Ayoki Fabricon Pvt.

Ltd
TEAM MEMBERS (RESP.) HAZARD IDENTIFICATION,RISK ASSESSMENT (HIRA)
1) JOB:- Alignment and erection Of Kiln Shell
2) ROUTINE/NON ROUTINE: Daily
3) DEPARTMENT / SECTION:- Mechanical
4) APPROVED BY : ISSUED BY :

RISK WITH EXISTING RESIDUAL RISK WITH

N/ CONTROL(R=EXSXP) ADDITIONAL CONTROL
Sl R/ EMS/
Activity Hazards/Concern A/ EXISTING CONTROL MEASURE ADDITIONAL CONTROLS PRIORITY
No NR OHS
E
E S P R E S P R

1. Soil condition is good & well leveled..

1 Crane /Hydra placement
1. Toppling of crane/hydra .
2. Failure of crane/hydral.
(*Person may sustain severe injuries .
R N
* Persons working at lower level get
injured.
* Property damage.)
2. Compacted soil. .
3. Ensure proper base plates or sol plates are provided
under the jack.
4. Check over head clearance like live lines etc…
5. The out riggers are fully extended.
6. Not provide any other supports on jack.
7. Crane has a valued test certificate.
8. The operator had availed driving license. 1.Ensure SWP to be followed.
9. No haudraulic leakages 2.Ensure checklst of crane to
OHS 1 4 1 4 0.5 1 0.5 0.25 4
10. Proper load chart is available be filled by opt.
11. Proper PPEs are wearing all work force in evolving this
activity
12. Ensure that the crane had its SLI unit and over hoist
limit switch.
13. Competed riggers are trained & medically fit.
14. Keep fire extinguishers in crane.
15. Proper bed should made for movement of crane

1. Use proper PPE. 1.Ensure SWP to be followed.

Lifting hook welding and
2 R
sling arraignments.
2. Select proper size of plate for hook purpose.
3. Proper ribs provided in hooks.
4. Know the accurate weight of the material should lift.
5. Calculate the CG of the material.
6. Choose the appropriate sling.
1. Failure of hook. 7. Mark the SWL of the sling.
2. Electrocution. 8. Ensure the third party inspection certificates are
3. Cut injury. available for all lifting tools & tackles and its validity..
N OHS 1 4 1 4 0.5 1 0.5 0.25 4
4. Scratch injury. 9. Check the all the tools before in use.
5. Failure of slings. 10. Check the welding of lifting hook.
11. If the work is above 1.8 mtr height wear double lanyard
safety harness.

1. Proper stacking of material. 1.Ensure SWP to be followed.

Shifting material with the
3 R
help of trailer.
2. Proper packing in material..
3. Proper stoppers are provide.
4. properly tie the material with the help of secure chain
and ropes.
5. Periodical maintenance of vehicle.
1. Toppling of trailer and material. .
6. All indicators are in working condition.
(* Fatal accident.
7. The operator have valued driving license.
* Fire/Explosion.
N OHS 8. Proper signal man displayed. 1 4 1 4 1 1 0.5 0.5 4
* Material/property damage.
9. Proper leveled roads and adequate space.
* Serious injury.)
10. Check the over head clearance like live lines.
11. Ensure the pressure in tires is sufficient.

Unloading of material with
4 the help of crane/hydra
etc…
Making of temporary roller
5 for kin shell alignment and
welding purpose
1. Ensure the all work involved the activity is wearing all 1.Ensure SWP to be followed.
PPEs.
2. Very well leveled and compacted soil condition.
3. Valued third party certificates available. .
4. Check the area before placement of crane..
5. Inspection and corrective action to follow correct
handling procedures.
1. Toppling of crane.. 6. Proper guide rope provided for unwanted swinging of
2. Failure of crane. material.
3. Failure of lifting tools and tackles. 7. Ensure that the lifting tools which are using in lifting
4. Improper handling. process is in good condition and capable to hold the load.
5. Non use of PPE. 8. Lifting tools have a valued test certificates.
(* Fatal accident. 9. All persons involving the activity is competened and
R N 1 4 1 4 1 1 0.5 0.5 4
* Serious injury. medically fit for job.
* Hit injury. 10. Ensure that proper sleepers are provided in the beneath
* Struck between materials . of material.
* Cut injury.) 11. Proper packing to be provided.
12. The operator had a valued licence.
13. Ensure the swl is clearly marked in lifting tools.
1. Wear all work force proper PPEs Like helmet With chin 1.Ensure SWP to be followed.
strap safety shoes safety jacket , safety harness in height
elevations Etc.. .
2. .Provide all connections through ELCB or RCCB only
3. Choose right tools and tackles for erection purpose..
4. Check the lifting tools for any kind of damages .
1. Improper handling. 5. Display the permit.
2. Loose connections. 6. Ensure tool box meeting is conducted.
3. Improper usage of PPEs 7. Check for any type of loose connection & damages in
4. Damage of cable cable.
5. Falling of men and material from 8. Ensure that if the work is above 1.8 mtr ,take height
height. work protection & permit.
R N 9. Ensure that the rollers are inter locked well before the 1 4 1 4 1 1 0.5 0.5 4
erection of kiln shell.
(* cut & scratch injury 10. Proper access & egress are provided.
* Electric shock. 11. Only trained work force should engage the activity.
* Burn injury 12. Only One signal man should give signals for the crane
* Eye injury.
* Fatal)

