JSA (Mechanical Jobs)

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Sheet 2: Sheet1
Job Safety Analysis
Main activity : Vehicle Entry inside the plant for loading/unloading material
Plant :
JSA Sheet No: 1 Date of JSA :
S
No
1
Sub Activity
Preparation &
Checking
2 Entry inside plant
Hazards & Risks
Fire explosion due to
spark generated
Control Measures to be implemented
Vehicle must have a valid permit for entry
inside red roads.
Vehicle must be certified for use by P&M
department.
Driver must have safe driving licence.
Spark Arrestor must be healthy
Check LEL inproposed route of vehicle
Switch off engine and evacuate if F&G Alarm
is sounded
Vehicle will move at speed of less than
10kmph.
Vehicle will not enter paved area of plant; if
such an entry is required, necessary permission
from plant ______________/production
______________ will be necessary.
Damage to work place
Identify all pits near to the route,
due to hitting against
barricade/highlight if required.
pipe/equipment
Use wheel jammers to avoid accidental
movement of vehicle
Keep vehicle on gear when parked.
Do not leave vehicle unattended when
parked near plant & machinery.
Follow vehicle entry procedure.
Do not allow people to move in route of
vehicle
Vehicle reverse horn must be working and an
Injury to people around
assisstant must guide reversing.
Use correct tools.
Use mandatory PPEs
3
Loading/Unloading
of material
4 All Sub Activities (1-3)
Do not use bare handsd to handle heavy
material.
Injury to people during Use crane/Hydra wherever required.
material handling
Do not drop material from height Use correct
lifting/lowering devices.
Use correct tools. Use propper PPEs.
Physical Injury while
working
Use correct tools. Use mandatory PPEs.
Done by :
Name :______________________________ Designation: AM Sign ____________________ Date:
Name :_______________________________ Designation: Sign _________________________ Date:
(Note: JSA Sheet to be done by issuer and requestor of work permit . In case of need,
representative from other discipline should also be involved )
Sheet 3: Sheet2
Job Safety Analysis
Main activity : PM of Pumps
Plant :
JSA Sheet No: Date of JSA :
S
No
Sub Activity
Hazards & Risks
Coupling guard removal
1 and checking pump free
rotation
Injury during pump
Foundation bolt tightness dismantling due to
2
checking
improper electrical isolation
3
Checking tightness of
thrower grub screw
Control Measures to be implemented
Electrical isolation will be done from
substation.
Electrical isolation tag shall be
available with the permit.
Field engineer shall cross check
isolation by pressing start button
before commencing of job
4 Cleaning of the breather
Checking Coupling
5
condition
6
Checking Lube oil/seal
oil/greasing
7
Casing bolt tightness
checking
8
Checking seal flush line
for choking & cleaning
Physical injury to workers
Use correct tools.
Use mandatory PPEs
Health hazard due to
handling grease/oil (long
exposure)
Use Chemical resistant gloves.
Wash hands after job
Exposure to toxic gases/HC
Draining of equipment will be
required
Physical Injury while working
Use correct tools
Use mandatory PPEs.
Checking cooling water
9 line for choking &
cleaning
10 All Sub Activities (1-9)
Done by :
Name :______________________________ Designation: AM Sign __________________________ Date:
Name :_______________________________ Designation: ______________ Sign
_________________________ Date:
(Note: JSA Sheet to be done by issuer and requestor of work permit . In case of need,
representative from other discipline should also be involved )
Sheet 4: Sheet3
Job Safety Analysis
Main activity : PM/Maintenance of Fin Fans
Plant :
JSA Sheet No: 1 Date of JSA :
S
No
Sub Activity
1
Opening Safety
guard of fan
2
Foundation bolt
tightness checking
Checking
tightness of
3
thrower grub
screw
4
Cleaning of the
breather
Working inside fin
5 fan plenum
chamber
Hazards & Risks
Control Measures to be implemented
Injury due to movement of
fan
Electrical isolation will be done from
substation.
Follow LOTO procedue.
Electrical isolation tag shall be available
with the permit.
Field engineer shall cross check isolation by
pressing start button.
Despite electrical isolation fan might move
due to wind velocity, to arrest such
movement, tie fan blades or provide
mechanical lock.
Exposure to noise
Use ear plugs.
Use mandatory PPEs
Hazards of confined space
(Fire O2 deficiency, Toxic
Substances)
Follow Confined space entry procedure
Check O2 level at fixed intervals and note
down the same in permit
Ensure presence of standby persons all the
time
Ensure entry & exit record of persons
Fall from height
Use platform to go inside plenum chamber
Heat stress due to hot
pipes/equipment
Drink water at regular intervals
Avoid going near finned tubes
Persons to come out at regular intervals
6
Greasing of
bearings
health hazard due to
handling oil & grease
Use Chemical resistant gloves.
Wash hands after job
7
All Sub Activities
(1-6)
Physical Injury while working
Use correct tools
Use mandatory PPEs.
Done by :
Name :______________________________ Designation: AM Sign _________________________ Date:
Name :_______________________________ Designation: ______________ Sign
_________________________ Date:
(Note: JSA Sheet to be done by issuer and requestor of work permit . In case of need,
representative from other discipline should also be involved )
Sheet 5: Sheet4
Job Safety Analysis
Main activity : Insulation Removal and Refixing
Plant :
JSA Sheet No: 1 Date of JSA :
S
Sub Activity
No
1
2
Cladding
Removal
Insulation
Removal
Insulation
3
Refixing
4
Cladding
Refixing
Hazards & Risks
Control Measures to be implemented
Injury due to use of sharp
equipment and sharp
edges of cladding sheet
Use proper tools for cutting/bending.
Tie or keep weight on cladding removed to
prevent flying off
Health Hazard due to
exposure to insulation
material
Insulation material is injurious to health Use dust
mask, gloves, and full body apron for handling.
Fire (oil soaked insulation
fire)
Insulation being removed might be oil soaked and
may catch fire when exposed to air. Check that it is
free from oil. Keep fire extinguisher ready if oil is
present
Injury/Leakage due to
insulation material falling
from height
Do not collect insulation material in too large bags
which make handling difficult.
Use rope to lower bags of collected insulation
material. Keep area underneath barricaded
Burn due to contact with
hot surfaces
Pipeline/equipment inside will be hot use leather
gloves.
Health Hazard due to
exposure to insulation
material
Insulation material is injurious to health Use dust
mask, gloves, and full body apron for handling.
Burn due to contact with
hot surfaces
Pipeline/equipment inside will be hot use leather
gloves.
Injury due to use of sharp
equipment and sharp
edges of cladding sheet
Use proper tools for cutting/bending.
Tie or keep weight on cladding removed to
prevent flying off
Use certified scaffolding/hydraulic platforms/troleys
with wheel lock
Area must be barricaded. No superfluous material
All Sub
to be kept at work site
5 Activities (1- Injury due to fall from height Use tray for small tools
4)
Tools, tackles etc are not to be carried with hands
while climbing; use pouch,belt, other
lifting/lowering device
Ladder must be free of oil/grease and must be
firmly placed to prevent slip
Ladder to be provided perpendicular to the
working platform wherever possible
Gloves with good gripmust be used while climbing
While climbing always maintain 3 point contact
Physical Injury while working Use correct tools. Use mandatory PPEs.
Done by :
Name :______________________________ Designation: AM Sign ____________________ Date:
Name :_______________________________ Designation: ______________ Sign
_________________________ Date:
(Note: JSA Sheet to be done by issuer and requestor of work permit . In case of need,
representative from other discipline should also be involved )
Sheet 6: Sheet5
Job Safety Analysis
Main activity : PM of Steam Turbines
Plant :
JSA Sheet No: 1 Date of JSA :
S
No
1
Sub Activity
Hazards & Risks
Isolation of the turbine and
depressurization
Coupling guard removal and Physical injury during
decoupling due to
decoupling
improper isolation
Checking free rotation of
3
turbine rotor
2
Checking the tightness of
4 foundation bolts and
supports
Control Measures to be
implemented
Isolate inlet and outlet of the
turbine and depressurize through
drain lines
Check that the turbine is in
unlatched condition
Provide chain lock to steam inlet
and outlet isolation valves
Injury due to improper tools Use correct tools.
5 Check LO
6
Check trip function
correctness
7
Flush governer & check for
leakage
8
Check freeness of governing
Burn Injury
system arm link
9
Check freeness of control
valve spindle
10 Check Coupling condition
11 Check for steam leakage
12 All Sub Activities (1-11)
Use full body aprons
Stay away from hot lines
Health Hazard dur to
handling oil/grease
Use Chemical resistant gloves.
Wash hands after job
Physical Injury while
working
Use correct tools
Use mandatory PPEs.
