LARSEN & TOUBRO LIMITED

L&T ENERGY - HYDROCARBON

MODULAR FABRICATION FACILITY, KATTUPALLI
HAZARD IDENTIFICATION & RISK ASSESSMENT REGISTER
DEPARTMENT NAME : PLANT & MACHINERY DATE: 10-05-2022
Note : If the Risk Score is ≥ 90 then the Risk level is Significant (S)
If the Risk Score is ≤ 89.9 then the Risk level is Low (L)

RISK LEVEL (S=Significant

RISK ASSESSMENT (L X E

RISK ASSESSMENT (L X E
ROUTINE / NON ROUTINE

RESIDUAL RISK LEVEL

(S=Significant L=Low)
CONSEQUENCES (C)

CONSEQUENCES (C)
Legal Requirement
LIKELIHOOD (L)

LIKELIHOOD (L)
EXPOSURE (E)

EXPOSURE (E)
PROBABILITY/

PROBABILITY/
ACTIVITY

L=Low)
S.No

ADDITIONAL

X C)

X C)
HAZARDS EFFECT / RISKS EXISTING CONTROLS
CONTROLS

Provision of earth fault relays,

Ensure isolation certificate, LOTO system (If
Required), Trained and certified electrician, Work
Exposure to live bus bars or Very Serious injury, severe or permit, Rubber sheet in place
1 1 15 15 L
conductors minor burn & shock injury, Required PPE's like Fiber toe safety shoes,
Rubber hand glove
Department head / Senior person has to
authorized the PTW system for high risk activity

Maintenance of Panel /
switch box / Transformer / Generation of heat due to Exhaust fan, Cross ventilation, Preventive
1 Routine Fire 1 1 7 7 L
DB / PDB ineffective ventilation maintenance

Fall due to work on Un-obstructed walk way, Standard staircase and

Factories Act,
unprotected elevated Physical Injury ladder, Adequate ligting, Standard walkway 3 2 7 42 L
1948
platform width, Use of Full body harness

Provion of earth fault relays, LOTO system,

Unisolated & unused bare Trained and authorized electrician, HT / LT Work
Electric Shock 1 1 15 15 L
cables permit, Rubber sheet, Fiber toe safety shoes,
Rubber hand glove, Discharge rod

Periodical maintenance of electrical equipment.

Contact with leakage electric
Skilled and certified electrcian, Periodical
current due to bare / Electrical shock to the persons
checking of the breakers, Periodical maintenance 1 1 15 15 L
uninsulated cable, while in the vicinity
of electrical appliances, Display of DO's and
working in water logged area
Don'ts

Provision of ELCB and MCB, Earthing continuity

Burn injury to operator /
Fire due to contact of rain test, Provision of Closed DB in open yard,
electrician / Helper or person in 1 1 15 15 L
water with CMB / DB / STN Provision of shop / shed, Trained and skilled
the vicinity
operator
Maintenance in outdoors
2 during Monsoon / wet Non-routine Physical Injury to the operator or Immediate cleaning, Slip resistance Safety shoes,
condition / Storm Fall due to slip 1 2 15 30 L
person in the vicinity Tool box talk , Display of DO's and Don'ts

Monitoring the
Contol of contractors
Skilled and Certified electrcian, Periodical owned electrical
Exposure to electric current
checking of the breakers, Periodical maintenance equipments, Spot
due to use of faulty breakers Electric shock 1 1 15 15 L
of electrical appliances, Replacement of MCB by correction on
or bypassing the breakers
EL-MCB Weekly / Fort nightly
electrical safety
inspection

MFFK-HSE-FRM-5001-A, Rev 05, 18.04.2022 Page 1 of 17

 RISK LEVEL (S=Significant
RISK ASSESSMENT (L X E

RISK ASSESSMENT (L X E
ROUTINE / NON ROUTINE

RESIDUAL RISK LEVEL

(S=Significant L=Low)
CONSEQUENCES (C)

CONSEQUENCES (C)
Legal Requirement
LIKELIHOOD (L)

LIKELIHOOD (L)
EXPOSURE (E)

EXPOSURE (E)
PROBABILITY/

PROBABILITY/
ACTIVITY

L=Low)
S.No

ADDITIONAL

X C)

X C)
HAZARDS EFFECT / RISKS EXISTING CONTROLS
CONTROLS

Use of DG Set with (Acoustic enclosure) low noise

Noise induced hearing loss to
generation. Ear muff/ear plug & Exposure control
Exposure with high noise DG set operator and person in 3 2 7 42 L
by job rotation, Periodical Noise monitoring and
the vicinity
Medical Check up.

Start maintenance after shutdown the power

supply completely using " Job Card & Isolation of
power with " DO NOT SWITCH ON " sign board.

Implementation of LOTO & PTW with continuous

monitoring
Electrical Power Generation
3 Routine
by Diesel generator set
Serious injury, severe or minor
Training on "Maintenance Safety Awareness
burn & shock injury, Very
Contact with live electrical Session"
Serious injury to operator and 1 1 15 15 L
current
person in the workplace due to
exposed to live conductors PPE's usage such as Rubber gloves, insulated
ladder, instruments & Inspected tools

Visual inspection for insulation damage.

Protective earthing, ELCB, Regular inspection.

Training on "Electrical Safety Awareness"

Flammable materials must not be kept or stored in

generator room, Hot work restricted area,

Preventive maintenance and periodical Inspection

Fire due to source of ignition Burn injury due to fire if comes
Visual display, Spot
or hot work in the vicinity of in contact with sparks & hot 1 1 15 15 L
check
flammable material ignition sources
Daily checks for leakages & spillages. Provision of
adequate fire extinguishers. Training and
awareness to operate fire extinguishers. In case
of DG room, provision of emergency lighting,
Display of escape roots and signs
Electrical Power Generation
Routine
by Diesel generator set
(Contd...)
(Contd...) Restricted hot work area, Hot work only through
Burn injury to operator due to
Fire due to Unauthorized hot work permit, Provision of adequate fire Visual display, Spot
fire if comes in contact with 1 1 7 7 L
work near DG set extinguishers. Training and awareness to operate check
sparks & hot ignition sources
fire extinguishers

Physical injury to operator and Machine guarding to all moving parts, Trained
Caught in between Factories Act,
person in the vicinity due to operator, No loose clothing 1 1 7 7 L
Unguarded moving parts 1948
trapping in between. Earthing to be provided for all metal bodies

Fire due to Malfunctioning of

the DG set because of Physical injury , Electric shock
Initiate LOTO system alog with LOTO Procedure
operation by Unauthorized to unauthorized person & 1 1 15 15 L
prior to the maintenance
person while under maintenance persons
maintenance

MFFK-HSE-FRM-5001-A, Rev 05, 18.04.2022 Page 2 of 17

 RISK LEVEL (S=Significant
RISK ASSESSMENT (L X E

RISK ASSESSMENT (L X E
ROUTINE / NON ROUTINE

RESIDUAL RISK LEVEL

(S=Significant L=Low)
CONSEQUENCES (C)

CONSEQUENCES (C)
Legal Requirement
LIKELIHOOD (L)

LIKELIHOOD (L)
EXPOSURE (E)

EXPOSURE (E)
PROBABILITY/

PROBABILITY/
ACTIVITY

L=Low)
S.No

ADDITIONAL

X C)

