GEA PROCESS ENGINEERING Date-06/03/2023

Project Name - ESP erection & commissioning Document No:- HIL/JSA/EHS-010

Activity- Cutting area Dismantling/removing of Insulation at

Rev-0
cutting marked area casing,cone and Roof

JOB SAFETY ANALYSIS

Location of Work : Smelter -1 ,ESP JSA No- 10
Sr. Sub Activities / Tasks Hazards Impact in case of Risk Control measures (There can be multiple control Responsibility
No. exposure measure for one hazard)
1 Work start-up Un authorized work Physical Injury Must be followed HIL permit system site engineer
preparation & obtaining Invalid permit emergency plan must be prepared before work start and Supervisor
work permit Lack of competency Property damage Supervisor must insure that all work activities are
Poor communication carried out by competent person
Hast or shortcuts worker stuck at work Conduct tool box talk meeting
un aware with plant emergency place in case of proper illumination in night shift work
gas expouser emergency Review the method
low illumination at night work Responsible person will conduct inspection
Consider all potential hazards: weather, wet or
slippery conditions, overhead hazards, proximity to
trails and/or visitor traffic patterns/volume, slope,
loose footing, elevation, fatigue, hazardous insects or
plants, etc.
tbt coducted regarding plant emergency

2 shifting of tools Toppling or Falling of material Physical Injury Only competent and approved operator shall be Rigger and Site
&materials from storage Mechanical failure of lifting tools Property damage deployed for equipment operations. engineer and
area to esp area by and tackles pinch point Equipment to be tested and certified by competent Supervisor
hydra or manually. Improper lifting Procedure person before deployment.
using of defective equipment ( No overloading allowed.
Tools and Tackles ) Follow procedures.
Over loading. Training and assistance of Banks man / Rigger
traffic accident Must be followed HILPermit
approved lifting plan must for crane / hydra lifting
All equipment must be third party certified.
Operators should be certified and valid license holder
Equipment to be inspected daily and all defects
reported

3 reached the job location Un trained workmen Physical Injury Must be followed HIL work at hight procedure Site engineer
at elevated working improper communication Property damage only work at hight pass trained worker perform job and Supervisor
platform via scaffold medically unfit fall of person medically fit person shall be allowed fot hight work
platform or esp stair damage grating platform fall of materilas only certified & green tag scaffold shall be used hse person
non certified scaffold pinch point use full body safety harness with 100% tie off
access not clear fatal scaffold inspection shall be done before work start
hand engage with materilas ergonomical injury tbt shall be conducted regarding hight work before
when going on platform dehydration work started
slippary platform lungs desease must be followed three point contact when use ladder
dust electrocution access must be free from obstucle
heat strokes use only HIL certified tools and equipments
damage electrical cables use lifting bag for material shifting at hight
emergency proper illumination at night work
ppe's violation
low illumination at night
slip and trip

4 Cutting and removing of Dust expouser Incident/injury Must be followed HIL insulation material handling site engineer
insulation Fall from hight fatal accident procedure. and Supervisor
fall of materials injury due to falling Must be followed HIL hight work procedure
insulation wool contact with materials Tbt shall be conducted before work start. hse person
skin lungs desease Use dust mask when handling insulation materials.
ergonomics hazards cut injury Lagging material shall be covered by plastic.
Sharp edges dehydration Working area shall be barricade.
high wind speed skin desease use full body safety harness with 100% tie off.
heat dont use damage tools.
incomplete scaffold use certified scaffold
use lifting bag for shifting tools
only hight pass trained worker shall work.
dismental insulation waste materials store in plastic
bag.
housekeeping must be maintain

5 Remove and disposed fall of person personal injury Must be followed HIL hot work procedure Site engineer/
waste insulation fall of materials fatal accident Work area should be barricated and sigage posted. Supervisor/site
materials from platform slip and trip property damages only trained and competent person only allowed hse
by the help of collapse of scaffold lungs desaese use dust mask ringing team
basket/lifting bag & damage grating platform skin and eye irritation use job specific ppe's operator
mobile crane improper lifting procedure dehydration waste insulation material shall be disposed as per HIL
damage tools & tackles air and soil pollution guidlines.
incompetent person use only 75% of swl of crane capacity
hot weather waste insulation material shall be packed in plastic
high wind bag and sealed.
dust expouser during transport waste insulation material must be
disposed at un designated place tied off
use full body safety harness eith 100 % tie off.
use inspected & certified lift basket
use two tag line rope for control basket
lifting and working area shall be barricade and signage
posted.
maintain good housekeeping.

6 Housekeeping and Personal injury Incident / Injury Must be used dust mask Site Supervisor
material removal after Slip and trip Property Damage. Followed material handling technique
job complete. Dust exposure Proper communication
ergonomic Housekeeping awareness program to all employee

Prepared & Analysis by :- Danish (HSE),s.mujmdar(site incharge), Approved By-

P.chinnamaharaja(senior eng),
Anoop(Global site incharge)
GEA PROCESS ENGINEERING Date-06/03/2023

Project Name - ESP erection & commissioning Document No:- HIL/JSA/EHS-011

Activity- Dismantling of seal air heater, transformer,hot roof Rev-0

JOB SAFETY ANALYSIS

Location of Work : Smelter -1 ,ESP
JSA No- 11

Sr. Sub Activities / Tasks Hazards Impact in case of Risk Control measures (There can be multiple control Responsibility
No. exposure measure for one hazard)
1 Work start-up Un authorized work Physical Injury Must be followed HIL permit system site engineer
preparation & obtaining Invalid permit Property damage emergency plan must be prepared before work start and Supervisor
work permit Lack of competency worker stuck at work Supervisor must insure that all work activities are hse person
Poor communication place in case of carried out by competent person
Hast or shortcuts emergency Conduct tool box talk meeting
un aware with plant emergency proper illumination in night shift work
gas expouser Review the method
low illumination at night work Responsible person will conduct inspection
Consider all potential hazards: weather, wet or
slippery conditions, overhead hazards, proximity to
trails and/or visitor traffic patterns/volume, slope,
loose footing, elevation, fatigue, hazardous insects or
plants, etc.
tbt coducted regarding plant emergency
shall be prepared work at hight emergency plan before
work start

2 shifting of tools Toppling or Falling of material Physical Injury Only competent and approved operator shall be Rigger and Site
&materials from storage Mechanical failure of lifting tools Property damage deployed for equipment operations. engineer and
area to esp area by and tackles pinch point Equipment to be tested and certified by competent Supervisor
hydra or manually. Improper lifting Procedure person before deployment.
using of defective equipment ( No overloading allowed.
Tools and Tackles ) Follow procedures.
Over loading. Training and assistance of Banks man / Rigger
traffic accident Must be followed HILPermit
approved lifting plan must for crane / hydra lifting
All equipment must be third party certified.
Operators should be certified and valid license holder
Equipment to be inspected daily and all defects
reported
3 reached the job location Un trained workmen Physical Injury Must be followed HIL work at hight procedure Site engineer
at elevated working improper communication Property damage only work at hight pass trained worker perform job and Supervisor
platform via scaffold medically unfit fall of person medically fit person shall be allowed fot hight work
platform or esp stair damage grating platform fall of materilas only certified & green tag scaffold shall be used hse person
non certified scaffold pinch point use full body safety harness with 100% tie off
access not clear fatal scaffold inspection shall be done before work start
hand engage with materilas ergonomical injury tbt shall be conducted regarding hight work before
when going on platform dehydration work started
slippary platform lungs desease must be followed three point contact when use ladder
dust electrocution access must be free from obstucle
heat strokes use only HIL certified tools and equipments
damage electrical cables use lifting bag for material shifting at hight
emergency proper illumination at night work
ppe's violation
low illumination at night
slip and trip
rusted & damage grating
platform
4 Electrical equipment Dust expouser Incident/injury Must be followed HIL loto procedure site engineer
disconnection and verify Fall from hight fatal accident verify electrical disconnection loto physically before and Supervisor
loto system fall of materials injury due to falling work start
ergonomics hazards materials Must be followed HIL hight work procedure hse person
Sharp edges electrocution Tbt shall be conducted before work start.
high wind speed lungs desease Working area shall be barricade.
heat cut injury use full body safety harness with 100% tie off.
incomplete scaffold dehydration dont use damage tools.
untrained person skin desease use certified scaffold
loto failure electrical fire use lifting bag for shifting tools
only hight pass trained worker shall work.
housekeeping must be maintain
use lifeline rope where anchor place not available
drink penalty of water when working in direct sunlight

5 removing /dismantling fall of person personal injury Must be followed HIL hot work procedure Site engineer/
of air fall of materials fatal accident Use specified shielding devices and other PPE of Supervisor/
heater,transformer,hot slip and trip property damages correct specifications firewatcher/
roof and pipe line by collapse of scaffold lungs desaese Move out any leaking cylinder hse supervisor
using gas damage grating skin and eye irritation Keep trolley for transportation of cylinders and chain
cutting/plasma Burns dehydration them
cutting/grinding /hot Fire hazard fire Use flash back arresters
work Explosion Use double stage regulatores
Leaking gas cylinder or hoses Purge regulators immediately and then turn off.
Electrocution Never use grease or oil on oxygen line connections
Dust and copper fittings on acetylene lines
Flying object eye injury Work area should be barricated and signage posted.
ultraviolet and infrared rays fire fighting equipment shall be available near work
Improper placement of oxygen area
and acetylene cylinders only trained and competent person only allowed
Leakage / cuts in hoses use dust mask /resiperatory mask
Opening – up of cylinders use job specific ppe's(face shield,safety goggles,leather
Splinters / slag gloves,apron,hand and foot sleeve)
Toxic fumes & gases prepare checklist of electrical equipment
trained firewatch shall be available full time during hot
work

6 dismentling,removing of Toppling or Falling of material Physical Injury Must be followed HIL lifting procedure rigger/operator
dismantling materials Mechanical failure of lifting tools Property damage Must be followed HILPermit and Site
from top to ground level and tackles pinch point lifting plan shall be prepare before work start engineer and
by using mobile Improper lifting Procedure fatal Only competent and approved operator shall be Supervisor
crane/manlift/farrana using of defective equipment ( deployed for equipment operations. site hse person
Tools and Tackles ) Equipment to be tested and certified by competent
Over loading. person before deployment.
traffic accident No overloading allowed.
Overloading due to load Follow procedures.
oscillation use only 75% of swl of crane capacity
Collision with structure & Training and assistance of Banks man / Rigger
pipelines approved lifting plan must for crane / hydra lifting
All equipment must be by hil/ third party certified.
Operators should be certified and valid license holder
Equipment to be inspected daily and all defects
reported
use two tagline rope for control load
lifting area shall be barricade & display signages
don't stay under suspended load
avoid line of fire

7 dismental hot dismantle scrap materials burn must be followed hil procedure
materials/scrap road traffic injury or fatal due to dismental scrap material area shall be barricade and
materials hazardeous materials road accident signages display
segregating/transportin un competent person property damage don’t allow unauthorised person
g & disposed to sharp edges personal injury lifting plan must be available for material lifting and
designated place by unfit vehicle cut injury shifting
usingtrailor/farrana/cra damage lifting tools and tackles pinch point used only certified and inspected tools and tackles
ne improper material handling toppling of load from use only HIL certified electrical tools and machine
simultanious job at same area trailer only certified operator and rigger shall be perform job
hazards due to near by hot work trained person shall be perform job
job fire watcher shall be available near
work area
scrap material shall be proper tied and anchor on
trailor
scrap material shall be disposed only designated
place.
use job hot work specific ppe's

7 Housekeeping and Personal injury Incident / Injury Must be used dust mask Site Supervisor
material removal after Slip and trip Property Damage. Followed material handling technique
job complete. Dust exposure Proper communication
ergonomic Housekeeping awareness program to all employee

Prepared & Analysis by :- Danish (HSE),s.mujmdar(site incharge), Approved By-

P.chinnamaharaja(senior eng),
Anoop(Global site incharge)
 Date-06/03/2023
GEA PROCESS ENGINEERING
Project Name - ESP erection & commissioning Document No:- HIL/JSA/EHS-012

