Job Hazard Analysis

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1. Slide 1

   Module # 2

   • Job Hazard Analysis
2. Slide 2

   Disclaimer

   • This material was produced under grant number SH-05144-SH9 from the Occupational Safety and Health Administration, U.S. Department of Labor. It does not necessarily reflect the views or policies of the U.S. Department of Labor, nor does mention of trade names, commercial products, or organizations imply endorsement by the U.S. Government.
3. Slide 3

   Learning Objectives

   • Hazard analysis of critical processes in wind tower construction, maintenance and demolition include:
   • Working at heights
   • Wind turbine and tower assembly
   • Working around electricity
   • Working in exposed environments
   • Wind turbine component offloading
   • Rotor assembly and Nacelle placement
   • Mechanical completion and commissioning
4. Slide 4

   What is a Hazard?

   • Any agent with the potential to:
   • Cause harm to humans
   • Damage to property
   • Damage environment
   • Exposure to it creates risk
   • Can be natural or man made
5. Slide 5

   What are the Types of Hazard? (1)

   • Hazards types include:
   • Fall
   • Fire
   • Electrical
   • Mechanical
   • Physical
6. Slide 6

   What are the Types of Hazard? (2)

   • Hazards types include:
   • Struck-by
   • Health
   • Safety
   • Confined space
7. Slide 7

   What is Job Hazard Analysis?

   • The process of identifying the dangers associated with specific job tasks before they occur.
   • To eliminate or reduce the risk of injuries and fatalities to workers
   • To investigate accidents.
   • To train workers on job safety.
8. Slide 8

   Process for Conducting Job Hazard Analysis

   • Discuss with the workers about what is to be done.
   • Involve workers in the entire process
   • Identify the necessary steps involved in the execution of each job task.
   • Identify and include the OSHA standards and requirements that apply to the jobs.
9. Slide 9

   Job Hazard Analysis Form

   • Job Task Procedure
   • Potential Hazards
   • Control Measures
10. Slide 10

    Working at Height Hazard Analysis (1)

    • Existing Hazards: Fall from height
    • Control Measures:
    • Perform work during friendly weather.
    • Use harness and fall arrest system properly.
    • Collapse of the tower
    • Ensure that all sections and components are bolted and welded correctly.
    • Periodically inspect and maintain all equipment.
    • Inspect PPE and all work platforms before every use.
    • Collapse of mobile work platform
    • Ensure that crane is properly installed.
    • Avoid overloading crane.
    • Failure of fall arrest system Inspect the personal arrest system before and after every use.
    • Stay away from swinging crane load.
    • Struck by swinging load
    • Do not carry out work in a windy atmosphere.
    • Collapse of crane
11. Slide 11

    Working at Height Hazard Analysis (2)

    • Existing Hazards: Struck by falling or flying object
    • Hit by collapse crane
    • Electrical fire
    • Control Measures: Measures:
    • Ensure that no one stands under the tower where others are working on top.
    • Do not work on, nor go near the tower during strong winds.
    • Perform work in little to no wind speed.
    • Carry all tools in a handy man’s bag.
    • Be aware of the surroundings.
    • Ensure that the crane:
    • Pad is well constructed
    • Properly erected
    • Not overloaded
    • Provide a fire extinguisher in nacelle.
    • Train workers to use extinguisher for small fires.
    • Fire insulation should be considered in nacelle design. Ensure that rotating components are well lubricated to prevent fire due to friction.
    • Provide parachutes for quick decent to escape from fire.
12. Slide 12

    Working at Height Hazard Analysis (3)

    • Existing Hazards:
    • Control Measures:
    • Heat stress
    • Gradually acclimatize worker to heat.
    • Perform work in coolest part of the day or on cooler days to avoid heat stress.
    • Cold stress
    • Ensure that workers dress properly for the cold.
    • Train workers to recognize the symptoms of cold stress.
    • Create buddy system among workers and encourage them to monitor their physical condition and that of their coworkers.
13. Slide 13

    Hazard Analysis of Mechanical Assembly of Large Components (1)

    • Existing Hazards: Fall from height
    • Control Measures:
    • Use harnesses and fall prevention equipment properly.
    • Minimize amount of slack in fall arrest system.
    • Avoid overreaching.
    • Struck by:
    • Be aware of your surroundings.
    • Keep away from swinging crane load.
    • Falling object
    • Swinging crane load
    • Collapse of tower structure
    • Collapse of crane
    • Confined space
    • Ensure to bolt and weld tower sections and components properly.
    • No one should be near the tower during strong winds.
    • Ensure proper installation of crane.
    • Avoid overloading of crane.
    • Place “Confined Space” warning label on tower, nacelle, hub and blades.
14. Slide 14

    Hazard Analysis of Mechanical Assembly of Large Components (2)

    • Existing Hazards: Trapped between
    • Control Measures:
    • Avoid getting into narrow spaces between components.
    • Grinding of fingers by Watch your fingers and prevent them from being caught gear components
    • between moving parts.
    • Electrocution
    • Only properly trained technicians should work on electrical components.
    • De-energize electrical equipment and components of turbine before working on it.
    • Caught on spinning shaft.
    • Disengage rotor to prevent blades from spinning while work is being done.
    • Place a lock on the controls to prevent them from being turned back on while work done.
    • Keep loose ends of your cloths attached to your body, to prevent them from being caught on moving parts.
15. Slide 15

    Hazard Analysis of Working around Electricity (1)

    • Existing Hazards: Fall from height
    • Electrocution
    • Electrical shocks
    • Control Measures:
    • Use harnesses and fall prevention equipment properly.
    • Minimize amount of slack in fall arrest system.
    • Avoid overreaching.
    • Keep your feet and hands free from slippery substances.
    • Only properly trained technicians should work on electrical components.
    • De-energize electrical equipment and components of turbine.
    • Avoid working in damp conditions.
    • Use custom logout-tagout system on parts being worked on. Disengage rotor to prevent blades from spinning.
    • Place a lock on the controls to prevent them from being turned back on while working on electrical components.
    • Overhead cables should be de-energized before working close.
16. Slide 16

    Hazard Analysis of Working around Electricity (2)

    • Existing Hazards: Control Measures:
    • Prevent overheating in the nacelle. Explosion
    • Prevent friction in rotor at blade pivoting points. Arc flash
    • Lubricate all moving joints. Arc blast
    • Prevent leakage of hydraulic oil. Electrical fire
    • Prevent short circuiting of electrical components. Burns
    • The parking brakes should not be configured to apply on the Lightning blades during high winds to avoid high heat and explosion.
    • A slip clutch should be used to ensure that any loss of yaw control will not generate excessive heat.
    • Use fire retardant materials in the design and construction.
    • A fire detection mechanism should be installed in the nacelle. Provide parachutes for quick decent in case of fire.
17. Slide 17

    Hazard Analysis of Working in Exposed Environments

    • Existing Hazards:
    • Falls and fatigue
    • Confined space
    • Heat stress
    • Cold stress
    • Respiratory problems from harmful gases, dust and vapor.
    • Explosion
    • Fire
    • Electrical hazards
18. Slide 18

    Heat stress:

    • Control Measures for Hazards in Exposed Environments (1)
    • Perform work on cooler days to avoid heat stress.
    • Nacelle should be ventilated and air-conditioned
    • Conduct air sampling in nacelle before working in it.
    • Establish buddy system among workers. Train them to watch for first symptoms of heat stress.
19. Slide 19

    Heat stress:

    • Control Measures for Hazards in Exposed Environments (2)
    • Encourage workers to drink water at least every 20 minutes.
    • Gradually acclimatize workers to heat.
    • Workers should take regular breaks to cool off in airconditioned site office.
20. Slide 20

    Cold stress:

    • Control Measures for Hazards in Exposed Environments (3)
    • Train workers to recognize the symptoms of cold stress.
    • Encourage workers to monitor their physical condition and that of their coworkers.
    • Ensure that workers are adequately dressed for the weather.
    • Stay dry. Moisture or dampness increases the rate of heat loss from the body.
21. Slide 21

    Cold stress:

    • Control Measures for Hazards in Exposed Environments (4)
    • Keep extra clothing handy when there is a need to change outfits
    • Drink warm fluids
    • Use proper engineering controls, safe work practices, and personal protective equipment (PPE)
22. Slide 22

    Hazard Analysis of Wind Turbine Assembly and Erection

23. Slide 23

    Hazard Analysis of Wind Turbine Assembly and Erection (1)

    • Existing Hazards: Falls due to:
    • Slipping
    • Tripping
    • Overreaching
    • Over balancing
    • Collapse of tower
    • Collapse of crane
    • (i) Object hit (ii) Fatigue
    • Control Measures: Measures:
    • Consider weather conditions in planning the work, with emphasis on:
    • Wind speed:
    • All works can be executed in little or no wind conditions
    • All internal works can be done in moderate wind speed
    • No work should be done in strong winds on turbines.
    • Lightning:
    • No work when there is a lightning forecast.
    • Ensure proper use of lanyards and PFAS, together with the following:
    • Keep your hands and feet free from slippery substances and work area from cluster
    • Avoid overreaching and over balancing.
    • Ensure proper erection of tower.
    • Avoid working on the tower during strong winds.
    • Ensure that crane is properly installed.
    • Be aware of your surroundings.
    • Take regular breaks to avoid fatigue.
24. Slide 24

