TIKARIA EXPANSION PROJECT, ACC Rev: 1

HAZARD IDENTIFICATION RISK ASSESSMENT Doc. No. : ACC/TKP/HIRA/LNVT/00

MOS No. : ACC/TKP/MS/LNVT/00
Title: Fabrication Work
Assessment Date: 6/21/2021

KEY POINTS:
1-All necessary permits to be obtained from ACC concerned person prior to work commences.
2-All persons must be Safety Inducted.
3-Mandatory job specific PPEs must be worn by all engaged person
4-Life saving talk must be conducted prior to start each shift, All person to be participate the task
5-All engaged person must be aware about their job, potential hazards and control measures
6-Rest Shelter to be provided for the workers
7-Welfare facilities to be provided according to workmen strength
8-Job specific Training to be provided, if required
9- Safety awareness signage to be displayed at site
10-Probability, Severity & risk Table is attached for reference

INITIAL RISK RESIDUAL RISK

Probability

Probability
Risk Level

Risk Level
Consequence

Severity

Severity
SN Job Steps Potential Hazards Current Control Measures Additional control measure Person responsible
(who will harm)

1 Power 1. Electrocution Workers, 1. Power connection activity to be performed only by 3 4 12 1. Danger Sticker should be displayed at 2 2 4
Connection 2. Unauthorised person. Electrician authorised person. panel board.
2. All connection to be gone through RCCB/MCB. 2. Fire extinguisher to be placed near panel
3. All power cable to be in healthy condition. board.
Cable management to be in practice 3. All RCCB/MCB should be done tripping
4. All DB must be placed under weather protection. test on regular basis.
5. All DB/panel board must be tested by ACC concerned 4. Periodically test must be done with
person and marked with quarterly tested sticker. RCCB tester and it will recorded in register.
6. All DB/panel board must be facilitated with double body 5. If cable cross the road, it should be
earth, and door properly locked covered by channel/pipes
7. Joint lugs to be in use for cable joint/connection. 6. Max joint is allowed (2 nos) after
8. Industrial plug top to be used for get connection from DB. approved of E&I head
9. All installed RCCB/MCB must be in working condition with 5. Area should be barricaded Site Engineer
30mA sensitive.
10. Authorized person details should be display at DB also
Rubber mat should be provided
11. All the cable should be above the ground
12. Use job specific PPEc.

2 Manual 1. Cut Injury Workers 1. Don’t allow the person to lift more than 20-22kg for 2 3 6 1. Ensure any heavy loads or any irregular 1 2 2
Materials 2. Pinch points materials shifting from one place to other. dimension job having less load shall be
handling 3. Hit by Object/Load 2. Provide Trolley for materials shifting. unloaded mechanically if possible.
4. Slip, Trip & fall 3. Cut resistance hand gloves shall be used for metallic
5. Injuries and handling.
musculoskeletal disorders 4. Ensure that workmen keep their hands / leg away from
pinching points. Site Engineer
5. Proper communication & co ordination with co worker.
6. Shoulder pad should be provided during shifting of
materials
3 Materials 1. Toppling of Operator, 1. Pre-lifting plan should be prepared before start of lifting 3 3 9 1. Ensure trained & competent crane 2 3 6
handling( Mec Farana/crane Worker any materials by crane. operators are deployed.
hanical) 2. Failure of lifting 2. It is to be ensured that it should not cross the SWL of 2. Use only good condition, tested &
appliances crane/hydra. certified appropriate lifting gears, tools,
3. Hit by object/person 3. Before staring of loading/unloading by crane proper tackles & slings.
4. Electrocution to levelled & compact surface should be provided. 3. Proper selection & placement of the
Farana/Crane. 4. Farana boom should e kept as low possible during shifting crane.
5. Fall/rolling of materials of material. 4. Overhead services must be detected &
6. Struck by moving load 5. The load should not be lifted beyond the Safe Working isolated properly & follow safe lifting
Load (SWL) procedure.
6. Ensure crane capacity at lifting radius of the load. 5. Ensure sleeper or jack plate to be
7. Area should be barricaded & no person should be allowed provided below out rigger on any type of
near the swinging area, safe distance to be maintained. soil
8. Tag line must be provided to prevent swinging of the load 6. Ensure engine on mobile should off of
while lifting. farana/crane operator Site Engineer
9. Ensure proper stacking of material & proper slinging to be 7. Dedicated signal man is must
done. 8. Batten light to be used in night
10. Ensure all safety gears must be in working condition 9. Plate clamp, chain clamp, web sling
11. FLRA should be prepare with sketch before lifting activity should be in good condition
by execution team member
12. After sunlight special permit required for lifting

4 Storage of Gas 1. Fire and explosion Workers, 1. All compressed gas cylinders or empty shall be secured to 3 3 9 1. Use Trolley for shifting of gas cylinder. 2 2 4
Cylinder 2. Damage of Cylinders Property damage racks, walls, work benches and locked by a strong chain or 2. Use Charged fire extinguisher at storage
3. cylinder fall on person strap, or secured by any other approved method capable of area.
preventing the cylinder from falling or being knocked over. 3. Flammable materials should not be
2. Properly secure cylinders in a well ventilated and placed or stock near cylinder storage area.
protected area away from heat, flames, and the sun/weather 4. All empty cylinders shall be handled with
protection shed. the same care as full cylinder.
3. Always screw on an appropriate gas cap on cylinders that 5. Valve-protection caps shall not be used
are not in use. for lifting cylinders from one vertical
4. Cylinders shall not be dropped/struck/strike each other position to another place.
during storage or transporting to site. 6. Cylinders shall be kept far enough away
5. Full & empty gas cylinder must be stored segregate with from the actual welding or cutting
identification mark- “EMPTY” / "FULL" operation so that sparks, hot slag, or flame
6. All compressed gas cylinders must bear labels that clearly will not reach them, or fire-resistant
identify the contents. shields shall be provided. Site Engineer
7. Compressed gas cylinders must be in an upright position and 8. Slide wrench not allowed for cylinder
supported at all times, whether full or empty-wall-mounted or opening
bench-mounted gas cylinder brackets. 9. Oil and grease should not use for torch
8. All cylinders must having valve protection cap fitting
9. Cylinders shall never be used as rollers or supports, whether 10. Don't try to repair A cylinder, if any
full or empty. leakage detected.
10. Cylinder should not be stored in direct sunlight
5 Welding work 1. Fire hazard, Electrical Welder/worker 1. All welding machine must be checked by ACC concerned 2 3 6 1. Welding cable must be in healthy 2 2 4
shock, person and marked with quarterly tested sticker. condition with cable management to be in
2. Hot spatters & loose 2. All welding machine must be facilitated with double body practice practice.
joints of welding, earth and kept under weather protection shed. 2. Daily Checklist for welding work/welding
3. Tripping hazard due to 3. Industrial plug top to be used for power connection. machine to be in practice.
improper cable routing. 4. fire extinguisher to be placed at easy approach 3. Maintain good housekeeping by
4. Dust & welding fumes Area free from combustible material. removing all combustible material
5. Eye injury due to slag 5. Returned earthing to be attached with the job. regularly.
6. Welding work to be performed by only respective person. 4. All cable should be in healthy condition
7. Use job specific PPEs-full body apron, face shield with 5. Don't do the welding while wet cloth,
helmet etc shoes, and wet area
8. Ensure combustible material should be removed from the Site Engineer
working area before the start of the work.
9. ELCB/RCCB must be installed with welding machine
10. Ensure electrode/earthing holder should be in good
condition

6 Grinding work 1. Fire hazard Grinder, Worker 1. Grinding machine must be inspected by ACC concerned 2 3 6 1.Area free from combustible materials. 2 2 4
2. Electrical shock person and marked with quarterly inspected sticker.
3. Unguarded rotating 2. Grinding wheel RPM must be higher then Grinding wheel
parts of the grinding and selection of g/wheel as per IS standard
machine 3. Selection of grinding wheel must be match standard
4. Tripping hazard specification.
5. Unauthorized 4. Power connection for G/machine must be gone through
operation RCCB.
6. Defective machine 5. Use Industrial plug top for getting connection.
7. Pinch points & hot 6. Grinding work to be performed by only respective person.
spatter 7. Dead band switch should be fixed with g/machine
8. Eye injury due to flying 7. Always maintain good body posture
object 8. Ensure the availability of guard on wheel Site Engineer
9. fire extinguisher to be available at easy approach Wear
10. Job specific PPEs- Apron, face shield with helmet etc.
7 Gas cutting 1. Fire & explosion Gas cutter, 1. Cylinders should be mounted on gas trolley and locked by 3 3 9 1. All empty cylinders shall be handled with 2 2 4
2. Burn injury Worker chain. the same care as full cylinder.
3. Back fire 2. Gas trolley shall be kept away from sources of heat. 2. Gas hoses must be matched IS standard.
4. Dragging of cylinders 5. 3. Flash back arrestor must be installed at both point. 3. Housekeeping must be maintained at
Damaged Hose & joints 4. All gas hoses must be joint/fixed by clamp. working site.
6. hot spatter 5. Water shop must be placed with trolley for leakage test.
7. Toxic fumes 6. Valve protection cap must be fixed with all cylinders-
either empty cylinder.
7. Cylinders shall never be used as rollers or supports-
whether full or empty.
8. A charged fire extinguisher must be available at site at easy
approach.
9. Triple pipe cutting torch provided as per ACC guidelines
10. Gas Hose should be free from cut & damage
11. Pressure gauge should be fixed in both cylinders & should Site Engineer
be in working condition
12. Open the DA/LPG regulator then cutting torch valve and
light the . then open the 02 valve as per the required
pressure.
13. Job specific PPEs should be provided

