Job Safety Analysis

Dept E&I
Unit / Task Description Replacement of Ammonia Plant MV Switchgear in 2202-K Substation
section Electrical
Equipment name

Risk Rating Work Permit Required: Electrical/Hot /Cold/Vehicle Entry/Load Lifting

Reviewed By
Developed By Approved By
Operations Safety Craft Electrical
Name

Initials

PPEs Required Cotton Gloves, Mandatory PPEs (Safety Helmet, Safety Shoes, Safety Goggles)

Special PPEs Required

1) Pre-work

2) Isolation

3) Alternative Supply Arrangement

4) Disconnection and Dismantling

Sequence of Events, (SOE) 5) Lifting of switchgears and shifting old SWGR's. out of 2202-K and new SWGR's. into 2202-K

6) Shifting, fixing and installation of new switchgears

7) Power and control cables termination

8) Testing and Commissioning

9) Job completion

Probability
Sr # Task Step Potential Hazards Level Control Measures Responsibility

1. Trained personnel will be assigned on this job. AE /sub-

engineer electrical will supervise complete activity

2. Tool box talk and method statement to be delivered to

concerned team members (including contractor's team) Electrical
● Unskilled manpower L
prior to start the job Craft
Operation

1. All contractor personnel shall undergo HSE induction

2. Permit to work procedure to be complied

3. Proper PPEs shall be worn & extreme care to avoid

● Non-compliance of procedures injury during shifting of panels

4. Ensure all equipments are inspected and certified Electrical

M Craft
5. All power and lifting equipments shall meet the PFL Operation
● Equipment/tools failure
requirement

1 Pre-work
 1. Site kick off meeting will be fixed

2. Activities shall be properly planned and briefed prior to

start work

3. Ensure equipments are certified and visually inspected

prior to start work and fit for the intended purpose
● Poor task planning 4. Check the ground conditions are safe
Electrical
M 5. Barricade the area of activity
● Area of activity 6. No unauthorized personnel/visitors shall be allowed

1. Phase sequence will be checked before de-energization

of 2202-K MV bus

2. Both upstream MV incomers (C-7 and C-15) of 2202-K

will be switched off and racked out from MV Room

3. LOTOTO will be implemented

● Electrocution (MV supply) M Electrical
4. Separate locks by electrical, operation and safety shall
be installed

5. Zero Voltage will be ensured at both downstream MV

incomers (Incoming-1 and Incoming-2) in 2202-K
2 Isolation substation.

1. 230V control supply will be switched off from DB-XXX

2. Zero voltage will be ensured in control compartment at

● Electrocution (control supply) M terminal strip/point XXXX Electrical

3. Battery charger will be switched off and DC outgoing

cable in battery charger will be disconnected

1. All electrical supply of 2202-K substation will

interrupted for one hour, approximately. Operations to
take alternative measures Electrical
● Equipment/facility shutdown L Operation
2. Supply of DCS rack room, DCS UPS, control room Instrument
circuits on normal supply i.e lighting and sockets shall not
be available during alternate supply arrangement

1. Both LV incomers (LV Incomer-1 and LV Incomer-2) in

2202K SS will be switched off and racked out

2. Transformer feeder MV cables will be disconnected

from MV panel
Alternative Supply 3. Emergency busbar shall be energized by closing F46
3
Arrangement breaker from cogen LV, then close F52 breaker from
2205K emergency bus
● Back feeding to MV panels
4. Emergency incomer will be switched ON in 2202-K and Electrical
M
complete LV busbar will be energized by putting LV
● Electrocution coupler in service

5. After energization of LV busbar, zero voltage will be

ensured at both MV buses
 1. All MV cables shall be tagged and listed before
disconnection

2. All control cables shall be tagged and marked on

drawing

3. All remote cables for motor feeders i.e field ON/OFF,

ammeter etc. shall be tagged and marked on drawing
before disconnection
● Loss of tagging 4. All remote cables for transformer feeders i.e Buchhloz
relay, temperature gauge etc. shall be tagged and marked
on drawing before disconnection
M Electrical
● Damage of cables 5. Concrete demolition for cables back-pulling shall be
Disconnection and done manually only and power tools shall not be used
4
Dismantling
6. After disconnection and backlpulling, all MV cables will
be properly tied up and hanged

1. HVACs will be switched off/locally off

● Fall/damage of duct L 2. Proper platform will be build for handling/relocation of Electrical

duct

1. Ensure all lifting tackles and slings are inspected and

certified
2. Conduct a visual inspection of all lifting tools and
tackles and ensure no visible damage prior to use for
lifting

3. Load shall be properly balanced prior to lift and swing

● Failure of lifting tackles and slings 4. Rigging must be performed by competent riggers

5. All sharp edges of the load,may contact with the slings

shall be adequately protected
M CRAFT
● Unauthorized person under 6. Insert packing (wood/ rubber) with slings to avoid
suspended load damage to structure specially on corners if require

7. Working crew shall not be permitted to work under the

suspended load

8. No unauthorized personnel/visitors shall be allowed in

activity area

9. Rigging plan to be developed and implemented for

critical lift
Lifting of switchgears and
shifting old SWGR's. out of
5 2202-K and new SWGR's. into
2202-K

1. Trained/skill certified crane operator shall be allowed

to operate machine/Crane

2. One signal man will be provided by craft department

who will be available throughout the job
● Crane operation failure H Craft
3. Crane operator will not leave his seat till the end of
crane operation

4. Do not exceed the safe working load "SWL" of the

crane as per standard under any circumstances

1. Anchor 02 tag lines with transformer in order to control

its movement
● Poor visibility and bad weather
conditions H 2. Work will stop for any bad weather conditions i.e high Craft
wind velocity etc. for which supervisor decides that work
environment is unsafe
 1. Equipment (if any) below core cutting point to be
removed before starting the job

2. Nearby DB's and panels will be covered by liner to

● Damage of equipment during core protect against dust ingress
cutting
M 3. Area below core cutting point to be barricaded Electrical
● Personnel injury during core
cutting 4. Proper lighting and ventilation will be arranged during
core cutting

1. Proper PPEs shall be worn and extreme care to avoid

pinch point while shifting of switchgears on roller
shaft/pipe

2. Competent supervision will be ensured while shifting

the panels at the marked location
Shifting, fixing and installation
6 of new switchgears 3. Load shall be handled with caution and sufficient
manpower for proper balancing and shifting

● Damage of equipment 4. Pathways of switchgear shall be cleared of material and

all tripping hazards shall be remover
● Personnel injury
5. Ensure switchgears are properly bolted and Electrical
H
secured/balanced in the position Craft
● Misalignment of panels

● Loose/over-tightness 6. Busbars will be tightened with torque wrench as per

desired torque.

1. Verification of tags and and terminal list will be done

before termination
● Swaping/interchange of
cables/cores H Electrical
2. Continuity will be checked for cross verification

1. Sharp bends will be avoided

Power and control cables
7
termination 2. Quality checks of new terminations will be done by
AE/SE electrical to ensure zero oil leakage
● Damage of cables H Electrical
3. Tan Delta/IR test of all MV Cables will be carried out
before new termination

1. 1st Energization checklist (xx ) to be filled before

energization

2. Parameterization of protection relays according to

study will be done before energization
● Equipment failure
3. Only authorized person to be present in Substation
H during 1st energization Electrical
● Personnel injury
4. Faced shield and fire suit to be used for 1st
energization

1. Setting of protection relays will be checked before

energization

2. Control circuit will be energized first and it will be

ensured that all auxiliaries i.e.
voltmeter/ammeter/analyzer etc are energized
8 Testing and Commissioning Electrical
3. Operation of all breakers will be verified in test position
through local and field/remote signals

● Intended sequence failure

H
● Intended operation failure
 ● Intended sequence failure
1. Phase sequence will be checked after switching ON 6KV
H supply from MV room
● Intended operation failure
2. All MV motors will be decoupled and test run will be
conducted on solo

3. All MV motors will be tested in coupled condition in Electrical

coordination with operations team Operation
4. All transformers will be energized and phase sequence
of LV side to be re-verified

1. Ensure proper wind up and housekeeping at work site

2. The accessories and tools shall be checked, cleaned and

● Scattered tools and accessories store properly
9 Job completion L Electrical
● House keeping 3. Remove berrication , where not required