Hira Register

PMPL/HSE/HIRA/01
Rev.01
HIRA REGISTER Page |1
HAZARD IDENTIFICATION
AND
RISK ASSESSMENT REGISTER
PMPL/HSE/HIRA/01
Rev.01
INDEX
S.NO DISCRIPTION PAGE NO.
1 INDEX 2
2 DEFINITION 3
3 HIRA INTRODUCTION 4-6
4 HIRA PROCEDURE 7-15
5 HIRA FORMAT 16
6 HIRA CONTENTS LIST 17-21
7 HIRA ACTIVITY WISE 22-61

PMPL/HSE/HIRA/01
Rev.01
DEFINITIONS
1. ACTIVITY
Broad group of tasks
2. CONSEQUENCE
Severity of Injury or damage
3. CONTROL MEASURES
Methods of controlling the hazard
4. HAZARD
Source, situation or act with a potential for harm in terms of human injury or ill health, or a combination of these
5. RECOVERY MEASURES
Measures to reduce the gravity of consequence and regain control if an undesired event or emergency situation arises
6. TASK
Any work conducted on the basis of a fixed procedure
HIRA INTRODUCTION
HAZARD MANAGEMENT PROCESS
Comprises of:
a) Identifying hazards and threats
b) Analyzing hazards to assess the threats and gravity of consequences
c) Instituting control measures to prevent accidents
d) Adopting recovery measures in case any contingency arises
PMPL/HSE/HIRA/01
Rev.01

HAZARD CONTROL
The following control measures generally apply to all hazards:
a) Wearing of PPE
b) Training and instructions related to the job
c) Obtaining work permits if applicable
d) Conducting Toolbox Meetings
e) Deploying right person for the right job
f) Good house keeping
g) Keeping adequate warning signs, barricading etc
h) Use of recommended tools and equipment
i) Adequate and effective supervision
RECOVERY MEASURES
In case any undesired event or incident does happen at the worksite or camp, inspite of essential precautionary measures in place, (may be due to at-risk behavior
of individuals) such emergencies shall be handled in such a way as to reduce the gravity of consequence (Severity of human injury or property damage) and to
regain control over the situation within the least possible time. The following will be the action plan in such contingencies.
In the case of major events such as fatalities, severe injuries, fire and explosion, leakage of toxic gases, natural calamities etc. the work will be stopped
immediately and emergency response procedure will be adopted to control the situation.
The incident will reported to the client / local authority etc by the easiest available means, seeking assistance and resources to handle the situation.
Further work will be resumed only on getting clearance from the Emergency Controller. A special emergency meeting of the workforce shall be convened to
explain the incident, the immediate and underlying causes (if identified), the learning points and corrective action required to prevent reoccurrence of similar
incident.
A First Information Report (FIR) shall be sent to HO within four hours of occurrence. Subsequent investigation shall be completed and Detailed Investigation
Report (DIR) furnished to all concerned within seven days.
In less serious cases, medical aid shall be given to the injured victims, if any, and the matter intimated to concerned authorities.
Emergency vehicle shall readily be available at site for transportation of injured persons to clinic.
The following hazards have been identified as existing or likely to exist in the project area:
a) Hydrocarbons
b) High pressure liquids and gases
PMPL/HSE/HIRA/01
Rev.01

c) Heavy Plant
d) Road Transport Vehicles
e) Material Handling (Manual and Mechanical)
f) Rock breaking
g) Working at heights
h) Working at OH lines
i) OH line pole erection and stringing
j) Electrical tools / equipment
k) Static equipment
l) Steel bar bending and cutting
m) Trenching, underground services
n) Radiation
o) Spillage
p) Confined Space
q) Blasting, Coating & GRE lining
r) Manual Operations (cutting, grinding, welding etc)
s) Heat, dust, vibration, noise
t) Concreting
Procedure for Hazard identification & Risk Assessment and development of risk control measures
(HIRA)
1. INTRODUCTION
The process of Hazard Identification and Risk Assessment is intended to establish a standard procedure for determining Occupational Health and Safety Risks
and their overall significance relating to the organizational activities. Risks arise from the interaction between people, equipment, materials and the work
environment.
This Procedure is primarily concerned with personal injury and ill health risks and does not address damage to plant and equipment, except when such damage
may injure people. The task of risk assessment should involve both identification of the hazards and undertake an evaluation of the impacts of the risks
Involved.
2. PURPOSE
PMPL/HSE/HIRA/01
Rev.01

1) To identify hazards in respect of all ongoing activities of the organization, particularly at project construction sites,
2) To carry out risk assessment corresponding to all identified hazards.
3) To design, document and implement necessary control measures, either to eliminate the risks or to reduce the consequences of the identified risks.
3. SCOPE
This procedure is applicable to:
1) All activities, products or services, whether existing or new at all PMPL construction Projects and at HO.
2) To all employees and contractors of PMPL.
4. RESPONSIBILITIES
The overall responsibility of ensuring success of risk control measures remain with the Directors and HOD-HSE.
Project Managers, Engineers and supervisors are responsible for the effective implementation of this Procedure by identifying the hazards in all the activities at
their project site, assessing the risk associated with the identified hazards, rating the risk and initiating risk control measures.
“Master Hazard Identification and Risk Assessment Register” (HSER – 01) to be maintained with the HOD – HSE & “Site HIRA Register” to be maintained by
Site HSE In-charge
5. REFERENCES
A. OHSAS 18001:2007 - Occupational Health and Safety Management System-Requirements
B. OHSAS 18002:2004 - Guidelines for implementation
6. PROCEDURE
Project Managers shall constitute a core group for conducting Hazard Identification and Risk Assessment of all project activities before the activities are
performed at site. The process of Risk Assessment is based on the steps described here.
A. Identification of hazards associated with a task or activity, considering the following:

a) Type of activity or work being carried out
b) How it is carried out
c) Where it takes place (work environment)
d) Who undertakes the activity?
e) How many people are involved?
f) Whether task is of short or long duration?
g) Potential for safety management failure
h) Potential for human error failure
PMPL/HSE/HIRA/01
Rev.01

i) What are the consequences?
B. Assessment of Risk
Following steps are used to identify, assess and control the identified hazards at work place:
a) Collect information about existing hazards and potential hazards for all the project activities.
b) Assess the risk
c) Set priorities.
d) Communicate information about the hazards and risks
e) Develop, select and implement controls and monitor their effectiveness.
f) Maintain Records.
g) To determine whether a hazard present is acceptable or not, Risk Values (Probability and Severity Factors) are assigned with weightage factors as
detailed in Table P 1.1
h) Risk Level and Risk Rating is obtained from the Risk Rating Matrix, Table P 1.2. Interpretation of Risk rating is described in Table P 1.3
C. INTOLERABLE RISK LEVEL
a) The assessed risks with a risk rating of 1 or 2 are within the tolerable limit.
b) A risk rating above 2 (that is 3, 4, or 5) is considered as intolerable (or unacceptable) risk.
c) The higher the number the higher is the risk.
d) This will assist in deciding priorities for risk control measures.
D. REVIEW OF HIRA REGISTER

Project Managers shall review HIRA Register for effectiveness atleast once a year or after any LTI at project location.
Table P 1.1: RISK VALUES FOR WEIGHTAGE FACTORS
PROBABILITY FACTORS
PROBABILITY PROBABILITY OCCURENCE

FACTOR
5 Always whenever the work is taken up Very high

PMPL/HSE/HIRA/01
Rev.01

4 Continuous or frequent (more than once per week) High
3 More than once per month Moderate
2 More than once in six months Low
1 More than once in one year Very Low
0 Never None
SEVERITY FACTORS
SEVERITY SEVERITY
FACTOR
5 Permanent/ partial disability with hospitalization or death (LTI / FATALITY)
4 Injury resulting in more than 3 days off work (LTI)
3 Injury resulting in 1-2 days off work (RWC)

PMPL/HSE/HIRA/01
Rev.01

2 Minor injury with medical attention (MTC)
1 Minor injury with no medical attention (FAC)
0 No harm
TABLE P 1.2 RISK RATING MATRIX

4
0 1 2 3 4 5
PMPL/HSE/HIRA/01
Rev.01
HIRA REGISTER P a g e | 10
SEVIRITY FACTOR
PROBABILITY FACTOR
Risk Rating Risk Level Inference
TRIVIAL
1 No action needed but controls may still be justified
(Tolerable)
No additional controls are required. Consideration may be given to more cost-

LOW
2 effective solution or improvement that imposes no additional cost burden.
(Tolerable)
Monitoring is required to ensure that controls are Maintained.
PMPL/HSE/HIRA/01
Rev.01
Risk may be intolerable. Efforts should be made to reduce the risk to the
MODERATE
3 tolerable level but the cost of prevention should be carefully measured and
(Intolerable)
limited.
HIGH Unacceptable risk level. Urgent action is required. Work should not be started
4 (Unacceptable) or continued until the risk has been reduced to bring it within the tolerable limit.
Highly unacceptable risk level. Work should not be started or continued until the
EXTREME
risk has been reduced to an acceptable level. Immediate action is needed. If it is
5 (Highly
not possible to reduce the risk even with unlimited resources, work has to remain
Unacceptable)
prohibited.
RISK CONTROL MEASURES
Avoid Eliminate Hazard altogether
SUBSTITUTE Change to less hazardous

alternative
ISOLATE Separate people from hazard

PMPL/HSE/HIRA/01
Rev.01
Process of Risk Control
In practice, all these methods mentioned above are used in industry. Also it is important to
a) Identify, plan and provide safety training.
b) Identify and provide relevant health and safety information to site personnel e.g. warning signs, visual and audible alerting signals etc.
c) Identify and provide personal protective equipment (PPE) corresponding to the risks
FORMAT
PMPL/HSE/HIRA/01
Rev.01
HAZARD IDENTIFICATION AND RISK ASSESSMENT – DEVELOPMENT OF RISK CONTROL MEASURES
C.C. NO.: PROJECT NAME:
ACTIVITY
:
HIRA WORK GROUP MEMBERS:
1 2
3 4
S. No. Activity Hazard Consequence Probability Severity Risk Level Risk

Control Measures
Factor Factor Rating
PROJECT MANAGER
HAZARD IDENTIFICATION AND RISK ANALYSIS (HIRA)

PMPL/HSE/HIRA/01
Rev.01
HIRA CONTENTS LIST
SL. NO. ACITIVITY PAGE NO.
CIVIL WORKS
ACTIVITY – 1 BLOCK WORKS 22
ACTIVITY – 2 CONCRETE CHIPPING 23
ACTIVITY – 3 CONCRETE FOUNDATION BREAKAGE USING JACKHAMMER 23
ACTIVITY – 4 CONCRETING 23
ACTIVITY – 5 CONCRETE MIXTURE OPERATION 24
ACTIVITY – 6 MANUAL EXCAVATION 25
ACTIVITY – 7 MECHANICAL EXCAVATION 27
ACTIVITY – 8 ROCK BREAKING 29
ACTIVITY – 9 PLASTERING 30
ACTIVITY – 10 SHUTTERING AND SHORING 30
ACTIVITY – 11 WORK ON REBAR 31
MECHANICAL WORKS
ACTIVITY – 12 REINFORCEMENT 32
ACTIVITY – 13 SCAFFOLDING , FORMWORK AND LADDERS 33
ACTIVITY – 14 GRINDING 34
ACTIVITY – 15 USING ENGINE GENERATOR SET 34

PMPL/HSE/HIRA/01
Rev.01
ACTIVITY – 16 HANDLING OF PORTABLE ELECTRICAL TOOLS 34
ACTIVITY – 17 HANDLING PORTABLE HAND TOOLS 35
ACTIVITY – 18 GAS WELDING 35
ACTIVITY – 19 ARC WELDING 36
ACTIVITY – 20 WORKING IN CONFINED SPACE 36
ACTIVITY – 21 MATERIAL HANDLING (MANUAL) 37
ACTIVITY – 22 MATERIAL HANDLING (MECHANICAL) 37
ACTIVITY – 23 WORK AT HEIGHTS 37
ACTIVITY – 24 WORKING UNDER CRANE / LIFTING EQUIPMENT. 38
ACTIVITY – 25 LOADING / UNLOADING ON TRUCK / TRAILER. 38
ACTIVITY – 26 MATERIAL HANDLING WITH CRANE 39
ACTIVITY – 27 HYDROTESTING OMMITED
ACTIVITY – 28 HANDLING OF GAS CYLINDERS 40
ACTIVITY – 29 RADIOGRAPHY OMMITED

GENERAL
ACTIVITY – 30 TANK ISOLATION AND CLEANING OMMITED
ACTIVITY – 31 ERECTION, DISMANTLING AND WORKING ON SCAFFOLDING 41
ACTIVITY – 32 STRUCTURAL WORKS OMMITED
ACTIVITY – 33 PIPELINE WORKS 42

PMPL/HSE/HIRA/01
Rev.01
ACTIVITY – 34 WORKING IN HOT ENVIRONMENT 42
ELECTRICAL
ACTIVITY – 35 WORKING IN DUSTY ENVIRONMENT 42
ACTIVITY – 36 WORKING DURING NATURAL CALAMITIES 43
ACTIVITY – 37 STAY IN CAMPS 43
ACTIVITY – 38 SLIPS, TRIPS AND FALLS AT WORK PLACE. 44
PLANT AND MACHINERY
ACTIVITY – 39 FIRE PREVENTION AND PROTECTION 44
ACTIVITY – 40 LAYING ELECTRICAL CABLES 44
ACTIVITY – 41 POLE ERECTION OMMITED
ACTIVITY – 42 PASSAGE UNDERNEATH OVERHEAD LINES. OMMITED
ACTIVITY – 43 WORKING NEAR OVERHEAD LINES 45
ACTIVITY – 44 ELECTRICAL INSTALLATION AND USAGE 45
ACTIVITY – 45 DENTING WORK OMMITED
ACTIVITY – 46 DRIVING / OPERATING VEHICLES & EQUIPMENTS 46
ACTIVITY – 47 PARKING OF VEHICLES IN PARKING AREA OMMITED
ACTIVITY – 48 EMERGENCY STARTING / JUMP STARTING OMMITED
ACTIVITY – 49 HANDLING BATTERY OMMITED
ACTIVITY – 50 OPERATION OF COMPACTOR 47

PMPL/HSE/HIRA/01
Rev.01
ACTIVITY – 51 OPERATION OF CRANE 47
ACTIVITY – 52 OPERATION OF FORKLIFT OMMITED
ACTIVITY – 53 OPERATION OF VIBRATOR 48
ACTIVITY – 54 REMOVAL AND REFITTING OF GEAR BOX 49
ACTIVITY – 55 CHANGING OF ALTERNATOR 50
ACTIVITY – 56 CHANGING OF HEAVY VEHICLE WHEEL 51
ACTIVITY – 57 TOWING OF DEFECTIVE VEHICLE 51
ACTIVITY – 58 SPRAY PAINTING. 53
ACTIVITY – 59 WIRE ROPE REPLACEMENT (CRANE) 54
ACTIVITY – 60 HANDLING AND LIFTING EUIPMENTS (GENERAL) 55
ACTIVITY – 61 BATCHING PLANT OPERATION 56
ACTIVITY – 62 CHIMNEY CONSTRUCTION OMMITED
ACTIVITY – 63 GRIT BLASTING OMMITED
ACTIVITY – 64 PRECAST YARD OPERATIONS 57
ACTIVITY – 65 FABRICATION YARD OPERATIONS 59
H.O. ACTIVITIES
ACTIVITY – 66 LIFT OPERATION AT H.O. OMMITED
ACTIVITY – 67 MENTAL WORKLOAD AT H.O. OMMITED
ACTIVITY – 68 USE OF VDU’s OMMITED

PMPL/HSE/HIRA/01
Rev.01
ACTIVITY – 69 ILLUMINATION IN H.O. OMMITED
ACTIVITY – 70 VENTILATION IN H.O. OMMITED

PMPL/HSE/HIRA/01
Rev.01
S. ACTIVITY HAZARD CONSEQUENCE PROBABILIT SEVIRITY RISK RISK CONTROL MEASURES
No. Y FACTOR FACTOR LEVEL RATING
ACTIVITY - 1: BLOCK WORKS
1 Storage of blocks 1. Height above 1.5 M 1. Fall of blocks 4 3 MODERAT 3 1. Restrict height of storage to 1.5M
2. Improper Storage 2. Personal Injury E 2. Adopt cross tier system of storage.
2 Transportation of 1. Unsecured blocks 1. Breakage of blocks 3 2 LOW 2 1. Ensure blocks carried are properly secured
blocks to the site 2. Rough and uneven Road. 2. Personnel injury. 2. Defensive driving.
3 Unloading blocks 1. Fall of blocks 1. Personnel injury 4 3 MODERAT 3 1. Safe handling

2. Wrong lifting method. 2. Back pain. E 2. Education of correct posture.
4 Shifting blocks to 1. Use of defective dumper 1. Damage to dumper 3 4 MODERAT 3 1. Use serviced dumper
the building site 2. Mis-operation. 2. Tilting of dumper. E 2. Deploy trained operator
by dumper 3. Operate slowly and carefully on rough road
4. Provide trained banksman.
5 Shifting blocks, 1. Defective wheelbarrow 1. Overturning of wheelbarrow 3 2 LOW 2 1. Use good serviceable wheel barrow
cement mortar, 2. Loosing balance due to 2. Personnel injury. 2. Use planks wherever necessary
concrete etc., uneven / loose surface 3. Be cautious.
manually, (wheel 3. Absent mindedness 4. Concentrate on Job
borrow) 4. Hurry. 5. Know your surroundings
6 Preparation of 1. Improper handling of 1. Back pain 4 3 MODERAT 3 1. Follow ergonomics

cement mortar cement bags. 2. Skin allergy E 2. Use of adequate PPE
and placing of
blocks with
1.Evolution of cement dust at 1. Dust allergy to the workmen 3 3 LOW 2 1. Use of adequate PPE
work place 2. Eye/Skin injury.
2. Splashing of cement
mixture.
7 Shifting of 1. Defective dumper 1. Damage to dumper 4 3 MODERAT 3 1. Use serviced dumper

cement mortar by 2. Mis-operation. 2. Tilting of dumper E 2. Deploy experienced operator.
dumper

PMPL/HSE/HIRA/01
Rev.01
ACTIVITY - 2: CONCRETE CHIPPING
1 Chipping 1. Bad condition of tools 1. Personnel injury 2 3 LOW 2 1. Do not use defective tools. Select the right tool for
2. Foreign particles 2. Eye injury the job.
3. Tripping hazard 2. Use adequate PPE.
3. Maintain good housekeeping.
4. Remove debris immediately.
ACTIVITY - 3: CONCRETE FOUNDATION BREAKAGE USING JACKHAMMER

1 Dismantling 1. Fall of Jack hammer. 1. Injury. 4 3 MODERAT 3 1. Hold firm.
concrete 2. Vibration. 2. Prolonged exposure causes E 2. Secure chisel firm to jack.
(foundation) occupational disease called white 3. Rotation of work force to avoid prolonged
finger exposure.
ACTIVITY - 4: CONCRETE MIXTURE OPERATION

1 Deployment of 1. Poor mechanical condition 1. Failure of equipment. 3 4 MODERAT 3 1. Use good serviced equipment.
concrete pump of 2. Accident /personal injury E 2. Deploy only licensed operators.
the equation. 3. Engage banksman.
2. Unauthorized operation
2 Batching plant. 1.Poor mechanical condition of 1. Failure of equipment. 4 3 MODERAT 3 1. Use good serviceable equipment.
Truck Mixer. the equipment. 2. Accident /personal injury E 2. Deploy only licensed operators.
Cement bulk 2. Unauthorized Operation 3. Engage Banksman.
carrier.
3 Deployment of 1. Improper placement of 1. Tilting of mixture. 4 3 MODERAT 3 1. Ensure concrete mixer is placed on even surface
concrete mixture. mixer 2. Damage to concrete mixer. E with proper pegs.
machine on uneven surface . 3. Electrical shock. 2. Check for proper electrical connections and
2. Mis-operation. 4.Fire hazard . insulation.
3. Loose contact with electric 5. Personnel injury. 3. Keep adequate fire extinguishers.
connections. 6. Unwanted movement of concrete 4. Proper guards at all rotating parts of machinery.
4. Rotating parts of machine. truck. 5. Position the mixer machine to disperse smoke
5. Unblocked wheels of 7. Mis- operation and injury to crew. easily into atmosphere.
concrete mixer. 8. Breathing problems. 6. Clean the mixer machine after the concreting is
6. Improper coordination over.
among
crew members.

PMPL/HSE/HIRA/01
Rev.01
ACTIVITY - 5: CONCRETING

1 Concreting 1. Air pollution by cement. 1. May affect Respiratory System. 3 3 MODERAT 3 1. Wear respirators or cover mouth and nose with wet
2. Handling of ingredients. 2. Hands may get injured. E cloth.
3. Protruding reinforced rods. 3. Feet may get injured. 2. Use gloves and other PPE.
4. Earthing of electrical 4. Can cause electrocution/ 3. Use Safety shoes.
mixers, asphyxiation. 4. Provide platform with wooden planking above
vibrators etc. not done. 5. Persons may get injured. reinforcement for movement of workers.
5. Falling of materials from 6. Causes tiredness of workers and 5. Ensure earthing of equipments and proper
height. may lead to accident. functioning of electrical circuit before commencement
6. Continuous pouring of by 7. Parts of body or clothes may get of work .
same gang. entrapped. 6. Use hard hats.
7. Revolving of concrete 7. Remove surplus material immediately from work
mixer/ place.
vibrators 8. Ensure lighting arrangement during night hours.
9. Insist on shift pattern.
2 Super- structure 1. Air pollution by cement. 1. Shuttering /props may collapse 4 3 MODERAT 3 10.Use
1. Provide
PPE adequate rest
like gloves, to workers
shoes, between
helmets etc.
2. Handling of ingredients. and prove fatal. E 2. Avoid usage of make-shift tools.
3. Protruding reinforced rods.
4. Earthing of electrical
mixers,
vibrators etc. not done.
5. Falling of materials from
height.
6. Continuous pouring of by
same gang.
7. Revolving of concrete
mixer/
vibrators
8. Deflection in props or
3 Access to shuttering
1. Passagematerial
to work place 1. Improperly tied and designed 3 3 MODERAT 3 1. Ensure the stability and strength of passage before
workplace props/planks may collapse. E commencement of the work.
2. Do not overload or stand under the passage.
PMPL/HSE/HIRA/01
Rev.01
ACTIVITY - 6: MANUAL EXCAVATION

1 Piling Work 1. Failure of pile- driving 1. Can hurt people. 2 3 LOW 2 1. Inspect Piling rigs and pulley blocks before the
equipment. 2. Can cause deafness and beginning of each shift.
2. Noise pollution. psychological imbalance. 2. Use personal protective equipment like ear plugs,
3. Extruding rods/ casing. 3. Can hurt people. muffs, etc.
4. Working in the vicinity of 4. Can cause electrocution 3. Barricade the area and install sign boards.
'Live- Electricity ' /Asphyxiation 4. Keep sufficient distance from Live Electricity as per
IS code.
5. Shut off the supply, if possible.
2 Pit Excavation 1. Falling into pit. 1. Personal injury. 3 4 MODERAT 3 1. Provide guide rails/ barricade with warning signal.
upto 3m 2. Earth collapse. 2. Suffocation / Breathlessness. E 2. Provide atleast two entries/ exits.
3. Contact with buried electric 3. Buried. 3. Provide escape ladder.
cables. 4. Electrocution. 4. Provide suitable size of shoring and strutting if
4. Gas / Oil Pipelines 5. Explosion required.
5. Keep soil heaps away from edge equivalent to 1.5m
or depth of pit whichever is more.
6. Don't allow vehicles to operate too close to
excavated areas . Maintain atleast 2m distance from
edge of cut..
7. Maintain sufficient angle of repose. Provide slope
not less than 1:1 and suitable bench of 0.5m width at
every 1.5m depth of excavation in all soils except
hard rock.
8. Battering/Benching the sides.
9. Obtain permission from competent authorities, prior
to excavation, if required.
10. Locate the position of buried utility by referring to
plant drawings.
11. Start digging manually to locate the exact position
of buried utility and thereafter use mechanical means.
3 Pit excavation 1. Falling into pit. 1. Personal injury. 3 4 HIGH 4 1. Prevent ingress of water
beyond 3m. 2. Earth collapse. 2. Suffocation / Breathlessness. 2. Provide ring buoys.
3. Contact with buried electric 3. Buried. 3. Identify and provide suitable dewatering pump or
cables. 4. Electrocution. well point system.
4. Gas / Oil Pipelines 5. Explosion 4. Obtain prior approval of excavation method from
3. Flooding due to excessive 6. Can cause drowning situation. local authorities, if required.
rain/ underground water. 7. Building / structure may collapse. 5. Use under-pining method.
4. Digging in the vicinity of the 8. Loss of health and wealth. 6. Barricade the excavated area with proper lighting
existing building / structure. 9. May cause cave-in or slides. arrangements..
5. Movement of vehicles / 10. Persons may get buried. 7. Maintain atleast 2m distance from edge of cut and
equipments close to the edge use stop blocks to prevent over-run.
of 8. Strengthen shoring and strutting.
cut.
PMPL/HSE/HIRA/01
Rev.01
4 Rock excavation 1. Improper handling of 1. May prove fatal. 4 4 HIGH 4 1. Ensure proper storage, handling and carrying of
by blasting explosives. 2.. May cause severe injuries or explosives by trained personnel.
2. Uncontrolled explosion. Prove fatal. 2. Comply with the applicable explosive acts and
3. Scattering of stone pieces 3. Can hurt people. rules.
in 4. May cause severe injuries 3. Allow only authorized persons to perform blasting
atmosphere. 5. May explode suddenly. operations.
4. Entrapping of animals / 4. Smoking and open flame are to be strictly
persons. prohibited.
5. Misfire 5. Use PPEs like gloves, goggles, face mask, etc.
5. Barricade the area with red flags and blow siren
before blasting.
6. Do not return to site for atleast 20min. or unless
announced safe by designated person.
5 Narrow deep 1. Frequent cave-in or slides. 1. May cause cave-in or slides.. 4 3 MODRATE 3 1. Battering / benching of sides .
excavations for 2. Flooding due to Hydrostatic 2. Persons may get buried. 2. Provide escape ladders.
pipelines, etc. testing 3. May cause severe injuries or 3. Bail out accumulated water.
prove 4. Maintain adequate ventilation.
fatal.
4. May arise drowning situation
PMPL/HSE/HIRA/01
Rev.01
No. ACTIVITY HAZARD CONSEQUENCE FACTOR FACTOR RISK RATING CONTROL MEASURES
LEVEL
ACTIVITY - 7: MECHANICAL EXCAVATION
1 Excavation using 1. Defective machinery 1. Damage to the machinery 3 5 HIGH 4 1. Adhere to Permit to Work System if applicable.
machinery 2. Mis-operation 2. Damage to underground 2. Check machine thoroughly before starting the job.
3. Inadvertent operation electrical, 3. Use good and serviced machines.
4. Working near the edge of telecom cables and water services. 4. Look for route markers.
excavation 3. Fall of machinery into the pit. 5. Make trial pits and expose underground cables, if
5. Working near utilities. 4. Pipe lines rupture/explosion any.
6. Working near overhead injury. 6. Look for warning tapes, cable covering mats
lines. 5. Shock/Fatality concrete saddles and padding.
7. Fall of heavy objects Stone, 6. Fatal injury 7. Use cable detectors.
boulder, soil etc. into 7. Lung complaints 8. Adhere strictly to manual excavation in case
excavated 8. Eye injuries. underground cables are present.
pit. 9. Hit injuries. 9. Follow safety procedure.
8. Fall of persons into the pits. 10. Hearing impairment. 10. Operate machinery, keeping safe distance to
9. Dust. 11. Injury due to hit or collision. avoid excavation area landside.
10. Congested work site, too 12. Hit and damage to overhead 11. Deploy trained banks man.
many persons working in the structure. 12. Keep away from the edge of the excavation.
pits or trenches. 13. Provide barrier away from the edge of excavation.
11. Noise during rock 14. Provide sign boards and blinking lights.
breaking, heavy equipment 15. Edge of excavation shall be 0.5 m away from
operation. high pressure lines.
16. Keep 1.5 m away from overhead LT lines.
17. Use only approved equipment and competent
operators.
18. No entry into the pit during excavation.
19. Keep removed earth at least 1m away from the pit.
20. Provide shuttering/shoring.
21. Remove the excavated earth immediately.
22. Do not keep heavy objects on the edge of the pit.
23. Provide barricading with warning signals ( warning
light at night)
24. Provide proper ladder to get into the pits.
25. Provide walkway for lengthy trenches.
26. Use dust mask and goggles.
27. Allow only minimum number of persons to work at
the same time.
28. Train for safe manual working procedures.
29. Provide adequate emergency access always.
30. Use earplugs or earmuffs.
31. Provide trained banksman.
32. Keep distance of minimum 5m between two
equipment while in use.
33. Use only approved equipment and employ
competent operators.
34.Keep safe overhead distance.
35. Observe special permits wherever required.
36. Strictly adhere to banks men’s signals and
directions.
PMPL/HSE/HIRA/01
Rev.01
2 Incomplete 1. Un-noticed hazard area. 1. Fall of persons/animals into the 3 4 MODERAT 3 1. Impart proper instruction to all workmen.
excavation. 2. Improper barricading. pit. E 2. Proper demarcation around the pit.
3. Bad weather. 2. Fall of machinery into pit. 3. Keep sign board "Danger".
3. Landslide due to weather effect. 4. Barricade pits / trenches.

ACTIVITY - 8: ROCK BREAKING
1 Rock excavation 1. Jolts to operator. 1. Ill health. 4 3 MODERAT 3 1. Employ trained operator with license.
using pneumatic 2. Obstruction to vision 2. Damage, injury to facilities and E 2. Avoid applying excessive force to hammer to avert
equipment, rock between people jolting.
breaker, operator and banksman. 3. Injury/Damage to asset. 3. Banksman to stand in direct view with operator.
excavators. 3. Flying Projectiles. 4. Hearing impairment. 4. Extreme care to prevent projectiles flying from
4. Noise. 5. Pulmonary disorders. hammer point.
5. Dust. 6. Fall of material, equipment, 5. Do not operate the hammer if window cabin or
6. Excavated Trench persons and animals shield is not in place.
6. Use ear muff / plug.
7. Use dust mask / Balaclava.
8. Barricade the area with warning sign.
9. Ensure overnight safety.
10. Provide ladder for deep pits.
2 Removal of 1. Hydraulic pressure jet 1. Loss of Hydraulic oil. 3 2 LOW 2 1. Disconnect Hydraulic hose only after closing pressure
Hydraulic 2. Environmental impact and return line stop valves.
Hammer
3 Laying hammer 1. Fall. 1. Physical injury & back pain. 3 4 MODERAT 3 1. Position the hammer horizontal on wooden block and
down E remove pins by gentle tapping.
4 Working near 1. Fall of hammer on nearby 1. Damage to Hammer chisel. 2 5 HIGH 4 1. Employ trained and licensed operator.
overhead lines facilities. 2. Physical injury. 2. Careful operation.
and pressure 2. Overhead lines. 3. Damage to assets. 3. Edge of excavation shall be 0.5m away from high-
lines 3. Hitting, striking, reversing 4. Shock. pressure pipelines.
incidents. 5. Fatal injury 4. Keep 1.5 m away from overhead LT lines.
5. Strict adherence to conditions stipulated by
excavation work permit.
6. Keep adequate signboards and barricade the area.
7. Keep work force 5m away from Rock Breaker.
8. Strict adherence to Banks man's instructions.
PMPL/HSE/HIRA/01
Rev.01

ACTIVITY - 9: PLASTERING
1 Plastering/ 1. Inhalation of cement dust. 1. Bronchial disease 4 3 LOW 2 1. Wear respiratory protection.
Grouting 2. Absorption of cement 2. Irritation 2. Wear safety goggles and coverall.
3. Ingestion. 3. Prolonged exposure causes 3. Wash hands before taking food
dermatitis. 4.Take shower after reaching camp.
4. Gastro-intestinal disorders.
ACTIVITY - 10: SHUTTERING AND SHORING

1 Shuttering / 1. Protruding nails. 1. Personal injury. 3 4 MODERAT 3 1. Avoid Protrusion/projection of sharp edges.
Handling of 2. Unsafe / Improper handling. 2. Tripping/Slipping hazard. E 2. Secure the load properly.
wooden planks 3. Improper house keeping 3. See that there is no strain on back.
and supports.
2 Cutting wood to 1. Misuse of cutting device. 1. Hand injury . 3 3 LOW 2 1. Deploy trained carpenter.
required size. 2. Fall of tools & wood from 2. Improper cutting resulting in
height. material loss.
3. Personnel injury.
3 Preparation of 1. Flying nails while 1. Eye injury. 3 4 MODERAT 3 1. Wear safety goggles.
shuttering on hammering. 2. Flying of hammer head resulting E 2. Ensure that hammer handle is properly wedged and
ground. 2. Use of loose hammer. in hammer is in good condition.
personnel injury 3. Keep persons away from hammering area.
4 Erection of 1. Fall of shuttering 1. Physical injury & back pain. 2 4 MODERAT 3 1. Erection should be done standing over firm supports.
shuttering. E
5 Erection of 1. Fall of person or shutter. 1. Personal injury 3 4 MODERAT 3 1. Use approved scaffolding.
shuttering on 2. Fall of loose materials. 2. Damage to the shutter. E 2. Do not keep away loose material on platform.
height. 3. Loss of materials. 3. Deploy experienced workers.
6. De-shuttering & De- 1. Fall of shuttering. shoring 1. Injury to persons. 2 3 LOW 2 1. Deploy experience workers.
2. Protruding nails. 2. Keep and alert third party persons to be away from
3. Loose nails on floor. the de-shuttering area.
3. Remove nails and stack shuttering materials
properly.
4. Keep all removed nails in one container.
5. Maintain good housekeeping.
PMPL/HSE/HIRA/01
Rev.01

ACTIVITY - 11: WORK ON REBAR

1 Manual bar 1. Defective tools 1. Personnel injury. 2 3 LOW 2 1. Do not use sub-standard tools.
bending. 2. Wrong application of tools. 2. Damage to tools. 2. Ensure usage of right tools for right job.
3. Wrong posture. 3. Back pain. 3. Do not push tools while bending.
4. Hold firmly.
5. Adhere to correct and safe posture
2 Bar bending on 1. Defective machinery. 1. Personal injury 3 3 LOW 2 1. Do not use defective tools.
bending machine 2. Difference in level between 2. Damage to the machine. 2. Secure machine and table on level ground.
table and machine. 3. Damage to the table. 3. Keep area clear around machine.
3. Improper guard. 4. Misoperatorion. 4. Provide switch for emergency stoppage.
4. Inexperienced operator. 5. Ensure guards are provided on all rotating parts.
6. Hold the bars firmly.
7. Stack bars properly and away from machine.
3 Manual cutting 1. Toppling of chisel. 1. Personal injury. 3 4 MODERAT 3 1. Safe handling of tools.
2. Slippage of bar under 2. Flying bar. E 2. Keep hand away from cutting chisel.
tension. 3. Hold bar firmly.
4. Ensure safety while operating handle.
4 Binding bar with 1. Haphazard placement of 1. Personal injury 3 3 LOW 2 1. Keep wires initially bend downward.
wire steel bar.
5 Cutting bar by 1. Defective machine. 1. Personnel injury. 4 3 LOW 2 1. Do not use defective tools.
machine 2. Improper guard. 2. Damage to the machinery. 2. Use serviced machine.
3. Loose electrical 3. Personnel injury. 3. Provide stand on both sides of the machine for
connections. 4. Fire hazard. moving steel.
4. Defective blade. 5. Personnel injury 4. Provide switch for emergency stoppage of machine.
5. Ensure proper electrical connections.
6. Do not use defective blade.
7. Keep hands away from cutting blade while in
operation.
6 Cutting wire by 1. Defective tools. 1. Personal injury. 3 3 MODERAT 3 1. Use proper binding.
tools. 2. Damage of tools. E 2. Take extra care while walking around the work site
7 Manual 1. Loose binding of 1. Slippage of binding steel 3 3 LOW 2 1. Ensure proper binding .
placement of bar. reinforcement. reinforcement. 2. Give proper instructions.
2. Improper co-ordination. 2. Personal injury. 3. Deploy trained and experienced persons.
3. Inexperienced persons. 4. Ensure proper co-ordination among the crew.
5. Avoid sharp edges.
PMPL/HSE/HIRA/01
Rev.01

ACTIVITY - 12 REINFORCEMENT
1 Reinforcement 1. Curtailment and binding of 1. Persons may get injured . 3 3 MODERAT 3 1. Use PPE like gloves, shoes, helmets,etc.
rods. 2. Workers may get injured on their E 2. Avoid usage of make-shift tools.
2. Carrying of rods for short hands and shoulders. 3. Provide suitable pads on shoulders and use safety
distances/ at height. 3. Rods may cut or injure the gloves.
3. Checking of clear distance/ fingers. 4. Tie up rods in easily liftable bundles.
cover with hands. 4. Persons may get injured and fall 5. Ensure proper staging.
4. Hitting projected rods and down. 6. Use measuring devices like tape, measuring
standing on cantilever rods. 5. May prove fatal. rods,etc.
6. Protruded rods may hit the 7. Use safety shoes and avoid standing unnecessarily
persons on cantilever rods.
8. Avoid wearing of loose cloths.
9. Provide safety nets.
2 Transportation of 1. Fall of material from height. 1. Personal injury 4 3 MODERAT 3 1. Use red flags / lights at the end s.
Rebar 2. Hit by protruding bar 2. May prove Fatal E 2. Do mot protrude the rods in front of or by the side of
3. Damage to Material/property the drivers cabin.
3. Do not extend the rods 1/3rd. of deck length or
1.5m whichever is less.
PMPL/HSE/HIRA/01
Rev.01

ACTIVITY - 13 SCAFFOLDING , FORMWORK AND LADDERS
Scaffolding , 1. Person can fall down . 1. Person may sustain severe MODERAT 1. Provide guard rails for working at height .
formwork and 2. Failure of scaffolding injuries and prove fatal. 4 3 E 3 2. Face ladder while climbing and use both hands.
1 ladder material. 2. Persons working at lower level get 3. Ladder shall exend about 1m above landing for easy
3. Material can fall down injured. access and tying up purpose.
4. Do not place the ladder against a movable objects and
maintain base at 1/4 ratio of the working length of the
ladder.
5. Suspended scaffolds shall not be less than 500mm
wide and tied securely with ropes.
6. No loose planks shall be allowed.
Use PPE, like helmets, safety shoes etc.
7.
10.
thickness lumber or equivalent. These shall be cleared or
secured and must extend over the end supports by
atleast 150 mm and not more than 300mm.
11.
12.
Vertical ladders shall not exceed 6m.
Remove excess material and scrap immediately
8.
anchor with permanent structures.
9.
13.
thickness lumber or equivalent. These shall be cleared or
secured and must extend over the end supports by
atleast 150 mm and not more than 300mm.
14.
15.
Vertical ladders shall not exceed 6m.
16.
17.
18.
PMPL/HSE/HIRA/01
Rev.01

ACTIVITY - 14: GRINDING
1 Grinding and 1. Grinding without goggle. 1. Injury to eyes by flying chips. 3 4 MODERAT 3 1. Use proper PPE.
grinding wheel 2. Absence of tool rest on 2. Accident and injury E 2. Mount the tool rest on both sides.
replacing. bench grinder. 3. Replace the wheel.
3. More gap between the 4. Gap more than 3mm is unsafe.
wheel 5. Use grinding wheel of correct size.
and tool rest of bench grinder. 6. Training & instruction.
4. Improper /wrong size 7. Provide fire extinguisher.
grinding 8. Use fire blanket to cover nearby vents, drains and
wheel. open ends of pipes.
5. Excess pressure on wheel. 9. Application of mud plug prior to pipe after cold
6. Breakage of wheel. cutting.
10. Proper tightening of wheel.
11. Use of correct size spacer washers.
ACTIVITY - 15: USING ENGINE GENERATOR SET

1 Use of Engine 1.Improper earthing . 1. Electrical shock/ burn injury. 2 5 HIGH 4 1. Proper earthing.
Generator Set for 2. Improper insulation. 2. Fire/Explosion. 2. Adequate insulation (check).
ARC-welding. 3. Faulty appliances/control 3. Asphyxiation 3. Proper preventive maintenance.
system. 4. Poisoning. 4. Ventilation
4. Poor exhaust. 5. Periodical gas testing and monitoring at all areas.
5. Poor ventilation. 6. Prevent leakages. Check before use.
6. Hydrocarbons.
7. Oil leakages.
8. Toxic gases.
ACTIVITY - 16: HANDLING OF PORTABLE ELECTRICAL TOOLS

1 Working with 1. Damaged cable . 1. Electric shock. 3 4 MODERAT 3 1. Daily check up before start.
portable electric 2. Defective tool. 2. Spark /shock. E 2. Replace defective tools.
tools 3. Loose components (wheel, 3. Hit injury. 3. Proper maintenance.
switch) 4. Accident and injury. 4. Training on proper use & care.
4. Excess pressure on tool. 5. Bodily injury. 5. Inspection and corrective action to follow correct
5. Improper handling. 6. Shock/eye and bodily injuries. handling procedures.
6. Non use of PPE. 6. Use adequate PPE (Face shield/goggles, gloves)
PMPL/HSE/HIRA/01
Rev.01

ACTIVITY - 17: HANDLING PORTABLE HAND TOOLS
1 Working with 1. Defective / damaged tools 1. Accident and bodily injuries. 4 3 MODERAT 3 1. Replacing defective / damaged tools.
portable hand and tools without protective 2. Property damages. E 2. Use tools only with protective handles.
tools. handles. 3. Training & instruction to use right tool for the right
2. Improper handling. job.
3. Improper storage. 4. Keep tools only in toolboxes.
4. Misuse /abuse. 5. Training & instruction to use right tools for the right
job.
ACTIVITY - 18: GAS WELDING

1 Gas welding / 1. Welding radiates invisible 1. Radiation can damage eyes and 2 5 HIGH 4 1. Use specified shielding devices and other PPE of
cutting / heating. ultraviolet and infrared rays. skin. correct specifications.
2. Improper placement of 2. Explosion may occur. 2. Avoid throated tungsten electrodes for GTAW.
oxygen and acetylene 3. May cause fire. 3. Move out any leaking cylinder.
cylinders. 4. Cylinder may burst. 4. Keep trolley for transportation of cylinders and
3. Leakage /cuts in hoses. chain them .
4. Opening - up of cylinder. 5. Use flashback arrestors.
5. Welding of tanks, container 6. Purge regulators immediately and then turn off.
or pipes storing flammable 7. Never use grease or oil on oxygen line connections
liquids. and copper fittings on acetylene lines.
8. Inspect regularly gas carrying hoses.
9. Always use red hose for acetylene and other fuel
gases and blue for oxygen.
10. Always stand back from regulator while opening
the cylinder.
11. Turn valve slowly to avoid bursting.
12. Cover the lug terminals to prevent short circuiting .
13. Empty & purge them before welding.
14. Never attach the ground cable to tanks, container
or pipe storing flammable liquids.
15. Never use LPG for gas cutting.
PMPL/HSE/HIRA/01
Rev.01

ACTIVITY - 19: ARC WELDING
1 Arc welding 1. Radiation harmful to naked 1. Welder's cataract. 2 5 HIGH 4 1.Use welding shield / goggles.
eyes. 2. Burn injury. 2. Fireproof apron / gloves / screen.
2. Splinters / slag. 3. Lung ailments 3. Ventilation (local or exhaust if possible)
3.Toxic flames. 4. Dermatitis. 4. Full-sleeved coverall and gloves.
4. Dislocation / fall of job piece 5. Hit injury / crush injury. 5. Proper clamping system / material handling
due to faulty clamping. 6. Electric shock. techniques.
5. Loose connections / Loss of 7. Fire / explosion. 6. Use shock proof boots and hand gloves.
insulation. 8. Asphyxiation. 7. Provide earthing to the plant.
6. Flammable gases. 8. Periodical gas testing.
7. Poor ventilation 9. Keep fire extinguisher (DCP/CO2) standby.
10. Adequate ventilation.
11. Training & instructions.
ACTIVITY - 20: WORKING IN CONFINED SPACE

PMPL/HSE/HIRA/01
Rev.01
1 Working in 1. Suffocation / drowning. 1. Unconsciousness, death. 1 5 HIGH 4 1. Use respiratory devices, if required.
confined spaces 2. Presence of foul smell and 2. Inhalation can pose threat to life. 2. Avoid over crowding inside a confined space.
(tank, vessel, toxic substances. 3. Person may sustain burn injuries 3. Provide exhaust fans for ventilation.
static equipment, 3. Ignition/ flame can cause or 4. Do not wear loose clothes, neck ties, etc.
excavation fire. explosion may occur. 5. Fulfill conditions of the permit.
beyond 3m etc) 6. Check for presence of hydrocarbons and oxygen
level.
7. Obtain work permit before entering a confined
space.
8. Ensure that the connected piping of the equipment
which is to be opened is pressure free, fluid has been
drained, vents are open and piping is positively
isolated by a blind flange.
9. Check for hydrocarbon and Aromatic compounds
before entering a confined space.
10. Depute one person outside the confined space for
continuous monitoring and for extending help in case
of an emergency.
11. Keep the fire extinguishers at hand distance.
12. Remove surplus material and scrap immediately.
13. Do not smoke inside a confined space.
14. Do not allow gas cylinders inside a confined
space.
15. Use low voltage (24V) for hand held lighting.
16. Use tools with air motors or electric tools with max.
Voltage of 24V.
17.Remove all equipments at the end of the day.
S. No. ACTIVITY HAZARD CONSEQUENCE PROBABILITY SEVIRITY RISK LEVEL RISK CONTROL MEASURES
FACTOR FACTOR RATING
ACTIVITY - 21: MATERIAL HANDLING (MANUAL)
1 Material handling 1. Non-use of PPE. 1. Accident/ injury. 3 4 MODERATE 3 1. Use adequate PPE.
(manual) 2. Inadequate manpower. 2. Back pain, sprain,etc. 2. Provide adequate manpower for lifting of heavy
3. Lack of co-ordination in 3. Property damage. loads.
group effort. 4. Injury /property damage. 3. Training & instructions.
4. Wrong body posture. 5. Loss of property. 4. Use hand gloves/ packing materials.
5. Lifting error. 5. Remove protruding nails before handling.
6. Sharp edges / corners / 6. Use proper lifting devices for good grip.
projecting parts / protruding 7. Fasten the item properly or use suitable packing /
nails. container.
7. Slippery materials.
8. Loose materials.
ACTIVITY - 22: MATERIAL HANDLING (MECHANICAL)
PMPL/HSE/HIRA/01
Rev.01
1 Material handling 1. Lack of knowledge / skills. 1. Accident / injury. 2 4 MODERATE 3 1. Only competent and approved operator shall be
with forklift , crane 2. Defective equipment. 2. Material losses. deployed for equipment operations.
etc. 3. Defective lifting jacks. 3. Tilting of jacks / boom. 2. Equipment to be tested and certified by competent
4. Overloading. 4. Injury due to accident and property person before deployment.
5. Untrained operator. damage. 3. No overloading allowed.
4. Follow procedures.
5. Training and assistance of banksman / rigger.
ACTIVITY - 23: WORK AT HEIGHTS

1 Working at 1. Person can fall down. 1. May sustain sever injuries or prove 2 5 HIGH 4 1. Provide guard rails/ barricade at the work place.
elevated places. 2. Material can fall down fatal. 2. Use PPE like full body harness, life line, helmets,
2. May hit the scrap/ material stacked safety shoes, etc.
at the ground or in between. 3. Obtain the permit before starting the work at height
3. May hit the workers working at above 3m.
lower levels and prove fatal. 4. Fall arrest and safety nets, etc, must be installed.
5. Provide adequate working space (min.0.6m).
6. Tie / weld working platform with fixed support.
7. Use roof top walk ladder while working on a
slopping roofs.
8. Avoid movement on beams.
9. Keep the work place neat and clean.
10. Remove the scrap immediately.
11. Do not throw or drop materials or equipment from
height. i.e. do not bomb materials.
12. All tools to be carried in a tool- kit Bag or on
working uniform.
13. Remove scrap from the planks.
14. Ensure wearing of helmet by the workers working
at lower levels.

ACTIVITY - 24: WORKING UNDER CRANE / LIFTING EQUIPMENT.
1 Working under 1. Working without PPE. 1. Fatality / injury due to fall of loads. 2 5 HIGH 4 1. Use required PPE.
crane / lifting 2. Failure of slings. 2. Material damage. 2. Use only certified slings as per colour coding.
equipment 3. Improper handling. 3. No person to stand under lifted load.
4. Overloading. 4. Follow safe lifting procedures.
5. Defective equipment. 5. Only approved equipment to be used.
6. Lack of awareness. 6. Ensure prompt servicing.
7. Training to operator and providing banks man /
rigger for assistance.
ACTIVITY - 25 LOADING / UNLOADING ON TRUCK / TRAILER.

PMPL/HSE/HIRA/01
Rev.01
1 Loading and 1. Loaded material due to fall. 1. Accident / injury 1 5 HIGH 4 1. Follow lifting procedure.
unloading of 2. Defective equipment. 2. Damage of materials. 2. Use correct equipment & lifting tackles.
materials on 3. Overloading 3.Damage to equipment. 3. Supervision by competent persons.
trucks / trailers. 4. Provide trained banksman/rigger.
5. Do not jump out from vehicle till clearance is
obtained.
6. Proper supervision.
7. Refer to load chart.
8. Use platform ladder for safe access.
9. Never deactivate or de-energize over riding devices
on lifting equipment.
2 Loading near live 1. Live facilities / OH lines etc. 1. Fire 2 5 HIGH 4 1. Keep Safe distance from Live facilities.
facilities 2. Electric shock.
3. Injury.
4. Property Damage

ACTIVITY - 26: MATERIAL HANDLING WITH CRANE
1 Crane positioning 1. Outriggers on soft 1. Tilting of crane & consequent 3 4 MODERA 3 1. Outrigger base plates to rest on firm ground or on
ground/loose soil damage & loss. TE timber blocks/ steel plates
2 Operating of PTO 1. Operating levers not in 1. Inadvertent operation of crane on 4 MODERAT 3 1. Make sure control levers are all in neutral position
neutral position. engagement of PTO 2 E
PMPL/HSE/HIRA/01
Rev.01
3 Extending 1. Outriggers not extended 1. Tilting of the crane. 2 4 MODERAT 3 1. Extend outrigger fully.
outriggers fully 2. Retracting of outriggers & tilting of E 2. Lock the outrigger beam.
2. Outrigger not locked. the crane
5 Passage under 1. High tension electric current 1. Electric shock. 1 5 HIGH 4 1. No movement with raised boom
OH lines with . 2. Fall of load & tilting of crane. 2. Provide Banksman
raised boom 2. Traveling with load. 3. Do not travel with lifted load.
4 Loading 1. Side loading / dragging of 1. Tilting of the crane due to uneven 2 5 HIGH 4 1. Lifting only vertically.
operation load. load. 2. No dragging of load.
2. Overload. 2. Damage to crane and loss of 3. No overload.
3. Swinging the load. materials. 4. No swinging of load.
4. Abrupt operation of control 3. Instability & tilting of crane. 5. Operate the levers slowly and smoothly.
levers. 4. Jerking, fall of load, hitting 6. Do not keep the load in the elevated position.
5. Keeping the load in the person. 7. Do not allow any person to be under the load.
elevated position. 5. Fall of load due to mechanical 8. No movement with raised boom.
6. Persons standing below the failures. 9. Provide Banksman.
lifted load. 6. Fall of load causing human 10. Do not travel with lifted load.
injuries.
7. Electric shock.
8. Fall of load & tilting of crane.

S. No. ACTIVITY HAZARD CONSEQUENCE PROBABILIT SEVIRITY RISK RISK CONTROL MEASURES
Y FACTOR FACTOR LEVEL RATING
ACTIVITY - 28: HANDLING OF GAS CYLINDERS

PMPL/HSE/HIRA/01
Rev.01
1 Transporting gas 1. Cylinders kept horizontal. 1. Fire and explosion by leakage 2 5 HIGH 4 1. Keep charged cylinder only.
cylinders: 2. Cylinder kept untied and 2. Keep vertically and tie with chain to a fixed
* Oxygen /unlocked in welding truck property damage. structure.
* Acetylene. /mobile welding unit. 2. Gas leakage due to valve 3. Keep in specially fabricated cage to prevent fall.
* Argon. 3. Valve leakage. damage. 4. Keep valve cap in position during transportation.
* Nitrogen. 3. Human injury by fall of cylinder. 5. Different types of gas cylinders not to be loaded in
* LPG. 4. Damage to cylinder/valve. the same vehicle at a time.
5. Leakage of gas. 6. Only authorized vehicle and specially trained driver
shall be engaged in gas cylinder transportation.
7. Do not use leaking cylinder.
8. Keep cylinder tied up/chained & locked
independently on truck to prevent falling of one
cylinder while loading/unloading the other.

No. ACTIVITY HAZARD CONSEQUENCE FACTOR FACTOR RISK RATING CONTROL MEASURES
LEVEL
PMPL/HSE/HIRA/01
Rev.01
ACTIVITY - 31: ERECTION, DISMANTLING AND WORKING ON SCAFFOLDING
1 Scaffolding 1. Improper manual handling. 1. Personal injuries. 2 5 HIGH 4 1. Train on proper manual lifting procedures.
erection 2. Fall of scaffolding materials. 2. Material damage. 2. Use only tested and certified equipment & lifting
3. Hitting. 3. Collapse of scaffolding and fall of tackles.
4. Defective lifting equipment / persons. 3. Erection only by experienced persons under
improper use. supervision of a competent person.
5. Faulty erection. 4. Daily inspection and certification by competent
person.
5. PTW in place.
2 Working on 1. Defective scaffolding. 1. Injury due to fall. 1 5 HIGH 4 1. Daily inspection & certification by competent
scaffolding 2. Improper use. person.
3. Faulty access to platform. 2. Training & supervision.
4. Inadequate size of platform. 3. Provide access (Ladders or Stairs_ as per
5. Overloading. specification.
6. Faulty / unguarded access 4. Adequate size as per job requirement.
ladder/stairs 5. No overloading permitted.
5. Only minimum number of persons allowed to work at a
time.
3 Dismantling 1. Fall of persons. 1. Fatality / injury. 1 5 HIGH 4 1. Follow dismantling procedures.

scaffolding 2. Fall of scaffolding materials. 2. Do not allow persons to be under the scaffolding
3. Fall of hand tools (hammer structure.
etc.) 3. Use PPEs (helmet, gloves)
4. Keep tools in proper holder.
ACTIVITY - 32: STRUCTURAL WORKS

1 Structural works 1. Personal negligence and 1. Can cause injury or casualty. 4 5 HIGH 4 1. Do not take rest inside rooms built for welding
danger of fall. machines or electrical distribution system.
2. Lifting / slipping of material 2. Avoid walking on beams at height.
3. Wear helmet with chin strap and full body harness
while working at height.
4. Use hand gloves and goggles during grinding
operations.
5. Cover or mark the sharp and projected edges.
6. Do not stand within the operation radius of cranes.
7. Do not stand under the lifted load.
8. Stack properly all the materials .Avoid slippage
during handling.
9. Control longer pieces lifted by cranes from both
ends with guidelines.
10. Remove loose materials from height.
11. Ensure tightening of all nuts & bolts.

PMPL/HSE/HIRA/01
Rev.01
ACTIVITY - 33: PIPELINE WORKS
1 Pipe laying 1. Erection/ lowering failure. 1. Can cause injury. 4 5 HIGH 4 1. Do not stand under the lifted load.
2. Others 2. Can cause injury. 2. Do not allow any person to come within the radii of
the side boom handling pipes.
3. Check the load carrying capacity of the lifting tools
and tackles.
4. Use safe Load Indicators.
5. Use appropriate PPEs.
6. Wear gum boots in marshy areas.
7. Allow only one person to perform signaling
operations while lowering the pipes.
8. Provide night caps on pipes.
9. Provide end covers on pipes for stoppage of pigs
while testing / cleaning operations.
ACTIVITY - 34: WORKING IN HOT ENVIRONMENT

1 1. Working in hot 1. Heat stress due to failure of 1. Heat ailments such as heat 2 4 MODERAT 3 1. Drink plenty of cold water.
environment. thermo-regulatory system of exhausting, heat cramps and heat E 2. Intermittent rest under shades.
2. Hot work such the stroke. 3. Eating more vegetables and fruit items.
as welding, body. 4. Provide shade for work in static posture (welding).
cutting, 2. Dehydration due to excess 5. Appropriate PPE to protect body against direct
heating, cooking, loss of body fluids. exposure to heat or hot sun.
etc.
ACTIVITY - 35: WORKING IN DUSTY ENVIRONMENT

1 Working in dust 1. Dust (Inhalation and striking 1. Lung disorders (silicosis) and eye 5 1 MODERAT 3 1. Sprinkle water to suppress dust generation wherever
the eye) injury. E possible.
2. Use PPE (dust mask, goggles)
PMPL/HSE/HIRA/01
Rev.01
ACTIVITY - 36: WORKING DURING NATURAL CALAMITIES
1 Working / driving 1. Flood. 1. Drowning and washing away in 1 5 HIGH 4 1. Do not go into flood.
during natural 2. Fog. flood water. 2. No driving of vehicles in fast flowing water.
calamities. 3. Storm / high wind. 2. Injury /fatality due to hitting or 3. Ascertain the depth of water and the firmness of the
vehicle accident. road surface.
3. Injury due to collapse of buildings. 4. Keep on elevated terrain till flood subsides.
5. Vehicle /equipment movements only in clear vision.
6. Drive slowly with head lights and wipers on.
7. Sufficient anchoring of office cabins.
8. Outside doors fitted with auto hinges.
ACTIVITY - 37: STAY IN CAMPS

1 Staying in 1. Biological hazards (Malarial 1. Ill health. 2 4 MODERAT 3 1. Prompt disposal of wastes, concealment of
residential camps mosquitoes, contaminated E drainage.
water / food stuff) 2. Use of insecticides.
3. Ventilation in living accommodation.
4. Keeping food wastes in garbage bags/closed
buckets and prompt disposal to the food waste to
dump yard as per Waste Management Plan.
5. Dead slow driving in camp premises.
6. No night driving.
7. Extremely cautious against crossing of stray
animals.
8. Do not cause harm to any livestock.
9. Observe warning signals on roads against stray
animals.
PMPL/HSE/HIRA/01
Rev.01
ACTIVITY - 38: SLIPS, TRIPS AND FALLS AT WORK PLACE.
1 Moving in the 1. Timbering blocks, wooden 1. Bodily injury due to fall of 3 4 MODERAT 3 1. Remove all timber blocks, planks, pipe pieces etc
work area. planks, steel rod bits. persons, E immediately after use to the designated place.
2. Pipe pieces. fall of heavy objects, tools etc. 2. Do not keep objects / tools etc at heights without
3. Protruding bolts on 2. Hitting on overhead projections. safe containment against fall.
concrete 3. Provide barricading with warning tags.
foundations of pipe supports. 4. Provide plastic/soft material cap to projecting pipes
4. Paint tins, polythene and warning tags to caution the workers.
papers, 5. Maintain good housekeeping by frequent
electric cable/wire insulations, appraisals, supervision, inspection, audit and follow
steel wire insulations, steel up.
wire
cuttings, tools & tool boxes.
5. Overhead projection of
pipes.
ACTIVITY - 39: FIRE PREVENTION AND PROTECTION
1 Fire prevention 1. Small fires can become big 1. Cause burn injuries and may 3 4 HIGH 4 1. In case a fire breaks out, press fire alarm system
and protection ones and may spread to the prove and shout "Fire, Fire".
surroundings areas. fatal. 2. Keep buckets full of sand and water / fire
2. Improper selection of Fire 2. Complete extinguishment of fire extinguishers in all hazardous locations.
extinguishers. may not be possible. 3. Confine smoking to 'Smoking Zones' only.
3. Short circuiting of electrical 3. Can cause electrocution 4. Train people for using specific type of fire
system. equipments under different classes of fire.
5. Maintain good housekeeping and first -aid boxes.
7. Don't obstruct access to fire extinguishers.
ACTIVITY - 40: LAYING ELECTRICAL CABLES

1 Laying out 1. Unstable Cable drum. 1. Fatality / service injury due to fall 4 5 HIGH 4 1. Cable shall be handled by experienced persons.
electrical cables 2. Wrong position of jack. of 2. Adopt proper procedure.
(Cable drum 3. Inadequate jack / spindle. cable drum or jack. 3. Use only tested and certified jack and spindle.
handling) 4. Defective jack / spindle. 2. Injury by hitting / caught in. 4. Keep fingers away from nip points.
5. Rotating parts. 3. Finger injury due to trapping 5. Use hand gloves.
6. Drum rollers. between drum / rollers. 6. Tool box meeting.
7. Pulling in wrong posture. 4. Serious injury due to slip & fall of 7. Proper position.
8. Open trench. cable. 8. Trained person.
9. Theft. 5. Loss of cable. 9. Use cable roller.
10. Planning
11. Keep cable-laid trenches backfilled before leaving
site.
PMPL/HSE/HIRA/01
Rev.01
ACTIVITY - 43: WORKING NEAR OVERHEAD LINES
1 Working near 1. Live lines. 1. Electrocution (fatality / severe 2 5 HIGH 4 1. PTW in place.
overhead lines. injury) 2. Use guide rope for lifting load.
2. Damage to equipment and 3. Avoid working if lightning threat is suspected.
property. 4. Work area shall be clearly identified before start of
3. Fire / Explosion. work.
ACTIVITY - 44: ELECTRICAL INSTALLATION

1 Electrical 1. Short circuiting. 1. Can cause Electrocution or Fire. 4 5 HIGH 4 1. Use rubberized hand gloves and other PPE.
installation works 2. Overloading of Electrical 2. Bursting of system can occur 2. Don’t lay wires above ground or under carpets,
System which mats or door ways. Lay cables overhead or buried.
leads to fire 3. Allow only licensed electricians to perform on
electrical facilities.
4. Use only approved and insulated wires or cables.
5. Don't place bare wire ends in a sockets. Use
Plug tops.
6. Ensure earthing of all machines and equipments.
7. Do not use damaged cords and avoid temporary
connections.
PMPL/HSE/HIRA/01
Rev.01
ACTIVITY - 46: DRIVING / OPERATING VEHICLES & EQUIPMENTS
1 Driving /operating 1. Lack of knowledge and 1. Fatality / injury. 2 5 HIGH 4 1. Only authorized persons to be deployed for driving /
vehicles/ skill. 2. Loss of property / material. equipment operation.
equipment 2. Untrained drivers / 3. Damage to equipment. 2. Training / refresher training to drivers / operators.
operators. 3. Use of appropriate vehicles /equipments.
3. Defective vehicles / 4. Inspection & supervision.
equipments. 5. Provide banksman as appropriate.
4. Over speed / overload.
2 Driving on 1. Loose surface, erosion, pot 1. Injury / fatalities due to accidents. 1 5 HIGH 4 1. Provide speed limiters.
graded roads holes. 2. Use tyres with a minimum of 2 mm tread.
3. Drive with dipped headlights and high intensity
lights on.
3 Speed driving 1. Crossing the speed limits 1. Personnel injury 3 4 HIGH 4 1. Obey speed limits and traffic rules strictly.
(Rash driving) 2. Always expect the unexpected and be a defensive
driver.
3. Use seat belts/ helmets.
4. Blow horn at intersections and during overtaking
operations.
5. Maintain the vehicle in good condition.
6. Do not overtake on curves , bridges and slopes.
4 Driving in 1. Adverse weather condition. 1. Personnel injury. 4 5 HIGH 4 1. Read the road ahead and drive to the left.
adverse condition 2. Falling objects/ Mechanical 2. May prove fatal 2. Keep the wind screen and lights clean.
failure 3. Do not turn at speed.
4. Recognize the hazard, understand the defense and
act correctly in time.
5. Ensure effective braking system, adequate visibility
for the drivers, reverse horn.
6. Proper maintenance of the vehicle as per
manufacturer's instructions.
5 Drunken Driving 1. Consuming alcohol before 1. Accident 4 5 HIGH 4 1. Alcohol and driving do not mix well. Either chooses
and during the driving 2. Personal injury alcohol or driving.
operation 2. If you have a choice between hitting a fixed object
or an on-coming vehicle ,hit the fixed object.
3. Quit the steering at once and become a passenger.
Otherwise take sufficient rest and then drive.
4. Do not force the driver to drive fast and round the
clock.
5. Do not day dream while driving.
PMPL/HSE/HIRA/01
Rev.01

ACTIVITY - 50: OPERATION OF COMPACTOR

1 1. Starting by 1. Inadvertent contact with 1. Accidents. 2 4 MODERAT 3 1. Pull the string gently avoiding contact or hit against
pulling up with vibrator. 2. Damage. E compactor or nearby personal.
string. 2. Rotating parts. 2. Guarding.
2. Running 3. Fall. 3. Hold firm and move slowly.
compactor
ACTIVITY - 51: OPERATION OF CRANE

1 Operation of 1. Inadvertent movement of 1. Accidents. 1 5 HIGH 4 1. Make sure PTO levers are in neutral position
Power Take Off crane 2. Damage.
(PTO)
2 Positioning 1. Outriggers can sink in soft 1. Lifting of vehicle. 1 5 HIGH 4 1. Crane must be set on firm ground. On soft ground
outrigger. ground. 2. Tilting of vehicle. place strong wooden blocks or steel plates on ground
2. Improper extinction of the 3. Physical injury. and set outriggers on them.
outriggers. 4. Equipment damage. 2. Extend the outrigger beam fully as far as possible
3. Improper locking of 5. Material damage. during operation.
outriggers. 3. Be sure to lock the outrigger beams with lock pins.
3 Locking 1. Side loading or 1. Cause serious damage to 1 5 HIGH 4 1. Avoid side looking or dragging loads.
operation. dragging of equipment. 2. Strict adherence to SWL.
loads will exert extra load on 2. Crane becomes unstable & 3. Ensure crane is installed with safety limits.
crane. causes 4. Move the levers in a slow manner.
2. Excess load. accident. 5. Attention on operation.
3. Abrupt load. 3. Electrocution 6. Do not allow workers to stand within the working
4. Careless radius.
4 Inspection of 1. Damaged or less turns of 1. Cause serious accidents 1 5 HIGH 4 1. Inspect rope for any damage or twist and replace in case
winch rope. winch rope. of any damage.
5 Travelling 1. Travelling with lifted load. 2. 1. Unstability. 2 4 MODERAT 3 1. While travelling, disengage PTO.
Travelling with engaged PTO. 2. Causes serious accidents E
6 Signals 1. Improper signs 1. Leads to confusion and accidents. 2 4 MODERAT 3 1. Competent banksman to be detailed for signals.
E
PMPL/HSE/HIRA/01
Rev.01

ACTIVITY - 53: OPERATION OF VIBRATOR

1 Starting by 1. Inadvertent contact with 1. Injury. 2 4 MODERAT 3 1. Pull the string gently avoiding contact or hit against
pulling up with vibrator. 2. Contact with body. E vibtator or nearby personnel.
string 2. Rotating parts. 3. Damage. 2. Guarding.
Kick back of hose. 4. Burn hazard. 3. Hold the hose firm while vibration is in use.
3. Cement splash. 4. Keep in safe place.
4. Fall of vibrator into 5. Keep away from naked flames.
excavation concreting location. 6. Keep DCP Fire Extinguisher ready.
5. Fire hazard
PMPL/HSE/HIRA/01
Rev.01

ACTIVITY - 54: REMOVAL AND REFITTING OF GEAR BOX
1 Cleaning the 1. Slip hazard. 1. Physical injury. 2 4 MODERAT 3 1. Person cleaning should wear protective clothes like
vehicle for 2. Injury due to high pressure 2. Burn injury. E gum boots, face shield, hand gloves & helmet.
removal of gear water hose. 3. Vehicle damage 2. Clear the floor from oil and grease.
box. 3. Hit hazard. 3. Vehicle is to be parked on level ground with all four
4. Vehicle can roll. wheel chokes.
5. Hot surface. 4. First make the pressure hose straight & hold the
spray nozzle in hand away from self & others.
5. Make sure that the washing is not done on hot
surface.
2 Parking vehicle 1. Vehicle rolling of. 1. Physical injury. 2 4 MODERAT 3 1. Arrest all wheels with chokes, apply hand brake,
for the job. 2. Vehicle under a live 2. Vehicle damage. E remove ignition key & remove battery terminal.
mechanism 3. Material damage. 2. Put the caution boards indicating off road.
3. Select correct & good tool for specific job.
4. Authorized trolley jack by competent person should
be used.
3 Removal of 1. Material falling. 1. Damage to the parts. 2 4 MODERAT 3 1. Deploy a competent / experienced workman for this
propeller shaft 2. Handling hazards. 2. Physical injury E work.
2. Use trolley jack for removal of propeller shaft.
4 Removal of gear 1. Tilting & falling of gear box. 1. Damage to engine. 2 4 MODERAT 3 1. Use inspected / authorized trolley.
box 2. Physical injury. E 2. After unloading, tie the gear box with chain to jam
platform to avoid the tilting and falling.
3. Pull out the jack outside vehicle and remove the
gear box to working place.
5 Re-fixing of gear 1. Material handling. 1. Back strain. 2 4 MODERAT 3 1. Use inspected or authorized trolleys.
box 2. Falling. 2. Physical injury. E 2. Deploy experienced persons.
3. Trapping of fingers. 3. Damage to engine. 3. Strict supervision.
4. Gently push the gear box under the vehicle to
position.
5. During transportation tie the parts with the trolley
jacks.
6. Re-check all nuts & bolts of gear box, fly wheel
housing, gear shaft mechanism.
PMPL/HSE/HIRA/01
Rev.01

ACTIVITY - 55: CHANGING OF ALTERNATOR

1 Prepare a vehicle 1. Rolling of vehicle. 1. Physical injury . 2 4 MODERAT 3 1. Park the vehicle on even and hard surface.
for replacing 2. Hit. 2. Vehicle injury E 2. Choke all the four wheels.
alternator. 3. Apply hand brake.
4. Remove ignition key.
5. Deploy a skilled electrician for the work.
2 Removing of 1. Manual handling . 1. Physical injury. 2 4 MODERAT 3 1. Disconnect battery terminal, - ve terminal first &
alternator. 2. Sparking 2. Vehicle damage. E then + ve terminal.
3. Material damage. 2. Use right tools.
3. Remove belt & alternator.
3 Disassembly & 1. Material handling. 1. Personal injury. 1 4 MODERAT 3 1. Use proper, goods tools.
assembly of 2. Fire hazard. 2. Vehicle damage. E 2. Do the work with trained person.
alternator. 3. Use rubber hand gloves, while using cleaning
components.
4 Testing of 1. Nip hazard. 1. Physical injury. 1 4 MODERAT 3 1. Fit the alternator correctly with motor for testing .
Alternator 2. Electrical shock. 2. Fire causes damage to materials. E 2. Check the correct connection of terminals.
3. Fire hazard
5 Fitting alternator. 1. Hit against short circuit . 1. Head injury. 2 4 MODERAT 3 1. Fix alternator properly.
2. Fire 2. Electrical shock. E 2. Check the correct terminals connections.
3. Material loss. 3. Cross check the alternator function in presence of
electrician.
PMPL/HSE/HIRA/01
Rev.01

ACTIVITY - 56: CHANGING OF HEAVY VEHICLE WHEEL
1 Parking vehicle 1. Rolling vehicle. 1. Personal injury. 2. Vehicle 2 4 MODERAT 3 1. Park the vehicle on an even, hard ground without
for removal of damage. E obstruction.
tyre. 2. Barricade vehicle boarder.
3. Prove wooden chock on 4 wheels and apply hand
brake.
2 Handling tools. 1. Slip. 1. Personal injury. 3 4 MODERAT 3 1. Select appropriate tools such as pneumatic box,
2. Hit. 2. Hit hazard E spanner
3. Fall. 2. Test heavy duty trolley jack special lever and
4. Tyre roll over pressure gauge.
3 Removal of 1. Slip. 1. Personal injury. 1 4 MODERAT 3 1. Ensure that jack is of correct capacity.
wheel from the 2. Hit. 2. Back sprain. E 2. Check any oil / pressure leaks.
vehicle 3. Fall. 3. Vehicle damage. 3. Provide wooden blocks after lifting to a suitable
4. Tyre roll over height.
4. Remove the wheel carefully.
5. Roll the tyres carefully with the help of others.
ACTIVITY - 57: TOWING OF DEFECTIVE VEHICLE

1 Assess the 1. Hot surfaces. 1. Physical injury. 1 4 MODERAT 3 1. During inspection do not touch any hot spots. Allow
causes of break 2. Inadvertent movements. 2. Heat burn. E it to cool.
down. 3. Hit hazard. 3. Vehicle damage / injury. 2. Choke all 4 wheels & apply the hand brake.
3. Retain the key of the vehicle before going out of
vehicle.
2 Prepare the 1. Defective movable parts. 1. Nip hazard. 1 4 MODERAT 3 1. If the transmission is found defective, remove the
vehicle for 2. Improper towing devices / E drive shaft connecting engine to gear box and gear
towing. hook / chain. box to differential.
2. If steering system is damaged or axle assembly is
defective the vehicle is to be bought by towing.
3. Proper towing bar is to be used to tow a vehicle.
PMPL/HSE/HIRA/01
Rev.01
3 Towing 1. Defective brake . 1. Accident. 2 5 HIGH 4 1. Ensure the vehicle to be towed is having enough
2. Defective hazard light. braking power.
3. Taking sharp turns and 2. Check the hazard light & horn is working.
sudden stops. 3. Avoid abrupt starting & stopping.
4. While towing, make sure that close contact is
maintained between both the drives.
5. Towing to be at low speed.
6. Make sure that the gear shift level on the vehicle to
be towed is in the neutral position.
7. Towing should be done straight as far as possible.
4 Towing 1. Improper method & 1. Vehicle accident. 2 5 HIGH 4 1. After deciding to carryout the tow, select the vehicle
equipment to carryout towing 2. Brake down of the towing vehicle. capacity to be towed.
2. Lack of pilot vehicle at the 2. Provide pilot vehicle if hazard light is not working.
rear in case of no hazard light 3. The towing vehicle should have the capacity of
from towed vehicle. lifting the broken down vehicle with valid test
3. Vehicle capacity & validity certificates.
certificate. 4. No passenger is to be carried out in the cabin at the
4. Carrying passengers inside rear of the towed vehicle.
the towed vehicle. 5. Towed vehicle is to be properly locked with the
towing to avoid collision on braking and turning.
6. Co- passenger should guide the drive of towing
vehicle.
PMPL/HSE/HIRA/01
Rev.01

ACTIVITY - 58: SPRAY PAINTING
1 Washing 1. Slip hazard. 1. Physical injury. 3 4 LOW 3 1. Keep the area clean of loose materials like wooden
Vehicle/ 2. Flying objects 2. Vehicle damage. skids, pipe pieces, etc.
equipment 3. Vehicle rolls. 3. Hot burns. 2. Clean the floor free of oil, grease and mud.
thoroughly by 4. High pressure hose. 4. Cuts. 3. Vehicle wheels to be checked.
steam or high 5. Hot surface. 5. Material damage. 4. Seal the hydraulic and fuel tanks before washing.
pressure water. 6. Sharp corners. 5. Make sure that washing is not done on hot engine
7. Electrical contacts. or any other hot parts of vehicles.
7. Keep the water hose after winding in a proper place.
2 Preliminary jobs 1. Vehicle roll over. 1. Physical injury. 2 4 MODERAT 3 1. Vehicle to be parked with four wheels choked with
before vehicles / 2. Lack of space around the 2. Hit against. E wooden pieces.
equipment vehicle. 3. Suffocation. 2. Enough space for movement & for escape during
painting. 3. Slip hazard. 4. Burn injury. emergency.
4. Health hazard due to 5. Dermatitis. 3. Proper ventilation by providing exhaust fans &
painting. 6. Electric shock. exhaust hoods.
5. Fire hazard. 4. Flame proof light fittings / exhaust fans.
6. Fall. 5. No smoking in the area.
7. Handling putty. 6. Available of fire extinguishers.

8. Dust. 7. No unauthorized entry into the painting area.
9. Electrical Hazard. 8. Approved electrical tools should be used.
10. High pressure hose. 9. Compressed air lines should be handled with care.
10. Use proper, approved scaffolds with platform &
hand rails.
3 Spray painting 1. Fire hazard. 1. Burn injury. 3 4 MODERAT 3 1. Cordpn off the area and place sign boards.
2. Fall. 2. Physical injury. E 2. Strictly no smoking.
3. High pressure air line. 3. Dermatitis. 3. Wear respiration protection.
4. Solvent contact with skin. 4. Pulmonary disorders. 4. Effective exhaust system.
5. Inhaling of paint vapours 5. Compressed air hoses should be handled carefully.
and 6. Use authorized scaffolds for painting.
dust. 7. No unauthorized entry into this area.
PMPL/HSE/HIRA/01
Rev.01

ACTIVITY - 59: WIRE ROPE REPLACEMENT (CRANE)

1 Parking the crane 1. Inadvertent movement 1. Accident 3 4 MODERAT 3 1. Select open place, level area, hard surface away
2. Physical injury. E from traffic.
3. Equipment damage 2. Barricade and keep warning signs.
2 Cleaning. 1. Slipping & Falling. 1. Personal injury. 1 4 MODERAT 3 1. Proper housekeeping.
E
3 Tools. 1. Improper tools, broken / 1. Personal injury. 3 4 MODERAT 3 1. Special tools recommended by manufacturer to be
damage tools slipping can E used.
cause severe injury.
4 Shifting new rope 1. Toppling of forklift. 1. Personal injury. 2 4 MODERAT 3 1. Deploy only trained persons.
drum. 2. Machine damage. E 2. Load to be handled with specified S.W.L of forklift.
3. Equipment damage. 3. S.W.L. to be tested & certified by competent
4. Personnel injury. persons.
5. Equipment damage. 4. Load shall not be lifted so high which obstructs the
vision.
5 Transportation of 1. Boom hits on object / 1. Personal injury. 3 4 MODERAT 3 1. Obstruction shall be checked before lowering.
drum to site by personal. 2. Material damage. E 2. No personnel shall be present near the boom.
fork lift / crane 2. Electrical contact. 3. Do not operate crane without outrigger / banksman.
truck. 3. Handling hazard.
6 Removal of 1. Entangling of wire rope. 1. Electrical shock. 2 4 MODERAT 3 1. Disconnect main switch & remove the ignition key.
damaged cable 2. Damage to equipment . E 2. Wear safety helmets, goggles, shoes, gloves.
from drums. 3. Ensure no tension in the wire rope.
4. With proper banksman signal wire rope has to be
removed carefully.
5. Engine to be stopped after removal of wire rope.
6. Make sure rope is not under tension.
7 1. Dismantling of 1. Whip lashing. 1. Damage to equipment. 1 4 MODERAT 3 1. Tie the wire rope with nylon cord & tie to the nearby
wire rope from 2. Personal injury. E frame.
the drum. 2. Safe drawing of cable out.
8 1. Assembly of 1. Handling hazard. 1. Personal injury. 1 4 MODERAT 3 1. Lift the cable drum with forklift or crane truck and
wire rope 2. Slip hazard. 2. Damage to machine. E mount it on a proper rope drum stand.
3. Falling hazard. 2. Strict supervision.
PMPL/HSE/HIRA/01
Rev.01

ACTIVITY - 60: HANDLING AND LIFTING EUIPMENTS (GENERAL)
1 Handling and 1. Failure of load lifting and 1. Can cause accident and prove 3 4 HIGH 4 1. Avoid standing under the lifted load and within the
lifting equipments moving equipment. fatal. operating radius of cranes.
2. Overloading of lifting 2. Can cause electrocution and fire 2. Check periodically oil, brakes, gears, horns and tyre
equipments. pressures.
3. Overloading electrical wires 3. Check size and condition of all chain pulley blocks,
slings, U-clamps, D- shackles, wire ropes etc.
4. Allow crane to move only on hard, firm and leveled
ground.
5. Allow lifting slings as short as possible and check
gunny packing's at the friction points.
6. Do not allow crane to lift its boom while moving.
7. Install Safe Load Indicator.
8. Ensure load test certification by competent
authority.
9. Safe lifting capacity of winches written on them
shall be followed.
10. The max. Safe working load shall be marked on all
the lifting equipments.
11. Check the weight of columns and other heavy
items painted on them and accordingly decide about
the crane capacity, boom and angle of erection.
12. Allow only trained operators and riggers during
crane operation.
13. Do not allow the boom or other parts of crane to
come within 3m reach of overhead HT cables.
14. Hook and load being lifted shall preferably remain
in full visibility of Riggers and Operators.
PMPL/HSE/HIRA/01
Rev.01

ACTIVITY - 61: BATCHING PLANT OPERATION

1 Moving parts of 1. Hit by machine to workers 1. Physical Injury 2 4 MODERAT 3 1. Proper enclosure of all moving parts of machines.
Batching Plant working nearby. E 2. Only trained and experienced workmen should be
permitted for operation.
2 Loading of 1. Health Hazard 1. Silicosis, Pneumonia, Headache 5 2 Low 2 1. Enclosure around input hopper of Batching plant, to
cement into 2. Health hazard due to etc. contain cement dust spread.
hopper generation of cement dust. 2. Eye irritation 2. Water sprinkling in the area
3. Use of Dust Masks and safety goggles.
3 Transporting of 1. Hit by Machine to the 1. Physical Injury 2 2 TOLERABL 1 1. Deployment of Banksman

Materials workers. 2. Eye irritation E 2. Trained drivers and workers
2. Health Hazard due to 3. Breathing problems 3. Use of PPEs (Dust mask and Safety Goggles)
generation of dust. 4. Water Spraying in the area.
4 Handling of 1. Crush of hands and fingers 1. Hand/Fingure injury 2 3 TOLERABL 1 1. Deploy trained workers
Plastic Drums between drums 2. Eye injury E 2. Use PPEs, like handgloves, safety goggles
2. Splash of chemicals
PMPL/HSE/HIRA/01
Rev.01

ACTIVITY - 64: PRECAST YARD OPERATIONS

1 Manual Bar 1. Cut / Crush while bending 1. Physical Injury 2 3 LOW 2 1. Proper type of tools.
bending 2. Deploy experienced Persons.
3. Use of hand gloves.
4. Concentration of the job, no horseplay.
2 Machine Bar 1. Unguarded / Improper 1. Physical Injury. 3 3 LOW 2 1. Proper Guarding of the moving parts.
bending Guard 2. Damage to the machine. 2. House keeping in the area.
of the machine 3. Shock. 3. Provision of emergency switch.
2. Defective Machinery. 4. Trained and experience persons.
3. Electric shock. 5. Proper Earthing and daily inspection of electrical
connections.
5. Proper Insulation.
6. PPE usage.
3 Shuttering / 1. Unsafe / Improper 1. Physical Injury 3 3 LOW 2 1. Watch and Keep away from protruded nails.
Handling of Handling. 2. Eye injury. 2. Secure the shutters properly and rigidly.
Wooden planks 2. Protruded nails. 3. Use Safety Shoes and Hand Gloves.
and supports. 3. Poor Housekeeping. 4. Maintain Housekeeping.
4. Hit by hammer. 5. Use Safety goggles.
5. Flying nails. 6. Maintain hand tools like hammers and their handles
in good condition.
4 Cutting Wood to 1. Unauthorized use of cutting 1.Physical Injury 3 3 LOW 2 1. Deploy trained carpenter.
required size machine. 2. Electric Shock. 2. Unauthorized use shall be strictly prohibited.
2. Fall of tools & wood on foot. 3. Short Circuit. 3. Use of hand gloves & goggles.
3. Improper Electrical 4. Use of Plug tops.
connections. 5. Proper Insulation at joints.
5 Preparation of 1.Flying nails while 1. Eye injury. 3 4 MODERAT 3 1. Wear Safety goggles.
shuttering on hammering. 2.Use of loose 2. Flying hammer hitting body parts. E 2. Ensure that hammer handle is properly welded &
ground. hammer. 3. Tripping hazard 3. Foot injury by spilled nails in the hammer is in good condition.
area. 3. Maintain good housekeeping.
4. Carry Tools in boxes and collect nails in bins.
6 De shuttering 1.Fall of shuttering. 1. Physical Injury. 2 3 LOW 2 1. Deploy experienced workers.
and deshoring 2.Protruding nails 3.Loose 2. Maintain good housekeeping in the area.
nails on floor. 3. Collect remove nails in bins and stack shuttering
materials properly.
PMPL/HSE/HIRA/01
Rev.01
7 Loading & 1. Fall of loaded material. 1. Physical Injury. 1 5 HIGH 4 1. Follow lifting plan and procedure.
unloading of 2. Defective equipment. 2. Damage of equipment and 2. Use correct equipments and certified lifting tools.
precast materials 3. Failure of Lifting Tools and material. 3. Provide trained Rigger.
on tractors/ Tackles 4. Do not jump out from vehicle till clearerance is
Trailers. 4. Overloading. obtained.
5. Carrying out lifting operations under complete
supervision.
6. Follow load chart.
7. Use platform/ladder for safe access.
8 Shifting of precast 1.Failure of Equipment. 1. Serious physical Injury. 1 5 HIGH 4 1. Follow lifting procedure.
beams with gantry 2. Failure of Lifting Tools and 2. Damage of materials. 2.Use correct equipment and certified lifting tools.
crane. Tackles. 3. Damaged of equipments. 3. Provide trained foreman/Rigger.
3. Persons working near the 4. Electric Shock and Short circuit. 4. Complete gantry to be tested by third party
moving crane. (competent person ).
4. Electrical short circuit. 5. Proper supervision.
6.Follow load chart.
7. Use platform/ladder for safe access.
8. Inspection of gantry and lifting tools and tackles,
everyday before commencement of operations as per
check list.
9 Moving in the work 1. Hit by wooden planks and 1. Physical injury due to fall of 3 4 MODERATE 3 1. Remove all planks, pipes pices etc. and stack
area. steel rods. persons, fall of heavy objects, tools properly.
2. Struck by protruding bolts. etc. 2. Do not keep objects/tools etc. at height/on the way.
3. Slip and trip hazard by Loose 2. Hitting of overhead protection. 3. Provide barricading with caution tags.
electrical cables laying on 4. Maintain good housekeeping.
ground.
10 Concreting REFER ACTIVITY - 4: CONCRETING

PMPL/HSE/HIRA/01
Rev.01

ACTIVITY - 65: FABRICATION YARD OPERATIONS
1 Grinding and 1. Absence of tool rest on 1. Eye / face injury 3 4 MODERAT 3 1. Use proper PPE. ( Face shield )
grinding wheel bench grinder. 2. Hand injury E 2. Mount the tool rest on both sides.
replacing. 2. More gap between the 3. Gap more than 3mm is unsafe.
wheel 4. Use grinding wheel of correct size.
and tool rest of bench grinder. 5. Training & instruction.
3. Improper/wrong size 6. Provide fire extinguisher.
grinding 7. Proper tightening of wheel.
wheel. 8. Use of correct size spacer washers.
4. Excess pressure on wheel.
5. Breakage of wheel.
2 Working with 1. Damaged cable. 1. Electric shock. 3 4 MODERAT 3 1. Daily check up before start.
portable electric 2. Defective tool. 2. Spark/shock. E 2. Replace defective tools.
tools 3. Loose components (wheel, 3. Physical injury. 3. Proper maintenance.
switch) 4. Training on proper use & care.
4. Excess pressure on tool. 5. Inspection and corrective action to follow correct
5. Improper handling. handling procedures.
6. Non use of PPE. 6. Use adequate PPE (Face shield/goggles, gloves)
3 Gas welding / 1. Backfiring. 1. Fatality / burn injury, fire / 2 5 HIGH 4 1. Work only after wearing PPE.
cutting / heating. 2. Splashing splinters. explosion. 2. Fit flash back arrestor and NRV on both cylinder
3. Gas leakage. 2. Gas leakage due to fall of cylinder outlets.
4. Wrong positioning of and damage of valves. 3. Use face shield and fire proof gloves.
cylinders. 4. Daily check up before start of work.
5. Presence of flammable 5. Keep cylinders in trolleys or chain to some firm
gases. structure to prevent fall.
6. Gas testing before start of work.
7. Employ competent and trained welder.
8. Provide windshield.
4 Arc welding 1. Radiation harmful to naked 1. Welder's cataract. 2 5 HIGH 4 1.Use welding shield / goggles.
eyes. 2. Burn injury. 2. Fireproof apron / gloves / screen.
2. Splinters / slag. 3. Lung ailments 3. Ventilation (local or exhaust if possible)
3.Toxic flames. 4. Electric shock. 4. Full-sleeved coverall and gloves.
4. Loose connections / Loss of 5. Fire / explosion. 5. Proper clamping system / material handling
insulation. 6. Asphyxiation. techniques.
5. Flammable gases. 6. Use shock proof boots and hand gloves.
6. Poor ventilation 7. Provide earthing to the plant.
8. Periodical gas testing.
9. Keep fire extinguisher (DCP/CO2) standby.
10. Adequate ventilation.
11. Training & instructions.
PMPL/HSE/HIRA/01
Rev.01
5 Material handling 1. Lack of co-ordination in 1. Back pain sprain etc. 3 4 MODERATE 3 1. Training & instructions.
(manual) group effort. 2. Body Injury 2. Use hand gloves/ packing materials.
2. Wrong body posture. 3. Remove protruding nails before handling.
3. Lifting error. 4. Use proper lifting devices for good grip.
4. Sharp 5. Fasten the item properly or use suitable packing /
Edges/corners/projecting container.
parts/protruding nails.
5. Slippery materials.
6. Loose materials.
6 Material handling 1. Lack of knowledge / skills. 1. Body injury. 2 4 MODERATE 3 1. Only trained and approved operator shall be
with forklift / crane 2. Defective equipment. 2. Material losses. deployed for equipment operations.
etc. 3. Defective lifting jacks. 3. Tilting of jacks / boom. 2. Equipment to be tested and certified by competent
4. Overloading. person before deployment.
3. No overloading allowed.
4. Follow procedures.
5. Training and assistance of banksman / rigger.
7 Transporting gas 1. Falling of cylinders 2. Gas leakage due to valve damage. 2 5 HIGH 4 1. Keep charged cylinder only.
cylinders: 2. Explosion 3. Human injury by fall of cylinder. 2. Keep vertically and tie with chain to a fixed
* Oxygen 4. Fire / body injury due to explosion structure.
* Acetylene. 3. Keep in specially fabricated cage to prevent fall.
* Argon. 4. Keep valve cap in position during transportation.
* Nitrogen. 5. Different types of gas cylinders not to be loaded in
* LPG. the same vehicle at a time.
6. Only authorized vehicle and specially trained driver
shall be engaged in gas cylinder transportation.
7. Do not use leaking cylinder.
8. Keep cylinder tied up/chained & locked
independently on truck to prevent falling of one
cylinder while loading/unloading the other.
8 Laying out 1. Unstable Cable drum. 1. Body injury due to fall of cable 3 4 MODERATE 3 1. Cable shall be handled by experienced persons.
electrical cables 2. Wrong position of jack. drum or jack. 2. Adopt proper procedure.
(Cable drum 3. Inadequate jack / spindle. 2. Injury by hitting / caught in. 3. Use only tested and certified jack and spindle.
handling) 4. Rotating parts. 3. Finger injury due to trapping 4. Keep fingers away from nip points.
5. Drum rollers. between drum / rollers. 5. Use hand gloves.
6. Pulling in wrong posture. 6. Use cable roller.
7. Open trench. 7. Keep cable-laid trenches backfilled before leaving
site.

Hira Register

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Hira Register

Uploaded by

Copyright:

Available Formats

PMPL/HSE/HIRA/01

HIRA REGISTER Page |1

HIRA REGISTER Page |2

S.NO DISCRIPTION PAGE NO.

3 HIRA INTRODUCTION 4-6

4 HIRA PROCEDURE 7-15

6 HIRA CONTENTS LIST 17-21

7 HIRA ACTIVITY WISE 22-61

HIRA REGISTER Page |3

HIRA REGISTER Page |4

HIRA REGISTER Page |5

HIRA REGISTER Page |6

A. Identification of hazards associated with a task or activity, considering the following:

HIRA REGISTER Page |7

D. REVIEW OF HIRA REGISTER

Table P 1.1: RISK VALUES FOR WEIGHTAGE FACTORS

PROBABILITY PROBABILITY OCCURENCE

5 Always whenever the work is taken up Very high

HIRA REGISTER Page |8

3 More than once per month Moderate

2 More than once in six months Low

1 More than once in one year Very Low

5 Permanent/ partial disability with hospitalization or death (LTI / FATALITY)

4 Injury resulting in more than 3 days off work (LTI)

3 Injury resulting in 1-2 days off work (RWC)

HIRA REGISTER Page |9

1 Minor injury with no medical attention (FAC)

TABLE P 1.2 RISK RATING MATRIX

Risk Rating Risk Level Inference

No additional controls are required. Consideration may be given to more cost-

RISK CONTROL MEASURES

Avoid Eliminate Hazard altogether

SUBSTITUTE Change to less hazardous

ISOLATE Separate people from hazard

Process of Risk Control

C.C. NO.: PROJECT NAME:

S. No. Activity Hazard Consequence Probability Severity Risk Level Risk

HAZARD IDENTIFICATION AND RISK ASSESSMENT – DEVELOPMENT OF RISK CONTROL MEASURES

HAZARD IDENTIFICATION AND RISK ANALYSIS (HIRA)

SL. NO. ACITIVITY PAGE NO.

ACTIVITY – 1 BLOCK WORKS 22

ACTIVITY – 2 CONCRETE CHIPPING 23

ACTIVITY – 3 CONCRETE FOUNDATION BREAKAGE USING JACKHAMMER 23

ACTIVITY – 5 CONCRETE MIXTURE OPERATION 24

ACTIVITY – 6 MANUAL EXCAVATION 25

ACTIVITY – 7 MECHANICAL EXCAVATION 27

ACTIVITY – 8 ROCK BREAKING 29

ACTIVITY – 10 SHUTTERING AND SHORING 30

ACTIVITY – 11 WORK ON REBAR 31

ACTIVITY – 13 SCAFFOLDING , FORMWORK AND LADDERS 33

ACTIVITY – 15 USING ENGINE GENERATOR SET 34

ACTIVITY – 17 HANDLING PORTABLE HAND TOOLS 35

ACTIVITY – 18 GAS WELDING 35

ACTIVITY – 19 ARC WELDING 36

ACTIVITY – 20 WORKING IN CONFINED SPACE 36

ACTIVITY – 21 MATERIAL HANDLING (MANUAL) 37

ACTIVITY – 22 MATERIAL HANDLING (MECHANICAL) 37

ACTIVITY – 23 WORK AT HEIGHTS 37

ACTIVITY – 24 WORKING UNDER CRANE / LIFTING EQUIPMENT. 38

ACTIVITY – 25 LOADING / UNLOADING ON TRUCK / TRAILER. 38

ACTIVITY – 26 MATERIAL HANDLING WITH CRANE 39

ACTIVITY – 27 HYDROTESTING OMMITED

ACTIVITY – 28 HANDLING OF GAS CYLINDERS 40