HDPE Piping Hydrostatic Test Procedure NS2-DD09-P0ZEN -740027

FOR INFORMATION

0 03 AUG 2020 L.X. Giang Y.S. Kwon K.Y. Yang FOR INFORMATION
Rev Date Prepared Checked Approved Details of Revision
Owner

Owner’s Engineer

Contractor

Doosan Heavy Industries Vietnam

Sub-Supplier
LILAMA CORPORATION

Project

NGHI SON 2 BOT THERMAL POWER PLANT PROJECT

(2 x 600MW)
Title

HDPE PIPING HYDROSTATIC TEST PROCEDURE

Document No. Rev. Page-No.

NS2-DD09-P0ZEN-740027
0 7

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HDPE Piping Hydrostatic Test Procedure NS2-DD09-P0ZEN -740027

CONTENTS
1. PURPOSE. .............................................................................................................................................................................. 3
2. SCOPE. .................................................................................................................................................................................... 3
3. REFERENCES CODES AND STANDARD. .............................................................................................................. 3
4. WORK PROCEDURE. ....................................................................................................................................................... 3
4.1 PRESSURE WORK FLOW CHART. ............................................................................................................. 3
4.2 PREPARATION WORK. ............................................................................................................................ 3
4.3 FILLING AND VENTING .......................................................................................................................... 4
4.4 TESTING/ PRESSURIZING ....................................................................................................................... 4
4.5 DRAINING. ............................................................................................................................................. 6
4.6 TEST RECORDS...................................................................................................................................... 6
5. SAFETY PREPERATION ................................................................................................................................................. 7
5.1 SAFETY PREPARE. ................................................................................................................................... 7
5.2 HYDRAULIC TEST STAGE. ....................................................................................................................... 7
5.3 EMERGENCY PREPAREDNESS/ RESPONE.................................................................................................. 8
6. ATTACHMENT (JSA & RA)

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HDPE Piping Hydrostatic Test Procedure NS2-DD09-P0ZEN -740027

1. PURPOSE
The purpose of this procedure is to provide guidelines for pressure test (hydrostatic, pneumatic) of
above ground and underground piping to meet project specification and reference code and
standards for Nghi Sơn 2 BOT Thermal Power Plant Project.

2. SCOPE
This procedure preparation is for HDPE piping pressure test.

3. REFERENCES CODES AND STANDARD

- ASME B 31.1: Power Piping

- NS2-DD09-P0ZEN-740008 Rev 2: Method Statement for Boiler and Bop Piping Installation

4. WORK PROCEDURE

4.1 Pressure work flow chart

4.2 Preparation Work

4.2.1 Document

- The test section of the line has been installed in accordance with approved drawings.

- The joints of the test section shall be complete inspection following with Inspection test plan.

- Category A Punch shall be complete before hydro testing.

- Construction team shall be marked blinding point, pressure gauge isolation valves and temporary
line(if necessary) on the Drawing.

- Approval of test packages shall be secured before Hydro test.

- All Equipments / Instruments shall be certificate by manufacture. If certificate period is over

expiration date, those equipments and instrument shall be re-calibrating by third party
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HDPE Piping Hydrostatic Test Procedure NS2-DD09-P0ZEN -740027
- User shall be recording to the “Pressure Test Report”

4.2.2 Equipment

- Pressure water pump

- Calibrated pressure gauges

- Blind flanges with bolts/nuts and temporary gaskets

- Valves and pipes for connection with gauges and the pump, safety valves

- Safety tapes, warning signs etc.

- Consumables

- Hand tools

4.2.3 Test fluid

a. Water

- Water shall normally be used as the test medium. Test water shall be clean such as quality for
minimize corrosion of the materials in the piping system.

b. Minimum test temperature

- Hydrostatic test pressure shall be applied until the piping and its contents are at approximately
the same temperature.

-The minimum test temperature for hydrostatic pressure testing shall not be metal temperatures
below 20C (350F).

- Temperature gun prepare and checking if required.

4.3 Filling and Venting
- Test water should be supplied through lowest point of testing line.

- Highest vent point shall be open to remove all air under the water filling stage.

- Construction shall be checked fully overflowing the highest vent point after then monitoring
within minimum 1 minute at highest vent point

4.4 Testing/ Pressurizing

- Before Pressurizing
• Construction is completed according to the design requirements.
• System restraints such as thrust restraints, other supports and anchors are in place and
properly cured with the no deflects.
▪ Pressure gauges shall be checked to install such as lowest, highest and end points of
test boundary
▪ Construction shall be checked condition such as hydraulic hose, temporary line and
testing equipment.

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HDPE Piping Hydrostatic Test Procedure NS2-DD09-P0ZEN -740027
▪ Construction and safety team shall be checked caution tapes in the boundary, if caution
tapes cannot apply instead to use signboard or signalman.

- During Pressurizing:

• User shall be one more venting on the highest vent point by pressure pump with in
2minutes.

• User shall be slowly supplied pressurizing to read the highest point and adjustment
with lower point. During pressurizing lowest point is usually high pressure than
highest point, however User shall be control to supply pressurizing to consider lower
point pressure and does not exceed the capacity of pipe, meter and valve.

• During pressurizing process, if there are any leakages noticed, stop further pressurizing,
mark the leakage locations and carry out inspection. Ensure pipeline strength reliability
before continue pressurizing slowly to expose all the problems till reaching the testing
pressure. Inspect whether the leakages increase and any other new leakages found,
mark all the leakage points, record leakage patterns in order to analyze the causes and
prepare for the repair proposal.

