JHA 27 for Online Weld Repair of Shell Butt Joint

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JOB HAZARD ANALYSIS FORM Page No. 1 of 13

JSA Number: 27( METHOD STATEMENT No. PT/4648/MS/M/12) REV No. 0 DATE 17/09/2012

Job being analyzed: Procedure for online weld repair of shell butt joint

Department / Section Projects JHA Members Project Manager , Project Engineer

Area / Location: Halul Job Performer Petroserv limited

APPOVALS Name Signature Date General job requirements /Common PPE

Project Engineer Anand-Coveralls-Safety Helmet -Safety Shoes (Shoes must not be smooth)

-Safety Glasses (Clear)-Safety Gloves -Barricade / Sign the Area.-Pre-Start Safety Toolbox Talk

Safety Representative Eldho Koloth

Project Manager Ganesh

Any Other

Emergency Situation / Evacuation

Hazardous Gases, Fire

Note

Format No .PT-IMSP-10-F-03

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Sequence of Basic Job Steps

Potential Hazards Hazard Control

OIL TRANSFERING PRESENCE OF FLAMMABLE / TOXIC VAPOR OR LIQUID

FIRE & EXPLOSION

DEFECTIVE EQUIPMENT & ACCESSORIES

COLLAPSE OF HOSE / SPLASH OF HAZARDOUS FLUID

ENSURE THE WORKSITE IS FREE FROM TOXIC / FLAMMABLE VAPOR.

CARRY OUT GAS TEST FOR SAFE WORKING AREA

PROVIDE RESPIRATORY PROTECTIVE EQUIPMENT

ENSURE THE AVAILABILITY OF SPARK / FLAME ARRESTER MOUNTED IS BEING USED ON THE EXHAUST OF EQUIPMENT & SHALL BE 50 FEET AWAY FROM THE TANK

CONFIRM THE AVAILABILITY OF EARTHING ON THE EQUIPMENT TO DISSIPATE THE ELECTROSTATIC CHARGES.

ENSURE THE AVAILABILITY OF SUITABLE & APPROVED FIRE EXTINGUISHERS AT SITE.

NEVER BRING A NAKED FLAME OR SPARK GENERATING TOOL NEAR TO WHILE COLLECTING A FLAMMABLE LIQUID.

ENSURE THE PUMP, ISOLATION VALVE AND HOSES ARE FREE FROM DEFECT.

DO NOT OVERLOAD THE PIPE/ HOSE WHILE OIL TRANSFERRING THROUGH THE PIPE / HOSE.


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HOSE LEAK OR RUPTURE

SPILLAGE

USE SAFETY GOGGLES

USE CORRECT TYPE OF TOOLS TO OPEN & HOLD THE FLANGE

USE HOSE OF SUITABLE PRESSURE RATING.

STOP THE PUMPING IMMEDIATELY IN CASE OF LEAK.

IMMEDIATELY ALERT OTHERS IN THE AREA AND THE QP SUPERVISOR, AND EVACUATE THE AREA IF NECESSARY.EVACUATE ALL PERSONNEL, SEAL OFF ACCESS FROM DANGER AREA (IF SAFE TO DO SO WITHOUT PERSONAL RISK)ISOLATE ANY IGNITION SOURCE.FOR EXTERNAL SPILLS, COVER DRAINS TO PREVENT THE MATERIAL GOING INTO DRAINS AND OR WATER COURSES. DO NOT WASH SPILLAGE INTO DRAINSENSURE SAFE DISPOSAL OF THE SPILLED SUBSTANCES AND ANY ABSORBENT MATERIAL USED.ACQUIRE RECOMMENDED PERSONAL PROTECTIVE EQUIPMENT AND TRAINING IN ITS PROPER USE. SAFETY PERSONAL PROVIDES SHALL TRAINING TO WORKERS IN THE PROPER USE OF PERSONAL PROTECTIVE EQUIPMENT, INCLUDING RESPIRATORS, GLOVES, AND EYE AND FACE PROTECTION


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WORKING AT HEIGHT FALL OF MATERIAL FROM HEIGHT

FALL OF PERSON FROM HEIGHT

MANUAL TOOLS

TOOLS AND OTHER ARTICLES AND MATERIALS SHALL BE PROPERLY LOWERED AND SHALL NOT BE THROWN DOWN FROM HEIGHT. THEY SHALL BE LOWERED / RAISED BY ROPE.

PPES – HARD HATS & SAFETY SHOES SHALL BE USED BY THE WORKERS WORKING BELOW

TOOLS SHALL BE CARRIED IN BAGS & SECURED

EXPERIENCED WORKERS SHALL BE USED.

