HIRA O&M Rev 10

Ratting Severity
Permanent Disability, May not

4 Extreme
be possible for rejoining
Permanent Disability but may

3 High be join after relevant treatment
& Period
Temporary Disability & may

2 Moderate
join in 2-3 weeks
Temporary Discomfort and

1 Low
may join immediately
Hazard and Risk Identification
Activities having Occupational

Health and Safety concerns
Sr. No. Activity Code Function Activity
1 BOP-1 Boiler Start up of Boiler

2 AQC-1 Boiler Start up of Boiler:
5 BOP-2 Boiler Operation of Boiler
10 BOP-3 Boiler Bed material feeding / Handling

11 BOP-4 Boiler Sample collection
12 BOP-5 Boiler Operation of vents and drains
13 BOP-7 Boiler Hot bed material drain
14 BOP-7 Boiler Hot bed material drain
15 FFS0P-1 Fuel Feeding System Operation of drag chian feeders
Removal of choking during the

16 FFS0P-2 Fuel Feeding System
wet coal feed in the chutes
Rapping of chutes for removal

17 FFS0P-3 Fuel Feeding System of blockages during operation
in the chutes
Start up and engagement of

18 TOP-1 Turbine
barring gear
19 TOP-2 Turbine Operation

21 TOSOP-1 Turbine Oil system Operation of oil coolers
23 BOP-6 Boiler Pumps Start up and operation
26 AHPOP-1 Ash handling System Operation of ESP
27 AHPOP-2 Ash handling System Operation of Ash silo

Removal of jamming inside the
29 AHPOP-3 Ash handling System economizer or ash handling
hopper.
Dome valve cleaning, jamming

30 AHPOP-3 Ash handling System
removal
31 FHPOP-1 Fuel Handling Plant Operation of fuel handling plant

Storage of fuels, like Bagase,
38 FHPOP-1 Fuel Handling Plant
Petcoke, & Coal, Rice Husk.
39 FHPOP-1 Fuel Handling Plant Operation of RAV (Jamming)
Operation of DCS/I/O unit

/PLC Server/urbosupervisory
40 IS0-1 Instrumentation System
Instruments panel/Turbine
control panel
41 GM-2 General Activites Civil Works, Painting etc
AC outdoor unit refrigeration

45 GM-5 General Activites gas leakage testing and
arresting work
General Human Behaviour

46 HB General Activites
Related Actvity

Related Actvity
Related Actvity

Related Actvity

Related Actvity

Related Actvity

Related Actvity

Related Actvity

Related Actvity
55 GM-5 General Activites Housekeeping

Coal Ash and LDO

61 GM-5 General Activites Transportation in and out of
plant
62 BM1 ESP & Boiler Cleaning of internals

Light Diesel Oil (LDO)

Unloading & Storage & LDO Unloading, storage,
67 LDO U/L
Transferring to plant Tranferring operation
operations

Unloading & Storage & LDO Unloading, storage,
68 LDO U/L
Transferring to plant Tranferring operation
operations
69 BOP-7 Boiler Fans Start up and operation
70 BOP-7 Boiler Fans Start up and operation
71 AHPOP-4 Ash handling System Air Compressor for ash conveyance
72 AHPOP-4 Ash handling System Air Compressor for ash conveyance
73 AQC-1 Boiler Shutdown work Cyclon refectory Job

74 AQC& PH Boiler AQC Boiler Internal Tube cleanning
Operation of drag chian & RAV'S

75 AQC& PH Boiler
feeders
76 AQC& PH Boiler Operation of Boiler:
77 AQC& PH Boiler Boiler dampers checking

78 AQC& PH Ash handling System
Cyclone RAV -130&160.
79 AQC Boiler ID fan dampers checking
80 STG Turbine Start up and engage of barring gear
81 STG Turbine Oil Leakage in oil Systam
82 STG Turbine Operation

83 BOP Boiler Pumps Start up and operation
84 BOP Boiler Pumps Start up and operation
General Human Behaviour Related

85 WHRS General Activites
Actvity
86 BHS-1 Bagasse Operation of Bagasse
87 BHS-1 Bagasse Friction of fine Bagasse at conveyor
88 BHS-1 Bagasse Hot work in Bagasse
89 BHS-1 Bagasse Operation of Bagasse feeding
Fire in Tractor due to fine bagasse

90 BHS-1 Bagasse
accumulation at engine area.
91 BHS-1 Bagasse Scrap found in Bagasse

92 BOP-2 Boiler Operation of Boiler:
97 BOP-3 Boiler Bed material feeding
98 BOP-4 Boiler Sample collection
99 BOP-5 Boiler Operation of vents and drains
Removal of choking during the wet

100 FFS0P-2 Fuel Feeding System
coal feed in the chutes
Rapping of chutes for removal of
101 FFS0P-3 Fuel Feeding System blockages during operation in the
chutes
Start up and engagement of barring

102 TOP-1 Turbine
gear

110 AHPOP-1 Ash handling System Operation of ESP

economizer or ash handling hopper.
Dome valve cleaning, jamming

removal

Storage of fuels, like Bagase,

122 FHPOP-1 Fuel Handling Plant
Petcoke, & Coal, Rice Husk.
123 FHPOP-1 Fuel Handling Plant Operation of RAV (Jamming)

HAZARD IDENTIFICATION, RISK ASSES
Example
Personnel Rating Likelyhood
Injury
Almost
Fatal/Death 4 Daily
Certain
Major Less than

3 Likely
impairment One month
Person Less than

injured,minor 2 Five Moderate
disorders Months
More Than
First Aid
1 Five Unlikely
Treatment
months
Risk Evaluation
Type of
Base Risk
Activity
R/NR/L Hazard Risk SEV POC
NR Back fire from furnace Burn Injury 4 2

Back fire from Frash air
NR damper due to positive Burn Injury 2 2
pressure.
NR Fire Burn Injury 1 2
Burn due to contact with Hot

NR Burn Injury 1 2
surfaces
R Flue gas leakage Burn Injury 4 1
R Guage glasss leakge Burn Injury 4 1
R Burn from hot drain material. Burn Injury 3 3
Boiler passingcertificate /
L Legal
Licence
Steam Leakage /Condensate

R Burn Injury 3 2
splash
Strain/
Carrying of Materials in
R Discomfort/ 1 3
Inappropriate postures
Body Pain
R Hot condensate splash Burn Injury 2 2

R Burn Injury 3 4
surfaces
R Exposure to Fumes Discomfort 1 4
R Limbs caught in nip injury 3 1
R Fall of man injury 3 1
NR Limbs caught in nip Injury 3 1
Burn Injury,
NR Fire property 2 1
damage
R Exposure Noise Hearing Loss 2 1
R Fire Burn Injury 3 1
Working in hot
R Discomfort 1 1
surroundings/Heat radiation
R Failure of Gaskets/seals Burn Injury 1 2
R Limbs caught in nip Injury 3 1
R Electric flash over Burn Injury 3 1
R Electric Shock Fatal injury 5 1
Allergy/
R Exposure to Dust 1 2
Irritation

NR Burn injury 4 2
Caught in between rotating

NR injury 4 2
eq.
R Belt Sway injury 1 1
Allergy/
R Exposure to Dust / fines 1 2
Irritation
R Vehicular Movement Injury 4 3
R Exposure to Noise Discomfort 1 3

R Failure of Interlocks Injury 4 2
NR Contact With Sharp Edges Injury 1 2
Allergy /
NR Exposure to Dust 1 2
Discomfort
NR Fall of man Injury 4 2
NR Fall of object Injury 1 2
NR Blast in compressor Injury 4 2
NR Inattention in work Injury 2 4
Unauthorised entry to
hazardous area/Unauthorised Injury 2 2
area
In adequate Knowledge,
NR Injury 1 1
illterate
NR Fatal injury 4 2
illterate
Stress/
NR Frustration 1 1
Bodyache
Tolleration of un safe acts Lead to

NR 1 2
and behaviour multiple risk
In compatible physical
NR Multiple risk 1 2
capabilites
Excess personal stress or

fatigue
NR Supervisor is over tasked Multiple risk 1 2
NR Fall or Slip or Trip Multiple risk 1 3
Struck by /Struck against the

Objects
NR Exposure to Dust Multiple risk 2 1
NR Exposure to Noise Multiple risk 2 2
Allergy /
R Contact With Chemicals 4 8
Discomfort
Potential risk contact with

R Infection 1 4
biological matter / Garbage
R Movement of vehicles Injury 4 2
Allergy/
NR Dust exposure 2 1
Irritation
NR Fall or Slip or Trip Injury 2 2
Strain,
Struck by / Struck against
NR Discomfort, 1 1
object
Body pain
NR Working in confined space Injury 1 2

Strain,
Working in inappropriate
NR Discomfort, 2 2
postures
Body pain
NR Bursting of Oil Hose, Line Injury 1 2
R Caught in between rotating eq. injury 4 2
injury,Body
NR Injury, Fall or Slip, 4 2
pain
injury,Body
NR Slip 2 2
pain
R Burn from hot drain Ash material. Burn Injury 4 2

R Burn Injury 3 2
splash In Sampling Time
NR Fall or Slip, Injury 3 2
NR Burn, Elecrical Shock injury,Fatal 4 1
NR Ash dumping injury 2 2
NR Limbs caught in nip/Slip Injury 3 2
Burn
NR Fire , Slip, 3 2
Injury,injury

NR Failure of Gaskets/seals Burn Injury 1 3
Burn
NR Electric flash over 4 1
Injury,Fatal
Unauthorised entry to hazardous

R Injury 2 2
area/Unauthorised area
Allergy/
R Exposure of Dust 2 2
Irritation
R Vehicular Movement,Collision Injury 4 1
NR Struck/fall object Injury 2 1

R Flue gas leakage Burn Injury 4 1
R Guage glasss leakge Burn Injury 4 1
R Burn from hot drain material. Burn Injury 3 3

R Burn Injury 3 2
splash
Strain/
R Discomfort/ 1 3
Body Pain

R Fall of man injury 3 1
NR Limbs caught in nip Injury 3 1
Working in hot surroundings/Heat

R Discomfort 1 1
radiation
R Failure of Gaskets/seals Burn Injury 1 2

R Electric Shock Fatal injury 4 1
Allergy/
R Exposure to Dust 1 2
Irritation
NR Burn injury 4 2
NR Caught in between rotating eq. injury 4 2
R Belt Sway injury 1 1
Allergy/
R Exposure to Dust / fines 1 2
Irritation

R Vehicular Movement Injury 4 3
R Exposure to Noise Discomfort 1 3

N, RISK ASSESSMENT AND ESTABLISHMENT OF CONTROLS
Risk Rating
Extreme Risk : Cannot be accepted 4
<=3,"Low"
Risk
High Impact : Must implement
Rating>3," 3
extensive risk controls
Moderate"
Risk
Moderate risk : Conduct formal risk
Rating>=7, 2
analysis , may require risk controls
"High"
Risk
Rating>=11 Low Risk : Tolerable risk 1
,"Extreme"
Evaluation
ase Risk Risk Rating Existing controls Residual Risk
Rating SEV
8 High OCP - SOP, Interlock protection, PPE 3

1. Safe suppervision.
4 Moderate 2
2. Interlock to be create with ID Fan
2 Low OCP - SOP, Interlock protection 1
All hot line need to be insulated, Boiler

2 Low 1
Suit, Hand gloves
4 Moderate Barication of the area under exposure. 1
Close isolation valve, Barricate the

4 Moderate 1
area, Boiler Suit, Hand gloves
Spray cold water, Hand gloves safey

9 High shoes, Boiler suit / coveralls, Barricate 2
area
Boiler passing certificate, Operatros

Low with BoE Certification and
Qualification
Barricate the area, Close isolation

6 Moderate valve, Open drain lines, Heat resistance 2
PPE
Training, Provision of breaks and use

3 Low 1
of machine for lifitng
Open valve slowly, Heat resistance PPE
4 Moderate 1
/ coveralls.
Use F rods, Heat resistance PPE /

4 Moderate 1
coveralls.
Barricate the area, Unauthorized entry

prohibited, Spray cold water, Use metal
12 Extreme 3
sheet on trolley, Hand gloves safey
shoes, Boiler suit coveralls.
Do not enter inside the premises untill

4 Moderate clearance, Provision of ventillation, 1
Dust Mask
50 mm X 50 mm mesh on inspection
hole, Machine Guards, provison of
3 Low 2
covers on casing, Caution board,
Training
Electrical isolation, use long tools or
steel rod for cleaning, Training,
3 Low 2
Machine Guards, provison of covers on
casing
Provision of working platforms,

3 Low 2
Hammering to chute
Training , Tool box talk and

3 Low Supervision of Job, use of emergency 3
stop.
Periodic inspections of lube lines,

2 Low joints, flanges etc, replace flexible hose 1
if vibration occured
caution boards, Health Check,
2 Low 2
Provision of PPEs
Fire extinguishers, Periodic inspection

3 Low 2
of Leakages, sign boards of changeover
Provision of rest at Intervals, drinking

1 Low 1
water, heat resistance PPE
periodic inspection, clearance from

2 Low 1
field, Hand gloves, goggles boiler suit,
Machine Guards Provison of

3 Low emergency stops, caution boadrs, 2
Training, .
3 Low Hand gloves, goggles/ face shield. 2
SOP, Warning signs, Do's Don’t's,

5 Extreme tripping interlocks, unauthorized entry 3
prohibited
Ash condensor in operation, provison

2 Low of bag filters, Dust mask, Lung function 1
test Health Check up
6 Moderate Machne guard, Training 1

Mechanical jamming removal eq. to be
used, like vibrator, pocking hole,
8 High 2
hammering, heat resistance PPE to be
used, PTW for confined space.
Pneumatic cylinder to be guarded,

8 High 2
PTW, LOTO, isolation, JSA
House keeping- Removal of coal fines
accumulated on platforms struturals and
floor to ensure cleanliness,
4 Moderate 3
water Spray during summer, Check
electrical connections for tightness,
door closed weekly.
Belt sway Switches, perodically
1 Low 1
inspection.
Dust mask, dust extraction system

2 Low 1
operational, water spray
Siren, Machine guards, Pull cord

6 Moderate 2
switches, caution boards, training.
Provision of reverse horn and signal

12 Extreme man, sign boards, unauthorized entry 2
prohibited
3 Low Ear Plug / ear muff 1
9 High Machne guard, Training, caution boards 1

Stored in shade and periodic shuffeling
of stored fuel.
1 Low Hot work permit area. 1
Maintain Water Sprays at regular
intervals, fire fighting arrangement
Isolation Permit, Air Cleaning

4 Moderate 1
provison, use long tools for removal.
Maintenance, Inspection, checklist

8 High 2
before every lightup
2 Low Hand gloves, safety shoes, helmet 1
2 Low Dust mask 1
TBT, Height work permit & JSA,

8 High 1
Approach
Falling meterial need to be tied up,

2 Low Training , Tool box talk and 1
Supervision of Job
8 High OCP 59 2
8 High Job supervison, Provision of rest 1
Barication of the area under exposure.

4 Moderate Mass tool box talk to be conducted on 1
human behaviour aspects as per format
1 Low Training 1
Issue gate pass only after safety

induction.
8 High 2
Skill and knowledge based allocation of
work.
1 Low Councelling 1
2 Low Training 1
2 Low 1
Provison of rest to the worker at

1 Low 1
intervals.
2 Low Councelling 1
Hoouse keeping - Removal of slippery

3 Low 1
material
1 Low Helmet, Safety shoes 1

2 Low Dust mask 2
4 Moderate Ear Plug 1
MSDS, Hand gloves Aprons Safety

32 Extreme 1
Shoes.
Hand gloves Aprons Safety Shoes, Dust

4 Moderate 1
Mask
Provion of speed limit warning, reverse

8 High 2
horn and signal man
2 Low Dust mask 2
4 Moderate Removal of slippery materials 2
Provision of cushion on sharp edges,

1 Low 1
Helmet & Shoes
2 Low Confined space work permit 1

Provision of rest to the worker at
4 Moderate 2
intervals
8 High Work permit, Truck Earthing 1
Inspection of hoses / lines periodically

2 Low 1
and before taking to use
Moderate Training, Machine Guards Provison of

3 2
emergency stops.
3 Moderate Hand gloves, goggles/ face shield. 2
High Pneumatic cylinder to be guarded, PTW,

8 2
LOTO, isolation, JSA
3 Moderate Hand gloves, goggles/ face shield. 2
High Safety belts and Supervision of job( Comfind

8 2
space) O2 level; Mainten 21 % & Room temp
Supervision of job( Comfind space) O2 level;
4 Moderate Mainten 21 % & Room tempWork permit, 24 2
V DC Hand lamp,Dust mask.
8 High Laher hand glouse 18'', High temp boiler shut 2
6 Moderate Hand gloves, Ear Plug, gagules 2
6 Moderate Safety belts and Supervision of job 2
Mechanical jamming removal eq. to be used,

4 Moderate like vibrator, pocking hole, heat resistance 2
PPE to be used, .
Moderate Work permit, Training and Supervision of Job.

4 2
Moderate Training , Tool box talk and Supervision of

6 2
Job, use of emergency stop.
6 Moderate Periodic inspections of lube lines, 2
12 Extreme Health Check, Provision of PPEs 2

3 Low Hand gloves, goggles, Boiler suit, 1
Moderate Rabber Hand gloves, Proper erting goggles/

4 2
face shield.
Barication of the area under exposure. Mass

4 Moderate tool box talk to be conducted on human 1
behaviour aspects as per format
Moderate Provision of Water Spray sprikler,Dust

4 1
Mask,Extend belt skirting
Housekeeping-Removal of fine bagasse

4 Moderate accumulated on platforms, strucure, Pulley. 2
Water spraying at exposure area.
4 Moderate Hot work permit,OCP 2
Moderate Provision of speed limit & reverse horn,signal

4 2
man
Provision of Extinguisher,timely remove the

3 Low bagasse with the help of Air,Provide traning to 1
driver in fire sitiuation
2 Low Provision of Magnetic seprator 1

4 Moderate Barication of the area under exposure. 1
4 Moderate Boiler Suit, Hand gloves 1
High Hand gloves safey shoes, Boiler suit /

9 2
coveralls.
Low Operatros with BoE Certification and

0
Qualification
Moderate Hand gloves, boiler suit. Routing of vents to

6 2
drain lines
Low Training, Provision of breaks and use of

3 1
machine for lifitng
Moderate Hand gloves safey shoes, Boiler suit /

4 1
coveralls.
Moderate Hand gloves safey shoes, Boiler suit /

4 1
coveralls.
Low Training, Machine Guards, provison of covers

3 2
on casing
3 Low Provision of working platforms 2
Low Training , Tool box talk and Supervision of

3 3
Job, use of emergency stop.
2 Low Periodic inspections of lube lines, 1
2 Low Health Check, Provision of PPEs 2
Low Fire extinguishers, Periodic inspection of

3 2
Leakages.
Low Provision of rest at Intervals, drinking water,

1 1
handgloves, safety shoes.
2 Low Hand gloves, goggles boiler suit, 1
Low Training, Machine Guards Provison of

3 2
emergency stops.
3 Low Hand gloves, goggles/ face shield. 2

4 Moderate Warning signs 4
Low Dust mask, Lung function test Health Check

2 1
up
6 Moderate Machne guard, Training 1
Mechanical jamming removal eq. to be used,

8 High like vibrator, pocking hole, heat resistance 2
PPE to be used, PTW for confined space.
High Pneumatic cylinder to be guarded, PTW,

8 2
LOTO, isolation, JSA

accumulated on platforms struturals and floor
4 Moderate to ensure cleanliness, 4
water Spray during summer, Check electrical
connections for tightness monthly.
1 Low Belt sway Switches. 1
2 Low Dust mask 1
Moderate Siren, Machine guards, Pull chord switches,

6 3
training.
12 Extreme Provision os reverse horn and signal man 2
3 Low Ear Plug 1
9 High Machne guard, Training, 1
Stored in shade and periodic shuffeling of

Low stored fuel.
1 1
Hot work permit area.
Maintain Water Sprays at regular intervals
4 Moderate Isolation Permit, Air Cleaning provison 1

F CONTROLS
Doc Number
Format Number
REV
Date
1 2 3 4
Legal / Other
Residual Risk Risk Rating Proposed Controls
Requirements
POC Rating
2 6 Moderate Yes
1 2 Low
2 2 Low Yes
2 2 Low IBR
1 1 Low IBR
1 1 Low IBR
3 6 Moderate IBR
Low IBR
2 4 Moderate IBR
3 3 Low
2 2 Low
2 2 Low
Bed ash
conveying
line need to
4 12 Extreme
be
operational
always.
4 4 Moderate
Factories
1 2 Low Act Safety
provision
Factories
1 2 Low Act Safety
provision
1 2 Low OHS
Factories
1 3 Low Act Safety
provision
1 1 Low
Factoes Act
1 2 Low Safety
Provision
1 2 Low
1 1 Low
2 2 Low
Factories
1 2 Low Act Safety
provision
1 2 Low IER
1 3 Low OHS
Factory Act
2 2 Low Safety
Provison
Factories
2 2 Low Act Safety
provision
2 4 Moderate OHS
2 4 Moderate OHS
Emergency
1 3 Low
Manual
1 1 Low No
2 2 Low No
2 4 Moderate Yes
3 6 Moderate No
3 3 Low Yes
3 3 Low Yes
1 1 Low
2 2 Low Yes
2 4 Moderate No
2 2 Low No
2 2 Low No
2 2 Low OHS
2 2 Low No
2 2 Low
4 4 Moderate No
2 2 Low No
1 1 Low No
2 4 Moderate No
1 1 Low No
2 2 Low No
2 2 Low No
1 1 Low No
2 2 Low No
3 3 Low No
1 1 Low No
1 2 Low No
2 2 Low Yes
8 8 High Yes
4 4 Moderate No
2 4 Moderate No
1 2 Low No
2 2 Low No
1 1 Low No
2 2 Low OHS
2 2 Low No
2 1 Low No
2 1 Low No
Factories Act
1 2 Low Safety
provision
1 2 Low IER
2 4 Moderate OHS
1 2 Low IER
1 2 Low
1 2 Low
1 2 Low
1 2 Low
1 2 Low
1 2 Low
1 2 Low
1 2 Low
1 2 Low
1 2 Low
2 2 Low
1 2 Low
2 2 Low
2 2 Low No
1 2 Low No
1 2 Low No
1 2 Low No
1 1 Low No
1 1 Low 1
1 1 Low IBR
1 1 Low IBR
3 6 Moderate IBR
0 Low IBR
2 4 Moderate IBR
3 3 Low
2 2 Low
2 2 Low
Factories Act
1 2 Low Safety
provision
1 2 Low OHS
Factories Act
1 3 Low Safety
provision
1 1 Low
Factoes Act
1 2 Low Safety
Provision
1 2 Low
1 1 Low
2 2 Low
Factories Act
1 2 Low Safety
provision
1 2 Low IER
1 4 Moderate OHS
Factory Act
2 2 Low Safety
Provison
Factories Act
2 2 Low Safety
provision
2 4 Moderate OHS
2 4 Moderate OHS
Moderate Emergency
1 4
Manual
1 1 Low No
2 2 Low No
2 6 Moderate Yes
3 6 Moderate No
3 3 Low Yes
3 3 Low Yes
1 1 Low
2 2 Low Yes
OHS/D 01
OHS/FT01
10
10.07.2018
Remarks
Residual Risk severity

increased to 3 from 2 after
incident at MCL4 on
28.07.2015
IBR
IBR
IBR
IBR
IBR
IBR
IBR
Modofy after learning from
incident (DCW 24.08.16)
incident (GPPL 22.08.16)
Modified after case study

of BORL incidence and at
tuticorin power plant fire.
Severity Modified for

residual risk from 2 to 3
after Lost time injury at
WCL
Modified After 2nd

surevllance audit in Dec 12
Factories Act
Factories Act Safety

provision
Modified After
recommendation from
recertification audit in Dec
16
Modified after DCW
incident on 29.05.2016
LTI - Fire Explosion at

USTKWPCL
LTI- at JK Paper.
FATAL Incident at
KSPCL
Factories Act
MSIHC
Modified After 2nd

Modified After 2nd

Modified After 2nd

Modified After 2nd

Modified After 2nd

Modified After 2nd

Modified After 2nd
Modified After 2nd

IBR
IBR
IBR
IBR
IBR
incident (DCW 24.08.16)

incident (GPPL 22.08.16)
Modified after case study

of BORL incidence and at
tuticorin power plant fire.

WCL
Modified After 2nd
Factories Act

provision
Modified After
recommendation from
recertification audit in Dec
16
Modified after DCW

incident on 29.05.2016
HA
Example
Ratting Severity Personnel
Injury
Extreme Permanent Disability, May not be possible for

4 Fatal/Death
rejoining
Permanent Disability but may be join after Major

3 High
relevant treatment & Period impairment
Person
2 Moderate Temporary Disability & may join in 2-3 weeks injured,minor
disorders
Temporary Discomfort and may join First Aid

1 Low
immediately Treatment
Activities having Occupational Health and Type of

Safety concerns Activity
Activity
Function Activity R/NR/L
Code
Maintenance of Bed coils, All superheater coils

& Water walls - pressure parts which involves
BM-1 Boiler NR
Cutting ,Welding & replacement of Pressure
Parts
BM-1 Boiler NR
Parts
BM-1 Boiler NR
Parts
BM-1 Boiler NR
Parts

BM-1 Boiler NR
Parts

BM-1 Boiler NR
Parts

BM-1 Boiler NR
Parts
BM-1 Boiler NR
Parts
BM-1 Boiler NR
Parts
BM-1 Boiler NR
Parts
BM-1 Boiler NR
Parts
BM-1 Boiler NR
Parts
BM-1 Boiler NR
Parts
BM-1 Boiler L
Parts
BM-1 Boiler NR
Parts
BM-2 Boiler Maintenance of Coal Nozzles & Air Nozzles NR

BM-3 Boiler Maintenance of Refractory NR
BM-4 Boiler Maintenance of Boiler Drum & internals NR

Maintenance of Economizer - pressure parts

BM-5 Boiler which involves Cutting ,Welding & NR
replacement of Pressure Parts











AFPM-2 Air & Flue path Air & Flue gas path Ducts NR
BM-6 Boiler Maintenance of Oil Burner NR

Burner Light
BM-8 Diesel Oil Maintenace of Boiler fuel Oil System NR
System
Burner Light
System
Burner Light
System
Burner Light
System
Burner Light
BM-8 Diesel Oil Maintenace of Boiler fuel Oil System R
System
Burner Light
System
Burner Light
System
Burner Light
System
Burner Light
System
BFM-1 Fans Maintenance of Fans NR
AFPM-1 Air & Flue path Maintenance of Windbox NR

APH-1 Air & Flue path Maintenance of Air Preheater NR

APH-2 Air & Flue path Maintenance of Steam Cooled Air Preheater NR
APH-2 Air & Flue path Maintenance of Steam Coiled Air Preheater NR
Fuel Feeding Maintenance of Rotary, screw feeders & Drag

FFSM-1 NR
System chain feeders

FFSM-1 NR

FFSM-1 NR

FFSM-1 NR

FFSM-1 NR

FFSM-1 NR

FFSM-1 NR

FFSM-1 NR

FFSM-1 NR
Fuel Feeding
FFSM-2 Maintenance of Bunker & Chutes NR
System
Fuel Feeding
System
Fuel Feeding
System
Fuel Feeding
System
Fuel Feeding
System
Fuel Feeding
System
Fuel Feeding
System
Fuel Feeding
System
Maintenance of Primary Air

Fuel Feeding
FFSM-3 Horizontal/Vertical lines, Mixing Nozzles, Bed NR
System
drains & drain gates

Fuel Feeding
System

Fuel Feeding
System

Fuel Feeding
System
Fuel Feeding
System

Fuel Feeding
System

Fuel Feeding
System

Fuel Feeding
System

Fuel Feeding
System
TM-1 Turbine Maintenance of bearings NR

Maintenance of Turbine - shaft / blades /

TM-2 Turbine NR
Casing etc

TM-2 Turbine NR
Casing etc

TM-2 Turbine NR
Casing etc

TM-2 Turbine NR
Casing etc

TM-2 Turbine NR
Casing etc

TM-2 Turbine NR
Casing etc

TM-2 Turbine NR
Casing etc

TM-2 Turbine NR
Casing etc

TM-2 Turbine NR
Casing etc
TM-2 Turbine NR
Casing etc
TM-3 Turbine Maintenance of Main Oil Pumps NR

Maintenance of speed reduction gear
TM-4 Turbine NR
box/turning gear system & couplings

TM-4 Turbine NR

TM-4 Turbine NR

TM-4 Turbine NR

TM-4 Turbine NR

TM-4 Turbine NR

TM-4 Turbine NR

TM-4 Turbine NR

TM-4 Turbine NR

TM-4 Turbine NR
Maintenance of turbine governor and

TM-5 Turbine NR
extraction QCNRV
TM-5 Turbine NR
extraction QCNRV

TM-5 Turbine NR
extraction QCNRV

TM-5 Turbine NR
extraction QCNRV

TM-5 Turbine NR
extraction QCNRV

TM-5 Turbine NR
extraction QCNRV

TM-5 Turbine NR
extraction QCNRV

TM-5 Turbine NR
extraction QCNRV

TM-5 Turbine NR
extraction QCNRV

TM-5 Turbine NR
extraction QCNRV

TM-5 Turbine NR
extraction QCNRV
TM-6 Turbine Valves Maintenance of Turbine Emergency stop valve NR


Maintenance of Main steam stop valve and all
TM-7 Turbine Valves NR
Extraction MOVs

Extraction MOVs

Extraction MOVs

Extraction MOVs

Extraction MOVs

Extraction MOVs

Extraction MOVs

Extraction MOVs

Extraction MOVs

Extraction MOVs

Extraction MOVs
Extraction MOVs

Extraction MOVs
Maintenance of Control / Auxilary /

Turbine Oil
TOSM-1 Emergency oil pumps & Main / Overhead oil NR
system
Tank system

Turbine Oil
system
Tank system

Turbine Oil
system
Tank system

Turbine Oil
system
Tank system

Turbine Oil
system
Tank system

Turbine Oil
system
Tank system

Turbine Oil
system
Tank system

Turbine Oil
system
Tank system

Turbine Oil
system
Tank system
Turbine Oil
system
Tank system

Turbine Oil
system
Tank system

Turbine Oil
system
Tank system
Turbine Oil
TOSM-2 Maintenance of Oil purification system NR
system
Turbine Oil
system
Turbine Oil
system
Turbine Oil
system
Turbine Oil
system
Turbine Oil
TOSM-3 Maintenance of Oil coolers NR
system
Turbine Oil
system
Turbine Oil
system
Turbine Oil
system
Turbine Oil
system
Turbine Oil
system
Turbine Oil
system
Turbine Oil
system
Turbine Oil
system
Turbine Oil
system
Turbine Oil
TOSM-4 Maintenance of oil Actuator NR
system
Turbine Oil
TOSM-4 Maintenance of oil Actuator NR
system
CONM-1 Condensor Cleaning of tubes. NR
CONM-1 Condensor Cleaning of tubes. NR

BM-9 Boiler Pumps Maintenance Boiler Feed Water Pump NR
Maintenance High & Low Pressure Dosing

BM-10 Boiler Pumps NR
Pump

Pump
Pump

Pump

Pump

Pump
Mechanical
Maintenance of Safety valves /Mechanical
isolation Valves /
BM-11 isolation valves /Control Valves/ NRVs - NR
NRV / Safety
Steam/Hot water Circuit
valves
Mechanical
isolation Valves /
NRV / Safety
valves
Mechanical
isolation Valves /
NRV / Safety
valves
Mechanical
isolation Valves /
NRV / Safety
valves
Mechanical
isolation Valves /
NRV / Safety
valves
Mechanical
isolation Valves /
NRV / Safety
valves
Mechanical
isolation Valves /
NRV / Safety
valves
Mechanical
isolation Valves /
NRV / Safety
valves
Mechanical
isolation Valves /
NRV / Safety
valves
Mechanical
isolation Valves /
NRV / Safety
valves
Mechanical
isolation Valves /
NRV / Safety
valves
Mechanical
isolation Valves /
NRV / Safety
valves
Mechanical
isolation Valves /
BM-12 Maintenance of Control Valves- Cold water NR
NRV / Safety
valves
Mechanical
isolation Valves /
NRV / Safety
valves
Mechanical
isolation Valves /
NRV / Safety
valves
Mechanical
isolation Valves /
NRV / Safety
valves
Mechanical
isolation Valves /
NRV / Safety
valves
Mechanical
isolation Valves /
NRV / Safety
valves
Mechanical
isolation Valves /
NRV / Safety
valves
Mechanical
isolation Valves /
NRV / Safety
valves
Mechanical
isolation Valves /
BM-12 Maintenance of Control Valves- Cold water R
NRV / Safety
valves
Mechanical
isolation Valves /
NRV / Safety
valves
BM-13 MOVs Maintenance of MOVs in water circuit NR

