Ref No:

ACTIVITY– Refrigerant piping installation and Pressure Testing Rev.No:01

Page 1 of 9

Serial Sub-Activities Risk Rating

No. Hazards Identified Risks Involved Residual
Initial Control Measures
(Generic & Task) (People & Property) Severity Probability Risk
Risk
· TBT/DSTI to be conducted by the foreman/
safety officer prior to work commencement
· Task specific safety training to be provided Low
· Unauthorized, untrained · Cuts
1. Prepare work area 2 A L (ALARP)
workers · Abrasions · Authorized personnel to undertake the job
· Daily safety inspection should be carried and
eliminate the hazard.
· TBT/DSTI to be conducted by the foreman/
safety officer prior to work commencement
· Task specific safety training to be provided
·Incorrect lifting of loads ·Back Injuries ·Any lifting tasks shall be carried out by
2. Manual Handling · Sharp edges. · Cut to finger persons physically capable to do so Low
3 C M •No employee should be asked to carry loads (ALARP)
· Placing the object while · Strain
above his capacity and in any case no load
fingers underneath. • Musculoskeletal shall exceed 30kg per man.
• Slip/trip/fall ( same level ) Injuries • Mass of the load is more then to be equally
• Unsafe posture shared
·Deploy enough number of personnel for lifting
shall be appointed to the task depending upon
the type of load to be lifted.
·Use easy mode of transport like trolley etc.
• Load not to be lifted above your shoulder
Height
• Keep your fingers away from pinch point
While placing the load
• Area to be illuminated with adequate lighting.
·Proper personal protective equipments to be
used while manual handling of materials and
loads.
∙ Unauthorized, untrained •Crush · TBT/DSTI to be conducted by the foreman/ Low
3. Stacking and Storing workers · Cut and abrasion 3 B M safety officer prior to work commencement (ALARP)
· Material fall from height ∙ Task specific safety training to be provided
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ACTIVITY– Refrigerant piping installation and Pressure Testing Rev.No:01
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Serial Sub-Activities Risk Rating

No. Hazards Identified Risks Involved Residual
Initial Control Measures
(Generic & Task) (People & Property) Severity Probability Risk
Risk

• Improper stacking ·Damage to property · All materials shall be stored below 2 meter
• Collapse
height.
• If the material is too heavy, use hydraulic
trolley to shift the material.
• No storage of materials to be done in the work
place, only required quantity to be taken for the
job.
• Personnel protective equipment must worn at
all time during the activity. (Helmet, shoe, vest,
overall, gloves, goggles, mask.)

•TBT/DSTI to be conducted by the foreman/

safety officer prior to work commencement
• Slip, trip and fall • Task specific safety training to be provided
Working with Hand • Damaged warn out hand • Defective tools should not be issued or used
4. tools ( knife, cutter, tools • Fatigue 3 C M to perform the task, to be checked by store Low
scissors, razor, scraper) • Flying objects • Trigger finger keeper (ALARP)
∙ Mushroom Heads • Cuts and abrasions • Don’t extend the spanner by using a pipe as
• Using incorrect type an extension bar
• Keep hand behind the cutting edge when
Working.
• Keep tools in racks or boxes when not in use.
• Protect sharp edges of tools that are to be stored
or covered.
• Never use a screw driver as a chisel
•Don’t work with oily or greased hands
• Use eye/ face protection when there is flying
materials hazard, wear gloves while required to
protect the hands
• Use right tools for the job
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ACTIVITY– Refrigerant piping installation and Pressure Testing Rev.No:01
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Serial Sub-Activities Hazards Identified Risks Involved Risk Rating Residual
No. Initial Control Measures
(Generic & Task) (People & Property) Severity Probability Risk
Risk
•TBT/DSTI to be conducted by the foreman/
safety officer prior to work commencement
• Job related training to be provided
• PTW to be applied and obtained prior to start,
 Defective equipment If spark producing activity is performed
 Electricity  Eye injury · Defective tools should not be issued or used to
 Improper use of  Back injury perform a task.
equipment  Burns • Monthly inspection should be carried out by the
 Poor maintenance  Electric shock 3 C M electrician and record to be kept at the store M
5. Working with power  Untrained workers · All portable power tools should be fitted with (ALARP)
tools ( Drill machine)  Flying object adequate fuse protection either in the tool body
 Vibration or in its electrical plug.
 Fire • The power tools and it should be checked by
 Dust store keeper/ operator prior to start the activity
 Crushing ·The weight, size and type of tool should be
selected to suit the job being carried out.
• Don’t lay the cables around the access way, it
should be proper routing
• Industrial distribution board and socket only to
be used at site
• No joints shall be made in electrical cable.
• Electrical connection shall be routed through
ELCB only.
• Correct rate of ELCB should be used ( Ex:-
30ma only acceptable)
· Only those persons who have been adequately
trained and experienced in the use of the tool
should be allowed to use the same.
• Power tools shall have inspection sticker.
• Tools should be stored and maintained in good
working condition.
· Appropriate PPE Should use ( Goggles, Mask,
Ear plug, Gloves, Shoe, Helmet, Overall, Vest )

