HAZARD IDENTIFICATION AND RISK ASSESSMENT

Department: CIVIL HIRA No. AAL/CIVIL/HIRA/1136 Date: 17.08.2022

Job Title: POT ROOM PUNCH POINT WELDING WORKS Section/ Location:
Date of Review at Job site: 08.02.2023 Reference OCP (SOP/SMP) No.
Area : POT ROOM Routine /NonRoutine NON-ROUTINE
Risk assessment team members Normal/Abnormal/Emergency NORMAL
SN Basic step of the Job Hazard(s) associated with the step Existing control measure to mitigate hazard Existing / Base Additional control measure Responsible Implementation Residual Risk
Impact Risk Official to Status
P S Risk implement P S Risk
LOADING,SHIFTING,UNLOADING,ERECTION,ALIGNMENT AND WELDING/BOLTING OF STRUCTURAL ITEM.
Implemented
Line of fire Seriuos injury to workmen 1-Maintain Distance from technological Vehicles. 1 4 4 PA 1 4 4

1-Water not allowed inside POTROOM. Implemented

Explosion Seriuos injury to workmen 1 4 4 PA 1 4 4
1 Area Identification 2-Ensure Door of Pot before start of Job.
Implemented
Slip & Trip Injury 1-Housekeeping to be done at the working area. 1 3 3 PA 1 3 3
Cut from sharp edges Injury to workmen Use good condition of hand gloves. 2 1 2 PA Implemented 2 1 2
Implemented
1-Designated route to be finalized and adhered to.
2- Only trained person engaged for shifting.
Hiting with other vehicle on road. Injury 1 4 4 PA 1 4 4
Shifting of Material 3- Before start the job trolley condition to be
2 from yard to working checked manually.
site by trolley
Implemented
1-Road Housekeeping to be done.
Slip & Trip Injury 2 3 6 PA 2 3 6
2-Always follow cable management procedure.

Implemented
1-Always follow cable management procedure.
2-Hosekeeping to be done
Slip of material while lifting injury to person 1 4 4 PA 1 4 4
3-Area to be barricaded.
4-Right tools to inspected and use.
Unloading material
Implemented
3 outside Potroom near 1-Barricading and supervision by WG/PA/AO
entry 2-Area cleaned of obstruction.
Hit By Technological Vehicle Seriuos injury to workmen 1 3 3 PA 1 3 3
3-Swing area cleared of unauthoriseed entries.
4-Demarcate and cordon off work area.

Implemented
Cut from sharp edges Injury to workmen 1-Proper PPE's to be use for handling of materials. 2 1 2 PA 2 1 2

1-Fall from height. Implemented

1-DSL isolation by Elect.
4 Pre Job Check 2- Slip & Trip Serious injury to Workmen 1 1 2 PA 1 1 2
2-Ensure door of POT before start of job.
3-Explosion near work area.
SN Basic step of the Job Hazard(s) associated with the step Existing control measure to mitigate hazard Existing / Base Additional control measure Responsible Implementation Residual Risk
Impact Risk Official to Status
P S Risk implement P S Risk
1-Unstable base Seriuos injury to workmen 1- Only insulated man lifter should be used In pot Implemented
2-Damage of Overhead lighting due to electric shock room.
cablesand DSL. Fatal Injury to workmen 2- Insulated base plate should be provided at the
3-Colision with pta and other due to collapse of manlift base of the outrigger of the man lifter.
vehicles running inside pot room 3- Man lifter should be placed on stable base only.
4.electrocution/shutcircuit due to 4- Outriggers should be fully extendible.
touch with power source. 5- During placement it be ensured that mercury
5-Hydraulic Failure label should be at centre for assuring the proper
6-Line of Fire label of men lifter.
7-Slip & Trip 6- Area should be barricaded horizontally as well
as longitudinally.
7-Incase of any problem in pot operation shift-
Placement of Man Incharge shall able to stop the job till pot
5 normalizes. 1 4 4 PA 1 4 4
lifters
8-Manlifter should be certified by competent
authority.
9-Only trained and authorized operator should
operate the manlifter.
10-Training should be provided for usages of man
lifter inside the potroom to the new operator.
11- Supervison by civil and WG supervisor shall be
ensured.

1- Barrication of the area. Implemented

Stuck while swing Physical Injury 2 3 6 PA 2 3 6
2-Work in progress board to be displayed.
Improper Condition Failure of Boom 1-Daily checklist ensured 2 3 6 PA Implemented 2 3 6
Implemented
1- Release of Swing lock of manlift bucket ensured
Fall of workmen from manlift during access and locking while working ensured.
Physical Injury 2 3 6 PA 2 3 6
bucket 2- Workmen trained on safe use of manlift.
Access to height 3- Height pass obtained for workers.
6
through manlift.
Implemented
1- No loose material kept at height.
2- Area barricaded.
3- Attendent made available during work.
Fall of material from height Serious injury to workmen 2 2 4 PA 2 2 4
4- Strict supervision ensured.
5-Tools are to be tied with tools string and tied to
the safety harness.

7 Welding of Structure Implemented

1- Welding face shield, leather gloves, apron, hand
sleeve, leg guard and safety shoe mandated.
2- Welding appron to be provided to the welder.
long term health hazard to
Emission of gases/fumes 3-Use respirator while cutting/welding activity 1 4 4 PA 1 4 4
workmen
ensured.
4-Breaks planned every hour to avoid prolonged
exposure.

1- Face shield ensured for helper & welding shield Implemented

long term health hazard to for welder.
Exposure to radiation and light 2 3 6 PA 2 3 6
workmen 2- Trained and certified welders only allowed to
work.
SN Basic step of the Job Hazard(s) associated with the step
Fall of person from height
Fall of materials from height
FIRE
Electrocution/ Short circuit
Existing control measure to mitigate hazard Existing / Base Additional control measure Responsible Implementation Residual Risk
Impact Risk Official to Status
P S Risk implement P S Risk
1- Hot work & Height work PTW should be taken. PA Implemented
2- checked & certified manlift bucket.
3- Height pass for all workmen working at height
Injury to workmen ensured.
4- workmans trained to connect his harness in
anchor point in bucket.
1- No loose material kept at height. PA Implemented
2-Tools are to be tied with tools string and tied to
the safety harness.
3-All tools must be kept in tool kit/bag.
4- No weld butt should be thrown to shop floor. All
Injury to workmen weld butt to be collected and reconciled during
work closure.
5-Ensure no any man or equipment stand under
the lifter's boom.
6-No person see up during during chipping of
material.
1- Covering of power cables and DSL in working PA Implemented
area by fire blanket.
2- Pot superstructure, where chances of fall of weld
spatters exists should be covered with aluminium
sheet along with fire blanket.
3-Fire extinguisher (DCP Type) should be available
at site.
Burn Injury 4- Fire department person shall be available at site
during the job.
5-Daily checksheet to be filled before use of
1 4 4 1 4 4
portable ladder.
6-Use 3 point contact to be maintained.
7-Ladder should be placed as per standard 1:4 of 75
angle to be maintained.
Seriuos injury to workmen 1- Welding connection should be given by AAP PA Implemented
due to electric shock E&I department inside potroom.
2- No body earthing & RCCB should be provided
for welding machine job should be done as per the
clearance given from operation side.
3- Daily checklist of welding machine should be
filled up before welding.
4-Adequate PPE's should be used by welder.
5- Only training and authorized person should be
engaged with the job.
6- Nonmagnetic safety shoes,Safety helmet,welding
apron with leg & elbow guard , face shield ,HF
cartridge type nose mask,leather handgloves for
welidng should be provided.
7-All activity should be carried out in presence of
proper supervision.
8-During up/down movement the bucket locking
valve should be closed after placement to prevent
fall hazard due the unstable movement of bucket.
Also proper training must be given for usage of
bucket.
SN Basic step of the Job Hazard(s) associated with the step Existing control measure to mitigate hazard Existing / Base Additional control measure Responsible Implementation Residual Risk
Impact Risk Official to Status
P S Risk implement P S Risk
Electrocution/ Short circuit Seriuos injury to workmen 9- Only insulated tools must be used for the job. PA Implemented
due to electric shock 10- All job must be carried out with the cordination
of operation team only.
11-Welding return path should done through
welding cable only and it shold be continued up to
the job (Fixed in 3 Mtr Distance)
12 -Training on hot and height work,Usages of
PPE's should be provided.
13-Display board of work at height in progress at
boath end must be ensured.
14-Emergency contact no are FIRE-8018043000,
1 4 4 1 4 4
AMBULANCE-8018043300 in case of emergency all
should assemble near emergency assembly point.
15- Poly carbo shocket should be provided.
16-Dadicated fire watcher should be available with
fire extinguisher.
17- No one will be standing inside the barricaded
area and below the welding area during the
welding job.

1.Slip and trip Workman 1.Unwanted materials to be removed from height 1 2 2 PA Implemented 1 2 2
2.Poor housekeeping basis.
8 Housekeeping 3.Falling objects 2.Unwanted materials to be removed from work
place.

Prepared by: Approved by: