job safety analysis

JOB SAFETY ANALYSIS FOR JET A1 TANK ERECTION P&M and Equipment involved: Welding machine, grinding m/c, gas cutting sets,

crane, drilling m/c, lifting tools & tackles, Hydraulic jacks, small tools & tackles, NDT kits etc.

PPE / safety device required: Safety Helmet, Safety shoe, Safety Goggles, Hand Gloves (Leather & Cotton), Safety belt, Lifeline rope, Fire extinguisher, Fire bucket etc.

Identity of Task: Erection (Mechanical / Hydraulic jacking system) and Testing of storage tanks.

Sl. No.

Sequence of Operation -

Activity Steps

Tools & tackles

used and manpower deployed

Hazards involved at

various steps

Safety measures / precautions

Responsibility / Action by

1 Marching of crane Crane operator, rigger, signalman, and supervisor.

Hit by crane

Toppling of crane

Deep Excavation

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2 Laying annular plates on the periphery of the tank by crane

Supervisor, Operator, Rigger, Khalasi, Helper, welder, RT persons

Failure of the crane.

Fall of material

Hit by crane

Hit by object

Crane shall be placed on a stable and compacted ground for stability of the crane.

The entire swing area shall be barricaded and no unauthorised entry shall be allowed within the swing area.

Before lifting process starts, all the lifting tools & tackles shall be certified.

Experienced rigger shall be present during the entire lifting process.

Only experienced signalman has to give the signal to the crane.

During welding, the entire area shall be free from

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any combustible materials like cotton waste, paints, thinner etc.

All the plates to be stacked in proper manner at site to reduce hindrance for personnel movement and other activities.

3 Laying of bottom plates on the tank foundation by crane

Supervisor, rigger, welder, gas cutter, khalasi, fitter, crane operator, signalman, QA/QC asst.

Same as point 1

Improper stacking of plates at site.

Unwanted swing of the plates during lifting.

Damage of welding cable or gas cutting hose or electrical cable due to sharp edge of the plates.

Access thru curvature of the tank

Improper lifting of plates

Only experienced signalman shall give the signal to the crane operator.

Proper access to be ensured along the curvature of the tank.

During lifting and swinging with the plates, nobody shall work under the suspended load.

Entire swinging area shall be barricaded.

Double tag rope shall be used during lifting of the plates.

All the plates shall be stacked in proper manner with sufficient packing outside the tank area to prevent any injury due to pressed in-between during handling or sling fixing.

All the plates shall be stacked according to the priority basis from top to bottom to prevent pulling of the plates kept at bottom.

Tank pad area shall be free from any cables, hoses during placing of the plates.

Personnel movement shall be restricted inside the tank

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area to prevent any trip injury as well as burn injury due to hot metal.

4 Placing of stool around the periphery of the tank

Supervisor, rigger, welder, gas cutter, khalasi, fitter, helper, crane operator, signalman

Personnel injury during material handling

Hit by object by toppling of the beam

Stool shall be placed at the levelled area.

If reqd, proper support to be given to prevent toppling.

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5 Erection of 2nd shell course along the periphery, welding and radiography.

Supervisor, rigger, welder, gas cutter, khalasi, fitter, crane operator, signalman, QA/QC asst, radiographer.

Less stability of the bent plates at stacking yard.

Toppling of plates after positioning along periphery

Personnel injury.

Fall of person from height during welding at outside.

Electrocution

Radiography hazard

Injury due to improper access provision

Injured person to take out from tank inside

Bent plates to be stacked properly in sequential manner. If plates kept in horizontal position, proper packing to be provided. During lifting, utmost care shall be taken. If plates stacked in vertical position, enough support shall be given. And support shall be removed only after the plate has been hooked with the crane for lifting.

If the bent plates stacked on a saddle, utmost care shall be taken during fixing of sling, lifting operation and other handling activities.

After placing the each bent plate along the periphery, sufficient supports to be given for each plate.

Personnel movement to be restricted during placing of the 2nd shell plates.

No body shall be allowed to work under any suspended load.

Before removing the angular support, all the

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vertical joints in between the plates shall be fully welded.

Suitable access to be ensured to take out injured person, in case of emergency.

SAFETY DURING RADIOGRAPHY BEING DISCUSSED IN POINT NO 17.

6 Erection of 1st shell course along the periphery on the 2nd shell, welding and radiography.

Supervisor, rigger, welder, gas cutter, khalasi, fitter, crane operator, signalman, QA/QC asst, radiographer.

Personnel injury due to caught in-between the 2nd shell & 1st shell.

Burn injury

Fall / slip of 1st shell plates during placing over 2nd shell plates.

Trip hazard due to improper housekeeping

Fall of person during welding from height

Access / egress

No body shall keep his finger or hand in between two plates while in the process of alignment.

There shall be stopper arrangement in between the plate edges to prevent any fall of plates after putting one over another.

Before doing full welding, proper & sufficient support to be given to each shell plate to prevent toppling.

Inside the tank area, good housekeeping to be maintained.

While working at height, proper doka staging to be made and supported. Handrail to be provided in the tower and safety belt to be tied at shoulder height.

Doka tower to be fixed in levelled condition.

Safe access/egress to be provided in & outside of the tank for personnel movement as well as material shifting.

Suitable access / egress space to

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be ensured.

7 Erection of roof structure – Central drum, main rafter, side rafter, central girder and welding & bolting.


Fall of central drum

Hit by object

Collapsing of the roof structure

Not maintaining sequence of erection

Working in the same location in different levels.

Fall of unstable truss

Proper support to be given to the central drum when it is being kept at 2m(apprx) height on the doka tower.

Materials shall be stacked in such manner that it shall not create any hindrance to the movement as well as other activities.

No loose materials to be kept at height.

While doing assembling of main rafter outside, proper space to be ensured to carry out the job smoothly.

During erection of main rafter and placing in between the central drum and shell plate, all the joints (bolted & welded) to be inspected by competent person and then give signal for lifting.

All the bolt joints to be moderate tighten for erection.

No personnel shall stand below the suspended load.

To ensure the stability of the trusses, proper sequence of erection e.g. fixing of main rafter, secondary rafter, secondary truss, secondary beam to be followed as per drawing.

After fixing all structural materials, immediately the entire bolt joints to be tightened

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moderately to withstand its self-load.

8 Placing of roof plates by crane and welding.


Fall of plates

Fall of loose materials

Fall of person

Hit by plates due to unwanted swing by crane caused by wrong signal.

Fall of loose tools & tackles

Proper sequence of the erection to be maintained.

During erection of the roof plates, nobody shall be inside the tank under the suspended load.

Lifeline to be provided for tying the safety belt.

Experienced signalman shall give the signal to crane operator.

Roof plate erection shall be allowed only during daytime.

All small tools & tackles shall be provided with safety sling.

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9 Arrangement of jack system (40 nos or more) with power pack outside the tank in parallel with the roof plate fixing and welding

Rigger, khalasi, welder, gas cutter, fitter, helper, jack operator.

Slip & trip hazard

Injury due to fall of plates or loose materials from top

Lack of ventilation

Hydraulic oil leakage

Fire

Bursting of hydraulic hose or damage due to fall of material from the top.

At the same location, different levels job shall not be carried out.

No conflict at different scope of works.

Area shall be barricaded for movement restriction inside the tank while plate fixing is going on at top.

Sufficient ventilation shall be provided for the people working inside the tank.

All the pressurized parts of the power pack and the jacks shall be certified.

No hot work shall be carried out nearby the hydraulic oil to prevent any fire accident.

Experienced & competent person shall supervise the jack fixing

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arrangement.

If any leakage of hydraulic oil occurs, immediately it is to be cleaned.

Sufficient illumination shall be provided inside the tank area.

Activity at the top shall be restricted while hydraulic hose being fixed at the bottom.

Hydraulic oil shall not be kept in a loose container and it shall be away from the hot job.

10 Placing and lifting of 3rd shell and subsequent by jacks – welding and NDT

Supervisor, Rigger, khalasi, welder, gas cutter, fitter, helper, jack operator, signalman.

Fall of shell plates during lifting or placing

Failure of jacks

Failure of cleat

Personnel injury due to pressed in between

Access / egress

Fall of loose & small tools & tackles

Portable oven electrocution

Before lifting of plates from the saddle, lifting hook to be welded and it is to be physically checked for giving clearance.

Tag rope to be provided for any lifting materials.

All the plates to be stacked on the saddle in such place, it shall not create any hindrance to the other activities.

All the weld joints of the cleats to be checked by the QA/QC engineer and to be certified for using as lifting hook.

During placing of the lifted plates on the existing erected plates, hands shall not be kept in between the two plates.

During fixing of wedge piece, person shall hammer slowly in initial phase and then go for more.

Before starting the lifting operation by

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jack, all the jacks to be checked personally by the competent person.

All the hydraulic hoses shall be free from any damage.

All the jack lifting points fitted with the cleats to be checked on regular basis.

During lifting operation, nobody shall be allowed to move below the shell to go inside / outside the tank. During movement, jacks shall be locked and it is to be ensured.

While lifting of tank by jack shall be carried out, required number of people only shall be allowed inside the tank.

Inside the tank, proper & sufficient illumination shall be provided.

DC oven machine.

11 Fixing of other accessories like pipe supports, staircase with supports etc (both inside & outside) for each shell in parallel as soon as particular shell plate erected


Fall of materials

Fall of person

Wrong sequence maintaining

Proper scaffolding of required height with handrail and working platform to be erected.

No loose materials to be kept at higher elevation.

Proper access / egress to be maintained at the tower and working platform.

Required materials to be shifted at higher platform as and when required. Do not stack any materials at working platform at higher elevation.

All the activities to be carried out in a proper sequential

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manner.

12 Erection of bottom shell plates - Removal of jacks and stool one by one as soon as the particular plate is being erected and placed, welded – cutting of manhole – removal of entire materials inside the tank - welding


Personnel injury during material handling

Improper access / egress

Trip hazard

The jacks and the stool shall be removed in sequential way.

Proper supervision and guidance to be there during jack and stool removal.

Before closing the last shell plate i.e ‘make-up’ plate, manhole to be cut and access / egres to be ensured.

Sufficient ventilation to be ensured. If required, exhaust fan to be fixed.

Before transferring the entire load on the bottom shell plates, it shall be ensured that all joints are properly welded.

Sufficient illumination to be provided inside the tank.

All the materials except few to be taken out of the tank inside before placing the ‘make-up’ plate.

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13 Fixing of roof plate – balance one

Supervisor, Rigger, khalasi, welder, gas cutter, fitter, helper, signalman.

Same as point 7

Same as point 7 Site Engineer

14 Vacuum box test Vacuum pump

Electrocution

Electrician shall give all the electrical connections and it shall be routed through ELCB.

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15 Diesel oil chalk test for welding joints of bottom with the last shell plates

Supervisor, Khalasi, helper.

Fire

Suffocation due inadequate ventilation

Oil spillage

Trip & fall

No hot job shall be allowed nearby, inside, top of the tank.

Sufficient ventilation to be ensured

It is to be ensured

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that no oil spillage occurs. If require, catch tray to be used.

Housekeeping to be ensured to prevent any trip hazard.

16 Settlement test / leakage test for the tank

Supervisor, Khalasi, helper.

Failure of manholes due to loose bolts

Before starting filling of water inside the tank, all the bolts and nuts to be properly tightened and it is to be inspected properly.

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17 Painting of the tank from both inside & outside

Supervisor, Painter, Helper

Fall of person

Fall of materials

Fire hazards

Suffocation

All the scaffolding shall be erected on firm and levelled ground.

Working platform shall have proper handrail and suitable access / egress.

Sufficient illumination to be ensured inside the tank.

Inside and outside, scaffolding shall be properly supported.

Excessive paints shall not be stacked inside the tank. Quantity of paints can be taken inside as and when required.

Sufficient ventilation shall be provided (if reqd, exhaust fan) during painting job inside the tank.

No loose, open paints and thinner drums shall be stored or kept at site.

All the people must wear safety belt (double lanyard) hooked properly at shoulder level.

Suitable access /

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egress to be ensured going inside the tank.

While going to the height of the scaffolding, person shall not carry the paint container along with him.

Spillage of paints to be controlled and area shall be cleared off any spillage.

No hot job shall be allowed in and around the painting area.

18 Radiography Radiographer Exposed to radiation

Date & Time of radiography shall be informed to all concerned well in advance.

The area of radiography to be cordoned off, warning sign to be displayed and flashlights to be displayed to caution the surrounding people and passer by.

Before starting the radiography, visual check shall be there about the surrounding and other agencies working nearby shall be informed.

While doing radiography, dosimeter and survey meter shall be available with people executing the radiography.

Source strength shall be known and accordingly barrication distance shall be fixed.

Before doing the radiography, available format to be filled and signed by the

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radiographic agency and concerned site Incharge and approval shall be taken from the HSE Dept.

When blasting operation is planned, radiography shall not be permitted and radiographic source shall be kept inside the source holder.

When radiography is being done, blasting operation shall not be performed, detonators shall be kept inside the explosive magazine and vice-versa.

18 Others Relative work permits to be obtained from the SALPG along with all complimentary work permits.

Welding cables, gas-cutting hoses, electrical cables shall not overlap with each other.

All the persons involved in the job shall have suitable PPEs like goggles, nose masks, safety belts, hand gloves etc.

Excess working hour (more than 12 hours) shall be restricted.

Pep talk to be given before commencing of the job on regular basis.

Entire area shall be free from any unauthorised entry.

PA / Responsible person shall be present during

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entire operation.

Good housekeeping to be maintained in and around tank area.

In case of multiple work fronts at different levels, proper co-ordination, communication shall be in place.

Nobody shall work under suspended load at any circumstances.

‘TAG’ system to be followed for the scaffolding.

During plate erection, lifting of the tank by jack area to be restricted for unauthorised entry.

Only authorised and experienced person shall be engaged for jack operation.

Proper guard to be provided for the rotating part of the machineries.

Precaution to be taken for crane movement in between the area of crude oil line and both the tanks.

During loading or unloading of materials from the trailor parked at he main road, movement along the pedestrian path to be restricted for the moment.

Housekeeping shall be done on regular basis and all the scrap materials to be taken out of the site.

No combustible

materials to be kept in and around the tank area.

Gas cylinders to be kept in upright position in the stand.

In case of LPG cylinder, it is to be industrial and having the related regulator and flash back arrestor.

No personnel movement within crane swing area.

Trained ‘Fire watcher’ shall be present near the hot job.

Fire bucket, fire extinguisher shall be in place near the hot job.

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