Risk Assessment of Maintenance Activities
Hutchison Ports Jazan
Issue Date:
Document No: HPJZ- HSF-
Page 1 of 5
Department
Engineering
Location
Workshop
Assessment By
Activity
Modification of the 3 Pinning Station
Assessment Date
28-MAY-2025
Approved BY
Risk Assessment
No.
010-FMAM
Issuing Date
Reason of
Review
Date
Date of Reviews
Probability (Likelihood)
Risk Level
Determination 5x5
Matrix
Frequent
(5)
Moderate
(4)
Occasional
(3)
Remote
(2)
Unlikely
(1)
Color
Score
Date
Reason of
Review
Approval Date
Date
Reason of
Review
Date
Reason of
Review
Date
Reason of
Review
Outcome (Severity)
Critical (5)
Very Serious (4)
Serious (3)
Marginal (2)
Negligible (1)
25
High Priority
20
High Priority
15
Medium Priority
10
Review at appropriate time
5
Risk acceptable
20
High Priority
16
High Priority
12
Medium Priority
8
Review at appropriate time
4
Risk acceptable
15
Medium Priority
12
Medium Priority
9
Review at appropriate time
6
Risk acceptable
3
Risk acceptable
10
Review at appropriate time
8
Review at appropriate time
6
Risk acceptable
4
Risk acceptable
2
Risk acceptable
5
Risk acceptable
4
Risk acceptable
3
Risk acceptable
2
Risk acceptable
1
Risk acceptable
Risks
15 - 25
High
11 - 15
Medium
8 -10
Low
1-6
Risk Acceptable
Action
Operation not Permissible
Stop operation & review controls. If necessary, abort experimentation.
High priority remedial action
Proceed with extreme caution with PI present at all times. Implement additional (secondary) controls immediately. Review within 7 days. Emergency
control measures shall be in place.
Take remedial action at appropriate time
Proceed with care. Additional control is advised. Review shall be implemented within 30 days.
Risk acceptable: Residual risk
If possible, risk reduction should be further considered, particularly severity.
There are no imminent dangers. Frequent review shall be in place especially changes in procedures, materials, or environment.
Risk Assessment of Maintenance Activities
Hutchison Ports Jazan
Issue Date:
Document No: HPJZ- HSF-
Page 2 of 5
Summary of activities covered by this assessment:
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
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
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
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Summary of Equipment/Tools used:



Use of Powered Machinery and Machining Operations.
Surface preparation, welding, grinding, painting at pinning station.
Use of Handheld Portable Power Tools.
Use of Hand Tools.
Hot Work Processes.
Workplace and Working Environment.
Use of Electricity in the Workplace.
Fabrication.
Compressed Gas Cylinders.
Arc Welding machine, angle grinder, paint spray gun, manual tools (hammer, pliers).
Manual Hand Tools (ex: Hammer).
Risk Evaluation
Hazard
Who at risk
Risk
L S RL
Additional
Significant


Fumes from Welding
& Painting


Welders, Painters.
Supervisor
3
4
12
Medium
Priority








Fire due to
sparks/flammables

All Persons
4
5
20
High Priority



Correct guarding in place.
Authorized users only who are competent,
having had proper training.
No loose clothing or jewelry, long hair tied
back.
Use eye/face protection, and proper gloves.
TBTs.
Safety Induction.
Warning Signage.
Wearing job specific gloves.
Covering the risk during the TBT at the beginning
of each shift.
Fire extinguisher, remove combustibles, hot
work permit
Ensuring that all people attended the job
specific training
Manual handling assessment/training.
Risk Evaluation After
Controls
Risk
Significant
L S RL
Action by
1
4
4
Risk
Acceptable
Head of Safety
Task Supervisors
1
5
5
Risk
Acceptable
Head of Safety
Task Supervisor
Risk Assessment of Maintenance Activities
Hutchison Ports Jazan
Issue Date:
Grinder kickback or
disc burst
Electric shock
(tools, cables)
Eye injury
(grinding/welding)
Paint spray
inhalation/skin
contact
Document No: HPJZ- HSF-
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

Welders, helper
Supervisors
All Operators
Workers
Painters
4
4
4
3
Page 3 of 5
4
4
4
4
16
Review at
appropriate
time
8
Review at
appropriate
time
16
High Priority
12
Medium
Priority
Poor/Inadequate
Lighting

Welders
3
4
12
Medium
Priority
Exposure to dust
from material
being machined.


Welders
Supervisor
4
4
16
High Priority



Agree on a way of communication prior to the task.
Ensure that linguistic barriers are overcome.
Share the message of (Never-Assume) to the team
and ensure they understand it.
1
3
3
Risk
Acceptable
Head of Safety
Task Supervisors



Pre-use inspection
Earthing, dry conditions
PPE
1
4
4
Risk
Acceptable
Head of Safety
Task Supervisors


1
4
8
Review at
appropriate
time
Head of Safety
Task Supervisors

Use Eye/face shield
Ensure that all welders are physically ready for the
assigned tasks (not sleepy or drowsy).
Welding goggles

Skin barrier creams.
1
4
4
Risk
Acceptable
Head of Safety
Task Supervisors


Ensure that natural and artificial lighting is
provided to appropriate standards.
Covering the risk during the TBT at the beginning
of each shift.
1
4
4
Risk
Acceptable
Head of Safety
Task Supervisors



PPE.
TBT.
Installing Local Exhaust.
1
4
4
Risk
Acceptable
Head of Safety
Task Supervisors

Ensure that gas cylinders are securely stored in a
designated area.
Ensure that gas cylinder valves are turned off
when not in use.
Ensure that gas welding torches and hoses and
regularly checked and maintained to comply with
standards.
Covering the risk during the TBT at the beginning
of each shift.
PPE.
Safety Induction.
1
5
5
Risk
Acceptable
Head of Safety
Task Supervisors

Compressed Gasses



Welders, painter
Supervisor
Passer-by
3
5
15
Medium
Priority




Risk Assessment of Maintenance Activities
Hutchison Ports Jazan
Issue Date:
Electrical Shocks
Document No: HPJZ- HSF-

Welders
4
Page 4 of 5
4
16
High Priority

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












Open flames



Passer-by
Welders
Supervisors
4
5
20
High Priority




Materials with rough
surfaces and sharp
edges

Welders
3
4
12
Medium
Priority



PPE.
TBTs.
Safety Induction.
Check electrical cables.
Spark arrestor.
Earthing.
Supervision.
Remove combustible materials.
Firefighting extinguisher.
Good housekeeping
Provide fire watcher
TBTs.
Safety Induction.
Ensure that suitable tools for holding and
moving hot workpieces are provided and
used to prevent burns and fires.
Ensure that suitable welding shields and
goggles are supplied and used to protect the
eyes from flames and sparks during welding
and soldering activities.
Ensure that suitable fire-resistant overalls and
gloves are provided and used to protect the
skin against burns from hot surfaces, flames,
sparks, and UV radiation.
Ensure that working combustible materials
and waste are kept in covered containers.
Ensure that welding benches are constructed
from non-flammable and heat resistant
material to prevent fires.
Ensure that access to welding area is restricted
to authorized and qualified persons only.
Good Housekeeping
Use Proper PPE (gloves – long sleeve overalls)
Handle gently/carefully.
1
4
4
Risk
Acceptable
Head of Safety
Task Supervisors
Engineering
Manager
Head of Safety
Task Supervisors
Head of Safety
Task Supervisors
1
5
5
Risk
Acceptable
1
4
4
Risk
Acceptable
Risk Assessment of Maintenance Activities
Hutchison Ports Jazan
Issue Date:
Document No: HPJZ- HSF-
Page 5 of 5
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
Inadequate hygiene
arrangements

Welders
3
3
9
Review at
appropriate
time







Fire



Workers
Contractors
Visitors
4
5
20
High Priority






Maintenance
Activity on
Operational Areas

Welders
4
4
16
High Priority



Ensure that personal hygiene facilities such as
a sink, soap, and water are provided.
Ensure that toilet facilities are available
nearby and are kept sanitary.
Ensure that workers are provided with lockers
and a changing room.
Ensure that workers have access to a
common room for the consumption of food
and drink.
Ensure that workers have access to a clean
supply of drinking water.
Areas near welding activities are kept clear of
flammable materials.
CO2 fire extinguisher located in proximity –
test date < 12 months old.
Fire risk assessment undertaken as required
by law.
(If Any) Ensure that a full detection fire alarm
system is in place, maintained and tested in
accordance with fire regulations.
Ensure that there are adequate fire escape
routes that are cleared of obstructions.
Ensure that emergency lighting is provided.
Ensure that fire drills are performed regularly.
Ensure that fire extinguishers are accessible
at strategic points in the workshop and
properly maintained.
Ensure that workers are trained in the use of
fire extinguishers.
Ensure that all combustible waste materials
are disposed of on a daily basis.
Following PTW System procedures
Coordinating with operations duty manager
before proceeding with PTW.
Cordoning the area of work.
1
3
3
Risk
Acceptable
Head of Safety
Task Supervisors
Engineering
Manager
Head of Safety
Task Supervisors
Task Supervisors
2
5
10
Review at
appropriate
time
1
4
4
Risk
Acceptable