Risk Assessment
Activity: Hydro Static Test Project / Site location: BUN
/Department Involved: Mechanical Department
Description of Work: . Hydro Static Test for the pipe line inside BUN
Job Supervisor: Mohammed Kareem
Localized Shutdown: □ Required □ Not Required HSE Supervisor: Abdulla Basheer
Analysis criteria:
Severity
Probability
Insignificant (1) Minor (2) Moderate (3) Major (4) Catastrophic (5)
Rare (1) 1 2 3 4 5
Possible (2) 2 4 6 8 10
Likely (3) 3 6 9 12 15
Often (4) 4 8 12 16 20
Frequent (5) 5 10 15 20 25
15 – 25 Extreme Risk (E) Activity must not proceed in current form.
8 – 12 High Risk (H) Activity must be modified to include further control measures and be subject to detailed HSE dept. assessment.
4–6 Moderate Risk (M) Activity can proceed subject to appropriate direct and continuous supervision and/or task modification.
1–3 Low Risk ((L) No action required. Activity can proceed subject to compliance with the specified control measures.
Descriptor Likely Frequency Probability
Environment Health and Safety
Frequent Continuous or will happen frequently. Occurs several times a year at location. 5
Often 5 – 12 times per year. Occurs several times a year in similar industries in Iraq 4
Likely 1 – 5 times per year. Has occurred at least once in Iraq 3
Possible Once every 5 years. Has occurred in industry (Worldwide). 2
Rare Less than once every five years Never encountered in industry. 1
Descriptor Consequence Severity
Environment Health and Safety
Catastrophic Long term severe / permanent impact on ecosystem Multiple fatalities 5
Major Significant widespread impact on ecosystem Fatality 4
Moderate Significant localized impact on ecosystem Serious injuries – off site medical treatment 3
Minor Minor changes to ecosystem Injuries – on site medical treatment 2
Insignificant Insignificant occasional change to ecosystem Minor injuries – first aid 1
Ac
Analysis Residual
Consequence Analysis
Activities Hazards Risk Control Measures criteria risk
criteria
P S P S
3 2 6 . The test supervisor must ensure that all 2 1 2 Job
stress tests are performed HSE
The gauges etc. are in good condition,
Rupture/failure of pump
intact and undamaged Current valid
during testing
calibration
Secondly. All pumps must be in good
Use at high Pipe/connection failure condition and any exposed items such as
1. Pressure pressure pressure gauges L
testing
Third. The supervisor should ensure the
equipment M
connection and perform a comprehensive
system check
Instrument failure Before applying for a work permit. and
resulting in system provide all safety requirements
over-pressurization
. The engineer must physically walk
through the test area with all necessary
Checks completed. If any corrections are
required, they must be made before the
test is allowed to begin.
The HSE supervisor must ensure that the
work is safe
Permitting practices and all other
requirements described in the work permit
It is strictly adhered to during the task
being performed.
2 4 8 2 1 2 Job
HSE
Personal injury Perform TBT with driver, before work start.
Water truck failure Driver follow speed limits according to the L
Unsafe driving road conditions and not exceed 30km/h.
H
Over speeding and Provide flagman to control vehicle
overturning movement and reverse alarm.
2. Water Using a truck Driver not fit for his Guide vehicle shall observe the speed of
transportation job (license, health) truck to maintain safe distance from the
existing facilities. Route should be planned
and checked in advance.
3 4 12 2 2 4 Job
Body injury. Hand Valid PTW to be obtained from HSE
injury. Concern Authority. PTW system and
Damage to JSA shall be strictly followed. TBT done
Equipment. before test in on. Explain the task.
3. Hydro- High pressure to Defective Emergency Contact List attached to
Pressure- pipework; Tools/Equipment. PTW, in cases that is need it
Testing Only trained person is allowed to do
Changing Test
the pressure test.
Duration.
Do not change (exceed / decrease) the
Failure of houses H M
duration of pressure test - Follow
and/or spools –
approved procedure -.
Explosion,
Work area should be isolated by yellow
Bursting -. tape and warning signs in place.
Failure of Hydro Never increase the test pressure more
Test Equipment than the maximum allowable pressure
(Gauges, as per approved procedure. Monitor
Manifold, PSV). the pressure gauge from a safe
Untrained/unauth distance away from the potential
orized person source of high-pressure jetting (Such
operating the as Flange Joint, Spade, and Coupling
pressure test. etc.).
Exceeding Provide stand by person around the
Maximum working area. During hydro test other
allowable activity not allowed nearby. Only
pressure authorized personals are allowed to
Unsafe enter inside pressure test area (testing
Depressurization team).
Whip arrester will be installed at the
connecting ends. Use hoses with
higher pressure value. Test line
supported and secure.
All staff should receive specific training
Lack of supervision
and instructions regarding manual
Personal Injury.
handling to avoid any accident, timing
Heat Stroke /
of the hydro test and mitigation
Overexposure to
actions in case of malfunctions.
sunlight.
Provide suitable PPE for involved
Unauthorized work
workers.
Lack or poor
Provide safe access to hydro test
communication.
location.
Training missing
Job rotation and frequent rest shall be
maintained and provided. Water for
drinking present in place. First aid box
and Stand by vehicle need to be
placed at the site – ambulance, and
other emergency services need it -.
Continuous Gas Monitor and Heat
Index, through all duration of this test.
2 4 8 2 1 2 Job
Area should be barricaded; appropriate sign HSE
boards should be placed. Safe distance should
be maintained at all time.
Only authorized personals are allowed to enter
inside Dewatering / Depressurizing area.
Monitor the pressure gauge from a safe L
H distance away from the potential source of
high pressure (Flange Joint, Spade, and
Failure of
Coupling etc.).
gauges, an/or
Ensure the workers are wearing required PPE.
Manifold.
Housekeeping should be done after the
Failure of PSV.
activity, leave area clean as it was.
Slip and trip.
Proper access and egress should be provided
Fall from same
during depressurization.
level.
Depressurizing/ High pressure Close supervision shall be provided at the work
Muddy area.
Draining of water to pipework; location.
High pressure
No work and/ or repairs shall be done on the
water burst.
line when is under pressure.
Flying metal
Depressurization area should be mark clearly,
chips, small
avoid flooding - if water is collected inside
rocks from
trucks, post this trucks at safe distance from
inside pipes.
line and provide clear signage.
Ergonomics.
Fatality. Provide suitable PPE for workers, personal gas
detectors and ear plugs/muffs for noise.
Drinking water, job rotation schedule, gas
monitor and temperature monitor, will be
