Comments Resolution Sheet (CRS)

Date : 17.01.2022 Project Name :Integrated Field Plan Execution Services in Satellite Fields in RJ-ON 90/1
Block

Dwg/ Doc Number: S340HAL-SRX-Q-PRO-0047

Revision Number:- A4
From, To,
Halliburton Offshore services Inc..
CAIRN INDIA LTD.
DLF Atria Building, DLF Phase-2,
GURGAON-122002, HARYANA, INDIA
We are in receipt of your comments on our deliverable(s) which are tabulated in the following table. Clarifications / resolutions to each comment are furnished below.
Based on this resolution sheet we shall revise our deliverable(s) and resubmit.
Sl.
Clause/ Ref. No. Comment Clarifications / Resolution Comments
No.

1) This procedure shall be applicable irrespective of no of contractors engaged 1) Noted

by HSOI 2) Noted
2) Note: Training shall be ensured on the procedure and daily toolbox talk. 3) Noted
1 Page 1 of 13
3) Procedure shall be available at the point of use. 4) It will mark in the
4) Provide schematic diagram of test set up. P & ID
5) List out tools /tackles/M/c / Instruments to be used. 5) Noted & Incorporated

Clause 3.0 RJON-RX-OP-PRO-0060- Rev 1 RJ Gas Procedure for Pressure vessels, plant
2 Noted & Incorporated
Page 3 of 13 piping and

Page 1 of 3
 1) All hydro test crew shall be competent and certified by Cairn before starting
the job
Clause 5.0
3 2) All materials involved in the test shall be suitably rated and certified including Noted & Incorporated
Page 4 of 13 Manifold, Pressure gauges, PSV, Fittings and other attachments.
3) Cairn Hydro check list compliance shall be ensured .
Clause 5.0
4 Valves shall be opened only 70% during testing. Noted & Incorporated
Page 7 of 13

In case vent and drain is not provided in ISO, Piping / Hydro-test engineer shall
5 Page 8 of 13 provide / Ensure Vent & drain at appropriate location and the same shall be Noted
pluged after hydro testing included in in ISO.
1) Selection of PSV shall be as per RJON-RX-OP-PRO-0060- Rev 1
2) Handling and storage of Calibrated Gages, Chart recorder and PSV's shall be
handled by Hydro testing engineer only.
6 Page 10 of 13 Noted
3) Gauges / Chart recorders / psv's shall be calibrated by NABL Accredited Lab
with NABL Certificate.
4) MTC of PSV's shall be available.
1) Hydro testing engineer shall ensure that the check list in RJON-RX-OP-PRO-
0060- Rev 1 is signed of by Company's representative prior to Pressurization of
7 Page 11 of 13 System Noted
2) Hydro test pressure shall be increased gradually holding at intervals
Clause 5.0 The system shall be dewatered from the lowest available drain point With vent
8 Noted & Incorporated
Page 12 of 13 open

Clause 5.0 Drain, instrument airline, plant airline, relief and blow-down lines are to
9 Noted & Incorporated
Page 12 of 13 be tested as per line list
Clause 5.0
10 The processes shall start immediately after test Noted & Incorporated
Page 12 of 13

Page 2 of 3
 Doc. No.: S340HAL-
11 SRX-QITP-0047, In column of Inspection by “Sub Con” Noted & Incorporated
Rev.A3
Doc. No.: S340HAL-
SRX-QITP-0047,
12 In column of Inspection by Sub Con “H” Noted & Incorporated
Rev.A3, Sl No.10(c)
& 10 (d)
Doc. No.: S340HAL-
SRX-QITP-0047,
13 In column of Inspection by HOSI “W” Noted & Incorporated
Rev.A3, Sl No.10(c)
& 10 (d)

 Mentioned Clause No./Ref No. as per commented document.

Page 3 of 3
 VEDANTA LIMITED
Cairn Oil & Gas

Project: Integrated Field Plan Execution Services in Satellite Fields in RJ-ON

90/1 Block - Surface Facilities

Document Title: WORK PROCEDURE FOR HYDROSTATIC / PNEUMATIC

TESTING OF STATION PIPING

Cairn Doc No:- S340HAL-SRX-Q-PRO-0047

A4 17.01.2022 Revised & Re-issued for Client Review BP BP VP RMJ/TR

A3 22.12.2021 Revised & Re-issued for Client Review BP BP VP RMJ/TR

A2 06.12.2019 Issued For Client Review AG AS SB MJ

A1 20.11.2019 For Review AG AS SB TR

Approved By
Rev Date Purpose of Issue Prepared By Checked By Approved By
(HOSI)

MAIN LSTK CONTRACTOR ENGG CONSULTANT

EPC-CONTRACTOR

Page 1 of 14
1.0 Project Background
Cairn Oil & Gas (Vedanta Limited) is India’s largest private upstream O&G company with operating interests in several producing fields in India contributing ~27%
of India’s domestic crude production. Cairn Oil and Gas (Vedanta Limited) is the operator of the onshore RJ-ON-90/1 block, on behalf of itself and its Joint
Venture (JV) partners Cairn Energy Hydrocarbons Limited (CEHL) and Oil and Natural Gas Corporation Limited (ONGC), located in Barmer district, in the state of
Rajasthan, India. Cairn Oil & Gas (Vedanta Limited) holds 70% participating interest in the block which contains 38 major oil and gas discoveries, with significant
gas potential in the southern area and oil in the northern area of the Barmer Basin. Apart from 4 major discoveries in the basin, viz. MBA (Mangala, Bhagyam &
Aishwariya) & RDG (Raageshwari Deep Gas), remaining 34 discoveries are relatively marginal in nature, and are geographically widespread across the basin and
are under various stages of execution.

Cairn Oil and Gas (Vedanta Limited) intended to fast track the execution of 14 identified fields in RJ-ON-90/1 block in order to maximize the resource
monetization with cost optimization. To achieve these objectives, Cairn Oil and Gas (Vedanta Limited) intended to partner with global Oil & Gas Service/EPC
companies and/or consortiums, with capabilities for end to end Integrated Oil well construction (including but not limited to drilling, completion, frac and
associated well services) and development of surface facilities (including but not limited to well pad, intra-field network and evacuation facilities / pipeline to
designated hook-up point).

Halliburton Offshore Services Inc. (HOSI) has been awarded the Engineering, Procurement and Construction (EPC) contract for Integrated Field Plan Execution
Services in the identified 14 fields in RJ-ON-90/1 block in Barmer District of Rajasthan, India as Contract No.8500002333 dated 01 October 2019.

