Hydraulic Hose Replacement on Smartrock T45 Drill Machine

Assessment Date: [DATE]

Assessor: [ASSESSOR NAME]

Department/Area: [DEPARTMENT/AREA]

Review Date: [REVIEW DATE]

1. Assessment Scope

This Job Safety Analysis (JSA) covers the hydraulic hose replacement procedure on a Smartrock T45 drill machine. It includes all steps from preparation to completion, focusing on potential hazards and control measures. The scope excludes major repairs or overhauls of the hydraulic system beyond hose replacement.

2. Risk Assessment Methodology

This risk assessment employs a systematic approach based on hazard identification, risk evaluation, and control implementation. The methodology follows these steps:

1. Job Step Breakdown: Dividing the hose replacement task into sequential steps. 2. Hazard Identification: Identifying potential hazards associated with each step through observation, experience, and consultation with workers. Questions are used to identify potential hazards, such as 'Can any body part get caught in or between objects?' and 'Do tools, machines, or equipment present any hazards?' 3. Risk Assessment: Evaluating the initial risk for each hazard based on likelihood and severity. 4. Control Measures: Determining and implementing control measures based on the hierarchy of controls (Elimination, Substitution, Engineering, Administrative, PPE). 5. Residual Risk Assessment: Evaluating the residual risk after implementing control measures. 6. Documentation: Documenting the entire process in a JSA.

The risk assessment uses a 5x5 risk matrix to determine risk ratings (Low, Medium, High, Extreme) based on likelihood and severity. [1] [1]

4. Hazard Identification and Risk Evaluation

1. High-pressure hydraulic fluid injection

Potential Consequences: Hydraulic fluid can penetrate the skin and cause serious tissue damage, infection, and potential amputation.

Affected Persons: Workers, nearby personnel

Initial Risk Assessment

Likelihood	Severity	Risk Rating
Possible	Major	High

Control Measures

• Ensure hydraulic system is depressurized before disconnecting hoses.
• Use proper tools and techniques for disconnecting and connecting hoses.
• Wear appropriate PPE, including safety glasses, gloves, and face shield.
• Never use bare hands to check for leaks; use a piece of cardboard or wood.
• Implement a lockout/tagout procedure to isolate the hydraulic system.

Residual Risk Assessment

Likelihood	Severity	Risk Rating
Unlikely	Moderate	Low

2. Hose whipping due to sudden release of pressure

Potential Consequences: Uncontrolled hose movement can cause impact injuries, lacerations, and fractures.

Affected Persons: Workers, nearby personnel

Initial Risk Assessment

Likelihood	Severity	Risk Rating
Possible	Moderate	Medium

Control Measures

• Secure hoses with safety whips or restraints during disconnection.
• Ensure hoses are properly clamped and supported to prevent uncontrolled movement.
• Depressurize the system before disconnecting hoses.
• Inspect hoses regularly for wear and damage.

Residual Risk Assessment

Likelihood	Severity	Risk Rating
Unlikely	Minor	Low

3. Exposure to hydraulic fluid

Potential Consequences: Skin irritation, dermatitis, eye damage, and respiratory irritation from inhalation of mist or vapors.

Affected Persons: Workers

Initial Risk Assessment

Likelihood	Severity	Risk Rating
Possible	Moderate	Medium

Control Measures

• Wear chemical-resistant gloves and safety glasses.
• Use proper ventilation when working in enclosed spaces.
• Avoid direct skin contact with hydraulic fluid.
• Provide readily accessible eyewash stations and safety showers.
• Ensure proper disposal of used hydraulic fluid and contaminated materials.

Residual Risk Assessment

Likelihood	Severity	Risk Rating
Unlikely	Minor	Low

4. Musculoskeletal strain from lifting and handling heavy hoses and tools

Potential Consequences: Back injuries, sprains, and strains.

Affected Persons: Workers

Initial Risk Assessment

Likelihood	Severity	Risk Rating
Likely	Moderate	High

Control Measures

• Use proper lifting techniques (bend knees, keep back straight).
• Use mechanical aids (e.g., hoists, dollies) to move heavy hoses and tools.
• Provide ergonomic tools and equipment.
• Ensure adequate workspace to prevent awkward postures.
• Implement a stretching and warm-up program.

Residual Risk Assessment

Likelihood	Severity	Risk Rating
Possible	Minor	Medium

5. Slips, trips, and falls due to spills and obstructions

Potential Consequences: Fractures, sprains, lacerations, and contusions.

Affected Persons: Workers, visitors

Initial Risk Assessment

Likelihood	Severity	Risk Rating
Possible	Minor	Medium

Control Measures

• Maintain a clean and organized work area.
• Clean up spills immediately.
• Use drip pans to contain hydraulic fluid leaks.
• Ensure adequate lighting.
• Provide slip-resistant footwear.
• Mark and barricade potential trip hazards.

Residual Risk Assessment

Likelihood	Severity	Risk Rating
Unlikely	Negligible	Low

6. Crushing hazard from machine components

Potential Consequences: Crush injuries, fractures, and potential fatalities.

Affected Persons: Workers

Initial Risk Assessment

Likelihood	Severity	Risk Rating
Unlikely	Major	Medium

Control Measures

• Implement lockout/tagout procedures before starting work.
• Ensure machine is stable and supported before removing or replacing hoses.
• Use appropriate lifting equipment and rigging techniques.
• Never place body parts under unsupported machine components.
• Conduct thorough pre-work inspections.

Residual Risk Assessment

Likelihood	Severity	Risk Rating
Rare	Moderate	Low

7. Fire hazard from hydraulic fluid leaks near hot surfaces or ignition sources

Potential Consequences: Burns, explosions, and property damage.

Affected Persons: Workers, nearby personnel

Initial Risk Assessment

Likelihood	Severity	Risk Rating
Rare	Major	Medium

Control Measures

• Regularly inspect hydraulic hoses and fittings for leaks.
• Keep hydraulic fluid away from hot surfaces and ignition sources.
• Ensure fire extinguishers are readily available and workers are trained in their use.
• Implement a hot work permit system for any work involving open flames or sparks.
• Use non-flammable hydraulic fluids where possible.

Residual Risk Assessment

Likelihood	Severity	Risk Rating
Rare	Moderate	Low

5. General Control Measures

• Implement a comprehensive Lockout/Tagout (LOTO) program.

Ensure all energy sources are identified, isolated, and locked out before starting any maintenance or repair work. Train all employees on LOTO procedures and regularly audit the program for effectiveness.

• Conduct regular inspections of all tools and equipment.

Inspect tools and equipment before each use and remove any damaged or defective items from service. Maintain inspection records and ensure timely repairs or replacements.

• Provide and enforce the use of appropriate Personal Protective Equipment (PPE).

Ensure all employees wear appropriate PPE, including safety glasses, gloves, and footwear, when performing maintenance or repair work. Provide training on the proper use, maintenance, and storage of PPE.

• Maintain a clean and organized work area.

Keep work areas free from clutter, spills, and obstructions. Implement a regular cleaning schedule and ensure proper waste disposal.

• Ensure adequate ventilation in work areas.

Provide adequate ventilation to prevent the accumulation of hazardous fumes, vapors, or dust. Use local exhaust ventilation when necessary.

6. Emergency Preparedness

• In case of hydraulic fluid injection injury, immediately seek medical attention. Do not delay, as this is a serious injury requiring specialized treatment.
• In case of a fire, activate the fire alarm, evacuate the area, and use a fire extinguisher if safe to do so. Contact emergency services.
• For hydraulic fluid spills, contain the spill using absorbent materials and dispose of properly according to environmental regulations. Report the spill to the appropriate authorities.

7. Training Requirements

• Hydraulic System Safety Training: Training on the hazards of hydraulic systems, including high-pressure injection injuries, hose whipping, and exposure to hydraulic fluid. This training should cover safe work practices, control measures, and emergency procedures.
• Lockout/Tagout (LOTO) Training: Comprehensive training on the LOTO procedures, including energy isolation, lockout device application, and verification of isolation. This training is essential for preventing accidental start-up of machinery during maintenance.
• Personal Protective Equipment (PPE) Training: Training on the proper selection, use, maintenance, and storage of PPE, including safety glasses, gloves, and footwear. This training should emphasize the importance of wearing appropriate PPE for specific tasks.
• Spill Response Training: Training on how to respond to hydraulic fluid spills, including containment, cleanup, and disposal procedures. This training should also cover reporting requirements and the use of spill response kits.
• Emergency Response Training: Training on emergency procedures, including fire response, evacuation, and first aid. This training should include regular drills to ensure employees are familiar with emergency procedures.

8. Monitoring and Review

Review Frequency: Annually, or after any incident or change in procedure

Monitoring Type	Frequency	Responsible Party	Description
Regular Inspection	Weekly	Maintenance Supervisor	Inspect hydraulic hoses, fittings, and connections for leaks, damage, and wear. Document inspection findings and initiate corrective actions as needed.
Performance Indicator	Monthly	Safety Manager	Track the number of hydraulic fluid spills and near-miss incidents. Analyze trends and implement preventive measures to reduce the frequency of spills and incidents.
Audit	Annually	Safety Department	Conduct a comprehensive audit of the hydraulic hose replacement program, including LOTO procedures, PPE usage, and training records. Identify areas for improvement and implement corrective actions.

9. Special Circumstances

• Adverse weather conditions (e.g., rain, snow, extreme temperatures) can increase the risk of slips, trips, and falls. Schedule hose replacements during favorable weather conditions or provide additional safeguards.
• Night work increases the risk of accidents due to reduced visibility. Provide adequate lighting and reflective clothing for workers performing hose replacements at night.
• Lone work can increase the severity of injuries due to delayed response times. Implement a buddy system or provide a communication device for workers performing hose replacements alone.

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 change in procedure or when significant changes occur.

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