PEW-SHE-MSA-R0

METHOD STATEMENT ANALYSIS

L&T Heavy Engineering. (Repair of Gas Cooler & EO reactor- 4R-1101-A/B)

BASIC JOB STEPS

1. Mobilization & Preparation

HIGH RISK IEDNTIFIED

MITIGATION STEPS TO REDUCE/ELIMINATE THE RISK

Ensure fitness of all trucks, vehicles, mobile plant and equipment. Flag man to be provided while movement of vehicle

REMARKS

Vehicle damage and personnal enjury

Provide tool box talks before mobilization.Equipment used will be maintained in a good condition Load will be closely monitored by line supervision Flagman shall wear reflective vest for personal identification Trailer shall have rotating beacon light. Portable and other material shall be secured on trailer bed by means of sling cables and tightened by chain pullers. Back of trailer shall be required to have signal light during transport Check list to be done before work start

Wear PPE with adequate protection. Use correct size of sling, shackles & crane for given load. Need Lifting plan in Sharq Format (SHEMS 08.07)Operators and rigger shall be trained & competent Certified Operators & Riggers inspect rigging equipment by colour coding prior to lift. Toolbox Talk for crew involve in lifting Lifting Operation Training as tool box talk topic Daily crane inspection before to start of work High Visibility vest required Ensure appropriate barricades & sign board placed around the area during lifting. Only rigger shall signal crane Daily inspection of chain block prior to use to use and color coded. Planning of all lifting activity is certified to minimize risk to

Overloading of rigging equipment

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PEW-SHE-MSA-R0

METHOD STATEMENT ANALYSIS

L&T Heavy Engineering. (Repair of Gas Cooler & EO reactor- 4R-1101-A/B)

BASIC JOB STEPS

HIGH RISK IEDNTIFIED

People working in operating area

MITIGATION STEPS TO REDUCE/ELIMINATE THE RISK

Ensurefitness ofbaricadingvehicles, one to be allowed below people all trucks, and no mobile plant and equipment. Ensure hanging. to be provided while movement of vehicle Flag man Obey stie safety rules for speed restrictions and access routes.

REMARKS

Only qualified and trained drivers and crane operators to be Damage plant facility or equipment by vehicles used. Vehicle damage and personnal enjury Loading and hauling (hit by chain binder/pinch points/dropped load) All vehicles, mechanical and electrical equipment to be inspected & approved by SHARQ. All loads hauled on vehicles MUST be securely tied down with approved rope, straps or chain. Under no circumstances shall a load be hauled without proper tie downs. Utilize rachet straps when possible. Rachet binders are preferred over chain binders to avoid injury. When loading a flat bed place load as far as possible preferably against a stationary object such as a head ache rack. When this is not feasible place the load centered over the rear axle. Before hauling a load make a quick walk around the vehicle to assure all tool boxes are closed and that the load is secured.

When hauling a load check to be sure the load stays secure while under way.

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PEW-SHE-MSA-R0

METHOD STATEMENT ANALYSIS

L&T Heavy Engineering. (Repair of Gas Cooler & EO reactor- 4R-1101-A/B)

BASIC JOB STEPS

HIGH RISK IEDNTIFIED

MITIGATION STEPS TO REDUCE/ELIMINATE THE RISK

Ensure fitness of all trucks, vehicles, mobile plant and equipment. It's the driver's responsibilitymovement of vehiclevehicle is rated Flag man to be provided while to assure that the

REMARKS

for the weight that is carried on it.

Ensure that hand protection or wear heavy gloves. Hand injury while setting up 2. Setting up and taking down equipment Vehicle damage and personnal enjury Back injury Foot injury 3. Moving Heavy Objects 3.1 Lifting heavy object. Saving Back injury yourself from injury is more important that avoiding damage to what you're lifting. Bend knee to lessen pressure on the lower back. NEVER place your hand under the load. To minimize injuries, there should be 2 peolple moving posts. Keep feet away from the goal post.

Use legs as the source of power to lift object. Solicit the help of others or employ tools if object is to heavy to be lifted by one person.

