Final Hira Skem

Sl No JSA slide link DEPARTMENT JSA Number
1 JSA SLIDE NO-01 MECHANICAL UAIL/BHP/O&M/HIRA/001



Subject (Description) STATUS
Platform/Structure Erection DONE
Structure modification. DONE
Impact Pad replacement DONE
Vibrating screen Hardrox mesh replacement. DONE
Vibrating screen PM DONE
Skirt rubber replacement. DONE
Diverter Gate PM DONE
Conveyor belt patching DONE
Scraper replacement. DONE
Chute liner replacement DONE
REPLACEMENT OF GEAR BOX & COUPLING DONE
Deflector plate replacement DONE
Oil replacement DONE
Conveyor PM DONE
Vertical Take-up Pulley lagging DONE
Trolley Take-up Pulley lagging DONE
Screw Take-up Pulley lagging DONE
Chute Mother plate Replacement DONE
Inspection door replacement/ modification. DONE
Take-up Pulley position adjustment DONE
Triporcar Pulley lagging
Boom Conveyor Pulley lagging
Belt Patching DONE
Carrying Idler replacement. DONE
GEAR BOX & MOTOR ALLIGMENT. DONE
Air blaster fixing/ replacement DONE
Slew Bolt Torquing of Stacker and Reclaimer DONE
PM of PCRD and CCRD DONE
Rail bolt tightening DONE
Boom Conveyor PM.
Divertor Gate replacement DONE
Drive base strenghting. DONE
Take-up Pulley replacement DONE
Drive Pulley replacement
Snub Pulley replacement.
Replacement of conveyor belt CV-230-007/008
Screen PM
TBP Shaft replacement
Toe Bar replacement
Crusher PM
Screen Bearing replacement
Gear Box and Coupling Replacement DONE
Removing the TBP Link pin
Screen PM
crusher cage bar Replacement
Screen Motor Replacement
Toe bar Adjustment
Screen marshmellow replacement
Screen pad plate replacement
Crusher Motor replacement DONE
Existing Takeup Structure with counter box shifting
and errection at new foundation
JSA for Drive base strengthen & alignment
Replacement of conveyor belt CV-230-007/008
JSA for re-joint of conveyor belt (CV231-004A)
JSA for re-joint of conveyor belt (CV231-006A)
JSA FOR RUSHER231-001B TBP DRIVE SHAFT'S
THREE NOS SPROCKET REPLACEMENT
PM of Luffing Cylinder of Stcaker and Reclaimer DONE
PM of LT of Stacker and Reclaimer DONE
Boom Conveyor coupling inspection. DONE
Carrying Idler frame replacement. DONE
HAZARD IDENTIFICATION AND RISK ASSESSMENT
Department: Mechanical HIRA No. UAIL/BHP/O&M/HIRA/001 Date:- 12/12/2020
Job Title Platform/Structure/Beam Erection/Monorail Erection Section/ Location: BHP
Date of Review at Job site: Reference OCP (SOP/SMP) No.
Area BHP Routine /NonRoutine Routine
Risk assessment team members Mr. P.P.Bal, Mr. S.Rangaswami, Mr. K.Bharghav Normal/Abnormal/Emergency Normal
SN Basic step of the Job Hazard(s) associated Existing control measure to Existing / Base Additional control measure Responsible Implementation Residual Risk
Impact
with the step mitigate hazard P Risk S Risk Official to Status P S Risk
1 Positioning of crane Crane wheel/jack may Injury or property 3 4 12 The ground should be PA&implement
WG Before start the job 1 2 2
go down in soil damage due to toppled Iron plate should be placed on compacted and levelled. it was complited
the crane ground before posting of crane.
Hydra may be hit to Injury to 3 3 9 1.Ensure Reverse horn on the PA& WG Training 1 3 3
workman at the time people/workman Keep distance minimum 3 mtr hydra. 2. Proper signalling implimentaid
base plate fixing. from hydra. during marching should be
ensured.
2 Fixe the siling with lifting Hand injury during hand injury 1.Tested / standard hand tools 3 1 3 WG Implemented
material & Lift it from fixing the sling. to be used. 2. Use cotton
ground to Fixing position. hand gloves. 3. Avoid to use D-
spanner.
Fall of Material due to Possibility of serious to 1.Load should be lifted as per 4 5 20 First lift it 500mm from ground PA& WG During the Job 1 5 5
failure of lifting tools or fatal accident crane capacity. 2.Encure & take hold for 10m then start ensure the load
machine. Crane & lifting tools & Tackles lift. 2. Area lifting
with valid test certificate to be should be evacuated.
use. 3.Barricading should be done in
the surrounding area.
Fall from height of Possibility of serious to 1.Make ensure proper working 3 5 15 1.Manlift use in place of AO,PA & WG Training provided 1 5 5
person or object at the fatal accident platform for work at height. working platform. to the workers.
time of guide to fix the 2. Use double lanyard safety 1.Make
platform. harness. ensure proper working
platform for work at height.
2. Use double lanyard safety
3 Fix & bolting the platform Electrocution Fire burn /Possibility of 1.Use ELCB with 30mA.2. Use 3 5 15 harness.
1.before start the work ensure PA& WG Implemented 1 5 5
on the base serious to fatal accident dry safety shoes.2.Welding the ELCB in good condition by
machine connection to be taken manually tripping method.2.
from ELCB & VRD. Use rubber mat during welding
work.
Fall of bolts & slip tools Head injury Proper hand tools to be used. 4 2 8 1.Area should be evacuated. WG Implemented 2 1 2
from hands. 2.Barricading should be done in
4 Remove the sling from Fall from height of 1.Make ensure proper working 3 5 15 1.Manlift use in place of AO,PA & WG Training provided 1 5 5
platform. person or object at the Possibility of serious to platform for work at height. working platform. to the workers.
time remove the sling. fatal accident 2. Use double lanyard safety 2. Height
harness. pass approved
person/technician engaged for
height work
Prepared by: Reviewed by: Approved by:

Signature: Signature: Signature:
Name Name Name

HAZARD IDENTIFICATION AND
Department: Mechanical HIRA No.
Job Title Platform/Structure Erection
Date of Review at Job site:
Area
Risk assessment team members Mr. P.P.Bal, Mr. S.Rangaswami, Mr. K.Bhargav
SN Basic step of the Job Hazard(s) associated

Impact
with the step
Fall & Slip hazard Chance of Body injury
Fire hazard Born injury
Material (Bauxite) fall Body injury

hazard
Injury Hand injury
Remove of existing
1 damaged one & fit-up new
one.
Electric shock may be Possibility of serious to

connecting with fatal accident
technicians
Failure of Lifting tools Possibility of serious to

injury
Prepared by:
Signature:
Name
UAIL/BHP/O&M/HIRA/002 Date:- .
Section/ Location: 230-TT-1
Reference OCP (SOP/SMP) No.
Routine /NonRoutine Non Routine
Bhargav Normal/Abnormal/Emergency Normal
Existing control measure to Existing / Base Additional control measure Responsible

mitigate hazard P Risk
S Risk Official to
1.Make clean & dry working 4 3 12 1.Keep good housekeeping implement
PA&WG
platform. 2. Use platform as per before start the work. 2. proper
standard. laying welding cable & gas
cutting hose on different way.
3. Unwanted material removed
from the working platform.
1.Fire extinguisher keep near by 3 1 3 WG

work place. 2. Depute fire
watcher on the job.
keep clean the deposited 4 2 8 1.Issolate the before conveyor. AO,PA& WG
bauxite from the chute or 2.Use water to clean the bauxite
structure. if required.
1.Standatd/ tested hand tools 4 1 4 WG

to be used. 2. Use cotton hand
gloves. 3. Avoid to use D-
spanner.
1.Use ELCB with 30mA.2. Use 3 5 15 1.before start the work ensure PA& WG
dry safety shoes.2.Welding the ELCB in good condition by
from ELCB & VRD. Use rubber mat during welding
work.
1.Load should be lifted as per 3 5 15 1. Physical inspection ensure WG

lifting tools capacity. before used. 2. Unauthorized
2.Encure all lifting tools & persons are not allowed.
Tackles with valid test 3.Barricading should be done in
certificate to be use. the surrounding area. 4. Use
oversize lifting tools & tackle.
Reviewed by: Approved by:

Signature: Signature:
Name Name
-1
outine
l
Implementation Residual Risk

Status P S Risk
implemented 1 3 3
During the Job
Area cleaned 1 2 2
implemented
Another earthing 1 5 5
through earth rod is
provided
all lifting tools are 3 1 3

tested.
HAZARD IDENTIFICATION AND RI
Job Title Impact Pad replacement
Area
Risk assessment team members Mr. P.P.Bal, Mr. S.Rangaswami, Mr. K.Bharghav

with the step Impact
Faliour of lifting tools Possibility of serious to
fatal accident
Making arrangement for

1 lifting the conveyer belt
by chain block. Injury due to Possibility of serious to
Drive/Conveyor start. fatal accident
Injury non standard Possibility of body
tools injury
2 Fire hazard Possibility of Born injury
Failure of hand tools. Possibility of body injury
Injury non standard Possibility of body

tools injury
Remove of Impact Pad

Frame with old damage Failure of Lifting tools. Possibility of serious to
impact pad & inset fatal accident
another new impact pad
and frame.
Possibility of serious to
fatal accident
Electrocution
3 Injury due to Possibility of serious to

Drive/Conveyor start. fatal accident
Remove all lifting Injury non standard Possibility of body

arrangement. tools injury
Prepared by:
Signature:
Name
UAIL/BHP/O&M/HIRA/003 Date:-
ghav Normal/Abnormal/Emergency Normal

mitigate hazard P Risk S Risk Official to
1.Load should be lifted less 4 4 16 1. Physical inspection ensure implement
PA & WG
than lifting tools capacity, 2. before used. 2. Unauthorized
Lifting tools with valid test persons are not allowed.
certificate. 3.Barricading should be done in
the surrounding area. 4. Use
Proper isolation to be done of 4 5 20 LOTOTO procedure ensure AO&PA

same & before conveyor. before the job.
1.Standatd/ tested hand tools 4 1 4 PA & WG
spanner.
1.Fire extinguisher keep near by 3 1 3 WG

watcher on the
1.Standatd/ job.hand tools
tested 4 1 4 WG
to be used. 2. Avoid to use D-
spanner.

spanner.
1.Load should be lifted less 4 5 20 1. Physical inspection ensure WG

than lifting tools capacity, 2. before used. 2. Unauthorized
Lifting tools with valid test persons are not allowed.
certificate. 3.Barricading should be done in
1.Use ELCB with 30mA.2. Use 3 5 15 1.before start the work ensure PA & WG
machine connection to be manually tripping method.2.
taken from ELCB & VRD. Use rubber mat during welding
work.
Proper isolation to be done of 4 5 20 LOTOTO procedure ensure AO&PA

1.Standatd/ tested hand tools 4 1 4 wG

spanner.

Name Name
1
utine

Status P S Risk
Already trained 1 3 3
workers on material
lifting system.
LOTOTO system 1 5 5
implemented
implemented.
During the Job

same production to
be immplitaid
implemented.
implemented.
implemented. 1 3 3
implemented. 1 5 5
LOTOTO system 1 5 5
implemented
implemented.
HAZARD IDENTIFICATION A
Job Title Vibrating screen Hardrox mesh replacement.
Area 231
SN Basic step of the Job Hazard(s) associated with

the step Impact
Hand Injury to
the person
Spanner slip.
Fall & Slip hazard Bodily Injury to

the person
Remove old hardrox

1 mesh & install a new Fire hazard
one.
Possibility of
Born injury
Possibility of
start the screen drive. serious to fatal
accident
Body Injury to
the person due
Material (Bauxite) fall
from 231-DG-1. to material fall.
Prepared by:
Signature:
Name
cement. Section/ Location:
Routine /NonRoutine
K.Bharghav Normal/Abnormal/Emergency
Existing control measure to mitigate Existing / Base Risk Additional control measure
hazard P S Risk
1.Standatd/ tested hand tools to be
used. 2. Use cotton hand gloves. 3.
Avoid to use D-spanner. 4 1 4
1.Screen discharge chute guarding

properly. 2.Apart from using
mandatory PPEs(Safety Harness). 4 2 8
1.Fire extinguisher keep near by

work place. 2. Depute fire watcher
on the job.3. Cover Fire blanket 3 1 3
over the conveyor .
Proper isolation to be done of LOTOTO procedure ensure

same & before conveyor. 4 5 20 before the job.
Proper locking of diverter gate.

2.Chute proper cleaning before 3 2 6
start the job.
Reviewed by:
Signature:
Name
SN 1/2
Non Routine
Normal
Responsible Implementation Residual Risk

Official to Status P S Risk
implement
WG implemented
implemented &
workmen are
awarded on
WG PPE's.
during the job

same will be
WG implemented.
LOTOTO system
implemented 1 5 5
AO&PA
Before starting
the job it will be
PA&WG implemented
Approved by:
Signature:
Name
Job Title Vibrating screen PM
Area 231

Drive motor, coupling Possibility of

(Cardoon shaft), & hand injury
bearing housing bolt spanner slip.
tightness checking
Fall & Slip hazard Possibility of

1
body injury
Possibility of
start the screen
serious to fatal
drive.
accident
2 Screen deck, Marsh Possibility of
mellow & hardox plat hand injury
checking. spanner slip.

hand injury
3 Screen bearing checking Possibility of

& lubrication. Foreign particle may eye injury
be inside to the eye.
Prepared by:
Signature:
Name
Section/ Location:
Routine /NonRoutine
ami, Mr. K.Bharghav Normal/Abnormal/Emergency
hazard P S Risk
1.Work on the working platform.

2.Apart from using mandatory
4 2 8
PPEs(Safety Harness).
Proper isolation to be done of same LOTOTO procedure ensure

& before conveyor. 4 5 20 before the job.

1.Screen discharge chute guarding

properly. 2.Apart from using
mandatory PPEs(Safety Harness). 4 2 8
Apart from using mandatory

3 2 6
PPEs(Safety goggles).
Reviewed by:
Signature:
Name
SN 1/2
Non Routine
Normal

implement
WG implemented
implemented &
workmen are
WG awarded on PPE's.
LOTOTO system
implemented 1 5 5
AO & PA
WG implemented
implemented &
workmen are
PA & WG awarded on PPE's.
implemented &
workmen are
WG awarded on PPE's.
Approved by:
Signature:
Name
HAZARD IDENTIFI
Job Title Skrit rubber replacement.
Area 230/231

Impact
with the step
Remove all fitted bolts Fall & Slip hazard Possibility of
from skirt rubber frame. body injury
1
Possibility of
start the screen drive. serious to fatal
accident
Remove all damage Possibility of

skirt rubber from skirt hand injury
2 rubber frame & install spanner slip.
new.
Install skritrubber frame Possibility of
at discharge chute. hand injury
3 spanner slip.
Prepared by:
Signature:
Name
Section/ Location:
Routine /NonRoutine
mi, Mr. K.Bharghav Normal/Abnormal/Emergency
Existing control measure to Existing / Base Risk Additional control measure

mitigate hazard P S Risk
1.Standatd/ tested hand tools
to be used. 2. Use cotton
hand gloves. 3. Avoid to use 4 1 4
D-spanner.
same & before conveyor. 4 5 20 before the job.

D-spanner.
D-spanner.
Reviewed by:
Signature:
Name
Non Routine
Normal

implement
WG
implemented
AO & PA LOTOTO system 5
implemented 1 5
WG
implemented
WG
implemented
Approved by:
Signature:
Name
Department: Mechanical HIRA No. UAIL/BHP/O&M/HIRA/007
Job Title Diverter Gate PM
Area 231
SN Basic step of the Job Hazard(s) associated Existing control measure

with the step Impact to mitigate hazard
Remove all fitted Fall & Slip hazard Possibility 1.Standatd/ tested hand
bolts from skirt of body tools to be used. 2. Use
rubber frame. injury cotton hand gloves. 3.
Avoid to use D-spanner.
1
Possibility of Proper isolation to be
serious to done of same & before
start the screen drive. fatal accident
conveyor.
Remove all damage Possibility 1.Standatd/ tested hand

skirt rubber from of hand tools to be used. 2. Use
2 skirt rubber frame & spanner slip. injury cotton hand gloves. 3.
install new. Avoid to use D-spanner.
Install skritrubber Possibility 1.Standatd/ tested hand

frame at discharge of hand tools to be used. 2. Use
3 chute. spanner slip. injury cotton hand gloves. 3.
Prepared by: Reviewed by:

Name Name
&M/HIRA/007 Date:-
Section/ Location:
Normal/Abnormal/Emergency Normal
Existing / Base Additional control measure Responsible Implementation Residual Risk

Risk Official to Status
implement
P S Risk P
WG
4 1 4
implemented
LOTOTO procedure ensure AO & PA LOTOTO system
before the job. implemented
4 5 20 1
WG
4 1 4
implemented
WG
4 1 4
implemented
Approved by:
Signature:
Name
Residual Risk
S Risk
5
5
Job Title Conveyor belt patching
Area 230/231
SN Basic step of the Job Hazard(s) associated with Existing control measure
the step Impact to mitigate hazard
Injury due to Possibility of Proper isolation to be
Drive/Conveyor start. serious to fatal done of same & before
accident conveyor.
Possibility of 1.Wheel locknut proper

Body injury due to hit by serious body tightning. 2. ensure the
grinder wheel. injury the grinding wheels RPM
capacity more tham
Possibility of 1. Industrial socket with
machines.
serious to fatal IP44 specification to be
Grinding the
accident due to used, .2.Use ELCB with
1 damage / patching
electrocution 30mA.
area
Shock while applying
power tool socket
Possibility of Apart from using

Eye injury due to foreign eye injury mandatory PPEs(Safety
particles(Conveyor Dust) goggles).
Cut injury while using Possibility of
hand injury Hand gloves to be used
knife
Add soluction on the
2 Possibility of Apart from using
same place Eye injury due to foreign eye injury mandatory PPEs(Safety
particles (Joint Soluction) goggles).

Name Name
&M/HIRA/008 Date:-
Section/ Location:
Existing / Base Risk Additional control measure Responsible Official Implementation

P S Risk to implement Status
LOTOTO procedure ensure AO,PA&WG LOTOTO system
4 5 20 before the job. implemented
WG
implemented &
3 2 6 workmen are
awarded on PPE's.
1.before start the work PA & WG
ensure the ELCB in good
condition by manually
tripping method.2. Use
3 5 15 rubber mat or work on the
belt during grinding work.
3. Use cotton Handgloves
implemented
WG implemented &
2 2 4 workmen are
awarded on PPE's.
implemented &
WG workmen are
2 2 4
awarded on PPE's.
WG
implemented &
2 2 4 workmen are
awarded on PPE's.
Approved by:
Signature:
Name
Residual Risk
P S Risk
1 5 5
2 1 2
Job Title Scraper replacement.
Area 230/231
SN Basic step of the Job Hazard(s) associated with Existing control measure
the step Impact to mitigate hazard
1 Remove all fitted Possibility of 1.Standatd/ tested hand
bolts from scraper hand injury tools to be used. 2. Use
frame. Hand Injury due to cotton hand gloves. 3.
spanner slip. Avoid to use D-spanner.
Injury due to Possibility of Proper isolation to be

Drive/Conveyor start. serious to done of same & before
fatal accident conveyor.
2 Remove Scraper Possibility of 1.Standatd/ tested hand

frame & install new. Hand Injury due to hand injury tools to be used. 2. Use
spanner slip. cotton hand gloves. 3.
3 Proper engaged & Possibility of 1.Standatd/ tested hand
fighting the frame hand injury tools to be used. 2. Use
bolt. Hand Injury due to cotton hand gloves. 3.
spanner slip. Avoid to use D-spanner.
Possibility of Hold with additional

serious body rope.
injury
scraper frame fall hazard

Name Name
&M/HIRA/009 Date:-
Section/ Location:
Existing / Base Risk Additional control measure Responsible Official Implementation

P S Risk to implement Status
WG
4 1 4
implemented
LOTOTO procedure ensure AO&PA LOTOTO system
4 5 20
WG
4 1 4
implemented
WG
4 1 4
implemented
WG
3 1 3
implemented
Approved by:
Signature:
Name
Residual Risk
P S Risk
1 5 5
Job Title Chute liner replacement
Area 230/231

the step Impact
Injury due to failure of Possibility of

Lifting tools. serious body
injury

lifting & fixing manual Injury due to Possibility of
working platform inside Drive/Conveyor start. serious to fatal
chute. accident
Fall from height of person Possibility of

during ascending & serious to fatal
descending in side chute. accident
Fire hazard Possibility of

serious to
burn injury
Suffocation. Possibility of
serious to fatal
accident due
to breathing
problem.

serious body
injury
Possibility of
serious to
Fire hazard burn injury
Possibility of
Injury due to material serious body
(Bauxite) fall from chute. injury
Remove of existing
2 damaged Liner plate &
Possibility of
fit-up new one.
Hand Injury due to hand injury
spanner slip.
Electric shock may be Possibility of

connecting with serious to fatal
technicians accident due
to
electrocution

Lifting tools. serious body
injury
Possibility of
Hand Injury due to serious hand
injury
spanner slip.
Remove of working
3 platform & all
Accessories
Remove of working
3 platform & all Possibility of
Accessories serious to
burn injury
Fire hazard
Prepared by:
Signature:
Name
Section/ Location:
Routine /NonRoutine
Mr. K.Bharghav Normal/Abnormal/Emergency

Chain block(Lifting tools) in 1. Physical inspection ensure
good condition & with valid before used. 2. Unauthorized
test certificate. persons are not allowed.
3.Barricading should be done
4 3 12 in the surrounding area. 4.
Use oversize lifting tools &
tackle.

4 5 20
1.Make ensure proper 1.Manlift use in place of

working platform for work at working platform.
height. 2. Height
2. Use double lanyard safety 3 5 pass approved
harness. person/technician engaged for
height work
1.Gas Test should be done 1. If flammable gas present
before starting the job & then purging should be done.
Ensured that no flammable 2.A Proper rescue plane
gas should be present inside should be available & brief to
the confined space. the workman. 3. 24 Volt DC
2. Fire extinguisher keep near 4 4 16 light Should be used inside the
by work place. 3. There confined space.
should be proper means of
access should be provided
for the access & egress.
1. Gas Test should be done Worker with confined space
before starting the job & pass should be work inside the
Oxygen level should be confined space.
ensured 19.5% to 23.5% 3 4 12
1. Work on the working

platform. 2. Additional
locking by PP rope. 3.Apart
from using mandatory 3 2 6
1.Fire extinguisher keep near

by work place. 2. Depute fire
watcher on the job.3. Cover 1 3 3
Fire blanket over the
conveyor .
1.Chut proper cleaning
before start the job.2. Before
2 2 4
& after conveyor drive
should be isolated.
1.Standatd/ tested hand
tools to be used. 2. Use
cotton hand gloves. 3. Avoid 4 1 4
to use D-spanner.
1.Use ELCB with 30mA.2. 1.before start the work ensure
Use dry safety the ELCB in good condition by
shoes.2.Welding machine manually tripping method.2.
connection to be taken from Use rubber mat during
ELCB & VRD. 3 5 15 welding work.

good condition & with valid 4 3 12 before used. 2. Unauthorized
1.Standatd/ tested hand in the surrounding area. 4.
tools to be used. 2. Use Use oversize lifting tools &
cotton hand gloves. 3. Avoid 4 1 4 tackle.
to use D-spanner.
1.Fire extinguisher keep near
by work place. 2. Depute fire
watcher on the job.3. Cover
1 3 3
Fire blanket over the
conveyor .
Reviewed by:
Signature:
Name
Non Routine
Normal
Responsible Official Implementation Residual Risk

to implement Status P S Risk
PA & WG 2 2 4
implemented
AO,PA&WG LOTOTO 1 5 5
procedure
ensure before the
job.
PA & WG 1 3 3
implemented &
workmen are
awarded on
PPE's.
AGT,AO&PA It is the part of 1 4 4
Hot work PTW
system, and also
same was
implemented.
PA & WG It is the part of 1 3 3
PTW system,
and also same
was
implemented.
WG
implemented &
workmen are
awarded on
PPE's.
WG It is the part of
Hot work PTW
system, and also
same was
implemented.
PA & WG Before start the
Job
WG
implemented
WG 1 5 5
implemented &
workmen are
awarded on
electrical safety.
PA & WG 2 2 4
implemented
WG
implemented
WG It is the part of
Hot work PTW
system, and also
same was
implemented.
Approved by:
Signature:
Name
HAZARD IDENTIFICATIO
Job Title
Area
SN Basic step of the Job Hazard(s) associated with Existing control measure to
the step Impact mitigate hazard
ZARD IDENTIFICATION AND RISK ASSESSMENT
BHP/O&M/HIRA/011 Date:-
Section/ Location:
Existing / Base Risk Additional control measure Responsible Official to Implementation

P S Risk implement Status
Residual Risk
P S Risk
Job Title Deflector plate replacement
Area 230/231
Risk assessment team members Mar. P.P.Bal, Mr. S.Rangaswami, Mr. K.Bharghav

the step Impact
Fall from height of person or Possibility of

object at the time fixing the serious body
sling or chain blocks. injury
Injury due to Fall of bolts & Possibility of

slip of hand tools from serious hand
hands. injury
Making arrangement
for lifting & fixing Injury due to Possibility of
1 Drive/Conveyor start. serious to fatal
manual working
platform inside chute. accident

Lifting tools. serious to fatal
accident

serious body
injury
Possibility of
serious to
burn injury
Fire hazard
Remove of existing
Possibility of
Injury due to material serious body
(Bauxite) fall from chute. injury
Remove of existing Possibility of

2 damaged deflector hand injury
plate & fit-up new one. Hand Injury due to spanner
slip.
Electric shock may be Possibility of

connecting with technicians serious to fatal
accident due
to
electrocution

Lifting tools. serious to fatal
accident
Possibility of
hand injury
Hand Injury due to spanner
slip.
Remove of working Possibility of

3 platform & all serious to
Accessories burn injury
Fire hazard
Prepared by:
Signature:
Name
Section/ Location:
Routine /NonRoutine
Mr. K.Bharghav Normal/Abnormal/Emergency

Ladder should be provided for
ascending & descending of
workmen for fixing & removal of
3 1 3
the slings
1.Standatd/ tested hand tools to

be used. 2. Use cotton hand
gloves. 3. Avoid to use D- 4 1 4
spanner.

4 5 20

good condition & with valid test before used. 2. Unauthorized
certificate. persons are not allowed.
3.Barricading should be done in
4 3 12 the surrounding area. 4. Use
1. Work on the working

platform. 2. Additional locking
by PP rope. 3.Apart from using
3 2 6
mandatory PPEs(Safety
Harness).

watcher on the job.3. Cover Fire
blanket over the conveyor . 1 3 3
1.Chut proper cleaning before
start the job.2. Before & after
2 2 4
conveyor drive should be
isolated.
spanner.
1.Use ELCB with 30mA.2. Use 1.before start the work ensure
from ELCB & VRD. 3 5 15 Use rubber mat during welding
work.

good condition & with valid test before used. 2. Unauthorized
certificate. persons are not allowed.
4 3 12 the surrounding area. 4. Use

spanner.

watcher on the job.3. Cover Fire
blanket over the conveyor . 1 3 3
Reviewed by:
Signature:
Name
Non Routine
Normal

WG
implemented &
workmen are
awarded on
work at height.
WG
implemented &
workmen are
awarded on
same work
procedure
ensure before
the job.
PA & WG 2 2 4
implemented
WG
implemented &
workmen are
awarded on
PPE's.
WG,PA It is the part of
Hot work PTW
system, and also
same was
implemented.
PA & WG Before start the
Job
WG
implemented &
workmen are
awarded on
same work
WG 1 5 5
implemented &
workmen are
awarded on
electrical safety.
PA & WG 2 2 4
implemented &
workmen are
awarded on
work at height.
WG
implemented &
workmen are
awarded on
same work
WG,PA It is the part of
Hot work PTW
system, and also
same was
implemented.
Approved by:
Signature:
Name
Department: Mechanical
Job Title Oil replacement
Area 230/231
SN Basic step of the Job Hazard(s) associated with the

step
1 Clean the surrounding area Sharp edge.
Injury due to Drive/Conveyor

start.
Dust hazard
2 Remove the top inspection chamber,

drain nut & collect all used oil in a
container. spanner slip.
Eye injury due to foreign

particles (Joint Solution)
slip hazard due to oil may be

spread on the floor.
3 Drain nut fixing & its tightness condition

checking. Hand Injury due to spanner
slip.
4 Add fresh oil inside the gearbox through

Eye injury due to foreign
inspection chamber(By oil pump /
particles (Joint Solution)
manually).
Fall of Oil drum
5 Fixed the Inspection chamber & Air
breather. Hand Injury due to spanner
slip.
Prepared by:
Signature:
Name
HIRA No. UAIL/BHP/O&M/HIRA/013 Date:-
Section/ Location:
Reference OCP (SOP/
Routine /NonRoutine
gaswami, Mr. K.Bharghav Normal/Abnormal/E
Existing control measure to mitigate hazard Existing / Base Risk

Impact
P S Risk
use cotton Hand gloves
4 1 4
hand Injury due to
sharp edge.
Possibility of serious Proper isolation to be done of same &
to fatal accident before conveyor. 4 5 20
Use Nose Mask

can create breathing 5 1 5
problems.
1.Standatd/ tested hand tools to be used.
2. Use cotton hand gloves. 3. Avoid to use
4 1 4
Hand Injury due to D-spanner.
spanner slip.
Possibility of eye Apart from using mandatory PPEs(Safety
injury goggles). 2 2 4
Possibility of serious 1. Use a appropriate size container to

body injury collect the oil. 2.funnel used to collect 3 1 3
through it.
Possibility of hand 1.Standatd/ tested hand tools to be used.
injury 2. Use cotton hand gloves. 3. Avoid to use
D-spanner. 4 1 4
Possibility of eye Apart from using mandatory PPEs(Safety

injury goggles). 2 2 4
Possibility of serious 1. Its placed on the plane surface. 2. Use oil

body injury pump to feed fresh oil inside gearbox,
3.Fitter (technicians) should be engaged for 2 1 2
the same work.
Possibility of hand 1.Standatd/ tested hand tools to be used.
injury 2. Use cotton hand gloves. 3. Avoid to use
D-spanner. 4 1 4
Reviewed by:
Signature:
Name
Date:-
Section/ Location:
Additional control Responsible Official Implementation Residual Risk

measure to implement Status P S Risk
WG implemented & 1 5 5
workmen are
awarded on same
work
LOTOTO procedure AO,PA&WG LOTOTO procedure 1 5 5
ensure before the job. ensure before the
job.
WG implemented
WG implemented &
workmen are
awarded on same
work
WG implemented &
workmen are
awarded on PPE's.
WG All area /surface are
clear.
WG implemented &
workmen are
awarded on same
work
WG implemented &
workmen are
awarded on PPE's.
WG All area /surface are
clear.
implemented &
workmen are
awarded on same
work
During the Job
Approved by:
Signature:
Name
Job Title Conveyor PM
Area 230/231
SN Basic step of the Job Hazard(s) associated with the step

Impact
1 Drive motor & gear box base

bolt tightness checking
spanner slip. Possibility of
fracture
injury
Injury due to Drive/Conveyor Possibility of
start. serious to
fatal
accident
2 Coupling checking, cleaning &

lubrication.
Spanner slip. Possibility of
fracture
injury
Possibility of
Foreign particle may be inside to eye injury
the eye.
3 All pulleys Plummer block base

bolt tightness & lubrication.
Hand Injury due to spanner slip. Possibility of
fracture
injury
4 Discharge chute liner checking

fracture
injury
5 Plumber block bearing
conduction checking with
lubrication & base tightness. Hand Injury due to spanner slip. Possibility of
fracture
injury
Possibility of
Foreign particle may be inside to eye injury
the eye.
6 Scarper base bolt & jamming
condition checking.
fracture
injury
Prepared by:
Signature:
Name
Section/ Location:
Routine /NonRoutine
.Bharghav Normal/Abnormal/Emergency
Existing control measure to mitigate hazard Existing / Base Risk Additional control
P S Risk measure
D-spanner. 4 1 4
Proper isolation to be done of same & LOTOTO procedure

before conveyor. ensure before the job.
4 5 20

D-spanner. 4 1 4
Apart from using mandatory PPEs(Safety

goggles). 2 2 4

D-spanner. 4 1 4

D-spanner. 4 1 4

D-spanner. 4 1 4

3 1 3
goggles).
D-spanner. 4 1 4
Reviewed by:
Signature:
Name
Non Routine
Normal
Responsible Official to implement Implementation Residual Risk

Status P S Risk
WG
implemented &
workmen are
awarded on same
work
AO,PA&WG LOTOTO procedure 1 5 5
ensure before the job.
WG
implemented &
workmen are
awarded on same
work
WG
implemented &
workmen are
awarded on PPE's.
WG
implemented &
workmen are
awarded on same
work
WG
implemented &
workmen are
awarded on same
work
WG
implemented &
workmen are
awarded on same
work
WG
WG
implemented &
workmen are
awarded on same
work
Approved by:
Signature:
Name
Job Title Vertical Take-up Pulley lagging
Area 230/231
SN Basic step of the Job Hazard(s) associated with the step Impact
1 Both side conveyor Injury due to Drive/Conveyor Possibility of

belt locking. start. serious to fatal
accident
Fall of materials Possibility of

fracture injury/
Fatal accident

object at the time locking the belt. fracture injury/
Fatal accident

hand fracture
2 Making arrangement Dust hazard Can be create

for lift the take-up breathing
pulley & lift by chain problems.
block.
Fall from height of person during Possibility of
lift the chain block. fracture injury/
Fatal accident
Injury due to failure of Lifting Possibility of
tools. fracture injury/
Fatal accident
3 Removal of old Fall from height of person or Possibility of

lagging for surface object at the time lagging the fracture injury/
preparation& lagging rubber sheet/pulley. Fatal accident
new rubber sheet
Electric shock may be connecting Possibility of

with grinder. serious to fatal
accident due to
electrocution
Chemical hazard (May belt joint Possibility of

solution split over the body/ eye eye injury
during lagging work).
4 Take-up to be fixed Fall from height of person or Possibility of

back & all object at the time remove locking fracture injury/
arrangements, tools, from conveyor belt. Fatal accident
tackle & belt locking
removing.

hand fracture
Prepared by:
Signature:
Name
Section/ Location:
Routine /NonRoutine
arghav Normal/Abnormal/Emergency
Existing control measure to mitigate hazard Existing / Base Risk Additional control measure
P S Risk
Proper isolation to be done of same & 4 5 20 LOTOTO procedure ensure
before conveyor. before the job.
1.Area should be cleaned. 2. .Standard/ 3 5 15 1.Area should be

tested hand tools to be used. evacuated. 2.Barricading
should be done in the
surrounding area.
1.Make ensure proper working platform for 3 5 15 1. Take height permit.

work at height. 2.
2. Use double lanyard safety harness. Height pass approved
person/technician engaged
for height work
1.Standatd/ tested hand tools to be used. 4 1 4

D-spanner.
Use Nose Mask 5 1 5
1.Make ensure proper working platform for 3 5 1.Fixed ladder to be

work at height. provide.
2. Use double lanyard safety harness. 2. Height pass
approved
for height work
Chain block(Lifting tools) in good 4 3 12 1. Physical inspection
condition & with valid test certificate. ensure before used. 2.
Unauthorized persons are
not allowed. 3.Barricading
surrounding area. 4. Use
oversize lifting tools &
tackle.

work at height. 2.
for height work
1.Use ELCB with 30mA.2. Use dry safety 3 5 15 1.before start the work
shoes.2.Grinding machine connection to be ensure the ELCB in good
taken from ELCB. condition by manually
rubber mat during welding
work.
Apart from using mandatory PPEs(Safety 2 2 4

goggles).

work at height. 2.
for height work

D-spanner.
Reviewed by:
Signature:
Name
Non Routine
Normal
Responsible Official to Implementation Residual Risk

implement Status P S Risk
ensure before the
job.
WG/PA During the job area 3 1 3

will be cleaned &
standard tools are
already
implemented at site.
WG/PA implemented & 1 5 5

Work at height
trained already
given to workers.
Also they are very
well know about use
of PPE.
WG implemented &
workmen are
awarded on same
work
WG implemented
PA & WG implemented & 1 3 3

Work at height
trained already
given to workers.
Also they are very
well know about use
of PPE.
workmen are
awarded on same
work

Work at height
trained already
given to workers.
Also they are very
well know about use
of PPE.

workmen are
awarded on
electrical safety.
WG implemented &
workmen are
awarded on PPE's.

Work at height
trained already
given to workers.
Also they are very
well know about use
of PPE.
WG implemented &
workmen are
awarded on same
work
Approved by:
Signature:
Name
Job Title Trolley Take-up Pulley lagging
Area 230/231
1 Position the crane for lift the Crane wheel/jack may go down in Possibility of
counter weight of take-up till soil & injury or property damage serious fatal
required height & rest on zero due to toppled the crane. accident &
height. property damage.
Hydra may be hit to workman at Possibility of

the time base plate fixing. serious fatal
accident.
Hand injury during fixing the Possibility of

sling. hand injury
Fall of counterweight due to Possibility of

failure of lifting tools or machine. serious fatal
accident

fixed the D-shackle. fracture injury/
Fatal accident
2 Both side conveyor belt locking. Injury due to Drive/Conveyor Possibility of

start. serious to fatal
accident

fracture injury/
Fatal accident
Fatal accident

hand fracture
3 Making arrangement for lift the Dust hazard can create

conveyor by chain block for make breathing
clearance to work. problems.

Fatal accident

tools. fracture injury/
Fatal accident
4 Removal of old lagging for surface Fall from height of person or Possibility of
preparation& lagging new rubber object at the time lagging the fracture injury/
sheet rubber sheet/pulley. Fatal accident

with grinder. serious to fatal
accident due to
electrocution
Chemical hazard (May belt joint Possibility of eye

solution split over the body/ eye injury
5 Convert to be fixed back & all Fall from height of person or Possibility of
arrangements, tools, tackle & belt object at the time remove locking fracture injury/
locking removing. from conveyor belt. Fatal accident

hand fracture
6 Lift the counter weight of take-up Crane wheel/jack may go down in Possibility of
till required height for conveyor soil & injury or property damage serious fatal
tension. due to toppled the crane. accident &
property damage.
Hydra may be hit to workman at Possibility of

the time base plate fixing. serious fatal
accident.
Prepared by:
Signature:
Name
Section/ Location:
Routine /NonRoutine
ghav Normal/Abnormal/Emergency

P S Risk
3 4 12
Iron plate should be placed on ground
before posting of crane.
3 3 9
Keep distance minimum 3 mtr from hydra.
1.Tested / standard hand tools to be used. 3 1 3

2. Use cotton hand gloves. 3. Avoid to
use D-spanner.
1.Load should be lifted as per crane 4 5 20

capacity. 2.Encure Crane & lifting tools
& Tackles with valid test certificate to be
use.
1.Make ensure proper working platform for 3 5 15

work at height.
2. Use double lanyard safety harness.
Proper isolation to be done of same & 4 5 20

before conveyor.
1.Area should be cleaned. 2. .Standard/ 3 5 15

tested hand tools to be used.
work at height.

D-spanner.
Use Nose Mask 5 1 5
1.Make ensure proper working platform for 3 5

work at height.
Chain block(Lifting tools) in good 4 3 12

condition & with valid test certificate.

work at height.
1.Use ELCB with 30mA.2. Use dry safety 3 5 15

shoes.2.Grinding machine connection to be
taken from ELCB.
Apart from using mandatory PPEs(Safety 2 2 4

goggles).
work at height.

D-spanner.
3 4 12
Iron plate should be placed on ground
3 3 9
Reviewed by:
Signature:
Name
Date:-
Section/ Location: CV230-002, CV230-006, CV231-004A,
Additional control measure Responsible Official to Implementation Status

implement
The ground should be compacted and WG/PA Area already compacted &
levelled. implemented all necessary
requirement as per lifting
standard.
1.Ensure Reverse horn on the hydra. 2. WG/PA Use of Hydra SWI already
Proper signalling during marching should implemented at site.
be ensured.
WG Implemented
First lift it 500mm from ground & take hold WG/PA Tools & tackles are tested
for 10m then start lift. before use & good
2. Area should be evacuated. condition machine used at
3.Barricading should be done in the site.
surrounding area.
1.Fixed ladder to be provided. PA/WG implemented & workmen

2. Height pass approved are awarded on same
person/technician engaged for height work work
3. Take height permit.
LOTOTO procedure ensure before the job. AO,PA&WG LOTOTO procedure

1.Area should be evacuated. 2.Barricading WG/PA During the job area will be
should be done in the surrounding area. cleaned & standard tools
are already implemented
at site.
1. Take height permit. WG/PA implemented & Work at
2. Height pass approved height trained already
person/technician engaged for height work given to workers. Also
they are very well know
about use of PPE.
WG implemented
WG implemented
1 Ladder to be provide. PA & WG implemented & Work at

about use of PPE.
1. Physical inspection ensure before used. PA & WG implemented

2. Unauthorized persons are not allowed.
3.Barricading should be done in the
surrounding area. 4. Use oversize lifting
tools & tackle.

about use of PPE.
1.before start the work ensure the ELCB in WG/PA implemented & workmen
good condition by manually tripping are awarded on electrical
method.2. Use rubber mat during welding safety.
work.
WG implemented & workmen

are awarded on PPE's.
about use of PPE.

are awarded on same
work
The ground should be compacted and WG/PA Area already compacted &
levelled. implemented all necessary
requirement as per lifting
standard.
1.Ensure Reverse horn on the hydra. 2. WG/PA Use of Hydra SWI already
Proper signalling during marching should implemented at site.
be ensured.
Approved by:
Signature:
Name
Residual Risk
P S Risk
1 4 4
1 3 3
1 5 5
1 5 5
1 5 5
3 1 3
1 5 5
1 3 3
2 2 4
1 5 5
3 1 3
1 5 5
1 4 4
1 3 3
Job Title Screw Take-up Pulley lagging
Area 230/231

step
1 Relies the tension of conveyors by free of Injury due to Drive/Conveyor
screw take-up. start.
Fall of materials
Hand tools/ spanner slip.
2 Making arrangement for lift the conveyor Dust hazard

by chain block for make clearance to work.
Fall from height of person

during lift the chain block.
Injury due to failure of Lifting

tools.
3 Removal of old lagging for surface Fall from height of person or
preparation& lagging new rubber sheet object at the time lagging the
rubber sheet/pulley.
Electric shock may be

connecting with grinder.
Chemical hazard (May belt

joint solution split over the
body/ eye during lagging
work).
4 Conveyor to be fixed back & all Fall from height of person or

arrangements, tools, tackle & belt locking object at the time remove
removing. locking from conveyor belt.
hand tools/ spanner slip.
5 Make conveyor tension by screw take-up hand tools/ spanner slip

adjust. during the job.
Prepared by:
Signature:
Name
HIRA No. UAIL/BHP/O&M/HIRA/017 Date:-
y lagging Section/ Location:
Routine /NonRoutine
angaswami, Mr. K.Bharghav Normal/Abnormal/Emergency
Impact Existing control measure to Existing / Base

mitigate hazard Risk
P S Risk
Possibility of serious Proper isolation to be done of 4 5 20
to fatal accident same & before conveyor.
Possibility of fracture 1.Area should be cleaned. 3 1 3

injury 2. .Standard/ tested hand
tools to be used.
Possibility of fracture 1.Standatd/ tested hand 4 1 4

injury tools to be used. 2. Use
cotton hand gloves. 3. Avoid
to use D-spanner.
Can be create Use Nose Mask 5 1 5

breathing problems.
Possibility of fracture 1.Make ensure proper 3 5

injury/ Fatal accident working platform for work at
height.
harness.
Possibility of fracture Chain block(Lifting tools) in 4 3 12

injury/ Fatal accident good condition & with valid
test certificate.
Possibility of fracture 1.Make ensure proper 3 5 15
height.
harness.
Possibility of serious 1.Use ELCB with 30mA.2. 3 5 15

to fatal accident due Use dry safety
to electrocution shoes.2.Grinding machine
connection to be taken from
ELCB.
Possibility of eye Apart from using 2 2 4

injury mandatory PPEs(Safety
goggles).
Possibility of fracture 1.Make ensure proper 3 5 15

height.
harness.

to use D-spanner.

to use D-spanner.
Reviewed by:
Signature:
Name
Date:-
Section/ Location: CV230-003, CV231-002A/B, CV231-003A/B, CV231-0
Additional control measure Responsible Implementation Residual Risk

implement
LOTOTO procedure ensure PA &WG LOTOTO procedure 1 5 5
before the job. ensure before the
job.
WG/PA During the job
WG implemented &
workmen are
awarded on same
work
WG implemented
1.Fixed ladder to be provide. PA & WG implemented & 1 3 3

2. Work at height
Height pass approved trained already
person/technician engaged for given to workers.
height work Also they are very
well know about use
of PPE.
1. Physical inspection ensure PA & WG implemented & 2 2 4

before used. 2. Unauthorized workmen are
persons are not allowed. awarded on same
3.Barricading should be done in work
1. Take height permit. WG/PA implemented & 1 5 5
2. Height Work at height
pass approved trained already
well know about use
of PPE.
1.before start the work ensure WG/PA implemented & 3 1 3

the ELCB in good condition by workmen are
manually tripping method.2. awarded on
Use rubber mat during welding electrical safety.
work.
WG implemented &
workmen are
awarded on PPE's.
1. Take height permit. WG/PA implemented & 1 5 5

2. Height Work at height
pass approved trained already
well know about use
of PPE.
WG implemented &
workmen are
awarded on same
work
WG implemented &
workmen are
awarded on same
work
Approved by:
Signature:
Name
Job Title Chute Mother plate Replacement
Area 230/231
1 Making arrangement for lifting & Injury due to failure of Lifting Possibility of
fixing manual working platform tools. serious hand
inside/outside chute. injury
Injury due to Drive/Conveyor Possibility of

start. serious to fatal
accident
Suffocation Possibility of
serious to fatal
accident due
to breathing
problem.

ascending & descending in side fracture
/outside of chute. injury/ Fatal
accident

serious to
burn injury
2 Chute clinging Fall & Slip hazard Possibility of

serious body
injury
2 Chute clinging
Dust hazard Can be create

breathing
problems.
3 Remove all fitted bolts from skirt Hand Injury due to spanner slip. Possibility of
rubber frame. serious hand
injury
4 Remove all damage skirt rubber hand tools/ spanner slip during Possibility of
from skirt rubber frame the job. fracture injury
5 Remove of existing damaged mother Fall & Slip hazard Possibility of

plate plate & fit-up new one. serious body
injury

serious to
burn injury
Injury due to material (Bauxite) fall Possibility of

from chute. serious body
injury
hand tools/ spanner slip during Possibility of

the job. fracture injury

with technicians serious to fatal
accident due
to
electrocution

tools. serious hand
injury
6 Install new skirt rubber from skirt hand tools/ spanner slip during Possibility of
rubber frame & skirt rubber. the job. fracture injury
7 Remove of working platform & all hand tools/ spanner slip during Possibility of
Accessories the job. fracture injury

serious to
burn injury
Prepared by:
Signature:
Name
Section/ Location:
Routine /NonRoutine
harghav Normal/Abnormal/Emergency
Existing control measure to mitigate Existing / Additional control measure

hazard Base
P S Risk
Risk
Chain block(Lifting tools) in good 4 3 12 1. Physical inspection ensure before
condition & with valid test certificate. used. 2. Unauthorized persons are not
allowed. 3.Barricading should be done
in the surrounding area. 4. Use oversize
lifting tools & tackle.
Proper isolation to be done of same & 4 5 20 LOTOTO procedure ensure before the
before conveyor. job.
1.Must be tested Oxygen leave 3 4 12 1. Training is required for all employees

between 19.5 to 23.5 inside chute by working in / with Permit required
multi gas tester. 2. Take confined confined spaces. 2. pass holder only
space permit from authorization allow to work inside confined space. 3.
person. Attendant must be deployed near the
entrance location.
1.Make ensure proper working 3 5 15 1.Manlift use in place of working

platform for work at height. platform.
2. Use double lanyard safety harness. 2. Height pass approved
person/technician engaged for height
work
1.Gas Test should be done before 4 4 16 1. If flammable gas present then purging
starting the job & Ensured that no should be done. 2.A Proper rescue plane
flammable gas should be present should be available & brief to the
inside the confined space. workman.
2. Fire extinguisher keep near by
work place. 3. There should be proper
means of access should be provided
for the access & egress.
Proper isolation of before & after 3 2 6

conveyor. 2.Chute proper cleaning
before start the job.
Use Nose Mask 5 1 5
1.Standatd/ tested hand tools to be 4 1 4


1. Work on the working platform. 2. 3 2 6

Additional locking by PP rope.
1.Fire extinguisher keep near by work 1 3 3

place. 2. Depute fire watcher on the
job.3. Cover Fire blanket over the
conveyor .
1.Chut proper cleaning before start 2 2 4

the job.2. Before & after conveyor
drive should be isolated.

1.Use ELCB with 30mA.2. Use dry 3 5 15 1.before start the work ensure the ELCB
safety shoes.2.Welding machine in good condition by manually tripping
connection to be taken from ELCB & method.2. Use rubber mat during
VRD. welding work.
Chain block(Lifting tools) in good 4 3 12 1. Physical inspection ensure before

condition & with valid test certificate. used. 2. Unauthorized persons are not
allowed. 3.Barricading should be done
in the surrounding area. 4. Use oversize
lifting tools & tackle.


conveyor .
Reviewed by:
Signature:
Name
Non Routine
Normal
Responsible Implementation Status Residual Risk

Official to P S Risk
implement
PA & WG Implemented 2 2 4
AO,PA&WG LOTOTO procedure ensure 1 5 5

before the job.
PA & WG It is the part of PTW system, 1 3 3

and also same was
implemented.
PA & WG implemented & Work at 1 3 3

height trained already given
to workers. Also they are
very well know about use of
PPE.
AGT,AO&PA It is the part of Hot work 1 4 4

PTW system, and also same
was implemented.
Same will be implemented

before the job.
WG Implemented
WG Same will be implemented

before the job.
WG implemented & workmen are

awarded on same work
WG Same will be implemented

before the job.
WG During the job
PA & WG Same will be implemented

before the job.

WG implemented & workmen are 1 5 5

awarded on electrical safety.
PA & WG Before start the Job 2 2 4


WG During the job
Approved by:
Signature:
Name
Job Title Inspection door replacement/ modification.
Area 230/231
1 Making arrangement for Injury due to failure of Lifting tools. Possibility of

lifting the inspection door. serious hand
injury

serious to
burn injury
2 Chute clinging Fall & Slip hazard Possibility of

serious body
injury

breathing
problems.
3 Remove all damage skirt hand tools/ spanner slip during the Possibility of
rubber from skirt rubber job. fracture injury
frame
4 Remove of existing damaged Fall & Slip hazard Possibility of

door & fit-up new one. serious body
injury
door & fit-up new one.

serious to
burn injury
hand tools/ spanner slip during the Possibility of

job. fracture injury
Electric shock may be connecting with Possibility of

technicians serious to fatal
accident due
to
electrocution
Injury due to failure of Lifting tools. Possibility of

serious hand
injury
5 Remove of working platform Hand Injury due to spanner slip. Possibility of

& all Accessories fracture injury

serious to
burn injury
Prepared by:
Signature:
Name
Section/ Location:
Routine /NonRoutine
hazard P S Risk
Chain block(Lifting tools) in good 4 3 12 1. Physical inspection ensure
condition & with valid test certificate. before used. 2. Unauthorized
persons are not allowed.
in the surrounding area. 4.
tackle.

conveyor .
Proper isolation of before & after 3 2 6

conveyor. 2.Chute proper cleaning
before start the job.
Use Nose Mask 5 1 5

1. Work on the working platform. 2. 3 2 6

conveyor .

1.Use ELCB with 30mA.2. Use dry 3 5 15 1.Before start the work ensure
safety shoes.2.Welding machine the ELCB in good condition by
connection to be taken from ELCB & manually tripping method.2.
VRD. Use rubber mat during
welding work.

condition & with valid test certificate. before used. 2. Unauthorized
in the surrounding area. 4.
tackle.


conveyor .
Reviewed by:
Signature:
Name
Non Routine
Normal

workmen are
awarded on same
work
WG It is the part of Hot

work PTW system,
and also same was
implemented.
Same will be
implemented
before the job.
WG Implemented
WG implemented &
workmen are
awarded on same
work
WG implemented
work PTW system,
and also same was
implemented.
WG implemented &
workmen are
awarded on same
work
workmen are
awarded on
electrical safety.

workmen are
awarded on same
work
WG implemented &
workmen are
awarded on same
work

work PTW system,
and also same was
implemented.
Approved by:
Signature:
Name
Job Title Take-up Pulley position adjustment
Area 230/231
1 Both side conveyor Injury due to Drive/Conveyor Possibility of

belt locking. start. serious to fatal
accident

fracture injury

Fatal accident
Hand Injury due to spanner slip. Possibility of hand

fracture
2 Making arrangement Dust hazard Can be create

for lift the take-up breathing
pulley & lift by chain problems.
block.
Fatal accident

tools. serious hand injury
3 Making arrangement Sudden Jerk due to hanging of Possibility of
for pull / lift the loose belt serious body injury
conveyor by chain due to belt
block. movement.

breathing
problems.

Fatal accident

Injury due to unexpectedly Possibility of

running of conveyor serious to fatal
accident
4 Open all base bolts Hand Injury due to spanner slip. Possibility of
of plumber block for fracture injury
cover remove.
5 Pull the pulley shaft Chances of leakages of hydraulic Possibility of eye

and make shifted to oil with pressure. injury.
original position by
hydraulic.
hydraulic.

6 Alignment and fit up Packing Sims may be cut the Possibility of finger
all bolts. finger pressed under load
or get cut injury on
finger.

fracture injury
7 Start to be fixed back Fall from height of person or Possibility of

& all arrangements, object at the time remove locking fracture injury/
tools, tackle & belt from conveyor belt. Fatal accident
locking removing.

fracture injury
8 Take-up to be fixed Fall from height of person or Possibility of

back & all object at the time remove locking fracture injury/
arrangements, tools, from conveyor belt. Fatal accident
removing.

fracture injury
Prepared by:
Signature:
Name
Section/ Location:
Routine /NonRoutine
hav Normal/Abnormal/Emergency
Existing control measure to mitigate Existing / Base Additional control measure

hazard Risk
P S Risk
1.Area should be cleaned. 3 5 15 1.Area should be evacuated.

2. .Standard/ tested hand tools to be 2.Barricading should be
used. done in the surrounding
area.
1.Make ensure proper working 3 5 15 1. Take height permit.

platform for work at height. 2.
for height work

Use Nose Mask 5 1 5
1.Make ensure proper working 3 5 1.Fixed ladder to be provide.

for height work

condition & with valid test certificate. before used. 2.
tackle.
1.After slight loose of belt, 2 Nos. of 3 2 6
Belt Holding clamps-ISMC-200 has to
be fixed at take up bend area & belt
clamp is to be fixed at turn over
are.2.Unauthorized persons should
not be entry inside the work area.
Use Nose Mask 5 1 5
1.Make ensure proper working 3 5 1.Fixed ladder to be provide.

for height work

tackle.


1.Use proper PPE like safety shoe, 3 1 3

safety helmet, Safety goggles, cotton
dress & hand gloves. 2.Trained fitter
should be permit to operate the
hydraulic cylinder.
tackle.
Use cotton hand gloves. 3 1 3


for height work


for height work

Reviewed by:
Signature:
Name
(CV230-007,CV230-008A,CV231-005A,CV231006A)
Non Routine
Normal
Responsible Official to Implementation Status Residual Risk

implement P S Risk
AO,PA&WG LOTOTO procedure ensure 1 5 5
before the job.
WG/PA implemented & workmen 3 1 3

are awarded on same work
WG/PA implemented & Work at 1 5 5

PPE.

WG Implemented

PPE.
PA & WG implemented & workmen 2 2 4

WG & PA Implemented & checked
after locking.
WG Implemented

PPE.

PA &WG implemented & workmen 1 5 5



are used safety goggles
during job.
WG Implemented.


PPE.


PPE.

Approved by:
Signature:
Name
HAZAR
Job Title Triporcar Pulley lagging
Area 230

Impact
1 Position the crane for lift the Crane wheel/jack may go down in soil
counter weight of take-up till & injury or property damage due to
required height & rest on zero toppled the crane.
height.
Hydra may be hit to workman at the
time base plate fixing.
Hand injury during fixing the sling.
Fall of counterweight due to failure of

lifting tools or machine.
Fall from height of person during fixed

the D-shackle.
2 Both side conveyor belt locking. Injury due to Drive/Conveyor start.
Fall of materials
Fall from height of person or object at
the time locking the belt.
Hand Injury due to spanner slip.
3 Making arrangement for lift the Dust hazard

conveyor by chain block for make Fall from height of person during lift the
clearance to work. chain block.
Injury due to failure of Lifting tools.
4 Removal of old lagging for Fall from height of person or object at

surface preparation& lagging the time lagging the rubber
new rubber sheet sheet/pulley.
Electric shock may be connecting with

grinder.
Chemical hazard (May belt joint solution

split over the body/ eye during lagging
work).
5 Convert to be fixed back & all
arrangements, tools, tackle & belt Fall from height of person or object at
locking removing. the time remove locking from conveyor
belt.

6 Lift the counter weight of take-up Crane wheel/jack may go down in soil
till required height for conveyor & injury or property damage due to
tension. toppled the crane.
Hydra may be hit to workman at the

time base plate fixing.
Prepared by:
Signature:
Name
Section/ Location:
Routine /NonRoutine
Normal/Abnormal/Emergency

P S Risk
Iron plate should be placed on ground 3 4 12


3 3 9
1.Tested / standard hand tools to be used.

2. Use cotton hand gloves. 3. Avoid to 3 1 3
use D-spanner.
1.Load should be lifted as per crane

capacity. 2.Encure Crane & lifting tools
& Tackles with valid test certificate to be
use.
4 5 20
1.Make ensure proper working platform for

work at height.
3 5 15
Proper isolation to be done of same &

before conveyor. 4 5 20
1.Area should be cleaned. 2. .Standard/

3 5 15
work at height.
2. Use double lanyard safety harness. 3 5 15

2. Use cotton hand gloves. 3. Avoid to use 4 1 4
D-spanner.
Use Nose Mask 5 1 5

work at height.
2. Use double lanyard safety harness. 3 5
Chain block(Lifting tools) in good

4 3 12

work at height. 3 5 15
1.Use ELCB with 30mA.2. Use dry safety
taken from ELCB & VRD.
3 5 15
1.Apart from using mandatory PPEs(Safety

goggles & hand gloves). 2 2 4

work at height.

D-spanner.
Iron plate should be placed on ground 3 4 12
Keep distance minimum 3 mtr from hydra. 3 3 9
Reviewed by:
Signature:
Name
SMENT
Date:-
Section/ Location: Stracker
Additional control measure Responsible Official to Implementation Residual Risk

implement Status P S
The ground should be WG/PA Before start the job
compacted and levelled. 1 4
1.Ensure Reverse horn on the WG/PA During the Job

hydra. 2. Proper signalling
during marching should be 1 3
ensured.
First lift it 500mm from ground WG/PA During the Job

& take hold for 10m then start
lift. 2. Area
should be evacuated.
3.Barricading should be done in 1 5
1.Fixed ladder to be provided. PA/WG During the Job

2.
Height pass approved
person/technician engaged for 1 5
height work 3. Take height
permit.
LOTOTO procedure ensure PA &WG Before start the Job

before the job. 1 5
1.Area should be evacuated. WG/PA During the job

the surrounding area. 3 1
1. Take height permit. WG/PA Before the job
2. Height
pass approved 1 5
height work
WG During the Job
1 Ladder to be provide. PA & WG During the job

2.
Height pass approved 1 3
height work
1. Physical inspection ensure PA & WG Before start the Job
before used. 2. Unauthorized
the surrounding area. 4. Use 2 2

2. Height 1 5
pass approved
1.before start the work ensure WG/PA During the job
height work
the ELCB in good condition by
manually tripping method.2.
Use rubber mat during welding 3 1
work.

2. Height
pass approved 1 5
height work
WG During the Job
The ground should be WG/PA Before start the job
compacted and levelled. 1 4
1.Ensure Reverse horn on the WG/PA During the Job

hydra. 2. Proper signalling 1 3
during marching should be
ensured.
Approved by:
Signature:
Name
Residual Risk
Risk
3
5
5
4
3
HAZARD IDEN
Job Title Boom Conveyor Pulley lagging
Area 230

Impact
1 Relise the tension of Injury due to Drive/Conveyor
boom conveyors by start.
free of screw take-up.
Fall of materials
2 Proper isolation to be Dust hazard

done of same &
before conveyor.
1.Area should be Fall from height of person during

cleaned. lift the chain block.
2. .Standard/ tested
hand tools to be used.
1.Standatd/ tested Injury due to failure of Lifting

hand tools to be used. tools.
2. Use cotton hand
gloves. 3. Avoid to
use D-spanner.
3 Proper isolation to be
done of same & Fall from height of person or object
before conveyor. at the time lagging the rubber
sheet/pulley.
1.Area should be
cleaned.
hand tools to be used. Electric shock may be connecting
with grinder.
1.Standatd/ tested
2. Use cotton hand Chemical hazard (May belt joint
gloves. 3. Avoid to solution split over the body/ eye
use D-spanner. during lagging work).
4 Proper isolation to be
done of same & Fall from height of person or object
before conveyor. at the time remove locking from
conveyor belt.
1.Area should be
cleaned.
5 1.Standatd/ tested
2. Use cotton hand
gloves. 3. Avoid to Hand Injury due to spanner slip.
use D-spanner.
Prepared by:
Signature:
Name
Section/ Location:
Routine /NonRoutine
rghav Normal/Abnormal/Emergency

P S Risk
Proper isolation to be done of same & before
conveyor.
4 5 20
1.Area should be cleaned. 2. .Standard/

tested hand tools to be used. 3 1 3
1.Standatd/ tested hand tools to be used. 2.

Use cotton hand gloves. 3. Avoid to use D- 4 1 4
spanner.
Use Nose Mask

5 1 5

work at height.
3 5 15
Chain block(Lifting tools) in good condition

& with valid test certificate.
4 3 12

work at height.
1.Use ELCB with 30mA.2. Use dry safety
taken from ELCB & VRD.
3 5 15
1.Apart from using mandatory PPEs(Safety

goggles & hand gloves).
2 2 4

work at height.

Use cotton hand gloves. 3. Avoid to use D-
spanner.
4 1 4
1.Standatd/ tested hand tools to be used. 2. Use

cotton hand gloves. 3. Avoid to use D-spanner.
4 1 4
Reviewed by:
Signature:
Name
SSESSMENT
Date:-
Section/ Location: Stacker/ Reclimer

LOTOTO procedure ensure PA &WG
before the job.
1 5 5
WG/PA
WG
1 Ladder to be provide. PA & WG

2.
1 3 3
for height work
1. Physical inspection ensure PA & WG

before used. 2.
should be done in the 2 2 4
tackle.
1. Take height permit. WG/PA

2.
Height pass approved 1 5 5
for height work
1.before start the work WG/PA
ensure the ELCB in good
condition by manually
tripping method.2. Use 3 1 3
work.

2.
for height work
WG
WG
Approved by:
Signature:
Name
Job Title Belt Patching
Area 230/231
1 Grinding the damage Injury due to Drive/Conveyor Possibility of

area. start. serious to
fatal accident

with grinder. serious to
fatal accident
due to
electrocution
Body injury due to free grinder Possibility of

wheel serious to
fatal accident
or cut injury.
Eye injury due to foreign Possibility of

particles(Conveyor Dust) eye injury
2 Add solution on the Chemical hazard (May belt joint Possibility of

same place solution split over the body/ eye eye injury
3 Hammering the jointed May hit one own finger Hand Injury
area
Prepared by:
Signature:
Name
Section/ Location:
Routine /NonRoutine
harghav Normal/Abnormal/Emergency
hazard P S Risk
shoes.2.Grinding machine connection to ensure the ELCB in good
be taken from ELCB. condition by manually
work.
Wheel locknut proper tightening. 3 3 9 1. Use grinding wheel RPM

must be maximum from
RPM from grinding
machine.2. No workman
standing in font of the job.
Apart from using mandatory 2 2 4

Apart from using mandatory 2 2 4

1.Hammering should be done under 2 2 4 Trained Jointer / Technician

supervison should be deployed for the
2.First aid should be kept near the work job.
place.
Reviewed by:
Signature:
Name
All Conveyor
Non Routine
Normal

procedure ensure
before the job.

workmen are
awarded on
electrical safety.
WG/PA Good condition 2 3 6

machine & wheel
used.
WG implemented &
workmen are
awarded on
PPE's.
WG implemented &
workmen are
awarded on
PPE's.
WG/PA
Approved by:
Signature:
Name
Job Title Carrying Idler replacement.
Area 230/231
Risk assessment team membersMr. P.P.Bal, Mr. S.Rangaswami, Mr. K.Bharghav
1 Making arrangement Injury due to Drive/Conveyor Possibility of

for lifting the start. serious to
conveyer belt by fatal
chain block. accident

tools. serious hand
injury
2 Removals of old Hand Injury due to spanner slip. Possibility of

carrying/return idler fracture
& replace a new. injury
Fall of idler Possibility of

brunt /
facture
injury
3 Lowering the belt & Hand Injury due to spanner slip. Possibility of
remove the chain fracture
block. injury
Fall from height of person or object Possibility of

at the time lowering of belt. brunt /
facture
injury
Prepared by:
Signature:
Name
Section/ Location:
Routine /NonRoutine
Bharghav Normal/Abnormal/Emergency
hazard P S Risk
Proper isolation to be done of same 4 5 20 LOTOTO procedure ensure
& before conveyor. before the job.

condition & with valid test before used. 2.
certificate. Unauthorized persons are
tackle.

1. Trained technicians should be 3 1 3

engaged for lifting the conveyor.
2.Use cotton hand gloves.

1. Trained technicians should be 3 1 3

engaged. 2.Apart from using
mandatory PPEs (Safety harness).
Reviewed by:
Signature:
Name
Non Routine
Normal

procedure ensure
before the job.

workmen are
awarded on same
work
WG implemented &
workmen are
awarded on same
work
WG implemented &
workmen are
awarded on same
work
WG implemented &
workmen are
awarded on same
work
WG implemented &
workmen are
awarded on same
work
Approved by:
Signature:
Name
Job Title GEAR BOX & MOTOR ALIGNMENT.
Area 230/231
1 Make arrangement Fall from height of person or object Possibility of

for lifting/shifting at the time fixing the sling or chain fracture
the gear box. blocks. injury/ Fatal
accident
Fall of bolts & slip of hand tools Possibility of

from hands. hand fracture

tools. fracture
injury/ Fatal
accident
2 Open the all coupling Injury due to Drive/Conveyor Possibility of

bolt and gear box start. serious to
base bolts. fatal accident

hand fracture
3 Lift the gear box and Injury due to failure of Lifting Possibility of
shifted from original tools. fracture
position injury/ Fatal
accident
Fall of materials/gearbox Possibility of

fracture
injury/ Fatal
accident.
Also chance
of equipment
damage.
4 Make arrangement Hand tools may be slip from hand Possibility of

for remove the fracture
damage coupling. injury
Coupling may be fall on ground Body injury

& property
damage.
Hand may be compact with gear Possibility of

box & coupling. finger
pressed
under load or
get cut injury
on finger.
5 Heating the new Electric shock may be connecting Possibility of
coupling up to 160 with technician. serious to
Degree Celsius. fatal accident
due to
electrocution
Heating coupling may be contact Possibility of
with body. burn injury
due to hot
material
contact.
6 Fitting the new Fall of heated coupling. Possibility of

coupling. body injury
7 Lifting the Gear box Failure of chain block/ sling Possibility of

and fit up all base serious hand
bolts. injury
Fall of materials/gearbox Possibility of

fracture
injury/ Fatal
accident.
Also chance
of equipment
damage.
8 Alignment and fit up Slip tools/bolt from hands. Possibility of
all coupling bolts. hand injury
Finger may be compact with base Possibility of

& gear box. finger
pressed
under load or
get cut injury
on finger.
Packing Sims may be cut the finger Possibility of

cut injury on
finger.
9 Remove the all lifting Fall from height of person or object Possibility of
arrangement at the time remove the sling or fracture
chain blocks. injury/ Fatal
accident
Fall of bolts & slip of hand tools Possibility of

from hands. hand fracture
Prepared by:
Signature:
Name
Section/ Location:
Bharghav Normal/Abnormal/Emergency Normal
Existing control measure to mitigate Existing / Additional control measure Responsible

hazard Base Risk
P S Risk Official to
implement
1.Make ensure proper working 3 5 15 1. Take height permit. WG/PA
for height work
1.Standatd/ tested hand tools to be 4 1 4 WG

Chain block(Lifting tools) in good 4 3 12 1. Physical inspection ensure PA & WG

tackle.
Proper isolation to be done of same & 4 5 20 LOTOTO procedure ensure AO,PA&W

before conveyor. before the job. G

tackle.
1.Area should be cleaned. 3 5 15 1.Area should be evacuated. WG/PA

area.

Coupling hold by chain block. 2 1 2
1. Trained technicians should be 3 1 3 WG

engaged for lifting the equipment.
1.Use ELCB with 30mA.2. Use dry 3 5 15 1.before start the work WG/PA
safety shoes.2.Heatter connection to be ensure the ELCB in good
taken from ELCB/MCB.. condition by manually
rubber mat during electric
work.
Use Cotton dress. 2 1 2 WG/PA
Trained MWF should be engaged to 2 1 2

fixing the coupling

tackle.
1.Area should be cleaned. 3 5 15 1.Area should be evacuated. WG/PA

area.
Proper hand tools may be used. 3 1 3

engaged for lifting the equipment.
Proper hand tools may be used. 3 1 3

1.Make ensure proper working 3 5 15 1. Take height permit. WG/PA
platform/ Ladder for work at height. 2.
for height work
Area should be evacuated. Load 3 1 3 WG

should be lifted less than chain
block /wire rope sling/ load capacity
Reviewed by: Approved by

Name Name
on Routine
ormal
Implementation Status Residual R

P S Risk
implemented & Work 1 5 5
at height trained
already given to
workers. Also they are
very well know about
use of PPE.
implemented &
workmen are awarded
on same work

at height trained
already given to
use of PPE.
LOTOTO procedure 1 5 5
implemented &
workmen are awarded
on same work
at height trained
already given to
use of PPE.
implemented & 3 1 3
workmen are awarded
on Equipment lifting
procedure.
implemented &
workmen are awarded
on same work
implemented &
workmen are awarded
on same work
implemented & 3 1 3
workmen are awarded
on electrical safety.
implemented &
workmen are awarded
on handle hot material
implemented &
workmen are awarded
on handle hot material
implemented & 2 2 4
workmen are awarded
on same work
implemented & 3 1 3
workmen are awarded
on Equipment lifting
procedure.
implemented &
workmen are awarded
on same work
implemented &
workmen are awarded
on same work
implemented &
workmen are awarded
on same work
at height trained
already given to
use of PPE.
implemented &
workmen are awarded
on same work
HAZARD IDENT
Job Title Air blaster fixing/ replacement
Area 230/231

Impact
step
1 Making arrangement for Failure of chain block/ sling Possibility of serious
lifting & fixing manual hand injury
working platform inside
chute.
Injury due to Drive/Conveyor Possibility of serious

start. to fatal accident
Fall from height of person during Possibility of fracture

ascending & descending in side injury/ Fatal accident
chute.
Suffocation Possibility of serious

to fatal accident due to
breathing problem.
Fire hazard Possibility of serious
to burn injury
Hand Injury due to spanner slip. Possibility of fracture

injury
2 Remove of existing Liner Fall & Slip hazard Possibility of serious

plate &Chute mother plate hand injury
as per required.

to burn injury
Injury due to material (Bauxite) fall Possibility of serious

from chute. body injury
Hand Injury due to spanner slip. Possibility of fracture

injury
Electric shock may be connecting Possibility of serious

with technicians to fatal accident due to
electrocution
Injury due to failure of Lifting Possibility of serious
tools. hand injury
3 Lift the air blaster & fixing Failure of Lifting tools. Possibility of serious
at fixing point. hand injury
Fall & Slip hazard Possibility of serious

body injury

to burn injury
Electric shock may be connecting Possibility of serious

with technicians to fatal accident due to
electrocution
4 Remove of working Hand Injury due to spanner slip. Possibility of fracture

platform & all Accessories injury

to burn injury
Prepared by:
Signature:
Name
Section/ Location:
Routine /NonRoutine
Existing control measure to mitigate Existing / Base Additional control

hazard P RiskS Risk measure
Chain block(Lifting tools) in good condition 4 3 12 1. Physical inspection ensure
& with valid test certificate. before used. 2.
tackle.
Proper isolation to be done of same & before 4 5 20 LOTOTO procedure ensure

conveyor. before the job.
1.Make ensure proper working platform for 3 5 15 1.Manlift use in place of

work at height. working platform.
2. Use double lanyard safety harness. 2.
for height work
1.Must be tested Oxygen leave between 19.5 3 4 12 1. Training is required for all
to 23.5 inside chute by multi gas tester. 2. employees working in /
Take confined space permit from with Permit required
authorization person. confined spaces. 2. pass
holder only allow to work
inside confined space. 3.
Attendant must be deployed
near the entrance location.
1.Gas Test should be done before starting the 4 4 16 1. If flammable gas present
job & Ensured that no flammable gas should then purging should be
be present inside the confined space. done. 2.A Proper rescue
2. Fire extinguisher keep near by work plane should be available &
place. 3. There should be proper means of brief to the workman.
access should be provided for the access &
egress.
1.Standatd/ tested hand tools to be used. 2. 4 1 4

spanner.
1. Work on the working platform. 2.

Additional locking by PP rope. 3.Apart from
using mandatory PPEs(Safety Harness). 3 2 6
1.Fire extinguisher keep near by work place.

2. Depute fire watcher on the job.3. Cover
Fire blanket over the conveyor . 1 3 3
1.Chut proper cleaning before start the job.2. 2 2 4

Before & after conveyor drive should be
isolated.

spanner. 4 1 4
shoes.2.Welding machine connection to be ensure the ELCB in good
taken from ELCB & VRD. condition by manually
work.
tackle.

tackle.
1. Work on the working platform. 2.

Additional locking by PP rope. 3.Apart from
using mandatory PPEs(Safety Harness). 3 2 6

shoes.2.Welding machine connection to be ensure the ELCB in good
taken from ELCB & VRD. condition by manually
work.

spanner.

Reviewed by:
Signature:
Name
Non Routine
Normal

workmen are
awarded on same
work

ensure before the
job.

Work at height
trained already
given to workers.
Also they are very
well know about use
of PPE.
PA & WG It is the part of PTW 1 3 3

system, and also
same was
implemented.
AGT,AO&PA It is the part of Hot 1 4 4
work PTW system,
and also same was
implemented.
WG implemented &
workmen are
awarded on same
work
WG

work PTW system,
and also same was
implemented.
PA & WG Same will be

implemented before
the job.
WG
workmen are
awarded on
electrical safety.
WG Same will be
implemented before
the job.
WG
workmen are
awarded on
electrical safety.
WG implemented &
workmen are
awarded on same
work

work PTW system,
and also same was
implemented.
Approved by:
Signature:
Name
HAZARD IDEN
Job Title Slew Bolt Torquing of Stacker and Reclaimer
Area 230/231

Impact
lifting tools may slip Hand injury
Drive/Conveyor may be start Slip, Trip, Fall
Breathing Diffi
Suffocation
Move position of Boom
conveyor receiving
1
chute to create space
for working Trap in fire
Fire hazard
2 Torque wrench may slip. Hand injury

Fall & Slip hazard Slip injury
Slew bolt torqueing
Foreign particle may be inside to the eyeEye sight
lifting tools may slip Hand injury
Drive/Conveyor may be start Slip, Trip, Fall
Breathing Diffi
Suffocation
conveyor receiving
3
Breathing Diffi
Suffocation
conveyor receiving
3
chute to create space
for working
Trap in fire
Fire hazard
Prepared by:
Signature:
Name
Section/ Location:
Routine /NonRoutine
av Normal/Abnormal/Emergency

P S Risk
Load should be lifted less than lifting tools capacity 2 2 4
Trained technicians should be engaged for lifting th
Proper isolation to be done of boom conveyor & LT. 2 3 6
Gas Test should be done before starting the job & 2 4 8

Oxygen level should be ensured 19.5% to 23.5%
A entry & exit register/document should be maintain
Fire extinguisher keep near by work place. 2 4 8
Gas Test should be done before starting the job &

Ensured that no flamable gas should be present
inside
There the confined
should space.
be proper means of access should
be provided for the access & egress.
Fire extinguisher to be kept near work place.
Standard hand tools to be used 2 2 4

Make standard working platform. 2 3 6
Trained fitter & rigger should be engaged
Along with standard PPE's ; Safety googles to be us 2 3 6
Trained technicians should be engaged for lifting th

Proper isolation to be done of boom conveyor & LT. 2 3 6

A entry & exit register/document should be maintain

inside
There the confined
should space.
be proper means of access should
be provided for the access & egress.
Fire extinguisher to be kept near work place.
Reviewed by:
Signature:
Name
ESSMENT
Date:-
Section/ Location:

Chain block with valid test WG&PA Checked and
certificate 1 2 2
Use hand should
gloves. be used verified
LOTO & permit should be WG&PA

display on work permit display 2 2 4
board.
Authorised gas tester to be WG&PA
deployed for the job
Worker with confined space
pass should be work inside the 2 2 4
confined
24 Volt DCspace.
light Should be used
inside the confined space.
Rescue plane should be WG&PA
available & briefed to the
workman.
Rescue Signal system should
be provided.
24 Volt DC light Should be used 2 2 4
Standard gas cutting set cutting
set with NRV / FBA o be used
House keeping to be ensured WG&PA 2 2 4

near thesafety
Tested surroundings
harness to be WG&PA
2 2 4
used
WG&PA 2 2 4
Chain block with valid test WG&PA
certificate should be used 2 2 4
Use hand gloves.
LOTO & permit should be WG&PA
display on work permit display 2 2 4
board.
Authorised gas tester to be WG&PA
deployed for the job
2 2 4
WG&PA

pass should be work inside the
confined space. 2 2 4
24 Volt DC light Should be used
Rescue plane should be WG&PA

available & briefed to the
workman.
Rescue Signal system should
be provided.
24 Volt DC light Should be used 2 2 4
Standard gas cutting set cutting

set with NRV / FBA o be used
Approved by:
Signature:
Name
HAZARD IDENTIF
Job Title PM of PCRD and CCRD
Area

Impact
1 Check for wear in torque Hand

arm ,pins & plane Injury
bearings of gear box Spanner slip.
torque arm. Dust and Foreign Particle emission Eye Injury
All pulleys Plummer

2 Spanner
block base bolt tightness slip.
& lubrication. Hand
Injury
Grease/oil may splash in eye Eye Injury
3 Lubricate torque arm planGrease/oil may splash in eye Eye Injury
4 Check tightness of base Spanner slip. Hand Injury

5 Lubricate all bearing blocSpanner slip. Hand Injury
6 Check tension in Spanner slip. Hand Injury
pendulum drive chain in
both PCRDby:
Prepared & CCRD &
adjust if
Signature:required
Name
Section/ Location:
Routine /NonRoutine

P S Risk
Tools of Proper size to be used 2 3 6
Dust or Nose masks to be used 2 3 6
Safety Goggles to be used 1 3 3
Safety Goggles to be used 1 3 3

Reviewed by:
Signature:
Name
ESSMENT
Date:-
Section/ Location:
Additional control measure Responsible Official Implementation Residual Risk

Hand Gloves to be used and PA & WG 1 2 2
Trained technician to be
deployed
House Keeping to be ensured PA & WG 2 2 4
Hand Gloves to be used PA & WG 2 2 4
Trained Technician to be PA & WG 1 3 3

deployed
Trained Technician to be PA & WG 1 3 3
deployed
Approved by:
Signature:
Name
HAZARD ID
Job Title JSA for Rail bolt tightening
Area BHP

Impact
Spanner may slip. Minor

Equipmen
t may
collide
Rail base bolt tightness Long Travel may be strike.
1 with
checking personnel
working
Dust Emission Dust
entering
into Eyes
Prepared by: and Nose
Signature:
Name
Section/ Location:
Routine /NonRoutine

P S Risk
Spanner of exact size is used 2 1 1
Ensure elctrical Isolation of Long Travel and 2 3 6
Equipment
Working at a safe distance from Equipment
Wear Standard Dust Masks & Mono goggles 2 2 4
Reviewed by:
Signature:
Name
SSESSMENT
Date:-
Section/ Location: Reclimer & Stracker

Ensuring exact tool size PA & WG 1 1
Supervison of Job PA & WG 1 2
Area to be barricated PA & WG
Ensure Hooter Sound while PA & WG
Running the equipment
PA & WG
Following Covid -19 precautions PA & WG 1 1
PA & WG
Approved by:
Signature:
Name
Residual Risk
Risk
1
2
1
HAZARD IDEN
Job Title Boom Conveyor PM.
Area BHP

Impact
Drive motor & gear

1 box base bolt Spanner slip.
tightness checking
Spanner slip.
Coupling checking,
2 cleaning &
lubrication.
Foreign particle may be inside to
the eye.
All pulleys Plummer

3 block base bolt Spanner slip.
tightness &
lubrication.
Spanner slip.
Discharge chute liner
4 checking
Material (Bauxite) fall hazard
Removals of old Fall of idler

carrying/return idler
& replace a new. Hand injury
5
6 Internal & external Spanner slip.

scraper checking.
Spanner slip.
7 Skirt rubber checking.
Conveyor may be start

Prepared by:
Signature:
Name
Section/ Location:
Routine /NonRoutine

P S Risk
spanner.

4 1 4
spanner.

3 1 3
goggles).

spanner.

spanner.
2 2 4
1.Chut proper cleaning before start the job.2.
Before & after conveyor drive should be isolated.
1. Trained technicians should be engaged for

3 1 3
lifting the conveyor. 2.Use cotton hand gloves.
spanner.

spanner.

spanner.
Proper isolation to be done of same & before

conveyor. 4 5 20
Reviewed by:
Signature:
Name
SSESSMENT
Date:-
Section/ Location: Tripercar

WG/PA
WG
WG
WG
WG
PA & WG
WG
WG
WG
WG

before the job. 1 5
Approved by:
Signature:
Name
Residual Risk
Risk
5
Job Title JSA for Divertor Gate replacement
Area BHP
Risk assessment team membersMr. P.P.Bal, Mr. S.Rangaswami, Mr. K.Bharghav
SN Basic step of the Job Hazard(s) associated with Impact

the step
1 Making arrangement Fall from height of person Possibility of fracture
for chain block fixing during platform injury/ Fatal accident
& scaffolding fixing prepairaction.
in side chute.
Injury due to Possibility of serious

Drive/Conveyor start. to fatal accident
Hand injury Possibility of fracture

injury
Electric shock may be Possibility of serious

connecting with technicians to fatal accident due
to electrocution
to burn injury
2 Side flanch bolt Injury due to failure of Possibility of serious

remove & actuator Lifting tools. hand injury
assemble
dismantling.
Hand injury Spanner slip. Possibility of fracture

injury
3 Non-drive side Hand injury Spanner slip. Possibility of fracture

plumber block injury
assemble removing.
4 Side plate with Fall from height of person or Possibility of fracture
divetor gate object at the time fixing the injury/ Fatal accident
dismantling. sling or chain blocks.
Failure of lifting tools & Possibility of fracture

tackles. injury

to burn injury
5 New divetor gate Spanner slip. Possibility of fracture

fixing. injury
fixing.
Failure of lifting tools & Possibility of serious

tackles. body injury/ fatal.

to burn injury

connecting to the to fatal accident due
technicians. to electrocution
Fall & Slip hazard Possibility of serious
body injury
6 Existing side plate Spanner slip. Possibility of fracture

fixing & bolting. injury
Failure of lifting tools & Possibility of fracture

tackles. injury

connecting to the to fatal accident due
technicians. to electrocution
Prepared by:
Signature:
Name
Section/ Location:
Routine /NonRoutine
arghav Normal/Abnormal/Emergency
Existing control measure to mitigate Existing / Base Additional control

hazard Risk
P S Risk measure
1.Make ensure proper working platform for 3 5 15 1.Height pass approved
work at height. person/technician engaged
2. Use double lanyard safety harness. for height work
Proper isolation to be done of same & before 4 5 20 LOTOTO procedure ensure

conveyor. before the job.

spanner.
shoes.2.Welding machines will be connected ensure the ELCB in good
through VRD in the secondary unit & ELCB condition by manually
in the primary unit 3. Proper electrical tripping method.2. Rubber
connection shall be provided to machine & mat shall be provided for
switches. welding machine. 3.
Competent / authorized
and licensed electrician with
trade validation certificate
shall only be permitted to
work on electrical lines.
1. Valve protection caps shall be in placed on 3 4 12 1. Gas cutter must be use
gas cylinder and secured properly. 2. Flash safety helmet, safety shoes,
back arrester must be connected at both end hand gloves, full sleeve
of cutting set. Hose shall be connected with cotton dress, leg guard etc.
cutting torch as well as with the cylinder by Hose pipe, regulator, cutting
crimping clamp only. 3. Gas cutting work torch, Flash back arrester
shall be done in enclosed areas with proper shall be checked before use.
supervision. Cotton dress shall be used
by gas cutters. 2. Fire
extinguishers, sand buckets,
water shall be kept ready at
site. Ceramic cloth/Spatter
arrester tray shall be used
for arrest the spatters falling
from height.

tackle.

spanner.

spanner.
1.Make ensure proper working platform for 3 5 15 1.Fixed ladder to be
work at height. provided.
2. Use double lanyard safety harness. 2. Height pass
approved person/technician
engaged for height work 3.
Take height permit.
1.Load should be lifted as per lifting tools 4 3 12 1. Physical inspection ensure

capacity. 2.Encure all lifting tools & before used. 2.
Tackles with valid test certificate to be use. Unauthorized persons are
tackle.

from height.

spanner.
tackle.

from height.
1. Proper approach.2. Use of Full body 3 5 15 1. Take height permit.
harness with shock absorber double lanyards, 2.
for height work
spanner.

tackle.
Reviewed by:
Signature:
Name
Non Routine
Normal

Work at height
trained already
given to workers.
Also they are
very well know
about use of PPE.
procedure ensure
before the job.
WG implemented &
workmen are
awarded on same
work
workmen are
awarded on
electrical safety.
WG/PA Same will be 3 1 3
implemented
before the job.
PA & WG Before start the 2 2 4

Job
WG implemented &
workmen are
awarded on same
work
WG implemented &
workmen are
awarded on same
work
PA/WG implemented & 1 5 5
Work at height
trained already
given to workers.
Also they are
very well know
about use of PPE.

workmen are
awarded on same
work

implemented
before the job.
WG implemented &
workmen are
awarded on same
work
workmen are
awarded on same
work

implemented
before the job.
workmen are
awarded on
electrical safety.
implemented
before the job.
WG implemented &
workmen are
awarded on same
work

workmen are
awarded on same
work
Work at height
trained already
given to workers.
Also they are
very well know
about use of PPE.
Approved by:
Signature:
Name
Job Title JSA for Drive base strenghting.
Area BHP
1 Make proper working Fall from height of person during Possibility of fracture
platform(Scaffold). platform preparation. injury/ Fatal accident
2 Make arrangement for Spanner slip. Possibility of fracture injury

fixing the chain block.
Failure of chain block. Possibility of serious hand

injury
3 Lifting the beam to Failure of lifting tools during lift Possibility of serious body
fixing location & locking the load. injury/fatal accident.
by proper welding.
Fall from height of person or object Possibility of fracture
at the time of lift. injury/ Fatal
accident/property damage.
Fire hazard Possibility of serious to burn

injury
4 Welding the stipneer Fall & Slip hazard Possibility of serious body
plate for beam injury
strengthen.
strengthen.

injury
Conveyor may be start. Possibility of serious to fatal

accident
Hand Injury Possibility of fracture injury
Failure of Lifting tools. Possibility of fracture injury

Fall from height of person or object Possibility of fracture
at the time of lifting . injury/ Fatal
5 Remove all arrangement. Fall from height of person or object Possibility of fracture
at the time remove the sling. injury/ Fatal
Prepared by:
Signature:
Name
Section/ Location:
Routine /NonRoutine

P S Risk
work at height.

spanner.
Chain block(Lifting tools) in good condition 4 3 12

1.Load should be lifted as per lifting tools 4 3 12

capacity. 2.Encure all lifting tools &
Tackles with valid test certificate to be use.
work at height.
1. Valve protection caps shall be in placed on 3 4 12

gas cylinder and secured properly. 2. Flash
back arrester must be connected at both end
of cutting set. Hose shall be connected with
cutting torch as well as with the cylinder by
crimping clamp only. 3. Gas cutting work
shall be done in enclosed areas with proper
supervision.
1. Proper approach.2. Use of Full body 3 5 15

harness with shock absorber double lanyards,
supervision.
Proper isolation to be done of same & before 4 5 20

conveyor.

spanner.

work at height.

work at height.
Reviewed by:
Signature:
Name
Date:-
Section/ Location:

1.Height pass approved PA & WG implemented & 1 3
person/technician engaged Work at height
for height work trained already
given to workers.
Also they are very
well know about use
WG of PPE.
implemented &
workmen are
awarded on same
work
1. Physical inspection ensure PA & WG implemented & 2 2

before used. 2. workmen are
Unauthorized persons are awarded on same
not allowed. 3.Barricading work
tackle.

tackle.
1.Fixed ladder to be PA/WG implemented & 1 5
provided. Work at height
2. Height pass trained already
approved person/technician given to workers.
engaged for height work 3. Also they are very
Take height permit. well know about use
of PPE.
1. Gas cutter must be use WG/PA Same will be 3 1

safety helmet, safety shoes, implemented before
hand gloves, full sleeve the job.
cotton dress, leg guard etc.
Hose pipe, regulator, cutting
torch, Flash back arrester
shall be checked before use.
Cotton dress shall be used
from height.
1. Take height permit. WG/PA 1 5

2.
for height work
1. Gas cutter must be use WG/PA Same will be 3 1
safety helmet, safety shoes, implemented before
hand gloves, full sleeve the job.
from height.
LOTOTO procedure ensure AO,PA&WG LOTOTO procedure 1 5

before the job. ensure before the
job.
WG implemented &
workmen are
awarded on same
work

tackle.
of PPE.

of PPE.
Approved by:
Signature:
Name
Risk
Risk
3
4
5
5
3
4
5
5
Job Title JSA for Take-up Pulley replacement
Area BHP
SN Basic step of the Job Hazard(s) associated with Impact

the step
1 Positioning of crane Crane wheel/jack may Injury or property damage
for lifting the take-up go down in soil due to toppled the crane
pulley.
Hydra may be hit to Injury to people/workman

workman at the time
base plate fixing.
Hand injury during hand injury

fixing the sling.
Fall of pulley due to Possibility of serious to fatal

failure of lifting tools accident
or Crane.
Fall from height of Possibility of serious to fatal

person during fixed accident
the D-shackle.
2 Both side conveyor Injury due to Possibility of serious to fatal

belt locking. Drive/Conveyor start. accident
Fall of materials Possibility of serious to fatal

accident
Fall from height of Possibility of serious to fatal
person or object at the accident
time locking the belt.
Hand Injury due to Possibility of fracture injury

spanner slip.
3 Lift the counter weight Dust hazard Can be create breathing

of take-up till required problems.
height.
Fall from height of Possibility of fracture injury/
person during lift the Fatal accident
chain block.
Injury due to failure of Possibility of fracture injury

Lifting tools.
Drive/Conveyor may be Possibility of serious to fatal

start. accident
4 Remove the Fall & Slip hazard Possibility of serious body

beam/channel/sheet / injury
handrails from the
lifting position.
beam/channel/sheet /
handrails from the
lifting position.

injury
5 Lift the take-up pulley Personal injury due to Possibility of serious body
from ground to take-up unauthorized person injury
floor. inside the erection area.
Failure of crane, Possibility of fracture injury

slings/D-shackle.
Fall of materials Possibility of serious to fatal

accident
6 Both side conveyor belt Fall of tools and Belt Possibility of serious to
locking/ clamping. clamp injury.
locking/ clamping.
Fall of persons/ trip Possibility of fracture injury/

hazard on the conveyor Fatal accident/property
due to unstable surface
damage.
Prepared by:
Signature:
Name
Section/ Location:
Routine /NonRoutine

P S Risk
3 4 12
Iron plate should be placed on ground before
posting of crane.
3 3 9
1.Tested / standard hand tools to be used. 3 1 3

D-spanner.
1.Load should be lifted as per crane capacity. 4 5 20

2.Encure Crane & lifting tools & Tackles
with valid test certificate to be use.

work at height.

conveyor.

work at height.

spanner.
Use Nose Mask 5 1 5

work at height.


conveyor.

supervision.
Trained flagman & supervisor shall be 3 3 9

deployed attraction area to minimize the
hazard.


