HAZARD IDENTIFICATION AND RISK ASSESSMENT HIRA FOR TANK HYDRO TEST DOC.

NO:OIL/PDPP/T/HIRA/HSE/006 Rev: 01
Recommend
ed control
Risk Action
Risk Identification Desired controls and Existing gaps, if any actions to Remarks
assessment by
reduce the
risk level
Activity Type

Associated
Condition
(N/AN/E)
Consequences Desired Control Gaps If

Risk

Risk
Risk
S.N Activity P S
/ Hazards Measures Any

01 HYDRO R  Over E 1. Hazards from the 1 3 3 L  Tool box Engineer/

TESTING Pressure effects of work-  Use of pressure relief valve to be ensured. talk Supervisor
 Pressure related stress, Valves & vents should have adequate should be
gauge & violence and work- provided
pressure rating. prior to
blind related fatigue.
 To comply with EIL's work permit. Lines & hydro test
rupture.
 Damage to
joints under test adequately restrained.  Training &
Test area shall be barricaded properly & Awareness
nearby
existing unauthorized entry shall be restricted. All  , Regular
check &
equipment electrical equipments shall be protected
Inspection
 Property from water.
damage  Block valve shall be provided on the line
 Burst of
from the test pump to the equipment
pipe,
under test.
 Water
lodging,  Lines under pressure identified and traffic
Severe should be restricted near hydro testing
Injury activities.
 Pressure gauges should be calibrated prior
to use.
 Existing equipments shall be protected
from hydro test affected area.
 Dewatering facility should be provided.
 All the temporary lugs, clits, brackets. tack
welds etc used for erection purpose shall
be removed before hydro test.

Level of consequence – Refer Guidance criteria for this i.e. possible degree of damage; Condition- N: Normal, AN: Abnormal, E-Emergency Activity Type: R- Routine, NR- Non Routine

Low Risk (1-3) Medium Risk (4- 9) High Risk (10- 25)
 HAZARD IDENTIFICATION AND RISK ASSESSMENT HIRA FOR TANK HYDRO TEST DOC.NO:OIL/PDPP/T/HIRA/HSE/006 Rev: 01
Recommend
ed control
Risk Action
Risk Identification Desired controls and Existing gaps, if any actions to Remarks
assessment by
reduce the
risk level
Activity Type

Associated
Condition
(N/AN/E)
Consequences Desired Control Gaps If

Risk

Risk
Risk
S.N Activity P S
/ Hazards Measures Any

 No pipe should be connected to the

newly build tank during water test
except the one used to fill used to fill
the tank with water.

 All radiography work including

repairing and re-radiography shall be
completed prior to start radiography
test.

 All the temporary lugs, Clits, brackets,

tack weld, etc, used for erection
purpose shall be removed before
hydro test.

 All the shell nozzles shall be properly

blinded with blind flanges and gaskets
tightened with nuts and bolts.

 Fixed Roof/ Floating roof opening

should be kept open.

 Water access line and sufficient no of

pumps shall be arranged before
testing starts.

Level of consequence – Refer Guidance criteria for this i.e. possible degree of damage; Condition- N: Normal, AN: Abnormal, E-Emergency Activity Type: R- Routine, NR- Non Routine

Low Risk (1-3) Medium Risk (4- 9) High Risk (10- 25)
 HAZARD IDENTIFICATION AND RISK ASSESSMENT HIRA FOR TANK HYDRO TEST DOC.NO:OIL/PDPP/T/HIRA/HSE/006 Rev: 01
Recommend
ed control
Risk Action
Risk Identification Desired controls and Existing gaps, if any actions to Remarks
assessment by
reduce the
risk level
Activity Type

Associated
Condition
(N/AN/E)
Consequences Desired Control Gaps If

Risk

Risk
Risk
S.N Activity P S
/ Hazards Measures Any

 Fresh clean water shall be used for the

hydrostatic test.

 Hydrostatic testing shall be carried out

at an ambient temperature but not
less than 4 degree centigrade.

 After hydro test, Water should be

drained properly at area designated by
EIL/ BPCL-KR and tank should be
allowed dry.

 Safety signage board should be hung

at the tank undergoing hydrostatic
testing.

 Access to be provided for decking.

 Permit to work (PTW) from EIL/BPCL

Shall be obtained for hydro testing.

 Tool Box meeting should be conducted before the start of the job / HIRA to be strictly implemented
 In night time proper and adequate lights should be provided and arranged.
 Housekeeping around the area / 100% supervision from staff level.
 All job to be performed with the proper authorization PTW.

Level of consequence – Refer Guidance criteria for this i.e. possible degree of damage; Condition- N: Normal, AN: Abnormal, E-Emergency Activity Type: R- Routine, NR- Non Routine

Low Risk (1-3) Medium Risk (4- 9) High Risk (10- 25)
 HAZARD IDENTIFICATION AND RISK ASSESSMENT HIRA FOR TANK HYDRO TEST DOC.NO:OIL/PDPP/T/HIRA/HSE/006 Rev: 01
Recommend
ed control
Risk Action
Risk Identification Desired controls and Existing gaps, if any actions to Remarks
assessment by
reduce the
risk level
Activity Type

Associated
Condition
(N/AN/E)
Consequences Desired Control Gaps If

Risk

Risk
Risk
S.N Activity P S
/ Hazards Measures Any

Risk Matrix

Impact

RISK MATRIX 1 2 3 4 5

Slight Minor Major Single Multiple

DATE REV.NO. PREPARED BY Injury Injury BY
CHECKED & APPROVED Injury
REVIEWED BY Fatality fatalities
APPROVED BY
OIL OIL EIL EIL
L 5 Continuous 05 10 15 20 25
i
18.06.2018 01
k 4 Frequent 04 08 12 16 20
e HIGH
l
3 Very Likely 03 06 9 12 15
i
MODERATE
h
o 2 Likely 02 04 6 08 10
o
d 1 Unlikely 01 02 3 04 05
LOW

Level of consequence – Refer Guidance criteria for this i.e. possible degree of damage; Condition- N: Normal, AN: Abnormal, E-Emergency Activity Type: R- Routine, NR- Non Routine

Low Risk (1-3) Medium Risk (4- 9) High Risk (10- 25)