JOB SAFETY ANALYSIS FRONT SHEET
INSTALLATION / SITE DATE
JSA REF NUMBER JSA TEAM (NAME LIST)
DEPARTMENT Mechanical NAME Position
PERMIT TO WORK NO
TASK DESCRIPTION
High Pressure Test
REFERENCES AND ANY OTHER RELEVANT INFORMATION ( e.g P &
ID's , Drawings,Procedure , Work Instructions, Certificates , Special Tools or Equipment) CONFIRMED ALARP JSA APPROVED BY (Installation / Facility /Site Man
Name
Signature
Position
Date
Signature
cility /Site Manager)
JOB SAFETY ANALYSIS WORKSHEET
Task Description Summary - Hydro Test
JSA Ref No
4. IR 7. RR
1. 2. 3. 5. 6.
STEP
Activity Description Potential Hazard Hazard Effect Existing Controls & Controls Required Responsible
E P R E P R
1. Working without work 1. Illegal operation [Link] compliance to the PTW procedure and requirements
permit 2. Clash of activities [Link] must be kept visible at work location
2. Absence of Performing authority 3. Permit issuer and receiver must conduct work site inspection Site Engineer
1 Obtain Permit To Work 2 1 L Performing 2 1 L
from work location Prior issuing the permit auhthority
4. Performing authority must be present at work location
1. Slippery surface [Link], trip and fall on same 1. Inspection of work location prior starting the job
2. Defective tools level 2. Floor opening should be hard barricaded .
3. Floor openings 2. Personal Injury 3 Clear the area and indentify safe access
3. Damage to equipment's Site Engineer
2 Work Area prepration 3 2 M Performing 3 1 L
tools & tackles auhthority
4. Fall of personnel due to
floor opening
1. Inadequate use of hand 1. Finger Caught in between [Link] tools before using
tools 2. Personal Injury [Link] right tools for the job Site Engineer
3 Use of hand tools 2. Failure to use PPE 3. Damage to equipment 3 2 M 3. Use appropriate PPE Perfoming 3 1 L
authority
3. Using makeshift tools 4. Do not use any makeshift or damaged tools at site
[Link] handling 1. Personal Injury 1. Only competent personnel shall carry out the job
[Link] Point 2. Hand , finger caught in between 2. Equipment shall be tested for its working condition
3. Exposed electrical cable 3. Electrocution 3. Ensure pump is earthed
4. Failure to earth 4. Water Spillage 4. Communicate the hazards while assembling the pipes
5. Failure to use correct equipment 5. Brusting of hoses 5. Use ring spanner instead of D spanner
6. High Pressure 6. Hit by swinging hose 6. All pressure testing equipment shall have current calibration certificate
7. Defective hoses 7. Property Damage 7. Minimum 2 pressure guages shall be fixed for hydro testing
8. Failure to secure 8. Unthorised entry 8. Whip Lash Arrestor must be used on pressure hose connections
9. Failure to cordon off 9. Ensure cable joints are as per standard , no tapping in allowed
[Link] insulation shall be aavioded in all electrical cables Site Engineer
Setting up equipment and
4 hydro Test 3 3 H 11. test certificate of manifold shall be attached with test pack Performing 3 1 L
auhthority
12. Certified flanges with correct rating shall be used
13. PSV / PRV gauges shall be calibarated and tested
14. Pressure withstanding capacity of connecting hoses shall be clearly
identified
15. Rusted bolt shall not be used
16. Threaded plugs and bolts shall be of correct size
17. Cheater bar shall not be used to increase leverge of spanner
18. Prominent signage's shall be installed before starting the job
19. Area shall be cordon off to avoid any unauthorised entry
1. Flying objects 1. Personal Injury 1. Appropriate PPE's shall be used by all engaged crew
2. Unguarded rotating parts 2. Water spillage 2. Prominent signages shall be installed
3. Under Pressure water 3. Safety relief valve shall be installed on manifold
4. Air inlet and outlet area shall be barricaded
5. Effective TBT shall be conducted Site Engineer
Air blowing/ cardboard blasting and
5 water flushing 3 2 M 6. Area shall be cordon off and no one shall be allowed in air outlet area Performing 3 1 L
auhthority
7. Temporary guard shall be set at the air outlet for card board blasting
8. Water shall be disposed to recharge pit
1. Electrical driven pump 1. Electrical shock 1. Prior water filling hydro test checklist shall be filled
2. Damage pipes 2. Leakage of water 2. Ensure all rotating parts of pump are guarged
3. Damage electrical cable 3. Personal injury 3. Venting shall be provided at higher location
4. Entanglement 4. Pump shall be inspected and tagged Site Engineer
6 Water filling works 3 2 M Performing 2 1 L
5. Pipes shall be protected from vehicle collision auhthority
6. Close and adequate supervsion is required
1. High Pressure 1. Blasting of pipes 1. Barricade the entire area adequately
2. Failure of guages 2. Personal Injury 2. Warning in english and local language" Keep Away Pressure Test in
progress"
3. Personnel should not be allowed to stand infornt of pressurized blinds
and threaded parts Site Engineer
7 Pressurizing and holding 3 3 H Performing 3 1 L
4 Dummy flanges should be on proper pound rated , corrision on thread auhthority
shal be checked
5. No work on pipe shall be allowed while It in under pressure
1. Leakage of water 1. Water spillage on ground 1. After depressurising open the vent valve before opening the drain valve
2. Dewatering shall be done after releasing pressure inside the pipe Site Engineer
8 Dewatering 2 1 M 3. Treated water shall be disposed to recharge pit Performing L
auhthority
4. Water drain pipe shall be protected from passing vehicles
[Link] of debris 1. Tripping /Falling hazard 1. Housekeeping shall be maintined during
2. Non closure of permit the activity and at the end of job
2 Remove all debris from the site Site Engineer
Housekeeping & close Performing
9 of work for the day 2 1 L 1 1 L
3 Permit must be closed and submitted to auhthority
CIL upon completion of job
1. Extreme weather condition 1 Collapse of individual [Link] procedure shall be in place
2 Lack of supervision 2. Fire 2. Effective TBT , shall include Emergency
[Link] of toxic or flamable [Link] response Site Engineer
10 Emergency Response 2 2 M Performing 2 1 L
gases 4 Unvailbility of emergency 3. Ensure emergency vehicle arrangement auhthority
vehcile is on place
1. Poor communication 1. Human fatigue [Link] enagaged crew is trained in working
2. Inadequate illumination 2. Poor Visibility night shift
3. Lack of supervision 3. Attracting Live Reptiles 2. Ensure adequate lighting arrangement
4. Eating at site are made.
5. Working withour extension 3. Ensure effective night shift supervision Site Engineer
11 Night Shift Work 2 2 M Performing 3 1 L
of permit 4. Stop work in the event of adverse climate auhthority
5. Ensure night shift personnel get enough sleep or rest during day
6. Ensure personnel are trained to meet any emergency that may
occur at night
1. Unvailbility of drinking water 1. Heat related illness [Link] plenty of cold drinking water is available at site
2. Lack of or inadequate rest shed [Link] of workmen 2. Ensure adeqaute rest shelter is available for workmen to take rest Site Engineer
12 Heat Stress Management 3. Failure to follow heat index flag 2 3 M as per procedure and heat index flag system Performing 2 1 L
auhthority
system
RISK MATRIX
Severity
1. 2. 3. 4.
Minor Moderate Serious Major
No or Minor Off Site Serious Injury & More than One
Injury Medical Treatment LTI LTI
5.
Will Occur in 5 10 15 20
present state
Probability (Likelihood of the Occurance)
4.
More likely to 4 8 12 16
occur than not
3.
Possible 50/50 3 6 9 12
chance
2.
Unlikely Could
2 4 6 8
occur less than
50/50 chance
1.
Very Unlikely
1 2 3 4
little or no chance
of occurrence
1-3 Low Risk Managed by routine [Link] be acceptable,however review
to see if risk can be reduced further
4-6 Modrate Risk Task should only proceed with appropriate management
authorisation
8-12 High Risk Task needs further review and consultation with specialists and
where possible the task should be re-defined to take account
of the hazards involved or the risk should be reduced to further before
the task is allowed to commence
15-25 Extreme Risk Task should not proceed
5.
Significant
Permanent
Disability and
Fatality
25
20
15
10
able,however review
h specialists and
take account
duced to further before
