L&T Hydrocarbon Engineering

Indmax FCCU Project ,LSTK-1, IOCL-Bongaigaon

JOB SAFETY ANALYSIS

Job No. 600244 Date- 13.03.2018

Job Description- Pressure Test JSA No.- LTHE/CS/BGR/JSA-30

Job classification- Mech. Rev. No.- 03 on 24.04.2019

P&M and Equipment, Pump, Hand tools, Slings & D shackles.

tools & tackles involved-
PPE’S / safety device PPE’S- Safety Helmet, Safety Jacket, Safety shoes, Safety goggles, Job
required- relevent hand gloves, Nose mask, Ear plug etc.

Barrication tape & warning poster.

Prepared by Mr.Virendra kushwaha
( Name of Site Engineer)

Checked By- Mr. Syed Shamsudeen

( HSE)
Approved By- Mr.Prashanta Guchait
 Work Activity
A. Pre -pressure testing 1.Fall of person
activity ( Arrangment and
installation of Hydrotest
Pumps blinds, flanges,
valves etc.)
Hazards Present Required Safety Measures Responsibility
1. Ensure before start pressure test Concerned
NDT,PWHT & PMI activities are Engineer
completed. Work permit system shall be /Supervisor
followed.Joint walkthrough by
execution and HSE team.Positive valve
isolation where applicable and blind to
be indicated in sketch drawing. Ensure
testing area shall be cordoned off.
Ensure only green tagged scaffold is
used. Scaffolding shall be equipped
with access ladder, mid rail, top rail &
toe board. Workmen engaged in Hydro
test & pneumatic test at height worker
must use full body harness (FBH)
Ensure & monitor 100% anchoring of
Full body harness with double lanyard
& shock absorber.

2. Fall of materials. 2. Proper securing of equipment/spool Concerned

at height. Display warning / Caution Engineer
signage . Proper support of job shall be /Supervisor
ensured before water filling. Tools shall
be lashed with rope during
WAH.Ensure test equipment are
secured and use lifting bag for carrying
tools with rope pulley arrangement.

3. Toppling of 3.Ensure area should be properly Concerned

Equipment / Job levelled & well compacted before Engineer
placement of any equipments. /Supervisor
Approach should be free from
obstruction. Ensure the loop to
be hydro tested are provided
with adequate support so
withstand the load of dead
weight of loop & fluid.

4.Collapse of 4.Ensure proper scaffolding and avoid Concerned

Scaffold transfer of load on to scaffold Engineer
Scaffold tag system should follow for /Supervisor
scaffold type work platform.
Provide ladders wherever possible for
better approach to the working
platform/work area.

5. Water drainage 5. Ensure the job is flushed with Concerned

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 clean water. Ensure waste water Engineer
is properly drained at nearby /Supervisor
drainage. Remove all scrap & dirt
from water before draining.
Ensure availability of stand by
dewatering pump to avoid site
site flooding due to release of
hydro testing water. Ensure
proper draining arrangement for
used hydrotest water.

6. Ergonomic 6. Ensure person shall not lift Concerned

hazards weight more than 55kg for Engineer
materials shifting from one place /Supervisor
to other. Provide Trolley for
materials shifting. Body posture
to be maintained and correct
tools to be used during work.

7.Manual Handling Mechanical lifting aid to be used as Concerned

applicable.All equipments should have Engineer
safety inspection tag.All workers in the /Supervisor
area shall wear mandatory PPE.

Safety sign boards shall be displayed and

informed to the workmen via tool box
talk.

8. Pinching of leg Use hand gloves during material Concerned

/hands, handling. Engineer
/Supervisor
Ensure the workmen if there
hands / legs are away from
pinching points . Use hand tools
or any other suitable arrangement
to avoid such type of pinch point
hazards. All mandatory PPE's shall
be use at site.

9. Improper Ensure stacking of material should Concerned

material stacking, be in such a manner there should Engineer
not be any chance of rolling of /Supervisor
materials. Housekeeping to be
maintained properly. Ensure that
the height of stacked materials
should not be more than 1.5
meters.

10. Improper Ensure proper communication &

Concerned
communication & coordination between working crew while
Engineer
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 coordination engaging multiple persons to work. /Supervisor
between working Training shall be provided to improve
crew, communication skill.

11. Improper Ensure availability of valve in the vent

Concerned
arrangement / provided at top most point.Ensure PSV
Engineer
condition of fittings/ in the testing loop as per pressure test
/Supervisor
devices. procedure.Ensure proper drainage
arrangement for used hydrotest water.
Ensure two no's of calibrated pressure
gauges are fitted in a testing loop.
Before start testing, all arrangement
shall be rechecked by concerned job
supervisor.

12. Improper
Ensure that emergency road should be Concerned
approach/access.
obstacle free always. Work area Engineer
housekeeping to be maintained /Supervisor
properly. Ensure area should be free
from any tripping hazards , cable laying
etc. Ensure proper & safe access is
provide to the vent area.
Water filling to be taken up strictly as per
B. Water charging for Concerned
the procedure. Follow checklist. Ensure
Hydrotest Engineer
area cordoned, Restrict unauthorized
/Supervisor
entry. Ensure Charging isolation valve is
fully open.Ensure vent is open . Inspect
the condition of charging pipe / hose .
Ensure water is charging slowly into the
job. Ensure all trapped air displaced from
1. Bursting of
the job. Use of PPEs. Effective
charging pipe or
supervision shall be ensured. Use of
leakage
fixed hard metal pipe for water charging.
Use of barriers for charging pipe. Keep
minimum charging pressure. Ensure no
unauthorized person shall operate valve
during water filling.
One person should be awaited at pump
for any emergency stoppage.
Only authorized persons are allowed to
work.
2.Fall of person Ensure workmen use fall arrester while
Concerned
climbing vertical ladder. Ensure the
Engineer
proper use of double lanyards full body
/Supervisor
harness with shock absorber. Working
platform to be made on beam for worker
movement. Ensure lifeline (12 mm wire
rope / steel pipe) provided in all places
where worker suppose to go. All hazards

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 to be communicated to concerned
workmen in daily tool box talk. Effective
supervision shall be ensured.
Proper securing the job at height. Display
Concerned
warning / Caution signage . Proper
Engineer
support of job shall be ensured before
/Supervisor
3. Fall of material start water filling. Loose materials shall
be tied by rope at higher elevation. Area
shall be cordon off.
Proper drainage to be ensured to avoid
4. Improper Concerned
water logging. Continuos monitoring to
drainage. Engineer
be ensured.
/Supervisor
No persons are allowed in the testing
Holding Period
area during holding period.
Only authorized persons are allowed to
work
Area shall be cordoned off with
appropriate visual sign board.
Strict monitoring and visual during
Leakage/ bursting of holding period
charged pipe Activity shall be carried out under
competent supervisor, if differential
settlement observed work shall be
stopped
Required level of illumination shall be
ensured while activity.
In event of pressure drop, do not allow
any activity on pressurized system
C. Hydro test 1. Bursting or leakage Pressure testing permit shall be taken Concerned
during Hydrotesting . before start work.Follow Hydrotesting Engineer
2.Over Pressure checklist. /Supervisor
3.Rupture the testing Ensure area is cordoned, Restrict
system unauthorized entryEnsure warning /
caution signage.
Use of all mandatory PPE's. Ensure
trapped air is completely removed.
Ensure all the joints & openings are
isolated
Ensure use of duel & calibrated pressure
gauges with appropriate range. Ensure
both the pressure gauges indicating zero
pressure before pumping.
Ensure no person near the joints.
Ensure connecting hose between pump
& job is in good condition.
Ensure gradual pressure rise in the

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system & hold period as per the
schedule & is recorded.
Monitor both pressure gauges & data to
be recorded.
Ensure supply is isolated properly &
pumping is stopped after reaching of
desired pressure.
Ensure condition of hydro testing pump
& its validity.
Ensure PRV is tested & calibrated.
Deployment of experienced & trained
person only.
All joints are to be covered with strong
barriers
Ensure competent & trained personel
are engaged for hydro & pneumatic
testing work. Ensure safe distance is
maintained from the pressure testing
area. Ensure only de-pressurized line to
be deglaned by experienced & trained
personel.
Compressors to be inspected by P&M
and HSE personnel before mobilization.
Calibrated instrument to be ensured
Experienced and trained persons to be
engaged.
Proper barrication with caution board
should be provided at both ends
Regular monitoring shall be done
Daily tool box talk prior to work
No work should be carried out on
pressurized system
Care should be taken to avoid any
external mechanical forces on the
systems in pressurizing time i.e.
hammering.
Accessories as per the design pressure
to be used.
Follow approved test procedure
sequence
PSV shall be calibrated 10% of the test
pressure
Gauges shall be visible

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 Ensure calibrated and certified PSV &
gauge shall be used
Use whip arrestors for all connecting
hoses.
2. Welding fumes 2. Welding goggles shall be provided to Concerned
welder's helper for eye Engineer
protection.Welding shall be done with /Supervisor
adequate ventilation.
All electrode bits to be collected in a
container. Provide suitable nose mask
for welders & helpers.
3. Welding spark. Area shall be cleared of Flammables and Concerned
combustibles before commencing Engineer
welding.Use fire blanket or other /Supervisor
suitable means to arrest the welding
spatter. Qualified welders to be
deployed.
Ensure all rotating parts must be
4. Unguarded
guarded
rotating parts
Pumps shall be inspected and tagged
Tool box talk prior to work
1. Failure and
. Pneumatic test Deploy good condition Air Compressor. Concerned
breakdown of
Equipments must be inspected before Engineer
equipment
use. Inspection shall be ensured before /Supervisor
using Air Compressor. It must be
inspected and properly tagged.
Equipment shall be earthed. Correct size
and capacity of temporary materials or
Standard shall be utilised to prevent
bursting during pneumatic test.All
temporary material should be tested,
inspected and record to be maintained.
Availability of TPI certificate for Air
compressor to be ensured
All fitting with hoses must be secured Concerned
with whip chain and second tie with Engineer
wires.Coordination works to other /Supervisor
2. Struck by Hose groups at elevated area. Responsibility
shall be allocated to execute the work.
Hose condition shall be checked
properly.
3. Tripping hazard
3 a. Area shall be cordon off and strictly Concerned
imposed. Engineer
/Supervisor
b. Sign board shall be displyed “ Pressure
Test Keep Out” at strategic location.

