Work Activity:
Strength and Tightness pressure testing of F Gas Test Rig piping.
With or Without Vice Cover. / Thornliebank Industrial Estate Glasgow G46 8JW
Tel: 0141 638 7916 Fax: 0141 638 8111
e-mail:
Site/Location:
Star Branches
Those at Risk / Y/N / Comments - enter names or general groups
Star Employees:
Other workers:
General Public: / Y
Y
N / Engineers and Assistants
Candidates, workers at site locations and visitors
Hazards
1. Explosion of system during Strength Test
2. Asphyxiation due to uncontrolled or careless release of pressure test medium
3. Explosion of pressure test medium cylinders (as a result of toppling over or being struck)
4. Injury from flailing charging hose if it breaks free.
5. Eye injury from projectiles or jets of high pressure gas
Note:
This risk assessment covers the strength and tightness pressure testing of systems where the age, quality of workmanship, materials and test pressures are known.
Control Measures (existing or planned)
Control / DetailsPPE: / 1. Overalls/protective clothing.
2. Safety glasses/eye protection (for protection against projectiles and jets of high pressure gas).
3. Gloves.
4. Safety boots.
5. Ear Defenders (for hearing protection against sudden pressure release / component failure)
Equipment: / 1. Test medium cylinders (secured upright) Double check contents for type of gas and pressure contained within the cylinders!
2. Nitrogen pressure regulator selected with:
a. The lowest possible maximum outlet pressure.
b. 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.
3. Hoses for pressure testing shall be provided with test kit.
4. Test gauge.
5. Vent OFN to safe area.
6. Tie Wraps/wire to secure ends of hoses to prevent flailing should they break free.
7. Vice Cover for optional strength testing on the bench.
Information, Instruction, and Training / 1. No candidate will be allowed to carryout pressure testing before being questioned and then closely supervised by the Assessor.
2. Do not tamper with or modify the regulator in any way.
3. Pressure testing will be carried out in accordance with the requirements of EN 378
4. Only Oxygen Free Nitrogen (OFN) will be used DO NOT USE OXYGEN
5. Do not attempt repairs until that part of the system is vented to atmospheric pressure.
Vent test medium to outdoors or ensure good ventilation if venting indoors to prevent an asphyxiation hazard.
Control Measures Continued
Supervision: / Assessors will1. Ensure that candidates are competent to carry out pressure testing, if in any doubt the Assessor will stop the assessment.
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 the inlet pressure is suitable for the pressure source (cylinder or pack 230 Bar or 300 Bar).
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. If the vice cover is not used there must be a wall between personnel and equipment/components under test.
3. Warning signs (tape, cones and notices) should be displayed around area.
4. 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. Any site safety rules over and above the control measures listed here must be followed.
2. 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, and release pressure from system slowly and safely.
2. First-Aiders to be made aware that the test medium is an Asphyxiant.
Access: / 1. The Assessor supervising the test should strictly control access to the area.
Risk Evaluation of Identified Hazards
Likelihood / Highly unlikely = 1 / Unlikely = 2 / Likely = 3Severity / 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
2. Asphyxiation due to uncontrolled or careless release of Nitrogen 1x3
3. Explosion of Nitrogen cylinders (as a result of toppling over or being struck) 1x3
4. Injury from flailing charging hose if it breaks free. 1x2
5. 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 requiredFurther 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 31/07/11 or earlier if the nature of the work changes or there is a dangerous occurrence.
Assessor: / (Sign) / DateReferences: HSE guidance note GS4 – Safety in Pressure Testing.
BS EN 378: 2008 Refrigerating Systems and Heat Pumps Safety and Environmental Requirements.