Procedure for Jsa

SAF/2 /10 Revision: 0

Page 1 of 17 Date Prepared: May 25, 2006 Date Revised:

M:\SET Manuals\PROCEDURE FOR JSA.doc



SCOPE: This Document describes the Guideline for conducting Job Safety Analysis (JSA). The document contains:

Table of Contents Section Description Page No. 01 Guideline Basis 03 02 Job Safety Analysis Methodology 04 03 JSA Training & Team 09 04 Review Meeting 10 05 JSA Training Guide 11 06 JSA Example 12 07 JSA Format 17



SECTION - 1 Guideline Basis Engro Asahi Polymer & Chemicals Limited is committed to the safe operations of its facilities. This commitment requires that all jobs with a potential safety hazards are systematically identified, and the risk from these jobs are analyzed in such a way that potential injury or equipment damage instances are identified, so that necessary protections are put in place to eliminate chances of injury or major equipment damage. Job Safety Analysis Guidelines address the following areas:

1) JSA methodology to be used. 2) Requirement of Job Safety Analysis to be clearly defined. 3) JSA training requirements & qualifications of the team members to be defined. 4) Job safety Analysis format to be used.



SECTION 2: JOB SAFETY ANALYSIS METHODOLOGY The National Safety Council (USA) gives a detailed methodology for conducting a Job Safety Analysis. Job Safety Analysis (JSA) is a procedure that provides a systematic & effective method to review job methods and uncover hazards so that the safeguards can then be identified. This method is different from other hazard identification as it focus on each task step of a job to identify specific hazards in them. JSAs are very useful in initial and periodic upgrading of procedures, strengthening workplace safety, reducing and eliminating injuries/illnesses and improving safety attitudes. As a job is analyzed, it will be found that some job steps have no hazards associated with them. On the other hand, an individual job step may reveal several hazards or potential accident triggering items. Obviously, some of hazards revealed will be conditions & some will arise out of employees action. JSA will address all the possible hazards. Key elements in preparing a JSA are:

y Selection of a job suitable for analysis (Basis hazard classification). y Describe the sequence of steps to perform the job. y Determine the hazards and potential accidents for each job step. y Identify ways to eliminate and control each hazard.

Selection of Job for JSA Selection of jobs to be analyzed for JSA and establishment of the order of analysis is based on the following factors: Frequency of Incidents/Injuries: The greater the number of accidents associated with a job, the greater its priority claim for JSA. Every job that has had disabling injuries should also be given a JSA, particularly if the injuries prove that prior preventive action was not adequate. Severity Potential Some jobs may not have a history of accidents but may have the potential for producing severe injury. These jobs are generally not done frequently therefore merit a special review. A guideline attached with this procedure can be used for assigning a hazard class and then JSA can be performed for all jobs having 20 or more Hazard Score. Area owner (Mostly Maint. Unit Manager) will call up the JSA. A numeric guideline for the scoring of consequences is given in Table-1 and should be used before embarking upon the JSA activity. Maint. Unit manager in consultation with SET Advisor will assign scores and call for the JSA of an activity. The overall Hazard score is obtained by multiplying the Consequence and Frequency scores. Activities bearing high consequences have to go through JSA as per following table. All activities lying outside the GREEN areas need to Analyzed using JSA technique.



Table-1: Classification of hazard for JSA Continuous

10 30 60 70 80 90 100

4-5 times a day 9 27 54 63 72 81 90

1-3 times a day 8 24 48 56 64 72 80

2-3 times a day 6 18 36 42 48 54 60

Few times per month 4 12 24 28 32 36 40

1-2 times a year 3 9 18 21 24 27 30

Less than once per year 1&2 3 6 7 8 9 10

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New or non-routine Jobs Changes in equipment or in the process obviously have no history of accidents. A JSA of job should be done before embarking on the activity. Analysis should not be delayed until accident or nearmiss occur. Similarly, all non-routine jobs of higher hazard classification are also required to be given a JSA. Others: JSA call up can also be recommended by the SUBSOCs for any jobs. Also, any other non-routine and potentially hazardous jobs defined by Safety Advisor and Area in charges.



