JOB SAFETY ANALYSIS

Piping Erection With In Battery Limits

Installation / Location:
QSTec Polysilicon Project; Phase-I
Contract Ref No. P5QA07-11

Leader: Signature:
ANIL KUMAR.V

Area : QSTec Project Site

Pages :22

MS Ref. No. : PS14333-21393-G0000-ME-A4-0002

Date : 25.02.2013

Attendees:

SHAH ALI

R. SANCHEZ

RIC DIMAUNAHAN

SABU BABY

SRINIVASAN

R. JENAGARAJAN

TONY KURIAN

UMANAG SHAH

DAVID BINDING

PRAMOD. V.P

POULOSE JOSEPH

Site Visit :N/A

Date: 27-02.2013

Duration: 2.5 Hr

Job Description:

1. Apply / Renewal/Closure of PTW

2. Preparation for the job
3. Survey, Site inspection, Measurement and marking.
4. Mobilization and demobilization of manpower to job site.

CONTRACT No. P5QA0711

JSA NO. PS14333-21393-G0000-JSA-A4-0001

REV.B

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JOB SAFETY ANALYSIS

Piping Erection With In Battery Limits

5. Mobilization and demobilization of Tools, materials and equipments
6. Use of hand and power tools.
7. Erection of Pipe spools using Crane, Lifting Gears.
8. Working on scaffolding & at height.
9. Manual handling.
10. Fit up, welding, grinding, drilling and cutting using diesel welding generator, electric grinder & drilling machine.
11. Torqueing Reinstatement, Final box up &
12. Handling and storage of Compressed gas cylinders.
13. Diesel filling for welding generators, machineries and equipments.
14. Emergency preparedness, Heat Stress
15. Housekeeping
16. Night work
17. Human Behavior

No

Job steps

CONTRACT No. P5QA0711

Hazard

JSA NO. PS14333-21393-G0000-JSA-A4-0001

Control Measures

REV.B

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JOB SAFETY ANALYSIS

Piping Erection With In Battery Limits

1.

Apply /
Renewal/Closure
of PTW

Un authorized personal

Supporting documents
are not properly
identified
PTW is not closed /
renewed in due time.

Preparation for
the job

CONTRACT No. P5QA0711

Failure to follow PTW

procedure and
misunderstanding/
miscommunication of
work instructions.

Verify the personnel involved in Permit applying

process are trained and authorized.

Every individual must attend project HSSE

induction prior to mobilize to site

Make sure everyone involved in PTW systems read

and understand the task to be carried out and all
job details are covered and verified in the Permit
prior to leave the building.

Permit work holder & Issuing authority to verify

that all the supporting documents such as MS,
JSA, Drawing etc. are appropriately completed
and attached.

Site HSEO to cross check the PTW prior to start

the job

Renew/ close the permit on due time.

Check all the Permit to work procedure &

confirm all the task are carried out and deal
accordingly to the procedures specified on the JSA
& Method statement for all activities.

Proper coordination with Operation, maintenance

and Contractor. Ensure that all requirements and
necessary preparation for the activity & work
permit has been reviewed and verified.

JSA NO. PS14333-21393-G0000-JSA-A4-0001

REV.B

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JOB SAFETY ANALYSIS

Piping Erection With In Battery Limits

Survey, Site
inspection,
Measurement and
marking

Mobilization and
demobilization of
manpower to job
site.

CONTRACT No. P5QA0711

Lack of Awareness of the

system for marking/
Wrong Location on
marking.

Incompetence / Lack of
site awareness

Inspection and survey to be carried out according

to the procedures.
Access control procedure to be followed.
Communication to be maintained during survey.
Identify location from approved drawing.

All task to be carried out by trained, authorized

and competent personnel only.

Every individual must attend project HSSE

induction & mandatory project trainings prior to
mobilize to site

Wear the PPE as per Project requirement coverall,

helmet, Safety goggles, safety shoes etc. Use
double ear & eye protection if necessary.

Supervisor to check the work front at all times.

JSA NO. PS14333-21393-G0000-JSA-A4-0001

REV.B

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JOB SAFETY ANALYSIS

Piping Erection With In Battery Limits

Mobilization and
demobilization of
Tools, materials
and equipments
using pick up and
lifting devices.

1
Unauthorized entry,
Incompetent person to
carry out the job.
Unauthorized vehicle
entry.
Incorrect manual
handling.

PTW and vehicle pass to be obtained and all the

requirements to be followed.

Good condition vehicles/crane with all related

valid documents (licensed / TPI certified) of
driver / operator to be ensured prior to job.

All lifting operations must be pre- planned.

For all critical lifting operation must be

conducted with approved Lifting plan and need to
be attached with permit.

Rigging operation must be carried under the

supervision of competent rigging foreman/
supervisor

No unauthorized persons allowed inside working

area and barricade, signage to be posted.

Make sure all emergency procedure are discussed

and understood during Tool Box talk.

All task carried out by trained, authorized and

competent personnel only.
Proper manual handling technique to be followed
and provide sufficient manpower for the task.

Improper lifting & Rigging

Of materials.

CONTRACT No. P5QA0711

Pre job communication to be established at work

site among the team via Tool Box Talk including
correct lifting and Manuel handling technique.
Ensure work area and access route to be free of
obstruction and safe to work prior to start the
job.
Job supervisor must be present always on job
location and ensure that the standard procedures
are being followed.

JSA NO. PS14333-21393-G0000-JSA-A4-0001

REV.B

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Piping Erection With In Battery Limits

CONTRACT No. P5QA0711

Ensure the availability of proper hoisting and

rigging equipment for lifting / lowering materials
and make sure those devices is being color coded
and certified.
Barricade the area with signage to avoid
unauthorized entry.
Use correct PPE for all tasks.

JSA NO. PS14333-21393-G0000-JSA-A4-0001

REV.B

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JOB SAFETY ANALYSIS

Piping Erection With In Battery Limits

Use of hand and

power tools

Fall of tools from

height
Contact with sharp
edges
Faulty equipment.
Ergonomic Hazards
Pinch point
Hand & body injury

CONTRACT No. P5QA0711

Assign only trained and experienced personnel for hand

power tools
Hand tools tying method with hand to be followed
while working at height work with hand tools
Barricade & install signage the area and unauthorized
entry in the barricaded area to be strictly controlled.
Ensure proper PPE is being used as per project PPE
Procedure.
Always use right tool for the right job.
Assign only trained and experienced personnel for hand
tools and pneumatic tools
Ensure Inspect electrical equipment prior to use and
provide inspection sticker or color code.
Do not use damaged or faulty equipment.
Ensure dead man trigger is available for Power tools
Ensure proper PPE is being used as per PLL PPE
Procedure. Rotation of people shall be in place.
Ergonomically consideration shall be given and no
twisting, bending, extending portion work shall be
allowed.
Always avoid Line of Fire & Pinch points
Housekeeping shall be maintained at all the time.

JSA NO. PS14333-21393-G0000-JSA-A4-0001

REV.B

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Piping Erection With In Battery Limits

7

Erection of Pipe
spools using by
Crane, Lifting
Gears.

Congested Access
Unauthorized Entry
Incompetent Person to
carry out the jobs
Incorrect manual
handling

Improper Lifting and

rigging of materials.

Area obstructed with

unwanted materials.
Fall and slip.

Falling objects
Pinch points
Hand & body injury

CONTRACT No. P5QA0711

PTW to be Obtained and the requirements to be

followed.
Approved lifting plan, plot plan and risk
assessment to be attached with permit.
Certified and color coded lifting
gears/equipments to be used and checked prior to
use.
While positioning the crane soil stability &
compaction rating should be checked with Civil
Dept
Daily inspection checklist must be completed by
operator

Rigging operation must be carried under the

supervision of competent rigging foreman/
supervisor
Rigging activities to be carried out by third party
certified riggers only.
Provide Hi- Visibility jacket for the rigger.
In no circumstances must any load be lifted over
personnel
Ensure trained banks man being provided during
crane movement.
Use double taglines while lifting the materials to
control the load.
Secure all the hooks during crane movement.
Use appropriate PPE (Use heavy duty leather
gloves for rigging operations)
Be cautious about the trap points.
Avoid line of fire.
Do not leave the load suspended and never
stand / walk or work beneath a hoist
Isolate hoisting area (swing radius) with barriers,

JSA NO. PS14333-21393-G0000-JSA-A4-0001

REV.B

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Piping Erection With In Battery Limits

CONTRACT No. P5QA0711

Ensure outriggers of the crane is on firm and level

surface, supported on spread weight and ground
conditions to be suitable for lifting load.
Crane operator must check breaks before
attempting to lift any loads.
Operator must not leave the controls while crane
is running or while a load is suspended.
While rigging operation is ongoing effective 2 way
communication must be ensured and one signal
man to give signal to the operator
No oiling, or hydraulic repairs while a crane is in
operation.
Close monitoring of weather condition should be
carried out and needs to communicated with
working crew
Be cautious about hands; make sure it is not
caught between the sling and its load when the
sling is being tightened around the load.
Supervisor must be present always on job location
to control the work behavior of the workers and
ensure that the standard procedures are being
followed.
Provide sufficient manpower for the task.
Good housekeeping

JSA NO. PS14333-21393-G0000-JSA-A4-0001

REV.B

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Piping Erection With In Battery Limits

8

Working on
scaffolding & at
height.

Drop Object
Unsecured scaffolds
Obstructed access &
Egress and congested
work area.
Slip & trip
Fatality

Scaffold collapse
Falls from heights

CONTRACT No. P5QA0711

Only trained and authorized scaffolders to erect,

modify and dismantling scaffolding
Trained, experienced & authorized scaffolding
supervisor to monitor the scaffolding at all times
Unwanted tools and materials must be removed
from the platform of the scaffold to avoid
unnecessary drop of objects.
When working from a scaffold, always use body
harness system and 100 % tie off when exceeding
outside handrails of scaffold.
At or above 1-6 meter full body harness & double
lanyard with shock absorber must be used
Do not use any scaffold tagged "Out of Service."
Do not use a scaffold unless guardrails and all
flooring are in place.
Do not load scaffolds in excess of their maximum
load limits.
Do not work on scaffolds in high winds or during
storms.
Tool tie be to used where ever it is applicable
Never use scaffold on inclement weather
conditions
Do not allow tools, equipment, or other debris to
accumulate on scaffolds.
Inspect all scaffolds, scaffold components, and
personal fall protection equipment before each
use.
Guard rails and toe boards shall be installed on all
open sides and ends of scaffolds

JSA NO. PS14333-21393-G0000-JSA-A4-0001

REV.B

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JOB SAFETY ANALYSIS

Piping Erection With In Battery Limits

9

Manual handling

Sharp/Protruding objects.
Struck by existing facilities.
Heavy load
Crush injury
Pinch points
Body & Hand Injury
Back pain
Line of fire

Be cautious about the trap points.

Close supervision of rigging activity by

certified rigger.
Correct PPE (Use leather gloves for rigging
operations)
Avoid unauthorized persons and
unnecessary materials at site.
Proper manual handling techniques should
be applied at all times
Maximum load can be lifted by an
individual will be 22 kg (Subjected to
individual physic condition)
Use mechanical lift or ask for help for
heavier load.
Maintain good housekeeping

Avoid line of fire

o
o
o
o

CONTRACT No. P5QA0711

JSA NO. PS14333-21393-G0000-JSA-A4-0001

REV.B

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JOB SAFETY ANALYSIS

Piping Erection With In Battery Limits

CONTRACT No. P5QA0711

Check the ladders for any damage before using as

an access to the work area
No tools and materials must be carried by hand
while climbing up and down the access ladder of
scaffold
Scaffolders needs to identified by wearing hi vest
jacket at all times
Always use 3 point contact while using
access/egress ladder.
Work to be carried out on approved scaffolding
only and always check for valid inspection scafftag.

JSA NO. PS14333-21393-G0000-JSA-A4-0001

REV.B

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10

Fit up, welding,

grinding, drilling
and cutting using
welding diesel
generator, electric
grinder.

Sparks / fire
Electrocution
Poor cable management.

Flying objects
Hot surfaces
Exposure to fumes
Working at height
Fall from height
Falling objects

CONTRACT No. P5QA0711

PTW and supporting documents to be obtained

and all requirements to be followed.
Conduct toolbox talk and explain job details and
associated hazards also communicate the
emergency procedures, emergency numbers and
nearest muster point prior to commence the job.
Hoses/ Welding cables to be protected and laid
properly
Welding fire retardant blanket screen (if
necessary) to be in place and welding shield to be
used.
Trained and competent electrician to check all
equipments and earthling
All welding & hot work location needs to be
protected with appropriate fire habitat must be
provided
Ensure LEL is zero prior to commence hot work.
Fire extinguisher to be in place at work site and
near to welding generator.
Proper PPE to be worn as per PTW & PPE
procedures
All welders need to provided and in use of
respiratory protection
Barricade the area and place warning signs.
Ensure grinding machine is properly guarded;
Inspection & color code must be updated.
Electrical tools shall be inspected and color coded
Proper ground earthing shall be provided for the
electrical equipments.

JSA NO. PS14333-21393-G0000-JSA-A4-0001

REV.B

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CONTRACT No. P5QA0711

Use of face shield, safety glass and ear protection

when grinding and buffing.
Provide proper container for hot welding rod ends
and welding slag.
Maintain a good cable management, welding
cables not to be routed with other cables.
Disconnect and switch off all electrical
equipments when not in use
Trained fire watch to be provided.
Proper housekeeping to be ensured.
Full compliance of project wet weather procedure
Supervisor to ensure the safe job execution.

JSA NO. PS14333-21393-G0000-JSA-A4-0001

REV.B

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Piping Erection With In Battery Limits

11

Handling and
storage of
Compressed
gas cylinders

Pinch points
Fire & explosion
Hand& body injury
Line of fire

Heavy load

Crush injury

CONTRACT No. P5QA0711

All compressed gas cylinders will be stored and

shipped with the caps in place.
All cylinders will be stored in upright positions.
Flash back arrestor shall be installed on oxy
acetylene torches and cylinders
Proper segregation of empty and full cylinder
need to be done
Cylinder transportation needs to be done by
competent personal according to project
standards
Combustible materials will not be stored in the
same area with oxygen and acetylene.
Always use trolley to shift the cylinders with
chained
Ensure that cylinder hoses do not come to contact
with hot surfaces.
Supervisor to ensure the compliance of all safety
requirements.
Appropriate MSDS must be readily available site
Soap test needs to be done to identify leaks
Cylinder 3rd party certificate must be available
All gages and regulator and must be calibrated
Hoses and fittings must be under international
and BS standard
Do not handle oxygen cylinders if your gloves are
greasy or oily.
Close the cylinder valve when work is finished,
when the cylinder is empty or at any time the
cylinder is moved.

JSA NO. PS14333-21393-G0000-JSA-A4-0001

REV.B

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12

Diesel filling for

welding generator.

Diesel spillage
Inhalation
Electrical shocks/ short
circuit and fire.
Exposed to traffic.

CONTRACT No. P5QA0711

Operatives to avoid stay within the hazardous

area as much as possible
Pressurization / depressurization are conducted
gradually/ slowly.
Proper grounding and earthling should be done
and checked by competent electrician
Only WOQOD tanker will used for re fuelling
activities
Fuelling is to be done prior to the commencement
of Work.
Competent person shall be employed for filling
job.
Ensure to provide drip tray to all welding
generators for filling operations.
Ensure the good operating condition of automatic
nozzle dispenser.
Use correct PPE as per diesel MSDS.
Keep fire extinguisher and no hot work near filling
activity.
Spill kit needs to provided with trained personal
Equipment shall be switched off before diesel
filling.
Vehicle will be parked at a safe distance from any
traffic while filling of diesel is in progress.

JSA NO. PS14333-21393-G0000-JSA-A4-0001

REV.B

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13

Heat Stress
Emergency
preparedness

Heat exhaustion

Illness

Heat cramps

Heat stroke

Miscommunication

Acclimatization
Working alone

CONTRACT No. P5QA0711

Heat stresses prevent procedures to be strictly

followed.
Heat stress awareness and importance of drinking
water to be discussed during tool box talk on a
daily basis.
Frequent breaks to be followed during hot season
especially when flag color changes.
Eat / take food on time, dont skip breakfast and
dinner & Shelter to be provided if necessary.
Do not stay/work on direct sun light for long time,
take intervals.
Comfortable and approved clothing to be worn.
Water source to be made available at work site
and all personnel need to carry water thermos all
time on work site.
Watch flag for any changes on the weather and
follow the rules accordingly.
Any persist of stress symptoms should be reported
immediately.
Supervisor must be monitor his people all the
times and check any signs of heat stress.
Numbers of emergency response team must be
known by all workers including the locations of
Muster Points.
Buddy system must be applied & Cold water
should be available at site
Acclimatization should be identified and avoided
Heat stress awareness training should be
conducted & project Heat Stress procedure should
be followed
Work & rest ratio should be identified and
cascaded to work crew in the TBT

JSA NO. PS14333-21393-G0000-JSA-A4-0001

REV.B

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14

Housekeeping

CONTRACT No. P5QA0711

Improper waste
management
Slips and trips
Contamination to
environment
Fire

All waste generated shall be segregated and

removed from site and dispose in designated
waste skip.

Remove warning tape when hazard is

removed/when job is finished.

Make sure area is safe before starting

housekeeping activity.

JSA NO. PS14333-21393-G0000-JSA-A4-0001

REV.B

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Piping Erection With In Battery Limits

4
15

Night Work

Poor Visibility
Slip & Trip
Being struck by moving
vehicles / equipment
Eye strain
Ergonomic

CONTRACT No. P5QA0711

Ensure all people assigned for the night shift should

complete all mandatory trainings like Night Work
Procedure, Emergency Response Procedure, PPE
Procedure, Work at Height, project security
requirements etc
All workers assigned for night shift should be
weared with reflective jacket & clear glasses
Ensure that adequate lighting arrangement has
made available at all site locations, entry, exit,
muster points, rest rooms, toilets etc and that
should meet the Lux requirement based on the
approved night work procedure.
Ensure to check Lux measurement with a
Calibrated Lux Meter
Ensure PLL IERG for night work is in place with all
necessary arrangement like First Aid clinic, Male
nurse, emergency vehicle, communication system
etc.
Ensure that no one is sleeping/ resting under any
equipments, vehicles, suspended loads etc
Ensure the fulltime safety and job supervision for
the every jobs
Ensure that proper handing and taking over done
between day shift & Night shift supervisors
Ensure the Job Specific TBT before starting any
work during night time.
Buddy system must be followed
Emergency backup light should be available
Ensure that all vehicle will be used with Head
Lights & Beacon Lights during night time

JSA NO. PS14333-21393-G0000-JSA-A4-0001

REV.B

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16

Human Behavior

CONTRACT No. P5QA0711

Human error,
Drugs & Alcohol,
Stress / Work overload
Tiredness,
Violence
Compliancy

Good Supervision, Inspection and Tool Box talk to

be carried out.

Adequate training and instructions to be provided.

Drug& Alcohol policy to be introduced to all

employees during the HSSE induction.

Workload management through Project engineer /

Supervisor

Stress Awareness toolbox talk.

Safety incentive programs to influence behavior,

i.e. Safety Quiz, Best employee, Best PTW
awareness, etc.

Strict implement on site rules and Golden safety

rules

JSA NO. PS14333-21393-G0000-JSA-A4-0001

REV.B

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NAME

CONTRACT No. P5QA0711

DATE

JSA NO. PS14333-21393-G0000-JSA-A4-0001

SIGNATURE

REV.B

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C- Severity of Consequence, L-Likelihood

H- High Risk, M Medium Risk, L Low Risk.

Crew Declaration: I have reviewed

and understood this JSA.

Legend
Job step
Hazard
Cause
Consequences
Potential risk H/M/L
Recommended Controls
Residual Risk H/M/L

Sequence of work activities

The potential to cause harm (Health, injury, property damage, environment etc
Possible causes that will potentially release the Hazard
The harm which could possibly occur
With no controls in place
Describe additional controls that are required
With control in place

Mandatory Requirements:
1.
2.
3.
4.
5.
6.
7.
8.

Daily Tool Box talks

Consolidated Permit to Work
Mandatory Personal Protective Equipment i.e.
(Coverall, Safety Shoes and hardhat) Job related PPE Hand gloves
, Safety Harness etc.
Drinking water and Rest Shelter
Emergency Standby Vehicle
First Aider with adequate First Aid Kit.
Safety supervisor on site
Full time supervision

PREPARED BY

CONTRACT No. P5QA0711

APPROVED BY:

JSA NO. PS14333-21393-G0000-JSA-A4-0001

AGREED BY:

REV.B

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