PMT/Contractor JSA Form - 1/12/2008

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JOB SAFETY ANALYSIS WORK SHEET

✘ New D / M / Y Contractor: Br. C.A.T. International Co. Limited.
JSA # MGS-008 Date
Revised 10 / Jun / 2015 Contract #/JO#: 660003283/10-01282-0002

JSA Function Name Badge# Job Title Mobile Phone #

CAT Site Supv./ Frmn. John v. Philip Welding Supervisor 0535365596

CAT Project Engineer Omar Turkmani Construction Manager 0558080192

CAT Site Safety Supervisor Zahid Mahmood Bhatti HSE Supervisor 0504638022

SAPMT Safety Advisor Neeraj Safety Advisor 0561752243

SAPMT Representative Abdul Hai Mechanical Engineer 0503546065

Proponent Rep. (Issuer)

Proponent Rep. (Oprtn.)

DESCRIPTION OF TASK: Hot Tap tie-in connection

Work Location/(Area then station numbers): See attached list for location and reference.
Prepared by/ Signature: (Contract Reviewed By/ Signature: (SAPMT) Approved By/ Signature: (Client)

______________ ____________ ____________

CAT Representative. Signature Safety Advisor Signature Lead Proj. Engr. Signature

______________ ____________ Operation Rep. ____________

HSE Supervisor Signature SAPMT Rep. Signature Signature
PMT/Contractor JSA Form - 1/12/2008
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References (G.I, OIM, etc.)

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, Inspection and Testing of Requirements of Elevating/Lifting Equipment G.I. 7.030, Street and Road Closure; Excavations, Reinstatement and
Traffic Controls G.I. 1021.000, Fire Fighting Training Company Personnel G.I. 1783.001, Safety Spectacles G.I. 8.002, Protective (Safety) Footwear G.I. 8.005, Pressure
Testing Safety GI 2.012, SAEP-311 Installation of Hot Tap Connection. Saudi Aramco Construction Manual 5 th Edition API Recommended Practice 2201

Item SEQUENCE/ BASIC POTENTIAL HAZARDS HAZARD CONTROLS ACTION

STEPS BY

1.  Unauthorized entry into pump stations  Make sure survey crew members have valid Saudi
Aramco plant ID or approved access paper for entry
and only survey work. Follow all security requirements
to conform your identity for plant security.

 Unauthorized tools and equipment entry into  Only surveying equipment and hand tools will be
pump stations allowed to enter to perform the job. Don’t carry
prohibited items according to safety and security point
Entry to the pump station CAT, SAPMT
of view. Do not carry mobile phones inside the
and valve stations (follow-up)
prohibited locations.

 Unauthorized vehicles entry  Only vehicle with inspection & plant access sticker will
be allowed to enter.

 Improper PPE  FRC must be worn by all personnel entering to the

2.  Work without authorization, personal injury,
property damage or environment loss
facility for work and job required mandatory PPE shall
be used.
 Comply with SA G.I 2.100 (work permit), Issue
& receive proper Work Permit for work. Stick with
work permit requirements.

 Wrong marking or identification for hot tap  Surveyor will mark clearly hot tap location on the CAT,
Survey work
point existing pipe with the help of IFC drawings. Location Operation,
(Identification and marking
and marking will be inspected by SAPMT/PID and SAPMT
for HT point) (follow-up)
concerned parties.

 Miss communication/miss understanding/doubt  Conduct pre-work meeting with all concerned to

or confusion discuss work scope, responsibilities, work hazard and
control measures.
PMT/Contractor JSA Form - 1/12/2008
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Item SEQUENCE/ BASIC POTENTIAL HAZARDS HAZARD CONTROLS ACTION

STEPS BY

3.  Improper supervision  A competent supervisor/foreman will be deployed full

time to supervise and monitor the job.

 Unexperienced workers  Only competent workers will be involved in the

activity. Conduct safety TBT, discuss JSA with workers
to highlight the work/area hazards and safety
precautions.

