Procedure for Identification Of Legal And Other Requirements-OHSMS

1.0 PURPOSE:

To establish, implement and maintain a procedure for identification of legal and other requirements to which XXX subscribes & to identify how legal & other requirements are applicable to identified OH&S hazards covered under the scope of the Occupational Health and Safety Management system.

2.0 SCOPE: 

This procedure covers the method to identify and have access to applicable Legal and other requirements related to activities, processes, products, and services of XXX.

3.0 RESPONSIBILITY:

Legal Team Members (LTM). (EHS-ML-14) The legal Team Members consists of HS MR, DGM –HR, AM-Safety, Officer Admin

4.0   DEFINITION:

4.1 Legal Requirements: These are regulatory requirements as defined by the Central or State regulatory authorities to which the XXX is liable to identify and comply.

4.2 Other Requirements: Any customer-specific requirements, statutory requirements by financial bodies, corporate-specific requirements & any other agreements with public authorities. (Ex: Customer requirements)

5.0 PROCEDURE:

5.1 The details of the List of Applicable legal requirement & other requirements to be compiled by the Safety Officer, along with the frequency of retrieval and personnel responsible for maintaining the records are defined in the Legal Register

5.2 Head responsible for compliance to legal requirement shall obtain information on the legal requirement, by referring to any of the following agency.

  • Notification from Kuwait Ministries
  • Information in Newspapers.
  • Communication with the National Safety Council and Confederation of Kuwait Industry & Authorized Publishers.
  • Subscription/contact with Bureau of Indian Standard, Book Supply Bureau, etc.
  • By referring to various Factories Acts & Rules Book
  • Through visiting the website to get information on the latest updates and also through member

5.3 The application for renewal of Consents / License /Authorization under Government statutory requirements shall be submitted in advance as specified in the Acts / Rules. Renewal frequency mentioned in the list of legal & other requirements may subject to change/alter as per Notification / Intimation from the government authorities from time to time. Responsible persons shall communicate relevant information on legal and other requirements to all concerned.

5.4 The following are the other requirements pertaining to the OH&S Hazards of the activities, processes, products & services, which are to be complied with:

  • Customer Specific Requirements – Marketing & Quality Departments are responsible for receiving the requirement from the Customer and forwarding it to the concerned department to ensure fulfillment.
  • The statutory requirement by Financial Institutions – Some of the financial institutions, Banks, Insurance companies may require the organization to comply with certain statutory norms. The finance dept shall identify and comply with those requirements and they are responsible for receiving and responding to the fulfillment of the above.
  • Corporate specific Requirements – MR shall identify any corporate-specific requirements and incorporate the same and periodically check for compliance.
  • Agreement with public Authorities – Public authorities like social bodies OR Industrial development authorities may require the organization to comply with their requirements. HR is responsible for receiving and responding to ensure fulfillment of such requirements.

5.5 Legal & other requirements applicable to OH&S Hazards are determined during significant HIRA study. Description of legal requirements & how legal & other requirements applicable to OH&S hazards are also described in the significant HIRA study.

6.0 Document / Record reference: 

S. No.Document /Record DescriptionReference No.
1.Legal RegisterEHS-RG-01
2.List of Legal Team MembersEHS-ML-14

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Procedure for Identification Of Legal And Other Requirements -EMS

1.0 PURPOSE:

To establish, implement and maintain a procedure for identification of legal and other requirements to which XXX subscribes & to identify how legal & other requirements are applicable to identified environmental aspects &for maintaining access to these requirements covered under the scope of the EHS Management system.

2.0 SCOPE: 

This procedure covers the method to identify and have access to applicable Legal and other requirements related to activities, processes, products, and services of XXX. This procedure applies to all relevant legal and other requirements applicable to the environmental aspects of XXX and its suppliers and contractors. Legal requirements include those specified in legislations / regulations and technical memoranda that are legally binding. Other requirements include contract requirements, business codes, guidance notes, code of practices, other technical memoranda and other practice notes produced by overseas government agencies, client requirements as well as professional institutions.

3.0 RESPONSIBILITY:

Legal Team Members (LTM). The legal Team Members consists of EHS MR, DGM –HR, AM-Safety, Officer Admin

4.0   DEFINITION:

4.1 Legal Requirements: These are regulatory requirements as defined by the Central or State regulatory authorities to which the XXX is liable to identify and comply.

4.2 Other Requirements: Any customer-specific requirements, statutory requirements by financial bodies, corporate-specific requirements & any other agreements with public authorities. (Ex: Customer requirements)

5.0 PROCEDURE:

5.1 The details of the List of Applicable legal requirement & other requirements to be compiled by LTM, along with the frequency of retrieval and personnel responsible for maintaining the records are defined in the Legal Register

5.2 Head responsible for compliance to legal requirement shall obtain information on the legal requirement, by referring to any of the following agency.

  • Notification from Kuwait Ministries
  • Information in Newspapers.
  • Communication with the National Safety Council and Confederation of Kuwait Industry & Authorized Publishers.
  • Subscription/contact with Kuwait/OHSA Standards, Book Supply Bureau, etc.
  • By referring to various Factories Acts & Rules Book
  • Through visiting the website to get information on the latest updates and also through member

5.3 The application for renewal of Consents / License /Authorization under Government statutory requirements shall be submitted in advance as specified in the Acts / Rules. Renewal frequency mentioned in the list of legal & other requirements may subject to change/alter as per Notification / Intimation from the government authorities from time to time. Responsible persons shall communicate relevant information on legal and other requirements to all concerned.

5.4 The following are the other requirements pertaining to the Environmental aspects of the activities, processes, products & services, which are to be complied with:

  • Customer Specific Requirements – Marketing & Quality Departments are responsible for receiving the requirement from the Customer and forwarding it to the concerned department to ensure fulfillment.
  • The statutory requirement by Financial Institutions – Some of the financial institutions, Banks, Insurance companies may require the organization to comply with certain statutory norms. The finance dept. shall identify and comply with those requirements and they are responsible for receiving and responding to the fulfillment of the above.
  • Corporate specific Requirements – MR shall identify any corporate-specific requirements and incorporate the same and periodically check for compliance.
  • Agreement with public Authorities – Public authorities like social bodies OR Industrial development authorities may require the organization to comply with their requirements. HR is responsible for receiving and responding to ensure fulfillment of such requirements.

5.5 Legal & other requirements applicable to environmental aspects are determined during significant Impact Aspect study. Description of legal requirements & how legal & other requirements applicable to environmental aspects s are also described in the significant Impact study.

6.0 Document / Record reference: 

S. No.Document /Record DescriptionReference No.
1.Legal RegisterEHS-RG-01
2.List of Legal Team MembersEHS-ML-14

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Procedure for Environmental Emergency Preparedness and Response

1.0 Objectives

This procedure describes the preparedness and response procedures for potential accidents and emergency situations giving rise to significant environmental impacts.

2.0 Scope

This procedure applies to all the processes of XXX for which potential accidents and emergency situations may arise. The procedures for preventing and mitigating the following emergency situations are described:

  • Fires, explosions;
  • Rainstorms, typhoon or other unexpected weather conditions;
  • Major Chemical Spillage or leakage;
  • Accidental wastewater discharge as a result of equipment failure

3.0 Responsibility

3.1 Environmental Management Representative

The EMR shall review the suitability and effectiveness of the emergency procedures after each accident or emergency situation.

3.2 Function / Departmental Manager

The Function / Departmental Manager shall prepare an Emergency Response Plan to minimize the likelihood of accidents and emergency situations.  The Function / Departmental Manager shall ensure that all staff and contractors who work on site are aware of and familiar with the requirements of the emergency procedures. The Function / Departmental Manager shall arrange appropriate drills at various department / area and ensure that the requirements of the emergency procedures are communicated to all staff and are implemented. In case of emergency situations in the facility, the Function / Departmental Manager shall be informed and review the accident reports and remediation works taken by responsible staff.

3.3 Emergency Team

When emergency incidents occur, the Emergency Team is responsible for the execution of the appropriate emergency procedures as advised by the EMR and/or Function / Departmental Manager.

3.4 All staff

All staff shall be familiarized with the emergency procedures and follow them in case of accidents or emergency situations.

4.0 Procedure

  1. Potential emergency situations that may have impacts to significant environmental aspect(s) shall be identified by EMR, taking proactive steps to prevent emergency incidents, and completing tasks in preparation for emergencies.
  2. Function / Departmental Managers may prepare their own Emergency Response Plans relevant to their activities and inform such plans to the EMR for compilation.
  3. The EMR shall coordinate the preparation and maintenance of the Emergency Response Plan that contains all emergency procedures.
  4. The Function / Departmental Managers shall familiarize and train their staff and Emergency Team members on the procedures described in the Emergency Response Plan.  This shall be accomplished in accordance with the Training Procedure.
  5. The EMR and involved staff shall identify the root causes and any preventive actions and report the accident by completing an Accident Report after each accident or emergency situation and submit the completed form to the EMR to review.
  6. The EMR shall ensure emergency drill and periodic testing of the procedures are conducted where practical and maintain the emergency drill summary report for the General Manager to review.
  7. The EMR shall review the suitability, adequacy and effectiveness of the emergency procedures after each accident or emergency situation and revise the emergency plan as necessary.
  8. The EMR shall maintain documentation on emergency response and preparedness, and emergency incidents for at least 3 years.

Records

Record DescriptionRecord Location/ Retention ResponsibilityMinimum Retention Time
Emergency Drill Report EMR3 years
Accident Report EMR3 years

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Procedure for Emergency Preparedness and Response-OHSMS

1.0 Objective

The objective is of this procedure is to establish and maintain a system for carrying out emergency preparedness and response actions within the premises of the company and areas of its operations, with the aim of minimizing the impacts of emergency situations on the environment, including risks & injury to employees, subcontractors, general public and other interested parties.

  • To locate the emergency, control it and prevent it spreading further.
  • To safe guard the employees and to minimize the effort of accident.
  • To minimize damage to property.
  • To attain normalcy at the earliest.
  • ensure minimum damage to environment

2.0 Scope

This procedure is applicable to all emergency situations which can have significant impacts to the environment, including occupational health & safety risk to employees. This procedure is applicable to ISO 45001:2018.

Ensuring safety is the prime responsibility of a company and its employees. Even though we try to ensure total safety in the plant, occurrence is unavoidable. Planning for meeting such as emergency situation is to be made and everyone should be aware of such an emergency plan, so that, all employees remain prepared for such emergency situation.

This plan aims at identifying possible accidents and explores ways and means to meet such an emergency situation.

3.0 Responsibility

MR has overall responsibility as unit head, Section In-charge and Emergency response team members and security personnel. The Safety Officer is responsible for ensuring that this procedure is executed consistently and effectively. Members of the Emergency Response Team (ERT) are responsible for ensuring proper implementation of the company’s emergency response plans.

4.0 Description

4.1 Mock Drills: Are practical drills designed to test the capability of personnel or organization to perform a specific function (i.e., Fire, Spill response, communications, First Aid and Rescue).

4.2 Emergency Response Team: Consists of personnel who are knowledgeable, trained and skilled in basic incident stage firefighting, first aid and rescue operations and other site specific hazard response.

5.0 Procedure

The Safety Engineer, in co-ordination with other departments, shall identify all potential emergency situations or scenarios arising from the risk assessment associated with the company’s activities, operations and processes, including the means to eliminate, control and minimize the hazards and risk associated with it.

5.1 Emergency Drills

5.1.1 The Safety Engineer, in coordination with the MR and GM, including all other departments in the organization, shall plan and conduct company-wide emergency drills at least once every 6 months.

5.1.2 Emergency drills shall cover all but not limited to different types of emergencies as follows:

  1. Evacuation
  2. Fire fighting
  3. First aid
  4. Oil or Chemical spills/leaks.

5.1.3 Designated fire exits and evacuation areas (or “assembly points”) within or near the company premises shall be clearly marked and made clear to all personnel. Selected and assigned personnel shall supervise the evacuation, including headcount.

5.1.4 Where appropriate, an evacuation plan and vicinity map or site layout shall be posted in strategic locations of the company premises for the general awareness of everyone. The maps should show evacuation routes, recovery routes, closest exits, fire protection equipment location, eye wash and shower station, spill control station and whatever is applicable. All employees should follow these instructions and be familiar with the evacuation map.

5.1.5 If planned results are not achieved, appropriate corrective actions shall be planned and carried out in accordance with “Non-conformance, Corrective & Preventive Action Procedure”.

5.1.6 The H&S Department shall prepare and maintain records of “Emergency Drill Report” duly signed by the MR.

5.2 Emergency Equipment Monitoring & Inspection

5.2.1 The MR/ Safety Officer shall ensure that appropriate emergency equipment is provided, deployed and easily accessible in strategic areas of the company premises, where a potential environmental emergency and associated risk could potentially occur.

5.2.2 Emergency equipment shall cover all but not limited to the following:

  • Fire Extinguishers
  • Fire Alarms
  • Fire Hose
  • Emergency Lights
  • Spill kits (in the event of chemical/oil spills)
  • First Aid Kit

5.2.3 The MR/Safety Officer and/or its assigned staff shall periodically check and monitor all emergency equipment. Frequency of inspection and maintenance shall be specified in the list.

5.2.4 It shall be the responsibility of the Safety Officer and his designated staff to ensure that all emergency equipment are in good operational condition and easily accessible in the event of an incident and other emergency situation.

5.3 Emergency Situations

 Emergency situation in the company can arise due to:

5.3.1 Fire

Sr.NoActivitiesResponsibility for Mitigation
AVulnerable areas for fire are identifiedMR
BAdequate first aid, fire fighting equipment is made available during emergency 
CFire alarm provided at security and relevant locationsSecurity
DOn information fire core group acts immediately.Emergency Response team
EEmergency escape routes are earmarked and Emergency Plans displayedMR
FEmergency power supplies cut-off system available.Maintenance Personnel
GEmployees are imparted awareness on emergency preparedness.MR, Core team
HAssess the loss/damage and submit report to the management.Supervisor
ITrain existing and new employees on emergency response/evacuation as part of their induction program.Core team

Steps for Mitigation:

  1. Conduct Fire mock drill
  2. Used Fire Extinguishers with low pressures /invalid ones are to be refilled.    
  3. Display Emergency contact information

5.3.2   Handling Fire Emergency:

5.3.2.1 The person who discovered the fire shall promptly report the matter to any ERT member and/or the MR/Safety Officer through telephone, mobile phone or any other means of communication. In the event of fire, the following guidelines shall be as follows:

  1. Call the ERT and report the location of fire.
  2. Use the nearest fire extinguisher.
  3. Wait for announcement.
  4. Move out of the affected area.
  5. Press the fire alarm.
  6. Or shout “fire, fire, fire!”

5.3.2.2 Upon receipt of emergency call, the ERT shall respond immediately and shall act according to the following:

  1. Use firefighting techniques.
  2. Responds to emergencies as required.
  3. Initiate orders and command activity with firefighting.
  4. Call external Fire Department if the situation is out of control.
  5. If situation is getting worse, evacuation shall be planned upon H&S’s recommendation and approval of the GM.