Sequence of steps to perform the JSA A job should be broken down into a sequence of task steps each describing what is being done. Do not breakdown the job in such a detail that an unnecessarily large number of steps result. Similarly, the job breakdown should not be so general that basic steps are missed. To do a job breakdown, select experienced & capable employee who are knowledgeable to identify the hazards & can suggest measures to eliminate or control them. Determine the hazards and potential for accident in each job step. Each step in the job breakdown should be carefully analyzed for hazards & accident potential with a view to identifying all the possible hazards whether produced by the environment or job procedures. The familiar & usual safety questions should be answered. Some of the questions are as under: 1) Is there a potential for injury when any object is struck? 2) What about slipping or tripping? 3) Could one fall on the same level or from one level to other? 4) Are toxic, corrosive gases/liquid mists, vapor, dust, heat, fumes & radiation present? 5) Can the employee be caught in, by or between objects? Close observation & knowledge of particular

jobs is required for an effective JSA. When inspecting a particular machine or operation or writing a procedure, ask the question Can an Accident Occur? Through observation and discussion, a reliable list of hazards & potential accidents can be developed.

Frequency/Probability Level All the potential hazards should be assigned a probability level based on the potential to cause an injury or extreme unsafe condition in the area. The probability levels to be used are given in the Table-1 The final step in a JSA is to develop a safe job execution way to prevent occurrence of accidents. There are four ways we can develop solutions that will eliminate or control hazards & offset accident potential. These are: 1) Find an entirely new different way to do the job. 2) Change the physical condition that create the hazard. 3) Revise/Change the procedure. 4) Limit the use of job by reducing frequency with which it is done (particularly helpful in maintenance &,

material handling). To find entirely a new way to do a job, determine the work goal of the job & then analyze the various ways of reaching this goal to see which way is the safest. Consider work-saving tools & equipment. If a new way cannot be found, then ask this question about each hazard and potential cause listed: What change in physical condition (such as change in tools, materials, equipment, layout or location) will eliminate the hazard or prevent the accident. To investigate the changes in the job procedure, ask the following questions about each hazard and potential accident cause listed: What should the employee do or not do to eliminate this particular hazard or this potential accident? How should it be done?



While making the procedure consider the following:

1) Engineering the hazard out. 2) Providing personal protective equipment. 3) Job instruction training. 4) Good housekeeping. 5) Good ergonomics (positioning the person in relation to the machine or other element in the

environment.) 6) Human error factors List recommended safe operating procedure and required PPE for each step of the job. Be specific; say exactly what needs to be done to address the hazard. Avoid general statements. Give a recommended action or procedure for every hazard. Below are some of the guidelines to be used for identifying the Human Factor related items in a JSA. Human Factors It is important to consider human factors and their impact on the likelihood of accidents. Human factors may result in an increase in the likelihood of a human error, by utilizing the guideline (given below) during JSA, human error situations can be identified and necessary actions to address the issue developed.

Hazard Contribution Factor Example Situation Which May lead to Accident

Labeling Mislabeled, or not labeled at all Access Hard to reach or access Operability Difficult to operate/change position Layout Confusing/inconsistent arrangement Uniqueness Several components look alike Mode Manual operation, many manual steps with a potential for

error Involvement Operator detached from process, not fully involved Displays Unclear/complex/non-representational Feedback None or potentially misleading Noise Level Area where hearing protection required but not used Climate Extremes in temperature, humidity, precipitation, wind

etc.



