GANNON DUNKERLEY & Co., Ltd.

Q&HSE DEPARTMENT
B-228, OKHLA INDUSTRIAL AREA PHASE - 1
NEW DELHI - 110020

Phone: +91-11-42785500
Fax: +91-11-42785512
Email: gdc.delhi@airtelmail.in, cdricsharma@gdcl.in
Website: www.gannondunkerley.com

HAZARD IDENTIFICATION
AND RISK ASSESSMENT
HIRA REGISTER
(AS PER OHSAS 18001:2007 OCCUPATIONAL HEALTH & SAFETY MANAGEMENT SYSTEM)

HSER – 001
ISSUE 04/2013

Note: This manual is the property of Gannon Dunkerley & Co., Ltd. and is not to be reproduced in part or full without the permission of
Managing Director / Management Representative.
Version: 0.04 Dated: 26.09.2013 Page 1 of 1
 Gannon Dunkerley & Co., Ltd.
Health, Safety and Environmental Manual Module HSER
No. 001
REV No. 2
INDEX

S. DESCRIPTION PAGE No.

No.

0 COVER PAGE 1

1 INDEX 2

2 DISTRIBUTION LIST 3

3 DEFINITIONS 4

4 HIRA INTRODUCTION 5–6

5 HIRA PROCEDURE HSEP-001 7 – 13

6 HIRA FORMAT 14

7 HIRA CONTENTS LIST 15 – 16

8 HIRA PART – II – ACTIVITY WISE (61 ACTIVITIES) 01 – 50

 Gannon Dunkerley & Co., Ltd.
Health, Safety and Environmental Manual Module HSER
No. 001
REV No. 1
DISTRIBUTION LIST

Copy No Copy Holder

1 Managing Director, Mumbai Office, Mumbai
2 Executive Director, HO, Mumbai
3 Vice President (Taxation), HO, Mumbai
4 Vice President (Finance) & Company Secretary, HO Mumbai
5 Divisional Head, CED, Hyderabad
6 Divisional Head, Delhi Division, New Delhi
7 Divisional Head, Mumbai Division, Mumbai
8 Divisional Head, CED, Kolkata
9 Divisional Head, WTD, New Delhi
10 Factory Manager, Rayagada Sleeper Factory, Rayagada
11 Advisor
12 Copy for Certification Body and audits– retained by MR

13 Management Representative- Original/Master Copy

101 to 199 For sites and functions controlled by Delhi Division, New Delhi, AMR Delhi Division

201 to 299 For sites and functions controlled by Mumbai Division, Mumbai, AMR Mumbai Division

301 to 399 For sites and functions controlled by CED, Kolkata, AMR Kolkata CED

401 to 499 For sites and functions controlled by CED, Hyderabad, AMR Hyderabad CED

501 to 599 For sites and functions controlled by WTD, New Delhi, AMR WTD

Note:
a.) The distribution of the IMS Manual, Procedures, Work Instructions and forms of Railway RCC Sleeper Factory, Rayagada, is done as per
details given in the Sleeper Factory Manual.

b.) Copy no 101 onwards are assigned to controlled copies of the manuals that are issued to each site/department by the Associate
Management Representative of the respective Divisions as per procedure and controlled by them.
 Gannon Dunkerley & Co., Ltd.
Health, Safety and Environmental Manual Module HSER
No. 001
REV No. 1
DEFINITIONS

ACTIVITY:
Broad group of Tasks.
CONSEQUENCE:
Severity of Injury or Damage.
CONTROL MEASURES:
Methods of controlling the Hazard.
HAZARD:
Source, situation or act with a potential for harm in terms of Human Injury or Ill
Health, or a combination of these.
RECOVERY MEASURES:
Measures to reduce the gravity of consequence and regain control if an undesired
event or emergency situation arises.
TASK
Any work conducted on the basis of a fixed procedure.
 Gannon Dunkerley & Co., Ltd.
Health, Safety and Environmental Manual Module HSER
No. 001
REV No. 1
HIRA INTRODUCTION
HAZARD MANAGEMENT PROCESS
Comprises of:

a. Identifying hazards and threats

b. Analyzing hazards to assess the threats and gravity of consequences
c. Instituting control measures to prevent incidents
d. Adopting recovery measures in case any contingency arises

HAZARD CONTROL

The following control measures generally apply to all hazards:

a. Wearing of PPE
b. Training and instructions related to the job
c. Obtaining work permit if applicable
d. Conducting Toolbox Meetings
e. Deploying right person for the right job
f. Good Housekeeping
g. Keeping adequate warning signs and barricading etc.
h. Use of recommended tools and equipment
i. Adequate and effective supervision

RECOVERY MEASURES

In case any undesired event or incident does happen at the work site or labour
camp, inspite of essential precautionary measures in place, (may be due to at-
risk behavior of individuals) such emergencies shall be handled in such a way
as to reduce the gravity of consequence (Severity of human injury or property
damage) and to regain control over the situation within the least possible time.
The following will be the action plan in such contingencies.

In the case of major events such as fatalities, severe injuries, fire and explosion,
leakage of toxic gases, and natural calamities etc. the work will be stopped
immediately and emergency response procedure will be adopted to control the
situation.

The incident will be reported to the client / local authority etc. by the easiest
available means, seeking assistance and resources to handle the situation.

Further work will be resumed only on getting clearance from the Emergency
Controller. A special emergency meeting of the work force shall be convened to
explain the incident, the immediate and underlying causes (if identified), the
learning points and corrective actions required to prevent reoccurrence of similar
incident.

A First Information Report (FIR) shall be sent to MD’s Office and Divisional
Office within Four (4) hours of occurrence. Subsequent investigations shall be
completed and Detailed Investigation Report (DIR) furnished to all concerned
within Seven (7) days.

In less serious cases, medical aid shall be given to the injured victims, if any,
and the matter intimated to the concerned authorities.

Emergency Vehicle shall readily be available at Project Site for transportation of

injured persons to clinic.

The following hazards have been identified as existing or likely to exist in the
Project Site area:

• Hydrocarbons
• High pressure liquids and gases
• Heavy Plant
• Road Transport Vehicles
• Material Handling (Manual and Mechanical)
• Rock Breaking
• Working at Heights
• Working at OH Lines
• OH Line pole erection and stringing
• Electrical tools / equipment
• Static Equipment
• Steel Bar bending and cutting
• Trenching and Underground Services
• Radiation
• Spillage
• Confined Space
• Blasting, Coating and GRE lining
• Manual Operations (cutting, grinding and welding etc.)
• Heat, Dust, Vibration and Noise
• Concreting
 Gannon Dunkerley & Co., Ltd.
PROCEDURE Procedure for Hazard Identification & Risk Assessment and
HSEP – 001 development of Risk Control Measures (HIRA)

1. INTRODUCTION

The process of Hazard Identification and Risk Assessment is intended to establish

a standard procedure for determining occupational health and safety risks and their
overall significance relating to the organizational activities. Risks arise from the
interaction between people, equipment, materials and the work environment.

This procedure is primarily concerned with personal injury and ill health risks and
does not address damage to plant and equipment, except when such damage may
injure people. The task of risk assessment should involve both identification of the
hazards and undertake an evaluation of the impacts of the risks involved.

2. PURPOSE

a. To identify hazards in respect of all ongoing activities of the organization,

particularly at Project Construction Sites.
b. To carry out risk assessment corresponding to all identified hazards
c. To design, document and implement necessary control measure, either to
eliminate the risks or to reduce the consequences of the identified risks.

3. SCOPE

This procedure is applicable to

i) All activities, products or services, whether existing or new at all GDCL

project sites and offices.
ii) To all employees, contractors and sub-contractors of GDCL.

4. RESPONSIBILITIES

The overall responsibility of ensuring success of risk control measures remain with
the Divisional Heads and Divisional HSE Managers.

Project Site In-charges, Engineers and Supervisors are responsible for the effective
implementation of this procedure by identifying the hazards in all the activities at
their Project Site, assessing the risk associated with the identified hazards, rating
the risk and initiating the Risk Control Measures.

Master Hazard Identification and Risk Assessment Register, HSER – 001, is

maintained with the Divisional HSE Manager and Project Site HIRA Register is
maintained by Project Site HSE Officer.

5. REFERENCES

a. OHSAS 18001:2007 – Occupational Health and Safety Management System

Requirements.

b. OHSAS 18002:2008 – Guidelines for Implementation.

6. PROCEDURE

Project Site In-charges shall constitute a core group for conducting Hazard
Identification and Risk Assessment of all Project Site Activities before the activities
are performed at the Project Site. The Process of Risk Assessment is based on the
steps described here.

A. Identification of Hazards associated with a task or activity, considering the

following

a. Type of activity or work being carried out

b. How it is carried out
c. Where it takes place (work environment)
d. Who undertakes the activity
e. How many people are involved
f. Whether the task is of short or long duration
g. Potential for safety management failure
h. Potential for human error failure
i. What are the consequences

B. Assessment of Risk

Following steps are used to identify, assess and control the identified hazards at
work place:

a. Collect information about existing hazards and potential hazards for all the
Project Site activities
b. Assess the Risk
 c. Set priorities
d. Communicate information about the hazards and risks
e. Develop, select and implement controls and monitor their effectiveness
f. Maintain Records

To determine whether a hazard present is acceptable or not, risk values (probability

and severity factors) are assigned with weightage factors as detailed in Table P1.1.

