HIRA-POM/MEC/TBN/NROU 09 HAZARD IDENTIFICATION, RISK ASSESSMENT AND

DOCUMENT
DETERMINING CONTROLS (HIRADeC)

DEPARTMENT MECHANICAL MAINTENANCE

TITLE Maintenance of Heat exchanger NORMAL - ROUTINE / NON-ROUTINE ACTIVITIES
VER. NO : 02 REV. NO : 03 PAGE 1 OF 1 Date:29/08/2021
Hazard Identification Existing Risk Assessment Residual Risk Assessment

No. of Persons exposed

PERSON

Refer SOP/WI
Risk Score= S*P

Risk Score= S*P

(S)
Proposed controls (Elimination,
Hazard No.

POTENTI

Risk level

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

S
P

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

Ensure proper PPEs, 30 mA ELCBs to be ensured,

Electrocutio injury to E/C WPS,AWS,PP Subst loose cables should be tied up, ensure no cut marks Adequ
Electrical Works 9.1 3 4 4 16 S 3 3 9
n body parts E antial on cables, all electronic devices should be properly ate
earthed use approved power tools

Supervision to be maintained, ensure proper tools

Manual & tackkles, use trolly if required, chain block to be
Injury to E/C Adeq Adequ
9.2 Handling of WI,AWS,PPE 3 2 4 8 NS propely anchored if necessary, ensure proper PPEs, 2 3 6
body parts uate ate
Materials color coding & proper test certificates to be
ensured, area cleaning & barricading

Injury to E/C Adeq Supervision to be maintained, proper PPEs to be Adequ

HIR-POM/MMD/TBN 09
9.3
Hitting by object WI,AWS,PPE 3 2 4 8 NS 2 3 6
body parts uate worn, Tool box talk to be given ate

Heat Exchanger
dismantling
 HIR-POM/MMD/TBN 09
Heat Exchanger
dismantling

Platform/scaffolding to be ensured with lifeline

Injury to installed , height pass to be insured, supervision to
Fall from E/C Adeq Adequ
9.4 body AWS,PPE 3 2 4 8 NS be maintained, area to be barricaded and ensure 2 3 6
height uate ate
parts/fatal scaffolding checklist by autorized person, while
working at heights use full body harness.

tools and tackles to be tied properly, supervision to

Fall of Injury to E/C Adeq Adequ
9.5 WI,AWS 3 2 4 8 NS be maintained, certified tools & tackles to be only 2 3 6
objects body parts uate ate
used and area barricading

All tools & tackles must have valid test certificates,

color coding of lifting tools & tackles must be
Failure of
Cleaning of Injury to E/C Adeq ensured, supervision must be mainatained at all Adequ
9.6 lifting tools WI;PPE 3 2 4 8 NS 2 3 6
plates or tubes body parts uate times, TBT to be given, proper PPEs must be ate
& tackles
ensured use appropriate tools, avoid hand made
tools

Contact with
MSDS to be displayed at work site, chemical
Chemical / E/C Adeq Adequ
9.7 burn injury AWS,PPE 3 2 4 8 NS spillage kit to be kept ready, supervision to be 2 3 6
cleaning uate ate
maintained, all job specific PPEs to be worn
agents

Cleaning of
plates or tubes

Platform/scaffolding to be ensured with lifeline

Injury to installed , height pass to be insured, supervision to
Fall from E/C Subst Adequ
9.8 body AWS,PPE 3 3 4 12 S be maintained, area to be barricaded and ensure 2 3 6
height antial ate
parts/fatal scaffolding checklist by autorized person, while
working at height use of full body harness.

Supervision to be maintained, ensure proper tools

Manual & tackkles, use trolly if required, chain block to be
Injury to E/C Adeq Adequ
9.9 Handling of WI,AWS,PPE 3 2 4 8 NS propely anchored if necessary, ensure proper PPEs, 2 3 6
body parts uate ate
Materials color coding & proper test certificates to be
ensured, area cleaning & barricading

Plate or Tube
leakage test
 Plate or Tube
leakage test

9.1 E/C SWP,AWS,PP Adeq Adequate lighting, Proper supervison to be Adequ

Contact with hot surface
burn injury 3 2 4 8 NS 2 3 6
0 E,PTW uate aintained, TBT to be followed, esnure proper PPEs. ate

Ensure proper Personal Protective Equipments,

9.1 contact with injury to E/C WPS,AWS,PP Subst supervision to be maintained, Tool Box Talk to be
3 3 4 12 S 3 3 9 Adequate
1 hot surface body parts E antial given and followed, heat resistant gloves to worn .
Use steam suit

HIR-POM/MMD/TBN 09
Steam suit to be worn/Face shield to be used,
Shell side steam
Supervision to be maintained by
bath of Heat 9.1 splash of injury to E/C WPS,AWS,PP Subst
3 4 4 16 S sernior/experienced supervisor, Tool box talk to be 3 3 9 Adequate
exchanger/ 2 steam body parts E antial
followed, depressuarization to be done as much as
Cooler
possible working area to be barricated

All tools & tackles should be tied properly, use

Fall of
9.1 Body E/C WPS,AWS,PP Subst proper PPEs, supervision, ground level guarding,
object and 3 3 4 12 NS 3 3 9 Adequate
3 Injury E antial ensure toe guard working area to be barricated,
tools
ensure presence of no loose material on edge area

Supervision to be maintained, ensure proper tools

Manual & tackkles, use trolly if required, chain block to be
9.1 Injury to E/C Adeq Adequ
Handling of WI,AWS,PPE 3 2 4 8 NS propely anchored if necessary, ensure proper PPEs, 2 3 6
4 body parts uate ate
Materials color coding & proper test certificates to be
ensured, area cleaning & barricading

Gasket
installation and 9.1 Injury to E/C Adeq Supervision to be maintained, proper PPEs to be
Hitting by object WI,AWS,PPE 3 2 4 8 NS 2 3 6 Adequate
box up of Heat 5 body parts uate worn, Tool box talk to be given
exchanger
 Gasket
installation and
box up of Heat
exchanger

Platform/scaffolding to be ensured with lifeline

installed , height pass to be insured, supervision to
Injury to
9.1 Fall from E/C Adeq be maintained, area to be barricaded, ensure height Adequ
body AWS,PPE 3 2 4 8 NS 2 3 6
6 height uate PTW, use safety harness, scaffolding to be ate
parts/fatal
approved by authorized scaffolder & tagging to be
ensured.

Manual
Water supply for 9.1 Injury to E/C Adeq Supervision to be maintained, ensure proper tools, Adequ
Handling of WI,AWS,PPE 3 2 4 8 NS 2 3 6
cleaning 7 body parts uate use trolly if required, area cleaning & barricading ate
Materials

Note: S= Severity, P= Probability, BC=Business concern

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