X C)
HAZARDS EFFECT / RISKS EXISTING CONTROLS
CONTROLS

Short circuit due to over Use of MCB-ELCB and heavy insulated cables
Electric shock , fire 1 1 15 15 L
current pulling and earthing

Auto OFF mechanism, Provisions of guards,

Pinching / caught in between Trained and Skilled operator, No loose clothing
Physical injury 1 1 7 7 L
moving parts Use Appropriate PPE's like cut resistant gloves
and shield,etc…

Contact with electric current

Use of ELCB and heavy insulated cables and
due to damaged cables &
Electric shock earthing, Preventive maintenance and Periodic 1 1 15 15 L
loose contacts, earthing not
inspection
connected

Skilled and certified electrcian (Authorization of

Contract Safety
contractor's electrician) , Periodical checking of
Contact with electric current Management Team,
the breakers, Periodical maintenance of electrical
due to use of faulty breakers Electric shock 1 1 15 15 L Contol of contractors
appliances, Periodical electrical safety inspection,
or by passing the breakers owned electrical
Checklist for Portable equipment,
equipments,
Usage of portable electrical Quaterly inspection of RCCB
4 appliances (e.g. Drilling Routine
Machine)
Factories Act,
Exposure to noise Hearing impairment Provision and use of ear plug, Job rotation 3 2 7 42 L
1948

Fall of unsecured machine at Physical injury, property Skilled operator, Never leave machine unattended
3 1 7 21 L
height damage at workplace

Fall and trip due to improper

Cable tray / cable conduit, Cable hangers. Safety
cable management at the Physical Injury 3 1 7 21 L
tool box talk, Illumination maintained
work area

Damaged cable due to the

movement of vehicles or Heavy isulated cable shall be used through Cable
Electrocution 1 1 15 15 L
passing cables unders sharp conduit / Cable tray
edge material through it

Contact with electric current

Preventive maintenance, Monthly checking,
due to inserting cables w/o Electric shock 1 1 7 7 L
Routine electrical safety inspections
plug

Contact with terminals of

Electric shock Insulated terminals 1 1 15 15 L
megger

Provision and use of PPE's like Safety goggles,

5 Earthpit checking Routine Exposure with dust Cut / Abrasion to hand tool user 3 1 3 9 L
Hand gloves

Cut or finger pinch due to

contact with sharp edges of Cut injury to operator Use of PPE's like Cut resistant Hand gloves 1 1 3 3 L
earth rods

Spark in battery while Physical injury to the

maintenance by incompetent maintenance person and person Skilled and Athorized persons need to carry out 3 1 7 21 L
person in the vicinity
Skin burn / eye injury of the
Contact with acid due to Appropriate PPE's like chemical resistant gloves
maintenance operator due to 3 1 7 21 L
spillage and face shield, etc…
6 Battery Maintenance Non-routine acid splash

Fire due to development of

Burn injury to maintenance
static charge due to Skilled and Athorized persons need to carry out 1 1 3 3 L
operator due to fire
damaged earthing / bonding

MFFK-HSE-FRM-5001-A, Rev 05, 18.04.2022 Page 3 of 17

 RISK LEVEL (S=Significant
RISK ASSESSMENT (L X E

RISK ASSESSMENT (L X E
ROUTINE / NON ROUTINE

RESIDUAL RISK LEVEL

(S=Significant L=Low)
CONSEQUENCES (C)

CONSEQUENCES (C)
Legal Requirement
LIKELIHOOD (L)

LIKELIHOOD (L)
EXPOSURE (E)

EXPOSURE (E)
PROBABILITY/

PROBABILITY/
ACTIVITY

L=Low)
S.No

ADDITIONAL

X C)

X C)
HAZARDS EFFECT / RISKS EXISTING CONTROLS
CONTROLS

Preventive maintenance of DB / CMB/ PDB and,

Protective earthing, Provision of ELCB, Covered
Exposure to or contact with
shed / shop to protect rain water, Provision of
electric current due to
Closed DB
Working near/with bare Electrical shock , burns , Very
conductor of power cable or Serious injury to operator due to 3 1 15 45 L
improper earthing contact with bare conductor
connection to LSR
Training on "Electrical Safety Awareness"
Equipment

Control panel of the DG set consisting of overload

and short circuit protection, earth leakage
protection, ammeter, and voltmeter. Area
ISR/LSR / Pre heating cordoned off
7 Non-routine
(By electrical heating)
Electrical Isolator Panel having MCB, Arc Chute in
Contactors of control Panels
Fire due to over heating of Burn injury to operators /
cables because of uneven helper / people in the vicinity 3 1 7 21 L
load due to overheating of cables Flammable materials kept away from ISR / LSR

Provision of adequate fire extinguishers. Training

and awareness to operate fire extinguishers.

Visual display or cordon off the hot job. Permit to

work

Wire mesh anchored to the RCF sheets

Storing RCF in polythene bags, Removal of RCF

Mild skin irritation , immediately after LSR/ISR is over, Maintain
Housekeeping in order. Blanketing RCF fiber
Contact with harmful Pneumoconiosis to operator /
1 1 3 3 L pads to avoid
substance like RCF cleaner / People in the vicinity
exposure
due to exposure with RCF
Maintain Housekeeping in order

Respiratory protection, Hand gloves, Boiler suit

Scaffolding with green tag

Fall of a person while Serious Physical Injury to Display of Do's and
working on unelevated operator due to fall down from 1 1 7 7 L Don’t's for
platform unelevated platform scaffolding
Use of full body safety harness

PTS/TTS or noise induced Use of air DG Set with low noise emission Ear
Exposure with high noise hearing loss to DG set operator muff/ear plug & Exposure control by job rotation, 1 1 7 7 L
and person in the vicinity Periodical Noise monitoring and Medical Ceck up.

ISR/LSR / Pre heating

Non-routine
(By electrical heating)
(Contd...)
(Contd...)

MFFK-HSE-FRM-5001-A, Rev 05, 18.04.2022 Page 4 of 17

 RISK LEVEL (S=Significant
RISK ASSESSMENT (L X E

RISK ASSESSMENT (L X E
ROUTINE / NON ROUTINE

RESIDUAL RISK LEVEL

(S=Significant L=Low)
CONSEQUENCES (C)

CONSEQUENCES (C)
Legal Requirement
LIKELIHOOD (L)

LIKELIHOOD (L)
EXPOSURE (E)

EXPOSURE (E)
PROBABILITY/

PROBABILITY/
ACTIVITY

L=Low)
S.No

ADDITIONAL

X C)

X C)
HAZARDS EFFECT / RISKS EXISTING CONTROLS
CONTROLS

Start maintenance after shutdown the power

supply completely using Job card, Isolation
certifiacte, LOTO system (If required) with " DO
NOT SWITCH ON " (Caution) sign board.

Training for "Safe maintenance practices"

ISR/LSR / Pre heating
Non-routine Very Serious injury, severe or
(By electrical heating)
(Contd...) minor burn & shock injury, Very
(Contd...) Contact with live electrical
Serious injury to operator and Periodically Inspected instruments & tools 1 1 15 15 L
wire
person in the vicinity due to
exposed to live conductors
Protective earthing, ELCB/GFCI, Regular
inspection
Use of PPE's like LT/HT rubber gloves & insulated
tools

Training on "Electrical Safety"

LSR Checklist, Flammable materials must not be

kept or stored in generator room, Hot work
restricted area,

Preventive maintenance & Periodical inspection

Fire due to source of ignition Burn injury due to fire if comes
Visual display, Spot
or hot work in the vicinity of in contact with sparks & hot 1 1 7 7 L
check
flammable material ignition sources
Daily checks for leakages & spillages. Provision of
adequate fire extinguishers. Training and
awareness to operate fire extinguishers. Display
of fire order, Provision of emergency lighting,
Display of escape routes and signs

Restricted hot work area, Hot work only through

Burn injury to operator due to
Fire due to Unauthorized hot work permit, Provision of adequate fire Visual display, Spot
fire if comes in contact with 1 1 7 7 L
work inside DG Room extinguishers. Training and awareness to operate check
sparks & hot ignition sources
fire extinguishers

Caught in between Physical injury to operator and

Machine guarding to all moving parts, Trained
Unguarded moving parts, person in the vicinity due to 1 1 7 7 L
operator, No loose clothing
Loose clothing trapping in between

Provision of fume extractor

Exposure with Fumes & Respiratory problem, irritation to
Gases emitted from gas eyes throat to operator/ person 3 2 7 42 L
cutting activity in the vicinity
Use of DIN approved Goggles and Half face mask

Exposure with high noise

Hearing impairment to operator Provision and use of Ear Muff, Ear Plug 3 1 7 21 L
while plazma cutting

Preventive maintenance of DB / CMB/ PDB and

cutting machine , Protective earthing,Provision of
Exposure to or contact with ELCB
Electrical shock , burns , Very
electric current due to
Serious injury to operator due to 1 1 15 15 L
Working near/with bare
contact with bare conductor
conductor of power cable Testing of ELCB and earthing connectivity by
operator before cutting, Trained operator and pre -
check & periodic-check

Maintenance of CNC pipe

cutting machine (Gas
8 Routine
cutting & plazma cutting
activity)

MFFK-HSE-FRM-5001-A, Rev 05, 18.04.2022 Page 5 of 17

 RISK LEVEL (S=Significant
RISK ASSESSMENT (L X E

RISK ASSESSMENT (L X E
ROUTINE / NON ROUTINE

RESIDUAL RISK LEVEL

(S=Significant L=Low)
CONSEQUENCES (C)

CONSEQUENCES (C)
Legal Requirement
LIKELIHOOD (L)

LIKELIHOOD (L)
EXPOSURE (E)

EXPOSURE (E)
PROBABILITY/

PROBABILITY/
ACTIVITY

L=Low)
S.No

ADDITIONAL

X C)

X C)
HAZARDS EFFECT / RISKS EXISTING CONTROLS
CONTROLS

Job rotation, Intermediate break, Visual display

Exposure with non ionizing Arc eye, Cataract , photophobia
radiation (UV) which emits to operator due to exposure with 1 1 7 7 L
from cutting activity UV radiation Appropriate DIN classified UV filter glasses are
used.

Exposure with hot Job rotation, Intermediate break, Visual display

Eye injury, Burn injury to cutting
substances / objects Display or
Maintenance of CNC pipe operator and helper due to 1 1 7 7 L
( Sparks,spatters,hot slag) Appropriate DIN classified UV filter glasses, Boiler barrication the area
cutting machine (Gas contact with hot jobs
8 Routine while gas cutting activity suit, Leather hand gloves, Safety shoes and
cutting & plazma cutting
Safety helmet
activity)

Approved Flash Back Arrester

Periodical check of flash back arrestor

Fire ( Back Fire ) due to
Serious Burn Injury to operator
clogging of gas cutting 1 1 7 7 L
due to Back fire and explosion
nozzles by metal slag
Provision of adequate fire extinguishers,Trained
operator and pre -check & periodic-checks of gas
cutting nozzles. Provision of emergency lighting,
Display of escape routes and signs

Use of standard gas cutting accessories (Gas

hoses, Pressure gauges, Clamps, Flash back
arrestors etc)

Periodical maintenance of Plasma cutting

Fire due to Leakage of machine On the job training to
Flammable gas from hose, Burn injury to operator & helper b imparted and work
1 1 7 7 L
hose connections, Pressure due to Fire instruction to be
gauge connections etc Trained plasma cutter and pre -check & periodic- displayed
checks of plasma cutting accessories.Provision of
adequate fire extinguishers. Training and
awareness to operate fire extinguishers. Provision
of emergency lighting, Display of escape routes
and signs

Fall of gas cylinder due to Physical Injury to operator due Trained / skilled operator , Follow safe material
3 1 3 9 L
handling by unskilled labor to fall / trip of cylinder handling practice

Provision of protection cap and chain fastening

Fire / Explosion due to
Burn injury / Physical injury to arrangement, Gas cylinders not stacked one upon
Maintenance of CNC pipe damage of valve because of 6 1 7 42 L Spot checking,
operator. another. Filled / Empty gas cylinder to be
cutting machine (Gas Routine fall of cylinder
segregated
cutting & plazma cutting (Contd...)
activity) (Contd...)
Fall of person from work
table of CNC & Plasma Physical Injury due to fall Chair / table with hand rest,foot rest & side rail 3 1 7 21 L
cutting machine.

Disconnection or bursting of Physical Injury to the person in Standard hose and other accessories, Trained
3 1 3 9 L
high pressure hoses the vicinity personnel.

MFFK-HSE-FRM-5001-A, Rev 05, 18.04.2022 Page 6 of 17

 RISK LEVEL (S=Significant
RISK ASSESSMENT (L X E

RISK ASSESSMENT (L X E
ROUTINE / NON ROUTINE

RESIDUAL RISK LEVEL

(S=Significant L=Low)
CONSEQUENCES (C)

CONSEQUENCES (C)
Legal Requirement
LIKELIHOOD (L)

LIKELIHOOD (L)
EXPOSURE (E)

EXPOSURE (E)
PROBABILITY/

PROBABILITY/
ACTIVITY

L=Low)
S.No

ADDITIONAL

X C)

X C)
HAZARDS EFFECT / RISKS EXISTING CONTROLS
CONTROLS

Use of air compressor with low noise generation.

Noise induced hearing loss to
Exposure to high noise Ear muff/ear plug & Exposure control by job 3 1 7 21 L
operator / People in the vicinity
rotation.

Securely coupling & clamp of hose pipe.

Striking due to Wipping of
Hit injury due to striking by air
compressed air hose pipe 1 1 3 3 L
hose pipe to operator
(Pneumatic) All air hose couplings & connections must be
checked prior to work.

