Hydro Testing JSA || Job Safety Analysis Doc
What is JSA (Job Safety Analysis)?
Job safety analysis is a safety technique or tool examine
a site activity to identify the potential hazards to control the risk of harm
by applying suitable & practicable safety control measures.
What Is Hydro Testing?
Hydro testing also called hydrostatic testing, hydro
testing is a type of test for pressure vessels, pipe lines to check leaks from
joints and from other welded parts.
In hydro testing water pressurized in vessels or pipes
with the help of manual and powered water pump on a certain required pressure. Safety
precautions must be taken and JSA for Hydro testing must be done before starting
hydro testing to prevent workmen from harm and accidents.
hydro testing jsa
How to Calculate Safe Distance for Hydro Testing?
Safe Distance: - (0.15)×(D)×(a)^0.4×(q)^0.6
Here
D = Internal diameter in Meter
a = Length of system/diameter in Meter
p = Test Pressure in Bar
hydro testing job safety analysis
Activities involve in Hydro testing: -
- Site preparation
- Hydro testing (Pressurizing water in vessels or pipers by pump.
- Depressurizing (Releasing pressure)
- Equipment fitting work.
- Water drainage.
Hazards & Risks involved in Hydro testing: -
- Improper job planning
- Injury due to use of improper tools
- Unauthorized entry
- Injury due to failure of fittings used for hydro test
- Injury/Property damage while testing flanges joints during hydro testing
- Injury due to fall from height (if applicable)
- Property damage due to over pressurization
- Fire/electrical hazard due to non-flame proof equipment and/or diesel operated engine
- Equipment damage
- Injury during depressurization
- Physical injury while working
- Electric shock during water draining
- Competent supervisor shall be engage for hydro test work
- Permit system to be followed
- Mechanical/Electrical LOTO system must be available as applicable
- Pressure safety valve, Manifolds used shall have MTC/Authorized certificates before being used
- Relocating electrical panel/welding booth it, any in water filling area/Draining area to be done
- TBT must be given by job supervisor
- Use standard job specific tools and PPEs
- Use good condition third party certified tools and tackles
- Area to be barricaded (Line of Fire)
- Provide sign board/Do not allow too many person during pressurization
- Ensure Blinds used area of correct rating to withstand hydro test pressure
- Avoid threaded connections and plugs. Check for all fittings before hydro test includes gaskets
- Check for pump hoses for any kind of damage. Only one person will check for leakages
- Web check arrestors in hose connection
- Refer and comply to Work at Height JSA (this will apply to all sub activities)
- Be clear about the hydro test pressure; do not pressurize beyond hydro test pressure
- Use standard and calibrated gauges only
- Follow SOP and know test pressure
- Only Authorized operator shall allow to operate the Hydro test pump
- Electric machine must be certified by competent authority and have valid certificate
- All Electric connection to be crosschecked for loose fittings etc. Earthling of the equipment must be done
- LEL must be checked in the area periodically
- DCP cylinder to be kept ready for use
- Provide adequate venting to avoid equipment going to vacuum during draining
- Keep body away from the fluid path
- Open valve slowly
- Corrects tools must be used during hydro testing work. Use mandatory PPEs on the working area
- Correct area will be provided for draining, where the electric power tools are not placed
Hydro Testing JSA || Job Safety Analysis Doc
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