Unit IG2: Risk assessment

Part 1: Background

Include in here the organisation’s name* and location* and number of workers. You must then go on to give a description of the main
activities/products/services carried out. You must also describe the area to be risk assessed eg, whole site, and anything else that you
consider relevant (approximately 150 to 200 words):
My organisation is ZENITH ERECTORS LTD. located in cochin which consist of 84 employees.

ZENITH ERECTORS LTD. is a reputed firm in the field of boiler erection, piping related engineering industrial projects, maintenance shutdown project related to
oil field engineering. company focuses their projects in south India.

Presently an ongoing project of 16Ton boiler plant is constructing in pondichery India. The total area of the site is around 20 acres and almost 45 workers are
involved in this project including technicians, supervisors, engineers and other staffs.

Project includes activities such as erection of package type boiler which probably includes lifting and installation of equipments, piping erection which includes
cutting, grinding, welding operations. also underground pipelines where installing for water supply which is done by excavation for trenches.There is a material
yard provided nearby of the site where different equpiments, materials, pipes of different grades and sizes, Mild steel columns, angles are arranged for work. The
working time is from 8.00 am to 5.00 pm on weekdays and provide holidays at weekends. Sometimes have overtime work after scheduled working time for some
important activities. The project manager is responsible for Health and Safety and Safety incharge personal give direction for achieving good health and safety
culture.

The risk assessment will cover the area of boiler unit area, maintenance department and material yard.

You must now give a brief outline on how you completed the risk assessment (approximately 200 words):
I started internet surfing for information about ILO had any codes of practice related to occupational safety and health at work in the mechanical as well as oil and
gas field. The British HSE website (http://www.hse.gov.uk/search/constuction)had adequate sources of information for example, site safety, working at height and
guidance for health and safety in the construction industry. Refered books published such as International Health and Safety at work(Third edition from Phil
Hughes MBE and Ed Ferrett) and prepare notes from these information and consulted with the project manager to know the different process.

With the knowledge that I occured from the information and my studies, I visited the site where the work is going on. I walk through the working area and gathered
information of the activies carryout there by visual inspection. From the permission granted by the site engineer I got a chance to interact with some workers at
rest brake. From my enquiries I found how much they where aware about risk perception and hazards in there work place, precautions to prevent accident, ill
health conditions. procedures to comply with emergency situation etc. Also checked accident records and sickness absence records to understand the causes of
accidents and accident rates, ill health conditions.

Learner number: Learner name: Page 1 of 17

* If you’re worried about confidentiality, you can invent a false name and location for your organisation but, all other information provided must be
factual.

Learner number: Learner name: Page 2 of 17

 Part 2: Risk Assessment

Organisation name: Zenith Erectors

Date of assessment:
Scope of risk assessment: Boiler unit area, Maintenance department and material yard.

Hazard category Who might be harmed
and hazard and how?
Work at height Erection gang, supervisors,
other employees, or anyone
Risk of fall from who where at the place of
height while erection ongoing erection area.
of steel columns,
beams, Chances of fall from height
Horizontal and if they worked in unsafe
vertical bracings, method or improper use of
istallation of safety harness. inadequate
equipment. control measures will
increase the risk level and
dangerous occurance.
What are you already doing? What further controls/actions are Timescalesfor Responsible
required? further actions person’s job
to be completed title
(within …)
1.Scaffolding is provided. 1.Instruction,information, training should 1 week Project
be given regularly. manager(2, 8,
2.PPE's such as safety belt with 13)
fall arrester, safety helmet, safety 2.A safe system of work to be develop 1 week
shoes etc are given to the for the most risky erection work. Safety
workers. incharge(10, 9,
3.possible safety nets should be 2 weeks 12)
3.Permit to work system to introduced below the workplace to
carryout work. prevent falling of objects. Project co-
ordinator(1, 3,
3.Temprory handrails are 4. horizontal life line should be 1 week 6, 11)
implemented. introduced for anchoring.
Project
4.works carryout under 5.Check the handrails, ladders, gratings 2 days engineer/super
supervison and instructions from are fixed properly and firmly. visor(4, 5, 7)
foreman.
6.provide assistants and regular
communication system for lone working
people who might worked at 1 day
height.(example: some grinding ,cutting
welding work activites will done by
individuals at height)

7.Regular checking the control measures

like scaffolding, safety equipments,for Daily
safe work.

