HIR-POM/MEC/TBN/NROU 03 HAZARD IDENTIFICATION, RISK ASSESSMENT AND

DOCUMENT
DETERMINING CONTROLS (HIRADeC)
DEPARTMENT MECHANICAL MAINTENANCE
MAINTENANCE OF CONDENSER Online / Offline NORMAL - ROUTINE / NON-ROUTINE
TITLE
ACTIVITIES
VER. NO : 02 REV. NO : 03 PAGE 1-1 Date:30/08/2021
Residual Risk
Hazard Identification Existing Risk Assessment
Assessment

No. of Persons exposed

PERSON

Refer SOP/WI
Risk Score= S*P

Risk Score= S*P

(S) Proposed controls (Elimination,
Hazard No.

POTENTI S/

Risk level

Risk level
Existing Existing BC Subsitution, Engg, Sign/Admin &
ALLY NS
Activity Hazard Potential Control PPE)/Opportunities

S
P

P
EXPOSE
harm Measures
D
(E/C/V/L
C)

Ensure proper platform or i.e tempeorary

scaffolding to be made to be check by
authorise person & ensure check sheet of
Fall from Injury to WPS, TRG, EGC, Subst scaffolding, Fitness tag to be ensure of Adequ
3.1 E/C 3 3 4 12 S 3 3 9
height body parts ATC, PPE antial scaffolding ,use of safety belt, height pass is ate
required, life line to be installed if needed.
Condenser all
sufficient illumination level to be provided in
manhole
day light working.
opening

All tools & tackles should be tied properly,

Fall of Injury to WPS, TRG,EGC, Adeq use proper PPEs, supervision, ground level Adequ
3.2 E/C 3 2 4 8 NS 2 3 6
object body parts ATC, PPE uate guarding, ensure toe guard.All loose materials ate
to be remove from height edge.

Foldable plarform or proper platform to be

installed as per standard, supervison to be
Fall of man
Injury to WPS, TRG,EGC, Subst maintained at all times, safety belt to be used, Adequ
3.3 and material E/C 3 4 3 12 S 3 3 9
body parts ATC, PPE antial All tools & tackles should be tied properly, ate
life line to be installed if needed, certified
tools & tackles to be only used
Water Box
cleaning
 Water Box
cleaning
Ensure confined space register, stand-by
person & confined pass, confined space work
Working in
Injury to WPS, TRG, EGC, Subst permit, ensure blower/ air piepline,ensure Adequ
3.4 Confined E/C 3 4 3 12 S 3 3 9
body parts PPE antial proper oxygen (19.5-23.5) & co level, ensure ate
space
24V DC bulb supply. Gas test to be done in
each shift renewal.

Ensure proper platform or i.e tempeorary

scaffolding to be made to be check by
authorise person & ensure check sheet of
Fall from Injury to WPS, TRG, EGC, Subst Adequ
3.5 E/C 3 3 4 12 S scaffolding, Fitness tag to be ensure of 3 3 9
height body parts ATC, PPE antial ate
scaffolding or use of safety belt, height pass
Installation of
is required, ensure no water logging, life line
gags for
to be installed if needed
condenser
spring support

All tools & tackles should be tied properly,

Fall of Injury to WPS, TRG, ATC, Adeq Adequ
3.6 E/C 3 2 4 8 NS use proper PPEs, supervision, ground level 2 3 6
object body parts PPE uate ate
guarding, ensure toe guard

Cut with Injury to WPS, TRG, ATC, Adeq Proper PPEs to be worn, cut ressistant gloves Adequ
3.7 E/C 3 2 4 8 NS 2 3 6
sharp object body parts PPE uate to be worn, supervision to be maintained ate
Installation of
gags for
condenser
30mA ELCB to be ensure, VRD to be used,
spring support Eye
proper PPEs to be worn, supervision to be
exposure to Irritation Adeq Adequ
3.8 E/C WPS, PPE, TRG 3 2 4 8 NS maintained, fire blanket to be ensure, fire 2 3 6
welding to eyes uate ate
extinguisher to kept on site, ensure welding
spark
checklist.

