Risk Assessment Form

• Emergency equipment’s and Team stand

by
• PTW in place
• Emergency Shut down of the cold venting
available
• Rupture of N2 supply Improper / • Ensure the tools are good and inspected
hoses and coupling Defective Tools (such as N2Unit, Pump, Hose, Coupling &
• Lack of oxygen Rupture of Nitrogen • Pressure Gauges etc) to be used are free
Exposure of natural Supply from defect.
gas/ Nitrogen. Hoses & Couplings • Ensure the N2 supply hoses and
Unsafe Disposal of couplings are rated for the required
Nitrogen purging Purged Fluid 3 2 6 2 1 2
service and pressure.
Lack of Oxygen • Stay away from the pressurized N2 hose
& coupling to avoid cold burn in case of
leak.
• Do not enter a vessel / tank / pipeline
which is purged with N2
Blind removal and • Mechanical sparks • Physical injury • Make a grinding and welding booth with
installation from • Grinding Wheel may • Fire and fire blanket to contain the grinding sparks /
existing line break & scatter explosion spatters generated.
And during operation • Electric shock • Fire tender to be standby during the hot
Grinding, welding & • Improper electrical • Burn Injury work
gas cutting connection • Ignition source • Fire watcher to be deployed as applicable
• Welding sparks resulting in fire to work.
• Spatters and explosion 4 4 16 • Keep 02 no. 10 kg DCP fire extinguisher 3 2 6
• Improper positioning nearby.
of earthing cable of • Fire Tender shall be kept stand by.
welding machine • Continuous LEL monitoring to be done for
• Use of inadequate any leaks. Ensure LEL is 0%. One portable
tools and equipment Gas detector to be placed at work place.
• Improper handling of • Ensure the gas detector in the area are
gas cylinder functional.

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• Gas cylinder hose • Ensure Flame detector in the area is
without flashback override
arrester • Use face shield while grinding. The grinding
• Electrocution machine to have guards in good condition.
• Dropped Object • Grinding wheel to be checked for integrity.
• Inhalation of toxic gas Pre-use check of grinding machine.
• Inhalation of welding • Integrity of electrical connection to be
fumes checked
• Ensure proper grip and wear PVC dotted
hand gloves during grinding activity
• The Grinding machine is to be inspected
• Pre use check of welding generator to be
done
• Use welding face shield
• Integrity of electrical connection and ELCB
to be checked.
• Ensure earthling is done near to the job.
• Keep welding machine away from the plant
equipment
• Use spark free tools for torqueing & de-
torqueing work
• Use leather hand gloves during welding
• Ensure proper PPE must be worn by all
personnel
• Ensure flashback arrester with the gas
cutting set
• Soap solution bottle shall be kept with gas
cutting set
• Gas Cylinder shall be kept in trolley with
chain lock
• Struck/hit by • Personal injury • Only certified equipment’s to be used
Torqueing and De- • Exposure to high • Property damage • Ensure only rated hose to be used
3 2 6 2 2 4
torqueing Activities pneumatic • Environmental • Area to be barricaded
pressure/hydraulic oil impact • Pre-use inspection prior to use

Controlling Document Number: PEC-HS-PRO-X-30024

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 Risk Assessment Form
• Electrocution • Ensure whip check secured the hose
• Pinch point properly
• Material handling • Crew must aware about relevant hazards
• Dropped object • Ensure us of adequate of PPEs
• Crew are trained in material handling
training
• Drip tray placed for compressor machine
• Compressor properly inspected and
tagged.
• No horse play at work place.

Radiographic Test • Radiation Hazard • Chronic health • Ensure only AERB certified radiographer
• Radioactive effect shall handle the radioactive source.
contamination • Environmental • Ensure valid documents are available with
effect the radiography crew
• Ensure cordoning off of the area
3 2 6 • Ensure proper signage are in place and 1 3
3
PAGA system
• Ensure the radiographer uses calibrated
survey meter and radiation is within
limits.
• Ensure radiation source is handled safely
as per guidelines.
Pressure testing • High pressure • Personal
• Area to be barricaded and secured and
release injury/Fatality
sign boards are in place
• Snapping of high- • Environmental
• Ensure certified tools and equipment are
pressure hose impact
used
• Manual material • Property
3 3 9 • Ensure entry is restricted to authorized 1 3
handling damage 3
person only
• Pinch points
• Ensure the pressure is raised in steps as
• Failure to secure
defined in procedure
• Uncertified hydro
• Ensure only competent crew is
test manifold
employed for the job
• Uncertified pumps

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 Risk Assessment Form
• Ensure whip check are in place for
pressurized hoses.
• Ensure
tools/tackles/equipment/manifold /
gauges etc are certified and calibrated as
applicable.
• Crew are aware and trained about the
job.
Confined space • Slippery surface • Personal injury • Ensure positive isolation and LOTO
• Presence of • Back pain • Ensure proper cleaning/purging prior to
hydrocarbon • WRULD any work
liquid/gas • Asphyxiation/Su • Limited person will be allowed to get entry
• Awkward ffocation in tank or seller pit on 45 minutes work and
access/egress • Breathlessness 10 minutes break.
• Lack of oxygen • Unconsciousnes • Continuous O2/LEL level monitoring, use
• Lack of s calibrated meter.
communication • Fatality • Oxygen must be 19.6 to 23 % and LEL%
• Lack of illumination must be 0%
• Maintain Entry Register (Log sheet)
• Proper PPE uses
3 3 9 • Ensure Good housekeeping 2 2 4
• TBT talk must be done and ensuring all
crew are well aware about associated
hazard and risk
• Ensure JSA/RA shared to all crew
• Crew must have relevant training
• Provision of proper access/egress as ladder
or scaffold stair case
• Continuous supervision
• No horseplay at work place
• Stand by Ambulance and First aider
• Work area shall be barricaded
• Electrical supply must be 110 A or 24 Volt

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 Risk Assessment Form
• Establish communication system as
whistle/walki-talkie/ phone etc
• Ensure Provision of Rescue equipment
• Ensure Availability of Blower working at
cellar pit.
• Ensure presence of fire watcher and
attendant
Painting and • Lack of hand tool • Personal injury
stencilling of piping • Failure to use proper • Property damage
works and PPE • Environmental • Inspect tools before using
equipment • Spillage and soil impact • Use right tools to the job
contamination 2 2 4 • Use appropriate PPEs 2 1 2
• Exposure to skin/eye • Ensure provision of secondary containment
• Fire hazard • MSDS must be available
• Fume

Removal and • Slippery surface • Skin

application of • Pinch point/Sharp rashes/irritation
insulation/cladding • Ensure uses of proper PPE
edge • Personal injury
of Piping works • Proper anchorage of lanyard with 100% tie
• Damaged tools • Property
2 2 4 off 2 1 2
• Hot works damage
• Hand tools are inspected prior to use
• Use of homemade • Environment
• Trained crew and well aware about job
tools impact
• Fall from height
Use of • Diesel spillage • Personal • Provision of secondary containment
DG/DB/Compresso • Electrocution injury/fatality • Stand by fire extinguisher
r/DG Lighting • Fire • Property damage • DG/DG/Compressor shall be inspected and
• Noise • Environmental 3 2 6 tagged. 2 1 2
impact • Spark arrestor to be installed
• Ensure proper earthing connection

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 Risk Assessment Form
Use of pressurized • Gas leak • Personal • Ensure trolleys are provided for all cylinders
gas cylinders • Explosion injury • Ensure availability of
• Fire • Property • PESO certificate
• Toppling of cylinders damage 3 3 9 • Soap test and other inspection as applicable 2 2 4
• Proper manual handling procedure followed
• Provision of Fire extinguisher
• Display of MSDS
• Poor illumination • Poor visibility • Ensure adequate lighting arrangement are
• Reptiles and insects • Stress and made
• Extreme weather fatigue • Ensure competent person are employed
• Lack of supervision • Ensure effective night shift supervision
• Improper job
• Eating at site • No work in case adverse weather
execution 2 2 4 2 1 2
Night Shift • Working without • Ensure proper job rotation
permit • Health hazard • Ensure rest shelter are in place.
• Extension • Personal
• Sleeping/resting injury/Fatality
other than designated
areas
• Tripping and • Physical • Ensure work area is cleared after the
slipping hazard. injury completion of job
Improper disposal • Good housekeeping being a first line defence
of waste. against accident and injury
• Tools and equipments are kept in safe
manner to prevent any tripping hazard.
• All the waste material on the ground should
House keeping 3 2 6 be collected and disposed of in a safe way. 2 1 2
• While disposing, the waste material must be
segregated and disposed to designated dust
bins.
• Inform control room the completion status
of the job.

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