GUJARAT REFINERY

JOB SAFETY ANALYSIS

JSA No.: OCCPL/HSE-IOCL/1059/JSA/66  Date:12.03.2019
Unit: BS-IV Area Location: VGO -HDT
:
Job Title: ANALYSIS PERFORMED BY:  
Confined Space Entry & Internal Work with Catalyst Loading in Reactor Name: Designation
(R02,R01) 1. Mr. Ajay Kumar RCM (OCCPL)
Job to be Executed By :
Department Client/PMC / Contractor 2. Mr. Mr. Syeed Ali Eng. (OCCPL)
PROJECT M/s IOCL/TKIS/OCCPL
3. Mr. Pankaj Kumar Kushwaha HSE(OCCPL)

4. Mr. K. Layek ACM (tkIS)

5. Mr. Kuldeep Sharma RCM (tkIS)

6. Mr. Vijay Swamy HSE (tkIS)

7. Mr. D P Dongre PJM-IOCL

8. S Margabandhu PNM-IOCL

9. N Venkatesh SPNM-IOCL

10. P. Diwakar SPNM-IOCL

 JSA Reviewed By : 1- Mr. Y. M. Parmar (DGM-Project)

2- Mr. A.K. Roy (DGM-PN)

Page 1 of 7
Sl. No. Activities Hazards Recommended action/ Procedures
Remarks
1 Entry in confined space Poor Communication TBT shall be conducted for all work forces about the hazard associated
and controlled measure prior to start the activity.
Ensure that employees are familiar with safety precautions and
procedures associated with confined space signage must be displayed.
Display warning board regarding restriction of unauthorized entrance
and Confined Space
Make sure all workforces are trained about the confined space entry
system.
Attendant must be fully aware for response and communication while
emergency.
2 Hoisting/ lowering Fall of person/ Fall of materials Air/pneumatic hoist shall be used for lowering and hoisting man inside
man and materials the confined space
inside Retractable block arrestor shall also be used for ascending and
descending.
Inspected full body harness is to be wear in safe manner.
Extended ladder shall be used apart from air hoist and block arrestor.
While lowering and lifting materials no one work/ stand underneath the
suspended load inside.
Materials shall be lower and lift by using gin/rope pulley.
3 Man Entry in confined Unauthorized entry may result into Obtain confined space entry permit
space casualty/ Health Hazard Maintain log book for the persons entering & exit
Display warning board regarding restriction of unauthorized entrance
Standby person must be available at the entrance point with whistle /
radio.
Make sure all workforces are trained about the confined space entry
system.
Provision of adequate access and egress
Check oxygen level prior to entry and periodically in confined space and
maintain the record as per confined space permit requirement.
Clear / make the confined space free from toxic,
hydrocarbons and other flammable gases prior to entry of people.
Working in confined Asphyxiation , suffocation or shortness of All connected piping’s are to be blinded.
4 space ( Tray removal breath, Death due to oxygen deficiency Medically fit workforces are only allowed to work inside the confined
and reinstallation) space.

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 Make necessary arrangements for ventilation system for clear breathing
air circulation
Proper aeration inside of the reactor to be ensured, if possible associate
flanges are to be kept open for aeration
If required air supply to be given through hose. Ensure that it must not
be Nitrogen
Always keep all escape routes clear of all obstruction.
“Job in Progress inside the reactor” tag/display board is to be
provided at man entry points.
Gas testing for LEL/H2S/O2 is to be done before man entry and
record to be maintained. It is to be allowed if gases are within the
limit. Provide adequate fume extractors / blowers/dehumidifier to
throughout contaminated gases. Ensure availability of gas detector
on location

