DATE: Formal Risk Assessment and Job Safety Analysis Plant and Department: U&O HAZARD 1. Un-inspected, uncertified rigging tools and tackles Crane / incompetent personnel that could lead to personal injury. 1. Mobilization (Cable Materials, cable drum and Equipment’s by using crane,focklift,boom truck & drum truck) 2.Damage to the vehicles, plant facilities and equipment. 3. Heat coming from Internal combustible engine that could cause fire. 1. Fall of suspended load that could lead to property damage and personal injury. 2. Lifting and positining of Cable drum & cable stand. Activity/Task Title: Electrical and Instrunmentation work (Cable Pulling, Terminations, Piping Modification,Cable tray work,Support welding ) 1 2 3 4 5 6 7 8 9 10 11 Job Steps & Sub Tasks Job steps s# Project Title: To install C20+ truck loading facility in united U&O Mobilization (Cable Materials, cable drum and Equipment’s by using crane,focklift,boom truck & dump truck) Lifting and positining of Cable drum & cable stand. Cable Meggering and Instrument loop checking. Installation of new breaker in substation & Cable termination and Card installation,DCS Configuration in RIB. Cable Pulling. Termination of power & control cables in control panels & JB’s and in RIB. Dismantling & removal of existing Panels JB’s and conduits & installation of new JB's,transformers and heat tracing equipments. Installing cable Trays/conduits & Tubes, threading and bending, Drilling and knock out. Support welding activity Cable splicing, cad welding, Heat shrinking by Heat gun or gas torch. Cable lugging and termination. Initial/raw risk Control measures Consequences Likelihood Risk C4 C3 C3 C3 L3 L3 L3 L3 Consequences Residual Risk Likelihood Risk Responsibility Responsible person Minor 1.Obtain valid work permit and vehicle entry certificate for the task. 2. Ensure that Crane,Forklift & truck must be inspected by UNITED mobile equipment & must have a valid inspection sticker. 3. Only UNITED authorized crane & forklift operator, riggers, flag man (rigger) are allowed to perform their job. 4. All lifting tools and tackles should be inspected and current color coded by UNITED mobile equipment. C4 L4 Insignificant HKSS/UNITED Significant 1. Ensure to comply with SHEM-08.06 lifting procedure. Enroute area shall be inspected prior to mobilizing (unsafe ground condition). 2. Ensure to obtain a vehicle entry certificate, approved basic/critical lifting certificate (SHEM 08.06) and work permit for crane lifting ,Boom truck & forklift activity prior to entry into the job site. 3. Ensure proper distance between equipment (congested area, other activities). 4. Follow the UNITED traffic rules and regulations. 5. Follow equipment route map as per vehicle movement certificate. 6. Conduct gas test to ensure 0% LEL. C3 L4 Minor HKSS/UNITED Significant 1. Gas test shall be conducted to ensure 0% LEL. 2. Combustible/flammable materials should be removed from the area. 3. While refueling vehicle engine should be shut down, no Hot work activity shall be allowed nearby area. 4. Cover all sewer lines by using fire blanket on the radius of 3 meters. 5. Fire extinguisher should be placed near the crane. 6. Grounding cable should be connected at proper grounding point. C3 L4 Minor HKSS/UNITED Significant 1. Lifting area should be barricaded with proper sign board. No personnel are allowed to walk, stand or work under suspended load. Rigging Supervisor shall conduct tool box talk to workers and explain jsa/work permit. 2. Rigger should be visible to the crane operator/enough riggers should be provided. 3. Lifting tools and tackles shall be verified by authorized rigger. Softners shall be provided for slings wound around sharp edges. 4. Only authorized person by riggers shall be allowed to enter inside the barricaded area. 5. Lifting shall be performed as per approved lifting certificate. 6. Proper planning and supervision by related supervisor at all the time. C3 L4 Minor HKSS 1. Fall of suspended load that could lead to property damage and personal injury. 2. Lifting and positining of Cable drum & cable stand. C3 L3 Significant 2. Rigger should be visible to the crane operator/enough riggers should be provided. 