JSA

1. Generic JSA for Pipe Flushing / Hydrotesting / Pneumatic Leak Test on Bridge PS 17 / PS 18
No. Job Steps Potential Hazard System And Checks
Needed
Action By
1. Inspection line walk Injury to personnel due to:
 Trip or fall
 Hit against material / item.
 To ensure proper access and
working platform are available.
 To ensure the use of proper
PPE.
 To conduct pre-job briefing.
2. Flushing:
2.1 Prepare flushing equipment:
 Temporary Pump
 Electrical supplies
 Pressure gauge
 Valves
 Hoses
 Couplings
Injury to personnel or damage to
property due to flushing equipment
failure or electrocution
 To ensure the test equipment
are checked for approved
types, correct size and correct
functioning.
 To obtain the necessary
certificate / specification report
of the test equipment.
2.2 Transporting of flushing
equipment to bridge
Injury to personnel due to:
 Falling object
 Trip or fall.
 Improper manual handling
 To ensure all lifting equipment
/ appliance are in good
condition and have valid
certificates.
 To ensure proper rigging.
 To ensure no obstruction in
the way of rigging path.
 To ensure proper access and
working platform are available.
 To ensure the use of proper
PPE.

2. No. Job Steps Potential Hazard System And Checks
Needed
Action By
2.3 Flushing the line Injury to personnel due to:
 Improper manual handling.
 Fall or trip.
 Electrocution.
 To ensure proper drainage
arrangement is made prior to
flushing the line.
 To ensure proper access and
working platform are available.
 To ensure the use of proper
PPE.
 To conduct pre-job briefing.
3. Preparation for hydrotest /
pneumatic leak test:
3.1 Prepare test / drying equipment:
 Temporary pump
 Electrical supplies
 Pressure gauge
 Relief valves
 Manifolds
 Pressure recorder
 Valves
 Hoses / tubes
 Couplings
 Flanges / blinds
 Gas cylinder (for pneumatic
test)
Injury to personnel or damage to
property due to test / drying equipment
failure
 To ensure the test equipment
are checked for approved
types, correct size and correct
functioning.
 To obtain the necessary
certificate / specification report
of the test equipment.
 To ensure the relief valves are
set to release at 10% above
the test pressure.
 To ensure the pressure
recorder is correctly set in
relation to the test pressure.
 To ensure correct recording
chart is used on the pressure
recorder.

3. No. Job Steps Potential Hazard System And Checks
Needed
Action By
3.2 Transporting of test / drying
equipment to bridge
Injury to personnel due to:
 Falling object
 Trip or fall.
 Improper manual handling
 To ensure all lifting equipment
/ appliance are in good
condition and have valid
certificates.
 To ensure all temporary pad-
eyes passed MPI. To ensure
proper rigging.
 To ensure no obstruction in
the way of rigging path.
 To ensure proper access and
working platform are available.
 To cordon off the test area and
display warning signs at
prominent locations.
 To ensure the use of proper
PPE.
3.3 Prepare the test site. Injury to personnel due to:
 Trip and fall
 Improper manual handling
 To identify and remove items
that may cause unnecessary
obstruction to movement of
personnel.
 To ensure proper access and
working platform are available.
 Cordon off the test area and
display warning signs at
prominent locations:
 Minimum 2 m from the test
pack for hydrotest
 Minimum 8 m from the test
pack for pneumatic leak
test
 To ensure the use of proper
PPE.

4. No. Job Steps Potential Hazard System And Checks
Needed
Action By
3.4 Set up the test equipment. Injury to personnel or damage to
property due to:
 Wrong method of work
 Wrong connection.
 Over or under tightening of
temporary connections / joints.
 Trip or fall.
 Improper manual handling
 To ensure the test equipment
are set up as per test
procedure for hydrotest /
pneumatic leak test.
 To ensure proper access and
working platform are available.
To display warning signs on
the test pack (pipes) at every 3
m interval.
 To ensure the test equipment
are positioned at proper
location.
 Ensure proper tightening of all
temporary connections / joints.
 Ensure the hoses / tubes are
properly laid and protected.
 To ensure the use of proper
PPE.
 To conduct pre-job briefing.
3.5 Apply permit to work.  Non-conformance to in-house PTW
system
 Injury to personnel due to un-
coordinated activities.
 To ensure the PTW is duly
filled, endorsed and approved
prior to commencement of the
test.
 To discuss and coordinate the
work in the Safety
Coordination Committee
meeting.

5. No. Job Steps Potential Hazard System And Checks
Needed
Action By
4. Hydrotest / pneumatic leak test
proper:
4.1 Pressurizing the system  Injury to personnel due to hit by
high-pressure jet or bursting line /
blind
 Damage to the equipment / system
due to over-pressure.
 To ensure that the test is
carried out as per test
procedure for hydrotest /
pneumatic leak test.
 To ensure the test is carried
out in step and pressurized by
increment of maximum 25% of
test pressure.
 Only competent authorized
person is to carry out the test.
 To ensure no impact is applied
to the test equipment and the
system.
 To ensure all temporary pipes
are secured.
 To ensure no over-
pressurizing of pipes.
 To ensure only correct blinds
are used.
 Pneumatic leak test is to be
carried out in silence hours or
with minimum barricade of 8 m
from the test pack (for test
pressure < 15 bars).
 To conduct pre-job briefing for
all third party personnel.

6. No. Job Steps Potential Hazard System And Checks
Needed
Action By
4.2 Checking the system for leak Injury to personnel due to:
 Hit by high-pressure jet
 Bursting line / blind
 Trip or fall
 To ensure no impact is applied
to the test equipment and the
system.
 To adopt safe position when
checking / inspecting the
system.
 To ensure proper access and
working platform are available.
 To ensure no line inspection is
carried out while the pressure
is being increased.
 To ensure the use of proper
PPE.
4.3 Repair the system (when
necessary).
Note: this section is to be read
in conjunction with section 4.4
below.
Injury to personnel due to:
 Hit by high-pressure jet
 Trip or fall
 Improper manual handling
 To ensure that the system is
de-pressurized prior to any
repair as per test procedure
for hydrotest / pneumatic leak
test.
 To ensure proper access and
working platform are available.
 To ensure the use of proper
PPE.

7. No. Job Steps Potential Hazard System And Checks
Needed
Action By
4.4 De-pressurizing the system Injury to personnel due to:
 Hit by high-pressure jet
 Trip or fall
 To ensure that the system is
de-pressurized as per test
procedure for hydrotest /
pneumatic leak test.
 To adopt safe position when
de-pressurizing the system.
 To ensure no impact is applied
to the test equipment and the
system.
 To ensure the pressure is
released at a controlled rate
(for pneumatic leak test).
 To ensure the use of proper
PPE.
4.5 Draining the water from the
system (for hydrotest)
 Work area flood or wet with water.
 Personnel injury due to:
 Collapse of the pipe / system.
 Electrocution.
 Trip or fall.
 Improper manual handling
 To ensure proper drainage
arrangement is made prior to
draining of the water.
 To ensure the sufficient vent is
provided prior to the draining
of the water.
 To ensure the following if
compressed air is used as
assisting medium to drain the
water:
 Compressed air pressure
is less than 6 bars.
 Compressed air lines must
be in good condition and
properly laid
 To adopt safe position.
 To ensure the use of proper
PPE.

8. No. Job Steps Potential Hazard System And Checks
Needed
Action By
5. Pack up or relocate the test
equipment.
Injury to personnel or damage to
property due to:
 Wrong method of work
 Trip or fall.
 Improper manual handling
 To ensure safe work methods
are applied.
 Ensure the hoses / tubes are
properly kept.
 Cordon off the test area.
 To ensure the use of proper
PPE.
 To conduct pre-job briefing.
6. Reinstate the lines. Injury to personnel due to:
 Falling object
 Trip or fall.
 Improper manual handling
 To ensure all lifting equipment
/ appliance are in good
condition and have valid
certificates.
 To ensure all temporary pad-
eyes passed MPI.
 To ensure proper rigging.
 To ensure no obstruction in
the way of rigging path.
 To ensure proper access and
working platform are available.
 To cordon off the test area and
display warning signs at
prominent locations.
 To ensure the use of proper
PPE.