JHA Number: sap/035 Job Title: Sulfuric Acid Plant -

Shift Engineer
Persons Accountable
Oprns / Maint
** Any Applicable legal requirement: AP factories Act/En
Staff/contract
Persons doing job:
work men

**Frequency: Routine / Non routine: Continuous / Daily / Weekly / Monthly / Yearly

**Affected Parties: Staff Contractor Visitors Others

Hazard

Consequence
Potential
No. Steps in Task Source &
Human Act
Situation

Climbing up/down cat

1 ladder to approach Slips/trips/falls Horse play injury
manways area

Objects fall
2 Opening the manways Horse play injury
from height

Draining of acid from Horse play / over

3 Confined space Acid burns
tower bottom confidence

Confined space Over confidence Acid burns

3 Inspection of internals
Exposure to Respirator
Over confidence
acidic fumes y problem

Confined space Over confidence Acid burns

Distribution headers
4
removal / re-fixing
 Exposure to Respirator
Distribution headers Over confidence
4 acidic fumes y problem
removal / re-fixing
Slippery /
uneven
ground /
Over confidence Injury
manual lifting /
awkward
posture

Confined space Over confidence Acid burns

Exposure to Respirator
Over confidence
5 Spouts removal / re- fixing acidic fumes y problem

Slippery /
uneven
ground /
Over confidence Injury
manual lifting /
awkward
posture

Confined space Over confidence Acid burns

Exposure to Respirator
Troughs removal / re- Over confidence
6 acidic fumes y problem
fixing
Slippery /
uneven
ground /
Over confidence Injury
manual lifting /
awkward
posture

Confined space Over confidence Acid burns

Exposure to Respirator
Over confidence
acidic fumes y problem
Saddles removal and
7
lowering to ground
 Saddles removal and
7 Slippery /
lowering to ground
uneven
ground /
Over confidence Injury
manual lifting /
awkward
posture
Injury /
Material fall
Horse play material
from height
damage

Acid
burns /
Exposure to Respirator
8 Saddles cleaning Horse play
acidic fumes y problem /
land
depletion

Confined space Over confidence Acid burns

Exposure to Respirator
9 Saddles loading Over confidence
acidic fumes y problem

uneven
ground /
manual lifting / Over confidence Injury
awkward
posture

Confined space Over confidence Acid burns

Shell corroded portion

10 brick / rephonal lining Exposure to Respirator
removal / re-fixing Over confidence
acidic fumes y problem

Collapse of
Injury
brick lining

Confined space Over confidence Acid burns

Shell damaged plates

11 cutting / welding with new
plate
 Shell damaged plates Exposure to Respirator
11 cutting / welding with new acidic fumes Over confidence
y problem
plate

Fire / explosion Injury

 Task: DA 503 IAT tower jobs – 1) Acid headers, spouts,
itle: Sulfuric Acid Plant - 1 troughs removal and re-fixing 2) Saddles removal and
reloading 3) Acid draining 4) Brick lining & shell repairs

al requirement: AP factories Act/Environment Act / Petroleum Act/Boiler Act/ Explosives Act / SMPV Rules/MSIHC Rules/Motor
Vehicles Act

y / Weekly / Monthly / Yearly

Others
Controls in Place R

social
Natural
Health & and
Engineering Administrative Work Practices PPE
safety
Environ
cultural
ment
heritage

Cat ladder
Helmet,
with D
Training Contract control gloves, safety 2 1 1
guard
shoe
available

Helmet,
Work permit /
No Contract control gloves, safety 1 1 1
Supervision
shoe
Contract control / PVC suit &
Work permit / 2 1
No behavior gloves, gum 2
Supervision
reinforcement boot, Hood

Isolation of PVC suit &

Work permit / 2 1
pump/mot gloves, gum 2
Supervision
or boot, Hood

PVC suit &

Isolation of
Work permit / gloves, gum 2 1
pump/mot 2
Supervision boot, Hood,
or
canister mask

Isolation of Contract control / PVC suit &

Work permit / 2 1
pump/mot behavior gloves, gum 2
Supervision
or reinforcement boot, Hood
 PVC suit &
Isolation of Contract control /
Work permit / gloves, gum 2 1
pump/mot behavior 2
Supervision boot, canister
or reinforcement
mask, Hood

Contract control / PVC suit &

Work permit /
behavior gloves, gum
No Supervision / 1 1 1
reinforcement/ right boot, canister
Training
tools mask, Hood

Isolation of Contract control / PVC suit &

Work permit / 2 1
pump/mot behavior gloves, gum 2
Supervision
or reinforcement boot, Hood

PVC suit &

Isolation of Contract control /
Work permit / gloves, gum 2 1
pump/mot behavior 2
Supervision boot, canister
or reinforcement
mask, Hood

Contract control / PVC suit &

Work permit /
behavior gloves, gum
No Supervision / 1 1 1
reinforcement/ right boot, canister
Training
tools mask, Hood

Isolation of Contract control / PVC suit &

Work permit / 2 1
pump/mot behavior gloves, gum 2
Supervision
or reinforcement boot, Hood

PVC suit &

Isolation of Contract control /
Work permit / gloves, gum 2 1
pump/mot behavior 2
Supervision boot, canister
or reinforcement
mask, Hood

Contract control / PVC suit &

Work permit /
behavior gloves, gum
No Supervision / 1 1 1
reinforcement/ right boot, canister
Training
tools mask, Hood

Isolation of Contract control / PVC suit &

Work permit / 2 1
pump/mot behavior gloves, gum 2
Supervision
or reinforcement boot, Hood

PVC suit &

Isolation of Contract control /
Work permit / gloves, gum 2 1
pump/mot behavior 2
Supervision boot, canister
or reinforcement
mask, Hood
 Contract control / PVC suit &
Work permit /
behavior gloves, gum
No Supervision / 1 1 1
reinforcement/ right boot, canister
Training
tools mask, Hood

Work permit / Contract control / PVC suit &

No Supervision / behavior gloves, gum 2 1 1
Training reinforcement boot, Hood

PVC suit &

Isolation of Contract control /
Work permit / gloves, gum 2 1
pump/mot behavior 2
Supervision boot, canister
or reinforcement
mask, Hood

Isolation of Contract control / PVC suit &

Work permit / 2 1
pump/mot behavior gloves, gum 2
Supervision
or reinforcement boot, Hood

PVC suit &

Isolation of Contract control /
Work permit / gloves, gum 2 1
pump/mot behavior 2
Supervision boot, canister
or reinforcement
mask, Hood
PVC suit &
Work permit / Contract control /
gloves, gum
No Supervision / behavior 2 1 1
boot, canister
Training reinforcement
mask, Hood

Isolation of Contract control / PVC suit &

Work permit / 2 1
pump/mot behavior gloves, gum 2
Supervision
or reinforcement boot, Hood

PVC suit &

Isolation of Contract control /
Work permit / gloves, gum 2 1
pump/mot behavior 2
Supervision boot, canister
or reinforcement
mask, Hood
Contract control / PVC suit &
behavior gloves, gum 2 1 1
reinforcement boot, Hood
Isolation of Contract control / PVC suit &
Work permit / 2 1
pump/mot behavior gloves, gum 2
Supervision
or reinforcement boot, Hood
 PVC suit &
Isolation of Contract control /
Work permit / gloves, gum 2 1
pump/mot behavior 2
Supervision boot, canister
or reinforcement
mask, Hood
Helmet,
Work permit / Explosive mixer gloves, safety 2 2 2
Supervision check up available shoe, welding
goggles
cid headers, spouts, Revision No: Date:
addles removal and 0 26.02.2019
ining & shell repairs

/MSIHC Rules/Motor **Meeting Legal

Yes / No
Requirement

Risk Assessment
communi
ty,govern Occuran % Occuran
Risk level of Remarks
ment,rep legal ce in likelihoo ce in
utation,m future d factor past rating risk
edia

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