 Damage to existing facility  Always maintain safe clearance from existence facility.
Secure the existence utilities to avoid any damage. Do
not enter or work into restricted area, not covered in
scope of work.

 Improper/defective work tools & equipment
Work area preparation
 Faulty or no fire extinguisher
 Make sure all work hand tools, equipment are
inspected and color coded to ensure its safe condition
for use.
CAT,
 Comply with SA G.I 7181.001 (inspection, Operation,
SAPMT
testing & maintenance of fire protection
(follow-up)
equipment), provide enough and suitable fire
extinguisher at work location. Make sure firefighting
equipment must be inspected and color coded.

 Local traffic (while working in pipe corridor)  Comply with SA G.I 6.030 (traffic & vehicle
safety), secure the work area from local’s vehicle
using right of way. Deploy flagman to control the
approaching vehicles.

 Personnel or equipment falling into  Secure the excavation with barricades and display
excavations. safety sign boards to warn approaching personnel.

 Minor/serious multiple injuries  Always use job required personal protective

equipment. Ensure good housekeeping in work area.

4. UT reading for pipe  Uncertified third party/uncertified UT  Only Saudi Aramco approved third party and certified CAT,
thickness technician technician will be allowed to perform the UT testing. Operation,
PMT/Contractor JSA Form - 1/12/2008
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Item SEQUENCE/ BASIC POTENTIAL HAZARDS HAZARD CONTROLS ACTION

STEPS BY

 Non-calibrated/faulty testing equipment  Make sure testing equipment calibrated with current
inspection sticker.

 Unapproved procedure  UT procedure must be approved from SAPMT and SAPMT

concerned parties prior to conduct pipe thickness test. (follow-up)

 Non use of PPE  All workers involved into activity shall worn all job
required personal protective equipment. FRC must be
worn while throughout the activity.
5.  Uncertified operators  Comply with SA G.I 7.025 (Heavy Equipment
Operator Testing and Certification), only certified
drivers and operator with valid particular license or
certificate (SAG or Saudi Aramco) will be allowed to
drive or operate the equipment.

 Traffic hazards  Follow posted speed limit and use seat belt. Drive
carefully at blind sections, intersections and road
crossings.

 Falling of load equipment or material  Ensure all tools / equipment / are pre-inspected
before mobilization. All equipment / tools are properly
secured on trailer/truck. Pre-journey inspection to be CAT/
Equipment mobilization to conducted.
work location Operation
SAPMT
 Roaming animals/camels  Where animals romancing near the road or R.O.W (follow-up)
slow down the vehicle, turn on hazard light and cross
carefully.

 Blind spots while reversing  Get help while reversing the equipment to avoid
accident hitting or damage. Operate the equipment at
safe distance from open excavations.
PMT/Contractor JSA Form - 1/12/2008
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Item SEQUENCE/ BASIC POTENTIAL HAZARDS HAZARD CONTROLS ACTION

STEPS BY

6.  Presence of toxic or flammable gasses  Comply with SA G.I 2.100 & 2.709 (work permit
& gas testing), Issuer & receiver will conduct joint
site inspection and gas testing will be done prior to
issue & receive confined Space Entry work Permit.

 Improper access  Provide proper access ladder or stair rack for safe
entry/exit.

 Cave-in  Excavation will be protected against cave-in through

sloping, benching or shoring prior to enter or work.
CAT/
Confined Space Entry  No standby man  Deploy competent standby man with entry/exit log Operation
wherever have hot tap sheet and necessary emergency equipment. SAPMT
below ground level Emergency response procedure will be followed in (follow-up)
case of any emergency.
(Excavation deeper than 4
feet or 1.2 meter)  Falling of people or equipment into excavation  Excavation will be protect after the work with
barricades, sign boards and beacon lamps will be
installed for night safety.

