JOB SAFETY ANALYSIS

Section 1: Details

Section: PIPING JSA Date:

Process / Activity: HYDRO PRESSURE TESTING

Work Location: Pipe shop testing bay Permit Number:

Tools and Equipment Used: Hose, pump, pressure gauge, blank-off flange, gasket, bolts and nut, coupling

Section 2: Hazards and Controls

S/N Work Activity / Job Steps Hazards Control Measures

Arrange testing equipment & work
1 shall be used
tools.
 Approved written procedure to be cascaded to involved personnel to
ensure they understand the safe operational procedure prior testing
to be carried out
 Ensure all gasket shall be specified according to standard
 Take 5 briefing shall be conducted to involved personnel prior to start
Damaged equipment and tools
the activity
 Only calibrated pressure test gauges with current calibration stickers
Non – compliance of Method
Statement and PTW system
 Pump discharge gauges must be visible to the pump operator for the
duration of the test
 Check the inspection date is valid & condition of tools before use.
 Ensure calibration certificate for the pressure gauges is available
 Location of the pump will be kept outside the pressure testing bay if
carryout high pressure testing

Walk through the line to be tested,
locate & identify install inlet point,
2 breathing point & outlet point.
Blank-off openings identified; install
inlet points, breathing point & outlet
3 Falling from height.
point.
4 Fill-up the line with fluid/water
JOB SAFETY ANALYSIS
Untrained personnel
Unsafe position of the testing vessel
/materials
Overloading of pipe/vessel support
Defective Tools / Equipment
Falling & Tripping.
Poor illumination and ventilation
Fall or strike by materials
Overflow from outlet or at the
breathing point
 Piping vessel supports and foundation designed for service shall not be
overloaded by the extra weight of the test fluid.
 Only (trained) on-job personnel allowed to perform the task
 Provide additional temporary supports and braces maybe required.
 Minimum of the pressure gauges with block and bleed valve shall be
provided in the system
 Barricade the area where Hydro-test is to be carried minimum 3 meter
maximum can be decided by task testing officer.
 Post safety warning notice
 Ensure the equipment / tool to be used for hydro – testing(such as
hose, pump, coupling, pressure gauge, spade, gasket, etc.) are free
from defect and suitable for the pressure rating of the system.
 Mechanical ventilation shall be in place if required
 Adequate lighting shall be provided on the testing site.
 Ensure safe access & egress of work activity
 Minimum number of people in the area by restricting access
unauthorized personnel in the testing area.
 Test verification record hall be made of each piping system during the
testing by conducting physical inspection of the piping system
 Ensures the skillet blanks or test plugs are appropriate for use and
free of obvious defects
 Valves must be isolated any ancillary equipment not under test
 PTW shall be applied
 Manual handling techniques for lifting the pipelines and materials shall
be made
 Provide safe working platform to work at height
 Secure the working platform with hard railing support if the height is
above 1.8meter high
 All joints and connections shall be examined for leaks.
 Frequent crosschecking of the filling line
 After filling the pipeline system with the fluid crosschecking shall be
made to ensure no leaking at the end of piping to be tested
 JOB SAFETY ANALYSIS
Slippery
Fluid leaking
Electric shock
Untrained personnel
Close valve & connect testing hose to
Fluid leaking on the floor
5 inlet point & to testing pump.
Connect appropriate pressure gauge.
Slippery
Nearby existing electrical equipment’s
Serious injury from pipe rapture or
high-pressure water blast
Exceeding maximum allowable
pressure
Apply required pressure rating for the
6 Leakage & causing flood, pipes &
line
hoses burst.
Nearby existing electrical equipment
Inaccurate pressure gauge readings
 Remove electrical cables /equipment laid on the floor which is
potential for electrical hazard
 Suitable safety precautions during Take 5 briefing shall be conducted
to involved personnel
 Only (trained) on-job personnel allowed to perform the task
 All personnel involved in system testing should be competent for their
role including understanding the hazards involved
 Ensure the control steps and the required Personal Protective
Equipment observed
 Pre-inspection of coupling and joints to ensure bolt tightness
 Testing officer shall perform pre-meeting /Take 5 to review the scope
of test, risks involved, equipment and tools required, and mitigation
actions are taken to involve personnel
 Personal should keep away from the pressurized segment of the
system being hydro tested.
 Whip arrester shall be provided at the joint fittings of the hoses in the
vent of accidental rupture
 No personnel in the proximity of the lines being 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.)
 Ensure the pressure relieving device is set at maximum allowable
pressure for weakest portion of the segment to be hydro-tested
 Pressurizes the system, raising the pressure in the system gradually
until the designated test pressure is achieved
 Pressure test shall be increase gradually with 5-10 minutes hold at
each step no rapid change in pressure
 Maintains test pressure for 5-10 minutes before inspection.

Inspect the entire line with client’s
7
representative or surveyor.
Release water pressure through the
8
outlet point
9 Working under extreme temperature
JOB SAFETY ANALYSIS
Un-attended pressurized tool
/equipment
Pipe or hose burst
Improper disposal of test fluid
Flooding
Leakage (slip and fall)
Heat stress
 If test is above maximum allowable working pressure it must be
reduces to a certain pressure while making a full thorough inspection
for leaks.
 Calibrated test gauge shall always be visible from the operator
 Constant communication between the operator and the person
performing the line system inspection
 Ensure along the access route free from any obstruction
 Do not leave the pressurized hose or pump unattended when the
hydro-test is going on.
 System under test shall be depressurized before any work is done to
stop leak or repair weakness including tightness of bolt
 Before taking out nut bolt loose the nut bolt and knock the blind
flange to release trap pressure.
 Air shall not be used to release water to displace from under water
equipment unless it has been determined the equipment will not float
 Drain the lines through the appropriate openings and dismantle the
valves, manifolds & blind flanges.
 Disposing, and/or discharging the test fluids shall follow the local laws
and regulation (DB-QG1-LQ-U-72-00-52-1018)
 Provisions of spill kit
 Drink plenty of water. Wear cool comfortable clothing like cotton
 Ensure work schedules have adequate rest periods to limit exposure
 Know the heat index and check the flag system implemented in
NKOM.
 Monitor the color of your urine to avoid dehydration
 Wear light clothing
 Ensure the provision of rest shelter with easy access on drinking water
 Ensure buddy system will be followed
 Supervisors or above is mandatory to be at the job site while the job is
on going
 JOB SAFETY ANALYSIS
 Ensure proper wind up & housekeeping at worksite.
 The accessories (hoses & pump) not being used must be disconnected
10 Windup &Housekeeping Scattered materials and stored separately.
 PSV (in case isolated) to be lined up after hydrotest completion

Section 3: Participants

Name Employee Number Signature Name Employee Number Signature

 JOB SAFETY ANALYSIS
Section 4: Agreement
The job had been analysed for potential hazards, appropriate guidance had been obtained in identifying the hazards and the required controls were discussed and greed in the JSA Team
Briefing.

JSA Team Leader Name Date Signature

All controls stated in the JSA are in place and the hazards and controls indicated in the JSA have been cascaded to the workforce

Supervisor Name Date Signature

Verified and endorsed by HSE Personnel

Name Date Signature