5638 e1 1500 ca pro 220 rev.3_ construction procedure for tank hydrostatic test
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7/25/2019 5638 e1 1500 CA Pro 220 Rev.3_ Construction Procedure for Tank Hydrostatic Test
1/29
FORCONSTRUCTION
OF OIL TERMINAL AT HFZ(EPC-1)
AGREEMENT NO. 10-5638-E-1
ABU DHABIOIL REFINING COMPANY PROJECT PROCEDURE
CONSTRUCTION PROCEDURE FOR
TANK HYDROSTATIC TESTDOC.NO.:5638-E1-1500-CA-PRO-220 Page
1/18
Rev.3
PROCEDURE
FOR
TANK HYDROSTATIC TEST
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2/29
FORCONSTRUCTION
OF OIL TERMINAL AT HFZ(EPC-1)
AGREEMENT NO. 10-5638-E-1
ABU DHABIOIL REFINING COMPANY PROJECT PROCEDURE
CONSTRUCTION PROCEDURE FOR
TANK HYDROSTATIC TESTDOC.NO.:5638-E1-1500-CA-PRO-220 Page
2/18
Rev.3
This page is a record of all revision of this document. All previous issues are hereby superseded
and are to be destroyed.
REV DATE DESCRIPTION PRPD CHKD REVD APPRD COMPANY
3 19/Dec/13Approved for
ConstructionLQL TCS ZHQ AJL
2 12/Dec/13Reissued for
Approval withAmendment
LQL TCS JHB AJL
1 26/Nov/13Reissued for
Approval withAmendment
LQL TCS JHB AJL
0 26/Apr/12Approved for
ConstructionLQL AGS JHB AJL
B 16/Mar/12
CommentsIncorporated and
Reissued ForApproval
LQL AGS JHB AJL
A 05/Mar/12For Approval/
CommentLQL AGS JHB AJL
SIGNED(Initials)
QA/QC manager
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FORCONSTRUCTION
OF OIL TERMINAL AT HFZ(EPC-1)
AGREEMENT NO. 10-5638-E-1
ABU DHABIOIL REFINING COMPANY PROJECT PROCEDURE
CONSTRUCTION PROCEDURE FOR
TANK HYDROSTATIC TESTDOC.NO.:5638-E1-1500-CA-PRO-220 Page
3/18
Rev.3
PARAGRAPHS REVISED IN THIS ISSUE
Para. No. Para. No. Para. No. Para. No.
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FORCONSTRUCTION
OF OIL TERMINAL AT HFZ(EPC-1)
AGREEMENT NO. 10-5638-E-1
ABU DHABIOIL REFINING COMPANY PROJECT PROCEDURE
CONSTRUCTION PROCEDURE FOR
TANK HYDROSTATIC TESTDOC.NO.:5638-E1-1500-CA-PRO-220 Page
4/18
Rev.3
TABLE OF CONTENTS
No. DESCRIPTION PAGE
1 INTRODUCTION ............................................................................................................... 5
1.1 General ......................................................................................................................... 5
1.2 Scope ............................................................................................................................ 5
2 DEFINITIONS .................................................................................................................... 5
3 REFERENCE CODES AND DOCUMENTS .................................................................... 6
4 RESPONSIBILITIES .......................................................................................................... 7
5 WATER TEST .................................................................................................................... 7
6 HYDROSTATIC TESTING REQUIREMENTS FROM CODE ....................................... 8
7 TANK FILLING ................................................................................................................. 9
7.1 Initial Filling: ............................................................................................................... 9
7.2 Water Filling: ............................................................................................................. 10
8 MONITORING AND SETTLEMENT LIMITS .............................................................. 11
9 TESTING OF THE ROOF ................................................................................................ 14
9.1 Fixed Dome roof ........................................................................................................ 14
9.2 Floating Roof (Single Deck Pontoon Type) ............................................................ 14
9.3 Roof Drains ................................................................................................................ 15
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FORCONSTRUCTION
OF OIL TERMINAL AT HFZ(EPC-1)
AGREEMENT NO. 10-5638-E-1
ABU DHABIOIL REFINING COMPANY PROJECT PROCEDURE
CONSTRUCTION PROCEDURE FOR
TANK HYDROSTATIC TESTDOC.NO.:5638-E1-1500-CA-PRO-220 Page
5/18
Rev.3
1 INTRODUCTION
1.1 General
The purpose of this procedure is to establish the job instruction for hydrostatic testing of StorageTanks shall be tested in accordance with API standard 650 and compliance with the requirementsof the project specification.
This job instruction in conjunction with job safety is intended to describe the sequence of activitiesto be carried out to ensure hydrostatic and pneumatic testing is conducted in a safe andcontrolled manner.
1.2 Scope
The scope of this procedure covers all types of Storage Tanks like external floating roof, internalfloating roof with fixed dome roof and fixed dome roof. The test of each tank shall be carried outafter completion of all mechanical works with the mechanical completion check list witnessed byCONTRACTOR and the COMPANY.
For hydrostatic testing the method of filling, the fill rate and flow, static and pneumatic testing,emptying or transfer the water to other tank for testing. During testing we shall verify the tanks allweld seams for leaks, settlement of tank foundation, movement of floating roof, roof drain nozzleand all fixed roof nozzles shall be in open condition during filling and emptying, All shell openingsshall be closed with temporary blind flanges and gaskets with proper size of fasteners for bolting.
For hydrotesting of storage tanks, clean water will be used.CONTRACTOR should follow theapplicable rules and regulations and obtain the approval from HFZA , Sharjah Port Authority
SPA. and Sharjah Municipality.
2 DEFINITIONS
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FORCONSTRUCTION
OF OIL TERMINAL AT HFZ(EPC-1)
AGREEMENT NO. 10-5638-E-1
ABU DHABIOIL REFINING COMPANY PROJECT PROCEDURE
CONSTRUCTION PROCEDURE FOR
TANK HYDROSTATIC TESTDOC.NO.:5638-E1-1500-CA-PRO-220 Page
6/18
Rev.3
EPC = Detailed Engineering, Procurement, Construction andCommissioning
FEED = Front End Engineering and Design
IT = Information Technology
Licensor = Any firm or company contracted to provide theirproprietary licensed technology for this Project
Site = Hamriyah free Zone, Sharjah, UAE
Project = Construction of Oil Terminal at Hamriyah Free Zone
(EPC-1)
Subcontractor = Any person, form, or company employed byCONTRACTOR to perform any work or duty on theirbehalf
3 REFERENCE CODES AND DOCUMENTS
API 650 Welded steel Tanks for oil storage
ASME Section II, part-c Welding rods, Electrodes and Filler materials
ASME Section V Nondestructive Examination
ASME Section IX Welding and Bracing Qualifications
ASME Section VIII,Div-1 Pressure Vessels
5638-E1-1500-MEQ-DS-201-207 Data Sheet for Tanks
5638-E1-1500-MEQ-DWG-201-231
5638-E1-1500-MEQ-DWG-251-281
5638-E1-1500-MEQ-DWG-301-331
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FORCONSTRUCTION
OF OIL TERMINAL AT HFZ(EPC-1)
AGREEMENT NO. 10-5638-E-1
ABU DHABIOIL REFINING COMPANY PROJECT PROCEDURE
CONSTRUCTION PROCEDURE FOR
TANK HYDROSTATIC TESTDOC.NO.:5638-E1-1500-CA-PRO-220 Page
7/18
Rev.3
5638-E1-1500-SA-PRO-001 Project HSE plan
5638-E1-1500-SA-PRO-006 Permit To Work Procedure
5638-E1-1500-SA-PRO-009 Fall Prevention And Protection Procedure5638-E1-1500-SA-PRO-011 Confined Space Entry Procedure
DGS-MF-001 Design Basis Tanks
DGS-MF-002 Field Erected Welded Steel Storage Tanks
DGS-MW-003 Welding of Storage Tanks
DGS-MX-001 Painting
STD-MF-00024 Methods of Tank Erection
DGS-PU-009 Flange bolting
DGS-MX-002 Galvanising
DGS-MX-004 Lining
Hamriyah Free Zone Authority Guidelines
Sharjah Municipality Guidelines
SEWA - Sharjah Electricity and Water Authority
4 RESPONSIBILITIES
The hydrotesting of Storage Tanks shall be headed by Project Manager of the CONTRACTOR
supported by overall project safety, quality, and tech service departmental heads. Eachdepartment shall provide designates for this work for proper control. Construction Managerreporting to Project Manager shall be responsible for related construction activities.
Competent persons shall be assigned for the hydrotesting work. Since the hydrotesting shall beon 24 hrs basis, for proper coverage to oversee the operation, The competent personnel shall bed l d i i h hif ll Ad li h i h ll b d k f d i
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FORCONSTRUCTION
OF OIL TERMINAL AT HFZ(EPC-1)
AGREEMENT NO. 10-5638-E-1
ABU DHABIOIL REFINING COMPANY PROJECT PROCEDURE
CONSTRUCTION PROCEDURE FOR
TANK HYDROSTATIC TESTDOC.NO.:5638-E1-1500-CA-PRO-220 Page
8/18
Rev.3
Water drainage from the storage tank will be disposed to HFZA approved area or disposal ofhydrotest water shall be drained through approved agency as per the rules and regulationsof HFZA.
6 HYDROSTATIC TESTING REQUIREMENTS
Here are the hydrostatic testing requirements from Project codes and specifications ,Detailedplan refer to section 9 Site Tank Hydrostatic Testing Water Execution Plan subject to sitecondition.