 Slip trip hazard  Always ensure good housekeeping in work area. Do

not pull cables through walking areas. Store the
material properly. Housekeeping will be done prior to
leave the job site.
PMT/Contractor JSA Form - 1/12/2008
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Item SEQUENCE/ BASIC POTENTIAL HAZARDS HAZARD CONTROLS ACTION

STEPS BY

7.  Uninspected or uncertified crane and lifting  Comply with SA G.I. 7.028, 7.029 (crane lift
tackles type and procedure, rigging hardware
Crane lifting operation requirements), lifting equipment must be certified
by Saudi Aramco or third party with valid inspection
sticker. All lifting tackles must be inspected.

 Load falling while lifting might damage to  Ensure lifting belts and shackles are fixed properly
CAT,
existing facility and secured before lifting. Use proper lifting
Operation,
techniques. No one will be allowed to stay or walk SAPMT
under the suspended or lifted load. Display sign board (follow-up)
“LIFTING IN PROGRESS”.

 Load or equipment struck by workers or other
equipment
 Prior to start lifting operation remove unnecessary &
unauthorized personnel and remove other work
equipment from working area to the safe place. Tang
line will be used to control the movement of lifted
load.
PMT/Contractor JSA Form - 1/12/2008
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Item SEQUENCE/ BASIC POTENTIAL HAZARDS HAZARD CONTROLS ACTION

STEPS BY

8.  Uncertified welders  Only Saudi Aramco certified and competent welders will
perform the activity under competent and continuous
supervision.

 Uninspected welding equipment and tools  Welding equipment must be inspected and in good working
condition. Power and grounding cables must be free from
cuts or damage. Welding equipment shall be properly
grounded.

 Electric shock  All extension cords must be free from damage and provided
with GFCI.

 Eye injuries while grinding  Must use double eye protection with safety glasses and face
shield. Secure the area to prevent flying sparks.

 Welding fumes and arc flash  Use disposable N95, 3M respirator for respiratory protection. CAT/
Split Tee installation Wear welding helmet with proper filter lens (shade number) Operation
(grinding & welding) for eye protection against arc flash and radiation. SAPMT
(follow-up)
 Flying sparks and spatters  Wear welding helmet, welding gloves, welding shoes, fire
proof clothing. Cover the work location with fire blanket/tent
to control the flying sparks and spatters. Remove possible
combustible/flammables from working area.

 Fire or explosion  Follow approved welding procedure. Remove

combustible/flammable materials from work location.
Perform gas testing. Cover the work location with fire
blanket/tent. Deploy fire watch and provide dry chemical
fire extinguisher on job location. Always maintain good
housekeeping in working area.

 Slipping & Tripping  Don’t place cable and wires in walking areas. Where
possible hanged them. Keep the tools in safe place. Ensure
good housekeeping through the activity.
9. NDT (MPI/DP) testing and  Uncertified or unexperienced NDT technician  Only Saudi Aramco approved third party and certified CAT,
Inspection for welded technician will be allowed to perform the NDT testing. Operation,
area SAPMT
(follow-up)
 Minor or serious injuries  Wear job required personal protective equipment
while inspection.
PMT/Contractor JSA Form - 1/12/2008
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Item SEQUENCE/ BASIC POTENTIAL HAZARDS HAZARD CONTROLS ACTION

STEPS BY

 Slip trip and fall  Watch your step while moving around the work area.
Ensure proper housekeeping within the work area.
10. Sticker test  Unapproved hydro test procedure or work  Comply with SA GI. 2.012 (pressure testing CAT,
(Pressure testing) safely), hydrostatic procedure shall be approved prior Operation,
method statement SAPMT
to start testing and strictly followed.
(follow-up)
 Non calibrated pressure gauges  Pressure gauges must be calibrated with current
inspection sticker.

 Non calibrated pressure relief valve  Pressure relief valve must be tested with current
inspection tag.