3. Lifting tools and tackles shall be verified by authorized rigger. Softners shall be provided for slings wound around sharp edges. 4. Only authorized person by riggers shall be allowed to enter inside the barricaded area. 5. Lifting shall be performed as per approved lifting certificate. 6. Proper planning and supervision by related supervisor at all the time. C3 L4 Minor HKSS 2. Lifting and positining of Cable drum & cable stand. 2. High wind speed/ bad weather conditions that could cause property damage and personal injury. C3 L3 Significant 3. Congested area and pinch point that can cause personal injury/slip,trip and fall C4 L3 Minor C3 L3 Significant 4.Swinging load / Hitting rigger/Assets / equipments/facility. C3 L4 Minor HKSS 1. Always wear PPE ( hand gloves, goggles) at all times while doing rigging. 2. Keep away your hand from pinch point. 3. Rigger should always stand to safe side where the crane operator can directly see. C4 L4 Insignificant HKSS 1. Rigger shall not stay in line of fire or shall come under suspended load. Use tag lines to control movement of load. 2. The rigger shall ensure the load is rigged properly consider the centre of gravity and use tag lines to control unexpected movement of load. 3. Rigger shall stay away from line of fire. C3 L4 Minor HKSS C4 L4 Insignificant HKSS/UNITED 1. Electrical Shock C4 L3 Minor 1. Obtain valid permkit for the task. 2. Barricade area, place wiith warning signs. 3. Use insulated tools. Make sure free end of cable is insulated to ensure no one touches it. 4. Discharge current after test, confirm with multimeter. 5. Use of calibrated multimeter & hart communicater for loop check. 2. Cuts, personal injury. C4 L3 Minor 1. Use proper PPE, insulated low voltage eltectrical gloves shall be used. C4 L4 Insignificant HKSS C4 L4 Insignificant HKSS/UNITED 3. Cable Meggering and Instrument loop checking. 4. Installation of new breakers in substation & Cable termination, Card installation,DCS Configuration in RIB. 1. Avoid lifting during wind speed >32Km/hr. 2. Avoid lifting during bad weather conditions (Rain/Fog/dust storm). Provide adequate lighting for night time. Ensure lights not reflecting eyes of rigger / crane operator. 1. Wrong installation of breakers. C4 L3 Minor 1.Obtain valid and proper work permit for the task. 2. Only allow competent electrician/person for the task. 3.All the cable termination and breaker installation by the presence of UNITED authorised person. 4. Make sure the breakers are installing asper the drawing. 5. All the RIB configuration shall be done by authorized person. 2. Electrocution & Pinch point. C4 L3 Minor 1. Use of proper PPE ( low voltage electrical gloves). 2. Keep your hands away from pinch points. 3. Make sure all the tools should be insulated. 4.Secure tools and nut bolts properly to prevent fall or contact with live systems. C4 L4 Insignificant HKSS 3.Slip,Trip,Fall. C4 L3 Minor 1. Maintain good housekeeping all the time and watch your steps. C4 L3 Insignificant HKSS 1. Falling cable drum. C4 L3 Minor 1. Place cable drum on level ground. 2. Apply proper lubricant on rotating point of drum for smooth running. 3. Barricade work area place warning signs. C4 L4 Insignificant HKSS 2. Personnel injury,ergonomical hazards,heat stress. C4 L3 Minor 1. Use leather gloves Give enough rest breaks to workers , provide cool drinking water and juice to workers.Do not strain back muscles. C4 L4 Insignificant HKSS Minor 1. Use full body harness, If needed to extend body part out of handrails or unprotected edges with scaffolding tag yellow. 2. Ensure scaffolding having valid inspection tag. ( If scaffolding is tagged green,Full body harness is not required). 3. Always maintain three point contact. C4 L4 Insignificant HKSS 5. Cable Pulling. 3. Falling from heights (Personnel ,cable ) C4 L3 5. Cable Pulling. 3. Falling from heights (Personnel ,cable ) C4 L3 Minor 1. Use full body harness, If needed to extend body part out of handrails or unprotected edges with scaffolding tag yellow. 2. Ensure scaffolding having valid inspection tag. ( If scaffolding is tagged green,Full body harness is not required). 3. Always maintain three point contact. 4. Damage to insulation cable. C4 L3 Minor 1. Use roller for pulling cables to prevent damage. 2. Ensure cables don’t strike scaffolding parts while pulling. C4 L4 Insignificant HKSS 1. Confirm LOTO, Confirm panels and MCC’s are grounded. Use multimeters to Check for current. Use insulated tools. 2. Do not carry or wear any metal objects such as rings, watches, chains etc. 3. Confirm panels & JB’s are grounded before beginning work. 4. Make sure multimeters are calibrated. C3 L4 Minor HKSS/UNITED C4 L4 Insignificant HKSS 1. Electric shock C3 L3 Significant 2. Personnel injury & ergonomical hazards C4 L3 Minor 1. Use safety goggles,electrical gloves. 2. Avoid awkward movements. C4 L4 Insignificant HKSS 3. Slips, trips, & falls. C4 L3 Minor 1. Keep walkways clear of tools and cables. Post warning signs,Barricade area. C4 L4 Insignificant HKSS 1. Wrong Panel & Conduits removals C4 L3 Minor 1. Make sure, double check and reconfirm from site engineer and mark the panels and conduits to be removed. C4 L4 Insignificant HKSS 2. Personal injury C4 L3 Minor 1. Use leather gloves, proper PPE. 2. Use proper tools for the job & Inspect tools for damage before use. C4 L4 Insignificant HKSS 3. Damage to plant property & assets. C4 L3 Minor 1. Make sure of shape, weight and size of new JB’s and panels & Conduits before installation. 2. Use proper lifting and handling techniques to avoid damage to equipment. C4 L4 Insignificant HKSS C4 L4 Insignificant HKSS 6. Termination of power & control cables in control panels & JB’s, and in RIB. 7. Dismantling & removal of existing Panels JB’s and conduits & installation of newJB's,transformers and heat tracing equipments. 8. Installing cable Trays/conduits & Tubes, conduit threading & Bending, Drilling and knock out. 1. Working at heights Falling from heights. C4 L3 Minor 1. Use full body harness, If needed to extend body part out of handrails or unprotected edges with scaffolding tag yellow. 2. Ensure scaffolding having valid inspection tag. ( If scaffolding is tagged green,Full body harness is not required). 3. Always maintain three point contact. while ascending or descending ladder. 2. Dropping tools and Materials. C4 L3 Minor 1. Ensure scaffolding plat form is free from tools and materials. make sure toe boards are installed on scaffolding. 2. Secure all tools with nylon rope, before using on heights. Lift material and tools using baskets and securing with rope. C4 L4 Insignificant HKSS Minor 1. Maintain good housekeeping all the time and watch your steps. 2. Keep your hands away from rotaing parts. 3. Do not wear loose clothings. 4. Maintain good working posture to avoid ergonomic hazards. 5. Make sure all the power tools should be inspected by UNITED and inspection sticker on it. 5. Use proper PPE. C4 L4 Insignificant HKSS 3. Slips, trips, & falls, Pinch point ,Possibilty of entaglement, Awkward movement, cut injury, C4 L3 Bending, Drilling and knock out. 3. Slips, trips, & falls, Pinch point ,Possibilty of entaglement, Awkward movement, cut injury, C4 L3 Minor 1. Maintain good housekeeping all the time and watch your steps. 2. Keep your hands away from rotaing parts. 3. Do not wear loose clothings. 4. Maintain good working posture to avoid ergonomic hazards. 5. Make sure all the power tools should be inspected by UNITED and inspection sticker on it. 5. Use proper PPE. C4 L4 Insignificant HKSS 9. Support welding activity 1. Arc rays/IR/UV radiation that could cause personal injury. C4 L3 Minor 1. obtain valid permit for the task. 2. Welders shall use proper welding hood and fire watch & other workers shall not stare at the welding Arc. 3. Welders and gas cutter, fabricator shall use correct shade filter lens as mentioned in SHEM-10.9. C4 L4 Insignificant HKSS/UNITED 2. Welding fumes and gases that could lead to personal injury. C4 L3 Minor 1. Keep Electrode is as close as possible to welding surface to avoid generating fumes. 