JSA - Shut Down and Tie in Work

COMPANY ABC Sdn Bhd

JSA No. Rev No.

Company/ Contractor

Company ABC

Job Number/ Project Name Prepared By,

Department/ Discipline

Piping & Mechanical - Shut Down & Tie-In

Reviewed By,

Location/ Area/ Elevation

N/A

Approved By,

Job Description

Shut down and tie in work for process line and utility line.

Job Safety Analysis (JSA) Worksheet

No.

Sequence Of Basic Job Steps Understand job sequence

1.1

2.

Construction material/ equipment mobilization

2.1

Vehicle/equipment failure

2.2

Mechanical operated machine may produce Fire spark and have oil leakage.

2.3

Accident may occurs due to mishandling of Personnel injury vehicle/ traffic issues.

2.4

Loading and unloading accident may occur Personnel injury during operations.

2.5

Obstruction of access road

Personnel injury

3.1

Wrongly isolate valve

Plant/ system upset

Isolation of piping system for the shutdown and tie-in work.

0

Personnel injury

Date

22nd July.2010

Page

Project ABC

Hazard Identification Hazard Effects Misunderstand of job sequence Non compliance on safety requirement

1.

3.

JSA-Mechanical-011- Shut Down & Tie-In

Determining Control Measures 1.1.1 Supervisors have to brief on JSA before work. 2.1.1 All vehicle/ equipments to be used must be inspected and approved vehicle/ equipment will be pasted with a sticker of approval. 2.2.1 Obtain Vehicle Entry Permit/Certicate. 2.2.2 Provide fire extinguisher and spark arrestor for vehicles. 2.3.1 The driver must have the valid driving license and vehicle should meet JPJ requirement 2.3.2 Follow road signage and speed limit. 2.3.3 Ensure vehicles have reverse alarm. 2.3.4 Use the approved route by client. 2.3.5 To check condition of soil/access route for heavy traffic movement. 2.4.1 Ensure crane with PMA and Crane Operator possess valid licence and registered as DOSH competence. 2.4.2 Signal man to direct movement of vehicle. 2.4.3 Workers shall never stand under a suspended and always stand clear of load 2.4.4 Workers shall recheck all the lifting equipment before used. 2.4.5 Operators and drivers should inspect their crane /vehicle/equipment before starting work for the day in order ensure in good confition. 2.4.6 To barricade the working area and put necessary signage to warn others. 2.4.7 Signalman shall used two way communication when visual signal is not possible. 2.5.1 Obtain Road Obstruction Certificate from client. 3.1.1 Obtain LOTO (lock Out Tag Out) Certificate / Permit from client.

Additional Actions

COMPANY ABC Sdn Bhd Job Safety Analysis (JSA) Worksheet Company/ Contractor

Company ABC

JSA No. Rev No. Job Number/ Project Name Prepared By,

JSA-Mechanical-011- Shut Down & Tie-In 0

Date

Project ABC

22nd July.2010

Page

JSA No.

COMPANY ABC Sdn Bhd

Rev No.

Job Safety Analysis (JSA) Worksheet No.

Sequence Of Basic Job Steps

JSA-Mechanical-011- Shut Down & Tie-In 0

Job Number/ Project Name Hazard Identification

Hazard

Date

22nd July.2010

Page

Project ABC

Effect

Determining Control Measures 3.1.2 Project team (together with client person in charge) to chain lock and tag the valve with LOTO on the isolation valve to ensure that the valve will not accidentally opened. 3.1.3 Ensure that the valve tagging in placed. 3.1.4 Valve isolation shall be done with client person in charge presence.

4

5

Installation of blinding as per blinding diagram

Pipe spool/ valve/ pipeline lifting and laying into tie -in location.

3.2

People accidentally open the valve

Personnel injury

3.2.1 Project team (together with client person in charge) to chain lock and tag the valve with LOTO on the isolation valve to ensure that the valve will not accidentally opened.

4.1

Hydrocarbon/ others toxic or flammable gas Personnel injury in piping system

4.1.1 To break the flange slowly and check the flange with gas detector to confirm pipe is free from any flammable/ toxic gas.

4.2

Wrongly blind on existing line

Personnel injury

4.2.1 Ensure that the blinding tagging number in placed as per blinding diagram. 4.2.2 Blinding work shall be done with client person in charge presence. 4.2.3 Supervisor(person in charge) shall be reconfirm diagram before proceeding with next activities. 4.2.4 LOTO procedure shall be strictly followed to ensure the correct method is used.

5.1

Loading and unloading accident may occur Personnel injury during operations.

5.1.1 Load does not exceed the capacity of the lifting equipment 5.1.2 Signal man to direct movement of vehicle. 5.1.3 Workers shall never stand under a suspended and always stand clear of load 5.1.4 Workers shall recheck all the lifting equipment before used. 5.1.5 Operators and drivers should inspect their crane /vehicle/equipment before starting work for the day in order ensure in good confition. 5.1.6 To barricade the working area and put necessary signage to warn others. 5.1.7 Signalman shall used two way communication when visual signal is not possible. 5.1.8 Padding shall be provided on sharp edge to prevent lifting slings from damage 5.1.9 Sling of the correct length and capacity for the job must be used 5.1.10 Rigging the load is carried out by a competent person

Additional Actions

JSA No.

COMPANY ABC Sdn Bhd

Rev No.

Job Safety Analysis (JSA) Worksheet No.

6

Sequence Of Basic Job Steps

Field welding for tie-in work

JSA-Mechanical-011- Shut Down & Tie-In 0

Job Number/ Project Name Hazard Identification

Hazard

Date

22nd July.2010

Page

Project ABC

Effect

Determining Control Measures

3.1.2 Project team (together with client person in 5.2.1 Ensure that the load and boom is lowered when the cranes left unattended. 5.2.2 Lifting work shall only commence after confirming that the crane is set up satisfactory 5.2.3 Outrigger shall be resting on flat and firm ground with steel plate and wooden plank. 5.2.4 To barricade the working area and put necessary signage to warn others. 5.2.5 Signalman shall used two way communication when visual signal is not possible. 5.2.6 Crane and trailer parking location shall be approved by client prior to start any lifting work

5.2

Crane topple

Personnel injury/ property damage

5.3

Obstruction of access road

Personnel injury

5.3.1 Obtain Road Obstruction Certificate from client.

6.1

Welding spark

Fire, face and eye injury

6.1.1 To standby fire extinguisher (ABC Type 9.0 kg) 6.1.2 To ensure sufficient fire blanket provided to cover the hotwork area & below hotwork area. 6.1.3 To cover and protect any near by cable, pipe or instrument with fire blanket. 6.1.4 To remove any combustible material from directly coming into contact with the spark. 6.1.5 Ensure flash back arrestor are fitted to oxygen and acetylene gas regulators. 6.1.6 To ensure the oxygen and acetylene cylinders are mounted to cylinder trolley with chain or in cylinder cradle. 6.1.7 All gas hoses, fittings and gauges shall be check in good condition and no leak before start work. 6.1.8 Provide standby water hose with stop valve (If required) 6.1.9 Welder must wear face shield and leather glove for protection during the works progress

6.2

Welding machine / generator may produce Fire spark

6.2.1 To stand - by fire watch & fire extinguisher near to engine driven equipment 6.2.2 Engine driven equipment shall be fitted with spark arrestor. 6.2.3 Engine shall be checked daily to ensure is in good condition and without leakage 6.2.4 Engine shall be stopped while fill-in-diesel. 6.2.5 Welding set used shall properly grounded.

6.3

Electrocution

6.3.1 Regular check the extension cable to ensure

Personnel injury/fatal

Additional Actions

JSA No.

COMPANY ABC Sdn Bhd

Rev No.

Job Safety Analysis (JSA) Worksheet No.

Sequence Of Basic Job Steps

JSA-Mechanical-011- Shut Down & Tie-In 0

Job Number/ Project Name Hazard Identification

Hazard

Date

22nd July.2010

Page

Project ABC

Effect

Determining Control Measures 3.1.2 Project (together with client person in in good team condition. 6.3.2 To ensure extension cables are not to lay across on wet ground or stagnant water. 6.3.3 All electrical tools are to be inspected before 6.3.4 All hotwork to be stop when heavy rain.

7

Deblinding work and Joint Integrity Test (JIT) for flange joint.

6.4

Workers fall from height

Personnel injury

6.5

Falling object

Personnel injury, property damage

7.1

Wrongly remove blinding point

Personnel injury

7.2

Line leaking due not proper tightening work Personnel injury at flange joint.

6.4.1 Workers shall wear full body harness with double lanyard and hook to fixed structures while working at height. 6.4.2 No work on structure/slippery condition before grating installation. 6.4.3 Supervisor has to closely supervise all the elevated works. 6.4.4 Provide lifeline if there is no anchorage point to hook lanyard.(Steel cable) 6.4.5 Workers are allowed to use scaffolding platform displayed Green Tag only. 6.5.1 Proper barricade and signage below working area to prevent unauthorized entry. 6.5.2 Handling loose materials by throwing from height are strictly prohibited 6.5.3 Use container to store tools and consumable and transfer by using rope. 6.5.4 Safety net shall be installed under the surface or structure on which employees are working. 6.5.5 Obtain Certificate for The Removal & Reinstallation of Gratings, Handrails, Stair Treads & Other Pieces of Equipment when required to open grating, handrails and other steel structure member. 7.1.1 Ensure that the blinding tagging number in place as per blinding diagram. Supervisor person in charge to reconfirm on the de-blinding point as per diagram before blind removal. 7.2.1 JIT team to check and confirm specification gasket and flange surface cleanesess before flange reinstatement. 7.2.2 Proper torquw and sequence of bolt tightening as per procedure. 7.2.3 To carry out Joint Integrity Test during the re-instatement work.

Additional Actions

JSA No.

COMPANY ABC Sdn Bhd Job Safety Analysis (JSA) Worksheet No.

Sequence Of Basic Job Steps

8

Re- Isolate valve for the shutdown tie-in work

JSA-Mechanical-011- Shut Down & Tie-In

Rev No. Job Number/ Project Name Hazard Identification

0

Date

22nd July.2010

Page

Project ABC

8.1

Hazard Wrongly reopening valve isolation

Effect Personnel injury

8.2

People accidentally closed the valve

Personnel injury

Determining Control Measures 3.1.2 Project (together with client person in 8.1.1 Ensure team that the valve tagging number in placed as per blinding diagram. 8.1.2 Supervisor person in charge to reconfirm on the valve location as per valve isolation diagram. 8.1.3 Valve re-isolation shall be done with client person in charge presence. 8.2.1 Ensure that the line already de-blinding, JIT has been carry out and valve chain lock has been removed before handover to client person in charge for tagged out (LOTO).

Additional Actions