Journal of Recent Trends in Mechanics

Volume 4 Issue 2

Hazard Identification and Risk Assessment in Welding Shop and

Powder Coating
Sundarapandian D*1, Muthukumar K2
1
PG Student, 2Professor, Department of Mechanical Engineering,
Bannari Amman Institute of Technology, Coimbatore, Tamil Nadu, India
Email: sundarapandian.is18@bitsathy.ac.in

Abstract
Hazard identification and risk assessment is a procedure which comprises of various
consecutive advances. It is a chance of estimation depends on the current controls and
suggestions to lessen those dangers which are not under adequate points of confinement. It
also suggests additional control measures to reduce the risk to an acceptable level. The
hazard identification process improves the efficiency of occupational and health safety. It is
used to predict the severity rate and probability of the risk in the hazard process. According
to the HIRA process, we can improve the work efficiency. The HIRA process in the welding
shop and powder coating shop alert the people. We can eliminate the hazard with the help of
HIRA by calculating the risk factors.

Keywords: Control measures, hazard identification process, risk factors, welding shops
powder coating

INTRODUCTION murdered in a fire or other blast. The

Due to the absence of work supervision
and lack of training in the work place,
many accidents occurred in the industry.
Each industry is having own machines
which may create hazards. Recognizing
risks related to the activities and select
most pessimistic scenario situations for the
estimation of outcomes. Presumed
programming models will be utilized for
outcome estimation. In view of the
evaluated recurrence of the event, hazard
decrease estimates will be recommended
to the administration for powerful
execution.
The threats that welders have presented
today till date, can cause life-changing
wounds or result in their demises. Some of
these injuries include electrical shocks,
electrical burn, lung diseases, nerve
damages, skin diseases. Due to the high
warmth of the welding circular segment
and the risky exhaust, gases, and synthetic
concoctions welders work with, they face a
genuine danger of being harmed or
19 Page 19-23 © MAT Journals 2019. All Rights Reserved
powder coating process involves many
health hazards. Spray painting including
electrostatic shower painting is a
procedure by which fluid paint is
connected compelled to an item. Shower
painting might be done by hand or
consequently. In that, some hazardous
chemicals have fire and explosion risks.
The HIRA process includes the following
studies.
 Study of the plant operations.
 Identification of the individual tasks
involved in carrying out the above
operations.
 Identification of potential health and
safety hazards in these tasks.
 Assurance of the degree of hazard by
consolidating the probability of a
danger happening with its seriousness
utilizing the risk framework.
 Analyzing the existing control
measures available to control these
risks. Provide recommendations for
additional risk control measures to
bring the risk to
 acceptable level.
 Journal of Recent Trends in Mechanics
Volume 4 Issue 2

Table 1: Classification of blood pressure.

Control
Sl. No. Activity Hazards Consequences Risk Level
Measures
Powder Coating Unit p s r

Maintenance and
The material Chances of Unnecessarily time
good
1 storing in the slippage and loss and material 5 2 10
housekeeping is
path way fall damage
needed

Chances of
The material
accumulation Unnecessarily time Safety goggle is
handling by
2 of coating loss in emergency provided for 5 3 15
employee
powder on eye situation protection
without goggle
and eyelash

While checking Chance of

the acid tank stacking the The operator must
3 the employee crane, May be Dermatitis disease follow the safe 4 2 8
does not wear failure of and burn injury operating
PPE crane procedure

The overall
Apron should be
control panel Chances of body
4 Fire hazard provided for 3 4 12
exits without injury
protection
barrier
While
transferring the
crane trolley,
chance of May be trolley fall on
the loading Suitable
5 spillage on the the tank 3 4 12
chain precaution should
body
unnecessarily be provider for
touching the loading chain
tank

In the powder coating, it involves many
hazardous chemicals which create many
accidents and deaths. So, we use safety
masks with appropriate chemicals. While
handling coating materials, workers should
follow the standard operating procedures.
The workers should know about the
chemicals for protecting the body from
harm.
Table 1 depicts the entire hazardous areas
which may cause an accident in an
industry. In that, employers should follow
standard operating procedures. The
employers fit the crane loading chains with
the appropriate place. Table 1 shows that
the material handling without safety gloves
has the maximum risk factors Which may
create health hazards to the workers.
In powder coating plant, the HIRA process
should be carried out frequently to
eliminate the hazards and risk level. The
employer should not wear damaged safety
gloves, safety masks, apron and other
safety materials. The employers should
check the maintenance report for
eliminating unnecessary time loss and
wastage of money.
The raw material should not store near the
control panel which create unnecessary
time loss in an emergency situation. The
new employer should undergo the safety
training.

20 Page 19-23 © MAT Journals 2019. All Rights Reserved

 Journal of Recent Trends in Mechanics
Volume 4 Issue 2

Table 2: welders operating procedures.

Sl. No Activity Hazards Consequences Control Measures Risk Level
Welding Unit p s r
Chances of hand
overexertion,
sustained awkward Unnecessarily Frequent time
Operator's hands are
1 postures time loss, changing is 5 3 15
bending frequently
or repetitive Body injuries required
movement can cause
muscular strain
The operator doing The employer
welding operation should follow
Chances of body It may create
2 without leather shoes safety equipment 5 3 15
injuries health hazards.
and safety gloves and to handle the
apron. product

The operator doing Chances of eye The operator

Dermatitis
3 welding operation irritation, weakening must follow the 4 4 16
disease and
without face shields. eye vision. safe operating
burn injury
procedure
The operator doing
The proper
welding operation
4 Fire hazard Electrical shock grounding should 3 4 12
without proper
be given
grounding.
The operator storing The combustible
16
combustible The explosion material should
5 Fire hazard 4 4
materials near to the may occurred not store near gas
gas cylinders. cylinders

The welders should follow standard to your wellbeing. Welding smoke

operating procedures. Electric stun is a
standout amongst the most genuine and
impending dangers confronting a welder.
Electric stun can prompt extreme damage
or passing, either from the stun itself or
from a fall brought about by the response
to a stun.
It's nothing unexpected that overexposure
to welding exhaust and gases can be risky
contains conceivably hurtful complex
metal oxide mixes from consumables, base
metal and the base-metal coatings, so it's
imperative to keep your head out of the
vapor and utilize enough ventilation and
additionally fumes to control your
introduction to substances in the smoke,
contingent upon the sort of bar and base
metal being utilized.

Figure 1: Risk rating.

21 Page 19-23 © MAT Journals 2019. All Rights Reserved


RESULT AND DISCUSSION
The hazard identification and risk
assessment show the frequency and
probability of the hazards. The
management should record the hazard
report for future reference and also
eliminate the hazards with suitable control
measures. The management should
consider the HIRA report for any
emergency situations. The red color shows
maximum risk factor which may cause
severe accidents in the industry. The green
color shows that minimum risk which may
cause a minor accident.
The risk factor formula:
Risk = severity × Likelihood
CONCLUSION
The hazard identification and risk
assessment report will help to identify the
hazard-prone area in the industry. One of
the most hazardous areas is the welding
shop which may create burn injuries and
health diseases. The management should
follow the standards to eliminate hazards.
The mock drill should conduct periodically
to eliminate unnecessary time loss while in
emergency situations. This hazardous
report shows the severity rate and risk
factor. The maximum risk factor shows the
most important hazardous part of the
industry.
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Journal of Recent Trends in Mechanics
Volume 4 Issue 2
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