KAMLESH KUMAR SINGH ENGINEERS PVT.

LTD
JOB SAFETY ANALYSIS FOR INTERNAL WORK OF REACTOR

JOB NO 25511378 Date: 05/11/2019

Project Location : New NHT/CCR. JSA No.: 24
P&M and Equipment, Crawler crane/Winch Machine, Lifting tools & tackles, Rev. No.: 01
Tools & tackles involved Rope pulley block, Handtools, Power tools, Gas detector
& Experienced manpower.
Job Description: Internal work of Reactor (Fixing of centre Pipe & Hot Prepared By: Mr. Jayjay Ram
work inside reactor) (Contractor Site
Eng. Sup)
Sequence of Operation – Activity Tools &tackles Hazards Safety measures / precautions
Job Classification:
Sl.
Steps Mechanical used & involved at
Risk Reviewed By: Mr. Hareesh
Risk level Kumar.S
Responsibility
No. level after
manpower various (Contractor Action by
H/M/L control
deployed steps HSEM)
1. L 1.1.1 Prepare the Job Safety L Site
Name of the Site Approved
Analysis and apply forBy:
approval. Mr. Sajal Sarkarengineer/RCM
Mr. Jayjay Ram
Engineer:
1. Work (Contractor
1.1.2 Prior to start of any activity
interruption RCM/Site
proper work permit should be
2. obtained Manager)
by Daily Permit Clearance
for confined space.
PPE / safety device Unauthorize Status. Issued for
Safety Helmets, Safety Goggles, Safety Shoes, Hand
required d Person implementation/ review
Gloves, Leather hand glove, Welding helmet, Boiler 1.1.3
suit, Permit shall be displayed at
Full Body Safety Harness, fall arrestor, Dust Mask, worksite.
Aluminum Ladder, Scaffolding platform, Exhaust Fan/ Air
Permit procedure & Area Job supervisor 1.1.4 Prior to applying for the
clearance Blower, 24 volt Light, intrinsically safe torches, ear plug
permit to the IOCL/Technip, all
etc. requirement of job activities such as
tools, tackles, Safety devices and
manpower should be available at
worksite along with Proper
housekeeping and it should be
ensuring by concerned Job
Supervisor/Job Engineer.

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 1.2.1 All persons involved in the job
must discuss and understand the
work permit & JSA by concerned
Engineer/Supervisor.
1.2.2 All the persons who working
inside the confined space shall
trained & shall identified specially
with trade sticker(Confined space
trained).

2.1.1 Ensure proper access &

scaffolding platform for opening of
bottom gum with handrails.

2.2.1Ensure tagline in hand tools

while opening the bottom gum. Site
Opening of Bottom gum Hand tools, engineer/RCM
Rigger. 2.2.2 Ensure PPE`s of all person.
1. Improper 2.3.1 Use other objects such as
Access hooks or bars to remove bottom
2. Fall of gum.
hand tools
from height.  2.3.2 Make good communication
3. Losing with each other while opening the
control on bottom gum.
2. body while H L
trying to 2.3.3 Ensure that equipment
remove platform shall fully cleared &
bottom gum. handrails are in position.
4. Pinch
hand & feet. 2.3.4 No loose materials shall kept
in equipment platform.

2.3.5 Platform around the equipment

shall properly covered & barricaded.

2.4.1 Keep hands and feet out of the

way while removing the bottom
gum.
.
1. H 3.1.1 Ensure that sufficient L
Insufficient

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 3. accessibility accessibility is available.
2.
Unauthorize 3.2.1 Ensure proper hard barricading
d personnel is done in the work area and proper
movement type of sign boards are in place.
3. Oxygen
deficiency / 3.3.1 Ensure gas testing should be
enrichment done and maintained periodically &
4. continuous monitoring.
Accumulate
d toxic/
3.3.2 Oxygen level shall be 19.5%
flammable
to 23.5 %.
gases
5.
Hand tools, Inadequate
Preparation of works Competent illumination 3.4.1 Ensure that all Personnel’s are Site
person 6. Lack of aware of the hazards and takes engineer/RCM
trained appropriate precautions.
employees
7. Lack of 3.5.1 Ensure adequate lighting is
proper provided in the area and inside the
communicat column.
ion
8. Lack of 3.5.2 Illumination level shall be 100
watch man lux.
9. Lack of
ventilation 3.5.3 Electrical tools shall be
maximum 24V capacity.

3.6.1 Ensure all the personnel

entering in the reactor are
adequately trained & experienced.

3.7.1 Use walkie-talkie for

communication which will be
provided by Technip/IOCL as per
required.

3.8.1 Assign watch man for the

personnel entering in to the reactor.

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 3.8.2 Watchman also maintain the in
out log-sheet.

3.8.3 Frequent communication

should be there in between the
personnel inside the reactor and
watchman.

3.8.4 Work supervisor shall always

available at site.

3.9.1 Provided forced ventilation

(Exhaust fan +Air blower) if
required
4. H L
4.1.1 Ensure adequate proper
1. Man, scaffold, use of wire lifeline/ 100%
Materials use of safety harness with double
and tools lanyard from height of 1.8-meter,
Fall from safety net and job specific PPE for
height. all personnel.
4.1.2 All access and aggress to be
cleared.
4.1.3 Tool kit bag shall used to carry
tools.
4.1.4 Manual material handling by
rope Pulley with derrick arm,
beneath area must be barricaded.
4.1.5 Tag line to be use for all loose Site
Hand tools, tools used at height work. engineer/RCM
General (Access & work at height. Scaffolder, 4.1.6 Continuous monitoring by the
etc.) Rigger
Supervisors to ensure that nobody is
working or moving without hooking
the Safety harness, use of wire rope
life line while on climbing up /
climbing down,
4.1.7 The scaffolding supervisor
shall ensure scaffolding be done by

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 the trained scaffolders and same
shall be bearing with green tags
after ensuring to make the same as
per standard.
4.1.8 FBH with detachable lanyard /
shock absorber/ double lanyard and
snap hook shall be used and
anchored to a hand rail / rigid
structure while working at scaffold.
Small material to be secured
properly at height.
4.1.9 Heavy material shall not be
stored in scaffolding platform.
4.1.10 Engage trained &
experienced personnel.
4.1.11 Area barricading to be
ensured.
4.1.12 Ensure Materials /tools to be
properly secured
4.1.13 All openings should be
covered or fenced properly
4.1.14 Ensure Certified Tools &
tackles and equipment’s and safe
working load prior to their use.
4.1.15 Ensure proper material
handling.

4.1.16 Pre-Employment Health

check-up to be done for all
concerned workmen.

5.1.1 The scaffolding shall be

1. Collapse erected on a firm ground with soul
of the timbers and steel base plates
scaffolding
2. Fall of 5.1.2 Scaffolding shall be erected by
person or a competent scaffolding crew
material 5.1.3 Red for unsafe and Green for

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 from safe for use identification marks
platform. shall be used identified the
3. Fall of condition of the scaffolding after
person from
inspected by concerned scaffolding
ladder
4. Fall of supervisor.
material 5.1.4 Certified scaffolding materials
Hand tools, during shall be used.
Scaffolder, shifting H 5.1.5 All damaged pipes and clamps L Site
5. Scaffolding Erection Fitter, Rigger activity. shall not be used. engineer/RCM
5. Fall of 5.2.1 No loose materials shall be
spanner or
kept on the platform leaving it
bolt during
bolting unsecured, toe board shall be
activity for ensured along with tools tied off to
scaffolding the tool lanyard.
work. 5.2.2 The spanners should be
secured to the harness to prevent it
from falling.
5.3.1 The ladder should be in good
condition and having non-slip
rubber shoes.
5.3.2 The ladder shall be inspected
weekly and monthly along with the
checklist
5.3.3 The ladder shall be secured
with ladder clamps in a position of
75 degree (1:4 ratio)
5.3.4 The person climbing on the
ladder should climb with three-point
contact and secured properly.
5.3.5 Holding of materials and
climbing the ladder is not allowed.
5.3.6 The safety shoes shall be free
of mud /Greece /oil.
5.4.1 Rope pulley with PP rope shall
be used for shifting the materials.
5.4.2 Rope pulley/PP rope with tool
kit bag shall be used for shifting the

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 tools at height.
5.5.1 Trained & experience person
will perform the task.
5.5.2 Tool box talk should be
conducted, prior to work.
5.5.3 Position fingers away from
pinch point.
5.5.4 Secure spanner with tagline to
avoid fall of spanner.
5.5.5 Ensure fully tied of bolt.

6.1.1 No loose materials shall be Site

kept on the platform leaving it engineer/RCM
unsecured, toe board shall be
Cleaning activity inside reactor Hand tools, ensured along with tools tied off to
through scaffolding platform. Competent
person the tool lanyard.
6.1.2 Ensure tagline of wire brush to
avoid from fall.
1. Fall of No flammable materials shall stored
person or inside the confined space.
material
6.2.1 Ensure all person should wear
from height
6. H dust mask & cotton hand glove to L
2. Hand
Injury avoid hand injury during cleaning
3. Eye activity.
Injury 6.2.2 Only trained & competent
person perform the job.
6.3.1 All person should wear clear
safety goggle which protect your
eye from dust & flying object.
6.3.2 Ensure all person should wear
dust mask inside the reactor.

7 1. Crane H 7.1.1Ensure that the ground is Site

tripping due stable; fully extended outriggers; L engineer/RCM
to unstable use outrigger pads; use steel plates
ground as pads if ground is suspected or not
conditions stable.
and over 7.1.2 Ensure the capacity of lifting
loading. tools & lifting equipment.

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 2. Falling of 7.2.1Ensure, proper lifting tools and
Hand tools, load due to tackles used.
Lifting tools & improper 7.2.2 Ensure only inspected &
Lifting & shifting of centre pipe tackles and lifting tools. certified lifting tools & tackles to be
inside reactor by crawler competent 3 Falling of used.
crane/Winch Machine. Rigger loose 7.3.1Ensure the material secured
materials properly before lifting the material.
while 7.3.2 Ensure both side of tagline
lifting. while shifting of material.
4. Critical 7.4.1Lifting plan should be provided
lift. for all critical lifts & above 10TON.
5. Injury due 7.4.2 Only qualified Rigger must be
to pinching deployed.
or crushing 7.4.3All lifting gears must be
inside the inspected and certified. Prior to use
reactor. any lifting gear, a pre inspection to
6. be conducted.
Moving
part hazard. 7.5.1Communicate the pinching
hazards through daily JSTI.
7.5.2 Ensure area should be
barricaded as required distance.
7.6.1 Keep hands clear of wire
rope, hook and fairlead opening
during operation and when
spooling. Stand clear of wire
rope and load during operation.
7.6.2 Keep others away. Inspect
winch operate and wire rope
condition before operating
winch.
7.6.3.Do not exceed winch’s
rated capacity.
7.6.4.Take your time, sloppy
rigging causes accidents. Know
your winch, take the time to fully
understand your winch and the
winching operation.
7.6.5 Do not use winch to secure
a load during transport. Do not

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 submerse in water. Wear heavy
leather gloves when handling the
wire rope. Never winch with less
than five
7.6.6 wraps of wire rope around
the drum.
7.6.7Check manual - seek
manufacturer’s advice. Check oil
level regularly. Grease
frequently, more is best. Check -
fill and grease regularly.

7.6.8 Follow all safety procedures

and stay well clear of the load, use
only certified lifting equipment,
make sure winch is fitted with a
brake, clean and tidy the work site,
take time to overlook the whole
procedure, position the lifting point
correctly.

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 Site
engineer/RCM

8.1.1 Trained & experience person

will perform the task.
8.2.1 Tool box talk should be
conducted, prior to work.
1.
8.3.1 Position fingers away from
Incompetent
workers. pinch point.
2. Lack of 8.3.2 Make good communication
safety with each other in working group.
awareness 8.4.1 Always maintain good
8 3. Fingers H housekeeping to avoid slip, trip & L
Bolting activity for fixing of centre Hand tools & trapped. Site
fall hazard.
pipe competent 4. Slips, engineer/RCM
person 8.5.1 Ensure tools should be in good
trips and
falls. condition & also inspected before
5. Tools use it.
failure.

9 1. Improper 9.1.1 Ensure proper access to

access or approach at height & access to be
Working cleared.
platform 9.1.2 Access shall be by using chain
2. Fall of ladder.
person from 9.1.3 Ensure ladder should be
height inspected & certified.
3. Flying of 9.1.4 Ensure proper working

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 Spark platform for work at height.
particles. 9.2.1 Ensure all person should have
4. Welding Safety harness belt with 100% hook
flash. up.
5. Burn 9.2.2 Ensure all person should use
injury due to safety harness with shock observer
welding. after 6m.
6. Electric 9.3.1 Wear eye protection.
shock. 9.3.2 Welding activity should be
Hand tools, 7. Fire perform in welding booth which
power tools, Hazard. should be covered by fire blanket.
welder, fitter & 8. Health 9.3.3 Ensure area should be also Site
Welding activity inside reactor Helper Hazard. H barricade at ground level & safety L engineer/RCM
9. Use of signage to be displayed.
damage 9.4.1Ensure availability of Running
tools. water hose during welding activity.
9.5.1 Ensure no loose connection of
welding cable/cable lugs.
9.5.2Use certified & inspected
welding machine.
9.5.3 Only authorized person
perform their job.
9.5.4Welding helmet, leather hand
gloves, leather leg guard & leather
apron need to be used with
mandatory PPE's.
9.6.1 Distribution boards fitted with
RCCB with rating of 30ma.
9.6.2 Ensure proper grounding
/earthing of equipment.
9.6.3 Maintain standard connections
in electrical wires & no joint cable
allowed inside confined space.
9.6.4 Only authorized person
perform electrical connection.
9.7.1Charged Fire Hose shall be
kept ready along with firewatcher.
9.7.2 Work Area to be cleaned for
any combustible material.
9.7.3 Proper fire blanket/welding
booth to be prepared before the hot
work.
9.7.4 Ensure fire extinguisher to be

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 placed at work location.
9.8.1 Appropriate PPE's shall be
used by all
9.9.1 Always select right tools for
job.

10.1.1 All access and aggress to be

cleared.
1. Slip, trip 10.1.2 Housekeeping shall be done
10 & fall H L Site
on daily basis.
Housekeeping. hazard engineer/RCM

11. H 11.1 Ensure emergency vehicle L

arrangement at workplace.
11.2 Siren/ Signalling system of
IOCL are to be known to all Site
workers and Engineer/supervisor. engineer/RCM
11.3 Always keep emergency exit
route clear of obstacles free from
easy movement.
11.4 Emergency procedure and
telephone numbers are to be known
to all and same shall be prominently
displayed at site.
11.5 The working crew should be
aware of the nearest Assembly point
Emergency Response location.
11.6 Supervisor/Engineer should be
aware of the first aid centre location Site
and emergency contact numbers. engineer/RCM
11.7All workers or employees
should be trained and well known
for extinguishing fire, about
firefighting device, Positioning and
holding fire hose in case of
emergency.
11.8 In case of any emergency,
immediately inform to safety in-
charge & Field Engineer.
11.9 Rescue tripod & man basket
shall ket standby.

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 General precaution for Demolition:

1) Ensure access wherever you work.

2) Check for defective tools.
3) The included angle for the ladder is 75 degree and the ladder should extend at least 1 m beyond the landing platform.
4) The ladder must be secured at the top and bottom. Do not use top rung or top step of the ladder.
5) Required permit should be available at work place.

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