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 8.Stop the work if it includes any unsafe
conditions such as bad weather or in 1 month
emergency situation.(Develop an
emergency plan give training and
conduct mock drill for evacuation and
multiple casuality accident exercises
should be practised if they are
foreseeable.)

9.entry exit only through staircase.if find

improper pathway in use enclose the 1 week
area and take necessary action to the
workers after warning.(for same to
improper method of work)
Daily
10. ensure that PPE provided to the
workers are used in proper manner.

11.competency of the workers efficiency,

ability, experience should confirmed after 1 day
stringent checking when deployed to the
work.(example: fear of height, work skill,
physical and mental stability by task
analysis)

12. Improve workers awareness on Daily

health and safety issues by conducting
tool box talk or health awareness
program.
1 month
13. Tower scaffolding must be
implemented for the side structural work
which includes toe board, platform, cross
bracing, out triggers, locking wheel and
internal ladders.

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Fire welding workers,
technicians, helpers who
Hot work involved in the work and
Includes of pipes other persons who
welding, grinding accidently come in the
activities at different area.(may be staff,
places of the site. trespassers etc..)
Injuries and illness may be
caused by burning, eye
damage from arc produced
by the welding torch, skin
injury and inhalation of
fumes and dust produced
during the task.
Lone working Work is carried out without
any supervision, so the
Found worker worker may be in danger at
cutting pipes and anytime.
grinding at the edge
opening face in yard
area. He is a regular
worker in yard.
Learner number: Learner name:
1. Isolate the area and make 1. check the work equipment (welding Daily Safety
sure no combustible materials machine, grinding machine)and cables incharge(2, 4,
are nearby of the work. regularly before work is carried out. 5, 7)
2.permit to work system to carry 2.Display sign boards should be placed 1 week Purchase
out activities. at work site. department(6)
1 day
3.Appoint competent person for 3.proper storage and handling of Project
welding after welder testing combustible materials. supervisor(1, 3,
approval. 1 week 8)
4.Develop work plan procedure for safe
4.Personal protecting work.
equipments are adequate.
5.Enure all safety precautions are 1 day
5.Fire mock drill for fire undertaken and personal protective
prevention and protection should equipment are using in proper manner.
be carried out periodically.
6. Fire extinguisher 2-A:10-B:C must be 1 week
put in nearby of hot working zone.
7.workers should get training for 3 days
handling and storage of equipment, use
of PPE and to comply with proper work
procedures.
2 days
8.Good housekeeping should be ensure.
1.worker data is entered in the 1. supervision needed to monitoring the Safety
logbook of yard. work, proper material stacking and giving 1 day incharge(2, 8,
direction to the worker. 11)
2. provide welfare facilities like
drinking water and washing 2.provide first aid kit. 2 days Project co-
station is at nearby of the work. ordinator(4, 5,
3.Remove scraps and other waste 9, 10)
2. communication through mobile occured during the work regularly.(house 1 day
phones with supervisor. keeping suggested). A helper should be Project
provided to the worker for work supervisor(1, 6,
3. Face mask and other relevant arrangement and for cleaning. 7)
PPE's like helmet, goggles etc
are provided. Yard
2 days supervisor(3)
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 4.Sign boards are adequate and
location is well known to worker.
5.Worker knows the emergency
procedures and competent to do
the work.
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4. consider physical and mental stabillity
of the worker and job rotation system
implemented in yard. 1 day
5. Make sure that worker not involving in
other activities.
1 day
6. Ensure proper use of ppe and clothing
should match the job profile. Ensure that
safety mask and goggles are using. Daily
7.Inspect the work area and ensure the
work arrangements are adequate.
3 days
8. Give training, Instruction , information
about the material movements,
locomotives and other activities in the
yard so that worker will be vigilant to
handle any situation.
5 days
9.Competency of the worker to comply
with health and safety procedures and
consider factors like health condition,
medical fitness, strength ability to do job,
experience etc.
10.Ensure the condition of the
equipment used for working, check the Daily
grinding machine, guard is placed to
prevent from injury cut. ensure worker
aware about proper working method and
working as per suggestion made by
manufactures operational manual. Daily
11. Avoid lone working if possible.
