Mabar Power Station

Management Document
Risk Assessment & Job Safety Analysis

Document No. PT-MB-O&M-16

Mabar Power Station Management Document

Risk Assessment & Job Safety Analysis

This instru ction will be re viewed and re -issue every 2 -year or whenever necessary. If
there is no a mend men t in the con ten t, only th e co ver page will be re -issued and sent to
the do cu men t co ntrolle rs. New version of th e instruction s will be up loaded to the
Integ rated Info rma tion P latfo rm. The co ver page will list ou t the newest version
nu mber, the da te o f issue and signed b y Orig inator, Checked B y, Co nsented B y,
Approver an d Execu ter.

Version Revised Portion

0 Original

1
 Version Issue Originator Checked Consented Approved By Executed By
Date By By

0 24/01/20 Alex Lo Martin Chen Alex Lo Operations Manager;

17 Chen; Shengbing
Maintenance Manager;
Stephen Su;
General Support Services
Xu Mao Yi; Manager
Loretta Lu
1

Effective DateXX/XX/2017
 C O N T E N T S
******************

1. INTRODUCTION

2. RISK ASSESSMENT

3. PREPARING FOR A JOB SAFETY ANALYSIS (JSA)

4. FORMING A JSA TEAM

5. PERFORMING A JOB SAFETY ANALYSIS

6. APPROVAL OF AND KEEPING RECORD FOR RISK

ASSESSMENTS & JSAs

7. USING A JOB SAFETY ANALYSIS

8. FOLLOW UP ACTIONS FOR THE APPROVED JSAs

9. REVIEW OF RISK ASSESSMENTS AND JSAs

APPENDIX 1 FORM 1 RISK ASSESSMENT FORM

APPENDIX 2 FORM 2 JOB SAFETY ANALYSIS FORM

APPENDIX 3 FLOW CHART FOR CONDUCTING RISK ASSESSMENT

AND JOB SAFETY ANALYSIS (JSA)
1. INTRODUCTION

Both risk assessment and Job Safety Analysis (JSA) are processes to identify
the hazards associated with a job. Normally, risk assessment is done prior to
JSA.

Risk assessment and JSA both looks for all the hazards associated with a job,
not only relating to safety and health of the employees but also to the
environment.

JSA involves listing the basic steps of a job; identifying any existing or potential
hazards associated with each step; assessing the risk level of each step and then,
developing control measures for eliminating or controlling each of those hazards.
Hence, Job Safety Analysis is also known as Job Hazard Analysis (JHA).

2. RISK ASSESSMENT

2.1 CONDUCTING RISK ASSESSMENT FOR VARIOUS JOBS

Section Chief can assign competent persons to carry out risk assessments on
various jobs. The purposes of risk assessment are to estimate the overall risk
levels of a job, develop the required control measures and to decide if JSA
should be conducted.

Competent persons can be supervisors who are trained to carry out risk
assessments. They may use Form 1 - 'Risk Assessment Form' or modify
it appropriately to conduct risk assessments.

2.2 DETERMINATION OF OVERALL RISK LEVELS OF VARIOUS JOBS

FROM RISK ASSESSMENT

A job may involve different hazards. These hazards, when acting together in a
particular situation, may result in a severe consequence. However, to simplify
risk assessments and yet providing adequate protection to the personnel relevant
to the job, the highest risk level of the identified hazards will be used as the
overall risk level of the job. For example, if a job involves 1 'High (H)' risk
hazard and 2 'Moderate (M)' risk hazards, the overall risk level of the job will be
'High (H)'.

Competent persons should determine the risk level of each identified hazard of
a job using the Risk Level Estimator as shown below.
 RISK LEVEL ESTIMATOR: Consequence of the harm
[Superficial (Lacerations; burns; (Amputations;
injuries; minor cuts concussions; serious major fractures;
& bruises; eye sprains; minor permanent
irritation from dust; fractures; deafness; disability;
nuisance and dermatitis; asthma; poisonings; multiple
irritation (e.g. work related upper injuries; fatal
headaches); limb disorders; injuries;
ill-health leading to ill-health leading to occupational
temporary permanent minor cancer; other severe
discomfort] disability.) life shortening
diseases; acute fatal
diseases.)
Slightly Harmful Harmful Extremely Harmful
Highly Unlikely
(So unlikely that Low risk (L) Low risk (L) Moderate risk (M)
probability is close to zero)
Likelihood Unlikely
of Hazards (Rather remote, though Low risk (L) Moderate risk (M) High risk (H)
will Cause conceivable)
harm Likely
(Occurs repeatedly/event Moderate risk (M) High risk (H) High risk (H)
only to be expected)

When assessing the risk level of each identified hazard, it is better to consider that
all the required control measures have been fully implemented for this hazard so
that the overall risk level is the 'residual' risk level of the job.

