Format No.

SFS-FR-05 HAZARD IDENTIFICATION AND RISK ASSESSMENT

DEPARTMENT SINTERPLANT 5 Routine/ Non-Routine Routine Past incident (Y/N) No HIRA No. Reviewed By Approved By

ACTIVITY POLYMER LINER FIXING Legal Requirments (Yes/No) Yes Revision No. Review Date 1/4/2024 Approval Date

HAZARD IDENTIFICATION CONSEQUENCE DETAILS EXISTING SAFEGUARD/CONTROLS (Will influence Likelihood Rating) EXISTING/CURRENT RISK ANALYSIS ADDITIONAL SAFEGUARD/CONTROLS RESIDUAL RISK ANALYSIS
RISK
COMMUNICATOR
RISK OWNER
(Responsible for
CAUSE (Responsible &
People - Safety or Training,
Sl NO. SUB ACTIVITY HAZARD (Source, Hazardous event (Possible cause of CONSEQUENCE Probablity of Probablity of Authorized to take
Health / Asset / Consequences Passive Administrative Consequences Competence
Situation, or exposure or unwanted event, or (May lead
Environment / Passive safeguards Active safeguards Administrative Safeguards failure of
( Severity Scale) Likelihood RISK RATING safeguards Active safeguards Safeguards
failure of
( Severity Scale) Likelihood RISK RATING action(s) to reduce development,
Circumstances) loss hazardous event or to….....) safeguard safeguard Risk)
Community Awareness creation
exposure or loss) etc.)

Safety Measures:
Implement confined Use confined space Use mechanical aids such as hoists or
Working at heights,
space entry entry permits and lifting equipment.
such as on Shift Engineer, Shift
Hazard: Working Confined Spaces procedures, have a rescue plan in People-Safety Not Available Not Available Train workers in proper lifting F1+F1=F2 C2 L4 R2 F1+F1=F2 C2 L4 R2 Shift Incharge
scaffolding or Incharge and Area
in confined including proper place. Provide techniques.
ladders, increases Incharge
spaces such as ventilation and confined space Provide ergonomic tools and
the risk of falls
narrow chutes atmospheric training for workers equipment to reduce strain.
1 can pose risks of monitoring.
suffocation,
entrapment, or
hazardous
atmospheres.

Unavailability of edge Shift Engineer, Shift

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

Unavailability of edge Shift Engineer, Shift

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

Lifting and handling 1. Use guardrails, toe boards, and

Workers may slip or heavy polymer liners personal fall protection systems.
Shift Engineer, Shift
Hazard: Working trip on uneven or equipment can People-Safety Not Available Not Available Ensure scaffolding and ladders are F1+F1+F1=F3 C3 L3 R2 F1+F1+F1=F3 C3 L3 R2 Shift Incharge
Incharge and Area
at heights, such surfaces, debris, or lead to properly erected and secured.
Incharge
as on scaffolding slippery materials musculoskeletal Provide fall protection training for
2 injuries to LTI workers.
or ladders,
increases the
risk of falls. Workers may slip or
Conveyor chute trip on uneven
polymer liner fixing surfaces, debris, or
slippery materials

Safety Measures:
Hazard: Tools, Hazard: Working in Secure tools and materials when
equipment, or confined spaces working at heights.
Shift Engineer, Shift
materials may fall such as narrow People-Safety Not Available Not Available Use toe boards, debris nets, or catch F1+F1+F1=F3 C3 L3 R2 F1+F1+F1=F3 C3 L3 R2 Shift Incharge
Incharge and Area
from heights, causing chutes can pose risks platforms to prevent objects from
Incharge
injuries to workers of suffocation lead falling.
below. to LTI Wear appropriate personal protective
equipment (PPE), such as hard hats.

1. Trained working person with full

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

Training and Education:

Provide comprehensive training to

workers involved in the installation of
Customized Designs for Material Flow:
Workers falling from risks of suffocation, polymer liners, covering topics such as
heights while entrapment, or safe work practices, equipment Shift Technician, Shift
Fall Hazards Expousure to People-Safety Designing the polymer liners with customized shapes or Not Available F3+F1+F1= F5 C3 L1 R1 F3+F1+F1=F5 C3 L1 R1 Shift Incharge
accessing or working hazardous operation, hazard recognition, and Engineer and Shift
Confined space configurations optimized for specific material flow patterns
inside the conveyor atmospheres lead to emergency procedures. Incharge
reduces the risk of blockages or jams in the conveyor
chute. LTI Ensure that workers are adequately
chute, improving operational safety and efficiency.
trained on the proper handling,
cutting, and installation techniques for
polymer liners, as well as the use of
The erection of personal protective equipment (PPE).
3 polymer liners in
conveyor chutes

Hazard: Heat Mitigation:

sources such as Implement strict hot work procedures, including obtaining
welding equipment, permits, conducting a hazard assessment, and
Fire due to spark cutting torches, or implementing fire watch protocols. Shift Engineer, Shift
Heat Sources People-Safety Not Available Charged fire hose with trained F3+F1=F4 C3 L2 R2 F3+F1=F4 C3 L2 R2 Shift Incharge
contact with nearby machinery Use spark-resistant tools and equipment in areas where Incharge and Area
operator provided
polymer liner can ignite polymer polymer liners are present. Incharge
liners if they come Provide fire blankets or shields to protect nearby polymer
into direct contact or liners from heat sources during welding or cutting
Spark generate sparks. operations.

1. Cable tray covered by Heat resistant

Cable damage, May Shift Engineer, Shift
Fall of spark on Uncovered cable tray Asset Not Available Not Available cloth (asbetos cloth) F1+F1=F3 C2 L4 R2 F1+F1=F2 C2 L4 R2 Shift Incharge
happen minor Incharge and Area
electrical cable below hot work area 2. Fire exitinguisher (CO2) provided
damage Incharge
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.

Asset Slight damage Minor damage Moderate 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