MM-1 MOVs Maintenance of MOVs in water circuit NR
Ash handling
ESPM-1 Maintenance of Electrostatic precipitator NR
System
Ash handling
System
Ash handling
System
Ash handling
System
Ash handling
System
Ash handling
System
Ash handling
System
Ash handling
System
Ash handling
System
Ash handling
System
Ash handling
System
Ash handling
System
Ash handling
System
Ash handling
ESPM-2 Maintenance of Dome valves & Seals NR
System
Ash handling
System
Ash handling
System
Ash handling
System
Ash handling
System
Ash handling
System
Ash handling
AHPM-1 Maintenance of ash conveying lines/Ash silo NR
System
Ash handling
System
Ash handling
System
Ash handling
System
Ash handling
System
Ash handling
System
Ash handling
System
Ash handling
System
Ash handling Maintenance of Ash conditioners/Air

AHPM-2 NR
System blowers/Rotory Air Lock Valve

AHPM-2 NR

AHPM-2 NR

AHPM-2 NR
AHPM-2 NR

AHPM-2 NR

AHPM-2 NR

AHPM-2 NR
Ash handling
DEM-1 Maintenance of Dust Extraction system NR
System
Ash handling
System
Ash handling
System
Ash handling
System
Ash handling
System
Ash handling
System
Ash handling
System
Ash handling
System
Ash handling
System
Ash handling
System
Ash handling
System
Ash handling
ARM-1 Maintenance of Ash handling air receiver NR
System
Ash handling
System
Ash handling
System
Boiler Blow Maintenance of Continous /Intermittent

BBDM-1 NR
Down system Blowdown vessel

BBDM-1 NR

BBDM-1 NR

BBDM-1 NR
BBDM-1 NR

BBDM-1 NR

BBDM-1 NR

BBDM-1 NR
Turbine
TAM-1 Maintenance of Steam Air Jet Ejectors NR
Auxilaries
Turbine
Auxilaries
Turbine
Auxilaries
Turbine
Auxilaries
Turbine
Auxilaries
Turbine
Auxilaries
Turbine
Auxilaries
Turbine
Auxilaries
Turbine
Auxilaries
Turbine
Auxilaries
Turbine Maintenance of Steam Air Jet Ejector

TAM-2 NR
Auxilaries condensers , Gland steam condenser

TAM-2 NR

TAM-2 NR

TAM-2 NR

TAM-2 NR

TAM-2 NR

TAM-2 NR

TAM-2 NR
TAM-2 NR

TAM-2 NR

TAM-2 NR
Turbine
HPLHM-1 Maintenance of HP / LP Heater NR
Auxilaries
Turbine
Auxilaries
Turbine
Auxilaries
Turbine
Auxilaries
Turbine
Auxilaries
Turbine
Auxilaries
Turbine
Auxilaries
Turbine
Auxilaries
Turbine
Auxilaries
Turbine
Auxilaries
Turbine
DAM-1 Maintenance of Deaerator & Storage tank NR
Auxilaries
Turbine
Auxilaries
Turbine
Auxilaries
Turbine
Auxilaries
Turbine
Auxilaries
Turbine
Auxilaries
Turbine
Auxilaries
Turbine
Auxilaries
Turbine
TAM-3 Maintenance of Steam traps NR
Auxilaries
Turbine
Auxilaries
Turbine
Auxilaries
Turbine
Auxilaries
Turbine Maintenance of Instrument Air /Ash handling

ACM-1 NR
Auxilaries Air Compressor

ACM-1 NR

ACM-1 NR

ACM-1 NR

ACM-1 NR

ACM-1 NR

ACM-1 NR

ACM-1 NR
ACM-1 NR

ACM-1 NR

ACM-1 NR
Cooling tower &

CTM-1 Maintenance of DM / RO / CT pumps pumps. NR
Water Pumps
Cooling tower &

Water Pumps
Cooling tower &

Water Pumps
Cooling tower &

Water Pumps
Cooling tower &

Water Pumps
Cooling tower &

Water Pumps
Cooling tower &

Water Pumps
Cooling tower &

CTM-2 Maintenance of Main cooling water pump NR
Water Pumps
Cooling tower &
Water Pumps
Cooling tower &

Water Pumps
Cooling tower &

Water Pumps
Cooling tower &

Water Pumps
Cooling tower &

Water Pumps
Cooling tower &

Water Pumps
Cooling tower &

CTM-3 Maintenance of Cooling tower NR
Water Pumps
Cooling tower &

Water Pumps
Cooling tower &

Water Pumps
Cooling tower &

Water Pumps
Cooling tower &

Water Pumps
Cooling tower &
Water Pumps
Cooling tower &

Water Pumps
Cooling tower &

CTM-4 Maintenance of Cooling tower fans NR
Water Pumps
Cooling tower &

Water Pumps
Cooling tower &

Water Pumps
Cooling tower &

Water Pumps
Cooling tower &

Water Pumps
Cooling tower &

CTM-4 Inspection & maintenance of cooling Tower NR
Water Pumps
Cooling tower &

SSFM-1 Maintenance of Side Stream Filter NR
Water Pumps
Cooling tower &

Water Pumps
Cooling tower &

Water Pumps
Cooling tower &
Water Pumps
Cooling tower &

Water Pumps
Cooling tower &

Water Pumps
Cooling tower &

Water Pumps
Cooling tower &

Water Pumps
Fuel Handling
FHPM-1 Maintenance of Coal Silo/Chutes NR
Plant
Fuel Handling
Plant
Fuel Handling
Plant
Fuel Handling
Plant
Fuel Handling
Plant
Fuel Handling
Plant
Fuel Handling
Plant
Fuel Handling
Plant
Fuel Handling
FHPM-2 Maintenance of Lime crusher NR
Plant
Fuel Handling
Plant
Fuel Handling
Plant
Fuel Handling
Plant
Fuel Handling
FHPM-3 Maintenance of Belt conveyors NR
Plant
Fuel Handling
Plant
Fuel Handling
Plant
Fuel Handling
Plant
Fuel Handling
Plant
Fuel Handling
Plant
Fuel Handling
FHPM-3 Maintenance of Bagase Carrier & Elevator NR
Plant
Fuel Handling
FHPM-4 Maintenance of Coal crusher NR
Plant
Fuel Handling
Plant
Fuel Handling
Plant
Fuel Handling
Plant
Fuel Handling
FHPM-5 Maintenance of Vibroscreen NR
Plant
Fuel Handling
Plant
Fuel Handling
Plant
Fuel Handling
Plant
Fuel Handling
Plant
Fuel Handling
Plant
Fuel Handling
Plant
Fuel Handling
Plant
Fuel Handling
FHPM-6 Maintenance of Dust Extraction system NR
Plant
Fuel Handling
Plant
Fuel Handling
Plant
Fuel Handling
Plant
Fuel Handling
Plant
Fuel Handling
FHPM-7 Maintenance of Magnetic separator NR
Plant
Fuel Handling
FHPM-7 Maintenance of Drag Chain conveyor NR
Plant
Fuel Handling
Plant
Fuel Handling
Plant
Fuel Handling
Plant
Fuel Handling
Plant
Fuel Handling
Plant
Fuel Handling
Plant
Fuel Handling
Plant
Fuel Handling
FHPM-8 Maintenance of Screw Feeder NR
Plant
Water treatment
DMPM-1 Maintenance of Raw water reservoir NR
plant
Water treatment
DMPM-2 Maintenance of Calarifier system NR
plant
Water treatment
plant
Water treatment
plant
Water treatment
plant
Water treatment
plant
Effluent
Treatment Plant
Effluent
Treatment Plant
Water treatment
DMPM-3 Maintenance of Chemical Storage Tank NR
plant
Water treatment
plant
Water treatment
plant
Water treatment
plant
Effluent Maintenance of Common effluent collection &

DMPM-4 NR
Treatment Plant disposal system

DMPM-4 NR

DMPM-4 NR
TGM-1 Turbo Generator Maintenance of stator/ rortor NR
TGM-2 Turbo Generator Maintenance of Exciter/PMG NR
TGM-2 Turbo Generator Maintenance of Exciter/PMG NR
TGM-3 Turbo Generator Maintenance of Alternator cooler NR
TGM-4 Turbo Generator Maintenance of NGR NR
TGM-4 Turbo Generator Maintenance of NGR NR
Maintenance of DCS/I/O unit /

Instrumentation
ISM-1 Server/urbosupervisory Instruments NR
System
panel/Turbine control panel
Instrumentation
System

Instrumentation
System
ACCM-1 ACC Maintenance during ACC fans NR
ACCM-2 ACC Maintenance of gear box, drive motors. R
General
GM-1 Maintenance of Structurals and Roof NR
Activites
General
Activites
General
Activites
General
Activites
General
Activites
General
Activites
General
GM-3 Insulation NR
Activites
General
GM-3 Insulation NR
Activites
General
GM-3 Insulation NR
Activites
General
GM-3 Insulation NR
Activites
General
GM-3 Insulation NR
Activites
General
GM-3 Insulation NR
Activites
General
GM-4 General Maintenance and adjustments R
Activites
Fuel Feeding Maintenance of DCF Outlet Fuel distribution

FFSM-2 R
System chutes
HAZARD IDENTIFICATION, RISK ASSESSMENT AN
Rating Likelyhood
Almost
4 Daily
Certain
Less than One

3 Likely
month
Less than Five

2 Moderate
Months
More Than Five

1 Unlikely
months
Risk Evaluation
Base Risk
Hazard Risk SEV POC
Exposure to Dust Allergy/ Irritation 2 1

Strain/ Discomfort/ Body Pain 1 1
Objects
Working in confined Space Injury 1 2
Fly off cut off Metal particles

Injury 1 2
during cutting/Grinding
Exposure to Fumes Discomfort 2 1

Burn Injury 3 1
surfaces
Bursting of Oil & Air lines &

Injury 2 1
Hoses
Improper Handling of Tools Injury 2 1
Exposure to Noise Discomfort 1 2
Postures
Working in confined Space Injury 2 2
Fall of man Fatal Injury 4 1
Flow / Ingress of hot bed

material from the inlet/outlet Fatal Injury 4 2
ducts.
Working in congested space Strain/ Discomfort/ Body Pain 1 1

Injury 1 2
Objects
Continuous Working Body Pain/ Discomfort 1 1

Injury 3 1

Burn Injury 3 1
surfaces

Injury 2 1
Hoses
Postures
Postures
Fall or Slip or Trip Injury 2 1
Exposure to dust Allergy/ Irritation 2 1
Working in confined Space Strain/ Discomfort/ Body Pain 2 2
Contact With Chemicals Allergy/ Irritation 2 1
Postures

Contact With Sharp Edges Injury 2 1

Injury 1 2
Objects

Injury 1 2

Burn Injury 2 1
surfaces

Injury 3 1
Hoses

Fall of man Injury 4 1
Postures

Injury 1 2
Objects

Injury 2 2

Injury 1 2
Objects

Postures
Electric Shock Fatal Injury 3 2

Injury 4 1
Hoses
Contact with Oil/ Grease Allergy/ Irritation 1 2

Injury 1 2
Hoses
Fire Burn Injury 1 2
Electric Shock Shock 1 1

Discomfort 2 2
surfaces

Injury 2 2
Objects

Burn Injury 1 3
surfaces
Limbs caught in nip Injury 4 3
Postures
Working in confined Space Suffocation 3 2


Injury 1 1
Objects

Injury 1 1
Postures

Injury 1 1
Objects

Injury 1 1

Injury 1 1
Objects

Burn Injury 1 1
surfaces
Working in hot
Discomfort 1 1
Postures

Injury 2 2
Objects

Injury 4 2
Improper Handling of Tools Strain/Injury 1 1
Postures
Contact with Oil/ Grease Discomfort/ Allergy 2 2


Injury 1 1
Objects

Injury 3 2

Injury 1 2
Objects

Injury 2 2

Burn Injury 3 2
surfaces
Postures
Fall of object Injury 4 2
Contact with Oil/ Grease Discomfort/Allergy 1 1

Injury 1 2
Objects
Postures

Injury 1 2
Objects
Postures
Contact With Chemicals Discomfort/Allergy 1 2
Working in congested space Injury 1 2

Failure of Gaskets/seals Burn Injury 2 2

Eye Injury 3 2
Postures
Contact with Oil/ Grease Allergy / Discomfort 1 2

Postures

Improper Handling of Tools Injury/Strain 1 1
Postures

Burn Injury 1 2
surfaces
Working in hot
Discomfort 1 2

Limbs caught in nip Cut / Injury 1 1
Working in congested Space Strain/ Discomfort/ Body Pain 1 1
Contact With Sharp Edges Cut / Injury 1 1
Failure of Gaskets/seals Injury 1 2
Improper Handling of Tools Strain / Injury 1 1
Postures

Burn Injury 1 2
surfaces
Working in hot
Discomfort 1 2
Contact with insulation glass

Skin / Nasal irritation 1 2
wool
Postures

Burn Injury 2 2
surfaces
Contact with Oil/ Grease Discomfort 1 2
Working in hot
Discomfort 1 2
wool
Electric Shock Fatal injury 4 2
Postures


Injury 1 2

Failure of Gaskets/seals Eye Injury 1 2
Postures
Contact with Oil / Cooling

Allergy / Discomfort 1 2
water
Potential risk of explosion of

Injury 1 2
oil cooler
Fall of object Cut / Injury 1 1


Burn Injury 1 2
surfaces
Working in hot
Discomfort 1 2

Failure of Gaskets/seals Irritatation/Allergy/ Injury 1 2
Contact With Chemicals Allergy/Irritation 1 2

Postures

Burn Injury 2 1
surfaces
Working in hot
Discomfort 2 1

wool

Postures
Explosion/ Failure of
Pneumatic Hoses / Injury 2 4
Connections

Burn Injury 2 4
surfaces
Working in hot
Discomfort 2 4
Postures
Ash drain drain through by

Burn Injury 3 2
pass drain of ESP


Injury 1 2
Objects
Fall of man Fatal injury 4 1

Burn Injury 2 2
surfaces

Postures

Injury 1 2
Objects

Postures
Postures

Burn Injury 1 2
surfaces

Burn injury 2 1
surfaces
Postures
Failure of Gaskets/seals Burn injury 2 1

wool

Postures

Burn Injury 2 1
surfaces
Working in hot
Discomfort 2 1
Postures
Burn Injury 1 2
surfaces
Working in hot
Discomfort 1 2
Postures

Burn Injury 2 1
surfaces
Working in hot
Discomfort 2 1

wool

Cut / Injury 1 1
Objects
Postures

Burn Injury 1 1
surfaces


Burn Injury 1 1
surfaces
Postures

Burn Injury 1 1
surfaces
Postures

Postures
Potential risk of contact with

Chemically treated water/ Allergy/Irritation 1 2
Sludge during cleaning

Potential risk of contact with
Chemically treated water/ Allergy/Irritation 1 1
Sludge during cleaning
Postures
Contact with Oil/ Grease Allergy/Irritation 1 2
Accidental start of fan Injury 4 2
Collapse of grating on
cooling tower due to Injury 4 1
corrosion

Injury 1 1
Objects

Postures
Working in confined Space Discomfort/ Suffocation 1 1
Contact with contaminated

Allergy/Irritation 1 1
filter Media

Injury 1 2
Objects

Injury 3 2


Injury 1 1
Objects

Accidental start of Vibro

Injury 3 2
Screen

Postures
Contact With Rotating Belt Injury 3 1

Injury 2 1
Objects
Injury 1 1
Contact with Oil/ Grease Discomfort/ Allergy 1 1
Handling of Sludge Allergy 1 2
Non-adherance to work
Injury 1 1
instructions
Injury 1 1

Burn Injury 1 1
surfaces

Injury 1 1
Objects
Postures
Contact With Chemicals Irritation/ Discomfort 2 1
Fire explosion Fatality 4 1
Postures
Exposure to Sludge Irritation/ Discomfort 1 1

Postures
Postures
Postures
Electric Shock Injury 3 2
Fall of man Fatal injury 4 1
Accidental start of fan Fatal injury 4 1

Injury 1 2

wool
Postures

Burn Injury 2 1
surfaces
Hot air Burn Injury 2 1

ESSMENT AND ESTABLISHMENT OF CONTROLS
Risk
Rating
<=3,"Lo
w"
Risk
Rating>3 High Impact : Must implement extensive
3
,"Modera risk controls
te"
Risk
Rating>= 2
7,"High"
Risk
Rating>=
Low Risk : Tolerable risk 1
11,"Extre
me"
k Evaluation
e Risk Risk Rating Existing controls Residual Risk
Rating SEV POC Rating
2 Low Dust mask 2 1 2

Provision of cushion on sharp edges.
1 Low 1 1 1
Helmet, Safety shoes
2 Low Confined space work permit 1 2 2
Face sheild for grinding.