 No calibrated manifold  Manifold must be tested with current inspection tag.

 Improper blind flange  Use proper rated capacity blind flange.

 Improper or damage pressure hoses and  All hoses must be proper rated capacity written on
them and in good condition. All connection must be
fittings secured with whip arrestors to avoid free movement
in case of accidental separation. Use standard fittings.

 Faulty hand pump for pressure  Ensure good operational condition of hand pump for
hydro testing.

 Stop pressurizing if leek detected. Release the

 Water leakage
pressure and tight the bolts. Never do hammering
while the system under pressure.

 Unauthorized entry  Only hydro test team, QC, safety and inspection
personnel shall be allowed to enter into testing
area. Stay at safe distance from pressurized unit
or system. Deploy standby man and display sign
boards “Hydro Test in-progress” or “Hydro Test
on going”.
PMT/Contractor JSA Form - 1/12/2008
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Item SEQUENCE/ BASIC POTENTIAL HAZARDS HAZARD CONTROLS ACTION

STEPS BY

 Minor/serious personal injuries  Wear job required personal protective

equipment to avoid injuries. Ensure good
housekeeping in work area. Do not lay pipes in
walking area.

NOTE: Same precaution will be followed while

further combine hydro test for valve + split Tee
& header machine + valve + split Tee.
11.  Caught in-between result in imputation  Do not insert finger or hand while valve placing. Look
the position of your hands.

 Damage to gas-kit  Ensure gas-kit fixed properly to prevent movement

while valve placing. CAT,
Operation,
Valve Installation
 Improper hand tools, spanner, hammer  Make sure hand tools are proper type and size. Only SAPMT
brass hammer will be used for bolt tightening (follow-up)
purpose.

 Valve in opened position  Ensure the valve is in close position prior to install.

12.  Unauthorized workers  Only Saudi Aramco special team for the hot tap
activity will perform the job.
CAT,
Header machine  Accidental damage to header machine  Deal with care while lifting and installation. Operation,
installation SAPMT
 Minor/serious personal injuries  Wear hand gloves to avoid hand injuries. (follow-up)

13. Hot tap cutting process  Faulty hot tap machine & tools  Comply with SAEP-311 (installation of hot tap CAT,
connection), Hot tap machine must be calibrated Operation,
NOTE: SAUDI ARAMCO with valid inspection sticker. Hand tools must be SAPMT
(follow-up)
PERSONNEL / HOT TAP inspected and color coded in good working condition.
CREW HAVE THEIR OWN
PROCEDURE ON SITE  Fire or explosion  Follow approved hot tap procedure for safe operation.
PROIR TO START THE Only competent technician will operate the hot tap
PMT/Contractor JSA Form - 1/12/2008
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Item SEQUENCE/ BASIC POTENTIAL HAZARDS HAZARD CONTROLS ACTION

STEPS BY

machine. Standby fire truck and fire water hoses to

deal possible fire emergency. FRC must be worn by
everyone involved in activity. Laid down emergency
response and evacuation procedure.

 Unauthorized entry  Only hot tap team, inspection and concerned

ACTIVITY personnel will be allowed to stay in work area. Area
will be barricaded and deploy standby man to stop
unauthorized entrants.

 Minor/serious injuries  Wear job required personal protective equipment to

avoid injuries. Ensure good housekeeping in work
area.
14.  Gas leakage  Make sure valve in close position and bleed valve
opened to release trapped gas, prior to open and
remove hot tap machine.
CAT,
Removal of hot tap  Sparking tools  Non-sparking tools such as brass hammer etc. Operation,
machine SAPMT
 Improper crane lifting operation  Strictly comply with lifting safety precautions to avoid (follow-up)
any accidental damage or injuries.

 Minor/serious injuries  Wear job required personal protective equipment.

