NUCLEAR POWER CORPORATION OF INDIA

LIMITED
(A Government of India Enterprise)
Directorate of Safety

JHA on MS-WELDING & GAS CUTTING

1. Machineries required : Cutting Machine, Gas cutting, oxy- acetylene/ LPG

Cylinders, Hoses, torch with flash arrester, Welding
Transformer etc.
2. PPE's required : Safety Helmets, Safety Shoes, Welding face Shield, Safety
Goggles, Hand Gloves
3. Authorization required : Hot Work Permit
4. Site Engineer : Electrical Engineer

Sl. Sequence of Potential Hazards Protective measures to be taken

No. the job

Planning  Ensure the worksite is free from Combustibles /

1 Presence of flammable / toxic vapor or liquid by safe
flammable / toxic preparation (isolation, depressurizing, draining,
Vapor or Liquid venting, flushing, purging as required)

 The entry of non – certified tools / equipment

(Welding Transformer, Generator etc) to be
authorized under Permit to Work System.
Fire & Explosion  Keep the fire extinguishers & in ready
condition.
 Keep trained fire watch supervisor/safety
steward.
 Take a Hot Work Permit and other associated
Unauthorized Work
permits from company.
2 Installation of  All the moving and rotating parts of the welding
Welding equipment shall be guarded.
Machine  Correct and proper electric earthing to be
provided for the welding machine.
Electric Shock  Welding cable to be completely insulated,
capable of handling maximum current
requirement.
 Welding machine shall be kept at a dry place.
3 Arc Welding Electric Shock  Work lead shall be short as possible. Attached
Work firmly to the welding machine.
Sl. Sequence of Potential Hazards Protective measures to be taken
No. the job

 All earth connection to be checked to determine

that they are mechanically strong and
electrically adequate for the required current.
 Cable shall not lie on wet surface nor shall it
pass through water.
 Welding cable shall be in good condition, metal
wire shall not be lie in on exposed state
anywhere.
 Cable shall not be laid across the passages.
 Pipelines carrying gases or flammable liquids or
conduits carrying electrical conductors shall not
be used for a ground return circuit.
 Terminal of the welding cables should be made
with terminal, kept tight and well insulated with
heat resistant tape.
 Cable should be free from joints at least of
three meters from electrode holder to avoid
shock.
 Never change electrode with bare hands or wet
gloves when standing on wet floors.
 Other electrical cables should not be kept laid
with welding cables to avoid insulation
damaged.
 P&M engineer shall check welding machine in a
regular interval to ensure that adequate
electrical connection & insulation on holder
available all time.
 Equipment shall be disconnected from the
source of power when not in use.
 NO welding shall be done in rain unless suitable
protection is provided.
 Welding equipment used in the open shall be
protected from inclement (rainy) weather
conditions.

 Apron and Helmet with welding screen shall be

used by the welder, if applicable.
 Adequate ventilation shall be ensured at the
area.
 Oil or Paint Drums (empty or with contents)
and any combustibles shall never be kept in the
vicinity of the welding area.
 Welding spatter collection arrangement shall be
Sl. Sequence of Potential Hazards Protective measures to be taken
No. the job

available.
 Separate arrangement to collect used electrode
Hazards of exposure to shall be available.
spark, hot metal and
fumes
4 Winding Up & Scattered Material &  Ensure proper wind up & housekeeping at
Housekeeping Spark worksite after completion of every welding
work.
 The accessories (torch, cable, electrode holder)
not being used must be disconnected from
transformer/generator and stored separately.
Unloading of Leakage of Fuel Gases  Cylinders shall not be dropped or struck or
5 Cylinder from rolled horizontally.
Truck  Access to be made for unload the cylinders
from truck; it should be kept in upright
position.
 Cylinders can be moved by tilting and rolling
them on their bottom edges; dragging and
sliding shall be avoided.
 Valve protection caps shall not be used for
lifting.

Storage & Hazards of poor  Floor of the storage area shall be level and free
6 Transportation storage and from undulation.
of Cylinders transportation, Gas  Gas cylinders shall be kept away from any fire
leakage or hot areas.
 Cylinders shall be stored in definitely assigned
places away from stairs or passageways.
 Cylinders containing oxygen and combustible
gases, such as acetylene and hydrogen should
not be stored in the same room.
 Cylinder shall always be stored upright and
chained to prevent from falling down.
 Cylinder shall not be kept unventilated
enclosure such as acetylene and hydrogen
should not be stored in the same room.
 Full cylinders of oxygen and fuel-gas shall be
used in rotation as received from the supplier.
 Cylinders stored in the open shall be screened
against the continuous direct rays of the sun.
 Full & Empty cylinders shall have their valves
Sl. Sequence of Potential Hazards Protective measures to be taken
No. the job

closed and stored separately.

 Cylinder Trolley shall be used to shift a set of
oxygen & fuel gas cylinder along with the other
accessories.
 Cylinders shall never be used as rollers or
support, whether ‘FULL’ or’ EMPTY’.
 No one shall tamper with the safety devices
provided in cylinders or valves.

7 Gas Cutting Fire & Explosion
Work
 Before starting gas cutting a written permit
clearance shall be obtained from authorized
person from NPCIL.
 Suitable fire Extinguisher shall be kept near the
cutting set.
 The rubber pipes, joints, gas torches, valve
connection shall be thoroughly checked for
leakages of gas.
 The Gas cutter shall use proper safety
appliances, like gas cutters, goggles, hand
gloves, safety shoes, Safety helmets and full
body harness.
 Rubber hose shall no come in contact with any
hot material and it shall not be taken through
hot areas.
 Regulators or automatic reducing valves shall
be used only for the gas and at pressure for
which they are intended.
 Defective torches shall not be used.
 Torches shall be lighted by friction lighters and
not by matches or from hot work.
 Torches in use shall be inspected weekly basis
for inspection & checking.
 Cylinder shall not be used to support the work,
nor shall the blowpipe flame be allowed to
come in contact with the cylinders.
 Nothing shall be placed on top of a fuel gas
cylinder when in use, which may damaged the
safety devices or interfere with the quick
closing of the valves.
 A Hammer or wrench shall not be used to open
oxygen cylinder valves.
 A sheet or any other screening object should
use below the job to arrest any sparks/hot slag
Sl. Sequence of Potential Hazards Protective measures to be taken
No. the job

from falling down.

 Gas cutting at or near fuel line/hazardous area
etc., shall be done only after obtaining a special
permission for the job.
 Nozzle of cutting torch should be properly
tightened and kept clean from dirt, dust, metal
deposition etc.
 Flash back arrestor shall be provided on the
oxygen and acetylene cylinder as an additional
precaution.
 CHECKLIST FOR MS-WELDING WORK
SL. NO DESCRIPTION STATUS REMARKS
1 Whether all the moving & rotating parts of welding machines are
guarded. YES NO
2 Ensure that Earthing shall be provided for the welding machine
YES NO
3 Ensure welding cables are completely insulated.
YES NO
4 Whether welding machine kept at a dry place, material not kept
around it. YES NO
5 Whether permit has taken before commence the welding work.
YES NO
6 All welding connections are checked mechanically & electrically
with adequate. YES NO
7 Ensure cables are not lie on wet surface or pass through water.
YES NO
8 Ensure welder not wear any wet dresses, footwear, hand gloves.
YES NO
9 Whether Conduit Pipes or conduits carrying electrical conductors
not use for a ground return circuit. YES NO
10 Joints in cables are made with terminals, kept tight and well
insulated. YES NO
11 Ensure Electrode not change with bare hands or wet gloves.
YES NO
12 Other electrical cables not kept with welding cables.
YES NO
13 Whether Welder keep his body insulated from both the work and
the metal electrode. YES NO
14 Welding machine checked in regular interval for all electrical
connection and insulation on holder. YES NO
15 Ensure Equipment is disconnected from the source of power when
not in use. YES NO
16 Restrict welding work in rain unless suitable protection is
provided. YES NO
17 Ensure Helmet with welding screen/welding glass is used by
welder. YES NO
18 Adequate ventilation available at welding work area.
YES NO
19 Ensure that oil or paint drums and combustible material not kept
in vicinity of the welding area. YES NO
 20 Ensure proper housekeeping at worksite after completion of
welding work. YES NO

Checked by Authorized by
Signature : ______________ _____________
Name : ______________ _____________
Date : ______________ ______________
CHECKLIST FOR GAS CUTTING WORK

SL.
DESCRIPTION STATUS REMARKS
NO
1 Whether Access to be made for roll down the cylinders from truck,
shall not dropped or struck. YES NO
2 Ensure valve protection caps not used for lifting cylinders.
YES NO
3 Whether floor of the storage area is leveled and free from
undulation. YES NO
4 Oxygen cylinder and combustible gases not stored in the same room.
YES NO
5 Whether cylinder store area is well ventilated, dry and well
protected from combustible materials. YES NO
6 Whether written permit available from authorized person of NPCIL.
YES NO
7 Suitable Fire Extinguisher is available near cutting set.
YES NO
8 All the connections are thoroughly checked for leakage of gas.
YES NO
9 Ensure Gas Cutter use all safety appliances.
YES NO
10 Ensure rubber hose is not come in contact with any hot material.
YES NO
11 Availability of Regulators/Reducing valves for the gas at a pressure
for which it intended. YES NO
12 Prohibition on use of defective torches.
YES NO
13 Ensure torches lighted only by friction Lighters, not by matches or
from hot work. YES NO
14 Cylinder not used to support work.
YES NO
15 Ensure that Hammer or wrenches not used to open oxygen cylinder
valves. YES NO
16 Provide sheet or other screening objects below the cutting job.
YES NO
17 Take a special permission for gas cutting near fuel line/hazardous
area. YES NO
18 Check whether cutting torch properly tight & free form dirt, dust,
metal deposition. YES NO
19 Ensure Experienced gas cutter deployed at work site.
YES NO
20 Availability of Flash Back Arrestor on both the cylinders.
YES NO
Checked by Authorized by
Signature : ______________ _____________
Name : ______________ _____________
Date : __________________ _________________