This document provides a job safety analysis for erecting jet fuel storage tanks. It outlines 13 key steps in the erection process and identifies potential hazards at each step, such as falls, being struck by objects, fires, and more. Safety precautions are also listed to mitigate the hazards, including using proper personal protective equipment, restricting access under suspended loads, following proper lifting and staging procedures, and more. The responsibilities of supervisors, riggers, welders and other roles are defined to ensure safety is prioritized throughout the tank erection work.

1. JOB SAFETY ANALYSIS FOR JET A1 TANK ERECTION
P&M and Equipment involved: Welding machine, grinding m/c, gas cutting sets,
crane, drilling m/c, lifting tools & tackles,
Hydraulic jacks, small tools & tackles, NDT kits
etc.
PPE / safety device required: Safety Helmet, Safety shoe, Safety Goggles, Hand
Gloves (Leather & Cotton), Safety belt, Lifeline
rope, Fire extinguisher, Fire bucket etc.
Identity of Task: Erection (Mechanical / Hydraulic jacking system) and
Testing of storage tanks.
Sl.
No.
Sequence of
Operation -
Activity Steps
Tools &
tackles
used and
manpower
deployed
Hazards
involved at
various steps
Safety measures /
precautions
Responsibility
/ Action by
1 Marching of crane Crane
operator,
rigger,
signalman,
and
supervisor.
 Hit by crane
 Toppling of
crane
 Deep
Excavation
 PPE Site Engineer
2 Laying annular
plates on the
periphery of the
tank by crane
Supervisor,
Operator,
Rigger,
Khalasi,
Helper,
welder, RT
persons
 Failure of
the crane.
 Fall of
material
 Hit by crane
 Hit by
object
 Crane shall be
placed on a stable
and compacted
ground for stability
of the crane.
 The entire swing
area shall be
barricaded and no
unauthorised entry
shall be allowed
within the swing
area.
 Before lifting
process starts, all
the lifting tools &
tackles shall be
certified.
 Experienced
rigger shall be
present during the
entire lifting
process.
 Only experienced
signalman has to
give the signal to
the crane.
 During welding,
the entire area
shall be free from
Site Engineer

2. any combustible
materials like
cotton waste,
paints, thinner etc.
 All the plates to be
stacked in proper
manner at site to
reduce hindrance
for personnel
movement and
other activities.
3 Laying of bottom
plates on the tank
foundation by crane
Supervisor,
rigger,
welder, gas
cutter,
khalasi, fitter,
crane
operator,
signalman,
QA/QC asst.
 Same as
point 1
 Improper
stacking of
plates at
site.
 Unwanted
swing of the
plates
during
lifting.
 Damage of
welding
cable or
gas cutting
hose or
electrical
cable due
to sharp
edge of the
plates.
 Access thru
curvature of
the tank
 Improper
lifting of
plates
 Only experienced
signalman shall
give the signal to
the crane
operator.
 Proper access to
be ensured along
the curvature of
the tank.
 During lifting and
swinging with the
plates, nobody
shall work under
the suspended
load.
 Entire swinging
area shall be
barricaded.
 Double tag rope
shall be used
during lifting of the
plates.
 All the plates shall
be stacked in
proper manner
with sufficient
packing outside
the tank area to
prevent any injury
due to pressed in-
between during
handling or sling
fixing.
 All the plates shall
be stacked
according to the
priority basis from
top to bottom to
prevent pulling of
the plates kept at
bottom.
 Tank pad area
shall be free from
any cables, hoses
during placing of
the plates.
 Personnel
movement shall
be restricted
inside the tank
Site Engineer

3. area to prevent
any trip injury as
well as burn injury
due to hot metal.
4 Placing of stool
around the
periphery of the
tank
Supervisor,
rigger,
welder, gas
cutter,
khalasi, fitter,
helper, crane
operator,
signalman
 Personnel
injury
during
material
handling
 Hit by
object by
toppling of
the beam
 Stool shall be
placed at the
levelled area.
 If reqd, proper
support to be
given to prevent
toppling.
Site Engineer
5 Erection of 2nd shell
course along the
periphery, welding
and radiography.
Supervisor,
rigger,
welder, gas
cutter,
khalasi, fitter,
crane
operator,
signalman,
QA/QC asst,
radiographer.
 Less
stability of
the bent
plates at
stacking
yard.
 Toppling of
plates after
positioning
along
periphery
 Personnel
injury.
 Fall of
person from
height
during
welding at
outside.
 Electrocutio
n
 Radiograph
y hazard
 Injury due
to improper
access
provision
 Injured
person to
take out
from tank
inside
 Bent plates to be
stacked properly
in sequential
manner. If plates
kept in horizontal
position, proper
packing to be
provided. During
lifting, utmost care
shall be taken. If
plates stacked in
vertical position,
enough support
shall be given.
And support shall
be removed only
after the plate has
been hooked with
the crane for
lifting.
 If the bent plates
stacked on a
saddle, utmost
care shall be
taken during fixing
of sling, lifting
operation and
other handling
activities.
 After placing the
each bent plate
along the
periphery,
sufficient supports
to be given for
each plate.
 Personnel
movement to be
restricted during
placing of the 2nd
shell plates.
 No body shall be
allowed to work
under any
suspended load.
 Before removing
the angular
support, all the
Site Engineer

