JSA Form PDF

Classification: Tasnee - General Information JSA FORM 51 Classification: Tasnee - General Information JSA FORM 52  Classification: Tasnee - General Information What to do bef...

Classification: Tasnee - General Information JSA FORM 51 Classification: Tasnee - General Information JSA FORM 52  Classification: Tasnee - General Information What to do before issuing work permit? ❑ All process and non process equipment to be worked on shall be made safe before the work permit is issued. ❑ Issuer shall ensure that the following are completed before the permit issued: Safe Making ❑ The equipment to be worked on shall be positively identify ❑ Identify potential hazards and take precautionary action to control / mitigate / eliminate the hazard. ❑ Isolate the energy sources. ❑ Isolate the Process from the equipment. ❑ Prepare the equipment itself for safe working on it. 53  Classification: Tasnee - General Information What To Do In Order To Achieve Safe Making? ❑ All process and non process equipment to be worked on shall be made safe before the work permit is issued. Safe Making ❑ All process equipment to be worked on must be positively identified by tagging prior to the start the work as follows: ❑ All required information must be written on the tag, equipment number, name, date and signature of safe maker. ❑ It is not allowed to display a general tag on equipment for work to be performed. ❑ Tags can be attached to equipment by any appropriate means suitable for the application. ❑ Tags must be placed in a clearly visible position. ❑ After completion of all task, it is the responsibility of the Safe maker (area operator) to remove the tags after work completion. ❑ No Tagging required: ❑ If it is not connected to process equipment ❑ Zero checks on transmitters ❑ MPI and wall thickness tests ❑ X-rays 54  Classification: Tasnee - General Information Energy Isolation ❑ Energy Isolation including: ❑ Electrical Isolation. ❑ Process Isolation. Safe Making ❑ Mechanical Isolation. ❑ Electrical Isolation. ❑ Before deenergizing, the equipment shall be off condition. ❑ Equipment tag information shall be matching with the Master Tag List. ❑ “Bump Test” shall be done to ensure equipment cannot be restarted. ❑ Low Voltage to be isolated by qualified and trained Operations representative. ❑ Medium and High Voltage to be isolated by qualified and trained Electrical Technician. ❑ Energy isolation form to be completed for each discipline. ❑ Process Isolation including the following categories: ❑ Positive Isolation by means of Installing Rated Blind or Disconnecting Pipe ( for Hot Work and/or Confide Space Entry ) ❑ Proved Isolation by Double Block & Bleed isolation method ( for Cold Work only) ❑ Isolation process Isolated by Single Valve & Bleed for Cold Work in very limited cases where prove isolation is not possible 55  Classification: Tasnee - General Information Energy Isolation ❑ Mechanical Isolation including physical restraining movement due to its weight, stored energy or affect of wind circulation even after power is isolated. Safe Making ❑ Rotating equipment, where available, shall be positively stopped (pinned, locked or equivalent) ❑ Some methods are used disconnecting belts, chain drives and mechanical links on shaft driven equipment’s, ❑ Disconnect mechanical drivers, shafts, secure mechanical parts, disconnect steam heat tracing, ❑ Pressurized actuators, fail open/ fail closed valves in accumulators and rundown tanks are considered mechanical isolation. ❑ Equipment / system isolation requirements any isolated equipment / system shall contain all and/or the following: ❑ Master Tag list that prepared and verified by shift supervisor for listing and identifying all locked valves and/or locked electrical source. ❑ Master blind list that prepared by area staff of operations, Approved by Area Owner for listing and identifying all blinds and pipe disconnection. ❑ Marked-up P&ID 56  Classification: Tasnee - General Information Process Isolation ❑ Process Isolation including the following categories: ❑ Positive Isolation Safe Making ❑ Process Isolated by Installing Rated Blind or Disconnecting Pipe. ❑ Considered as process isolation for Hot Work and/or Confide Space Entry. ❑ To verify that the isolation valves are holding, Bleeder must show no leakage. ❑ All valves shall be locked and tagged with a “Danger - Do Not Operate” tag. 57  Classification: Tasnee - General Information Process Isolation ❑ Process Isolation including the following categories: ❑ Proved Isolation ❑ Process Isolated by Double Block & Bleed method is Considered as Safe Making process isolation for Cold Work only. ❑ Double Block & Bleed method