This safety plan document outlines safety procedures and guidelines for project sites. It includes details on safety organization, roles and responsibilities, hazard identification, safety rules for various activities, incident reporting, inspections, training, protective equipment, emergency response, and safety requirements for subcontractors. The plan aims to ensure a safe working environment and compliance with local regulations for construction and operation of oil storage tank farms and terminals.
This safety plan document outlines safety procedures and guidelines for project sites. It includes details on safety organization, roles and responsibilities, hazard identification, safety rules for various activities, incident reporting, inspections, training, protective equipment, emergency response, and safety requirements for subcontractors. The plan aims to ensure a safe working environment and compliance with local regulations for construction and operation of oil storage tank farms and terminals.
This safety plan document outlines safety procedures and guidelines for project sites. It includes details on safety organization, roles and responsibilities, hazard identification, safety rules for various activities, incident reporting, inspections, training, protective equipment, emergency response, and safety requirements for subcontractors. The plan aims to ensure a safe working environment and compliance with local regulations for construction and operation of oil storage tank farms and terminals.
Disclaimer: This document was prepared for use at Indian Oiltanking Project Sites only. It contains typical safety plan. The stipulated conditions are liable to be changed as per local regulations / site conditions / future developments etc. No express or implied guarantee is made on correctness / usefulness of the provided guidelines.
Safety Plan
Health, Safety, Security & Environment Project Sites Document: HSSE/SP-001 Version: 1.1 Page: i Local file: HSSE-03 Table of Contents
Health, Safety, Security & Environment Project Sites Document: HSSE/SP-001 Version: 1.1 Page: ii Local file: HSSE-03
7 Permit to Work System ......................... ........... ...............................47 7.1 Types of Permit.................................................................... ............ ............47 7.2 Procedure..........................................................................49 7.3 Permit Validity.....................................................................................................50 7.4 Permit Suspension and Cancellation..................................................................50 7.5 Distribution, Administration and Display.................................................................50
9 Safety Orientation and Trainings ........... ........................ ........... ..........................53 9.1 New Employee Orientation............................................... ............ .............53 9.2 Periodical Safety Training ................................................................ ............53
10 Personal Protective Equipment............. ........... ................................ ........... ........54 10.1 Minimum requirement.......................................................... ............ ...........54 10.2 Additional requirements................................................................ ...........55 10.3 Suitability and Compatibility ..................................................................................57 10.4 Storage and maintenance.......................................................................57
11 Fire Safety and Emergency Preparedness............. ........... ................................ .58 11.1 In case of fire / emergency ................................................................. ..............58 11.2 When fire alarm sounds................................................................ ............58 11.3 Causes of Fire and preventive measures..............................................................59
12 HSSE for Sub-contractors............. ........... ................................ ........... ........... .......59 12.1 General Guidelines.................................................................. ............ ...........59 12.2 Format of declaration................................................................ ............59A
13 Rescue / Medical Treatment / First Aid... ........... ................................ ........... ....60 13.1 Equipment.................................................................... ............ .............60 13.2 Training................................................................ ..............62 13.3 Outside Medical Support.........................................................................................62
14 Commissioning safety......................................................................................63 14.1 Planning.............................................................................................................63 14.2 Tank Farms.............................................................................................................63 14.3 Electrical....................................................................................................................64 14.4 Aisles, floors and Staircases .............................................................................64 14.5 Fire Safety...............................................................................................................65 14.6 Miscellaneous........ ................ ..............................................................................65
Indian Oiltanking Limited (IOT) is a 50:50 joint venture company of Indian Oil Corporation Limited (IOC) and Oiltanking Gmbh (based in Hamburg, Germany).
IOC is the only Indian company listed in the Fortune 500. It has an overall market share of around 57% in the petroleum sector. IOC operates 6 of Indias 15 refineries having a refining capacity share of nearly 35%. It owns and operates nearly 80% of the domestic pipeline network of more than 5,000 kms and has an extensive marketing network of more than 17,000 retail stations / agencies backed by 178 depots and terminals and 35 LPG bottling plants. It also has nearly 70% Aviation market share with 94 aviation fuel stations
Oiltanking GmbH is the worlds second largest independent terminalling services company with the widest geographical presence with deep sea and inland terminals and deepwater jetties in Europe, USA, South America and Singapore. Oiltanking terminals cater to the requirements of various players in the international petroleum sector like oil refining and marketing companies, global oil traders, power and petrochemical plants and other bulk consumers.
IOT provides independent as well as dedicated Terminalling services and also engineering and construction services to the petroleum sector in the country. Independent terminalling is a specialised business of storage and handling of petroleum products including crude and refined oils for multiple users like petroleum companies, traders and direct users, remaining totally independent from refining, marketing and trading companies. IOT has introduced the concept of providing customized Terminalling and construction solutions to the Indian Oil Industry through various models BOO, BO, BOOT and O&M.
The activities of the Company are broadly divided under the following business segments:
Terminalling services from Owned Terminals
Construction of Terminals, Pipelines and related facilities
Engineering and Consultancy Services
Operations and Maintenance Services for Third Party Terminals
The Indian Oiltanking Limited is committed to provide its employees and contractors with a safe working environment. The purpose of Safety Plan is the provide project site personnel with the instructions, rules and guidance necessary to provide a safe working environment.
Safety is everybodys responsibility. Everybody concerned must co-operate whole- heartedly in the promotion of safety and in the prevention of accidents i.e. each of us should personally bear the responsibility to minimise and avoid accidents at all costs in order to create and maintain safe work place.
The company will provide the adequate protective equipment with a view to inculcate safety consciousness and awareness among all. Every one concerned must at all times observe strictly the companys HSSE Policy and the Govt. Safety Legislation.
1.2 Scope and Applicability
All project sites and persons deployed thereto including subcontractors. It is the intention that this manual will give the minimum requirements that are needed to comply with international best practices, Indian Oiltanking Standards and the HSSE Policy. The management of each Project Site should ensure that its organization and work practices are in line with the document as displayed. Furthermore, the manual should be used to educate employees and continuously improve the safe and efficient completion of the project.
In countries without sufficient HSSE related legislation this manual should be used as a guideline to improve construction standards. In places with HSSE legislation, such legislation takes precedence over this document in case of contradicting requirements.
Whilst it is anticipated that this manual will contribute to the development of consistent and effective practices and procedures, it should be appreciated that it is not intended to be complete or comprehensive in nature. The responsibility to prepare a complete set of documents and procedures, considering specific requirements and all applicable local and international laws and regulations, remains with the Project site management.
Safety Plan
Health, Safety, Security & Environment Project Sites Document: HSSE/SP-001 Version: 1.1 Page: 3 Local file: HSSE-03 Health, Safety, Security & Environmental Policy Indian Oiltanking is committed to the safe and efficient operation of its facilities. Our goal is to prevent all accidents, injuries and occupational illness and to protect the environment. In order to achieve this, we will:
O Promote Health, Safety, Security & Environment (HSSE) in all companies and manage it in the same way as any other critical business activity.
O Be prepared for a quick and efficient response to emergency situations to minimise the potential impact of incidents should they occur.
O Comply with all applicable laws and regulations and apply appropriate standards where respective legislation does not exist.
O Design, build and maintain facilities and utilize services in a manner to avoid risk to people and the environment.
O Have a sound HSSE Management System, in which competencies, responsibilities and communication channels are clearly defined.
O Provide training and job-specific education to all employees supported by internal standards, procedures and instructions.
O Provide a safe and healthy work environment for all employees and contractors with adequate facilities and appropriate protective equipment.
O Use energy and natural resources efficiently, prevent pollution and raise employees awareness to minimise adverse impacts on the environment.
O Identify and analyse potential hazards and security threats and implement measures to avoid, prevent, control and restrict the associated risks.
G Set targets and benchmark our performance to achieve continuous improvement and ensure compliance with all applicable standards.
The management will visibly and rigorously support the implementation of this policy. We expect the support of all employees, contractors and others working for us in order to make our HSSE performance one which will earn us the continuing confidence of our customers, neighbours and the community at large.
Hamburg, October 2004 Mumbai, October 2004
Gust Spaepen Jayanta Bhuyan Managing Director - Oiltanking GmbH Managing Director - Indian Oiltanking Ltd.
Indian Oiltanking Limited HSSE Organisation Chart Project Sites Project Manager HSSE Department HSSE Coordinator / Safety Officer (s) Indian Oiltanking Corporate Center Managing Director HSSE Department Manager - HSSE
2.2 HSSE Committee
Site HSSE Committee plays very important role in the field of Safety, Health & Environment. It provides the platform for the functioning worker and management jointly. Safety committee would meet periodically to review the companys HSSE programme and performance and recommended necessary steps for the improvements.
The major function of the HSSE Committee shall be;
Identify unsafe acts & conditions and suggest remedies Develop safety culture and comply with companys HSSE policy Enforce safety rules, procedures and accepted safe practices Encourage and enforce the use of PPEs Reduce hazards factor and to develop safe behaviour of all employees
Site HSSE Committee shall comprise of Project Manager as Chairman with Members from each function viz. Mech., Elect., Civil, Procurement etc. The Safety Officer / Safety Engineer shall be the Secretary of the Committee. The minimum number of members of safety committee shall be 4 (Four). Site head / Supervisors of subcontractors may also be included in safety committee meetings.
To provide necessary safety provisions and measures at the work site in accordance with government safety legislation.
To provide and maintain a safe and healthy working environment at all worksites.
To formulate and establish safety policy, rules, regulations, work practices, standards etc.
To provide all levels employees with adequate safety equipment.
To organize and promote safety activities and campaigns to raise their safety awareness.
To review safety issues and recommendations for the improvement of safety.
3.2 Supervisor
To implement the Companys Safety Policy, particularly on work areas under their direct charge, so as to provide and maintain safe working conditions and practices for all workers.
To inspect working areas daily for potential hazards and make rectifications to prevent accidents.
To conduct monthly safety talks/briefings and promote safety organize and participate in any other safety activities to inculcate safety awareness amongst workers.
To supervise and ensure that sub-contractors under their direct charge follow the Companys Safety Policy.
Conduct pep talk & exercise daily for workers.
To enforce safety rules and regulations ensuring that workers comply strictly to safety.
To report and assist in the investigation of accidents, incidents and safety violations to find out possible causes and take preventive measures.
Suitable PPEs to be issued to workers working under their supervisor.
Providing its employees with required personal protective items like safety shoes, hard hat, hand gloves, goggles, safety belts and other such items as and when may be required to be used during deliverance of duties.
To provide list of such hazardous chemicals as required to be stored at the job site and the MSDS of the same. Prior approval to be taken for the same.
To report immediately any injury, illness or first aid cases without fail to project in-charge.
To be present or depute representative in safety meetings and depute personnel to safety trainings as and when notified of.
To make themselves familiar with the job site and prevalent emergency procedure, safety plans, safety procedures and practices including positioning of emergency equipment.
3.4 Workers
To observe and comply with the Companys safety rules and regulations all times.
To use personal protective equipment, safety devices and other appliances provided for his protection.
To maintain good housekeeping in the work area.
To participate in any safety promotion activities such as safety talks, group meetings, training etc.
To report any unsafe act or condition to his supervisor immediately.
To strictly comply with safety work procedures and practice good safety habits so as to prevent injury to him self and others.
Learning and Practicing Safe Work Procedures.
Actively support and abide with all Health and Safety rules.
Reporting of, and if possible correcting any Safety/Health Hazards they may notice.
Contributing to incident/accident investigations when asked.
3.5 Security
Ensure that only authorize person enter the premises and are in possession of valid I-cards, gate pass etc.
To keep a watch on IOTLs property and ensure the intactness of fencing.
Control of the incoming and outgoing materials.
Ensure non-entry of prohibited items like lighters, matchbox, liquor, drugs, firearms, and explosives in to the site.
Carryout searches if necessary
Safety Plan
Health, Safety, Security & Environment Project Sites Document: HSSE/SP-001 Version: 1.1 Page: 8 Local file: HSSE-03 4. Hazard Identificaton and Control Hazard Activity Control Muscle pain, strain Lifting Proper equipment for the task, exercise, Proper lifting technique
Cuts, abrasions All Proper equipment for the specific job, Proper personal protective equipment, Enclosure guards etc. are in place
Flying objects Drilling, Grinding Proper equipment with guards for the job, Personal protective equipment (Goggles, Gloves)
Burns Welding, Grinding, Handling of chemicals Proper equipment, PPEs, MSDS available for chemicals
Inhalation of Air Borne Particles Welding, Grinding, Drilling, sandblasting, Handling of chemicals, Demolition, Ceiling tiles, Drywall etc. Proper PPEs, MSDS available, Look for probability of dangerous chemicals present in the system
Falls, tripping All Proper equipment use for jobs, Use of PPEs
Electrical Shock Use of power tools, working around energized equipment Ensure proper tools with grounding arrangement, extension cords are in good condition, look for wetness, use of lockout & tagouts
Noise Drilling, Cutting, Grinding, hammering, Operation of heavy vehicles PPEs Safety Plan
The construction site shall be considered a restricted area and unauthorised entry into the site is strictly prohibited. Anyone found trespassing shall be asked to leave the site immediately.
Photography shall be strictly prohibited unless express approval of project in- charge
Smoking, the use of fires (naked flame or open fires) and the use of spark producing equipment or tools are strictly prohibited except in approved areas of the site with valid work permit. It should be noted that smoking is not allowed even when the permit for use of fire or hot work is given at the place.
No drugs, narcotics ,alcoholic drinks are allowed at site also the personnel under infulence of the above shall not be allowed at site. To be in possession of, or under the influence of drugs or alcohol is strictly forbidden.
It is the employee's responsibility to conduct himself/herself in a manner that enables them to maintain a safe work environment for themselves and their fellow workers.
Every effort must be made by the employee to keep the job sites clear of scrap material and other hazards.
All employees should be aware of first-aid box locations and the names of employees holding valid St. John Ambulance First-Aid certificates.
The Company reserves the right to take disciplinary action when an employee refuses to abide by any safety rule/policy/procedure. The disciplinary action may go as far as dismissal.
Horseplay of any degree is not permitted and will not be tolerated. There is to be no fighting with or threatening of fellow employees.
Each employee should be familiar with the Emergency exits and Fire Extinguisher in the work area.
All safety hazards observed are to be corrected or immediately reported to your supervisor including any defects or damage to machinery, machine parts, equipment, or tools.
Common hazard involved in welding / cutting are sparks, molten metal, flying objects, harmful light rays, electrical shock etc. Hot work includes Welding, Gas Cutting, Burning, Grinding, Soldering, Sand Blasting, Chipping, Riveting, Drilling, Power Tools, IC Engine Operations, Open Flames etc.
A dry chemical type fire extinguisher shall be made availabe in work area.
A running water hose and responsible standby person is mandatory for carrying out work in hazardous zone or in proximity of operating areas.
Adequate ventilation shall be ensured by opening manholes, and fixing a shield or foreced circulation of air etc. while doing work in cofined space. However flammable vapour concetration shall be verified beforehand.
All the adjoining drains / trenches should be cleaned / free from any organic matter and should be covered suitably.
All opening / pipelines ends / manholes of tanks who could contain flammable vapours should be properly blinded off if in vicinity of hot work. Proper arragements for isolation / covering the area from the process side may be necessary if work is being done in close vicinity of process activities.
Adequate measures for containment of spark produced should be taken before starting of hot work.
Proper PPEs should be worn as per the requirement of specific job.
Ensure that only approved and well-maintained apparatus, such as torches, manifolds, regulators, pressure indicators and pressure regulating valves and acetyle generators are used for gas cutting.
All covers and panels shall be kept in place, when operating an electric ark welding machines
Return earthing / ground cable should be provided directly to the equipment / work piece being welded and both the ground and welding cables should be intact and not cracked or worn out or with joints. The connection should not be established indirectly through pipelines / structures / equipmet etc.
The welding recepticles shall be rated for 63A suitable for 415 V, 3-phase system with a scraping earth. Recepticles shall have neceaary mechanical interlocks and earthing facility.
An energised electrode should never be left unattended and the power source shall be turned off at the end of job.
Proper earthing of the welding machine itself should be ensured. The connection of the welding cable with the output pole of the welding machine should be done with proper fittings.
Electrode holder shall be of good quality with proper insulation. The welder should never be allowed to weld when he is wet. Also the usage of proper personal protective equipment shall be ensured.
Oil or paint drums (whether full or empty) shall be never be kept in vicinity of the welding area.
All gas cylinders shall be shall be properly secured in upright position and acetylene cylinders shall be turned and kept is such a way that the valve outlet points away from oxygen cylinder and vice-versa.
Acetylene cylinder valve key shall be readily available at valve stem. When not in use cylinder valves shall be kept closed.
Storage of cylinder (either full or empty) shall be done at cool, dry place under shed. Filled and empty cylinders should be stored separately, Acetylene and Oxygen cylinder should be stored separately.
Lighted gas torch should also never be left un attended. Also cylinder should be kept well away from heat sources.
Flash back arrester shall be provided on the oxygen and acetylene cylinder as an additional precaution.
Cylinders should be transported on trolleys and should never be dragged. All cylinder should be checked for leakage, color coding and valve cap before accepting. No cylinder should be accepted without proper color coding and valve cap.
Hoses of the cutting torch should be properly coloured (red for acetylene and black for oxygen) and of same length. The ligting of the torch shall be done by friction lighter instead of machbox. Hoses shall be checked for leakage before use. Also the hoses should not be dragged.
Lubricants should not be used in Oxy-acetylene cutting set.
Shut down, isolate (not just closing valves), depressurise and purge the vessel / Tank / Confined space as per laid down procedure.
Entry inside teh vessel adn to carry out any job should be done after issuance of valid permit only.
Ensure proper and accible means of exit before entry inside a confined space
The number of persons allowed inside the vessel should be limited.
At least one person shall invariably act as standby at nearby exit / manway.
Before entering inside vessels underground or located at lower elevation, probability of dense vapours accumulating nearby should also be considered in addition to inside of vessel.
Ensure that O2 level shall be above 19.5% by volume in air. Also simulteneously it should be ensured that no Hydrocarbon or toxic substances ( such as H2S) are present or are below permissible levels before entry and the checks should be continued periodically during course of the vessel entry. Otherwise use of online air respirators / SCBA (Self contained breathing apparatus) with other personal protective equipment should be considered.
Barrication of the confined space should be considered during hoisting, radiography, blasting, pressure testing etc.
Only use of 24 V DC flameproof lamp fittings should be used for illumination inside confined spaces irrespective of the fact that all requisite checks and gas freeing have been carried out.
Preferably compressed air driven tools should be used while working in confined spaces or 24DC electically driven tools should be considered instead.
Minimum PPEs, Safety Helmet, Safety Shoes and Safety belt with a guy line shall be worn by every person entering confined space.
Dont wear loose clothing whilst working in confined spaces.
In case of hot work going on the welding electrode holder / gas cutting torches should be kept outside of the confined space immediately after completing the job. Cylinders should also be kept outside of confined space. Safety Plan
All cables , hoses, welding equipment etc. shall be removed from confined space at the end of each work day, even if the work is to be resumed in the same space next day.
To the extent possible sludge shall be cleared and removed from outside before entering.
No naked light or flame or hot work such as welding, cutting and soldering should be permitted inside a confined space or area unless it has been made completely free of the flammable atmosphere, tested and found safe by a competent person and a permit to that effect must have been obtained prior to starting of work.
Communication should be always maintained between the worker and the person standby.
5.4 Excavation, Trenching and Backfilling
All excavation work should be planned and the method of excavation and the type of support work required shall be decided considering the following. I. The stability of the ground; II. The excavation will not effect adjoining buildings, structures, roadways; III. To prevent hazard, the gas, water, electrical and other public utilities should be shut off or disconnected if necessary, IV. Presence of underground pipes, cables conductors etc. V. The position of culvert / bridges, temporary roads and spoil heaps should be determined. Before digging at the site, all excavation work should be planned and the method of excavation and the type of support work required decided.
All excavation work must be supervised.
Sites of excavation should be thoroughly inspected I. daily, prior to each shift and after interruption in work of more than one day; II. after every blasting operation; III. after an unexpected fall of ground; IV. after substantial damage to supports; V. after a heavy rain, frost or snow; VI. when boulder formation are encountered.
Safe angle of repose of particular type of soil while excavating trenches exceeding 1.5m (5) depth up to 3.0m should be maintained. Based on site condition, proper sloping should be provided corresponding to the angle of repose of the soil (usually 45 deg), and suitable bench of 0.5m width at every depth of 1.5m of excavation in all soils except hard rock. Otherwise proper shoring and strutting to prevent cave-in or slides.
As far as possible, excavated earth should not be placed within one meter or the edge of the trench or half of depth of the trench, whichever is greater.
Dont allow vehicles to operate too close to excavated area. Maintain atleast 2m distance from edge of excavation. No load, plant or equipment should be placed or moved near to the edge of exacvation where it is likely to cause collapse and thereby endanger any person unless precautions such as the provision of shoring or piling are taken to prevent the sides from collapsing.
Adequately anchored stop blocks and barriers should be provided to prevent vehicles being driven into the excavation. Heavy vehicles should not be allowed near the excavation unless the support work has been especially designed to permit it.
If an excavation is likely to affect the security of an structure on which persons are working, precautions should be taken to protect the structure from collapse.
Barricade of 1m height (with red and white band / self glowing caution board) should be provided for excavations beyond 1.5m depth. Provide two entries / exits for such excavation.
Necessary precautions should be taken for underground utility lines like cables, sewers etc. and necessary approvals / clearances from the concerned authorities shall be obtained before commencement of the excavation job.
Water shall be pumped / bailed out, if any accumulates in the trench. Necessary precautions should be taken to prevent entry of surface water in trenches.
During rains, the soil becomes loose. Take additional precaution against collapse of side wall.
In excavations where hazardous atmospheres have the potential to exist, the atmosphere must be tested before entry. If a hazardous atmosphere is found, then Confined Space Entry section of this document should be followed. Locations that are most likely to result in a hazardous atmosphere include excavations in landfills, in other areas where there is significant decomposition of organic materials, and in areas next to hazardous materials storage areas.
In case of blasting, follow strictly IS:4081-1986 & Indian Explosive Act and rules for storage, handling and carrying of explosive materials and execution of blasting operations.
All narrow trenches 4 or more deep shall at all times be supplied with one ladder for each 100 lenght with a minimum of two.
Proper approach to be made to pit which is required to be back filled as well as to the source of backfilling materials.
All vehicles engaged in backfilling to be provided with reverse horn.
Before pushing backward any vehicle to the spot of backfilling nearby area to be cleared of workmen.
The point upto which a vehicle could be reversed should be clearly demarcated preferably by lime or other suitable measures.
In case of backfilling in night proper lighting arragements to be made.
Proper PPEs (dust mask etc.) to be provided to workmen engaged in backfilling.
5.5 Working at heights
General Provision
While working at a height of more than 2 meters, ISI marked safety belts shall be used.
While working at a height of more than 2 meters, permit should be issued by competent person before commencement of job.
Worker should be well trained on usage of safety belt including its proper usage at the time of ascending / descending.
All tools shall be carried in tool kits to avoid their falling.
If the job is on fragile / sloping roof, roof walk ladders shall be used.
Provide lifeline wherever required.
Additional safety measures like providing Fall Arrester type safety belt, safety net should be provided depending upon the site conditions, job requirements.
Keep working area neat and clean. Remove scrap material immediately.
Don't throw or drop material/equipment from height.
Avoid jumping from one member to another. Use proper passageway.
Keep both hands free while climbing. Don't try to bypass the steps of the ladder.
Try to maintain calm at height. Avoid over exertion.
Avoid movements on beam.
Elevated workplaces including roofs should be provided with safe means of access and egress such as stairs, ramps or ladders.
Access and egress to the work area should be properly made by means of Ramps, stairs, ladders, scaffolds and platforms.
Stairs, Ladders, Platforms etc. should have preferred slope, handrail, mid rail, toeboard & antiskid properties.
Safety belt / full body harness should be provided to the all workmen involved in working at height more than 2m. Anchorage should be ensured to a permanent structure.
In special circumstances fall arrester should be used when use of safety belt is not practical.
Roof work
All roof-work operations should be pre-planned and properly supervised.
Roof work should only be undertaken by workers who are physically and psychologically fit and have the necessary knowledge and experience for such work.
Work on roofs shouldn't be carried on in weather conditions that threaten the safety of workers.
Crawling boards, walkways and roof ladders should be securely fastened to a firm structure.
Roofing brackets should fit the slope of the roof and be securely supported.
Where it is necessary for a person to kneel or crouch near the edge of the roof, necessary precautions should be taken.
On a large roof where work have to be carried out at or near the edge, a simple barrier consisting of crossed scaffold tubes supporting a tubing guardrail may be provided.
All covers for openings in roofs should be of substantial construction and be secured in position.
Roofs with a pitch of more than 10 should be treated as sloping.
When work is being carried out on sloping roofs, sufficient and suitable crawling boards or roof ladders should be provided and firmly secured in position.
During extensive work on the roof, strong barriers or guardrails and toe-boards should be provided to stop a person from falling off the roof.
Where workers are required to work on or near roofs or other places covered with fragile material, through which they are liable to fall, they should be provided with suitable roof ladders or crawling boards strong enough and when spanning across the supports for the roof covering to support those workers.
A minimum of two boards should be provided so that it is not necessary for a person to stand on a fragile roof to move a board or a ladder, or for any other reason.
Work on tall chimneys
For the erection and repair of tall chimneys, scaffolding should be provided. A safety net should be maintained at a suitable distance below the scaffold.
The scaffold floor should always be at least 65 cm below the top of the chimney.
Under the working floor of the scaffolding the next lower floor should be left in position as a catch platform.
The distance between the inside edge of the scaffold and the wall of the chimney should not exceed 20 cm at any point.
Catch platforms should be erected over; a) the entrance to the chimney; b) Passageways and working places where workers could be endangered by falling objects.
For climbing tall chimneys, access should be provided by: a) stairs or ladders; b) a column of iron rungs securely embedded in the chimney wall; c) Other appropriate means.
When workers use the outside rungs to climb the chimney, a securely fastened steel core rope looped at the free end and hanging down at least 3 m should be provided at the top to help the workers to climb on to the chimney.
While work is being done on independent chimneys the area surrounding the chimney should be enclosed by fencing at a safe distance.
Workers employed on the construction, alteration, maintenance or repair of tall chimneys should not: a) work on the outside without a safety harness attached by a lifeline to a rung, ring or other secure anchorage; b) put tools between the safety harness and the body or in pockets not intended for the purpose; c) haul heavy materials or equipment up and down by hand to or from the workplace on the chimney; d) fasten pulleys or scaffolding to reinforcing rings without first verifying their stability; e) work alone; f) climb a chimney that is not provided with securely anchored ladders or rungs; g) Work on chimneys in use unless the necessary precautions to avoid danger from smoke and gases have been taken.
Work on independent chimneys should not be carried on in high winds, icy conditions, fog or during electrical storms.
While working in suspended condition (painting etc.) in unavoidable circumstances it should be ensured that a Fall Arrester system (with full body harness) should be taken in to use and the work should be supervised closely.
All portable tools are to be connected through control bus with ELCB.
All contractors should ensure proper Earthing of all electrical equipments used by them. Suitable earthing pits must be made if required.
Examine electric cable for defects before use.
Do not ever insert free ends of wires into sockets and hold them in place with matchsticks / other means. Always use industrial three pin plugs.
Check the RPM rating of grinding wheels. The RPM rating must be greater than or same to that of the driver. Wheel guard should be used in proper position before grinding. Also proper PPEs must be ensured (goggles & hand gloves).
Do not tie electric cords to metal rods or nails.
No cable should run under the ground. It must run overhead at a 2 m height to avoid pinch point and creating trip hazard
All tools and Tackles must be examined daily before commencing work and record to be maintained.
Defective tools are to return to store.
All electrical tools must be inspected at regular intervals by an authorized electrical person and record to be maintained.
The weight, size & type of tool should be selected to suit the job carried out.
The handles of tools should be intact and properly tightened. Split handles should be replaced. To avoid slippage, grease and oil should be wiped off. Insulated and non-conducting tools shall be tested for electrical resistance.
Wrenches should not be pushed but pulled. Chisels struck by others should be held by tongs and not by hands.
Chipping should always be done away from self.
Hand tools should not be allowed to lie down on benches, scaffoldings etc. from where they can fall. They should be properly stored.
There should be a well-planned schedule to ensure that all the lifting appliances and lifting gear are selected, installed, examined, tested, maintained, operated and dismantled with a view to preventing the occurrence of any accident;
All lifting appliances shall be examined by competent persons at frequencies as specified in "The Factories act, 1948 and Rules made thereof" and records maintained in specified Forms under Factories Rule (Applicability different in different states).
Check thoroughly quality, size and condition of all lifting tools like chain pulley blocks, slings, U-clamps, D-shackles etc. before putting them in use.
Safe lifting capacity of all lifting & handling equipment, tools and shackles should be got verified and certificates obtained from competent authorities before its use. The safe working load shall be marked on them.
Check periodically the oil, brakes, gears, horns and tyre pressure of all moving equipments like cranes, forklifts, trailers etc as per manufacturer's recommendations.
Check the weights to be lifted and accordingly decide about the crane capacity, boom length and angle of erection.
Allow lifting slings as short as possible and check packing at the friction points.
While lifting/placing of the load, no unauthorised person shall remain within the radius of the boom and underneath the load.
While loading, unloading and stacking of pipes, proper wedges shall be placed to prevent rolling down of the pipes.
Control longer jobs being lifted up from both ends.
Only trained operators and riggers should carry out the job. While the crane is moving or lifting the load, the trained rigger should be there for keeping a vigil against hitting any other object.
During high wind conditions and nights, lifting of heavy equipments should be avoided. If unavoidable to do erection in night, operator and rigger should be fully trained for night signaling. Also proper illumination should be there.
Allow crane to move on hard, firm and leveled ground.
When crane is in idle condition for long periods or unattended, crane boom should either be lowered or locked as per manufacturer's guidelines.
Hook and load being lifted shall remain in full visibility of crane operators, while lifting, to the extent possible.
Don't allow booms or other parts of crane to come within 3 meters reach of overhead electrical cables.
No structural alterations or repairs should be made to any part of a lifting appliance, which may affect the safety of the appliance without the permission and supervision of the competent person.
Hoists
Hoist shafts should be enclosed with rigid panels or other adequate fencing at: a) ground level on all sides; b) all other levels at all points at which access is provided; c) all points at which persons are liable to be struck by any moving part.
The enclosure of hoist shafts, except at approaches should extend where practicable at least 2mt above the floor, platform or other place to which access is provided except where a lesser height is sufficient to prevent any person falling down the hoistway and there is no risk of any person coming into contact with any moving part of the hoist, but in no case should the enclosure be less than 1mt in height.
The guides of hoist platforms should offer sufficient resistance to bending and, in the case of jamming by a safety catch, to buckling.
Where necessary to prevent danger, adequate covering should be provided above the top of hoist shafts to prevent material falling down them.
Outdoor hoist towers should be erected on firm foundations, and securely braced, guyed and anchored.
A ladderway should extend from the bottom to the top of outdoor hoist towers, if no other ladderway exists within easy reach.
Hoisting engines should be of ample capacity to control the heaviest load that they will have to move.
Hoists should be provided with devices that stop the hoisting engine as soon as the platform reaches its highest stopping place.
Winches should be so constructed that the brake is applied when the control handle is not held in the operating position.
It should not be possible to set in motion from the platform a hoist, which is not designed for the conveyance of persons.
Winches should not be fitted with pawl and ratchet gears on which the pawl must be disengaged before the platform is lowered.
Hoist platforms should be capable of supporting the maximum load that they will have to carry with a safety factor.
Hoist platforms should be equipped with safety gear that will hold the platform with the maximum load if the hoisting rope breaks.
If workers have to enter the cage or go on the platform at landings there should be a locking arrangement preventing the cage or platform from moving while any worker is in or on it.
On sides not used for loading and unloading, hoist platforms should be provided with toe-boards and enclosures of wire mesh or other suitable material to prevent the fall of parts of loads.
Where necessary to prevent danger from falling objects, hoist platforms should be provided with adequate covering.
Counterweights consisting of an assemblage of several parts should be made of specially constructed parts rigidly connected together.
Counterweights should run in guides.
Platforms should be provided at all landings used by workers.
Following notices should be posted up conspicuously and in very legible characters:
a) on all hoists on the platform: the carrying capacity in kilograms or other appropriate standard unit of weight; on the hoisting engine: the lifting capacity in kilograms or other appropriate standard unit of weight; b) on hoists authorised or certified for the conveyance of persons: on the platform or cage: the maximum number of persons to be carried at one time; c) on hoists for goods only: on every approach to the hoist and on the platform: prohibition of use by persons.
Hoists intended for the carriage of persons should be provided with a cage so constructed as to prevent any person from falling out or being trapped between the cage and any fixed part of the structure when the cage gate is shut, or from being struck by the counterbalance weight or by articles or materials tailing down the hoistway.
On each side in which access is provided, the cage should have a gate fitted with devices which ensure that the gate cannot be opened except when the cage is at a landing and that the gate must be closed before the cage can move away from the landing.
Every gate in the enclosure of the hoist shaft which gives access from a landing place to the cage should be fitted with devices to ensure that the gate cannot be opened except when the cage is at that landing place, and that the cage cannot be moved away from that landing place until the gate is closed.
Derricks Stiff leg Derricks
Derricks should be erected on a firm base capable of taking the combined weight of the crane structure and maximum rated load.
Devices should be used to prevent masts from lifting out of their seating.
Electrically operated derricks should be effectively earthed from the sole plate or framework.
Counterweights should be so arranged that they do not subject the backstays, sleepers or pivots to excessive strain.
When derricks are mounted on wheels: a) a rigid member should be used to maintain the correct distance between the wheels; b) they should be equipped with struts to prevent them from dropping if a wheel breaks or the derrick is derailed.
The length of a derrick jib should not be altered without consulting the manufacturer.
The jib of a scotch derrick crane should not be erected within the backstays of the crane.
Guy Derricks
The restraint of the guy ropes should be ensured by fitting stirrups or anchor plates in concrete foundations.
The mast of guy derricks should be supported by six top guys spaced approximately equally.
The spread of the guys of a guy derrick crane from the mast should not be more than 45 0 from the horizontal.
Guy ropes of derricks should be equipped with a stretching screw or turnbuckle or other device to regulate the tension.
Gudgeon pins, sheave pins and fool bearings should be lubricated frequently.
When a derrick is not in use, the boom should be anchored to prevent it from swinging.
Gin Poles
Gin poles should be; a) be straight & consist of steel or other suitable metal; b) be adequately guyed and anchored; c) be vertical or raked slightly towards the load; d) be of adequate strength for the loads that they will be required to lift/move.
Gin poles should not be spliced and if a gin pole is composed of different elements, they should be assembled in conformity with their intrinsic material strength.
Gin poles should be fastened at their feet to prevent displacement in operation.
Gin poles, which are moved from place to place and re-erected, should not be taken into use again before the pole, lifting ropes, guys, blocks and other parts have been inspected, and the whole appliance has been tested under load.
When platforms or skips are hoisted by gin poles, precautions should be taken to prevent them from spinning and to provide for proper landing.
Tower Cranes
Where tower cranes have cabs at high level, persons, capable and trained to work at heights, should only be employed as crane operators.
The characteristics of the various machines available should be considered against the operating requirements and the surroundings in which the crane will operate before a particular type of crane is selected.
Care should be taken in the assessment of wind loads both during operations and out of service. Account should also be taken of the effects of high structures on wind forces in the vicinity of the crane.
The ground on which the tower crane stands should have the requisite bearing capacity. Account should be taken of seasonal variations in ground conditions.
Bases for tower cranes and tracks for rail-mounted tower cranes should be firm and level. Tower cranes should only operate on gradients within limits specified by the manufacturer. Tower cranes should only be erected at a safe distance from excavations and ditches.
Tower cranes should be sited where there is clear space available for erection, operation and dismantling. As far as possible, cranes should be sited so that loads do not have to be handled over occupied premises, over public thoroughfares, other construction works and railways or near power cables.
Where two or more tower cranes are sited in positions where their jibs could touch any part of the other crane, there should be direct means of communication between them and a distinct warning system operated from the cab so that one driver may alert the other of impending danger.
The manufacturers' instructions on the methods and sequence of erection and dismantling should be followed. The crane should be tested before being taken into use.
The climbing operation of climbing tower cranes should be carried out in accordance with manufacturers' instructions. The free-standing height of the tower crane should not extend beyond what is safe and permissible in the manufacturers' instructions.
When the tower crane is left unattended, loads should be removed from the hook, the hook raised, the power switched off and the boom brought to the horizontal. For longer periods or at times when adverse weather conditions are expected, out of service procedures should be followed. The main jib should be slewed to the side of the tower away from the wind, put into free slew and the crane immobilised.
A windspeed measuring device should be provided at an elevated position on the tower crane with the indicator fitted in the drivers' cab.
Devices should be provided to prevent loads being moved to a point where the corresponding safe working load of the crane would be exceeded. Name boards or other items liable to catch the wind should not be mounted on a tower crane other than in accordance with the manufacturers' instructions.
Tower cranes should not be used for magnet, or demolition ball service, piling operations or other duties, which could impose excessive loading on the crane structure.
Lifting Ropes
Only ropes with a known safe working capacity should be used as lifting ropes.
Lifting ropes should be installed, maintained and inspected in accordance with manufacturers' instructions.
Repaired steel ropes should not be used on hoists.
Where multiple independent ropes are used, for the purpose of stability, to lift a work platform, each rope should be capable of carrying the load independently.
Capacity a) support own weight and 4 X the maximum intended load. b) suspension rope & hardware, 6 X the maximum intended load. c) stall load of scaffold hoist not to exceed 3 times its rated load. d) designed by a qualified person and built and loaded to design.
Scaffold platform construction a) Platforms fully planked or decked b) no more than 1 gaps c) scaffold platforms and walkways 18 wide d) ladder jack, top plate bracket, roof bracket, and pump jack scaffold at least 12 wide e) guardrails and/or personal fall arrest systems for platforms and runways not less than18 wide f) Front edge of all platforms No more than 14 from the face of the work, 3 from the face for outrigger scaffolds &18 from the face for plastering and lathing operations g) Platforms 10 and less to extend at least 6 but not more than 12 past support unless designed and installed and/or guarded properly h) Platforms greater than 10 no more than 18 past support unless designed and installed and/or guarded properly i) Each abutted end of plank shall rest on a separate support surface. j) Overlap platforms not less than 12 only over supports, unless restrained to prevent movement. k) On direction changes, any platform on a bearer at other than a right angle shall be laid first, and platforms which rest at right angles over the same bearer laid second. l) No paint on wood platforms, except edges that may be marked for identification m) Fully planked between front upright and guardrail support n) No mixed scaffold components used unless compatible and integrity maintained o) No modification of mixed scaffold components unless a competent person approves p) No components of dissimilar metals unless approved by competent person
Criteria for supported scaffold a) Higher than 4:1 ratio restrained from tipping by guys, ties, or equivalent. Safety Plan
b) Guys, ties, installed per recommendations or at the closest horizontal member to the 4:1 height c) Bear on adequate foundations d) Plumbed and braced
Criteria for suspended scaffold a) Support devices, 4 X the imposed load. b) Direct connections evaluated by competent person c) Minimum lengths for suspension ropes on hoists d) Tied to prevent swaying e) Safety devices not used as platforms f) the safety of workers should be safeguarded by an extra rope having a point of attachment independent of the anchorage arrangements of the scaffold; g) the anchorage and other elements of support of the scaffold should be designed and built in such a way as to ensure sufficient strength; h) the ropes, winches, pulleys or pulley blocks should be designed, assembled, used and maintained in line with local regulations. i) Before use, the whole structure should be checked by a competent person.
Access a) Must have safe access, No access by cross braces b) Bottom rung not more than 24 high
Use a) Never overload b) No shore or lean-to scaffolds c) Inspected by competent person d) Immediately removed or repaired, braced if found substandard e) Maintain clearance near powerlines f) Erected, moved, dismantled or altered only under supervision of competent person g) No work on snow, ice covered platforms h) Tag lines on swinging loads i) Protect suspension ropes from heat, acid, sparks, abrasion etc. j) No work during storms or high winds
Fall Protection a) Required at 10 foot b) Personal Fall Arrester System (PFAS) in lieu of guardrails on some scaffolds c) PFAS & guardrails on suspension scaffolds d) Use crossbracing in lieu of top or midrails in suitable cases
Falling object protection a) Hardhats required b) Protect employees below c) Barricades to exclude working below d) Toe boards at edges of platforms e) Allows panels and screens f) Canopies may be used where suitable
Materials used in the construction of scaffolds should be stored under good conditions and apart from any material unsuitable for scaffolds.
Couplers should not cause deformation in tubes. Couplers should be made of drop forged steel or equivalent material.
Tubes should be free from cracks, splits and excessive corrosion and be straight to the eye, and tube ends cut cleanly square with the tube axis.
A scaffold should never extend above the highest anchorage to an extent which might endanger its stability and strength.
Loose bricks, drainpipes, chimney-pots or other unsuitable material should not be used for the construction or support of any part of a scaffold.
Inspection should more particularly ascertain that: a) the scaffold is of suitable type and adequate for the job; b) materials used in its construction are sound and of sufficient strength; c) it is of sound construction and stable; d) that the required safeguards are in position.
A scaffold should not be erected, substantially altered or dismantled except by or under the supervision.
Every scaffold should be maintained in good and proper condition, and every part should be kept fixed or secured so that no part can be displaced in consequence of normal use.
If out-rigger scaffolding is to be used, it should be specifically designed and inspected before putting in use.
When a lifting appliance is to be used on a scaffold; a) the parts of the scaffold should be carefully inspected to determine the additional strengthening and other safety measures required; b) any movement of the scaffold members should be prevented; c) if practicable, the uprights should be rigidly connected to a solid part of the building at the place where the lifting appliance is erected.
Prefabricated scaffolds
In the case of prefabricated scaffold systems, the instructions provided by the manufacturers or suppliers should be strictly adhered to. Prefabricated scaffolds should have adequate arrangements for fixing bracing.
Frames of different types should not be intermingled in a single scaffold.
Scaffolding shall be erected on firm and level ground.
All members of metal scaffolding shall be checked periodically to screen out defective / rusted members. All joints should be properly lubricated for easy tightening.
Entry to scaffolding should be restricted.
Erection, alteration and removal shall be done under supervision of experienced personnel.
Use of barrels, boxes, loose bricks etc., for supporting platform shall not be permitted.
Erect ladders in the four up-one out position, Lash ladder securely with the structure.
Using non-slip devices, such as, rubber shoes or pointed steel ferules at the ladder foot, rubber wheels at ladder top, fixing wooden battens, cleats etc.
When ladder is used for climbing over a platform, the ladder must be of sufficient length, to extend at least one meter above the platform, when erected against the platform in four up-one out position.
Portable ladders shall be used for heights not more than 4mt. Above 4mt flights, fixed ladders shall be provided with at least 24 landings at every 6mt or less. Safety Plan
In general, it should be avoided as far as possible. It should not be used in the unit/off-site areas and where hot work is to be done.
For construction and maintenance of residential and office buildings, situated outside explosive licensed area, bamboo scaffold, if used, should conform to provisions given in lS-3696 (Part 1)-1987.
5.9 Structural work, Laying of reinforcement, cementing & concreting
General Requirements
The erection or dismantling of buildings, structures, civil engineering works, formwork, falsework and shoring should be carried out by trained workers only under the supervision of a competent person.
Precautions should be taken to guard against danger to workers arising from any temporary state of weakness or instability of a structure.
Formwork, falsework and shoring should be so designed, constructed and maintained that it will safely support all loads that may be imposed on it.
Formwork should be so designed and erected that working platforms, means of access, bracing and means of handling and stabilising are easily fixed to the formwork structure.
Erection and dismantling of steel and prefabricated structures
The safety of workers employed on the erection and dismantling of steel and prefabricated structures should be ensured by appropriate means, such as provision and use of: a) ladders, gangways or fixed platforms; b) platforms, buckets, boatswain's chairs or other appropriate means suspended from lifting appliances; c) safety harnesses and lifelines, catch nets or catch platforms; d) Power-operated mobile working platforms.
Steel and prefabricated structures should be so designed and made that they can be safely transported and erected.
In addition to the need for the stability of the part when erected, the design should explicitly take following into account: a) the conditions and methods of attachment in the operations of transport, storing and temporary support during erection or dismantling as applicable;
b) Methods for the provision of safeguards such as railings and working platforms, and, when necessary, for mounting them easily on the structural steel or prefabricated parts.
The hooks and other devices built in or provided on the structural steel or prefabricated parts that are required for lifting and transporting them should be so shaped, dimensioned and positioned as: a) to withstand with a sufficient margin the stresses to which they are subjected; b) Not to set up stresses in the part that could cause failures, or stresses in the structure itself not provided for in the plans, and be designed to permit easy release from the lifting appliance. Lifting points for floor and staircase units should be located (recessed if necessary) so that they do not protrude above the surface; c) To avoid imbalance or distortion of the lifted load.
Storeplaces should be so constructed that: a) there is no risk of structural steel or prefabricated parts falling or overturning; b) storage conditions generally ensure stability and avoid damage having regard to the method of storage and atmospheric conditions; c) racks are set on firm ground and designed so that units cannot move accidentally.
While they are being stored, transported, raised or set down, structural steel or prefabricated parts should not be subjected to stresses prejudicial to their stability.
Every lifting appliance should: a) be suitable for the operations and not be capable of accidental disconnection; b) be approved or tested as per statutory requirement.
Lifting hooks should be of the self-closing type or of a safety type and should have the maximum permissible load marked on them.
Tongs, clamps and other appliances for lifting structural steel and prefabricated parts should: a) be of such shape and dimensions as to ensure a secure grip without damaging the part; b) be marked with the maximum permissible load in the most unfavourable lifting conditions.
Structural steel or prefabricated parts should be lifted by methods or appliances that prevent them from spinning accidentally.
When necessary to prevent danger, before they are raised from the ground, structural steel or prefabricated parts should be provided with safety devices such as railings and working platforms to prevent falls of persons.
While structural steel or prefabricated parts are being erected, the workers should be provided with appliances for guiding them as they are being lifted and set down, so as to avoid crushing of hands and to facilitate the operations. Use of such appliances should be ensured.
A raised structural steel or prefabricated part should be so secured and wall units so propped that their stability cannot be imperiled, even by external agencies such as wind and passing loads before its release from the lifting appliance.
At work places, instruction should be given to the workers on the methods, arrangements and means required for the storage, transport, lifting and erection of structural steel or prefabricated parts, and, before erection starts, a meeting of all those responsible should be held to discuss and confirm the requirements for safe erection.
During transportation within the construction area, attachments such as slings and stirrups mounted on structural steel or prefabricated parts should be securely fastened to the parts.
Structural steel or prefabricated parts should be so transported that the conditions do not affect the stability of the parts or the means of transport result in jolting, vibration or stresses due to blows, or loads of material or persons.
When the method of erection does not permit the provision of other means of protection against fall of persons, the workplaces should be protected by guardrails, and if appropriate by toe-boards.
When adverse weather conditions such as snow, ice and wind or reduced visibility entail risks of accidents, the work should be carried on with particular care, or, if necessary, interrupted.
Structures should not be worked on during violent storms or high winds, or when they are covered with ice or snow, or are slippery from other causes.
If necessary, to prevent danger, structural steel parts should be equipped with attachments for suspended scaffolds, lifelines or safety harnesses and other means of protection.
The risks of falling, to which workers moving on high or sloping girders are exposed, should be limited by all means of adequate collective protection or, where this is impossible, by the use of a safety harness that is well secured to a strong support.
Structural steel parts that are to be erected at a great height should as far as practicable be assembled on the ground.
When structural steel or prefabricated parts are being erected, a sufficiently extended area underneath the workplace should be barricaded or guarded
Steel trusses that are being erected should be adequately shored, braced or guyed until they are permanently secured in position.
Load-bearing structural member should not be dangerously weakened by cutting, holing or other means.
Structural members should not be forced into place by the hoisting machine while any worker is in such a position that he could be injured by the operation.
Open-web steel joists that are hoisted singly should be directly placed in position and secured against dislodgment.
While using spanners, hammers etc. at height, they should be tied with a rope fixed to nearby structure so that it will not drop in any case of slip.
Loose bolts, nuts and tools must be kept in boxes and not on structures and the boxes must have proper anchorage.
During structure erection only one signaler shall give proper signals. However STOP signal should be obeyed whoever gives.
No person shall walk, stand or work beneath a suspended load.
Proper quality of pulley block should be used. In no case pulley block suitable for fiber ropes should be used for steel wire ropes.
The structural members should be kept in orderly manner on the ground so that they do not roll down while being handled
Ensure that workers use Personnel Protective equipment like safety helmet, safety shoes, gloves etc.
Don't place the hand below the rods for checking clear distance. Use measuring devices.
Don't wear loose clothes while checking the rods.
Don't stand unnecessarily on cantilever rods.
To carry out welding/cutting of rods, safety procedures/precautions as mentioned in Hot work section of this document.
For supplying of rods at heights, proper staging and/or bundling to be provided.
Ensure barricading and staging for supplying and fixing of rods at height.
For short distance carrying of materials on shoulders, suitable pads to be provided.
While transporting material by trucks/trailers, the rods shall not protrude in front of or by the sides of driver's cabin. In case such protrusion cannot be avoided behind the deck, then it should not extend 1/3rd of deck length or 1.5M which ever is less and tied with red flags/lights.
Concreting
Ensure stability of shuttering work before allowing concreting.
Barricade the concreting area while pouring at height/depths.
Keep vibrator hoses, pumping concrete accessories in healthy conditions and mechanically locked.
Pipelines in concrete pumping system shall not be attached to temporary structures such as scaffolds and formwork support as the forces and movements may affect their integrity.
Check safety cages & guards around moving motors/parts etc. provided in concreting mixers.
Use Personal Protective Equipment like gloves, safety shoes etc. while dealing with concrete and wear respirators / dust masks for dealing with cement.
Earthing of electrical mixers, vibrators, etc. should be done and verified.
Cleaning of rotating drums of concrete mixers shall be done from outside. Lockout devices shall be provided where workers need to enter.
Where concrete mixers are driven by internal combustion engine, exhaust points shall be located away from the worker's workstation so as to eliminate their exposure to obnoxious fumes.
Don't allow unauthorised person to stand under the concreting area.
Ensure adequate lighting arrangements for carrying out concrete work during night.
Don't allow the same workers to pour concrete round the clock. Insist on shift pattern.
During pouring, shuttering and its supports should be continuously watched for defects.
Road work
Site shall be barricaded and provided with warning signs, including night warning lamps at appropriate locations for traffic diversion.
Filled and empty bitumen drums shall be stacked separately at designated places.
Road rollers, Bitumen sprayers, Pavement finishers shall be driven by experienced drivers with valid driving license.
Workers handling hot bitumen sprayers or spreading bitumen aggregate mix or mixing bitumen with aggregate, shall be provided with PVC hand gloves and rubber shoes with legging up to knee joints.
Mixing aggregate with bitumen shall preferably be done with the help of bitumen batch mixing plant, unless operationally non-feasible.
At the end of day's work, surplus hot bitumen in tar boiler shall be properly covered by a metal sheet, to prevent anything falling in it.
During field radiography, nearby area around the radiation source should be cordoned off.
If the field radiography is to be done at the same location repeatedly, it is advisable to provide either a wire fencing around or a temporary brick enclosure.
Special permission/permit should be taken for radiography from area-in- charge.
As far as possible, field radiography should be done only during night time when there is little or no occupancy there.
Radiation warning signals should be pasted all along the cordoned off area.
Entry into the restricted area by unauthorised persons should be strictly prohibited during exposure.
The radiation level alongwith the cordon should be monitored by a suitable and well-calibrated radiation survey meter.
All personnel working with radiography sources should wear appropriate protective equipment and film badges issued by BARC.
Protection facilities such as manipulator rod, remote handling tongs, lead pots, radiation hazard placards and means of cordon off shall be available at each site.
The radiography source shall never be touched or handled directly with hands.
The package containing radiography cameras and sources should never be carried by public transport like bus, train etc.
Radiography sources and cameras, when not in use, should be stored inside a source pit with lock and key arrangement as approved by BARC (Bhabha Atomic Research Center). The storage room should preferably be located in an isolated area of minimum occupancy and radiation level outside the storage room should not exceed 0.25 mR/hr as per BARC Regulations.
In case of an accident (due to loss or of damage to radiography source), action should be taken in line with BARC Safety Rules/Guidelines. Safety Plan
When the demolition of any building or structure might present danger to workers or to the public: a) necessary precautions, methods and procedures should be adopted, including those for the disposal of waste or residues; b) the work should be planned and undertaken only under the supervision of a competent person.
Before demolition operations begin: a) structural details and builders' drawings should be obtained wherever possible; b) details of the previous use should be obtained to identify any possible contamination and hazards from chemicals, flammables, etc.; c) an initial survey should be carried out to identify any structural problems and risks associated with flammable substances and substances hazardous to health. The survey should note the type of ground on which the structure is erected, the condition of the roof trusses, the type of framing used in framed structures and the load- bearing walls; d) a method of demolition should be formulated after the survey and recorded in a method statement having taken all the various considerations into account and identifying the problems and their solutions;
All electric, gas, water and steam service lines should be shut off and, as necessary, capped or otherwise controlled at or outside the construction site before work commences.
If it is necessary to maintain any electric power, water or other services during demolition operations, they should be adequately protected against damage.
As far as practicable, the danger zone round the building should be adequately fenced off and sign posted. To protect the public a fence 2m high should be erected enclosing the demolition operations and the access gates should be secured outside working hours.
The fabric of buildings contaminated with substances hazardous to health should be decontaminated. Protective clothing and respiratory devices should be provided and worn.
Where plant has contained flammable materials, special precautions should be taken to avoid fire and explosion.
The plant to be demolished should be isolated from all other plant that may contain flammable materials. Any residual flammable material in the plant should be rendered safe by cleaning, purging or the application of an inert atmosphere as appropriate.
Care should be taken not to demolish any parts, which would destroy the stability of other parts.
Demolition activities should not be continued under adverse climatic conditions such as high winds, which could cause the collapse of already weakened structures.
To prevent hazards parts of structures should be adequately shored, braced or otherwise supported.
Structures should not be left in a condition in which they could be brought down by wind pressure or vibration.
Where a deliberate controlled collapse technique is to be used, expert engineering advice should be obtained, and: a) it should only be used where the whole structure is to come down because it relies on the removal of key structural members to effect a total collapse; b) it should only be used on sites that are fairly level and where there is enough surrounding space for all operatives and equipment to be withdrawn to a safe distance.
When equipment such as power shovels and bulldozers are used for demolition, consideration should be given to the nature of the structure, its dimensions, as well as to the power of the equipment being used.
If a swinging weight is used for demolition, a safety zone having a width of at least one-and-a-half times the height of the building or structure should be maintained around the points of impact. Demolition of structural steelwork
All precautions should be taken to prevent danger from any sudden twist, spring or collapse of steelwork, ironwork or reinforced concrete when it is cut or released.
Steel construction should be demolished tier by tier. Structural steel parts should be lowered and not dropped from a height.
Only persons having valid licenses should be allowed to work on electrical facilities.
No person should be allowed to work on live circuit. The same, if unavoidable, special care and authorisation need to be taken.
Treat all circuits as "LIVE" unless ensured otherwise.
Electrical "Tag Out" procedure "MUST" be followed for carrying out maintenance jobs.
Display voltage ratings prominently with "Danger" signs.
Put caution/notice signs before starting the repair works.
All electrical equipment operating above 250V shall have separate and distinct connections to earth grid.
Proper grounding to be ensured for all switch boards and equipment including Portable ones prior to taking into service.
Make sure that electrical switch boards, portable tools, equipments (like grinding machine etc.) don't get wet during their usage. If it happens, stop the main supply, make the tools dry and then only use them. Check proper earthing.
All temporary switch boards/ KIOSKS put up at work site should be suitably protected from rain and the level of same should be high enough to avoid contact with water due to water logging.
Don't work wet on electrical system.
Don't overload the electrical system.
Use only proper rated HRC fuses.
Industrial type extension boards and Plug sockets are only to be used.
ELCB for all temporary connections must be provided. Use insulated 3-pin plug tops.
All power supply cables should be laid properly and neatly so that they don't cause hindrance to persons working and no physical damage also takes place to the cables during various construction activities.
All Power cables to be properly terminated using glands and lugs of proper size and adequately crimped.
Use spark-proof/flame proof type electrical fittings in Fire Hazard zones as per area classification under relevant codes and standards.
Check installations of steel plates/pipes to protect underground cables at crossings.
Don't lay unarmored cable directly on ground, wall, roof or trees. All temporary cables should be laid at least 750 mm below ground and cable markers should be provided. Proper sleeves should be provided at road crossings. In case temporary cables are to be laid on wooden poles/steel poles, the minimum cable heights should be 4.5 M.
Maintain safe overhead distance of HT cables as per Indian Electricity Rules and relevant acts.
Don't connect any earthing wire to the pipelines/structures.
Don't make any unsafe temporary connections, naked joints/wiring etc.
Ensure that temporary cables are free from cuts, damaged insulation, kinks or improper insulated joints.
Check at periodic intervals that pins of sockets and joints are not loose.
Protect electrical wires/equipments from water and naked flames.
Illuminate suitably all the work areas.
All switchboards should be of MS structure only and incoming source should be marked.
Hand lamps should not be of more than 24V rating.
Fire extinguishers (DCP/CO2/Sand buckets) should be kept near temporary switch boards being used for construction purposes. Don't use water for fighting electrical fires.
Insulating mats shall be provided in the front and back end of switch boards.
All parts of electrical installations should be so constructed, installed and maintained as to prevent danger of electric shock, fire and external explosion.
Periodic checking/certification of electrical safety appliances such as gloves, insulating mats, hoods etc. to be done/witnessed along with maintaining a register at site signed by competent authority.
A notice displaying following, should be kept exhibited at suitable places: a) prohibiting unauthorised persons from entering electrical equipment rooms or from handling or interfering with electrical apparatus; b) containing directions as to procedures in case of fire, rescue of persons in contact with live conductors and the restoration of persons suffering from electric shock; (including first aid procedures) c) specifying the person to be notified in case of electrical accident or dangerous occurrence, and indicating how to communicate with him.
No other cables/pipes to be laid in trench used for electrical cables.
Utmost care should be taken while excavating Earth from cable trench to avoid damage or any accident.
Sub-station floor cut-outs meant for switch board installations to be covered wherever installation is incomplete.
NOTE: A Residual Current Operated Circuit Breaker (RCCB) or Earth Leakage Circuit Breaker (ELCB), when installed, protects a human being to the widest extent. RCCB or ELCB should be provided as per Indian Electricity Rules.
Inspection and maintenance
All electrical equipment should be inspected before taking into use to ensure suitability for its proposed use.
At the beginning of every shift, the person using the electrical equipment should make a careful external examination of the equipment and conductors, especially the flexible cables.
Apart from some exceptional cases, where due precautions should be taken, work on or near live parts of electrical equipment should be forbidden.
Before any work is begun on conductors or equipment that do not have to remain live: a) the current should be switched off by a responsible authorised person; b) precautions should be taken to prevent the current from being switched on again; c) the conductors or the equipment should be tested to ascertain that they are dead; d) the conductors and equipment should be earthed and short- circuited; e) neighbouring live parts should be adequately protected against accidental contact.
After work has been done on conductors and equipment, the current should only be switched on again on the orders of a competent person after the earthing and short-circuiting have been removed and the workplace reported safe.
Electricians should be provided with approved and tested tools, and personal protective equipment such as rubber gloves, mats etc.
All conductors and equipment should be considered to be live unless there is a proof of the contrary.
When work has to be done in dangerous proximity to live parts the current should be cut off. If for operational reasons this is not possible, the live parts should be fenced off or enclosed by qualified staff from the sub-station concerned.