Risk Level and Risk Rating is obtained from the Risk Rating Matrix Table P1.2.

Interpretation of the Risk Rating is described in Table P1.3.

C. INTOLERABLE RISK LEVEL

The assessed risks with a risk rating of 1 or 2 are within the tolerable limit.
A risk rating above 2 (that is 3, 4 or 5) is considered as intolerable (or un-
acceptable) risk.
The higher the number, the higher is the risk.
This will assist in deciding the priorities for risk control measures.

D. REVIEW OF HIRA REGISTER

Project Site In-Charges shall review HIRA Register for effectiveness at-least once a
year or after any LTI at Project Site Location.
 GDCL Procedure for Hazard Identification and Risk Assessment and
Development of Risk Control Measures

Table P 1.1: RISK VALUES FOR WEIGHTAGE FACTORS

PROBABILITY FACTORS
PROBABILITY PROBABILITY OCCURRENCE
FACTOR
3 Continuous or frequent (more than once per week) High
2 More than once per month Moderate
1 More than once in six months Low
0 More than once in one year Very Low
SEVERITY FACTORS
3 Permanent / partial disability with hospitalization or death
(LTI/Fatality)
2 Injury resulting in one – two (1 – 2) days off work (RWC)
1 Minor injury with medical attention (MTC)
0 Minor injury with no medical attention (FAC)

Table P 1.2: RISK RATING MATRIX

3 3 6 9

2 2 4 6
SEVERITY FACTOR

1 1 2 3

0 1 2 3
PROBABILITY FACTOR
TABLE P 1.3 INTERPRETATION OF THE RISK RATING

Risk Risk Level Inference

Rating
=SxP
1 TRIVIAL No action needed but controls may still be
(Tolerable) justified.
2 LOW No additional controls are required.
(Tolerable) Consideration may be given to more cost
effective solution or improvement that imposes
no additional cost burden. Monitoring is
required to ensure that Controls are
maintained.
3&4 MODERATE Risk may be intolerable. Efforts should be
(Intolerable) made to reduce the Risk to the tolerable level
but the cost of prevention should be carefully
measured and limited.
6 HIGH Unacceptable Risk Level. Urgent Action is
(Unacceptable) required. Work should not be started or
continued until the Risk has been reduced to
bring it within the tolerable limit.
9 EXTREME Highly Unacceptable Risk Level. Work should
(Highly not be started or continued until the Risk has
Unacceptable) been reduced to an acceptable level.
Immediate action is needed. If it is not possible
to reduce the Risk even with unlimited
resources, work has to remain prohibited.
7. RISK CONTROL MEASURES

The Principles of Risk Control is shown below in Figure P 1.1

AVOID Eliminate Hazard altogether

SUBSTITUTE Change to less hazardous alternative by

Engineering Control

ISOLATE Separate people from Hazard by

Administrative Control

REDUCE Reduce amount of Exposure by Engineering

and Administrative Controls

PROTECT Provide Personal Protective Equipment (PPE)

FIGURE P 1.1 PROCESS OF RISK CONTROL

In practice, all these methods mentioned above are used in Construction Industry.
Also it is important to

1. Identify, plan and provide Safety Training.

2. Identify and provide relevant health and safety information to Project Site
personnel e.g. Warning Signs, Visual & Audible Alerting Signals etc.
3. Identify and provide Personal Protective Equipment (PPE) corresponding to
the Risks.
8. RECORDS

The following records are maintained at Project Sites:

a. HIRA – Development of Control Measures (Form HSEF – 001)

b. HIRA Register (Register HSER – 001)
c. Records for Review of HIRA Register
 Gannon Dunkerley & Co., Ltd.
GDCL Procedure for Hazard Identification and Risk Assessment and
Development of Risk Control Measures

GDCL – HSEF – 001 Rev 0

HAZARD IDENTIFICATION AND RISK ASSESSMENT – DEVELOPMENT OF RISK CONTROL MEASURES

C.C. No. PROJECT SITE NAME:

ACTIVITY:

HIRA WORK GROUP MEMBERS:

1 2
3 4
S. Activity Hazard Consequence Probability Severity Existing Risk Control Revised
No. Factor Factor Risk Rating Measures Risk Level
Level = P x S (after
Control
Measures)

Project Site In-charge

 GDCL Procedure for Hazard Identification and Risk Assessment and
Development of Risk Control Measures

HAZARD IDENTIFICATION AND RISK ANALYSIS (HIRA) PART II – COVER PAGE 01

HIRA CONTENTS LIST
S. No. ACTIVITY PAGE
No.
CIVIL WORKS
ACTIVITY-01 BLOCK WORKS 02
ACTIVITY-02 CONCRETE CHIPPING 03
ACTIVITY-03 CONCRETE FOUNDATION BREAKAGE USING JACK HAMMER 03
ACTIVITY-04 CONCRETING 04
ACTIVITY-05 CONCRETE MIXURE OPERATION 05
ACTIVITY-06 MANUAL EXCAVATION 06 – 07
ACTIVITY-07 MECHANICAL EXCAVATION 08 – 09
ACTIVITY-08 ROCK BREAKING 10
ACTIVITY-09 PLASTERING 11
ACTIVITY-10 SHUTTERING & SHORING 11
ACTIVITY-11 WORK ON REBAR 12
MECHANICAL WORKS
ACTIVITY-12 REINFORCEMENT 13
ACTIVITY-13 SCAFFOLDING, FORM WORK AND LADDERS 14
ACTIVITY-14 GRINDING 15
ACTIVITY-15 USING DIESEL ENGINE GENERATOR SET 15
ACTIVITY-16 HANDLING OF PORTABLE ELECTRIC TOOLS 15
ACTIVITY-17 HANDLING PORTABLE HAND TOOLS 16
ACTIVITY-18 GAS WELDING 16
ACTIVITY-19 ARC WELDING 17
ACTIVITY-20 WORKING IN CONFINED SPACE 17
ACTIVITY-21 MATERIAL HANDLING (MANUAL) 18
ACTIVITY-22 MATERIAL HANDLING (MECHANICAL) 18
ACTIVITY-23 WORK AT HEIGHTS 19
ACTIVITY-24 WORKING UNDER CRANE / LIFTING EQUIPMENT 19
ACTIVITY-25 LOADING / UNLOADING ON TRUCK / TRAILER 20
ACTIVITY-26 MATERIAL HANDLING WITH CRANE 20
ACTIVITY-27 HYDROTESTING 21
ACTIVITY-28 HANDLING OF GAS CYLINDERS 22
ACTIVITY-29 RADIOGRAPHY 22
GENERAL
ACTIVITY-30 TANK ISOLATION AND CLEANING 23
ACTIVITY-31 ERECTION, DISMANTING AND WORKING ON SCAFFOLDING 23
ACTIVITY-32 STRUCTURAL WORKS 24
ACTIVITY-33 PIPE LINE WORKS 24
ACTIVITY-34 WORKING IN HOT ENVIRONMENT 24
ELECTRICAL
ACTIVITY-35 WORKING IN DUSTY ENVIRONMENT 25
ACTIVITY-36 WORKING DURING NATURAL CALAMITIES 25
ACTIVITY-37 STAY IN LABOR CAMPS 25
ACTIVITY-38 SLIPS, TRIPS AND FALLS AT WORK PLACE 26
S. No. ACTIVITY PAGE
No.
PLANT AND MACHINERY
ACTIVITY-39 FIRE PREVENTION AND PROTECTION 26
ACTIVITY-40 LAYING ELECTRICAL CABLES 27
ACTIVITY-41 POLE ERECTION 27
ACTIVITY-42 PASSAGE UNDERNEATH OVERHEAD LINES 27
ACTIVITY-43 WORKING NEAR OVERHEAD LINES 28
ACTIVITY-44 ELECTRICAL INSTALLATION AND USAGE 28
ACTIVITY-45 DENTING WORK 29
ACTIVITY-46 DRIVING / OPERATING VEHICLES AND EQUIPMENT 30
ACTIVITY-47 PARKING OF VEHICLES IN PARKING AREA 31
ACTIVITY-48 EMERGENCY STARTING / JUMP STARTING 31
ACTIVITY-49 HANDLING BATTERY 32 – 33
ACTIVITY-50 OPERATING OF COMPACTOR 34
ACTIVITY-51 OPERATION OF CRANE 34
ACTIVITY-52 OPERATION OF FORK LIFT 35
ACTIVITY-53 OPERATION OF VIBRATOR 35
ACTIVITY-54 REMOVAL AND REFITTING OF GEAR BOX 36
ACTIVITY-55 CHANGING OF ALTERNATOR 37
ACTIVITY-56 CHANGING OF HEAVY VEHICLE WHEEL 38
ACTIVITY-57 TOWING OF DEFECTIVE VEHICLE 39 – 40
ACTIVITY-58 SPRAY PAINTING 41 – 42
ACTIVITY-59 WIRE ROPE REPLACEMENT (CRANE) 43 – 44
ACTIVITY-60 HANDLING AND LIFTING EQUIPMENT (GENERAL) 45 – 46
GDCL OFFICE IN NEW DELHI
ACTIVITY-61 GDCL OFFICE IN NEW DELHI 47 – 50