JOB HAZARD ANALYSIS

JHA Preparation Date: 21 DECEMBER 2022 Working Date: Work Duration: TILL COMPLETE PTW No:

Job Title: EPCC OF NEW K440 AT TRAIN 1 – FORKLIFT OPERATIONAL HER No:
Ethylene / Polyethylene
Plant Area: PCPSB Equip. Tag No.: Service / Medium: EAI No :

ZETO RULES

Permit to Work? √ Safety Critical Equipment? Working at Height? Excavation? Ignition Source Control? √

Energy Isolation? Confined Space Entry? Chemical Handling? Lifting Operations? √ Driving Safety? √

References used in this JHA
(Tick if applicable)
 PTS: __________________________________
 Company Procedure (Specify):
_____________________________________
_____________________________________
 Company / PETRONAS Memo / Notice:
_____________________________________
Legislations :
 OSHA  FMA  EQA  BOMBA  AELA
 Guidelines (Specify): __________________________________
____________________________________________________
 COP (Specify): ______________________________________
____________________________________________________
 Others (Specify): _____________________________________
____________________________________________________
 Job Method Statement (JMS)
 Hazard & Effect Register (HER)
 Environmental Aspect & Impact (EAI)
 HAZOP
 Environmental Impact Assessment (EIA) Report
 QRA Report
 CIMAH Report
 Chemical Health Risk Assessment (CHRA) report
 Chemical Exposure Monitoring Report
 Noise Exposure Monitoring Report
 Health Risk Assessment (HRA) Report
 Local Exhaust Ventilation (LEV) Report
 Safety Data Sheet (SDS)
 Chemical Reactivity Matrix
 Others Report :
_________________________________
_________________________________
_________________________________

EMERGENCY RESPONSE / RESCUE PLAN

Emergency Escape Route & Nearest Assembly Point: 2 Nearest Break Glass Location: PE-1-MS-3001
Emergency Notification: WALKIE TALKIE Nearest Fire Extinguisher Location: 184
Nearest Emergency Eyewash / Shower: GROUND FLOOR Nearest Hose Reel/Hydrant Location: HB9

RECEIVING AUTHORITY (RA) JHA REVIEWED BY SUBJECT MATTER

WORK LEADER (WL) JHA APPROVAL BY AREA OWNER
The JHA reviewed and will ensure EXPERT (SME) or HSE
The JHA has been discussed and understood The JHA Reviewed and Approved to use
the control measures are in place (For special activities only)

Signature: Signature: Signature: Signature:

Name: Name: Name: Name:

Dept./ Company: Dept.: Position / Dept.: Position / Dept.:

Date: Date: Date: Date:

JHA RISK MATRIX

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 JOB HAZARD ANALYSIS

SEVERITY SEVERITY
1 2 3 4 5
Insignificant Minor Moderate Major Catastrophic

E
E1 E2 E3 E4 E5
Almost Certain
LIKELIHOOD

D
D1 D2 D3 D4 D5
Likely

C
C1 C2 C3 C4 C5
Possible

B
B1 B2 B3 B4 B5
Unlikely

A
A1 A2 A3 A4 A5
Remotely likely
to happen

RISK CATEGORY
Descriptions

Work should not be started until the risk has been reduced. Considerable resources shall be
VERY HIGH allocated to reduce the risk. Where the risk involves work in progress, urgent action
(immediately, minimum admin control shall be taken)

Efforts SHALL be made to reduce the risk. Risk reduction measures should be implemented
HIGH
within a defined time period.

Efforts MAY be made to reduce the risk. Risk reduction measures should be implemented within
MEDIUM
a defined time period.

LOW No additional controls required. Monitoring required to ensure existing controls are maintained.