▪ First step: Pressure reaches the Design pressure and then holding 10 minutes to check
without pressure drop.(Refer. 4.6 Test Record in this procedure)

▪ Second step: Pressure reaches the Test pressure (1.5 times design pressure) and then
holding 30 minutes to check pressure drop. (Refer. 4.6 Test Record in this procedure)

▪ Final Step: Pressure drop the Design pressure to check leakage point for all joints such
as weld, bolting and etc. (Refer. 4.6 Test Record in this procedure)

▪ Acceptance criteria: If no leakage point and no pressure drop during the hydro test it is
accepted.

▪ Design pressure is following with attached ISO mark-up drawing section 1 of Test
package.

Sample

DP(bar_g)

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HDPE Piping Hydrostatic Test Procedure NS2-DD09-P0ZEN -740027
4.5 Draining
- After successful completion of the test, the system shall be depressurized gradually and then
drain completely. The depressurizing rate shall be 3.0 to 5.0 bar (g) per minute.

- After the hydro-test has been completed, pressure shall be released in a manner and at a rate
so as not to endanger personnel or damage equipment’s.

- All vent and drains shall be opened under the draining stage, after draining then air blowing
shall be used to remove remaining water and making dry condition.

- If using water is over 5 tons, water quality should be checked with Third party following with
QCVN 40:2011/BTNMT before discharged. After then Hydro test water should be discharged
to environment, otherwise water is draining to the waste water treatment facility following
with local regulation.

4.6 Test Records

- Test Records. Records shall be made of each piping system during the testing, including

• Date of test

• Identification of piping system tested.

• Test fluid

• Test fluid temperature

• Ambient temperature
• Test pressure

Figure.Hydrostatic test diagram

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HDPE Piping Hydrostatic Test Procedure NS2-DD09-P0ZEN -740027
5. SAFETY PREPARATION
5.1 SAFETY PREPARE & INSTALLATION SAFETY METHOD.
- Installation of safety facilities when moving aerial places such as scaffolding and side for
hydrotest inspection

- Tag valve (Open and Close) apply to each valve when hydrotest.

- The pressure gauge will install at two location, one lowest point and one highest point. we will
using 02 gauge (The pressure gauge uses a maximum scale of 1.5 to 5 times the pressure test
pressure ).

- Provision of safety protective equipment to hydraulic test workers (seat belt, Safety shoes paid,
hard hat and face protection).

- Establish safety work procedures including risk assessment results for each pressure test and
provide training to the inspectors and others, all hydraulic test workers will be apply safety
training before working.

5.2 HYDRAULIC TEST STAGE

- Follow safety procedures when pressurized for water pressure test.

- Check all safety devices (vents valves, pressure gauges) and valves before water pressure test.

- Confirmation of personnel control in all areas at the start of the water pressure test.

5.3 EMERGENCY PREPARDNESS/ RESPONE

- Establish emergency contact system for critical risk that may occur during hydraulic test.

- Prepare emergency response / preparation scenario for each emergency.

- Training and training workers for each emergency before starting the hydraulic test.

6. ATTACHMENT (JSA & RA)

7|Page
RISK ASSESSMENT AND JOB SAFETY ANALYSIS
Risk Assessment
Risk level Matric:
RISK ASSESSEMENT
BASE RISK
RESIDUAL RISK
(WITHOUT
Cause of (WITH CONTROL)
CONTROL)
Job / Task People at Risk Adverse Mitigating Controls
Risk Residu
Effect L
S1 Rate L2 S2 al Rate
1
(RFN) (RRN)

worker
abnormal
physical Slip/ Check the health condition during
3 2 6 1 1 1
condition ( Trip/Fall the TBM
Drunken &
fatigue)
Workers
Worker not
familiar with
the scope of TBM to be filled and discussed by
1 2 2 1 1 1
works or supervisor to workers
workplace
hazards
checking the access round before
2 4 8
passing the area
Transportat Traffic Designate a signalman when
Collision 3 3 9 1 2 2
ion of accident moving the equipment
equipemnt
keep the speed limited 10km/h
& delivery
of materials Defective/Faul Ensure all required pre-start
Falling
ty machinery checklist are carried out prior to 1 3 3
object
or tools start any work
Only a qualified and Certified
operators. Signalman, riggers
should be in-place
Complied with Vietname Molisa
Heavy
Material regulations with Circular 44
Lifting Falling object 4 4 16 1 3 3
fall Preparation of a lifting plan list and
Works
plans for lifts from 10 tons or
greater.
Do not stand under the load and
working radius of crane
 Isolated lifting area and warning
no access
Ensure loads are fixed with Wire
sling correctly
All lifting equipment must be in
good conditions
Experienced lifting supervisors at
all times
Only lifting tools with color
coding following site regulation
allowed to use
All lifting tools must have
identification tag (including serial
number, certification number,
SWL inspection date and due
date)
Check the Windspeed before
Equipme Lifting. Windspeed 10m/s
Collapse nt 2 5 10 Check the ground condition and 2 3 6
collapse level including any type of
matting.
Ensure that no one touch the load
Squeezed and wire sling before give the
Caught in 5 3 15 2 3 6
by the signal for lifting
sling Use proper hands PPE
Ensure distance between steel
Equipme structure and crane in lifting plan
collision nt 3 5 15 study and communication 2 3 6
collapse between signal man and crane
operator
Put taglines with enough length to
the load from the ground during
lifting for proper guide control.
Squeezed
Ensure that no one stay within the
Caught in by the 4 3 12 2 2 4
restricted area from the load
materials
before lifting.

Barricade the loading / unloading

 area and crane working radius

Designate only one Signalman for

Lifting and / or additional signal
man for every location ( if
necessary)
Cause of Risk Residua
Job / Task People at Risk Adverse L1 S1 Rate Mitigating Controls L1 S1 l Rate
Effect (RFN) (RRN)

All scaffolders must be trained and

tested with scaffolding course in
training centre of DVN’s Training
and trained person entering
working at height only.

All scaffolders must be had

scaffolding certificate from the
third party. And qualified by DVN
EHS scaffold supervisor.
All scaffolders who is working at
Lack of
height shall be inducted and got
experienc
certificate from MOLISA (
falling hazard, e e
Scaffoldin Circular 44)
falling from and 4 2 8 2 2 4
g work All workers must be equipped
height knowled
with Safety helmet & strap chin,
ge/ not
safety google, fall arrestor device,
adequate
clothing uniform with yellow
PPE
helmet and sticker " Scaffolder"
All employees shall follow
manual handling methods.
Ensure all are wearing necessary
PPEs.
Ensure the dismantling is done
only by the following the
dismantling procedure.
Dismantling of scaffolding is not
allowed during head wind.
 Adequate supervision shall be
available at site during dismantling

Ensure a valid P.T.W “prior to the

commencement of the any work at
site and Permit to be made
available at the work site during all
the activities”. Confined space
entry permit shall be obtained from
area authority prior to start
Non- confined space works. Gas testing
complian to be performed prior." if
ce of scaffolding installation inside
permanent DVN’ confined space"
injury for EHS 4 4 16 ( Scaffolding PTW applied from 2 2 4
worker Procedur 10m and over and it was approved
es and by DVN’s EHS)
permit to Job specific T.R.A to be made
work available at the site & control
measures to be communicated to
all personnel involved in the job
through Tool Box Talk Meeting
Job specific Tool Box Talk to be
filled up prior to the
commencement of work and to be
kept in the site.
Fall of Avoid gaps in between planks
material/
Ensure that overhang is not more
Trips &
than 50 mm at the edges
permanent fall,
injury for stuck by 4 3 12 2 2 4
worker personal Provide toe boards to avoid fall of

- Injury materials and guard rails to prevent

to the fall of persons

persons
Sharp Ensure all hand tools are
Major injury 4 2 8 2 2 4
edged inspected and approved.
tools Cut Ensure trained and experienced
injury/ employees are assigned to the job.
Pinch Ensure all hand tools are checked
Point/Def for their good working condition
ected prior to the start of the job by
hand operators or users.
tools/Def Ensure no defected/
ected / handmade/modified tools are
Homema available at site
de /
modified All portable hand tool shall be tie
hand by lanyard for falling protection.
tools
Injury/im Scaffolding inspector shall
property visually inspect the scaffolding is
erected erected as per procedure by
scaffoldi qualified personnel's supervision.
ng, Ensure the materials used for the
partial/co construction are graded.
llapse During inspecting the higher level
scaffoldi platforms Inspector shall maintain
ng, 100% tie-off.
damage All scaffolding shall be inspected
materials after inclement weather or after
or seven days or
3 5 15 1 3 3
structure, if work has been carried out
unqualifi temporary on the structure by a
ed certified scaffolding inspector
personal whose findings shall be recorded
injuried on the scaff tag and in a register
or death, kept by him
unauthori
zed
No person other than a scaffolder
alteration
and/or his helper may be on a
of
scaffold which is
scaffoldi
ng
 Cause of Risk Residua
Job / Task People at Risk Adverse L1 S1 Rate Mitigating Controls L1 S1 l Rate
Effect (RFN) (RRN)

Workers are to check the

condition of all equipment for
Damaged defects prior to use: cables &
/ connections, earth clamps,
Welding
Electric shock Defective 4 4 16 inspection tag and electrode 1 4 4
work
Equipme holder.
nt Proper earthing and connection of
welding machines and generators
Proper PPE to be worn at all times
Flashback arrestor and gauge
should be installed prior to use
cutting by Gas cylinders
Always wear appropriate PPE
Fire/
4 3 12 (welding mask, welding gloves, 2 1 2
explosion Damaged welding jacket, Apron).
/
Workers are to check the
Defective
condition of all equipment for
Equipme
defects prior to use
nt
Check all electric tools prior to use
by competent person and color

Electric shock 4 4 16 tagged. 1 4 4

Cutting
and Check panels and earthing lines.

Welding No working on wet surface.

works All guards & safety features are to
be operable
Ensure that right disc are used for
a certain job, cutting disc for
Damaged
cutting and grinding disc for
/
grinding.
Flying object Defective 5 3 15 3 2 6
Ensure that the RPM of disc is
Equipme
higher than the RPM of the grinder
nt

Do not use damaged or wet disc.

