GUJARAT REFINERY

JOB SAFETY ANALYSIS

JSA No.: Zeeco India /HSE/Flare/JSA/01

Unit: BS-IV ( Flare Package) Area: Location: Flare area

Job Title: JSA for dismantling of Flare, Pipeline, Supporting structure, RCC
ANALYSIS PERFORMED BY:
works and blinding etc.
Job to be Executed By : Name: Designation
CONTRACTOR M/s Zeeco India Private Ltd. 1. Mr. K. V. Rao Project Manager ( Zeeco)
PMC M/s TKIS 2. Mr. Jayaraj Natarajan RCM ( Zeeco)
PROJECT M/s IOCL, Gujarat Refinery 3. Mr. Michael Agnael Planning Manager (Zeeco)
4. Mr. Dashrath Singh HSE (Zeeco)
5. Mr. Shanmugham .A RCM (TKIS)
6. Mr. Abdul Allam HSE (TKIS)

JSA Reviewed By : 1-Mr. Ashish Kamde ( IOCL)

2- Mr. Shivam Gupta ( IOCL)

Sl. No. Work Activity Hazards Required Safety Measures

1. PTW system need to be followed and obtain prior to start the job.
Injury to working personal due to wrong approach 2. Ensure route survey and ground condition before starting movement of heavy
of shifting equipment.
3. Wearing of Personal Protective gear while in work areas is mandatory.
1 Mobilization and site Preparation

4. Tool box Talks with team prior to job start.

Physical injury due to fall/slip / trip due to working
at height/ manually handling

5. Inform Client for approval before start the job.

1-Slip,Trip,Falls. 1.Wearing of Personal Protective gear while in work areas is mandatory.

2-Sharp edges and sharp object. 2.Tool box Talks with team prior to job start.

Moblization and site Prepration Tools &
2 5- Personal Injury/ Insect Bite
Materials
3 General, Habit
Loading & Unloading of derrick members
Movement / Parking of vehicles at site.
4 3- Environmental Hazards.
3- Cuts ,nips due to unsafe and incorrect
handling of hand tools.
4- Dust.
1 - Adopting shortcut method, negligence,
wrong perception, absent mind.
2-Work Related-stress,
3-In case of Emergency Situation
1-Crush Over Person
2- Fall into Deep Exavation
3.Inform Client for approval before start the job.
4. Workers shall keep loading way clear of slippery surface and any obstruction
as much as possible.
5.Keep fingers away from pinch and shear points
6. Makesure the visual Inspection of every tools & tackles before using it.
7. During cleaning the materials use appropriate PPEs( dust mask,hand gloves &
safety goggle).
8. Before start the job using wood/ metal stick made some noise to keep away
insects.
9. Ensure Goodhousekeeping at site.
1.Daily TBT should be given to workers.
2.Every one should know emergency procedure & contact No`s.
1.Ensure effective supervision. Same person shall not be allowed to work more
than 12 hours
2.TBT should be conducted and discussed about all associated hazards.
3.No one shall be allowed to sleep at site.
4. Job specific training is to be provided to workers.
1-Emergency Rescue Plan shall be available at site.
2-Ensure the availability of First-Aid facilities and an emergency vehicle so as to
shift victim to medical center if necessary.
3- To carry out headcount to find out missing personnel at ASSEMBLY POINT.
4.Break the nearest MCP in case of emergency.
1- All drivers should be prossessing valid driving license with safe driving permit
(SDP).
2- Drivers should take 360 degree turn around the vehicle and check
underneath for any person / material / animal prior to start of vechile.
3-Ensure before starting/driving/parking the vehicle the surrounding area is safe
to drive.
4- Vehicle speed to be controlled under identified speed limit at site.
5-Valid PUC must be carried with the vehicle.

5 Positioning of trailer.
6 Positioning of Crane
7 Riggining.
1- Uneven Surface.
2- Hit By load(While lifting).
1- Topling of crane
1- Failure of lifting Tools & Tackles
2-Personnel Injury (Hit by Load).
6.Means of access ladder to be used while climbing on trailer bed and at height.
1- Makesure before positioning the loaded trailor ground shall be leveled.
2- Vehicle chockes should be placed under tyres.
3- Hand break shall be applied.
4- During Reverse operation of trailor ,Ensure backward horn & back light shall
be working condition and flagman shall be present.
1- No vehicle shall be drive or parked near the lifting area.
1- Crawler Cranes shall be always placed on leveled ground.
2- If Tyre Mounted crane is in using,Ensure there outrigger are fully extended.
3-Ensure only SDP operator shall be engaged in Job.
4- Only Validated & certified by P&M, Cranes are used in site activity.
5.TPI certificate and Crane check list need to be verified and made available at
site.
1-Makesure use only validated,colourcoding & inspected(TPI Certified) Tools &
Tackle.
2-Ensure workers/riggers are trade validated and trained engaged in the job.
3- Only competent signalman to give signal.
4.Ensure TPI for all tools & tackles ( rigging gears)
5.Competent rigging foreman should ensure all lifting activity.
1- Providing adequate housekeeping at site.
2- Ensure workers / riggers / crane operator are trade validated and trained
engaged in the job.
3- Adequate PPE's shall be used. (Safety Helmet, Full body Safety Harness, Hand
gloves,Safety Goggles, Florescent Jacket etc).
4- Unauthorized persons are not allowed to work place. Provide Job specific
caution board & barricade the area.
5- Adequate Supervision at site.
1-Ensure workers / riggers are trade validated and trained engaged in the job.
 2- Adequate PPE's shall be used. (Helmet, Safety Harness, Hand gloves,
1- Fall of material/Tools Rubber Goggles, Florescent Jacket, etc)
3- Proper access should be provided to work comfortably.
4- Trained Personnel shall carry out task of sharp or heavy tools for particular
task.
8 Manual material & Tools Shifting. 1.Maintain good housekeeping at site.

2- Ensure workers / riggers are trade validated and trained engaged in the job.
3- Adequate PPE's shall be used. (Helmet, Safety Harness, Cotton Hand gloves,
2- Personal injury
Rubber Goggles, Florescent Jacket, etc).
4- Provide appropriate Illumination at site.

5- Evaluate the weight & carrying capacity of the person before handling.
1.Approprate PPE's shall be used. (Helmet,Safety Harness, Hand gloves,
Goggles,Florescent Jacket
2.Ensure Tool box talk is being carried out about the execution of the jobs and
about right tools used by the worker and the hazards related to work at height.

3.Proper working platform with standard raillings must be provided.

4.Ensure that Work permit, procedures are to be strictly followed.

5.Workers working at Heights should be identified and given “Work at Height
Training” before engaging in work.
9 Working at Height 1.Fall of person
6.Workers working at heights to be ensured fall protection like life line, fall
arresters, full body harness with double lanyard and shock obserber, proper
scaffolding, access ladder, safety net etc. are provided for height work.
7.Area should be baricaded with caution tape.

8.Use of cell phones should be strictly prohibited for all.

9.Proper supervision shall be ensured.

10.Ladder to be provided to climbing on scaffold and ensure three point contact
while climbing of ladder.
1- All the hand tools must be properly secured to tool laynyard while working at
height.
2- To ensure workers are engaged in height work has been attended the “Work
at Height Training”.
1-Falling of materials / tools while working
3- Area should be baricaded with sign boards
at height.

10 Working with power tool at height.
2- Damage of cable Insulation.
1.Mechanical failure.
2.Fall of person.
11 Use of Cherry Picker (Man Lift)
3.Fall of hand tools/equipment.
4.Topling of Cherry Picker / Man Lift
4- Proper working platform with all raillings must be provided.
5- Work related safety posters and banners should be provided a site.
1- All combustible material should be removed form the working area before
start of work and should alwalys maintain good housekeeping.
2- All the cables should be routed 6ft above from the ground level
3-Area should be baricaded with sign boards.
1.Use only if trained in proper operation, maintenance and safety equipment.
2.Always work in pairs.
3.Machine should be inspected by an autorized person and certified as fit to use
(TPI Certification).
4.As per check list periodical inspection must be done.
5.Operator should have the minimum qualification/experience to operator the
machine
6.All the maintenance should be done properly on time.
7.TPI for man basket is required & SWL need to be mentioned on man basket.
1.Only trained persons are allowed to work on Man Lift the machine.
2.Wind direction and speed to be monitored.
3.Use adequate p.p.e(safety harness,hand gloves,safety helmet etc) & tool
laynyard.
1.All the hand tools must be properly secured with full body safety Harness
while working at height.
2.Should not allow anybody to working are without proper PPE’s.
3.Working area should be barricaded and warning sign bords must be placed.
1.Ground leveling should be done before placing Cherry Picke/Man lift.
2.Equipment should be operated by authorized person only.
3.Working radius should be baricaded with sign boards.
4.All the safety guidelines from the manufaturer should be followed by the
operator as well as co-workers.
1.Should not place the equipment on the public road.
 2.If the equipment is placed on the public road then working radius must be
5.Heavy traffic or road accidents
hard barricaded and the road should be diverted properly.
3.Flag man should be provide for each equipment.
1.Proper PPE's should be used. (Helmet, Safety Harness, Hand gloves, Goggles,
Florescent Jacket, etc)
2.Ensure Tool box talk is being carried out about the execution of the jobs and
about right tools used by the contractor and the hazards related to work at
height.
3.Proper raillings must be provided for man basket.

4.Ensure that Work permit procedures are followed if applicable.

5.To ensure workers are engaged in height work has been attended the “Work
at Height Training”.
6.To be ensured fall protection e.i. life line, fall arrester, full body harness with
double lanyard and shock obserber, proper scaffolding, access ladder, safety net
etc. are provided for height work.
6.Area should be baricaded with caution tape.
1.Fall of person
7.Use of cell phones should be strictly probhited for all.

8.Proper supervision shall be ensured.

12 Working on man basket
9.Proper communication device should be provided for the workers on man
basket and the operator.
10.Only trained and medically fit person to engage in Manbasket.

11.Ensure use of a Man basket shall be approved by Area/Site Manager.

12.Only Crawler crane of varying capacity shall be used for man-basket lifting.
13.Ensure lifting and lowering speeds of man basket must not exceed 100 feet
(30.5 meters) per minute.
14.Ensure Wind Velocity must not exceed more than 7m/s.
1.Ensure workers / riggers / crane operator are trade validated and trained in
the engaged job.
2.Use of validated and inspected (TPI Certification) tools & tackles and crane /
2. Fall of man basket hydra for loading / unloading job.
3.Removal of unauthorized persons from the work place.

4.Provide caution board & barricade the area.

1. Materials projected outside the Truck bed 1. Material like Pipe /Ledger should be place on the Carrier bed with Vertical
due improper strapping arrangement arrestor , roll over stopper and lashed with ratchet arrangement
 2. Materials slip or dropping on the road or
during loading /unloading due to improper
strapping
Transportation of Scaffolding Material and 3.Vehicular accident , over speed and Brake
13
manual handling failures etc
1. Working Height – fall Hazard due
maneuvering and falling/ dropping material
hazard
2. Wrong installation method.
3. Failure of the Scaffolding due dynamic
loading
4. Toppling of Scaffolding due soil
subsidence , high wind , Hit by crane or by
Construction Vehicle
5. Cut injury due improper manual handling 5. Daily and regular inspection of the scaffolding should be carried by
14 Erection and installation of Scaffolding of the material
6.Extreme hot condition and sand storm
1. Fall hazard
2. Workmen suffering Vertigo
3. Dropping / falling material.
4. Parallel working
2. All the Loading and unloading works with Supervision only
3. Only workmen who have being, HSE inducted should deployed.
4. Loading carrier bed to avoided and over load to avoided
5. Adequate strapping with PP Belt or Rope should provide and vehicle speed in
the rough terrain should limited to 20KMP or less
6.Transport vehicle use should have quarterly inspection- valid stickers
1. Installation of the scaffolding only by HSE inducted and Trained & Approved
scaffolder only- Safety Belt and Life line is must as per site condition
2. Approver work methodology for erection of scaffolding site specific with
adequate factor of safety and area Cordon Off during installation
3. Approved design load should not be exceeded .
4. Inspection & Green tagged scaffolding with detail is mandatory for working
propose and NO unauthorized workmen permitted on the scaffolding.
competent engineer and supervisor – before allowing the workmen
6. NO modification or alteration should be permitted on the approved
scaffolding
7. Moment of crane or vehicle near the scaffolding, during height working,
should be stopped. Stop work to should be issued during high wind condition.
8. All the Scaffolding erection only under supervision of Qualified Scaffolding
supervisor.
9.All the scaffolder should undergo regular – material handling training.
10.Tagging system for safe scaffold to be certify be competent & qualified
inspector
11.Tools bag, holder or tie rope need to be used while working at height.
1. Scaffolding should be approved and green tagged before executing work
using arrangement.-Safety harness and life line are mandatory as site required
2. All workmen should under gone HSE induction & Specialized Heights
Training – program.
3. Workmen should be Physically and Mentally fit ;while permitting to work by
site engineer/ HSEO
4. Parallel work which under height works should be carried out with adequate
precaution with provision for; Catch Net - to prevent injury due to falling
objects.
15 Working at height
5. Extreme hot condition and sand storm
6.Failure scaffolding due Impact / pilferage /
unauthorized modification etc
1.Sliding or collapse of the scaffolding
structure due to – improper method of
Removing the Scaffolding.
2.Fall Hazard due wrong method.
3.Injury due to Thrown or falling Scaffolding
16 Dismantling- scaffolding arrangement 4.Injury due to edges
5.Damage to the Scaffolding items due
improper handling.
6.Extreme hot condition and sand storm
1.Fall of worker during embarking worker
17 Working on temporary platfrom
from man-basket to temporary plateform.
5. NO material should thrown for ground or Heights – use pulley arrangement
to lift and lower the material in use
6. Good housekeeping and stacking of material should carried on regular basis
.
7. Avoids over crowing the working platform with men or materials
When workmen are engaged in height works – no vehicle or erection work
permitted and daily check by competent personal before commencing the works
and no modification is allowed – unless approved by the scaffolding Inspector
1. Dismantling the scaffolding as per method and with Sequence only,
2. No parallel dismantling should be permitted under same structure
3. All the dismantling works should be by approved scaffolder under
supervision of Qualified Supervisor.
4. No material should be dropped or Thrown from the height- always use
pulley arrangement. – area to be cordon off during the dismantling works
5. Dismantle material should lowered safely and stacked in safe place as per
norms.
6. All the Qualified worker should have PPE including – cotton gloves
7. Dismantling work should be stopped in high wind condition.
8.Physically and Mentally fit personnel should be permitted in dismantling works
1.Ensure that there is a safe means of access to high level places of work.
2. Manbasket shall be lifted to required location with all precaution.
3. Personal in manbasket will secure properly.
4. After ensureing stability,doors of the manbasket will be opened inward and
personnel will transfer one by one to temporary platform safely with adequte
precaution i.e. during transfer one tag-line of harness will remain connected to
manbasket another will connected to guy rope of column after transferring into
temporary platform personnel should anchor their second tagline of harness to
the guy rope provided at derrick column for the specific purpose.
1. All the hand tools must be properly secured to safety harness while working
at height.

1.Falling of Person / Equipment / materials Height Training”.
/ tools while working at height.
18 Dismantling of Temporary Platform
2 .Heavy Wind
1.Physical injury
2.Sudden release of pressure of chemical.
19 Blinding & hose connection/Flange opening
1.Electrical shocks while working with
Welding machine
2.Ensure the workers are engaged in height work have attended the “Work at
3.Area should be baricaded with sign boards
4. Work related safety posters and banners should be provided a site.
1.Prior to each lift of Manbasket ensure provide two tagline for contro to
manbaskt.
2. Regularly monitoring of wind velocity.
3.Only traineed person (Scaffolder) shall be engaged with proper supervision.
4.Ensure materials shall not be thrown from height.
5.Ensure all materials shall be lowered by using gin wheel.
6.Ensure the wind velocity is not more than 25 kmph .
1.Positive Isolation of equipment as per requiurement.
2. Follow the line break proedure.
3. Ensure proper drain & depresserization of the Equipment/loop.
4.Tool box talk should be conduct before start the work.
5. Work permit shall be taken from client before start the work.
6. Access must be clear & unobstructed.
7. Provision of proper access by ladder / staging work.
8. Provision of proper working platform.
9. Provision & ensure use of Life line & full body harness safety belt.
1.Electrical cable loose connection should not be allowed.
2.Proper earthing should be provided for welding M/C.
3.Proper size of cable to be ensured before charging of welding M/C, ZIG to be
earthed.
4.Earthing to be provided away from working area.
5.Regular inspection of welding machine and power cable to be done by
Welder/Electrician/Supervisor.
 6.Live cables should not lay on the floor.

7.ELCB should be provided for each extension board.

8.Periodical inspection of ELCB should be done and it must be recorded.

1.Equipment Calibration certificate should be available at site.

2.Use of welding Face shield for Protection from Rays.

2.Exposure to UV and IR rays.
3.Should not allow Unauthorized persons to the working area.

4.Working area should be barricated with sign boards

3.Fall of the materials /tools while working at 1.Materials to be lifted to elevated area by using poly proplyne rope and hooks,
height. tools shall be secured to safety Harenss while working at height.
1. All combustible material should be removed form the working area before
20 Welding / Drilling / Cutting / Grinding Activity start of work
2.Maintain good housekeeping by removing all combustible materials regularly.
3.ABC / Co2 type Fire extinguisher and sand buckets (min 3 in stand) should be
available at work loacation.
4. Fire and explosion 4.Fire extinguisher should be available near work location

5.Fire blanket should be used at welding location.

6.Working area should be barricated with sign boards.

7.Only trained persons are allowed to operate the equipement.

1.Flash back arrestor to be used at both the end (At cylinder end and cutting set
(torch) end).
2.Only trained persons are allowed to operate the equipement.
5.Back fire
3. ABC / Co2 type Fire extinguisher and sand buckets (min 3 in stand) should be
available at work loacation.
4. Workers should know the basic knowledge of Fire Extinguisher and Fire
Fighting.
1.Grinding wheel, Drill bit should be tighten properly.

2.Proper PPE's should be used.(Helmet,Hand gloves,Goggles,Face Shield etc)

6. Personal Injury while Welding/ Drilling/
Cutting/ Grinding
3.All the equipement should be used by the trained/certified person only.

4.Should not allow Unauthorized persons to the working area.

 1.Ensure welding booth while doing hot work to control spark/spatter, use fire
blanket.
2. Running hose to be connected while hot work carried out.
21 Hot Works
3. Fire Extinguisher to be placed at site .

4. Isolation, blinding or LOTO system to be followed.