Duqm Refinery Project EPC

Package One

PROJECT NO: 10121 UNIT: 310

PURCHASE ORDER NUMBER (RFP): 1012125370 EQUIPMENT: 310F-101 & 310-201

REVIEW RESPONSE BY PURCHASER:

Purchaser review and comments do not indicate either responsibility or liability for accuracy and
completeness of this document or alter any contractual terms and conditions:

REJECTED. NOT ACCEPTED REVIEWED WITH COMMENTS REVIEWED WITHOUT COMMENTS

COMMENTS AS NOTED REVIEWED AS BUILT FOR INFORMATION

VOID

DATE:28.03.2022

SUBCONTRACTOR IDENTIFICATION : TECNICAS REUNIDAS LLC

DOCUMENT TITLE:

JSA for Removal of Broken Eye Bolt Stud

SUBCONTRACTOR DOCUMENT No.: REV: 0 CODE:

DRP001-TES-JSA-C-00029
DRP001-PUC-TRL-O94-000-4128

CONTRACTOR DOCUMENT No.: REV: 0 DOCUMENT CLASS:

 Duqm Refinery Project
EPC Package One

CLIENT: DUQM REFINERY CONTRACT NO:

MAIN CONTRACTOR: TECNICAS REUNIDAS LLC DRPIC CONTRACT NO:

SUBCONTRACTOR: TOWELL ENGINEERING SERVICES CO. LLC IFCR:

PROJECT LOCATION: DUQM, OMAN DOCUMENT CATEGORY: CLASS 1

CRITICALITY RATING:

JSA for Removal of Broken Eye Bolt Stud

SIGNATURE :

DATE : 28-Mar-2022 28-Mar-2022 28-Mar-2022

Prabakar BA. MOHAMED SENRAYAN

NAME :
IBRAHIM RAMASAMY

HSE OFFICER HSE MANAGER PROJECT MANAGER

DESIGNATION :
PREPARED BY CHECKED BY APPROVED BY APPROVED BY

COMPANY NAME : TESCO TR

DOCUMENT TITLE: JSA for Removal of Broken Eye Bolt Stud REVISION

DOCUMENT NUMBER: DRP001-TES-JSA-C-00029 1

 Duqm Refinery Project EPC Package One
JSA – REMOVAL OF BROKEN EYE BOLT STUD (Rev-00)

Contractar Name: TECNICAS REUNIDAS LLC Sub-Contractor Name: Towell Engineering Services Co. LLC

Project: REFORMERS MECHANICAL AND E&I ERECTION Address: Azaiba

Location: AREA-2,UNIT-310-TRAIN-01& 02 Site Engineer: RAMASAMY

Type of JSA: REMOVAL OF BROKEN EYE BOLT STUD JSA No: DRP001-TES-JSA-C-00029 New: : Revise:

Job Description: -
1. Replacement of installed eyebolts with new supplied bolts.
2- Extraction / drilling of broken bolt.
3- Reinstallation of dismantled covers.

Prepared by Subcontractor:
Name: BA.MOHAMED IBRAHIM Position: HSE MANAGER Signature: Date:

Reviewed and Approved by Subcontractor:

Name: RAMASAMY Position: PROJECT MANAGER Signature: Date:

Reviewed and Approved By TRD:
Name: Position: Signature: Date:

Reviewed and Approved By TRD:

Name: Position: Signature: Date:

Page1 / 14
 Duqm Refinery Project EPC Package One
JSA – REMOVAL OF BROKEN EYE BOLT STUD (Rev-00)

Incident Likelihood or Probability

Incident Severity
Improbable Remote Occasional Probable Frequent
Productivity or Severity
Environment Property Personnel A B C D E
Downtime Level

Fatality or
Permanent damage
total
> 2 weeks beyond project Total facility loss 5 L M H H H
permanent
boundary
disability

Permanent damage
Damage to an
within project Permanent
1 week to entire facility or loss
boundary or partial 4 L M H H H
2 weeks of multiple systems
reportable release disability
in a facility
beyond boundary

Reportable release Damage to an entire

facility or multiple
> 1 day to within project
systems in a facility Days away 3 L L M H H
< 1 week boundary with no requiring repair or
permanent damage replacement
Release within project Damage to a facility
boundary below OSHA
½ day to element or system
reporting quantity with Recordable 2 L L M M H
1 day requiring repair or
clean-up by external or E-1
replacement
source
Release within project Damage to a facility
boundary below element or system
< ½ day
reporting quantity with
First aid 1 L L L M M
requiring negligible
clean-up by internal or no repair
source

Operation not permitted; must implement Operation permitted with

Operation permitted with a time
Risk Mitigation High controls to reduce risk to an acceptable or Medium Low implementation of core HSE program
limited waiver endorsed by
Controls manageable level. (M) (L) elements.
(H) management.