3.2 Transporting Heavy object.

Foot injury from dropping heavy object

Get a secure hold on object. Wear gloves to aid in a secure grip. Wear steel-toed shoes, or similar. Evaluate condition of floor along path from origin to destination.
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Slipping on wet or slick floor

PEW-SHE-MSA-R0

METHOD STATEMENT ANALYSIS

L&T Heavy Engineering. (Repair of Gas Cooler & EO reactor- 4R-1101-A/B)

BASIC JOB STEPS

HIGH RISK IEDNTIFIED

Slipping on wet or slick floor

MITIGATION STEPS TO REDUCE/ELIMINATE THE RISK

Ensure fitness of all trucks, vehicles, mobile plant and equipment. Do not move heavy loads until floor is dry. Flag man to be provided while movement of vehicle

REMARKS

4. Working from elevated surfaces

Fall protction equipment failure

Fall protection equipment must be inspected for excessive wear or damage prior to each use. Prohibit the use of standard waist type safety belts.

Slips Vehicle damage and personnal enjury Trips

4. Working from elevated surfaces

Utilize tie-off points capable of withstanding 5,400 pounds.

Falls

Utilize safety harnesses that fit snugly and comportable. Utilize safety harnesses with appropraite lanyards with shock/absorber systems. Safety harnesses must have double locking self-closing hooks. Do not modify fall protection equipment, other than those performed by the manufacturer. All fall oprotection equipment must be worn in accordance with the manufacturer's recommendation. Any fall protection equipment that is worn or damaged must destroyed so that it is no longer usable, and then discarded. Safety harnesses and lanyards that have been used to stop a fall must be destroyed and discarded.

5. Operating motorized vehicle

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PEW-SHE-MSA-R0

METHOD STATEMENT ANALYSIS

L&T Heavy Engineering. (Repair of Gas Cooler & EO reactor- 4R-1101-A/B)

BASIC JOB STEPS

5.1 Entering vehicle 5.2 Driving motorized vehicle

HIGH RISK IEDNTIFIED

Injury from entering

MITIGATION STEPS TO REDUCE/ELIMINATE THE RISK

Ensure fitness of all trucks, vehicles, mobile plant and equipment. Be carefull when opening the door. Flag man to be provided while movement of vehicle

REMARKS

Fasten the seltbelt before driving. Use defensive driving skills. Injury to self from accidents Vehicle damage and personnal enjury Obey SHARQ speed limit. Never leave unattended car running.

6. Use of Scaffolding

Fall of Objects/Tools Unstable Scaffold Weak Scaffold

Ensure guardrail & toe board to prevent falling of tools/objects. The scaffold must be inspected, certified & tagged by the competent/qualified person confirming its suitability. The scaffold tag must indicate the maximum load that it can bear. The scaffolding is to be inspected at least weekly for any damage due to weather condition (water spillage, high wind, spark by gouging/welding etc..) In case of any modification, addition in the scaffold, it has to be re-inspected & certified. Ensure scaffold is securely supported on a rigid ground and not on process piping/vessel or equipment. Do not use if greenTag is missing.

Damaged Scaffold

Modified Scaffold

Improper Support of Scaffold

Incomplete Scaffold
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PEW-SHE-MSA-R0

METHOD STATEMENT ANALYSIS

L&T Heavy Engineering. (Repair of Gas Cooler & EO reactor- 4R-1101-A/B)

BASIC JOB STEPS

HIGH RISK IEDNTIFIED

Incomplete Scaffold

MITIGATION STEPS TO REDUCE/ELIMINATE THE RISK

Ensure fitness of all trucks, vehicles, mobile plant and equipment. Do not use beit does not have valid inspection tag attached. if Flag man to provided while movement of vehicle

REMARKS

7. Hand held portable power tools

Cuts/Bruises/Electroc ution/Slips/Trips/Fall s Vehicle damage and personnal enjury

Inspect hand tools prior to each use. Appropriate PPE, including gloves shall be available when using hand tools. Never remove safety guards from power tools. Before servicing any power tool, such as changing drill bits, saw blades, or grinding wheels, you must unplug the tool first. Pneumatic power tools shall be secured to the air hose either by an approved quick connect fitting or by chicago fittings with safety clips.

