Tuesday, December 29, 2020

Pneumatic Test-Job Hazard Analysis

Activities, Potential Hazards and Control Measures

1. Mobilization of Materials & Tools

Potential Hazard

  • Slips and tripping hazard
  • Material Falling
  • Hand Injury
  • Strike against any equipment
  • Manual handling

Control/Mitigation Measures

  • Correct Sign Board should be posted.
  • Proper arrangement of all materials proper barricading to avoid any trips & slips
  • Secured All materials before transporting from one point to another
  • Removed all sharp objects
  • Use proper PPE to carry any kind of all potential obstacle/trip hazards.
  • Provide train banks man while the vehicle is moving
  • As per QP procedure transport should follow the speed limit
  • Supervised the workers and follow ergonomics while doing manual handling.
  • Proper communication while lifting the objects.

2. Site Preparation for the Work Activities

(Using Air compressor, Hydro-jetting machine, Vacuum Tanker, Diesel Generator, Trailer, Self-Loader, Crane, Pneumatic pump, Fork Lift) (If Requires)

Potential Hazard

  • The entry of equipment without a valid gate pass.
  • Poor communication between work parties.
  • Lack of safety awareness/Knowledge & inexperience
  • Injury from improper manual lifting
  • Improper tools

Control/Mitigation Measures

  • Must require valid gate passes for all equipment.
  • Supervision to be at the work front at all times by performing party to ensure that the workforce has a good understanding of the task and working to the approved JHA and Permit Requirements.
  • Good coordination and communication between team members.
  • All workers shall be instructed in safe lifting techniques/procedures.
  • If loads are awkward, gawky, too heavy, difficult to grasp, high traffic areas, two (2) men are required for carrying loads.
  • Proper tools should be used.

3. Pneumatic Test

Potential Hazard

  • Exceeding Maximum Allowable Pressure
  • injury to Workers
  • Damage to Equipment / System
  • Un-attended Pressurized Tool /Equipment
  • Changing the Duration of the pneumatic test
  • Unsafe Depressurization of pneumatic test
  • Fatal physical Injuries from Pipe fracture/damage / Or High-Pressure Water Blast
  • No Distance Barricades
  • No Preliminary Walkthrough
  • improper Disposal 

Control/Mitigation Measures

  • Ensure the pressure-relieving device such as Pressure Relief Valve (PRV) is set at maximum permissible pressure for the weakest part of the segment to be hydro-tested.
  • Always keep away from the pressurized portion of the system being pneumatic tested.
  • Appropriately monitor and observe the pressure gauge from a safe distance away from the possible potential source of high-pressure jetting (Such as Flange Joint, Spade, and Coupling etc.)
  • Ensure the workers are wearing required PPE
  • Never increase the pneumatic test pressure more than the maximum allowable pressure for the weakest portion in the segment or pressure rating of the hose & coupling
  • Never leave the pressurized hose or pump unattended when the pneumatic test is being in progress.
  • Make the isolation of equipment from all source of energy (electricity, water, lubrication/gas) when not in use.
  • Do not exceed or decrease the planned or pre-set duration of hydro-test without permission from Inspection Engineer/supervisor or other technical personal.
  • Hazardous and highly flammable or suffocated types of gases or vapours must be ventilated appropriately and essentially and clear of any area where personnel are working or where there is any possible source of ignition.
  • Valves of the energy sources must isolate any ancillary device or equipment not under test.
  • Mere calibrated test gauges shall be utilized and they shall be kept in the upright position. 
  • Pump discharge gauges must be visible to the pump operator during the duration of the pneumatic test.
  • The equipment/vessel shall have appropriate and essential vacuum relief capacity to avoid any severe destruction or collapse draining the test liquid.
  • The tested line shall be supported and secured.
  • Water supply Lines shall be drained and dried mechanically when the test liquid is corrosive or otherwise extremely hazardous.
  • A system under test shall be depressurized (except pressure due to a compressed airhead) before any work is done to stop leaks or repair weakness, including the tightening of bolts.
  • A block valve is needed on the line from the test pump to the equipment and or device under test.
  • Air shall not be used to displace test air from underwater equipment unless it has been determined that the equipment will not float.
  • All Piping, vessels, supports and foundations designed for gas service shall not be overloaded by the additional weight of the test liquid. Temporary supports and braces may be needed.
  • An accessible bleed valve shall be provided for the protection and prevention of the piping system in case an immediate depressurizing is required.
  • Pressure shall be increased slowly and steadily with 10 minutes hold at each step, no swift change in energy source pressure
  • Proper barricade and sign should be posted
  • Do not walkthrough while the test is performing
  • secure the area and do not block the area by materials
  • Disposal of waste should be properly stored
  • Any spill or leaks of waste should be cleaned immediately 

4. In the Event of Emergency Alarm

Potential Hazard

  • Panic 
  • Unfamiliar with an emergency alarm
  • Slips trips and falls.
  • Lack of knowledge of the emergency procedure.

Control/Mitigation Measures

  • In the event of plant alarm or gas detector alarming following actions are to be taken
  • Immediate STOP/suspend all activities.
  • Do not run-in case of emergency to avoid to trip, slip, fall
  • Familiarized of emergency evacuation procedures.
  • Drivers stop vehicles and switch off the engine and other equipment also should be switched off
  • All personnel should proceed to the nearest muster point
  • Wait at the muster point for further instruction
  • Make sure the Supervisors level attended the HSE induction and the information to be transferred to all workers)

5. Housekeeping

Potential Hazard

  • Slips trips and falls. 
  • Scattered materials

Control/Mitigation Measures

  • Regular housekeeping at the site shall be performed. 
  • Ensure proper wind-up & housekeeping at the worksite.
  • Adequate and correct stacking of materials.
  • Regular inspection and immediate corrective action. Keep always clear of obstruction.
  • Regular clearing of worksite shall be implemented.
  • Access & Walking ways or Working Places Always Clear.

6. Manual Handling

Potential Hazard

  • Hand injury
  • Back injury

Control/Mitigation Measures

  • Use proper PPE
  • Follow the ergonomics and ensure good supervision by a responsible person.

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