5.3.2.3 The ERT and/or designated personnel (referred to as “fire fighters”) shall direct and lead all personnel/workers towards the designated evacuation area (or “assembly point”).

5.3.2.4 Employees and visitors shall follow the following evacuation guidelines:

  1. Proceed to the nearest exits or stairs.
  2. Walk fast. Do not run.
  3.     Proceed to the designated evacuation area.
  4. Do not go back to get personal items.
  5. Wait for a further announcement.

5.3.2.5 The Safety Officer, in consultation with the Chairman/MR shall make a recommendation if there is to be suspension of work, and shall take any necessary action if suspension is announced.

5.3.3 Handling Injury/illness of Personnel

5.3.3.1 In case of serious injured:

  1. Shout for help.
  2. Recover the injured person and administer first Aid as per injury treatment.
  3. Do not attempt to move the injured person if you are not aware of handling back or neck injuries.
  4. Call the ambulance and report the accident to the management as well as to control room.
  5. If the injured person conscious ask if can walk, transport him to the nearest hospital.
  6. If injured person is unconscious wait for the arrival of the rescue team

5.3.3.2 In case of illness:

  1. Inform the supervisor.
  2. The Supervisor or first aid nominated person must transfer the sick person to the hospital for proper medical treatment.
  3. If vehicle not available call : AMBULANCE

5.3.3.3 Reporting & Meeting:

  1. The Safety Officer, MR and other relevant personnel shall review and discuss any reported incident and shall plan corrective measures to avoid recurrence of the same environmental and OH&S emergency situation and incident.
  2. Emergency procedures shall be reviewed and revised as necessary to reflect continual improvement on the company’s emergency preparedness and response plan
  3. All matters discussed shall be communicated to all employees, contractors and other person working for or on behalf of the company through meetings and bulletin boards for general awareness.

5.3.4 Handling Chemical/Oil Spills

The guidelines below shall be used in H&S emergencies such as oil or chemical spills and leaks resulting from handling, accidents and explosions that pose immediate danger to employees and environment:

  1. For minor spills, clean the spills or leaks with absorbent materials and put the contaminated materials in a hazardous waste bin.
  2. For major spills, call the ERT and report immediately the matter to Safety Officer and theSafety Engineer.
  3. Then identify the type of chemical or oil spilled in the area and determine the source of all spills or leaks.
  4. Use appropriate protections in handling spilled chemicals or oils.
  5. Stop the source of leaks or spills.
  6. Contain the spill or leaks using the techniques that best fit the situation.
  7. For oil leaks, place an empty container under the source of the leak.
  8. Tie-up the pipe or hose where a chemical comes out.
  9. Replaced the defective pipe or hose.
  10. Put the leaking container in a recovery or inside another container.
  11. Rotate or shift the container to a position that stops the leak.
  12. Use appropriate absorbent materials to remove the spills or leaks.
  13. Limit the spill or leak to as small an area as possible.
  14. Contain the spill chemicals within a salvage drum.
  15. Remove the contaminated clothing & dispose them accordingly, then shower.
  16. Decontaminate any tools used in the removal and clear-up of hazardous materials.
  17. ERT shall ensure that appropriate PPE (Personal Protective Equipment) is used when handling chemical or oil spills.

5.4 Preparedness

5.4.1 Test the plans and procedures for adequacy at least once in 6 months.

5.4.2 Ensure the effectiveness of the emergency training through exercises and Mock drills.

5.4.3 Regularly inspect the existing emergency facilities, supplies and equipment and rectify any deficiencies.

5.4.4 Ensure provisions for notification, initial assessment and communication during an emergency situation.

5.5 Response

5.5.1 Ensure a safe and efficient evacuation during emergencies.

5.5.2 Ensure to maintain right level of security during any emergencies.

5.5.3 Communicate to news media and general public in the event of any emergency, accident or other incident, only after seeking concurrence from Chairman.

5.5.4 The steps taken in response to a fire, hazardous material incident, and situations requiring medical and/or rescue response shall be documented in detail.

5.6 Duties and responsibilities

 5.6.1   Safety Officer

  1. He will be in-charge of handling any emergency under the overall guidance of the Chairman.
  2. Guiding the various controllers end and co-ordinates in carrying out their function effectively.
  3. Depending on the seriousness of the emergency ensure outside help.

5.6.2   Service Center Manager

  1. Immediately on knowing about the emergency he will proceed to the scene.
  2. Quickly assess the scale of emergency.
  3. To give instructions to managers for control of operations in other sections/shutdown
  4. Ensure safety of personnel at site. Evacuate all unwanted persons from the site through operators or supervisors

6.0 RECORDS

  • Emergency Response Plan
  • Emergency Contact Numbers
  • Mock Drill Record

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Example of Emergency Preparedness Plan-OHSMS

1.0 EMERGENCY

An emergency is a situation, which may lead to or cause large-scale damage or destruction to life or property within or outside the factory. Sometimes the Emergency results in uncontrollable situations and leads to disaster. Such an unexpected severe situation may be too great for the normal workforce in the area within the plant. In any industry, an emergency can arise at any moment and this depends on the type of

  • Structure
  • Raw Materials
  • Machines / Plant
  • Nearby Industries etc.

2.0  NATURE OF EMERGENCY

The emergency has been identified and can be specified in one or more of the followings with source and effect:

Sr. No.EmergencySourceEffect
1Fire / ExplosionElectrical Panels, Flammable oil storage tanks, Compressors, coolants,  paints, etc.Small fires, complete equipment loss, complete Area burn out.
Dangers to Human beings
2Spillage of flammable / Hazardous Oils & coolants etc Hydraulic oil, Furnace Oil, Coolant etc.Fire
Burns
Soil pollution.
Injury by slippage
3Electric ShockElectrical panels, Power Distribution Board, DG Set, Overhead Crane, Voltage stabilizer, Electric Transformer & Machine Operated by electricity, etc.Burns, suffocation, Death. Toxic chemical ingestion into the bloodstream
4Accidents – Factory (Major)Fall from height & Falling of Heavy Materials, Dies, Bins or other Heavy objects.Fracture
5Accidents-TransportAccident due to the transportation of man & materialDeath or Injury to Body
6Personal confinementToilets, offices, BasementSuffocation
7Natural calamities such as storm,  earthquakes, etc.NatureStructural collapse, Death
8Structure collapseOffice building, & Any Wall or a part Of Factory building.Serious injury, Major Fracture, Death
9Riots, Arson, SabotationAnti-Social elements.Serious injury, major Fracture, Death.
10LPG leakageFire HazardSerious injury, Death
11TANK DYKE FireFire HazardSerious injury, Death
12Electric fireFire HazardSerious injury, Death
13Office fireFire HazardSerious injury, Death
14Person on flamesFire HazardSerious injury, Death
15Food/Water PoisoningHealth HazardPoisoning, Death
16Bomb hoaxBomb ThreatExplosion, Death, fear
17Burn-MinorHealth HazardBurn injury
18Electric shock casualtiesHealth HazardInjury, Death

3.0 OBJECTIVES:

The objective of the major emergency procedure should be to make maximum use of the combined resources of the works and the outside services to

  • Effect the rescue and treatment of casualties;
  • Safeguard other people;
  • Minimize damage to property and the environment;
  • Initially, contain and ultimately bring the incident under control;
  • Identify any deed and provide for the needs of relatives;
  • Provide authoritative information to news media;
  • Secure the safe rehabilitation of affected areas;
  • Preserve relevant records of equipment by the subsequent inquiry into the cause and circumstances of emergency;

4.0  EMERGENCY MANAGEMENT & KEY PERSONS                                        

During an emergency situation, it is generally seen that chaos and confusion rules leading to more damage. In Emergency Management, just like in normal operations where there are managers, engineers, supervisors, operators, etc., who are assigned specific tasks to run the business, similarly during an emergency also there are persons with specific duties. These persons are known as ‘Key Personnel’.

Following are the persons who are responsible to face the emergencies.

NAMEDESIGNATIONCONTACT NO
   
   
   
   
   
   
   

If required external help in case of an Emergency will be sought from appropriate sources. The required assistance from the probable sources has already been informed and consent obtained for the same.

5.0  ROLES & RESPONSIBILITIES:

5.1 Name & Address of the persons furnishing the information:

XXXXXX

XXXXXX

5.2 Any Individuals  

When an emergency occurs, the person who observes it must evaluate the gravity of the emergency and he should alert all the factory personnel by activating the Emergency Siren.  The emergency siren is activated just by pressing the Emergency Siren push button located at the main gate & other different locations. Then he immediately reports to the Emergency Control Centre (Main Security gate) and informs about the Emergency location.

5.3 Site Controller:

The Site Controller will assume overall responsibility for the factory/storage site and its personnel. His duties are to:

i) Assess the magnitude of the situation and decide if staff needs to be evacuated from their assembly points to identified safer areas

ii) Exercise direct operational control over areas other than those affected.

iii) Undertake a continuous review of possible developments and areas in consultation with key personnel as to whether shutting down of the plant or any section of the plant and evacuation of personnel are required.

iv) Liaise with senior officials of Police, Fire Brigade, Medical, and Factories Inspectorate and provide advice on possible effects on areas outside the factory premises.

v) Look after rehabilitation of affected persons on discontinuation of emergency.

vi) Issue authorized statements to news media and ensures that evidence is preserved for inquiries to be conducted by the statutory authorities.

5.4 Incident Controller:

The Head of the unit will act as an incident controller for that unit. Immediately on knowing about an emergency, he will rush to the incident site and take overall charge and report to the Site Controller. On arrival, he will assess the extent of emergency that exists and inform the Communication Officer accordingly. His duties will be to:

i) Direct all operations to stop within the affected area taking into consideration priorities for the safety of personnel, minimize damage to the plant, property and environment and minimize loss of materials

ii) Provide advice and information to the Fire/Security Officers and local fire service;

iii) Ensure that non-essential workers/staff of the areas affected are evacuated to the appropriate assembly point and the areas are searched for causalities

iv) Set up communication points and establish contact with the Emergency Control Centre in the event of failure of electric supply and internal telephones

v) Report on all significant developments to the communication officer and

vi) Have regard to the need to preserve the evidence so as to facilitate an enquiry into the cause and circumstances which caused or escalated the emergency.

5.5 Communication Officer:

He will also work as Liaison Officer and will be stationed at the main entrance (GateHouse) during the emergency. He will handle police, Press, and other inquiries, receive reports from roll-call leaders from assembly points, and pass on the absentee information to the Incident Controller. He shall maintain regular communication with the Incident Controller. He will:

  1. Ensure that casualties receive adequate attention/ to arrange additional help if required and inform relatives;
  2. Control traffic movements into the factory and ensure that alternative transport is available when the need arises; and
  3. When an emergency is prolonged, arrange for the relief of personnel and organize refreshments/food.
  4. Advise the Site controller of the situation, recommending evacuation of staff from assembly points if necessary.
  5. Maintain proper agreed inventory in the control room.
  6. Maintain a log of the incident on tape
  7. In case of a prolonged emergency involving risk to outside areas by wind-blown materials, he shall contact the local meteorological office to receive early notification of changes in weather conditions.

5.6 Security Officer-

Security Officer will be responsible for fire fighting. On hearing the fire alarm, he shall reach the fire station immediately and advise fire and security staff in the factory of the incident zone. He will convey the message to the communication officer, Incident Controller and Site Controller about the incident zone. He will direct emergency services. He shall

1) Announce over the PAS in which zone the incident has occurred and on the advice of the Shift Executive In-charge inform the staff to evacuate the assembly service.

2) Inform the Shift Executive In-charge

3) Call Incident Controller, Engineering/ Production Manager, Personnel and Administrative Manager, Departmental Head in whose plant the incident occurred.

4) Security Supervisor for each unit will act as the Security officer for that unit.

5.7 Receptionist:

On hearing the emergency alarm, the receptionist shall immediately contact the Site Controller and on his advice will call the local Fire-brigade and or Police station and safety committee members. In case the PAS and telephone system becomes inoperative, she shall inform the communication officer through the messenger. In case the fire is detected and the alarm is not in operation, she shall receive information about the location from the person who detected the fire and immediately consults the Incident Controller. On his advice, she shall contact the Security Guard and advised him to make an announcement on PAS about the incident and the location of the incident and to evacuate to their assembly point. She will continue to operate the switchboard advising the callers and pass all calls connected with the incident to the Communication Officer.

5,8 Departmental Heads:

The HODs will report to the Incident Controller and provide assistance as required. They will decide the staff they require at the incident site.

5.9 Maintenance In-Charge and Electricians: 

They will report the scene of the incident and close down the services as directed by the Incident Controller

  5.10 Shift Executive In-charge:

As soon as he becomes aware of the emergency and its location, he will proceed to the scene. He shall assess the scale of the incident and direct operations within the affected areas with the following priorities:

  1. Secure the safety of persons, which may require evacuation to the assembly points in the event of an escape of materials if the wind is from an adverse direction.
  2. Minimize damage to plant, property and the environment.
  3. Prevent spreading and damage to outside the premises.
  4. Minimize loss of materials;
  5. Have regard to the need for preserving evidence that may facilitate subsequent enquiry.
  6. Inform shift engineer-in-charge as to what services are needed or not needed.
  7. Hand over the charge of the operation to the Incident Controller when he arrives at the site.
  8. Advice the Security Officer at Gate whether to make an announcement on PAS or not to call the Senior Staff to the factory, if necessary.

5.11 First-Aid Teams:

The Personnel Manager shall keep the roll call lists for the fire and First Aid team on duty. The First Aid team is appointed by each Departmental Head for his shift team. Roll call leaders shall check their roles as a member of the services and report for emergency duty. The name of unaccounted persons or absentees will be informed to the Security Officer. Members of First Aid teams will report to the shift Executive In-Charge or Incident Controller on hearing the alarm and follow his directions.

3.12 Factory Fire Fighting Personnel:

The duty of the Fire Fighting personnel under the command of the Security Officer shall be responsible for fire fighting and rescue. On hearing the alarm they shall proceed to the place of the incident if know, or otherwise, they shall report to the Security Gate. The men at the security Gate shall find the location of the emergency, the equipment and proceed to the site or occurrence. At the site, the team will respond to the directions given by the Incident Controller

1

6.0  Roles  & Responsibilities for Safety Teams:                                                                         

After confirmation of the emergency location from the Emergency Control Centre, concerned teams will start functioning. The team leaders will coordinate and communicate with the management. The team member fights the emergency under the instructions of the leader. The team will ensure that:

  • The emergency does not spread.
  • The head count is taken in consultation with Liaison Manager and if necessary search operation for missing person/s. is undertaken.
  • Every member of the team uses the required Personal Protective Equipment while the operation is going on.
  • First aid is arranged.
  • Additional fire fighting equipment for the fire fighting team is arranged.
  • The smooth rescue operation is facilitated.
  • The emergency will be informed to fire brigade, neighbouring industries.
  • Medicines are provided.
  • Send injured to the hospital if necessary.
  • Records of first aid and hospitalization are maintained.
  • The help of other people is taken to control the emergency.
  • Remaining part of the plant is safe.
  • The area is cordoned off.
  • Necessary tools, equipment to handle any repair work are mobilized.
  • The main power supply line is cut – off if necessary.
  • Maintenance and repair are undertaken.
  • Conduct safety committee meetings every 3 months or in case of an emergency.

