JSW Standard Procedures

Hazard Identification & Risk Assessment

Revision 0
February 2015 Page 1 of 14
Document Control Details

Revision Issue Date Compiled By Document Owner Approved by

0 Safety&FS Safety&FS Apex Safety

06.02.2015
Department Department Committee

Document
Revision Date Procedure Document No.
Revision No.

- - JSW/SAFETY/PROCEDURE/28

User Notes: - Safety & Fire Services is the custodian of this document and is responsible for the
Administration and Authorization of this Procedure. Safety & Fire Services is responsible for
confirming the accuracy and integrity of content and proposed changes to the Procedure.

Controlled copy of the current version of this document is held at JSW and also available on portal.
Any printed / electronic copy of this document is uncontrolled. It is recommended that users verify
that the version being used by them is the current version by referring to the controlled version

Revision 0
February 2015 Page 2 of 14
Table of Contents
Page No.

1. DOCUMENT CONTROL DETAILS 1–2

2. TABLE OF CONTENTS 3

3. APPROVAL AUTHORITIES 4

4. REFERENCE & ABREVIATIONS 5

5. DEFINITIONS 6

6. DESCRIPTION 7

7. RISK ASSESSMENT PROCESS 8

8. RISK CONTROL/DETERMINING CONTROLS 9

9. SETTING OF OBJECTIVES & MANAGEMENT PROGRAMS 10-11

10. RISK CLASSIFICATION MATRIX & RISK RATING 12

11. RISK ASSESSMENT FORMAT 13

Revision 0
February 2015 Page 3 of 14
DOCUMENT ISSUE

The procedure of Hazard Identification and Risk assessment is issued by the Safety & Fire
Serices department on behalf of JSW Steel Limited Management and form a part of the of
JSW Safety management system.

Rajendra Kumar Singh P Rajashekhar

Head of Safety & FS R&P Subcommittee Chairman

Surender Ranade
EDO

Dr. Vinod Nowal

Deputy Managing Director

Date of Release:

This document contains proprietary and confidential information of JSW steel Limited and is
intended solely for the internal use of authorised personnel. This should be treated as
BUSINESS CONFIDENTIAL and its external use or disclosure, unless specifically authorised, is
strictly prohibited

Revision 0
February 2015 Page 4 of 14
1.0 PURPOSE : To establish a system for identification of hazards and assessment of
risks, their classification and determining the risk control measures.

2. 0 SCOPE : - All routine and Non-routine activities

 Emergency situations
 Facilitates at the workplace
 Activity of all personnel having access to the workplace
 New facilities/modification

3.0 REFERENCE :
a. IMS System Manual
b. JSW Steel Limited Standards
 Working at Height
 Confined Space Entry
 LOTO
 PTW
 Electrical Safety
 Conveyor Safety
 Machine Guarding
 Personnel Protective Equipments
 Scaffolding
c. IFC Guidelines
d. OHSAS 18001:2007

3.1 Abbreviations:

 HOD – Head of Department

 SI— Section In-charge
 OHS—Occupational Health & Safety
 MP—Management Program
 SOP—Standard Operating Procedure
 ALRP—As Low As Reasonably Practicable

Revision 0
February 2015 Page 5 of 14
4.0 DEFINITIONS :
Risk Risk = Hazard Severity multiplied by Probability,
Combination of Likelihood of Occurrence of a hazardous event or exposure
and the severity of injury or ill-health that can be caused by the event or
exposure
Risk A process whereby hazards are identified and the likelihood of the hazard
Assessment being realised is calculated /assessed.
Acceptable Risk that has been reduced to a level that can be tolerated by JSW Steel Ltd
Risk having regard to its legal obligations and its own OH&S policy
Risk A process which ensures that controls are put in place so that should a hazard
Control/ be realised, the effects are mitigated to a level which is as low as reasonably
Determinin practicable[ALARP]
g control
Reasonably The degree of risk in a particular activity can be balanced against the time,
Practicable trouble, cost and physical difficulty of taking measures to avoid the risk. In
determining what is reasonably practicable i.e acceptable risk, JSW Steel Ltd
will reckon:
 Legislation, Codes of Practice and Industry Standards,
 OHS Policy,
 Actions and opinions of others, including Contractors, Competitors and
Employees.
 Voluntary commitment made if any
Incident Work related event(s) in which an injury or ill health (regardless of severity) or
fatality occurred or could have occurred. Incident includes near miss, accident,
dangerous occurrence, emergency situation
Lone and Someone working out of verbal and line of sight communication with a
Isolated supervisor, other workers, or other persons capable of providing aid and
Work assistance, for continuous periods exceeding one hour.
Working  Working in close proximity to water where there is a reasonable
over or by likelihood of falling in (Eg. Ponds, Cooling Tower, Reservoir, etc.)
water
 major hazards associated : falling into the water, slips/trips falls

Ergonomic Include repetitive motion, overexertion, and manual handling. Injuries or ill-
Factors health associated with ergonomic factors take prolonged and repeated
exposures to develop, and typically require periods of weeks to months for
recovery

