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SCOPE:

This Document describes the Guideline for conducting Job Safety Analysis (JSA).

The document contains:

Section Description Page No.

01 Guideline Basis 03
02 Job Safety Analysis Methodology 04
03 JSA Training & Team 09
04 Review Meeting 10
05 JSA Training Guide 11
06 JSA Example 12
07 JSA Format 17
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SECTION - 1 Guideline Basis

Engro Asahi Polymer & Chemicals Limited is committed to the safe operations of its facilities. This
commitment requires that all jobs with a potential safety hazards are systematically identified, and the risk
from these jobs are analyzed in such a way that potential injury or equipment damage instances are identified,
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SECTION – 2: JOB SAFETY ANALYSIS METHODOLOGY

The National Safety Council (USA) gives a detailed methodology for conducting a Job Safety Analysis. Job
Safety Analysis (JSA) is a procedure that provides a systematic & effective method to review job methods and
uncover hazards so that the safeguards can then be identified. This method is different from other hazard
identification as it focus on each task step of a job to identify specific hazards in them. JSAs are very useful
in initial and periodic upgrading of procedures, strengthening workplace safety, reducing and
eliminating injuries/illnesses and improving safety attitudes.

As a job is analyzed, it will be found that some job steps have no hazards associated with them. On
the other hand, an individual job step may reveal several hazards or potential accident triggering
items. Obviously, some of hazards revealed will be conditions & some will arise out of employees’ action.
JSA will address all the possible hazards.

Key elements in preparing a JSA are:

 Selection of a job suitable for analysis (Basis hazard classification).

 Describe the sequence of steps to perform the job.
 Determine the hazards and potential accidents for each job step.
 Identify ways to eliminate and control each hazard.

Selection of Job for JSA

Selection of jobs to be analyzed for JSA and establishment of the order of analysis is based on the following
factors:

Frequency of Incidents/Injuries:

The greater the number of accidents associated with a job, the greater its priority claim for JSA. Every job
that has had disabling injuries should also be given a JSA, particularly if the injuries prove that prior preventive
action was not adequate.

Severity Potential

Some jobs may not have a history of accidents but may have the potential for producing severe injury. These
jobs are generally not done frequently therefore merit a special review. A guideline attached with this
procedure can be used for assigning a hazard class and then JSA can be performed for all jobs having 20
or more Hazard Score. Area owner (Mostly Maint. Unit Manager) will call up the JSA.

A numeric guideline for the scoring of consequences is given in Table-1 and should be used before embarking
upon the JSA activity. Maint. Unit manager in consultation with SET Advisor will assign scores and call for the
JSA of an activity. The overall Hazard score is obtained by multiplying the Consequence and Frequency
scores. Activities bearing high consequences have to go through JSA as per following table. All activities lying
outside the GREEN areas need to Analyzed using JSA technique.
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Table-1: Classification of hazard for JSA

Continuous
10 30 60 70 80 90 100
4-5 times a day
9 27 54 63 72 81 90
1-3 times a day
8 24 48 56 64 72 80
2-3 times a day
6 18 36 42 48 54 60
Few times per
month 4 12 24 28 32 36 40
1-2 times a year
3 9 18 21 24 27 30
Less than once
per year 1&2 3 6 7 8 9 10

Fatality, serious damage

Catastrophe (Level-II),
Noticeable equipment
First Aid injury, minor

to equipment, NEQS
LWI, VCM exposure,

equipment damage
Noticeable impact

Noticeable impact

Major equipment
damage, multiple
fire or moderate
Serious Injury,

violation.

fatalities.
damage

damage,

New or non-routine Jobs

Changes in equipment or in the process obviously have no history of accidents. A JSA of job should be done
before embarking on the activity. Analysis should not be delayed until accident or nearmiss occur. Similarly,
all non-routine jobs of higher hazard classification are also required to be given a JSA.

Others:

JSA call up can also be recommended by the SUBSOCs for any jobs. Also, any other non-routine and
potentially hazardous jobs defined by Safety Advisor and Area in charges.
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Sequence of steps to perform the JSA

A job should be broken down into a sequence of task steps each describing what is being done. Do not
breakdown the job in such a detail that an unnecessarily large number of steps result. Similarly, the job
breakdown should not be so general that basic steps are missed.

To do a job breakdown, select experienced & capable employee who are knowledgeable to identify the
hazards & can suggest measures to eliminate or control them.

Determine the hazards and potential for accident in each job step.

Each step in the job breakdown should be carefully analyzed for hazards & accident potential with a view to
identifying all the possible hazards whether produced by the environment or job procedures. The familiar &
usual safety questions should be answered. Some of the questions are as under:

1) Is there a potential for injury when any object is struck?

2) What about slipping or tripping?
3) Could one fall on the same level or from one level to other?
4) Are toxic, corrosive gases/liquid mists, vapor, dust, heat, fumes & radiation present?
5) Can the employee be caught in, by or between objects? Close observation & knowledge of
particular jobs is required for an effective JSA. When inspecting a particular machine or operation
or writing a procedure, ask the question “Can an Accident Occur”? Through observation and
discussion, a reliable list of hazards & potential accidents can be developed.

Frequency/Probability Level

All the potential hazards should be assigned a probability level based on the potential to cause an injury or
extreme unsafe condition in the area. The probability levels to be used are given in the Table-1

The final step in a JSA is to develop a safe job execution way to prevent occurrence of accidents. There are
four ways we can develop solutions that will eliminate or control hazards & offset accident potential. These
are:

1) Find an entirely new different way to do the job.

2) Change the physical condition that create the hazard.
3) Revise/Change the procedure.
4) Limit the use of job by reducing frequency with which it is done (particularly helpful in maintenance &,
material handling).

To find entirely a new way to do a job, determine the work goal of the job & then analyze the various ways
of reaching this goal to see which way is the safest. Consider work-saving tools & equipment. If a new
way cannot be found, then ask this question about each hazard and potential cause listed: What change in
physical condition (such as change in tools, materials, equipment, layout or location) will eliminate the
hazard or prevent the accident.

To investigate the changes in the job procedure, ask the following questions about each hazard and potential
accident cause listed: “What should the employee do or not do to eliminate this particular hazard or
this potential accident? How should it be done?
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While making the procedure consider the following:

1) Engineering the hazard out.

2) Providing personal protective equipment.
3) Job instruction training.
4) Good housekeeping.
5) Good ergonomics (positioning the person in relation to the machine or other element in the
environment.)
6) Human error factors

List recommended safe operating procedure and required PPE for each step of the job.

Be specific; say exactly what needs to be done to address the hazard. Avoid general statements. Give a
recommended action or procedure for every hazard.

Below are some of the guidelines to be used for identifying the Human Factor related items in a JSA.

Human Factors

It is important to consider human factors and their impact on the likelihood of accidents. Human factors may
result in an increase in the likelihood of a human error, by utilizing the guideline (given below) during JSA,
human error situations can be identified and necessary actions to address the issue developed.

Hazard Contribution Factor Example Situation Which May lead to

Accident
Labeling Mislabeled, or not labeled at all
Access Hard to reach or access
Operability Difficult to operate/change position
Layout Confusing/inconsistent arrangement
Uniqueness Several components look alike
Mode Manual operation, many manual steps with a potential for
error
Involvement Operator detached from process, not fully involved
Displays Unclear/complex/non-representational
Feedback None or potentially misleading
Noise Level Area where hearing protection required but not used
Climate Extremes in temperature, humidity, precipitation, wind
etc.
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Hazard Contribution Factor Example Situation Which May lead to

Accident
Lighting Inadequate lighting for task
Content of Procedures Incomplete/too general/out of date
Identification Ambiguous device/action identification
Format of procedures Confusing/inconsistent, difficult to read
Aids Task sequence done by memory
Alarms Many simultaneous or false alarms
Coverage Operator not always present
Time Inadequate time to respond
Preparedness No drills/simulation of scenarios
Last-Resort Shutdown discouraged or unsafe
Overtime Extreme enough to affect performance
Consistency Inconsistent shift rotations/schedules
No. Of Tasks Tasks required exceed time available
Intensity/frequency of activity Very infrequent, lack of experience
Shift Change Differing tasks in rapid succession
Field/Control Inadequate communications between shifts on Plant status
Supervision Little or no supervisory checks
Emergency Communication No distinction between alarms in areas or types
Initial Training Little or no job specific training
Refresher Training Overdue or nonexistent
Safety Awareness Little or no training on procedural or process changes