Serial Sub-Activities Hazards Identified Risks Involved Risk Rating Control Measures Residual
 Ref No:
ACTIVITY– Refrigerant piping installation and Pressure Testing Rev.No:01
Page 4 of 9
No. (Generic & Task) (People & Property) Severity Probability Initial Risk
Risk
• TBT/ DSTI and Visual inspection to be done
before using the ladder
• Jobs specify training to be provide
• The ladder should extend minimum one meter
from the top for safe movement
• Heavy materials should not be carried
• Fall from height • Do not erect in slippery, uneven surface
• Over reaching • Sprain and strain • Should be set up with a 4 vertical to 1 Low
6. Working with ladder • Over loading • Fracture 3 C M horizontal slope( 4:1 ) (ALARP)
• Obstructing the access way • Spinal cord damage • Inspection carried out by competent person on
• Slippery or uneven surface a regular basis
• Step ladder must fully open and lock and the
devices to be as per manufacturer
• Defective ladder should not be used and report
it immediately
• Do not work from the top of two rungs
• Remember the 3 point contact
• Do not work in front of the door. If work is
carried then lockedthe door or blocked off
• Ladder to be used for short duration works only
limited to 15 min.
• Colour coded system to be implemented on
monthly basis.
• Uneven surface • Sprain and strain • TBT/ DSTI to be provide prior to start work
• Overhead structure and cable • Fracture • Jobs specify training to be provide Low
• Materials and worker fall • Spinal cord damage 3 C M • Do not stack materials on to the scaffold (ALARP)
7. Working on mobile from height • Musculoskeletal • Visual inspection should carry before use
scaffold • Untrained, unauthorized Injury • Out rigger fitted and breaks are locked on
Workers • Fatality • Only certified erection person do the alteration
• Collapse of scaffold and Modify
•No person to be on the scaffold while it is
being moved
• Scaffold only use in on level and surface area

Serial Sub-Activities Risk Rating

Hazards Identified Risks Involved Residual
No. Control Measures
(Generic & Task) (People & Property) Severity Probability Initial Risk
 Ref No:
ACTIVITY– Refrigerant piping installation and Pressure Testing Rev.No:01
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Risk
• Safety harness to be used above 2mtr height
and anchored in above shoulder height at all time
• Tagging system to be implemented ( i.e., all
safe scaffolds shall be provided with green tags
and unsafe scaffolds with red tag )
• Keep walkways free of obstacles, tools and
Equipment
• Never stand and sit on the hand rails
• Mobile scaffold height should be restricted to
3.5 to 4 times the shortest base width, If height
of scaffold exceeds raker support or it should be
tied to the structure properly.
· TBT/DSTI to be conducted by the foreman/
safety officer prior to work commencement
· Task specific safety training to be provided
·Material/equipment fall ·Fatality •PTW to be applied and obtained prior to
8. Working in near floor Low
start work
openings from height ·PropertyDamage 4 B M (ALARP)
· Rigidbarricationand toe boardto be providedto
· Slip/trip/fall • Fracture
all external edges and where a fall can occur.
•Warning signboards to be provided in
thoseareas.
· PPE to be used at all times ( Helmet, Shoes,
Vest, Overall, Harness )
• Ensure the chemicals are stored as per the
· Skin injury manufacturer recommendation and
• Unauthorized, untrained identification. Low
· Ingestion
9. Handling chemicals workers 3 C M •Adequate lighting and ventilation to be provided (ALARP)
(Flux, adhesive glue) • Spillage • Eye injury • MSDS to be referred prior and to follow the
• Poor ventilation • Environment affect manufacturer instruction
•MSDS safety requirements shall be
communicated to the work force through
TBT.

Serial Sub-Activities Risk Rating

No. Hazards Identified Risks Involved Residual
Initial Control Measures
(Generic & Task) (People & Property) Severity Probability Risk
Risk
 Ref No:
ACTIVITY– Refrigerant piping installation and Pressure Testing Rev.No:01
Page 6 of 9
• Trained and authorized person to do the job
• Only required quantity to take for the work
• Do not store chemicals at non designated areas.
• Old/ empty container return to store for proper
Dispose
• Check the containerfor leakage before
Handling
• Prevent materials from entering drains and
water ways.
•if spill follow the manufacturer instruction and
dispose that as per the instruction.
• Personnel hygiene to be maintained while and
after use of chemicals.
• Suitable fire extinguisher ( foam )shall be
placed in thestorage area.
• Appropriate PPE to be worn (Rubber gloves,
overall, helmet, vest, shoe, goggles, respirator.)
• PTW to be applied and obtained prior to start,
If spark producing activity is performed
· Authorized personnel to undertake the job
• Fire • Warning boards should be provided and
• Untrained, Unauthorized Barricaded Low
10. Pipe Joining Work Worker •Burns 3 C M • Soldering apparatus shall be provided with (ALARP)
With use of soldering • Electricity •Property damage industrial socket.
• Hot surface •Electrical shock • Proper lighting and ventilation to be provided
•Poor lighting and • Appropriate fire extinguisher should be placed
ventilation in to the work area ( Dry powder, CO2, Fire
• Improper identification blanket )
• Fumes • All Flammable /combustible materials should
be removed from the area
• Appropriate PPE Should use ( Goggles,
Gloves, Shoe, Helmet, Overall, Vest )