Hazard Contribution Factor Example Situation Which May lead to Accident

Lighting Inadequate lighting for task Content of Procedures Incomplete/too general/out of date Identification Ambiguous device/action identification Format of procedures Confusing/inconsistent, difficult to read Aids Task sequence done by memory Alarms Many simultaneous or false alarms Coverage Operator not always present Time Inadequate time to respond Preparedness No drills/simulation of scenarios Last-Resort Shutdown discouraged or unsafe Overtime Extreme enough to affect performance Consistency Inconsistent shift rotations/schedules No. Of Tasks Tasks required exceed time available Intensity/frequency of activity Very infrequent, lack of experience Shift Change Differing tasks in rapid succession Field/Control Inadequate communications between shifts on Plant status Supervision Little or no supervisory checks Emergency Communication No distinction between alarms in areas or types Initial Training Little or no job specific training Refresher Training Overdue or nonexistent Safety Awareness Little or no training on procedural or process changes

Review & Approval All the JSAs would be review by the Area Incharge / Safety Advisor & approved by the Sub SOC(Mechanical) chairman.



SECTION - 3 JSA Training & Team Training Job Safety Analysis leader should go through a formal Safety Supervision Course in which Job Safety Analysis is covered in detail & must have participated in a JSA before leading one. Adequate training of the JSA study team must be done to ensure a high quality analysis. Training is most effective when atleast a re-fresher is provided shortly before the beginning the study. Team training requirements typically include a team resource, or leader, with in-depth knowledge of the JSA methodology and experience in applying the method atelast once or twice. Team members should receive overview training using the JSA Guideline & referring to previous JSAs. Team The team leader should be technically trained on JSA methodology. The team members must represent a cross section of the disciplines involved in executing the job. It is extremely important to put the most experienced and knowledgeable resource for this activity as inexperienced team tend to conduct a poor quality JSA . The team should contain people from supervision and the operating levels. The membership must include individuals with the following skills: 1) Knowledge of the basic technology involved in the operation / maintenance of the process and

equipment. 2) Hands-on operating / maintenance experience on the process or equipment.

3) One team member who is knowledgeable in the JSA method. 4) Other appropriate knowledge or expertise needed to accomplish the aims of the study. Experts in

specific disciplines not represented on the team can be called in as part time resources for the team. A typical JSA team in EAPCL would have the following membership: 1) Area Incharge / Section Head or appropriate trained designate JSA leader. 2) Safety & Training Engineer / S.E.T. Advisor 3) Area Maintenance Engr. 4) Project Engineer. (If required). 5) Maintenance Technicians. (Contract/permanent)



SECTION 4: REVIEW MEETING The first team meeting is usually a training session & organizational meeting, where the task to be done is outlined and agreement is reached on how to proceed. The maximum time scheduled for a JSA should be no more than two working days. This also includes the training of the members as well. The JSA team must conduct a field tour of the facility being studied. The team member with hands-on experience should serve as the guide. The tour gives the team a clear picture of the job process and the layout. The team members should break the job in logical task steps, identify potential hazards, assign a probability level & then suggest the control measures. The JSA final document should be reviewed with the Safety Advisor and approved by the relevent Sub SOC chairman.



SECTION - 5 JSA Training Guide Typical JSAs are documented using a four-column format (Sequence of Basic task steps, Potential Hazards, Probability level & Control Measures). The example is give below:

Sequence of Basic Job Steps

Potential Hazards Prob. Level Recommended Safe Job Procedure

Break down the job into its basic steps e.g. what is done first, what is done next & so on. You can do this by:

1) Observing the job. 2) Discussing it with the employee. 3) Drawing on your knowledge of the job. 4) A combination of the three.

Record the job steps in their normal order of occurrence. Describe what is done, not the details of how it is done. Usually three or four words are sufficient to describe each basic job step. For example, the first basic job step in using a pressurized water fire extinguisher would be to:

1)Remove the extinguisher from the wall bracket.

For each job step, identify all hazards. Some find it easier to identify possible accidents & work in reverse to identify hazards, listing type of injury in parenthesis following the hazard. You can get the answers by:

1) Observing the job. 1) Discussing it with the employee. 1) Recalling past accidents. 1) A combination of the three.

