Element 6 – Safe Operation

Job Safety Analysis (JSA)

SMS 6.17.3 JSA Record sheet
JOB SAFETY ANALYSIS RECORD SHEET
DATE PREPARED: DATE ISSUED:
DEPARTMENT: WRTD
PLANT/EQUIPMENT: K01-CTF/ T-01
02/16/2020
Unit: YNTOD / YNTTF UNIT JSA NO: YCTF-JSA-2020- 01

DESCRIPTION OF JOB/TASK: Conduct the T&I of Tank K01-T-01 as per T&I scope of work and according to Inspection work sheets. Work includes
product transfer, sludge removal, confined space entry, inspection and repairs.
Reviewed Name: Signature: Date: Approved By
Prepared By:
Maintenance Rep
Md. Hameemdin
Engineering Rep
(Superintendent) Unit Foreman.
Muruganandham.k
(Safety Advisor) Operation Rep

REFERENCES:
 GI 2.100 “Work permits Saudi Aramco  TOD SMS 6 “Safe Operations”
 GI 2.709 "Gas Testing Procedure”  SMG-06-007-2016 (SIMOPS)
 GI 6.012 “Isolation, LOTO and Use of Hold Tags”  Safety Hand Book
 GI 1021. " Street and Road Closure”  Construction Safety Manual (CSM) I.6 “Confined Space”
 GI 7.028 “CRANE LIFTS TYPES AND PROCEDURES”  CSM I.11 “Hand Tools and Power Tools”
 GI 8.001 “Safety Requirements for Scaffolds”  CSM II. 1 “Excavations and Shoring”
 TIM # 103101 “Work Permits”  CSM II. 9 “Painting and coating”
 TIM # 101101 “Personal Protective Equipment”  CSM II. 8 “Abrasive Blasting”
 TIM # 101003 “Fire / Safety Watch”  CSM III “Mechanical and Electrical”
 TIM # 103104 “Isolation, Lockout and Use of Hold Tags”  T-08 T&I SOW

SAFETY EQUIPMENT REQUIRED: Personal Protective Equipment (PPE): Required to wear Personal Protection Equipment (PPE), including safety helmet, safety
glasses, gloves, and safety shoes. Special PPE for Blaster as per CSM-II-8.
Full Body Harness, SABA, Face shield, Hearing protection, FRC, Rattler T-40, MX4, and Radio Explosion proof lighting, ventilation fans, warning signs, night flash
lights. Equipment shall be grounded and positioned upwind. Inspected fire extinguishers shall be available at work Site.