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Vibration Jack hammer is a power
tool.It produced continous
Demolishing of vibration during its
cement mortar floor operation. Workers who
RCC(reinforced engaged with demolishing
cement concrete) work using jackhammers
using 5 ton jack will effect hand vibration
hammer. Large also his whole body get
amount of vibrations vibrated. exposure to
is produced from the vibration will lead to Hand
jack hammer Arm Vibration
Syndrome(HAVS),
Symptoms include muscle
weakening, joint damage,
numbness, tingling, and
loss of nerve sensitivity.
prolonged exposure that
with whole body will lead to
whole body vibration
syndrome(WBVS) causes
headache, stomach
problems and loss of
balance etc..
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1. Men at work sign boards are
placed nearby.
2.Mask provided to prevent
inhalation of dust.
3.Work carried out under
supervision.
4.Rest work brakes provided
after regular time interval.
5.Different pathways provided for
other workers.
6.Entry of others like
trespassers, other workers, staffs
are prohibited by proper
barrication.
7. Welfare facilities are
provided.(drinking water,
washing station are nearby)
8.cotton gloves provided.
1.Anti vibration gloves and warm clothes 4 days Safety
should be provided to the incharge(4, 7)
workers.(vibration gloves absorb
vibration energy produced from the Project co-
power tool) ordinator(5)
2.Regular maintenance of the power Purchase
tools(check oil level, cleaning, sufficient Daily department(1)
grease inside bit holder) for safe use and
tool handling during work.
Maintenance
3.maintenance documents are kept in Daily department(2,
record. 3)
4.Physical capability of the worker Project
should be identified( Jackhammer is a supervisor(6, 8,
heavier equipment and operation is 2 days 9)
difficult so it needs special care to
handle during operation)
5.Concrete waste produced during
demolishing should be removed from
work place and damped in a proper 2 days
place and it will not disturb the power
tool handling workers also others.
6. Ensure that not individual are carrying
out jack hammer work continously. job 1 day
rotation may be implemented.
7. Training should be provided for safe
use of equipment as well as the 1 week
importance of personal protectives.
8.Reduce the exposure time of worker. 2 days
9. Interact workers to ensure that they
have any any problem, ill health situation 1 week
with vibration exposure.
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Material/load The operator and other 1. Operator follows the 1. supervisor and operator must ensure 3 days Project
handling equipment. persons who where at the instruction of yard supervisor. that pick and carry crane always lift safe manager(3)
place of lifting or come load for loading into the truck.
Pick and carry crane across the crane path. 2. Locations details and Safety
used in the yard for idenfication number of the 2. Inspect the yard and find incharge(2)
loading the material Obstruct the visiblity of materials are provided by the obstucles/barriers that where in the 3 days
to truck and for operator while material is supervisor. pathway and immidietly remove or Yard
material stacking in lifted and carrying too much replace it. supervisor(1, 4,
the yard. yard load will causes accidents. 3.Details of the operator, truck 5, 6, 7, 8)
consist of 6 acres Immidiate reverse driver, supervisor, helpers are 3. provide better road(uneven ground
land area where movement of the crane at registered in the log book of should be cleared) for smooth operation 2 week
different types of turning inside yard will yard. of crane and truck.
materials are cause harm to others who
stacked in various came across. 4. Locations inside the yard is 4.Proper speed limit should be
location. A seprate separately numbered and implemented inside the yard (sign 1 week
pathway is provided identification sign boards are boards should be placed showing speed
inside the yard for placed in different places so that limit)
locomotive operators can easily pick up the
movements and for spot. 5. Nylon lifting sling belt used for lifting
material shifting. load should be checked 3 days
5.material stacking details are regularly.(visually inspect and verify it
kept in records. and ensure that does not have any
damage, also ensure the load barring
6.Reverse horn, hazard light of capacity of the belt.)
the crane are working properly. 1 day
6. Special care should be taken while
7.maintenance of Pick and carry loading in to the truck. Material may slip
crane and truck is done and fall down from the truck.
periodically by a trained 3 days
mechanic. 7. Ensure good housekeeping before
leaving the yard. Changed in location of
the material should be rearranged.
2 days
8.Only allow to load the truck as per the
load capacity of the vehicle and report
to the yard supervisor when the truck
carrying the load reached the site.

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Slip and trip Maintenance staffs, vehicle 1.Displays are provided at 1.House keeping should be improved. 3 days Project
drivers, operators and other maintenance booth. manager(7)
Spilling of diesel and staffs who walk through the 2.Inspection carried out periodically,
oil at maintenance area chances to slip and 2.Amount of diesel kept in the Identify issues and work for improvement 1 week
area of vehicles, can causes minor injury, booth and regular maintenance such as disposal of wastages and for Maintenance
crane and other fractures etc.. work details are registered in the proper workplace arrangement. work
equipment. record book. incharge(1, 2,
3.Maintenance work is carried 3. Proper use of hand diesel pump and 2 days 3, 5, 6)
out using operation manual. PPE's

Electricity Electrician, supervisor,
other staff or employees
Panel board and who operate panel board
cabling of different and maintenance
equipment, earthing, equipment such as water
equipment which run pump, dosing pump, blower
4.Regular reports are given to 4. spill kits must provided and absorbent Purchase
purchase department and the pads should be used for cleaning of oil 1 week department(4)
daily usage of diesel and oil are spills.
set and limited.
5. Supervision and monitoring of 1 day
5.Vehicle details are entered in activities.
separate log book.
6.Diesel barrels should be kept
6.Personal protective equipment separately from other tools and 1 week
such as hard gip safety shoes, equipment.
gloves and hand washing
facilities are provided. 7.5S methodology should be
implemented, which has done by,
7.Hand diesel pump is using to (a)sort
transfer fluid. (b)set in order
(c)shine
(d)standardize 1 week
(e)sustain
It gives idea about organizing a
workplace, identifying of storing items,
maintaining the area, sustaining the new
items and the employees understand
how should they can done the work in a
proper way.
1.Danger signage sticker 1. Place a fire extinguisher near the 1 week Electical
provided panel board. engineer/super
visor(1, 2, 3)11
2.Seprate MCB are provided for 2. Provide training, instruction,
different circuit in the panel information to the employees dealing 1 week
board. with electricity.

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by electricity such as will likely to cause electric
water pump,dosing shock and may cause 2.Intermidiate 3pin industrial 3. Check the electrical connection
pump, for water death in worst socket and the main switch with periodically. 2 week
filter, blower for case.(electrocution) high amperage capacity(32A)
maintenance booth and RCB is provided.
station are checked.
4.Energy meter connected with
parallel circuit for knowing
regular power consuming rate.

3.Breaker switch with fuses are

given.

4.Indicating lights and operation

switches provided are adequate.

5.Armed cables(having double

insulation polyvinyl chloride
material within middle portion
steel wired armoured and after
second insulation inside which is
the electricity conducting copper
which may be solid or stranded)
provided for water pump and for
blower through cable tray which
is firmly fixed and did not
interfere anything in its pathway.

6.panel board, motor, blower are

well earthed and are well
maintained.

7.Panel board and other

electrical equipments are well
guarded and is placed far from
flammable substances.

