JOB SAFETY ANALYSISA SUCCESSFUL EXPERIENCE IN FAUJI FERTILIZER COMPANY

Prepared by:Usman SharifTaufeeq Arshad

FFC Safety Culture & Commitment

Safety Indicators

Job Safety Analysis

Steps for JSA

Benefits of JSA

JSA-A successful experience in FFC

OUTLINE

Safety is our top priority

Safety is main consideration for plant operation /

maintenance

Our safety goal is human and

equipment safety

FFC is certified for • Quality management

system ISO 9001:2008

• Occupational health & Safety Assessment Series OHSAS 18001:2007

• Environment Management System ISO 14001:2004

We have 23.46 million man-hours

without LTI

SAFETY CULTURE

FFC SAFETY COMMITMENT

Considering the link between organizational failures and mistakes,

‘SAFETY as a goal’ is mandatoryFFC’S COMMITMENT

Safety is more important than ProductionSafety is my responsibility

Individual’s Mistake

Organizational Lapses

Accident Causes

SAFETY INDICATORS

• Measurements of past incidents, successes and failures

• Prediction of future performance and commitment to achieve safe execution of the job

• As Job Safety Analysis (JSA) is also a pro-active approach, it therefore falls in the category of leading indicators

LAGGING INDICATORS

LEADING INDICATORS

JOB SAFETY ANALYSIS (JSA)

OSHA Standard 3071 pertains to Job Safety Analysis.

“It is a technique that focuses on job tasks as a way to

identify hazards before they occur. It focuses on the

relationship among the worker, task, tools and work

environment”

JSA should be conducted by a group of experienced personnel from all concerned disciplines

JSA team should not conduct the analysis in isolation; all concerned employees to be involved in the process

JSA should be conducted in the same environment in which the job is planned for execution

JSA team should come up with practical control measures and avoid mentioning vague instructions

JSA will be useful only when all the defined control measures are implemented in letter and spirit

JOB SAFETY ANALYSIS (JSA)

1- Select a job

BASIC STEPS FOR JSA

1- SELECTION OF JOB

JSAs are not feasible

For routine jobs

For jobs defined too broadly, for example, ‘overhauling of urea

plant centrifugal pumps’;

For jobs defined too narrowly, for example, ‘dismounting of anti friction bearings from the shaft.’

1- SELECTION OF JOB

• Factors to be considered in setting a priority for

analysis of jobs include:

– Accident frequency and severity

– Newly established jobs

– Infrequently performed jobs

2- Break the job into sequence of steps

1- Select a job

BASIC STEPS FOR JSA

2- SEQUENCE OF STEPS

A ‘job step’ is defined as a segment of the operations necessary to advance the work.

• All critical steps should be written down

• The sequence of steps must be maintained

• The breakdown of steps should be discussed among all

the participants (always including the worker) when

completed.

2- Break the job into sequence of steps

1- Select a job

3- Identify potential hazards & associated risk level

BASIC STEPS FOR JSA

3- HAZARDS & RISK LEVELS

any source of potential damage or adverse health

effects on something or

someone under certain

conditions at work.

is the chance or probability that a person

or property will be harmed to

a certain level, if exposed to a

hazard.

HAZARD RISK

HAZARDS CLASSIFICATION

HAZARDS

BiologicalBacteria, viruses, insects, animals

Chemical Toxic properties of the chemical.

Ergonomics improper set up of workstation

Electrical Electric shock, electric fire

Noise Hearing loss, inability to communicate

Excavation Soil collapse in trench / pit

HAZARDS

To help identify potential hazards, the team members should follow a questioning attitude and may use

questions such as:

• Can any body part gets caught in or between objects

• Is the temperature of working area is comfortable

• Does any particular tool or machine pose any hazard

• Can the worker slip, trip, or fall in the working area

• And so on ------

RISK LEVELS

Risk reduction measures should be implemented or activity to be suspended / restricted. Considerable resources to be allotted

No additional controls are required unless they can be implemented at very low cost (in terms of money, time and effort