is closing of two positives shut off valves and opening a bleed (vent/drain) valve in between. ❑ The theory behind this method is that if the first isolation valve fails, the material in the line would discharge through the bleed valve and not into the work area. ❑ In some cases, valves used for a double block and bleed may be remotely or automatically operated. ❑ In some cases, the energy supply (air, electricity, etc.) shall be disconnected and the position of the valve shall be assured by a spring, pin or other locking device. ❑ Isolation valves shall verify are properly holding and Bleeders must show no leakage. ❑ All valves shall be locked and tagged with a “Danger - Do Not Operate” tag. ❑ Safe maker shall visit the area frequently to check and ensure the isolation integrity. 58  Classification: Tasnee - General Information Process Isolation ❑ Process Isolation including the following categories: ❑ Isolation ❑ Process Isolated by Single Valve & Bleed is Considered for Cold Work in Safe Making very limited cases where provision of Double Block & Bleed not available at asset and with satisfying protection and mitigation condition. ❑ Single valve with bleed method limited to be used for non-hazardous materiel (such as LP water, LP air, LP N2, etc.). ❑ In-case hazardous materiel involved and required to use this method then area owner approval is required. ❑ Single valve with Bleed limited as isolation for Cold Work activities ❑ Isolation valves shall properly hold, and Bleeder(s) must show no leakage. ❑ All valves shall be locked and tagged with a “Danger - Do Not Operate” tag. ❑ Safe maker shall visit the area frequently to check and ensure the isolation integrity and no hazards in the area. ❑ Repair jobs on equipment shall continue without interruption and without the technician leaving the equipment. 59  Classification: Tasnee - General Information Blinding Guidelines ❑ The blind handle shall extend out several (3 inches) beyond the outside diameter of the flanges and serves as an indicator that a blind is in place to install the blind tag number. ❑ Blind shall be seen from ground level if it is on pipe rack or high elevation. Safe Making ❑ For single activity yellow strip shall be tie to blind location to be visible from any distance and red strip for more than one activity. ❑ Orifice flanges may be used for blinding, but the following actions shall be taken to ensure orifice plates are not mistaken for blinds: ❑ Highlight on the blind list the fact that a blind has been installed in an orifice flange. ❑ The orifice plate should be hung on the flange from which it is removed, or nearby to verify its removal. ❑ Blind tag number shall be reflected in Master blind list ❑ Maintenance review shall be obtained for correct size, gasket type, pressure class and bolts before installation. ❑ Maintenance and Operation shall verify the blind(s) are installed as per the Master blind list 60 and then signs.  Classification: Tasnee - General Information LOTO Safe Making 61  Classification: Tasnee - General Information Energy Isolation Form Safe Making 62  Classification: Tasnee - General Information Master Blind List MASTER BLIND LIST Plant Area Equipment Number Equipment Description Purpose Of Isolation 1) No scratch or change on this form is allowed & no changes to the form design & content is allowed. 2) Confirmation of installation & removal shall be filled & signed by the person who physically implemented it in the field. 3) Shortcuts: RB: Rated Blind. DL: Disconnect line. P/C: Plugged/Capped Isolation Box Number: Issuer Lock Number Maintenance Operation Safe Making Method Blind Tag Confirmation for correct size, gasket type, pressure class, bolts SN P&ID Number Line Number Size Description Installation Confirmation Removal Confirmation Number & installation RB DL P/C Name Date Time Signature Name Date Time Signature Name Date Time Signature 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Prepared by (Area Staff) Area Owner Remarks (if any): Final Installation acceptance (Operation Supervisor) Final Removal acceptance (Operation Supervisor) Name Date Signature Name Date Signature Name Date Signature Area Owner Approval Name Date Signature Long Term isolation exceeding 30 days from initial date of implementation 1st quarter 2nd quarter 3rd quarter 4th quarter 1st quarter 2nd quarter 3rd quarter 4th quarter Area Owner Area Owner Area Owner Area Owner Area Owner Area Owner Area Owner Area Owner I declare that the equipment that has been blinded well maintained under my control and audited regularly in Date Date Date Date Date Date Date Date quarterly basis confirming the equipment conditions are not