Team members of the safety committee:

NAMEDESIGNATIONCONTACT NO
   
   
   
   
   
   
   

7.0 EMERGENCY CONTROL CENTRE                                         

For the purpose of handling the emergency, Emergency Control Centre is very much essential. In the factory, Security Office at the Main Entrance is declared as Emergency Control Centre. All activities pertaining to the emergency will be carried out from this centre. The emergency Control Centre will be equipped with

  • Plant Layout indicating storages of hazardous material and fire fighting equipment and first aid box locations.
  • Material Safety Data Sheet of all chemicals handled in the premises.
  • List of all employees with addresses, tel. No., contact person and if possible blood group.
  • List of important telephone numbers such as police, fire brigade, hospitals, Directorate of Industrial Safety and Health, Pollution Control Board, etc.
  • A separate list of team members with their addresses and telephone numbers.
  • The facility of Direct Telephone Line.
  • Equipment such as Torch, Rope, and necessary Personal Protective Equipment, whistle, etc.
  • Note pads and pen/pencils to record the messages and record of activities pertaining to emergency
  • First aid box with proper medicines.

8.0 ASSEMBLY POINT      

Assembly point is displayed in front of the main gate and known to everyone which is ensured at the time of safety audit. The area of the assembly point has been set farther from the location of likely hazardous events, where employees, contractors, and visitors must assemble in case of emergency. Up- to date list of pre-designated employees must be available with the Site in charge at the assembly point in case of assembly of the employees.  The site in charge shall then do the roll call of the people present so that their presence can be marked.

9.0 ALARM RAISING SYSTEM

The factory Main “Emergency Siren” is located at the main gate. This will be used for raising the alarm and also for “All Clear” signals in case of emergency.

10.0 EMERGENCY RESPONDING PROCEDURE

In case of Fire / Explosion / natural calamity etc., any person noticing it must evaluate the severity of the emergency and he should alert all the factory personnel by activating the Emergency Siren.  The emergency siren is activated just by pressing the Emergency Siren push button located at the main gate. Then he immediately reports to the Emergency Control Centre and informs about the Emergency location. As soon as the alarm is heard, the safety team members will contact the Security office at the Main Entrance and the safety team will rush to the Emergency location. The safety Team & other team members will assemble at the assembly point.

11.0 Communication System:

Alarms should be followed by an announcement over the Public Address System or verbally by shouting. In case of failure of alarm system communication should be by the security guard who will make an announcement through the Public Address system. Mobile Phones, landlines, etc could be used as a mode of communication for an emergency. If everything fails a messenger could be used for sending the information.

12.0 Action Plan For Various Emergencies.

A) Fire

Actions to mitigate the emergencyResponsibility to Respond
Raising emergency alarmOne who observes Fire  or explosion
Shut down machines and Main power supplyOne who observes Fire  or explosion / Prod incharge
Evacuation, Assembly at Assembly Point.All employees
Fire fightingAll employees
Rescue OperationAll employees
First aid or HospitalizationAll employees
Final Declaration of  “All Clear” SituationMR / CEO

B) Major Spillage of flammable/ hazardous oils

Actions to mitigate the emergencyResponsibility to Respond
Raising emergency alarmOne who observes the major spill
Switch Off Power Supply of the equipmentConcerned supervisor, Maintenance engineers
Evacuation, Assembly at Assembly Point.All employees
Isolate & Barricade the area of spillSecurity
Control the spillage to avoid spreadDH
Stop all the work of welding, electrical etcDH
Fire fightingFire fighting team
Final Declaration of  “All Clear” SituationMR

C) Electric Shock

Actions to mitigate the emergencyResponsibility to Respond
Switch Off Power Supply of the equipmentConcerned supervisor, Maintenance engineers
Rescue the person.Concerned supervisor, Maintenance engineers
Call the ambulance, provide first aidDepartmental Head

D) Accidents – Factory (Major)

Actions to mitigate the emergencyResponsibility to Respond
Contact company doctor/hospitalDepartmental Head
Rescue OperationSafety  team

E) Accidents-Transport

Actions to mitigate the emergencyResponsibility to Respond
Contact Ambulance/ Hospital,
provide first aid
Inform HR Dept

Inform Police
Concerned Person    



HR dept

F) Personal confinement

Actions to mitigate the emergencyResponsibility to Respond
Call fire brigadeDepartmental Head
Raising emergency alarmOne who observes the calamity such as storm, earthquake

G) Natural calamities Such as storm, earthquakes, etc.

Actions to mitigate the emergencyResponsibility to Respond
Evacuation, Assembly at Assembly Point.All employees
Raising emergency alarmOne who observes the sabotage, terrorism or civil commotion
Isolate & Barricade if necessarySecurity
Fire fightingAll Employees
Rescue OperationAll Employees
HospitalizationAll Employees
Evacuation, Assembly at Assembly Point.All Employees
Final Declaration of  “All Clear” SituationChief controller

H) Structure collapse

Actions to mitigate the emergencyResponsibility to Respond
Raising emergency alarmOne who observes the calamity such as storm, earthquake
Evacuation, Assembly at Assembly Point.All employees
Isolate & Barricade if necessary,Security
Rescue Operation,Rescue team
Hospitalization,First aid team
Final Declaration of  “All Clear” SituationChief controller

I) Riots, Arson, Sabotaging (Inside the premises of the organization)

Actions to mitigate the emergencyResponsibility to Respond
Inform HR Head, Plant Head, MD, Security, Immediately.  Concern Person.      
Inform the Police immediately.HR Head
The Security shall isolate the area of Rioting with its total force.Security In charge
All work should stop immediately. The employees from rest of the premises shall be evacuated  immediately. The ambulance should be kept in Stand by to meet any eventually. Inform Hospital immediately to prepare for any emergencies. As soon as police arrives the area of rioting should be handed over to police.   Admin In charge.  

J) Riots, Arson, Sabotaging(Outside the premise)

Actions to mitigate the emergencyResponsibility to Respond
Inform HR Head, Plant Head, MD, Security, Immediately.Concerned person      
Inform the Police immediately.HR Head
The ambulance should be kept in Stand by to meet any eventually. Inform Hospital immediately to prepare for any emergencies.HR dept
The gates should be closed and no person and vehicle should be allowed to leave the company premises. Security should man the gates with full force and should prevent entry of any unauthorized person in side the company premises.Security In charge  
In case of more than 8 hours of riot situation the Admin should ensure adequate food and water is available for the employees. Admin In charge
Once all clear signal is received from the police, normal operation shall resume in the organization  Dept HOD  

K) LPG leakage

Actions to mitigate the emergencyResponsibility to Respond
1. Take immediate steps to stop LPG leakage
2. Stop all operations
3. All out effort should be made to contain the spread of leakage/fire
4. Saving the human shall get priority in comparison to stock/assets.
5. Plant personnel without specific duties should assemble at the nominated place.
6. All vehicles except those required for emergency use should be moved away from the operating area, in orderly manner at pressure –nominated route
7. Depending upon severity, electrical system except for control supplies, utilities, lighting and fire fighting system, should be isolated
8. If the feed to the fire cannot be cut off, the fire must be controlled and not extinguished.
9. Start water at areas involved in or exposed to fire risks.
10. In case of leakage of LPG without fire and inability to stop the flow, take all precautions to avoid source of ignition.
11. Block all roads in the adjacent area and render internal/external support for the purpose if warranted.
Fire Fighting Team

L) Tank Dyke Fire

Actions to mitigate the emergencyResponsibility to Respond
1. In case fire occurs in the dyke area due to flange leak in manifold area, the fire is to be extinguished with the help of foam.
2. Use of DCP if the fire is small, otherwise use water spray or foam.
3. Cooling of lines /flanges is to continued till incident/site controller gives the instructions to stop.
4. If tank collapses and product is spread in the dyke area with fire.
5. Withdraw manpower in and around the tank dyke area.
6. Use foam monitors of vehicles to spray and spread foam in the affected dyke area
If tank dyke area is on fire and full product is in the dyke then water to be used judiciously otherwise flooding of dyke area may cause overflow of oil from the dyke area to open drains.
Fire fighting team

M) Electrical Fire

Actions to mitigate the emergencyResponsibility to Respond
Disconnection of the electric supply of the affected area.Attempt to extinguish the fire with the help of DCP/CO2 fire extinguishersIf the fire still persists, ensure complete isolation of electric supply of that area and use of water.Maintenance and fire fighting team

N) Office Fire

Actions to mitigate the emergencyResponsibility to Respond
Disconnection the electric supply of the affected area.Attempt to extinguish the fire with the help of DCP/CO2 fire extinguishersSave all records from fire.  Office staff and fire fighting team

O) Person on Flames

Actions to mitigate the emergencyResponsibility to Respond
1) Bring the water gel blanket
2) Open the bag inside the container to remove blanket. If the bag is already open such blanket should not be used for burn victims
3) The blanket can be held as a screen between the victim and the fire
4) If possible lay down the victim and wrap the blanket around the victim. Leave the victim wrapped in blanket and seek medical help  
Fire fighting team

P) Food/Water Poisoning

Actions to mitigate the emergencyResponsibility to Respond
1) Persons observing the symptom should inform the location in charge for assessing the situation
2) Shift in charge should call the doctor and ambulances and also alert all hospitals to meet any exigencies
3) To render first aid and induce vomiting to the affected persons
4) The ambulances and vehicles available should be mobilized to be in readiness to transport large number of people if required Assistant Manager-SHE to report to location in charge for required sanitation and medical assistance.
First Aid team

Q) Bomb Hoax

Actions to mitigate the emergencyResponsibility to Respond
1) Person noticing on object like bomb, should bring it to the notice of the nearest available officer.
2) The officer should carefully observe the same from a distance and raise alarm
3) The area should cordon off.
4) Police control and fire control to be informed for their arrival and inspection of the area. After the bomb is diffused, all clear siren should be sounded by the watchmen.
Concerned person/ Admin dept

R) Burn –Minor

Actions to mitigate the emergencyResponsibility to Respond
Pour cool water on the burn area till the burning sensation is reduced.Cover it lightly with a clean cotton cloth.Do not apply butter, oil, ointments or any home remediesGet Medical help  First aid team

S) For Electric shock casualties

Actions to mitigate the emergencyResponsibility to Respond
Electric shock results in irreversible damage to brain cells followed by deterioration of the other organsRescue and first aidDo first thing first, quickly and without fuss or panic. Switch off the supply if this can be done at once. If not possible, use a dry stick, dry cloth or other non conductor to separate the victim of electrical contact. The rescuer must avoid receiving shock himself be wearing gloves or using a jacket to pull the victim.First aid team

12.0 DO’S AND DON’T’S

12.1 All Company Employees

Do’sDon’t’s
 Stop work on getting information or hearing the alarm.
 Switch off the machines and main power supply.
 Gather at assembly point.
 Contact Management
 Take visitors to safer place.
 Do not panic & cause stampede.
 Do not run and prevent others from doing so.
 Do not go anywhere else.
 Do not wait to collect personal belongings.

12.2 VISITORS & CONTRACTORS

After hearing the alarm they will follow the following steps:

  1. Give attention to all instructions.
  2. Stop work. Do not panic.
  3. Do not wait for personal belongings.
  4. Assemble at the assembly point.
  5. Do not go to the emergency site.
  6. Do not spread rumours.
  7. Do not engage in communication systems.

13.0 TRAINING

The employees will be informed about the ‘On–Site Emergency Plan’ in detail, with the help of training programs. For the success of this plan not only training will be organized but mock drills also will be organized a minimum of once a year. Mock drills will help to understand the role to be played by everyone during the emergency. The Core members of the Disaster / Emergency control will be given refresher training at the interval of every One Year.

14.0 MOCK DRILL PROCEDURE

The success of the “On-site emergency plan” is very much dependent on planned and unplanned mock drills. Mock drills help employees to be familiar with their roles and ensure accuracy of the onsite Emergency Plan. Following is the procedure for conducting a Mock drill.

  • Inform all the employees about mock drill procedures.
  • Fix the date and time for mock drill.
  • The mock drill will be monitored by the observer/s not involved in the exercise.
  • The emergency alarm will be raised.
  • After hearing the alarm, the Emergency Procedure will be followed. All clear signals will be given after the emergency is over.
  • Observer/s will note down the activities with respect to the time.
  • Lacunae observed in the system will be studied carefully.
  • Records of drills will be maintained.

After each drill, the plan will be thoroughly reviewed to take into account the omissions or shortcomings for improvement.

15.0 Details of liaison arrangement between the Organization:

All the organizations involved in assisting during the emergency were contacted and apprised of the details of the plant, like process; hazardous material handled; likely emergency incidents; steps taken to avoid/reduce risk mitigation methods, resource availability, etc. The details are as follows:

 15.1 POLICE

Sr.NoName of Police StationTel.No
   
   
   
   
   
   
   

15.2  FIRE BRIGADE STATION

SR. noFire StationTel no
   
   
   

15.3 HOSPITALS AND DOCTORS

Sr.NoName of HospitalTel No
   
   
   
   
   
   
   
   

16.0  UPDATING THE PLAN

As and when required, this ‘On–Site Emergency Plan’ will be updated and informed to all. If necessary, after each drill the plan will be thoroughly reviewed to take account of shortcomings.

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Example of Emergency Preparedness Plan-EMS

1.0 EMERGENCY

An emergency is a situation, which may lead to or cause large-scale damage or destruction to environment within or outside the factory. Sometimes the Emergency results in uncontrollable situations and leads to disaster. Such an unexpected severe situation may be too great for the normal workforce in the area within the plant. In any industry, an emergency can arise at any moment and this depends on the type of

  • Environment impacts
  • Structure
  • Raw Materials
  • Machines / Plant
  • Nearby Industries etc.

4.0  EMERGENCY MANAGEMENT & KEY PERSONS                                        

During an emergency situation, it is generally seen that chaos and confusion rules leading to more damage. In Emergency Management, just like in normal operations where there are managers, engineers, supervisors, operators, etc., who are assigned specific tasks to run the business, similarly during an emergency also there are persons with specific duties. These persons are known as ‘Key Personnel’.

Following are the persons who are responsible to face the emergencies.

NAMEDESIGNATIONCONTACT NO
   
   
   
   
   
   
   

If required external help in case of an Emergency will be sought from appropriate sources. The required assistance from the probable sources has already been informed and consent obtained for the same.

5.0 FIRE/ EXPLOSION  

1.) Preparation for a fire incident

  • Prepare and maintain an up to date list of chemical / dangerous goods and chemical wastes indicating their location on a site map
  • Maintain up-to-date copies of all MSDS Sheets for chemicals stored on site
  • Store readily accessible copies of (i) and (ii) above in an area of the unlikely to be affected by fire.  The information should be used to ensure fire-fighting activities are undertaken safely and with minimum impact to the environment.
  • Check that licensed contractors regularly maintain fire-fighting equipment.
  • Ensure that sandbags are maintained and readily accessible
  • Maintain periodic drill fire fighting procedures

2) During and Incident

  • Follow “Fire Procedure”, alert the emergency services.  Brief Fire Service Department in all aspects of the incident and where appropriate provide the Chemical / DG list, MSDS sheets and site map.
  • Ensure sandbags are available to the emergency services, to prevent the contamination of the storm water drains / foul sewer, inform the emergency services of their availability for use should tome / urgency of the situation permit.

3) After the Incident

  • Following the steps outlined in the procedure of Waste Management, to contain and dispose of liquid and solid chemical waste
  • Investigate the causes of the incident and prepare a report describing any environmental impacts which have resulted and how they have been mitigated.
  • Amend this environmental instruction and the emergency plan based on the findings described in the report if necessary.

6.0 Rainstorms and typhoons

Wastewater potentially contaminated with chemicals after typhoons:

  • Contain wastewater (with sand bags, etc) to prevent from entering water treatment facilities, drainage systems or watercourses
  • Pump the wastewater into a suitable container and dispose of as chemical wastes according to EI-03 Waste Management.
  • The EMR / DEMR will then determine if other parties (e.g. Environmental Department, neighboring communities) need to be informed.

7.0 SOLID WASTES:

  • Contain (and if necessary, treat) the waste containment to minimize drainage into sewerage system
  • The EMR shall determine if the wastes are chemical waste and dispose of in accordance to EI for Waste Management
  • The EMR will then determine if other parties (e.g. EPD, neighboring communities) need to be informed.

8.0 Major Chemical / Untreated Wastewater / Diesel Spillage     

  • Contain the spill to minimize drainage into sewerage system
  • Inform the Production Manager / EMR immediately.
  • The Production Manager / EMR or his / her delegate shall arrange for appropriate removal and disposal of the chemicals / untreated wastewater / diesel by authorized collectors, and determine if other parties (e.g. EPD, FSD, neighboring communities) need to be informed.

9.0 Accidental Release of Toxic Gas

  • Terminate the source of toxic gas emission and contain the toxic gas to minimize the emission into atmosphere whenever applicable and practicable.
  • Inform the Production Manager / EMR immediately.
  • The Production Manager / EMR or his / her delegate shall arrange for appropriate cleanup by skilled professionals, and determine if other parties (e.g. EPD, FSD, neighboring communities) need to be informed.

10.0 Shut Down of Wastewater Treatment Plant


  • For emergency situation, resulting in shutdown of plant, it shall inform the Production Manager.
  • The Production Manager shall determine if stop of production is necessary, and action shall be taken in accordance with the operation manual of wastewater treatment plant and contact the contractor for repair immediately.
  • Inform EMR and EMR shall inform Environment Dept if untreated wastewater is discharged to drainage.

11.0 Spillage of Hazardous Materials

  • Ensure that any spillage of chemical should apply sand / sawdust to absorb the spilled chemical, in order to control the spilled area. To wear protective clothing and appropriate equipment to handle any chemical spillage situation.
  • After cleaning, any used absorbent (e.g. sand / sawdust) should be treated as chemical waste material.
  • Record the occurrence of chemical spillage in the accident report, in order to discuss the preventive action for future.
  • Arrange at least once a year of chemical spillage drill.

12.0 Details of liaison arrangement between the Organization:

All the organizations involved in assisting during the emergency were contacted and apprised of the details of the plant, like process; hazardous material handled; likely emergency incidents; steps taken to avoid/reduce risk mitigation methods, resource availability, etc. The details are as follows:

 12.1 POLICE

Sr.NoName of Police StationTel.No
   
   
   
   
   
   
   

12.2  FIRE BRIGADE STATION

SR. noFire StationTel no
   
   
   

12.3 HOSPITALS AND DOCTORS

Sr.NoName of HospitalTel No
   
   
   
   
   
   
   
   

13.0  UPDATING THE PLAN

As and when required, this ‘On–Site Emergency Plan’ will be updated and informed to all. If necessary, after each drill the plan will be thoroughly reviewed to take account of shortcomings.

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Example of Risk assessment of OHSMS and EMS

Example of Risk Assessment of Occupational Health and Safety Management System.

Sr. noDate of Entry
(7/1/2019)
Areas/ LocationActivityActivity Type ( R/NR)Hazards
Risk
 E (emergency)IPC (Interested Party Concern)LC (Legal Concern)RSP (Resource saving potential)Present / Existing controlsSeverityFrequency of OccurrencesTime to noticePresent risk factor Controls added to reduce risksSeverityFrequency of OccurrencesTime to noticePresent risk factorFinal  (S/NS)Link to Objective / Program, OCP
011/7/19Shop FloorMaterial handling using cranesR  Fall of object handled by crane & being struck by itBody injury, fatalYNYPreventive Maintenance, Trained operators, PPEs, Supervision & vigil while lifting 55125S  Inspection and Certification by competent authority53115NSOCP05
021/7/19Shop FloorMaterial handling using cranesRDefective tackles, slings etcFall of object which may cause body injuryYNYRegualr Inspection of tackels & tools for wear & tear, Regualr testing & Maintenance &  Trained operators, PPEs55125SInspection and Certification by competent authority53115NSOCP05
031/7/19Shop FloorMaterial handling using cranesRExcess loadFall of object which may cause body injuryYNY Care whiling Lifting , Trained operators, PPEs55125SOperator Training & counselling not to lift excess laod , Marking of Lifting equipments for Safe lifting load 53115NSOCP05
041/7/19Shop FloorMaterial handling using cranesRDefects in craneFall of object which may cause body injuryYNYPreventive Maintenance, Trained operators, PPEs55125SInspection and Certification by competent authority53115NSOCP05
051/7/19Shop FloorMaterial handling using cranesRUnskilled operator or improper handlingBody injury or fatalYNY Trained operators55125STraining for crane operation & Hnadling of material 53115NSOCP05
061/7/19Shop FloorManual material handlingRExcessive lifting, pushing, pulling, holding and carryingStrain/sprain injuryNNNWork planning and control assistance from others, mechanical assistance from others32318NSTraining for proper lifting 3139NSOCP 02
071/7/19Shop FloorManual material handlingRErgonomics due to Lifting of heavy materialBack Pain/ Personal InjuryNNNUse of  Cranes / Trolley23530SUse of Lifting equipments , Training for proper lifting 22520NSOCP 02
081/7/19Shop FloorManual material handlingRInjury /Cuts to hand while handling Injury to handsYNNUse of Hand Gloves , Precaution2319NSPrecuation while handling , workers have access to, provided with and use personal protective equipmentsuch as gloves, safety glasses and safety shoes toprotect against cuts and impacts.2214NSOCP 02
091/7/19Shop FloorManual material handlingRFall of Heavy object on feetInjury to toes and feetYNNUse of safety shoes 43112NSPrecuation while handling , Use of safety shoes with steel toes 3216NSOCP 02
101/7/19Shop FloorWeldingR  Electrical Shock due to Unearthed Welding machine /Transformer Fatality or Severe BurnYNNProrper earthing /PM54120NSPreventive Maintenance , Experineced Operator , Regular inspection 53115NSOCP 02
111/7/19Shop FloorWeldingRElectric Shock due to exposed  joints of welding cables Fatality  or Severe BurnYNNPrecaution while welding , PM 54120SUse of  Cable without Joints , Isnpection of cables every day , If joints are there then proper taping 5115NSOCP 02
121/7/19Shop FloorWeldingRContact with hot surfaces Severe BurnYNNUse of Hand Gloves , Precaution55125Ssuitable  overalls and gloves are provided and used to protect the skin against burns from hot surfaces, flames and sparks43112NSOCP 02
131/7/19Shop FloorWeldingRExplosion of gas  Cylinder Fire & Fatal InjuryYYYPrecaution while welding 53115SUse of Flash Back arrestors , Work permit 52110OCP 02
141/7/19Shop FloorWeldingRExposure to UV RaysVision ProblemsNNYWear goggles and face mask.43560SPPEs provided42540SOCP 02
151/7/19Shop FloorWeldingRInhalation of FumesBronchial ProblemsNNYWear goggles and face mask. 43560SMask provided33545SOCP 02
161/7/19Shop FloorWeldingRFlashes/FlamesVision ProblemsNNNWear goggles and face mask. 43560Ssuitable welding shields and gogglesare supplied and used to protect the eyes fromflames and sparks during welding33545SOCP 02
171/7/19Shop FloorWeldingRFire HazardBurnsYNNworking combustible materials andwaste are kept in covered containers3319NSFire extinguishers providedNSOCP 02
181/7/19Shop FloorWeldingRHot work piecesSevere BurnYNNsuitable tools for holding andmoving hot work-pieces are provided and usedto prevent burns and fires43112NS NSOCP 02
191/7/19Shop FloorWeldingRHeat stress or heat exhaustionBurnsYNNsuitable welding shields and gogglesare supplied and used to protect the  flames and sparks during welding3319NSNSOCP 02
201/7/19Shop FloorGrindingRContact with Grinding WheelCutYNNProper training for grinding3319NSTrained manpower deployedNSOCP 11
211/7/19Shop FloorGrindingRGeneration of NoiseHearing ProblemsNNYNoise measurements are with in limits 35115S Providedwith suitable personal protective equipmentsuch as ear plugs to protect them from high noise levels25110NSOCP 11
221/7/19Shop FloorGrindingRWrong size of Grinding WheelPossibility of cut and injury to surround peopleNNNTrained manpower deployed, 3319NSNSOCP 11
231/7/19Shop FloorGrindingRInhalation of Dustill healthNNYWear goggles and face mask.35575SProvide face mask, Helth checkup and rotation of manpower 33545NSOCP 11
241/7/19Shop FloorGrindingRSparks and dust in eyes.Eye injuryYNNWear goggles and face mask.43224NSWelding Google & shields 33218NSOCP 11
251/7/19Shop FloorGrindingRRotating abrasive wheels. Cuts & abrasionsYNNTrained manpower deployed3319NSNSOCP 11
261/7/19Shop FloorGrindingRUse of a worn grinding wheel causing injuries to userYNNWheels to be inspected for wear before use3319NSTraining provided for grindingNSOCP 11
271/7/19Shop FloorGrindingRStopping wheels by applying pressure to them cause work piece to be ejected and cause injuriesYNNWheels not to be stopped by applying pressure to them. Wheels to be allowed to run down and stop of their own accord
43112STraining provided for grinding4218NSOCP 11
281/7/19Shop FloorGrindingR Failure to wear the correct personal protective equipment (PPE) lead to injuriesYNNAll users to wear eye protection.  All users to wear respiratory protection when grinding creates a dust.User to ensure that clothing is worn so that there is no risk of entanglement.53115STraining provided for PPE usage4218NSOCP 11
291/7/19Shop FloorGrindingRContact with revolving cutters Body InjuryYNNSafe Working Platform provided43112STraining for safe operation4218NS 
301/7/19Shop FloorGrindingRLong hair and loose clothing can become entangled in moving parts of the machineYNNCoverall worn when operating the machine, long hair should be tied back and protected from entanglement. Loose clothing  should be tucked in / removed. 54120SNo Loose clothing , Training of safe working 52110NS 
311/7/19Shop FloorGrindingRBroken cutters, swarf and work pieces can be violently ejected.Body InjuryYNN work piece is securely clamped tight prior to milling34112NSTraining for safe operation3319NS 
321/7/19Shop FloorGrindingRSharp edges on tools, work pieces and swarf  cause cutsNNNOperator has been trained in safe work practices and appropriate PPE (e.g. eye, foot hearing and clothing protection) is worn during operation. 44116STraining for safe operation4218NS 
331/7/19Shop FloorGrindingR Contact with cutting fluids, oil and
grease
 can irritate the skinNNNAppropriate PPE is worn whilst operating the metal milling machine.34112NS      
341/7/19Shop FloorGrindingRMilling machines repair & maintenanceelectrical shock.NNNOperator to check for damaged electrical cords prior to use and proper earthinh 53115SIsolation of machines befroe repair or maintenance lock ot & Tag our procedure to be followed 3218NS 
351/7/19Shop FloorGrindingRClosing movement between parts, under power feedCan result in finger trappingNNNOperator has been trained in safe work practices and appropriate PPE (e.g. eye, foot hearing and clothing protection) is worn during operation. 44116STraining for safe operation4218SPut additonal control / OCP
361/7/19Shop FloorGrindingRHeavy objects such as vices and index fixtures .can fall from the table & cause injuryNNNOperator has been trained in safe work practices and appropriate PPE (e.g. eye, foot hearing and clothing protection) is worn during operation. 44116STraining for safe operation, USE of Steel toe safety shoes 4218NS 
371/7/19Shop FloorGrindingRInadvertent starting of the machine .Injury to body part , Shock etc NNNOperator has been trained in safe work practices and appropriate PPE (e.g. eye, foot hearing and clothing protection) is worn during operation. 52110STraining for safe operation, Inspection before start up of machine 5115NS 
381/7/19Shop FloorGrindingRLack of space around the machine lead to the operator being pushed by passers-by.NNNProper  work space & ergonomics 3319NS 
391/7/19Shop FloorGrindingRSlippery floor surfaces or loose items around the machine
can cause slips that result in contact with moving parts.NNNAppropriate cleaning and housekeeping practices are maintained to minimise the risk of a slip, trip or fall.34112NS 
401/7/19Shop FloorGrindingRGases and metal dust generated from the work process  hazardous to health.NNYlocal exhaust/ventilation system is switched on and in good working order. 44580SUse of exhuast system / Vnetillation , Provide PPE , Health checkup &  rortation of operators 43560SOCP
411/7/19Shop FloorPolishing (Buffering)RLong hair and loose clothing can become entangled in moving parts of the machinecan become entangled in moving parts of the machineYNNCoverall worn when operating the machine, long hair should be tied back and protected from entanglement. Loose clothing  should be tucked in / removed. 53115NS 
421/7/19Shop FloorPolishing (Buffering)RWork pieces, wires from brushes and particles from
the polishing process can be ejected from the
machine. Sharp edges can cause cuts.
Body InjuryNNN work piece is securely clamped tight prior to polishing3319NS 
431/7/19Shop FloorPolishing (Buffering)RHot work pieces can cause burns.BurnsNNNOperator has been trained in safe work practices and appropriate PPE 3319NS 
441/7/19Shop FloorPolishing (Buffering)RPolishing machines can present a hazard of electrical shock. Inadvertent starting of the machine
can present a hazard.
electrical shock.NNNOperator to check for damaged electrical cords prior to use. 54120SRegular inspection of damaged electric cords  & Replacing or taping of open wires 53115 
451/7/19Shop FloorPolishing (Buffering)RDust can be inhaledBreathing problemsNNNPPE to be worn44580SUse of Nose mask , Health check up &  exhaust 42540SOCP
461/7/19Shop FloorPolishing (Buffering)RLack of space around the machine lead to the operator being pushed by passers-by.NNNProper work space & ergonomics 3319NS 
471/7/19Shop FloorPolishing (Buffering)RSlippery floor surfaces or loose items around the machine
can cause slips that result in contact with  moving parts.NNNAppropriate cleaning and housekeeping practices are maintained to minimise the risk of a slip, trip or fall.34112NS 
481/7/19Shop FloorTurning lathesRUncontrolled moving or swinging partsBody InjuryNNNOperator has been trained in safe work practices and appropriate PPE 34112NS 
491/7/19Shop FloorTurning lathesRSharp edges, corners, rough surfaces Body InjuryNNNOperator has been trained in safe work practices and appropriate PPE (e.g. eye, foot hearing and clothing protection) is worn during operation. 44116STraining for safe operation43112NS 
501/7/19Shop FloorTurning lathesRWorkpiece clampingCrushing
YNN work piece is securely clamped tight prior to machining44116STraining for safe operation43112NS 
511/7/19Shop FloorTurning lathesRWhipping bar stock CrushingYNNOperator has been trained in safe work practices and appropriate PPE 44116STraining for safe operation43112NS 
521/7/19Shop FloorTurning lathesRRapid travel of table or spindle head Drawing in or trapping cause injuryYNNOperator has been trained in safe work practices and appropriate PPE 44116STraining for safe operation43112NS 
531/7/19Shop FloorTurning lathesRContact with Moving or rotating tool Body InjuryYNNOperator has been trained in safe work practices and appropriate PPE 44116STraining for safe operation43112NS 
541/7/19Shop FloorTurning lathesRMaintenance or repair Electrical contact (direct
or indirect)
NNNOperator to check for damaged electrical cords prior to use and isolate machine before maintenance54120STraining for safe operation, Follow Lock out & Tag out procedure 53115SOCP
551/7/19Shop FloorTurning lathesRLong hair and loose clothing can become
entangled in moving parts of the machine
NNNCoverall worn when operating the machine, long hair should be tied back and protected from entanglement. Loose clothing  should be tucked in / removed. Coverall worn during operation54120STraining for safe operation53115NS 
561/7/19Shop FloorTurning lathesR Contact with cutting fluids, oil and
grease
 can irritate the skinNNNAppropriate PPE is worn whilst operating the metal milling machine.34112NS 
571/7/19Shop FloorTurning lathesRLack of space around the machine lead to the operator being pushed by passers-by.NNNProper Design of workspace around plant and equipment 3216NS 
581/7/19Shop FloorTurning lathesRSlippery floor surfaces or loose items around the machine
can cause slips that result in contact with moving parts.NNNAppropriate cleaning and housekeeping practices are maintained to minimise the risk of a slip, trip or fall.3216NS 
591/7/19Shop FloorTurning lathesRImproper use of PPE Body InjuryNNNTraning on PPE usage in tool box meetings3319NS 
601/7/19Shop FloorTurning lathesRInconvenient climatic conditions – air
quality and humidity 
Uneasiness and uncomfortableNNYAir quality and humidity monitored33545SProper Ventillation , Air , Exhaust , Air quality check 32530OCP 
611/7/19Shop FloorTurning lathesRUnilateral workload, repeated working operations, forced positions (e. g. standing)Back pain, health problemsNNNLimiting working hours not more than 8 hrs3216NS 
621/7/19Shop FloorTurning lathesRHarmful effects of the vapors and aerosols while breathing Breathing problemsNNNAppropriate PPE is worn whilst operating 34112NS 
631/7/19Shop FloorTurning lathesRIrresponsibility, bad cooperation Stress and non cooperative atmosphereNNNCouselling during   tool box meetings34112NS 
641/7/19Shop FloorBoring OperationRFallBody InjuryYNNSafe Working Platform provided35115NS 
651/7/19Shop FloorBoring OperationRFlying of chipsEye injuryNNNGuards provided45120SUse of Safety goggles 3319 
661/7/19Shop FloorBoring OperationRSharp edges on Lathe Machine ControlsHand injury NNNPPE/ Preventive Maintenance2215NS 
671/7/19Shop floor Boring OperationRFalling of Heavy Object Like  Job etcBody InjuryYNNNFixtures/Use ofPPE3319NSSafety while handling  
681/7/19Shop FloorBoring OperationRBoring operation-Cross slide.InjuryNNNTrained personnel 3216NS 
691/7/19Shop FloorBoring OperationRSharp edges from machine caused injury on handInjuryNNNPPE’s provided/ Shutter no return system3216NS 
701/7/19Shop FloorBoring OperationRElectrical ShockFatalYNNPreventive Maintenance by competent personnel53115SIsolation of machines befroe repair or maintenance52110SOCP09
711/7/19Shop FloorBoring OperationREntanglementBody InjuryNNN Coverall worn during operation43112SUse of cover all , Safe working instructions 3218NS 
721/7/19Shop FloorGeneral Machine ShopRMechanical equipment
 Contact injuries e.g. entanglement, drawing-in, abrasions, cuts, burnsNNNNo one  operate workshop equipment unless they have received a sufficient training . Guards on the machines  used. 3319NS 
731/7/19Shop FloorGeneral Machine ShopRElectrical equipment
Electric shocks or burns from using faulty electrical equipment YNNElectrical cables and plugs are regularly visually inspected by the user for damage. 33110NS 
741/7/19Shop FloorGeneral Machine ShopRManual handling of heavy/bulky objects Back injuriesNNNTraining in lifting techniques is provided for workshop staff who undertake the lifting of heavy loads. Appropriate PPE for lifting operations must be worn 33218NS 
751/7/19Shop FloorGeneral Machine ShopRHazardous Substances
 irritating vapours, skin sensitisation, dermatitisNNNA Material Safety Date Sheet (MSDS) must be kept near the storage area33218NS 
761/7/19Shop FloorGeneral Machine ShopRSlips and tripsInjuryNNNWorkshop working areas are kept clear of obstructions and the floor must be kept free from oil and swarf.32212NS 
771/7/19Shop FloorGeneral Machine ShopRFireBurnsYNNFlammable substancesare kept away from naked flames and ignition sources. Workshop users areacquainted with the Fire emergency43224SFire extinguishers provided42216NS 
781/7/19Shop FloorGeneral Machine ShopNRWorking at height Fall YNNPermit for working at height43224SWorking at height permit  issued.3216NS 
791/7/19Shop FloorGeneral Machine ShopNRExcessive NoiseHearing ProblemsNNYAppropriate PPE is worn whilst operating 33218SNoise level is monitored      
801/7/19Shop FloorPaintingRFUMES –
emitted by some paints
Breathing problemsNNNMaterial safety data sheets available. Use of PPE 33218NS       
811/7/19Shop FloorPaintingRSOLVENTS –
cleaners, thinners, etc.
Contact with skin can cause irritationNNNMaterial safety data sheets available. Use of PPE 33218NS       
821/7/19Shop FloorPaintingRFIRE – paints / solvents that contain inflammable substances
fire fazardYNNTo keep all inflammable objects away. Fire extinguishers provided, emergency training43112S       
831/7/19Shop FloorPaintingRCUTS – handling Injury NNNTrained personnel3319NS       
841/7/19Shop FloorPaintingRCONTAMINATION OF THE EYES – spray painting, etc.
irritation of eyesNNNMaterial safety data sheets available. Use of PPE 33218NS      OCP10
851/7/19Shop FloorSand BlastingRMobilization of equipment Falling hazard – -Minor
injury
NNN-Trained vehicle/forklift operator -Qualified signal/rigger -Provide appropriate PPE3319NSSupervisor     OCP10
861/7/19Shop FloorSand BlastingRSetting up and testing of equipment Struck by  compressed
air/hose – Body injury
NNN-Equipment checklist -Adequate safety features -Provide PPE43112SRegular Inspection & Maintenance of parts & equipment4218SOCP10
871/7/19Shop FloorSand BlastingRTop up blasting grit
Falling hazard- body injuryNNNBarricade top area , Qualified signal/rigger43112SInstruction for Safe working 4218SOCP10
881/7/19Shop FloorSand BlastingRCommencement of  blasting Strike by compressed
air/ grit/ hose
NNN-Provide appropriate PPE43112SProvide PPE & Safe working instruction & Inspection of hoses and clamps 3216NSOCP10
891/7/19Shop FloorSand BlastingRCommencement of  blasting Trip and fallNNN-Provide adequate lighting/ no obstruction3319NSSupervisor     OCP10
901/7/19Shop FloorSand BlastingRCommencement of  blasting Dust
inhalation
NNNProvide Nose mask 43560SProvide PPE , Regular Health cehck up & Monitoring 42540SOCP10
911/7/19Shop FloorSand BlastingRGrit removal and emptying the grit
Ergonomic – -Back pain NNNProvide Proper  Lifting equipments & Material handling 33545SProvide proper lifting instruction & Safe work practice training 32530SInstruction & Training 
921/7/19Shop FloorSand BlastingRGrit removal and emptying
the grit
-Dust inhalationNNNProvide Nose mask 43560SHealth Checkup , Monitoring 42540SHealth chekup
931/7/19Shop FloorSand BlastingRBlasting  Operation High pressure – -Bodily injuries NNNPhysical check on hose
condition , Trained personnel 
43112SPhysical check on Hose condition & Clamping , Safe working practices 4218SOcp
941/7/19Shop FloorSand BlastingRBlasting  Operation  -Noise – Noise Induced
Deafness
NNY Provide Ear Plugs 44580SProvide PPE , Monitor for  implemntation & rotation of operaotrs 33545SOCP & PPE
951/7/19Shop FloorPressure testingRtest assembly rupture, creating flying fragmentsBody InjuryNNN Proper barricading , Safe working practces 43112SProvide PPE ,  Safe working instruction 4218SOCP
961/7/19Shop FloorPressure testingRcomponent or connector failure, creating missiles projected under force;FatalNNN Proper barricading , Safe working practces &  Prior checking of Components 52110SSafe working practces , Additional checks on components 5115SOCP
971/7/19Shop FloorPressure testingRtest hose failure including detachment, with consequential hose whipstriking people causing injuryNNN Barricading , Use of PPE , 43112SInspection of Hoses & Clamps 3216NS 
981/7/19Shop FloorPressure testingRsudden release of the test medium (liquid, gas, vapour, dust or other substance under pressure) causing injury, eg burns, eye damage or pressure injection into bodily tissue.NNN Use of PPE , Safe working practices 43112SSafe working practices 4218SOCP
991/7/19Shop FloorPressure testingRImproper use of PPE Body InjuryNNNTraining for Use of PPE3319NS       
1001/7/19Shop FloorPressure testingRInconvenient climatic conditions – air
quality and humidity 
Tirdness & Fatigue NNNProper ventillation & Air 33218NS       
1011/7/19Shop FloorPressure testingRUnilateral workload, repeated working operations, forced positions (e. g. standing)Tirdness & Fatigue NNNProper Ergonomics , Working hours , rotation of manpower 44232SHealth checkup, Monitoring , Rotation of manpower 33218NS 
1021/7/19Shop FloorPressure testingRHarmful effects of the vapors and aerosols while breathing Health Hazard , Bronchitis , Brething trouble NNNUse of Nose mask while working , ventillation 43560SVentillation & Air , Health Checkup & Air quality Monitoring 42540SUse of PPE 
1031/7/19Shop FloorPressure testingRIrresponsibility, bad cooperation  NNN             
1041/7/19Shop FloorPressure testingRLack of space around the testing equipmentlead to the
operator being pushed by passers-by.
NNNProper Design of workspace around plant and equipment 3319NS       
1051/7/19Shop FloorPressure testingRSlippery floor surfaces or loose items around the machine
can cause slips that result in contact with
moving parts.
NNNAppropriate cleaning and housekeeping practices are maintained to minimise the risk of a slip, trip or fall.3216NS       
1061/7/19Shop FloorPressure testingRElectric shock from cable or pump body, potentially fatal, or severe burnsNNN Pre-use checks on pump include checking Proper earthing/ electrical parts for cracks/defects etc.53115Suse of PPE , Earthing checks , checking of electrical parst52110SOCP
1071/7/19Shop FloorPressure testingRTrip Hazard from cables or pump delivery hoses.      Pump placed away from work area

Cables positioned away from work area. 
            
1081/7/19Shop FloorPressure testingRNoise from pump, leading to hearing impairmentDeafness , Hearing problem NNNYUse of PPE like ear plugs 43560SUse of PPE , instruction for using it without fail 32530SOCP & PPE
1091/7/19Shop FloorPressure testingRBio-hazards from handling contaminated pump/hoses.Skin Problem , Skin irritation NNN Use of Hand Gloves , Precaution34448SUse of PPE  without fail , Instruction & enforcement 22520NS 
1101/7/19Shop FloorAssembling  & dismantling of BOPsRFall of BOP or other equipmentFatalNNN Ensuring Proper placing of BOP & Equipment on level surface , Isolating areas  & Insturction for keeping away 52110SIsolation & Proper Placment of BOP 5115SOCP19
1111/7/19Shop FloorAssembling  & dismantling of BOPsRHit by equipmentFatalNNN Isolation while Lifitng or running 52110SSafety awarness & Isolation 5115SOCP19
1121/7/19Shop FloorAssembling  & dismantling of BOPsRSlipBody InjuryNNN Use of PPE , Proper Working & care 3319NS      OCP19
1131/7/19Shop FloorAssembling  & dismantling of BOPsRUnbolting Injury to handNNN Use of PPE, Use of Proper Spanners 3319NS      OCP19
1141/7/19Shop FloorAssembling  & dismantling of BOPsRLifting/carrying
 materials,
Strains, pulled muscles, skeletal
injuries and rope burns
NNN Use of Material handling equipments 3319NS      OCP19
1151/7/19Shop FloorAssembling  & dismantling of BOPsRInstallation of ties, ring
bolts, anchors etc.
Injury to Hand , Starin etc NNN Use of proper equipments , care while working 3319NS      OCP19
1161/7/19Shop FloorAssembling  & dismantling of BOPsRWorking at height during dismantling
Fall – Head injury & Body injury NNN Use of safety Belt , Safe working , Use of helmet 52110SUse of safety belts , precuation , PPE 4218SOCP19
1171/7/19Shop FloorTanks (Oil and Waste Water)NRTrip over from the tryInjuryNNNDifferent color Identification2112NS      OCP 08
1181/7/19Shop FloorTanks (Oil and Waste Water)NRMicrobiological HazardsIllnessNNNHealth check ups-closed lid2112NS      OCP 08
1191/7/19Shop FloorTanks (Oil and Waste Water)NROxygen Deficiencybreathing disorderNNNWork permit-Oxy measured2112NS      OCP 08
1201/7/19Shop FloorTanks (Oil and Waste Water)NRFlammable Vapoursbreathing disorderNNNWork permit-Exhaust2112NS      OCP 08
1211/7/19Shop FloorTanks (Oil and Waste Water)NRFire BurnsYNNAdmin control to avoid sources of ignition and Training3113NS      OCP 08
1221/7/19Shop FloorTanks (Oil and Waste Water)NRLid CollapseBody injuryYNNTrained personnel and Admin Control “do not stand over the lid”5115NS      OCP 08
1231/7/19Shop FloorTanks (Oil and Waste Water)NRFall when lid is openBody injuryYNNRed and White tape placement and Barricades2112NS      OCP 08
1241/7/19Shop FloorTanks (Oil and Waste Water)NRConfined space when cleaningSuffocationNNNWork permits and Training2214NS      OCP 08
1251/7/19Shop FloorTanks (Oil and Waste Water)NRProtrudments from the lidInjuryNNNDifferent color used 1212NS       
1261/7/19Shop FloorHuge Oil trayRslippery surfacesInjuryNNNPPE and Training2316NS       
1271/7/19Shop FloorHuge Oil trayRStruck by or against objectInjuryNNNAdmin control-Hazard Tape2316NS       
1281/7/19Shop FloorHuge Oil trayRExcessive manual material handling Back PainNNNUse of OH crane2418NS       
1291/7/19Shop FloorHuge Oil trayRTrip overInjuryNNNAdmin control-Hazard Tape2112NS       
1301/7/19Shop Floor Use of PPE RUse of Unsuitable , Damaged or contaminated PPE Contamination , Injury or Ill health NNN Use of  Proper , Inspected  PPE , Proper stoarge of PPE 22416NS      
1311/7/19Shop floor Use of Mobile Phones RAccidents , Falling & Hit to personInjury to BodyNNN Restriction of use of Mobiles on shop floor 35115NSCounselling & Prohibition of use       
1321/7/19Shop floor , Stores, Testing working In these location RInsufficient or Improper ventillation Uncomfortable working condition , Ill healthNNN Maintenance of Ventillation & provision of same 23212NS      
1331/7/19Shop floor , Stores, Testing Working  In these locations RStress due to work load Ill health NNN Monitoring  of  staff , workers 22416NS      
1341/7/19Shop Floorworking In these location RWork Place Violence Injury / StressNNN Counselling , Monitoring 32530SRegualr Counselling , Training on team work 22520NS 
1351/7/19Machine ShopMachine Shop OperationsRPoor Drinking Water Qualityill healthNNYPotable Drinking Water Provided0SDrinking Water Quality TestingNS     
1361/7/19Testing and RepairConsumption of FoodRIntake of Hazardous Constituents Digestive System ProblemsNN  NWashing facilities   35575SInstruction for washinbg hands , Soaps & Handwash provided 23318NS 
1371/7/19Overall machining operationsSand stormNRDust InhalationBronchial problemsYNYWork is carried out in closed place43112SSuspension of Work NS     
1381/7/19MaintenanceOverhead Tank Maintenance (Working at heights)NRFallFatalYNNFixed Ladder available, Safety Belt Use 52110SUse of safety belt , Precaution 4218SOCP
1391/7/19Overall machine shop operationsHigh temperature (50 degrees and above)NRExposure to sunSun stroke and dehydrationYNYWork is carried out in closed place SSuspension of Work NS     
1401/7/19Dinning RoomConsumption of FoodRLack of Pest Managementill healthNNYPest Control in PlaceSPesticide provided by the govt is usedNS     
1411/7/19Machine shopPesticide  PowderRIngestionFatalYNN Once in 6months/ Under high supervision2112SStrong Admin control NS     
1421/7/19SHUTTERShutter falling free when chain releasedRHitInjuryNNNPPE’s provided/ Shutter no return system15315NS     
1431/7/19Shop Floor Use of PPE RUse of Unsuitable , Damaged or contaminated PPE Contamination , Injury or Ill health NNN Use of  Proper , Inspected  PPE , Proper stoarge of PPE 22416NS      
1441/7/19Shop floor Use of Mobile Phones RAccidents , Falling & Hit to personInjury to BodyNNN Restriction of use of Mobiles on shop floor 35115NSCounselling & Prohibition of use       
1451/7/19Shop floor , Stores, Testing working In these location RInsufficient or Improper ventillation Uncomfortable working condition , Ill healthNNN Maintenance of Ventillation & provision of same 23212NS      
1461/7/19Shop floor , Stores, Testing Working  In these locations RStress due to work load Ill health NNN Monitoring  of  staff , workers 22416NS      
1471/7/19Shop Floorworking In these location RWork Place Violence Injury / StressNNN Counselling , Monitoring 32530SRegualr Counselling , Training on team work S     
1481/7/19Shop FloorDigging of concrete
floor
N/RDust generationInhalation NNN Use of PPE23212NSDust Mask providedNS     
1491/7/19Shop FloorDigging of concrete
floor
N/RFlying of concrete particlesEye InjuryNNN Use of PPE3319NSFace shield /Safety
Goggles use
NS     
1501/7/19Shop FloorDigging of concrete
floor
N/RNoise  GenerationLoss of HearingNNNLUse of PPE    SEar plug UseNS     
1511/7/19Shop FloorDigging of concrete
floor
N/RWorking with Jack HammerCause InjuryNNN Use of PPE2214NSSafety Shoes useNS     
1521/7/19Shop FloorDigging of concrete
floor
N/RTrip hazards on siteCause InjuryNNN Use of PPE43112NSSafety Shoes use
Hand Gloves
NS     
1531/7/19Shop FloorMixing and pouring of concreteN/RHandling of concrete during  concretingSkin contact NNN Use of PPE2316NSSafety handgloves
use
NS     
1541/7/19Shop FloorMixing and pouring of concreteN/RMoving and carrying materialsInjury or strain to back and limbsNNN Trained manpower deployed by subcontractor/Suggested frequent rest1224NS NS     
1551/7/19Shop FloorEpoxy CoatingN/RFlooring  of Epoxy coating InhalationRespiratory protectionNNN Use of mask25110NS NS     
1561/7/19Shop FloorEpoxy CoatingN/RContact with EyesInjury to EyesYNN Use of Safety face shield/Safety Goggles25110NS NS     
1571/7/19Shop FloorEpoxy CoatingN/RContact with Skin Dermitities to
 Skin/Burn
NNN Use of  Handgloves25110NS NS     
1581/7/19Shop FloorEpoxy CoatingN/RContact with Skin personal HygieneNNN Wash hand and faces before eating,drinking34112NS NS     
1591/7/19Shop FloorEpoxy CoatingN/REpoxy coating  in hot climateHeat StressNNN cotton Coverall with thick quality 2316NS       
1601/7/19Shop FloorWelding on
 rotating table
RBody/Foot  touch to Rotating tableSkin burnsNNN Motor fitted to Rotating
table/using appropriate PPE .
25110NS NS     
1611/7/19Shop FloorOil Leakage
through MHE Crane 
RSlipBody InjuryNNNNil25110NS      
1621/7/19Shop FloorRslippery surfacesInjuryNNNPPE and Training2316NS       
1631/7/19Shop FloorBoth Crane Movement during operation.NRFallFatalYNNPreventive Maintenance, Trained operatorsSS     
1641/7/19Shop FloorHeavy equipment lifting with both overhead cranes cranesRFall of equipment on any personBody InjuryYNYPreventive Maintenance, Trained operators35115NSInspection and Certification by competent authorityNS     
1651/7/19Shop FloorHeavy equipment lifting with both overhead cranes cranesRFall of Heavy object on the floorBreakage of floorNNNUse of safety shoes 2124NSPrecuation while handling S     
1661/7/19Employee camp Use of  used dirty bed for sleepingRHygeinic safetyHygeinic diseaseNNYNew bed provided2124NSStrong admin control     
1671/7/19Shop FloorWorking with self  propelled man liftNRPre-inspection of equipment before operation.Machine WORKING IN UNSAFE CONDITIONNNN Preinspection to be done ,complete daily checks15315NSPre-inspection done before operation with check list.      
1681/7/19Shop FloorWorking with self  propelled man liftNRUntrained OperatorMachine use in an unsafe conditionNNN Trained operators  to be deployed on job.15315NSTraining   provided to  operator      
1691/7/19Shop FloorWorking with self  propelled man liftNRElectrical shock  from overhead power lineShock/Injury or may be fatalYNY Insulate power line52110SWorking at height permit  issued, Use of PPE       
1701/7/19Shop FloorWorking with self  propelled man liftNRTools or material falling from  platformWorkers being crushed or injured.YNY Barricade off the work area
Clear all workers from  the area  before raising ,lowering  boom  or platform..
33218NSWorking area Barricaded      
1711/7/19M.S.Outside open passageSWT unit disassembling ,NRH2S Gas Leakage More than 5 ppm to 15ppm =can be smelled and is safe for 10 mins exposure without respiratory protection
100 PPM=Eyes,nose and throat become irritated,no permanent effects,loss of sense of smell.
 500 ppm=Dizziness,headaches,nausea,abdominal pains after 15 mins,dangerous after 30 mins.Exposure rapidly produces unconsciousness and death if effective resuscitation is not applied.
uitation is not applied.
At 1000PPM= victim is instantly unconscious and breathing stops death follows very quickly(1-2 minutes) 
YYYNContinuous monitoring of H2S by H2S Gas monitor device. If H2S concentration goes above 5ppm, the  work is suspended and no workers are allowed in the vicinity of the unit. 52110SContinous monitoring & Checks for leakage , Training in case of emergency 5115SOCP
1721/7/19QCMPIRToxic and flammable qualities of aerosols, inks and all other chemicals used in the inspections flammability
 flash fire 
NNNPPE and Training. Material safety data sheets available. Use of PPE 33218NSMaterial safety data sheets available. Use of PPE       
1731/7/19QCMPIRToxic and flammable qualities of aerosols, inks and all other chemicals used in the inspectionsHealth problems, dizziness & NauseaNNNPPE and Training. Material safety data sheets available. Use of PPE 33218NS       
1741/7/19QCMPIRToxic and flammable qualities of aerosols, inks and all other chemicals used in the inspectionsmist or vapor may irritate the respiratory tract NNNPPE and Training. Material safety data sheets available. Use of PPE 33218NS       
1751/7/19QCMPIRToxic and flammable qualities of aerosols, inks and all other chemicals used in the inspections eye and skin irritation in case of liquid contact NNNPPE and Training. Material safety data sheets available. Use of PPE 33218NS       
1761/7/19QCMPIRToxic and flammable qualities of aerosols, inks and all other chemicals used in the inspectionsfast evaporating vapors can reach hazardous levels quickly in unventilated spacesNNNPPE and Training. Material safety data sheets available. Use of PPE 33218NS       
1771/7/19QCMPIRHandling of YokeRisk of muscle strainNNNBreaks in between work3319NS       
1781/7/19QCMPIRHandling of YokeRisk of back strain NNNBreaks in between work3319NS       
1791/7/19QCMPIRHandling of YokeRisk of slip, trips and falls while doing testNNNTraining provided3319NS       
1801/7/19QCMPIRLack of space around the equipment under testlead to the operator being pushed by passers-by.NNNProper Design of workspace around plant and equipment 3319NS       
1811/7/19QCMPIRSlippery floor surfaces or loose items around the machine
can cause slips that result in contact with moving parts.NNNAppropriate cleaning and housekeeping practices are maintained to minimise the risk of a slip, trip or fall.3216NS       
1821/7/19QCMPIRElectrical hazardFatalYNNPreventive Maintenance by competent personnel53115SIsolation of machines befroe repair or maintenance52110SOCP09
1831/7/19QCPTRToxic and flammable qualities of dyes, developers and all other chemicals used in the inspections flammability
 flash fire 
NNNPPE and Training. Material safety data sheets available. Use of PPE 33218NS       
1841/7/19QCPTRToxic and flammable qualities of aerosols, dyes, developers, inks and all other chemicals used in the inspectionsmist or vapor may irritate the respiratory tract NNNPPE and Training. Material safety data sheets available. Use of PPE 33218NS       
1851/7/19QCPTRToxic and flammable qualities of aerosols, dyes, developers, inks and all other chemicals used in the inspections eye and skin irritation in case of liquid contact NNNPPE and Training. Material safety data sheets available. Use of PPE 33218NS       
1861/7/19QCPTRToxic and flammable qualities of aerosols, dyes, developers, inks and all other chemicals used in the inspectionsfast evaporating vapors can reach hazardous levels quickly in unventilated spacesNNNPPE and Training. Material safety data sheets available. Use of PPE 33218NS       
1871/7/19QCPTRCleaning of surfaceInjury to handNNNTraining provided3216NS       
1881/7/19QCPTRLack of space around the equipment under testlead to the operator being pushed by passers-by.NNNProper Design of workspace around plant and equipment 3319NS       
1891/7/19QCPTRSlippery floor surfaces or loose items around the machine
can cause slips that result in contact with moving parts.NNNAppropriate cleaning and housekeeping practices are maintained to minimise the risk of a slip, trip or fall.3216NS       
1901/7/19Stores Handling of MaterialsRInjury /Cuts to hadn while handling Injury to handsNNNUse of Hand Gloves , Precaution2316NS      
1911/7/19Stores Handling of MaterialsRFall of Heavy object on toe Injury to toes NNNUse of safety shoes 4218NSPrecuation while handling      OCP 02
1921/7/19Stores Handling of MaterialsRErgonomics due to Lifting of heavy materialBack Pain/ Personal InjuryNNNUse of  Cranes / Trolley32530SUse of Lifting equipments , Training for proper lifting NS     
1931/7/19Stores Leakage of LPGRFire BurnsYNYNilSAppropriate Storage / Fire ExtinguisherNS    OCP 18 & MP 12
1941/7/19Stores Leakage of Acetylene cylindersRFire BurnsYNNilSAppropriate Storage / Fire ExtinguisherS    OCP 18 & MP 12
1951/7/19Stores Storage of Gas cylindersRFallBody InjuryNNYStored Vertically tied with chainSStored Vertically tied with chainS     
1961/7/19Stores Storage of PaintRFire BurnsYNNNilSAppropriate Storage with Fire Extinguisher NS    OCP08 & MP 12
1971/7/19Stores Storage of ThinnerRFire BurnsYNYNilSAppropriate Storage / Fire ExtinguisherS    OCP08 & MP 12
1981/7/19Stores Storage of CylindersRFALLBody InjuryNNYTied with Chain SS    OCP18
1991/7/19Stores Storage of hazardous chemicals RContact with skin /bodyIrritation NNYHazardous substances to be stored according to guidance of Material Safety Data Sheet provided by supplier33218NS S     
2001/7/19Stores Issue of materialsRManual handlingStaff may suffer strains
or bruising injuries
NNNAll staff are trained how to lift properly. High shelves are for light goods onl33218NS       
2011/7/19Stores Issue of materialsRSlips, trips and fallsStaff may suffer sprains,fractures or bruising if they trip over objectsNNNAll staff are trained for proper handling3319NS       
2021/7/19Stores Issue of materialsRRusty or damaged shelvesInjury or cutsNNNAll staff are trained for proper handling3319NS       
2033/29/20MachineshopCOCID-19NRSpread of COVID-19 coronavirusInfectionYYYUse of PPEs,
Frequently cleaning and disinfecting objects and surfaces that are touched regularly particularly in areas of high use such as door handles, light switches, reception area using appropriate cleaning products and methods,
Social distancing to maintain 1 meter gap between the people,
Regular Handwash using soap or hand wash liquid,
Hand sanitizing,
Awareness training
555125SRemote working of employees who has direct contact with the outside peoples and one who are staying under lockdown areas and one who has direct contacts with medical employees,
Restrictions of outsiders or visitors to the facility. Maintaining the visitors log with their residancy location, travel history etc. and communication with them to track any positive case among those who visited our location.
Daily body temperature monitoring of the employeesand visitors who are entering in our facility.
Maintaining employees residancy history, any medical history and travel history.
Maintaining daily health check log to assure the safe work environement throughout.
Employees to be reminded on a regular basis to wash their hands for 20 seconds with water and soap and the importance of proper drying with disposable towels. Also reminded to catch coughs and sneezes in tissues – Follow Catch it, Bin it, Kill it and to avoid touching face, eyes, nose or mouth with unclean hands. Tissues will be made available throughout the workplace.
Encourage staff to report any health problems.
Reminding everyone of the public health advice.
Posters, display boards and other materials are placed for display.
Rigorous checks will be carried out by line managers to ensure that the necessary control measures are being followed.
Staff to be reminded on a daily basis of the importance of social distancing both in the workplace and outside of it. Management checks to ensure this is adhered to.
Staff to be reminded that wearing of gloves is not a substitute for good hand washing.
      

Example of Risk assessment of Environmental Management System

Sr. noAreas/ LocationActivityActivity Type (R /  NR  / E)Aspects
Impacts
 E (emergency)IPC (Interested Party Concern)LC (Legal concern)RSP (Resource saving potential)Present / Existing controlsSeverityFrequency of OccurrencesTime to noticePresent risk factorCalculated significance (S/NS)Link to Objective / Program, OCP
1Machine ShopFlame cutting and  weldingRGeneration of Welding fumesAir pollutionNNNNVentilators for fumes to escape to environment24216NSMP 10
2Machine ShopFlame cutting and weldingRGeneration of Waste rubber cablesLand pollutionNNNNDisposal of Rubber cables along with other wastes23212NS 
3Machine ShopFlame cutting and  weldingRGeneration of Waste molten fluxLand pollutionNNNNDisposal of waste molten flux along with other wastes22416NS 
4Machine ShopMachiningRGeneration of Waste coolant oilLand pollutionNNYNCollected in drums and disposed to Collection TankSOCP 15 MP #3
5Machine ShopMachiningRGeneration of Metal ChipsLand pollutionNNNNCollected and stored in Scrap area. Disposed to scrap vendor22416NS 
6Machine ShopMachiningRGeneration of FilingsLand pollutionNNNNCollected and stored in Scrap area. Disposed to scrap vendor22416NS 
7Machine ShopPaintingRGeneration of Waste paint / dust Land pollutionNNYNDisposed off along with other wastesSOCP 15 MP #5
8Machine ShopPaintingRGeneration of Empty paint and  thinner cansLand pollutionNNYNDisposed off along with other wastesSOCP 15 MP #5
9Machine ShopPaintingNRPaint spillageLand pollutionNNNN1111NSOCP 17 
10Machine ShopMaintenanceRGeneration of Waste oil Land pollutionNNYNCollected and stored in drumsSOCP 15 MP #5
11Machine ShopMaintenanceRGeneration of Waste GreaseLand pollutionNNYNCollected and stored in drumsSOCP 15 MP  #5
12Machine ShopMaintenanceRGeneration of oil soaked cotton wasteLand pollutionNNYNDisposed off along with other wastesSOCP 15 MP #5
13StoresHandling & Storage of MaterialRGeneration of Packing materialLand pollutionNNNNDisposed off along with other wastes25220NS 
14StoresHandling & Storage of MaterialRGeneration of Plastics (Polythene covers)Land pollutionNNNNDisposed off along with other wastes25220NS 
15Storescollection & Storage of used OilsRGeneration of cotton wasteLand pollutionNNYNDisposed off along with other wastesSOCP 15 MP #5
16Storescollection & Storage of used OilsNRSpillage of oilLand pollutionNNNNStored in drums2124NSOCP 13
17StoresStorage of Lead acid batteriesNRGeneration of Scarp due to old batteriesLand pollutionNNYNLead is removed and disposed off along with wastesSOCP 15 MP #5
18StoresHandling & Storage of Gas CylinderRLeakage of GasRisk of fireYNYNFire extingusihers available near the cylinders.SEmergency preparedness Procedure_ SOP14
19StoresStorage of Paints and ThinnerRGeneration of fumesRisk of fireYNYNSOCP 08
20StoresStorage of Tyres NRAccumulation of scrapLand pollutionNNNNStored in the factory22216NS 
21StoresStorage of Rubber cablesNRAccumulation of scrapLand pollutionNNNNDisposed off along with other wastes22216NS 
22WeldingWeldingRGeneration of used welding electrodesLand pollutionNNNNDisposed off along with other wastes22312NS 
23PaintPaintingRGeneration of paint sludgeLand pollutionNNYNDisposed off along with other wasteSOCP 15
24TestingHydraulic testing of BOP hydrailNRSpillage of oilLand pollutionYNNN3126NSOCP 13
25TestingCleaning of BOP HydrilRGeneration of Waste waterWater pollutionNNYN_SMP # 4
26KemplatingKemplatingRGeneration of waste waterWater pollutionNNYN_SMP # 4
27TestingCleaning of BOP HydrilRConsumption of waterResources depletionNNNY_3126NSOCP 16  & MP 08
28Machine shopMachining and Heat treatmentRPower consumptionResources depletionNNNYSOCP 16, MP 07
29Shop Floor activitiesGeneration of ReportsRpaper ConsumptionResources depletionNNNNControls during Issue of PaperSOCP14-Control on wastage of Resources
30Overall OperationsOverall OperationsRGeneration of Industrial  SludgeLand pollutionNNYN__S 
31Overall OperationsOverall OperationsRGeneration of Industrial and Sanitory SludgeLand pollutionNNYN__S 
32Shop Floor activitiesVehicular MovementR Vehicle Exhaust Air pollutionNNYNYearly Vehicle Fiteness InspectionS 
33Shop ParkingVehicular MovementROil spill from EnginLand pollutionNNNN__3216NSOCP 13
34Machine ShopCompressor Operation RGeneration of Noise and VibrationNoise PollutionNNYNProvide Ear Plugs 22520S 
35Machine ShopCompressor Operation RSpillage of  Oil from Compressor Land PollutionNNNNRegular Maintenance 1 14NS 
36Machine ShopCompressor Operation RAir Leakage Hence consumption of Electricity Resource DepletionNNNNMaintenance 44116SOCP 16
37Machine ShopKem Plating RSpillage of Acid Lan Pollution NNNNWhiping / Avoid Spillage 2316NS 
38Machine ShopKem Plating RRelease of  Acid Fumes Air Pollution NNYNProvide Nose mask 2316NS 
39Machine shopUse of Gas cylinders RLeakge of Gasess Air Pollution NNYNMaintenance 2214NS 
40Machine shopUse of  Diesel RConsumption of  diesel Resource DepletionNNNNControl Consumption 2316SEMP
41Machine shopUse of Raw MaterialsRConsumtpion of Metals , Paints , Diesel Resource DepletionNNNNReduce Wastage / Rejection 44116SOCP 16
42Machine shopUse of TIL CraneRSpillage of oil  through TIL Crane Land PollutionNNNNRegular Maintenance     SOCP-13 REV-01

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Example of Hazards/Risks Analysis Register

Sr NoActivityNature  Of Activity R/NR/EHazardLikely Hazardous Incidence/ SituationRisk InvolvedCurrent Risk Control SystemLikelihood  Of Occur  (A)Severity Of  Consequence   (B)Risk  Factor (AXB)Is Risk TolerableIf No, Proposed Risk Control System
1Forging PressEElectricityExpose to live currentElectric ShockInsulation on wire is provided4520NoWork Instructions, Alarm System, Training
2Forging PressEElectricityChances of FireFire HazardFire Extinguisher Provided4520NoFire Alarm System, Sand Buckets
3Forging PressELeakage of waterSlippage of PersonInjury to BodyCleaning regularly428YesPM, Spill Mob, Training
4Forging PressESpillage of Oil  Slippage of PersonInjury to BodyCleaning regularly428NoPM, Spill Mob, Training
5Forging PressESpillage of Oil   Chances of FireFire HazardFire Extinguisher Provided4520NoFire Alarm System, Sand Buckets
6Forging PressNRHandling of sparesFalling on bodyInjury to BodyPersonal Protective Equipments provided428NoTraining, Protective Plating for Platform
7Forging PressEWelding SparkExpose to SpattersBurn InjuryPersonal Protective Equipments provided4312NoSeparate Location for Welding, Welding Curtons, Training, WI
8Forging PressRWelding fumesExposed to fumesIrritation / UneasinessPersonal Protective Equipments provided2510NoSeparate Location for Welding, fume Exhaust System
9Forging PressEGas cutting processChances of fireFire HazardFire Extinguisher Provided4520NoFire Alarm System, Sand Buckets
10Forging PressRGas cutting processExposed to fumesIrritation / UneasinessPersonal Protective Equipments provided2510NoMask, Separate Location for Gas Cutting Process, Fume exhaust system
11Forging PressEWorking at heightsFall of PersonInjury to BodyPersonal Protective Equipments provided4520NoFlat form System, Safety Belts
12Forging PressNRUse of Broken ToolsSlippage of Tool from handInjury to BodyPersonal Protective Equipments provided428YesWork Instructions, Training
13Forging PressEUse  of improper equipment / ToolsSkin Cut / Burns / Slippage from handsInjury to BodyPersonal Protective Equipments provided428YesWork Instructions, Training
14Forging PressEHandling of heavy EquipmentsFalling on bodyInjury to BodyPersonal Protective Equipments provided4520NoTraining, Use of Crane, Fork Lift, WI
15Forging PressESlippage of person while doing maintenanceFalling on FloorInjury to BodyPersonal Protective Equipments provided4312NoTraining, WI
16Forging PressRHandling of Maintenance ToolsFalling / Hitting to bodyInjury to BodyPersonal Protective Equipments provided428NoTraining, WI
17CraneEWorking at heightschance of fallingDeath 4520NoSafety Belts, Training, WI
18CraneEElectricityExpose to live currentElectric ShockPersonal Protective Equipments provided4520NoWork Instructions, Alarm System, Training
19CraneEElectricityChances of FireFire HazardFire Extinguisher Provided2510NoFire Alarm System, Sand Buckets
20FurnaceEWelding SparkExpose to SpattersBurn InjuryPersonal Protective Equipments provided4312NoSeparate Location for Welding, Welding Curtons, Training, WI
21FurnaceRWelding fumesExposed to fumesIrritation / UneasinessPersonal Protective Equipments provided2510NoSeparate Location for Welding, fume Exhaust System
22FurnaceEGAS CUTTING PROCESSChances of fireFire Hazard 4520NoFire Alarm System, Sand Buckets
23FurnaceRGAS CUTTING PROCESSExposed to fumesIrritation / UneasinessPersonal Protective Equipments provided2510NoMask, Separate Location for Gas Cutting Process, Fume exhaust system
24FurnaceEElectricityExpose to live currentElectric ShockPersonal Protective Equipments provided4520NoWork Instructions, Alarm System, Training
25FurnaceEElectricityChances of FireFire HazardFire Extinguisher Provided2510NoFire Alarm System, Sand Buckets
26FurnaceNRUsing improper toolsSlippage of PersonInjury to Body 2510NoWork Instructions, Training
27FurnaceNRInspection of Polymer tankExposure of polymer to bodySkin irritation 236YesLeather Hand Gloves, Mask
28FurnaceESpillage of oilSlippage of PersonInjury to Body 428NoPM, Spill Mob, Training
29Shot BlastingEElectricityExpose to live currentElectric ShockPersonal Protective Equipments provided4520NoWork Instructions, Alarm System, Training
30Shot BlastingEElectricityChances of FireFire HazardFire Extinguisher Provided2510NoFire Alarm System, Sand Buckets
31Shot BlastingEWorking at heightschance of fallingDeath 4520NoSafety Belts, Training, WI
32Shot BlastingRWelding fumesExposed to fumesIrritation / UneasinessPersonal Protective Equipments provided2510NoFume extraction system, Separate location for Welding
33Shot BlastingEWelding SparkExpose to SpattersBurn InjuryPersonal Protective Equipments provided4312NoSeparate Location for Welding, Welding Curtons, Training, WI
34Shot BlastingESpillage of oilSlippage of PersonInjury to Body 428NoPM, Spill Mob, Training
35Shot BlastingNRUsing improper toolsSlippage of PersonInjury to Body 2510NoWork Instructions, Training
36Shot BlastingNRCleaning of dust bagsExposure to dustHealth Problem 236YesMask,Training,WI
37Band saw MachineESpillage of oilSlippage of PersonInjury to Body 428NoPM, Spill Mob, Training,Trays
38Band saw MachineEElectricityExpose to live currentElectric ShockPersonal Protective Equipments provided4520NoWork Instructions, Alarm System, Training
39Band saw MachineEElectricityChances of FireFire HazardFire Extinguisher Provided2510NoFire Alarm System, Sand Buckets
40Band saw MachineNRRemoval of spare partsSlippage during handlingInjury to Body 428YesWork Instruction, Training
41Band saw MachineNRUsing improper toolsSlippage of PersonInjury to Body 2510NoWork Instruction, Training
42Band saw MachineNRHandling of BearingsExposure to HacksawCut Injury 236YesWork Instruction, Training
43Hydrotel MachineESpillage of oilSlippage of PersonInjury to Body 428NoPM, Spill Mob, Training, Trays
44Hydrotel MachineEElectricityExpose to live currentElectric ShockPersonal Protective Equipments provided4520NoWork Instructions, Alarm System, Training
45Hydrotel MachineEElectricityChances of FireFire HazardFire Extinguisher Provided2510NoFire Alarm System, Sand Buckets
46Hydrotel MachineNRUsing improper toolsSlippage of PersonInjury to Body 2510NoWork Instruction, Training
47Hydrotel MachineNRRemoval of spare partsSlippage during handlingInjury to Body 428YesWork Instruction, Training
48EDM MachineESpillage of oilSlippage of PersonInjury to Body 428NoPM, Spill Mob, Training, Trays
49EDM MachineEElectricityExpose to live currentElectric ShockPersonal Protective Equipments provided4520NoWork Instructions, Alarm System, Training
50EDM MachineEElectricityChances of FireFire HazardFire Extinguisher Provided2510NoFire Alarm System, Sand Buckets
51EDM MachineNRUsing improper toolsSlippage of PersonInjury to Body 2510NoWork Instruction, Training
52CNC MachinesEElectricityExpose to live currentElectric ShockPersonal Protective Equipments provided4520NoWork Instructions, Alarm System, Training
53CNC MachinesEElectricityChances of FireFire HazardFire Extinguisher Provided2510NoFire Alarm System, Sand Buckets
54Hydraulic PressESpillage of oilSlippage of personInjury to body 428YesPM, Spill Mob, Training, Trays
55Hydraulic PressEElectricityExpose to live currentElectric ShockPersonal Protective Equipments provided4520NoWork Instructions, Alarm System, Training
56Hydraulic PressEElectricityChances of FireFire HazardFire Extinguisher Provided2510NoFire Alarm System, Sand Buckets
57Hydraulic PressNRUsing improper toolsSlippage of PersonInjury to Body 2510NoWork Instructions, Trainings
58Hydraulic PressNRRemoval of spare partsSlippage during handlingInjury to Body 428YesWork Instructions, Trainings
59CompressorESpillage of oilSlippage of PersonInjury to Body 428NoPM, Spill Mob, Training, Trays
60CompressorEElectricityExpose to live currentElectric ShockPersonal Protective Equipments provided4520NoWork Instructions, Alarm System, Training
61CompressorEElectricityChances of FireFire HazardFire Extinguisher Provided2510NoFire Alarm System, Sand Buckets
62CompressorEAir leakagesChances of burstInjury to Body 4312NoPM,Training ,WI,
63CompressorELeakage of waterSlippage Injury to Body 428YesPM, Trays, spill mob,
64CoiningEElectricityExpose to live currentElectric ShockPersonal Protective Equipments provided4520NoWork Instructions, Alarm System, Training
65CoiningEElectricityChances of FireFire HazardFire Extinguisher Provided2510NoFire Alarm System, Sand Buckets
66CoiningESpillage of oilSlippage of PersonInjury to Body 428NoPM, Spill Mob, Training, Trays
67CoiningEWorking at heightschance of fallingDeath 4520Nosafety belts,WI, Training, railing
68CoiningEWelding SparkExpose to SpattersBurn InjuryPersonal Protective Equipments provided4312NoSeparate Location for Welding, Welding Curtons, Training, WI
69CoiningNRWelding fumesExposed to fumesIrritation / UneasinessPersonal Protective Equipments provided2510NoSeparate Location for Welding, fume Exhaust System
70CoiningEGAS CUTTING PROCESSChances of fireFire Hazard 4520NoFire Alarm System, Sand Buckets, Trainings
71CoiningRGAS CUTTING PROCESSExposed to fumesIrritation / UneasinessPersonal Protective Equipments provided2510NoSeparate Location for Welding, fume Exhaust System

Note 1

R-Routine,

NR-Non-Routine,

E-Emergency

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Example of Aspects and Impact Analysis Register

Sr.No.ActivityAspect(R – O   – A)LCIPCImpactSCSEDuDeP( S* SE*P*DU *DE)SIGNIFICANT OR NON-SIGNIFICANTProposed Controls
1Lifting of Tote box  by overhead crane manuallyUse of electricityC  Resource Depletion5311115Non-Significant 
2Heating of Raw Materails(Induction Heater)
Use of electricityC  Resource Depletion55115125Non-Significant 
3Heating of Raw Materails(Induction Heater)
Generation of fumesCLCIPCAir Pollution2115550SignificantWork Instructions, Measurement
4Heating of Raw Materails(Induction Heater)
Generation of scalesC IPCWork place Environment32155150SignificantWork Instructions
5Heating of Raw Materails(Induction Heater)
Generation of heatC IPCWork place Environment24355600Significant  Blower provision, Exhaust System, Heat Mask, Measurement of Temperature, Leather Apron
6Heating of Raw Materails(Induction Heater)
Use of natural waterCLC Resource Depletion5311575Significant  Work Instructions and Measurement
7Heating of Raw Materails(Induction Heater)
Disposal of ScaleCLC Land contamination32155150Significant  Work Instructions
8Heating of Raw Materails(Induction Heater)
Generation of NoiseCLCIPCNoise Pollution455552500SignificantEar Plug, Silencer to be provide for Valve, Measurement of Noise
9Rolling of hot cut billetUse of electricityc  Resource Depletion54115100Non-Significant 
10Rolling of hot cut billetdisposal of toolsOLC Land contamination3215390SignificantWork Intsructions
11Rolling of hot cut billetGeneration of heatC IPCWork place Environment14355300SignificantBlower provision, Exhaust System, Heat Mask, Measurement of Temperature, Leather Apron
12Rolling of hot cut billetGeneration of NoiseCLCIPCNoise Pollution445552000SignificantEar Plug, Silencer to be provide for Valve, Measurement of Noise
13Rolling of hot cut billetSpillage of ScaleC IPCWork place Environment34155300SignificantDesign Team 
14Forging (edger operation) of rolled pieceUse of electricityC  Resource Depletion55115125Non-Significant 
15Forging (edger operation) of rolled piecedisposal of toolsCLC Land pollution3215390SignificantWork Instructions
16Forging (edger operation) of rolled pieceGeneration of heatC IPCWork place Environment14355300SignificantBlower provision, Exhaust System, Heat Mask, Measurement of Temperature, Leather Apron
17Forging (edger operation) of rolled pieceuse of waterCLC Resource Depletion52155250SignificantWork Instructions and Measurement
18Forging (edger operation) of rolled pieceuse of water base graphiteC  Resource Depletion54115100Non-Significant 
19Forging (edger operation) of rolled pieceuse of oilC  Resource Depletion54115100Non-Significant 
20Forging (edger operation) of rolled pieceuse of water base syntheticC  Resource Depletion54115100Non-Significant 
21Forging (edger operation) of rolled pieceGeneration of NoiseCLCIPCNoise Pollution455552500SignificantEar Plug, Silencer to be provide for Valve, Measurement of Noise
22Forging (edger operation) of rolled pieceGeneration of scalesC IPCWork place Environment23155150SignificantWork Instructions
23Forging (blocker operation ) of edger pieceUse of electricityC  Resource Depletion55115125Non-Significant 
24Forging (blocker operation ) of edger piecedisposal of toolsCLC Land pollution3211318SignificantWork Intsructions
25Forging (blocker operation ) of edger pieceGeneration of heatCLC Work place Environment14155100SignificantWork Instructions and Measurement
26Forging (blocker operation ) of edger pieceUse of waterCLC Resource Depletion5311575SignificantWork Instructions and Measurement
27Forging (blocker operation ) of edger pieceuse of water base graphiteC  Land pollution2421464Non-Significant 
28Forging (blocker operation ) of edger pieceuse of oilC  Land pollution34215120Non-Significant 
29Forging (blocker operation ) of edger pieceGeneration of NoiseCLCIPCNoise Pollution445552000SignificantEar Plug, Silencer to be provide for Valve, Measurement of Noise
30Forging (blocker operation ) of edger pieceGeneration of smokeCLCIPCAir pollution545552500SignificantSmoke emission exhaust system, Nose Mask, Measurement
31Forging (blocker operation ) of edger pieceuse of water base syntheticC  Land pollution3311545Non-Significant 
32Forging (blocker operation ) of edger pieceGeneration of scalesC IPCWork place Environment2411540SignificantWork Instructions  
33Forging (finisher operation) of blocker pieceUse of electricityC  Resource Depletion55115125Non-Significant 
34Forging (finisher operation) of blocker piecedisposal of toolsCLC Land pollution3211318SignificantWork Instructions  
35Forging (finisher operation) of blocker pieceGeneration of heatC IPCWork place Environment1411520SignificantWork Instructions and Measurement
36Forging (finisher operation) of blocker pieceuse of waterCLC Resource Depletion5311575SignificantWork Instructions and Measurement
37Forging (finisher operation) of blocker pieceuse of water base graphiteC  Land pollution2421464Non-Significant 
38Forging (finisher operation) of blocker pieceuse of oilC  Land pollution34215120Non-Significant 
39Forging (finisher operation) of blocker pieceuse of water base syntheticC  Land pollution3411560Non-Significant 
40Forging (finisher operation) of blocker pieceDisposal of scalesCLC Land pollution32155150SignificantWork Instructions
41Forging (finisher operation) of blocker pieceGeneration of scalesC IPCLand pollution24155200SignificantWork Instructions
42 spraying of water base graphite die lubricant on die’suse of electricityC  Resource Depletion5111525Non-Significant 
43 spraying of water base graphite die lubricant on die’suse of water base graphiteC  Land pollution2421580Non-Significant 
44 spraying of water base graphite die lubricant on die’suse of waterCLC Resource Depletion5311575SignificantWork Instructions and Measurement
45 spraying of water base graphite die lubricant on die’sgeneration of smokeCLCIPCAir pollution2211520SignificantWork Instructions and Measurement
46Swabbing of oil base graphite on diesGeneration of smoke LCIPCAir pollution445552000SignificantSmoke emission exhaust system, Nose Mask, Measurement
47Swabbing of oil base graphite on diesuse of oilCLC Resource Depletion54115100SignificantWork Instructions and Measurement
48Swabbing of oil base graphite on diesuse of oil base graphiteCLC Resource Depletion54115100SignificantWork Instructions and Measurement
49Carry finisher for next operationuse of electricityC  Resource Depletion5311575Non-Significant 
50Trimming and piercing operationuse of electricityC  Resource Depletion5311575Non-Significant 
51Trimming and piercing operationdisposal of toolOLC Land pollution4311336SignificantWork Intsructions
52Trimming and piercing operationgeneration of heatC IPCDiscomfort12255100SignificantWork Instructions and Measurement
53Trimming and piercing operationDisposal of scaleCLC Land pollution22155100SignificantWork Instructions
54Trimming and piercing operationgeneration of noiseCLCIPCNoise pollution22555500SignificantEar Plug, Silencer to be provide for Valve, Measurement of Noise
55Trimming and piercing operationgeneration of scaleC IPCLand pollution22155100SignificantWork Instructions
56Separation of slug/flash & finish gooddisposal of toolOLC Land pollution4311336SignificantWork Instructions
57Separation of slug/flash & finish goodgeneration of heatC IPCDiscomfort12                        55100SignificantWork Instructions
58Separation of slug/flash & finish goodgeneration of scaleC IPCLand pollution22155100SignificantWork Instructions
59Separation of slug/flash & finish goodDisposal of scaleCLC Land pollution22155100SignificantWork Instructions
60Lifting of finish good tote bin & flash bin by over head craneuse of electricityC  Resource Depletion5311575Non-Significant 
61preheating of diesuse of electricityC  Resource Depletion5311575Non-Significant 
62preheating of diesgeneration of heatC IPCDiscomfort1321530SignificantWork Instructions and Measurement
63preheating of diesdisposal of toolOLC Land pollution4311336SignificantWork Instructions  

Note 1 :

  1. LC-Legal Concern,
  2. IPC-Interested Party Concern,
  3. NR-Natural Resources,
  4. E-Emergency,
  5. SC-Scale,
  6. SE-Severity,
  7. P-Probability,
  8. DU-Duration,
  9. DE-Detection

Where E, SC, SE, P, DU, and DE are Crietria

and LC, IPC and NR are the overriding Criteria

Note 2:

  1. A-Accidental,
  2. O-Occasional,
  3. P-Periodic,
  4. R-Regular,
  5. C-Continuous

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Procedure for Welding Inspectors Qualification & Training

1.0 SCOPE

The scope of this procedure is to demonstrate the requirement of a welding inspector   to perform welding inspection for production welding, procedure qualification welding, or performance qualification welding in XXX

2.0 RESPONSIBILITY

  • It is the responsibility of QA/QC In-charge to ensure qualified/trained inspector is available to perform welding inspection
  • It is the responsibility of the Production Manager to ensure the welding is inspected by a qualified/trained welding inspector prior to the next operation
  • It is the responsibility of the QC Engineer to make sure that the welding is inspected by a qualified/trained inspector prior to release.

3.0 LEVELS OF CERTIFICATION

  • There are three levels of certification in XXX viz:
    • Welding Inspector(WI) – The person who certified in accordance with this procedure by an appointed Certified Welding Inspector or Certified Sr. Welding Inspector
    • Welding Inspector Supervisor (WIS) – A certified welding inspector with AWS or CWISP as CWI or CSWIP
    • Welding Inspector Trainer (WIT) – A certified or Sr Certified welding inspector with at least 10 years of experience in welding inspection

4.0 PERSONNEL QUALIFICATION

In order to go for welding inspector training the personnel should have the following minimum qualification:

  • A person qualified in NDE in accordance with ISO 9712, EN473, ASNT SNT-TC-1A or Equivalent standard for a minimum of Level 2 in any two or more of the disciplines such as MPI, PT, RT, UT, and VT.
  • A qualified engineer in Mechanical or Metallurgy with at least three years of experience in welding-related works.
  • A Supervisor in welding and fabrication with at least 10 years of experience in welding-related supervision with a level 2 in any of the 2 NDE processes.

5.0 MINIMUM QUALIFICATION TRAINING

A welding inspector shall be trained to do the welding inspection by training and examination in weld visual and understanding various types of defects, method of inspection, in-process inspection, and testing. A Welding Inspector shall be capable of determining weld defects through NDE inspection he is qualified

6.0 CONSULTATION AND PARTICIPATION

A welding inspector shall not approve any welding without proper inspection. If any doubt in making a decision about the welding for its acceptance he shall contact the company-appointed welding inspector. In the event, the company appointed a welding inspector or a certified welding inspector the MR shall make arrangements to contact a CSWIP or an ASME Authorised Inspector for consultation.

AUTHORITY AND RESPONSIBILITY OF WELDING INSPECTOR

TASKSWIWISWIT
Production Welding   
Selection of WPS – Material & ProcessXXX
Selection of welding processXXX
Selection of welder/welding operatorXXX
Weld visual – Root, Intermediate and FinalXXX
Weld NDE – Appropriate stages in accordance with the QPX X
Acceptance criteria XX
PQR Welding   
Verify welding equipment appropriatenessX X
Verify edge preparation complianceX X
Verify joint geometry complianceX X
Witness procedure qualification  X
Verify welding procedure qualification compliance  X
Develop welding procedures  X
Preparation of WPS XX
Monitoring & recording dataXXX
Visual Inspection Root – Intermediate and Final XX
Weld NDE Review XX
Witnessing Mechanical/Chemical TestingXXX
Acceptance criteria XX
Performance Qualification   
Witness welder performance qualificationXXX
Verify welder qualification compliance  X
Verify welder qualification records compliance  X
Request welder performance requalification  X
Inspection
Perform visual examinationsX X
Verify examination procedure compliance  X
Review examination results compliance  X
Develop visual inspection procedures (before, during, and after welding)  X
Provide NDE inspection planning and scheduling (before, during and after a project)  X
Review welding inspection reports  X
Verify implementation of nondestructive and destructive evaluation methods  X
Prepare visual inspection requirements  X
Prepare NDE requirements  X
Report investigation results of quality inspection disputes  X
Prepare destructive testing requirements  X
Safety
Verify safety requirements compliance  X
Develop safety procedures & policies  X
Quality Assurance   
Perform audits & surveillance  X
Develop quality assurance pans  X
Prepare base material control requirements  X
Prepare weld consumables control requirements  X
Prepare audit and surveillance plans  X
Prepare documentation control requirements  X
    
Training
Develop and provide a training program  X
Develop visual inspection training  X
Verify implementation of visual inspection training  X
Develop & provide a training program for the AWI  X
Provide technical leadership for welding inspectors  X
Develop quality assurance training program  X
Verify implementation of quality assurance training  X
Evaluation
Evaluate AWIs performance  X
Evaluate WIs performance  X
Perform inspection results trend analysis  X
    

RECORD

  • Welding Inspector Qualification Training Records
  • CWI – Certification
  • CSWIP – Certification

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