JSA23 Hydro Static Pressure Testing Various Pipe Auxiliaries

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 JOB SAFETY ANALYSIS WORK SHEET

 JOB SAFETY ANALYSIS WORK SHEET

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_Contractor:

_Contractor:

Contract No/ BI. No.:

Contract No/ BI. No.:

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CONTRACTOR Site

CONTRACTOR Site

Supv./ Frmn.

Supv./ Frmn.

CONTRACTOR Engineer

CONTRACTOR Engineer

CONTRACTOR Site

CONTRACTOR Site

Safety Supervisor

Safety Supervisor

SAPMT Safety Advisor

SAPMT Safety Advisor

SAPMT Representative

SAPMT Representative

DESCRIPTION OF TASK:

DESCRIPTION OF TASK: Hydrostatic Pressure Testing of MGS Filter Station Various Pipe Auxiliaries

Hydrostatic Pressure Testing of MGS Filter Station Various Pipe Auxiliaries

Work Location/

Work Location/ (Area then station numbers):

(Area then station numbers):

Prepared by/ Signature:

Prepared by/ Signature:

(Contractor)

(Contractor)

________________

________________

Project

Project Engineer Engineer SignatureSignature

________________

________________

HSE

HSE Supervisor Supervisor SignatureSignature

Reviewed By/ Signature:

Reviewed By/ Signature:

(SAPMT)

(SAPMT)

_____________

_____________

Safety

Safety Advisor Advisor SignatureSignature

_____________

_____________

SAPMT

SAPMT Supt. Supt. SignatureSignature

Reviewed By/ Signature:

Reviewed By/ Signature:

(LPD)

(LPD)

___________

___________

Loss

Loss Prevention Prevention SignatureSignature Representative

Representative

Approved By/ Signature:

Approved By/ Signature:

(Client)

(Client)

______________

______________

Lead

Lead Proj. Proj. Engr. Engr. SignatureSignature

Operation

Operation Rep.

Rep. ___________

______________

___

Signature Signature Revised Revised New New

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Reference GIs & SAES:

Work Permit GI. 2.100, Gas Testing Procedure using 3 in 1 Gas Monitor G.I. 2.709, Traffic and Vehicle Safety G.I. 6.030, Mobile Heavy Equipment Operator Testing and Certification G.I. 7.025, Crane Lifts: Types and Procedures G.I. 7.028, Inspection and Testing of Requirements of Elevating/Lifting Equipment G.I. 7.030, Fire Fighting Training Company Personnel G.I. 1783.001, Safety Spectacles G.I. 8.002, Protective (Safety) Footwear G.I. 8.005, Environmental Conservation Policy Implementation G.I. 2.714, Isolation, Lock Out and Use of Hold Tags G.I. 6.012, Safety Requirements for Scaffolds G.I. 8.001, Pressure Testing Safely G.I. 0002.102, General Requirements for Pressure Testing 004, Pressure Testing of Plant Piping and Pipelines SAES-L-150, Safety Instruction Sheet SAES-A-005, Hydrostatic Testing Fluids and Lay-up Procedure SAES-A-007, Disposal of Waste Water from Cleaning, Flushing and Hydrostatic Test SAEP-327, Pressure  Testing Saudi Aramco Construction Safety Manual Section III-V-3, Emergency Procedures Saudi Aramco Construction Safety Manual Section I-5

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SEQUENCE/ BASIC STEPS

POTENTIAL

_HAZARDS

HAZARD CONTROLS

ACTION BY  

1 1. Preliminary site inspection • Injury/Incident due to

work not being carried out safely.

• Permit Issuer and Receiver to conduct joint site

inspection to discuss the hazards and precautions required for conducting the job safely.

• Ensure no work is conducted in this area until signed

permits to work are in place.(GI- 2-100, GI-2-709)

• Ensure tool box meeting is conducted prior to start of 

work

1

2

2. Emergency evacuation • Panic

• Miscommunication

• Indentify the assembly area and put signboards • Provide full orientation on Emergency Procedure. • Post SA emergency NO.110 around work area. • Mobile phone with Supervisors & Safety personnel at

site.

CONTRACTOR/ Operation SAPMT(follow-up)

3. Movement of vehicle and construction equipment (pick up , water tanker, bus etc)

•  Traffic/safety hazard to

other users in the area

• Vehicle/equipment

collision

• Contact with personnel.

• Sign boards to be posted. Site speed restrictions to be

observed (40kmph)

• Spotters to control equipment and traffic.

• All drivers/operators shall have the necessary licenses

and certificates.

