This document provides a risk assessment for hydro testing and pressure testing of pipe works conducted by Arabian Bemco Contracting Co. It identifies several hazards associated with the work including high pressure leaks, over pressure, slips trips and falls. For each hazard, it lists the persons at risk, initial risk rating, and proposed control measures to reduce the risk. The control measures include training, use of personal protective equipment, safety signage, permitting, and having emergency response measures in place.

1. Arabian Bemco Contracting Co. KSA
Power Plant Project-10
RISK ASSESSMENT
Assessment No: RA- Assessed By: Activity: Hydro testing/Pressure Testing Of Pipe Works
Hazard Persons at Risk
Risk Rating
Proposed Control Measures
Risk
Rating
S L R S L R
Hydro Test, Gravity Water Test
• High Pressure Leak
• Supervisor
• Inspector
• Pipe Fitter
• Plumber
• Helpers
5 3 15 • Pipe Fitter Shall Be Trained And Competent.
• Plumber Shall Be Trained And Competent.
• Work Crews Will Use Appropriate PPE. (Hand Gloves,
Safety Goggles)
• STARRT Talks For Crews by supervisor Involve In Pressure
Test
• Ensure Appropriate Barricades (Tape) & Sign Boards Placed
Around The Area During Pressure Testing and watchman to
be assigned around the area by concern team.
• Proper Communication during Pressure Testing.
• Training for Proper Use of Hydro Test Manual and Hydro
Test Booster Pump.
• Hand Tools Training As Tool Box Talks Topic.
• Tools Will Be Used Only For Their Intended Purposes &
Inspect Daily Prior To Start Of Work.
• Obtain Pressure Test Permit Prior To Start Of Work
• First Aid Kit Will Be Available.
• Pressure relive valve to be installed.
• Emergency vehicle must be present on site.
2 1 2

2. Arabian Bemco Contracting Co. KSA
Power Plant Project-10
RISK ASSESSMENT
Assessment No: RA- Assessed By: Activity: Hydro testing/Pressure Testing Of Pipe Works
Hazard Persons at Risk
Risk Rating
Proposed Control Measures
Risk
Rating
Pneumatic Test
• Over Pressure
• Fire
• Gas Purging
• Supervisor
• Pipe Fitter
• Plumber
• Inspector
• Helpers
3 3 9 • Pipe Fitter Shall Be Trained And Competent.
• Plumber Shall Be Trained And Competent.
• Work Crews Will Use Appropriate PPE. (Hand Gloves,
Safety Goggles)
• STARRT Talks For All Crews Involve In Pneumatic Test
• Ensure Appropriate Barricades (Tape) & Sign Boards Placed
Around The Area During Pneumatic Test
• Compressed Air Training As Tool Box Talks Topic.
• Training For Proper Use Of Hydro Test Manual And Hydro
Test Booster Pump.
• Hand Tools Training As Tool Box Talks Topic.
• Tools Will Be Used Only For Their Intended Purposes &
Inspect Daily Prior To Start Of Work.
• Proper Communication During Pneumatic Test
• Provide Adequate Fire Protection (Provision Of Sand, Fire
Blanket, Fire Watchmen & Fire Extinguishers).
• Obtain Pressure Test Permit Prior To Start Of Work
• First Aid Kit Will Be Available.
2 1 2
Slips, Trips And Fall • Foreman
• Pipe Fitter
• Plumber
• Helpers
3 3 9 • STARRT Talks For Crews
• Work Crews Will Use Appropriate PPE.
• Housekeeping Training As Tools Box Talks Topic.
• Always Check The Area Free From Unnecessary Materials.
• Work Place Which Has Been Maintained In A Good
Condition And Which Is Clean And Tidy
2 1 2

3. Arabian Bemco Contracting Co. KSA
Power Plant Project-10
RISK ASSESSMENT
Assessment No: RA- Assessed By: Activity: Hydro testing/Pressure Testing Of Pipe Works
Hazard Persons at Risk
Risk Rating
Proposed Control Measures
Risk
Rating
Compressed Gas Cylinders
• Explosion
• Fire
• All 5 4 20 • Work Crews Will Use Appropriate PPE
• STARRT Talks For Crews
• Compressed Gas Training As Tool Box Talks Topic.
• Provide Adequate Fire Protection (Provision Of Sand, Fire
Blanket, and Fire Watchman & Fire Extinguisher).
• Always Use The Proper Regulator For The Type Of Gas In
The Cylinder.
• Oil and Grease Not To Contact with Cylinder or Their
Valves.
• Always Use A Cylinder Wrench.
• Cylinders Should Never Be Rolled Or Dragged.
• Ensure Stability For Moving Large Cylinders And Strap
Them To A Properly Designed Wheeled Cart.
• Cylinder Should Be Properly Secured.
• Never Lift Cylinders by the Cap. The Cap Is For Valve
Protection Only.
• Do Not Use A Wrench To Open Or Close A Hand Wheel
Type Cylinder Valve.
• Cylinder Should Be Stored in A Well Ventilated Area Away
from Flames, Spark Any Source Of Heat Or Ignition.
• Always Store and Transport In Upright Position.
2 2 4