The surface facilities development was initially awarded to a sub-contractor, but the project execution was stopped in between. Subsequent to various
discussions/negotiations and mutual understanding, a Memorandum of Understanding (MOU) is signed between HOSI and Cairn Oil and Gas (Vedanta Limited)
on 22nd of October 2021. Based on the MOU, the scope of work for the fields namely NL, Guda Oil, Raag South, Kaam , Shakti, KW3, KW6 and Tukaram ( except
Tukaram-1Z without Pipeline) were de-scoped from the original contract scope of work. Accordingly, the revised scope of work for the project will be limited to
the fields Raag , Tukaram , GSV, Guda South 7, SL-1, NP, Sawaswati SW and Tukaram 1 Z (No Pipeline) and associated piping in Raag and GSV only.

For the revised scope of work, Halliburton has subcontracted the surface facility works related to Guda South 7, SL-1, NP, Saraswati SW 1 and revised scope of
Tukaram 1 Z (No Pipeline) to M/s S. Mark Engineering (I) Pvt. Ltd.

M/s Oswal Infra project ltd was sub contracted for the surface facility works related to Raag , GSV and it`s associated pipelines.

PETROCIL has been retained as engineering consultant by M/s Oswal & M/s S Mark for the Basic and Detailed Design & Engineering services for the project.

This document shall read in conjunction with revised scope of work as per the MOU and is applicable for the field mentioned there in. i.e. Raag , , GSV, Guda
South 7, SL-1, NP, Saraswati SW 1 and revised scope of Tukaram 1 Z (No Pipeline) and associated pipelines in Raag and GSV only.

Disclaimer: In this document, if there is any specific sentence or words related to earlier contractor or activities related to de-scope, it has to be ignored.

Halliburton Offshore Services Inc. (HOSI) S. Mark Engineering (I) Pvt. Ltd (S. Mark)

MAIN LSTK CONTRACTOR EPC-CONTRACTOR ENGG CONSULTANT

Page 1A of 14
 Doc No.
S340HAL-SRX-Q-PRO-0047
Integrated Field plan execution services in satellite fields in RJ-ON 90/1
block- Surface Facilities
Document Title: WORK PROCEDURE FOR HYDROSTATIC / PNEUMATIC Revision A4
TESTING OF STATION PIPING

TABLE OF CONTENT

SR. NO. DESCRIPTION PAGE NO.

1 PURPOSE 3

2 SCOPE 3

3 REFERENCES 3

4 RESPONSIBILITIES 3

5 EQUIPMENTS 4

6 METHODOLOGY 5

7 HEALTH, SAFETY AND ENVIRONMENT 13

8 ITP/FORMATS 13

MAIN LSTK CONTRACTOR ENGG CONSULTANT

EPC-CONTRACTOR

Page 2 of 14
 Doc No.
S340HAL-SRX-Q-PRO-0047
Integrated Field plan execution services in satellite fields in RJ-ON 90/1
block- Surface Facilities
Document Title: WORK PROCEDURE FOR HYDROSTATIC / PNEUMATIC Revision A4
TESTING OF STATION PIPING

1.0 PURPOSE
The purpose of this procedure is to define methodology for Flushing and hydro
testing of all piping fabricated & installed for intermediate stations and terminals
of Integrated Field plan execution services in satellite fields in RJ-ON 90/1
block-Surface Facilities.

2.0 SCOPE
This procedure illustrates the general requirements for inspection, flushing,
testing and drying of piping systems.

3.0 REFERENCES
1. Specification for Inspection, Flushing and Testing of Piping System -
CAIRN-TSG-L-SP-0012-B1.
2. Contractor’s HSE Plan - S340HAL-SRX-R-PLN-0001.
3. Contractor’s PQP Plan – S340HAL-SRX-Q-PLN-1001.
4. ASME B31.3
5. ASME B31.4
6. ASME B31.8
7. RJON-RX-OP-PRO-0060- Rev 1 RJ Gas Procedure for Pressure
vessels, plant piping

4.0 RESPONSIBILITIES
Site Engineer
Shall report to the Construction Manager and shall be responsible for,

MAIN LSTK CONTRACTOR ENGG CONSULTANT

EPC-CONTRACTOR

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 Doc No.
S340HAL-SRX-Q-PRO-0047
Integrated Field plan execution services in satellite fields in RJ-ON 90/1
block- Surface Facilities
Document Title: WORK PROCEDURE FOR HYDROSTATIC / PNEUMATIC Revision A4
TESTING OF STATION PIPING

 Shall be responsible for control, supervision and direction for

implementation and execution of this procedure using calibrated Measuring
and Test Equipment’s.

QA/QC Engineer
Shall report to Construction Manager/Project Manager administratively and to
HO for technical matters and shall be responsible for,
 Shall be responsible for overall control of QC activities.
 Checks and verifies the activity.
 Verifies and countersigns report.

HSE Engineer
Shall report to Construction Manager/Project Manager administratively and to
HO for technical matters and shall be responsible for,
 Managing the implementation of all safety requirements during handling
operations.

5.0 EQUIPMENTS
Manifold, Pressure gauges, PSV, Chart recorders, Fittings and other
attachments. All materials involved in the test shall be suitably rated and
certified. Calibration of all instruments and associated equipments shall
be valid all the time.

MAIN LSTK CONTRACTOR ENGG CONSULTANT

EPC-CONTRACTOR

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 Doc No.
S340HAL-SRX-Q-PRO-0047
Integrated Field plan execution services in satellite fields in RJ-ON 90/1
block- Surface Facilities
Document Title: WORK PROCEDURE FOR HYDROSTATIC / PNEUMATIC Revision A4
TESTING OF STATION PIPING

6.0 METHODOLOGY
General
All hydro test crew shall be competent and certified by Cairn before
starting the job. Before Hydro testing of any piping system, it shall be
inspected for the following,
 Proper piping materials have been used.
 Piping has been erected as per latest approved drawings.
 All supports have been installed correctly and test preparation has been
carried out.
 All NDT & PWHT (if applicable) are completed.
 All materials involved in the test shall be suitably rated and certified
including Manifold ,Pressure gauges, PSV, Fittings and other
attachments.
 Cairn Hydro check list compliance shall be ensured.

CONTRACTOR shall prepare the hydro testing plan with the following
documents,
 Loop test schematic Diagram (Marked up P&ID with Test Packs/Hydro test
loop).
 As built Isometrics/line sketches with joint number markings, test limits and
radiography marking.
 Mechanical completion /clearance report.
 Line History Sheet (LHS) record.
 NDT Summary sheet & clearance report
 Piping support installation report.