    Hazard Analysis of Wind Turbine Assembly and Erection (2)

    • Existing Hazards:
    • Crane or heavy equipment.
    • Control Measures:
    • Don’t stand in front of a moving vehicle or crane.
    • Park vehicles and mobile equipment on levelled surfaces.
    • Be aware of the surroundings. Struck by:
    • Swinging crane load Stay away from loaded crane or machinery.
    • Falling objects
    • Avoid loitering at the base of tower.
    • Avoid working on tower during strong winds.
    • Consider adequate ventilation during design and
    • Confined space
    • resulting in low oxygen, construction.
    • Provide portable oxygen tanks for workers.
    • Asphyxiation.
25. Slide 25

    Hazard Analysis of Wind Turbine Assembly and Erection (3)

    • Existing Hazards:
    • Fire due to:
    • Accumulated hazardous gases in confined space.
    • Explosion
    • Lightning
    • Overheating
    • Physical exertion and fatigue
    • Control Measures:
    • Prevent overheating in the nacelle.
    • Prevent friction in rotor at blade pivoting points.
    • Lubricate all moving joints.
    • Prevent leakage of hydraulic oil.
    • Prevent short circuiting of electrical components.
    • Use fire retardant materials in the design and construction of turbine components
    • A fire detection mechanism should be installed in the nacelle.
    • Avoid physically lifting large components.
    • Take regular breaks.
26. Slide 26

    Hazard Analysis of Wind Turbine Assembly and Erection (4)

    • Existing Hazards:
    • Control Measures:
    • Confined spaces resulting in:
    • Lack of oxygen
    • leading to
    • Asphyxiation
    • Accumulation of hazardous gases
    • Hot toxic fumes
    • Hot and humid conditions, etc.
    • Consider ventilation in the design and construction. Provide portable oxygen tanks for workers.
    • Take regular breaks.
    • Perform air sampling in confined spaces.
    • Post warning signs at the entrance of confined spaces
    • Caught on moving parts
    • Beware of moving parts of turbine.
    • Disengage rotor to prevent blades from spinning.
    • Place a lock on controls to prevent accidental operations Keep loose ends of cloths attached to the body.
    • Drowning
    • Provide life vest for workers during offshore operations Experience in swimming must be a requirement on offshore turbines.
27. Slide 27

    Hazard Analysis during Offloading (1)

    • Photo by Mike Schultz
28. Slide 28

    Hazard Analysis during Offloading (2)

    • Existing Hazards:
    • Control Measures:
    • Crane collapse
    • Cranes should be carefully installed, not overloaded and maintained regularly.
    • Be aware of the surroundings.
    • Stay away from loaded cranes.
    • Avoid loitering at the base of tower while work is ongoing.
    • Avoid working in or around tower during strong winds.
    • Do not stand in front of a moving vehicle or mobile crane.
    • Park all vehicles and mobile equipment on levelled surfaces.
    • Keep your hands and feet free from slippery substances.
    • Keep work area and walkways free from cluster.
    • Struck-by hazards
    • Run-over hazards
    • Fall, tripping and slipping hazards
29. Slide 29

    Hazard Analysis of Tower Assembly (1)

    • Existing Hazards:
    • Control Measures:
    • Fall, slipping and tripping hazards
    • Perform work in appropriate weather.
    • Use harness and fall arrest system properly.
    • Keep your hands and feet free from slippery substances.
    • Keep work area and walkways free from cluster.
    • Avoid overreaching and over balancing.
    • Avoid working on the tower during strong winds.
    • Ensure that crane is correctly installed.
    • Be aware of your surroundings.
    • Take regular breaks to avoid fatigue.
    • Tower collapse
    • Bolt and weld tower sections and components correctly.
    • Avoid loitering around tower during strong winds.
30. Slide 30

    Hazard Analysis of Tower Assembly (2)

    • Existing Hazards: Struck-by hazards
    • Control Measures:
    • Be aware of your surroundings.
    • Stay away from mobile crane
    • Do not stand under or near the base of the tower.
    • Avoid working on the tower during strong winds.
    • Crane collapse
    • Crane should be properly installed and regularly maintained.
    • Do not stand in front of a moving vehicle or mobile crane.
    • Ensure vehicles and mobile equipment are parked on a levelled area.
    • Run-over hazards
31. Slide 31

    Hazard Analysis of Nacelle Placement (1)

    • Existing Hazards: Control Measures:
    • Fall, slipping and Work in an appropriate weather, with little to no wind tripping hazards
    • speed.
    • Workers must be trained in use of any scaffold, mobile equipment and/or lift and follow the manufacturer’s instructions.
    • Use harness and fall arrest system.
    • Keep hands and feet free from slippery substances and work area from cluster.
    • Avoid overreaching and overbalancing.
    • Ensure that the tower is correctly erected
    • Ensure that crane is correctly installed.
    • Be aware of your surroundings.
    • Take regular breaks to avoid fatigue.
    • Bolt and weld tower sections correctly.
    • Tower collapse
    • Avoid working during strong winds.
32. Slide 32

    Hazard Analysis of Nacelle Placement (2)

    • Existing Hazards: Struck-by hazards
    • Control Measures:
    • Be aware of your surroundings.
    • Stay away from mobile cranes.
    • Avoid loitering at the base of tower
    • Avoid working on tower during strong winds.
    • Crane collapse
    • Crane should be properly installed and maintained
    • Don’t stand in front of a moving vehicle or crane.
    • Park vehicles and mobile equipment on a levelled surface
    • Avoid narrow spaces between components.
    • Run-over hazards
    • Trapped-between
33. Slide 33

    Hazard Analysis of Nacelle Placement (3)

    • Existing Hazards: Control Measures:
    • Recognize and beware of moving parts of the turbine. Caught on
    • Disengage rotor to prevent blades from spinning spinning shaft
    • Place a lock on the controls to prevent accidental operations. Contact with
    • Keep loose ends of cloths attached to the body. moving parts
    • Electrical shocks
    • Electrocution
    • Only trained technicians should work.
    • Always de-energize electrical equipment and components of turbine.
    • Avoid working in damp conditions.
    • Use custom logout-tagout system on parts being worked on.
    • Disengage rotor to prevent blades from spinning
    • Place a lock on the controls to prevent accidental operations.
    • Recognize electrical components and proceed with caution.
34. Slide 34

    Hazard Analysis of Nacelle Placement (4)

    • Existing Hazards:
    • Confined space
    • Collapse of work platform
    • Control Measures:
    • Consider ventilation in the design and construction
    • Nacelle design should be air-conditioned.
    • Provide portable oxygen tanks for long works.
    • Take regular breaks.
    • Perform air sampling in confined spaces
    • Post warning signs at the entrance of confined spaces.
    • Periodically inspect and maintain all equipment.
    • Inspect PPE and all work platforms before every use.
    • Ensure that crane is installed correctly.
    • Avoid overloading crane.
35. Slide 35

    Hazard Analysis of Nacelle Placement (5)

    • Existing Hazards: Control Measures:
    • Fire
    • Explosion
    • Arc flash/blast
    • Heat stress
    • Prevent overheating in the nacelle.
    • Prevent friction in rotor at blade pivoting points
    • Lubricate all moving joints
    • Prevent leakage of hydraulic oil.
    • Prevent short circuiting
    • Use fire retardant materials in design and construction of turbine components
    • A fire detection mechanism must be installed in the nacelle.
    • Perform work on cooler days.
    • Nacelle design should be well-ventilated and air-conditioned. Conduct air sampling in nacelle before commencing operations. Establish a buddy system among workers.
    • Pracrtice fluid intake at least every 20 minutes.
    • Gradually acclimatize workers to heat.
    • Take regular breaks to cool off in airconditioned site office.
36. Slide 36

    Hazard Analysis of Rotor Assembly & Placement (1)

    • Photo source: Boss Crane (https://www.bosscrane.com/industries-served/wind-energy-services/)
37. Slide 37

    Hazard Analysis of Rotor Assembly & Placement (2)

    • Existing Hazards: Control Measures:
    • Fall, slip & trip hazards
    • Struck-by hazards
    • Be aware of the surroundings.
    • Perform work in an appropriate weather, with little to no wind speed. Use harness and fall arrest system properly.
    • Keep your hands and feet free from slippery substances and working area from cluster
    • Avoid overreaching and over balancing
    • Avoid working on the tower during strong winds.
    • Ensure that crane is correctly installed.
    • Take regular breaks to avoid fatigue.
    • If possible, assembly components on ground before lifting in place
    • Stay away from mobile cranes
    • Do not stand under or near the base of the tower
    • Avoid working on or approaching the tower during strong winds.
38. Slide 38

    Hazard Analysis of Rotor Assembly & Placement (3)

    • Existing Hazards: Run-over hazards
    • Crane collapse
    • Tower collapse
    • Rotor collapse
    • Control Measures:
    • Do not stand in front of a moving vehicle or mobile crane.
    • Park vehicles and mobile equipment on levelled surfaces
    • Crane pads should be well constructed.
    • Crane should be correctly installed and regularly maintained
    • Tower foundation should be well constructed.
    • Bolt and weld tower sections and components properly.
    • No one should be near the tower during strong winds.
    • Ensure:
    • Hub is always assembled correctly.
    • Blades are correctly attached and bolted
    • Work is done in little to no wind speed.
39. Slide 39

    Hazard Analysis of Rotor Assembly & Placement (4)

    • Existing Hazards: Collapse of work platform
    • Control Measures:
    • Periodically inspect and maintain all equipment.
    • Inspect PPE and all work platforms before every use.
    • Trapped between Avoid getting into narrow spaces between components.
    • Confined space in Ventilation should be considered in the design and hub
    • construction of the hub.
    • Provide workers with portable oxygen tanks for extended periods in the tower, nacelle and hub.
    • Take regular breaks outside confined spaces.
    • Perform air sampling in confined spaces, before commencing operations.
40. Slide 40

    Hazard Analysis of Mechanical Completion & Commissioning (1)

    • Existing Hazards: Control Measures:
    • Perform work in an appropriate weather, with little to no
    • Fall from height
    • wind speed.
    • Use harness and fall arrest systems properly.
    • Keep your hands and feet free from slippery substances.
    • Keep work area and walkways free from cluster.
    • Avoid overreaching.
    • Avoid over balancing.
    • Ensure that the tower is correctly erected.
    • Avoid operations during strong winds.
    • Be aware of your surroundings.
    • Take regular breaks to avoid fatigue.
    • Tower foundation should be well constructed.
    • Tower collapse
    • Bolt and weld tower sections and components correctly.
    • No one should loiter around tower during strong winds.
41. Slide 41

    Hazard Analysis of Mechanical Completion & Commissioning (2)

    • Existing Hazards: Control Measures:
    • Electrical shocks Only trained technicians should work
    • De-energize electrical equipment of turbine before working Electrocution
    • Avoid working in damp conditions.
    • Use custom logout-tagout system on active parts
    • Disengage rotor to prevent blades from spinning
    • Place a lock on the controls
    • Recognize electrical components throughout the turbine.
    • Inspect and test switchgear boxes and metal surfaces
42. Slide 42

    Hazard Analysis of Mechanical Completion & Commissioning (3)

    • Existing Hazards:
    • Fire/Explosion
    • Control Measures:
    • Prevent overheating in the nacelle.
    • Prevent friction in rotor at blade pivoting points
    • Lubricate moving joints
    • Prevent leakage of hydraulic oil
    • Prevent short circuiting of electrical components.
    • Use fire retardant materials in the design and construction phases
    • A fire detection mechanism should be installed in the nacelle.
43. Slide 43

    Hazard Analysis of Mechanical Completion & Commissioning (4)

    • Existing Hazards:
    • Contact with moving parts
    • Control Measures:
    • Beware of all moving parts of the turbine.
    • Disengage rotor to prevent blades from spinning
    • Caught on spinning shaft
    • Place a lock on the controls to prevent accidental operations.
    • Keep loose ends of cloths attached to the body
    • Confined space
    • Ventilation should be considered in the design Provide workers with portable oxygen
    • Take regular breaks
    • Perform air sampling
44. Slide 44

    Major Hazards

    • Fall from height
    • Struck-by:
    • Falling object
    • Swinging load
    • Flying object
    • Electrical shocks
    • Electrocution
    • Fire
45. Slide 45

    Control Measures (1)

    • There should be a dedicated safety coordinator assigned to every wind tower project site.
    • Plan and carry out work in little to no wind speed.
    • Provide and ensure proper usage of approved personal fall arrest systems (PFAS) by all workers exposed to fall hazards.
    • Stay away from mobile cranes.
    • Do not stand under or near the base of the tower while work is ongoing
46. Slide 46

    Control Measures (2)

    • Only trained technicians should work on electrical components.
    • De-energize electrical equipment and components of turbine before commencing operations.
    • Prevent overheating in the nacelle.
    • Prevent friction in rotor at blade pivoting points to avoid fire or explosion due to overheating.
47. Slide 47

    Review & Questions

    • Name three important things you learned in this section.