JOB SAFETY ANALYSIS (JSA)
ACTIVITY:
JSA Ref. No.
HYDROTESTING ABOVE GROUND PIPING JOUF BULK PLANT
Facility: AL JOUF BULK PLANT
Work Area / Equipment’s:
JSA / JOUF – M- 43 (REV : 01)
Date: 26 SEP 2021
ALL WORK LOCATIONS INSIDE JOUF BULK PLANT
v PERSONAL PROTECTIVE EQUIPMENT: Safety Glass, FRC, Safety Shoes, Hand Gloves, Fire Blanket, Hand Gloves,
TOOLS NEEDED FOR WORK ACTIVITIES: Test manifold, Calibrated torque wrench, mechanical pump unit, Manually operated pump, Air compressor, Test
hoses, Hose connector, Whip checks, manual tools.
JOB STEPS
1- Preparation
HAZARDS
1.1 Injury or property damage due to
inadequate resources.
HAZARD CONTROLS
1.1.1
A pressure test procedure shall be prepared by the responsible engineering group
and made available to responsible inspection group prior to conducting the test.
1.1.2 Ensure the loading rack is shutdown and isolation has been done and permit is
secured.
1.1.3 Before any test are carried out, PMT and plant O & M shall thoroughly inspect
equipment to ensure that appurtenances not adequate for the pressure test have been
isolated and the approved procedure is being followed.
1.1.4 Hydrotest activity shall be conducted as per GI 2.012, SAES-A-004.
1.1.5 Pressure gauges, relief valves and manifold shall be calibrated and tested.
1.1.6 Competent and experience engineer shall be available to supervise the task.
1.1.7 Ensure that the proper means of access and egress are available.
1.1.8 Ensure area is barricaded and signs “Hydrotest In Progress Do Not Enter” are
posted.
1.1.9 Ensure competent and certified fire watch, flagman and gas tester are present.
1.1.10 Joint walk through is to be conducted with PMT and Operation engineers prior
to start the work.
Page 1 of 12
JOB SAFETY ANALYSIS (JSA)
ACTIVITY:
HYDROTESTING ABOVE GROUND PIPING JOUF BULK PLANT
Facility: AL JOUF BULK PLANT
Work Area / Equipment’s:
JSA Ref. No.
JSA / JOUF – M- 43 (REV : 01)
Date: 26 SEP 2021
ALL WORK LOCATIONS INSIDE JOUF BULK PLANT
1.1.11 Approved method statement and IFC reference are available.
1.1.12 Toolbox talk to be conducted.
1.1.13 Saudi Aramco certified WPR shall obtain and maintain valid work permit/s as per
Saudi Aramco G.I 2.100.
1.1.14 All the equipment, rigging and hand tools are inspected and monthly color
coded.
1.1.15 Availability of blind shall be ensured.
1.1.16 Ensure all the operations/activity in the area of hydrotest has been suspended.
2- Internal Inspections
1.2 Injury or property damage due to
lack of communication.
1.2.1 TBT to be conducted for workers involved in the task as per approved MS & JSA.
1.2.2 Ensure that the Hydrotest activity is communicated to all the affected crews (i.e
tanker driver, plant maintenance workers, O & M employees and staff etc. )
2.1 Slip, Trip and Fall
2.1.1 Area shall be barricaded and warning signs to be installed to warn the workers.
2.1.2 Ensure the work area is kept clear of all obstructions.
2.1.3 Ensure all the sharp/protruding objects are identified and either eliminated or
protected.
2.1.4 Ensure that material and extra tools for the installation work are kept in the
area specified and barricaded.
2.1.5 Required PPE shall be worn all the time during the work.
3.1 Slip, trip and fall
2.1.6 Maintain good housekeeping all the time around the area of hydrotesting.
Page 2 of 12
JOB SAFETY ANALYSIS (JSA)
ACTIVITY:
JSA Ref. No.
HYDROTESTING ABOVE GROUND PIPING JOUF BULK PLANT
Facility: AL JOUF BULK PLANT
Work Area / Equipment’s:
JSA / JOUF – M- 43 (REV : 01)
Date: 26 SEP 2021
ALL WORK LOCATIONS INSIDE JOUF BULK PLANT
3- Water Filling & Venting
the System.
3.2 Manual handling
4- Pressurization
a. Bursting of Blinds / pipes / fittings
under pressure (Personal Injury due
to over Pressure.)
2.1.7
2.1.8
2.1.9
2.1.10
2.1.11
Use appropriate ladder while climbing on trailer.
Access shall be cleared and free from any obstruction.
Unwanted materials shall be removed from working area.
Slip resistant shoes must be worn all the time.
Trained and competent person will be allocated to the task.
2.1.12
2.1.13
2.1.14
2.1.15
2.1.16
2.1.17
2.1.18
Tool Box talk shall be conducted regarding hazards of the job.
Only experienced and qualified workers will do this activity.
Use of proper PPE’s.
Follow manual handling techniques and maintain proper body position.
No invented tools shall be used in the job.
Ensure sharp edges are eliminated and tools properly handled.
Pinch points shall be identified, marked and eliminated as much as possible.
4.1.1
4.1.2
Only experienced and competent personnel should conduct Hydro testing work.
Ensure blinds and fittings are of correct specification and properly tightened.
4.1.3 The system should never be pressurized above the test pressure specified by
support of the piping.
4.1.4 The test pump, if any, shall be located such that the pump operator will not be
4.1.5
exposed to danger in the event of a failure.
Only personnel involved with the test shall be allowed within the marked approach
barriers at any time during the test.
Page 3 of 12
JOB SAFETY ANALYSIS (JSA)
ACTIVITY:
HYDROTESTING ABOVE GROUND PIPING JOUF BULK PLANT
Facility: AL JOUF BULK PLANT
Work Area / Equipment’s:
JSA Ref. No.
JSA / JOUF – M- 43 (REV : 01)
Date: 26 SEP 2021
ALL WORK LOCATIONS INSIDE JOUF BULK PLANT
4.1.6 When hydrostatic testing is conducted, adequate precautions shall be taken
to protect personnel from the explosive nature of any failure. Ensure that
pressure gauges and relief valve to be used are properly calibrated and
should have valid calibration certificates.
4.1.7 Piping systems including equipment, while being tested using a mechanically
operated pump, shall be protected from over pressure by safety valve with
adequate capacity to relieve pressure at 5% above test pressure.
4.1.8 Ensure thorough inspection is done prior to the start of the job.
4.1.9 Air shall be removed from the system through vents at high points while the
system is filled at the low point.
4.1.10 The pressure rise during a pressure test shall be gradual and under control to allow
time for material to strain, and time for personnel to check for leaks.
4.1.11 Only after checking preliminary leaks at the above pressures, the pressure shall be
increased in steps with at least 10 minute holds at each step to permit inspection for
leaks and weaknesses.
4.1.12 The relief valves shall be tested, dated, and tagged.
4.2 Manual handling and poor
Ergonomic
4.2.1 Workers to be trained in manual handling and ergonomics.
4.2.2 Proper hand and body positioning to be maintained during the activity.
4.2.3 Overexertion shall not be done.
Page 4 of 12
JOB SAFETY ANALYSIS (JSA)
ACTIVITY:
JSA Ref. No.
HYDROTESTING ABOVE GROUND PIPING JOUF BULK PLANT
Facility: AL JOUF BULK PLANT
Work Area / Equipment’s:
JSA / JOUF – M- 43 (REV : 01)
Date: 26 SEP 2021
ALL WORK LOCATIONS INSIDE JOUF BULK PLANT
4.3 Use of hand tools.
5- Leak checking
5.1 Injury due to blind flange rupture
4.3.1 The ratchet spanner setting shall be done properly.
4.3.2 Right tool for the job to be used.
4.3.3 Avoid putting hand between the pipe flanges to during installation or
removal.
4.3.4 All the required PPE shall be provided. (i.e working gloves, safety goggles,
hard hat, FRC coverall, safety shoes and safety visor).
4.3.5 Pre job briefing shall be conducted prior to start the task.
4.3.6 No invented and modified tools are to be allowed on site.
4.3.7 All tools shall be inspected and color coded.
4.3.8 Trained and competent personnel shall be assigned the task.
5.1.1 Blanks/blind flanges, bolts and other test limits should be specified to withstand
the rated test pressure.
5.1.2 Personnel carrying out the test shall be provided with a safe place from which the
progress of the test can be observed and controlled.
5.2 Failure of gaskets
5.2.1 Gaskets to be used on flange connections be checked for defects/rating.
5.3 Release of high-pressure fluid
through defective weld joints and
flange
5.3.1 Proper PPEs shall be worn.
5.3.2 Only competent personnel shall do the job.
5.3.3 Extra precautions to be taken around joints and flanges when checking for
pressure leaks or defects to prevent injury to personnel. If in any case a flange
Page 5 of 12
JOB SAFETY ANALYSIS (JSA)
ACTIVITY:
JSA Ref. No.
HYDROTESTING ABOVE GROUND PIPING JOUF BULK PLANT
Facility: AL JOUF BULK PLANT
Work Area / Equipment’s:
JSA / JOUF – M- 43 (REV : 01)
Date: 26 SEP 2021
ALL WORK LOCATIONS INSIDE JOUF BULK PLANT
or other assemblies are found to be leaking during test, the piping shall first be
depressurized to zero before tightening the bolts.
6- Depressurize / Drain
the pipe.
6.1 Personnel Injury due to Release of
Pressure.
6.1.1 Extra precautions to be taken around joints and flanges when checking for
pressure leaks or defects to prevent injury to personnel. If in any case a flange
or other assemblies is found to be leaking during test, the piping system shall
first be depressurized to zero before tightening of bolts.
6.1.2 Wear proper PPEs.
6.1.3 The test system shall be emptied in such a way as not to cause vacuum and
collapse.
6.1.4 Don’t left the system unattended, the vent has to be kept open to prevent
temperature changes from causing an overpressure or vacuum.
6.1.5 Open valves and release pressure slowly as specified in the documents.
6.1.6 Drain out test medium in a controlled manner.
6.1.7 Leaking flanges to be rectified only after complete depressurization of the
system.
6.1.8 Depressurizing valve and piping shall be arranged for safe discharge of the test
medium upon completion of the test. Do not depressurize a system by loosening
bolts in a flange or by unscrewing fittings.
6.1.9 Use approved water drainage recommendations for draining on completion of
Hydrostatic test.
Page 6 of 12
JOB SAFETY ANALYSIS (JSA)
ACTIVITY:
HYDROTESTING ABOVE GROUND PIPING JOUF BULK PLANT
Facility: AL JOUF BULK PLANT
Work Area / Equipment’s:
JSA Ref. No.
JSA / JOUF – M- 43 (REV : 01)
Date: 26 SEP 2021
ALL WORK LOCATIONS INSIDE JOUF BULK PLANT
6.1.10 The bleed valve shall be readily accessible in case immediate depressurization is
required.
6.1.11 An isolation valve shall be provided between the pressure testing manifold and
the system being tested.
6.1.12 Before employing the pressure testing manifold in the actual system pressure
test, it shall be separately pressure tested to at least 1.2 times the system test
pressure but not less than the discharge pressure of the pump used for the
pressure testing.
6.2 Slip, trip and fall
6.2.1 Refer to 2.1
6.3 Falling Objects.
6.3.1 Ensure all tools are kept in tools Bags or Baskets.
6.3.2 Observe good housekeeping.
6.4 Temporary vents and drain
6.4.1 Vents shall be provided at all high points in the tested system as needed.
6.4.2 Adequate drains shall be provided at all low points in the system
6.5 Failure of flanges and temporary
supports
6.5.1 These supports shall not be removed until after the system has been fully drained.
6.5.2 The structural support system for stacked equipment shall be verified for hydrostatic
loads prior to testing.
6.5.3 Suitable blinds shall be installed to isolate the system to be tested.
Page 7 of 12
JOB SAFETY ANALYSIS (JSA)
ACTIVITY:
HYDROTESTING ABOVE GROUND PIPING JOUF BULK PLANT
Facility: AL JOUF BULK PLANT
Work Area / Equipment’s:
JSA Ref. No.
JSA / JOUF – M- 43 (REV : 01)
Date: 26 SEP 2021
ALL WORK LOCATIONS INSIDE JOUF BULK PLANT
7- Disconnect Fittings /
Hoses
8- Working on Scaffold
6.6 Manual handling Injury.
6.6.1 Refer to 3.2
7.1 Falling Objects.
7.1.1 Ensure all tools are kept in tools Bags or Basket.
7.1.2 Good House Keeping (a place for everything and everything in its place always)
7.2 Slip, trip and fall
7.2.1 Refer to 2.1
7.3 Manual handling Injury.
7.3.1 Refer to 3.2
7.4 scaffolding failure.