1.Area should be cleaned. 2. tools hold 3 5 15

properly.
work at height.
Reviewed by:
Signature:
Name
Date:-
Section/ Location:

The ground should be PA& WG Before start the 1 2 2
compacted and levelled. job it was
completed
1.Ensure Reverse horn on PA& WG Training 1 3 3

the hydra. 2. Proper implemented
signalling during marching
should be ensured.
WG Implemented
First lift it 500mm from PA& WG During the Job 1 5 5

ground & take hold for 10m ensure the load
then start lift. lifting
2. Area should be
evacuated. 3.Barricading
surrounding area.
1.Manlift use in place of AO,PA & WG Training 1 5 5

working platform. provided to the
workers.
1.Make ensure proper
working platform for work
at height.
harness.
LOTOTO procedure ensure AO&PA LOTOTO system 1 5 5

1.Area should be evacuated. WG/PA Implemented 3 1 3

2.Barricading should be
done in the surrounding
area.
1. Take height permit. WG/PA Training 1 5 5
2. provided to the
Height pass approved workers.
for height work
WG implemented &
workmen are
awarded on
same work
WG Implemented
1.Fixed ladder to be PA/WG implemented & 1 5 5

approved person/technician given to
engaged for height work 3. workers. Also
Take height permit. they are very
well know
about use of
PPE.

Unauthorized persons are awarded on
not allowed. 3.Barricading same work
tackle.
LOTOTO procedure ensure AO&PA LOTOTO system 1 5 5

1. Take height permit. WG/PA Same will be 1 5 5

2. implemented
Height pass approved before the job.
for height work
1. Gas cutter must be use WG/PA Same will be 3 1 3
safety helmet, safety shoes, implemented
hand gloves, full sleeve before the job.
from height.
Cordoning around erection WG Implemented 3 1 3

area shall be done by
indicative barricades.

Unauthorized persons are awarded on
not allowed. 3.Barricading same work
tackle.

area.

area.
1.Fixed ladder to be PA/WG implemented & 1 5 5
approved person/technician given to
engaged for height work 3. workers. Also
Take height permit. they are very
well know
about use of
PPE.
Approved by:
Signature:
Name
HAZARD IDEN
Job Title JSA for Drive Pulley replacement
Area BHP

Impact
Spanner slip.
Spanner slip.
Hand injury during fixing the

sling.
Positioning of crane for Fall of pulley due to failure of

1 lifting the take-up lifting tools or Crane.
pulley.
Fall from height of person during

fixed the D-shackle.

start.
Fall of materials
Both side conveyor belt

2
locking.
Both side conveyor belt Fall from height of person or object
2 at the time locking the belt.
locking.
Dust hazard
lift the chain block.

Lift the counter weight of tools.
3 take-up till required
height.
Drive/Conveyor may be start.
Failure of chain block/ sling

start.
Making arrangement for Fall from height of person during
4 lifting hood cover from ascending & descending in side chute.
drive
4 lifting hood cover from
drive
Fall & Slip hazard
Personal injury due to unauthorized

person inside the erection area.
Failure of crane,slings/D-shackle.
Lift the take-up pulley
5 from ground to take-up
floor.
Prepared by:
Signature:
Name
Section/ Location:
Routine /NonRoutine

P S Risk
Iron plate should be placed on ground before 3 4 12

posting of crane.

3 3 9

D-spanner.
1.Load should be lifted as per crane capacity.

4 5 20

work at height.
3 5 15

conveyor.
work at height.

spanner.
Use Nose Mask 5 1 5

work at height.


conveyor.
Chain block/ sling(Lifting tools) in good 4 3 12


conveyor.
1.Make ensure proper working platform/ 3 5 15
Ladder for work at height.
spanner.


deployed aterection area to minimize the
hazard.

Reviewed by:
Signature:
Name
SESSMENT
Date:-
Section/ Location:

The ground should be WG/PA
compacted and levelled. 1 4 4
1.Ensure Reverse horn on WG/PA

the hydra. 2. Proper
1 3 3
should be ensured.
First lift it 500mm from WG/PA

ground & take hold for 10m
then start lift.
2. Area should be
evacuated. 3.Barricading 1 5 5
surrounding area.
1.Fixed ladder to be PA/WG

provided.
2. Height pass
approved person/technician 1 5 5
Take height permit.

before the job. 1 5 5
1.Area should be evacuated. WG/PA

done in the surrounding 3 1 3
area.
2.
for height work
WG
1.Fixed ladder to be provide. PA & WG
2. Height pass approved

person/technician engaged 1 3 3
for height work

before used. 2.
tackle.


before used. 2.
tackle.


2.
for height work
WG

2.
for height work
Cordoning around erection WG

area shall be doneby
indicative barricades. 3 1 3
First lift it 500mm & take WG/PA

hold for 10m then start lift.
2. Area
3.Barricading should be 1 5 5
area.
Approved by:
Signature:
Name
HAZARD IDENTI
Job Title JSA for Snub Pulley replacement.
Area BHP

Impact
Spanner slip.
Spanner slip.
Hand injury during fixing the

sling.
Positioning of crane Fall of pulley due to failure of

1 for lifting the take-up lifting tools or Crane.
pulley.

fixed the D-shackle.

start.
Fall of materials
Both side conveyor

2
belt locking.
Both side conveyor
2 Fall from height of person or object
belt locking.
at the time locking the belt.
Dust hazard
lift the chain block.

Lift the counter weight tools.
3 of take-up till required
height.
Drive/Conveyor may be start.
Failure of chain block/ sling

start.
Making arrangement Fall from height of person during
4 for lifting hood cover ascending & descending in side chute.
from drive

Fall & Slip hazard
Personal injury due to unauthorized

person inside the erection area.
Failure of crane,slings/D-shackle.
Lift the take-up pulley
5 from ground to take-up
floor.
Prepared by:
Signature:
Name
Section/ Location:
Routine /NonRoutine

P S Risk
Iron plate should be placed on ground before 3 4 12

posting of crane.

3 3 9

D-spanner.
1.Load should be lifted as per crane capacity.

4 5 20

work at height.
3 5 15

conveyor.
work at height.

spanner.
Use Nose Mask 5 1 5

work at height.


conveyor.
Chain block/ sling(Lifting tools) in good 4 3 12


conveyor.
1.Make ensure proper working platform/ 3 5 15
Ladder for work at height.

spanner.

deployed aterection area to minimize the
hazard.

Reviewed by:
Signature:
Name
ESSMENT
Date:-
Section/ Location:

The ground should be WG/PA
compacted and levelled. 1 4 4
1.Ensure Reverse horn on WG/PA

the hydra. 2. Proper
1 3 3
should be ensured.
First lift it 500mm from WG/PA

ground & take hold for 10m
then start lift.
2. Area should be
evacuated. 3.Barricading 1 5 5
surrounding area.
1.Fixed ladder to be PA/WG

provided.
2. Height pass
approved person/technician 1 5 5
Take height permit.

1.Area should be evacuated. WG/PA

done in the surrounding 3 1 3
area.
2.
for height work
WG
1.Fixed ladder to be provide. PA & WG
2. Height pass approved

person/technician engaged 1 3 3
for height work

before used. 2.
tackle.


before used. 2.
tackle.


2.
for height work
WG
2.
for height work
Cordoning around erection WG 3 1 3
area shall be doneby
indicative barricades.
First lift it 500mm & take WG/PA 1 5 5

hold for 10m then start lift.
2. Area
area.
Approved by:
Signature:
Name
HAZARD IDENT
Job Title Replacement of conveyor belt CV-230-007/008
Area BHP

Impact
Tilting of stand while the belt is
being changed; personnel injury
, belt damage
New belt roll shoud
1 be put on a
fabricated stand
person may fall from height

while descending the ladder to
takeup platform
Lift the CW to slip of lifting tools /failure of
realease the chain blocks
2
tension on belt by
atleast 6-8 inches
finger injury due to slipping of

spanner during tightening
Clamp the belt at

conveyor deck plate loss of balance due to improper
by 4sets of jam grip between the clamps during
3 angles at tightening; hand injury
designated places
to restrict any belt
movement belt may snap away from the
clamping zone
Cutting of old belt to finger injury due to sharp tool
be discarded on
4 return side
The loose end of Hand injury

the old belt on tail electrocution while making drill
end side to be hole for fixing fasteners
attached to new belt
5
by belt fastener
The other end of the Hand injury

old belt to be
fastened to rope electrocution
sling attached to T
6
shape fore clamp
for pulling &
removal of old belt
person injury due to collision

with moving vehicle
Release the jam Sling distortion ,breakage and

angles and pull the fail if the load tension increases
old belt manually or while pulling
by some external
pulling device(like
7 winch or pay
loader).The new
belt to be pulled
from reel by inching
drive with local
switch if required
pulling device(like
7 winch or pay
loader).The new
belt to be pulled
from reel by inching The fore clamp/knot may
drive with local rupture and lead to accident if
switch if required not adequately secured to pull
the belt
1.Finger injury at idler nip

points/compression between
girders, plattens while setting of
belt for joint alignment
2.Cut injury while using knife
Once the entire belt 3.Failure of hook chuck during
profile is replaced splicing
with new belt, hold 4. Shock while plugging power
the ends of the belt tool to socket
8 by jam angles and 5.Trip hazard due to poor laying
perform of cable
vulcanisation as per 6. Spark due to loose
SMP to make the connection
belt endless 7.Fire
8.Eye injury due to flee
particulates during buffing
Fall of belt clamps
Finger injuring while fixing idlers

Removal of both
if stuck between belt and idlers
9
ends jam angles
after vulcanisation
and fixing idlers.
Prepared by:
Signature:
Name
/008 Section/ Location:
Routine /NonRoutine

P S Risk
1.heavy stand and recommended shaft
size for supporting belt roll;
2. Both side of belt roll locked by clamp
and stand placement is on an permanent
anchored foundation 2 4 8
certified safety harness to be used while

descending 1 4 4
1.Hard hat shall be worn at all times/Once

lifted the takeup centre beam is
additionaly held by suitable capacity
sling; 2 3 6
2.Takeup must be lifted and held with two
numbers of suitable & tested chain
blocks
To avoid slip a rubber piece is inserted in

between the conveyor belt & jam angles
2 3 6
Certified & appropiate spanner to be used
All the belt joints is inspected prior to

commencing of job
2 4 8
Hand glooves to be worn at all times
1 2 2
Hand glooves to be worn at all times 1 2 2

1.Power supply for drill machine shall be
through 30 mA ELCB;
2. technician shall be standing on rubber
mat 1 3 3
3. shock resistant safety shoe to be worn
Hand glooves to be worn at all times 1 2 2

1.Power supply for drill machine shall be
through 30 mA sensitivity
2.Double insulated portable tools to be
used
1 3 3
1.Co-ordation with the vehilce operator,

signal man with the help of walie-talkie;
the speed of pulling device shall be max
15 m/min
2.Refective jacket to be worn 1 4 4
3.Reverse horn should be in sound
condition
1.certified Sling of adequate capacity to

be used
2 3 6
1.Based on calculated belt load to
drag/pull the existing conveyor with wire
ropes slings force clamp & D-shackle to
be used.
2 2 4
1. Hand glooves to be used

2.Tested and certified hook chuck to be
used
3.Industrial socket with IP44 specification
to be used
4. cable to be routed properly
5.Inspect for loose connection and doubly
check.
6.Safety googles to be worn
7.Flammable materials to be moved away 2 2 4
& fire fighting equipments should be in
place.
1.Trained rigger should be engaged for

lifting & shifting 1 3 3
1.Trained technician should be engaged

with proper PPE such as hand gloves
2 2 4
Reviewed by:
Signature:
Name
SESSMENT
Date:-
Section/ Location:

Belt changing area to be
barricaded by safety
ribbon & a safety observer
should be deployed
throughout the job 2 2 4
It is desirable to place I
beam/channel at correct
position under the gravity
takeup to avoid free fall of 2 1 2
takeup during any
eventuality
Certified shop fabricated

belt clamps to be used to
ensure uniformity of
tightness along the enire 2 1 2
width of the belt
It is desirable to place I
beam/channel at correct
position under the gravity
takeup to avoid free fall of 2 2 4
takeup during any
eventuality
ELCB to be operated
manually before resuming
task to ensure that it's
functioning 1 2 2
ELCB to be operated
manually before resuming
task
1 2 2
the belt changing area to 1 3 3

be barricaded
1.Dynomometer to be 2 1 2
installed between the
wirerope sling and
payloader to ensure that
the force/tension while
pulling is within the sling
capacity
Approved by:
Signature:
Name
HAZARD IDE
Job Title Screen PM
Area 231

Impact
1 Drive motor, coupling Spanner slip.
(Cardon shaft), & bearring
housing bolt tightness
checking Fall of height hazard.
Hand injury
2 Spanner slip.
Screen deck
pannel,Eye bolts,
Marsh mellow and slip hazard
hardox plat checking.
3 Foreign particle may be inside to

Screen bearing the eye.
checking and
lubrication. Spanner slip.
Prepared by:
Signature:
Name
Section/ Location:
Routine /NonRoutine

P S Risk
Tested hand tools to be used 2 2 4
Make proper working platform. 2 2 4
2 2 4
Trained fitter & rigger should be engaged.
2 2 4
Trained technicians should be engaged for lifting
theguard

2 2 4
Use full body safety harness
1 1 1
Using PPEs and Safety plain goggles.
1 1 1
Tested hand tools to be used
Reviewed by:
Signature:
Name
ASSESSMENT
Date:-
Section/ Location:

Area should be evacuated 1 2
Use PPEs and Full Body Safety 1 2

Harness
1 2

1 2
Hard barricaded at screen

discharge.
Approved by:
Signature:
Name
Residual Risk
Risk
2
2
2
HAZARD IDENT
Job Title TBP Shaft replacement
Area 231

Impact
1 TBP shaft Hood cover Fall from height of person or object at the
opening & rest at ground time opening the top cover.
Fall of bolts & slip tools from hands.
Fall of materials/hood cover.
2 TBP Chain link looseness

by removing packing plate Fall of bolts & slip tools from hands
both sideby use of lift the
shaft by chainpully block
Failure of lifting tools & tackles.
Fall of materials/Packing Plate.
3 All 6 no's of link pin Fall from height of person or object at the
remove one by one & time fixing the chain block.
locking.
Slip link pin & tools from hands.
Failure of chains pulleys and chain
4 Sheared TBP shaft Failure of lifting tools & tackles.

Dismantling & Rest the
Ground.
Fall of TBP shaft.
5 New TBP Shaft erecting

and Fit up. Failure of lifting tools & tackles.
Fall of TBP shaft

6 Fit up all (6no’s) link pin &
Alignment of TBP shaft. Fall of link pin
Fall of packing plate
Hand compact with hand tools/shaft
7 Fall of bolts & slip tools from hands
All inspection door closed,

hood cover fit up & chain
tension by providing Failure of lifting tools & tackles.
required packing.
Prepared by:
Signature:
Name
Section/ Location:
Routine /NonRoutine

P S Risk
2 2 4
Make Proper Working Platform.
2 2 4
Proper hand tools to be used
2 2 4
2 2 4
2 2 4
Load should be lifted less than lifting tools capacity
Trained Technician Should be engaged. 2 2 4

2 2 4
Cover should be rest at ground proper by housing
chain block.
2 2 4
Trained technicians should be engaged.
Safety full body anchors it to a rigid point. 2 2 4
Trained rigger should be engaged to control the height 2 2 4

during removing & locking the lock pin
2 2 4
Good condition chains pulleys and chain to be used.
Trained technicians should be engaged for lifting the 2 2 4

TBP..
2 2 4
Tools tackles should be used not less than TBP shaft
2 2 4
Trained technicians should be engaged for lifting the
TBP..
Inadequate illumination if work is conducted at night. 2 2 4

Trained rigger should be engaged to control the height
during removing & locking the lock pin
Tested hand tools to be used.
Trained Technician Should be engaged.
Reviewed by:
Signature:
Name
SESSMENT
Date:-
Section/ Location:

Area should be evacuated. 1 2 2
Chain block with valid test

certificate should be used
Use Proper PPES.
Area of working platform should

be cleaned.
Apart from using mandatory PPE
like safety Harness, Safety Hamlet,
Gloves etc.
Proper hand tools may be used.

certificate should be used.
Barricading should be done in
Tools tackle with valid test

Unauthorized persons should not

be entry inside the work area
Use Proper PPE's.

Area should be evacuated

Make proper working platform.

Approved by:
Signature:
Name
HAZARD IDENTIF
Job Title Toe Bar replacement
Area 231

Impact
from height
TBP decouple. Fall of Materials from height

Fall of Materials.
Gear Box Shifted from
its location.
Fall from height of person or object at the
time fixing the chain block.
3
Packing Plate Fall of Materials.

Removed both side &
toebar hold bolt
removed.
Fall / slip of hand tools from hand.
Failure of Lifting Tolls & Tackels.

4
Fall Of materials.
Fall & Slips hazards( Hand Tools,
Toebar Dismentaling Persons, chain, etc.)
& rest the ground.
Fall of Toebar.
Electric shock may be connecting with

technicians.
5 Eye Injury due to air pressure.
Slip & trip hazrads.
Cleaning by Hydrojet
Fall Hazards.
m/c.
m/c.
6
Fall of Toebar.
Struck with workmen.

Toebar Erection &
Fittup.
Fall from height of person or object at the
time fixing the chain block.
7
Packing Plate Fall of Materials.

Mounting both side &
toebar hold bolt
fixing. Fall / slip of hand tools from hand.
8
Fall of bolts & slip tools from hands
Gear Box allignment Fall of Materials.

& fixing.
Fall from height of person or
object at the time opening the top
cover.
9 Fall of bolts & slip tools from
hands.
TBP Coupling fitting

and coupling bolts Fall of Materials.
tightning
Prepared by:
Signature:
Name
Section/ Location:
Routine /NonRoutine

P S Risk
2 2 4
Cover should be rest at ground proper by holsing 2 2 4

chain block.
Trained fitter & rigger should be engaged. 3 2 6

2 2 4
during removing & Safety Belt anchors it to a rigid
point.
3 2 6
3 2 6
Area Should Be baricated .
3 2 6
Lifting Tools & tackels certified by competent 3 2 6

person shall be used.
Trained rigger should be engaged to control the height 3 2 6

point.
3 2 6
Inadequate illumination if work is conducted at night. 3 2 4
Proper Earthing & insulation. 2 2 4
Use of Face Gurad, Nose mask .

Good Housekeeping & Material Storing & safe , free 3 2 6
access.
3 2 6
Proper Material Handling.
3 2 6
Lifting Tools & tackels certified by competent
person shall be used.
Tools & tackles should be used according to the 3 2 6
standard load capacity.
3 2 6
3 2 6
point.
3 2 6
3 2 6
Area Should Be baricated .
3 2 6
3 2 6
3 2 6

2 2 4
Make Working Platform.
2 2 4
2 2 4
Cover should be rest at ground proper by holsing

chain block.
Reviewed by:
Signature:
Name
SESSMENT
Date:-
Section/ Location:

use PPE like safety full body 1 2 2
Harness, Safety Halmet,Hand
Gloves.

2 2 4
PPE like safety full body Harness, 2 2 4

Safety Halmet, Gloves.
Area of working platform should 2 2 4

be cleaned.
2 2 4
Lifting tools & tackels with valid
test certificate should be used.
Use PPE like safety full body 2 2 4

Harness, Safety Halmet, Gloves.

be cleaned.
Proper cable rotation. 2 2 4
Ensuring Safe Railing/Barication. 2 2 4

use PPE like safety full body 2 2 4
Harness, Safety Halmet, Gloves.
continue supervision at workplace 2 2 4

.
Inadequate illumination if work is 2 2 4
conducted at night.
2 2 4
Use PPE like safety full body 2 2 4

Harness, Safety Halmet, safety
hand Gloves.
be cleaned.
2 2 4
Lifting tools & tackels with valid
test certificate should be used.
2 2 4
Use PPES. 2 2 4
1 2 2
Apart from using mandatory PPE
like safety Harness, Safety Halmet,
Gloves etc.
Approved by:
Signature:
Name
HAZARD IDEN
Job Title Crusher PM
Area 231

Impact
1 Spanner slip.
Drive motor, coupling

& bearring housing bolt
tightness checking Hand injury
2 Spanner slip.
Scoup coupling, Oil and dust may enter inside eye.
pump,hose & teeth
inspection.
slip hazard
3 Spanner slip.
Oil and dustmay be inside eye.
Scoup coupling,
pump,hose & teeth
inspection. slip hazard

the eye.
TBP bush, fluid Spanner slip.
coupling,gear coupling,
gear box checking &
lubrication. Fall hazard.
Prepared by:
Signature:
Name
Section/ Location:
Routine /NonRoutine

P S Risk
2 2 4

the guard.
JSA SLIDE NO-036 2 2 4

1 2 2
Use PPEs and Safety plain goggles
2 2 4
Use safety full body harness

Use PPEs and Safety plain goggles 2 2 4
2 2 4
Use safety full body harness
2 2 4
use PPEs and Safety plain goggles

Make proper working platform. 2 2 4
2 2 4
Reviewed by:
Signature:
Name
SESSMENT
Date:-
Section/ Location: BHP

Area should be evacuated 1 2 2
1 2 2
Use safety hand gloves.
1 2 2
discharge.
1 2 2
Use PPEs and Safetyfull body
Harness.
Approved by:
Signature:
Name
HAZARD IDE
Job Title Screen Bearing replacement
Area 231

Impact
1
Fall from height of person and at

Make Arrangement For the time fixing the sling.
fixing of Chain Pulley to
remove the screen
Bearing Failure of chain Pulley.
2
Fall & Slip hazard
All guard and coupling
decouple and
dismantling.
Fire hazard

hands.
Both side counter

weight, bearing along
with housing to be Failure of lifting tools during lift the
remove. load.

hands.
Both side counter Failure of lifting tools during lift the

weight, bearing along load.
with housing fitting &
bearing lubrication.
Eye injury due to foreign particles

5
Fall of bolts & slip tools from
hands.
coupling to be coupled
and bolts to be
tightness Failure of lifting tools during lift the
load.
6
All required platform
refitting and remove Fall of height & Slip hazard
the chain pulley.
Prepared by:
Signature:
Name
Section/ Location:
Routine /NonRoutine

P S Risk
3 2 6
Temprarey platform to be provided.
3 2 6

3 2 6
Make proper working platform. 2 2 4
Trained fitter & technicians should be 3 3 9

engaged.
2 3 6
Fire extinguisher keep near by work place.
Tested tools and trained technician should be 2 2 4

engagged.
2 2 4
Area should be evacuated.
3 3 9
Load should be lifted less than lifting tools

load capacity.
3 3 9
3 3 9
2 3 6
load capacity.
2 2 4
Safety plain goggles to be used
3 2 6
2 2 4
3 2 6

load capacity.
2 2 4
3 2 6
Trained fitter & Technicians should be
engaged.
Reviewed by:
Signature:
Name
SSESSMENT
Date:-

Area should be evacuated. 2 2
2 2
Use PPEs and safety full
body harness.
used tested tools & tackle 2 2
with valid certificate.
1 2
Use PPEs and Safety full 2 3

body Harness.
1 3
dust spared over spill area .
Proper housekeeping to be 1 2
done before start the job.
Tested and valied lifting 2 3

tools & tackle to be used.
Trained technicians should 2 3

be engaged.
Tested and Vailied lifting 1 3

Tested and valied lifting 1 2

2 2
Trained technicians should
be engaged.
Additional locking by PP 1 2
rope.
2 2
Use PPEs and Safety full
body Harness.
Approved by:
Signature:
Name
Residual Risk
Risk
4
2
6
3
4
4
Job Title Gear Box and Coupling Replacement
Area 230/231

step
1 Make arrangement for Fall from height of person
lifting and shifting the gear
box.
Fall of bolts & slip of hand tools

from hands.
Failure of D-shackle.
Failure of chain Pulley
2 Decouple the all coupling Fall of bolts & slip tools from
bolt and remove the gear hands.
box base bolts.
3 Lift the gear box and shifted Failure of chain Pulley

from original position
Failure of slings.
Height of Fall of gear box.
4 Make arrangement for Hand tools may be slip from

remove the old coupling. hand
4 Make arrangement for
remove the old coupling.
Coupling may be fall on ground
5 Heating the new coupling Electric shock may be

up to 160 Degree Celsius connecting with technician.
with the help of induction
coiler
Heating coupling may be
contact with body.
6 Fitting the new coupling. Fall of heated coupling.
7 Lifting the Gear box and fit Failure of chain Pulley

up all base bolts.
Failure of slings.
Height of Fall of gear box.
8 Alignment and coupling Slip tools/bolt from hands.

bolts tightning
Hand injurey with base & gear

box.
Packing Sims may be cut the

finger
Remove the all lifting Fall from height of person .
arrangement
Fall of bolts & slip of hand tools

from hands.
Prepared by:
Signature:
Name
HIRA No. UAIL/BHP/O&M/HIRA/042
g Replacement
gaswami, Mr. K.Bharghav
Impact Existing control measure to mitigate Existing / Base Risk

hazard P S
Possibility of fracture Ladder should be use for ascending & 3 3
injury/ Fatal accident descending of workmen for fixing &
removal of the slings
Possibility of serious 1.Standatd/ tested hand tools to be used. 4 1

hand injury 2. Use cotton hand gloves. 3. Avoid to
use D-spanner.
Possibility of fracture Trained fitter & rigger should be 3 3
injury/ Fatal accident engaged.
Possibility of fracture Load should be lifted less than chain 3 3
injury/ Fatal accident block or wire rope sling or load capacity

use D-spanner.
Possibility of fracture Load should be lifted as per chain Pulley 3 3

injury/ Fatal accident capacity
Possibility of fracture Slings with valid test certificate should be 3 3
injury/ Fatal accident used.
Possibility of fracture Area should be evacuated. 3 2
injury/ Fatal accident/
proporty damage

use D-spanner.
Possibility of fracture Chain Pulley with validate certificate 3 3
injury/ Fatal accident/ should be used. 2.Trained technicians
proporty damage should be engaged.
Possibility of serious to Use PPE, like safety shoes, Safety 3 3

fatal accident due to Helmet, Heat resistance gloves
electrocution
Possibility of serious to Trained technicians should be engaged. 3 3

burn injury
Possibility of serious Trained MWF should be engaged to 3 3

body injury fixing the coupling
Possibility of fracture Load should be lifted as per chain Pulley 3 3

injury/ Fatal accident/ capacity
proporty damage
Possibility of fracture Slings with valid test certificate should be 3 3

injury/ Fatal accident/ used.
proporty damage
Possibility of fracture Area should be evacuated. 2 3

injury/ Fatal accident/
proporty damage
Possibility of fracture 1.Standatd/ tested hand tools to be used. 4 1

injury 2. Use cotton hand gloves. 3. Avoid to
use D-spanner.
cut injury Safely sim plate removing and fitting. 2 2
cut injury Use safety hand gloves . 2 2

Possibility of fracture Ladder should be provided for ascending 3 3
injury/ Fatal accident & descending of workmen for fixing &
removal of the slings
Possibility of fracture 1.Standatd/ tested hand tools to be used. 4 1

injury 2. Use cotton hand gloves. 3. Avoid to
use D-spanner.
Reviewed by:
Signature:
Name
Date:-
Section/ Location:
/ Base Risk Additional control measure Responsible Implementation

Risk Official to Status
9 Trained technicians should be engaged. implement
WG implemented & Work
at height trained
already given to
use of PPE.
4 WG Same will be
implemented before
the job.
9 Tested tools & tackle with valid certificate. Implemented
9 Implemented
4 WG Same will be
implemented before
the job.
9 Tested Tools with valid test certificate Implemented

should be used.
9 Barricading should be done in the Implemented
surrounding area.
6 implemented &
workmen are awarded
on same work
4 WG Same will be
implemented before
the job.
9 Physical inspection should be done before implemented &
using, 2.Use safety hand gloves workmen are awarded
on same work
9 trained technician should be engaged implemented &

workmen are awarded
on electrical safety.
9 Use leather hand gloves. implemented &

workmen are awarded
on same job.
9 Area should be evacuated. implemented &

workmen are awarded
on same job.
9 Tools with valid test certificate should be Implemented

used.
9 Barricading should be done in the Implemented

surrounding area.
6 trained technician should be engaged implemented &

workmen are awarded
on same job.
4 WG implemented &
workmen are awarded
on same work
4 implemented &
workmen are awarded
on same job.
4 implemented &
workmen are awarded
on same job.
9 Trained technicians should be engaged. implemented & Work
at height trained
already given to
use of PPE.
4 WG implemented &
workmen are awarded
on same work
Approved by:
Signature:
Name
Residual Risk
P S Risk
2 3 6
2 3 6
2 3 6
2 3 6
2 3 6
2 3 6
2 3 6
2 3 6
2 3 6
2 3 6
2 3 6
1 3 3
2 3 6
HAZARD IDE
Job Title Removing the TBP Link pin
Area 231

Impact
1 Fall from height of person
TBP shaft Hood cover

opening & rest at Fall of bolts & slip tools from
ground hands.
Height of Fall of materials.
2 Fall from height of person .