MAIN LSTK CONTRACTOR ENGG CONSULTANT

EPC-CONTRACTOR

Page 5 of 14
 Doc No.
S340HAL-SRX-Q-PRO-0047
Integrated Field plan execution services in satellite fields in RJ-ON 90/1
block- Surface Facilities
Document Title: WORK PROCEDURE FOR HYDROSTATIC / PNEUMATIC Revision A4
TESTING OF STATION PIPING

Flushing
 Flushing of all lines shall be done before pressure testing.
 Flushing shall be done by fresh potable water or dry compressed air
wherever water flushing is not desirable, to clean the pipe of all dirt, debris
or loose foreign material. Flushing shall be done at high velocity as
practicable Min. 1.5 m/sec.
 Required pressure for water flushing shall meet the hydrant pressure or
utility water pressure. For air flushing the line /system will be pressurized
by compressed air at the required pressure which shall be 50psi max. This
shall than be released by quick opening of a valve, already in line or
installed temporarily for this purpose. This procedure shall be repeated as
many times as required until a clear stream of flushing medium exits the
piping, with minimum flush volume being equal to five (5) times the volume
of the piping being flushed.
 Inline instruments like control valves, orifice plates, Rota meters, safety
valves and other instruments like thermo-wells which may interfere with
flushing instruments shall not be included in flushing circuit.
 All permanent strainers the screen /mesh shall be removed before flushing.
 Screen /meshes shall be reinstalled after flushing but before testing.
 During flushing temporary strainers shall be retained. These shall be
removed, cleaned and reinstalled after flushing before testing.
 In case of equipment such as column, vessels, and exchanger etc. forms
part of a piping circuit during flushing, this shall be done with the approval
of engineer in-charge. However, equipment thus included in the circuit shall

MAIN LSTK CONTRACTOR ENGG CONSULTANT

EPC-CONTRACTOR

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 Doc No.
S340HAL-SRX-Q-PRO-0047
Integrated Field plan execution services in satellite fields in RJ-ON 90/1
block- Surface Facilities
Document Title: WORK PROCEDURE FOR HYDROSTATIC / PNEUMATIC Revision A4
TESTING OF STATION PIPING

be completely drained and dried with compressed air after flushing is

completed.
 Precaution shall be taken to prevent entry of water /foreign matter into
equipment’s, electric motors, instruments, electrical installations etc. in
vicinity of lines being flushed.
 During flushing all flanges used shall be provided with temporary gaskets.
 After flushing is completed and approved, the valve distance pieces, piping
specials etc. shall be reinstalled with permanent gaskets. However, flanges
of equipment nozzles and other places where isolation is required during
testing, only temporary gaskets shall be provided.

Extent of Testing
 With the exclusion of instrumentation, piping systems fabricated or
assembled in the field shall be tested.
 To facilitate the testing of piping systems, vessels and other equipment’s
may be included in the system with the approval of Engineer in-charge if
the test pressure specified is equal to or less than that for the vessels and
other equipment’s.
 Pumps, compressors and other rotary equipment’s shall not be subjected
to field test pressure.
 Lines which are directly open to atmosphere such as vents, drains, safety
valves discharge need not be tested but all joints be visually inspected
,Wherever necessary such line shall be tested by continuous flow of fluid to
eliminate the possibility of blockade.

MAIN LSTK CONTRACTOR ENGG CONSULTANT

EPC-CONTRACTOR

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 Doc No.
S340HAL-SRX-Q-PRO-0047
Integrated Field plan execution services in satellite fields in RJ-ON 90/1
block- Surface Facilities
Document Title: WORK PROCEDURE FOR HYDROSTATIC / PNEUMATIC Revision A4
TESTING OF STATION PIPING

 Seats of all valves shall not be subjected to a pressure in excess of the

maximum cold working pressure of the valve .Test pressure applied to
valves shall not be greater than the manufacturers recommendations nor
less than that required by the applicable code. Wherever allowable seat
pressure is less than test pressure, test shall be made through an open
valve. Valves shall be opened only 70% during testing.
 Instruments like pressure-relieving devices, level controllers and gauge
glasses, strainers, filters, flow nozzles, control valves, orifice plates, etc. in
the system to be tested shall be excluded from the test by isolation or
removals, unless approved otherwise by Engineer- in-charge.
 Orifice plates shall not be installed unless testing is complete. Control valve
should not be included in the test system. Where bypasses are provided
test shall be performed through the bypass and/ or necessary spool shall
be used in place of control valve.
 Pressure gauges which are part of finished system, but cannot withstand
test pressure shall not be installed until the system has been tested.
 Testing shall be carried out with permanent gaskets installed unless
specified otherwise. Testing shall not be carried against closed valves.
 Wherever in line any void is existing due to any reason for absence of
control valves, check valves etc. it shall be fitted with temporary spools.
 All joints welded, screwed or flanged shall be cleaned by wire brush to free
it from rust and any other foreign matter.
 Open ends of piping system where blanks cannot be used, shall be blinded
off by using blind flange of same rating.

MAIN LSTK CONTRACTOR ENGG CONSULTANT

EPC-CONTRACTOR

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 Doc No.
S340HAL-SRX-Q-PRO-0047
Integrated Field plan execution services in satellite fields in RJ-ON 90/1
block- Surface Facilities
Document Title: WORK PROCEDURE FOR HYDROSTATIC / PNEUMATIC Revision A4
TESTING OF STATION PIPING

 One test pressure gauge shall be located at the highest point and one test
pressure gauge shall be installed as close as possible to the lowest point in
the piping system to be tested to avoid overstressing of any of the lower
portion of the system.
 For longer /vertical lines more than two pressure gauges shall be installed
at locations decided by Engineer incharge.
 The test loop shall be inspected for the provision of high point vent & low
point drain.
 Check the correctness of testing arrangements.
 For lines containing check valves any of the following alternatives shall be
adopted for pressure testing:
 Whenever possible pressurize up-stream side of valve.
 Replace the valve by a temporary spool and reinstall the valve after
testing.
 Provide blind on valve flanges and test the upstream and downstream
of the line separately and remove the blind after testing. At these
flanges, temporary gaskets shall be provided during testing and shall
be replaced by permanent gaskets subsequently.
 For check valves in lines 11/2" and below flapper or seat shall be
removed during testing (if possible). After completion of testing the
flapper/seat shall be refitted.

Testing Medium
 In general all pressure tests shall be hydrostatic using iron free water, which
is clean and free of slit and suspended matters. Maximum chloride content

MAIN LSTK CONTRACTOR ENGG CONSULTANT

EPC-CONTRACTOR

Page 9 of 14
 Doc No.
S340HAL-SRX-Q-PRO-0047
Integrated Field plan execution services in satellite fields in RJ-ON 90/1
block- Surface Facilities
Document Title: WORK PROCEDURE FOR HYDROSTATIC / PNEUMATIC Revision A4
TESTING OF STATION PIPING

in water for hydro testing for SS piping shall be 15-20 ppm and Carbon steel
systems shall have chloride content not more that 250 ppm
 Potable water shall be used for the hydrostatic testing. The test fluids shall
be specified in the line schedule.
 Water used for hydrostatic testing shall be sampled and tested and tests to
be included for dissolved oxygen, ammoniac nitrogen, nitrates , nitrites and
COD and to be clean and contain corrosion inhibitors in the concentrations
recommended by the Manufacturers. It is required to verify with the
chemical contractor/agency, current requirements regarding proper
disposal procedures for the chemically inhibited test water.
 Calculate The amount of additional chemicals that may be required, if any.
i. pH : 6.5 to 10.5
ii. Total dissolved Solids : less than 30 Kg/m³
iii. H2S : Max. 0.001 Kg/m³
iv. Suspended Solids : 0.005 Kg/m³
v. Appearance/Turbidity : Clear with no visible sediment

Test Pressure
 Hydrostatic test pressure shall be as indicated in the line schedule for each
line number.

