From : PAT Middle East & Africa.

To : Encorp International E&C

Date : November 23, 2023.

METHOD STATEMENT FOR

Chilled Water Network Flushing, Cleaning & Passivation

BY

PAT Middle East and Africa

ARAB REPUBLIC OF EGYPT
 INDEX
Introduction ------------------------------------------------------------------------------1

Purpose----------------------------------------------------------------------------------2

Definitions----------------------------- --------------------------------------------------3

Scope of work-------------- -------------------------------------------------------------4

RESPONSIBLE PERSONNEL ---------------------------------------------------------------5

Process Procedures----------------------------------------------------------------------6

Inspection and test plan-------------------------------------------------------------------7

HSE-------------------------------------------------------------------------------------8

COSHH Form-----------------------------------------------------------------------------9

Risk Assessment------------------------------------------------------------------------10
Dear Sir,

We take an opportunity to introduce ourselves as a highly qualified and experienced

group of engineers engaged in the manufacturing of water and wastewater treatment
plants.

PAT Middle East & Africa is partners for global companies in water & waste water
treatment all are globally leading brands, with local assembling facilities. And we have made
elaborate arrangement for impeccable service-after-sales.

We enclose herewith, the following documents to provide your insight to our

organization, to enable you to take appropriate action, in this regard at your end.

This is our method statement of Chilled water Network Chemical Cleaning & Flushing.

For and on behalf of

PAT Middle East & Africa

PAT Technical Department
01. INTRODUCTION
After installation of the chilled water network complete, flushing and chemical cleaning
is a vital process to protect the piping and extend its life time.

02. PURPOSE
The purpose of this procedure is to define the sequence and methodology for flushing
and chemical cleaning for HVAC network.

03. DEFINITIONS
Client / Owner Name Encorp International E&C

Project The View - Zamalek

Consultant
Contractor
Water Treatment Specialist PAT Middle East and Africa

04. SCOPE OF WORK

This flushing method statement is applicable for the project and provides procedure to
identify a specific course of action to be followed for efficiently clean the chilled water system.

05. RESPONSIBLE PERSONNEL

Construction Manager.
Mechanical Engineer
Mechanical Supervisor
Chemist
06. Introduction to LSI, Corrosion & Chilled Water Treatment
1- What we mean by LSI ?
Langelier saturation index (LSI)
LSI is an equilibrium model derived from the theoretical concept of saturation and provides an indicator
of the degree of saturation of water so (LSI) is a measure of a solution ability to dissolve or deposit calcium
carbonate so it’s used as indicator of the corrosively of water.

LSI Indication

LSI > 2.0 Heavy scale forming

0.5 : 2.0 Scale forming but non corrosive

0.0 : 0.5 Slightly scale forming

LSI = 0.0 Balanced

-0.5 : 0.0 Slightly corrosive

-0.5 : -2.0 Serious corrosion

LSI < -2.0 Very aggressive

2- What we mean by Corrosion?

Corrosion is an electro chemical process in which differences in electrical potential develop between two
metals or between different parts of a single metal. This voltage can be measured when metal is electrically
connected to standard electrode.

- Anodic reaction:
Fe Fe+2 + 2e –

-Cathodic reactions:
O2 +H2O + 4 e- → 4OH-
2H+ + 2 e- → H2
 -Interaction between cathodic and anodic reactions:
Fe+2 + 2OH- → Fe (OH)2
4Fe (H)2 + O2 + 2H2O → 4Fe (OH)3
2Fe (OH)3 → Fe2O3 + 3H2O

Corrosion is naturally occurred and the pipe manufacturer giving life time for the pipe and the standard
corrosion rate for his pipe in (mpy) or (mm year -1) which mean when you convert it by ppm normally it
will be at range from 0.01 to 0.05 and this is accepted value and will not make any problem especially in
water color, but in your case due to aggressive water mechanism the values exceed these limits so you
have problems with water color.

Factors effecting corrosion:

- PH.

- Dissolved gasses carbon dioxide reduces pH and promotes acid attack. Oxygen depolarizes the corrosion
reaction at cathode. Nitrogen then aggravates cavitation corrosion.