8 Rolling 1. Electrocution, Operator, 1. Rolling machine must be fixed with pcc ground. 4 3 12 1. Loose clothes should not be used by any 2 1 2
wending 2. Hand injury Worker 2. Motor area must be covered by hard barricading/fencing. workers.
machine 3. Power connection must be gone through RCCB/MCB 2. Emergency switch/button must be in
Always maintain safe distance. working condition.
4. Use proper/cut resistance hand gloves for avoid to sharp 3. Inspect rolling bending machine at
edge of plate. regular intervals.
5. Keep your work surface clean and clear of metal scrap to 4. Ensure that there is no loose connection Site Engineer
avoid injury. and all guards and other protective devices
are in their proper places.
9 Laying, & 1. Failure of lifting sling Operator, 1. Only certified tools tackles should be taken into use. 3 3 9 1. Only trained & experienced workmen do 2 1 2
alignment of 2. Toppling of Worker 2. Selection of proper lifting tools & tackles according to SWL the job.
Metal farana/crane Only trained & experienced workmen do the job. 2. Dedicated gang should be deployed for
plate/sheet/pi 3. Caught between object 3. Crane & hydra RA sheet must be filled properly before rigging gang
pe. 4.Tripping & falling hazard starting the work Proper levelled & compact surface must be
5. Failure of crane provided.
6. Hit by object/person 4. The load should not e lifted beyond the Safe Working Load
(SWL).
5. Ensure crane capacity at lifting radius of the load. Ensure
competent & trained crane operators are deployed. Site Engineer
6. Provision of audio alarm for the lifting action being taken
place.
7. Guide rope to be used. Proper access & egress must be
provided.

10 Drilling 1.Physical injuries to body Operator, 1. Only inspected and validated drill machine shall be used. 2 3 6 1. Before using drill m/c power cable shall 1 2 2
parts 2.Defective power Worker 2. Before using the drill bit shall be checked for any physical be checked for any damage.
cable 3.Electric shock damage and good conditioned drill bit shall be used. 2. Ensure the to keep fire extinguisher at
4.Flying particles 3. Trade validation of driller shall be ensured and engaged in site in healthy condition.
5.Unskilled operator the job.
6.Defective drill machine 4. Use of face shield and eye protection to be ensured.
7.Slip, trip & fall 5. Power connection shall be taken though RCCB and double
insulated joint free cable shall be used. Site Engineer
6. Use of mandatory PPEs.

11 Plasma cutting 1. Electric Shock Operator, 1. Check whether plasma cutter is tested and tagged by ACC 2 4 8 1. Check whether compressed air receiver 2 3 6
2. Excess Fumes Worker Electrical department Ensure you are familiar with the tank has been tested (under Pressure
3. Hand Injury Plasma Cutter operations and controls. Vessel Act) and tagged. Air filter, moisture
4. Fire & Burn due to 2. Check whether compressed air receiver tank has been and oil trap are in good condition.
spark spray tested (under Pressure Vessel Act) and tagged. Compressor air should be free from
5. Compressed Gas- High 3. Check workspaces and walkways to ensure no slip/trip moisture and oil for better quality of
Pressure injection Injury hazards are present. cutting.
6. Explosion due to use 4. Ensure this plasma cutter has a suitable safe work area 2. Do not touch live electrical parts or
vicinity of containers 5. Ensure the work area is clean and clear of grease, oil and electrodes with bare skin, gloves or wet
under pressure, or in the any combustible and flammable materials. clothing.
presence of explosive 6. Ensure ABC type fire extinguishers are kept ready at site 3. Never dip the electrode in water for
dust, gases or fumes 7. Always turn the power “OFF” before changing tips, cooling.
electrodes, electrode adapters, baffles, brass ends or heat 4. Do not point the torch towards yourself
shields or others.
8. Use 30 mili Amps rated RCBO (tested) for power 5. Hand Torch & cable should be fully
connection insulated.
9. Work in the presence of adequate ventilation, and use 6. Keep your head away from fumes.
ventilators around the arc to prevent gases from forming in 7. Clean spatter and scale from the nozzle
the work area (Where inert gases are used they may frequently. If debris has collected inside of
accumulate in confined spaces causing an asphyxiation risk. the nozzle, rub the electrode on the inside Site Engineer
This is most likely to occur when the gas is significantly bottom of the nozzle to remove any oxide
heavier than air, argon/nitrogen mixtures) layer that may have built up

