JOB SAFETY ANALYSIS

Name of the Contractor:- Thermax Limited, Pune Work location :- Green “Boiler Project
Prepared by:- 03.05.2010
k.k.vishwakarma
(Name & Design. of Concern Date: -
Safety Officer
HSE Officer.) -
Erection of FM Boilers: xxxxxx
Title of method statement:- JOB SAFETY ANALYSIS Description of Activity:-

Sr. Preventive measures to be taken

Description of process Hazards Impact
No.
1.Safety talk- discuss about safe lifting process.
2.Barricade the area and post safety sign.
3.Conduct safety inspection of all tools and lifting
tackles/machines before starting the job.(as per
1. Fall of object from factory act specification).
1.Property damage.
Erection of main height. 4.Ensure good and standard quality of lifting tool
1 2.Serious injury.
column 2.Failure of lifting tools and usage.
3.Fatality
tackles. 5.Don’t leave loose materials inside the columns.
6.Use tag line during its erection.
7.Use proper ladder for open lings after its erection.
8.If its long than use guy rope for its tie up and fall
protection by heavy wind
2 Erection of main 1.Fall of the object from 1.Property damage 1.Give HSE training about Safe erection.
beam height. 2.injury. 2.Safety talk-discuss abut safe lifting process.
2.Contact with sharp edges. 3.serious Injury. 3.Barricade the area and post safety sign.
3.Failure of the lifting tools 4.Conduct safety inspection of all tools and lifting
and tackles. tackles/machines before starting the job.(as per
factory act specification).

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 JOB SAFETY ANALYSIS

5.Ensure good and standard quality of lifting tool

usage.
6. Use proper size nut bolts for its fit Up send only
competent personnel.
1.Appropriate ventilation.
1.Exposure to welding 2.Proper earthing.
fumes. 1.Lung injury 3.Keep ready fire protective arrangement.
2.Electric shock. 2Electrocution. 4.Ensure proper use of PPE.
Welding of main
3.Fire 3.Fire,explosion 5.Prepare SOP of welding work.
beam
4.Projectiles,flash 4.Eye/Burn injury. 6.Safety talk-discuss abut working at height and
5.Fall of material, tools, 5.Injury, fatality. welding work.
person from height. 7.Ensure proper housekeeping before and after
work.
1.Give HSE training about do or don’t in this work.
2.Training on-working at height, welding, gas
1.Fall of the object from cutting and use of PPE.
height 1.Property damage
Erection of main 3Conduct safety inspection of all tools and lifting
3 2.Contact with sharp edges. 2.injury.
bracing tackles/machines before starting the job.(as per
3.Failure of the lifting tools 3.serious Injury.
factory act specification).
and tackles.
4.Ensure good and standard quality of lifting tool
usages.
1.Appropriate ventilation.
1.Exposure to welding 2.Proper earthing.
fumes. 1.Lung injury 3.Keep ready fire protective arrangement.
2.Electric shock. 2Electrocution. 4.Ensure proper use of PPE.
Welding of main
3.Fire 3.Fire,explosion 5.Prepare SOP of welding work.
bracing
4.Projectiles,flash 4.Eye/Burn injury. 6.Safety talk-discuss about working at height and
5.Fall of material, tools, 5.Injury, fatality. welding work.
person from height. 7.Ensure proper housekeeping before and after
work.

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 JOB SAFETY ANALYSIS
1.Fall of the object from
height.
2.Contact with sharp edges.
Erection of top deck
4 3.Failure of the lifting tools
girders
and tackles.
4.Failure of safety belt.(if
damaged safety used).
1.Exposure to welding
fumes.
2.Electric shock.
Welding of top deck
3.Fire
girders
4.Projectiles,flash
5.Fall of material, tools,
person from height.
5 Erection of Platform 1.Fall of the object from
beams height.
1.Give HSE training about do or don’t in this work.
2.Barricade the area and post safety sign
3.Training on-working at height, welding, gas
cutting and use of PPE.
1.Property damage 4.Conduct safety inspection of all tools and lifting
2.injury. tackles/machines before starting the job. (as per
3.serious Injury/fatality. factory act specification).
4.Fall of the person from 5.Ensure good and standard quality of lifting tool
height. usages.
6.Use of full body harness and fall arrestor.
7.Periodic and pr-use checks of harness.
8.Life line for anchoring the safety belt.
9.Tool talk -discuss about fall protection.
1.Appropriate ventilation.
2.Ensure good quality of cables; Proper earthing.
3.Remove all combustibles and fire hazards from
welding area; Keep ready fire protective
arrangement.
1.Lung injury 4.Ensure proper use of PPE.
2Electrocution. 5.Prepare SOP of welding work.
3.Fire,explosion 6.Safety talk-discuss abut working at height and
4.Eye/Burn injury. welding work.
5.Injury, fatality. 7.Use of full body harness and fall arrestor.
8.Periodic and pr-use checks of harness.
9.Life line for anchoring the safety belt.
10.Ensure proper housekeeping before and after
work.
11. Barricade the area and post safety sign
1.Property damage 1.Give HSE training about do or don’t in this work.
2.injury. 2.Safety talk-discuss abut safe lifting process.
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 JOB SAFETY ANALYSIS

3.Barricade the area and post safety sign.

4.Conduct safety inspection of all tools and lifting
2.Contact with sharp edges. 3.serious Injury.
tackles/machines before starting the job.(as per
3.Failure of the lifting tools .
factory act specification).
and tackles.
5.Ensure good and standard quality of lifting tool
usages.
1.Appropriate ventilation.
1.Exposure to welding 2.Proper earthing.
fumes. 1.Lung injury 3.Keep ready fire protective arrangement.
2.Electric shock. 2Electrocution. 4.Ensure proper use of PPE.
Welding of platform
3.Fire 3.Fire,explosion 5.Prepare SOP of welding work.
beam
4.Projectiles,flash 4.Eye/Burn injury. 6.Safety talk-discuss abut working at height and
5.Fall of material, tools, 5.Injury, fatality. welding work.
person from height. 7.Ensure proper housekeeping before and after
work.
1.Give HSE training about do or don’t in this work.
2.Barricade the area and post safety sign
3.Training on-working at height, welding, gas
cutting and use of PPE.
1.Fall of the object from
4.Conduct safety inspection of all tools and lifting
height. 1.Property damage
tackles/machines before starting the job.(as per
2.Contact with sharp edges. 2.injury.
Erection of Drum factory act specification).
6 3.Failure of the lifting tools 3.serious Injury/fatality.
lifting structure
and tackles. 4.Fall of the person from 5.Ensure good and standard quality of lifting tool
4.Failure of safety belt.(if height. usages.
damaged safety used). 6.Use of full body harness safety belt and fall
arrestor.
7.Periodic and pre-use checks of harness.
8.Life line for anchoring the safety belt.
9.Tool talk -discuss about fall protection.
Welding of Drum 1.Exposure to welding 1.Lung injury 1.Appropriate ventilation, Appropriate respirators.

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 JOB SAFETY ANALYSIS
fumes.
2.Electric shock.
3.Fire
lifting structure
4.Projectiles,flash
5.Fall of material, tools,
person from height.
1.Fall of the object from
height.
2.Contact with sharp edges.
7 Erection of RH Panel 3.Failure of the lifting tools
and tackles.
4.Failure of safety belt.(if
damaged safety used).
RH panel alignment 1.Fall of the object from
height.
2.Contact with sharp edges.
3.Improper handling of Oil.
2.Ensure good quality of cables; Proper earthing.
3.Remove all combustibles and fire hazards from
welding area; Keep ready fire protective
arrangement.
4.Ensure proper use of PPE.
5.Prepare SOP of welding work.
2Electrocution.
6.Safety talk-discuss abut working at height and
3.Fire,explosion
welding work.
4.Eye/Burn injury.
7.Use of full body harness safety belt and fall
5.Injury, fatality.
arrestor.
8.Periodic and pr-use checks of harness.
9.Life line for anchoring the safety belt.
10.Ensure proper housekeeping before and after
work.
11. Barricade the area and post safety sign
1.Give HSE training about do or don’t in this work.
2Tool talk -discuss abut fall protection
3.Barricade the area and post safety sign
1.Property damage, injury. 4.Conduct safety inspection of all tools and lifting
2.injury. tackles/machines before starting the job.(as per
3.serious Injury/fatality. factory act specification).
4.Fall of the person from 5.Ensure good and standard quality of lifting tool
height. usages.
6.Use of full body harness safety belt and fall
arrestor.
7.Periodic and pre-use checks of harness.
1.Serious injury. 1.Give HSE training about do or don’t in this work.
2.Cut injury. 2.Barricade the area and post safety sign
3.Fire. 3.Use of right tool for right job.
4.Slip hazard. 4.Use of full body harness safety belt and fall
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 JOB SAFETY ANALYSIS
4.Due to piano wire on
ground trip hazard.
1.Exposure to welding
fumes.
2.Electric shock.
Welding of Header 3.Fire
Joint 4.Projectiles,flash
5.Fall of material, tools,
person from height.
6.Failure of scaffolding.
Welding of panel strip 1.Exposure to welding
fumes.
2.Electric shock.
3.Fire
4.Projectiles,flash
5.Fall of material, tools,
1.Lung injury
2Electrocution.
3.Fire,explosion
4.Eye/Burn injury.
5.Injury, fatality.
6.Injury, loss of property.
1.Lung injury
2Electrocution.
3.Fire,explosion
4.Eye/Burn injury.
5.Injury, fatality.
6.Injury, loss of property.
arrestor.
5.Proper storage and handling of oil.
6.Ensure proper housekeeping before and after
work.
1.Appropriate ventilation, Appropriate respirators.
2.Ensure good quality of cables; Proper earthing
arrangement.
3.Remove all combustible materials and fire
hazards from welding area; Keep ready fire
protective arrangement.
4.Ensure proper use of PPE.
5.Prepare SOP of welding work.
6.Safety talk-discuss abut working at height and
welding work.
7.Use of full body harness safety belt and fall
arrestor.
8.Periodic and pr-use checks of harness.
9.Life line for anchoring the safety belt.
10.Ensure proper housekeeping before and after
work.
11. Barricade the area and post safety sign.
12.Ensure good quality of scaffolding material
used.
1.Appropriate ventilation.
2.Proper earthing.
3.Keep ready fire protective arrangement.
4.Ensure proper use of PPE.
5.Prepare SOP of welding work.
6.Safety talk-discuss abut working at height and
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 JOB SAFETY ANALYSIS

welding work.
person from height. 7.Ensure proper housekeeping before and after
6.Failure of scaffolding. work.
8.Ensure good quality of scaffolding material used.
1.Give HSE training about do or don’t in this work.
2.Tool box talk -discuss abut fall protection
3.Barricade the area and post safety sign
1.Fall of the object from
4.Conduct safety inspection of all tools and lifting
height. 1.Property damage, injury.
tackles/machines before starting the job.(as per
Erection of Front 2.Contact with sharp edges. 2.injury.
factory act specification).
8 Panel-Panel and Top 3.Failure of the lifting tools 3.serious Injury/fatality.
5.Ensure good and standard quality of lifting tool
header and tackles. 4.Fall of the person from
usages.
4.Failure of safety belt.(if height.
6.Use of full body harness safety belt and fall
damaged safety used).
arrestor.
7.Periodic and pre-use checks of harness.

1.Use life line at height.

1.Fall of the object from
height.
2.Contact with sharp edges.
Front panel alignment
3.Improper handling of Oil.
4.Due to piano wire on
ground trip hazard.
Front panel-Welding 1.Exposure to welding
of header joints fumes.
2.Electric shock.
3.Fire
4.Projectiles,flash
5.Fall of material, tools,
1.Serious injury.
2.Cut injury.
3.Fire.
4.Slip hazard.
1.Lung injury
2Electrocution.
3.Fire,explosion
4.Eye/Burn injury.
5.Injury, fatality.
6.Injury, loss of property.
2.Barricade the area and post safety sign
3.Use of right tool for right job.
4.Use of full body harness safety belt and fall
arrestor.
5.Proper storage and handling of oil.
6.Ensure proper housekeeping before and after
work.
1.Appropriate ventilation.
2.Proper earthing.
3.Keep ready fire protective arrangement.
4.Ensure proper use of PPE.
5.Prepare SOP of welding work.
6.Safety talk-discuss abut working at height and

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 JOB SAFETY ANALYSIS
person from height.
6.Failure of scaffolding.
1.Exposure to welding
fumes.
2.Electric shock.
Front panel-Welding 3.Fire
of panel strip 4.Projectiles,flash
5.Fall of material, tools,
person from height.
6.Failure of scaffolding.
1.Fall of the object from
height.
2.Contact with sharp edges.
10 Erection of LH panel 3.Failure of the lifting tools
and tackles.
4.Failure of safety belt.(if
damaged safety used).
Alignment of LH 1.Fall of the object from
panel height.
2.Contact with sharp edges.
3.Improper handling of Oil.
4.Due to piano wire on
welding work.
7.Ensure proper housekeeping before and after
work.
8.Ensure good quality of scaffolding material used.
1.Appropriate ventilation.
2.Proper earthing.
1.Lung injury 3.Keep ready fire protective arrangement.
2Electrocution. 4.Ensure proper use of PPE.
3.Fire,explosion 5.Prepare SOP of welding work.
4.Eye/Burn injury. 6.Safety talk-discuss abut working at height and
5.Injury, fatality. welding work.
6.Injury, loss of property. 7.Ensure proper housekeeping before and after
work.
8.Ensure good quality of scaffolding material used.
1.Give HSE training about do or don’t in this work.
2Tool talk -discuss abut fall protection
3.Barricade the area and post safety sign
1.Property damage, injury. 4.Conduct safety inspection of all tools and lifting
2.injury. tackles/machines before starting the job.(as per
3.serious Injury/fatality. factory act specification).
4.Fall of the person from 5.Ensure good and standard quality of lifting tool
height. usages.
6.Use of full body harness safety belt and fall
arrestor.
7.Periodic and pre-use checks of harness.
1.Serious injury. 1.Give HSE training about do or don’t in this work.
2.Cut injury. 2.Barricade the area and post safety sign
3.Fire. 3.Use of right tool for right job.
4.Slip hazard. 4.Use of full body harness safety belt and fall
arrestor.
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 JOB SAFETY ANALYSIS
ground trip hazard.
1.Exposure to welding
fumes.
2.Electric shock.
Welding of header 3.Fire
joint 4.Projectiles,flash
5.Fall of material, tools,
person from height.
6.Failure of scaffolding.
Welding of panel strip 1.Exposure to welding
fumes.
2.Electric shock.
3.Fire
4.Projectiles,flash
5.Fall of material, tools,
person from height.
6.Failure of scaffolding.
1.Lung injury
2Electrocution.
3.Fire,explosion
4.Eye/Burn injury.
5.Injury, fatality.
6.Injury, loss of property.
1.Lung injury
2Electrocution.
3.Fire,explosion
4.Eye/Burn injury.
5.Injury, fatality.
6.Injury, loss of property.
5.Proper storage and handling of oil.
6.Ensure proper housekeeping before and after
work.
1.Appropriate ventilation, Appropriate respirators.
2.Ensure good quality of cables; Proper earthing
arrangement.
3.Remove all combustible materials and fire
hazards from welding area; Keep ready fire
protective arrangement.
4.Ensure proper use of PPE.
5.Give training about its hazards.
6.Safety talk-discuss abut working at height and
welding work.
7.Use of full body harness safety belt with shock
observer and double life line and fall arrestor.
8.Periodic and pr-use checks of harness.
9.Life line for anchoring the safety belt.
10.Ensure proper housekeeping before and after
work.
11. Barricade the area and post safety sign.
12.Ensure good quality of scaffolding material
used.
1.Appropriate ventilation,Appropriate respirators.
2.Ensure good quality of cables; Proper earthing
arrangement.
3.Remove all combustible materials and fire
hazards from welding area; Keep ready fire
protective arrangement.
4.Ensure proper use of PPE.
5.Prepare SOP of welding work.
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 JOB SAFETY ANALYSIS

6.Safety talk-discuss abut working at height and

1.Fall of the object from
height.
Erection of Rear 2.Contact with sharp edges.
11 Panel- Panel and top 3.Failure of the lifting tools
header and tackles.
4.Failure of safety belt.(if
damaged safety used).
Alignment of rear 1.Fall of the object from
panel height.
2.Contact with sharp edges.
3.Improper handling of Oil.
4.Due to piano wire on
ground trip hazard.
welding work.
7.Use of full body harness safety belt and fall
arrestor.
8.Periodic and pr-use checks of harness.
9.Life line for anchoring the safety belt.
10.Ensure proper housekeeping before and after
work.
11. Barricade the area and post safety sign.
12.Ensure good quality of scaffolding material
used.
1.Give HSE training about do or don’t in this work.
2.Tool talk -discuss abut fall protection
3.Barricade the area and post safety sign
1.Property damage,injury. 4.Conduct safety inspection of all tools and lifting
2.injury. tackles/machines before starting the job. (as per
3.serious Injury/fatality. factory act specification).
4.Fall of the person from 5.Ensure good and standard quality of lifting tool
height. usages.
6.Use of full body harness safety belt and fall
arrestor.
7.Periodic and pre-use checks of harness.
1.Serious injury. 1.Give HSE training about do or don’t in this work.
2.Cut injury. 2.Barricade the area and post safety sign
3.Fire. 3.Use of right tool for right job.
4.Slip hazard. 4.Use of full body harness safety belt and fall
arrestor.
5.Proper storage and handling of oil.
6.Ensure proper housekeeping before and after

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42
 JOB SAFETY ANALYSIS
1.Exposure to welding
fumes.
2.Electric shock.
Welding of header 3.Fire
joint-Rear panel 4.Projectiles,flash
5.Fall of material, tools,
person from height.
6.Failure of scaffolding.
Fit up and welding of 1.Exposure to welding
Joints-Rear panel fumes.
2.Electric shock.
3.Fire
4.Projectiles,flash
5.Fall of material, tools,
person from height.
6.Failure of scaffolding.
42
1.Lung injury
2Electrocution.
3.Fire,explosion
4.Eye/Burn injury.
5.Injury, fatality.
6.Injury, loss of property.
1.Lung injury
2 Electrocution.
3.Fire,explosion
4.Eye/Burn injury.
5.Injury, fatality.
6.Injury, loss of property.
work.
1.Appropriate ventilation, Appropriate respirators.
2.Ensure good quality of cables; Proper earthing
arrangement.
3.Remove all combustible materials and fire
hazards from welding area; Keep ready fire
protective arrangement.
4.Ensure proper use of PPE.
5.Give HSE training about do or don’t in this work.
6.Safety talk-discuss abut working at height and
welding work.
7.Use of full body harness safety belt and fall
arrestor.
8.Periodic and pr-use checks of harness.
9.Life line for anchoring the safety belt.
10.Ensure proper housekeeping before and after
work.
11. Barricade the area and post safety sign.
12.Ensure good quality of scaffolding material
used.
1.Appropriate ventilation.
2.Proper earthing.
3.Keep ready fire protective arrangement.
4.Ensure proper use of PPE.
5.Give HSE training about do or don’t in this work.
6.Safety talk-discuss abut working at height and
welding work.
7.Ensure proper housekeeping before and after
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 JOB SAFETY ANALYSIS
1.Fall of the object from
height.
2.Contact with sharp edges.
3.Failure of the lifting tools
and tackles.
4.Failure of safety belt.
Erection, alignment 5.Exposure to welding
12 and welding of buck fumes.
stay 6.Electric shock.
7.Fire
8.Projectiles,flash
9.Fall of material, tools,
person from height.
10.Failure of scaffolding.
Welding of bottom 1.Exposure to welding 1.Lung injury
header fumes.
2.Electric shock.
3.Fire
4.Projectiles,flash
42
1.Property damage, injury. per factory act specification).
2.injury.
3.serious Injury/fatality.
4.Fall of the person from 6.Use of full body harness safety belt and fall
height.
5.Lung injury
6.Electrocution.
7.Fire,explosion
8.Eye/Burn injury.
9.Injury, fatality.
10.Injury, loss of 12.Prepare SOP of welding work.
property.
2Electrocution.
3.Fire,explosion
4.Eye/Burn injury.
5.Injury, fatality.
work.
8.Ensure good quality of scaffolding material used.
1.Give HSE training about do or don’t in this work.
2.Tool talk -discuss abut fall protection
3.Barricade the area and post safety sign
4.Conduct safety inspection of all lifting tools and
lifting tackles /machines before starting the job.(as
5.Ensure good and standard quality of lifting tool
usages.
arrestor.
7.Periodic and pre-use checks of harness.
8.Welding: Appropriate ventilation.
9.Proper earthing.
10.Keep ready fire protective arrangement.
11.Ensure proper use of PPE.
13.Safety talk-discuss abut working at height and
welding work.
14.Ensure proper housekeeping before and after
work.
15.Ensure good quality of scaffolding material
used.
1.Appropriate ventilation.
2.Proper earthing.
3.Keep ready fire protective arrangement.
4.Ensure proper use of PPE.
5.Give HSE training about do or don’t in this
Page 12 of
 JOB SAFETY ANALYSIS

work..
6.Safety talk-discuss abut working at height and
5.Fall of material, tools,
welding work.
person from height. 6.Injury, loss of property.
7.Ensure proper housekeeping before and after
6.Failure of scaffolding.
work.
8.Ensure good quality of scaffolding material used.
1.Appropriate ventilation.
1.Exposure to welding 2.Proper earthing.
fumes. 1.Lung injury 3.Keep ready fire protective arrangement.
2.Electric shock. 2Electrocution. 4.Ensure proper use of PPE.
3.Fire 3.Fire,explosion 5.Give HSE training about do or don’t in this work.
Welding of End caps
4.Projectiles,flash 4.Eye/Burn injury. 6.Safety talk-discuss abut working at height and
5.Fall of material, tools, 5.Injury, fatality. welding work.
person from height. 6.Injury, loss of property. 7.Ensure proper housekeeping before and after
6.Failure of scaffolding. work.
8.Ensure good quality of scaffolding material used.
Pressure part 1.Fall of the object from 1.Serious injury. 1.Give HSE training about do or don’t in this work.
attachment height. 2.Cut injury. 2.Barricade the area and post safety sign
2.Contact with sharp edges. 3.Lung injury 3.Use of right tool for right job.
3.Exposure to welding 4.Electrocution,Eye/Burn 4.Use of full body harness safety belt and fall
fumes. injury. arrestor.
4.Electric shock. 5.Fire,explosion, 5.Appropriate ventilation.
5.Fire 6.Proper earthing.
7.Keep ready fire protective arrangement.
8.Ensure proper use of PPE.
9.Safety talk-discuss abut working at height and
welding work.
10.Ensure proper housekeeping before and after
work.

Page 13 of
42
 JOB SAFETY ANALYSIS

13 Erection of Steam 1.Fall of the object from 1.Property damage 1.Give HSE training about do or don’t in this work.
Drum height. 2.injury. 2.Barricade the area and post safety sign
2.Contact with sharp edges. 3.serious Injury/fatality. 3.Training on-working at height, welding, gas
3.Failure of the lifting tools 4.Fall of the person from cutting and use of PPE.
and tackles. height. 4.Conduct safety inspection of all tools and lifting
4.Failure of safety belt.(if tackles /machines before starting the job. (as per
damaged safety used). factory act specification).
5.Ensure good and standard quality of lifting tool
usages.
6.Proper lubrication to the pulley.
7.Use of full body harness safety belt and fall
arrestor.
8.Periodic and pre-use checks of harness.
9.Life line for anchoring the safety belt.
10.Tool box talk & JSA -discuss about fall
protection.
11.Made Critical Lift Plan.
12.Ensure Heavy lift permits.
13.Informed to HO and Client about drum erection.
14.Check Crane condition its load chart and all
parts visually with erection Engineer and eye test
should be there of Crane and Hydra Operators.
15.Check whether and soil condition and power
should be off during its erection.
16.Check all welding of structure before drum
erection.
17.Don’t go inside the erection and barricading
area.

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42
 JOB SAFETY ANALYSIS
1.Fall of the object from
1.Serious injury.
Alignment of steam height.
2.Cut injury.
drum 2.Contact with sharp edges.
14 Erection of convection 1.Fall of the object from
bank module height.
2.Contact with sharp edges.
3.Failure of the lifting tools
and tackles.
4.Failure of safety belt.(if
damaged safety used).
42
18.Engage only skilled and qualified manpower.
19. Use tag / guide rope before its erection.
20.Don’t kept loose materials on Drum.
21.Don’t climb on drum without proper PPEs and
fall protection.
22. Ensure first Aid facility with competent male
Doctors
and emergency vehicles should be there at side
1.Give HSE training about do or don’t in this work.
2.Barricade the area and post safety sign
3.Use of right tool for right job.
4.Use of full body harness safety belt and fall
arrestor.
5.Ensure proper housekeeping before and after
work.
1.Property damage 1.Give HSE training about do or don’t in this work.
2.injury. 2.Barricade the area and post safety sign
3.serious Injury/fatality. 3.Training on-working at height, welding, gas
4.Fall of the person from cutting and use of PPE.
height. 4.Conduct safety inspection of all tools and lifting
tackles/machines before starting the job.(as per
factory act specification).
5.Ensure good and standard quality of lifting tool
usages.
6.Proper lubrication to the pulley.
7.Use of full body harness safety belt and fall
arrestor.
Page 15 of
 JOB SAFETY ANALYSIS
1.Exposure to welding
fumes.
2.Electric shock.
Alignment and
3.Fire
welding of convection
4.Projectiles,flash
bank module
5.Fall of material, tools,
person from height.
6.Failure of scaffolding.
15 Super heater Headers 1.Fall of the object from
Erection and height.
alignment 2.Contact with sharp edges.
3.Failure of the lifting tools
and tackles.
4.Failure of safety belt (if
damaged safety used).
42
8.Periodic and pre-use checks of harness.
9.Life line for anchoring the safety belt.
10.Tool box talk -discuss about fall protection.
1.Appropriate ventilation, Appropriate respirators.
2.Ensure good quality of cables; Proper earthing
arrangement.
3.Remove all combustible materials and fire
hazards from welding area; Keep ready fire
protective arrangement.
4.Ensure proper use of PPE.
1.Lung injury
5.Prepare SOP of welding work.
2Electrocution.
6.Safety talk-discuss abut working at height and
3.Fire,explosion
welding work.
4.Eye/Burn injury.
7.Use of full body harness safety belt and fall
5.Injury, fatality.
arrestor.
6.Injury, loss of property.
8.Periodic and pr-use checks of harness.
9.Life line for anchoring the safety belt.
10.Ensure proper housekeeping before and after
work.
11. Barricade the area and post safety sign.
12.Ensure good quality of scaffolding material
used.
1.Property damage 1.Give HSE training about do or don’t in this work.
2.injury. 2.Barricade the area and post safety sign.
3.serious Injury/fatality. 3.Training on-working at height, welding, gas
4.Fall of the person from cutting and use of PPE.
height. 4.Conduct safety inspection of all tools and lifting
tackles /machines before starting the job.(as per
factory act specification).
Page 16 of
 JOB SAFETY ANALYSIS

