JSP For SS No. 1 Battery Charging and Testing

HAZARD IDENTIFICATION & RISK ASSESSMENT (HIRA)
OHS-PR-09-03-F07 (A) JOB SAFE PROCEDURE
Operating Area: Department:

Project Name:
Contract
Contractor Name: Project Type:
No.:
JOB/TASK TYPE: Battery charging and testing DATE:

JOB SAFETY PROCEDURE
COMPILED BY: DATE:
N0:
Name Designation Signature Name Designation Signature
HIRA
TEAM
Date Signature Date Signature

Reviewed by: Approved by:
: : : :
P.P.E. REQUIRED ☐ Helmet, ☐ Safety Goggles, ☐ Safety Shoes, ☐ Coverall, ☐ Respiratory Musk, ☐ Ear Protection, ☐ Full body Harness, ☐ Hand Protection, ☐ Arc Flash Protection,
FOR TASK: ☐ Others To be Specify: __________________________, ☐ Others To be Specify: __________________________
JOB SAFE PROCEDURE ANALYSIS
LIST ALL STEPS IN PERFORMING HAZARDS DANGER / RISK
STEP PREVENTATIVE CONTROLS REQUIRED TO MINIMIZE /
THIS TASK IN EACH STEP, WHAT COULD CAUSE INJURY, LOSS, (INJURIES, DAMAGE, ILLNESS,
No. DAMAGE INTERRUPTION, OR POLLUTION? POLLUTION, ETC)
ELIMINATE HAZARD
(IN SEQUENCE)
1. Obtain Permit to Work

1.1. Applying and filling-up permit to  Untrained personnel.  Accident resulting serious  Work permit receiver and issuer must be identified and with an
Work as per the required activity.  Wrong information or details are injury or death to worker appointment letter.
written in the PTW.  Significant property and  Permit Issuer and Receiver must be qualified, trained and
 Other activities may not be cover with appurtenances damage competent.
the PTW.  Loss of production  Work permit system shall be properly implemented as per the SEC
 Significant cost due to 5 Star Safety standard and work permit procedure.
damages  Ensure that all activities and the safety precautions are covered
 Governmental violation with the work permit.
 Environmental complaint  Ensure that all information required in the permit to work is
complete.
 Ensure that specific type of work permit for certain activities is
being used.
OHS Forms Procedure Reference Revision Number Revision Date

Page | 1 JOB SAFE PROCEDURE OHS-PR-09-03-F07 (A) 0 MAY 2021

ELIMINATE HAZARD
(IN SEQUENCE)
1.2. Attaching all the required  Incompetent assigned personnel.  Lack of Supervision  All the involved personnel dealing with all the required documents
documents such as a related  Unidentified or incomplete hazards  Unidentified Hazards shall be qualified, competent and trained.
checklist, risk assessment, and risk information. leading to an Accident.  A safe work practice shall be identified to reduce the possibilities of
method statement and other  Lack of productivity accident/incident.
forms necessary to fulfill the  Ensure that all required supporting documents shall be available as
request. per PTW requirements.
 All the required related documents as identified to be attached in
PTW shall be reviewed and evaluated by issuer and receiver to
ensure that all hazard and risk is identified and complete.
1.3. Verifying the site condition as per  Open areas, protruding sharp objects,  Lack of Supervision  The workplace shall be pre-checked, free from any obstruction and
requirements mentioned in the falling objects limited illuminations  Unidentified Hazards in safe good working condition prior to a combined verification
application of Permit to Work by and other construction hazards may leading to an Accident. visit.
both the Permit Receiver and cause accidents during the  Lack of productivity  All Issuer and receiver must be aware of the hazard present in the
Permit Issuer. verification visit. area and must be familiar with the ingress and egress of the project
 Unfamiliarity with access to the areas. site.
1.4. Issuance of approved Permit to  Untrained personnel.  Lack of Supervision  Permit Issuer and Receiver must be qualified, trained and
Work from Permit Issuer to  Incomplete information on Permit to  Unidentified Hazards competent.
Permit Receiver. work. leading to an Accident.  Permit Issuer shall ensure that the site was visited to ensure that
Lack of productivity workplace hazards and risk are adequately identified and mitigating
measure shall be established.
 Permit Issuer and Receiver shall ensure that all the information
required in the permit to work are reviewed, completed and
signed.
1.5. Verifying the approved Permit to  Inadequate coordination and area  Lack of Supervision  Permit to Work shall be displayed at the worksite
Work by the assigned SEC control protocol.  Unidentified Hazards  Permit Receiver shall not leave the area for the whole duration of
Consultant.  Unauthorized work to be performed leading to an Accident. permit to work.
within a defined location and  Lack of productivity  Work shall not proceed without the presence of approved PTW and
boundary. the Permit Receiver overseeing the activity.
 Permit Receiver shall account all workers under his Permit to Work
before the start of work.
 Work shall not be started until duly approved Permit to Work is
available at the site and that Safety Toolbox meeting was
conducted.
 Ensure all the information required in the permit to work shall be