5.0 DISTRIBUTION : All HODs/ Section Incharges / Safety Officers

Revision 0
February 2015 Page 6 of 14
6.0 RESPONSIBILITY :

6.1 Respective HODs and SIs are responsible for identification of hazards, risk
Assessment and determination of risk control measures.
7.0 DESCRIPTION :

7.1 HODs / SIs identify the hazards and risk involved in different activities being
performed in their deptts/sections.

7.2 While carrying out the risk assessment, the following activities are considered

a. Activities of all concerned personnel

b. Activities of the contractors/visitors
c. All routine and non-routine activities ( shut down, start-up, maintenance)
d. Operations of all plant machinery & supporting facilities
e. Emergency conditions
f. New facilities/modification

7.3 The following steps are followed for carrying out the H&S Risk Assessment :

Step 1- Identity the hazards

Step 2- Decide what might be affected, ie, people, Asset, Environment, Reputation
Step 3- Evaluate the risk and decide on precautions
Step 4- Record your findings and implement them
Step 5- Periodically review your assessment and update, if necessary

Basic steps - In sequence, the specific job steps are to be mentioned

Potential hazards - Indicate here the situation, which has the potential to cause ill
health, damage to property, environment or reputation or
combination of these

Consequence - Indicate here the potential consequence of the hazard upon

people, Asset, Environment or Reputation or any combination
of these.

Current control measures – indicate the existing risk controls.

Risk Rating - Indicates the relative severity should be assigned using the Risk
matrix Table given in annexure –1

Probability - Indicates here how the probability was established and what are
the assumptions.

Initial Risk - The impact and probability rating are applied to the Risk matrix
table given in Annexure 2 and the initial risk is determined for
each hazard .

Significant Risk - Where the Risk level is more than 8, it is considered as

Revision 0
February 2015 Page 7 of 14
 significant risk and the persons associated with the
corresponding activity are considered to be performing critical
task.

Additional Control Measures – Indicates those control measures required to be

taken over and above existing control measures to reduce the
risk level within acceptable limits (Risk Level <8)

7.4 The risk assessment will be reviewed / updated at least once in a year or in following
circumstances :

a. Additions /Deletions of equipments/activities.

b. Changes/ modifications in the process / operational techniques.
c. Transfer of key personnel handling the activities having significant risks
d. Any changes in the legal requirements
e. On the initiation of corrective / preventive actions as a result of accidents/
incidents and non-conformities observed during OH&S implementation.

8. Risk Assessment Process

The risk assessment process is illustrated below:

Id en tify lik ely h a za rd s

at all lo c atio n s

HAZARD
E n su re co m p lia n ce a n d ID E N T IF IC A T IO N
im p ro ve s ys te m A n alyse h a z ard s ev erity
an d lik e lih o o d o f o c cu rre n ce

A U D IT A N D R IS K
R E V IE W A N A L Y S IS

E va lu a te res u lts.
D e te rm in e ac ce p ta b ility

M O D IF IC A T IO N A N D R IS K R IS K
CHAN GE CONTROL MANAGEMENT A SSESSM EN T

A s se ss a ll c h an g e s
a n d m o d ifica tio n s

R IS K
M O N IT O R IN G
CONTROL

E lim in ate o r
E n s u re c o n tro ls are
red u ce ris ks
effe ctiv ely m a in tain ed
C O M M U N IC A T IO N

K ee p p e rs o n n e l in fo rm e d o f
a ll ris k s an d co n tro ls

Revision 0
February 2015 Page 8 of 14
 Occupational Safety Hazard – Any hazard leading to immediate impact on human-
being
Occupational Health Hazard – Any hazard that affect health of personnel over a
period of time
Note:
a. The hazard identification should cover the employees, contractors’ personnel as well as
visitors.
b. The hazard which may be identified during the hazard identification process includes,
but is not limited to the following list of hazards:

Occupational Safety hazards Occupational Health Hazards

 Contact with electricity  Physical Hazards
 Hit by moving object/equipment  Noise
 Entanglement with rotating  Vibration
parts/equipment  Pressure
 Manual handling of Machinery parts,  Radiation
loads  Heat / Cold
 Fall from height  Chemical Hazards
 Fall of objects  Dusts
 Use of hand tools / pneumatic  Fumes
 Splash of liquid/material  Vapours
 Contact with hot materials  Liquids
 Contact with hazardous chemicals  Gases
 Contact with hazardous waste  Ergonomics
 Confined space
 Slip & trip

9. RISK CONTROL/ DETERMINING CONTROLS

When determining controls, or considering changes to existing controls, consideration
should be given to reduce the risks according to the following hierarchy:

1. Elimination- Remove the hazard by eliminating the source (e.g. Use a non-
flammable solvent instead of a flammable solvent. Use cold cutting techniques
instead of oxy-acetylene cutting)

2. Substitution - Remove the hazard by substituting the source (e.g. Centrifugal

compressor in place of Reciprocating compressor)

Revision 0
February 2015 Page 9 of 14
 3. Engineering Controls- Reduce the hazards by means of design and engineering
controls (e.g. Enclose or segregate hazardous processes. Install emission control
equipment. Fit automatic shutdown systems)

4. Signage/warnings and/or Administrative controls (i.e. Implement sign

boards or warning/visual displays or Limit work periods in harsh environments).
Administrative controls could include;

- Restricting entry of specified personnel at the security gate(s)

- Stipulate that certain activities can be done in specified time only (e.g Day
time only)
- Carryout activities in the presence of designated authority
- Rotating people who are exposed to ill health on account of long exposure
after a specified time span

5. Personal Protective Equipment (PPE)-Use PPE to provide personnel with

protection against the hazard (e.g. Use ear hearing protection in high noise areas.
Use eye protection when using grinders).PPE is a “control of last resort” which must
never be used as a primary control. (e.g. During overhead work a catch net may be
rigged to catch any dropped tools or equipment. The catch net is the primary control
for dropped objects. The hard hats worn by personnel working below the catch net
are only secondary protection.)

10. SETTING OF OBJECTIVES

 Departments whose activities, after risk assessment giving rise to
Substantial/Unacceptable Risk, have to immediately take up on objectives covering
such risks so as to establish proposed controls in targeted time frame.

 Objectives are set for the engineering solutions which are technologically feasible and
economically viable and risk evaluation is done to assess the effectiveness in
reducing the risk Original Equipment Manufacturers (OEM) recommendations,
Codes of practice and industry standards are also taken into account.

The original copies of all the above studies are maintained by Departments. The copies are
distributed to the concerned departmental head, HOD-S&FS and any other controlled
copy holder(s), if indicated, for further action.

o Onsite Emergency preparedness & response procedure approved by Director

of Factories and Boilers are maintained for major emergency conditions.

o Change to the assessment has to be stated clearly in Document Approval

System and subsequent in particular SOP document amendment history.

o This assessment is treated as a document and hence can be included in the

master list of documents
Revision 0
February 2015 Page 10 of 14
 o The concerned people are trained on risks associated with the job, the
control measure in-place and must be aware of the high risk areas &
consequence of potential departure from the specified procedures and be
competent on the basis of appropriate education, skill & training.
10.1 Management Programme (MP):
These objectives are achieved through Management Programme maintained in the
concerned sections. The MP contains details of the action plan, target date by which
each of these planned steps are to be achieved and the designated responsibility to
achieve the concerned step.
After a MP is completed, the improved practices are documented in the concerned
procedure(s). Which includes the reference of the document where the
achievements/ changes/ improved practices of completed MP, has been
documented. After achievement of the objectives (and targets) these risks are again
subjected to risk assessment and further action, if necessary, is taken till the
desired result is achieved.

10.2 MONITORING AND REVIEW

The risk assessment on proactive basis will be revisited every year or as and when
there is a change in the activities, incidents in performing a particular activity,
decision taken by the management review meeting or commencement of new project
or on receipt of amended other legal & other requirements whenever required.

10.3 a) COMMUNICATIONS
The Hazard Identification and Risk Assessment output will be
discussed/communicated to all the concerned.
All the employees under the control of JSW Steel Ltd will be suitably involved in
Hazard Identification and Risk Assessment exercise. Similarly, changes will also be
subject to consultation process as well as communication process as appropriate.

b) PARTICIPATION & CONSULTATION

Safety committees are to be formed and meetings held as stipulated. This addresses
the requirement of participation & consultation. Hazards may be communicated in
these meetings for further assessing risks as per the procedure discussed earlier in
this document.

11.0 Annexures:-
1: Risk classification – Using the Risk Matrix Table
2: Risk Rating – Using the Risk matrix Table.
3: Risk Assessment Format

Revision 0
February 2015 Page 11 of 14
 Annexure-1

RISK CLASSIFICATION – MATRIX

Annexure - 2

RISK RATING

Risk Factor Classification Risk Level

"Unacceptable Risk"
It would be appropriate to prohibit the activity until
20 to 25 Very High
suitable improvements have been implemented to reduce
the level of risk to an acceptable level
"Substantial Risk"
15 to 19 High Hazards within this range should be proactively managed
to reduce risk to acceptable;
"Adequate" Risk"
Identified hazards within this range should be actively
9 to 14 Medium
managed with efforts to bring down risk level to
acceptable;
"Acceptable Risk" and therefore no further action would be
0 to 8 Low necessary. However it would still be important to ensure
that any existing controls are maintained.

Revision 0
February 2015 Page 12 of 14
 Annexure-3
RISK ASSESSMENT FORMAT
Activity :
Severity

Probability
Rating
S Potential Required control
Basic Job Steps Consequence Current control measures Risk
N Hazard measures
P E A R

Revision 0
February 2015 Page 14 of 14
Revision 0
February 2015 Page 15 of 14