// Risk Assessment Template Health, Safety and Environmental

RISK ASSESSMENT RECORD

Risk Assessment Number: BKGC-KM-RA-015

CONTRACTOR: BKGC
BRIEF DESCRIPTION OF WORK/ACTIVITY: ISSUE BASE - Welding

LOCATION: Kurmuk DATE: 6-Mar-24

Revision Record: Rev 1 Rev 2 Rev 3

RISK ASSESSMENT REVIEW TEAM:
Initials & Surname Title/Appointment Signature Reviewed: YES NO
Work Team
Responsible Appointee
Contractors Supervisor Construction Manager:
Contractors SHE Officer Comments:
Competent Person
SHE Representative
Employee Representative
DRA
Abiathar Otoo DRA Discipline Supervisor
Bernard Kwarteng DRA SHE Co-ordinator

EXISTING CONTROL MEASURES: (SUBMIT & ATTACH TO RISK ASSESSMENT)

Available Adequate Changes Required
Remarks
Yes No Yes No Yes No
Procedures (SOP/SWP): Yes Yes No
Training: Yes Yes No
Code of Practice: No No No

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RISK ASSESSMENT DEVELOPMENT TEAM:

Initials & Surname Title/Appointment Employee/ID Number Signature

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L = Likelihood C = Consequence RR = Risk Rating Actions Completed

Date for
Risk Rating Responsible Person
No. List Activities of the Task List Hazards List the Associated Risks Preventative Controls Corrective Controls Improvement Actions Completion
L C RR Name
Clearing the work area Fire Flammable materials or vapors in * Secure hot work permit Possible Minor Low
the work area may lead to
* Remove flammable materials from the work
* personal injuries and property area or use flame-retardant barriers.
damage
* Store combustible materials in designated
areas away from welding operations.

* Use fire extinguishers and fire blankets in

easily accessible locations.

2 Inspection of tools and Mechanical (Fixed) * Equipment malfunction leading to * Conduct regular inspections of welding Possible Minor Low
equipment poor weld quality or injury equipment for signs of wear, damage, or
defects.

* Ensure proper grounding of welding

equipment to prevent electric shock hazards.

* Use equipment only for its intended purpose

and follow manufacturer guidelines for
maintenance.

3 Set up Thermal Overheating of the generator set * Monitor the temperature of the generator set Possible Minor Low
may lead to and shut it down if it overheats.

* Property damage * Ensure proper airflow around the generator

set to prevent overheating.

* Keep the generator set clean and free of

debris to maintain proper cooling.

4 Noise Noise hazards from the generator * Use hearing protection when working near the Possible Minor Low
set may lead to generator set.

* Tinnitus * Position the generator set as far away from

work areas as possible.

* Enclose the generator set in a soundproof

enclosure if feasible.

* Regular maintenance of the generator

5 Personal / Behaviour Incorrect selection or use of * Use the correct type and size of welding Possible Moderate Medium
welding consumables may lead to electrodes or wire for the welding process and
base material.
* Poor quality welding
* Store welding consumables in a dry, clean
environment to prevent contamination.

* Inspect welding consumables for damage or

defects before use and discard if necessary

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6 Personal / Behaviour * Improper equipment setup * Ensure the welding machine is placed on Possible Moderate Medium
leading to unstable operation stable ground and properly leveled.

* Use appropriate welding cables and

connectors, and inspect them for damage
before use.

* Follow the manufacturer's guidelines for

setting up the welding machine and ground
clamp.

7 Dust / Inhalable particulates * Inadequate ventilation leading to * Use local exhaust ventilation (LEV) or Possible Moderate Medium
exposure to welding fumes and mechanical ventilation to remove welding fumes
gases from the work area.

* Ensure the work area is well-ventilated with

natural airflow if LEV or mechanical ventilation
is not available.

* Use respiratory protective equipment (RPE)

such as respirators if ventilation is inadequate.

8 Selection of welding process Personal / Behaviour * Inadequate weld strength or * Consider factors such as material type, Possible Moderate Medium
and materials: quality due to incorrect welding thickness, and joint design when selecting a
process selection welding process.

* Consult welding procedure specifications

(WPS) or welding supervisors for guidance on
process selection.

* Conduct weld qualification tests if necessary

to ensure the selected process meets the
required standards.

9 Personal / Behaviour * Weld defects due to incorrect * Use welding procedure specifications (WPS) Possible Moderate Medium
welding parameters or settings or equipment manufacturer guidelines to set
correct parameters.

* Conduct pre-welding trials to optimize settings

and ensure proper weld quality.

* Provide training to welding operators on the

proper use of welding equipment and
parameters.

10 Personal / Behaviour * Incompatibility of welding * Ensure welding consumables (electrodes, Possible Moderate Medium
materials leading to weld defects wires, etc.) are compatible with base materials.
or failures
* Check material certificates and specifications
to verify compatibility.

* Store welding consumables according to

manufacturer guidelines to prevent
contamination or degradation.

11 Welding Operations Electrical * Electric shock from welding * Ensure welding equipment is properly Possible Moderate Medium
equipment grounded.

* Use insulated gloves and dry clothing when

handling welding equipment.

* Use ground fault circuit interrupters (GFCIs)

for added protection.

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12 Fire * Personal injuries and Property * Keep flammable materials away from the Possible Moderate Medium
damage welding area.

* Use fire-resistant barriers or blankets to

protect nearby combustibles.

* Have fire extinguishers readily available and

ensure workers are trained in their use.

13 Dust / Inhalable particulates Exposure to welding fumes and * Use local exhaust ventilation (LEV) to remove Possible Moderate Medium
gases leading to welding fumes from the work area.

* Metal Fume Fever * Use respiratory protective equipment (RPE)

such as respirators if ventilation is inadequate.

* Position the welding helmet to minimize

exposure to fumes and gases.

* Intermittent breaks

14 Radiation * Eye injury from welding arc * Use a welding helmet with a proper shade Possible Moderate Medium
radiation lens for the welding process.

* Ensure the helmet is in good condition and fits

securely.

* Use safety glasses with side shields for

additional protection.

* Welding screen should be provided to cover

all the welding arc

15 Thermal * Burns from hot metal or * Use insulated gloves and clothing to protect Possible Moderate Medium
equipment. against burns.

* Allow welded materials to cool before

handling.

* Use welding screens or barriers to protect

nearby workers from sparks and heat.

* Use task-specific gloves

16 Ergonomics * Ergonomic injuries from awkward * Use ergonomic welding equipment and Possible Moderate Medium
postures or repetitive motions accessories to reduce strain.

* Take regular breaks and stretch to prevent

fatigue.

* Provide training on proper lifting techniques

and workstation setup.

* Weld on suitable plateforms

17 Fire * Weld splatter causing burns or * Wear appropriate clothing and PPE to protect Possible Moderate Medium
fires. against splatter.

* Keep welding cables and hoses away from

the work area to prevent tripping hazards.

* Use welding curtains or blankets to contain

splatter.

* Ensure fire watchers are always available and

stop all activities if fire watcher is not around

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18 Quality Control Personal / Behaviour * Inadequate weld penetration or * Ensure welding parameters are set correctly Possible Moderate Medium
fusion leading to weak welds and within the WPS limits.

* Conduct visual inspection and non-destructive

testing (NDT) to verify weld quality.

* Provide training to welding operators on

proper welding techniques.

19 Personal / Behaviour * Weld discontinuities such as * Use proper welding techniques and Possible Moderate Medium
porosity, cracks, or lack of fusion. parameters to minimize discontinuities.

* Conduct pre-welding inspections to identify

potential issues.

* Implement corrective actions for any

discontinuities found during inspection.

20 Personal / Behaviour * Inadequate cleaning or * Follow proper cleaning and preparation Possible Moderate Medium
preparation of welds leading to procedures before welding.
defects.
* Use appropriate cleaning tools and materials
for the base material and welding process.

* Conduct visual inspections before and after

welding to ensure proper cleaning.

21 Personal / Behaviour * Inadequate documentation of * Maintain detailed records of welding Possible Moderate Medium
welding procedures and procedures, parameters, and inspection results.
inspections
* Use standardized forms and documentation
templates for consistency.

* Conduct regular audits of welding

documentation to ensure compliance with
standards.

22 Personal / Behaviour * Inadequate training of personnel * Provide comprehensive training on welding Possible Moderate Medium
involved in quality control standards, procedures, and inspection
techniques.

* Ensure personnel are qualified and certified

as required by relevant standards.

* Conduct regular refresher training to keep

personnel up to date with best practices.

23 Post-Welding Inspection and Personal / Behaviour * Inadequate inspection leading to * Conduct thorough visual inspections of welds Possible Moderate Medium
Cleanup undetected defects using proper lighting and magnification if
necessary.

* Use non-destructive testing (NDT) methods

such as ultrasonic testing or radiographic
testing to detect hidden defects.

* Ensure inspectors are trained and qualified to

perform inspections according to relevant
standards.

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24 Waste * Improper disposal of welding * Store welding residues in designated Possible Moderate Medium
residues leading to environmental containers and dispose of them according to
contamination. local regulations.

* Use environmentally friendly cleaning agents

where possible.

* Conduct regular inspections of cleanup areas

to ensure compliance with environmental
standards.

25 Thermal Exposure to hot surfaces or * Allow welded components to cool before Possible Moderate Medium
residual heat may lead to handling.

* Hand and finger injuries * Use insulated gloves and clothing to protect
against burns.

* Use thermal imaging cameras to identify hot

spots and ensure they are cool before cleanup.

26 Personal / Behaviour * Slips, trips, and falls during * Keep work areas clean and free of debris. Possible Moderate Medium
cleanup
* Use non-slip flooring or mats in areas where
water or welding residues are present.

* Provide adequate lighting and visibility to

reduce the risk of tripping hazards.

* Remove trailing cables from walk ways and

make sure they are well coiled

27 Fire * Property Damage * Ensure work areas are well inspected by the Possible Moderate Medium
supervisor after 30 minutes of any welding or
hot work activities

* Remove all combustible and flammable

materials from the work area

28 Not assessed
29 Not assessed
30 Not assessed
31 Not assessed
32 Not assessed
33 Not assessed
34 Not assessed
35 Not assessed

36 Not assessed
37 Not assessed
38 Not assessed

39 Not assessed

40 Not assessed

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Actions Completed
Responsible Person
Signature

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Typical Hazards/Energies
Hazard / Aspect Description

Biological Potential for positive or negative impacts resulting from interaction of activities with biological agents. This could be harm by exposure to biological hazards,
flora and fauna including insect stings, bites, bacteria and other disease agents, viruses and natural poisons or environmental harm to biodiversity.
Chemical Potential for harm by chemicals. Includes acids, alkalis, organic substances (eg. gases, fuels, lubes, degreasers, solvents, paints), ozone depleting
substances etc.
Climatic/ Natural Potential for harm by exposure to extreme natural , environmental or climatic sources and events (incl. lightening, high winds, flooding)
Events
Confined Spaces Potential for harm resulting from suffication due to working in/being trapped in a confined space.
Dust / Inhalable Potential for harm by exposure to fine dry particles of matter in the air. Dusts, mists, vapours and aerosols (coal dust, silica dust or environmental
particulates nuisance/community complaints)
Electrical Potential for harm to people, equipment/assets or the environment by exposure to electrical sources
Ergonomics Potential for exposure to physical actions or forces, including poor design, thus presenting the potential for harm associated with exertion, excessive,
unnatural or repetitive movement, poor posture or other undesired physical stress on the human body
Explosives Potential for harm by exposure to explosive materials (e.g. unexploded detonators, tie down lines etc.)
External Threats Potential for harm resulting from an external event outside of the operations direct control (e.g. legislation, government actions, community lobby groups,
Fire etc.)
Potential for harm by exposure to a burning mass of material (e.g. building fires, spontaneous combustion)
Gravitational Potential for harm by exposure to falling objects, unexpected movement (ground, slope, structures) due to uncontrolled gravitational forces
(Objects)
Gravitational (People) Potential for harm to people caused by their being subject to falling, unexpected movement or in any other way resulting from their being exposed to
uncontrolled gravitational forces (incl. slips, trips, falls)
Kinetic Kinetic energy is a form of energy that an object or a particle has by reason of its motion. If work, which transfers energy, is done on an object by applying a
net force, the object speeds up and thereby gains kinetic energy.
Land Potential harm on the naturally occurring environment due to the use or management of land resulting from pollution, clearance or any other degradation
Lighting Potential for harm resulting from excess light or inadequate lighting in the workplace
Mechanical (Fixed) Potential for harm by exposure to interaction with sources of fixed mechanical energy (including those powered be electrical, hydraulic, pneumatic,
combustion etc)
Mechanical (Mobile) Potential for harm by exposure to interaction with sources of mobile (self propelled) mechanical energy (including those powered be electrical, hydraulic,
pneumatic, combustion etc)
Magnetic Potential for harm to people, equipment/assets or the environment by exposure to magnetic sources (incl. handling metal objects in strong magnetic fields)
Noise Potential for harm by exposure to sudden or prolonged exposure to excessive noise or community complaints
Personal / Behaviour Potential for harm associated with intentional undesired behavioural actions, stresses or stressors
Pressure / Explosions Potential for harm by exposure to sudden release of pressure from a specific source (incl. pressure waves from explosions, pressurised systems, cylinders,
springs, chains, flying bits, or community complaints associated with air blast overpressure etc)
Psychological Potential for harm associated with stressors from situations, conditions or events that could create negative emotional, cognitive or behavioural outcomes
Radiation Potential for harm by exposure to radiation waves whether natural or manufactured sources (characterised as either ionising or non-ionising sources)
Social/ Cultural Potential for positive or negative impacts resulting from interaction of business' activities with social or cultural expectations includes social license to operate
Thermal Potential for harm by exposure to or variations in temperature (hot or cold) but excludes anything that is on fire which has a separate category
Vibration Potential for harm resulting from prolonged exposures to excessive vibration or blast vibration
Waste Potential for harm caused by the inappropriate use of resources, inadequate management or disposal of waste material (includes pollution and Green House
Gases)
Water Potential for harm caused by the inappropriate use of water resources or inappropriate management or disposal of water
Other Potential for harm by exposure to other hazard/aspects e.g. friction, bio-chemical
Other: Define Provide description
Other: Define Provide description
Other: Define Provide description
Other: Define Provide description
Other: Define Provide description
Other: Define Provide description
Other: Define Provide description
Other: Define Provide description
Other: Define Provide description
Other: Define Provide description
Other: Define Provide description