Page |2 JOB SAFE PROCEDURE OHS-PR-09-03-F07 (A) 0 MAY 2021

ELIMINATE HAZARD
(IN SEQUENCE)
completed, signed and updated by the authorized personnel.
2. Mobilization of manpower, tools, equipment, and materials inside Battery Room
2.1. Perform physical inventory for all  Unsecured tools, equipment &  Materials, tools, and equipment to be used shall be checked by a
the tools, materials, equipment materials qualified, trained and competent person.
 Accident results in physical
and manpower to be used.  Untrained personnel  Materials, tools, and equipment should be maintained in good
injuries.
working condition.
 Property damage.
 Closed supervision by the Engineer, Supervisor or Foreman must be
observed.
 The use of appropriate equipment.
2.2. Lifting and loading of tools and  Unsecured tools, equipment &  Lifting accessories should be checked and inspected.
materials onto trailer bed either materials  Vehicular accident.  Equipment operator must be certified.
manually and/or mechanical  Unstable load  Accident resulting Injury to  Equipment shall have a valid third-party inspection.
handling.  Defective sling belt personnel.  Daily equipment checklist should be conducted and completed by
 Property damage of the certified operator.
adjacent structure or  Materials should be secured properly.
appurtenances.  Provision of certified flagman/banks man.
 Close supervision is required.
2.3. Transporting/shifting of the load  Over speeding  Accident resulting injuries
from the laydown area to site  Uneven surfaces to the operator or driver
activity (substation).  Unsecured tools, equipment & once struck the structure  Observe the speed limit in the area.
materials  Significant property  Mobilization of materials on normal weather condition.
 Unsafe driving damage to adjacent  The permanent lighting system should be working.
 Adverse weather condition structure  First aid kit should be available with adequate quantity of
 Injuries to other personnel medicines.
involved to the activity  Driver must have a valid SAG driving license.
 Damage to property by the
equipment.
2.4. Unloading/carrying of loads going  Unsecured tools, equipment &  Equipment failure during  Materials should be secured properly.
inside the substation. materials operation  Only qualified and trained personnel on the job.
 Unstable and uneven ground surface  Accident resulting injury or  Provision of certified flagman/banks man.
 Fall or drop death to personnel  Lifting accessories should be checked and inspected.
 Sling failure  Significant property  Equipment operator must be certified.
damage  Equipment shall have a valid third-party inspection.
 Vehicular accident or  Closed supervision by the Engineer, Supervisor or Foreman must be

ELIMINATE HAZARD
(IN SEQUENCE)
observed.
collision  The use of appropriate equipment.
 Provision of certified flagman/banks man.
3. Setting and preparation of battery room for desired temperature, ventilation, exhaust system
3.1. Selecting the appropriate and  Accumulation of flammable  Fire Incident.  Provide hydrogen sensor and ensure it is operable.
adequate exhaust ventilation concentration of Hydrogen gas  Lack of Oxygen  The room should always keep clean and dry.
system that provides natural or  Drowsiness  Ensure to maintain required and sufficient room temperature,
mechanical dilution sufficient to lighting, ventilation, and exhaust system as per manufacturers
limit the accumulation of design.
hydrogen gas in air at the  Warning and regulatory signage should be installed inside and
charging site to levels below the outside the battery room.
lower explosive limit of 4.1.  Only non-sparking tools must be used inside the battery room.
 Housekeeping like electrical cables, materials on the floor, the
material arrangement should be observed.
 Only anti-static clothing is allowed inside the battery room.
observed.
3.2. Check and inspect equipment  Equipment failure (alarm and sensor  Poor housekeeping may  Pre checks should be conducted (battery charger installation,
condition such as performance monitoring system is not working) cause injury of a person connections & torque requirement, alarm system, first aid box,
indicator instruments, such as  Accumulation of hazardous/toxic gas due to slip trip and fall emergency eyewash, sensors, and monitoring system).
manometers on hood ducts,  Damage to property  Materials should be kept away from batteries cell surfaces.
should be installed so that the  Fire and explosion,  Indicators instruments must have a valid third-party inspection.
employer and employees can  Accident resulting injury of  First aid kit should be available with adequate quantity of
determine and record, if a person. medicines.
necessary, the performance rate  Appropriate personal protective equipment should be observed.
of the system. Closed supervision by the Engineer, Supervisor or Foreman must be
observed.
3.3. Verify if it has been assembled  Poor housekeeping of tools and  Proper manual handling if  Installation of equipment should follow as per manufacturers
correctly (e.g., fan rotation) and materials not observe could cause design.
according to agreed drawings  Equipment failure injury to a person  The adequate number of fire suppression equipment should be
and plans.  Sharp edges if not installed in a strategic location.
identified and isolated  Appropriate personal protective equipment should be observed.
causes skin laceration and  Closed supervision by the Engineer, Supervisor or Foreman must be
cuts observed.


ELIMINATE HAZARD
(IN SEQUENCE)
 Poor supervision by
engineer or foreman could
cause accidents.
4. Charging the battery
4.1. Before switching on the charger  Incompetent worker  Using an inappropriate  Workers performing the battery charging shall be competent in
or controller, ensure that  Poor supervision tool may cause short doing the job.
shipping vent plugs are removed,  Inappropriate tools circuit, electric shock or  Worker conducting the test and measurement shall wear PPE as
and flame arrestors are installed electrocution to a person required by the manufacturer with arc flash rated clothing.
and damage to property  Only non-sparking tools must be used inside the battery room.
 Inhalation of fumes causes  Any source of naked flames and sparks should be prohibited,
dizziness, irritation of prevented inside the battery room.
throat, passage way,
chronic disease or fatality
 Equipment failure will
result to fire and
explosion.
4.2. Using external constant voltage  Overcharging  Electrocution.  Workers performing the battery charging shall be competent in
charger, charge at a constant  Equipment failure  Fire Incident. doing the job.
voltage of 2.40 VPC at 77°F,  Asset loss.  Regular document review and verification should be done.
corrected for temperature, for a  SEC required full supervision by the Commissioning Engineer at all
minimum of 48hrs. Current times while activity is ongoing.
should be limited to 0.14C.  Interval battery test and measurement shall be done as per the
manufacturer’s recommendation.
 Check all wiring and connection of battery charger and make sure
all are intact and properly secured.
 Special personal protective equipment must be observed like anti-
static clothing, rubber gloves, respiratory equipment, clear goggles
and etc.
 Ensure no power interruption during the whole operation.
 Supervising Engineer and Foreman shall ensure that workers
performing the job are competent and certified by the
manufacturer.
 Ensure to maintain required and sufficient room temperature,
lighting, ventilation, and exhaust system as per manufacturers


