Hydrotest Risk Assessment new

(1)

Risk Assessment Tables

(Guidance for assessing risk)

Risk Tolerability/Acceptance Table

Likelihood of Occurrence Risk Rating &

Rating Number Remedial Action and Timescale

High Likelihood Regular occurrence within the area of operations to which it refers, with the possibility of being realised once per day/shift.

Moderate LikelihoodOccasional occurrence with the possibility of being realised once per job/project/contract/month.

5 Intolerable Risk

Work shall not be started or continued until the risk has been reduced. If it is not possible to reduce the risk even with unlimited resources, work shall remain prohibited.

Low Likelihood Unlikely to occur but known to have occurred in the relevant industry/operation/type of work it refers to.

4 Substantial Risk

Work shall not be started until the risk has been reduced. Considerable resources may be required to do this. Where the risk involves work in progress, urgent action shall be taken.

Severity (injury)

High Severity Major Injury/Disablement/Fatality (e.g. amputation, major fracture, poisoning, multiple injuries, occupational cancer or other severe life shortening diseases, acute fatal diseases).

Moderate Severity Lost Time Injury (off work for more than 3 working days)-(lacerations, burns, concussions, serious sprains, minor fractures, deafness, dermatitis, asthma, work related upper limb disorders, ill health leading to permanent minor disability).

3 Moderate Risk

Work may proceed but efforts should be made to reduce the risk below this level. The resources/costs required for prevention should be carefully measured and limited. Risk reduction measures and remedial action shall be implemented as soon as practicable and within one month as a maximum. Where the moderate risk (level 3) involves high severity consequences, further assessment may be necessary to establish the likelihood more precisely and determine the need for improved control measures.

Low Severity First Aid Injury, Medical Aid Treatment Injury (return to work after loss of 1-2 shifts/working days)-(e.g. superficial injuries, minor cuts/bruises, eye irritation, headaches, temporary discomfort.

Severity (property/equipment)

High Severity Property/Equipment Damage costs exceeding $50,000.

Moderate Severity Property/Equipment Damage costs (direct and indirect) between $50,000 and $5,000.

2 Tolerable Risk

No additional costs are required. Consideration may be given to more cost effective remedial actions or improvements that involve no additional resources/cost burden. Monitoring is required to ensure that controls are maintained and in place.

Low Severity Property/Equipment Damage costs (direct and indirect) not exceeding $5,000.

Severity (environmental) 1 Low Risk Risk Acceptable. No action required. Document

findings.

High Severity Environmental damage is catastrophic and/or involves prosecution, severe damage to company image and substantial costs.

Moderate Severity Environmental damage external to local area and/or damage to company image and profits.

Low Severity Environmental damage is local and has minimal external impact.

Risk Rating & Rating Number Table Notes: For each hazard: - 1) Estimate Likelihood of Occurrence. 2) Estimate Severity of potential injury, property

damage or environmental damage. 3) Combine estimates to allocate Initial Risk Rating. 4) Assess Risk Tolerability or Acceptance. 5) Introduce Control Measures to reduce risk. 6) Reassess revised estimates of Likelihood and Severity after controls implemented and allocate new risk rating. 7) Reassess Risk Tolerability and if acceptable, enter Residual Risk Rating and associated Likelihood and Severity levels. If not repeat stages 5-7.

High Likelihood Moderate Likelihood Low Likelihood

High Severity 5 Intolerable risk 4 Substantial risk 3 Moderate risk

Moderate Severity 4 Substantial risk 3 Moderate risk 2 Tolerable risk

(2)

Risk Assessment Form

Base/Area/Dept/Project: Dubai/MEAP/Operations/Azeri Baku Pipelines Project

Assessed by:

Activity/Operation/Job: Pre-commissioning/Hydrotesting/MEPPS

Date:

Task/Job Steps

Hazard

Initial Risk

Controls

Residual Risk

Hazard Description and Effect for each Task. Note: Additional hazards may arise from interaction with other work.