- Temperature. Increased temperature favors oxygen depolarization, lowers hydrogen overvoltage, and
increases corrosion

- Dissolved salts, chloride, and sulfate can penetrate passive metal oxide films and promote local attack.
Calcium, magnesium, and alkalinity may precipitate to form protective barrier deposit.

- Suspended solids.

- Microorganisms.

- Velocity can promote erosion corrosion.

- Heat transfer.

- Metallurgy surface flaws-cuts, nicks, scratches favor anodic site formation

Corrosion Inhibitors:
One of the most effective solutions to control corrosion is corrosion inhibitor: is any substance which
effectively decreases the corrosion rate when added to an environment. Passivation (anodic) inhibitors,
form a protective oxide film on the metal surface which tends to be rapidly repaired if damaged.
Precipitating (cathodic) inhibitors are simply chemicals which form insoluble precipitates that can coat and
protect the surface.

The most common type of corrosion inhibitors is the inorganic one.

-Anodic Inhibitors
Anodic inhibitors act by reducing the anodic reaction, blocks the anodic reaction and support the natural
passivation reaction for the metal due to film formation which adsorbed on the metal, in general inhibitor
react with corrosion product which is initially formed resulting in a cohesive and insoluble film on the
metal surface.

Anodic Inhibitor Mechanism

Examples for anodic inorganic inhibitors are:

Nitrates, Molybdates, Sodium chromate, Phosphates and Silicates.

-Cathode Inhibitors:
During the corrosion process the cathodic inhibitors prevent the occurance of the cathodic reaction of the
metal,these inhibitors have metal ion able to produce cathodic reaction (react instead of the original metal)
thus producing insoluble compounds which will deposit over the metal restricting the diffusion of
reducible species like oxygen.

Cathode Inhibitor Mechanism

Examples of cathodic inorganic inhibitors are the ions of:

-Magnesium (Mg) and Zinc ( Zn) which react with hydroxyl (OH-) forming insoluble hydroxides Mg(OH)2
and Zn(OH)2 which are deposited on the cathodic site of the metal and protect it.

- Calcium (Ca) which deposited as calcium carbonate CaCo3 on the cathodic site of the metal and protect
it.

07. Process Procedures:

- Flushing is carried out methodically by circulation and soaking.

- Sensitive equipment shall be bypassed, isolated, completely removed or replaced to ensure

system flow continuity.

- The use of flexible connections on terminal units may provide an easymeans of bypassing the
terminal coils.

- Every effort shall be made for the flushing water velocity to be generated externally and not by
the use of system pumps.

- All section valves are open including bypass to drain.

- Each section is isolated in turn until clean strainers are inspected at regular intervals.

08. Flushing Methodology:

The process involves the following six steps:

1. Initial static flushing with plain water

2. Dynamic flushing
3. Chemical cleaning
4. First Inhibition
5. Passivation
6. Recommendations after flushing completion
1. Initial static flushing with plain water
• Fill the system with fresh water.
• After filling the system drain the entire system should be carried out twice.
• Fill the system again
• Circulate the system for 8 hours
• During circulation, the strainers have to visually checked and cleaned at least once an
hour.
• After circulation open the drain valves at the drain points.
• Flushed water should be disposed out of the storm water drain.
• The system is again refilled and dynamic flushing started.

2. Dynamic flushing
• Keep the system at continues circulation for 8 hours.
• Open the clean water feed to the system.
• Slowly open the drain valves at the drain points and adjust to adequate makeup and
drainage.
Note: The drainage flow must never be more than the clean makeup flow to avoid system
pressure loss
During dynamic flushing it’s important that the velocity of the circulating water is sufficient to
force all debris from the system out.
Flow reading must be taken at every available branch and riser measuring station to ensure the
correct velocities are being achieved.
• Carry out filling, draining & circulating until the water is visibly clear.
• During the dynamic flushing all strainers that have flow through them must be checked
and cleaned regularly until no more deposits are found on them.
• Filter elements in the filtration skid to be checked and cleaned regularly during dynamic
flushing, on completion of dynamic flushing all of them must be isolated before chemical
cleaning.
. We will confirm acceptance of water quality as mentioned below

PARAMETER VALUE (ppm)

PH 7.00 – 8.5
Conductivity
Max 800
(µ Siemens / cm)
TDS (ppm) Max 400
Max 200
Chlorides (ppm)