Hammering Ensure proper PPEs, supervision to be

Injury to Adeq Adequ
3.9 the plug into E/C WPS, PPE, TRG 3 2 4 8 NS maintained, ensure proper tools to be used 2 3 6
body parts uate ate
the tube with proper gripping

Ensure confined space register, stand-by

person & confined pass, confined space work
Working in
Condenser Tube 3.1 Confined Injury to E/C
WPS, TRG, EGC,
3 4 3 12
Subst
S
permit, ensure blower/ air piepline,ensure
3 3 9
Adequ
plugging 0 body parts PPE antial proper oxygen (19.5-23.5) & co level, ensure ate
space
24V DC bulb supply.Gas test to be done in
each shift renewal.
Condenser Tube
plugging

Foldable platform or proper platform to be

Fall of man installed as per standard, supervison to be
3.1 Injury to WPS, TRG,EGC, Subst Adequ
and material E/C 3 4 3 12 S maintained at all times, safety belt to be used, 3 3 9
1 body parts ATC, PPE antial ate
All tools & tackles should be tied properly,
life line to be installed if needed

Condenser Tube 3.1 Contact with Burn WPS, PPE, AWS, Subst Ensure proper PPEs, supervision to be Adequ
E/C 3 3 4 12 S 3 3 9
plugging 2 hot surface injury TRG antial maintained, TBT to be given and followed ate

Ensure confined space register, stand-by

person & confined pass, confined space work
Working in
3.1 Injury to WPS, TRG, EGC, Subst permit, ensure blower/ air piepline,ensure Adequ
Confined E/C 3 4 3 12 S 3 3 9
3 body parts PPE antial proper oxygen (19.5-23.5) & co level, ensure ate
space
24V DC bulb supply. Gas test to be done in
each shift renewal.

High
TBT to be given, Confined space suit to be
3.1 velocity Injury to WPS, TRG, ATC, Adeq Adequ
E/C 4 3 3 9 NS worn, ensure proper PPEs, supervison to be 3 3 9
4 water spray body parts PPE uate ate
mainatined
on body

Bullet
GI sheet to be installed at the CEP side of
hitting while
3.1 Injury to WPS, TRG, ATC, Adeq condenser water box, oulet to be barricaded by Adequ
exit from E/C 4 3 3 9 NS 3 3 9
Bullet/ Water jet 5 body parts PPE uate signage boards, supervison to be maintained at ate
the outlet
cleaning all times
side

Supervision to be maintained, Pressure to e

maintained <= 100 Kg/cm2 ,ensure proper
Pressurized tools & tackkles, use trolley if required, chain
3.1 Injury to WPS, TRG, ATC, Adeq Adequ
water jet E/C 4 3 3 9 NS block to be propely anchored if necessary, 3 3 9
6 body parts PPE uate ate
cleaning ensure proper PPEs, color coding & proper
test certificates to be ensured, area cleaning &
barricading

Foldable platform or proper platform to be

Fall of man installed as per standard, supervison to be
3.1 Injury to WPS, TRG,EGC, Subst Adequ
and material E/C 3 4 3 12 S maintained at all times, safety belt to be used, 3 3 9
7 body parts ATC, PPE antial ate
All tools & tackles should be tied properly,
life line to be installed if needed
 Ensure proper PPEs, 30 mA ELCBs to be
ensured, loose cables should be tied up, ensure
no cut marks on cables, all electronic devices
should be properly earthed.All power cable
3.1 Electrical Injury to WPS, PPE,TRG, substa Adequ
E/C 3 4 3 12 S should have proper going on 3 3 9
8 shock body parts AWS ntial ate
earthing. .Isolation provision for Electrical
equipment from Supply DB and power for any
Eddy current
electrical tools should be drawn through
test
industrial plugs

Foldable platform or proper platform to be

Fall of man
3.1 Injury to WPS, TRG,EGC, Subst installed, supervison to be maintained at all Adequ
and material E/C 3 4 3 12 S 3 3 9
9 body parts ATC, PPE antial times, safety belt to be used, All tools & ate
tackles should be tied properly

Ensure confined space register, stand-by

person & confined pass, confined space work
Working in
Eddy current 3.2 Injury to WPS, TRG, EGC, Subst permit, ensure blower/ air piepline,ensure Adequ
Confined E/C 3 4 3 12 S 3 3 9
test 0 body parts PPE antial proper oxygen (19.5-23.5) & co level, ensure ate
space
24V DC bulb supply.Gas test to be done in
each shift renewal.

