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BASIC JOB STEPS REMARKS

METHOD STATEMENT ANALYSIS

L&T Heavy Engineering.

HIGH RISK IEDNTIFIED

MITIGATION STEPS TO REDUCE/ELIMINATE THE RISK

(Repair of Gas Cooler & EO reactor- 4R-1101-A/B)

People working in operating area

Damage plant facility or equipment by vehicles

Loading and hauling (hit by chain binder/pinch

points/dropped load)

All loads hauled on vehicles MUST be securely tied down with

approved rope, straps or chain.

Only qualified and trained drivers and crane operators to be

used.

All vehicles, mechanical and electrical equipment to be

inspected & approved by SHARQ.

Under no circumstances shall a load be hauled without proper

tie downs. Utilize rachet straps when possible. Rachet binders

are preferred over chain binders to avoid injury.

When loading a flat bed place load as far as possible preferably

against a stationary object such as a head ache rack. When this

is not feasible place the load centered over the rear axle.

Before hauling a load make a quick walk around the vehicle to

assure all tool boxes are closed and that the load is secured.

When hauling a load check to be sure the load stays secure

while under way.

Ensure people baricading and no one to be allowed below

hanging.

Obey stie safety rules for speed restrictions and access routes.

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3. Moving Heavy Objects

Back injury

3.2 Transporting Heavy object.

3.1 Lifting heavy object. Savingyourself from injury is more important

that avoiding damage to what you're

lifting.

It's the driver's responsibility to assure that the vehicle is rated

for the weight that is carried on it.

Ensure that hand protection or wear heavy gloves.

Slipping on wet or slick floor

2. Setting up and taking down

equipment

Hand injury while setting up

Back injury

Foot injury

Foot injury from dropping heavy object

Use legs as the source of power to lift object.

Solicit the help of others or employ tools if object is to heavy

to be lifted by one person.

Get a secure hold on object.

Wear gloves to aid in a secure grip.

Wear steel-toed shoes, or similar.

Evaluate condition of floor along path from origin to

destination.

NEVER place your hand under the load.

To minimize injuries, there should be 2 peolple moving posts.

Keep feet away from the goal post.

Bend knee to lessen pressure on the lower back.

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5.1 Entering vehicle

5.2 Driving motorized vehicle

6. Use of Scaffolding

Injury from entering

Injury to self from accidents

Fall of Objects/Tools

Unstable Scaffold

Weak Scaffold

Damaged Scaffold

Modified Scaffold

Improper Support of Scaffold

The scaffold must be inspected, certified & tagged by the

competent/qualified person confirming its suitability.

Be carefull when opening the door.

Fasten the seltbelt before driving.

Use defensive driving skills.

Obey SHARQ speed limit.

Never leave unattended car running.

Ensure guardrail & toe board to prevent falling of

tools/objects.

The scaffold tag must indicate the maximum load that it can

bear.

The scaffolding is to be inspected at least weekly for any

damage due to weather condition (water spillage, high wind,

spark by gouging/welding etc..)

In case of any modification, addition in the scaffold, it has to

be re-inspected & certified.

Ensure scaffold is securely supported on a rigid ground and not

on process piping/vessel or equipment.

Do not use if greenTag is missing.

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7. Hand held portable power tools

Cuts/Bruises/Electroc

ution/Slips/Trips/Fall

s

7. Hand held portable power tools

Cuts/Bruises/Electroc

ution/Slips/Trips/Fall

s

Do not use if it does not have valid inspection tag attached.

Inspect hand tools prior to each use.

Appropriate PPE, including gloves shall be available when usinghand tools.

Never remove safety guards from power tools.

Before servicing any power tool, such as changing drill bits,

saw blades, or grinding wheels, you must unplug the tool first.

Pneumatic power tools shall be secured to the air hose either

by an approved quick connect fitting or by chicago fittings with

safety clips.

Never plug in a wheel grinder or a wire brush without first

making sure the power switch is in "off" position.

All tools and equipment shall be maintained in good condition.

Damage tools or equipment shall be removed from service and

tagged "DEFFECTIVE".

Pipe or stillson wrenches shall not be used as a substitute for

other wrenches.

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8. Working around Electrical

8.1 Power poles

8.2 Conduits

8.3 Panels

Noise

Potential for Electrical shock

Potential for serious burns or enjury

Potential for Equipment Damage

Fire

A screw driver shall not be used as a chesil.

Only appropraite tools shall be used for the job.

Portables electric tools shall not be lifted or lowered by means

of the power cord.

Electric cords shall not be exposed to damage from vehicles

driving over them.

Appropriate placed fire extinguisher, remove all conbustibles

and fire hazards materials from machine area.

Hearing protection/ear plug.

Electrical installation and maintenace shall only be performed

by certified electricians.

Lock-Out and Tag-Out procedures must be used if any

electrical or mechanical equipment is being serviced (this may

include changing light bulb).

All electrical equipment shall have ground fault circuit

interrupters or assured equipment grounding.

Lockout and Tagout electrical equipment prio to exposing

personnel.

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9. Heat treatment using Electrical

Heaters

Presence of flamable/toxic vapor

Deffective tools/equipment

Electric shock

Unauthorized Personnel

Avoid lifting long dimensional conductors over live electrical.

Keep the area dry insuring no water spillage.

Do not bring any flammable or gas at the location where the

heat treatment is under progress.

All extension cords shall free of frays.

Panel boxes must be covered to prevent accidental contactwith live parts.

Conductive items of jewelry or clothing shall not be worn

unless they are rendered non-conductive by covering, wraping

or other insulating means.

Barricade the area where heat reatment is to be carried out.

Post warning notice.

Ensure that equipment tool to be used for heat treatment

(such us trcings, cables, terminals, switches and panels etc..)

are free from defects and suitable for the temperature ratings

of the system.

Ensure the area where heat treatment will take place is free

from flammable/toxic vapor.

Ensure proper insulation of heat tracing coil and terminals.

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10. Fuel Transfer Pump

Proper Ventilation arrangement to be done, provide proper

Personal Protective Equipment

9. Heat treatment using Electrical

Heaters

Expose to high temprature

DHT

Burn

Unattended tool/equipment

Eye injury due to fuel splashes

Changing the temperature or duration of heat

treatment

Scattered material

Refer heat treatment procedure or contact inspection

engineer in case in doubt.

The accessories (heating elements, tracing, cables, terminals

etc..) not being used must be disconnected and stored

separately.

Keep the fire extinguishers in ready condition.

Do not touch the area which is being treated use timpilstik.

Do not leave the tool/equipment in energized condition when

the heat treatment is in progress.

Isolate power to the equipment which not in use.

Do not change(exceed/decrease) the temperature or duration

of heat treatment without permission from the Inspection

Engineer.

Monitor the temperature in the heat treatment

panel/recorder.

Use googles

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Strain and Sprains

Strain and Sprains

11. Cutting /Heating torch using

Oxygen and Acetylene

Fire explosion

Pressure Hazards

Slips & Falls

Defective tools

Pinch points and obstructions11. Cutting /Heating torch using

Oxygen and Acetylene Ensure the gas cutting equipment (blowpipe, hoses, oxygen

cylinders, pressure gauge) are free from defect.

Ensure a good working surface.

Do not move or store cylinders without properly installing the

protective cap ove the valve.

Oxygen cylinders should not be tored within 20 feet of

combustible gas cylinders or near any other substance where a

fire could result, unless protected by a wall at least 5 feet high

having a fire resistance rating at least 30 minutes.

Cylinders should be properly secured with chain to prevent

falling.

Use regulators and pressure gauges only with gases and

pressure ratings for which they are designed and intended.

Close the cylinder valve before attemting to stop leakes

between the cylinder and regulator.

never permit sparks, molten metal, electric currents, excessive

heat or flames to contact the cylinder or attachments.

No smoking or exposure to sparks or open flame during

fueling. Fill stem shall be bonded to the container during filling

operations by means of a bond wide. Appropriate placed fire

extinguisher.Make the area barrication use the vechile entry

certificate, Ensure the use of spark arrestor

Use proper hand protection.

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12. Gouging

12. Welding

Exposing to fumes

Burns

Falling Sparks

Flash back fire

Exposing to fumes

Ensure proper ventilation and fume extration equipment in

case of welding/gouging inside an enclosure. Provide dust

mask , if required to be use

BurnsWear long sleeve (fire resistant) coverall, leather aprons and

hood.

Falling Sparks

Enclose the welding/gouging area through fire froof

blanket/tarpaulin.Provide the stand by water hose running,

Fire Extinguisher (DCP)

Radiation from Welding/Gouging flame/rays

(flash eye)

Provide a check valve( flash back arrester) between oxy-

acetylene hose & gas regulator.

Wear protective googles & clothing for welding, PPE as per

SHEM 8.08 , the helmet should be atttached to the face shield

Ensure proper ventilation and fume extration equipment in

case of welding/gouging inside an enclosure. Ensure the

availability of dustmask , if required to be use

Radiation from Welding/Gouging flame/rays

(flash eye)

Wear long sleeve (fire resistant) coverall, leather aprons and

hood.

Enclose the welding/gouging area through fire froof

blanket/tarpaulin.Provide the stand by water hose running,

Fire Extinguisher (DCP)

Wear protective googles & clothing welding PPE as per SHEM

8.08 , the helmet should be atttached to the face shield

Empty and full cylinders should be stored separately, and

palinly identified.

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Grinding

NDT (Dye Penetration Test)

13. Elevated Lift Operation

Mount the wheel properly, Train the grinder and welder /

Wheel mounting shall be done with keyImproper wheel breaking

Using of DPT Cans at site causing Eye irritation,

Respiratory problems - Flammable vapoursUse of Nose Mask, Use of Safety Goggles

Expolsion if working in enclosed place Use 24 V handlamp with cage & provide proper ventilation

Fire & Explosion of empty cans & Cotton WasteDisposed of cans & Cotton Waste at designated place as per

MSDS.

Safe Handling, Use of PPEsEnvironment Hazard - Handling of the Dye - Spillage

Electric shock Ensure proper insulation of heat tracing coil and terminals.

Check any crack, Use Standardized wheels

Select proper RPM wheel, Select proper rpm wheel, Wheel

RPM is less than spindle RPMWheel breaking

Wheel breaking

Burns due to flying particlesWear long sleeve (fire resistant) coverall, leather aprons and

the helmet should be atttached to the face shield

Flying Hot Particles

Enclose the grinding area through fire froof

blanket/tarpaulin.Provide the stand by water hose running,Fire Extinguisher (DCP).

Exposing to Dusty Environment

Fire - Disposal of used cans

Fire in the storage area

Perform pre-use inspection prior to use.

Ensure lift is operated by qualified operator.

Storage of chemicals as per MSDS

Ensure proper ventilation in case grinding inside an enclosure.

Provide dustmask , if required to be use

As per Clients instruction

Faulty equipment

Falll Hazards

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Dropping tools onpersonnel

13. Elevated Lift Operation

Heat Stress

Air Movement, Clothing, Rediant Heat,

Humidity, Work Rate

Shift the person to cool area, loosen or remove heavy clothing,

provide cool drinking water,

Heat Cramp: Pale Skin, Nausteated,Tired,

Muscle Twitching, Muscle Cramp

Heat Exhaution: Heavy Sweating, Weak &

Fatigue, Headache & Dizzy, Nauseated, Rapidly

Breathing, Intense Thirst, Vomiting

Heat Stroke: Hot Red Skin, No Sweating, Rapid

Pulse Rate, Diffulty in Breathing,Vomiting,

Coma

Start Drining Water, Ensure adequate ventilation,

Check your Urine colour, Job Rotation, Keep eye on your

workmates

Avoid tea / coffee or heavy meals

Wear light weight, light colour, loose f ittng cloths

Only use lift on flat level ground.

Do not use lift withion 10 feet of energized power lines,

distance should be increased per approach charts for high

voltage lines.

Tie off tools or otherwise secure them from falling below.

Tape off of barricade work area.

Employees must stand firmly on the floor , and not sit or climb

on the edge of the basket or use planks, ladders, or other

devices for a work pisition.

Never work or walk under loads.Potential for roll over

Electrical Hazards

Dropping tools on personnel

Start job early and provide rest breaks to workmen

Pinch points

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Position Date Signature

Approved by Area Owner

(Manager/Superintendent/Supervisor)

6

4

5

2

3

Name(s)

1

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Final MSA