7. Hand held portable power tools

Cuts/Bruises/Electroc ution/Slips/Trips/Fall s

Never plug in a wheel grinder or a wire brush without first making sure the power switch is in "off" position.

All tools and equipment shall be maintained in good condition. Damage tools or equipment shall be removed from service and tagged "DEFFECTIVE". Pipe or stillson wrenches shall not be used as a substitute for other wrenches.

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PEW-SHE-MSA-R0

METHOD STATEMENT ANALYSIS

L&T Heavy Engineering. (Repair of Gas Cooler & EO reactor- 4R-1101-A/B)

BASIC JOB STEPS

HIGH RISK IEDNTIFIED

MITIGATION STEPS TO REDUCE/ELIMINATE THE RISK

Ensure fitness of all trucks, vehicles, mobile plant and equipment. Only appropraite tools shall be used for the job. Flag man to be provided while movement of vehicle

REMARKS

A screw driver shall not be used as a chesil. Portables electric tools shall not be lifted or lowered by means of the power cord. Vehicle damage and personnal enjury Electric cords shall not be exposed to damage from vehicles driving over them. Appropriate placed fire extinguisher, remove all conbustibles and fire hazards materials from machine area. Hearing protection/ear plug. Electrical installation and maintenace shall only be performed by certified electricians. Lock-Out and Tag-Out procedures must be used if any electrical or mechanical equipment is being serviced (this may include changing light bulb). Lockout and Tagout electrical equipment prio to exposing personnel. All electrical equipment shall have ground fault circuit interrupters or assured equipment grounding.

Fire

Noise

8. Working around Electrical

Potential for Electrical shock

8.1 Power poles

Potential for serious burns or enjury

8.2 Conduits

Potential for Equipment Damage

8.3 Panels

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PEW-SHE-MSA-R0

METHOD STATEMENT ANALYSIS

L&T Heavy Engineering. (Repair of Gas Cooler & EO reactor- 4R-1101-A/B)

BASIC JOB STEPS

HIGH RISK IEDNTIFIED

MITIGATION STEPS TO REDUCE/ELIMINATE THE RISK

Ensure fitness of all trucks, vehicles, mobile plant and equipment. Avoid lifting long dimensional conductors vehiclelive electrical. Flag man to be provided while movement of over

REMARKS

All extension cords shall free of frays. Panel boxes must be covered to prevent accidental contact with live parts. Conductive items of jewelry or clothing shall not be worn unless they are rendered non-conductive by covering, wraping or other insulating means.
Barricade the area where heat reatment is to be carried out.

Vehicle damage and personnal enjury

9. Heat treatment using Electrical Heaters

Unauthorized Personnel Post warning notice. Presence of flamable/toxic vapor Ensure the area where heat treatment will take place is free from flammable/toxic vapor. Ensure that equipment tool to be used for heat treatment (such us trcings, cables, terminals, switches and panels etc..) are free from defects and suitable for the temperature ratings of the system. Ensure proper insulation of heat tracing coil and terminals. Keep the area dry insuring no water spillage. Do not bring any flammable or gas at the location where the heat treatment is under progress. Fire
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Deffective tools/equipment

Electric shock

PEW-SHE-MSA-R0

METHOD STATEMENT ANALYSIS

L&T Heavy Engineering. (Repair of Gas Cooler & EO reactor- 4R-1101-A/B)

BASIC JOB STEPS

Fire

HIGH RISK IEDNTIFIED

MITIGATION STEPS TO REDUCE/ELIMINATE THE RISK

Ensure fitness of all trucks, vehicles, mobile plant and equipment. Keep theto beextinguishers in ready condition. Flag man fire provided while movement of vehicle

REMARKS

Burn Expose to high temprature Vehicle damage and personnal enjury DHT

Do not touch the area which is being treated use timpilstik. Proper Ventilation arrangement to be done, provide proper Personal Protective Equipment

9. Heat treatment using Electrical Heaters

Unattended tool/equipment

Do not leave the tool/equipment in energized condition when the heat treatment is in progress. Isolate power to the equipment which not in use. Do not change(exceed/decrease) the temperature or duration of heat treatment without permission from the Inspection Engineer.

Changing the temperature or duration of heat treatment

Monitor the temperature in the heat treatment panel/recorder. Refer heat treatment procedure or contact inspection engineer in case in doubt. The accessories (heating elements, tracing, cables, terminals etc..) not being used must be disconnected and stored separately. Use googles

Scattered material

10. Fuel Transfer Pump

Eye injury due to fuel splashes

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PEW-SHE-MSA-R0

METHOD STATEMENT ANALYSIS

L&T Heavy Engineering. (Repair of Gas Cooler & EO reactor- 4R-1101-A/B)

BASIC JOB STEPS

HIGH RISK IEDNTIFIED

MITIGATION STEPS TO REDUCE/ELIMINATE THE RISK

No smoking or all trucks, vehicles, or open flame equipment. Ensure fitness ofexposure to sparksmobile plant andduring fueling. to stem shall while movement of vehicle Flag manFill be providedbe bonded to the container during filling operations by means of a bond wide. Appropriate placed fire extinguisher.Make the area barrication use the vechile entry certificate, Ensure the use of spark arrestor Use proper hand protection. Ensure the gas cutting equipment (blowpipe, hoses, oxygen cylinders, pressure gauge) are free from defect. Ensure a good working surface.

REMARKS

Fire explosion

Pinch points and obstructions 11. Cutting /Heating torch using Oxygen and Acetylene Vehicle damage and personnal enjury Defective tools

Pressure Hazards

Do not move or store cylinders without properly installing the protective cap ove the valve. Use regulators and pressure gauges only with gases and pressure ratings for which they are designed and intended. Close the cylinder valve before attemting to stop leakes between the cylinder and regulator. never permit sparks, molten metal, electric currents, excessive heat or flames to contact the cylinder or attachments. Cylinders should be properly secured with chain to prevent falling. Oxygen cylinders should not be tored within 20 feet of combustible gas cylinders or near any other substance where a fire could result, unless protected by a wall at least 5 feet high having a fire resistance rating at least 30 minutes.

Slips & Falls

Strain and Sprains

Strain and Sprains 11. Cutting /Heating torch using Oxygen and Acetylene

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PEW-SHE-MSA-R0

METHOD STATEMENT ANALYSIS

L&T Heavy Engineering. (Repair of Gas Cooler & EO reactor- 4R-1101-A/B)

BASIC JOB STEPS

HIGH RISK IEDNTIFIED

MITIGATION STEPS TO REDUCE/ELIMINATE THE RISK

Ensure fitness ofcylinders should be stored separately, and Empty and full all trucks, vehicles, mobile plant and equipment. Flag man to be provided while movement of vehicle

REMARKS

palinly identified.

Flash back fire

Provide a check valve( flash back arrester) between oxyacetylene hose & gas regulator. Wear protective googles & clothing for welding, PPE as per SHEM 8.08 , the helmet should be atttached to the face shield Ensure proper ventilation and fume extration equipment in case of welding/gouging inside an enclosure. Ensure the availability of dustmask , if required to be use Wear long sleeve (fire resistant) coverall, leather aprons and hood. Enclose the welding/gouging area through fire froof blanket/tarpaulin.Provide the stand by water hose running, Fire Extinguisher (DCP) Wear protective googles & clothing welding PPE as per SHEM 8.08 , the helmet should be atttached to the face shield Ensure proper ventilation and fume extration equipment in case of welding/gouging inside an enclosure. Provide dust mask , if required to be use Wear long sleeve (fire resistant) coverall, leather aprons and hood. Enclose the welding/gouging area through fire froof blanket/tarpaulin.Provide the stand by water hose running, Fire Extinguisher (DCP)
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12. Gouging

Vehicle damageWelding/Gouging flame/rays Radiation from and personnal enjury (flash eye)

Exposing to fumes

Burns

Falling Sparks

12. Welding

Radiation from Welding/Gouging flame/rays (flash eye)

Exposing to fumes

Burns

Falling Sparks

PEW-SHE-MSA-R0

METHOD STATEMENT ANALYSIS

L&T Heavy Engineering. (Repair of Gas Cooler & EO reactor- 4R-1101-A/B)

BASIC JOB STEPS

Grinding

HIGH RISK IEDNTIFIED

Exposing to Dusty Environment Burns due to flying particles

MITIGATION STEPS TO REDUCE/ELIMINATE THE RISK

Ensurefitness of all trucks, vehicles, grinding inside an enclosure. Ensure proper ventilation in case mobile plant and equipment. Provide dustmask , if required to be use vehicle Flag man to be provided while movement of Wear long sleeve (fire resistant) coverall, leather aprons and the helmet should be atttached to the face shield Enclose the grinding area through fire froof blanket/tarpaulin.Provide the stand by water hose running, Fire Extinguisher (DCP). Ensure proper insulation of heat tracing coil and terminals. Select proper RPM wheel, Select proper rpm wheel, Wheel RPM is less than spindle RPM Check any crack, Use Standardized wheels Mount the wheel properly, Train the grinder and welder / Wheel mounting shall be done with key
As per Clients instruction

REMARKS

Flying Hot Particles Vehicle damage and personnal enjury Electric shock Wheel breaking Wheel breaking Improper wheel breaking
Fire - Disposal of used cans

Environment Hazard - Handling of the Dye - Spillage Safe Handling, Use of PPEs

NDT (Dye Penetration Test)

Fire in the storage area

Storage of chemicals as per MSDS

Using of DPT Cans at site causing Eye irritation, Use of Nose Mask, Use of Safety Goggles Respiratory problems - Flammable vapours Expolsion if working in enclosed place Fire & Explosion of empty cans & Cotton Waste 13. Elevated Lift Operation Faulty equipment Falll Hazards Use 24 V handlamp with cage & provide proper ventilation Disposed of cans & Cotton Waste at designated place as per MSDS. Perform pre-use inspection prior to use. Ensure lift is operated by qualified operator.

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PEW-SHE-MSA-R0

METHOD STATEMENT ANALYSIS

L&T Heavy Engineering. (Repair of Gas Cooler & EO reactor- 4R-1101-A/B)

BASIC JOB STEPS

HIGH RISK IEDNTIFIED

Pinch points Potential for roll over Electrical Hazards Dropping tools on personnel Vehicle damage and personnal enjury

MITIGATION STEPS TO REDUCE/ELIMINATE THE RISK

Ensure fitness of all trucks, vehicles, mobile plant and equipment. Flag man to be provided while movement of vehicle

REMARKS

Never work or walk under loads. Only use lift on flat level ground. Do not use lift withion 10 feet of energized power lines, distance should be increased per approach charts for high voltage lines. Tie off tools or otherwise secure them from falling below. Tape off of barricade work area. Employees must stand firmly on the floor , and not sit or climb on the edge of the basket or use planks, ladders, or other devices for a work pisition.

13. Elevated Lift Operation

Dropping tools on personnel

Heat Stress Air Movement, Clothing, Rediant Heat, Heat Cramp: Pale Skin, Nausteated,Tired, Muscle Twitching, Muscle Cramp Humidity, Work Rate Shift the person to cool area, loosen or remove heavy clothing, provide cool drinking water,

Heat Exhaution: Heavy Sweating, Weak & Fatigue, Headache & Dizzy, Nauseated, Rapidly Start Drining Water, Ensure adequate ventilation, Breathing, Intense Thirst, Vomiting Heat Stroke: Hot Red Skin, No Sweating, Rapid Pulse Rate, Diffulty in Breathing,Vomiting, Coma Check your Urine colour, Job Rotation, Keep eye on your workmates Avoid tea / coffee or heavy meals Wear light weight, light colour, loose fittng cloths Start job early and provide rest breaks to workmen
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PEW-SHE-MSA-R0

METHOD STATEMENT ANALYSIS

L&T Heavy Engineering. (Repair of Gas Cooler & EO reactor- 4R-1101-A/B)

BASIC JOB STEPS

HIGH RISK IEDNTIFIED

Name(s) 1 2 3 Vehicle damage and personnal enjury 4 5 6

MITIGATION STEPS TO REDUCE/ELIMINATE THE RISK

Ensure fitness of all trucks, vehicles, mobile plant and equipment. Position Date Flag man to be provided while movement of vehicle

REMARKS
Signature

Approved by Area Owner (Manager/Superintendent/Supervisor)

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