Protected

MSRA sheet ownership by : Plant Safety management

#

Toyota Kirloskar Motors Ltd Bidadi Method statement and Risk Assessment Sheet Document type : Protected
Department & Division :UTILITY P2, Plant Maintenance Division Name of the contactor : Siemens Limited Location : P2 Weld Cooloing Tower Date: 04/10/2024
Activity Details : Weld Cooling Tower (WCT) Tank Cleaning Working area clearance by :

Activity validity : 1 week Department : Name : TKM ID : Sign :

RISK RATING RISK RATING
Risk RISK RISK
Severity Probability Severity Probability Risk rating
SI. No MAIN ACTIVITY SUB ACTIVITIES NAME OF CHEMICALS USED PHOTO PROBABLE HAZARD rating RANKIN COUNTERMEASURE SAFETY KEY POINT RANKI
R= G R= NG
S P S P
SxP SxP
GENERAL SAFETY INSTRUCTIONS AND KYT JOB SPEIFIC INSTRUCTIONS (TKM / contractor job leader instructions to all working team )
1. Job specific training and sticker confirmation by TKM job leader 2. Working team health confirmation by contractor job leader Height work Instructions
Example : Height work , Hot work a. Contractor working team free from sickness like Fever, Cold,
Helper - General sticker Cough, Breathing difficulty etc. 1.Team member must be anchored full body harness above the shoulder lever while working at Height
a. Only trained members must perform the job (Below 45 age yearly once and above 45 yearly twice ) 2.Always anchor the belt on truss while crossing one place to another place
b. Educate about social distance , Continuously wearing of mask ,not to share food, drinking water and PPE's to others 3. Both lanyard should not be unhook at same time
c. Confirm the medical test report (Eye test) for Special equipment operator like crane , forklift , cherry picker etc. 4. Barrication to be provided before work start and banner to be displayed to alert the people
d. Ensure no person carrying cigarettes, match box, lighter & tobacco/ Gutka and chewing gum to the work place 5. Cherry picker Do's and Don'ts to be explained
6. Ensure the over head power line supply is off while operating the cherry picker and farana

3. Ensure daily safety measures confirmation in work permit by TKM and Contractor job leaders 4. Ensuring of equipment healthiness in good condition by TKM / Contractor Job leader / Safety officer : Electrical safety Instructions :
Work Permits available in TKM are a. Kindly use TKM standard equipment check sheet to inspect the equipment healthiness
1. Height b. Ensure approved green tag displayed on machine and green tag within validity 1. Ensure Incoming Supply Is Off & LOTO Is applied for all working Member in Incoming feeder.
2. Hot c. Kindly check the equipment on daily basis before work start by using standard check sheet (Ownership - TKM /
3. Excavation Contractor job leader/Contractor safety officer)
4. Confined job
5. High Voltage Permit

5. Fire safety (Ensure six point check before doing hot work ) 6. Height
1. Suitable fire extinguisher depend on hazardous source & Fire Blanket - IS code :
2. Barricade the working area a. Confirm the healthiness of safe built scaffold as per standard TKM check sheet - Confirmation by Contractor safety
3. Fire watch man must available officer /Job leader and TKM job leader
4. No flammable material and combustible material at work site b. Cross confirm the built scaffold from plant safety management before work start and displayed the green tag on
5. Safe electrical connection example: No joints and damage free cable, ELCB connection, Industrial plug ). scaffold
6. Display the hot and height work banner

Risk assessment details :

RISK Assessment RISK RATING

RISK
Severity Probability Risk rating RISK Severity Probability Risk rating
Sl No MAIN ACTIVITY SUB ACTIVITIES NAME OF CHEMICALS USED PHOTO PROBABLE HAZARD RANKING
COUNTERMEASURE SAFETY KEY POINT RANKIN
R= R= G
S P S P
SxP SxP

1. Method statement to be explained to all team in local languages by

job leader
2. Last day activity discussion / Safety concern review and 1. Ensure the all member attend the KYT
1) Assembling all the team Members at KYT Area communication to the TM
2) Confirmation of attendants in KYT. 3. Equipment checking before start of work 2. Checked all member Safety shoes, ID card, Safety
3) Explaining about TKM Basic guidelines for contractors. 1. Miss-understanding between works and method Helmet.
4) Explaining about work based safety precautions 3. Explain the DOs and Don't in their respective activity.
Conducting KYT for 2. Communication not clear 4. Work permit checked and confirmation before start the activity 4. Endure No Jewellery like ring, Chain and other
1 5) Explanation of risks involved in similar activities. NA 2 2 4 B 2 1 2 C
all team members. 3. Improper Work Procedure 5. conduct exercise during KYT for refreshing the mind and body ornaments
6) Communicating General safety key points and Yokoten points. 4. Location of Work to be Specific
7) Explanation of daily activity and safety precautions for that. 6. Ensure all TM member having Valid TKM id card 5. Ensure all members are having training Certificates
8) Conducting work based KYT to seperate workforce. 7. Ensure the TM under gone general induction training and job like Height work for working in height.
9) Checking the healthiness of members PPE specific training. 6. Ensure previous day concerns are explained to the
8. Ensure refreshment exercise is given to the members in daily members in morning KYT.
KYT. 7. Ensure communication is given to the member
9. Confirm the PPE's and its healthiness for all the members before regarding the Assembly Point, Rest Room and Drinking
starting any activity in KYT. water Facilities
8. Ensure certified electrician only authorized to carryout
10. Ensure all team members using PPE's the activity.
 Protected

MSRA sheet ownership by : Plant Safety management

#

Toyota Kirloskar Motors Ltd Bidadi Method statement and Risk Assessment Sheet Document type : Protected
Department & Division :UTILITY P2, Plant Maintenance Division Name of the contactor : Siemens Limited Location : P2 Weld Cooloing Tower Date: 04/10/2024
Activity Details : Weld Cooling Tower (WCT) Tank Cleaning Working area clearance by :

Activity validity : 1 week Department : Name : TKM ID : Sign :

RISK RATING RISK RATING
Risk RISK RISK
Severity Probability Severity Probability Risk rating
SI. No MAIN ACTIVITY SUB ACTIVITIES NAME OF CHEMICALS USED PHOTO PROBABLE HAZARD rating RANKIN COUNTERMEASURE SAFETY KEY POINT RANKI
R= G R= NG
S P S P
SxP SxP
1. Safety officer and JL leader should ensure all tools and
equipment's condition & healthiness
1. Ensure proper selection of tools and equipment's
2. Check the Electrical connections.
2. Before start of work check all machine and equipment's must be
1. Fall of material
confirmed with job leader.
2. Coming in contact with sharp edges of the
3. Only competent person should select the tools and Equipments
Equipments. 3. All Accessories of equipment should be free from damage
Tools confirmation & required.
2 c NA 3. Incompetent person confirming the equipment. 2 2 4 B and shall be calibrated. 2 1 2 C
health check. 4. All tools and Equipments selected must be visually inspected and shall
be in sound condition.
4. Using unhealthy and damaged equipment. 4. Do not bring
5. Using non standard and non - calibrated equipment from store to work place any damage and Defective tools /
5. Ensure tools & Instrument safe for use
Equipment.
6. Wear Proper PPE's
5. Used only Planned Equipment at Work site.
1. Safetytrained
6. Only officer and JLareleader
persons should
allowed ensuretheall Safety
to operate
PPE's
Equipments.
2. Confirm the usage of mandatory PPEs during the work.
1. Ensure proper PPE's
3. Provide the job specific ppe's to those who are involve
1) Safety PPE's Daily Pre Check 2. Before start of work check all Safety PPE's like( helmet, Gloves,
in electrical work, etc.
Googles.)
1. Expired PPEs 4. Job specific training to be provided for the operator
2) Gathering all the Safety PPE's 3. Giving awareness regarding usage of PPEs
2. Usage of contaminated PPEs prior to start of the activity
3) Checking the helmet, cotton gloves, 4. Ensure PPE's without any damage
3 PPE Confirmation NA 3. Damaged PPE usage 2 2 4 B 2 1 2 C
4) Confirmation of PPE's condition. 5. Dispose damaged PPEs at designated location and do not use
4. Wearing loose clothing
5) Ensure the healthiness of PPE. contaminated PPEs.
5. Using inadequate PPE

5.Check and confirm the PPEs are not damaged.

6. Ensure all the PPEs selected are healthy.
1. Only allowing certified vehicles and competent drivers.

1. Improper selection of the equipment.

2.Competent & driver operator must be deployed
2. Incompetent operator / driver 3. Vehicle to be stopped at the designated parking locations.
3. Crane/Farana and trailer parking at unauthorized
places.
1. TPI certificate of lifting Equipments, tools and tackles
4. Arranging lifting Equipments with invalid TPI 4. Ensuring TPI certificate of the vehicle during arrangement.
must be ensured.
certificate. 5. Ensure all the safety devices of the lifting equipments are in
2. Park the crane/Farana and trailer only on the
5. Unsafe driving method working condition.
designated parking location.
6. Selecting uncertified lifting tools and tackles. 6. Ensure inspection tag and healthiness of the tools and tackles
3. Recheck of the lifting tools and tackles must be done.
Mobilizing and demobilizing 23MT crane & Trailer to the 7. Use of damaged lifting tools. using check sheet.
4 NA 3 1 3 B 4. Ensure crane/Farana and trailer healthiness and 2 1 2 C
Transformer room 8. Over speeding. 7. Examine TPI certificate of the lifting tools and tackles during
function according to the inspection checklist.
9. Over head electrical line coming in induction selection.
5. Ensure that load charts are displayed on the
zone 8. Ensure TKML green tag availability on the vehicle.
crane/Frane.
10. Pathway obstruction.
6. Operator &
driver competence must be examined.
11. Operate in inclement weather condition 9. Do not over speed the vehicle
10. Lifting Equipments can be operate suitable weather condition
12. Operate in uneven ground condition/ less
ground pressure areas
11. Should not allowed the Crane/ Farana and on the uneven ground
or less density areas
12. Over head obstruction and path way obstruction shall be cleared.
 Protected

MSRA sheet ownership by : Plant Safety management

#

Toyota Kirloskar Motors Ltd Bidadi Method statement and Risk Assessment Sheet Document type : Protected
Department & Division :UTILITY P2, Plant Maintenance Division Name of the contactor : Siemens Limited Location : P2 Weld Cooloing Tower Date: 04/10/2024
Activity Details : Weld Cooling Tower (WCT) Tank Cleaning Working area clearance by :

Activity validity : 1 week Department : Name : TKM ID : Sign :

RISK RATING RISK RATING
Risk RISK RISK
Severity Probability Severity Probability Risk rating
SI. No MAIN ACTIVITY SUB ACTIVITIES NAME OF CHEMICALS USED PHOTO PROBABLE HAZARD rating RANKIN COUNTERMEASURE SAFETY KEY POINT RANKI
R= G R= NG
S P S P
SxP SxP

1. Check the healthiness of full body harness using by the team

member.
2. Hook the full body harness on cooling tower's rigid body.
1. During cherry picker movement, workers should not
1. Person May Fall From Height stand on the bucket ,also hook the safety belt at two
2. Mobile crane/Farana and trailer may hit to 3. Crane must be positioned in even ground surface. different points
members ,over head obstruction ,vehicle, over 2. Ensure the communication between operator and
head other object working team throughout activity.
Move the crane/ Farana and triler to designated location loading 3. Overturning of crane due to uneven ground 4. Ensure that the Equipments are not used in inclement weather. 3. Ensure all operators are competent.
NA 3 2 6 A 2 1 2 C
point surface. 5. Maintained the safe distance from equipment. 4. Ensure all team members in complete PPE usage such
4. Inclement weather 6. Ensure radius of swing and pathway doesn't have any structural as Safety goggles, safety shoe, safety helmet, hand gloves
5. Collapse of trailer and crane due to mechanical obstruction and overhead power lines full body harness, etc.
failure. 7. Ensure all the operators are competent. 5. Ensure outtrigger of the crane are extended and firm
8. Ensure the outrigger of the crane are completely extended and 2.5 with the ground
1. Crane/ Farana must be use on the even ground condition and
mtr away from the trench.
should not operate loose soil.
9. Pre inspection of the crane and cherry picker shall be done.
10. Signalman must be available to guide the cherry picker and crane
2. All the physical parameter of Crane / Farana should be thoroughly
to the location.
1. Toppling of Crane / farana due to uneven place examined before the work activity
or less density sand
2. Collapse due to uneven tyre pressure , 3. Competence operator must be allowed.
mechanical failure, over load limit

