Crane Operations Job Hazard Analysis - Reformer Unit

Assessment Date: [DATE]

Assessor: [ASSESSOR NAME]

Department/Area: [DEPARTMENT/AREA]

Review Date: [REVIEW DATE]

1. Assessment Scope

This job hazard analysis (JHA) covers crane operations during maintenance and construction activities within the reformer unit. It includes all tasks directly related to lifting, rigging, and moving equipment or materials using a crane. The scope excludes general scaffolding erection/dismantling, but includes crane-related activities performed on scaffolding.

2. Risk Assessment Methodology

This risk assessment employs a 5x5 risk matrix to determine risk ratings based on likelihood and severity. The hierarchy of controls (Elimination, Substitution, Engineering Controls, Administrative Controls, and PPE) is used to identify and implement control measures to reduce risks to acceptable levels.

3. Risk Matrix Reference

The following matrix is used to evaluate risk levels based on likelihood and severity:

		Likelihood
Rare	Unlikely	Possible	Likely	Almost Certain
Severity	Catastrophic	Low	Low	Medium	High	High
Major	Low	Medium	Medium	High	Extreme
Moderate	Medium	Medium	High	Extreme	Extreme
Minor	Medium	High	High	Extreme	Extreme
Negligible	Low	Medium	Medium	High	Extreme

4. Hazard Identification and Risk Evaluation

1. Dropped object from crane load due to rigging failure, improper load securement, or equipment malfunction.

Potential Consequences: Serious injury or fatality to personnel, damage to equipment or structures, environmental release.

Affected Persons: Workers, visitors, public

Initial Risk Assessment

Likelihood	Severity	Risk Rating
Possible	Major	High

Control Measures

• Eliminate the need for crane operations by using alternative methods where feasible.
• Use cranes with higher lifting capacities to reduce the number of lifts required.
• Implement engineering controls such as load moment indicators (LMI) and anti-two-block devices.
• Establish and enforce safe lifting procedures, including load weight verification and proper rigging techniques.
• Require the use of hard hats, safety glasses, and high-visibility clothing.

Residual Risk Assessment

Likelihood	Severity	Risk Rating
Unlikely	Moderate	Medium

2. Rigging failure due to overloading, improper selection of rigging hardware, or inadequate inspection.

Potential Consequences: Load dropping, equipment damage, serious injury or fatality.

Affected Persons: Workers

Initial Risk Assessment

Likelihood	Severity	Risk Rating
Possible	Major	High

Control Measures

• Ensure that all rigging equipment is inspected regularly and certified for its intended use.
• Use appropriate rigging techniques and hardware for the load being lifted.
• Provide training to riggers on proper rigging practices and load securement.
• Implement a tag line system to control the load and prevent swinging.
• Establish a designated lifting zone and restrict access to unauthorized personnel.

Residual Risk Assessment

Likelihood	Severity	Risk Rating
Unlikely	Moderate	Medium

3. Contact with overhead power lines resulting in electrocution or electrical shock.

Potential Consequences: Electrocution, burns, equipment damage, power outage.

Affected Persons: Workers, public

Initial Risk Assessment

Likelihood	Severity	Risk Rating
Unlikely	Catastrophic	High

Control Measures

• Identify and mark the location of all overhead power lines in the work area.
• Maintain a safe distance from power lines in accordance with regulatory requirements.
• Use insulated crane booms or barriers to prevent contact with power lines.
• Designate a spotter to monitor the crane's proximity to power lines.
• De-energize power lines if possible or coordinate with the utility company to implement safety measures.

Residual Risk Assessment

Likelihood	Severity	Risk Rating
Rare	Major	Medium

4. Crane instability or overturning due to uneven ground, high winds, or exceeding the crane's load capacity.

Potential Consequences: Crane collapse, equipment damage, serious injury or fatality.

Affected Persons: Workers

Initial Risk Assessment

Likelihood	Severity	Risk Rating
Possible	Major	High

Control Measures

• Ensure that the crane is set up on a stable and level surface.
• Use outriggers or stabilizers to provide additional support.
• Monitor wind conditions and cease crane operations if wind speeds exceed the manufacturer's recommendations.
• Provide training to crane operators on safe crane operation in various weather conditions.
• Implement a crane maintenance program to ensure that the crane is in good working order.

Residual Risk Assessment

Likelihood	Severity	Risk Rating
Unlikely	Moderate	Medium

5. Collision between the crane and other equipment, structures, or personnel.

Potential Consequences: Equipment damage, serious injury or fatality.

Affected Persons: Workers

Initial Risk Assessment

Likelihood	Severity	Risk Rating
Possible	Major	Medium

Control Measures

• Develop and implement a traffic management plan to separate crane operations from other work activities.
• Use barriers or cones to delineate the crane's work area.
• Provide training to all personnel on the traffic management plan.
• Use spotters to direct traffic and prevent collisions.
• Ensure that the crane operator has clear visibility of the work area.

Residual Risk Assessment

Likelihood	Severity	Risk Rating
Unlikely	Moderate	Low

6. Uncontrolled crane movement due to operator error, equipment malfunction, or inadequate communication.

Potential Consequences: Equipment damage, serious injury or fatality.

Affected Persons: Workers

Initial Risk Assessment

Likelihood	Severity	Risk Rating
Possible	Major	Medium

Control Measures

• Ensure that the crane operator is properly trained and certified.
• Provide the crane operator with clear instructions and communication.
• Use a signal person to direct the crane operator when visibility is limited.
• Implement a lockout/tagout procedure to prevent unauthorized crane operation.
• Regularly inspect the crane's controls and safety devices.

Residual Risk Assessment

Likelihood	Severity	Risk Rating
Unlikely	Moderate	Low

5. General Control Measures

• Conduct daily pre-use inspections of all crane components, rigging equipment, and lifting devices to identify any defects or damage. Remove any defective equipment from service immediately.
• Ensure that all personnel involved in crane operations are properly trained and certified for their respective roles, including crane operators, riggers, and signal persons.
• Establish and enforce a clear communication protocol between the crane operator, signal person, and ground personnel using hand signals or radio communication.
• Implement a dropped object prevention program, including the use of tool lanyards, debris netting, and exclusion zones.
• Maintain a safe distance from overhead power lines and other electrical hazards. If work near power lines is unavoidable, implement appropriate safety measures such as de-energization or the use of insulated barriers.

6. Emergency Preparedness

• Ensure that the emergency shutdown procedure for the crane is clearly documented and readily accessible to the operator.
• Establish and communicate emergency evacuation routes and assembly points in case of a major incident.
• Maintain a fully stocked first aid kit on-site and ensure that personnel are trained in first aid and CPR.
• In the event of a dropped object, immediately stop all crane operations and initiate an incident investigation to determine the root cause and prevent recurrence.

7. Training Requirements

• Crane Operator Training: Crane operators must receive comprehensive training on crane operation, load charts, rigging techniques, and safety procedures.
• Rigger Training: Riggers must be trained on proper rigging practices, load securement, and inspection of rigging equipment.
• Signal Person Training: Signal persons must be trained on standard hand signals and communication protocols.
• Dropped Object Prevention Training: All personnel involved in crane operations must receive training on dropped object prevention measures.
• Emergency Response Training: All personnel must be trained on emergency response procedures, including evacuation routes, first aid, and incident reporting.

8. Monitoring and Review

Review Frequency: Annually, or after any incident or significant change in procedures

Monitoring Type	Frequency	Responsible Party	Description
Regular Inspection	Daily and Monthly	Crane Operator and Maintenance Personnel	Regularly inspect crane components (wire ropes, hooks, brakes) for wear, damage, and proper function.
Performance Indicator	Continuous during crane operations	Crane Operator	Monitor wind speed and direction using a calibrated anemometer.
Audit	Quarterly	Safety Department	Conduct periodic audits of crane operations to verify compliance with safety procedures and regulatory requirements.
Incident Review	After each incident	Safety Department and Management	Review incident reports and near-miss investigations to identify trends and areas for improvement in crane safety.
Certification Review	Annually	Human Resources and Training Department	Ensure that all crane operators and riggers maintain valid certifications and licenses.

9. Special Circumstances

• Crane operations during adverse weather conditions (e.g., high winds, rain, snow) may increase the risk of accidents. Implement additional precautions such as reducing lift heights, increasing safety factors, and ceasing operations if conditions become too hazardous.
• Crane operations at night or in low-light conditions require adequate illumination to ensure clear visibility of the work area and potential hazards.
• Crane operations performed by lone workers may increase the risk of delayed response in the event of an emergency. Implement a buddy system or use communication devices to maintain contact with other personnel.

Approval and Sign-off

This risk assessment has been reviewed and approved by:

Assessor: _________________________ Date: __________

Manager/Supervisor: _________________________ Date: __________

Safety Representative: _________________________ Date: __________

This risk assessment must be reviewed annually, or after any incident or significant change in procedures or when significant changes occur.

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