Production

Note : If the Risk Score is ≥ 90 then the Risk level is Significant (S)
If the Risk Score is ≤ 89.9 then the Risk level is Low (L)
RISK ASSESSMENT
RISK ASSESSMENT
Legal Requirement
CONSEQUENCES
CONSEQUENCES
LIKELIHOOD (L)
LIKELIHOOD (L)
RESIDUAL RISK
ROUTINE / NON
EXPOSURE (E)
EXPOSURE (E)
PROBABILITY/
PROBABILITY/
(S=Significant
(S=Significant
RISK LEVEL
(L X E X C)
(L X E X C)
ACTIVITY
ROUTINE
L=Low)
L=Low)
LEVEL
S.No
ADDITIONAL
(C)
(C)
HAZARDS EFFECT / RISKS EXISTING CONTROLS
CONTROLS
1. Complete Checking of Jacking system prior

to use
Tilting of Job/Deck & Very
Slippage of hydraulic jacks 2. Trial Lifting to ensure jack functioning. 1 1 15 15 L
Serious injury .
3. Stand by Jacks & Maintenance technicians
to use
2. Trial Lifting to ensure jack functioning & hose
leakages.
Injury due to oil splash, Fire
Leakage in Hydraulic
Hazard, tripping due to slippery 3. Fire Extinguishers & Saw Dust 6 1 3 18 L
system
floor
4. Good House keeping
5. Cordoning of the Complete area

NON- to use
1 Deck Weighing Tilting of job due to error in
ROUTINE TN Factories
pressure gauges or load Very Serious Injury 2. Calibrated Pressure gauges & Load cells 3 1 15 45 L
Rules 1950
cells
3. Approved Weighing Procedure
1. Calibrated Pressure gauges & Load cells
2. Approved Weighing Procedure
3. Fire Extinguishers & Saw Dust

Bursting of Oil hose, injury due
Excess / Unequal Lifting 3 1 3 9 L
to oil spill
5.Cordoning of the Complete area
6. Co ordination by identified team members for

weighing activity.
1. Pre Weighing survey to ensure no loose

materials on deck

Fall / Movement of Loose Injury due to falling loose
3 1 3 9 L
items from Deck materials
4. Ensure No Workmen on the Deck
5. Ensure disconnection of power supply to

Deck other than weighing activities
6. Use of Appropriate PPE like Hard hat,Safety
Goggles, Steel toe shoes (Additional PPE if
NON-
required)
Deck Weighing (Contd...) ROUTINE
(Contd...) 1. Good House keeping

Tripping due to Cables & Electrical shock, Injury due to
3 2 7 42 L
Hoses on the Ground tripping 3. Ensure disconnection of power supply to
unused locations.
4. Ensure No Workmen on the Deck

Prepared By
Approved By
Name :
Name:
Sign: Assessment Team
Sign:
MFFK-HSE-FRM-5001-A, Rev 04, 03.10.2019 Page 1 of 31
RISK ASSESSMENT
RISK ASSESSMENT
Legal Requirement
CONSEQUENCES
CONSEQUENCES
LIKELIHOOD (L)
LIKELIHOOD (L)
RESIDUAL RISK
ROUTINE / NON
EXPOSURE (E)
EXPOSURE (E)
PROBABILITY/
PROBABILITY/
(S=Significant
(S=Significant
RISK LEVEL
(L X E X C)
(L X E X C)
ACTIVITY
ROUTINE
L=Low)
L=Low)
LEVEL
S.No
ADDITIONAL
(C)
(C)
CONTROLS
1. Cordon off the Area
Personal Injury , Property 2. Ensure No Workmen on the Deck

Fall of Deck 0.1 1 40 4 L
Damage
3. Proper maintenance of Hydraulic Jacks
4. Calibrated Pressure gauges & Load cells
Improper use of hammers Hit / Crush injury or blunt injury 2. Use of Standard hammers 3 6 3 54 L
3. Ensure that required all auxiliary tools
available to perform the work.
1. Right use of tools with right procedure
2. Use of Proper Wedges & Proper Storage of

loose wedges & tools
Improper use & handling of Hit / Crush injury, blunt injury or 3. Employ skilled workmen
3 6 3 54 L
wedges bone fracture, Material Damage
4. Tool box talks
5. Use of Appropriate PPE like Hard hat,Safety

required)
1. Training on "Safety while using Hydraulic
Jacks"
2 Fitting & aligning of steel ROUTINE
Slip or break of hydraulic
Minor injury 2. Strict supervision by supervisors 3 2 3 18 L
jacks
3. Right hydraulic oil & preventive maintenance
as per OEM guideline
1. Checking of Hydraulic oil & compressed air

hoses & couplings before testing or
maintenance vis-à-vis test certificate.
Rupture of High pressurized
TN Factories
hydraulic hoses & couplings Hit injury 3 2 3 18 L
2. Rated hose pipe as per the max. pressure Rules 1950
(Hydraulic)
that can be developed by hydraulic pumps.
3. Use of tools which are in good condition

PPE Non compliance non HSE Trainings, Mandatory PPE requirement
wearing of safety belt, Serious Injury areas identified and marked, Tool Box Talks, 3 2 7 42 L
Horse play Penalty guide lines, Safety field Audits
Avoiding Prolonged sun exposure & staying
Heat Exhaustion, Heat Stoke &
Dehydration & Heat Stress hydrated by drinking water and Calcium 2 5 3 30 L
Hyperpyrexia
Gluconite Gel
High level of Noise Noise induced hearing loss Ear muff / Ear plug 1 6 7 42 L
TN Factories
Rules 1950
Flying abrasive particles Eye injury Face screen / shield & screen to protect others 3 6 3 54 L
Guarding, Grinding wheel to be compatible with

Bursting of grinding wheels Minor or Very Serious Injury grinding machine, Trained grinders, Use of 3 2 7 42 L
PPE.
1. Protective earthing
2. ELCB
Bare conductor of power
Prepared By
Approved By
Name :
Name:
Sign:
RISK ASSESSMENT
RISK ASSESSMENT
Legal Requirement
CONSEQUENCES
CONSEQUENCES
LIKELIHOOD (L)
LIKELIHOOD (L)
RESIDUAL RISK
ROUTINE / NON
EXPOSURE (E)
EXPOSURE (E)
PROBABILITY/
PROBABILITY/
(S=Significant
(S=Significant
RISK LEVEL
(L X E X C)
(L X E X C)
ACTIVITY
ROUTINE
L=Low)
L=Low)
LEVEL
S.No
ADDITIONAL
(C)
(C)
CONTROLS

Electrical shock or burns 3. Electrically double insulated machine 1 3 7 21 L
cable or insulation damage
4. Insulation testing -periodic basis
5. Training on "Electrical Safety"
1. Firm gripping
Grinding in uneven surfaces Cut injury due to slip of grinding 2. Use light weight grinding machine. TN Factories
3 3 3 27 L
3 Grinding ROUTINE or corner machine 3. Face shield & other PPE's such as Hard Rules 1950
hat,Safety Goggles, Steel toe shoes, ear plug
(Additional PPE if required)
Loosing control on machine Competent operator.Ref Procedure MFFK-HSE-
Personal Injury 3 6 3 54 L
during operation PRO-5201
1) Avoid use of grinding near flammable
material.
Hot sparks/ particles in
Fire / Property damage 2) Use of fire blankets 1 1 7 7 L
contact flammable material
3) Fire extinguisher

1. Proper guard on the grinding machines
Contact with rotating parts Personal injury 2. Periodical inspection of grinding machines & 3 2 3 18 L
Maintenance
3. Training & Toolbox talk
1) Qualified scaffolders & Scaffolding foreman
2) Training & competency checking
3) Scaffolding Inspection Check list Form No

MFFK-HSE-FRM-5102-B
4) Housekeeping
Fall of Loose scaffolding Personal Injury / Material
5) Tool box talks 3 3 7 63 L
material / Other Material Damage
6) Cordoning of Area
7) Proper tying & handling of loose scaffolding

materials
8) Use of Appropriate PPE like Hard hat,Safety

required)
1. Cordoning of Area.
Scaffolding Erection &
4 ROUTINE
Dismantling 2. Scaffolding Check list. / Procedure
Personal Injury, Material 3. Use of Proper & sufficient Scaffolding
Collapse of Scaffolding 6 3 3 54 L
damage materials
4. Use of Appropriate PPE like Full body Safety
Harness,Hard hat,Safety Goggles, Steel toe
shoes (Additional PPE if required)
Prepared By
Approved By
Name :
Name:
Sign:
RISK ASSESSMENT
RISK ASSESSMENT
Legal Requirement
CONSEQUENCES
CONSEQUENCES
LIKELIHOOD (L)
LIKELIHOOD (L)
RESIDUAL RISK
ROUTINE / NON
EXPOSURE (E)
EXPOSURE (E)
PROBABILITY/
PROBABILITY/
(S=Significant
(S=Significant
RISK LEVEL
(L X E X C)
(L X E X C)
ACTIVITY
ROUTINE
L=Low)
L=Low)
LEVEL
S.No
ADDITIONAL
(C)
(C)
CONTROLS
1) Qualified scaffolders & scaffolding foreman
2) Procedure for scaffold
3) Training & competency checking

Slip & Fall of scaffolders
Very Serious / Serious Injury to
during scaffolding erection / 4) Scaffolding Inspection Check list 1 6 7 42 L
scaffolders
Dismantling
5) Housekeeping
6) Tool box talks

7) Use of double lanyard full body safety
harness with shock absorber
Scaffolding Check list.
Unauthorized modification in Personal injury due to Fall /
Daily surveillance / Scaff tag system 3 3 3 27 L
scaffolding Slip of persons & materials
Tool box talks
Use of Proper & sufficient Scaffolding
materials
Scaffolding Erection & ROUTINE Trained / Qualified scaffolders & supervisors

Dismantling (Contd...) (Contd...) Personal injury due to Fall /
Improper Scaffolding Tool box talks 1 3 3 9 L
Slip of persons & materials
Daily surveillance / Scaff tag system
Scaffolding Check list.

Hyperpyrexia
Gluconite Gel
Very Serious injury / Toppling of 1. Don't keep load above SWL.

Overloading 3 2 3 18 L
Man lift 2. Follow of OEM instructions
1) To be operated by Licensed operator.
Periodical inspection by competent person
Usage of Hydraulic Man lift Hinge pins failure Injury to person 1 1 3 3 L
5 ROUTINE
/ scissor platform 2) Regular Checkups / maintenance
Use of fall prevention & Protection such as

Fall from height Very Serious injury 3 2 3 18 L
guard rail and full body safety harness
Improper operation Damage to platform & person Trained / Qualified operators 3 2 3 18 L
1. Standard Ladder and Scaffolding. 1. HSE Induction and
regular HSE trainings
2. Checklist for ladder & scaffolding. on work at height.
3. Green -"SAFE FOR USE" & Red-"DO NOT
2. Organise HSE
USE" tags.
campaigns on Work at
Height to sensitize
Person Fall from height on Personal Injury, Property 4. Full body harness with shock absorber,
3 2 7 42 L personnels on work at
the roof, Human error Damage safety net & other fall arresting devices
height hazards.
5. Training and tool box talk,
3. Scaffolder
competency verified
6. Scaffold shall be erected by only trained
by Scaffolding
scaffolders
Inspector before
deploying to project.
Prepared By
Approved By
Name :
Name:
Sign:
RISK ASSESSMENT
RISK ASSESSMENT
Legal Requirement
CONSEQUENCES
CONSEQUENCES
LIKELIHOOD (L)
LIKELIHOOD (L)
RESIDUAL RISK
ROUTINE / NON
EXPOSURE (E)
EXPOSURE (E)
PROBABILITY/
PROBABILITY/
(S=Significant
(S=Significant
RISK LEVEL
(L X E X C)
(L X E X C)
ACTIVITY
ROUTINE
L=Low)
L=Low)
LEVEL
S.No
ADDITIONAL
(C)
(C)
CONTROLS
Inspector before
7. Periodic scaffolding inspections. deploying to project.
Working at Height (e.g. 1. Procedure for scaffold. Scaffolding inspection

scaffolding erection & Gap between two Injury due to fall of material or checklist and modification request. Scaffolding
3 1 15 45 L
6 dismantling, platform, ROUTINE scaffolding planks person foreman for inspection, Full Body Harness, Tag
working on roofs, system implementation (Gree /Red)
temporary shed etc.)
Overstepping of ladder due
Injury due to fall of person. 1. Awareness talk on ladder usage 3 3 7 63 L
to negligence.
Damaged rung or rail of 1. Inspection of ladders, Removal of Damaged
Injury due to fall of person. 6 3 3 54 L
ladder ladders from site.
PPE Non compliance non 1. HSE Trainings, Mandatory PPE requirement

1. Regular House keeping

Leaving loose items on top
Hit injury due to fall of
of platforms / Elevations, 2. Tool box talks 3 3 3 27 L
materials
Human error
3. Proper storage / tying of loose materials
1. Avoiding Prolonged sun exposure & staying

Hyperpyrexia
Gluconite Gel
a) Provision of Rope
1. Fragile Work permit system grab system along
with height
b) Apply GI of the at
Mesh
2. Mediical Fitness (if necessary)
bottom of all
c) Install permanent
3. Workers must be competent
provision for tying line
4. All necessary PPE's such as full body safety
harness,Hard hat,safety shoes,goggles, lifelines
, safety nets and use of Man lift for climbing the
Overstepping of access Injury due to fall from height, roof.
3 2 7 42 L
ladder Material Damage
5. Training and tool box talk
7 Working on fragile roof ROUTINE
6. Inspections and Audits- Inspection of the fall
protection arrangements,
7. ERP Procedure No MFFK-HSE-PRO-5006
8.Mobile phones are not permitted during height

work.

