Hazard Identification and Risk Assessment (HIRA) in the Construction of Large-Scale Solar Power Plants in India

Engineering notes

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Chinese explanation / 中文解读

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Original abstract

The rapid transition towards renewable energy in India, driven by ambitious national targets and the need for sustainable development, has catalyzed a massive surge in the construction of utility-scale solar power plants. While these mega-projects are indispensable for achieving energy independence and reducing the national carbon footprint, their extensive and fast-paced construction phases introduce highly complex occupational health and safety challenges. This research presents a comprehensive investigation into Hazard Identification and Risk Assessment (HIRA) meticulously tailored for the unique environment of large-scale solar project sites across India Renewable power plants are booming these days. Constructions of renewable power plants pose serious risks to workers safety and health. To ensure its success we need to make sure that it remains safe, reliable and sustainable throughout its construction and operation phase. This can be achieved by effectively evaluating a power plant’s health and safety, associated hazards and risks and implementing necessary control measures. In this study, we have used a HIRARC (Hazard Identification, Risk assessment & Risk control) model to identify all the hazards and associated risk to the worker’s safety and health on a 350MW Solar Power plant unit-I and Unit-II. Hazard identification is carried out by critically analyzing existing risk assessments, interviewing personnel and conducting walkthroughs. Risk assessment is carried out using qualitative analysis of hazard’s likelihood and its consequence severity. Quantitative analysis is used to divide the risk in high, medium and low categories using simple 5X5 risk matrix. The findings were then used to identify and recommend necessary control measures to deal with high risk activities and bring down its risk level to an acceptable range. The aim of this study is to make solar power projects much safer and accident free by identifying significant hazards, evaluating the associated risks and determining the necessary control measures based on the basic risk control hierarchy. These measures will help in making solar power projects a safer project sites, reducing accident rates at site, reducing staff turnover rates, improving safety culture and increasing worker’s satisfaction in terms of safety. The study systematically evaluates the entire construction lifecycle—ranging from initial site clearing, heavy earthmoving, and foundation piling, to the erection of Module Mounting Structures (MMS), Photovoltaic (PV) panel installation, deep trenching, and the critical commissioning of high-voltage electrical infrastructure such as inverters and transformers. Through a robust methodology combining rigorous site observations, historical incident analysis, and structured questionnaire surveys distributed among site engineers, safety officers, and project managers, a wide spectrum of unsafe acts and environmental conditions was documented. The research highlights critical occupational hazards, including high-voltage electrical risks (arc flashes and shocks), mechanical entrapments during heavy material lifting, ergonomic strains from repetitive module handling, and fall hazards during structural erection, and extreme thermal stress due to prolonged exposure to harsh Indian weather conditions. Utilizing both quantitative and qualitative risk assessment tools, including the Relative Importance Index (RII) and standardized Risk Matrices, the identified hazards are systematically ranked based on their probability of occurrence and potential severity. The analysis isolates the most acute safety vulnerabilities that demand immediate managerial intervention. Consequently, this study proposes a site-specific framework of mitigation strategies, integrating engineering controls, stringent administrative protocols, and the mandate of specialized Personal Protective Equipment (PPE). Ultimately, this research provides a pivotal safety management blueprint for industry stakeholders, aiming to eliminate workplace accidents, ensure strict regulatory compliance, minimize costly project delays, and foster a sustainable safety culture within India's booming solar infrastructure sector

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