Using proper PPE as face mask
protection
 Ensure that installation of proper
working platform such as
scaffolding with highest standard
The lifeline shall be a minimum of
12 millimeter (½ - inch) wire rope.
Work at Or it shall have a design capacity
height of 22 kilo-Newton
without Safety nets shall be provided
Fall 4 4 16 2 3 6
proper when workplaces are more than
working 7.5 meter above the ground
platform Safety harness must be worn
before work and lanyard must be
connected with proper anchor
Work at point
height<1.8 5-minute safety training before
m over> or work
ladder Put the material in secure
container.
Tie the tools to your safety belts or
harness with rope having enough
length to reach the working point
connection.
Improper
Prevent unauthorized entry the
Falling object storage 4 4 16 1 4 4
area can be had falling object by
material /
securing area with barricade and
tools
signage.
Installation of safety net for
prevent falling object if needed
Ensure that wearing the proper
PPE
Cause of Risk Residua
Job / Task People at Risk Adverse L1 S1 Rate Mitigating Controls L1 S1 l Rate
Effect (RFN) (RRN)

Confine suffocation,Pre Failure to Provide the adequate ventilation:

space sence of properly 5 3 15 Use mechanical air movers 2 2 4
entry work residual ventilate (in/out) for ventilation.
harmful fume, Check the oxygen level prior to
dust, smoke... entry on confined space.
Ventilation and extraction should
be performed at least (30) minute
before the entrants are allowed to
go inside the CS.
Ensure atmosphere is safe by
having oxygen concentration
between 19.5% & 23.5% and
should be monitored and
maintained.
Workers should undergo a
mandatory Confined Space
training before allowing to enter
the CS.
Gas free test tobe conducted by a
competent person before and
during the work confirm the level
of toxic substances does not
exceed the permissible exposure
limit.
The confined space shall be
monitor continuously using at least
1 no of 4 in 1
Gas monitor.
Ensure the 4 in 1 gas meter is
having a valid calibration cert.
( All workers shall be brief
everyday about hazards of
confined spaces and its control
measures before commencing of
work- all works shall be stopped
and all workers shall
evacuate immediately from the gas
monitor and inform the person in
charge
 2 people 1 team or 3 people 1team
do work and have to sign on the
paper when out the entrance and
exit times. (You should check the
time when you wear an oxygen
mask, work the work up to the
given time, and end the shift and
work.)
Following procedures and actions
are to be followed
in a case a victim is to be rescued
from an enclosed space:

Raise the alarm and inform Master

Obtain necessary assistance and
equipment including medical
support
Lifelines, breathing apparatus,
resuscitation equipment and other
items of rescue equipment are
Failure to ready for use
comunica First aid squad fully equipped near
tion to the scene
Emergency 4 4 16 1 4 4
device or Communication link established.
walkies Use approved VHF/UHF radios
talkies The officer in charge of the rescue
must remain outside the space,
where he can exercise the most
effective control
Before entry, officer in charge
must inform in briefly the squads
about the peculiarities of the
relevant space (if possible consult
relevant plan)
During rescue operation adequate
ventilation shall be provided
continuously
 Any case in emergency contact to
DVN’EHS Department and
LILMA HSSE Department with
Telephone number:
023.7386.2595
Cause of Risk Residua
Job / Task People at Risk Adverse L1 S1 Rate Mitigating Controls L1 S1 l Rate
Effect (RFN) (RRN)

All workers must be training and

have to take part in TBM and
compliance with PTW ( grating
and handrail removal permit)
A piece of grating or handrail will
never be removed or left
May be
without:Pre – Installing a hard
falling
barricade, guardrail, or equivalent,
objects ,
which will entirely encompass the
workers
opening or:Properly covering the
may
opening.
falling
falling hazard, If a floor hole cover ( s) it used, it
Grating from
falling from 4 4 16 must be constructed to adequately 1 4 4
installation hole
height support without failure, at least
opening
twice the weight of any person (
cause
s) and . Or equipment to which the
fatal
cover may be subjected .
injury,
Be cleated or secured by means of
serious
wire tie downs, clips, or other
injury
equivalent fastening method.
-visibly identify the hazard on the
cover ( DANGER – HOLE
COVER- DO NOT REMOVE)
- All signal boards, tags, hard
barricade must be available.
Cause of Risk Residua
Job / Task People at Risk Adverse L1 S1 Rate Mitigating Controls L1 S1 l Rate
Effect (RFN) (RRN)

Workers Hydraulic & Pneumatic pressure

Hydraulic
Worker may be 3 2 6 testing shall only be carried out by 1 1 1
test
get injury competent personnel
 or • Visibly identify the
potential hazard on the cover, DANGER –
injury, High pressure testing in progress
falling at – unauthorized person keep out
height, (Barricades, Signs, ).
explosion
Damaged
tools and
-All tools and equipment must be
equipme
checked and stamped by HSSE
nt may
department
be lead
- All gauges, Air compressor, air
worker to
tank, pump hose for pressure test
injury
must be had calibration certificate
Explosio
from the third party and checked
n of
by Dvn’EHS department and
Nitrogen
Tools, stamped.
cylinders
materials and All coupling from hydraulic pump
(as a 4 4 16 1 4 4
equipment connected to hose must be using
result of
mobilization Hose restraints for protection.
toppling
All Nitrogen cylinders must be
over or
kept upright, secured from falling
being
and protected from accidental
struck)
impact.
Uncontro
Do not enter a closed space if you
lled
suspect that nitrogen may be
release of
present following a leak or
Nitrogen
release.
or
missile
Wrong test Check with supervisor before
pressure. mobilizing equipment & ensure
Incomplete the test item is correctly identified.
Identificati
test pack. Ensure the test pressure is verified
on of
No proper 4 4 16 by QA/QC Dept. 1 4 4
Work Test
coordination All hydro-Testing team must be
Pack
among team trained and understand about
members, method statement for Hydro -
insufficient
 information to Test.
concerned
parties, TBM
not done
before start of
the activity,
incomplete
attendance of
key personnel
on site
No permit - no work. . Ensure a
Hazardous
valid P.T.W
activities
Read and understand permit prior
without
to commencement of work.
sufficient
Ensure compliance with permit
preparation &
requirements.
safety
Permit requestor to supply relevant
measures.
Permit P & ID's with Blanks List.
Inadequate
Applicatio 5 3 15 Adhere to Permit-to-Work system 2 3 6
safety control
n in compliance with safe work
measures due
practices, wear the required
to the delay
personal protection aside from the
of securing
basic PPE, complete supervision
work permits
by key personnel on site, provide
Specific
full safety coverage from start to
requirements
finish
of PPE not

Test package Obtain permit as required.

not clearly Additional PPE: Face shield when
Pre
identified due checking flanges, Gloves
Hydro-
to wrong Dispose of used gaskets in the
Testing:
information receptacle supplied.
Installing
Delay of Use rigger and rigging equipment
Test
work permit whilst installing large blinds or
Flanges
issuance removing spools.
and Spec
because of Comply with the Permit-to-Work
Blinds
unsafe site system, obtain corresponding
condition work permits as required,
 Test gaskets coordinate with all parties
and blinds involved and identify correctly the
not the correct test package with respect to
type and P&ID’s, all personnel must wear
classification the required PPE and adhere to
safe work practices, wear the
correct PPE’s Use correct tools -
Use correct lifting techniques.
Loosen bolts away from face.
Comply with the Permit-to-Work
system, obtain corresponding
work permits as required,
coordinate with all parties
involved and identify correctly the
test package with respect to
P&ID’s, all personnel must wear
the required PPE and adhere to
safe work practices, wear the
correct PPE’s
Personnel Bunt off area and erect signs at
injury due to least 2m around test zone.
exposure to Warn personnel.
high pressure
water and Only authorized personnel to be
associated in the vicinity.
‘flying’ debris’ Ensure correct test gauges are
etc used.
Inadequate Ensure correct equipment is
Hydro-
barricading of 4 3 12 checked before use. 3 1 2
testing
the test area Check all flanges and spades for
with leaks before pressurizing.
incomplete Do not check for leaks with bare
signage hands, avoid close contact.
No corrective Install hard barricade around the
action on the potential hazard points of
unsafe accidental pressure release
conditions Placement of warning signboards
observed and close supervision of
 Test area not competent person on site
define to keep Entry should be close to personnel
out workers with no direct involvement on the
and traffic test as well as construction
entering the equipment.
controlled area
Unauthorized
entry of some
discipline into
the test area
which may
result to
undesirable
situation
De – pressured water be drained to
waste water treatment pond. The
water shall be treated by Local
environment law.
Clean-up work areas.
Secure all work permits each day
after work completion, conduct
housekeeping and remove all
Effected to
De- debris and excessive materials on
environment at 4 3 12 3 1 2
pressured site
workplace
Collect all waste to disposal area,
All hazardous waste shall be either
contained onsite in a suitable
hazardous waste storage area or be
disposed of by a recognized and
approved hazardous waste
disposal storage of DVN’s EHS
Department
Cause of Risk Residua
Job / Task People at Risk Adverse L1 S1 Rate Mitigating Controls L1 S1 l Rate
Effect (RFN) (RRN)

Persons Registered under Radiation

RADIOACTIVE receiving Effects Protection Regulations following

5 3 15 2 3 6
SUBSTANCE which
excessive Vietnamese regulations
exposure to appear Exempt from registration
radiation; during Registered under Radiation
Radiation lifetime Protection Regulations (check
levels not of local regulations)
being exposed Where practicable, exposure to be
monitored; individua restricted by shielding and
Operatives not l and containment of radioactive
wearing dose include: substances (eg. carrying out
badges; radiography in a suitable
Sources and Radiolog enclosure and using suitable
containers not ical collimators).
properly dermatiti Exposure to be restricted by
maintained s; provision of a safe system of
and sealed; work, including controlled and
Persons not Loss of supervised areas marked by
wearing hair; barriers and notices.
personal Persons likely to receive specified
protective Skin minimum dose to be designated
equipment burns, classified persons and wear
which suitable film badges or dosimeters
are slow and be medically examined.
to heal The appointment of a radiation
and may protection officer and supervisor.
become Information, instruction and
malignan training to persons working with
t; ionizing radiation and others
concerned with the work.
Where practicable, radioactive
Anemia; substances to be in the form of
sealed sources and leaks tested
Cataracta regularly.
nd Records of quantities and
locations of radioactive
Bone substances to be kept.
cancer. Radioactive substances not in use
should be kept in suitable
receptacles which should be
marked if transported.
Monitoring instruments should be
 provided.
Any significant losses or spillage
to be reported to the relevant
authorities in the country of
operation.
Other relevant legislation and
regulations should be referred to
and compiled with where
appropriate
Emergency procedure must be
revised to accommodate the risk
of losing harmful radio active
sources or being unable to reel
isotopes back into their protective
containment.

* Prepare Job Safety Analysis and Safety Checklist

Frequency
when
1: unlikely/improbable RRN is ≥6
** Prepare Safety Verification Checklist when RFN is
2:Remote
≥6.
3:Quite possible/Occasional
4:Likely/Probable L1 : Likelihood as is
5:Very likely/Frequent L2 : Likelihood with mitigating controls in place

Severity S1 : Severity as i
1.Negligible S2 : Severity with mitigating controls in place
2.Slight
3.Moderate
4.Critical/High
5.Catastrophic/Very high
Risk Factor Number ( RFN) Residual Risk number ( RRN)
1-2 Trivial/Acceptable 1-2 Trivial/Acceptable
3.5: Tolerable 3-5 Tolerable
6.-9: Moderate/Acceptable with review 6-9: Moderate/Acceptable with review
10-15 Substantial 10-15: Substantial
16-25:Intolerable/Unacceptable
 Method Statement For Boiler & BOP Piping Installation NS2-DD09-P0ZEN-740008

