JOB SAFETY ANALYSIS

Name of the Site In-charge : Mr. XYZ

Name of the Safety Co-ordinator
Name of the Site Engineer
P&M and Equipment involved
PPE / safety device required
: Mr. S. M, Mr. D. Das, Mr. S.S. Chakraborty
: Mr. K Rao, Mr. Rakesh Kr. Gosala, Mr. Babu
: Welding machine, grinding m/c, gas cutting
sets, crane (TATA 320, TFC 280), hydra, drilling
m/c, lifting tools & tackles, Hydraulic jacks,
small tools & tackles, theodolite, NDT kits etc.
: Safety Helmet, Safety shoe, Safety Goggles,
Hand Gloves (Leather & Cotton), Safety belt,
Lifeline rope, Fire extinguisher, Fire bucket etc.

Identity of Task: Erection (Mechanical / Hydraulic jacking system) and

Testing of storage tanks.

Sl. Sequence of Tools & Hazards Safety measures / Responsibility /

No. Operation - tackles involved at precautions Action by
Activity Steps used and various steps
manpower
deployed
1 Marching of crane Crane Hit by crane Entire path through Site Engineer
(TATA 320) along operator, Toppling of which the crane shall
the road (south of rigger, crane march, it is to be
electrical sub signalman, Crude oil line inspected prior to
station building), and hazard bring the crane.
move in between supervisor. Proper ramp has to be
the area of SALPG made at the path in
office and the tank between the SALPG
and placing in office and firewater
between the two tank movement of the
firewater tanks crane.
south side. Area shall be levelled
and compacted along
which crane shall
move and work.
Personnel movement
shall be restricted
during crane
movement.
Experienced
rigger/signalman shall
give the signal to the
crane operator.
Entire crane
movement area shall
be free from any other
material or installation.
Required distance to
be maintained
between crude oil line
& crane positioning
 place.
2 Laying annular Supervisor, Failure of the Crane / hydra shall be Site Engineer
plates on the Operator, crane. placed on a stable and
periphery of the Rigger, Fall of material compacted ground for
tank by crane / Khalasi, Hit by crane stability of the crane.
hydra, welding & Helper, Hit by object The entire swing area
NDT welder, RT shall be barricaded
persons and no unauthorised
entry shall be allowed
within the swing area.
Before lifting process
starts, all the lifting
tools & tackles shall be
certified.
Experienced rigger
shall be present during
the entire lifting
process.
Only experienced
signalman has to give
the signal to the
crane / hydra.
During welding, the
entire area shall be
free from any
combustible materials
like cotton waste,
paints, thinner etc.
All the plates to be
stacked in proper
manner at site to
reduce hindrance for
personnel movement
and other activities.
3 Laying of bottom Supervisor, Same as point 1 Only experienced Site Engineer
plates on the tank rigger, Improper signalman shall give
pad by welder, gas stacking of the signal to the crane
crane/hydra, cutter, plates at site. operator.
welding and DPT khalasi, fitter, Unwanted swing Proper access / egress
crane of the plates to be ensured along
operator, during lifting. the S-E curvature of
signalman, Damage of the tank.
QA/QC asst. welding cable or During lifting and
gas cutting hose swinging with the
or electrical plates, nobody shall
cable due to work under the
sharp edge of suspended load.
the plates. Entire swinging area
Access / egress shall be barricaded.
thru S-E Double tag rope shall
curvature of the be used during lifting
tank of the plates.
Improper lifting All the plates shall be
of plates stacked in proper
manner with sufficient
packing outside the
tank area to prevent
any injury due to
pressed in-between
during handling or
sling fixing.
 All the plates shall be
stacked according to
the priority basis from
top to bottom to
prevent pulling of the
plates kept at bottom.
Tank pad area shall be
free from any cables,
hoses during placing
of the plates.
Personnel movement
shall be restricted
inside the tank area to
prevent any trip injury
as well as burn injury
due to hot metal.
4 Placing of stool Supervisor, Personnel injury Stool shall be placed Site Engineer
(ISMB 600) around rigger, during material at the levelled area.
the periphery of the welder, gas handling If reqd, proper support
tank cutter, Hit by object by to be given to prevent
khalasi, fitter, toppling of the toppling.
helper, crane beam
operator,
signalman

5 Erection of 2nd shell Supervisor, Less stability of Bent plates to be Site Engineer
course along the rigger, the bent plates stacked properly in
periphery, welding welder, gas at stacking yard. sequential manner. If
and radiography. cutter, Toppling of plates kept in
khalasi, fitter, plates after horizontal position,
crane positioning along proper packing to be
operator, periphery provided. During lifting,
signalman, Personnel injury. utmost care shall be
QA/QC asst, Fall of person taken. If plates stacked
radiographer. from height in vertical position,
during welding at enough support shall
outside. be given. And support
Electrocution shall be removed only
Radiography after the plate has
hazard been hooked with the
Injury due to crane for lifting.
improper If the bent plates
access / egress stacked on a saddle,
provision utmost care shall be
Injured person to taken during fixing of
take out from sling, lifting operation
tank inside and other handling
activities.
After placing the each
bent plate along the
periphery, sufficient
supports to be given
for each plate.
Personnel movement
to be restricted during
placing of the 2nd shell
plates.
No body shall be
allowed to work under
any suspended load.
Before removing the
 angular support, all the
vertical joints in
between the plates
shall be fully welded.
Suitable access /
egress space to be
ensured to take out
injured person, in case
of emergency.
SAFETY DURING
RADIOGRAPHY
BEING DISCUSSED
IN POINT NO 17.
6 Erection of 1st shell Supervisor, Personnel injury No body shall keep his Site Engineer
course along the rigger, due to caught finger or hand in
periphery on the 2nd welder, gas in-between the between two plates
shell, welding and cutter, 2nd shell & 1st while in the process of
radiography. khalasi, fitter, shell. alignment.
crane Burn injury There shall be stopper
operator, Fall / slip of 1st arrangement in
signalman, shell plates between the plate
QA/QC asst, during placing edges to prevent any
radiographer. over 2nd shell fall of plates after
plates. putting one over
Trip hazard due another.
to improper Before doing full
housekeeping welding, proper &
Fall of person sufficient support to be
during welding given to each shell
from height plate to prevent
Access / egress toppling.
Inside the tank area,
good housekeeping to
be maintained.
While working at
height, proper doka
staging to be made
and supported.
Handrail to be
provided in the tower
and safety belt to be
tied at shoulder height.
Doka tower to be fixed
in levelled condition.
Safe access/egress to
be provided in &
outside of the tank for
personnel movement
as well as material
shifting.
Suitable access /
egress space to be
ensured.
7 Erection of roof Supervisor, Fall of central Proper support to be Site Engineer
structure Central rigger, drum given to the central
drum, main rafter, welder, gas Hit by object drum when it is being
side rafter, central cutter, Collapsing of the kept at 2m(apprx)
girder and welding khalasi, fitter, roof structure height on the doka
& bolting. helper, crane Not maintaining tower.
operator, sequence of Materials shall be
signalman erection stacked in such
 Working in the manner that it shall not
same location in create any hindrance
different levels. to the movement as
Fall of unstable well as other activities.
truss No loose materials to
be kept at height.
While doing
assembling of main
rafter outside, proper
space to be ensured to
carry out the job
smoothly.
During erection of
main rafter and placing
in between the central
drum and shell plate,
all the joints (bolted &
welded) to be
inspected by
competent person and
then give signal for
lifting.
All the bolt joints to be
moderate tighten for
erection.
No personnel shall
stand below the
suspended load.
To ensure the stability
of the trusses, proper
sequence of erection
e.g. fixing of main
rafter, secondary
rafter, secondary truss,
secondary beam to be
followed as per
drawing.
After fixing all
structural materials,
immediately the entire
bolt joints to be
tightened moderately
to withstand its self-
load.
8 Placing of roof Supervisor, Fall of plates Proper sequence of Site Engineer
plates by rigger, Fall of loose the erection to be
crane/hydra and welder, gas materials maintained.
welding. cutter, Fall of person During erection of the
khalasi, fitter, Hit by plates due roof plates, nobody
helper, crane to unwanted shall be inside the tank
operator, swing by crane under the suspended
signalman caused by wrong load.
signal. Lifeline to be provided
Fall of loose for tying the safety
tools & tackles belt.
Experienced
signalman shall give
the signal to crane
operator.
Roof plate erection
shall be allowed only
 during daytime.
All small tools &
tackles shall be
provided with safety
sling.
9 Arrangement of Rigger, Slip & trip hazard At the same location, Site Engineer
jack system (18 khalasi, Injury due to fall different levels job
nos or more) with welder, gas of plates or loose shall not be carried
power pack outside cutter, fitter, materials from out.
the tank in parallel helper, jack top No conflict at different
with the roof plate operator. Lack of scope of works.
fixing and welding ventilation Area shall be
Hydraulic oil barricaded for
leakage movement restriction
Fire inside the tank while
Bursting of plate fixing is going on
hydraulic hose or at top.
damage due to Sufficient ventilation
fall of material shall be provided for
from the top. the people working
inside the tank.
All the pressurized
parts of the power
pack and the jacks
shall be certified.
No hot work shall be
carried out nearby the
hydraulic oil to prevent
any fire accident.
Experienced &
competent person
shall supervise the
jack fixing
arrangement.
If any leakage of
hydraulic oil occurs,
immediately it is to be
cleaned.
Sufficient illumination
shall be provided
inside the tank area.
Activity at the top shall
be restricted while
hydraulic hose being
fixed at the bottom.
Hydraulic oil shall not
be kept in a loose
container and it shall
be away from the hot
job.
10 Placing and lifting Supervisor, Fall of shell Before lifting of plates Site Engineer
of 3rd shell and Rigger, plates during from the saddle, lifting
subsequent by khalasi, lifting or placing hook to be welded and
jacks welding and welder, gas Failure of jacks it is to be physically
NDT cutter, fitter, Failure of cleat checked for giving
helper, jack Personnel injury clearance.
operator, due to pressed Tag rope to be
signalman. in between provided for any lifting
Access / egress materials.
Fall of loose & All the plates to be
small tools & stacked on the saddle
 tackles in such place, it shall
Portable oven not create any
electrocution hindrance to the other
activities.
All the weld joints of
the cleats to be
checked by the QA/QC
engineer and to be
certified for using as
lifting hook.
During placing of the
lifted plates on the
existing erected plates,
hands shall not be
kept in between the
two plates.
During fixing of wedge
piece, person shall
hammer slowly in
initial phase and then
go for more.
Before starting the
lifting operation by
jack, all the jacks to be
checked personally by
the competent person.
All the hydraulic hoses
shall be free from any
damage.
All the jack lifting
points fitted with the
cleats to be checked
on regular basis.
During lifting
operation, nobody
shall be allowed to
move below the shell
to go inside / outside
the tank. During
movement, jacks shall
be locked and it is to
be ensured.
While lifting of tank by
jack shall be carried
out, required number
of people only shall be
allowed inside the
tank.
Inside the tank, proper
& sufficient illumination
shall be provided.
If portable oven is AC
machine, then running
earth as well as local
earth to be provided.
Otherwise it is
suggested to use DC
oven machine.
11 Fixing of other Supervisor, Fall of materials Proper scaffolding of Site Engineer
accessories like Rigger, Fall of person required height with
pipe supports, khalasi, Wrong sequence handrail and working
 staircase with welder, gas maintaining platform to be erected.
supports etc (both cutter, fitter, No loose materials to
inside & outside) helper, jack be kept at higher
for each shell in operator, elevation.
parallel as soon as signalman. Proper access / egress
particular shell to be maintained at the
plate erected tower and working
platform.
Required materials to
be shifted at higher
platform as and when
required. Do not stack
any materials at
working platform at
higher elevation.
All the activities to be
carried out in a proper
sequential manner.
12 Erection of bottom Supervisor, Personnel injury The jacks and the Site Engineer
shell plates - Rigger, during material stool shall be removed
Removal of jacks khalasi, handling in sequential way.
and stool one by welder, gas Improper access Proper supervision
one as soon as the cutter, fitter, / egress and guidance to be
particular plate is helper, jack Trip hazard there during jack and
being erected and operator, stool removal.
placed, welded signalman. Before closing the last
cutting of manhole shell plate i.e make-
removal of entire up plate, manhole to
materials inside the be cut and access /
tank - welding egress to be ensured.
Sufficient ventilation to
be ensured. If
required, exhaust fan
to be fixed.
Before transferring the
entire load on the
bottom shell plates, it
shall be ensured that
all joints are properly
welded.
Sufficient illumination
to be provided inside
the tank.
All the materials
except few to be taken
out of the tank inside
before placing the
make-up plate.
13 Fixing of roof plate Supervisor, Same as point 7 Same as point 7 Site Engineer
balance one Rigger,
khalasi,
welder, gas
cutter, fitter,
helper,
signalman.
14 Vacuum box test Vacuum Electrocution Electrician shall give Site Engineer
pump all the electrical
connections and it
shall be routed through
ELCB.
15 Diesel oil chalk test Supervisor, Fire No hot job shall be Site Engineer
 for welding joints of Khalasi, Suffocation due allowed nearby, inside,
bottom with the last helper. inadequate top of the tank.
shell plates ventilation Sufficient ventilation to
Oil spillage be ensured
Trip & fall It is to be ensured that
no oil spillage occurs.
If require, catch tray to
be used.
Housekeeping to be
ensured to prevent any
trip hazard.
16 Settlement test / Supervisor, Failure of Before starting filling of Site Engineer
leakage test for the Khalasi, manholes due to water inside the tank,
tank helper. loose bolts all the bolts and nuts
to be properly
tightened and it is to
be inspected properly.
17 Painting of the tank Supervisor, Fall of person All the scaffolding shall Site Engineer
from both inside & Painter, Fall of materials be erected on firm and
outside Helper Fire hazards levelled ground.
Suffocation Working platform shall
have proper handrail
and suitable access /
egress.
Sufficient illumination
to be ensured inside
the tank.
Inside and outside,
scaffolding shall be
properly supported.
Excessive paints shall
not be stacked inside
the tank. Quantity of
paints can be taken
inside as and when
required.
Sufficient ventilation
shall be provided (if
reqd, exhaust fan)
during painting job
inside the tank.
No loose, open paints
and thinner drums
shall be stored or kept
at site.
All the people must
wear safety belt
(double lanyard)
hooked properly at
shoulder level.
Suitable access /
egress to be ensured
going inside the tank.
While going to the
height of the
scaffolding, person
shall not carry the
paint container along
with him.
Spillage of paints to be
controlled and area
 shall be cleared off
any spillage.
No hot job shall be
allowed in and around
the painting area.
18 Radiography Radiographer Exposed to Date & Time of Site Engineer
radiation radiography shall be
informed to all
concerned well in
advance.
The area of
radiography to be
cordoned off, warning
sign to be displayed
and flash lights to be
displayed to caution
the surrounding people
and passer by.
Before starting the
radiography, visual
check shall be there
about the surrounding
and other agencies
working nearby shall
be informed.
While doing
radiography, dosimeter
and survey meter shall
be available with
people executing the
radiography.
Source strength shall
be known and
accordingly barrication
distance shall be fixed.
Before doing the
radiography, available
format to be filled and
signed by the
radiographic agency
and concerned site
Incharge and approval
shall be taken from the
HSE Dept.
When blasting
operation is planned,
radiography shall not
be permitted and
radiographic source
shall be kept inside the
source holder.
When radiography is
being done, blasting
operation shall not be
performed, detonators
shall be kept inside the
explosive magazine
and vice-versa.
18 Others Relative work permits Site Engineer
to be obtained from
the SALPG along with
 all complimentary work
permits.
Welding cables, gas-
cutting hoses,
electrical cables shall
not overlap with each
other.
All the persons
involved in the job
shall have suitable
PPEs like goggles,
nose masks, safety
belts, hand gloves etc.
Excess working hour
(more than 12 hours)
shall be restricted.
Pep talk to be given
before commencing of
the job on regular
basis.
Entire area shall be
free from any
unauthorised entry.
PA / Responsible
person shall be
present during entire
operation.
Good housekeeping to
be maintained in and
around tank area.
In case of multiple
work fronts at different
levels, proper co-
ordination,
communication shall
be in place.
Nobody shall work
under suspended load
at any circumstances.
TAG system to be
followed for the
scaffolding.
During plate erection,
lifting of the tank by
jack area to be
restricted for
unauthorised entry.
Only authorised and
experienced person
shall be engaged for
jack operation.
Proper guard to be
provided for the
rotating part of the
machineries.
Precaution to be taken
for crane movement in
between the area of
crude oil line and both
the tanks.
During loading or
 unloading of materials
from the trailor parked
at he main road,
movement along the
pedestrian path to be
restricted for the
moment.
Housekeeping shall be
done on regular basis
and all the scrap
materials to be taken
out of the site.
No combustible
materials to be kept in
and around the tank
area.
Gas cylinders to be
kept in upright position
in the stand.
In case of LPG
cylinder, it is to be
industrial and having
the related regulator
and flash back
arrestor.
No personnel
movement within
crane swing area.
Trained Fire watcher
shall be present near
the hot job.
Fire bucket, fire
extinguisher shall be in
place near the hot job.

Signature &
Date

-------------------- ------------------
Site Engineer SSC