SAF/2 /10 Page 2 of 16 Date Prepared:

Revision: 0 Date Revised:

SAF/2 /10 Page 2 of 16 Date Prepared:
Revision: 0 Date Revised:

SCOPE:

Document describes the Guideline for conducting Job Safety Analysis (JSA).

The document contains:

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,
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:

• Selection of a job suitable for analysis (Basis hazard classification).

• Describe the sequence of steps to perform the job.

• Determine the hazards and potential accidents for each job step.

• 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 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.

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 Potential Prob. Level Recommended

Basic Hazards Safe
Job Steps Job Procedure
Break down the job For each job For each job For each hazard,
into its basic steps e.g. step, identify step hazard determine how the
what is done first, all hazards. assign a employee should perform
what is done next & so probability level the job step to eliminate or
on. Some find it easier of High, Medium minimize the hazard that
to identify possible or Small. could lead to an injury.
You can do this by: accidents & work in Determine if you can
reverse to identify remove the hazard, change
1) Observing the hazards, listing type the work procedure,
job. of injury in change physical
2) Discussing it parenthesis conditions and/or provide
with the following the personal protective
employee. hazard. You can get equipment. You can get
3) Drawing on the answers by: your answers by:
your knowledge 1) Observing the
of the job. 1) Observing job for leads.
4) A combination the job. 1) Discussing
of the three. 1) Discussing it precautions with
with the experienced
Record the job steps in employee. employees.
their normal order of 1) Recalling past 1) Drawing on
occurrence. Describe accidents. your
what is done, not the 1) A combination experience.
details of how it is done. of the three. 1) A combination of
Usually three or four the three.
words are sufficient to Ask yourself: Can Describe specifically the
describe each basic job he or she be struck precautions the
step. by or contacted by employee must take. Do
anything? Can he or not omit important
For example, the first she strike against details. Number each
basic job step in or come in contact separate recommended
using a pressurized with anything? Can precaution with the
water fire he or she fall? Can same number you gave
extinguisher would be he or she the potential hazard (see
to: overexert? Is he or center column) that the
she exposed to precaution seeks to
1)Remove the anything injurious, avoid. Use simple do or
extinguisher such as gas, do not statements to
from the wall radiation, welding explain recommended
bracket. rays or other precautions as if you
hazards that could were taking to the
cause acid burns, employee. For example:
inhalation of “Lift with your legs, not
noxious fumes or your back”. Avoid such
other problems? generalities as “Be
Careful”, “Be Alert”,
In the fire “Take Caution”.
extinguisher
example, one In the extinguisher
hazard would be: example, one
 safeguard would be:
1)Foot struck by
extinguisher 1)Grasp extinguisher
(fracture, handle firmly.
bruise).
 SECTION – 6: JSA Example:
Uni UT Task Description: Loading of polisher resin.
t: Y
Zon WP
e: U
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 Coveralls, Splash goggles.
Required: All special safety equipment or tools to be examined by Safety
Section before execution of the job.

Sr. Task Step Potential Hazard Prob. Control Measures

No. Level
1 Shutdown vessel, Vaccum if the M Keep the top bleeder open
and drain. top bleeder is at all times and car-seal-
not kept open. open it. Install a
combination gauge on top
and keep
checking the pressure on
it.
2 Blind all lines Exposure to M Inspect all lines with
entering/exiting hazardous blinds list. Identify and
vessel materials. 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 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).

Slip/trip hazards Secure hoses, etc. on

 outside of vessel
walkways/scaffolding
. Ensure hose joints
are clamped and tied
M securely to handrails.
Heat stress – (Resp : CR- Asia)
accessing and
settingup Rest cycle as required.
equipment (Resp: CR-Asia)
H Sufficient supply of
potable water and soft
drinks on converter
top. (Resp : EAPCL)
Hoses/
equipment
Hoses/leads on top of
falling from
vessel to be neatly
height
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 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)

Confined space entry

permit system to be
adhere to – continuous
 atmospheric
monitoring of
atmosphere in and on
top of vessel. (Resp :
CR-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).

Slip/trip 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 Dropping S Ensure containers
catalyst moved by certified
(risk of pyrophoric loading crane operator and
incident in case of containers rigger. (Resp : EAPCL)
pre- reduced from height H
catalyst – need to Ensure barricading in
use nitrogen place to prevent
purge/blanket. Exposure unauthorized entry
to/inhalation below vessel. (Resp :
However, loading of catalyst dust EAPCL)
to be performed CR-Asia to use their
under normal PPE while EAPCL
atmospheric personnel to use dust
conditions in case masks if around
of unreduced screening area.
catalyst .
Inspection to be Personnel loading
done after catalyst to wear
displacing nitrogen breathing apparatus
inside the vessel). (CR and EAPCL
confined space
procedures to be
 adhered to).
Wrong S Load as per EAPCL
loading loading diagram. Pre-
sequence reduced and
unreduced catalyst
drums to be placed in
H separate stacks.

Temperature Rise 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 Rain entering S Place boards and traps
decommissioning of vessel over manway plus
site tarpaulin. No water to
enter vessel.
Follow the EAPCL
rain contingency
H plan.
Slip/trip
All movements to and
from top of vessel to be
Falling equipment via stairs.
from top of vessel
M 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 Environme S Waste to be disposed
ntal of as per EAPCL ISO-
contamina 14001
tion procedure or
recommended by HSE.
 SAF/2 /10 Page 17 of 16 Date Prepared: May 25, 2006 Revision: 0
Date Revised:
HYPERLINK \l

"_bookmark0" JSA
Unit Task Description:
::
Zon
e:
Equipment No. Hazard Score: Requirements:
Developed by: Reviewed by : Approved by:
PPE (Standard):

Special PPEs
Required:
Sr. Ta Step Potential Hazard Prob. Control Measures
No. sk Level

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