RISK ASSESSMENT FOR TESTING AND COMMISSIONING OF CHILLED WATER PUMPS

 

RISK ASSESSMENT FOR TESTING AND COMMISSIONING OF CHILLED WATER PUMPS

HSE Documents Ensuring a chilled water system functions efficiently and reliably relies on the proper testing and commissioning of its pumps. This process verifies the pump's performance meets design specifications and identifies any potential issues before full operation. It typically involves pre-commissioning checks, operational testing, and performance monitoring. Pre-commissioning ensures correct installation, cleanliness, and proper rotation of pump components. 

Operational testing involves starting the pump with closed discharge valves, recording pressure readings as valves open, and monitoring for overheating vibration, and motor performance. Finally, performance is compared to pump curves to confirm flow and pressure meet design requirements. This systematic approach safeguards the chilled water system's integrity and optimizes its overall efficiency

Work Activity

• Document arrangements
• Site Arrangement
• Working in summer
• Testing and Commissioning of Chilled Water Pumps
• Manual Handling
• Hand Tools
• Emergency arrangements

Hazard

1

• Improper & Incomplete PTW
• Incomplete LOTO procedure requirements

2

• Slip and trip

3

• Heat stress
• Heatstroke
• Dehydration

4

• Electrocution.
• Poor Lighting
• Spillage of Water

5

• Injuries such as Back Strain,
• Bruised or broken toes or feet.
• Sharp edges

6

• It may cause injuries such as Back Strain,
• Defective hand tools

7

• Fire
• First aid
• Dizziness
• Heat stroke

Possible Accident / Health &Persons at Risk

1

• Operatives

2

• Operatives

3

• Fatigue To involved personnel

4

• Personal Injury
• Finger Injury
• Hand Injury

5

• Muscle pain
• Eye strain, headache, and fatigue
• Stress
• Minor injuries

6

• Hand injuries
• Property damage

7

• Injury and property damage

Existing Risk Control (if Any)

1

• T & C engineer will request to the main contractor for PTW before one day.
• [HSE Documents] will follow the approved LOTO procedure (0000)
• Proper signage will be provided regarding the testing and commissioning procedures and authorized personnel only.
• PPEs will be given to all operatives relevant to their job.

2

• PPEs will be given to all operatives relevant to their job.
• Access ways shall be ensured by a competent person that all access and egress points are free from obstructions.
• The material will be stacked properly at the designated place.

3

• [HSE Documents]-approved Heat stress plan (0000) will be followed.
• Proper monitoring of temperature
• Breaks and rotations will be given to all involved workers
• Easy access to cool water

4

• The system under test has been correctly installed and inspected.
• Ensure approved work permit is available before the beginning of any testing 48 Hrs' notice to CCC before the testing and approval shall be obtained/coordinated.
• Calibrated equipment will be used
• Tools & equipment TPC to be available at the site.
• The area shall be barricaded (Physical barrier) and Signs placed for unauthorized entry.
• Ensure availability of water spill kit during testing of CHW Pumps.
• The main contractors' approved heat stress plan will be followed.
• Sufficient lighting will be provided by the main contractor.

5

• Task Briefing conducted to workers on ergonomics and manual handling safety
• Training related to manual handling
• Close supervision by the site supervisor
• Manual Handling Risks briefed to the workforce by the task in charge before the commencement of work.

6

• All equipment will be inspected before use.
• Use of Personal Protective Equipment at all times (hard hats, safety glasses, gloves, Ear Protection, etc.)

7

• The main contractor rescue plan will be followed.
• Provision of sufficient and suitable fire extinguishers at the site
• Provision of first aid box, Stretcher, and eyewash at the site
• Designated fire wardens team
• Designated first-aider teams

Additional Risk Control

1

• HSE Officer to verify/ensure PTW is in place for the T&C activity before start.
• Proper LOTO shall be secured to avoid any unauthorized operation
• All the contractors and working teams will be informed and coordinated properly about ongoing testing and their hazards.
• Third-party certification of LOTO in-charge engineer.
• Start briefing before starting the activity.

2

• Housekeeping of area before the start and while leaving the work area.
• A designated team will be assigned for housekeeping.

3

• Glucose juice shall be given.
• Close supervision
• Proper communication arrangements
• Training will be given to all workers on heat stress.

4

• Only trained personnel shall conduct tests.
• In-house training will be given to the workers.
• Proper, hand protection gloves shall be worn.
• The electrical Engineer / Supervisor shall be available on task
• LOTO procedure (0000) shall be followed.
• Acquired permit to work from the contractor.
• In case of an emergency, the Emergency Rescue plan of the main contractor will be followed.
• A Fire Extinguisher shall be placed nearby in the area of the task activity.
• Proper supervision of the testing activities shall be implemented.
• PPEs will be provided as per their job.
• Task lights will be provided for illumination.
• A Proper Communication system shall be provided.

5

• Only competent personnel will be allowed
• The main contractor's PTW will be followed
• [HSE Documents]-approved HSE plan will be followed
• Ensure housekeeping of all areas.

6

• Task Briefing conducted to workers on ergonomics and the use of hand tools safely
• The colour code will be followed by the main contractor.
• Training related to hand tools.

7

• Task Briefing conducted to workers on ergonomics and the use of hand tools safely
• The colour code will be followed by the main contractor.
• Training related to hand tools.

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