Hyperpyrexia
Gluconite Gel
1. Confined space entry permit. Ref -MFFK-

HSE-PRO-5103
2.Forced, dilution & Local Exhaust ventilation
Asphyxiation , suffocation or 3.Calibrated oxygen meter TN Factories

Oxygen deficiency 3 2 7 42 L
loss of consciousness Rules 1950
4.Toolbox talk, training on confined
space
Prepared By
Approved By
Name :
Name:
Sign:
RISK ASSESSMENT
RISK ASSESSMENT
Legal Requirement
CONSEQUENCES
CONSEQUENCES
LIKELIHOOD (L)
LIKELIHOOD (L)
RESIDUAL RISK
ROUTINE / NON
EXPOSURE (E)
EXPOSURE (E)
PROBABILITY/
PROBABILITY/
(S=Significant
(S=Significant
RISK LEVEL
(L X E X C)
(L X E X C)
ACTIVITY
ROUTINE
L=Low)
L=Low)
LEVEL
S.No
ADDITIONAL
(C)
(C)
CONTROLS
5. Use of PPE's like Hard hat,Steel toe

8 Working in confined space ROUTINE shoes,safety goggles and respiratory mask,
SCBA(Additionally if required)
1. Forced, dilution & Local Exhaust ventilation
2. Calibrated oxygen meter

Presence of unknown
Suffocation, Metal fume fever, TN Factories
gases.
Irritation to eyes & throat
3. Toolbox talk, training on confined 3 1 15 45 L
Rules 1950
Fumes & gas due to welding space
shoes,safety goggles and respiratory mask,
1. Confined space entry permit. Ref -MFFK-

HSE-PRO-5103
2. Forced dilution & Local Exhaust ventilation

TN Factories
Chemical or toxicity Respiratory problem 1 2 7 14 L
Rules 1950
3.Toolbox talk, training on confined space

1. Hot Work Permit, Fire Fighting Facilities
2. Fire blankets, fire proof tarpaulin

Flammable materials,
vapor/gases, pressurized TN Factories
Fire & Serious injury 3. Toolbox talk, training on confined 3 2 7 42 L
Working in confined space containers (DP Rules 1950,
(Contd...)
ROUTINE
consumables) space
1. No leakage from Cylinders and Hoses

2. Calibrated oxygen meter
Breathing diffculty, Severe
Oxygen enrichment 3. Forced dilution & Local Exhaust ventilation 3 2 7 42 L
burns
4. Standby person to monitor continuously for all
activities
1. Standard Ladder and Scaffolding.
2. Lifeline, full body harness, PPE
Fall from height Injury or Very Serious injury 3. Housekeeping, adequate illumination, 1 3 15 45 L
designated safe access way
4. Headcount & controlled entries/exits
1. Protective earthing, ELCB, Regular
Bare conductor of power inspection & PPE.Use of 24 V Hand lamp.
Electrical shock , burns ,
cable & welding cable or 3 2 7 42 L
Serious injury 2. Job earthing, Insulation checking & testing
insulation damage
3. Training on "Electrical Safety"
1. Housekeeping, adequate illumination,
Slippery surfaces, pits, designated safe access way
Injury 3 2 3 18 L
uneven surfaces
2. Proper cable routing
Prepared By
Approved By
Name :
Name:
Sign:
RISK ASSESSMENT
RISK ASSESSMENT
Legal Requirement
CONSEQUENCES
CONSEQUENCES
LIKELIHOOD (L)
LIKELIHOOD (L)
RESIDUAL RISK
ROUTINE / NON
EXPOSURE (E)
EXPOSURE (E)
PROBABILITY/
PROBABILITY/
(S=Significant
(S=Significant
RISK LEVEL
(L X E X C)
(L X E X C)
ACTIVITY
ROUTINE
L=Low)
L=Low)
LEVEL
S.No
ADDITIONAL
(C)
(C)
CONTROLS
Working in confined ROUTINE 1. Ensure proper working entry

space(Contd...) (Contd...) 2. Sufficient opening size
Small / insufficient size entry
Unusual movement injury 3. Permit to work system 3 2 3 18 L
& exit
4. Standby person to monitor continuously for all
activities
1. PPE's Like Ear plug ,Ear muff,etc..,
The noise
Noise induced hearing loss 2. Standby person to monitor continuously for all
Grinding noise 6 2 3 36 L pollution rules
(NIHL)/ headache/ fatigue activities 2000
3. Toolbox talk to grinders
1. Permit to work system with Tool Box talk 1. Stop work if wind
speed is more than
2. Monitoring of wind speed with Calibrated the specified limits
anemometer
3. Full body harness with shock absorber 2. Guide rope
Very Serious injury / Property
Swinging due to heavy wind 3 1 40 120 S provision 3 1 15 45 L
Damage 4. Use of Appropriate PPE like Full body Safety
Harness,Hard hat,Safety Goggles, Steel toe 3. Continuos
shoes (Additional PPE if required) Monitoring by Rigging
9 Working in Man Basket ROUTINE foreman
5. Restricted workmen as per notified weight
1) Procedure for maintaining and safe use of

lifting tools and tackles
2) Permit to Work MFFK-HSE-PRO-5206
Failure of lifting tools & TN Factories
Serious injury, Material damage 3 2 7 42 L
tackles 3) Periodical inspection of lifting tools & tackles Rules 1950
and Manlift by competent person
4) Barrication/ cordoning of working area
1) Procedure for working at a height
2) Permit to Work MFFK-HSE-PRO-5206
3) Experience rigger foreman and trained rigger
4) Toolbox talk TN Factories

Improper Slinging Fall & Injury 3 2 3 18 L
Rules 1950
5) Full body safety harness with double lanyard
Working in Man Basket ROUTINE(C
6) Separate lifeline for anchoring safety harness
(Contd...) ontd...)
4. Use of Appropriate PPE like Full body Safety
Harness,Hard hat,Safety Goggles, Steel toe
shoes (Additional PPE if required)
Hyperpyrexia
Gluconite Gel
Defensive Driving
Training for drivers,
Reverse horn, speed limit, Designated area
Collision between human Physical injury minor or major, display of Road safety
identified for vehicle parking, Seat belt, Speed 3 2 15 90 S 3 1 15 45 L
and vehicle Property damage guidelines,Driver
barriers,
Men and Vehicles counselling, Vehicle
10 movement across the road ROUTINE inspection
/ yard
Prepared By
Approved By
Name :
Name:
Sign:
RISK ASSESSMENT
RISK ASSESSMENT
Legal Requirement
CONSEQUENCES
CONSEQUENCES
LIKELIHOOD (L)
LIKELIHOOD (L)
RESIDUAL RISK
ROUTINE / NON
EXPOSURE (E)
EXPOSURE (E)
PROBABILITY/
PROBABILITY/
(S=Significant
(S=Significant
RISK LEVEL
(L X E X C)
(L X E X C)
ACTIVITY
ROUTINE
L=Low)
L=Low)
LEVEL
S.No
ADDITIONAL
(C)
(C)
CONTROLS
/ yard
Speed limit, Stopper on vehicle, Provision of
Material roll over from Physical injury minor or major, dunnage during material transportation.
1 2 7 14 L
vehicle Property damage Monitring of vehicle movement by Security
team,Traffic cones,
1) HSE procedure for Heat treatment (MFFK-

HSE-PRO-5203)
2) Procedure for Safe Electric Work (MFFK-

HSE-PRO-5202)
a) Exposure to live 3) PTW for Heat Treatment(MFFK-HSE-FRM-
Electrical Shock 3 2 7 42 L
conductors 5203-A)
4) Cordoning of the area

5) Licensed electrician
6) Toolbox talk
1) Area cordoning
2) Covering of surface by proper insulation
b) Exposure to high
Severe or minor burn injury 3) PTW for Heat Treatment(MFFK-HSE-FRM- 3 3 7 63 L
temperature surface
5203-A)
4) Procedure for Safe Electric Work (MFFK-
HSE-PRO-5202)
Intermediate Stress 1) PTW for Heat Treatment(MFFK-HSE-FRM-
Reliving / Local Stress 5203-A)
11 ROUTINE
Reiving /Stress Reliving,
Pre Heating (Electrical) 2) Safe installation, inspection, maintenance &
use of Electrical system.
3) Licensed Electrician
c) Short Circuit / Fire to the
Burn injury / property damage 3 2 3 18 L
nearby flammable material 4) Testing of ELCB/ RCD’s, Earthing/ grounding
resistance
5) Availability of Firefighting equipments

6) Insulation test between cables and between
job & cables
1) Proper Removal of Insulation material after

the LSR completion
2) Avoiding the usage of damaged insulation
wool.
d) Exposure to insulating
Skin irritation / Lung diseases 3) House Keeping at Regular Intervals 3 2 7 42 L
material (glass wool)
4. Use of Appropriate PPE like Full body
Coverall,Respiratory mask, Hard hat,Safety
required)
1) Cordon off the hydro test area.
2) Use of appropriate rated hoses.
a) Disengage of high 3) Issue of permit MFFK-HSE-FRM-5104-A TN Factories
Injury to the person working 3 3 7 63 L
pressurized water hose Rules 1950
4) Identified manpower for conducting the hydro
test.
12 Hydro test ROUTINE 5) Use of calibrated instruments.
Prepared By
Approved By
Name :
Name:
Sign:
RISK ASSESSMENT
RISK ASSESSMENT
Legal Requirement
CONSEQUENCES
CONSEQUENCES
LIKELIHOOD (L)
LIKELIHOOD (L)
RESIDUAL RISK
ROUTINE / NON
EXPOSURE (E)
EXPOSURE (E)
PROBABILITY/
PROBABILITY/
(S=Significant
(S=Significant
RISK LEVEL
(L X E X C)
(L X E X C)
ACTIVITY
ROUTINE
L=Low)
L=Low)
LEVEL
S.No
ADDITIONAL
(C)
(C)
CONTROLS
12 Hydro test ROUTINE

1) Use of suitable rated flanges & fittings.
2) Cordoning of hydro test area.
b) Shooting of temporary
Injury to the person working &
flanges & stud nuts other 3) Issue of permit MFFK-HSE-FRM-5104-A 3 2 7 42 L
property damage
fittings
4) Use of calibrated instruments.
5) Tool box talk before hydro test
c) High pressure water jet 1) Use of trained manpower TN Factories

ROUTINE(C during venting Rules 1950
Hydro test (Contd...) 2) Use of long hoses for venting
ontd...)
d) Water spillage on the TN Factories
Injury due to slippery surface 1) Cordon off the hydro test area. 1 3 3 9 L
floor Rules 1950
1) Cordon off the pneumatic test area.
2) Use of appropriate rated hoses.
a) Bursting of high 3) Issue of permit MFFK-HSE-FRM-5104-A
pressurized pneumatic hose
4) Identified manpower for conducting the
Pneumatic test.
5) Use of calibrated instruments.
1) Normal case pneumatic tests are replaced

with hydro test if project not demanding it.
2) Use of suitable rated flanges & fittings.
13 Pneumatic test ROUTINE 3) Use of calibrated instruments.
4) Torque tightening of all nut and bolts
b) Hit by flying nuts and Very seious Injury to the person 5) Installing pressure gauges always in vertical Gas Cylinder
1 1 15 15 L
other fittings working & property damage position, Rules 1981
6) NDT test to be carried out for temporary blind
& nipple joint
7) Blind face area shall be isolated from man
movement
8) Cordoning of pneumatic test area.
9) PTW for Pressure testing (MFFK-HSE-FRM-

5104-A)
1) Disposal of scrap wool at designated places.
a) Skin contact with wool, 2) Display of MSDS

14 Insulation work ROUTINE Skin irritation, rashes, 1 3 3 9 L
inhaling of dust 3) Use of skilled manpower
4) Use of Appropriate PPE's like respiratory
mask.
Prepared By
Approved By
Name :
Name:
Sign:
RISK ASSESSMENT
RISK ASSESSMENT
Legal Requirement
CONSEQUENCES
CONSEQUENCES
LIKELIHOOD (L)
LIKELIHOOD (L)
RESIDUAL RISK
ROUTINE / NON
EXPOSURE (E)
EXPOSURE (E)
PROBABILITY/
PROBABILITY/
(S=Significant
(S=Significant
RISK LEVEL
(L X E X C)
(L X E X C)
ACTIVITY
ROUTINE
L=Low)
L=Low)
LEVEL
S.No
ADDITIONAL
(C)
(C)
CONTROLS
1) Inspection & testing of lifting tools & tackles

and lifting appliances by competent person.
2) Color coding of lifting tools.
Improper fitting & condition 3) Special training on "Safe material handling"

of lifting tools & tackles or to all riggers & crane operators and some
Injury to person, Damage to TN Factories
SWL of lifting tools & tackles refresher training. 3 2 3 18 L
material Rules 1950
are lesser than steel weight
to be handled. 4)On spot visual inspection of tools and tackles
by foreman before operation.Material handling
by competent person.
5)Proper selection of tools & tackles based on

requirement.
1) Keep minimum distance between hoisted

load and ground as far as reasonably
Unloading and stacking of practicable.
15 ROUTINE 2) Special training on "Safe material handling"
steel
to all riggers & crane operators.
Injury to person, Damage to
Falling from height 3) On spot visual inspection of tools and tackles 6 3 3 54 L
material
by foreman before operation.
4) Competent operator are doing material
handling.
5) Proper selection of tools & tackles based on
requirement.
Material handling by Injury to person, damage to

Competent operator for material handling. 3 2 3 18 L
Incompetent persons material
Remote control function check ups by operator
before handling materials. Preventive
Malfunctioning of remote
Injury to person, damage to maintenance of remote control & other safety TN Factories
control or other safety 3 2 3 18 L
material devices. Visual identification & information to all Rules 1950
devices (Gantry Crane)
concerned to shut off crane supply in case of
emergency
Sideway movement of Ensuring wind speed is less than 1.7 km/hr
Injury to person 3 6 3 54 L
suspended material Provide tagline for controlling load in air.
Unprotected sharp edges of Provide appropriate PPE like cut resistant

Cut, abrasion, contusion injury 3 3 3 27 L
steel materials gloves for personnel.
Only competent operators are allowed to

Mobile crane C.G.out of Injury to person, damage to
operate. Load test & other safety checks by 3 2 3 18 L
stability range material
authorized competent person.
1) Training on "Safe material handling" to all

Riggers.
Stacked plates without 2) Providing spacers between the horizontally
Crush injury 3 2 7 42 L
spacers stacked plates
3) Racks shall be used for vertical stacking
plates
Only competent operators are allowed to

Injury to person
Overloading of Crane, EOT, operate. TN Factories
3 2 3 18 L
Gantry Rules 1950
Prepared By
Approved By
Name :
Name:
Sign:
RISK ASSESSMENT
RISK ASSESSMENT
Legal Requirement
CONSEQUENCES
CONSEQUENCES
LIKELIHOOD (L)
LIKELIHOOD (L)
RESIDUAL RISK
ROUTINE / NON
EXPOSURE (E)
EXPOSURE (E)
PROBABILITY/
PROBABILITY/
(S=Significant
(S=Significant
RISK LEVEL
(L X E X C)
(L X E X C)
ACTIVITY
ROUTINE
L=Low)
L=Low)
LEVEL
S.No
ADDITIONAL
(C)
(C)
CONTROLS
3 2 3 18 L
Gantry Rules 1950
Provision of engineering controls to indicate
Damage to material
overloading.
Unloading and stacking of ROUTINE Crane shall not be used for lifting or pulling
steel (Contd...) (Contd...) beyond vertical line.
Hoisting the load which is Injury due to striking Training on "Safe material handling" to all TN Factories
3 2 7 42 L
not in vertical line with hook. Damage to material riggers. Rules 1950
All pulleys & sheaves wire ropes should be
guarded to prevent slip out & checked
periodically.
Framing / Poles to be provided on trolley/trailer
Steel Plates may fall down Injury to person, damage to
periphery to prevent falling of object during 3 2 3 18 L
from vehicle while shifting material
movement
Any person standing near
by material which is being No person shall be allowed to stand near
Injury to personnel 1 2 3 6 L
lifted by hydra/crane or EOT material movement area.
crane.
Practice to be made that if remaining slings are

Use of two chain slings in a Non used chain sling may hit TN Factories
no longer required, non used slings/chains shall 3 3 3 27 L
Four sling chain. worker & cause injury. Rules 1950
be removed/hooked back to main ring.
1) Permit to work (MFFK-HSE-FRM-5104-B)
2) Placement of screen to trap the flying objects TN Factories

a) Shooting of particles Injury 3 2 3 18 L
Rules 1950
3) Cordoning the area and display
b) Bursting of pneumatic TN Factories

NON Injury to the nearby person 1) Cordoning of area 3 2 7 42 L
16 Cardboard blasting hose Rules 1950
ROUTINE
The
c) Dust climate Arc eye/dust allergy 1) Permit to work (MFFK-HSE-FRM-5104-B) 6 2 3 36 L Environment
Act 1986
1) Provide appropriate PPE like ear plug & ear The noise
d) Noise Noise induced hearing loss muff and mandatory PPE's like hard hat,safety 6 2 3 36 L pollution rules
goggles , steel toe shoes 2000
1) Area cordoning
a) Slippery surface due to Injury to the person due to
2) Permit to work (MFFK-HSE-FRM-5104-B) 1 6 3 18 L
water spillage on the floor falling
3) Use of proper flushing scheme
1) Use of standard hoses & fittings

17 Flushing ROUTINE b) Disengagement of hoses Injury to the person working 3 3 3 27 L
2) Trained manpower
1) Use of standard hoses & fittings

c) Electrical shock due to TN Factories
Injury 2) All ELCBs should be maintained proprely 1 3 15 45 L
spillage/Leakage of water Rules 1950
3) Use of proper flushing scheme
a) Air compressors enclosed to reduce noise

emissions at source.
The noise
Noise induced hearing loss b) Exposure control by job rotation, Daily Tool
Noise 3 3 3 27 L pollution rules
(NIHL) box Talk, Rest / break etc.
2000
c) Periodic Inspection / Maintanence of Air
compressor. Use of Ear muff/ear plug & etc.
Prepared By
Approved By
Name :
Name:
Sign:
RISK ASSESSMENT
RISK ASSESSMENT
Legal Requirement
CONSEQUENCES
CONSEQUENCES
LIKELIHOOD (L)
LIKELIHOOD (L)
RESIDUAL RISK
ROUTINE / NON
EXPOSURE (E)
EXPOSURE (E)
PROBABILITY/
PROBABILITY/
(S=Significant
(S=Significant
RISK LEVEL
(L X E X C)
(L X E X C)
ACTIVITY
ROUTINE
L=Low)
L=Low)
LEVEL
S.No
ADDITIONAL
(C)
(C)
CONTROLS
a) Use of Air controlling valve at outlet,

b) Use of standard and rated hose pipe,
c) Use of whip check / Quick Coupling on hose
TN Factories
Exposure to Pressurised air Physical Injury connections, 6 2 3 36 L
Rules 1950
d) Periodic Inspection / Maintanence of Air
Compressed air generation compressor
18 ROUTINE
by air compressors e) Use of PPE's
Periodic Checking and testing by authorized

Injury due to fragile particles , TN Factories
Rupture of air receiver tanks competent person. Water drainage from 3 2 3 18 L
Property Damage Rules 1950
receiver tank at regular intervals.
Apply Lock Out Tag Out.

Exposed to live conductors Burn injury Training for "Safe maintenance practices" 1 2 15 30 L
Insulated gloves & instruments & tools
Expose to radiator fan Physical Injury Guard, No loose clothing 3 1 7 21 L

The
Leak diesel to be collected in container, Spillage
Diesel Spillage Fire 3 3 3 27 L Environment
to be immediately cleared
Act 1986
Use of two EOT / Gantry Injury to person, Property Anti-collision device, trained operator, Marking
19 ROUTINE Collision of cranes 1 6 7 42 L
cranes on same rails damage of work area
Included angle beyond 45- Personal injury due to falling of Tank rotator included angle must be between
1 1 7 7 L
60 degree Tubular 45-60 degree.
Tank rotator must be aligned properly-

Aligning & rotating of Slipping of tank rotators or Personal injury due to falling of vertically, horoizontally & diagonally as per the
20 ROUTINE 3 2 3 18 L
Tubular on tank rotators roller beds Tubular Tank Rotator Safety Guidelines. All roller beds
must be locked by locking pin only.
Personal injury due to failure of

Overloading Marking of loading capacity on tank rotators 3 2 3 18 L
tank rotator, Material Damage
Metal fume fever, Irritation to General dilution & natural ventilation Provide TN Factories
Fumes & Gases 3 6 3 54 L
eyes & throat forced ventilation for confined space. Rules 1950
Welding Face shield & Welding glasses as per TN Factories

UV radiation Arc eye, Cataract , photophobia 3 3 3 27 L
DIN standard. Rules 1950
Cut, abrasion, contusion injury
Sharp edges of steel plates Provide PPE like cut resistant Gloves 3 6 3 54 L
during handling operation
Protective earthing, ELCB, Regular inspection &
PPE. Insulation checking & testing Reduce
cable & welding cable or Electrical shock & burns 3 3 7 63 L
number of joints as less as possible Training on
insulation damage
"Electrical Safety"
Use of PPE's like Welding face shield, leather

Shielded Metal Arc Spatters, sparks, hot slag Eye injury, Skin burn 3 3 7 63 L
hand gloves, leg guard, apron
Welding or Manual Metal
21 ROUTINE
Arc Welding (SMAW or
MMAW) Scattered electrode stubs Injury to person due to skidding Use stub bins, Returing stubs to consumable
3 3 7 63 L
on floor Burn injury stores
Maintain safe distance from the high heat area.

Use thermal chalk to avoid overheating, Use
Heat due to preheating Heat stress, burns heat resisting devices & materials. Use thick 3 6 3 54 L
leather gloves. Ensure that no body parts get
exposed or get in contact with preheated job.
Prepared By
Approved By
Name :
Name:
Sign:
RISK ASSESSMENT
RISK ASSESSMENT
Legal Requirement
CONSEQUENCES
CONSEQUENCES
LIKELIHOOD (L)
LIKELIHOOD (L)
RESIDUAL RISK
ROUTINE / NON
EXPOSURE (E)
EXPOSURE (E)
PROBABILITY/
PROBABILITY/
(S=Significant
(S=Significant
RISK LEVEL
(L X E X C)
(L X E X C)
ACTIVITY
ROUTINE
L=Low)
L=Low)
LEVEL
S.No
ADDITIONAL
(C)
(C)
CONTROLS
Check leakages before starting the work. Keep

Leakage of Flammable gas cylinder away from heat source (at least 2m)
(LPG cylinder for pre Fire & burn injury Avoid connections in hose. Provide LPG 1 6 7 42 L
heating), Spatters cylinder covers. Keep valves close to the
burners for emergency shutoff.
Metal fume fever, Irritation to General dilution & natural ventilation, Provide
eyes & throat forced ventilation for confined space.
UV radiation (Open Arc) Arc eye, Cataract , photophobia Sufficient and uninterrupted flux supply. 3 2 7 42 L
Sharp edges of steel plates, Cut, abrasion, contusion injury
Use of PPE's like Cut resistant gloves 3 3 3 27 L
pipes during handling operation
PPE.
Bare conductor of power Insulation checking & testing

cable & welding cable or Electrical shock & burns 3 1 15 45 L
insulation damage Reduce number of joints as less as possible
Submerged Arc Welding

Training on "Electrical Safety"
22 (SAW) by boom & platform/ ROUTINE
trolley
Use of PPE's like leather hand gloves & Black
Sparks, hot slag Skin burn, eye injury 3 3 7 63 L
goggles.

Use thermal chalk to avoid overheating. Use
leather gloves. Ensure that no body parts get
exposed or get in contact with preheated job.
Check leakages before starting the work. Keep
Leakage of Flammable gas cylinder away from heat source (at least 2m)
(LPG cylinder for pre Fire & burn injury Avoid connections in hose Provide LPG 3 3 7 63 L
heating) cylinder covers. Keep valves close to the
Follow manufacturer's recommendations about
limit & safe working load. Provide limit
switch/stopper to avoid over travel in any
Toppling of SAW boom Serious injury, Material damage direction. Ensure that sufficient counterweight 1 2 15 30 L
provided as per the extension length of the
boom beyond the recommended limit as per
Production engg.
Restrict entry to unauthorized person and
Falling of hot slag from
Submerged Arc Welding Burn injury cordoning of area. Fire blanket to prevent falling 3 3 7 63 L
ROUTINE(C height
(SAW) by boom & platform/ form height.
ontd...)
trolley (Contd...) Fall of person Serious injury Provide handrails/barrications 3 2 7 42 L
Head/body injury to person
Fall of tools from platform Provide tool box for keeping tools 3 3 3 27 L
standing beneath
striking on boom/ trolley movement of boom / trolley only by qualified
Hit injury 3 3 3 27 L
against other object operator
Crush or impact Injury to
Loading and unloading of Supervision, Avoiding lifting of heavy
person due to fall of material,
wire spools in SAW / MIG objects.Group lifting,Use of PPE, use of hand 1 3 3 9 L
Pain in upper or lower limbs,
welding gloves.
Backpain, Cut, Fatigue
General dilution & natural ventilation. Provision
Metal fume fever, Irritation to
Fumes & Gases of forced ventilation for confined space. Nose 3 6 3 54 L
eyes & throat
mask to FCAW welders.
Welding Face shield & Welding glasses as per
UV radiation Arc eye, Cataract , Photophobia 1 6 3 18 L
DIN standard.
Prepared By
Approved By
Name :
Name:
Sign:
RISK ASSESSMENT
RISK ASSESSMENT
Legal Requirement
CONSEQUENCES
CONSEQUENCES
LIKELIHOOD (L)
LIKELIHOOD (L)
RESIDUAL RISK
ROUTINE / NON
EXPOSURE (E)
EXPOSURE (E)
PROBABILITY/
PROBABILITY/
(S=Significant
(S=Significant
RISK LEVEL
(L X E X C)
(L X E X C)
ACTIVITY
ROUTINE
L=Low)
L=Low)
LEVEL
S.No
ADDITIONAL
(C)
(C)
CONTROLS

Sharp edges of steel plates,
resulted during handling Use of PPE's like Cut resistant gloves 3 6 3 54 L
pipes
operation
Gas Tungston Arc Welding Protective earthing, ELCB, Regular inspection &
(GTAW) / Electrical shock , burns , Cardio PPE. Insulation checking & testing. Reduce
Gas Metal Arc Pulmonary arrest number of joints as less as possible. Training
23 ROUTINE insulation damage
Welding(GMAW)/ on "Electrical Safety"
Flux Cored Arc Welding
(FCAW) Cylinders to be kept in cylinder trolley in upright
Fall of gas cylinder (for Injury to person, damage to
condition with proper fastening. Provide nozzle 3 2 3 18 L
GMAW, GTAW) property, cylinder
guard to cylinder
Use of PPE's like Welding face shield, leather

Spatters, sparks, hot slag Eye injury, Skin burn 3 2 7 42 L
hand gloves, leg guard, apron
Scattered wire stubs on Use stub bins. Returing stubs to consumable

Injury to person due to skidding 1 3 3 9 L
floor stores

Use thermal chalk to avoid overheating. Use
Gas Tungston Arc Welding leather gloves. Ensure that no body parts get
(GTAW) / exposed or get in contact with preheated job.
Gas Metal Arc ROUTINE
Welding(GMAW)/ (Contd...)
Flux Cored Arc Welding Check leakages before starting the work. Keep
(FCAW) (Contd...) Leakage of Flammable gas cylinder away from heat source (at least 2m).
(LPG cylinder for pre Fire & burn injury Avoid connections in hose. Provide LPG 1 6 7 42 L
heating) cylinder covers. Keep valves close to the
Ear muff/ear plug & Exposure control by job

Noise Noise induced hearing loss 6 3 3 54 L
rotation.
Metal fume fever, Irritation to General dilution & natural ventilation. Provide
eyes & throat forced ventilation for confined space
Welding Face shield & Welding glasses as per
UV radiation Arc eye, Cataract , photophobia 1 3 3 9 L
DIN standard.

Electrical shock , burns , Cardio PPE. Insulation checking & testing. Reduce
Pulmonary arrest number of joints as less as possible. Training on
insulation damage
Arc Gouging (Removal of "Electrical Safety"
24 ROUTINE
Metal)
Welding face shield, leather hand gloves, leg
Spatters, sparks, hot slag Eye injury, Skin burn guard, apron . Try to do down hand gauging as 3 2 7 42 L
far as possible.
Scattered electrode stubs
Injury to person due to skidding Use stub bins 1 3 3 9 L
on floor
Rotating parts in
Hand injury Provide guards for every rotating part. 3 2 3 18 L
compressor
Provide engineering controls ( eg safety relief
Bursting of compressor
Very Serious Injury valve). 0.5 6 15 45 L
hose
Hydro testing of tank at regular time.
Leakage of Pressurized air High rating compressed air hose with couplings
Severe injury 3 1 7 21 L
from baking oven Checking of air hose couplings on daily basis.
Baking of welding
25 ROUTINE
Prepared By
Approved By
Name :
Name:
Sign:
RISK ASSESSMENT
RISK ASSESSMENT
Legal Requirement
CONSEQUENCES
CONSEQUENCES
LIKELIHOOD (L)
LIKELIHOOD (L)
RESIDUAL RISK
ROUTINE / NON
EXPOSURE (E)
EXPOSURE (E)
PROBABILITY/
PROBABILITY/
(S=Significant
(S=Significant
RISK LEVEL
(L X E X C)
(L X E X C)
ACTIVITY
ROUTINE
L=Low)
L=Low)
LEVEL
S.No
ADDITIONAL
(C)
(C)
CONTROLS
Baking of welding
25 ROUTINE Protective earthing, ELCB, Regular inspection &
electrodes & fluxes Bare conductor of power PPE.Insulation checking & testing. Reduce
cable & welding cable or Electrical shock & burns , 6 1 7 42 L
number of joints as less as possible. Training
insulation damage
on "Electrical Safety"
Heat Burns Heat resistant gloves and scoop(for flux) 3 6 3 54 L
Inspection & testing of lifting tools ,tackles and

lifting appliances by competent person and
color coding the same.
Training on Safe material handling to all riggers
Improper lifting tools &
Injury to person, & crane operators and some refresher training.
tackles or overloading of 3 2 3 18 L
Damage to sling On spot visual inspection of tools and shackles
lifting tools & tackles.
by foreman before operation.
Fixing of upending ( Roll Competent operator for material handling.
NON- Proper selection of tools & tackles based on
26 up) /rigging slings on jacket
ROUTINE requirement.
legs
Competent people, supervision,

Use of man basket
As far as possible work will be done during
Working at height Physical injury minor or major 3 2 15 90 S with PTW- MFFK-HSE- 1 2 15 30 L
daytime. While working at night proper
FRM-5106-A
illumination will be provided.
Use of man basket
Competent riggers and foreman, supervision,
Use of multiple crane Crane damage ,injury 3 2 15 90 S with PTW- MFFK-HSE- 1 2 15 30 L
Lifting Scheme
FRM-5106-A
Lifting heavy, unstable, Crush or impact Injury to Avoiding lifting of heavy objects, Supervision,
3 3 3 27 L
sharp objects person due to fall of material, Use of PPE's like Cut resistant gloves
27 Manual Material Handling ROUTINE Avoiding lifting of heavy objects, Use of PPE
Slipage of material Material Damage like shoulder pad and trolleys, Training on Safe 1 3 3 9 L
Materail Handling
Pain in upper or lower limbs, Supervision, Group lifting, Avoiding lifting of

Wrong Posture 1 3 3 9 L
Backpain, Fatigue heavy objects.
a) Storage as per Gas Cylinder Rules-2004.
b) Keep cylinders upright & properly chained.
Storage & handling of Fall of compressed gas Crush injury, Fire and Property TN Factories
28 ROUTINE c) Storage away from ignition source. 3 3 7 63 L
compressed gas Cylinders cylinder, Leakage of gases damage Rules 1950
d) Use of PPE's like Hard hat, safety goggles,
steel toe shoes and Hand gloves.
Sharp objects (Use of Guard on machine, Trained person
Injury to person 3 3 3 27 L
circular Saw) Use of PPE's like Cut resistant gloves
Proper maintainence of Handtools. Trained

Usage of improper Hand
Injury to Person workmen. Use of PPE's like tool lanyard, hard
tools
hat, safety goggles, steel toe shoes.
NON- Housekeeping, Proper storage and disposal of

29 Carpentry work Saw dust Ill health, Fire saw dust, Placement of fire extinguisher, Use of 1 2 3 6 L
ROUTINE
Dust mask
Proper housekeeping, Experienced carpenter,

Protruding nails Puncture injury Appropriate PPE's like safety googles, steel toe 3 3 3 27 L
shoes and hard hat
Use of ELCB, MCCB, Placement of fire

Electricity Electrical shock, Fire 3 2 3 18 L
extinguisher, Cable management.
Prepared By
Approved By
Name :
Name:
Sign:
RISK ASSESSMENT
RISK ASSESSMENT
Legal Requirement
CONSEQUENCES
CONSEQUENCES
LIKELIHOOD (L)
LIKELIHOOD (L)
RESIDUAL RISK
ROUTINE / NON
EXPOSURE (E)
EXPOSURE (E)
PROBABILITY/
PROBABILITY/
(S=Significant
(S=Significant
RISK LEVEL
(L X E X C)
(L X E X C)
ACTIVITY
ROUTINE
L=Low)
L=Low)
LEVEL
S.No
ADDITIONAL
(C)
(C)
CONTROLS
Eliminating sharp edges and projecting parts.

Material & scrap Sharp edged or projected
30 ROUTINE Cut, abrasion, contusion injury Use of PPE like Cut resistant gloves and 3 3 3 27 L
segregation and disposal parts
madantory PPE's
Low temperature liquid spills Only authorized person to operate, Safety valve
Cold burns, frostbite 1 2 3 6 L
Storage & handling of NON- or leakages & bursting disc. Dedicated Supervision.
31
cryogenic liquid ROUTINE Oxygen enrichment & fire, No flammable materials or oil or grease shall be
Leakage of oxygen 3 2 3 18 L
Property Damage kept or used within 6 m peripheral area
Storage as per Legal requirements , Display of
MSDS
Use of PPE's like respiratory mask or filter

Toxic fumes & vapors Respiratory problem 3 2 7 42 L
catridge mask and SCBA (Additionally if
required)
Segregated & separate store for chemicals

Storage & handling of The
32 ROUTINE Storage as per Legal requirements, Display of
hazardous chemicals Manufacture,
MSDS
Storage and
Flammable chemicals & its severe injury or Fire, Material
Segregated & separate store for chemicals 3 3 7 63 L Import of
vapors Damage
Hazardous
Placement of Fire extinguishers, Use of PPEs Chemical
Rules 1989
The
Fall, Burn injury, Fire, Material Chemical issued in packed condition, Spill
Spillage of chemical 3 3 7 63 L Environment
Damage containment tray
Act 1986
Storage & handling of Storage of scrap wool at designated places.
Skin contact with wool, Skin irritation, rashes,
33 Insulation, Refractory ROUTINE Use of PPE like respiratory mask and 3 2 3 18 L
inhaling of dust carcinogenic material
material mandatory PPE's
Safe Access to height, full body harness with

Unprotected High elevation Fall from height 3 3 3 27 L
life line, Fall arresting device & scaffolding.
Use of Inspected lifting equipments, tools and
tackles
Collapse of truss Injury to person Trained operator, Rigger, rigging foreman 3 2 3 18 L

34 Truss work ROUTINE
Use of tag lines
Cordoning of area
Securing of hand tools
Fall of material Injury to person Cordoning of area 3 3 3 27 L
Removal of loose material from the height.
Only 500ml bottle of Acetone-cleaning agent
shall be kept to reduce quantity exposure
Personal exposure to Housekeeping, MSDS of chemicals.
35 Dye Penetration Test ROUTINE Vapor of cleaning agents Chemical vapor & Fire, Skin 3 2 3 18 L
Irritation & Breathing Problem Trained & Qualified Level I / II Operators
Adequate Ventilation & Illumination
PPE - Hand gloves & mask
Prepared By
Approved By
Name :
Name:
Sign:
RISK ASSESSMENT
RISK ASSESSMENT
Legal Requirement
CONSEQUENCES
CONSEQUENCES
LIKELIHOOD (L)
LIKELIHOOD (L)
RESIDUAL RISK
ROUTINE / NON
EXPOSURE (E)
EXPOSURE (E)
PROBABILITY/
PROBABILITY/
(S=Significant
(S=Significant
RISK LEVEL
(L X E X C)
(L X E X C)
ACTIVITY
ROUTINE
L=Low)
L=Low)
LEVEL
S.No
ADDITIONAL
(C)
(C)
CONTROLS
Only 500ml bottle of Acetone-cleaning agent

shall be kept to reduce quantity exposure.
Personal exposure to Housekeeping, Trained & Qualified Level I / II
Vapor of cleaning agents Chemical vapor & Fire Skin Operators. Adequate Ventilation & Illumination 3 2 3 18 L
Irritation & Breathing Problem Adherence to Manufacturer’s Safety
36 Magnetic Particle Test ROUTINE recommendations Ensure sufficient fire fighting
facilities. PPE - Hand gloves & mask
Exposure to bare All electrical cables must be sufficiently

Electrical Shock 3 1 3 9 L
conductors insulated.
Handling of Electromagnetic
Physical injury Trained operator 1 10 3 30 L
Yoke
1) HSE Procedure for Radiography Testing

(MFFK-HSE-PRO-5204)
2) PTW for Radiography Testing (MFFK-HSE-
Vomiting situation (Acute FRM-5204-A) 3) Cordon off ropes with warning
radiation syndrome), skin symbol, warning sign with blinking red lamp,
The Atomic
erythema, cataract in the eyes, Radiation survey meters, Radiation dosimeter,
Ionizing radiation 3 3 7 63 L Energy Rules
cancer(chronic), genetic TLD badges, Visual display, Radiation shield if
2004
37 Radiography test ROUTINE effects after prolonged required, Ensure zero occupancy levels within
exposure cordon-off area before starting exposure.
Emergency preparedness, Storage of isotopes
in Pit room when not in use, BARC Qualified &
Trained Radiographers
Exposure to developing Use of PPE's like Hand gloves, nose mask,

Ill health / Skin irritation 3 3 7 63 L
chemicals goggles
Cordon off ropes with warning symbol
Trained Operators
Tool Box talks

Preheating & Post Heating Exposure to Hot metal
38 ROUTINE Burn injury, Fire 3 2 3 18 L
of Weld Joints surface Ensure sufficient fire fighting facilities.
Ensure ventilation, House keeping

Use of PPE's like goggles,Hand gloves & mask
Exposure to sharp metal Use of PPE like Cut resistant Hand gloves
Hand injury 1 1 3 3 L
surface Trained & Qualified Level I / II Operators
Standard ladder & scaffolding,

39 Ultrasonic Test ROUTINE
Checklist for ladder & scaffolding Green -"SAFE
Fall from height, Fall of
Unprotected high elevation FOR USE" & Red-"DO NOT USE" tags , Full 1 3 15 45 L
equipment
body harness & other fall arresting devices,
Securing the equipment safely
Ref - HSE Procedure for Abrasive Blasting and

Painting (MFFK-HSE-PRO-5209).
Keep distance from other working area.
Covering of the job.. Periodic Inspection / The noise
Threshold of shift and noise
Noise Maintanence of Air compressor Periodic 3 6 3 54 L pollution rules
induced hearing loss (NIHL).
Medical Check up of Blasters. Exposure control 2000
by job rotation, Training, Daily Tool box Talk,
Rest break etc. . Use of PPE's like Ear Plug, Ear
Muff, etc
Prepared By
Approved By
Name :
Name:
Sign:
RISK ASSESSMENT
RISK ASSESSMENT
Legal Requirement
CONSEQUENCES
CONSEQUENCES
LIKELIHOOD (L)
LIKELIHOOD (L)
RESIDUAL RISK
ROUTINE / NON
EXPOSURE (E)
EXPOSURE (E)
PROBABILITY/
PROBABILITY/
(S=Significant
(S=Significant
RISK LEVEL
(L X E X C)
(L X E X C)
ACTIVITY
ROUTINE
L=Low)
L=Low)
LEVEL
S.No
ADDITIONAL
(C)
(C)
CONTROLS
Ref - MFK-HSE-PRO-5209
Abrasive Blasting of job ROUTINE Keep distance from other working area.
Covering of the job. Permit to Work System
MFF-PTW-HSE-008. Periodic Inspection /
Maintanence of Air compressor( Form 11),
Exposure to Particulate Permit to Work System. Training, Daily Tool box
Irritation to nose & throat 1 3 3 9 L
matter / Respirable dust Talk, Rest break etc. Periodic Medical Check up
of Blasters. Use of PPE's like Ear Plug, Ear
Muff, Coverall, Safety Goggles, Safety Helmet,
Safety Shoes, Safety hand Gloves, Blasting
40 Hood (Air Line Respirator with Filter assembly)
etc.
Ref - MFFK-HSE-PRO-5209
Keep distance from other working
area.Covering of the job. Permit to Work
System. Use of standard and rated hose pipe,
Use of Remote Control System (Dead Man
Handle), Use of whip check / Quick Coupling on
Presuurised air and abrasive
hose connections,Area cordoning, Periodic
ROUTINE Pressurized air, Pressurised materials may enter in the TN Factories
Abrasive Blasting of job Inspection / Maintanence of Air compressor, All 3 6 3 54 L
(Contd...) abrasive human body in case of any cut Rules 1950
air hose couplings & connections must be
injury.
checked prior to work.Exposure control by job
rotation, Training, Daily Tool box Talk, Rest
break etc, Use of PPE's like Ear Plug, Ear Muff,
Coverall, Safety Goggles, Safety Helmet, Safety
Shoes, Safety hand Gloves, Blasting Hood (Air
Line Respirator with Filter assembly) etc.
1) HSE Procedure for Blasting and Painting.

Designated painting shop -far away from hot
work & other ignition sources. Storage area -far
Paint Vapors, Fire & away from hot work or other ignition sources,
Irritation to eyes & throat,
explosion if comes in well ventilated & facilitated with sufficient fire TN Factories
Respiratory Irritation,Fire burns, 1 3 3 9 L
contact with sparks & hot fighting facilities.Availability of Material Safety Rules 1950
Property damage.
ignition sources data Sheet, Caution sign & barrication, Use of
PPE's like Air line Respirator / Nose mask,
Safety goggles , Coverall,Hand Gloves, Safety
Shoes etc.
Rated compressed air hose pipe. All air hose
couplings & connections must be checked prior
Bursting & Wiping of Hose Physical Injury to work. Whip check . PPE’s Safety goggles , 3 6 3 54 L
Coverall,Hand Gloves, Safety Shoes etc.
Cordoning of area..
1) HSE procedure for Abrasive blasting and
41 Painting of steel of job ROUTINE painting (MFFK-HSE-PRO-5209)
2) Storage area -far away from hot work or

other ignition sources,
3) Well ventilated & facilitated with sufficient fire
fighting facilities.
Slippery surface due to 4) Availability of Material Safety data Sheet,

Fire, Injury to person Good housekeeping. 1 3 7 21 L
Spillage of Paints
5) Local Exhaust Ventilation system to be
maintained.
Prepared By
Approved By
Name :
Name:
Sign:
RISK ASSESSMENT
RISK ASSESSMENT
Legal Requirement
CONSEQUENCES
CONSEQUENCES
LIKELIHOOD (L)
LIKELIHOOD (L)
RESIDUAL RISK
ROUTINE / NON
EXPOSURE (E)
EXPOSURE (E)
PROBABILITY/
PROBABILITY/
(S=Significant
(S=Significant
RISK LEVEL
(L X E X C)
(L X E X C)
ACTIVITY
ROUTINE
L=Low)
L=Low)
LEVEL
S.No
ADDITIONAL
(C)
(C)
CONTROLS
6) Caution sign & barrication.
7) Use of PPE's like Air line Respirator / Nose

mask, Safety goggles , Coverall,Hand Gloves,
Safety Shoes etc.
Storage area -far away from hot work or other

ignition sources, well ventilated & facilitated with The
sufficient fire fighting facilities.Availability of Manufacture,
Material Safety data Sheet, Caution sign & Storage and
Toxic Vapors of paints & Fire & explosion, Effects to
barrication, Eye Wash Shower, Fume 1 3 15 45 L Import of
solvents respiratory system
Storage & handling of Extraction System installed inside Blast & Paint Hazardous
42 ROUTINE
paints and solvents shop. Use of PPEs like Coverall, Safety Chemical
Goggles, Safety Shoes, Hand Gloves, Rules 1989
Respiratory Protection / Nose masks.
Workers may fall due to The

Spillage of Paints slippery surface, Fire, Land Good house keeping, Spill containment Trays 1 3 3 9 L Environment
contamination Act 1986
Sharp edges of metal scrap Use of Cut resistant gloves 3 2 3 18 L
during handling operation
Nose mask, Safety goggles and other
House keeping (Yard, Irritation to respiratory system,
43 ROUTINE Exposure to chemicals appropriate PPE's like shield for face protection, 3 2 3 18 L
Shops etc.,) Eye irritation
Air line respirator and chemical resistant gloves
Pneumoconiosis, Irritation to
Respirable / flying dust Water sprinkling, Nose mask, Safety goggle 1 6 3 18 L
nose, eye & throat
Start maintenance after switch off power supply

Exposure to live electrical Serious / Very Serious electric
completely with " DO NOT SWITCH ON " sign 1 2 15 30 L
connection shock.
board. Insulated gloves & instruments & tools.

Use heat resisting devices & materials.
NON Ensure that no body parts get exposed or get in
44 Thermal spray aluminium Property damage, Heat stress,
ROUTINE Fire, Heat contact with heated job . Use thick leather 1 2 3 6 L
burns
gloves .
Keep away all combustible materials away form
heat source.
General dilution & natural ventilation

Fumes & Gases Respiratory protection, Air supplied painting 1 2 3 6 L
eyes & throat
hood as per MSDS.
Following the Sequence of crane Assembly/

dismantling &Modification, PTW (Ref. MFFK-
Fall of person from boom
Personal injury HSE-PRO-5207), Trained and Competent 3 2 7 42 L
insert
persons invoved, Tool box talks, Cordoning the
area.
Major crane maintenance /
45 ROUTINE
Crane boom modification Inserting pin, sling reeving Being carried out under supervision of L&T
Nips & Finger crushing 1 2 3 6 L
and use of hammer supervisor
1) Experienced and trained personnel only

Very serious injury / Property
Fall of boom insert involved. 2) Work only be performed in the 1 2 15 30 L
damage
presence of a Rigger foreman.
1) Use adequate number of supports
Prepared By
Approved By
Name :
Name:
Sign:
RISK ASSESSMENT
RISK ASSESSMENT
Legal Requirement
CONSEQUENCES
CONSEQUENCES
LIKELIHOOD (L)
LIKELIHOOD (L)
RESIDUAL RISK
ROUTINE / NON
EXPOSURE (E)
EXPOSURE (E)
PROBABILITY/
PROBABILITY/
(S=Significant
(S=Significant
RISK LEVEL
(L X E X C)
(L X E X C)
ACTIVITY
ROUTINE
L=Low)
L=Low)
LEVEL
S.No
ADDITIONAL
(C)
(C)
CONTROLS
2) PTW for Crane Boom Modification. (MFFK-

HSE-FRM-5207-A)
Entrapment of person
Very Serious injury 3) Experienced and trained personnel only 1 2 15 30 L
between insert
Major crane maintenance / involved
ROUTINE(C
Crane boom length
ontd...) 4) Work only be performed in the presence of a
alteration (Contd...)
Rigger foreman.
Personal injury due to fall of
Swinging of boom insert Proper securing of boom 3 6 3 54 L
person
Sling entangling while Personal injury due fall of
Periodic Inspection of slings 3 2 3 18 L
pulling person
Greasy hands Slip injury due to fall of person Ensure grease is whipped off while working 1 2 3 6 L
Outsourced to certified/qualified agencies with
Over turning of trailer Property Damage, Major Injury 3 3 3 27 L
certified equipments.
Security informed and area cordoned off. The Motor

Road accident with other Trained signal man. Axles remote control in Vehicle act
vehicle. Workmen hit by Property Damage, Major good condition. Ensure no personnel on job, 2016 and The
3 3 7 63 L
axles, moving the axles with personal injury Unnecessary personnel to be kept away from Central Motor
person on load workplace. Adequate illumination in case of Vehicle Rules
poor visibility. 1989
Route survey before movement, Escorts

Inland transportation of Collision with adjacent jobs Property Damage provided, Slow movement so that any collision 1 3 3 9 L
46 finished job up to gate/jetty ROUTINE can be restricted
by hydraulic axles / trailers
Failure of hydraulic system
Property Damage certified equipments. Equipments have in built 3 3 3 27 L
(Break/steering/Bed level)
redundancy
Tyre puncture Time loss and property damage Magnetic sweeping 6 3 3 54 L
Local soil failure Time loss and property damage Movement avoided during rains and wet soil 3 1 3 9 L
Approved drawings , Use of certified slings, Use

Failure of lashing (fastening) Time loss of certified welders for and inspection before 3 3 3 27 L
movement
Permit (MFFK-HSE-
Failure of hydraulic system Outsourced to certified/qualified agencies with FRM-5205B) for
Property Damage 3 2 3 18 L
(Break/steering/Bed level) certified equipments. loadout of Modules or
Strutures has been
Tyre puncture Time loss and property damage Magnetic sweeping 6 2 3 36 L
Approved drawings, Use of certified slings, Use

Property Damage, Capsizing, of certified welders for and inspection before
Failure of lashing (fastening) 3 2 3 18 L
Personal injury movement. Trained axles movement operator.
Avoid jerks.

certified equipments. Equipments have buffer
Failure of ballasting pumps Property Damage 3 2 3 18 L
capacity as per warranty surveyor's
recommendations. Spare Pumps
Ramp plate made based on design and as per

Failure of ramp plate Property Damage 1 1 40 40 L
job procedure, Inspection before use.
certified equipments. Equipments have buffer
Stronger tide than estimate Property Damage 3 2 3 18 L
capacity as per warranty surveyor's
NON-
47 Load out by axle recommendations.
ROUTINE
Prepared By
Approved By
Name :
Name:
Sign:
RISK ASSESSMENT
RISK ASSESSMENT
Legal Requirement
CONSEQUENCES
CONSEQUENCES
LIKELIHOOD (L)
LIKELIHOOD (L)
RESIDUAL RISK
ROUTINE / NON
EXPOSURE (E)
EXPOSURE (E)
PROBABILITY/
PROBABILITY/
(S=Significant
(S=Significant
RISK LEVEL
(L X E X C)
(L X E X C)
ACTIVITY
ROUTINE
L=Low)
L=Low)
LEVEL
S.No
ADDITIONAL
(C)
(C)
CONTROLS
47 Load out by axle

ROUTINE
Approved mooring drawings with bollard pull
Property Damage,Serious
Failure of mooring due to used. Certified and tested mooring ropes used,
injury, Damage to third party 1 1 40 40 L
heavy current Third parties and port authorities informed about
property
the load out.
Over turning of job due to certified equipments. Equipments have buffer
Tilting/capsizing of barge and
miscalculation of ballasting capacity as per warranty surveyor's 1 1 40 40 L
job
calculation recommendations. Scheme approved by
competent warranty agency
Interference of
trailer/Job/leg pot with Property damage Route marking, Survey before movement. 3 1 3 9 L
bollard/slings/ramp plates
House keeping, Sufficient fire extinguishers in
Personal injury, Burn due to place, Restricted entry, Sufficient lifebuoys
Oil spillage on barge 3 2 3 18 L
fire. available, Permanent lookout. Mock drill carried
out for man overboard.
Usage of walkie talkies,Issue of Loadout entry

Personal Injury, Property permit badge, Separate workpermit for Loadout
Failure in communication 3 2 3 18 L
Damage activity, Job Safety Analysis for Load out activity
and Pre loadout inspection checklist
Failure of mooring due to Property damage, Serious Approved mooring drawings with bollard pull
3 1 15 45 L
heavy current injury used.Certified and tested mooring ropes used.
Inspection & testing of lifting tools ,tackles and

NON- Sling failure Property damage 3 2 3 18 L
48 Load out by crane lifting appliances by competent person.
ROUTINE
Crane overturning due to Very serious injury, Property
Lifting schemes & Plan 0.5 1 15 7.5 L
wrong radius estimate damage
Collision of job with existing
Property damage Route marking, Survey before movement. 3 2 3 18 L
job on jetty/barge
Failure of Property damage, Serious Inspection & testing of lifting tools ,tackles and TN Factories
3 1 15 45 L
slings/belt/shackles injury lifting appliances by competent person. Rules 1950
Trained & competent crane operators & rigging

Overloading due to load Property damage, Serious
foreman are deployed for the operation. 3 3 3 27 L
oscillation injury
Provision of Tag lines.
Equipment (Like
Toppling of Material
compressor, Turbines, Property damage, Serious Trained & competent crane operators & rigging
Handling Equipments 1 0.5 40 20 L
49 Seperators skids etc..) ROUTINE injury foreman are deployed for the operation.
(MHE)
handling by material
handling equipments
Property damage, Serious Restricted Entry, PTW, Lifting scheme, Job
Falling of Load from height 3 1 15 45 L
injury Inspected before Lifting

Property damage, Serious
Collision with structure foreman are deployed for the operation. Pre 3 2 3 18 L
injury
survey before installation.
Collision with person Serious injury Cordon off the work area. 1 3 7 21 L
The Coastal
Collision with existing Regulation
Property damage Port authority informed & clearance obtained 1 2 3 6 L
channel traffic Zone
Notification
Prepared By
Approved By
Name :
Name:
Sign:
RISK ASSESSMENT
RISK ASSESSMENT
Legal Requirement
CONSEQUENCES
CONSEQUENCES
LIKELIHOOD (L)
LIKELIHOOD (L)
RESIDUAL RISK
ROUTINE / NON
EXPOSURE (E)
EXPOSURE (E)
PROBABILITY/
PROBABILITY/
(S=Significant
(S=Significant
RISK LEVEL
(L X E X C)
(L X E X C)
ACTIVITY
ROUTINE
L=Low)
L=Low)
LEVEL
S.No
ADDITIONAL
(C)
(C)
CONTROLS

Ditching of barge due to low
Property damage, time loss certified equipments. Continuous monitoring of 6 2 3 36 L
draft/tide
draft level.
50 Sail out ROUTINE Outsourced to certified/qualified agencies with

Breakage of tow wire Personal injury certified equipments, Standby tow wire 3 2 3 18 L
available.

Drifting of barge due to high Damage to third party property
certified equipments 1 2 40 80 L
current Property damage
Standby tugs available
Approved drawings
Failure of sea fastening Property damage Use of Qualified welders and NDT / Inspection 1 2 40 80 L
before movement.
Sufficient lifebuoys available

Man overboard Fall and drowning of personnel 1 3 15 45 L
Permanent lookout.
Barge movement during
man movement over Personal injury Restricted Entry. Caution Sign Board. 3 2 3 18 L
NON- gangway
51 Working on jetty and barge
ROUTINE Stampede during
Injury Restricted Entry. Mock Drill. 1 2 3 6 L
emergency
Working on barge and jetty
Fall and drowning Wearing of Life Jacket and Use of Life buoy's 1 2 15 30 L
edges
Jetty edge covered with crash barriers.
NON-
52 Unauthorized entry in jetty Fall into the water Drowning Security Posted especially for Jetty 3 1 15 45 L
ROUTINE
Painted Yellow Line in Jetty
1. Procedure for maintaining and safe use of

Failure of lifting tools & Property damage lifting tools & tackles TN Factories
2 7 3 42 L
tackles Severe Injury 2. Inspection of lifting tools & tackles by Rules 1950
competent person.
1. Overloading due to load

1.Trained & competent crane operators &
oscillation Property damage
rigging foreman are deployed for the operation. 2 7 3 42 L
2. Collision with structure Serious injury
2.Provision of Tag lines.
3. Improper Rigging
Property damage 1. Preventive maintenance and regular load test TN Factories

Toppling of MHE 2 7 2 28 L
Very Serious injury as per factories act Rules 1950
1.Preventive maintenance and regular load

Property damage TN Factories
Falling of load from height test 2 7 2 28 L
Very Serious injury Rules 1950
2.Use of certified tools and tackles.
Property damage, Trained & competent crane operators & rigging

Incorrect crane positioning 1 7 2 14 L
Very Serious injury foreman are deployed for the operation.
1.Identified rigger shall provide signal during

Miscommunication / multiple Property damage lifting.
2 3 2 12 L
signals Injury 2.฀Use of communication equipment’s.
3.Tool box talk before start of operation
Prepared By
Approved By
Name :
Name:
Sign:
RISK ASSESSMENT
RISK ASSESSMENT
Legal Requirement
CONSEQUENCES
CONSEQUENCES
LIKELIHOOD (L)
LIKELIHOOD (L)
RESIDUAL RISK
ROUTINE / NON
EXPOSURE (E)
EXPOSURE (E)
PROBABILITY/
PROBABILITY/
(S=Significant
(S=Significant
RISK LEVEL
(L X E X C)
(L X E X C)
ACTIVITY
ROUTINE
L=Low)
L=Low)
LEVEL
S.No
ADDITIONAL
(C)
(C)
CONTROLS
Incorrect weight estimate & 1.Calculated weight estimate and COG

53 Lifting ROUTINE Property damage 1 3 2 6 L
COG 2.Calibrated load cell available in cranes
1.Preventive maintenance as per OEM

guidelines
Property damage, 2.Load test as per Factory act TN Factories
Failure of Crane 2 7 2 28 L
Very serious injury 3.Use of competent personnel certified cranes Rules 1950
(3rd party)
4.Ensure the wind speed & weather forecast
Malfunction of safety Property damage 1.Preventive maintenance.

1 3 2 6 L
devices Injury 2.Daily inspection by operator
Property damage
Poor visibility. Periodic internal Illumination survey 1 3 2 6 L
Injury to person
Failure of Lifting lugs / Property damage

Inspection and NDT / MPT of lifting lugs. 2 3 2 12 L
Trunnion , Personal injury
Placement of approprite number of wedges

Roll over of round structures
Personal Injury while loading / unloading on the ground / shop 2 3 3 18 L
such as pipes
floor / trailer bed or any other flat surface.
1.Training on "Safe material handling" to all

Trapping of person in riggers & crane operators.
between load / MHE and Personal injury 2.Work shall not be carried out in crane 1 3 3 9 L
rigid structure swinging area
3.Swing alarm shall be available
1)
PTW for heavy erection (MFFK-HSE-FRM-5105-
A)
Failure of lifting tools & Property damage 2) Procedure for maintaining and safe use of TN Factories
3 3 7 63 L
tackles Severe Injury lifting tools & tackles Rules 1950
3) Lifting plan/scheme
4) Inspection of lifting tools & tackles by
competent person.

foreman are deployed for the operation.
Overloading due to load Property damage,
Crane loading beyond 85% of rated capacity is 3 3 7 63 L
oscillation Serious injury
only with specific permissions and precautions.
Heavy lift (>50 MT) & / or Provision of Tag lines.
54 Tandem lift (Structural ROUTINE
Frames) Property damage, Very Serious
injury Lifting schemes & PTW in place
Toppling of MHE 3 1 15 45 L
Preventive maintenance and regular load test
Property damage, Very Serious Area cordoning and restricted entry

Falling of load from height injury Preventive maintenance and regular load test 1 2 15 30 L
Use of certified tools and tackles.
Lifting schemes with marching path marking.
Collision with structure Property damage 3 3 3 27 L
Survey of crane marching path.

Improper Rigging Property damage foreman are deployed for the operation. 3 3 3 27 L
Lifting schemes & PTW in place
Prepared By
Approved By
Name :
Name:
Sign:
RISK ASSESSMENT
RISK ASSESSMENT
Legal Requirement
CONSEQUENCES
CONSEQUENCES
LIKELIHOOD (L)
LIKELIHOOD (L)
RESIDUAL RISK
ROUTINE / NON
EXPOSURE (E)
EXPOSURE (E)
PROBABILITY/
PROBABILITY/
(S=Significant
(S=Significant
RISK LEVEL
(L X E X C)
(L X E X C)
ACTIVITY
ROUTINE
L=Low)
L=Low)
LEVEL
S.No
ADDITIONAL
(C)
(C)
CONTROLS
Property damage, Very Serious

injury Trained & competent crane operators & rigging
Incorrect crane positioning foreman are deployed for the operation. Crane 1 3 15 45 L
positioning as per lifting plan.
Miscommunication / multiple Property damage Single person identified for a specific heavy lift.
3 3 3 27 L
signals Injury Use of communication equipments.
Tool box talk before start of operation
"Lifting schemes with calculated weight estimate

Incorrect weight estimate & and COG
Property damage 3 3 3 27 L
COG & PTW in place.
Calibrated load cell available in cranes
1.Deck supports are removed, once deck

1. Keeping the lifting
comes above the supports.
equipments, tools and
Removal of supports under 2. Safe removal of deck support (Fork lift,
tackles in good
the load / Crane) 3. Placing of deck supports away from
Very serious injury 3 2 15 90 S condition. 2. 3 1 15 45 L
(working under suspended crane marching area.
Continuous monitoring
load) 4. PTW System.
and supervision
5. Trained and competent riggers involved in
during removal.
heavy lifting operation.
Number of personnel entry restricted , however

Guiding while stabbing deck Very serious injury persons are sent below the load to remove 1 2 40 80 L
supports & guide the load while stabbing.
Heavy lift (>50 MT) & / or

ROUTINE Preventive maintenance and regular load test
Tandem lift (Structural
(Contd...) Property damage, Use of certified cranes
Frames) (Contd...) Failure of Crane 3 1 15 45 L
Very serious injury Crane loading beyond 85% of rated capacity is
only with specific permissions and precautions.
Preventive maintenance.
Malfunction of safety Property damage
Check list along with PTW before every heavy 3 3 3 27 L
devices Injury
lift.
PTW in place which restrict the erection under

Poor visibility. Property damage 3 2 3 18 L
poor lights.
Area cordoning and restricted entry

Falling of loose material Property damage House keeping before lifting.
3 3 7 63 L
from height Major Injury Use of mandatory PPE like safety
helmet,goggles and steel toe shoes
Obstructions to load (Space

Personal injury Lifting schemes & PTW in place, 1 2 3 6 L
constraint)
Failure of Lifting lugs / Property damage

Inspection and NDT of lifting lugs. 1 3 15 45 L
Trunion , Personal injury
Trapping of body parts in
Training on "Safe material handling" to all
between load / MHE and Personal injury 3 3 3 27 L
riggers & crane operators.
rigid structure
Poor weather conditions Property damage PTW in place. 3 2 3 18 L
Prepared By
Approved By
Name :
Name:
Sign:
RISK ASSESSMENT
RISK ASSESSMENT
Legal Requirement
CONSEQUENCES
CONSEQUENCES
LIKELIHOOD (L)
LIKELIHOOD (L)
RESIDUAL RISK
ROUTINE / NON
EXPOSURE (E)
EXPOSURE (E)
PROBABILITY/
PROBABILITY/
(S=Significant
(S=Significant
RISK LEVEL
(L X E X C)
(L X E X C)
ACTIVITY
ROUTINE
L=Low)
L=Low)
LEVEL
S.No
ADDITIONAL
(C)
(C)
CONTROLS

Dehydration & Heat Stress Heat Exhaustion, hydrated by drinking water and Calcium 2 5 3 30 L
Gluconite Gel
Use of PPE's like Ear plug & Ear Muff.

Noise Noise induced hearing loss 1 2 7 14 L
Unauthorised people entry restricted.

Fumes & Gases 1. Proper ventilation 2. Use of PPEs like air line 3 3 3 27 L
eyes & throat
respiratory mask
Profile Cutting / Plasma
55 ROUTINE
Cutting UV radiation Arc eye, Cataract , photophobia UV filter glasses for operators. 3 2 3 18 L
Hot spatter Burn injury Keep away from spatter zone. Use of Shield. 3 3 7 63 L
The Electricity
Use of ELCB
Electrical leakage Electrical shock 3 2 7 42 L Act 2003,
Proper body earthing
Rules2005
Fumes & Gases General dilution & natural ventilation 3 3 3 27 L
eyes & throat
UV radiation Arc eye, Cataract , UV filter glasses for operators 3 3 3 27 L
1) Use of fire blanket

2) Use of PPE's like faceshield, Hard hat,safety
googles and Steel toe shoes
Sparks, spatters, hot slag Eye injury, Fire 1 6 7 42 L
3) Keep away flammable materials from Gas
cutting activity
4) House keeping
1) Cutting gas cylinder ,gas hoses & torch

leakage test before starting work
The
2) Ensure no ignition sources near cutting gas
Manufacture,
set.
56 Gas Cutting ROUTINE Storage and
Fire 3) Cylinder must be in upright position & tied
Leakage of Flammable gas 3 3 7 63 L Import of
with chains
Hazardous
4) Maintaining the mechanical integrity of
Chemical
equipments like torches, valve fittings, hoses
Rules 1989
etc.
5) Use of fire blanket to cover the cylinder
1) Cylinder must be stored in trolley in upright

Injury to person, damage to position & secured with chains
Fall of cylinders 3 3 3 27 L
valve & hose 2) Head cap for cylinders
3) Workers are trained on handling of cylinders
1) Use of standard regulator & hoses

TN Factories
Bursting of hose Fire, Material Damage 2) Regular inspection of hoses 3 6 3 54 L
Rules 1950
3) Avoid joints in hoses
1) Use of Flash Back Arrester

Clogging of gas cutting
Back fire 2) Trained gas cutter and pre -check & 3 3 3 27 L
nozzles by metal slag
periodic-checks of gas cutting nozzles.
1) Use of Cut resistant gloves

Cut, abrasion, contusion injury 2) Use of Mandatory PPE's like Cut resistant
Sharp edges of steel plates 3 6 3 54 L
during handling operation gloves, Hard hat, Safety goggles, steel toe
ROUTINE
Gas Cutting (Contd...) shoes.
(Contd...)
Prepared By
Approved By
Name :
Name:
Sign:
RISK ASSESSMENT
RISK ASSESSMENT
Legal Requirement
CONSEQUENCES
CONSEQUENCES
LIKELIHOOD (L)
LIKELIHOOD (L)
RESIDUAL RISK
ROUTINE / NON
EXPOSURE (E)
EXPOSURE (E)
PROBABILITY/
PROBABILITY/
(S=Significant
(S=Significant
RISK LEVEL
(L X E X C)
(L X E X C)
ACTIVITY
ROUTINE
L=Low)
L=Low)
LEVEL
S.No
ADDITIONAL
(C)
(C)
CONTROLS
1) Protective earthing,
2) ELCB,
Bare conductor of power Electrical shock, burns, Cardio 3) Regular inspection
3 3 7 63 L
cable (For pug gas cutting) Pulmonary arrest 4) Use of Mandatory PPE's like HT/LT rubber
Gloves Hard hat, Safety goggles, steel toe
shoes.
Contaminated containers,
Handling of hazardous Fire, Explosion, As per Waste Management Procedure Number
57 ROUTINE sharp edges, solvents 3 3 3 27 L
waste Toxicity,Dermatitis MFFK-HSE-PRO-5208
/chemicals
1) Availability of sufficient "L" clits to secure

vertical plate.
Fall of vertical plate due to Hit / Crush injury, blunt injury or 2) Ensure Tack welding to vertical plate before
6 3 3 54 L
failure to secure bone fracture removing the "L" clits.
3) Continous supervision.
4) Experienced manpower (ie. Fitter & Rigger) .
Fitting and alligning of 1) Work area, access free from obstructions.

Work area congestion,
58 vertical plate to the load out ROUTINE Personal injury. 2) Availability of sufficient working place. 3 3 3 27 L
restricted access
beam / Leg pot 3) Daily housekeeping.
1) Unauthorised people not to be allowed to
stand under the suspended material.
Cut injury , Personal injury due 2) Cordoning of work area.
Falling loose material /
to fall of material. Material 3) Daily housekeeping. 1 3 3 9 L
protruding material
Damage due to fall of material 4) Adequate use of work related PPEs like Cut
resistant gloves, Hard hat and safety goggles,
steel toe shoes.
Metal fume fever, Irritation to General dilution & natural ventilation

Fumes & Gases / Ozone 6 2 3 36 L
eyes & throat Provide forced ventilation for confined space
UV radiation Arc eye, Cataract , photophobia Welding Face shield & Welding glasses. 6 2 3 36 L
Cut,abrasion,contusion injury
Sharp edges resulting from handling Use of PPE like Cut resistant Hand gloves. 3 3 3 27 L
operation
59 Aluminium Welding Non Routine Protective earthing,ELCB,Regular inspection &
Electrical shock , burns , Cardio PPE. Insulation checking & testing
Pulmonary arrest Reduce number of joints as less as possible
insulation damage
Training on "Electrical Safety"
Welding face shield, leather hand gloves,leg
Sparks & High Heat Eye injury, Skin burn 3 2 7 42 L
guard,apron
Scattered electode stubs on Use stub bins

Injury to person due to skidding 6 3 3 54 L
floor Returing stubs to consumable stores
Exposure to Acid Vapors Irritation to respiratory system, 1) Respiratory masks for particular chemicals.
3 6 3 54 L
(acetone used for cleaning) Eye irritation 2) MSDS display at workplace
1) Keeping acid away from working zone

Eye & Skin contact with 2) Safety shower & eye wash
Acid ,eye burns 3 3 7 63 L
Acetone 3) MSDS display at workplace
4) Use of PPE's like leather gloves,
Prepared By
Approved By
Name :
Name:
Sign:
RISK ASSESSMENT
RISK ASSESSMENT
Legal Requirement
CONSEQUENCES
CONSEQUENCES
LIKELIHOOD (L)
LIKELIHOOD (L)
RESIDUAL RISK
ROUTINE / NON
EXPOSURE (E)
EXPOSURE (E)
PROBABILITY/
PROBABILITY/
(S=Significant
(S=Significant
RISK LEVEL
(L X E X C)
(L X E X C)
ACTIVITY
ROUTINE
L=Low)
L=Low)
LEVEL
S.No
ADDITIONAL
(C)
(C)
CONTROLS
Aluminium Welding Non Routine 1) Neutralising of acids (Confirming with ph

(Contd...) (Contd...) Property damage / paper test
Spillage of acetone 3 3 3 27 L
environmental damage 2) Storing in separate identified area.
3) MSDS display at workplace
Noise induced hearing loss, 1) Booth provided, Rest breaks

Noise 1 3 3 9 L
Threshod shift 2) Use of PPE's like Ear plug / Ear Muff
Suffocation,nausea,vomiting,
Leackge Test of argon gas before use , Proper
Use of Argon gas for and loss of consciousness,
ventilation , Use of PPE's like fac shiled and 3 1 15 45 L
sheilding headached due to high
appropriate mask
concerntation of argen gas
Noise Threshold shift, NIHL. Hearing protection (Ear plug), Job rotation. 3 3 3 27 L
Asphyxiation, Toxic fumes

Local exhaust ventilation system, respiratory
Generation of dust, fumes generated from coated metals
protective equipment system, MSDS of metals 3 3 3 27 L
& gases can damage respiratory system
to be cut, coatings etc.
and may be cancerous.
Hot metals & spark Burn injury, Eye damage, Fire & Guarding the point of operation, Adequate
3 3 3 27 L
generation. explosion. PPE’s including safety glasses, Aprons etc.
Proper equipment earthing, RCCB, LOTO,

Electrocution. Shock, fall, Severe burns. 1 3 15 45 L
Trained people opeating, periodic mainanance
Working with Plasma

60 Non Routine Cyllinders kept away from electrical
cutting machine.
Fire & explosion and Property circuits/cutting areas by proper chaining in
Pressure cylinder handling. 3 2 3 18 L
Damage upright position, Weekly Checklists based
inspection.
Use of protective clothing, protective

screens/barriers to protect others from flash,
UV, IR radiation Eye burns, Skin burns. 3 3 7 63 L
glare and sparks; warn others not to watch the
arc, safety glasses with proper shade number.
Protective clothing, protective barriers,

Thermal burns. Quickly cut
Plasma arc. Appropriate PPE’s like Thick leather apron and 3 2 3 18
through gloves and tissues.
gloves also mandatory PPE's.
1.Fullbody safety harness anchored.

Fall of person from height Personal injury due to fall 2. Providing life line wherever necessary. 3 1 3 9 L
3. Working on safe scaffold
1. Barricading the area where load is

suspended.
Injury to person/ property
Fall of material from hieght 2. Using inspected lifting tools & tackles. 3 2 3 18 L
damage
3. Qualified & tarined riggers for material
handling operations.
1. Adequate supports should be given to pre

Sudden stress release while 1. Structural members may hit
assembled structure while dismantling.
seperation of strcutural to persons working near by 3 1 3 9 L
Dismantling of structure / 2. Final cutting position should be kept away
61 Non Routine members resulting to injury
fabricated frames from the human body.
Prepared By
Approved By
Name :
Name:
Sign:
RISK ASSESSMENT
RISK ASSESSMENT
Legal Requirement
CONSEQUENCES
CONSEQUENCES
LIKELIHOOD (L)
LIKELIHOOD (L)
RESIDUAL RISK
ROUTINE / NON
EXPOSURE (E)
EXPOSURE (E)
PROBABILITY/
PROBABILITY/
(S=Significant
(S=Significant
RISK LEVEL
(L X E X C)
(L X E X C)
ACTIVITY
ROUTINE
L=Low)
L=Low)
LEVEL
S.No
ADDITIONAL
(C)
(C)
CONTROLS
During separation of pre

Crane should not be in loaded condition while
assembled structure by cutting,
Struck by held load cutting, it is to be used only for holding the job to 6 1 3 18 L
the load holded by crane may
prevent its fall
swing suddenly due to stress
Injury to person working inside Inspection of manlift thoroughly by competent

Failure of manlift 3 2 3 18 L
the basket person.
Trained signal man to be present for this

Trapping of body parts
operation. Good communication between
between Manlift and Personal injury 3 1 15 45 L
manlift operator and signal man shall be
Structure
maintained.
1) Check knurling portion before use of torque

wrench
a) Slippage of wrench Injury to the working person 2) Use of trained manpower 3 3 7 63 L
3) Use of rope for tying the wrench and
anchoring it.
NON
62 Bolt tightening and torquing
ROUTINE
b) Bursting hydraulic hose in 1) Cordoning of the working area
Injury to the working person 3 2 7 42 L
case of hydraulic torqing 2) Use of trained manpower
c) Oil spillage Injury due to slipping. 1) Cordoning of the working area 3 2 3 18 L
Proper access to approach the work place &

working platform
Area to be barricaded
Working at Height a) Fall of Person b) Fall of Fall protection arrangements if required

63 Routine Injury to Person 1 2 15 30 L
(Inspection) Material
Pep talk /Tool box talk before starting of job,
Provision & Use of PPEs (Safety harness, life

line & fall arresters)
Work Permit system

working platform
Area to be barricaded
Work at Height -(Stress a)Fall of Person b)Fall of
64 Routine Injury to Person Fall protection arrangements if required 1 2 15 30 L
Relieving) Material
Provision & use of PPEs (Safety harness, life

line & fall arresters)
Ensure adequate access
Use of Safety harness with shock absorber
Area cordoned if required
Removal of combustible material and no hot

work simultaneously.
Prepared By
Approved By
Name :
Name:
Sign:
RISK ASSESSMENT
RISK ASSESSMENT
Legal Requirement
CONSEQUENCES
CONSEQUENCES
LIKELIHOOD (L)
LIKELIHOOD (L)
RESIDUAL RISK
ROUTINE / NON
EXPOSURE (E)
EXPOSURE (E)
PROBABILITY/
PROBABILITY/
(S=Significant
(S=Significant
RISK LEVEL
(L X E X C)
(L X E X C)
ACTIVITY
ROUTINE
L=Low)
L=Low)
LEVEL
S.No
ADDITIONAL
(C)
(C)
CONTROLS
Ensure all electrical installations & machines TN Factories

Fall of material / person, Injury to person, Property
65 Painting work at height Routine are properly covered or protected Rules 1950
Fire, Health hazard damage, Ill health
Ensure painter is fit for height work
Ensure paint containers are kept securely at

elevation
Keep attendant stand by near air compressor if 1 2 15 30 L
spray gun is used
Fire extinguisher stand by and adequate

illumination .
Continuous watch on painter for anchoring of

harness
Disconnect all electrical equipment & isolate if

required
Painting work at height Routine TN Factories
(Contd...) (Contd...) Use of effective ventilation system
Rules 1950
Periodial Health check up
Use of PPEs like chemical resitant gloves &

apron also mandatory PPE's
Work permit for Radiography Testing
Ensure Adequate access
Training for work at height
Area is barricaded and securing of camera at TN Factories

66 Radiography work at height Routine Fall of person / Material Injury to person height 1 2 15 30 L Rules 1950
Use of remote for operating cameras
Anchoring of safety harness while moving on

narrow area like beam
Use of PPEs like Hard hat,safety goggles,steel

toe shoes & Fall arrester
Ensure grinding wheel is locked properly
Proper access & working platform with suitable

Braking of wheel, Fall of railing
67 Grinding work at Height Routine person / material, Injury to person, Burn TN Factories
Ensure job is properly locked.
Uncovered spatters Rules 1950
Use of Fire blanket
Removal of combustible material
Fire extinguisher kept stand by.
Periodic training. 1 2 15 30 L
Ensure grinder is wearing cotton cloth free from

oil grease or paint.
Prepared By
Approved By
Name :
Name:
Sign:
RISK ASSESSMENT
RISK ASSESSMENT
Legal Requirement
CONSEQUENCES
CONSEQUENCES
LIKELIHOOD (L)
LIKELIHOOD (L)
RESIDUAL RISK
ROUTINE / NON
EXPOSURE (E)
EXPOSURE (E)
PROBABILITY/
PROBABILITY/
(S=Significant
(S=Significant
RISK LEVEL
(L X E X C)
(L X E X C)
ACTIVITY
ROUTINE
L=Low)
L=Low)
LEVEL
S.No
ADDITIONAL
(C)
(C)
CONTROLS
Grinding work at Height Routine Area is barricaded

(Contd...) (Contd...)
Ensure safe distance is maintained between job TN Factories
& grinder Rules 1950
Ensure ON/OFF is provided with deadman

switch.
Use of PPEs & Fall protection Face Shield,

Safety harness, Safety nets

working platform
Area barricading
Fire blanket
Fire Extinguisher stand by close to job
Person Stand by near gas cylinder
Work area free from combustible material

Work at Height - Gas Fall of person & Fall of Injury to person, Property
68 Routine 1 2 15 30 L TN Factories
cutting material,fire spatters Damage, Fall of material Only striking lighter shall used to light the torch.
Rules 1950
Torch shall be checked for any kind of damage

prior to start of the job
Removal of grease, oil or paint from job before

cutting
Ensure Cutter has worn cotton cloth & free from
any grease, oil or paint.
Removal of cut pieces.
Ensure gas hoses are away from flame & hot

job. Provision of PPEs (Safety harness, life line
& fall arresters)
Prepared By
Approved By
Name :
Name:
Sign:
RISK ASSESSMENT
RISK ASSESSMENT
Legal Requirement
CONSEQUENCES
CONSEQUENCES
LIKELIHOOD (L)
LIKELIHOOD (L)
RESIDUAL RISK
ROUTINE / NON
EXPOSURE (E)
EXPOSURE (E)
PROBABILITY/
PROBABILITY/
(S=Significant
(S=Significant
RISK LEVEL
(L X E X C)
(L X E X C)
ACTIVITY
ROUTINE
L=Low)
L=Low)
LEVEL
S.No
ADDITIONAL
(C)
(C)
CONTROLS

working platform with proper guard rail
Fall protection arrangements if required
Provision of PPEs (Safety harness, life line fall

arresters)
Combustible materials are removed from the
area below welding activity
Injury to person, Property Spatters are arrested by providing fire blankets TN Factories
Fall of person & Fall of
69 Welding- Work at height Routine Damage dure to fire, Eye injury or the area below are barricaded 1 2 15 30 L Rules 1950
material,fire spatters
and elcetric shock
Fire extinguishers provided
Proper ventilation if required.

Daily inspection of fall protection arrangements
and PPEs
Helper will be present below the welding area
Welders are provided with container to collect

all the waste electrode bits
a) Fall of compressed gas
Crush Injury a) Keep Cylinders upright & properly secured 2 6 5 60 L
cylinder
b) Leakage of Gases Fire & Explosion b) Storage away from ignition source 2 2 7 28 L
c) Use of PPE's like Hard hat,safety goggles,

c) Disengagement of Hoses Property Damage 1 2 6 12 L
Steel toe shoes.
Transfer of Gases from The
70 Non Routine d) Use of standard hoses, fittings & calibrated Manufacture,
Cylnder
instruments Storage and
d) Bursting of the high Injury to the person working e) Trained Manpower Import of
2 4 4 32 L Hazardous
pressurized hose nearby f) Whip check to be used between both end s of
Chemical
a connection
Rules 1989
g) Cordoning of area
Prepared By
Approved By
Name :
Name:
Sign:

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Note : If the Risk Score is ≥ 90 then the Risk level is Significant (S)

1. Complete Checking of Jacking system prior

5. Cordoning of the Complete area

1. Complete Checking of Jacking system prior

1. Calibrated Pressure gauges & Load cells

2. Approved Weighing Procedure

3. Fire Extinguishers & Saw Dust

5.Cordoning of the Complete area

6. Co ordination by identified team members for

1. Pre Weighing survey to ensure no loose

2. Cordoning of the Complete area

3. Good House keeping

5. Ensure disconnection of power supply to

2. Cordoning of the Complete area

4. Ensure No Workmen on the Deck

1. Cordon off the Area

Personal Injury , Property 2. Ensure No Workmen on the Deck

1. Right use of tools with right procedure

2. Use of Proper Wedges & Proper Storage of

5. Use of Appropriate PPE like Hard hat,Safety

1. Checking of Hydraulic oil & compressed air

3. Use of tools which are in good condition

Guarding, Grinding wheel to be compatible with

Bare conductor of power

5. Training on "Electrical Safety"

PPE Non compliance non HSE Trainings, Mandatory PPE requirement

1. Proper guard on the grinding machines

3. Training & Toolbox talk

1) Qualified scaffolders & Scaffolding foreman

2) Training & competency checking

3) Scaffolding Inspection Check list Form No

7) Proper tying & handling of loose scaffolding

8) Use of Appropriate PPE like Hard hat,Safety

1) Qualified scaffolders & scaffolding foreman

2) Procedure for scaffold

3) Training & competency checking

6) Tool box talks

Scaffolding Erection & ROUTINE Trained / Qualified scaffolders & supervisors

Scaffolding Check list.

Avoiding Prolonged sun exposure & staying

Very Serious injury / Toppling of 1. Don't keep load above SWL.

Use of fall prevention & Protection such as

Working at Height (e.g. 1. Procedure for scaffold. Scaffolding inspection

PPE Non compliance non 1. HSE Trainings, Mandatory PPE requirement

1. Regular House keeping

1. Avoiding Prolonged sun exposure & staying

7. ERP Procedure No MFFK-HSE-PRO-5006

8.Mobile phones are not permitted during height

Avoiding Prolonged sun exposure & staying

1. Confined space entry permit. Ref -MFFK-

2.Forced, dilution & Local Exhaust ventilation

Asphyxiation , suffocation or 3.Calibrated oxygen meter TN Factories

5. Use of PPE's like Hard hat,Steel toe

1. Forced, dilution & Local Exhaust ventilation

2. Calibrated oxygen meter

1. Confined space entry permit. Ref -MFFK-

2. Forced dilution & Local Exhaust ventilation

4. Use of PPE's like Hard hat,Steel toe

1. Hot Work Permit, Fire Fighting Facilities

2. Fire blankets, fire proof tarpaulin

1. No leakage from Cylinders and Hoses

Working in confined ROUTINE 1. Ensure proper working entry