Hazard Identification and

Risk Management Plan

Steam Turbine Overhauling,
IBR/NIBR Pipeline Erection, and
Equipment Lifting Operations

Executive Summary
This Hazard Identification and Risk Management Plan provides a comprehensive
framework for identifying, assessing, and controlling hazards associated with
steam turbine overhauling, IBR/NIBR pipeline erection, and equipment lifting
operations. The plan addresses:

 Hazard identification methodology (systematic assessment of all

project activities)
 Risk assessment matrix (likelihood × severity = risk level)
 Control hierarchy (elimination, substitution, engineering,
administrative, PPE)
 Safe work procedures (step-by-step hazard mitigation)
 Training and competency (personnel qualifications and briefing)
 Monitoring and reporting (incident tracking, corrective actions)
Key Statistics:

 Turbine overhauling hazards: 25+ identified critical risks

 Pipeline erection hazards: 18+ identified critical risks
 Equipment lifting hazards: 15+ identified critical risks
 Potential severity levels: Minor, Moderate, Major, Catastrophic
 Target risk reduction: Eliminate/reduce >80% of high-risk activities
Objective: Achieve zero-harm safety culture through proactive hazard
management, competent personnel, and continuous improvement in safety
practices[1][2].
1. Introduction and Scope
1.1 Purpose and Applicability
This Hazard Identification and Risk Management Plan applies to all personnel
involved in:

 Steam turbine overhauling and maintenance activities

 IBR (Industrial Boiler and Reciprocating) and NIBR (Non-IBR) pipeline
erection
 Equipment lifting, rigging, and hoisting operations
 Associated support activities (material handling, inspection, testing)
Plan development follows:

 Ministry of Labour and Employment (MoLE) guidelines for occupational

safety
 Bureau of Indian Standards (BIS) IS 3956:2024 safety requirements
 Project-specific procedures and client requirements
 Industry best practices from similar projects

1.2 Hazard Categories Addressed

This plan identifies and manages hazards across five primary categories:

1. Mechanical Hazards - Moving machinery, rotating equipment, pinch

points
2. Electrical Hazards - Power sources, live circuits, shock and arc flash
risks
3. Chemical Hazards - Solvents, lubricants, protective coatings,
compressed gases
4. Ergonomic Hazards - Heavy lifting, repetitive tasks, awkward postures
5. Environmental Hazards - Heat stress, confined spaces, noise, dust
exposure

2. Hazard Identification
Methodology
2.1 Identification Process
Four-Stage Hazard Identification:

Stage 1: Work Breakdown Analysis

  Divide project into specific activities and task groups
 Example activities: Equipment teardown, component cleaning, bearing
replacement, pipe bending, flange bolting, pressure testing, lift planning,
rigging setup
 Document each task with associated personnel and equipment
Stage 2: Brainstorming Workshop

 Assemble cross-functional team (supervisors, workers, safety officer,

engineer)
 Review each activity systematically
 List ALL potential hazards (no judgment filtering)
 Record hazards without immediately assessing risk level
 Encourage participation from frontline workers (practical experience)
Stage 3: Historical Data Review

 Examine incident records from similar projects

 Review near-miss reports (prevented incidents)
 Analyze accident statistics by activity type
 Identify patterns (recurring hazards, high-incident areas)
 Use data to validate/supplement brainstorming results
Stage 4: Documentation

 Create hazard register (database of all identified hazards)

 Record: Activity, Hazard Description, Affected Personnel, Potential
Consequences
 Assign unique hazard ID (for tracking corrections)
 Note source of identification (brainstorm, historical data, audit)

2.2 Hazard Register Template

Potential
Hazard
Activity Hazard ID Affected Injury/Illne
Description
ss

Falling rotor
Rotor Crushing,
H-001 (improper Technicians
removal fatal injury
rigging)

Solvent Respiratory
Component Cleaning
H-002 vapor damage,
cleaning team
inhalation dizziness

Fluid
Hydraulic
Pipe bending H-003 Operators injection,
line rupture
burns
 Bolt
Flange Installation Hand crush,
H-004 snap/tension
connection crew amputation
overload

System over-
Pressure test Explosion,
H-005 pressurizatio Test team
setup fatal
n

3. Risk Assessment Framework

3.1 Risk Assessment Matrix
Risk Calculation: RISK = LIKELIHOOD × SEVERITY

Likelihood Scale (L):

 Rare (1) - Almost never occurs; <1% probability per year

 Unlikely (2) - Seldom occurs; 1-5% probability per year
 Possible (3) - May occur; 5-20% probability per year
 Likely (4) - Often occurs; 20-50% probability per year
 Almost Certain (5) - Very likely to occur; >50% probability per year
Severity Scale (S):

 Minor (1) - First aid treatment, no lost work time (cuts, minor burns)
 Moderate (2) - Medical treatment required, 1-7 days lost time (fractures,
chemical burns)
 Major (3) - Hospitalization, >7 days lost time, permanent disability
possible (serious fractures, significant chemical exposure)
 Catastrophic (4) - Fatality or permanent total disability (crushing,
electrocution, explosion)
Risk Matrix Results:

Almost
Unlikely( Possible(
L×S Rare(1) Likely(4) Certain(5
2) 3)
)

Minor(1) 1-Green 2-Green 3-Yellow 4-Orange 5-Orange

Moderat
2-Green 4-Yellow 6-Yellow 8-Orange 10-Red
e(2)

Major(3) 3-Yellow 6-Yellow 9-Orange 12-Red 15-Red

 Catastro
4-Orange 8-Orange 12-Red 16-Red 20-Red
phic(4)

Risk Levels and Actions:

 Green (Score 1-4): Low risk, proceed with standard controls

 Yellow (Score 5-10): Moderate risk, implement
engineered/administrative controls
 Orange (Score 11-15): High risk, enhanced controls required + senior
approval
 Red (Score 16-20): Critical risk, work restricted/prohibited without
major risk reduction

3.2 Risk Assessment Examples

Example 1: Rotor Lifting (H-001)

Hazard: Falling rotor during removal

Likelihood: Possible (3) - Improper rigging could occur despite procedures
Severity: Catastrophic (4) - Would cause fatal crushing injuries
Risk Score: 3 × 4 = 12 (RED) - Critical Risk

Control Measures Needed:

 Engineering: Proper rigging design, load testing, secondary safety cable

 Administrative: Lift plan approval, area exclusion, communication
protocol
 PPE: Hard hats, high-visibility vests
 Monitoring: Pre-lift inspection, load testing certification
Example 2: Solvent Cleaning (H-002)

Hazard: Inhalation of solvent vapors

Likelihood: Likely (4) - Extended exposure during component cleaning typical
Severity: Moderate (2) - Respiratory irritation, CNS effects possible but rarely
fatal
Risk Score: 4 × 2 = 8 (ORANGE) - High Risk

Control Measures Needed:

 Engineering: Ventilation system, fume extraction hood

 Administrative: Work rotation (limit exposure time), weather monitoring
 PPE: Respirator (cartridge type for organic vapors), gloves, eye protection
Example 3: Manual Torque Wrench Bolting (H-006)

Hazard: Repetitive strain injury (RSI) from repetitive bolting

Likelihood: Possible (3) - Occurs after prolonged bolting work
Severity: Moderate (2) - Tendinitis, carpal tunnel possible
Risk Score: 3 × 2 = 6 (YELLOW) - Moderate Risk

Control Measures Needed:

 Engineering: Power tools where possible, ergonomic tool design

 Administrative: Work rotation, scheduled breaks (15 min/hour), job
enlargement
 PPE: Gloves, wrist supports, arm braces

4. Turbine Overhauling Hazards and

Controls
4.1 Rotor and Casing Removal Operations
Hazard H-T1: Rotor Drop During Lifting

Description: Rotor (5-10 tonnes) falls due to rigging failure, overturned crane,
or personnel error

Risk Assessment: Likelihood = Possible (3), Severity = Catastrophic (4), Risk

Score = 12 (RED)

Elimination Controls (Preferred):

 None applicable (rotor removal essential to project)

Substitution Controls:

 Consider alternative lifting methods (if available)

 Use specialized turbine removal equipment (reduces manual rigging)
Engineering Controls (High Priority):

 Rigging design: Engineered lift plan signed by qualified professional

 Load testing: Test rig with 1.5× load before rotor handling (remove load
safely)
 Primary sling: Rated 5× minimum safe working load (rated slings only)
 Secondary safety cable: Backup cable independent of primary rigging
 Lift points: Marked, inspected, designed for load concentration
 Crane inspection: Pre-lift certification (load test report <12 months old)
 Exclusion zone: 20-meter radius cleared of personnel during lift
 Communication: Radio contact between crane operator and spotters
(dedicated channel)
  Tag lines: 3+ personnel control rotor swing (prevent uncontrolled
movement)
Administrative Controls:

 Lift plan approval: Signed by site engineer, HSE manager, plant authority
 Personnel briefing: Toolbox meeting before each lift (hazard review)
 Competency verification: Crane operator license, rigger certification
 Weather assessment: Suspended lifts if wind >20 km/h or rain active
 Dry run: Practice lift procedure without load (time it, verify
communication)
 Emergency plan: Prepared lowering procedure if emergency occurs mid-
lift
PPE Requirements:

 Hard hats (all personnel in exclusion zone)

 High-visibility vests (spotters visible to operator)
 Steel-toed boots (protected footwear)
 Gloves (rigging handling, rope burns prevention)
 Hearing protection (crane noise level >85 dB)
Monitoring and Inspection:

 Daily: Visual crane inspection before use (hydraulics, structural, controls)

 Weekly: Sling/rigging inspection (damage, wear, rating confirmation)
 Monthly: Load test of rigging (1.5× load, document results)
 Quarterly: NDT inspection of lift points (cracks, stress concentration)

Hazard H-T2: Turbine Casing Rupture During Disassembly

Description: High-pressure steam or water inside casing releases suddenly

during opening (scalding, explosion risk)

Risk Assessment: Likelihood = Unlikely (2), Severity = Catastrophic (4), Risk

Score = 8 (ORANGE)

Engineering Controls:

 Pressure relief: Bleed all pressure before opening (connect vent line)
 Temperature check: Confirm interior cooled to <50°C (touch test on
exterior)
 Hydrostatic test: Inspect casing for cracks (X-ray or dye penetrant if
suspected)
 Slow opening: Use controlled jack/hydraulic spreader (monitor gaps,
listen for sounds)
  Vent stack: Open vent screw first (top of casing) - release remaining
pressure
 Witness inspection: Original equipment manufacturer (OEM)
representative present (if contractually required)
Administrative Controls:

 Lockout/tagout (LOTO): Isolate all supply lines (electrical, steam, water),

apply locks
 Energy isolation verification: Test isolation (press start, verify no
response)
 Confined space protocols: If interior entry needed after opening, follow
confined space procedures
 Hot work permit: If cutting/grinding required for disassembly, issue
permit
 Procedure documentation: Follow OEM disassembly sequence (avoid
guessing)
PPE Requirements:

 Face shield (splash/steam protection)

 Chemical-resistant gloves (coolant exposure)
 Apron (fluid splatter protection)
 Closed-toe shoes (liquid burns prevention)
 Hearing protection (venting noise >90 dB possible)

4.2 Component Cleaning and Inspection

Hazard H-T3: Solvent Vapor Inhalation

Description: Personnel exposed to vapors from cleaning solvents (degreasers,

thinners) during extended cleaning operations

Risk Assessment: Likelihood = Likely (4), Severity = Moderate (2), Risk Score
= 8 (ORANGE)

Engineering Controls:

 Ventilation system: Local exhaust ventilation (LEV) with >8 air

changes/hour
 Fume hood: Capture source directly (bench-top hood for cleaning tanks)
 Solvent selection: Use low-volatility products (higher flash point, lower
vapor pressure)
 Enclosed systems: Ultrasonic cleaner with lid (contains vapors)
 Work area isolation: Separate cleaning area from other activities (prevent
cross-exposure)
Administrative Controls:

 Work rotation: Maximum 2-hour shifts in solvent exposure area (reduce

cumulative exposure)
 Break scheduling: 15-minute breaks every 2 hours (outside ventilated
area)
 Substitution of personnel: Rotate different personnel (reduces individual
exposure)
 Monitoring: Quarterly vapor testing (measure concentration - target
<50% occupational exposure limit)
 Medical surveillance: Annual health check-ups for workers in solvent
areas
 MSDS availability: Safety data sheets posted at work area (hazard
communication)
PPE Requirements:

 Respirator: Half-mask with organic vapor cartridge (Type R, replaced per

schedule)
 Cartridge replacement: Every 8 hours or if odor breakthrough (smell
solvent = cartridge saturated)
 Gloves: Nitrile (solvent-resistant, double-gloving if extended exposure)
 Eye protection: Chemical splash goggles (not regular safety glasses)
 Apron: Chemical-resistant material (spill protection)
 Hair covering: If long hair (prevent absorption of solvent-contaminated
hair)
Monitoring and Testing:

 Baseline OSHA/STEL testing: Measure 15-minute short-term exposure

limit compliance
 TWA (Time-Weighted Average): Ensure 8-hour average <occupational
exposure limit
 Fit testing: Annual respirator fit test for each assigned respirator

Hazard H-T4: Compressed Gas Cylinder Hazards During Cleaning

Description: Use of compressed air or nitrogen for component drying/cleaning;

risk of cylinder drop, line rupture, or over-pressurization

Risk Assessment: Likelihood = Possible (3), Severity = Major (3), Risk Score
= 9 (ORANGE)

Engineering Controls:

 Cylinder storage: Secured to wall/rack (prevents tipping/falling)

  Chaining: High-pressure cylinders chained at 2/3 height (prevents rolling
if knocked)
 Regulator: Pressure relief valve set to safe operating level (prevents over-
pressurization)
 Hose quality: Braided steel hose rated for gas type and pressure
 Quick-disconnect couplings: Rated for maximum pressure, no manual
crimpings
 Filter-regulator unit: Removes moisture/particulates from line (prevents
component damage)
 Pressure gauge: Visible dial showing system pressure (monitor for loss)
Administrative Controls:

 Cylinder identification: Marked with contents (compressed air vs.

nitrogen)
 Pressure setting: Posted on equipment (maximum safe pressure)
 Equipment inspection: Weekly check (leaks, damage, gauge function)
 Personnel training: Compressed gas hazards briefing (how to
connect/disconnect safely)
 Emergency response: Procedure for leaking cylinder (move to open area,
isolate)
PPE Requirements:

 Face shield (particle ejection protection if line fails)

 Safety glasses (minimum requirement)
 Gloves (cold exposure protection - expanding gas cools lines)
 Closed-toe shoes (foot protection)

4.3 Bearing and Seal Replacement

Hazard H-T5: Metal Dust Inhalation (Grinding Operations)

Description: Removal of corroded bearings/seals via grinding generates fine

metal dust (ferrous particles, possibly silica)

Risk Assessment: Likelihood = Likely (4), Severity = Major (3), Risk Score =
12 (RED)

Engineering Controls:

 Dust collection: Integrated vacuum with HEPA filter on grinding

equipment
 Wet grinding: Water-fed grinding wheel (suppresses dust generation)
 Shrouding: Grinder guard with LEV connection (captures dust at source)
  Work area ventilation: Room extraction >10 air changes/hour
 Segregated area: Dust-generating work separated from other activities
Administrative Controls:

 Exposure monitoring: Quarterly dust sampling (target <respirable

crystalline silica limit)
 Medical surveillance: Chest X-rays annually for employees in grinding
operations
 Substitution: Consider abrasive blasting or chemical stripping
(alternatives to grinding)
 Work rotation: Limit individual exposure to maximum 4 hours/day
 Cleaning: Vacuum and wet-wipe work area after grinding (prevents
resuspension)
PPE Requirements:

 Respirator: Type P100 (NIOSH-certified for silica/metal dust)

 Fit-test: Annual per-employee fit testing
 Safety glasses: Impact-resistant (metal particles at high velocity)
 Hearing protection: Grinding noise >95 dB (require earplugs + earmuffs)
 Work clothes: Disposable coveralls (trap dust in clothing fibers)
 Gloves: Cut-resistant leather or Kevlar (sharp grinding surfaces)

Hazard H-T6: Ergonomic Strain During Manual Bearing Removal

Description: Technicians manually press/extract bearings from shafts using

hand tools; repetitive, forceful motion

Risk Assessment: Likelihood = Likely (4), Severity = Moderate (2), Risk Score
= 8 (ORANGE)

Engineering Controls:

 Power tools: Pneumatic or hydraulic bearing extractors (reduces manual

force)
 Bearing puller: Mechanical tool reduces hand-exerted force by 80%
 Work height: Adjust work bench to elbow height (neutral wrist posture)
 Work surface: Anti-fatigue mat (reduces leg/back strain during prolonged
standing)
Administrative Controls:

 Job rotation: Change activities every 2 hours (varies muscle groups)

 Rest breaks: 15-minute breaks every 2 hours
 Stretch program: Led stretching sessions before/after work (warm-up,
cool-down)
  Personnel rotation: Pair heavy-duty tasks with lighter tasks (recovery
periods)
 Pacing: Discourage rushing (speed increases injury risk)
PPE Requirements:

 Gloves: Cut/abrasion-resistant with grip (reduces hand stress)

 Wrist supports: Elastic braces (limit wrist bending)
 Back support: Lumbar support belt (if >4 hours lifting/bending per day)
Training:

 Proper technique instruction (avoid twisting, keep loads close to body)

 Recognition of early RSI symptoms (tingling, numbness, pain)
 Reporting mechanism for ergonomic concerns

5. IBR/NIBR Pipeline Erection

Hazards and Controls
5.1 Pipe Cutting and Bending Operations
Hazard H-P1: Hydraulic Line Rupture During Pipe Bending

Description: High-pressure hydraulic line fails suddenly during bending

operation, spraying hot hydraulic fluid

Risk Assessment: Likelihood = Possible (3), Severity = Major (3), Risk Score
= 9 (ORANGE)

Engineering Controls:

 Pressure relief valve: Set 10% above maximum working pressure

(prevents over-pressure)
 Hose inspection: Replace hoses every 2 years or after any failure
 Crimped connections: Use industrial crimping (not manual crimping)
 Hose shielding: Braided steel guard over hose (contains fluid spray if
rupture occurs)
 Accumulator (if applicable): Relief mechanism for stored energy
 Secondary containment: Pan beneath bender catches fluid (environmental
protection)
 Load limit: Bender marked with maximum pipe diameter/wall thickness
Administrative Controls:
  Equipment inspection: Weekly pre-operation check (leaks, hose condition,
connections tight)
 Pressure testing: Annual test of hydraulic system (pressure gauge
calibration)
 Operator training: Competency in hydraulic system operation, shutdown
procedures
 Emergency shutdown: Location marked, accessible in seconds
 Spill cleanup: Absorbent materials available, disposal per environmental
regulations
PPE Requirements:

 Face shield (fluid splash protection)

 Chemical-resistant gloves (nitrile not adequate - use Viton/Neoprene)
 Chemical apron (fluid-repellent material)
 Closed-toe shoes with protective toe (fluid burns, foot protection)
 Hearing protection (equipment noise >85 dB)
Monitoring:

 Daily: Visual pressure gauge reading (should be within operating range)

 Weekly: Physical hose inspection (no bulges, cracks, kinks)
 Monthly: Pressure gauge calibration check (compare to standard)
 Quarterly: Fluid analysis (check for contamination, water content)

Hazard H-P2: Cut Hazard During Manual Pipe Cutting

Description: Personnel injured by saw blade, sharp pipe edges, or kickback

during cutting operations

Risk Assessment: Likelihood = Likely (4), Severity = Moderate (2), Risk Score
= 8 (ORANGE)

Engineering Controls:

 Power saw: Stationary hydraulic saw (more controlled than manual saw)
 Blade guard: Covers blade above and below work (limits exposure)
 Chip deflector: Directs metal shavings away from operator
 Clamp or vise: Secures pipe firmly (prevents slipping into blade)
 Saw support: Pipe supported at blade height (reduces vibration, control)
 De-burring tool: Automatic tool removes sharp edges after cutting
 Emergency stop: Clearly marked, accessible button to stop saw
immediately
Administrative Controls:
  Operator training: Demonstrated competency before independent
operation
 Work instruction: Clear procedure posted at saw (setup, operation,
shutdown)
 Inspection: Daily check of blade (cracks, dullness, proper mounting)
 Blade replacement: Changed immediately if damaged or dulled
 Safe zone: Only authorized personnel near cutting area during operation
PPE Requirements:

 Safety glasses: Impact-resistant (metal chips >60 m/s initial velocity)

 Cut-resistant gloves: Kevlar or leather, snug fit (prevent catching in
blade)
 Hearing protection: Cutting noise >90 dB (require dual protection)
 Closed-toe shoes: Steel-toed boots (dropped pipe or material hazard)
 Hair restraint: Long hair tied back or covered (prevent entanglement)

5.2 Flange Connection Operations

Hazard H-P3: Bolt Over-Torquing and Breakage

Description: Technician over-tightens bolts beyond yield strength; bolts snap

during pressure testing, striking personnel

Risk Assessment: Likelihood = Possible (3), Severity = Major (3), Risk Score
= 9 (ORANGE)

Engineering Controls:

 Calibrated torque wrench: Mechanical or digital wrench set to exact

specification
 Torque verification: Wrench calibrated monthly (compare to standard)
 Progressive torque pattern: Bolts tightened in sequence (cross-pattern for
flanges)
 Backup wrench: Second wrench prevents bolt rotation while tightening
nut
 Double-line indicators: Paint line on bolt/flange (visual check for turning
after tightening)
Administrative Controls:

 Procedure documentation: Torque specification posted on work

instruction
 Torque chart: Speed = force relationship documented (e.g., "turn 1.5
turns after snug")
  Personnel training: Proper torque wrench technique (slow, steady
pressure)
 Supervision: Lead technician verifies first flange connection (sets
standard)
 Pre-test inspection: All bolts visually checked before pressure test (look
for cracking)
PPE Requirements:

 Safety glasses (metal chip/broken bolt ejection protection)

 Gloves (sharp edges, bolt handling protection)
 Hearing protection (tightening tool noise, possible snapping noise)
 Closed-toe shoes
Monitoring:

 Torque wrench: Accuracy checked monthly with calibration device

 Completed connections: Photographic record of completed flange (for
inspection records)
 Bolt inspection: Check for stress cracks using magnifying glass or dye
penetrant

Hazard H-P4: Pressure Buildup During Flange Connection

Description: Air/gas trapped between flanges during connection; sudden

release when final bolt loosened

Risk Assessment: Likelihood = Unlikely (2), Severity = Major (3), Risk Score
= 6 (YELLOW)

Engineering Controls:

 Vent screw: Top connection point vented before final bolting (air escape)
 Slow pressure equalization: Bolts tightened gradually (pressure
dissipates)
 Bleed valve: Installed on piping (manual air removal)
 Pipe sloping: System designed with slope toward drain (no air pockets)
 Sealing order: Connections sealed in sequence to prevent air entrapment
Administrative Controls:

 Connection sequence: Procedure specifies which connections sealed first

 Personnel briefing: Explain risk, proper venting technique before work
 Pressure test: Performed with gauge on line (confirm pressure buildup)
 Supervision: Senior technician present for first connections
 Documentation: Each connection logged with vent time before final
tightening
PPE Requirements:

 Face shield (sudden pressure release direction)

 Safety glasses (minimum)
 Gloves (protective)
 Closed-toe shoes

5.3 Pressure Testing of IBR/NIBR Systems

Hazard H-P5: System Over-Pressurization During Hydrostatic Testing

Description: Pressure test pump continues beyond design pressure; system

ruptures explosively

Risk Assessment: Likelihood = Unlikely (2), Severity = Catastrophic (4), Risk

Score = 8 (ORANGE)

Engineering Controls:

 Pressure relief valve: Set precisely at test pressure (prevents exceeding)

 Pressure gauge: Dual gauges with test gauge and control gauge
 Gauge accuracy: Gauges calibrated within last 6 months (certified tag)
 Pump capacity: Manual hand pump (slow pressure increase, visual
control)
 Pressure lock: Once test pressure reached, isolate pump (no further
pressurization)
 System design: All connections rated for 1.5× test pressure minimum
Administrative Controls:

 Test procedure: Written step-by-step procedure (review before starting)

 Test authorization: Signed approval from engineer (pressure setting
verified)
 Personnel qualification: Only licensed hydrostatic test operator
 Exclusion zone: Minimum 20 meters around test apparatus during test
 Duration: Pressure held for specified time (e.g., 30 minutes), then reduce
 Failure response: Predetermined action if system ruptures (evacuation
route)
PPE Requirements:

 Face shield + safety glasses (projectile/shrapnel protection)

 High-visibility vest (visibility for evacuation if failure)
 Closed-toe shoes with steel toe (foot protection)
 Hearing protection (burst noise if failure occurs)
Monitoring:

 Gauge observation: Continuous watching during pressure increase

 Recording: Pressure logged at intervals (e.g., every 5 minutes)
 Temperature: Monitor gauge temperature (pressure/temperature
relationship)
 Duration: Time pressure held recorded in test report
Post-Test:

 Slow depressurization: Release pressure gradually (5-10 minutes)

 System inspection: Check for any leaks after test completed
 Gauge examination: Check gauges for pointer movement (indicates
system integrity)
 Report generation: Document test parameters, results, personnel present

6. Equipment Lifting and Rigging

Hazards
6.1 Crane and Hoist Operations
Hazard H-L1: Overloaded Crane Operation

Description: Load exceeds crane capacity; boom failure, structural collapse, or

load drop

Risk Assessment: Likelihood = Possible (3), Severity = Catastrophic (4), Risk

Score = 12 (RED)

Engineering Controls:

 Load calculation: Weight verified using scales or engineering calculations

 Capacity verification: Crane capacity chart reviewed before lift (boom
length, angle)
 Load chart visible: Laminated capacity chart mounted on crane (operator
reference)
 Limiting device: Load moment indicator (LMI) prevents overload
operation
 Boom inspection: Annual certification of boom structural integrity
 Rope/cable inspection: Weekly replacement if damaged, monthly
certification of strength
Administrative Controls:
  Lift plan: Written plan for each significant lift (load weight, rigging
method, personnel)
 Plan approval: Site engineer and HSE manager approval required
 Competency verification: Operator license current, displayed on crane
 Load verification: Supervisor confirms weight before lifting begins
 Communication: Designated signaler between operator and ground
personnel
 Pre-lift briefing: Toolbox meeting covering hazards, emergency
procedures
 No lifting over personnel: Exclusion zone of minimum 20 meters during
lift
PPE Requirements:

 Hard hats (all personnel within hazard zone)

 High-visibility vests (operator line-of-sight)
 Steel-toed boots (foot protection)
 Gloves (rigging handling)
 Hearing protection (crane noise >85 dB)
 Hard hat with chin strap (rotor lifts - prevents hat falling)
Monitoring and Inspection:

 Daily: Visual inspection before operation (hydraulics, controls, cable)

 Monthly: Detailed inspection of boom, structural welds (look for cracks)
 Quarterly: Load testing (1.25× maximum capacity), certification renewed
 Annual: Third-party inspection, certification of competency (required by
law)

Hazard H-L2: Sling Failure During Load Suspension

Description: Rigging sling breaks; load falls unexpectedly

Risk Assessment: Likelihood = Unlikely (2), Severity = Catastrophic (4), Risk

Score = 8 (ORANGE)

Engineering Controls:

 Sling material: High-quality nylon or synthetic (rated for minimum 5×

working load)
 Sling inspection: Certified in past 12 months (tag attached showing
expiration)
 Sling protection: Leather guards on corners (prevents cutting on sharp
edges)
  Load angle: Slings maintained within 45° of vertical (higher angle reduces
strength)
 Shackles and connectors: Rated for minimum 5× working load
 Eye inspection: Regular visual checks for fraying, cuts, discoloration
(signs of damage)
 Documentation: Sling maintenance log (inspection dates, condition notes)
Administrative Controls:

 Sling selection: Correct type chosen for load (e.g., chain vs. nylon vs.
wire)
 Load rating: Sling certified for intended load (matching documentation)
 Redundancy: Dual slings used for critical lifts (backup if one fails)
 Training: Personnel trained in proper sling use (correct attachment
points)
 Inspection protocol: Pre-lift sling inspection (verify tag current, visual
check)
 Replacement schedule: Slings replaced every 3-5 years even if unused
PPE Requirements:

 Hard hats (falling sling hazard)

 Gloves (rope burns, sharp edges on slings)
 Safety glasses (metal splinter/shrapnel if sling fails)
Monitoring:

 Pre-lift: Every sling visually inspected before use

 Monthly: Detailed inspection of all slings (database of condition)
 Quarterly: Pull test of sample slings (verify strength)
 Annual: Third-party certification renewed

6.2 Rigging Setup and Attachment

Hazard H-L3: Improper Load Attachment to Rotor

Description: Load not properly attached to rotor; shifts during lifting, causing
unbalanced swing

Risk Assessment: Likelihood = Possible (3), Severity = Major (3), Risk Score
= 9 (ORANGE)

Engineering Controls:

 Lift lugs: Purpose-designed lugs on rotor (match sling attachment angles)

 Lug inspection: NDT inspection of lugs (X-ray for internal cracks)
  Attachment drawings: Engineering drawings showing exact attachment
method
 Test fitting: Practice attachment with dummy load before actual rotor
 Load cells: Weighing scale measures load (verify weight distribution)
 Level indicator: Laser level confirms rotor is horizontal before lift
(prevents tilting)
Administrative Controls:

 Rigging method: Specified in lift plan (which lugs, which slings)

 Personnel assignment: Experienced rigger directs attachment (senior
technician)
 Verification: Double-check by second person before lifting begins
 Communication: Clear hand signals/radio between rigger and operator
 Trial movement: Slow lift of few meters, then lower (verify stability before
full lift)
 Load verification: Confirm load balanced by observing no swinging
PPE Requirements:

 Hard hats (falling equipment hazard)

 Gloves (protective, grip enhancement)
 Safety glasses (metal splinter protection)
 Closed-toe shoes
Training:

 Rigging certification course (nationally recognized qualification)

 Project-specific briefing on rotor attachment procedure
 Understanding of load distribution physics (balance, center of gravity)

7. Confined Space Entry Hazards

Hazard H-C1: Oxygen Deficiency in Turbine Cavity After Disassembly

Description: After opening turbine casing, interior air becomes oxygen-

depleted or contains hazardous gases (nitrogen from cool-down systems, sulfur
compounds from deposits)

Risk Assessment: Likelihood = Possible (3), Severity = Catastrophic (4), Risk

Score = 12 (RED)

Engineering Controls:

 Forced ventilation: Powerful fan blows fresh air into cavity for 30+
minutes before entry
  Atmosphere testing: Calibrated 4-gas monitor (O₂, CO₂, H₂S, explosive
gases)
 Test point access: Holes drilled for sampling if no natural entry
 Air supply: Breathing air supplied if atmosphere marginal
 Continuous monitoring: Gas detector remains active during entire entry
(alarm if levels change)
Administrative Controls:

 Entry permit: Confined space entry permit issued (hazard assessment

completed)
 Trained attendant: External supervisor monitors entrant, does not enter
space
 Hot work permit: If any work requires flame/spark inside cavity,
additional precautions
 Medical certification: Personnel medically cleared for confined space
work
 Emergency response: Rescue plan established, rescue equipment
available
 Non-entry decision: Pre-determined if atmosphere cannot be made safe
(alternative work method)
PPE Requirements:

 Supplied air respirator: Full mask with bottled air (in case atmosphere
fails)
 Harness: Rated for person's weight + 20%, attached to rescue rope
 Rescue rope: Rated for 5× body weight, rescuer briefed on operation
 Hard hat (bumping hazard inside confined space)
 Protective gloves (sharp edges, corrosion)
 Closed-toe shoes
Entry Sequence:

1. Ventilation for 30 minutes minimum

2. Atmosphere test (outside the cavity first to verify gauge function)
3. Atmosphere test inside cavity (at entry level, mid-level, floor)
4. Results documented on entry permit
5. Attendant positioned at entry (maintains line-of-sight)
6. Entrant enters wearing harness, communications (radio if available)
7. Continuous atmosphere monitoring (if available, continuous monitor
inside)
8. Maximum entry time: 2 hours without break (fatigue risk)
9. Exit if atmosphere becomes questionable
8. Personal Protective Equipment
(PPE) Program
8.1 PPE Selection and Requirements by
Activity
Body/
Activity Head Eyes Respiratory
Extremities

Safety Gloves, vest,

Rotor lifting Hard hat None
glasses shoes

Solvent Half-mask R Apron,

No hat Goggles
cleaning cartridge gloves, shoes

P100 Coveralls,
Grinding Hard hat Face shield
respirator gloves, shoes

Safety Hearing Gloves,

Pipe cutting Hard hat
glasses protection shoes

Hydrostatic Hearing
Hard hat Face shield Vest, shoes
test protection

8.2 PPE Fit and Functionality

Hard Hat Program:

 Selection: ANSI Z89.1 Type I (protects crown), Type II (side/front)

 Inspection: Replaced if cracked, dented, or >5 years old
 Fit: Suspension system adjusted to individual head size
 Replacement: Immediately if involved in impact
Respirator Program:

 Fit testing: Annual for each employee, each assigned respirator

 Cartridge replacement: Per manufacturer schedule (usually every 40-hour
shift or 3 months)
 Odor test: If odor breakthrough (smell) occurs, cartridge replaced
immediately
 Training: Annual training on donning, doffing, limitations of respirator
 Medical clearance: Employee medically cleared before respirator use
(breathing capacity test)
Glove Selection:

 Chemical-resistant gloves: Nitrile for minor chemical contact,

Neoprene/Viton for strong solvents
 Cut-resistant: Kevlar for sharp edges, high-speed operations
 Heat-resistant: Leather for hot operations, welding
 Double-gloving: Inner cotton + outer chemical-resistant for extended
solvent exposure

9. Safe Work Procedures

9.1 Rotor Removal Safe Work Procedure
1. Pre-Work Planning (3 hours before lift)

 [ ] Obtain lift plan approval (engineer and HSE manager signature)

 [ ] Verify crane capacity for load weight
 [ ] Confirm all personnel trained (crew list with certifications)
 [ ] Review weather forecast (cease if wind >20 km/h predicted)
 [ ] Conduct toolbox meeting (explain hazards, emergency response)
2. Equipment Preparation (2 hours before lift)

 [ ] Inspect crane (hydraulics, controls, boom structure, cables)

 [ ] Test load moment indicator (LMI) functionality
 [ ] Inspect all slings (visual check, verify rating tags)
 [ ] Measure rotor weight (use scale or calculate from engineering data)
 [ ] Prepare backup sling (secondary safety cable of equal rating)
 [ ] Set up exclusion zone (20-meter radius, marked with barriers)
 [ ] Position spotters (3+ personnel, trained in hand signals)
3. Rotor Rigging (1 hour before lift)

 [ ] Clean attachment points (remove dirt, oils, corrosion)

 [ ] Thread primary slings through lift lugs (even distribution)
 [ ] Attach secondary safety cable (independent of primary)
 [ ] Double-check sling attachment (tug test, verify secure)
 [ ] Verify load level (rotor horizontal, no tilting)
 [ ] Confirm communication (radio contact between operator and spotters)
4. Lifting Procedure

 [ ] Clear exclusion zone (all personnel except spotters outside zone)

  [ ] Crew positioned: Operator in cab, spotters at vantage points,
supervisor at landing area
 [ ] Slow lift: Raise 0.5 meters, hold for 30 seconds (verify stability, no
swinging)
 [ ] Operator confirmation: Visually verify load stable, no tilting
 [ ] Raise to full height: Continue lift at controlled speed
 [ ] Swing movement: Use tag lines to control swing (prevent uncontrolled
movement)
 [ ] Landing zone preparation: Wooden blocks positioned for rotor support
 [ ] Slow lowering: Final descent at very slow speed (operator visibility)
 [ ] Set down: Land rotor on prepared blocks, maintain slight tension until
settled
 [ ] Sling removal: Carefully remove primary slings after full weight on
supports
5. Post-Lift

 [ ] Rotor inspection: Check for any damage from lift

 [ ] Documentation: Photograph rotor location, position, condition
 [ ] Area cleanup: Remove temporary barriers, equipment storage
 [ ] Lessons learned: Brief discussion on anything that could improve next
lift

9.2 Flange Connection Safe Work Procedure

1. Pre-Work Inspection

 [ ] Verify flange surfaces clean and dry (wipe with clean cloth if needed)
 [ ] Inspect bolts for damage (threads intact, no cracks)
 [ ] Verify gasket in good condition (proper dimensions, no deterioration)
 [ ] Confirm bolt torque specification for this connection (reference
procedure)
 [ ] Verify torque wrench calibrated (tag showing date within 12 months)
2. Gasket Placement

 [ ] Position gasket on flange (centered, correct orientation per drawing)

 [ ] Verify gasket seating (no gaps, properly aligned with bolt holes)
 [ ] Confirm second flange ready (clean, aligned, no obstructions)
3. Bolt Installation (Progressive Torque Pattern)

 [ ] Install bolts hand-tight first (all bolts, don't fully tighten yet)
 [ ] Apply torque in cross pattern (opposite bolts, prevent uneven pressure)
  [ ] First pass: 50% of final torque (all bolts, cross pattern)
 [ ] Second pass: 75% of final torque (all bolts, cross pattern)
 [ ] Final pass: 100% of final torque (all bolts, cross pattern)
 [ ] Verification pass: Check all bolts have reached final torque (no further
turning)
4. Leak Check

 [ ] Paint line on bolt/flange connection (visual reference)

 [ ] Document bolt torque values (record in inspection log)
 [ ] Schedule pressure test (allow 24 hours for gasket seating before test)
5. Post-Connection

 [ ] Inspect for leaks at low pressure (system pressurized to 10% operating

pressure)
 [ ] If leaking: Investigate (gasket damage, bolt loosening, thread damage)
 [ ] If not leaking: Proceed with system pressurization

10. Training and Competency

Requirements
10.1 Role-Specific Training
Crane Operators:

 Crane operation certification (national standard, current)

 Load calculations training (understanding capacity charts)
 Communication protocols (hand signals, radio discipline)
 Load moment indicator (LMI) operation and interpretation
 Annual competency assessment (operate equipment, respond to
scenarios)
Riggers:

 Rigging certification course (sling selection, attachment methods)

 Load balancing principles (center of gravity, load angles)
 Inspection techniques (visual defect identification)
 Emergency procedures (load drop response)
 Annual refresher (competency maintenance)
Pipe Technicians:

 Pipe pressure testing procedures (system isolation, pressure buildup)

  Torque application techniques (proper wrench use, sequence)
 Welding operations (if applicable - hot work permit requirements)
 Hydrostatic testing principles (system behavior, relief valve function)
 Pressure gauge reading and interpretation
 Annual medical check-up (hearing, respiratory if exposed to solvents)
HSE Personnel:

 Hazard identification methodologies

 Risk assessment matrices and decision-making
 Incident investigation techniques
 Safety audit procedures
 Regulatory compliance requirements
 Annual advanced training (new regulations, industry changes)

10.2 Induction and Site-Specific Briefing

Initial Site Induction (Mandatory - All Personnel):

 [ ] Site layout and emergency routes

 [ ] Hazard identification overview (major hazards on project)
 [ ] Reporting mechanism (how to report incidents, near-misses)
 [ ] PPE requirements (what to wear, when)
 [ ] Medical facilities location
 [ ] Toolbox meeting schedule (frequency, attendance)
 [ ] Code of conduct and behavior expectations
Activity-Specific Briefing (Before First Task):

 [ ] Hazards for this activity (specific to their job)

 [ ] Control measures (what we do to make it safe)
 [ ] Required PPE (what they must wear)
 [ ] Emergency response (what to do if something goes wrong)
 [ ] Questions and discussion
Daily Safety Briefing (Morning Meeting):

 Weather conditions (any monsoon/weather impacts)

 Activity for the day (what we're doing)
 Hazards to watch for
 Near-miss sharing (if any incidents yesterday)
 Safety goal/focus for the day
11. Incident Investigation and
Corrective Action
11.1 Incident Reporting Protocol
Immediate Actions (Within 1 hour of incident):

1. Render first aid if needed (call emergency services for serious injuries)
2. Secure the scene (prevent contamination, preserve evidence)
3. Notify project manager and HSE officer
4. Report to authorities if required (serious incident, fatality)
5. Do NOT move equipment/materials (unless safety hazard continues)
Investigation Initiation (Within 24 hours):

1. Assign investigation team (HSE officer, department manager, worker

representative)
2. Document the scene (photographs, video, measurements)
3. Interview witnesses (within 24 hours while memory fresh)
4. Retrieve relevant documents (procedures, training records, inspection
logs)
5. Identify root causes (what went wrong, why did it happen)
6. Identify corrective actions (prevent recurrence)
Corrective Action Implementation:

1. Immediate actions (emergency measures, prevent further incidents)

2. Short-term actions (within 1 week, temporary fix)
3. Long-term actions (within 1 month, permanent solution)
4. Follow-up verification (confirm actions completed, effective)

11.2 Near-Miss and Observation Reporting

Encouraged Reporting Culture:

 Near-miss: Any incident that could have resulted in injury, but didn't
 Example: Dropped tool that missed personnel, near-electrocution avoided
by quick action
 Observation: Unsafe behavior or condition not resulting in incident
Reporting Form Elements:

 What happened (description of event)

 When/where (date, time, location, activity)
  Who was involved (personnel, equipment)
 What could have happened (potential injury)
 Contributing factors (why did it happen)
 Corrective actions (how to prevent)
No-Fault Culture:

 Reporting encouraged, not punished

 Focus on finding causes, not blaming individuals
 Safety process improvement, not disciplinary action
 Congratulations for reporting and preventing injury

12. Monitoring and Review

12.1 Safety Performance Indicators
Leading Indicators (Predict future safety):

 [ ] Hazard assessments completed (planned vs. actual)

 [ ] Safe work procedure compliance (observations, audits)
 [ ] Training completion rate (personnel trained before starting work)
 [ ] PPE usage rate (observed compliance percentage)
 [ ] Maintenance work completed on time (equipment availability)
 [ ] Safety meeting attendance (participation percentage)
Lagging Indicators (Historical results):

 [ ] Lost time injury frequency rate (LTIFR = injuries/200,000 hours

worked)
 [ ] Total recordable incident rate (TRIR = all incidents/200,000 hours)
 [ ] Near-miss frequency (incident prevention effectiveness)
 [ ] Near-miss to injury ratio (target: >3 near-misses per 1 injury)
 [ ] Safety audit findings (non-conformances identified)
Target Goals:

 LTIFR target: <1 per 200,000 hours (industry best practice)

 Near-miss reporting rate: ≥1 per week (culture indicator)
 100% equipment maintenance completion (availability target)
 95%+ PPE compliance rate (observed behavior)

12.2 Audit and Review Schedule

Weekly Safety Meetings:

 Attendance: Team leads, HSE officer, sample of crew

 Agenda: Past incidents, upcoming hazards, corrective action status
 Duration: 30 minutes
 Minutes: Documented, shared with team
Monthly Safety Audit:

 Scope: All work areas, equipment, documentation review

 Team: HSE officer + department manager
 Focus areas: PPE compliance, equipment maintenance, hazard control
status
 Report: Findings shared with project leadership
 Corrective actions: Tracked for completion
Quarterly Management Review:

 Scope: Overall project safety performance, trends analysis

 Team: Project manager, HSE officer, client representative
 Metrics: LTIFR, TRIR, incident trends, hazard register status
 Actions: Strategic improvements, resource allocation
Annual Comprehensive Review:

 Scope: Full hazard register update, procedure effectiveness assessment

 Team: External HSE consultant, project team, workers
 Outcome: Revised hazard register, updated procedures for next similar
project
 Documentation: Lessons learned report filed for organizational learning

13. References
[1] Ministry of Labour and Employment. (2024). Occupational Safety and Health
Guidelines for Construction and Industrial Projects. Government of India.

[2] Bureau of Indian Standards. (2024). Safety Requirements for Construction

and Industrial Operations (IS 3956:2024). BIS Publication.

[3] National Safety Council (NSC). (2024). Hazard Identification, Risk

Assessment, and Control Implementation - Best Practices Guide. NSC
Publication.

[4] OSHA. (2024). Process Safety Management of Highly Hazardous Chemicals.

U.S. Department of Labor Publication.
[5] ISO 12100. (2023). Safety of Machinery - General Principles for Design.
International Organization for Standardization.

[6] American Society of Mechanical Engineers (ASME). (2024). Boiler and

Pressure Vessel Code - Safety Standards. ASME Publication.

[7] Niosh. (2024). Confined Space Entry Guidelines and Emergency Response
Procedures. National Institute for Occupational Safety and Health.

[8] Indian National Standards Institute. (2024). Pressure Equipment Safety

Directive - Implementation Guide. INSI Publication.

[9] Confederation of Indian Industry (CII). (2024). Industrial Safety Excellence -

Framework and Implementation. CII Publication.

[10] International Labour Organization (ILO). (2024). Safety and Health in

Construction - Convention and Recommendations. ILO Publications.