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JOSOP 499 - Hazard Analysis Procedure

Approved 27 February 2008 Version 1.2.1.A Posted 26 March 2009

©2008 by Chevron Corporation

This document contains proprietary information of Chevron Corporation. Any use of this document without express, prior, written permission from Chevron Corporation and/or its affiliates is prohibited.

JO – Hazard Analysis Procedure

Version 1.2.1.A Posted 26 March 2009 i Printed 6 July 2009. Uncontrolled when printed. JOSOP499JO_MSW_HazardAnalysisProcedure.doc

Contents

Introduction ........................................................................................................................................ 3

Requirements ...................................................................................................................................... 3

Planning Phase Hazard Analysis (JHA) ............................................................................................. 3 Job Safety Analysis ............................................................................................................................ 3 Think Incident-Free (TIF) .................................................................................................................. 4

Performing a Hazard Analysis .......................................................................................................... 5

Identifying the Task............................................................................................................................ 5 Forming the Analysis Team ............................................................................................................... 5 Breaking Down the Task .................................................................................................................... 5 Identifying Potential Hazards ............................................................................................................. 6 Developing Solutions/Control Measures............................................................................................ 6 Hazard Analysis Content .................................................................................................................... 6

How Should I Document My Analysis?............................................................................................ 7

Form Selection Matrix........................................................................................................................ 8

Life of a Hazard Analysis .................................................................................................................. 9

How Do I Ensure Competency? ........................................................................................................ 9

Personnel Competency ....................................................................................................................... 9 Field Visits and Reviews .................................................................................................................... 9 Document and Procedure Quality Review ......................................................................................... 9

Document Retention......................................................................................................................... 10

Document Control Information ...................................................................................................... 10

Document List................................................................................................................................... 10

Appendix A: Standard Hazard Analysis Worksheet .................................................................... 12

Appendix B: Standard Hazard Analysis Worksheet with Risk Assessment............................... 13

Appendix C: JSA Worksheet with Checklist ................................................................................. 15

Appendix D: JO JSA Worksheet ................................................................................................... 17

Appendix E: Pocket Card (front).................................................................................................... 20

Appendix F: TIF Analysis ............................................................................................................... 22

Appendix G: Example Hazard Analysis......................................................................................... 23

Appendix H: JSA Guidance ............................................................................................................ 25

Appendix I: What to Look For in a Hazard Analysis ................................................................... 27

Appendix J: Hazard Analysis Screening Checklist ....................................................................... 29

Appendix K: How do I use “Think Incident-Free” (TIF)............................................................. 31

List of Tables

Table 1. Use of Analysis Methods...................................................................................................... 4 Table 2. Hazard Analysis Content ...................................................................................................... 7


ii Version 1.2.1.A Posted 8 December 2008. Printed 6 July 2009. Uncontrolled when printed.

JOSOP499JO_MSW_HazardAnalysisProcedure.doc

Table 3. Hazard Analysis Tool Selection ........................................................................................... 8 Table 4: Document Control Information .......................................................................................... 10 Table 5: Document History .............................................................................................................. 10 Table 6: Document List .................................................................................................................... 10


Version 1.2.1.A Posted 8 December 2008 3 Printed 6 July 2009. Uncontrolled when printed. JOSOP499JO_MSW_HazardAnalysisProcedure.doc

Introduction This procedure follows the three phases of hazard analysis as it applies to our work. From the initial planning phase, to the work group pre-job onsite Job Safety Analysis (JSA) discussion, to the individual’s ongoing effort to Think Incident Free (TIF), hazard analysis tools are critical to identifying potential hazards and developing actions and strategies to prevent incidents from occurring. Hazard analyses may also be used as a training tool for new employees, as the basis for health, environment and safety (HES) checklists, behavior based safety (BBS) observations and safety meeting topics, and to write HES procedures and standard operating procedures (SOPs) for new or modified jobs.

Figure 1. Phases of Hazard Analysis.

Requirements A hazard analysis shall be conducted for work performed where Joint Operations has operational control. For contractor activities where Joint Operations does not have operational control, we will encourage them to use their hazard analysis tools. The following table lists the analysis methods discussed in this procedure.

Planning Phase Hazard Analysis (JHA) The hazard analysis performed as part of job planning provides a structured approach for identifying potential hazards and developing control measures. This should ensure that that the proper people, equipment, preparation and HES processes are identified and acted upon prior to commencing work. This also provides the opportunity to adjust the work plan to reduce risk.

A qualified SOP may be used as the hazard analysis for job planning. Strategic business units (SBUs) should consider incorporating completed hazard analysis into new and existing SOPs.

Job Safety Analysis The Job Safety Analysis (JSA) is a tool for analyzing a task, specifically in the area of Health, Environment and Safety. This analysis occurs at the work site prior to work beginning, and involves those individuals that may be affected by the task. The JSA should identify the hazards present at the time the work starts as well as identify specific mitigation actions necessary to prevent incidents. After the analysis is done, it may be kept as a reference for future similar operations. Since the JSA is a tool intended for individuals and teams performing the work, it should be developed in the language appropriate for the entire work crew (sometimes multiple languages and/or verbal translation may be needed).


