Electrical Maintenance Department

(Bongaigaon Thermal Power station)

Standard Maintenance Procedure

Motor Overhaul and Maintenance Works

Digitally signed by Sajeev

Sajeev Mohandas, AGM- Mohandas, AGM-EMD, NTPC
EMD, NTPC Limited. Limited.
Date: 2022.09.01 15:21:05 +05'30'
Approved for Implementation

Sajeev Mohandas, AGM

HOD (EMD)

Date:

1 Bongaigaon Thermal Power Station

 INDEX

S. No. Description Page No.

1.0 Scope & Objectives 3

2.0 Exclusions 3

3.0 Superseded documents 3

4.0 Revision details 3

5.0 Roles & accountability 3

6.0 Requirements 4

7.0 Records 10

8.0 Compliance audit 10

9.0 Review 10

Annexures

Annexure-1 11
Annexure-2 12
Annexure-3 23

2 Bongaigaon Thermal Power Station

 Standard Maintenance Procedure (SMP) for motor overhaul and
maintenance works
1.0 Scope & Objectives

This document would cover SMP for Motor Overhaul and Maintenance Works in
Main plant, CHP and offsite areas of NTPC-BgTPS.

A standard maintenance procedure (SMP) is a detailed list of steps that describes how
to perform a maintenance task and is also a documented standard to which the job or task
should be performed. All repetitive maintenance tasks shall be covered by SMP.

The objective is:

• To protect the health and safety of employees and Service/Maintenance personnel.

• To help ensure that everyone performs a task to the same degree of precision.
• To save time when performing a task.
• To help ensure that systems are maintained so that standards and regulations are met.
• To minimize the effects of personnel turnover.
• To increase equipment reliability.
• To serve as a training document.
• To help document the equipment management procedure.
• To help protect the environment.
• To provide a basis for accident investigation.

This SMP will cover

i. Preventive maintenance of all Motors.

ii. Breakdown maintenance and repair of Motors.
iii. Schedule maintenance of Motors.

2.0 Exclusions - This SMP will not cover motor maintenance of BgTPS Township.

3.0 Superseded Documents – Nil.

4.0 Revision details – Nil.

5.0 Roles & Accountability

Head of Department (HOD) is accountable and responsible to ensure the following:

a. Identification of aspect & impacts related to environmental aspects, hazards & risk
assessment & control to ensure compliance towards implementation of this SMP.
b. Ensuring training of workers in the area of work and awareness about the hazards
applicable to work covered in this SMP.
c. Ensuring that the contractor has deployed safety equipment relevant to its area of
operation.
3 Bongaigaon Thermal Power Station
 d. Ensuring regulatory compliance & communications with regulatory bodies.
e. Communications of work instructions and management programs to the relevant
personnel for effective implementation.
f. Ensuring preventive & corrective actions for any deviation caused from workflow
expected under this SMP.

Engineer in Charge (EIC) and Area Engineers shall ensure:

a. Safety of Man, Machine and Material.

b. Jobs/tasks are being performed as per SMP.

c. Work to be carried out as specified under the Safety Rules (Electrical & Mechanical).

d. Work related general safety hazards are assessed as per Department HIRA documents.

e. Job based Job Safety Analysis (JSA) is carried out for SMP related task.

f. All workers on jobs are very well informed about hazards associated with works that are
expected to be carried out under this SMP.

6.0 Requirements

6.1 Legal compliance: Refer Annexure - 1 for legal compliance requirement.

6.2 Safety, Health, Environment & Quality:

6.2.1 All Maintenance activities carry various hazards like Electrocution, Fire, dust, Height,
uneven floor, slippery floor, heavy vehicle movement etc. Detailed Hazard Identification
and Risk assessment (HIRA) document shall be considered BEFORE start of work. Refer
Annexure 2.

The following points need to be observed for safe maintenance of the equipment:

a) Maintenance should be undertaken only with the valid permit issued by the S enior
A uthorized Person (SAP).
b) Suitable and tested job specific tools and tackles required for the particular type of
work and the same equipment should be used.
c) Follow the instructions, detailed in the work specification to ensure safety during work.
d) While working at heights, use scaffolding inspected by Scaffolding Inspector.
e) After completion of work, ensure thorough housekeeping of work area including
removal of scrap and waste material.
f) All tools & tackles are to be tested and healthiness to be certified by competent person.

4 Bongaigaon Thermal Power Station

6.2.2 LMI/BgTPP/OGN/OPS/SYST/018, Issue: 01, Revision: 02, Feb--2021 Quality
Management in Maintenance / Overhauling shall be referred for planned and
systematic maintenance to revive the unit health, performance, and efficiency to its
original or near original state such that –

- Availability is maximized
- Downtime is reduced
- Recurrence of shutdowns for same faults is avoided and cost of maintenance is
minimized.

- Class of checks are categorized into class A & B.

- Responsibility for this class of check is as follows:

Class of Check Responsibility

A To be done by FQA
B To be done by O&M

For details of quality checks and responsibility applicable to this SMP, refer LMI -
LMI/BgTPP/OGN/OPS/SYST/018, Issue: 01, Revision: 02, Feb’2021, Sr. No 3.18 and 3.19.

6.3 Technical Requirements:

6.3.1 Introduction

Motors in power plant are very critical for productivity. The purpose of an electric
motor is to convert electrical energy into mechanical energy. This mechanical energy can then
be used to many applications like fluid flow, fuel grinding/transportation and air blowing
etc.,

6.3.2 Areas and types of Motors

1) HT Motors (6.6 kV): Boiler, Turbine, CHP and Offsite area

2) LT Motors (415V): Boiler, Turbine & Generator, CHP and Offsite area.
3) DC Motors (220V): Boiler, Turbine and Generator area.

6.3.4 : Preventive Maintenance Instructions:

a. The reliable operation and life of the motor is strongly influenced by the standard
Preventive maintenance of the equipment.
b. It is imperative that regular checks are carried out in respect to lubrication, operating
efficiency, wear and tear to replace damaged and worn parts.
c. The frequency of such check and the associated maintenance works is dependent on
the length of operation, type and location of the equipment.
d. Rotating machine parts must only be cleaned when they are at a standstill whereby
the respective safety and accident prevention regulation must be observed.
e. Area EMD Executive does hazard identification associated with the job and prepares
Job Safety Analysis (JSA) and applies for required permit one day in advance as per
5 Bongaigaon Thermal Power Station
 PM schedule and maintenance group availability and obtains PTW from operation
and hands over to contract agency with necessary instructions/training/pep talk/TBT
for safe execution of the work.
f. In case of any constraints, the PM jobs are re-planned in next day meeting.
g. Area EMD Executive closes PM order after attending the PM Job, ensuring workmen
and materials clearing at location and thorough housekeeping, closes the notifications
in SAP.

6.3.4.1 Job / Task: Preventive Maintenance of Motors

a) Personal protective equipment required: Safety Helmet, safety shoes, safety belt, Nose
Mask, Hand gloves as per the technical requirement given in Annexure 3.
b) Tools and Material required: Spanners, Grease & Oil, Multimeter, standard tool kit,
Tester, Crimping tool, Megger, Chain pulley block.
c) Personal required: Three to Four (04) Numbers.
d) Number of hours required: 08 hrs.
e) Frequency: As per PM Schedule given in SAP.
f) Safety & Environmental Hazards: Coal Dust, Smoke, Standing Platform, Walkway plate,
Uneven Steps, Power cables, Rain, Heat, scattered material and debris on walkway and
platform etc. Please refer Annexure 1 for control measures.
g) List of Steps for performing Job/Task: DO NOT Start the work without valid Permit-to-
work and JSA.

1) Identify the Correct Unit / Motor as on which maintenance must to be done.

2) Ensure the isolation of the equipment at corresponding switchgear.
3) Ensure corresponding breaker / module is locked and tagged.
4) Clean motor externally.
5) Clean cooler tubes.
6) Remove fan cover, clean fan cover, ventilation tubes & blades.
7) Check healthiness of space heater.
8) Open the terminal box, do earthing and check tightness of terminals & lug
condition.
9) Check and tighten foundation bolts.
10) Check for proper double earthing and tightness of earthing bolts.
11) Clean / Check tightness of neutral terminals.
12) Check grease nipples and tube connections.
13) Measure the IR value of the motor.
14) Close power TB, neutral TB and restore the fan cover.
15) Return the PTW after ensuring all the men and material are cleared.
16) Check starting and running Amps on trial from control room (If drive is taken
into service by operation department immediately after cancellation of permit).

6.3.4.2 Job/Task: Motor Overhauling.

a) Personal protective equipment required: Safety Helmet, safety shoes, safety belt, Nose
Mask, Hand gloves as per the technical requirement given in Annexure 3.
b) Tools and Material required: Spanners, Grease & Oil, Multimeter, standard tool kit,
Tester, Crimping tool, Megger, Chain pulley block.

6 Bongaigaon Thermal Power Station

c) Personal required: Depending on the work.
d) Number of hours required: Depending on the work.
e) Safety & Environmental Hazards: Coal Dust, Smoke, Standing Platform, Walkway
plate, Uneven Steps, Power cables, Rain, Heat, scattered material and debris on
walkway and platform etc. Please refer Annexure 1 for control measures.
f) List of Steps for performing Job/Task: DO NOT Start the work without valid Permit-
to-work and JSA.

1) Identify the correct Unit / Motor as on which maintenance has to be done.

2) Ensure the isolation of the equipment at corresponding switchgear.
3) Ensure corresponding breaker / module is locked and tagged.
4) Disconnect power cable, neutral TB, space heater, C&I connections.
5) Decouple the motor from mechanical equipment.
6) Loosen the foundation bolts, lift the motor from foundation, transport to
workshop maintenance bay and unload.
7) Dismantle the motor.
8) Drain the oil from the bearing.
9) Clean all the parts of motor with respective cleaning agents.
10) Dry-out the stator winding.
11) Apply varnish, bectol red as per the requirement to the stator and the rotor.
12) Check the condition of power leads, space heater, RTDs, gaskets, bushings etc, and
replace if required.
13) Check the bearing clearances, replace the bearings if required.
14) Check for NDE bearing housing insulation.
15) Rectify any problems in stator/rotor.
16) Measure the winding resistance/IR value.
17) Reassemble the motor.
18) Measure the IR value & PI value.
19) Carryout external paining of the motor.
20) Shift the motor to foundation and tight the foundation bolts.
21) Connect all the power cables, neutral TB, space heater, C&I connections.
22) Clean motor externally.
23) Open the TB cover and earth the terminals.
24) Check IR value of the motor.
25) Take decoupled trial, record DOR, bearing & winding temperatures, run for four
hours for overhauled motors and record no load vibration readings.
26) Align & couple the motor to mechanical equipment & record the readings.
27) Clear all materials and workmen from the location.
28) Take load trial run, record load current, bearing & winding temperatures and
record vibration readings.
29) Return the PTW if the values are within limits.
30) Close the maintenance order in SAP.

6.3.5 Predictive and Planned Maintenance Instructions:

6.3.5.1 Job/Task: Breakdown maintenance.

a) Personal protective equipment required: Safety Helmet, safety shoes, safety belt,

7 Bongaigaon Thermal Power Station

 Nose Mask, Hand gloves as per the technical requirement given in Annexure 3.
b) Tools and Material required: Spanners, Grease & Oil, Multimeter, standard tool kit,
Tester, Crimping tool, Megger, Chain pulley block.
c) Personal required: Depending on the work.
d) Number of hours required: Depending on the work.
e) Safety & Environmental Hazards: Coal Dust, Smoke, Standing Platform, Walkway
plate, Uneven Steps, Power cables, Rain, Heat, scattered material and debris on
walkway and platform etc. Please refer Annexure 1 for control measures.

f) List of Steps for performing Job/Task: DO NOT Start the work without valid Permit-
to-work and JSA.

a. Planned maintenance is a proactive approach to maintenance in which maintenance

work is scheduled to take place on a regular basis.
b. Area in-charge decides the replacement of spare or rectification to be carried-out
based on the feedback obtained from Preventive Maintenance (PM), Notification,
Walk-down checks, Site inspections, Condition monitoring report.
c. Area in-charge verifies at stores for spares availability. If not available, the same is
procured through planning dept/EMD and job is planned.
d. Area EMD Executive does hazard identification associated with the job and
prepares Job Safety Analysis (JSA) and applies for permit and obtains PTW from
operation and hands over to contract agency group with necessary instructions/
training/pep talk/TBT for safe execution of the work.
e. Area EMD Executive issues required spares from stores to contract agency/shift
maintenance group.
f. Contract agency group carries out the job as per Job Plan.
g. Area EMD Executive cancels PTW after completion of work, restoration /
normalization of system / equipment, material and workmen clearing from at site.
h. Area EMD Executive records the job done in SAP.

6.3.6 Breakdown Maintenance Instructions:

a. Breakdown maintenance is maintenance performed on equipment that has broken

down and is unusable.
b. Area EMD Executive inspects the equipment under breakdown after receiving
WOC/information from SCE.
c. Area EMD Executive assesses the spares required for rectification to be carried out
and verifies the spares availability and decides the work to be done.
d. Area EMD Executive does hazard identification associated with the job and
prepares Job Safety Analysis (JSA) and applies for permit and obtains PTW from
operation and hands over to contract agency or shift maintenance group with
necessary instructions/ training/ pep talk /TBT for safe execution of the work.
e. Area EMD Executive issues required spares from stores to contract agency/shift
maintenance group.
f. Contract agency group/shift maintenance group carries out the job as per
respective OEM manual.
g. Area EMD Executive cancels PTW after completion of work and restoration /
normalization of system / equipment at site.

