Job Safety Analysis A PART OF PROCESS SAFETY MANAGEMENT OSCA No-Shows A no-show is reported to us when an employee fails to show up for scheduled training at OSCA or when training is not cancelled or re- scheduled at least 24 hours prior to the training start time (OSCA policy). So far in 2015, No-Shows have cost the Long Beach office $ We understand certain events are out of everyones control (i.e., illness, car trouble, etc.) but we ask that employees do their part in committing to attending the scheduled training or providing sufficient cancellation notice when possible. Thank you! What to expect Why a JSA? Hazardous Application A Living Document Policy Why a JSA? A job hazard analysis is a technique that focuses on job tasks as a way to identify hazards before they occur. It focuses on the relationship between: the worker the task the tools and the work environment Ideally, after you identify uncontrolled hazards, you will take steps to eliminate or reduce them to an acceptable risk level Consider some of the hazardous environments we work in Very dusty in FCC, catalyst, insulation, etc. wear eye protection at all times. Be aware of areas with live virus. Be aware of high temperatures involved. X-ray work going on near compressors. Watch for x-ray caution tape. 28 degrees, dress in layers for the conditions. Very high temp 109F. Stay hydrated, drink water, take breaks in shaded area. Low hanging pipe is wrapped in foam padding to prevent people from getting hurt if they hit their heads. Several turnaround prep activities going on in this unit. Scaffold, building, equipment placement, temporary piping, cables & hoses. Be very careful & aware. Watch out around open trenches. Cutover during stormy weather. Need to be aware of heavy and rain and potential lighting and its effects on our work tasks. Working And some of the processes Prior to beginning work, review the site LOTO procedure HSE-PC-001 and the Hazardous Energy Control Procedure (HECP) for the bulk area autoclave. Cutting over shutdown circuits take extra precautions to ensure the process is unaffected. Chillers were reported to have a control issue. Verified that the issue was equipment related and not due to program controls. Helped to get the system restarted and running smoothly. Always communicate activity in the field with cutover lead at console to prevent process issues that could otherwise be quickly identified / resolved. A complete and thorough understanding of equipment and process operations prior to any work. Leave cell phone in the vehicle so there are no distractions. Even though working with low electrical power always be aware of other potential energy sources. Working JSA Hazard Control Information obtained from a job hazard analysis is useless unless hazard control measures recommended in the analysis are incorporated into the tasks. Project Managers and project team members should recognize that not all hazard controls are equal. Some are more effective than others at reducing the risk. The order of precedence and effectiveness of hazard control is the following: Engineering controls Administrative controls Personal protective equipment JSA Hazard Control Engineering controls include the following: Elimination/minimization of the hazard -- designing the facility, equipment, or process to remove the hazard, or substituting processes, equipment, materials, or other factors to lessen the hazard Enclosure of the hazard using enclosed cabs, enclosures for noisy equipment, or other means Isolation of the hazard with interlocks, guards, blast shields, or other means Removal or redirection of the hazard such as with local and exhaust ventilation JSA Hazard Control Administrative controls include the following: Written operating procedures, work permits, and safe work practices Exposure time limitations (used most commonly to control temperature extremes and ergonomic hazards) Monitoring the use of highly hazardous materials Alarms, signs, and warnings Buddy system, and Training Performing electrical work on analyzer. Work performed with a buddy. Lots of cranes and taped areas 2. Use buddy system when climbing towers. When working in the cellar use buddy system. Can not work down there alone. And must have 3-way monitor along with H2S. This was an after-hours call-in for support. Per lone worker guidelines, I utilized Mangan buddy via cell phone (aka Phone buddy). Routine calls were made to inform my buddy of my work status as well as when it was completed and I was heading off site. I recently began working at a client's facility 75 miles away from the Mangan office in Cary, NC. I follow the Mangan Lone Worker policy for traveling alone to remote areas to ensure safe travel. You can not access the upper deck of the cooling tower without operator permission. Use of Mangan's Lone Worker policy & client escort is required. Lone Worker Rule Working JSA Hazard Control Personal Protective Equipment -- such as respirators, hearing protection, protective clothing, safety glasses, and hardhats -- is acceptable as a control method in the following circumstances: When engineering controls are not feasible or do not totally eliminate the hazard While engineering controls are being developed When safe work practices do not provide sufficient additional protection, and During emergencies when engineering controls may not be feasible Ensure system is fully purged before blocking in and opening. Wear proper PPE, system extremely hot. Dust respirators and hearing protection is needed in some areas of the facility. Stay away from them unless you need to enter. SCADA development room is now level 1 gowning. Eye protection/booties over street shoes req. Rusty ladders, always wear gloves when climbing. Check your safety PPE regularly & replace if necessary. My boots looked fine on the top, but were worn on the bottom. Got new boots. The evacuation procedure for the new maintenance shops building is unclear. The nearest evacuation area requires full PPE, but going to the main. Bldg. does not always require full PPE. When opening live switchgear always wear 40 Cal suit and have qualified person spot you. Never open switchgear without proper PPE. And PPE Working JSA Hazard Control Use of one hazard control method over another higher in the control precedence may be appropriate for providing interim protection until the hazard is abated permanently. In reality, if the hazard cannot be eliminated entirely, the adopted control measures will likely be a combination of all three items instituted simultaneously. If any hazards exist that pose an immediate danger to an employee's life or health, take immediate action to protect the worker. Any problems that can be corrected easily should be corrected as soon as possible. Do not wait to complete your job hazard analysis. For those hazards determined to present unacceptable risks, defer the work. Main breaker failed to open when beginning shut down. Following procedure put on arc flash suit to confirm no voltage was present. That's when we realized power was still on. Stopped work and closed panel. Will schedule utility outage for repairs. Steam from the turbines fogged up my safety glasses as we were walking by. Stopped moving until glasses cleared so I would not run into something. The consultant with me did not have camera permit and started to take a picture. I stopped him and volunteered to come back later and take the picture. Mangan engineer started to make PLC programming changes w/o permit due to miscommunication w/client. Work was stopped, we filled out a permit; had a toolbox talk, received permit and then started the job. While assisting a co-worker in an equipment check-out, I observed him hitting a star wheel with his hand to try to align it. I stopped him and got a rubber mallet from the tool cabinet. Using the correct tool for the job is always important to avoid injury. Take Immediate Action Working JSA Hazard Control Good hazard scenarios describe: Where it is happening (environment) Who or what it is happening to (exposure) What precipitates the hazard (trigger) The outcome that would occur should it happen (consequence), and Any other contributing factors JSA Hazard Control Lessons Learned While conducting field verification tasks, an employee needed to take readings from the clients facility main breaker in the electrical equipment room. (Environment) The data was not clear through the relay protection panel, so the employee removed the panel to get a clear picture. The data was not at eye level, so the employee used a step ladder to reach the height of the information. (Exposure) While on the ladder, the employee lost their balance and caught themselves on the open relay panel. (Trigger) JSA Hazard Control Lessons Learned The clients facility operation was linked to this specific breaker and the employees contact with the breaker caused it to trip, effectively shutting down all operations. The client operators proceeded to re-engage the relay and associated equipment. The Mangan employees were asked to leave the site while restorative operations were under way. The clients operations were shut down for one hour prior to their ability to bring the facility back to full operating conditions. (Outcome) JSA Hazard Control Lessons Learned Breakdown in the JSA process: On this specific visit to the field, the employee did not use the client electrician for work on or around the electrical equipment. The client had not yet posted the permit for the work. The High Hazardous Checklist was completed at the time of the JSA Risk Analysis meeting and not just prior to the high hazardous activities. The employees did not complete a SMART card prior to the work activity (required for every visit to the field as per the JSA). (Contributing Factors) JSA A Living Document Periodically reviewing your job hazard analysis ensures that it remains current and continues to help reduce workplace accidents and injuries. Even if the job has not changed, it is possible that during the review process you will identify hazards that were not identified in the initial analysis. It is particularly