Prepared by Mr. Le Thanh Hai Approved by:

Position: LLM HSSE Manager Position
Signature: Signature
Date: 24th May,2019 Date:
 JSA (Job Safety Analysis)

JOB SAFETY ANALYSIS

NGHI SON 2 BOT THERMAL POWER PLANT PROJECT
( Developing a habit of analyzing method to identify hazards & unsafe practices than developing solutions that
control, minimize or eliminating hazards)

Task: HDPE Piping Hydrostatic Test Procedure

Prepared by Mr. Le Xuan Giang Reviewed by Mr. Approved by Mr.
Original date: 03-Aug-2020 Revised by: Revised date: Revision: 0
PPE required (Tick as applicable – state > category/specific type)

Safety googles: Gloves: Face shield Barricade Lock out: Dust Mask:
needed Tack out:
Safety harness Long sleeves Hearing MSDS Group fault Others
protection need/Review interrupter
Other safety equipment required:
Remark:

LIST OF ALL JOB STEPS LIST OF ALL KNOWN HAZARDS HOW TO ELIMINATE HAZARDS
Transportation of Equipment & Crash/Traffic accident 1. All Truck and trailer operators must
Delivery of Materials Falling materials and equipment from be got EHS conduction from DVN EHS
trailer or truck. training center and had certificate
following Vietnam Molisa regulations
2. Check The access road before
passing area
3.Designate a signalman when moving
equipment
4. Lashings (such as webbing, chains,
cables or clamps) should be in
serviceable condition and be checked for
damage at regular intervals to ensure
their tension has not been lost. Use
sleeves and/or corner protectors to
prevent damage to both the load and the
lashing or sheet if it passes over a sharp
edge or corner.
5. Ropes and buckle straps suspended
from a roof rail and/or the curtains of a
standard curtain-sided vehicle are
generally not suitable for securing a
load.

Heavy lifting work - loading and Potential fatality and serious injury due 1.Regular inspection and maintenance
unloading to lifting work shall be carried out and a register kept
Fatality/Serious injury to workers by a qualitied person, for the lifting
tackle under DVN EHS control.
This equipement checking for
deformation, cracks or any faults
includes: Wire slings, Hooks, Shackles,
swivels, spreader bars, Shear –Legs or
Soft/uneven ground may cause crane similar equipment.
topple 1. Ground bearing to be tested and
Potential fatality to workers property endorsed by competent person.( Crane
damage operators and lifting supervisors ensure
safe condition positioning of crane)
Over loading of crane’s SWL may cause 2.Steel plates to be laid for the
crane toppled positioning of crane, if necessary.
Damaged sling –unsecured loose 3.Lifting supervisor to maintain
materials visibility and supervision during lifing
High potential fâtl incident and work.
damage to property. 3.Adhere to approved lifting plan
4. Ensure a valid permit to work
5.All necessary check list to be update
6.Wire slings must be properly stored
off the ground without casing kinking
7.Wire slings must be cleaned and
inspected before and after using.
8The issuing and control of slings shall
be performed by a qualified person.
9.Wire slings and web slings shall be
uniquely membered and a register kept
of all.
10.Besides the regular inspection
following their use, Wire slings and web
sling must be inspected on monthly
basic and the finding entered on the
record sheet.
Worn slings must be cut into two and
properly disposed of: Not allow:
1. Using a wire sling over sharp corner
without padding.
2.Force the sling into position
3.Overload the slings
4.Use a damaged slings, or one that is
Rigging improper method,high potential worn
fatality due to falling object 5.Drag a sling from under the load
6.Allow loads to pass over a slog laying
on the ground
( Tagline to be used at all time during
lifting works) Adhere to the approved

Grating installation and removal
1.High potential falling object due to fall
or material drop down.
2.Pinch point, serious injury hand
lifting plan)
7.Lifting supervisor to ensure the proper
centre of gravity.
(Lifting supervisor brief the method
statement in TBM)
Suspend the load 300mm above ground
and confirm stability
1.Ensure a valid permit to work is in
placed before work commencement
2.lifting plan placed before lifting
3.Only appreciated and competent
rigger to carry out rigging
4. inspect lifting gear prior to use
5. Any person employed on site as a
rigger shall be trained and experienced
in this capacity.
2riggers working on scaffolding and /or
steel structure must not wear soft shoes
unless they approved steel capped toe
safety type.
Protective gloves must be worn when
handling wire ropes
1. All workers must be trained by DVN
EHS and comply with safety regulations
with working at height.
1.1 comply with P.T.W ( Grating and
handrail removal permit)
1.2 Before removal grating on the floor
of Boiler must be identified grating’s
location exactly and install hard
barricade for isolated and prevent
worker access.install warning
signalboard “ Warning opening hole
– keep away”
1.3.Workers in this task have to using
the hooks for falling protection -
hanging grating during the time remove
or installation.
1.4 All portable hand tool machine or
tools as scratch spanner, or portable
drilling machine must be secure with
lanyards for falling protection.
Ergonomic and manual handling must
be trained and TBM before working in

Equipment and material preparation
for temporary facilities
Working and operation during night
time
this task.
1. Collision between machine, 1.Alway keep the site clear of any
overturning may cause death or obstruction
permanent injury, collapsed 1.2.Toolbox talks on daily basic
1.3Adequate warning signal
board
2. Unnecessary movements of 1.4 Checklist on all vehicle must be
equipments a person that causes injury provide every day.
1.5 Siren for warning before lifting.
2.Designate a signalman who wear the
hi –vest suite to control the work
2.1 Heavy machinery should have
backward movement warning light
3. Equipment oil leak during operation beacon.
2.2 Equipment used to clear the site
should be controlled and sorted by
banksman
2.3 Provide safe entrance and exit way
for the workers going to the area
2.4 All vehicles entering on the site
must turn on their headlights day and
nighttime
3. Daily check of the equiment prior to
work
1.working operation of the equipments 1.Must provide sufficient lightning on
may cause serious injury to personnel due the entire working area
to: 1.2 All equipments must be ensure all
lights are operation
1.3 Supervisor must always be present
for entire working
1.4 All workers must be wearing proper
PPE ( Hi –Vest)
1.5 First aid box should be prepared for
the first aid in case injury.
1.6.Temporary electrical system must be
used and connect 03 core and separated
distribution panel ( with ELCB with
electrical leakage 30ma) and avoid from
2.Generator (Diesel equiment oil leakage) any water effect
1.7 provide safe access way and exit
access road for the workforces passing
1.8All kinds of electrical cable must be
hanged over ground at least 2m and
must be industrial socket and flugs
3.Chemical storage 2.Daily check of the equipment prior to
start work

Welding and cutting work Electrical shock, fire, burn to body and
injury to eye may cause death or
permanent injury
Fire accident due to electrical wire aging
during welding
Working on scaffolding Potential incident and fatality and
serious injury due to falling from height
2.1.Regular inspection and monitoring
of the equipment prior to use.
2.2 Provide secondary containment
protection under the equipement to
prevent contamination soil by oil
spillage
3.Diezel chemical shell be stored in
secondary containment and MSDS must
be showed and communicated to all
workers who concerned.
All hazardous waste must be collected
and keep inside the hazardous waste
disposal bin and handover to DVN EHS
to treatment by the Nghison
Environment company following
Vietnam environment regulations.
All workers must be trained with special
hot work training from DVN EHS
training center and also equipped with
PPE as: Safety mask for face protection
and face mask for welding or cutting,
leather gloves,Arpon.
1. Proper earthing and connection of
welding machines and generators.
2.Flash bask arrestor and Gas flow
regulator should be installed to Gas
cylinder and cutting gears or cutting
torch prior to using cutting.
2.1. Must be used fire blanket to isolated
welding area and used ask tray for
prevent welding slags drop.
2.2. fire watchman should be available
at welding area
2.3. Portable fire firefighting
extinguisher must be available at
workplace.
2.3. All flammable and combustion
materials should be moved way from
welding or gas cutting area at least from
5m to 10m depend on actual location at
workplace and ensure method for
isolated with fire hazards.
1.Make sure all workers who working at
height must be trained safety induction
by DVN EHS training and
also must be got safety certificated for
Cir: 44 following MOLISA and
DOLISA Vietnam regulations.
1.2 Must be sured all workers must be
weared safety harness and used 100% tie
off all the time when they are working at
height.
1.3 Scaffolding system must be install
and dismantling by competent persons
and all scaffolders must be got qualified
and trained by DVN EHS department.
1.4 Scaffolding have to reach up with
DVN EHS standards
( Supervisors and EHS supervisors must
be inducted and training to all workers
who is working at height)
1.5 All scaffolding system must be
inspected by scaffolding supervisor and
inspector and apply with scaffolding
tags. ( Green – Yellow – Red)
2. All workers must be followed and
comply with Safety rules and principles
as: Climb on the ladder must be
complied with three points principle.
2.1.Do not face away from the ladder
while carrying out work from the ladder
2.2 Do not stand close than 900mm to
the top of ladder
3.Lifeline must be designed allowable
carrying load capacity
3.2 Using fall arrestor device( Rope
grap) using for vertical lifeline
applicated on ladders (Nylon rope
diameter with  16)
3.3 Lifeline system must be done before
working
Horizontal lifeline must be used wire
rope Min 10 Max 12
4. Ladders must be inspected frequently
before working and those which have
developed defects must be withdraw
from service for repair or destruction
and tagged marked as ( Dangerous not
use)
4.2 Damaged ladders or missing rungs,
broken with side rails or other faulty
 equipment must be not used.
Improvised repair are not allowed

Confined space entry work
Death due to reduced oxygen 1.All workers who working inside
concentration confined space must be attend and
Or toxic gas. safety training at DVN EHS training
center and must be carry out before
working
2.Complied with PTW following DVN
EHS procedures.
3. before entering confined space must
be using ventilation air force for gas
monitoring and using multi-gas device 4
in 1 for checking ( Apply with oxygen
form 19.5% to 23.5%) and checking
every 02 hours one time ( but no limited
for checking atmosphere inside confined
space following DVN EHS requested or
instructed on site)
4. Establish for communication system
from inside and outside of confined
space.
5. Do not working alone and at least
working inside confined space 03
persons.
6. Establish a tripod and pulley for
rescues in case emergency
When workers working inside must be
used safety harness for rescues reasons
and ERT member must be available
during the time workers working inside
and comply with Emergency procedure
of DVN EHS.

