Bharat Heavy Electricals Limited Doc No.

BHEL/JHA 14
NPCIL
TGPP for KAPP (3&4) Date: 11/03/2016
Rev No: 00
PS-WR

JOB HAZARD ANALYSIS

FOR

HYDROLIC TEST OF MSR

 Bharat Heavy Electricals Limited Doc No. BHEL/JHA 14
NPCIL
TGPP for KAPP (3&4) Date: 11/03/2016
Rev No: 00
PS-WR

Document Acceptance Note

Procedure No.: BHEL/JHA 14

Name of Procedure: JHA for Hydraulic test of MSR

Submitted by: BHEL

Work Order No: CMM/MEQ/23-40-2-1024/PO-6055 DT- 31/03/2011

Name of Work: TG Plant Package

Name & Designation Signature

Reviewed by:
B.R. Chaudhari

Engineer SO/E (TG)

Reviewed by:
Indresh Yadav

Safety Officer (NPCIL)

Concurred by:
Ajay S. Naranje

Head (IS & F)

Approved by:
B.L. Sahu

ACE (TG)
 Bharat Heavy Electricals Limited Doc No. BHEL/JHA 14
NPCIL
TGPP for KAPP (3&4) Date: 11/03/2016
Rev No: 00
PS-WR

JHA for hydraulic test of MSR

Work Order No: CMM/MEQ/23-40-2-1024/PO-6055 DT-31/03/2011

BHEL DOCUMENT NO: BHEL/JHA 14

NPCIL PROCEDURE REG. NO. :

DATE:

PREPARED BY: ENGINEER (BHEL)

REVIEWED BY: SO (BHEL)

APPROVED BY: CM (BHEL)

 Bharat Heavy Electricals Limited Doc No. BHEL/JHA 14
NPCIL
TGPP for KAPP (3&4) Date: 11/03/2016
Rev No: 00
PS-WR

JHA for Hydraulic test of MSR

1. Engineer - in – Charge : Sh. Chandan Kumar

2. Manpower required for the job
3. PPE's required
4. Tools and tackles required
5. Authorization required
: Riggers, Electrician and helpers
: Helmet, Safety shoe, Gloves, Reflective jacket, Safety belt,
and fire extinguisher
: Booster pump, pressure gauge, hose pipe, valves etc
: Safety Work Permit, Rigger authorization etc.

Sl. Sequence of the Potential Protective measures to be Action By

No. job Hazards taken
1. Planning  Unauthorized  Barricade the area where Execution
personal. hydro test is being carried Engineer
out.
 Post warning sign boards.
 Injury due to  Ensure equipment/ tool to
defective tool & be used for hydro test-
tackles. such as (Hose, pump,
coupling, pressure gauge
and gasket etc) are free
from defect and should
be done in presence of
competent person.
 Bharat Heavy Electricals Limited Doc No. BHEL/JHA 14
NPCIL
TGPP for KAPP (3&4) Date: 11/03/2016
Rev No: 00
PS-WR

2. Hydro test

Inspection of Fall of person Provide safe approach for Execution

piping for all inlet inspection of hydro test Engineer
readiness. Proper anchorage
and outlet lines.
system will be provided and
enforcement of full body
harness will be implemented.

Mark all leak point and correct

them before proceeding the
Hydro-test

Lashing of tools will be Execution

implemented and correct size Engineer
of wrenches will be made in
use.

Pressurizing the Hose pipe or The hydro test team will check Execution
system up to valves can be all gaskets, bolting for Engineer
pressure 13.5 burst suitability and healthiness. The
kg/cm2 and hydro test crew will check to
temperature confirm for all bolt tightening.
more than 7oc. Hose should be connected
tightly so that it can withstand
pressure if possible whip lock
arrester should be installed.
Use calibrated pressure gauge
and safety relief valve and TPI
implemented pressure vessel.

MSR vent should be open for Execution

removing air vent from MSR. Engineer
after filling close that vent
before pressurizing.

The system will be pressurized

Execution
gradually as mentioned in the
procedure (0.2 kg/mm2) and Engineer
over pressure than the
 Bharat Heavy Electricals Limited Doc No. BHEL/JHA 14
NPCIL
TGPP for KAPP (3&4) Date: 11/03/2016
Rev No: 00
PS-WR

recommended pressure will be

strictly forbidden. Continuous
pressure monitoring &
recording will be implemented.

Pump gradually and constant

observation

Safety relief valve should be

installed and it should be
calibrated.

Electrical Hazard The electrically operated Execution

equipment will be competent Engineer
enough for the operation. The
electrical equipment will be
provided with healthy ear-
thing system and provided
with emergency off system.
The electrical equipment will
be isolated from hydro test
zone. The electrical panel of
hydro test system will be made
easy identification with
warning signs.

Leakage and Slip and trip will be managed Execution

cable & hose management.
seepage Engineer
Slip will be controlled by
leakage containment.

Water seepage and leakage

will be minimized by tightening
the fasteners of mechanical
joint and gum boot will be
provided to avoid slip.
Execution
Water can be The draining of water will be Engineer
Drainage accumulated only at authorized area. If any
excess water is accumulated it
will be de-watered.
 Bharat Heavy Electricals Limited Doc No. BHEL/JHA 14
NPCIL
TGPP for KAPP (3&4) Date: 11/03/2016
Rev No: 00
PS-WR

Check List of Hydraulic test of MSR

Date:
SL.
NO DESCRIPTION STATUS REMARKS
1 All workers inducted & medically fit YES NO
2 Height pass verified YES NO
All persons working use PPE's like helmet, shoes ,Gloves, Reflective jacket
3 ,gum boot, nose mask, etc. YES NO
4 Experienced /authorized rigger and electrician are deployed. YES NO
All equipment / tools & tackles are tested and calibrated, record is made to be
5 available YES NO
6 All workers are given pre job briefing. YES NO
7 Proper barricading with warning signs/barricading tape is put. YES NO
8 Electrical motor & pump are properly grounded. YES NO
9 Unauthorized entry in pressure testing zone should be strictly prohibited. YES NO
10 Slip and trip will be managed by leakage containment. YES NO
Pressure relief valve should be installed for avoid bursting hose pipes and
11 valves. YES NO
Lashing of tools will be implemented and correct size of wrenches will be
12 made in use. YES NO
13 Walkways should be clear from debris and easy to access. YES NO
14 Adequate illumination is available in the working area YES NO
15. Two workers should be specially nominated for chemical handling YES NO
Chemical handling workers should wear full body apron, safety shoes,
16 helmet, face shield, PVC hand gloves and face shield. YES NO
17. Clean water made available near mixing tank YES NO
18. All chemicals should keep away from fire prone area. YES NO

Checked by Authorized by

Signature : ______________ _____________

Name : ______________ _____________

Date : ______________ ______________