R I S K A S S E S S M E N T

SITE: LOCATION:
UNITS INVOLVED:
DESCRIPTION OF TASK:

1. HYDROTESTING ACTIVITY MAXIMUM TEST PRESSURE – 140 BAR

 R I S K A S S E S S M E N T

ACTIVITY / CONDITION (S) THAT HAZARD PROBA- SAFE GUARDS NEEDED TO CONTROL RISK RISK RESPONSIBLE
ITEM RISK
HAZARD DEVELOP THE HAZARD EFFECT BILITY TO ACCEPTABLE LEVEL ALARP PERSON

1. ACTIVITY : HYDRO TEST PREPARATORY ACTIVITY

1.1 Injury to personnel / Loose fittings H L M - System to be flushed prior to hydrotest. L Hydro test Supvr.
damage to asset
- Only hydro testing personnel will be allowed in the
vicinity of the hydro testing area. Other crew will stay L Hydro test Supvr.
at a distance from the testing area. Unnecessary
personnel to clear the platform.
- Correct tools will be used to tighten the bolts/ Hydro test Supvr..
fittings.
- A dedicated Hydro test supervisor will be assigned Hydro test Supvr
to supervise the testing.

Wrong test pressure, Over test
pressure system, Test system
below pressure.
Incorrect injection point. Over
pressurise system. Failure to
pressurise system.
Incorrect depressurisation
routes. System not fully de-
pressurised.
Rupture of high pressure hose,
fittings
H L M - Test Pack to be prepared, checked and approved by L FE – NPCC / ABB
NPCC/ABB/ADMA
- Test Pack to be prepared, checked and approved by L FE – NPCC / ABB
NPCC/ABB/ADMA
H L M - Test Pack to be prepared, checked and approved L FE – NPCC / ABB
by NPCC/ABB/ADMA
H L M - ABK work permits to be in force. L Hydro test Supvr..
- Prior to start pressure test all hoses / fittings to be L Hydro test Supvr
checked. A checklist to be prepared by Hydro test
supervisor and implemented by test technician and
to be included in the work permit.

- Testing crew to be liaised with radio room of the L Hydro test Supvr.
barge during pressurisation. PA will be announced
before the hydro testing start and after the
completing the testing.

- All gauges to be calibrated. All fittings should not be L Hydro test Supvr
under rated to the pressure required. All equipment
to be used will be certified by the 3rd parties.

- Whip checks shall be installed on all hoses L Hydro test Supvr

connections.
 R I S K A S S E S S M E N T

ACTIVITY / CONDITION (S) THAT HAZARD PROBA- SAFE GUARDS NEEDED TO CONTROL RISK RISK RESPONSIBLE
ITEM RISK
HAZARD DEVELOP THE HAZARD EFFECT BILITY TO ACCEPTABLE LEVEL ALARP PERSON

- All hoses to have burst pressure higher than the test L Hydro test Supvr
pressure.

- In case of leak, pressure will be released before re- L Hydro test Supvr
tightening of the bolts

- Physical checks to all fittings and hoses will be Hydro test Supvr
conducted by hydro test supervisor prior to install L
the fittings.

- Radio will be available to hydro testing supervisor L Hydro test Supvr

for communication.

- A TOOLBOX TALK for all personnel needs to be L Hydro test Supvr

carried-out by SUPERVISOR to brief the work force
on location prior to start work.

2. ACTIVITY : RIG UP OF EQUIPMENT

Injury to personnel / Manual Handling H L M - Team trained in manual handling techniques. Only L Hydro test Supvr
damage to asset certified lifting equipment to be used
Rig up to wrong system, over H L M - Injection point identified in procedure. Pre- test L NPCC / ABB
pressure system safety check by NPCC AND ABB.
Hoses causing obstruction / M L M - Hoses route to be checked by NPCC Supervisor L NPCC
tripping hazard before rig up.
3 ACTIVITY: TAPING OF JOINTS TO BE TESTED.

3.1 Injury to personnel by Poor / incorrect access H L M - Access to all flanges by platform or authorized L NPCC
falling scaffold only
3.2 Missed system joints. Wrong rev P & ID's. Incorrect H L M - Test Pressure to be prepared, checked and L NPCC/ABB
procedure. Poor lighting. approved by NPCC/ABB/ADMA.
- Ensure work area has good lighting.

4 ACTIVITY: ALIGNMENT OF SYSTEM VALVES AND ISOLATIONS

4.1 System incorrectly System not checked correctly, M L M - Insulation checklist checked and signed by NPCC L NPCC / ABB
isolated. Over damage valves. supervisor. Double block and bleed where possible.
pressure adjacent Secondary vent paths identified and aligned.
system
 R I S K A S S E S S M E N T

ACTIVITY / CONDITION (S) THAT HAZARD PROBA- SAFE GUARDS NEEDED TO CONTROL RISK RISK RESPONSIBLE
ITEM RISK
HAZARD DEVELOP THE HAZARD EFFECT BILITY TO ACCEPTABLE LEVEL ALARP PERSON

4.2 System internal System not checked correctly, H L M - Valve checklist checked and signed by NPCC L NPCC / ABB
valves closed, system damaged valves. Pressure relief supervisor. System walked and alignment checked
not fully pressurised, settings incorrectly set. by NPCC Supervisor.
over pressure system.
5 ACTIVITY : ERECT WARNING SIGNS AND BARRIERS

Injury to personnel / Access routes left open.
damage to asset Unauthorized access to system
under pressure
6 ACTIVITY: CLEAR UNAUTHORIZED PERSONNEL
H L M - Area barriers agreed with Hook - up superintendent. L NPCC / ABB
Barriers checked by NPCC and enforced by NPCC
watchers. Pre-test check signed by NPCC. Work on
test controlled by TABK. Authorised personnel only.

Injury to personnel Unauthorized access to system H L M - Area checked prior to testing. PA announcement L NPCC
interference with system under before testing. Inform TABK complex.
pressure.