10. Protect your eyes with welding screen fitted with filtered
lenses
11. Protect your body with appropriate safety garments
12. Keep away your fingers/hand from the plasma jet
13. Practice good housekeeping at all times
14. Sparks (sprays) may cause fires and burn the skin; you
should therefore make sure there are no flammable
materials in the area, and wear appropriate protective
garments like welding apron (long sleeves), welding hand
gloves, Arm sleeve.
 12. Keep away your fingers/hand from the plasma jet
13. Practice good housekeeping at all times
14. Sparks (sprays) may cause fires and burn the skin; you
should therefore make sure there are no flammable
materials in the area, and wear appropriate protective
garments like welding apron (long sleeves), welding hand
gloves, Arm sleeve.

12 Vehicle 1. Collision with moving Workers, 1. Vehicle and pedestrian routes are clearly defined and are 1. Speed restriction signs are in place and
Movement vehicle Operator separated by use of physical barriers, where possible. enforced.
2. Hit the person 2. Vehicle parking spaces are marked appropriately. 2. Provide bankskman, if required
3. Procedures are in place to manage vehicles carrying out 3. While unloading wheel chock should be
reversing manoeuvres i.e. banks person. applied and trailer engine should be in off site Engineer
condition and ignition key to be removed
from its place

13 Work at 1. Fall of person workers 1. Persons engaged in the work at height will completion of 2 3 6 1. Never anchor with electrical wires or 2 2 4
Height 2. Slip & Trip hazards the mandatory height work training. other areas who is not designated for
3. Pinch point/ sharp 2. Person work at height should not lean out side the work anchorage points
edges platforms 2. 3 Point contact must be maintained and
4. Weather condition. 3. Persons working at height should be wear the FBH while no material to be carried during climbing
5. Fall from ladders working at height more than 1.8m. on ladder while working at height sufficient
6. Injury due to over head 4. On working on step ladder working on top most step distance should be maintained from over
installation. should be avoid. head installation
7. Fall of materials 5. Step ladder should be opened completely. And it should be 3. If any rotating equipment is available
locked properly against closing. above the work area it should be positively
6. Ladders should be shifted only after descending the person locked while in its vicinity
working on it.
7. Stepladder should not be allowed to shift while person is site Engineer
on it.
8. Only one person allowed work on ladder at a time. Only
one person allowed work on ladder at a time.
9. Provide fall protection system handrails to every platform

14 Work in dark 1.slip/trip/fall hazards Personal Injury 1. Proper illumination to be provided at site. 2 4 8 1. All connection to be checked by ACC 2 2 4
hour 2. All power connection for illumination lamp to be get concerned person.
through industrial plug top.
3. All power cable must be in healthy condition. Site Engineer

Prepared By LNVT Reviewed By LNVT/KEC/ACC Approved By ACC

 TIKARIA EXPANSION PROJECT, ACC Rev

HAZARD IDENTIFICATION RISK ASSESSMENT Doc. No.

Title: Fabrication Work MOS No.

Assessment Date
person to be participate the task
5-All engaged person must be aware about their job, pote
Conse Curre INITIAL RISK Additi RESIDUAL RISK
Poten quenc nt onal
Probability

Risk Level

Job tial e Contr contr

Severity

S N Steps Hazar (who ol Severity

ol
ds will Meas meas
harm) ures ure
 Rev: 0

ACC/
TKP/
Doc. No. : HIRA
/
LNVT
/00

ACC/
TKP/
MOS No. : MS/
LNVT
/00

Assessment Date: ###

their job, potential

RESIDUAL RISK
Probability

Risk Level

Person responsible