2

HAZARD IDENTIFICATION & RISK ASSESSMENT DOC,NO /EHS/HIRA TPL /SGIC / Rev: Date: 24/07/2021

( Support Installation, Ultra Pure Water (PPH) Piping and Chemical REVISION NO 2 Rev 1

Distribution System) DATE

7/27/2022
Date: 13/07/2021

COMPANY NAME : LOCATION: Pillaipakkam HYD-101

PREPARED BY : Approved by :

Legal Concern(Y/N)
Base Risk Analysis Residual Risk
Sr. No.

Routines

Acceptable(

Acceptable(
Probability

probability
Activity Sub-Activity R /Non Potential Hazard Consequence Present Control Proposed Control

Remarks
A)/Non-
Severity

Severity
routine (NR)

Risk

1 VEHICLE MOVEMENT
Transport of material
and vehicle entry by
road
NA)
Risk
1.Hit to property/humans 1.property damage 1.inspection of vehicle and documents
2.stuck in ground /fall o f vehicle in ground 2.vehicle accident 2.training and induction about logistic plan. 1.CONCERN SUPERVISOR SHOULD BE ALONG WITH THE VEHICLE .
3.overspeed 3.personal injury/fatal 2.Speed limit 10km/hr shoul be maintained by following proper logistic plan
R 4.Overhead Obstruction 4.Hit to overhead Cable/Object 3.Induction about Logistic Plan 1 3 3 A
4.Overhead obstruction shall be identified and communicated

Y 3 3 9
a) Fall of material due to damage D- 1) Inspect all slings, D-shackle for any wear and tear 1. a) Ensure fitness certificate of F-15 & third party certificate of all lifting tools & tackles (Slings, D-shackles, pulley, wire rope
shackle,sling belt before its use . slings etc.) b) Visual inspected front/ back horn, limit switch, hook letch, SWL indicator of F-15 & maintain checklist.a) Safety
inducted, well experienced & trained worker/ supervisor / engineer for this activity. c) All rigging & slinging operations shall be
b) Improper assessment of load done by trained rigger man.
c) Injury due to fall of material on 2) check all safety devices for
person standing nearby its healthiness 2. a) F-15 shall be operated by only a competent & HMV licensed operator.
b) Supervisor shall ensure that no person is
d) Injury due to caught in between the coming / standing in the vicinity of the swing radius area
objects. 3) Never lift c) Do not stand below the Suspended load.
e) Collision of lifted material the load above the rated capacity of material . d) Working area to be barricaded with warning tape to avoid entry of unauthorized persons.
material shifting by

2 Loading and unloading
3 Manual material handling
low
Hydra/ crane
NR with other material resulting in material fatal/body injury/ Property damage Y 4 4 15 e) Ensure PPE’s (e.g. Safety Shoes, Helmet, Hand gloves etc.) 4 2 4 A
damage. f)collapse of crane due to poor 3. a) Work to be done as per lifting plan.
ground condition. b) Eye test color blind test must
4) lifting machine and tool should be third party be done for operator.,area should be clear.
g)over head cable or obstructions inspected with validity. 5) all
h) Suspended Load Tag line should be tied to the lifting material. area should be barricated.
i) Line of tire arrange sign board 4a.material was stacked
j) Hit by Load properly.Providing stack guard to protect collapse the materials. Barricading the stacked materials and scrap area.Rolling
material should be provided with proper stopper
6) No one should be allowed to stand
below the lifted load.
1. Accident/ injury. 1. Use adequate PPE.
2. Back pain,sprain,etc. 3. 2. provide adequate manpower for lifting
Property damage. 4. of heavy loads.
Injury /property damage. 3. Training & instructions. on manual handling
5. Loss of property. 4. Use hand
1. Non-use of PPE. 6.cut injury gloves/ packing materials.
2. Inadequate manpower. 5. Remove protruding nails before handling. 1. Don't allow the person to lift more than 25 Kg for materials one place to other.
3. Lack of co-ordination in group effort. 6. Use proper lifting devices for good grip. 2.provide trolley for materils shifting.
4. Wrong body posture. 7. Fasten the item properly or 3. person handling the materials should fit to do work.
use suitable packing / container. 4. use proper hand gloves during materils handling.
5. Lifting error.
5. Before heavy materils lifting ( according to size ) arrange tarining .
Shifting of materials R 6. Sharp edges / corners / projecting parts / Y 3 4 12 2 3 6 A
6.sharp edge to be covered
protruding nails.
7.access should be free from obstruction
7. Slippery materials
8. Pallet should stop atumatically once released
8. Loose materials.
9.Use Stopper in slope area.
9.Poor Posture
10.Proper board should be placed it on unlevelled surface.
10.Ergonomic Hazard
11.Over reaching

