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Assessment Criteria
Risk Assessment Cr
Catastrophic (5) o Death o Significant Production or Property Loss (>Rs.100,000) o Offence against law or regulation
Most Certain (5) PROBABILITY Likely (4) Moderate (3) Unlikely (2) Rare (1)
Will happen anytime in the year Will happen in 1 5 years Will not happen in 5 years Will not happen in 10 years Will not happen in 20 or more years
25 20 15 10 5
Legend: Score-20-25 Score- 12-18 Score- 6-10 Score- 1- 5 Extreme Risk High Risk Moderate Risk Low Risk
sk Assessment Criteria
CONSEQUENCES (SEVERITY) Critical (4) o Serious illness or permanent disability o Major Production or Property Loss (>Rs.10,000) Moderate (3) Minor (2) o 1 day absence o More than 2 days o First Aid absence o Minor o Medical treatment production or property loss o Moderate (>Rs.1,000) production or property loss (>Rs.5,000) 15 12 9 6 3 10 8 6 4 2 Negligible (1) o No lost day o Discomfort or irritation o No property damage or production loss
20 16 12 8 4
5 4 3 2 1
BACK
BACK
Base Risk
Risk Assessment Probability Risk Evaluation Severity
Residual Risk
Risk Assessment Risk Evaluation Severity
WHIS# 001:
No Specific Hazard Area
Quarrying Process
Hazard Description Affected Person(s) Harm Safety Measure(s)
1 Storage of Explosives
Storing of explosives with triggers Storage of other goods Bad housekeeping Bordering and labeling Failing to comply with the FIFO Use of work or personal equipment that create sparks Housekeeping and Explosive Multiple deaths from Handling and electrical safety explosion Procedures Periodic checks/ Audit
1.1
Store
25
Extreme
10
Medium
Insufficient Entry of unauthorized persons 1.2 security in the Failing to comply with the safe keeping warehouse area and securing procedures
Existence of operational procedures Storekeeper Multiple deaths from Periodic checks People working explosion Trained personnel in the area Preventive maintenance of the building (check for Multiple deaths from humidity on walls and floors, explosion due to electrical wiring) wiring failure or from Periodic checks/ Audit humidity Trained personnel
20
Extreme
10
Medium
Badly maintained building with the Insufficient possibility of entry of humidity 1.3 Maintenance of Unauthorized maintenance of electrical building wiring
20
Extreme
Medium
2 Transport of Explosives
The use of improper vehicles The transport of explosives together with capsules as well as not keeping the necessary labeling during transport The carrying of passengers The unplanned stoppage The transport of explosives during bad weather Driver Drivers helper Passengers Nearby people Use of approved vehicles Protection of explosives from high temperatures Periodic vehicle checks Use of appropriate signage Multiple deaths from during transport explosion Existence of operationalprocedures for the transportation of explosives during unstable weather Periodic checks and stock control Strict procedure for use of explosives Trained personnel
25
Extreme
10
Medium
3 Use of Explosives
3.1 Unauthorized use of explosives Unnecessary use of explosives Ignorance of the special instructions of use Person in charge Surrounding Multiple deaths workers
25
Extreme
10
Medium
Failure to In case of un-triggered explosives there 3.2 comply with the will be confusion explosion plan
Death from Existence of written unexpected explosion instructions of the charging and triggering process Un-triggered Training of personnel explosive Periodic audits
25
Extreme
10
Medium
3.3
Training and retraining of Death from personnel unexpected explosion of UnPeriodic audits of operational triggeredexplosive instructions
20
Extreme
10
Medium
3.4
Failing to implement the company rules and regulations The use of unauthorized explosives Failing to use the approved explosion plan The existence of unexploded boreholes Failing to prevent unauthorized person to Death from approach the explosives area People working unexpected explosion Allowing the transport of more than in the area of Unrequired explosives quantity triggeredexplosive Leaving the explosives unprotected from excessive temperature or near flame Using mobile telephony or wireless near explosives Using unauthorized equipment Triggering the explosives by unauthorized personnel or outside the agreed timetable People working Not giving the necessary and timely in the area warning prior to triggering
Transportation of the explosives to be used only Protection of the explosives from high temperatures Forbid the use of mobiles or wireless near the explosives Isolation of area from unauthorized personnel Explosive handling and use policy
25
Extreme
10
Medium
3.5
Unplanned triggering
Existence and Death from communication of the unexpected explosion triggering plan of UnUse of trained personnel triggeredexplosive Work audits
25
Extreme
10
Medium
4 Bore Holing
Moving parts of Mechanical hazards due to the moving 4.1 the bore holing parts of the bore holing machinery machine Material falling from height from the above quarry table 4.2 Material falling from height Nearby workers Severe injury Operatives Death Training of personnel Periodic audit of protective measures of the bore holing machine Checks of the quarry table Existence of a drilling plan Never drill on an older bore hole
25
Extreme
10
Medium
20
Extreme
10
Medium
Material falling from height from the above quarry table 4.2 Material falling from height Nearby workers Severe injury Operatives Death
Checks of the quarry table Existence of a drilling plan Never drill on an older bore hole