PERSONNEL SHALL BE INFORMED OF THE HAZARDS AND PRECAUTIONS OF WORKING AT HEIGHT.

FULL BODY SAFETY HARNESS MUST BE USED.

PPES SHALL BE USED.

TOOLS SHALL BE INSPECTED BEFORE USE.

CORRECT TOOLS SHALL BE USED.

PPE SHALL BE USED.

INSTALLATION OF SCAFFOLDING (RIGGING UP/DOWN SCAFFOLDING MATERIALS FROM GROUND LEVEL TO THE DESIRED HEIGHT)

INJURY / DAMAGE AS A RESULT OF DROPPING TOOLS AND SCAFFOLD COMPONENTS

USE APPROPRIATE BARRICADES TO PROTECT PERSONNEL.

KEEP TOOLS IN TOOL BAG OR BASKETS SECURED PROPERLY.

LOOSE MATERIAL SHALL NOT BE KEPT ON PLATFORM


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INJURY / DAMAGE DUE TO COLLAPSE OF SCAFFOLD OR BY PERSONNEL FALLING FROM SCAFFOLD.

A SUITABLE CAPACITY CRANE SHALL BE USED TO SHIFT THE SCAFFOLDING MATERIALS FROM TANK GROUND LEVEL TO THE RESPECTIVE LEVEL.

ALL COMPONENTS TO BE CHECKED PRIOR TO INSTALLATION.

AVOID BROKEN, BENT AND EXCESSIVELY RUSTED OR DAMAGED FRAMES / ACCESSORIES.

ERECT AND DISMANTLE ALL SCAFFOLD TO COMPLY TO REQUIREMENTS.

SCAFFOLD MUST BE ERECTED/DISMANTLED BY TRAINED / EXPERIENCED PERSONNEL UNDER THE DIRECTION OF COMPETENT SUPERVISOR.

SCAFFOLD SHALL BE ERECTED ON A PLAIN LEVEL SURFACE AND SECURED TO PERMANANET STRUCTURES. ADDITIONAL PLATES SHALL BE PROVIDED TO SCAFFOLDING BASE WHEN ERECTING ON SOFT GROUND.

SCAFFOLD SHALL BE INSPECTED BY A COMPETENT PERSON AND SCAFF TAG SYSTEM SHALL BE FOLLOWED.

SUFFICIENT ACCESS / EGRESS SHALL BE PROVIDED CONSIDERING EMERGENCY SITUATION.

CHECK SPECIFIED LIMITS OF SCAFFOLD BEFORE UTILIZATION.

USE SAFETY HARNESS AND LANYARD ANCHORED TO SECURE POINT WHEN WORKING ABOVE 2.0 METERS HEIGHT.


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ACCESS / LADDERS, GUARD RAIL SYSTEM AND TOE BOARD SHALL BE PROVIDE & SECURELY FIXED.

GRINDING UNAUTHORIZED WORK

INVALID PERMIT

COMPETENCY OF PERSONNEL

LACK OF POOR COMMUNICATION

HASTE OR SHORTCUT

FIRE HAZARD BURNS

OBTAIN HOT WORK PERMIT BEFORE STARTING THE JOB.

GET THE PERMIT VALIDATED FOR THE DAY

SUPERVISOR MUST ENSURE THAT ALL WORK ACTIVITIES ARE CARRIED OUT BY EXPEREINCE AND COMPETENT PERSONNEL.

TOOLBOX TALK SHALL BE CONDUCTED BY THE SUPERVISOR.

SAFETY OFFICER SHALL CONDUCT INSPECTION, MONITOR WORK ACTIVITIES AND SHALL ENSURE SAFETY STANDARDS AND PROCEDURES ARE STRICTLY ADHERED TO.

GAS TESTING SHALL BE CARRIED OUT BY CERTIFIED AND AUTHORIZED GAS TESTER (QP PERSONNEL).

HOT WORK SHALL HAVE APPROPRIATE HABITAT OR ENCLOSURE TO PREVENT SPARKS AND NAKED FLAME EXPOSURE.

NO COMBUSTIBLE / FLAMMABLE MATERIAL SHALL BE AVAILABLE NEAR THE WORK.

TRAINED FIRE WATCH SHALL BE POSTED AND STAND- BY FIRE WATCHER SHALL BE AVAILABLE DURING GRINDING.

CORRECT FIRE EXTINGUISHERS SHALL BE MAINTAINED


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INJURY WHILE GRINDING & GRINDING SPARKS

ELECTROCUTION / INJURY DUE TO ELECTRIC SHOCK

CABLES SHALL BE LAID PROPERLY.