2 Low 1 2 2
Goggles for chipping & hammering work
2 Low Provision of ventillation, 2 1 2
3 Low Hand gloves, Safety Shoes, Boiler Suit 2 1 2
Inspection of gas hose periodically and

2 Low before usage. 2 1 2
2 Low Training 2 1 2
2 Low Ear Plug 1 2 2
1 Low Provision of breaks. 1 1 1
4 Moderate Confined space work permit 1 2 2

4 Moderate Height work permit 3 1 3
Inspection by Boiler Inspector and

0 Low 0 0
apporval.
A. Ensure purging of all ducts chutes

which which enter work area required to
8 High eneter for maintenance. 1 2 2
B. Provison of fire suits.
C .Min 72 hours time for cooling.
1 Low Provison of rest to the worker at intervals. 1 1 1
Provison of cushion on sharp edges,

2 Low 1 2 2
helmet Safety Shoes.

3 Low 2 1 2
2 Low Provision of ventillation, Dust Mask 2 1 2
Heat Resistant hand gloves, Safety Shoes,

3 Low 2 1 2
Boiler Suit
Inspection of gas hose before usage.

2 Low 2 1 2
1 Low Provision of rest to the worker at intervals. 1 1 1
4 Moderate Provision of rest to the worker at intervals. 1 2 2
4 Moderate Provision of breaks. 1 2 2
Removal of sand and other objects from

2 Low 2 1 2
walkways.
2 Low Hand glves for chemical handling 2 1 2

2 Low 2 1 2

2 Low 1 2 2

2 Low 1 2 2
2 Low Hand gloves, Safety Shoes, Coveralls 2 1 2
3 Low Inspection of gas hose before usage. 2 1 2


2 Low 1 2 2
Moderate Face sheild for grinding.

4 1 2 2

2 Low 1 2 2
4 Moderate Training 2 2 4
4 Moderate Removal of spilled oil, water logging 1 2 2
Moderate Electrical Work permit, hand gloves,

6 1 2 2
safety Shoes
Moderate Inspection of equipment before usage.

4 1 1 1
Moderate Removal of spilled oil and water logging ,

4 1 2 2
warning signs
MSDS, Hand gloves Aprons Safety Shoes.

2 Low 1 2 2
Inspection of hoses periodically and

2 Low 1 2 2
before taking to use.
Hot work permit for welding and hot work

2 Low 1 2 2
activities.

2 Low 1 2 2
Electrical Work permit, hand gloves,

1 Low 1 1 1
safety Shoes
4 Moderate Hand Gloves Safety Shoes, 1 2 2
Moderate Hot work permit for welding and hot work

4 1 2 2
activities.
4 Moderate Helmet Safety Shoes. 1 2 2
3 Low Hand gloves, Safety Shoes, 1 3 3
12 Extreme Work permit, Machine guarding, traning 2 3 6


1 Low 1 1 1

1 Low 1 1 1

1 Low 1 1 1

1 Low 1 1 1

1 Low 1 1 1
1 Low Leather Hand Gloves 1 1 1

1 Low 1 1 1
water, handgloves, safety shoes.
4 Moderate Provison of rest to the worker at intervals. 1 2 2
Moderate Provison of cushion on sharp edges,

4 1 2 2
High Face sheild for grinding.

8 1 2 2
Moderate MSDS, Hand gloves Aprons Safety Shoes.

4 1 2 2
3 Low Hot Work permit, 2 1 2
6 Moderate Work permit for Isolation of Equipment. 3 2 6
2 Low Removal of spilled oil, water logging 1 2 2

1 Low Helmet Safety Shoes. 1 1 1

6 1 2 2
3 Low Hot Work permit, Binding and earthing. 2 1 2
8 High Height work permit 1 2 2
2 Low Helmet, Safety shoes 1 2 2

4 1 2 2
4 Moderate Provision of ventillation, Dust Mask 1 2 2

6 Moderate Hand gloves, Safety Shoes, Boiler Suit 1 2 2
8 High Training Tool box talk and job supervision 1 2 2
2 Low Removal of spilled oil 1 2 2

1 Low 1 1 1

2 Low Removal of spilled oil on time 1 2 2

2 Low 1 2 2
Chemical handling hand gloves, apron,

2 Low 1 2 2
Safety shoes, MSDS

2 Low Rigging plan. 1 2 2

2 Low 1 2 2
material
2 Low Training, Machine Guards 1 2 2
4 Moderate Hand gloves, goggles 1 2 2

6 2 2 4

2 Low 1 2 2
2 Low Hot work permit, 1 1 1

2 Low 1 2 2
material
6 Moderate Training, 1 2 2
1 Low Hand gloves, safety shoes, helmet 1 1 1
2 Low Hand gloves, goggles boiler suit, 1 2 2

2 Low 1 2 2
Training , Tool box talk and Supervision

2 Low 1 2 2
of Job

2 Low 1 2 2
material
2 Low Work permit 1 2 2
2 Low OCP , work permit 1 2 2

2 Low 1 2 2

2 Low 1 2 2
of Job

2 Low 1 2 2

2 Low 1 2 2
material
1 Low Work permit for Isolation of Equipment. 1 1 1

2 Low 1 2 2

2 Low 1 2 2
material
4 Moderate Hand gloves, safety shoes, helmet 1 2 2
4 Moderate Leather Hand Gloves 1 2 2

2 Low 1 2 2

2 Low 1 2 2
High Electrical Work permit, hand gloves,

8 4 2 8
safety Shoes
2 Low Hoouse keeping 1 2 2

2 Low 1 2 2
6 Moderate Hot work permit, 4 2 8

2 Low 1 2 2
2 Low Provision of ventillation 1 2 2
4 Moderate Training, Machine Guards 1 2 2

2 Low 1 2 2
material

2 Low Hand Gloves 1 2 2
2 Low Emergency Manual 1 2 2
1 Low Training, 1 1 1

2 Low 1 2 2
material

2 Low 1 2 2
2 Low Training on operation tube cleaning. 2 1 2
3 Low Height work permit 3 1 3


2 Low 1 2 2

2 Low 1 2 2


2 Low 1 2 2

2 Low 1 2 2

2 Low 1 1 1
material
2 Low Training, Hand Gloves, Face Shileds 1 1 1
4 Moderate Ear Plug 1 2 2


1 Low 1 1 1

2 Low 1 1 1

1 Low 1 1 1
material
8 High Work permit for Isolation of Equipment. 1 4 4
8 High Training, Hand Gloves 1 4 4
4 Moderate Ear Plug 1 2 2

8 High Provision of breaks. 1 4 4

1 Low 1 1 1
8 High Work permit, Face sheild, Training 1 4 4
Extreme Hoouse keeping - Removal of slippery

12 1 6 6
material
8 High Work permit for Isolation of Equipment. 1 4 4
8 High OCP , work permit 1 4 4
8 High Ear Plug 1 4 4
8 High Leather Hand Gloves 1 4 4

Moderate MSDS, Hand gloves Aprons Safety Shoes.
4 1 2 2
High Provision of rest at Intervals, drinking

8 1 4 4
6 Moderate No 3 2 6

2 Low Dust mask, Hand Gloves, 1 1 1
4 Moderate Electrical Work permit 2 1 2

2 Low 1 2 2

2 Low 1 2 2
material
4 Moderate Leather Hand Gloves 1 2 2


2 Low 1 2 2


2 Low 1 2 2
material

2 Low Provision of ventillation 1 2 2
2 Low Hand gloves 1 2 2
Moderate Training, Hand Gloves, Face Shileds, Dust

4 1 2 2
mask.

2 Low Hand gloves, helmet with Face shield 1 1 1

1 Low 1 1 1
material


2 Low 1 1 1

2 Low 1 2 2
material


2 Low 1 2 2

2 Low 1 1 1
material

2 Low 1 1 1

1 Low 1 1 1
material

1 Low 1 1 1

2 Low Training, Hand Gloves, Face Shileds 1 1 1


1 Low 1 1 1

1 Low 1 1 1
material

1 Low 1 1 1


2 Low 1 2 2
2 Low MSDS, warning signs 1 2 2

2 Low 1 2 2
of Job

1 Low MSDS, warning signs 1 1 1

2 Low 1 2 2
8 High Isolation Permit, LOTO 4 2 8
Moderate Painting as per frequency, replace the

4 3 1 3
damage platform, checklist

1 Low 1 1 1
of Job
1 Low Hand Golves, Shoes Goggles. 1 1 1
4 Moderate Dust mask 1 2 2

2 Low 1 2 2

6 1 2 2
4 Moderate Provision of ventillation, Dust Mask 1 2 2
6 Moderate Hot Work permit, Binding and earthing. 1 2 2

6 Moderate Machne guard, Training, 1 2 2
1 Low MSDS, Dist Mask 1 1 1

1 Low 1 1 1
Work permit for Isolation of Equipment,

Moderate Pull chord switch,
6 1 2 2
Machine guard,
Siren.
4 Moderate Dust mask, Hand Gloves, 1 2 2

6 Moderate Machne guard, Training, Isolation 1 2 2
6 Moderate Machne guard, Training, Isolation 1 2 2
Moderate Hoouse keeping - Removal of slippery

4 1 2 2
material
Moderate Work permit for Isolation of Equipment,

4 1 2 2
Communication
6 Moderate Isolation Permit, LOTO 1 2 2
4 Moderate Dust Mask 1 2 2

2 Low 1 2 2
material
3 Low Isolation Permit, LOTO 1 1 1

2 Low 1 1 1
1 Low 1 1 1

1 Low 1 1 1
Work permit for Isolation of Equipment.

3 Low 1 1 1
Machine Guard

2 Low 1 2 2
material

2 Low 1 2 2
material
2 Low Hand gloves shoes/gumboot goggles. 1 2 2

1 Low 1 1 1
of Job
1 Low 1 1 1
1 Low Hand gloves 1 1 1

1 Low 1 1 1

1 Low 1 1 1
material
Chemical handling hand gloves, apron,

2 Low 1 1 1
Safety shoes, MSDS
Moderate Hot work permit for welding and hot work

4 4 1 4
activities.

1 Low 1 1 1
material
1 Low Hand Gloves, Shoes And Apron 1 1 1


6 1 2 2
safety Shoes
Moderate Romove combustibles before work start.

4 1 2 2
Provision of fire extinguishers.
Grating are fitted properly to avoid

Moderate accidental fall of person on to running fan.
4 2 1 2
Entry restriction and enrty with work
permit only to authorised person.
To be carried out only in OFF condition.

4 Moderate Work permit & LOTO preocedure to be 2 1 2
followed.
Moderate Training, Earthing of welding machine

4 2 1 2
and job, use of rubber mats, ELCB.

2 Low 1 2 2
Removal of protruding objects sand and

2 Low 1 1 1
other material on the walkways.
High Work only in off condition. Work permit,

9 2 3 6
LOTO, training
2 Low Hot Work permit, Binding and earthing. 2 1 2

Doc Number OHS/D 01
Format
OHS/FT01
Number
REV 10
Date 10.07.2018
Risk Legal / Other Proposed

Remarks
Rating Requirements Controls
Low
Low
Low OHS
Low
Low
Low
Low
Low
Low Factories Act
Low
Low OHS
Low
Low OHS
Low IBR
Low FATAL Incident at

BORL
Low
Low
Low
Low
Low
Low
Low
Low
Low
Low
Low
Low
Low
Low
Low
Low OHS
Low Trainig on
MSIHC
MSDS
Low
Low OHS
Low
Low OHS
Low
Low
Low
Low
Low
Low
Low
Low
Low Factories Act

Low Factories Act
Low Factories Act
Low Factories Act
Low Factories Act

Safety provision
Low Factories Act
Low Factories Act
Low Factories Act
Low Factories Act

Safety provision
Low Factories Act
Low Factories Act

Safety provision
Moderate Factories Act

Low Factories Act
Safety provision
OHS/TP/MCL1 -
Low O&M/02
MSIHC
OHS/OCP/MCL1-
O&M/17
Low Factories Act

Safety provision
Low Factories Act
Low Factories Act

Safety provision
Low Factories Act
Low Factories Act

Safety provision
Low Factories Act
Low Factories Act

Safety provision
Low Factories Act
Low Factories Act

Low Factories Act
Safety provision
Low Factories Act
Low Factories Act

Safety provision
Low Factories Act
Low Factories Act

Safety provision
Low Factories Act

Safety provision
Low Factories Act
Moderate MSIHC
Low Factories Act

Safety provision
Low Factories Act
Low Factories Act

Low Factories Act
Safety provision
Low Factories Act
Low Factories Act

Safety provision
Low Factories Act

Safety provision
Low Factories Act

Safety provision
Low Factories Act

Safety provision
Low Factories Act

Safety provision
Low Factories Act
Low Factories Act

Safety provision
Low Factories Act
Low Factories Act

Safety provision
Low Factories Act
Low Factories Act

Safety provision
Low Factories Act

Safety provision
Low Factories Act

Safety provision
Low Factories Act
Low Factories Act

Safety provision
Low Factories Act
Low WCL LTI
Low Factories Act

Safety provision
Low Factories Act

Safety provision
Low
Low
Low
Low
Low
Low
Low
Low
Low
Low

Safety provision
Low Factories Act

Low Factories Act
Safety provision
Low Factories Act
Low Factories Act

Safety provision
Low MSIHC
Low Factories Act

Safety provision
Low Factories Act
Low Factories Act

Safety provision
Low Factories Act
Low Factories Act

Safety provision
Low Factories Act
Low Factories Act

Safety provision
Low Factories Act
Low Factories Act

Safety provision
Low Factories Act

Safety provision
Low Factories Act
Low Factories Act

Safety provision
Low Factories Act
Low Factories Act

Safety provision
Low Factories Act

Safety provision
Low Factories Act
Low MSIHC
Low Factories Act
Safety provision
Low Factories Act
Low Factories Act
Low Factories Act

Safety provision
Low Factories Act
Low Factories Act

Safety provision
Low Factories Act

Safety provision
Low Factories Act

Safety provision
Low Factories Act

Safety provision
Low Factories Act

Safety provision
Low Factories Act

Low Factories Act
Safety provision
Low Factories Act
Low Factories Act

Safety provision
Low Factories Act

Safety provision
Low Factories Act

Safety provision
Low Factories Act

Safety provision
Low Factories Act
Low Factories Act

Safety provision
Low Factories Act
Low WCL LTI

Low Factories Act
Safety provision
Low Factories Act

Safety provision
Modified after
recommendation
Low from
Recertifcation
audit in Dec 2016
Low
Low Factories Act

Safety provision
Low Factories Act

Safety provision
Low
Low
Low
Low
Low
Low Factories Act
Safety provision
Low Factories Act
Low Factories Act

Safety provision
Low Factories Act
Low Factories Act

Safety provision
Low Factories Act
Low Factories Act

Safety provision
Low Factories Act
Low Factories Act

Safety provision
Low Factories Act
Low Factories Act

Safety provision
Low Factories Act
Safety provision
Low Factories Act
Low MSIHC
Low Factories Act

Safety provision
Low Factories Act
Low Factories Act
Low Factories Act

Safety provision
Low Factories Act
Low Factories Act

Safety provision
Low Factories Act

Safety provision
Low Factories Act

Safety provision
Low Factories Act
Safety provision
Low Factories Act

Safety provision
Low Factories Act
Low Factories Act

Safety provision
Low Factories Act
Low Factories Act

Safety provision
Low Factories Act

Safety provision
Low Factories Act

Safety provision
Low Factories Act

Safety provision
Low Factories Act

Safety provision
Low Factories Act

Low Factories Act
Safety provision
High Factories Act
Low WCL LTI
Low Factories Act

Safety provision
Low Factories Act

Safety provision
Modified after
recommendation
Low from
Recertifcation
audit in Dec 2016
Low
Low Factories Act