2.3 DETERMINATION OF FURTHER ACTIONS FROM RISK ASSESSMENT

2.3.1 Action for 'Low' Overall Risk Level

For jobs with a 'Low (L)' overall risk level, the work can commence provided that:

- The competent person considered that the overall risk level is 'acceptable';
and

- The result of the corresponding pre-job risk assessment, if any, as stated in

Pre-Job Risk Assessment is 'acceptable'.

Only when all relevant statutory and in-house requirements are met and the
risk is at, or has been reduced to, the lowest possible level that is reasonably
practicable should a risk be considered 'acceptable'.

Toolbox talks or safety briefings should be provided to the working party before
the work commences. Appropriate personal protective equipment (PPE) should
also be provided.

The competent person should consider conducting a JSA also for a job with a
'low' overall risk level as JSA can help identify hazards and determine the
required control measures systematically and thoroughly.
2.3.2 Action for 'Moderate' or 'High' Overall Risk Level:

JSA shall be conducted for any job with an overall risk level of 'Moderate (M)'
or 'High (H)'.

3. PREPARING FOR JOB SAFETY ANALYSIS

3.1 ESTABLISHING PRIORITIES FOR CONDUCTING JSA

Some jobs pose greater risk to health and safety of the workers than others.
Section Chiefs shall assign competent persons to determine the priorities of
carrying out JSA's on the following jobs:

3.1.1 Jobs with a 'High' Overall Risk Level

Jobs with a 'high' overall risk level identified from risk assessment may pose a
greater risk to the health & safety of workers, and therefore they should have a
higher priority.

3.1.2 High Frequency of Accidents or Near-Misses

Jobs with a high frequency of accidents or near misses pose a significant threat
to employees' health and safety.

3.1.3 History of Serious Accidents or Fatalities

Jobs that have caused fatalities, disabling injuries, illnesses or environmental

impact in the past - despite the frequency, should have a high priority. Jobs
which are similar to those which caused accidents in other organisations should
also be considered.

3.1.4 Potential of Causing Serious Harm

Jobs that have the potential of causing serious injury or harm should be
analysed, even if they have never caused an injury or illness before.

3.1.5 New Jobs

Whenever a new job is introduced, a JSA should be performed wherever

practicable before any employee is assigned to it.

3.1.6 Changes in Procedures or Standards

Priority should also be given to jobs that have changes in procedure, equipment
or materials, and jobs whose operation may have been affected by new legal
requirements or standards.
4. FORMING A JSA TEAM

Conducting JSA should always be a team effort. By involving others in the

process, it can reduce the possibility of overlooking an individual job step, or
the potential hazard involved. It can also increase the likelihood of identifying
the most appropriate measures for eliminating or controlling hazards.

An effective JSA team should generally include:

- A supervisor who has received training on risk assessment;

- The employee most familiar with how the job is done and its related
hazards;

- Other employees who perform the job; and

- Experts or specialists where necessary, such as Maintenance personnel,

Chemistry personnel, Operations personnel, SHEQ personnel or
outside parties etc.

By involving as many knowledgeable and experienced people as necessary, the

JSA will be more accurate and comprehensive.

5. PERFORMING A JOB SAFETY ANALYSIS

5.1 PROCEDURE FOR CONDUCTING JSA

Once the JSA team has been selected, it needs to make sure that everyone
involved is familiar with what a JSA is and how it is performed.

JSA is a four-stage process:

i. List the basic steps necessary to perform the job from start to finish;

ii. Identify every existing or potential hazard associated with each job step
[hazards identified from the Risk Assessment Form (Form 1), if any,
should be referred to];

iii. Develop control measures to eliminate or control each hazard; and

iv. Determine the risk level of each job step (job-step risk level) using the Risk
Level Estimator in Section 2.2.

It should be noted that a job-step risk level is the remaining risk level after the
recommended control measure(s) for the job step have been fully implemented.
 When determining control measures, the following risk-control hierarchy shall
be adopted, as far as is reasonably practicable, to reduce the risks:

- Elimination;
- Substitution;
- Engineering controls;
- Signage/warnings and/or administrative controls; and
- Personal protective equipment (PPE).

