SL Main Activities/JOB

3
4

Material handling

7
8

10

11
12

13

14

15
16

17

18

19

Equipment overhaulling
 Equipment overhaulling

20

21

22

23
24

25

26

27

28
29

30

Fabrication of structural /
31 Pipeline items

32

33
34

35

36

37

Erection of structural items or

pipelines
38

39

40

41
42

43

44

45

46

47

48

49

50
Working in HSD circuit

51

52

53
54

55

Pneumatic system Operation and

Maintenance
56

57

58

59 Chemical Dosing

60

61

Chemical handling and drum

shifting
62 Chemical handling and drum
shifting

63

64

65
Working in Water line system

66

67

68

Boiler Operation
 Boiler Operation

69

70

71

72
Softwater plant operation and
maintenance

73

74

75

76

DG Operation & maintenance.

77
DG Operation & maintenance.

78

79

80

81

82

83

84

Roof sheeting activity

85
86

87

88

89

90

91

92

Vertical sheeting activity

93

94
95

96

Filter bag cleaning or

97 replacement

RAV maintenance and

98 replacement

99
Compressor Section Operation &
maintenance
100

101

102
Tank Cleaning
103

104

105 Walking in Stairs

106 Air Dryer Maintenenace

107

108 Cooling tower Maintenance

109

110

111 Cold Well & Hot well Pump

112
 Activity -Routine / Non
Sub activity /JOB
Routine job

Routine

Handling of heavy materials above 35 kgs on

Routine
trolley

Routine
 Routine

Shifting of DA & Oxygen cylinder and welding

machine

Routine

Use of crane Routine

Routine

Handling of light weight materials below 35 kgs

Handling of light weight materials below 35 kgs

Routine

Non Routine

Use of Hydra / Forklift

Non Routine

Routine
 Routine

Welding & gas cutting

Routine

Routine

Fitting of bearing Routine

 Use of hammer Routine

Use of spanner Routine

Cleaning of items Routine

Use of oil and grease Routine

 Routine

5 S activity

Routine

Dismantling & fittings of items Routine

Repair of cylinders & valves Routine

 Use of hydraulic jack Routine

Routine

Grinding operation by hand grinding m/c Routine

Routine

Routine

Replacement of spare items at machine (Valves,

hose, etc)
Replacement of spare items at machine (Valves,
hose, etc)

Routine

Handling of structural material Routine

Routine

Erection of structural items

Routine

Grinding operation Routine

Grinding or Cutting Wheel replacement Routine

Cutting operation Routine

Routine

Routine

Welding & gas cutting

Routine

Routine

Routine
Erection by chain block
Routine
 Routine
Erection by FX
Routine

Routine
Erection by EOT Crane
Routine

Erection by Mobile Crane Routine

Routine
Tighteneing operation
Routine

Routine
Pump servicing
Routine

Gasket replacement Routine

Pressure gauge/switch replacement Routine

Line strainer cleaning Routine

 Valve servicing / replacement Routine

Air receiver TBM activity Routine

Arresting the lekages Routine

Tighteneing operation Routine

Routine

Maintenance of chemical dosing pump

Routine

Dosing pipelines repairing / replacement Routine

Chemical store stock maintaining Routine

 Chemical store chemical handling Routine

Chemical drum shifting by hand trolley Routine

Routine
Flange bolts tightening
Routine

Overhead pipe line maintenance Routine

Boiler DCS operation & daily water parameters Routine

monitoring

Boiler & equipments daily monitoring &

Routine
counteractions
 Boiler & auxiliary yearly servicing Routine

Boiler auxiliary equipments maintenance Routine

Regeneration for soft water Routine

Salt stock loading / unloading Routine

Vessel servicing / Filter media replacement Routine

Water / air leakage identification / rectification Routine

Generator operation Routine

Routine

Flange bolts tightening

 Flange bolts tightening

Routine

Diesel top up Routine

Filter replacement Routine

Lubricantion Routine

Sheet replacement Routine

Sheet Cleaning & Inspection Routine

Material shifting Routine

Sheet cutting Routine

Roof shed monitoring for lifeline / lifeline

monitoring & installation of lifeline Routine
Job execution using lifeline anchoring method Routine

Old sheet stock disposal & housekeeping Routine

Screw fixing Routine

Sheet replacement Routine

Sheet Inspection Routine

Material shifting Routine

Sheet cutting Routine

Job execution by rope access method Routine

Job execution using fabricated hanging cage

method Routine
 Job execution by Boomlift machine method Routine

Screw fixixng Routine

Bag cleanaing or replacement Routine

Spare parts repalcement & inspetion Routine

Operation Routine

Spare parts repalcement & inspetion Routine

Working at confined space area Routine

Daily sludge pit cleaning activity Routine

Equipment condition monitoring & maintenance Routine

Equipment operation Routine

Walking in concrete Stairs Routine

Spare parts repalcement & inspetion Routine

Cleanaing & Inspection Routine

Operation Routine

Cleanaing & Inspection Routine

Routine

Maintenance & Servicing

Routine

Operation Routine
 Hazard
(Source, hazardous situation or Hazardous Event
circumstances with a potential to (Uncertainity)
cause injury & illhealth)/ (Work related hazardous event
Environmental Aspect or exposure)

Carrying of material on uneven

Material may fall / slip road

Material may fall / slip Carrying of materials by EOT

During loading hand or leg may be

Materials loading on trolley
entrapped
 Carrying of Oxygen & DA cyd ,
Cylinder & welding machine may welding machine on uneven
fall / slip
road

Loading and empty of Oxygen,

Cylinder may strike people hand DA cylinders and welding
or leg
machine

Crane / chain pulley tear and fall Materials can slip/fall

Material may fall / slip Carrying of materials by hand

 Back pain During lifting of materials

Without proper cantering of

Material fall /Strike materials /use of damage lifting
tackles /Improper material
shifting technics.

Earth moving equipment can Improper operate earth moving

damage people equipment's

Electrocution of the people Electric shock during welding/

related to welding use of wet hand gloves
Sparks & hot slags causes fire Fire during welding & gas
cutting on hazardous items

Welding at Flammable Area Fire Hazard

People may be affected by People may be effected by

inhaling Fumes & gases inhaling

Use of chisel & hammer Both

Hand injury may mis hit
Hand injury during parts assembly Slippage of Spanner/ hammer
/dismantling from hand

Hand injury during bolt loose Slippage of Spanner

/tight

Skin irritation due to contact of

dust and dirt Skin contact wih
Skin irritation
dust/oil/thinner during
cleaning

Skin irritation due to contact of

Skin irritation dust and dirt Skin contact with
hyd oil and grease
 Foreign parts can go inside eye
and nose during cleaning Use of pneumatic air

Carrying of material on uneven

Material may fall / slip
floor

Injury at hand / foot due to Fall of Process of dismantling & fitting

spare part/ tools of parts

Dismantling & fitting of

Hand / finger may entrap or hydraulic & pneumatic
squeeze
equipment
Body part may be entrapped High Material dismantling/assembly
pressure by use odf hyd jack

Flying of metal chip & dust eye Flying of metal chip during
and body injury grinding

Flying of Broken pieces of

Grinding operation m broken
Grinding wheel and hit any wheel can cause injury
persons

Chance of electrification during

Electric shock during grinding grinding

Hand /bodyinjury Manual handling of lifting tools

 Use of faulty spanner &
Hand /bodyinjury
hammer

Carrying of roller on uneven

Structure materials may fall / slip
road

Erection of items during

Fall from height working at height

Structure items may fall & can

Fall of material during working make injury

Flying of metal chip & dust eye Flying of metal chip during
and body injury grinding
 Hand /bodyinjury Use of faulty spanner &
hammer

Fire during gas cutting on

Sparks & hot slags causes fire
hazardous items

Electrocution of the people Electric shock during welding/

related to welding use of wet hand gloves

Fire during welding & gas

Sparks & hot slags causes fire cutting on hazardous items

Welding at Flammable Area Fire Hazard

People may be affected by People may be effected by

inhaling Fumes & gases inhaling

Erection of items during

Fall from height working at height
Structure items may fall & can
Fall of material during working make injury
 Erection of items during
Fall from height working at height
Structure items may fall & can
Fall of material during working make injury
Erection of items during
Fall from height working at height
Structure items may fall & can
Fall of material during working make injury
Structure items may fall & can
Fall of material during working make injury

Hand injury during parts assembly Slippage of Spanner/ hammer

/dismantling from hand

Hand injury during bolt loose

Slippage of Spanner
/tight
Hand injury during parts assembly Slippage of Spanner/ hammer
/dismantling from hand

Hand injury during bolt loose Slippage of Spanner

/tight

Hand / finger may entrap or Fitting of gaskets in line

squeeze equipment

Hand /bodyinjury Use of faulty spanner

Hand injury during cleaning

Hand /bodyinjury
parts assembly /dismantling
 Hand /bodyinjury Use of faulty tools

Hand /bodyinjury Use of faulty wrench / spanner

tools

Hand / finger may entrap or Fitting of gaskets in line

squeeze equipment

Hand /bodyinjury Use of faulty spanner

Hand /body burn / injury Spillage of chemical

Hand / finger may entrap or Fitting of gaskets in line

squeeze equipment

Hand /body burn / injury Spillage of chemical

Hand /body burn / injury Spillage of chemical

 Hand /body burn / injury Spillage of chemical

Hand /body burn / injury Spillage of chemical

Hand injury during parts assembly Slippage of Spanner/ hammer

/dismantling from hand

Hand /bodyinjury Use of faulty spanner

Hand / finger may entrap or Fitting of gaskets in line

squeeze equipment

Hand /bodyinjury Burn / spillage

Hand /bodyinjury Burn / spillage

 Burn / Slippage of Spanner/
Hand /bodyinjury hammer from hand

Hand /bodyinjury Burn / Slippage of Spanner/

hammer from hand

Salt squeeze on body Spillage of salt solution

Manual handling or using lifting

Hand /bodyinjury tools

Hand /bodyinjury Burn / Slippage of Spanner/

hammer from hand

Hand injury during parts assembly Slippage of Spanner/ hammer

/dismantling from hand

Chance of electrification during

Electric shock during operating operating

Hand injury during bolt loose

Slippage of Spanner
/tight
 Hand /bodyinjury Use of faulty spanner

Hand /bodyinjury Diesel spillage & Fire

Hand /bodyinjury Use of faulty tools

Grease can leak Insert into eye

Fall from height Structure items may fall & can

make injury

Structure items may fall & can

Fall from height & dust make injury

Hand /bodyinjury Use of faulty tools

Hand /bodyinjury Use of faulty tools

Structure items may fall & can

Hand /bodyinjury make injury
 Hand /bodyinjury Structure items may fall & can
make injury

Manual handling or using lifting

Hand /bodyinjury tools

Hand /bodyinjury Use of faulty tools

Structure items may fall & can

Fall from height
make injury

Structure items may fall & can

Fall from height & dust
make injury

Hand /bodyinjury Use of faulty tools

Hand /bodyinjury Use of faulty tools

Structure items may fall & can

Hand /bodyinjury make injury

Structure items may fall & can

Hand /bodyinjury make injury
 Hand /bodyinjury Use of faulty tools

Hand /bodyinjury Use of faulty tools

People may be affected by People may be effected by

inhaling dust inhaling

Hand /bodyinjury Use of faulty tools

Chance of electrification during

Electric shock during operating operating

Hand /bodyinjury Use of faulty tools

Body injury during walking May fall / slip in confined space

Body injury during walking May fall / slip in confined space

Body injury during walking May fall / slip in confined space

Chance of electrification during

Electric shock during operating operating

Body injury during walking May fall / slip

Hand /bodyinjury Use of faulty tools

 Body injury during working May fall / slip

Chance of electrification during

Electric shock during operating operating

Body injury during working Carrying of material on uneven

surfaces

Hand injury during parts assembly Slippage of Spanner/ hammer

/dismantling from hand

Hand injury during bolt loose

/tight Slippage of Spanner

Chance of electrification during

Electric shock during operating operating
 Cause
Consequnce
(Likely Cause(s) of Hazardous People
(Impact)
Event )

properly not placed on trolley Minor Injury C1

Not properly anchor, Use of faulty

Fatal C4
lifting tools

Improper handling & placing on

LTI C3
trolley
properly not placed on trolley &
use of Chain lock during shifting, First aid C2
Improper handling

Improper handling & placing on First aid

trolley C2

Carrying load by crane without

visual inspection or latch lock . Fatal C4
Behaviour issue

Not carried properly Minor Injury C1

 Improper lifting of weight Minor Injury C1

Behaviour issue, Poor materials LTI/Fatal

handling technics C4

Behaviour issue of driver Fatal C4

Improper earthing & insulation LTI C3

 Improper welding/cutting
techniqs, Poor safety protection LTI C3
maintain during hot work

Welding and Gas Cutting Work at

Near Zinc Dust, Hydraulic Oil, Paint LTI C4
Area

Not using proper PPE Minor Injury C1

Absent minded or use of improper

tool First aid C2
 Improper tools and technics Minor Injury C1

Improper tools and technics and

Untrained work Minor Injury C1

Use of improper PPE Minor Injury C1

Use of improper PPE Minor Injury C1

Use of improper PPE and improper
technics Minor Injury C1

properly not placed on trolley Minor Injury C1

Untrained work & lack of

knowledge Minor Injury C1

In the process sharp & metallic

part is used and Absent minded of Minor Injury C1
fitter
 Absent mind & Untrained work First aid C2

Improper use of PPE First aid C2

Proper tools and technics amd use

of wheel guard & proper PPE LTI C4

Damaged cable & damaged switch

board First aid C2

Absent minded or low skill Fatal C4

Absent minded or use of improper
tool. Lack of skill Minor Injury C1

properly not placed on trolley/

Fatality C4
earth mover

Improper technics, lacs of use of

PPE Fatal C4

Improper technics, lacs of use of C4

PPE LTI

Improper use of PPE First aid C2

Absent minded or use of improper
tool. Lack of skill Minor Injury C1

Improper cutting techniqs, Poor

safety protection maintain during LTI C3
hot work

Improper earthing & insulation LTI C3

Improper welding/cutting
techniqs, Poor safety protection LTI C3
maintain during hot work

Welding and Gas Cutting Work at

Near Zinc Dust, Hydraulic Oil, Paint LTI C4
Area

Not using proper PPE Minor Injury C1

Improper technics, lacks of use of

Fatal C4
PPE
Improper technics, lacs of use of C4
PPE LTI
Improper technics, lacks of use of C4
PPE Fatal

Improper technics, lacs of use of C4

PPE LTI

Improper technics, lacks of use of C4

PPE Fatal

Improper technics, lacs of use of

PPE LTI C4

Improper technics, lacs of use of

PPE LTI C4

Improper tools and technics Minor Injury C1

Improper tools and technics and

Untrained work Minor Injury C1

Improper tools and technics Minor Injury C1

Improper tools and technics and

Untrained work Minor Injury C1

In the process sharp & metallic

part may cause injury and Absent Minor Injury C1
minded of fitter

Absent minded or use of improper

tool. Lack of skill Minor Injury C1

Absent minded or low skill Fatal C4

Absent minded or use of improper
tool. Lack of skill Minor Injury C1

Absent minded or use of improper

tool. Lack of skill Minor Injury C2

In the process sharp & metallic

part may cause injury and Absent Minor Injury C1
minded of fitter

Absent minded or use of improper

tool. Lack of skill Minor Injury C1

Lack of skills Absent minded or use

of improper tool. Minor Injury C2

In the process sharp & metallic

part may cause injury and Absent Minor Injury C1
minded of fitter

Lack of skills Absent minded or use

of improper tool. Minor Injury C2

Lack of skills Absent minded or use

of improper tool. Minor Injury C2
Lack of skills Absent minded or use
of improper tool. Minor Injury C2

Lack of skills Absent minded or use

of improper tool. Minor Injury C2

Improper tools and technics Minor Injury C1

Absent minded or use of improper

tool. Lack of skill Minor Injury C1

In the process sharp & metallic

part may cause injury and Absent Minor Injury C1
minded of fitter

Steam equipment handling First aid C2

Steam equipment handling First aid C2

 In the process sharp & metallic
part may cause injury and Absent Minor Injury C1
minded of fitter

In the process sharp & metallic

part may cause injury and Absent Minor Injury C1
minded of fitter

Lack of skills Absent minded or use

of improper tool. Minor Injury C2

Absent minded or low skill Minor Injury C2

In the process sharp & metallic

part may cause injury and Absent Minor Injury C1
minded of fitter

Improper tools and technics Minor Injury C1

Damaged cable & damaged switch

board First aid C2

Improper tools and technics and

Untrained work Minor Injury C1
Absent minded or use of improper
tool. Lack of skill Minor Injury C1

Absent minded or Lack of skills First aid C2

Absent minded or use of improper

tool. Lack of skill Minor Injury C1

Imporper Techniques, LOTOTO not

Minor Injury C2
followed

Improper technics, lacs of use of C4

PPE LTI

Improper technics, lacs of use of

PPE LTI C5

Absent minded or use of improper

tool. Lack of skill Minor Injury C1

Absent minded or use of improper

tool. Lack of skill Minor Injury C1

Improper technics, lacs of use of

PPE LTI C4
Improper technics, lacs of use of C4
PPE LTI

Absent minded or low skill Minor Injury C2

Absent minded or use of improper

tool. Lack of skill Minor Injury C1

Improper technics, lacs of use of

LTI C4
PPE

Improper technics, lacs of use of

LTI C5
PPE

Absent minded or use of improper

tool. Lack of skill Minor Injury C1

Absent minded or use of improper

tool. Lack of skill Minor Injury C1

Improper technics, lacs of use of

PPE LTI C4

Improper technics, lacs of use of

PPE LTI C4
Absent minded or use of improper
tool. Lack of skill Minor Injury C1

Absent minded or use of improper

tool. Lack of skill Minor Injury C1

Not using proper PPE Minor Injury C1

Absent minded or use of improper

tool. Lack of skill Minor Injury C1

Damaged cable & damaged switch

board First aid C2

Absent minded or use of improper

tool. Lack of skill Minor Injury C1

Slippery surface Minor Injury C1

Slippery surface Minor Injury C1

Slippery surface Minor Injury C1

Damaged cable & damaged switch

board First aid C2

Slippery surface Minor Injury C1

Absent minded or use of improper

tool. Lack of skill Minor Injury C1
 Slippery surface Minor Injury C1

Damaged cable & damaged switch

board First aid C2

Uneven surface Minor Injury C2

Improper tools and technics Minor Injury C1

Improper tools and technics and

Untrained work Minor Injury C1

Damaged cable & damaged switch

board First aid C2
Asset Community Environment

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 Existing Safeguard to Probability of Risk as per
reduce the hazard / Occurance as per Available
consequnce Available Safeguard Safeguard

Follow SOP, Impart training F1 R3

Follow SOP, Impart

training, Use of certified
lifting tools, audio siren, F3 R2
Radio remote controlled
overhead crane

Follow SOP, Impart training F1 R2

 Follow SOP, Impart
training, Use chain to tie R3
the cylinder to the moving F2
trolley

Follow SOP, Impart training F1 R2

Follow SOP, Impart

training, Load test of lifting F2 R1
tools & tackles

Follow SOP, Training, Use

of trolley for material F2 R3
movement
Follow SOP, Use of trolley R3
for material movement F2

Follow SOP, Impart

training, constant F2 R1
supervision

Follow SOP, Constant

Supervision, Reverse F3 R2
Parking Horn

Follow SOP, check sheet F2 R2

 Follow SOP, Sand Bucket
and Fire Extinguisher F2 R2

SOP, Training, Sand Bucket,

Suitable Fire Extinguisher, F3 R2
Continous Supervision

Follow SOP, Impart training F1 R3

Follow SOP, Impart

training, Bearing Heating F2 R3
arrangement
Follow SOP, Impart training F1 R3

Follow SOP, Impart training F1 R3

Follow SOP, Impart

training, follow MSDS F2 R3

Follow SOP, Impart

training, follow MSDS F2 R3
Follow SOP, Impart training F2 R3

Follow SOP, Impart training F2 R3

Follow SOP, Impart training F1 R3

Follow SOP, Impart training F1 R3

 Follow SOP, Impart
training, periodic checking F2 R3
of hydraulic jack

Follow SOP, Impart

training, grinding zone F2 R3
prepared

Follow SOP, wheel guard F2 R1

Follow SOP, Impart

training, F1 R2

Follow SOP, Impart

training, Use of certified
lifting tools, audio siren, F4 R3
Radio remote controlled
overhead crane
Follow SOP, Impart training F1 R3

Follow SOP, Impart

training, Constant F2 R1
supervision

Follow SOP F2 R1

Follow SOP F2 R1

Follow SOP, Impart

training, grinding zone F2 R3
prepared
Follow SOP, Impart training F1 R3

Follow SOP, Sand Bucket

and Fire Extinguisher F2 R2

Follow SOP, check sheet F2 R2

Follow SOP, Sand Bucket

and Fire Extinguisher F2 R2

SOP, Training, Sand Bucket,

Suitable Fire Extinguisher, F3 R2
Continous Supervision

Follow SOP, Impart training F1 R3

Follow SOP F2 R1

Follow SOP F2 R1
 Follow SOP F2 R1

Follow SOP F2 R1

Follow SOP F2 R1

Follow SOP F2 R1

Follow SOP F2 R1

Follow SOP, Impart training F1 R3

Follow SOP, Impart training F1 R3

Follow SOP, Impart training F1 R3

Follow SOP, Impart training F1 R3

Follow SOP, Impart training F1 R3

Follow SOP, Impart training F1 R3

Follow SOP, Impart
training, Use of certified
lifting tools, audio siren, F4 R3
Radio remote controlled
overhead crane
Follow SOP, Impart training F1 R3

Follow SOP, Impart training F2 R3

Follow SOP, Impart training F1 R3

Follow SOP, Impart training F1 R3

Follow SOP, Impart training F2 R3

Follow SOP, Impart training F1 R3

Follow SOP, Impart training F2 R3

Follow SOP, Impart training F2 R3

Follow SOP, Impart training F2 R3

Follow SOP, Impart training F2 R3

Follow SOP, Impart training F1 R3

Follow SOP, Impart training F1 R3

Follow SOP, Impart training F1 R3

Follow SOP, Impart

training, grinding zone F2 R3
prepared

Follow SOP, Impart

training, grinding zone F2 R3
prepared
Follow SOP, Impart training F1 R3

Follow SOP, Impart training F1 R3

Follow SOP, Impart training F2 R3

Follow SOP, Impart training F3 R3

Follow SOP, Impart training F1 R3

Follow SOP, Impart training F1 R3

Follow SOP, Impart

training, F1 R2

Follow SOP, Impart training F1 R3

Follow SOP, Impart training F1 R3

Follow SOP, Impart

training, F1 R2

Follow SOP, Impart training F1 R3

LOTOTO, sensor, SOP

F3 R3
Followed

Follow SOP F2 R1

Follow SOP F3 R1

Follow SOP, Impart training F1 R3

Follow SOP, Impart training F1 R3

Follow SOP F2 R1
 Follow SOP F2 R1

Follow SOP, Impart training F3 R3

Follow SOP, Impart training F1 R3

Follow SOP F2 R1

Follow SOP F3 R1

Follow SOP, Impart training F1 R3

Follow SOP, Impart training F1 R3

Follow SOP F2 R1

Follow SOP F2 R1
Follow SOP, Impart training F1 R3

Follow SOP, Impart training F1 R3

Follow SOP, Impart training F1 R3

Follow SOP, Impart training F1 R3

Follow SOP, Impart

training, F1 R2

Follow SOP, Impart training F1 R3

Follow SOP, Impart training F2 R3

Follow SOP, Impart training F2 R3

Follow SOP, Impart training F2 R3

Follow SOP, Impart

training, F1 R2

Follow SOP, Impart training F2 R3

Follow SOP, Impart training F1 R3

Follow SOP, Impart training F2 R3

Follow SOP, Impart

training, F1 R2

Follow SOP, Impart training F3 R3

Follow SOP, Impart training F1 R3

Follow SOP, Impart training F1 R3

Follow SOP, Impart

training, F1 R2
 Residual
Recommendation (OFIs) Residual Consequence Probability of
Occurance
Residual Risk
Risk Owner
Risk Communication
 Updated (10.08.23)
Almost
Certain
42 8 1 0 0
F1
Likely
F2
11 14 5 19 0
Possible
F3
0 2 0 4 2
Unlikely
F4
0 0 0 2 0
Rare
F5
0 0 0 0 0
Slight Minor Moderate Major Massive
C1 C2 C3 C4 C5