JHA Number: sap/035 Job Title: Sulfuric Acid Plan

Shift Engineer
Persons Accountable ** Any Applicable legal re
Oprns / Maint

Staff/contract AP factories Act/Environment Act / Petroleum Act/Boiler

Persons doing job:
work men Rules/Motor Vehicle

**Frequency: Routine / Non routine: Continuous / Daily / Weekly / Monthly / Yearly

**Affected Parties: Staff Contractor Visitors Others

Hazard

Consequence
Potential
No. Steps in Task Source & Engineeri
Human Act ng
Situation

Cat
ladder
Climbing up/down cat
with D
1 ladder to approach Slips/trips/falls Horse play injury
guard
manways area
availabl
e
Objects fall
2 Opening the manways Horse play injury No
from height
Draining of acid from Horse play / over Acid
3 Confined space No
tower bottom confidence burns
Isolation
Acid of
Confined space Over confidence
burns pump/m
otor

3 Inspection of internals
Isolation
Respirat
Exposure to of
Over confidence ory
acidic fumes pump/m
problem
otor

Isolation
Acid of
Confined space Over confidence
burns pump/m
otor
 Isolation
Respirat
Exposure to of
Over confidence ory
acidic fumes pump/m
problem
otor
Distribution headers
4
removal / re-fixing

Slippery /
uneven
ground /
Over confidence Injury No
manual lifting /
awkward
posture

Isolation
Acid of
Confined space Over confidence
burns pump/m
otor

Isolation
Respirat
5 Spouts removal / re- fixing Exposure to of
Over confidence ory
acidic fumes pump/m
problem
otor

Slippery /
uneven
ground /
Over confidence Injury No
manual lifting /
awkward
posture
 Isolation
Acid of
Confined space Over confidence
burns pump/m
otor

Troughs removal / re- Isolation

6 Respirat
fixing Exposure to of
Over confidence ory
acidic fumes pump/m
problem
otor

Slippery /
uneven
ground /
Over confidence Injury No
manual lifting /
awkward
posture

Isolation
Acid of
Confined space Over confidence
burns pump/m
otor

Isolation
Respirat
Exposure to of
Over confidence ory
acidic fumes pump/m
problem
otor

Saddles removal and

7
lowering to ground
 Saddles removal and
7
lowering to ground

Slippery /
uneven
ground /
Over confidence Injury No
manual lifting /
awkward
posture

Injury /
Material fall
Horse play material No
from height
damage
Acid
burns /
Respirat Isolation
Exposure to ory of
8 Saddles cleaning Horse play
acidic fumes problem pump/m
/ land otor
depletio
n Isolation
Acid of
Confined space Over confidence
burns pump/m
otor

Isolation
Respirat
Exposure to of
9 Saddles loading Over confidence ory
acidic fumes pump/m
problem
otor

uneven
ground /
manual lifting / Over confidence Injury No
awkward
posture

Isolation
Acid of
Confined space Over confidence
burns pump/m
otor

Shell corroded portion

10 brick / rephonal lining
 Isolation
Respirat
Exposure to of
Over confidence ory
Shell corroded portion acidic fumes pump/m
problem
10 brick / rephonal lining otor
removal / re-fixing

Collapse of
Injury
brick lining

Isolation
Acid of
Confined space Over confidence
burns pump/m
otor

Isolation
Respirat
Exposure to of
Over confidence ory
acidic fumes pump/m
Shell damaged plates problem
otor
11 cutting / welding with new
plate

Fire / explosion Injury

e: Sulfuric Acid Plant - 1 Task: DA 503 IAT tower jobs – 1) Acid headers, spouts, trou
removal and re-fixing 2) Saddles removal and reloading 3) A
draining 4) Brick lining & shell repairs

** Any Applicable legal requirement:

ent Act / Petroleum Act/Boiler Act/ Explosives Act / SMPV Rules/MSIHC

Rules/Motor Vehicles Act

ekly / Monthly / Yearly

hers
Controls in Place

Administrative Work Practices PPE

Training

Work permit /
Supervision
Work permit / Helmet, gloves,
Contract control
Supervision safety shoe

Work permit / Helmet, gloves,

Contract control
Supervision safety shoe

Work permit / Contract control / behavior PVC suit & gloves,

Supervision reinforcement gum boot, Hood
Work
Practices

Work permit / PVC suit & gloves,

Supervision gum boot, Hood
 Work
Practices

PVC suit & gloves,

Work permit /
gum boot, Hood,
Supervision
canister mask

Work permit /
Contract control / behavior PVC suit & gloves, Contract
Supervision / control
reinforcement gum boot, Hood
Training

PVC suit & gloves,

Work permit / Contract control / behavior Contract
gum boot, canister control
Supervision reinforcement
mask, Hood

Contract
PVC suit & gloves, control /
Work permit / Contract control / behavior
gum boot, canister behavior
Supervision reinforcement/ right tools reinforcem
mask, Hood ent

Work permit /
Contract control / behavior PVC suit & gloves,
Supervision /
reinforcement gum boot, Hood
Training
 PVC suit & gloves,
Work permit / Contract control / behavior
gum boot, canister
Supervision reinforcement
mask, Hood

Contract
PVC suit & gloves, control /
Work permit / Contract control / behavior
gum boot, canister behavior
Supervision reinforcement/ right tools reinforcem
mask, Hood ent

