EHS-S-01 (Risk Assessment Procedure) - Rev 01

HabibUllah Coastal Power Company
Occupational Health, Safety and Environment Risk Assessment Procedure
EHS-S-01 Revision : 01 Rev. Date:05.02.2012 Page 1 of 17
1. Purpose
The purpose of this procedure is to define mechanism and responsibilities for ongoing
identification of Safety, Environment and Occupational Health hazards and their
associated risks.
2. Scope
This procedure is applicable to the identification of hazards and their risks as a result of
activities and processes of HCPC.
It is applicable for:
Initial risk assessment
Annual Review for updating the information
Conducting risk assessment at the time of change in existing activities and
processes.
3. Responsibility
EHS Manager is responsible for the implementation of this procedure.
Zonal Incharges are responsible for identification of OH&S and environmental
hazards and risks in their respective areas.
4. Procedure
4.1 Risk Assessment Team

The OH&S and Environment hazards of activities, process and products at HCPP are
identified through risk assessment process conducted by the EHS Task Force.
The EHS Task Force comprises of EHS Manager, Zonal Incharges and employee. The
team members must be familiar with the processes and situations to be assessed (eg;
location, equipment, task).
4.2 Competency and Training of members of Risk Assessment Team

EHS Manager ensures before initiating the risk assessment exercise, the members of the
task force must be competent to perform the risk assessment process.
Safety, Health & Environment Management System

The members must have sufficient knowledge of:

the area, department, or activity to be assessed
the risk assessment process
an understanding of hazards and the ability to identify hazards
current health and safety practices
when and how to seek specialist advice.
The competency requirements must be fulfilled through one day formal training on the
risk assessment process. The training contents covers:
(a) Types of OH&S and Environment hazards
(b) Identification of hazards
(c) Risk assessment methodology
(d) Knowledge of common OH&S and Environment Operational Controls
4.3 Occupational Health & Safety Hazard Identification and Risk Assessment Process
The hazard identification and risk assessment covers:

i. Routine & non-routine activities/processes (normal, startup, shutdown,
abnormal/ emergency conditions);
ii. Activities of all personnel having access to the work place (including
subcontractors and visitors);
iii. Facilities at work place whether provided by HCPP or others; such as contractor,
customer etc.

4.3.1 Division of Organization into segment and Preparation of Inventories
For managing the OH&S and Environment risks in effective manner, the HCPC site has
been divided into thirteen zones.
Zones Area/ Location

Zone 1 Admin Building+Main Control Room building+Black Start Diesel Engine
Zone 2 Switch Yard+Transformers(1,2,3&4)
Zone 3 Gas yard+Gas compressor room+Cooling water pumps
Zone 4 ACC+Steam turbine
Zone 5 By-pass Station Area+Start-up boiler
Zone 6 Unit #1(HRSG+LCR+GT package+Fuel oil skid+Gen lube oil skidDB skid)
Zone 9 Demin Plant+Water Basins+Chemical Storage Area
Zone 10 Air Compressors+Water tanks+Fire fighting pumps area+Water Well area
Zone 11 Fuel oil storage area+Lube oil storage area+waste oil storage
area+Veronesi+Dyke Area
Zone 12 Work shop+ware house+work shop office area
Zone 13 Container Area+Coastal buildind+Maintenance Building
The EHS Manager ensures that the division of HCPC site into zones is updated whenever
there is change in the department/ geographical area etc.
The inventory for each zone is prepared for the following:
i. Location
A distinct place within a site. For example: tanker off-loading area, confined spaces,
offices, laboratory etc.

ii. Process Installations/Process Equipment
Equipment which is specifically designed and dedicated to Electrical Substation, Gas

Turbines, Waste Heat Recovery Boilers, Steam Condensing Turbine, Air Condenser,
Natural Gas Compressors, Transformers, Transmission Lines etc.
iii. Auxiliary Equipment/Facilities
Equipment other than the process equipment. It includes HSD storage tanks, service
utilities (DEM-Water Plant, Clear Water Basin, Fire Fighting system, Water Storage,
tools, vehicles etc.
iv. Common Tasks
Task which is undertaken by many different people, often in various locations, and
where the hazards, risks, controls and defenses are always the same. For example:
manual handling, hot work, work at heights etc.
v. Facilities run by other parties:
These include SSGC Fuel Gas Area and WAPDA Metering Room.
vi. Specific Tasks
Task where the hazards, risks, controls and defenses are specific to an individual task.
This may arise because of nature of the task itself and/or the location where it is to be
undertaken and/or the equipment which is to be used. For example: Manual sampling of
tanks, cleaning pump filters etc.
The record of inventory is reviewed by the EHS Manager and is maintained on Location,
Process, Task and Equipment Inventory Record EHS-F-02.
4.3.2 Occupational Health & Safety Hazards

The hazards identification is carried out for the following hazards:
1. Ergonomics (Physical)
2. Mechanical (Associated with power driven machine)
3. Falling
4. Impact & Acceleration
5. Heat & Temperature
6. Pressure

7. Electrical
8. Fire
9. Toxicity & Explosion
10. Radiation
11. Noise
12. Vibration
13. Biological
While conducting the hazard identification, the information regarding the hazards and
the risk involved is determined from any of the following sources:
Interviewing people associated with the process/ activity
Self-examination, observation, results of measurements and monitoring
Examination of existing management practices and procedures
Feedback from previous incidents/ accidents
Views of interested parties (if any)
Applicable Legal and Regulatory requirements.
The hazards associated with the location and equipment are listed on OH&S Risk
Assessment Sheet EHS-F-02.
Note: For Common and Specific tasks Task Hazard Analysis (THA) methodology is
followed. (Refer Section 4.5)
4.3.3 Evaluation of Occupational Health & Safety Risks

The OH&S risks are determined by rating them in two phases, i.e. with existing controls
(HRN I) and with additional control (HRN II) if risk exceeds the tolerable limits.
(a) Hazard Rating Number (HRN I)
In HRN I the OH&S risks are assessed keeping in view the existing operational
controls.
The OH&S risks are determined on the basis of following parameters:

i. Likelihood of occurrence (a)
ii. Frequency of Exposure (b)

iii. Degree of Possible Harm to Human Life (c)

iv. Degree of Possible Harm to asset (d)
v. No. of Persons at Risk (s) (e)
The factors are rated on the scale of 0, 1,2,3.., as per criteria defined in the Rating
Criteria for OH&S Risk Assessment (APPENDIX I).
The overall significance of risks is determined by putting the above mentioned five
factors in the following formula.
OH&S Risk = a b (c + d) e
All OH&S risks having rating above 20 shall be treated as Significant Occupational
Health & Safety Risks.
The significant OH&S risks require control measures to eliminate or reduce the risk of
loss to a tolerable level.
Basis for categorizing significant risk are:

Potential for violation of HCPCs OH&S Policy
Potential for legal violation
Potential for fatalities or multiple injures or significant asset loss or damage to
environment.
The record of OH&S Risk Assessment (HRN I) is maintained on OH&S Risk Assessment
Sheet EHS-F-02.
The hazards with significant risks are controlled by establishing Objective and Targets
and or through application of additional operational controls by considering the
following hierarchy:
i. Elimination
ii. Substitution (reduction)
iii. Isolation (enclosure)
iv. Defenses (protection)

v. PPEs
The record of additional operational controls on significant OH&S risks is maintained on

OH&S Risk Assessment Sheet EHS-F-02.
(b) HRN II (Significant Risks that requires Additional Controls)

After application of additional operational controls on the significant risks identified in
HRN I, their risks are re-determined, in accordance with the same formula as used for
HRN I {refer section 4.3.3 (a)}.
The record of HRN II (risk rating with additional controls) is maintained on OH&S Risk
Assessment Sheet EHS-F-02.
4.4 Evaluation of Environmental Hazards & Risks
4.4.1 Environmental Hazards

While conducting Environmental hazards assessment, the hazards considered will be the
following:
1. Emissions to air
2. Water Discharges
3. Solid non-hazardous waste
4. Solid Hazardous Waste
5. Consumption of natural resources/ Energy
6. Noise
7. Heat
8. Odor
9. Dust
10. Vibration
11. Effect on visual/ aesthetics
12. Use of Ozone depleting substances
13. Use of radioactive/ nuclear material
For identification of environmental hazards and risks, each process/ activity, product and
service is assessed for its inputs and out puts. The inputs can be raw materials, utilities
etc. The out put can be atmospheric emissions, liquid effluents, noise, waste, products
etc.

4.4.2 Evaluation of Environment Risks

The environmental risks are determined by rating them in two phases, i.e.; with existing
controls (HRN I) and with additional control (HRN II), if risk exceeds the tolerable limits.
(a) Hazard Rating Number (HRN I)
In HRN I the environmental risks are assessed keeping in view the existing operational
controls.
The following formula is used for environmental risk assessment:

a) Likelihood of occurrence (X)
b) Severity (Y)
Severity
The associated factors considered for Severity are:
Health effects (A)
Safety hazards (B)
Effect on air quality (C)
Effect on land (D)
Effect on water quality (E)
Size of impact (F)
Extent of regulatory violation (G)
Effect on the public image of the organization (H)
Cost of correcting the impact (I)
Severity (Y )= (A + B + C + D + E) F G H I
The factors are rated on the scale of 0, 1,2,3.... as per criteria defined in Criteria of
Environmental Risk Assessment (APPENDIX II).
The overall significance of risks is determined by using the formula.
Environmental Risk = Likelihood of Occurrence X Severity
The results of environmental risk assessment (HRN I) will be maintained on

Environmental Risks Sheet EHS-F-44.
All environmental risks having rating equal to or above 30 shall be treated as
Significant.

Significant Environmental Risks are those which are not tolerable due to any of the
following reasons:
Violation of HCPCs policy, objectives and targets.
Violation of legal or regulatory requirements.
The significant environmental risks require control measures to eliminate or reduce the
risk of impact to a tolerable level either establishing objective or through application of
additional controls by considering the 4R methodology i.e; Reduce, Reuse, Recover,
Recycle.
The record of additional operational controls on significant environmental risks is

maintained on Action Plan for Significant Environmental Risks EHS-F-44.
(b) HRN II (Significant Environmental Risks that requires Additional Controls)

After application of additional operational controls on the environmental hazards with
significant risks identified in HRN I, their risks are re-determined, in accordance with the
same formula as used for HRN I {refer section 4.4.2 (a)}.
The results of environmental risk assessment (HRN II) will be maintained on Register of
Environmental Risks EHS-F-44.
4.5 Task Hazard Analysis (THA)
For common and specific tasks THA is conducted. The methodology for conducting the
THA is defined below:
(a) Clearly define the task.
(b) Break down the task into sequence of steps.
(c) Identify Hazards Associated with each step and harm/ loss that may result from each
hazard.
(d) Identify existing controls

(e) The risk is evaluated by using formula Severity X Likelihood. The criteria for
rating has been defined in the appendix 3. All risks having rating equal to or above
24 shall be treated as Significant.
OR
The risk can also be calculated in accordance with the procedure defined in para
4.3.3 of the procedure. In such cases the significant risk rating will be 15.
The hazards with significant risks are controlled by establishing Objective and Targets
and or through application of additional operational controls
The record OH&S risks of tasks and their controls is maintained on Task Hazards
Analysis Record EHS-F-01.
4.6 Risk Assessment Update

EHS Manager ensures that hazards and risk related to the activities/processes, tasks and
equipment are kept current by conducting the same assessment:
After every year- (to update the system) and
Before change in existing activities/ Processes/products/ facility/ equipment.
Change in laws & regulations.
5.0 Records to be maintained
Number Records Retention Maintained by

Period
Location, Process, Task and Ongoing EHS Manager
Equipment Inventory Record
EHS-F-02 OH&S Risk Assessment Sheet Ongoing EHS Manager
Action Plan for Significant OH&S Ongoing EHS Manager
Risks/Management Program
Environmental Impact Assessment Ongoing EHS Manager
EHS-F-44
Sheet

Action Plan for Significant Ongoing EHS Manager

Environmental Risks / Management
Program
EHS-F-01 Task Hazard Analysis Sheet Ongoing EHS Manager
on going means only current record shall be maintained.
Reviewed by: Date:

EHS Manager
Approved by: Date:

Plant Manager

APPENDIX I (Rating Criteria for OH&S Risks)
LIKELIHOOD OF OCCURRENCE (a)

SCALE
Impossible --cannot happen 0
Almost Impossible --Possible in extreme circumstance 0.1
Highly Unlikely --though conceivable 0.5
Unlikely --could happen but only rarely 1
Possible --but unusual 2
Even Chance --could happen 5
Probable--Not surprised 8
Likely--To be expected 10
Certain ---No doubt 15
SEVERITY OF RISK
FREQUENCY OF EXPOSURE (b)
SCALE
Infrequently 0.1
Annually 0.2
Monthly 1
Weekly 1.5
Daily 2.5
Hourly 4
Constantly 5
DEGREE OF POSSIBLE HARM TO HUMAN LIFE (c)

SCALE
Scratch or bruise 0.1
Laceration or mild ill-health effect 0.5
Break of a minor bone, or minor temporary occupational
1
illness
Break of a major bone, or minor permanent occupational
2
illness
Loss of one limb, one eye, or serious temporary
4
occupational illness
Loss of limbs, eyes, or serious permanent occupational
8
illness
Fatality 15

DEGREE OF POSSIBLE HARM TO ASSET (d)
SCALE
No effect / Insignificant 0
Negligible damage to asset / facility that can be repaired in very less
1
time.
Minor damage -- to a facility or equipment 2
Major damage -- Cause complete damage to a part of facility or
3
equipment
Catastrophic--cause complete damage to the facility 4
No. of PERSONS AT RISK (e)
SCALE
0-2 persons 1
3-7 persons 2
8-15 persons 4
16-50 persons 8
More than 50 persons 12

APPENDIX 2 (Rating Criteria for Environmental Risks)
LIKELIHOOD OF OCCURRENCE
CLASSIFICATION RATING
Amost Impossible- Possible in extreme circumstances 1
Highly Unlikely- though conceivable 2
Possible- but unusual 3
Even chance- could happen 4
Likely- to be expected 5
Certain- no doubt 6
SEVERITY
(A) HEALTH EFFECT
SEVERITY
CLASSIFICATION OF
IMPACT
No significant effect 0
Cause only irritation on exposure 1
Temporary incapacitation or injury due to continued exposure 2
On short exposure cause serious temporary or residual injury 3
Kill/deform people or animals on very short exposure 4
(B) SAFETY HAZARDS
SEVERITY
CLASSIFICATION OF
IMPACT
Not combustible 0
Must be pre heated before ignition can occur 1
Materials that must be moderately heated or exposed to 2
relatively high ambient temp. before ignition occurs
Materials can be ignited under almost ambient temperatures 3
Materials can be rapidly or completely vaporize at atmospheric 4
temperatures

(C) EFFECT ON WATER QUALITY

CLASSIFICATION SEVERITY OF
IMPACT
No impact 0
Contaminate water but no long term effect and or effect
aquatic life
May have long term effect on water quality 2
Poison to aquatic and human life 3
(D) EFFECT ON LAND
IMPACT
No impact 0
Causes minor soil contamination rectifiable in short term 1
Cause ground water contamination 2
Long term effect on land 3
(E) EFFECT ON AIR QUALITY
IMPACT
No impact on air quality 0
Contaminate air and produce odor but immediately reversible
1
impact
Contaminate air and impact reversible in medium to long term 2
Poison to life 3
(F) SIZE OF IMPACT
IMPACT
No significant effect 1
Confined within plant boundaries/localize boundary 2
Effect nearby area 3
Within city 4
Country/Global 5

( G) EXTENT OF REGULATORY VIOLATIONS

IMPACT
Not mentioned in the regulations/ No Violation 1
Partial violation of laws/regulations 2
Violation due to process constraint 3
Complete violation 4
(H) EFFECT ON PUBLIC IMAGE OF THE COMPANY
IMPACT
No effect 1
City/local repute 2
Country wide repute 3
International repute 4
(I) SOCIAL & ECONOMIC COST
IMPACT
Cost impact insignificant 1
Low 2
Medium 3
High 4

APPENDIX 3 Rating Criteria for THAs
Consequences (S)
Multiple Death 10
Single Death 8
Major injury , Disabling illness, major damage 6
Loss time injury , illness, damage 4
Minor injury, minor damage 2
Delay only 1
Likelihood (L)
Certain on imminent 10
Very likely 8
Likely 6
May happen 4
Unlikely 2
Very Unlikely 1

EHS-S-01 (Risk Assessment Procedure) - Rev 01

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HabibUllah Coastal Power Company

Occupational Health, Safety and Environment Risk Assessment Procedure

EHS-S-01 Revision : 01 Rev. Date:05.02.2012 Page 1 of 17

4.1 Risk Assessment Team

4.2 Competency and Training of members of Risk Assessment Team

Safety, Health & Environment Management System

Occupational Health, Safety and Environment Risk Assessment Procedure

EHS-S-01 Revision : 01 Rev. Date:05.02.2012 Page 2 of 17

The members must have sufficient knowledge of:

The hazard identification and risk assessment covers:

Safety, Health & Environment Management System

Occupational Health, Safety and Environment Risk Assessment Procedure

EHS-S-01 Revision : 01 Rev. Date:05.02.2012 Page 3 of 17

4.3.1 Division of Organization into segment and Preparation of Inventories

Zones Area/ Location

Zone 2 Switch Yard+Transformers(1,2,3&4)

Zone 3 Gas yard+Gas compressor room+Cooling water pumps

Zone 4 ACC+Steam turbine

Zone 5 By-pass Station Area+Start-up boiler

Zone 9 Demin Plant+Water Basins+Chemical Storage Area

Zone 10 Air Compressors+Water tanks+Fire fighting pumps area+Water Well area

Zone 13 Container Area+Coastal buildind+Maintenance Building

The inventory for each zone is prepared for the following:

Safety, Health & Environment Management System

Occupational Health, Safety and Environment Risk Assessment Procedure

EHS-S-01 Revision : 01 Rev. Date:05.02.2012 Page 4 of 17

ii. Process Installations/Process Equipment

Equipment which is specifically designed and dedicated to Electrical Substation, Gas

iii. Auxiliary Equipment/Facilities

4.3.2 Occupational Health & Safety Hazards

Safety, Health & Environment Management System

Occupational Health, Safety and Environment Risk Assessment Procedure

EHS-S-01 Revision : 01 Rev. Date:05.02.2012 Page 5 of 17

4.3.3 Evaluation of Occupational Health & Safety Risks

The OH&S risks are determined on the basis of following parameters:

Safety, Health & Environment Management System

Occupational Health, Safety and Environment Risk Assessment Procedure

EHS-S-01 Revision : 01 Rev. Date:05.02.2012 Page 6 of 17

iii. Degree of Possible Harm to Human Life (c)

Basis for categorizing significant risk are:

Safety, Health & Environment Management System

Occupational Health, Safety and Environment Risk Assessment Procedure

EHS-S-01 Revision : 01 Rev. Date:05.02.2012 Page 7 of 17

The record of additional operational controls on significant OH&S risks is maintained on

(b) HRN II (Significant Risks that requires Additional Controls)

4.4 Evaluation of Environmental Hazards & Risks

4.4.1 Environmental Hazards

Safety, Health & Environment Management System

Occupational Health, Safety and Environment Risk Assessment Procedure

EHS-S-01 Revision : 01 Rev. Date:05.02.2012 Page 8 of 17

4.4.2 Evaluation of Environment Risks

The following formula is used for environmental risk assessment:

Environmental Risk = Likelihood of Occurrence X Severity

The results of environmental risk assessment (HRN I) will be maintained on

Safety, Health & Environment Management System

Occupational Health, Safety and Environment Risk Assessment Procedure

EHS-S-01 Revision : 01 Rev. Date:05.02.2012 Page 9 of 17

The record of additional operational controls on significant environmental risks is

(b) HRN II (Significant Environmental Risks that requires Additional Controls)

4.5 Task Hazard Analysis (THA)

Safety, Health & Environment Management System

Occupational Health, Safety and Environment Risk Assessment Procedure

EHS-S-01 Revision : 01 Rev. Date:05.02.2012 Page 10 of 17