Job Safety Analysis Form (Form 2) should be used to record the JSA findings
and recommendations.

The JSA Form (Form 2) should be completed one column at a time. In other
words, all of the basic job steps should be listed before moving to the second
column. Then, all the existing and potential hazards for each job step should be
identified before recommending control measures to eliminate or control the
hazards in the third column. Finally, the risk level of each job step shall be
entered in the last column.

Concentrating on one column at a time helps to ensure that the information in

each column is accurate and complete.

5.2 DETERMINATION OF AN OVERALL RISK LEVEL FROM JSA

The overall risk level of a job determined from JSA is the highest job-step risk
level of any of the identified hazards. It is defined as the remaining risk level
with recommended control measures for all the job steps fully implemented.

5.3 DETERMINATION OF FURTHER ACTIONS FROM JSA

The JSA team shall reduce the overall risk level of the job, as far as is
reasonably practicable, through reducing the job-step risk levels. It can be done
by adopting elimination, substitution, extra engineering controls; implementing
stringent control measures; etc.

A job can only be allowed to commence provided that:

- the JSA team considers that the overall risk level is 'acceptable'; and

- the result of the corresponding pre-job risk assessment, if any, as stated in

Pre-Job Risk Assessment is also 'acceptable'.

Only when the control measures met the relevant statutory and in-house
requirements and the risk is at, or has been reduced to, the lowest possible level
that is reasonably practicable should a risk be considered 'acceptable'.
 If the JSA team considers that a job is dangerous based on its JSA results, the
job shall not be allowed to commence unless:

- A further JSA is done which shows that the overall risk level is 'acceptable'
and the job can be done safely through modifying the work procedure,
implementing more stringent control measures or issuing a Safety
Document, etc.; and

- The result of the corresponding pre-job risk assessment, if any, as stated in

Pre-Job Risk Assessment is 'acceptable'.

Upon completion of the JSA Form (Form 2), the corresponding Risk
Assessment Form (Form 1), if any, should be reviewed so that the overall risk
level of the Risk Assessment Form is consistent with that of the corresponding
JSA Form.

More resources should be allocated to implementation of control measures for

jobs with a higher overall risk level.

6. APPROVAL OF AND KEEPING RECORD FOR RISK ASSESSMENTS

& JSAs

All risk assessments and JSAs must be approved by the relevant Section Chief
before its recommended control measures are implemented. The completed risk
assessment and JSA forms should be kept by the relevant section for future
reference.

The JSA form (Form 2) and their corresponding Risk Assessment Form
(Form 1), if any, should be filed together for easy cross-reference and
retrieval.

7. USING A JOB SAFETY ANALYSIS

The information provided by a JSA can be used as the basis for:

7.1 DEVELOPING OR UPDATING STANDARD OPERATING PROCEDURES

OR SAFETY CODES OF PRACTICE

The result of a JSA provides an excellent foundation for creating or improving

the standard operating procedures or working instructions for a job. Each of
the necessary steps to perform the job is listed and all the hazards and control
measures associated with the job are identified. Supervisors should use the
result of JSA to develop written procedures for performing the job in the safest
and healthiest way possible. Furthermore, the JSA Form (Form 2) can be used
as a working instruction for employees where appropriate.

7.2 EMPLOYEE TRAINING

Results of JSAs are especially useful for training employees. The JSA can be
used as a step-by-step guide for ensuring that each job step is performed safely
and efficiently, and for pointing out particular job steps or hazards that require
special control measures. JSAs can also be used to provide refresher training on
 jobs that are performed infrequently, to ensure that employees are aware of any
hazards that may be present and know how to protect themselves from those
hazards. Where appropriate, the result of a JHA can be used for toolbox talks or
safety briefings.

7.3 OBSERVING EMPLOYEE PERFORMANCE

JSAs can also be used as guides for observation of employees' performance. A

JSA allows supervisors to focus on particular hazardous job steps to ensure that
the employee is performing those steps according to standard procedures.

7.4 CONDUCTING INSPECTIONS

When developing inspection checklists, supervisors can use JSAs to help

identify hazardous conditions that may need to be included.

7.5 INVESTIGATING ACCIDENTS

In case of an accident, a JSA can provide a valuable investigation tool.

Comparing the procedures which led up to the accident with those outlined in
the JSA will allow the supervisor to determine if the job was performed
incorrectly, or if a hazard was overlooked.

