HPCL-Mittal Energy Ltd
Metal Crafts Constructors Pvt Ltd
Main Activity: Stub welding & hot tap at 18" WS 578 1604 A3A
Sl. No. Sub Activities
(List the tasks required to
perform the activity in the
sequence they are carried out
1 STUB WELDING
Job Safety Analysis
Hazards (Both Existing as well as potential) Against
each task list the hazards that could cause injury/damage
to people, equipment or the environment.
PHYSICAL HAZARDS
Damage to work place due to hitting/ climbing
on pipes, specially SBCs in turn it relese of toxic
gases/ fire Approach to be identified in such a way that emergency escape route is availible alternate escape
route to be identified depending on critical of the job
Injury due to fall ( slip, trip) while climbing up
Control Measures. (List the control
measures required to eliminate or minimize the risk of injury arising from the identified hazard.)
Protection against slip trip fall hazards in work are with cables, hoses, and lines proper laid to
prevent fall hazard & physical injury.
Use of normal work place PPE (head foot , eye, respiratory and thermal protection
Protection from electric hazard associated with welding machine and electric lighting in
the area ( use of bonding, grounding, low voltage of GFL are the same for other
maintenance)
Face shield to be used against protection of eye &face injuries by flying particles
Scaffolding erected should not blocked identified escape route of the plant
All SCBs at work location must be identified electrical and instument cable must be identified and
scaffolding pipes should not touch these cables
Adequate care must be taken to avoid hitting on SBCs
Scaffolding pipes must be at least 6" away from SBCs
JSA availible for scaffolding preparation and dismantling to be referred
Scaffolding must bear the green tag before starting work on it.
Tools tackles etc are not to be carried with hands while climbing. Use pouch , belt or other lifting/
lowering device.
Ladder must be free oil/ grease and must be firmly placed to prevent slip
Ladder to be provided 75 degree to the working platform where ever possible. U clamp to be used
to fixed the ladder.
Gloves with good grip must be used while climbing
Keep landing area near the ladder free from loss pipes and other scaffolding material while
climbing maintain 3 point contact always
Welding parameter (current volt etc) to be maintained as per the WPS provided and mock
up test done in presence of all. This activity will be done by certified welder
 Velocity to be maintained at .4 to 1 meter/sec ,TS to provide the flow required and arrange
for velocity measurement on continuous basis as there is no flow measurement available

Service water line leak due to line puncture

Stand by fire vehicle to be provided (foam tender provided while carrying out the activity)

10KG DCP fire extinguisher to be provided near the hot jobs tapping location

Check LEL continuously. Continue observe the flow rate if any fluctuation observed then immediate
stop the welding work.
Fire blankets to be spread to cover near by pipeline and facilities
In case of leak, Based on the situation, unit shut down / slow down to be Initiated by operations, under
instruction of unit manager and information regarding the leak to be communicated to CT personnel.

Increased temperature in service water Line stub welding / hot tap may lead to loss of
vacuum/over pressurization of the vacuum column. Necessary action based on actual loss of
Transfer of heat to process side leading to disturbance vacuum will be communicate to CS by unit manager .In case of pressurization of the column ,
in process condition column need to be de depressurized from column PSV by pass

Mandatory PPE to be worn

Pressure to be regulate carefully during hydro test activity
Calibrated pressure gauges and hand pump to be used while hydro test
2 Hydro test of stub Over pressurization of stub leads to personal injury

Proper tools and tackles to be used along with necessary mandatory PPEs while installing the
equipment
3 Installation of machine Physical injury while installation

Coupen stuck in parent line with machine leads to Machine healthiness to be checked by project and further clearance for execution to be given by
service water leak projects

Ensure hot tapping condition meeting all the time

New cutter blade checked by projects to be used for cutting

Protection against slip trip fall hazards in work are with cables, hoses, and lines proper laid to
prevent fall hazard & physical injury.
Physical hazards Use of normal work place PPE (head foot , eye, respiratory and thermal protection

Protection from electric hazard associated with welding machine and electric lighting in the area ( use
of bonding, grounding, low voltage of GFL are the same for other maintenance)
Face shield to be used against protection of eye &face injuries by flying particles

Damage to work place due to hitting/ climbing
on pipes, specially SBCs in turn it relese of toxic
gases/ fire
Injury due to fall ( slip, trip) while climbing up
Coupen cutting on parent line
4 using hot tapping machine
Service water line leak due to line puncture
Transfer of heat to process side leading to
disturbance in process condition
5 Dismantling of machine Physical injury while installation
Done by:
Approach to be identified in such a way that emergency escape route is availible alternate escape
route to be identified depending on critical of the job
Scaffolding erected should not blocked identified escape route of the plant
All SCBs at work location must be identified electrical and instument cable must be identified and
scaffolding pipes should not touch these cables
Adequate care must be taken to avoid hitting on SBCs
Scaffolding pipes must be at least 6" away from SBCs
JSA availible for scaffolding preparation and dismantling to be referred
Scaffolding must bear the green tag before starting work on it.
Tools tackles etc are not to be carried with hands while climbing. Use pouch , belt or other lifting/
lowering device
Ladder must be free oil/ grease and must be firmly placed to prevent slip
Ladder to be provided 75 degree to the working platform where ever possible. U clamp to be used
to fixed the ladder.
Gloves with good grip must be used while climbing
Keep landing area near the ladder free from loss pipes and other scaffolding material while
climbing maintain 3 point contact always
Welding parameter (current volt etc) to be maintained as per the WPS provided and mock up test
done in presence of all. This activity will be done by certified welder.
Velocity to be maintained at 4 to 1 meter/sec ,TS to provide the flow required and arrange for
velocity measurement on continuous basis as there is no flow measurement available
Stand by fire vehicle to be provided (foam tender provided while carrying out the activity)
10KG DCP fire extinguisher to be provided near the hot jobs tapping location
Check LEL continuously. Continue observe the flow rate if any fluctuation observed then immediate
stop the welding work.
Fire blankets to be spread to cover near by pipeline and facilities
In case of leak, Based on the situation, unit shut down / slow down to be
initiated by operations , under instruction of unit manager and information regarding the leak to be
communicated to CT personnel.
Increased temperature in srevice water line stub welding / hot tap may lead to loss of
vacuum/over pressurization of the vacuum column. Necessary action based on actual loss of
vacuum will be communicate to CS by unit manager .In case of pressurization of the column ,
column need to be de depressurized from column PSV by pass
Proper tools and tackles to be used along with necessary mandatory PPEs while installing the
equipment .Depressurization of the hot tap machine to be ensure by hot tap contractor as per the
standard
 Name :____________________________ Designation : ________________________Sign : _________________ Date: ______________

Name :____________________________ Designation : ________________________Sign : _________________ Date: ______________

(Note – JSA Sheet to be done by issuer and acceptor of work permit. In case of need, representative from other discipline should also be involved.)