INDIAN OIL CORPORATION LIMITED

PARADIP REFINERY
JOB SAFETY ANALYSIS - 84
PART-A : JSA No.: HY/PE&SD/ SC-
Date:
PROJECTS/ 2025-26/ TCC/ IOCL- Work Permit No: No of Pages: 13
21-05-2025
PARADIP/JSA/84
Work permit type:
Cold Work permit
Area:
Job Title: Location: SRU-III & Hot Work permit
SRU-III Project
Tie-In and Hook Up activities for OWS & CRWS pits Incinerator Area Excavation Work
Site
Confined Space
working
Job to be Executed By: ANALYSIS PERFORMED BY:
Name & Designation Sign with Date
M/s Bharat Heavy Electricals Ltd
BHEL – Mechanical Engineer

BHEL – Lead Engineer

BHEL - Lead HSE

BHEL - RCM

PMC – Execution

PMC - Lead HSE

IOCL - Project

IOCL - Production

IOCL – F&S

JSA Reviewed By:

Projects: Production F&S

Executing HOD Issuing HOD Fire & Safety HOD

JSA Approved By:

Page 1 of 13
 Sequence Hazards involved
Sl. No Safety measures / precautions
of Steps at various steps
1. General /  Personal Injuries  Obtain PTW and shift clearance prior to the
site  Pinch point. commencement of the work and a copy of
preparation.  Slip, Trip and fall. PTW to be kept at the worksite for
 Uneven ground submission on demand.
level for  Survey work areas and address safe work
Machinery methods, hazards and precautions.
movement  Barricade the area and display warning
 Electrocution signages.
 Fires/ Explosions  All hand and power tools shall be inspected,
color coded as per IOCL procedure.
Equipment shall be displayed with valid TPI
certificates.
 Level the ground for safe movement.
 JCB Operator and Hydra Operators shall
have in their possession valid driving
license and driving authorization.
 Dedicated & trained flagman shall be
assigned to assist the operator by signage
& signal man using his red and green flags.
 All personnel to wear appropriate PPE
required for the job.
 All personnel shall have completed the
Safety Induction Training prior to
mobilization to site.
 Conduct TBT and explain the Hazards
involved.
 Close supervision from BHEL and PMC is
required.
 Ensure good housekeeping at the work
location.
 All distribution and extension boards should
be metallic for industrial use and
connected with ELCB. All necessary tools
and tackles should be insulated.
 Ensure double earthing for all the electrical
equipment and must be checked by the
electrician.
 All electrical connections should be routed
through ELCB /RCCB

2. Excavation  Soil collapses.  Ensure the Excavation pit side there is no

near OWS/  Fall of person into cave in or chances of soil collapse.
CRWS pit excavated pit  Ensure work under supervision.
 Fall of material  Maintain proper shoring and shuttering to
into excavation avoid collapse of soil.
 Oil spillage or  All open excavations are to be properly
contaminated oily hard barricaded.
water  Excavated soil to be kept away at least
 Accidental hitting 1.5 mtr away from excavation.
by the boom of  Provide warning signages near
the excavator in excavations.
case of people  Maintain access and egress points into the
present in the excavated pit from two sides.
swing area of the  Gas testing inside pit and surrounding
boom area.

Page 2 of 13
 Sequence Hazards involved
Sl. No Safety measures / precautions
of Steps at various steps
 Hindrances of  Take care about existing UG lines and
buried service power cables.
 Safety Signage to be made available in
strategic locations.
 Only manual exaction is to be done at the
identified UG lines.
 After identified UG lines, adequate
support (with concrete sleepers) to be
provided for protecting the lines.
 If oil leaking from UG pipeline is heavy,
inform IOCL for suitable action. Take
suitable actions for decreasing the water
level in adjacent pits.
 Conduct gas test prior to allowing people
inside the pit.
 Follow all the safety precautions, as per
confined space working.
 Ensure barricading of the swing area. No
unauthorized entry to be ensured.
 Arrangement for shifting Excavated soil to
be ensured.
 Ensure Confined Space PTW for deep
excavated pit.

