Thermax Ltd.

Job Safety Analysis - Heater

Job No. – PG 0423, PG 0422, PG 421 Heater, BPCL -Mahul
Capacity – 11.64 mmkcal/ Hr, 8.26 mmkcal/Hr, / 2.05 mmkcal/Hr

Rev-01 Prepared By Checked by Approved by

Date 18.06.18 18.06.18 18.06.18

Signature

Name Safety Officer Site In charge CM/Safety

Coordinator
 UNLOADING AND SHIFTING OF MATERIALS
WORK ACTIVITY TYPE AND EFFECT OF PREVENTIVE MEASURES
HAZARDS
1. Unloading & shifting of columns, 1. Fall of material. 1. Tool box talk shall be conducted before start
radiation petals from trailer by crane of the work
and Hydra/Farana. 2. Physical Inspection of lifting tools, tackles,
crane / hydra before use.
3. Valid third party certificates for all the tools
and tackles by competent person shall be
available.
4. License of the crane/hydra/trailer’s operator
shall be available & must be valid. Only
experience operator shall be engaged.
5. Packing shall be provided on the edges to
prevent the sling damage while lifting.
6. Tag line/guide rope shall be tied to the
material to prevent its swing.
7. Area shall be barricaded while material
2. Caught in between handling and no person shall move below the
Objects. suspended load.
8. PPEs like helmet, goggle, hand gloves, shoes
shall be ensured.
9. Safe distance shall be maintained.
3. Crane toppling. 10. Crane shall be placed at firm and compact
place.
4. Failure of lifting tools & tackles. 11. Experienced and authorized operator shall be
engaged.
5. Hand injury while releasing the 12. Over loading shall be strictly avoided.
sling from crane and while keeping the 13. Work shall be supervised by trained
material on ground. supervisor/Engineer.
14. Proper approach and soil compactness shall
6. Extended boom my contact with be ensured.
live overhead power line. 15. Steel plates / wooden slippers shall be
provided for out rigger bottom support.
16. Loaded materials shall be securely tied with
trailer.
17. Crane must be park away from overhead
power line.
18. Trade validation for all workers.
19. Florescent jacket for crane signaler.
20. Selection of crane as per approved Load
Chart.
2. Painting of columns, beams, and 1.Fire 1. All Paint barrels to be stored in isolated area
casing and pipe lines. (Brush 2.Eye injury from heat source and designated area.
painting). 3.Inhalation of paint 2. Dust Mask, safety goggles, PVC safety hand
4. Generation of Hazardous waste. gloves to be used by the painter.
3. No hot work to be performed in the vicinity.
4. All mandatory PPE’S must be used.

3. Lifting & trailing the columns/casing 1.Failure of crane 1. Crane checklist to be followed.
petals by cranes. 2.Fall of material on person 2. Tandem shifting shall not be carried out.
3.Failure of lifting tackle 3. Rigging plan to be as per load chart.
4.Fall of person from height 4. Capacity above 75% of the lifting capacity as
5.Toppling of crane per the radius to be considered as critical.
6.Suspended load 5. Erection area shall be barricaded
 7.Collapse of temporary platform 6. Height work permit shall be followed.
8.Shearing of bolts 7. Fall protection (life line & fall arrester) shall
9. Slipping of locking pins. be available on the column before erection.
10.Swinging / hit of the load 8. Welding of temporary platform shall be
checked before the erection.
9. Good communication to be ensured between
signal man & crane operators
10. PPEs like helmet, shoes, safety harness with
double lanyard with fall arrester to be used.
11. Guide/tag line shall be provided.
12. Ground compactness to be checked before
erection.
13. Obstruction for crane boom in its radius area
to be checked.
14. Welding of the lifting hook to be checked
impact test & visually before erection.
15. Man movement under suspended load shall
be restricted.
16. Bolted structure to be properly tightened if
required welded.
17. Proper approach and soil compactness shall
be ensured.
18. Steel plates / wooden slippers shall be
provided for out rigger bottom support.
19. Trade validation to be done for all workers.
20. Fluorescent jacket to be wear for signaler.
21. Daily crane check list to be maintained.

4. Release of wire ropes from the a) Fall of Persons 1. Safe access to be provided for the person
column/casing petals. going to perform the de slinging activity.
b) Fall of materials 2. Usage of required PPEs to be ensured.
3. Proper bolting / welding to be checked before
releasing the winch.
4. Loose materials like spanners, hammer, and
clits shall not be kept on the open surface area at
height.
5. All loose materials shall be carried securely.
6. Fall arrestor & use of full body harness to be
ensured.
 WORK ACTIVITY TYPE AND EFFECT OF PREVENTIVE MEASURES
HAZARDS
5.WELDING 1. Exposure to welding fumes. 1. Replace or repair defective cable immediately.
2. Never change electrodes with bare hands, wet
2. Electric shock. gloves or when standing on wet floors.
3. Use of leather hand gloves for taking
3.Fire electrode from heating oven.
4. Keep welding cable dry and free of grease and
oil to prevent breakdown of insulation.
5. If cables have to run some considerable
distance from the welding unit then consider
placing them on to overhead supports.
6. Protect cables that lie on the floor or ground
so they will not interfere with safe passage or
become damaged or entangled.
7. If it is necessary to weld or cut near
combustible materials, the combustible materials
will be moved to a safe distance away or
protected by non-combustible curtains or sheet
metal. Floors of wood or other combustible
materials will be swept clean and, if possible,
protected with a flame resistant covering supply
cables or high-tension wires.
8. Fire blanket, a fire watch and a fire
extinguisher will be maintained throughout the
welding or cutting operation and continued for at
least 30 minutes after job completion.
9. Use local exhaust ventilation or general
ventilation systems in confined areas, such as
tanks and pressure vessels. This precaution will
maintain toxic gases, fumes, or dusts below the
maximum allowable concentrations.
 GAS CUTTING

WORK ACTIVITY TYPE AND EFFECT OF HAZARDS PREVENTIVE MEASURES

6.Gas Cutting Operation 1. Fire. 1. Conduct Tool box talk before start the hot work at site.
2. Ensure proper use of PPE.
2. Explosion. 3. Check all connections and joints for leak.
4. Never use matches for lighting torches.
3. Burn. 5. Ensure the use of flashback arrestor both side in cylinders
and in cutting sets also.
4. Eye injury. 6. Never use acetylene at pressure above 15 psi.
7. Never use lubricants on oxygen-DA equipment.
5. Inhalation of fumes. 8. Keep fire extinguisher available near the hot work area.
9. Ensure proper housekeeping before and after work.
10. Ensure metal ring of gas cylinders that shows expiry date
of Cylinders and cylinder cap must be on cylinder while
unloading at site.
11. Use hoses and cylinders as per its color coding.
12. Don’t use domestic compressed cylinders.
13. Ensure proper handling of Gas Cylinders.
14. Ensure leak test of Gas Cylinders by soap solution before
start the job.
15. The length of DA and 02 hose to be maintained of equal
length/size during height work in order to kinking with each
other.
16. Ensure all equipment’s of cutting set should be ISI
standard.

7. Grinding Work 1.Fire 1. Conduct Tool box talk before start the hot work at site.

2.Burn 2. Proper use of PPE.

3.Eye Injury 3.Fire blanket shall be used while grinding works

4.Cut Injury 4. Fire extinguisher shall be keep near to hot work.

5. Wheel break during operation

 APH MODULES UNLOADING AND ERETION

WORK ACTIVITY TYPE AND EFFECT OF HAZARDS PREVENTIVE MEASURES

8.Unloading,Erection of 1. Fall of material. 1. Physical Inspection of lifting tools, tackles, crane before
the APH Modules by use with respective colour code.
crane 2. Caught in between Objects.
2. Valid certificates for all the tools and tackles by competent
3. Crane toppling. person shall be available.
4. Failure of lifting 3. License of the crane/hydra/trailer operator shall be
tackles available & must be valid.
5. Hand injury while releasing the sling 4. Packing shall be provided on the edges to prevent the sling
from crane and while keeping the damage while lifting.
material on ground.
5. Guide rope shall be tied to the material.
6. Fall of person.
6. Area shall be barricaded while material handling and no
7. Failure of crane boom person shall move below the suspended load.

7. PPEs like safety helmet, safety goggle, safety hand gloves,

shoes shall be ensured.

