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Hot Work JSA
Hot Work JSA
Hot Work JSA
SCOPE:
بسDocument describes the Guideline for conducting Job Safety Analysis (JSA).
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,
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.
• Determine the hazards and potential accidents for each job step.
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 scori 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 1
0
0
4-5 times a
day 9 27 54 63 72 81 9
0
1-3 times a
day 8 24 48 56 64 72 8
0
2-3 times a
day 6 18 36 42 48 54 6
0
Few times
per 4 12 24 28 32 36 4
month 0
1-2 times a
year 3 9 18 21 24 27 3
0
Less than
once per 1 3 6 7 8 9 1
year & 0
2
Catast
N Serio LWI, Fatali
First rophe
ot Notic us VCM ty,
(Level
ic eable Injur expos seriou
-II),
e impa y, ure, s
Major
a ct Noti fire or dama
equip
bl ceab mode ge to
ment
e le rate equip
dama
i equi equip ment,
ge,
m pme ment NEQS
multip
p nt dama violat
le
ac dam ge ion. fatalit
t age, ies.
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:
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:
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:
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.
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.
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:
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 Buildup of static S Earth all electrical
equipment on electricity – supply connections. All
top of vessel possible ignition earthing connections on
source converter top to be
through ELCB (Resp :
M 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 Fall while accessing S Person entering vessel
remove catalyst vessel and moving. to be secured to “grip
and/ or converter tech” fall protection
internals. equipment when
entering vessel and
moving within the
vessel (vertical entry).
In addition to this, life
LEL situation in S line also to be
(and on top of provided. (Resp : CR-
vessel) Asia)
Breathing apparatus to
Heat stress be worn by personnel
M entering vessel – CR
inert procedures
reviewed by EAPCL and
entry conditions apply.
(Resp : CR-Asia)
Temperature rise. H
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
Ladder H by 9 deg F CR-Asia to
be informed, vessel
entry to be
swings Air discontinued and
introduction of massive
amount of nitrogen
supply fails. S into the vessel. For
details refer to the
process specification.
(Resp : EAPCL).
Rescue of
personnel Secure ladder at the
required from bottom if needed.
inside the (Resp : CR-Asia).
vessel.
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 doesn’t allow
then use cradle
arrangement. First aid
to be administered
and to be taken to the
clinic. (Resp : CR-Asia/
EAPCL).
5 Inspection Exposure to S Disconnect nitrogen.
(under normal hazardous Test atmospheric
atmospheric atmospheric conditions inside vessel
conditions) conditions in prior to entry (monitor
vessel all levels of vessel).
Oxygen to be 21% and
LEL to be nil. (Resp :
M EAPCL).
Special PPEs
Required:
Sr. Ta Step Potential Hazard Prob. Control Measures
No. sk Level