Tank shall be hydrotested on completion of all construction work directly associated with the
tank and its welded attachments and on completion of all non destructive testingrequirementsexcept painting activities.
No project connections are to be made between the tank and any product line until the tankand all mountings have been satisfactorily tested.
No welding is to be carried out on the shell when the tank is full of water. Any leaks foundshall be repaired with the water level at least 300 mm below the point being repaired to anagreed welding procedure and retest.
Internal bottom elevation measurements shall be made before and after hydrostatic testing.measurements shall be made at maximum intervals of 3m measured on diametrical linesacross the tank. The diametrical lines shall be spaced at equal angles, with a maximumseparation measured at the tank circumference of 10m. A minimum of four diametrical linesshall be used.
All dimensional tolerances required in accordance to API Std 650.
For fixed roof tanks, testing shall be done by filling the tanks with fresh water to the level ofthe top leg of the top curb angle, and noting any leaks over a period of at least 24 hours.
For open top tanks and floating roof tanks the maximum test water level is approximately 150mm below the top of the shell.
Any tank showing evidence of leakage from the bottom during test must be emptied
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FORCONSTRUCTION
OF OIL TERMINAL AT HFZ(EPC-1)
AGREEMENT NO. 10-5638-E-1
ABU DHABIOIL REFINING COMPANY PROJECT PROCEDURE
CONSTRUCTION PROCEDURE FOR
TANK HYDROSTATIC TESTDOC.NO.:5638-E1-1500-CA-PRO-220 Page
9/18
Rev.3
After completion of the hydrotest only non-structural small attachments may be welded to thetank in accordance with 7.2.1.11. Any welded joints above the test-water level shall beexamined for leakage by one of the following methods.
1. Coating all of the joints on the inside with a high penetrating oil, such as automobile springoil, and carefully examining the outside of the joints for leakage.
2. Applying vacuum to either side of the joints or applying internal air pressure as specifiedfor the roof test in 7.3.7 and carefully examining the joints for leakage.
3. Using any combination of the methods stipulated in subitems 1 and 2.
The CONTRACTOR shall be responsible for preparing the tank for testing. This shall includeremoval of all trash, debris, grease, oil, weld scale, weld spatter, and any other foreign matterfrom the interior and the roofs of the tank.
The CONTRACTOR shall be responsible for furnishing, laying, and removing all pipe linesfrom the clean water source tie-in locations and to the water disposal point. To obtain requiredpermission for taking clean water for filling and then after testing disposal of water with priorapproval from the COMPANY and the concerned authority of HFZA and Sharjah Municipality.
During emptying the tank or after hydrotest CONTRACTOR shall be responsible for cleaningthe tank with clean water, which is kept outside the tank on the ground with jet pump.
The CONTRACTOR shall be responsible for monitoring the settlement measurements inaccordance to code.
The CONTRACTOR shall be responsible for furnishing all other test materials and facilities,including blinds, bolting, and gaskets.
The CONTRACTOR shall be responsible for checking the wind girders for proper drainageduring or following the hydrotest . If water is retained, additional drainage shall be providedsubject to the COMPANY approval.
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FORCONSTRUCTION
OF OIL TERMINAL AT HFZ(EPC-1)
AGREEMENT NO. 10-5638-E-1
ABU DHABIOIL REFINING COMPANY PROJECT PROCEDURE
CONSTRUCTION PROCEDURE FOR
TANK HYDROSTATIC TESTDOC.NO.:5638-E1-1500-CA-PRO-220 Page
10/18
Rev.3
with API 653, Appendix B. The CONTRACTOR shall take jacking and leveling into considerationfor the tank design.
Uneven settlement of the tank on its foundation shall be reported immediately to the COMPANYand filling shall be stopped at any signs of excessive settlement pending a decision by theCONTRACTOR and the COMPANY on the action to be taken.
In the case of excessive soil settlement, the situation shall be reported to the soil mechanicsspecialist and his recommendations considered.
The temperature of the test water shall be not lower than that specified by API 650 for the
conditions concerned.
7.2 Water Filling:
The CONTRACTOR and COMPANY representative shall witness the tank filling operations.
The tank shall have all shell in-out connections blanked off except a nozzle used to allow asteady inflow or outflow of hydrotest water. Isolating and check valves shall be fitted to thisnozzle in case of filling failure and shall be served by mean of a manifold from the temporaryline.
Appropriate roof connections (manholes) must be open to allow free venting of air duringfilling.
For floating roof tanks, the maximum and minimum annular space between the shell and theroof rim plate prior to initial floatation and at the maximum test fill height shall be measuredand recorded.
If settlement measurements are specified by the COMPANY, any differential settlementgreater than 13mm per 10m of circumference or a uniform settlement over 50mm shall bereported to the COMPANY for evaluation. Filling of the tank shall be stopped until cleared bythe COMPANY.