Activity- Dismantling of hot roof cutting/dismantling Rev-0

JOB SAFETY ANALYSIS

Location of Work : Smelter -1 ,ESP JSA No- 12

Sr. Sub Activities / Tasks Hazards Impact in case of Risk Control measures (There can be multiple control Responsibility
No. exposure measure for one hazard)
1 Work start-up Un authorized work Physical Injury Must be followed HIL permit system site engineer
preparation & obtaining Invalid permit Property damage emergency plan must be prepared before work start and Supervisor
work permit Lack of competency worker stuck at work Supervisor must insure that all work activities are hse person
Poor communication place in case of carried out by competent person
Hast or shortcuts emergency Conduct tool box talk meeting
un aware with plant emergency Review the method
gas expouser proper illumination in night shift work
low illumination at night Responsible person will conduct inspection
Consider all potential hazards: weather, wet or
slippery conditions, overhead hazards, proximity to
trails and/or visitor traffic patterns/volume, slope,
loose footing, elevation, fatigue, hazardous insects or
plants, etc.
tbt coducted regarding plant emergency
shall be prepared work at hight emergency plan before
work start

2 shifting of tools Toppling or Falling of material Physical Injury Only competent and approved operator shall be Rigger and Site
&materials from storage Mechanical failure of lifting tools Property damage deployed for equipment operations. engineer and
area to esp area by and tackles pinch point Equipment to be tested and certified by competent Supervisor
material handling Improper lifting Procedure person before deployment.
equipments or using of defective equipment ( No overloading allowed.
manually. Tools and Tackles ) Follow procedures.
Over loading. Training and assistance of Banks man / Rigger
traffic accident Must be followed HILPermit
approved lifting plan must for crane / hydra lifting
All equipment must be third party certified.
Operators should be certified and valid license holder
Equipment to be inspected daily and all defects
reported

3 reached the job location Un trained workmen Physical Injury Must be followed HIL work at hight procedure Site engineer
at elevated working improper communication Property damage only work at hight pass trained worker perform job and Supervisor
platform via scaffold medically unfit fall of person medically fit person shall be allowed fot hight work
platform or esp stair damage grating platform fall of materilas only certified & green tag scaffold shall be used hse person
non certified scaffold pinch point use full body safety harness with 100% tie off
access not clear fatal scaffold inspection shall be done before work start
hand engage with materilas ergonomical injury tbt shall be conducted regarding hight work before
when going on platform dehydration work started
slippary platform lungs desease must be followed three point contact when use ladder
dust electrocution access must be free from obstucle
heat strokes use only HIL certified tools and equipments
damage electrical cables use lifting bag for material shifting at hight
emergency proper illumination at night work
ppe's violation
low illumination at night
slip and trip
rusted & damage grating
platform
4 dismantling & cutting of fall of person personal injury Must be followed HIL hot work procedure Site engineer/
hot roof by using fall of materials fatal accident Must be followed HIL work at hight procedure Supervisor/
oxygen lance slip and trip property damages shall be prepare work at hight emergency rescue plan firewatcher/
cutting,gas collapse of scaffold lungs desaese before work start hse supervisor/
cutting/plasma incomplete scaffold skin and eye irritation use full body safety harness with 100 % tied off lance cutter
cutting/grinding /hot damage grating dehydration use 12mm wire rope for lifeline for anchore harness
work Burns fire lancing operator must be fully trained and qualified.
Fire hazard suffocation due to the lance cutting operator and all assistant shall
metal slag & sparks fumes & dust required to wear appropiate,extream heat resistance
Explosion burn enjury ppe's
Leaking gas cylinder or hoses aluminizing heat resistance apron shall be used
Electrocution fire retrdant full head and face mask hood shall be
toxis fumes, gases & dust used
Flying object eye injury thick fire retrandant mitten /gloves/boots shall be
ultraviolet and infrared rays used
Improper placement of oxygen standard heavy duty respiratory for each worker
and acetylene cylinders lancing should be carried out in open air,although
Leakage / cuts in hoses good ventilation
Opening – up of cylinders remove all flamable material from place of work.
Splinters / slag use only high pressure oxygen hose
Fall arrestor with vertical life line (12 mm wire rope) to
be used during ascending/descending by vertical
ladder.

