Al-Khafji Joint Operations

JOB SAFETY ANALYSIS

pcd PROJECT: Water treatment facilities 3

Facility/Plant Location:

WTF-3 PJdescription of work:

HYDRO TESTING ON PIPING SYSTEM UTILITY AND PLANT PIPINGcontractor:JGULF Intl. Co. Ltd.REVISION: 0

JSA No.: MACE - 2012

JSA PARTICIPANTS:

Aldrin C. Alcantara Ghassan D. Matta(Sub-contractor HSE / Construction Manager)APPROVED BY:

Jose N. Banugan (Contractor HSE Manager/Engineer)M.S. No.: V-3154-004-A-261

REVIEWED BY:

Andres C. Moreno(PCD Safety Engineer)

DATE:DATE:DATE:

S.No.Steps Required to Complete TaskIdentify Hazards & Assess RiskControls to Eliminate/Reduce Risk

1. Planning/Site preparation Working Without PTW. Untrained Personnel.

Pinch Point.

Slip, Trip & fall.

Personal Injury. KJO 6412 work permit procedure shall be strictly implemented. Only trained personnel and competent personnel shall be allowed to do the job.

All required PPEs shall be worn by concerned personnel for the job. All involved departments and contactor shall have a joint inspection and a meeting prior to start of the job.

Survey work area and address safe work method, hazards and precautions.

JSA must be followed and to be explained to all employees during Tool Box Talk prior to start of activities and it must be made available at the site. Warning signs and barricades shall be provided around the testing area.

All personnel shall have completed the Safety Orientation Course prior to mobilization to site.

Only authorized personnel are allowed to perform the job.

All tools/equipment shall be prepared, inspected, color coded and only good conditioned tools shall be used at site.

Close supervision of work supervisor is required during the whole duration of work.

2. Water Filling. Slip, Trip & Fall. Hand Injury.

Un-displaced air in the system. Personnel for the job shall be briefed prior to filling the pipe with water to watch their steps while moving around the area. Opening of pipe valve and connection of water hoses shall be done slowly and gently. If it is difficult, use designed valve wrench.

Vent at the highest locations shall be kept open until system is full of water.

3. Pressurizing Activity. Release of Energy. Overpressure.

Use of un-calibrated relief Valve & Pressure Gauge.

Loose Connection/Parts. Personal Injury.

Unauthorized Entry.

Short cut.

No safety Signs & barricades.

Slip, Trip & fall. A STARRT shall be conducted prior to start of job wherein all the hazards shall be identified with corresponding preventive measures. A currently calibrated relief valve and a pressure gauge shall be properly installed on the manifold prior to testing.

Manifold shall be tested and certified.

PRV shall be rated properly to adequately prevent over pressurizing.

All connection shall be thoroughly inspected prior to test activity. Any damaged part/s shall be replaced with good conditioned ones or properly fixed/tightened loose connections prior to use.

Hydro test pump (manual or pneumatic) shall be inspected by competent person and must be in good condition prior to use. Air hose from the air compressor shall be provided with whip lash arrester and joints shall be with pin lock.

Hose/s used for hydro-test shall be inspected and ensure that the rated capacity is more than the desired pressure.

No repair or leak stopping activity shall be allowed without depressurizing the system. System to be tested shall be adequately supported. Only trained and competent personnel shall be allowed to do the hydro test.

Limit the number of persons near the equipment being hydro tested to only essential personnel.

Do not allow any work to be done on the equipment while being tested.

Make sure all equipment is properly & safely prepared for hydro testing. Pressurization shall be gradual and in accordance procedure

Personnel assigned for the job shall be well versed on hydro testing job.

Approved procedure for hydro testing shall be strictly implemented. Short cutting shall be totally prohibited.

All required PPEs shall be worn by concerned personnel for the job.

No unauthorized personnel shall be allowed to enter the work place.

Test equipment shall be placed at a sufficient distance away from any equipment/pipeline.

Barricades and sign boards shall be installed around the work area and at every event to warn other workers from entering the area. Area shall be cleared from unnecessary materials. Tools/materials shall be properly arranged and placed in a safe area.

If hydro-test is conducted at heights, full body harness shall be worn by personnel and shall be tied-off at all times.

Supervisor concerned shall closely supervise and monitor the job till completion.

4. Depressurization. Pressurized Water Blast. Hand and face injury. Personnel shall be briefed on the safe and proper way of opening the valve. Remove people around the valve before opening and depressurizing by slowly releasing the pressurized water.

Depressurization shall be gradual in accordance to procedure.

Use designed wrench to open valve if it cannot be opened by hand.

5. Welfare / Facilities. Heat Stress / heat stroke. Over fatigue due to excessive work. Working personnel shall be provided with heat shelter where they can have a rest during hot days. Cool drinking water shall be provided including electrolyte drinks whenever required.

Working personnel shall not be allowed to work more than what they can do in a day.

Ambulance shall be on standby near the work location during working hours.

6. Housekeeping Slip, Trip and fall. Good housekeeping shall be properly done after the days works. Close work permit promptly each day before leaving the site.

Required Training.: Safety Orientation; Manual Handling; Hand and Power Tools; Hot Works, Fire Protection and Prevention; Fire Watch Training; JSA and Risk Assessment; Crane and Rigging; Electrical Safety; Lock Out/Tag Out.

REQUIRED SAFETY EQUIPMENT

Hard Hats Yes Other GlovesYesFace ShieldYesHand Tools YesCranesNo

Safety GlassYesWork VestYesGogglesYesCompactorNoForkliftNo

Steel Toe BootsYesSafety HarnessNoBarricadesYesLifting GearNoJackhammerNo

Leather GlovesYesSelf Retracting Lifeline (SRL)NoFire ExtinguihsersYesAir Hoist/Man RiderNoOther Equipments/MaterialsYes

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