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RISK ASSESSMEMT

Project Description
Construction of 10000 KL capacity (Dia: 31 m, Height: 14.63 m) vertical storage tank for HSD at
New Faisalabad Depot.
Scope of work includes:
i) Constrcution of Tank Ring Wall
ii) Supply, fabrication and erection of steel plates and structure for vertical tank.
iii) Hydrostatic Testing of Tank.
iv) Surface preparation & painting.
v) Complete testing and commissioning of the tank
S.No

1-

DESCRIPTION

ACTIVITY

Civil Works
Excavation levelling, dressing,watering, dewatering and compaction of base with plate
vibrator or 10 ton roller. Lifts & leads & backfilling the excavated stuff and compaction

23-

Laying and compacting existing retrieved earth


laying sand fill including compacting with plate vibrator and 10 ton road roller (if required)
and watering in layers

4-

laying CC 1:4:8 (using S.R cement) including approved form work and its removal as per
drawing, levelling, compacting, rodding vibrating,finishing and curing

5-

Providing and laying CC 1:2:4 (using S.R cement) including approved form work and its
removal as per drawing, levelling, compacting, rodding vibrating,finishing and curing

6-

Laying Tor steel reinforcement bars including straightening, removing of twists cutting,
bending, binding, wastages and such overlaps as are not in drawings, placing imposition on
precast cc or steel chairs, tying with bending wire

7-

laying Bitumen Sand Layer 75 mm thick. Including compaction of layer with 4 tons
mechanical roller / plate compactor.

8-

Cleaning, grading and leveling of site & removal of debris, trees, shrubs and any other
undesired material from site.

9-

Providing transportation facility

10-

lay 3/4" th. Plaster with cement mortar 1:4 including providing and fixing expanded metal at
the junction of structural members and brick walls, making chamfered edges rounding of
corners at junctions, plaster stopper metal corner beads, drip course where required,
hacking of RCC surface and curing also include chipping off the deteriorated plaster
wherever required.
Fab./Erection of Tank

2
3

SHIFTING (INCLUDING LOADING/UNLOADING) ALL HANDLING, LIFTING, LAYING,


PLACING IN POSITION, ALIGNING, CUTTING, MACHINING, BENDING, ROLLING,
FORGING, DRILLING, GRINDING, FABRICATION AND WELDING IN POSITION OF
STEEL PLATES AND STRUCTURAL MATERIAL
VACCUM BOX TESTING OF BOTTOM PLATES BY VACCUM BOX AND SOAP SUD
METHOD
HYDROSTATIC TESTING OF TANKS.

4
5

SOAP SUD / VACCUM BOX TESTING OF ROOF AND PRESSURE TESTING OF


REINFORCEMENT PADS/DOUBLERS BY COMPRESSOR .
CALIBRATION OF THE TANK BY OPTISTRAP METHOD

6
7
8

SAND BLASTING THE ROOF PLATES (EXTERIOR),BOTTOM, SHELL PLATES


EXTERIOR, SHELL PLATES INTERIOR 1ST COURSE, ROOF RAILING, SPLASH
PLATES ETC.
MECHANICAL CLEANING
APPLICATION OF PAINT

Page 1 of 17

RISK ASSESSMEMT
Assessed by:
Munazza Khan

Checked / Validated by:


Hasan

Atif

Location:

Project Description
Construction of 10000 KL capacity (Dia: 31 m, Height: 14.63 m) vertical storage tank for HSD at New Faisalabad Depot.

S#

Activity

Hazard

Process Safety Control Measures

Civil Works
1

Excavation levelling, dressing,watering, dewatering and


compaction of base. Lifts & leads & backfilling the excavated
stuff and compaction

Page 2 of 17

Cave-In due to Soil condition/


vibration by excavator or nearby
activities

Soil Testing,Shoring, battering, benching


or backfilling.
Consultation with an expert is required

Falling Load (Debris/Equipment)

Keep all equipment and excavation


material away from the edge of the
excavation.
Consider barriers around the zone of
influence to prevent plant straying onto
this area.

Falling People

The perimeter should be fenced or


appropriate barriers in place with clear
signage.

Allergy from Dust

Watering

Injuries by Equipment/Tools

Skilled Workers/ no unauthorized entry/


Florescent clothing for padestrians/
separate paths

Damaging Nearby Structures

Underpinning of the adjoining structure or


construction of retaining walls.
Minimise vibration on the excavation site
by appropriate choice of plant to
undertake the work.
Review the system of work to minimise
the times that vibration causing plant are
working simultaneously.

S#

Activity

Hazard

Damaging Underground Utilities

Process Safety Control Measures

All services should be located and clearly


marked on site prior to work commencing.
Services can be located by digging trial
holes, core hole drilling, gas detectors,
remote location devices or hand digging.

Contaminants uncovered. Tinclude; Prior to excavation work an expert with


gases, toxic chemicals,
appropriate detection equipment needs to
microorganisms, radioactive waste, be consulted.
dust, asbestos, synthetic mineral
fibres.can be breathed in, swallowed
or absorbed through the skin.

Unexpected water flows digs below Use devices which lower the water table
the water table or the level which the around the excavation site.
water table rises to after rain.
Use sumps to pump any seepage from
the excavation.
Fence off or cover any holes where any
water is retained.
Ensure there is quick access out of the
excavation.
Ensure rescue equipment and buoyancy
devices are on hand.

Laying CC 1:4:8/1:2:4 (using S.R cement) including approved form work and Skin Contact / Eye Contact/
its removal as per drawing, levelling, compacting, rodding vibrating,finishing Inhalation
and curing

Wash exposed areas thoroughly with


soap and water .

Noise

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Injuries by Equipment/Tools

Skilled Workers/ no unauthorized entry/


Florescent clothing for padestrians/
separate paths

Loose/Inadequate Shuttering

Skilled Workers/ no unauthorized entry

S#
3

Activity

Hazard

Laying Tor steel reinforcement bars including straightening, removing of


twists cutting, bending, binding, wastages and such overlaps as are not in
drawings, placing imposition on precast cc or steel chairs, tying with bending
wire

Process Safety Control Measures

Carrying heavy/ awkward


Manual handling training, use lifting
materials/tools/Sprains/ strains, device where possible,
Cuts/lacerations
Injuries by Equipment/Tools

Skilled Workers

Eye Injury by flying particles


Noise, Heat,
Personnel Injury/Property damage.

Laying Bitumen Sand Layer 75 mm thick. Including compaction of layer with 4 Equipment failure
tons mechanical roller / plate compactor.

Cleaning, grading and leveling of site & removal of debris, trees, shrubs and
any other undesired material from site.

Ensure well ventilated workplace. Use


earplugs/muffs,
Skilled manpower
Continous
Supervision
No unauthorized entry
All Equipment must be inspected prior to
start of job.
Skilled manpower

Injuries by Equipment/Tools

Skilled Workers/ no unauthorized entry/


Florescent clothing for padestrians/
separate paths

Personnel Injury/Property damage.

Skilled manpower
Supervision
No unauthorized entry

Trip over debris or materials.


Sprains/strains/cuts/
lacerations/impact injury

Clear pathway of obstacles before


proceeding Check pathway and
footwear before proceeding. No
unauthorized entry

Continous

Carrying heavy/ awkward


Manual handling training, use lifting
materials/tools/Glass
device where possible, Ensure glass
Sprains/strains, Cuts/lacerations is packaged in cardboard,
Dropping materials/tools
Sprains/strains, Cuts/
lacerations and Impact injury.

Page 4 of 17

Manual handling training,use lifting


device where possible. Ensure glass
is packaged in cardboard,

Activity

S#

Hazard

Providing transportation facility

Waster Management

Waste should be segregated in


particulars garbage drums

Collision with Other Vehicles/


Pedestrains/ Fixed Objects

Licensed Driver/ no unauthorized entry/


Florescent clothing for padestrians/
separate paths/ Use of Horn/ Reverse
alarm

Vehicle Loss of control/ Overturn

Licensed Driver, Follow speed limits,


Donot overload
Donot Overload, Secure Load, Drive on
ramp with heavy end uphill, Engage
parking brakes,

Falling Load

Process Safety Control Measures

Plastering with cement mortar 1:4 including providing and fixing expanded
Skin Contact / Eye Contact/
metal at the junction of structural members and brick walls, making
Inhalation
chamfered edges rounding of corners at junctions, plaster stopper metal
corner beads, drip course where required, hacking of RCC surface and curing
also include chipping off the deteriorated plaster wherever required.

Wash exposed areas thoroughly with


soap and water .