Safety provision
Low Factories Act

Safety provision
Low
Low
High
Low
Low
Low
Low Factories Act

Safety provision
Low Factories Act

Safety provision
Low Factories Act

Safety provision
Low Factories Act

Safety provision
Low Factories Act

Safety provision
Low Factories Act

Safety provision
Low Factories Act

Low Factories Act
Safety provision
Low Factories Act
Low Factories Act

Safety provision
Low Factories Act

Safety provision
Low Factories Act

Safety provision
Low Factories Act

Safety provision
Low Factories Act

Safety provision
Low Factories Act
Low Factories Act

Safety provision
Low Factories Act
Low Factories Act

Safety provision
Low Factories Act
Low Factories Act

Safety provision
Low Factories Act

Safety provision
Low Factories Act

Safety provision
Low Factories Act
Low Factories Act

Safety provision
Low Factories Act
Low WCL LTI
Low Factories Act

Safety provision
Low Factories Act

Safety provision
Low
Low
Low
Low
Low MSIHC
Low Factories Act

Safety provision
Low Factories Act
Low Factories Act
Low Factories Act

Safety provision
Low Factories Act
Low Factories Act

Safety provision
Low Factories Act

Safety provision
Low Factories Act
Safety provision
Low Factories Act

Safety provision
Low Factories Act

Safety provision
Low Factories Act

Safety provision
Low Factories Act
Low Factories Act

Safety provision

Factories Act
Safety provision
Low Factories Act

Safety provision

Safety provision
Low Factories Act

Safety provision
Low Factories Act

Low Factories Act
Safety provision
Low WCL LTI

Safety provision

Safety provision

Safety provision
Low
Moderate
Low

Safety provision
Moderate
Low
Moderate
Low
Low Factories Act

Safety provision
Low
Low
Low
Low
Low
JKLC incindet on
By pass drain 25/10/2012:
Moderate extension and Modified after
water spray finding of first
arrangement survellance audit
on 15.12.14
Low OHS
Low
Low OHS
Low
Low OHS
Low
Low Factories Act

Safety provision
Low
Low
Low
Low
Low
Low Factories Act
Safety provision
Low
Low
Low
Low
Low
Low OHS
Low
Low Factories Act

Safety provision
Low
Low
Low
Low
Low
Low
Low
Low Factories Act

Safety provision
Low
Low
Low
Low
Low
Low
Low
Low
Low OHS
Low
Low OHS
Low
Low
Low
Low
Low
Low
Low OHS
Low
Low
Low
Low
Low
Low
Low Factories Act

Safety provision
Low
Low Factories Act

Safety provision
Low
Low
Low
Low
Low
Low
Low
Low Factories Act

Safety provision
Low
Low Factories Act

Safety provision
Low
Low
Low
Low
Low
Low
Low Factories Act

Safety provision
Low
Low
Low Factories Act

Safety provision
Low
Low
Low
Low
Low
Low
Low Factories Act

Safety provision
Low
Low
Low
Low
Low OHS
Low Factories Act

Safety provision
Low
Low
Low
Low
Low Factories Act

Safety provision
Low
Low
Low
Low
Low Factories Act

Safety provision
Low
Low
Low
Low
Low
Low Factories Act

Safety provision
Low
Low
Low Factories Act

Safety provision
Low Factories Act

Safety provision
Low Factories Act

Safety provision
Low Factories Act

Safety provision
Low Factories Act
Safety provision
Low Factories Act

Safety provision
Low Factories Act

Safety provision
Low Factories Act

Safety provision
Low Factories Act

Safety provision
Low Factories Act

Safety provision
Low Factories Act

Safety provision
Low Factories Act

Safety provision
Low Factories Act

Safety provision
Low Factories Act

Safety provision

Safety provision
Low Factories Act
Safety provision
Low Factories Act

Safety provision
Low Factories Act

Safety provision
Low Factories Act

Safety provision
Low Factories Act

Safety provision
Low Factories Act

Safety provision
High Factories Act

Safety provision
PM/Painting of Modified after

Low Factories Act gratings Incident at
Safety provision regularly to USDPCL on
avoid corrosion 20.06.2014
Low Factories Act

Safety provision
Low Factories Act

Safety provision
Low Factories Act

Safety provision
Low Factories Act
Safety provision
Low Factories Act

Safety provision
Low Factories Act

Safety provision
Low Factories Act

Safety provision
Low Factories Act

Safety provision
Low Factories Act

Safety provision
Low Factories Act

Safety provision
Low Factories Act

Safety provision
Low Factories Act

Safety provision
Low Factories Act

Safety provision
Low Factories Act

Safety provision
Low Factories Act
Safety provision
Low Factories Act

Safety provision
Low Factories Act

Safety provision
Low Factories Act

Safety provision
Low Factories Act

Safety provision
Low Factories Act

Safety provision
Low Factories Act

Safety provision
Low
Low
Low
Low OHS
Low
Modified after
Low Factories Act recommendation
Safety provision from Recertifcation
audit in Dec 2016
Low Factories Act

Safety provision
Low
Low
Low
Low
Low Factories Act

Safety provision
Low OHS
Low
Low
Low
Low
Low
Low
Low Factories Act

Safety provision
Low
Low
Moderate OHS
Low
Low
Low
Low
Low
Low
Low
Low
Modified after
audit in Dec 2016
Modified after
audit in Dec 2016
Low
Low
Low
Low
Low
Low
Name Changed
Low from WTP to ETP
after audit finding
at JK Nimbahera
Name Changed
Low from WTP to ETP
after audit finding
at JK Nimbahera
Low
Low
Low MSIHC
Modified after the

fatal accindnet at
Safety provision
DCW.
Name Changed
Low Factories Act from WTP to ETP
Safety provision after audit finding
at JK Nimbahera
Name Changed
Low Factories Act from WTP to ETP
Safety provision after audit finding
at JK Nimbahera
Name Changed
Low from WTP to ETP
after audit finding
at JK Nimbahera
Low Factories Act
Safety provision
Low
Low
Low Factories Act

Safety provision
Low Factories Act

Safety provision
Low Factories Act

Safety provision
Low Factories Act

Safety provision
Low Factories Act

Safety provision
Low Factories Act

Safety provision
Low
Low
Low OHS
Low
Low FATAL Incident at

OHS
KSPCL and BORL
Low OHS
Low
Low
Low OHS
Low
Low
Procedure to
work on frigile
Reviewed after
Moderate roof in case of
OHS incident at DCW
Asbestos roof
on 11/7/2014
is to be
followed
Low
Low
Low
Low
Low
Moderate OHS
LTI- Caught in
between at MCL4
Safety provision
and IMFA
Low
HAZARD IDENTIFIC
Example
Injury
Extreme Permanent Disability, May not be

4 Fatal/Death
possible for rejoining
Permanent Disability but may be join Major

3 High
after relevant treatment & Period impairment
Person
Temporary Disability & may join in
2 Moderate injured,minor
2-3 weeks
disorders

1 Low
Activities having Occupational Type of

Health and Safety concerns Activity
Sr. No. Activity Code Function Activity R/NR/L Hazard
Electrical Operation & Maintenance of Struck by /Struck

1 ES-1
System Electrical equipments
R
against the Objects
Electrical Operation & Maintenance of Improper Handling

2 ES-1
R
of Tools
Electrical Operation & Maintenance of

3 ES-1
R Exposure to Noise
Carrying of
Electrical Operation & Maintenance of Materials in
4 ES-1
R
Inappropriate
postures
5 ES-1
R Electric Shock
Electrical Operation & Maintenance of Fire due to short

6 ES-1
R
circuiting
Electrical Operation & Maintenance of Unauthorised access

7 ES-1
R
to Electrical panels
Electrical
8 ES-2
System
Operation and maintenance of starters R Electric flash over
Electrical Accidental start of

9 ES-2
System
Operation and maintenance of starters R
starter

10 ES-3
System Transformers
NR Exposure to Dust
Electrical Operation & Maintenance of Improper Handling

11 ES-3
System Transformers
NR
of Tools
Working in
12 ES-3
System Transformers
NR inappropriate
Postures
Electrical Operation & Maintenance of Contact with Oil/

13 ES-3
System Transformers
NR
Grease

14 ES-3
System Transformers
NR Electric Shock
Electrical Operation & Maintenance of Fire Improper Handling

15 FA-1
System Alarm System
NR
of Tools
Electrical Operation & Maintenance of Fire

16 FA-1
System Alarm System
NR Electric Shock
Electrical Operation & Maintenance of Fire
17 ES-1
System Alarm System
NR Fall of man
Electrical
18 UPS-1
System
Operation & Maintenance of Batteries NR Exposure to Fumes
Electrical Struck by /Struck

19 UPS-1
System
Operation & Maintenance of Batteries NR
against the Objects
Electrical Improper Handling

20 UPS-1
System
of Tools
Electrical Contact With

21 UPS-1
System
Chemicals
Electrical
22 ES-4
System
Cable laying and Termination NR Fall or Slip or Trip
Electrical
23 ES-4
System
Cable laying and Termination R Exposure to Dust
Electrical Contact With Sharp

24 ES-4
System
Cable laying and Termination NR
Edges
Electrical Improper Handling

25 ES-4
System
of Tools
Electrical
26 ES-4
System
Cable laying and Termination NR Fall of man
Carrying of
Electrical Materials in
27 ES-4
System
Inappropriate
postures
Electrical
28 ES-4
System
Cable laying and Termination NR Fall of object
Electrical Working In
29 ES-4
System
Confined space
Electrical
30 ES-4
System
Cable laying and Termination NR Electric Shock
Electrical
31 ES-4
System
Cable laying and Termination NR Fire
32 ES-2 Generator Maintenace of Alternator NR Electrical Shock
37 ES-2 Generator Maintenace of Alternator NR Fall of Material
38 ES-2 Generator Maintenace of Alternator NR slip and trip
loss of Man
39 ES-2 Generator Maintenace of Alternator NR Material and
Machine
Exposure to
40 ES-2 Generator Maintenace of Alternator NR
fumes
Exposure to
41 ES-2 Generator Maintenace of Alternator NR
noise
42 ES-3 NR Electric Shock
System Brakers
Electrical Operation & Maintenance of Fire due to short

43 ES-3 NR
System Brakers circuiting
Electrical Operation & Maintenance of Electric flash

44 ES-3 NR
System Brakers over
Electrical Operation & Maintenance of Unauthorised

45 ES-3 NR
System Brakers access to panels
Electrical Operation & Maintenance of Improper

46 ES-3 NR
System Brakers handling of tools
Maintanence of the HT
Electrical
47 ES-3 Switchgear Incomer NR Electric Shock
System
Maintenance
Electrical
48 ES-3 Lighting Maintenance R Electric Shock
System
Electrical Working In
49 ES-3 Lighting Maintenance R
System Confined space
Electrical
50 ES-3 Lighting Maintenance R Fall of object
System
Carrying of
Electrical Materials in
System Inappropriate
postures
Electrical
52 ES-3 Lighting Maintenance R Fall of man
System
Improper
Electrical
53 ES-3 Lighting Maintenance R Handling of
System
Tools
Electrical Fall or Slip or
System Trip
Electrical Exposure to
System Dust
Electrical Contact With
System Sharp Edges
Working in
Electrical
57 ES-3 Lighting Maintenance R inappropriate
System
Postures
Electrical Fall of man or
58 ES-1 Cable laying NR
System material
Electrical Electric shock,

59 ES-2 Cable joint replacement NR
System flash over
Back charge by
Electrical grid, electric
60 ES-2 Work at Switch yard NR
System shock, fall from
height
Electrical ACB, VCB and SF 6 Electric shock,

61 ES-2 NR
System maintenance flash over
62 ES-3 ESP ESP charging NR Electric shock
63 ES-3 ESP ESP dis - charging NR Electric shock

RD IDENTIFICATION, RISK ASSESSMENT AND ESTABLISHMENT OF CO
Rating Likelyhood
Risk
Almost
4 Daily Rating Extreme Risk : Cannot be accepted
Certain
<=3,"Low"
Risk
Less than One High Impact : Must implement
3 Likely Rating>3,"
month extensive risk controls
Moderate"
Risk
Less than Five Moderate risk : Conduct formal risk
2 Moderate Rating>=7,
Months analysis , may require risk controls
"High"
Risk
More Than Rating>=1
1 Unlikely Low Risk : Tolerable risk
Five months 1,"Extreme
"
Base Risk
Risk SEV POC Rating Risk Rating Existing controls
Moderate Provison of cushion on sharp edges,

Injury 1 4 4
Injury 2 4 8 High Training
Discomfort 1 4 4 Moderate Ear Plug
Strain/
Discomfort/ 2 4 8 High Provision of breaks.
Body Pain
Electrical Work permit, hand gloves,
Injury 4 4 16 Extreme
safety Shoes
High No combustibles to be stored in the

Burn Injury 2 4 8
vicinity
Moderate Restricted entry to panel rooms and

Injury 4 1 4
locking of panels
Burn Injury 3 2 6 Moderate Do not by pass controllers.
Injury 4 2 8 High Isolation permit LOTO
Allergy/ Low
2 1 2 Dust mask
Irritation
Injury 1 1 1 Low Training
Strain/
Low Provision of rest to the worker at
Discomfort/ 2 1 2
intervals.
Body Pain
Discomfort/ Low MSDS, Hand gloves Aprons Safety

2 1 2
Allergy Shoes.
High Electrical Work permit, hand gloves,

Burn Injury 4 2 8
safety Shoes

Burn Injury 3 1 3
safety Shoes
Injury 3 1 3 Low Height Work Permit
Respiratory Low
1 2 2 Ventillation , MSDS
disorders
Low Provison of cushion on sharp edges,

Injury 1 2 2
Low Chemical handling hand gloves,

Burn Injury 2 1 2
apron, Safety shoes, MSDS
Injury 1 1 1 Low Removal of Protruding objects
Allergy/ Low
1 1 1 Dust mask
Irritation
Injury 1 1 1 Low Hand Gloves
Injury 3 1 3 Moderate Height Work Permit
Strain/
Discomfort/ 1 1 1 Low Provision of breaks.
Body Pain

Injury 1 1 1 Low Confined space work permit

Injury 4 1 4
safety Shoes
Romove combustibles before work

Burn Injury 2 1 2 Low start.
Provision of fire extinguishers.
Proper Eathing Grounding,

and discharge electrod should
Injury 4 1 4 Moderate be connected through out
Maintenance and Proper
Handgloves
Moderate Proper PPE's as per desire

Injury 4 1 4
voltage
Moderate Supply of AVR must be

Injury 4 1 4
switched off
All aux. power and control

Injury 4 1 4 Moderate power must be switched off
before maintenace
All aux. power and control
Injury 4 1 4 Moderate power must be switched off
before maintenace
Moderate Rotor lifting tool must be proper

Injury 4 1 4
Certified and tested
body injury 4 1 4 Moderate proper housekeeping
injury / loss
Moderate Authorised and certified
of property 4 1 4
Manpower
and time
discomfort Low
2 1 2 use of proper PPEs
and irritation
discomfort Low
2 1 2 use of Ear muff
and irritation
follow SOP,Used 33KV hand
Electrocution 4 2 8 High gloves, safety Shoes,kept
standard rubber matts
follow SOP,Used Arc Flash
Suit,33KV Handgloves,Safety
Burn Injury 4 2 8 High Shoes ,Trained person allowed
for activity, Do not by pass
controllers
follow SOP,Do not by pass
Burn Injury 3 2 6 Moderate controllers , check the relay
healthiness
Restricted Unauthorized entry
Injury 4 1 4 Moderate to panel rooms and locking of
panels
Injury 3 1 3 Low Training,Follow SMP,Permit
Befor start the work line

clerance has taken from Cement
Burn Injury 4 4 16 Extreme plant electrical team. Thermax
Electrical LOTO also applied
in incomer at MRSS.
Moderate Electrical Work permit, hand

Injury 4 1 4
gloves, safety Shoes
Injury 1 1 1 Low Confined space work permit
Strain/
Discomfort/ 1 1 1 Low Provision of breaks.
Body Pain
Injury 3 1 3 Moderate Height Work Permit
Injury 1 1 1 Low Removal of Protruding objects
Allergy/ Low
1 1 1 Dust mask
Irritation
Injury 1 1 1 Low Hand Gloves

Strain/
Low Provision of rest to the worker
Discomfort/ 2 1 2
at intervals.
Body Pain
Moderate Proper appraoch, harness,

Injury 3 2 6
lifting tools and tackles
PTW, Ensure all power supply
Injury 4 1 4 Moderate is isolate from main incomer,
LOTO, Isulated tools to be use
PTW, Proper appraoch, harness,
isolation from both ends,
Injury 4 1 4 Moderate LOTO, ground the residual
power supply clearnace from
grid.
Moderate PTW, Isolation from main

Injury 4 1 4
incomer, LOTO
Moderate Door interlocks, all doors are

Injury 4 1 4
closed, earthing
PTW, ground the residual

Injury 4 1 4 Moderate power, isolate from main
incomer, LOTO.
LISHMENT OF CONTROLS
Doc
4
Number OHS/D 01
Format
3 OHS/FT01
Number
2 REV 10
1 Date 10.07.2018
Residual Risk
Risk Legal / Other Proposed

SEV POC Rating Remarks
Rating Requirements Controls
1 4 4 Moderate
1 4 4 Moderate
1 4 4 Moderate Factories Act Factories Act
1 4 4 Moderate
1 4 4 Moderate OHS
1 4 4 Moderate
4 1 4 Moderate IER
Modfiied after
1 2 2 Low OHS DCW inidence
08.01.2012
Modfiied after
1 2 2 Low OHS DCW inidence
08.01.2012
1 1 1 Low
1 1 1 Low
1 1 1 Low
1 1 1 Low
1 2 2 Low OHS
1 1 1 Low
1 1 1 Low OHS
3 1 3 Low OHS
1 2 2 Low
1 2 2 Low
1 1 1 Low
1 1 1 Low MSIHC
1 1 1 Low
1 1 1 Low
1 1 1 Low
1 1 1 Low
1 1 1 Low
1 1 1 Low
1 1 1 Low
1 1 1 Low OHS
1 1 1 Low OHS
1 1 1 Low
Factories Act
1 1 1 Low Safety
provision
Factories Act
1 1 1 Low Safety
provision
Factories Act
1 1 1 Low Safety
provision
Factories Act
1 1 1 Low Safety
provision
Factories Act
1 1 1 Low Safety
provision
Factories Act
1 1 1 Low Safety
provision
Factories Act
1 1 1 Low Safety
provision
Factories Act
1 1 1 Low Safety
provision
Factories Act
1 1 1 Low Safety
provision
Factories Act
1 1 1 Low Safety
provision
2 2 4 Moderate OHS No
1 2 2 Low No
1 2 2 Low OHS
3 1 3 Moderate No
1 1 1 Low No
1 4 4 Moderate
1 1 1 Low OHS
1 1 1 Low OHS
1 1 1 Low
1 1 1 Low
1 1 1 Low
1 1 1 Low
1 1 1 Low
1 1 1 Low
1 1 1 Low
1 1 1 Low
1 1 1 Low
MTC recorded in
2 1 2 Low USDPCL - June
2018
2 1 2 Low
2 1 2 Low
2 1 2 Low
2 1 2 Low
HAZARD IDENTIFICATI
Example
Injury
Extreme Permanent Disability, May

4 Fatal/Death
not be possible for rejoining
Permanent Disability but may

Major
3 High be join after relevant
impairment
treatment & Period
Person
2 Moderate injured,mino
join in 2-3 weeks
r disorders
Temporary Discomfort and First Aid

1 Low
may join immediately Treatment

Activities having Occupational Type of
Health and Safety concerns Activity
Activity
Sr. No. Function Activity R/NR/L Hazard
Code
Water treatment
1 DMPM-1 Acid / Alkali Chemicals Handling R Contact with skin
plant
Water treatment
2 DMPM-1 Acid / Alkali Chemicals Handling R Inhalation of vapors
plant
Water treatment
3 DMPM-1 Acid / Alkali Chemicals Handling R Contact with eyes
plant
Water treatment Operation of RO /DM plant/ Cooling Improper handling of

4 ROP-1 R
plant Water Make-up System Chemicals
Water treatment Operation of RO /DM plant/ Cooling
5 ROP-1 R Fall or Slip or Trip
plant Water Make-up System
Water treatment Operation of RO /DM plant/ Cooling Carrying of Materials in

6 ROP-1 R
plant Water Make-up System Inappropriate postures
Water treatment Operation of RO /DM plant/ Cooling Potential risk of Leakage of

7 ROP-1 R
plant Water Make-up System Chlorine Gas
Water treatment
ROM-1 Cleaning of RO NR Contact With Chemicals
plant
Water treatment Non-adherance to work

ROM-1 Cleaning of RO NR
plant instructions
Water treatment Carrying of Materials in

ROM-1 Cleaning of RO NR
plant Inappropriate postures
10
Cooling tower & Manual dosing of chemicals during

CTOP-1 R Contact With Chemicals
Water Pumps operation
11

12 CTOP-1 R Fall of man

13 CTOP-1 R Drowning Hazrd in the sump
N-pit Cleanning Fall or Slip or
14 WHRS WTP NR
work/Dewatarring Trip ,Elc Shock
Water
15 CTOP-1 Treatment Cleaning of N-pit NR Contact with skin
Plant
Cooling
tower & Cooling tower sump
16 CTOP-1 NR Fall or Slip or Trip
Water cleaning
Pumps
Water
Elctrical shock &
17 ROP-1 Treatment DM Plant Dewatering NR
Fall or Slip
Plant
Sulphuric Acid Tins Potential risk of

WTP &
18 ROP-1 Shifting from wtp to R Leakage of
C.T
Cooling tower Chlorine Gas
ZARD IDENTIFICATION, RISK ASSESSMENT AND ESTABLISHMENT OF
Rating Likelyhood
Almost Risk Rating

4 Daily Extreme Risk : Cannot be accepted
Certain <=3,"Low"
Risk
Less than One High Impact : Must implement
3 Likely Rating>3,"Mode
month extensive risk controls
rate"
Risk
Less than Five Moderate risk : Conduct formal risk
2 Moderate Rating>=7,"Hig
Months analysis , may require risk controls
h"
Risk
More Than
1 Unlikely Rating>=11,"Ext Low Risk : Tolerable risk
Five months
reme"
Risk Evaluation
Base Risk Existing controls
Risk SEV POC Rating Risk Rating
Irritation / Allergy / Training, MSDS, PVC Full suit, Gumboot &

Chemical burn
1 4 4 Moderate Goggles
Training, MSDS, PVC Full suit, Gumboot &

Discomfort 1 4 4 Moderate Goggles

Impairment of vision 3 4 12 Extreme Goggles
Allergy/Irritation 2 4 8 High Training, MSDS

Injury 1 4 4 Moderate Hoouse keeping - Removal of slippery material
Strain/ Discomfort/
Body Pain
1 4 4 Moderate Provision of breaks.
Asphyxiation 3 1 3 Low
Chemical handling hand gloves, apron, Safety

Irritation/ Allergy 1 2 2 Low shoes, MSDS
Injury 1 2 2 Low Training , Tool box talk and Supervision of Job
Strain/ Discomfort/
Body Pain
1 2 2 Low Provision of breaks.
Irritation / Allergy /
Chemical burn
3 2 6 Moderate Hand Gloves, Shoes And Apron, MSDS
Injury 4 2 8 High Provison of hand rails, full body harness
R 4 2 8 High Training, Provison of Life Jackets. Handrails

High Work permit, Rabber Hand
Multiple risk 2 4 8
gloves, GumShoes,
Irritation /
Low Training, MSDS, PVC Full suit,
Allergy / 1 2 2
Gumboot & Goggles
Chemical burn
Moderate Training , Tool box talk and

Injury 1 4 4
Supervision of Job
1. MCC Incomer Power OFF,

Death or Injury 4 3 12 Extreme 2. LOTO Applied.
3. Proper PPEs
Training ,Tool box talk

Chemical Burn or
Moderate Chemical handling hand
Chemical 4 1 4
gloves,apron Saftey shoes,
Spilliage
MSDS,Supervision of Job
SHMENT OF CONTROLS
Doc
4
Number OHS/D 01
Format
3 OHS/FT01
Number
2 REV 10
1 Date 10.07.2018
Residual Risk
Proposed
SEV POC Rating Risk Rating Remarks
Controls
Modified After
1 4 4 Moderate 2nd surevllance
audit in Dec 12
Modified After
audit in Dec 12
Modified After
audit in Dec 12
1 4 4 Moderate
1 4 4 Moderate
1 4 4 Moderate
Elimination of
3 1 3 Low Chlorine
usage
1 2 2 Low MSIHC
1 2 2 Low
1 2 2 Low
1 2 2 Low MSIHC
Reviwed on
2 2 4 Moderate OHS
30.06.2014
Provision of
4 2 8 High dosing pumps
for dosing
2 1 2 Low
1 2 2 Low
1 2 2 Low
3 1 3 Low
3 1 3 Low
HAZARD ID
Example
Injury
Extreme Permanent Disability, May not Fatal/

4
be possible for rejoining Death
Permanent Disability but may Major

3 High be join after relevant treatment impairmen
& Period t
Person
Temporary Disability & may injured,mi
2 Moderate
join in 2-3 weeks nor
disorders

1 Low

Activities having Occupational Health Type of
and Safety concerns Activity
Activity
Sr. No. Function Activity R/NR/L Hazard
Code
Operation of DCS/I/O unit /

1 ISM-1 Instrumentation System Server/urbosupervisory Instruments R Failure of Interlocks
Opearation of DCS/I/O unit /

2 ISM-1 Instrumentation System Server/urbosupervisory Instruments NR Fire

3 ISM-1 Instrumentation System Server/urbosupervisory Instruments NR Fall or Slip or Trip

4 ISM-1 Instrumentation System Server/urbosupervisory Instruments NR Electric Shock
Calibration/Maintenance
Instrumentation Fall or Slip or
5 ISM-1 of SOX/NOX/SPM NR/L
System Trip
analyser
on line
Instrumentation Flushing/Maintenance of
6 ISM-1 NR Burn Injury
System transmitters (FW &MS
line)
Instrumentation Operation & Maintenance Improper

7 ISM-1 NR
System of Fire Alarm System Handling of Tools
Instrumentation Operation & Maintenance

8 ISM-1 NR Fall of man
System of Fire Alarm System
Instrumentation Maintenance of
9 ISM-2 R Fall or Slip
System Positioner/Actuator
Instrumentation Maintenance of Working in

10 ISM-2 R
System Positioner/Actuator congested Space
Instrumentation Maintenance of Improper

11 ISM-2 R
System Positioner/Actuator Handling of Tools
Instrumentation Maintenance of
12 ISM-2 R Fall of object
System Positioner/Actuator
Fall from height,

Instrumentation
13 ISM-3 Cable laying NR Tools may be fall,
System
Slip & Trip
Operation of DCS/I/O
unit /
Instrumentation Failure of
14 ISM-3 Server/urbosupervisory R
System Interlocks
Instruments panel/Turbine
control panel
MOV Mentatanace , Like Electric Shock &

Instrumentation Power Card,Relay Card Material or Man
15 ISM-3 Ststem &Motor checking ,Tourque NR may fall from
Limit Setting Height
Control valve
maintenance,like Actuator
Instrumentation Material & Man fall
16 ISM-3 Ststem dismentaling & NR from Height
Bonnet ,Postioner
dismentaling
Instrumentation RTD and thermocouple Body injury , man
17 ISM-3 Ststem NR
maintenance, Checking fall from height
Instrumentation Man fall from
18 ISM-3 Ststem SPM / GAS anyalzer NR Height
ETP Mainatanace, like Man fall from
Instrumentation
19 ISM-3 Ststem sensor cleaning & NR height, Chemical
calibation of sensores Hazards
Chemical hazards ,
Instrumentation highe pressure
20 ISM-3 Ststem NR
SWAS pannel maintatance lines Hot work if
like claening & Calibartion plant running
of sensor condition
Chemical
WTP setion hazards ,Taken
Instrumentation
21 ISM-3 Ststem Valve ,Tramitters servicing NR pemission WTP
& Calibration incharge Hot work
if plant running
condition
Instrumentation Body injury ,High

22 ISM-3 Ststem All instrument Calibrtion NR Pressure pump &
Temp calibartion
Instrumentation
23 ISM-3 Ststem O2 Analyzer R Dust irritation
HAZARD IDENTIFICATION, RISK ASSESSMENT AND ESTABLISHMENT OF CONTROLS
Rating Likelyhood
Risk
Almost
4 Daily Rating Extreme Risk : Cannot be accepted
Certain
<=3,"Low"
Risk
Less than High Impact : Must implement extensive risk
3 Likely Rating>3,"
One month controls
Moderate"
Risk
Less than Moderate risk : Conduct formal risk analysis ,
2 Moderate Rating>=7,
Five Months may require risk controls
"High"
Risk
More Than Rating>=1
1 Unlikely Low Risk : Tolerable risk
Five months 1,"Extreme
"
Risk Evaluation
Base Risk Risk Rating Existing controls
Risk SEV POC Rating
Fatal injury 4 4 16 Extreme Maintenance, Inspection
Romove combustibles
Burn Injury 1 2 2 Low Provision of fire extinguishers.
Injury 1 2 2 Low Removal of spilled water logging
Injury 3 2 6 Moderate Electrical Work permit, hand gloves, safety Shoes
High Height work permit, Safety Belt, PPE,

Major injury 4 2 8
Safety googles, Vertigo test
Moderate Heat resistance Hand gloves, Safety
Injury 3 2 6
shoes, PTW,SOP
Injury 2 2 4 Moderate Training
Injury 3 1 3 Low Height Work Permit
Low Hoouse keeping - Removal of slippery

Injury 1 2 2
material
Strain/
Moderate Provision of rest to the worker at
Discomfort/ 2 2 4
intervals.
Body Pain
Injury 2 2 4 Moderate Rigging plan.
Specific training on Cable laying and

Serious 3 2 6 Moderate height wor, Proper Access, Proper Ppes,
Proper monataring
Serious 4 2 8 High Maintenance, Inspection
Electical Work Permit & Safety Belt & Safety

Injury 4 1 4 Moderate
hand gloves
Height work permit,Air line Isolation from

Injury 4 1 4 Moderate Header ,Using Proper Tools,Safety
belts ,Gloves , wire rope if applicable
Height work permit, use ladder /safety balt ,

Burn Injury 4 1 4 Moderate
safety hand gloves
Serious 4 1 4 Moderate Height Work permit, safety Belt,Fall
arrester,man fit for work
Burn Injury 4 1 4 Moderate Height Work permit, safety Belt,Safety hand

gloves for chemical
Hot work permit , isolation from main

inlet ,Safety goggale,hand gloves
Chemical Hazards Permission from WTP

incharge,Safety goggale,hand gloves
Tested & Certified (Calibartaed from NABL)

Injury 3 1 3 Low Instruments use for calibartion ,Specific tools
use
Infection 2 2 4 Moderate
Safety Mask, Hand gloves must proved
T OF CONTROLS
4 Doc Number OHS/D 01
3 Format Number OHS/FT01
2 REV 10
1 Date 10.07.2018
Residual Risk Risk Rating Proposed Controls Remarks
SEV POC Rating
2 4 8 High OHS
1 2 2 Low No
Lost Time Injury at

1 2 2 Low No
BORL
1 2 2 Low OHS
2 2 4 Moderate OHS
1 2 2 Low OHS
1 1 1 Low
3 1 3 Low OHS
1 2 2 Low
1 2 2 Low Factories Act
Factories Act
1 1 1 Low Safety
provision
Factories Act
2 2 4 Moderate Safety
provision
1 1 1 Low
2 2 4 Moderate
2 1 2 Low
2 1 2 Low
2 1 2 Low
2 1 2 Low
2 1 2 Low
2 1 2 Low
2 1 2 Low
2 1 2 Low
1 2 2 Low
Example Personnel
Ratting Severity
Injury
Extreme Permanent Disability, May

4 Fatal/Death
not be possible for rejoining
Permanent Disability but

3 High may be join after relevant Major impairment
treatment & Period
Person
2 Moderate injured,minor
join in 2-3 weeks
disorders

1 Low
Activities having Occupational

Type of Activity
Health and Safety concerns
Sr. No. Activity Code Function Activity R/NR/L
1 GA -1 General Activites Housekeeping R

Unloading of Boiler
6 ST-1 STORES NR
Parts by Hydra
Unloading of Boiler
7 ST-1 STORES NR
Parts by Hydra
Unloading of Boiler
8 ST-1 STORES NR
Parts by Hydra
Unloading of Boiler
9 ST-1 STORES NR
Parts by Hydra
Unloading of Boiler
10 ST-1 STORES NR
Parts by Hydra
Unloading of Boiler
11 ST-1 STORES NR
Parts by Hydra
12 ST-1 STORES Storage of Chemicals NR

Loading / Unloading
13 ST-1 STORES NR
Chemicals
Loading / Unloading
14 ST-1 STORES NR
Chemicals
Loading / Unloading of
15 ST-1 STORES NR
Cylinders
16 ST-1 STORES NR
Cylinders
17 GA -1 General Activites Housekeeping NR

20 ST-1 STORES Resistance Test NR
Supplier vehicle
21 ST-1 STORES NR
moment
22 ST-1 STORES NR
goods by worker
23 ST-1 STORES NR
goods by worker
24 ST-1 STORES NR
goods by worker
Unloading of Boiler
25 ST-1 STORES NR
Parts by Hydra
Civil Works like
26 GM-2 General Activites NR
Painting etc
Civil Works like
Painting etc
Civil Works like
Painting etc
Civil Works like
Painting etc
AC outdoor unit
refrigeration gas
leakage testing and
arresting work
General Human
31 HB General Activites Behaviour Related NR
Actvity
General Human
32 HB General Activites Behaviour Related
Actvity
General Human
Actvity
General Human
Actvity
General Human
Actvity
General Human
Actvity
General Human
Actvity
General Human
Actvity
General Human
Actvity
Coal, Bagasse, rise
husk, Ash and LDO
40 GM-5 General Activites R
Transportation in and
out of plant

LDO Unloading,
Unloading & Storage &
41 LDO U/L storage, Tranferring NR
Transferring to plant
operation
operations
LDO Unloading,
Unloading & Storage &
42 LDO U/L storage, Tranferring NR
Transferring to plant
operation
operations
43 GA -1 Office or Field All activity R
44 GA -1 Office or Field All activity R

HAZARD IDENTIFICATION, RISK ASSESSMENT AND ESTABLISHMENT OF CO
Rating Likelyhood
Almost Risk Rating

4 Daily
Certain <=3,"Low"
Risk
Less than One
3 Likely Rating>3,"Mode
month
rate"
Risk
Less than Five
2 Moderate Rating>=7,"High
Months
"
Risk
More Than
1 Unlikely Rating>=11,"Ex
Five months
treme"
Risk Evaluation
Base Risk
Hazard Risk SEV POC Rating
Fall or Slip or Trip Multiple risk 2 3 6
Struck by /Struck against

Multiple risk 3 2 6
the Objects
Exposure to Dust Multiple risk 4 1 4
Exposure to Noise Multiple risk 4 3 12

Infection 4 2 8
biological matter / Garbage
Repetative Job Loading &
Fatigue 1 2 2
Unloading
Periodic Inspection of
Lifting tools and tackles, Potential Risk of death 4 2 8
test Hydra / Crane Failure
Potential chance of hit by
Potential Risk of death 4 3 12
hydra
material while Injury 4 3 12
transportation
electrocuti due to open Electrocution 4 2 8
wires / damaged cables
Lifting tools and tackes, test Injury 4 2 8
failure slings
Leakage of Chemicals Injury 2 2 4
Injury 2 3 6
postures
Potential Risk of Contact
Injury 2 2 4
with chemicals
Carrying of Materials
Injury 1 1 1
inappropriate posuters
Potential risk of Chloring
Fatal Injuries 4 1 4
gas from cylinder
Exposure to dust Discomfort 1 3 3

Exposure to Noise Discomfort 2 3 6
Potential contact with
Infection 1 3 3
cleaning chemicals
Electrocution Potential Risk of death 4 2 8
Vehicle hit to workers Personal Injury 2 2 4
Exposure to sharp edges Stress 1 4 4
Repetative Job Loading &

Fatigue 1 2 2
Unloading
Chance of falldown of parts Potential Risk of death 4 2 8
Exposure to sharp edges Stress 1 4 4
Contact With Sharp Edges Injury 1 2 2
Exposure to paint Allergy / Discomfort 1 2 2
Fall of man Injury 3 2 6
Fall of object Injury 2 2 4

Blast in compressor Injury 4 2 8
Inattention in work Injury 2 4 8
Unauthorised entry to
hazardous Injury 2 2 4
area/Unauthorised area
Injury 1 1 1
illterate
Fatal injury 4 2 8
illterate
Frustration Stress/Bodyache 1 1 1
Tolleration of un safe acts

Lead to multiple risk 1 2 2
and behaviour
In compatible physical
Multiple risk 1 2 2
capabilites
Excess personal stress or

Multiple risk 1 1 1
fatigue
Supervisor is over tasked Multiple risk 1 2 2
Movement of vehicles Injury 4 2 8
Fire Burn Injury 4 2 8

Bursting of Oil Hose, Line Injury 1 2 2
Stress / Workload Distraction / Injury 2 3 6
Fatigue Distraction / Injury 2 3 6

ND ESTABLISHMENT OF CONTROLS
High Impact : Must implement

3
extensive risk controls

2
Risk Rating Existing controls Residual Risk Risk Rating
SEV POC Rating
Moderate Hoouse keeping - Removal of Low

1 2 2
slippery material
Moderate Helmet, Safety shoes 1 2 2 Low
Moderate Dust mask 2 1 2 Low
Extreme Ear Plug 2 1 2 Low
High Hand gloves Aprons Safety Low

1 2 2
Shoes, Dust Mask
Low Provision of rest every 2 Low
1 2 2
Hours
High Certification by competent Low

2 1 2
person rigging plan
Extreme Use of tag lines while lifting 2 2 4 Moderate
Extreme Use of tag lines while lifting 2 1 2 Low

High Cable laying overhead 2 2 4 Moderate
High Certification by competent Low

2 1 2
person rigging plan
Moderate Moderate training on MSDS 2 1 2 Low
Moderate Trainings 2 1 2 Low
Moderate Hand gloves, gumboots, face Low

1 2 2
sheild, apron
Low Trainings 1 1 1 Low
Moderate Emergency Trainings 4 1 4 Moderate
Low Dust Mask 1 3 3 Low
Moderate Ear plugs 1 3 3 Low
Low Hand gloves, Aprons, Shoes 1 2 2 Low
High Training, hand gloves shoes 2 1 2 Low
Barrication of Area of work

Moderate and machine moment, 2 1 2 Low
supervision of job
Moderate Hand gloves, shoes 1 2 2 Low
Low Provision of rest every 2 Low

1 2 2
Hours
High Training and job superivision 4 2 8 High
Moderate Hand gloves, Shoes 1 2 2 Low
Low Hand gloves, safety shoes, Low

1 2 2 No
helmet
Low Dust mask 1 2 2 Low No
Moderate Height work permit, appraoch Low

1 2 2 OHS
and harness
Moderate material tied up or keep on Low
1 2 2 No
floor.
High OCP 2 2 4 Moderate
High Job supervison, Provision of Moderate

1 4 4 No
rest
Barication of the area under

exposure. Mass tool box talk
Moderate to be conducted on human 1 2 2 Low No
behaviour aspects as per
format
Low Training 1 1 1 Low No
Issue gate pass only after

High safety induction. Moderate
2 2 4 No
Skill and knowledge based
allocation of work.
Low Councelling 1 1 1 Low No
Low Training 1 2 2 Low No
Low 1 2 2 Low No
Low Provison of rest to the worker Low

1 1 1 No
at intervals.
Low Councelling 1 2 2 Low No
Provion of speed limit

High warning, reverse horn and 2 2 4 Moderate No
signal man, speed breakers
High Work permit, Truck Earthing 1 2 2 Low No

Inspection of hoses / lines
Low periodically and before taking 1 2 2 Low No
to use
Moderate Time of work limit, Rest

break, No exceptions etc. 1 3 3 Low
Moderate Time of work limit, Rest

break, No exceptions etc. 1 3 3 Low
Doc Number OHS/D 01
Format
OHS/FT01
Number
REV 10
Date 10.07.2018
Proposed Controls Remarks

LTI - Fire
Explosion at
USTKWPCL
LTI- at JK
Paper.
FATAL
Incident at
KSPCL
Modified After
2nd surevllance
audit in Dec 12
Modified After
2nd surevllance
audit in Dec 12
Modified After
2nd surevllance
audit in Dec 12
Shift limit
8 hours,
Work
rotation,
Shift limit
8 hours,
Work
rotation,
Ratting Severity
4 Extreme
3 High
2 Moderate
1 Low
Sr. No. Activity Code Function
Operation
1 BOP-1 Boiler
2 BOP-2 Boiler
3 BOP-2 Boiler
4 BOP-3 Boiler
5 BOP-7 Boiler
6 BOP-7 Boiler
7 TOP-1 Turbine
Ash handling
8 AHPOP-1
System
Ash handling
9 AHPOP-3
System
Ash handling
10 AHPOP-3
System
Fuel Handling
11 FHPOP-1
Plant
Fuel Handling
12 FHPOP-1
Plant
Fuel Handling
13 FHPOP-1
Plant
Fuel Handling
14 FHPOP-1
Plant
Fuel Handling
15 FHPOP-1
Plant
Instrumentation
16 IS0-1
System
19 GM-5 General Activites

23 BM-1 Boiler
24 BM-5 Boiler
Maintenance
1 BM-6 Boiler
2 BFM-1 Fans
3 FFSM-1 Fuel Feeding System
4 FFSM-3 Fuel Feeding System

5 TM-3 Turbine
6 TM-7 Turbine Valves
7 TOSM-1 Turbine Oil system
Mechanical isolation
8 BM-12 Valves / NRV /
Safety valves
Safety valves
Safety valves
Safety valves
12 BM-13 MOVs
13 BM-13 MOVs
14 BM-13 MOVs
15 BM-13 MOVs
16 BM-13 MOVs
17 MM-1 MOVs
18 ESPM-1 Ash handling System
Cooling tower &

19 CTM-3
Water Pumps
Cooling tower &

20 CTM-4
Water Pumps
21 FHPM-6 Fuel Handling Plant
22 DMPM-3 Water treatment plant

26 BM-6 Boiler
27 BM-6 Boiler
28 TM-7 Turbine Valves
29 TM-3 Turbine
30 TM-2 Turbine
31 BM1 ESP & Boiler
32 BM1 ESP & Boiler
33 BM1 ESP
34 BM-13 MOVs
35 MM-1 MOVs
36 ESPM-1 Ash handling System

Cooling tower &
37 CTM-3
Water Pumps
Cooling tower &

38 CTM-4
Water Pumps
Cooling tower &

39 CTM-4
Water Pumps
40 FHPM-6 Fuel Handling Plant
Electrical
1 ES-1 Electrical System

WTP
4 ROP-1 Water treatment plant

Cooling tower &

7 CTOP-1
Water Pumps
Cooling tower &

8 CTOP-1
Water Pumps
Instrumentation
Instrumentation
1 ISM-1
System
Instrumentation
2 ISM-1
System
Instrumentation
3 ISM-2
System
Instrumentation
4 IS0-1
System
Other
1 ST-1 STORES
2 ST-1 STORES
3 ST-1 STORES
4 ST-1 STORES

HAZARD IDENT
Example
Personnel
Injury
Permanent Disability, May not be possible

Fatal/Death
for rejoining
Permanent Disability but may be join after Major

relevant treatment & Period impairment
Person
Temporary Disability & may join in 2-3
injured,minor
weeks
disorders

Activities having Occupational Health and Type of

Safety concerns Activity
Activity R/NR/L Hazard
Start up of Boiler: NR Back fire from furnace

Burn from hot drain
Operation of Boiler: R
material.
Steam Leakage
Operation of Boiler: R
/Condensate splash
Bed material feeding R
Burn due to contact with

Hot bed material drain R
Hot surfaces
Hot bed material drain R Exposure to Fumes
Start up and engagement of barring

NR Limbs caught in nip
gear
Operation of ESP R Electric Shock

NR Burn
economizer or ash handling hopper.
Dome valve cleaning, jamming Caught in between

NR
removal rotating eq.
Operation of fuel handling plant R Fire
Operation of fuel handling plant R Limbs caught in nip
Operation of fuel handling plant R Vehicular Movement
Operation of fuel handling plant R Exposure to Noise
Operation of fuel handling plant R Limbs caught in nip

Server/urbosupervisory Instruments R Failure of Interlocks
General Human Behaviour Related

NR Inattention in work
Actvity
General Human Behaviour Related In adequate Knowledge,

NR
Actvity illterate
Housekeeping NR Fall or Slip or Trip

Housekeeping R Contact With Chemicals

Housekeeping R biological matter /
Garbage
Coal Ash and LDO Transportation

R Movement of vehicles
in and out of plant
Maintenance of Bed coils, All

superheater coils & Water walls -
pressure parts which involves NR Fall of man
Cutting ,Welding & replacement of
Pressure Parts
Maintenance of Economizer -
pressure parts which involves
NR Fall of man
Cutting ,Welding & replacement of
Pressure Parts
Maintenance of Oil Burner NR Improper Handling of Tools
Maintenance of Fans NR Limbs caught in nip
Maintenance of Rotary, screw feeders &

Drag chain feeders

Horizontal/Vertical lines, Mixing Nozzles, NR Fall of man
Bed drains & drain gates
Maintenance of Main Oil Pumps NR
Maintenance of Main steam stop valve

NR Electric Shock
and all Extraction MOVs

Emergency oil pumps & Main / Overhead NR Fire
oil Tank system
Maintenance of Control Valves- Cold

water

NR Failure of Gaskets/seals
water
Maintenance of Control Valves- Cold Carrying of Materials in

NR
water Inappropriate postures
Explosion/ Failure of
NR Pneumatic Hoses /
water
Connections
Maintenance of MOVs in water circuit NR Fall or Slip or Trip
Maintenance of MOVs in water circuit NR Limbs caught in nip
Maintenance of MOVs in water circuit NR Failure of Gaskets/seals
Maintenance of MOVs in water circuit NR Exposure to Noise

Maintenance of MOVs in water circuit NR
surfaces
Working in hot
Ash drain drain through by

Maintenance of Electrostatic precipitator NR
pass drain of ESP
Maintenance of Cooling tower NR Fall of man
Maintenance of Cooling tower fans NR Accidental start of fan
Maintenance of Dust Extraction system NR Fall of man
Maintenance of Chemical Storage Tank NR Fire explosion
Maintenance of Structurals and Roof NR Fall of man
Insulation NR Fall of man
General Maintenance and adjustments R Limbs caught in nip

Maintenance of Boiler bank - pressure
parts which involves Cutting ,Welding & NR Exposure to Fumes
Maintenance of Boiler bankr - pressure

Electric shock due
parts which involves Cutting ,Welding & NR
welding/grinding work.
Maintenance of Main steam stop valve

NR Electric Shock
and all Extraction MOVs
Maintenance of Turbine - shaft / blades / Fly off cut off Metal particles
NR
Casing etc during cutting/Grinding

NR Fall of object
Casing etc
Cleaning of internals NR Fall or Slip or Trip
Cleaning of internals NR
postures
Cleaning of internals NR Electric shock

surfaces
Working in hot
Ash drain through by pass

Maintenance of Electrostatic precipitator NR
drain of ESP
Maintenance of Cooling tower NR Fall of man
Maintenance of Cooling tower fans NR Accidental start of fan
Inspection & maintenance of cooling Collapse of grating on cooling

NR
Tower tower due to corrosion
Maintenance of Dust Extraction system NR Fall of man
Maintenance of Chemical Storage Tank NR Fire explosion
Maintenance of Structurals and Roof NR Fall of man
Insulation NR Fall of man
General Maintenance and adjustments R Limbs caught in nip

Operation & Maintenance of Electrical equipments R
Objects
Operation & Maintenance of Electrical equipments R Improper Handling of Tools
Operation & Maintenance of Electrical equipments R Exposure to Noise

Operation & Maintenance of Electrical equipments R Electric Shock
Operation & Maintenance of Electrical equipments R Fire due to short circuiting
Unauthorised access to Electrical

panels
Operation & Maintenance of Brakers NR Electric Shock
Operation & Maintenance of Brakers NR Unauthorised access to panels
Maintanence of the HT Switchgear

NR Electric Shock
Incomer Maintenance
Acid / Alkali Chemicals Handling R Contact with skin
Acid / Alkali Chemicals Handling R Inhalation of vapors
Acid / Alkali Chemicals Handling R Contact with eyes
Operation of RO /DM plant/ Cooling Improper handling of

R
Water Make-up System Chemicals
Operation of RO /DM plant/ Cooling

R Fall or Slip or Trip
Water Make-up System
Operation of RO /DM plant/ Cooling Carrying of Materials in
R
Water Make-up System Inappropriate postures
Manual dosing of chemicals during

R Fall of man
operation
Manual dosing of chemicals during

R Drowning Hazrd in the sump
operation

Calibration/Maintenance of
NR/L Fall or Slip or Trip
SOX/NOX/SPM analyser
Maintenance of Positioner/Actuator R Fall of object


Unloading of Boiler Parts by Hydra NR
hydra
Unloading of Boiler Parts by Hydra NR electrocuti due to open wires /
damaged cables
Potential risk of Chloring gas
Loading / Unloading of Cylinders NR
from cylinder
Loading / Unloading of goods by worker NR Chance of falldown of parts
AC outdoor unit refrigeration gas leakage

NR Blast in compressor
testing and arresting work
General Human Behaviour Related Actvity NR Inattention in work
General Human Behaviour Related Actvity NR
illterate
Coal, Bagasse, rise husk, Ash and LDO

R Movement of vehicles
Transportation in and out of plant
HAZARD IDENTIFICATION, RISK ASSESSMENT AND
Likelyhoo
Rating
d
Risk
Almost
4 Daily Rating
Certain
<=3,"Low"
Risk
Less than
3 Likely Rating>3,"
One month
Moderate"
Less than Risk

2 Five Moderate Rating>=7,
Months "High"
Risk
More Than
Rating>=1
1 Five Unlikely
1,"Extreme
months
"
Risk Evaluation
Base Risk Risk Rating
Risk SEV POC Rating
Burn Injury 4 2 8 High

Strain/ Discomfort/
1 3 3 Moderate
Body Pain
Burn Injury 3 4 12 Extreme
Discomfort 1 4 4 Moderate
Fatal injury 4 1 4 Moderate
injury 4 2 8 High
injury 4 2 8 High
Injury 3 3 9 High
Fatal injury 4 2 8 High
Injury 2 4 8 High
Multiple risk 1 3 3 Moderate

Allergy /
4 8 32 Extreme
Discomfort
Infection 1 4 4 Moderate
Injury 4 2 8 High
Fatal Injury 4 1 4 Moderate
Injury 2 4 8 High
Eye Injury 3 2 6 Moderate
Cut / Injury 2 4 8 High
Injury 2 4 8 High
Strain/ Discomfort/ High

2 4 8
Body Pain
Injury 2 4 8 High
Cut / Injury 2 4 8 High
Discomfort 2 4 8 High
Injury 4 2 8 High
Injury 4 2 8 High
Injury 3 3 9 High
Fatality 4 1 4 Moderate
Injury 4 2 8 High
Injury 3 3 9 High
Major injury 4 1 4 High
Eye Injury 3 2 6 Moderate
Strain, Discomfort, Moderate

2 2 4
Body pain
Serious 4 2 8 High

Injury 4 2 8 High
Injury 4 2 8 High
Falaity 4 1 4 Moderate
Injury 3 3 9 High
Fatality 4 1 4 Moderate
Injury 4 2 8 High
Injury 3 3 9 High
Injury 2 4 8 High
Strain/ Discomfort/ Body High
2 4 8
Pain
Electrocution 4 2 8 High
Burn Injury 4 4 16 Extreme
Irritation / Allergy / Moderate

1 4 4
Chemical burn
Impairment of vision 3 4 12 Extreme
Allergy/Irritation 2 4 8 High
Strain/ Discomfort/ Moderate
1 4 4
Body Pain
Injury 4 2 8 High
R 4 2 8 High
Fatal injury 4 4 16 Extreme
Serious 4 2 8 High
Potential Risk of death 4 3 12 Extreme
Electrocution 4 2 8 High
Fatal Injuries 4 1 4 Moderate
Potential Risk of death 4 2 8 High
Injury 4 2 8 High
Injury 2 4 8 High
Injury 4 2 8 High
ESSMENT AND ESTABLISHMENT OF CONTROLS
High Impact : Must implement extensive risk

3
controls
Moderate risk : Conduct formal risk analysis ,

2
may require risk controls
Existing controls Residual Risk
SEV POC Rating
OCP - 3 2 6
Hand gloves safey shoes, Boiler suit /
2 3 6
coveralls.
Hand gloves, boiler suit. Routing of

2 2 4
vents to drain lines
Training, Provision of breaks and use of

1 3 3
machine for lifitng
Hand gloves safey shoes, Boiler suit

3 4 12
coveralls.
Provision of ventillation, Dust Mask 1 4 4
Training , Tool box talk and

Supervision of Job, use of emergency 3 1 3
stop.
Warning signs 4 1 4
Mechanical jamming removal eq. to be

used, like vibrator, pocking hole, heat
2 2 4
resistance PPE to be used, PTW for
confined space.
Pneumatic cylinder to be guarded,

2 2 4
PTW, LOTO, isolation, JSA
accumulated on platforms struturals and
floor to ensure cleanliness,
4 1 4
water Spray during summer, Check
electrical connections for tightness
monthly.
Siren, Machine guards, Pull chord

3 2 6
switches, training.
Provision os reverse horn and signal

2 3 6
man
Ear Plug 1 3 3
Machne guard, Training, 1 3 3
Maintenance, Inspection 2 2 4
Job supervison, Provision of rest 1 4 4
Issue gate pass only after safety

induction.
2 2 4
Skill and knowledge based allocation of
work.

1 3 3
material
MSDS, Hand gloves Aprons Safety
1 8 8
Shoes.
Hand gloves Aprons Safety Shoes, Dust

1 4 4
Mask
Provion of speed limit warning, reverse

2 2 4
horn and signal man
Height work permit 3 1 3
Training 2 2 4
Work permit, Machine guarding, traning 2 3 6
Work permit for Isolation of Equipment. 3 2 6

2 2 4
Electrical Work permit, hand gloves, safety

4 2 8
Shoes
Hot work permit, 4 2 8
Training, Hand Gloves 1 4 4
Provision of breaks. 1 4 4
Work permit, Face sheild, Training 1 4 4

1 6 6
material
OCP , work permit 1 4 4
Ear Plug 1 4 4
Leather Hand Gloves 1 4 4
Provision of rest at Intervals, drinking water,

1 4 4
No 3 2 6
Isolation Permit, LOTO 4 2 8

4 1 4
activities.
Work only in off condition. Work permit,

2 3 6
LOTO, training
Provision of ventillation, Dust Mask 2 2 4
Proper insulated cable,Use of 30mA ELCB. 2 1 2
Electrical Work permit,Isolation, LOTO, hand

2 2 4
gloves, safety Shoes with fiber toe

2 2 4
Rigging plan. 2 2 4
Removal of slippery materials 2 2 4
Provision of rest to the worker at intervals 2 2 4
Electrical isolation, LOTO and OCP 65 2 2 4
Leather Hand Gloves 1 4 4
Provision of rest at Intervals, drinking water,

1 4 4
Area barricated, communication, water

2 2 4
spreaying, control of valve opening
Isolation Permit, LOTO 4 2 8
No 4 1 4

4 1 4
activities.
Work only in off condition. Work permit,

2 3 6
LOTO, training
Provison of cushion on sharp edges, helmet Safety

1 4 4
Shoes.
Training 1 4 4
Ear Plug 1 4 4
Electrical Work permit, hand gloves, safety Shoes 1 4 4
No combustibles to be stored in the vicinity 1 4 4
Restricted entry to panel rooms and locking of panels 4 1 4
follow SOP,Used 33KV hand gloves, safety

2 2 4
Shoes,kept standard rubber matts
Restricted Unauthorized entry to panel rooms

3 1 3
and locking of panels
Befor start the work line clerance has taken

from Cement plant electrical team. Thermax
1 4 4
Electrical LOTO also applied in incomer at
MRSS.

1 4 4
Goggles

1 4 4
Goggles

1 4 4
Goggles
Training, MSDS 1 4 4

1 4 4
material
Provison of hand rails, full body harness 2 2 4
Training, Provison of Life Jackets. Handrails 4 2 8
Height work permit, Safety Belt, PPE, Safety

2 2 4
googles, Vertigo test
Rigging plan. 2 2 4
Use of tag lines while lifting 2 2 4
Cable laying overhead 2 2 4

Emergency Trainings 4 1 4
Training and job superivision 4 2 8
OCP 2 2 4
Job supervison, Provision of rest 1 4 4
Issue gate pass only after safety induction.

2 2 4
Skill and knowledge based allocation of work.
Provion of speed limit warning, reverse horn

2 2 4
and signal man, speed breakers
CONTROLS
Doc Number
Format Number
REV
Date
Risk Rating Legal / Other Requirements Proposed Controls
Moderate Yes
Moderate IBR
Moderate IBR
Moderate
Extreme
Moderate
Moderate
provision
Moderate OHS
Moderate OHS
Moderate OHS
Moderate Emergency Manual
Moderate Yes
Moderate
Moderate Yes
Moderate Yes
Moderate
Moderate
Moderate
Moderate
High Yes
Moderate No
Moderate No
Moderate OHS
Moderate MSIHC
Moderate Factories Act Safety

provision

provision
provision
High Factories Act
High

provision

provision

provision

provision
Moderate

provision
Moderate
Moderate
Moderate By pass drain extension and

water spray arrangement

provision
High Factories Act Safety

provision
Moderate OHS

provision
Procedure to work on frigile

Moderate OHS roof in case of Asbestos
roof is to be followed
Moderate OHS

provision
Moderate No
Moderate No

provision

provision
Moderate No
Moderate No
Moderate OHS
Moderate
Moderate
Moderate By pass drain extension and

water spray arrangement
provision
High Factories Act Safety

provision
Moderate Factories Act Safety PM/Painting of gratings

provision regularly to avoid corrosion
Moderate OHS

provision
Procedure to work on frigile

Moderate OHS roof in case of Asbestos
roof is to be followed
Moderate OHS

provision
Moderate
Moderate

Moderate
Moderate OHS
Moderate
Moderate IER
Moderate OHS No
Moderate No
Moderate
Moderate
Moderate
Moderate
Moderate
Moderate
Moderate
Moderate OHS
High Provision of dosing pumps

for dosing
High OHS
Moderate OHS

provision
Moderate No
Moderate
Moderate
Moderate
High
Moderate
Moderate No
Moderate No
Moderate No
OHS/D 01
OHS/FT01
10
10.07.2018
Remarks
Residual Risk severity

increased to 3 from 2
after incident at MCL4
on 28.07.2015
IBR
IBR
Modofy after learning

from incident (DCW
24.08.16)
Modofy after learning

from incident (GPPL
22.08.16)
Modified after case
study of BORL
incidence and at
tuticorin power plant
fire.

WCL
Modified After 2nd

surevllance audit in Dec
12
Factories Act

provision
FATAL Incident at
KSPCL
MSIHC
Modified After 2nd

surevllance audit in Dec
12
provision
JKLC incindet on
25/10/2012: Modified after
finding of first survellance
audit on 15.12.14
Modified after the fatal

accindnet at DCW.
Reviewed after incident at

DCW on 11/7/2014
LTI- Caught in between at

MCL4 and IMFA
Modified After 2nd
Modified After 2nd

JKLC incindet on
25/10/2012: Modified after
finding of first survellance
audit on 15.12.14
Modified after Incident at
USDPCL on 20.06.2014
Modified after the fatal

accindnet at DCW.
Reviewed after incident at

DCW on 11/7/2014
LTI- Caught in between at

MCL4 and IMFA
Factories Act
Modified After 2nd
Modified After 2nd

Modified After 2nd

Reviwed on 30.06.2014
LTI - Fire Explosion at
USTKWPCL
FATAL Incident at KSPCL
Modified After 2nd

OCCUPATIONAL HEALTH AND SAFETY MANAGEMENT SYSTEM Doc. No :
HAZARD IDENTIFICATION, RISK ASSESSMENT AND
ESTABLISHMENT OF CONTROLS
Revision History
SL No Document Number Rev No Changes Revised Date
1 OHS/D01 0 0- Fresh Issue 12th Aug 2011
All sections Hazards added as per

2 OHS/D01 1 the findings in the 1st Survellance 15th Dec 2011
audit.
HIRA Modified based on the

3 OHS/D01 2 13th Aug 2012
learning from BORL incident
4 OHS/D01 2 Acitivity Number added 13th Aug 2012
HIRA Modified based on the

5 OHS/D01 2 learning from KSPCL incident 13th Aug 2012
and other LTI in the year.
HIRA modified after

6 OHS/D01 3 recommendations from second 25th Jan 2013
survellance audit
HIRA upated for LTIs at WCL,

DCW Fatal Accident, and LTI at
7 OHS/D01 4 13th Oct 2013
USTKWPCL in O&M Section. List
of significant Hazard Modified.
Name of Equipment is changed

8 OHS/D01 5 from WTP to ETP after audit 25th Dec 2013
findings at JK NImbahera
Sections of O&M and EPC are

9 OHS/D01 6 modified to include hazards of 7th Nov 2014
arising out of LTI
modified to include Legal and
10 OHS/D01 7 other requirements and audit 8th January 2015
findings of firsrt survellance audit
on 15.12.2014

modified to include changes in
11 OHS/D01 8 17th November 2015
severity & hazards during EPC
stages
Sections of O&M are modified to

include learnings from incidents
12 OHS/D01 9 at DCW and GPPL sites. Seections 8th September 2016
of HO, EPC & O&M HIRA are
seperated.
Sections of Operation and

maintenance are modified to
13 OHS/D01 10 inlcude the hazards from storage 5th January 2017
of fuels, Bagasse, rice husk &
Petcoke.
New activities have been added

14 OHS/D01 10 in all sections. Revised the Base 10th July 2018
risk, risk rating, controls etc.

HIRA O&amp;M Rev 10

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Ratting Severity

Permanent Disability, May not

Permanent Disability but may

Temporary Disability & may

Temporary Discomfort and

Hazard and Risk Identification

Activities having Occupational

Sr. No. Activity Code Function Activity

1 BOP-1 Boiler Start up of Boiler

3 BOP-1 Boiler Start up of Boiler

4 BOP-1 Boiler Start up of Boiler

5 BOP-2 Boiler Operation of Boiler

6 BOP-2 Boiler Operation of Boiler

7 BOP-2 Boiler Operation of Boiler

8 BOP-2 Boiler Operation of Boiler

9 BOP-2 Boiler Operation of Boiler

10 BOP-3 Boiler Bed material feeding / Handling

12 BOP-5 Boiler Operation of vents and drains

13 BOP-7 Boiler Hot bed material drain

14 BOP-7 Boiler Hot bed material drain

15 FFS0P-1 Fuel Feeding System Operation of drag chian feeders

Removal of choking during the

Rapping of chutes for removal

Start up and engagement of

19 TOP-2 Turbine Operation

21 TOSOP-1 Turbine Oil system Operation of oil coolers

22 TOSOP-1 Turbine Oil system Operation of oil coolers

23 BOP-6 Boiler Pumps Start up and operation

24 BOP-6 Boiler Pumps Start up and operation

25 BOP-6 Boiler Pumps Start up and operation

26 AHPOP-1 Ash handling System Operation of ESP

27 AHPOP-2 Ash handling System Operation of Ash silo

28 AHPOP-2 Ash handling System Operation of Ash silo

Dome valve cleaning, jamming

31 FHPOP-1 Fuel Handling Plant Operation of fuel handling plant

32 FHPOP-1 Fuel Handling Plant Operation of fuel handling plant

33 FHPOP-1 Fuel Handling Plant Operation of fuel handling plant

34 FHPOP-1 Fuel Handling Plant Operation of fuel handling plant

35 FHPOP-1 Fuel Handling Plant Operation of fuel handling plant

36 FHPOP-1 Fuel Handling Plant Operation of fuel handling plant

37 FHPOP-1 Fuel Handling Plant Operation of fuel handling plant

39 FHPOP-1 Fuel Handling Plant Operation of RAV (Jamming)

Operation of DCS/I/O unit

41 GM-2 General Activites Civil Works, Painting etc

42 GM-2 General Activites Civil Works, Painting etc

43 GM-2 General Activites Civil Works, Painting etc

44 GM-2 General Activites Civil Works, Painting etc

AC outdoor unit refrigeration

General Human Behaviour

General Human Behaviour

General Human Behaviour

General Human Behaviour

General Human Behaviour

General Human Behaviour

General Human Behaviour

General Human Behaviour

55 GM-5 General Activites Housekeeping

56 GM-5 General Activites Housekeeping

58 GM-5 General Activites Housekeeping

59 GM-5 General Activites Housekeeping

60 GM-5 General Activites Housekeeping

Coal Ash and LDO

62 BM1 ESP & Boiler Cleaning of internals

63 BM1 ESP & Boiler Cleaning of internals

HIRA O&M Rev 10

HIRA O&M Rev 10