4. vertical joints in
between the
plates shall be
fully welded.
 Suitable access to
be ensured to take
out injured person,
in case of
emergency.
 SAFETY DURING
RADIOGRAPHY
BEING
DISCUSSED IN
POINT NO 17.
6 Erection of 1st shell
course along the
periphery on the 2nd
shell, welding and
radiography.
Supervisor,
rigger,
welder, gas
cutter,
khalasi, fitter,
crane
operator,
signalman,
QA/QC asst,
radiographer.
 Personnel
injury due
to caught
in-between
the 2nd shell
& 1st shell.
 Burn injury
 Fall / slip of
1st shell
plates
during
placing over
2nd shell
plates.
 Trip hazard
due to
improper
housekeepi
ng
 Fall of
person
during
welding
from height
 Access /
egress
 No body shall
keep his finger or
hand in between
two plates while in
the process of
alignment.
 There shall be
stopper
arrangement in
between the plate
edges to prevent
any fall of plates
after putting one
over another.
 Before doing full
welding, proper &
sufficient support
to be given to
each shell plate to
prevent toppling.
 Inside the tank
area, good
housekeeping to
be maintained.
 While working at
height, proper
doka staging to be
made and
supported.
Handrail to be
provided in the
tower and safety
belt to be tied at
shoulder height.
 Doka tower to be
fixed in levelled
condition.
 Safe
access/egress to
be provided in &
outside of the tank
for personnel
movement as well
as material
shifting.
 Suitable access /
egress space to
Site Engineer

5. be ensured.
7 Erection of roof
structure – Central
drum, main rafter,
side rafter, central
girder and welding
& bolting.
Supervisor,
rigger,
welder, gas
cutter,
khalasi, fitter,
helper, crane
operator,
signalman
 Fall of
central
drum
 Hit by
object
 Collapsing
of the roof
structure
 Not
maintaining
sequence
of erection
 Working in
the same
location in
different
levels.
 Fall of
unstable
truss
 Proper support to
be given to the
central drum when
it is being kept at
2m(apprx) height
on the doka tower.
 Materials shall be
stacked in such
manner that it
shall not create
any hindrance to
the movement as
well as other
activities.
 No loose materials
to be kept at
height.
 While doing
assembling of
main rafter
outside, proper
space to be
ensured to carry
out the job
smoothly.
 During erection of
main rafter and
placing in between
the central drum
and shell plate, all
the joints (bolted &
welded) to be
inspected by
competent person
and then give
signal for lifting.
 All the bolt joints
to be moderate
tighten for
erection.
 No personnel shall
stand below the
suspended load.
 To ensure the
stability of the
trusses, proper
sequence of
erection e.g. fixing
of main rafter,
secondary rafter,
secondary truss,
secondary beam
to be followed as
per drawing.
 After fixing all
structural
materials,
immediately the
entire bolt joints to
be tightened
Site Engineer

6. moderately to
withstand its self-
load.
8 Placing of roof
plates by crane and
welding.
Supervisor,
rigger,
welder, gas
cutter,
khalasi, fitter,
helper, crane
operator,
signalman
 Fall of
plates
 Fall of loose
materials
 Fall of
person
 Hit by
plates due
to
unwanted
swing by
crane
caused by
wrong
signal.
 Fall of loose
tools &
tackles
 Proper sequence
of the erection to
be maintained.
 During erection of
the roof plates,
nobody shall be
inside the tank
under the
suspended load.
 Lifeline to be
provided for tying
the safety belt.
 Experienced
signalman shall
give the signal to
crane operator.
 Roof plate
erection shall be
allowed only
during daytime.
 All small tools &
tackles shall be
provided with
safety sling.
Site Engineer
9 Arrangement of
jack system (40
nos or more) with
power pack outside
the tank in parallel
with the roof plate
fixing and welding
Rigger,
khalasi,
welder, gas
cutter, fitter,
helper, jack
operator.
 Slip & trip
hazard
 Injury due
to fall of
plates or
loose
materials
from top
 Lack of
ventilation
 Hydraulic
oil leakage
 Fire
 Bursting of
hydraulic
hose or
damage
due to fall
of material
from the
top.
 At the same
location, different
levels job shall not
be carried out.
 No conflict at
different scope of
works.
 Area shall be
barricaded for
movement
restriction inside
the tank while
plate fixing is
going on at top.
 Sufficient
ventilation shall be
provided for the
people working
inside the tank.
 All the pressurized
parts of the power
pack and the jacks
shall be certified.
 No hot work shall
be carried out
nearby the
hydraulic oil to
prevent any fire
accident.
 Experienced &
competent person
shall supervise the
jack fixing
Site Engineer

7. arrangement.
 If any leakage of
hydraulic oil
occurs,
immediately it is to
be cleaned.
 Sufficient
illumination shall
be provided inside
the tank area.
 Activity at the top
shall be restricted
while hydraulic
hose being fixed
at the bottom.
 Hydraulic oil shall
not be kept in a
loose container
and it shall be
away from the hot
job.
10 Placing and lifting
of 3rd shell and
subsequent by
jacks – welding and
NDT
Supervisor,
Rigger,
khalasi,
welder, gas
cutter, fitter,
helper, jack
operator,
signalman.
 Fall of shell
plates
during lifting
or placing
 Failure of
jacks
 Failure of
cleat
 Personnel
injury due
to pressed
in between
 Access /
egress
 Fall of loose
& small
tools &
tackles
 Portable
oven
electrocutio
n
 Before lifting of
plates from the
saddle, lifting hook
to be welded and
it is to be
physically
checked for giving
clearance.
 Tag rope to be
provided for any
lifting materials.
 All the plates to be
stacked on the
saddle in such
place, it shall not
create any
hindrance to the
other activities.
 All the weld joints
of the cleats to be
checked by the
QA/QC engineer
and to be certified
for using as lifting
hook.
 During placing of
the lifted plates on
the existing
erected plates,
hands shall not be
kept in between
the two plates.
 During fixing of
wedge piece,
person shall
hammer slowly in
initial phase and
then go for more.
 Before starting the
lifting operation by
Site Engineer

8. jack, all the jacks
to be checked
personally by the
competent person.
 All the hydraulic
hoses shall be
free from any
damage.
 All the jack lifting
points fitted with
the cleats to be
checked on
regular basis.
 During lifting
operation, nobody
shall be allowed to
move below the
shell to go inside /
outside the tank.
During movement,
jacks shall be
locked and it is to
be ensured.
 While lifting of
tank by jack shall
be carried out,
required number
of people only
shall be allowed
inside the tank.
 Inside the tank,
proper & sufficient
illumination shall
be provided.
 DC oven machine.
11 Fixing of other
accessories like
pipe supports,
staircase with
supports etc (both
inside & outside)
for each shell in
parallel as soon as
particular shell
plate erected
Supervisor,
Rigger,
khalasi,
welder, gas
cutter, fitter,
helper, jack
operator,
signalman.
 Fall of
materials
 Fall of
person
 Wrong
sequence
maintaining
 Proper scaffolding
of required height
with handrail and
working platform
to be erected.
 No loose materials
to be kept at
higher elevation.
 Proper access /
egress to be
maintained at the
tower and working
platform.
 Required
materials to be
shifted at higher
platform as and
when required. Do
not stack any
materials at
working platform
at higher
elevation.
 All the activities to
be carried out in a
proper sequential
Site Engineer

9. manner.
12 Erection of bottom
shell plates -
Removal of jacks
and stool one by
one as soon as the
particular plate is
being erected and
placed, welded –
cutting of manhole
– removal of entire
materials inside the
tank - welding
Supervisor,
Rigger,
khalasi,
welder, gas
cutter, fitter,
helper, jack
operator,
signalman.
 Personnel
injury
during
material
handling
 Improper
access /
egress
 Trip hazard
 The jacks and the
stool shall be
removed in
sequential way.
 Proper
supervision and
guidance to be
there during jack
and stool removal.
 Before closing the
last shell plate i.e
‘make-up’ plate,
manhole to be cut
and access /
egres to be
ensured.
 Sufficient
ventilation to be
ensured. If
required, exhaust
fan to be fixed.
 Before transferring
the entire load on
the bottom shell
plates, it shall be
ensured that all
joints are properly
welded.
 Sufficient
illumination to be
provided inside
the tank.
 All the materials
except few to be
taken out of the
tank inside before
placing the ‘make-
up’ plate.
Site Engineer
13 Fixing of roof plate
– balance one
Supervisor,
Rigger,
khalasi,
welder, gas
cutter, fitter,
helper,
signalman.
 Same as
point 7
 Same as point 7 Site Engineer
14 Vacuum box test Vacuum
pump
 Electrocutio
n
 Electrician shall
give all the
electrical
connections and it
shall be routed
through ELCB.
Site Engineer
15 Diesel oil chalk test
for welding joints of
bottom with the last
shell plates
Supervisor,
Khalasi,
helper.
 Fire
 Suffocation
due
inadequate
ventilation
 Oil spillage
 Trip & fall
 No hot job shall be
allowed nearby,
inside, top of the
tank.
 Sufficient
ventilation to be
ensured
 It is to be ensured
Site Engineer