8 Bongaigaon Thermal Power Station

6.3.6.1 Job/Task: Breakdown maintenance.

a) Personal protective equipment required: Safety Helmet, safety shoes, safety belt,
Nose Mask, Hand gloves as per the technical requirement given in Annexure 3.
b) Tools and Material required: Spanners, Grease & Oil, Multimeter, standard tool
kit, Tester, Crimping tool, Megger, Chain pulley block.
c) Personal required: Depending on the work.
d) Number of hours required: Depending on the work.
e) Safety & Environmental Hazards: Coal Dust, Smoke, Standing Platform, Walkway
plate, Uneven Steps, Power cables, Rain, Heat, scattered material and debris on
walkway and platform etc. Please refer Annexure 1 for control measures.
f) List of Steps for performing Job/Task: DO NOT Start the work without valid
Permit-to-work and JSA.

1. Identify the correct Unit / Motor as on which breakdown work has to be done.
2. Ensure the isolation of the equipment at corresponding switchgear.
3. Ensure corresponding breaker / module is locked and tagged.
4. Check the required component and rectify / replace depending on breakdown.
5. Clean motor externally.
6. Open the terminal box, do earthing and check tightness of terminals & lug condition.
7. Check NDE bearing insulation.
8. Check and tighten foundation bolts.
9. Check for proper double earthing and tightness of earthing bolts.
10.Clean / Check tightness of neutral terminals.
11.Check grease nipples and tube connections.
12.Measure the IR value of the motor.
13.Close all the covers.
14.Return the PTW after ensuring all the men and material are cleared.
15.Check starting and running amps on trial.

6.4 Training & Awareness Requirements:

1. Site Induction Training to include:

a. Consequences of Violations of Safety requirements

b. Safe Driving & Speed limits;
c. Use of PPE;
d. Emergency Plan & Assembly Points;
e. Incident reporting requirements & process;
f. Falls - Slips & Trips;
g. Run-over hazards in project.

2. Mass Pep Talks to include topics on:

a. Housekeeping
b. Importance in accident & fire prevention.
c. Material Stacking. - Material Handling.
d. Work at Height.

9 Bongaigaon Thermal Power Station

 e. Caught-in between & Caught-by Hazards
f. Fall of objects.
g. Struck-by objects & Equipment/Vehicles.

3. Tool Box Talks:

- Tool Box talk by the area engineer as per the job plan.

4. Employee Refresher Training

The following are the suggested topics for annual training / refresher training for employees:

1) Safety Policy & Role Accountabilities under Safety Framework.

2) Legal & Other Requirements.
3) On-Site Emergency Plan / Disaster Management Plan.
4) Fire prevention & safety.
5) Hazard Identification & Risk Assessment.
6) Incident Reporting & Basic Incident Investigation.
7) PTW system and Responsibilities under E&M Safety Rules.
8) Work at Height including fall prevention and ladder safety.
9) Work in Confined Spaces.
10) Managing Contractors & Workers.

7.0 Records

a) Record of duly signed PM Checklist, walk down checklist, shall be maintained by area
engineer and Uploaded as part of WO records in SAP.
b) Competencies Training records of outsourced persons with date of training, trainer
and trainee signatures by Engineer In charge.
c) Tool Box Talks shall be carried out before start of any maintenance work. Record shall
be maintained and uploaded as per SFW 210 WORKER TRAINING TOOL BOX
TALKS by the Area Engineer.

8.0 Compliance Audit

Compliance assessments/audits should be conducted at least annually by internal

auditors. HOD/HOS is accountable to demonstrate Compliance.

9.0 Review

Head of Department (HOD) will be responsible for reviewing this document on Three
(03) yearly basis or as & when required.

10 Bongaigaon Thermal Power Station


Legal Compliance requirements.
S.No Legal compliance
law
1 Factories Act,
1948 & The Assam
Factories Rules, 1950
2 Factories Act,1948
3 Factories Act,1948
4 Factories Act,1948
& The Assam
Factories Rules, 1950
5 Factories Act,1948
6 Factories act, 1948
Annexure 1
Section / Brief details of the Section Form / Record
Rule No
7A (a) & The provision and maintenance Permit System
Ch-3, of plant and systems of work in
Rule 29 to
31
the factory that are safe and
without risks to health.
17 Providing and maintaining Illumination
sufficient lighting (natural or inspection
artificial or both) Records
22 Work on or near machinery in TBT Register
motion: such examination or
operation shall be made or
carried out only by a specially
trained adult male worker
wearing tight fitting clothing.
32 – 1 (c) When any person has to work at Work at height
& Ch-IV, a height from where he is likely permit / TBT /
Schedule-
II, 61 (E)
to fall, provision shall be made, Job specific PPEs
so far as is reasonably inspection reports
practicable, by fencing or
otherwise, to ensure the safety of
the person so working
29 (2) / 59 Report of examination of Lifting Load test reports
(7) (ii), (9) machines, Chains, Ropes and from competent
Lifting Tackles as per the given authority
particulars by competent person
once in every 12 months
32 Floors, stairs and means of Walk check
access. registers
11 Bongaigaon Thermal Power Station
 Annexure - II
Hazard Identification & Risk Assessment Form
Step - 1
Work / Task: Preventive Work Type: Routine Project / BgTPS /EMD Number: BgTPS/EMD/HIRA/LT MOTOR-01
Maintenance Department:
Work / Task Description: LT Motor PM / Servicing EIC: EMD - LT Group

Step-2 Step-3 Step-4 Step-5 Step-6 Step-7 Step-8 Step-9 Step-11

S. Sub tasks / Potential hazards Existing Control measures Risk Ranking Additional Risk control measures Residual Risk Action to be
No. Activity steps taken by /
initials
Conseque Likelih Risk Consequ Likelih Residual
nce ood rating ence ood Risk
01 PTW to be taken Work without 1) Ensuring permit for all 1) PTW along with JSA to be followed
before start of permit may lead to maintenance related works strictly for every maintenance work.
work miscommunication before work starts. 2) HIRA to be done every time before
and operation may 2) If required, work area is start of actual work.
run the equipment barricading to avoid 3) All PPEs and insulated tools must be EMD – LT
while work in unauthorized entry. 4 2 8 ensured with staff before start of 2 1 2 Group
progress thereby 3) Skilled and trained workers work.
causing shock / are deploying to carry out 4) Ensure for following of Standard
electrocution all maintenance works. Maintenance Procedure / check list.

02 Read the PTW Collection of PTW 1) Verifying the PTW details 1) Visit switchgear location and ensure
for allotted job on wrong and confirming the unit Lock out / Tag out of the equipment
confirmation equipment may number, equipment name 4 1 4 breaker/module before start of the 2 1 2 EMD – LT
lead to shock / and location before start of maintenance activity. Group
electrocution. the work.
03 Ensure all Live equipment 1) Isolations confirmed in the 1) Ensure isolations are done as per
isolations as may be touched PTW are verifying at PTW requirement at switchgear and
mentioned in which will cause switchgear and location. location.
PTW shock / 2) Verifying unit number, 2) Before start of work, ensure wearing EMD – LT
electrocution. switch board and breaker / 4 1 4 of all job specific PPEs. 2 1 2 Group
Injury may also module name before start of 3) All insulated tools must be ensured
happen due to work. with staff before start of work.
body coming in
contact with
rotating parts
04 Confirm motor is Live equipment 1) Ensuring visual verification 1) HIRA to be done on every occasion
in stopped maybe touched to confirm motor is in before start of actual work.
condition which will cause stopped condition. 2) Unauthorized entry to be restricted.
shock / 2) Ensuring trained staff for 4 1 4 3) Pep-talk to be given staff on 2 1 2 EMD – LT
electrocution. carrying out works. potential hazards present during Group
Injury may also 3) Ensuring following of maintenance activities.
happen due to standard maintenance
body coming in procedure / check list.
contact with
rotating parts.
05 Open the motor Live terminals if 1) Ensuring use of proper PPE, 1) Pep-talk to be given staff on
terminal box and touched will cause tools and tackles, assistance potential hazards present during
ensure no voltage shock / for handling the terminal maintenance activities.
Page 12 of 24
 on terminals electrocution box cover. 2) Standard Maintenance Procedure /
2) Ensuring trained and 2 2 4 check list to be followed. 2 1 2 EMD – LT
experienced staff for all 3) Proper illumination and ventilation to Group
maintenance related works. be ensured to avoid fatigue due to
3) Ensuring no voltage with continuous works.
multimeter / non-contact
voltage tester.
06 Discharge the Live / static 1) Ensuring use of proper 1) Pep-talk to be given staff on potential
motor terminals voltage maybe earthing rod to earth the hazards present during maintenance
with suitable touched which will terminals in accordance activities.
earthing rod. cause shock / with the supply voltage. 2) Standard Maintenance Procedure /
electrocution. 2) Ensuring clamping and check list to be followed.
discharging by a single 3 2 6 3) Experienced and trained staff to be 2 1 2 EMD – LT
person, first clamp will be ensured. Group
connected to earth and then 4) All PPEs to be ensured with staff.
discharge rod will be 5) If required, area barricading to be
connected to terminals. done to avoid unauthorized entry.
07 Terminal box Hand injury from 1) Ensuring use of proper PPE, 1) Standard Maintenance Procedure /
cleaning, cable the edges of tools and tackles, IR tester check list to be followed.
tightness, terminal boxes. in accordance with supply 2) Ensure completion of job specific
attending minor Shock during IR voltage. trainings to all workers.
defects if any and measurement, 2) Ensuring that no person is 2 2 4 3) Ensure proper ventilation and 1 1 1 EMD – LT
IR measurement Shock / touching the phase or illumination. Group
Electrocution neutral side terminals 4) Ensure area is free from water, scraps
while tapping during IR measurement. and other debris.
power supply for 3) Also ensuring standard 5) Ensure completion of all job specific
air blowing. fixtures for tapping power trainings to workers.
supplies for air blowers if
used.
08 Removal of Loose / foreign 1) Ensuring visual verification 1) Ensure double verification before
earthing rod and material inside the for no loose or foreign TB box closing.
all tools and terminal box may material left inside the 2 2 4 2) Ensure removal all T&P, materials 1 1 1 EMD – LT
tackles and box cause flashover in terminal box. etc., Group
up. the terminal box 3) Standard Maintenance Procedure /
check list to be followed.
09 Motor terminal Entry of foreign 1) Ensuring sealing near cable 1) Pep-talk to be given staff on potential
box proper materials in the glands and the healthiness hazards present during maintenance
sealing checking motor may cause of terminal box cover activities.
flashover gaskets. 2) Standard Maintenance Procedure /
2) Ensuring canopy or check list to be followed.
Tarpaulin / Polythene 2 2 4 3) Proper illumination and ventilation to 2 1 2 EMD – LT
covering for motor terminal be ensured to avoid fatigue due to Group
box. continuous works.
3) Ensuring trained and
experienced staff for all
maintenance related works.

10 Double earthing Shock or 1) Ensuring use of proper PPE, 1) Standard Maintenance Procedure /
of motor to be electrocution tools and tackles 2 2 4 check list to be followed. EMD – LT
ensured 2) Ensure proper illumination and 1 1 1 Group
ventilation.
11 Return the Return of permit 1) Ensuring Return of PTW 1) Ensure following of Standard
Permit to work prior to completion only after job completion. Maintenance Procedure (SMP) /
after job may cause shock / Check list throughout the
Page 13 of 24
 completion electrocution and 2 2 4 maintenance activity. 1 1 1 EMD – LT
injury due to body 2) Ensure with great care at location Group
contact with before cancellation of permit.
moving parts.
Step – 9 Highest Remaining Residual Risk 2

Step - 10
Risk assessment prepared by: 1) Murali Mohan Date: 01.07.2022
2) Souvick Sen
Consultation conducted with: Nil Work can proceed: Yes

Residual Risk Step 12. APPROVAL REQUIRED TO PROCEED Approved by Approval Date

Low (L) Work can be commenced by EIC when all identified control measures are in place. EIC can sign-off this risk category. Sajeev Mohandas

Hazard Identification & Risk Assessment Form

Step - 1
Work / Task: Preventive / Breakdown Work Type: Routine Project / BgTPS /EMD Number: BgTPS/EMD/HIRA/LT MOTOR-02
Maintenance Department:
Work / Task LT Motor Overhauling or Replacement EIC: EMD - LT Group
Description:

Step-2 Step-3 Step-4 Step-5 Step-6 Step-7 Step-8 Step-9 Step-11

S. Sub tasks / Potential hazards Existing Control measures Risk Ranking Additional Risk control measures Residual Risk Action to be
No. Activity steps taken by /
initials
Conseque Likelih Risk Consequ Likelih Residual
nce ood rating ence ood Risk
01 PTW to be taken Work without 4) Ensuring permit for all 5) PTW along with JSA to be followed
before start of permit may lead to maintenance related works strictly for every maintenance work.
work mis before work starts. 6) HIRA to be done every time before
communication 5) If required, work area is start of actual work.
and operation may barricading to avoid 7) All PPEs and insulated tools must be EMD – LT
run the equipment unauthorized entry. 4 2 8 ensured with staff before start of 2 1 2 Group
while work in 6) Skilled and trained workers work.
progress thereby are deploying to carry out 8) Ensure following of Standard
causing shock / all maintenance works. Maintenance Procedure / Check list.
electrocution
02 Read the PTW Collection of PTW 2) Verifying the PTW details 2) Visit switchgear location and ensure
for allotted job on wrong and confirming the unit Lock out / Tag out of the equipment
confirmation equipment may number, equipment name 4 1 4 breaker / module before start of the 2 1 2 EMD – LT
lead to shock / and location before start of maintenance activity. Group
electrocution. the work.
03 Ensure all Live equipment 3) Isolations confirmed in the 4) Ensure isolations are done as per
isolations as may be touched PTW are verifying at PTW requirement at switchgear and
mentioned in which will cause switchgear and location. location.
PTW shock / 4) Verifying unit number, 4 1 4 5) Before start of work, ensure wearing 2 1 2 EMD – LT
electrocution. switch board and breaker of all job specific PPEs. Group
Injury may also name before start of work. 6) All insulated tools must be ensured
happen due to with staff before start of work.
body coming in
contact with
Page 14 of 24
 rotating parts
04 Confirm motor is Live equipment 4) Ensuring visual verification 4) HIRA to be done on every occasion
in stopped maybe touched to confirm motor is in before start of actual work.
condition which will cause stopped condition. 5) Unauthorized entry to be restricted.
shock / 5) Ensuring trained staff for 4 1 4 6) Pep-talk to be given staff on potential 2 1 2 EMD – LT
electrocution. carrying out works. hazards present during maintenance Group
Injury may also activities.
happen due to 7) Ensure following of Standard
body coming in Maintenance Procedure / Check list.
contact with
rotating parts
05 Open the motor Live terminals if 4) Ensuring use of proper PPE, 4) Pep-talk to be given staff on
terminal box and touched will cause tools and tackles, assistance potential hazards present during
no voltage on shock for handling the terminal maintenance activities.
terminals. /electrocution box cover. 2 2 4 5) Standard Maintenance Procedure / 2 1 2 EMD – LT
5) Ensuring no voltage on check list to be followed. Group
terminals with multimeter 6) Proper illumination and ventilation to
or non-contact voltage be ensured to avoid fatigue due to
tester. continuous works.
06 Discharge the Live / static 3) Ensuring use of proper 6) Pep-talk to be given staff on potential
motor terminals voltage maybe earthing rod to earth the hazards present during maintenance
with suitable touched which will terminals in accordance activities.
earthing rod. cause shock with the supply voltage. 7) Standard Maintenance Procedure /
/electrocution. 4) Ensuring clamping and check list to be followed.
discharging by a single 3 2 6 8) Experienced and trained staff to be 2 1 2 EMD – LT
person, first clamp will be ensured. Group
connected to earth and then 9) All job specific PPEs to be ensured
discharge rod will be with staff.
connected to terminals. 10) Area barricading to be done to avoid
unauthorized entry.
07 Disconnect the Foot / Hand Injury 1) Ensuring use of proper PPE, 1) Standard Maintenance Procedure /
power / control tools and tackles, assistance check list to be followed.
cables for handling. 2) Proper illumination and ventilation to
2) Ensuring trained and 2 2 4 be ensured. 1 1 1 EMD – LT
experienced staff for all 3) All job specific PPEs to be ensured Group
maintenance related works. with staff.
08 Removal of Foot / Hand Injury 1) Ensuring use of proper PPE, 1) Standard Maintenance Procedure /
Motor from tools and tackles, assistance check list to be followed.
foundation & for handling. 2) Proper illumination and ventilation to
coupling bolts, 2) Ensuring trained and 2 2 4 be ensured. 1 1 1 EMD – LT
nuts, earthing experienced staff for all 3) All job specific PPEs, Tools and Group
connections maintenance related works. tackles to be ensured with staff.
removal
09 Lifting of motor, Foot, Hand and 1) Ensuring use of proper PPE, 1) Standard Maintenance Procedure /
placing on truck body Injury tools and tackles, assistance check list to be followed.
and shifting of for handling. 2) Area to be cleared from materials,
motor to 2) Ensuring trained and 3 2 6 scraps and any other obstruction for 2 1 2 EMD – LT
workshop experienced staff with easy movement of hydra/hoist. Group
Hydra/Hoist. 3) Enough quantity of rated slings to be
3) Ensuring barricading of ensured at location.
area to avoid unauthorized
entry.
10 Coupling half Foot, Hand and 1) Ensuring use of proper PPE, 2 2 4 1) Standard Maintenance Procedure / 2 1 2 EMD – LT
removal from body Injury tools and tackles, assistance check list to be followed. Group
Page 15 of 24
 motor shaft for handling.

11 Overhauling jobs Foot, Hand and 1) Ensuring use of proper PPE, 1) Standard Maintenance Procedure /
on motor (Not body Injury tools and tackles, assistance check list to be followed. EMD – LT
applicable for for handling. 2 2 4 2) All job specific PPEs, Tools and 2 1 2 Group
motor tackles to be ensured with staff.
replacement with 3) Ensure experienced and trained
spare motor) workers for deployment of job.
12 Mounting of Foot, Hand and 1) Ensuring use of proper PPE, 1) Standard Maintenance Procedure /
coupling half on body Injury tools and tackles, assistance check list to be followed. EMD – LT
spare / for handling. 2 2 4 2) Ensure completion of job specific 2 1 2 Group
overhauled motor training to all workers.
13 Shifting of spare Foot, Hand and 1) Ensuring use of proper PPE, 1) Standard Maintenance Procedure /
/ overhauled body Injury tools and tackles, assistance check list to be followed.
motor to its for handling. 2) Area to be cleared from materials,
location on truck 2) Ensuring trained and 3 2 6 scraps and any other obstruction for 2 1 2 EMD – LT
(for overhauling experienced staff with easy movement of hydra/hoist. Group
done in Hydra/Hoist. 3) Enough quantity of rated slings to be
workshop / 3) Ensuring barricading of ensured at location.
motor is being area to avoid unauthorized
replaced) entry.
14 Lifting of motor Foot, Hand and 1) Ensuring use of proper PPE, 1) Standard Maintenance Procedure /
and placing on body Injury tools and tackles, assistance check list to be followed. EMD – LT
foundation. for handling. 2 2 4 2) Ensure area is barricaded to avoid 2 1 2 Group
Tightening of 2) Enough quantity of rated unauthorized entry.
foundation bolts. slings to be ensured at 3) Ensure completion of job specific
location. training to all workers.
15 Motor power and Foot / Hand Injury, 1) Use of proper PPE, tools 1) Standard Maintenance Procedure /
control cable, IR Shock during IR and tackles. check list to be followed. EMD – LT
measurement measurement 2) Ensure that no person is 2) Area barricading to be done to avoid 2 1 2 Group
touching the phase or 2 2 4 unauthorized entry.
neutral side terminals
during IR measurement.
16 Removal of all Foreign material 1) Ensuring visual verification 1) Pep-talk to be given staff on potential
tools and tackles inside the terminal for no loose or foreign hazards present during maintenance
and box up the box may cause material left inside the activities.
motor terminal flashover in the terminal box. 2 2 4 2) Standard Maintenance Procedure / 2 1 2 EMD – LT
box terminal box. 2) Also ensuring sealing near check list to be followed. Group
cable glands and the 3) Proper illumination and ventilation to
healthiness of terminal box be ensured to avoid fatigue due to
cover gaskets. continuous works.
3) Canopy or Tarpaulin /
Polythene covering for
motor terminal boxes will
be ensured.
17 Foundation bolt Foot / Hand Injury 1) Use of proper PPE, tools 1) Standard Maintenance Procedure /
tightness and and tackles. 2 2 4 check list to be followed. 2 1 2 EMD – LT
earthing 2) All job specific PPEs, Tools and Group
connections tackles to be ensured with staff.
18 Motor decoupled Live equipment 1) Use of proper PPE, tools 1) HIRA to be done on every occasion
trial, DOR check, maybe touched and tackles. before start of actual work.
temperature and which will cause 2) Ensuring trained staff for 2) Unauthorized entry to be restricted.
vibration shock / carrying out works. 3) Pep-talk to be given staff on potential
measurement electrocution. 3) Ensuring area is clear from 4 1 4 hazards present during no load trial 2 1 2 EMD – LT
Page 16 of 24
 Injury may also scraps, materials and T&P. activities. Group
happen due to
body coming in
contact with
rotating parts
19 Double earthing Shock or 1) Visual verification of 1) Standard Maintenance Procedure /
of motor to be electrocution double earthing of motor is check list to be followed.
ensured after ensuring. 2 2 4 2) All job specific PPEs, Tools and 2 1 2 EMD – LT
alignment / 2) Ensuring of following tackles to be ensured with staff. Group
coupling jobs by Standard Maintenance
mechanical Procedure / check list.
department
20 Return the Return of permit 1) Ensuring return of permit 1) Standard Maintenance Procedure /
Permit to work prior to completion only after physical check list to be followed.
after job may cause shock / verification at location. 2) Ensure clearing of all T&P, Materials
completion and electrocution 2 2 4 and scraps from location before 2 1 2 EMD – LT
removal of all /injury due to body cancellation of permit. Group
T&P, scraps and contact with
materials moving parts.
Step – 9 Highest Remaining Residual Risk 2

Step - 10
Risk assessment prepared by: 3) Murali Mohan Date: 01.07.2022
4) Souvick Sen
Consultation conducted with: Nil Work can proceed: Yes

Residual Risk Step 12. APPROVAL REQUIRED TO PROCEED Approved by Approval Date

Low (L) Work can be commenced by EIC when all identified control measures are in place. EIC can sign-off this risk category. Sajeev Mohandas

Hazard Identification & Risk Assessment Form

Step - 1
Work / Task: Preventive Maintenance Work Routine Project / BgTPS /EMD Number: BgTPS/EMD/HIRA/HT MOTOR-01
Type: Department:
Work / Task Description: HT Motor PM / Servicing EIC: EMD - HT Group

Step-2 Step-3 Step-4 Step-5 Step-6 Step-7 Step-8 Step-9 Step-11

S. Sub tasks / Potential hazards Existing Control measures Risk Ranking Additional Risk control measures Residual Risk Action to be
No. Activity steps taken by /
initials
Conseque Likelih Risk Consequ Likelih Residual
nce ood rating ence ood Risk
01 PTW to be taken Work without 7) Ensuring permit for all 9) PTW along with JSA to be followed
before start of permit may lead to maintenance related works strictly for every maintenance work.
work mis before work starts. 10) HIRA to be done every time before
communication 8) If required, work area is start of actual work.
and operation may barricading to avoid 11) All PPEs and insulated tools must be EMD – HT
run the equipment unauthorized entry. 4 2 8 ensured with staff before start of 2 1 2 Group
while work in 9) Skilled and trained workers work.
progress thereby are deploying to carry out
causing shock / all maintenance works.
electrocution
Page 17 of 24
02 Read the PTW Collection of PTW 3) Verifying the PTW details 3) Visit switchgear location and ensure
for allotted job on wrong and confirming the unit Lock out / Tag out of the equipment
confirmation equipment may number, equipment name 4 1 4 breaker before start of the 2 1 2 EMD – HT
lead to shock / and location before work maintenance activity. Group
electrocution. starts.
03 Ensure all Live equipment 5) Isolations confirmed in the 7) Ensure isolations are done as per
isolations as may be touched PTW are verifying at PTW requirement at switchgear and
mentioned in which will cause switchgear and location. location.
PTW shock / 6) Verifying unit number, 4 1 4 8) Before start of work, ensure wearing 2 1 2 EMD – HT
electrocution. switch board and breaker of all job specific PPEs. Group
Injury may also name before work starts. 9) All insulated tools must be ensured
happen due to with staff before start of work.
body coming in
contact with
rotating parts
04 Confirm motor is Live equipment 6) Ensuring visual verification 8) HIRA to be done on every occasion
in stopped maybe touched to confirm motor is in before start of actual work.
condition which will cause stopped condition. 9) Unauthorized entry to be restricted.
shock / 7) Ensuring trained staff for 10) Pep-talk to be given staff on potential
electrocution. carrying out works. 4 1 4 hazards present during maintenance 2 1 2 EMD – HT
Injury may also 8) Ensuring following of activities. Group
happen due to Standard maintenance
body coming in Procedure / check list.
contact with
rotating parts
05 Open the motor Foot or hand injury 6) Ensuring use of proper PPE, 7) Pep-talk to be given staff on
terminal box may be caused due tools and tackles, assistance potential hazards present during
to improper for handling the terminal maintenance activities.
handling. box cover. 2 2 4 8) Standard Maintenance Procedure /
7) Ensuring trained and check list to be followed. 2 1 2 EMD – HT
experienced staff. 9) Proper illumination and ventilation to Group
be ensured.
06 Discharge the Live/static voltage 5) Ensuring use of proper 11) Pep-talk to be given staff on potential
motor terminals maybe touched earthing rod to earth the hazards present during maintenance
with suitable which will cause terminals in accordance activities.
earthing rod. shock/electrocutio with the supply voltage. 12) Standard Maintenance Procedure /
n. 6) Ensuring clamping and check list to be followed.
discharging by a single 3 2 6 13) Experienced and trained staff to be 2 1 2 EMD – HT
person, first clamp will be ensured. Group
connected to earth and then 14) All PPEs to be ensured with staff.
discharge rod will be 15) Area barricading to be done to avoid
connected to terminals. unauthorized entry.
07 Terminal box Hand injury from 4) Ensuring use of proper PPE, 6) Standard Maintenance Procedure /
cleaning, cable the edges of tools and tackles, IR tester check list to be followed.
tightness, terminal boxes. in accordance with supply 7) Ensure completion of job specific
attending minor Shock during IR voltage. trainings to all workers.
defects if any and measurement, 5) Ensuring that no person is 8) Ensure proper ventilation and
IR measurement Shock / touching the phase or 2 2 4 illumination. 1 1 1 EMD – HT
Electrocution neutral side terminals 9) Ensure area is free from water, scraps Group
while tapping during IR measurement. and other debris.
power supply for 6) Ensuring standard fixtures
air blowing for tapping power supplies
for air blowers if used.
08 Removal of Loose / foreign 2) Ensuring visual verification 1) Ensure double verification before TB
Page 18 of 24
 earthing rod and material inside the for No loose or foreign box.
all tools and terminal box may material left inside the 2 2 4 2) Ensure removal all T&P, materials 1 1 1 EMD – HT
tackles cause flashover in terminal box. etc., Group
the terminal box
09 Box up the motor Foot or hand injury 4) Ensuring use of proper PPE, 4) Pep-talk to be given to staff on
terminal box may be caused due tools and tackles, assistance potential hazards present during
to improper for handling the terminal maintenance activities.
handling box cover. 2 2 4 5) Standard Maintenance Procedure /
5) Ensuring trained and check list to be followed. 2 1 2 EMD – HT
experienced staff for all 6) Proper illumination and ventilation to Group
maintenance related works. be ensured.
10 Double earthing Shock or 2) Ensuring use of proper PPE, 3) Standard Maintenance Procedure /
of motor to be electrocution tools and tackles 2 2 4 check list to be followed. EMD – HT
ensured 4) Ensure proper illumination and 1 1 1 Group
ventilation
11 Return the Return of permit 2) Ensuring Return of PTW 3) Ensure following of Standard
Permit to work prior to completion only after job completion. Maintenance Procedure (SMP) /
after job may cause shock / Check list throughout the EMD – HT
completion electrocution and 2 2 4 maintenance activity. 1 1 1 Group
injury due to body 4) Ensure with great care at location
contact with before cancellation of permit.
moving parts.
Step – 9 Highest Remaining Residual Risk 2

