JSA23 Hydro Static Pressure Testing Various Pipe Auxiliaries

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 JOB SAFETY ANALYSIS WORK SHEET  JS A #

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Revised

JSA Function

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Name

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Badge#

Contractor: Contract No/ BI. No.: Job Title

Mobile Phone #

CONTRACTOR Site Supv./ Frmn. CONTRACTOR Engineer CONTRACTOR Site Safety Supervisor SAPMT Safety Advisor

SAPMT Representative

DESCRIPTION OF TASK: Hydrostatic Pressure Testing of MGS Filter Station Various Pipe Auxiliaries Work Location/ (Area then station numbers): Prepared by/ Signature: (Contractor)

Reviewed By/ Signature: (SAPMT)

Reviewed By/ Signature: (LPD)

Approved By/ Signature: (Client)

________________ Project Engineer

Signature

_____________ Safety Advisor

Signature

___________ Loss Prevention Representative

______________ Lead Proj. Engr.

________________ HSE Supervisor

Signature

_____________ SAPMT Supt.

Signature

Signature

Operation Rep.

Signature

______________ ______________ Signature

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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 SAES-A-004, Pressure Testing of Plant Piping and Pipelines SAES-L-150, Safety Instruction Sheet SAES-A005, 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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1.

SEQUENCE/ BASIC STEPS Preliminary site inspection

POTENTIAL HAZARDS •

Injury/Incident due to work not being carried out safely.

HAZARD CONTROLS •

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2.

Emergency evacuation

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Panic Miscommunication

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3.

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

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 Traffic/safety hazard to other users in the area Vehicle/equipment collision Contact with personnel.

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4.

Check equipment

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Personnel injury

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Permit Issuer and Receiver to conduct joint site inspection to discuss the hazards and precautions required for conducting the job safely.

ACTION BY   1

CONTRACTOR/ Operation

2

SAPMT (follow-up)

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

CONTRACTOR/ Operation SAPMT (follow-up)

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. Sign boards to be posted. Site speed restrictions to be3 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)

Daily check of all tools & equipment prior to start of   job.

4

Communicate defects found in equipments and organise for replacements so that defective equipment is never used.  Tag the defective tools as

“Do not use”.

CONTRACTOR/ Operation SAPMT (follow-up)

CONTRACTOR/ Operation SAPMT (follow-up)

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Hydro test preparation

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Personal injury

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2.

Hydro testing

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Failure of joints Failure of pipe Personal injury Damage to property

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.

SAPMT (follow-up)

(Refer to GI- 2-102, SAES-A-004, SAES-L-150) 7  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.

CONTRACTOR/ Operation SAPMT (follow-up)

Ensure the pumps, hoses, spades and gasket are suitable for the pressure rating (GI- 2-102)

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Pressure tests the equipment prior to putting in service.

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CONTRACTOR/ Operation

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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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3.

Depressurizing and housekeeping

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Injury from high pressure  jets Slips trips and falls Damage to environment

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Ensure that an Emergency Repair Kit is readily available incase of any leaks. 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 per SAEP 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

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Recommendations/Notes

Assigned to

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.

4

Use the JSA to identify hazards and list the precautions on the work permit.

5

Garbage’s shall be disposed properly on a daily basis.

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

Mobile Phone #

CONTRACTOR Project Engineer CONTRACTOR / Operation CONTRACTOR Safety Officer & Foremen

EMERGENCY RESPONSE PROCEDURE

EMERGENCY CONTACT NUMBERS:

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

Inside Saudi Aramco EMERGENCY  Dial

1. ALL work is stopped at once. 2. ALL Equipment is shut down. 3. ALL personnel are evacuated to the pre-

CONTRACTOR

1. Saudi Aramco Landline 110

When reporting an emergency give the clear information’s such as: 1. 2. 3. 4.

Your exact location. Nature of emergency. Service required and repeat the message. Your name & badge number.

Page 5 of 5 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. By Mobile Phone – (03) 8720650 (03) 8743000 (03) 8742006 (03) 6787836 (03) 6787116 (03) 6730110 0506837 304

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