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Movement of All employees on the site.
people and vehicles.
Over speed without
Movement of following sign boards and
different vehicles, harsh driving may leads to
trucks carrying load collision with pedastrians
to construction site. and with other vehicles.
over loading and
overturning of the vehicles
may causes accident.
Employees came across
the moving vehicle may hit
and causes minor or major
injury and may leads to
death.
Hazardous Maintenance staffs ,
substances technicians who handling
with these fluid substances
Use of oil, paints daily are affected.
and diesel in
maintenance Skin irritation may occur
workshop. with continous exposure of
diesel, Also irritating to
eyes, causes dermatitis.
also badly affect respiratory
system (asthma, lung
disease) and carcinogenic.
Learner number: Learner name:
1. convex traffic safety 1.Improve road surface condition uneven 1 month Project co-
mirror(road safety mirror) road surface must be repair. ordinator(1)
installed at the entry of two way
road inside site premises. 2.Induction training must be given to the
new employees which must includes 3 days Safety
2.sign boards are placed at instruction and information about incharge(2, 3)
dangerous turnings and at the location, walkways, crossing etc...
different locations of the road.
3. Barrication provided at workplaces
3.visitors vehicle parking area is and ensure that no obstacles are in the 2 weeks
provided. pathways.
4.Site speed limit is set at 15mph
5.seperate site accessing entry
gate is provided for pedestrians
and vehicles.
6. Visitor's purpose details are
scribbled in the registor book and
id card is provided.
1. Eye washing facilities 1.Good housekeeping must ensured. 1 week Maintenance
provided. work
2.Reduce the time of exposure and incharge(1, 2,
2.Safety goggles, safety shoes adequate rest brakes should be 3 days 3, 4)
gloves and face mask, are provided.
provided. Safety
3.Ensure safe disposal of the hazardous 4 days incharge(5)
3.Dilution ventilation provided. substance.
4.half mask respirator is provided 4.contaminated cloths and equipment
while spray painting. should be kept seperately and clean in 3 days
regular basis.
5.sign boards are provided at
work area. 5.Health surveillance should be
conducted. 2 week
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Noise Mechanics and other
employees working near
Exessive sound will be affected. physical
produced from the effects while exposing for a
blower/compressor prolonged period will cause
room. temporary reduction in
hearing sensitivity,
temporary ringing in the
ears, noise induced hearing
loss, tinnitus etc.. and
psychological effects may
be stress, difficult
concentrating, increased
errors.
1. periodic check up is carried 1. Sign board should be placed near by. 1 week Maintenance
out such as oil level, cleaning of work
filters, dust removal, allignment 2.check the operation manual for safe 1 day incharge(1, 2,
of motor belt etc.. working method of equipment. 3)
2. ear muff is provided. 3.Noise absorbant screen should be Safety
fixed in the wall. 2 week incharge(4)
3.personal protectives like face
mask, hand gloves etc are using 4. give instruction, information about ill
while checkup. health effects of noise in induction. 3 days
4.silencer to reduce noise is
inbuilted in the blower.
5.air hose are well fitted to the
out let of the blower.

6. blower is well anchored to the

concrete floor so vibration is
less.

7. control valve implemented in

the air flowing line and pressure
gauge is also installed in the
equipment so working procedure
is more easier and comfortable
to mechanic.

8. Only operational for a limited

time.

Health ,welfare and All employers working for
work environment. prolonged time in day time.
Workers daily According to Centre for
exposure of daylight. Disease Control and
Prevention(CDC) increase
in temperature may result in
excessive loss of water and
1.All employees are allowed for
rest brake at periodic intervals.
2.adequate toilet and washing
facilities are provided.
3.chlorinted drinking water is
stored in the water tank at work
place.
1. job rotation for some activities which 2 days Project
prolonged for long time such as workers supervisor(1)
who engaged with erection.
2.sunscreen with an SPF(sun protection
factor) of minimum 30 will be provided 2 days Safety
to employees who engaged with work at incharge(2, 3)
height for long time.

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 salt from the body usually
by sweating.
Symptoms may be
headache, weakness,
nausea, irritability, thirst,
decreased urine output,
heavy sweating etc.. also
sun burn, heat rash, skin
cancer, head stroke,
wrinkles are the worst
scenario.
Hazardous Employees who deals with
substances insulation material and who
engaged with the cladding
Dust process(rockwool insulation
Cutting and installing sheet fixing to the pipe and
of glass fibre and tied up with wire string) and
mineral wool for visitors, other staff who
piping insulation came there will be affected.
produce hazardous
substance Inhalation of high level dust
may cause inflammation to
nasal and result in cough,
sneezing, itchy nose, throat
infection. allergic dust may
result difficulty in breathing,
chest tightness, asthma etc.
Dust also may irritant to
eyes and skin allergies.
Equipment handling Store keeper, employees,
staff who came in the store.
Working
equipments, welding Falling of object from the
equipment, gas shelf may injured the
cylinders used for person, inhalation of
welding, chemicals, hazardous chemicals will
Learner number: Learner name:
4.filtered drinking water and cool
water available nearby to the
site.
5. maintenance and good
housekeeping is carrying out.
1.Normal face mask and other
relevant PPE's provided.(safety
goggles, hand gloves etc..)
2.workplace area properly
barricaded.
3.Welfare facitilies are provided.
drinking water.
4. work carried out under
supervision.
1. Material stacking record is well
maintained.
2.provide proper labelling of
different objects in shelf.
3.Health surveillance program should be
conducted which includes activities like 2 weeks
checking medical records, safety
awareness, contamination, work stress,
environmental factors etc..
1.N95 air purifying respirator should be 3 days Safety
provided. incharge(1)
2. Full time supervision must ensure 1 day Project
supervisor(2,
3.give information to workers regarding 3)
dust effects to our body and advice them 1 day
about the importance of hygiene.
1.Arrange material as per work 2 week Store
order(example: welding related keeper(1)
equipments kept separatly, grinding
equipments such as grinding wheel,
grinding machine kept seperately.)
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paint, PPE's, first cause damage to several
aid kit, grinder etc in respiratory organs, dealing
the store room. with inflammable material
such as hazardous paint,
gas in improper way will
lead to danger.
3.hazardous materials like
chemicals, paints are separately
kept.
4.Material check list is available.
5.some important material
standards and hazardous
subtance details are displayed.
2.provide seprate provision for
inflammable gas cylinders.(Do not 1 month Maintenance
messd up with other things. Cylinders engineer(2)
should be well chained and should
placed in a properly fenzed cage.provide
a locking door for the cage and must be
isolated.)

6.cctv camera installed for

surviallance.

7.only authorised person are

allowed to enter inside.

8.proper cleaning, ventilation are

provided.

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 Part 3: Prioritise three actions and justification for the selection

You must pick the three highest priority/most urgent actions and justify your choice. Your justification must include moral, legal and financial arguments
(500 to 700 words); consideration of likelihood and probable severity of injury, ill-health and/or harm (150 to 250 words); description of how effective each
action is likely to be in controlling the risk (250 to 350 words)

The highest prioritised actions are,

1.Build a tower scaffolding tower near 2 tier structural of erection area which includes proper platform, toe board and proper handrail. Make sure access
and exit are appropriate while in emergency.(Hazard category 'work at height')

2.Purchase N-95 air purifying respiratory mask for those who dealing with rock wool insulation material.(Hazard category ' Toxic dust')

3.Provide separate provision for the storage of gas cylinders used for welding

Zenith Erectors Ltd has a policy, obligation and moral duty to ensure safety of their employees by all means. We know 'The first wealth is health.' It's our
moral and ethical reason to reduce accident, ill health and disease rate. Each and everyone in our organisation helps to achieving our goal and
they are our essential employees to fulfil it. Mental, stress, fatigue condition of an employee in a work condition with less facility will adversely
affect the work as well to the health of our workers. Injuries/ill health will create negative impact to staff morale and workers may lose the job in
some cases where the injuries may lead to a permenent disability and it will intern affect their family income too. To reduce this our organisation
must provide adiquate facility and provision to do work with in a standard health and safety management system.

Financial/economic issues faced by Zenith erectors Ltd includes work related illhealth/disease, direct and indirect cost followed by accidents(fall from height
with improper work method and avoidance of safety measures are at high alarming rate usually in construction erection work now a days.)Increased rate of
minor and major injuries causes high financial cost to the organisation which may happened by work pattern, work environment and work load. Avoidance
of certain basic safety arrangements will lead to severe consequences like fire blast occured from cumbustable material causing life threatening major
accident will be a huge financial problem to the firm. So proper equipment and provison should be allocated for safe working.

Enforcement action such as prohibition notice, warning letter would be recieved from the authority for not completing the safety requirement
അഅഅഅഅഅഅഅഅഅഅഅ with in certain time period.(sometimes not complying with safety regulation for

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Part 4: Review, communicate and check

You must now give a review date for your risk assessment and say why you have chosen this date (10 to 50 words).

You must now indicate how the risk assessment findings will be communicated (including who needs to know the information) (100 to 150 words).

You must now indicate how you will follow-up on the risk assessment to check that the actions have been carried out (100 to 150 words).

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Learner number: Learner name: Page 17 of 17