushing for subsequent disposal.
 Rags, cloths and other materials contaminated with
flammable solvents shall be stored in containers.
 Proper housekeeping shall be done.
13 Checking by dry film

thickness (DFT) 2 3 Caution  Keep space between then to go and check. 1 2 Care
gauge  Maintain proper housekeeping, keep enough
space.
 Fall of personnel
and equipment
14 Hand Cleaning
 Ingestion due to 2 3 Caution  Do not use thinner to wash hands. Use safe clean 1 2 Care
to wash the hands.
incorrect cleaning of
hands
15 House keeping  Waste materials accumulated after the activity

2 3 Caution should be removed from the place of work and 1 2 Care
 Nips, Cut, Pinch stored in the appropriate waste bins.
point  Supervisor should ensure that the housekeeping is
carried out at the place of activity prior to the start
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 Slips trips and fall and also at the end of job.

 Access to be kept clear always.
16 Heat Stress  Rest shall be taken at regular intervals, as per the

2 3 Caution Heat stress Management procedure. 1 2 Care
 Worker Health  Rest stress shelters shall be provided.
Condition  Keep water bottles always as a part of PPE.
 Drinking water stations should be arranged near to
the work location.
 Temperature and humidity shall be monitored and
safety precautions to be followed.
17 Cold Stress  Rest shelters shall be provided.

2 3 Caution  Person working in the high elevated area should be 1 2 Care
 Worker Health medically fit.
condition  Temperature & Humidity shall be monitored &
Safety precautions to be followed.
 Coverall shall be worn properly so that direct
exposure of body from outside weather is
prevented.
18 Inadequate Emergency  Educate the workforce about emergency procedure

procedure 2 3 Caution  In case of any emergency all work will be stopped, 1 2 Care
shutdown all running equipment and machineries
and report to muster point
 Proper Access/Egress shall be available
 Emergency vehicle shall be available at site at all
times.
 All work forces shall know the MUSTER POINT /
ASSEMBLY POINT location.
 Contact immediately safety in charge/ Project in
charge.
Key: ALARM-Serious or major harm will probably occur, ALERT-Moderate harm probable, major harm unlikely to occur
CAUTION-Minor harm probable, major harm very unlikely to occur, CARE-Minor harm possible, major harm very unlikely to occur
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PMC Superintendent PMC-HSE

Issuer Executor (Leader) EPC(JGSK)–HSE
(Reviewed)
Signature
Name
Emp#
Note: 1. Master copy (original) shall be retained in file for record and future reference
2. Photo copy shall be attached with work permit
3. Ref.no. Guidance: - Example LOCATION–DEPT./DIV.RISKANALYSIS–YEARSERIALNO. e.g.1.MAA–XXXXRA–05- 1001, 2. PRJ– XXXXRA–05-1—1
4. If same Risk assessment is being used again, it must be reviewed to check relevancy.
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Page 1 of 12

Subcontractor’s Name : Nasser S. Al-Hajri Corporation

Subcontractor No. : 0-6798-Z-3100-003

Project Name : KNPC Clean Fuels Project

Subcontractor Work Package : General Construction Works

: Risk Assessment for Thermal Spray Aluminium (TSA) Coatings by

Subcontractor’s Doc. No. : VJ3100-003-A-4052

KNPC CLEAN FUELS PROJECT

NASSER S.AL-HAJRI CORP.

RISK ASSESSMENT FOR THERMAL SPRAY ALUMINIUM (TSA)

Operation Center JOB CODE 0-6798-20-0000

Operation Center Doc No. VJ3100-003-A-4052

F1 12-Mar-2016 Issued for Final Bibin Mohan Michael O Bailli PV Santhosh

Rev. No Date Description Orig. by Checked by Approved by

Kuwait National Petroleum Company (K.S.C.)

O1 09-Mar-2016 Issued for JGSK Comments

O2 10-Mar-2016 Issued for JGSK Comments

F1 12-Mar-2016 Issued for Final

No Hazards Likelihood Severity Risk Control in place Likelihood Severity Risk

1 Non-compliance of  Approved Work Method Statements should be

5 Material Lifting,  Proper PTW shall be obtained prior to the start of

 Operators shall carry out a daily inspection on their

6 Loading on TSA Wire  Report problems immediately.

7 Cleaning by  Wear cartridges type nose mask and goggle.

8 Abrasive Blasting  Area shall be barricaded and adequate signage

 Blast Technicians shall wear the correct and

9 Application on  Proper PPE as per MSDS should be used, skilled

 Yard should be closed while in use. Hot works not

10 Maintenance of  Check the diagram of the spools. Check incoming

12 Waste Handling  MSDS and Hazchem Signage shall be prominently

13 Checking by dry film

15 House keeping  Waste materials accumulated after the activity

 Slips trips and fall and also at the end of job.

16 Heat Stress  Rest shall be taken at regular intervals, as per the

17 Cold Stress  Rest shelters shall be provided.

18 Inadequate Emergency  Educate the workforce about emergency procedure

PMC Superintendent PMC-HSE

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