5 Removing of dismantel Toppling or Falling of material Physical Injury Must be followed HIL lifting procedure rigger/operator
materials from top to Mechanical failure of lifting tools Property damage Must be followed HILPermit and Site
ground level by using and tackles pinch point lifting plan shall be prepare before work start engineer and
mobile Improper lifting Procedure fatal Only competent and approved operator shall be Supervisor
crane/manlift/farrana using of defective equipment ( deployed for equipment operations. site hse person
Tools and Tackles ) Equipment to be tested and certified by competent
Over loading. person before deployment.
traffic accident No overloading allowed.
Overloading due to load Follow procedures.
oscillation use only 75% of swl of crane capacity
Collision with structure & Training and assistance of Banks man / Rigger
pipelines approved lifting plan must for crane / hydra lifting
All equipment must be by hil/ third party certified.
Operators should be certified and valid license holder
Equipment to be inspected daily and all defects
reported
use two tagline rope for control load
lifting area shall be barricade & display signages
don't stay under suspended load
avoid line of fire

6 dismental hot dismantle scrap materials burn must be followed hil procedure
materials/scrap road traffic injury or fatal due to dismental scrap material area shall be barricade and
materials hazardeous materials road accident signages display
segregating/transportin un competent person property damage don’t allow unauthorised person
g & disposed to sharp edges personal injury lifting plan must be available for material lifting and
designated place by unfit vehicle cut injury shifting
usingtrailor/farrana/cra damage lifting tools and tackles pinch point used only certified and inspected tools and tackles
ne improper material handling toppling of load from use only HIL certified electrical tools and machine
simultanious job at same area trailer only certified operator and rigger shall be perform job
hazards due to near by hot work trained person shall be perform job
job fire watcher shall be available near
work area
scrap material shall be proper tied and anchor on
trailor
scrap material shall be disposed only designated
place.
use job hot work specific ppe's

7 Housekeeping and Personal injury Incident / Injury Must be used dust mask Site Supervisor
material removal after Slip and trip Property Damage. use ppe's
job complete. Dust exposure Burn Followed material handling technique
ergonomic Proper communication
hot metals Housekeeping awareness program to all employee

Prepared & Analysis by :- Danish (HSE),s.mujmdar(site incharge), Approved By-

P.chinnamaharaja(senior eng),
Anoop(Global site incharge)

Date-06/03/2023
GEA PROCESS ENGINEERING

Project Name - ESP erection & commissioning Document No:- HIL/JSA/EHS-013

Activity- Disconnect of internals with collecting electrode & Rev-0

discharge electrod(rapping bar,d.e anvil,distance bkt)

JOB SAFETY ANALYSIS

Location of Work : Smelter -1 ,ESP
JSA No- 13

Sr. Sub Activities / Tasks Hazards Impact in case of Risk Control measures (There can be multiple control Responsibility
No. exposure measure for one hazard)
1 Work start-up Un authorized work Physical Injury Must be followed HIL permit system site engineer
preparation & obtaining Invalid permit Property damage emergency plan must be prepared before work start and Supervisor
work permit Lack of competency worker stuck at work Supervisor must insure that all work activities are hse person
Poor communication place in case of carried out by competent person
Hast or shortcuts emergency Conduct tool box talk meeting
un aware with plant emergency Review the method
gas expouser proper illumination in night shift work
low illumination at night Responsible person will conduct inspection
Consider all potential hazards: weather, wet or
slippery conditions, overhead hazards, proximity to
trails and/or visitor traffic patterns/volume, slope,
loose footing, elevation, fatigue, hazardous insects or
plants, etc.
tbt coducted regarding plant emergency
shall be prepared work at hight emergency plan before
work start

