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

Classification Risk
(R/NR)Activity Type

(N/AN/E)Condition

RiskAssociated

R= PXSRisk
Consequences Desired Control Gaps If
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.
joints under test adequately restrained.  Training &
 Damage to
Test area shall be barricaded properly & Awarenes
nearby
unauthorized entry shall be restricted. All s
existing
electrical equipments shall be protected  , Regular
equipment
check &
 Property from water. Inspection
damage  Block valve shall be provided on the line
 Burst of from the test pump to the equipment
pipe, under test.
 Water  Lines under pressure identified and traffic
lodging,
should be restricted near hydro testing
Severe
activities.
Injury
 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.

 No pipe should be connected to the

newly build tank during water 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

Classification Risk
(R/NR)Activity Type

(N/AN/E)Condition

RiskAssociated

R= PXSRisk
Consequences Desired Control Gaps If
S.N Activity P S
/ Hazards Measures Any

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.

 Fresh clean water shall be used for the

hydrostatic test.

 Hydrostatic testing shall be carried out

at an ambient temperature but not

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

Classification Risk
(R/NR)Activity Type

(N/AN/E)Condition

RiskAssociated

R= PXSRisk
Consequences Desired Control Gaps If
S.N Activity P S
/ Hazards Measures Any

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

Classification Risk
(R/NR)Activity Type

(N/AN/E)Condition

RiskAssociated

R= PXSRisk
Consequences Desired Control Gaps If
S.N Activity P S
/ Hazards Measures Any

Risk Matrix

Impact

RISK MATRIX 1 2 3 4 5

Slight Minor Major Single Multiple

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