Ensure proper platform, use of safety belt,

3.2 Fall from Injury to WPS, TRG, EGC, Subst Adequ
E/C 3 3 4 12 S height pass, lifelines to be installed if needed, 3 3 9
1 height body parts ATC, PPE, AWS antial ate
life line to be installed if needed
Water Box
coating
All tools & tackles should be tied properly,
3.2 Fall of Injury to WPS, TRG, ATC, Adeq Adequ
E/C 3 2 4 8 NS use proper PPEs, supervision, ground level 2 3 6
2 object body parts PPE, AWS uate ate
guarding, ensure toe guard

Engulfment Blower scution to be installed at the manhole

Subst
3.2 due to Injury to AWS, TRG, ATC, opening , discharge duct opening should be Adequ
E/C 3 3 4 12 antial S 3 3 9
3 copper slag body parts PPE, WPS outside the turbine hall and towards ate
Risk
blasting switchyard side
Water Box
Chemical
coating
spillage Irritaion to
MSDS to be ensure at sit, ensure proper PPEs,
inside water body parts Subst
3.2 WPS, TRG, AWS, supervisior to be present at site, first aid box Adequ
box and i.e. E/C 4 4 3 12 antial S 3 3 9
4 ATC should be present on site, appron to be ate
inlet & Chemical Risk
ensured
outlet C.W. burns
pipelines
 Entangleme
Esnure proper electrical islocation & LOTO,
3.2 nt with Injury to WPS, TRG, AWS, Adeq Adequ
E/C 2 3 3 9 NS proper PPEs, supervision to be maintained, 3 3 9
5 rotating body parts PPE uate ate
ensure machine guarding while running
parts

cut resistant gloves to be worn which are in

3.2 Collector Injury to WPS, TRG, AWS, Adeq Adequ
E/C 3 3 3 9 NS good condition, tool box talk to be followed, 3 3 9
6 inspection body parts PPE uate ate
supervision to be maintained

Ensure confined space register, stand-by

person & confined pass, confined space work
Working in
Ball Cleaning 3.2 Injury to WPS, TRG, AWS, Subst permit, ensure blower/ air piepline,ensure Adequ
Confined E/C 3 4 3 12 S 3 3 9

WI-POM/MMD/TBN/03 ; WI-POM/MMD/COM/05
system 7 body parts ATC, PPE antial proper oxygen (19.5-23.5) & co level, ensure ate
space
24V DC bulb supply. Gas test to be done in
each shift renewal.

Entangleme
Esnure proper electrical islocation & LOTO,
3.2 nt with Injury to WPS, TRG, AWS, Adeq Adequ
E/C 2 3 3 9 NS proper PPEs, supervision to be maintained, 3 3 9
8 rotating body parts PPE uate ate
ensure machine guarding while running
parts

3.2 Pump Injury to WPS, TRG, AWS, Adeq TBT to be followed, ensure proper PPEs, Adequ
E/C 3 2 3 6 NS 2 3 6
9 inspection body parts PPE uate certified tools & tackles only to be used ate

Foldable plarform or proper platform to be

installed as per standard, supervison to be
Fall of man
3.3 Injury to WPS, TRG,EGC, Subst maintained at all times, safety belt to be used, Adequ
and material E/C 3 4 3 12 S 3 3 9
0 body parts ATC, PPE antial All tools & tackles should be tied properly, ate
life line to be installed if needed, certified
tools & tackles to be only used
Hotwell
cleaning
Ensure confined space register, stand-by
person & confined pass, confined space work
Working in
3.3 Injury to WPS, TRG, AWS, Subst permit, ensure blower/ air piepline,ensure Adequ
Confined E/C 3 4 3 12 S 3 3 9
1 body parts ATC, PPE antial proper oxygen (19.5-23.5) & co level, ensure ate
space
24V DC bulb supply. Gas test to be done in
each shift renewal.
Condenser all
3.3 Fall from Injury to WPS, TRG, EGC, Subst Ensure proper platform, use of safety belt, Adequ
manhole door E/C 3 3 4 12 S 3 3 9
2 height body parts ATC, PPE antial height pass is required at all times ate
closing

All tools & tackles should be tied properly,

Condenser all
3.3 Fall of Injury to WPS, TRG, ATC, Adeq use proper PPEs, supervision, ground level Adequ
manhole door E/C 3 2 4 8 NS 2 3 6
3 object body parts PPE uate guarding, ensure toe guard, certified tools & ate
closing
tackles must be used

Ensure proper platform i.e tempeorary

3.3 Fall from Injury to WPS, TRG, EGC, Subst scaffolding if require to be make, use of Adequ
E/C 3 3 4 12 S 3 3 9
4 height body parts ATC, PPE antial safety belt, height pass, life line to be installed ate
if needed

Contact with
LP cylinder cut resistant gloves to be worn which are in
3.3 sharp injury to WPS, AWS, PPE, Adequ
spray nozzle E/C 3 3 4 12Adequate S good condition, tool box talk to be followed, 3 3 9
5 edges / body parts TRG ate
inspection supervision to be maintained
objects