Erection of material KILN
Shell with the help of
6 crane, hydra R N
,winch machine etc…..
Gas welding / cutting /
7 R or pipes storing flammable
heating.
Alignment of Kiln Shell
1.Tieing of piano wires &
8 R
providing packing under
the base frame
1. Failure of crane
2. Improper handling.
3. Failure of lifting tools.
4. Toppling of crane
5. Fall of material & man from height.
1. Welding radiates invisible
ultraviolet and infrared rays.
2. Improper placement of
oxygen and acetylene cylinders.
3. Leakage /cuts in hoses.
4. Opening - up of cylinder.
5. Welding of tanks, container
N 1
liquids.
(1. Radiation can damage eyes and
skin.
2. Explosion may occur.
3. May cause fire.
4. Cylinder may burst.
) 15. Never use LPG for gas cutting.
1.Cut injury due to tying piano wire
2. Struck between materials while
lifting of base frame
3. Failure of hydraulic jack.
4. Slipping of material
N pressure
(1. Cut injury
2. Scratch injury
3. Hit injury
4. series injury
)
1. Replacing defective / damaged tools. 1.Ensure SWP to be followed.
2. Use tools only with protective handles.
3. Training & instruction to use right tool for the right
job.
4. Keep tools only in toolboxes.
5. Use proper tested tools and tackles.
6. Provide proper packing in slings.
7. Check for any obstructions in lifting area.
8. Ensure that no over head obstructions.
9. Ensure that all work force involved in job is wearing all
type of PPEs
10. Proper access & egress are provided.
11. Area is properly barricaded.
13. Proper ladder is provided to reach the height.
14. Ensure that the tools which are using in height is
properly tied to never fell down. 1 4 1 4 1 1 0.5 0.5 4
15. Ensure that no falling material is keeping in height
elevations.
16. Proper life line arrangements are done.
17. All tools have its safety appliance.
18. Provide guide ropes for avoid unwanted swing of
material.
19 . Tools which are using erection activity is done third
party inspection and a valid test certificates
1. Use specified shielding devices and other PPE of 1.Ensure SWP to be followed.
correct specifications.
2. Avoid thoriated tungsten electrodes for GTAW.
3. Move out any leaking cylinder.
4. Keep trolley for transportation of cylinders and
chain them .
5. Use flashback arrestors.
6. Purge regulators immediately and then turn off.
7. Never use grease or oil on oxygen line connections
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
4 1 4 1 1 0.5 0.5 4
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.
1.All workforce have to wear all type of PPEs 1.Ensure SWP to be followed.
2. Provide an indication on piano wire
3. Check the hydraulic jack & hydraulic pipes
4. Ensure that a valid test certificate is available.
5. Proper maintenance should be done.
6. Proper packing should be provide before releasing the
1 4 1 4 1 1 0.5 0.5 4

• Fire hazards
Grinding of MS plates & • Electrical shock
9 R
structural steel. • Crack in grinding wheel
Fire hazard
Burn hazard
10 Arc Welding R Trip hazard
Electric shock(p)
Inhalation of Smoke/harmful gases(P)
1. Person can fall down.
2. Material can fall down
. May sustain sever injuries or prove
fatal .
11 Working at elevated places. R 2. May hit the scrap/ material stacked
at the ground or in between.
3. May hit the workers working at
lower levels and prove fatal.
• Entire working area shall be free from flammable material. 1.Ensure SWP to be followed.
• Before use, check the physical condition of grinding
machine; ensure that grinding machine must have good
condition guard.
• Grinding machine power cable must have three pin
industrial sockets and connected through RCCB/ELCB.
• Before grinding work check the grinding wheel for expiry
date.
• Grinding operation to be performed by the competent
person only.
• Grinder shall be use all the necessary PPEs like lather
apron, glasses apart from mandatory PPEs.
N • Good housekeeping to be maintained in the area. 1 4 3 12 0.5 1 0.5 0.5 4
• During grinding, person shall be away from the job.
• Ergonomic Work station shall be provided.
• Only certified grinding machine and its accessories to be
used.
• Correct speed & feed.
Welding machines are kept inside welding booth / rain 1.Ensure SWP to be followed.
protection arrangements
• All welding machine are routed through ELCBs
• Body earthing is done by 8 gauge GI wire
• Welders provided with PPEs (Leather hand gloves, safety
shoes)
• Overlapping of power and welding cable avoided.
• Avoid electrician standing on wet places or with wet
shoes or gloves.
N • Certified electrician 1 4 1 4 1 1 0.5 0.5 4
• Ensure surrounding area free from
• combustible materials
• Providing non conducting mat
• Periodic inspection of power cables
• Usage of signage
• Follow check list
1. Provide guard rails/ barricade at the work place. 1.Ensure SWP to be followed.
2. Use PPE like full body harness, life line, helmets,
safety shoes, etc.
3. Obtain the permit before starting the work at height
above 3m.
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.
N 11. Do not throw or drop materials or equipment from 1 4 1 4 1 1 0.5 0.5 4
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.
 1.Ensure SWP to be followed.

1. Working without PPE. 1. Use required PPE.

2. Failure of slings. 2. Use only certified slings as per colour coding.
3. Improper handling. 3. No person to stand under lifted load.
4. Overloading. 4. Follow safe lifting procedures.
Working under crane / 5. Defective equipment. 5. Only approved equipment to be used.
12 R N 1 7 1 7 0.5 1 0.5 0.5 4
lifting equipment 6. Lack of awarness. 6. Ensure pronpr servicing.
1. Fatality / injury due to fall of loads. 7. Training to operator and provinding banks man /
2. Material damage. rigger for assistance.
)

1.Ensure SWP to be followed.

. Follow lifting procedure.

2. Use correct equipment & lifting tackles.
3. Supervision by competent persons.
1. Loaded material due to fall.
4. Provide trained banksmen/rigger.
2. Defective equipment.
5. Do not jump out from vehicle till clearence is
Loading and unloading of 3. Overloading
obtained.
13 materials on trucks / R . Accident / injury N 2 4 1 8 1 1 0.5 0.5 4
6. Proper supervision.
trailers. 2. Damage of materials.
7. Refer to load chart.
3.Damage to equipment.
8. Use platform ladder for safe access.
9. Never deactivate or deenergise over riding devices
on lifting equipment.

1.Ensure SWP to be followed.

1. Keep charged cylinder only.

1. Cylinders kept horizontal. 2. Keep vertically and tie with chain to a fixed
2. Cylinder kept untied structure.
Transporting gas /unlocked in welding truck 3. Keep in specially fabricated cage to prevent fall.
cylinders: /mobile welding unit. 4. Keep valve cap in position during transportation.
* Oxygen 3. Valve leakage. 5. Different types of gas cylinders not to be loaded in
* Acetylene. 4. Fire and explosion by leakage and the same vehicle at a time.
14 R N 2 4 3 24 1 1 0.5 0.5 4
* Argon. property damage. 6. Only authorized vehicle and specially trained driver
* Nitrogen. 5. Gas leakage due to valve damage. shall be engaged in gas cylinder transportation.
* LPG. 6. Human injury by fall of cylinder. 7. Do not use leaking cylinder.
7. Damage to cylinder/valve. 8. Keep cylinder tied up/chained & locked
8. Leakage of gas. independently on truck to prevent falling of one
cylinder while loading/unloading the other.

1.Suffocation / drowning.
2. Presence of foul smell and
toxic substances.
Working in confined 3. Ignition/ flame can cause fire.
15 R N
spaces (Inside Kiln Shell) 4. Unconsciousness, death.
5. Inhalation can pose threat to life.
6. Person may sustain burn injuries or
explosion may occur.
1. Timbering blocks, wooden
planks, steel rod bits.
2. Pipe pieces.
3. Protruding bolts on concrete
foundations of pipe supports.
4. Paint tins, polythene papers,
electric cable/wire insulations,
16 Moving in the work area. R N
steel wire insulations, steel wire
cuttings, tools & tool boxes.
5. Overhead projection of pipes.
. Bodily injury due to fall of persons ,
fall of heavy objects, tools etc.
6. Hitting on overhead projections.
1. Small fires can become big
ones and may spread to the
surroundings areas.
2. Improper selection of Fire
extinguishers.
3. Short circuiting of electrical
Fire prevention and
17 R system. E 2
protection
4 Cause burn injuries and may prove
fatal.
5. Complete extinguishment of fire
may not be possible.
6. Can cause electrocution
1. Use respiratory devices, if required. 1.Ensure SWP to be followed.
2. Avoid over crowding inside a confined space.
3. Provide exhaust fans for ventilation.
4. Do not wear loose clothes, neck ties, etc.
5. Fulfill conditions of the permit.
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 .
1 7 1 7 1 1 0.5 0.5 4
13. Do not smoke inside a confined space. 1.Ensure SWP to be followed.
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.
1.Ensure SWP to be followed.
1. Remove all timber blocks, planks, pipe pieces etc
immediately after use to the designated place.
2. Do not keep objects / tools etc at heights without
safe containment against fall.
3. Provide barricading with warning tags.
4. Provide plastic/soft material cap to projecting pipes 2 4 1 8 0.5 1 0.5 0.25 4
and warning tags to caution the workers.
5. Maintain good house keeping by frequent
appraisals, supervision, inspection, audit and follow
up.
1.Ensure SWP to be followed.
1. In case a fire breaks out, press fire alarm system
and shout "Fire, Fire".
2. Keep buckets full of sand and water / fire
extinguishers in all hazardous locations.
3. Confine smoking to 'Smoking Zones' only.
4 1 8 0.5 1 0.5 0.25 4
4. Train people for using specific type of fire
equipments under different classes of fire.
5. Maintain good housekeeping and first -aid boxes.
7. Don't obstruct access to fire extinguishers.

18 Emergency preparedness
Exposure :-
Very rarely (less then one per year)
Rarely (Few time per year)
Sometimes (once are twice) per month
Now and then (Weekly)
Frequently (Daily)
Continuous (More then two times per day)
1.Non availability of the vehicle. 2. 1.Ambulance must be available in close proximity. 1.Ensure SWP to be followed.
Absence of the Rescue person. 3. 2.One dedicated person always present in this job. 3.
First Aid not available. First aid box facilities available at work spot.
4) Access blocked by material. 5. 4) Ensure passage way always free from any obstruct.
Fire hazard
5. Keep fire fighting equipments near to the work please
R E 1 4 0 4 0.5 1 0.5 0.25 4
NOTE:-
Severity :- Probability :- Risk:-
1. Only R<20 can result in acceptable s
0.5 Minor (Injury without time/work restriction - FAC) 1 Virtually Impossible: only theoretical case (once in a life time) 0.2 Risk Score Priority for the R=>20, I
Interpretation(1)
(R) measures to be taken reason should be documented
1 Major (Injury with time/work restriction - MTC RWC) 4 Conceivable but improbable: once in a career (once in 20 Y) 0.5 <20 Very limited risk - ­acceptable 4
2 Serious (Irreversible effect handicap-LWC) 7 Improbable/borderline case (1/10Y) 1 20 - ­70 Measures required (in 6m) 3
Unusual,: ( once in 3y) R/NR-Routine/Non Routine
3 Critical (One fatality, instantly or afterwards) 15 3 70 - ­200 Immediate measures required 2 N/A/E-Normal/Abnormal/Emergency
Disaster (more than one fatality, instantly or Possible (once every six months) S/NS-Significant/Not Significant
6 afterwards) 40 6 >200 Stop work until measures are taken 1 EMS-Environment Management System
OHS-Occupational Health & Safety
10 Can be expected (once per week) 10
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Ref
Not Complying legal S/
Doc(SOP/SMP/SW
Requirment(Y/N) NS
P/MP)
<20 can result in acceptable situation.
R=>20, If no action is taken, the
hould be documented

utine/Non Routine
rmal/Abnormal/Emergency
ificant/Not Significant
ronment Management System
upational Health & Safety