58.ABB-VL-ABRA_58_ABRA- cable tray work-Compressor house and gallery

Activity Based Risk Assessment
1. Description
ABRA Document Number: ABB-VL-ABRA-058, Date:02.11.2022, (REV-01)
Name of the Assessor: Avik Chakraborty

A R Neelakandan, Project In-charge, VL-refinery (expansion project) Contact No: +91
99372 92879
Name of the Approver:
Rupesh Mohanty, Project In-charge (TCE), VL-refinery (expansion project) Contact No: +91
94397 00363
Division: PA-PI
3 MTPA ALUMINA REFINARY PLANT EXPANSION PROJECT, VEDANTA-
Project Title:
LANJIGARH
Scope of work for which risk Cable tray installation and earth flat installation work – SS4(61E) to Compressor House and
assessment is prepared: Air comp cooling tower gallery and inside Air compressor house and cooling tower.
Project Manager: Srikanth RS, Project Manager (ABB India Ltd), +91 97408 33665
Reporting Manager: Dhulekar SP, Mob: +91 99020 20617, E-Mail: dhulekar.s.p@in.abb.com
HSE In Charge: Rajkumar Sahoo, Safety Officer (ABB India Ltd), +91 97780 87288
Contractor / Working party details: M/S SSELLP, Nandalal Dandapat, Mob: +91 90642 45238,
Emergency Contact (Personal): Avik Chakraborty: +91 77355 35067/ Madan Muthu: +91 87906 76882
A R Neelakandan, Project In-charge, VL-refinery (expansion project) Contact No: +91
Customer Contact: 99372 92879
(Name &Number) Rupesh Mohanty, Project In-charge (TCE), VL-refinery (expansion project) Contact No: +91
94397 00363
ABB HSE ABB ENGINEER TCE REPRESENTATIVE TCE/VL HSE VL REPRESENTATIVE

Cable tray installation and earth flat installation work – SS4(61E) to
 Compressor House and Air comp cooling tower gallery and inside
Air compressor house and cooling tower.
Risk Assessed By Ref
Version 1
Avik Approved By Date
02.11.2022
Review Due Date Last Review Date ABB-VL-ABRA-058
Chakraborty Last review by
2. Plant / Site Emergency Contact Number
3. Work Planning
Planned Works : Cable tray installation and earth flat installation work – SS4(61E) to Compressor House and
Air comp cooling tower gallery and inside Air compressor house and cooling tower.
Shift timing or working hours: As per project requirement.
Location of work including Substation 4 to Compressor House to Substation 1/E

elevation, landmark, building,
equipment details:
Note: The following risk assessment is valid only when STOP TAKE 5 is carried on day-to-day basis.
Stop Take 5
1 STOP – Stand back, look at your environment.
2 THINK – How you will carry out your task safely.
3 IDENTIFY – The risk to yourself and others.
4 CONTROL – What can you do to reduce the risk to yourself and others.
5 COMPLETE – Complete your task safely, if you satisfy yourself.
Don’t Look the other way – Safety is our license to operate

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02.11.2022
4. Sequence of Operation
(Break the entire task into simple job steps as per the sequence of operation)
Sl. No Sequence Responsibility

Preparation for the Job.
1  Clearance to be taken from VL/TCE to start and mobilize
Workmen to the compressor house through Mail communications.
 Area clearance to be taken from customer. Multi-agency/Unauthorised Entry
 Covid 19/Omicron Protocol to be followed and instruct to all the site crew members.
 Steady and stable construction power supply to be taken from Customer.
 Appoint Site Engineer and Site Supervisor. Mr. Avik Chakraborty
 Pre-Check of all tools & tackles, PPE’ s related to grinding, cutting, welding activity at Mr. Nandalal Dandapat
site. Mr. Rajkumar Sahoo
 Inspection of Trailer as per SOP.
 Inspection of Hydra and MEWP as per SOP.
 Shifting of material at work location.
 Movement of person / Crossing of Roads
 SCC/SWP (VL PTW Format) to be taken from TCE /VL, before commencing the
activities.
 Summer time precaution for open area activity.
 General Precautions.
 MS and ABRA to be communicated and understandable to all working crews.
Erection of Scaffolding work platform:

2 1.Certification of Scaffolder Inspector and Scaffolder.
2.Identify the Scaffolding Erection Locations.
3. Shifting of scaffolding materials from store to site by goods carrying vehicle
4. Erection of scaffolding work platform Mr. Avik Chakraborty
Mr. Nandalal Dandapat
Mr. Rajkumar Sahoo
3 Arrangement of Lifeline and temporary work platform.
1.Lifeline arrangement (welding of channel for anchoring the wire rope lifeline)
2.Temporary arrangement of working platform with 600mm Perforated cable Tray in entire
route.
Health assessment of Existing installed cable tray and structural support throughout the Mr. Avik Chakraborty
4 pipeline gallery: Mr. Nandalal Dandapat
1.Checking the structure health assessment and stability report provided by customer. Mr. Rajkmar Sahoo
2.Approach to gallery
3.Visual inspection.
4.Physical check up.