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 c. Safe means of access and egress to be
provided and maintained for the
workers.
d. Good Housekeeping must be
maintained at all times.
Test area should be barricaded and
unauthorised entry restricated.
4.Rotating parts of
All rotating parts shall be adequately Concerned
machine.
covered or guarded. Loose cloth shall be Engineer
avoid to use while working with rotating /Supervisor
machine.
5. Fire hazards due to
Keep adequate Fire Extinguisher and Fire Concerned
fuel, electric short
Bucket stand near the equipment area. Engineer
circuit.
Approved method statemet-Activities to /Supervisor
be performed as per approved Method
Statement.

6. Work procedure
Pressure testing permit shall be taken Concerned
and sequence not
before starts the work. Pressure gauges Engineer
followed
shall be calibrated and in good working /Supervisor
condition.
Pressure shall be applied gradually as per
method statement.
Qualified & trained workers under
competent supervision should be
allocated to execute the work.
All involved personnel shall recieve
specific training,instruction and Job
safety analysis.

7.Overpressure due
Job shall be pressurized as per approved Concerned
to failure of pressure
procedure , Method Statement & ITP. Engineer
control/regulating
Permanent PRV shall be tested to verify /Supervisor
device.
the set points prior to installation
Surrounding area shall be cordon off
while pneumatic test. Proper Watch /
monitoring shall be available in access
area to control unauthorized entry. Keep
person away from all venting locations
while the full test pressure is applied.
8.Improper work
Ensure Scaffolding shall be equipped Concerned
location.
with access ladder, mid rail, top rail & Engineer
toe board. Ensure pressure testing work /Supervisor
is carried out under stict supervision.

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 Ensure work at height permit is to be
obtained prior to start hydro /
pneumatic test at height. Simultaneous
work in top & bottom shall be avoided.
Regular pressure reading & monitoring
De-Pressurisation
Air shall be released within the control
pressure
Proper rated needle Valve should be
Uncontrolled release provided based on test pressure.
of pressure Daily tool box talk prior to work
Experienced and site authorized persons
shall be engaged
Inspected & tagged equipment shall be
used
1. Loose bolt at
F. Post pressure testing Bolts loosing shall be carried out under Concerned
height.
Activity proper supervision. Lifting bag to be Engineer
used for lifting / carrying loose materials. /Supervisor
Guy rope shall be used to pull by taking
support from rigid body.Use drift pin to
match holes.
2. Poor
Work area should be cleaned & Concerned
Housekeeping at
obstruction free. After pressure test Engineer
work place.
ensure all materials must be in orderly /Supervisor
placed.
3. Improper
Proper drainage to be ensured to avoid Concerned
drainage.
water logging. Continios monitoring to Engineer
be ensured.Remove all scrap & dirt from /Supervisor
water after cleaning of job before
draining into the drainage.
Water Spillage / Ensure all the drain lines are closed.
Dewatering
flooding Water shall be disposed in approved
area as per project environment
guidelines.
Tool box talk to be given prior to work
Water disposing pipe should be
undergrounded where ever vehicle way
is there
Heat Stress Drinking plenty of water
High wind Wear light breathable clothing
Rain Rest & cool off several times during the
day time at rest shelter
Follow heat stress prevention guideline
No height work during high wind & rain.
After inspection work should be started
during rain & wind

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 Do not allow or insist workmen to work
at water logged area in bare foot
Poor Illumination Proper illumination should be provided
Work during night shift
as per standards
Night work procedure to be followed
Ensure proper housekeeping at site.Rest
only at rest shelter
G.Adverse weather Earth quake, heavy Advance intimation of Earth quake & Concerned
condition & Emergency rain, flood , cyclone , other climatic changes to be regularly Engineer
prepardness. scaffold collapse and checked/monitoring from forecast & /Supervisor
any other emergency necessary communication also to be
situations. passed to all concerned.Ensure crane
boom / hook must be lower down in
case of heavy wind.Ensure proper
drainage at work place. Lightning
arrestor to be placed at suitable position.
Use gum shooes in case of water
logging / mudy soil. Ensure all sheds to
be properly secured.
Emergency response system training to
be provided to working crew. Ensure
Emergency vehicle to be available at site.
Round the clock First aid facility with
Ambulance should be available. In case
of emergency , people will assembled at
nearest assembly point. Ensure access
should be free from any obstruction.
Emergency man busket equipped with
sling & D shackle to be available at
reachable distance of crane. Ensure
adequate Fire extinguisher should be
available at work area. Emergency light
should be in working condition , will be
used in case of any power failure.

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