LIKELIHOOD
Descriptions

ALMOST CERTAIN (E) Happens several times per year at PCE/PCPSB

LIKELY (D) Happens several times per year in PETRONAS

POSSIBLE(C) Incident has occurred in our PETRONAS

UNLIKELY (B) Heard of incident in Oil & Gas / Petrochemical Industry

REMOTELY LIKELY TO HAPPEN (A) Never heard of in Oil & Gas / Petrochemical Industry

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 JOB HAZARD ANALYSIS

NO DESCRIPTION

1. First aid injury or slight health effects not affecting work performance or causing disability e.g. first aid injury, exposure to
non-hazardous dusts.
1
INSIGNIFICANT 1. Spill/leak causing negligible impact to local environment, contained within the secondary containment and does not reach
water and soil, and no volatilization to atmosphere.
2. Noise, air emission, discharges not exceeding company or legislative limits.

1. Medical Treatment Case , Restricted Work Case, Lost Time Injury or minor health effects (involving health hazards
capable of minor health effects which are reversible, e.g. irritant agents, defatting agents, food poisoning bacteria) affecting
work performance, such as restriction to work activities or a need to take a few days to fully recover.
2
MINOR 1. Spill/leak contained within secondary containment causing volatilization to atmosphere causing limited contamination of
soil or water within the containment area causing non-permanent impacts to the environment.
2. Noise, air emission, discharges not exceeding legislative limit but exceeding company limit (where available).
3. No immediate cumulative and/or delayed effect.

1. Permanent Partial Disability, significant health effects (capable of irreversible health damage without loss of life, e.g. noise,
poor manual handling tasks, hand/arm vibration, chemicals causing systemic effects, sensitizers), exposure to possible
human or animal carcinogens, or results of injury/illness in the lower categories (category 1 & 2 above) which affect
performance in the longer term such as prolonged absence from work for more than 4 days.

1. Spill/leak causing limited contamination to soil or water outside the secondary containment but remain contained within
3 facility perimeter (for onshore operation) ** OR resulting in Potential Consequence A, B or C below;
MODERATE 2. Noise , air emission, discharges exceeding legislative limit OR resulting in Potential Consequence as below;
Note:
Potential Consequence
a) Cumulative and/or delayed environmental impact,
b) Short term recovery action < 1 month
c) Rehabilitation period < 6 months

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 JOB HAZARD ANALYSIS

1. Permanent Total Disability, single fatality from accident or occupational illness or major health effects caused by health
hazards capable of irreversible damage with serious disability or death e.g. exposure to corrosives, probable human
carcinogens, extreme heat and cold, psychosocial risk factors

1. Spill/leak spreading outside the facility perimeter, managed to be contained/recovered but causing major contamination OR
4 resulting in Potential Consequence A, B or C below;
MAJOR 2. Noise , air emission, discharges exceeding legislative limit with possible prosecution OR resulting in Potential
Consequence as below;
Note:
Potential Consequence
a) Immediate effect with serious damage to environment
b) Medium term recovery action (1- 3 months)
c) Rehabilitation period 6 – 12 month

Multiple fatalities or Multiple Permanent Total Disability from accident or occupational illness caused by health hazards with
the potential to cause multiple fatalities, e.g. chemicals with acute toxic effects (hydrogen sulphide, carbon monoxide), known
human carcinogens.

1. Spill/leak spreading outside the facility perimeter, causing massive contamination OR resulting in Potential Consequence
5 A, B or C below;
CATASTROPHIC 2. Noise , air emission, discharges resulting in legal prosecution with possible shutdown of facility, OR resulting in Potential
Consequence as below;
Note:
Potential Consequence
a) Severe environmental damage
b) Long term recovery action (> 3 months)
c) Rehabilitation period > 12 month

