JSA FOR MECHANICAL ACTIVITY

ALARP Demonstrated
Resudial risk
Risk rating

Action by

(Yes / No
Activity Task sequence Hazard Risk Existing barriers /control Recommended Control

H/M/L H/M/L
Vehicle collisions with people and Spare tire and tools shall be
Crushing
other vehicles Driver should possess valid available
Driving Assessment card certified by
TPI.
Poor visibility Injury. First Aid Box available.

No one allowed to drive under

Driver and co worker should wear
Unsafe Driving. Property Damage the influence of alcohol or
seat belt.
drugs

Maintain a Daily maintenance Job should be carried out under

Falling of loads./ unsecure loads.
checklist. the competent supervisor

Preventive maintenance schedule to

PROJECT ENGINEERS
Poor maintenance of the vehicles.
be followed.

Travel and mobilization of

prefabricated steel structures , pipes H Load material shall be fastened with L YES
& Materials ratchet web slings at every 2mts.
distance.

Follow Road Signs and speed limits.

No Driving during low visibility

condition.

Compliance to journey management

system.

Trained/ competent banks men must

be assigned to control
vehicle/equipment movement on
site.
Transportation of materials
(By
crane/hydra/Forklift/trailor)
Transportation of materials
(By
crane/hydra/Forklift/trailor) Designated pedestrian walkways to
avoid man machine interface.

Un authorized entry inside the

Only certified tools would be used
Fall of material Crushing barricaded area will be
during loading & unloading .
prohibited.

LINE SUPERVISOR
Proper barricading would be done Proper supervision would be
Injury
around the loading , unloading area . carried out during the process
Loading & Unloading of structures ,
H L YES
pipes & materials
Proper Tag line would be used while
Unauthorized operation loading & unloading of materials.

Property damage
Only authorized person would be
allowed to conduct the loading &
unloading activity

Proper supervision of the job

Conduct TBT on manual handling
Handling heavy load. Personal injury would be carried out under
before commencing the work.
competent supervisor .

Untrained worker/New worker. Use proper PPE (Hand gloves)

LINE SUPERVISOR
Manual Handling of the
prefabricated structures & Pipe H Use correct manual handling L YES
spools Exposure to sharp and hot techniques as per the guidelines
structures given in Manual handling
Musculoskeletal assessment activities.
disorders

Team handling
Pushing, pulling, lifting, holding
the loads for long time
Good house keeping

RISK MATRIX

Task needs further review and consultation with specilists

and where possible the task should be redifined to take
account of the hazards involved or the risk should be
HIGH RISK reduced further before the task is allowed to commence
MEDIUM RISK Task should only proceed with appropriate management
authorisation

LOW RISK Appropriate control measures

 Risk rating
Activity Task sequence Hazard Risk

Welding Fumes Injuries

Fire / Sparks Loss of Limbs

UV Rays Fire

Flying object Loss of life

Noise & vibration Hearing loss

Welding Grinding &

H
Gas Cutting
Slips, trips and falls from
Vibration white finger
cables.

Electrocution Electrical shock

Fabrication of
steel structures &
pipes SIMOPS
burns

Improper placement of
oxygen and acetylene
cylinder

Falling from Height

 Material/scrap can fall down

Handling heavy load. Personal injury

Untrained worker/New worker.

Manual Handling of
the prefabricated
H
structures & Pipe
spools

Exposure to sharp and hot

structures Musculoskeletal disorders

Pushing, pulling, lifting,

holding the loads for long
time
 ALARP Demonstrated
Resudial risk
Action by

(Yes / No
Existing barriers /control Recommended Control

Obtain Hot work permit &

Ensure there are sufficient fire
fighting equipments at site .

Obtain Work Permit

where necessary
especially during
Welding Face shield & Welding SIMOPS.
glasses as per EN or equivalent
standard

Abrasion resistant hand gloves

First Aid Kit available

Protective earthing,
MCB/ELCB, Regular inspection
& P.P.E.s., Insulation checking & Training & awareness
testing. to grinders, Gas
cutters & welders
Site Sup r/Consr supvr

Maintain safe distance from the Fire Watchers should

hot work area, be available
Site HSE Rep

L
Visual inspection of gas cutting
hoses and bimonthly inspection
of gas cutting set to be carried
out .

Keep cylinder in vertical

position, Use trolley for
transportation of cylinders &
always chain them, move out
any leaking cylinder, Use
flashback arrestor.

Use proper PPE’s .

Use machine with Guard only,

Face shield, proper mounting of
the wheel/disc & dry run for 30
seconds after changing the new
wheel.
Face shield, proper mounting of
the wheel/disc & dry run for 30
seconds after changing the new
wheel.

Conduct TBT on manual

handling before commencing the
work.

Use proper PPE (Hand gloves)

LINE SUPERVISOR
Proper supervision of
the job would be
L
carried out under
competent supervisor .
Use correct manual handling
techniques as per the guidelines
given in Manual handling
assessment activities.

Team handling
Good house keeping
 Risk rating
Existing barriers
Activity Task sequence Hazard Risk
/control

Assembly and Erection / fit up of

erection of steel steel structures & pipes Damage to nearby Conduct TBT before
structures & pipes structure/Suspended Crushing, impact commencing the
load / Swinging of load work.

Inspect the lifting

equipment and
Failure of lifting gears Personal Injury ensure all are
suitable and in good
condition.

Pre lift checklist for

Incompetent /untrained
Asset Damage routine works must
operators/ riggers
be filled up
Operator having
Improper erection. valid driving
/Operator License.

Check the capacity

of crane & lifting
Defective TOOLS
tackles and approved
certificate.

Unstable ground
Proper supervision.
condition.

Only certified,
trained and
/unsuitable equipment experienced operator
and rigger shall be
used.

H
Swing radius should
be barricaded with
Poor/Damaged lashing
warning tape and
strap/slings
sign board to be
posted.

Falling of steel Use tag lines to

structures control the
movement of the
load.

Include traffic
management during
 Falling of steel
structures

Lifting activities
shall be suspended
during weather
conditions like sand
storms , strong winds
, rain etc .
Include traffic
management during Ensure outriggers
erection of steel are fully extended.
structure. Road maybe Loads should be
blocked and limited secured during
access erection.
Assess the load/
lifting tackles not to
be overloaded
beyond its SWL.

Load test certificates

for all lifting/rigging
devices with SWLs
should be available.
 ALARP Demonstrated
Resudial risk
Action by

(Yes / No
Recommended
Control

Any employee,
authorized to stop a
lift operation when it
becomes apparent that
something is not safe.
enter in barrication
area during erection
except authorized

Trained banks man

should be assigned to
control the equipment
movement

L YES

Color code system

should be followed.
PTW shall be adhered.
VISOR
LINE SUPERVISOR
 Risk rating
Task Existing barriers
Activity Hazard Risk Recommended Control
sequence /control

Hot work Welding Obtain Hot work

Grinding & Obtain Work Permit
permit & Ensure there
Gas Cutting where necessary
Welding Fumes Injuries H are sufficient fire
especially during
fighting equipments at
SIMOPS.
site .
Welding Face shield &
Welding glasses as per
Fire / Sparks Loss of Limbs H First Aid Kit available
EN or equivalent
standard
Training & awareness
Abrasion resistant
UV Rays Fire H to grinders, Gas
hand gloves
cutters & welders.
Protective earthing,
MCB/ELCB, Regular
Fire Watchers should
Flying object Loss of life H inspection & P.P.E.s.,
Insulation checking & be available
testing.
Maintain safe distance
Noise & vibration Hearing loss H from the hot work Use proper hear
area, protection
Visual inspection of
gas cutting hoses and
Slips, trips and falls from Vibration white bimonthly inspection maintain house
H of gas cutting set to be
cables. finger keeping
carried out .

Keep cylinder in
vertical position, Use
trolley for
transportation of
Electrocution Electrical shock H
cylinders & always
chain them, move out
any leaking cylinder,
Use flashback arrestor.

SIMOPS burns H Use proper PPE’s .

Use machine with
Guard only, Face
shield, proper
Improper placement of mounting of the
oxygen and acetylene H wheel/disc & dry run
cylinder for 30 seconds after
changing the new
wheel.

Falling from Height H

Material/scrap can fall H
down
Painting metal Fumes & vapors
Activity paintaing Fire & explosion if comes
Personal injury
in contact with sparks &
Skin irritation . Pre Medical Checkup
hot ignition sources Respiratory protection
Dizziness by medical officer
Mixing of Painting
Static Electricity H

Special painting zone

MSDS available at site
-far away from hot
property damage & MSDS guidelines to
work & other ignition
be followed
sources.
 Demonstrated
Resudial risk
Action by

(Yes / No
ALARP
Recommended Control

Obtain Work Permit

where necessary
L
especially during
SIMOPS.

First Aid Kit available L

Training & awareness

to grinders, Gas L
cutters & welders.

Fire Watchers should

L
be available
LINE SUPERVISOR/Construction supervisor /hse rep

Use proper hear L

protection

maintain house
L
keeping
yes

L
 LINE SUPERVISOR
Pre Medical Checkup
L
by medical officer
YES

MSDS available at site

& MSDS guidelines to L
be followed
 Risk rating
Task Existing barriers
Activity Hazard Risk Recommended Control
sequence /control

Working Working at a Obtain permit as deemed Tool Box Talk to be conducte

Fall from height Injury to the personnel
at height permanent required. prior to start the work
tower
/Suspended Establish good materials
access equipment layout Emergency Plan should be
Collapse of pipe
intended for the job to available .
suit good flow of work.
Property damage
Ensure compliance with 100
Manual handling .
tie up .

Personnel to be aware on
the ground conditions of
Only Trained scaffolders to b
Structural failure the work area and other
used .
inherent hazards in the
workplace.

Dropped objects Right use of tools with

right
Obtain proper
communication and
Body Positioning coordination among
workers & secure work
area.
In addition to basic PPE
use safety harness,
H
lanyards, inertia reels &
Weather conditions other fall arrest device as
(windy/humid/heat) deemed necessary.

Appropriate protective
gloves should be used
when handling rough or
sharp materials.

Obtain firm and stable

supports.

Regular visual inspection

o be carried out of access
Lack of coordination & ladder or tower before
communication start of work activity .
Lack of coordination &
communication

Use of scaff tags for

identifying safe structure
.

Works to be suspended
during adverse weather
condition.

Toe boards to be ensured

at the tower
 ALARP Demonstrated
Resudial risk
Action by

(Yes / No
Recommended Control

Tool Box Talk to be conducted

prior to start the work

Emergency Plan should be

available .

Ensure compliance with 100%

tie up .

Only Trained scaffolders to be

used .
LINE SUPERVISOR

L YES
 Risk rating
Activity Task sequence Hazard Risk

Non destructive
Test(NDT) Unauthorized entry Personal Injury

Unauthorized RT
Property damage
Technician
Failure of source to
Radiation illness
return to projector
Breakdown of
Delay of work
vehicle

Slip / Trip/Fall
hazard Radiation exposure of
personnel

Fire / Personnel
accident

H
Over speeding

Unauthorized
vehicle/driver

Breakdown of Vehicle

Beam Coping Cutting of Fall of material Personnel injury

beam using Damage to
coping machine structure / Material Property damage

Incompetent/untraine Electrocution
d operators.
Clashing with
structure Project Delay

H
Person hit or struck by load
 H

Pinch Point

Fall of beam

Hydraulic Hose bursting

 ALARP Demonstrated
Resudial risk
Action by

(Yes / No
Existing barriers /control Recommended Control

Send notification 6 hrs before inspection of the work

to contractor and copy it to area by HSE and NDT
HSE. team before the
issuance of the work
Conduct tool box talk before Use of ROP approved
start of the work. transportation vehicle .
Ensure proper stacking of Site Follow the emergency
materials. procedure .
Ensure proper illumination in radiographers with
the enclosure at night shift. only ASNT Level II
certificate conduct the
Maintain the contact number of availability of survey
duty electricians during night meter, dosimeter and
TLD badges must be
RT Technicians , QC Deptt & HSE

shift
wornthe
Recoil bypower
the
All necessary radiation signs cables and remove the
shall be displayed while signage after the
carrying source source is removed.
Unauthorized passengers are
not allowed to travel with L YES
source carrying vehicle. Only
RT crew will be permitted
inside the vehicle.
Ensure the area is barricaded
with trefoil signed warning
tape.
Blinking lights & alarm are all
working and visible to avoid
unauthorized entry.
Exclusion zone shall be
marked using survey meter
The radiography source shall nev
Use of proper PPE and turn off
siren & blinker lights after
completion of work.
operator to be trained
Crane area to be barricaded. and certified
Flagman shallbybeThird
party or should
Cut material to be stacked in a assigned with have a
proper manner. Hydra/Forklift while
The job being lifted should be carrying load.
free from loose items. Tag lines shall be used
to control the load.
SUPERVISOR /FOREMAN

General housekeeping, Ensure that provision

remove all unwanted material
after performing task.
Adequate illumination should
be ensured prior to start the
task.
of FA box is given at
centralized location.
Acclimatization
program shall be L YES
implemented for new
employees
 SUPERVISOR /FOR
L YES

Trays to be emptied on a
regular interval or as per Buddy system
schedule.
ORS shall be provided
Personnel to avoid contact as recommended by
with hot surfaces. medic
Watch out / be cautious while
moving especially in congested
area.
 Risk rating
Activity Task sequence Hazard Risk

Task not briefed or Error in Project

documentation Involvement Delay
of incompetent.Personnel

Uneven ground /Lack of Personnel

compaction Injury

Bad weather Property

Damage
failure (Wire rope sling,
shackles ,Pad Eye)

Over speed

Swinging

Wind affect

Working near suspended load

.
Heavy Lift & erection H
Over speed

Swinging
injury to personnel &
property damage
 ALARP Demonstrated
Resudial risk
Action by

(Yes / No
Existing barriers /control Recommended Control

Obstruction to be provided
Ensure all documents are approved
in the scaffold platform
and drawings and lifting plan/scheme
near the column to avoid
is reviewed and understood by all
personnel’s entering below
involved personnel.
the suspended load .
Ensure all weld joints are tested
(NDT) and passed as per requirement Appropriate PPE shall be
provided
shall be in place(stand by
The area shall be inspected and
vehicle, medical team shall
confirm safe to proceed
Only competent personnel shall be be notified, FA box and
assigned for the task Proper communication
Only shall be maintained
TPI certified Riggers will be assigned between day & night shift
for the job. night(holding for extended
Only TPI certified equipment will be hours) and ensure proper
used. supervision during night
Crane moving path to be clearly
marked
Construction Manager , Lifting Supervisor & HSE

Proper communication
shall be established.
Maintain good housekeeping in the
area and remove all unwanted
materials.
Erect barriers and warning signs in
the affected area and restrict
unauthorized personnel entry. L YES
Ensure the ground is even and
adequately compacted

Positioning of the cranes should be as

per the erection scheme at the
designated location.
weather forecast to be checked.
In case of heavy wind/ poor visibility,
work will be suspended till weather
permit (10 m/s)Briefing shall be
conducted by the PIC/Rigging
Supervisor.
Obtain Heavy lift work permit prior
to lifting activity.
Obtain Heavy lift work permit prior
to lifting activity.
Crane must have load test certificate
and in good working condition prior
to use.

Only TPI certified personnel to

operate the equipment.
Adequate Safety harness to be
provided
 Risk rating
Activity Task sequence Hazard Risk

Pressure Test Hydro Test & Retrojet

Manual / Mechanical
Hand injury
handling

Awkward position Slip, trip and fall

Fatigue Personnel
Repetitive movements
injury Defective tools

Waste Water Generation Rupture of the line

Rupture of Test
Skid mounted Diesel Engin
Equipment

Noise induced hearing

loss
Rotating parts of
equipment exposed

Noise Oil spillage , fumes,

Heat stress

High Pressure
H
 ALARP Demonstrated
Resudial risk
Action by

(Yes / No
Existing barriers /control Recommended Control

Ensure area is clear from obstacles Ensure all personnel

prior to moving material - Ensure involved fully
authorized personnel will only be understand hydro test
entered in to the area Barricade all procedures and task
area with warning signs
specific training being
carried out.

Meeting of all personnel involved prior

All components shall
to test. Review procedure(s), safety
have pressure rating
precautions (JSA), required PPE,
marking
signed PTW

Confirm flushing / internal cleaning is

complete and acceptance certificate
and contained within test pack

Joints should not be fully painted

,Must be with Primer only.

