HAZARD IDENTIFICATION AND RISK ASSESSMENT – DEVELOPMENT OF RISK CONTROL

MEASURES

S. ACTIVITY HAZARD CONSEQUENCE PROBABILITY SEVIRITY RISKLEVEL RISK CONTROL MEASURES

No. FACTOR FACTOR RATING
ACTIVITY - 65: FABRICATION YARD OPERATIONS
1 Fabrication of
plate Rolling
work.

1 Grinding and 1. Absence of tool rest on 1. Eye / face injury 3 4 MODERATE 3 1. Use proper PPE. ( Face shield )
grinding wheel bench grinder.
replacing. 2. Hand injury 2. Mount the tool rest on both sides.
2. More gap between the wheel
and tool rest of bench grinder. 3. Gap more than 3mm is unsafe.

3. Improper/wrong size grinding 4. Use grinding wheel of correct size.

wheel.
5. Training & instruction.
4. Excess pressure on wheel.
6. Provide fire extinguisher.
5. Breakage of wheel.
7. Proper tightening of wheel.
2 Working with 1. Damaged cable . 1. Electric shock. 3 4 MODERATE 3 1. Daily check up before start.
portable electric
tools 2. Defective tool. 2. Spark/shock. 2. Replace defective 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.
3 Gas welding / 1. Backfiring. 1. Fatality / burn injury, fire / 2 5 HIGH 4 1. Work only after wearing PPE.
cutting / heating. explosion.
2. Splashing splinters. 2. Fit flash back arrestor and NRV on both cylinder
2. Gas leakage due to fall of cylinder outlets.
3. Gas leakage. and damage of valves.
3. Use face shield and fire proof gloves.
4. Wrong positioning of
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.

 HAZARD IDENTIFICATION AND RISK ASSESSMENT – DEVELOPMENT OF RISK CONTROL
MEASURES

S. ACTIVITY HAZARD CONSEQUENCE PROBABILITY SEVIRITY RISK LEVEL RISK CONTROL MEASURES
No. FACTOR FACTOR RATING
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.Toxic flames. 3. Lung ailments 3. Ventilation (local or exhaust if possible)

4. Loose connections / Loss of 4. Electric shock. 4. Full-sleeved coverall and gloves.

insulation.
5. Fire / explosion. 5. Proper clamping system / material handling
5. Flammable gases. techniques.
6. Asphyxiation.
6. Poor ventilation 6. Use shock proof boots and hand gloves.

7. Provide earthing to the plant.

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.
 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 deployed for equipment operations.
etc. 2. Defective equipment. 2. Material losses.
2. Equipment to be tested and certified by competent
3. Defective lifting jacks. 3. Tilting of jacks / boom. person before deployment.

4. Overloading. 3. No overloading allowed.

4. Follow procedures.

HAZARD IDENTIFICATION AND RISK ASSESSMENT – DEVELOPMENT OF RISK CONTROL

MEASURES

S. ACTIVITY HAZARD CONSEQUENCE PROBABILITY SEVIRITY RISK LEVEL RISK CONTROL MEASURES
No. FACTOR FACTOR RATING
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 structure.
4. Fire / body injury due to explosion
* 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

the same vehicle at a time.
* LPG.
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 drum or jack.
(Cable drum 2. Wrong position of jack. 2. Adopt proper procedure.
handling) 2. Injury by hitting / caught in.
3. Inadequate jack / spindle. 3. Use only tested and certified jack and spindle.
3. Finger injury due to trapping
4. Rotating parts. between drum / rollers. 4. Keep fingers away from nip points.

5. 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.