JSA for Tank Modification and Repair Service

1. Site Preparation

A. Hazards

• Poor communication between work parties.
• Inexperience persons/lack of safety awareness
• Heat stress
• Noise
• Vehicles Movement

B. Control Measures                                            

• Work permit from the client, with all concurring party’s signatures approval, must be obtained before the start of work and displayed at the site
• Safety requirements mentioned in the permit to work (PTW) must be available on-site and strictly followed
• Toolbox talk shall be conducted with all personnel on-site & documented before the start of work.
• Appropriate PPE shall be worn by all personnel at the site.
• Assigned trained dedicated Banks man for the job with a reflective jacket.
• Enough availability of water should be there.
• Work Schedule according to Heat Index
• Ear protection shall be worn where required.
• Noise meter will be made available at the site.
• Maintenance of equipment regularly.
• Use of Approved/Trained licensed drivers.
• banks man must be always available for vehicle movement control.
• Appropriate signage to be provided.
• Scaffolding erection dismantling and modification work including inside Tanks

2. Transportation of material/shifting of scaffolding by Using Crane, Trailer, Boom Truck Pickup, etc.

A. Hazards

• Failure of equipment/crane /Trailer/ Pickup/Truck etc.
• Road vehicle traffic accident during transportation of Tanks shell plates, pipe spools/ supports, and other material and or objects.
• Body part injury during
• Loading and unloading operation
• Pinch point.

B. Control Measures

• Conduct toolbox talk and MOL before the start of work at the specific location.
• Ensure the condition of equipment, is inspected, sticker Placed, and for appropriate color cod
• All rigging gear shall be certified.
• Fabricated belts or nylon slings shall be used instead of steel wire rope for holding material.
• Make sure that crane operators and riggers are competent and fully understand all work tasks and hazards. 
  
• The load shall be secured on the trailer bed to prevent accidental falls.
• Crane operator shall have the third party, certified, competent, experienced, and applicable license.
• Use appropriate tagline during loading /offloading material or other heavy objects.
• The access route shall be properly surveyed before transporting the Shell Plates, pipes & support material, or other objects, etc.
• Barricade with an appropriate signboard on the effective area.
• Riggers shall be experienced and the third party certified.
• Use leather gloves for hand protection.
• Always Keep away parts of the body (hand, feet, head, etc.) from the line of fire.
• The appropriate length of the trailer shall be arranged according to the length of Shell Plates, pipe spools, material, supports, etc.

3. Scaffolding Erection Dismantling Including Material Storage

A. Hazards

• Simons
• Segregation and Stacking Failure
• Incorrect Manual Handling
• Pinch point  
• Eye injury
• Fire
• Slips, Trips, and Falls
• Lack of proper and enough knowledge by scaffolders regards correct erection and Safe Working Load (SWL), wind speeds, scaffold ties incorrect, etc.
• Incorrect or no supervision at the worksite
• Not up to standard. Do not conform to BS
• Not inspected leading to failure. Not sufficient for the purpose or task
• Injury to worker/employee through incorrect mechanical or improper manual handling.
• Musculoskeletal damage, dropped objects, pinch points.
• Lack of competence
• Dropped objects
• Working overhead.
• People entering the danger zone
• Dropped tools, work carried out incorrectly
• Lack of experience.
• The incorrect sequence of work
• Incorrect Couplers were used.
• Lack of training in manual handling techniques
• Incorrect Couplers were used.
• Lack of training in manual handling techniques
• Falls through access openings placed centrally without handrails
• Incorrect erection procedure
• Does not meet and Safe Working Load (SWL) or there is a potential for the scaffold to fall over if not tied
• Potential falls of end-users and scaffolders
• The likelihood scaffold will fall over at the early stages of the height-to-base ratio is exceeded or if ties are removed
• The scaffold has a high potential to fall over
• Scaffold falling over and or collapse causing serious injury or asset damage
• No design.
• No competent person.
• Lack of supervision
• No experience.
• Use of two systems.
• Use of incompatible material.
• Supporting structure inadequate.
• Use of inferior materials
• Potential falls of scaffolders and end-users
• Not fit for purpose
• Incorrect couplers were used.
• Lack of training in manual techniques.
• Incorrect erection procedure.
• The likelihood that the scaffold will fall over at an early stage.
• Not fit for purpose Incorrect couplers used.
• Lack of training in manual handling techniques
• Joints in the same bay.

B. Control Measures

• Conduct ‘TBT’ before the start of the activity.  Prepare, develop, and conduct toolbox talks based on JSA and specific job site requirements Obtain PTW, review, and communicate to all involved in the task.
  
• Participate and communicate with area management to ensure no adverse interface impact or hazard.
• Install correct warning signage and barricading for observation by other parties
• Follow recommended maximum stacking guidelines. 
• All scaffold materials shall be stacked and segregated safely and by type.
• Stacking and storage guidelines shall be prominently signposted in an easy visual display.
• Shelving/racking shall be stable and appropriate; pallets
• When used shall be in good condition without defects.
• Pipes and/or tubular components shall be adequately chocked.
• All scaffold personnel shall have attended and passed the project ‘Manual Handling’ training programs.
• Weight and packaging shall be checked and evaluated before handling. 
• Pinch Pints shall be identified and hands shall not be placed in the ‘Line of Fire’ between unsecured items or under loads being raised or landed.
• Eye protection shall be worn for dust particle injury.
• Eyewash facilities shall be provided and First Aid equipment and personnel shall be available
• Scaffold personnel shall be trained in the use of fire extinguishers and/or other firefighting equipment (blankets, etc.).
• Emergency numbers and fire hazard signage shall be prominently displayed.
• The work areas shall be maintained with good housekeeping. Access ways and Scaffolds are clear and free of obstruction Determine at PTW and Toolbox talk stage what type of scaffold is required (BASIC, ADVANCED, SUPPORT, DESIGN required)
• A supervisor or foreman is present at the work area to oversee the work site.
• Meet all BS/EN requirements. 
• Are inspected before delivery to the site
• All lifting equipment is inspected regularly as per site procedure.
• Manual handling techniques, inspected cranes, forklifts, ancillary equipment, etc.
• Materials to be stored in a safe manner
• Do not stack too high to prevent collapse
• Third-party training.
• Ensure all of the workforce including supervisors, vehicle operators, and other technical staff have enough experience, and theoretical and practical training before commencing the scaffold work.
• Make sure that barricades, multi-language HSE warning signs, warning tape, and flagman (where applicable) are in place before the work commences
• Ensure Gin Wheel areas are barricaded
• Place correct warning signage ‘men working overhead’.
• Adequate Gin Wheel and Lifting bag signage are displayed.
• A flagman was placed preventing entry to a high-risk area.
• PPE hall is worn at all times.
• Tools shall be of the correct type and secured with lanyards at height.
• Competent scaffolders with knowledge of basic scaffolding.
• Ensure the base is adequate to support the scaffold
• Ensure the correct sequence of the erection and that all components meet the BS EN criteria.
• Joints in standards are to be diagonally conflicted or opposed with no more than Two-2 joints per bay.
• Ensure the correct sequence of the erection and that all components meet the BS EN criteria.
• Joints in standards are to be diagonally opposed with no more than 2 joints per bay.
• Ensure the correct sequence of the erection and that all components meet the BS criteria
• Joints in standards are to be diagonally opposed with no more than 2 joints per bay.
• Follow the PRL procedure on scaffolds.
• Always make sure that correct ladder access is placed with ladders at a 75-degree angle or 1 in 4.
• Ensure ties are fixed and are not removed throughout the scaffolds ‘life’.
• Any activity such as the removal of ties should be undertaken by a competent and advanced scaffolder or under the direct supervision of the Foreman.
• Remove the Scaff-Tags, bring workforce/visitors or people off and away from the scaffold
• Full design drawings and calculations are available 
• Scaffolders must be competent with knowledge of Advanced scaffolding competency training and certifications.
• Ensure the existing structure is appropriate to support the suspended scaffold.
• Follow the TG20:2008 and JGC procedure on scaffolds
• Ensure proper fall arrest equipment is used for the specific job e.g. full body safety harness, inertia reel, and has been inspected and in proper working condition.
• Inertia reel to have a valid test certificate and be correctly color-coded.
• Follow BS EN applicable standards, and requirements.
• Lift to be no more than 2 m vertically.
• Ensure the correct sequence of the erection and that all components meet the BS EN criteria.
• Joints in standards are to be diagonally opposed with no more than 2 joints per bay.
• Communication between the scaffolding supervisor and the end-user supervisor to ensure the scaffold is fit for the purpose intended
• Ensure the correct sequence of the erection and that all components meet the BS EN criteria
• Ensure sleeves are used and staggered.
• Joints in various bays at each level of the scaffolding to ensure ‘sound’ construction methods or techniques.

4. Confined Space Entry

A. Hazards

• Lake of Communication
• Ventilation.
• Damage material
• Oxygen deficiency
• Accumulation of toxic gases
• Physical hazards
• Improper stacking of material 
• Unauthorized entrant
• Lack of oxygen /oxygen/ air deficiency

B. Control Measure

• All personnel working in confined spaces must have confined space training.
• PRL confined space procedure shall be followed.  
• The hole watcher is active/attentive all the time during confined space work.
• Lighting provided in CSE to be 24V.
• Effective, easily understandable communication between hole watcher and supervisor is established all the time.
• Proper access/agreement should be maintained.
• Gas test to be done by AGT before entering into the confined area
• A well-trained, competent, and qualified individual should be outside the tank with the accountability of ensuring the safety of authorized work performers (such as Fabricator, Fitter, Welder e.tc) through the performance pre-task entry briefing, checking and inspecting PPE, equipment, and tools and performing regular monitoring ensuring person conducting work activity inside pipe remains safe and secure for entry and occupation.
• A written Emergency situation rescue plan that has provision for carrying out a timely rescue of individuals working inside the pipe (Confined Space) should be kept on site.
• Raising the Fire Alarm (FA) in the event of an emergency situation.
• Using the radio/mobile phones provided to them.
• Make sure that an effective communication system for entry is tested and in place.
• Enough and appropriate required light should be provided less than 25v.
• All material stacks are proper and category-wise.
• Emergency situation Rescue arrangements shall be made while working more than five-meter inside a large bore size.
• HSE Procedure shall be followed.
• Close supervision is required while working inside.
• Carry out the work under close supervision and the presence of a hole watcher. 
• Proper air supplies to be provided or an air mover will be provided.
• Proper ventilation shall be there.
• Working crew shell is trained for confined space work.

5. Protracted/Lengthy Working Hour/Night Works

A. Hazards

• Improper lighting in and around work areas causes shadows or poorly lit work areas that could result in unsafe acts and the possibility of severe and critical injuries.

B. Control Measures

• Inadequate lighting at the work area and Access/Egress area.
• The emergency route to the muster point is to be illuminated.
• Proper cable management
• Use clear safety goggles for night work shift hours for good visibility to avoid any unwanted incidents.
• Warning Lights and signboards.
• Trained Flagman for equipment movement provided with a signal torch.
• Close supervision is needed while working in night shift.

6. Emergency Procedure/Response 

A. Hazards

• Poor Communication
• Improper Access/ Egress

B. Control Measures

• Educate the workforce about Emergency Procedures.
• All safety signboards shall be displayed properly at the site.
• In case of any Emergency, all work will be stopped, Shut down all running equipment & Machinery, and reported to Muster Point 
• Proper Access & Egress shall be available. 
• All Workforce shall have the proper knowledge of the Muster Point location. 
• Emergency Procedure to be followed.
• Emergency # 999/911, etc.

7. Housekeeping

A. Hazards

• Trips and fall
• Sharp Objects
• Equipment damage

B. Control Measures

⦁    All waste generated shall be contained and disposed of in designated waste skips.
⦁    Do not store materials/equipment inside the plant area.
⦁    Use appropriate and essential Personal protective equipment (PPE) for handling of waste. 

 Note: All materials, and wastes or shall be removed from the worksite to a safe storage location ASAP after the work.

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JSA for Tank Modification and Repair Service