Sample Risk Assessment for 50-

75MW Solar PV Plant Activities

Hazard Identification, Risk Assessment and Risk

Control
A) Work activity: Erection of Column Post

Working steps for Erection of Column Post:

1. Boring Holes using DTH or Auger machinery depending upon the type of soil.
2. Column posts handling (material handling).
3. Erecting and fixing templates with column post into the bore holes.
4. Preparing mix concrete using mixers (Ajax) or Ready Mix Concrete Mixers.
5. Concreting the column post.

Hazard Identification:
Hazards identified are as follows

 Working environment hazards:

1. Extreme temperature: High climate temperature.
2. Dust: Dust while boring into the earth.
3. Mental stress: continuous work.
4. Vibration: DTH helper controlling the bit controls.
5. Dehydration: Excessive heat.
6. Ergonomics: DTH controller stand.
7. Falling into the bore: More than 1 mtr / 1.5mtr / 2 mtr of depth.
 Machinery hazards:
1. Mobile DTH vehicle: Its mobile.
2. Drill bits of DTH or Auger: Bits having edges.
3. Mobile cement mixers (Ajax): Its mobile.
 Material handling hazards:
1. Shifting column posts from warehouse to the working area: Posts having sharp
edges.
2. Handling of cement bags: Handling cement.
 3. Handling of templates: Manual handling.
4. Handling bolts, nuts, spanners and other tools: manual handling.

Risk Assessment:
Risk could be calculated by calculating Likelihood and severity.

 Likelihood of identified hazards:

HAZARD LIKELIHOOD LEVEL
Extreme temperature Most likely 5
Dust Possible 4
Mental stress Remote 2
Vibration Remote 2
Ergonomics Conceivable 3
Falling into the bore holes Conceivable 3
DTH Vehicle Remote 2
Drill bits of DTH Conceivable 3
Cement mixers Conceivable 3
Shifting column post Possible 4
Handling of cement bags Most likely 5
Handling of templates Conceivable 3
Handling bolts, other tools Conceivable 3
Dehydration Possible 4

 Severity of identified hazards:

HAZARD SEVERITY LEVEL
Extreme temperature Minor 2
Dust Minor 2
Mental stress Negligible 1
Vibration Negligible 1
Ergonomics Negligible 1
Falling into the bore holes Minor 2
DTH Vehicle Fatal 4
Drill bits of DTH Serious 3
Cement mixers Fatal 4
Shifting column post Negligible 1
Handling of cement bags Serious 3
Handling of templates Minor 2
Handling bolts, other tools Negligible 1
Dehydration Serious 3
  Risk level as per Risk Matrix of the identified hazards:
HAZARD RISK (S*L) RISK LEVEL
Extreme temperature 10 Medium
Dust 8 Medium
Mental stress 2 Low
Vibration 2 Low
Ergonomics 3 Low
Falling into the bore holes 6 Medium
DTH Vehicle 8 Medium
Drill bits of DTH 9 Medium
Cement mixers 12 Medium
Shifting column post 4 Low
Handling of cement bags 15 HIGH
Handling of templates 6 Medium
Handling bolts, other tools 3 Low
Dehydration 12 Medium

Risk Control, Elimination and Reduction:

1. Extreme temperature: Risk can be controlled by providing training to the workers
on how to be protected from heat strokes, providing glucose water, Suggesting
increase water consumption by the body, wear light color clothes.
2. Dust: Risk can be controlled by sprinkling water and by using respirator masks.
3. Mental Stress: suggesting work in shifts or take rest while lunch in resting shelters.
4. Vibration: Risk is tolerable.
5. Ergonomics: Risk is tolerable and could carry out work in shifts.
6. Falling into bore holes: Risk can be controlled by Barricading the area and
assigning work permit.
7. DTH vehicle: Risk can be control by ensuring that the vehicle has competent driver
and having back horn all lights and signals are working appropriately or by using
red flag when in operation and by providing vehicle permit.
8. Drill bits of DTH: Risk could be control by not allowing any other work by
providing work permit and by providing specific training.
9. Cement mixers: Risk can be control by ensuring that the vehicle has competent
driver and having back horn all lights and signals are working appropriately or by
using red flag when in operation and by providing vehicle permit and could use
sirens also while mobile.
10. Shifting column post: Risk can be controlled by providing training to the workers
for safe material handling and using proper PPE’s.
11. Handling cement bags: Risk severity is very high and only solution is to train the
workers for safe handling of cement and using proper PPE’s specially Masks.
12. Handling of templates: Risk can be controlled by providing training to the workers
for safe material handling and using proper PPE’s.
13. Handling of bolts, tools: Risk can be reduced by providing training to the workers
for safe material handling and using proper PPE’s.
14. Dehydration: Risk can be reduced by training the workers for consuming more and
more water, taking rest in shelters when the temperature is more than 42 degree.
B) Work Activity: Erection of Module Mounting Structure (MMS)
Working steps for Module Mounting Structure is as follows:
1. Shifting of rafter, purlin and side bracings from warehouse to the working area.
2. Shifting of bracing plates, connecting plates and suitable nut, bolts and washers.
3. Fixing rafter on the post, then fixing bracings and then fixing purlin completing the
whole structure.
4. Erecting solar modules on the structure.