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FORCONSTRUCTION
OF OIL TERMINAL AT HFZ(EPC-1)
AGREEMENT NO. 10-5638-E-1
ABU DHABIOIL REFINING COMPANY PROJECT PROCEDURE
CONSTRUCTION PROCEDURE FOR
TANK HYDROSTATIC TESTDOC.NO.:5638-E1-1500-CA-PRO-220 Page
11/18
Rev.3
One day for settlement reading at 50%One day for settlement reading at 75%One day for settlement reading at 100%
Total four days for settlement observation
The tank shall be observed for signs of leakage. Careful inspection of all welded seams in theshell, including shell to bottom and all welds around openings and pipe joints, shall be carriedout. Besides shall be ensured there is no evidence of water seeping from beneath the tank.
8 MONITORING AND SETTLEMENT LIMITS
Monitoring shall be consist in the measurement of settlements along the tank circumference byoptical level instrument reading.
Level measurement on tank circumference
The tank shall be provided with reference points, equally spaced along the circumference andmade of steel elements welded to the shell approx. one meter above the edge of the bottomcourse. A set of level reading on all reference points shall be performed at the following times:
a) After tank complete construction, before start of filling for hydrastatic testb) With the water level at 25% of max. levelc) With the water level at 50% of max. leveld) With the water level at 75% of max. levele) With the water level at 100% levelf) 24 hours after reaching max. level of water in the tankg) In empty tank without waterh) 24 hours after emptying of the tank
Level measurements shall be referred to a permanent bench mark, both the bench mark and therequired permanent station joints shall be located at least 0.75 tank diameter from the tank edgeto avoid ground settlements that may influence the reading. The level instrument shall be set upat least 1 times tank diameter away from the tank when tank elevation readings are taken.
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FORCONSTRUCTION
OF OIL TERMINAL AT HFZ(EPC-1)
AGREEMENT NO. 10-5638-E-1
ABU DHABIOIL REFINING COMPANY PROJECT PROCEDURE
CONSTRUCTION PROCEDURE FOR
TANK HYDROSTATIC TESTDOC.NO.:5638-E1-1500-CA-PRO-220 Page
12/18
Rev.3
9.1.4 Water vendor will use 15-20nos water tanks of 5000 gallons each to transport water fromtheir factory to Contractor site. The sufficient water will be stored in waste water Sumpbefore hydro test start.
9.1.5 Manpower
Description Quant.
Mechanical engineer 2
QA/QC engineer 1
Safety officer 2
Surveyor 2
Site supervisor 2
Welder 4
Fitter 2
Rigger 4
Driver /Operator 5Labours 6
9.2 Water filling & drains arrangement
9.2.1 Contractor to use T901 waste water sump as buffering pool for water filling operation.Contractor shall Clean the waste water Sump (WWS) thoroughly before using it .Sample ofwater should be taken from WWS for testing.
9.2.2 The total 16 tanks farm site will be divided into two areas for hydrostatic testing gradually :
(1)The first tank area testing sequence is as follows:
T201, T202T203T204T101, T103T102, T205T211, T212
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FORCONSTRUCTION
OF OIL TERMINAL AT HFZ(EPC-1)
AGREEMENT NO. 10-5638-E-1
ABU DHABIOIL REFINING COMPANY PROJECT PROCEDURE
CONSTRUCTION PROCEDURE FOR
TANK HYDROSTATIC TESTDOC.NO.:5638-E1-1500-CA-PRO-220 Page
13/18
Rev.3
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FORCONSTRUCTION
OF OIL TERMINAL AT HFZ(EPC-1)
AGREEMENT NO. 10-5638-E-1
ABU DHABIOIL REFINING COMPANY PROJECT PROCEDURE
CONSTRUCTION PROCEDURE FOR
TANK HYDROSTATIC TESTDOC.NO.:5638-E1-1500-CA-PRO-220 Page
14/18
Rev.3
9.2.4 Official hydrostatic testing water filling
This official hydrostatic testing water filling should be followed only after all the tank fittingsand structure were completed and inspected. The water filling shall strictly comply with tankhydrostatic testing requirements and contractor to keep good water filling and settlementrecords.
9.3 Official Tank Hydrostatic Testing Water Filling Schedule
Categ.In.
Dia.TankShell
Height
Total
FillingHeight(HLL)
1stStage(25%)
Settle.Observ.
2ndStage(50%)
Settl.Observ
3rdStage(75%)
Settle.Observ.
4thStage(100%)
Settle.Observ.
JET A1TANK
41m 22m 19.81m 4.95m 24hr. 9.9m 24hr. 14.86m 24hr. 19.81m 24hr.
ULG &GAS OIL
TANK
36m 22.7m 21.25m 5.31m 24hr. 10.63m 24hr. 15.94m 24hr. 21.25m 24hr.
Note:
(1) The total filling height is from Data Sheet for Tanks Rev.0 .HLL--- High liquid level(2) The balance tank T205, fire water tanks and slop tanks will apply to this schedule either.
(3) Take the I.D.36m tank for calculation , using 260m/hr. pump and spend 10hr.each day to fill
water, It will take approx. 15 days to complete High liquid level hydrostatic test (excluding waterdraining).
10 TESTING OF THE ROOF
10.1 Fixed Dome roof (If Required)
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FORCONSTRUCTION
OF OIL TERMINAL AT HFZ(EPC-1)
AGREEMENT NO. 10-5638-E-1
ABU DHABIOIL REFINING COMPANY PROJECT PROCEDURE
CONSTRUCTION PROCEDURE FOR
TANK HYDROSTATIC TESTDOC.NO.:5638-E1-1500-CA-PRO-220 Page
15/18
Rev.3
It is essential for a floating roof to be liquid-tight for it to function safely and well. To ensure thatweld seams and joints, which are required to be liquid-tight fulfill this requirement, they shall beinspected and tested carefully. The following procedure shall be adhered to.
Center Deck of Pontoon-Type Roofs:
The weld seams of the single center deck plates shall be checked for liquid-tightness by thevacuum box method or by the penetration oil/chalk method.
Pontoon of pontoon-type roofs:
Before the top plates of the pontoons are installed the following seams in particular, shall betested for tightness, using liquid penetrates or any other test method:
a) The single-fillet welds on the upper surface of the pontoon bottom plates.b) The single-fillet welds between the bottom and the side walls of the pontoon.c) The single-fillet welds between the bulk heads and the bottom and side walls of the pontoon.d) The welds at the bottom corners of the bulk heads. These should be tested with particular
care, since the bulk heads are mostly shaped at these points to clear the longitudinal weldbetween the bottom and the side walls. The gaps so formed in the corners shall be closed
thoroughly, as leaks in one compartment will allow oil to penetrate into the adjacentcompartments.
e) The longitudinal welds joining the center deck to the pontoon.
Before all weld seams mentioned above are tested for tightness, they shall be thoroughlycleaned of slag and dirt.
10.3 Roof Drains
Drain pipe systems of storm water drains shall be tested with water to a pressure of 3.6kg/cm2(g).
During the flotation test, the roof drains shall be kept open and observed for leakage of tankcontents into the drain lines.
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FORCONSTRUCTION
OF OIL TERMINAL AT HFZ(EPC-1)
AGREEMENT NO. 10-5638-E-1
ABU DHABIOIL REFINING COMPANY PROJECT PROCEDURE
CONSTRUCTION PROCEDURE FOR
TANK HYDROSTATIC TESTDOC.NO.:5638-E1-1500-CA-PRO-220 Page
17/18
Rev.3
For the hydrotest water below valve level, suction pumps shall be utilized to remove theremaining water from the bottom sump.
The tank shall be completely drained and free from standing water.
15 CLEANING OF INTERNAL TANK AFTER DRAINING
After the completion of draining of clean water from the tank, blinds covering the manholes ornozzle openings shall be removed prior to the cleaning activity. The operators and relativepersonnel will go up to the top of tank from outside spiral stair and go into tank inside floating
deck ,which acts as the work cleaning platform , from tank inside floating stairway. PTW andconfine space entry procedure shall be always followed before work start.
A temporary storage tank filled with potable water is to be kept outside the tank on theground and connected to a jet pump.
The jet pump shall be positioned near the movable working platform with adequate length ofhose and spray nozzle at the end. Minimum pressure at nozzle and is approximately 30 bargauge and output is 290/600 litres/hour.
Cleaning of the shell plates shall be start from the highest course downward by standing onthe floating deck ,using the spray nozzle from the jet pump.
16 CALIBRATION OF TANK
Tank shall be calibrated in the presence of Third Party Inspection approved Agency by
COMPANY. After obtaining Third party Inspection procedure for Tank calibration and same shall
be submitted to COMPANY for further approval.
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FORCONSTRUCTION
OF OIL TERMINAL AT HFZ(EPC-1)
AGREEMENT NO. 10-5638-E-1
ABU DHABIOIL REFINING COMPANY PROJECT PROCEDURE
CONSTRUCTION PROCEDURE FOR
TANK HYDROSTATIC TESTDOC.NO.:5638-E1-1500-CA-PRO-220 Page
18/18
Rev.3
Refer to 5638-E1-1500-QA-ITP-MEQ-01 Inspection and Test Plan for Storage Tank and ProjectQuality Plan 5638-E1-1500-QA-PRO-001. Hydro test report shall be well prepared as per sitetesting course.
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OIL TERMINAL CONSTRUCTION PROJECT (EPC-1), HFZ, SHARJAH
RISK ASSESSMENT (Page 2 of 11)
2 Transportatio
n and Lifting
of HydroTesting
Materials
* Collide with
other vehicle or
adjacent objectsduring lifting/
swinging
* Clash with
adjacent operations
*Nip points
*Sharp edges of
materials
*Under load*Overload/over turn*Load failure
*Roll over
*Fatality
*Injury
*PropertyDamage*Workstoppage
*Crane and all the lifting accessories
shall be 3rd
party certified and the
serial numbers of slings shall bematched with the certificates
*Crane operator, rigger shall be withvalid 3
rdparty Certificate.
*Valid PTW* Lift plan if required
*Pipe clamps shall be appropriate tothe pipe size.
*All the slings, clamps shall beinspected by rigger before each lift
*Only trained and authorizedpersonnel be allowed
*Barricades and caution sign boardsbe displayed
*Proper supervision and pre plan oneach activity
*Other adjacent activities are to be
restricted during the work*Riggers must be instructed well todecide the slinging points depends tolength and weight of pipes/materials
*Slinging techniques shall be
implemented correctly*Wind speed must be considered*Load chart must displayed visible in
the operator cabin.
*Radius and angle of boom and slingsmust be planned and monitored.*SWL of slings and cranes must be
considered and planned well.
*Spreader shall be used always ifrequired.* Minimum two tag lines are required
(Tag line not less than
3m)
4 C H *Allocation of safelocation for positioning
of Trailer and crane,materials stacking,
Flagman and riggers*Proper plan required
for material handling,sequential operation
always*Mandatory PPEs and
accoutrements shall bedonned
*All the equipmentsand tools shall be
inspected as perchecklist daily and
periodically and colourcoded.
*Weight of each load
shall be calculatedbefore slinging.*Fork lift shall not be
used to lift any size ofpipe.
*Dimension of piperacks shall beconsidered and planed
well the lifting path
*Man positioning,working platform shallbe planed and explained
to the work force.
Performer 3 C M
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OIL TERMINAL CONSTRUCTION PROJECT (EPC-1), HFZ, SHARJAH
RISK ASSESSMENT (Page 3 of 11)
3 Fabrication,
Blinding/
Weldingbefore Hydro
testing
* Caught under
load
* Collide withother objects/
operation
*Sharp edges
*Electrocution
*UV/IR radiation
*Injury
*Property
Damage*Electric
burn/Bruise
*Arc eye
*All the equipments, electrical
and hand tools shall be inspected
prior to use, maintainedperiodically and colour coded
accordingly.
*Equipments shall be inspected
and certified by a 3rd party
(Depends on the equipment).
*All the operatives shall be
competent and trained.* All the DBs, sockets and cables
shall be of project standards and
with GFCI and inspected
monthly.
* All the Welding machines,
shall be calibrated & grounding
shall be ensured for all electrical
equipments (Oven, work-piece,welding machine).
* All the electrical tools shall be
with deadman switch.
* No material shall be placed by
creating hinder to any access, exit
or any fire extinguisher.
*Proper supervision shall beensured always.*PPEs for Welding-Welding shield
shall be attached to helmet, Welding
Gloves, shall be used apart from
project mandatory PPEs.
*All the electrical
cables shall be routed
UG/above minimum
2m height & away from road, sharp,
hot parts
3 C M * Scrap & used buts
shall be stored
seperately andemptied regularly.
*Proper housekeeping
shall be ensured
always.
*Proper aisle,
workspace shall be
planned and defined.
*Material movementshall be planned &
executed sequentially
*Proper lighting,
ventilation shall be
ensured always.
*External ventilation,
mechanical exaustion
shall be provided ifrequired.
*Man positioning,
proper working
platform shall be
planed, provided and
explained to the work
force.
Performer 2 B L
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OIL TERMINAL CONSTRUCTION PROJECT (EPC-1), HFZ, SHARJAH
RISK ASSESSMENT (Page 4 of 11)
4. Laying andfixation of
hose, clamps,couplings,
pressuregauges and
other hydrotest materials
*Falling of
material
*Slip, Trip Fall
*Injury
*Falatlity
*Flood
*Rooting of hose, and fixing/clamp
points shall be planned well
considering the integrity of structureand weight of hydro test material
including the water volume and
pressure.
*Vertical and horizontal routing of
hoses shall be routed safe duly
ensured the tighness to avoid any
move and burst.
*Tightness of Hose connectors shallbe ensured.
*All the hose, connector/couplings
shall be rated to the required bar
pressure and back water thrust.
*proper ramps shall be installed at
road crossingss and routed safely to
avoid slip trip fall.
*Pressure gauges shall be installedat easily monitoring height levels.
3 C M *Personnel shall be
trained and issued
with proper PPE*Grounding/earthing
shall be ensured on
the routings.