10. that no oil spillage
occurs. If require,
catch tray to be
used.
 Housekeeping to
be ensured to
prevent any trip
hazard.
16 Settlement test /
leakage test for the
tank
Supervisor,
Khalasi,
helper.
 Failure of
manholes
due to
loose bolts
 Before starting
filling of water
inside the tank, all
the bolts and nuts
to be properly
tightened and it is
to be inspected
properly.
Site Engineer
17 Painting of the tank
from both inside &
outside
Supervisor,
Painter,
Helper
 Fall of
person
 Fall of
materials
 Fire
hazards
 Suffocation
 All the scaffolding
shall be erected
on firm and
levelled ground.
 Working platform
shall have proper
handrail and
suitable access /
egress.
 Sufficient
illumination to be
ensured inside the
tank.
 Inside and
outside,
scaffolding shall
be properly
supported.
 Excessive paints
shall not be
stacked inside the
tank. Quantity of
paints can be
taken inside as
and when
required.
 Sufficient
ventilation shall be
provided (if reqd,
exhaust fan)
during painting job
inside the tank.
 No loose, open
paints and thinner
drums shall be
stored or kept at
site.
 All the people
must wear safety
belt (double
lanyard) hooked
properly at
shoulder level.
 Suitable access /
Site Engineer

11. egress to be
ensured going
inside the tank.
 While going to the
height of the
scaffolding,
person shall not
carry the paint
container along
with him.
 Spillage of paints
to be controlled
and area shall be
cleared off any
spillage.
 No hot job shall be
allowed in and
around the
painting area.
18 Radiography Radiographer  Exposed to
radiation
 Date & Time of
radiography shall
be informed to all
concerned well in
advance.
 The area of
radiography to be
cordoned off,
warning sign to be
displayed and
flashlights to be
displayed to
caution the
surrounding
people and passer
by.
 Before starting the
radiography,
visual check shall
be there about the
surrounding and
other agencies
working nearby
shall be informed.
 While doing
radiography,
dosimeter and
survey meter shall
be available with
people executing
the radiography.
 Source strength
shall be known
and accordingly
barrication
distance shall be
fixed.
 Before doing the
radiography,
available format to
be filled and
signed by the
Site Engineer

12. radiographic
agency and
concerned site
Incharge and
approval shall be
taken from the
HSE Dept.
 When blasting
operation is
planned,
radiography shall
not be permitted
and radiographic
source shall be
kept inside the
source holder.
 When radiography
is being done,
blasting operation
shall not be
performed,
detonators shall
be kept inside the
explosive
magazine and
vice-versa.
18 Others  Relative work
permits to be
obtained from the
SALPG along with
all complimentary
work permits.
 Welding cables,
gas-cutting hoses,
electrical cables
shall not overlap
with each other.
 All the persons
involved in the job
shall have suitable
PPEs like
goggles, nose
masks, safety
belts, hand gloves
etc.
 Excess working
hour (more than
12 hours) shall be
restricted.
 Pep talk to be
given before
commencing of
the job on regular
basis.
 Entire area shall
be free from any
unauthorised
entry.
 PA / Responsible
person shall be
present during
Site Engineer

13. entire operation.
 Good
housekeeping to
be maintained in
and around tank
area.
 In case of multiple
work fronts at
different levels,
proper co-
ordination,
communication
shall be in place.
 Nobody shall work
under suspended
load at any
circumstances.
 ‘TAG’ system to
be followed for the
scaffolding.
 During plate
erection, lifting of
the tank by jack
area to be
restricted for
unauthorised
entry.
 Only authorised
and experienced
person shall be
engaged for jack
operation.
 Proper guard to
be provided for
the rotating part of
the machineries.
 Precaution to be
taken for crane
movement in
between the area
of crude oil line
and both the
tanks.
 During loading or
unloading of
materials from the
trailor parked at
he main road,
movement along
the pedestrian
path to be
restricted for the
moment.
 Housekeeping
shall be done on
regular basis and
all the scrap
materials to be
taken out of the
site.
 No combustible

14. materials to be
kept in and around
the tank area.
 Gas cylinders to
be kept in upright
position in the
stand.
 In case of LPG
cylinder, it is to be
industrial and
having the related
regulator and flash
back arrestor.
 No personnel
movement within
crane swing area.
 Trained ‘Fire
watcher’ shall be
present near the
hot job.
 Fire bucket, fire
extinguisher shall
be in place near
the hot job.