20
Extreme
10
Medium
Workers
Implementation of operational procedures including checks prior to working on a quarry table Make sure that there is adequate space between the bore holing machinery and the quarry table edge
20
Extreme
10
Medium
4.4
Failure of a quarry table due to instability Workers Severe injury following the previous explosion Person in charge Death
Check prior to working on a quarry table for possible cracks and drops
20
Extreme
10
Medium
4.5
Blasting of material
25
Extreme
10
Medium
Presence of dust and noise during the operation of the drilling machinery 4.6 Presence of dust and noise
PPEs Training
16
High
Low
Crushing of employees working on the quarry tables 4.7 Movement of earth moving equipment
Workers
Severe injury
Implementation of operational directives relating to the movement of transportation equipment and personnel in the quarry
25
Extreme
10
Medium
Failure to secure the machinery Maintenance of 4.8 the bore holing machinery Maintenance by un-trained personnel
Maintenance technician
Implementation of operational directives relating to the securing of machinery for the execution of maintenance work
20
Extreme
10
Medium
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Residual Risk
Risk Assessment Risk Evaluation Severity
WHIS# 002:
No
Crushing Process
Hazard Description Affected Person(s) Harm Safety Measure(s)
1 Crusher
1.1 Moving parts of Crusher
25
1.2 Electricity
20
16
4
Training of personnel Construction of a control room made from concrete to withstand possible crushing
20
Extreme
1.4 Maintenance while machinery is in operation 1.5 Inappropriate loading of material on heavy vehicle
Maintenance technicians
Authorized personnel
20
5
Training of personnel Breathing problems Serious injury Use of PPE
25
4
Training of personnel Presence of an observer Check the stability of rocks inside the hopper Adequate light
16
20
Medium
Extreme
Necessary work in the hopper for Operators the purpose of unblocking the mouth of the hopper
Medium
High
Medium
Extreme
The vehicle can hit an operative Operators while reversing or making him fall in the hopper
Medium
Extreme
Inappropriate loading can cause Operators the shifting of the load with the result that rocks and material is flung in the area of the hopper
Medium Medium
High
Operators
Medium
Extreme
During the maintenance of the Maintenance electrical parts there is a hazard technicians from the electric cables
Authorized Personnel
Medium
Extreme
The moving parts of the crusher Operators to come into contact with people Maintenance technicians
Use of Guards. Use of securing procedures so that all personnel is removed from the area
BACK
Residual Risk
Risk Assessment Risk Evaluation Severity
WHIS# 003:
No Specific Hazard Area
Harm
Safety Measure(s)
4
Dust Suction System 1.2 Conveyor moving parts Contact with moving parts, the Operatives risk of entrapment Serious Injury Guarding
16
High
Low
5
Serious Injury Side Guarding
20
Extreme
Medium
1.3
Cleaning of overflows
4
Serious Injury Death Restricted entry Use of appropriate safety signage
16
High
12
High
1.4
Use of Use of unauthorized passages unauthorized Travelling over and under of the passages transportation system
Operatives Technicians
25
Extreme
Medium
Operatives Technicians
20
Extreme
Medium
1.6
Unauthorized tampering
Operatives Technicians
25
Extreme
Low
1.7
Supervision platforms
Operatives Technicians
20
Extreme
Low
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Base Risk
Risk Assessment Probability Risk Evaluation
Residual Risk
Risk Assessment Severity
WHIS# 004:
No
16
High
1.2 Mechanical moving parts of mills 1.3 Falling material 1.4 Contact with moving parts Operators Serious Injury Death Proper guarding PPEs
25
Extreme
Operators
20
Extreme
Operators Operators falling from Operatives falling from height by not Maintenance height using approved passageways Technicians
20
Extreme
1.5 Maintenance/ Increased risk if carried out by cleaning activity on unauthorized personnel operating machinery 1.6 Exposed to excessive noise levels in the milling areas due to the crushing Operators Exposure to Excessive of material inside the mill and due to Maintenance noise levels the operation of the homogenization Technicians blowers 1.7 Work in confined space 1.8 Back firing Hot gases returning back due to insufficient respiration of the furnace Operators Maintenance Technicians Serious Injury from burn Death from burns Operators Maintenance Technicians Serious Injury Death
PPEs Supervision Minimize noise at source or isolate noise PPEs Secure the doors of the homogenization rooms
20
Extreme
16
High
Work in confined spaces during the repair of the mill inner walls or the replacement of the milling balls
PPEs Supervision
20
Extreme
16
High
1.8 Back firing Hot gases returning back due to insufficient respiration of the furnace Operators Maintenance Technicians Serious Injury from burn Death from burns Use of an automatic fuel interruption system (fusible link)
16
High
Residual Risk
Risk Evaluation
BACK
Medium
Medium
Medium
Medium
Medium
Medium
Medium
Medium
Medium
Base Risk
Risk Assessment Risk Evaluation Probability Severity Severity
Residual Risk
Risk Assessment
20
Extreme
10
1.2
20
Extreme
1.3
Airborne dust
Operators/ cleaners
Breathing problem
12
High
1.4
Falling of material
Operators/ cleaners
Serious injury
PPEs Cleaning from top to bottom Approved and tested lifting devices
20
Extreme
1.5
Use of hand held work equipment Operators/ cleaners during the cleaning operation.
Serious injury
PPEs
16
High
1.6
Exposure to noise
Operators/ cleaners
PPEs
16
High
Residual Risk
Risk Evaluation
BACK
Medium
Medium
Medium
Medium
Medium
Low
Base Risk
Risk Assessment Probability Risk Evaluation
Residual Risk
Risk Assessment Severity
WHIS# 006:
Clinker Production
Hazard Description Affected Person(s)
Technicians
Harm
Safety Measure(s)
PPEs Checked lifting devices PPEs
20
Extreme
10
1.2 Work in confined Work in confined spaces inside the furnace and Technicians spaces the pre-heater
4
Supervision PPEs Dust suction system Ventilation system PPEs Supervison PPEs
20
Extreme
10
1.3
Airborne dust
Airborne dust inside the clinker furnace, the pre-heater and the cooler
Technicians
Breathing problems
12
High
Falling of material
Technicians
16
High
Technicians
3
Supervison PPEs Technicians Serious injury
15
High
1.6 Use of manual Use of manual work equipment work equipment 1.7 Exposure to noise 1.8 Use of high pressure equipment Exposure to noise in the furnace area
4
Operatives Gradual hearing impairment Technicians Operatives Serious injury Technicians Supervison PPEs
16
High
3
Maintenance and check of the high pressure line PPEs PPEs Supervison PPEs
Medium
Use of the high pressure water pump to clean the linings (WOMA)
16
High
1.9
Exposure to thermal load in the clinker furnace area Gaseous emissions from pre-heater
Medium
1.1
5
Fumes and spillage of these fuels can cause fire Operatives Serious Injury Technicians Death Existance of operational procedures Fire fighting arrangement Trained personnel
20
Extreme
1.11
25
Extreme
10
25
Extreme
10
Residual Risk
Risk Evaluation
BACK
Medium
Medium
Low
Medium
Medium
Medium
Low
Medium
Low
Low
Medium
Medium
Base Risk
Risk Assessment Probability Risk Evaluation Severity
Residual Risk
Risk Assessment Risk Evaluation Severity
WHIS# 003:
No
Filtering Plant
Hazard Description Affected Person(s) Harm Safety Measure(s)
Operatives
Serious injury
20
Extreme
10
Medium
Falling of operatives Operatives from height during maintenance and Technicians operation
Serious injury
20
Extreme
10
Medium
1.3 Exposure to dust Exposure to dust during normal operation and maintenance
Operatives Technicians
Adequate securing of the filters prior to any maintenance work. Use of PPEs.
Medium
Low
1.4 Work in confined Work in confined space space inside the electrostatic filters
Operatives Technicians
Adequate securing of the filters. Use of PPEs Authorized and trained Personnel
20
Extreme
Medium
Static electricity can Operatives be created if the filter is not earthed Technicians properly, can be a source of ignition
Serious injury
15
High
Medium
BACK
Base Risk
Risk Assessmen t Probability Risk Evaluation
Residual Risk
Risk Assessmen t Severity
WHIS# 008:
No
1.1
The Mechanical movement Operators of machinery can be a source of hazard particularly when the operatives work near the machine Dusty environment in the bagging area Operators
Serious injury
PPEs Existence of the necessary guards, Safety labeling Restricted access areas PPEs
20
Extreme
10
1.2
Dusty environment
3
PPEs Existence of the necessary guards, Safety labeling Restricted access areas PPEs Existence of the necessary guards, Safety labeling Restricted access areas PPEs Existence of the necessary guards, Safety labeling Restricted access areas PPEs Existence of the necessary guards, Safety labeling Restricted access areas PPEs Existence of the necessary guards, Safety labeling PPEs Existence of the necessary guards, Safety labeling Restricted access areas PPEs Existence of the necessary guards, Safety labeling Restricted access areas
Medium
1.3
25
Extreme
10
1.4
Maintenance of machinery
Technicians
Serious Injury
20
Extreme
10
1.5
Stored Bags
Operatives
20
Extreme
2 Loading Area
2.1 Fall form height Fall form height of operatives or truck drivers working on trucks Operators Truck drivers Serious Injury
20
Extreme
10
Operators
Serious Injury
20
Extreme
10
2.4 Movement of trucks and Movement of trucks and Operators operatives heavy material movement vehicles
Serious Injury
25
Extreme
10
Dusty environment
Operators
Serious Injury
20
Extreme
20
Extreme
Residual Risk
Risk Evaluation
BACK
Medium
Low
Medium
Medium
Low
Medium
Medium
Medium
Medium
Medium
Base Risk
Risk Assessment Risk Evaluation Probability Severity
Residual Risk
Risk Assessment Risk Evaluation Severity
WHIS# 009:
No
Fuel Storage
Hazard Description Affected Person(s) Harm Safety Measure(s)
1.1 Use of open flame Use of open flame can create ignition
All personnel
25
Extreme
10
Medium
Hot spots are created during the maintenance activities which can be a source of ignition
All personnel
25
Extreme
10
Medium
Hurling of hot particles All personnel from an other fire source in the area
Multiple deaths Hot working operating Instructions Emergency response plan in case of another fire source in the area
25
Extreme
10
Medium
Electrical spark during maintenance work on the coal dust piping system
All personnel
Multiple deaths Authorization procedures for working on the coal transportation system
25
Extreme
10
Medium
1.5 High temperature High temperatures created All personnel within the coal storage stock piles
25
Extreme
10
Medium
1.6
Atmospheric discharge
Multiple deaths
25
Extreme
10
Medium
QC Personnel
20
Extreme
Low
BACK
Base Risk
Risk Assessment Probability Risk Evaluation
Residual Risk
Risk Assessment Risk Evaluation Severity
WHIS# 010:
No
25
Extreme
10
Medium
25
Extreme
10
Medium
Machine guarding Existence of operational procedures Trained personnel Guard rails Existence of operational procedures PPEs
25
Extreme
10
Medium
Operatives
20
Extreme
10
Medium
1.5
Exposure to heat
All personnel
25
Extreme
10
Medium
BACK
Base Risk
Risk Assessment Probability Risk Evaluation Severity
Residual Risk
Risk Assessment Risk Evaluation Severity
WHIS# 011:
No
20
Extreme
10
Medium
1.2 Persons falling from Operatives may fall from ladder / scaffold height
Operatives
20
Extreme
10
Medium
Hurling of material
Serious Injury
20
Extreme
10
Medium
Operatives
Injury
16
High
10
Medium
1.5 Slips
Operative
15
High
Medium
BACK
Base Risk
Risk Assessment Probability Risk Evaluation Severity
Residual Risk
Risk Assessment Risk Evaluation Severity
WHIS# 012:
No
15
High
Low
1.2
High Voltage
Electrocution
Operatives
25
Extreme
15
High
1.3
Spillage
25
Extreme
Medium
1.4
Mechanical Movement
Guards PPEs
25
Extreme
Medium
1.5
Technicains
PPEs Supervison
4
Confined space program
20
Extreme
Low
1.6
Hazardous gases
PPEs
4
Procedures
16
High
Medium
BACK
Risk Assessment
Risk Assessment
Probability
Probability
Risk Evaluation
No
Hazard Description
Affected Person(s)
Harm
Safety Measure(s)
20
Extreme
10
Medium
1.2 Explosions may explode by catching fire from welding operations 1.3 Spatters
20
Extreme
10
Medium
Spatters may burn exposed Operatives Skin burns skin or enter eyes and ears Personnel working Damage to nearby ears and eyes
16
High
16
High
1.5 Trips
Injury
Welding procedures
16
High
Medium
2.6 Asphyxiation
Inert gases, such as argon, Operatives helium, nitrogen and carbon dioxide displace air in confined space as they build up. Poisonous carbon monoxide can be formed by the flame of any oxy-fuel torch.
Suffocation Death
12
High
Risk Evaluation
Severity
Severity
WHIS# 013:
Hazard Identification, Risk Assessment and Safety Measures Welding, Cutting, Brazing
Base Risk
Residual Risk
Low
Low
Low
BACK
Risk Assessment
Risk Assessment
Probability
Probability
Risk Evaluation
No
Hazard Description
Affected Person(s)
Harm
Safety Measure(s)
15
High
Medium
Illness
20
Extreme
Medium
Injury
12
High
1.4 Stress
Illness
Rest time
2
Counselling
Medium
Risk Evaluation
Severity
Severity
Hazard Identification, Risk Assessment and Safety Measures WHIS# 014: Medical Services (Administring & Using)
Base Risk
Residual Risk
Low
Low
BACK