Test Pressure Gauges

 All Pressure Gauges shall be in good working condition and are calibrated,
with having a valid calibration certificate not older than one year.

MAIN LSTK CONTRACTOR ENGG CONSULTANT

EPC-CONTRACTOR

Page 10 of 14
 Doc No.
S340HAL-SRX-Q-PRO-0047
Integrated Field plan execution services in satellite fields in RJ-ON 90/1
block- Surface Facilities
Document Title: WORK PROCEDURE FOR HYDROSTATIC / PNEUMATIC Revision A4
TESTING OF STATION PIPING

 All pressure gauges shall have suitable range. Pressure gauges used in
testing shall be graduated over a range of about double the intended
maximum test pressure, but in no case shall the range be less than 1 ½
times nor more than 4 times that pressure. Pressure gauge dial shall be
minimum 150 mm. Size of Bourdon shall not be less than 75% of nominal
diameter of dial range.
 Any gauge showing an incorrect zero reading or error of more than +/- 2%
of full scale range shall be discarded.

Testing Method
 Instrument air lines and utility air lines shall be tested with compressed air
of instrument quality.
 Water shall be introduced in the system from low point to avoid air pocket
formation. All Vents at high point shall be left open and not closed until
water flows out. All air shall be removed before pressurizing.
 Pressure shall be applied by means of suitable pump which shall be
isolated from the system as soon as the test pressure is reached and
stabilized in the system.
 The rate of pressure increase in approaching the test shall not exceed 5
bars per minute.
 Test pressure shall be maintained for a period of minimum 01 Hour or the
time required for thorough checking of all the joints.
 The pump shall be attended constantly during the pressurization by an
authorized person.

MAIN LSTK CONTRACTOR ENGG CONSULTANT

EPC-CONTRACTOR

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 Doc No.
S340HAL-SRX-Q-PRO-0047
Integrated Field plan execution services in satellite fields in RJ-ON 90/1
block- Surface Facilities
Document Title: WORK PROCEDURE FOR HYDROSTATIC / PNEUMATIC Revision A4
TESTING OF STATION PIPING

 Care shall be taken to avoid increase in the pressure due to temperature

variation during the test.
 Check all valves kept open & confirm that testing is not done against closed
valves.
 Leakage, if any, noticed during testing shall be rectified immediately and
retesting of the system / line shall be done after repair.
 Hydrostatic test pressure readings shall be taken from the test gauge at
fifteen (15) minute intervals during the test, and recorded on form provided
by CONTRACTOR.
 All joints, including welds, are to be left un-insulated and exposed during
the hydrostatic test. Only hydrostatic tests with ending pressures equal to
or above starting pressure will be accepted.

DE-PRESSURIZATION
 After the acceptance of a successful test, the system shall be immediately
depressurized and vented in a gradual and safe manner.
 The system shall be dewatered from the lowest available drain point with
vent open.

OTHER SERVICES TESTING BY PNEUMATIC TESTING

 Drain, instrument airline, plant airline, relief and blow-down lines are to
be tested as per line list unless otherwise noted. The test pressure
shall be as per line list (110% of design pressure as minimum and in no
case it shall not exceed the 1.33 time of design pressure).

MAIN LSTK CONTRACTOR ENGG CONSULTANT

EPC-CONTRACTOR

Page 12 of 14
 Doc No.
S340HAL-SRX-Q-PRO-0047
Integrated Field plan execution services in satellite fields in RJ-ON 90/1
block- Surface Facilities
Document Title: WORK PROCEDURE FOR HYDROSTATIC / PNEUMATIC Revision A4
TESTING OF STATION PIPING

DRYING
 Upon completion of hydro test and dewatering, the piping/ loop system shall
be completely dried by passing compressed air. The processes shall start
immediately after test.

7.0 HEALTH, SAFETY & ENVIRONMENT

 The approved procedure of Health, Safety & Environment shall be followed
during the execution.
 A safety-restricted zone shall be defined and marked off with red and white
buntings.
 Only authorized personnel as defined/identified shall be allowed within the
test area.
 Warning signs both in English & Hindi shall be placed in prominent about
above ground piping and test area to warn any personnel and public.
 No stage of activity shall progress without the specific clearance of the
Activity in-charge.
 Proper lightning arrangement shall be done at site. All electrical circuits,
wiring, circuit board etc. shall be checked for electrical hazard.
 Walkie-talkies may be used during complete activity.

8.0 ITP / FORMATS

Inspection And Test Plan : S340HAL-SRX-Q-ITP-0047 Rev. A4.
Mechanical Completion Report : S340HAL-SRX-Q-IR-0047-1 Rev. A2.
Checklist for Mechanical Completion : S340HAL-SRX-Q-IR-0047-2 Rev. A2.
Piping Safety Checklist : S340HAL-SRX-Q-IR-0047-3 Rev. A2.

MAIN LSTK CONTRACTOR ENGG CONSULTANT

EPC-CONTRACTOR

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 Doc No.
S340HAL-SRX-Q-PRO-0047
Integrated Field plan execution services in satellite fields in RJ-ON 90/1
block- Surface Facilities
Document Title: WORK PROCEDURE FOR HYDROSTATIC / PNEUMATIC Revision A4
TESTING OF STATION PIPING

Hydrostatic /Pneumatic Test Report : S340HAL-SRX-Q-IR-0047-4 Rev. A2.

Checklist for piping boxing up : S340HAL-SRX-Q-IR-0047-5 Rev. A2.
Punch Points : S340HAL-SRX-Q-IR-0047-6 Rev. A2.

Note- In case of any conflict between the requirements of this procedure and CAIRN Contract
specification the later shall govern.