3.3 Awkard injury to WPS, AWS, PPE, Ensure TBT, supervisior to be present at site, Adequ
E/C 2 2 4 8Adequate NS 2 3 6
6 access body parts TRG proper access to be ensured ate

Slip and trip

due to pipe
3.3 Injury to AWS, TRG,ATC, Adeq Tool box training required. Condenser top Adequ
line E/C 4 3 3 9 NS 3 3 9
7 body parts PPE uate side platforms to be ensured. ate
erections at
platforms

Entangleme
Coupling guards to be installed.ensure LOTO
Chemical 3.3 nt with Injury to Subst Adequ
E/C WPS, AWS, TRG 4 4 3 12 S ,Area to be isolated and baricaded, supervsion 3 3 9
cleaning 8 rotating body parts antial ate
to be maintained, ensure proper PPEs
parts

Steam
leakages Welding joints must be strengthened. Isolation
3.3 Injury to WPS, AWS, TRG, Subst Adequ
from aux. E/C 4 3 4 12 S valves operation to be ensured, proper PPEs to 2 3 6
9 body parts EGC antial ate
steam pipe be worn
lines
 Chemical
spillage MSDS must be ensured. Competent person to
irritaion to
from the be supervise the job.all punch points before
Chemical 3.4 body parts Subst Adequ
condenser, E/C WPS, TRG, AWS 4 4 3 12 S the trail to be complied, first aid box should be 3 3 9
cleaning 0 i.e.Chemic antial ate
mixing tank present on site, ensure proper PPEs with
al burns
and shield or goggles
pipelines.
Adequate lighting & Proper supervison, TBT
Dummy Plate Fall of man Subst to be given , life line to be installed if
3.4 Injury to WPS, AWS, TRG, Adequ
installation in and material E/C 4 4 3 12 antial S requried, safety belt to be used, proper 3 3 9
1 body parts ATC, PPE ate
Inlet outlet pipes inside Pipe Risk PPEsmust be ensured..Proper platform or
tempeorary scaffolding to be installing.
Exposure to
heat while Ensure the regulators of gas cylinders are in
Dummy Plate
3.4 cutting & Injury to WPS, AWS, TRG, Adeq working condition. Ensure proper PPEs, gas Adequ
installation in E/C 4 3 3 9 NS 3 3 9
2 contact with body parts ATC, PPE uate cylinder checklist should be ate
Inlet outlet pipes
sharp updated,calibrated done of gas cylinder guage.
objects

Contact with
3.4 hot surface Injury to WPS, AWS, TRG, Adeq Adequate lighting, proper supervison, TBT to Adequ
E/C 4 3 3 9 NS 3 3 9
3 during body parts ATC, PPE uate be followed ate
welding
Dummy Plate
installation in
Ensure confined space register, stand-by
Inlet outlet pipes
person & confined pass, confined space work
Working in
3.4 Injury to WPS, TRG, ATC, Subst permit, ensure blower/ air piepline,ensure Adequ
Confined E/C 3 4 3 12 S 3 3 9
4 body parts PPE antial proper oxygen (19.5-23.5) & co level, ensure ate
space
24V DC bulb supply.Gas test to be done in
each shift renewal.

Foldable platform or proper platform to be

Fall of man installed, supervison to be maintained at all
3.4 Injury to WPS, TRG,EGC, Subst Adequ
and material E/C 3 4 3 12 S times, safety belt to be used, All tools & 3 3 9
5 body parts ATC, PPE antial ate
inside Pipe tackles should be tied properly, life line to be
installed if needed

Exposure to
heat while Ensure the regulators of gas cylinders are in
Condenser 3.4 cutting & Injury to WPS, AWS, TRG, Adeq working condition, esnure proper PPEs, Adequ
cooling water 6 contact with body parts E/C 4 3 3 9 NS 3 3 9
ATC, PPE uate oxygen & co level to be checked in every 2 ate
pipe line sharp hrs, fire extinguisher to be kept on site
inspection objects

Adequate lighting, Proper supervison to be

Contact with maintained, TBT to be followed, esnure
3.4 hot surface Injury to WPS, AWS, TRG, Adeq proper PPEs, fire extinguisher should be kept Adequ
E/C 4 3 3 9 NS 3 3 9
7 during body parts ATC, PPE uate on site, person shouldn't be more than 2hrs ate
welding. inside confined space, ensure double flash-
back arrestor.
 Ensure confined space register, stand-by
Working in
Condenser person & confined pass, confined space work
Confined
cooling water 3.4 Injury to WPS, AWS, TRG, Subst permit, ensure blower/ air piepline,ensure Adequ
space to E/C 4 4 3 12 S 3 3 9
pipe line 8 body parts ATC, PPE antial proper oxygen (19.5-23.5) & co level, ensure ate
inspect the
inspection 24V DC bulb supply. Gas test to be done in
pipe line
each shift renewal.

