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Hazard Identification And Risk Assessment Approved by:(Signature)

Business Unit: _____CDT Division_____________________________________Division/Department/Location:_______CDT Division______________________

Reviewed by :Jaypal Solanki ______Review Date :02 Feb 2015__Next review :01 Feb 2016___

Name: Swapnil PatilDate: 02 Feb 2015

Hazard Identification (HI) Risk Assessment (RA) Risk Control (RC)

No Area / Activity / Process /

Machine / MaterialHazard Possible injury/

Ill-healthExisting Risk Controls S L

Risklevel

Additional ControlsS L

RiskLevel

Responsibleperson

Remarks

F-SP-HSE06-01 Rev. 03 Issue date: July 14, 2011 Page 1 of 18

1

Equipment Preparation – (Servicing of Engine/Waterpump’s Gearbox changingof engine/gear oil)

Oil spillage -causingtripping hazard

Bodily injuries

Wear safety shoe

Use oil absorbentrags to clean awaythe spill oil

Use oil tray to containthe leak

2 24

Low All crew

Noise Hazard Noise induceddeafness

Wear ear plugs ormufflers

Exhaust silencerinstalled

2 2 4Low

All crew

Pinch point &MechanicalHazard

Cuts & bruises

Staffs are advised tostay focus

Staffs attended in-house training andhave hand-onexperience onsite

Wear gloves whereapplicable

2 612

Medium All crew

EnvironmentHazard - oilspill to thedrain ways

Contaminatewaterways

Have to use a suitable

container to containthe oil for transferringto storage drum

2 24

Low All crew

Human Factor-Lack of focusandcompetencyresulting inaccident

Bodily injuries/Noise induceddeafness/ Cuts

& bruises/Contaminatewaterways

Health & Safety briefperformed prior tocommencement of job

Only competent staffsare allowed performthe task

4 624

MediumProject

Supervisor

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Risklevel


RiskLevel

Responsibleperson

Remarks


2Equipment Preparation – (Servicing of Enginechanging of oil filters)

Slipping ofhand tool dueto oiliness andcost handinjury

Sprains /bruises

Need to remove theoil from the surface ofthe filter so that it willhave a good grib.

Wear proper PPE(cotton glove)

2 48

Low All crew


Cuts & bruises


Staffs attended in-house training andhave hand-onexperience onsite


2 48

Low All crew

EnvironmentHazard - oilspill to thedrain ways

Contaminatewaterways

Use oil absorbentrags to clean awaythe spill oil & disposestain rag appropriately

2 24

Low All crew


Bodily injuries/Cuts & bruises/Contaminatewaterways



2 612

MediumProject

Supervisor

Equipment Preparation –

(Test running of waterNoise Hazarddue to engine

Noise induceddeafness

Wear ear plugs or

mufflers 2 24

Low All crew

Reviewed by :Jaypal Solanki ______Review Date :02 Feb 2015__Next review :01 Feb 2016


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Risklevel


RiskLevel

Responsibleperson

Remarks


3 pump) running

Slip & Triphazard due towater leakage

Bodily injuries

Wear safety shoe

Use water absorbentmat or rags to cleanaway the waterleakage

4 624

Medium All crew


Cuts & bruises



2 48

Low All crew


Noise induceddeafness/ Bodilyinjuries/ Cuts &

bruises/Contaminatewaterways



2 612

MediumProject

Supervisor

Whippingreaction frompressurisedhose maycause injuries

Bodily injuries

Staff are to ensure thehoses are wellsecured

To ensure whipchecks are connected

They are instructed tomaintain a safedistance when systemis pressurised

2 24

Low All crew

4

Mobilisation/demobilisationfrom yard to & fro clientsite/ lifting of piggingmachine to trailer

CranedroppingMachinecontainer to

Equipment and

propertydamage

Ensure routine

maintenance iscarried out by crane

4 624

Medium All crew



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Risklevel


RiskLevel

Responsibleperson

Remarks


the ground – contractor by doing aspot check on hisequipments

Check the physicalcondition of the liftingslings and lugs

Barricade off area ofoperation

Ensure every part of

Machine container iswell secured prior tolifting operation

Control the movementof the containermachine via ropeswhile it sling in the air

Human Factor – lack of

competencyand

coordinationerror

Bodily injuries

Check the cranedriver licence toensure he is aqualified operator

Our staff are to

discuss and confirmthe way the wholeprocess should behandled prior tocommencement of job

4 416

MediumProject

Supervisor

5Mobilisation/demobilisationfrom yard to & fro clientsite/ crane and trailerdriving in/out the yard

Crane/trailercan damageequipment orinjuringpersonnelwhile driven

Damage toequipment or

injuringpersonnel

All traffic rules mustbe followed strictly.