5.Ensure good and standard quality of lifting tool

usages.
6.Proper lubrication to the pulley.
7.Use of full body harness safety belt and fall
arrestor.
8.Periodic and pre-use checks of harness.
9.Life line for anchoring the safety belt.
10.Tool box talk -discuss about fall protection.
1.Give HSE training about do or don’t in this work.
2.Barricade the area and post safety sign.
3.Training on-working at height, welding, gas
cutting and use of PPE.
1.Fall of the object from 4.Conduct safety inspection of all tools and lifting
height. 1.Property damage tackles/machines before starting the job.(as per
Erection of pendent 2.Contact with sharp edges. 2.injury. factory act specification).
16 /primary SH coils 3.Failure of the lifting tools 3.serious Injury/fatality. 5.Ensure good and standard quality of lifting tool
erection and tackles. 4.Fall of the person from usages.
4.Failure of safety belt (if height. 6.Use of full body harness safety belt and fall
damaged safety used). arrestor.
7.Periodic and pre-use checks of harness.
8.Life line for anchoring the safety belt.
9.Tool box talk -discuss about fall protection.

Alignment and 1.Exposure to welding 1.Lung injury 1.Appropriate ventilation, Appropriate respirators.
welding of SH coils fumes. 2Electrocution. 2.Ensure good quality of cables; Proper earthing
2.Electric shock. 3.Fire,explosion arrangement.
3.Fire 4.Eye/Burn injury. 3.Remove all combustible materials and fire
4.Projectiles,flash 5.Injury, fatality. hazards from welding area; Keep ready fire

Page 17 of
42
 JOB SAFETY ANALYSIS
5.Fall of material, tools,
person from height.
6.Failure of scaffolding.
1.Fall of the object from
height.
2.Contact with sharp edges.
Erection of SH
17 3.Failure of the lifting tools
secondary coils
and tackles.
4.Failure of safety belt (if
damaged safety used).
42
protective arrangement.
4.Ensure proper use of PPE.
5.Give HSE training about do or don’t in this work.
6.Safety talk-discuss abut working at height and
welding work.
7.Use of full body harness safety belt and fall
arrestor.
6.Injury, loss of property.
8.Periodic and pre -use checks of harness.
9.Life line for anchoring the safety belt.
10.Ensure proper housekeeping before and after
work.
11. Barricade the area and post safety sign.
12.Ensure good quality of scaffolding material
used.
1.Give HSE training about do or don’t in this work.
2.Barricade the area and post safety sign.
3.Training on-working at height, welding, gas
cutting and use of PPE.
4.Conduct safety inspection of all tools and lifting
1.Property damage tackles/machines before starting the job.(as per
2.injury. factory act specification).
3.serious Injury/fatality. 5.Ensure good and standard quality of lifting tool
4.Fall of the person from usages.
height. 6.Proper lubrication to the pulley.
7.Use of full body harness safety belt and fall
arrestor.
8.Periodic and pre-use checks of harness.
9.Life line for anchoring the safety belt.
10.Tool box talk -discuss about fall protection.
Page 18 of
 JOB SAFETY ANALYSIS

1.Appropriate ventilation, Appropriate respirators.

2.Ensure good quality of cables; Proper earthing
arrangement.
3.Remove all combustible materials and fire
hazards from welding area; Keep ready fire
protective arrangement.
1.Exposure to welding
4.Ensure proper use of PPE.
fumes. 1.Lung injury
5.Give HSE training about do or don’t in this work.
2.Electric shock. 2Electrocution.
Alignment and 6.Safety talk-discuss abut working at height and
3.Fire 3.Fire,explosion
welding of SH welding work.
4.Projectiles,flash 4.Eye/Burn injury.
secondary coils 7.Use of full body harness safety belt and fall
5.Fall of material, tools, 5.Injury, fatality.
arrestor.
person from height. 6.Injury, loss of property.
8.Periodic and pr-use checks of harness.
6.Failure of scaffolding.
9.Life line for anchoring the safety belt.
10.Ensure proper housekeeping before and after
work.
11. Barricade the area and post safety sign.
12.Ensure good quality of scaffolding material
used.
18 Erection, Fit-up and 1.Fall of the object from 1.Property damage, injury. 1.Give HSE training about do or don’t in this work.
welding of height. 2.injury. 2.Tool box talk -discuss abut fall protection
attemparator header- 2.Contact with sharp edges. 3.serious Injury/fatality. 3.Barricade the area and post safety sign
connecting pipe 3.Failure of the lifting tools 4.Fall of the person from 4.Conduct safety inspection of all lifting tools and
and tackles. height. lifting tackles/machines before starting the job.(as
4.Failure of safety belt. 5.Lung injury per factory act specification).
5.Exposure to welding 6.Electrocution. 5.Ensure good and standard quality of lifting tool
fumes. 7.Fire,explosion usages.
6.Electric shock. 8.Eye/Burn injury. 6.Use of full body harness safety belt and fall
7.Fire 9.Injury, fatality. arrestor.

Page 19 of
42
 JOB SAFETY ANALYSIS

7.Periodic and pre-use checks of harness.

8.Welding: Appropriate ventilation.
9.Proper earthing.
10.Keep ready fire protective arrangement.
8.Projectiles,flash
11.Ensure proper use of PPE.
9.Fall of material, tools,
10.Injury, loss of 12.Prepare SOP of welding work.
person from height.
property. 13.Safety talk-discuss abut working at height and
10.Failure of scaffolding.
welding work.
14.Ensure proper housekeeping before and after
work.
15.Ensure good quality of scaffolding material
used.
1.Give HSE training about do or don’t in this
work..
1.Fall of the object from 2.Barricade the area and post safety sign.
height. 1.Property damage
3.Conduct safety inspection of all tools and lifting
Erection of supports 2.Contact with sharp edges. 2.injury.
tackles/machines before starting the job.(as per
of attemparator 3.Failure of the lifting tools 3.serious Injury/fatality.
header and tackles. 4.Fall of the person from factory act specification).
4.Failure of safety belt (if height. 4.Ensure good and standard quality of lifting tool
damaged safety used). usages.
5.Use of full body harness safety belt.
6.Tool box talk -discuss about fall protection.
19 Erection and fit-up of 1.Fall of the object from 1.Property damage 11.Give HSE training about do or don’t in this
steam supply pipes height. 2.injury. work.
2.Contact with sharp edges. 3.serious Injury/fatality. 2.Barricade the area and post safety sign.
3.Failure of the lifting tools 4.Fall of the person from 3.Conduct safety inspection of all tools and lifting
and tackles. height. tackles /machines before starting the job.(as per
4.Failure of safety belt (if factory act specification).
damaged safety used). 4.Ensure good and standard quality of lifting tool

Page 20 of
42
 JOB SAFETY ANALYSIS
1.Exposure to welding
fumes.
2.Electric shock.
Welding of sat. steam 3.Fire
supply pipes 4.Projectiles,flash
5.Fall of material, tools,
person from height.
6.Failure of scaffolding.
20 Erection of down 1.Fall of the object from
comers height.
2.Contact with sharp edges.
3.Failure of the lifting tools
and tackles.
4.Failure of safety belt (if
damaged safety used).
42
usages.
5.Use of full body harness safety belt.
6.Tool box talk -discuss about fall protection.
1.Appropriate ventilation, Appropriate respirators.
2.Ensure good quality of cables; Proper earthing
arrangement.
3.Remove all combustible materials and fire
hazards from welding area; Keep ready fire
protective arrangement.
4.Ensure proper use of PPE.
1.Lung injury
5.Prepare SOP of welding work.
2Electrocution.
6.Safety talk-discuss abut working at height and
3.Fire,explosion
welding work.
4.Eye/Burn injury.
7.Use of full body harness safety belt and fall
5.Injury, fatality.
arrestor.
6.Injury, loss of property.
8.Periodic and pr-use checks of harness.
9.Life line for anchoring the safety belt.
10.Ensure proper housekeeping before and after
work.
11. Barricade the area and post safety sign.
12.Ensure good quality of scaffolding material
used.
1.Property damage 1.Give HSE training about do or don’t in this work.
2.injury. 2.Barricade the area and post safety sign.
3.serious Injury/fatality. 3.Training on-working at height, welding, gas
4.Fall of the person from cutting and use of PPE.
height. 4.Conduct safety inspection of all tools and lifting
tackles/machines before starting the job.(as per
factory act specification).
Page 21 of
 JOB SAFETY ANALYSIS
1.Exposure to welding
fumes.
2.Electric shock.
Fit-up and welding of 3.Fire
down comers 4.Projectiles,flash
5.Fall of material, tools,
person from height.
6.Failure of scaffolding.
Erection and welding 1.Fall of the object from
of down comer's height.
support 2.Contact with sharp edges.
3.Failure of the lifting tools
and tackles.
4.Failure of safety belt.
5.Exposure to welding
fume.
6.Electric shock.
42
5.Ensure good and standard quality of lifting tool
usages.
6..Use of full body harness safety belt and fall
arrestor.
7.Periodic and pre-use checks of harness.
8.Tool box talk -discuss about fall protection.
1.Lung injury 1.Appropriate ventilation, Appropriate respirators.
2Electrocution. 2.Ensure good quality of cables; Proper earthing
3.Fire,explosion arrangement.
4.Eye/Burn injury. 3.Remove all combustible materials and fire
5.Injury, fatality. hazards from welding area; Keep ready fire
6.Injury, loss of property. protective arrangement.
4.Ensure proper use of PPE.
5.Prepare SOP of welding work.
6.Safety talk-discuss abut working at height and
welding work.
7.Use of full body harness safety belt and fall
arrestor.
8.Periodic and pr-use checks of harness.
9.Ensure good quality of scaffolding material used.
1.Property damage, injury. 1.Give HSE training about do or don’t in this work.
2.injury. 2.Tool box talk -discuss about material handling
3.serious Injury/fatality. safety.
4.Fall of the person from 3.Barricade the area and post safety sign
height. 4.Ensure good and standard quality of lifting tool
5.Lung injury usages.
6.Electrocution. 5.Use of full body harness safety belt and fall
7.Fire,explosion arrestor.
8.Eye/Burn injury. 6.Periodic and pre-use checks of harness.
Page 22 of
 JOB SAFETY ANALYSIS
7.Fire
8.Projectiles,flash
9.Injury, fatality.
9.Fall of material, tools,
10.Injury,
person from height.
property.
10.Failure of scaffolding.
1.Fall of the object from
height.
2.Contact with sharp edges.
Erection of In Bed
21 3.Failure of the lifting tools
Evaporator coils
and tackles.
4.Failure of safety belt (if
damaged safety used).
1.Fall of the material from
Alignment of In bed height.
evaporator coils 2.Contact with sharp edges.
22 Welding of In bed 1.Exposure to welding
evaporator coil fumes.
42
7.Welding: Appropriate ventilation.
8.Proper earthing.
9.Keep ready fire protective arrangement.
10.Ensure proper use of PPE.
11.Prepare SOP of welding work.
loss of 12.Ensure proper housekeeping before and after
work.
13.Ensure good quality of scaffolding material
used.
1.Give HSE training about do or don’t in this work.
2.Barricade the area and post safety sign.
1.Property damage 3.Conduct safety inspection of all tools and lifting
2.injury. tackles/machines before starting the job.(as per
3.serious Injury/fatality. factory act specification).
4.Fall of the person from 4.Ensure good and standard quality of lifting tool
height. usages.
5.Use of full body harness safety belt.
6.Tool box talk -discuss about fall protection.
1.Prepare SOP of Alignment of steam drum.
2.Barricade the area and post safety sign
1.Serious injury. 3.Use of right tool for right job.
2.Cut injury. 4.Use of full body harness safety belt and fall
arrestor.(if required)
5.Ensure proper housekeeping before and after
work.
1.Lung injury 1.Appropriate ventilation, Appropriate respirators.
2Electrocution. 2.Ensure good quality of cables; Proper earthing
Page 23 of
 JOB SAFETY ANALYSIS

arrangement.
3.Remove all combustible materials and fire
hazards from welding area; Keep ready fire
protective arrangement.
2.Electric shock. 4.Ensure proper use of PPE.
3.Fire 3.Fire,explosion 5.Prepare SOP of welding work of In bed
4.Projectiles,flash 4.Eye/Burn injury. evaporator coil header to header.
header to header
5.Fall of material, tools, 5.Injury, fatality. 6.Safety talk-discuss abut working at height and
person from height. welding work.
7.Use of full body harness safety belt and fall
arrestor.
8.Periodic and pr-use checks of harness.
9.Ensure proper housekeeping before and after
work..
Welding of RH panel 1.Exposure to welding 1.Lung injury 1.Appropriate ventilation, Appropriate respirators.
tube with header stub fumes. 2Electrocution. 2.Ensure good quality of cables; Proper earthing
2.Electric shock. 3.Fire,explosion arrangement.
3.Fire 4.Eye/Burn injury. 3.Remove all combustible materials and fire
4.Projectiles,flash 5.Injury, fatality. hazards from welding area; Keep ready fire
5.Fall of material, tools, protective arrangement.
person from height. 4.Ensure proper use of PPE.
5.Prepare SOP of welding work of RH Panel tube
with header stub.
6.Safety talk-discuss abut working at height and
welding work.
7.Use of full body harness safety belt and fall
arrestor.
8.Periodic and pr-use checks of harness.
9.Ensure proper housekeeping before and after

Page 24 of
42
 JOB SAFETY ANALYSIS
1.Exposure to welding
fumes.
2.Electric shock.
Welding of LH panel 3.Fire
tube with header stub 4.Projectiles,flash
5.Fall of material, tools,
person from height.
6.Failure of scaffolding.
23 Erection of In bed SH 1.Fall of the object from
height.
2.Contact with sharp edges.
3.Failure of the lifting tools
and tackles.
4.Failure of safety belt (if
42
work.
10. Barricade the area and post safety sign.
1.Appropriate ventilation, Appropriate respirators.
2.Ensure good quality of cables; Proper earthing
arrangement.
3.Remove all combustible materials and fire
hazards from welding area; Keep ready fire
protective arrangement.
4.Ensure proper use of PPE.
1.Lung injury
5.Prepare SOP of welding work of LH panel tube
2Electrocution.
with header stub.
3.Fire,explosion
6.Safety talk-discuss abut working at height and
4.Eye/Burn injury.
welding work.
5.Injury, fatality.
7.Use of full body harness safety belt and fall
6.Injury, loss of property.
arrestor.
8.Periodic and pr-use checks of harness.
9.Ensure proper housekeeping before and after
work.
10. Barricade the area and post safety sign.
11.Ensure good quality of scaffolding material
used.
1.Property damage 1.Give HSE training about do or don’t in this work.
2.injury. 2.Barricade the area and post safety sign.
3.serious Injury/fatality. 3.Conduct safety inspection of all tools and lifting
4.Fall of the person from tackles/machines before starting the job.(as per
height. factory act specification).
4.Ensure good and standard quality of lifting tool
Page 25 of
 JOB SAFETY ANALYSIS
damaged safety used).
1.Exposure to welding
fumes.
2.Electric shock.
Alignment and 3.Fire
welding of In bed SH 4.Projectiles,flash
5.Fall of material, tools,
person from height.
6.Failure of scaffolding.
24 Erection, fit-up and 1.Fall of the object from
welding of SH height.
interconnecting 2.Contact with sharp edges.
piping 3.Failure of the lifting tools
and tackles.
4.Failure of safety belt.
5.Exposure to welding
fumes.
6.Electric shock.
7.Fire
42
usages.
5.Use of full body harness safety belt.
6.Tool box talk -discuss about fall protection.
1.Appropriate ventilation, Appropriate respirators.
2.Ensure good quality of cables; Proper earthing
arrangement.
3.Remove all combustible materials and fire
hazards from welding area; Keep ready fire
1.Lung injury protective arrangement.
2Electrocution. 4.Ensure proper use of PPE.
3.Fire,explosion 5.Prepare SOP of welding work.
4.Eye/Burn injury. 6.Use of full body harness safety belt and fall
5.Injury, fatality. arrestor.
6.Injury, loss of property. 7.Periodic and pr-use checks of harness.
8.Ensure proper housekeeping before and after
work.
9. Barricade the area and post safety sign.
10.Ensure good quality of scaffolding material
used.
1.Property damage, injury. 1.Give HSE training about do or don’t in this work.
2.injury. 2.Tool box talk -discuss abut fall protection
3.serious Injury/fatality. 3.Barricade the area and post safety sign
4.Fall of the person from 4.Conduct safety inspection of all lifting tools and
height. lifting tackles /machines before starting the job.(as
5.Lung injury per factory act specification).
6.Electrocution. 5.Ensure good and standard quality of lifting tool
7.Fire,explosion usages.
8.Eye/Burn injury. 6.Use of full body harness safety belt and fall
9.Injury, fatality. arrestor.
Page 26 of
 JOB SAFETY ANALYSIS
8.Projectiles,flash
9.Fall of material, tools,
10.Injury,
person from height.
property.
10.Failure of scaffolding.
1.Fall of the object from
height.
Erection of SH 2.Contact with sharp edges.
interconnecting 3.Failure of the lifting tools
piping's support and tackles.
4.Failure of safety belt (if
damaged safety used).
25 Erection, fit-up and 1.Fall of the object from
welding of risers height.
2.Contact with sharp edges.
3.Failure of the lifting tools
and tackles.
4.Failure of safety belt.
5.Exposure to welding
42
7.Periodic and pre-use checks of harness.
8.Welding: Appropriate ventilation.
9.Proper earthing.
10.Keep ready fire protective arrangement.
11.Ensure proper use of PPE.
12.Prepare SOP of welding work of SH
loss of
interconnecting piping.
13.Safety talk-discuss abut working at height and
welding work.
14.Ensure proper housekeeping before and after
work.
15.Ensure good quality of scaffolding material
used.
1.Give HSE training about do or don’t in this work.
2.Barricade the area and post safety sign.
1.Property damage 3.Conduct safety inspection of all tools and lifting
2.injury. tackles/machines before starting the job.(as per
3.serious Injury/fatality. factory act specification).
4.Fall of the person from 4.Ensure good and standard quality of lifting tool
height. usages.
5.Use of full body harness safety belt.
6.Tool box talk -discuss about fall protection.
1.Property damage, injury. 1.Give HSE training about do or don’t in this work.
2.injury. 2.Tool box talk -discuss abut fall protection
3.serious Injury/fatality. 3.Barricade the area and post safety sign
4.Fall of the person from 4.Conduct safety inspection of all lifting tools and
height. lifting tackles/machines before starting the job.(as
5.Lung injury per factory act specification).
6.Electrocution. 5.Ensure good and standard quality of lifting tool
Page 27 of
 JOB SAFETY ANALYSIS

usages.
6.Use of full body harness safety belt and fall
arrestor.
7.Periodic and pre-use checks of harness.
fumes. 8.Welding: Appropriate ventilation.
6.Electric shock. 9.Proper earthing.
7.Fire,explosion
7.Fire 10.Keep ready fire protective arrangement.
8.Eye/Burn injury.
8.Projectiles,flash 11.Ensure proper use of PPE.
9.Injury, fatality.
9.Fall of material, tools, 12.Prepare SOP of welding work of risers.
10.Injury, loss of
person from height. 13.Ensure proper housekeeping before and after
property.
10.Failure of scaffolding. work.
14.Ensure good quality of scaffolding material
used.

1.Give HSE training about do or don’t in this work.

1.Property damage 2.Barricade the area and post safety sign.
2.injury. 3.Conduct safety inspection of all tools and lifting
Erection of riser's 3.serious Injury/fatality. tackles/machines before starting the job.(as per
support 4.Fall of the person from factory act specification).
height. 4.Ensure good and standard quality of lifting tool
5. Injury, loss of property.
usages.
5.Use of full body harness safety belt
26 Erection and 1.Fall of the object from 1.Property damage 1.Give HSE training about do or don’t in this work.
alignment of main height. 2.injury. 2.Barricade the area and post safety sign.
column assembly 2.Contact with sharp edges. 3.serious Injury/fatality. 3.Conduct safety inspection of all tools and lifting
(Economizer) 3.Failure of the lifting tools 4.Fall of the person from tackles/machines before starting the job.(as per
and tackles. height. factory act specification).

Page 28 of
42
 JOB SAFETY ANALYSIS

4.Ensure good and standard quality of lifting tool

4.Failure of safety belt (if
damaged safety used).
1.Fall of the object from
height.
Erection and
2.Contact with sharp edges.
alignment of main
3.Failure of the lifting tools
beam and platforms
and tackles.
beam
4.Failure of safety belt (if
damaged safety used).
1.Fall of the object from
height.
Erection and 2.Contact with sharp edges.
27 alignment of 3.Failure of the lifting tools
Economizer header and tackles.
4.Failure of safety belt (if
damaged safety used).
Erection of 1.Fall of the object from
Economizer coil height.
2.Contact with sharp edges.
3.Failure of the lifting tools
and tackles.
4.Failure of safety belt (if
damaged safety used).
usages.
5.Use of full body harness safety belt.
6.Tool box talk -discuss about fall protection.
1.Give HSE training about do or don’t in this work.
2.Barricade the area and post safety sign.
1.Property damage 3.Conduct safety inspection of all tools and lifting
2.injury. tackles/machines before starting the job.(as per
3.serious Injury/fatality. factory act specification).
4.Fall of the person from 4.Ensure good and standard quality of lifting tool
height. usages.
5.Use of full body harness safety belt.
6.Tool box talk -discuss about fall protection.
1.Give HSE training about do or don’t in this work.
2.Barricade the area and post safety sign.
1.Property damage 3.Conduct safety inspection of all tools and lifting
2.injury. tackles/machines before starting the job.(as per
3.serious Injury/fatality. factory act specification).
4.Fall of the person from 4.Ensure good and standard quality of lifting tool
height. usages.
5.Use of full body harness safety belt.
6.Tool box talk -discuss abut fall protection.
1.Property damage 1.Give HSE training about do or don’t in this work.
2.injury. 2.Barricade the area and post safety sign.
3.serious Injury/fatality. 3.Conduct safety inspection of all tools and lifting
4.Fall of the person from tackles/machines before starting the job.(as per
height. factory act specification).
5. Injury, loss of property. 4.Ensure good and standard quality of lifting tool
usages.

Page 29 of
42
 JOB SAFETY ANALYSIS
5. Failure of scaffolding.
1.Exposure to welding
fumes.
2.Electric shock.
Alignment and
3.Fire
welding of
4.Projectiles,flash
Economizer coil
5.Fall of material, tools,
person from height.
6.Failure of scaffolding.
28 Erection, fit-up and 1.Fall of the object from
welding of Integral height.
piping 2.Contact with sharp edges.
3.Failure of the lifting tools
and tackles.
4.Failure of safety belt.
5.Exposure to welding
fumes.
6.Electric shock.
42
5.Use of full body harness safety belt.
6.Tool box talk -discuss about fall protection.
7. Ensure good quality of scaffolding material used.
1.Appropriate ventilation, Appropriate respirators.
2.Ensure good quality of cables; Proper earthing
arrangement.
3.Remove all combustible materials and fire
hazards from welding area; Keep ready fire
protective arrangement.
1.Lung injury
4.Ensure proper use of PPE.
2Electrocution.
5.Prepare SOP of alignment and welding work of
3.Fire,explosion
economizer coil (loose).
4.Eye/Burn injury.
6.Use of full body harness safety belt and fall
5.Injury, fatality.
arrestor.
6.Injury, loss of property.
7.Periodic and pr-use checks of harness.
8.Ensure proper housekeeping before and after
work.
9. Barricade the area and post safety sign.
10.Ensure good quality of scaffolding material
used.
1.Property damage, injury. 1.Give HSE training about do or don’t in this work.
2.injury. 2.Tool box talk -discuss abut fall protection
3.serious Injury/fatality. 3.Barricade the area and post safety sign
4.Fall of the person from 4.Conduct safety inspection of all lifting tools and
height. lifting tackles/machines before starting the job.(as
5.Lung injury per factory act specification).
6.Electrocution. 5.Ensure good and standard quality of lifting tool
7.Fire,explosion usages.
8.Eye/Burn injury. 6.Use of full body harness safety belt and fall
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 JOB SAFETY ANALYSIS

7.Fire
8.Projectiles,flash
9.Injury, fatality.
9.Fall of material, tools,
10.Injury,
person from height.
property.
10.Failure of scaffolding.
29 Erection and welding 1.Fall of the object from
of Motorized & safety height.
valves 2.Contact with sharp edges.
3.Failure of the lifting tools
and tackles.
4.Failure of safety belt.
5.Exposure to welding
fumes.
6.Electric shock.
7.Fire
8.Projectiles,flash
9.Fall of material, tools,
person from height.
10.Failure of scaffolding.
arrestor.
7.Periodic and pre-use checks of harness.
8.Welding: Appropriate ventilation.
9.Proper earthing.
10.Keep ready fire protective arrangement.
11.Ensure proper use of PPE.
loss of 12.Prepare SOP of welding work of Integral piping.
13.Safety talk-discuss abut working at height and
welding work.
14.Ensure proper housekeeping before and after
work.
15.Ensure good quality of scaffolding material
used.
1.Property damage, injury. 1.Give HSE training about do or don’t in this
2.injury. work..
3.serious Injury/fatality. 2.Tool box talk -discuss abut fall protection
4.Fall of the person from 3.Barricade the area and post safety sign
height. 4.Conduct safety inspection of all lifting tools and
5.Lung injury lifting tackles/machines before starting the job.(as
6.Electrocution. per factory act specification).
7.Fire,explosion 5.Ensure good and standard quality of lifting tool
8.Eye/Burn injury. usages.
9.Injury, fatality. 6.Use of full body harness safety belt and fall
10.Injury, loss of arrestor.
property. 7.Periodic and pre-use checks of harness.
8.Welding: Appropriate ventilation.
9.Proper earthing.
10.Keep ready fire protective arrangement.
11.Ensure proper use of PPE.

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 JOB SAFETY ANALYSIS

12.Prepare SOP of welding work of motorized and

safety valves.
13.Safety talk-discuss abut working at height and
welding work.
14.Ensure proper housekeeping before and after
work.
15.Ensure good quality of scaffolding material
used.
30 Erection and welding 1.Fall of the object from 1.Property damage, injury. 1.Give HSE training about do or don’t in this work.
of Process valves height. 2.injury. 2.Tool box talk -discuss abut fall protection
2.Contact with sharp edges. 3.serious Injury/fatality. 3.Barricade the area and post safety sign
3.Failure of the lifting tools 4.Fall of the person from 4.Conduct safety inspection of all lifting tools and
and tackles. height. lifting tackles /machines before starting the job.(as
4.Failure of safety belt. 5.Lung injury per factory act specification).
5.Exposure to welding 6.Electrocution. 5.Ensure good and standard quality of lifting tool
fumes. 7.Fire,explosion usages.
6.Electric shock. 8.Eye/Burn injury. 6.Use of full body harness safety belt and fall
7.Fire 9.Injury, fatality. arrestor.
8.Projectiles,flash 10.Injury, loss of 7.Periodic and pre-use checks of harness.
9.Fall of material, tools, property. 8.Welding: Appropriate ventilation.
person from height. 9.Proper earthing.
10.Failure of scaffolding. 10.Keep ready fire protective arrangement.
11.Ensure proper use of PPE.
12.Prepare SOP of welding work process valves.
13.Safety talk-discuss abut working at height and
welding work.
14.Ensure proper housekeeping before and after
work.
15.Ensure good quality of scaffolding material

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 JOB SAFETY ANALYSIS
1.Fall of the object from
height.
Air Preheated (APH)- 2.Contact with sharp edges.
31 Tube sheet insertion
3.Fall of material, tools,
and expansion
from height.
4.Failure of scaffolding.
1.Fall of the object from
height.
2.Contact with sharp edges.
Fit -up of APH casing
3.Fall of material, tools,
from height.
4.Failure of scaffolding.
32 Erection & welding of 1.Fall of the object from
staircase and ladders, height.
grills and hand railing 2.Contact with sharp edges.
3.Failure of the lifting tools
and tackles.
4.Failure of safety belt.
5.Exposure to welding
fumes.
6.Electric shock.
7.Fire
8.Projectiles, flash
42
used.
1.Give HSE training about do or don’t in this work.
2.Tool box talk -discuss abut fall protection
1.Property damage, injury.
3.Barricade the area and post safety sign
2.injury.
4.Ensure good and standard quality of lifting tool
3.serious Injury/fatality.
usages.
4.Fall of the person,
5.Ensure proper use of PPE.
material from height.
6.Ensure proper housekeeping before and after
work.
7.Ensure good quality of scaffolding material used.
1.Give HSE training about do or don’t in this work.
1.Property damage, injury. 2.Tool box talk -discuss abut fall protection
2.injury. 3.Ensure good and standard quality of lifting tool
3.serious Injury/fatality. usages.
4.Fall of the person, 4.Ensure proper use of PPE.
material from height. 5.Ensure proper housekeeping before and after
work.
6.Ensure good quality of scaffolding material used.
1.Property damage, injury. 1.Give HSE training about do or don’t in this work.
2.injury. 2.Tool box talk / JSA -discuss abut welding,
3.serious Injury/fatality. material handling safety and fall protection
4.Fall of the person from 3.Barricade the area and post safety sign
height. 4.Ensure good and standard quality of lifting tool
5.Lung injury usages.
6.Electrocution. 5.Use of full body harness safety belt and fall
7.Fire,explosion arrestor.
8.Eye/Burn injury. 6.Periodic and pre-use checks of harness.
9.Injury, fatality. 7.Welding: Appropriate ventilation.
8.Proper earthing.
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 JOB SAFETY ANALYSIS

9.Keep ready fire protective arrangement.

9.Fall of material, tools,
10.Ensure proper use of PPE.
person from height.
11.Enure proper housekeeping before and after
work.
1.Give HSE training about do or don’t in this work.
2.Tool box talk / JSA -discuss abut welding,
material handling safety and fall protection
3.Barricade the area and post safety sign
4.Ensure good and standard quality of lifting tool
1.Fall of the object from
1.Property damage, injury. usages.
height.
Erection of Bunker 2.Contact with sharp edges. 2.injury. 5.Use of full body harness safety belt and fall
column and Bunker 3.serious Injury/fatality. arrestor.
33 3.Fall of material, tools,
Plates 4.Fall of the person from 6.Periodic and pre-use checks of harness.
from height.
height 7.Welding: Appropriate ventilation.
4. Failing of lifting tools
5.Injury, fatality 8.Proper earthing.
and tackles
9.Keep ready fire protective arrangement.
10.Ensure proper use of PPE.
11.Enure proper housekeeping before and after
work

34 Erection of Bunker 1.Fall of the object from
platform beam and height.
chequer plats 2.Contact with sharp edges.
3.Fall of material, tools,
from height.
4. Failing of lifting tools
and tackles
1.Property damage, injury. 1.Give HSE training about do or don’t in this work.
2.injury. 2.Tool box talk / JSA -discuss abut welding,
3.serious Injury/fatality. material handling safety and fall protection
4.Fall of the person from 3.Barricade the area and post safety sign
height 4.Ensure good and standard quality of lifting tool
5.Injury, fatality usages.
5.Use of full body harness safety belt and fall
arrestor.
6.Periodic and pre-use checks of harness.

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 JOB SAFETY ANALYSIS

7.Welding: Appropriate ventilation.

8.Proper earthing.
9.Keep ready fire protective arrangement.
10.Ensure proper use of PPE.
11.Enure proper housekeeping before and after
work

1.Give HSE training about do or don’t in this work.

2.Tool box talk / JSA -discuss abut welding,
material handling safety and fall protection
1.Property damage, injury.
3.Barricade the area and post safety sign
2.injury.
4.Ensure good and standard quality of lifting tool
1.Fall of the object from 3.serious Injury/fatality.
usages.
height. 4.Fall of the person from
Erection of Bunker 5.Use of full body harness safety belt and fall
2.Contact with sharp edges. height.
platform beam and arrestor.
3.Fall of material, tools, 5.Lung injury
chequer plats 6.Periodic and pre-use checks of harness.
from height. 6.Electrocution.
7.Welding: Appropriate ventilation.
4. Failing of lifting tools 7.Fire,explosion
8.Proper earthing.
and tackles 8.Eye/Burn injury.
9.Keep ready fire protective arrangement.
9.Injury, fatality.
10.Ensure proper use of PPE.
11.Enure proper housekeeping before and after
work
12.Use of catch net
35 Erection of Bunker 1.Fall of the object from 1.Property damage, injury. 1.Give HSE training about do or don’t in this work.
hoppers height. 2.injury. 2.Tool box talk / JSA -discuss abut welding,
2.Contact with sharp edges. 3.serious Injury/fatality. material handling safety and fall protection
3.Fall of material, tools, 4.Fall of the person from 3.Barricade the area and post safety sign
from height. height. 4.Ensure good and standard quality of lifting tool
4. Failing of lifting tools 5.Lung injury usages.

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 JOB SAFETY ANALYSIS

5.Use of full body harness safety belt and fall

arrestor.
6.Electrocution. 6.Periodic and pre-use checks of harness.
7.Fire,explosion 7.Welding: Appropriate ventilation.
and tackles 8.Eye/Burn injury. 8.Proper earthing.
9.Injury, fatality. 9.Keep ready fire protective arrangement.
10.Ensure proper use of PPE.
11.Enure proper housekeeping before and after
work
36 1.Foreign particles entering 1.Eye injury 1.Give HSE training about do or don’t in this work.
Gas Cutting in eye 2.Ensure proper use of PPE.
Operation 2.Leak from the cylinder 2.fire, explosion. 3.Check all connections and joints for leak.
valve, at cylinders fusible 4.Never use matches for lighting torches.
plug etc. 3.Fire, explosion. 5.Ensure the use of flashback arrestor both side in
3.Flash back and Back fire 4.Fire, Explosion. cylinders and in cutting sets also.
4.Fire, Explosion. 6.Never use acetylene at pressure above 15 psi.
7.Never use lubricants on oxygen-DA equipment.
8.Cuduct Tool box talk / JSA before start the hot
work at site.
9.Keep ready fire protective arrangement.
10.Ensure proper housekeeping before and after
work.
11. Ensure metal ring of gas cylinders that shows
expiry date of Cylinders.
12. Use hoses and cylinders as per its colour
coding.
13. Don’t use LPG domestic in plant.
14. Ensure proper handling of Gas Cylinders.
15. Ensure leak test of Gas Cylinders by soap

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 JOB SAFETY ANALYSIS

solution before start the job.

12. Cover all using Gas cylinders by wet gunny
beg.
15. Kept near Co2 fire Extinguishers and sand
fillup buckets and water fillup berrles also.
16. During height work Use equal size hose.
17.Ensure all equipment’s of cutting set should be
ISI standard.
1.Give HSE training about do or don’t in this work.
2.Observance of safe distance.
3.Follow the works permit system before start the
work.
4.Tool box talk- discuss about NDE testing safety.
1.Radiation cataract 5.Barricade the area and post safety sign.
1.Occupational cataract
2.Skin cancer 6.Ensure use of proper PPE and film badges, survey
2.Affects on Skin
3.Affects on reproductive meter issued by BARC.
NDE Testing of IBR 3.Affects on Reproductive
37 system 7.Restrict the entry of unauthorized persons.
and Non IBR parts system
4.Affect on health of the 8.Proper shielding of radioisotopes by lead,
4.Radio isotopes.
human being concrete, and lead line concrete block, lead steel
5.Radioactive waste
combinations.
9.Use of lead shielded aprons. Film badge provided
to individual for dose.
10.Surveys and monitoring.
11.Radiography waste-Destroy properly mostly in
sea
38 Insulation of boiler 1.Dust 1. Lung disease 1.Give HSE training about do or don’t in this work.
parts 2.Fire 2.fire 2.Ensure proper use of PPEs.
3.Trip 3. Fall of the material 3.Tool box talk- discuss abut safety in insulation
from height. work.

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 JOB SAFETY ANALYSIS

4.Barricade the area and post safety sign.

5.Ensure good and standard quality of lifting tool
usages.
6. Ensure proper housekeeping before and after
work.
Make proper scaffolding.
7.Use proper lifting tools Tackles for its erection.
8.Ensure proper storage and made rain protection of
it.
1.Give HSE training about do or don’t in this work.
2.Ensure proper use of PPE.
3.Tool box talk- discuss abut safety in refractory
1.Dust 1. Lung disease
work.
2.Fire 2.fire
39 Refractory
3.Trip 3. Fall of the material 4.Barricade the area and post safety sign.
5.Ensure good and standard quality of lifting tool
from height.
usages.
6.Ensure proper housekeeping before and after
work.
40 Painting & Keroshine 1.Standing position for 1.Fatigue 1.Give HSE training about do or don’t in this work.
for welding inspection prolong time. 2.Eye injury, 2.Ensure proper use of PPE.
2.Contact with Toxic co 3.Skin disease. 3.Tool box talk- discuss abut safety in refractory
louring agents. 4.Fire work.
3.Dermatitis 5.Explosion 4.Barricade the area and post safety sign.
4.Fire 5.Ensure good and standard quality of lifting tool
usages.
6.Ensure proper housekeeping before and after
work.
7. Prepare MSDS for Inflammable materials.

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 JOB SAFETY ANALYSIS

1Give HSE training about do or don’t in this work.

2.Ensure proper use of PPEs.
3.Ensure proper venting and water filling
arrangement.
Hydrostatic test of 1. Personal injury. 4.Ensure use of calibrated pressure gauge.
Boiler pressure parts 1.Pipe, tube rupture. 2. Fatal 5.Barricade whole area.
41
and IBR and non IBR 2.Excess pressure for water 3. Property damage. 6.During air blasting don’t go front side pressure.
Parts 7.Don’t wash or clean your body part by air.
6.Tool box talk -discuss about fall protection.
7. Ensure good quality of pressure gauges.
8. Stop power in Boiler during hydro Test if may
possible.
1.Ensure that the fuses from the incoming panel and
put Boards of “MENS AT WORK, Do NOT
SWITCH ON”.
1.Improper lock out while 2.For Cable termination the sequence shall be
working with electrical live followed from the main equipment’s to supply
power supply during point’s e.g. MCC/ ACP to TRCC to TR set. First
installation / sequence of 1.Personal injury. set cable termination to be done followed by
cable termination 2. Fatal termination at TRCC and than MCC /ACP.
42 Electrical Installation
2. Improper way of cables 3. Property damage. 3.While pulling the cable vertically upwards,
pulling sufficient manpower to be deployed at various
3.Unsafe way of cable joints elevation with suitable PPEs.
(hand 4.Proper / suitable arrangement to be ensured for
lamps/Tools/Earthing) pulling / dropping the cables.
5.Cables extortion boards to be used.
6. Proper earthing to be provided for all electrical
appliances being used at site.

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 JOB SAFETY ANALYSIS

1.The work group / Supervisors should be briefed

1.Accidents due to lack of
knowledge of equipment’s
& poor communication /
inadequate work procedure
and wrong erection
43 Ground Assembly sequence.
2.Fetal accidents
permanent disability.
3.Inadequate facility to
reach at higher elevation,
resulting into fetal accident
on the equipment’s knowledge.
2.For effective communication arrange meeting for
allocating responsibilities before commencing the
work.
3. For the sequence of mechanical installation.
4. Always responsible and authorize person must be
available out side the Boilers while workmen are
working inside the Boilers / parts.
. 1.Personal injury. 1.Use of PPEs i.e. Safety belt full body harness
2. Fatal with double life line and shock observer, helmets,
3. Property damage. Safety Shoes, Gloves, Goggles etc.
/
2.Provision of proper scaffolding and ladder
arrangement for working people at higher elevation.
1.Provide proper ladders to have approach to
Boilers Columns / girders after erection. Use of fall
arrester for the working men at height.
2.Provide the lugs / supports on upper end of
materials being erected, so that workmen can hook
the safety harness while doing the work at high
elevation.

44 Pre Commissioning 1.Serious accidents due to 1.Fetal accidents 1.Proper work permit must be obtained ensuring
and commissioning inhalation of dust inside the 2.Heavy lose to property. power logout / men on work at panels, before
activities boiler furnace and drums Fetal Accidents entering in to confined spaces.
(confined spaces) during 2.Use of PPEs must be ensured before entering
Boiler GD test. insdie the confined spaces.
2.Hazards associated with 3.Before entering inside the confined spaces ensure
electrical instrumentation, that there is no dust passing through Boiilers. This

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 JOB SAFETY ANALYSIS

mechanical works i.e. entry
in confined spaces (narrow
are inside the Boilers) non-
availability of inter locking
system & improper
communication for the work
activity.
3.Serious accident due to
poor illumination inside the
confined spaces.
4.Chanches of explosions
inside the confined Spaces
i.e. due to CO accumulation
inside the confined spaces
carry over of un-controlled
un burned inside the
confined spaces. Improper
sequence of plant start up or
shut down – all resulting
into Boilers internal
damages Boilers parts
damages / fetal accidents /
heavy loses to property.
running the Fans.till stack is clean visually before
entering inside the confined spaces of BOILERS.
4.Proper communication tools must be used while
conduction GD test.
5.Always responsible authorized person must be
available near, outside Boilers confined spaces
while conduction GD test.
Proper work permits.
6.Sufficient illumination 24V / 100W lamps are to
be provided. Minimum two lamps must be provide
per group out of this one must be used as stand by.
7.Install Co analyzer.
8. Arrest false air leakage inside the Boilers
confined spaces.

For Thermax Limited

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 JOB SAFETY ANALYSIS

k.k.vishwakarma
safety coordinator

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