HSE-RA-057 Hydro Test Rev 0

DOC No DS/CA006P02/00022
PAGE No 1 of 15
AL SHAFAR GENERAL CONTRACTING LLC. REV 0
DATE 05/01/2017
SAFETY, HEALTH AND ENVIRONMENTAL PROCEDURE
Project Name: Festival Living Stream-02 HSE-RA 057
Job Description: Pressure Testing (Hydro testing and Air testing)-MEP
Index:
Form 1 Task Analysis Initiation
Form 2 Risk Assessment Process As per Risk Assessment Procedure.
Form 3 Written Safe Work Procedure Result
Compiled by the following team:
NAME DESIGNATION SIGNATURE
Project Manager
Construction Manager
Site Engineer
Safety Officer
Risk Assessment Review 1 Review 2 Review 3 Review 4
Review Date: Date : Date : Date:
Name and Signature

of person reviewing :
AUTHORISATION
Prepared by: Approved by
Signature Date Signature Date
HSE Manager Project Manager
HSE QUALITY SYSTEM DOCUMENTATION

PAGE No 2 of 15
DATE 05/01/2017
TASK ANALYSIS - FORM 1

Impact
SEQUENCE OF TASK STEPS POTENTIAL INJURIES OR HAZARDS RECOMMENDED CONTROLS
H, S, E
Pre-use inspection and use of all equipment Failure of equipment will cause injuries to  Faulty equipment to be repaired/maintained or replaced.
persons and / or property damage.  Guards to be on all Machinery and appropriate PPE to
. be worn.
Fuel/oil leaks could cause environmental  Engine ran machinery to have fire extinguishers
1. concerns. H, S, E
available locally.
 Drip trays/heavy gauge plastic to be provided in case of
leaks and spill kit to be within the project for accidental
spills.
Wear appropriate Personal Protective Failure to use Personal Protective
Equipment. Equipment will cause injuries to employees.
Gloves.
Safety boots.  Enforce the use of Personal Protective Equipment AT
2. H
Overalls. ALL times
Hard hat.
Hearing protection.
Eye protection
Use trained employees only Failure may result in injuries to persons and  All Enforce the use of competent persons only
property damage.  All employees assigned to this task must be Safety
Inducted also they will have to attend a safety
meeting, which will include the Standard Operating
3. H, S Procedures, types of potential hazards, and actual
hazards present and controls for those hazards.
 Workers should be legally appointed & having their
Id’s.
4. Competent supervision Failure will cause injuries to employees and H, S  Competent supervisor should be appointed for every
PAGE No 3 of 15
DATE 05/01/2017
activity to monitor the workers. Work task instruction

should be provided for every activity.
or property damage
 Testing equipment will be installed a safe distance away
from the pipe connection.
 Pressure measurement tools are calibrated and their
statuses of calibration are still valid.
 The pressure gauges are recommended to have 150%
of the maximum allowable working pressure.
 Proper lighting should be provided in work place.
 All the temporary tools (such as, valve, hoses, fittings,
 Equipment failure flanges, blind plate, etc.) have to be rated more than the
 Personnel struck by equipment maximum hydrostatic pressures.
5. Use of portable Hydraulic Test Pump H, S  Make sure all the pipe and vessel supports are in good
Failure of all above stated will cause injuries
condition and have been inspected.
to person and/or property damage
 Make sure Safety relief valve is calibrated & all hoses
must be tied down.
 Isolate other equipments and pipe lines that are not
included in the hydrostatic test.
 Do not start the test if a problem is identified.
 Choose drain valve at the lowest point in order to
completely empty the vessel and pipe
 All the emergency escape routes must be kept clear.
6. Using Hand & Power Tools  Defective tools H,S,E  All the tools must be inspected before use.
 Extension cords with worn  Any or all faulty tools must be removed from the services.
insulations  Special tools should be certified as safe for use and also
 Tripping hazards must be inspected before use.
 Use of tools not intended for the job  All type of power tools must be colour coded and tagged

PAGE No 4 of 15
DATE 05/01/2017
 Use of improper PPE as safe for use also must be entered in register.
 Permit to work system should be in place.
 PPE should be worn by all operators as per the job
nature.
 Avoid any unnecessary and unwanted materials in the
workplace that can cause tripping hazard.
 Failure to cordoned off the area and

not secured  Area must be barricaded to stop unauthorized entry in
 Unauthorized entry / Lack of the similar area.
supervision  Supervision of work should be done under the
7. Barricading & supervision of work  Failure to provide signage / noticed competent supervision such as, an Engineer or
board H,S Competent Supervisor only.
 Signage and notification warning signs should be fixed in
Failure of all above stated will cause injuries the pipe line and also in the testing area.
to person and/or property damage
 Failure to detect leakage of joints  Test equipments should be operated by a trained

during the testing personal only.
 Non-observance of personnel on  Unauthorized personal should not be allowed to stay in
proper testing procedure testing area.
8. Pressure testing  Failure to provide trained person to H, S  Only one person should take the charge of operations.
do the operation  Specification sheet of the equipments and or pipe lines’
Failure of all above stated will cause injuries which mentions pressure and temperatures designs are
to person and/or property damage available and compete.
9. Pressuring procedure  Failure to adopt the correct H, S  Remove all air from the vessel and pipe line by water
procedure through vent line.
 Non-observance of personnel on  Pressurization is conducted gradually/slowly.
proper testing procedure
PAGE No 5 of 15
DATE 05/01/2017
 Lack of monitoring  Mark all leak points and repair them before proceeding
Failure of all above stated will cause injuries with the test.
to person and/or property damage  Do not monitor during pressurization step directly from
the front of sight glass or level glass.
 Failure to adopt the correct  Start de-pressurization by opening gradually the vent
procedure valve “ Do it slowly”
 Non-observance of personnel on  Do not open the drain valve if the vent valve is still
proper testing procedure closed. This is to avoid vacuum condition inside the
10. De-pressurization process  Lack of monitoring H, S vessel.
Failure of all above stated will cause injuries  Open the lowest drain point to completely remove water
to person and/or property damage from the vessel and pipeline.
 Ensure that no remaining pressure trapped inside the
pipe line or vessel.

PAGE No 6 of 15
DATE 05/01/2017
RISK ASSESSMENT – FORM 2

Risk Rating Calculation
Risk Rating = A + B + C + D.
A + B + C + D
Injury Severity Potential Damage / Loss Frequency or Likelihood Environmental Impact
0 No injury 0 No damage 0 Never happened before 0 No effect
1 Minor – (FAC) 1 Minor < 500 AED, No delay 1 Happened somewhere 1 Minor Effect - Short term < less 1 month
2 Major – (MTC) 2 Major > 500 AED, No delay 2 Happens occasionally 2 Major Effect - Long term > Greater 1 month
3 LTI 3 Major > 10 000 AED, one day delay 3 Happened before
4 Disabling Injuries 4 Serious > 100, 000 AED, >1 day delay 4 Happens regularly
Risk Rating Matrix
5 Fatality 5 Severe > 1, 000, 000 AED, Weeks delay. 5 Daily occurrence
Result Classification:
Risk Rating
Critical = 17►15 High = 14►11 Medium = 10►7 Low = 6►0 16
Immediate action. Action in 24 hours. Action in a week. ASAP. 14

12
10
Risk Reduction Hierarchy: 8
6
1. Engineering to reduce risk. 4
2. Replacement with lower risk. 2

0
3. Isolation of risk – Barricading or Guarding. 1
5
2 4
4. Reduction of exposure to risk. 3
4 3
5 Probability
5. PPE and Training Potential Impact 6
7 2 (C)
(A / B / D) 8
9 1

PAGE No 7 of 15
DATE 05/01/2017
RISK ASSESSMENT – FORM 2 (continued)
RISK ASSOCIATED WITH Impact HOW IS HAZARD TO BE BY Result

No HAZARD IDENTIFIED H, S, E RR BY WHOM RR
HAZARD DEALT WITH WHEN
 Faulty hand tools Bruises, cuts. Gloves, trowels in good Supervisor Before &
condition. during
 Mechanical guards not in Entanglement, Skeletal Damage. the use
place Guards in place and equipment of
1 H,S,E 13 regularly maintained. equipme 6
nt
 Unwanted Fuel/Oil Contamination of the soil, Care to be taken refuelling and
Spillages atmospheric pollution, risk of fire. drip trays/heavy gauge plastic to
be in place as required.
Injury to project employees Potential Death, Major/Minor Following PPE to be worn Supervisor Before &
Skeletal damage, cuts and bruises to appropriately to the task – during
all parts of the body, asthma. Gloves. work
Safety boots.
2 H,S 10 5
Overalls.
Hard hat.
Hearing protection.
Eye protection
Un trained employees Poor quality of work, chance for Provided trained/competent PE/FM Always
3 accident /incident or property H,S 7 worker and supervision 5
lost/damage
Poor Supervision Poor quality of work, chance for Ensure the availability of PE/FM Always
accident /incident or property competent supervisor at work
lost/damage place.
4 H,S 10
Work task instruction should be
3
provided to the workers prior to
the commencement of activity
PAGE No 8 of 15
DATE 05/01/2017

Testing equipment will be installed a safe
distance away from the pipe connection.
Pressure measurement tools are
calibrated and their statuses of calibration
are still valid.
The pressure gauges are recommended
to have 150% of the maximum allowable
working pressure.
Proper lighting should be provided in work
place.
All the temporary tools (such as, valve,
hoses, fittings, flanges, blind plate, etc.)
have to be rated more than the maximum
hydrostatic pressures.
Before
Injuries to person and / or property Make sure all the pipe and vessel Supervisor
5 Handling pipes and material H, S, 12 supports are in good condition and have starting 3
damage. Operator
been inspected. work.
Make sure Safety relief valve is calibrated
& all hoses must be tied down.
Isolate other equipments and pipe lines
that are not included in the hydrostatic
test.
Do not start the test if a problem is
identified.
Choose drain valve at the lowest point in
order to completely empty the vessel and
pipe
All the emergency escape routes must be
kept clear.
6 Faulty Hand Tools and Potential Death, Major/Minor H,S,E 9 Proper hand tool & machinery PE/FM/ Before 6
Machinery Skeletal damage, cuts and bruises to and daily checking/ check list. supervisor work
all parts of the body. Competent operator and
supervision and safe working

PAGE No 9 of 15
DATE 05/01/2017

procedures to be adopted.
Safe temporary electric supply.
Environmental damage Improper disposal of waste materials Clear briefing to workforce to

dispose of waste materials in the
designated areas.
Environmental concern Excessive Noise & Dust Noise levels to be monitored and
restricted to social able timings
where ever practicably possible.
Dust control system must be
applied.
Failure to barricade the area. Falling materials Major/minor 12 Ensure the work area has been FM Before &
injuries, potential death, property barricaded and warning sign /Supervisor during
damage. placed. work
7 H.S 4
Watchman should be posted in
necessary positions.
8 Injuries to person and / or property H, S 8 Permit to work should be Supervisor Always 2
Failure adhere procedures on damage obtained prior the work
pressure testing commences.
Test equipments should be
operated by a trained personal
only.
Unauthorized personal should
not be allowed to stay in testing
area.
Only one person should take the

PAGE No 10 of 15
DATE 05/01/2017

charge of operations.
Specification sheet of the
equipments and or pipe lines’
which mentions pressure and
temperatures designs are
available and compete.
Failure adhere procedures on Remove all air from the vessel
pressurizing and pipe line by water through
vent line.
Pressurization is conducted
gradually/slowly.
During
Mark all leak points and repair Supervisor
9 H,S 9 pressuriz 2
them before proceeding with the
ation
test.
Do not monitor during
pressurization step directly from
the front of sight glass or level
glass.
10 Injuries to person and / or property H,S 9 Start de-pressurization by Supervisor During 4
Failure adhere procedures on damage opening gradually the vent valve de-
de-pressurizing “ Do it slowly” pressuriz
Do not open the drain valve if the ation
vent valve is still closed. This is
to avoid vacuum condition inside
the vessel.
Open the lowest drain point to
completely remove water from
the vessel and pipeline.

PAGE No 11 of 15
DATE 05/01/2017

Ensure that no remaining
pressure trapped inside the pipe
line or vessel.
* RR = Risk Rating

PAGE No 12 of 15
DATE 05/01/2017
WRITTEN SAFE WORK PROCEDURE

1. OBJECTIVE
1. To prevent injuries to employees and / or property damage incidents.
2. PROCEDURE
1. Do pre-use inspection of all equipment to be used and replace or repair faulty items.
2. Use trained competent employees only.
3. Use appropriate Personal Protective Equipment i.e.:
3.1. Hardhat.
3.2. Safety boots.
3.3. Overalls.
3.4. Ear Plugs
3.5. Masks
3.6. Safety Glasses
Prior to work commencement
1. Must have PPE – safety footwear, gloves, hardhat, goggles, face musk, protective clothing etc.
2. Must have appropriate tools and equipment in good condition.
3. Must have weatherproof covers for materials and equipment, waste containers, warning tape.
4. Consider risks and hazards in work area. Refer any concerns to supervisor. Are relevant permits in place?
5. Check if it is necessary to secure area adjacent to work. Refer to supervisor if appropriate.
6. Arrange for transport of materials and equipment to site via supervisor.
7. Ensure materials and equipment are secure or removed when site unattended, eg overnight or during breaks.
PAGE No 13 of 15
DATE 05/01/2017
Hazards
1. Manual handling of materials (Lifting and shifting of materials) LITE to be considered at all times.
2. Fall from height (Working near edges and inside shafts)
3. Slips and trips and fall
4. Falling materials (eg:, Tools, equipments ,components etc)
5. Collapse of the pipes and valves due to high pressure.
6. Contact with sharp edges of materials.
7. Working at heights.
8. Adverse weather conditions. If any doubts refer to the supervisor.
Harm
Potential Death, Minor/major cuts and contusions, loss of limbs, fractures, concussion to fatality, property damage
Persons in danger
1. Plumbers, technicians ordinary labours

2. Other workers and visitors at vicinity
Control measures
No lone working

PAGE No 14 of 15
DATE 05/01/2017
Work involving in pressure testing / pipe leakage test
1. Appropriate PPE must be worn by all workers on site & special PPE should be provided for those who are directly involved in this
activity.
2. Site Induction and tool box talks should be given prior to start job.
3. Equipment to be used in transporting pipes should be inspected and must be safe for use.
4. Pipes shall be properly secured while being transported.
5. Pipes stand and shafting capable of carrying the load. Pressure capacity clearly marked on every unit.
6. Employees shall be educated in keeping out of possible crush on steel pipes turn into pieces
7. Permit to work system should be followed by all supervisors and engineers.
8. Daily, weekly and monthly inspection to be done regularly any defect found must be reported immediately.
9. Physical barricade to installed and maintained with entry and exit points.
10. Only personnel involve in pressure testing activities are allowed inside the barricaded area. Enforce the use of competent persons
only.
11. All hand and power tools must be inspected before use
12. All hand and power tools must be safe for use
13. All type of power tools must be colour coded and tagged as safe for use also must be entered in register.
14. Permit to work system should be in place.
15. PPE should be worn by all operators as per the job nature.
16. Only competent person shall operate the Hydraulic test pump
17. Maintain work area isolated with means of barricade and appropriate signage should be in place.
18. Remind personnel through toolbox talk to observe proper positioning when working
19. All the work should be done under the competent supervision.

PAGE No 15 of 15
DATE 05/01/2017

HSE-RA-057 Hydro Test Rev 0

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DOC No DS/CA006P02/00022

Job Description: Pressure Testing (Hydro testing and Air testing)-MEP

Name and Signature

HSE QUALITY SYSTEM DOCUMENTATION

Job Description: Pressure Testing (Hydro testing and Air testing)-MEP

TASK ANALYSIS - FORM 1

Job Description: Pressure Testing (Hydro testing and Air testing)-MEP

activity to monitor the workers. Work task instruction

HSE QUALITY SYSTEM DOCUMENTATION

Job Description: Pressure Testing (Hydro testing and Air testing)-MEP

 Failure to cordoned off the area and

 Failure to detect leakage of joints  Test equipments should be operated by a trained

Job Description: Pressure Testing (Hydro testing and Air testing)-MEP

HSE QUALITY SYSTEM DOCUMENTATION

Job Description: Pressure Testing (Hydro testing and Air testing)-MEP

RISK ASSESSMENT – FORM 2

Immediate action. Action in 24 hours. Action in a week. ASAP. 14

2. Replacement with lower risk. 2

HSE QUALITY SYSTEM DOCUMENTATION

Job Description: Pressure Testing (Hydro testing and Air testing)-MEP

RISK ASSESSMENT – FORM 2 (continued)

RISK ASSOCIATED WITH Impact HOW IS HAZARD TO BE BY Result

Job Description: Pressure Testing (Hydro testing and Air testing)-MEP

RISK ASSOCIATED WITH Impact HOW IS HAZARD TO BE BY Result

HSE QUALITY SYSTEM DOCUMENTATION

Job Description: Pressure Testing (Hydro testing and Air testing)-MEP

RISK ASSOCIATED WITH Impact HOW IS HAZARD TO BE BY Result

Environmental damage Improper disposal of waste materials Clear briefing to workforce to

HSE QUALITY SYSTEM DOCUMENTATION

Job Description: Pressure Testing (Hydro testing and Air testing)-MEP

RISK ASSOCIATED WITH Impact HOW IS HAZARD TO BE BY Result

HSE QUALITY SYSTEM DOCUMENTATION

Job Description: Pressure Testing (Hydro testing and Air testing)-MEP

RISK ASSOCIATED WITH Impact HOW IS HAZARD TO BE BY Result

HSE QUALITY SYSTEM DOCUMENTATION

Job Description: Pressure Testing (Hydro testing and Air testing)-MEP

WRITTEN SAFE WORK PROCEDURE

Job Description: Pressure Testing (Hydro testing and Air testing)-MEP

1. Plumbers, technicians ordinary labours

HSE QUALITY SYSTEM DOCUMENTATION

Job Description: Pressure Testing (Hydro testing and Air testing)-MEP

Work involving in pressure testing / pipe leakage test

HSE QUALITY SYSTEM DOCUMENTATION

Job Description: Pressure Testing (Hydro testing and Air testing)-MEP

HSE QUALITY SYSTEM DOCUMENTATION

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