Ask yourself: Can he or she be struck by or contacted by anything? Can he or she strike against or come in contact with anything? Can he or she fall? Can he or she overexert? Is he or she exposed to anything injurious, such as gas, radiation, welding rays or other hazards that could cause acid burns, inhalation of noxious fumes or other problems? In the fire extinguisher example, one hazard would be:

1)Foot struck by extinguisher (fracture, bruise).

For each job step hazard assign a probability level of High, Medium or Small.

For each hazard, determine how the employee should perform the job step to eliminate or minimize the hazard that could lead to an injury. Determine if you can remove the hazard, change the work procedure, change physical conditions and/or provide personal protective equipment. You can get your answers by:

1) Observing the job for leads. 1) Discussing precautions with experienced employees. 1) Drawing on your experience. 1) A combination of the three.

Describe specifically the precautions the employee must take. Do not omit important details. Number each separate recommended precaution with the same number you gave the potential hazard (see center column) that the precaution seeks to avoid. Use simple do or do not statements to explain recommended precautions as if you were taking to the employee. For example: Lift with your legs, not your back. Avoid such generalities as Be Careful, Be Alert, Take Caution. In the extinguisher example, one safeguard would be:

1)Grasp extinguisher handle firmly.



SECTION 6: JSA Example:

Unit: Zone:

UTY WPU

Task Description: Loading of polisher resin.

Equipment No. Hazard Score: Requirements: Work permits have been obtained.

Developed by: Reviewed by : ARK Approved by: FIQ PPE (Standard): Hard hat, safety glasses or goggles, safety boots, and long sleeved shirt etc..

Special PPEs Required:

Coveralls, Splash goggles. All special safety equipment or tools to be examined by Safety Section before execution of the job.

Sr. No.

Task Step Potential Hazard Prob. Level

Control Measures

1 Shutdown vessel, and drain.

Vaccum if the top bleeder is not kept open.

M Keep the top bleeder open at all times and car-seal-open it. Install a combination gauge on top and keep checking the pressure on it.

2 Blind all lines entering/exiting vessel

Exposure to hazardous materials.

M Inspect all lines with blinds list. Identify and confirm lines isolated use permit system. Blinds to be inspected on shift basis and sealing verified and blind tags to be installed. Tyvek overalls to prevent the resin contact with skin. Each time a person comes out of the vessel, the overalls are disposed off and new overalls worn for the next entry (Resp : CR-Asia).

3 Set up equipment on top of vessel

Buildup of static electricity possible ignition source Slip/trip hazards

S

M

Earth all electrical supply connections. All earthing connections on converter top to be through ELCB (Resp : EAPCL). Secure hoses, etc. on



Heat stress accessing and settingup equipment Hoses/equipment falling from height

M

H

outside of vessel walkways/scaffolding. Ensure hose joints are clamped and tied securely to handrails. (Resp : CR-Asia) Rest cycle as required. (Resp: CR-Asia) Sufficient supply of potable water and soft drinks on converter top. (Resp : EAPCL) Hoses/leads on top of vessel to be neatly coiled. (Resp : CR-Asia). Toe boards to be provided on scaffolding. And scaffolding to be certified (Resp : EAPCL) Equipment to access top of vessel via crane as per EAPCL mechanical procedure. (Resp : EAPCL) Barricade around vessel to prevent unauthorized entry to remain in place for duration of project. (Resp : EAPCL) Area to be barricaded to be decided by EAPCL and CR-Asia.

4 Entry into vessel to remove catalyst and/ or converter internals.

Fall while accessing vessel and moving. LEL situation in (and on top of vessel)

S S

Person entering vessel to be secured to grip tech fall protection equipment when entering vessel and moving within the vessel (vertical entry). In addition to this, life line also to be provided. (Resp : CR-Asia) Confined space entry permit system to be adhere to continuous



Heat stress Temperature rise. Ladder swings Air supply fails. Rescue of personnel required from inside the vessel.

M

H

H

S

atmospheric monitoring of atmosphere in and on top of vessel. (Resp : CR-Asia) Breathing apparatus to be worn by personnel entering vessel CR inert procedures reviewed by EAPCL and entry conditions apply. (Resp : CR-Asia) Standby personnel (minimum of 2) on top of vessel at all times (constant communication with person inside) (Resp : CR-Asia) Temperature monitoring by EAPCL on TDC. If temperature increases by 9 deg F CR-Asia to be informed, vessel entry to be discontinued and introduction of massive amount of nitrogen into the vessel. For details refer to the process specification. (Resp : EAPCL). Secure ladder at the bottom if needed. (Resp : CR-Asia). Personnel to vacate the vessel and EAPCL supervisor to be informed. Seconday and tertiary air supply is, however, available. (Resp : CR-Asia) Please refer to the process specification for details. EAPCL supervisor to be informed. The first priority is to pull him out by using grip tech fall equipment or life line. In case this is nt



possible then the stand by person to go in and hook him to the equipment. Person to be placed on stretcher (if required). (Resp : CR-Asia). Preference is to use stairs but if the condition of the patient doesnt allow then use cradle arrangement. First aid to be administered and to be taken to the clinic. (Resp : CR-Asia/ EAPCL).

5 Inspection (under normal atmospheric conditions)

Exposure to hazardous atmospheric conditions in vessel Slip/trip

S

M

Disconnect nitrogen. Test atmospheric conditions inside vessel prior to entry (monitor all levels of vessel). Oxygen to be 21% and LEL to be nil. (Resp : EAPCL). Person entering vessel to be secured to grip tech fall protection equipment when entering vessel and moving within the vessel. CR-Asia to extend their help and equipment.

6 Load catalyst (risk of pyrophoric incident in case of pre-reduced catalyst need to use nitrogen purge/blanket. However, loading to be performed under normal atmospheric conditions in case of unreduced catalyst . Inspection to be done after displacing nitrogen inside the vessel).

Dropping catalyst loading containers from height Exposure to/inhalation of catalyst dust

S

H

Ensure containers moved by certified crane operator and rigger. (Resp : EAPCL) Ensure barricading in place to prevent unauthorized entry below vessel. (Resp : EAPCL) CR-Asia to use their PPE while EAPCL personnel to use dust masks if around screening area. Personnel loading catalyst to wear breathing apparatus (CR and EAPCL confined space procedures to be



adhered to). Wrong loading

sequence Temperature Rise

S

H

Load as per EAPCL loading diagram. Pre-reduced and unreduced catalyst drums to be placed in separate stacks. Temperature monitoring (Resp : EAPCL) Inject massive amount of nitrogen into the vessel. (Resp:EAPCL) O2 and LEL monitoring. (Resp : CR-Asia)

7 Close vessel and decommissioning of site

Rain entering vessel Slip/trip Falling equipment from top of vessel

S

H

M

Place boards and traps over manway plus tarpaulin. No water to enter vessel. Follow the EAPCL rain contingency plan. All movements to and from top of vessel to be via stairs. Barrication to be done at the bottom. (Resp : EAPCL)Housekeeping and removal of unwanted articles from the converter top. (Resp : CR-Asia)

8 Disposal of catalyst Environmental contamination

S Waste to be disposed of as per EAPCL ISO-14001 procedure or recommended by HSE.



JSA Format

Unit: : Zone :

Task Description:

Equipment No. Hazard Score: Requirements: Developed by: Reviewed by : Approved by: PPE (Standard):

Special PPEs Required:

Sr. No.

Task Step Potential Hazard Prob. Level

Control Measures

Legend: S=Small probability, M=Medium probability, H=High Probability.

Table of Contents SECTION - 1 Guideline Basis SECTION - 5 JSA Training Guide Task StepProb. LevelTask StepProb. Level

Documents

Procedure for Jsa