JOB HAZARD ANALYSIS

MIDHANI

Swing Grinding
Job Description: Operation

Area: Conditioning Shop, HRM

Work Area/ Equipment: Grinding Machines
Perosonal Protective Equipments/Tools:Safety Glasses with side shields/goggles, Safety toed shoes, gloves, Face shield as necessary, Ear Plugs, protective cl
necessary.Etc.
S. No

Description of task

Potential or Existing
HAZARDS
1a) Body strain from
lifting/twisting

Remove any potential fire

hazards and combustibles
from the area
1b) Potential fire if materials are
not moved
2a) Operator getting caught in a
pinch point
2b) Body strain from lifting

Inspect the grinder to

assure it is in good
operating condition

2c) Dust or particles in eye from

previous activity or unkempt
workplace
2d) Potential for breaking
grinding wheel if inspection is
not performed or performed
improperly

Assure all castings and

materials to be ground are
accessible, but out of way

3a) Wasted energy to start and

stop grinder if materials are not
accessible

Assure all castings and

materials to be ground are
accessible, but out of way 3b) Potential fire or tripping
of any direct hazards
hazard if materials are in the
way.

Double check the the

operation

4a) Potential to break grinding

wheel if improper size or type
for operation

5a) Hearing loss from excessive

noise

5b) Burns from grinding dust

and sparks
5

Put on Personal Equipment

5c) Body strain from lifting,
movement while grinding and/or
vibration

5d) Dust or particles in eye

Turn grinder on

6a) Potential for breaking

grinding wheel if inspection is
not performed or performed
improperly
7a) Body strain from
lifting/twisting

7b) Potential fire if materials are

not moved

7c) Operator getting caught in a

pinch point, or laceration from
contact with grinding surface
7d) Dust or particles in eye from
previous activity or unkempt
workplace
7e) Potential for breaking
grinding wheel if inspection is
not performed or performed
improperly
7

Grind castings

7f) Wasted energy to start and

stop grinder if materials are not
accessible
7g) Potential fire or tripping
hazard if materials are in the
way.
7h) Hearing loss from excessive
noise

7h) Hearing loss from excessive

noise

7i) Burns from grinding dust

and sparks

7j) Body strain from lifting,

movement while grinding and/or
vibration
7k) Dust or particles in eye

JOB HAZARD ANALYSIS

JHA reference Number : JHA/FORGE/1
Date:

h side shields/goggles, Safety toed shoes, gloves, Face shield as necessary, Ear Plugs, protective clothing as

Control Measures/ Preventive Measures

1)Assure operator is trained in how to lift/twist without injury
2) Assure operator has the strength/capability of operating the grinder
1) Have a checklist or other system to assure materials are moved to their correct distance or location. The operator must
check off the items on the list prior to beginning the operation.
2) Assure that materials to be ground are in non- combustible containers
1) Assure that pinch points are properly guarded.
2) Assure that operator is aware of where pinch points are.
1) Assure operator is trained in how to lift/twist without injury
2) Assure operator has the strength/capability of operating the grinder
1) Assure proper eye protection (full face shield or welding mask).
2) Assure housekeeping is performed after each grinding operation, as needed between grinding operations and as needed
during grinding operations to reduce or eliminate dust from area.
Assure operator or other appropriate individual performs appropriate inspection(s) prior to each grinding operation or
weekly, whichever is more frequent. (The inspection can be part of the checklist in 1b1.)

Have a checklist or other system to assure materials are moved to their correct distance or location. The operator must check
off the items on the list prior to beginning the operation.

