RA No : EHS/SLP/RA/ Rev.

00

Erection of steel flue liners

Risk Rating (RR) guideline:

Rating Definition
1 - Negligible the occurrence is extremely unlikely to happen and has never happened
2 - Low according to ourisknowledge
the occurrence unlikely to happen in the foreseeable future but has alread
3 - Moderate been experienced
the occurrence is predictable to happen in the mid-term
4 - High the occurrence is predictable to happen in the short term
5 - Definite the occurrence is certain and immediate.
Operating Conditions: Normal / Abnormal / Emergency
Reviewed By
EHS Representative (Name, Signature and Date)

Sl. No. Activity Hazard Risk and affected person

(Job steps in sequence)
1 Planning Confusion Personal Injury, Damage to plant &
equipments

2 Management & Staffing Communication Gap Personal Injury, Damage to plant &
equipments

Improper staffing Personal Injury, Damage to plant &

equipments
2 Transportation of man at Fall of person due to Personal Injury, Damage to plant &
working deck through failure of passanger equipments
Passanger Hoist winch/wire rope breaks

3 Transportation of steel Fall of load Personal Injury, Damage to materials

can from fabrication yard
to erection site using 80 T
Crawler Crane
4 Placing of steel flues over Fall of load/ tilting of load Personal Injury, Damage to materials
trunion trolley

5 Making 900 rotation of Tilting of load Damage to materials, Personal Injury

steel liner through
Trunion

6 Pulling can trolley inside Tilting of load Personal Injury, Damage to materials
the shell using 2.5T
winch/ pushing can
trolley using Farana &
Making 900 rotation again

7 Fixing PCLR strands to Manual fixing of strands to Personal Injury [cut/abression]

lifting bracketswelded fixed anchore
with Can1A

Hit by the strands in Personal Injury

tension
 8 Lifting of steel can using Fall of load Personal Injury/ damage to materials
Orione 50 Strand Jacks to
accommodate another can

9 Lowering of steel can Fall of load Personal Injury/ damage to materials

using Orione 50 Strand
Jacks for fit up/ welding
with accommodated
another can

10 Fit upof cans Work at height Fall from Height /fall of materials
(GE Priya Constructions)
 Hit by the hammers/clits Personal Injury

Noise Temporary or permamnent hearing

loss[personnel Injury]

11 Gas Cutting Fire/Explosion/Back fire Personal Injury

Damaged hoses /Joints Fire/ chances of burn [ Personnel

Injury]

Dragging of cylenders Personal Injury

8 Grinding Struck by grinding wheel. Hand and Finger Damage

Personal injury (GE,Priya
construction)
8 Grinding

Electricity Electrical Shock Skin Damage/Fatal

Personal injury (GE,Priya
construction)

Hot spatter. Personal injury (GE,Priya

construction)

Noise Temporary or permamnent hearing

loss[personnel Injury]

9 Welding of joints Electricity Electric shock [Personnel Injury]

Fire Burn [Personnel Injury]

 Spatters Burn, Skin Damage [Personnel Injury]

Welding flash [ UV/IR ] Damage to eye [Personnel Injury]

Welding fumes Prolonged exposure may lead to

lever/lungs/kidney disorder,
irritation to nose [Personnel Injury]

10 Emergency situation Fall, Electrical , Injury to people

 Participants Name
Arvind Kumar
Ameer Hasan
of steel flue liners Sandip Lal
Anmol jadhav
Raju Masih

Severity (S): Importance of harm, damage or impact caused by the e

Definition Rating
y unlikely to happen and has never happened 1 - Minor
o happen in the foreseeable future but has already 2 - Moderate
le to happen in the mid-term 3 - High
le to happen in the short term 4 - Major
nd immediate. 5 - Catastrophic

By Appro
Competent Discipline Engineer (Name, Signature and Date)

Risk and affected person Initial assessment Control Measures

L S RR
Personal Injury, Damage to plant & 3 4 12 1. Proper planning for the job
equipments 2. Fixing of of responsibilities to each and
every individual associated with the job.
3. Deployment of responsible supervision

Personal Injury, Damage to plant & 3 3 9 1. Organisation flow Chart

equipments 2. Selection of efficient employees
3. Delegation of accountability.

Personal Injury, Damage to plant & 9 Selection of staffs competent for the nature
equipments of job right from the planning stage.
3 3
Personal Injury, Damage to plant &
equipments
Personal Injury, Damage to materials
3 4 12 Check installation of winch m/c @ foundation
of for healthiness,Protect hoist way and lift
way by an enclosure constructed as to
prevent any person from falling
materials,Mark the maximum safe working
load on every hoist or lift, and no load
greater than such load shall be carried
thereon,The cage of every hoist or lift used
for carrying persons shall be fitted with a
gate on each side from which access is
afforded to a landing & every gate shall be
fitted with interlocking or other efficient
device to secure that the gate cannot be
opened except when the cage is at the landing
and that the cage cannot be moved unless the
gate is closed,Proper access & its barrication
from access plat form to working deck,Install
overtravelling device.
2 4 8 Daily checks of ground condition & lifting
equipments before start of work by the
operator/ supervisor,third party certification
of crane,Competent operator, Banksman,
structural components tied properly, checking
of wire rope/webbing slings, Use of guide
rope , Job specific training to Slingers,
Signalers,Operator.
Assessment of load & marking of proper
smooth approach shall be prerequisite to
start the activity.
Lifting Plan shall be devised and get
approved.
Personal Injury, Damage to materials
Damage to materials, Personal Injury
Personal Injury, Damage to materials
Personal Injury [cut/abression]
Personal Injury
2 4 8 Daily checks of trunion/geared part of the
trolley, Desgined as per approved drawings,
proper communication between the signaler &
operator , making an exclusion zone around
the swing area of load, Display of sign board
& proper monitering.
3 3 9 Selection of gear block of adequate rating,
checking of chains, proper instruction and
have a tool box talk before start of the
activity, adequate supervision.
3 3 9 Making the path of traverse of trolley over
rail an exclusion zone. Adequate strengthning
& smoothness of the rail lines.
While making rotation, additional rachet
installed with the trolley shall be
fixed/clamped with the rail to prevent
tilting.
2 3 6 Fixing/handling of strands shall be done by
the workmen trained for the job.
Strands shall be firmly inserted through grips
to the fixed anchorand tightened securely.
3 3 9 Strands shall be seciurely handled. None shall
stay within the fire zone of the strands.
Personal Injury/ damage to materials
Personal Injury/ damage to materials
Fall from Height /fall of materials
(GE Priya Constructions)
3 4 12 1. Proper Inspection,checking & maintenance.
2. Inspection & certification of arrangement
as an integral by the competent Person.
3. Barrication , Display of sign board &
proper monitering.
4. . Vacate the GL of Chimney shell while load
is lifted till its locking.
5. Walky-talky shall be used for clear
communication between the Jack operator
and signar.
3 4 12 1. Proper Inspection,checking & maintenance.
2. Inspection & certification of arrangement
as an integral by the competent Person.
3. Barrication , Display of sign board &
proper monitering.
4. . Vacate the GL of Chimney shell till load is
locked.
5.Walky-talky shall be used for clear
communication between the Jack operator
and signar.
3 3 9
1. Full
body harness shall be invariably be used and
anchored at suitable anchorage points.
2. Only worked at height trained personal
shall be allowed to do the job.
3. Hand rail, mid rail & toe board shall be
installed with both the external & internal
working platforms.
5. Suspended workinh platforms shall have TPI
certification under the specified sections of
the Factories Act.
 Personal Injury 3 3 9

1.Trained and competent by experienced

Temporary or permamnent hearing
loss[personnel Injury]
workmen shall be permitted to do the job.
2. Hammers shall be of sound quality &
strength.
3. None shall be allowed to stand in the
closed proximity of work.
3 3 9

workmen shall use ear plug.

Personal Injury 2 3 6

1. Area should be free from

Fire/ chances of burn [ Personnel
Injury]
flammable/combustible materials.
2. Gas hoses and power cable should be
routed properly.
3. Availability of fire extinguisher shall be
ensured.
4. Flash back arrestor& Fire preventor shall
be installed at the nossel and regulator end
respectively.
2 3 6
1. Torn or multiple joints in hoses shall be
avoided.
2.Hose pipes and joints should be checked
with soap solution to check leakage before
start of work.

Personal Injury 2 3 6
Cylenders shall be kept upright and moved
using cylender trolley.
Hand and Finger Damage 2 2 4 1. Proper wheel shall be used as per the
Personal injury (GE,Priya grinding machine specification.
construction) 2. Ensure grinding machine used with wheel
guard.
3. Check the condition of the wheel based on
the expery date.
Electrical Shock Skin Damage/Fatal
Personal injury (GE,Priya
construction)
Personal injury (GE,Priya
construction)
Temporary or permamnent hearing
loss[personnel Injury]
Electric shock [Personnel Injury]
Burn [Personnel Injury]
3 2 6 1. Ensure power supply must be through ELCB.
2 Grinding cables shall not mixed with
welding cables.
3 Power cable should be routed in such a way
that passage way & access should not be
blocked.
4 All the cables shall be protected from
damage.
5 Use job specific PPE’s for job.
6. Only Trained electricians shall be deployed
to do electrical works.
2 2 4
1. Ensure no combustibale & flammable
materials near Hot work 10 mtr.
2. Ensure fire watcher & stand by person.
3. Ensure fire hose must be connected near
hot work.
3 3 9 Workmen shall use ear plug.
3 4 12 1. Ensure Double body earthing of the welding
m/c. power shall be terminated through a
RCCB of 30mA tripping value.
2. Power cable shall be fully insulated.
3. Welding lead/ return lead shall be fully
insulated and if necessary joints shall be
made through lugs& got insulated as well.
4. Only Trained electricians shall be deployed
to do electrical works.
2 3 6 1. Area should be free from
flammable/combustible materials.
2. Availability of fire extinguisher shall be
ensured.
3. Fire watch shall be stationed during the
hot work.
Burn, Skin Damage [Personnel Injury] 2 3 6 Welders shall wear clean, dry welding gloves
and coverall. Coverall or other clothing shall
be worn to minimise the direct exposure of
naked skin, particularly on arms and legs.

Damage to eye [Personnel Injury] 2 3 6 Welders shall wear mask with rate eye
protection glasses. Helpers shall also, wear
protective spectacle.

Prolonged exposure may lead to 3 3 9 1. Stay upwind/ away of welding fumes

lever/lungs/kidney disorder, 2.Welders shall be at job in rotation.
irritation to nose [Personnel Injury] Frequent break shall be provided to them.
3. Ventilation/air circulationshall be ensured.

Injury to people 2 3 6 Emergency preparedness: In case of any

emergency.
Rescue stretcher shall be kept avilable for
resuce from height.

A) Ambulance and Trained first aider shall be

called upon.
B) Higher Authorities shall be informed
immediately.
C) In case of any minor injury primary first
aid shall be provided by trained first aider
d) the ambulance must be well equipped with
life supporting facilities to cope up with
serious conditions,
e) The person in emergency shall be taken to
the nearest hospitel after providing First-Aid.

f) Important contact numbers of higher

officials has been mentioned at site:-

1.First Aider- 8888529124

2. 24X7 Medical Assistance-7743907694

g) AED Kit shall be taken into use in case of

high emergency.h) No Work shall be done in
case of poor climatic conditions (High wind
situations, Heavy rains). i)Fire brigade shall
be called upon in case of fire emergency.
 Job Title Signature
Supervisor
Supervisor
EHS Officer
EHS Officer
Supervisor

impact caused by the event.

Definition
None or very limited consequences on people (e.g. first aid injury) or property
(e.g.
Injuryscratch on equipment
requiring painting)without lost work days or property damage /
medical treatment
business
Lost Timeinterruption below
Injuries, with full 50 k€ of cost
recovery, involved damage/business interruption
or property
below
Severe200 k€ of cost
Accident involved
as per Alstom e-book definition
Several Severe Accidents

Approved By
ture and Date)

Re-assessment Additional Control Measures Residual risk assessment

L S RR L S RR
2 2 4 Schedule checks shall be
performed & documemnted
before putting the equipment 2 2 4
into use.

2 2 4 Made each supervisor accountable

for their job.
2 1 2

2 2 4
2 2 4

2 2 4
2 2 2 1. While fixing the steel can with 1 2 2
the trolley, load shall be securely
held by the crane. As the bolts
are tightened, load shall be
securely transferred to trolley
taking utmost careof stability of
the load.

2 2 4 Additional rachets shall be 1 2 2

installed at all four sides of the
trolley to hold the rails for
additional stability while making
rotation of can.

2 2 4 Adequate/vigilant supervision. 1 2 2

2 2 4 Adequate/vigilant supervision. 1 2 2

2 2 4
2 2 4 Vigilant supervision shall be 2 1 2
ensured. Checking of all
accessories including fixed
anchor, hose connections, Power
pack shall be checked before
lifting starts.Surrounding
clearance shall also, be
soughtwithin the periphery of
steel flue.

2 2 4 Vigilant supervision shall be 2 1 2

ensured. Checking of all
accessories including fixed
anchor, hose connections, Power
pack shall be checked before
lifting starts.Surrounding
clearance shall also, be
soughtwithin the periphery of
steel flue.

2 2 4 Internal & external both the

working platforms shall be
designed & approved for the
purpose.
2 2 4 Vigilant supervision shall be
ensured.

1 3 3

2 2 4 Fire Watch shall be stationed in 2 1 2

the closed proximity of hot work.

1 3 3

1 3 3

1 2 2 1 1 1
2 2 4 Ensure Powe supply must be 1 2 2
thruough ELCB of 30mA tipping
capacity. Welding m/c shall have
doubly earthed .

1 3 3 Ensure enclosure fire booth & 1 2 2

DCP type of Fire extinguisher
must be available at the work
place.

1 3 3

1 3 3 Vigilant supervision shall be 1 2 2

ensured.
2. PTW shall be obtained prior to
start hot work.
 1 3 3

1 3 3

1 3 3

1 3 3 All the emergency contact nmbers 2 1 2

are displayed in visible locations
at site.