MAIN LSTK CONTRACTOR ENGG CONSULTANT

EPC-CONTRACTOR

Page 14 of 14
 INTEGRATED FIELD PLAN EXECUTION SERVICES IN SATELLITE FIELDS IN RJ-ON 90/1 BLOCK-SURFACE FACILITIES
OWNER : VEDANTA LTD. CAIRN OIL & GAS
CONTRACTOR : HALLBURTON EPC CONTRACTOR: S. MARK ENGINEERING (I) PVT LTD Doc. No.: S340HAL-SRX-QITP-0047, Rev.A4

INSPECTION AND TEST PLAN FOR HYDROSTATIC / PNEUMATIC TESTING OF STATION PIPING
Method Quantum Inspection BY
Sl. Description of Sub COMPANY
of of Reference Document Acceptance Criteria Verifying Records Remarks
No. Activity/Inspection
Con HOSI
Check Check
s

Tech Spec. CAIRN-TSG-L-SP- Work Procedure-

Submission & Obtaining At the Tech Spec. CAIRN-TSG-L-SP-0012-
1 Review 0012-B1, ASME B31.3,ASME Sec- S340HALSRX-Q-PRO- P R/A A
Approval of Procedure Beginning B1, ASME B31.3
IX 0047.

P&ID, Work Procedure- Work Procedure- S340HALSRX-Q-

2 Loop Identification Review 100% P&ID , ISO Drawing P R R
S340HALSRX-Q-PRO-0047 PRO-0047

Mechanical Clearance Work Procedure- S340HALSRX-Q- Work Procedure- S340HALSRX-Q-

3 Review 100% Inspection Report P DR S
of the pipe section PRO-0047 PRO-0047

NDT clearance of pipe Work Procedure- S340HALSRX-Q- Work Procedure- S340HALSRX-Q-

4 Review 100% Inspection Report P H S
section PRO-0047 PRO-0047

Submission of
Calibration Certificates Work Procedure- S340HALSRX-Q- Work Procedure- S340HALSRX-Q-
5 Review 100% Calibration Certificates P R R
of Pressure Gauge/ PRO-0047 PRO-0047
Temperature Gauge

Install all temporary Work Procedure- S340HALSRX-Q- CAIRN-TSG-L-SP-0012-B1,

6 Visual 100% Inspection Report P S S
piping equipment filters PRO-0047 ASME B31.3

Installation of Water
Holding devices or Work Procedure- S340HALSRX-Q- Work Procedure- S340HALSRX-Q-
7 Visual 100% Inspection Report P S S
piping from sources PRO-0047 PRO-0047
etc.

Ensuring Work Procedure- S340HALSRX-Q- Work Procedure- S340HALSRX-Q-

8 Visual 100% Inspection Report P S S
communication System PRO-0047 PRO-0047

Page 1 of 3
 INTEGRATED FIELD PLAN EXECUTION SERVICES IN SATELLITE FIELDS IN RJ-ON 90/1 BLOCK-SURFACE FACILITIES
OWNER : VEDANTA LTD. CAIRN OIL & GAS
CONTRACTOR : HALLBURTON EPC CONTRACTOR: S. MARK ENGINEERING (I) PVT LTD Doc. No.: S340HAL-SRX-QITP-0047, Rev.A4

INSPECTION AND TEST PLAN FOR HYDROSTATIC / PNEUMATIC TESTING OF STATION PIPING
Method Quantum Inspection BY
Sl. Description of Sub COMPANY
of of Reference Document Acceptance Criteria Verifying Records Remarks
No. Activity/Inspection
Con HOSI
Check Check

Ensuring Safety Work Procedure- S340HALSRX-Q- Work Procedure- S340HALSRX-Q-

9 Visual 100% Inspection Report P S S
Requirements PRO-0047 PRO-0047

10 Pressure Test Operation

Work Procedure- S340HALSRX-Q- Work Procedure- S340HALSRX-Q-

a) Water Filling Filling 100% Inspection Report P S S
PRO-0047 PRO-0047
Work Procedure- S340HALSRX-Q- Work Procedure- S340HALSRX-Q-
b) Venting Visual 100% Inspection Report P S S
PRO-0047 PRO-0047
Work Procedure- S340HALSRX-Q- Work Procedure- S340HALSRX-Q-
c) Pressurization Visual 100% Inspection Report H W S
PRO-0047 PRO-0047
Detection Of leak if any
Work Procedure- S340HALSRX-Q- Work Procedure- S340HALSRX-Q-
d) and extn. of hydrotest / Visual 100% Inspection Report H W S
PRO-0047 PRO-0047
pneumatic test
Acceptance and
Work Procedure- S340HALSRX-Q- Work Procedure- S340HALSRX-Q-
11 Evaluation of recorded Visual 100% Inspection Report P DR S
PRO-0047 PRO-0047
data
De-pressurization and
Work Procedure- S340HALSRX-Q- Work Procedure- S340HALSRX-Q-
12 dewatering to the Visual 100% Inspection Report P S S
PRO-0047 PRO-0047
accepted point.
Work Procedure- S340HALSRX-Q- Work Procedure- S340HALSRX-Q-
13 Drying of test loop Visual 100% Inspection Report P S S
PRO-0047 PRO-0047
Removal of Temporary Work Procedure- S340HALSRX-Q- Work Procedure- S340HALSRX-Q-
14 Visual 100% Inspection Report P S S
Blinds /Supports PRO-0047 PRO-0047
Re-installation & Box- Work Procedure- S340HALSRX-Q- Work Procedure- S340HALSRX-Q-
15 Visual 100% Inspection Report P S S
up PRO-0047 PRO-0047

Page 2 of 3
 INTEGRATED FIELD PLAN EXECUTION SERVICES IN SATELLITE FIELDS IN RJ-ON 90/1 BLOCK-SURFACE FACILITIES
OWNER : VEDANTA LTD. CAIRN OIL & GAS
CONTRACTOR : HALLBURTON EPC CONTRACTOR: S. MARK ENGINEERING (I) PVT LTD Doc. No.: S340HAL-SRX-QITP-0047, Rev.A4

INSPECTION AND TEST PLAN FOR HYDROSTATIC / PNEUMATIC TESTING OF STATION PIPING
Method Quantum Inspection BY
Sl. Description of Sub COMPANY
of of Reference Document Acceptance Criteria Verifying Records Remarks
No. Activity/Inspection
Con HOSI
Check Check

LEGENDS

H -Hold R-Review M-Measurement A- Approval LTR-Lab Test Report from in house lab/Third Party
W-Witness RW-Random Witness V-Visual P-Perform IR- Inspection Report
S-Surveillance DR-Document Review LT-In house Lab Testing JR-Joint Record Sub Con – S. MARK ENGINEERING (I) PVT LTD.
HOSI - HALLIBURTON OFFSHORE SERVICES INC.
For Sub Con For HOSI For COMPANY
Sign : Sign : Sign :
Name: Name: Name:
Date: Date: Date:

Page 3 of 3
 INTEGRATED FIELD PLAN EXECUTION SERVICES
IN SATELLITE FIELDS IN RJ-ON 90/1 BLOCK-
SURFACE FACILITIES

CLIENT VEDANTA LTD. CAIRN OIL & GAS

CONTRACTOR HALLIBURTON
EPC CONTRACTOR S. MARK ENGINEERING (I) PVT. LTD.