8. FOLLOW UP ACTIONS FOR THE APPROVED JSAs

To ensure the overall risk levels determined from JSA are valid, every Section
Chief should make sure that all recommended control measures of the JSAs he
approved are fully implemented as far as is reasonably practicable in following
ways:

i. Incorporate the control measures in the procedures or work instructions for

a job. All actions that have been taken should be registered on the JSA
Forms (Form 2).

ii. To modify the plant up to the required standards.

iii. To train the employees up to the required standards.

9. REVIEW OF RISK ASSESSMENTS AND JSAs

A Section Chief should assign a competent person to review the results of risk
assessments and JSAs at least once every 2 years in order to keep the
information at the most updated conditions. When the results of new risk
assessments or JSAs have been obtained, the obsolete risk assessments or JSA
forms should be destroyed or should have a remark on them.

KHL/
 Appendix 1 Form 1

Mabar Power Station

Risk Assessment Form
Job
Section Assessed By
Description
Date of
Workplace Endorsed By
Assessment

Hazard Items to be Considered Likelihood Consequence Risk Level Remark

(Please as appropriate) (L) (C) (L x C) L=low
1=highly unlikely 1=slightly harmful (1,2) M=moderate
2=unlikely 2=harmful (3,4) H=high (6,9)
3=likely 3=extremely harmful
Biological Bacterial/virus infection
Attack by animals/insects
Others:
Chemical Toxic, flammable, corrosive, irritant,
oxidizing, harmful and explosive
substances
Others:
Electrical Electric shock/burn
Electrocution
Others:
Ergonomic Workstation design
Display screen equipment
Others:
Fire and Flammable substances
Explosion Hot or spark work
Others:
Health Stress/fatigue
Hygiene/Carcinogen
Manual handling operation
Dust/particulate/fume/smoke/mist
Others:
Mechanical Entanglement/puncturing by object
Nipping/crushing by object
Striking against or being struck by object
Others:
Natural Heavy rain/flooding/thunderstorm
Typhoon
Others:
Physical Temperature/pressure
Lighting
Noise
Infrared/Ultraviolet/non-ionizing
radiation
Ionizing radiation/particle
Others:
Workplace Tripping/slipping
Falling of person/object
Trapping/cutting by object
Collapse/overturning of object
Ventilation/Asphyxiation/Suffocation
Transport/congested space
Others:
Others Please specify:

Overall Risk Rating:

(Select the highest risk rating above)
Action Required with Conduct toolbox talks or Conduct Job Safety Analysis Others
completion date, if any (optional for Low overall risk level from this risk (Please
safety briefing/training
(Please as appropriate) Date: assessment) specify)
Date:
Use PPE Adopt elimination/substitution/
Date: engineering control/administration control/PPE
Date: Date:
Note: The completed Risk Assessment Form should be kept together with the relevant JSA Form, if any.
 Appendix 2 Form 2
Mabar Power Station
Job Safety Analysis

JSA No. JSA results acceptable? Y Overall Risk Level ( L / M / H ) :

N
( Check the appropriate box ; ) (Equivalent to the highest risk level of any job step of the work

Job or Operation Title: Department: Performed by

Verified by
Job Location: Section: Approved by
Date of JSA
PPEs Required or Recommended
Basic Job Steps Existing & Potential Hazards Recommended Control Measures Control Measures Job-Step Risk Level
(Refer to Form 1 if required) (for controlling the identified hazards) Completion Date (L/M/H)
 Appendix 3

FLOW CHART FOR CONDUCTING RISK ASSESSMENT (RA) & JOB SAFETY ANALYSIS (JSA)

Start

Section Chief to assign

assessors to conduct
RA & JSA for a job Document:

Assessor to conduct RA & Risk Assessment

determine overall risk level Form
of the job from RA

Overall risk level* N (i.e. overall risk level* from RA = M or H)

from RA = L?

Assessor to Assessor to conduct JSA &

Y JSA Form
conduct JSA? determine overall risk level of
(optional) the job from JSA

N Accept overall risk N

A
level* from JSA?
Accept overall risk
Y
N level* from RA?
Review the overall risk level Implement control measures
Y from RA to ensure consistency as recommended from JSA
with that from JSA

- Conduct safety briefing

or toolbox talk
A
- Use PPE

No work is allowed Work is allowed#

End Remark: * Overall Risk Level Low (L), Moderate (M) or High (H)
# provided that the prejob risk assessment result, if any, is acceptable.