3. Operate by incompetent person 4. Signal man to be appointed.

1. Ensure barricades around the work area
4. Operate without signal man
5. crane/ Farana can be operate only in good weather condition 2. Ensure the wind speed below 32 km/hr (As per OSHA
5. operate in inclement weather 1926.1431 (K)(8)(i))

6. Operate without extend the outrigger or partial 6. Outrigger must be extend fully before lifting 3.Ensure the clear visibly of operator and ensure the
Positioning of Crane / Farana and trailer to load the transformers NA 3 3 9 A 3 1 3 B
extended condition of wind shield
7. visual obstruction to the operator
7. Limit switch and ASLI must be checked before lifting
8. Limit switch and alarm malfunction 4. Tyre pressure must be checked before lifting.

8. Ensure there is no over head power lines

9. ASLI malfunction

10. Damaging wire rope and Hook , latch 9. Wire rope condition and hook, latch must be checked and ensure 1.Ensure rollers placed properly under the equipment
its healthiness
11. Contact with over head power line and hit to 2.Ensure signalman
the personnel 10. Crane / farana should not be over loaded deployment
1. Ensure Trained Job leader presence at Site 3.Confirm the
1. Person may get injured
2. Ensure Proper PPE"s weight of the equipment and Rollers capacity.
Shifting of 2. Material may fall on person 11. Barricades to be provided and no personnel should be allowed 3.
Lift the transpormers using our jacks, place the rollers and lead the
Transformers from 3. Material may get damaged 3 2 6 A 1. Crane/ Farana must be use on the even ground condition and
inside 3 1 3 c
transformers from insdie the room Ensure proper slings 4.Ensure the Lowering path is clear and in good
Transformer Room to 4. Fingers may get injured should not operate loose soil and should not overloaded
4. Ensure Proper Material condition
Spare Room 5. Rollers may slip.
Handling 5. Barricade the working area to restrict the un-
2. All the physical parameter of Crane / Farana should be thoroughly
authorized entry
examined before the work activity
1. Toppling of Crane / farana due to uneven place
3. Competence operator must be allowed.
or less density sand
2. Collapse due to uneven tyre pressure ,
mechanical failure, over load limit
4. Signal man to be appointed.
3. Operate by incompetent person
5. Crane/ Farana can be operate only in good weather condition
4. Operate without signal man

5. operate in inclement weather

6. Outrigger must be extend fully before lifting
5 1. Ensure no man movement inside the lifting area/ line
6. Operate without extend the outrigger or partial
of fire
extended
7.Clear visibility must be provided. The rigging of transformer can 2. Packing to be provided if sharp edges present
7. visual obstruction to the operator
be done by means of mobile platform with anchoraging the safety
Lead out the Transpormerns onto the trailer at Transformer Room harness on the railings. 3. Minimum 12mm thickness 6m length two guide rope
8. Limit switch and alarm malfunction 3 3 9 A 3 1 3 B
and transport near to Spare Room to be used

8. Limit switch and ASLI must be checked before lifting. 4. Ensure proper communication between signal man and
9. ASLI malfunction
operator
5.Ensure the limit switch and ASLI function good
10. Damaging wire rope and Hook , latch.
9. Ensure there is no over head power lines.
11. Fall of materials

12. Contact with over head power line and hit to

10. Wire rope condition and hook, latch must be checked and ensure
the personnel / property
its healthiness. 11. Check the healthiness of anchoring
points (lifting points) provided on the transformer by visual
13.Using damaged tools & tackles
inspection and NDT.
14. Collapse of Cherry picker and Crane/Farana
12.Safe distance maintain from over head power lines.
15. Man movement below the boom radius
13. Two guide rope must be provided for controlling the oscillation
of gear box during lifting
14. No personnel should allow inside the line of fire 15. Ensure the
load is placed on the trailer with proper packing and in secured
condition.
 Protected

