L&T Hydrocarbon Engineering Limited

MEG Project, LSTK‐1, IOCL-PARADIP

JOB SAFETY ANALYSIS FOR UG PIPING WELDING,

FABRICATION AND LAYING

Job No. 6389/IPEG Date‐ 07.07.2019

Job Description ‐ Underground Piping Welding JSA No.‐ LTHE/CS/PR/LSTK-1/JSA‐01

Fabrication and Laying
Job classification‐ Mech. Rev. No.‐ 1

P&M, Equipment, Tools and Hydra, Crane, Excavator, Trailer, Electrical power tools, Welding Machines, Gas
Tackles involved cutting, Sling and D Shackles.

PPE S / safety device

required PPE’S‐ Safety Helmet, Safety Jacket, Safety shoes, Safety goggles, Job
relevant hand gloves, Nose m ask, Ear plug etc.

Barricading tape & warning poster.

Pre pared by
( Name of Site Engineer)
Muthuazhaguraj.A
Checked By‐
( HSE In charge) Ajay Kumar Sahoo

Approved By‐
M.Keshavamurthy Madhusudan
 Work Activity Hazards Present Required Safety Measures Responsibility
1.Unauthorized Operation of 1.1.Only authorized operator Concerned
A. Shifting of pipes by
vehicle. allowed to operate the vehicle. Engineer
trailer to Fabrication yard
Proper license holder driver /Supervisor
& site , unloading
materials by crane or should operate the vehicle.
Hydra.
1.2 Signal man will be deployed
to coordinate the lifting operation
and only trained Rigger will be
deployed

2.Untrained persons, 2.Designated persons are only Concerned

allowed to travel in the cabin Engineer
.Don’t Carry the passenger on /Supervisor
Tipper bed , Along with the
material in the Tailor / Truck
,Tractor ( Beside Driver seat )
Tractor – bed joint assembly.
Nobody shall be allowed
standing in the footsteps or
Hanging in the bed.

3.Non following of traffic rules, 3. Driver under Intoxication are Concerned

not allowed to drive the vehicle. Engineer
Driver should not use mobile /Supervisor
phone during driving. Removing
the Suspected Driver / Helper.

4.Over loading of vehicle, 4. Vehicles shall not overloaded beyond Concerned

its rated capacity. Loading capacity shall Engineer
be checked by supervisor. /Supervisor

5.Projecting materials beyond 5.Not allowing materials projection Concerned

the bed. more than 1 mtr from the end of the Engineer
bed for Trailor.No material projection /Supervisor
allowed for tipper / Truck / Tractor.
Projection made with red flag for
Caution.

6.Improper vehicular 6.Approach area for the vehicle should Concerned

movement. be obstacle free, physical condition of Engineer
the approach road should be /Supervisor
proper. Ensure that the vehicular
movement is to be restricted where the
shifting or handling of material is
carried out. Maintain speed limit inside
the working premises 15km/hr. &
inside the plant 25km/hr. Helper/ flag

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 man should assist driver to check the
condition of the soil during parking /
reversing the vehicle. Proper signage at
the conspicuous place & should be
cautious enough during turning the
vehicle. Ensure that no person should
not take rest below the vehicle; use of
stopper is to be ensured.

7.Failure of crane, tools & 7. Ensure nobody stands under the Concerned
tackles. suspended load from crane. Ensure Engineer
Crane , tools & tackles shall have valid /Supervisor
TPI certificate & periodically inspected.
Quarterly colour coding shall be
ensured. Ensure crane shall be work
under rated capacity. Daily check
condition of Crane, tools & tackles
before use.Crane work area shall be
cordon off. Effective supervision shall
be ensured.

8.Un attended Crane swing area. 8.Ensure Crane swing area shall be Concerned
properly barricaded. Ensure nobody Engineer /
shall available at crane swing area. One Supervisor.
dedicated person must be deploy for
monitoring this activity.
9. Non deployment of 9. Authorized signal man with wearing Concerned
competent signal man. reflective jacket should be employed. Engineer /
Communication between signalman & Supervisor.
operator shall be proper.
B. Excavation 1.Barrication 1.Hard barrication / soft barrication
shall installed before starting of
excavation as required
2.Adquate slope gradient for Assess
with hand rail shall be installed as
required
3.Flag man/Banks man shall be
provided to regulate movement of
tippper in congested area
1.Damaged to underground 1. Area has been scanned and no Concerned
utilities. underground utilities were found. If any Engineer
such utility were found inform to /Supervisor
PMC/Owner. Excavation permit to be
followed.
2.Dust during excavation . 2. All mandatory PPE to be used along Concerned
with nose mask. Engineer
/Supervisor

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 3.Collision due to vehicle 3. Ensure reverse horn in the vehicles. Concerned
movement. Provide visible stopper near the Engineer
excavation trench before reversing /Supervisor
transit mixer or dumper. Provide a
signalman for signaling equipment /
vehicles.
4.Soil sliding / collapse of 4. Monitoring the soil condition. Safe Concerned
nearby structure. angle of repose should be maintained Engineer
when excavation is deeper than 1.2m /Supervisor
deep. Slope should not be less than 45
deg . Suitable bench of 0.5m depth shall
be provided for every 1.5m depth. If
slope is not possible proper
shoring/shuttering to be done.
Excavated earth should not be placed
within 1.5m of edge of the
excavation. No material to be stacked
within 1.5m from the edge of
excavation.
5.Fall of materials / person in 5. Provide hard barrication when depth Concerned
excavation. is more than 1.2 m depth all around the Engineer
pit. Don’t keep any materials near the /Supervisor
edge of excavated pit. Access ladder
need to be provided in excavated pit.
Minimum 500mm wide access way with
proper handrail to be provided.
Ensure proper lighting arrangement at
excavated area.
6.Water logging. 6. Dewatering pump to be used for Concerned
removing water from excavated Engineer
pit.Ensure coupling guard for /Supervisor
dewatering pump. Ensure power
connection routed through ELCB 30ma
for dewatering pump.
7. Tilting & toppling of 7. Marching path of excavator must be Concerned
excavator. pre identified. Special care to be taken Engineer
for loose & slide soil. Excavator /Supervisor
condition should be checked regularly.
Effective supervision shall be ensured.
8. Unauthorized operation of 8. Authorized Operator should be Concerned
excavator. deployed. Un‐authorized person entry Engineer
restricted. One person shall be available /Supervisor
during operation of Equipment if
required.
C. Pipe fit up 1. Improper access and egress 1. Safe means of access and egress Concerned
must be ensured. Ensure that Engineer
emergency road should be obstacle free /Supervisor

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 always.
2.Defective tools and tackles 2. Ensure nobody stands under the Concerned
suspended load from crane. Ensure Engineer
Crane , tools & tackles shall have valid /Supervisor
TPI certificate & periodically inspected.
Quarterly colour coding shall be
ensured. Ensure crane shall be work
under rated capacity.
3.Pinching of leg /hands, 3. Use hand gloves during material Concerned
handling. Ensure the workmen if there Engineer
hands / legs away from pinching points /Supervisor
.

4. Pipe roll over 4.Wedge stopper shall be provied to

pipe prevent roll over
Pipe fit up area to be Barriacarted
D.Welding work 1. Electrical hazards, 1. Body earthling must be ensured for Concerned
welding machine. All welding m/c’s Engineer
shall be double earthed.All electrical /Supervisor
connection must be routed through
30mA RCCB / ELCB.Welding shall not be
done outdoors while raining. Welding
shall not be done on a wet
ground/floor.Welding Cables shall not
be laid along with other power
cables.Tor rods/scrap steel sections or
other materials shall not be used in
place of welding return cable.
Welding machines are kept inside
welding booth / rain protection
arrangements. Welding cables to be
made under ground / over head at
road crossings. No cable joints to be
allowed within 3m of welding machine
and holders. Jointing of cables to be
avoided if required proper jointing with
lugs to be done. All the welding cables
shall be fully insulated.
2. Welding fumes., 2. Welding goggles shall be provided Concerned
to welder's helper for eye Engineer
protection.Welding shall be done with /Supervisor
adequate ventilation.
All electrode bits to be collected in a
container. Provide suitable nose mask
for welders & helpers.
3. Welding spark. 3.Area shall be cleared of Flammables Concerned

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 and combustibles before commencing Engineer
welding.Use fire blanket or other /Supervisor
suitable means to arrest the welding
spatter. Qualified welders to be
deployed.
E. Grinding Work 1. Improper guard of 1. All the grinding m/c’s shall be used Concerned
Grinding machine , with wheel guard. Provide mandatory Engineer
PPE's and face shield with safety helmet /Supervisor
to grinder. Also ensured safety goggles
to be used while working. Experience
grinder to be deployed.Proper access to
be maintained in grinding area for
emergency .
Wearing loose cloth to be avoided.
2. Breaking of wheel, 2.Check validity of grinding wheel and Concerned
use approved product of wheel.Provide Engineer
proper storage for wheel. The operating /Supervisor
speed mentioned on the wheel shall be
greater than the spindle speed of the
grinding machine. Ensure m/c to be as
per manufacture specification . The
wheel shall be held at an angle between
15 to 30 degree. If any doubt quality of
wheel shall be reviewed. Wheel shall be
subjected to ring test to check if they
have invisible cracks or damages. While
performing Cutting work,the wheel
shall be straight in the cut.No grinding
shall be use for cutting job.
3. Electrical hazards, 3. Hand held grinding machine having Concerned
its body made of non conductive Engineer
material is preferred.It shall be ensured /Supervisor
that the body of the machine is
earthed, if it is made of conductive
material.Power supply for the machine
shall be through RCCB / ELCB 30mA
sensitivity. Proper plug top must be
ensured, and inserting bare wires into
sockets for tapping power supply shall
be prohibited.
4. Flying objects, 4.Provide safety goggles to all workers. Concerned
Provide booth or any sheets incase Engineer
grinding work near by approach area if /Supervisor
required. No work to be allowed near
by grinding work.
5. Fire hazards. 5.Area shall be cleared of Flammables Concerned
and combustibles before commencing Engineer
Grinding. Use fire blanket or other /Supervisor

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 suitable means to arrest the Grinding
spatter. Experienced & trained Grinder
shall be deployed.
F. Gas cutting work 1.Improper handling of gas 1. Cylinders should be keeping at Concerned
cylinders, upright direction.Ramp with coir Engineer
mattress or sand should be provided /Supervisor
incase unloading at hard surface.Use
cylinder trolley while shifting inside the
site. Don’t carry the cylinder alone at
shoulder. Valve protective cap for all
cylinders. Floor of the storage area will
be level and free from undulations.
2 Improper cylinder Storage , 2. Cylinders will be stored in a cool, dry, Concerned
well ventilated place under cover, away Engineer
from flames, steam pipes or any /Supervisor
potential sources of heat and such
place of storage will be easily accessible
Gas cylinders shall be kept in upright
and chained position. Full & Empty
cylinders will have their valves closed
and valve caps will be ensured Cylinders
shall be kept in a shed to protect from
direct sun ray.Provide adequate fire
extinguisher at storage area. Cylinder
will be marked EMPTY or FULL clearly
and will be kept separately. Oxygen &
DA cylinder will be marked properly and
full O2 & DA cylinder are to be kept
separately at safe distance. Cylinder
storage area shall be free of
combustible materials.
3. Improper cylinder 3. All gas cylinders will be kept upright Concerned
transportation. and cylinders will not strike each other Engineer
at the time of transport. Proper loading /Supervisor
of cylinders shall be ensured.Cylinders
are tied with chains during
transportation. Tyre of cylinder trolley
will be maintained in a good condition.
Cylinder will never be rolled on ground;
it will be carried by cylinder trolley
only.Ensure Valve caps are available
and properly tight.
4. Improper method of 4. Providing Flash back arrestor each Concerned
gascutting. side of gas cutting set. Provide fire Engineer
extinguisher while working at site. /Supervisor
Cutting area free from combustible
materials.Use standard hose, regulators
and torch.Using fire blanket incase of

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 fall of metal slag.Keep the cylinder
away from cutting area and fall of
materials. Leak check to be done by
using of soap solution before start of
gas cutting work. Experienced gas
cutter to be deployed.
g. Pre heating / Post weld 1.Electrical hazards. 1.Ensure proper earthing. Ensure no Concerned
heat treatment joints in cables. Properly disconnection Engineer
of power connection. Tool box meeting /Supervisor
shall be done before start the
job.Proper PPEs like hand gloves, safety
shoes shall be ensured.
2. Fire hazards. 2.Use of ceramic hand gloves. Work Concerned
area free from combustible material. Engineer
Display caution board.Barricading the /Supervisor
work area. Fire extinguisher to be
available. Ensure heating pads are free
from burns. Cross check the
temperature.Ensure the job is at normal
temperature after completion of
heating
h. Lowering of pipe. 1.Failure of lifting gears and 1.Inspect all lifting tools & tackles with Concerned
appliances. valid TPI & also recheck before each Engineer
use.Ensure crane capacity at the lifting /Supervisor
radius of load and Ensure guy ropes do
not come under the way of movement
of equipment which may disturb it. Flag
to be tie with guy ropes.Ensure no body
stands under suspended load. Cordon
the area.
2.Over loading of crane. 2.Material lifting as per load chart or Concerned
specification show in SLI. Ensure Engineer
materials lifting within the capacity of /Supervisor
crane.
3.Unexperienced rigging crew & 3. Skilled & trained persons shall be Concerned
signal man. engaged to rigging work. Proper PPE's Engineer
shall be use. /Supervisor
4. Pinch point hazards. 4. Ensure that workmen keep their Concerned
hands / leg away from pinching points. Engineer
Ensure proper coordination between /Supervisor
workers during manual handling.
5. Pipe rolling. 5. Roll protection arrangement ( sand Concerned
bag / wooden wages etc.) shall be put. Engineer
/Supervisor
6. Toppling of crane during 6. Critical lifting permit shall be taken Concerned
critical lifting. for critical lifting. Lifting scheme/ plan is Engineer

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 required for critical lift. Proper /Supervisor
Positioning of cranes to be checked
during tandem lifting. Load distribution
of cranes shall be properly calculated
when use more than one crane.
I. Back filling & base 1.Damaged to Cables & other 1. Area has been check and no Concerned
compaction. utilities during back filling. underground utilities were found. If any Engineer
such utility were found inform to /Supervisor
PMC/Owner. Excavation permit to be
followed.
2. Roller toppling due to 2. Ground condition shall be checked Concerned
uneven ground condition, before starts compaction by Roller Engineer
machine. /Supervisor
3. Poor illumination 3. Adequate illumination shall be Concerned
available at work area. Engineer
/Supervisor
4. Exposed Excavation pits . 4.Temperoray barrication shall be
provided in back filled area
J. Hydro-testing of pipe. 1. Over‐pressurizing of line. 1.Test pressure not to be exceeded Concerned
more than recommendation. Engineer
Ensure use of duel & calibrated /Supervisor
pressure gauges with appropriate
range.Ensure both the pressure
gauges indicating 0 pressure before
pumping. Ensure Charging isolation
valve is fully open. Ensure all
trapped air displaced from the job.
All mandatory PPE'S shall be used.
2. Failure of equipment. 2. Ensure condition of hydro testing Concerned
pump. Ensure PSV is calibrated, Engineer
tested & as per requirement. /Supervisor
Ensure connecting hose between
pump & job is in good condition.
Ensure vent is open. Inspect the
condition of charging pipe / hose.
Work permit system shall be
followed. Follow checklist during
Hydrotesting. Area should be
barricaded with caution signage
where hydro testing activity is going
on.Ensure the job is flushed &
cleaned with clean water. Ensure
gradual pressure rise in the system
& hold period as per the schedule &
is recorded.
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 3. Fall of person 3. Adequate support shall be Concerned
provided as roll protection. Engineer
/Supervisor
K. DPT test 1. Splashing of chemical. 1. Use chemical protected safety Concerned
goggles. Rubber hand gloves to be Engineer
used. Full body cover cloth shall be /Supervisor
used.
2. Spillage of chemicals. 2. Use dip tray in case of any spillage Concerned
of chemicals. Fire extinguisher shall Engineer
be keep at work area. No hot hot /Supervisor
work shall be allowed near by area.
Work area housekeeping to be
maintained properly. Ensure work
area should be free from
combustible materials.

3. Inhalation of chemical. 3.Use suitable chemical type nose Concerned

mask as per MSDS recommendation. Engineer
MSDS shall be displayed. All hazards /Supervisor
shall be communicated to working
crew through TBT.
4. Fire & explosion hazards. 4. Adequate Fire extinguisher shall Concerned
be available at work area. Chemicals Engineer
keep away from hot work area. /Supervisor
Follow MSDS instruction during
handling of chemicals such as
Penetrant, Developer and Cleaner.
L. Holiday test. 1.Electrical hazards, 1. Separate Earthing shall be Concerned
provided with pipe during Holiday Engineer
testing. Holiday test shall not be /Supervisor
done on a wet ground/floor. Cables
shall not be laid along with other
welding or power cables. Proper
cable management shall be ensured.
No cable joints to be allowed.
Holiday machine handle shall be
fully insulated.
2.Unauthorized Operation., 2. Only experienced & authorized Concerned
person shall be engaged to work. Engineer
Ensure activity shall be done by /Supervisor
close supervision.
3. Improper approach. 3. Proper housekeeping at work Concerned

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area shall be ensured. Suitable Engineer
access shall be available incase of /Supervisor
testing inside the excavated pit.
Work area approach shall be cleared
& obstruction free.

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