1) Have a checklist or other system to assure materials are moved to their correct distance or location. The operator must
check off the items on the list prior to beginning the operation.
2) Assure appropriate fire protection systems are in place and operational.
1) Assure operator or other appropriate individual performs appropriate inspection(s) prior to each grinding operation or
weekly, whichever is more frequent. (The inspection can be part of the checklist in 1b1.)
2) Assure proper eye protection (full face shield or welding mask)
1) Assure proper hearing protection is used by operator and any other exposed people.
2) Assure noise levels require hearing protection
3) Assure grinder is operating at appropriate velocity and parts are properly secured to reduce vibration, noise and potential
for breakage.
1) Assure proper clothing (long pants, long sleeve shirts, leggings and/or protective sleeves, and gloves) are worn during
operation.
1) Assure operator is trained in how to lift/twist without injury
2) Assure operator has the strength/capability of operating the grinder
3) Assure grinder is operating at appropriate velocity and parts are properly secured to reduce vibration.
1) Assure proper eye protection (full face shield or welding mask)
2) Assure housekeeping is performed after each grinding operation, as needed between grinding operations and as needed
during grinding operations to reduce or eliminate dust from area.

1) Assure operator or other appropriate individual performs appropriate inspection(s) prior to each grinding operation or
weekly, whichever is more frequent. (The inspection can be part of the checklist in 1b1.)
2) Assure grinder is operating at appropriate velocity and parts are properly secured to reduce vibration.
1) Assure operator is trained in how to lift/twist without injury
2) Assure operator has the strength/capability of operating the grinder.
1) Have a checklist or other system to assure materials are moved to their correct distance or location. The operator must
check off the items on the list prior to beginning the operation.
2) Assure appropriate fire protection systems are in place and operational.
3) Assure housekeeping is performed after each grinding operation, as needed between grinding operations and as needed
during grinding operations to reduce or eliminate dust from area.
1) Assure that pinch points are properly guarded.
2) Assure that operator is aware of where pinch points are.
7c3) Assure that proper protective clothing (long pants, long sleeve shirts, leggings and/or protective sleeves, and gloves)
are worn during operation.
1) Assure proper eye protection (full face shield or welding mask)
2) Assure housekeeping is performed after each grinding operation, as needed between grinding operations and as needed
during grinding operations to reduce or eliminate dust from area.
1) Assure operator or other appropriate individual performs appropriate inspection(s) prior to each grinding operation or
weekly, whichever is more frequent (The inspection can be part of the checklist in 1b1.)
2) Assure grinder is operating at appropriate velocity and parts are properly secured to reduce vibration, noise and potential
for breakage.
3) Assure grinding wheel is properly guarded.
4) Assure materials are properly secured during grinding.
Have a checklist or other system to assure materials are moved to their correct distance or location. The operator must check
off the items on the list prior to beginning the operation.
Have a checklist or other system to assure materials are moved to their correct distance or location. The operator must check
off the items on the list prior to beginning the operation.
1) Assure proper hearing protection is used by operator and any other exposed people.
2) Assure noise levels require hearing protection velocity and parts are properly secured to reduce

3) Assure grinder is operating at appropriate vibration, noise and potential for breakage.
1) Assure that proper protective clothing (long pants, long sleeve shirts, leggings and/or protective sleeves, and gloves) are
worn during operation.
2) Assure proper eye protection (full face shield or welding mask)
3) Assure housekeeping is performed after each grinding operation, as needed between grinding operations and as needed
during grinding operations to reduce or eliminate dust from area.
4) Assure proper eye protection (full face shield or welding mask)
1) Assure grinder is operating at appropriate velocity and parts are properly secured to reduce vibration, noise and potential
for breakage.
2) Assure operator is trained in how to lift/twist without injury
3) Assure operator has the strength/capability of operating the grinder
1) Assure proper eye protection (full face shield or welding mask)
2) Assure housekeeping is performed after each grinding operation, as needed between grinding operations and as needed
during grinding operations to reduce or eliminate dust from area.

