Job Safety Analysis
DATE:
JSA Number
22 / 05 / 2024
Main Contractor:
H.K.AL SADIQ SONS CO
HKSS-APOC-HSE-JSA-006
Rev : 01
Job Safety Analysis By
Name
ID # (if any)
Main Contractor Construction (HKSS)
Arun Ravindran
056 423 9154
Main Contractor HSE (HKSS)
Arunkumar S
059 763 1724
DESCRIPTION OF TASK:
Hydro Test
WORK LOCATION:
APOC ( METERING AREA) / SAMSUNG PR 1951
Required Tools:
Phone #
REQUIRED SAFETY EQUIPMENT
Test manifold, Calibrated torque wrench, mechanical pump unit,
Manually operated pump, Air compressor, Test hoses, Hose
connector, Whip checks, and manual tools.
1. Required to wear proper PPE, FRC, Safety shoes, Helmet, Glasses, hand gloves
(where applicable), ear plug/ muffs, high-visibility vest, dust mask.
2. Barricades, Sign Boards, warning sign, (fire watch man, standby man, and
fire extinguishers where applicable)
Prepared by (HKSS):
Reviewed by (HKSS):
Approved by (HKSS):
Arunkumar (HSE Lead)
Arun Ravindran (Construction
Manager)
Afeef Rasheed (Project Manager)
Signature
Signature
Signature
DOC NO.: HKSS-APOC-HSE-JSA-006
Approved by (APOC):
Signature
Page 1 of 15
Job Safety Analysis
S/N SEQUENCE OF JOB STEPS
POTENTIAL HAZARDS
1.1 Inadequate resources
01 Preparation
HAZARDS CONTROLS
1.1.1
1.1.2
1.1.3
1.1.4
1.1.5
1.1.6
1.1.7
A pressure test procedure shall be
prepared by the responsible engineering
group and made available to responsible
inspection group prior to conducting the
test.
Ensure the loading rack is shut down and
isolation has been done and permit is
secured.
ACTION BY
Permit Issuer/Receiver
Site Engineer/CM/ Site
Supervisor/HSEO
Pressure gauges, relief valves and manifold
shall be calibrated and tested.
Competent and experience engineer shall
be available to supervise the task.
Ensure that the proper means of access
and egress are available.
Ensure area is barricaded and signs
“Hydro test In Progress Do Not Enter”
are posted.
Ensure competent and certified fire watch,
flagman and gas tester are present.
1.1.8
Approved method statement and IFC
reference are available.
1.1.9 Toolbox talk to be conducted.
1.1.10 Ensure all the operations/activity in the
area of hydro test has been suspended
DOC NO.: HKSS-APOC-HSE-JSA-006
1.1.11 coded.
1.1.12
Page 2 of 15
1.1.11 All the equipment, rigging and hand
tools are inspected and monthly color
coded
1.2 Lack of communication
02
Internal Inspections
2.1 Slip, Trip and Fall
03
Preparation of spool
(Blinding, De blinding and
Bolt torqueing Using Hand
tools)
3.1 Defective hand tools
1.2.1 TBT to be conducted for workers involved
in the task as per approved MS & JSA.
1.2.2 Ensure that the Hydro test activity is
communicated to all the affected crews.
Permit Issuer/Receiver/ Site
Engineer/CM/ Site
Supervisor/HSEO
Permit Issuer/Receiver/ Site
2.1.1 Area shall be barricaded and warning signs
Engineer/CM/ Site
1.2.3 to be installed to warn the workers.
Supervisor/HSEO
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 All hand tools shall be inspected by the
Permit Issuer/Receiver/ Site
3.1.1
Engineer/CM/ Site
competent person prior to use.
Supervisor/HSEO
3.1.2 Users shall inspect their hand tools before
and after each use.
3.1.3 Defective hand tools shall be
immediately removed or replace.
3.1.4 Hand tools constructed of good quality
materials shall be used.
3.1.5 Use of “homemade” tools is prohibited.
3.1.6 After using the hand tools, users shall place to
the designated storage area or rack.
DOC NO.: HKSS-APOC-HSE-JSA-006
Page 3 of 15
3.2 Bolt torch machine failure
3.2.1 Bolt torqueing machine shall be inspected by the
competent person prior to use.
Permit Issuer/Receiver/ Site
Engineer/CM/ Site
Supervisor/HSEO
3.3 Falling of materials and tools 3.3.1 Scaffold platform shall be secured with a
guardrail, toe board, mid rail, top rail where there is
from scaffold platform
danger to personnel struck by from falling of materials
and tools.
3.3.2 Crew shall be use tool lanyard for the tool being
used to protect below personnel struck by from falling.
3.3.3 Personnel shall be protected from falling objects
during assembly or installation.
3.4 Poor ergonomics
3.4.1 Workers shall be instructed in proper manual
material handling techniques and practices prior to
their work assignment
3.4.2 Personnel with feeling discomfort shall be
immediately reported
3.4.3 Site supervisor/foreman shall strictly implement
the WORK-REST system to those personnel working
with prolonged exposure and/or physical activity.