Page2 / 14
 Duqm Refinery Project EPC Package One
JSA – REMOVAL OF BROKEN EYE BOLT STUD (Rev-00)

Activity / Task: REMOVAL OF BROKEN EYE BOLT STUD Date: 28.03.2022

Work Location: Duqm Refinery EPC-1 Company: TESCO- TRLLC Supervisor: NAGESHWARAN
JSA No: DRP001-TES-JSA-C-00029 Rev.01
Please mark () appropriate boxes - (A new JSA is required if the job scope or work conditions changes)
 Cold Work Permit  Safe Work Permit
Permit(s)
1.0 Required:  Confined Space  Hot Work
Permit
 Hard Hat  Clear Safety Glasses  Dark Safety Glasses  Chemical Goggles  Cutting Goggles
 Dust Mask  Face Shield  Welding Hood  Welding Aprons  Welding Leggings
 Ear Plugs  Earmuffs  Cartridge Respirator  Escape Respirator  SCBA
2.0 PPE Required:  Cotton Gloves  Leather Gloves (rigging)  Leather Gloves (welding)  Rubber Gloves  Rubberized Cotton
 Coverall  Disposable Coverall  Full Body Harness  Hi-visVest/ jacket
 Safety Shoes
 Cut resistant gloves  Nitrile gloves  Elect Insulated gloves  Arm Sleeves
 Dielectric footwear
 Air supplied respirator  Fire resistant coverall  Rain Suit
 Gas Badge  Multi-Gas Monitor  Gas Detector  Light Meter  Anemometer
Special Tools  Dosimeter  Thermometer  Ventilation Fans  Air Blower  Fire Extinguisher
3.0 and Equipment  Lifeline  Retrieval Line  Padlock, Hasp, Tags  Lighting (low  Lighting (high lux)
Required:  Air Horn  Whistle  Traffic Flags voltage)
 Spill Kits
 Traffic Cones
Potential  Noise  Air Pollution (dust)  Air Pollution (smoke)  Air Pollution (vapor)
4.0 Environmental  Soil erosion  Spills (to ground)  Spills (Water)  Hazards to Flora & Fauna
Hazards
Hazardous
5.0 Materials (attach  Carcinogen  Irritant  Highly Flammable  Toxic  Explosive
MSDS)
 Electrical  Pressure (air, water,  Mechanical (crush points)  Ergonomics  Temperature (±)
Other Potential  Light / Dark gas)  Dust / Vapor  Suffocation  Other Trades
6.0 Hazards  Ignition Sources

EMERGENCY: call TRD HOT LINE: 97864422 and follow the Emergency Response Plan; First aid facilities shall be available
COVID 19: respect the protocol Wearing facemask, Maintain social distance, Use of sanitizers and soap liquids, Avoid
touching eyes, mouth or nose before washing hands. Follow with MOH instructions. In case of COVID19 symptoms, report
Additional
7.0 Instructions
to your supervisor immediately
HEAT STRESS: Drink water and take rest breaks; Don`t work in open area for too long
CONFINED SPACES: if confined space entry is applicable a separated PTW with JSA is required
ENVIRONMENT: respect the Environment HSE Plan in all aspects

Page3 / 14
 Duqm Refinery Project EPC Package One
JSA – REMOVAL OF BROKEN EYE BOLT STUD (Rev-00)

RISK RESIDUAL
S.No JOB STEPS POTENTIAL HAZARDS PREVENTIVE AND CONTROL MEASURES RESPONSIBLE
RATING RISK

 Comply with TRD’s PTW procedure (DRP001-PUC-PRO-Z-

000-015) and other relevant procedures applicable for
the activity
 Supervisor
 Only TRD approved PTW receiver can apply for PTW
Untrained PTW Receiver M L  PTW Receiver
 Implement and maintain control measures stated in the
PTW and other related documentation
 Permit Holder shall be available at site all the times and
ensure compliance with permit conditions