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Think Incident-Free (TIF) Think Incident-Free should be used by everyone prior to beginning any activity. These self assessments focus on the fact that, in order to achieve incident-free operations, each worker must take responsibility for his or her own health and safety in all activities, as well as protecting the environment. Many tasks have risks associated with them that could potentially result in injuries, environmental impact, and losses. Before these risks can be eliminated or controlled, they must be identified. TIF enables employees to observe day-to-day operational and procedural systems to identify potential hazards that could threaten the health or safety of our personnel or contract workforce, company facilities, or the environment.

The steps in an effective TIF assessment are:

Determining the potential hazards

Determining what can be done to eliminate the hazard

Take action to prevent any negative consequences

SBUs may use other nomenclature and/or tools for their TIF assessments.

Table 1. Use of Analysis Methods

Analysis Method When to use Intent

Hazard Analysis (e.g. Risk Assessment, Job Hazard Analysis, Job Safety Analysis, Safety Plan)

During the planning phase of work: pre-work

To identify anticipated hazards and plan mitigations

To ensure that the right number of people, skill sets, equipment and PPE are included in the plan

To identify the types of certificates required to do the work

To identify the SWP standards and SOPs applicable to the work

For use as starting point for onsite JSA

Job Safety Analysis (JSA)

During the permitting phase of work: prior to start of work

To involve the work team to make sure that the people doing the work understand the tasks, hazards and mitigations

To address onsite conditions on the day of the work

To insure that mitigation measures are in place To verify that work team has proper skill level

and tools

Think Incident-Free (TIF)

Anytime To prompt workers to think before they act To ensure that the worker is looking for

hazards while they are doing work To support Stop Work Authority and the

Tenets of Operation

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Performing a Hazard Analysis A hazard analysis involves the following activities:

Identifying the task

Forming the team (for simple tasks, this may be one person)

Breaking down the task into steps

Identifying potential hazards

Developing solutions/control measures to mitigate the identified hazards

Identifying the Task A task is a sequence of steps or activities to complete the work. Tasks are identified and evaluated to the appropriate level of detail. “Drilling a well” or “performing a shutdown on a gas plant” is too broad to be a single task, and tasks such as “turning on a switch” are too narrow for effective analysis. The appropriate level of detail for a task is typically the type of assignments that a supervisor would make (e.g., removing a pump for maintenance, collecting an oil sample from a vessel, or installing a blind in piping).

A hazard analysis (JSA) used onsite by an individual work crew should cover a single specific task. However, in the planning phase for a large scope of work (e.g., capital project) the hazard analysis may consist of a single assessment covering many tasks.

Forming the Analysis Team Person(s) performing the analysis should:

Be experienced and knowledgeable about the task and hazards

Understand the hazard analysis procedure

Be an experienced facilitator, if appropriate

When forming the team, consider factors such as the complexity of the task, the location of the work and the size of the work group. In addition to the person doing the job, team members should be selected as appropriate and may include other workers, supervisors and HES professionals. In some cases, it may be acceptable for an analysis to be prepared by one person.

Breaking Down the Task Before the search for potential hazards begins, the task is broken down into a sequence of steps, each step describing what is being done. Begin by asking, “What step starts the task?” then, “What is the next basic step?” and so on. (See Appendix G: Example Hazard Analysis for a sample hazard analysis.) If too many steps result from the analysis (over 15), consider breaking that job into more than one task.

When beginning to document the analysis, describe and number each step on the analysis form. Each step tells what is done, not how. The description for each step should begin with an action word such as “remove,” “climb,” “open” or “weld.” The description of the step is completed by naming the item to which the action applies, for example, “remove extinguisher,” or “carry to fire.”

Check the breakdown of the steps with other team members, particularly someone who is knowledgeable about performing the task. Obtain agreement on the description of what is done and the order of the steps.




Identifying Potential Hazards Once the basic steps have been determined, begin the search for potential and existing hazards. Look at physical conditions (chemicals, tools, work space, etc.), environmental factors (heat, cold, noise, lighting, wet conditions, etc.) and actions or behaviors (need to stand on a slippery or unstable surface, extended reach to operate a valve, lifting bulky objects). Additional information on increasing hazard identification skills is located in the MSW Support Materials. Examples of what to look for during an analysis are located in Appendix H: JSA Guidance, Appendix I: What to Look For in a Hazard Analysis, and Appendix J: Hazard Analysis Screening Checklist.

Developing Solutions/Control Measures The final step in an assessment is to develop solutions/control measures to eliminate potential hazards, or mitigate them to an acceptable level of risk. The principal solutions/control measures are:

Determine if the work is necessary. Eliminate unnecessary work that adds risk and does not contribute to achieving the desired result.

Change the physical conditions that create the hazards – change in tools, materials, equipment, layout or location. This is the preferred approach until there is general agreement that work conditions are as safe as reasonably practical.

Change the work procedure – ask, “What should the employee do, or not do, to eliminate this particular hazard or prevent this potential accident?” The answer might be as simple as standing to the side when opening the valve, or getting a good stance before lifting an item.

Add barriers between the hazard and the receptors – fire blankets, warning tape, personal protective equipment (PPE), etc.

Find a completely new way to do the job – if the above steps have not yielded a safe, efficient way to perform the task, and then look at the task itself. Determine the goal of the job and analyze alternative ways of reaching this goal.

Solutions/control measures shall be stated so that people clearly understand what to do. There is usually not enough space on the assessment form to explain how to do it. The needed level of detail shall be included in procedures, manuals, employee training, or in some other form so that everyone understands how to do the task safely.

NOTE: Identifying associated procedures (when/ where applicable) is a viable mitigation when incorporated by review and thorough understanding of individuals involved in job task planning.

Hazard Analysis Content A hazard analysis is not:

A detailed work procedure (either maintenance or operating)

A Permit to Work (PTW), and a PTW is not a JSA

A recyclable document (it must be refreshed for each job)

Items that should be included in the different levels of hazard analysis are listed in Table 2.

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Table 2. Hazard Analysis Content

Hazard Analysis

JSA TIF Content

Includes a review of the use of Stop Work Authority by all employees and contractors. Discuss specific conditions associated with the task that are potential triggers for stopping work.

Includes a review the Tenets of Operation.

Is used as an onsite tool to engage workers involved in the work.

Documents work location.

Is dated (using the actual date work is performed).

Is written for all designated job tasks and all new job tasks.

Identifies, by documentation, workers associated with work described in the specific JSA.

Identifies potential spill sources or items lost overboard, along with preventive and/or backup containment plans.

Uses a hazard analysis worksheet as a checklist tool to ensure potential hazards, controls and emergency/contingency plans, and safety equipment required have been addressed.

Is adaptable to changing conditions by following what’s written. If not written, the task shall be stopped, discussed and changes documented accordingly.

Is reviewed and signed (including permits) by personnel new to the task location upon arriving at the ongoing work location.

If the supervisor or person in charge of work is replaced, the Permit Approver will be notified to ensure additional communications occur as needed.

Work must also be stopped if errors are identified in SOPs or JSAs while performing the work. In these cases, the JSA or SOP must be updated to address the changes.

NOTE: It is acceptable to reference and use applicable data from an archived/library hazard analysis/JSA preparation (e.g., list task steps), but caution shall be taken to prevent complacency in evaluating the job task detail. When using a library document, it is important to ensure that additional hazards are identified, site-specific actions/protective systems are added, and the person responsible for eliminating or mitigating each hazard is designated.

How Should I Document My Analysis? The SBU may select the hazard analysis tools that best fit their purposes. Examples are provided at the links below. An SBU may use several types of tools as appropriate to their needs.

Standard Hazard Analysis Worksheet (3 column)

http://dominous2.chevron.com/ctop/oeproc.nsf/main/4400b38e6f6f3a338825740800702d66/$FILE/Standard%20Hazard%20Analysis%20Worksheet.doc




Hazard Analysis Worksheet with Risk Assessment

JSA Worksheet with Checklist

Planning and Implementation JSA Worksheet

Pocket size Checklist

Refer to a site specific "electronic library" and pull job task specific hazard analysis for review and editing, or

“TIF” Analysis

Form Selection Matrix Guidance on selecting hazard analysis tools is provided below.

Table 3. Hazard Analysis Tool Selection

Criteria (considered cumulatively)

Use When Use When Use When

Complexity of Work or Task More Less None

No. of Safe Work Practices

engaged Many One None

SimOps Many None None

Severity of Consequences Major Minor Very Low

SOP in place No Yes Yes

Any permit required?

Hazard Assessment, SOP or JSA Worksheet

(Long Form)

Yes

Pocket Size Checklist

No

TIF Self

Assessment

No

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http://dominous2.chevron.com/ctop/oeproc.nsf/main/4400b38e6f6f3a338825740800702d66/$FILE/JSA%20Worksheet%20with%20Checklist.doc

http://dominous2.chevron.com/ctop/oeproc.nsf/main/4400b38e6f6f3a338825740800702d66/$FILE/Planning%20and%20Implementing%20JSA.doc

http://dominous2.chevron.com/ctop/oeproc.nsf/main/4400b38e6f6f3a338825740800702d66/$FILE/JSA%20Pocket%20Card.pdf

http://dominous2.chevron.com/ctop/oeproc.nsf/main/4400b38e6f6f3a338825740800702d66/$FILE/Think%20Incident%20Free.doc



Life of a Hazard Analysis Determine if an existing SOP or hazard analysis for the same or similar activity is available as a

starting point.

Develop specific hazard analysis for work plan.

Communicate identified hazards and mitigations to the person(s) developing onsite JSA.

Utilize existing documents such as an SOP, hazard analysis developed as part of work plan or pre-existing hazard analysis for the same activity as a starting point.

Initiate the JSA immediately prior to commencing work. This JSA must be reviewed, rewritten or modified for each shift change as appropriate. The modifications must include any changes in hazards and working conditions.

Utilize hazard identification techniques to appropriately identify location and task specific hazards that have the potential to affect the people performing the work.

Develop appropriate mitigation steps to be taken to reduce or eliminate the potential for injury, environmental incident or property damage.

Include hazard analysis documentation with PTW for approval.

Develop or discuss the JSA in a common language(s) for those performing the work.

Ensure the JSA is accessible and reviewed by everyone at the work location affected by this work.

If changes occur after this JSA is reviewed and signed, everyone involved should re-sign and review as appropriate.

When Stop Work Authority (SWA) is initiated, a JSA review by the affected work crew is required prior to resuming work.

The JSA should be retained with the other MSW specific permits for later review and update per SBU retention requirements.

How Do I Ensure Competency?

Personnel Competency Personnel performing hazard analysis should receive training and competency assessment as appropriate to their role(s). Reference JO MSW Training Requirements Tool for specific competencies associated with hazard analysis.

Field Visits and Reviews The Field Review is a process to ensure, throughout the year, that hazard analyses are prepared correctly, the procedure is followed, and that feedback is given to the work group so that they can improve their adherence to the procedure. This field review should be initiated and completed as defined in the SBU verification matrix. Field reviews must be documented and submitted to the SBU designated location, for review by the SBU Process Sponsor and Advisor.

Document and Procedure Quality Review Document and Procedure Quality Reviews will be used periodically (as determined by SBU) by Supervisors and the MSW Process Sponsor/Advisor to provide evidence of consistency and effectiveness of hazard analyses. Results of the Document and Procedure Quality Reviews should be communicated to the workforce.




Document Retention In order to facilitate the review process and improve the quality of assessments, hazard analyses shall be retained at the Division location for one year or as otherwise defined by the SBU.

Document Control Information

Table 4: Document Control Information

Description GU Common SBU-Specific

Approval Date 27 February 2008 17 December 2008

Next Revision Due 27 February 2011 17 December 2011

Control Number

Table 5: Document History

Version Number

Date Notes

1.0 27 February 2008 Initial Release

1.1 30 May 2008 Add link to Hazard Analysis Risk Matrix

1.2 8 December 2008 Added bookmarks for OE Mentor

1.2.1 17 December 2008 SAC Adoption of MSW

1.2.1.A 26 March 2009 JO Version Created

Document List The following table provides a list of the documents referenced in this procedure.

Table 6: Document List

Attachment Title File Name

Joint Operations – MSW SOP Qualification Procedure

JO_MSW_StopworkAuthorityProcedure.doc

Standard Hazard Analysis Worksheet Standard Hazard Analysis Worksheet.doc

Standard Hazard Analysis Worksheet with Risk Assessment

Standard Hazard Analysis Worksheet With Risk Assessment.doc

JO JSA Worksheet JSA Worksheet With Checklist.doc

Planning and Implementation JSA Worksheet

Planning And Implementing JSA.doc



Attachment Title File Name

Pocket Card JSA Pocket Card.pdf

TIF Analysis Think Incident Free.doc

Hazard Analysis Risk Matrix Hazard Analysis Risk Assessment Matrix.doc




Appendix A: Standard Hazard Analysis Worksheet

Work Location: Date:

Describe Work to Be Done:

JSA Performed By:

JSA Reviewed By:

No. Sequence of basic steps Potential Accidents or

Hazards Actions to eliminate/reduce

hazards



Appendix B: Standard Hazard Analysis Worksheet with Risk Assessment

Hazard Analysis Form

JOB/TASK OBSERVATION TEAM ORGANIZATION WORK LOCATION

DATE PAGE 1 of

HA #:

Required PPE: Required Tools:

Sr. #

MAJOR STEPS OF THE JOB/TASK

POTENTIAL/ ASSOCIATED HAZARDS

SOLUTIONS/CONTROL MEASURES

Ris

k R

anki

ng

Cod

e

Init

ial i

f ri

sk

leve

l ac

cept

ed

The risk associated with this job/task has been evaluated and reduced to acceptable level.

Signature (job supervisor) ____________________________________

Continue on separate sheet if available space is not sufficient.

Discuss each control measure in pre-job briefing.

Deviation to the control measure must be approved by appropriate authority.




Risk Ranking Code As Applied to the Hazard Analysis

Low (L) Control measures are acceptable.

Additional controls should be considered if cost-effective.

Medium (M) Additional control measures are required.

Should only proceed with appropriate authorization after additional controls are implemented.

High (H) Do not proceed. Remaining risk is imminent or potential severity is unacceptable with current control measures.

Task shall be redefined or further control measures shall be put in place to reduce risk.

Controls shall be reassessed prior to the task commencing.

In all cases, the hazard analysis team shall verify that identified control measures exist and are effective. Job cannot proceed without verification.

The risk ranking code may be updated or defined to reflect the risk level after verifying that control measures are in place and are effective.

Hazard Analysis Risk Assessment Matrix

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Appendix C: JSA Worksheet with Checklist

Work Location: Date: Description of work to be done: (should define scope):

Sequence of Basic Steps Potential Accidents or

Hazards

Recommendation to Eliminate/Reduce

Hazards Responsible Person




JSA Worksheet with Checklist (page 2)

Zero Discharge Analysis

Potential Spill Sources or Items that Could be Dropped

Overboard

Recommendations to Prevent Discharge and Backup

Containment Procedures Responsible Person

Potential Hazards

Chemical Exposure Ignition Sources Fire/Explosion Hazardous Atmosphere Pressure Spills Confined Spaces Lifting Slips/Trips Noise Overhead Chips/Slivers Working/Walking Surfaces Falls Pinch Points Environment/Weather Machinery Hot Surface Arc/Flash Heat Stress Simultaneous Operation Open Hole Other -

Hazard Controls and Emergency/Contingency Plans

Personnel Protective Equipment Spill Control/Contingency Plan Physical Barriers Fire Fighting Safety Equipment Emergency Evacuation Procedures Ignition Source Controls Eyewash/Safety Shower Location Lock Out Tag Out Material Safety Data Sheets Hot Work Permit(s) Simultaneous Operations Fall Protection/Open Hole Policy Hot Bolting Policy Flag/Bypass/Monitor SSE/alert crew/identify mentor Confined Space Plan/Permit(s) Other - Describe