• All operators/drivers advised via TBT of driving safety. • Designated parking areas.

• (GI- 006- 030)

3

4. Check equipment • Personnel injury • Daily check of all tools & equipment prior to start of 

 job.

• Communicate defects found in equipments and

organise for replacements so that defective equipment is never used.

•  Tag the defective tools as “Do not use”.

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1. Hydro test preparation _{• Personal injury} • Conduct tool box talk with the team. • Barricade the area and sign board. • Limit entry for authorized personnel.

• Ensure the tools and equipment is free from defects. • Ensure the measuring and monitoring devices are

having valid calibration.

• Ensure the pumps, hoses, spades and gasket are

suitable for the pressure rating(GI- 2-102)

• Pressure tests the equipment prior to putting in

service.

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2. Hydro testing  Failure of joints  Failure of pipe  Personal injury  Damage to property

• (Refer toGI- 2-102, SAES-A-004, SAES-L-150)

•  The test procedure to be reviewed and approved by

Inspection/SAPMT.

• During water filling vent the line from the highest

elevation point.

• Raise the pressure gradually. Pressurization shall not

exceed 2bar/min.

• Ensure the pressure relieving device is set at

maximum allowable pressure for weakest portion of  the segment to be hydro-tested.

• Never increase the hydro-test pressure more than the

maximum allowable pressure for the weakest portion in the segment or pressure rating of the hose & coupling.

• Keep away from the pressurized segment of the

system being hydro-tested.

• Monitor the pressure gauge from a safe distance away

from the potential source of high pressure jetting (Such as Flange Joint, Spade, and Coupling etc.)

• Support the system adequately to withstand the

pressure and weight.

• Conduct a low pressure leak test before pressure test. • Do not work or strike on the line to stop leakage while

it is under pressure.

• Ensure the workers are wearing Appropriate

PPE.

• Do not leave the pressurized hose or pump unattended

when the hydro-test is going on.

• Isolate the equipment from all source of energy when

not in use.

• Do not change (exceed / decrease) the duration of 

hydro-test without permission from I nspection

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Engineer.

• Ensure that anEmergency Repair Kit is readily

available incase of any leaks. 3. Depressurizing and housekeeping  Injury from high pressure

 jets

 Slips trips and falls  Damage to environment

• Ensure the depressurization is done at a safe and slow

rate.

• Do not depressurize by loosening flanges; use the

depressurizing valves and piping.

• Dispose the test fluid as perSAEP 327

• All accessories and equipments to be disconnected

and stored.

• Hoses and cables to be kept away from walkway • Clean the spillage

• Barricades and warning signs for slippery areas

CONTRACTOR

#

Recommendations/Notes

Assigned

to

Mobile

Phone

#

1 All site personnel are required to wear PPE/ such as safety helmet, safety glasses, gloves, and safety shoes.

CONTRACTOR/ Operation & SAPMT

2 Conduct Tool Box Safety Meeting prior to every work activity. CONTRACTOR Safety Officer & Foremen

3 Explain to key personnel the purpose of the JSA and enforce the implementation of content. CONTRACTOR Project Engineer

4 Use the JSA to identify hazards and list the precautions on the work permit. CONTRACTOR / Operation 5 Garbage’s shall be disposed properly on a daily basis. CONTRACTOR Safety Officer

& Foremen 6 If an injury or near miss occurs, the JSA shall be reviewed immediately to determine

whether changes are needed in the job procedures.

CONTRACTOR Safety Supervisor 7.

Incase of any emergencies, the Project Emergency Response Plan / Procedure shall be followed by ALL affected personnel and a Certified First Aider and Ambulance shall be readily available.

CONTRACTOR Project Engineer EMERGENCY RESPONSE PROCEDURE

In an EMERGENCY, or on hearing the “Stop Work Alarm”, every supervisor shall ensure the following:

1. ALL work is stopped at once. 2. ALL Equipment is shut down.

3. ALL personnel are evacuated to the

pre-EMERGENCY CONTACT NUMBERS: Inside Saudi Aramco EMERGENCY  Dial

1.

When reporting an emergency give the clear information’s such as:

1. Your exact location. 2. Nature of emergency.

3. Service required and repeat the message. 4. Your name & badge number.

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determined assembly area.

4. A roll call is taken and every man is accounted for.

5. No one is permitted to return to work until notification has been received from operations or from the company representative that it is safe to do so.

2.

Stay on the telephone until you are told to hang-up. If possible, post a lookout to direct the ambulance, fire truck or helicopter to the right location.