Noise

Fab./Erection of Tank
LOADING/UNLOADING, ALL HANDLING, PLACING IN POSITION, ALIGNING,

Injuries by Equipment/Tools

Skilled Workers/ no unauthorized entry/


Florescent clothing for padestrians/
separate paths

Trip over debris or materials.


Sprains/strains/cuts/
lacerations/impact injury

Clear pathway of obstacles before


proceeding Check pathway and
footwear before proceeding. No
unauthorized entry

Dropping materials/tools
Sprains/strains, Cuts/
lacerations and Impact injury.

Manual handling training,use lifting


device where possible. Ensure glass
is packaged in cardboard,

Carrying heavy/ awkward


Manual handling training, use lifting
materials/tools/Glass
device where possible, Ensure glass
Sprains/strains, Cuts/lacerations is packaged in cardboard,

Page 5 of 17

S#
9

Activity

Hazard

CUTTING, MACHINING, BENDING, ROLLING, FORGING, DRILLING,


GRINDING, FABRICATION AND WELDING

Process Safety Control Measures

Equipment failure

All Equipment must be inspected prior to


start of job.
Skilled manpower

Shock, fire,

Keep Fire extinguisher/ Firstaid Kit nearby


Continous Supervision Cylinders in
upright position.
Flash back flame arrestor installed on
cylinder side. Gauges installed on
acetylene & oxygen cylinders
Proper grounding of equipment

Eye Injury/Hand/Body Burn

Use welding shield/Face Shield


Welding & working gloves, Fire resistant
cloths, Safety shoes.

Noise, Heat, Dust, Fumes & Gases

Ensure well ventilated workplace.

Disc Broken/Looseness

Grinding/Cutting disc to be matched with


grinder RPM.
Permit To Work, Skilled manpower
Continous Supervision, no authorized
entry , JHA meeting before start of job

Personnel Injury/Property damage.

10

VACCUM BOX TESTING OF BOTTOM PLATES BY VACCUM BOX AND SOAP


SUD METHOD

Equipment failure

All Equipment must be inspected prior to


start of job.
Skilled manpower

11

HYDROSTATIC TESTING OF TANKS.

Equipment failure

All Equipment must be inspected prior to


start of job.
Skilled manpower

SOAP SUD / VACCUM BOX TESTING OF ROOF AND PRESSURE TESTING OF Equipment failure
REINFORCEMENT PADS/DOUBLERS BY COMPRESSOR .

All Equipment must be inspected prior to


start of job.
Skilled manpower

Page 6 of 17

Activity

S#

Hazard

Process Safety Control Measures

12

CALIBRATION OF THE TANK BY OPTISTRAP METHOD

Equipment failure

All Equipment must be inspected prior to


start of job.
Skilled manpower

13

SAND BLASTING THE ROOF PLATES (EXTERIOR),BOTTOM, SHELL PLATES Equipment failure
EXTERIOR, SHELL PLATES INTERIOR 1ST COURSE, ROOF RAILING, SPLASH
PLATES ETC.

All Equipment must be inspected prior to


start of job.
Skilled manpower

14

15

MECHANICAL CLEANING

APPLICATION OF PAINT

Injuries by Equipment/Tools

Skilled Workers/ no unauthorized entry/


Florescent clothing for padestrians/
separate paths

Equipment failure

All Equipment must be inspected prior to


start of job.
Skilled manpower

Injuries by Equipment/Tools

Skilled Workers/ no unauthorized entry/


Florescent clothing for padestrians/
separate paths

Allergy from Dust


Eye Injury by flying particles

Watering

Inhalation of paint, lung damage.

Take regular breaks

Skin irritation

Wash exposed areas thoroughly with


soap and water after handling.
Do not wash skin or hands with paint
thinner or lacquer thinner, use hand
cleaner.

Paint Spillage causing slips, trips

Use drop sheets


Wipe up all spills, and pick up dropped
items, immediately.

Running over or coming into contact Follow directions and instructions


with buried / exposed electrical wires provided on where the work is to be
undertaken.
Dust from plaster and paint removal
Contamination of clothing

Page 7 of 17

Wash work clothes separately from other


clothing; rinse washer thoroughly after
use

Activity

S#

Hazard

Process Safety Control Measures

Eye irritation

Confined area without adequate


ventilation.

Provide proper ventilation

Fire

Follow instructions of MSDS Properly


store paints that may be combustible.
No smoking in
or around painting storage area.
Promptly clean up spills and
leaks.
Keep combustibles away from ignition
sources.
Keep
fire extinguisher near painting and storage
area.

GENERAL ACTIVITIES
16

Working at height

Falling material/People

Secure tools/material
Install net to prevent fall
Signs and barricade to restrict entry

17

Working on Ladder

Ladder tipping over

Check Ladder for any damage before


use.
Donot
carry heavy loads.
Set ladder
feet on solid level surface, follow 1:4 ratio.
If
possible secure from both above and
below.
If
can't secure have a person hold the
ladder at all times
Set Ladder 1m above required
working height/Use Hand holds.
Donot over reach.

Page 8 of 17

Activity

S#
18

Hazard

Working on Scaffold

Process Safety Control Measures

Collapse

Erect, alter and dismantle by competent


people.
Donot overload
Load is evenly distributed.
Donot apply any horizontal loads like
ladder on working platform:
Donot fix ties to the centers of thin walled
aluminum tubes;
Donot move the tower by applying force
at platform level;

Fall of material/people
Hitting overhead structure/power
lines cr moving on uneven ground

Double guard rails, toe boards and


additional
brick or
guards
No
power lines
overhead obstructions
Working
platforms fully boarded. Donot
in
the way.
Climb
outside
of tower
reach platform.
No holes
or dips
in the to
ground.
Also
working
No worker or any material onsee
platform
at
height
when moving.

19

Step Ladder

Ladder tipping over

Fully open stepladder and lock spreaders


in place.
Donot stand on the top two steps and
bucket shelf.
Fully open stepladder and lock spreaders
in place.

20

Working Environment

Clean up and pack up tools and


materials.

All rubbish to be disposed off as


instructed and to be secured to prevent
projectile hazards.

Personnel Injury/Property damage. No unauthorized entry, Signs and


Trip
Barrication, even floor, good
housekeeping standards
Fall/Slips/Trips

Maitain good Hosue keeping standards/


no unauthorized entry/ separate paths

Bad weather

Avoid activity during rain & bad


weather(high wind & rain)
Drink water

Dehydration

Page 9 of 17

ASSESSMEMT
Review date:

for HSD at New Faisalabad Depot.


PPEs

Helmets

Helmets

Face Mask, Gloves


Helmets/ Gloves/ Safety
Shoes
Helmets/ Facemasks/
Gloves/ Safety Shoes

Page 10 of 17

PPEs

Gloves, long sleeves


and pants, Safety
Shoes. Goggles, Dust
Masks
Use earplugs/muffs,
Helmets/ Facemasks/
Gloves/ Safety Shoes

Helmets, Safety Shoes,


Harness (incase of
working at height)

Page 11 of 17

PPEs

Gloves, Safety Shoes.

Gloves, Safety
Shoes. Goggles, Dust
Masks
Googles

Helmets/ Facemasks/
Gloves/ Safety Shoes

Wear safety Shoes,

use Gloves, Safety


Shoes

Wear safety Shoes,


Gloves.

Page 12 of 17

PPEs

Seat Belt

Seat Belt

Gloves, long sleeves


and pants, Safety
Shoes. Goggles, Dust
Masks
Use earplugs/muffs,
Helmets/ Facemasks/
Gloves/ Safety Shoes

Wear safety Shoes,

Wear safety Shoes,


Gloves.
use Gloves, Safety
Shoes

Page 13 of 17

PPEs

Use earplugs/muffs,
welding/face
shields/welding
googles

Page 14 of 17

PPEs

Helmets/ Facemasks/
Gloves/ Safety Shoes/

Face Mask, Gloves


Googles
Wear a respirator
and other PPE as
recommended by
MSDS.
Wear gloves that are
impervious to paint
and thinners.
Wear
long-sleeved,
clothing that covers
all exposed skin.
Wear sturdy shoes with
slip-resistant soles;

Use of Dust mask and


eye protection.
Wear apron if
possible

Page 15 of 17

PPEs

Wear goggles that


seal eyes from paint.
Wear respirator that
will protect for these
conditions such as
S.A.R. (supplied air
respirator) or P.A.P.R.
(power air purifying
respirator)

helmet with chinstrap


slip resistant
shoes
safety harness
helmet with chinstrap
slip resistant
shoes
safety harness

Page 16 of 17

PPEs

helmet with chinstrap


slip resistant
shoes
safety harness

helmet with chinstrap


slip resistant
shoes
safety harness

Page 17 of 17