phos acid job safety hazard analisis (jsha) · pdf filejob safety hazard analysis initial...

PHOS ACID JOB SAFETY HAZARD ANALISIS (JSHA)

Table of ContentsClean Sluice Headers and Cloth Wash Sprays .................................................................................................................................................. 2Catch Attack Sample .......................................................................................................................................................................................... 3Clean Vacuum Scrubber Strainer ....................................................................................................................................................................... 4Catching Filter Cake Sample .............................................................................................................................................................................. 5Set Up Sulfuric to Evaporators............................................................................................................................................................................ 6Cutting Filter Cloths Off Pans ............................................................................................................................................................................. 7Run Acid Sample ................................................................................................................................................................................................ 8Cleaning Barometric Condensers ....................................................................................................................................................................... 9Packing Change – Primary and Secondary Vacuum Scrubbers....................................................................................................................... 10Clean Pond Water Strainers ............................................................................................................................................................................. 11Cleaning Catchalls ............................................................................................................................................................................................ 12Cleaning Slurry Distribution Boxes with Filter Down......................................................................................................................................... 13Clean Pump Impeller ........................................................................................................................................................................................ 14Waterblasting Tubes or Piping.......................................................................................................................................................................... 15Change Filter Cloths ......................................................................................................................................................................................... 16Patching Filter Cloth.......................................................................................................................................................................................... 17Packing Change on East & West Fume Scrubbers .......................................................................................................................................... 18Clean Flash Cooler Nozzles ............................................................................................................................................................................. 19Packing Change—Flash Cooler Vacuum Scrubber .......................................................................................................................................... 20Opening and Closing All Manual Sulfuric Acid Valves...................................................................................................................................... 21Pressurizing a line with Sulfuric, Phos Acid, Scrub Water or Pond Water. ....................................................................................................... 22Clean acid trap, receivers and vacuum scrubber seal tank .............................................................................................................................. 23Clean filtrate seal tanks, hot wells, attack tanks ............................................................................................................................................... 24Clean Flash Cooler Piping on Ground .............................................................................................................................................................. 25Unplug Sample Ports ........................................................................................................................................................................................ 26Mark Tubes in Evaporators............................................................................................................................................................................... 27Clean Inside Flash Coolers............................................................................................................................................................................... 28Clean Attack Agitators and 3rd Flash Cooler Pumps on Ground....................................................................................................................... 29Packing Change on 3rd Fume Scrubbers .......................................................................................................................................................... 30Put New Floc Bag on Hopper ........................................................................................................................................................................... 31Cleaning Slurry Distribution Boxes with Filter Running..................................................................................................................................... 32Clean Filter Crown ............................................................................................................................................................................................ 33

JOB SAFETY HAZARD ANALYSIS

INITIAL REVIEWED

Area: Phos Acid Prepared by: Steve McAfee Prepared by:

Facility: New Wales Reviewed: Reviewed:

JSA No.: 001 Date written: 2/25/08 Date reviewed: 01/30/09

Approval (name): Approval (name): Mark DenzTask:

Clean Sluice Headers and Cloth Wash SpraysApproval signature: ______________ Approval signature: ______________

Step Work Step Potential Hazards Corrective Actions

1 Verify that all equipment is properly isolated andlocked out.

None. None.

2 Go inside gyp hopper. Slipping and falling. Watch footing and use hand holds. Wear gloves and safetyharness.

3 Roll spray bar end caps. Rod all sluice nozzles andremove and clean sprays.

Hand injury due to wrench slipping. Slipping andfalling.

Wear gloves and watch for pinch points. Wear face shield.Watch footing and wear safety harness. Pull wrench towardbody to prevent slipping.

4 Exit gyp hopper. Slipping and falling. Watch footing and use hand holds. Wear gloves.

5 Flush Sprays and sluice header. None. None.

6 Go back inside gyp hopper. Slipping and falling. Watch footing and use hand holds. Wear gloves and safetyharness.

7 Bolt end caps back together and install sprays. Hand injury due to wrench slipping. Slipping andfalling.

Wear gloves and watch for pinch points. Wear face shield.Watch footing and wear safety harness. Pull wrench towardbody to prevent slipping.

8 Exit gyp hopper. Slipping and falling. Watch footing and use hand holds. Wear gloves.

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INITIAL REVIEWED





Catch Attack SampleApproval signature: ______________ Approval signature: ______________


1 Walk out on top of attack. Tripping Eyes on Path

2 Fill sample cup to a few inches from top. Splash, Burn Wear acid jacket, rubber gloves and face shield when catchingsample.

3 a) Return to lab with lid on sample cup.b) If using cup without lid.

a) Trippingb) Tripping, Splash, Burn

a) Keep eyes on pathb) Keep eyes on path. Wear rubber gloves, face shield andlong acid jacket when transporting sample.

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INITIAL REVIEWED





Clean Vacuum Scrubber StrainerApproval signature: ______________ Approval signature: ______________


1 Valve out strainer and open drain. Hand injury on valve. Wear gloves.

2 Open the strainer, remove and clean. Water may spray out, pinch points, cut hand onstrainer. Hand injury due to wrench slipping.

Make sure drain is clear. Wear gloves. Pull wrench towardbody to prevent slipping.

3 Reinstall Strainer Pinch points, cut hand on strainer. Hand injury due towrench slipping.

Wear gloves. Pull wrench toward body to prevent slipping.

4 Open water valves. Hand injury on valve. Get sprayed with water. Wear gloves, make sure drain is closed, open valve slowly.checking for leaks

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INITIAL REVIEWED





Catching Filter Cake Sample

Approval signature: ______________ Approval signature: ______________


1 Use shovel or dipper to scoop cake sample. Shovel or dipper getting caught on filter pan. Splintersfrom shovel.

Penetrate cake in front as far as possible. Wear gloves.

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INITIAL REVIEWED





Set Up Sulfuric to EvaporatorsApproval signature: ______________ Approval signature: ______________


1 Close all drains on sulfuric line to evaporators. Acid leaks, hand injury. Wear acid jacket with hood, acid pants, face shield, goggles,chemical gloves and boots Watch for pinch points.

2 Open the manual valves on the sulfuric line to theEvaporator

Acid leaks, hand injury. Wear acid jacket with hood, acid pants, face shield, goggles,chemical gloves and boots. Watch for pinch points.

3 Make sure evaporator is full of water. None. None.

4 Open auto valve to start flow of sulfuric. Acid leaks. Check line for leaks and secure line if it is leaking.

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INITIAL REVIEWED





Cutting Filter Cloths Off PansApproval signature: ______________ Approval signature: ______________



None. None.

2 Cut the filter cloths off. Cuts to hands and fingers. Falling off filter. Wear cut resistant gloves. Use only lock blade knife. Keepfree hand behind the knife during cutting. Wear safety harnessand lanyard when not in hand rail area.

3 Pull cloth and fold up for easy handling. Put them inthe basket.

Back strain or slipping hazard. Use good footing and proper lifting techniques.

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INITIAL REVIEWED





Run Acid SampleApproval signature: ______________ Approval signature: ______________


1 Run Sample Broken Glass, Burn, Splash in eyes. Use PyrexPlus glass ware, safety glasses or goggles.

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INITIAL REVIEWED





Cleaning Barometric CondensersApproval signature: ______________ Approval signature: ______________



None. None.

2 Place scaffolding boards across downleg. Pinch points, hand injury, falling into condenser. Wear gloves, safety harness and be aware of surroundings.

3 Climb inside condenser. Falling in downleg and pinch points. Falling build-up. Make sure scaffolding boards are covering downleg properly.Check overhead for build-up. Wear gloves, face shield, acidjacket. Use safety harness and lanyard.

4 Air hammer build up. Falling in downleg. Noise. Falling build-up. Hosecoming apart.

Make sure scaffolding boards are covering downleg properly.Be aware of surroundings. Wear gloves, face shield, acidjacket, ear plugs and ear muffs. Use safety harness andlanyard. Use safety pins in air hose.

5 Shovel build-up out manway. Falling in downleg and pinch points. Back and musclestrains.

Make sure scaffolding boards are covering downleg properly.Be aware of surroundings. Wear gloves. Use safety harnessand lanyard. Use proper lifting techniques.

6 Exit condenser. Pinch points, hand injury, falling into condenser. Wear gloves, safety harness and be aware of surroundings.

7 Remove scaffolding boards. Pinch points, hand injury, falling into condenser. Wear gloves, safety harness and be aware of surroundings.

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INITIAL REVIEWED





Packing Change – Primary and SecondaryVacuum Scrubbers.




None. None.

2 Remove top grid from scrubber. Pinching hand under grid. Wear gloves.

3 Remove packing. None. None.

4 Remove lower grid from scrubber. Pinching hand under grid. Wear gloves.

5 Climb down into scrubber for inspection. Falling into scrubber. Use ladder and maintain 3 points of contact. Wear harness incase of rescue.

6 Install lower grid from scrubber. Pinching hand under grid. Wear gloves.

7 Install packing. None. None.

8 Install top grid from scrubber. Pinching hand under grid. Wear gloves.

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INITIAL REVIEWED





Clean Pond Water StrainersApproval signature: ______________ Approval signature: ______________


1 Verify that all equipment is properly isolated andlocked out. PRODUCTION-NO PERMIT REQUIRED

None. None.

2 Open drain on bottom of strainer. Splash from pond water. Wear acid jacket, face shield and chemical gloves.

3 Remove bolts from strainer lid. Splash from pond water. Hand injury. Wear acid jacket, face shield and chemical gloves. Use wrenchto hold bolts when using impact wrench. Pull wrench towardbody to prevent slipping.

4 Remove strainer. Splash from pond water. Muscle strain. Wear acid jacket, face shield and chemical gloves. Use hoist topull strainer if necessary.

5 Wash out strainer. Splash back. Wear acid jacket, face shield and chemical gloves.

6 Install strainer. Muscle strain. Use hoist to install strainer if necessary.

7 Bolt lid back in place. Hand injury. Use wrench to hold bolts when using impact wrench. Pullwrench toward body to prevent slipping.

8 Put strainer back in service. Blown gasket, spray from pond water. Wear acid jacket, face shield and chemical gloves.

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INITIAL REVIEWED





Cleaning CatchallsApproval signature: ______________ Approval signature: ______________



None. None.

2 Enter catchall. Could slip and fall. Falling build-up. Have watchman assist you. Inspect over head before entering.Wear safety harness and lanyard. Tie off outside of catchall.

3 Clean catchall. Could fall through the floor. Could easily slip on domefloor. Heat and fumes may be a hazard.

Wear safety harness and lanyard. Tie off outside of catchall. .Wear rubber boots and watch footing. Were respirator ifneeded. If you get hot, get out.

4 Exit catchall. Slip or fall. Have watchman assist you.

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INITIAL REVIEWED



JSA No.: 012 Date written: 2/27/08 Date reviewed:

Approval (name): Date reviewed: 01/30/09Task:

Cleaning Slurry Distribution Boxes with FilterDown Approval signature: ______________ Approval (name): Mark Denz



None. None.

2 Remove lids. Falling through fume hood,. Fumes. Stand on I-Beams and grating. Do not stand on fume hood.Use respirator if necessary.

3 Clean boxes. Splash back. Falling through fume hood. Wear face shield and gloves. Stand on I-Beams and grating.Do not stand on fume hood.

4 Install lids. Falling through fume hood. Stand on I-Beams and grating. Do not stand on fume hood.

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INITIAL REVIEWED





Clean Pump Impeller Approval signature: ______________ Approval signature: ______________



None. None.

2 Clean lumps from impeller. Getting cut from sharp edges on impeller. Wear cut resistant gloves and use caution.

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INITIAL REVIEWED





Waterblasting Tubes or PipingApproval signature: ______________ Approval signature: ______________



None. None.