MIDHANI

JOB HAZARD ANALYSIS

Job Description: GRINDING, WELDING & GAS CUTTING

Area: FORGE SHOP, HRM
Work Area/ Equipment :
Perosonal Protective Equipments/Tools:Safety Glasses with side shields/goggles, Safety toed shoes, gloves, Face shield as necessary, protective clothing as n
S. No Description of
Task Step
1

Work start-up &

obtaining PTW

Potentional or Existing Hazard

1. Unauthorized work
Invalid permit
of competency
poor communication
shortcut

2.
3. Lack
4. Lack or
5. Haste or

Grinding

Gas Cutting

1. Rotating equipment sparks.

Damaged grinding disc
Electrocution.
Pressure air
object/eye injuries

1. Burns.
Fire Hazard.

2.
3.
4.High
5. Flying

2.
3.Explosion.
4. Tripping.
5.Damaged or leaking cylinders or hoses

ZARD ANALYSIS
JHA Reference No.: JHA/FORGE/2
Date:

s, Safety toed shoes, gloves, Face shield as necessary, protective clothing as necessary.Etc.
Control Measures/ Preventive Measures
1.Obtain a hot work permit before starting the job.
2.Supervisor must ensure that all work activities are carried out by
competent personnel.
3.Conduct
Toolbox meeting, review the Method statement and Job safety analysis
to all craftsmen involved in the work activities.
4. Responsible person will conduct
inspection, monitor the work activities and have to ensure safety
standards and procedures are strictly adhered to.

Responsible Person

PTW applicant
Supervisor PTW
holder

1.Make sure guards are fitted to all moving parts.

2.Ensure the
proper use of guards.
3.Inspect the grinding discs
prior to starting work (ring test). 4. Make sure that disc is compatible
with the grinding machine.
5.Check the RPM of disc & machine
6. Proper PPE (Gloves + Mask).
7.Correct
installation of Grinder Wheel.
8.Gas monitor
correctly sited.
9. Spark containment to
be used.
10.Only experienced personnel to use
the equipment. 11.Wear a face shield while grinding.
12 Make sure an eye wash station is available nearby.

1. Proper isolation of system.

2.All
cylinders to be secured.
3. Flame
arrestor between the cylinder & torch.
4. Hoses in good
condition.
5. Proper PPE.
6.Trained Fire Watch.
7.Gas Monitor correctly sited
8.Correct Fire Extinguisher(s).
9.Deployment of
Experienced personnel
10.Cordoning of the area.
11. Fire Blanket.
12.Inspect the cylinders & hoses before starting the job

Supervisor

Supervisor &
Workers

JOB HAZARD ANALYSIS

MIDHANI

Job Description: Cylinder Storage

Area: Forge Shop, HRM

JHA Reference No. : JHA/FORGE/3

Date:

Perosonal Protective Equipments/Tools:

Safety
Helmets, Safety goggles, Safety toed shoes, Hand gloves, Dust Masks. Etc.
S. No Description of Task Step

Potentional or Existing Hazard

1. Falling or rolling injuries from improper

gas cylinder storage
2.Valve opening or break off, exposing
workers to toxic fumes and flammable gas,
caused by improper gas cylinder storage
1

Control Measures/ Preventive Measures

1.Ensure cylinders are properly stored in an upright
position and chained in separate racks.
2. Store full and empty cylinders separately.
1. Store cylinder properly.
2. Always remove gauges and regulators, and install
protective valve caps before transporting.
1. Store cylinders in a dry, well-ventilated location.

Storage of Gas Cylinders

3.Gas cylinders causing fires or explosions

2. Avoid storing flammable substances in the same area

as gas cylinders.
3. Avoid storing cylinders of oxygen within 20 feet of
cylinders containing flammable gases.
4. Store all cylinders upright and chained in separate
racks.
5. Store full and empty cylinders separately.

Responsible Person

JOB HAZARD ANALYSIS

MIDHANI

Job Description: Fork Lift Operation

Area: FORGE, HRM
Work Area/ Equipment :

JHA Reference No.JHA/FORGE/4

Date:

Personal Protective Equipment (PPEs)/Tools:

Safety Vest,
safety-toed boots should be worn at all times. Appropriate gloves should be
worn as needed. Safety Helmet.Etc.
S. No Description of Task Step

Potentional or Existing Hazard Control Measures/ Preventive Measures

*Training on forklift design, controls and
instrumentation.

Pre-operation Safety Check

*Untrained operator

*Training on the forklift stability and the

proper way to transport, load, and stack on
the forklift.

*Spills/oil & fuel on hands &

clothing

*Wear protective clothing (coveralls) or have

change of clothes available

*Pinch points
Walk around inspection: tires,
lights, frame (stress), leaks, fluid *Slip, trip & fall
levels, mirrors
*Back strain

Vehicle startup: check gauges,

oil & air pressure, hydraulics,
and brakes

*Slip, trip & fall climbing into

vehicle

*Wear appropriate gloves

*Awareness/condition of work area, obstacles
*3 point contact
*Proper bending & lifting technique
*Maintain 3 point contact

Vehicle startup: check gauges,

oil & air pressure, hydraulics,
and brakes

Cranking & Driving

Operating the forks

*Slip, trip & fall climbing into

vehicle

*Rolling the wheels off an edge,

ramps and loading docks.

*Running into obstacles

* Check for ice build up if working outside in

cold months
*Buckle your seat belt when youre in the
truck.
*Stay well back from any edge.
*Never turn around on the slope.
*Drive with your load on the uphill side. This
means you drive up slopes with your load in
front and drive down slopes in reverse.
*Slow down and sound your horn at corners,
intersections and places with limited view.
*Slow down for turns.
*Drive in reverse if your vision is obstructed.
*Make sure that you have enough overhead
clearance.

Loading

*Load falling off forklift.

*Spread forks as wide as possible for

transporting the load.

*Damage to material by loading

improperly.

*Tilt the mast slightly forward and align the

forks with the base of the load.

*Overloading

*Proceed slowly and insert the forks into the

base of the load. Ensure that at least 2/3rd the
length of the fork enter the base of the load.

Loading
*Lift forks approximately 8 inches for the
load to clear the floor.

*Pinching hands between the truck

*Tilt mast back in preparation for traveling.
and other objects.
*Struck against - Running into
objects.
7

Transporting the load

*Struck by - Collisions with other

equipment.
*Injury to other personnel

Unloading
*Damage to other equipment

*Running over and crushing the

operator.

*BE ALERT
*Wear gloves to protect your hands.
*Keep your arms and hands in the truck.
*Keep the controls and your hands clean and
dry.
*Position the truck at the desired location.
*If stacking loads, adjust the height of the
load as appropriate.
*Tilt the mast forward to place the forks
parallel to the ground.
*Once the load is set, slowly back away from
the load.
*When clear of the load, place the forks at
the proper height for traveling.
*Never leave the truck until you lower the
lifting mechanism, put controls in neutral and
set the brakes. Turn the truck off.
*Always administer the emergency brake.

Parking the Forklift

*Slip, trip, and fall

Parking the Forklift

*Slip, trip, and fall

*Leave the truck- Keeping your balance by

maintaining a 3 point stance.
*Be aware of condition of walking surface.

Responsible Person

MIDHANI

JOB HAZARD ANALYSIS

Job Description: Shifting of the Materials

JHA reference Number
Date:
Area: All Shops
Work Area/ Equipment:
Perosonal Protective Equipments/Tools: Safety Glasses with side shields/goggles, Safety toed shoes, gloves, Face shield as necessary, protective cloth
necessary.
S. No Description of Task Potentional or Existing Hazard
Step
Projectiles may cause injury to Eyes, Head.

Control Measures/ Preventive Measures

Wear Helmet, Safety glasses with side shield or
appropriate safety goggles.

Projectiles, moving parts, point of operation, Situational awareness, PPE, protective clothing,
pinch points, flying items may cause Trauma machine guards
1

Shifting of the
Materials

Drop object on foot may cause Foot injury

Wear safety shoes

Point of operation, pinch points, moving

parts, flying items may cause Hand injury

Use Gloves, machine guards, situational awareness

ield as necessary, protective clothing as

Responsible Person

JOB HAZARD ANALYSIS

MIDHANI

Job Description: Operation of CO2 Flooding System

Area: CRM, HRM, FORGE
Work Area/ Equipment:

JHA reference Number: JHA/HRM/1

Date:

Perosonal Protective Equipments/Tools:Safety Glasses with side shields/goggles, Safety toed shoes, gloves, Face shield as necessary, protective clothing as
necessary.
S. No

Description of Task Step Potentional or Existing Hazard

1. Non compliance of HSE MS
Procedures

Control Measures/ Preventive Measures

Take a Cold Work Permit from Asset Owner
Refer manufacturer instruction for functional testing & CO2
Flooding System
Asses the risk & Override the Fire Shutdown & CO2 actuationof
the zone where CO2 Flooding System is to be tested.

2. Unintended Shutdown of Facility

/Equipment
1

Planning

Do not remove override prior to resetting the alarm in thepanel

Plan the work involving personnel responsible for preparationof
CO2 Flooding System functional testing.

3.Lack of Communication

Conduct Tool Box Talk.

3.Lack of Communication
Maintain a radio communication between worker at CO2
Flooding System location & person attending the job.
Accidental Release of CO2
CO2 Exposure / Asphyxiation
Defective Appliances
2

Functional Testing

Leaking / Empty CO2 Cylinder

Close the isolation valve on CO2 Cylinder Bank Manifold

or isolate CO2 bottles individually before function testing
Ensure no body is inside the enclosure for which CO2 Flooding
System is to be function tested.
Keep the spare appliances (such as pneumatic switch,actuator etc)
for replacement in case found defective.
Ensure CO2 Cylinders are not leaking.
Replace empty CO2 Cylinder
Confirm the alarm through radio communication; whenever CO2

Fault Alarm

Leaking Discharge Nozzles

Failure to Reset the Fire Alarm
3

Windup &Housekeeping

Scattered Materials & ResidueHazard

Flooding System is function tested

Ensure the closure of pneumatic switch / actuator before liningup
CO2 Cylinder Bank after completion of functional testing
Do not line up CO2 Cylinder prior to resetting the fire
detectionalarm on F & G panel
Reset the fire detection alarm at F & G panel.
Remove the Fire Shutdown override after evaluating the risk.
Ensure proper wind up & housekeeping at worksite

ctive clothing as

Responsible Person

JOB HAZARD ANALYSIS

MIDHANI

Job Description: WELDING

JHA Reference No.: JHA/FORGE/2
Area: FORGE SHOP, HRM
Date:
Work Area/ Equipment :
Perosonal Protective Equipments/Tools:Safety Glasses with side shields/goggles, Safety toed shoes, gloves, Face shield as necessary, protective cloth
necessary.Etc.
S. No Description of Task Step

Welding

Potentional or Existing Hazard

Control Measures/ Preventive Measures

1.Fire Hazard
2.
Burns.
3.Electrocution/
Spatter burns.
4. Damage cable.
5.Hot tabs end pieces of welding
rods.
6.
Sparking.
7.
Damaging Cables
8. UV
rays.

1. Before starting welding make sure the area is clear of all

types of combustible materials.
2. Provide a
fire blanket on site.
3.Make sure fire
extinguishers are available on site. 4. Wear proper PPE for
welding ie., leather jackets, Gloves, welding goggles/welding
mask.
5. Gas Monitor correctly sited
6.Certified Equipment and to be sited as near as possible to
work site.
7.Proper earthing of
equipment.
8.Certified Welder.
9.Make sure spark containment is used such as a
welding hood/fire blanket.
10.Ensure that
rod holder is in good condition 11.Ensure that forward and
return cables are in good working condition.
12. Use proper cable connector for
extension.
13.If cables are crossing the road then ensure
proper protection.
14.The welder & the welder helpers must wear welding
goggles.

, protective clothing as
Responsible Person

Supervisor & Workers