8. Tool box talk shall be conducted before start of the work.

9. Work shall be supervised by trained supervisor/Engineer.

10. Proper approach and soil compactness shall be ensured.

11. Steel plates / wooden slippers shall be provided at bottom

for out rigger support.

12. Loaded materials shall be securely tied with trailer.

13. Crane will not move with load.

14.Erection scheme to be prepared & get it approved by

lead/CM.
 RADIATION CASING PETALS ERETOIN

WORK ACTIVITY TYPE AND EFFECT OF HAZARDS PREVENTIVE MEASURES

9. Unloading, shifting and 1. Fall of material. 1. Physical Inspection of lifting tools, tackles, crane before
erection of radiation use with respective of month colour code.
casing petals by crane. 2. Caught in between Objects.
2. Valid certificates for all the tools and tackles by
3. Crane toppling. competent person shall be available.
4. Failure of lifting 3 License of the crane/hydra/trailer shall be available &
tackles must be valid
5. Hand injury while releasing the sling 4. Packing shall be provided on the edges to prevent the
from crane and while keeping the material sling damage while lifting.
on ground.
5. Guide rope shall be tied to the material.
6. Fall of person.
6. Area shall be barricaded while material handling and no
7. Failure of crane boom person shall move below the material.

7. PPEs like helmet, goggle, hand gloves, shoes shall be

ensured.

8. Tool box talk shall be conducted before start of the work.

9. Work shall be supervised by trained supervisor/Engineer.

10. Proper approach and soil compactness shall be ensured.

11. Steel plates / wooden slippers shall be provided at

bottom for out rigger support.

12. Loaded materials shall be securely tied with trailer

while transportation.

13. Crane will not move with load.

14. Physical conditions and approach to be checked.

15.Erection scheme to be prepared & get it approved by

lead/CM.
 CONVECTION MODULE ERECTION

WORK ACTIVITY TYPE AND EFFECT OF HAZARDS PREVENTIVE MEASURES

10.Unloading,shifting and 1. Fall of material. 1. Physical Inspection of lifting tools, tackles, crane before
erection of the convection use with respective of month colour code.
module by crane 2. Caught in between Objects.
2. Valid certificates for all the tools and tackles by
3. Crane toppling. competent person shall be available.

4. Failure of lifting 3 License of the crane/hydra/trailer shall be available &

tackles must be valid

5. Hand injury while releasing the sling 4. Packing shall be provided on the edges to prevent the
from crane and while keeping the material sling damage while lifting.
on ground.
5. Guide rope shall be tied to the material.
6. Fall of person.
6. Area shall be barricaded while material handling and no
7. Failure of crane boom person shall move below the material.

7. PPEs like helmet, goggle, hand gloves, shoes shall be

ensured.

8. Tool box talk shall be conducted before start of the

work.

9. Work shall be supervised by trained

supervisor/Engineer.

10. Proper approach and soil compactness shall be

ensured.

11. Steel plates / wooden slippers shall be provided at

bottom for out rigger support.

12. Loaded materials shall be securely tied with trailer

while transportation.

13. Crane will not move with load.

14. Physical conditions and approach to be checked.

15.Erection scheme to be prepared & get it approved by

lead/CM.
 ELECTRICAL INSTALLATION

WORK ACTIVITY TYPE AND EFFECT OF HAZARDS PREVENTIVE MEASURES

11.Electrical Installations 1. Improper lock out while working with 1. Prepare a SOP of Electrical
electrical live power supply during installation and usage.
installation / sequence of cable 2. Ensure proper use of rubberized
termination. hand gloves and other PPE.
2. Improper way of cables pulling. 3. Don’t lay wires under carpets, mats
3. Unsafe way of cable joints (Lugging, or doorways.
termination of cables, use of electrical 4. Allow only licensed/certified
equipments like hand lamps/tools/earthing. electricians to perform electrical
facilities.
4. Fire. 5. Use one socket for one connection.
6. Ensure usage of only fully insulated
wires or cables.
7. Don’t place bare wire ends in a
socket.
8. Ensure earthing of machinery’s and
equipments.
9. Do not use damaged wires and avoid
temporary connections.
10. Use spark proof/ flameproof type
field distribution boxes.
11. Do not allow open / bare
connections.
12. Provide all connections through
ELCB.
13. Protect electrical cables /
equipments from water and naked
flames.
14. Ensure proper earthing of
machines.

15. No joints on the power cable and

lying underground or above ground
(above human approach).

16. Use of ELCB (30 mA) on the

power panel and each welding
machine in DTA area.

17. Proper cabling.

18. Deploy qualified electrician.

19. Use of PPE like rubber mat, rubber

hand gloves, leather hand gloves
during connection.

20. Use of proper tools.

21. Maintain CO2 fire extinguisher

near power panels.
22. Display of caution board.

23. Periodical maintenance of

electrical equipment.

24. Use of 24Volts bulbs in confined

space.

25. Rain protection for the electric

equipment, panel board, other moving
equipment.

26. Do not keep any inflammable

items near the electrical panels.
 FLOOR PLATES ERECTION

WORK ACTIVITY TYPE AND EFFECT OF HAZARDS PREVENTIVE

MEASURES
12. Erection of Floor Plates 1. Fall of object from height. 1. Safety talk- discuss about safe
2.Failure of lifting tools and tackles lifting process.
3. Contact with sharp edges. 2. Barricade the area and post safety
4. Failure of safety belt sign.
5.Failure of fall arrestor system 3. Conduct safety inspection of all
tools and lifting tackles/machines
before starting the job.(as per factory
act specification).
4. Ensure good and standard quality
of lifting tool usage.
5. Don’t leave loose materials inside
the panel.
6. Use tag line during its erection.
7. Use proper ladder for open lings
after its erection.
8.If its long than use guy rope for its
tie up and fall protection by heavy
wind
9.Use of fall arrestor system ( Fall
arrestor, life line ) and personal
protective equipment

13.Welding of Floor Plates 1. Exposure to welding fumes. 1. Appropriate ventilation.

2. Electric shock. 2.Proper earthing and Use of ELCB
3.Fire 3. Keep ready fire protective
4.Projectiles,flash arrangement.
5. Fall of material, tools, person from 4. Ensure proper use of PPE.
height. 5. Prepare SOP of welding work.
6. Safety talk-discuss about working
at height and welding work.
7. Ensure proper housekeeping before
and after work.
8. Proper approach
9.Proper scaffolding with guard rail

1. Fall of the object from height. 1. Give HSE training about do or

14.Erection of Roof plates 2. Contact with sharp edges. don’t in this work.
3. Failure of the lifting tools and tackles. 2.Barricade the area and post safety
4. Failure of safety belt. sign
(If damaged safety used). 3. Training on-working at height,
welding, gas cutting and use of PPE.
4. Conduct safety inspection of all
tools and lifting tackles/machines
before starting the job.(as per factory
 act specification).

5. Ensure good and standard quality

of lifting tool usage.
6. Use of full body harness safety belt
and fall arrestor.
7. Periodic and pre-use checks of
harness.
8. Life line for anchoring the safety
belt.
9. Tool talk -discuss about fall
protection.

1. Appropriate ventilation.
13.Welding of Roof Plates 1. Exposure to welding fumes. 2.Proper earthing and Use of ELCB
2. Electric shock. 3. Keep ready fire protective
3.Fire arrangement.
4.Projectiles,flash 4. Ensure proper use of PPE.
5. Fall of material, tools, person from 5. Prepare SOP of welding work.
height. 6. Safety talk-discuss about working
at height and welding work.
7. Ensure proper housekeeping before
and after work.
8. Proper approach
9.Proper scaffolding with guard rail

WORK ACTIVITY TYPE AND EFFECT OF HAZARDS PREVENTIVE MEASURES

15.Erection of radiation 1. Fall of the object from height. 1. Give HSE training about do or
2. Contact with sharp edges. don’t in this work.
coils
3. Failure of the lifting tools and tackles. 2. Barricade the area and post safety
4. Failure of safety belt.(if damaged safety sign.
used). 3. Conduct tool box talk on-working
at height, welding, gas cutting and use
of PPE.
4. Conduct safety inspection of all
tools and lifting tackles /machines
before starting the job. (As per
factory act specification).
 5. Ensure good and standard quality
of lifting tool usages.
6. Use of full body harness safety belt
and fall arrestor.
7. Periodic and pre-use checks of
harness.
8. Life line for anchoring the safety
belt.
9. Ensure Heavy lift permits.
10. Check Crane condition its load
chart and all parts visually with
erection Engineer and eye test should
be there of Crane and Hydra
Operators.
11. Check all welding of structure
before drum erection.
12. Don’t go inside the erection and
barricading area.
13. Engage only skilled and qualified
manpower.
14. Use tag / guide rope before its
erection.
15. Don’t kept loose materials on
Drum.
16. Don’t climb on drum without
proper PPEs and fall protection.
17. Ensure first Aid facility with
competent male Doctors
And emergency vehicles should be
there at side.

16. Alignment of radiation 1. Fall of the object from height. 1. Give HSE training about do or
coil 2. Contact with sharp edges. don’t in this work.
3. Use of right tool for right job.
4. Use of full body harness safety belt
and fall arrestor.
5. Ensure proper housekeeping at
work area.
17.Ground Assembly 1. Accidents due to lack of knowledge of 1. The work group / Supervisors
equipment’s & poor communication / should be briefed on the equipment’s
inadequate work procedure and wrong knowledge.
erection sequence. 2. For effective communication
2. Fatal accidents/ permanent disability. arrange meeting for allocating
3. Inadequate facility to reach at higher responsibilities before commencing
elevation, resulting into fetal accident. the work.
4. Always responsible and authorize
person must be available outside the
Heater while workmen are working
inside the heater / parts.
5.Use of PPEs i.e. Safety belt full
body harness with double life line and
shock observer, helmets, Safety
Shoes, Gloves, Goggles etc.
6. Provision of proper scaffolding and
ladder arrangement for working
people at higher elevation.
7. Provide proper ladders to have
approach to Boilers Columns / girders
after erection. Use of fall arrester for
the working men at height.
8. Provide the lugs / supports on
upper end of materials being erected,
so that workmen can hook the safety
harness while doing the work at high
elevation

WORK ACTIVITY TYPE AND EFFECT OF HAZARDS PREVENTIVE MEASURES

18.CONFINED SPACES
1. Presence of foul smell and 1. Confined space permit to be taken.
toxic substances. 2. Ensure proper use of PPE’s Use
respiratory devices if required.
3. Tool box Talk to be conducted.
4. If necessary, Provide exhaust fans
for ventilation.
5. Do not wear loose cloths.
6. Avoid overcrowding inside a
confined space.
7. Check for hydrocarbon and
aromatic compounds before entering
a confined space.
8. Depute the one person outside the
confined space for continuous
monitoring and for help in case of
emergency & also prepared
emergency plan.
 9. Prepare a SWP of Working in
2.Suffocation confined space.
10. Ensure proper use of PPE’S, Use
respiratory devices if required.
11. Tool box Talk: - discuss about
safety at confined space.
12. Only 30 mA ELCB with welding
machine use.
13. Only trained workers should be
engaged in confined space work.
14. Keep ready fire protective
arrangement.
15. Do not smoke inside a confined
space.
3. Fire – due to ignition and flame. 16. Do not allow compressed gas
cylinder inside a confined space.
17. Ensure use of low voltage (24 V)
lamps for lighting.
18. Ensure proper housekeeping
before and after work.
19. Regular air monitoring as per
permit requirement.

19.Working at height 1. Fall Hazard: Person can fall down. 1. Provision of proper scaffolding and
2. Fall Hazard: Material / tools can fall ladder arrangement for working
down. people at higher elevation.
3.Physically fitness poor vision workmen 2. Training about Working at Height.
while working at height 3.No men movements, on ground /
lower elevation is allowed while any
4. High wind flow causing disturbance in work (cutting, erection, materials
work activity results in accidents. handling, welding etc.) is going on at
higher elevation.
4. All tools being used at high
elevation should be tied to job, with
proper chain to not to allow to fall.
5. Provide the safety barricade tapes
below working area to avoid the entry
of the personal.
6. Physical fitness certificate to be
obtained by authorized physician.
7. Continuous restless work, which
can affect workmen fitness, should
not be allowed.
8. No work should commence, if
heavy wind flow affects in safe work
conditions.
9. Ensure proper use of PPE like
safety belt, full body harness, lifeline,
helmets, and Safety shoes, Apron.
Goggles etc.
10. Ensure the installation of fall
arrest systems like safety nets, fall
 arrestor etc.
11. Tool box Talk: - discuss about
safety during Working at height.
12. Provide guardrails / barricade at
the work place.
13. Tie/weld working platform with
fixed support.
14. Avoid movement on beam / pipes/
bracing/vehicles boom.
15. Do not throw or drop materials or
equipment from height.
16. All tools to be carried in a tool
box or on working platform.
17. Remove the scrap from the
platforms.
18Ensure proper use of PPE like
safety belt, full body harness lifeline,
helmets, and safety shoes.
19. Trained person should be allowed
to work at height.
20.Erection of stack 1 .Fall of the object from height. 1. Give HSE training about do or
2. Contact with sharp edges. don’t in this work.
3. Failure of the lifting tools and tackles. 2. Barricade the area and post safety
4. Failure of safety belt (if damaged safety sign.
used). 3. Training on-working at height,
welding, gas cutting and use of PPE.
4. Conduct safety inspection of all
tools and lifting tackles /machines
before starting the job.(as per factory
act specification).

5. Ensure good and standard quality

of lifting tool usages.
6. Proper lubrication to the crane
pulley.
7. Use of full body harness safety belt
and fall arrestor.
8. Periodic and pre-use checks of
harness.
9. Life line for anchoring the full
body harness.
10. Tool box talk -discuss about fall
protection.
21. NDE Testing of IBR and Non IBR 1. Occupational cataract. 1. Give HSE training about do or don’t
parts. in this work.
2. Affects on Skin. 2. Observance of safe distance.
3. Follow the works permit system
3. Affects on Reproductive system. before start the work.
4. Tool box talk- discuss about NDE
4. Radio isotopes. testing safety.
5. Barricade the area and post safety
5. Radioactive waste. sign.
6. Ensure use of proper PPE and film
badges, survey meter issued by BARC.
7. Restrict the entry of unauthorized
persons.
8. Proper shielding of radioisotopes by
lead, concrete, and lead line concrete
block, lead steel combinations.
9. Use of lead shielded aprons. Film
badge provided to individual for dose.
10. Surveys and monitoring.
11. Radiography should perform in
night shift only taking prior approval
from competent authorities.

12. Operator with Dosimeter /TLD

badge to be ensured.
22.Erection of ducting 1. Fall of the object from height. 1. Ensure proper use of PPE.
2. Contact with sharp edges. 2. Prepare SOP of welding work.
3. Failure of the lifting tools and tackles. 3. Safety talk-discuss about
4 Failure of safety belt (if damaged safety working at height and welding
used). work.
5. Fall of material, tools, person from 4. Use of full body harness safety
height. belt and fall arrestor.
6. Failure of scaffolding. 5. Periodic and pr-use checks of
harness.
6. Life line for anchoring the safety
belt.
7. Ensure proper housekeeping
before and after work.
8. Barricade the area and post
safety sign.
9. Ensure good quality of
scaffolding material used.

1. Give HSE training about do or

23.Painting 1. Standing position for prolong time. don’t in this work.
2. Contact with Toxic 2. Ensure proper use of PPE.
Colorings agents. 3. Tool box talk- discuss about
3.Dermatitis safety in refractory work.
4.Fire 4. Barricade the area and post
safety sign.
5. Ensure good and standard
quality of lifting tool usages.
6. Ensure proper housekeeping
before and after work.
7. Prepare MSDS for Inflammable
materials.
8. Separate from materials.
25. Insulation of Header and piping. 1.Dust 1. Give HSE training about do or don’t
in this work.
2.Fire 2. Ensure proper use of PPEs.
3. Tool box talk- discuss about safety in
3.Trip insulation work.
4. Barricade the area and post safety
sign.
5. Ensure good and standard quality of
lifting tool usages.
6. Ensure proper housekeeping before
and after work.
7. Make proper scaffolding.
8. Use proper lifting tools Tackles for its
erection.
9. Ensure proper storage and made rain
protection of it.

26. Refractory 1.Dust 1. Give HSE training about do or don’t

2.Fire in this work.
3.Trip 2. Ensure proper use of PPE.
3. Tool box talk- discuss about safety in
refractory work.

4. Barricade the area and post safety

sign.
5. Ensure good and standard quality of
lifting tool usages.
6. Ensure proper housekeeping before
and after work.
7. MSDS & safety aspects to be
communicated.
27. Fabrication like arrangement of 1.Fall of person 1. Flammable material shall be kept away
temporary platform, hooking and from the grinding sparks.
pulley arrangement at height. 2.Fire 2. Grinder wheel guard shall be ensured.
3. Industrial plug top to be used for
Activity like involved welding,
3.Electrical shock electrical connections.
cutting, grinding and slinging. 4. Helmet with face shield shall be used
4.Body and face injury for grinding and welding.
5. Required RPM of grinding wheel shall
5.Cylinder blast be checked.
6. Expiry date grinding wheel to be
checked before use.
7. Gas cylinders shall be kept in vertical
position securely supported.
8. Flashback arresters shall be used on
both sides of gas cutting set.
9. Hose pipe leakage to be checked before
use with soap water.
10. Goggles to be used during the gas
cutting activity.
11. Cylinders to be kept away from
spark.flame etc
12. Fire extinguishers to be available near
to hot work area and Three phase welding
rectifier type machines to be used only.
13. Supply for welding machine to be
taken from 30mA ELCB.
14. Leather hand gloves to be used by the
welder for welding.
15. Welding not to be performed in wet
conditions.
16. Earthing shall be provided.
17. All power tools should be validated.
18. Housekeeping to be maintained.
19. Use full body harness & fall arrestor
at height.
20.Inspection & certification of any
elevated work platform to be done before
taking it in to use.
28. Erection & welding of staircase 1. Fall of the object from height. 1. Give HSE training about do or don’t in
and ladders, gratings and hand 2. Contact with sharp edges. this work.
railing. 3. Failure of the lifting tools and 2.Tool box talk / JSA -discuss abut
tackles. welding, material handling safety and fall
4. Failure of safety belt. protection
5. Exposure to welding fumes. 3.Barricade the area and post safety sign
4. Ensure good and standard quality of
6. Electric shock. lifting tool usages.
7.Fire 5. Use of full body harness safety belt and
8.Projectiles, flash fall arrestor.
9. Fall of material, tools, person from 6. Periodic and pre-use checks of harness.
height. 7. Welding: Appropriate ventilation.

8. Proper earthing.
9. Keep ready fire protective
arrangement.
10. Ensure proper use of PPE.
11. Ensure proper housekeeping before
and after work.

1 Give HSE training about do or don’t in

this work.
29.Hydrostatic test of heater pressure 1. Pipe/ tube rupture. 2. Ensure proper use of PPEs.
2. Excess pressure for water. 3. Ensure proper venting and water filling
parts
arrangement.
4. Ensure use of calibrated pressure
gauge.
5. Barricade whole area.
6. During air blasting don’t go front side
pressure.
7. Don’t wash or clean your body part by
air.
6. Tool box talk -discuss about fall
protection.
7. Ensure good quality of pressure
gauges.
8. Stop power in Boiler during hydro Test
if possible.

9. Hydro test pump should be validated &

PSV to use above ensure 50kg/cm2.

10. No repair /maintenance of pipe line

under pressure.

11.Sccaffolding Installation 1. Slip Trip of Person. 1. Give HSE training about do or don’t in
this work.
2. Fall of person from height. 2. Tool box talk / JSA -discuss about
material handling safety and fall
3. Fall of hand tools. protection.
3. Barricade the area and post safety sign.
4. Failure of clamp. 4. Ensure good and standard quality of
lifting tool usages.
5. Fall of scaffolding pipe. 5. Use of full body harness safety belt and
fall arrestor.
6. Periodic and pre-use checks of harness.
7. Base Plate/soil Plate must provide
under scaffolding pipe.

8. Rope & pulley arrangement for

raising/lowering material from height
location.

9. Use of standard canvas bag for shifting

scaffolding clams.

10. Only validated Scaffolders, riggers to

be engaged.

11. Checking & certification of

scaffolding by EIL before taking in to
use.

12. All hand tools should be secured with

rope. /to prevent fall of any tool.

13. Ensure Top rails, mid rail and toe-

guard at landing platforms.

14. Ensure proper use of PPE.

15. Ensure proper housekeeping before
and after work.

16. No loose material should be left over

the platform.
Note : This form is referenced in numerous practices

Note: This JSA has been developed through consultation with all personnel involved in the task
Outlined in the JSA.