ADVANCES in NATURAL and APPLIED SCIENCES

ISSN: 1995-0772 Published BYAENSI Publication

EISSN: 1998-1090 http://www.aensiweb.com/ANAS
2017 May 11(7): pages 823-827 Open Access Journal

Hazard Identification And Risk Assessment

For Generator Test Bed In Heavy
Engineering Industry
1Periyasamy. E, 2Senthil. M, 3Rajmohan. P, 4Dheenadhayalan. T
1PG Research Scholar, Centre for Environmental Health &Safety, Knowledge Institute of Technology, Salem
2Associate Professor, Department of Mechanical Engineering, Knowledge Institute of Technology, Salem
3Deputy General Manager (Safety), Toshiba JSW Power Systems Pvt Ltd, Chennai
4Assistant Professor, Department of Mechanical Engineering, Knowledge Institute of Technology, Salem

Received 28 January 2017; Accepted 22 April 2017; Available online 12 May 2017

Address For Correspondence:

Periyasamy. E, PG Research Scholar, Centre for Environmental Health &Safety, Knowledge Institute of Technology, Salem

Copyright © 2017 by authors and American-Eurasian Network for ScientificInformation (AENSI Publication).
This work is licensed under the Creative Commons Attribution International License (CC BY).
http://creativecommons.org/licenses/by/4.0/

ABSTRACT
HIRA is a systematic risk assessment tool that can be used to assess the risks of various hazards involving process activities.
Hazard which may leads to an accident or incident. Accident is an unwanted or unexpected event is never scheduled or planned.
Many factors contribute to an accident that may cause a significant losses and even body injury. That is always occurs in heavy
engineering industry.HIRA is a structural and systematic method to examine the existing and also planned process.HIRA is a part
of the OHSAS 18001:2007 standard in clause 4.3.1.HIRA is performed to prevent an efficient operation through identify the
hazards in work activities and assess the risk and provide a control measures and review the control measures. That will reduce
level of losses and injury.

KEYWORDS: Hazard Identification, Risk Assessment, Accident, Generator Test Bed, OHSAS 18001:2007

INTRODUCTION

In this paper deals with the HIRA for generator test bed in heavy engineering industry. Based on the
hazard identification and risk assessment in operation area the following potential hazard has been identified.
The potential hazards are given as follow
1. Fire and explosion hazard
2. Electrical hazard
3. Ergonomic hazard
4. Dust Hazard
After the risk assessment the necessary control measures are given the each hazard including the low level
risk.

Need For Hazard Identification And Risk Assessment:

 Risk Assessment will useful for identify the low, medium, high risks.
 Provide the information on the probability of harm and severity of harm
 Useful for in safety improvements.
 Useful for in manage the risks.
 Reduce the risk at the acceptable region.
ToCite ThisArticle: Periyasamy. E, Senthil. M, Rajmohan. P, Dheenadhayalan. T., Hazard Identification And Risk
Assessment For Generator Test Bed In Heavy Engineering Industry. Advances in Natural and Applied Sciences. 11(7); Pages:
823-827
824 Periyasamy. E et al., 2017/Advances in Natural and Applied Sciences. 11(7) May 2017, Pages: 823-827

About Generator Test Bed:

Generator Test Bed used for testing the outgoing generators process parameters and check its satisfying the
specified requirements. Generators run by the connect the generator rotor to motor driving unit. The running
time, the generators is check which is satisfying the requirements or not. Oils are used for the cooling,
lubrication purposes with different pressures. Major process are given as follow

STATOR ASSEMBLY

ROTOR ASSEMBLY

ROTOR INSERT TO
STATOR

LOCATE THE
GENERATOR

FLUSHING

GENERATOR RUN
TEST

DISPATCH THE
GENERATOR

Fig. 1: Process Flow in Generator Test Bed

Methodology:
4.1 Hazard Identification and Risk Assessment:
Hazard identification and risk assessment are developed when plans are forms meet the organisations
OH&S Policy. Assess the level of the risk for each identified hazards which useful for assess the probability and
possible consequence of injury, illness. The next step is reducing the level of risk.

