Drawing/Document Transmittal

GHANTOOT GENERAL MECHANICAL ENGINEERING L.L.C.

Project Title : Petrochemical Terminal at Plot B052F02

: Mechanical & Piping Works
Project No : 425841/TC02B/M&P
Ref. No. : 425841/TC02B/M&P-DT-0586

: CX-393

14/06/2023
GGME JOB No

Sheet No. 1 of 1 Date of Issue :

Title Ref Revision

MS for Jetty piping Holiday Test GGME/CX-393/MSRA/PHT/01 0

RA for Jetty piping holiday test GGME/CX-393/RA/PHT/01 1

CRS - Holiday Testing

CT-8118-R00-GGME-DT0560_MSRA Holiday Testing R0

Distribution No.of copies / Medium

Mott MacDonald:
Mr. Alex Alexander – Resident Engineer
1E
Mr. Anup Sera – Engineering Manager
Petrochem:
1E
Mr. Cherian George – Chief Project Manager
Mr. Bright Thomas – Project Manager
Purpose of Issue
State the purpose of issue
Example: IN = For Information, FR = For Review, TR = For Tender, CN = For Construction, AB = As-Built AP
IM = For Implementation, FC = For Comments, AP = For Approval, RC = For Records, EN = For Enquiry,
FP = For Purchase,
SC = Site Confirmation, FP = For Processing

State the medium employed C = CDROM; D = Diskette = E= Email; P = Paper

Issued by Siddiqui
 Comment Document – Piping
Client: Petrochem Terminals FZE
Project: Petrochemical Terminal at Plot B052F02

Correspondence Ref: 425841/TC02B/M&P-DT-0560 MM Ref: 425841/TC02B/M&P/CT-8118 Rev 00

Correspondence Date: 06/06/2023 Page: 1 of 2 Date: 10/06/2023

Receipt Date: 06/06/2023 Status: (Delete as appropriate)

Distribution: A CONSENT TO PROCEED

B CONSENT TO PROCEED
Contractor: Mr. Siddiqui K SUBJECT TO COMMENTS
GGME LLC. C NO CONSENT TO PROCEED
Dubai, UAE DRAWING / DOCUMENT TO
BE RESUBMITTED
Client: Mr. Cherian George / Mr. Bright Thomas
D FOR INFORMATION
Petrochem Terminals FZE
Dubai, UAE
ARA/ADS/MM

Submission: MS for Pipe Holiday Test Procedure - ITI-NDT-CSP-0117 Rev 0

RA for Jetty piping holiday test - GGME/CX-393/RA/PHT/01

Comments from previous submission: First submission

Comments from this submission:

1. The document title for ITI-NDT-CSP-0117 Rev 0 states that it is for High Voltage Holiday
Testing as snapped below:

However, detailed procedure for Low Voltage Holiday Testing, its equipment is specified
in the document. Sections that are not required shall not be included in the Method
Statement

2. The document shall be project and equipment specific and shall be revised.

3. There is no reference to the project, project documentation, drawings, specifications etc

and/or the Client, the Engineer, the Contractor, TPI etc in the submitted document.

4. The basis for selection of High Voltage shall be established

5. Section 8.2.c calculations shall be included to demonstrate that the voltage selected and
required are firm.

6. Reference to clearance by Contractor’s QA/QC, TPI and their involvement shall be

provided.

7. Report format shall include the following:

a. Reference P&ID, Piping GAs
b. Pipeline number & MOC
c. Pipeline size
DUB - FT071
https://mottmac.sharepoint.com/teams/pj-f7567/do/Develop/CONSTRUCTION PHASE/02. M&P - GGME/03. COMMENT SHEETS/08.
PIPING/CT-8118-R00-GGME-DT0560_MSRA Holiday Testing R0.docx
 Comment Document – Piping
d. Details of the wrapping (brand, technical information, thickness) provided including
details of primer coat
8. Report shall be prepared for individual pipelines

The above comments and/or approval in no way relieve the Contractor from his obligations under the
Contract to ensure conformance to the Specification. Any deviations from the Specification found
subsequent to approval shall be corrected by the Contactor to the satisfaction of the Engineer.

______________________ _______________________

Resident Engineer Project Engineer

Mott MacDonald Mott MacDonald

DUB - FT071
https://mottmac.sharepoint.com/teams/pj-f7567/do/Develop/CONSTRUCTION PHASE/02. M&P - GGME/03. COMMENT SHEETS/08.
PIPING/CT-8118-R00-GGME-DT0560_MSRA Holiday Testing R0.docx
 COMMENTS RESOLUTION SHEET FOR CONSULTANT COMMENTS
GGME MOTT MAC DONALD / PETROCHEM

COMMENT RESOLUTION DOC NO : ITI-NDT-CSP-0117 /CRS-001 Rev.00

SUBMITTAL NO : GGME/CX-393/MSRA/PHT/01- Rev. 0

Date : 13/6/2023
Project : Petrochemical Terminal at Plot B052F02
Item : MSRA - Holiday Testing of Jetty Piping
CLIENT : Petrochem Terminals FZE
Consultant : Mott Mac-Donald
M&P Contractor GGME LLC
GGME Job No.: CX-393
GGME DT NO : 425841/TC02B/M&P-DT-0560 MM CT NO : 425841/TC02B/M&P/CT-8118 Rev 00 dated 10/06/2023

Sl No Comments From Mott Mac Donald GGME response / Actions Taken

METHOD STATEMENT
The document title for ITI-NDT-CSP-0117 Rev 0 states that it is for High
Voltage Holiday Testing. A Low voltage holiday detector system is used only in applications where coating
1 However, detailed procedure for Low Voltage Holiday Testing, its thickness is less than 0.508 mm ( 20 mils) microns . Coating thickness above 0.508
equipment is specified in the document. Sections that are not required mm high voltage holiday detector shall be used . Jetty line coating is more than
shall not be included in the Method Statement specified limit of 0.508 mm - Not required sections are removed from MS.
The document shall be project and equipment specific and shall be Complied and Incorporated in the Method Statement.
2 revised.
There is no reference to the project, project documentation, drawings,
3 specifications etc and/or the Client, the Engineer, the Contractor, TPI etc in Complied & the mentioned details are incorporated in the Method statement.
the submitted document.

The basis for selection of High Voltage shall be established High voltage is selected on the basis that all the jetty pipes to be tested is having a
4 coating thickness above 0.508 mm

Section 8.2.c Calculations shall be included to demonstrate that the
5 voltage selected and required are firm.
Reference to clearance by Contractor’s QA/QC, TPI and their
6
involvement shall be provided.
Voltage selection is dependent on the pipe coating thickness and the required
voltage is generated and displayed automatically once the coating thickness is
entered in the holiday detector.
Prior to start the holiday test, the holiday test technician will demonstrate the same
to the client/consultant/TPI.
Complied and Incorporated in the Method Statement.

Page 1 of 2
 COMMENTS RESOLUTION SHEET FOR CONSULTANT COMMENTS
GGME MOTT MAC DONALD / PETROCHEM

Sl No Comments From Mott Mac Donald GGME response / Actions Taken

Report format shall include the following: Complied.

a. Reference P&ID, Piping GAs
b. Pipeline number & MOC
7
c. Pipeline size.
d.Details of the wrapping (brand, technical information, thickness)
provided including details of primer coat.
Report shall be prepared for individual pipelines Complied.
8

For information

1 Nil

2 Nil

For GGME- For Consultant / Client-

Prepared By:- Reviewed By:-
R. Anandaram
(Project Manager)

Page 2 of 2
GHANTOOT GENERAL MECHANICAL ENGINEERING L.L.C.
P.O. Box No. 5718, Dubai, U.A.E.
Tel. No. (04) 3472740
Fax. No. (04) 3473609
Doc. Ref: GGME/CX-393/MSRA/PHT/01- Rev. 0
METHOD STATEMENT Date: 13/06/2023
HOLIDAY TESTING OF JETTY PIPING Page 1 of 9

METHOD STATEMENT
Doc Ref: GGME/CX-393/MSRA/PHT/01- Rev. 0
Date: 13/06/2023

HOLIDAY TESTING OF
JETTY PIPING

PROJECT : PETROCHEMICAL TERMINAL AT PLOT B052F02 , JAFZA,DUBAI,UAE

ITEM : STORAGE TANKS, PIPING AND OTHER MECHANICAL WORKS
CLIENT : PETROCHEM TERMINALS FZE
CONSULTANT : MOTT MACDONALD(MMD)
MECH, CONTRACTOR : GHANTOOT GEN. MECH. ENGG. LLC (MECHANICAL WORKS)
GGME JOB NO : CX- 393

Prepared by Reviewed & Approved By

GGME MOTT MAC-DONALD PETROCHEM TERMINALS FZE

GHANTOOT GENERAL MECHANICAL ENGINEERING L.L.C.
P.O. Box No. 5718, Dubai, U.A.E.
Tel. No. (04) 3472740
Fax. No. (04) 3473609
Doc. Ref: GGME/CX-393/MSRA/PHT/01- Rev. 0
METHOD STATEMENT Date: 13/06/2023
HOLIDAY TESTING OF JETTY PIPING Page 2 of 9

1.0 SCOPE:

This document describes the procedure for detecting holidays in jetty pipeline coating in
accordance with Client’s Technical Specification (References given below in this
document) at Petrochem Petrochemical Terminal at Plot B052F02, Dubai, United Arab Emirates.

For holiday testing, High Voltage Holiday Detector is used to detect holidays such as pinholes and
voids in pipeline coatings; but because of the higher applied voltages, it can also be used to detect
thin spots in the coating. This method can be used on any thickness of pipeline coating and utilizes
applied voltages between 900 and 20 000 Vdc.
The purpose of this procedure is to ensure that the holiday testing is conducted in a safe manner
based on sound engineering practice and satisfies the requirements of relevant Technical
Specifications, International Codes and Site Requirements.