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JOB To
SEQUENCE OF BASIC
STEP POTENTIAL HAZARDS REQUIRED HAZARD CONTROLS/SAFE WORK PROCEDURES check
JOB STEPS
NO. (Ticked)
1. Preparation &  Absence of qualified & Aramco  T&I activities shall be well defined with priorities and target dates
mobilizing of tools to certified competent personnel based on the SOW
work location,  Unavailability of resources such as  Defined roles and responsibilities to all levels of the participating
barricading work area inadequate equipment and Materials organizations
and posting signage  Inappropriate planning & scheduling  MOC and SIMOPS to be consider in advance if required
 Heat Stroke & Heat stress  Align workload and manpower with the T&I scope
 Slip, trips, falls  Plan for procurement of materials and equipment as well as develop
 Injury due to improper handling of contingency plans require if necessary
materials  Portable pumps or vacuum trucks to be positioned outside the
 Sharp edges common dike in order to keep the ignition source away from the area
 Heavy load and weights  All hazardous materials must be completely pumped out
 Electrocution: testing of electric  All required equipment for T&I must be prepared and approved
tools  Cover sewers within 75 feet
 Workers and machineries can fall  Identify the location for the rest area for the contractors
due the lack of signage  Proper grounding to be implemented to prevent static electricity.
 Lack of awareness during  Valid fire extinguishers to be available on site
emergency evacuation  All electrical equipment to be operated via adequate rated distribution
panel equipped with GFCI’s
 Drink plenty of water during heat season
 Provide shelter
 Maintain good housekeeping around the Area at all times by
organizing a Housekeeping Team to monitor the site
 Shall provide appropriate Personal Protective Equipment or PPE to all
personnel involved in the task
 Conduct Joint Site Inspection to the work location to discuss all risks,
ways of protection, & work plan
 Shall maintain good housekeeping around the Area at all times by
organizing a Housekeeping Team to monitor the site
 Comply work permit system per GI 2.100 Work Permit System
 Work permit issuer and receiver shall be certified and competent
 JSA shall be reviewed with the entire work force frequently and with
all concern parties based on the JSA sequence
 Conducting pre – task Tool Box Talk on proper techniques/ways of
manual handlings and lifting, body postures, and positioning shall be
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2. Hot bolting &  Flammable gases
Securing Expansion  Toxic gases
Joints  Hydrocarbon Leak
 Source of Ignition
 Fire & explosion
 Property Damage
 Potential injury
 Property damage
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done prior to performing the task
 Provide crew with detail information on the work permit by
specifying the work to be done, the equipment to be used, and the
location of the work
 Shall provide covering and protection for sharp and pointed edges of
tools and materials before lifting and transferring from one place to
the other
 Shall use mechanical equipment to lift and to transfer heavy tools and
materials
 Testing & use of any electrical tools shall be limited to the authorized
and competent users
 Proper sign board and blinker lights shall be posted
 Evacuate to assembly point upon hearing stop work siren
 Report emergency situations by dialing the following numbers
o By telephone 911
o By cellular 014-397-0911
 Conduct once evacuation drill as required
 Maintain Heat Stroke Plan at job site.
 Ensure MOV valve in closed position, Check the internal pressure of
pipeline and expansion.
 Obtain the Work permit systems.
 Use brace hammers to loosening the bolts.
 Keep your position always on 5’O clock.
 Always Keep the Personnel Gas monitors with crew members.
 Make Additional care while working.
 Use rubber gloves while using the paint removing solvent.
 Do not open more than one bolt on the same time. If you finish one bolt
tight back it firmly again. Then start to loosening the another bolt to
avoiding flange leak.
 Always positioning the body on safe zone.
 Check the all hand tools prior to the job.
 Maintain adequate level in tank so joint is completely filled with
product with no gases
 If possible, continuously circulate through the subject joint to provide
cooling
 Barricade area with warning signs
  Survey all flanges, connections and potential leak location for signs of
leak
 Have portable fire extinguishers at work site
 Use fire blankets around the expansion joint
 Personnel not involved in the operation must be kept out of the area
 Emergency exit points must be free of obstruction
 Welder must closely monitor the Flange to avoid damaging the
pipe/joint
 Continuous gas testing
 Continuously monitor Flange and other connections for possible leaks
 Maintain good housekeeping of working area before, during and after
job
Draining, Isolation and  Flammable gases  Clear Isolation Procedure shall be developed and followed
Blinding  Toxic gases  Ensure using proper rated blinds and gaskets as per blind list
 Hydrocarbon Leak  Continuous Gas testing
 Back flow could be happened  No Hot Work allowed within 75’ of Tank Shell
 Potential injury / Fatality due to  All Sources of electrical energy must be de-energized, isolated and
energized cables, equipment or Tools locked-out, including lighting, Tank Mixer, RTG and/or MOVs if
 Wrong isolation applicable
3.  Fire & explosion  Residual energy must be removed before work begins
 Property damage  Install chains and locks and use SA 525 form for hold tags at the
isolated points
 Tags and locks must be where feasible and according to GI-6.012
 Contractor shall install their own locks and tags
 Ensure the isolated pipelines are breathing to prevent thermal
expansion
 Make sure all blinds are in write size and install in correct location as
per blind list
4. Gas Freeing  Flammable gases  Review the degassing procedure and ventilation plan.
 Toxic gases  As per plan Install Mechanical ventilation (air blowers and/or movers)
 Oxygen deficiency.  Provide the Grounding to ventilation equipment 7 compressor.
 Static electricity  Provide certified Air compressor & comply every day pre use
 Damaged and/or Unsecured hoses checklist. All pressure hoses should be secured by whip lock.
 Frequent Gas testing at tank vicinity
 No Hot Work allowed within 75’ of Tank Shell
 Tank must be safely ventilated. Refer to SA CSM I-6, Table 6.2

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5. Confined Space, Initial  Breathing air decencies
entry, sludge removal,  Poor visibility
Pontoon cleaning  High ambient temperature
 Slip, trip and fall
 Flammable vapor accumulation
 Toxic gases & Hydrocarbon
 Improper illumination
 Fire Explosion
 Vehicle Collision
 In adequate Communication
 Health illness & work stress
 Noise

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Ventilation Requirements for Confined Spaces in order to identify the
required ventilation per the tank size
 Area shall be free from obstructers
 Fire watch must be trained & competent and be positioned near Air
compressors
 Monitor wind direction
 Make no entry to all vehicle while blowers running time.
 De gassing crew must possess the one multi gas monitor and adequate
number of H2S detectors.
 Conduct initial entry by SA operation in front of proponent
 The Initial Entrant should have the SCBA certification.
 Before enter the Communication Device, Rescue device to be ensured.
(Like Rope OTH system)
 In the initial test the gas reading LEL should be 0 %, And H2S should
be 00 PPM and Oxygen Should be 20% to 23%. If the gas reading is
meet this requirement, can start the further confined space entry for
cleaning work. If not meet the requirements the gas freeing to be
continued until meet the requirement.
 Emergency response plan and confined space entry plan should be
present at work site.
 All procedures (JSA, ERP, CSE Plant etc..) Should be explained to all
workers. Everyone should be awarded about this.
 Continuous air ventilation at all times (ventilation should be started at
least 15 minutes Before enter)
 Frequent Gas testing to be carried out for every 1 hour at confined
space and vacuum point.
 Assign competent Confined space man at used tank entrances
 Maintain accurate Confined Space log sheet
 Barricade manways/entrances not in use
 Identify emergency exits and assembly point
 Each entrant should use the Chemical canister mask for protect from
organic and crude vapor, Mist etc.
 All entrant should use the ear plug, Clear glass & Dupoint disposable
coverall while cleaning the sludge.
 The work duration/Exposure duration should not be longer time. It
should be scheduled with frequent intervals (like 1-hour job 1-hour
Rest)
 Maintain safe and accessible entries and exits at tank manways,
 stairway, and stair entrances. No access blocking is allowed
 Provide inspected fire extinguishers at work areas within and outside
the Tank
 Cleaner should use only non-metallic tools at the sludge.
 All workers should have awareness about crude sludge and Cleaning
solvent.
 New SAW dust should be stored away from ignition sources. &
Contaminated SAW dust should not be stocked at work site it should
be contained at bags and disposed from work site in safe manner.
 Ensure safe operation of vacuum truck and associated equipment shall
meet the requirement of construction safety manual CSM and API
2219.
 More than 2 vacuum trucks do not allow to work at same time
 Tanker Should be positioned at least 50’ away from the source.
 Grounding, Wheel Chocks and Hazard diamond should be with tanker.
 Operator should be certified and Trained about emergency controls.
 Each Cargo hoses should be tested and certified for sucking the crude
sludge.
 Hose continuity should be tested at actual job location to ensure the
continuity.
 Dispose all waste water, sludge as per SAEP-327, SAES-A-103, and as
per GI 0430.001

Working At night.
 Provide “Class 1, Zone 0” lights for working at night at crude presence
locations to improve the illumination.
 Do not work with improper illumination & Never use the non-standard
Electrical lights or lamps at sludge point.
 Provide high mast flood light for surround lighting.
 High mast light should be placed 75’ feet away from tank shell.
 Every People should aware about emergency response numbers &
Emergency Procedures.
 Communication Devices should available with supervisor Safety
officer & standby man
 Emergency contact number should be posted at entry point ( it should
be visibly)
 night watchmen and security (area Controlling) personnel as needed to
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 control access to the site after hours
 To prevent serious fatigue, contractor and subcontractor personnel shall
not work excessive hours, with a maximum of 12 hours daily, except as
may be requested/approved by the SAPO (e.g., during an emergency or
unforeseen circumstances). Worker rotation and additional supervision
may require.
 Make more shifts and crews to Avoid the excessive working hours.
 Assigning maximum physically fitted workers to avoid un necessary un
health issues at night time.
 Communicate with rescue team and take extra safety measures such as
adequate lighting, area barricading, work during night-time
 Communication with FrPD for the readiness in emergency situations
that may occur.
 All stand by man & fire watch should hold the florescent reflective life
jackets during night.
 Additional supervision need to monitoring the people at night.
 Do not allow the workers alone to work or rest during night work.
 Before starting the job and while left from the work location make head
count on every night shift.

6. Working at elevated  Slip, trip & fall  Erection, Modification and dismantling of scaffolding as per GI 8.001
location, Erection and  Injury Safety Requirements for Scaffold.
Dismantling of  Fatigue  Provide Scaffold plan if scaffolding is more than 12.2 m height.
Scaffolding.  Improper housekeeping Forward plan for LP review prior to erect scaffold.
 Material Fall from height  Wear full body safety harness with shock absorbing double lanyard
 Falling from height.  Condition of the floor board shall be flat and shall not be slippery or
uneven.
 The ladder beams must be cleaned of any oil or grease
 Foot wear to be used shall be in good condition and properly laced
 Make sure ladders are properly secured
 Ensure that the working platforms and ladders are clean and dry
 Always maintain good housekeeping on elevated platform.
 Only competent scaffolders are allowed to erect and dismantle scaffold
 Only certified scaffolding inspector is allowed to check and certify
scaffolding installations
 Ensure all scaffolding parts, access ladders, braces, brackets, boards,
couplers, base plates, and guardrails are visually inspected and are in
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 good condition prior to erection of scaffold
 Take periodic rest
Lifting Material /  Falling Object  Always secure tools when working at heights
Equipment  Worn-out rigging equipment  Clear area underneath when working at elevated areas
 Inadequate equipment use / load  Ensure the overhead clearance before boom up.
 Source of ignition  Always assign the Flag man for each movements of crane.
 Always prepare the lifting plans for each lifting’s
 Only certified Crane Operators & Riggers during cane lifting’s
 Use tug ropes for all heavy lifts
7.  Out riggers always fully extended.
 Sole Board should be provided.
 Barricade lifting areas
 Grounding should be provided to Crane. Fire extinguisher should be
place at lifting zone
 All tools and tackles should be inspected and color code should be
provided.
 Tag line should be provided to all suspended load at all lifting activity.
8. Cutting and welding  Toxic Fumes  Always Obtaining Work permits before starting the jobs.
 Hydrocarbon fumes  Make tool box talk on every day bassis.
 Sharp edges  Maintain ventilation during all confined space activities
 Other flammable material  Cutting and welding areas shall be cleared of all obstruction
 Cutting and welding areas shall be cleared of all non-essential
material/tools/equipment especially filmable ones
 Continuous gas testing
 Proper gloves shall be used when handling sharp edges
 Proper Welding Safety gears shall be used when cutting and welding
 Adequate number of Inspected Fire extinguisher shall available at work
location
 Use fire blanket when cutting or welding to containing the spark
 SA certified or Third party certified Fire watch shall be at site.
 The fire watch should remain at the work site at least 30 minutes after
completion of work.
 Welding machine should be certified and welder should have Aramco
welding clearance certification.
 All cutting sets should be placed at proper trolley and secured with
chain links.

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  All cutting hoses should have the flash back arrester at cylinder &
Torch end.
 All welders and cutters should wear the face shields, Long cuff leather
gloves, Leather aprons, goggles and nose mask.
 Provide additional training to all hot work crew.
 All gas Cylinders should be stored at ventilated and shadowed store
and it should have proper signage’s & fire extinguisher at storage point.
 Minimum 6.1 Meter distance should be provided between to DA and
Oxygen store.
 Cylinder should be carry by trolley only. Do not leave the cylinder un
attend at work site.

9. Blasting / Coating  Dust / fumes inhalation   The abrasive blaster should wear the NIOSH/MSHA (or equivalent
 Slip, trip and fall organization) approved particulate filter for breathing air.
 Struck by  The breathing air should have equipped with Continuous carbon
 Noise monoxide (CO) monitoring device with audible alarm set at 10 ppm
 Source of Ignition shall be provided for oil lubricated breathing air compressor.
 Exhaustion  Air purifier filter should be replaced every 3 months.
 Losing control of blasting nozzles  The Co monitor should be monitored by stand by person.
 Flammable fumes  Every 2 blaster required one CO monitor
 Flammable material  Provide warning signs and install barricades around the work area
 Hydrocarbon gases maybe present  Only SA certified blasters and painters are allowed to work
 Health Hazards  SA certified Blasting/Coating crew supervisor shall be available at site
 Falling hazards  Breathing Air delivery system shall be inspected
 Poor visibility  Hoses and fittings shall be properly secured to prevent connection
disengagement Always secured by Chicago with whip lock.
 All sand Pot should be inspected and All sand blasting equipment
should be grounded.
 Portable Air receiver should possess the calibrated Safety Relief valve,
Pressure gauge and It should be Hydro tested prior to use.
 Air compressor should be certified and equipped with PRV. Every day
pre use checking to be carried out.
 Silica free slag or Abrasive only to be used for blasting.
 Blasting Dead man switch shall not be tampered with at all times.
 All air hoses to be maintained in safe manner and hose arrangement
should not create tripping environment.
 Fire extinguisher shall be available at wok site

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  Use full body harness with shock absorber when working at heights
(e.g. man lift, scaffolding, sky climber, etc. …)
 Man lift should be certified by third party inspector and It should be
pre checked every day prior to use.
 2 persons only allowed on the basket. Anti-Entrapment device should
be with man lift & I might be on working condition.
 Operator should be certified by third party.
 Dispose of all flammable material prior to blasting
 Allow enough time after coating and before attempting hot work at
same area
 Maintain ventilation of tank at all times.
 Do not allow any hot work around 75 feet and inside the tank while
doing the Painting.
 Each painting crew, whoever exposed with paint mist they should use
the chemical canister mask (Painter, Helper, Mixer, etc.)
 Paint should be stored at ventilated and shadowed location only.
 Paint MSDS should be posted on the store and flammable sign board
to be posted.
 Large and huge amount of paint storing is prohibited (Paint should be
stored on daily demand basis)
 Painting area should be free from Ignition sources.
 Empty paint containers should not stock at work site it should be
removed on daily basis.
 Paint pump should be inspected by third party and it should have the
calibrated PRV & pressure gauges.
 Paint hose should be new and good condition.
Vehicles entry etc.  High Speed  Only licensed drivers are allowed to enter the plant premises
 Fire  Aramco approved access sticker is required for all vehicles
 Collision  Drivers must make sure that the road is clear from moving
 Equipment damaged equipment/vehicles
 Improper routes  Follow the posted speed limit while traveling
10.  Use only approved parking area
 Do not park the vehicle / heavy equipment in front of firefighting
emergency equipment and access ways
 Contractor must provide trained flag man for controlling the vehicle
movements while reversing
 Contractor must provide qualified standby man
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 Internal Tank Repairs,  Slip, trip and fall  Maintain proper air ventilation at all times
MFL  Struck into objects/structures  Do not attempt to run, jump or climb inside tank
 Ambient temperature  Always watch your steps
 Air quality  Ensure tank bottom is dray
 Electrocution  Install proper lighting
 Only Competent crew should perform the MFL inspection for bottom
11. plates.
 All the cables and batteries of MFL equipment should be properly
secured while operating.
 After completion of the shift all the electrical connections should be
disengaged.
 Do not remove basic PPE while inside tank (e.g. Helmet, glasses,
gloves, etc..)
Radiography Testing  Exposure to radiation  Careful handling of radioactive source is required to avoid damage to
 Loss of containment the source shield
 Radiography technicians shall wear proper protection during testing
 Radiography is advised to be conducted at non-working time (breaks
and holidays) to minimize people exposure
12.  During Radiography, area shall be brocaded and entry to the vicinity
of the testing area shall be prohibited during RT
 Non-essential personnel shall be advised of the radiography testing
taking place, explain the hazards and shall be advised to keep safe
distance

13. Manual Excavation &  Cave-in  Hand excavation tools shall be maintained in good condition at all
Ring wall repair  Tripping over equipment, debris and times
spoil  Remove all obstruction on walkways such as stones, sharp objects,
 Inhalation of dirt or dust during work plastic bottles, electric cables, and other unnecessary tools and
activities materials that blocking the ways
 Slip trip fall  Spoil piles shall be at least 0.6 m (2 ft.) from the edge of the
 Side wall collapse excavation
 Contaminant Soil  Proper barricades, as necessary, shall be installed a safe distance
 Toxic & Flammable vapor Presence from the excavation to protect individuals and mobile operating
 UG utilities equipment above the excavation
 Vibration  Work Permit system to be obtained
 Noise  Warning signs should be provided.
 Dust Accumulation  Do not store any materials at pit head.
 Use the Nose mask while doing excavation and Chipping activity.
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  Improper Body position  Pneumatic concrete chipper should be inspected and secured by
 Puncturing whip lock.
 Sharp Object  Worker should use the Proper hand gloves, Face shield with glass
 Improper manual handling Ear muff and Mutt guard shoe while working with chipper.
 Material Fall on  Chipped debris to be sent out from work location.
 Using inspected tools and equipment to make shuttering and bar
binding.
 Need flag man for transits mixer.
 Whoever working with concrete pouring work they should wear
clear glass and disposable cover all.
 Do not working under the boom placer.
 Removed shuttering material kept in safe manner.
 Before backfilling ensure the excavation free from unwanted
materials.
 Used dust masks while excavating and backfilling
 Do the compaction with mutt guard shoe, Face shield and ear muff.

Hydro Test  Damaging Tank  Do not over fill tank while filling. Water level shall be provided in the
 Flooding work site with water testing instructions
14.  Monitor Tank level while filling
 Test water shall be safely disposed through an appropriate water
drainage system
Handling and Disposal  Manual handling  Waste materials must be properly treated or disposed according to
Of Material  Sharp edges requirements and including management of all disposal options in the
 Lifting heavy objects Manually most environmentally responsible manner
 Use proper hand gloves
15.  Dispose of at approved Saudi Aramco landfill
 Always lift objects with strait back and bent knees
 Do not attempt to lift heavy objects alone
 Do not attempt to drag heavy objects
 Use proper lifting equipment when required
16. Housekeeping  Slips, Trips and falls  Shall remove all obstructions such as wastes, unnecessary tools
 Sharp edges and materials that blocked along the door, stairways and any
 Lifting / picking up heavy loads walkways or access
 Shall protect with proper coverings all sharp edges and
protruding/pointed nails and pipes and must be properly arranged
at the designated area with barriers and barricades and safety
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 signs/warning signs
 Shall apply the proper ways and techniques on manual lifting and
handling including correct body postures and positioning prior to
lift or pick loads
 Shall evaluate or assist the loads carefully as to its shape, weight,
and the person’s capability prior to perform the manual lifting
 Shall use mechanical equipment such as forklift, boom truck, or if
necessary crane if the loads are heavy enough for any human being
to lift and to carry from one place to the other
 Shall provide appropriate Personal Protective Equipment (PPE) to
workers involved in the tasks
 Shall regularly inspect the work locations to monitor the
implementation of housekeeping and wastes disposals
 Shall maintain goo d housekeeping and proper material handlings
and storing as per Saudi Aramco standards and requirements
TANK BOX-UP  Foreign objects inside equipment  Conduct box-up walkthrough prior to closing tank manways
 Leak of hydrocarbon  Ensure tank internal is free of tools, rags, waist and any other foreign
objects prior to closing manways
 Make sure all source of leaks such as nozzles, instrument ports and
17.
drains are properly installed and secured
 Use proper gaskets for manways and flanges
 Closely monitor leak sources when tank is put back in service

Closing the work  Non-compliance of work Permit  Work permit issuer and receiver should inspect the work area to ensure
permit closure procedure that the area is left is a safe position
18.  Lack of awareness  If there are comments from the issuer for rectification, then do it
immediately before sign off the work permit

19. Working night shifts  Poor visibility  Supply sufficient lighting especially where critical activities are on-
 Slip, trip and fall going properly grounded lighting sufficient to cover the entire work
 SA property damage site (inside tank and outside) at night.
 Fire & explosion  Ensure availability of safety officer on site at all times
 Potential injury  No working at elevated heights without prior management approval
 No lifting activities shall be made without management approval
 Limit heavy equipment movement and entry during night shift
 Shift Turnover / Communication between Key Persons for incoming
and outgoing shifts.
 Maintenance Field coordinator shall be assigned to attend all T&I
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 activities during night shift

Observation/Revision: Date observed: Observed by:

Changes, if any: Changes, if any: Changes, if any:

Changes to Operating or Maintenance Procedure Required? Yes No

By: ____________________________________

Approved by : __________________________________________ Date:__________________________

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