GALFAR ENGINEERING & CONTRACTING
HAZARDS AND EFFECTS MANAGEMENT PLAN
Contract No – 131/ 853
Doc No: SLPG-H-1000-03001-035-001-4
Task / Activity
PNEUMATIC TESTING
HSE Hazard
(Potential to do Harm)
Mobilization of Pneumatic
Testing Materials.
 Unsecured load of
equipment
 Inexperienced drivers and
lack of training
 Unsafe Manual handling
 Uneven road surface
 Obstructed access and
egress
 Poor weather condition
 Defective vehicle and Poor
tyre condition
SALALAH LPG PROJECT
HEMP FOR PNEUMATIC TESTING
HAZARDS AND EFFECTS MANAGEMENT ASSESSMENT
(Potential Severity)
Recovery Measures
(Letter & Number)
(Severity Rating)
Rating (Control in
Consequence
Risk Rating
Probability
Residual Risk
Control Measures Proposed
Hazard Effect
place)
(If the Hazard is released)
 Loading of equipment with the instruction of manual
 Personal injury  Maintain the equipment stable and steady and maintain the
 Slip/trip/fall centre of gravity.
 Property damage  Secure the load with proper wire and ties
 Crush injury  Maintain the speed limit ERP, First aid, &
 Pinch points  Maintain the safe distance from other vehicle MEDEVAC
2 B B2PA Contact / inform
 Stress and strain  Follow manual handling techniques always 1B respective authorities
Client/Company/ROP/
 Roll over the vehicle  Do not lift / pull abruptly or drop the pipe; place / move
POS/SFZ
 Heat stress slowly & cautiously.
 Cut due to sharp  Be watchful & cautious of the presence of objects, vehicle,
edges equipment, etc., in the surroundings
 Abrasion  Maintain good communication and coordination with team
 Never put your body parts under the suspended loads
Page 1 of 7
GALFAR ENGINEERING & CONTRACTING
HAZARDS AND EFFECTS MANAGEMENT PLAN
Contract No – 131/ 853
Doc No: SLPG-H-1000-03001-035-001-4
Task / Activity
PNEUMATIC TESTING
HSE Hazard
(Potential to do Harm)
Setting up of pneumatic
Testing
 Lack of barrication & signs
 Poor manual handling
 Obstructing the access and
egress
 Failure to use mandatory
PPEs
 Poor communication with
nearby supervisor
 Lack of inspection before
setting up the equipment
 Lack of experience and
training
 Inadequate competency
 Lack of calibration
certificate or sticker
 Flexible high pressure hose
not anchored
 Electric equipment not
earthed
 Unavailability of Whip
checks.
 Lack of supervision
 No test certificate for hoses
and other fittings
 Improper use of gasket
 Poor visibility
 Unsecured pipe or fitting/
connection in the elevated
location
(Severity Rating)
Consequence
Hazard Effect
(If the Hazard is released)
 Personal injury
 Slip/trip/fall
 Fall of fittings or pipes
from height
 Crush injury
 Pinch points
 Stress and strain
 Back pain due to poor
manual handling
 Cut due to sharp edges
 Abrasion
 Electric shock due to
faulty connection
 Stress due to poor
ergonomic posture
 Musculoskeletal
Disorder
 Stress due to poor
ergonomic posture
 Leak due to used gasket
 Eye strain due to poor
lighting in case of night
work
 Fatigue due to lack of
rest
 Land contamination oil
spill
SALALAH LPG PROJECT
(Potential Severity)
Recovery Measures
(Letter & Number)
Rating (Control in
Risk Rating
Probability
Residual Risk
Control Measures Proposed
place)
 Discuss the STARRT before starting the job
 Undergone adequate training as per the job requirement
 Maintain an effective communication with the crew
members
 Maintain a good housekeeping at the site always
 All defective items should remove immediately from the
site.
 Report all unsafe condition and unsafe behaviour to the
supervisor
 Verify the pressure ratings of hoses, fittings, gaskets, and
other manifold materials.
 Ensure components are assessed for continued use.
 Use mandatory PPES and specific PPEs if required such
as helmet, gloves, safety goggles, ear plugs etc.
 Follow manual handling techniques always
 A competent electrician must be available at site
ERP, First aid, &
 Valid Calibration certificate or sticker must be available MEDEVAC
 Flexible high pressure hose must be secured Contact / inform
3 B B3PA  Flexible hose assembly must be restrained or shielded to 1B respective authorities
restrict whiplash hazard in the event of a failure/rupture. Client/Company/ROP/
Restraint may be achieved using whip checks POS/SFZ
 Effective communication system must be maintained
 All electrical equipment must be earthed
 Whip flash for securing the hose must be used whenever
required
 A competent supervision must be available at the time of
operations
 All relevant test certificate must be available for the hoses
and other fittings
 Sufficient light must be provided in case of required
 Drip tray must be provided in case the use of diesel engine
and avoid contamination due to diesel spill
 Call emergency number if required
 Stop the job in case of adverse weather condition
 Maintain good housekeeping before, during after the job
 Secure the nearby appliances during the hydrostatic test
 Maintain a good posture to avoid ergonomic
Page 2 of 7
GALFAR ENGINEERING & CONTRACTING
HAZARDS AND EFFECTS MANAGEMENT PLAN
Contract No – 131/ 853
Doc No: SLPG-H-1000-03001-035-001-4
Task / Activity
PNEUMATIC TESTING
HSE Hazard
(Potential to do Harm)
 Diesel leak while filling in
the diesel engine
 Lack of competent
electrician for connecting
electrical appliances
 Inadequate tightening of
flange joints
 Poor ergonomic posture
 Bad weather condition
 Poor housekeeping
Performing Pneumatic
Testing
 High pressure leaking
 Lack of signage and
barrication
 Unauthorized entry
 Failure to use mandatory
PPEs
 Rupture of pipe line
 Rupture of hose and gauge
line
 Flying of loosen fasteners
due to high pressure
 Sudden increase of
pressure
 Failure to valve and gauge
 Failure of control valve
 Failure to meet the
emergency situation
 Lack of supervision
 Over pressurized plant
 Unguarded rotating parts of
Air compressor
SALALAH LPG PROJECT
(Potential Severity)
Recovery Measures
(Letter & Number)
(Severity Rating)
Rating (Control in
Consequence
Risk Rating
Probability
Residual Risk
Control Measures Proposed
Hazard Effect
place)
(If the Hazard is released)
 Rectify all faulty electrical connections
 Proper and adequate torqueing should be applied while
tightening the bolts in the joints
 Secure all elevating hose connection
3 B B3PA  Keep away from line of fire
 Take periodic rest
 Personal injury  Use required ear plug and ear muff if required
 Slip/trip/fall  Stop the pump in case of high pressure leaking
 Damaging the property  Signage and barrication should provide for unauthorized
 Injury due to loosen bolts entry and warning tape should be “yellow and black”
due to high pressure  Relevant and Mandatory PPE must be worn such as
 Fall of fittings or pipes helmet, gloves, goggle, coverall , etc
from height  Evacuate and report in case of any emergency situation
 Crush injury comes
 Fatality due to flying  Stop the job in case of failure in the hydrostatic
objects generated due to  Remove all defective and damaged fitting and equipment
high pressure rupture and put ‘Do not use’ Tag ERP, First aid, &
 Pinch points  Tighten all bolts and ensure the tightness of bolts with MEDEVAC
 Structure damage due to torque wrenches Contact / inform
4 B B4PA
rupturing of pipe  Never give sudden increase of pressure and put gradual 1B respective authorities
 Stress and strain increase of pressure to avoid rupture of pipe Client/Company/ROP/
 Leak due to used gasket  Check every valve and gauge before starting the work. POS/SFZ
 Eye strain due to poor  Effective and adequate supervision must be available
lighting in case of night before, during the task
work  Check the calibrated pressurized gauge always whether
 Noise Induced Hearing the pressure is increasing beyond the designed mark or
Loss limit
 Call emergency team in case of such situation arises
 Remove the defective and damaged manifold
 Use ear plug and ear muff accordingly
 Maintain a safe distance from the high pressurized line
 All rotating parts should have guard and never remove it.
Page 3 of 7
GALFAR ENGINEERING & CONTRACTING
HAZARDS AND EFFECTS MANAGEMENT PLAN
Contract No – 131/ 853
Doc No: SLPG-H-1000-03001-035-001-4
Task / Activity
PNEUMATIC TESTING
HSE Hazard
(Potential to do Harm)
 Damaged manifold or
other fittings
 Defective pipes fittings
 Defective and damaged
pressure valve
 Oil Leakage of diesel
engine or air compressor
due to defects
 Incorrect isolation of line
SALALAH LPG PROJECT
(Potential Severity)
Recovery Measures
(Letter & Number)
(Severity Rating)
Rating (Control in
Consequence
Risk Rating
Probability
Residual Risk
Control Measures Proposed
Hazard Effect
place)
(If the Hazard is released)
 Land contamination  Adequate lighting should provide if required
due to diesel leak  Never ever encounter in between line of fire
 Body parts in line of  Use the signage such as “ HYDRO TESTING IN
fire area PROGRESS, KEEP AWAY”
 Maintain an effective communication with crew members
 Never ever do job if the job hazards are unknown and
ask the supervisor
 During the test, from filling up and until the end of
pressurization all non-essential people must be out of
the test area
 Provide proper identification for each legitimate crew ERP, First aid, &
on their helmet either by colored tape on safety helmet
MEDEVAC
or stickers to easily identify authorized personnel in the Contact / inform
4 B B4PA working area.
1B respective authorities
 Calibrated safety pressure relief valve to be installed to Client/Company/ROP/
ensure no over pressurization and control sudden POS/SFZ
 Never tamper with or tighten any fittings (i.e.
connections, bolts, hoses, and the like) while under
pressure or during pressure up stage.
 Good coordination is essential to avoid performing
pneumatic test at the same time with other
 During holding time, the system pressure gauge shall be
observed from a safe distance for the indication
of the leakage
 Never tighten connections that are under pressure. If a
leak develops,
 Depressurize to a safe level and then re-tighten.
Page 4 of 7
GALFAR ENGINEERING & CONTRACTING
HAZARDS AND EFFECTS MANAGEMENT PLAN
Contract No – 131/ 853
Doc No: SLPG-H-1000-03001-035-001-4
Task / Activity
PNEUMATIC TESTING
HSE Hazard
(Potential to do Harm)
 Damaged pneumatic line
 Wrong calculation of
pressure requirement
 Defective valve and gauge
 Lack of competency
 Lack of training
 Raise the pressure beyond
the capacity of the
designed marking
 Damaged pressure relief
valve
 Lack of valid calibration and
other certificates
 Not barricaded and cordon
the area
 Unauthorized entry of
personnel
 Sudden increase of air
pressure in the line
 Rupture of the pipe line and
hose fittings
 Improper anchoring of
tubing
 Lack of supervision
 Part under test break-ups
 Explosive noise and
pressure wave or pulse
develop from gross rapture
 Equipment motions
resulting from gross rapture
(Severity Rating)
Consequence
Hazard Effect
(If the Hazard is released)
 Personal injury
 Slip/trip/fall
 Damaging the property
 Injury due to loosen bolts
due to high pressure
 Fall of fittings or pipes
from height
 Injury due to flying
objects generated due to
high pressure rupture
 Pinch points
 Structure damage due to
rupturing of pipe
 Stress and strain
 Eye strain due to poor
lighting in case of night
work
 Noise Induced Hearing
Loss
 Fragmentation into
shrapnel.
 By reflex action from
sudden noise personnel
nearby could expose
themselves to injury
 Lightweight materials
could cause the part to
act as projectile,
propelled by the
resulting discharge force
SALALAH LPG PROJECT
(Potential Severity)
Recovery Measures
(Letter & Number)
Rating (Control in
Risk Rating
Probability
Residual Risk
Control Measures Proposed
place)
 Discuss the STARRT before starting the job
 Obtain valid Permit from PEC prior to start activity
 Undergone adequate training as per the job requirement
 Maintain an effective communication with the crew
members
 Maintain a good housekeeping at the site always
 All defective items should remove immediately from the
site.
 Report all unsafe condition and unsafe behaviour to the
supervisor
 Use mandatory PPES and specific PPEs if required such
as helmet, gloves, safety goggles, ear plugs etc.
 Follow manual handling techniques always
 Valid Calibration certificate or sticker must be available
 Provide signage and barrication of the activity to alert the
nearby
 Never give sudden air pressure in the line and give only
gradual increasing the air pressure ERP, First aid, &
 Maintain a safe distance from the high pressurized line MEDEVAC
3 B B3PA specially on each pipe and hose connections Contact / inform
 Must be available effective supervision during the job 1B respective authorities
 All valid calibration documents or sticker must be available Client/Company/ROP/
in the site and the test equipment should be in good POS/SFZ
condition and adequately maintained.
 Prohibit all unauthorized entry and alert the nearby
activities personnel
 Maintain a proper anchoring or securing of tubing and the
test equipment shall be examined to ensure that it is totally
tight
 Never tamper with or tighten any fittings (i.e. connections,
bolts, hoses, and the like) while under pressure or during
pressure up stage.
 Good coordination is essential to avoid performing
pneumatic test at the same time with other operation
 written safety plan required securing the exclusion zone for
the duration of the test. Ensure communication is
established between all patrols and incident commander.
 No authorized entry at pressure-testing event unless you
are part of the testing team.
 work will be suspended where pressure testing is being
conducted
Page 5 of 7
GALFAR ENGINEERING & CONTRACTING
HAZARDS AND EFFECTS MANAGEMENT PLAN
Contract No – 131/ 853
Doc No: SLPG-H-1000-03001-035-001-4
Task / Activity
PNEUMATIC TESTING
HSE Hazard
(Potential to do Harm)
Use of nitrogen gas cylinder
 Wrong handling of
compressed gas cylinder at
site
 Unsafe transportation of
nitrogen cylinders to site
SALALAH LPG PROJECT
(Potential Severity)
Recovery Measures
(Letter & Number)
(Severity Rating)
Rating (Control in
Consequence
Risk Rating
Probability
Residual Risk
Control Measures Proposed
Hazard Effect
place)
(If the Hazard is released)
 During pressure testing events, distinct warning signs,
such as DANGER – HIGH PRESSURE
 TESTING IN PROGRESS must be posted at the test site
and additional locations identified in the job specific safety
plan.
 Shall inspect test heads to confirm all components are in
good condition and meet working Pressure requirements.
 Always use gas cylinders trolley for moving cylinder one
location to another location and make sure secured with
chain blocks.
 Property damage  Always use protective caps for all gas cylinders
 Personnel  Use proper transportation facility (up right position/vertical
Injury/Fatality and fall prevention used) store to site.
 Always check joints by using of leak detection fluid(don’t
use household soaps or detergents)
 During the test, from filling up and until the end of
pressurization, all non-essential people must be out of the
test area
 Provide proper identification for each legitimate crew on
their helmet either by colored tape on safety helmet or
ERP, First aid, &
stickers to easily identify authorized personnel in the
MEDEVAC
working area.
Contact / inform
4 B B4PA  Blinds, valves, flanges and connection joints not pressure 2B respective authorities
tested shall be left un-isolated and expose for examination Client/Company/ROP/
during testing, provided that the valve closure is suitable POS/SFZ
for the propose test pressure
 During holding time, the system pressure gauge shall be
observed from a safe distance for the indication of the
leakage
 Calibrated safety pressure relief valve to be installed to
ensure no over pressurization and control sudden increase
`in pressure during testing
 Ensure there is overpressure protection. The set pressure
of a pressure relief device should not be more than the
greater of the test pressure plus the maximum test
pressure. The device must be tested prior to each strength
test to ensure it is fit for service.
 Third part certificate required for pressure relief valve
Page 6 of 7
GALFAR ENGINEERING & CONTRACTING SALALAH LPG PROJECT
HAZARDS AND EFFECTS MANAGEMENT PLAN
Contract No – 131/ 853
Doc No: SLPG-H-1000-03001-035-001-4

Existing : Information OK Training: Controls Adequate? : OK Controlling Authority : Construction

Manager/ Supervisor

Signed: Date : 02.10.2019

Prepared by: SIBIN

Signed: Date : 02.10.2019

Reviewed by: SAMI DABAS

Signed: Date :
Approved by:

APPENDIX 1: HAZARDS AND EFFECTS MANAGEMENT ASSESSMENT

Page 7 of 7