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02.11.2022
5 Installation of cable tray in overhead pipleline gallery and in/out side of Compressor house
and adjacent Air comp cooling tower– The following sequence will be followed during cable
tray installation.
1. Area clearance and Barrication.
2. Transportation of Fabricated tray support, cable trays and earthing flat from store to
location and manually unloading outside of the building.
Mr. Avik Chakraborty
3. Dismantling of damaged /rusted cable tray. Mr. Nandalal Dandapat
Mr. Rajkmar Sahoo
4.Erection of cable tray and earth flat with structural steel support wherever applicable on
existing gallery/Inside compressor house, Trench and cooling tower area.
5.Chipping of welding spatters lying on the steel support/ cable trays and touch up paint.
6.All the scrap material to be picked, clear from the specific area and put in bins designated
for metal waste.
7. Releasing Hydra/trailer/MEWP and workmen from the job , and moving the vehicle
towards safe parking zone.
Mr.Avik Chakraborty
6  Closing the PTW Mr.NandalalDandapat
Mr.Rajkumar Sahoo
5. Drawing / Sketch (Please provide a hand sketch / image or a screenshot indicating work location / area / equipment and
arrangement where necessary)

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02.11.2022
6. Life Saving Rules

(Select by choosing the Life Saving Rule that is to be followed in the task)

Cable tray installation and earth flat installation work – SS4(61E) to Compressor House and Air comp cooling tower gallery
 and inside Air compressor house and cooling tower. Activity Based Risk Assessment
Approved By Version 1 Ref. –
Risk Assessed By Date
Avik Chakraborty VL/TCE 02.11.2022
Last review by
Risk Persons at Risk Risk Level

P= Probability Extreme Intolerable – The activity must not progress until controls are put into place to adequately control the risks.
This is an activity with inherently high risks which must be controlled. The activity may proceed with a residual risk level assessed as
I= Impact High “High” if the appropriate formal measures are implemented to reduce and control the risk (e.g.,method statements, permits to work,
specialist training, specific engineering controls, etc.).
RL = Risk Level Work may proceed when the identified controls are in place. A safe system of work, method statement, safe working instruction, or
Medium
equivalent, shall support these activities – see the ABB Way Standard for more information, if required.
Low
Work may proceed when the identified controls are in place.
Very low
NOTE: An assessment of local conditions must be made, and additional control measures implemented if identified as necessary by that assessment.
Risk Risk
Task P x I = RL Control Measures P x I = RL
Step Hazards (reason and likely consequence) All the following measures must be implemented to reduce the risk Category
factor to a tolerable level. R
P I RL P I
L
1. Preparation a.Site Inspection Visiting site without proper PPE’s will lead to injury. 5 5 25 a)Always wear 6 no’s mandatory PPE’s while entering the Safety 2 1 2
for the job (Joint Inspection site (refer PPE selection chart)
Points) Wild grass on the way to entrance of cable cellar lead to 4 4 16 a)Proper access, egress shall be arranged with help of Safety 1 2 2
tripping of person. customer.
b)Pedestrian walkway to be followed.
Floor opening backside the Panel may lead to fall of person. 4 4 16 a)All floor openings shall be protected with hard barriers like Safety 1 2 2
Chequered plate or hard barricading.
Poor Housekeeping, Unwanted material scattered inside panel a)Housekeeping should be checked before start of job.
room lead to tripping hazard
Power source , welding ,grinding ,cutting machine faulty cause 3 3 9 a)Industrial sockets to be used with inspected ones and tagged Safety 1 2 2
of unwanted incident b)All electrical tools required for welding grinding, cutting
should be inspected, tagged and proper earthing to be ensured.
Poor Illumination-Chances of slip and trip, Hit Injury 4 4 16 a)Illumination to be provided such a way so work can be Safety 1 2 2
done in safe manner.
Presence of sharp edge of hard barricading may lead to injure 4 4 16 a) Rebar’s sharp edges should be covered with cap. Safety 1 2 2
to person.
Non-certified & Un insulated Tools and Tackles may lead to 3 4 12 a)All the tools and tackles being used should be certified and Safety 1 2 2
failure during working monthly colour code to be provided. All tools and tackles
shall be insulated.

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Building surrounding area jungle and bushes, there might be a) Work areas must be inspected prior to activities in any
possibly of Insect or Snake Bites animal habitats and insect repellent shall be sprayed.
b) Before visiting any grassy area, that should be cleaned
prior to visit the site, the matter should rise with all
concern authority and needs to submit the report.
c) If a snake bite has occurred, help the person out of that
area if necessary. If the bite is on a limb, immobilize the
limb, with a splint if possible.
d) Reassure and advise to remain calm to movement
encourage circulation of venom
Call the ambulance immediately and refer for the further
treatment and inform VL occupational health centre.
b)Area clearance Fall of objects or working tools of other agency working 4 4 16 a) Multi-layer work to be avoided. Safety 1 2 2
to be taken from around compressor building area. b) Stop and report concern authorized representative of
customer. Multi- customer if multi-layer work carried out nearby area.
agency/Unauthori Noisy environment will lead to miscommunication between 4 4 16 a) Any other agency jobs involved noisy shall not be Safety 1 2 2
sed Entry supervisor/workmen working near cable cellar entrance area permitted during process of dismantling.
b) Flow of communication required during planning of
dismantling activities where noises make create
disturbance.
No barricading/danger signals of workplace will lead to 4 4 16 a) Proper Barricading is to be provided Safety 1 2 2
unauthorized entry and chances to get hit injury. b) Activity related signage to be posted nearby area.
Collapse of other agency scaffolding/ structure/ Pipeline 3 4 12 a)No work below other agency scaffolding structure. Safety 1 2 2
Road accident due to Concrete loaded vehicle movement 4 4 16 a)No work near the vehicle movement area; working area to Safety 1 2 2
inside compressor house be clearly isolated
c)Covid-19 Covid Transmission 5 5 25 a) Thermal Screening to be done and maintain logbook /TBM Health 2 4 8
controls: Form.
b) Awareness to be given for engineers and electrician. All
new jonnies should undergo COVID-19 test before coming
to site. As per VEDANTA latest covid guideline RT PCR
test not before than 72 hrs ,
c) 5 days isolation, rapid antigen test on 6th day mandatory
before entry to site.

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Lack of Awareness among the work crew. 5 5 25 a) Daily hand sensitization to be done every interval and Health 2 4 8
regular interval of hand wash.
b) Ensure 6ft or 2mtr distance to be maintained in the toolbox
meeting along with mandatory PPE’s.
c) Use face shield for wherever close to each other.
d.Temporary Exposed bare conductors will lead to electrocution. 4 5 20 a) Check the cable insulation and healthiness before using it. Safety 1 2 2
stable power
supply three/
single phase Failure of RCCB/RCBO, main switch while fault occur which 4 5 20 a) RCCB/RCBO, main switch, indicator lamps and welding Safety 2 2 4
arrangement for may lead to arc flash. sockets to be fixed first before powering the board. Class –
cutting 3 insulation rubber mats to be placed in front of the PDB.
tools/grinding Absence of PDB/Sub DB earthing will lead to electrocution. 4 5 20 a) Double body earthing to be provided for PDB. Earth Safety 1 2 2
machine/welding resistance to be measured and the value shall be acceptable
machine level.
Improper routing and external affects may cause damage of 4 5 20 a) Proper routing to be ensured with help of customer. Safety 1 2 2
cable and short circuit.
Loose/wrong connection at PDB will lead to spark or arc flash. 4 5 20 a) Strict supervision to be ensured before switching ON Safety 2 2 4
Electrocutions while using welding machine/cutting wheel. 4 5 20 a) Welding/Cutting machine to be inspected in every 30 days Safety 2 2 4
interval(For single phase machine) and 90 days(For three
phase welding machine) and logbook to be maintained,
inspection checklist must be complied, cutting wheel must
have guard.
e.Appoint Site Lack of awareness/less experience engineer/Supervisor/Fitter. 4 4 16 a) ABB Skill assessment interview process is mandatory Safety 1 2 2
Engineer and site before deployment of any skilled workmen; all has to go
supervisor. through Vedanta induction and specific training to obtain
authorization from Vedanta.
b) Site Engineer & Contractor supervisor should be present at
the job site until activities completion.
Lack of PPE’s availability (not as per ABB standard) which 4 4 16 a) Proper PPE’s shall be used like Arc Flash suit (according Safety 2 1 2
will lead to cut injury/Hit injury and getting injured. to System/working voltage), Safety shoes, helmets, face
mask & shield, Hand-Gloves, safety goggles, sanitizer and
maintain social distancing (ABB Standard PPE’s)- Refer
ABB matrix attached herewith – Annexure – 1

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f.Precheck of all Faulty electrical tools will lead to shock injury. 4 4 16 a) All electrical tool’s function and calibration certificate/test Safety 2 2 4
tools & tackles certificate is to be checked/visual inspection mandatory.
g.Inspection of Wrong operation of trailer/Incompetent driver lead serious 4 4 16 a) Trailer must be inspected by concerned inspection agency Safety 1 2 2
Trailer as per incident. and has to comply VEDANTA Road safety checklist specific
SOP. to trailer.
b) Driver should have valid license and trained by Vedanta.
For permanent driver must have authorization card.
c) Trailer position before loading of equipment must be
ensured ; wheel chock is mandatory.
d) Flag man required for both trailer and Hydra throughout
the entire process. The flag man should not be involved in any
other type of job apart from flagging of the vehicle.
h.Inspection of Wrong operation of Hydra and MEWP /Incompetent operator 4 4 16 a) Hydra and MEWP must be inspected by concerned Safety 1 2 2
Hydra and lead serious incident. inspection agency and has to comply VEDANTA Road safety
MEWP as per checklist specific to Hydra and MEWP.
SOP. b) Operator should have valid license and trained by Vedanta.
For permanent operator must have authorization card.
c) Hydra and MEWP position before any activity must be
ensured ; wheel chock is mandatory.
d) Flag man required for both Hydra and MEWP throughout
the entire process. The flag man should not be involved in any
other type of job apart from flagging of the vehicle.
i.Shifting of tools, Ergonomics (Wrong body posters will lead to body ache) 4 3 12 a)Guidance shall be given to the Crew for safe handling of Safety 2 2 4
and tackles tools & tackles.
Mishandling of equipment may result in cut and crush Injury 4 3 12 a)Personnel must wear hand gloves and shoulder pad Safety 2 1 2
and damage of equipment’s individually.
b)One’s gloves or shoulder pad should not be used by others
to avoid Covid transmission.
Not maintaining social distancing during shifting of 4 3 12 a)During shifting of the equipment persons will maintain Safety 1 4 4
equipment’s may cause transmission of COVID-19 social distancing,
b)All the tools and tackles to be sanitized before use of them.

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j. Movement of Mobile usage while walking. 4 5 20 a)Do not used mobile phone and earphone while walking, Safety 1 4 4
person / Crossing Selection of Wrong Side/Walking on Roads stand at one place and talk.
of Roads b)Always stop, look left right and only cross the road using
the zebra Crossing.
k.SCC/SWP (VL Unauthorised work may lead to incident. 4 3 12 a. PTW to be taken from the Vedanta (Operation and Project Safety 1 2 2
PTW Format) to team) prior to the start of the work and after physically
be taken from checking all potential hazards and its control measures are
TCE /VL, before in its place to work safely and to get extended on daily
commencing the basis.
activities. b. SCC-Standard Clearance certificates which is the Drive the
PTW. Any kind of job which triggers the requirement of
PTW, SCC to be issued as a basic requirement of PTW
System. SSC is the driving permit which may or may not
require SWP and EWP for the execution of assigned task.
But any job that without SCC cannot be carried out even if
EWP & SWP are available.
c. EWP- Electrical Work Permit- To be taken for all Isolation
work. VL or TCE will Issue the PTW and Isolate the
energy. Authorized Person for isolation to be certified by
VL.
d. SWP-Special Work Permit- This PTW to be taken for the
work at height work and along with the electrical PTW.
e. SWP-Height work and Hot work PTW required for this
job.
f. The permit hierarchy is as follows.
ABB will request Vedanta for issue of work permit.
Issuer: The issuer will be VL(Operation) Personnel after
the cross checking all the checklist.
Receiver: VL/TCE projects team will be receiver
For specific permit, there will be specific supervisor.
Issuing the PTW means the client has given the clearance
in all respect to work on that mentioned locations. If there
is NO PTW-There is NO WORK
Non-Compliance against checklist may lead to unwanted 4 3 12 a)Check each point of the PTW; ensure the control measures Safety 1 2 2
incident. are taken against each point before starting the job.

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l.Summer time a.Heat stroke. 4 5 20 a) Proactive planning of external activities for minimum heat Health 2 2 4
precaution for b.Dehydration. exposure
open area c.Fainting /Vomiting. b) Schedule of site activities for compliance of mandatory
activity. mid-day break
c)Mid-day break communication to all contractors
d) Plan finalized about workers stay either at site or travelling
to camp during break time.
e)Provision of tent / canopy / shelter where is to be carried
under direct sunlight.
f)Toolbox talk on heat stress management
g)Toolbox talk on proper diet & wearing during summer
h)Training for supervisory staff for monitoring
i)Display of information posters at site
j)Identify workers with medical illness history who needs
special monitoring
k) Easy availability of drinking water
l)Water storage tanks are cleaned and well maintained
m) Water thermoses provide for work crew
n) Awareness for workers to consume more water to maintain
body fluid
o) Proper resting area provided to the work crew
p) Rest area clean and hygienic
q) Proper ventilation provided in closed areas
r)Work crew food properly stored without exposing to
sunlight
s) Sufficient quantity of glucose and ORS powder available
for no. of workers
t) No. of first aiders at site
u) First aid arrangement sufficient at site
v)Emergency vehicle available at site

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m.General a. All Mandatory PPEs-Safety hard Hat, Shoes, Reflective
Precautions Jacket, Goggles, Hand gloves, and Nose mask to be wear
during the site visit and during the work.
b. All the activates should be carried out under the
supervision of concern VL/TCE authorised supervisor
or engineer and should not left alone.
c. Any kind of minor incident to be reported to area VL
engineer without fail.
d. Long sleeved shirts and long trousers to be worn.
e. Planned tasks to include regular rest breaks & task
rotation.
f. Assessment of slippery conditions Floor Cut outs, Hazards
at site to be carried out. Take into account movement of
machinery as well personnel.
g. PTW to be extend if work carried out beyond the time
permitted on PTW (General Shift)
h. Night approval to be taken from BU HSE Manager, Client
Unit Head, Area I/C of Mechanical and Electrical with
Client Safety Head.
i. Ensure for the illumination and proper lux availability,
proper access before commencing the night height work
job.
j. All the covid protocol strictly to be adhered at site.
k. For minor injury, crew member should inform to site
manager and safety officer and help the injured person to
move to nearest office which is equipped with First Aid
arrangements and approved first aider shall perform
necessary. For major injury, crew member should call
ambulance immediately then inform to site manager and
safety officer.
l. Any reptiles found at working area, don’t to be panic and
immediately vacate the area and inform to site manager
and safety officer. Reptiles should not be disturbed/beaten.
m. No work to be carried out where honeybee presence found
and immediately inform to the concern official in return
by supervisor.

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n. When attack of honeybee happens, person give noise for
help and crew member should immediately call
ambulance and inform site manager and safety officer.
o. In case any sudden medical emergency - Person has to be
rescued to the OHC /nearest medical enter depending on
potential of emergency.
The incident to be communicated to concerned officials
through proper channel on immediate basis.
p.Work to be stopped in incident location ; workmen to be
assembled in nearest assembly point. Incident to be
communicated in proper way to all the crew members. After
getting clearance from assembly point coordinator crew shall
be allowed to move their respective work location or as per
the direction of assembly point coordinator.
q. All the outdoor job to be stopped in between 11.00 AM to
03.30 PM till 15th June 2022. Only indoor work is allowed.
n.MS and ABRA Incident can happen if the sequence of operation not followed 4 4 16 a)Both the Method statement and Risk Assessment to be Safety 1 2 2
to be properly. communicated with all the site crew team and that to be
communicated and recorded.
understandable to Wrong in sequence of work lead to rework of the same. b)Pre job Training to be conducted by the concerned Engineer
all working crews. for that job.
2. Erection of a.Certification of Unauthorized workmen. 4 4 16 a. The scaffolder inspector must have minimum 3-5 years of Safety 2 2 4
Scaffolding Scaffolder experience and should be certified by the VL.
work platform: Inspector and b. The scaffolder inspector and scaffolder must have
Scaffolder. qualified from a certified third-party agency.
p. All the mandatory training like work at height, material
handling, firefighting, first aid training to be taken by all
the scaffolder team members.
b.Identify the Misutilisation of scaffolding work platform 3 3 9 a) The concerned engineer should take clearance from all Safety 2 2 4
Scaffolding stakeholders and shall give clearance to the scaffolder
Erection Locations. team to proceed for scaffolding.
b) As per the requirement of dismantling and new
installation, the scaffolder inspectors identify and plan the
activity.
c. If the height more than 10mtr, the scaffolder inspector
should design the drawing and share for VL approval.

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c.Shifting of Hit injury during loading of materials 3 3 9 a) All the materials will be manually loaded on the vehicle. Safety 2 2 4
scaffolding c) Cut resistance Hand gloves are to be used during the
materials from manual loading on the scaffolding materials.
store to site by Fall of materials during shifting 3 2 6 a) All the materials must be secure and tie with vehicle. Safety 2 2 4
goods carrying b) Ensure the cabin should be enclosed after loading of all the
vehicle materials.
d.Erection of Uneven Surface 4 4 16 a) The scaffolder inspector and the site engineer should Safety 2 2 4
scaffolding work ensure the uneven surface, multi-layer working along with
platform surrounding hazards.
b) The area should back fill, levelled and no loose soil/water
logging before erecting the scaffolding work platform.
c) The area below cable gallery near to SS61E to road
crossing ,bushes and jungle to be cleaned(VL Suppport);
piping material to be removed(VL Support).

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Fall of Person from Height/ working in pipeline gallery top. 5 4 20 a) Ensure all the scaffolder should have trained of work at Safety 2 2 4
height.
b) Working at an elevation of 1.5mtrs and above to be
considered as "Work at height".
c) Safety harness to be used while working at height above
1.5 metres height.
d) Rope grab type fall arrestor to be used while ascending and
descending
e) No work should be done near floor openings until safety
net to be provided below and still Full body harness to be
used. Work platform width should not be less than
600MM.
f) Only approved quality of scaffold boards should be used.
Wooden ply, wooden blocks should not be used.
g) Usage of mobile phone is strictly prohibited. Gate pass
without approval of height work is not valid for working at
height.
h)Person should not work at height without such permission.
Person if found to be in the influence of alcohol or any such
substances should not allow to work.
i) Through put the pipeline gallery in every junction
point/road crossing fabricated ladder to be provided by
customer to climb on top of the gallery.
j) If gallery tray elevation is above 10 mtr then every 9 mtr
height through the ladder one small landing platform with
edge protection to be provided by customer.
k)Rope grap Fall arrestor to be used in fixed ladder for
ascending and descending of workers.
Inspection & Tagging of scaffolding work platform. 4 4 16 a) The scaffolder inspector only authorised to check, cross Safety 2 2 4
verify the scaffolding work platform and tag it.
h) Tags are as Red-Erection & Dismantling, Yellow-Under
Progress & Green- Fit for used.

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3.Arrangement 1.Lifeline a.Fall of Person 4 5 20 a)Firstly, the welder has to weld the first channel at height of Safety 3 3 9
of Lifeline and arrangement 2 mtr and fix the lifeline with three u-clamp and same has to
temporary (welding of be confirm at the other end with the help of either scaffolding
work platform channel for work platform or Manlifter.
anchoring the wire b)Ensure during the welding the welder and his helper should
rope lifeline) have proper arrangement for anchoring the fullbody harness.
c)Only trained and certified workman is allowed to work at
height.
d)Only 12mm wire rope to be used for the lifeline, ensure the
third party inspection of the wire rope lifeline.
2.Temporary Fall of cable tray, tools and tackles 4 4 16 a)Safety net to be fix beneath the area.
arrangement of b)Beneath area to be barricaded.
working platform c)Safety signage to be display with emergency contact
with 600mm number.
Perforated cable d)The site supervisor must be alert and should have the
Tray in entire contact details of emergency no with rescue team no.
route. e)No loose materials to be kept at height, hand told to be tied
with hand.
f)More than two person is not allowed on a single
tray.Contious movement allowed.
4.Health a.Checking the Unavailability of report lead structural failure during 4 5 20 a) Valid document must be taken from customer. Safety 2 2 4
assessment of structure health manpower movement.
Existing assessment and Collapse of pipeline cable gallery due to unknown reason.
installed cable stability report
tray and provided by
structural customer.
support b.Approach to Improper surface for MEWP Placement lead hi-po incident 4 4 16 a)Area levelling required before MEWP placement Safety 2 3 6
throughout the gallery Unavailability of step ladder with proper welding lead fall b) Ladder to be fixed from customer side for ascending and
pipeline injury. descending of manpower with fall arrestor and lifeline
gallery: arrangement.

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c.Visual Improper horizontal lifeline arrangement (12 mm wire rope) 4 4 16 a)Life line to be properly clamped in both side of gallery with Safety 2 2 4
inspection. may lead fall injury vertical welded channel support.
Un Trained and not-tested worker involving in job may leads b) Worker must have safety harness to be fixed with lifeline
to fall of persons during movement on platform.( In case platform not available
same to be arranged by fixing perforated type cable tray on
existing ladder tray(Perforated tray size should be smaller
than ladder tray).From 61 E SS to road crossing where
existing tray will be used for cable laying; visual inspection
will be conducted by help of MEWP.
d.Physical check Improper platform arrangement lead fall injury 4 5 20 a)Arrange suitable and approved scaffolding to claim on the Safety 1 2 2
up. Cut Injury by tray sharp edge busduct
Slip, Trip and Fall during Physical Check-Up. b)All workers working at height must have valid height pass
and authorisation card for the same.
c) Workmen using man lifter must have valid authorization
card and well trained.
d)Ensure usage of safety harness.
e) Ensure usage of cut resistance hand gloves.
5.Installation a. Area clearance Chance of fall injury. 4 4 16 a) Cleaning of area Safety & 1 2 2
of cable tray in and barication. Insect/ Snake Bite b)Inform to Vedanta before commencing any work inside the Health
overhead Hit by moving vehicle building area, cable trench to investigate invasive animals and
pipleline Collapse of other agency installed scaffolding structure. insects.
gallery and c)Unwanted metals to be removed
in/out side of d) No work near to concreate vehicle movement area.
Compressor e) No work shall be allowed below any other agency
house and scaffolding structure.
adjacent Air
comp cooling b.Transportation Slip, Trip and Fall during unloading of structural support and 4 3 12 a) All wild vegetation to be cleaned below the cable gallery. Safety 1 2 2
tower of Fabricated tray cable tray/earth flat b) Proper PPE’s to be ensured for the work to be executed and
support, cable 1. Wild vegetation. use Cut resistance gloves (L3).
trays and earthing 2. Hand injury while unloading the cable trays. c) Inside cable trench space constraints, single person can go
flat from store to 3. Space constraint. at a time, all material to be kept outside of trench.
location and d) Material to be stack properly near to SS-61 Outgoing
manually gallery and next after road crossing below cable gallery,
unloading outside inside compressor house and near to air comp cooling tower
of the building. as per drawing and requirement.
Improper placement of trailer and Hydra may lead serious 2 4 8 a) The area should be cleared for trailer placement and hydra Safety 1 2 2
incident placement. The location of their placement should be
discussed and marked.
b)Wheel choker to be given in both sides of the trailer.

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Risk Risk
P I RL P I
L
Wrong lifting equipment selection 3 4 12 a)Proper capacity lifting tools & tackles selected (Nos of web Safety 1 2 2
slings and capacity to be decided), Safe Working Load
Calculation as per material weight and dimension to be
calculated and mentioned in the lifting plan.
Wrong capacity calculation and hydra selection 4 4 16 a)Hydra to be selected as per SWL Capacity. Safety 1 2 2
Sling may be failed during lifting 3 4 12 a)Belt sling test certificate and visual inspection of sling and Safety 1 2 2
bow shackles need to be verified. Random cross checking of
belt sling will be done by customer or customer
representative.
Major hit injury/ cut injury. 4 4 16 a)Guide rope fixing before lifting. The lifting radius to be 360 Safety 2 2 4
degree baricated.
b)No one should stand below suspended load.
Failure of Hydra 4 4 16 a)The hydra should be placed at the demarked area for Safety 1 2 2
unloading the material from panel trailer.
b)The area soil should be compact and soild for placement of
out riggers of the hydra, a MS plate to be placed below the
out rigger of the hydra for solidity and proper level.
c)The fitness certificate of the hydra, SWL chart of the hydra,
license of the operator, third party certificate of lifting tools
and tackles to be verified before placing of the hydra at the
location.
d)The lifting radius of the hydra should be soft barricated and
traffic should be restricted on the road while the lifting is
going on.
e)A signal man should be placed for lifting and unloading
from trailer.
f)Afterall if Hydra got failed it has to be removed from that
work location with immediate effect and shifted to a safe
location.
Movement of trailer 3 4 12 a)Fitness certificate of trailer and license of the driver should Safety 1 2 2
be verified.
b)After placement of the trailer at the location demarcated
wheel choker to be placed to restrict the unwanted movement.

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Fall of person during removal of sling after panel placement on 4 4 16 a)Sling to be removed at ground level ,when boom is totally Safety 1 2 2
trailer down.
c.Dismantling of Slip trip ,fall during dismantling. 4 4 16 a)While moving in MEWP, Safety belt must be used Safety 2 2 4
damaged /rusted Eye irritation due to foreign particle b) While moving by walk above gallery after road crossing,
cable tray Cut injury due to rusted edge of tray. belt to be anchored with lifeline.
c) Mono goggles must be used while removing rusted tray or
any touch up paint will be applied.
d) Cut resistance hand gloves to be used.
e) Dismantled tray must be kept at ground level with help of
rope pully and properly stacked and later shifted to scrap yard
with proper transportation arrangement.
f) After road crossing where side by side existing cable tray
installed on same elevation , after removal of rusted tray
immediately new tray to be installed to cover the opening
with proper welding and support arrangement.
g)Ensure lifeline arrangement is there in vertical ladder of
gallery.
h) On top of gallery where side by side tray is there one
temporary platform to be erected by 3 mm checker plate to
keep the installation material ; and in case any emergency for
rescue operation.

Last review by
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d. Erection of Non-availability of approved (GFC) Drawing lead 4 3 12 a) Approved good for construction drawing must be available Safety 2 1 2
cable tray and rework/exposed to unsafe condition. before starting execution.
earth flat with b) Proper PPE’s to be ensured for the welding and cutting job
structural steel Cut in hand, burn injury, Electric shock, eye irritation happen c) Use of fire blanket to be ensured
support wherever during erection of cable tray due to: - d) Proper use of face shield, welding gloves to be ensured.
applicable on 1. Improper use of cutting machine e) Proper use of tools and tackles
existing 2. No use of face shield and welding gloves and safety f) Trench to be hard barricaded during fixing of support and
gallery/Inside googles tray inside trench.
compressor 3. Improper way of chipping excess welding material from g) Person has to go at trench by using 3 mtr AL ladder.
house, Trench supports and cable trays h) The supply of welding machine should be through RCCB,
and cooling tower the welding machine should be inspected and tagged “OK”
area. before starting the job. PDB to be properly inspected with
proper double earthing.
i) One certified welder only has to do the welding job.
j) A 4 kg DCP type fire extinguisher to be kept at work
place.
k) The welder to use welding apron,welding gloves, welding
face shield, and nose mask along with other mandatory
PPEs. The helper also has to use nose mask, apron,
welding gloves .
l) The helper will hold the tray support channel and angle
while fixing by welding, wearing welding gloves, apron
and black goggles along with mandatory PPEs.
m)Earth flat 50 x 6 (100 mm overlapping ) welding to be
done ;with all PPEs.
n) The area to be barricaded and no material will be stacked
near it.
Fall of cable tray , coupler , nut bolt . 4 4 16 a)The cable tray will be shifted in gallery by use of rope Safety 2 2 4
Damage/Bend of cable tray. pulley, to stack on platform above gallery, tie with rope to
Cut ,eye and hand injury avoid free fall.
b) The cable tray will be shifted to the compressor house
trench by tying rope one by one. The coupler and nut bolt
should be shifted in a bag,box.
c) A person will hold the tray when other person will fix it on
the support.
d) The workmen will wear cut proof hand gloves , safety
spectacles along with other mandatory PPEs.

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e. Chipping of Eye injury. 4 4 16 a)During chipping one person has to hold the tray. Safety & 2 2 4
welding spatters Inhalation of smell of paint b) Using of safety goggles is mandatory. Health
lying on the steel c) Nose mask to be used during touch up painting on earth flat
support/ cable joint and tray welding joint.
trays and touch
up paint.
f. All the scrap Not getting clearance from the customer the material storing 3 4 12 a)Take the clearance from the customer from scrap material Safety 1 2 2
material to be area may be changed which will lead to rework. shifting.
picked, clear from b)The location should be reachable by the material loaded
the specific area Cable tray scraps causing slip trip hazard vehicle and free from over head hazards and it should not be
and put in bins near any excavation point.
designated for Vehicle movement. c) proper house keeping to be ensured after completion of job.
metal waste.
g.Releasing After finishing the job, keeping the moving vehicle at work 4 5 20 a) Placement of vehicle at safe parking zone and release the Safety 1 2 2
Hydra/trailer/ME location lead chance of incident/damage of operator.
WP and workmen equipment/Unauthorized access. b)Wheel chocks to be placed.
from the job , and
moving the
vehicle towards
safe parking zone.
6.Closing the Final checks Not doing disconnection of temporary sourced may be possible 4 4 16 a)Ensure that the same DB, Socket to be cross checked before Safety 1 2 2
PTW. removal of to contact and resulting electrical shock starting the job next day.
temporary power b)Ensure all tools-tackles taken for the job the same are
connections Lleft Tool/loose material in Equipment may leads injury. returned and recorded before leaving the site
before closing the c)Leave the place by keeping it tidy and clean.
PTW and on daily Poor Housekeeping leads to Trip & fall resulting injury to the d)All the tools and tackles to be sanitized on daily basis
basis. person. before used.
e)STA to be checked on regular basis.

Last review by
7. PPE Selection chart (Select√all those required for the task)

√ Safety helmet √ Gum boots Ear muffs Organic vapour / Cartridge √ Leather gloves
Safety helmet (FRP) √ Full body harness Ear plugs FFP3 Cartridge √ Cut resistant gloves
√ Safety goggles √ Horizontal lifeline √ Dust / Nose mask √ Welding face shield Insulated gloves
√ Hand gloves √ Ver. Lifeline Rescue mask √ Welding apron full Chemical gloves
√ Reflective jacket √ Fall arrestor Half face mask √ Welding glasses Gum boots
√ Safety shoes Rescue mask SCBA √ Cutting face shield FR Jacket

Others:
√ 08 Cal Arc rated PPE 25 Cal Arc rated PPE 40 Cal Arc rate PPE √ Cutting glasses
8. Work permit selection chart(Select√all those required for the task)

√ SCC Confined Space √ Height Work √ Lifting
Electrical permit to work √ Hot Work Radiography Excavation
Isolation Energy
9. Work permit selection chart(Select√all those required for the task)

√ Welding machine √ Power tools Pallet truck √ Shackles √ Fixed scaffolding √ Multi-meter
√ Electrical PDB Hydraulic tools Panel gantry Winch Mobile scaffolding IR Test kit
√ Gas cutting set Handheld tools Rigging line √ Mobile crane √ Portable ladder √ RCCB Tester
√ Grinder / Cutter √ Insulated tools √ Sling / Chains Lifts / elevators A type/FRP ladder Discharge rod
√ Drilling machine √ Voltage detector √ Hoists / Pulleys √ Trailer √ MEWP CRM/Hi-pot kit
√ Chop saw cutter Backhoe loader √ Ropes EOT Crane Scissor lifts √ Pick up van
Impact
Very Minor (1) Minor (2) Moderate (3) Major (4) Critical (5)

Last review by
Occurs Almost
frequently,
expected Certain Medium Medium High Extreme Extreme
(e.g., daily) (5)
Occurs
often, Likely
common Medium Medium High High Extreme
(4)
(e.g.,weekly)
Probability
Likely,
probable Possible
(e.g., Low Medium Medium High High
(3)
annually)
Unlikely,
un-common Unlikely
(e.g.,once in Low Medium Medium High High
(2)
business)
Extremely
unlikely,
rare Rare
(e.g., never Very low Low Medium Medium High
(1)
realized in
business)
Short-term symptoms (illness)/ condition which does not result in Illness which requires medical treatment or attention, but still fit Illness, rendering them unfit for normal duties (UNABLE TO
Health lost time. Reversible effects. for normal duties. Reversible effects. WORK). Reversible effects but severe in nature.
Debilitating, terminal and/or lasting ill health issues. Terminal health conditions which could affect multiple people.
Basic medical treatment (not amputations or broken bones), lost

Minor injury, no worse than first aid required – First aid Incident Broken bones, musculoskeletal injury, significant burns (significant Single fatality or disabling Injuries (i.e., amputations, loss of sight,
Safety only.
time or restricted workday incident - quick return to work(absence
beyond the shift it occurred).
absence from work). etc.).
Fatalities (multiple).
Minimal, short-term (hours) environmental damage, contained Minor, short-term (days) environmental damage, contained within Short-term (weeks) environmental damage, contained within the Serious, medium-term (months) environmental damage and/or Very serious, long-term (years) or permanent environmental
Environment within the immediate area. the facility boundary. site boundary. has local offsite impact. damage and/or has national/international impact.
Actual losses with a value less than $25,000 USD. Actual losses greater than $25,000, but less than $100,000 USD. Actual losses with a value greater than $100,000 USD. Actual losses with a value greater than $1,000,000 USD.
Actual losses with a value less than $1,000 USD.
Acts of violence, not involving a weapon, not perpetrated by Acts of violence which involved a weapon and resulted in injuries Acts of violence which involved a weapon and resulted in injury Acts of violence which involved a weapon and resulted in one
Threat of violence, not involving a weapon, not perpetrated by
employees, contractors, or related third-party individuals, resulting requiring emergency medical treatment or hospitalization less requiring hospitalization for more than 48hours or resulting in a or more fatalities.
Security employees, contractors or related third-party individuals, resulting in
no injuries.
in no injuries or injuries requiring no more than first aid treatment. than 48hours. fatality. Dramatic and material impact on market perception of ABB
Potential for escalation and/or minor impact on market perception Moderate potential or material impact on market perception of ABB Major impact on market perception of ABB requiring immediate requiring immediate executive management intervention and
Local issue with no, or limited, impact on market perception.
requiring executive management attention and consideration. which requires executive management attention and intervention. executive management attention and intervention. management.
Enterprise (Business) <10% impact on your budgeted EBITA. <25% impact on your budgeted EBITA. <50% impact on your budgeted EBITA. <80% impact on your budgeted EBITA. >80% impact on your budgeted EBITA.
ACTIVITY BASED RISK ASSESSMENT ACKNOWLEDGEMENT

Employee Acknowledgement
Team Member to print name Team Member to Sign Date Team Member to print name Team Member to Sign Date

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I agree that the work described will proceed in accordance with the controls/precautions specified in Activity Based Risk Assessment and associated documentation.
Client to print name Client to Sign

Supervisor to print name Supervisor to Sign Date Date
(If applicable) (if applicable)

Last review by
APPENDIX 1
I confirm that the proposed actions have
Expected risk after
Planned action Actual been completed and that the expected
completion of actions
Proposed actions/risk reduction Action Owner completion completion risk reduction has been achieved.
measures (hazard being reduced) date date
Impact Probability Risk Factor Name Signature Date
1
actions will be effective in reducing the risk.
2
Re-assess risks to show how proposed
Also consider whether any new

hazards will be introduced.
4
↓↓↓↓
10
This section should only be used to insert actions which have been identified (but not yet completed) which will reduce risks and improve the process.

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Activity Based Risk Assessment

Name of the Assessor: Avik Chakraborty

ABB HSE ABB ENGINEER TCE REPRESENTATIVE TCE/VL HSE VL REPRESENTATIVE

2. Plant / Site Emergency Contact Number

Location of work including Substation 4 to Compressor House to Substation 1/E

Don’t Look the other way – Safety is our license to operate

Sl. No Sequence Responsibility

Erection of Scaffolding work platform:

Don’t Look the other way – Safety is our license to operate

ABB HSE ABB ENGINEER TCE REPRESENTATIVE TCE/VL HSE VL REPRESENTATIVE

Don’t Look the other way – Safety is our license to operate

6. Life Saving Rules

Don’t Look the other way – Safety is our license to operate

Risk Persons at Risk Risk Level

Don’t Look the other way – Safety is our license to operate

Don’t Look the other way – Safety is our license to operate

Don’t Look the other way – Safety is our license to operate

Don’t Look the other way – Safety is our license to operate

Don’t Look the other way – Safety is our license to operate

Don’t Look the other way – Safety is our license to operate

Don’t Look the other way – Safety is our license to operate

Don’t Look the other way – Safety is our license to operate

Don’t Look the other way – Safety is our license to operate

Don’t Look the other way – Safety is our license to operate

Don’t Look the other way – Safety is our license to operate

Don’t Look the other way – Safety is our license to operate

Don’t Look the other way – Safety is our license to operate

Don’t Look the other way – Safety is our license to operate

Don’t Look the other way – Safety is our license to operate

Don’t Look the other way – Safety is our license to operate

7. PPE Selection chart (Select√all those required for the task)

√ Safety shoes Rescue mask SCBA √ Cutting face shield FR Jacket

8. Work permit selection chart(Select√all those required for the task)

9. Work permit selection chart(Select√all those required for the task)

Don’t Look the other way – Safety is our license to operate

Basic medical treatment (not amputations or broken bones), lost

ACTIVITY BASED RISK ASSESSMENT ACKNOWLEDGEMENT

Don’t Look the other way – Safety is our license to operate

Client to print name Client to Sign

Don’t Look the other way – Safety is our license to operate

Also consider whether any new

ABB HSE ABB ENGINEER TCE REPRESENTATIVE TCE/VL HSE VL REPRESENTATIVE

Don’t Look the other way – Safety is our license to operate

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