Project Site / Area: HZL -SK Mill III Location: Graphite Area Date: 3th August 2019

Name of Assessor- Md Wasim Khan CBRE

Task/ Work Description: Civil / Mechanical / Electrical / Hot Work (Welding and Gas cutting) Review Period: HZL /SK -

Risk Level
Existing Control Measures to be Followed

Likelihood (L)

Severity (S)

Risk=(L X S)

Likelihood (L)

Severity (S)
Action By

Residual Risk
Activity Hazard, hazardous event and Hierarchy Control of Risk Additional Control Measures
Equipment/Substance consequences E/S/EC/AC/ PPE/BBS to reduce the risk

Civil Activity / Scaffolding

1.Loading unloading and 1.1 Trip and falls causing injury to
shifting of scaffolding the person.
materials
1.1.1 Ensure materials to be kept properly in sequence.
Stack and store at reasonable location at heights for ease of access and Follow scaffolding SOPs
stability of stacked components. erection,dismantling,
Ensure materials to be kept free from obstruction of pathways. modification and movement.
1.1.2 Appropriate method of lifting aid to be use such as pick & Carry crane

E /S /EC /AC/PPE
for shifting of materials in place of manual handling.
1.1.3 Ensure person are deployed are well trained and educated for

Medium
materials shifting and loading purposes.
1.1.4 Competent person are to be deployed for mechanical handling for 3 3 9 PM / SE / SI
material shifting.Scafolding materials kept to be barricaded with caution
tape and signage's.
Scaffolding erection workplace to be cordoned off.
Ensure scaffolding materials to kept at low height.

2.Erection activity 2.1 Trip and falls falling from height 2.1.1 Ensure scaffolding is to be erected by trained and competent
causing injury to the person.
2.2 Struck by vehicles, trip hazards.
Refer to Scaffolding and work
person (holding a relevant scaffolding certificate of competency). at height activity SOPs.
2.1.2 Scaffolding is to be
erected on leveled and compacted surface. Refresher training to be
2.1.3 Ensure appropriate traffic management is in place for all imparted to the height
vehicular and pedestrian traffic. workers.
2.1.4 Scaffolding is to be inspected and certified by competent Adhere to site specific rules
scaffolding inspector or supervisor (holding a relevant scaffolding regarding use of appropriate
certification of competency). PPE and guidance notes on
2.1.5 Ensure damaged ,bend ,corroded scaffolding not to be erected. scaffolding activity.
2.1.6 Person are engaged for
work at height activity at 1.8 meter or more to be equipped with
harness with polyamide lanyard.

E / PPE/BBS
2.1.7 Vertical scaffolding standard to be erected on base plate

High
supported with sole plate where soil is loosened. 4 3 12 PM / SE / SI
Guard rail to be installed such as top and mid rail with toe board
maintaining by height ratios.
2.1.8 Person deployed for erection activity to be undergone vertigo
test.
Ensure that there is good clear access to work areas.
Vertical scaffolding to be fastened by required bracings or tying.

3.Dismantling Activity Trip and falls falling from height
causing injury to the workers
,nearby person moving.
1.Scaffolding dismantle workplace are to be cordoned off.
2. Scaffolding to be dismantled by
competent person In presence of scaffolding supervisor (holding
competency certificate).
1. Dismantled scaffolding to be neatly stacked and arranged.
2. Pathways and walkway to be
E / AC / PPE /BBS

clear from stacking of dismantle scaffolding members.

3. Caution signage's to be displayed at scaffolding dismantling
Medium

workplace.
4. Scaffolder must be equipped with required personal fall arresting 3 3 9 PM / SE / SI
system.

4.1 Soil Collapse or Cave-in
4. Excavation Activity 4.2 Fall of men ,machine and
material
5.1 Mechanical Failure
5.2 Failure of Tools and Tackles
5.3 Fall of Person and Material
5.4 Person hit and strike by moving
object and Machinery.
5.5 Slip, trip, falls from height,
falling object, property damage.
5.Erection activity (Piping
,Structural and
Equipment)
system.
E / AC
Civil Activity / Excavation
4.1.1 Ensure excavation shall be done in angle of repose as per soil
strata.
4.1.2 Soil survey shall be done before commencing excavation
activity.
4.1.3 Excavation shall be done by mechanical equipment to be In
good condition physically.
4.1.4 Excavated soil shall be kept at least 5 ft away from side edges
of excavated pit.
E /S /EC /AC/PPE
4.1.5 Excavated side edges to be protected by safety net to prevent
soil collapse. REFER to Excavation safety
4.1.6 Continuous Dewatering to be ensure to prevent cave-in. SOPs , JSA
High
3 4 12 PM / SE / SI
4.1.7 Excavated pit to be barricaded surrounding the open pit.
4.1.8 No men, machine and material shall be kept nearly to side Guidance Note
edges of excavated pit.
4.1.9 General PTW to be issued along with Excavation work permit.
4.1.10 Excavation clearance shall be taken to prevent accidental
contact with underground utility such as buried electrical cable, Pipe
lines ,service line etc.
4.1.11 Portable ladder shall be so fixed that person will get access
easily inside and outside the excavated pit.
4.1.12 Ensure BIOLOGICAL hazard to be removed from inside the
excavated pit before commencing activity.
Mechanical Activity
5.1.1 Ensure TPI certified Plant and Machinery being used for
erection activity. Ensure Authorized personal to be deployed for
signaling. 1.Safer distance to be
5.1.2 Personal Fall arresting device to be used Person engaged for maintained near overhead
work at height activity. electrical HT line.
5.1.3 TPI certified PFAS to be use. 2. SOPs to be prepared also
5.1.4 Erection workplace periphery to be cordoned off has to be implemented.
5.1.5 Ensure Defective Tools and Tackles not to be used. 3. Proper information
5.1.6 Ensure Site specific procedure such as Risk assessment or JSA ,instruction ,training and
and SWPs to be developed and approved. supervision.
5.1.7 Tag line to be used both end of material to control or balance 4.Adhere to site rules
E /S /EC /AC
the lifted load. regarding critical lift criteria
Medium
5.1.8 Tools and Tackles are to be color coded and TPI marked also as mentioned in SOPs for
Dry run test to be conducted before commencing erection for all 3 3 9 lifting and shifting. PM / SE / SI
blind lift erection.
5.1.9 Person are engaged for work at height activity to be height
phobia tested.
5.1.10 Pre lift talk to be done before commencing erection activity.
 6.1 Mechanical Failure
6.2 Failure of Tools and Tackles
6.3 Person hit and strike by moving
object and Machinery.
6.4 Fall of Materials
6.5 Collapse of Machinery or Lifting
Equipment.
6.1.1 Ensure TPI certified Plant and Machinery being used for Refer. Site specific procedure
erection activity. and JSA for lifting and shifting
6.1.2 Ensure Authorized personal to be deployed for signaling. activity.
6.1.3 Ensure Defective Tools and Tackles not to be used
6.1.4 Ensure Site specific procedure such as Risk assessment or JSA Proper information
and SWPs to be developed and approved ,instruction ,training and
6.1.5 Ensure Pre lift talk to be conducted. supervision.
6.1.6 Ground surface to be properly leveled and compacted where
material shifting shall be done.
and loading / unloading and shifting activity area to be cordoned off.

E /S /EC /AC
Medium
6. Loading / Unloading 6.1.7 Lifting equipment such as pick and carry ,mobile crane to be
equipped with SLI and MLI,SLI to be calibrated by TPI. 3 3 9 PM / SE / SI
and Shifting of Material

7.1 Electrocution ,Fire occurrences , 7.1.1 Ensure welding machine power connection are routed through
Burn injury ,Arc eye ,Arc Flash
Refer to HOT WORK SOPs.
RCCB / ELCB (Make sure Welding machine are installed with RCD).
7.1.2 Make sure Welding Machine having installed with VRD System.
7.1.3 Ensure Use of double insulated power cable. Proper information
7.1.4 Ensure welding terminals to be properly insulated with heat ,instruction ,training and
resistance insulating tape. supervision.
7.1.5 Ensure Welding Machine having double body earthing.
7.1.6 Periodical Physical inspection of welding machine to be
conducted.
7.1.7 Whether Welding Machine RCD or RCCB inspection and testing

E /S /EC /AC /PPE

has been done.
7.1.8 Ensure Hot work permit issued.
7. Welding / Hot Work

High
7.1.9 Whether housekeeping or removal of combustible and 3 4 12 PM / SE / SI
Activity flammable items has been done nearby welding activity.
7.1.10 Proper use of JOB Specific PPE'S to be use before commencing
welding operation.

8.1.1 Ensure Proper use of JOB Specific PPE'S to be worn by gas Refer to HOT WORK SOPs.
cutter.
8.1.2 Whether Flash back arrestor device are installed with cutting
torch and cylinders regulator? Proper information

E /S /EC /AC /PPE

8.1.3 Ensure housekeeping are maintained nearby gas cutting ,instruction ,training and
8.1 Burn Injury ,Flash back ,Hose workplace. supervision.
8. Gas Cutting / Hot
bursting ,Major fire occurrence ,Eye 8.1.4 Ensure leakage test has been conducted for regulator and

High
3 4 12 PM / SE / SI
Work Activity torch in valve fitting and flash back arrestor joint.
injury.
8.1.5 Whether visual inspection has been conducted being used with
inspection checklist.

9.1 Electrocution ,Burn injuries
9. Use of Electrical
Equipment
9.2 Fire hazard due to short circuit
and spark
9.1.1 Periodical physical inspection and testing of portable power
tools and equipment shall be conducted by authorized electrical
personal.
9.1.2 Authorized electrical personal shall be carryout repair or
maintenance of equipment.
9.1.3 Equipment to be positively isolated before commencing any
repair or maintenance activity.
9.1.4 Connection to be taken through standard socket or outlets ,no
makeshift arrangement are allowed.
9.1.5 Electrical equipment power supply to be routed through RCD
device such as RCCB or ELCB.
9.1.6 Equipment must have double body earthed.
9.1.7 Improper Power cable jointing shall not be use and are
allowed.
9.1.8 Tested electrical resistance Insulating rubber mat to be placed
at electrical and welding booth.
9.1.9 RCD or RCCB shall be tested periodically by authorized
electrical personal.
9.1.10 Double insulation power cable to be used for all power
operated tools and equipment.
9.1.11 Electrical resistance PPE'S to be use while inspection and
testing or Maintenance of electrical equipment.
Refer GESM SOPs.
E /S /EC /AC /PPE
High
3 4 12 PM / SE / SI /Electrician
Proper instruction
,information ,training and
supervision.
9.2.1 Electrical system shall be equipped with ELCB or RCCB devices.
And it must be tested periodically to check its functioning.
9.2.2 Electrical connection shall be carryout by trained and
authorized electrical personal.
9.2.3 Electrical system to be use in area classified.
9.2.4 Appropriate number of fire extinguisher to be used at
workplace and ensure how to use it,awarness and training to be
delivered to the exposed.
9.2.5 No power cable joint shall be use to prevent cross connection
while touching with live parts or metals.
9.2.6 Proper housekeeping to be maintained nearby electrical and
welding booth or nearby energize electrical panel or equipment.
 10 .Chemical Handling 10.1 Fire due to hot work or spark
and Storage and ignition source
10.2 Leakage of gas
10.3 Bursting of cylinders
10.4 Chemical and Soil
contamination
10.5 Inhalation of Toxic gasses
10.6 Skin disorder or Disease
11.1.Crush Injury
11. Maintenance Activity
11.2 Shearing and cuts injury
(Mechanical Equipmen,
11.3 Fatal due to accidentally relase
LMV and HMV Vehicles
of energy.
and HEMM)
11.4
10.1.1 NO SMOKING signage and Dos and Don'ts instruction to be
displayed at chemical storage area.
10.1.2 No hot work such as welding ,gas cutting ,grinding and
drilling operation shall be carryout.
10.1.3 Acetylene and Oxygen cylinders valve to be properly covered
with appropriate cap.
10.1.4 Acetylene and Oxygen cylinders to be fastened securely by
chaining arrangement.
10.1.5 Secondary containment trays shall be use to prevent soil
contamination.
10.1.6 No changing and clothing shall be done inside the chemical
PM / SE / SI / Store In charge
storage room.
10.1.7 Sufficient numbers of fire extinguisher to be available
Refer to Chemical Handling
E /S /EC /AC /PPE
10.1.8 Proper handling of cylinders to be carryout by trolleys.
10.1.9 Every chemical containers product label to be available to and Storage SOPs.
ease identification.
High
10.1.10 MSDS to be displayed at chemical storage room. 3 4 12 Proper IITS
10.1.11 INVENTORY of chemical to be in record and it has to be
displayed at respective storage. Displaying of site safety
10.1.12 Ensure PPE Matrix are displayed at required places of notice board
storage.
10.1.13 JOB SPECIFIC PPE'S to be use by person who will be carryout
chemical handling activity.
LOTO / Isolation Activity (Maintenacne Activity)
11.1.1 Isolation and LOTO to shall be done before commencing
maintenance for equipment and HEMM Vehicles.
11.1.2 Maintenance activity shall be carryout by Authorised, Trained
and competent person.
11.1.3 PTW of Isolation and LOTO shall be taken for removal of
electrical ,mechanical or stored energy to carryout maintenance
activity.
11.1.4 Isolation and LOTO nine mandatory isolation steps will be
followup.
11.1.5 Lockout and Tagout shall be use before carryout maintenance
work.
Risk Level/ Rating = Likelihood of occurrence (Probability) X Hazard Severity

