Sr

Job Steps Potential Hazards Control Measures / Mitigation Plan Responsibility

No.
 Refer to Sadara Safety Policy Supervisor
 Conduct Too Box Talk
Non-compliance of Safety
 Wear proper PPE as per the Job at all the times (i.e Hard hat, Supervisor/
Policy
Dust mask, safety glasses/goggles, Leather gloves, Face shield, Technician
leather apron etc.)
 Barricade the area where pressure-test is to be carried out. Supervisor/
Unauthorized Personnel
 Post warning notice. Technician
 Check and Ensure the equipment / tool to be used for pressure
testing (such as hose, coupling, pressure gauge, spade, gasket
1 Planning
etc.) are free from defect and suitable for the pressure rating
of the system
 Usage of tools shall be based on the recommendations stated
Supervisor/
Defective Tools/Equipment in the manufacturer manual and test shall be based on
Technician
standard.
 Handling and storing of tools and equipment shall be based on
the recommendations given by manufacturer.
 All tools and equipment needed to be used shall be inspected
by a competent person prior usage.
2 Pressure Testing  Check any rupture of Pressure Equipment due to brittle Supervisor/
fracture and ductile fracture. Technician
Unintentional release of  Check if attachment of blanking plates and their clamps/
stored energy attachment bolts, screwed plugs, isolation valves, etc.
 Check the attachment of temporary welds on plug at pipe ends
and nozzles
 Check the quality of the gaskets
Exceeding Maximum  Ensure the pressure relieving device is set at maximum
Allowable Pressure allowable pressure for weakest portion of the segment to be
pressure-tested.
 Damage to Equipment /  Never increase the test pressure more than the
System maximum allowable pressure for the weakest portion in the
segment or pressure rating of the hose & coupling.
 Do not leave the pressurized hose unattended when the
Un-attended Pressurized Tool
pressure-test is going on.
/ Equipment
 Isolate the equipment from all source of energy when not in
use.
Changing the Duration of  Do not change (exceed / decrease) the duration of pressure
Testing test without permission from Inspection Engineer.
 Keep away from the pressurized segment of the system being
pressure-tested.
Injury to Workers  Monitor the pressure gauge from a safe distance away from
the potential source of high pressure jetting (Such as Flange
Joint, Spade, and Coupling etc.)
 Ensure the workers are wearing required PPE
Unsafe Depressurization  Ensure the safe depressurization of air
Tools / Instruments Failure  All instruments that will be used shall be calibrated and
inspected prior to use.
 Calibration shall be based on the manufacturer’s
recommendation. Color coding for the month shall be
complied.
 Instruments / Tools maintenance plan shall be adhered to.
 Visual inspection of the tools to be used shall be conducted
before using it.
 Defective tools and equipment shall be removed from the site.
 Continuity testing shall be performed with the use of
calibrated multi meter.
 Use appropriate power cable and supply for the specified
voltage current to be tested
 and used.
 Proper planning to be carried out when conducting

Ergonomic Hazards
Scattered Material
Windup &
3 Housekeeping
Sharp Edge Tools / Materials
Personal without required
PPEs
4 Working in an Working in Extreme
Adverse Temperature
instruments tests.
 1.5.1 Training for ergonomics shall be provided around the
work area.
 1.5.2 Use proper body mechanics when lifting materials and
tools manually.
 1.5.3 Team lifting or sharing of load shall be applied when
manually transferring load which exceeds 25 kg.
Supervisor/
 1.5.4 Avoid monotonous task and take breaks on regular
Technician
interval.
 1.5.5 Only use specific / recommended tools for the job.
 1.5.6 When working on tight spaces, Plan properly the
sequence of the job to manage time and exposure of the
worker to awkward and extreme body positions while dealing
with the task.
 Ensure proper wind up & housekeeping at worksite. Supervisor/
 The accessories (hoses & compressor) not being used must be Technician
disconnected and the hoses are stored properly
 PSV (in case isolated) to be lined up after pressure test
completion.
 Cover Sharp Edges of materials with softener in handling and
work.
 Secure sharp-edged materials and safety store sharp tools
after use
 Substandard / improvised hand & special tools are strictly
prohibited.
 Wear appropriate PPE while performing the task (E.g.: Cut
Resistant Gloves)
 Wear proper PPE as per the Job at all the times (i.e Hard hat,
Dust mask, safety glasses, Leather gloves, Face shield, leather
apron etc.)
 Heat Stress campaign and heat stress management program to
be applied.
 Site safety measures including proper shading, well ventilated
 Environment and heated break areas and sufficient cold fluids provided etc.
 Pre-job heat stress monitoring checklist.
 Adequate information, Training, Instruction and supervision.
 Implement flag system to provide guidance to all workers on
site.
 Work rotation regular work intervals.
 Dust mask shall be provided and worn as needed, to limit
exposure level.
Dust  If applicable, apply dust suppression control measure by
spraying water over the area.
 Training course for toxic gasses and awareness shall be
provided to all workers on site.
Toxic Gas (release)  Gas detector must be provided to key personnel on site, Gas
test shall be conducted regularly.
 Smoking shall be done in designated areas.
 Personnel shall strictly comply with the smoking policy on site.
 All workers must strictly comply with the recommendations
Fire stated in the permit.
 Fire Watcher shall be assigned in every hot work / activity
inside the brown field area.
 Emergency drills shall be conducted as scheduled to ensure
emergency preparedness
 of all personnel on site.
 All Personnel shall be informed on the emergency contact
Unawareness of Emergency Supervisor/
5 Emergency number to be used in case
Procedure  of emergency. Technician
 Personnel must know the procedure of emergency evacuation.
 All equipment to be shut down if safe to do so.
 Follow emergency muster procedure.