MSRA sheet ownership by : Plant Safety management

#

Toyota Kirloskar Motors Ltd Bidadi Method statement and Risk Assessment Sheet Document
1. Crane/ type : Protected
Farana must be use on the even ground condition and
Department & Division :UTILITY P2, Plant Maintenance Division Name of the contactor : Siemens Limited should not operate
Location : P2loose
Weldsoil.
Cooloing Tower Date: 04/10/2024
Activity Details : Weld Cooling Tower (WCT) Tank Cleaning Working area clearance by :
2. All the physical parameter of Crane / Farana should be thoroughly
examined before the work activity
Activity validity : 1 week Department : Name : TKM ID : Sign :
1. Toppling of Crane / farana due to uneven place
RISK RATING 3. Competence operator must be allowed. RISK RATING
or less density sand
2. Collapse due to uneven tyre pressure , Risk RISK RISK
Severity Probability Severity Probability Risk rating
SI. No MAIN ACTIVITY SUB ACTIVITIES NAME OF CHEMICALS USED PHOTO mechanical failure, over load
PROBABLE limit
HAZARD rating RANKIN COUNTERMEASURE SAFETY KEY POINT RANKI
4. Signal man to be appointed.
R= G R= NG
3. Operate by incompetent person S P S P
SxP SxP
1. Ensure barricades around the work area
5. crane/ Farana can be operate only in good weather condition
4. Operate without signal man
2.Ensure the wind speed below 35 km/hr
5. operate in inclement weather
6. Outrigger must be extend fully before lifting
3.Ensure the clear visibly of operator and ensure the
Position of Crane F-23 crane and trailer to unload the 6. Operate without extend the outrigger or partial condition of wind shield
3 3 9 A 3 1 3 B
Transformers from the trailer extended
7. Limit switch and ASLI must be checked before lifting
7. visual obstruction to the operator
4. Tyre pressure must be checked before lifting.
8. Limit switch and alarm malfunction
8. Ensure there is no over head power lines 9. Check the
5. Ensure safe clearance between cherry picker and
healthiness of anchoring points (lifting points) provided on the
Crane/ farana
transformer by visual inspection and NDT.
9. ASLI malfunction

10. Damaging wire rope and Hook , latch

10. Wire rope condition and hook, latch must be checked and ensure
its healthiness
11. Contact with over head power line and hit to
the personnel
11. Crane / farana should not be over loaded

12. Barricades to be provided and no personnel should be allowed

inside. 13. Ensure the load is placed on the trailer with proper
packing and in secured condition.
 Protected

MSRA sheet ownership by : Plant Safety management

#

Toyota Kirloskar Motors Ltd Bidadi Method statement and Risk Assessment Sheet Document type : Protected
Department & Division :UTILITY P2, Plant Maintenance Division Name of the contactor : Siemens Limited Location : P2 Weld Cooloing Tower Date: 04/10/2024
Activity Details : Weld Cooling Tower (WCT) Tank Cleaning Working area clearance by :

Activity validity : 1 week Department : Name : TKM ID : Sign :

RISK RATING RISK RATING
Risk RISK RISK
Severity Probability Severity Probability Risk rating
SI. No MAIN ACTIVITY SUB ACTIVITIES NAME OF CHEMICALS USED PHOTO PROBABLE HAZARD rating RANKIN COUNTERMEASURE SAFETY KEY POINT RANKI
G 1. Crane/ Farana must be use on the even ground condition and NG
R= R=
S P should not operate loose soil and should not overloaded S P
SxP SxP
2. All the physical parameter of Crane / Farana should be thoroughly
examined before the work activity

3. Competence operator must be allowed.

4. Signal man to be appointed.

5. crane/ Farana can be operate only in good weather condition

1. Ensure no man movement inside the lifting area/ line
of fire
6. Outrigger must be extend fully before lifting 2. Packing to be provided if sharp edges present

6. Unloading of Transformers at P2 Spare room with the help of 3. Minimum 12mm thickness 6m length two guide rope
3 3 9 A 3 1 3 B
F-23 crane 7.Clear visible must be provided to be used

4. Ensure proper communication between signal man and

8. Limit switch and ASLI must be checked before lifting operator
5.Ensure the limit switch and ASLI function good

9. Ensure there is no over head power lines

10. Wire rope condition and hook, latch must be checked and ensure
its healthiness

11.Safe distance maintain from over head power lines

1.Ensure rollers placed properly under the equipment
12. Two guide rope must be provided for controlling the oscillation
2.Ensure signalman
of gear box during lifting
deployment
13. No personnel should allow inside the line of fire
1. Ensure Trained Job leader presence at Site 3.Confirm the
1. Person may get injured
2. Ensure Proper PPE"s weight of the equipment and Rollers capacity.
2. Material may fall on person
Lift the transpormers using our jacks, place the rollers and lead the 3.
6 3. material may get damaged 3 2 6 A 3 1 3 c
transformers from insdie the room Ensure proper slings 4.Ensure the Lowering path is clear and in good
4. Fingers may get injured
4. Ensure Proper Material condition
5. Rollers may slip.
Handling 5. Barricade the working area to restrict the un-
authorized entry
1.Ensure Jack COG
2.Do not rest
body to the equipment,
1. Ensure Trained Job leader presence at Site
1.Jig may fall down 3.Ensure proper
2. Ensure Proper PEE"s
2. Fingers may get injured material handlig equipments.
3. Pinch hazard
7 Position the transformers as required by the user NA 3 2 6 A 3. Ensure Abreaction for Work Area 3 1 3 c
4. Material 4 Do not drag/swing the load
4. Ensure lifting tools
may fall down. 5.
properly.
Fingers may get injured
5. Ensure Proper Material Handling equipment
5.
1.Ensure
Barricadethat
the the fencing
working should
area remove
to restrict the to position the
un-authorised
Crane
entry pointed to you
2. Ensure all
1. Ensure Trained Job leader presence at Site 2. regulatory documents at place
Ensure Proper PEE"s 3.Ensure Pre
3. Ensure Barrication for Work Area entry check at the gate.
3 2 6 A 4. Ensure Proper KYT to be given. 4.Ensure 3 1 3 c
5. authorised operator,
Ensure Proper Material Handling
1. Toppling of Crane
5.Ensure signalman deployment
2. Crane may hit to member or property
8 Demobilisation of Crane and trailer NA 6.Confirm the weight of the equipment and Crane
3. Overloading
capacity. 7.Ensure
the movement path is clear and in good condition
8. Barricade the
working area to restrict the un-authorised entry
9. Ground condition
should bear load.
10. Avoid Crane
operations in winding conditions

1. Provide proper ppe's

2. After the work area is completely cleaned and 4s activity has to be 1. Confirm with check list no tools left
1) Removing of all waste & unwanted materials from work site
1) Bad 4s. done 2. Ensure that all the materials are stacked properly and
9 4s activity 2) Area cleaning by manually NA 1 2 2 C 1 1 1 C
2) Slipping and tripping hazard. 3. Check all machinery and tools have been removed physically no loose materials are left uneven on the ground.
3) Vacate the site after ensuring the complete 4s.
4. collect the generated waste in segregated manner.
5. send the waste to value yard without fail.

Additional comments :

1
2
3

Note:
To Submit MSRA to PAD safety kindly follow SOP
Chemicals need to declare:
1. Liquids 2. Gasses 3. Semi-solid/semi/liquid 4. Granular/Powder 5. Solids which may/can change to above states during handling/usage
Activity confirmation before work start by job leader Confirmation by
 Protected

MSRA sheet ownership by : Plant Safety management

#

Toyota Kirloskar Motors Ltd Bidadi Method statement and Risk Assessment Sheet Document type : Protected
Department & Division :UTILITY P2, Plant Maintenance Division Name of the contactor : Siemens Limited Location : P2 Weld Cooloing Tower Date: 04/10/2024
Activity Details : Weld Cooling Tower (WCT) Tank Cleaning Working area clearance by :

Activity validity : 1 week Department : Name : TKM ID : Sign :

RISK RATING RISK RATING
Risk RISK RISK
Severity Probability Severity Probability Risk rating
SI. No MAIN ACTIVITY SUB ACTIVITIES NAME OF CHEMICALS USED PHOTO PROBABLE HAZARD rating RANKIN COUNTERMEASURE SAFETY KEY POINT RANKI
R= G R= NG
S P S P
SxP SxP
yes TKM job leader Name : TM No: Sign:
MSRA Preparation & execution team Are Same ?
1
If No: job leader change point details need to be mentioned & MSRA need to be study thoroughly by job leader. No Contractor Job Leader: Sign:
TKM Job Leader Name: TM No: Sign:
Accordingly to MSRA safety facility confirmed before start up ?
2 yes
Example: cherry picker, Life line, safety belt etc. Contractor Job Leader: Sign: