Gas Welding Risk Assessment.pdf

Project Name & Details
RISK ASSESSMENT FOR GAS WELDING
REF:
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DATE:
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S.N
S.N
.
.
A
AC
CT
TI
IV
VI
IT
TY
Y H
HA
AZ
ZA
AR
RD
D
CAUSES OF
CAUSES OF
HAZARD
HAZARD
RISK
RISK
EVALUATION
EVALUATION
RISK
RISK
LEVEL
LEVEL IM
IM LEMENTED
LEMENTED CONTROL
CONTROL
MEASURES
MEASURES
RESIDUAL RISK
RESIDUAL RISK
ACCE
ACCE T
T Y/N?
Y/N?
S
S H
H/
/M
M/
/L
L S
S H
H/
/M
M/
/L
L
1
1
ermitting
ermitting work
work
and preparation
and preparation

 Work condition not
Work condition not
safe
safe

 Procedures and tasks
Procedures and tasks
not clear or respected
not clear or respected

 Lack of supervisory
Lack of supervisory

 Miscommunication
Miscommunication

 Not correct PPE worn
Not correct PPE worn

 Equipment not
Equipment not
inspected and
inspected and
certified
certified
Material
Material
damage
damage
Personnel
Personnel
injury
injury
2
2 4
4 4
4

 HSE team to assess the conditions
HSE team to assess the conditions
of work in the assigned area prior
of work in the assigned area prior
and during the work
and during the work

 Competency of personnel and
Competency of personnel and
supervision for the different
supervision for the different
activities
activities

 Define hierarchy and reporting
Define hierarchy and reporting
flowcharts
flowcharts

 Check inspection certificates of
Check inspection certificates of
equipment for the job
equipment for the job

 CONTRACTOR PTW system should
CONTRACTOR PTW system should
be implemented
be implemented

 Attend CONTRACTOR safety
Attend CONTRACTOR safety
trainings
trainings

 Equipment checklist should be
Equipment checklist should be
made for all new equipment coming
made for all new equipment coming
to site
to site

 Weekly equipment checklist should
Weekly equipment checklist should
be made and kept at engine
be made and kept at engine

 Toolbox talks
Toolbox talks
Define proper PPE to be used for the
Define proper PPE to be used for the
work
work
1
1 1
1 1
1 Y
Y
1
1 Unloading
Unloading
Equipment
Equipment
(Mechanical
(Mechanical

 Dropped object while
Dropped object while
unloading equipments /
unloading equipments /
swinging or tip over of
swinging or tip over of
Personnel
Personnel
injuries/
injuries/
fatalities
fatalities
2
2 4
4 4
4

 lifting/ unloading of material under
lifting/ unloading of material under
PTW / JSA/ TBT/WMS
PTW / JSA/ TBT/WMS
1
1 1
1 1
1 Y
Y
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REV: 00
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and manual)
and manual)
load /
load /

 collision between load &
collision between load &
facilities
facilities


Mechanical failure/ fire
Mechanical failure/ fire

 Lifting gears failure
Lifting gears failure 

Operating in a windy
Operating in a windy
weather
weather 
 Spills
Spills 
 Uneven
Uneven
Floor
Floor

 Musculoskeletal
Musculoskeletal
disorder (MSDS) from
disorder (MSDS) from
manual heavy lift
manual heavy lift

 Hands injuries from the
Hands injuries from the
sharp edges
sharp edges

 Pinch Point / dropped
Pinch Point / dropped
loads
loads
Work in classified area
Work in classified area
Material
Material
damage
damage
Environmental
Environmental
impact
impact

 Standard PPE Must Be worn
Standard PPE Must Be worn

 Certified forklift / 70Tcrane
Certified forklift / 70Tcrane

 Weekly checklist for the lifting
Weekly checklist for the lifting
equipment
equipment 
 Certified lifting accessory &
Certified lifting accessory &
gears Coded color ongoing
gears Coded color ongoing

 Visual Inspection for the lifti
Visual Inspection for the lifting gears
ng gears
in prior to start any lift
in prior to start any lifting task
ing task

 Close supervision / QHSE Supervisor
Close supervision / QHSE Supervisor
assigned at site
assigned at site

 Never stand under suspended loads
Never stand under suspended loads

 Respect the radius swing
Respect the radius swing

 Competent & Certified operator
Competent & Certified operator

 No blind lifting
No blind lifting

 Lifting Area barricaded
Lifting Area barricaded

 Certified containers pad eyes
Certified containers pad eyes

 restricted access area (using warning
restricted access area (using warning
tape & safety signs)
tape & safety signs)

 Banks man to guide the lifting
Banks man to guide the lifting
operation
operation

 prohibit the lifting @
prohibit the lifting @ a wind speed
a wind speed
more than of 50 km/h
more than of 50 km/h

 check the ground state
check the ground state

 Apply the right manual handling
Apply the right manual handling
techniques / use a mechanical help if
techniques / use a mechanical help if
required
required

 Use the SMART GRIP Technique
Use the SMART GRIP Technique

 shadowed Shelters to be provided
shadowed Shelters to be provided
Continuous gas monitoring
1
1 Dismantling of
Dismantling of 
 Pinch point / hand
Pinch point / hand People
People 2
2 4
4 4
4 
 PTW/JSA/TBT
PTW/JSA/TBT 1
1 1
1 1
1 Y
Y
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the existing
the existing
corroded pipe
corroded pipe
injuries
injuries

 Falling from height
Falling from height

 MSDs(musculoskeleta
MSDs(musculoskeleta
l disorder/wrong
l disorder/wrong
posture)
posture)

 Dropped object
Dropped object

 Potential Sparks
Potential Sparks
ignition
ignition
Work in classified
Work in classified
area
area
assets
assets

 Proper PPE: gloves (EN 388)
Proper PPE: gloves (EN 388)

 Take extra attention when carrying
Take extra attention when carrying
out the dismantling task
out the dismantling task

 Only green Tagged scaffold to be
Only green Tagged scaffold to be
used
used

 Wear personnel fall arrest system if
Wear personnel fall arrest system if
required
required

 Apply the right kinetic postures
Apply the right kinetic postures


Clear and isolate the lower area to
Clear and isolate the lower area to
prevent injuries from falling object
prevent injuries from falling object

 Use only bronze tools
Use only bronze tools
1
1 H
Ho
ot
t w
wo
or
rk
k
(cutting,
(cutting,
grinding and
grinding and
welding)
welding)
Toxic fumes
Toxic fumes
inhalation
inhalation
Eyes irritation
Eyes irritation
Electrocution
Electrocution
/electrical shock
/electrical shock
Fire eruption
Fire eruption
Burns
Burns
Explosion
Explosion
Flying debris broken
Flying debris broken
disc
disc
Naked wires
Naked wires
Noise
Noise
Backfiring
Backfiring
Explosion due to
Explosion due to
overpressure of the
overpressure of the
compressed gas
compressed gas
cylinders
cylinders
Work in classified
Work in classified

 People
People
Asset
Asset
2
2 4
4 4
4

 Hot PTW/JSA/TBT
Hot PTW/JSA/TBT

 Pressurized welding habitat
Pressurized welding habitat

 Fire blanket
Fire blanket

 Atex equipment
Atex equipment


Clear the nearby area from the
Clear the nearby area from the
combustibles
combustibles

 Proper PPE (welding glovesEN
Proper PPE (welding glovesEN
407)/welding mask/face
407)/welding mask/face
shield/welding apron/ear plugs
shield/welding apron/ear plugs

 RPM of the disk should be larger
RPM of the disk should be larger
than the angle grinder RPM
than the angle grinder RPM

 Flashback arrestor
Flashback arrestor

 Compressed gas cylinders should
Compressed gas cylinders should
be kept in upright position and
be kept in upright position and
secured , capped if not in use
secured , capped if not in use

 Pressure gauge should be calibrated
Pressure gauge should be calibrated

 Safety signs in place
Safety signs in place
1
1 1
1 1
1 Y
Y
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area
area 
 Fire watch man in place
Fire watch man in place

 Continuous gas monitoring
1
1 V
Ve
eh
hiic
clle
es
s a
an
nd
d
Machinery
Machinery
Moving
Moving

 Road Crossings
Road Crossings

 vehicle crash
vehicle crash
Struck personnel
Struck personnel

 Material
Material
damage
damage

 Personnel
Personnel
injury
injury
2
2 4
4 4
4

 Traffic if necessary will be
Traffic if necessary will be
controlled.
controlled.

 Site drawings are available all the
Site drawings are available all the
time and used when needed
time and used when needed


Roads to be market and
Roads to be market and supervisors
supervisors
to be informed
to be informed

 All crossing with main road should
All crossing with main road should
be secured with hard barriers if not
be secured with hard barriers if not
used or properly identified with
used or properly identified with
adequate road signs when in use.
adequate road signs when in use.

 Permanent presence of the
Permanent presence of the
banksman
banksman

 Speed limit 10km/h in the ROW
Speed limit 10km/h in the ROW

 Warning signs
Warning signs

 Road signs
Road signs

 Correct hand signals
Correct hand signals
1
1 1
1 1
1 Y
Y
1
1 C
Clle
ea
an
niin
ng
g &
&
Housekeeping
Housekeeping
Musculoskeletal from
Musculoskeletal from
repetitive motion including
repetitive motion including
bending, stretching,
bending, stretching,
reaching etc.
reaching etc.
Personnel
Personnel
injury
injury
2
2 4
4 4
4 
 Training for good work practices to
Training for good work practices to
be held on site
be held on site

 TBT in place before job,
TBT in place before job,
housekeeping issues to be
housekeeping issues to be
mentioned in all TBT
mentioned in all TBT

 Personnel to perform cleaning and
Personnel to perform cleaning and
housekeeping without abuse to
housekeeping without abuse to
their bodies
their bodies

 Good lifting practice to be applied
Good lifting practice to be applied
1
1 1
1 1
1 Y
Y
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Page4 of 8

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REV: 00
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1
1 C
Clle
ea
an
niin
ng
g &
&
Housekeeping
Housekeeping
Pollution, Waste
Pollution, Waste
Environmental
Environmental
damage
damage
2
2 4
4 4
4

 No waste is tolerated during the job
No waste is tolerated during the job
execution.
execution.

 Personnel to end the day by
Personnel to end the day by
cleaning, inspecting equipment and
cleaning, inspecting equipment and
goodhousekeeping.
goodhousekeeping.

 All waste has to be collected and
All waste has to be collected and
removed to a designated area.
removed to a designated area.

 Any spill is to be contained in time, a
Any spill is to be contained in time, a
report to be issued to HSE
report to be issued to HSE
Manager.
Manager.

 All ground disturbing has to be
All ground disturbing has to be
remained to its normal situation
remained to its normal situation
after work.
after work.

 Any pollution or ground disturbing to
Any pollution or ground disturbing to
be reported directly to HSSE site
be reported directly to HSSE site
Manager and CONTRACTOR
Manager and CONTRACTOR

 Waste disposal unit, containers in
Waste disposal unit, containers in
place
place

 Plastic bags to collect waste
Plastic bags to collect waste

 Waste separation to be applied
Waste separation to be applied
1
1 1
1 1
1 Y
Y
1
1 C
Clle
ea
an
niin
ng
g &
&
Housekeeping
Housekeeping Biological hazard
Biological hazard
Scorpion
Scorpion
stings / vipers
stings / vipers
bites
bites
2
2 4
4 4
4 
 Awareness regarding
Awareness regarding
scorpion/vipers risks.
scorpion/vipers risks.
1
1 1
1 1
1 Y
Y
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REV: 00
DATE:
DATE:

 Area inspection before operations to
Area inspection before operations to
ensure no insects.
ensure no insects.

 Equipment appropriately stored after
Equipment appropriately stored after
the end of operations (not left on
the end of operations (not left on
the ground along the night).
the ground along the night).

 Sand bags “under check” before
Sand bags “under check” before
removing.
removing.

 Rests away insects shelters (stones,
Rests away insects shelters (stones,
bushes…)
bushes…)

 PPE.
PPE.

 TBT.
TBT.
ersons
ersons in da
in danger
nger

 Workers undertaking the work
Workers undertaking the work

 Persons passing the site location/ truck routes, e.g. members of the public and persons in the V
Persons passing the site location/ truck routes, e.g. members of the public and persons in the Vehicles.
ehicles.
ersonal
ersonal protective
protective equipment
equipment

 Safety Helmet, Gum Boot, Proper Gloves &
Safety Helmet, Gum Boot, Proper Gloves & Safety Goggles
Safety Goggles
Information, instruction and training
Information, instruction and training

 All personnel in the team are to be made aware of the sa
All personnel in the team are to be made aware of the safe systems of work.
fe systems of work.

 Ensure that good housekeeping standard is maintained t
Ensure that good housekeeping standard is maintained throughout.
hroughout.

 Training and experience for personnel to
Training and experience for personnel to use electrical equipments and vibratory equipments.
use electrical equipments and vibratory equipments.

 Educate the personnel to handle chemicals such
Educate the personnel to handle chemicals such as concrete…
as concrete…
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Page6 of 8

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REV: 00
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Emergency procedures
Emergency procedures

 Site emergency procedures should make provision for t
Site emergency procedures should make provision for the rescue of individuals from
he rescue of individuals from heights.
heights.

 First-aid facilities should be available to cope with any
First-aid facilities should be available to cope with any significant injuries that may arise from the work.
significant injuries that may arise from the work.
Monitoring and review
Monitoring and review

 Work should be monitored by Foreman and charge hand who are trained to ensure that any additional
Work should be monitored by Foreman and charge hand who are trained to ensure that any additional
precautions or equipment required are provided.
precautions or equipment required are provided.
RISK ASSESSMENT COMMITTEE
RISK ASSESSMENT COMMITTEE:
: Project
Project Manager/
Manager/ Project
Project Engineer
Engineer
Safety Manager/ Safety Officer
Safety Manager/ Safety Officer
Reviewed by:
Reviewed by: (Safety Officer)
(Safety Officer) Approved by:
Approved by: (Project Manager)
(Project Manager)
RISK MATRIX
RISK MATRIX
Risk Rating (RR) – Severity x Likelihood
Risk Rating (RR) – Severity x Likelihood
LIKELIHOOD
LIKELIHOOD
( ROBABILITY)
( ROBABILITY)
(
( )
)
SEVERITY
SEVERITY
(IM ACT)
(IM ACT)
(S)
(S)
Rare
Rare
Remote possibility
Remote possibility
(once every 3
(once every 3
years or more)
years or more)
1
1
Unlikely
Unlikely
Could happen but
Could happen but
rare (typically once
rare (typically once
in a year)
in a year)
2
2
ossible
ossible
Could happen
Could happen
occasionally (on
occasionally (on
average quarterly)
average quarterly)
3
3
Likely
Likely
Could happen often
Could happen often
(on average once a
(on average once a
month or more)
month or more)
4
4
Almost certain
Almost certain
Could happen
Could happen
frequently (once a
frequently (once a
week or more)
week or more)
5
5
Page7 of 8
Page7 of 8

REF:
REF:
REV: 00
REV: 00
DATE:
DATE:
I
In
ns
siig
gn
niif
fiic
ca
an
nt
t 1
1
Low
Low
1
1
Low
Low
2
2
Low
Low
3
3
Low
Low
4
4
Medium
Medium
5
5
M
Miin
no
or
r 2
2
Low
Low
2
2
Low
Low
4
4
Medium
Medium
6
6
Medium
Medium
8
8
Medium
Medium
10
10
M
Mo
od
de
er
ra
at
te
e 3
3
Low
Low
3
3
Medium
Medium
6
6
Medium
Medium
9
9
Medium
Medium
12
12
High
High
15
15
S
Siig
gn
niif
fiic
ca
an
nt
t 4
4
Low
Low
4
4
Medium
Medium
8
8
Medium
Medium
12
12
High
High
16
16
High
High
20
20
M
Ma
ajjo
or
r 5
5 Medium
Medium
5
5
Medium
Medium
10
10
High
High
15
15
High
High
20
20
High
High
25
25
RISK
RISK BASED
BASED CONTROL
CONTROL LAN
LAN
R
RI
IS
SK
K L
LE
EV
VE
EL
L A
AC
CT
TI
IO
ON
N A
AN
ND
D T
TI
IM
ME
ES
SC
CA
AL
LE
E
1-4
1-4
Low
Low
Quick, easy controls should be implemented immediately and further action planned for when resources permit.
Quick, easy controls should be implemented immediately and further action planned for when resources permit.
Monitoring required ensuring controls are maintained.
Monitoring required ensuring controls are maintained. Manage through routine procedures. Go for economic
Manage through routine procedures. Go for economic
improvements where possible. Incident report must
improvements where possible. Incident report must be completed.
be completed.
5-12
5-12
Medium
Medium
Aim to reduce risks but costs of prevention may be limited. Underta
Aim to reduce risks but costs of prevention may be limited. Undertake a risk assessment of the situation / task and
ke a risk assessment of the situation / task and
implement the appropriate actions. Actions should have a timescale and should be monitored. Where the risk
implement the appropriate actions. Actions should have a timescale and should be monitored. Where the risk
involves work in progress undertake a risk assessment as soon as possible to ensure the safety of the situation or
involves work in progress undertake a risk assessment as soon as possible to ensure the safety of the situation or
task.
task. Work should not start until the risk is
Work should not start until the risk is reduced to an acceptable level.
reduced to an acceptable level. Considerable resources may have to be
Considerable resources may have to be
allocated. Contact your Manager and Risk Manager by telephone about the actions that should be taken to reduce
allocated. Contact your Manager and Risk Manager by telephone about the actions that should be taken to reduce
the risk/s. incident report must be completed. Incident must be added to service risk
the risk/s. incident report must be completed. Incident must be added to service risk register.
register.
15-25
15-25
High
High
Do not commence the activity until
Do not commence the activity until a risk assessment has been completed to ensure the safety of the situation or
a risk assessment has been completed to ensure the safety of the situation or
task. If it is
task. If it is not possible to reduce or eliminate the risk even with
not possible to reduce or eliminate the risk even with unlimited resources, work must remain prohibited.
unlimited resources, work must remain prohibited.
Inform your relevant Director, your Manager and the Risk Manager immediately by telephone. Incident report must be
Inform your relevant Director, your Manager and the Risk Manager immediately by telephone. Incident report must be
completed. Incident must be added to service risk register.
completed. Incident must be added to service risk register.
Page8 of 8
Page8 of 8

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