Maintenance of air Eye Injury/ physical injury to

9 Routine Periodic Checking and testing by authorized Gas Cylinder
compressors Rupture of Air receiver tank operator due to fragile particles 1 1 3 3 L
competent person. Rules
from rupture of air receiver tanks

Start maintenance after shutdown the power

Contact with live electric Electric shock , Very Serious supply completely using Job card, Isolation
current at the time of injury to operator / maintenance certifiacte, LOTO system (If required) with " DO
maintenance which is carried person due to exposure to live NOT SWITCH ON " (Caution) sign board. 1 1 15 15 L
out without switching off the conductors or exposure to
main supply radiator fan Periodically inspected instruments & tools
Use of appropriate PPE's like Hand gloves and
ear plug,etc…

Caught in between
Physical injury to operator Guard, No loose clothing 1 1 7 7 L
unguarded moving parts

Maintenance of air Routine(Conte

compressors (Contd...) d...) Physical injury to operator and Steel chains must be
Bursting and rupture of hose helper due to bursting of pipe or Rated compressed air hose pipe, Regular used for extra
1 1 3 3 L
pipes and fittings fittings or person hit by inspection of hose pipes, Training and awareness. protection with hose
pressurized pipe couplings & clamps

Improper end stopper or

Periodical checking of strcuture column, END
failure of Long Travel (LT) /
Serious physical injury to person Stoper and LT / CT Limit switch 3 3 7 63 L
Cross Travel (CT) Limit
Mechanical stopper provided to stop manually.
switch

Operator Card
Unauthorized Operations Trainings provided by OEM to authorized operator
Maintenance of Gantry Serious physical injury to person 3 3 7 63 L Provided to the
10 Routine and maintenance and job card required for maintenance activity
crane competent person

Direct Suppy Line Protection guards, CT Limit

Contact of wire rope with
Serious physical injury to person switch, Trained operator, Relay protection, Work 1 1 7 7 L
Direct Supply Line
at far distance

Serious physical injury to person Maintenance kit, Periodical maintenance as per

Fall of loose material 1 1 7 7 L
in the vicinity OEM recommendations

Burn injury to operator / Person Storage tank in isolated area. Restriction of

Fire due hot work activity in the vicinity due to fire, unauthorized hot work. Provision of adequate fire
1 1 7 7 L
without any precaution asphyxiation, fainting due to extinguishers. Training and awareness to operate
vapors fire extinguishers

Earth pit monitoring at the defined frequency .

Fire due to development of
Burn injury to operator / Person Provision of adequate fire extinguishers. Training
static charge due to
in the vicinity due to fire, and awareness to operate fire extinguishers. 1 1 7 7 L
discontinuation of bonding /
asphyxiation Provision of emergency lighting, Display of
11 Diesel storage & handling Routine earthing
escape routes and signs

Slip / trip / fall of a person

Injury to operator / helper due to
while handling diesel Material handling by trained operator 1 1 7 7 L
Slip / trip / fall.
container

Fire due to nearby hot work

Fire due to overflow of diesel
resulting in burn injury to Usage of Spill kit in case of spillage, No Hot work
which may come in contact 1 1 7 7 L
operator and person in the near by , restricted entry.
with source of ignition
vicinity

MFFK-HSE-FRM-5001-A, Rev 05, 18.04.2022 Page 7 of 17

 RISK LEVEL (S=Significant
RISK ASSESSMENT (L X E

RISK ASSESSMENT (L X E
ROUTINE / NON ROUTINE

RESIDUAL RISK LEVEL

(S=Significant L=Low)
CONSEQUENCES (C)

CONSEQUENCES (C)
Legal Requirement
LIKELIHOOD (L)

LIKELIHOOD (L)
EXPOSURE (E)

EXPOSURE (E)
PROBABILITY/

PROBABILITY/
ACTIVITY

L=Low)
S.No

ADDITIONAL

X C)

X C)
HAZARDS EFFECT / RISKS EXISTING CONTROLS
CONTROLS

Ensure required PPE's like cut resitant gloves and

safety goggles
Contact with sharp edges of Cut injury (Ingestion) to worker
the hazardous waste empty due to sharp edges of scrap 1 1 7 7 L
containers container
Specialize Training sessions for workers doing
this activity & only trained workers are allowed to
do this activity.

Segregation and Disposal Provision of bin at isolated location, Follow strictly

12 of Hazardous waste Non-routine Fire due to unauthorized hot
Burn injury to person in the hot work permit, visual display, Provision of
material work near by flammable 1 1 7 7 L
vicinity. adequate fire extinguishers. Training and
material
awareness to operate fire extinguishers.

Strain to workers while

Handling wastes with wrong Backache, MSD to workers Proper lifting arrangement, Safe material handling
1 1 7 7 L
body posture and excess handling hazardous waste procedures
weight.

Contact with hazardous Skilled persons for handling, usage of adequate

Physical injury to works handling
material while Handling in PPE like hand gloves, safety shoes, safety 1 1 7 7 L
the waste bin
open / damage container helmet, safety goggles

Handling with vision / sight

obstruction

Handling of load which is

more than the permissible
limit
Use of mechanical aids like Forklift, stackers,
Trolley etc. Training and awareness, Obstruction
Handling load in ackward WRULD, MSD, Serious injury to
13 Manual Material Handling Routine free walk ways, Visual display. Use of proper PPE 3 2 7 42 L
posture. the persons in the vicinity
like shoulder pad,hard hat,goggle and steel toe
shoes
Handling job with obstruction
in walk way

Handling job having sharp

edge

Fall from height due to

Railing on Crane, Un obstructed walk way,
Working / walking on Personal injury to inspection
Standard staircase and ladder, Adequate ligting,
unprotected High elevation / team / maintenance persons 1 1 7 7 L
Standard walkway width, Use of Full body
inadequate platform / unsafe due to fall from height
harness
working practice

Caught in between wire

Personal injury to the Trained personnel, hard barrications, sign boards,
rope on drum / Trolley & end 1 1 15 15 L
maintenance crew provision of guards for moving parts
stopper or any structural part

Periodical Inspection / Fall from height while Personal injury to inspection / Trained operator, Standby helpers for
14 maintenance of Lifting m/c, Routine 1 1 7 7 L
sudden operation of crane maintenance persons due to fall communication, hard barrications, sign boards,
Lifting tools / tackles during inspection from height Full body harness

Fracture / Cut /
Trained and skilled Inspection team / technicians,
Abration/Contusion injury to
Fall of lifting tools and Use of mandatory PPEs such as Hard hat, sagety
Inspection team and person in 3 1 7 21 L
tackles while inspection goggles, hand gloves, steel toe shoes and cover
the vicinity due to lifting tools
all.
and tackles falling

Preventive maintenance of machine, Provision of

Contact with live electrical Electrical shock to inspection /
ELCB and MCB, Earting continuity test, Trained 1 1 15 15 L
cable maintenance personnel
inspection / maintenance team

MFFK-HSE-FRM-5001-A, Rev 05, 18.04.2022 Page 8 of 17

 RISK LEVEL (S=Significant
RISK ASSESSMENT (L X E

RISK ASSESSMENT (L X E
ROUTINE / NON ROUTINE

RESIDUAL RISK LEVEL

(S=Significant L=Low)
CONSEQUENCES (C)

CONSEQUENCES (C)
Legal Requirement
LIKELIHOOD (L)

LIKELIHOOD (L)
EXPOSURE (E)

EXPOSURE (E)
PROBABILITY/

PROBABILITY/
ACTIVITY

L=Low)
S.No

ADDITIONAL

X C)

X C)
HAZARDS EFFECT / RISKS EXISTING CONTROLS
CONTROLS

Tripping, Slipping and Falling

Clearing floor area to keep free from slip /trip/fall
due to cluttered or cramped
Cut / Abrasion to hand tool user hazards where tools are being used. Training and 3 1 3 9 L
work spaces, or slippery &
Awareness
obstructed floors

Mushroom or burred heads Inspection before use, Periodical checking,

Cut / Abrasion to hand tool user 3 1 3 9 L
of chisels, file, Pliers etc. Trained and skilled user.

