# INSILOS INDUSTRIAL GROUP — STANDARD OPERATING FORM ## FORM-05: MASTER HAZARD IDENTIFICATION & 5X5 QUANTITATIVE RISK ASSESSMENT (HIRA) REGISTRY **Document Identifier**: `INSILOS-FRM-HSE-005` **Revision**: `3.0` **Governing Standard**: `ISO 45001:2018 Clause 6.1.2, ISO 31000:2018, SOP-02 (INSILOS-SOP-HSE-002), Decree 39/2016/ND-CP` **GRC Master Collections**: `risk_models` & `hse_risk_register` **ERP Integration**: Insilos ERP Preventive Maintenance (`maintenance.equipment`) Risk Multiplier --- ### SECTION 1: REGISTRY ADMINISTRATIVE SPECIFICATION | Administrative Parameter | Registry Record Data | | :--- | :--- | | **HIRA Registry ID** | `HIRA-REG-2026-Q4` | | **Facility / Plant Complex** | Insilos Heavy Mechanical Fabrication & Cát Lái Maritime Logistics Terminal | | **Governing Business Unit** | Insilos Operations, Industrial Automation & Logistics Division | | **Effective Assessment Date** | `2026-10-01` (Mandatory Annual / Q4 Master Review) | | **Lead Risk Assessment Engineer**| Tran Van Duc (Lead Automation & Reliability Engineer — Badge: `INS-EMP-10492`) | | **HSE Compliance Reviewer** | Hoang Thi Mai (Senior HSE Compliance Officer — Badge: `INS-HSE-00088`) | | **Executive Approval Authority** | Vu Dinh Quang (Director of Plant Operations — Badge: `INS-DIR-00004`) | --- ### SECTION 2: 5x5 QUANTITATIVE SCORING MATRIX CRITERIA $$\text{Risk Score } (R) = \text{Probability } (P) \times \text{Severity } (S)$$ - **Probability Scale (1 to 5)**: 1 = Improbable ($< 1$ per 10 yrs); 2 = Remote (1 per 3-10 yrs); 3 = Occasional (1 per 1-3 yrs); 4 = Frequent (Monthly to Quarterly); 5 = Continuous (Daily / Weekly). - **Severity Scale (1 to 5)**: 1 = Negligible (First aid, $< 10\text{M}$ VND); 2 = Minor (Medical treatment $\le 3$ lost days, $10\text{M}-100\text{M}$ VND); 3 = Moderate (Lost time $> 3$ days, $100\text{M}-500\text{M}$ VND); 4 = Major (Amputation, single fatality, $500\text{M}-2.5\text{B}$ VND); 5 = Catastrophic (Multiple fatalities, $> 2.5\text{B}$ VND). - **Risk Classification Bands**: * **1 to 4: LOW (Green)** — Acceptable under routine operational controls. * **5 to 9: MEDIUM (Yellow)** — Tolerable if ALARP; supervisory oversight and JSA required. * **10 to 14: HIGH (Amber)** — Undesirable; engineered controls and mandatory e-PTW required. * **15 to 25: CRITICAL (Red)** — Strictly prohibited; immediate work stoppage until redesigned. --- ### SECTION 3: COMPREHENSIVE INDUSTRIAL RISK REGISTER ``` +----------------------------------------------------------------------------------------------------------------------------------------------------+ | INSILOS MASTER HIRA REGISTER — QUANTITATIVE 5x5 RISK EVALUATION & BOWTIE BARRIER CONTROL MATRIX | +------------+-----------------------+-----------------------------+-------+--------------------+--------------------+-------+-----------------------+ | Risk ID / | Work Activity & | Hazard Description & | Inh. | Preventive | Mitigating | Res. | Action Owner & | | Location | Operational Step | Hazardous Top Event | P S R | Barriers (Left) | Barriers (Right) | P S R | Status in GRC | +------------+-----------------------+-----------------------------+-------+--------------------+--------------------+-------+-----------------------+ | RSK-W02-01 | Operation of 20kW | High-pressure N2 line | 4 4 16| 1. Dual PSV valves | 1. Ambient O2 dump | 1 