Total Iron (ppm) Max 0.5

Turbidity (NTU) Max 5

3. Chemical Cleaning
Prior to startup of chemical cleaning, close all drain valves which were opened during dynamic
flushing.
• Required dosages of cleaning materials will be as follow:
DOSAGES OF PACIFC-110 , PACIFIC – 102 BCL AND PACIFIC – 407
Chemical Chemical
Chemical consumption
Network Volume consumption consumption
(PACIFIC-110) (PACIFIC-102 BCL) (Pacific -407)
CH.W Network 5 m3 20 Kg 7.5 Kg 5 Kg
NOTE: Caustic soda solution may be added if needed in order to adjust the solution pH

• The pumps are switched on and will continue for a minimum period 24 hours until the
recorded dissolved iron stay constant.
• When dissolved iron level reaches a constant value clear the system of contaminated water
by carrying out the filing & draining procedure stated before until the water sample taken
from a minimum of 2 separated drain points on the system show the water per parameters
as mentioned below or as the same quality as the water being filled into the system,
whichever is of the “highest “quality.
• Flushed water can be disposed out to the storm water drain at the site subject to
compliance with the norms set by municipality for disposal of water; otherwise it may be
taken away by tankers and disposed of in a suitable location.
 PARAMETER VALUE
PH 7 - 8.5
CONDUCTIVITY (µ Siemens / cm.) MAX 800
TDS (ppm) MAX 400
CHLORIDES (ppm) MAX 200
IRON (ppm) MAX 0.5 ppm
TURBIDITY (NTU) MAX 50 NTU.

4. FIRST INHIBTION (processing to passivation)

• When the correct water condition have been achieved with the circulation pumps, close all
the drain points.
• Processing to final inhibition (Passivation) will takes place by injecting and circulating the
second chemical solution (PACIFIC 8000 DWT) at least for 12 hours.
• The dosage for (PACIFIC 8000 DWT) as mentioned below:

DOSAGES OF PACIFC-8000 DWT

Chemical consumption
Network Volume
(PACIFIC-8000 DWT)
3
CH.W Network 5m 10 Kg

• When dissolved iron level reaches constant value turbidity, phosphate and silica content
reach limits as acceptance criteria mentioned below. clear the system of contaminated
water by carrying out the filling & draining procedure stated before until the water sample
taken from a minimum of 2 separated drain points on the system show the water per
parameters as mentioned below or as the same quality as the water being filled into the
system , whichever is of the “highest “ quality.

Acceptance criteria:
• PH (8.5 – 10.5)
• Recirculation till the residual phosphate in range (20 – 30) ppm.
• Recirculation till the residual silicate in range (30 – 40) ppm.
• Residual iron after flushing Max. 0.5 ppm
• TURBIDITY (MAX. 50 NTU)
5. FINAL INHIBTION (Passivation)
• When the correct water condition have been achieved with the circulation pumps, close all
the drain points.
• Passivation and micro biocide chemicals will be added at this step.
• Circulate the water for 4 hours.
• Chemical dosages will add as mentioned below:

DOSAGES OF PACIFC-301 CLT

Chemical consumption (KG)
Network Volume
(PACIFIC-301 CLT)
CH.W Network 5 m3 20 Kg

• Keep the system in circulation including al the equipment’s for minimum period 24 hours.
• Water samples have to be collected from the designated areas for measuring and testing
the corrosion inhibitor level (Nitrite – minimum 1200 ppm).
• A final water analysis indicating all the required parameters as mentioned below.

PARAMETERS VALUE
pH 9.5 -10.5
CONDUCTIVITY ( µ siemens / cm.) MAX 3000
TDS (ppm) MAX 2000
CHLORIDES (ppm) MAX 200
IRON (ppm) MAX 0.5
TURBIDITY (NTU) MAX 50
Nitrite (ppm) 1200 -1500

NOTE: After addition of final treatment chemical, the system must be left full and completely
circulated without any stagnancy.
Biological Control
Chilled water system is an ideal breeding ground of bacterial and other micro-organisms
and it’s necessary to control them by using our non-oxidizing biocide (PACIFIC-328)