3. Dewatering,  Spillage of water  PTW shall be ensured prior to start of work.

Flushing of on ground  CRWS/ OWS MH level to be lowered by
existing pit  In case of leakage pump (if no Hydrocarbon is present inside)
of gas and and MOSRU (if Hydrocarbon present
presence of inside).
source of ignition.  Flush the pit adequately with water.
 Flammables  Any spillage of water or oil shall be cleaned
flowing along with to avoid any slip trip and fall.
water.  No Hot Work in the surrounding of pit
cleaning shall be ensured.
 The water in OWS/ CRWS tanks shall be
transferred into another OWS/ CRWS tanks.
Not to be transferred to open drains.
 Only trained person shall be engaged to
perform the flushing work by close
monitoring of site execution and HSE.
 Barricade the area, display warning
signages, alert workforce.

4. Working  Manual handling.  Conduct TBT and explain the hazards

inside the  Slip, trip and fall. involved.
excavated  Impalement of  Obtain Confined space work permit.
nails.  Conduct gas test before allowing people
pit for
 Safe access for into the pit.
levelling, materials  Provided adequate access ways into the
formwork handling. pit.
and  Maintain adequate shoring to avoid
concreting collapse of soil into the pit.
 Use cut resistant hand gloves while
handling rebar and tie wires.
 Unwanted nails to be removed from

Page 3 of 13
 Sequence Hazards involved
Sl. No Safety measures / precautions
of Steps at various steps
shuttering wood.

5. Concrete  Sparks generation  Obtain PTW (Hot work) and clearance

breaking for  Fires  Conduct daily TBT and explain the hazards
the  Electric shocks involved.
 Electrocution  Barricade (Hard barricade) the area of work
OWS/CRWS
 Slips and trips and display warning signages.
Pits  Eye Injuries due  Wear appropriate PPE like Face shield,
to flying debris Hand gloves, Helmet, Safety shoe, Dust
 Inhalation of Mask, IFR Coverall, Earplugs.
Dust/Harmful  Flush the wall and floor with water
Chemicals frequently. Keep the wall and floor in wet
 Noise hazards condition to minimize sparks.
 In case of leakage  Fill a layer of foam inside the MH to
of gas and avoid vapor generation.
presence of  Continuous gas monitoring is
source of ignition required.
- Fire, explosion  The activity shall be conducted in the
presence of IOCL/ PMC personnel
 Close supervision is required.
 Ensure the electrical connections are
intact. No loose cables/ multiple joints are
allowed.
 Provide DCP fire extinguisher at the spot.
 Fully cover the OWS manholes with fire
blankets, during concrete breaking.
 Keep power cable out of the pathway or
vehicle movement area.
 Alternate workers throughout the day if
working with tool for 8 hours
 Use Hand gloves, safety glasses/goggles,
dust mask, Helmet and hearing protection
 Keep Fire hose connected to fire hydrant
always in ready condition in addition to
basic firefighting equipment.
 Fire fighting arrangements like
extinguisher, fire hose to be kept near the
pit.
6. Using Hydra/  Swing and fall of  Only 2nd generation Mobile crane/ Hydra is
Farana for the material to be used as per the IOCL specification.
shifting of during shifting  SLI working to be ensured
 Hydra toppling  Hard surface to be ensured for Hydra
pipe and
 Hitting of lengthy movement
other pipes to workmen  Use both sides tagline while shifting
materials  Failure of slings material.
 Undulated surface  Deploy dedicated flag man for safe
 Failure of tools movement.
and tackles  Keep a safe distance while holding lengthy
 Collide of Hydra pipes with guide ropes
with people or  Lifting areas shall be cordon with
plant equipment barricading and signages
 Use only inspected and monthly colour
coded web slings, wire rope slings & D
shackles. These tools and tackles shall be
duly tested and certified by TPI.

Page 4 of 13
 Sequence Hazards involved
Sl. No Safety measures / precautions
of Steps at various steps
 Hydra should not be used for shifting
material.
 Daily checklist to be maintained
7. Pipe Laying  Collapse of soil  Ensure PTW
inside the  Temperature and  Ensure Mandatory and Job specific PPEs
excavated Humidity used before starting of job.
 Slip, Trip and  Adequate lighting has to been provided.
pit
falls  Two entry and exit points must be provide
 Poor Visibility for excavated pits.
 Poor  Precautions to be taken to avoid soil
Access/Egress collapse.
 Atmospheric  Do not allow any person inside the pit,
Hazard while lowering the pipe/ other
 Accumulation of material.
water in pits  Do not allow lone working inside a pit.
 Injuries due to  Do not allow anyone to stand under a
protruding objects suspended load.
 Route access must be cleared from all kind
of obstacles.
 Platform provided inside confined space,
must have secure and inspected before
use.
 Conduct Atmospheric testing by Gas
detector, to ensure no harmful gases are
present inside the pit.
 Ensure accumulated water is dewatered
before allowing the personnel inside the
pit.
 Do not engage electrical submersible
pumps for dewatering. Display warning
signs.
 All materials used at height must be
secured
 Housekeeping must be maintained at work
place

8. Manual  Musculoskeletal  Correct posture should be followed during

material disorder like back lifting of load.
Handling injury/neck injury  Use mechanical aids like Hydra/ Chain
due to Improper Pulley blocks for carrying/ lowering loads
posture wherever possible.
 Slip, Trip and Fall  Proper housekeeping should be maintained
Hazards to avoid any incident related to slip, trip
and fall hazard.
 The working area should be free from any
kind of spillage of oil, leakage of water etc.
 Never carry a heavy load, always seek help
in such circumstances.
 Practice Team lifting and load balancing
during manual lift.
 Use Shoulder pads, while long pipes are
being shifted manually.
 Rotation of work should be maintained.
 Sufficient manpower should be used for
manual handling to prevent muscle strain

Page 5 of 13
 Sequence Hazards involved
Sl. No Safety measures / precautions
of Steps at various steps
and fatigue.

9. Confined  Deficiency of  Obtain Confined Space Entry work permit.

space Entry oxygen,  Check for the sufficient Oxygen levels and
for mud  Lack of Natural absence for hazardous gases inside the MH
Ventilation. before allowing for confined space entry.
plugging and
 Improper access.  Ensure for ventilation inside the pit. Keep
layer cement  Temperature and the manhole cover in open condition.
line inside Humidity  No Hot work is allowed, while the person is
Manhole  Poor inside the Manhole.
Access/Egress  Proper access & egress to be provided.
 Presence of toxic  Attendant and confined space register to
fumes be maintained, confined space training to
be organized for worker.
 All workers engaged inside confined space,
must have rotation and rest in periodic
interval, ensure nobody engaged for
prolong period of time
 Time limit for confined space (30min) or as
per the site condition.
 Job specific PPE to be used.
10. Welding/  Fire &  Surrounding areas are to be cleared of
grinding/ explosions due flammable materials, before starting the
cutting to to spatters activity.
entering into  Always wear leather hand gloves. All the
the pipeline
the Manhole people in hot work zone should wear IFR
 Hot Surfaces Coverall, Leather Hand gloves.
 Pinch Point  Welder face shield with helmet must be
 Welding rays. worn.
 Electrical  Do not allow any parallel activity during hot
shocks. work.
 Thermal burns  Gas tests should be conducted before
 Wet working starting hot work and throughout the shift.
condition  Fire watch and standby man with
 Poor cable firefighting equipment such as fire
insulation and extinguisher, fire blanket, etc... must be
routing cause available on site.
electrocution  Block the end portion of pipeline
(inside the Manhole) with mud/ clay to
avoid contact of sparks with
flammable vapors.
 Fill a layer of foam inside manhole to
avoid vapors.
 Ensure there are no oil seepage from the
Manhole wall or from the ground. If any oil
traces are found, inform to IOCL/ PMC.
 Use only inspected, and colour coded tools
for the job.
 Electrical cable should be properly routed
at working area and free from joints.
 The hot work area should be adequately
covered with a fire booth or fire-retardant
blankets to prevent sparks from spattering
and minimise exposure of surrounding
people to welding rays.

Page 6 of 13
 Sequence Hazards involved
Sl. No Safety measures / precautions
of Steps at various steps
 Wear appropriate PPE. (Safety glass, face
shield, leather gloves). Fire watchers or
helpers also should wear eye protection
and hand protection.
 Adequate ventilation arrangements are to
be made, while carrying hot works in
confined spaces.
 Welding machines/ grinding machines are
to be provided with suitable protective
devices like ELCB / RCCB. Welding
machines to be provided with double
earthing.
 Always maintain dry area for welding works

11. Positioning  Uneven ground/  Ensure proper ground condition, level the
for fit-up pipe condition ground, provide adequate sleepers.
 Pinch injury due  Use proper PPE’s like hand gloves
to material  Ensure perfect communication between the
handing. gang members.
 Fall of material  Ensure proper blocking spools.
during  Arrange proper Hot work booth.
positioning.

12. Back-filling  Worker hit by  Person shall not be allowed to work in front
compactor; of compactor.
persons may get  Reverse Alarm shall be mandatorily used
injured. along with a flag man in the backside.
 While reversing  Deploy banks man/ flagman with proper
the identification.
Tripper/Tractor,  Hard barricade the area for minimizing the
may hit the man movement in the seeing of tipper/
person Backhoe loader.
 Person may  Arrange for adequate lighting or signalling
injured/ fatal for working during low lights/ nigh hours.
 Compaction of  Ensure that all machines used in backfilling
soil. are in a proper working condition and fitted
with reverse alarms.
 Trained experience workmen only to be
deployed.
 During compaction of soil, using vibrio
roller vibration, other excavation pit’s soil
may collapse. So, stop other excavation
jobs.

13. Special  Hand injury  Gas testing shall be done and register to
Safety  Strong Wind be maintained for confined space
Precautions  Heat Stress/ entries.
Exhaustion  Ensure all activities are carried out
 Fire under supervision.
 Eye Injury  Ensure proper communication
 Nearby subsequent pits to be identify
and mud plugging to be ensure in each
pit after lowering the H/C level cleaning.

Page 7 of 13
 Sequence Hazards involved
Sl. No Safety measures / precautions
of Steps at various steps
 Ensure double plugging before start any
hot job.
 Arrangement of MOSRU to be done.
 Coordination with upstream and
downstream unit to be done, Production
department to be informed to control
water flow in OWS/ CRWS pit.
 Valid Hot work permit, Cold work Permit
and Confined space entry permit are to
be maintained.
 Standby arrangement for SCBA set, to
use incase required.

14. Fire  Potential injury.  Block the end portion of pipeline (inside
 Damage to the Manhole) with mud/ clay to avoid
property. contact of sparks with flammable
 Potential for vapors.
equipment  Fill a layer of foam inside manhole to
damage & avoid vapors.
personnel injuries  Fire extinguishers shall be deployed
due to fire. near the hot work.
 Arrange fire hose connect and ready to
operate, incase of emergencies.
 Deploy Fire watcher.
 Ensure no oil seepage/ leakages from
the Manhole/ excavated pit
 Spark arrester must be ensured of Hydra
& crane.

15. Housekeepin  Accumulation of  Ensure that all the unwanted material is

g. debris. removed from the site.
 Tripping hazards.  Ensure there are no obstructions in the
 Access access ways.
obstruction.  Maintain good housekeeping standards. All
walkways must be obstruction-free.
 Engage sufficient workers for lifting heavy
material.
 Always use nose mask to avoid inhalation
of dust or other things.
 All appropriate PPEs must be used at site.
 Loose clothing should be avoided.
 Strict supervision to be maintained during
work.

16. Emergency Safety  Only trained people should be allowed to

Evacuation evacuation of work inside the confined spaces.
entrant  Standby person should maintain
continuous communication to ensure
safety of the entrant.
 The entrants should wear FBH along with
extended lifeline. So that the entrant can
be pulled outside safely, without allowing
another person into hazardous area.

Page 8 of 13
Additional Points:

1. Follow the work permit system, as applicable.

2. Tool box meeting should be done before starting the job.
3. Ensure the availability of portable fire extinguishers, running water hose pipe.
4. Free and safe access to excavated pits shall be made available.
5. If the job is done at night, arrange adequate lighting and ensure emergency lamps are in
operation.
6. Ensure the availability of portable gas detectors at the site, for continuous gas monitoring.
7. No parallel activities shall be followed.
8. Ensure all safety features (SLI, over hoist limit switch) of crane / farina are functional.
9. All Electrical panel & power distribution board should be equipped with 30 MA RCCB
/ELCB.

Page 9 of 13
 INDIAN OIL CORPORATION LIMITED
PARADIP REFINERY
JOB SAFETY ANALYSIS

Sr. No PPE Required Provided ( Yes / No/ NA)

1 Full body double lanyard safety harness Yes

2 Ear plug Yes

3 Gumboot Yes

4 Protective clothing / IFR Coverall Yes

5 Safety helmet Yes

6 Hand gloves Yes

7 Grinding visors/ face shield Yes

8 Caution tape/ barricading pipes Yes

9 Sign/Display boards Yes

10 Lifeline/Fall Arrestor NA

11 Safety net Yes

12 ELCB NA

13 Fire extinguisher Yes

14 Fire blanket Yes

15 Gas Detector Yes

16 Any Other NA

Page 10 of 13
 INDIAN OIL CORPORATION LIMITED
PARADIP REFINERY
JOB SAFETY ANALYSIS

Part B : Compliance Audit by the Location In- Charges/DSO while the job is being
executed:
Sl. Recommended Observations Complian Checked by
No Actions/ Procedures ce Status
. and Control Name of
Measures Officer with
Sign, date &
time

Note:
1. To make JSA process effective, the defined job shall be broken down into
sequential steps. Actions / activities for each steps shall be logical & linked
with previous & forward action steps. All possible hazards associated with
each job step shall be deliberated among team members and recorded
carefully. JSA recommendations / control measures for each hazard / job
step should be validated by team members & recorded in the Part-A of JSA
sheet. Use additional JSA sheets as per requirements.
2. Review of JSA shall be done by HODs of respective Operation & Executing
Departments. After reviewing respective HODs to put their signature with
name & date.
3. The Job shall be carried out with safety precautions as per JSA
recommendations. In order to ensure that job is being executed as per JSA
recommendations, the job shall be audited by the JSA Team Members while
the job is in progress and recorded in the Part-B of JSA Sheet with
compliance status, name, signature, date & time of audit by the Officers.
HODs & higher management personnel may also check compliance of JSA
recommendations while doing checking of jobs during schedule visit to the
unit / Location.
Page 11 of 13
 4. Waste Management: managing the empty packaging, used protective suits and
other personal protective equipment and collected dust.
5. Owners’ PTW system shall be followed

ANNEXURE-I

PROCEDURE OF UG PIPELINE (OWS / CRWS) HOOK UP WITH EXISTING MANHOLE

1. Existing Manhole to be cleaned by pump or MOSRU depending upon the

level of hydrocarbon present. Divert the water to next manhole if required
using pump and by blocking the flow through sandbags.
2. After complete cleaning and inspection, both incoming and outgoing line to
be mud plugged (if hydrocarbon is present in network)
3. During mud plugging, necessary precaution to be taken and confined space
procedure to be followed.
4. After mud plugging the pipe end, excavate the soil, for inserting UG
pipeline.
5. Fill a layer of foam inside the manhole, to avoid vapours.
6. Tie-in point to be exposed in manhole & opening to be done by manual
concrete breaker.
7. After opening in wall, prefabricated puddle with connected pipe to be
placed and another end of the pipe to be welded with end pipe of newly
installed manhole.
8. During same time puddle area to be grouted with RCC.
9. After complete curing, the mud plugged portion to be removed.
10. The back filing to be completed and pavement to be completed for the area
(as per the requirement.)

Page 12 of 13
 ANNEXURE-II

Location of Tie-In point (Unit-90)

TP-004

Page 13 of 13
 ANNEXURE-III

Location of Tie-In points (Unit-88)

TP-006

TP-005

TP-003

Page 14 of 13