4 4 | T. V. Duc | | Zone A | Fiber Laser CNC | rupture at 30 bar. | (CRIT)| calibrated 33bar| ventilation fan | (LOW) | `INS-EMP-10492` | | Bay 03 | Assist Gas System | Top Event: Gas explosion | | 2. Auto ESD shutoff| 2. Polycarbonate | | Status: ACTIVE | | | | and sudden asphyxiation. | | 3. Quarterly NDT. | blast shield. | | GRC ID: `RSK-1049` | +------------+-----------------------+-----------------------------+-------+--------------------+--------------------+-------+-----------------------+ | RSK-W02-02 | Robotic Arc Welding | 6-axis robot arm collision | 4 4 16| 1. Interlocked dual| 1. High-speed E-Stop| 1 3 3 | D. T. Hieu | | Zone B | Cell 02 (SS400 Frame | with technician during teach| (CRIT)| optical curtain | cable trip. | (LOW) | `INS-EMP-10933` | | Bay 02 | Jig Alignment) | mode. Top Event: Blunt-force| | 2. Deadman 3-pos | 2. Impact-absorb | | Status: ACTIVE | | | | mechanical crushing trauma. | | teach pendant. | padded vest. | | GRC ID: `RSK-1052` | +------------+-----------------------+-----------------------------+-------+--------------------+--------------------+-------+-----------------------+ | RSK-W02-03 | Confined Space Entry | Nitrogen buildup & oxygen | 3 5 15| 1. LOTO positive | 1. Standby winch | 1 4 4 | D. Q. Cuong | | Zone A | in Recovery Buffer | depletion in vessel. | (CRIT)| pipe blinding | tripod rescue. | (LOW) | `INS-EMP-10811` | | Cistern | Cistern (TNK-02) | Top Event: Asphyxiation of | | 2. Continuous 4-gas| 2. 15-min EEBA | | Status: ACTIVE | | | | technician inside cistern. | | sniffing probe. | escape packs. | | GRC ID: `RSK-1058` | +------------+-----------------------+-----------------------------+-------+--------------------+--------------------+-------+-----------------------+ | RSK-W02-04 | Working at Height on | Technician slip/fall from | 4 4 16| 1. Certified 4.5m | 1. Dual shock- | 1 3 3 | P. M. Tuan | | Zone A | Elevated Laser Duct | temporary scaffold platform.| (CRIT)| scaffold with | absorbing lanyard| (LOW)| `INS-EMP-11450` | | Bay 03 | Mezzanine (+4.5m) | Top Event: High-altitude | | toe-boards. | 2. Trauma relief | | Status: ACTIVE | | | | worker fall to concrete. | | 2. Green Scafftag. | suspension loop.| | GRC ID: `RSK-1064` | +------------+-----------------------+-----------------------------+-------+--------------------+--------------------+-------+-----------------------+ | RSK-TRM-01 | Ship-to-Shore Gantry | Heavy container hoist wire | 3 5 15| 1. Auto LMI load | 1. Automated AI | 1 4 4 | P. V. Long | | Berth 03 | Crane 40-Ton Container| rope fatigue snapping. | (CRIT)| cell limiter. | CCTV geofence | (LOW) | `INS-EMP-10651` | | Cát Lái | Discharge Operation | Top Event: Uncontrolled 30T | | 2. Daily wire rope | 2. 10m physical | | Status: ACTIVE | | | | container drop on dock. | | magnetic NDT. | exclusion zone. | | GRC ID: `RSK-1070` | +------------+-----------------------+-----------------------------+-------+--------------------+--------------------+-------+-----------------------+ | RSK-TRM-02 | Terminal Tractor & | High-speed terminal tractor | 4 4 16| 1. Segregated green| 1. High-vis Class 3| 1 3 3 | N. T. Kien | | Marshaling | Heavy Forklift Mobile | collision with pedestrian. | (CRIT)| pedestrian lane | reflective vest.| (LOW) | `INS-LOG-00412` | | Yard 02 | Traffic Co-Location | Top Event: Person run-over | | 2. 