Done by :
Name :______________________________ Designation: AM Sign ____________________ Date:
Name :_______________________________ Designation: ______________ Sign
_________________________ Date:
(Note: JSA Sheet to be done by issuer and requestor of work permit . In case of need,
representative from other discipline should also be involved )
Sheet 7: Sheet6
Job Safety Analysis
Main activity : Pump seal/bearing replacement/overhauling
Plant :
JSA Sheet No: 1 Date of JSA :
S
No
Sub Activity
Hazards & Risks
Control Measures to be
implemented
Exposure to HC/Toxic
gas release due to
improper isolation
Isolation procedure will be
planned,reviewed and
implemented by FS/FE.
All valves will be tight closed and
tagged
Remote and local push buttons of
XV should be in stopped condition
(if applicable)
Lock to be provided for suction
and disc XVs (if applicable)
Ensure no hot work is in progress in
radius of 15m
Injury /Electric Shock
during pump
dismantling due to
improper electrical
isolation
Electrical isolation to be done from
substation
Electrical isolation tag should be
available with permit
FE shall crosscheck isolation by
pressing start button before
commencement of job
LOTO procedure to be followed.
Preparing the pump for
handover.
1
Electrical & Mechanical
isolations
Wherever possible draining/venting
wil be done to closed system/flare.
Completion of draining to be
Exposure to HC/Toxic
ensured by checking the level rise
2 Draining of pump holdup liquid release fue to improper in CBD vessels.
draining methods
Ensure with open drain with help of
personal H2S meter
If hot service allow sufficient time to
cool after isolation
Blinding of pump
3 suction/discharge lines and
seal flush lines
Exposure to HC/Toxic
release due to holdup
material or passing
valve
Stay in upwind direction
FE will physically show the correct
flange to be opened
First loosen the flange on the side
away from the body, check for any
leakage. Use LEL/H2S detectors.
If valve seems passing immediately
tighten the flange. Keep
arrangement (tray/bucket) ready
for collecting oil
Check seal pot level has been fully
drained
Keep cartridge mask ready for
escape
If holdup material is expected to
be more (for gas services) use
airline mask
Use full body apron, gloves and
mask
Fire hazard due to
holdup material falling
on hot lines
Collect holdup oil in trays
Use wet blankets over hot surfaces
Fire due to oil soaking
insulation
Don’t allow oil into insulation
Check that the insulation cladding
faces/ends are not damaged
Remove oil soaked insulation after
the job
Injury due to improper
tool/lifting methods
Use certified and right capacity
slings/chains (if required)
Use spanner tied with strings
Protect SBCs nearby during
lowering
Do not engage too many persons
Use correct hand tools
Injury during pump
Pump Coupling guard removal dismantling due to
4
and decoupling
improper electrical
isolation
Pump Removal/Opening:
Injury to workers
Coupling hub removal
Opening bearing housing and
5
bearing removal
Dismantling seal assembly
Health hazard due to
Cleaning of seal flush lines
handling oil/grease
See Sno 1
Use correct tools
Use mandatory PPEs.
Proper lifting procedure to be
followed if applicable
Use Chemical resistant gloves.
Wash hands after job
Dispose all oily rags in accordance
with procedure
Pump Assembling installation,
deblinding, warm-up,
6
alignment, checking &
coupling
As above
All Above control applies
7 All Sub Activities (1-6)
Physical Injury while
working
Use correct tools. Use mandatory
PPEs.
Done by :
Name :______________________________ Designation: AM Sign ____________________ Date:
Name :_______________________________ Designation: ______________ Sign
_________________________ Date:
(Note: JSA Sheet to be done by issuer and requestor of work permit . In case of need,
representative from other discipline should also be involved )
Sheet 8: Sheet7
Job Safety Analysis
Main activity : Pump Decoupling for motor replacement etc
Plant :
JSA Sheet No: 1 Date of JSA :
S
No
Sub Activity
Pump coupling guard
1 removal and
decoupling
Pump Alignment
2 Checking and coupling
after job completion
3 All Sub Activities (1-2)
Done by :
Hazards & Risks
Control Measures to be implemented
Injury during pump
dismantling due to
improper electrical
isolation
Electrical isolation to be done from
substation
Electrical isolation tag should be
available with permit
FE shall crosscheck isolation by pressing
start button before commencement of
job. LOTO procedure to be followed.
Injury to workers
Use correct tools. Use mandatory PPEs.
Proper lifting procedure to be followed if
applicable
Health hazard due to
handling oil/grease
Use Chemical resistant gloves. Wash
hands after job
Dispose all oily rags in accordance with
procedure
Electrical isolation to be done from
substation
Injury during pump
Electrical isolation tag should be
couplingdue to improper available with permit
electrical isolation
FE shall crosscheck isolation by pressing
start button before commencement of
job. LOTO procedure to be followed.
Injury to workers
Use correct tools. Use mandatory PPEs.
Proper lifting procedure to be followed if
applicable
Health hazard due to
handling oil/grease
Use Chemical resistant gloves. Wash
hands after job
Dispose all oily rags in accordance with
procedure
Physical Injury while
working
Use correct tools. Use mandatory PPEs.
Name :______________________________ Designation: AM Sign ____________________ Date:
Name :_______________________________ Designation: ______________ Sign
_________________________ Date:
(Note: JSA Sheet to be done by issuer and requestor of work permit . In case of need,
representative from other discipline should also be involved )
Sheet 9: Sheet8
Job Safety Analysis
Main activity : Hose connection & Disconnection
Plant :
JSA Sheet No: 1 Date of JSA :
S
No
1
Sub Activity
End blind removal from
line
Hazards & Risks
Asphyxiation due to
exposure of Nitrogen
Control Measures to be implemented
Ensure isolation valve is tightly closed
Stay in upwind direction
First loosen the flange on the side away
from the body, check for any leakage.
Keep escape route clear
use airline mask if the valve is suspected
passing
Tie hose with static object. Use standard
Connection of hose
Injury to persons due and correct tools
2 between nitrogen line and to improper tools and Rated hoses are to be used during
process location
hitting of hose
purges and are to be fastened to
platform or railing
3
Depressurisation and
disconnection of hose
Asphyxiation due to
exposure of Nitrogen
Ensure isolation valve is tightly closed.
Stay in upwind direction
First loosen the flange on the side away
from the body, and allow it to
depressurize.
Do not engage more persons
use airline mask if the valve is suspected
passing
4
Execution of job at height Injury due to fall from
(if applicable)
height
5 All Sub Activities (1-4)
Physical Injury while
working
Use certified scaffolding/hydraulic
platforms/troleys with wheel lock
Area must be barricaded. No superfluous
material to be kept at work site
Use tray for small tools
Tools, tackles etc are not to be carried
with hands while climbing; use
pouch,belt, other lifting/lowering device
Ladder must be free of oil/grease and
must be firmly placed to prevent slip
Ladder to be provided perpendicular to
the working platform wherever possible
Gloves with good gripmust be used while
climbing
While climbing always maintain 3 point
contact
Use correct tools. Use mandatory PPEs.
Done by :
Name :______________________________ Designation: AM Sign ____________________ Date:
Name :_______________________________ Designation: ______________ Sign
_________________________ Date:
(Note: JSA Sheet to be done by issuer and requestor of work permit . In case of need,
representative from other discipline should also be involved )
Sheet 10: Sheet9
Job Safety Analysis
Main activity : Blinding/Deblinding Job
Plant :
JSA Sheet No: 1 Date of JSA :
S
No
1
2
Sub Activity
Hazards & Risks
Asphyxiation due
to exposure of
Nitrogen
Ensure the valves are tightly closed and
tagged; LOTO procedure to be followed.
Ensure the line is depressurised. Stay in upwind
direction.
FE to physically show correct flange to be
opened
First loosen the flange on side away from body,
check for any leakage
Keep escape route clear.
Use airline mask. Do not engage too many
persons
Injury due to
improper
tool/lifting
methods
Only standard and approved blinds to be
used with complete bolting and new gaskets.
Use certified and right capacity slings/ chains
(if required).
Use spanner tied with strings.
Protect SBCs nearby during lowering. Use
standard hand tools
Opening of flanges and
blind removal/installation
Execution of job at height Injury due to fall
(if applicable)
from height
3 All Sub Activities (1-2)
Control Measures to be implemented
Physical Injury
while working
Use certified scaffolding/hydraulic
platforms/troleys with wheel lock
Area must be barricaded. No superfluous
material to be kept at work site
Use tray for small tools
Tools, tackles etc are not to be carried with
hands while climbing; use pouch,belt, other
lifting/lowering device
Ladder must be free of oil/grease and must be
firmly placed to prevent slip
Ladder to be provided perpendicular to the
working platform wherever possible
Gloves with good gripmust be used while
climbing
While climbing always maintain 3 point
contact
Use correct tools. Use mandatory PPEs.
Done by :
Name :______________________________ Designation: AM Sign ____________________ Date:
Name :_______________________________ Designation: ______________ Sign
_________________________ Date:
(Note: JSA Sheet to be done by issuer and requestor of work permit . In case of need,
representative from other discipline should also be involved )
Sheet 11: Sheet10
Job Safety Analysis
Main activity : Flange tightening in loop under pressure test with Nitrogen
Plant :
JSA Sheet No: 1 Date of JSA :
S
No
Sub Activity
Hazards & Risks
Control Measures to be implemented
Stay in upwind direction.
FE to physically show correct flange to be
opened
Asphyxiation due to
First loosen the flange on side away from body,
exposure of Nitrogen
check for any leakage
1 Tightening of flanges
Keep escape route clear. Use airline mask
Do not engage too many persons
Injury due to
improper tool
Execution of job at
2 height (if
applicable)
3
All Sub Activities (12)
Use spanner tied with strings.
Protect SBCs nearby during lowering. Use
standard hand tools
Use certified scaffolding/hydraulic
platforms/troleys with wheel lock
Area must be barricaded. No superfluous
material to be kept at work site
Use tray for small tools
Tools, tackles etc are not to be carried with
hands while climbing; use pouch,belt, other
Injury due to fall from
lifting/lowering device
height
Ladder must be free of oil/grease and must be
firmly placed to prevent slip
Ladder to be provided perpendicular to the
working platform wherever possible
Gloves with good gripmust be used while
climbing
While climbing always maintain 3 point contact
Physical Injury while
working
Use correct tools. Use mandatory PPEs.
Done by :
Name :______________________________ Designation: AM Sign ____________________ Date:
Name :_______________________________ Designation: ______________ Sign
_________________________ Date:
(Note: JSA Sheet to be done by issuer and requestor of work permit . In case of need,
representative from other discipline should also be involved )
Sheet 12: Sheet11
Job Safety Analysis
Main activity : PSV Removal/Fixing
Plant :
JSA Sheet No: 1 Date of JSA :
S
No
Sub Activity
Opening the
1 flanges for PSV
removal
Hazards & Risks
Control Measures to be implemented
Stay in upwind direction
FE will physically show the correct flange to
be opened
First loosen the flange on the side away from
the body, check for any leakage.
Use LEL/H2S detectors.
If valve seems passing immediately tighten
Exposure to HC/Toxic
the flange. Keep arrangement (tray/bucket)
release due to holdup
ready for collecting oil
material or passing valves
Keep tray/bucket ready for collecting oil.
Keep cartridge mask ready for escape
If holdup material is expected to be more
(for gas services) use airline mask
Use full body apron, gloves and mask
Ensure Checklist is filled for PSV droppng and
follow SOP
Collect holdup oil in trays. Use wet blankets
Fire hazrad due to holdup
over hot surfaces
material falling on hot
Keep fire hose ready and continuously wet
lines (if applicable)
the line expecting pyrophoric materila inside
2 Blinding
Fire (oil soaked insulation
fire)
Insulation being removed might be oil
soaked and may catch fire when exposed
to air. Check that it is free from oil. Keep fire
extinguisher ready if oil is present
Check that the insulation cladding
faces/ends are not damaged
Injury due to improper
tool/lifting methods
Use job specific standard tools and PPEs
Injury due to improper
tool/lifting methods
Only standard and approved blinds to be
used with complete bolting and new
gaskets. Use standard tools
Injury/Property damage
3 PSV Dropping/Lifting due to improper lifting
methods
4
End blind removal
from flanges
Use certified and right capacity slings/chains
Ensure that valves are tightly closed and
tagged follow LOTO procedure
Ensure line is depressurised and drained
Stay in upwind direction
FE will physically show the correct flange to
be opened
First loosen the flange on the side away from
the body, check for any leakage. Use
Exposure to HC/Toxic
LEL/H2S detectors.
release due to holdup
If valve seems passing immediately tighten
material or passing valves the flange. Keep arrangement (tray/bucket)
ready for collecting oil
Keep tray/bucket ready for collecting oil
Keep cartridge mask ready for escape
If holdup material is expected to be more
(for gas services) use airline mask
Use full body apron, gloves and mask
Ensure Checklist is filled for PSV droppng and
follow SOP
Collect holdup oil in trays. Use wet blankets
Fire hazrad due to holdup
over hot surfaces
material falling on hot
Keep fire hose ready and continuously wet
lines (if applicable)
the line expecting pyrophoric materila inside
Fire (oil soaked insulation
fire)
Insulation being removed might be oil
soaked and may catch fire when exposed
to air. Check that it is free from oil. Keep fire
extinguisher ready if oil is present
Check that the insulation cladding
faces/ends are not damaged
Injury due to improper
tool/lifting methods
Use job specific standard tools and PPEs
5 PSV Boxup
6
Injury due to improper
tool/lifting methods
All Sub Activities (1- Physical Injury while
5)
working
Do not use finger to align the flange holes.
Use standard tools
Ensure the rating of gaskets
Use correct tools. Use mandatory PPEs.
Done by :
Name :______________________________ Designation: AM Sign ____________________ Date:
Name :_______________________________ Designation: ______________ Sign
_________________________ Date:
(Note: JSA Sheet to be done by issuer and requestor of work permit . In case of need,
representative from other discipline should also be involved )
Sheet 13: Sheet12
Job Safety Analysis sheet
BLINDING & DEBLINDING
Plant :
JSA Sheet No: 1 Date of JSA :
S.
No.
1
Sub Activity
Opeing of flanges
and blind removal /
installation
Hazards and Risks
Control measure to be implemented
Ensure the valves are tightly closed and
tagged. Follow LOTO
Ensure the line is depressurised, properly
drained, Pruged,flushed
Exposure to HC/Toxic
Ensure there is no condensate pocket left
release due to holdup
after steam out.
material or passing valves Stay in upwind direction. Execute will
physically show the correct flange to be
opened
First loosen the flange on side away from
the body, Check for any leakage. Use
LEL/H2S detectors
if seems like passing valve, immediately
tighten the flange
Keep arrangement (tray? Bucket) ready
for collecting oil
keep cartage mask ready for escape. Use
full bodyappron,gloves and goggles
if hold up material is expected to be more
(for gas service) use air line mask
Only standard and approved blinds to be
used with complete bolting and new
gaskets
Fire hazard due to holdup Collect holdup oil trays. Use wet blankets
material falling on hot
over hot trays. Ensure no hot work in 15
lines
meter radius
fire due to Oil soaking
insulation
Don not allow oil into insulation. check that
the insulation cladding faces/ends are not
damaged
Injury due to improper
tool/lifting method
Use certified and right capacity
slings/chain (if require)
Use spanner tied with strings. Protect SBCs
nearby during lowering
Do not engage too many person. Use
correct hand tools
2
Execution of job at Injury due to fall from
height (if Applicable) height (if applicable)
Use certified scaffolding/hydraulic
platforms/trolleys with lock
Area must be barricaded. No superfluous
material to be kept at work site.
Use tray for small tools.
Tools, tackles etc. are not to be carried
with hands climbing. Use pouch, belt or
other lifting/lowering devices.
Ladder must be freet of oil/grease and
must be firmly placed to prevent slip
Ladder to be provided perpendicular to
the working platform wherever possible
gloves with good grip must be used while
climbing.
3
All sub activities(1-2) Physical Injury while
working
Use correct tools. Use mandatory PPEs
Done by :
Name :______________________________ Designation: AM Sign ____________________ Date:
Name :_______________________________ Designation: ______________ Sign
_________________________ Date:
(Note: JSA Sheet to be done by issuer and requestor of work permit . In case of need,
representative from other discipline should also be involved )
Sheet 14: Sheet13
Job Safety Analysis sheet
Main activity : Buffing (Power Brush) for Surface Cleaning
Plant :
JSA Sheet No: 1 Date of JSA :
S.
No.
Sub Activity
Hazards and Risks
Control measure to be implemented
Use certified scaffolding/Hydraulic
Injury due to from height platforms/trolleys with wheel lock
(if Applicable)
Use safety full body harness (this shall apply when
job is at height and to all sub activates)
Electrical Shock Hazards
1
Buffing of
Surfaces
Electrical machine must be certified by competent
authority and have valid certificate
All electrical connections to be crosschecked for
loose fittings etc.
Earthing of the equipment must be done.
check expiry date of the wheel before fixing new
wheel
always run the wheel for one minute idle, while
fixing the new wheel for the first time.
Injury due to breakage of
Always take a ring test for vitrified before mounting
grinding wheel
a new wheel
Always store the buffing wheels properly
Never stand in straight line of buffing wheel.
Use the special spanner for tightening the wheel
LET must be checked in the area periodically
Fire Hazards due possible
DCP cylinder to be kept ready for use. (Hot work
spark generation
permit require)
Exposure to noise
Wear earplug, as while grinding noise level will go
beyond 85 dB
Health hazards due to
dust
Use Dust mask
2
All sub
activities
Physical Injury while
working
Use correct tools. Use mandatory PPEs
Done by :
Name :______________________________ Designation: AM Sign ____________________ Date:
Name :_______________________________ Designation: ______________ Sign
_________________________ Date:
(Note: JSA Sheet to be done by issuer and requestor of work permit . In case of need,
representative from other discipline should also be involved )
Sheet 15: Sheet14
Job Safety Analysis sheet
Main activity : Hot Bolting of pipe line/equipment Flanges
Plant :
JSA Sheet No: 1 Date of JSA :
S.
Sub Activity
No.
1
Hot bolting of
flanges
Hazards and Risks
Control measure to be implemented
Hot burns/heat stress
due to working on hot
flanges
Flanges may be hot, leather gloves and full
body aprons must be used
Adequate drinking water must be available
and people at work are to be rotated
Exposure to Hot HC
vapor
release/toxic gas
release
Do not overtight or loosen the flange bolts to
the extent or leak
Loosen/fasten only one bolt at a time
Job to be done under complete supervision.
Keep escape route clesr
Struck by (Insury)
working tools
Use standard tools. Use rope strings for holding
spanner
Use Correct and without damage sling/rope to
lower elbow
Execution of job
2 height (if
applicable)
3
Injury due to fall from
height (if applicable)
All sub activities (1- Physical Injury while
2)
working
Use certified scaffolding/hydraulic
platforms/trolleys with wheel lock
Area must be barricaded. No superfluous
material to be kept at work site.
Use tray for small tools.
Tools, tackles etc. are not be carried with
hands while climbing. Use pouch, belt or other
lifting/lowering device
Ladder must be free of oil/grease and must be
firmly placed to prevent slip
Ladder to be provided perpendicular to the
working platform wherever possible
Gloves with good grip must be used while
climbing while climbing maintain 3 point
contract always
Use Correct tools. Use mandatory PPEs
Done by :
Name :______________________________ Designation: AM Sign ____________________ Date:
Name :_______________________________ Designation: ______________ Sign
_________________________ Date:
(Note: JSA Sheet to be done by issuer and requestor of work permit . In case of need,
representative from other discipline should also be involved )
Sheet 16: Sheet15
Job Safety Analysis sheet
Main activity : Scaffolding Removal
Plant :
JSA Sheet No: 1 Date of JSA :
S. Sub Activity
Hazards and Risks
Control measure to be implemented
No.
1
Damage to
workplace due to
hitting on pipes,
specially SBCs
Scaffolding material which removed should not
block escape route
All SBSs at work locaiton must be identified
Depending on critically, SBC may be marked by
wraping with barricading tape Adequate care
must be taken to avoid hitting on SBCs. Do not
kept pipes/clamps over the cable trays
Injury due to fall
(slip/trip) while
climbing up/down
Tools,tackles etc are not to be carried with
hands while climbing up/down. Use pouch, belt
or other lifting/lowering device. Ladder must be
free of oil/grease.
Do not use scaffolding braces for climbing
down, Use ladders
Gloves with good grip must be used while
climbing up/down
Use safety belt during climbing up or down
ladder
Sturck (injury) by
falling objects
Standard lifting procedure to be used for
lifting/lowering objects Scaffolding rods/planks
should not be manually shifted. Do not keep
planks loose at height
No person to be allowed to stand under weight
being lefted. Area must be barricaded
If scaffoling removal is above normal walkways,
use safety net
Injury due to fall
(slip/trip) from the
worklocation
Use safety full body harness
Injury due to sudden
collapse of
scaffolding
Ensure proper tightening of bolts and nuts and
follow sequence of dismantling( dismantling
should be done from top)
Removal of
Scaffolding
Use trolly for shifting the scaffolding material. Do
not use bare hands.
Shifting of
Injury due to improper For shifting scaffolding material from height eg,
2 scaffolding material
handling
coke drum structure , use rope and pully
after dismentaling
arrrangement with sufficient manning and
barricading; tie rodsproperly to avoid slips
Injury due to improper Materials to be kept at one location away from
keeping
walking area. Area to be barricated.
3
All sub activities (1- Physical Injury while
2)
working
Use correct tools. Use mandatory PPEs
Done by :
Name :______________________________ Designation: AM Sign ____________________ Date:
Name :_______________________________ Designation: ______________ Sign
_________________________ Date:
(Note: JSA Sheet to be done by issuer and requestor of work permit . In case of need,
representative from other discipline should also be involved )
Sheet 17: Sheet16
Job Safety Analysis sheet
Main activity : Scaffolding Erection / Modification
Plant :
JSA Sheet No: 1 Date of JSA :
S.
No.
Sub Activity
Shifting of
1 scaffolding
material
2
Erection of
Scaffolding
Hazards and Risks
Control measure to be implemented
Injury due to improper
handling
Use trolley the scaffolding material. Do not use
bare hands
For shifting scaffolding material to height eg,
Coke drum structure, use rope and pully
arrangement with sufficient manning and
barricading; tie rods properly to avoid slips
injury due to improper
house keeping
Material to be kept at one location away from
walking area. Area to be barricaded.
Scaffolding erected should not block identified
escape routes of the plant
All SBCs work location must be identified
Depending on critically, SBC may be marked
Damage to workplace due
by wrapping with barricading tape
to hitting/climbing on
Adequate care must be taken to avoid hitting
pipes, specially SBCs
on SBCs
Scaffolding pipes must be at least 6" away form
all SBCs and process line
Do not kept pipes/clamps over the cable trays
Injury due to fall (Slip/trip)
while climbing up
tools, tackles etc. are not to be carried with
hands while climbing. Use pouch, belt or other
lifting device. Ladder must be free of Oil/grease
Do not use Scaffolding branches for climbing
up, use ladders
Gloves with good grip must be used while
climbing.
3
All sub
activities (1-2)
Struck (Injury) be falling
objects
Standard lifting procedure to be used for lifting
objects
Scaffolding rods/planks should not be manually
shifted (do not shift with hands alone).
Do not keep planks loose at height. Area must
be barricaded
No persons to be allowed to stand under
weight being lifted
if Scaffolding errection is above normal
walkways, use safety net
injury due to fall (Slip/trip)
from the work location
Use Safety full body harness
injury due to sudden
collapse of incomplete
Scaffolding
Ensure proper tightening of bolts and nuts and
follow sequence of erection.
Physical Injury while
working
Use correct tools. Use mandatory PPEs
Done by :
Name :______________________________ Designation: AM Sign ____________________ Date:
Name :_______________________________ Designation: ______________ Sign
_________________________ Date:
(Note: JSA Sheet to be done by issuer and requestor of work permit . In case of need,
representative from other discipline should also be involved )
Sheet 18: Sheet17
Job Safety Analysis sheet
Main activity : PM of ID/FD fan
Plant :
JSA Sheet No: 1 Date of JSA :
S.
No.
Sub Activity
Coupling guard
removal and
1
checking rotor free
rotation
Hazards and Risks
Injury during
decouplinf of fan due
to improper electrical
isolation
Control measure to be implemented
Electrical isolation will be done from substation
Electrical Isolation tag shall be available with the
permit Operator shall cross check isolation by
pressing start button before commencing of the
job
2
Foundation bolt
tightness checking
Electrical isolation will be done from substation
Injury during
Electrical Isolation tag shall be available with the
decouplinf of fan due
permit Operator shall cross check isolation by
to improper electrical
pressing start button before commencing of the
isolation
job
3
Cleaning of the
breather
Physical injury while
working and due to
fall from height
Use correct tools. Use mandatory PPEs. Use
platform to approach
4
Physical injury while
Checking coupling
working and due to
condition at height
fall from height
Use correct tools. Use mandatory PPEs. Use
platform to approach
Checking lube oil /
5
seal oil / greasing
Health hazards (Long
term exposure) due Use chemical resistant hand gloves. Wash hand
to handling of oil /
properly after the job
grease
Casing bolt
6
tightness checking
Health hazards (Long
term exposure) due Use chemical resistant hand gloves. Wash hand
to handling of oil /
properly after the job
grease
Checking damper
7 freeness and
greasing
Health hazards (Long
term exposure) due Use chemical resistant hand gloves. Wash hand
to handling of oil /
properly after the job
grease
Checking cooling
water line for
8
choking and
cleaning
Health hazards (Long
term exposure) due Use chemical resistant hand gloves. Wash hand
to handling of oil /
properly after the job
grease
9
All sub activities (18)
Physical injury while
working
Use correct tools. Use mandatory PPEs
Done by :
Name :______________________________ Designation: AM Sign ____________________ Date:
Name :_______________________________ Designation: ______________ Sign
_________________________ Date:
(Note: JSA Sheet to be done by issuer and requestor of work permit . In case of need,
representative from other discipline should also be involved )
Sheet 19: Sheet18
Job Safety Analysis sheet
Main activity : Hydrojetting of heater transfer line
Plant :
JSA Sheet No: 1 Date of JSA :
S.
Sub Activity
No.
1
2
Line preparation
before hand over
Hazards and Risks
Control measure to be implemented
System/loop must be completely isolated,
tagged, de-pressurized, drained, blinded,
steam/water flushed before handing it
over for HJ. Also ensure required elbows
Exposure to H2S. Steam flash
have been dropped and kept tied in safe
due to improper isolation
location
Ensure all purge steam are isolated
Ensure there is no condensate pocket left
after steam fushing (if applicable)
Fire hazards due to
nonflame proof equipment
and/or diesel operated
engine
Electric mechine must be certified by
competent authority and have valid
certificate
All electrical connection to be
crosschecked for loose fitting, etc.
Earthing of the equipment must be done.
LEL must be checked in the area
periodically
DCP cylinder to be kept ready for use
Fire water hose is readily available
Damage to work place
and/or injury due to
overpressurization of hose
The hydrojeting mechine at all times
should have safety equipment in tested
and good working condition
Pressure gauges, Safety Valves etc.
should be calibrated every 3 months.
HP Hoses should have valid test certificate
for pressure test and visually checked for
Trial of hydrojetting
machine
cuts/damage etc. before putting it in use
every time.
Hydrojetting machine must be looked at
safe distance from pipes/equipment
hydrojetting operator shall have minimum
3 years of hydrojetting experience
Area must be kept barricaded
All pipes/ material laid on ground level
are wrapped with barricating tape or
painted
Laying of hoses and Injury due to fall
scaffolding completion and certification
preparing for
(slip/trip)due to running
done much in advance
3 hydrojetting/
against laid pipes/cables or
While climbing up ladder maintain 3 point
removal hoses after due to use of incomplete
contact
HJ
scaffolding
Gloves with good grip muct be used
while climbing
Adequate lighting ensured
Healthiness of the manchine and hoses to
be used are verfied prior to use cover the
hoses with metal pipe wherever possible
vehicle movement is there and provide
caution tape over the pipe
Ensure exertnal padding of hoses
Mechanical failure oh hoses wherever it touches metal surfaces
of the hyrojetting machine All rotating/moving parts of the machine
are guarded
Connecting between two hoses are
safety locking chain to be provided sway
arrester wherever possible
Continious monitoring to be done when
the machine is in operation
4
Hydrojetting of
trasfer line
Injury arising out of high
pressure jet
All trip systems of the machine are verified
to the working prior to use
stand by person available near pressure
realising pedesdal with walkie talkie
All PPEs as specified in the work permit to
be used (faceshields, PVC approns,
rubber gloves, gum boots)
Use certified scaffolding
Use safety full body harness with double
life line
Injury due to fall from height While cilmbing up ladder maintain 3 point
contact
Gloves with good grip must be used while
climbing
Injury due to coke flakes
hitting/flying
Hydrojetter to be used face shield and
other mandatory PPEs
Area must be barricaded
Minimum number of persons to be
present at work site; people around to be
kept informed
5
Ergonomics hazards due to
non approachable
locations
Proper scaffolding to be prepared
considering the approach to working
person.
Material falling from height
and damage the pipeline
and causes injury
Ensure dropped elbows are tied & kept in
safe location.
Ensure no human movement below
hydrojetting area
No superfluous material to be kept at
work site
Use tray for small tools.
The tools spares wherever possible.
All sub activities (1Physical Injury while working
4)
Use correct tools .Use mandatory PPEs
Done by :
Name :______________________________ Designation: AM Sign ____________________ Date:
Name :_______________________________ Designation: ______________ Sign
_________________________ Date:
(Note: JSA Sheet to be done by issuer and requestor of work permit . In case of need,
representative from other discipline should also be involved )
Sheet 20: Sheet19
Job Safety Analysis sheet
Main activity : Burner (PG/FG) dropping
Plant :
JSA Sheet No: 1 Date of JSA :
S.
Sub Activity
No.
Isolation of
1 Burner.
Hazards and Risks
Exposure to toxic/ HC gas due
to improper isolation.
Control measure to be implemented
Identification of the burner must be done by
field executive
proper isolation of the burner,by double
isolation and tagging
portable H2S meter to be kept by working
person
Opening of
2 the line
flanges
3
Dropping of
burner
Identification of the burner must be done by
field executive
Flammable gas release/fire due proper isolation of the burner,by double
to wrong burner flange
isolation and tagging
opening or passing of isolation flanges be gradually loosend first to check
wales
for leakage, if any.
Portable H2S meter to be kept with working
person
Injury due to fall from movable
trolley
Trolley to be properly positioned and lock to
be applied to wheels
Property damage (burner
damage)
Excess strength should not be applied to
remove out the burner if it gets stuck
somewhere. Handlinng burner properly while
lifting and lowering
Injury due to fall from movable
trolley
Trolley to be properly positioned and lock to
be applied to wheels
physical injury to personnel on
work
Standard job specific tools must be used
Draft must be kept negative all the time. Use
leather gloves as burn tip will be hot
Injury due to hot surfaces of the Use full sleeve apporns
burner assembly/ tracing steam Use face shield to gaurd against any hot
lines or flash back from the box material falling from the burner block
Ergonomic hazard while lifting
or lowering the burner block
All sub
Physical injury while working
4 activities (1-3)
Burner block to be supported by 2 persons
Use correct tool. Use mandatory PPEs
Done by :
Name :______________________________ Designation: AM Sign ____________________ Date:
Name :_______________________________ Designation: ______________ Sign
_________________________ Date:
(Note: JSA Sheet to be done by issuer and requestor of work permit . In case of need,
representative from other discipline should also be involved )
Sheet 21: Sheet20
Job Safety Analysis sheet
Main activity : Heat Exchanger Tube Insertion
Plant :
JSA Sheet No: 1 Date of JSA :
S.
No.
Sub Activity
Hazards and Risks
Injury to People
Tubes shifting
during material
1 nearby exchanger handling.
Manually
Injury to people
around
Control measure to be implemented
Do not use bare hands to handle material. Do not
drop the material from height.
Secure material properly from hitting the long
tubes to people and any equipment/machine
around.
Do not allow the excess person in the work area.
Communication should be proper in between
Physical injury by
persons who are invoved in the activity. Maintain
making contact
good housekeeping in work area. The area
with12m tube with
should be free from unwanted hardwares i.e
reemer. Injury due to electrical cables, extention boards etc. Portable
handling of protable electrical tools should have cables longer enough
electrical machine. to keep its extention board out of work area.
The tubes should not kept within visinity of high
movement area and should be barricaded.
Baffle's holes
clearance for tube
insertion by
2 reemring with
or/and without
Portable electrical
tool.
Fire Hazard due to
spark generation
while using portable
electrical machine
for reemering
LEL must be checked in the area periodically.
DCP cylinder to be kept ready for use. (Hot work
permit required).
Portable Electric machine and related extention
boards and/or distribution boards must be
certified by competent authority and have valid
certificate.
Electric shock from
portable electric
mechine.
Portable Electric machine and related extention
boards and/or distribution boards must be
certified by competent authority and have valid
certificate.
All Electric connectionc to be crosschecked for
loose fittings etc.
Earthing of the distribution boards must be done.
Injury due to fall from If required, prepare scaffolding plateform. Refer
height when working and comply to RA of scaffolding errection. Use
on height
Full body Harness
3 Tubes Insertion and Physical injury while
Do not allow the excess person in the work area.
alligenment
tube insertion
Injury while using
hammer
Communication should be proper in between
persons who are invoved in the activity on both
end of exchangers. Maintain good housekeeping
in work area. The area should be free from
unwanted hardwares i.e electrical cables,
extention boards etc.
Use only inspected tools. Do not use
contaminated or oil handgloves. Ensure a proper
grip to the handle of hammer.
Injury due to fall from If required, prepare scaffolding plateform. Refer
height when working and comply to RA of scaffolding errection. Use
on height
Full body Harness
4
All sub activities (1- Physical injury while
3)
working
Use correct toolS. Use mandatory PPEs
Done by :
Name :______________________________ Designation: AM Sign ____________________ Date:
Name :_______________________________ Designation: ______________ Sign
_________________________ Date:
(Note: JSA Sheet to be done by issuer and requestor of work permit . In case of need,
representative from other discipline should also be involved )
Sheet 22: Sheet21
Job Safety Analysis sheet
Main activity : Hydrotest of Pipes /Equipment
Plant :
JSA Sheet No: 1 Date of JSA :
S.
No.
Sub Activity
Hazards and Risks
1 Preparing for hydrotest Health hazard due to
Control measure to be implemented
Ensure equipment is positively isolated
(blindding and
connection
pump/hoses)
exposure to HC/toxic gas
Injury due to use of
improper tools
Injury due to failure of
fittings used for hydrotest
2 Hydrotest
Use standard job specific tools and PPEs
Ensure Blinds used area of correct rating
to withstand hydrotest pressure
Avoid threaded connections and plugs.
Check for all fittings before hydrotest
includes gaskets
Check for pump hoses for any kind of
damage. Only one person will check
for leakages
Barricade the area of hydrotest . Do not
allow too many person around during
pressurisation
Injury due to fall from height Refer and comply to Work at Height
(if applicable)
JSA (this will apply to all subactivities)
Property damage due to
overpressurisation
Be clear about the hydrotest pressure;
do not pressurize beyond hydrotest
pressure Use standard and calibrated
gauges only
Fire/electrical hazard due
to nonflame proof
equipment and/or diesel
operated engine
Electric machine must be certified by
competent authority and have valid
certificate All Electric connectionc to
be crosschecked for loose fittings etc.
Earthing of the equipment must be
done
LEL must be checked in the area
periodically.
DCP cylinder to be kept ready for use
Equipment damage
Provide adequate venting to avoid
equipment going to vaccum during
draining
Injury during
depressurisation
Keep body away from the fluid path.
Open valve slowly
3 Depressurisation
4 All sub activities (1-3)
from all HC (process) connections.
Ensure line or equipment is free from
HC/toxic gas i.e check LEL and H2S.
Physical injury while working Use correct tools. Use mandatory PPEs
Done by :
Name :______________________________ Designation: AM Sign ____________________ Date:
Name :_______________________________ Designation: ______________ Sign
_________________________ Date:
(Note: JSA Sheet to be done by issuer and requestor of work permit . In case of need,
representative from other discipline should also be involved )
Sheet 23: Sheet22
Job Safety Analysis sheet
Main activity : Valve Servicing (other than gland and bonnet)
Plant
:
JSA Sheet No: 1 Date of JSA :
S.
No.
Sub Activity
Hazards and Risks
Physical Injury due to
improper tools
1
Use job specific tools and PPEs Stay away
from hot lines
Use certified scafolding/Hydraulic
Fall due to not following
platforms/trolleys with wheel lock
Valve
work at height
Use safety full body harness with double
york/stem/gear box procedure (if
lifeline Use tray for small tools. Maintain 3
servicing
applicable)
point contact while climbing the ladders
Health hazard due to
handling grease (long
exposure)
2
Control measure to be implemented
All sub activities (1)
Physical injury while
working
Use chemical resistant gloves and wash
hands properly
Use correct tools. Use mandatory PPEs
Done by :
Name :______________________________ Designation: AM Sign ____________________ Date:
Name :_______________________________ Designation: ______________ Sign
_________________________ Date:
(Note: JSA Sheet to be done by issuer and requestor of work permit . In case of need,
representative from other discipline should also be involved )
Sheet 24: Sheet23
Job Safety Analysis sheet
Main activity : Removal of structure by cutting
Plant :
JSA Sheet No: 1 Date of JSA :
S.
Sub Activity
No.
Hazards and Risks
Job preparation
(lifting and
1 shifting of
Injury due to fall from height
material from
Ground level)
Structural
member
2
removal by gas
cutting
Injury due to fall fronm height
Explosion due to mishandling of
the cylinder/Fire due to gas
release hose and fitting Burn
injury due to mishandling flame
Fire hazards due to combustile
material around
Control measure to be implemented
Tools, tackles etcare not be carried with
hands while climbing.
Use pouch, belt or other lifting/loweing
device. Ladder must be free of
oil/grease
Gloves with good grip must be used for
climbing
While climbing or stepping down the
ladder three point contact must be
there
Scaffolding must be ready for use and
certified. Use safety fullbody harness
with double lifeline
Provide proper scaffolding as per
Scaffolding Procedure
Always use safety full body harness.
Cylinder must be kept chained on trolly.
Cylinder must have safety cap
Hoses should not be in damaged
condition. It should be tested
periodically for fitness and clamped at
all joints. There should be flask back
arrestors on either side
Torch must be in good working
condition. When not in use , Isolate from
the cylinder
Safe lying of hoses without sharp bends
and not near to sharp edges Alawys
Keep the flame away from the body.
Use leather gloves Use dark goggles The
spark coming out may lead to fire if any
inflammbles material is lying near by
Barricade area with Fire blanket. Clear
the area of all flammble substances
within 8 m radius Keep DCP cylinder as
standby. Keep fire hoses ready. Keep
the area wet, if required Periodically
monitor LEL and record
Dimentalling of
3 structure
members
Lifting and
shifting of
4
structural
members
5
Injury due to fall from
heightingInjuruy due to fallng of
structural member from height
Physical injury due to
slippage/damage of spanners
Use Certified scaffolding. Use Full body
Harness. Block the monkey ladder
access of antisurge platform.
Ensure proper tieing of the structural
member with rope /chain pulley beforre
operating thebolts.
Use only tested lifting machine &
tackles. Barricate the area.
Use only inspected tools. Use correct
tools.
Physical injury during shifting of
structural member/grating.
Damage of near by instruments
Barricate the possible affecting area.
Ensure proper tieing of the member
during lowering.
Use tested Lifting tools & tackles for
dropping structural members
Jobs to be executed under proper
supervision. Inform area executive
before starting the jobs
All sub activities Physically Injury while working
(1-4)
Use correct tools. Use mandatory PPEs
Done by :
Name :______________________________ Designation: AM Sign _________________________ Date:
Name :_______________________________ Designation: ______________ Sign
_________________________ Date:
(Note: JSA Sheet to be done by issuer and requestor of work permit . In case of need,
representative from other discipline should also be involved )
Sheet 25: Sheet24
Job Safety Analysis sheet
Main activity : Hackshaw cutting o
Plant :
JSA Sheet No: 1 Date of JSA :
S.
Sub Activity
No.
Hazards and Risks Control measure to be implemented
Exposure to
Chemical ( toxic/
flammble gas
release)
Hachshaw
1 cutting
(manual )
Hackshaw cutting to be employed on lines which are
difficult to flush out.
Attempt to be made fush the lines to the extent possible
to aviod uncontrolled/ excessive relesae of HC/toxic
gas during cutting Arrangement to be made for
continous remote venting / drianing of the line.
All care must be taken expecting toxic gas/HC release.
Air line mask to be used during cutting. Area to a
diameter of 15m atleast to be evacuated.
Not hot work to be allowed in the area
LEL & H2S to be continously monitored in the area. Keep
running water ready for dilutioin
Drain abd vent arrangement to be provided on the line
Fire /explosion due
at remote location
to excessive Hc gas
Cutting surface to be continiously cooled by pouring
release
water
Cut injury to
working personnel
No person to be allowed to stand undre weight being
lifted
Area must be barricated. No superflous material to be
kept at work site.
Use tray foe small tools. The tools , spares wherever
possible
2
3
Use gloves during cutting. Keep hand at safe distance
from the sharpm edges
All sub
Physically Injury
activities (1-2) while working
Done by :
Use correct tools. Use mandatory PPEs
Name :______________________________ Designation: AM Sign ____________________ Date:
Name :_______________________________ Designation: ______________ Sign
_________________________ Date:
(Note: JSA Sheet to be done by issuer and requestor of work permit . In case of need,
representative from other discipline should also be involved )
Sheet 26: Sheet25
Job Safety Analysis sheet
Main activity : Non flameproof Electrical Equipment usage inside plant
Plant :
JSA Sheet No: 1 Date of JSA :
S.
Sub Activity
No.
Operation of Non
falmeproof
1
Electrical
Equipment-
2 All sub activities (1)
Hazards and
Risks
Control measure to be implemented
Electrical shock
Hazards
Electrical machine must be certified by competent
authority and have valid certificate All electrical
connection to be crooschecked for loose fitting,etc
Earthing of the equipment must be done
Fire Hazard due
possible spark
generation
LEL must be checked in the area periodically DCP
cylinder to be kept ready for use ( Hot work permit
required )
Physically Injury
while working
Use correct tools Use mandatory PPEs
Done by :
Name :______________________________ Designation: AM Sign ____________________ Date:
Name :_______________________________ Designation: ______________ Sign
_________________________ Date:
(Note: JSA Sheet to be done by issuer and requestor of work permit . In case of need,
representative from other discipline should also be involved )
Sheet 27: Sheet26
Job Safety Analysis sheet
Main activity : Hydrojetting of exchangers
Plant :
JSA Sheet No: 1 Date of JSA :
S.
Sub Activity
No.
Trail of
1 hydrojetting
machine
Hazards and Risks
Control measure to be implemented
Electric mechine must be certified by
competent authority and have valid
certificate All electrical connection to be
crosschecked for loose fitting, etc.
Earthing of the equipment must be done. LEL
must be checked in the area periodically
DCP cylinder to be kept ready for use. Fire
water hose is readily available
The hydrojeting mechine at all times should
have safety equipment in tested and good
Fire hazards due to nonflame
working condition
proof equipment and/or
Pressure gauges, Safety Valves etc. should be
diesel operated engine
calibrated every 3 months.
Damage to work place
Foot valve should be inspected bry mech CES
and/or injury due to
person and should have valid certificate. HP
overpressurization of hose
Hoses should have valid test certificate for
pressure test and visually checked for
cuts/damage etc. before putting it in use
every time.
Hydrojetting machine must be looked at safe
distance from pipes/equipment Minimum
personnel to be allowed for trial
Hydrojetting operator shall have minimum 3
years of hydrojetting experience
Area must be kept barricaded
Laying of
hoses and
2
preparing for
hydrojetting
3 Hyrojetting
4
Injury due to fall (slip/trip)due
to running against laid
pipes/cables or due to use of
incomplete scaffolding
Area must be barricated.
Scaffolding completion and certification
done in advance.
Adequate lighting ensured
Mechanical failure for hoses
or the Hyrojetting machine
Injury due to coke particles
hitting/flying
healthiness of the machine and hoses to be
used are verfied prior to use
Cover the hoses with metal pipe wherever
possible vehisle movement is there and
provide caution tape over the pipe. Ensure
external padding of hoses wherever it
touches metal surfaces
All rotating /moving parts of the machine are
gaurded
Connecting betwen two hoses are safety
locking chain to be provided. Sway arrester
wherever possible Continious monitoring to
be done when the machine is in operation .
The area around the Hyrojetting should be
properly cordoned with rope/ chian to
prevent unauthorized persons entering into
hyrojetting area. diesel engine operated
hyrojetting machines should have flame
arrestor on exhaust
All PPE's ae specified in the work permit to be
used ( gum boots ). Area must be barricated
Minimum number of persons to be present at
work site;
All sub
Physically Injury while working
activities (1-3)
Use correct tools. Use mandatory PPEs
Done by :
Name :______________________________ Designation: AM Sign ____________________ Date:
Name :_______________________________ Designation: ______________ Sign
_________________________ Date:
(Note: JSA Sheet to be done by issuer and requestor of work permit . In case of need,
representative from other discipline should also be involved )
Sheet 28: Sheet27
Job Safety Analysis sheet
Main activity : Bundle pulling of Heat Exchanger
Plant :
JSA Sheet No: 1 Date of JSA :
S.
Sub Activity
No.
Channel cover &
1
channel opening
Hazards and Risks
Control measure to be implemented
Ensure that decontamination done effectively.
Fire due to pyrophoric Keep water hose ready
iron
Exchanger must be kept wet to prevent residual
pyrophoric iron from lighting
Continuously wet the tubes surface during
Fire due to pyrophoric bundle pull out operation. (Ensure water flow is
iron
minimum and it is continuously draining outside.
Water should not hold inside exhanger )
Fire hazard due
bundle puller/ crane
operartion Inside
plant
Tube bundle
2 pulling using puller
/crane
Get Hot work permit, check LEL in 15mt of
surrounding area Spark arrestor must be installed
in healthy condition. Inhibit nearby DGX for
vehicle movement
Refer and comply to RA for Crane/Hyrda
deployment
Shell must be locked with Puller Lock. Puller lock
sling must be properly bolted with exchanger
flange.
Exchanger Saddle support should be properly
Properly damage/
supported
Injury due to improper
Use correct I-Bolt at Exchanger an dcertified
lifting/pulling of
slings for Pulling tube bundle
bundle
Properly aligns sling with puller and exchanger.
Bundle tube baffle must be safely rested Refer
and comply to RA for crane /Hyrdra deployment.
Keep the area barricaded
Use standard and job specific tools. Use certified
Injury due to improper
chain blocks and slings. Do not move under lifted
tools/handling
loads.
Periocally monitor LEL within 15mts of sorrounding
Fire hazard due to
area and record.
combustible material Refer comply to RA for hot work (Gas
around
cutting/grinding/welding) on structure/ New line
Temporary Support
errection
3 structurre provision
Injury due to fall from If required ,.prepare scaffolding platform. Use full
as per requirement
height
body harness
Injury due to falling of Ensure proper tieing of the structural member
structural member
with rope / chain pulley.
from height
Use only tested Lifting tools & tackles. Barricate
the area If required pepare a working scaffolding
platform below the structural members
Physicaly injury due to
slippage/ damage of
spanners
Use only inspected tools. Use correct tools.
4
All sub activities (1- Physically Injury while
3)
working
Use correct tools. Use mandatory PPEs
Done by :
Name :______________________________ Designation: AM Sign ____________________ Date:
Name :_______________________________ Designation: ______________ Sign
_________________________ Date:
(Note: JSA Sheet to be done by issuer and requestor of work permit . In case of need,
representative from other discipline should also be involved )
Sheet 29: Sheet28
Job Safety Analysis sheet
Main activity : Heat Exchange tubes removal by gas cutting
Plant :
JSA Sheet No: 1 Date of JSA :
S.
Sub Activity
No.
Hazards and Risks
Control measure to be implemented
Physical Injury while
shifting the cylinders
Mobilise the gas Cylinders in trolly, and don’t roll it
Prepartion
1 for cutting of Fall from height while
tubes
lining up cylinder hoses in
trays
Use full body harness while climbing in ladder
2 Gas cutting
Ensure integrity of working platform and there
should be no gap between planks
Fall from the Height during
Use Certified scaffolding.
cutting
Ensure there is more ways of access and no pipings
are obstructing the escape route
Cylinder must be kept chained on trolly and
identified with labels. Cylinder must have safety
cap
Hoses should not be in damaged condition. It
shuold be tested periodically for fitness and
Explosion due to
clamped at all joints
mishandling of the
There should be flash back arrestors on either side.
cylinder/ Fire due to gas
Torch must be in good working condition When not
release by improper hose
in use, isolate from the cylinder. ( Ensure the tag
and fittings
no. in cylinder before isolating ) Safe laying of
hoses without sharp bends and near to sharp
edges
Hose laying should be through cable tray to avoid
bend and damage to the hoses
Burn injury due to to
mishandling flame
Always keep the flame away from the body and
nearby working crew. Use leather gloves Use dark
goggles
Asphyxiation due to
vapours generated
during cutting
Use dusk mask. Interchange the working persons
frequently and allow them to breath fresh air
Do not allow person to stand at tube bundle both
ends, where more vapours will come during
cutting
Fire due to any HC hold
up inside tubes and
exposure of phyrophoric
material
Keep the area wet. Keep DCP extinguisher and
Fire hoses ready
Fire hazards due to
combustible material
around
The spark coming out may lead to fire if any
inflammble material is lying near by
Barricade area with fire blanket or Aluminum
sheets
Clear the area of all flammble substance within 8m
radius
Keep DCP cylinder as standby. Keep the area wet,
if required Periocally monitor LEL and record
Burn injury due to hot
surface
3
Removal of
tubes
Shifting oe
4 cut piece
tubes
Use leather gloves
Physical Injury due to
sharp edges
Do not pull the tubes bu touching at edges.
Take care of nearby working crew while pulling the
tubes
Dust Exposure
Wear Dust mask. Remove the sediments over tubes
before pulling the tubes
Stop the work and clean the area frequently. if
require do hydrojetting to clean the surface of
tubes
Burn injury due to
mishandling of cut tubes
Always keep the cut tubes away from the body.
Dip the hot cut tubes in water for cooling Use
leather gloves
Physical injury while
shifting
Shift the cut tubes in trolly are using fork lift ( Refer
RA 120 for Using Fork lift)
Trolley/ Fork lift should not be overloaded
All sub
5 activities (14)
Physically Injury while
working
Use correct tools. Use mandatory PPEs
Done by :
Name :______________________________ Designation: AM Sign ____________________ Date:
Name :_______________________________ Designation: ______________ Sign
_________________________ Date:
(Note: JSA Sheet to be done by issuer and requestor of work permit . In case of need,
representative from other discipline should also be involved )
Sheet 30: Sheet29
Job Safety Analysis sheet
Main activity : Housekeeping inside plant
Plant :
JSA Sheet No: 1 Date of JSA :
S.
Sub Activity
No.
1
2
3
Hazards and Risks
Control measure to be implemented
slip injury due to rags rags & garbags to be kept in identified bins , insure that
/ garbage / grease spllied oil / grease are cleaned immideately, wash the
or oil
hands with soap at the end of work
injury due to
material lying here & material to bekept at identified & safe places , scrap
housekeeping there
materialto be sent to scrap bins afetr housekeeping
injury due to sharp
edges of wires or
structures
use mandatory PPEs
dust
use dust mask along with mandatory PPEs
burn injury due to
hot surface
4
use mandatory PPEs, use leather gloves if require
Done by :
Name :______________________________ Designation: AM Sign ____________________ Date:
Name :_______________________________ Designation: ______________ Sign
_________________________ Date:
(Note: JSA Sheet to be done by issuer and requestor of work permit . In case of need,
representative from other discipline should also be involved )
Sheet 31: Sheet30
Job Safety Analysis sheet
Main activity : Fan/ blower fixing on manways for air circulation
Plant :
JSA Sheet No: 1 Date of JSA :
S.
Sub Activity
No.
lifting the fan/ blower
1
2
fixing the fan /blower
on the manway
Hazards and Risks
Control measure to be
implemented
use correct & certified slings/ wire
properly damage /injury due rope
to improper lifting methods
keep body away from lifted load
Don't move under lift at load
struck by (injury) tools while
working
use standerd tools , use rope string
for holding spaner
exposure to toxic gas/
nitrogen
carry personal H2s metre ,
check O2 level at manway ,
keep SCBA set ready,
Stand in upwind direction or side of
manway
3
Electrical connection
on the fan/ blower
4
all sub activities (1 to 3)
elecrical fire hazards
Job to be done under different
permit with relavent electrical JSA
physical injury while working
use correct tools, use mandatory
PPEs
Done by :
Name :______________________________ Designation: AM Sign __________________________ Date:
Name :_______________________________ Designation: ______________ Sign
_________________________ Date:
(Note: JSA Sheet to be done by issuer and requestor of work permit . In case of need,
representative from other discipline should also be involved )
Sheet 32: Sheet31
Job Safety Analysis sheet
Main activity : Material handling manualy
Plant :
JSA Sheet No: 1 Date of JSA :
S.
Sub Activity
No.
Hazards and Risks
lifting of material on
trolley, shifting of
material on trolley
1
injury to people during material
handling
Control measure to be
implemented
Do not use barehands to handle
material
use portable lifting trolley and
shifting on trolley only,
Use crane hydra wherever
required if material is heavy
Refer & follow respective RA for
lifting with crane/ hydra
Don't drop material from height,
use correct lifting lowering
devices
Secure material properly on
trolley
fixing & removal of
2 chain blocks for lifting injury due to fall from height
the material manualy
3
lifting of material
using chain pulley
all sub activities (1 to
4 3)
wear safety full body harness
clamped to fix structure & not to
the pipings ,
use certified ladder
Maintain three point contact
while climbing the ladders
Use certified ,valid & with no
damage slings ,chain pulley
blocks for lifting
Don't use edged support for
slings
Use rigid & firm support for
hooking the slings /chain
damage to the equipment near by
Don't load any scaffolding or
lines
other temporary structure
directly or indirectly by slings
/chains
Area to be barricated during
lifting
Keep minimum person during
lifting
toxic gas, hydrocarbon release
due to hitting nearby
pipelines,instruments tubings
clearly identified the lifting route
well in advanced an marked all
SBCs ,
wrap with barricating tape if
deemed necessary
use standard lifting devices ,
For critical lift JE /FS will
personally supervise the job
physical injury while working
use correct tools, use mandatory
PPEs
Done by :
Name :______________________________ Designation: AM Sign ____________________ Date:
Name :_______________________________ Designation: ______________ Sign
_________________________ Date:
(Note: JSA Sheet to be done by issuer and requestor of work permit . In case of need,
representative from other discipline should also be involved )
Sheet 33: Sheet32
Job Safety Analysis sheet
Main activity : Conditioning monitoring of equipment
Plant :
JSA Sheet No: 1 Date of JSA :
S.
Sub Activity
No.
recording vibration
reasings with
designnated meter
1
Hazards and Risks
check all rotating /moving parts are
injury due to body parts
adequately guarded ,don't move close to
getting traped between
the rotating parts,use hand gloves & goggles
moving machinery
,don't wear loose fitting attire or neckwears
use only authorised spark free devices for
fire/explosion due to use
measurement in hazards areas ,check
of non flame proff tolls
measurement devices is certified
burn injury due to
touching nearby hot
surface
4 All sub activities (1)
Control measure to be implemented
Physical injury while
working
use leather gloves near hot service pumps
Use correct tool. Use mandatory PPEs
Done by :
Name :______________________________ Designation: AM Sign ____________________ Date:
Name :_______________________________ Designation: ______________ Sign
_________________________ Date:
(Note: JSA Sheet to be done by issuer and requestor of work permit . In case of need,
representative from other discipline should also be involved )
Sheet 34: Sheet33
Job Safety Analysis sheet
Main activity : Manway opening and boxup of process equipments
Plant :
JSA Sheet No: 1 Date of JSA :
S.
No.
Sub
Activity
Hazards and Risks
Human error
Opening
1 the
manway
Control measure to be implemented
Identify the correct manway to be opend from the
permit description
Field Executive should physically show the right
manway to be opend
The equipment and connected process lines are
made free from HC and toxic material using
deconamination techniques
There should not be any condensate pocket left in
the loop after steaming .
All the process , utility & insert gas connection must
be disconnected & positively blinded with standard
blind before opening manway. All such location
Chemical (toxic/
must be identified & marked clearly on P&ID &
flammabled/insert gas)
separate blind list must be prepared. The same must
release / fire due to
be check jointly by permit issuer &requestor before
residual HC/toxic gas left in
allowing Man Entry Keep Escape set ready for
the vessel
escape in case of residual H2S release
USE Air line mask or SCBA, if advised in the permit.
Stop Hot job in radius of 15 meters
First gently loosen the flange; body position should
be away from the opening such that residual
steam/gas released do not affect.
First keep the manway 20-30% open. Put "DO NOT
ENTER WITHOUT PERMIT" board
Struck by (injury) tools while Use standard tools. Use rope strins for holding
working
spanner
2
Boxup of
manway
Persons trapped inside
Ensure all the persons who were worked inside came
out from the vessel /Equipment.
Crosscheck the same from Man-entry register. Give
sound and ensure no reply from inside
Struck by (injury) tools while Use standard tools. Use rope strins for holding
working
All sub
activities
3 (1-2)
spanner
Physical Injury while working Use correct tools. Use mandatory PPEs
Done by :
Name :______________________________ Designation: AM Sign ____________________ Date:
Name :_______________________________ Designation: ______________ Sign
_________________________ Date:
(Note: JSA Sheet to be done by issuer and requestor of work permit . In case of need,
representative from other discipline should also be involved )
Sheet 35: Sheet34
Job Safety Analysis sheet
Main activity : Work at height
Plant :
JSA Sheet No: 1 Date of JSA :
S.
Sub Activity
No.
Hazards and Risks
Control measure to be implemented
Approach to be identified in such a way that
emergency egrees route is avilable Alternate
escape route to be identified depending on
criticallity of the job
Scaffolding errrected should not block
identified Escape routes of the plant
ALL SBCs at work location must be identified
Damage to workplace
Identifying the best
Electrical and instrument cable must be
due to hitting/
approach to work
identified and scaffolding pipes should noy
climbing on pipes,
1 location and
touch these cables Adequate care must be
specially SBCs in turn it
scaffolding
taken to avoid hitting on SBCs Scaffoding pipes
release of toxic gases /
preparation
must be atleast at least 6'' away from SBCs
fire
JSA avilable for scaffolding prepartion and
dismantlling to be referred Scaffodling must
meet all standard requirement. Scaffolding
certification must be done Scaffolding check
list must be filled.
ALL above also applies if Hyraullic platform /
trolley is being used
Tools , tackles etc are not to be carried with
hands while climbing. Use pouch, belt or other
lifting / lowering device
Ladder must be free of oil/ greese and must be
firmly placed tp prevent slip
Shifting of tools,
Injury due to fall (
Ladder to be provided perpendicular to the
2 tackles, spare etc to slip/trip) while climbing working platform wherever possible
work location
up
Gloves with good grip must be used while
climbing
Keep landing area near the ladder free form
looses pipes and other scaffolding material
While climbing maintain 3 point contact
always
Execution of the job
at height
3
4
All sub activities (13)
Struck by falling
objects
No person to be allowed to stand under
weight being lifted
Area must be barricated. No superfluous
mateiral to be kept at work site.
Use tary for small tools. Tie tools, spare
wherever possible
Injury due to fall (
slip/trip) from the
working platform
Use certified scaffolding / Hydraulic platform /
trolleys with wheel locl
Use safety full body harness with double lifeline
Physically Injury while
working
Use correct tools. Use mandatory PPEs
Done by :
Name :______________________________ Designation: AM Sign ________________________ Date:
Name :_______________________________ Designation: ______________ Sign
_________________________ Date:
(Note: JSA Sheet to be done by issuer and requestor of work permit . In case of need,
representative from other discipline should also be involved )
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