Safety Equipment Required

Hard Hats Work Vest/Life Jacket Respirator Safety Shoes Full Body Harness Fire Extinguisher Safety Glasses Double Lanyard w/ Shock Fire Retardant Tarps Face Shield Life Line Lock Out Tag Out Goggles Safety Cable Gas Detector Cotton Gloves Safety Barricade Hearing Protection Leather Gloves Caution Tape Adsorbent Pads Rubber/Chemical Clothing Containment Pans Chemical Apron Work Permit Proper Tools


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Appendix D: JO JSA Worksheet Job/Task: ___________________________________________________ Date: ___________ Work Location: _____________________________________ Employee(s): _________________________________________________________________

In case of an incident, the following people will be contacted:

Supervisor:________________________ Safety:___________________________ Other:

New Revised

What is the most hazardous part of this job and what are you going to do to control the hazard? Are you properly trained to complete these tasks? What do you need to ensure this job is completed incident and injury free? What conditions, job changes or distractions could prevent this job from being incident and injury free?

Sequence of Job Steps Potential Hazard(s) Recommended Action/Procedure

Additional Personal Protective Equipment Req’d

face shield chemical goggles chemical protective clothing rubber boots chemical resistant gloves leather gloves cut resistant gloves respiratory protection ______________________ arm protection hearing protection fall protection Other ____________________________________________________

Required Permits/Safe Work Plans

General SWP Hot Work Permit Confined Space Entry Excavation and Trenching Lift Plan/Crane Ops Work in proximity to Overhead Conductors

Gas Detection Equipment Needed

H2S monitor LEL, O2, H2S, CO Monitor Other _______________________________________________

List hazardous substances

Examine each step carefully to find and identify hazards or potential dangers that could lead to injury, illness or damage. Consider the following: Chemical Hazard: _Inhalation _Skin Contact _Absorption _Injection _Ingestion Biological Hazards: _Bloodborne Pathogens _Mold _Valley Fever _Plant/Insect/Animal Physical Hazards: _Electrical _Fire/Explosion _Noise _Radiation _Thermal Stress _Pinch Point/Line of Fire _Slips/Falls _Strike against/Struck by Ergonomic Hazards: _Repetition _Forceful exertion _Awkward Posture _Contact Stress _Vibration _Work Area Design


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MSDS reviewed? yes n/a

Site Control barricades post signs caution tape designated area for vehicles heavy equipment spotter establish meet and greet process

Environmental Conditions Weather: Terrain: Wildlife:

Hazardous Energy Control LO/TO checklist complete LO/TO devices in place energy isolation verified

Tools and Equipment pre-use inspection complete trained in use of tool/equipment List tools/equipment being used:____________________________________________________

Work Site Diagram – Include equipment set-up, evacuation route, assembly area and identified hazards

JSA Reviewed by:

_________________________________ _____________________________________ ____________________________________

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_________________________________ _____________________________________ ____________________________________ _________________________________ _____________________________________ ____________________________________ _________________________________ _____________________________________ ____________________________________ ___________________________________ _____________________________________ ____________________________________ What is missing from SWP that is covered on JSA? JSA is a tool to look methodically at a job, break out the hazards step by step and proactively implement controls that aren’t necessarily covered on the SWP.

Vehicle repositioning Plan of action for work rest cycles (heat stress prevention) Review for identification of required permits IIF focus: Identify and address barriers to safe completion of tasks (distractions, conditions, training) Allows for greater detailed site characterization Will be completed whether or not the SWP is completed for that task.

When do we do a JSA?

When completion of a JSA will mitigate the risk of the task. When a new task/hazard is identified New or changes in tools, equipment, machinery, process. Job accident/ near miss frequency dictates History or potential for incident s may not be known (due to newness). Good time to learn/educate. Job injury severity dictates. Potential severity dictates. Anytime anyone thinks it is necessary. When any normal job becomes abnormal.


Appendix E: Pocket Card (front)


Version 1.2 Posted 8 December 2008 21



Pocket Card (back)


Version 1.2 Posted 8 December 2008

Appendix F: TIF Analysis



Version 1.2 Posted 8 December 2008 23

Appendix G: Example Hazard Analysis

Example 1: Pallet Banding

Continue on separate sheet if available space is not sufficient.Discuss each control measure in pre-job briefing.Deviation to the control measure must be approved by appropriate authority.

The risk associated with this job/task has been evaluated and reduced to acceptable level

Signature (job supervisor)____________________________________

Pull strap with arm motion toward body (while keeping torso straight). Straighten body and then pull strap up to machine.

Same as above.Pull it through pallet and up to banding machine.

7

Crouch with back straight and hold onto one edge of pallet before bending forward. While holding onto pallet, reach to grab strap.

Splinters on pallet (puncture to hands and arms). Poor body position while bending and pulling (back or leg strain).

Crouch down, bend forward and grab strap (under pallet).

6

Keep eyes on walking path.Sharp corners on pallet (strike feet or ankles against corners).

Walk around load back to strapping machine.

5

Same PPE listed above.Splinters on pallet (puncture to hands and arms). Sharp strap edges (cut hands, fingers and arms)

Pull out strap and feed it under pallet.

4

Wear safety shoes. Keep eyes on path as you walk around pallet.

Sharp corners on pallet (strike feet or ankles against corners).

Walk around load while holding strap with one hand.

3

Wear gloves, eye protection and long sleeves.

Sharp edges on strapping (cut hands, fingers and arms).

Withdraw strapping and bend back about 3 inches.