Usage of General purpose Blunt blades (Knives, Screw Inspection before use, Periodical checking,
15 Routine Cut / Abrasion to hand tool user 3 1 3 9 L
hand tools drivers etc) Trained and skilled user.

Slip due to Incorrect grip of Trained and skilled user. Worn out tools
Abrasion to hand tool user 3 1 3 9 L
tools discarded.

Electrical power tools to be inspected and tested

Incorrect Voltage of electric Electric shock to user / quaterly, Validation tag. Use correct fuse rating for
3 1 7 21 L
tools technician electric tools, Protective earthing, ELCB, Regular
inspection

Fall of tools while working at Crush injury to the people

Provision and use of Tool kit 3 1 3 9 L
height working nearby.

Provision and use of Safety goggles, Respiratory

Exposure to dust and fumes Throat irritation 3 1 3 9 L
mask, Hand gloves

Usage of General purpose Routine(Contd. Electrical power tools to be inspected and tested
hand tools (Contd...) ..) at regular intervals. Validation tag, Protective
Contact with live electric
Electric Shock earthing, ELCB,Regular inspection, Covered shed 3 1 3 9 L
cable
/ shop to protect rain water, Provision of Closed
DB

Use of improper tools Cut / Abrasion to hand tool user Right tool for right job. Training and awareness 3 1 3 9 L

Fully hand spliced or mechanically spliced wire

rope slings, Use of locking type clamps. Permit to
work implemented.

Regular Inspection of lifting m/c, tools & tackles

and lifting appliances by competent person. only
inspected tools and tackals being used with TPI
certifiacte

Special training on "Safe material handling" to all

riggers & crane operators and same refresher
training

Tools& tackles are inspected before every use.

Fall of material from height Fracture / Cut /

Competent operator (Trained and Skilled) are
due to improper lifting Abration/Contusion injury to the
doing material handling. 6 2 3 36 L
tools/tackles, damaged lifting operator / rigger due to steel
tools tackles plate falling
Crane boom modification, Right selection of tools & tackles based on
16 Handling of boom and other Non-routine requirement.
accessories
Keep minimum distance between hoisted load
and ground as far as reasonably practicable.

Visual display related to safe rigging practice

Use of Appropriate PPE's such as Hard hat, Cut

resitant gloves , safety goggles and steel toe
shoes

Guide rope to maintain safe distance.

MFFK-HSE-FRM-5001-A, Rev 05, 18.04.2022 Page 9 of 17

 Crane boom modification,
16 Handling of boom and other Non-routine
accessories

RISK LEVEL (S=Significant

RISK ASSESSMENT (L X E

RISK ASSESSMENT (L X E
ROUTINE / NON ROUTINE

RESIDUAL RISK LEVEL

(S=Significant L=Low)
CONSEQUENCES (C)

CONSEQUENCES (C)
Legal Requirement
LIKELIHOOD (L)

LIKELIHOOD (L)
EXPOSURE (E)

EXPOSURE (E)
PROBABILITY/

PROBABILITY/
ACTIVITY

L=Low)
S.No

ADDITIONAL

X C)

X C)
HAZARDS EFFECT / RISKS EXISTING CONTROLS
CONTROLS

Cut or finger pinch due to Use of Appropriate PPE's such as Hard hat, Cut
Cut, contusion injury to operator
contact with sharp edges of resitant gloves , safety goggles, steel toe shoes 1 1 3 3 L
/ rigger / People in the vicinity.
material and boiler suit

Follow the procedure, Use of full body Safety

Fall of person while working Serious physical injury to the
harness, Ensure hand and boom pipe are free 1 1 7 7 L
on boom workmen
from oil / greese, Trained rigger.

Trained and Skilled rigger and Operator, Work

Person getting trapped in Serious physical injury to the
under constant supervision, Following the 1 1 15 15 L
between the load (Boom) rigger
procedures.

Competent operator (Trained and Skilled) are

doing material handling.

Right selection of tools & tackles based on

requirement.

Fracture / Cut / Keep minimum distance between hoisted load

Fall of lifting load while Abration/Contusion injury to and ground as far as reasonably practicable.
Crane boom modification, Material handling by operator / rigger / person in the 1 1 7 7 L
Non-routine Incompetent person vicinity due to lifting tools and
Handling of boom and other
(Contd...) tackles falling Visual display related to safe rigging practice
accessories (Contd...)

Use of Appropriate PPE's such as Hard hat, Cut

resitant gloves , safety goggles and steel toe
shoes
Special training on "Safe material handling" to all
riggers & crane operators and same refresher
training

Competent operator (Trained and Skilled) are

doing material handling.

Fall of lifting load (Boom) Fracture / Cut / Special training on "Safe material handling" to all
while use of mobile crane/ Abration/Contusion injury due to riggers & crane operators and same refresher
1 1 7 7 L
hydra with C.G.out of steel plate falling may result in training
stability range lost time injury
Use of Appropriate PPE's such as Hard hat, Cut
resitant gloves , safety goggles and steel toe
shoes

Contact by harmful Follow Departmental procedure, wear adequate

substances by inhalation , PPE such as chemical resistant gloves while
Adverse health effect to STP
ingestion or absorption dealing with different chemicals and contaminated 6 1 3 18 L
plant operator
during sewage water water, Only authorized and trained operator
treatment allowed to work. MSDS Display at STP.

Exposure to or contact with

Electric current, Exposure to Electric Shock to STP operator Preventive maintenance, Periodical inspection 3 1 7 21 L
17 STP Operation Routine Live Cable

Caught between unguarded Cut injury to STP operator due Guarding of all moving parts, Use of appropriate
1 1 3 3
moving part to entarpment. PPE like hand gloves and safety shoes

Fall of a person while

Physical injury due to Person Wall / Fencing surrounding the tank, caution
working near Unprotected / 1 1 15 15 L
fall in to tank or outside the tank board , trained operator, safe access
unbarricated tank

MFFK-HSE-FRM-5001-A, Rev 05, 18.04.2022 Page 10 of 17

 RISK LEVEL (S=Significant
RISK ASSESSMENT (L X E

RISK ASSESSMENT (L X E
ROUTINE / NON ROUTINE

RESIDUAL RISK LEVEL

(S=Significant L=Low)
CONSEQUENCES (C)

CONSEQUENCES (C)
Legal Requirement
LIKELIHOOD (L)

LIKELIHOOD (L)
EXPOSURE (E)

EXPOSURE (E)
PROBABILITY/

PROBABILITY/
ACTIVITY

L=Low)
S.No

ADDITIONAL

X C)

X C)
HAZARDS EFFECT / RISKS EXISTING CONTROLS
CONTROLS

Exposure with Fumes & Respiratory problem, irritation to Use of approved Goggles and Half face mask,
Gases emitted from gas eyes throat to operator/ person maitain adequate distance from cutting operation 3 6 3 54 L
cutting activity in the vicinity is in progress

Exposure with high noise

Noise induced hearing loss, Use of PPE's such as Ear plugs 3 6 3 54 L
while plazma cutting

Preventive maintenance of DB / PDB and cutting

Exposure to or contact with
Electrical shock , burns , Very machine , Protective earthing,Provision of ELCB,
electric current due to
Serious injury to operator due to Testing of ELCB and earthing connectivity by 1 3 15 45 L
Working near bare conductor
contact with bare conductor operator before cutting, Trained operator and pre -
of power cable
check & periodic maintenance of machine

Job rotation, Intermediate break, use of approved

Exposure with non ionizing Arc eye, Cataract , photophobia
filter glasses, use of intended type of fuel, while
radiation (UV) which emits to operator due to exposure with 1 6 7 42 L
plasma cutting use protective goggles of class 11-
from cutting activity UV radiation
13

Operation & Maintenance of

18 Routine
Plate cutting machine
Exposure with hot
Eye injury, Burn injury to cutting Use of Appropriate PPE's such as Hard hat, Cut
substances / objects
operator and helper due to resitant gloves , safety goggles, steel toe shoes 1 6 7 42 L
( Sparks,spatters,hot slag)
contact with hot jobs and boiler suit
while gas cutting activity

Fire ( Back Fire ) due to Serious Burn Injury to operator Daily cleaning of nozzles, approved flash back
clogging of gas cutting due to Back fire and explosion, arrestors, maintenance of flash back arrestors, 1 6 7 42 L spot check
nozzles by metal slag property damage use of emergency off switch

Usage of srandard flash back arrestors, hoses,

Fire due to Leakage of
Serious Burn Injury to operator pressure gauges etc. Competenet person only to
Flammable gas from hose,
due to Back fire and explosion, operate the machine, opertor trained on usage of 1 6 7 42 L Spot check.
hose connections, Pressure
property damage fire extinguisher, provision of emergency lighting,
gauge connections etc
use of emergency off switch

Usage of trolley for holding the cylinders, usage of

Fall of gas cylinder due to fire, Injury to persons, Propert
chains for arresting the movement of cylinders, 3 3 7 63 L
handling by unskilled labor damage
training on proper material handling techniques
Operation & Maintenance of
Routine(Contd.
Plate cutting machine Disconnection or bursting of Physical injury, property Usage of whip check in the gas connections
..) 1 6 3 18 L
(Contd...) high pressure hoses damage points, use of standard hoses

Fall of material from over Physical injury, property Competenet rigger deployed for the job, use of tag
1 6 3 18 L
head EOT crane damage lines for controlling the job

MFFK-HSE-FRM-5001-A, Rev 05, 18.04.2022 Page 11 of 17

 RISK LEVEL (S=Significant
RISK ASSESSMENT (L X E

RISK ASSESSMENT (L X E
ROUTINE / NON ROUTINE

RESIDUAL RISK LEVEL

(S=Significant L=Low)
CONSEQUENCES (C)

CONSEQUENCES (C)
Legal Requirement
LIKELIHOOD (L)

LIKELIHOOD (L)
EXPOSURE (E)

EXPOSURE (E)
PROBABILITY/

PROBABILITY/
ACTIVITY

L=Low)
S.No

ADDITIONAL

X C)

X C)
HAZARDS EFFECT / RISKS EXISTING CONTROLS
CONTROLS

Slippery floor due to oil

Physical Injury Regular cleaning of shop floor, usage of drip trays 3 3 3 27 L
spillage from machine

Nose generated while in

Noise Induced hearing loss Use of PPE's such as Ear plugs 3 3 7 63 L
operation

Exposure to Cutting fluids Use of proper PPE such as safety goggles, hand
Opearation & Maintenance Infections to skin 1 3 3 6 L
19 Routine used for machining gloves and apron
of Radial Drilling Machine

Preventive maintenance of DB / CMB/ PDB and

Exposure to or contact with
Electrical shock , burns , Very cutting machine , Protective earthing,Provision of
electric current due to
Serious injury to operator due to ELCB, Testing of ELCB and earthing connectivity 3 3 7 63 L Spot check
Working near bare conductor
contact with bare conductor by operator before cutting, Trained operator and
of power cable
pre -check & periodic maintenance of machine

Exposure to High Noise

Noise induced hearing loss Use of PPE's such as Ear plugs 3 6 3 54 L
during blasting

Exposure to abrasives used Use of proper PPE such as safety goggles, hand
Eye injury, health problems 3 6 3 54 L
for blasting gloves and apron

Fall of material while using Physical injury, property

Competent rigger deployed for material handling 3 6 3 54 L
over head EOT crane damage

Incompetent person Physical injury, property Competent operator deployed for operating the
1 6 7 42 L
operating the machine damage machine

Physical injury, cuts, hand & leg

Exposure to rotating parts Provide mechanical guards to the rotating parts 1 6 7 42 L
injury
Operation & Maintenance of
20 Routine
Auto Blast Machine Exposure to slippery floor
Physical Injury Regular house keeping in the area 1 6 3 18 L
due to abrasives

Automatic cut off switch functioning if anyone

Enter into conveyor chamber
Physical injury, cuts, hand & leg open the chamber door
for maintenance activity 1 6 3 18 L
injury Ensure Confined space permit required with
(Confined space)
proper job card prior to commence the activity

Preventive maintenance of DB / PDB and cutting

Exposure to or contact with
Electrical shock , burns , Very machine , Protective earthing,Provision of ELCB,
electric current due to
Serious injury to operator due to Testing of ELCB and earthing connectivity by 3 3 7 63 L Spot check
Working near bare conductor
contact with bare conductor operator before cutting, Trained operator and pre -
of power cable
check & periodic maintenance of machine

Slippery floor due to oil

Physical Injury Regular cleaning of shop floor, usage of drip trays 3 3 3 27 L
spillage from machine

Nose generated while in

Noise Induced hearing loss Use of PPE's such as Ear plugs 3 3 7 63 L
operation

Exposure to Cutting fluids Use of proper PPE such as safety goggles, hand
Infections to skin 1 3 3 6 L
Opeartion & Maitenance of used for machining gloves and apron
21 Routine
Pedestal Drilling machine

Preventive maintenance of DB / PDB and cutting

Exposure to or contact with
Electrical shock , burns , Very machine , Protective earthing,Provision of ELCB,
electric current due to
Serious injury to operator due to Testing of ELCB and earthing connectivity by 3 3 7 63 L Spot check
Working near bare conductor
contact with bare conductor operator before cutting, Trained operator and pre -
of power cable
check & periodic maintenance of machine

MFFK-HSE-FRM-5001-A, Rev 05, 18.04.2022 Page 12 of 17

 RISK LEVEL (S=Significant
RISK ASSESSMENT (L X E

RISK ASSESSMENT (L X E
ROUTINE / NON ROUTINE

RESIDUAL RISK LEVEL

(S=Significant L=Low)
CONSEQUENCES (C)

CONSEQUENCES (C)
Legal Requirement
LIKELIHOOD (L)

LIKELIHOOD (L)
EXPOSURE (E)

EXPOSURE (E)
PROBABILITY/

PROBABILITY/
ACTIVITY

L=Low)
S.No

ADDITIONAL

X C)

X C)
HAZARDS EFFECT / RISKS EXISTING CONTROLS
CONTROLS

Competent operator (Trained and Skilled) are

doing material handling.
Right selection of tools & tackles based on
requirement.

Keep minimum distance between load and ground

Fracture / Cut / as far as reasonably practicable.
Fall of lifting load while Abration/Contusion injury to
Material handling by operator / rigger / person in the 1 1 7 7 L
Incompetent person vicinity due to lifting tools and Visual display related to safe rigging practice
tackles falling
Provision and use of Safety shoes, Thick leather
hand gloves and Safety helmet

Special training on "Safe material handling" to all

riggers & operators and same refresher training

Cut or finger pinch due to

Cut, contusion injury to operator Use of appropriate PPE's like cut resistant gloves,
connection of Hydraulic 3 1 3 9 L
/ rigger / People in the vicinity. Boiler suit, Safety shoes, Safety helmet.
Hoses

Complete Checking of weighing system prior to

use

Opeartion & Maitenance of Trial Lifting to ensure jack functioning.

22 8 Point Synchronous Non - Routine Spillage of Hydraulic Jacks &
Weighing System Land Condimination 3 1 3 9 L
Leakage in Hydraulic System Trial Lifting to ensure no hoses are leaking.

Fire Extinguishers

Good House-keeping

Preventive maintenance of DB / CMB/ PDB and

Exposure to or contact with
Electrical shock , burns , Very cutting machine , Protective earthing,Provision of
electric current due to
Serious injury to operator due to ELCB, Testing of ELCB and earthing connectivity 3 3 7 63 L Spot check
Working near bare conductor
contact with bare conductor by operator before cutting, Trained operator and
of power cable
pre -check & periodic maintenance of machine

Complete checking of Weighing System prior to

use
Possible injury, possibly Very
Tilting of job due to
Serious injury. Potential damage 1 1 40 40 L
imbalance loads
to equipment
Approved Weighing Procedure

Maintain Good House Keeping

Tripping due to Cables &

Physical injury 6 1 3 18 L
Hoses on the Ground
Provision of Cable Tray

MFFK-HSE-FRM-5001-A, Rev 05, 18.04.2022 Page 13 of 17

 RISK LEVEL (S=Significant
RISK ASSESSMENT (L X E

RISK ASSESSMENT (L X E
ROUTINE / NON ROUTINE

RESIDUAL RISK LEVEL

(S=Significant L=Low)
CONSEQUENCES (C)

CONSEQUENCES (C)
Legal Requirement
LIKELIHOOD (L)

LIKELIHOOD (L)
EXPOSURE (E)

EXPOSURE (E)
PROBABILITY/

PROBABILITY/
ACTIVITY

L=Low)
S.No

ADDITIONAL

X C)

X C)
HAZARDS EFFECT / RISKS EXISTING CONTROLS
CONTROLS

Competent operator (Trained and Skilled) are

doing material handling.

Right selection of tools & tackles based on

requirement.

Fracture / Cut / Keep minimum distance between hoisted load

Fall of Tubular while Material Abration/Contusion injury to and ground as far as reasonably practicable.
handling by Incompetent operator / rigger / person in the 1 1 7 7 L
person vicinity due to lifting tools and
tackles falling Visual display related to safe rigging practice

Operation & Maintenace of Provision and use of Safety shoes, Thick leather
23 Routine
Rotators & Idlers hand gloves and Safety helmet

Special training on "Safe material handling" to all

riggers & crane operators and same refresher
training

Preventive maintenance of DB / PDB and cutting

Exposure to or contact with
Electrical shock , burns , Very machine , Protective earthing,Provision of ELCB,
electric current due to
Serious injury to operator due to Testing of ELCB and earthing connectivity by 3 3 7 63 L
Working near bare conductor
contact with bare conductor operator before cutting, Trained operator and pre -
of power cable
check & periodic maintenance of machine

Physical injury, cuts, hand & leg

Exposure to rotating parts Provide mechanical guards to the rotating parts 1 6 7 42 L
injury

Incompetent person Physical injury, property Competent operator deployed for operating the
1 6 7 42 L
operating the machine damage machine

Operation & Maintenace of Routine(Contd.

Rotators & Idlers (Contd...) ..) Cut or finger pinch due to
Cut, contusion injury to operator Use of appropriate PPE's like cut resistant gloves,
contact with sharp edges of 1 1 3 3 L
/ rigger / People in the vicinity. Boiler suit, Safety shoes, Safety helmet.
material

Property damage, physical Over load hoist limit switch, over load alarm,
Overloading of crane 1 6 7 42 L
injury competent rigger deployed for the job

Suspended load area is strictly cleared while

Property damage, physical
Exposure to suspended load shifting load, competent rigger deployed for the 1 6 7 42 L
injury
job

Preventive maintenance of DB / PDB and cutting

Exposure to or contact with
Electrical shock , burns , Very machine , Protective earthing,Provision of ELCB,
electric current due to
Serious injury to operator due to Testing of ELCB and earthing connectivity by 1 3 15 45 L
Working near bare conductor
contact with bare conductor operator before cutting, Trained operator and pre -
of power cable
check & periodic maintenance of machine

Opearation and
24 Routine
maintenance of EOT crane
Exposure to height while Use of safety harness, hand rails provided on the
fall from height, physica injury 1 2 15 30 L
manitenance rails of EOT crane

Strict selection of person before being deployed to

job, HSE induction to be carried out, Material
Operation by Incompetent Property damage, physical
handling training 1 6 7 42 L
person injury
Operator card provided to authorized person
OEM Training provided for authorized person

Improper end stopper or

failure of Long Travel (LT) / Periodical checking of strcuture column, END
Serious physical injury to person 3 3 7 63 L
Cross Travel (CT) Limit Stoper and LT / CT Limit switch
switch

MFFK-HSE-FRM-5001-A, Rev 05, 18.04.2022 Page 14 of 17

 RISK LEVEL (S=Significant
RISK ASSESSMENT (L X E

RISK ASSESSMENT (L X E
ROUTINE / NON ROUTINE

RESIDUAL RISK LEVEL

(S=Significant L=Low)
CONSEQUENCES (C)

CONSEQUENCES (C)
Legal Requirement
LIKELIHOOD (L)

LIKELIHOOD (L)
EXPOSURE (E)

EXPOSURE (E)
PROBABILITY/

PROBABILITY/
ACTIVITY

L=Low)
S.No

ADDITIONAL

X C)

X C)
HAZARDS EFFECT / RISKS EXISTING CONTROLS
CONTROLS

Respiratory problem, irritation to Use of approved Goggles and Half face mask,
Exposure to welding fumes eyes throat to operator/ person maitain adequate distance when welding is in 3 6 3 54 L
in the vicinity progress

Exposure to welding sparks Burns, eye injury, physical injury Use of approved Goggles 3 6 3 54 L

Exposure to rotating parts Physical inmjury, pinch points Mechanical guards to be provided 1 6 7 42 L
Opeartion and maintenance
25 Routine
of Welding column boom
Exposure to hieght while Use of proper working platforms, use of safety
Physical injury, bruises 1 2 15 30 L
maintenance harness while working at a height of 1.8 m

Exposure to suspended load Suspended load area is strictly cleared while

while shifting material using Head injury, property damage shifting load, competent rigger deployed for the 1 6 3 18 L
EOT Crane job, adherence to L&T safety golden rules

Strict selection of person before being deployed to

Operation by Incompetent Physical injury, property
job, HSE induction to be carried out, Material 1 6 7 42 L
person damage
handling training

1) Ensure adequate load bearing capacity of soil

by doing soil analysis/testing by competent person

2) Yearly Inspection by Third party competent

person
Physical injury, property
Failure of lifting equipment 3) Over Load alarm and automatic cut off is 1 1 15 15 L
damage
installed

4) Quarterly Inspection and Maintenance carried

out by P&M team

5) Deployment of experienced operator

1) Lifting tools & tackles certified by third party

competent person
Breakage of Tools & Tackles
Failure of lifting tools & 2) Deployment of experienced rigger foreman and
Physical injury, property 1 1 7 21 L
tackles riggers
damage
3) Physical inspection of lifting tools & tackles
before use

1) Deployment of experienced rigger foreman &

riggers

2) C.G. should be maintained.

