Hydrotest Risk Assessment new

Risk Assessment Tables (Guidance for assessing risk)

Risk Tolerability/Acceptance Table Likelihood of Occurrence Regular occurrence within the area of operations to which it refers, with the possibility of being realised once per day/shift. High Likelihood Moderate Likelihood Occasional occurrence with the possibility of being realised once per job/project/contract/month. Unlikely to occur but known to have occurred in the relevant industry/operation/type of work it refers to. Low Likelihood Severity (injury) High Severity Moderate Severity Low Severity

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

Risk Rating & Rating Number 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.

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.

3 Moderate Risk

Severity (property/equipment) Property/Equipment Damage costs exceeding $50,000. High Severity Moderate Severity Low Severity

Property/Equipment Damage costs (direct and indirect) between $50,000 and $5,000. Property/Equipment Damage costs (direct and indirect) not exceeding $5,000.

2 Tolerable Risk

Severity (environmental) Environmental damage is catastrophic and/or involves prosecution, severe damage to company image and substantial costs. High Severity Moderate Severity Environmental damage external to local area and/or damage to company image and profits. Environmental damage is local and has minimal external impact. Low Severity Risk Rating & Rating Number Table High Likelihood Moderate Likelihood

1 Low 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. 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. Risk Acceptable. No action required. Document findings.

Notes: Low Likelihood

High Severity

5 Intolerable risk

4 Substantial risk

3 Moderate risk

Moderate Severity

4 Substantial risk

3 Moderate risk

2 Tolerable risk

3 Moderate risk

2 Tolerable risk

1 Low risk

Low Severity

Remedial Action and Timescale

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.

Page 1 of 6

Risk Assessment Form

Base/Area/Dept/Project: Dubai/MEAP/Operations/Azeri Baku Pipelines Project Activity/Operation/Job: Pre-commissioning/Hydrotesting/MEPPS Task/Job Steps

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

Initial Risk

Assessed by: Date: Controls

Residual Risk

Personnel / Equipment / Hazard Likelihood of Risk List and describe fully all Controls Required. Cross-refers Hazard Likelihood of Risk Environment at Risk Severity Occurrence Rating to any other relevant assessment (PPE, COSHH, Manual Severity Occurrence Rating No. No. Handling, LOLER etc).

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

Prepare detailed test procedure

Nominate wrong test limits 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

Prepare detailed test procedure

Failure to identify NRV’s and valves Damage to to be mechanically opened within client system the test limits Trapped pressure in 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 system Ongoing 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 equipment Muscle / 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 Tools Trapped / 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 height Fall from high levels

Personnel injury High

Mod

4

Only use approved scaffolding, wear correct harness above 2m from floor.

Mod

Approved by (Name): Signature:

Approved by (Title): Date:

Low

Page 2 of 6

2

Task/Job Steps

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

Initial Risk

Controls

Residual Risk

Personnel / Equipment / Hazard Likelihood of Risk List and describe fully all Controls Required. Cross-refers Hazard Likelihood of Environment at Risk Severity Occurrence Rating to any other relevant assessment (PPE, COSHH, Manual Severity Occurrence No. Handling, LOLER etc).

Risk Rating 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 Use of hand Tools Trapped injured body parts

BJ equipment and personnel injury

Mod

High

4

Adhere at all times to procedure. All Mod temporary equipment to be pre-tested prior to hook up to clients system.

Low

2

Personnel injury Mod

Mod

3

Follow all guidelines laid out during safety induction and BJ HSE manual

Mod

Low

2

Prepare for hydrotest Hydrotest system

Over pressurise system Client system Critical failure / rupture of pipework

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

Mod

Low

2

Depressurise / drain

Trapped Pressure in system

Personnel injury Mod

Mod

3

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

Mod

Low

2

Approved by (Name): Signature:

Approved by (Title): Date:

Page 3 of 6

Task/Job Steps

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

Initial Risk

Controls

Residual Risk

Personnel / Equipment / Hazard Likelihood of Risk List and describe fully all Controls Required. Cross-refers Hazard Likelihood of Environment at Risk Severity Occurrence Rating to any other relevant assessment (PPE, COSHH, Manual Severity Occurrence No. Handling, LOLER etc).

Risk Rating No.

system

Future release of pressurised fluid critical failure

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 Personnel injury Mod Muscle / back / strain from moving heavy equipment

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 Personnel injury Mod torquing equipment Muscle / back / strain from moving heavy equipment

Mod

3

Trained and qualified personnel on Mod site to carry out bolt tensioning works. Assistance given when handling heavy objects. Two man lifting.

Low

2

Re-instate system

Use of hydraulic bolt tensioning and Client system equipment Incorrect tensioning, loose bolts

Mod

4

Bolt tensioning procedures followed, Mod fully trained personnel to carry out the bolt tensioning operations.

Low

2

Approved by (Name): Signature:

work. Adhere to barriers / signs recommended in procedure.

High

Approved by (Title): Date:

Page 4 of 6

Risk Assessment – Job Site Review Form Page No: Assessment No:

5

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).

Use continuation sheet if out of space.

Control Measures to be utilised to minimise these additional Hazards / Risks: (Full Description of Control Measures to be implemented).

Use continuation sheet if out of space.

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).

Name (Printed)

Signature

Name (Printed)

Signature

Risk Assessment – Job Site Review Form Continuation Sheet Assessment No:

Page No:

6

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).

Use continuation sheet if out of space.

Control Measures to be utilised to minimise these additional Hazards / Risks: (Full Description of Control Measures to be implemented).

Use continuation sheet if out of space.