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DRA Standardized Risk Matrix

Every day Almost certain 5 Low Medium High Extreme Extreme
Probability/Likelihood

Once a month Likely 4 Low Medium High Extreme Extreme

Once a quarter Possible 3 Low Low Medium High Extreme

Once a year Unlikely 2 Low Low Medium High High

Once every ten

Rare 1 Low Low Low Medium High
years
Impact/Consequences
1 2 3 4 5
Description
Insignificant Minor Moderate Major Catastrophic

First-Aid case / Exposure to minor health Medical Treatment case / Exposure to Lost time injury / Reversible impact on Single fatality or loss of quality of life / Multiple fatalities / Impact on health
Impact on the Health and Safety of Personnel
risk major health risk health Irreversible impact on health ultimately fatal

Minimal environmental harm – Material environmental harm - remediable Serious environmental harm - remediable Major environmental harm - remediable Extreme environmental harm - Incident
Environmental Impact
Remediable within same shift over short term < 3 months within LOM post LOM irreversible

May result in overall project budget May result in overall project budget May result in overall project budget
Less than 1% impact on the budget of the May result in overall project budget
Financial Impact/ Property Damage overrun equal to or more than 1% and overrun of equal to or more than 5% and overrun of equal to or more than 20% and
project overrun of 50% or more
less than 5% less than 20% less than 50%

No disruption to operation Brief disruption on operation Partial shutdown Partial Loss of operation Substantial or total loss of operation
Business Interruption Less than 1% impact on overall project Between 1 and 5% impact on overall Between 5 and 20% impact on overall Between 20 and 50% impact on overall Over 50% impact on overall project
timeline project timeline project timeline project timeline timeline

Threat of minor litigation requiring private Single moderate litigation or numeorus Single major litigation or multiple
Single minor litigation Major multiple litigations
compensation minor litigation moderate litigation
Legal & Regulatory Breach of law subject to internal Breach of any law subject to significant
Unintentional breach of law subject to Breach of any law subject to minor Breach of any law subject to major
mediation penalties
internal remediation external remedial action/private disclosure external remedial action/public disclosure

Slight impact - public awareness may Considerable impact - regional public International impact - international public
Impact on Reputation / Social / Community Limited impact - local public concern National impact - national public concern
exist but no public concern concern attention

Extreme Cease activity immediately until the residual risk is reduced to an acceptable level
High Eliminate, avoid, implement specific action plans/procedures to manage & monitor daily
Medium Proactively manage & monitor weekly
Low Actively manage & monitor monthly

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