3) All loose materials should be secured

4) Working area should be barricaded, wherever

practically possible.
Fall of material Personal injury 1 6 7 42 L
26 Tower Crane Operation Routine 5) Tag line to be tied up from both end of the
material being lifted ,wherever practically possible.

6) Adequate illumination (min 150 lux) for night

activities

7) Instructions Manual for Tower Crane -

TC6020A should be followed.

MFFK-HSE-FRM-5001-A, Rev 05, 18.04.2022 Page 15 of 17

 RISK LEVEL (S=Significant
RISK ASSESSMENT (L X E

RISK ASSESSMENT (L X E
ROUTINE / NON ROUTINE

RESIDUAL RISK LEVEL

26 Tower Crane Operation Routine

(S=Significant L=Low)
CONSEQUENCES (C)

CONSEQUENCES (C)
Legal Requirement
LIKELIHOOD (L)

LIKELIHOOD (L)
EXPOSURE (E)

EXPOSURE (E)
PROBABILITY/

PROBABILITY/
ACTIVITY

L=Low)
S.No

ADDITIONAL

X C)

X C)
HAZARDS EFFECT / RISKS EXISTING CONTROLS
CONTROLS

1) Wearing and anchoring of full body safety

harness with double lanyard and shock absorber

2) Using of fall arrestor system while

ascending/descending on tower crane, if
practically possible

3) Provision of interval landing/rest platform

4) Medical fitness of workmen involve in working

at height

5) Implementation of ERP (availability of man lift,

suspension straps / lifting belts, standby person)

6) Proper illumination for night shift activities.

Fall of person Personal inujury 1 1 15 15 L
7) No extra hour’s duty for workmen, which may
cause of fatigue.

8) Provision of life line temporary/permanent

9) Provision of walkways/catwalks on jib sections

10) Provision of man lift

11) Monitoring of wind speed

12) Availability of anemometer

14) Proper housekeeping at workplace

15)During
1. The wind speed
Crane Moveat ,ensure
top (the that
highest crane
no crane
Collision with nearby Cranes Personal injury point) should be by
ensured 1 1 40 40 L
movement near area. safe

1. Confined space permit to be followed

Woking inside the pit
Personal Injury 2. Adequate illumination to be ensure 3 1 7 21 L
(Confined Space)
3. buddy system to be followed

1. LOTO register should be follow before starting

activity
Electricity Electrocution & person injury 2. All electrical connections should be routed 1 6 7 42 L
through RCCB
3. Ensure Proper Earthing

1. Protect all rotating parts with the guards

Pinch point Injury to person 1 6 3 18 L
2. Wear proper Hand gloves
Maintenance of Plate
27 Routine
Rolling Machine
Enter into chamber for
Ensure Confined space permit required with
maintenance activity Physical Serious injury 1 6 3 18 L
proper job card prior to commence the activity
(Confined space)

1. Lifting tools & tackles certified by third party

competent person
Falling of material 1 1 15 15 L
Injury to person 2. Deployment of skilled manpower
Barrication & signage
& property damage
Incompetent person 1. Competent operator deployed for operating the
1 6 7 42 L
operating the machine machine

1. Full time Supervisor for wire rope replacement

activity
Entanglement Person injury 3 1 7 21 L
2. Trained manpower allocated for job & Follow
OEM instructions
Maintenance of MHE(Wire
28 rope replacement & sub Routine
components) Usage of Proper PPE, Visually infection of wire
Pinch point Injury to person 1 1 7 7 L
rope

Usage of full body Safety hardness beyond 1.8m,

Working on Equipment Fall of person 1 1 7 7 L
Proper platform to be arrange

MFFK-HSE-FRM-5001-A, Rev 05, 18.04.2022 Page 16 of 17

 RISK LEVEL (S=Significant
RISK ASSESSMENT (L X E

RISK ASSESSMENT (L X E
ROUTINE / NON ROUTINE

RESIDUAL RISK LEVEL

(S=Significant L=Low)
CONSEQUENCES (C)

CONSEQUENCES (C)
Legal Requirement
LIKELIHOOD (L)

LIKELIHOOD (L)
EXPOSURE (E)

EXPOSURE (E)
PROBABILITY/

PROBABILITY/
ACTIVITY

L=Low)
S.No

ADDITIONAL

X C)

X C)
HAZARDS EFFECT / RISKS EXISTING CONTROLS
CONTROLS

Slippage of equipment from Person injury & Equipment

Placing of jacks on level ground/over plates, 1 3 3 9 L
Jack damage

Person injury & Equipment Visual inspection of jacks preior to use, Following
Failure of jacks 1 3 7 21 L
damage OEM instructions

Adequate PPE's such as Hand gloves, Safety

Maintenance of MHE Falling of tyres on person Injury to person shoes and safety goggles to be followed, 1 3 3 9 L
29 Routine
(Tyre replacement) Skilled manpower allocated for job

Usage of proper tools,

Pinch point Injury to person 1 3 7 21 L
Skilled manpower to carry out job

Usage of calibrated pressure gauge, Increase the

Person injury due to blast of
Pressurized air pressure in stage manner, Frequent checking of 3 3 7 63 L
tube
pressure

Usage of drip trays/ emergency spill kit & adapting

Oil spillage Soil Pollution 1 6 3 18 L
proper disposal methods

Maintenance of
Usage of adequate PPEs like hand gloves as per
30 MHE(Lubrication/ Oil Routine Eye contact with oil Eye injury 1 6 7 42 L
MSDS
service)

Failure of Improper tools Person injury Select the right tools for the right job 1 6 3 18 L

Engage trained manpower for job

Entanglement Person injury 3 2 7 42 L
Follow OEM instructions
Maintenance of MHE(Chain
31 Routine
Tightening)
Person injury & Equipment Visual inspection of jacks perior to use, Following
Failure of jacks 1 3 7 21 L
damage OEM instructions

Following OEM recommendations,

Person Injury & property
Failure of equipment PTW to be followed if required, 1 3 15 45 L
damage
Barrication & skilled manpower

32 Load test of MHE Routine

Failure of object usage of certified tools & Tackles, Barrication 1 3 7 21 L

Person Injury

Unauthorized entry Barrication displaying with sign boards 3 1 15 45 L

PREPARED BY APPROVED BY
Assessment Team
N. Giridhar, Sivaguru, Sankar GR, Sachin,
Manoj kuruvilla, Goutham
Sankar G R Giridhar NVR

MFFK-HSE-FRM-5001-A, Rev 05, 18.04.2022 Page 17 of 17