UltraTech Cement Limited - Andhra Pradesh Cement Works
Format for HIRA / JSA
Type of Activity: Routine / Non Routine / Critical Date: 14.12.2012 Doc. No: APCW/TPP/0018
Department: Mech/TPP
Section:
Job Title / Activity: Duct Assembly & Erection Name of the working Agency: Tessy Engineer & enterprises
Valid for the period: From 14.12.2012 to 13.01.2013 Work Order Number: 2M0028
Reference
Persons
Standard &
Sr. Activities Initial Risk Final Risk Responsible
Hazard Priority Safety Precautions Procedure /
No. (sequence of Work) (E X S X P) (E X S X P) :
SOP /
Documents
1.1 Duct Assembly 1. Slippage of 3X 4 X 6= 72 2 1. Proper arresting and locking of the 1X4X3=12=4 Site
loose materials member to be insured. engineer
from platform. 2. Level platform should be prepared.
1. All tools & tackle must be valid test
2. Tools & 2 X7X 6=84 2 1X4X3=12=4
certificate.
Tackles
1.2 Gas Cutting & 1. Burn 3X 4 X 6= 72 2 1.All workers follow PPEs 3X1X6=18=4 Site APCW/L2/GC-
welding. injury. 2. Fire Extinguisher should be available at engineer WLD/SWP/01
work place.
2. Fire hazard 6 X7X 6=252 1 1. while the carry of LPG and O2 should be
use of trolley
2. At the time of gas cutting cylinder should
1X7X1 = 7=4
be kept in upright position.
3. Ensure Hot work permit
4. Fire Extinguisher should be available at
work place.
1.3 Erection of Duct 1. Failure of 6x7x6=272 1 1. All lifting tools must have valid test 1X4X1=4=4 Site
lifting Tools certificate. engineer
2. Before starting of work ensure that sling
must be fixed properly with D-Shackle.
3. Area must be barricaded properly.
4. Lifting tools must be used as per safe
working load procedure.
1. Area to be barricaded properly.
2. Fall of 6 X7X 6=252 1 2. Fitting of duct carried out from inside. 1X7X1 = 7=4
material 3. Temporary platform required inside the
from height duct.
6 X7X 6=252 1 1. fall protection equipment must be used 1X7X1 = 7=4
as per the standard
3. Fall of 2. Workmen must be trained and certified
person. to work at heights.
3. Fall protection equipments must be
tested valid test certificate available.
4. Safety net / permanent platform should
be provided around the area.
5. Temporary platforms & life lines are
required for welding & fitting.
6. Step rods to be provided for proper
approach.
7. Sling arrangement to be done such that it
can be open from side.
1.4 Crane Activity 1. Crane 6x7x6=272 1 1. Ground level should be done by 1X4X1=4=4 Site APCW/TPP/HYD
Positioning Compactor /Roller. engineer -CRN/SWP/002
2. Way should be clear by obstructed
materials.
3. Proper Jacking to be done.
2. Failure of 6 X7X 6=252 1 1. Tools and tackles tested valid test 1X7X1=7=4
certificate available.
lifting tools
2. Before starting of work ensure that sling
must be checked and fixed properly with D-
Shackle.
3. Area to be barricaded properly.
4. Project work permit must be taken.
3. Injury of 3X15X6=270 1 1. All persons should keep some distance 1X4X3=12=4
from the lifted material
Person
2. While the materials lifting balance to
material with guide rope
4. Overall 2 X7X 6=84 1 1. All legal Documents Is available with load 1X4X3=12=4
Supervision chart. Site
2. Daily check list to be insured. engineer
3. All safety devices (Anti two blocking &
SLI, Fire Extinguisher, Seat belt, Reverse
horn, Rear view mirror & wiper) are in
working condition.
4. Operator having Heavy license for
operating.
5. PPEs to be maintained.
6. Two guide Rope should be fixing with
material.
7. Signal man should be available.
1.5 Housekeeping. 1. Injury due 2 X7X 6=84 2 1. All the tools and tackles, angles/channels 1X4X3=12=4 Site
to left over must be removed from the work place after engineer
material completion of job.
2. Clean the work place thoroughly.
E = Exposure; S = Severity; P = Probability; R = Risk = EXSXP
The Risk Assessment was led by:
Risk Assessment Team Members
1. B. Rajeshwar Rao
2. Ravikant Mohanty
3. Surya Bhushan
4. Pinoy P
5. Edvel Raja
6. Akhil G
Verified by Working Agency
* Have you briefed the Risk involved in the process to all the persons engaged : Y/N
* Have you obtained all necessary work permits : Y/N
Calculation Methods: HAZARD = Exposure x Severity ::::: RISK = Exposure x Severity x Probability
Exposure Facto Elimination
r 1. Lockout equipment
Very Rarely (less than one per year ) 0.5 2. Install blind /blank
Rarely ( few times per year) 1 3. Modify process to eliminate need for hazardous activity (e.g., auto sampling)
Sometimes ( once or twice ) 2 4. Fully automate process
Now and then( weekly) 3
Frequently ( daily) 6 Substitution
Continuous ( more than two times per day) 10 1. Use alternate materials (e.g., lower flash point)
2. Use tools instead of handling with bare hands
Severity Factor 3. Use trolley and truck (instead of carrying)
Minor ( injury without time/work restriction-FAC 1 4. Automate process
Major ( injury with time/work restriction- MTC,RWC) 4
Serious ( irreversible effect, handicap-LWC) 7 Engineering Control
Critical ( one fatality, instantly or afterwards) 15 1. Installing interlocks
Disaster ( more than one fatality, instantly or afterwards 40 2. Modifying equipment
3. Use special tools for the job
4. Redesign workplace layout
Probability Facto 5. Install noise enclosure
r 6. Machine guarding
Virtually Impossible: only theoretical case( once in a life time) 0.2
Conceivable but improbable: once in a career (once in 20 Y) 0.5 Administrative Control
Improbable/borderline case (1/10Y) 1 1. Implementing permit-to-work system
Unusual,: ( once in 3y) 3 2. Barricading area
Possible (once every six months) 6 3. Job rotating (to reduce fatigue)
Can be expected (once per week) 10
4. Following job procedures /work instructions
5. Working in pairs
Risk Priority for the 6. Testing for hazardous atmosphere
Interpretation(1)
Score (R) measures to be taken
<20 Very limited risk - acceptable 4
Personal Protective Equipment
1. Wearing safety harness
20 - 70 Measures required (in 6m) 3 2. Wearing Cut Resistant gloves
70 - 200 Immediate measures required 2 3. Wearing Heat Resistant coverall
4. Wear respirators
>200 Stop work until measures are 1
taken