4. Arabian Bemco Contracting Co. KSA
Power Plant Project-10
RISK ASSESSMENT
Assessment No: RA- Assessed By: Activity: Hydro testing/Pressure Testing Of Pipe Works
Hazard Persons at Risk
Risk Rating
Proposed Control Measures
Risk
Rating
Power Tools
• Rotating Parts
• Electrocution From Damage Cables
• Inhalation (Dust)
• Dust/Objects In Eye
• Pipe Fitter
• Foreman
• Helpers
• Plumber
5 3 15 • Pipe Fitter Shall Be Trained & Competent.
• Plumber Shall Be Trained And Competent.
• Work Crews Will Use Appropriate PPE.( Safety Goggles,
Face Shields, Dust Mask )
• STARRT Talks For All Crews.
• Power Tools Training As Tool Box Talks Topic.
• Power Tools And Cables Shall Be Inspected Daily And
Color Coded Prior To Start Of Work.
• Damage Or Defective Power Tools Shall Be Tagged Out Of
Service And Immediately Returned To The Tool Room for
Repair.
• Grounding/Earthing Will Be Provided On All Mobile
Generators.
3 1 3
Foreign Body In Eye • All 3 3 9 • STARRT Talks for All Crews.
• Work Crews Will Use Appropriate PPE.( Face Shield, Safety
Goggles )
• Eye Protection Training as Tool Box Talks Topic.
2 1 2
Confined Space Entry • Supervisor
• Plumbers
• Pipe Fitter
• Inspectors
5 3 15 • Obtain Confined Space Entry Permit Prior To Beginning
Works.
• STARRT Talks With Crews Entering Confined Space.
• Confined Space Training As Tool Box Talks Topic.
• Authorized Entrants Shall Be Trained And Competent.
• Implement Confined Space Entry Program.
• Ensure Appropriate Barricades (Tape) & Sign Boards Placed
Around The Area Of Confined Space.
2 1 2
Working At Heights
• Fall Person
• Fall Material
• Foreman
• Pipe Fitter
• Plumber
• Helpers
3 3 9 • Working At Heights Training As Tool Box Talks Topic.
• STARRT Talks For Crews Working At Heights.
• Scaffold Erection By Competent Person.
• Scaftag Inspection Approval before Use.
2 1 2

5. Arabian Bemco Contracting Co. KSA
Power Plant Project-10
RISK ASSESSMENT
Assessment No: RA- Assessed By: Activity: Hydro testing/Pressure Testing Of Pipe Works
Hazard Persons at Risk
Risk Rating
Proposed Control Measures
Risk
Rating
• Inspector • Scaftag Work Permit Required.
• Safety Full Body Harness Required (Fall Protection).
Electrical Equipment
• Fire & Explosion
• Electrocution
• Electricians
• Plumbers
• Pipe Fitters
• Welders
• Helpers
• Foreman
• Inspectors
5 3 15 • Electricians Shall Be Trained & Competent.
• Work Crews Will Use Appropriate PPE.
• Safe Insulated Tools Will Be Used In Order To Carry Out
Electrical Work.
• Grounding/Earthing Will Be Provided On All Mobile
Electrical Generators.
• Ground Fault Circuit Interrupter (GFCIs) / Earth Leakage
Circuit Interrupter (ELCBs) Will Be Provided For All Areas
Having A Wet Atmosphere Where Electrical Equipment Or
Portable Electrical Tools May Be Used.
• Equipment Shall Be Maintained in a Good Condition And
Color Coded.
• STARRT Talks For All Crews.
• Site Electricity Training as Tool Box Talks Topic.
• Lock Out/Tag out System.
• Power Tools & Cables Inspected And Color Coded.
3 1 3

