HP Carbamate Pump P-102A Failure (Task Force Report)

Report
JOB SAFETY ANALYSIS
A SUCCESSFUL EXPERIENCE IN
FAUJI FERTILIZER COMPANY
Prepared by:
Usman Sharif
Taufeeq Arshad
OUTLINE
FFC Safety Culture & Commitment
Safety Indicators
Job Safety Analysis
Steps for JSA
Benefits of JSA
JSA-A successful experience in FFC
SAFETY CULTURE
Safety is our top
priority
We have 23.46
million man-hours
without LTI
Safety is main
consideration for
plant operation /
maintenance
FFC is certified for
• Quality management
system
ISO
9001:2008
• Occupational health &
Safety
Assessment
Series
OHSAS
18001:2007
• Environment
Management System
ISO 14001:2004
Our safety goal is
human and
equipment safety
FFC SAFETY COMMITMENT
Individual’s
Mistake
Considering the link between
Accident
organizational failures and mistakes,
Causes
Organizational
‘SAFETY
as
a
goal’
is
mandatory
FFC’S COMMITMENT
Lapses
SAFETY INDICATORS
• Measurements of past incidents, successes and
failures
• Prediction of future performance and commitment
to achieve safe execution of the job
• As Job Safety Analysis (JSA) is also a pro-active
approach, it therefore falls in the category of
leading indicators
JOB SAFETY ANALYSIS (JSA)
OSHA Standard 3071 pertains to Job Safety Analysis.
“It is a technique that focuses on job tasks as a way to
identify hazards before they occur. It focuses on the
relationship among the worker, task, tools and work
environment”
JOB SAFETY ANALYSIS (JSA)
JSA should be conducted by a group of experienced personnel from all
concerned disciplines
JSA team should not conduct the analysis in isolation; all concerned
employees to be involved in the process
JSA should be conducted in the same environment in which the job is
planned for execution
JSA team should come up with practical control measures and avoid
mentioning vague instructions
JSA will be useful only when all the defined control measures are
implemented in letter and spirit
BASIC STEPS FOR JSA
1- Select a job
1- SELECTION OF JOB
JSAs are not feasible
For routine jobs
For jobs defined too broadly, for
example, ‘overhauling of urea
plant centrifugal pumps’;
For jobs defined too narrowly,
for example, ‘dismounting of
anti friction bearings from the
shaft.’
1- SELECTION OF JOB
• Factors to be considered in setting a priority for
analysis of jobs include:
– Accident frequency and severity
– Newly established jobs
– Infrequently performed jobs
BASIC STEPS FOR JSA
1- Select a job
2- Break the job into sequence of steps
2- SEQUENCE OF STEPS
A ‘job step’ is defined as a segment of the
operations necessary to advance the work.
• All critical steps should be written down
• The sequence of steps must be maintained
• The breakdown of steps should be discussed among all
the participants (always including the worker) when
completed.
BASIC STEPS FOR JSA
1- Select a job
2- Break the job into sequence of steps
3- Identify potential hazards & associated risk level
3- HAZARDS & RISK LEVELS
HAZARD
any source of potential
damage or adverse health
effects on something or
someone under certain
conditions at work.
RISK
is
the
chance
or
probability that a person
or property will be
harmed to a certain level,
if exposed to a hazard.
HAZARDS CLASSIFICATION
Biological
Bacteria, viruses, insects, animals
Chemical
Ergonomics
Toxic properties of the chemical.
improper set up of workstation
HAZARDS
Electrical
Noise
Excavation
Electric shock, electric fire
Hearing loss, inability to communicate
Soil collapse in trench / pit
HAZARDS
To help identify potential hazards, the team members
should follow a questioning attitude and may use
questions such as:
• Can
any body part gets caught in or between objects
• Is the temperature of working area is comfortable
• Does any particular tool or machine pose any hazard
• Can the worker slip, trip, or fall in the working area
• And so on ------
RISK LEVELS
Risk reduction measures should be
HIGH
implemented or activity to be suspended
/ restricted. Considerable resources to
be allotted
Additional
MEDIUM
controls
are
taken
considering the cost, the risk level to be
lowered to an acceptable level
No additional controls are required
LOW
unless they can be implemented at very
low cost (in terms of money, time and
effort
RISK LEVELS
JOB NATURE
HAZARDS
EXPOSURE
HIGH
RISK
LEVEL
TENDENCY TO
FOLLOW SHORT
CUTS
TENDENCY TO
LOSE
CONCENTARTION
HUMAN NATURE
BASIC STEPS FOR JSA
1- Select a job
2- Break the job into sequence of steps
3- Identify potential hazards & associated risk level
4- Determine control measures to mitigate hazards
4-CONTROL MEASURES
4- CONTROL MEASURES
Elimination /
substitution
• Wiping off the spilled oil from the floor
• Using a brass hammer instead of conventional
steel hammer on the natural gas line.
Engineering
Controls
• Incorporating ventilation systems to control
fumes
• Installing an acoustic hood on the blower for
abating the sound
Administrative
Controls
• Altering schedules to day time when the hazard
is less likely to occur
• Strict compliance of work permit procedures
Personal protective
equipment (PPE)
• Using engineering or administrative controls, if a
hazard cannot be reduced to an acceptable risk
level, appropriate PPEs should be used
BENEFITS OF THE JSA
Provides a written step wise procedure, which improves
communication between workers and supervisors.
Provides minor details / guidance in the management of the hazards
and risks that are embedded in the job.
Unveils the latent hazards of the job, this can be best achieved if
experienced personal of all discipline taken on board.
JSA can be a valuable tool for the training of new inductees
JSA can be used to help refine safe work procedures described in
safety manuals or standard operating procedures.
JSA- A SUCCESSFUL EXPERIENCE
SAFETY
EXCELLENCE
ROUTINE FOR
MAJOR JOBS/
INFREQUENT JOBS
THE FIRST JSA WAS
CARRIED OUT IN
YEAR 2007
ZERO SAFETY INCIDENT
IN ALL CRITICAL /
INFREQUENT JOBS
JSA- A SUCCESSFUL EXPERIENCE
JOB SAFETY ANALYSIS
Department
Section/ Unit
Area
Equipment
Production-II
Ammonia-II
43
C-4321
Job
C-4321, Replacement of damaged portion (6th, 7th & 8th shell course)
Required personal
Protective
Helmet, Safety Glasses, Harness, Ammonia Escape Mask, Leather bags,
Required Machines / Crane, Trailer, Grinders, Spanners, Hammer, welding tools, Chain blocks,
Tools
Shackles, Slings, Tacking Cleats
Conducted by:
abc / xyz
Risk Level
High
Medium
Low
Hazard Level:
JSA- A SUCCESSFUL EXPERIENCE
Sequence of Basic Job
Steps
Possible Hazards
Risk Level
Corrective Measure
Pre – Turnaround Activities
•
•
Pre
turnaround
scaffolding
Removal of
permanent
plate forms &
Monkey
Ladder(s)
-
Falling hazard
-
Falling Object
-
Ammonia release
-
Falling Object
-
Falling of
platform during
rigging
-
Ammonia release


Medium



Medium

Use Safety harness.
Use Tie strip on spanners
against falling
Use bags for transferring Joints
Take ammonia mask while
going for any job at height
Use Lan yard with spanners to
avoid falling
Halt rigging if wind velocity
exceeds 25 km/hr
Hazard Level:
JSA- A SUCCESSFUL EXPERIENCE
Turnaround (Field) Activities
•
Rigging of
upper portion
of C-4321
-
Falling of column
Medium
during rigging
2) Inspect all rigging hardware
1) Follow confined space entry
1) Confined space
procedure.
entry.
•
Tacking/weldin
g of Upper
portion with
lower portion
2) Use ELCB with electric board
2) Electric shock
while using
electric grinder.
3) Disc/metal
particles fly off.
4) Fire hazards
1) Follow the rigging plan
3) Make enclosure for capturing
Medium
grinding/welding spatters
4) Remove flammable material
before start of hot job.
5) Use healthy welding equipment
& associated hardware
JSA- A SUCCESSFUL EXPERIENCE
Pre arrangements
Safe rigging

similar documents