DOSAGES OF PACIFC-328 MB
Chemical consumption (KG)
Network Volume
(PACIFIC-328 MB)
3
CH.W Network 5m 1.25 Kg

6. Recommendations after flushing completion:

-After reinstatement of all plant items the level of inhibitor must be re-checked and re-dosed as
necessary.
-After flushing completion, we have to take into consideration these points:

1- The preservator shall last in the system for 10-12 months as long as no water drainage.
2- Any partially drainage shall be done in the most minimum and in strict circumstances
and this will be in cooperation and coordination with PAT MIDDLE EAST COMPANY.
3- PAT MIDDLE EAST COMPANY shall supply a reserve amount from both (PAT-301 and
PAT- 328).
4- PAT MIDDLE EAST COMPANY shall perform a monthly visit with full chemical analysis to
determine if any action has to be taken.
09. Recommended Readings:
Parameter Units Recommended Range
pH PH 9.5 - 11.5

Total Dissolved Solids (TDS) ppm 1200+Raw Water

Nitrite (Corrosion Inhibitor) ppm 1200-1500

Total Hardness at 25 degree C ppm 0-25

NTU 50 max.
Turbidity

Conductivity μmhos/cm TDS depend

Chlorides ppm 250 max.

Iron ppm 1 max.

LSI LSI -0.2 to +0.2

Cooper ppm Zero

10. Chilled Network Cleaning Procedure
Step 1
Wetting and Sequestration step:
1- Prepare solution consist of (4 kg/m3 PACIFIC-110), (1.5 kg/m3 PACIFIC-102 BCL) and (1 kg/m3
PACIFIC- 407) by using chlorine free water.
2- Temperature must be less 95 F◦ (25-40̊ ˚c).
3- Adjust the pH of the cleaning solution to (10: 11) by using caustic soda if needed.
4- HCl and NaOH can be used for pH corrections when needed.
5- Pump the solution through the injection point for each loop as shown in charts by using low
speed pump.
6- Circulate the solution by the very low speed pump for 24 hours.
7- Record PH reading and apply correction during this period of circulation.
8- Adjust PH at (10:11)
9- If we note the color changed dramatically or increasing in iron concentration this will be
indication for cleaning effectiveness.
10- Cartridge filter elements should be monitored, cleaned and changed
11- Iron levels and pH should be monitored and recorded in cleaning form.
12- Circulate by high-speed flow for 2 hours. (as recommended in method statement)
13- Circulation, soaking and flushing depends on complete analysis at the site for iron and pH
changes during each step.
14- After iron levels and pH become constant values start flushing out the system.
15- Flushing is finished when the pH, conductivity of the solution and those of makeup water are
the same.

Step 2
First Inhibition:
1- Prepare solution (2 kg / m3) of PACIFIC-8000 DWT by using chlorine free water.
2- Temperature must be less 95 F (25-40̊ c).
3- Adjust the PH of the solution to (8.5 - 10) by using caustic soda.
4- NaOH can be used for pH corrections when needed.
5- Pump the solution through the stage by using very low speed pump.
6- Circulate the solution by the low-speed pump for 12 hours.
7- Record pH, iron, silicates and phosphates readings and apply correction during this period of
circulation.
8- Adjust pH at (8.5 – 10).
 9- If we note the color changed dramatically or increasing in iron concentration this will be
indication for cleaning effectiveness.
10- Cartridge filter elements should be monitored, cleaned and changed.
11- Circulate by high-speed flow for 2 hours.
12- Circulation, soaking and water removing depends on complete analysis at the site for iron,
pH, turbidity silicates and phosphates changes during each step.
13- Flush out the cleaning solution with chlorine free Fresh water.
14- Flushing is finished when the pH and conductivity of the solution and the makeup water are
the same.
Step 3

PASSIVATION
1- Prepare solution of (4 kg / m3) of PACIFIC-301CLT by using chlorine free water.
2- Maintain pH between (8.5 – 10.5).
3- Prepare solution of (0.25 kg/m3) of PACIFIC-328MB by using chlorine free water.
4- Circulate with low flow rate for 24 hours with monitoring the inhibitor concentration.
5- Note, it’s highly recommended to deliver this solution to each point in the circuit including
piping, pumps and equipment.
6- Keep monitoring iron and inhibitor concentration to be comply with attached acceptance
criteria
 PAT Cleaning Form

CHEMICALS
SOLUTION. NO DATE & TIME WATER QTY. M3 SILCATES PHOSPHATES TOTAL IRON TURBIDITY CHLORIDES
QTY. KG PH

2
7. Inspection & Test Plan
We will use our laboratory test devises (attached) On Site
We will use the Consultant test devises if available
8. Health, Safety and Environment (HSE):

8.1. Our HSE Objectives

• Secure a healthy and safe working environment

• Identifying and controlling workplace hazards

• Considering health and safety in all activities

• Minimize emissions and discharges to the environment

• Complying with all applicable health and safety and environmental regulations and legislation.

8.2. Our HSE Policy

Health, Safety and the Environment is the number one priority for PAT, its employees and its clients. PAT is committed to:
• Pursuing the goal of no harm to people including but not limited to employees, the public, clients, client employees, service
providers and service provider employees

• Protecting the health, safety and security of our employees and clients

• Preventing all injuries

• Protecting the environment

•Using materials and energy efficiently in provide our products and services

• Minimizing emissions and discharges to the environment consistent with industry standards and local regulations

• Promoting best practices in our services

• Managing HSE matters as any other critical business activity

• Promoting a culture in which all PAT employees and service providers share this commitment.
Our goal is to achieve HSE performance that we can be proud of, to earn the confidence of our clients & society and to contribute
to sustainable development.
 8.3. Employees Health and Life Insurance Policy:
PAT employees are covered under whole company insurance policy with ALICO/AIG Insurance Company to
cover the following
• Accidents, disability
• Life insurance
• Medical
• Pension and retirement.

8.4. Personal Protective Equipment (PPE):

Eye Protection
Safety goggles are recommended in areas where potentially heavy exposure can occur from misting or
splashing of fluids or chemicals around any mixing areas; Safety glasses fitted with side shields are suitable in
other areas.
Protective Clothing
Long sleeve, impermeable coveralls for torso and limb protection are recommended for individuals involved
with long term exposure to the any fluids or rotationally hazard chemicals. Nitrile or neoprene coated nylon
coveralls offer the best combination of protection and durability. The coverall should cover as much
exposed skin area as possible. Gloves and foot wear should overlap with the coveralls. Aprons coated with
nitrile or neoprene rubber maybe used in other areas. All personal protective equipment should be checked
frequently for cracks and tears.
Gloves
Impermeable gloves should be worn by all personnel coming into contact with the chemicals. Gloves made
from neoprene or nitrile rubber are required. Nitrile or neoprene latex blends offer a more flexible glove.
Glove surfaces should be textured to provide a more effective gripping area. Gloves should be discarded if
the interior surface becomes contaminated. Cloth or leather gloves should not be worn at any time.
Footwear
Neoprene or synthetic rubber safety boots or over boots with non-slip soles are recommended. Leather
boots that become impregnated with fluid should bediscarded.
Barrier Creams
Use barrier creams to cover those areas not covered by personal protective equipment. These areas include
the face and neck and portions of the legs and arms where the pieces of PPE overlap.
 9. PAT Middle East & Africa
COSHH Assessment Form
Date Site:-
Person(s)
Process:-
Involved in
COSHH
Assessment
1. Eliminating the need to use hazardous substances, consider is it possible to avoid Yes No 
the need to use hazardous substances? 
2. Before beginning work on the COSHH assessment process ensure you have a copy of the latest
Manufacturers Safety Data Sheet (MSDS). MSDS’s are available from suppliers and manufacturers of products
YES  NO 
Describe of the activity or How long?
work process

How Often

Location of work

Persons at risk: Workers  Residents  Others  Authorized Persons 

Name of the substance

Classification

Highly Flammable 
Acute Toxicity  Serious Eye Irritation 

Very Toxic (fatal)  Respiratory Sensitizer  Extremely Flammable 

Serious long term health Dangerous to the

Corrosive  
hazard  environment

Gasses under pressure 

Harmful   Oxidising

Explosive  Flammable 

3. Substitution Yes  No 
Is it possible to use a less harmful substance to do the work?
 Indicate below which form the substance takes
Gas  Vapor  Mist  Granular  Dust  Liquid  Solid  Powder
Indicate below which route(s) of exposure the substance takes
Inhalation  Skin  Eyes  Ingestion  Other State 
Workplace Exposure Limits (WELs)
Long-term exposure level (8hrTWA): Short-term exposure level (15 mins):

List of the risks to health from exposure to the substance

Inhalation:

Ingestion:

Skin Contact:

Eye Contact:

Chronic Exposure:

Control Measures: List below control measures eg extraction, ventilation, supervision, include additonal controls for
vulnerable persons where necessary
Engineering Controls:
Procedure to be followed : In case of Leak or Spill.
Precautions:
Clean-Up:

Is health surveillance or monitoring required? Yes  No 

Personal Protective Equipment identify type and specification

Dust mask Visor

 

Respirator Goggles
 

Gloves
Overalls
 

Footwear
 Other

First Aid Measures
Step 1. Stop the source
Remove the person from contact with the chemical spill, airborne particles, or fumes. (Wear gloves or use other safety
equipment as needed to protect yourself from exposure to the chemical.)
Take off any clothes or jewelry that have been in contact with the chemical. Chemical injuries, just like heat burns, continue
to worsen as long as the source is in contact with the body.

Step 2. Clear the lungs

Take the Person to fresh air. This may mean going into another room or leaving the building.

Perform rescue breathing or CPR, if needed.

Step 3. Flush the eyes

Flush the affected eye with water for at least 15 minutes. Make sure the water is cool, especially if its source is an outside
hose or eyewash station.

Don't accidentally flush chemicals into an unaffected eye. Hold the head so that the injured eye is on the bottom. Flush from
the nose downward.

Step 4. Clean the skin

Brush water-activated chemicals, such as lime, from the skin, instead of using water. Be careful not to brush particles into the
eyes.

If the chemical does not react with water, flush the affected skin with cool water for at least 15 minutes. Make sure the water
flow is not forceful enough to cause pain or break blisters.

Don't brush away chemicals with your bare hands.

When to call your healthcare provider

Chemicals may cause serious damage not only to the outside of the body, but also to the inside. If absorbed into the
bloodstream, chemicals may launch a silent attack on the kidneys or liver. Call your healthcare provider right away if any of
the following is true:

A chemical has come into contact with the eyes, nose, or mouth.

The Material Safety Data Sheet calls the chemical hazardous or likely to cause damage.

The container label warns of corrosive contents, which can wear away skin.

The chemical causes a large burn.

There is difficulty breathing after exposure.

Call The Ambulance

Call The Ambulance right away if the Person has:

Symptoms of shock

Trouble breathing

Burns over a large area.

FIRE FIGHTING MEASURES

Explosion:

Fire Extinguishing Media:

In the event of a fire, wear full protective clothing and NIOSH-approved self-contained breathing
apparatus with full-face piece operated in the pressure demand or other positive pressure mode.
Dry Powder  CO2  Water  Foam  Fire Blanket 
Handling and Storage
Storage Colour Code :
Handling:

Storage:

DISPOSAL CONSIDERATION

Hazardous Waste  General waste  Biological waste  Return to Supplier  Other 

Is exposure adequately controlled?

Yes  No 

For the Review

Signature(s) Date Review

10. Task Risk Assessment:

Performing
TRA Team leader Job performer HSE Area Authority
Authority
Name: Name: Name: Name: Name:
Team
Members
Signature

Tools & equipment Used

Zone 0/1 Yes /No Zone 2 Yes /No Zone classification : Restricted area
Hazardous Area Classification

References :

Notes:
1. Area Authority Confirms all the controls are in place before job starts
2. TRA Team Leader signs All pages
3. Method statement to be made available BEFORE conduction TRA
 RISK RATING
RISK RATING
NO. ACTIVITY HAZARD CONSEQUENCES EXISTING CONTROLS ACTION BY WITH CONTROL ALARP Completion date

S L R S L R
1-Provision of earthing connection for the PA
1- Operation of - Explosion (Fire). - Serious/fatal generator. Till the end of process
generator and - Electric shock. injuries 2-Inspection for all power tools before starting its AA/PA
power tools - Lack of skills. - Major equipment operation.
- Uncertified equipment damage 3-Good housekeeping should be implemented.
- Indefinite emergency 4-Cable connection should be reviewed and PA/HSE
preparedness. protected.
- Improper access way. 5-All Cables should be inspected and free from PA/HSE
- Improper cable connection. any damage. PA/HSE Till the end of process
- Improper panel inspection. 6-Access way should be always free from any PA/HSE
obstacles.
7-Operation of generator should be through
competent person. PA/HSE Till the end of process
8-Competent person should be involved in this
task. PA
4 4 16 9-All panels and power tools should be inspected.
4 2 8 YES Till the end of process
10-Removing any combustible materials from the
AA/HSE/PA
working area regularly. Till the end of process
11-Proper safety signs should be posted.
12-Ear plugs should be provided PA/HSE

PA/HSE

PA/HSE

RISK RATING
NO. ACTIVITY HAZARD CONSEQUENCES RISK RATING EXISTING CONTROLS ACTION BY ALARP Completion Date
WITH CONTROL
 S L R S L R
2- Chemical handling -Improper chemical handling. -Personal injury 1-All workers should be competent. PA/HSE
-Chemical spill. -Environmental damage. 2-Chemical Handling procedure should be followed. PA/HSE
-Direct contact with human body. 3-MSDS for all chemicals should be in place.
4-All workers should be trained.
PA/HSE Till the end of process
5-Emergency safety shower and eye wash station should be provided.
4 4 16 6-Chemical spill kits should be in place. AA/PA/HSE 4 2 8 YES
7-Chemical storage area should be barricaded and Identified.
8-Proper safety signs should be posted. AA/PA/HSE
9-Proper PPE should be provided. AA
10-Housekeeping should be implemented.
11-Access ways should be kept clear.
PA/HSE
12- SSOW and SPOW should be implemented.
13-Emergency response plan should be followed. PA/HSE
14-All working area should be barricaded.
PA/HSE
PA/HSE

PA/HSE
PA/HSE

AA/PA/HSE

RISK RATING
RISK RATING
NO. ACTIVITY HAZARD CONSEQUENCES EXISTING CONTROLS ACTION BY WITH CONTROL ALARP Completion Date
S L R S L R
 Isolation as - Improper isolation method. - Serious/fatal -Isolation should be performed by competent AA Till the end of process
5- mentioned in marked - Chemical spill. injuries persons.
P&ID - - Major equipment -ICC should be issued with identification of AA
damage. isolation points.
- Environmental -Safe System Of Work should be followed.
damage 4 4 16 -LOTO system should be implemented and in AA
place. Till the end of process
-Empty barrels and spill kits should be in place. AA
-Isolation method should be approved by Client
(JV).
AA 4 2 8 YES Till the end of process

-Positive isolation is highly recommended.

AA
-All isolation points should be checked and
Till the end of process
reviewed.
-TBT should be conducted to all workers. AA

AA/HSE/PA
HSE/PA

RISK RATING
RISK RATING
NO. ACTIVITY HAZARD CONSEQUENCES EXISTING CONTROLS ACTION BY WITH CONTROL ALARP Completion Date

S L R S L R
 Chemical cleaning - Pressurized system. - Serious/fatal 1-PTW should be issued and all work pack PA/HSE Till the end of process
6- operation - Chemical spill. injuries should be attached (TRA-MOS-P&ID-ICC).
(Loading and - Direct contact to human body. - Major equipment 2-Work site should be clear from unauthorized Till the end of process
Soaking) damage persons. PA/HSE
- Environmental 3-SIMOPS is prohibited during chemical cleaning
damage operation. Till the end of process
4-All HPH should be secured by using whip check AA
(Certified and inspected). Till the end of process
5-ICC should be attached and reviewed. PA/HSE
4 4 16 6-work location must be evacuated during
4 2 8 YES
PA/HSE Till the end of process
chemical cleaning operation.
7-Emergency shower and eye wash station
PA/HSE Till the end of process
should be in place.
8-Proper safety signs should be posted. AA/PA/HSE
9-TBT should be conducted before starting work. Till the end of process
10-Emergency response plane should be PA/HSE
followed. Till the end of process
11-Proper PPE should be implemented. PA/HSE
12-Proper communication mean should be
provided. PA/HSE Till the end of process
13-Close supervision should be implemented
during chemical cleaning operation PA/HSE
14-Working area should be barricaded and
secured PA/HSE

PA/HSE

PA/HSE

RISK RATING
NO. ACTIVITY HAZARD CONSEQUENCES RISK RATING EXISTING CONTROLS ACTION BY ALARP Completion Date
WITH CONTROL
 S L R S L R
Loading and -Falling objects. ▪ Injury to persons due to fall ▪ Follow proper lifting / loading procedures PA During Work
7- offloading materials -Mechanical Failure. from the vehicle ▪ Close supervision should be provided
from and to truck / -Damage in rigging tools. ▪ Injury to persons due to fall ▪ Certified rigging tools should be used. PA
All Time
trailer -Unsuitable lifting equipment. of load from the vehicle ▪ Ensure competence of the personnel involved PA
-Turnover. ▪ Material damage ▪ Lifting gears to be certified and inspected by
▪ Movement of load during competent person AA
transportation, due to ▪ Crane to be certified. All Time
improper restraining. ▪ Banks man will wear high visibility vest. AA
Accidents, personal injury / ▪ All lifting rigging will wear site specific PPE AA
All time
death, property damage due ▪ At least two tag lines used to control lift
to load collapse ▪ Nobody allowed under the load. AA
▪ All rigging tools must be inspected and color coded. All time
PA/HSE
▪ The lifting area should be barricaded.
▪ Lifting equipment should have certification for lifting PA/HSE Before starting work
points.
HSE All time
4 6 12 ▪ TBT should be conducted. 4 1 4 YES
▪ Ground must be leveled and handed over from civil PA/HSE
discipline. PA/HSE Before starting work
▪ All equipment should be inspected before off-loading.
▪ Crane operator should follow lifting plan
▪ Using clear signals between banks man and crane AA
operator. PA/HSE All time
▪ Only banks man have authority to operate the crane PA \ HSE All time during work
operator PA/HSE
▪ Plastic sheet must spread beneath the equipment and All time during work
materials. Lifting supervisor
▪ SSOW should be followed. PA \ HSE
PA/HSE
All time during lifting
PA/HSE
 Likelihood
Unlikely Possible Likely Very likely Imminent

People Assets Environment

1 2 3 4 5

Extensive
Massive effect
damage 5 5 10 15 20 25
Multiple fatalities

Major
damage
Major effect 4 4 8 12 16 20
Severity Single Fatality

Localized effect
Local damage 3 3 6 9 12 15
Major Injury

Minor Minor effect

damage
2 2 4 6 8 10
Minor Injury

Slight Slight effect

Slight Injury 1st aid damage
1 1 2 3 4 5
Hazard Checklist figure 1

Hazards Hazardous Hazardous activities

conditions
• Hydrocarbon liquids/gases - Flammable • Vibration • Manual handling
materials • Lighting • Use of machinery
• Explosives - Material under pressure • Extreme ambient temperatures • Driving
• Differences in elevation - Objects under stress • Temporary facilities • Climbing/working at heights
• Moving equipment/vehicles - Natural • Non-breathable conditions • Confined spaces
occurrences (weather, tides, etc.) • Stacking
• Extreme temperatures - Open flame • Excavation work
• Electromagnetic radiation - Radio actives
• Noise - Toxic substances/chemicals
• Biological conditions

Work environment Task factors Organizational factors

• access/egress/escape routes • workload • training/familiarization
- scaffolds • workplace, effort, exertion • language/communication
- suspended access • skill, knowledge and experience • supervision
- mobile platforms • complexity • rules and procedures
- ladders/lightweight staging • time, timing • controls
• general workplace conditions • decision making • forms/ permits
- work space- noise/vibration - light • repetitiveness • resource levels
- weather/atmosphere - heat/cold
stress
• special workplace conditions
- at heights - over water
- in excavations - in/near live plant
• plant and equipment
- portable tools - abrasive wheels
- cartridge-operated tools - hand tools
• services and consumables
- electricity - compressed air
- Steam - Consumables (e.g. LPG, petrol,
etc.)
- hazardous substances - process fluids
/ solids
- dusts, mists, smoke and fumes
- construction materials - chemicals
Hazard Checklist figur