6. Arabian Bemco Contracting Co. KSA
Power Plant Project-10
RISK ASSESSMENT
Assessment No: RA- Assessed By: Activity: Hydro testing/Pressure Testing Of Pipe Works
Hazard Persons at Risk
Risk Rating
Proposed Control Measures
Risk
Rating
Hot Works
• Fire
• Electrocution
• Health Impairment
• Impaired Vision
• Explosion
• Welders
• Helpers
• Pipe fitters
• Plumber
5 4 20 • Welders Will Wear Safety Boots with Steel Toe, Welding
Shield With Helmet, Welding Apron & Welding Gloves.
• STARRT Talks For All Crews Involve In Hot Works.
• Hot Works Training As Tool Box Talks Topic.
• Ensure Appropriate Barricade & Sign Boards Placed Around
All Hot Works Activities.
• Provide Adequate Fire Protection (Provision Of Sand, Fire
Blanket, Fire Watchmen & Fire Extinguishers).
• Daily Inspection Of Welding Machines & Earthing Prior To
Start Of Work.
• Welders Shall Be Trained & Competent.
• Welders Shall Have A Valid Certification.
• Welding Cables Shall Be Inspected And Color Coding To
Ensure Good Condition.
• Obtain Hot Works Permit Prior To Beginning Works.
• First Aid Kit Will Be Available.
• Welding Screens Must Be Erected To Protect Others From
The Arc (Flush Burn).
2 2 4
Hazardous Substances
• Skin Burning
• Eye Irritations
• Health Impairment-Inhalation
• Fire
• Plumber
• Pipe Fitter
• Foreman
• Helpers
5 3 15 • Material Safety Data Sheet (MSDS) Shall Be Provided.
• STARRT Talks For Crews Working In Hazardous
Substances.
• Control Of Substances Hazardous To Health Training As
Tool Box Talks Topic.
• Appropriate Training Prior To Start Of Work.
• Work Crews Will Use Appropriate PPE.( Rubber Gloves,
Dust Masks)
• First Aid Kit Will Be Available.
3 1 3

7. Arabian Bemco Contracting Co. KSA
Power Plant Project-10
RISK ASSESSMENT
Assessment No: RA- Assessed By: Activity: Hydro testing/Pressure Testing Of Pipe Works
Hazard Persons at Risk
Risk Rating
Proposed Control Measures
Risk
Rating
Vehicle Operation
• Collision
• Persons Struck By Vehicles
• Drivers
• Operators
• Banksmen
• Pipe Fitter
• Helpers
• Plumber
• Pedestrian
5 3 15 • Implement Defensive Driving Program.
• Trained & Competent Drivers With Project Driving Permit.
• Traffic Control Plan Shall Be Implemented.
• Trained & Competent Banks men Directing Vehicles.
• Traffic Rules Shall Be Enforced.
• Instructions To All Drivers As Tool Box Talks Topic.
• STARRT Talks For All Crews.
• Routine Preventive Maintenance Program To Ensure Good
Working Condition Of Vehicles.
• High Visibility Vest Will Be Worn.
• Headlights Always On For Visibility.
3 1 3
Noise (Equipment )
• Ear Damage
• Operators
• Pipe Fitter
• Plumber
• Helpers
3 3 9 • Work Crews Will Use Appropriate PPE (Ear Muff, Ear
Plug).
• STARRT Talks For Crews Working In Noisy Environment.
• Noise (Ear Protection) As Training In Tool Box Talks Topic.
• Ensure Appropriate Barricades (Tape) & Sign Boards “Ear
Protectors Must Be Worn In This Area” Placed Around In
The Equipment.
• All Silencers Must Be Inspected To Ensure The Proper
Condition Of Equipment Prior To Start Of Work
• All Motorized On Site Must Utilize Silencer.
2 1 2
Noise ( Power Tools )
• Ear Damage
• Pipe Fitter
• Helpers
• Plumber
• Supervisor
3 3 9 • STARRT Talks For Crews Working In Noisy Environment.
• Noise (Ear Protection) As Training In Tool Box Talks Topic.
• Work Crews Will Use Appropriate PPE (Ear Muff, Ear
Plug).
2 1 2

8. Arabian Bemco Contracting Co. KSA
Power Plant Project-10
RISK ASSESSMENT
Assessment No: RA- Assessed By: Activity: Hydro testing/Pressure Testing Of Pipe Works
Hazard Persons at Risk
Risk Rating
Proposed Control Measures
Risk
Rating
General Welfare • All 5 4 20 • Work Crews Will Use Appropriate PPE.
• Dust Masks Required In Windy/Dusty Condition.
• Provide Sufficient Cool Drinking Water Near Workers.
• Provide Sufficient Toilets In Close Vicinity Of Workers.
• Provide Shaded Rest Areas In Close Vicinity Of Workers.
• Provide Sufficient Lights Near Workers At Night.
• Employees Shall Be Trained On Heat Stress Prevention,
Recognition And Treatment.
2 2 4
Fluid Spills From Vehicles Equipment
• Ground Contamination
• Water Contamination
• Environment 3 3 9 • Daily Inspection of Equipment For Leaks.
• Routine Preventive Maintenance Program.
• Maintenance Performed By Competent Persons.
• Drip Pans Sheets Used During Service.
• Spills Kit (Sand) Available In Service Area.
• Impervious Material under Fuel Tanks (Bonded) Fuelling
Area, Service Area.
• Impervious Material under Waste Oil Storage Area.
2 1 2
Originator: Sajid Ali Date: 14 March 2015