HAZARD RISK
RISK CONTROL
IDENTIFICATION ASSESSMENT

Fig. 2: Steps for Hazard Identification and Risk Assessment

4.2 Hazard Identification:

Hazard identification means to recognize Hazard and define its characteristic and impacts. That will useful
to identify hazards in each activity and know who can harm and how and what may damage and how.
825 Periyasamy. E et al., 2017/Advances in Natural and Applied Sciences. 11(7) May 2017, Pages: 823-827

4.2.1 Types of Hazard:

a) Mechanical hazard
b) Electrical hazard
c) Fire and explosion hazard
d) Radiation hazards
e) Toxic release
f) Natural calamities

4.2.2 Hazard identification tools:

Tools of the hazard identification are follows,

a)Inspection:
visual/checklist inspections done in work environment.

b) Accident/Incident records:
past incident records useful to identify the sources of potential to harm.

c) Expert advice:
some hazards can be identified with help of expert advice/information.

d) Consultation:
consult people who have experience in job aspects of hazardous activities.

e) Task analysis:
Breaking of individual’s element hazards associated with some tasks is identified.

f) Hazard analysis methods:

HAZOP/HAZAN/HIRA methods are used for identifying hazards.

g) Questionnaire’s:
three questions useful for identified hazards,
Is there a source of harm?
Who and what could be harmed?
How could harm occur?

h) Safety audit:
safety audit is a critical appraisal of the effectiveness of existing of safety program in the plant.

4.3 Risk Assessment:

Risk Assessment is estimate of magnitude of risk and decides the level of risk. Risk assessment is
considered for severity of harm and likelihood of harm will occur.
Risk=likelihood *severity

4.3.1 Severity of harm:

The severity of harm considered follows,
a) The parts to be affected
b) Nature of harm from slightly harm to extremely harm
1) Slightly harm
2) Harmful
3) Extremely harmful

Table 4.3.1: for Severity of harm

NOT RETURN TO
NON DISABLING FIRST AID
SEVERITY JOB WITH IN 48 MAJOR INJURY FATAL
INJURY TREATMENT
HOURS
SEVERITY
1 2 3 4 5
SCORING

4.3.2 Likelihood of harm:

a) Frequency and duration of hazard
b) Number of personnel exposed
826 Periyasamy. E et al., 2017/Advances in Natural and Applied Sciences. 11(7) May 2017, Pages: 823-827

Table 4.3.2: for likelihood of harm

ONCE IN A 3
PROBABILITY OF
ONCE IN A MONTH /ONCE ONCE IN A
OCCURRENCE DAILY WEEKLY
MONTH IN A SIX YEAR
/LIKELIHOOD
MONTH
PROBABILITY
5 4 3 2 1
SCORING

4.3.3 Level of the Risk:

Table 4.3.3: for level of risk

UN ACCEPTABLE
RISK LEVEL LOW RISK MEDIUM RISK HIGH RISK
RISK
RISK SCORING 1-9 10-12 13-19 20-25

4.4 Risk Control:

Risk control is an action for eliminating the causes of detected risk or undesirable action. The hierarchy of
control is an effective method to controls a risk as follows,
a) Elimination: completely remove the hazardous process, substances from a work place.
b) Substitution: completely removes the process or a hazardous substance for a less hazardous one.
c) Engineering control: reduce the risk level with mechanical aids.
d) Administrative control: follow the safety work policies, procedures, practices.
e) Personal protective equipment: least risk control method is PPE; it protects the employee from exposure
of hazard.

Engineering Personal
Administrativ
Elimination Substitution Protective
Control e Control
Equipment

Fig. 3: Hierarchy of control

4.5 Hira In Generator Test Bed:

Table 4.5: for HIRA in Generator Test Bed

HAZAR - PROBABILI- SEVERITY LEVEL OF CONTROL
PROCESS ACTIVITY RISK
D TY RISK MEASURES

Connect the
STATOR slings of the Fall From
Fatal 3 5 HIGH ENGINEERING
ASSEMBLY Crane to the Height
CONTROL
Rotor Job
(FULL BODY
HARNESS)

Conclusion:
Safety is the one of the key element for any type of the industry. To improve safety in work place by
various risk analyzing tools and assess the level of risk. Risk level has to be reduced by using engineering and
administrative control methods in work area. Some suggestions are given from my site for reducing a risk level
in generator test bed. After Hazard identification and risk assessment tool is useful for reducing the level of risk
and bring it to a tolerable level. The HIRA method is useful for identify the hazard the implementation of the
control measures the effectiveness of these will revised.

REFERENCES

1. Khairul Akmal Shamsuddin, Mohd Norzaimi CheAni, Ahmad Kamal Ismail, 2015. “Investigation The
Effective Of The Hazard Identification, Risk Assessment And Determining Control(HIRADC)In
Manufacturing Process” International Journal of Innovative Research in Advanced Engineering (IJIRAE)
ISSN: 2349-2163 8(2).
2. GokulRaj, S., N. Shivasankaran, 2014. “Hazard Identification And Risk Assessment In Deinking Plant”
International journal of research in Aeronautical and mechanical engineering, 2(3): 202-208.
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3. SaravanaKumar, M., Dr.P. SenthilKumar, 2015. “Hazard Identification And Risk Assessment In Foundry”
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