Personnel / Equipment /

Environment at Risk SeverityHazard Likelihood ofOccurrence RatingRisk No.

List and describe fully all Controls Required. Cross-refers to any other relevant assessment (PPE, COSHH, Manual Handling, LOLER etc).

Hazard

Severity Likelihood ofOccurrence Rating No.Risk

Prepare detailed test

procedure Nominate wrong test pressure Over pressure system Damage to client system Mod Mod 3 Procedure/job card will be prepared, checked and approved by 3 separate BJ & client personnel.

Mod Low 2

procedure Nominate wrong test limitsOver pressure system Damage to client system Mod Mod 3 Procedure/job card will be prepared, checked and approved by 3 separate BJ & client personnel.

Mod Low 2

procedure Failure to identify NRV’s and valvesto be mechanically opened within the test limits

Trapped pressure in system

Damage to

client system Mod Mod 3 Procedure/job card will be prepared, checked and approved by 3 separate BJ & client personnel.

Mod Low 2

Prepare system for

flooding Failure of permit to work systemOngoing conflicting work on the same system

Personal injury and BJ

equipment damage

Mod Mod 3 Permit to work system is adhered to

rigidly and shortcomings/potential conflicts reported to PTW office immediately.

Mod Low 2

Prepare system for

flooding Rig up all flooding equipmentMuscle / back strain from moving heavy equipment

Personal injury Mod Mod 3 Follow all guidelines laid out during

safety induction and BJ HSE manual. Personnel trained in manual handling techniques. Items over 40 Kgs to be lifted by 2 or more people.

Low Low 1

Prepare system for

flooding Install incorrectly rated temporary hose / blinds / spades Overpressure of temporary equipment

BJ equipment

damage Mod Mod 3 Adhere at all times to procedure, all temporary equipment to be certified and pre-tested.

Mod Low 2

Prepare system for

flooding Use of hand ToolsTrapped / cut injured body parts Personnel injury Mod Mod 3 Follow all guidelines laid out during safety induction and BJ HSE manual Mod Low 2 Prepare system for

flooding Working at heightFall from high levels Personnel injury High Mod 4 Only use approved scaffolding, wear correct harness above 2m from floor. Mod Low 2

Approved by (Name):

Approved by (Title):

(3)

Task/Job Steps

Hazard

Initial Risk

Controls

Residual Risk

Hazard

Severity Likelihood ofOccurrence RatingRisk No.

Flood system Draining water

Soaking adjacent working personnel

Personnel injury Low Mod 2 When draining water warn as many

people as possible and monitor the drainage path of the water. Cover all electrical equipment.

Low Low 1

Flood system Splashed by high velocity water

Eye injury Personnel injury High Low 3 Use of correct PPE advised during induction and in HSE manual. Low Low 1

Prepare for hydrotest Working at height

Fall from high levels Personnel injury High Mod 4 Only use approved scaffolding, wear correct harness above 2m from floor. Mod Low 2

Prepare for hydrotest Failure of permit to work system

Ongoing conflicting work on the same system

Equipment and

plant damage High Mod 4 Permit to work system is adhered to rigidly and shortcomings/potential conflicts reported to PTW office immediately.

Mod Low 2

Prepare for hydrotest Rig up all Hydrotesting equipment

Muscle / back /strain from moving heavy equipment

Personnel injury Mod Mod 3 Follow all guidelines laid out during

safety induction and BJ HSE manual Low Low 1

Prepare for hydrotest Install incorrectly rated temporary pipework / hoses / blinds / spades Overpressure of temporary equipment

BJ equipment and personnel injury

Mod High 4 Adhere at all times to procedure. All

temporary equipment to be pre-tested prior to hook up to clients system.

Mod Low 2

Prepare for hydrotest Use of hand Tools

Trapped injured body parts Personnel injury Mod Mod 3 Follow all guidelines laid out during safety induction and BJ HSE manual Mod Low 2

Hydrotest system Over pressurise system

Critical failure / rupture of pipework Client system High Mod 4 Utilise system over pressure protection device fitted upstream of test gauge on hydrotest injection manifold.