Hazards Identification:
Hazards identified are as follows:

 Work environment hazards:

1. Excessive temperature: High climatic temperature.
2. Dehydration: Excessive heat.
3. Mental Stress: continuous work.
 Material handling hazards:
1. Handling purlin, rafters, bracings: sharp edges, hot metal surface.
2. Handling nut, bolts, bracing plates, connecting plates and tools:
Sharp edges, hot surfaces.
3. Handling module: Module is expensive has to be handled with care.
4. Muscular stress: Handling purlin and modules.

Risk Assessment:
Risk could be calculated by calculating Likelihood and severity.

 Likelihood of identified hazards:

HAZARD LIKELIHOOD LEVEL

Excessive temperature Most likely 5
Dehydration Possible 4
Mental stress Remote 2
Handling purlin, rafters etc Most likely 5
Handling connecting plates Possible 4
Handling modules Most likely 5
Muscular stress Conceivable 3
 Severity of identified hazards:
HAZARD SEVERITY LEVEL
Excessive temperature Minor 2
Dehydration Serious 3
Mental stress Negligible 1
Handling purlin, rafters etc Serious 3
Handling connecting plates Negligible 1
Handling modules Catastrophic 5
Muscular stress Negligible 1

 Risk level as per Risk Matrix of the identified hazards:

HAZARD RISK (S*L) RISK LEVEL
Excessive temperature 10 Medium
Dehydration 12 Medium
Mental stress 2 Low
Handling purlin, rafters etc 15 High
Handling connecting plates 4 Low
Handling modules 25 High
Muscular stress 3 Low

Risk Control, Elimination and Reduction:

1. Excessive temperature: Risk can be controlled by providing training to the
workers on how to be protected from heat strokes, providing glucose water,
Suggesting increase water consumption by the body, wear light color clothes.
2. Dehydration: Risk can be reduced by training the workers for consuming more
and more water, taking rest in shelters when the temperature is more than 42
degree.
3. Mental Stress: Suggesting work in shifts or take rest while lunch in resting shelters.
4. Handling purlin, rafters etc: Risk can be controlled by providing Proper training
for manual handling of all MMS material, gloves are must to wear, use of proper
PPE’s, two worker should carry a single purlin and permit has to be issue carry out
such activity.
5. Handling connecting plates and Bolts etc: Risk can be reduced by providing
training to the workers for safe material handling and using proper PPE’s.

6. Handling modules: Here risk is for both, for module and for worker as module is
expensive, module has to be carried and installed as per safe operating procedure,
i.e. 2 worker should handle module. Proper PPE’s is to be used while handling
modules, Proper training is to be provided to the workers as per safe operating
procedures and permit is to be issue to carry out such activity.
7. Muscular stress: Risk can be eliminated by handling the purlins and modules by 2
workers, by carrying out proper manual handling procedure as guided and by
providing training to the workers.
C) Work Activity: Erection of Inverter Room and Transformer.
Working steps for Erection of Inverter Rooms and Transformer:
1. Excavation of 1.5 mtr depth.
2. PCC and bar bending work with shuttering.
3. The concrete mix from the mixer i.e. Ajax, is then used for RCC in the footings of
trafo and ICR.
4. Brick work of the side walls.
5. Erection of ICR and Trafo with the help of Hydra of 16 Ton.
6. Welding of the base plates with the ICR and welding of the cover plates with the
trafo channel.

Hazard Identification:
Hazard identified are as follows:

 Work environment hazard

1. Excessive temperature: High climatic temperature
2. Dehydration: Excessive heat
3. Mental stress: Continuous work
4. Fall into the excavated area: Excavation is more than 1 mtr
5. Bar bending tools: Tools have complex work with sharp edges.
 Material handling hazards
1. Handling TMT bars: Shifting bars, hot surfaces and cutting them.
2. Handling ISMC channels: Channel is heavy, hot surface and it has to be cut
into desired size.
3. Shuttering Fixing: Formworks work involves iron nails and shuttering plates.
4. Handling of plumb, planner, hammer and other tools: sharp edges, hot metal
surface.
5. Erecting ICR and Trafo using Cranes: ICR and Trafo are of 8 and 15 tons
respectively and some delicate accessories using cranes for erection.
 Chemical Hazard
1. Handling cement: Chemically hazardous for skin and lungs.
2. Handling oil in shuttering covers: Chemically hazardous.
 Mechanical hazards
1. Mobile concrete mixer: Its mobile.
2. Mobile cranes: Its mobile and it has to carry heavy weight.
3. Welding: Hot work, electrically powered and produces harmful rays.
4. Vibrator: Diesel powered and having complex parts.
 5. Cutter: Machining equipment with sharp edging cutting wheel and electrically
powered.

Risk Assessment
Risk could be calculated by calculating Likelihood and severity.

 Likelihood of identified hazards:

HAZARDS LIKELIHOOD LEVEL

Excessive temperature Most likely 5
Dehydration Possible 4
Mental stress Inconceivable 1
Fall into the Excavated area Most likely 5
Bar bending tools Possible 4
Handling TMT bar Remote 2
Handling ISMC Conceivable 3
Shuttering Conceivable 3
Handling planners etc Remote 2
Erection of ICR and Trafo Most likely 5
Handling cement Most likely 5
Handling oil Conceivable 3
Mobile concrete mixer Remote 2
Mobile Crane Most likely 5
Welding Most likely 5
Vibrator Remote 2
Cutter Possible 4
 Severity of identified hazards:
HAZARDS SEVERITY LEVEL
Excessive temperature Minor 2
Dehydration Serious 3
Mental stress Negligible 1
Fall into the Excavated area Minor 2
Bar bending tools Negligible 1
Handling TMT bar Negligible 1
Handling ISMC Minor 2
Shuttering Negligible 1
Handling planners etc Negligible 1
Erection of ICR and Trafo Catastrophic 5
Handling cement Serious 3
Handling oil Negligible 1
Mobile concrete mixer Fatal 4
Mobile Crane Catastrophic 5
Welding Fatal 4
Vibrator Minor 2
Cutter Serious 3
  Risk level as per Risk Matrix of the identified hazards:

HAZARDS RISK (S*L) RISK LEVEL

Excessive temperature 10 Medium
Dehydration 12 Medium
Mental stress 1 Low
Fall into the Excavated area 10 Medium
Bar bending tools 4 Low
Handling TMT bar 2 Low
Handling ISMC 6 Low
Shuttering 3 Low
Handling planners etc 2 Low
Erection of ICR and Trafo 25 High
Handling cement 15 High
Handling oil 3 Low
Mobile concrete mixer 8 Medium
Mobile Crane 25 High
Welding 20 High
Vibrator 4 Low
Cutter 12 Medium

Risk Control, Elimination and Reduction:

1. Excessive temperature: Risk can be controlled by providing training to the workers
on how to be protected from heat strokes, providing glucose water, Suggesting
increase water consumption by the body, wear light color clothes.
2. Dehydration: Risk can be reduced by training the workers for consuming more
and more water, taking rest in shelters when the temperature is more than 42
degree.
3. Mental Stress: Suggesting work in shifts or take rest while lunch in resting shelters.
4. Fall into excavated area: Risk can be reduced by properly barricading the area by 2
layers of caution tapes and using sign board of excavation.
5. Bar bending tools: Risk can be reduced by using proper PPE’s i.e. gloves.
6. Handling TMT bar: Risk can be reduced by using proper PPE’s and by barricading the
area of work.

7. Handling ISMC: Risk can be reduced by using hydra to place the ISMC and using
2 labor to reduce momentum of the ISMC from opposite sides while placing.

8. Shuttering: Risk can be controlled by carrying the activity by a competent person and
using proper PPE’s.

9. Handling planners and other tools: Risk can be controlled by carrying the
activity by a competent person and using proper PPE’s.

10. Erection of ICR and Trafo: Risk can be controlled by first grading and leveling the
 area where erection has to be done and issuing work permit. A competent crane
operator and competent rigger person should be used to erect these. The crane
should be fit to use and proper statutory requirements should be ensured before
use. For 16 ton of crane, 1 / 2 crane has to be used to carry the trafo and ICR
positioned diagonal to the 2 adjacent corner of the wide face of the ICR or trafo.
Proper supervision should be there of a competent person.
11. Handling cement: Risk can be controlled by providing training to the workers for safe
handling of cement, using proper PPE’s specially Masks and by issuing work permit.
12. Handling oil: Risk can be controlled by providing proper training to the workers for
handling oil and disposal procedures and using proper PPE’s.
13. Mobile concrete mixer: Risk can be control by ensuring that the vehicle has
competent driver and having back horn all lights and signals are working
appropriately or by using red flag when in operation and by providing vehicle
permit and could use sirens also while mobile.
14. Mobile crane: Risk can be controlled by ensuring that the driver is a competent driver
along with competent rigger helper. The crane has passed fitness test report and its
slings to be used also have passed the fitness test and properly labeled it’s
maximum limit value. There should be a back horn, emergency siren for over
loading and tyres should be guarded properly, after ensuring all the point the crane
should be provided with lifting vehicle permit.

15. Welding: Risk can be controlled by providing hot work permit, ensuring that the area is
properly grounded, ensuring that a fire extinguisher has been placed , welder is a
competent welder, using proper PPPE’s i.e. leather gloves, Face shield with UV
protected glass etc and proper training is to be provided to the welder for any kind of
emergency .
16. Vibrator: Risk is tolerable
17. Cutter: Risk can be controlled by properly guarding the cutter, using proper PPE’s,
ensuring cutter is running below its maximum rpm and properly grounded.
D) Work activity: DC, AC Cable Laying and Termination.
Working steps for DC, AC Cable Laying and Termination:
1. Excavation of 1m depth and 1m width trench.
2. Sand laying into the trench.
3. Cable drums shifting and jacking at some plane surface.
4. Unrolling the cable and laying into the trench.
5. Sand laying above the cable and backfilling the trench.
6. Placing cable trays b/w ICR and trafo.
7. Cutting the cable, fixing lugs, covering with heat sleeves and terminating with the ICR,
SCB’s, Trafo and ICOG’s.

Hazard identification
Hazard identified are as follows:

 Work environment hazard

1. Excessive temperature: High climatic temperature
2. Dehydration: Excessive heat
3. Falling into the trench: Excavation is of 1m.
4. Inadequate access: Trench are in between the MMS tables
 Mechanical hazards
1. Cable cutters: Having sharp edges and are strong cutters
2. Excel blades: Having sharp edges
3. Fixing jacks with cable drums: Drums are of 3 Ton and have to be jacked
accurately and at a plane surface with the help of a lifting vehicle.
4. Lifting vehicle (14 Tons): Its mobile and it has to carry heavy weight.
5. Lug clamping device: Having punching set.
6. Welding machine: Hot work, electrically powered and produces harmful rays.
7. Heat blower: Hot work and electrically powered.
8. DG set: Diesel generator producing electricity.

 Material handling hazards

1. Shifting cable drums: Weigh 3 Ton.
2. Laying cable: Excessive length of cable to be unrolled, pulled and laid.
3. Handling tools: Tools having sharp edges.
4. Handling cable trays: Cable trays are of sharp edges and hot surface.
5. Muscular stress: laying cable is a muscular activity.
Risk Assessment:
Risk could be calculated by calculating Likelihood and severity.

 Likelihood of identified hazards:

HAZARDS LIKELIHOOD LEVEL
Excessive temperature Most likely 5
Dehydration Possible 4
Falling into trench Possible 4
Inadequate access Remote 2
Cable cutter Conceivable 3
Excel blades Possible 4
Fixing jacks Most likely 5
Lifting vehicle Conceivable 3
Lug clamper Remote 2
Welding machine Most likely 5
Heat blower Conceivable 3
DG set Possible 4
Shifting cable drums Possible 4
Laying cables Conceivable 3
Handling tools Remote 2
Handling cable trays Conceivable 3
Muscular stress Conceivable 3

 Severity of identified hazards:

HAZARDS SEVERITY LEVEL
Excessive temperature Minor 2
Dehydration Serious 3
Falling into trench Negligible 1
Inadequate access Negligible 1
Cable cutter Minor 2
Excel blades Minor 2
Fixing jacks Serious 3
Lifting vehicle Fatal 4
Lug clamper Negligible 1
Welding machine Fatal 4
Heat blower Serious 3
DG set Catastrophic 5
Shifting cable drums Fatal 4
Laying cables Negligible 1
Handling tools Negligible 1
Handling cable trays Minor 2
Muscular stress Minor 2
  Risk level as per Risk Matrix of the identified hazards:
HAZARDS RISK (S*L) RISK LEVEL
Excessive temperature 10 Medium
Dehydration 12 Medium
Falling into trench 4 Low
Inadequate access 2 Low
Cable cutter 6 Low
Excel blades 8 Medium
Fixing jacks 15 High
Lifting vehicle 12 Medium
Lug clamper 2 Low
Welding machine 20 High
Heat blower 9 Medium
DG set 20 High
Shifting cable drums 16 High
Laying cables 3 Low
Handling tools 2 Low
Handling cable trays 6 Low
Muscular stress 6 Low

Risk Control, Elimination and Reduction:

1. Cable cutters: Risk can be reduced by carrying out the cutting activity by a skilled
labor using proper PPE’s.

2. Excel blades: Risk can be reduced by carrying out the cutting activity by a skilled
labor using proper PPE’s.

3. Fixing jacks with cable drums: Risk can be reduced by carrying out the activity with
skilled and trained labor using proper PPE’s and issuing work permit for the work.

4. Lifting vehicle (14 Tons): Risk can be controlled by ensuring that the driver is a
competent driver along with competent rigger helper. The crane has passed fitness
test report and its slings to be used also have passed the fitness test and properly
labeled its maximum limit value. There should be a back horn, emergency siren for
over loading and tyres should be guarded properly, after ensuring all the point
the crane should be provided with lifting vehicle permit.
5. Lug clamping device: Risk is tolerable.
6. Welding machine: Risk can be controlled by providing hot work permit, ensuring
that the area is properly grounded, ensuring that a fire extinguisher has been
placed , welder is a competent welder, using proper PPPE’s i.e. leather gloves,
Face shield with UV protected glass etc and proper training is to be provided to the
welder for any kind of emergency .

7. Heat blower: Risk is controlled by issuing hot work permit, using proper PPE’s and
ensuring proper supply with the help of distribution boards.

8. DG set: Risk can be reduced by properly checking the DG as per check list and
 ensuring that proper earthing is provided to the DG, MCB is used in the supply unit,
proper wire clamps are there, the silencer is positioned at acceptable height as per
the norms and wires are connected properly and insulated well.
9. Excessive temperature: Risk can be controlled by providing training to the workers
on how to be protected from heat strokes, providing glucose water, Suggesting
increase water consumption by the body, wear light color clothes
10. Dehydration: Risk can be reduced by training the workers for consuming more
and more water, taking rest in shelters when the temperature is more than 42
degree.
11. Falling into the trench: Risk can be reduced by properly barricading the area by 2
layers of caution tapes and using sign board of excavation specialy near the approach
roads.
12. Inadequate access: Risk is tolerable the worker should know the site map.
13. Shifting cable drums: Risk can be reduced by not directly handling the cable drums,
just tying rope and directing the moment of cable drums with the help of 2 labors and

14. Laying cable: Risk can be reduced by using trained labor and proper planning before
carrying out the work and using proper PPE’s.

15. Handling tools: Risk can be reduced by properly maintaining tool kit and using proper
PPE’s.

16. Handling cable trays: Risk can be reduced by ensuring proper PPE’s usage.
17. Muscular stress: Risk can be reduced by carrying out proper manual handling
procedure as guided and by providing training to the workers.
E) Work activity: MCR and Switch Yard Foundation
Working steps for MCR and Switch Yard Foundation are as follows:
1. Excavation of 2 to 3 meters below the NGL.
2. PCC and laying steel mash and binding the steel bars for the column foundation.
3. Shuttering of the steel work for concreting.
4. RCC using concrete mixers.
5. Placing ICMC and steel rail.
6. Placing Base plates into the column and bolts for the super structures.

Hazard identification
Hazard identified are as follows:

 Work environment hazard:

1. Excessive temperature: High climatic temperature.
2. Dehydration: Excessive heat.
3. Falling into the trench: Excavation is more than 1m.
4. Bar bending tools: Tools have complex work with sharp edges.
 Material handling hazards:
1. Handling TMT steel bars: Shifting bars, hot surfaces and cutting them.
2. Handling ISMC channel: Channel is heavy, hot surface and it has to be cut
into desired size
3. Handling steel rail: Steel rail is too heavy and require lifting vehicle for its placing.
4. Handling shuttering plates and fixing: Formworks work involves iron nails and
shuttering plates.
5. Handling nails, tools etc: Nails and other tools are having sharp and pointed
edges and are of steel.
6. Handling concrete: Chemically hazardous for skin and lungs.
 Mechanical hazards:
1. Welding: Hot work, electrically powered and produces harmful rays.
2. Mobile concrete mixer: It’s mobile.

3. Mobile crane: Its mobile and it has to carry heavy weight.

Risk assessment:
Risk could be calculated by calculating Likelihood and severity.
 Likelihood of identified hazards:
HAZARDS LIKELIHOOD LEVEL
Excessive temperature Most likely 5
Dehydration Possible 4
Falling into trench Possible 4
Bar bending tools Possible 4
Handling TMT bars Conceivable 3
Handling ISMC Conceivable 3
Handling shuttering plates Possible 4
Handling rail Conceivable 3
Handling nails, tools Remote 2
Handling concrete Most likely 5
Welding Most likely 5
Mobile concrete mixer Remote 4
Mobile crane Most likely 5

 Severity of identified hazards:

HAZARDS SEVERITY LEVEL
Excessive temperature Minor 2
Dehydration Serious 3
Falling into trench Negligible 1
Bar bending tools Negligible 1
Handling TMT bars Negligible 1
Handling ISMC Serious 3
Handling shuttering plates Serious 3
Handling rail Serious 3
Handling nails, tools Negligible 1
Handling concrete Serious 3
Welding Fatal 4
Mobile concrete mixer Fatal 4
Mobile crane Catastrophic 5

 Risk level as per Risk Matrix of the identified hazards:

HAZARDS RISK (S*L) RISK LEVEL
Excessive temperature 10 Medium
Dehydration 12 Medium
Falling into trench 4 Low
r bending tools 4 Low
Handling TMT bars 3 Low
Handling ISMC 9 Medium
Handling shuttering plates 12 Medium
Handling rail 9 Medium
Handling nails, tools 2 Low
Handling concrete 15 High
Welding 20 High
Mobile concrete mixer 16 High
Mobile crane 25 High
Risk Control, Elimination and Reduction:
1. Excessive temperature: Risk can be controlled by providing training to the
workers on how to be protected from heat strokes, providing glucose water,
Suggesting increase water consumption by the body, wear light color clothes
2. Dehydration: Risk can be reduced by training the workers for consuming more
and more water, taking rest in shelters when the temperature is more than 42
degree.
3. Falling into the trench: Risk can be reduced by properly barricading the area by
2 layers of caution tapes and using sign board of excavation and providing a
ladder for access to and from the excavated area.
4. Bar bending tools: Risk can be reduced by using proper PPE’s i.e. gloves.
5. Handling TMT steel bars: Risk can be reduced by using proper PPE’s and by
barricading the area of work.

6. Handling ISMC channel: Risk can be reduced by using hydra to place the ISMC
and using 2 labor to reduce momentum of the ISMC from opposite sides while placing.
7. Handling steel rail: Risk can be reduced by carrying out lifting operation with
the help of lifting equipment like a crane and controlling its moment with the
help of rope with 2 workers and issuing work permit for that.

8. Handling shuttering plates and fixing: Risk can be controlled by carrying the
activity by a competent person and using proper PPE’s.

9. Handling nails, tools etc: Risk can be controlled by using proper PPE’s.
10. Handling concrete: Risk can be controlled by providing training to the workers for safe
handling of cement, using proper PPE’s specially Masks and by issuing work permit.
11. Welding: Risk can be controlled by providing hot work permit, ensuring that the
area is properly grounded, ensuring that a fire extinguisher has been placed ,
welder is a competent welder, using proper PPPE’s i.e. leather gloves, Face shield
with UV protected glass etc and proper training is to be provided to the welder for
any kind of emergency .

12. Mobile concrete mixer: Risk can be control by ensuring that the vehicle has
competent driver and having back horn all lights and signals are working
appropriately or by using red flag when in operation and by providing vehicle
permit and could use sirens also while mobile.
13. Mobile crane: Risk can be controlled by ensuring that the driver is a competent
driver along with competent rigger helper. The crane has passed fitness test report
and its slings to be used also have passed the fitness test and properly labeled its
maximum limit value. There should be a back horn, emergency siren for over
loading and tyres should be guarded properly, after ensuring all the point the crane
should be provided with lifting vehicle permit.
F) Work activity: Erection of Structures, Isolators, Panels,
CT, PT, LA, BPI, Trafo and Pre Fabricated MCR.

Working steps for Erection of Structures, Isolators, Panels, CT,

PT, LA, BPI, Trafo and Pre Fabricated MCR:
1. Erecting angles of the structures on the various respective columns.
2. Crane is to be used for fixing the pre fabricated beams on the MCR roof.
3. Puff sheets has to be cut in desired shape and then fixed to MCR walls and roofs.
4. Welding is to be done for sheet supporting rails inside the MCR.
5. Erecting TNS towers using stub bolts at one of the column for climbing upon.
6. Erecting trafo on the trafo foundation with the help of 60 Ton crane.
7. Erecting various electrical instruments like CT, PT, LA, CVT, BPI on the respective
structures with the help of crane of 14 Ton.
8. Stringing is to be done on the TNS and clamping wires to the various electrical
instruments.
9. Welding earth strips to structures of various instruments.

Hazard Identification
Hazard identified are as follows:

 Work environment hazard

1. Excessive temperature: High climatic temperature
2. Dehydration: Excessive heat
3. Inadequate access: Trench are in between the MMS tables
4. Work at height: Falling from height of 13m
 Material handling hazards
1. Handling angles and beams of structure: Hot surfaces, manual handling.
2. Handling puff sheets: Puff sheets are having puffs and are having sharp edges.
3. Handling earth strips: Earth strips are of heavy and has to be placed by group of
workers.
4. Handling nut, bolts, tools: Nuts, bolts and tools has to be fixed at height.
5. Erecting trafo with the help of 60 Ton crane: Trafo is of 45 Tons and has to
erected with the help of 60 Ton crane.
6. Handling and erecting electrical instruments: Electrical instrument
7. Ergonomics: Improper posture while working at height and stringing.
8. Handling stringing wire: Aluminum wire of 200 sq mm has to be tied at bus bars.
 Mechanical hazards
1. Crane 14 and 60 Tons: 14 Ton crane is a mobile crane, 60 Ton crane has to place
trafo.
2. Welding: Hot work, electrically powered and produces harmful rays.
 3. Cutter m/c: Machining equipment with sharp edging cutting wheel and
electrically powered.
 Chemical hazards
1. Silicon filling: Silicon is a hazardous chemical.

Risk Assessment
Risk could be calculated by calculating Likelihood and severity.

 Likelihood of identified hazards:

HAZARDS LIKELIHOOD LEVEL

Excessive temperature Most likely 5
Dehydration Possible 4
Inadequate access Conceivable 3
Work at height Most likely 5
Handling angles and beams Possible 4
Handling puff sheets Possible 4
Handling earth strips Remote 2
Handling bolts, tools Remote 2
Erecting trafo Most likely 5
Erecting electrical Possible 4
instrument
Ergonomics Conceivable 3
Handling stringing wire Conceivable 3
Crane 14 and 60 Tons Most likely 5
Welder Possible 4
Cutter Remote 2
Silicon filling Remote 2

 Severity of identified hazards:

HAZARDS SEVERITY LEVEL

Excessive temperature Minor 2
Dehydration Serious 3
Inadequate access Minor 2
Work at height Fatal 4
Handling angles and beams Serious 3
Handling puff sheets Catastrophic 5
Handling earth strips Negligible 1
Handling bolts, tools Negligible 1
Erecting trafo Catastrophic 5
Erecting electrical Fatal 4
instrument
Ergonomics Minor 2
Handling stringing wire Negligible 1
Crane 14 and 60 Tons Catastrophic 5
Welder Fatal 4
Cutter Serious 3
Silicon filling Serious 3
  Risk level as per Risk Matrix of the identified hazards:
HAZARDS RISK RISK LEVEL
Excessive temperature 10 Medium
Dehydration 12 Medium
Inadequate access 6 Low
Work at height 20 High
Handling angles and beams 12 Medium
Handling puff sheets 20 High
Handling earth strips 2 Low
Handling bolts, tools 2 Low
Erecting trafo 25 High
Erecting electrical 16 High
instrument
Ergonomics 6 Low
Handling stringing wire 3 Low
Crane 14 and 60 Tons 25 High
Welder 16 High
Cutter 6 Low
Silicon filling 6 Low

Risk Control, Elimination and Reduction:

1. Excessive temperature: Risk can be controlled by providing training to the workers
on how to be protected from heat strokes, providing glucose water, Suggesting
increase water consumption by the body, wear light color clothes
2. Dehydration: Risk can be reduced by training the workers for consuming more
and more water, taking rest in shelters when the temperature is more than 42
degree.
3. Inadequate access: Risk can be controlled by properly using steel ladders for
access and using safety harness while working above structures.
4. Work at height: Risk can be reduced by ensuring that the worker working at
height is medically fit by ensuring it’s medical test, by providing proper training to
the worker about the measures for working at height safety, by proper use of fall
arrester while climbing on the structure and towers and then using safety harness
fixed at proper position, by issuing separate work at height work permit to the worker.
5. Handling angles and beams of structure: The angles and beams may have sharp
edges hence gloves is to be used, should be carried by 2 or more person when
carried manually, while tying it to a cranes always ensure that the moment of the
beam is controlled with the help of 2 ropes tied at 2 ends of the beam and using
proper PPE’s.
6. Handling puff sheets: Puff sheets are having sharp edges, hence should be
carried safely with the help of gloves. The puff sheets having puffs inside could
get into our lungs while cutting thus proper respirator mask has to be used while
working with that.
7. Handling earth strips: Risk can be reduced by properly using PPE’s and carrying the
earth strips with the help of more than 1 worker.

8. Handling nut, bolts, tools: Risk is tolerable, then also PPE’s are must.
9. Erecting trafo with the help of 60 Ton crane: Risk can be controlled by first
grading and leveling the area where erection has to be done and issuing work
permit. A competent crane operator and competent rigger person should be used to
erect these. The crane should be fit to use and proper statutory requirements should
be ensured before use. Proper supervision should be there of a competent person
and to control its moment 4 ropes is to be tied at 4 corner then trafo has to be
handled from distance.

10. Handling and erecting electrical instruments: All electrical instrument are delicate
as having porcelain material and they are quite heavy also thus need to be placed
with the help of a crane thus its moment could be controlled by tying 2 ropes at its
end, The worker erecting the instruments should also be competent and should use
proper PPE’s and safety harness while erecting them on the structures.
11. Ergonomics: Risk can be controlled by ensuring work is carried by a competent
person only and it should be carried out in shifts and there should be proper use of
safety harness.
12. Handling stringing wire: Risk can be controlled by using proper PPE’s specially
gloves.
13. Crane 14 and 60 Tons: Risk can be controlled by ensuring that the driver is a
competent driver along with competent rigger helper. The crane has passed fitness
test report and its slings to be used also have passed the fitness test and properly
labeled it’s maximum limit value. There should be a back horn, emergency siren for
over loading and tyres should be guarded properly, its base should also be fixed at
proper levels, after ensuring all the point the crane should be provided with lifting
vehicle permit.
14. Welding: Risk can be controlled by providing hot work permit, ensuring that the
area is properly grounded, ensuring that a fire extinguisher has been placed , welder
is a competent welder, using proper PPPE’s i.e. leather gloves, Face shield with UV
protected glass etc and proper training is to be provided to the welder for any kind of
emergency .
15. Cutter m/c: Risk can be controlled by properly guarding the cutter, using proper
PPE’s, ensuring cutter is running below its maximum rpm and properly grounded.
16. Silicon filling: Silicon is chemically hazardous thus it has to be handled carefully by
using proper PPE’s and special mask.