STEP POTENTIAL HAZARDS & RISK ASSESSMENT RESPONSIBLE ACCOUNTABLE

BASIC JOB STEPS CONTROLS TO AVOID HAZARDS DEADLINE
NO. CONSEQUENCE Likelihood Severity Risk Cat. PERSON PERSON
1 Loading / unloading equipment /  Forklift shall be inspected by
material using forklift Sparks from the exhaust and PCPSB prior to enter site
Memunggah barang daripada lori ke engine compartment Forklift hendaklah diperiksa
lay down area menggunakan forklift Keluar percikan api daripada oleh pihak PCPSB sebelum
ekzos dan bahagian enjin memasuki kawasan loji
 Perform LEL gas test
 Fire Lakukan pemeriksaan gas LEL Prior to
Kebakaran  Install spark arrestor at exhaust start work
Site
MEDIUM Pasang spark arrestor pada Sebelum
C 3 Supervisor / RA
Sederhana ekzos kenderaan memulakan
Work leader
 Standby fire extinguisher with kerja
valid BOMBA certification and
first aid box in vehicle
Sediakan alat pemadam api
yang sah dan mempunyai
persijilan BOMBA dan peti
pertolongan kecemasan di
dalam kenderaan

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 Perform forklift inspection and

Vehicle components damaged/ replaced immediately the
broken/ malfunction damaged/ broken components
Komponen kenderaan rosak/ Lakukan pemeriksaan forklift Prior to
pecah menyebabkan kenderaan dan gantikan dengan segera start work
hilang kawalan komponen yang rosak/ pecah Site
LOW Sebelum
C 2  Ensure that forklift part Supervisor / RA
Rendah memulakan
 Accident (reverse alarm, side mirror, Work leader
kerja
Kemalangan etc.) in good condition
Pastikan bahagian forklift
dalam keadaan baik

 Follow plant speed limit

Over speed limit (20km/h)
Melebihi had laju Patuhi had laju loji (20km/j)
 Wear seat belt while driving
 Accident Pakai tali pinggang keledar During work Site
Kemalangan LOW semasa memandu
C 2 Semasa Supervisor / RA
Rendah  Not allowed to use walkie bekerja Work leader
talkie while driving
Dilarang menggunakan walkie
talkie semasa memandu

 Driver have valid competent

Incompetent driver/ operator certificate and complete all
Pemandu tidak mahir required document
 Pemandu mestilah
 Asset damage mempunyai sijil kompetensi
Prior to Site
Kerosakan harta benda yang sah dan melengkapi
start work Supervisor /
LOW semua dokumen yang
C 2 Sebelum Work leader /
Rendah diperlukan RA
memulakan Vehicle
 Ensure competent certificate
kerja operator
endorse in safety passport
Pastikan sijil kompeten di cop
di dalam buku taklimat
keselamatan

C 4 HIGH  Assign a signalman to make Site RA

Blind spot/ limited space / narrow Tinggi sure the work area is safe to During work Supervisor /
path pass Semasa Work Leader
Titik buta/ kawasan sempit / jalan Arahkan seorang penunjuk bekerja
sempit arah untuk pastikan kawasan
kerja selamat daripada laluan

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 Personal injury forklift

Kecederaan  Reverse alarm, honk and side
mirror must be functional in
 Asset damage good condition.
Kerosakan harta benda Reverse alarm, hon dan
cermin sisi hendklah berfungsi
dalam keadaan baik
 No unauthorized person in
barricaded area and display
signage
Pastikan tiada orang yang
terlibat dalam kawasan
barricade dan pamerkan
papan tanda

 Switch off engine if necessary

Toxic fume from vehicle (CO) Matikan enjin kenderaan jika
Asap beracun/ toksik daripada perlu
During work Site
kenderaan LOW  Do not stand opposite to the
B 2 Semasa Supervisor / RA
Rendah exhaust direction
bekerja Work Leader
Jangan berdiri bertentangan
dengan arah ekzos kenderaan

