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FAUJI FERTILIZER COMPANY LIMITED 1J \ __

Plantsite - MM
MIRPUR MATHELO

JOH SL\FETV ANL\l,,VSIS

Department -~- Section/ Unit Equipment J
e--·~~ Pl~ODlJ~-:i'I~N -+=-- _____ Urea UCT K, L (J~-800
l\:f) __J_ an~l
Rehabilitation of UCT (Louver Replacement (E-800 t<&L), Stack
-- --=~-~~=-=-----------
.Job
! Repla~~_l'll~n!JE-800 I<, L_ ~_l\/]}, _~l!i:_a _S~_nd_?_e_a_l_ C~ating) _________ _
- - - - -- - - - r - - - -
Req uired personal Safety helmet with chin strip, Safety Harness, Goggles, Cotton gloves, Dust mask,
Protective ______,__S_a_ fc_
'tYll<!!.QS'~----------- _______ _ _________ _____________ _
Drill Machine, Gas Cutter, Grinder, Chipping Ilammcr, Chisel, Civil works tools,
Required Tools
. __ j>crws:_i:_ Br1.1_~l1,JZCC c;_
utt_cr, ~cldingM_'=!.c:l~inc__~_c:_:__ _____ _ ---·--
1 Task Responsibility ___ l_~c_
1
1u~~11c1~1\1a~_tc_n_ancc_~~~c~ ~1~ductioi:_ ________

Hazard Level:
I High Medium I- Low

Sequ.ence of Basic - 11 - Possible Precautions and Risk Additional Hisk

.Job Steps . Resources Level Controls Level

Old Stack Demolishing/Installation of New Stack/Civil Work Job

• Material sh iftin g with cradle • l·: mployin g
Shifting of • Falling Material
having valid load testing permanent ri gger
scaffolding material Underneath M L
certi ficatc
at co<Jling tmver top. • hillin g of tools

• Use safety harness with • Displa y checklist of

double lanyard. scaffo Id i ng
• Falling of • Use toe board. • Use standa1·d and
sea ffolder • Cover gaps between wooden M ce1tified scafTold in g L
Sea !'folding erection
• hil lin g Material planks as max imum as materi al
around stack outside.
Underneath possible
• Falling oltoo ls • Use tool lan yard .
• Use safety helmet with chin
str ip.
• Prnvide scaffolding platform • Use standmd and
fully coverin g under fan cert ifi ed sc afTo ldin g
gear box loundation lo avoid 111at.ni a l.
fallin g olmaterial inside
basin.
• hilling of
• Use salcty harness with
Scaffolding erection sca!To ld er
double lanyard . Tl M
inside stack • Falling Material
• Use tool lanyard.
• Falling of tools
• Ensure comp lete dismantle
of'MK-800 K/ UM (hm,
Gearbox and motor).
• Entry on confined space
. ____________, __e_r1t~)' J"._e1::i21it.

Page 1 or 5
 FAUJI FERTILIZER COMPANY LIMITED Plantsite - MM
. f MIRPUR MATHELO

• Take necessary precaution to • Depute ski lied

avoid pinchin g of fingers persons for the job .
(e.g. use of gloves, to be • J-:nsurc scaffolding
attentive while using tools check list di sp lay.
etc.) • 1·'. nsurc no other job
• Use ELCB with 22 0V is bein g carried out
grinder. in s ide the stack.
• J·'. nsure grinder safe guard is • Ensure hamm er
installed. handle & Chisel
• Ensure grinder disc is in condition is ok
healthy condition and is not before usage . Usc
expired. tested tool s from tool
• Cutting of stack to be carried room .
out top to bottom from inside " Do not allow the jobs
to outside to avoid collapse at diffe1·ent elevations
of stack and falling of up and down at the
concrete lumps over same ti me.
scaffolding platform inside
• l'inchin g/cutting II M
of fin ge rs. ran stack.
• Stt·iking of • 13cfore final cutting of stack
Breaking/Cutting of concrete porti ons, ho Id it
grinder blade
fan stack llCC with frame and crane. (in
• Electrocution
Material including case of concrete portion
• 1-'alling Material
Metallic Bars by rigg ing)
• Falling of tools
Chipping/cutting • Cover vertical portion of
• Striking of
around stack (inside scaffolding platform outside
hammer on
and outside) stack to avoid falling of
band.
material.
• 1:ire at packing
• Cover inside of stack
of cell
completely with scaffolding
• Dust platform
• Use sa fe ty harness with
double lan ya rd while
wmking at he ig ht
• J\rea to be cordon off around
the stack to avoid movement
of personnel while chipping
• Hnclosure with a green mesh
cloth to be made around the
stack at stairs s ide to avoid
falling of objects on walk
way.
• Keep packing wet by
opening distributor valve or
using water hose (in off time)
• Use dust mask.
• Water will be used for de-
dusting . __
Shuttering for New • [-'ailing of Tool • Cover inside of stack
M
Stack Base (If • Falling of completely with scaffolding M
rcq uircd) material platform.
Repair/Filling of • Do not al low the other jobs at
Crnuting l-' alling or different elevations up and
down at the same time. L
Matcrial/RCC )1'01· ·I'oo I/mate ri a I
L
New Stack Base

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 • ~ JFJJ@
• •• • FAUJI FERTILIZER COMPANY LIMITED
'b , Plantsi te - MM
MIRPUR MATHELO

• Cover in s ide or stack

completely w ith scaffo ldin g
platform .
• Use du st mask.
• J·: nsurc ha mm er handl e &
C hi se l condition is ok befo re
usage. Use tested tools from
tool ro om.
• C utting o r stack to be • l'rcpare prope r ri gging
carried o ut to p to bottom plan and procedure.
from in s ide to ou ts id e to J\ rca to be cordo n o fT
avo id col lap se or stack a nd aro un d the stack to
a void mo ve ment of' L
fa lli ng or conc rete lumps
over scaffo ld in g platform person nel w hil e
inside fan stack. ri ggin g.
• Before fin a l c ulling of
stack concrete portions ,
hold it wi th fi·ame a nd
• Fa lling of crane. ( in case o f' concrete
Rigging removal of Tool/material portion rigging) M
RCC sb1ck pieces • Falling of stack • ln case or week portion I
RCC piece piece, concrete w ill be
removed in tested crad le.
• Do not all ow th e other jobs
at diffe rent elevat ions up
and cl own at th e sam e tim e.
Use prop er 1·igg in g
arrange ment , ri ggin g ba rs
for ri gg in g of RCC pieces.
Use safety harness with
double lanyard while
_ ~~rk in g at hei ght.
• Use prope r ri ggin g • l)o not al low the other
arrangement and ri ggin g bars jobs at di fTercn t
for ri ggin g of new FRI' stack elevati on s up and
panels. down at the sa me
• Falling of • l·:nsure proper ri gg in g ti me.
Rigging for
Too l/material procedure co mpli ance.
installation of new M J,
• l' allin g of l·'R I' • Use safety har ness with double
FRP stack stack panels lan yard whil e work in g at
heigh t.
• Arca to be cordo n off arou nd
the stack to avo id mo ve ment
of person ne l wh il e riggi!]g.__ _
• Do not all ow the ot her j obs at • Use stand ard and
different elevation s up and tes ted too ls ' ro r wo rk.
• l' allin g or materi al
Installation of new clown at the sam e ti me.
• l' alli ng o[" l'oo ls L
FRP stack Panels • Use saf"cty harn ess with dou bl e
• Damagin g of' Too l lan ya rd whil e wo rkin g at
_ J:icight.
Installation of Gear • Securing of fa n blade to avoid
Box and one fan free movement
• Free movement o f
blade for checking
single fan blade
cl ea rance with new
stack panel

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 FAUJI FERTILIZER COMPANY LIMITED ~ JJIFCG
Plantsite - MM
MIRPUR MATHELO

Louver Replacement E-800 K & L

Potential
Sequence of basic Job Control Measures Risk *Additional Risk
Hazards
Steps in Place Level Control lVIcasurcs Level
• Using the cast side staircase to
Shifting of shift the material inside
scaffolding material • Struck by object cooling tower cold basin L L
in cold basin • l' ollow confined space entry
protocol
• Skilled manp ower
• !' ailin g of
• Use of harn ess • Use of chinstrap
Scaffolding e1·ection l' c1·son ncl/too l
• Use of standard l'l'l :s M • l·:nsmc scaffolding l\![
inside cold basin • Material Cal lin g
• Use of too l lanyard erection as per
standard/check I isl.
--· !--~··

Struck by • Use of ha1:ncss and tool • Use of toe bo ards

Object lanyard.
I ailing of • Arca to be hard barricaded on
material the ground floor
Removal of damaged
Fallin g of • l)o not allow the other jobs at M L
louvers
Tools different elevations up and
Damagin g of down at the same time.
Too • !ensure scaffolding erection as
p_cr st.<1ndard/chccklist
• Do not all ow the other jobs at • Do not al low th e other
di ffcrcnt elevations up and jobs at different
down at the same time. el evations up and
Use proper rigging cl own at the sam e
arran gement, ri ggin g bars for tim e.
• l' alling of
ri gg ing of RCC pieces. • Use proper 1·iggin g
R.igging/ Installation of Tool/ material
• l·:nsmc proper ri gg ing M arrangem ent, ri ggin g L
new louvers • !' ailin g of stack procedure co mplian ce. bars for ri gging of
RCC pi ece
• 1\rca to be cordon off to avoid RCC pieces/or shiftin g
movement ofpc1·sonncl while of pieces in prnpcr
rigging. bags.
• J·: nsurc scaffolding erection as
per standard/checklist

Civil J{epair and Ultra-Sand Seal Chemical Application E-800 (K, L,

and M) internal surface
Risk
Sequence of basic Potential Hazards Control Measures Risk '"Additional
Level
Job Steps in Place Level Control Measures
Scaffolding material • Entry on confined space work • E-800L walkway to
shifting inside the permit be completely
• Follow confined space entry covered with Old S/F
cell. (S/F material
• Struck by Object protocol II planks due to M
will be shifted from corroclccl platfom1
• I lard Barricaded passage to be
UCT west side specified by Arca Engineer chcq ucrccl plat e
staircase

i>age ~ of 5
 ~ ..rl Wii<frl~
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FAUJI FERTILIZER COMPANY LIMITED Plantsitc" - MM
MIRPUR MATHELO

• Use saCcty harness and hook up • Use standa1·d

al I the time durin g activity. sca ffoldin g materi al
Scaffolding erection • Do not allow the jobs at different and display Si l:
• !'ailing ofscaffoldcr
/removal inside cell
• 1-'alling o f' material
elevations up and cl own at the II approved check! isl M
E -800 K/J ) M same tim e. • Vess el entry
• J ~ nt1·y on co nfined space work requirements as per
--··-----·-····· \--· p_~~~1.1it , _ . -·- WI'

• l·: nsurc scaffolding erection as per

• 1:a llin g of' material standard/check! isl
!c h irping and rqrni1·
• l)u st • Use of tool lanyard. L L
in te rnal walls
• Cotton g loves
• Use dust mask.
• l ~ nsurc scaffoldin g erection as per • 1:ol low iVIS DS
standard/check! ist
• Cal I hazard
A pplication of U ltra • Cotton gloves to be used wh iJc
• Chemi cal J·:xposurc M L
Sa nd Seal ch e micals handlin g th e chemi ca l
• Use dust rmi sk.

• Use dust mask.

S pray ing of Sand • Dust • Water will be used for dc- L L
dustin g.

Note :
> Safety Lalk specific to maintenance job with all the work force is to be conducted on daily
ba sis before job execution. Aspect of heavy ammonia leakage is also to be covered in
safely talk. (R esponsibility : Arca Engineer EM)
> Independent operators to be deputed at cooling tower top I cold basin f()r supervision/
vessel entry. (Responsibility: Shift Engineer Urea)
> Al! the casual labor is to be checked for "No smoking" in the area. They should be told
to avoid taking any matches/lighter/cigarettes on daily basis before job execution.
(Responsibility: Field Operator on Duty & Job Supervisor)
> Avoid parallel jobs at different heights . (Respons ibility: Shift Engineer UREA)