SAFETY

HEALTH
EMD BASELINE RISK ASSESSMENT ENVIRONMENT
& RISK
ROUTINE MAINTENANCE
BASE LINE RISK ASSESSMENT

RISK ASSESSMENT TEAM MEMBERS DEPARTMENT TOOLS & EQUIPMENT

Drill machines, Low Voltage Testers, HV Testers, Screw drivers,

Electrical Maintenance Department (Ext 267, Ext 275, Primary and Secondary injection kit, Megger tester, Spanners, Hack
S.Neeli,Samuel & Larona, P.Koloi, Aniket, Thuso M, Shell Ngele, Lefutswe, Isaac M
Ext 271) saw, Pliers, Side cutter, Pipe wrench, Step ladder, Allen keys,
Scaffolding, Potables Earths, Testers and Safery harness.

OCCUPATIONS INVOLVED ACTIVITY / TASK ACTIVITY DESCRIPTION / OBJECTIVE

Engineers, Technicians, Artisan, Artisan Assistant and SHE Officer, SHE REP and External parties System Maintanance and repairs Ensure high plant availability and reduce equipment down time

After
Before After
Additional
Controls Controls
Controls

Risk Score* (S x L)
Likelihood (L)

Likelihood (L)

Likelihood (L)
Risk* (S x L)

Risk* (S x L)
Severity (S)

Severity (S)

Severity (S)
Harm / Impact
Key Job Steps /Task Hazard/Aspect Initial Controls Additional Controls
&
How it can happen

LIGHTING SYSTEM

Skilled manpower deployment, Regular

Fall from height leading to
inspection of Safety harness, Use of
Maintenace of Indoor and Outdoor injuries with potential for
Working from heights 5 4 20 scaffolders and Safety harness,Training 5 3 15 Safe Working Procedure (SWP) 5 1 5
lighting fatality for heights above
to the employees, PTW, Proper
5m
Ladders

Inspection Insulation of Tools to be

Electrocution from contact used. Use of insulated tools, skilled
Electric Insulation gloves, Use of metal
with live cables / capacitor manpower deployment, Pre task risk
Buldged / faulty capacitor 5 4 20 5 2 10 free toe cap boots with non-conductive 5 2 10
Flashover leading to assesment, Training of technicians.
electric shock resistant sole.
injuries / fatality Inspection of Safety harness,
Insulated/rubber Ladders, PTW

Printed copies are not document controlled.

 Inspection of Tools. Use of insulated
tools, skilled manpower deployment,
Electrocution from contact Electric Insulation gloves, Use of metal
Pre task risk assesment, Training of
Bare electrical conductors with live cables leading to 5 4 20 5 2 10 free toe cap boots with non-conductive 5 2 10
technicians. Inspection of Safety
injuries / fatality electric shock resistant sole.
harness, Insulated/rubber Ladders,
PTW

Maintenace of Indoor and Outdoor Use of tool vest, proper communication,

lighting Sheeting of work area or use of
Material/Tools falling from skilled manpower deployment,Training
Property Damage 4 4 16 4 3 12 Meshes at point of work. Tethered 4 2 8
height of technicians. PTW, Proper storage of
Tools. Safe work procedures
tools

Use of tool vest, proper communication,

Sheeting of work area or use of
Material/Tools falling from Tools falling from height skilled manpower deployment,Training
4 4 16 4 3 12 Meshes at point of work. Tethered 4 2 8
height leading to severe injuries of technicians. PTW, Proper storage of
Tools. Safe work procedures
tools

Printed copies are not document controlled.

 HV / LV BREAKER AND
SWITCHGEAR

Authorised persons, proper tools &

Material falling from height
Material falling from height 4 3 12 tackles, Training awareness, Inspection 4 2 8 Maintaining SMP,PPE 4 1 4
leading injuries
of trolleys

Insulated mats. SMP, Use of Electric

Electrocution, Electric Use of proper tools, sufficient lighting,
Insulation gloves, Use of metal free toe
Live Electric Wires shock if not discharged 5 4 20 good communication, Usage of HV 5 2 10 5 1 5
cap boots with non-conductive electric
leading to injuries / fatality detector
shock resistant sole.(PPE)

HV/LV Breaker & switch gear

Maintenance / repair Exposure to dust leading to
Dust extraction system, Wearing of
Coal/Ash Dust repiratory Infections / lung 4 4 16 4 2 8 Training awareness.SMP 4 1 4
approved safety clothing, Toolbox talk
damage

Use of proper tools, good

communication, Usage of Scaffold/ step
Falling from height leading Training awareness, Safety tools
Working from height 5 4 20 ladders, Supervision of Senior 5 2 10 5 1 5
to injuries / fatality usage,SMP
Authorized person.Wearing of
approved safety clothing

Use of tool vest, proper communication, Training of technicians. Inspection of

Material falling from height Property Damage 2 4 8 skilled manpower deployment, 2 3 6 Safety harness, Ladders, Tools. Safe 2 2 4
inspection of trolleys work procedures

Tool Box talk, ensure for discharge of

Electrocution, Electrical
LV/HV panels,use of std electrical hand Training awareness, Arch flash suit to
Live Electric Wires burns / Electric shock 5 4 20 5 3 15 5 2 10
gloves, Safety tools usage, use of be provided, SMP
leading to injuries / fatality
competant personnel
Maintenance / repair of HV & LV
feeders

Dust inhalation leading to Dust extraction system, Tool Box talk,

Dust 3 3 9 3 2 6 Training awareness, proper ventilation 3 1 3
respiratory infection Use of dust mask

Printed copies are not document controlled.

BLACK START DG AND
EMERGENCY DG SET

Use of Insulated tools, sufficient

Electrocution, Electric
Live electric wires and lighting, good communication, Training awareness,Providing Insulated
shock leading to injuries / 5 4 20 5 3 15 5 2 10
Electricaly charged batteries Deploying skilled man power, Wearing tools.
fatality
of approved electrical gloves

Use of proper tools, Pre task risk

assessment, Deploying skilled man
Acid spill leading to body Training awareness, SWP, Chemical
Acid 3 4 12 power,Wearing of approved PPE (Acid 3 3 9 3 2 6
Battery maintenance burns / eye injuries spill kit, Follow MSDS.
resistant overalls / gloves / Apron /
Goggles).

Sufficient lighting,Pre task risk

Dust / Gases (hydrogen Dust inhalation, Gas assessment, dust extraction system,
Exhaust Fans, Providing tools of
Sulfide, sulfur dioxide and inhalation leading to 3 3 9 Deploying skilled man power, Training 3 3 9 3 2 6
approved type.
Hydrogen) Respiratory problem awareness, Wearing of approved safety
clothing

UPS , DC SYSTEM AND

BATTERY

Use of Insulated tools, sufficient

Electrocution, Electric
Live electric wires and lighting, good communication, Training awareness,Providing Insulated
shock leading to injuries / 5 4 20 5 3 15 5 2 10
Electricaly charged batteries Deploying skilled man power, Wearing tools.
fatality
of approved electrical gloves

Use of proper tools, Pre task risk

assessment, Deploying skilled man
Acid spill leading to body Training awareness, SWP, Chemical
Acid 3 4 12 power,Wearing of approved PPE (Acid 3 3 9 3 2 6
Battery maintenance burns / eye injuries spill kit, Follow MSDS.
resistant overalls / gloves / Apron /
Goggles).

Sufficient lighting,Pre task risk

Dust / Gases (hydrogen Dust inhalation, Gas assessment, dust extraction system,
Exhaust Fans, Providing tools of
Sulfide, sulfur dioxide and inhalation leading to 3 3 9 Deploying skilled man Electrocution,Electric
power, Training 3
shock leading
### to injuries / fatality 3 2 6
approved type.
Hydrogen) Respiratory problem awareness, Wearing of approved safety
clothing

Printed copies are not document controlled.

 Use of Insulated tools, sufficient
Electrocution, Electric
lighting, good communication, Training awareness,Providing Insulated
Live Electric Wires shock leading to injuries / 5 4 20 5 3 15 5 2 10
Deploying skilled man power, Wearing tools.
fatality
of approved electrical gloves
Maintenance of UPS

Dust inhalation leading to Dust extraction system, Tool Box talk,

Dust 3 3 9 3 2 6 Training awareness, proper ventilation 3 1 3
respiratory infection Use of dust mask

Use of Insulated tools, sufficient

Electrocution, Electric
lighting, good communication, Training awareness,Providing Insulated
Live conductors shock leading to injuries / 5 4 20 5 3 15 5 2 10
Deploying skilled man power, Wearing tools.
fatality
of approved electrical gloves
Maintenance and repairs of DCDB

Dust inhalation leading to Dust extraction system, Tool Box talk,

Dust 3 3 9 3 2 6 Training awareness, proper ventilation 3 1 3
respiratory infection Use of dust mask

GENERATOR

Use of Insulated tools, sufficient

Electrocution, Electric
lighting, good communication, Training awareness,Providing Insulated
Live Electric Wires shock leading to injuries / 5 4 20 5 3 15 5 2 10
Deploying skilled man power, Wearing tools.
fatality
of approved electrical gloves

Property damage, due to

Use of tool vest and proper tools,
tools falling into rotating Training awareness, Supervision from
Generator carbon brush replacement Property damage 3 3 9 sufficient lighting, Deploying skilled man 3 2 6 3 1 3
equipment while replacing Sr Engineer who is authorised to Work.
power, Good communication
the brushes
Sufficient lighting, good
Entangled by rotating communication,Deploying skilled man
Moving machinery equipment leading injuries / 5 4 20 power,Competant person,wearing of 5 2 10 Training awareness 5 1 5
fatality approved safety clothing, use of proper
tools,

Printed copies are not document controlled.

AIR CONDITIONERS AND
HVAC (Heating, ventilation
and Air conditioning)

Use of Insulated tools, sufficient

Electrocution, Electric
lighting, good communication, Training awareness,Providing Insulated
Live conductors shock leading to injuries / 5 4 20 5 3 15 5 2 10
Deploying skilled man power, Wearing tools.
fatality
of approved electrical gloves
Material falling from height Training awareness on proper material
leading to Equipment 3 3 9 handling, Deployment of skilled 3 2 6 SWP 3 1 3
A/C Maintenance and repair damage manpower, Use of tool vest
Material falling from height
Usage of Scaffold/ step ladders,
Material falling from height Deployment of skilled manpower,
5 4 20 Wearing of approved safety clothing, 5 2 10 5 1 5
leading to injuries / fatality Training awareness,SMP
use of proper tools
Dust inhalation leading to Dust extraction system, Tool Box talk,
Dust 3 3 9 3 2 6 Training awareness, proper ventilation 3 1 3
respiratory infection Use of dust mask
Conducting tool box talks, Skilled man Using proper Tools & tackles, Periodic
Leading to severe injuries,
Fire
skin burns
4 4 16 power, keeping fire extinguisher near by, 4 2 8 inspection of Tools, Deploying skilled 4 1 4
area barricading. manpower, Training, SMP
Excessive light leading to
Light intensity 4 3 12 Deployment of skilled manpower 4 2 8 Training, PPE 4 1 4
impaired vision
Brazing
Pre task risk assessment, proper
Fumes inhalation, Gas
ventilation, deploying skilled man
Fumes inhalation leading to 3 3 9 3 3 9 Use of gas mask 3 2 6
power, Training awareness, Wearing of
Respiratory problem
approved safety clothing

HV/LV MOTOR

Proper Discharging the system before

Electric shock due to work, Supervision, Use of electric
residual voltage if fails to insulation gloves, Tool box talk, Pre
Cable stored capacitive charge 5 4 20 5 3 15 Training 5 2 10
discharge after isolation task risk assesment, Strict adharance
leading to Injuries / fatality of Electrical safety rules, Deploying
skilled Manpower.

Material falling from height Training awareness on proper material

leading to Equipment 3 3 9 handling, Deployment of skilled 3 2 6 SMP 3 1 3
damage manpower, Use of tool vest
Material falling from height
Usage of Scaffold/ step ladders,
Maintenance of HV/LV Motor Material falling from height Wearing of approved safety clothing,
5 4 20 5 2 10 Training awareness,SMP 5 1 5
leading to injuries / fatality use of proper tool,Deployment of skilled
manpower

Printed copies are not document controlled.

Maintenance of HV/LV Motor

Can lead to occupational Deploying skilled man power, MSDS,

Safety solvent (Cleaning diseases due to Wearing of approved safety clothing, Training awareness, SMP, Chemical
3 4 12 3 3 9 3 2 6
Chemical) inhilation,ingestion and (Acid resistant overalls / gloves) use of spill kit.
penetration through skin proper tools, good communication,

Dust inhalation leading to Dust extraction system, Tool Box talk,

Dust 3 3 9 3 2 6 Training awareness, proper ventilation 3 1 3
respiratory infection Use of dust mask

ESP SYSTEM

SMP, Supervision, External Skilled Man

Electric shock leading to power, Using rated tools & tackles, Pre-
Live Electric Wires 5 4 20 5 2 10 Risk Assessment, Training awareness 5 1 5
injuries/fatality check of Tools, use of Electric insulation
Hand gloves.PTW, Tool box talk
ESP Hopper heaters Checking &
replacement
SMP, Supervision, External Skilled Man
power, Using rated tools & tackles, Pre-
Equipment / property
Working from height 4 3 12 check of Tools, use of Hand 4 2 8 Risk Assessment, Training awareness 4 1 4
damage
gloves.PTW,Tool box talk, proper
scaffolding with scaff tag

SMP, Supervision, External Skilled Man

Electric shock leading to power, Using rated tools & tackles, Pre-
Maintenance of Rapping System Live Electric Wires 5 4 20 5 2 10 Risk Assessment,Training awareness 5 1 5
injuries check of Tools, use of Electric insulation
Hand gloves.PTW, Tool box talk

Printed copies are not document controlled.

HT / LT PANEL CLEANING

Electrical shock due to

SMP, Tool Box talk, ensure for discharge of
mistakenly space heater
Live Electric Wires
supply made on, leading to
4 4 16 LV/HV panels,use of std electrical hand 4 2 8 Training awareness 4 1 4
gloves
injuries and skin burns

HV/ LV panel cleaning

Dust inhalation leading to Dust extraction system, Tool Box talk,

Dust 3 3 9 3 2 6 Training awareness, proper ventilation 3 1 3
respiratory infection Use of dust mask

HV/LV MOTOR

Using proper Tools & tackles, Conducting

Leading to severe injuries,
Motor Bearing replacement Fire
skin burns
4 4 16 tool box talks, Skilled man power, keeping 4 2 8 Periodic inspection of Tools, Training, SMP 4 1 4
fire extinguisher near by, area barricading.

RISK RANKING*
HIGH 20 to 25 HOD APPROVAL

MEDIUM 10 to 19 NAME
LOW 0 to 9
SIGNATURE

DATE
REVIEW DATE

Printed copies are not document controlled.

SEVERITY/CONSEQUENCE OF IMPACT / HEALTH EFFECT

Descriptor Description of Consequence or Health Effect

Safety: Any fatality or potential multiple fatalities.; permanent disability. Health:
Life threatening or disabling illness. Examples: cancer; HIV/AIDS; irreversable reproductive disorder or respiratory disease.
Critical (5) Environment: Off-site impact with
severe localised or chronic widespread harm e.g. off-site ground water and soil contamination; on-site impact with potential for
long term off-site harm e.g. tailings facility collapse.
Safety: Serious injury with potential for fatality.; Significant lost time i.e. weeks.
Health: Irriversible health effect of concern. Examples: noise induced hearing loss; vibration induced degeneration of
bones, joints, nerves or muscles; occupational asthma; cumulative lung disease.
High (4)
Environment: Off-site impact with localised harm that can be recovered e.g.
contamination, spill, non-complience; on-site event causing harm that cannot be immediately recovered e.g. ground water
contamination
Safety: Extensive injuries LTI > 3 days; hospitalisation.
Health: Severe, reversible health effect of concern. Examples: back/muscle strain,repetitive strain injury,
Moderate (3) sunstroke, Infection with hepatitis B & C or tuberculosis; acute/short term effect of some chemicals (Solvents, SO2 )
Environment: On-site environmental damage
immediately and totally recoverable

Safety: Injury requiring medical treatment; loss of conciousnes; one day lost time..
Health: Reversable health effect. Examples: sunburn; work-related stress; moderate irritation of eyes, skin, nose
Low (2)
or throat. Environment: Single or
multiple on-site environmental incident(s) causing minor damage that is easily repairable

Safety: Minor injury requiring first aid treatment; no lost time

Health: Reversible effect of low concern. Examples: minor irritation of eyes, nose, throat or skin; minor
Negligible (1)
muscular or cardiovascular discomfort; headache, earache.
Environment: Single on-site incident causing little or no damage that is easily reversible.

LIKELIHOOD/PROBIBILITY OF THE IMPACT OCCURING / HEALTH EXPOSURE

Descriptor Designation of Probibility or Health Exposure

Probibility of repeared incidents. Approximately once or more per week
Frequent (5) Health exposure: Frequent contact with the potential hazard at very high concentrations; frequently can
expect exposure to equal or exceed 50% of OEL or infrequently equal or exceed 100% OEL
Possibility of isolated incidents. Approximately once per month
Probable (4) Health exposure: Frequent contact with the potential hazard at high concentrations; frequently can expect exposure
to equal or exceed 50% of OEL or infrequently equal or exceed 100% OEL
Possibility of occuring sometime. Approximately once per year
Health exposure: Frequent contact with the potential hazard at moderate concentrations or infrequent exposure to
Occasional (3)
hazard at high concentration; frequently can expect exposure to equal or exceed 10% of OEL or infrequently equal 50% of
OEL
Not likely to occure. Approximately once in 5 to 10 years
Remote (2) Health exposure: Frequent contact with the potential hazard at low concentrations or infrequent exposure at moderate
concentration; frequently can expect exposure to be less than 10% of OEL or infrequently between 10% and 50% of OEL
Practically impossible. Approximately once in 50 to 100 years
Improbable (1) Health exposure: Infrequent contact with the potential hazard at low concentrations; can expect exposure to be always
less than 10% OEL
 Practically impossible. Approximately once in 50 to 100 years
Improbable (1) Health exposure: Infrequent contact with the potential hazard at low concentrations; can expect exposure to be always
less than 10% OEL
HIERARCHY OF RISK CONTROLS

1 ELIMINATE Remove the hazard completely by changing the work process

Less Effective
2 SUBSTITUTE Replace the hazard with a less hazardous alternative
3 ENGINEERING CONTROL Relocate the hazard, guarding, barriers, lockout
4 ADMINISTRATIVE CONTROL Written procedures, permit to work, training, audits,inspections
5 PPE Use of personal protective equipment