changed Area Owner Approval Initial /Signature Initial /Signature Initial /Signature Initial /Signature Initial /Signature Initial /Signature Initial /Signature Initial /Signature Name Date Signature 63  Classification: Tasnee - General Information Blind list marked up P&IDs Safe Making 64  Classification: Tasnee - General Information Master Tag List Safe Making 65  Classification: Tasnee - General Information Tag list marked up P&IDs Safe Making 66  Classification: Tasnee - General Information Confined Space Outlines Confined Spaces outlines: ❑ Confined space categories. ❑ Confined Space Entry Package and preparation ❑ Confined space hazard identification: ❑ confined Space Entry preparation ❑ Ventilation Requirements and gas testing for Confined Space. ❑ Rescue plan Preparation and requirements for confined Space Entry. ❑ Safe Access and Exists for confined Space. ❑ Condition Changes during confined Space Entry Permit. ❑ Work inside confined Space. Factors Contributing to Confined Space injuries: ❑ Failure to recognize confined spaces ❑ Underestimating the danger ❑ Unspecialized people attempt to rescue their colleagues. 67 67  Classification: Tasnee - General Information ❑ Confined space categories. Confined Space Requirements ❑ “A” Category Confined Space Authorization: Confined space where it is possible for hazardous substances to be present and permanent breathing apparatus shall be worn during the execution of the task. ❑ “B” Category Confined Space Entry Authorization: Confined space where there are no hazardous substances or where the environment can and has been made safe and can be kept safe during execution of the task. ❑ Confined Space Entry Package and preparation: ❑ JSA. ❑ Ventilation plan. ❑ Master blind list & marked up P&IDs ❑ Master tag list & marked up P&IDs ❑ Energy isolation form. ❑ Lifting plan. ❑ Excavation request certificate. ❑ Fire interruption / isolation form ❑ Rescue plan 68 68  Classification: Tasnee - General Information ❑ Confined space hazard identification: Confined Space Requirements shall be recognized by posting sign boards stating the confined space condition as follows: ❑ “Oxygen Deficient atmosphere”. ❑ “DANGER CONFINED SPACE – ENTER BY PERMIT ONLY”. ❑ DANGER Nitrogen / Inert Gas Purge in Progress”. 69 69  Classification: Tasnee - General Information ❑ Confined Space Entry preparation ❑ Free of dangerous chemical substances / liquid As far as practically possible for “A” Confined Space Requirements category and mandatory for “B” category ❑ Energy isolation in terms of: ❑ Electrical Isolation for energy sources of all driven equipment as well as Lockout/Tagout process. ❑ Positive Isolation by installing rated blind / disconnecting line. ❑ Process or utility lines entering or leaving the equipment / unit must be positively isolated at the nearest location to working asset ❑ Radiation sources removed / isolated. ❑ No process material remains. ❑ Sewer openings in immediate area shall be covered. ❑ Air shall be tested, and Ventilation shall be provided. ❑ Communication systems shall be available. 70 70  Classification: Tasnee - General Information Confined Space Requirements ❑ Ventilation Requirements and gas testing for Confined Space. ❑ Oxygen content between 19.5% to 22.0%. ❑ Flammable gases and vapors (LEL) below 5%. ❑ Potential toxic air contaminants in terms of CO and NH3 maximum allowable concentration is 25 PPM. ❑ Wet bulb globe temperature ≤ 35°C or Ambient Temp ≤ 46 °C as maximum. ❑ Atmospheric temperature according to the Weather Condition Health & Safety Advisory reported by TASNEE clinic. ❑ Depending on the situation, type of ventilation shall be selected ( natural draft, use of fans, or air movers or air conditioning systems ) ❑ Pure Oxygen shall not be used to ventilate confined spaces. ❑ Plant air shall not be used to ventilate unless it is used for pull out ventilation. ❑ Air movers shall be listed for the area electrical classification and grounded to prevent the accumulation and discharge of static electricity. Please note that : All confined spaces must be considered “A” category until tested and verified as a “B” category. 