CONDITION OF CABLES SHALL BE MONITORED REGULARLYFIRE BLANKET SHALL BE MAINTAINED NEAR THE WORK.

PPES SHALL BE USED FOR THE SPECIFIC JOB

MAKE SURE THAT EQUIPMENT IS PROVIDED WITH GUARDS

UNAUTHORIZED PERSONNELSHALL BE KEPT AWAY FROM THE AREA

ENSURE ALL EQUIPMENTS HAVE BEEN CONNECTED TO EARTHING / GROUNDING TO PREVENT ELECTROCUTION.

DYE-PENETRATING TEST IRRITATION OF SKIN, EYES, DIZZINESS & NAUSEA

AVOID LONG AND REPEATED CONTACTS WITH DYE PENETRANT MATERIAL. IT CAN CAUSE IRRITATION.

SAFETY GOGGLES AND COVERALL SHALL BE USED DURING THE TEST.

IF DYE, DEVELOPER AND CLEANER CANISTER ARE USED, THEY SHALL BE STORED AND DISPOSED OFF PROPERLY AFTER USE.

AT NO TIME SHALL THE CANISTER BE DISPOSED OF IN FIRE.

ALL WASTE MATERIALS SHALL BE DISPOSED OFF PROPERLY.

WELDING UNAUTHORIZED WORK OBTAIN HOT WORK PERMIT BEFORE STARTING THE JOB.


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INVALID PERMIT

COMPETENCY OF PERSONNEL

LACK OF HAZARD KNOWLEDGE

HASTE OR SHORTCUT

FIRE HAZARD BURNS, EXPLOSION

ELECTROCUTION

GET THE PERMIT VALIDATED FOR THE DAY

SUPERVISOR SHALL ENSURE THAT ALL WORK ACTIVITIES ARE CARRIED OUT BY EXPEREINCE AND COMPETENT PERSONNEL.

TOOLBOX TALK SHALL BE CONDUCTED BY THE SUPERVISOR.

SAFETY OFFICER SHALL CONDUCT INSPECTION, MONITOR WORK ACTIVITIES AND SHALL ENSURE SAFETY STANDARDS AND PROCEDURES ARE STRICTLY ADHERED TO.

GAS TESTING SHALL BE CARRIED OUT BY CERTIFIED AND AUTHORIZED GAS TESTER (QP PERSONNEL).

HOT WORK SHALL HAVE APPROPRIATE HABITAT OR ENCLOSURE TO PREVENT SPARKS AND NAKED FLAME EXPOSURE.

BEFORE STARTING WELDING MAKE SURE THAT THE AREA IS CLEAR OF ALL TYPES OF COMBUSTIBLE MATERIALS.

ENSURE FIRE EXTINGUISHERS ARE AVAILABLE ON SITE.

TRAINED FIRE WATCH SHALL BE POSTED AND STAND-BY FIRE WATCHER SHALL ALSO BE AVAILABLE DURING HOT WORK.

HOUSE KEEPING SHALL BE MAITAINED.

CORDONING OF THE AREA.

ENSURE ALL EQUIPMENTS / GENERATORS HAVE BEEN


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DAMAGE CABLE

HOT TABS END PIECES OF WELDING RODS.

SPARKING

UV RAYS

TOXIC FUMES

CONNECTED TO EARTHING / GROUNDING TO PREVENT ELECTROCUTION.

ENSURE CABLES ARE IN GOOD CONDITION

ENSURE THE ROD HOLDER ARE IN GOOD CONDITION.

HOT TABS SHALL NOT BE THROWN BUT COLLECTED IN TIN CANS.

USE PROPER CABLE CONNECTOR FOR EXTENSION.

WHERE CABLES ARE CROSSING THE WALKING AREA THEN ENSURE PROPER PROTECTION.

WELDER & HELPERS SHALL WEAR WELDING GOGGLES

USE APPROPRIATE RPE & PPE

USE OF EQUIPMENTS, WELDING M/C, GENERATORS ETC

FIRE HAZARD DURING REFUELING

SWITCH OFF EQUIPMENT BEFORE STARTING REFUELING

ENSURE SAFE ACCESS TO THE EQUIPMENT TO BE REFULED

STAY NEAR THE EQUIPMENT FUELING POINT WHEN FUELING.

NEVER OVERFILL THE FUEL TANK

REFULLING TO BE DONE AT SLOW RATE TO REDUCE THE POTENTIAL FOR SPILLAGE AND STATIC IGNITION.

FIRE EXTINGUSHER SHALL BE MAINTAINED.


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NO IGNITION SOURCE SHOULD BE AVAILABLE DURING & NEAR REFUELING.

USE PROPER PPE

WORK IN OPEN AREA HEAT STRESS & INJURY SUMMER WORKING TIME SHALL BE FOLLOWED.

ADEQUATE SHADE OR REST AREA SHALL BE PROVIDED

BREAKS SHALL BE TAKEN AND JOB ROTATION MAY BE FOLLOWED.

USE PROPER PPE

VEHICLE MOVEMENT ACCIDENTS – INJURY & DAMAGE TO PROPERTY

LICENSED DRIVERS SHALL ONLY OPERATE VEHICLES.

VEHICLES SHALL BE MAINTAINED PROPERLY AND NOT OVERLOADED.

SPEED LIMITS & TRAFFIC RULES SHALL BE ADHERED.PAINTING

FIRE AND EXPLOSION

WORK PERMIT SHALL BE OBTAINED BEFORE COMMENCING OF WORK.

STORAGE FOR PAINT, THINNERS ETC. SHALL BE AWAY FROM THE WORK AREA.

SIGN BOARD ‘FLAMMABLE MATERIAL’; AND 'NO SMOKING; 'NO NAKED LIGHT' ETC. DISPLAYED.


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CAUSED BY FLAMMABLE MATERIALS. E.G. PAINT, THINNERS, TOXIC VAPORS.

ONLY WORKING CREW PERSONS ENTER THE PAINTING AREA, UNAUTHORIZED SHALL NOT BE ALLOWED.

FLAMMABLE MATERIAL SHALL BE ISOLATED AND KEPT AWAY FROM OTHER SUBSTANCES / MATERIALS.

REMOVE COMBUSTIBLE SUBSTANCE FROM THE WORK AREA AND MAINTAIN TIDY HOUSEKEEPING.

CONTROL THE IGNITION SOURCES I.E. NO SMOKING, NO NAKED LIGHTS.

ADEQUATE FIRE EXITS TO BE PROVIDED. SUCH EXITS SHALL NOT BE OBSTRUCTED (INSIDE AND OUTSIDE).

FIRE EXTINGUISHERS TO BE KEPT ON STANDBY IN THE WORKING AREAS.

WEAR PERSONAL PROTECTIVE EQUIPMENT: SAFETY HELMET, SAFETY SHOE, SAFETY FULL BODY HARNESS, FOR ELEVATION WORK, EYE PROTECTION, AND HAND PROTECTION AND AS REQUIRED RESPIRATORY PROTECTION.

ALL PAINTS AND THINNERS ETC. TO BE USED IN ACCORDANCE WITH THE MSDS SHEETS SPECIFYING THE HAZARDS ASSOCIATED IN USING THE SUBSTANCES.


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HOUSE KEEPING SLIP, TRIP, FALL HAZARD

WORK LOCATION, EQUIPMENT AND BUILDINGS ARE TO BE KEPT CLEAN AND ORDERLY AT ALL TIMES.

ALL WORK AREAS ARE TO BE FREE OF DANGEROUS PROJECTIONS OR OBSTRUCTIONS, AND ARE TO BE MAINTAINED FREE OF RUBBISH, OIL, GREASE AND WATER.

ALL TOILET FACILITIES, INCLUDING HAND BASINS MUST BE MAINTAINED IN A CLEAN AND HYGIENIC CONDITION.

ALL SCRAP AND REFUSE BINS MUST BE CLEARLY MARKED AS TO THE TYPE OF THE SCRAP OR REFUSE THAT MUST BE DEPOSITED IN THEM.

SCRAP AND GARBAGE BINS MUST BE EMPTIED & CLEANED ON A DAILY BASIS.

FLAMMABLE WASTE MUST BE STORED IN METAL CONTAINERS LOCATED AT A SAFE DISTANCE FROM ANY POSSIBLE IGNITION SOURCE.

SPILLAGES OF OIL, GREASE ETC. MUST BE CLEANED UP AS SOON AS IS PRACTICABLE.

ALL STACKING OF MATERIAL MUST BE MADE ON GROUND THAT IS LEVEL AND ALL STACKS MUST BE NEAT AND STABLE.

ALL CIRCULAR OBJECTS MUST BE SUITABLY CHOCKED TO PREVENT THEM FROM ROLLING.


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ALL EMPTY PAINT/OIL DRUMS, PACKING MATERIAL SHALL NOT BE STORED FOR MORE THAN A WEEK AT THE SITE.

COVER / SECURE CABLE / CORDS, WIRES / ROPES AWAY FROM WALKWAYS AND OTHER PATHWAYS.

KEEP WALK WAYS, AISLE, AND STAIRCASES CLEAR OF MATERIALS, EQUIPMENTS AND OTHER ITEMS.


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JHA 27 for Online Weld Repair of Shell Butt Joint