3.5 Slip, trip and fall
3.5.1 Access shall be cleared and free from any
obstruction.
3.5.2 Unwanted materials shall be removed from
working area.
3.5.3 Slip resistant shoes must be worn all the time
3.5.4 Trained and competent person will be
allocated to the task.
3.5.4 Maintain good housekeeping all the time
around the area of hydro testing.
DOC NO.: HKSS-APOC-HSE-JSA-006
Page 4 of 15
04
Water Filling & Venting the
System in both ground and
elevated level
4.1 Slip, trip and fall
4.1.1 Use appropriate ladder while climbing on
trailer.
4.1.2 Access shall be cleared and free from any
obstruction.
4.1.3 Unwanted materials shall be removed from
working area.
4.1.4 Slip resistant shoes must be worn all the
Time.
4.1.5 Trained and competent person will be
allocated to the task.
Permit Issuer/Receiver
Site Engineer/
Site Supervisor/HSEO
4.1.6 Maintain good housekeeping all the time
around the area of hydro testing.
4.2 Manual handling
4.2.1 Tool Box talk shall be conducted regarding
hazards of the job.
Permit Issuer/Receiver
Site Engineer/
Site Supervisor/HSEO
4.2.2 Only experienced and qualified workers
will do this activity.
4.2.3 Use of proper PPE’s.
4.2.4 Follow manual handling techniques and
maintain proper body position.
4.2.5 Ensure sharp edges are eliminated and
tools properly handled.
4.2.6 Pinch points shall be identified, marked
and eliminated as much as possible.
DOC NO.: HKSS-APOC-HSE-JSA-006
Page 5 of 15
4.3 Fall of personnel /
Material from height
4.3.1. Only trained personnel shall be working at
height.
Permit Issuer/Receiver
Site Engineer/
Site Supervisor/HSEO
4.3.2. Use full body harness when required and
should follow 100 % tie off.
4.3.3. never carry a load while going up and
down the ladder
4.3.4 Maintain 3 point contact while accessing
ladder
4.3.4 User shall inspect the safety harness before
each use.
4.3.5 Ensure fall protection are complying
ANSI/ASSE fall protection system
4.3.6 Adequate proper and secured ladder shall
be installed
4.3.7 Use proper PPE ( safety shoe, gloves, hard
hat, FRC)
4.3.8 Scaffold platform shall be secured with a
guard rail, toe board, mid rail, top rail to avoid
man material fall
4.3.9 All the worker should wear chin strap.
4.3.10 Area needed to be barricaded to avoid
unauthorized entry.
DOC NO.: HKSS-APOC-HSE-JSA-006
Page 6 of 15
05
Pressurization using Air
compressor/ Leak checking
5.1 Bursting of Blinds / pipes 5.1.1 Only experienced and competent personnel
/ fittings under pressure
should conduct Hydro testing work.
Permit Issuer/Receiver
Site Engineer/CM
Site Supervisor/HSEO
5.1.2 Ensure blinds and fittings are of correct
specification and properly tightened.
5.1.3 The system should never be pressurized
above the test pressure specified by support of
the piping.
5.1.4 The test pump, if any, shall be located
such that the pump operator will not be
exposed to danger in the event of a failure.
5.1.5 Only personnel involved with the test
shall be allowed within the marked approach
barriers at any time during the test.
5.1.6Ensure thorough inspection is done prior to the
start of the job.
4.1.3
4.1.4
4.1.5 nature of any failure. Ensure that
pressure gauges and relief valve
to be used are properly calibrated
and should have valid calibration
certificates
DOC NO.: HKSS-APOC-HSE-JSA-006
Page 7 of 15
5.1.7 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.
5.1.8 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.
5.1.9 Air shall be removed from the system
through vents at high points while the system is
filled at the low point.
5.1.10 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.
5.1.11 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.
5.1.12 The relief valves shall be tested, dated,
and tagged
DOC NO.: HKSS-APOC-HSE-JSA-006
Page 8 of 15
5.2 Manual handling and poor 5.2.1 Workers to be trained in manual handling and
Ergonomic
ergonomics.
5.2.2 Proper hand and body positioning to be
maintained during the activity.
5.2.3 Overexertion shall not be done.
Permit Issuer/Receiver
Site Engineer/
Site
Supervisor/HSEO/operator
5.3.1 The ratchet spanner setting shall be done
properly.
5.3.2 Right tool for the job to be used.
5.3.3 Avoid putting hand between the
pipe flanges during installation or
removal.
5.3.4 All the required PPE shall be provided.
(i.e working gloves, safety goggles, hard hat,
FRC coverall, safety shoes and safety visor).
5.3.5 Pre job briefing shall be conducted prior to
start the task.
5.3.6 No invented and modified tools are to be
allowed on site.
5.3.7 All tools shall be inspected and color coded.
5.3.8 Trained and competent personnel shall be
assigned the task.
Permit Issuer/Receiver
Site Engineer/
5.4 Injury due to blind flange 5.4.1 Blanks/blind flanges, bolts and other test
rupture
limits should be specified to withstand the rated
test pressure.
Permit Issuer/Receiver
Site Engineer/
5.3 Use of hand tools.
Site Supervisor/HSEO
Site Supervisor/HSEO
5.4.2 Personnel carrying out the test shall be
provided with a safe place from which the progress
of the test can be observed and controlled.
DOC NO.: HKSS-APOC-HSE-JSA-006
Page 9 of 15
5.5 Failure of gaskets
5.5.1 Gaskets to be used on flange connections be
checked for defects/rating.
Permit Issuer/Receiver
Site Engineer/
Site Supervisor/HSEO
Permit Issuer/Receiver
5.6 Release of high-pressure 5.6.1 Proper PPEs shall be worn.
Site Engineer/
fluid through defective weld
5.6.2 Only competent personnel shall do the job.
Site Supervisor/HSEO
joints and flange
5.6.3 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 or other assemblies are found to be leaking
during test, the piping shall first be depressurized to
zero before tightening the bolts.
5.7 Personnel getting struck 5.7.1 Only authorized involved personnel shall allow
by unexpected disconnection entering and performing the activity.
5.7.2 All personnel of hydro test activity shall be
of hose , Nozzle and high
trained in the correct use and hazards associated with
pressure
Permit Issuer/Receiver
Site Engineer/
Site Supervisor/HSEO
hydro testing.
5.7.3 Isolate the working area by providing proper
barricade and warning sign.
5.7.4 Hoses and nozzle fittings shall be securely fixed
to prevent unplanned disengagement during
pressurizing operations. All twist-lock fittings (“Chicago”
fittings) shall have a safety pin or wire installed to
prevent disengagement.
5.7.5 Hose connections shall be equipped with whip
arrestors (Whip checks) to restrain the hose in case
of accidental disconnection.
5.8 High Noise
5.8.1 Earmuff/ear plug shall be worn
5.8.2 Unauthorized personnel shall not enter to a high
noise area.
Permit Issuer/Receiver
Site Engineer/
Site Supervisor/HSEO
5.8.3 The air compressor must be properly maintained
DOC NO.: HKSS-APOC-HSE-JSA-006
Page 10 of 15
06
Depressurize / Drain the
pipe.
6.1 Personnel Injury due to
Release of Pressure.
Permit Issuer/Receiver
Site Engineer/
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.
Site Supervisor/HSEO
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.
DOC NO.: HKSS-APOC-HSE-JSA-006
Page 11 of 15
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.
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
DOC NO.: HKSS-APOC-HSE-JSA-006
6.2.1 Refer to 2.1
Page 12 of 15
6.3 Falling Objects.
6.3.1 Ensure all tools are kept in tools Bags or
Baskets.
Permit Issuer/Receiver
Site Engineer/
Site Supervisor/HSEO
6.3.2 Maintain 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.
Permit Issuer/Receiver
Site Engineer/
Site Supervisor/HSEO
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.
Permit Issuer/Receiver
Site Engineer/
Site Supervisor/HSEO
6.5.3 Suitable blinds shall be installed to isolate
the system to be tested.
07
08
Disconnect Fittings / Hoses
Housekeeping
7.1 Falling Objects
7.1.1 Ensure all tools are kept in tools Bags or Basket. Permit Issuer/Receiver
Site Engineer/
7.1.2 Good House Keeping (a place for everything
Site
Supervisor/HSEO
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
8.1.Slip, trip and fall
8.1.1
8.1.2
8.1.3
DOC NO.: HKSS-APOC-HSE-JSA-006
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.
Remove all equipment used in the test
from the worksite
.
All surrounding materials shall be cleared
properly.
Permit Issuer/Receiver
Site Engineer/Site
Supervisor/HSEO
Page 13 of 15
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.
8.1.3
8.2 Cuts and laceration due to 8.2.1
sharp objects.
8.2.2
8.2.3
8.2.4
DOC NO.: HKSS-APOC-HSE-JSA-006
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.
Permit Issuer/Receiver
Site Engineer/Site
Supervisor/HSEO
Page 14 of 15
09
Water disposal using pump
9.1 Unauthorized
personnel entry
9.1.1 Only authorized involved personnel shall
allow entering and performing the activity.
Permit Issuer/Receiver/Site
Supervisor/HSEO
9.1.2 Isolate the area by providing barricade and
warning sign (restricted area, hydro test in
progress).
9.2 Water pump failure
9.2.1 Water pump shall be inspected by the
competent person prior to use.
9.2.2 Area need to be barricaded.
9.2.3 The test pump shall be located such that
the pump operator will not be exposed to
danger of a failure. Preventive maintenance
record shall be carried out by the competent
mechanic to ensure that the equipment have
been monitor the safe condition equipment.
9.3 Personnel getting slip
from hose and scattered
disposed water.
9.3.1 Hose shall have sufficient length going to
the made water pit.
9.4 Water spilled
9.4.1 Hose shall have sufficient length going to
the made water pit.
9.3.2 Drainage going to the made water pit, to
prevent The spilled water from spreading, and
shall be isolated by barricade and warning
signage shall be posted.
9.4.2 De-watering shall be done slowly with vents
open
DOC NO.: HKSS-APOC-HSE-JSA-006
Page 15 of 15