2

Leave ample room between cart and pallet to feed strapping.

Cart positioned too close to pallet (strike body or legs against cart or pallet).

Position portable banding cart and place strapping guard on top of boxes.

1

Initial if risk level accepted

Risk Ranking Code

SOLUTIONS/CONTROL MEASURESPOTENTIAL/

ASSOCIATED HAZARDSMAJOR STEPS OF

THE JOB/TASKSr. #

Banding cartRequired Tools:

Work Gloves, Eye Protection, Long Sleeves, Safety ShoesRequired PPE:

JHA #:

PAGE 1 of 1

DATE:

Name of work locationName of organizationTeam member namePallet Banding

WORK LOCATIONORGANIZATIONOBSERVATION TEAMJOB/TASK

Job Hazard Analysis




Pull strap with arm motion toward body (while keeping torso straight). Straighten body and then pull strap up to machine.

Same as above.Pull it through pallet and up to banding machine.

7

Crouch with back straight and hold onto one edge of pallet before bending forward. While holding onto pallet, reach to grab strap.

Splinters on pallet (puncture to hands and arms). Poor body position while bending and pulling (back or leg strain).

Crouch down, bend forward and grab strap (under pallet).

6

Keep eyes on walking path.Sharp corners on pallet (strike feet or ankles against corners).

Walk around load back to strapping machine.

5

Same PPE listed above.Splinters on pallet (puncture to hands and arms). Sharp strap edges (cut hands, fingers and arms)

Pull out strap and feed it under pallet.

4

Wear safety shoes. Keep eyes on path as you walk around pallet.

Sharp corners on pallet (strike feet or ankles against corners).

Walk around load while holding strap with one hand.

3

Wear gloves, eye protection and long sleeves.

Sharp edges on strapping (cut hands, fingers and arms).

Withdraw strapping and bend back about 3 inches.

2

Leave ample room between cart and pallet to feed strapping.

Cart positioned too close to pallet (strike body or legs against cart or pallet).

Position portable banding cart and place strapping guard on top of boxes.

1


Risk Ranking Code


ASSOCIATED HAZARDSMAJOR STEPS OF

THE JOB/TASKSr. #

Banding cartRequired Tools:

Work Gloves, Eye Protection, Long Sleeves, Safety ShoesRequired PPE:

JHA #:

PAGE 1 of 1

DATE:

Name of work locationName of organizationTeam member namePallet Banding


Job Hazard Analysis



24 Version 1.2.1.A Posted 8 December 2008

Example 2: Repair Leak




Use rope and bag to shift hand tools to ground from wind girder. Do not let any item fall free.Remove equipment, tools, unwanted materials and men out of the tank dike.Close out the Permit to Work. Remove lockout/tagout. Maintain good housekeeping.

Falling objectsDemobilize equipment and tools

7

If leak noticed, repeat steps 3 to 5 again. If no leak, proceed further.6

Remove welding leads to groundKeep away from leak point

Water/foam spillageLeak test (Pressurizing the line)

5

Contain spark within the welding area above wind girder.Use PPE as specified in the permit especially safety boot, welding gloves, welding goggles, hardhat, fire retardant coverall

Spark/hot slagWelding4

Conduct gas test for H2S and hydrocarbon inside tank above the floating roof. Proceed further if H2S and Hydrocarbon readings are zero.Provide flame retardant blanket along the tank shell near welding spot in order to ensure that no spark fly into the tank. Pull welding cables to wind girder. Connect return current wire to the foam ring.

H2S gas and hydrocarbon vapors inside the tank (above floating roof)Stray current

Preparation for welding

3

Obtain Permit to Work for hot workIsolate tank (maintain at lowest level of crude in static position)Authorized Gas Tester to conduct gas test for H2S and hydrocarbon (Use Self Contained Breathing Apparatus while conducting Gas Test)Isolate the foam system. Apply lockout/tagout.Mobilize equipment and tools if H2S and hydrocarbon (LEL) reading are nil.Inspect hand tools

H2S gas and hydrocarbon vapors inside dike and at the tank’s wind girderPressure in foam ringIgnition sourceDefective tools

Mobilizing equipment and tools for welding

2

Obtain Permit to Work for cold workConduct Pre-Job safety meetingAuthorized Gas Tester to conduct Gas Test for H2S and hydrocarbon (Use SCBA while conducting Gas Test)If H2S and hydrocarbon are nil at the tank’s wind girder, two persons carrying escape units and H2S monitors climb the tank and conduct visual inspection to locate the leak.

H2S gas and hydrocarbon vapors inside dike and at the tank’s wind girder

Pre-inspection to locate the leak

1


Risk Ranking Code


ASSOCIATED HAZARDS

MAJOR STEPS OF THE

JOB/TASK

Sr. #

H2S and Hydrocarbon gas detector, flame retardant blanketRequired Tools:

SCBA, Safety shoes, working gloves, welding goggles, hardhat, coverall Required PPE:

JHA #:

PAGE 1 of 2

DATE: June 8, 2005

Name of work locationName of organizationTeam member nameRepair leak on the foam ring at Tank 4Task involves welding at wind girder


Job Hazard Analysis




Use rope and bag to shift hand tools to ground from wind girder. Do not let any item fall free.Remove equipment, tools, unwanted materials and men out of the tank dike.Close out the Permit to Work. Remove lockout/tagout. Maintain good housekeeping.

Falling objectsDemobilize equipment and tools

7

If leak noticed, repeat steps 3 to 5 again. If no leak, proceed further.6

Remove welding leads to groundKeep away from leak point

Water/foam spillageLeak test (Pressurizing the line)

5

Contain spark within the welding area above wind girder.Use PPE as specified in the permit especially safety boot, welding gloves, welding goggles, hardhat, fire retardant coverall

Spark/hot slagWelding4

Conduct gas test for H2S and hydrocarbon inside tank above the floating roof. Proceed further if H2S and Hydrocarbon readings are zero.Provide flame retardant blanket along the tank shell near welding spot in order to ensure that no spark fly into the tank. Pull welding cables to wind girder. Connect return current wire to the foam ring.

H2S gas and hydrocarbon vapors inside the tank (above floating roof)Stray current

Preparation for welding

3

Obtain Permit to Work for hot workIsolate tank (maintain at lowest level of crude in static position)Authorized Gas Tester to conduct gas test for H2S and hydrocarbon (Use Self Contained Breathing Apparatus while conducting Gas Test)Isolate the foam system. Apply lockout/tagout.Mobilize equipment and tools if H2S and hydrocarbon (LEL) reading are nil.Inspect hand tools

H2S gas and hydrocarbon vapors inside dike and at the tank’s wind girderPressure in foam ringIgnition sourceDefective tools

Mobilizing equipment and tools for welding

2

Obtain Permit to Work for cold workConduct Pre-Job safety meetingAuthorized Gas Tester to conduct Gas Test for H2S and hydrocarbon (Use SCBA while conducting Gas Test)If H2S and hydrocarbon are nil at the tank’s wind girder, two persons carrying escape units and H2S monitors climb the tank and conduct visual inspection to locate the leak.

H2S gas and hydrocarbon vapors inside dike and at the tank’s wind girder

Pre-inspection to locate the leak

1


Risk Ranking Code


ASSOCIATED HAZARDS

MAJOR STEPS OF THE

JOB/TASK

Sr. #

H2S and Hydrocarbon gas detector, flame retardant blanketRequired Tools:

SCBA, Safety shoes, working gloves, welding goggles, hardhat, coverall Required PPE:

JHA #:

PAGE 1 of 2

DATE: June 8, 2005

Name of work locationName of organizationTeam member nameRepair leak on the foam ring at Tank 4Task involves welding at wind girder


Job Hazard Analysis




Appendix H: JSA Guidance

Sequence of Basic Steps

Potential Accidents or Hazards

Recommendation to Eliminate/Reduce Hazards

Responsible Person

Safety Meeting and JSA is required. Stop Work Authority is discussed and pre/post-job review.

Accidents, injuries, pollution and equipment damage.

JSAs need to be reviewed each day; observations are use to measure at-risk behaviors. Emergency procedures, alarms, muster areas and smoking areas shall be discussed during safety meetings.

All standard PPE is required for each job.

Bodily injuries. Slips, trips, falls, cuts, pinch points, various other injuries.

Steel toe b oots, Safety glasses, Hard hats, Hearing protection, Proper work attire, Gloves, Face shields, Fall protection, PFD' s.

Do not do anything that would put safety at risk. Do not operate, repair or adjust equipment unless operator is informed.

Injuries, accidents, spills Discuss - PPE, Communication, Job planning, JSAand Lock Out/Tag Out.

Is this a Hot Bolt procedure? Has analysis of equipment to be hot bolted been done to determine if safe to proceed?

Injuries, accidents, spills, fires Have supervisor assess equipment safety. Should Hot Bolting proceed or be deferred until equipment has been shut in and rendered inert?

Does job require creating an open hole, removing a barrier or handrail?

Injuries, accidents, falls and fatalities

Review company policy. Review JSA and make appropriate changes if job scope changes. Notify the platform operator and insure all open holes are properly guarded.

Does job require climbing, working at heights above 6 ft. or open decks with 4-ft elevations?

Slips, trips, falls, injuries and fatalities.

Use safety harness with correct lanyards for the job. If not sure, consult supervisor or safety rep. Always maintain 3-point contact on stairs, get help carrying large or heavy items or use lifting equipment

Will this job generate waste? If yes, it must be seperated. Metal, trash and oily rags must be seperated.

Non-compliance, company policy violation.

Communicate with platform operator. Have proper containers on hand before starting job.

Is there a risk of spilling oil or chemical overboard? Do not put any oil down drains, in trash or leave in open containers!

Spills, incidents and damage to the environment or marine equipment.

Job planning, communication with platform operator. Use spill pads and store them in proper container after use. Always cover ends of hoses when not in use or when being transferred.

Does everyone know and understand that housekeeping is their responsibility?

Trip hazards, walking, working surfaces. Accidents, incidents and fires.

Post-job inspection by the platform operator and the job supervisor. Don’t leave the platform without making final round. Tools, equipment and all trash must be removed or properly stored.

Is there potential for workers to come in contact with chemicals or hazardous material?

Chemical burns, explosions, fires and death.

Can chemical be relocated to safe area? Does piping or vessels contain chemicals? Does everyone have proper PP&E? Have all applicable MSDSs been reviewed and emergency procedures established?

Does everyone know their station in the event of an emergency? Are there any new hires?

Confusion in an emergency situation. Panic and wrong decisions can occur.

Identify new hires or SSEs.




Sequence of Basic Steps

Potential Accidents or Hazards

Recommendation to Eliminate/Reduce Hazards

Responsible Person

Is there any equipment that has to be operated, connected or disconnected? (Mechanical, electrical or pressurized)

Injuries, electrocution, and death. Also, pollution or equipment damage.

Communication with str. operator. Lock out - Tag out is required for all energized equipment. Consult operator or person in charge to determine if lock out tag out is needed.

Does everyone understand that any accident, chemical exposure, spill or leak are to be reported to the person in charge immediately?

Accidents or exposures, environmental or equipment damage.

Report to person in charge immediately. Communication via structure alarms, giatronics or radio. Know where your emergency equipment, eye wash and shower stations are located.



Appendix I: What to Look For in a Hazard Analysis

What to Look for During a Hazard Analysis

Environmental Conditions Are there conditions that may be hazardous to safety or health?

Are there any gases, vapors, mists, fumes or dust in the area? Is the ventilation adequate to remove any air contaminants? Are there any sources of heat or cold? Are there environmental pollution concerns? Are there high wind, snow or other concerns? Are there any radiation sources? Is there adequate lighting to see the complete job?

Injurious Contact Is there a danger of striking against, being struck by, caught between, caught on, caught in or otherwise making harmful contact with an object?

Can people come in contact with, be struck by or snagged by moving parts of equipment?

Are there any in-running nip points between two moving parts, such as belt and pulley?

Is there sufficient room to work? To stay out of the line of fire? Out of traffic?

Is there any material being ejected (water, mud, oil, rocks, etc.) or part which could strike people?

Are energy sources controlled [by way of a lock out/tag out (LO/TO) program]?

Are machine controls safeguarded?

Overexertion Can a strain be caused by pushing, pulling, lifting, bending, twisting or by repetitive motions?

Does the employee have good body position or placement? Does job require lifting an excessive amount of weight? Does employee twist while lifting? Does this job have repetitive motions?

Slips, Trips and Falls Is there a potential for this type of occurrence?

Are there spills of water, oil or other slick material on the floor? Are there any lowered or elevated surfaces? Are there any tripping hazards on the floor? Is the area picked up? Is there any chance of a fall to another level?




What to Look for During a Hazard Analysis

Other Key Safety Behaviors

(to be used when observing a job covered by a JHA)

Is the job (task) performed as outlined in the JHA? Do employees wear the proper PPE for the job? Do employees use the correct tools for the job? Do employees lift heavy or awkward objects with equipment

rated for load? Is communication good on jobs involving several people or

work crews? Does someone ensure that equipment receives regular

maintenance?



Appendix J: Hazard Analysis Screening Checklist This checklist can be used at the start of the hazard analysis to identify items already known to exist, and then periodically as the hazard analysis is developed. Ensure that this information is incorporated into the hazard analysis and transferred to work permits, if the job (task) will be permitted.

Potential/Associated Hazards

Hazardous Substances

Hazardous Atmosphere

Confined Space

Working in Noisy Area

Environmental Impact

Loss of Containment (spill/release)

Arc/Flash

Radiation Work

Ignition Source

Pressure

Lifting Plan Required

Manual Handling

Simultaneous Operations

Additional Workers

Lone Working

Over-the-Side Work

Overhead Hazards

Working at Height

Diving Operations

Machinery/Moving Objects

Heat Stress

Adverse Weather

Power/Hand Tools

Fire/Explosion

Slips/Trips/Falls

Pinch Points

Hot Surfaces

Adequate Lighting

Excavations

Bees/Snake Attack

Others (specify)

Hazard Controls Safety Equipment Required

PPE

Buddy System

Physical Barriers

Access scaffolding

Temporary Lighting

Ignition Source Controls

Continuous Gas Testing

Hazardous Energy Isolation

Manual Handling Assessment

Spill Control Plan

Fire Fighting/ERT Standby

Emergency Evacuation Plan

Face Shield/Goggles

Hand Protection

Chemical Gloves

Chemical Apron

Work Vest/Life Jacket

Full Body Harness

Life Line

Safety Barricade

Respirator

Fire Retardant Tarps

Hearing Protection

Spill Control

Fire Extinguishers




Eyewash/Safety Shower Location

Material Safety Data Sheets

Hot Bolting Procedure

Rigging Assessment

Temporary Lighting

Others (specify)

Others (specify)

This is not intended to be an exhaustive list; the team may (should) identify additional items to include in the hazard analysis.



Appendix K: How do I use “Think Incident-Free” (TIF) The intent of the TIF tool/process is that it should be used every time we take action. This tool is designed as a memory-jogger to help ensure that we recognize and address workplace hazards before they become an issue.

When beginning a task, scan the area and determine what could possibly go wrong. Use the TIF card as a reminder of things to look for while scanning the area.

What is my state of mind?

Am I ready and focused on the job at hand?

Have I made an effort to reduce the hazards associated with this work?

Do I have the proper training necessary to perform the work safely?

Have I planned the work so that it can be completed without affecting other systems or on going work?

Do I have the proper tools and equipment needed to perform the work?

Will any additional equipment or tools be needed?

What will I do if I don’t have the right tool or equipment?

Are my tools in good working condition?

Once you are confident that all of the necessary precautions have been taken, proceed with your planned work. If the work situation or conditions change, stop the work and determine if any additional precautions are necessary to ensure that you can work safely.

The TIF card is a friendly reminder of our focus on and commitment to incident-free operations.