Review & Approval

All the JSAs would be review by the Area Incharge / Safety Advisor & approved by the Sub SOC(Mechanical)
chairman.
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SECTION - 3 JSA Training & Team

Training

Job Safety Analysis leader should go through a formal Safety Supervision Course in which Job Safety Analysis
is covered in detail & must have participated in a JSA before leading one. Adequate training of the JSA study
team must be done to ensure a high quality analysis. Training is most effective when atleast a re-fresher is
provided shortly before the beginning the study.

Team training requirements typically include a team resource, or leader, with in-depth knowledge of the
JSA methodology and experience in applying the method atelast once or twice. Team members should
receive overview training using the JSA Guideline & referring to previous JSAs.

Team

The team leader should be technically trained on JSA methodology. The team members must represent a
cross section of the disciplines involved in executing the job. It is extremely important to put the most
experienced and knowledgeable resource for this activity as inexperienced team tend to conduct a poor
quality JSA . The team should contain people from supervision and the operating levels. The membership
must include individuals with the following skills:

1) Knowledge of the basic technology involved in the operation / maintenance of the process and
equipment.
2) Hands-on operating / maintenance experience on the process or equipment.

3) One team member who is knowledgeable in the JSA method.

4) Other appropriate knowledge or expertise needed to accomplish the aims of the study. Experts in
specific disciplines not represented on the team can be called in as part time resources for the team.

A typical JSA team in EAPCL would have the following membership:

1) Area Incharge / Section Head or appropriate trained designate JSA leader.

2) Safety & Training Engineer / S.E.T. Advisor
3) Area Maintenance Engr.
4) Project Engineer. (If required).
5) Maintenance Technicians. (Contract/permanent)
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SECTION – 4: REVIEW MEETING

The first team meeting is usually a training session & organizational meeting, where the task to be
done is outlined and agreement is reached on how to proceed. The maximum time scheduled for a
JSA should be no more than two working days. This also includes the training of the members
as well.

The JSA team must conduct a field tour of the facility being studied. The team member with hands-
on experience should serve as the guide. The tour gives the team a clear picture of the job process
and the layout. The team members should break the job in logical task steps, identify potential
hazards, assign a probability level & then suggest the control measures. The JSA final document
should be reviewed with the Safety Advisor and approved by the relevent Sub SOC chairman.
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SECTION - 5
Typical JSAs are documented using a four-column format (Sequence of Basic task steps, Potential Hazards,
Probability level & Control Measures). The example is give below:
Sequence of Basic
Job Steps
Break down the job into its
basic steps e.g. what is done
first, what is done next & so
on.
You can do this by:
1) Observing the job.
2) Discussing it with
the employee.
3) Drawing on your
knowledge of the
job.
4) A combination of the
three.
Record the job steps in their
normal order of occurrence.
Describe what is done, not
the details of how it is done.
Usually three or four words
are sufficient to describe
each basic job step.
For example, the first
basic job step in using a
pressurized water fire
extinguisher would be to:
1)Remove the
extinguisher from the
wall bracket.
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JSA Training Guide
Potential Hazards
For each job step, For each job step
identify all hazards. hazard assign a
probability level of
Some find it easier to High, Medium or
identify possible Small.
accidents & work in
reverse to identify
hazards, listing type of
injury in parenthesis
following the hazard. You
can get the answers by:
1) Observing the
job.
1) Discussing it with
the employee.
1) Recalling past
accidents.
1) A combination of
the three.
Ask yourself: Can he or
she be struck by or
contacted by anything?
Can he or she strike
against or come in
contact with anything?
Can he or she fall? Can
he or she overexert? Is
he or she exposed to
anything injurious, such
as gas, radiation, welding
rays or other hazards
that could cause acid
burns, inhalation of
noxious fumes or other
problems?
In the fire
extinguisher example,
one hazard would be:
1)Foot struck by
extinguisher
(fracture, bruise).
Date Prepared:
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Prob. Level Recommended Safe
Job Procedure
For each hazard, determine
how the employee should
perform the job step to
eliminate or minimize the
hazard that could lead to an
injury. Determine if you can
remove the hazard, change
the work procedure, change
physical conditions and/or
provide personal protective
equipment. You can get your
answers by:
1) Observing the job for
leads.
1) Discussing precautions
with experienced
employees.
1) Drawing on your
experience.
1) A combination of the
three.
Describe specifically the
precautions the employee
must take. Do not omit
important details. Number
each separate recommended
precaution with the same
number you gave the
potential hazard (see center
column) that the precaution
seeks to avoid. Use simple do
or do not statements to
explain recommended
precautions as if you were
taking to the employee. For
example: “Lift with your legs,
not your back”. Avoid such
generalities as “Be Careful”,
“Be Alert”, “Take Caution”.
In the extinguisher example,
one safeguard would be:
1)Grasp extinguisher
handle firmly.
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SECTION – 6: JSA Example:

Unit: UTY Task Description: Loading of polisher resin.
Zone: WPU
Equipment No. Hazard Score: Requirements: Work permits have
been obtained.
Developed by: Reviewed by : ARK Approved by: FIQ
PPE (Standard): Hard hat, safety glasses or goggles, safety boots, and long sleeved shirt etc..

Special PPEs Coveralls, Splash goggles.

Required: All special safety equipment or tools to be examined by Safety Section before
execution of the job.

Sr. Task Step Potential Hazard Prob. Control Measures

No.
1 Shutdown vessel, and
drain.
2 Blind all lines
entering/exiting vessel
Level
Vaccum if the top
bleeder is not kept
open.
Exposure to hazardous
materials.
M Keep the top bleeder open at
all times and car-seal-open
it. Install a combination
gauge on top and keep
checking the pressure on it.
M Inspect all lines with blinds
list. Identify and confirm
lines isolated – use permit
system.

3 Set up equipment on
top of vessel
Buildup of static
electricity – possible
ignition source
Slip/trip hazards
Blinds to be inspected on
shift basis and sealing
verified and blind tags to
be installed.
Tyvek overalls to prevent
the resin contact with
skin. Each time a person
comes out of the vessel,
the overalls are disposed
off and new overalls worn
for the next entry (Resp :
CR-
Asia).
S Earth all electrical supply
connections. All earthing
connections on converter
top to be through ELCB
(Resp : EAPCL).
M
Secure hoses, etc. on
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4 Entry into vessel to
remove catalyst and/
or converter internals.
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Heat stress – accessing
and settingup
equipment
Hoses/equipment
falling from height
Fall while accessing
vessel and moving.
LEL situation in (and
on top of vessel)
outside of vessel
walkways/scaffolding.
Ensure hose joints are
clamped and tied
M securely to handrails.
(Resp : CR- Asia)
Rest cycle as required.
(Resp: CR-Asia) Sufficient
H supply of potable water
and soft drinks on
converter top. (Resp :
EAPCL)
Hoses/leads on top of
vessel to be neatly coiled.
(Resp : CR-Asia).
Toe boards to be
provided on scaffolding.
And scaffolding to be
certified (Resp : EAPCL)
Equipment to access top of
vessel via crane as per
EAPCL mechanical
procedure. (Resp : EAPCL)
Barricade around vessel to
prevent unauthorized entry
– to remain in place for
duration of project. (Resp
: EAPCL)
Area to be barricaded to be
decided by EAPCL and CR-
Asia.
S Person entering vessel to be
secured to “grip tech” fall
protection equipment when
entering vessel and moving
within the vessel (vertical
entry). In addition to this,
life line also to be provided.
(Resp : CR-Asia)
S
Confined space entry
permit system to be adhere
to – continuous
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atmospheric monitoring of
atmosphere in and on top
of vessel. (Resp : CR-Asia)