A suitable connection on the blind

flanges should be provided for water
inlet, vent, drain, pressure gauge, Test
PSV ,test pump, pressure recorder etc.
Drains should be provided at low
points in the equipment to allow
complete draining at conclusion of test

Check gauge , relief valve chart

recorders and all test equipment in line
are calibrated for specific test pressure
before test commences

Use of over rated equipment

All fittings, couplers, test plugs, PSV
relief lines, vent discharges and flanges
should face the test cell/pit walls or
floor where practicable

Minimize the number of fittings and

hoses used to lessen potential failure
points and leak paths
Use of whip checks

Pressurize the Test in increments of 5%

of final test pressure

Lowering pressure should be done in

5% pressure increment

Pro.sup.
L YES
Keep out of line of fire

Use of blast shield whenever practical

Equipment should have demonstrated

pressure stabilization/integrity of
screwed connections for a pre-
determined hold period (Minimum 5-
10mins) before being approached by
any personnel. No access needed if no
leak/pressure drop

Under no circumstances should a

pressurized connection be adjusted
while pipe work is under pressure.
Pressure must be bled down to zero
prior to adjustment or disassembly of
test set up (ensure no trapped pressure)

Restricted access

Access to the immediate test area

should be strictly limited to Authorized
personnel

Flashing light through to completion of

test (or adequate signage)

No lift over hydro test area

Ensure calibrated pressure gauges
/PSV Chart Recorders are used.

Drip tray should be provided.

High noise signage will be provided.

Stand by person.
All rotating parts shall be guarded
Use of whip checks
Wakie talkie should be used for
communication. If required
Disposal By Methodology approved
By CIL
Tidy area store equipment and
material neatly
Dispose of any waste in correct waste
bins. Dispose of any waste in correct
waste bins.
Ensure pass is clear from obstacle prior
to move material
Spill kit for hydraulic spills
 Risk rating
Activity Task sequence Hazard Risk

E&I Work (ELECTRICAL Cable Laying Inadequate load restraining provision

Personal injury
& INSTRUMENTATION ) (Strike/hit or crushed
by)
Not following traffic rules Property damage

Incompetent crew Over Insurance cost

loading
Uneven ground for placing of Project delay
jack.
Uneven ground for placing of Muscular &
jack. skeletal injuries
Inadequate compaction/ Bone fracture,
loose soil under jack. spinal injury if fall
from height.
Improper use of jack
Hand Injury
Improper use of
jack/Defective jacks
Substandard or fabricated
drum spindle.personnel
involved in pulling.

Incorrect positioning &

alignment of cable drum.

Hand trapped between

rollers while pulling cables

Mis communication while

Pulling of cables having long
distance for e.g from 1st level
to 3rd level.

Lifting gears failure (Wire

rope sling, shackles)

Hit or strike by existing

structure/pipe.

Expose to electric
Extreme weather

Damage to environment
 ALARP Demonstrated
Resudial risk
Action by

(Yes / No
Existing barriers /control Recommended Control

All emergency requirement shall be in

Ensure all documents are
approved and correct
Following road traffic rules.
place (stand by vehicle, medical team
shall be notified, FA box and First aider,
man liftcommunication
Proper etc.) shall be
maintained between day & night shift

All require certificates to be kept with

Competent driver/operator.
the permit
Good condition of
equipment’s/vehicles. TBT prior commence of work
No over loading shall be
Training for safe lifting and rigging.
allowed.

Only competent personnel

Close supervision.
shall be assigned for the task.

Ensure the ground is level Stop lifting operation during bad

and adequately compacted weather(wind/poor
visibility/rain/extreme hot)

Ensure the jack is defect free

Ensure spindles are in good

condition

Only competent personnel

shall be assigned for the task.

Appropriate PPE to be
provided and used

Proper coordination among

crew members

Follow working at height

procedure.
Proper job & procedure
(P7512-05-003-QC-PRC-
0027)knowledge
Supervisor & HSE.
 E&I supervisor, Lifting Supervisor & HSE.
Unavailability of
communication media at right
time.

L yes

All lifting equipment must be

certified, color-coded and in
good working condition.

All lifting equipment shall be

with rated SWL.

Verify inspection and

certification records of all
lifting equipment

Visual inspection of lifting

equipment must be conducted
prior to use.

Proper co-ordination between

employees.

Adequate safety harness to be

provided.

Safe and secured platform

Obtain necessary permits.
Provide appropriate access to
work at height by means of
scaffolding platform.