2.0 KEY PERSONS

GGME
Cont. Cont.
Name Designation Name Designation
No. No.
Mr. Anandaram Project Manager
Mr. Gopal Pitta Const. Manager
Mr. Shamim HSE Advisor
Mr. Sundar QA/QC Engineer
Mr. Ramakrishnan Piping Engineer
Mr. Aravind Site Engineer

MOTT MACDONALD PETROCHEM TERMINALS FZE

Mr. Alex.R Project Manager Mr. Cherian Chief Project Manager

Mr. Mansumon Project Engineer. Mr. Bright Thomas Asst. Project Manager
Mr. Mahendra Singh Sr. HSE Officer Mr. Bhavik Patel Project Engr.
GHANTOOT GENERAL MECHANICAL ENGINEERING L.L.C.
P.O. Box No. 5718, Dubai, U.A.E.
Tel. No. (04) 3472740
Fax. No. (04) 3473609
Doc. Ref: GGME/CX-393/MSRA/PHT/01- Rev. 0
METHOD STATEMENT Date: 13/06/2023
HOLIDAY TESTING OF JETTY PIPING Page 3 of 9

3.0 REFERENCE DOCUMENTS:

3.1 Addendum 01 Mechanical and Piping Works 1 July 2022. - 425841-MMD-00-XX-SP-

U-7104-C01
3.2 Tender Addendum 02 Mechanical and Piping Works 7 July 2023.- 425841-MMD-00-
XX-SP-U-7105 - C01
3.3 Tender Addendum 03 Mechanical and Piping Works 12 July 2022 - 425841-MMD-00-
XX-SP-U-7106 C01
3.4 Tender Addendum 04 Mechanical & Piping Works 23 August 2022- 425841-MMD-00-
XX-SP-U-7107 -C01
3.5 Contract Drawings Overall Key Plan Drg.No.425841-MMD-00-XX-DR-C-0001 &
Terminal Layout Drg. No. 425841-MMD-00-XX-DR-C-0002, Piping GA & P&IDs.
3.6 Drawings – Approved / Issued for construction & Isometric Drawings and other relevant
datasheet.
3.7 Client’s Technical Specification: -
 Piping Design Basis
 Piping Material Specification
3.8 Inspection and Test Plan-ITP Ref: CX-393/ITP/01 Rev.0 approved by TPI/MM/PME.
3.9 Safety Standards -PME/MM/JAFZA/DP World/JAFZA
3.10 Project Execution Plan Ref: GGME/CX-393/PEP/01 Rev.1– Approved by MM /
PME
3.11 Project HSE Plan Ref: GGME/CX-393/HSE/01 Rev.3– Approved by MM / PME
3.12 Calibration Certificates for High Voltage Holiday Detector – Will be submitted to
RE/HSE Prior to commencement of works
3.13 WPS, PQR and WQT (Approved by TPI/MM/PME)
3.14 Material Index with MTC.
4.0 WORK PERMITS FROM RESPECTIVE PERMIT AUTHORITY.

I. For jetty pipe holiday testing inside the site plot limit – Consultant/Client approved
Site Permit to Work System shall be followed.
II. For jetty pipe holiday testing outside the site plot limit (i.e. jetty area outside tanker
berth) – Occupation of Work Site permit shall be obtained from DP World. Civil
contractor shall be responsible for obtaining the permit upon request by M & P
contractor.
III. For working inside Tanker Berth Area – Tanker Berth Safe Work Permit shall be
obtained from Trakhees. Trakhees certified Permit Issuer, performing authority and
Gas Inspector shall be responsible for issuing the permit.
 GHANTOOT GENERAL MECHANICAL ENGINEERING L.L.C.
P.O. Box No. 5718, Dubai, U.A.E.
Tel. No. (04) 3472740
Fax. No. (04) 3473609
Doc. Ref: GGME/CX-393/MSRA/PHT/01- Rev. 0
METHOD STATEMENT Date: 13/06/2023
HOLIDAY TESTING OF JETTY PIPING Page 4 of 9

5.0 DETAILS OF JETTY PIPELINES FOR HOLIDAY TESTING: -

Jetty Piping /Pipelines from Berth: - (Under Ground)

a. Dia.8” SS316L Pipelines (Piping Class DX1A) between New Berth and
Hose Exchange 1 for generic liquid chemicals including Monomers. 3 Nos.

b. Dia.8” SS316L pipeline (Piping Class DC1A) between New Berth and Hose
Exchange 1 for Acetic Acid. 1 No.

c. Dia.8” SS316L Pipelines (Piping Class DX1A) between PME Existing Berth and
Hose Exchange 1 for generic liquid chemicals including Monomers. 2 Nos.
d. Dia.3” SS316L (Piping Class DC1A) to transfer Nitrogen from the
Terminal to the New Berth for pigging operations 1 No.
e. Dia.3” SS316L (Piping Class DC1A) for vapor balancing between the
Terminal and New berth 1 No.

6.0 TEST EQUIPMENT

High-Voltage Holiday Detector

A holiday detector tester having an electrical energy source of 900 to 20 000 Vdc; an exploring
electrode consisting of wire brush, coil-spring, or conductive silicon electrode capable of moving
along the pipeline coating; and an audio indicator to signal a defect in a high-electrical resistance
coating on a metal substrate. A ground wire connects the detector with the low-resistance metal
surface.