Contract
Work permit / control /
Contract control / behavior PVC suit & gloves,
Supervision / behavior
reinforcement gum boot, Hood reinforcem
Training ent

Contract
PVC suit & gloves, control /
Work permit / Contract control / behavior behavior
gum boot, canister reinforcem
Supervision reinforcement
mask, Hood ent/ right
tools

Contract
PVC suit & gloves, control /
Work permit / Contract control / behavior
gum boot, canister behavior
Supervision reinforcement/ right tools reinforcem
mask, Hood ent
 Contract
Work permit / control /
Contract control / behavior PVC suit & gloves,
Supervision / behavior
reinforcement gum boot, Hood reinforcem
Training ent

Contract
Work permit / PVC suit & gloves, control /
Contract control / behavior behavior
Supervision / gum boot, canister reinforcem
reinforcement
Training mask, Hood ent/ right
tools

Contract
PVC suit & gloves, control /
Work permit / Contract control / behavior
gum boot, canister behavior
Supervision reinforcement/ right tools reinforcem
mask, Hood ent

Contract
Work permit / Contract control / behavior PVC suit & gloves, control /
behavior
Supervision reinforcement gum boot, Hood reinforcem
ent

Contract
PVC suit & gloves, control /
Work permit / Contract control / behavior behavior
gum boot, canister reinforcem
Supervision reinforcement
mask, Hood ent/ right
tools

Contract
Work permit / control /
Contract control / behavior PVC suit & gloves,
Supervision / behavior
reinforcement gum boot, Hood reinforcem
Training ent

Contract
PVC suit & gloves, control /
Work permit / Contract control / behavior
gum boot, canister behavior
Supervision reinforcement reinforcem
mask, Hood ent
 Contract
PVC suit & gloves, control /
Work permit / Contract control / behavior behavior
gum boot, canister reinforcem
Supervision reinforcement
mask, Hood ent/ right
tools

Contract
Contract control / behavior PVC suit & gloves, control /
behavior
reinforcement gum boot, Hood reinforcem
ent

Contract
PVC suit & gloves, control /
Work permit / Contract control / behavior
gum boot, canister behavior
Supervision reinforcement reinforcem
mask, Hood ent

Contract
control /
Work permit / Contract control / behavior PVC suit & gloves, behavior
Supervision reinforcement gum boot, Hood reinforcem
ent

Contract
Work permit / Contract control / behavior PVC suit & gloves, control /
behavior
Supervision reinforcement gum boot, Hood reinforcem
ent

Contract
control /
PVC suit & gloves, gum boot,
Contract control / behavior reinforcement behavior
canister mask, Hood
reinforcem
ent

Contract
control /
Helmet, gloves, safety shoe,
Explosive mixer check up available behavior
welding goggles
reinforcem
ent
 Contract
control /
Work permit / Supervision behavior
reinforcem
ent

Contract
control /
behavior
reinforcem
ent

Contract
control /
Work permit / Supervision behavior
reinforcem
ent

Contract
control /
Work permit / Supervision behavior
reinforcem
ent

Explosive
mixer
Work permit / Supervision
check up
available
Acid headers, spouts, troughs
emoval and reloading 3) Acid
pairs

Work Place Environment damage

Occupational health

PPE
 Work Place Envir
Occupatio

Helmet,
gloves,
1 1
safety
shoe

Helmet,
gloves,
1 1
safety
shoe

PVC suit &

gloves,
2 2
gum boot,
Hood

PVC suit &

gloves,
1 1
gum boot,
Hood
PVC suit &
gloves,
gum boot,
2 1
Hood,
canister
mask

PVC suit &

gloves,
1 1
gum boot,
Hood

PVC suit &

gloves,
gum boot,
2 1
canister
mask,
Hood

PVC suit &

gloves,
gum boot,
2 1
canister
mask,
Hood

PVC suit &

gloves,
1 1
gum boot,
Hood
PVC suit &
gloves,
gum boot,
2 1
canister
mask,
Hood

PVC suit &

gloves,
gum boot,
2 1
canister
mask,
Hood

PVC suit &

gloves,
1 1
gum boot,
Hood

PVC suit &

gloves,
gum boot,
2 1
canister
mask,
Hood

PVC suit &

gloves,
gum boot,
2 1
canister
mask,
Hood

PVC suit &

gloves,
1 1
gum boot,
Hood

PVC suit &

gloves,
gum boot,
2 1
canister
mask,
Hood
PVC suit &
gloves,
gum boot,
2 1
canister
mask,
Hood

PVC suit &

gloves,
2 2
gum boot,
Hood

PVC suit &

gloves,
gum boot,
1 2
canister
mask,
Hood

PVC suit &

gloves,
1 1
gum boot,
Hood

PVC suit &

gloves,
gum boot,
1 1
canister
mask,
Hood

PVC suit &

gloves,
gum boot,
1 1
canister
mask,
Hood

PVC suit &

gloves,
1 1
gum boot,
Hood
PVC suit &
gloves,
gum boot,
2 1
canister
mask,
Hood

PVC suit &

gloves,
4 4
gum boot,
Hood

PVC suit &

gloves,
1 1
gum boot,
Hood

PVC suit &

gloves,
gum boot,
2 1
canister
mask,
Hood

Helmet,
gloves,
safety
2 2
shoe,
welding
goggles