Project: Safira Fabrication Yard Projects Location: Ras Al Khair JHA No.: ZP. 022 Rev. No.

00

Department: Mechanical Section: Construction Date: 06-03-2025

Activity or Production Process: HVAC Mechanical Works *Replaces:
D7365-VD-C07-01-F03-0016
Activity Steps Hazards Control Measures
Steps in sequence required to perform the activity or Inherent hazards in the activity steps and possible Control measures required to eliminate or minimize the
process. consequence. hazards.

1. Pre-Task Briefing and Inspection • Lack of understanding of task requirements Pre-Task Briefing HSE Control Measures

1. Define Task Objectives: Clearly outline the task's

objectives, expected outcomes, and potential
hazards.
2. Identify Potential Hazards: Discuss hazards specific
to the task, such as fall risks, hazardous materials,
or operating near utilities, and share recent near
misses or incidents if applicable to reinforce
learning.
3. Roles and Responsibilities: Ensure all team
members understand their roles, emergency
contacts, and reporting protocols.
4. PPE Requirements: Confirm that everyone has the
necessary personal protective equipment (PPE)
and understands how to use it properly.
5. Emergency Procedures: Review the emergency
action plan, including evacuation routes, assembly
points, and first aid availability.
 Inspection HSE Control Measures

1. Equipment Checks: Verify that equipment (tools,

machinery, PPE) is in good working order, with
pre-use inspections documented.
2. Site Conditions: Assess the site for any new
hazards, including slips, trips, falls, and weather-
related risks, and ensure housekeeping is
maintained.
3. Compliance with Procedures: Confirm compliance
with safety procedures, work permits, and any
specific control measures related to the task.
4. Communication Systems: Ensure communication
systems are functional, including radios or mobile
phones, especially in remote or noisy areas.
5. Record and Report Findings: Document any
observations, deficiencies, or required corrective
actions, and ensure that they are promptly
communicated and addressed.