Mod Low 2

Hydrotest system Non testing personnel working on

systems under pressure Critical failure

All personnel in

test area High Mod 4 Follow all guidelines on Permit to work. Adhere to barriers / signs recommended in procedure. No unauthorised personnel in test area.

Mod Low 2

(4)

Task/Job Steps

Hazard

Initial Risk

Controls

Residual Risk

Hazard

Severity Likelihood ofOccurrence RatingRisk No.

system Future release of pressurised fluid

-critical failure work. Adhere to barriers / signs recommended in procedure.

Depressurise / drain

system Draining water Soaking adjacent working

personnel

Personnel injury Low Mod 2 When draining water warn as many

people as possible and monitor the drainage path of the water. Cover all electrical equipment.

Low Low 1

Re-instate system De-rig of Hydrotesting equipment

Muscle / back / strain from moving heavy equipment

Personnel injury Mod Mod 3 Follow all guidelines laid out during

safety induction and BJ HSE manual Low Low 1

Re-instate system Use of hand Tools

Trapped injured body parts Personnel Injury Mod Mod 3 Follow all guidelines laid out during safety induction and BJ HSE manual Mod Low 2

Re-instate system Working at height

Fall from high levels Personnel Injury High Mod 4 Only use approved scaffolding, wear correct harness above 2m from floor. Mod Low 2

Re-instate system Install equipment incorrectly

Future failure of process system Client system High Mod 4 Completion of Reinstatement Check sheet by BJ and client. Mod Low 2

Re-instate system Use of hydraulic bolt tensioning and

torquing equipment

Muscle / back / strain from moving heavy equipment

Personnel injury Mod Mod 3 Trained and qualified personnel on

site to carry out bolt tensioning works. Assistance given when handling heavy objects. Two man lifting.

Mod Low 2

Re-instate system Use of hydraulic bolt tensioning and

equipment

Incorrect tensioning, loose bolts

Client system High Mod 4 Bolt tensioning procedures followed,

fully trained personnel to carry out the bolt tensioning operations.

Mod Low 2

Approved by (Name):

Approved by (Title):

(5)

Risk Assessment – Job Site Review Form

Page No:

5 Assessment No:

Job No/Project No:

Work Scope:

Location:

Note: If Procedure Change Control provisions apply during the job this form shall be used for the required assessment review.

Hazards / Risks on General Risk Assessment which are not applicable for this Work Scope:

(Identify by no. and description).

Use continuation sheet if out of space.

Hazards / Risks which have not been identified in General Risk Assessments which are applicable

for this Work Scope :

(Brief description of Hazards / Risks identified).

Control Measures to be utilised to minimise these additional Hazards / Risks:

(Full Description of Control Measures to be implemented).

I confirm that I have read the General Risk Assessment provided for this Work Scope and have surveyed the work site, where the additional risks have been identified. They are listed above and control measures suggested.

Job Site Review Performed by:

Date:

I confirm that I have read and understood both the General Risk Assessment and this Job Site Assessment Review, which are provided for this Work Scope. (To be signed by all personnel involved in this Work Scope i.e. all BJ and Client/Third Party as appropriate). (Use reverse if not enough space below for signatures).

(6)

Risk Assessment – Job Site Review Form

Continuation Sheet

Page No:

6 Assessment No:

Job No/Project No:

Work Scope:

Location:

Note: If Procedure Change Control provisions apply during the job this form shall be used for the required assessment review.

Hazards / Risks on General Risk Assessment which are not applicable for this Work Scope:

(Identify by no. and description).

Hazards / Risks which have not been identified in General Risk Assessments which are applicable

for this Work Scope :

(Brief description of Hazards / Risks identified).

Control Measures to be utilised to minimise these additional Hazards / Risks:

(Full Description of Control Measures to be implemented).