Method Statement Risk

Assessment Revision: Date

Issue 1 08/04//2020

METHOD STATEMENT RISK ASSESSMENT

Contractor Details Name: Address: Tel:

Fobesvyncke M/s Forbes Vyncke Pvt Ltd. Kasarawadi, Pune - E-mail:

411034
Project Name: Boiler Erection Document Risk Yes
MSRA-FM-09 Assessment
Hot Insulation Work Number: Attached?

Description of the
Hot Insulation work activities (Insulation work of Equipment’s, Pipes, Ducts & Pressure parts )
Task/Activity:

1. Boiler House Start Date/Time: 15.07.2023

Exact Work Location: 2. ESP Area
Finish Date/Time
31.09.2023

Prepared by: Name: Mr.Kathiresan Assessment Team: Mr.Kathiresh, Mr. Pawan & Mr Shyam

General Project Permits Working Hot Confined Excavation Electrical Pressure Lifting &
required for the activity at Work Space Permit Works Testing Shifting
Heights Permit Permit Permit Permit
Permit
Yes No No No No No Yes

Others Permits:

Personnel Involved Name Role/Trade

Rigger

Insulation & Sheet Fitter

Leagers

Foreman / Supervisor

Scaffolder

Site Supervisor: Mr. Shyam Contact Tel No: 9447912115

Safety Officer Mr. Pawan Lokhande Contact Tel No: 8380829025

Project Manager Mr. Kathireshan Contact Tel No: 9442589676

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Details of Crew  An Electrician holding a license & certificate of competency issued or recognized by the State
Personnel specific Government
certification  Experienced and trained Insulation worker for temporary works and other miscellaneous works
 Experienced and Trained Fitter (Insulation & Sheet), Scaffolder &Sheet Cutter for all temporary and other
works
 Trained Lager shall be listed and utilized for all Insulation Shifting & Fixing work.
 Externally Trained & Certified Fire Fighting Team shall be listed and available for Fire Emergency
 Externally Trained & Certified First Aid Team shall be listed and available for Medical Emergencies
Key Plant , Tools and  Hand Tools & DCP Fire Extinguishers
equipment  Periodic test & Inspection of Full body harness
(Attach Certification as  Regular Inspection by a responsible person not less than 15 days for all Fire Extinguishers
required)
Safe Working Load’s
(SWL’s) for Lifting Third party load test certificate for Life line (Only metal rope of 10 mm is allowed for work)
Equipment:

Specific Identified
Residual Hazards: 1. Fire hazards
(or refer to the task 2. Body Skin / eye injury, Irritation
specific risk 3. Property Loss / damage
assessment(s)) 4. Fall of material during shifting & lifting
5. Inhalation of insulation.
6. Fall of person from height
7. Unskilledd Worker
Specific Training 1. Material Handling Training
required for Activity: 2. Hand tools use & safe operational procedure training Safety
3. Firefighting training.
4. Emergency Evacuation / Fire Mock Drill
5. Height work safety ( Vertigo Test) & PPEs Usage Training
1. Work Method Hot Insulation activity for equipment & Pipes:
Sequence:
1. Obtain general & height work permit from concern approval authorities
2. (Include sketches if 2. Conduct job specific Tool Box Talk to all the crew before commencing insulation activities.
required) 3. Engage Inducted, trained and authorised watcher for insulation& cladding works
4. All welding works must be carried out under the dedicated supervision
5. Inspection of Scaffolding Hand tools before using at site with standard LTTS checklist and provide
Fitness Tag
6. Using Certified MEWP Vehicle for height work insulation purpose
7. Hand tools & machines shall be inspected for any kind of damaged.
8. Ensure that working area shall be in good condition with proper material segregation.
9. If any defect found that should be rectified by electrician/ Mechanic only, and allow to use after
rectification
10. Prior to start insulation work inspect the area that no other workers are working surrounding place
because insulation material can create skin irritation to them.
11. Follow 5s rules before start the work and after work completion.
12. Provide Proper stacking of material on site & it should be covered.
13. Provide barricading surrounding the Insulation work area to avoid unauthorised entry and highlight
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the hazards with relevant cautionary signage

14. Display emergency contact details, CPR signage, SLD, Fire Point / Logistics plan nearby Insulation
work area
15. Provide adequate fire extinguishers with fire buckets filled with water/sand nearby Insulation area
16. Provide scaffold as per requirement and standard for insulation work required at height level
17. Once Erected responsible person inspect the scaffolding by using checklist and provide green tag
prior to use
18. Before Starting the scaffolding erection & dismantling work must be provide the yellow tag
19. All PPES Inspection before start of work.
20. Insulation fitter, helpers, fire watcher, Leagers must wear PPE’s like helmet, goggles/shield, leather
apron, filter mask or job related PPE,s during Insulation work.
21. Height workers must wear safety harness with shock absorber having double lanyard
22. Remove all the unwanted materials and scraps from the workplace and shifted to designated yard
23. All material Should stack properly.
24. Step Wise activity For insulation work

A Material Shifting By manually

B Cutting of LRB Sheets
C Scaffolding erection as per standard of LTTS checklist
D Scaffoldding inspection by competent person
E Application of LRB mattress on surface of Equipment / Pipe.
F Binding of LRB with binding wire
G Inspection Of LRB application by QA & QC
H Aluminum sheet fabrication
I Application of aluminum sheet on LRB ( this will be the final work)

List Of Boiler Equipments for Insulation work

Sr No Name of Equipment
01 Boiler Drum
02 Economizer
03 Membrain Panel
04 MDC
05 Piping
06 Ducting
07 Diverter Dumper
08 ESP Area
09 Pressure Parts
10
11

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Temporary Supports
and Props needed to
facilitate the works: NA

Note: any temporary

design requirements
must be detailed

Method of Access and 1. Safe access shall be provided to the workplace means of proper scaffolding with ladder provision
Egress to the work 2. Keep the access route clear
area:

Fall Protection 1. Provide hand railing for scaffolding platforms

Measures: 2. No any loose materials kept at the floor edge or at platform
(Where work at height 3. Use rope / lanyard to secure the hand tools while working at height
cannot be eliminated – 4. Fix toe board for prevention of material from scaffolding platform
consider both Personnel 5. Workers must wear full body harness during height work.
& Materials)
Are any Hazardous Rockwool Insulation
Substances to be
used/present/potentiall
y present for the
Activity?

Required
Personnel
Protective
Equipment:
Safety Safety Hearing Respiratory
Hard Hats Hi-Vis
Boots Gloves Protection Eye Protection
Protection Clothing

√ √ √ √ √ √ √

Please Tick: √ / X

Other: Leather Apron, Face shield, Leg Guard, Hand sleeve, Leather hand gloves &Full body safety
harness with shock absorber having double lanyard.

Emergency 1. Mock Drill for Fire Emergency shall be conducted to the crew and well trained
Procedures: 2. Periodically Firefighting training should be conducted
3. Adequate Fire Points shall be located in prominent locations and details must be marked in
logistics plan and same shall be displayed
4. Eye wash / shower shall be kept available
5. Standby emergency vehicle available with all necessary equipment and first aider.

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Location of nearest
safety shower and Near Emergency assembly area (as per logistic plan).
emergency exit:

Monitoring /  Regular inspection by concern engineers and safety officer at every 7 days on Scaffolding & hand
inspection tools.
requirements for
 Avoid to work near high noise / smoke area
the activity:
(E.g. noise / dust
 Close, constant and effective supervision by concern supervisor required
monitoring / safety
inspections by EHS
etc.)
Housekeeping Maintain 5 S at site as part of each job.
Control Measures:
Traffic  Follow all traffic control regulation at the site.
management
 Conduct training for driver and operator for safe control and introduce regulations.
requirements:

Waste Management Yes

requirements:
 Insulation dust, metal scraps.
 Store waste, PPEs waste, etc.
 Classification  Sheet Waste
of waste  Damaged material Of sheet & Insulation
generated:

(hazardous or
non-hazardous)
 For segregation - Identified scrap / waste has to be collected and segregated in a
separate place / yard with colour codes and must have proper signage as ‘’NOT IN USE’’
 Segregation
methods:

 How waste is  Manually or by tractor shifting the scrap materials from work location to designated scrap yard
transported to
designated
waste
collection areas
etc.:

Other  Insulation Material & metallic Sheet

environmental  Electrical energy consumption, scrap metal...
controls to be put  Dust generate
 Provide bin for waste and periodically remove the scrap from site
in place:

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Services to be
supplied by
Insulation Material & sheets
Others:

Other information
& Comments:
NA
Identification & Protection of “Live Services”

Area(s) Walked:

Job has been walked Mr. Kathiresan SiteManager (FM)

by:

Mr. MukeshMaurya PM (Fluid Line)

Identification of Existing Live Services at Risk: Protection of Identified Live Services:

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In the event of damage to the service, Depend on repairs – Service will be carried out at work location or send back to
is all repair equipment on site? service stations.

Location of repair equipment: At P&M workshop whenever possible

Name and contact number of the Name: Shiv Kumar

person dedicated to performing repair
work: Contact No: 9973666611

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Risk
Process Steps Potential Hazards Control Measures
Evaluation

Consequence Rating
Responsibility

Probability Rating
S. No
List the basic steps Consider Safety, Health, Consider Design, Procedure, Practices, Skill

Risk Score
for the task Damage, Fire, Quality, Training, Special Rules, Health & Hygiene Control,
Production Problems, etc. Personal Protective Equipment, etc.

1 Manpower Mobilization 1.Unfit workmen 1.Ensure all workmen undergone on medical examination
and Induction Training 2.Lack of skill & awareness 2.Before sending to an Induction program proper screening /
skill test need to be conducted
3.All the workmen properly inducted by Fluid line & LTTS
Fluidline /
4.Maintain all the Medical / Screening / Induction record at site 2 2 4
office Forbes
5.Issue ID card to them
6.Provide Induction sticker on helmet to all Inducted workmen
for identification
7.Provide sticker about Worker’s trade on their helmet
2 Conducting Training on 1.No adequate knowledge related 1.Workmen should know each & every work step 3 2 6 Fluidline /
MSRA and Daily Tool Box to the job 2.Before start the work conduct training on approved MSRA Forbes
Talk 2.Negligence towards safety and all workers must be briefed about the work methodology
3.Behavioral issues and associated risks
MSRA must be briefed to 3.Periodic training must be identified and to be conducted
all the workmen & staff according to the EHS training requirements & as per training
involved in the task schedule
4.Training material must be most relevant to the subject and to
make them understand from their level of knowledge
5.Trained all the Insulation workers & sheet fitters and work
supervisors involved in the hot insulation work activity
6. Conduct firefighting training and emergency mock drill

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periodically to all workers & staff.

7.Proper Evaluation need to be carried out with feedback form
8.Training record and all forms should be maintained at office
9.Job specific Tool box talk must be given by the concern
frontline supervisor to all workmen prior to start the activity and
make attendance record
3 Selection & Use of 1.Using damaged or 1.Check the physical condition of PPEs Safety Helmet,
Personal Protective contaminated PPEs (Safety Reflective vests, Safety Shoes, Safety Goggles, & safety
Equipment’s (PPEs), Helmet, Hand Gloves, apron, harness, Nose Mask.
firefighting Equipment & Safety Shoes & Safety Harness 2.Not allowed to use damaged & contaminated PPEs
fall protection equipment’s 2.Improper usage of PPEs 3.Training & job specific tool box talks about usage of PPE's
Improper handling and storage of 4.PPEs issue register need to be maintained at store
PPEs 5.Strict supervision required on wearing 100% PPEs Fluidline /
3 2 6
3.Using poor quality products implementation Forbes
4.No aware of wearing safety 6.Maintain adequate no. of suitable fire extinguishers which is
harness for height works relevant to work DCP – , C02 – Electrical Panel & D.G, Foam –
5.Using unsuitable fire Oil/Diesel storage area
extinguishers for relevant work 7.Use Ceramic fire blanket with vermiculating on both sides
6.Poor maintenance and placing and MTC must be available
discharged extinguisher 8.Inspection checklist must be filled periodically for Safety
Harness & fire extinguishers
4 Comply to PTW system 1.Unaware of PTW systems 1.LTTS & Fluid line will provide training to every staff &
1.General Work Permit 2.PTW Non compliance workmen representative on PTW
2.Electrical Work Permit 2.Authorized Permit Issuer / Receiver details shall be updated Fluidline /
3 2 6
3.Hot Work Permit regularly and details displayed Forbes
3.Close monitoring required for PTW implementations
4.PTW register and Permit display box shall be maintained at
security cabin
5 Competent & strict 1.Lack of supervision 1.No work will be allowed without competent supervision
Supervision 2.No aware of present hazards & 2.Frontline supervisor to be ensured the safety compliance and
risks implementations Fluid line /
2 2 4
3.Continuous site round to be taken by safety officer for finding Forbes
the gaps/risk during the execution
4.Trained fire watcher shall be deployed in assist to Welder,
Grinder, Gas Cutter for fire accident prevention

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6 1 Fire & explosion. 1. Close and continues supervision by CONTRACTOR.

2. Irritation & Itching
Insulation Work on plat 3. Fall of material 2. Pre check of work location and scaffold material and
form & Scaffolding 4 Unskilledd workers accessories.
5 Failure of Scaffold components.
6 Collapse of scaffold. 3. Deploy skilled & trained workers .
7 Fall of man and material
8 Improper access and egress on 4 No multi layer activity plan on particular area during work.
plat form & scaffold.
5 Ground compaction must be check before start any activity.
9 Defective tool and tackles
10 Damage scaffold material and 6 During insulation material & scrap removal throwing is not
accessories permitted. Fluidline /
11 Bad Weather (Rain/Fog/High 3 3 9
Forbes
wind pressure) 7 At the time of insulation below and surrounding area must be
12 Physical Hazard cordon off.
13 Multi Layer Activity
14 Untrained Workforce/ 8 Proper dispose of scrap material through certified vendor.
Unauthorized worker.
15 Improper supervision 9 Work location and surrounding area house keeping on daily
16 Loose soil condition basis.
17 Skin and eye diseases 10. Anchoring point of safety belt should be proper not to any
18 Soil and land contamination utility line.
19. Improper work platform & 12. Use only Metallic wire rope more than 10mm dia for life line
anchoring point. purpose.
20 Improper following MSDS
7 Scaffolding Tower 1. Non competent scaffold 1. Competent scaffolder shall erect & dismantle scaffold. 3 2 6 Fluidline /
Erection& Dismantling erectors 2. Before start the activity, Addressed to crew at the time Forbes
2. Sub-standard erection / of TBT.
methodology 3. Stack the material to avoid trip hazard. Always keep
3. Use of bend, damaged work area clean & tidy.
components 4. Scaffolding shall be erected dismantled or altered in
4. Slippery access, ladders, accordance with approved method statement and
planks specification.
5. Falling of scaffolding 5. Scaffold (and all necessary accessories) erection
materials, hand tools shall be done in compliance with relevant Indian / BS
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6. Incomplete scaffold standards, applicable project standards and approved

7. Scaffold collapse drawing.
8. Person fall from height 6. Barricading the area below into which objects can fall
9. Personal injury and not permitting workers to enter the hazard area &
10. Property damage display cautionary signage.
7. Erection / alteration /dismantling task direct
competent supervision under only
8. Before start the erection, ensure ground condition
should be firm base
9. Scaffolder shall be use access ladder for scaffold
erection.
10. Ensure minimum 2 planks for scaffolding erection &
dismantling practice.
11. Only essential personnel and equipment to be
allowed on to the working platforms
12. All connections on a scaffold lift shall be made secure
and fully tightened before assembly of the next lift.
13. At the time of Mobile crane / farana Movement shall
be monitor closely.
14. l) Scaffolding structure properly tie with rigid structure
as per approved drawing
15. Never allow material to throw from higher elevation.
16. Working hand tools shall be tie with lanyard and secure with
17. harness.
18. Scaffolder shall use full body harness with double
hook lanyard & they must hook their lanyard on the
rigid member or life line.
19. Every 7 days scaffolding inspection shall be carried
out.
20. All the incomplete scaffold shall be place the ‘RED’
tag.
21. At the time of night shift, good illumination shall be
provided Dismantling task hidden hazard shall be
identify and address to the crew.
22. All dismantling activities shall be carried out

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progressively reversing the erection sequence

23. When a scaffold is being dismantled, the components
above each tie shall be dismantled or removed before
the tie is removed. Stability shall be maintained while
the scaffold is being dismantled.
24. Ensure work area is free from material, obstruction,
spillage & trailing cables to avoid Slip / Trip / Fall.
Scaffold material around work place shall be properly
stacked.
25. Once a scaffold is partly dismantled all access to the
dismantled section shall barred and a warning sign
prominently displayed.
26. All material shall be lowered carefully, planks & fitting
to be removed from platform as the work progress

11 Hot insulation work 1. Boom lift failure 1. Vehicle documents like insurance, PUC, TPI to be 3 3 9 Fluidline /
using by Boom Lift 2. Material / person fall ensured Forbes
3. Un-authorized operation 2. Operator’s driving license (LMV) and experience
Operating a Telescopic 4. Person entry into swing certificate to be verified
Boom Lift area 3. Inspect boom lift as per checklist and provide
5. Injuries to operator, inspection tag
Prepare work area workers, standby 4. Daily inspection to be carried out prior to use the
6. Fire to boom lift due to equipment
Operate Boom lift hydraulic oil. 5. Ensure safe access and firm ground for safe
movement of boom lift
6. Only authorized operator allowed to operate
7. Warn people in work area, utilize barricades, traffic
cone or caution tapes to keep bystanders a safe
distance from swing area, job area, buildings & power
lines
8. Operator enters the bucket and attaches lanyard to
designated anchorage point and worker must use full
body harness while working inside the bucket
9. Never exceed the posted lifting capacity (including
worker,materials and tools)

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10. Never use a lift as a crane or hoist to lift or lower

material
11. Deploy flagman while marching / take the boom lift
12. Maintain a minimum clearance of 10ft if 50KV less
and 10ft plus 4/10 inch for each kilovolt greater than
50KV
13. Never move the lift when the boom is elevated in a
working position with an operator /worker in the
bucket
14. Maintain distance from boom lifts radius.
15. During boom lift ascending on height worker will be sit
inside the bucket Standing mode not allowed.
16. Provide fire Extinguisher near the boom lift
12 Material stacking and 1. Access obstructions 1. Unwanted materials shall be removed from work
housekeeping 2. Uneven surface location
3. Slip, trip and falling 2. Ensure safe stacking practice followed Fluidline /
2 2 4
hazard 3. Do not stack /obstruct materials at passage Forbes
4. Material slide 4. Remove all unwanted materials and scraps regularly
5. Ensure use of all relevant PPEs like cotton gloves,
mask, goggles etc.

MSRA Induction Verification. To be signed by all participants in the task prior to commencement.

I have read this MSRA, understand its content and acknowledge its conditions and my responsibilities :

Attendees Name: Title / Trade Classification Signature: Date:

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MSRA Prepared By: Forbes Marshall

This MSRA has been prepared and the works may proceed based on compliance with the requirements outlined in MSRA, respective work permits, applicable EHS
legislation, codes and specifications.
Project Manager/Construction Manager Safety Manager /Safety Lead

Name: Kathiresan Name: Pawan Lokhande

Prepared By (Forbesvyncke)
Sign & Date: Sign & Date:

Name: Name:
Reviewed By (Archytype)
Sign & Date: Sign & Date:

Name: Name:
Approved By (BUNGE)
Sign & Date: Sign & Date:

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RISK ASSESSMENT 5x5 MATRIX

Step 1 Decide S - How severely could it hurt someone? Step 2 Decide Likelihood - How likely is it that an incident will happen?

Step 3 Assess the risk - Decide Risk Level (Score) Step 4 Decide Action

Severity Insignificant = 0-1

Low = 2-4
1 In 2 3 4 5
Medium = 5- 10
signification Low Medium High Extreme High = 11 – 19
Extreme = 20 - 25
5
5
Extreme 10 15 20 25

4
4
High 8 12 16 20
Liklihood

3
3
Medium 6 9 1122 15

Low 2 4 6 8 10

1
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In signification 2 3 3 3
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