 Plan the work involving Permit receiver & Worksite

Permit to Work
1. Supervisor
(PTW)
 PTW and all required documents shall be attached
including approved JSA.
 TBT shall be done prior to start the work, based in the JSA
and site conditions.
Non-compliance of TRD  Permit receiver shall be available at site with compliance  Supervisor
H L
PTW and Procedures on permit conditions  PTW Receiver
 All employees have to undergo mandatory trainings from
TRD related to the activity performing.
 PTW shall be kept and displayed on the working area at all
times.
 Approved method statement for activity shall be in
place
 Supervisor shall be responsible for conducting TBT
specific for the activity in a clear manner, using this JSA
Startup Lack of Knowledge/ as reference and other relevant support documentation  Supervisor
2. preparation and Understanding of the H  Supervisor shall translate the TBT in a language that L  Site engineer
Pre-task briefing work / activity workers can easily understand
 Supervisor shall check personal protective equipment to
each crew prior to the start the activities.

Page4 / 14
 Duqm Refinery Project EPC Package One
JSA – REMOVAL OF BROKEN EYE BOLT STUD (Rev-00)

 Two-way communication shall be ensured.

 The crew shall be competent, trained and experienced.
 Job planning shall take into consideration all HSE aspects
and preventive measures
 Supervisor
 Joint site visit prior start work
Poor work planning H L  Site engineer
 All approved relevant documentation: MS, Plans and
Procedures, JSA, etc. and all relevant information shall
be available on site for consultation
 All the equipment, after verified the documentation,
Poor equipment  Site engineer
must pass TRD inspection prior to start the activities
monitoring and control / H L  Supervisor
defective equipment  Verify the workplace to ensure correct task, equipment  Fitter
and location have being identified

 Ensure all employees shall undergo TRD job specific

training programs prior to engage in task to increase the
awareness on site
 Ensure employees competency level by affirming the  Site engineer
Lack competency and or educational qualification, training (external & internal),  Supervisor
H L
training experience prior to deploy into site.  Const. Manager
 The crew must be competent for the execution of the  HSE manager
job with proven knowledge, experience and training
 All personnel involved in the activity must attend hand
and power tools training prior to start the activity
 All access, egress and Muster Points must be clear with
proper signage and illuminated
 Emergency evacuation routes must be available and  Site engineer
3. Site condition Poor access & egress H provided in the workplace. L  Supervisor
 Openings providing access need to be sufficient large
and free from obstructions and the openings needs to
be kept clear.
 Site Engineer
 Ensure that the path of area is clear and free from
Slip, Trip & Fall M L  Supervisor
materials or obstruction

Page5 / 14
 Duqm Refinery Project EPC Package One
JSA – REMOVAL OF BROKEN EYE BOLT STUD (Rev-00)

 Ensure proper cable management

 Ensure proper housekeeping and material management
 Proper illumination shall be ensured
 Ensure proper planning of activities and communication
to avoid simultaneous activities
Proximity with other  Assess the workplace and surrounding activities those
 Site Engineer
work parties and H can impact the work raising awareness of both parties if L
 Supervisor
possible SIMOPS is essential to work in close proximity
 Ensure barricading, signage and proper communication
with teams
 Manual handling training shall be given to the team
 Mechanic movement of loads shall be applicable rather
than manual
 Follow TRD manual handling standard procedure
 Load shall be kept close the body
 Judge the load for the weight and shape
4. Ergonomics / Incorrect
Manual Handling M  If the weight is more than 20kg ask for team support L  Site Engineer
body posture
 Firm grip and caution on sharp edge  Supervisor
 Firm footing
 Keep spine upright position, don’t lift and twist
 Squat and use leg muscles for lifting
 Do not shelf objects manually above shoulder height if
possible
 Ensure operative complies appropriate PPE like Heavy
duty hand gloves along with mandatory PPE
Punching the
broken eye bolt  Tools must be inspected and color-coded for their good
stud by hand held Pinch point & Crush condition
 Supervisor
5. center punch point M  Keep hands and other parts of body away from line of L
 Site engineer
metal tool with fire
hammer  Ensure to hold center punch tool at right angles to the
work surface to prevent side-slipping.
 Be sure to strike the punch squarely with the hammer to

Page6 / 14
 Duqm Refinery Project EPC Package One
JSA – REMOVAL OF BROKEN EYE BOLT STUD (Rev-00)

prevent its slipping off and hitting fingers

 Make sure the handle is tight. Never use a hammer with
a loose or damaged handle.
 Ensure to hold the hammer with wrist straight and hand
tightly wrapped around the handle.
 Address hazards associated with pinch points & crush
point in TBT
 Wear appropriate hand gloves safety glasses or goggles
when using punches or stamping tools
 Always select a hammer style and size that is
appropriate for the punch selected
 Ensure before striking punch, the striking face of the  Fitter
Striking and impact M
hammer should have a diameter at least 1/2 inch (1 cm.  Supervisor
+) larger than the struck face of the tool.
 Ensure to hold the hammer with wrist straight and hand
tightly wrapped around the handle.
 Avoid Excessive force with the hammer.
 Do not use mushroom head center punch to prevent
sharp fragments flying particles.  Fitter
Eye injuries M
 Wear appropriate safety glasses and face shield when  Supervisor
using punches.
 Const.manager
 Pre Task briefing to all involved employees using this JSA
 Site engineer
 Work shall be carried out under proper Supervision  Supervisor
Use of Portable  Make workers aware of the specific hazards / risk related
hand Drilling
to the activity and control measures to be cascaded to
machine & Unauthorized, non-
6 extraction of H employees before starting the work on daily basis. L
competent personnel
broken eye bolt  Ensure employees involved in task had undergone TRD
stud hand and power tools training.
 Ensure competent personnel’s are deployed and proper
supervision shall be done.

Page7 / 14
 Duqm Refinery Project EPC Package One
JSA – REMOVAL OF BROKEN EYE BOLT STUD (Rev-00)

 Awareness training on flying particle hazards and

precautions to be taken during daily TBTs
 Mandatory double protection (Safety goggles and Face  Site supervisor
Flying shield) for the person carrying the activity in addition to  Fitter
particles H
site mandatory PPE. L  Man lift operator
 Drill bit must be in correct position mounted firmly.  HSE supervisor
 Mandatory eye protection (Safety Goggles) for the people
working around the area of work

 All drilling machines must be inspected and approved by

TRD Competent Person.
 If mounted in horizontal position 100% tie off shall be
done using tool lanyard chain.
 Drilling machines to be inspected and color coded on a  Fitter
Failure of drill H L
monthly basis.  Supervisor
 Do not use high speeds steel (HSS) bits without cooling or
using lubrication.
 Only use machine with a 'cut-off' switch, do not use lock
button for continuous operation.

 No loose clothing allowed in the vicinity of machinery

 Jewelry not to be worn.  Fitter
Caught in rotating parts H L
 All rotating parts to be guarded.  Supervisor
 Wear mandatory & task specific PPE’s.

 Ensure all employees shall undergo TRD job specific

Applying rust
removal by training programs (chemical handling & spill prevention)
Irritation to skin  Fitter
7 aerosol spray & H prior to engage in task to increase the awareness on site L
 Supervisor
Anti-seize Pastes  Ensure & follow all PPEs compliance as per MSDS
instructions & requirements.

Page8 / 14
 Duqm Refinery Project EPC Package One
JSA – REMOVAL OF BROKEN EYE BOLT STUD (Rev-00)

 Avoid prolonged contact with skin

 Avoid contact with eyes

 Ensure placement of Eyewash unit at perimeter of
workplace
Irritation to eyes  Ensure all PPEs compliance as per MSDS instructions  Fitter
H L
 Ensure Full face shield shall be used for supplementary  Supervisor
but never for primary protection of eyes
 Ensure to avoid prolonged exposure & provide
intermediate break for the operative.

 Avoid breathing vapors or aerosols, Ensure all PPEs

compliance as per MSDS instructions
Irritation respiratory  Fitter
H  Use only with adequate ventilation L
tract  Supervisor
 All personnel should be appropriately trained in
emergency procedures

 Keep away from heat, sparks, pilot lights, hot surfaces and
open flames
 Fitter
Fire H  Unplug electrical tools, motors and appliances before L
 Supervisor
spraying or bringing the can near any source of electricity
 Ensure to place dry powder fire extinguisher.

