25548419

DATE:
Formal Risk Assessment and Job Safety Analysis
Plant and Department: U&O
Project Title: To install C20+ truck loading facility in united U&O
Activity/Task Title: Electrical and Instrunmentation work (Cable Pulling, Terminations, Piping Modification,Cable tray work,Support welding )
Job Steps & Sub Tasks
1
Mobilization (Cable Materials, cable drum and Equipment’s by using crane,focklift,boom truck & dump truck)
2
Lifting and positining of Cable drum & cable stand.
3
Cable Meggering and Instrument loop checking.
4
Installation of new breaker in substation & Cable termination and Card installation,DCS Configuration in RIB.
5
Cable Pulling.
6
Termination of power & control cables in control panels & JB’s and in RIB.
7
Dismantling & removal of existing Panels JB’s and conduits & installation of new JB's,transformers and heat tracing equipments.
8
Installing cable Trays/conduits & Tubes, threading and bending, Drilling and knock out.
9
Support welding activity
10
Cable splicing, cad welding, Heat shrinking by Heat gun or gas torch.
11
Cable lugging and termination.
Job steps s#
HAZARD
Initial/raw risk
Control measures
Residual Risk
Responsibility
Consequences
Likelihood
Risk
Consequences
Likelihood
Risk
Responsible person
1. Mobilization (Cable Materials,
cable drum and Equipment’s by
using crane,focklift,boom truck &
drum truck)
1. Un-inspected, uncertified rigging tools
and tackles Crane / incompetent
personnel that could lead to personal
injury.
C4
L3
Minor
1. Obtain valid work permit and vehicle entry certificate for the task.
2. Ensure that Crane,Forklift & truck must be inspected by UNITED mobile equipment &
must have a valid inspection sticker.
3. Only UNITED authorized crane & forklift operator, riggers, flag man (rigger) are
allowed to perform their job.
4. All lifting tools and tackles should be inspected and current color coded by UNITED
mobile equipment.
C4
L4
Insignificant
HKSS/UNITED
2.Damage to the vehicles, plant facilities
and equipment.
C3
L3
Significant
1. Ensure to comply with SHEM-08.06 lifting procedure. Enroute area shall be inspected
prior to mobilizing (unsafe ground condition).
2. Ensure to obtain a vehicle entry certificate, approved basic/critical lifting certificate
(SHEM 08.06) and work permit for crane lifting ,Boom truck & forklift activity prior to
entry into the job site.
3. Ensure proper distance between equipment (congested area, other activities).
4. Follow the UNITED traffic rules and regulations.
5. Follow equipment route map as per vehicle movement certificate.
6. Conduct gas test to ensure 0% LEL.
C3
L4
Minor
HKSS/UNITED
3. Heat coming from Internal
combustible engine that could cause fire.
C3
L3
Significant
1. Gas test shall be conducted to ensure 0% LEL.
2. Combustible/flammable materials should be removed from the area.
3. While refueling vehicle engine should be shut down, no Hot work activity shall be
allowed nearby area.
4. Cover all sewer lines by using fire blanket on the radius of 3 meters.
5. Fire extinguisher should be placed near the crane.
6. Grounding cable should be connected at proper grounding point.
C3
L4
Minor
HKSS/UNITED
1. Fall of suspended load that could lead
to property damage and personal injury.
C3
L3
Significant
1. Lifting area should be barricaded with proper sign board. No personnel are allowed
to walk, stand or work under suspended load. Rigging Supervisor shall conduct tool box
talk to workers and explain jsa/work permit.
2. Rigger should be visible to the crane operator/enough riggers should be provided.
3. Lifting tools and tackles shall be verified by authorized rigger. Softners shall be
provided for slings wound around sharp edges.
4. Only authorized person by riggers shall be allowed to enter inside the barricaded
area.
5. Lifting shall be performed as per approved lifting certificate.
6. Proper planning and supervision by related supervisor at all the time.
C3
L4
Minor
HKSS

2. Lifting and positining of Cable
drum & cable stand.
2. High wind speed/ bad weather
conditions that could cause property
damage and personal injury.
C3
L3
Significant
1. Avoid lifting during wind speed >32Km/hr.
2. Avoid lifting during bad weather conditions (Rain/Fog/dust storm). Provide adequate
lighting for night time. Ensure lights not reflecting eyes of rigger / crane operator.
C3
L4
Minor
HKSS
3. Congested area and pinch point that
can cause personal injury/slip,trip and
fall
C4
L3
Minor
1. Always wear PPE ( hand gloves, goggles) at all times while doing rigging.
2. Keep away your hand from pinch point.
3. Rigger should always stand to safe side where the crane operator can directly see.
C4
L4
Insignificant
HKSS
4.Swinging load / Hitting rigger/Assets /
equipments/facility.
C3
L3
Significant
1. Rigger shall not stay in line of fire or shall come under suspended load. Use tag lines
to control movement of load.
2. The rigger shall ensure the load is rigged properly consider the centre of gravity and
use tag lines to control unexpected movement of load.
3. Rigger shall stay away from line of fire.
C3
L4
Minor
HKSS
3. Cable Meggering and Instrument
loop checking.
1. Electrical Shock
C4
L3
Minor
1. Obtain valid permkit for the task.
2. Barricade area, place wiith warning signs.
3. Use insulated tools. Make sure free end of cable is insulated to ensure no one
touches it.
4. Discharge current after test, confirm with multimeter.
5. Use of calibrated multimeter & hart communicater for loop check.
C4
L4
Insignificant
HKSS/UNITED
2. Cuts, personal injury.
C4
L3
Minor
1. Use proper PPE, insulated low voltage eltectrical gloves shall be used.
C4
L4
Insignificant
HKSS
4. Installation of new breakers in
substation & Cable termination,
Card installation,DCS Configuration
in RIB.
1. Wrong installation of breakers.
C4
L3
Minor
1. Obtain valid and proper work permit for the task.
2. Only allow competent electrician/person for the task.
3. All the cable termination and breaker installation by the presence of UNITED
authorised person.
4. Make sure the breakers are installing asper the drawing.
5. All the RIB configuration shall be done by authorized person.
C4
L4
Insignificant
HKSS/UNITED
2. Electrocution & Pinch point.
C4
L3
Minor
1. Use of proper PPE ( low voltage electrical gloves).
2. Keep your hands away from pinch points.
3. Make sure all the tools should be insulated.
4. Secure tools and nut bolts properly to prevent fall or contact with live systems.
C4
L4
Insignificant
HKSS
3.Slip,Trip,Fall.
C4
L3
Minor
1. Maintain good housekeeping all the time and watch your steps.
C4
L3
Insignificant
HKSS
5. Cable Pulling.
1. Falling cable drum.
C4
L3
Minor
1. Place cable drum on level ground.
2. Apply proper lubricant on rotating point of drum for smooth running.
3. Barricade work area place warning signs.
C4
L4
Insignificant
HKSS
2. Personnel injury,ergonomical
hazards,heat stress.
C4
L3
Minor
1. Use leather gloves Give enough rest breaks to workers , provide cool drinking water
and juice to workers.Do not strain back muscles.
C4
L4
Insignificant
HKSS

3. Falling from heights (Personnel ,cable )
C4
L3
Minor
1. Use full body harness, If needed to extend body part out of handrails or unprotected
edges with scaffolding tag yellow.
2. Ensure scaffolding having valid inspection tag. ( If scaffolding is tagged green,Full
body harness is not required).
3. Always maintain three point contact.
C4
L4
Insignificant
HKSS
4. Damage to insulation cable.
C4
L3
Minor
1. Use roller for pulling cables to prevent damage.
2. Ensure cables don’t strike scaffolding parts while pulling.
C4
L4
Insignificant
HKSS
6. Termination of power & control
cables in control panels & JB’s, and
in RIB.
1. Electric shock
C3
L3
Significant
1. Confirm LOTO, Confirm panels and MCC’s are grounded. Use multimeters to Check
for current. Use insulated tools.
2. Do not carry or wear any metal objects such as rings, watches, chains etc.
3. Confirm panels & JB’s are grounded before beginning work.
4. Make sure multimeters are calibrated.
C3
L4
Minor
HKSS/UNITED
2. Personnel injury & ergonomical
hazards
C4
L3
Minor
1. Use safety goggles,electrical gloves.
2. Avoid awkward movements.
C4
L4
Insignificant
HKSS
3. Slips, trips, & falls.
C4
L3
Minor
1. Keep walkways clear of tools and cables. Post warning signs,Barricade area.
C4
L4
Insignificant
HKSS
7. Dismantling & removal of
existing Panels JB’s and conduits &
installation of
newJB's,transformers and heat
tracing equipments.
1. Wrong Panel & Conduits removals
C4
L3
Minor
1. Make sure, double check and reconfirm from site engineer and mark the panels and
conduits to be removed.
C4
L4
Insignificant
HKSS
2. Personal injury
C4
L3
Minor
1. Use leather gloves, proper PPE.
2. Use proper tools for the job & Inspect tools for damage before use.
C4
L4
Insignificant
HKSS
3. Damage to plant property & assets.
C4
L3
Minor
1. Make sure of shape, weight and size of new JB’s and panels & Conduits before
installation.
2. Use proper lifting and handling techniques to avoid damage to equipment.
C4
L4
Insignificant
HKSS
8. Installing cable Trays/conduits &
Tubes, conduit threading &
Bending, Drilling and knock out.
1. Working at heights
Falling from heights.
C4
L3
Minor
1. Use full body harness, If needed to extend body part out of handrails or unprotected
edges with scaffolding tag yellow.
2. Ensure scaffolding having valid inspection tag. ( If scaffolding is tagged green,Full
body harness is not required).
3. Always maintain three point contact. while ascending or descending ladder.
C4
L4
Insignificant
HKSS
2. Dropping tools and
Materials.
C4
L3
Minor
1. Ensure scaffolding plat form is free from tools and materials. make sure toe boards
are installed on scaffolding.
2. Secure all tools with nylon rope, before using on heights. Lift material and tools using
baskets and securing with rope.
C4
L4
Insignificant
HKSS
3. Slips, trips, & falls, Pinch point
,Possibilty of entaglement, Awkward
movement, cut injury,
C4
L3
Minor
1. Maintain good housekeeping all the time and watch your steps.
2. Keep your hands away from rotaing parts.
3. Do not wear loose clothings.
4. Maintain good working posture to avoid ergonomic hazards.
5. Make sure all the power tools should be inspected by UNITED and inspection sticker
C4
L4
Insignificant
HKSS

on it.
5. Use proper PPE.