2060
Rev. 02/2009
WORK PLANNING and HAZARD ANALYSIS
Introduction
Careful
planning of work assures that the work is performed efficiently and
safely. Hazard analysis is a critical
part of work planning. Work planning
ensures the scope of work is understood, appropriate materials are available,
all hazards have been identified and mitigative efforts established, and all
affected employees understand what is expected of them.
This policy
applies to all Fermilab personnel, including experimenters, temporary employees
and subcontract/ term employees.
Specific procedures for service and construction subcontractors may be
found in the FESHM 7000 chapter series.
DEFINITIONS
Hazard
Analysis – Tool used to
plan work.
Job Site
Walk Down – A visit to
the job site for the purpose of identifying work control and ES&H issues
that must be addressed prior to beginning work.
Pre-job
Briefing – Dialogue
between supervisor and those involved in the work to ensure that all understand
the scope of what is to be accomplished, procedural steps, roles and
responsibilities, and hazards and controls.
Post-job
Review – A review of
the work that has been performed to identify any improvements or experiences
that should be recorded for future job planning efforts.
Work Planning
– Systematic process
for determining methods for completing the assigned task safely and
efficiently. The process includes
defining the work to be performed and the methods for performing the work,
identifying the hazards and their controls, hazard analysis (possibly a written
one) and a pre-job briefing.
POLICY
All work
activities shall be subjected to work planning and hazard analysis (HA). Depending on the complexity of the task and
the hazards involved, the HA process may be a mental exercise and verbal
discussion, or it may be more formal with a written hazard analysis and pre-job
briefing. Table 1 provides guidelines
to assist in making that determination. Employees
and supervisors are to use their professional judgment in determining the need
for a written HA. The advice of the division/section Senior Safety Officer
(SSO) or ES&H Section should be sought if assistance is needed.
Responsibilities
Division/Section Heads are responsible for ensuring that this
policy is implemented within their division/section.
Note:
A division/section head may choose to impose more stringent requirements
than those described in this policy.
Additional requirements must be documented by internal procedures.
Supervisors and employees are responsible for planning their
work, and identifying those activities that require a written HA. Table 1 is a guideline in determining when a
written HA is required. The supervisor
is also responsible for:
·
Ensuring that HAs are developed and
reviewed by the employee before work begins.
·
Ensure written Has are signed by the
affected employees.
·
Seeking advice from Senior Safety
Officer or others, as appropriate.
·
Approving written HAs completed by
employees in their group.
·
If allowed by the work environment,
conducting a job walk-down in those instances where a written hazard analysis
is required.
·
Conducting a pre-job briefing with
employees before work begins.
·
Ensuring that employees are trained in
the process of developing an HA.
·
Ensuring that employees are trained to
work in the area of the job and trained in the tools/equipment to be used in
the completion of the job.
·
Assuring that the work is performed in
accordance with the hazard analysis.
Senior Safety Officers
(SSO) or designee, are responsible for providing technical expertise in job
planning and preparing written HAs.
The ES&H Section
will provide training support by developing a standard lesson plan for
preparing a work plan and writing HAs.
The ES&H Section will also provide assistance in preparing and
reviewing HAs upon request.
Work PLan
Process
In
those instances where the job site can be safely accessed, an inspection of the
job site shall be conducted. Ideally this inspection should be conducted prior
to developing the hazard analysis in order to assure all job site hazards and
work control issues are identified and addressed. Otherwise, the job site walk down shall be
conducted by the workers performing the work prior to beginning work, as part
of the pre-job briefing.
2.
Hazard
Analysis
a. The supervisor and employees develop the
hazard analysis. The results of the job
site walkdown shall be incorporated into the hazard analysis. ES&H
professionals are available within all divisions/sections to assist in the
development of that HA.
b. Using Table 1 as guidance, the
supervisor and employees will determine if a written hazard analysis needs to
be prepared, and then do so if required.
Technical Appendix 2060-1 provides guidance in completing a written
HA.
c. If a written HA already exists, it must
be reviewed and revised as appropriate for actual job site conditions and to
incorporate previous work experiences and lessons learned.
d. The preparation of the HA will include
or involve the following aspects.
·
Detailed scope of work, including how
the person/team intends to complete the work;
·
Walk down or inspection of the work area
and equipment while planning the work;
·
Identification of materials to be used
·
Identification of hazards;
·
Identification of work requirements,
controls, procedures, instructions and personal protective equipment necessary
to perform the work safely (including permits); and
·
Involvement of the workers in the
preparation of the work plan.
e. The level of detail in the HA should be
relative to the complexity of the work and the hazards involved with the
activity. For instance, cleaning and painting magnet components on an
open worktable would require less detail than
the same activity in the Main Injector Tunnel while standing on a
ladder. The attached form shall be used to document the HA.
f. The supervisor will review the HA for
completeness and thoroughness and determine
whether the hazards for the work activity have been adequately
identified and controlled. Permits,
Material Safety Data Sheets, etc., shall be attached to the written hazard
analysis (to the extent possible) to consolidate the work package. The supervisor will then approve the HA.
g. An additional written HA is not required
if the work activity is performed under a standard operating procedure or if
the work activity involves the use of a permit where all the hazards and
their mitigation requirements are identified and addressed. Examples of this could include lockout/tagout
procedures, radiation work permits, confined space permits, excavation permits,
and electrical hazard analysis/work permits.
In all cases, job planning and some form of pre-job briefing are
required.
h. “Generic” HAs may be used. Generic HAs are those that would be routinely
used for a specific activity (e.g., asbestos removal). They shall be reviewed by employees and
updated as necessary prior to each specific activity to ensure that all hazards
of the work and the job site are addressed.
In all cases, some form of pre-job briefing at the job site is
required.
i.
Emergency repair activities may be required during off-shift
hours. If a written procedure or hazard
analysis for the work to be performed exists, it shall be reviewed and updated
to incorporate field conditions. If a
hazard analysis needs to be written, this can be done in the field. Verbal approval from the supervisor is to be
sought in lieu of a signature. In all
cases, a pre-job briefing is required. Under no circumstances shall an
emergency serve as reason for ignoring established safe work practices.
3.
Pre-Job
Briefing
a. Regardless of whether the HA is a mental
or written exercise, the supervisor and employees performing the job shall
discuss the work plan to ensure everyone is aware of how the job will
proceed. For low-risk tasks the briefing
may be a quick exchange between the supervisor and employee(s), or a mental review
by the employee. For more complex and
higher-risk tasks, a more detailed and formal pre-job briefing is
required. The HA form can be used to
conduct this briefing. The pre-job
briefing shall consist of the following:
§ Summarizing
the critical steps and materials.
This
would include steps where the success depends solely on the individual work,
and that serious injury or significant loss of property could result from not
following the prescribed safe work procedures.
§ Anticipating
what can go wrong or where errors can occur.
This
would include distractions, confusing procedures, inexperience and
assumptions. Examining what errors have
occurred with the activity in the past may be helpful.
§ Foreseeing
consequences
What
is the worst that could happen? Work
plans should incorporate defenses to prevent the incident.
§ Review
operating experience.
How
has the task gone in the past? Work
plans should incorporate defenses to prevent a repeat incident. The SSO is a good informational source in
this area.
§ Review
of Equipment
Review of PPE, equipment necessary for the job, engineering controls, and
equipment controls.
b.
All who review the written HA will
document the review by signing the form.
Only then will the supervisor allow the work to begin.
4.
Performance of Work
a.
The work plan/hazard analysis shall be
posted in the work area or shall be readily available to those performing the
work. Any visitors to the job site must
also review and sign the written HA.
b.
The work activity must be completed in
accordance with the HA. If there is a
change in the work scope, if work conditions change or if new hazards are
identified, or the controls prove inadequate or ineffective, the work activity
shall cease immediately. The HA shall be
reviewed by the employees and supervisor, revised as necessary, and approval/concurrence
obtained before the work is continued.
5.
Post Job Review
After the activity
has been completed, the HA should be updated to include improvements that were
identified while performing the work.
This will help assure better planning and a safer work experience the
next time the job has to be performed.
6.
HA Record Retention
The supervisor will keep a copy of the HA for
training employees. These will be made
available to the SSO or anyone who requests them, for the purposes of providing
oversight, trending, and/or lessons learned.
In general, a written work plan/hazard analysis
should be kept on file for 1 year.
Table 1 Written Hazard Analysis
Guideline
These
are guidelines for determining when a written hazard analysis is
necessary.
They
are intended to be used as guidance and not to limit sound professional
judgment.
|
Category |
High-Level Hazard |
|
Radiological Work |
·
When
a Radiation Work Permit is required and not all hazards can be incorporated
into the RWP. (See FRCM Article 322) |
|
Electrical work |
·
Work
activities near or on exposed electrical conductors, circuits, or equipment
that are or may be energized and where there is a significant and unmitigated
exposure to electrical shock or a significant potential for arcing, flash
burns, electrical burns, or arc blast* (FESHM 5042) ·
When
not all hazards can be incorporated into the Electrical Hazard Analysis/Work
Permit. |
|
Confined Space Work |
·
Permit
required confined space entry (FESHM 5063) where and when hazards cannot be
adequately addressed in the permit |
|
Crane & Hoist Usage |
·
Load
requires exceptional care in handling because of size, shape, weight,
close-tolerance installation, high susceptibility to damage, or other unusual
factors (FESHM 5021) ·
Load
tests at 100% or 125% of rated capacity (FESHM 5021) |
|
Excavation and digging |
·
Digging
or excavating in area where the potential exists for encountering buried
utilities (FESHM 7030) ·
Employees
entering excavation/trench that is > 4 feet in depth ·
When
not all hazards can be incorporated into the Excavation Permit. |
|
Hazardous substances & regulated
pollutants |
·
Potential
for release of hazmat on-site in quantities > 50% of “Reportable
Quantities” (40 CFR 302 and 40 CFR 355) ·
Potential
for release of 42 gallons or more of petroleum, fuel oil, oil refuse, and oil
mixed with wastes (40 CFR Part 112.4(a)) |
|
Chemical Usage |
Use of materials that are flammable,
combustible, corrosive, reactive, toxic, caustic, poisonous, where the
quantity or manner of use is hazardous to the health of the workers, the
environment, or presents a potential for fire/explosion |
|
Respiratory and Hearing Protection |
Work requiring hearing or respiratory
protection due to exceedance of Permissible Exposure Limits (FESHM 5061 and
5103) |
|
Hazardous Substance Abatement
Activities |
Work involving abatement of asbestos,
lead, PCBs, or mercury |
|
Cryogenic Systems |
·
Potential
for exposure to reduced atmospheric oxygen ·
Working
on cryogenic systems |
|
Magnetic Fields |
·
Potential
for exposure in excess of action limits established in FESHM 5062.5 |
|
Lasers |
·
Use
of Class IIIB or IV lasers (FESHM 5062.1) |
|
Working at heights |
Fall potential is > 4 feet when
performing maintenance work, and > 6 feet when performing construction
work, and additional fall
protection is required (FESHM 5066) |
|
Stored Energy |
·
Potential
for inadvertent startup of equipment ·
Potential
for unexpected release of energy (hydraulic, pneumatic, thermal, potential,
etc.) where lockout/tag out is required |
|
Tools & Fixtures |
·
In
house designed or modified tools or tooling required for work activities
where a tool or tooling failure could pose a risk of injury to workers. ·
In
house designed or modified fixtures used for work activities where a fixture
failure could pose a risk of injury to workers. |
|
Sharp Instruments |
Non-routine work
requiring the use of sharp instruments or cutting tools where the worker is
exposed to the unguarded cutting surface. |
|
Other |
·
Working
with systems or equipment which are pressurized > 15 psig ·
Working
with vacuum vessels (FESHM 5033) ·
Work
requiring welding, brazing, or open flames ·
Concrete
coring and cutting when hazards cannot be adequately addressed in the
Electrical Work Permit. (FESHM 7040) ·
Work
requiring construction, altering, and/or repair, including painting and
decorating. ·
Materials
being used in a state that is altered from its original form, that as a
result may be is hazardous to the health of the workers, the environment, or
presents a potential for fire/explosion ·
Activity involving a lower level hazard, but
involving multiple organizations participating ·
Potential
for job-induced alertness reduction (e.g., long hours, short deadlines) ·
Activities
presenting lower hazards, but are performed infrequently ·
Activities
presenting hazards unfamiliar to employees |