Step - 10
Risk assessment prepared by: Murali Mohan & Souvick Sen Date: 29.06.2022
Consultation conducted with: Nil Work can proceed: Yes

Residual Risk Step 12. APPROVAL REQUIRED TO PROCEED Approved by Approval Date

Low (L) Work can be commenced by EIC when all identified control measures are in place. EIC can sign-off this risk category. Sajeev Mohandas

Hazard Identification & Risk Assessment Form

Step - 1
Work / Task: Electrical Work Type: Routine Project / BgTPS /EMD Number: BgTPS/EMD/HIRA/HT MOTOR-02
Department:
Work / Task Description: HT Motor Overhauling or Replacement EIC: EMD - HT Group

Step-2 Step-3 Step-4 Step-5 Step-6 Step-7 Step-8 Step-9 Step-11

S. Sub tasks / Potential hazards Existing Control measures Risk Ranking Additional Risk control measures Residual Risk Action to be
No. Activity steps taken by /
initials
Conseque Likelih Risk Consequ Likelih Residual
nce ood rating ence ood Risk
01 PTW to be taken Work without 10) Ensuring permit 12) PTW along with JSA to be followed
before start of permit may lead to for all maintenance related strictly for every maintenance work.
work mis works before work starts. 13) HIRA to be done every time before
communication 11) If required, work start of actual work.
and operation may area is barricading to avoid 4 2 8 14) All PPEs and insulated tools must be 2 1 2 EMD – HT
run the equipment unauthorized entry. ensured with staff before start of Group
while work in 12) Skilled and trained work.
Page 19 of 24
 progress thereby workers are deploying to 15) Area to be barricaded to avoid
causing shock / carry out all maintenance unauthorized entry.
electrocution works.
02 Read the PTW Collection of PTW 4) Verifying the PTW details 4) Visit switchgear location and ensure
for allotted job on wrong and confirming the unit Lock out / Tag out of the equipment
confirmation equipment may number, equipment name and 4 1 4 breaker before start of the 2 1 2 EMD – HT
lead to shock / location before work starts. maintenance activity. Group
electrocution.
03 Ensure all Live equipment 7) Isolations confirmed in the 10) Ensure isolations are done as per
isolations as may be touched PTW are verifying at PTW requirement at switchgear and
mentioned in which will cause switchgear and location. location.
PTW shock / 8) Verifying unit number, 4 1 4 11) Before start of work, ensure wearing 2 1 2 EMD – HT
electrocution. switch board and breaker of all job specific PPEs. Group
Injury may also name before start of work. 12) All insulated tools must be ensured
happen due to with staff before start of work.
body coming in
contact with
rotating parts
04 Confirm motor is Live equipment 9) Ensuring visual verification 11) HIRA to be done on every occasion
in stopped maybe touched to confirm motor is in before start of actual work.
condition which will cause stopped condition. 12) Unauthorized entry to be restricted.
shock / 10) Ensuring trained staff for 13) Pep-talk to be given staff on
electrocution. carrying out works. 4 1 4 potential hazards present during 2 1 2 EMD – HT
Injury may also 11) Ensuring following of maintenance activities. Group
happen due to Standard Maintenance
body coming in Procedure /check list.
contact with
rotating parts
05 Open the motor Foot or hand injury 8) Ensuring use of proper PPE, 10) Pep-talk to be given staff on
terminal box may be caused due tools and tackles, assistance potential hazards present during
to improper for handling the terminal maintenance activities.
handling. box cover. 2 2 4 11) Standard Maintenance 2 1 2 EMD – HT
9) Ensuring trained and Procedure / check list to be followed. Group
experienced staff for all 12) Proper illumination and
maintenance works. ventilation to be ensured.
06 Discharge the Live / static 7) Ensuring use of proper 16) Pep-talk to be given staff on potential
motor terminals voltage maybe earthing rod to earth the hazards present during maintenance
with suitable touched which will terminals in accordance activities.
earthing rod. cause with the supply voltage. 17) Standard Maintenance Procedure /
shock/electrocutio 8) Ensuring clamping and check list to be followed.
n. discharging by a single 3 2 6 18) Experienced and trained staff to be 2 1 2 EMD – HT
person, first clamp will be ensured. Group
connected to earth and then 19) All PPEs to be ensured with staff.
discharge rod will be 20) Area barricading to be done to avoid
connected to terminals. unauthorized entry.
07 Disconnect the Foot / Hand Injury 3) Ensuring use of proper PPE, 4) Standard Maintenance Procedure /
power / control tools and tackles, assistance check list to be followed.
cables for handling. 2 2 4 5) Proper illumination and ventilation to 1 1 1 EMD – HT
4) Ensuring trained and be ensured Group
experienced staff.
08 Removal of Foot / Hand Injury 3) Ensuring use of proper PPE, 4) Standard Maintenance Procedure /
Motor from tools and tackles, assistance check list to be followed.
foundation & for handling. 5) Proper illumination and ventilation to
coupling bolts, 4) Ensuring trained and 2 2 4 be ensured. 1 1 1 EMD – HT
Page 20 of 24
 nuts, earthing experienced staff for all 6) Area to be barricaded. Group
connections maintenance related works. 7) Proper illumination and ventilation to
removal be ensured.
09 Motor canopy Foot, Hand and 1) Ensuring use of proper PPE, 1) Standard Maintenance Procedure /
removal body Injury tools and tackles, assistance check list to be followed.
for handling. 2) Area to be cleared from materials,
2) Ensuring trained and 3 2 6 scraps and any other obstruction for 2 1 2 EMD – HT
experienced staff with easy movement of hydra/hoist. Group
Hydra/Hoist. 3) Enough quantity of rated slings to be
3) Ensuring barricading of ensured at location.
area to avoid unauthorized
entry.
10 Lifting of motor, Foot, Hand and 4) Ensuring use of proper PPE, 4) Standard Maintenance Procedure /
placing on truck body Injury tools and tackles, assistance check list to be followed.
and shifting of for handling. 5) Area to be cleared from materials,
motor to 5) Ensuring trained and 3 2 6 scraps and any other obstruction for 2 1 2 EMD – HT
workshop experienced staff with easy movement of hydra/hoist. Group
Hydra/Hoist. 6) Enough quantity of rated slings to be
6) Ensuring barricading of ensured at location.
area.
11 Coupling half Foot, Hand and 2) Ensuring use of proper PPE, 2) Standard Maintenance Procedure /
removal from body Injury tools and tackles, assistance 2 2 4 check list to be followed. 2 1 2 EMD – HT
motor shaft for handling. Group
12 Overhauling jobs Foot, Hand and 2) Ensuring use of proper PPE, 4) Standard Maintenance Procedure /
on motor (Not body Injury tools and tackles, assistance check list to be followed.
applicable for for handling. 5) Proper illumination and ventilation to EMD – HT
motor 3) Ensuring trained and 2 2 4 be ensured. 2 1 2 Group
replacement with experienced staff. 6) Ensure area is clear from unwanted
spare motor) 4) Ensuring completion job materials and scrap.
specific training to staff.
13 Mounting of Foot, Hand and 2) Ensuring use of proper PPE, 3) Standard Maintenance Procedure /
coupling half on body Injury tools and tackles, assistance check list to be followed. EMD – HT
spare / for handling. 2 2 4 4) Proper illumination and ventilation to 2 1 2 Group
overhauled motor 3) Ensuring trained and be ensured.
experienced staff.
14 Shifting of spare Foot, Hand and 4) Ensuring use of proper PPE, 4) Standard Maintenance Procedure /
/ overhauled body Injury tools and tackles, assistance check list to be followed.
motor to its for handling. 5) Area to be cleared from materials,
location on truck, 5) Ensuring trained and 3 2 6 scraps and any other obstruction for 2 1 2 EMD – HT
lifting of motor experienced staff with easy movement of hydra/hoist. Group
and placing on Hydra/Hoist. 6) Enough quantity of rated slings to be
foundation 6) Ensuring barricading of ensured at location.
area to avoid unauthorized
entry.
15 Tightening of Foot, Hand and 3) Ensuring use of proper PPE, 4) Standard Maintenance Procedure /
foundation bolts body Injury tools and tackles, assistance 2 2 4 check list to be followed. 2 1 2 EMD – HT
for handling. Group
16 Motor power and Foot/Hand Injury, 3) Use of proper PPE, tools 3) Standard Maintenance Procedure /
control cable, IR Shock during IR and tackles. check list to be followed. EMD – HT
measurement measurement 4) Ensure that no person is 2 2 4 4) Area barricading to be done to avoid 2 1 2 Group
touching the phase or unauthorized entry.
neutral side terminals
during IR measurement.
17 Removal of all Foot or hand injury 4) Ensuring use of proper PPE, 4) Pep-talk to be given staff on potential
Page 21 of 24
 tools and tackles may be caused due tools and tackles, assistance hazards present during maintenance
and box up the to improper for handling the terminal activities.
motor terminal handling box cover. 2 2 4 5) Standard Maintenance Procedure /
box 5) Ensuring trained and check list to be followed. 2 1 2 EMD – HT
experienced staff for all 6) Proper illumination and ventilation to Group
maintenance related works. be ensured to avoid fatigue due to
continuous works.
18 Foundation bolt Foot / Hand Injury 2) Use of proper PPE, tools 3) Standard Maintenance Procedure /
tightness and and tackles. check list to be followed.
earthing 2 2 4 2 1 2 EMD – HT
connections Group
19 Motor decoupled Live equipment 4) Use of proper PPE, tools 4) HIRA to be done on every occasion
trial, DOR check, maybe touched and tackles. before start of actual work.
temperature and which will cause 5) Ensuring trained staff for 5) Unauthorized entry to be restricted.
vibration shock / carrying out works. 6) Pep-talk to be given staff on potential
measurement electrocution. 4 1 4 hazards present during no load trial 2 1 2 EMD – HT
Injury may also activities. Group
happen due to
body coming in
contact with
rotating parts
20 Double earthing Shock or 3) Visual verification of 3) Standard Maintenance Procedure /
of motor to be electrocution double earthing of motor is check list to be followed.
ensured after ensuring 4) Ensure proper illumination at
alignment / 2 2 4 location. 2 1 2 EMD – HT
coupling jobs by 5) Ensure all job specific PPEs with Group
mechanical workers.
department
21 Return the Return of permit 2) Ensuring return of permit 3) Standard Maintenance Procedure /
Permit to work prior to completion only after physical check list to be followed.
after job may cause shock / verification at location.
completion and electrocution 2 2 4 2 1 2 EMD – HT
removal of all /injury due to body Group
T&P, scraps and contact with
materials moving parts.
Step – 9 Highest Remaining Residual Risk 2

Step - 10
Risk assessment prepared by: 5) Murali Mohan Date: 01.07.2022
6) Souvick Sen
Consultation conducted with: Nil Work can proceed: Yes

Residual Risk Step 12. APPROVAL REQUIRED TO PROCEED Approved by Approval Date

Low (L) Work can be commenced by EIC when all identified control measures are in place. EIC can sign-off this risk category. Sajeev Mohandas

Page 22 of 24
Page 23 of 24
 Annexure 3.
New Technical Specifications for safety PPEs and safety equipment.

S.No Parts to be Protection Technical Specifications

protected against
1 Respiratory Inhalation of Dust Respirator with exhalation valve:
harmfuldust (IS: 9473) marked. Class: FFP1 or EN 149 with CE
marking
2 Ear Hearing losses 1) Earplug:
(if noise level Conforming to IS: 9167 or EN 352 with CE
is above85db) marking
Types*:
a. Permanent type (reusable) minimum
three flanges. Carry box for flanges.
b. Disposable type
2) Ear muffs:
Conforming to IS 9167 or EN 352 with CE
marking
3 Body Fall from height Full Body Safety Harness:
EN 361 with CE marking.
Double lanyard polyamide rope & shock
absorber. Opening of connecting hook should be
minimum 55 mm
Class : A & L.
4 Hand Contact with Leather Hand Gauntlet:
moderately Conforming to EN 407: For hot substances
hot EN 388: For uneven surfaces
substances/un Gauntlet type
evensurfaces
Electrical Shock Hand gloves:
EN 60903 with CE marking
Classes:
Class 00 up to 500V, Class 0 up to 1000V Class
1 up to 7500V Class 2 up to 17000VClass 3 up
to 26500VClass 4 up to 36000V
5 Eye 1.Radiation Zero power Spectacles:
due to sparks Conforming to IS 5983 or EN 166 with CE
flames marking.
2. Eye injuries Type*:
due to a. Radiation due to sparks flames(color:
Flying objects Polycarbonate lens)
Eye Injuries due to flying objects (plain
polycarbonate)

Page 24 of 24