6 HOT WORK
Welding, Grinding,
1. Hot flying fragments, breaking of grinding, cutting
wheels.
2. Explosion
3. Contact with Hot objects, rotating parts
4. Fall of person from height 5.
Fall of material & equipment's
6. Exposure to Ultra violet, Infrared light rays
R 7. Hot work near combustible / flammable materials
1. Electrocution 2. 1. Qualified Welder to be deployed for welding activity
Weld flash 2. Trained, experienced & authorized gas cutter, grinder,
3. Burn Injury brazer operator, etc. to be deployed for the applicable activity
4. Fire
5. Head Injury 3.check the welding machine tags,earthing and rods.
4.check the powerline.and put fre watcher ,fire blanket
and fire extinguisher.
5. Safety helmet, Safety Shoes, Leather Hand Gloves, Face
shield (grinding - shade-4, welding - shade-11) leather apron,
ear plugs, ear muffs, safety goggles to be used. Safety
harness to be used while working at height. and machine
guards are mantatory
6.PTW,LMRA & Checklist compliance
Y 4
1. Working platform will be provided with mid rail, hand rail, toe board, access and egress free from obstructions for work at height.
2. Prevention of fall of welding slag to be done by providing fire blanket or by restricting the personnel movement below the hot work area by deploying a fire
watcher, barricading the area below the activity, caution / warning signages.
3. Fire watcher and fire extinguisher should be present there .
4.barrication and working area should be isolated .
5.inspection on machine with tag should be present.
6. Welding return cable with clamp to be connected near to the welding spot.
7. Lighting will be provided for clear visibility
8.Flammables shall be removed
4 16 9.Fire Blanket shall be provided for overhead welding 1 4 4 Y
10.Barrication & Signal is to be provided

7 Working at heights
Scaffolding scissor lift
1. PTW should take pror to erection of work. 1. Any person working above 2m height shall beconsidered as working at height.
2. Ensure close supervision. 2. Ensure all personnel assigned to work at height arenot afraid of height and medically fit for heightworks.
3.Height pass shall implimentated. 3. Work shall not be allowed to be carried outstanding over wooden boxes; empty barrels andother make shift arrangements.
4. Work shall be carryed under the supoervision. 5. No 4. In case of any practical difficulties to provideproper working platform, safety harness with fallarrestors (self inertia reels) shall be installed andused.
obstruction should be made in the passage at height. 5. Temporary edge protection with top hand rails at aheight of 1.1mand mid rail at a height of 0.55 mand with toe board shall be installed in all
around the openings in floor slabs.
1. Fall from heights. 6. No loose meterials shall be placed at edged. 7. 6..For small openings floor covers shall be providedwith adequate strength. 7.Stop work at height in
2. Unsafe working platforms and working conditions. Proper housekeeping to be ensured. 8.trained high wind velocity. 8.Home made ladders not to be used, ladders with broken rug not to be used;
1. Head enjury.
Working &
2. Born francture. 3. scaffolder is allowedto erect. 9.use tags and
Dismantling of R 3. Unsafe access/egress. barricate the area Y 4 4 16 1 4 4 Y
Lose of life.
4. Hit by the structure. 10.material should not be throwed 11.scaffolding
4. Drowing/hypothermia
5.Collapse of Scaffolding scheme should be followed 12.red tag shall be used
6.Fall Through Gap 7.machinery failure for erection and green for working.

13. ensure all safe elements

1.burn injury 2 approptiate PPE S to be provided only experience person only use
1.working with out PPE /unguard roating/moving parts 2 cut injury only 1. inspection of power tools and calibration sticker. 2. use
POWER TOOLS USAGE
chipping & cutting& improper cable routed 3. major injury 4. elecrtrical shock 5.fire poper tool for the job doing. 3. follow color coding.
8 FOR DIFFERENT R Y 2 2 4 To be discussed in specific TBT & Trainings & authorised card to be provived specific job purpose. 1 2 2 A
ACTIVITIES braffing 2.Electricity Slip & Trip Entanglement

a) Fall of material due to damage D-shackle,sling
belt
b) Improper assessment of load
c) Injury due to fall of material on person
standing nearby
d) Injury due to caught in between the objects.
e)
Collision of lifted material with other material
resulting in material damage. f)collapse of
crane due to poor ground condition.
1.Person injury.
10 Laying of pipes Shifting,erection & Lifting R g)over head cable or obstructions
2.Damage to property.
h) Fall of material due to damage D-shackle,sling
aid injuries
belt
i) Improper assessment of load
j) Injury due to fall of material on person
standing nearby
k) Injury due to caught in between the objects.
l)
Collision of lifted material with other material
resulting in material damage. m)collapse of
crane due to poor ground condition.
n)over head cable or obstructions
1.Submit MIPs
2.Fire.
3.. Hot flying fragments, breaking of grinding,
cutting wheels.Explosion
4. Contact with Hot objects, rotating parts
5. Fall of person from height
6. Fall of material & equipment's
Chemical usage and 7. Exposure to Ultra violet, Infrared light rays
11 Jointing of pipe welding
R 8. Hot work near combustible / flammable
materials
D-shackle for any wear and tear before its
1.Deployed trained and experienced crew.
use .
2.Provide proper training and instructions for the pipes laying activites.
3.All equipements abd support properly inspected before start the work.
6) check all safety devices for its
4.Ensure piping material free from any damages.
healthiness
5.Using proper appropriate ppe.
6.Area should be properly housekeeping and proper material stacking.
7)
7. a) Ensure fitness certificate of F-15 & third party certificate of all lifting tools & tackles (Slings, D-shackles, pulley, wire rope slings etc.)
Never lift the load above the rated capacity of material .
b) Visual inspected front/ back horn, limit switch, hook letch, SWL indicator of F-15 & maintain checklist.a) Safety inducted, well
experienced & trained worker/ supervisor / engineer for this activity. c) All rigging & slinging operations shall be done by trained rigger
man.
8) lifting machine and tool should be
8. a) F-15 shall be operated by only a competent & HMV licensed operator.
third party inspected with validity. 9)
3.First Y 3 3 9 b) Supervisor shall ensure that no person is coming / standing in the vicinity of the 2 3 6 A
Tag line should be tied to the lifting material.
swing radius area
c) Do not stand below the Suspended load.
d) Working area to be barricaded with warning tape to avoid entry of unauthorized persons.
10) No one should be allowed to stand
e) Ensure PPE’s (e.g. Safety Shoes, Helmet, Hand gloves etc.)
below the lifted load.
9. a) Work to be done as per lifting plan.
b) Eye test color blind test must be done for operator.,area should be clear.
11) Area
should be clear and barricaded with a caution board.
all area should be barricated.
12) No person should be allowed
arrange sign board 4a.material was stacked properly.Providing stack
in the swinging area of crane.
guard to protect collapse the materials. Barricading the stacked materials and scrap area.Rolling material should be provided with
13) before carrying of the lifting operation check the route
proper stopper
that the material has to be lifted.
1. Electrocution 2. 1. Qualified Welder to be deployed for welding activity 1. Working platform will be provided with mid rail, hand rail, toe board, access and egress free from obstructions for work at height.
Weld flash 2. Trained, experienced & authorized gas cutter, grinder, 2. Prevention of fall of welding slag to be done by providing fire blanket or by restricting the personnel movement below the hot work area by
3. Burn Injury brazer operator, etc. to be deployed for the applicable activity deploying a fire watcher, barricading the area below the activity, caution / warning signages. 3. Fire watcher and fire extinguisher
4. Fire should be present there . 4.barrication and working area
5. Head Injury 3.check the welding machine tags,earthing and rods. should be isolated . 5.for chemical use
6.allergy 4.check the powerline.and put fre watcher ,fire blanket MSDS should be attached and workers have to get the knowlege of the certain chemical.
and fire extinguisher. 6. Welding return cable with clamp to be connected near to the welding spot.
5. Safety helmet, Safety Shoes, Leather Hand Gloves, Face 7. Lighting will be provided for clear visibility
shield (grinding - shade-4, welding - shade-11) leather apron,
ear plugs, ear muffs, safety goggles to be used. Safety
harness to be used while working at height. and machine
guards are mantatory Y 2 4 8 1 4 4 Y

1. Hydro test test Area shall be barricaded and provide warning boards to prevent personnel entry.
2. Calibrated pressure gauges and Pressure safety valves only shall be used.
1. Prepare test procedure and obtain owner's approval.
3. Rating of fittings, pressure gauges, vent valves, gaskets shall be suitable for the test pressure.
2. Provide separate gauge for
4. Flanges and Plates shall be as per the line class.
pressurizing pump and piping / equipment .
5. All the temporary welding shall be performed by qualified welders and approved by Client QA/QC.
3.
6. Ensure air vent provided at the highest elevation.
Check the calibration status of all pressure gauge, dead
7. Gradual filling of lines shall be done keeping vent to open.
weight testers and temperature recorders.
8. Ensure that the line is vented to remove air pockets before pressurization.
9. Pressure should be raised gradually under control to allow time for pipes to strain and time for personnel to check for leaks.
4. Take dial reading at suitable defined intervals and ensure
10. There shall be at least two pressure gauges, one at lowest point and another at the highest point in the system
most of them fall below 11 bar pressure of the gauge scale
1. Bursting of piping. 11. Hydro testing crew should not stay in the direction of the blind flanges to prevent injury in case of flange rapture.
12 range. 4 4 16
Hydro Testing Pressure Testing R 2. Collapse of tanks. 3. 1. May cause injury and prove fatal Y 12. All hoses/ piping/gaskets and connectors/clamps shall be of adequate rating to withstand pressure. 3 3 9 A
5. Provide safety relief valve.( set at pressure
Tanks flying off. 13. Whip lash arrestor shall be provided at hose connection.
slightly higher than test pressure )
14. Personnel shall not approach the system under high Pressure.
6. Ensure
15. Only essential and trained persons shall be allowed at the Hydro test work location
necessary precautions, stepwise increase in pressure ,
16. Access shall be free from any obstacle.
tightening of bolts/nuts, grouting, etc before and during
17. Supervisors shall be present at work location during hydro testing activities are done.
testing.
18.signage to be provided.
7. Keep the vents open before opening any
19.PTW to be followed for pressure testing
valve while draining out of water used for hydrotesting of
20. Vertical Line Shall be supported as per Horizontal line
Pipes.
21. Barrication of the entire area
22. Provide enough Signals
23. Provide alert system
1 Cut Injury
2 Non-use of PPE. 1 Area should be isolated.
3 Personnel injury due to sharp edged objects 1 Electrocution 1 Ensure job specific PPE’s are provided. 2 Provide supervision for monitoring the activity.
16 Housekeeping Housekeeping R 4 Dust 2 May sustain several cut injuries 2 Competent person should be allowing working Y 3 3 9 3 Confirm All PPEs are in good condition. 2 2 4 A
5 Wrong body posture. 4 Sprinkle water to suppress dust generation wherever possible
6 Electricity 5 Follow lock out / Tag out.

Person responsible for executing the Safe Work Method Statement

Name Designation EHS Representative Designation
VIGNESH K HSE OFFICER

I understand the risk controls listed above to be implemented to mitigate the identified hazards associated with the works to be undertaken.
Name Designation

Prepared by HSEM Name & Sign

Approved By TPL PM Name & Signature: