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JOB SAFETY ANALYSIS (JSA)

Cleaning & Hydro testing of Test Separator at LBDP

Doc No.: SunPetro/SONG/HAZ/O&M/ON/JSA/R0 Date of Issue: 11/06/2019


And Hydrotest

Purpose Cleaning & Hydro testing of Test Separator at LBDP

Department Mechanical/ Production Location LBDP

Material Requirements General tools and tackles, Lifting tools and tackles, Disposable coverall, Pump for hydro test,
Pump for separator cleaning , Water tank
Required PPEs Helmet , safety shoes, goggles, gloves, coverall, ear muff

No of person Involved Production & Maintenance team, Third party.

Type of PTW Hot work / Cold Work

Note:

1. Tool box talks must be done before starting the job every day.

2. Work must be carried out in day light only.

3. Working screw must wear Approved PPE

4. Use Non-sparking tools & Inspect all tools and tackles before using for job.

JOB STEP Potential Hazard/Loss Control Statement

Isolate the Separator 1. Personal Injury 1. Isolation sheet must attach and followed
2. Falling hazard as per specified and sign and verified it.

Page 1 of 7
JOB SAFETY ANALYSIS (JSA)
Cleaning & Hydro testing of Test Separator at LBDP

Doc No.: SunPetro/SONG/HAZ/O&M/ON/JSA/R0 Date of Issue: 11/06/2019


And Hydrotest

3. Process upset 2. Proper communication with control room

Erection and dismantling (after 1. All components of scaffolding (Pipes,


completion of work) of scaffolding couplers, ladder etc.) must be checked prior
to installation by Sunpetro Person.
2. Scaffolding must be erected or altered by
1. Fall of material, tools or competent personnel under competent
personnel supervision.
2. Personal injury due to fall 3. Barication of area will be done to prevent
from high or fall from material unauthorized person entry
or tools 4.Tools to be lifted or lowered by securing
3. Limited Competency, rope
incomplete training, 5. Scaffolding must be erected as per
4. Scaffold collapse company standard (Crossbrasing and
(improper design, failure of outriggers shall be provided wherever
parts) necessary as per std)
- Ladder must be secured.
- Scaffolding should not be loaded at any
point of time in excess of 6 personnel
- Use FBSH during Scaffolding erection and
dismantling job.
Depressurize and draining the 1. Personal Injury 1. Depressurize the vessel slowly through
Separator 2. Pressurized Vessel needle valve at Daniel meter.
3. Falling Hazard 2. Use FBSH during work at height
4. Spillage 3.Inform ETP prior to draining
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JOB SAFETY ANALYSIS (JSA)
Cleaning & Hydro testing of Test Separator at LBDP

Doc No.: SunPetro/SONG/HAZ/O&M/ON/JSA/R0 Date of Issue: 11/06/2019


And Hydrotest

5. Land contamination 4. Use Secondary containment tray.


5. Use Oil Spill kit.

1. Personal Injury due to fall


from height, mishandling of
1. Use FBSH during work at height
material or equipment
2. Kept one no vent valve in Open condition
Remove all connected 2. Falling Hazard
3.Ensure zero pressure prior to open the
instrument/equipment from vessel like 3. Excessive Pulling/Pushing
instruments or equipment.
LG, PT, TT etc & lifting.
4. Secure the instrument/equipment with
4. Trap Pressure
rope so that it will not fall.
5. Property damage due to
fall from height
1. Personal Injury 1. Use FBSH during work at height
2. Falling Hazard 2. Use specific rated blind for positive
3. Excessive Pulling/Pushing isolations (Ref Size and class of flange list)
& lifting. 3. Qualified person must do the blinding job.
4. Gas Leakage which lead 4. Venting of gas to environment shall not be
Provide the rated blind Flange at all to fire explosion. done.
nozzle of vessel (Positive Isolation). 5. Lockout & Tag out procedure shall be
All flanges are of 300# 5. Personnel injury due to
heavy load and unskilled followed during isolation
manpower. 6. Use Non-Spark tools during work
6. Property damage during 7. Precaution shall be taken to prevent
using of hydra. ignition sources during venting

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JOB SAFETY ANALYSIS (JSA)
Cleaning & Hydro testing of Test Separator at LBDP

Doc No.: SunPetro/SONG/HAZ/O&M/ON/JSA/R0 Date of Issue: 11/06/2019


And Hydrotest

7. Spark of vehicle and Fire 8. Used lifting arrangement for lifting heavy
Hazard or awkward load.

8. Qualified hydra operator must operate the


hydra and Rigger must be qualified.

9. If hydra to be used, is belong to third


party, vehicle check list and all safety
precautions to be taken.

1. Use of proper draining hose and collect


the liquid in the drums.
2. Use PPE during clean up
1. Spillage of liquid
3. NO HOT WORK in the area
Clean the separator using fresh water hydrocarbon
4. Ensure proper trained man power and
2. Personal injury
supervision at all time during the job
5. Use secondary containment to prevent
land contamination
1. Use PPE
2. Thickness measurement equipment must
1. Personal injury be calibrated
NDT to be carried out by third party 2. Wrong reading 3. Clean the area if found any seepage
(Thickness measurement of vessels) 3. Slippery surface 4. Use scaffolding for work at height. Wear
4. Falling from height FBSH during job.
5. Scaffolding must be erected as per
standard.

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JOB SAFETY ANALYSIS (JSA)
Cleaning & Hydro testing of Test Separator at LBDP

Doc No.: SunPetro/SONG/HAZ/O&M/ON/JSA/R0 Date of Issue: 11/06/2019


And Hydrotest

6. Thickness measurement must be done by


govt approved third party

1. Fill the vessel with water slowly by using


pump.
Fill the vessel with water (use from 2. Ensure top vent point is open.
1. Personal injury.
portable water tank) from lowest point 3. Barricade the area.
2. Falling hazard.
of the vessel by using pump. Total 4. Use FBSH during work at height.
3. Air trapped
volume is 16 m3 5. Ensure earthing and function of ELCB
4. Electric shock
prior to use the equipment.
6. Check the cable condition proper to use.
1. Conduct hydro test up to 1.25 times of
design pressure of vessel.
Conduct the hydro test in slowly 1. Vessel rupture.
2. Barricade the Area when Hydro test is
manner up to 187.5 Kg/cm2 (1.25 2. Personal injury.
followed and restrict the movement of
from design pressure). 3. High pressure energy.
persons.
4. Flexible hose rupture.
3. Only authorized personals should be
5. Wrong pressure reading
present on site.
watch
4. Slowly pressurize the vessel and keep
watch on pressure of vessel from field.
5. Use Calibrated Pressure gauge (2 nos).
Vessel Design Pressure : 150 Kg/cm2
6. Ensure no leakage from any point.
7. Pump must be capable to pressurize up
to 200 kg/cm2.
8. Safety Standby.

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JOB SAFETY ANALYSIS (JSA)
Cleaning & Hydro testing of Test Separator at LBDP

Doc No.: SunPetro/SONG/HAZ/O&M/ON/JSA/R0 Date of Issue: 11/06/2019


And Hydrotest

9. Checked for the rated capacity of hose


connections.
10. Continuous monitoring of pressure build-
up.
11. Minimum 30 min holding time for
pressure
12. Remove trapped air from vessel
13. Checked for the rated capacity of hose
connection.
1. Slowly depressurize the vessel.
1. High pressure. 2. Barricade the Area.
2. Personal injury. 3. Only authorized personals should be
After hydro test, depressurize &
3. Spillage present on site.
drained water to portable tank
4. Land contamination 4. Connection to be made to divert the water
to portable tank.
6. Use Secondary containment tray.
1. Personal Injury
Remove all positive isolation after
2. Fall from height 1. Use scaffolding;
hydro test and inspection is
3. Scaffolding collapse 2. Do not stand more than the load bearing
completed and line connection with
4. Failure of lifting equipment capacity of the scaffolding.
vessel and accessories
5. Trapped Pressure 3. Ensure the separator is depressurized
6. Excessive pulling / 4. Used certified lifting equipment
pushing & lifting
Leak test of vessel and put into 1. Personal Injury 1. Properly leak checks the vessel from all
operation 2. Fall from height points
3. Gas Leakage
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JOB SAFETY ANALYSIS (JSA)
Cleaning & Hydro testing of Test Separator at LBDP

Doc No.: SunPetro/SONG/HAZ/O&M/ON/JSA/R0 Date of Issue: 11/06/2019


And Hydrotest

4. Process upset 2. Use soap solution and masking tape for


leak test
3. Ensure zero Oxygen

Signature:

Prepared By: Production /Mech Reviewed By : Installation Manager Reviewed By : HSE Manager
Supervisor

Approved By: Asset Manager

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