Equipment Installation and Commissioning HIRA (Hazard Identification and Risk Assessment)
Equipment installation and commissioning are critical phases in industrial, construction, and infrastructure projects. These stages involve positioning, assembling, aligning, connecting, testing, and activating machinery or systems. The work is often complex and requires coordination between multiple teams, including civil, mechanical, electrical, and instrumentation.
This process presents numerous hazards including moving equipment, working at height, electrical exposure, manual handling, and system failures. A structured HIRA is necessary to identify and control these risks before, during, and after the installation and commissioning process.
Objective of HIRA for Equipment Installation and Commissioning
- To systematically identify hazards associated with installation and commissioning tasks.
- To assess risks and assign appropriate control measures.
- To reduce equipment-related injuries, property damage, and commissioning failures.
- To ensure compliance with applicable safety, mechanical, and electrical standards.
Scope
This HIRA applies to:
- Installation of static and rotating equipment (e.g., pumps, compressors, HVAC units, generators)
- Electrical and instrumentation panel setup and integration
- Piping connection and alignment tasks
- Pre-commissioning and testing activities (dry and wet runs)
- Energization and live commissioning of systems
Step-by-Step HIRA for Equipment Installation and Commissioning
1. Activity Description
Installation, alignment, wiring, anchoring, testing, and commissioning of equipment or systems as per approved drawings and manufacturer specifications.
2. Hazard Identification Table
| S. No. | Hazard | Potential Effects | Persons at Risk |
|---|---|---|---|
| 1 | Uncontrolled movement of equipment | Crush injury, amputation | Workers, riggers |
| 2 | Fall from height during overhead work | Fractures, fatality | Technicians, supervisors |
| 3 | Electrical shock during connection/testing | Burns, cardiac arrest | Electricians, testers |
| 4 | Contact with moving parts | Finger/hand injury | Installers, testers |
| 5 | Manual handling of heavy components | Back strain, sprain | Helpers, technicians |
| 6 | Misalignment or improper anchoring | Equipment failure, vibration | Operations and maintenance crew |
| 7 | Hot testing/fluid leaks | Burns, slips, chemical exposure | Commissioning team |
| 8 | Pressure release during system testing | Injury from jet or pipe rupture | Mechanical crew |
| 9 | Improper tool usage | Cuts, tool breakage | Fitters, assistants |
| 10 | Fire due to short circuit | Burns, equipment damage | Electrical technicians |
3. Risk Assessment Matrix
Risk Rating = Likelihood (L) × Severity (S)
(Scale: 1–5 for both Likelihood and Severity)
| Hazard | L | S | Risk Rating | Risk Level |
|---|---|---|---|---|
| Equipment movement | 3 | 5 | 15 | High |
| Fall from height | 3 | 5 | 15 | High |
| Electrical shock | 2 | 5 | 10 | High |
| Contact with moving parts | 3 | 3 | 9 | Medium |
| Manual handling | 4 | 3 | 12 | High |
| Misalignment | 3 | 3 | 9 | Medium |
| Fluid leaks | 3 | 3 | 9 | Medium |
| Pressure release | 2 | 5 | 10 | High |
| Improper tools | 3 | 2 | 6 | Medium |
| Fire due to short circuit | 2 | 5 | 10 | High |
4. Control Measures
Engineering Controls:
- Use certified lifting tools, cranes, and slings.
- Install temporary platforms, railings, and ladders for elevated work.
- Use lockable power isolation panels and circuit breakers.
- Provide proper anchoring, baseplate alignment, and anti-vibration pads.
- Install pressure gauges, relief valves, and test ports for safe commissioning.
Administrative Controls:
- Prepare and approve Method Statement and Installation Plan.
- Issue Permit to Work (PTW) for electrical, height, and pressure-related work.
- Conduct pre-job briefing and Job Safety Analysis (JSA).
- Assign only qualified personnel for electrical, mechanical, and instrumentation tasks.
- Maintain toolbox talks and daily safety checks.
Personal Protective Equipment (PPE):
- Electrical-rated gloves, arc flash suit (for testing).
- Hard hats, safety glasses, and flame-resistant clothing.
- Safety shoes with anti-slip soles and steel toes.
- Hearing protection near noisy or rotating machinery.
- Full body harness for height work.
5. Safe Work Procedure (SWP)
Pre-Installation:
- Verify concrete foundation, grouting, and leveling.
- Check lifting equipment inspection certificates and SWL limits.
- Review manufacturer’s manuals and drawings.
- Isolate electrical and mechanical energy sources.
- Confirm availability of correct tools and torque wrenches.
During Installation:
- Maintain clear communication between lifting supervisor and operator.
- Avoid body positioning between suspended loads and fixed objects.
- Use calibrated tools for tightening bolts and couplings.
- Ensure proper alignment using dial gauges or laser alignment tools.
- Clean flanges and sealing surfaces before connecting piping or fittings.
During Commissioning:
- Use a checklist for all pre-commissioning and dry-run procedures.
- Apply lockout-tagout (LOTO) before energizing any panel.
- Conduct insulation resistance and continuity tests.
- Monitor all temperature, pressure, vibration, and RPM parameters.
- Use appropriate PPE and barriers during live testing.
6. Emergency Preparedness
- Fire extinguishers near live panels and commissioning zones.
- First aid kits and trained first responders on site.
- Eyewash stations and chemical spill kits for leak handling.
- Emergency shutdown switch for each equipment.
- Alarm systems for temperature, pressure, and electrical trips.
7. Roles and Responsibilities
| Role | Responsibility |
|---|---|
| Site Engineer | Approve installation layout and material verification |
| Safety Officer | Ensure JSA, PTW, and PPE compliance |
| Supervisor | Allocate manpower and enforce safe practices |
| Electrician | Perform panel termination and test connections |
| Mechanical Technician | Align and anchor static/rotating equipment |
| Instrument Technician | Calibrate and test control loops/sensors |
| Rigger | Conduct safe lifting and positioning of equipment |
| First Aider | Respond to any injury or emergency on-site |
Summary of Key Recommendations
- Prepare detailed procedures for both installation and commissioning.
- Use lifting plans and rigging tools appropriate for the equipment.
- Implement lockout/tagout procedures before energizing.
- Assign qualified technicians for electrical and instrumentation tasks.
- Provide structural checks before operating rotating or heavy units.
- Always use PPE and verify it is suited for specific operations.
- Maintain a commissioning checklist and logbook.
- Conduct trial runs and observe all parameters before handing over.
Monitoring and Review
- Daily pre-task briefings and post-task safety reviews.
- Weekly audits of electrical/mechanical safety compliance.
- Calibration and load testing of tools and devices used.
- Review near-miss reports and revise HIRA accordingly.
- Maintain records of installation approvals and commissioning certificates.
Conclusion
Equipment installation and commissioning are complex, multi-disciplinary processes that require detailed planning, skilled workforce, and rigorous safety protocols. A structured HIRA minimizes risks, avoids costly rework, and ensures smooth handover of operational systems.
By following best practices, enforcing control measures, and maintaining a collaborative safety culture, project teams can deliver installations that are safe, reliable, and efficient.
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