TBP Chain link
looseness by removing
packing plate both
sideand lift the shaft by
chain pulley Failure of chains
3 fire hazards
Remove the link of TBP
link pin
Fall of link pin
After fit-up inset the

packing plate & Fall of packing plate
Alignment of TBP shaft.
Hand compact with hand tools

5
hands
All inspection door

closed, hood cover fit
up & chain tension by
providing required
packing.
Prepared by:
Signature:
Name
Section/ Location:
Routine /NonRoutine

P S Risk
3 3 9
Make Standared Working Platform.
tested and valied certified hand tools to be 3 3 9

used
3 3 9
Trained technicians should be engaged. 3 3 9

3 3 9
Use indivisual life line for each person

3 3 9
Trained rigger should be engaged to control
the height during removing & locking the
lock pin
3 3 9
Good condition chains to be used.
Load should be lifted less than lifting tools 3 3 9

capacity
use cutting set for cutting the link pin 3 3 9

purpose
3 3 9
lock pin
3 3 9
Trained technicians (MF) should be engaged.
3 3 9

3 3 9
3 3 9
capacity
3 3 9
Reviewed by:
Signature:
Name
SSESSMENT
Date:-

2 3
Trained technicians and
safety full body harness
should be used.
Before using physical 2 3

verification should be done
2 3
Safety Belt anchors it to a 2 3

rigid point.
2 3
use safety hand gloves
2 3
Before using physical
2 3
Tested and valied certified
chain pulley should be used
2 3
Trained cutter and leather
apron should be used for
the job
Use PPEs and safety Hand 2 3

gloves.
2 3
Before using physical
2 3
2 3
2 3
Make standered working
platform.
Approved by:
Signature:
Name
Residual Risk
Risk
6
6
6
6
6
6
HAZARD IDE
Job Title Screen PM
Area 231

Impact
1 Drive motor, coupling Spanner slip.
(Cardon shaft), & bearring
housing bolt tightness
checking Fall of height hazard.
Hand injury
2 Spanner slip.
Screen deck pannel,Eye
bolts, Marsh mellow
and hardox plat slip hazard
checking.

the eye.
Screen bearing
checking and
lubrication. Spanner slip.
Prepared by:
Signature:
Name
Section/ Location:
Routine /NonRoutine

P S Risk
Make proper working platform. 2 2 4
2 2 4
2 2 4
theguard

2 2 4
Use full body safety harness
1 1 1
Using PPEs and Safety plain goggles.
1 1 1
Reviewed by:
Signature:
Name
SSESSMENT
Date:-

Use PPEs and Full Body Safety 1 2

Harness
1 2

1 2

discharge.
Approved by:
Signature:
Name
Residual Risk
Risk
2
2
2
HAZ
Job Title crusher cage bar Replacement
Area 231

Impact
hands
Making arrangement Fall of materials
for removing
coupling guard & Slip from hands
rotor lock.
Drive shaft may be move.
2
Eye Injury
Slip & trip hazards.

machine or water
hose. Fall Hazards.
3 Bauxite to be
removed & Cleaning Hand tools may slipped.
to be done.
fall of material.
4 Making arrangement
for lifting & fixing
manual working
platform inside chute.
Deficiency of Oxygen

ascending & descending in side
chute.
Hand injury
5 Remove of existing
damaged Cage bar
one by one & also fit-
up new one in same Fall & Slip hazard
sequence.
Fire hazard
Jammed bauxite fall hazard
Hand Injury
Failure of Lifting tools.
6
Spanner slip.
Remove of working
platform & all
6
Hand injury
Remove of working
platform & all
Accessories
Fire hazard
7
hands
Crusher all inspection Fall of materials/hood cover

door & hood cover
box-up to be done
rotor lock to be Slip coupling bolt,inspection
removed & coupling door,hood cover bolts & tools from
guard to be fitup.. hands
Drive shaft rotate.

Spanner slip.
Prepared by:
Signature:
Name
Section/ Location:
Routine /NonRoutine

P S Risk
Tested and vailed certified hand tools to be 3 3 9
used
Cover should be mechanically Locked . 4 3 12
3 2 6
3 3 9
Mechanical lockingto be done
Use of Face Guard, Nose mask . 3 3 9
Good Housekeeping & Material Storing & 3 3 9

safe , free access.
3 3 9
Use full body harness protection
3 3 9
Lifting Tools & tackles certified to be used.

3 3 9
Trained technician should be engaged to
control the cleaning activity.
4 3 12
before starting job check the chute condition
for any material jamming
4 3 12

If flamable gas present then purging should 3 3 9
be done.
3 3 9
An entry & exits register should be maintained.

Trained technicians should be engaged for 3 3 9

lifting theplatform material..
4 3 12
Make working platform to perform the job.
3 3 9
3 3 9
Tested by multi gas tester before entry the

confined area.
3 3 9

illumination required. 3 3 9
3 3 9
3 3 9
cleaning to done before enter into the chute.

remove the frame.
3 3 9
Chain pulley and di-shycacle in good
3 3 9
Tested and valied certified hand tools to be
used
the job.
3 3 9

Illumination required. 3 3 9
3 3 9
3 3 9
Tested and valied certified hand tools to be
used
3 3 9
Cover should be rest at ground proper by
holing chain pulley.
3 3 9

control the height during removing & locking
the lock pin
3 3 9
Reviewed by:
Signature:
Name
D RISK ASSESSMENT
Date:-

implement Status P
2
Area of working platform should be cleaned 2

Use PPE safety full body Harness, Safety Hamlet, 2
Gloves .
2
Trained persons should be engage for the job 2
Before using hose should be verified physically. 2
Use PPE safety full body Harness, Safety Hamlet, 2

Gloves .
Use PPE safety Harness, Safety Hamlet, Gloves 2
If Oxygen level more then 23.5% or below 19.5% no worked

should be carried out.
2
Worker with confined space pass should be work inside the

confined space.
Rescue plane should be available & brief to the 2
workman.
use PPEs and Safety full body harness to be used . 2
Use cotton hand gloves. 2
2
Mechanical locking to be done
Use PPEsa and Safety full body Harness.
check oxygen level in every 4 hour intervels 2
If flamable gas present then purging should be done. 2
24 Volt DC light Should be used inside the confined 2

space.
Conveyor covered with bauxite dust and GI sheet. 2
use hydrojet for cleaning

Physical verification done bofore using. 2
2
If flamable gas present then purging should be done. 2
24 Volt DC light Should be used inside the confined 2

space.
Conveyor covered with bauxite dust and GI sheet. 2
2
2
Mechanical locking should be done
Area of working platform should be cleaned
2
isolationtghe crusher drive motor
Area should be evacuated 2
Approved by:
Signature:
Name
Residual Risk
S Risk
3 6
3 6
2 4
3 6
3 6
3 6
3 6
3 6
3 6
3 6
3 6
3 6
3 6
3 6
3 6
3 6
3 6
3 6
3 6
3 6
3 6
3 6
3 6
3 6
3 6
3 6
3 6
3 6
3 6
3 6
3 6
3 6
3 6
3 6
HAZARD IDENTIFICATION AN
Job Title : Screen Motor replacement
Area 231
Risk assessment team members

1 Make arrangements for 1.Failure of chain pulley Body injury

fixing the chain Block block
2.Fall ofperson during
fixing of Chain Block
2 Disconnect the cardon shaft 1.Drive may be start 1.Body injury

from motor & motor base 2. Fall of bolts & slip tools 2.Hand Injury
bolts. from hands.
3 Make arrangement for fitting 1.Hand tools may be slip 1.Body injury
coupling. from hand 2.Hand Injury
2.Hand may compact
with coupling while fixing
3.Fire
injury if Coupling is
heated .
4 Lift the new motor with 1.Failure of chain pulley Body injury
coupling and place it on block
base. 2.Fall ofperson during
5 Alignment and fit up the 1.Hand tools may be slip 1.Body injury
codon shaft with motor. from hand 2.Hand Injury
2.Hand may compact
with coupling while fixing
6 Remove the all lifting 1.Failure of chain pulley Body injury

arrangement. block
removal of Chain Block
Prepared by:
Date:17-02-2021
Section/ Location: BAUXITE Handling plant
Routine /NonRoutine : Routine
Normal/Abnormal/Emergency : Normal

1.Proper platform to be used for 2 3 6 implement
1.Height pass for technicians is PA & WG
height job. mandotory
2.Certified chain Blocks to be 2.People should not be allowed
used. below the chain block
3.Load lifted should be within 3.Valid and certified to
the capacity of chain Block. be sued.
1.Isolate the motor and make 2 3 6 1.LOTO and Permit system to PA & WG
the divertorgate in other screen be implemented
position. 2.Proper
Hand tools to be used.
1.Tools of suitable size to be 2 3 6 1.Coiler operator to be properly PA & WG

used. trained. 2.Good
2.Trained technicians should be House keeping to be ensured.
engaged.
3.Tested gas cutting set with
FBA and working guages
shouldd be used.
4.Tested Industrial coiler to be
used.
1.Proper platform to be used for 2 3 6 1.Height pass for technicians is PA & WG

1.Tools of suitable size to be 2 3 6 1.Good House keeping to be PA & WG
used. ensured.
2.Trained technicians should be
engaged.


Status P S Risk
Implemented 2 2 4
Implemented 2 2 4
Implemented 2 2 4
Implemented 2 2 4
Implemented 2 2 4
Implemented 2 2 4
HAZARD IDENTIFICATION AND RIS
Job Title Crusher Motor Replacement
Area

1 Positioning of crane for 1. Crane wheel/jack may May lead to fatal incident
lifting the motor. go down in soil.
2. Hydra may be hit the
workman.
2 Fixing the sling for lifting & 1. Fall from height of Body Injury
person or object at the
time fixing the sling.
2. Fall of bolts & slip tools

from hands.
3 Lift the old motor from CR- 1. Failure of crane. Hand injury
231-001A/CR-231-001B to 2. Failure of slings.
ground level 3. Fall of Material.
4. Fall from height of
time of lifting the motor
4 Dismantling of coupling 1. Chances of Hand tools Finger Entrapment
from old motor & may be slip from hand .
assembling in new motor. 2 Coupling may be fall on
ground.
3. Fire may be
cache on the hydraulic
oil.
5 Remove the sling from old 1. Fall from height of Leg injury
motor & fixing in new motor. person or object at the
2.Fall of bolts & slip tools

from hands.
6 Lifting the new motor from 1. Failure of crane. Hand injury

ground level to CR-231- 2. Failure of slings.
001A/B. 3. Fall of Material.
time of fixing the sling.
7 Fix & bolting the motor on t 1. Fall from height of 1.Hand injury
person or object at the 2.Slip ,Trip and fall
2. Fall of bolts & slip tools

from hands.
8 Remove the sling from motor1. Fall from height of 1.Hand injury

from hands.
9 Dismantling of temporary Fall of bolts & slip tools 1.Hand injury

loose support provided from hands.
under motor & Removal of
all Tools & Tackles.
Prepared by:
Signature:
Name
Section/ Location:

1.The ground should be 3 4 12 implement
1. During work on hydra follow PA&WG
compacted and leveled. the SWI of hydra operation.
2. Iron plate should be placed
on ground before posting of 2. 6mtr guide rope to
crane. be used.
3. Proper signaling during
marching should be ensured.
4. Keep distance minimum 3 mtr
from hydra.
1. Area should be evacuated. 2 4 8 1.Proper housekeeping to be PA&WG

2. Trained technicians should be done before start the job.
engaged.
3. Proper hand tools to be used.
4.Make proper working platform.
1. Load should be lifted as per 2 4 8 1. Slings with valid test PA&WG

crane capacity. certificate should be used.
2. Crane with valid test
certificate should be used. 2.Trained rigger should be
3. Crane operator should be engaged to control the height
engaged for operation of crane. during lifting the motor.
4. Area should be evacuated. 3. Trained foreman should be
5. Barricating should be done in engaged to guide the crane
the surrounding area. operator.
1.Proper hand tools used as per 2 2 4 1.fire bucket & fire extinguisher PA&WG
requirements. to be present at site.
2. Coupling hold by chain block.
3. Chain block with validate
certificate should be used.
4. Use proper PPE, like safety
shoes, Safety Helmet & Cotton
hand gloves
1. Trained technicians should be 2 3 6 1.Proper housekeeping to be PA&WG

engaged. done before start the job.
2. Proper hand tools may be
used.
3.Use proper PPE, like safety
hand gloves.
1. Load should be lifted as per 2 4 8 1. Slings with valid test PA&WG

crane capacity. certificate should be used.
certificate should be used. 2.Trained rigger should be
3. Crane operator should be engaged to control the height
engaged for operation of crane. during lifting the motor.
5. Barricating should be done in engaged to guide the crane
the surrounding area. operator.
1. Area should be evacuated. 2 2 4 1.Proper housekeeping to be PA&WG

2. Trained technicians should be done before start the job.
engaged.
4.Make proper working platform.
2 2 4 PA&WG
1. Trained technicians should be
engaged.
used.
hand gloves.
1. Area should be evacuated. 2 3 6 Proper illumination must be PA&WG

2. Trained technicians should be ensured.
engaged.
3. Proper hand tools should be
used.

Name Name
utine

Status P S Risk
1 3 3
1 3 3
2 2 4
2 2 4
2 2 4
2 2 4
2 2 4
Job Title
Area

Position the crane for lift Hydra may be hit to
the counter weight of workman at the time
take-up lifting & lift the base plate fixing.
counterweight up-to
500mm for relise
conveyor tension.
Fall of counterweight
due to failure of lifting
tools or crane.
Fall from height of

person during fixed
the D-shackle & sling.
Lift the counterweight & Injury due to

remove the D.Shackle & Drive/Conveyor start.
rope clamps.
Counter box locking

with take-up structure
Remove all lifting

arrangement from take-
up counter weight &
fixed at take-up lifting
point.
Remove all lifting
up counter weight &
fixed at take-up lifting
point.
Takeup structure's base

grouting dismentaling of
4 Nos of base by
Braker/Chisel/Hammer
Both Guide box & all

foundation bolt cut by
cutting set
Takeup complete
structure's lifting from
existing base and re-
fixed at new
foundation(Mechanical
stool base) by 200MT
crane. And fixed by
proper welding.
Remove all lifting

up lifting
Zero levelpoint & pulley
Sheave fixed
fitted(welding).
New wire rope

120M(approx) laying by
the help of existing rope.
Counter box Unlocking

by Cutting set & lift the
counter weight for fixing
the D-Shackle with take-
up trolley frame.
Guide box base fitting &

welding.
Guide box base fitting &
welding.
Start to be fixed back &

all arrangements, tools,
removing.
Removeall lifting tools &
tackle from Take-up.
Section/ Location:

3 4 12 1.Ensure Reverse horn on implement
WG/PA
1. Iron plate should be the hydra. 2. Proper
placed on ground before signalling during marching
posting of crane. 2.Keep should be ensured. 3.The
distance minimum 3 mtr ground should be
from hydra. compacted and levelled.
1.Load should be lifted as 4 5 20 1. Physical inspection ensure

per crane capacity. before used. 2. Use oversize
2.Encure Crane & lifting lifting tools & tackle.
tools & Tackles with valid
test certificate to be use.
1.Make ensure proper 3 5 15 1.Fixed ladder to be

working platform for work provided.
at height. 2. Height pass
2. Use double lanyard safety approved person/technician
harness. engaged for height work 3.
Take height permit.
utine

Status P S Risk
Job Title PM of Luffing Cylinder of Stcaker and Reclaimer
Area

1 Motor, gear box & coupling Spanner may slip Hand Injury
checking with base bolt
tightning.
2 All pulleys Plummer block Fall hazard. First aid case
base bolt tightness &
lubrication.
3 Top-up of Transformer oil in Oil and Dust splash in eyeEye Injury
4 thruster.
Torqueing of Slew bolts if Spanner /torque wrench Hand Injury
necessory may slip
5 Lube pump checking & Spanner /torque wrench ma Hand Injury
lubrication.
6 Hydraulic pump checking & Oil and Dust splash in eyeEye Injury
oil top-up.
Prepared by:
Signature:
Name
imer Section/ Location:

Tested hand tools to be used 2 2 4 Hand gloves use should be implement
PA &WG
mandotory
Standard working platform to be 2 3 6 Plat form should be certified by PA &WG
Scaffolding SME
Safety goggles to be used along 2 6 4

Standard hand tools to be used 2 2 4 House keeping to be ensured PA &WG
Standard hand tools to be used 2 2 4 Trained Technicians to be

deployed
Safety goggles to be used along 2 3 6 Nose masks and Eye goggles PA &WG
uuse should be mandotory

Name Name
utine

Status P S Risk
2 1 2
2 2 4
2 2 4
2 2 4
2 2 4
2 2 4
Job Title PM of LT of Stacker and Reclaimer
Area

1 Check base bolt tightness 1.Spanner slip. 1.Hand Injury

of motor & gear box. 2.Fall hazard from 2.Body Injury
working area.
2 Check tightness of shrink 1.Spanner slip. 1.Hand Injury

discs bolts at o/p shaft of 2.Fall hazard from 2.Body Injury
gear box working area.
3 Check the condition of all 1.Spanner slip. 1.Hand Injury

coupling pins and bushes 2.Fall hazard from 2.Body Injury
working area.
4 Check tightness of all 1.Spanner slip. 1.Hand Injury

bearing flanges of wheels. 2.Fall hazard from 2.Body Injury
working area.
5 Check for leakage in grease 1.Spanner slip. 1.Hand Injury

line & arrest if required 2.Fall hazard from 2.Body Injury
working area.
6 Check for condition of 1. Foreign particle may 1.Eye Injury

grease and replace if hit the eye
required
7 Tighten all bolts and 1.Spanner slip. 1.Hand Injury
fasteners 2.Fall hazard from 2.Body Injury
working area.
Prepared by:
Signature:
Name
Section/ Location:

1.Hand Tools of Exact size to be 2 2 4 1.Hand Gloves use should be implement
PA &WG
used 2. mandotory.
Working Area should be
evacuated
1.Hand Tools of Exact size to be 2 2 4 1.Hand Gloves use should be PA &WG
used 2. mandotory.
evacuated
used 2. mandotory.
evacuated
used 2. mandotory.
evacuated
used 2. mandotory.
evacuated
1.Safety goggles should be 2 2 4 1.Areahouse keeping should be PA &WG
used ensured.
2.Area should be barricated.
used 2. mandotory.
evacuated

Name Name
utine

Status P S Risk
1 2 2
1 2 2
1 2 2
1 2 2
1 2 2
1 2 2
1 2 2
Job Title :Boom Conveyor coupling inspection.
Area

1 Fixing of chain block for 1.lifting tools may be slip Body Injury
lifting Fluid Coupling 2..Fall
from height of person or
object at the time fixing
the chain block.
2 Remove all fitted bolts from fl 1.Drive may be start. Hand injury
2.Spanner slip.
3.material Fall hazard
3 Lift the fluid coupling by 1.Failure of chain block Hand injury

chain block & place on the 2. Failure of slings.
platform.
4 Gear coupling Inspection. 1.Foreign particle may hit Eye injury

the eye.
2.Spanner slip.
5 Lift the fluid coupling from 1.Failure of chain block Hand injury
platform to its position by 2. Failure of slings.
chain block.
6 Fitting of removed bolts of flu 1.Drive may be start. Hand injury
2.Spanner slip.
7 Removing the chain blocks 1.lifting tools may be slip Body Injury
2..Fall
the chain block.
Prepared by:
Signature:
Name
Section/ Location:

1.Chain Blocks within loaded 2 3 6 1.Chain block with valid test implement
PA&WG
capacities should be used certificate by third party should
be used
2.Safety Harness use to be 2.Trained technicians to be
mandotory. engagaed for the job
1.Proper hand tools to be used 2 4 8 1.Permit and LOTO should e PA&WG

2.Make displayed.
Standard working platform. 2.Area should be evacuated
3.Trained fitter & rigger 3.Hand Gloves usage to be
should be engaged. mandotory
4.Boom conveyor Isolation
should be done
1.Chain Blocks within loaded 2 4 8 1.Chain block with valid test PA&WG
be used
mandotory. 3.Sling engagaed for the job
inspection should be Done 3.Ensure area Barrication
before usage
1.Safety Goggles should be 2 2 4 1.House jkeeping to be ensured PA&WG
used 2. Hand tools of in surroundings
exact size to be used
be used
mandotory. 3.Sling engagaed for the job
inspection should be Done 3.Ensure area Barrication
before usage
1.Proper hand tools to be used 2 4 8 1.Permit and LOTO should e PA&WG
2.Make displayed.
Standard working platform. 2.Area should be evacuated
3.Trained fitter & rigger 3.Hand Gloves usage to be
should be engaged. mandotory
4.Boom conveyor Isolation
should be done
be used
mandotory. engagaed for the job

Name Name
utine

Status P S Risk
2 2 4
2 2 4
2 2 4
2 2 4
2 2 4
2 2 4
2 2 4
HAZARD IDENTIF
Job Title Carrying Idler frame replacement.
Area BHP
Injury due to Drive/Conveyor start. Possibility of serious to
fatal accident
Injury due to failure of Lifting tools. Possibility of serious hand

Making arrangement injury
1 for lifting the conveyer
belt by chain block.
Possibility of hand fracture
Fire injury
Removals of old
2 carrying/return idler
Fire hazard
frame & replace a new.
Possibility of brunt /
facture injury
Fall of idler
Possibility of hand fracture
Lowering the belt & Possibility of brunt /

3 facture injury
remove the chain block.

the time lowering of belt.
Prepared by:
Signature:
Name
UAIL/BHP/O&M/HIRA/060 Date:
Section/ Location:
Routine /NonRoutine Routine
Existing / Base Risk Responsible

Existing control measure to
Additional control measure Official to
implement
Proper isolation to be done of 4 5 20 LOTOTO procedure ensure before AO,PA&WG
same & before conveyor. the job.
Chain block(Lifting tools) in 4 3 12 1. Physical inspection ensure PA & WG

good condition & with valid before used. 2. Unauthorized

hand gloves. 3. Avoid to use
D-spanner.
1. Valve protection caps shall 1. Gas cutter must be use safety

be in placed on gas cylinder helmet, safety shoes, hand gloves,
and secured properly. 2. Flash full sleeve cotton dress, leg guard
back arrester must be etc. Hose pipe, regulator, cutting
connected at both end of torch, Flash back arrester shall be
cutting set. Hose shall be checked before use. Cotton dress
3 4 9 WG/PA
connected with cutting torch shall be used by gas cutters. 2. Fire
as well as with the cylinder by extinguishers, sand buckets, water
crimping clamp only. 3. Gas shall be kept ready at site. Ceramic
cutting work shall be done in cloth/Spatter arrester tray shall be
enclosed areas with proper used for arrest the spatters falling
supervision. from height.

engaged for lifting the conveyor.
hand gloves. 3. Avoid to use
D-spanner.

engaged. 2.Apart from using
mandatory PPEs (Safety
harness).

Name Name
e
Residual Risk
Implementation Status
P S Risk
LOTOTO procedure 1 5 5
implemented & 2 2 4
workmen are awarded
on same work
implemented &
workmen are awarded
on same work
It is the part of Hot work

PTW system, and also
same was implemented.
3 1 3
implemented
implemented &
workmen are awarded
on same work
implemented & Work at

height trained already
given to workers. Also
about use of PPE.
HAZARD
Job Title :Boom Conveyor coupling inspection.

Area 230

with the step
1 Fixing of chain block for lifting Fluid Coupling 1.lifting tools may be slip
2..Fall
the chain block.
2 Remove all fitted bolts from fluid coupling. 1.Drive may be start.
2.Spanner slip.
3 Lift the fluid coupling by chain block & place 1.Failure of chain block
on the platform. 2. Failure of slings.
4 Gear coupling Inspection. 1.Foreign particle may hit

the eye.
2.Spanner slip.
5 Lift the fluid coupling from platform to its 1.Failure of chain block
position by chain block. 2. Failure of slings.
6 Fitting of removed bolts of fluid coupling 1.Drive may be start.

2.Spanner slip.
7 Removing the chain blocks 1.lifting tools may be slip
2..Fall
the chain block.
Prepared by:
HIRA No. Date:
Section/ Location:

Normal/Abnormal/Emergency :Normal

Impact
P S Risk
Body Injury 1.Chain Blocks within loaded capacities should be 2 3 6
used
2.Safety Harness use to be mandotory.
Hand injury 1.Proper hand tools to be used 2 4 8

2.Make Standard working platform.
3.Trained fitter & rigger should be engaged.
4.Boom conveyor Isolation should be done
Hand injury 1.Chain Blocks within loaded capacities should be 2 4 8

used
3.Sling inspection should be Done before usage
Eye injury 1.Safety Goggles should be used 2. 2 2 4

Hand tools of exact size to be used
Hand injury 1.Chain Blocks within loaded capacities should be 2 4 8

used
3.Sling inspection should be Done before usage
Hand injury 1.Proper hand tools to be used 2 4 8

2.Make Standard working platform.
3.Trained fitter & rigger should be engaged.
4.Boom conveyor Isolation should be done
Body Injury 1.Chain Blocks within loaded capacities should be 2 3 6
used
Reviewed by:
1/11/2021
Bauxite Handling Plant
ence OCP (SOP/SMP) No.

ne /NonRoutine : Routine
al/Abnormal/Emergency :Normal
Additional control measure Responsible Implementation Residual Risk

1.Chain block with valid test implement
PA&WG 2 2 4
certificate by third party should
be used
2.Trained technicians to be
engagaed for the job
1.Permit and LOTO should e PA&WG 2 2 4

displayed.
2.Area should be evacuated
3.Hand Gloves usage to be
mandotory
1.Chain block with valid test PA&WG 2 2 4

be used
3.Ensure area Barrication
1.House jkeeping to be ensured PA&WG 2 2 4

in surroundings

be used
3.Ensure area Barrication
1.Permit and LOTO should e PA&WG 2 2 4

displayed.
2.Area should be evacuated
3.Hand Gloves usage to be
mandotory
be used
Approved by:
HAZA
Job Title Boom Conveyor Replacement
Area HM 452 and 453
1 Loosing the screw take up to zero. Fall and slip of hand tools and bolt from
hand.
2 Existing conveyor cutting & clamp with a new 1.Fall of persons/ trip hazard on the
conveyor by mechanical fastener. conveyor due to unstable surface 2.Belt
cutting knife may cut the hand during
conveyor cutting work
3 Winch/Exavator/Pay loader rope fixing at carrying 1.The fore clamp/knot may rupture and
site of old belt for carrying purpose. lead to accident if not adequately
secured to pull the belt
2.Failure of winch and tools tackle
3.Injury to near by workmen
4 Existing conveyor belt dismantling & new conveyor 1.Failure of winch and tools tackle
belt laying 2.Fall of persons/ trip hazard on the
conveyor due to unstable surface
5 Conveyor belt splicing buffering, grinding &jointing

Mis Handling of Knife
Cut injury while using knife
Failure of Hook chuck
Shock while applying power tool

socket
Trip hazard due to poor laying of cable
Spark due to loose connection
Foreign particles may enter the eye.
Fire
Chemical may splash in eye
6 Removing of clamps after new belt jointing 1.Fall of persons/ trip hazard on the
conveyor due to unstable surface 2.Belt
cutting knife may cut the hand during
conveyor cutting work
7 Provide tension to conveyor belt by screw take-up fall and slip of hand tools and bolt
from hand.
Prepared by:
HIRA No. Date:
Section/ Location:
Existing control measure to mitigate hazard Existing / Base

Impact Risk
P S Risk
Hand Injury 1.Trained Technicians to be deployd for the job 2 4 8
2. Hand Tools
of exact sizes to be used
Hand Injury 1.Standard/proven belt clamps to be used for 3 3 9

clamping with proper fastening of bolts. Uniformity
of tightness along the width of the belt to be
ensured, if required packing has to be provided.
2.Trained conveyor
jointer should be engaged for cutting work.
Body Injury 1.Based on calculated belt load to drag/pull the 2 3 6

existing conveyor with wire ropes slings force
clamp & D-shackle to be used.
2.Proper fastening of existing conveyor belt with
new conveyor. 3.Winch
machine and tool tackles with valid third party
certificate to be ensured.
4.Permit has to be taken and that need to be
displayed to make all aware
5.Area to be barricaded prior to start the job
Hand Injury 1.Winch machine and tool tackles with valid third 2 4 8
party certificate to be ensured.
2.Hand railing to be provided
3.Certified safety harness to be used.
4.Line line should be used.
hand Injury 2 3 6
Hand gloves to be used
Hand injury 2 3 6
Hand gloves to be used
Body injury 2 3 6
Tested and visullay checked hook chuck to be
used
Electric shok Industrial socket with IP44 specification to be 3 3 9

used
Electric shok 3 3 9
Laying of cable where movement is less
Electric shok 3 3 9
No loose connection to be done
Eye injury Safety goggles to be used

2 2 4
BodY injury 2 3 6
Flammable materials should be taken away & fire
fighting equipments should be in place.
eye injury Solution sholud be kept away from contact to eye 2 3 6
Hand Injury 1.Standard/proven belt clamps to be used for 2 3 6

clamping with proper fastening of bolts. Uniformity
of tightness along the width of the belt to be
ensured, if required packing has to be provided.
2.Trained conveyor
jointer should be engaged for cutting work.
Hand Injury 1.Trained technicians should be engaged. 2 2 4

2. Use proper hand tools as for requirement
Reviewed by:
2/4/2021
Section/ Location: Bauxite Handling

to implement Status
P S Risk
1.Proper hosuekeeping to PA & WG Implemented 2 2 4
be ensured in surroundings.
2.Hand Gloves
o be worn.
1.The entire belt profile to PA & WG Implemented 2 2 4

be inspected for any tension
or stuck in the structure.
2.Standard
Kinife to be used. 3. Trained
Riggers to be deployed with
Hand Gloves.
1.Single point co-ordination PA & WG Implemented 2 2 4

to be ensured while pulling
the belt to bring it to its
position 2.After
Proper inspection and
ensure of proper color
coding as UAIL safety
standard the winch machine
and tools should be used.
3.
1.After Proper inspection PA & WG Implemented 2 2 4
and ensure of proper color
coding as UAIL safety
standard the winch machine
1.Trained technicians and PA & WG Implemented 2 2 4

jointer should be deployed
for the job.
2.Working platform should PA & WG Implemented 2 2 4
be intact and strong.
3.Standard Safety harness PA & WG Implemented 2 2 4

4.Firee Extinguisher should PA & WG Implemented 2 2 4

be kept near .
5.Trained electrician should PA & WG Implemented 2 2 4
be deployed
5.Trained electrician should PA & WG Implemented 2 2 4
be deployed
PA & WG Implemented 2 2 4
Fire Extinguisher should be PA & WG Implemented 2 2 4

kept near place.
Expiry date of solution PA & WG Implemented 2 2 4

should be checked
1.The entire belt profile to PA & WG Implemented 2 2 4
be inspected for any tension
or stuck in the structure.
2.Standard
Kinife to be used. 3. Trained
Riggers to be deployed with
Hand Gloves.
1.Area should be clean PA & WG Implemented 2 2 4
Approved by:
Departmen Mechanical HIRA No.
Job Title Cardon Shaft replacement of Vibrating screen
Area 231 - Screen Floor Crusher House

1 Fixing of chiain Block to 1.Fall from height of Body Injury

standard Structure in person or object at the
crusher House. time fixing the sling or
chain blocks.
2.Fall of bolts & slip of
hand tools from hands
3.Failure of lifting tools &
tackles
2 Removing the counter 1.Fall hazard of guard & Body Injury

weight guard,Shaft slip tools from hands.
guard,cardon shaft &
counter weight plate both
side DE and NDE
3 Removing of both DE and 1.Fall hazard of tools and Body Injury

NDE bearing tackles 2.fire
hazard 3.Fall
of Beraing from hand
4 Existing Shaft removing 1.Fall from height of Body Injury
from NDE side by the help person or object at the
of chain block & new shaft time fixing the sling or
fixing. chain blocks.
2.Fall of bolts & slip of
hand tools from hands
3.Failure of lifting tools &
tackles
5 Both side bearing with 1.Fall hazard of tools and Body Injur& eye injury
housing fitting and tackles 2.fire
lubrication hazard 3.Fall
of Beraing from hand
4.Grease
may splash in eye
6 Cardon shaft fitting .Fall hazard of guard & Hand Injury

slip tools from hands.
6 Counter weight cover fixing 1.Fall hazard of guard & Body Injury
back to original position slip tools from hands.
7 Fixing the counter weight 1.Fall hazard of guard & Body Injury
guard,cardon shaft slip tools from hands.
Prepared by:
Date: 2/10/2021
Normal/Abnormal/Emergency: Normal

1.Ladder/ standard platform 3 3 9 implement
1.Trained technicians should be WG & PA
should be provided for deployed for the job.
ascending & descending of 2.Slings and chain pulleys
workmen for fixing & removal of should have proper validity
the slings and Chain Block certificates or 3rd party
2.Area should be inspection certifictes
evacuated. 3.Load lifted should
be less than the lifting capacity
of sling and chain Block
1.Guards should be tied with 2 3 6 1.Counter weight should be WG & PA

chain block. removed one after one.
2.Proper sized hand tools to be 2.They should be stacked at a
used. designated location.
1.Proper sized hand tools to be 2 3 6 1.Area should be evacuated WG & PA

used. 2.Fire 2.Bearing parts should be
extingusher should be kept near removed one after another
work place. 3.Trained slowly
technicians should be engaged.
1.Ladder/ standard platform 3 3 9 1.Trained technicians should be WG & PA
should be provided for deployed for the job.
ascending & descending of 2.Slings and chain pulleys
workmen for fixing & removal of should have proper validity
the slings and Chain Block certificates or 3rd party
2.Area should be inspection certifictes
evacuated. 3.Load lifted should
be less than the lifting capacity
of sling and chain Block
1.Proper sized hand tools to be 2 3 6 1.Area should be evacuated WG & PA

used. 2.Fire 2.Bearing parts should be
extingusher should be kept near removed one after another
work place. 3.Trained slowly
technicians should be engaged. 3.goggles to be used.
Tools of perfect size to be used. 2 2 4 1.Trained technician to be

deployed.

Status P S Risk
implemented 2 2 4
implemented 2 2 4
implemented 2 2 4
implemented 2 2 4
implemented 2 2 4
implemented 2 2 4
implemented 2 2 4
Job Title Dust Extraction system PM
Area 231

Spanner slip.
Hand Injury
Drive motor base bolt
1
tightness checking. Drive may be start.
Body Injury
2 'V' belt condition checking & Spanner slip.
replacement. Hand Injury
Spanner slip. Hand Injury
Compressed air hazard. Body Injury

All airlines checking &
3
leakage arrest.
Fall from height of person
during ascending &
descending Body Injury
Spanner slip. Hand Injury

All lubricating points
4
checking and inspection. Foreign particle may
hit inside to the eye. Eye Injury
5 All damper checking & fall hazard
adjusting. Body Injury
Prepared by:
Date: 28th Jan 2021
Section/ Location: Bauxite Handling plant

Proper hand tools to be use 3 3 9 Trained Technicians Should be implement
PA & WG
deployed
Proper isolation to be ensure. 2 3 6 LOTO & permit display at panel. PA & WG
V- belt of suited size should be 3 3 9 Trained fitter & technician should PA & WG
used be engaged.
Proper hand tools to be use 2 3 6 Area should be evacuated PA & WG

Compressed airline should be 3 3 9 Proper isolation to be ensured PA & WG
isolated
Trained fitter & rigger should be 3 3 9 LOTO to be displayed PA & WG
engaged.
Standard ladder to be used for 3 3 9 Safety harness use should be PA & WG
ascending and descending mandotory and anchored to fixed
point.
Proper hand tools to be used 2 3 6 Trained Technicians Should be PA & WG

deployed
Safety goggles use should be 2 3 6 Nose mask should be used PA & WG
mandotory
standard working platform should 2 3 6 Safety harness use should be PA & WG
be made mandotory and anchored to fixed
point.

Handling plant

Status P S Risk
2 2 4
2 2 4
2 2 4
1 2 2
2 2 4
1 2 2
2 2 4
2 2 4
2 2 4
2 2 4
Department: Bauxite Handling plant HIRA No.
Job Tit Magnetic seperator bearing Replacement
Area All area


2 Base bolt removal &Lift 1.Below conveyor may Body Injury

the magnetic seperator start
pulley with damaged 2.Failure of lifting tools
Bearing during lift the load.
from hands. 4.Fire
hazard
3 Existing damage bearing 1.Tools and tackes may Body Injury

removing & new bearing fall during Handling.
fitting. 2.Person may fall
during replacing the
ebaring
4 Base bolt tightening 1.Below conveyor may Body Injury
start
2.Failure of lifting tools
during lift the load.
from hands.
5 Removal of chain block 1.Failure of chain pulley Body injury

block
Prepared by:
Date: 2/10/2020

1.Proper platform to be used for 2 3 6 1.Height pass for implement
PA & WG
height job. technicians is mandotory
2.Certified chain Blocks to be 2.People
used. should not be allowed
3.Load lifted should be within below the chain block
the capacity of chain Block. 3.Valid and
certified to be sued.
1.Proper isolation to be done of 2 3 6 1.Permit and LOTO system PA & WG

below conveyor implementation should be
2.Area should be evacuated. done and displayed.
3.Load should be lifted less than 2. Tested Tools and
lifting tools load capacity tackes to be used.
4.Proper hand tools to be used. 3.Gas cutting set with NRV
5.Fire and FBA should be used
extinguisher to be kept near 4.Gas cutter
work place. shoul work with all proper
PPE
1.Tools and tackles of proper 2 2 4 1.Dust hazard should be PA & WG

size should be used. taken into consideration
2.Bearing should be handles
carefully while removing and
installing
below conveyor implementation should be
2.Area should be evacuated. done and displayed.
3.Load should be lifted less than 2. Tested Tools and
lifting tools load capacity tackes to be used.
4.Proper hand tools to be used.
1.Proper platform to be used for 2 3 6 1.Height pass for PA & WG

height job. technicians is mandotory
2.Certified chain Blocks to be 2.People
used. should not be allowed
3.Load lifted should be within below the chain block
the capacity of chain Block. 3.Valid and
certified to be sued.

Status P S Risk
Implemented 2 2 4
Implemented 2 2 4
Implemented 2 2 4
Implemented 2 2 4
Implemented 2 2 4
Job Title : Magnetic Seperator Motor replacement
Area All Area


2 Base bolt removal &Lift the 1.Below conveyor may Body Injury
magnetic seperator motor start
with chain blocks. 2.Failure of lifting tools
from hands. 4.Fire
hazard
3 Installing new motor and 1.Below conveyor may Body Injury

base bolt tightening start
2.Failure of lifting tools
from hands.
4 Removal of chain block 1.Failure of chain pulley Body injury

block
2.Fall of person during
Prepared by:
Date: 2/11/2021
Normal/Abnormal/Emergency : Routine


below conveyor implementation should be done
2.Area should be evacuated. and displayed. 2.
3.Load should be lifted less than Tested Tools and tackes to be
lifting tools load capacity used. 3.Gas cutting set
4.Proper hand tools to be used. with NRV and FBA should be
5.Fire used 4.Gas
extinguisher to be kept near cutter shoul work with all proper
work place. PPE

below conveyor implementation should be done
2.Area should be evacuated. and displayed. 2.
3.Load should be lifted less than Tested Tools and tackes to be
lifting tools load capacity used.
4.Proper hand tools to be used.

Status P S Risk
Implemented 2 2 4
Implemented 2 2 4
Implemented 2 2 4
Implemented 2 2 4
Job Title : Oil replacement of Gear Box
Area All area BHP

1 Clean the surrounding area 1.Drive may start. 1.Hand Injury

with comprrssed air / clean 2.Dust hazard 2.Eye injury
cloth
2 Remove the top inspection 1.Spanner slip. 1.Hand Injury

chamber, drain nut & collect 2.Foreign particle may be 2.Eye injury
all used oil in a container. inside to the eye. 3. Oil
may be spill on the floor.
3 Drain nut fixing & its 1.Spanner slip. Hand Injury

tightness condition
checking.
4 Add fresh oil inside the 1.Spanner slip. 1.Hand Injury
gearbox through inspection 2.Foreign particle may be 2.Eye injury
chamber(By oil pump / inside to the eye. 3. Oil
manually). may be spill on the floor.
4.Oil
container may fall
5 Fixed the Inspection 1.Spanner slip. Hand Injury

chamber & Air breather.
Prepared by:
Date: 2/11/2021

1.Proper isolation to be done 3 2 6 1.Compressed air in safe implement
PA & WG
2.Safety goggles to be used. condition to be used
2.Trained technicains to be
used.
1.Tools of proper size to be 2 2 4 1.Hand Gloves to be used. PA & WG
used.
2.Use appropriate sized
container to collect the removed
oil.
used.

used.
2.Use appropriate sized
container to discharge the
removed oil.

used.

Status P S Risk
Implemented 2 2 4
Implemented
Implemented
Implemented
Implemented
Job Title Online Lubrication and Checking of Conveyor
Area All Area BHP

1 Drive motor & gear box Spanner slip. Hand Injury/ Body Injury
base bolt tightness
checking
2 All pulleys Plummer block Spanner slip. Hand Injury/ Body Injury
base bolt tightness &
lubrication.
3 Internal & external scraper Spanner slip. Hand Injury/ Body Injury
checking & adjustment
4 Skirt rubber checking and Spanner slip. Hand Injury/ Body Injury
adjusting
Prepared by:
Date: 28th Jan 2021
Section/ Location: Bauxite Hadling

1.Spanner / Tools of exact size 2 2 4 1.Trained Technicinas to be implement
PA & WG
should be used deployed
2.Area Surroundings house
keepin to be ensured.
3. Technicians should be kept
away from running belt.
1.Spanner / Tools of exact size 2 2 4 1.Trained Technicinas to be PA & WG




Status P S Risk
2 2 4
2 2 4
2 2 4
2 2 4
Job Title : Pulley lagging
Area All Area BHP


lifting the take up along with block
counter weight for getting 2.Sudden Jerk due to
slackness in belt. hanging of loose belt
2 Both side converyor belt 1.Fall of tools and Belt Body Injury
locking/ clamping. clamp.
2.Fall of persons/ trip
hazard on the conveyor
3.Conveyor may start
3 Making arrangement for 1.Failure of chain pulley Body injury

lifting the conveyor by block
chain block. 2.Sudden Jerk due to
hanging of loose belt
4 Removing the old lagging 1.Knife may cut the 1.hand Injury
sheet with knife and finger/hand 2.Finger injury
grinding the pulley surface 2.Grinding wheel may cut
body parts during
operation
5 laying of new lagging sheet 1. Solution may spill on 1.Eye injury
and applying along the the eye 2.Fire Hazard
pulley surface with help of 2.Fire hazard may 3.chemical hazard
vulcanization solution happen as solutionis
flammable
6 Releasing the take up along 1.Failure of chain pulley Body injury

with counter weight for block
getting tension in the belt. 2.Sudden Jerk due to
7 Both side converyor belt 1.Fall of tools and Belt Body Injury
locking/ clamping opening clamp.
Prepared by:
Date: 2/11/2020
Section/ Location: Buaxite Hnadling Plant

3.After slight loose of belt, 2
Nos. of Belt Holding clamps-
has to be fixed at take up bend
area & belt clamp is to be fixed
at turn over are.
4.Load lifted should be
within the chain pulley capacity
1.Standard Clamps to be used 2 3 6 1.Conveyor should be isolated. PA & WG

for Clamping 2.LOTO and
2. permit should be displayed.
Tools of suitable size to be 3.If work at height
used. life line should be used.
3.Proper platform to be made
for techicians to work.

at turn over are.
1.Knife to be used carefully and 2 3 6 1.Trained Belt jointer to be PA & WG
slowly deployed.
2.Tested and certified grinding 2.Electric tools to be tested
tools to be used. before usage.
1.Solution to be applied slowly. 2 2 4 1.House keeping to be ensured. PA & WG
2.Flammable materials should

be kept away in work site.

at turn over are.


Status P S Risk
Implemented 2 2 4
Implemented 2 2 4
Implemented 2 2 4
Implemented 1 2 2
Implemented
Implemented 2 2 4
Implemented 2 2 4
Job Title : Crusher Toe bar and Rotor cleaning
Area: 231

1 Making arrangement to 1.Failure of chain pulley 1.Body injury

guide / lifting the inspection block 2.Hand Injury
door by chain block. 2.Work at height while
installing Chain Block
2 Crusher inspection door & 1.Fall of bolts & slip tools 1.Body Injury
top cover to be removed. from hands 2.Fall 2.Hand Injury
of materials/hood cover.
3 Making arrangement for 1.Slip link pin & tools 1.Hand Injury
removing coupling guard & from hands 2.Body Injury
rotor lock. 2.Rotor may move.
4 Bauxite dust & Lumps to be 1.Hand tools may slip. 1.Hand Injury
removed & cleaning to be 2.Material fall from 2.Body Injury
done. screen.
5 If any foreign material found Fall of person Body injury

inside crusher it should be
removed manually.
6 Crusher box-up to be done 1.Fall of bolts & slip tools 1.Body Injury
rotor lock to be removed & from hands 2.Fall 2.Hand Injury
coupling guard to be fixed. of materials/hood cover.
Prepared by:
Date: 2/15/2020
Normal/Abnormal/Emergency :Normal

3.Load lifted
should be within the chain pulley
capacity
1. Proper hand tools to be used 2 2 4 1.Area should be evacuated PA&WG

2.Cover and house keeping to be
to be in rest while holding with mantained.
chain block
1.Proper Hand tools to be used. 3 2 6 1.Trained rigger should be PA&WG
2.Rotor engaged to control the height of
isolation to be ensured. hood plate during removing &
locking of the lock pin
1.Screen to be isloated. 2. 2 2 4
Trained techicians should be
engaged to control the cleaning
activity.
Trained operators to be 2 2 4
deplpyed
1. Proper hand tools to be used 2 2 4 1.Area should be evacuated PA&WG

2.Cover and house keeping to be
to be in rest while holding with mantained.
chain block

Status P S Risk
Implemented 2 2 4
Implemented. 2 2 4
Implemented. 2 2 4
Implemented. 2 2 4
HAZARD IDENTIFICA
Departmen Mechanical HIRA No.
Job Title Shieve pulley replacement
Area BHP all area

1 Positioning of crane for lifting counter 1. Crane wheel/jack may May lead to fatal incident
weight go down in soil.
workman.
2 Remove Counter weight rope from take-up 1.Hand Injury Hand injury
pulley 2.Fall of D-shackle & slip
tools from hands
3 Fit-up a new sheave pulley & lubricate. 1. Electric shock may be 1.Electric Hazard
connecting with 2.Hand Injury
technician during 3.Eye injury
welding.
2.Fire during gas cutting.
3.fall and
slip of hand tools and bolt
from hand.
4.Grease may splash
in the eye.
4 Take-up to be fixed back & fixing of D- 1.Hand Injury 1.Hand Injury

shackle. 2.Fall of D-shackle & slip 2.Body Injury
tools from hands
5 Releasing counter weight of take-up till 1. Crane wheel/jack may May lead to fatal incident
required height for conveyor tension. go down in soil.
workman.
Prepared by:
Date: 2/10/2021
Section/ Location: Bauxite handling plant
Existing control measure to Existing / Base Risk Additional control measure Responsible
mitigate hazard P S Risk Official to
1.The ground should be 3 4 12 implement
1. During work on hydra follow PA&WG
crane. be used.
3. Proper signaling during 3.Trained workmen should be
marching should be ensured. engaged for the job.
from hydra.
1.Trained technicians should be 3 2 6 1.Proper housekeeping to be PA&WG

engaged for remove the D- done before start the job.
shackle. 2.
1.Welding M/C connect with 3 3 9 1.Trained Technicains should PA&WG

VRD & ELCB. be deployed for the job
2.Flammable materials should 2.Flammable materials should
be taken away & gas not be kept near hot zone.
extinguishers equipments
should be in place.
3.Use proper hand tools as for
requirement
4.safety oggles to be used.
1.Trained technicians should be 2 3 6 PA&WG

engaged for remove the frame.
2. Proper
hand tools to be used
1.The ground should be 3 4 12 1. During work on hydra follow PA&WG
crane. be used.
3. Proper signaling during 3.Trained workmen should be
marching should be ensured. engaged for the job.
from hydra.

handling plant

Status P S Risk
Implemented 1 3 3
Implemented 2 2 4
Implemented 1 2 2
Implemented 2 2 4
Implemented 1 3 3
HAZARD IDENTIFICATION
Department: Bauxite Handling HIRA No.
Job Title Tail Pulley Adjustment
Area All area BHP

1 Make arrangements for lifting 1.Failure of chain pulley Body injury

the take up along with counter block
weight for getting slackness in 2.Sudden Jerk due to
belt. hanging of loose belt
2 Both side converyor belt locking/ 1.Fall of tools and Belt Body Injury
clamping. clamp.
3 Making arrangement for lifting 1.Failure of chain pulley Body injury

the conveyor by chain block. block
2.Sudden Jerk due to
4 Open the all base bolts and Fall of bolts & slip tools Hand injury
pumber block cover bolts. from hands.
5 Move the pulley shaft to 1.Chances of leakages of hand injury & body injury
original position with Hydraulic hydraulic oil with
jack pressure.
2. Failure of slings.
3. Failure of chainblock.
6 Alignment of base and fit up all 1.Slip tools/bolt from hand injury & Finger
bolts hands. injury
2.Finger may be contact
and crush with base.
3.Packing
Shims may be cut the
finger
7 Releasing the take up along 1.Failure of chain pulley Body injury

with counter weight for getting block
tension in the belt. 2.Sudden Jerk due to
8 Both side converyor belt locking/ 1.Fall of tools and Belt Body Injury
clamping opening clamp.
Prepared by:
Date: 2/10/2020

implement
at turn over are.


at turn over are.
Toos of suitable size to be 2 2 4 House keeping to be maintanied PA & WG
used. in area surroundings
1.Trained fitter should operate 2 3 6 Tools with valid test certificate PA & WG
the hydraulic jack. should be used.
2.Tested and visullay checked
sling to be used along with
tested. 3.Load
should be lifted as per chain
block capacity
1.Proper Hand Tools to be 2 3 6 1. Area house keeping to be PA & WG

sued. done.
2.Shims to be placed and
removed slowly and carefully
3.Use of gloves is mandotory

at turn over are.


Status P S Risk
Implemented 2 2 4
Implemented 2 2 4
Implemented 2 2 4
Implemented 2 2 4
Implemented 2 2 4
Implemented 2 2 4
Implemented 2 2 4
Implemented 2 2 4
Job Title : Crusher Toe Bar adjustment
Area

1 Isolation (Screen, Crusher, 1.TBP drive my start 1.Hand Injury

Below Conveyor) 2.Body Injury
2 Making arrangement for 1.Failure of chain pulley 1.Body injury

lifting the toebar by chain block 2.Hand Injury
block. 2.Work at height while
3 Both side packing plate 1.Chain Block may fall 1.Body injury
Removal & toebar hold bolt 2. Fall of Materials. 3. 2.Hand Injury
removal Fall / slip of hand tools
from hand
4.Failure of tools abnd
Tackles
5.hand struck between
toe bar and its base
4 Cleaning by Hydro jet m/c. 1.High Pressure air can 1.Eye Injury
damage eye 2.Slip &
trip hazards.
5 Installing both side packing 1.Chain Block may fall 1.Body injury
plate and hold bolt 2. Fall of Materials. 3. 2.Hand Injury
Fall / slip of hand tools
from hand
4.Failure of tools abnd
Tackles
6 Making arrangement for 1.Failure of chain pulley 1.Body injury
removing the chain Block block 2.Hand Injury
2.Work at height while
Prepared by:
Date: 2/12/2020
Section/ Location: Bauxitte Handling Plant
Normal/Abnormal/Emergency : Routine

1.Isolation and permit system to 2 2 4 implement
1.Trained electrician should be PA & WG
be implemented deployed for isolation job.

3.Load lifted
capacity
1.Load should be lifted less than 2 3 6 1.Trained technicians to be PA & WG
lifting tools capacity 2. deployed.
Proper hand tools to be used 2.Area House keeping to be
maintained
1.Air pressure of required 2 2 4 1.Trained operaror to be

quantity to be used. deployed
2.person to be deployed near
the air valve to immediately
close it.
1.Load should be lifted less than 2 3 6 1.Trained technicians to be PA & WG

lifting tools capacity 2. deployed.
Proper hand tools to be used 2.Area House keeping to be
maintained
3.Load lifted
capacity

Status P S Risk
Implemented 2 2 4
Implemented 2 2 4
Implemented 2 2 4
Implemented 2 2 4
Implemented 2 2 4
Job Title Material Handling
Area

the step Impact
1. Crane wheel/jack may
go down in soil.
2. Hydra may be hit to
workman at the time
base plate fixing.
Possibility of serious
to fatal accident due
1 Positioning of crane
to Crane go down in
soil

2.
Loose support may
Fixing the sling for lifting topple.
2 the Platform. 3. Hand injury. Serious injuries
Lift of platform from 1. Fall from height of

3 ground to Fixing person or object at the Serious injuries
position. 2.
2.
Fall of bolts & slip tools
from hands.
3. Fall from height
Fix & bolting the of person or object at
4 the time of bolting & Serious injuries
platform on the base welding.

Remove the sling from time remove the sling.
5 Serious injuries
platform.
from hands.
Prepared by:
Signature:
Name
Section/ Location:
av Normal/Abnormal/Emergency Normal

1.The ground should be 1. During work on hydra implement
WG/PA
compacted and leveled. follow the SWI of hydra
2. Iron plate should be operation.
placed on ground before 2.
posting of crane. 6mtr guide rope to be used.
3. Proper signaling during
4. Keep distance minimum 3 3 5 15
mtr from hydra.
1. Area should be evacuated. 1.Proper housekeeping to be WG/PA

2. Trained technicians should done before start the job.
be engaged.
3. Proper hand tools to be
used.
4.Make proper working
platform. 3 4 12
1. Load should be lifted as 1. Slings with valid test WG/PA

per crane capacity. 3 4 12 certificate should be used.
certificate should be used. 2.Trained rigger
1. Area should be evacuated. 1.Proper housekeeping to be WG/PA
2. Trained technicians should done before start the job.
be engaged.
3. Proper hand tools to be
used.
4.Make proper working
platform. 5. Welding
machine connection to be
taken from ELCB & VRD. 3 4 12
1. Area should be WG/PA

1. Trained technicians should evacuated.
be engaged.
used.
shoes, Safety Helmet & 3 4 12
Cotton hand gloves.

Name Name
utine

Status P S Risk
Provide quality
training
3 1 3
Fall protection
guideline for worker
3 1 3
Fall protection
guideline for worker 3 1 3
Fall protection
3 1 3
Fall protection
3 1 3
HAZARD IDENTIFICATION AND R
Job Title Wintch Machine Fitting / dismentaling & Rope Laying
Area

step Impact
1 Fixing / remove the Rope Fall from height of person or Possibility of serious to
pulley on the monorail object at the time fixing the fatal accident
beam. sling/pulley.
Hand injury during fixing the hand injury

wire rope.
Fall of martial during loading Injury to

lowering or lifting the rope. people/workman
2 Winch machine lift by Hand injury during fixing the hand injury
Hydra. sling.
Hydra may hit to workman. Injury to

people/workman
fatal accident
Fall of martial or person
during loading and unloading.
3 Hand injury during Machine hand injury

fitting & dismentaling.
Manual Material Handling
for positing in proper
place.
3

for positing in proper
place. Fall of bolts & slip tools from Head injury
hands.
Fall from height of person or Possibility of serious to

object at the time fixing the D- fatal accident
shackle/pulley.
Arrangement for rope laying

4
by manually.
Material slip/fall hazard. Head injury
Prepared by:
Signature:
Name
ying Section/ Location:

1.Trained rigger should be 3 5 15 implement
PA& WG
engaged to control the height 1.Make ensure proper working
during fixing the pulley/rope. platform for work at height.
2. Use double lanyard safety 2. Use double lanyard safety
harness. harness.
3.Height pass worker to be
conduct the height work.
1.Tested / standard hand tools 3 1 3 WG

hand gloves. 3. Avoid to use D-
spanner.
1.Trained technicians should be 4 5 20 1.Barricading should be done in PA& WG
engaged. 2.Wire the surrounding area. 2.
rope proper tie by PP rope. Area should be evacuated.

spanner.
3 3 9 1.Ensure Reverse horn on the PA& WG
Keep distance minimum 3 mtr hydra.
from hydra. 2. Proper signalling during
3.During work on hydra follow
the SWI of hydra operation.
1.Load should be lifted as per 4 5 20 1.6mtr guide rope to be used. PA& WG

Hydra capacity. 2. Area
2.Encure Hydra & lifting tools should be evacuated.
& Tackles with valid test 3.Barricading should be done in
certificate to be use. the surrounding area.

spanner.
Proper hand tools to be used. 4 2 8 1.Area should be evacuated. WG
1.Trained rigger should be 3 5 15 PA& WG

2. Use double lanyard safety 2.Height pass worker to be
harness. conduct the height work.

the surrounding area. 3.Use
Proper PPE.

Name Name
utine

Status P S Risk
Training provided 1 5 5
to the workers.
Implemented
During the Job 1 3 3

ensure the load
lifting
Implemented
Training 1 3 3
implimentaid

ensure the load
lifting
Implemented
Implemented 2 1 2
to the workers.
Implemented 2 1 2
Job Title Wintch Machine Fitting & dismentaling.
Area

1 Winch machine lift by Hand injury during hand injury
Hydra. fixing the sling.
Hydra may hit to Injury to

workman. people/workman
Fall of martial or person fatal accident
during loading and
unloading.
2 Hand injury during hand injury

Machine fitting &
dismentaling.

for positing in proper Material slip/fall hazard. Head injury
place.
Prepared by:
Signature:
Name
Section/ Location:

1.Tested / standard hand tools 3 1 3 WG implement
spanner.
1.Load should be lifted as per 4 5 20 1.6mtr guide rope to be used. PA& WG

Hydra capacity. 2. Area
2.Encure Hydra & lifting tools should be evacuated.
& Tackles with valid test 3.Barricading should be done in
certificate to be use. the surrounding area.
spanner.
Proper PPE.

Name Name
utine

Status P S Risk
Implemented
Training 1 3 3
implimentaid

ensure the load
lifting
Implemented
Implemented 2 1 2
Job Title Counter weight replacement from take-up
Area BHP

the step Impact
Making arrangement for lifting & Failure of Lifting tools. Possibility of fracture
fixing the rope pulley & chain injury
block on the take-up.
Fall from height of person Possibility of serious

during ascending & to fatal accident
1 descending in side chute.
Hand injury during fixing hand injury

the sling.
Remove of existing damaged Fall & Slip hazard

counter weight & placed on the
platform/ground.

people/workman
2
Conveyor may be start. Possibility of serious
to fatal accident

the sling.
Failure of Lifting tools. Possibility of serious

to fatal accident
Fall from height of person or Possibility of serious

object at the time removing to fatal accident
the wire rope pulley.
3 Remove of all Accessories

Pulley may be hit to the Injury to
worker. people/workman
Prepared by:
Signature:
Name
Section/ Location:
v Normal/Abnormal/Emergency Normal

Rope pulley/ chain 4 5 20 1. Area should be implement
PA& WG
block(Lifting tools) in good evacuated. 2.Barricading
condition & with valid test should be done in the
certificate. surrounding area.
3.Unauthorized persons
should not be entry inside
the work area.
1.Make ensure proper 3 5 15 1.Manlift use in place of AO,PA & WG

height.
2. Use double lanyard safety 1.Make ensure proper
harness. working platform for work
at height.
harness.
1.Tested / standard hand 3 1 3 WG

tools to be used. 2.
Use cotton hand gloves.
3. Avoid to use D-
spanner.
1.Make proper working 4 2 8 1.Area should be WG
platform.2.Trained fitter & rigger evacuated.2.Apart from using
should be engaged. mandatory PPEs(Safety
Harness).
1.Proper isolation to be done. 3 5 15 1.LOTOTO & work permit AO,PA & WG
2. Before & after conveyor display at panel.
drive should be isolated. 2.Barricading should be
area.
Trained technicians should be 3 1 3 WG

engaged for remove the
frame.
Rope pulley(Lifting tools) in 4 5 20 PA& WG

good condition & with valid
test certificate. Unauthorized persons should
not be entry inside the work
area.

height.
at height.
1. Trained technicians should be 3 5 15 LOTOTO
harness.
& work permit AO,PA & WG
engaged.2.Before & after display at panel.
conveyor drive should be isolated.

Name Name
utine

Status P S Risk
ensure the load
lifting
Training 1 5 5
provided to the
workers.
Implemented
Implemented 2 1 2
Training 1 3 3
implimentaid
LOTOTO system 1 5 5
implemented
Implemented

ensure the load
lifting
Training 1 5 5
provided to the
workers.
LOTOTO system 1 5 5
implemented
Job Title Counter weight replacement from take-up
Area BHP

the step Impact
Making arrangement for lifting & Failure of Lifting tools. Possibility of fracture
fixing the rope pulley & chain injury
block on the take-up.
Fall from height of person Possibility of serious

during ascending & to fatal accident
1 descending in side chute.

the sling.
Remove of existing damaged Fall & Slip hazard

counter weight & placed on the
platform/ground.

people/workman
2
2 Conveyor may be start. Possibility of serious
to fatal accident

the sling.
Failure of Lifting tools. Possibility of serious

to fatal accident
Fall from height of person or Possibility of serious

object at the time removing to fatal accident
the wire rope pulley.
3 Remove of all Accessories
Pulley may be hit to the Injury to

worker. people/workman
Prepared by:
Signature:
Name
Section/ Location:
v Normal/Abnormal/Emergency Normal

Rope pulley/ chain 4 5 20 1. Area should be implement
PA& WG
the work area.

height.
at height.
harness.
1.Tested / standard hand 3 1 3 WG

tools to be used. 2.
Use cotton hand gloves.
3. Avoid to use D-
spanner.
1.Make proper working 4 2 8 1.Area should be WG
platform.2.Trained fitter & rigger evacuated.2.Apart from using
should be engaged. mandatory PPEs(Safety
Harness).
1.Proper isolation to be done. 3 5 15 1.LOTOTO & work permit AO,PA & WG
2. Before & after conveyor display at panel.
drive should be isolated. 2.Barricading should be
area.
Trained technicians should be 3 1 3 WG

engaged for remove the
frame.
Rope pulley(Lifting tools) in 4 5 20 Unauthorized persons should PA& WG

good condition & with valid not be entry inside the work
test certificate. area.

height.
at height.
harness.
1. Trained technicians should be 3 5 15 LOTOTO & work permit AO,PA & WG

engaged.2.Before & after display at panel.
conveyor drive should be isolated.

Name Name
utine

Status P S Risk
ensure the load
lifting
Training 1 5 5
provided to the
workers.
Implemented
Implemented 2 1 2
Training 1 3 3
implimentaid
LOTOTO system 1 5 5
implemented
Implemented

ensure the load
lifting
Training 1 5 5
provided to the
workers.
LOTOTO system 1 5 5
implemented
HAZARD IDENTIFICATION AND
Department: HIRA No.
Job Title Counter weight rope & hook replacement.
Area

step Impact
1 Both side conveyor belt Fall of tools and Belt clamp Possibility of fracture injury
locking/ clamping.
Fall of persons/ trip hazard on Possibility of fracture injury.

the conveyor due to unstable
2 Fixing the chain block for Fall from height of person or Possibility of serious to
lifting the counter weight. object at the time fixing the fatal accident
sling/chain block.
Hand injury during fixing the hand injury

sling.
Making arrangement & lift Failure of chain block/Lifting Possibility of fracture injury
the take-up counter weight tools tackle.
by chain block.
Injury due to unexpectedly Possibility of serious to

running of conveyor fatal accident
Sudden Jerk due to hanging of

loose belt
4 Remove D-shackle & wire Fall of bolts & slip tools from Possibility of fracture injury
rope from lifting base. hands.
Remove the old lifting base Fall & Slip hazard

& install a new lifting base
one by one.
Fire hazard
Material (Bauxite) fall

hazard
Hand Injury
5
Electric shock may be
connecting with technicians.
Failure of Lifting tools. Possibility of fracture injury
6 Installs of new wire Lock pin may be hit to

rope. the worker.
Fall from height of lock
pin/ D-shackle.
Fall of wire rope
7 Installs of new wire Lock pin may be hit to

rope. the worker.
Fall from height of lock
pin/ D-shackle.
Fall of wire rope
8 Removal of both ends Fall of belt clamps

the clamps after
complied the job.
Fingers may get stuck between

belt and idler while removing
leading to injury
Prepared by:
Signature:
Name
Section/ Location:
Routine /NonRoutine

Clamping will be carried out on 3 3 9 1.Area should be implement
WG.PA
platform evacuated.2.Standar hand tool
should be used.
1.Hand railing provided. 2.Use 3 3 9 1.Life line to be used 2.Use WG.PA

proper hand tools as for proper PPE such as hand
requirement gloves.
1.Trained rigger should be 3 5 15 PA& WG
2. Use double lanyard safety 2. Use double lanyard safety
harness. harness.
3.Height pass worker to be
conduct the height work.

spanner.
3 3 9
Good condition chains to be Before using physical

used. verification should be done
WG,PA
Permit & LOTOTO to be done 3 5 15 1.LOTOTO & work permit AO,PA & WG
display at panel.
area.
After slight loose of belt, 2 Nos. 4 3 12 Unauthorized persons should AO,PA & WG
of Belt Holding clamps-ISMC- not be entry inside the work
200 has to be fixed at take up area.
bend area & belt clamp is to be
fixed at turn over are.
1.Proper hand tools may be 3 3 9 1.Area should be WG.PA
used 2.Keep-up good evacuated.2.Standar hand tool
housekeeping. should be used.3.Trained
1.Make proper safe working 4 2 8 1.Area should be evacuated. WG

platform.2.Trained fitter & rigger 2.Barricading should be done in
should be engaged.
Proper PPE.
Fire extinguisher keep near 3 1 3
by work place.
outside to be clean by 3 1 3
housekeeping labor.
Trained technicians should 3 1 3 WG

be engaged for remove or
install the frame/ structure.
Authorize electrician 3 3 9 Follow all appropriate AO,PA & WG

connected the power supply. precaution as per standard..
Rope pulley/ chain 4 5 20 1. Area should be PA& WG

the work area.
Trained technicians should 1 3 3

be engaged.
1.Area should be 1 3 3
evacuated.2.Proper hand
tools to be used.
Proper locking on structure. 2 3 6 Guide rope to be provided.
Trained technicians should 1 3 3

be engaged.
1.Area should be 1 3 3
evacuated.2.Proper hand
tools to be used.
Proper locking on structure. 2 3 6 Guide rope to be provided.
Trained rigger should be 3 3 9 The entire belt profile to be AO,PA & WG

engaged for remove the inspected for any tension or
belt.2.standard/proven belt stuck in the structure.
clamps to be used for clamping
with proper fastening of bolts.
Uniformity of tightness along the
width of the belt to be ensured, if
required packing has to be
provided.
Trained technician should be 1 3 3 WG.PA

engaged with proper PPE such
as hand gloves

Name Name
Status P S Risk
Training 1 3 3
provided to the
workers.
Implemented 1 3 3
to the workers.
Implemented
Training 2 3 6
provided to the
workers.
LOTOTO system 1 5 5
implemented
Training 1 3 3
provided to the
workers.
Training 1 3 3
provided to the
workers.
Implemented 2 1 2
Implemented
1 3 3

ensure the load
lifting
ensure the load
lifting
HAZARD IDENTIFICAT
Job Title Counter weight replacement of Reclimer & Stracker
Area

Impact
1 Electrical & instrumentation 1. Electric shock may be connecting Possibility of serious to fatal
isolation of Reclaimer. with technicians. accident
2. Motor may be start.
2 Position bucket wheel boom 1. Rest platform may be toppled. Possibility of serious to
and mast over the pre 2. Fall from height of person or fatal accident
erected loose support near object at the time of bolting &
suspension pin welding.
1. Crane wheel/jack may go down in

soil.
2. Hydra may be hit to workman.
Crane positioning for
3 fatal accident/fracture
counter weight removal. injury.
4 Injury to people/workman
Under carriage arresting in 1. Lock pin may be hit to the

longitudinal and transverse worker.
direction by wind pin 2. Fall from height of lock pin.
(locking assembly)
1. Failure of crane. Possibility of serious to fatal

2. Failure of slings. accident/Fracture injury.
3. Fall of Material.
4. Fall from height of person or
object at the time of fixing the
Remove counter weight sling.
5
from boom. 5. Fall of man basket
6 Erection of removed 1. Failure of crane. Possibility of serious to fatal

counters weights at 2. Failure of slings. accident/Fracture injury.
boom. 3. Fall of Material.
4. Fall from height of person
or object at the time of fixing
the sling.
5. Fall of man basket.
Disengage slew lock 1. Reclaimer wheel may be

pin and travel locking move.
arrangement 2. Lock pin may be fallen
down on the workers body.
7
8 Dismantling of 1. Fall from height of person or Possibility of serious to fatal

temporary loose object at the time fixing the sling. accident/Fracture injury
support provided 2. Fall of bolts & slip tools from
under boom & hands.
Removal of all Tools &
Tackles.
8 Dismantling of 1. Fall from height of person or Possibility of serious to fatal
temporary loose object at the time fixing the sling. accident/Fracture injury
support provided 2. Fall of bolts & slip tools from
under boom & hands.
Removal of all Tools &
Tackles.
Prepared by:
Signature:
Name
Section/ Location:
Routine /NonRoutine

hazard P Risk S Risk
1.Use proper PPE like safety shoe, 3 5 15 1. Use proper PPE like safety shoe,
safety helmet & rubber hand gloves. safety helmet & rubber hand gloves.
2.
Take proper permit from authorized 2. Provide LOTO on the
person. 3.Remove system. 3.Unauthorized
power supply from electrical control persons should not be entry inside the
room. 4.Take LOTO work area.
on electrical panel board.
1. Proper welding & bolting the 3 5 15 1.Before participate in height worker

reclaimer boom rest platform. most be take safety training about the
2. Area should be evacuated. use of the required PPEs for height
3. After rest the boom on the platform it work and should be explained about
should be locked. the different hazards associated in
4. Apart from using mandatory PPE, use height work and how to handle them.
Safety Belt & anchor it to a rigid point.
5. Life line will provided for all working 2. Before going for
place. working at height wear the full body
harness with double lanyard.
1.The ground should be compacted

and leveled. 4 5 20 1. During work on hydra follow
2. Iron plate should be placed on
ground before 2. 6mtr guide rope to be used. 3.
Posting of crane. Training Technician Should be
3. Proper signaling during marching angaged.
should be
ensured.
from hydra.
2 4 8 1.Area where erection has to take
place shall be roped off and “No
1. Area should be evacuated. Entry” sign shall be placed to keep
2. Trained technicians should be out un authorized persons.
engaged.
4. Apart from using mandatory PPEs use
5. Make proper working platform.
1. Load should be lifted as per crane 4 5 20 1. Slings with valid test certificate
capacity. should be used.. 2.Trained
rigger should be engaged to control
2. Crane with valid test certificate should
the height during lifting the counter
be used. weight.
3. Crane operator should be engaged for 3. Trained foreman should be
operation of crane. engaged to guide the crane
4. Area should be evacuated. operator.
5. Barricading should be done in the 4. Man basket proper locking with
surrounding area. crane hook.
1. Load should be lifted as per crane 4 5 20 1. Slings with valid test certificate
capacity. should be used.. 2.Trained rigger
2. Crane with valid test certificate should be engaged to control the
should be used.
3. Crane operator should be engaged height during lifting the counter
for operation of crane. weight.
5. Barricading should be done in the engaged to guide the crane
surrounding area. operator.
4. Man basket proper locking with
crane hook.
1. Trained technicians should be 3 3 9 1.All hand tools and powered

engaged. operated tools shall be maintained
2. Proper hand tools may be used. and kept in safe condition.
3. Use proper PPE like safety shoe,
safety helmet, & cotton hand gloves 2.Lock pin fasten the PP rope.
1. Area should be evacuated. 3 3 9 1.Proper illumination most be

2. Trained technicians should be ensured. 2.
engaged. Use of within Safe Working Load of all
3. Proper hand tools should be used. lifting Tool, Tackles & Machinery. 3.
Use PP rope.
1. Area should be evacuated. 3 3 9 1.Proper illumination most be
2. Trained technicians should be ensured. 2.
engaged. Use of within Safe Working Load of all
3. Proper hand tools should be used. lifting Tool, Tackles & Machinery. 3.
Use PP rope.
Reviewed by:
Signature:
Name
implement
PA & AO LOTOTO system 1 5 5
implemented
AO,PA & WG Training Provided 1 5 5

to the workers
before job.
AO,PA & WG Training 1 5 5

provided to the
workers.
WG.PA Training 1 4 4
provided to the
workers.
to the workers.
WG.PA
AO,PA & WG Training provided 1 5 5

to the workers.
WG Implementation 1 3 3
Status
wg During the Job 1 3 3

ensure the load
lifting
wg During the Job 1 3 3
ensure the load
lifting
Approved by:
Signature:
Name
HAZARD IDENTIFICAT
Job Title Counter weight trolly frame modification & reposition.
Area BHP

Impact
1 Lift the counter weight of Crane wheel/jack may go down in Possibility of serious to
take-up till required height. soil. fatal accident
2. Hydra may be hit to workman.
2 1.Hand Injury . Hand Injury

2.Fall of D-shackle & slip tools from
Remove Counter hands
weight rope from take-
up pulley.
1.Fall & Slip hazard. 2.Hand

Remove Counter weight Injury. 3.Fall from
from take-up . height of person or object at the
time removing same.
1. Fall & Slip hazard .

2. Fire hazard .
3. Hand Injury.
4. Electric shock may be
5.Failure of Lifting tools. 6.Fall
from height of person or object at Possibility of serious to fatal
Counter weight frame
4 the time removing same. accident/Fracture injury/Cut
modification
injury.
3. Hand Injury.
4. Electric shock may be
5.Failure of Lifting tools. 6.Fall
from height of person or object at Possibility of serious to fatal
Counter weight frame
4 the time removing same. accident/Fracture injury/Cut
modification
injury.
5 Fit-up a new sheave 1. Electric shock may be Possibility of serious to fatal

pulley or inspection & connecting with technician accident/Fracture injury.
lubricate. during welding.
2. Fire during gas cutting.
3.Hand Injury.
4. fall and slip of hand tools
and bolt from hand.
Lift new counter 1. Fall from height of person Possibility of serious to fatal
weight to take-up or object at the time removing accident/Fracture injury.
frame . same.
6
7 Take-up to be fixed 1. Fall of D-shackle & slip tools from Hand Injury
back & fixing of D- hands.
shackle. 2.Hand Injury
8 Lift the counter weight of 1.Crane wheel/jack may go down in Possibility of serious to fatal
take-up till required height soil. 2.Failure of accident/Fracture injury.
for conveyor tension. Lifting tools. 3.Fall from height
of person or object at the time of
lifting the counter weight.
Prepared by:
Signature:
Name
Section/ Location:
P Routine /NonRoutine

hazard P Risk S Risk
1.Area to be barricaded prior to start the 4 5 20 1. Trained technician should be
job. 2.The ground engaged.
should be compacted and leveled. 2. Soil test
3. Iron plate should be before the job. 3.Unauthorized
placed on ground before posting of persons should not be entry inside the
crane. 4.Permit has to be taken and that work area. 4.Job specific training to
need to be displayed to make all aware all technician/worker.
1.Trained technicians should be engaged 1 3 3

for remove the D-shackl. 2. Proper
hand tools to be used. 3.Use proper
PPE.
2 4 8 1.Area where erection has to take

place shall be roped off and “No
1. Area should be evacuated. Entry” sign shall be placed to keep
2. Trained technicians should be out un authorized persons.
engaged.
4. Apart from using mandatory PPEs use
5. Make proper working platform.
1.Make proper safe working platform. 4 5 20 1. Slings with valid test certificate
2. Trained fitter & rigger should be should be used.. 2.Trained
engaged.
3.Trained technicians should be engaged weight.
for remove the D-shackle . 3. Trained foreman should be
4.Proper platform to be provided. engaged to guide the crane
5.Fire extinguisher keep near by work operator.
place . 4. Unauthorized persons should not
6.Authorize electrician connected the be entry inside the work area.
power supply. 5.Use Proper PPE.
7.Chain block(Lifting tools) in good
2. Trained fitter & rigger should be
engaged.
3.Trained technicians should be engaged weight.
for remove the D-shackle . 3. Trained foreman should be
4.Proper platform to be provided. engaged to guide the crane
5.Fire extinguisher keep near by work operator.
place . 4. Unauthorized persons should not
6.Authorize electrician connected the be entry inside the work area.
5.Use Proper PPE.
power supply.
7.Chain block(Lifting tools) in good
1. Welding M/C connect with VRD & 5 5 25 1. Use proper PPE, like safety shoes,
ELCB. Safety Helmet, Heat resistance
2. Gas cutting set connect with FBA gloves. 2.Fire extinguisher placed
& NRV .
3. Flammable materials should be near work place.
taken away & fire fighting 3.Area should be clean.
equipments should be in place. 4. Earthing proper check before job.
4. Use proper hand tools as for 5.Unauthorized persons should not
requirement be entry inside the work area.
5. Barricading should be done in the
surrounding area.
6.Trained technicians should be
engaged
1.Make ensure proper working 3 5 15 1.Manlift use in place of working

platform for work at height. platform.
2. Use double lanyard safety 1.Make ensure proper working
harness.
1. Area should be evacuated. 1 3 3

2. Trained technicians should be
engaged.
3. Proper hand tools should be used.
1.Area to be barricaded prior to start the 5 4 20 1.Unauthorized persons should not be
job. 2.The entry inside the work area.
ground should be compacted and 2.Barricading should be done in the
leveled. 3. Iron surrounding area. 3.Job
plate should be placed on ground before specific training to all
posting of crane. 4.Permit has technician/worker.
to be taken and that need to be displayed
to make all aware. 5.Chain block(Lifting
tools) in good condition & with valid test
certificate .6.Trained rigger should be
engaged to control the height during
lifting the counter weight.
Reviewed by:
Signature:
Name
Non Routine

implement
PA & WG Training Provided 1 5 5
to the workers
before job.
WG.PA Training 1 4 4
provided to the
workers.
to the
workers./During
the Job ensure the
load lifting
WG.PA
workers./During
the Job ensure the
load lifting
WG.PA
PA & WG Training provided 1 5 5

to the workers.
AO,PA & WG Training provided to 1 5 5

the workers.
PA & WG Training Provided 1 4 4
to the workers
before job.
Approved by:
Signature:
Name
HAZARD IDENTIFICATION AND RISK
Job Title DSS PM
Area All area

Drive motor base bolt Spanner slip.

1 tightness checking. Hand injury
Spanner slip. Hand injury

Possibility of
serious to
injury.
Compressed air hazard.
Possibility of
serious to
injury.
Possibility of
All airlines/ water line serious body
2 checking & leakage arrest. injury
Fall from height of
person . Possibility of
serious body
injury
Eye Injury due to air

pressure. Eye injury
Hand injury Hand injury
Air filter / water filter cleaning and Possibility of

3 spray nozzle cleaning / Fall from height of
serious body
replacement person .
injury
Prepared by:
UAIL/BHP/O&M/HIRA/ Date:
, Mr. K.Bharghav Normal/Abnormal/Emergency Normal

implement
Tested hand tools to be used 2 1 2 Area should be evacuated WG & PA
Compressed airline should be Compressed air should be released

isolated 3 2 6 WG & PA
then work will be started
Trained fitter & rigger should be Use PPEs and Full Body Safety
engaged. 2 2 4 Harness WG & PA
Trained technicians should be

3 3 9
engaged.
Safety Belt anchors it to a rigid
WG & PA
point.
Use indivisual life line for each
person 3 3 9

engaged 2 2 4 Use of Face Gurad, Nose mask . WG & PA
Trained technicians should be use hand glooves

engaged 2 2 4 WG & PA

Tested hand tools to be used 2 1 2 WG & PA
engaged.
Use indivisual life line for each Safety Belt anchors it to a rigid
person 3 3 9 WG & PA
point.

engaged 2 2 4 use hand glooves WG & PA

0-TT-1
on Routine
ormal
Implementation Status Residual Risk

P S Risk
Before start the job
training was completed 1 2 2
implemented 1 2 2
implemented 1 2 2
implemented 1 2 2
2 3 6
height trainning given to
technicians.
2 3 6
implemented 1 2 2
implemented 1 2 2
implemented 1 2 2

height training given to 2 3 6
technicians.
implemented 1 2 2
Job Title FEEDING TABLE PM
Area RECLAIMER

Check proper fastening of Fall from height of person Possibility of

1 garland impact idlers & or object at the time fixing fracture injury
replace damage idlers. the roller

Check condition of skrit Possibility of
2 rubbers & replace if requird. Fall & Slip hazard serious body
injury

Check & tight all fastners of
3 feeding table with lower Possibility of
carriage. Fall & Slip hazard serious body
injury
Hand tools may be slip Hand injury
Check condition(replace if Possibility of

4 requird)of garland rubber & Fall & Slip hazard serious body
back rubber. injury
Prepared by:

implement
Tested hand tools to be used 2 1 2 Area should be evacuated WG / PA
1.Make ensure proper working 1. Take height permit.

platform for work at height. 2. Height pass
2. Use double lanyard safety 3 3 9 approved person/technician WG/PA
harness. engaged for height work
Trained technicians should be 2 1 2 Area should be evacuated WG / PA
engaged
1. Proper approach.2. Use of Full
body harness with shock 3 4 12 2. Height pass WG/PA
absorber double lanyards, engaged for height work
1. Proper approach.2. Use of Full 1. Take height permit.
body harness with shock 3 4 12 2. Height pass WG/PA
absorber double lanyards,
engaged for height work

1. Proper approach.2. Use of Full 2. Height pass
body harness with shock 3 4 12 approved person/technician WG/PA
absorber double lanyards,
engaged for height work
Trained technicians should be 2 2 4 use hand glooves WG & PA

engaged

0-TT-1
on Routine
ormal

P S Risk
Before start the job 1 2 2
training was completed

height training given to 1 3 3
technicians.
implemented 1 2 2
implemented 1 2 2
Same will be implemented 1 4 4

before the job.
implemented 1 2 2
Same will be implemented 1 4 4

before the job.
implemented 1 2 2
Same will be implemented

implemented 1 2 2
pproved by:
Job Title Online girth gear checking & lubrication
Area RECLAIMER / STACKER

Upper carriage may be Possible to body

strike. injury
Girth gear cleaning &

1 checking.
Hand Injury. Hand injury
Segment bolt tightness

2 checking. Spanner slip. Hand injury
3 Girth gear lubrication Foreign particle may be Eye injury

inside to the eye.
Prepared by:
brication Section/ Location: 230-TT-1

mitigate hazard Risk Official to
P S Risk implement
Proper supervision 2 1 2 Ensure hooter during slew WG/PA

movement.
Trained technicians should be 2 2 4 use hand glooves WG/PA

engaged

Tested hand tools to be used 2 1 2 engaged. WG/PA
Trained technicians should be 2 2 4 Apart from using mandatory WG/PA

engaged PPEs(Safety goggles).

0-TT-1
on Routine
ormal
P S Risk
Before start the job 1 2 2
training was completed
implemented 1 2 2
implemented 1 2 2
implemented 1 2 2
pproved by:
Job Title Flow meter installation & gate valve replacement.
Area All area

Physical Isolate the pump & Body

injury ,hand
1 drain the water from pipe Electrocution Hazard injury ,Fire
line. injury
Possibility of
Fall & Slip hazard serious body
injury
2 cut the pipe & install the

flow meter. Possibility of
Fire hazard serious to burn
injury
Failure of Lifting tools. Possibility of

fracture injury
Lifting the gate valve to
3 fixing location & locking by
proper welding. Possibility of
Fall from height of person fracture injury/
or object at the time of Fatal
lifting . accident/proper
ty damage.
Possibility of
Fall & Slip hazard serious body
injury
Possibility of
Electric shock may be serious to fatal
4 Welding the both end point connecting to the accident due to
of the pipe. technicians. electrocution
4 of the pipe.
Prepared by:
alve replacement. Section/ Location: 230-TT-1
Existing control measure to mitigate Existing / Base Additional control measure Responsi
hazard P Risk S Risk ble Official
1.Power supply for pump shall be
to
physically disconnect. ELCB to be operated manually before
2.Double insulated portable tools to 3 2 6 resuming task PA & WG
be used
Trained technicians should be 3 3 9 Barricading should be done in the PA & WG

engaged. surrounding area
1. Valve protection caps shall be in 1. Gas cutter must be use safety helmet,
placed on gas cylinder and secured safety shoes, hand gloves, full sleeve
properly. 2. Flash back arrester must cotton dress, leg guard etc. Hose pipe,
be connected at both end of cutting regulator, cutting torch, Flash back
set. Hose shall be connected with 3 4 12 arrester shall be checked before use.
cutting torch as well as with the Cotton dress shall be used by gas cutters. PA & WG
cylinder by crimping clamp only. 3. 2. Fire extinguishers, sand buckets, water
Gas cutting work shall be done in shall be kept ready at site. Ceramic
enclosed areas with proper cloth/Spatter arrester tray shall be used
supervision. for arrest the spatters falling from height.
1.Load should be lifted as per lifting 1. Physical inspection ensure before used.
tools capacity. 2.Encure all lifting 2. Unauthorized persons are not allowed.
4 3 12 3.Barricading should be done in the PA & WG
tools & Tackles with valid test surrounding area. 4. Use oversize lifting
certificate to be use.
tools & tackle.
1.Fixed ladder to be provided.

1.Make ensure proper working 2. Height pass approved
platform for work at height. 3 5 15 person/technician engaged for height PA/WG
work 3. Take height permit.
Trained technicians should be Barricading should be done in the

engaged. 3 3 9 surrounding area PA & WG
1.Use ELCB with 30mA.2. Use dry 1.before start the work ensure the ELCB in
safety shoes.2.Welding machines will good condition by manually tripping
be connected through VRD in the method.2. Rubber mat shall be provided
secondary unit & ELCB in the 3 5 15 for welding machine. 3. Competent / WG
primary unit 3. Proper electrical authorized and licensed electrician with
connection shall be provided to trade validation certificate shall only be
machine & switches. permitted to work on electrical lines.

230-TT-1
Non Routine
Normal

P S Risk
Before start the job training was

completed 1 2 2
Same will be implemented before 1 3 3

the job.
implemented & Work at height 3 1 3

training given to technicians.
implemented & workmen are 2 2 4

implemented & Work at height

training given to technician. Also
they are very well know about use
of PPE.
Same will be implemented before

the job. 1 3 3
implemented & Work at height

trained already given to workers. 1 5 5
Also they are very well know about
use of PPE.
implemented 1 2 2
Approved by:
Job Title SLD INSPECTION & REPLACEMENT
Area All area

Inspection & replacement of Fall & Slip hazard Body injury &
1 Cartridge,battery & also hand injury
Machine
Prepared by:
ENT Section/ Location: 230-TT-1
Existing control measure to mitigate Existing / Base Additional control measure Responsi
hazard Risk ble Official
P S Risk to
implement
Make working platform to perform
the job. 3 2 6 Mechanical locking to be done WG & PA
Trained technician should be 3 2 6 Use PPEsa and Safety full body Harness. WG & PA
engaged.

230-TT-1
Non Routine
Normal
P S Risk
Before start the job training was

completed 1 2 2
implemented 1 2 2
implemented 1 2 2
Approved by:
Department:Mechanical HIRA No.
Job Title:TBP Driven shaft replacement
Area:231

Impact
1 TBP shaft Hood cover Fall from height

opening & rest at ground Hand injury/leg injury
Fall of bolts & slip tools. hand injury
Fall of materials/hood cover. body injury
TBP Chain link looseness Fall of bolts & slip tools hand injury
by removing packing
plate both sideby use of Failure of lifting tools & tackles.
lift the shaft by
2 chainpully block
hand injury
Fall of materials/Packing Plate.
body injury
3 All 6 no's of link pin Fall from height
remove one by one & hand injury
locking.
body injury
body injury
Failure of chains pulleys and chain body injury

4 Sheared TBP shaft Failure of lifting tools & tackles.
Dismantling & Rest the Hand injury
Ground.
Fall of TBP shaft. body injury
5 New TBP Shaft erecting

and Fit up.
Failure of lifting tools & tackles. body injury
body injury
Fall of TBP shaft
6 Fit up all (6no’s) link pin

& Alignment of TBP Fall of link pin body injury
shaft.
Fall of packing plate hand injury
Hand compact with hand tools/shaft hand injury
7 Fall of bolts & slip tools from hands hand injury
All inspection door
closed, hood cover fit up hand injury
& chain tension by
providing required Failure of lifting tools & tackles.
packing.
7
All inspection door
closed, hood cover fit up
& chain tension by
providing required Failure of lifting tools & tackles.
packing. hand injury
Prepared by:
Date:
Section/ Location:bauxite Handling
Routine /NonRoutine :Routine
Normal/Abnormal/Emergency:Normal

P S Risk
2 2 4
used valied tested tools and slings 2 2 4

2 2 4
Cover should be rest at floor by housing chain pulley.
Proper hand tools to be used 2 2 4

2 2 4

Cover should be rest at ground proper by housing 2 2 4
chain block.
2 2 4
Safety full body anchors it to a rigid point. 2 2 4
Trained rigger should be engaged to control the 2 2 4

height during removing & locking the lock pin
2 2 4
Good condition chains pulleys and chain to be used.
Trained technicians should be engaged for lifting the 2 2 4

TBP..
2 2 4
Tools tackles should be used not less than TBP shaft
2 2 4
Trained technicians should be engaged for lifting the
TBP..
Inadequate illumination if work is conducted at 2 2 4

night.
Trained rigger should be engaged to control the 3 2 6

height during removing & locking the lock pin
2 2 4
Tested hand tools to be used. 2 2 4

Tested hand tools to be used. 2 3 6
3 3 9
2 3 6
Reviewed by:
SSESSMENT

Additional control measure Responsible Official to implement Implementation Status Residual Risk
P
Area should be evacuated. 1
When work done to be
PA&WG evacuated
PA&WG Ensure before use by PA 1
used valied testedchani pulley PA&WG Ensure before use by PA 1
should be used
Area should be evacuated PA&WG Ensure before use by WG 1
Chain block with valid test PA&WG Ensure before use by
certificate should be used PA&WG
1
Use Proper PPES. WG Ensure before use by PA 1
PA&WG Ensure before use by PA
1
Area of working platform should WG Ensure before use by PA
be cleaned. 1
Apart from using mandatory PPE PA&WG Ensure before use by WG
like safety Harness, Safety
Hamlet, Gloves etc.
1
Proper hand tools may be used. WG Ensure before use by PA
1
Tested with vailed date should WG Ensure before use by WG
be used 1
Chain block with valid test WG Ensure before use by WG
certificate should be used. 1
Barricading should be done in PA&WG Ensure before use by PA
1
Tools tackle with valid test PA&WG Ensure before use by PA
certificate should be used 1
1
Use Proper PPE's. PA&WG Ensure before use by PA
1
WG Ensure before use by WG
1
Chain block with valid test PA&WG Ensure before use by PA
Make proper working platform. PA&WG Ensure before use by PA 1
Area should be evacuated PA&WG Ensure before use by PA 1
Chain block with valid test PA&WG Ensure before use by PA
1
Approved by:
Residual Risk
S Risk
2 2
2 2
2 2
2 2
2 2
2 2
2 2
2 2
2 2
2 2
2 2
2 2
2 2
2 2
2 2
2 2
2 2
2 2
2 2
2 2
2 2
2 2
Job Title:TBP Link Replacement
Area:231

Impact
1 chain pulley to be fixed for removal of Fall from height of person

hood cover body injury
1 Fall from height of person

body injury
TBP shaft Hood cover opening &

rest at ground hand injury
hands.
Height of Fall of materials. body injury
2 Fall from height of person .

body injury
body injury
TBP Chain link looseness by Slip link pin & tools from hands.
removing packing plate both
hand injury
sideand lift the shaft by chain
pulley
Failure of chains body injury
body injury
3 fire hazards
Remove the link of TBP link pin body injury
4
Fall of link pin body injury
After fit-up inset the packing plate

& Alignment of TBP shaft. Fall of packing plate hand injury
Hand compact with hand tools hand injury

hands
body injury
All inspection door closed, hood
cover fit up & chain tension by hand injury
providing required packing. Failure of lifting tools & tackles.
body injury
Prepared by:
Date:
Section/ Location:Bauxite Handling

P S Risk
Trained technicians and safety full body
harness should be used. 3 3 9
3 3 9
Make Standared Working Platform.
tested and valied certified hand tools to be 3 3 9

used
Tested and valied certified chain pulley 3 3 9
should be used
3 3 9
3 3 9
Use indivisual life line for each person

3 3 9
lock pin
Good condition chains to be used for locking 3 3 9
purpose.
capacity
use cutting set for cutting the link pin 3 3 9
purpose
3 3 9
lock pin
3 3 9
Trained technicians (MF) should be engaged.
3 3 9
3 3 9

capacity
3 3 9
Reviewed by:
ASSESSMENT

P
full body harness should be used WG WHEN PERFORMED AT
JOB 2
PA&WG WHEN PERFORMED AT 2
Trained technicians and safety
full body harness should be JOB
used.
Area should be evacuated. wg WHEN PERFORMED AT 2
JOB
Before using physical PA&WG WHEN PERFORMED AT 2
verification should be done JOB
Use safety full body harness JOB

Safety Belt anchors it to a rigid PA&WG WHEN PERFORMED AT 2
point. JOB
WG WHEN PERFORMED AT 2
use cotton safety hand JOB
gloves&PPE
Before using physical PA&WG WHEN PERFORMED AT 2

Tested and valied certified PA&WG WHEN PERFORMED AT 2
chain pulley should be used JOB
Trained cutter and leather
apron should be used for the JOB
job
Area should be evacuated. WG WHEN PERFORMED AT 2
JOB
Use PPEs and safety Hand WG WHEN PERFORMED AT 2

gloves. JOB
Before using physical WG WHEN PERFORMED AT 2
WG WHEN PERFORMED AT 2
JOB
Chain block with valid test PA&WG WHEN PERFORMED AT 2
certificate should be used JOB
Make standered working PA&WG WHEN PERFORMED AT 2
platform. JOB
Approved by:
Residual Risk
S Risk
3 6
3 6
3 6
3 6
3 6
3 6
3 6
3 6
3 6
3 6
3 6
3 6
3 6
3 6
3 6
3 6
HAZA
Job Title:screen pad palte replacement
Area:231

Impact
1 Make Arrangement Fall from height of person or object Body injury

For fixing of Chain at the time fixing the sling. Body injury
pulley for removing
the bearing housing Failure of chain pulley.
hand injury
2 Both side working Fall from height of person. Body injury

platform fixing.
Movable working platform may be Body injury
move.
3 Non-drive side
counter weight, Body injury
bearing with housing Fall of bolts & slip tools from
removing . hands.
Body injury
Failure of lifting tools during lift the

load.
4 Coupling guard,Drive Fall of bolts & slip tools from
side cordon shaft, hands. hand injury
counter weight,
bearing with housing
removing. hand injury
hand injury
Failure of lifting tools.
5 drive shaft locking to
be done at one side
while removing Body injury
bearing housing. Fall from height of person or object
at the time fixing the sling.
6 Both site existing pad
plate dismantling. Body injury
Body injury
Fall from height of person or object
at the time removing same.
6 Both site existing pad
plate dismantling.
Fall from height of person or object Body injury

at the time removing same.
Fire hazard
Body injury
hand injury
Hand Injury
7 Both side pad plate
area grinding. Body injury
Body injury
Braking of grinding wheel.
Shock while applying power tool Body injury
socket
8 Both side new pad Failure of chain block. hand injury
plate fixing &
welding.
Body injury
Fire hazard
Body injury
Electrocution
9 Both side bearing hand injury
with housing fitting. Hand Injury
Failure of chain block. hand injury
Spanner slip. hand injury

10 Both side counter hand injury
weight & drive side Hand Injury
cardon shaft and
coupling guard fixing. hand injury

hands.
Prepared by:
Date:
Routine /NonRoutine :Non Routine

P S Risk
Proper platform to be provided. 2 3 6
3 3 9
Load should be lifted less than chain block

/wire rope sling/ load capacity
3 2 6
Wheels should be locked.
3 3 9

3 3 9
3 3 9
load capacity.
3 3 9
Proper hand tools to be used.

3 3 9

3 3 9

load capacity.
Use of Safety full body harness.

3 3 9
Proper platform to be provide.

3 3 9
4 3 12
4 3 12
3 3 9

3 2 6
Grinding wheel RPM must be heaver than
grinding machine to be used.
3 2 6
Proper PPE (Face guard & leather guard to be
used)
2 3 6
Industrial shocked with IP44 specification to be
used
3 3 9

3 3 9

3 3 9
Welding machine connection to be taken from
ELCB & VRD.
3 3 9
Trained technicians should be engaged for
remove the frame.
3 3 9

Proper hand tools to be used 3 3 9
3 3 9
Trained technicians should be engaged for
remove the frame.
3 3 9
Reviewed by:
RISK ASSESSMENT

Routine /NonRoutine :Non Routine
P
Use full body harness. WG IMPLEMENT AT JOB 1
Use PPEs. WG IMPLEMENT AT JOB 1
WG IMPLEMENT AT JOB 2
All tools & tackle are tested
with valid certificate to be
used
Trained technicians should PA&WG IMPLEMENT AT JOB 2
be engaged.
Proper housekeeping to be
Tested lifting tools & tackle
to be used.
to be used.
be engaged.
Proper housekeeping to be

to be used.
PA&WG IMPLEMENT AT JOB

be engaged.
Use of Safety full body
harness.
PA&WG IMPLEMENT AT JOB 2
All tools & tackle with valid
certificate.
cutting set with NRV / FBA.

Fire watcher to be depute at
same place.
Gas cutter with all PPE. WG IMPLEMENT AT JOB 2
Trained technician to be
deployed.
WG IMPLEMENT AT JOB
use face shield for grinding job PA&WG IMPLEMENT AT JOB
WG IMPLEMENT AT JOB

tested certificate.
cutting set with NRV / FBA.

Gas cutter with all PPE and
leather Apron.


tested certificate.
Area should be evacuated WG IMPLEMENT AT JOB 2
2
Trained technicians should WG IMPLEMENT AT JOB
be engaged.
Approved by:
Residual Risk
S Risk
3 3
3 3
3 6
3 6
3 6
3 6
3 6
3 6
3 6
3 6
3 6
3 6
3 6
3 6
3 6
3 6
3 6
3 6
3 6
3 6
3 6
3 6
3 6
3 6
3 6
3 6
HAZARD ID
Job Title:Replacement of marshmellow of screen
Area:231

Impact
1
Body injury
Fall from height of person or object
Make arrangement at the time fixing the sling.
Hand injury
for fixing the chain
block.
Failure of chain block.
Hand injury
2 Hand crush
Jacking arrangement
to be provided for Hand injury
lifting the pannel
3 pressure pipe holding tools slipage.

pipe bolts to be Hand injury
loosend
4
Failure of lifting tools tackles. Hand injury
Lift the Screen Panel
to remove Marsh
Mellow. Fall from height of person or object
at the time of lifting the panel. Body injury
damaged marsh Hand injury
Mellow & fit-up new Fall & Slip hazard
one. Hand injury
Hand Injury
Hand injury
Failure of Lifting tools.
Hand injury
Hand injury
6 pressure pipe holding Tools slipage

pipe bolts to Hand injury
beTightnend
7 Check the water level Hand crush
if required add shims Hand injury
for leveling.
8 Body injury
Remove all lifting Fall from height of person or object
arrangements at the time fixing the sling. Body injury
including jacking
&chain pulley Body injury
arrangement. Failure of chain block.
Prepared by:
Date:
Normal/Abnormal/Emergency:normal

P S Risk
3 2 6
Proper platform to be provided.
2 2 4
3 2 6

Tested and vailed certified only used.
2 2 4
Load should be lifted as per chain block 2 2 4
capacity.
2 2 4
the height during lifting the Panel.
2 3 6
3 3 9

remove the frame.
Hydraulic Jack inset for secondary support. 2 3 6
3 3 9
Chain block(Lifting tools) in good condition &
with valid test certificate.
Tools & tackle tested with valid certificate to

be used.
2 2 4
3 3 9
Proper platform to be provided.
3 3 9

3 3 9
Reviewed by:
SSESSMENT

Normal/Abnormal/Emergency:normal
Additional control measure Responsible Official to Implementation Status Residual Risk

implement P S
Area should be evacuated. PA&WG Implement at job 2 2
PPEs,safety full body WG Implement at job 1 2

harness,plain goggles
All tools & tackle are tested WG Implement at job 2 2
use cotton hand gloves. WG Implement at job
2 3
WG Implement at job
1 2
PA&WG Implement at job 1 2
visual inspections conduct
before used.
WG Implement at job

PA&WG Implement at job 1 3
Use PPEs and Safety full body WG Implement at job 2 3

Harness.
Use safety hand gloves. WG Implement at job 2 3
WG Implement at job
WG Implement at job 2 3
Unauthorized persons should
not be entry inside the work
area.
WG Implement at job
Use cotton Hand gloves PA&WG Implement at job
2 3
Area should be evacuated. PA&WG Implement at job 2 0
WG Implement at job 2 3
Use PPEs and safety full
body harness
All tools & tackle tested WG Implement at job 2 3
Approved by:
Residual Risk
Risk
4
2
2
6
6
6
6
HAZARD IDENT
Job Title:Crusher Cage Bar Replacement
Area:231

Impact

hands
Hand injury
Making arrangement Fall of materials Body injury

for removing
coupling guard &
rotor lock. Slip from hands Hand injury
Drive shaft may be move. Hand injury
2
Eye Injury Eye injury
Slip & trip hazards. Hand injury

machine or water
hose. Fall Hazards. Body injury
Failure of lifting tools & tackles. Body injury
3 Bauxite to be
removed & Cleaning Hand tools slippage. Hand injury
to be done.
fall of material. Body injury
4 Making arrangement
for lifting & fixing
manual working safagation
safagation
safagation

ascending & descending in side Body injury
chute.
Hand injury
Hand injury
damaged Cage bar Hand injury
one by one & also fit- Fall & Slip hazard
up new one in same Hand injury
sequence.
safagation
safagation
Fire hazard safagation
safagation
Body injury
Jammed bauxite fall hazard
Hand Injury Hand injury
Failure of Lifting tools. Body injury
6 Hand injury
Spanner slip.
safagation
Remove of working
platform & all
Accessories safagation
Fire hazard
safagation
7 Fall of bolts & slip tools from Hand injury
hands
Body injury
Fall of materials/hood cover
Crusher all inspection
door & hood cover Hand injury
Slip coupling bolt,inspection
box-up to be done
door,hood cover bolts & tools from
rotor lock to be
hands
removed & coupling
guard to be fitup.. Hand injury
Drive shaft rotate.
Hand injury
Spanner slip.
Prepared by:
Date:
Section/ Location:Bauxite handling
Routine /NonRoutine :Non routine

P S Risk
Tested and vailed certified hand tools to be 3 3 9
used
4 3 12
Cover should be mechanically Locked .
3 2 6
lock pin
3 3 9
Use of Face Guard, Nose mask . 3 3 9
Good Housekeeping & Material Storing & 3 3 9

safe , free access.
3 3 9
Use full body harness protection
3 3 9
Lifting Tools & tackles certified to be used.

Trained technician should be engaged to 3 3 9
control the cleaning activity.
3 3 9
before starting job check the chute condition
for any material jamming
3 3 9

If flamable gas present then purging should 3 3 9
be done.
3 3 9
An entry & exits register should be maintained.


lifting theplatform material..
3 3 9
Make working platform to perform the job.
3 3 9
Tested by multi gas tester before entry the 3 3 9

confined area.
3 3 9
illumination required. 3 3 9
3 3 9
3 3 9
cleaning to done before enter into the chute.

remove the frame.
Chain pulley and di-shycacle in good 3 3 9
Tested and valied certified hand tools to be 3 3 9
used
the job.
3 3 9
Illumination required. 3 3 9
3 3 9
Tested and valied certified hand tools to be 3 3 9
used
Cover should be rest at ground proper by 3 3 9
holing chain pulley.
3 3 9
control the height during removing & locking
the lock pin
3 3 9
3 3 9
Reviewed by:
SSMENT
Section/ Location:Bauxite handling

Routine /NonRoutine :Non routine

PA&WG implement at Job 2 3 6

Area of working platform
should be cleaned
Use PPE safety full body PA&WG implement at Job 2 2 4

Harness, Safety Hamlet,
Gloves .

isolation of crusher drive
motor
Trained persons should be PA&WG implement at Job 2 3 6
engage for the job
Before using hose should be PA&WG implement at Job 2 3 6
verified physically.
engage for the job
Use PPE safety full body PA&WG implement at Job 2 3 6
Harness, Safety Hamlet,
Gloves .
Use PPE safety Harness, PA&WG implement at Job 2 3 6

Safety Hamlet, Gloves
engage for the job
PA&AO implement at Job 2 3 6
If Oxygen level more then

23.5% or below 19.5% no
worked should be carried out.
PA&AO implement at Job 2 3 6
pass should be work inside the
confined space.
Rescue plane should be PA&AO implement at Job 2 3 6
available & brief to the
workman.
use PPEs and Safety full PA&AO implement at Job 2 3 6

body harness to be used .
Use cotton hand gloves. PA&WG implement at Job 2 3 6
Mechanical locking to be PA&WG implement at Job 2 3 6

done
Use PPEsa and Safety full PA&WG implement at Job 2 3 6
body Harness.
check oxygen level in every PA&WG implement at Job 2 3 6
4 hour intervels
If flamable gas present then PA&AO implement at Job 2 3 6
purging should be done.
24 Volt DC light Should be PA&AO implement at Job 2 3 6

used inside the confined
space.
Conveyor covered with PA&AO implement at Job 2 3 6

bauxite dust and GI sheet.

use hydrojet for cleaning
Physical verification done PA&WG implement at Job 2 3 6

bofore using.
If flamable gas present then PA&AO implement at Job 2 3 6

purging should be done.
24 Volt DC light Should be PA&AO implement at Job 2 3 6

used inside the confined
space.
Conveyor covered with PA&AO implement at Job 2 3 6

bauxite dust and GI sheet.
Mechanical locking should PA&WG implement at Job 2 3 6

be done
Area of working platform
should be cleaned

isolationtghe crusher drive
motor
Approved by:
JOB SAFE
DEPARTMENT: MECHANICAL
NAME OF WORKING AGENCY: JCPL
JOB TITLE: Crusher Scoop Replacement
JOB DURATION: 08Hrs.
AREA: 231
RISK ASSESSMENT TEAM MEMBERS:
S.NO Description of Task
Step ( Sequence of basic
steps )
Hazard
COVID-19 Viral attack
Crane wheel/jack may go down in soil.
2
Positioning of crane for
lifting the motor.
Hydra may hit the workman during
Iron plate Positioning .
Fall of person from height at the time

fixing the sling
Fixing of the sling for

3 lifting & removing the
bolts.
Falling of bolts and slipping of tools

from hands may occure.
Failure of crane may occure
Lifting the old motor

from CR-231-001A/CR-
4
231-001B from their
base and again dropping
down the same to
ground level. Failure of slings may occure.
Fall of Material from height may occurs
Failure of chain blocks may occure
Shifting of the scoop

5
from its position to
crusher motor base by
use of chain block.
Failure of slings may occure.
Failure of crane & lifting tools tackles.
Lifting of the scoop

6 coupling from motor
base to ground level
Fall of person from height during lifting

the scoop.
Lifting of the scoop

7 coupling from ground
level to motor base.

the scoop.
Failure of chain blocks may occure
Shifting of the scoop

coupling from crusher
8 motor base to its
position by using chain
block.
Failure of slings may occure.

Lifting of the existing
9
motor from ground level
to CR-231-001A/CR-231-
001B base.

the motor.
slipping of tools and bolts from hands

may occure
Starting of the
Allignment work from
crusher to scoop
10 coupling then scoop Finger
scoop .
may be trapped with base of
coupling to motor and
fitting up all coupling
bolts.
Allignment work from
crusher to scoop
10 coupling then scoop
coupling to motor and
fitting up all coupling
bolts.
Packing Sims may cut the finger
JSA PREAPARED BY (TEAM-AREA ENGINEER,SUPERVISOR & SAFETY OFFICER)

SL NO sc
1 Mr.
2 Mr.
3 Mr.
JSA briefed by Mr._____________________ to the workmen
Signature :
JOB SAFETY ANALYSIS
JSA NO.: JSA
Mr. XXX & Mr. XXX

RISK ASSESSMENT
Existing Controls Measures Sketch / Baseline Risk
Photo
P S R
Use nose mask,hand gloves,safety

goggles.maintain a safe distance
from adjecent person,don't make
any physical contact.do not spill at 4 5 20
work place.
1.The ground should be compacted 3 3 9

and leveled.
Proper signaling during marching

should be ensured. Minimum
distance of 3 mtr from hydra
2 2 4
should be maintained.
Make proper working platform.Trained

technicians should be engaged. Proper 2 3 6
Proper hand tools to be used. Area should

be evacuated.Proper housekeeping to be 2 1 2
done before starting the job
Load should be lifted as per crane
capacity.Crane with valid test certificate 2 3 6
should be used.
Slings with valid test certificate should be

2 2 2
used.
Chain block with validate certificate should

2 3 6
be used .

2 3 6
used

should be used.

2 3 6
should be used

2 3 6
Chain block with validate certificate should

2 3 6
be used .

2 3 6
used

should be used

2 3 6
Proper hand tools to be used. Area should

be evacuated.Proper housekeeping to be 2 1 2
done before starting the job
Sim plate removing and fitting work should

2 1 2
be carried out.
Proper hand tools should be used to avoid
2 1 2
injury
AFETY OFFICER) JSA REVIEWED BY (AREA MANAGER) & APPROVED

SIGNATURE NAME
REVIEWED BY-: Mr.
APPROVED BY JSA SME:
Mr.
WORK GROUP
Date: 16.02.2021
WORK OFDER NO.: XXXXX

DATE OF REVIEW AT JOB SITE: 15.09.2020
SECTION/LOCATION:- BHP
RISK CONTROL
Additional Control Residual Risk Respon Complet Ref to
Measures sible ion date SOP,
Person SMP,
SWI
P S R
Maintain social distancing

1 4 4
during job execution
Iron plate should be placed on 3 1 3

ground before posting of crane
6mtr guide rope to be

used.During work ,the SWI of
hydra operation should be 1 2 2
followed.
Full body harness should be used

by tecnician .Lanyard should be 2 1 2
bound in proper life line.
2 1 2
Crane operator should be engaged
for operation of crane. Area
should be evacuated.Crane with 2 2 4
valid test certificate should be
used.
1 2 2
visual inspection should be done
before performing work.Trained
technicians should be engaged
1 2 2
visual inspection of chain blocks

must be done & load should be
handled less than chain block 1 2 2
capacity.Barication should be
made.

technicians should be 1 2 2
engaged.Barication should be
made.

for operation of crane. Area 2 2 4

bind in proper life line.
should be evacuated

1 2 2
handled less than chain block
capacity.Barication should be
made.

technicians should be 1 2 2
engaged.Barication should be
made.

should be evacuated

2 1 2
2 1 2
2 1 2
A REVIEWED BY (AREA MANAGER) & APPROVED BY (AREA AUTHORITY)

NAME SIGNATURE
Name & signature of area engineer: Mr._______________

WORK GROUP
Name & signature of Safety officer:
Mr._________________
JOB SAFE
JOB TITLE: Hammer replacement for crusher
AREA: 231
steps ) Hazard
1 COVID-19 Viral attack
Fall of spillage material,bolts & tools

from hands.
Crusher Top Hood Top hood cover may be closed due

2 covers opening & to mishandling of hydraulics system
locking. or hydraulic system failure.

the time opening the top cover
Hand tool may be slipped

Dismentaling of crusher
3 bearing lubrication line
at NDE. oil pressure from hose may cause injury
to eye and body
Rotor may rotate by itself due to

uneven load , maintenance work,by its
nature.
Chain block and wire rope slings may fails

during removing the hammer pin .

4 removing the hammer
pins & hammers.
4 removing the hammer Fall of person from height while working at
pins & hammers. working area.
Slip of hammers from hands.
Failure of rope.
 Inadequate illumination if work is

conducted at night
Fit up of 1st (First) row Failure of rope.

5 hammer sets and
continues upto 4th row. Fall of hammer
S: Severity, P: Probability, R: Risk

SL NO NAME
1 Mr.
2 Mr.
3 Mr.
Signature :
JOB SAFETY ANALYSIS
JSA NO.: JSA
usher
Mr. XXX & Mr. XXX

RISK ASSESSMENT
Photo
P S R

from adjecent person,don't make 4 5 20
any physical contact.do not spill at
work place.
1.Spillage material should be

cleaned before starting the
work.2.Proper hand tools and PPEs
2 1 2
to be used & area should be
evacuated and barricated.
Hydraulic system isolated after opening the

top hood cover.Cover should be 1 3 3
mechanically locked with structure.
Engaged trained Tecnicians should

wear the full body harness ,proper
1 1 1
PPEs and anchored at proper rigid
point.
Trained technician should be engaged

1 1 1
with proper PPEs.
line pressure should be

released.Bleedinng operation should
1 2 2
be done at the time of opening the
fittings.
Scoup to crusher coupling should be

2 3 6
locked mechanically.
Chain block and sling with validate

certificate should be used and.Trained 2 3 6
tecnicians should be engaged
Engaged Tecnicians should use the full
body harness,proper PPEs and proper
2 3 6
anchoring of safety belt should be done
to a convinient rigid support.
Trained technician should be engaged with
1 2 2
proper PPEs.
Good condition PP rope to be used for
1 1 1
holding the hammer
Proper illumination must be ensured. 1 1 1
Good condition PP rope for use for hold

1 1 1
the hammer
Proper hand tools to be used & area
1 1 1
should be evacuated and barricated

SIGNATURE NAME
REVIEWED BY-: Mr.
Mr.
WORK GROUP
Date: 03.09.2020

RISK CONTROL
Person SMP,
P S R SWI

1 4 4
2 1 2
. 1 3 3
1 1 1
1 1 1
1 2 2
SWI shoud be follwed. 1 3 3

1 3 3
capacity.
1 3 3
working area should be cleaned.
1 2 2
1 1 1
1 1 1
1 1 1
1 1 1
SWI shoud be follwed.

NAME SIGNATURE

WORK GROUP
Mr._________________
JOB SAFE
JOB TITLE: Hammer replacement for crusher
AREA: 231
steps ) Hazard
1 COVID-19 Viral attack
Fall of spillage material,bolts & tools

from hands.
Crusher Top Hood Top hood cover may be closed due

2 covers opening & to mishandling of hydraulics system
locking. or hydraulic system failure.

the time opening the top cover
Hand tool may be slipped

Dismentaling of crusher
3 bearing lubrication line
at NDE. oil pressure from hose may cause injury
to eye and body
Rotor may rotate by itself due to

uneven load , maintenance work,by its
nature.
Chain block and wire rope slings may fails

during removing the hammer pin .

4 removing the hammer
pins & hammers.
4 removing the hammer Fall of person from height while working at
pins & hammers. working area.
Slip of hammers from hands.
Failure of rope.
 Inadequate illumination if work is

conducted at night
Fit up of 1st (First) row Failure of rope.

5 hammer sets and
continues upto 4th row. Fall of hammer
S: Severity, P: Probability, R: Risk

SL NO NAME
1 Mr.
2 Mr.
3 Mr.
Signature :
JOB SAFETY ANALYSIS
JSA NO.: JSA
usher
Mr. XXX & Mr. XXX

RISK ASSESSMENT
Photo
P S R

from adjecent person,don't make 4 5 20
any physical contact.do not spill at
work place.
1.Spillage material should be

cleaned before starting the
work.2.Proper hand tools and PPEs
2 1 2
to be used & area should be
evacuated and barricated.
Hydraulic system isolated after opening the

top hood cover.Cover should be 1 3 3
mechanically locked with structure.
Engaged trained Tecnicians should

wear the full body harness ,proper
1 1 1
PPEs and anchored at proper rigid
point.
Trained technician should be engaged

1 1 1
with proper PPEs.
line pressure should be

released.Bleedinng operation should
1 2 2
be done at the time of opening the
fittings.
Scoup to crusher coupling should be

2 3 6
locked mechanically.
Chain block and sling with validate

certificate should be used and.Trained 2 3 6
tecnicians should be engaged
Engaged Tecnicians should use the full
body harness,proper PPEs and proper
2 3 6
anchoring of safety belt should be done
to a convinient rigid support.
Trained technician should be engaged with
1 2 2
proper PPEs.
Good condition PP rope to be used for
1 1 1
holding the hammer
Proper illumination must be ensured. 1 1 1
Good condition PP rope for use for hold

1 1 1
the hammer
Proper hand tools to be used & area
1 1 1
should be evacuated and barricated

SIGNATURE NAME
REVIEWED BY-: Mr.
Mr.
WORK GROUP
Date: 03.09.2020

RISK CONTROL
Person SMP,
P S R SWI

1 4 4
2 1 2
. 1 3 3
1 1 1
1 1 1
1 2 2
SWI shoud be follwed. 1 3 3

1 3 3
capacity.
1 3 3
working area should be cleaned.
1 2 2
1 1 1
1 1 1
1 1 1
1 1 1
SWI shoud be follwed.

NAME SIGNATURE

WORK GROUP
Mr._________________

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Sl No JSA slide link DEPARTMENT JSA Number

1 JSA SLIDE NO-01 MECHANICAL UAIL/BHP/O&M/HIRA/001

51 JSA SLIDE NO-51 MECHANICAL UAIL/BHP/O&M/HIRA/051

56 JSA SLIDE NO-56 MECHANICAL UAIL/BHP/O&M/HIRA/056

Prepared by: Reviewed by: Approved by:

Name Name Name

SN Basic step of the Job Hazard(s) associated

Fire hazard Born injury

Material (Bauxite) fall Body injury

Injury Hand injury

Electric shock may be Possibility of serious to

Failure of Lifting tools Possibility of serious to

Existing control measure to Existing / Base Additional control measure Responsible

1.Fire extinguisher keep near by 3 1 3 WG

1.Standatd/ tested hand tools 4 1 4 WG

1.Load should be lifted as per 3 5 15 1. Physical inspection ensure WG

Reviewed by: Approved by:

Implementation Residual Risk

During the Job

all lifting tools are 3 1 3

SN Basic step of the Job Hazard(s) associated

Making arrangement for

2 Fire hazard Possibility of Born injury

Failure of hand tools. Possibility of body injury

Injury non standard Possibility of body

Remove of Impact Pad

3 Injury due to Possibility of serious to

Remove all lifting Injury non standard Possibility of body

Existing control measure to Existing / Base Additional control measure Responsible

Proper isolation to be done of 4 5 20 LOTOTO procedure ensure AO&PA

1.Fire extinguisher keep near by 3 1 3 WG

1.Standatd/ tested hand tools 4 1 4 WG

1.Load should be lifted less 4 5 20 1. Physical inspection ensure WG

Proper isolation to be done of 4 5 20 LOTOTO procedure ensure AO&PA

1.Standatd/ tested hand tools 4 1 4 wG

Reviewed by: Approved by:

Implementation Residual Risk

During the Job

SN Basic step of the Job Hazard(s) associated with

Fall & Slip hazard Bodily Injury to

Remove old hardrox

1.Screen discharge chute guarding

1.Fire extinguisher keep near by

Proper isolation to be done of LOTOTO procedure ensure

Proper locking of diverter gate.

Responsible Implementation Residual Risk

during the job

SN Basic step of the Job Hazard(s) associated

Drive motor, coupling Possibility of

Fall & Slip hazard Possibility of

Fall & Slip hazard Possibility of

3 Screen bearing checking Possibility of

1.Work on the working platform.

Proper isolation to be done of same LOTOTO procedure ensure

1.Standatd/ tested hand tools to be

1.Screen discharge chute guarding

Apart from using mandatory

Responsible Implementation Residual Risk

SN Basic step of the Job Hazard(s) associated

Remove all damage Possibility of

Existing control measure to Existing / Base Risk Additional control measure

1.Standatd/ tested hand tools

Responsible Implementation Residual Risk