*Hose, Clamps,
couplings, gauges
shall be international
standards towithstand the
pressure and be
inspected before
installation.*Callibrated Pressure
gauges be installed at
each section
*Proper access to allvalves, gauges shall
be provided
Performer 2 A L
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OIL TERMINAL CONSTRUCTION PROJECT (EPC-1), HFZ, SHARJAH
RISK ASSESSMENT (Page 5 of 11)
5 Water
Filling , Leak
TestingDrain, and
Settlement
Observation
*High pressured
liquid
*Structurecollapse
*Failure of
flanges
*Burst
*Buckling
*Fatality
*Injury
*Assetdamage
*Project delay
*PTW be obtained. Watter be filled
stage by stage duly monitoring
leake, pressure etc.*Involved area to be barricaded with
Warning signs.
*Continuous supervision
*Project Testing procedure shall be
followed
* Ensure that the test pack has been
signed and released for test to
proceed*A complete walk through
inspection shall be done always at
pressured.
*Ensure that adequate number of
spotters are in place at works
location and boundaries
*Ensure assigned test personnel are
in safe position prior to start test
*Hoses to be monitored, secured and
kept in a tidy nad no accumulation
of debris/sharp/hot objects.
*Ensure all flange bolts are secure
before test, Valves only to be
operated by authorised personnel
*Ensure inlet/outlet & safety valves,
pressure gauges are functional.
* Other personnel be removed fromthe testing area
*Nobody will be permitted to climb
up the roof/top portion of tank.
*Leak repair is not permited during
pressure test
* The rate of draining flow shall be
controled slowly and smooth duly
considering the integrity of tankwalls to avoid buckling damages.
4 C H *Medical aids and
rescue shall be
available foremergency
situations.*Pressurise & De
pressurise shall be in
steps and as per
specifications
*work and water filling
will be stoppedimmediately if sudden
increase/decrease/leak
monitored and be
alarmed.
*The whole system
(DG, Hose routing,
motor pump, valves,
test tank etc) shall bemonitored for 24
hours. Good
communication system
be provided and
ensured between
monitor, pump
operator etc.
*Alarm system/ overpressure valve shall be
installed & set to
required pressure.
*Test pieces shall not
be detached, repaired,
loosen or tighten until
clear depressurisation
after double checked.
*Hose be burried
properly
Performer 2 A L
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OIL TERMINAL CONSTRUCTION PROJECT (EPC-1), HFZ, SHARJAH
RISK ASSESSMENT (Page 6 of 11)
6 PneumaticTesting (if
required)
*High pressured
air
*Structurecollapse
*Failure of
flanges
*Fatality
*Injury
*Assetdamage
*Combustible gas are not allowed
to be used for pnenmatic test.
*Involved area to be barricadedwith Warning signs.
*Continuous supervision
*Project Testing procedure shall
be followed
* Ensure that the test pack has
been signed and released for test to
proceed
*A complete walk throughinspection on every non-welding
connection jont shall be done
always at pressured.
*Ensure assigned test personnel
are in safe position prior to start
test
*Hoses to be monitored,
securedwith whip lash arrestor, and
kept in a tidy no accumulation of
debris/sharp/hot objects.
*Ensure all flange bolts are tighten
before test, Valves be operated by
authorised personnel only.
*Ensure inlet/outlet & safety
valves, pressure gauges are fixed
properly and functional.
* Other personnel be removed fromthe testing area, near any valces or
blinds.
*Nobody will be permitted to climb
up the roof/top portion of tank.
*Leak repair is not permited during
pressure test.
4 C H *First aids and
rescue shall be
available foremergency
situations.*Pressurise & De
pressurise shall be in
steps as per
specifications
*Testing will be
stopped immediately ifsudden increase/
decrease/leak
monitored and be
alarmed.
*The whole system
(DG, Hose routing,
motor pump, valves,
test tank etc) shall bemonitored for 24
hours. Good
communication system
be established and
ensured between
monitor, pump
operator etc.
*Alarm system/ overpressure valve shall be
installed & set to
required pressure.
*Test pieces shall not
be detached, repaired,
loosen or tighten until
clear depressurisation
after double checked.
Performer 2 A L
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OIL TERMINAL CONSTRUCTION PROJECT (EPC-1), HFZ, SHARJAH
RISK ASSESSMENT (Page 7 of 11)
*Work plat form shall be robust to
withstand weight of test piece,
testors and helpers. Proper access,fall arrestors be worn by the testors
if required.
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OIL TERMINAL CONSTRUCTION PROJECT (EPC-1), HFZ, SHARJAH
RISK ASSESSMENT (Page 8 of 11)
7 Cleaning/
Flushing the
Tank WithHigh Pressure
Pump (If
required)
*Asphyxiation
*Hazardous Gas
*Fall from height
*Fatality
*Injury
*Propertydamage
*Only competent and project CSE
trained workers shall be involed in
the work. Alone worker is notpermitted.
*Safety supervisor, work supervisor,
Hole watch, Pressure pump &
compressor operator must be
available always
*Gas testing be done before
personnel entry
*All Equipment must be inspectedfor proper function.
*Required PPEs : high pressure
water jet protective clothing,
Helmet, Safety goggle & Gum Boot,
FBH .
*Safety and warning signs and
emergency rescue equipments be
made available ready.
*On/off switches of jet system be
out side of the tank and be
monitored always.
*Third party certified Manbasket
duly written clearly the SWL be
used by personnel going inside the
tank. Manbasket will remain inside
the tank until last person come out
from the tank. Manbasket shall notbe detached from the crane until
final removal of person from the
tank.
*3 Riggers will be used. 1 inside the
tank, 1 at the curb ring and 1 at the
vicinity of crane operator (Outside
the tank) and manbasket be moved
by relay the signals by the riggers.
3 C M *Emergency rescue
equipment, stretcher be
made available readily.*Job rotation be done
*Proper illumination,
ventilation be ensured
*all the entrant be
worn FBH and all PPE
* Nobody will enter
under the floating roof,
if water reside under it.*Bottom plate cleaning
will be done only if the
Bottom shell manhole
flange is opened fully
and possible dust
sedimentation is
removed.
*Proper
communication device,
emergency alarm be
provided to the
entrants.
*Self breathing
apparatus will be
available inside the
tank always for
emergency purpose
Performer 1 B L
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OIL TERMINAL CONSTRUCTION PROJECT (EPC-1), HFZ, SHARJAH
RISK ASSESSMENT (Page 9 of 11)
8 Confined
Space Entry
*Gas
*Lack of O2
*Supervisionmissed
*Poor
illumination
*Falling objects
*Fall from height
*Toxication
*Asphyxiation
*ElectricalBurn/Shock
*Fire
*Tumble*Injury
*Entry restriction Only well
trained & nominated person.
*Verify that the ventilation andlighting equipment & service are
well prepared and in good status
*Verify that rescue services such
(rope)life ladders & life line are
available and that the means for
summoning them are operable on
every ingress ,egress and
evacuation outlet*All Attendant Hole watch will be
adequately qualified via DEC Hole
watch training and follow up
supervisor directed training on the
job.
*Frequent breaks or change of
crews
*Prevent unauthorized individuals
to enter or attempt to enter the
confined space during entry
operations
*Adequate warning sign board
shall be placed.
*Clear communication and
coordination among crews
*Provision of attender.
*Verify the fitness of workers priorto entry into the tank
*Readiness of recovery equipments,
First aid & Respiratory apparatus.
*Provision of fire extinguishers
*No resting position works inside
the tank
*Before start of each shift work
proper atmosphere test to be carriedout by competent persons (AGT)
4 C H *Recording of
personnel Entry &
Exit.*Emergency horn
& light to
communicate an
Emergency situation.
*Provision of FBH &
Respirator (as per
requirement)
*Strict Supervision*Proper illumination
(100lux minimum)
*Proper ventilation
and external
ventilation shall be
arranged if required.
Performer 2 C L
OIL TERMINAL CONSTRUCTION PROJECT (EPC 1) HFZ SHARJAH
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OIL TERMINAL CONSTRUCTION PROJECT (EPC-1), HFZ, SHARJAH
RISK ASSESSMENT (Page 10 of 11)
9 Work At
Height (Tank
Top Testingor Testing
Observation
and Survey)
*Trip and Fall
*Fall of materials
*Sharp edges
*Injuries to
personnel
* Fatality*Property
damage
*Trip and Fall
*proper Work platform with ladders,
handrail, mid rail be provided
*FBH be worn by the personnelalways
*Testing personnel shall not enter
into the tank without permission and
proper arrangements and training
3 C M *Project WAH
procedure shall be
implemented.
performer 2 C M
10 General Task
(Applicable
to all
activities)
*Machineries
operation
*Sound
*Dust*Temperature
*Debris
*Tools
*Extreme weather
*Slip, Trip Fall
* Injury
*Fatality
*Heat related
illness*Fire
*Property
damage
*Work
stoppage
*TBT to be conducted daily to brief
the hazards of the task
*All the workers must be
Experienced & trained*A trained banksman/signalman
with flourescent jacket shall be
provided with each equipment.
*Use Mandatory PPEs to protect
Head, Eye, Ear, Body, Hands &
Foot.
*Provision of Shelter and water
points*Fire Extinguishers
*PTW requirement as per procedure
*Proper housekeeing shall be
ensured each shift start and end
*All the activities should be stopped
at any extreme weather conditions
*Work shall be resumed after
inspection on back to normalweather.
*All tools should be inspected
before start of work and shall be
colour coded periodicaly.
3 C M *Strict supervision
*Use the right tools /
Equipment in correct
manner.*All project employees
must be aware of
emergency response
plan.
*Muster point must be
visible at all times.
*Job rotation and
periodic rests*Home made tools are
prohibited
Performer 2 B M
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