TEST PACK INDEX

LOOP NO DATE:
SYSTEM NAME

NO OF
SL. NO. DESCRIPTION
SHEETS
1 LOOP TEST SCHEMATIC DIAGRAM
2 MECHANICAL COMPLETION REPORT
3 CHECKLIST FOR MECHANICAL COMPLETION
4 CHECK LIST FOR NDT
5 HYDROTEST ACCEPTANCE REPORT
6 MARKED-UP P&ID
7 MARKED-UP GAD
8 ISOMETRICS
9 LINE HISTORY SHEET
10 SUPPORT DETAILS
11 CHECKLIST FOR BOX-UP
12 SAFETY CHECK LIST
13 PRESSURE GAUGE CALIBRATION CERTIFICATE

S. MARK/HOSI COMPANY

Sign. Sign.

Name Name

Date Date
 INTEGRATED FIELD PLAN EXECUTION SERVICES IN
SATELLITE FIELDS IN RJ-ON 90/1 BLOCK-SURFACE
FACILITIES

CLIENT VEDANTA LTD. CAIRN OIL & GAS

CONTRACTOR HALLIBURTON
EPC CONTRACTOR S. MARK ENGINEERING (I) PVT. LTD.
Doc. No. S340HAL-SRX-Q-IR-0047-1, Rev.A2
MECHANICAL COMPLETION REPORT
Well Pad Report No. :
Name / No.
Location/Field Date :
LOOP NO.

LINE No. P & ID No. GAD No.

This is to Certify that all Welds of the Test Section have been Accepted.
All activities upto Line History Sheet is Completed (Attached).
Attached Checklist for Mechanical Completion

Remarks (If any):

S. MARK/HOSI COMPANY

Sign. Sign.

Name Name

Date Date
 INTEGRATED FIELD PLAN EXECUTION SERVICES IN
SATELLITE FIELDS IN RJ-ON 90/1 BLOCK-SURFACE
FACILITIES

CLIENT VEDANTA LTD. CAIRN OIL & GAS

CONTRACTOR HALLIBURTON
EPC CONTRACTOR S. MARK ENGINEERING (I) PVT. LTD.
Doc. No. S340HAL-SRX-Q-IR-0047-2, Rev.A2
CHECKLIST FOR MECHANICAL COMPLETION REPORT
Well Pad Name / No. Report No. :
Location/Field Date :
LOOP NO.

LINE No. P&ID No. & Rev. GAD No.& Rev. Isometric No. & Rev.

Checked by
Sl. No. Item To Be Checked
S. MARK/HOSI COMPANY
1 Installation Checked as per P&ID
2 Installation Checked as per Isometric Drg.
3 Installation Checked as per Piping Plan/GAD
4 Isometric sketched marked with
a) Welds Nos (as made)
b) As-Built Dimensions
c) Test Limit
5 Valve (Inc. Control and Safety Valve)
a) Type (Gate, Globe, Check valves)
b) Rating
c) Bolting / length / Type
d) Gaskets
e) Facing/Handle/Spindle direction
f) Flow Direction
6 Flanges
a) Bolting/Length/Type
b) Gaskets
c) Rating
d) Orifice Type Tap in right position
e) Check for alignment (Proper Gap/Parallelarity)
7 Seal Welding Screwed Connections (if required)
High Point Vents/ Low point Drains as per drawing &
8
any additional (if required)
9 Reinforcing Pads as per specification
10 Removal of Temporary Erection cleats, Cleaning etc.
11 Test Kit Verified at Site
12 Supports:
a) Correct Types, Materials
b) Correct Dimensions
c) Clearance of Guides
d) Fixed Point (Anchor)
e) Shoes, Special Supports (If Any)
f) Support welding
g) U-bolt for slide supports
13 Joint History Sheet enclosed for:
a) Material Traceability Report
b) Fit-up & Welding Reports

Page 1 of 2
 INTEGRATED FIELD PLAN EXECUTION SERVICES IN
SATELLITE FIELDS IN RJ-ON 90/1 BLOCK-SURFACE
FACILITIES

CLIENT VEDANTA LTD. CAIRN OIL & GAS

CONTRACTOR HALLIBURTON
EPC CONTRACTOR S. MARK ENGINEERING (I) PVT. LTD.
Doc. No. S340HAL-SRX-Q-IR-0047-2, Rev.A2
CHECKLIST FOR MECHANICAL COMPLETION REPORT
Well Pad Name / No. Report No. :
Location/Field Date :
LOOP NO.

LINE No. P&ID No. & Rev. GAD No.& Rev. Isometric No. & Rev.

Checked by
Sl. No. Item To Be Checked
S. MARK/HOSI COMPANY

c) NDT completed (RT,PT,MPT)

d) Stress Relieving & Hardness Completed
e) PMI
14 Check Removal & Blinding-Off of
a) Control, Safety & Check Valves
b) In-Line Instruments
c) Rupture Disc/Orifice Plate
d) Equipments Nozzles
e) Others
15 Checked for installation of (Indicate location in Drg.)
a) Temporary blinds & spades
b) Temporary strainers
c) Temporary dummy spools
d) Temporary gaskets
e) Others
16 Earthing
a) Check location
b) Check for dimension for lug
17 Cleanliness Internally & Externally
18 Rotating Equipment Final Alignment checked with piping
19 Removal of Unwanted construction supports
20 Instrument Tapping provided as per drawing
Physical walk through-the-line, checked for gross
irregularities including physical dimensions, un-wanted
21
tacks, arc strikes, spatters and spaces for thermal
expansion.
REMARKS:
The Installation is checked as per above and found satisfactory . System Released for Hydrotesting.
S. MARK/HOSI COMPANY

Sign. Sign.

Name Name

Date Date

Page 2 of 2
 INTEGRATED FIELD PLAN EXECUTION SERVICES IN
SATELLITE FIELDS IN RJ-ON 90/1 BLOCK-SURFACE
FACILITIES

CLIENT VEDANTA LTD. CAIRN OIL & GAS

CONTRACTOR HALLIBURTON
EPC CONTRACTOR S. MARK ENGINEERING (I) PVT. LTD.
Doc. No. S340HAL-SRX-Q-IR-0047-3, Rev.A2
PIPING SAFETY CHECK LIST
Well Pad Name / No.
Location/Field
LOOP NO.

S.NO. CHECK POINT YES NO

The test section has been isolated from all other pipeline section
1
except for those needed for pressurising and Hydrotesting
All temporary spools and other equipment connected to the
2
section are capable of withstand the test pressure
All instruments and gauges which are used have valid calibration
3
certificates
All warning notices , marker tapes, protective barriers and other
4 safety equipment have been positioned and all the concerned
informed
All persons who may be affected by the operations are informed of
5
the activity
Communication channel and equipment have been tested and
6 ensured that they are working properly. Backup instruments are
available.
Inform the person operating the pressurising equipment of the
7
maximum test pressure which shall be applied to the test section.

Note: Hydrotest Engineer/HSE Officer to add any other safety points to this list as per site circumstances (if
necessary).
S. MARK/HOSI COMPANY
Sign. Sign.

Name Name

Date Date
 INTEGRATED FIELD PLAN EXECUTION SERVICES IN SATELLITE
FIELDS IN RJ-ON 90/1 BLOCK-SURFACE FACILITIES

CLIENT VEDANTA LTD. CAIRN OIL & GAS

CONTRACTOR HALLIBURTON
EPC CONTRACTOR S. MARK ENGINEERING (I) PVT. LTD.
Doc. No. S340HAL-SRX-Q-IR-0047-4, Rev.A2
INSPECTION REPORT FOR HYDROSTATIC / PNEUMATIC TESTING
Well Pad Name / No. Report No. :
Location/Field Date :
LOOP NO.
P & ID No. : GAD No. : ISOMETRIC DRG. No. :

Line No. Joint No. From Joint No. To Details of Valves Details of Fittings

Pressure Gauge
Test Test Pressure Test Duration Pressure Gauge
Time On Time Off Calibration
Medium (Kg/Sq.cm) (Hold Period)
No. Range Date Valid Upto
Water / Air
Checked By Remarks
Sl. No. Item To be Check Yes No S. MARK/
COMPANY
HOSI
1 Field Installation Check List Prior to Hydrotest Signed
2 Pre-Hydrotest Punch Item Cleared
3 Test Limit Identification & Marked on Drawing
4 Pressure Gauge Location checked
5 Accessibility to Inspection / witness location.
6 Pre-Hydrotest Flushing carried out.
7 Corrdon-off area for the high pressure test as required.
8 System Checked and Released for Hydro Testing
9 Capacity of Pressurizing Pump checked
10 Water Drained
11 Temporary Blind Removed
12 Checked for Re-installation (if any)
13 Air drying

Sr. No. Time in Hrs. Pressure in Kg/Sq.cm Remarks

Result :- Hydrostatic Test / Pneumatic Test :- Accepted / Not Accepted

S. MARK/HOSI COMPANY
Sign. Sign.
Name Name
Date Date
 INTEGRATED FIELD PLAN EXECUTION SERVICES IN
SATELLITE FIELDS IN RJ-ON 90/1 BLOCK-SURFACE
FACILITIES

CLIENT VEDANTA LTD. CAIRN OIL & GAS

CONTRACTOR HALLIBURTON
EPC CONTRACTOR S. MARK ENGINEERING (I) PVT. LTD.
Doc. No. S340HAL-SRX-Q-IR-0047-5, Rev.A2
CHECKLIST FOR PIPING FABRICATION & ERECTION BOXING UP
Well Pad Name / No. Report No. :
Location/Field Date :

P & ID No. GAD No. / ISOMETRIC No.

CHECKED BY CHECKED BY
ACTIVITIES Remarks
S. MARK/HOSI COMPANY
Temporary Test Blind and Dummy Spools/Strainers Removed

Installed : Orifice / Flow Meter/Spade/Strainers Ring

Safety Relief Valve Installed

Control Valve Installed (Flow direction checked)

Check Valve Installed (Flow direction checked)

Strainers Installed

In Line Instruments Installed

Proper tightening of Flange Connection Bolts

Valve Extensions stems Installed

Others (if any)

The Installation is Checked as per above and Found Satisfactory.

S. MARK/HOSI COMPANY

Sign. Sign.

Name Name

Date Date
 INTEGRATED FIELD PLAN EXECUTION SERVICES IN SATELLITE
FIELDS IN RJ-ON 90/1 BLOCK-SURFACE FACILITIES

CLIENT VEDANTA LTD. CAIRN OIL & GAS

CONTRACTOR HALLIBURTON
EPC CONTRACTOR S. MARK ENGINEERING (I) PVT. LTD.
Doc. No. S340HAL-SRX-Q-IR-0047-6, Rev.A2
PUNCH LIST
Well Pad Name / No. Report No. :
Location/Field Date :
Loop No.-
Ref. Drawing :

Punch Confirmation (Sign. & Date)

Category /
Sl.
Description of Punch Points Priority S. MARK/ HOSI COMPANY
No.
Completed &
A/B/C Raised Completed Raised
Accepted

LEGEND: A-MUST BEFORE HYDRO TEST B:- CAN BE DONE AFTER HYDRO TEST C:- TO BE COMPLETED BEFORE COMMISSIONING.

Remarks :- Punch Points Liquidation/Confirmation Checked & Released for Hydro Testing.

S. MARK/HOSI COMPANY
Sign. Sign.
Name Name
Date Date
 JOB SAFETY ANALYSIS WORKSHEET
Task Description Summary ‐ Hydro Testing/Pneumatic Testing for Station Piping
1.                        2.                           3.                                      4.           IR 5.                                                                            6.             7.              RR
STEP

Activity Description Potential Hazard Hazard Effect E P R Existing Controls & Controls   Required  Responsible E P R

1. Working without work permit 1. Illegal Operation 1. Strict compliance of PTW procedure and requirements
Unlikely 
2. Performing authority not available 
2. Clash of activities Serious  could occur  2.PTW must be kept visible at work location Site engineer,  Serious  Very unlikely 
at work location
1 Obtain Permit To Work single injury  less than  L Performing  single injury  to chance of  L
3. Permit issuer and receiver must conduct work site inspection prior issuing the permit
and LTI 50/50  authority and LTI occurrence
chance 4. Performing authority must be available at site until the work is in progress

1. Slippery surface 1. Slip trip and fall  on same level 1. Inspection of work location prior to start the job

Unlikely 
2.Defective tools 2. Personal injury 2. Clear the area and access/ egress to be used identified us lines to be isolated if identify
could occur  Site engineer,  Serious  Very unlikely 
3. Damage to equipment tools and tackles Serious  3. Clear the area and access/ egress to be used identified us lines to be isolated if identify
2 Work Area Preparation less than  M Performing  single injury  to chance of  L
single injury  4. No unauthorized movement
50/50  authority and LTI occurrence
chance 5. heat stress flag to be used & all relevant certificate to be taken 
1. Inadequate use of tools 1.Finger caught in between Unlikely  1. Inspect tools before using
Site engineer,  Serious  Very unlikely 
2. Failure to use of PPEs  2. Personal injury Serious  could occur  2. use right tools for right job
3 Use of hand tools L Performing  single injury  to chance of  L
3. Using makeshift tools 3. Damage to equipment  single injury  less than  3. Use appropriate PPEs
authority and LTI occurrence
50/50  4. Do not use  makeshift or  damage tools at site
1. Exposure to CO.CO2. H2S 1. Gas monitoring to be done 
2. Fire  2. Area inspection checks to be done
3. Explosion 3. Ensure no combustible/Flammable material around and ensure good housekeeping
4. Strictly follow zero tolerance and life saving guideline
Very unlikely 
Possible  5. Appropriate fire extinguisher to be made available  Site engineer, 
1. Leakage of toxic and flammable  Major more  Major more  little or no 
4 Work on HC atmosphere 50/50  H 6. Ensure adequate supervision Performing  M
gases than one LTI than one LTI chance of 
chance 7. No  mobile allowed inside the working site authority
occurrence
8. Ensure atmospheric test to prevent exposure carry gas detector all time at working location
9. Crew should be aware about emergency  and response
10. Emergency action should be communicated during the TBT
11. All personals within well pad to be H2S trained and equipped with H2s mask
1. Working in direct line of fire 1. Personal injury  Unlikely  1. Permit to work system shall be strictly followed Escape H2S mask
Serious  Site engineer,  Serious  Very unlikely 
SIMPOS (Simultaneous  2. Human error 2. Damage to plant utility or material could occur  2. Permit issuer and receiver shall jointly inspect the job site. Identified site 
5 single injury  M Performing  single injury  to chance of  L
operation) 3. Damage of property 3. Damage to equipment  less than  3. Conflict in the task shall be assessed by issuing and performing authority
and LTI authority and LTI occurrence
4. Conflict of activities  50/50  4. Conduct job specific tool box talk before job start
1. Manual handling  Fracture / Broken bone 1. Area barricading shall be done and relevant safety sign boards shall be made available.
2. Pinch point 2. Proper rated capacity pipe spool & flanges shall be ensured.
3. Defective hoses Near by Property damage 3. Test shall be carried out as per P&ID & test pack.
4. Failure to use correct Fittings 4. Activity shall be carried out under competent supervisor by authorized personnel only.
5. Failure of gauges  5. Rated capacity & rated calibrated PSV & pressure gauges shall be ensured.
6. Use of uncertified pipe spool & 
 6. Proper guard shall be in place on all rotating parts.
flanges
 9. Improper water quality  7. Industrial socket / plug tops shall be ensured.
             8. Only inspected and Color coded electrical equipment shall be used. Very unlikely 
Possible  Site engineer, 
Major         All electrical connections should be routed through 30mA ELCB / RCCB for power tools and body  Major more  little or no 
6 Hydro Test Water Filling 10. Rotating machinery Personnal injury 50/50  H Performing  M
More than  earthling for DG sets.inspection stickers shall be ensured on all power tools & equipment than one LTI chance of 
chance authority
One LTI occurrence

9. After water filling hydro test shall be done stage wise  and hold  pressure shall be increased in gradual 
11. Electricity  Electric Shock
manner to observed any potential leak.
10. If any leak observed then hold the activity & assess the repair need.. Power cables shall be kept away 
12. Slippery surface due to water / oil 
from water.
leak
13. Test carried out by non certified 
personnel
1. Manual handling  Fracture / Broken bone 1. Area barricading shall be done and relevant safety sign boards shall be made available.
2. Pinch point  Electric Shock 2. Proper rated capacity pipe spool & flanges shall be ensured.
3. Defective hoses Near by Property damage 3. Test shall be carried out as per P&ID & test pack.
4. Failure to use correct Fittings 4. Activity shall be carried out under competent supervisor by authorized personnel only.
5. Failure of gauges  5. Rated capacity & rated calibrated PSV & pressure gauges shall be ensured.
6. Use of uncertified pipe spool & 
 6. Proper guard shall be in place on all rotating parts.
flanges
Very unlikely 
 7. Improper water quality Possible   7. Industrial socket / plug tops shall be ensured. Site engineer, 
Hydro Test Pressuring , Holding  Major more  Major more  little or no 
7 50/50  H Performing  M
& dewatering than one LTI 8. Only inspected and Color coded electrical equipment shall be used. than one LTI chance of 
chance authority
 All electrical connections should be routed through 30mA ELCB / RCCB for power tools and body  occurrence
8. Rotating machinery
earthling for DG sets.inspection stickers shall be ensured on all power tools & equipment

9. After water filling hydro test shall be done stage wise  and hold  pressure shall be increased in gradual 
9. Electricity
manner to observed any potential leak.
10. Slippery surface due to water / oil  10. If any leak observed then hold the activity & assess the repair need. Power cables shall be kept away 
leak from water.
11. Test carried out by non certified 
 1. Using air Compressor 1.Personnal injury Unlikely  1.All pressure equipments need to be calibrated and certified unlikely could 
Serious  Site engineer,  Moderate off 
2. Noise 2. Noise indused hearing glooves could occur  2. Area need to be baricated and sign boards to displayed. occur less 
8 Pneumatic Testing single injury  H Performing  site medical  M
less than  3. Hazards and control measures need to be explaied to working crew through TBT. than 50/50/ 
and LTI authority treatment
50/50  4. Ensure whip check to be fitted to the hoses. chance
1. Accumulation of debris 1. Slip trip and fall  on same level Unlikely  1. Housekeeping shall be maintained during the activity and end of the job unlikely could 
Serious  Site engineer,  Moderate off 
Housekeeping and close of work  2. Fire and explosion 2. Non closer of permit could occur  2. Remove all the debris from the site and disposed in designated place occur less 
9 single injury  M Performing  site medical  L
for the day 3. Electric shock 3. Electrocution  less than  3. Permit must be close and submit upon completion of job than 50/50/ 
and LTI authority treatment
4. Personal injury 50/50  chance
1. Extreme weather condition  1. Collapse of individuals Unlikely  1. Effective TBT shall include emergency response
unlikely could 
2. lack of supervision 2. Unavailability of emergency vehicle  Serious  could occur  2. Ensure emergency vehicle arrangement is in place  Site engineer,  Moderate off 
occur less 
10 Emergency response single injury  less than  M Performing  site medical  L
than 50/50/ 
3. Leakage of toxic or flammable gas 3. Fire and LTI 50/50  authority treatment
chance
chance
1.unavailibility of drinking water 1. Heat related illness Unlikely  1. Ensure plenty of cool drinking water is available at site
Moderate  unlikely could 
could occur  2. Ensure adequate rest shelter is available for workmen to take rest as per procedure and heat index flag  Site engineer,  Moderate off 
2. Lack of rest shad 2. Collapse of workmen off site  occur less 
11 Heat stress management less than  M system Performing  site medical  L
medical  than 50/50/ 
50/50  authority treatment
3. Failure to follow heat index flag treatment chance
chance