2 Inspect all blasting hoses before starting blaster. Being cut from metal braids sticking out of frayedhose.

Wear leather gloves and use caution.

3 Insert wand in tube or pipe. Hose turning around in pipe and coming back towardyou.

Make sure wand is at least twice as long as the pipe is wide.Example: A 6” pipe requires at least a 12” wand.

4 Begin water blasting. Ruptured hose, back spray, flying debris, hose comingout of tube or pipe.

Always have a watchman before water blasting. If hoseruptures, have watchman shut off water blaster. Wear rain suit,face shield, tall rubber boots, rubber gloves.

5 Release foot pedal. Foot pedal not releasing Have watchman shut off water blaster.

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INITIAL REVIEWED



JSA No.: 015 Date written: 2/27/08 Date reviewed:

Approval (name): Date reviewed: 01/30/09Task:

Change Filter Cloths Approval signature: ______________ Approval (name): Mark Denz



None. None.

2 Climb up on filter. Falling off ladder or filter. Maintain 3 points of contact when climbing ladder. Use fallprotection if out of handrail area.

3 Knock pins out and clean rails. Hammer slipping, pinch points, hitting self or someoneelse. Flying debris.

Use dry gloves and good grip on hammer. Be aware of othersin area. Wear face shield.

4 Wash rails and pan. Splash back. Wear face shield.

5 Inspect/Install new rubber. Cutting hand. Wear gloves. Use proper cutting technique.

6 Install new cloth. Hammer slipping, pinch points, hitting self or someoneelse. Flying debris.

Use dry gloves and good grip on hammer. Be aware of othersin area. Wear face shield.

7 Climb down off filter. Falling off ladder. Maintain 3 points of contact when climbing ladder.

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INITIAL REVIEWED





Patching Filter ClothApproval signature: ______________ Approval signature: ______________



None. None.

2 Cut new patches from spare cloth. Cutting hand. Wear cut resistant gloves. Use proper cutting technique.

3 Climb up on filter. Falling off ladder or filter. Maintain 3 points of contact when climbing ladder. Use fallprotection if out of handrail area.

4 Patch filter cloth. Cutting hand. Getting poked with needle from taggergun.

Wear cut resistant gloves. Use proper cutting technique. Usecaution when working with tagger gun.

5 Climb down off filter. Falling off ladder. Maintain 3 points of contact when climbing ladder.

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INITIAL REVIEWED





Packing Change on East & West FumeScrubbers




None. None.

2 Remove lids from scrubber. Falling into scrubber. Pinched between handrail. Wear fall protection. Be aware of surroundings.

3 Open bottom doors on scrubber. Pond water splash. Pinch points. Wear face shield and rubber gloves. Use wrench on boltswhen using impact wrench.

4 Remove packing from scrubber. Falling into scrubber. Splash back. Wear fall protection when on top of scrubber and as you godown with the packing. Wear face shield.

5 Remove spray nozzles. Pond water splash. Slip or trip. Wear face shield, rubber boots and rubber gloves. Watchfooting on sloped floor. Be aware of surroundings.

6 Wash packing. Splash back. Wear face shield.

7 Clean nozzles. Hand injury. Wear gloves.

8 Install nozzles. Slip or trip. Watch footing on sloped floor. Be aware of surroundings.

9 Close bottom doors on scrubber. Pinch points. Wear gloves. Use wrench on bolts when using impact wrench.

10 Put packing back in scrubber. Falling into scrubber. Pinched between handrail. Wear fall protection. Be aware of surroundings.

11 Put lids on scrubber. Falling into scrubber. Pinched between handrail. Wear fall protection. Be aware of surroundings.

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INITIAL REVIEWED





Clean Flash Cooler Nozzles Approval signature: ______________ Approval signature: ______________



None. None.

2 Remove cover from clean out shoot. Muscle strain, pinch points. Get help removing cover and be aware of surroundings.

3 Begin air hammering nozzle. Flying debris, falling off scaffolding. Pinch points.Hose coming apart.

Wear face shield and fall protection. Be aware of surroundings.Watch footing. Use safety pins in air hose.