71 71  Classification: Tasnee - General Information Confined Space Requirements ❑ Ventilation Requirements for Confined Space. ❑ For horizontal exchanger which are opened from both ends during the confined space entry, ventilation plan is not required. ❑ Do Not use Nitrogen to ventilate confined spaces, as this could lead to oxygen enrichment/deficiency of the space. ❑ Only pneumatic driven blower, fans and air movers are allowed to ventilate the confined spaces. ❑ Fans and air movers shall be ensured that it is electrically bonded and grounded to the vessel. ❑ Air conditioners can be installed as an alternate of ventilation wherever it is convenient. Air Conditioners capacity will be used to identify the ventilation rate required. However, in case of use of Air Conditioners for ventilation, Air Movers shall be kept ready to use in case of Air Conditioners shutdown or any emergency. ❑ A positive means of ventilating confined space shall be established and kept operated the entire time while work is in progress. ❑ Following tips shall be considered for ventilation: ❑ Positioning of mechanical aspirators, drawing of fresh air, routing of exhaust air. ❑ Ventilation plan shall be prepared and approved as per IMRS 13-02-01-23 Ventilation plan. ❑ Ventilation of a space will also vary depending on the type of material that is being ventilated from the space. 72 72  Classification: Tasnee - General Information ❑ Rescue plan Preparation and requirements for confined Space Entry. Confined Space Requirements If hazard cannot be mitigated, then Rescue shall be prepared prior to entry. ❑ When required ? ❑ Rescue Plan is mandatory for all Confined Space entry types. ❑ Rescue Plan shall consider the following: ❑ The hazards outcome of the JSA. ❑ The location of the work. ❑ Number of workers, even if there will be only single worker. ❑ The duration and period the of work. ❑ The resources needed for the rescue and the number of people required. ❑ Internal Configuration ❑ Elevation ❑ Manway Size ❑ Confined Space Access 73  Classification: Tasnee - General Information ❑ It is important to consider the following conditions when planning for a confined space entry work. ❑ Internal Configuration: Confined Space Requirements ❑ Confined space contains some type of obstruction that a rescuer would need to maneuver. For example, a baffle or mixing blade, large equipment, such as a ladder or scaffold, brought into the confined space for work purposes would be considered an obstruction if the positioning or size of the equipment would make the rescue difficult. ❑ Elevation: ❑ Elevated a confined space entry where the entrance or opening is above ground by 4 feet or more. This type of confined space usually requires knowledge of high angle rescue procedures because of the difficulty in packaging and transporting a victim to the ground from the confined space. ❑ Non-elevated a confined space entry with the entrance located less than 4 feet above ground. This type of space will allow the rescue team to transport an injured worker normally. ❑ Manway Size: ❑ Restricted a Manway of 24 inches or less in the smallest dimension. Manways of this size are too small to allow a rescuer to simply enter the space while using SCBA. The Manway size is also too small to allow normal spinal immobilization of an injured worker. ❑ Unrestricted A Manway of greater than 24 inches in the smallest dimension. These Manway allow relatively free movement into and out of the confined space. ❑ Confined Space Access: ❑ Horizontal the Manway is located on the side of the confined space Use of retrieval lines could be difficult. ❑ Vertical the Manway is located on the top or bottom of the confined space. Rescuers must climb down or up the permit space respectively to enter it. Vertical portals may require knowledge of rope techniques, or special patient packaging to safely retrieve a downed entrant. 74  Classification: Tasnee - General Information ❑ Rescue plan Preparation and requirements for confined Space Entry. ❑ All confined Space Entry shall have a developed Rescue plan as per the method (using Rescue plan form) how to enter, exit, escape, and rescue personnel working in Confined Space Requirements confined spaces it shall be done during the job planning phase and before confined entry Permit issuing. ❑ Confined spaces on a site visit shall be assessed to determine what special equipment or procedures may be involved when conducting a rescue operation ❑ Rescue Plan shall be prepared by task execution Supervisor or above from Tasnee team and contractor. ❑ Familiarize all execution team with the approved rescue plan before starting the activity. ❑ Provision of Rescue Equipment: ❑ Rescue Equipment shall be suitable and sufficient to respond to an emergency in a timely and safe manner. for example, rescue equipment may include: ❑ Full body harness with retrieval line attached. ❑ Hand-cranked mechanical winch and tripod (required when entrant is five feet or more below the entrance). ❑ Lifeline. ❑ Explosion-proof lighting. ❑ Breathing apparatus. ❑ Stretcher. ❑ Based on the type of the confined spaces entry and the condition of the work and location rescue plan need to be devolved. 75