RISK ASSESSMENT No / 003-F / Page 1 of 3
Work Activity:
Strength and Tightness pressure testing of packaged unit piping, site pipe work & pre-fabricated pipe and component assemblies. / 
Thornliebank Industrial Estate Glasgow G46 8JW
Tel: 0141 638 7916 Fax: 0141 638 8111
e-mail:
Site/Location:
Various site locations
Those at Risk / Y/N / Comments - enter names or general groups
Star Employees:
Other workers:
General Public: / Y
Y
N / Engineers and Assistants
Sub-contractors, workers at site locations and visitors
Comments: No young person (under 18 years) will be allowed to carryout pressure testing unless a competent person closely supervises them.
Hazards
  1. Explosion of system during Strength Test
  1. Asphyxiation due to uncontrolled or careless release of pressure test medium
  1. Explosion of pressure test medium cylinders (as a result of toppling over or being struck)
  1. Injury from flailing charging hose if it breaks free.
  1. Eye injury from projectiles or jets of high pressure gas

Note:
This risk assessment covers the strength and tightness pressure testing of new vessels, pipework, and systems where the age, quality of workmanship, materials and test pressures are known.
Testing of existing (old) plant or repairswill require the system Maximum Allowable Pressure(s) for it’s current condition to be determined andmay require an additional risk assessment.

Control Measures(existing or planned)

Control / Details
PPE: /
  1. Safety boots
  2. Overalls/protective clothing
2.Ear defenders
3.Safety helmet
4.Safety glasses/eye protection (for protection against projectiles and jets of high pressure gas)
5.Gloves
Equipment: /
  1. Test medium cylinders (in bank or secured upright) Double check contents for type of gas and pressure contained within the cylinders!
  2. Nitrogen pressure regulator selected with:
  1. The lowest possible maximum outlet pressure, e.g. do not use a 175 Bar outlet regulator on a 27 Bar test. Use a 40 Bar outlet regulator instead.
  2. Inlet pressure suitable for pressures on the cylinder side, e.g. 230 Bar and 300 Bar for standard cylinders.
NOTE: 230 Bar and 300 Bar regulators have different inlet fittings, therefore, it should not be possible to fit a 230 bar regulator to a 300 bar pressure source.
  1. Hoses for pressure testing shall be in accordance with the specification in SS125
  2. Calibrated test gauge
  3. Vent hose (secured - for the venting of the test medium to a safe place if necessary)
  4. Strength test relief valve or CVP set at the appropriate pressure shall be fitted in accordance with SS125
  5. Tie Wraps for the ends of hoses to prevent flailing should they break free

Control Measures Continued

Control / Details
Information, Instruction, and Training /
  1. Only engineers trained and approved as competent by their Manager may carryout pressure testing.
  2. Accompaniment by a second Star Refrigeration engineer (Not necessarily one who is on the register of competent persons for pressure testing but must be at least ST1) is mandatory during Strength testing but is not necessary during Tightness testing providing the system has previously been subjected to a Strength test at a higher pressure. The accompanying engineer is to double check each stage of the safe system of work (method statement) and assist during setting up and execution of the test.
  3. Do not tamper with or modify the regulator in any way.
  4. Pressure testing will be carried out in accordance with Star Standard Specification No 125 – Pressure Test Procedures
  5. Star Standard Specification No 125 will be issued to all approved engineers.
  6. Method statement MS005 or the method statement contained within SF813 must be followed.
  7. Only approved gases will be used DO NOT USE OXYGEN
  8. Do not attempt repairs until that part of the system is vented to atmospheric pressure.
  9. Vent test medium to outdoors or ensure good ventilation if venting indoors to prevent an asphyxiation hazard.
  10. The competent person must instruct the accompanying person what to do in case of an emergency
For some specific non-routine tests, a method statement and separate risk assessment will have been prepared – this must be read and observed.
Supervision: / Branch or Department Managers will:
  1. Maintain a register of competent engineers.
Branch, Department or Site Managers will:
  1. Ensure that only competent engineers carryout pressure testing.
  2. Ensure that nitrogen pressure regulators and test pressure gauges are regularly maintained, serviced and calibrated.
  3. Control the issuing of regulators so as to ensure that only the lowest possible outlet regulator is selected.
  4. Control the issuing of regulators so as to ensure that the inlet pressure is suitable for the pressure source (cylinder or pack 230 Bar or 300 Bar)
  5. Ensure that when apprentices are carrying out pressure testing as part of their training they are under strict and constant supervision by a competent engineer.

Environment / 1.Cylinders must be kept upright, secured from falling and protected from accidental impact.
2.The area of the test must be cordoned off and cleared of personnel to a safe distance during the strength test.
3.Warning signs (tape, cones and notices) should be displayed around area
4.Do not discharge test medium into a closed space
5.Do not enter a closed space if you suspect that the test medium may be present following a leak or release
Procedures, documents etc /
  1. A site may operate permit-to-work safe systems these must be adhered to.
  2. Any site safety rules over and above the control measures listed here must be followed
  3. Any site specific risk assessment or method statement must be adhered to

COSHH: / 1.Those undertaking the test should read and understand the COSHH assessment for the test medium.
Communications: /
  1. The manager or operator of the site must be informed that a test is about to be undertaken so that he can take any further precautions that he deems necessary. An emergency plan may be agreed.

Emergency action/ Procedures: /
  1. Close off cylinders, clear the area, ventilate the area, isolate the leak if without risk, release pressure from system slowly and safely.
  2. First-Aiders to be made aware that the test medium is an Asphyxiant.

Access: /
  1. The engineer performing the test should strictly control access to the area.

Risk Evaluation of Identified Hazards

Likelihood / Highly unlikely = 1 / Unlikely = 2 / Likely = 3
Severity / Slightly harmful = 1 / Harmful = 2 / Extremely harmful = 3
(Likelihood x Severity = Risk level) 1 = Trivial, 2 = Tolerable, 3-4 = Moderate, 6 = Substantial, 9 = Intolerable
Identified Hazards (base scores on existing or planned control measures) / Triv' / Tol' / Mod' / Sub' / Int'
  1. Explosion of pressurised system 1x3
  1. Asphyxiation due to uncontrolled or careless release of Nitrogen 1x3
  1. Explosion of Nitrogen cylinders (as a result of toppling over or being struck) 1x3
  1. Injury from flailing charging hose if it breaks free. 1x2
  1. Eye injury from projectiles or jets of high pressure gas 1x2
/ 2
2 / 3
3
3

Note:Moderate scores; Thought should be given to reducing risk, but the cost and time requirements of prevention

should be carefully considered and limited.

Substantial: Work should not be started until the risk has been reduced, for work in progress, urgent

action is required. Considerable resources may have to be allocated.

Intolerable: If unlimited resources cannot reduce risk, work will be prohibited.

Is risk adequately controlled using the above control measures Y/N / YES / If "NO" State further action required
Further action required: None

Note : This risk assessment is only valid when all control measures are in place before the work or activity commences and will be reviewed 10/08/14 or earlier if the nature of the work changes or there is a dangerous occurrence.

Assessor: / Chris Haslam / (Sign) / Date 10/08/09

References: HSE guidance note GS4 – Safety in Pressure Testing.

BS EN 378: 2007 Refrigerating Systems and Heat Pumps Safety and Environmental Requirements

Star Standard Specification No's 125.