4 Put cover back over clean out shoot. Muscle strain, pinch points. Get help installing cover and be aware of surroundings.

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INITIAL REVIEWED





Packing Change—Flash Cooler VacuumScrubber




None. None.

2 Rake packing out through bottom door. Pinch points. Keep eyes on task.

3 Enter scrubber to clean grating. Awkward positioning. Falling through loose grating. Keep eyes on task. Use proper body positioning. Check forloose grating before entering.

4 Clean grating with hammer. Pinch points. Flying debris. Keep eyes on task. Use proper body positioning. Wear faceshield and gloves.

5 Exit scrubber. Awkward positioning. Keep eyes on task. Use proper body positioning.

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INITIAL REVIEWED





Opening and Closing All Manual Sulfuric AcidValves



1 Open or close valve Piping, flange, valve ect… leaking sulfuric acid. Wear acid jacket with hood, acid pants, face shield, goggles,chemical gloves and boots.

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INITIAL REVIEWED





Pressurizing a line with Sulfuric, Phos Acid,Scrub Water or Pond Water.



1 Start acid pump. Line blowing out, line leaking andsplash from acid, scrub water, orpond water.

Verify that all drains and sample ports areclosed and all valves on the line are open.Make sure that all people in the area,including pipe racks, are clear when startingpump and establishing flow. Check line forleaks after flow is established.

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INITIAL REVIEWED





Clean acid trap, receivers and vacuumscrubber seal tank




None. None.

2 Climb into vessel. Slip, fall. Use correct body positioning. Be aware of surroundings.

3 Air hammer build-up. Pinch points, flying debris and noise. Hose comingapart.

Be aware of surroundings. Wear face shield, ear muffs andgloves. Use safety pins in air hose.

4 Wash vessel. Splash back. Wear face shield.

5 Climb out of vessel. Slip, fall. Use correct body positioning. Be aware of surroundings.

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INITIAL REVIEWED





Clean filtrate seal tanks, hot wells, attacktanks




None. None.

2 Enter tank. Product build up overhead ,and slipperyconditions.

Look overhead for build up and wear rubber boots.*If a Permit Required Class “A” Entry-Must wear safetyharness and lanyard unless entanglement becomes ahazard then lanyard not required.

3 Clean tank. Slippery conditions, splash back, and loudnoise. Hose coming apart.

Watch footing, wear face shield, acid suit, rubbergloves, rubber boots. Wear ear plugs and ear muffswhen using air hammer. Use safety pins in air hose.

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INITIAL REVIEWED





Clean Flash Cooler Piping on GroundApproval signature: ______________ Approval signature: ______________


1 Secure piping. Pipe rolling due to sloped surface or from build-upbeing removed.

Chalk piping.

2 Air hammer build-up in piping. Flying debris. Large pieces of build-up falling from topof piping. Hose coming apart.

Wear face shield. Cut build-up off top of pipe before entering.Use safety pins in air hose. Use ear muffs when inside pipe airhammering.

3 Wash piping. Splash back, others being splashed. Wear face shield. Barricade area.

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INITIAL REVIEWED





Unplug Sample PortsApproval signature: ______________ Approval signature: ______________


1 Shut down pump. Getting sprayed from around seal. Wear long acid jacket(or full acid suit) face shield, goggles andchemical gloves.

2 Rod out sample port. Line of fire. Getting sprayed when sample port clears. Stand to the side. Wear long acid jacket(or full acid suit) faceshield, goggles and chemical gloves

3 Start pump. Line blowing out, acid leaking. Verify that all valves on the line are open. Make sure that allpeople in the area, including pipe racks from Phos Acid toClarification and battery limits, are clear when starting pumpand establishing flow

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INITIAL REVIEWED





Mark Tubes in EvaporatorsApproval signature: ______________ Approval signature: ______________



None. None.

2 Mark tubes in top. Falling off ladder. Maintain 3 points of contact.

3 Mark tubes in bottom. Slippery surface. Acid dripping from tubes. Lay platform over lump screen for better footing. Wear faceshield, acid jacket and gloves.

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Clean Inside Flash CoolersApproval signature: ______________ Approval signature: ______________



None. None.

2 Enter flash cooler. Slip and fall (flash cooler has slopped floor). Fallingbuild-up.

Watch footing. Wear fall protection. Look over head beforeentering.

3 Air hammer nozzles. Pinch points. Noise. Flying debris. Be aware of surroundings. Wear ear muffs, face shield andgloves.

4 Shovel build up out of cooler. Slip and fall (flash cooler has slopped floor), musclestrain.

Watch footing. Wear fall protection, Use Proper bodypositioning.

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INITIAL REVIEWED





Clean Attack Agitators and 3rd Flash CoolerPumps on Ground



1 Remove buildup with sledge hammer and airhammer.

Flying debris. Getting cut by pump or agitator blades.Large falling lumps.

Wear face shield, long welding sleeves and cut residentgloves. Do not work under any large build-up. Cover bladeswith welding blanket finished.

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INITIAL REVIEWED





Packing Change on 3rd Fume ScrubbersApproval signature: ______________ Approval signature: ______________



None. None.

2 Remove lids from scrubber. Falling into scrubber. Pinched between handrail. Wear fall protection. Be aware of surroundings.

3 Open bottom doors on scrubber. Pond water splash. Pinch points. Wear face shield and rubber gloves. Use wrench on boltswhen using impact wrench.

4 Remove packing baskets from scrubber. Falling into scrubber. Pinched between handrail. Wear fall protection. Be aware of surroundings.

5 Remove spray nozzles. Pond water splash. Slip or trip. Wear face shield, rubber boots and rubber gloves. Watchfooting on sloped floor. Be aware of surroundings.

6 Wash packing. Splash back. Wear face shield.

7 Clean nozzles. Hand injury. Wear gloves.

8 Install nozzles. Slip or trip. Watch footing on sloped floor. Be aware of surroundings.

9 Close bottom doors on scrubber. Pinch points. Wear gloves. Use wrench on bolts when using impact wrench.

10 Put packing baskets back in scrubber. Falling into scrubber. Pinched between handrail. Wear fall protection. Be aware of surroundings.

11 Put lids on scrubber. Falling into scrubber. Pinched between handrail. Wear fall protection. Be aware of surroundings.

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INITIAL REVIEWED





Put New Floc Bag on HopperApproval signature: ______________ Approval signature: ______________


1 Inspect hoist before using. None. None.

2 Cut plastic wrapping off bag. Getting cut. Wear gloves. Use proper cutting technique.

3 Raise Floc bag over hopper. Bag fallen due to various reasons. Ensure bag is properly hooked to hoist and aligned properly.Inspect straps on bag. Never stand below a suspended load.

4 Set bag on holding frame. Bag fallen due to various reasons. Hand injury. Keep hands out from underneath bag until bag rest on frame.

5 Reach under frame and open Floc bag. Spilling Floc. Proper alignment with hopper.

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INITIAL REVIEWED





Cleaning Slurry Distribution Boxes with FilterRunning



1 Remove lids. Falling through fume hood,. Fumes. Stand on I-Beams and grating. Do not stand on fume hood.Use respirator if necessary.

2 Clean boxes. Splash back. Falling through fume hood. Getting Rodcaught on filter.

Wear face shield and gloves. Stand on I-Beams and grating.Do not stand on fume hood. Do not use rod that will go throughholes in bottom of slurry box.

3 Install lids. Falling through fume hood. Stand on I-Beams and grating. Do not stand on fume hood.

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Clean Filter CrownApproval signature: ______________ Approval signature: ______________



None. None.

2 Raise filter crown Pinch points. Raising to high. Be sure that everyone is clear. Have some watch if needed socrown doesn’t get raised to high.

3 Clean crown Crown lowering. Pinch points. Use blocks to chalk crown.

4 Lower crown Pinch points. Be sure that blocks are removed and everyone is clear beforelowering crown.

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phos acid job safety hazard analisis (jsha) · pdf filejob safety hazard analysis initial...

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