Hydraulic & Pneumatic pressure
testing
1. Lack of knowledge and misunderstand
about hazards
Workers may be get injury or potential
injury, falling at height, explosion
1“ special training course for high
pressure test by DVN’s EHS” Comply
with DVN’EHS procedure
Hydraulic & Pneumatic pressure testing
shall only be carried out by competent
personnel
1.2 Visibly identify the hazard on the
cover, DANGER – High pressure
testing in progress – unauthorised
person keep out (Barricades, Signs, ).
2.Damaged tools and equipment may be
lead worker to injury
Explosion of Nitrogen cylinders (as a
result of toppling over or being struck)
Uncontrolled release of Nitrogen or
missile
3. Wrong test pressure.
Incomplete test pack.
No proper coordination among team
members, insufficient information to
concerned parties, TBM not done before
start of the activity, incomplete
attendance of key personnel on site
4.Hazardous activities without sufficient
preparation & safety measures.
Inadequate safety control measures due
to the delay of securing work permits
Specific requirements of PPE
established
Safe access and egress to work surface
area not clearly define
5. Test package not clearly identified due to
wrong information
Delay of work permit issuance because of
unsafe site condition
Test gaskets and blinds not the correct type and
classification
2.1All tools and equipment must be
checked and stamped by HSSE
department
- All gauges, Air compressor, air tank,
pump hose for pressure test must be had
calibration certificate from the third
party and checked by Dvn’EHS
department and stamped.
All coupling from hydraulic pump
connected to hose must be using Hose
restraints for protection.
All Nitrogen cylinders must be kept
upright, secured from falling and
protected from accidental impact.
Do not enter a closed space if you
suspect that nitrogen may be present
following a leak or release.
3. Check with supervisor before
mobilizing equipment & ensure the test
item is correctly identified.
Ensure the test pressure is verified by
QA/QC Dept.
All hydro-Testing team must be trained
and understand about method statement
for Hydro - Test.
4. No permit - no work. . Ensure a valid
P.T.W
Read and understand permit prior to
commencement of work.
not Ensure compliance with permit
requirements.
Permit requestor to supply relevant P &
ID's with Blanks List.
Adhere to Permit-to-Work system in
compliance with safe work practices,
wear the required personal protection
aside from the basic PPE, complete
supervision by key personnel on site,
provide full safety coverage from start
to finish
5. Test package not clearly identified due to
wrong information
Delay of work permit issuance because of
unsafe site condition
Test gaskets and blinds not the correct type
and classification
 6. Personnel injury due to exposure to
high pressure water and associated
‘flying’ debris’ etc
Inadequate barricading of the test area
with incomplete signage
No corrective action on the unsafe
conditions observed
Test area not define to keep out workers
and traffic entering the controlled area
Unauthorized entry of some discipline
into the test area which may result to
undesirable situation
7. Effected to environment at workplace
radioactive substances Persons receiving excessive exposure to
radiation;
Radiation levels not being monitored;
Operatives not wearing dose badges;
Sources and containers not properly
maintained and sealed;
Persons not wearing personal protective
equipment
Effects which appear during lifetime of
exposed individual and include:
Radiological dermatitis;
Loss of hair;Skin burns, which are slow
to heal and may become malignant;
Anemia;
Cataractand
Bone cancer.
6. Bunt off area and erect signs at least
2m around test zone.
Warn personnel.
Only authorized personnel to be in the
vicinity.
Ensure correct test gauges are used.
Ensure correct equipment is checked
before use.
Check all flanges and spades for leaks
before pressurizing.
Do not check for leaks with bare hands,
avoid close contact.
Install hard barricade around the
potential hazard points of accidental
pressure release
Placement of warning signboards and
close supervision of competent person
on site
Entry should be close to personnel with
no direct involvement on the test as
well as construction equipment.
7. De – pressured water be drained to
waste water treatment pond. The water
shall be treated by the third party
( Environment company)
Registered under Radiation Protection
Regulations following Vietnamese
regulations
Exempt from registration
Registered under Radiation Protection
Regulations (check local regulations)
Where practicable, exposure to be
restricted by shielding and containment
of radioactive substances (eg. carrying
out radiography in a suitable enclosure
and using suitable collimators).
Exposure to be restricted by provision
of a safe system of work, including
controlled and supervised areas marked
by barriers and notices.
Persons likely to receive specified
minimum dose to be designated
classified persons and wear suitable
film badges or dosimeters and be
medically examined.
 The appointment of a radiation
protection officer and supervisor.
Information, instruction and training to
persons working with ionizing radiation
and others concerned with the work.
Where practicable, radioactive
substances to be in the form of sealed
sources and leaks tested regularly.
Records of quantities and locations of
radioactive substances to be kept.
Radioactive substances not in use
should be kept in suitable receptacles
which should be marked if transported.
Monitoring instruments should be
provided.
Any significant losses or spillage to be
reported to the relevant authorities in
the country of operation.
Other relevant legislation and
regulations should be referred to and
compiled with where appropriate
Emergency procedure must be revised
to accommodate the risk of losing
harmful radio active sources or being
unable to reel isotopes back into their
protective containment.
Rescues in emergency case Fatal or death for worker if not in time Any case in emergency contact to
DVN’EHS Department and LILMA
HSSE Department with Telephone
number: 0974.39.33.99 or DVN EHS
023.7386.2595
Following procedures and actions are to
be followed
in a case a victim is to be rescued from
an enclosed space:

Raise the alarm and inform Master

Obtain necessary assistance and
equipment including medical support
Lifelines, breathing apparatus,
resuscitation equipment and other items
of rescue equipment are ready for use
First aid squad fully equipped near to
the scene
Communication link established. Use
approved VHF/UHF radios
The officer in charge of the rescue must
remain outside the space, where he can
exercise the most effective control
Before entry, officer in charge must
inform in briefly the squads about the
peculiarities of the relevant space (if
possible consult relevant plan)
During rescue operation adequate
ventilation shall be provided
continuously