Ohs-Pr-09-03-F04 (A) Hazard Id & Categories Checklist

PLANT AND FACILITY SAFETY
OHS-PR-09-03-F04 (A) HAZARD ID & CATEGORIES CHECKLIST
Operating Area: Department:

Project Name:
Contractor Name: Project Type: Contract No.:
Table 1: HAZARD CATEGORIES CHECKSHEET

Highlight those Hazards that are Health
Hazard Category Hazards
Related
Mechanical
Electrical
Explosions
Liquid Escape
Gas Escape
Fire
Structural Failure
Entanglement
Crushing
Cutting, Stabbing & Puncturing
Shearing
Friction
Struck By
High Pressure Fluid
Slipping, Tripping & Falling
(including falling objects)
Suffocation
Underground Utilities
Overhead Utilities
Water
Demolitions
Tunnelling
Vehicles (Construction)
Mobile Plant (Construction)
Temperature
Physical Extremes
(Hot/Cold)
Physical Noise
Physical Pressure
Illumination
Physical (too little/too
much)
Physical Ventilation
Electromagnetic Fields (EMF)
Hazard
Chemical Gases
Substances
OHS Forms Procedure Reference Revision Number Revision Date Approved By
HAZARD ID & CATEGORIES CHECKLIST OHS-PR-09-03-F04 (A) 0 MAY 2021 OHSMS

Project Name:
Hazard
Chemical Fumes
Substances
Hazard
Dust
Chemical
(Coal/Ash)
Substance
Hazard
Chemical
Chemical
Vapours
Substance
Hazard
Chemical Chemical Mists
Substance
Hazard
Hazardous
Chemical
Waste
Substance
Hazard
Chemical Acids
Substance
Hazard
Chemical Solvents
Substance
Hazard
Chemical Oils
Substance
Hazard
Chemical Resins
Substance
Ergonomics and Manual
Handling
Radiation (ionising & non-
ionising)- e.g., ultraviolet,
welding; isotopes
Psychological- e.g., stress
Biological- e.g., bacteria, viruses,
fungi, moulds, insects
Environment – use the
Environmental Impact
Assessments (EIA’s); Impacts and
Aspects Register as a source of
info when completing this
section.
Confined Spaces
Housekeeping
Climatic


Project Name:
Bomb Threats
Other (Specify)
Table 2: GENERIC HAZARD TYPES
GENERIC HAZARDS EXPANDED DETAILS
Hazard Category Hazards
Explosions Overpressure
Collision
Corrosion / Erosion / External / Internal
Over temperature
Fire
Fabrication / Material Defect
Repairs / Modifications / Maintenance
Protection Failure (Safety Valves)
Environment (i.e., conditions of operation)
Contamination / Impurities
Ignition of contents
Malicious act
Temperature differential
Gas/dust ignition
Explosives
Gas bottles
Pressure vessels
Blasting
Mechanical Breakdown Consequential risks downstream
Valves / Safety Valves
Agitators / Bottom scrapers
Rotary steam joints
Syphons
Gaskets
Guarding
Impact
Thermal fatigue
Instrumentation (Dp cells)
Shaft failures
Bolts and/or fasteners
Bearings
Fire Housekeeping
Malicious act
Maintenance specifically to oxy-acetylene sets
Ignition of contents
Contamination
Exothermic process
Electrical faults
Electrical Isolation
Lockouts
Cable damage

Project Name:
Power failure
Fuses blowing
Flame proofing
Earthing
Tampering
Bridging out
Lightning strike
Short circuits and general electrical faults
Proximity to high voltage (HV)
Level indicators
Loss of pressure control
Temporary wiring installations
Water ingress into critical electrical systems
Corrosion of IC cards in a DCS
Contamination or failure of instrument air system
Gas Escape Maintenance
Mechanical failure
Crack leading to material failure
Fabrication faults not previously detected
Collision or impact
Protection devices failing open
Corrosion
Control system failures
Human error and/or procedures
Malicious act
Liquid Escape Maintenance
Mechanical Failure
Crack leading to Material Failure
Fabrication Faults not Previously Detected
Collision or Impact
Protection devices failing open
Corrosion
Control systems failures
Human error and/or procedures
Malicious act
Structural Failure Wind loading
Earthquake
Foundation collapse
Lightning strike
Corrosion / erosion externally
Corrosion / erosion internal on baffles
Over stress steel structures from pipe work
Over stress by weight overload e.g. waterlogged drier can
Collision / impact
Design / Fabrication / Modifications / Repair faults
Rupture


Project Name:
Process deviation
Radiation Exposure X - ray of welds after repairs
Instrumentation, like level detectors on digesters
Moving Parts Nip points
Operator protection
Maintenance
Guards
Load locks
Lockouts
Ergonomics Poor workstation set-up
Poor posture
Manual handling
Lifting/Pulling
Communication
Repetitive motions
Computer work
Environment Air emissions
Water pollution
Ground pollution
Waste management
Spills
Raw material consumption
Habitat destruction
Energy consumption
Table 3: EXAMPLES OF QUESTIONS THAT CAN BE ASKED WHEN CONDUCTING THE HAZARD IDENTIFICATION
[A] ENTANGLEMENT YES / NO
Can anyone's hair, clothing, gloves, necktie, jewelry, cleaning brushes, loose clothing, rags or other
materials become entangled with moving parts of the plant, or materials in motion?
[B] CRUSHING YES / NO
Can anyone be crushed due to:
a. material falling off the plant?
b. uncontrolled or unexpected movement of the plant?
c. lack of capacity for the plant to be slowed, stopped or immobilized?
d. the plant tipping or rolling over?
e. parts of the plant collapsing?
f. coming in contact with moving parts of the plant during testing, inspection, maintenance,
cleaning or repair?
g. being thrown off or under the plant?
h. being trapped between the plant and materials or fixed structures?
i. other factors not previously mentioned?
[C] CUTTING STABBING & PUNCTURING YES / NO
Can anyone be cut, stabbed or punctured due to:
a. coming in contact with sharp or flying objects?
b. coming in contact with moving parts of the plant during testing, inspection, operation,

Project Name:
maintenance, cleaning or repair of the plant?

c. the plant, parts of the plant or work pieces disintegrating?
d. work pieces being ejected?
e. the mobility of the plant?
f. uncontrolled or unexpected movement of the plant?
g. other factors not previously mentioned?
[D] SHEARING YES / NO
Can anyone's body parts be sheared between two parts of the plant, or between a part of the plant
and a work piece or structure?
[E] FRICTION YES / NO
Can anyone be burnt due to contact with moving parts or surfaces of the plant, or material handled
by the plant?
[F] STRIKING YES / NO
Can anyone be struck by moving objects due to:
a. uncontrolled or unexpected movement of the plant or material handled by the plant?
b. the plant, parts of the plant or work pieces disintegrating?
c. work pieces being ejected?
d. mobility of the plant?
e. other factors not previously mentioned?
[G] HIGH PRESSURE FLUID YES / NO
Can anyone come into contact with fluids under high pressure, due to plant failure or misuse of the
plant?
[H] ELECTRICAL YES / NO
Can anyone be injured by electrical shock or burnt due to:
a. the plant contacting live electrical conductors?
b. the plant working in close proximity to electrical conductors?
c. overload of electrical circuits?
d. damaged or poorly maintained electrical leads and cables?
e. damaged electrical switches?
f. water near electrical equipment?
g. lack of isolation procedures?
h. other factors not previously mentioned?
[I] EXPLOSION YES / NO
Can anyone be injured by explosion of gases, vapors, liquids, dusts or other substances, triggered by
the operation of the plant or by material handled by the plant?
[J] SLIPPING, TRIPPING & FALLING YES / NO
Can anyone using the plant, or in the vicinity of the plant, slip, trip or fall due to:
a. uneven or slippery work surfaces?
b. poor housekeeping, e.g., rubbish, scrap in the vicinity of the plant, spillage not cleaned up?
c. obstacles being placed in the vicinity of the plant?
d. other factors not previously mentioned?
Can anyone fall from a height due to:


Project Name:
a. lack of a proper work platform?

b. lack of proper stairs or ladders?
c. lack of guardrails or other suitable edge protection
d. unprotected holes, penetrations or gaps?
e. poor floor or walking surfaces, such as the lack of a slip-resistant surface?
f. steep walking surfaces?
g. collapse of the supporting structure?
[K] SUFFOCATION YES / NO
Can anyone be suffocated due to lack of oxygen, or atmospheric contamination?
[L] TEMPERATURE EXTREMES OR FIRE YES / NO
Can anyone come into contact with objects at high or low temperatures?
Can anyone suffer ill-health due to exposure to high or low temperatures?
Can anyone be injured by fire?
[M] MANUAL HANDLING YES / NO
Can anyone be injured from manual handling due to the following factors:
a. the force to be applied by the person?
b. the actions and movements involved in the manual handling?
c. the range of weights handled?
d. the duration and frequency of the manual handling?
e. the time, and distance, over which an object is handled?
f. the lack of mechanical aids?
g. the layout and condition of the workplace environment?
h. the way work is organized? (e.g., availability of people and materials; quotas, targets, job
rotation etc.)
i. the postural requirements imposed by the manual handling?
j. the age of the employee carrying out the manual handling?
k. the skill and experience of the employee carrying out the manual handling?
l. the nature of the object being handled? (e.g., size, shape, structure and material of load; sharp
edges; slippery; difficult to grasp/hold; unstable; live person or animal etc.)
m. other factors not previously mentioned? (Refer also to the Manual Handling Code of Practice
for further information).
[N] OTHER HAZARDS YES / NO
Can anyone be injured or suffer ill-health from exposure to:
a. chemicals?
b. toxic gases or vapors?
c. fumes?
d. dust?
e. noise?
f. vibration?
g. radiation?
[N] OTHER HAZARDS YES / NO


Project Name:
Can anyone be injured or suffer ill-health from exposure to:

a. chemicals?
b. toxic gases or vapors?
c. fumes?
d. dust?
e. noise?
f. vibration?
g. radiation?
[O] GENERAL ERGONOMIC FACTORS YES / NO
Can anyone be injured due to:
a. poorly designed seating?
b. repetitive body movement?
c. constrained body posture or the need for excessive effort?
d. design deficiency causing mental or physiological stress?
e. inadequate or poorly placed lighting?
f. lack of consideration given to human error or human behavior?
g. mismatch of the plant with human traits and natural limitations?
[P] PRODUCT ERGONOMICS YES / NO
Can anyone be injured due to product design factors:
a. how does it work & is it an appropriate solution?
b. will the sequence of actions for use of the product result in a hazardous situation?
c. can it be misused, & if so, what are the consequences of misuse?
d. is there parts that can fall off, shake loose or be removed through misuse?
e. is it prone to damage or excessive wear and tear?
f. if maintenance is required, can it be carried out?
g. can it be easily and adequately cleaned?
h. does the product require any special aptitude, physical ability or prior knowledge or
experience
i. are the points of contact with the user likely to be uncomfortable, or create pressure points?
j. is there any special considerations that apply, e.g., does it suit left handers; can it be used by
disabled persons;
k. does it need special storage requirements?
l. will transport during and between use be a problem?
m. if it is to be used in conjunction with other products are their adequate provisions made for
this interaction?
n. are the materials of manufacture and methods of fastening/joining/assembly appropriate?
o. are labels (instructions etc.) liable to obliteration, (peeling etc.) through use or maintenance?
p. other factors not previously mentioned?
[Q] ENVIRONMENTAL YES / NO
During the use of the plant or product is there any risk to the environment from:
a. spillage, e.g., of fuel or other substance from the plant itself or above/below ground storage

Project Name:
tanks?
b. leaking, e.g., of fuel or other substance from the plant itself or above/below ground storage
tanks?
c. the generation of fumes, dusts, or vapors?
d. the generation of excessive noise?
e. the generation of any wastes (liquid or solid) that will need to be disposed of?
f. will transport, handling or storage of the plant or product require any special consideration?
[R] OTHER YES / NO

Any other site-specific hazard/s not already addressed above.
TEAM:
S. Name Designation Badge # Signature S.# Name Designatio Badge # Signature
# n
1 3
2 4
COMPILED BY: MANAGER NAME :
COMPILATION DATE : DATE APPROVED :
SIGNATURE : SIGNATURE :


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PLANT AND FACILITY SAFETY

OHS-PR-09-03-F04 (A) HAZARD ID & CATEGORIES CHECKLIST

Operating Area: Department:

Table 1: HAZARD CATEGORIES CHECKSHEET

Operating Area: Department:

OHS Forms Procedure Reference Revision Number Revision Date Approved By

Operating Area: Department:

Operating Area: Department:

OHS Forms Procedure Reference Revision Number Revision Date Approved By

Operating Area: Department:

Operating Area: Department:

maintenance, cleaning or repair of the plant?

OHS Forms Procedure Reference Revision Number Revision Date Approved By

Operating Area: Department:

a. lack of a proper work platform?

OHS Forms Procedure Reference Revision Number Revision Date Approved By

Operating Area: Department:

Can anyone be injured or suffer ill-health from exposure to:

Operating Area: Department:

[R] OTHER YES / NO

OHS Forms Procedure Reference Revision Number Revision Date Approved By

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