 Forklift operator has valid

Falling equipment/ material license and complete all
Barang terjatuh required document
Operator forklift mestilah Prior to
 Personal injury LOW mempunyai lesen yang sah start work
Kecederaan C 2 Rendah dan melengkapi semua Sebelum Supervisor /
RA
dokumen yang diperlukan memulakan Work leader
 Asset damage  No unauthorized person kerja
Kerosakan asset nearby working area
Tiada orang yang berkenaan
berdekatan kawasan kerja

C 2 LOW  Assess and identify weight of Prior to Supervisor / RA

Overload Rendah load start work Work leader
Lebih muatan Kenal pasti berat beban Sebelum
 Load capacity do not exceed memulakan
 Asset damage the capacity of vehicle / SWL kerja
Kerosakan harta benda Muatan beban mestilah tidak
melebihi muatan kenderaan/
SWL

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 Signalman to guide vehicle

Congested / obstructed area movements, reversing &
Kawasan sempit entering narrow path Prior to
Signalman hendaklah start work
 Personal injury LOW membantu dalam memberi Sebelum Supervisor / RA
C 2
Kecederaan Rendah panduan dalam pergerakan memulakan Work leader
kenderaan(reverse & masuk kerja
 Asset damage ke kawasan sempit)elakkan
Kerosakan asset masuk ke kawasan berbatu

 Forklift to be inspected by
Hydraulic leaking PCPSB personnel
Prior to
Hydraulic bocor Forklift mestilah diperiksa oleh
LOW start work Supervisor / RA
B 2 PCPSB personnel
Rendah Sebelum Work leader
 Pollution  Prepare absorbent pad
memulakan
Pencemaran Sediakan absorbent pad
kerja
2 Menambah minyak ke dalam forklift Percikan api/ Minyak mudah C 2 Rendah  Menutup suis ketika Sebelum Supervisor/ RA
terbakar (diesel) menambah minyak ke dan
Refuel diesel into the forklift Fire sparks/ flammable oil Low dalam mesin semasa WL
(diesel) Switch off the engine kerja/
 Kebakaran during refuel diesel Before and
Fire  Pastikan jarak semasa during
menambah minyak dengan work
aktiviti hot work
sekurangnya 5 meter
Make sure the distance
during refuel diesel with
hot work activities is at
least 5 meters
 Meletakkan alat pemadam
api berhampiran dan
pastikan ianya telah lulus
dari pemeriksaan bomba
dan tidak tamat tempoh
Provide fire extinguisher
nearby and ensure it is
approved by BOMBA and
not expired
 Pastikan lebihan minyak
tidak disimpan di dalam

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plant
Make sure excess diesel not
store in the plant
Terdedah kepada bahan kimia C 2 Rendah  Memakai respirator (half Sebelum Supervisor/ RA
Exposed to chemical mask cartridge multigas), dan
Low dan sarung tangan getah semasa WL
Wear respirator (half mask kerja/
catridge multigas) and Before and
rubber glove during
 Pastikan ada SDS dan CLASS work
Labelling
Ensure SDS and CLASS
Labelling available

Tumpahan minyak C 2 Rendah  Sediakan takungan minyak Semasa Supervisor/ RA

Oil spillage ketika mengisi minyak kerja/
 Pencemaran alam Low kedalam mesin during WL
sekitar Standby drip tray during work
Environmental refuelling
pollution  Pastikan corong minyak
digunakan
Ensure oil funnel are used
 Menambah minyak dengan
menggunakan pump/
secara manual
Refuel oil used pump/
manual hand pump
 Sediakan pad penyerap
minyak
Provide absorbent pad

 Identify and avoid sharp edge

3 Performing housekeeping Sharp edge/ pinching and pinch point
Bucuan tajam/ tersepit Kenal pasti dan elakkan
Before start
LOW daripada bucuan tajam
C 2 and during Work Leader RA
 Finger injury Rendah  Wear semi leather glove
work
Kecederaan jari Pakai sarung tangan separa
kulit