High Voltage Holiday detector with spring electrode

 GHANTOOT GENERAL MECHANICAL ENGINEERING L.L.C.
P.O. Box No. 5718, Dubai, U.A.E.
Tel. No. (04) 3472740
Fax. No. (04) 3473609
Doc. Ref: GGME/CX-393/MSRA/PHT/01- Rev. 0
METHOD STATEMENT Date: 13/06/2023
HOLIDAY TESTING OF JETTY PIPING Page 5 of 9

7.0 PRINCIPLE OF OPERATION

Steel pipes are coated with paint and wrapped with coating sleeve with the thickness up to 5000
microns. High voltage holiday detectors are used to inspect these coatings for pin holes,
scratches or other coating faults. The handle of the instrument generates a high DC voltage
which is applied to the surface of coating via a probe. An earth signal return cable is connected
between the instrument and the substrate. When the probe is passed over a coating flaw, the
electrical circuit is completed and current flows from the probe to the substrate.
As a result, the instrument gives audible, visual alarms and a spark may be produced at the
flaw, Spray equipment check.

The electric connection between Equipment and test specimen shall be as described in the
image below.

8.0 PROPERTIES OF PIPE COATING

The coating under test can be electrically non-conductive or partially conductive (such as
coating which contain metallic or carbon particles). The coating must be at least 200 microns
(0.008”) thick, and preferably over 5000 microns thick.
The underlying substrate must be an electrically conductive material such as metal or concrete.
 GHANTOOT GENERAL MECHANICAL ENGINEERING L.L.C.
P.O. Box No. 5718, Dubai, U.A.E.
Tel. No. (04) 3472740
Fax. No. (04) 3473609
Doc. Ref: GGME/CX-393/MSRA/PHT/01- Rev. 0
METHOD STATEMENT Date: 13/06/2023
HOLIDAY TESTING OF JETTY PIPING Page 6 of 9

9.0 SURFACE PREPARATION

The testing location should be free from solvents or other ignitable materials from the coating
activities left in the test area.
Testing is applicable only on coating that are cured, thickness tested and visually inspected
and accepted.
10.0 PROCEDURE FOR HOLIDAY TESTING
 Use the high-voltage holiday detector.
 Determine the test voltage desired by multiplying the dielectric breakdown voltage per
millimeter (mil) of the coating times the minimum allowable thickness of the coating in
millimeters (mils). An alternative method of determining test voltage is by use of one of
the following equations depending on coating thickness.
 If the coating thickness is less than 1.016 mm (40 mils):
where:
V = test voltage
V 5 M=Tc (1)
Tc = coating thickness
M = 3294 if Tc is in millimeters
M = 525 if Tc is in mils.
11.2.3 If the coating thickness is greater than 1.041 mm (41 mils):
where:
V = test voltage
Tc = coating thickness
V 5 K =Tc (2)
K = 7843 if Tc is in millimeters
K = 1250 if Tc is in mils
 These equations are predicated on the amount of voltage needed to jump an air gap of the
same length as the coating thickness. Therefore, they are useful for testing voids, pinholes
and thin spots in the coating, but would not be useful as a coating thickness quality control
tool.
 Ground the test specimen by attaching the ground wire to a bare metal spot on the pipe
surface.
 Plug the ground wire into the holiday detector. Then make up the searching electrode in
accordance with the manufacturer’s recommendations, using a brush wire or conductive
silicon electrode. Plug the searching electrode into the holiday detector. Turn on the
holiday detector.
 CAUTION: Because of the high voltages involved, do not touch the ground wire and the
metal part of the electrode at the same time if the instrument is on.
 The detector is now ready to operate by passing the electrode over the test specimen. The
detector will ring if it passes any void, pinhole, or area of the coating thinner than the
minimum allowable thickness. When a holiday is detected by the audible alarm, the
electrode can be repositioned to determine the exact holiday area by observing the origin
of the spark jump.
 GHANTOOT GENERAL MECHANICAL ENGINEERING L.L.C.
P.O. Box No. 5718, Dubai, U.A.E.
Tel. No. (04) 3472740
Fax. No. (04) 3473609
Doc. Ref: GGME/CX-393/MSRA/PHT/01- Rev.0
METHOD STATEMENT Date: 13/06/2023
HOLIDAY TESTING OF JETTY PIPING Page 7 of 9

 Prior to making the inspection, ensure that the coated surface is dry. Dryness is critical
in a high voltage test. Take care to keep the electrode at least 12.7 mm (/2 in.) from any
bare sheared or slit edge.
11.0 SEQUENCE OF OPERATION
 Connect the high voltage handle to the instrument.
 Connect the clamp of the earth signal return cable to an exposed section of substrate and
plug the other end of the cable into the instrument.
 Select the probe/electrode best suited for the work and attach it to the high voltage handle.
 Check the cable connections, set test voltage and sensitivity etc. Voltage setting can be
done by manual or automatic. Automatic setting of voltage depends on the selection of test
standards and coating thickness.
 Perform the verification before conducting the test.
 Select the test voltage in kV according to the standards.
 Holding the high voltage handle firmly, ensure that finger grasp and squeeze the black
rubberized grip on the underside of the handle.
 With the probe in free air, press and release the button on the handle to switch on the high
voltage. The red light on the handle will illuminate and the instrument will emit a regular
clicking, indicating that the probe is at high voltage.
 Place the probe on the test surface.
 Keeping the probe in contact with the surface, move it over the work area at a speed of
approximately one meter in every four seconds, 0.25 m/s.
 Any flaws in the coating will be indicated by one or more of the following;
 A spark is seen between the probe and surface.
 The blue light on the high voltage handle flashes.
 The alarm sounds.
 The alarm icon is shown on the display.
 The display black light flashes.
 If need to test in more than one location, always switch off the instrument before
disconnecting any cables, re attaching the cables in new test locations and before
recommencing testing repeat the steps.
12.0 PERMIT TO WORK SYSTEM: -
a. Proper “Permit to Work” system established by client / consultant shall be strictly followed.
b. Permits for Cold work/testing&commissioning shall be taken separately from the respective
permit authority of Client / Consultant whichever is applicable.
c. Permits from respective authority (DP World, Trakhees etc.) shall be obtained for working
in jetty/tanker berth area
d. Permit shall be taken Weekly/ every day before start the work and close upon the
completion and signed off by the respective authorities.
13.0 HSE REQUIREMENTS FOR HOLIDAY TESTING: -
HSE requirements for holiday testing are as follows;
1. Trench should be inspected prior to start of holiday testing or after any adverse event
such as rain or sandstorm.
2. Do not work in trenches for holiday testing during adverse weather conditions. Evacuate
to safe area.
 GHANTOOT GENERAL MECHANICAL ENGINEERING L.L.C.
P.O. Box No. 5718, Dubai, U.A.E.
Tel. No. (04) 3472740
Fax. No. (04) 3473609
Doc. Ref: GGME/CX-393/MSRA/PHT/01- Rev. 0
METHOD STATEMENT Date: 13/06/2023
HOLIDAY TESTING OF JETTY PIPING Page 8 of 9

3. Provide proper access and egress to trench.

4. Extreme care to be taken while working near existing product pipelines/utility lines. Do
not touch/knock/hammer them.
5. Emergency escape route shall be defined for responding in case of any emergencies while
working in trench.
6. Do not walk over the laid or erected jetty pipelines. Even after laying/installation of
pipelines, enough space shall be ensured for easy movement of personnel inside the
trench.
7. Do not jump across the trench, even if narrow also.
8. Alone work shall not be allowed in trenches.
9. Personnel performing the holiday testing shall be trained and certified by company to
handle the testing.
10. Ensure that earth cable is connected between holiday detector and pipe to be tested prior
start of testing.
11. Prior to making the holiday testing, ensure that the pipe surface being tested is dry.
12. Do not touch the ground wire and the metal part of the electrode/probe at the same time if
the instrument is on.
13. Ensure that the Holiday Tester is turned off immediately after detecting some defects in
the pipe or before removal of the electrode.
14. Proper communication shall be ensured between all the personnel involved in testing.
15. Before carrying out the test procedure, consult the consultant HSE officer for clearing of
other personnel and keep the test area clear and to help with the testing procedure.
14.0 ACCEPTANCE CRITERIA: -
 The holiday test shall be accepted provided that there are no holidays in the tested
jetty pipelines. i.e. there is no presence of any voids or pinholes in the pipeline coatings.
 During the holiday test, if any holidays are detected in any section of the coated
pipelines, the same will be marked and repaired, i.e one layer of coating will be
wrapped over the pinhole/void and the section will be against retested to reconfirm the
holiday.
 During the holiday test, the contractor shall demonstrate to the satisfaction of the TPI
and consultant Engineer that the holiday is being done properly and all procedures are
being followed.

 Test Report: GGME QA/QC engineer shall prepare the test report and this will be
submitted to the TPI & Consultant Engineer for acceptance and signature. Test reports
shall include;
a) Reference P&ID, Piping GAs
b) Pipeline number & MOC
c) Pipeline size
d) Details of the wrapping (brand, technical information, thickness) provided including
details of primer coat.
Also, report shall be prepared for individual pipelines.
(Holiday Testing Report Format is attached in Annexure – 1)
15.0 DOCUMENTATION: -
GHANTOOT GENERAL MECHANICAL ENGINEERING L.L.C.
P.O. Box No. 5718, Dubai, U.A.E.
Tel. No. (04) 3472740
Fax. No. (04) 3473609
Doc. Ref: GGME/CX-393/MSRA/PHT/01- Rev. 0
METHOD STATEMENT Date: 13/06/2023
HOLIDAY TESTING OF JETTY PIPING Page 9 of 9

 The full documentation/QC Dossier pertaining to the jetty piping holiday test shall be
submitted to consultant as per provisions of the contract.

ANNEXURE-1
CLIENT: CONSULTANT:
PROJECT PETROCHEMICAL TERMINAL AT PLOT B052F02 IN JAFZA NORTH,
TITLE: DUBAI, UAE

DOC NO: GGME/CX-393/MSRA/PHT/01- Rev. 1

RISK ASSESSMENT FOR JETTY PIPING HOLIDAY TEST

RISK MATRIX
SEVERITY LIKELIHOOD
COMPANY EXTREMELY
PEOPLE ASSET DAMAGE ENVIRONMENT VERY UNLIKELY UNLIKELY PROBABLE REGULAR
REPUTATION UNLIKELY

Has Occurred in Has Occurred

Has occurred
Risk to safety Financial risk worldwide within industry Occasionally Frequently
Pollution Media exposure, infrequent in
or health Cost of damage industry but not but not in occurs in GGME occurs in GGME
Company image. GGME
in GGME GGME

1 2 3 4 5
Fatalities GLOBAL
INTERNATIONAL/
(or multiple severe Extensive (media interest,
MASSIVE IMPACT
5 5 10 15 20 25
permanent disablement) significant recovery work)
Major injury NATIONAL
NATIONAL/ MAJOR
(or severe permanent Major (on site impact, regional
IMPACT
4 4 8 12 16 20
disablement) media interest)
Disability
SERIOUS
(Electrical Shock, CONSIDERABLE
Broken Bone, Third
Localized (considerable recovery
IMPACT
3 3 6 9 12 15
works)
Degree Burn)
L.T.I. LIMITED
(Bruises, Stitches)
Minor
(small recovery work)
MINOR IMPACT 2 2 4 6 8 10
MINOR VERY SLIGHT
First aid Slight
(negligible recovery work) IMPACT 1 1 2 3 4 5

1 – 4 Low Risk 5 – 12 Medium Risk 13 – 25 High Risk

Risk (R) = Likelihood (L) x Severity (S)

GGME/CX-393/RA/PHT/01- Rev. 1 1|Page

CLIENT: CONSULTANT:
PETROCHEMICAL TERMINAL AT PLOT B052F02 IN JAFZA NORTH,
PROJECT TITLE: DUBAI, UAE

DOC NO: GGME/CX-393/MSRA/PHT/01- Rev. 1

RISK ASSESSMENT FOR JETTY PIPING HOLIDAY TEST

Operation / task : Jetty Pipe Holiday Testing Employees at risk : All Employees
Location / Area : Petrochem Terminal, JAFZ North, Dubai Other persons at risk : Client , Consultant, Sub-contractors & Visitors
Assessor : Risk Assessment Team Property at risk Company / Local Property
Persons responsible Project Manager Comment :
Residual Risk Additional
Sl Initial Risk Rating
Activity Hazard Risk Existing Control Measures Rating Control Risk level Action by
No.
L S R L S Risk measures
1. Mobilization of  Inadequate  Physical injuries 2 3 6  Provide site safety induction, 1 2 2  Before Low Permit issuer,
workmen to the knowledge of site  Fines and legal MSRA communication, essential mobilization, Permit
project site/jetty safety rules & consequences trainings to the workforce prior details of reviewer,
area/tanker regulation start of work personnels to
from DP
 Provide adequate information
Performing
berth area  Unaware of DP be mobilized
world/Trakhees.
about work location for authority.
World/Trakhees shall be
 Failure in mobilization. Holiday test
HSE rules. shared to
responding to
 Unaware of DP
emergency in
 Obtain necessary GGME HSE Technician
world/tanker berth permits/permission/approval prior Department.
jetty/tanker berth
emergency entering to jetty/tanker berth
area.
procedure. area.  Work
 Fall of person into
 Proximity to sea.  Awareness on DP personnels
sea.
 Incompetent World/Trakhees HSE rules for
 Accidents working in jetty/tanker berth shall
should have
personnel.
 Property be communicated to all workforce
valid
 Failure to follow damage. Emirates ID &
site safety rules. and strictly follow them.
JAFZA Pass.
 Unauthorized  DP World/Tanker berth
entry of vehicles emergency procedure shall be
and personnel to communicated and followed.
site.  Barricading and signage to avoid
 Entering the work personnel movement in close
area without PPE. proximity to sea.
 Communicate the pedestrian
access and vehicle movement
route to the mobilized
personnels.

GGME/CX-393/RA/PHT/01- Rev.1 2|Page

CLIENT: CONSULTANT:
PETROCHEMICAL TERMINAL AT PLOT B052F02 IN JAFZA NORTH,
PROJECT TITLE : DUBAI,UAE

DOC NO : GGME/CX-393/MSRA/PHT/01- Rev. 1

RISK ASSESSMENT FOR JETTY PIPING HOLIDAY TEST

Initial Risk Residual Risk Additional
Sl Rating Rating
Activity Hazard Risk Existing Control Measures Control Risk level Action by
No.
L S R L S Score measures
 Conduct Tool Box Talk prior to
carry the task for addressing all
the potential hazards and its
controls required for
implementation.
 Restrict unauthorized entry of
personnel to other work locations
in the site/jetty/tanker berth.
 Ensure all employees are using
right PPE while performing the
task.

GGME/CX-393/RA/PHT/01- Rev.1 3|Page

CLIENT: CONSULTANT:
PETROCHEMICAL TERMINAL AT PLOT B052F02 IN JAFZA NORTH,
PROJECT TITLE : DUBAI,UAE

DOC NO : GGME/CX-393/MSRA/PHT/01- Rev. 1

RISK ASSESSMENT FOR JETTY PIPING HOLIDAY TEST

Initial Risk Residual Risk Additional
Sl Rating Rating
Activity Hazard Risk Existing Control Measures Control Risk level Action by
No.
L S R L S Score measures
2. Working in  Unavailability of PTW  Fines and legal 3 3 9  Site PTW/DP World PTW/Tanker 1 2 2  Check Low Permit issuer,
excavated trench  Lack of access or consequences Berth PTW shall be followed. weather Permit
for holiday egress from DP  DP World/Tanker berth HSE conditions reviewer,
testing.  Entering the trench world/Trakhees rules/guidelines shall be strictly before work. Performing
without visual  Physical
followed.  Be careful of authority.
inspection.  Trench should be inspected every the location
injuries.
day prior to start of work or after Holiday test
 Adverse weather  Flooding or of utilities
any adverse event such as rain or underground Technician
condition. water sandstorm.  Educate and
 Loose Materials or accumulation  Do not work in trenches during
 Eye or skin train workers
tools kept on sides of adverse weather conditions.
irritation on potential
trench. Evacuate to safe area.
during hazards and
 No barricade and  Keep soil heaps, tools, work appropriate
sandstorm.
signage. equipment’s away from the edge safety
 Existing underground  Property of the excavations. measures.
damage
utilities.  Never throw hand tools/power  Ensure close
 Fall of
 Improper cable tools/materials into an excavation, supervision
person/equip always pass by hand only.
routing. during entire
ment.
 Poor housekeeping.  Provide edge protection around testing
 Underground the excavation and signage shall duration.
utilities be displayed.
damage
 Provide proper access and egress
 Electrocution to trench.
 Slip, trip &  Extreme care to be taken while
fall. working near existing product
pipelines/utility lines. Do not
touch/knock/hammer them.
Ensure they are supported and
adequately marked or otherwise
protected.
 All electrical cables used in the
trench shall be routed properly.
 Practice daily housekeeping and
waste shall be disposed daily

GGME/CX-393/RA/PHT/01- Rev. 1 4|Page

CLIENT: CONSULTANT:
PETROCHEMICAL TERMINAL AT PLOT B052F02 IN JAFZA NORTH,
PROJECT TITLE : DUBAI,UAE

DOC NO : GGME/CX-393/MSRA/PHT/01- Rev. 1

RISK ASSESSMENT FOR JETTY PIPING HOLIDAY TEST

Initial Risk Residual Risk Additional

Sl Rating Rating
Activity Hazard Risk Existing Control Measures Control Risk level Action by
No.
L S R L S Score measures

3. Use of all steel  Unstable ground.  Fall of 3 3 9  Conduct Tool box talk prior start of 2 2 4  All activities Low Permit
tubular A-frame  Damaged tubular A- materials work. shall be issuer,
with Chain block for  Load failure strictly Permit
frame.  Position the A-frame on a stable and monitored by
lifting and  No TPI certification.  Physical levelled ground. Ensure its stability reviewer,
site
positioning of jetty injuries prior lifting the load. Performing
 Lack of inspection. supervisors/E
pipe for holiday
 Unattended load in  Trench  All steel A-frame and lifting gears ngineers. authority.
testing. collapse shall be certified by Trakhees Holiday test
lifted position.
 Property approved TPI agency. Technician
 Overloading.
damage.  Daily lifting gear inspection to be
 Corroded or defective done by lifting supervisor and
chain block.  Lifting gear
verified by HSE.
 Chain vibration or jerk damage.  Never leave the load unattended in
during lifting. lifted position.
 Side pulling.  Do not stand or work under the lifted
 Pulling the chain too load unless it is properly secured.
hard.  Only load the A-frame and lifting
 Lack of supervision. gears within its rated capacity.
 Lack of PPE.  Use the chain block only for vertical
lifting.
 No side pulling of Chain block shall
be allowed.
 While lifting or lowering load using
chain block, keep your feet clear.
 Load shall be lifted gradually only
using chain block.
 Only competent workers shall do the
lifting activity.

GGME/CX-393/RA/PHT/01- Rev. 1 5|Page

CLIENT: CONSULTANT:
PETROCHEMICAL TERMINAL AT PLOT B052F02 IN JAFZA NORTH,
PROJECT TITLE : DUBAI,UAE

DOC NO : GGME/CX-393/MSRA/PHT/01- Rev. 1

RISK ASSESSMENT FOR JETTY PIPING HOLIDAY TEST

Initial Risk Residual Risk Additional
Sl. Rating Rating Risk
Activity Hazard Risk Existing Control Measures Control Action by
No. level
L S R L S Score measures
4. Use of high voltage  Unavailability of PTW  DP 4 3 12  Site PTW/DP World/Tanker Berth PTW 2 2 4  Ensure Low Permit issuer,
Holiday detector for  Unaware of DP World/Trak shall be followed. close Permit
holiday testing World/Tanker berth HSE hees fines  DP World/Tanker berth HSE supervision reviewer,
rules/guidelines or legal rules/guidelines shall be strictly followed. during Performing
 Incompetent personnel. consequen  Ensure that workers performing the entire
ce authority.
 Use of uncalibrated testing are trained and experienced in testing
detector.  Physical holiday testing. duration.
Holiday test
 Faulty instrument. injuries.  Unauthorized operator should not Technician
 No earthing connection  Electrocuti operate the tester.
between holiday tester on  Ensure that the equipment is inspected
and the pipe.  Slip, trip and calibrated prior use.
 Wet pipe surface and fall  Make sure that the equipment cables are
 Instrument not switched injuries. free from damage and in good condition.
off while connecting or  Back  Always refer to manufacturer’s
disconnecting any cables. injuries methodology of testing.
 Lack of PPE  Ensure that earth cable is connected
 Strains
 Tripping hazards. and between holiday tester and pipe to be
 Manual handling sprains. tested prior start of testing.
 Space constraints inside  Prior to making the inspection, ensure
the trench. that the pipe surface being tested is dry.
 No access for movement  Do not touch the ground wire and the
inside the trench. metal part of the electrode at the same
 Unauthorized personnel time if the instrument is on.
in the work area during  Ensure that during holiday testing, no
testing. other workers touches the pipe being
 Lack of communication tested.
b/w testing technician and  Ensure that the Holiday Tester is turned
workers. off immediately after detecting some
 Simultaneous activity. defects in the pipe or before removal of
the ring(electrode).
 If testing needs to be done in more than
one location, always switch off the
instrument before disconnecting any

GGME/CX-393/RA/PHT/01- Rev. 1 6|Page

CLIENT: CONSULTANT:
PETROCHEMICAL TERMINAL AT PLOT B052F02 IN JAFZA NORTH,
PROJECT TITLE : DUBAI,UAE

DOC NO : GGME/CX-393/MSRA/PHT/01- Rev. 1

RISK ASSESSMENT FOR JETTY PIPING HOLIDAY TEST

Initial Risk Rating Residual Risk Additional

Sl
Activity Hazard Risk Existing Control Measures Control Action by
No. L S R L S Score Risk level measures
cables, re attaching the cables in
new test locations.
 All necessary PPE (Helmet, rubber
gloves, goggles, protective
clothing, safety shoes) shall be
worn by the personnel carrying out
the test.
 Pathway for movement inside the
trench shall be clear of
materials/cables to avoid tripping
hazards.
 Ensure workers are following the
correct procedure for positioning
and lifting while preparing pipes for
holiday test. Get help if required.
 Use A-frames for positioning the
pipes for holiday test, avoid manual
handling of pipes.
 Ensure that enough space is
available for movement of
electrode on the circumference of
the pipe.
 Proper access shall be ensured for
movement of personnels inside the
trench for testing activity.
 Only authorized personnel shall be
allowed to enter the test area and
engage in holiday testing.
 Proper communication shall be
ensured between all the personnel
involved in testing.
 Avoid simultaneous activity during
holiday testing.

GGME/CX-393/RA/PHT/01- Rev. 1 7|Page

CLIENT: CONSULTANT:
PETROCHEMICAL TERMINAL AT PLOT B052F02 IN JAFZA NORTH,
PROJECT TITLE : DUBAI,UAE

DOC NO : GGME/CX-393/MSRA/PHT/01- Rev. 1

RISK ASSESSMENT FOR JETTY PIPING HOLIDAY TEST

Initial Risk Rating Residual Risk Additional

Sl.
Activity Hazard Risk Existing Control Measures Control Risk level Action by
No. L S R L S Score measures
5. Working in Adverse  Working directly under  Sweating  Avoid working at high temperature
weather condition sunlight for long time.  Dehydration 4 3 12  Ensure potable water/sufficient 2 2 4  Keep track of Low Permit issuer,
 Rain.  Dizziness shelter is available near test area weather Permit
 Sand storm. where workers are doing the job. forecast
 Fainting reviewer,
 High humidity  Ensure no works are performed updates.
Performing
 Electrocution
during heavy wind or rain or sand
 Strong wind.  Nausea storm.
authority.
 Holiday test
Fatigue  Secure all loose materials to avoid
 Tiredness falling of materials due to wind. Technician
 Heat stress/
stroke
 Falling and
flying of
materials by
wind.

6. Heat stress  Lack of training  Sweating  Heat stress training to be given to all  Air Permit issuer,
 High humidity  Dehydration 4 4 16 workforce. 2 3 6 conditioners Medium Permit
 Working directly under  Dizziness  Provision of cold drinking water in the reviewer,
sunlight for long time.  Provide rest shelters and frequent workers rest Performing
 Fainting
area shall be
 People working/  Tiredness
breaks for workers to rest authority.
 No person shall work/ walk under maintained
walking under direct
 Penalty from properly in
Holiday test
sunlight during mid-day direct sunlight during the summer Technician
Trakhees advance to
break. Mid-day break
avoid
 Dust suppression to be done
frequently.
breakdown.

GGME/CX-393/RA/PHT/01- Rev. 1 8|Page

 ASSESSOR: REVIEWED BY: APPROVED BY:
Mr. Deepak Nair Mr. Muhammed Shahar Mr. R. Anandaram
(HSE OFFICER) (HSE ADVISOR) (PROJECT MANAGER)

05-06-2023 05-06-2023 05-06-2023

GGME/CX-393/RA/PHT/01- Rev. 1 9|Page