Slip/trip/fall Proper ladder with tightened end to be used for entry /exit to the
column
Sufficient number of 24V bulbs to be provided from different
supply sources for ensuring there is no darkness inside during man
entry.
General healthiness of the working person to be ensured
Exposure of Toxic Ensure that no pyrophoric material inside the column. If pyrophoric
material present is too wetted with water and removed from
inside.
Keep the removed pyrophoric material wet till dumping under soil.
Gas test for LEL, H2S and O2 to be done before man entry.
Man entry only to be allotted if gases are within permissible limit.
Electric shock Only 24V bulb inside the reactor to be allowed.
Ensure that there is no cable joint inside reactor.
5 Scaffolding material Fall, slip and trip may result in to Stack the material in safe location properly to avoid sliding and
shifting & Erection/ casualty hindering passages.
Working at height Use full body harness and proper PPE to be ensured.
Use base plates in all corners of the scaffold pipe.
Use aluminum ladder which is properly fixed using clamp

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6 Hot job inside the vessel
7 Catalyst Loading/tray
installation.
pyrophoric fire
Fire Hazard/Burn Injury
Failure of crane/ toppling
Page 4 of 7
Use only certified scaffolding for working at height work.
Ensure no pyrophoric material inside the reactor.
Hot job permit/ clearance system to be followed.
OWS funnels /manholes/open channels of surrounding area to be
properly covered / sealed.
OWS vents to be sealed of nearby location.
A running water hose / fire extinguisher to be kept outside the
man hole.
Ensure fire watcher to be available near hot job.
Reactor must be jointly inspected by PN and Execution before
starting of hot job.
Minimum number of persons to be allowed inside the reactor
during the hot job.
All the hot job, first time to be started in presence of Production
personnel.
First time, torch to be lightened inside of the reactor standing
outside of the manhole by extending torch after checking LEL and
finding it within permissible limit.
Execution persons who are executing the hot job must come
outside the reactor at a regular interval so that he does not feel
fatigue and get exhausted.
After reactor confined space Entry, Gas test must be carried out
Every 2 Hours Interval and two stand by Person must always be
available at Entry man-way.
Welding cable and gas pipes should be in good physical condition.
Only one execution agency is to be given clearance for job inside
the reactor /confined space.
In case of any unforeseen event job is to be stopped and Reactor is
to be evacuated immediately SAFELY.
Welding machine and gas cylinders to be kept outside reactor
Ensure proper vehicle entry permit in place.
Crane shall be rest only on rigid surface and MS plate shall be used
underneath the out riggers
Lifting shall be perform in safe radius and in capacity.

Failure of lifting Tools & Tackles.
Uncontrolled movement/ Hitting
Fall of Hopper/Catalyst Drum
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Lifting area shall be barricaded and workmen movement shall be
restricted underneath the load.
All lifting tools & tackles shall be inspected and certified by
authorized person.
Prior to use all tools and tackle shall be physically inspected
No tools and tackles shall be overloaded.
Edge protection shall be provided wherever required with Sharpe
edge
Tag line shall be used to control the movement.
While lifting over existing facility like piping, equipment and
structure shall be protected.
For transporting catalyst drum by using hydra with flag man only
Loading hoper shall be properly installed and secured form tilting
while loading.
Ensure signaler to guide the hopper movement /loading activity
Catalyst Drum shall be safely lift and unload in hopper.
Unwanted and empty drum shall be removed from work location.
Name: Designation Signature
1. Mr. Ajay Kumar RCM (OCCPL)

2. Mr. Mr. Syeed Ali Eng. (OCCPL)

3. Mr. Pankaj Kumar Kushwaha HSE(OCCPL)

4. Mr. K. Layek ACM (tkIS)

5. Mr. Kuldeep Sharma RCM (tkIS)

6. Mr. Vijay Swamy HSE (tkIS)

7. Mr. D P Dongre PJM-IOCL

8. S Margabandhu PNM-IOCL

9. N Venkatesh SPNM-IOCL

10. P. Diwakar SPNM-IOCL

PART-B : Compliance Audit by JSA Team Members while the Job is being executed :

Sl. No. Recommended Actions / Checked By

Procedures & Control Measures Observations Compliance Status Name of Officer with Sign. date & time

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