 Housekeeping is to be
Scattered material C 2 LOW Daily/all the Supervisor/ RA

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Barang bertaburan maintained throughout work

duration and completion of
 Trip, slip and fall job.
Tersadung, tergelincir Kawasan tempat kerja
dan jatuh hendaklah sentiasa kemas
setiap masa. Work Leader
Rendah time
 Evaluate the work area and
identify safe routes to be used
Menilai kawasan kerja dan
kenalpasti laluan yang
selamat untuk digunakan

 Stop work and evacuate to

4 General precaution Emergency fire alarm activated nearest assembly point as During
Langkah-langkah berjaga yang asas Pengaktifan penggera kecemasan stated in PTW
LOW work Supervisor/
C 2 Berhenti kerja dan beredar ke RA
Rendah Semasa Work Leader
tempat berkumpul seperti
dinyatakan dalam PTW bekerja

 To carry out proper

Tripping hazard housekeeping during working During
Hazad tersadung and after work
LOW work Supervisor/
C 2 Menjalankan kekemasan di RA
Rendah Semasa Work Leader
 Injury tempat kerja semasa dan
Kecederaan selepas tamat kerja bekerja

 Immediately stop work and

Incident and accident inform site work supervisor/
Kejadian dan kemalangan work leader or inform SS on
duty at Control Room During
 Injury LOW Berhenti kerja dengan segera work Supervisor/
C 2 RA
Kecederaan Rendah dan maklumkan kepada ketua Semasa Work Leader
kerja/ penyelia atau Shift bekerja
Supervisor yang bertugas di
Control Room

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PTW No.: A3 / A4 - ……………………………………………………

THIS JHA HAS BEEN DEVELOPED BY (Name of Team Members)

NO. POSITION / COMPANY INITIAL DATE
Minimum Team Members shall consisting a Job Owner and Area Owner Reps.
1. (JHA LEADER)
2.
3.
4.
5.
6.
7.
8.
9.
10.

JHA requirements have been communicated by WL / RA and understood by every person working on the job.
Name Signature Date Name Signature Date
1. 14.
2. 15.
3. 16.
4. 17.

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5. 18.
6. 19.
7. 20.
8. 21.
9. 22.
10. 23.
11. 24.
12. 25.
13. 26.

HAZARD IDENTIFICATION FORM

(Before or During Working)

BAHAYA (HAZARD) & DIKEMASKINI OLEH

LANGKAH KAWALAN TINDAKAN OLEH
KESAN (CONSEQUENCE) NAMA & JABATAN MASA & TARIKH

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PERHATIAN
1. Borang ini hendaklah dikepilkan bersama PTW dan JHA dan dipamerkan di tempat kerja.
2. Perubahan Minor: Penemuan Hazad baru dan langkah kawalan yang diperlukan mencukupi – Auditor berbincang dengan WL dan RA. Kemas kini borang dan beritahu Approving Authority (AA) /
Shift Supervisor.
3. Perubahan Major: Perubahan dalan langkah kerja (STEP) ATAU penemuan Hazad baru yang mempunyai risiko yang tinggi dan memerlukan langkah kawalan yang lebih efektif – Auditor berbincang
dengan WL atau RA. Hentikan kerja dan beritahu Approving Authority (AA) / Shift Supervisor untuk tidakan selanjutnya. PTW perlu ditahan sementara dan JHA baru diperlukan sebelum boleh
dibenarkan untuk memulakan kerja semula.
4. JHA asal hendaklah dikemaskini dengan memasukkan maklumat yang terdapat di dalam borang ini semasa hendak memperbaharui PTW (Renew PTW).

TOOLS, VEHICLES AND MOBILE EQUIPMENT

TOOLS REQUIRED INSPECTION EXPIRY DATE

 HAND - Type of tools :

 PNEUMATIC - Type of tools :

 LOW VOLTAGE TEST EQUIPMENT :

 NON EX/IS TEST EQUIPMENT :

 OTHER (specify) :

VEHICLES AND MOBILE EQUIPMENT REQUIRED INSPECTION EXPIRY DATE

 CRANE :

 HYDRAULIC LIFT :

 COMPRESSOR :

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 JOB HAZARD ANALYSIS

 WELDING MACHINE :

 OTHER (Specify) :

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JOB HAZARD ANALYSIS (JHA) CHECKLIST

The intent of this checklist is to assist the identification of hazards related to job and the preparation of the JHA. Prior to
performing a JHA, check each item on the list that applies. All applicable items must be addressed in JHA.

PHYSICAL HAZARDS ENVIRONMENTAL ORGANIZATIONAL FACTORS

  Slippery Floor   Extreme Conditions (e.g. Heat /   Training (Competency)
  Soft Surface Cold / Heavy Rain)   Language / Communication
  Sharp Objects   Noise   Supervision
  Falling Object   Radiation   Rules & Procedures
  Hot Surfaces   Controls
  Moving Vehicle   New Employee
  Rotating Parts HAZARDOUS CONDITIONS   Work Permit (Visa)
  Collapse (Soil)   High Elevation   Competent Person
  Poor Lighting
  Extreme Weather
PHYSIOLOGICAL & ERGONOMIC Abnormal Temperature WORK ENVIRONMENT
  Wrong Posture High Wind   Access / Egress / Escape Routes
  Personal Disability Rain / Storm Scaffolds
  Claustrophobia Abnormal Humidity Suspended Access
  Workplace Fatigue Lightning Mobile Platforms
Inadequate rest time between   Temporary Facilities Ladders / Lightweight Staging
a work set   Non Breathable Conditions (e.g. Main Storm Drain
Long hours of work in a Nitrogen, Above PEL etc.)
single shift   Heavy / Abnormal Vibration   General Workplace Conditions
Long hours of work across   Limited Access Workspace
a work set   Chemical Reaction Light
Inadequate breaks within a Heat / Cold Stress
single shift Noise & Vibration
Changes to rosters HAZARDOUS ACTIVITIES Weather / Atmosphere
  Working in Confined Space Special Workplace Conditions
  Excavation Work At Heights
CHEMICAL   Lifting Over Water
  Hydrocarbon under pressure   Climbing / Working at Height In Excavations
  Toxic substances   Handling Hazardous Chemical On or Near Live Plant
  Pyrophoric Materials   High Pressure Water Jetting (HPWJ)
  Flammable   Driving   Plant and Equipment
  Corrosive (Acid / Alkaline)   Manual Handling Portable Tools
  Use of Tools and Machinery Abrasive Wheels
  Walking Through or Standing Cartridge-operated Tools
BIOLOGICAL Close to Moving Object / Hand Tools
  Bacteria / Air Borne Virus Rotating Equipment
  Marin Growth   Working on Machines and Doing   Services & Consumables
  Animal (e.g. Dog, Boar, Lizards etc.) Crushing, Cutting, Tearing, Electricity
  Venomous Insect (e.g. Bee, wasp, Shearing items or equipment Compressed Air
Centipede, scorpion etc.) Steam
Consumables (e.g. LPG, Petrol /
TASK FACTORS Gasoline etc.
ELECTRICAL   Workload Hazardous Substances
  High Voltage   Workplace, Effort, Exertion Process Fluids and Solids
  Electrical Current   Skill, Knowledge & Experience Dusts, Mists, Smoke and Fumes
  Short Circuit   Complexity Construction Materials
  Electrical Fire   Time, Timing
  Static   Decision Making
  Loss of Power   Repetitiveness   LEGAL REQUIREMENTS
  Radiological   Authority Notification
  Ionizing Radiation   Medical Surveillance
  Electromagnetic Field   OTHERS   Chemical/Noise Exposure Monitoring
  Laser Beam    Chemical Health Risk Assessment
   Scheduled Waste


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