7.1.1 Saudi Aramco certified Scaffold supervisor shall inspect the scaffold.
7.1.2 Scaffolding should be of SA approved material and installation.
7.1.3 Any modification to scaffold to be done by certified scaffold craftsmen under
the supervision of SA approved scaffolding supervisor.
7.1.4 No scaffold used with the sign of damage and repaint.
7.1.5 Scaffold to be loaded as per scaffold duty classification.
7.1.6 Scaffolding erection shall be strictly in accordance to G.I 8.001.
7.4.1 Scaffold shall be used only for allowed load rating.
7.5 Falling of tools and material.
7.1.7 The toe boards shall be ensured in the scaffolding.
7.1.8 Keep the material/tool at safety distance from the edges of working platform.
7.1.9 Safe mean of access shall be provided for the scaffold.
Page 8 of 12
JOB SAFETY ANALYSIS (JSA)
ACTIVITY:
HYDROTESTING ABOVE GROUND PIPING JOUF BULK PLANT
Facility: AL JOUF BULK PLANT
Work Area / Equipment’s:
JSA Ref. No.
JSA / JOUF – M- 43 (REV : 01)
Date: 26 SEP 2021
ALL WORK LOCATIONS INSIDE JOUF BULK PLANT
7.1.10 No tools and material shall be with the worker when climbing the ladder. An
approved bucket or any container shall be used and be lifted above with the use
of rope and tag line.
7.1.11 Barricade to a safe distance within working radius shall be in placed to avoid the
entry of non-related personnel to the job.
7.1.12 No loose materials shall be allowed to place on height.
7.1.13 All tools and materials whenever practicable shall be secured in a container and
container is secured.
7.1.14 No tools and materials will be left on height unattended; everything shall be
brought down before quitting time.
7.1.15 Area to be barricaded to prevent un authorized entry and signs to be installed.
7.5.1 No one should stay/rest under the ongoing installation work or under the
scaffold.
7.6 Falling from height.
7.1.16 Use scaffolding that is in good condition and is of adequate capacity for load
7.1.17 Working crews on top of the platform with 1.8 meters must be protected with
Fall Body Harness and Lanyards.
7.1.18 Emphasize the 3 points contact when moving along the ladder.
7.1.19 Emphasize the provision of lifelines should hook up point is concern. The work
location should be studied where workers would hook up their lanyard,
otherwise lifeline is required.
Page 9 of 12
JOB SAFETY ANALYSIS (JSA)
ACTIVITY:
JSA Ref. No.
HYDROTESTING ABOVE GROUND PIPING JOUF BULK PLANT
Facility: AL JOUF BULK PLANT
Work Area / Equipment’s:
JSA / JOUF – M- 43 (REV : 01)
Date: 26 SEP 2021
ALL WORK LOCATIONS INSIDE JOUF BULK PLANT
7.1.20 Emphasize the standard ladder placement and dimensioning, degree within the
wall and extension above platform.
7.6.1 Strict compliance to using of SA approved body harness and double lanyards
9- Housekeeping and final 8.1 Slip, trip and fall
site cleaning
8.2 Cuts and laceration due to sharp
objects.
Housekeeping should be on-going at all times during work. The area shall be kept
cleaned all the time and all unwanted materials to be removed immediately.
8.1.2 Remove all equipment used in the test from the worksite.
8.1.3 Remove the barricades after the test is over.
8.1.4 Get the permit closed after making the site clean and tidy.
8.1.5 All surrounding materials shall be cleared properly.
8.1.6 All the tools, pipe pieces etc. shall be removed.
8.1.7 Safety access and egress to be maintained.
8.1.8 All the material shall be properly managed.
8.1.9 Secure any loose material in bag or container.
8.1.10 Keep material in the designated area, barricade and install signages.
8.1.1
8.2.1
8.2.2
8.2.3
8.2.4
Proper hand gloves shall be used.
The workers shall be informed regarding the Hand Injury Prevention.
Wear Safety shoes and all the required PPE.
Once the test is completed, do not leave the test system unattended.
Page 10 of 12
5HY
ALL WORK LOCATIONS INSIDE JOUF BULK PLANT