• Missing PPE or tools • The PPE shall be job specific as per mentioned
in the JSA and considering
- Welding/Brazing: Fire-resistant clothing,
welding shields, gloves, respiratory
protection
- Refrigerant Handling: Chemical-resistant
gloves, gas detection monitors, emergency
eyewash availability
- Electrical Work: Insulated gloves, arc flash
protection if required
- Respirators for handling refrigerants or
insulation materials
 -
Fall protection (harness, lanyard, anchor
points) for working at heights above 1.8m
- Arc flash protection gear for electrical work
- Hand protection: cut resistant gloves as per
ANSI/ISEA 105
• Conduct a checklist to confirm all personnel
are equipped with required PPE (helmets,
gloves, goggles, etc.) and tools before starting.
• Distribute additional task specific PPE if
needed.
• Conduct regular inspections to ensure PPE is in
good condition.
• Ensue all workers know the purposes of their
PPE and how to use
• Inadequate hazard identification • HIT card to be discussed with all involved
persons for each task
• Encourage team members to report any
observed hazards immediately.
• HIT Revalidation to be conducted by HSE team
and supervisors.
2. Obtain Necessary Permit • Incomplete or inaccurate permit • Only trained and authorized PA and SS signed
documentation the work permit
• Ensure proper work permits obtained for
specific jobs and locations:
- Hot Work Permit (welding, brazing,
grinding, cutting)
- Lifting Permit (crane and boom truck
operations) – lifting plan for the loads
more than 10 tons as per approved
project lifting plan.
- Confined Space Permit (if working in
enclosed HVAC ducts or plant rooms)
 - Electrical Isolation Permit (for HVAC
electrical connections)
• Develop a checklist for permit requirements to
ensure accuracy and completeness.
• Implement a cross-verification step where
another supervisor or HSE representative
reviews the permit before work begins,
checking for accuracy and completeness.
• The PA / SS must conduct a joint site
inspection and discuss the potential hazards in
the area as per the PTW checklist.
• Lack of awareness of permit requirements • Post permit requirements and key PTW steps
in visible locations on-site, such as near work
zones or in break areas. Ensure these materials
are accessible and easy to understand.
• Maintain copies of relevant permits on-site for
easy access and reference.
• Ensure that all involved personnel are briefed
on permit conditions.
• Include PTW awareness in daily or weekly
toolbox talks, highlighting specific permits,
common errors, and critical points that need
attention before commencing work.
• Failure to follow conditions stated in the permit • Assign a designated individual to ensure that
all conditions of the permit are met
throughout the project.
• Perform regular checks during the task to
ensure compliance.
• Enforce accountability for permit adherence
among all team members.
 • Work permit revalidation must be conducted
daily and every shift, including the extended
hours
• Comply with the requirement listed in the
permit prior to the start of any work.
3. Initial Site Preparation and Survey • Slips, trips, and falls from uneven surfaces or • Level ground, remove obstacles, and ensure
obstructions adequate lighting.
• Demarcate and mark out hazards with warning
signs and tape.
• Limited visibility, especially during night work • Use floodlights in low-visibility areas
• Conduct pre-work risk assessments,
and require all personnel to wear high-visibility
vests.
4. Equipment Inspection and Setup (Forklift, • Equipment malfunction due to poor • Perform daily and pre-use equipment
Crane, Boom truck) maintenance inspections using a detailed checklist.
• Keep records of all maintenance and repairs.
• Limited visibility, especially during night work • Only certified operators should handle
equipment
• Use stabilizers and outriggers on cranes;
position equipment on stable ground.
• Trained and certified spotter and flagman to
assist the equipment setup
• Crane must be operating within the acceptable
wind speed limit of less than 10m/s
5. Lifting of Air-cooled Chillers by crane, boom • Incompetent operator and rigger • Operators & riggers to be certified by third
truck and forklift party and holding with valid certification.
• Operators and riggers must undergo ZP
specific training of the job.
• Hand injury • Keep hands out of pinch point while rigging.
Use hand gloves.
• Failure of rigging equipment’s • Know the weight to be lifted and its
configuration.
• Check weather condition and wind speed (low
or high)
• Emphasis more to stop work if they see
anything unsafe.
• Mechanical Failure • Ensure pre-inspection has been completed of
lifting equipment prior to lift.
• Checklist must be performed and accomplished
by competent operator and rigger.
• And it must be approved by the supervisor in
charge of the activity.
• Review load chart and ensure lift is within
capacity of crane, boom truck, forklift.
• Never leave equipment running and
unattended.
• Do not use cell phone while operating
equipment’s.
• Windows must be clear from any obstructions.
• Ensure the stability of soil. It should be
compacted.
• Dropped loads and rigging failure • Inspect all rigging equipment prior to use
• All lifting equipment must have third inspection
prior to use.
• Ensure proper rigging selection, sufficient size
and strength.
• Use acceptable rigging practices.
• Barricade the working radius of boom truck
operation. Place warning signage.
• Ensure lifted load is properly balanced.
• Stop lifting if the wind speed reach 32km/h and
poor visibility.
 • Refer to load chart and radius operation
• Certified rigger should be available to give signal
during lifting operation.
• Ensure operator cabin free from view
obstruction.
• Forklift fork place in the meddle of load.
• Ensure ground stable and firm enough for the
movement of equipment.
• Use tagline to control suspended load.
• Use softener pad to protect the sling.
6. Handling, Storage and transportation • Lack of handling knowledge • Before beginning any handling, ensure the
unit's manual, technical specifications, and
manufacturer’s instructions are reviewed.
• Always prioritize the manufacturer's safety
guidelines for lifting, transportation, and
storage.
• Equipment failure • Ensure that lifting equipment, like cranes,
forklifts, and slings, is rated for the
chiller/unit’s weight and dimensions. Double-
check that the equipment is in good working
condition.
• Inspection checklist to be filled by operator and
supervisor to ensure equipment with good
condition.
• Defective rigging equipment • When lifting or moving the chiller unit, use
slings, straps, and rigging that are rated for the
load. Follow the manufacturer's instructions on
lifting points and safe rigging techniques to
avoid damaging the chiller.
• Ensure all lifting tools inspected and approved
by third party.
• All chillers shall be off load one by one in
 temporary storage area near chiller yard.
• Ensure prior to lift the units make proper area
arrangements and plan.
• Follow manufacturer instruction during the
lifting & installation of chillers support.
7. Installation of AHU, Chillers/PACU, Chilled • Non-approved documents • All installation work will be carried out as per
water pump on foundation the approved HVAC IFC’s & shop drawing.
• All construction/inspection/testing works for
the chillers shall be carried out in accordance
with approved lifting plan & project
specification.
• Work shall be carried out by the site MEP staff
under the guidance of respective engineer and
shall further be checked and approved by
quality engineer.
• Check and ensure that utility building drawing
is approved by Company and same will be
available prior to start work at site.
• Mark the support locations as per approved
floor coordination drawings in the chiller’s
foundation slab.
• Heavy lifting • Conduct a site risk assessment to identify any
potential hazards (e.g., uneven ground,
electrical risks, environmental factors).
• Review Manufacturer's Instructions to ensure
proper installation methods and equipment
handling.
• Use a mobile crane or forklift rated for the
weight of the AHU, chiller/PACU, water pump.
• Ensure competent operator and rigger.
• Do not manually lift use mechanical equipment
for all heavy lifting.
 • Lift slowly and steadily to avoid sudden jerks or
movements that may damage the equipment
or cause injury.
• Clear the area of personnel and obstacles to
ensure safe lifting and maneuvering.
• Falling objects • Ensure that rigging (slings, chains, hooks) is
correctly secured to the designated lifting
points as per the manufacturer's instructions.
• Inspect all lifting equipment (e.g., cranes,
hoists) to ensure it is in good working
condition.
• Mark out safe zones and ensure that personnel
are kept clear of hazardous areas during heavy
lifting and installation.
• Electrical Hazards • Disconnect power sources before making
any electrical connections.
• Only qualified electricians should handle
electrical work.
• Ensure all electrical connections are in line
with national codes and manufacturer’s
instructions.
• Verify grounding of the unit to prevent
electric shock or short circuits.
• Inspect all cables for wear or damage
before installation.
• Ensure that the tools to be use is properly
inspected and tagged prior to use.
• Tools with damage or frayed wiring must not
be allowed to use and must be removed from
the worksite.
• Personnel Injuries • Ensure that all personnel wear appropriate PPE
hard hats, gloves, steel-toed boots, safety
glasses, hearing protection, and high-visibility
vests.
• Refrigerant Leaks • Ensure that refrigerant lines are properly
connected and tightened to prevent leaks.
• Check for leaks using a suitable detection
method (e.g., leak detectors, soapy water).
• Environmental Exposure • Follow environmental regulations for
handling and disposing of refrigerants.
• If using a refrigerant with high-pressure
systems, ensure that the unit is safely
pressurized as per guidelines.
• Slips, Trips, and Falls • Clear the work area of obstacles and ensure
the floor is level, dry, and clear of debris.
• Incorrect Alignment or Leveling • Ensure the foundation area is clean, dry, and
level to support the chiller/PACU unit.
• Confirm that the foundation or platform meets
weight-bearing requirements and is properly
aligned.
• Position the unit accurately on the foundation
or platform. Use measuring tools to verify that
the unit is centered and aligned.
• Ensure that the unit is placed in the correct
orientation (according to the manufacturer's
guidelines) for airflow, drainage, and
maintenance access.
• Ensure that the anchoring is tightened to the
recommended torque settings to avoid
instability during operation.
 • Double-check that the pump is correctly
aligned with the surrounding pipes and
equipment, and that there is enough clearance
for maintenance and future access.
• Ensure the pump is installed on a stable
foundation to prevent vibrations, which can
lead to mechanical failure or misalignment.
• Damage tools • Ensure tools (wrenches, screwdrivers, power
tools) are functional and rated for the task.
• Ensure all tools to be inspected and with color
cod.
• Isolate the defective tools to avoid use.
• Water leakage • When connecting piping, use pipe supports to
secure the pipes and prevent strain on the
pump flanges.
• Tighten all connections to the correct torque
specifications to avoid leaks.
• Inspect all gaskets and seals to ensure they are
properly seated and will prevent leaks when
the system is pressurized.
• Perform a leak test on the piping system by
pressurizing the chilled water circuit and
checking for any leaks at the connections.
8. Installation of split units • Electric Shock • Verify that the electrical panel is de-energized
and that no electrical work is conducted
without proper isolation.
• All power tools and cable ensure with good
condition free from damage and expose.
• Use appropriate PPE, especially electric
resistant hand gloves.
• Verify all connections are correct and tightened
to avoid faults or electrical fires.
• Improper copper pipe connection • Ensure that all refrigerant pipes are tight and
leak-free.
• Use thread sealant and ensure that
connections are properly tightened according
to manufacturer specifications.
• Sharp Edges • Use cut resistant hand gloves for the
protection against sharp edges.
• Falls from Height • Conduct a site-specific risk assessment to
identify potential fall hazards.
• Select appropriate equipment for the job,
including ladders, scaffolding, and fall
protection devices.
• Ensure that workers are equipped with a
personal fall arrest system (PFAS) when
working at heights (this includes a harness,
lanyard, and anchor point).
• Use safe, stable ladders rated for the weight of
the worker and equipment being carried.
Ensure that ladders are placed on stable, level
ground.
• Never overreach while on a ladder or
scaffold. Maintain three points of contact
at all times (e.g., two feet and one hand).
• Make sure that all anchor points used for fall
protection systems are stable, secure, and
capable of supporting the weight of the worker
in case of a fall (typically at least 5,000 pounds
of force per worker).
• Heavy weight • Use proper lifting equipment (e.g., cranes,
hoists, or forklifts) to safely position the
outdoor unit. Avoid manual lifting due to the
unit's weight.
 • Use of mechanical assistance wherever
possible, e.g., forklift, plant, lifting appliance
etc.
• Reduce loads by making them smaller or
lighter.
• Ensure the working environment is suitable
• Ensure that the individual is lifting correctly,
maintains good posture, and lifts with knees
bent and back kept straight.
• Ensure loads not greater than 23kg for one
person.
• Drop Object • Ensure that tools and materials are properly
secured to prevent them from falling from
height.
• Ensure the wall or ceiling where the unit will be
mounted can support the weight of the indoor
unit.
• Use proper mounting brackets and ensure they
are securely fixed. The unit must be leveled to
ensure proper drainage and airflow.
• Check that lifting mechanical equipment (e.g.,
hoists, forklifts, scaffold) is available and rated
for the weight of the indoor and outdoor units.
9. Installation of Refrigerant Copper Pipes • Cuts and Abrasions • Always wear cut-resistant gloves to protect
hands from sharp edges on copper pipes and
fittings.
• Flying object • Protect your eyes from debris, soldering flux,
and potential refrigerant leaks.
• Slip, Trip Hazard • Keep the work area organized, with materials,
tools, and equipment properly stored.
• Ensure all walkways are clear and well-lit.
 • Ensure workplace area free from wet and
scattered material.
• Damage and homemade tools • Always inspect tools before use to ensure they
are in good working condition. Look for cracks,
rust, missing parts, or any signs of wear that
could cause the tool to fail during use.
• If a tool is damaged or shows signs of wear,
repair or replace it immediately.
10. Installation of supports for the split unit and • Physical Strain and Injury Hand Injury • Use proper lifting techniques, and avoid lifting
pipes heavy objects alone—use lifting tools or team
assistance when necessary.
• Take regular breaks to prevent overexertion
and fatigue.
• Wear appropriate protective gear, including
gloves and sturdy footwear, to prevent hand
injuries or slips.
• If working at heights or in cramped spaces, use
ergonomic tools or supports to minimize strain.
• Falling Object • Ensure all material and tools secure while
working at height.
• Barricade the work at height activity area to
avoid unauthorized personnel entry and injury
from any fall object.
• Inadequate Support/Improper Installation • Follow the design specifications for the correct
type and placement of supports, ensuring they
are suitable for the type of pipe, weight, and
operating conditions.
• Double-check that pipe supports are securely
fastened to structural elements (walls, ceilings,
floors) and are level.
 • Falling from Heights • Always use proper fall protection equipment,
such as safety harnesses, guardrails, or
scaffolding.
• Ensure all ladders and scaffolds are stable,
properly secured, and have a safe working load
limit.
• Follow fall prevention protocols and ensure
workers are trained on using fall protection
systems.
• Ensure that the surface or structure where
scaffolding or ladders are placed is stable and
free from obstacles.
• Tools and Equipment Malfunction • Regularly inspect and maintain tools to ensure
they are in good working condition.
• Use the correct tool for the job (e.g., pipe
hangers, brackets, anchors, or fasteners) to
prevent tool-related accidents.
• Flying Object • Wear appropriate PPE (face shield, N95 mask
(if required) safety glass, hand gloves, safety
helmet, safety vest and shoes).
• Electrical Shock • Use insulated tools with inspection color cod.
• Ensure all electrical tools use without damage
and defect.
• Ensure all electrical sockets and plug with good
condition.
11. Marking, Labeling & Identification by spray • Eye\Skin-contact • Use proper gloves
paint • Use long-sleeved clothing.
• Use goggles.
• Provide eye wash stations nearby
• Keep a hard copy of the SDS if applicable in the
emergency station and working area
 • Respiratory irritation • Use exhaust ventilation where possible and
Ensure N95 masks are worn.
12. Brazing Joint and cutting • Burns from Heat • Always wear flame-resistant clothing, gloves,
and eye protection such as goggles or face
shields to protect from heat, splatter, and
radiation.
• Use insulated gloves and tools to handle hot
materials.
• Keep a fire extinguisher nearby in case of
sparks or accidental fire.
• Exposure to Harmful Fumes • Work in a well-ventilated area.
• Wear a respirator or a face mask to avoid
inhaling hazardous fumes if the ventilation is
inadequate.
• Ensure proper disposal of any waste materials
that might contain hazardous elements (such
as flux residues or metal dust).
• Explosion & Fire • Keep flammable materials away from the
brazing area.
• Store gas cylinders in a well-ventilated area
away from sources of heat, sparks, or open
flames.
• Keep cylinders upright and secure with proper
supports to avoid falling or rolling.
• Use appropriate regulators, valves, and hoses
that are compatible with the gas type and
pressure.
• Ensure that cylinders are properly labeled and
identified to prevent misuse.
• Avoid exposing cylinders to temperatures
above 50°C (122°F). If the cylinder becomes
overheated, it could rupture.
 • Never store gas cylinders near combustible
materials.
• Use fire-resistant blankets or barriers to
protect nearby surfaces.
• Keep a fire extinguisher nearby in case of
sparks or accidental fire.
• Assign fire watchman for the hot work activity
with appropriate fire emergency equipment
(water, sand, fire extinguisher, fire blanket etc.)
• Physical Injury from High-Pressure Gas • Always treat gas cylinders with care and handle
them gently to prevent damage to the valve or
cylinder.
• When cylinder is in use, it shall be placed in an
upright position in trolleys and secured by
chains to keep them from being knocked over.
• Compressed flammable gasses • Brazers must attend safety training regarding
using of compressed gas cylinder.
• Check the cylinder hoses from damages. Do
not use if damaged.
• Maintain the proper safe distance of gas
cylinder and building (6m away from the
building).
• Gauges/regulators must be in good condition.
Valve protection cap must be secured tight in
the cylinder if is not in use.
• Removed any flammable material from inside
the work area and keep the cylinder away
from any energized equipment or where there
is any ignition/spark & source of flames or
heat.
 • In transporting compressed gas cylinder,
tightly secured in an approved rack or
acceptable means of securing.
• Cylinders are not allowed inside buildings r
indoors. Ensure sufficient length of hoses.
• Flashback • Anti-flash back arrestor shall be installed at
the regulator end and the check valve at the
cutting torch end of each hose while in
operation.
• Injury from Hot Tools and Materials • Allow tools to cool down before handling them
after brazing.
• Use heat-resistant gloves and tongs when
handling hot parts.
• Ensure proper storage of tools in designated
areas to avoid accidental burns.
• Injury from sharp edges • Always deburr the cut pipe edges using a file or
deburring tool before handling.
• Wear heavy-duty gloves to protect hands from
sharp edges.
• Secure the pipe properly to prevent movement
while cutting.
• Ensure the cutting tool is sharp and in good
working order to avoid excessive force or
slippage.
• Flying Debris • Always wear safety goggles and a face
shield to protect against flying debris.
• Ensure the work area is clear of people or
other workers who may be exposed to flying
material.
• Use a protective apron or other clothing to
shield your body from debris.
 • Electric Shock • Always inspect electrical tools for defects
before use.
• Make sure cutting tools are properly grounded
and in good working condition.
• Explosion Risk with Gas Torches • Ensure that the pipe is empty of any gas,
liquid, or other flammable substances before
cutting.
• Always check for gas leaks in the torch before
use.
• Work in a well-ventilated area, and avoid
cutting near open flames, sparks, or electrical
sources.
• Awkward positioning • Maintain proper positioning is removing
obstructions, if awkward positioning inevitable
implement sufficient work breaks for
stretching and proper blood circulation to
body.

• Defective PPE • Ensure usage of good condition PPE as per

requirement of the job.
• Regular inspection conduct by the supervisor
to ensure safe to use.
13. Installation of Chilled water piping • Injury from Hand and Power Tools • Wear protective gloves to prevent hand
injuries and safety goggles or face shields to
protect the eyes from flying metal debris.
• Work in a clean, dry, and clutter-free area to
reduce tripping or tool accidents.
• Ensure that the tools to be use is properly
inspected and tagged prior to use. Tools with
damage or frayed wiring must not be allowed
to use and must be removed from the
worksite.
 • Falling from Heights • Always use proper fall protection equipment,
such as safety harnesses, guardrails, or
scaffolding.
• Ensure all ladders and scaffolds are stable,
properly secured, and have a safe working load
limit.
• Follow fall prevention protocols and ensure
workers are trained on using fall protection
systems.
• Ensure that the surface or structure where
scaffolding or ladders are placed is stable and
free from obstacles.
• Scattered material • Ensure material storage in proper way in
designated area.
• Access and workplace shall be free from slip
trip hazards.
• Storage of material in workplace with
minimum number to avoid obstruction.
• Provide barricade and sign board for the
material storage area.
14. Installation of support using by hand and • Electric Shock • Inspect all cables and plugs before use.
power tools • Ensure connections are protected from water
and moisture.
• Use only properly grounded machines and
keep electrical components away from water.
• Pinch point, Hand injury • Ensure that moving parts are adequately
guarded to prevent entanglement and
accidental contact.
• Use of heavy-duty gloves that provide padding
and cut resistance.
• Hand and wrist injuries • Wear gloves to protect your hands from
abrasions and vibrations, but avoid loose
gloves that could get caught in the drill.
• Maintain a stable stance and a firm grip on the
drill with both hands to reduce the risk of hand
strain and accidental injury.
• Defective or damage tools • Ensure that the tools to be use is properly
inspected and tagged prior to use. Tools with
damage or frayed wiring must not be allowed
to use and must be removed from the
worksite. Repair can only be done by an
authorized person with expertise to electrical
works
• Power tools must be properly guarded.
• Store tools securely when not in use. Don’t
leave hand tools lying around to cause a hazard
or be damaged. Return to store where
necessary.
• Eye injury • Use appropriate eye protection and provide
suitable welfare facilities for washing
immediately.
• Ensure proper distance away from other
workers in doing the job.
• Isolate the area by putting barriers and prevent
other workers to come near the activity.
• Place warning signs as precaution to other
workers.
• Incomplete work platform • Ensure that all work platforms are fully
constructed and have appropriate edge
protection, guardrails, and stable surfaces.
Use personal fall arrest systems (e.g.,
harnesses, lanyards) when working at
 height, especially if there’s any risk of
falling.
• Ensure that the work platform is equipped with
safe access points such as ladders or stairs.
• Always have a clear path for entry and exit, and
never use incomplete or makeshift access
methods.
• Use correct ladder if required for the light
work.
• Maintain three-point contact to avoid fall
down.
15. Threading and Grooving of chilled water pipe • Injury from equipment • Wear protective gloves to protect hands from
cuts.
• Use safety goggles or face shields to protect
from flying debris.
• Ensure all tools are in good condition and the
threading machine is properly maintained.
• Always wear protective gloves, safety goggles,
and hearing protection when using grooving
tools.
• Ensure that tools are securely fastened and
maintained.
• Metal Shavings and Debris • Always wear safety goggles or a face shield
when threading.
• Keep the work area clean and remove any
metal debris immediately.
• Strain and Fatigue • Take regular breaks to reduce muscle
fatigue.
• Use ergonomic tools and handle them
correctly to minimize physical strain.
• Tool Malfunction and Kickback • Inspect tools regularly for wear and tear.
Follow proper operating procedures and
ensure that the tool is securely positioned
before starting the grooving process.
• Before starting work, check that threading and
grooving tools are properly maintained and
sharp.

• Improper setup of equipment • Inspect all components for integrity before use
• Make sure that all parts are correctly
tightened, fastened, and locked into place.
• Perform routine inspections and maintenance.
• Provide barricade and safety sign board for the
workers awareness.
• Incompetent Operator • Ensure operator well trained and competent
for the operating of equipment.
• Follow the equipment manual book safety
instruction.
• Ergonomically hazards • Use of mechanical assistance wherever
possible, e.g., forklift, plant, lifting appliance
etc.
• Reduce loads by making them smaller or
lighter.
• Ensure the working environment is suitable
• Ensure that the individual is lifting correctly,
maintains good posture, and lifts with knees
bent and back kept straight.
• Ensure loads not greater than 23kg for one
person.
• Operatives must wear appropriate gloves.
 • Hand injury from rotating threads. • Wear gloves and don’t touch the rotating
threads.
• Use a steel brush or similar instrument to
clean the threads.
• Don’t wear loose clothing while operating the
threader.
• Keep your hand gloves away from rotating
pipe.
• Injury due to clothes catching on the threader. • Don’t wear loose clothing while operating the
threader.
• Keep your gloved hands away from the die and
the pipe.
16. Welding and Cutting Pipes and Supports • Eye injury due shuttering of grinding disc • Competent person must be the one who do
the job.
• Toolbox meeting shall be conducting by the
supervisor to all the worker and provide
awareness about the work.
• inspector before bringing and using on the
site. All power tools must be approved by
electrician.
• Cutting, grinding tools must have disc guard.
• Use only cutting disc for cutting and grinding
disc for grinding do not alter.
• Make sure that all welders, regardless of
experience level, wear the appropriate PPE.
This includes welding helmets, gloves, flame-
resistant clothing, respirators, safety boots,
and eye protection.
• Electrical shock • The assigned competent electrician must
inspect the portable power tools prior to use.
• All electrical cable must be above from the
ground 2-meter height.
 • Provide proper grounding of welding machine.
• All electrical connection shall be properly fixed
by competent person and free from damage.
• Transformer electric power cable shall be
secured place to avoid damaged.
• Fire, burns or Explosion • Fire extinguisher, fire blanket and fire watch
must be on the working area.
• Dry powder extinguisher to be at point of weld
and near welding machine.
• Fire blanket must be placed under welding,
burning operations to catch sparks and hot
metal.
• Provide trained and competent fire watchman
and for at least 30 minutes after the work
done of any portions of the work that involve a
potential source of ignition in the presence of
combustible material.
• Cylinders must be kept in upright position and
must be properly secured.
• Area should be free from combustible
material.
• Cylinders must have flashback arrestor.
• Use leather hand gloves only during hot
activities.
• Pinch point and Hand injury • All worker shall train by ZP regarding power
tools and hot work activities
• Only Competent person must do the welding
job.
• Area shall be barricade with red and white
tape, posted safety sign to keep unauthorized
person away from restricted area.
 • Inexperienced Workers • Supervise inexperienced welders closely,
especially during their early work. Provide
them with hands-on training and mentorship
from experienced professionals.
• Ensure only trained and third-party training
holder shall perform the welding job.
• Exposure to Fumes and Gases • Ensure that welders work in a well-ventilated
area and are provided with appropriate
respiratory protection like welding masks with
filters.
• Use local exhaust ventilation systems (LEV) or
fume extractors to minimize exposure to
hazardous fumes and gases.
• Improper Handling of Equipment • Ensure welders are properly trained on how to
handle and store welding equipment (welding
machine, cables, hose, torch, cylinders etc.)
safely.
• Use clear operational instructions and
checklists to guide welders in setting up and
using tools.
• Ensure equipment is in good working condition
and is regularly inspected for safety.
17. Insulation of Chilled Water / Refringent Pipes • Exposure to Hazardous Materials • Workers should wear protective gloves, safety
goggles, dust masks, or respirators to minimize
exposure to particles and fibers during
installation.
• Ensure the work area is well-ventilated or use
dust extraction systems to remove airborne
particles.
• Use long sleeves and pants to protect against
skin irritation caused by fiberglass or mineral
wool insulation.
• Cuts, Scrapes, and Pinch Points • Use cut-resistant gloves to protect hands from
sharp edges when handling pipes and
insulation.
• Ensure the work area is clear of obstacles and
workers are cautious of pinch points while
handling large sections of insulation or
equipment.
• Improper Handling & Storage • Ensure that insulation materials are stored in a
secure, dry area to prevent slips, trips, and
falls.
• Keep the workspace organized and free of
debris and obstructions.
• Insulation material storage in designated area
with barricade and safety signages.
• Do not left insulation waste material on the
workplace area to avoid flying insulation
particles in the air.
• Environmental pollution • Place the components and rags in a plastic
bag, seal or tie it and place it into a marked
plastic with the label lined prior to disposal in
the bin or skip.
• Clean up any spilled insulation material or
liquids immediately to maintain a safe work
environment.
• Properly dispose of waste materials, including
insulation offcuts, dust, and any potentially
hazardous materials, following environmental
and safety regulations as per approved waste
disposal plan.
• Use appropriate containers and methods for
disposal to prevent contamination or exposure
to harmful substances.
 • Damage Tools • Use only good condition tools (knife,
screwdriver, scissor, paint brush) with
inspection tag and color cod.
• Fall from Height • Always use proper fall protection equipment,
such as safety harnesses, guardrails, or
scaffolding.
• Ensure all ladders and scaffolds are stable,
properly secured, and have a safe working load
limit.
• Follow fall prevention protocols and ensure
workers are trained on using fall protection
systems.
• Ensure that the surface or structure where
scaffolding or ladders are placed is stable and
free from obstacles.
18. Manual handling of materials • Ergonomically hazards • Use of mechanical assistance wherever
possible, e.g., forklift, plant, lifting appliance
etc.
• Reduce loads by making them smaller or
lighter.
• Ensure the working environment is suitable
• Ensure that the individual is lifting correctly,
maintains good posture, and lifts with knees
bent and back kept straight.
• Ensure loads not greater than 23kg for one
person.
• Operatives must wear appropriate gloves.
19. Power and hand tools • Ergonomically hazards, Improper usage as per • Avoid executing the activity in awkward
design. position.
• Only competent workers will be allowed to use
the power tools.
• Use the correct tool, size and type for the job.
 • Use the equipment only to where it was
designed for.

• Fire • Work area must be free from the accumulation

of flammable/combustible materials and
assigned fire watch man.
• Ensure all power tools using with good
condition without damage.
• Personal Injury • Wear appropriate PPE as required.

• Electric shock • Ensure that the tools to be use is properly

inspected and tagged prior to use.
• Tools with damage or frayed wiring must not
be allowed to use and must be removed from
the worksite.
• Repair can only be done by an authorized
person with expertise to electrical works
• Power tools must be properly guarded.
• Poor storage of tools • Store tools securely when not in use.
• Don’t leave hand tools lying around to cause a
hazard or be damaged.
20. HVAC duct cutting and preparation • Injury from cutting tools (grinder, Hexa Blade) • Wear cut-resistant gloves, face shields, and
(cuts, abrasions) dust masks.
• Use tools with safety guards and ensure tools
are well-maintained.
• Sharp Edges of Ductwork • Wear heavy-duty gloves made of cut-resistant
material.
 • After cutting, use a metal file or deburring tool
to smooth the edges of the ductwork.

• Flying Debris and Metal Shards • Always wear safety goggles or face shields to
protect your eyes from flying debris.
• Ensure that the work area is clear of
unnecessary materials or people.
• Hearing Damage • Use ear protection, such as earplugs or
earmuffs, to protect your hearing from the
high noise levels.

• Tool Malfunctions • Inspect tools before use to ensure they are in

good working condition.
• Use the right tool for the job and maintain
them regularly.
• Electric Shock • Ensure that all tools are properly grounded
and check for any frayed wires or exposed
electrical components before use. Follow the
manufacturer’s instructions for safe operation.
• Falling Object • Ensure ducts are properly supported and
secured before handling.
• Use duct supports, straps, or hangers to
prevent falling.
•
• Musculoskeletal Injuries • Use proper lifting techniques—bend your
knees, not your back—when lifting heavy
materials. Consider using a team to lift larger
ducts or using lifting equipment (e.g., hoists).
• One worker only lifts the weight up to 23kg
only.
 • Fire Hazard • Keep the work area free of combustible
materials.
• Have a fire extinguisher nearby in case of an
emergency.
• If working in confined spaces, ensure proper
ventilation to avoid the buildup of flammable
gases.
21. HVAC Duct, grill, diffuser, MFSD, VCD, MVD, • Fall from heights • Ensure that the elevated working platform
BBD, hanger & support installation complies with the fall protection system and in
good condition.
• Guard rails must be complete and secured
clamped.
• Ladders must be properly inspected, in good
condition and use according to its design.
• Maintain 3 points contact.
• Ensure all workers will use full body harness
with two shock absorbing lanyard & 100% tie-
off while working at height.
• The Grills, Diffusers MFSD, VCD, MVD, BDD &
AD must be installed as per approved IFC’s &
shop drawing in a clean environment, free
from major airborne dust and civil work.

• Falling Objects. • Drop Zones shall be properly barricaded with

corresponding sign to avoid other workers
from entering
• A worker shall be assigned at ground level or
near drop zone to restrict other employee from
entering at work area.
• All material and tools hold properly.
• Heavy loads, improper repetition and awkward • Prevent awkward positioning such as
positioning overreaching & tilting by providing adequate
working platform.
• Wherever possible, a reduction in the amount
of heavy manual handling must be sought by
providing adequate mechanical means (e.g.,
jacks, hand trucks, rollers, wheelbarrows,
etc.,).
• Poor ventilation and low visibility inside • Ensure sufficient ventilation and illumination
buildings/facilities. by providing industrial fans and additional
lightings complying electrical safety
procedures. (minimum requirements of 50 lux
– general construction area lighting, 100 lux –
general construction plant and shops (e.g.,
mechanical and electrical equipment rooms,
30 lux – access ways).
• Hand injury • Wear gloves when handling any materials or
objects.
• Protect hands from sharp edges.

• Ergonomically hazards • Get a good footing and never try to lift

anything, which considered too heavy or too
bulky.
• Place the feet about shoulder width apart in a
comfortable, balanced position, close to the
load being lifted.
• Keep back straight – not vertical but straight.
It should not be arched or bent.
• Take a firm hold on the load with the palms of
the hands NOT just the fingers.
• Keep back as straight as possible, tucking chin
in to lock spine.
 • Do not twist the body or turn one of your feet
when lifting. If you have to change direction,
turn with both of your feet, not your body.
•
22. Installation of MFSD/VCD/MVD • Sharp Edges • Wear cut-resistant gloves and long sleeves;
deburr sharp edges after cutting.

• Heavy Lifting • Use proper lifting techniques, or use lifting

equipment; team up for heavy items.

• Personnel Injury from Tools • Inspect tools before use; wear protective gear
(gloves, goggles, hearing protection).
• Turn off power before working on electrical
components; use insulated tools.
• Wear safety glasses/face shield; keep the area
clear of unnecessary materials.
• Falling Object • Secure ductwork and dampers properly during
installation; use support brackets.

• Limited and confined Space • Ensure adequate ventilation; take breaks and
use proper personal safety equipment.
• Provide proper work platform for the task.
• All access must be free from obstruction.
• Ensure no presence of hazardous gasses.
23. Duct insulation • Inhalation of dust particles (Fiber glass wool) • All personnel working with insulation material
shall wear proper personal protective
equipment such as safety clear glass, face
masks,(N95) disposable cover all, etc., to avoid
inhaling dust particles and glass wool
penetration to the human skin.
 • Hazard communication briefing regarding the
important details including the hazards and
control measures of the material components
of the insulation to be use must be done with
the employees involve in the conduct of the
activity
• Chemical (Adhesives) • Chemical to be use in applying insulation such
as adhesives must have MSDS and must
inform the workers regarding the health
hazard it may affect them due to improper
usage. Such matters can be discussed in the
tool box meeting prior to commencement of
the activity.
• Use appropriate PPE like respiratory mask,
coverall, chemical gloves.
• Containers properly labeled and stored in
proper chemical storage area.
• Eyewash, spill kit and Firefighting equipment
should be available.
• Emergency contact number shall be posted on
the visible place.
24. Manual installation of duct, dumper, grill • Ergonomically hazards • Prevent awkward positioning such as
overreaching & tilting by providing adequate
working platform.

• Falling Objects • Drop Zones shall be properly barricaded with

corresponding sign to avoid other workers
from entering
• A worker shall be assigned at ground level or
near drop zone to restrict other employee from
entering at work area.
• All material and tools hold properly.
 • Fall of person • Arrange proper work platform for standing.
• Ensure fall protection system (safety harness,
guard rail).
• Ensure hundred percent tie off.
• Unstable ladder and platform • Ensure work platform inspected and in good
condition before use.
• Inspect the ladder for any cracks, bends, or
defects. Ensure that the rungs, steps, and rails
are in good condition.
• Set up the ladder on a flat, stable surface to
prevent tipping.
• Maintain three points of contact (two hands
and one foot, or two feet and one hand) for
balance.
• Ensure that the A-frame ladder is fully opened
and locked into place. Both sides should be
straight and secure.
25. Installation of Ventilation Fans • Heavy Lifting and Handling • Use proper lifting techniques (bend knees, not
back).
• Get help from another person for larger fans.
• Use a hoist or lifting equipment for heavy units.
• Sharp Edges • Wear heavy-duty gloves to protect hands from
sharp edges.
• Use protective clothing such as long sleeves.
• Smooth out sharp edges after cutting with a
deburring tool.
• Falling Tools or Equipment • Secure tools in a tool belt or pouch when
working at heights.
• Use a safety tether or lanyard for tools to
prevent dropping them.
• Ensure the work area is clear of tools when
working at height.
 • Use a stable ladder or scaffold when working
at height.

• Heavy Lifting • Use proper lifting techniques, or use lifting

equipment; team up for heavy items.
26. Out Doors Cladding Installation • Fall from Height • Use a sturdy ladder or scaffolding and ensure
it is on a stable surface.
• Wear a safety harness and fall protection
when working at heights.
• Ensure ladders are properly secured and
maintained.
• Do not overreach; always move the ladder to
the required position.

• Sharp Edges and Tools • Wear heavy-duty gloves and long sleeves to
protect hands and arms.
• Ensure all tools are in good working condition
with proper safety guards.
• Always use saws and cutting tools according to
the manufacturer’s instructions.

• Working in extreme weather conditions • Avoid working in adverse weather conditions

like heavy rain or strong winds.
• Protect the cladding materials from the high
wind and fly in the air.
• Stay hydrated and take frequent breaks in hot
conditions.
27. Erection & Dismantling of Scaffolding • Falling Objects • All tools shall be kept securely.
• Scaffold components will be lifted using safe
techniques (components will not be throw-up
to the scaffolder nor to the ground).
 • Drop Zones shall be properly barricaded with
corresponding sign to avoid other workers
from entering
• A worker shall be assigned at ground level or
near drop zone to restrict other employee
from entering at work area.
• Unsafe Access • Working platform and access must always be
maintained free of debris and tripping hazards.
• Unauthorized personnel will be excluded from
the area where scaffold erection is being
carried out.
• Overloading • Ensure that the scaffolding is able to withstand
4 times the maximum intended load it will
carry.
• Inadequate fall protection system • Fall protection system must be provided.
• Top rail, Mid-rail and Toe boards must be in
place and Personal Fall Arrest System (PFAS)
attached to a secured anchorage point must
be use by workers 1.8m above the ground.
Anchorage point must be able to withstand
5,000 pounds of force applied outward or
downward.
• Incomplete/unstable scaffold members, • Scaffold erection to be undertaken by trained
Defective and inadequate planking, uneven and certified scaffolders working under
ground and footings certified inspector.
• Inspection and tagging must be conducted
prior to usage of any scaffolding.
• Any gap of 2 feet elevation from ground to
access ladder of scaffolding, a step stool or
equivalent means must be provided.
 • Scaffolds must be leveled, rigid, plumb &
squared.
28. Clean-Up and Restoration • Environmental contamination from residual • Store hazardous materials in labeled containers
materials or solvents for proper disposal
• Conduct daily housekeeping and waste
disposal checks.
• Injuries from sharp pipe remnants or tools left • Require end-of-day clean-up for all work areas
on-site • Provide puncture-resistant disposal bags for
sharp objects and remnants
29. Work General Conditions\Weather • Environmental hazards such as Snake, bite, • Adequate shelter to be provided for workers to
Scorpion and reptiles, Sun Burn, Heat Stress take rest.
and dehydration, Sand storm • Sufficient quantity of cold drinking water to be
• made available always.
• Workers to be provide with dust mask.
30. Emergency Response • Life- saving knowledge not put into action. And • Sand storm shall be monitored in order to
Inadequate emergency response procedure or evaluate the stop of work when severe
Lack of communication device. weather condition.
• Ensure all people on site understand the action
required during emergency.
• Assembly areas shall be identified.
• Emergency contact numbers shall be posted on
prominent location.
• Ensure the availability of first aiders,
ambulance with driver as per ZP SHEMS
requirements.
• Ensure bravo or mobile phone is available on
site with supervision.
Prepared by: Reviewed by: (HSE Manager) Approved by: (Construction Manager)

Waheed Ahmad , Mohammed Zahid Mahmoud Abdel Aleem Imran Khan