15 km/h radar | 2. Ultrasonic cab | | Status: ACTIVE | | | | by 32-ton laden tractor. | | speed governor. | proximity horn. | | GRC ID: `RSK-1075` | +------------+-----------------------+-----------------------------+-------+--------------------+--------------------+-------+-----------------------+ | RSK-W01-01 | Central Electrical | High-energy electrical arc | 3 5 15| 1. 6-Step LOTO with| 1. 40 cal/cm2 arc | 1 4 4 | N. Q. Bao | | Substation | Switchgear Overhaul | flash during breaker racking| (CRIT)| master padlocks.| flash suit & hood| (LOW)| `INS-EMP-11028` | | Sub-01 | (22kV / 0.4kV Bus) | Top Event: Explosive arc- | | 2. Remote racking | 2. Auto optical arc| | Status: ACTIVE | | | | blast plasma vapor release. | | robot motorized.| detector trip. | | GRC ID: `RSK-1082` | +------------+-----------------------+-----------------------------+-------+--------------------+--------------------+-------+-----------------------+ | RSK-W03-01 | Chemical Surface | Nitric acid bath heating | 3 4 12| 1. Redundant RTD | 1. Emergency safety| 1 3 3 | L. V. Hai | | Chemical | Pickling & Passivation| coil runaway & boilover. | (HIGH)| temp shutoff. | deluge shower. | (LOW) | `INS-EMP-10884` | | Bay 01 | for Stainless Steel | Top Event: Acid splash & | | 2. 110% concrete | 2. Full chemical | | Status: ACTIVE | | | | toxic NOx plume release. | | containment bund| suit & respirator| | GRC ID: `RSK-1089` | +------------+-----------------------+-----------------------------+-------+--------------------+--------------------+-------+-----------------------+ ``` --- ### SECTION 4: BARRIER DEGRADATION & PREVENTIVE MAINTENANCE TELEMETRY In accordance with SOP-02 §8.3, every safety-critical barrier in this register is monitored dynamically via Insilos ERP Preventive Maintenance (`maintenance.equipment`): | Critical Safety Barrier | Linked Insilos ERP Maintenance Asset | Preventive Maintenance Frequency | Failure Action Protocol | | :--- | :--- | :--- | :--- | | **PSV-101A/B Pressure Relief** | `AST-PSV-NITRO-01` | Semi-Annual Bench Test & Calibration | If test fails, e-PTW auto-blocked; line locked out. | | **Robot Light Curtain Interlock** | `AST-ROBOT-WELD-02` | Monthly Optical & Response Time Audit | Light curtain bypass trips master production line halt. | | **Crane Load Moment Limiter** | `AST-CRANE-STS-03` | Bi-Weekly Load Cell Deadweight Check | Crane lifting speed electronically restricted to 10%. | | **Substation Optical Arc Trip** | `AST-SUB-01-SWG` | Annual Primary Injection & Lux Test | High-voltage feeder circuit breaker locked open. | --- ### SECTION 5: ANNUAL REVIEW & EXECUTIVE RE-CERTIFICATION ``` LEAD RISK ASSESSMENT ENGINEER: I certify that the hazard evaluations and quantitative 5x5 scores accurately reflect physical plant conditions and adhere to the ISO 45001:2018 ALARP standard. Name: Tran Van Duc Badge: INS-EMP-10492 Date: 2026-10-01 08:30:00 UTC Signature: [DIGITALLY SIGNED & VERIFIED IN GRC] CORPORATE HSE COMPLIANCE AUDITOR: Name: Hoang Thi Mai Badge: INS-HSE-00088 Date: 2026-10-01 09:00:00 UTC Signature: [DIGITALLY SIGNED & VERIFIED IN GRC] DIRECTOR OF PLANT OPERATIONS & EXECUTIVE COMMITTEE: Name: Vu Dinh Quang Badge: INS-DIR-00004 Date: 2026-10-01 09:30:00 UTC Signature: [DIGITALLY SIGNED & VERIFIED IN GRC] MASTER REGISTRY STATUS: [ VALIDATED & RELEASED TO GRC/ERP RUNTIME ] ```