Date-06/03/2023

GEA PROCESS ENGINEERING

Project Name - ESP erection & commissioning Document No:- HIL/JSA/EHS-014
Activity- cutting and dismantling of esp external casing
Rev-0
parts (field casing,inlet transition,inlet&outlet cone,roof
beem,hopper)
JOB SAFETY ANALYSIS
Location of Work : Smelter -1 ,ESP JSA NO-14
Sr. Sub Activities / Tasks Hazards Impact in case of exposure Risk Control measures (There can be multiple Responsibility
No. control measure for one hazard)
1 Work start-up Un authorized work personal injury/property Must be followed HIL permit system, site engineer and
preparation & Invalid permit damages/fatal get the permit validate for the specific date Supervisor
obtaining work permit and time & signed by by all concern before site hse supervisor
starting job

un aware with plant traffic accident/personal injury only plant inducted worker will perform job,
Conduct tool box talk meeting

gas/dust expouser eye & throat irritation use resiperatory mask/dust mask
Hast or shortcuts personal injury review the method statement and jsa to all
concern involved in activities,
lack of competency multiple injury Supervisor must insure that all work
activities are carried out by competent
person
emergency worker stuck in case of emergency emergency plan must be prepared for critical
activites before work start,
communicate about assembly point and
plant emergency system with woking team
before work start
low illumination at night personal injury insure workplace have proper illumination
work
2 Shifting of tools traffic accident personal injury/property Must be followed HIL traffic rules site engineer and
&materials from damages/fatal banksman should be available with material Supervisor
storage area to work handling equipments, storekeeper
location by material operator and rigging
handling equipment or Toppling or Falling of personal injury/property damages no overloading allowed, team
manually. material/overloading material shall be secure and tied with belt
during transporting, don’t allow uneven
loading
Sr. Sub Activities / Tasks Hazards Impact in case of exposure Risk Control measures (There can be multiple Responsibility
No. control measure for one hazard)
Mechanical failure of Only competent and approved operator shall
lifting tools and tackles physical injury/damage property be deployed for equipment operations.
Improper lifting Procedure Equipment to be tested and certified by
using of defective competent person before deployment.
equipment ( Tools and approved lifting plan must for crane / hydra
Tackles ) lifting
All equipment must be third party certified.
Operators should be certified and valid
license holder
Equipment to be inspected daily and all
defects reported

improper manual ergonomical injury/cut injuty use safe manual handling technique
handling use specific ppe's
3 reached the job non inspected fall of person/fall of Must be followed HIL work at hight site engineer and
location at elevated scaffold/incomplete materials/personal injury/fatal procedure/ Supervisor
working platform via scaffold don’t use red tag scaffold
scaffold platform or esp prepared scaffold checklist before work start
stair
medically unfit personal injury only medically fit person allowed for hight job

damage & rusted grating physical injury/damage visually and physically check grating
platform property/fatal platform before work start
worker without hight pass fall of person/fall of materials only work at hight pass trained worker
perform job
hand engage with fall of person/fall of materials/ must be followed three point contact when
materilas when going on personal injury use ladder
platform use lifting bag for material shifting at hight
Sr. Sub Activities / Tasks Hazards Impact in case of exposure Risk Control measures (There can be multiple Responsibility
No. control measure for one hazard)
4 dismentaling & cutting Splinters / slag fire Must be followed HIL hot work procedure site engineer and
of esp external parts by extreme heat temprature burn injury lancing operator must be fully trained and Supervisor
using oxygen lance heat stroke qualified.
cutting,gas lance cutting operator and all assistant shall site hse supervisor
cutting/plasma required to wear appropiate,extream heat
cutting/grinding /hot resistance ppe's fire watcher
work aluminizing heat resistance apron shall be
used hole watcher
fire retrdant full head and face mask hood
shall be used
thick fire retrandant mitten /gloves/boots
shall be used
remove all flamable material from place of
work.
Use specified shielding devices and other PPE
of correct specifications
Work area should be barricated and signage
posted.
fire fighting equipment shall be available near
work area
only trained and competent person only
allowed
toxic lungs desease/throat irritation use
use job
dustspecific
mask /ppe's(face shield,safety
resiparatory mask
fumes/gas/dust/smoke lancing should be carried out in open
expouser air,although good ventilation
damage electrical electrical fire/electrocution prepare checklist of electrical equipment
equipments & tools use only HIL certified electrical tools
use specific ppe's

medically unfit personal injury only medically fit person allowed for hight job

leaking oxygen pipe line fire explosion daily gas cutting set checklist shall be
/gas cylinders or hoses prepared before work start
soap leak test must be done before work start
use only certified hoses /cylinders
Use flash back arresters
Use double stage and certified regulators
use only high pressure oxygen hose
gas hose pipe must kept away hot metals
Move out any leaking cylinder
Keep trolley for transportation of cylinders
and chain them
Sr. Sub Activities / Tasks Hazards Impact in case of exposure Risk Control measures (There can be multiple Responsibility
No. control measure for one hazard)
emergency fatal/personal injury shall be prepare work at hight emergency
worker stuck in case of emergency rescue plan before work start
communicate about assembly point and
plant emergency system with woking team
before work start

untrained worker personal injury only trained person allowed for work
damage & rusted grating visually and physically check grating
platform physical injury/damage platform before work start
property/fatal
fall of person/materials fatal /personal injury Must be followed HIL work at hight procedure
incomplete injury due to falling materials work at hight pass worker only allowed
scaffold/scaffold collapse property damages don’t use red tag/incomplete scaffold
prepared scaffold checklist before work start
use full body safety harness with 100 % tied
off
use 12mm wire rope for lifeline for anchor
harness

worker without hight pass fall of person/fall of materilas only work at hight pass trained worker
perform job
ultraviolet /infra red rays eye itching/burning use anti ray safety goggles/
Sr. Sub Activities / Tasks Hazards Impact in case of exposure Risk Control measures (There can be multiple Responsibility
No. control measure for one hazard)
6 Removing of failure of crane/haydra personal injury Must be followed HIL lifting procedure site engineer and
dismantling materials property damage Must be followed HILPermit Supervisor
from top to ground collision with structure fatal lifting plan shall be prepare before work start
level by using mobile and pipelines Only competent and approved operator shall site hse supervisor
crane/manlift/farrana defective tolls and tackles be deployed for equipment operations.
Equipment to be tested and certified by operator/rigger foreman
un trained operator and competent person before deployment.
riggers No overloading allowed.
Follow procedures.
use only 75% of swl of crane capacity
Training and assistance of Banks man /
Rigger
approved lifting plan must for crane / hydra
lifting
All equipment must be by hil/ third party
certified.
Operators should be certified and valid
license holder Equipment to be inspected
daily and all defects reported
use two tagline rope for control load
lifting area shall be barricade & display
signages
Sharp edges don't stay gloves
use hand under when
suspended load
dealing with sharp
cut injury/skin scratches edges
use full ppe's

fall of person/materials fatal /personal injury Must be followed HIL hight work procedure
incomplete injury due to falling materials Tbt shall be conducted before work start.
scaffold/scaffold property damages Only work at hight pass trained worker
collapse/damage & perform job
rusted grating platform don’t use red tag scaffold
Working area shall be barricade.
use full body safety harness with 100% tie
off.
grating platform shall be physically test
before working on platform

high wind speed fall of materials/persons don’t work when wind speed is more than
dust throat irritation/lungs desease 30km/h
hot weather heat strokes follow HIL work at hight procedure
use dust mak
drink penalty of water
take rest interval when working in direct
sunlight
Sr. Sub Activities / Tasks Hazards Impact in case of exposure Risk Control measures (There can be multiple Responsibility
No. control measure for one hazard)
7 dismental improper lifting procedure personal injury/fatal Must be followed HIL lifting procedure site engineer and
materials/scrap property damage must be followed HIL lifting permit system Supervisor
materials non certified / damage approved lifting plan shall be prepared
segregating/transportin lifing tools & only trained and competent operator & rigger site hse supervisor
g & disposed to tackles/equipments allowed
designated place by use only 75% of swl of crane capacity operator/rigger foreman
using incompetent operator and certified lifting bag/basket shall be used
trailor/farrana/crane
rigger Work area should be barricated and sigage
posted.
used only certified and inspected lifting tools
and tackles
dont stay under suspended load
All equipment must be by hil/ third party
certified.
use full ppe's

dust expouser lungs desease/throat ittching use dust mask / resiparatory mask

traffic accident must be follow HIL road traffic procedure

physical injury/damage
property/fatal
fall of person/fall of materials don’t work when wind speed is more than
30km/h
follow HIL work at hight procedure

disposed at un designated soil & air pollution waste insulation material shall be disposed
place poor housekeeping as per HIL guidlines.
Waste insulation materials shall be disposed
at designated place
Overloading due to load vehicle accident/personal injury load waste insulation materials only witch
oscillation vehicle capacity
don’t allow overload
access obstructed/poor slip and trip always clear access
housekeeping maintain good housekeeping on daily basis

8 Housekeeping and sharp edges cut injury visually and physically check grating supervisor
material removal after dust expouser lungs desease platform before work start site hse supervisor
job complete. ergonomics muscles stress
Prepared & Analysis by :- Danish (HSE),s.mujmdar(site incharge), P.chinnamaharaja(senior Approved By-
eng),
Anoop(Global site incharge)