ELIMINATE HAZARD
(IN SEQUENCE)
design.
 Closed supervision by the commissioning engineer, supervisor or
foreman must be observed at all time while charging is ongoing.
4.3. End-of-charge is when all cell  Incompetent worker  Poor housekeeping may  Workers involve shall be trained by the battery manufacturer or
voltages and electrolyte specific  Equipment failure cause injury of a person vendor and certified to conduct charging and discharging.
gravities (corrected to 25°C)  Accumulation of hazardous/toxic gas due to slip trip and fall  Workers performing the battery charging shall be competent in
cease to rise for three  Damage to property doing the job.
consecutive hourly readings.  Fire and explosion,  Regular document review and verification should be done.
Continue charging until the  Accident resulting injury of  Supervising Engineer and Foreman shall ensure that workers
specific gravity of electrolyte for a person. performing the job are competent and certified by the
all cells rise to nominal specific manufacturer.
gravity at maximum level. Add  SEC required full supervision by the Commissioning Engineer at all
fluid if cells did not reach the times while activity is ongoing.
maximum level. Allow an  All equipment should have an emergency stop button.
additional 6 hours of charge for  First aid kit should be available with adequate quantity of
stirring of the electrolyte. medicines.
 Limit the duration of stay of personnel inside the battery room.
 Ensure fire suppression equipment is working and readily available
in a strategic location at all time.
 Ensure to maintain required and sufficient room temperature,
lighting, ventilation, and exhaust system as per manufacturers
design.
 Frequent rotation of workers.
 Battery charging shall not be allowed without the presence and
supervision of commissioning engineer.
5. Battery testing
5.1. Perform visual inspection and  Untrained personnel  Using inappropriate tools  Only certified and competent personnel will engage in the job.
looks for cracks, leaks, and could cause short circuit  Check visually the physical appearance of the battery case for any
corrosion. and equipment failure signs of bulging, spillage before allowing anyone to touch or open.
 Wearing inadequate PPE  Close supervision by Engineer or Foreman should be observed.
may cause physical injuries
 Mobilizing untrained
personnel could cause
accidents


ELIMINATE HAZARD
(IN SEQUENCE)
5.2. Verify that the battery has had a  Untrained personnel  Using inappropriate tools  Only certified and competent personnel will engage in the job.
high-rate charge completed  Inappropriate tools could cause short circuit  Regular training should be given to personnel.
more than 1 day and less than 30 and equipment failure  Test the battery as per the manufacturer’s recommendation.
days before the start of the test.  Wearing inadequate PPE  Close supervision by Engineer or Foreman should be observed.
may cause physical injuries
accidents
5.3. Perform the capacity testing by  Inappropriate tools  Using inappropriate tools  Only certified and competent personnel will engage in the job.
disconnect the charging source,  Inadequate PPE could cause short circuit  Test the battery as per the manufacturer’s recommendation.
connect the load to the battery, and equipment failure  Observe the “use the right tool” rule.
start the timing, and continue to  Wearing inadequate PPE  Check for air concentration inside the battery room before allowing
maintain the selected discharge may cause physical injuries personnel to enter.
rate.  Provide an adequate and safe standing platform to reach the
battery for specific gravity and another testing to be conducted.
 Close supervision by Engineer or Foreman should be observed.
5.4. Read and record the float voltage  Untrained personnel  Mobilizing untrained  Only certified and competent personnel will engage in the job.
of each cell just before and at  Inappropriate tools personnel could cause  Use approves and appropriate testing equipment.
the completion of the test. accidents  Check for air concentration inside the battery room before allowing
 Using inappropriate tools personnel to enter.
could cause short circuit  Appropriate personal protective equipment should be observed
and equipment failure like coverall, hand gloves, eye protection, and etc.
 Close supervision by Engineer or Foreman should be observed.
5.5. Read and record the  Untrained personnel  Using inappropriate tools  Only certified and competent personnel will engage in the job.
temperature of the battery  Inappropriate tools could cause short circuit  Check for air concentration inside the battery room before allowing
electrolyte to determine an  Poor supervision and equipment failure personnel to enter.
average temperature (every  Wearing inadequate PPE  Appropriate personal protective equipment should be observed
tenth cell is suggested). may cause physical like coverall, hand gloves, eye protection, and etc.
injuries.  Close supervision by Engineer or Foreman should be observed.
accidents
6. Mobilization, setting and preparation of load bank / disconnecting, demobilization of testing equipment load bank
6.1. Using the right battery charger is  Inappropriate tools  Proper manual handling if  The only trained worker should do the job.