TBT to be followed, Do not start the job

Fall of man when LP Turbine under Overhauling,
LPH 7 Cladding and material supervision to be maintained, safety belt to be
3.4 Injury to WPS, AWS, TRG, Subst Adequ
sheet inspection between E/C 4 4 3 12 S used, double flash back arrestor to be ensured, 3 3 9
9 body parts ATC, PPE antial ate
& Repair tube ensure checklist,proper platform or
chambers tempoeorary scaffolding if needed to be
make.

Exposure to
heat while TBT to be followed, Blowers/ air pipelines
LPH 7 Cladding
3.5 cutting & Injury to WPS, AWS, TRG, Adeq must be installed for proper ventilation to Adequ
sheet inspection E/C 4 3 3 9 NS 3 3 9
0 contact with body parts ATC, PPE uate carryout the job, ensure proper PPEs, 30mA to ate
& Repair
sharp be used
objects
 Adequate lighting & Proper supervison,
Contact with esnure VRD, 30mA ELCB to be used, ensure
3.5 hot surface Injury to WPS, AWS, TRG, Adeq proper PPEs, fire extinguisher to be kept on Adequ
E/C 4 3 3 9 NS 3 3 9
1 during body parts ATC, PPE uate site, ensure welding checklist & fire blanket to ate
welding. be kept on site, fire extinguisher to kept on
LPH 7 Cladding site
sheet inspection
& Repair Ensure confined space register, stand-by
person & confined pass, confined space work
Working in
3.5 Injury to WPS, TRG, Subst permit, ensure blower/ air piepline,ensure Adequ
Confined E/C 3 4 3 12 S 3 3 9
2 body parts ATC, PPE antial proper oxygen (19.5-23.5) & co level, ensure ate
space
24V DC bulb supply. Gas test to be done in
each shift renewal.

Supervison to be mainatained,ensure proper

Improper
3.5 Injury to AWS,TRG,PPE, Adeq tools & checklist, use trolley if needed, chain Adequ
Material Shifting material E/C 5 1 5 5 NS 1 3 3
3 body parts ATC uate block to be used if required, ensure proper ate
handling
PPEs, colour coding & test certificate

Inspection of air All tools & tackles should be tied properly,

ingress/ leakage 3.5 Fall of Injury to
E/C
WPS, TRG, ATC,
3 2 4 8
Adeq
NS use proper PPEs, supervision, ground level 2 3 6
Adequ
in turbine 4 object body parts PPE uate ate
guarding, ensure toe guard
bearing
pedestals
glands , pipe
line flanges,
Ensure proper platform,or tempeorary
valves, welded
3.5 Fall from Injury to WPS, TRG, EGC, Subst platform scaffoliding if required & installing Adequ
joints, condenser E/C 3 3 4 12 S 3 3 9
5 height body parts ATC, PPE antial use of safety belt, valid height pass must be ate
manhole , pump
ensured, life line to be installed if required
side

Contact with
TBT to be followed, ensure proper PPEs,
Inspection of air 3.5 sharp injury to WPS,AWS,PPE, Subst Adequ
ingress/ leakage 6 E/C 3 3 4 12 S supervision to be maintained, cut resistant 2 3 6
edges / body parts TRG antial ate
hand gloves to be used
in turbine objects
bearing
pedestals
glands , pipe
line flanges,
valves, welded
3.5 Contact with injury to WPS,AWS,PPE, Subst TBT to be followed, ensure proper PPEs, Adequ
joints, condenser E/C 3 3 4 12 S 3 3 9
7 hot surface body parts TRG antial supervision to be maintained ate
manhole , pump
side

Prepared by : Reviewed by : Approved by :

 NGSL PLANT HEAD

NGSL COORDINATOR NGSL HOD

VAL PLANT HEAD

VAL CO. VAL HOD

VAL SAFETY

NGSL SAFETY

Amendment History:

Sl No Revision Date Revised byReviewed Approved by Amendment

FORM:MRJ/HIRA/01-00