2 shifting of tools Toppling or Falling of material Physical Injury Only competent and approved operator shall be Rigger and Site
&materials from storage Mechanical failure of lifting tools Property damage deployed for equipment operations. engineer and
area to esp area by and tackles pinch point Equipment to be tested and certified by competent Supervisor
material handling Improper lifting Procedure person before deployment.
equipments or using of defective equipment ( No overloading allowed.
manually. Tools and Tackles ) Follow procedures.
Over loading. Training and assistance of Banks man / Rigger
traffic accident Must be followed HILPermit
approved lifting plan must for crane / hydra lifting
All equipment must be third party certified.
Operators should be certified and valid license holder
Equipment to be inspected daily and all defects
reported
 3 reached the job location Un trained workmen Physical Injury Must be followed HIL work at hight procedure Site engineer
at elevated working improper communication Property damage only work at hight pass trained worker perform job and Supervisor
platform via scaffold medically unfit fall of person medically fit person shall be allowed fot hight work
platform or esp stair damage grating platform fall of materilas only certified & green tag scaffold shall be used hse person
non certified scaffold pinch point use full body safety harness with 100% tie off
access not clear fatal scaffold inspection shall be done before work start
hand engage with materilas ergonomical injury tbt shall be conducted regarding hight work before
when going on platform dehydration work started
slippary platform lungs desease must be followed three point contact when use ladder
dust electrocution access must be free from obstucle
heat strokes use only HIL certified tools and equipments
damage electrical cables use lifting bag for material shifting at hight
emergency proper illumination at night work
ppe's violation
low illumination at night
slip and trip
rusted & damage grating
platform
4 entering inside esp Oxygen deficiency Suffocation Must be followed HIL Confined space entry permit & Site engineer
/confined space work Oxygen enrichment Fire work at hight permit system. and Supervisor
for disconnect of Fumes & gas due to Irritation to eyes & Emergency rescue plan shall be prepared before work
internals with C.E & welding/grinding/cutting throat start hse person
D.E Chemical or toxicity Respiratory problem trained hole watcher/firewatcher shall be deployed for stand by person
Flammable materials, Fire & explosion confined space work /fire watcher
vapor/gases, pressurized Electrocution Allowed only confined space trained person &
containers/ cylinders inside the Electrical shock , burns maintain entry and exit log sheet
confined space , Cardio Pulmonary gast test must be done before work start
damage cables arrest conducted tool box talk before work start
Slippery surfaces, pits, uneven Personal injury Gas cylinders are not allowed inside the confined
surfaces unusual movement, space
Insufficient size of entry & exit injury Fire Fighting Facilities must be available
High noise reduction in hearing / Use of 24 V Hand lamp
Dust headache/tinnitus electrical equipment must have Protective
Health illness of worker earthing,ELCB
Failure of energy isolation Periodical inspection of m/c (grinding & welding)
Un trained worker Designated safe access way
Low illumination awareness regarding emergency procedure
fall of person from ladder Proper communication
must be followed LOTO system
Arrengment of ventilation of air & chilled air if required
Use one hook of harness always hooked up during
work at height work.
use lifeline rope (12mm wire rope )
5 disconnection & cutting fall of person personal injury Must be followed HIL hot work procedure Site engineer/
of C.E & D.E by using fall of materials fatal accident Must be followed HIL work at hight procedure Supervisor/
oxygen lance slip and trip property damages Use only HIL inspected electrical tools firewatcher/
cutting,gas collapse of scaffold lungs desaese shall be prepare work at hight emergency rescue plan hse supervisor
cutting/plasma incomplete scaffold skin and eye irritation before work start
cutting/grinding /hot damage grating dehydration lancing operator must be fully trained and qualified.
work Burns fire use full body safety harness with 100 % tie off
Fire hazard suffocation due to Fall arrestor with vertical life line (12 mm wire rope) to
metal slag & sparks fumes & dust be used during ascending/descending by vertical
Explosion burn enjury ladder.
Leaking gas cylinder or hoses the lance cutting operator and all assistant shall
Electrocution required to wear appropiate,extream heat resistance
toxis fumes, gases & dust ppe's
Flying object eye injury aluminizing heat resistance apron shall be used
ultraviolet and infrared rays fire retrdant full head and face mask hood shall be
Improper placement of oxygen used
and acetylene cylinders thick fire retrandant mitten /gloves/boots shall be
Leakage / cuts in hoses used
Opening – up of cylinders standard heavy duty respiratory for each worker
Splinters / slag lancing should be carried out in open air,although
good ventilation
remove all flamable material from place of work.
use only high pressure oxygen hose

5 Removing of dismantel Toppling or Falling of material Physical Injury Must be followed HIL lifting procedure rigger/operator
materials from top to Mechanical failure of lifting tools Property damage Must be followed HILPermit and Site
ground level by using and tackles pinch point lifting plan shall be prepare before work start engineer and
mobile Improper lifting Procedure fatal Only competent and approved operator shall be Supervisor
crane/manlift/farrana using of defective equipment ( deployed for equipment operations. site hse person
Tools and Tackles ) Equipment to be tested and certified by competent
Over loading. person before deployment.
traffic accident No overloading allowed.
Overloading due to load Follow procedures.
oscillation use only 75% of swl of crane capacity
Collision with structure & Training and assistance of Banks man / Rigger
pipelines approved lifting plan must for crane / hydra lifting
All equipment must be by hil/ third party certified.
Operators should be certified and valid license holder
Equipment to be inspected daily and all defects
reported
use two tagline rope for control load
lifting area shall be barricade & display signages
don't stay under suspended load
avoid line of fire

6 dismental hot dismantle scrap materials burn must be followed hil procedure
materials/scrap road traffic injury or fatal due to dismental scrap material area shall be barricade and
materials hazardeous materials road accident signages display
segregating/transportin un competent person property damage don’t allow unauthorised person
g & disposed to sharp edges personal injury lifting plan must be available for material lifting and
designated place by unfit vehicle cut injury shifting
usingtrailor/farrana/cra damage lifting tools and tackles pinch point used only certified and inspected tools and tackles
ne improper material handling toppling of load from use only HIL certified electrical tools and machine
simultanious job at same area trailer only certified operator and rigger shall be perform job
hazards due to near by hot work trained person shall be perform job
job fire watcher shall be available near
work area
scrap material shall be proper tied and anchor on
trailor
scrap material shall be disposed only designated
place.
use job hot work specific ppe's

7 Housekeeping and Personal injury Incident / Injury Must be used dust mask Site Supervisor
material removal after Slip and trip Property Damage. use ppe's
job complete. Dust exposure Burn Followed material handling technique
ergonomic Proper communication
hot metals Housekeeping awareness program to all employee

Prepared & Analysis by :- Danish (HSE),s.mujmdar(site incharge), Approved By-

P.chinnamaharaja(senior eng),
Anoop(Global site incharge)

Date-06/03/2023
GEA PROCESS ENGINEERING
Project Name - ESP erection & commissioning Document No:- HIL/JSA/EHS-014

Activity- cutting and dismantling of esp external casing parts (field

casing,inlet transition,inlet&outlet cone,roof beem,hopper) Rev-0

JOB SAFETY ANALYSIS

Location of Work : Smelter -1 ,ESP JSA No- 14

Sr. Sub Activities / Tasks Hazards Impact in case of Risk Control measures (There can be multiple control Responsibility
No. exposure measure for one hazard)
1 Work start-up Un authorized work Physical Injury Must be followed HIL permit system site engineer
preparation & obtaining Invalid permit Property damage emergency plan must be prepared before work start and Supervisor
work permit Lack of competency worker stuck at work Supervisor must insure that all work activities are hse person
Poor communication place in case of carried out by competent person
Hast or shortcuts emergency Conduct tool box talk meeting
un aware with plant emergency Review the method
gas expouser proper illumination in night shift work
low illumination at night Responsible person will conduct inspection
Consider all potential hazards: weather, wet or
slippery conditions, overhead hazards, proximity to
trails and/or visitor traffic patterns/volume, slope,
loose footing, elevation, fatigue, hazardous insects or
plants, etc.
tbt coducted regarding plant emergency
shall be prepared work at hight emergency plan before
work start

2 shifting of tools Toppling or Falling of material Physical Injury Only competent and approved operator shall be Rigger and Site
&materials from storage Mechanical failure of lifting tools Property damage deployed for equipment operations. engineer and
area to esp area by and tackles pinch point Equipment to be tested and certified by competent Supervisor
material handling Improper lifting Procedure person before deployment.
equipments or using of defective equipment ( No overloading allowed.
manually. Tools and Tackles ) Follow procedures.
Over loading. Training and assistance of Banks man / Rigger
traffic accident Must be followed HILPermit
approved lifting plan must for crane / hydra lifting
All equipment must be third party certified.
Operators should be certified and valid license holder
Equipment to be inspected daily and all defects
reported

3 reached the job location Un trained workmen Physical Injury Must be followed HIL work at hight procedure Site engineer
at elevated working improper communication Property damage only work at hight pass trained worker perform job and Supervisor
platform via scaffold medically unfit fall of person medically fit person shall be allowed fot hight work
platform or esp stair damage grating platform fall of materilas only certified & green tag scaffold shall be used hse person
non certified scaffold pinch point use full body safety harness with 100% tie off
access not clear fatal scaffold inspection shall be done before work start
hand engage with materilas ergonomical injury tbt shall be conducted regarding hight work before
when going on platform dehydration work started
slippary platform lungs desease must be followed three point contact when use ladder
dust electrocution access must be free from obstucle
heat strokes use only HIL certified tools and equipments
damage electrical cables use lifting bag for material shifting at hight
emergency proper illumination at night work
ppe's violation
low illumination at night
slip and trip
rusted & damage grating
platform
 5 dismentaling & cutting fall of person personal injury Must be followed HIL hot work procedure Site engineer/
of esp external parts by fall of materials fatal accident Must be followed HIL work at hight procedure Supervisor/
using oxygen lance slip and trip property damages Use only HIL inspected electrical tools firewatcher/
cutting,gas collapse of scaffold lungs desaese shall be prepare work at hight emergency rescue plan hse supervisor
cutting/plasma incomplete scaffold skin and eye irritation before work start
cutting/grinding /hot damage grating dehydration lancing operator must be fully trained and qualified.
work Burns fire use full body safety harness with 100 % tie off
Fire hazard suffocation due to Fall arrestor with vertical life line (12 mm wire rope) to
metal slag & sparks fumes & dust be used during ascending/descending by vertical
Explosion burn enjury ladder.
Leaking gas cylinder or hoses the lance cutting operator and all assistant shall
Electrocution required to wear appropiate,extream heat resistance
toxis fumes, gases & dust ppe's
Flying object eye injury aluminizing heat resistance apron shall be used
ultraviolet and infrared rays fire retrdant full head and face mask hood shall be
Improper placement of oxygen used
and acetylene cylinders thick fire retrandant mitten /gloves/boots shall be
Leakage / cuts in hoses used
Opening – up of cylinders standard heavy duty respiratory for each worker
Splinters / slag lancing should be carried out in open air,although
good ventilation
remove all flamable material from place of work.
use only high pressure oxygen hose

5 Removing of dismantel Toppling or Falling of material Physical Injury Must be followed HIL lifting procedure rigger/operator
materials from top to Mechanical failure of lifting tools Property damage Must be followed HILPermit and Site
ground level by using and tackles pinch point lifting plan shall be prepare before work start engineer and
mobile Improper lifting Procedure fatal Only competent and approved operator shall be Supervisor
crane/manlift/farrana using of defective equipment ( deployed for equipment operations. site hse person
Tools and Tackles ) Equipment to be tested and certified by competent
Over loading. person before deployment.
traffic accident No overloading allowed.
Overloading due to load Follow procedures.
oscillation use only 75% of swl of crane capacity
Collision with structure & Training and assistance of Banks man / Rigger
pipelines approved lifting plan must for crane / hydra lifting
All equipment must be by hil/ third party certified.
Operators should be certified and valid license holder
Equipment to be inspected daily and all defects
reported
use two tagline rope for control load
lifting area shall be barricade & display signages
don't stay under suspended load
avoid line of fire

6 dismental hot dismantle scrap materials burn must be followed hil procedure
materials/scrap road traffic injury or fatal due to dismental scrap material area shall be barricade and
materials hazardeous materials road accident signages display
segregating/transportin un competent person property damage don’t allow unauthorised person
g & disposed to sharp edges personal injury lifting plan must be available for material lifting and
designated place by unfit vehicle cut injury shifting
usingtrailor/farrana/cra damage lifting tools and tackles pinch point used only certified and inspected tools and tackles
ne improper material handling toppling of load from use only HIL certified electrical tools and machine
simultanious job at same area trailer only certified operator and rigger shall be perform job
hazards due to near by hot work trained person shall be perform job
job fire watcher shall be available near
work area
scrap material shall be proper tied and anchor on
trailor
scrap material shall be disposed only designated
place.
use job hot work specific ppe's

7 Housekeeping and Personal injury Incident / Injury Must be used dust mask Site Supervisor
material removal after Slip and trip Property Damage. use ppe's
job complete. Dust exposure Burn Followed material handling technique
ergonomic Proper communication
hot metals Housekeeping awareness program to all employee

Prepared & Analysis by :- Danish (HSE),s.mujmdar(site incharge), Approved By-

P.chinnamaharaja(senior eng),
Anoop(Global site incharge)