The document outlines a risk assessment for hydrostatic pressure testing inside buildings, detailing potential hazards, control measures, and emergency procedures. It emphasizes the importance of permits, inspections, exclusion zones, and proper signage, along with specific procedures for re-testing after any failures. It provides a structured approach to assessing risks and implementing safety measures during pressure testing operations.

1. HEALTH SAFETY AND ENVIRONMENT Author: Approved:
RISK ASSESSMENT: ACT/HSE/RA 001 HYDROSTATIC PRESSURE TESTING INSIDE BUILDINGS
Issued: Rev. Date:
Revision: 0
Page 1 of 3 HSEQ -Rev-01(Aug-2018)
No
Specific Task Step
(In sequence of
works)
Hazard Details Consequence/Risk
Initial Risk
Rating Control Measures Residual Risks
Additional Control
Measures
RR
L C RR
1 Pressure testing
equipment
 Use at high
pressure;
 Rupture/failure ofpump during
testing;
 Valve/connection failure;
 Instrumentfailure resulting in system
over-pressurization;
3 3
9
MED
i. The supervisor in charge of the test shall ensure thatall pressure testing
gauges etc.are in good sound condition, undamaged,correctlydated with
the current valid calibration and that appropriate calibration certificates are
available;
ii. All pumps shall be in sound condition and complete with a valid test
certificate. Any vulnerable items such as manometers and pressure
switches shall be removed or isolated from the system prior to testing if
not required;
iii. The test supervisor shall carryout a thorough inspection ofthe system
before requesting the permitdetailed above to ensure that all isolations,
blanks and other specified safetydevices are in place before testing
commences;
No test
documentation
available
Quarantine equipmentuntil
valid documentation provided
Low
2 Permitto work system
 Interaction of
personnel and high
pressure system;
 Injury due to uncontrolled testing;
 Injury due to failure to ensure
adequate pre-checks undertaken;
3 4
12
HIGH
i. All pressure testing operations shall require a Permitto Work to ensure
that no pressure testing will be allowed to commence until all,or
applicable,considerations have been considered;
ii. The Permitshall be completed and distributed atleast2 hours in advance
of the pressure test.
iii. The test area shall be physicallywalked by the Engineer with all required
checks completed.If any rectifications are required these mustbe
completed before the test is allowed to commence.
iv. The responsible PermitHolder shall also ensure thatthe safe work
practices permitand all other requirements outlined on the Work Permit
are strictly adhered to during the task being performed.
v. Hazardous work to be carried out under the Permitto Work musthave risk
assessment/JSEA conducted prior to issue and shall be attached with
schematic drawing and the pre-inspection form (ifrequired) to the PTW on
request.Any additional or specific control measures mustalso be
indicated in the Work Permit.
vi. The Work Permitshall also be available at the Work Area;
vii. Where practicable, implementa Lock out/Tag out procedure to ensure no
lines are pressurized or valves opened/closed until all safetyprocedures
are in place and relevant parties informed.
Permitnot in area
Regular checks during test.
Briefed at TBT’s;
Low
Project Name: xxx
RA Ref No.: xxx
RA compilation
Date:
Review date:
Date:
Compiled by:
Reviewed by:
Approved by:
Overall Task Details
Hydrostatic pressure testing ofpipework inside buildings
Relevant Applicable MAS:

Additional Training required: NOC’s Required for task:
RISK SCORE CALCULATOR
Use the Risk Score Calculator to Determine the Level of Risk of each Hazard
What would be the
CONSEQUENCE
of an occurrence be?
What is the LIKELIHOOD of an occurrence? Hierarchy of Controls
Frequent/Almost certain (5)
Continuous or will happen
frequently
Often (4)
6 to 12 times a year
Likely (3)
1 to 5 times a year
Possible (2)
Once every 5 years
Rarely (1)
Less than once every 5
years
Can the hazard be Eliminated or removed
from the w ork place?
Catastrophic (5)
Multiple Fatalities
High 25 High 20 High 15 Medium 10 Medium 5
Can the product or process be substitutedfor
a less hazardous alternative?
Serious (4)
Class 1 single fatality
High 20 High 16 High 12 Medium 8 Low 4
Can the hazard be engineered aw ay w ith
guards or barriers?
Moderate (3)
Class2 (AWI or LTI) or Class 1
Permanently disabling effects
High 15 High 12 Medium 9 Medium 6 Low 3
Can Administration Controls be adopted
I.e. procedures, job rotation etc.
Minor (2)
Medical attention needed, no work
restrictions. MTI
Medium10 Medium 8 Medium 6 Low 4 Low 2 Can Personal Protective Equipment &
Clothing be w orn to safe guard against
hazards?Insignificant (1)
FAI
Medium10 Medium 4 Low 3 Low 2 Low 1

2. HEALTH SAFETY AND ENVIRONMENT Author: Approved:
RISK ASSESSMENT: ACT/HSE/RA 001 HYDROSTATIC PRESSURE TESTING INSIDE BUILDINGS
Issued: Rev. Date:
Revision: 0
Page 2 of 3 HSEQ -Rev-01(Aug-2018)
No
Specific Task Step
(In sequence of
works)
Hazard Details Consequence/Risk
Initial Risk
Rating Control Measures Residual Risks
Additional Control
Measures
RR
L C RR
3
Establishing exclusion
zones
 Personnel in area
 Unauthorized access to testarea;
 Workers struck by flying materials;
 Worker struck by High pressure water
release;
3 4
12
HIGH
i. The establishmentofan exclusion zone(s), (this zone shall be
dependenton the positioning,pressure,testzone and personnel in
adjacentarea) from the pressure source,around the testarea shall be
undertaken;
ii. Simple barrier tape is not an adequate control of any area where
personnel are presentand shall onlybe used on doorways etc., if a
sentry is to be presentat all times to control access;
iii. If practicable,the area may be securelyclosed off using plywood,
handrail or similar to prevent unauthorized access.The board/rails shall
be securelyfixed with suitable signage attached;
iv. Any doors shall,ifpracticable,be locked with keys retained by the permit
holder;
v. In areas where other contractors are working or other exposed areas,
the use of sentries shall be considered to prevent access,however this
shall be determined bythe locality and nature of the test. The sentries
shall be instructed as to emergencycontact details etc. and shall remain
in position for the duration of the test;
vi. All flange and valve connections,blank ends or clip connections etc.
shall be zoned off as a matter of general good practice;
vii. All drain or vent points mustbe fitted with a blanking plug.Any other
areas shall be secured as applicable;
viii. Under no circumstances will anypersons be allowed within safety
barriers during pressure testing.
Unable to secure
area during
normal working
hours
Test undertaken outof normal
work shifttimings,weekends
etc.
Low
4 Signage to testarea  Personnel in area
 Unauthorized access to testarea;
 Inadequate signage to testarea; 3 4
12
HIGH
i. The exclusion zone shall be clearly marked with suitable signage,
including ‘Warning – Pressure Test’,and emergencycontact details;
ii. Signs will be of adequate size and in languages as applicable (minimum
English and Arabic) and shall include the testdate;
iii. Simple paper signs are not to be used,as these can blow away or torn
off. Signs shall be fixed onto hard backing and secured to handrails etc.;
iv. On completion ofthe test all signage shall be removed to prevent
confusion.
Workers not
understanding
signage
Communicated atInduction Low
5 Pressure testing
 High pressure to
pipework;
 Uncontrolled Stored Energy release;
 Rupture/failure in Pipe lines during
testing;
 Valve/connection failure;
 Instrumentfailure resulting in system
over-pressurization;
 End caps/plugs ejecting under high
pressure;
 Weld/seal/fitting failure,flying objects;
 High pressure water/air injection.
3 4
12
HIGH
i. The initial pressurizing ofa system has the potentially highestrisk of
failure and sudden release ofpressure,possiblyresulting in serious
injury;
ii. High pressure testing on systems shall be reached in clearlydefined and
controlled stages;
iii. If required as partof the design,on completion ofeach stage and after a
period of stabilization an inspection ofthe testarea shall be completed
by the responsible person and his team,checking for leaks etc.;
iv. All pressure testdetails shall be recorded throughout the entire test
schedule;
v. The personnel carrying outthe test mustbe provided with a safe place
from which the progress ofthe test can be observed and controlled;
Low
6 Emergencyprocedures  High pressure to
pipework;
 Emergencyprocedures not briefed
to task workers;
 Poor response in the event of an
emergency;
3 4
12
HIGH
Emergencyprocedures shall be developed for the pressure test,to be
specific to the area/zone. These shall include:
i. EmergencyContact details;
ii. Persons responsible for shutting down the system;
iii. Actions to be taken in an emergency,escape routes;
iv. Means of communication between parties;
v. First aid response;
Low

3. HEALTH SAFETY AND ENVIRONMENT Author: Approved:
RISK ASSESSMENT: ACT/HSE/RA 001 HYDROSTATIC PRESSURE TESTING INSIDE BUILDINGS
Issued: Rev. Date:
Revision: 0
Page 3 of 3 HSEQ -Rev-01(Aug-2018)
No
Specific Task Step
(In sequence of
works)
Hazard Details Consequence/Risk
Initial Risk
Rating Control Measures Residual Risks
Additional Control
Measures
RR
L C RR
These will communicated to all personnel involved in the tests.
7
Re-testing in the event
of failure
 Re-testing with high
pressure
 Injury due to uncontrolled testing;
 Worker injury due to working on
pressurized system;
 Injury due to failure to ensure
adequate pre-checks undertaken;
3 4
12
HIGH
i. If on pressurization anyleaks are found in the system,the system shall
be depressurized and leaks repaired as required.
ii. Under no circumstances will personnel work on any pressurized systems
unless the leaking section can be successfullyisolated byvalves and
can be depressurized safely;
iii. A valve lock out/tag out system shall be adopted in these circumstances
on the closed valves to prevent unauthorized opening;
iv. No unauthorized personnel will be allowed in any testarea until
depressurization is complete. Only when leaks have been repaired and
control checks undertaken will the system be re-pressurized following
the same procedure as previous;
v. After full pressure has been achieved another inspection is to be
completed;
vi. If the leak was due to a weld failure or a fixing/valve failure then the
causation mustbe determined and other welds/fixings/valves with
possible similar defects investigated before a retestis undertaken;
Low