Format No.

SFS-FR-05 HAZARD IDENTIFICATION AND RISK ASSESSMENT

DEPARTMENT Coke Ovens 3 Routine/ Non-Routine Non-Routine Past incident (Y/N) No HIRA No. 1 Reviewed By Approved By
Replacement of damaged clean coke
ACTIVITY oven gas pipe line DN800 in coke Legal Requirments (Yes/No) No Revision No. Review Date Approval Date
oven#4 B rack
EXISTING SAFEGUARD/CONTROLS (Will influence Likelihood
HAZARD IDENTIFICATION CONSEQUENCE DETAILS RISK ANALYSIS ADDITIONAL CONTROLS RESIDUAL RISK
Rating) RISK COMMUNICATOR
RISK OWNER
(Responsible for
CAUSE (Responsible &
People - Safety or Training, Competence
Sl NO. SUB ACTIVITY Authorized to take
HAZARD (Possible cause of Probablity of Consequences Probablity of development,
Hazardous event or CONSEQUENCE Health / Asset / Administrative RISK Passive Administrative Consequences action(s) to reduce
(Source, Situation, unwanted event, or Passive safeguards Active safeguards failure of ( Severity Likelihood Active safeguards failure of Likelihood RISK RATING Awareness creation
exposure or loss (May lead to….....) Environment / Safeguards RATING safeguards Safeguards ( Severity Scale) Risk)
Circumstances) hazardous event or safeguard Scale) safeguard etc.)
Community
exposure or loss)

1. Two person with CO

monitor. In case
Expousure to gas Shift Engineer, Shift
CO gas leakage from Toxic gas inhalation leakage , leave area.
CO gas during valve People-Safety Not Available Not Available F1+F1=F2 C2 L4 R2 F1+F1=F2 C2 L4 R2 Incharge and Area Shift Incharge
gland/flange & may lead to MTC 2. Two person with one
operation Incharge
Closing of gas more CO detector & Two
1 valve DN ELBA set.
1000,water sealing.
Permanent hand
Unavailability of edge Shift Engineer, Shift
Physical injury & rails provided Use of safety harness,
Height Fall from height protection of working People-Safety Not Available F1+F3=F4 C4 L2 R2 F1+F3=F4 C4 L2 R2 Incharge and Area Shift Incharge
may lead to fatal surrounding the Trained Manpower
platform Incharge
working platform

Permanent hand
Unavailability of edge Shift Engineer, Shift
Physical injury & rails provided Use of safety harness,
Height Fall from height protection of working People-Safety Not Available F1+F3=F4 C4 L2 R2 F1+F3=F4 C4 L2 R2 Incharge and Area Shift Incharge
may lead to fatal surrounding the Trained Manpower
platform Incharge
working platform

1. CO monitors (In case

heavy leakage need to
leave the place)
2. Water sealing of
valves with continuous
Shift Engineer, Shift
Toxic gas inhalation monitoring of gas
CO gas leakage from gland People-Safety Not Available Not Available F1+F1+F1=F3 C3 L3 R2 F1+F1+F1=F3 C3 L3 R2 Incharge and Area Shift Incharge
& may lead to LTI concentration with
Incharge
another CO monitor by
dedicated manpower.
3. All the working person
should do the job after
Removal & fixing wearing BA set
2 of ring spacer and
blind plate Expousure to gas
during blanking and
Coke Oven Gas
deblanking of gas
valve

1. CO monitors (In case

heavy leakage need to
leave the place)
2. Water sealing of
valves with continuous
Shift Engineer, Shift
Gas leakage in case of Toxic gas inhalation monitoring of gas
People-Safety Not Available Not Available F1+F1+F1=F3 C3 L3 R2 F1+F1+F1=F3 C3 L3 R2 Incharge and Area Shift Incharge
Valve non holding & may lead to LTI concentration with
Incharge
another CO monitor by
dedicated manpower.
3. All the working person
should do the job after
wearing BA set

1. Trained working
person with full body
Unavailability of edge Uses of Fall arrestor safety harness and Shift Engineer, Shift
Physical injury &
Height fall from height protection of working People-Safety Not Available arrangement with lifeline. F2+F1+F1= F4 C4 L2 R2 F2+F1+F1 = F4 C3 L3 R2 Incharge and Area Shift Incharge
may lead to fatal
platform separate rope 2. Temporary working Incharge
platform secured with
handrailing.

1. CO monitor with
trained working person,
In case of any leakage
place has to leave.
Gas leakage in case of Blanking of the line 2. BA set as per the Shift Technician, Shift
Toxic gas inhalation
Valve or blanking non People-Safety and checked by Not Available numbers of personal F3+F1+F1= F5 C3 L1 R1 F3+F1+F1=F5 C3 L1 R1 Engineer and Shift Shift Incharge
& may lead to LTI
holding competent person working with another CO Incharge
monitor. In case of
heavy leakage BA has to
used and leave the
place.

Coke Oven Gas Expousure to Gas

Dismantling and 1. Purging of the line has
3 erection of DN 800 to be done before work
pipe lines and to be verifaied by
the expert person.
2. CO monitor with
trained working person,
In case of any leakage Shift Engineer, Shift
Availability of gas Toxic gas inhalation
People-Safety Not Available Not Available place has to leave. F1+F1+F1=F3 C3 L3 R2 F1+F1+F1=F3 C3 L3 R2 Incharge and Area
concentration in pipeline & may lead to LTI
3. BA set as per the Incharge
numbers of personal
working with another CO
monitor. In case of
heavy concentration BA
has to used and leave
the place.

Fire due to spark Blanking of the line Charged fire hose with Shift Engineer, Shift
Burn injury and may
contact with Coke Gas release People-Safety and checked by Not Available trained operator F3+F1=F4 C3 L2 R2 F3+F1=F4 C3 L2 R2 Incharge and Area Shift Incharge
lead as LTI
Oven Gas competent person provided Incharge

Spark
Spark
1. Cable tray covered by
Heat resistant cloth
Cable damage, May Shift Engineer, Shift
Fall of spark on Uncovered cable tray (asbetos cloth)
happen minor Asset Not Available Not Available F1+F1=F3 C2 L4 R2 F1+F1=F2 C2 L4 R2 Incharge and Area Shift Incharge
electrical cable below hot work area 2. Fire exitinguisher
damage Incharge
(CO2) provided with
trained operator
 Calculation of Probability
Type of safeguards
Likelihood of failure of safeguard
L5
F-1  Single Administrative
Almost Certain
L4  One Active or
Likely F-2
 Two Independent Administrative
L3  Passive or
Possible F-3  One Active + One Administrative or
 Three Independent Administrative
L2  Two Active or
Un Likely F-4  One Passive + One Administrative or
 Four Independent Administrative
L1  Two Active+ One Administrative or
Rare F-5  One Passive + One Active
 L5
(Almost Certain)
(L4)
Yellow (R3)
(Likely)
Likelihood

(L3)
Blue (R2)
(Possible)
(L2)
(Un Likely)
(L1)
Green (R1)
(Rare)
C1 C2 C3 C4
Consequence
No injury or
Major injury or Single Fatal /
Local Treatment / Minor injury or
People no ill health health effect
Reversible health Irreversible injury
effect or health effect
effects.
Moderate
Asset Slight damage Minor damage
damage
Major damage

Considerable
Community Slight impact Limited impact
impact
National impact

Effect can be
Minor effect that
recoverable with Effects is not
recovers on its
Environment No Effect
own and without
immediate action recoverable but
and or leads to no loss of life
any discomfort
minor discomfort
 Red (R4)

C5

Multiple Fatality /
Irreversible health
effect to many

Massive damage

International
impact
Endanger to
ecological balance
(chances of killing
marine life and
flora and fauna)
loss of life