2. Welder shall not be exposed to welding fumes. Proper PPEs to be worn. C4 L4 Insignificant HKSS 3. Electric Hazard that could lead to personal injury. C4 L3 Minor 1. Ensure that all electrical cords do not touch any hot/wet surface. 2. All power tools shall be double insulated and shall be protected with GFCI. 3. Use proper PPE as per work permit. C4 L4 Insignificant HKSS 4. Fire hazard. C3 L3 Significant C3 L4 Minor HKSS C4 L4 Insignificant HKSS 1. Privide DC fire extinguisher at site. 2. Nearby sewer line should be covered with fire blanket. Welding area should be covered with fire blanket to prevent spark going outside. 4. Assign fire watch for welding activity. 3. 5. Burns during hot work activity C4 L3 Minor 1. The welder shall use FRC clothing or leather apron and welding gloves. Synthetic clothing shall not be worn by the welder. 2. Use welding helmets and shields to protect face/forehead. 3. Fabricator or welder shall mark hot surface using chalk or marker to identify the hot surface. 1. Cut injury, Pinch point. C4 L3 Minor 1. Obtain valid and proper work permit for the task. 2. Use of proper PPE ( low voltage electrical gloves). 2. Keep your hands away from pinch points. C4 L4 Insignificant HKSS Minor 1. Use of proper PPE's (Leather gloves, dust mask,face shield). 2. Conduct gas test before start hot work activity. 3. All the Power tools should be inspected by UNITED and inspection sticker on it. 4.All the power tools Should be used by competent person only. 5. Use of fire watch incase of using gas torch & cad welding. 6. Ensure fire extinguisher at site. 7. Keep your hands away from hot surface. 8. Make sure the area is free from flammable and cumbustible materilas. C4 L4 Insignificant HKSS 10.Cable splicing, cad welding, Heat shrinking by Heat gun or gas torch. 2. Burns, fumes, spark & Possibilty of fire. C4 L3 11. Cable lugging and termination 1. Wrong connection/Loose connections C4 L3 Minor 1. Ensure authorised UNITED Electrical/Instrumentation focal standby man to be present while doing termination. 2. Use approved termination drawings, proper marking and identification. 3.Ensure inspection by UNITED electrical engineer/control system engineer to confirm prior to commissioning. 4. Use proper termination tools and ensure the termination is secured. 2. Electrical shocks C4 L3 Minor 1. Use multi meter to check voltage and current before start of job. 2. Use double insulated tools. 3. Use proper PPE. C4 L4 Insignificant HKSS 3. Eye & Hand Injury C4 L3 Minor 1. Use safety glass, low voltage electrical gloves and ensure to use all PPE mention in work permit. 2. Use proper tools to lugging and termination. C4 L4 Insignificant HKSS 4. Slip,trip Hazards C4 L3 Minor 1. Maintain good housekeeping all the time and watch your steps. C4 L4 Insignificant HKSS Team Members: SN NAME POSITION DEAPARTMENT 1 Maintenance/ Manager / Specialist/ Engineer/ Supervisor 2 Area Owner Manager / Specialist/ Engineer 3 EHSS Department rep’ 4 Contractor Supervisor as minimum (if the job is to be done through the Contractor). 5 Technical Supervisor /Engineer (Inspection/Control System/Rotating/..Etc.) if needed 6 Others (As needed, to be decided by the Leader). C4 L4 Insignificant HKSS/UNITED SIGNATURE DATE Approved By: (Approval to be taken based on the Residual Risk) Maintenance MANAGER (Insignificant/ Minor Residual Risk) Name: _______________________________ ID: _____________ Comments (If any): Acknowledged By: Sign: ___________________________ Date: __________________ Maintenance SR.MANAGER (Significant/ Major Residual Risk) Name: _______________________________ ID: _____________ Comments (If any): Name: _______________________________ ID: _____________ __________________ Comments (If any): Acknowledged By: Sign: ___________________________ Date: __________________ Note: All JSA's to be approved as per residual risk outcome. However, SAFER is not applicable for execution activities. Operations/ Area Owner MANAGER (Insignificant/ Minor Residual Risk) Sign: ___________________________ Date: Operations/ Area Owner SR.MANAGER (Significant/ Major Residual Risk) Name: _______________________________ ID: _____________ __________________ Comments (If any): Sign: ___________________________ Date:
