COMPANY ABC Sdn Bhd Job Safety Analysis (JSA) Worksheet

Company/ Contractor Department/ Discipline Location/ Area/ Elevation Job Description Company ABC Piping & Mechanical - Shut Down & Tie-In N/A Shut down and tie in work for process line and utility line.

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

JSA-Mechanical-011- Shut Down & Tie-In 0 Date 22nd July.2010 Page

Project ABC

No. 1. 2.

Sequence Of Basic Job Steps Understand job sequence Construction material/ equipment mobilization 1.1 2.1 2.2 2.3

Hazard Identification Hazard Effects Misunderstand of job sequence Non compliance on safety requirement Vehicle/equipment failure Personnel injury

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

Mechanical operated machine may produce Fire spark and have oil leakage. 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 3. Isolation of piping system for the shutdown and tie-in work. 3.1

Obstruction of access road Wrongly isolate valve

Personnel injury Plant/ system upset

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 22nd July.2010 Page

Project ABC

COMPANY ABC Sdn Bhd Job Safety Analysis (JSA) Worksheet

No. Sequence Of Basic Job Steps Hazard

JSA No. Rev No. Job Number/ Project Name Hazard Identification

JSA-Mechanical-011- Shut Down & Tie-In 0 Date 22nd July.2010 Page

Project ABC 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. Additional Actions

Effect

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. 4.1.1 To break the flange slowly and check the flange with gas detector to confirm pipe is free from any flammable/ toxic gas. 4.2.1 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. 5.1.1 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

Installation of blinding as per blinding diagram

4.1

Hydrocarbon/ others toxic or flammable gas Personnel injury in piping system Wrongly blind on existing line Personnel injury

4.2

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

5.1

Loading and unloading accident may occur Personnel injury during operations.

COMPANY ABC Sdn Bhd Job Safety Analysis (JSA) Worksheet

No. Sequence Of Basic Job Steps 5.2 Crane topple Hazard

JSA No. Rev No. Job Number/ Project Name Hazard Identification

JSA-Mechanical-011- Shut Down & Tie-In 0 Date 22nd July.2010 Page

Project ABC Determining Control Measures Additional Actions

Effect Personnel injury/ property damage

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 5.3.1 Obtain Road Obstruction Certificate from client. 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

5.3 6 Field welding for tie-in work 6.1

Obstruction of access road Welding spark

Personnel injury Fire, face and eye injury

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. 6.3.1 Regular check the extension cable to ensure

6.3

Electrocution

Personnel injury/fatal

COMPANY ABC Sdn Bhd Job Safety Analysis (JSA) Worksheet

No. Sequence Of Basic Job Steps Hazard

JSA No. Rev No. Job Number/ Project Name Hazard Identification

JSA-Mechanical-011- Shut Down & Tie-In 0 Date 22nd July.2010 Page

Project ABC Determining Control Measures 3.1.2 Project team (together with client person in in good 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. Additional Actions

Effect

6.4

Workers fall from height

Personnel injury

6.5

Falling object

Personnel injury, property damage

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.

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

7.1

Wrongly remove blinding point

Personnel injury

7.2

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

COMPANY ABC Sdn Bhd Job Safety Analysis (JSA) Worksheet

No. 8 Sequence Of Basic Job Steps Re- Isolate valve for the shutdown tie-in work 8.1

JSA No. Rev No. Job Number/ Project Name Hazard Identification

JSA-Mechanical-011- Shut Down & Tie-In 0 Date 22nd July.2010 Page

Project ABC Determining Control Measures 3.1.2 Project teamthe valve tagging number in placed 8.1.1 Ensure that (together with client person in 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

Hazard Wrongly reopening valve isolation

Effect Personnel injury

8.2

People accidentally closed the valve

Personnel injury