GMR KAMALANGA ENERGY LIMITED

Format No : GKEL/OHSMSM/1.12/F-02 HAZARD IDENTIFICATION AND RISK ASSESSMENT (HIRA)

Risk assessment carried out by Siba Mohanty,Amiya Behera,Nityananda Pati,Monish Shah,Debasis Satapathy,Sarthak Rout,Rakesh Biswal,Siddhartha Panda,Satya Prakash Arya,Prakash
Risk assessment number : GKEL/05/OPRN/HIRA/302 Department OPERATION (Name of Team members whome Lenka,Sangram Behera,Manoranjan Satapathy,Hemanta Kerketta,santosh banchor,shaktivel,vigneswaran,ABC Mohanty,Nirod samal,Supravat swain,Pranav
with consultation held ) Behera,Barun Mahakud, Lalu prasad samal,Rashmi ranjan Dash

Assessment Date : 01.03.2023 Next review Date 01.03.2024

Activity/Task ( describe the Task / activity or work in brief) H2 GAS FILLING

Activity/Task type ( Routine/ Non Routine) Routine Condition( N/A/E) N

Base risk analysis by considering Additional/Proposed Controls/ Residual risk analysis by considering
Existing/Curent Controls current control MP /OCP Ref proposed controls

Responsibility
Who might be

Target date
Hazard Class

Risk/ Consequence
harmed (Staff, Personal Protective Equipment Personal Protective Equipment
contractor, visitor, (state type and standard) (state type and standard)

Probability

Probability
Risk Level

Risk Level
Risk Value

Risk Value
Sub Activity/ Task Steps Hazard (Human Injury or ILL Administrative controls

Severity

Severity
pregnant or

(PXS)

(PXS)
Health) Engineering Administrative

(P)

(P)
nurshing women Engineering control (Refer Elemination Substitution

(S)

(S)
etc.) control controls
SOP-GKEL/05/OPRN/302)
PPE Standard PPE Standard

Ensure heater and its on/off Arc suit, Electrical NFPA 70E:2018 & IEC ,
switch are not drenched Hand gloves, safety 61482-2; IS 4770:1991
Taking CO2 in- line Injury due to electrocution Staff, Contractor
Physical Electrical Exposure with water.Tool Box Talk to shoes,Safety Is 15298:2002,IS

TR
2

8
heater in service and Compartment syndrome
be conducted. Training and Helmet,Hi-Visibility/Re 2925:1984, EN 471
awareness to be provided. flective Jacket

Do not stand close to

possible leak points,
Charging compressed Preventive and corrective
air into generator/ Using trolley for maintenance adherance, Cotton Hand Gloves,
Safety Helmet, safety Is 6994:1973, IS
Opening MIV at front High Pressure gas shifting of cylinder. Keeping hydrogen cylinder 2925:1984, Is
and rear of hydrogen Physical Body/ Eye Injury Staff, Contractor shoes, Safety

TR
2

8
pressure regulator and
(H2,CO2,Compressed air) Using designated cage in vertical position.Do not Goggles,Hi-Visibility/R
15298:2002, Is 5983, EN
to place the cylinder. stand close to defective 471
adjusting hydrogen eflective Jacket
pressure regulator cylinders , Tool Box Talk to
be conducted.Training and
awareness to be provided.

Ensure the pipe Boiler suit, Cotton

Taking CO2 in- line connected is in good Do not stand close to Hand Gloves, Safety
possible leak points, Tool IS:15298:2002, Is
heater in service and condition and Helmet, safety shoes, 6994:1973, IS 2925:1984,
charging hot water/ Physical Hot water leakage Burn injury Staff, Contractor Box Talk to be

TR
2

8
Opening CO2 cylinder connection with conducted.Training and Safety Goggles,Hi- Is 15298:2002, Is 5983,
condensate line is Visibility/Reflective EN 471
outlet valve awareness to be provided.
proper Jacket

Housekeeping to be done Cotton Hand Gloves,

Taking CO2 in- line Slip/Trip/Fall due to Safety Helmet, safety Is 6994:1973, IS
heater in service and Physical Surfaces (oily and wet Physical injury Staff, Contractor
properly.Tool Box Talk to be shoes, 2925:1984, Is

TR
2

4
charging hot water surface) conducted. Training and 15298:2002, EN 471
awareness to be provided. Hi-Visibility/Reflective
Jacket

Do not touch in bare hand

Rubber mat to be laid
to the cylinder and the
on floor where
cylinder to be connected pipes during CO2 Cotton Hand Gloves,
Shifting and connecting Cutting/ charging process. Tool Box Safety Helmet, safety Is 6994:1973, IS
CO2 cylinder to Crushing/Striking due to Physical Body Injury due to unloaded from truck.
Physical Staff, Contractor Talk to be shoes, 2925:1984, Is

TR
2

8
manifold/Opening CO2 fall of object (Handling of accidental hit Ensure In-line heater
cylinder outlet valve H2 and CO2 cylinder) in service and hot conducted.Ensuring proper Hi-Visibility/Reflective 15298:2004, EN 471
ventilation of area. Training Jacket
water charged on and awareness to be
cylinder and header. provided.

Cotton Hand Gloves,

Manual Handling Non sparking tools to Tool Box Talk to be Safety Helmet, safety Is 6994:1973, IS
Opening main valve H-2 Physical (Handslip during valve Physical Body Injury Staff, Contractor be used when conducted.Training and shoes, 2925:1984, Is

TR
2

4
& H-4 operation) required awareness to be provided. Hi-Visibility/Reflective 15298:2002, EN 471
Jacket

Opening main valve H-2 Inflammable items like

& H-4/ Opening and oil/hydrogen leakage to be
closing outlet air vent checked in nearby area for
valve of H2 blower, hot work. Use of
inlet and outlet blow Deluge Valve
nonsparking tool. Restricted
down valve of hydrogen healthyness, Spray Safety Helmet, safety
dryer, drain valve of
Staff, Contractor System Healthyness, entry of electronic devices. shoes, IS 2925:1984, Is
Availabilty of Local fire Ensuring no leakage and
Others Fire/ Explosion Burn injury
TR
2

checking by hydrogen leak Hi-Visibility/Reflective

various LLDs, air vent 15298:2002, EN 471
valve of leakage extinguishers, Static detector. Tool Box Talk to Jacket
detector pipeline, and discharge point.
air vent valve of be conducted, Fire alarm
hydrogen pressure healthyness checking
transmitter pipeline & periodically.Training and
humidity analyzer awareness to be provided.

Prepared By Reviewed By Approved By

Area Incharge Section Head Service provider HOD Head-EHS MA Plant Head
 Risk Assessment / Evaluation Criteria

Probability
Probability of causing Harm Code Remarks DETERMINATION OF RISK LEVEL
When probability of occurrence is rare. May possible but is not
Rarely 1 known to have
Severity (S) of Consequences

When probability of occurrence is low. Once/ Twice in a Negligible

Minor
Major Injury/
Permanent
Unlikely (Sometimes) 2 Injury/ Disability / Fatality
year(sometimes) Impact
Illness
Illness
Ailment

Probability(P) of causing harm

When probability of occurrence is moderate. Monthly or few times
Possible (Occasional) 3 Code 1 2 3 4 5
in a year (Occasional)
When probability of occurrence is high. Weekly of few times in a 1 2 3 4 5
Very Likely (Frequently) 4 Rarely 1
month (Frequently) AR AR AR TR TR
When probability of occurrence is very high. More than once a day 2 4 6 8 10
Certain to Occur (Very Frequently) 5 (Very Frequently)
Unlikely 2
AR TR TR TR SR
3 6 9 12 15
3
Severity(S) Possible
AR TR TR SR SR
4 8 12 16 20
Very Likely 4
Severity(S) of Consequences Code Remarks TR TR SR SR IR
Certain to 5 10 15 20 25
Negligible Impact 1 Minor Discomfort/ Minor Pain/ No Injury / Incidents reported Occur 5
TR SR SR IR IR
Minor Injury/Injury with first aid or local medication/Minor illness
Minor Injury/Illness 2 Absence due to injury does not exceed 48 hours
Major Bruise cuts/ Major Injury/Longer Term medication/ Long
Major Injury/Illness 3 term Illness / Absence due to injury exceeds 48 hours
Permanent Disability / Ailment 4 Permanent Disability / Ailment
Fatality 5 Fatality

DETERMINATION OF RISK LEVEL

Risk rating value Risk Level Action required
Acceptable Acceptable
1 to 3 Risk(AR)
Tolerable Risk No additional controls required. Monitoring is
4 to 9 (TR) required to ensure that current controls are maintained
Significant Additional controls measures required & Measures required within
10 to 16 Risk(SR) 6 months
Intolerable
17 to 25 Risk (IR) Stop work until additional control measures are taken
Hazard Class Hazard
Noise
Vibration
High Pressure
Extreme temperature(Cold)
Extreme temperature(Hot)
Instrument Air Exposure
Electrical Exposure
Working at Height
Sharp points/Edges
Physical
Manual Handling
Cutting/ Crushing/Striking by Mechanical action
Entaglement/ Entrapment by mechanical action
Confined Space
Asphyxiation due to poor ventillation
Housekeeping issue
Misuse/Untrained/Unauthorised person
Slip/ Trip/Fall due to poor Structure/ Layout/Design
Slip/Trip/Fall due to Surfaces

Ligtning
Rain
Environment
Terrain(incl.water)
Outdoor work- Insect/animal bites/stings

Hazardous Chemical-Burns-corrosive/ Thermal

Hazardous Chemical-Toxic/Poisonous
Hazardous gases
Chemical Hazardous vapours
Hazardous fumes
Hazardous dusts
Chemical, other

Biological contamination/release
Exposure to moulds, pathogens
Biological Exposure to viruses
Insect/animal bites/stings
Biological, other

Ultra Violet-non-ionising radiation

RF-Non-ionising radiation
Radiation X-ray/gamma-ionising radiation
Laser-emitted radiation
Infrared radiation

Machinery design
Operator posture
Ergonomic
 Ergonomic Workstation design
Seating
Repetitive body movement

Work overload
Harassment
Bullying/Intimidation
Work related stress
Working alone/Lonely working
Work environment
Psychosocial Violence at workplace
Lack of control over one’s work
Non-supportive supervisors or co-workers
Limited job opportunities
Role ambiguity or conflict
Drug/alcohol use at work place
Rotating shift work/Transfers
Reduced productivity

Fire
Other Transport
 Hazard Class
Physical
Chemical
Biological
Radiation
Ergonomics
Psychosocial