Additional controls are taken considering the cost, the risk level to be lowered to an acceptable level

HIGH

MEDIUM

LOW

HAZARDS EXPOSURE

TENDENCY TO FOLLOW SHORT

CUTS

TENDENCY TO LOSE

CONCENTARTION

HIGH RISK

LEVEL

RISK LEVELS

JOB NATURE

HUMAN NATURE

2- Break the job into sequence of steps

1- Select a job

3- Identify potential hazards & associated risk level

4- Determine control measures to mitigate hazards

BASIC STEPS FOR JSA

4-CONTROL MEASURES

Elimination/Substitution

Engineering

Admin

PPE

4- CONTROL MEASURES

•Wiping off the spilled oil from the floor

•Using a brass hammer instead of conventional steel hammer on the natural gas line.

Elimination / substitution

•Incorporating ventilation systems to control fumes

•Installing an acoustic hood on the blower for abating the sound

Engineering Controls

•Altering schedules to day time when the hazard is less likely to occur

•Strict compliance of work permit procedures

Administrative Controls

•Using engineering or administrative controls, if a hazard cannot be reduced to an acceptable risk level, appropriate PPEs should be used

Personal protective equipment (PPE)

Provides a written step wise procedure, which improves communication between workers and supervisors.

Provides minor details / guidance in the management of the hazards and risks that are embedded in the job.

Unveils the latent hazards of the job, this can be best achieved if experienced personal of all discipline taken on board.

JSA can be a valuable tool for the training of new inductees

JSA can be used to help refine safe work procedures described in safety manuals or standard operating procedures.

BENEFITS OF THE JSA

THE FIRST JSA WAS CARRIED OUT IN

YEAR 2007

ROUTINE FOR MAJOR JOBS/

INFREQUENT JOBS

ZERO SAFETY INCIDENT IN ALL CRITICAL /

INFREQUENT JOBS

JSA- A SUCCESSFUL EXPERIENCE

SAFETY EXCELLENCE

Department Section/ Unit Area Equipment

Production-II Ammonia-II 43 C-4321

Job C-4321, Replacement of damaged portion (6th, 7th & 8th shell course)

Required personal Protective

Helmet, Safety Glasses, Harness, Ammonia Escape Mask, Leather bags,

Required Machines / Tools

Crane, Trailer, Grinders, Spanners, Hammer, welding tools, Chain blocks, Shackles, Slings, Tacking Cleats

Conducted by: abc / xyz

JOB SAFETY ANALYSIS

High Medium Low

Risk Level

JSA- A SUCCESSFUL EXPERIENCE

Sequence of Basic Job Steps Possible Hazards Risk Level Corrective Measure

Pre – Turnaround Activities

• Pre turnaround scaffolding

- Falling hazard

- Falling Object

- Ammonia release

Medium

Use Safety harness. Use Tie strip on spanners

against falling Use bags for transferring Joints Take ammonia mask while

going for any job at height

• Removal of permanent plate forms & Monkey Ladder(s)

- Falling Object

- Falling of

platform during

rigging

- Ammonia release

Medium

Use Lan yard with spanners to avoid falling

Halt rigging if wind velocity exceeds 25 km/hr

Hazard Level:

JSA- A SUCCESSFUL EXPERIENCE

Hazard Level:

Turnaround (Field) Activities

• Rigging of

upper portion

of C-4321

- Falling of column

during riggingMedium 1) Follow the rigging plan

2) Inspect all rigging hardware

• Tacking/welding of Upper portion with lower portion

1) Confined space

entry.

2) Electric shock

while using

electric grinder.

3) Disc/metal

particles fly off.

4) Fire hazards

Medium

1) Follow confined space entry

procedure.

2) Use ELCB with electric board

3) Make enclosure for capturing

grinding/welding spatters

4) Remove flammable material

before start of hot job.

5) Use healthy welding equipment

& associated hardware

JSA- A SUCCESSFUL EXPERIENCE

Pre arrangements Safe rigging

JSA- A SUCCESSFUL EXPERIENCE

Thank You