important to review your job hazard analysis if: The scope of work has changed There has been a near miss reported surrounding the project activities There has been an interruption to the clients process An injury has occurred on the project JSA A Living Document The process of an effective JSA does not stop with the formality of completing a Risk Analysis and when necessary, a High Hazardous Checklist. The use of a SMART card is an extension of the JSAs purpose to evaluate your surroundings and mitigate any apparent risks. When hazards are identified on your SMART card, address the remediation as necessary; with the client, another contractor, a co- worker, or with your own situation. A personal evaluation addresses the ever-changing environments where we work because client sites do not stay static. Consider the work of others, construction activities, adjacent processes and equipment. Follow all risk mitigation procedures carefully. The unit tripped 2 days ago due to E&I error and another trip today could have major consequences. Cutover prep-work with ops for process mitigation steps. A risk assessment checklist has been reviewed and signed off by Mangan and refinery management. Follow steps carefully to unsure process is not impacted. Take the time you need before starting a task to do a thoughtful JSA, SMART card. Adjacent work areas are in construction mode. Equipment, material & personnel heavy in certain areas. Pay attention to the information on adjacent works JSA's. Job walk only - JSA to be reviewed prior to field cutovers. Energizing new panel, make sure to follow all risk assessment mitigation steps. Mitigate the Risks Working JSA Procedure This training has focused on the JSA process related to field activities. In-house activities are incorporated into the JSA process based on the potential outcome of the application, design, or scope. It is not the act of creating the application, drawing the design, or writing the scope, but the potential if it were to go wrong when implemented. Consider your sources for the design or scope: Is it second hand (meeting notes)? Is it current (outdated drawings)? Are the codes applied correctly? JSA Procedure Complete your risk analysis for in-house work as you would for the field with regards to: Health and Safety Environment Financial In all aspects of the JSA process, consider the worse case scenario and then apply your mitigation steps. JSA Procedure Work can begin only when it has been determined the risks are acceptable An initial JSA meeting is held with all project team members. Everyone signs onto the JSA using the JSA sign in sheet. For new project team members, or those who join the project at a later time, the Project Manager or JSA rep reviews the JSA with the new member and they sign the sign-in sheet. JSA Procedure Project team members are responsible to know the covered JSA task and the mitigation steps for the work they are performing. If there are any changes to the project that warrant an update to the existing JSA, the changes need to be reviewed with the team and acknowledged on a sign-in sheet. For jobs who have assigned Risk Values of 1 or 2 (High Hazardous), the High Hazardous Checklist is completed just prior to the start of actual work. JSA Documentation Completed JSAs are sent to for documentation prior to the start of A preliminary report is distributed by the Safety Department each Friday, followed by a final Compliance report each Monday. These reports include projects that have been recently opened with no JSA turned in yet. If charges have been applied, indicating that work has begun on the project, and the JSA has not been turned in, it will be listed as out of compliance on the report and subject to being shut down by Admin to any further charges until the JSA has been turned in. Remember, identifying the hazards and mitigating the risks through the risk analysis process is continuous throughout the life of the project. JSA Resources Utilize the Field Safety Rules to verify the actions it takes to complete the task are in-line with the companys rules for safe work concerning: The JSA process and site permits Process system activities Working from heights Working on or around electrical equipment and Lockout/Tagout Respiratory use, and Working in remote areas If the work is outside of the rules, a separate Safe Work Plan needs to be written and followed. The plan is to be authorized by the Project Manager and filed with the JSA and safety department. JSA Resources The safety department has resources available to help support the projects safety needs: Training for specific work activities above and beyond some of our normal activities (NFPA 70E, Lockout / Tagout, Fall Protection, etc.) are available. Site access clearances and client requirements for site access Drug testing protocols Remote site activity support Project specific SMART cards Resources Google: Safety Resource Center, Policies & Forms MSP-205, Job Safety Analysis MSP-204, Process Safety Management Google SMART Form site Field Safety Rules