Breathing apparatus to be
worn by personnel entering
vessel – CR inert
Heat stress procedures reviewed by
M EAPCL and entry
conditions apply. (Resp :
CR-Asia)

Temperature rise.
Standby personnel
H (minimum of 2) on top of
vessel at all times (constant
communication with person
inside) (Resp : CR-Asia)

Ladder swings
Air supply fails.
Rescue of personnel
required from inside
the vessel.
Temperature monitoring by
EAPCL on TDC. If
temperature increases by 9
deg F CR-Asia to be
informed, vessel entry to
be discontinued and
introduction of massive
amount of nitrogen into the
H vessel. For details refer to
the process specification.
(Resp : EAPCL).
S
Secure ladder at the bottom
if needed. (Resp : CR-Asia).
Personnel to vacate the
vessel and EAPCL
supervisor to be informed.
Seconday and tertiary air
supply is, however,
available. (Resp : CR-Asia)
Please refer to the process
specification for details.

EAPCL supervisor to be
informed. The first priority
is to pull him out by using
grip tech fall equipment or
life line. In case this is nt
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possible then the stand

by person to go in and
hook him to the
equipment.
Person to be placed on
stretcher (if required).
(Resp : CR-Asia).
Preference is to use stairs
but if the condition of the
patient doesn’t allow then
use cradle arrangement.
First aid to be administered
and to be taken to the
clinic. (Resp : CR-Asia/
EAPCL).
5 Inspection (under Exposure to hazardous S Disconnect nitrogen. Test
normal atmospheric atmospheric conditions atmospheric conditions
conditions) in vessel inside vessel prior to entry
(monitor all levels of
vessel). Oxygen to be 21%
and LEL to be nil. (Resp :
EAPCL).
Slip/trip M
Person entering vessel to be
secured to grip tech fall
protection equipment when
entering vessel and moving
within the vessel. CR-Asia
to extend their help and
equipment.
6 Load catalyst Dropping catalyst S Ensure containers moved by
loading containers certified crane operator and
(risk of pyrophoric from height rigger. (Resp : EAPCL)
incident in case of pre-
reduced catalyst – need H Ensure barricading in
to use nitrogen Exposure to/inhalation place to prevent
purge/blanket. of catalyst dust unauthorized entry below
However, loading to be vessel. (Resp : EAPCL)
performed under CR-Asia to use their PPE
normal atmospheric while EAPCL personnel
conditions in case of to use dust masks if
unreduced catalyst . around screening area.
Inspection to be done
after displacing nitrogen Personnel loading catalyst
inside the vessel). to wear breathing
apparatus (CR and EAPCL
confined space procedures
to be
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7 Close vessel and
decommissioning of site
8 Disposal of catalyst
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adhered to).
Wrong loading S Load as per EAPCL
sequence loading diagram. Pre-
reduced and unreduced
catalyst drums to be
placed in separate stacks.
H
Temperature Rise Temperature monitoring
(Resp : EAPCL)
Inject massive amount
of nitrogen into the
vessel. (Resp:EAPCL)
O2 and LEL
monitoring. (Resp :
CR-Asia)
Rain entering vessel S Place boards and traps over
manway plus tarpaulin. No
water to enter vessel.
Follow the EAPCL
rain contingency plan.
Slip/trip H All movements to and from
top of vessel to be via
stairs.
Falling equipment from M
top of vessel Barrication to be done at
the bottom. (Resp : EAPCL)
Housekeeping and removal
of unwanted articles from
the converter top.
(Resp : CR-Asia)
Environmental S Waste to be disposed of
contamination as per EAPCL ISO-14001
procedure or
recommended by HSE.
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JSA Format
Page 17 of 16
Date Prepared: May 25, 2006
Date Revised:

Unit: : Task Description:

Zone :
Equipment No. Hazard Score: Requirements:
Developed by: Reviewed by : Approved by:
PPE (Standard):

Special PPEs
Required:
Sr. Task Step Potential Hazard Prob. Control Measures
No. Level

Legend: S=Small probability, M=Medium probability, H=High Probability.