Likelihood Rating Likelihood

Highly improbable, never known to occur – Less than 1% chance of being
Rare 1 experienced by an organization/individual
Improbable, has happened occasionally – Typically experienced once during
Unlikely 2 the working lifetime of an organization/individual
Possible, has happened occasionally - Typically experienced once every five
Possible 3 years of less by an organization/individual
Probable, commonly occurs - Typically experienced once every year or less
Likely 4 by an organization/individual
Inevitable, define, continually occurs - Typically experienced at least once
Very Likely 5 every six months or less by an organization/individual

Severity/Harm Rating Severity

Negligible 1 No injuries low financial/environmental impact (e.g. Minor cut, burns, hairline fracture, eye irritation, tem

Slight 2 Minor injuries (e.g., superficial injuries; minor cuts and bruises; eye irritation from dust; nuisance and irri
Major injuries, loss or damage, Major fracture, 2nd degree burns, serious sprain, back injury, limb di
Moderate 3
pandemic risk(e.g., lacerations; burns; concussion; serious sprains; minor fractures; deafness; dermatitis;
Amputations, 3rd degree burns, poisoning, fatal injuries, occupational cancer, life shorting disease, sev
Severe 4
death. (e.g., amputations; major fractures; poisonings; multiple injuries; fatal injuries; occupational cance

Major 5 Catastrophic (e.g. fatality, explosions, major fire and destruction of property)
Risk Assessment Matrix

Severity of Harm Risk

Risk Level
Likelihood of Harm Negligible Slight Moderate Severe Major Rating
(1) (2) (3) (4) (5)
Rare (1) 1-5 Low
Low (1) Low (2) Low (3) Low (4) Low (5)

Unlikely (2)
Low (2) Low (4) Medium (6) Medium (8) Medium (10) 6 - 10 Medium

Possible (3) Low (3) Medium (6) Medium (9) High (12) High (15)
11 - 15 High

Likely (4)
Low (4) Medium (8) High (12) Very High (16) Very high (20)

16 - 25 Very High
Very likely (5)
Low (5) Medium(10) High (15) Very High (20) Very high (25)
 Severity
s, hairline fracture, eye irritation, temporary discomfort, low height falls or trips, dehydration, dizziness.)
rritation from dust; nuisance and irritation; ill-health leading to temporary discomfort)
serious sprain, back injury, limb disorders, leading to disability, asthma, reduced hearing or eyesight, sleep disorders, slight
minor fractures; deafness; dermatitis; asthma; work-related upper limb disorders; ill-health)
nal cancer, life shorting disease, severe head injury, complete loss heari ng and eyesight, severe pandemic (H1N1) leading to
ries; fatal injuries; occupational cancer; other severely life shortening diseases; acute fatal diseases)
property)
Risk Rating / Classification (R)

Risk
Risk Level Action and Timescale
Rating

Acceptable / No action. If simple action can reduce further then this must be done
1-5 Low
within one month.
Must be reduced to below 5 within in one week. Ensure control measures are
6 - 10 Medium maintained and reviewed as necessary to ensure so far as is reasonably practicable the
appropriate control of residual risk.
Additional Control measures to be introduced as soon as possible to reduce risk rating to
11 - 15 High level which is as low as is reasonably practicable and no later than 24 hrs after the
assessment.

Unacceptable / Activity not permitted – hazard to be avoided or additional controls

16 - 25 Very High
measures to condierably reduce the risk below 10. Immediate.