ELIMINATE HAZARD
(IN SEQUENCE)
the first step in protecting and  Poor supervision / untrained not observe could cause  Observe the “use the right tool” rule.
maintaining your expensive deep personnel injury to a person  Observe proper posture and natural working position.
cycle battery bank.  Sharp edges if not  Appropriate personal protective equipment should be observed
identified and isolated like coverall, hand gloves, eye protection, and etc.
cuts observed.
cause accidents
6.2. The battery charger should be  Poor supervision / untrained  Poor supervision by  Follow the battery as per the manufacturer’s recommendation.
switched off or disconnected personnel engineer or foreman could  Work should be done in a timely manner.
from its power supply before cause accidents  Appropriate personal protective equipment should be observed
making a connection with like coverall, hand gloves, eye protection, and etc.
battery cables for battery  Observe proper posture and natural working position.
charging.  Closed supervision by the Engineer, Supervisor or Foreman must be
observed.
6.3. Check that the polarities of  Poor supervision / untrained  Proper manual handling if  The only trained worker should do the job.
terminals of the battery and the personnel not observe could cause  Work should be done in a timely manner.
battery charger are correct  Inappropriate tools injury to a person  Observe the “use the right tool” rule.
before connecting the two for  Sharp edges if not  Appropriate personal protective equipment should be observed
charging. identified and isolated like coverall, hand gloves, eye protection, and etc.
cuts. observed.
cause accidents
6.4. Disconnect battery cables after  Poor supervision / untrained  Poor supervision by  Only a trained worker should do the job.
battery charging. personnel engineer or foreman  Appropriate personal protective equipment should be observed
could cause accidents. like coverall, hand gloves, eye protection, and etc.
observed.
7. Housekeeping (clearing the work area)
7.1. Prior to housekeep, wearing  Inadequate PPE  Wearing an inadequate  Install appropriate notices and signage.
personal protective PPE may cause skin  Special personal protective equipment must be observed like

ELIMINATE HAZARD
(IN SEQUENCE)
equipment such as safety irritation coverall clothing, rubber gloves, respiratory equipment, clear
gloves and mask must be goggles and etc.
fulfilled by the personnel  Close supervision by the Engineer, Supervisor or Foreman
involved. must observe.
7.2. Removal of tools, equipment,  Presence of sharp edges  Tools and materials if not  Appropriate personal protective equipment should be observed
and other excesses/ unused  Poor supervision / untrained properly arranged could like coverall, hand gloves, eye protection, and etc.
materials manually. personnel cause slip trip and fall  Tools and other materials should be properly arranged/ removed
which results to injury of a inside the battery room if not in use.
person.  First aid kit should be available with adequate quantity of
medicines.
 A spill kit should be available in the area.
 Close supervision by the Engineer, Supervisor or Foreman must
observe.
7.3. Disposing of waste to dedicated  Tools and materials scattered on the  Waste materials if not  Proper disposal and segregation of waste / used materials.
waste bin/container. floor properly segregated and  Provision of an appropriate waste container in the area.
disposed could cause  Close supervision by the Engineer, Supervisor or Foreman must
environmental observe.
contamination
7.4. Sweeping and cleaning the area.  Inadequate PPE  Tools and materials if not  Appropriate personal protective equipment should be observed
 Presence of waste material properly arranged could like coverall, hand gloves, eye protection, and etc.
 Inappropriate tools cause slip trip and fall  Observe the “use the right tool” rule.
which results to injury of a  Close supervision by the Engineer, Supervisor or Foreman must
person observe.
 Wearing an inadequate
PPE may cause skin
irritation
 Waste materials if not
properly segregated and
disposed could cause
environmental
contamination.
8. Closing of Permit to Work


ELIMINATE HAZARD
(IN SEQUENCE)
8.1. Returning of the Permit to Work
to Permit Issuer for closing.
8.2. Verifying the site condition as per  Poor housekeeping  Significant property and  Permit Receiver shall ensure that housekeeping is done before,
requirements mentioned in the  Undisposed waste materials appurtenances damage during and after the work.
closing of Permit to Work by  Unaccounted workers  Governmental violation  All waste materials generated from the work shall be properly
both the Permit Issuer and  Unsecured electrical equipment  Environmental complaint disposed and shall not be left unattended at the worksite.
Permit Receiver. /energized equipment  Loss of production  Electrical equipment shall be properly secured, distribution board
 Poor storage of chemical, flammable  Accident resulting serious closed and padlocked
and combustible materials and etc. injury or death to worker  All materials used at the site such as chemicals, flammable and
 Unattended unsafe condition  Significant cost due to combustible materials shall be stored at the designated storage at
 Unfamiliarity with access to the areas damages. the end of each day
and the present construction hazard.  Mobile equipment shall properly park on a designated equipment
laydown.
 Ensure that all workers are accounted and there was no
incident/accident occurred which is not reported
 All Issuer and receiver must be aware of the hazard present in the
area and must be familiar with the ingress and egress of the project
site.
8.3. Signing/clearing of the Permit to  Inadequate communication  Accident resulting serious  Work permit issuer and receiver must be qualified, trained and
Work by the Permit Issuer upon  Untrained personnel injury or death to worker competent.
verification of site condition and  Proper communication should be observed.
satisfactorily comply with the
requirements mentioned.
8.4. Keeping and recording of the
completed and signed Permit to
Work by ensuring that the permit
to work register is duly
accomplished.

P a g e | 10 JOB SAFE PROCEDURE OHS-PR-09-03-F07 (A) 0 MAY 2021

ELIMINATE HAZARD
(IN SEQUENCE)

P a g e | 11 JOB SAFE PROCEDURE OHS-PR-09-03-F07 (A) 0 MAY 2021

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HAZARD IDENTIFICATION & RISK ASSESSMENT (HIRA)

OHS-PR-09-03-F07 (A) JOB SAFE PROCEDURE

Operating Area: Department:

JOB/TASK TYPE: Battery charging and testing DATE:

Date Signature Date Signature

1. Obtain Permit to Work

OHS Forms Procedure Reference Revision Number Revision Date

LIST ALL STEPS IN PERFORMING HAZARDS DANGER / RISK

OHS Forms Procedure Reference Revision Number Revision Date

LIST ALL STEPS IN PERFORMING HAZARDS DANGER / RISK

LIST ALL STEPS IN PERFORMING HAZARDS DANGER / RISK

OHS Forms Procedure Reference Revision Number Revision Date

LIST ALL STEPS IN PERFORMING HAZARDS DANGER / RISK

OHS Forms Procedure Reference Revision Number Revision Date

LIST ALL STEPS IN PERFORMING HAZARDS DANGER / RISK

OHS Forms Procedure Reference Revision Number Revision Date

LIST ALL STEPS IN PERFORMING HAZARDS DANGER / RISK

OHS Forms Procedure Reference Revision Number Revision Date

LIST ALL STEPS IN PERFORMING HAZARDS DANGER / RISK

LIST ALL STEPS IN PERFORMING HAZARDS DANGER / RISK

OHS Forms Procedure Reference Revision Number Revision Date

LIST ALL STEPS IN PERFORMING HAZARDS DANGER / RISK

OHS Forms Procedure Reference Revision Number Revision Date

LIST ALL STEPS IN PERFORMING HAZARDS DANGER / RISK

OHS Forms Procedure Reference Revision Number Revision Date

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