15. Abrasive blasting and  Unfit or incompetent abrasive blaster  Abrasive blaster must be trained & experience and medically CAT,
painting for welded area. fit to perform the job. Abrasive blaster should be certified Operation,
from SA with valid certificate. SAPMT
(follow-up)
 Damage abrasive blasting gun and air hoses  Abrasive blasting gun must be fitted with dead-man
lever/switch to be shut-off the air in case of emergency. All
air-hoses must be in good condition and free from kinks,
cracks or cuts. Secure all connections with proper fittings
and whiplash arrestor.
 Dust hazard  Properly cover the work area to control the dust. All workers
working in surrounding area will wear respirators (N-95) for
respiratory protection.

 High Noise  Hearing protection equipment e.g. ear plugs or ear muffs
PMT/Contractor JSA Form - 1/12/2008
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Item SEQUENCE/ BASIC POTENTIAL HAZARDS HAZARD CONTROLS ACTION

STEPS BY

will be used by all workers working in vicinity.

 High vibration  Avoid continuous abrasive blasting activity; take frequent

rest intervals to avoid physical fatigue or stress, nerves
diseases & high blood pressure.

 Hazardous substances  Only trained workers will deals with hazardous substance to
carry out the spray painting activity. Respiratory protection
cartridge type mask will be used while dealing with
hazardous substances. Impervious rubber gloves, disposable
chemical suit and safety shoes will be used.

 Fire due to painting mist or improper storage of  Painting area will be covered properly to control the painting
paint mist to spread all over the working area. All paint canes and
tins will be stored properly and stock will be kept limited on
jobsite. Do not keep paint tins lid open. No any hot work will
be carried out near the spray painting locations. Keep ready
sufficient DCP type fire extinguisher to deal any fire
incident.

 Faulty spray gun or damage hose  All equipment must be inspected on daily basis prior to use.
Wear cartridge type respirators with full face & eye
protection. Wear impervious disposable chemical suit,
rubber gloves and impervious safety shoes. Paint delivery
hoses must be free from cut, kinks or any damage. All
equipment will be grounded properly.
16.  Multiple injuries  Maintain good housekeeping all the time especially before and
after the work.
CAT,
Housekeeping/work permit Operation,
 Tripping & slipping hazard.  Remove all redundant material and restore the area in original
close out SAPMT
condition. Permit issuer/receiver both should visit the area prior
(follow-up)
to close out the work permit.

17.  Serious incident, Personnel serious injuries, fatality  Call at Saudi Aramco emergency number 110 and report CAT,
or property damage emergency such as; Operation,
 Tell two times, “this is an emergency “ “this is an SAPMT
emergency” (follow-up)
Emergency Reporting
 Tell your name and SA ID number
 Tell the location and type of emergency
 Tell how many personnel are injured
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Item SEQUENCE/ BASIC POTENTIAL HAZARDS HAZARD CONTROLS ACTION

STEPS BY

 Tell what kind of emergency help is required

(ambulance or fire truck)
18.  Fire or explosion, release of toxic gas  In case of emergency raise the emergency evacuation alarm
and follow the following steps
 Stop all activities
 Shutdown work equipment
CAT,
 Evacuate to the safe assembly area
Operation,
Evacuation  A role call is taken to ensure all workers are
SAPMT
present
(follow-up)
 No one is permitted to return to work until
notification received from SA that it is safe to do
so.
 Keep First Aid kit on job site to deal with any first aid case.

# Recommendations/Notes Assigned to Remarks

1 All site personnel are required to wear PPE/ such as safety helmet, safety glasses, gloves, and safety shoes. CAT & SAPMT
CAT & SAPMT
2 Conduct Tool Box Safety Meeting prior to work activity.

CAT & SAPMT

3 Explain to key personnel the purpose of the JSA and enforce the implementation of content.

CAT & SAPMT

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

CAT & SAPMT

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

If an injury or near miss occurs, the JSA shall be reviewed immediately to determine whether changes are
6 CAT & SAPMT
needed in the job procedures.