 Avoid physical damage to containers.

 Ensure to Use in a well-ventilated area.  Supervisor
Handling and
8 storage Improper handling H  Ensure that atmosphere should be regularly checked L  Storekeeper
against established exposure standards to ensure safe  Store assistant
working conditions are maintained.

Use of hand and  Before using electrical equipment ensure it is visually

Electrical hazards  Fitter
9 power tools H inspected fro damage, especially to insulation and safety L
 Supervisor
devices

Page9 / 14
Duqm Refinery Project EPC Package One
JSA – REMOVAL OF BROKEN EYE BOLT STUD (Rev-00)

 Ensure the switch is in the off-position before

connecting to power source
 Ensure to remove any adjusting key or wrench before
turning the power tool “ON”
 Always use the lowest possible voltage rated equipment,
110v where possible.
 Never work in wet conditions with electrical equipment
 Never use the cord for carrying, pulling or unplugging
the power tool
 Disconnect the plug from the power source from the
power tool before making any adjustments

 All electric tools shall be inspected by competent

electrical person and color coded.
 All the crew must undergo TRD’s Hand & Power Tools
training.
 Conduct Task specific Toolbox meeting and explain the  Supervisor
Defective tools H L
electrical hazards and the control measures  Fitter
 Do not use any defective electrical equipment.
 Authorized electricians only allow to handle all electrical
panel & equipment’s are service and maintenance.
 Wear mandatory & task specific PPE’s.
L
 Awareness training on noise and hearing protection.
 Supervisor
Noise M  Use of ear Plugs / Muffs by the person carrying out
 Fitter
operations and the personnel nearby.

 Ensure that the operator is using vibration resistant hand

gloves.
 Ensure rotation and break intervals.
 Supervisor
Vibration M  Limit the time spent by operative on a vibrating surface L
 Fitter
 If abnormal vibration is observed, immediately inform the
concerned technician to inspect the machine.
 Ensure continuous supervision.

Page10 / 14
 Duqm Refinery Project EPC Package One
JSA – REMOVAL OF BROKEN EYE BOLT STUD (Rev-00)

 Use the auxiliary (second) handle for activity or

continuous operation
 Ensure to secure workpiece being drilled to prevent
movement.
 Slow the rate of feed force just before breaking through  Supervisor
Instability M L
the surface  Fitter
 Do not overreach. Always keep proper footing and
balance
 Do not use excessive force to drill into hard material.
Reduce drill speed if possible

Weld-on eyebolt Welding & grinding Refer JSA No- DRP001-PUC-TRL-O94-000-4008 Rev.2  Supervisor
10 with cover plate H L
Operation Hot work activity & Control measures.  HSE Supervisor
 Lifting supervisor is responsible for the pre-lift meeting
specific to the activity.
Lack of knowledge / Poor  Lifting Supervisor
understanding  Use Risk assessment / JSA as a reference before the
 Rigger
activity
 Site Supervisor
 Communication to the workforce shall be properly
 HSE Supervisor
H understood in a convenient language in pre lift
L
meeting.
H  Lifting zone shall be controlled by barricade and
Lifting of cover signage all over the lifting radius.
plate & connect  Dedicated stand by man shall be deployed to control
11 to manway in the unauthorized person and equipment entering  Lifting Supervisor
Unauthorized Entry L
steam drum inside the lifting area  Site Supervisor
 Display the Signage and provide barricade
 Notify the nearby other subcontractor about the lifting
operation.
 Cranes shall have third party certificated and approved
 Lifting Supervisor
by TRD (initial and monthly inspection stickers).
 Rigger
 Visual inspection must be carried prior lifting (using the L
Crane topple/ overturn  Site Supervisor
daily checklist)
 Operator
 De-rate all cranes involved in the lift by 25% of the load
chart as per TRD procedure

Page11 / 14
 Duqm Refinery Project EPC Package One
JSA – REMOVAL OF BROKEN EYE BOLT STUD (Rev-00)

H  All outriggers shall be fully extended.

Struck by or caught in H signboard
between by moving
equipment
 Ground must be compacted and level or FDT (field
density test)
 Do not overreach and adhere or follow the lifting plan.
 Slow swinging and dropping of load must be
maintained.
 Appropriate barricade must be provided with
L
 Site Supervisor
 Assign trained flagman
 Flag Man
 No unauthorized person in the area.

 All lifting tackles/ gears shall have third party certificate

 It must be inspected by competent person
 Lifting Supervisor
 Visual inspection must be carried out by competent
Failure of lifting tackles/  Rigger
person prior to use
gears  Site Supervisor
H  Damaged and worn out must be discarded from site
L  Operator
 Lifting tackles/ gears must be properly stored after
using and not allowed to keep on the ground
 Ensure lifting eye is intact and no cracked/ damaged
prior lifting by level 1 rigger or lifting supervisor
 Ensure appropriate lifting tackles to use for lifting such
the size and SWL as per lifting plan
 Ensure loads must be secured and stable
 Only approved rigger shall perform slinging
 Lifting Supervisor
 Hoist loads shall not beyond the crane capacity
H  Rigger
Falling of loads  Load with taglines must be manned by rigger with
 Crane Operator
third party certificate and approved by TRD
 Swinging radius of the crane must be barricaded with
signboard posted L
 Nobody under the suspended load during lifting
 Ensure the covers must be stable and secured with guy
rope.
 Crane operator and rigger must be physically fit  Lifting Supervisor
Human error  Not allowed to use mobile phone and using headset  Crane Operator
H L  Rigger

Page12 / 14
 Duqm Refinery Project EPC Package One
JSA – REMOVAL OF BROKEN EYE BOLT STUD (Rev-00)

while working to avoid distraction

 Perform accurate load spotting and control load swing.
 Constant communication between the operator and
rigger
 Crane operator is not allowed to go out of operator
cabin before completion of job.
 Any lifting activity shall be stopped when the wind
Adverse weather  Site supervisor
H speed for Crawler Crane 13.2-14 m/s and more & L
conditions  HSE Supervisor
Mobile crane 9.8 m/s and more
 Crane shall have third party certificate
 Crane must be inspected and approved by TRD
Equipment inspector
 Visual inspection (using the daily inspection checklist)
must be carried out by competent person prior lifting
 Monthly inspection shall be done by TRD approved  Lifting Supervisor
Mechanical failure of the L
H inspector along with TRD inspector. Upon satisfactory  Crane Operator
crane
sticker will be provided.  Rigger
 All equipment shall be checked along with TRD
inspection checklist
 LMI system must be functioning and followed
 Maintenance of the crane must be maintained all the
time.
 Monitor humidity and temperature; display the flags
according to the level
 Drinking water will be provided in the site always
 Direct sun light works will be suspended during the high
Adverse Climate  Site Engineer
temperature and humid in line with index
Extremely heat –heat  Site supervisor
12 Environment stress H  All workers will be advised to take short break if feel L
 Foreman
fatigue
 HSE Supervisor
 Rest Shed should be provided with fans
 Drink plenty of water
 Heat Stress Program shall be implemented.
 Workers shall always work in pairs when required.

Page13 / 14
 Duqm Refinery Project EPC Package One
JSA – REMOVAL OF BROKEN EYE BOLT STUD (Rev-00)

 Housekeeping shall be held on a daily basis at the end of

the shift. Proper time shall be allocated for this purpose.
 Site Engineer
Untidy and messy work  Unsafe conditions due to poor housekeeping shall be
13 Housekeeping M L  Site supervisor
place immediately eliminated from the workplace.
 All construction waste and unwanted materials shall be
removed from Site on a daily basis.

 In case of emergency the following emergency contact  Const. Manager

number can be used  Site medic
 TRD HOTLINE # 9786 4422  First aider
 HSE
 In case of any emergency the safety team must be
H L  Supervisor
immediately notified.
 Training should be given to all workers on emergency
procedures and they should be aware of the nearest
assembly points.
 In case of any emergency the workers must assemble at
the nearest assembly points.
14  First aid shall be rendered only by competent and
Emergency Medical emergencies at authorized personnel only.
site
 Refer emergency rescue plan attached with PTW
 Emergency Contact Numbers: -
TRD HOT LINE: 9786 4422
HSSE Manager (TRD): 9480 6875
Construction Manager (TRLLC): 9786 8292
Clinic No. – 92726855
HSE Manager (TESCO) – 99102075
Project Manager (TESCO) – 91258759

Page14 / 14