Brief the driversproperly

4 416

MediumCrane

operator

Pinch Point

Hazard whilemobilising &

Cuts & bruises

Staffs are advised to

stay focusWear gloves where

4 28

Low All crew



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Risklevel


RiskLevel

Responsibleperson

Remarks


demobilisingfrom crane &trailer

applicable

Human Factor – lack ofcompetencyand

coordinationerror

Damage toequipment /

Cuts & bruises

Drivers must haveapplicable licences

Our staff are todiscuss and confirmthe way the whole

process should behandled prior tocommencement of job

4 416

Medium

Driver &project

Supervisors

6

Mobilise/demobiliseequipment in & out jobsite/driving to site/liftingoperation

Crane/trailermovement candamage plantequipment andinjuring person

Damage toequipment or

injuringpersonnel

All traffic rules in therefinery must befollowed strictly.

Drivers must haveapplicable licences.

4 416

MediumCrane/

Trailer driver

Equipment ormaterial fallingfrom heightcausing injuryto personnel ordamage toclient propertyand ourequipment

Bodily injuries /damage toequipments

Lifting crew orpersonal is tobarricade the liftingzone and displaysignage before liftingwork start.

All personal to keepa safe distance andnot to walk underany load.

2 48

LowLifting

Supervisor

Crane toppledue to softground oroverloading

damaging ourequipment &

client property

Conduct lifting plan &pre-lifting operationchecklist for any liftingactivities. Inform allcrew on the intentionof the load.

All drivers must beextremely careful

2 48

LowLifting

Supervisor



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Risklevel


RiskLevel

Responsibleperson

Remarks


when operating theircrane and trailer inthe plant area

Area of operationmust be barricaded.

Ensure lifting safetyfactor for crane isspecified to craneprovider before hiring

them.Ensure lifting permit isobtained before lifting.

Ensure crane andlifting gear checklist ischecked before lifting.

Crane driver andsupervisor mustassess the groundcondition. Put metalon ground todistribute the load.

Must have good

knowledge of theweight of the load

Pinch PointHazard

Cuts & bruises



2 48

Low All crew

Human Factor – lack ofcompetencyandcoordination

error

Bodily injuries/damaging ourequipment &

client property

Ensure qualified liftingsupervisors are at site

Our staff are todiscuss and confirmthe way the wholeprocess should be

handled prior tocommencement of job

4 416

Medium

ProjectSupervisor &

LiftingSupervisor



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Risklevel


RiskLevel

Responsibleperson

Remarks


7Rigging up of hoses to thetop of the platform

Hoses canbreak loosedue to notsecuringproperlycausingpropertydamage andbodily injury.

Bodily injuries

Must ensure thatproper securing isdone through training.


2 24

LowLifting

Supervisor

Frames wherethe hoses aresecured maybreak

Bodily injuries

Check and ensure theframes are strong towithstand the weightand whipping action.

Inform client if anydeformities areobserved on theframes

4 624

Medium All crew

Human Factor – lack ofknowledge

Bodily injuries

Staff must be trained

on the rope tyingmethods

2 2 4Low

ProjectSupervisor

8During entire pigging jobexecution

Falling throughthe opening inthe handrailthat is used toaccess the catladder.

Bodily injuries

Always keep thesafety arm in thehorizontal positionwhen not in use.

Conduct safety talk

4 416

Medium All crew

Poor visibilityat night – mayfall from

vertical ladder

Bodily injuries

Mobile floodlightsmust be used toilluminate work area.

Always maintain a

3point contact whileaccessing the ladder

4 416

Medium All crew



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Risklevel


RiskLevel

Responsibleperson

Remarks


Conduct safety talk

Working duringdangerousworkingconditions,getting hit bylightning. Slipand fall on wetsurface.

Fatal/ Bodilyinjuries

Stop work duringdangerous weatherconditions

4 416

Medium All crew

Unauthorisedpeopleentering areaof operation

Bodily injuries

Barricade area ofoperation

Place signboards2 2

4Low

Human Factor- Accident

caused by mis-communication

betweenoperator andthe helpers

Bodily injuries

Must have a briefingto all the personnelonsite and ensurethey understand CDTFurnace decokingprocedure

4 416

Medium All crew

Fall fromheight whenworking on thescaffoldingplatform

Bodily injuries

All working at heightabove 1.8m fromground level must donsafety harness

Must obtain Permit ToWork before startwork

Conduct safety talk

Must check thescaffolding’s validity

4 416

Medium All crew

Human factor – lack of focus

on assignedtask

Bodily injuries

Health & Safety briefperformed prior to

commencement of job Attended the in-house

4 4

16

Medium

Project

Supervisor



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Risklevel


RiskLevel

Responsibleperson

Remarks


SIC

Hazardsarising fromexternalactivities

Bodily injuries

Receive allinformation from clienton the expectedworks that areperformed togetherwith our task andkeep our staff informof those.

Staff to ensure theyare vigilant at all timesand report anyabnormal activitiessighted at site

Stop work if sightedunsafe activities

4 416

Medium All crew

Hoses mayburst andcause injury topersonnel

Bodily injuries

Perform physicalinspection on thehoses prior to utilising

it Always maintain asafe distance from thepressurised hose

Maintaincommunication withrest of the staff thruwalkie talkie and handsignals

Alert and warn staff tokeep clear if neededto increase pressureon the pump

4 624

Medium All crew



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Risklevel


RiskLevel

Responsibleperson

Remarks


9Process to unlodge piggwhen it is being stucked in

the heater

Hoses mayburst andcause injury topersonnel

Bodily injuries

barricade off area ofoperation

inform client on thesituation & the actionwe are taking beforestart operation.

have to clear off otherinterested partiesbefore start operation

2 48

Low All crew

Human factor-Too confidentbehaviour &lack ofknowledge

Bodily injuries



4 624

MediumProject

Supervisor

10

Non-routine activités(maintenance work)Removing Waterpump/Gearbox/otherequipment from thePigging Container – (usingForklift)

Forkliftdamagingother

equipment andfacilities


client property

Driver must haveforklift license

Slow & careful liftingwith someone guidingthe driver.

Conduct toolboxbefore starting liftingoperation

4 416

MediumForklift

Operator

Injuringpersonnel bywrongoperation

Bodily injuries

Driver must haveforklift license

Slow & careful liftingwith someone guidingthe driver

4 416

MediumForklift

Operator

Injuringpersonnelwhen droppingload


client property

To ensure all staffinvolved in theoperation are vigilant

To ensure staffinvolves in the

6 424

MediumForklift

Operator



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Risklevel


RiskLevel

Responsibleperson

Remarks


operation a redonning theappropriate PPE

Human Factor – lack of focusandcoordinationerror

Bodily injuries/damaging our

equipment &client property


Our staff are todiscuss and confirm

the way the wholeprocess should behandled prior tocommencement of job

6 424

Medium

Project

Supervisor

Hazardsarising fromexternalactivities


client property

Receive allinformations on theexpected works thatare performed at yardby other contractorsand keep our staffinform of those.

Staff to ensure they

are vigilant at all timesand report anyabnormal activitiessighted at site

6 424

Medium All crew

11

Non-routine activités(maintenance work on jobsite)Removing Waterpump/Gearbox/otherequipment from thePigging Container – (usingchainblock)

Dropping load- damagingequipment &injuringpersonnel


client property

Ensure chainblock ishooked on a strongpoint before lifting.

Ensure there is morethan one persondoing this lifting.

Ensure the correctcapacity chainblock isutilized

4 416

Medium All crew

Reviewed by :Jaypal Solanki ______Review Date :02 Feb 2015__Next review :01 Feb 2016___


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Risklevel


RiskLevel

Responsibleperson

Remarks


Ergonomichazard (Heavyload)

Body strains

Ensure correctposture are used tocarry heavy items

Put up signs toremind staff of correctlifting posture

2 48

Low All crew

Pinch pointHazards Cuts & Bruises



4 4 16Medium All crew

Human Factor-lack of focus &knowledge


client property


Only the competentstaff are allowed tochoose the type ofchainblock for theoperation

4 416

MediumProject

Supervisor

12

Non-routine activités(maintenance work)Using grinding power toolduring repairactivities/cleaning partactivity

Electricalhazard

Burns

Ensure electrical tool

has its inspection tagupdated before using.

Ensure hand is notwet before using thetool

Ensure the tool do notget in contact withwater

Ensure proper PPE isdonned before startwork

Remind staff onelectric hazard via

safety meeting

2 48

Low All crew



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Risklevel


RiskLevel

Responsibleperson

Remarks


Dust inhalantRespiratoryproblems


2 48

Low All crew

Grinding discmay break andcause severeinjury

Cuts & Bruises

Ensure there is properguard on the grinderbefore using it

Work with extremecare

Supervisor to conductsafety talk before startwork

4 416

Medium All crew

Chemicalcontact (usingchemical forcleaning)

Skin irritation


Supervisor to conductsafety toolbox talkbefore start work

2 48

Low All crew

Hazardsarising fromexternal

activities

Bodily injuries

Receive allinformation on theexpected works thatare perfomed at yard.

Staff to ensure theyare vigilant at all timeswhile performing task

4 416

Medium All crew

Human Factor – lack of focus

Burns/Respiratory

problems/ Cuts& Bruises/ Skinirritation/ Bodily

injuries


4 416

MediumProject

Supervisor

13 Dismantling pipe fittings

Fire hazarddue to usageof gas cutter toexpand the

tight fittings

Burns

Use the appropriatePPE

Adequate ventilationprovided

Perform physical

check on gas cutter

2 48

Low All crew



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Risklevel


RiskLevel

Responsibleperson

Remarks


equipment

Pinch pointhazard

Cuts & Bruises



2 24

Low All crew

Human factor – lack of focus

Burns/ Cuts &Bruises

Health & Safety brief

performed prior tocommencement of job 2 48

LowProject

Supervisor

14Non-routine activités(maintenance work)Painting work

Chemicalcontact

Skin Irritation


2 48

Low All crew

Toxic Fumehazard

Respratoryproblems

Painting done in aproperly ventilatedspace or outdoors

2 48

Low All crew

15

Awareness of theemergency call pointssuch as fire assemblyarea, Fire & emergencycontrol room number,emergency telephonepoints & etc

Human Factor – Lack ofknowledge

Burns / Fatal

Collate all informationfrom client onemergency response

prior to start of jobDisemminate theinformation to all ourstaff involved in the job

Post the informationin prominent place sothat information canbe easily referedwhen in need

4 416

Medium All crew

16Placement of stowageitems

Pinch pointhazards

Cuts & bruises

Place all items neatly

Ensure all items arekept at safe distance

away from operationalmachinery

2 48

Low All crew



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Risklevel


RiskLevel

Responsibleperson

Remarks


17Communication betweenDDT team membersduring operation

Human Factor – Lack of co-ordination

Bodily injuries

CDT requires to carry2 walkie talkies forcommunicationbetween DDToperator and the staffat the top of reactor

CDT team should betrained on commonhand signals

4 416

Medium All crew

18Team member monitoringthe launcher at the toplevel

Physicalhazard – Pigcan burst outfrom luancherif the launchercover isn’tclosedproperly

Bodily injuries

Staff near to thelauncher shouldmaintain a safedistance away fromthe line of fire

2 48

Low All crew

19Pressurising the hoses forpigging operation

Physicalhazard – Hosemay burst dueto overpressure or

due to wear &tear

Bodily injuries/damage toequipments

Presure test on thewater hoses isrequired to beperformed by staffprior to deployment to

site

2 48

Low All crew

20Temporary recruitment offoreign General workersfrom manpower agencies.

Human factor – Lack ofknowledge ontask

Bodily injuries

Advise manpoweragencies to provideall their deployedworkers to CR withproper PPE

Employment agenciesto ensure the workersknow general safety

CDT Team to brief theworkers on process oftheir activity and it’ssafety requirement

4 624

MediumProject

Supervisor



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Risklevel


RiskLevel

Responsibleperson

Remarks


21Boarding taxis at foreigncountries

Dangerousdriving by taxidrivers

Bodily injuries /fatal

Brief the driver aboutsafe driving prior toboarding his taxi

4 624

Medium All crew

22Toolbag being loweredthru ropes from heights

Physicalhazard – itemsfrom thetoolbag can falldown fromheight if it isn’tproperlyzipped orsecured to arope

Bodily injuries /fatal

All toolbags must becompletedly zippedprior to lowering

Ropes must besecured tightly totoolbag sling beforelowering

Staff receiving thetoolbag at the bottomof reactor to maintaina safe distance awayfrom the line of fire

2 48

Low All crew

23Physically carrying theheavy hoses from themachines with bare hands

Ergonomichazard

Body strains

Utilise Chain Blocksto lift the hoses

Utilize sufficientmanpower to lift thehoses

2 48

Low All crew

24 Laying of hoses atworksite

Trip & FallHazard

Bodily injuries

“A” frame warningsignage be posted at

the work area to warnothers of the trip & fallhazard

2 4 8Low

All crew

25During Entire Job -Working at Height

Falling fromheight

Fatality or Bodilyinjuries

All workers workingat height are trainedon how to use andwear the safetyharness.

Housekeeping isdone accordingly toprevent trippinghazard.

Ensure the snap

hook is hooked to astrong Anchorage

4 624

Med

All projectsupervisors mustattend the MOM“Work at Height”for Supervisorscourse

Goh SP, TintZaw & Mannyhave attended

All crew



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Risklevel


RiskLevel

Responsibleperson

Remarks


point eg 4” processpipe or securedscaffold pipe)

All workers put onthe appropriatePPE(eg Safetyhelmet with chinstrap, safetyharness) at areas

which has spelled forsuch requirement. Self retractable

Lanyard(SRL)beutilized when workingat height which areless than 5.6 metersfrom the ground

Guardrails areprovided at workareas where chancesof falling is evident

Ladders, fallprevention and fall

protectionequipment’s& toolsare inspected prior touse

Check on thescaffolding’s(7day)validity status

Check the suitabilityof safety harnessbased on “F-CRAS-HSE-04 Rev 00Safety harrnessLanyard Shock

Absorber DailyChecklist”



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Cdt Div Hira 02022014