Serial Sub-Activities Risk Rating

No. Hazards Identified Risks Involved Residual
Initial Control Measures
(Generic & Task) (People & Property) Severity Probability Risk
Risk
 Ref No:
ACTIVITY– Refrigerant piping installation and Pressure Testing Rev.No:01
Page 7 of 9
· TBT/DSTI to be conducted by the foreman/
safety officer prior to work commencement
· Task specific safety training to be provided
· Authorized personnel to undertake the job
• Untrained, unauthorized • Cut and abrasion
Workers • Back Injuries · Daily safety inspection should be carried and
Installation, insulation • Fall of material • Fatigue 3 C M eliminate the hazard. Low
11. of pipes and its • Sharp edges • Musculoskeletal • Close supervision to be done at all times (ALARP)
accessories • Unsafe posture Injuries • Materials should notbekept in walkways,
• Slip, trip and fall edge of the opening.
·Deploy enough number of personnel for
material lifting shall be appointed to the task
depending upon the distance
• Proper communication to be maintained
between the workers while doing the
installation
• Avoid over reaching the pipes to reduce
from strain and pain.
• Maintain a good housekeeping policy to
prevent from slip, trip, fall hazards.
•Two level works to the openings and edges not
to be performed.
• PPE to be worn at all times( Gloves, goggles,
mask, helmet, shoe, vest, overall)
• PTW to be applied and obtained prior to
• Bursting of pipes start work
• Untrained, unauthorized • Fatality • Calibrated pressure gauge only to be used for
Workers • Property damage pressure testing Low
12. Pipe leakage testing • Faulty pressure gauge • Fractures 3 B M • Close supervision to be done at all times (ALARP)
Used with nitrogen gas • Poor lighting • Full body injury • Nitrogen cylinder should be kept very close
• Improper identification to the manifold as far as possible. If the
cylinder is away, proper communication shall
be in place.

Serial Sub-Activities Risk Rating

No. Hazards Identified Risks Involved Residual
Initial Control Measures
(Generic & Task) (People & Property) Severity Probability Risk
Risk
 Ref No:
ACTIVITY– Refrigerant piping installation and Pressure Testing Rev.No:01
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• Proper lighting to be provided in around the
working area.
• Warning signs and boards should be provided
And area to be well barricaded
• PPE to be worn while handling the cylinder
( Leather gloves, goggles, mask, helmet, shoe,
vest, overall and SCBA is required where
oxygen is low.)
· Proper illumination to be provided
∙ Poor illumination ∙ Fatality · light post to be secured from fall Low
13. While working at night 3 B M (ALARP)
· Slip/trip/fall • Cuts · Proper cable management system to be
shift
Followed
· All materials to be staged in proper manner
without obstacles
∙ Dehydration · Drink plenty of water Low
14. Working in hot · Heat · Sunburn 2 B M · Proper awareness of heat stress symptoms (ALARP)
weather
· Skin Cancer · Avoid highly physical tasks during the hottest
part of the day
· Isotonic drinks to be provided
· General housekeeping, Remove all surface,
· Poor housekeeping unwanted waste materials from the building Low
15. Work Completion 2 A L · All necessary precautions will be adopted to (ALARP)
· Slip/trip/fall · Fire
prevent fire
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ACTIVITY– Refrigerant piping installation and Pressure Testing Rev.No:01
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RISK MATRIX
Probability
A B C D E
Improbable Remote Occasional
Probable Frequent
Severity People Assets Environment Reputation 1 in 100,000 1 in 10,000 1 in 1000
1 in 100 years 1 in 10 years
Years Years years
Multiple
fatalities or
Extensive International
5-Catatrophic permanent Massive effect
damage impact
total
disabilities
Single
fatalities or
4-Severe permanent
Major
Major effect National impact
High Risk
damage
total
disabilities
Major injury
Local Considerable
Medium Risk
3-critical or health Localised effect
effects
damage impact (ALARP)
Minor
Minor
2-Marginal injury or Minor effect Minor impact
damage
health effects
Slight injury
Slight
1-Negligble or health
Damage
Slight effect Slight impact Low Risk
effects

3-E
HIGH 4-C,D,E
5-B,C,D,E
1-D,E
2-B,C,D,E
3-A,B,C,D
MEDIUM 4-A,B
5-A
LOW 1-A,B,C
2A