Testing
Electrical installations should be inspected and tested and the results recorded.
Periodic testing of the efficiency of the earth leakage protective devices should be carried out.
Particular attention should be paid to the earthing of apparatus, the continuity of protective conductors, polarity and insulation resistance, protection against mechanical damage and condition of connections at points of entry.
6. Accidents / Incidents, their Reporting and Investigation
All Project sites shall keep records of work accidents resulting in first aid treatment or in medical treatment. This applies to all incidents on the facility with regard to Indian Oiltanking employees (Engineers, operators and o1fice personnel) and third parties (contractors, inspectors, visitors etc.).
6.1 Internal Reporting
All near misses, Incidents & accidents shall be reported through prescribed format. It is the responsibility of all Indian Oiltanking employees and contractors on the facility to ensure that all near misses, Incidents & accidents are reported to their supervisors. The supervisors must ensure that those then are reported to the HSSE Coordinator and / or the Project Site Manager. This applies to all Indian Oiltanking Project sites world-wide.
Copies of all the reports shall be sent to corporate office.
6.2 External Reporting
Notification of accidents or dangerous occurrences to external authority is legally to be done by the factory manager designate of the facility to the authorities under the local regulations within stipulated time limits. If the facility where project work is under progress falls under jurisdiction of client or other agency, reporting to the authority shall be undertaken by them itself. In such cases, accident forms of the such agency should also be filled.
If the facility being worked is under license to IOTL, the factory manager designated shall be responsible for external communication according to local regulation i.e. Factories Rules of that state. For accidents and dangerous occurrences involving licensed premises under CCOE, the intimation of the accidents should also be given accordingly in addition to the guidelines under local factory rules.
HSSE Coordinator is responsible for the regular communication to third parties like local authorities, fire brigades, medical centre, hospitals, mutual aid organizations, contractors, client HSSE Dept. etc.
6.3 Incident Investigation
All accidents reported shall be initially investigated by HSSE Coordinator ASAP and upon the seriousness and local requirements a decision for a full fledged investigation shall be taken jointly by HSSE Coordinator and Profit Center Manger. Reports of such investigation shall be forwarded to corporate office.
All accidents and incidents shall be discussed in the routine HSSE Meetings. Lessons to be learned and progress with follow-up corrective actions should be covered during the discussion.
The HSSE Coordinator should report in the HSSE Committee Meetings all major and high potential loss accidents and incidents that have occurred since the previous meeting. Progress of the follow-up actions should also be discussed. Supervisors should discuss accidents and incidents occurring within their areas and those relevant from other areas at the day-to-day briefing meetings.
A "HSSE Alert" (Fomrat no. GD-007), which is a document alerting others to the probable causes of an accident/incident and which provides advice on preventing a recurrence, will be provided by the Corporate HSSE Department or prepared by the HSSE Coordinator. He must obtain approval of the Senior Manager before an internal HSSE Alert of any occurrence is distributed or discussed in safety meetings.
The HSSE Coordinator should prepare in co-operation with the Project Manager, a monthly follow-up/progress report on outstanding recommendations.
The permit-to-work system is an administrative control and communication system designed to clearly identify the various scopes of work to be carried out on the Project site and their associated hazards to prevent accidents, fire and equipment damage.
The permit-to-work system covers all the construction work on the Project site which may create potential hazards. Any work carried out on site must be covered by a work permit issued by Permit Approving authority.
The Project Site In-charge has the overall responsibility to ensure that the permit-to- work system is practiced in accordance with its purpose and intent and to review the system periodically to assess the effectiveness of the system and make necessary adjustments to improve the system.
7.1 Types of permits
Cold Work Permit
Any work carried out within the site must be covered by a work permit issued by concerned department or area incharge.In addition a clearence must be obtained from concerned departments officer before commencement of job.
Hot Work Permit
Hot work includes oxy-acetylene cutting, electric arc welding, drilling, chiselling, chipping, hacksawing and any other work requiring the use of a naked flame or heat generation, and work on electrical systems.
Whenever possible hot work is to take place in an allocated safe area preferably outside the Operational area if any on site. Sections of pipeworks for modification, for instance, can be unbolted and removed to a safe area.
In the event that the hot work must be carried out in the operational area, reasonable precautions will be taken. Additional fire fighting equipment such as fire hoses and dry power extinguishers shall be available. The presence of a safety officer (from the contractor) at the work site at all times is preferred.
A suitable permit shall be taken to this effect as per the procedure laid down.
Storage tanks are the main reason for confined space entry, but other confined spaces can be floating roofs, Oil Water Separators, boilers, water storage tanks, drain dumps, sewers, reactors, vessels and excavated pits. An otherwise harmless excavation can be rendered lethal by ground hugging gasses, ingress of toxic or flammable liquids leaking from the ground.
Before sanction entry to a confined space, an assessment of the work area must be made. Much greater care is to be taken where confined space would under normal circumstances appear innocuous. Examples are water tanks and excavations.
Before completion of a Confined Space Entry Permit, the space is to tested for: a) Oxygen Content, Explosive Vapour &, Toxic Vapour (H2S etc.)
The normal oxygen in air content is between 20% and 22% and any readings outside this range is to be treated as suspect and investigated. However in no case O2 contents shall be less than 19.5%. With respect to the explosive vapour reading, any reading above zero is to be regarded as positive.
Excavation Work Permit
For carrying out excavation at the site the permit shall be obtained. The permit shall be considered valid only when it is signed by authorized person of IOTL in addition to other signatories like HSSE Coordinator, Civil Engineer, The electrical section and engineer incharge of area where excavation is to be carried out.
Working at height permit
While working at height at more than 2m from floor level permit has to be obtained for working at height duly approved by competent authority.
Permit to work on electrical apparatus
Work carried out on electrical equipment, connected to an electrical power source exceeding 230 volts AC shall be de-energized. The details of the electrical isolation must be included on the relevant Permit issued for the work. Before any mechanical work is carried out on machinery driven by an electrical motor, the motor must be electrically isolated and a Do Not Operate signboard shall be displayed at the local start button and confirmed isolated by pressing the button.
The contractor who is responsible for the work which requires a work permit will fill out the APPLICATION part of the permit from stating the scope of work, equipment number, work location, etc. Prior discussion with the contractors who are performing the work must be held to ensure that they understand the job scope and safety precautions.
Permit Approval
The Permit Approving Authority (may be IOTLs representatives in site wholly controlled or the clients representative in other cases) will review the application with the contractors before issuing the permit. If the work has a potential to create hazards in the Project site such as welding job, the Permit Approving Authority shall specify all necessary safety precautions to be taken and visit at the work site to ensure that all such requirements are complied with before issuing the permit.
Confirmation and Acceptance of Permit Conditions
The Permit applicant and the Approving Authority must arrange for a site visit to confirm that all preparation works are completed and the permit conditions have been maintained. General conditions such as adequate emergency escape route, fire fighting equipment, emergency shower stations, personal protective equipment, and barricading of work area shall be confirmed.
Commencement of Work
Upon confirmation of site conditions and all parties concerned are satisfied with the safety precautions to be taken, the work shall be commenced with close monitoring by the permit applicant as the operating conditions in the Project site may change making the site conditions unsafe. In areas of major concern or proximity to process, a dedicated fire watch shall be deputed during the job.
Job Completion and Acceptance
It is essential that when the job is completed, the permit applicant must sign off the work permit and returns it to the Approving Authority indicating whether the job has been completed satisfactorily so that site check can be carried out to ensure that the site has been brought back to a safe condition e.g. all pipeline connections are properly secured and fixed in position for decommissioning and all housekeeping has been completed.
Hot Work Permits should only be valid for a specific period of time as mentioned in permit and in all cases be expired at the end of one working shift from the time of approval. The expired Hot Work Permit can only be extended if the safety conditions are maintained through physical confirmation by the in-coming or new shift team members together with the contractor.
Cold Work Permits should also be valid for a specific period of time. Under special circumstances, the Operations Manager or his deputy may authorise that Cold Work Permits be allowed to run up to six days so long as they are closed on last working week day whichever is earlier. The area where Cold Work Permits are allowed to run for extended period must be clearly defined.
Approving Authority must ensure that the special condition is communicated to all shifts. The contractors are informed that the Permits are limited to the defined area.
7.4 Permit Suspension and Cancellation
If there is an emergency such as fire outbreak in the site, all work permits issued will be automatically suspended and work must be stopped until clearance is given by the permit approving authority before work can be resumed. If the safety conditions established have changed due to the emergency, the work permit should be treated null and void and a fresh one should be re-issued if work is to be resumed after the emergency is called off.
Approving authority, HSSE Coordinator or any responsible person can suspend / cancel the permit if it is perceived to be in violation with the conditions stipulated in the permit. A fresh permit has be issued before work can resume again with due precautions.
7.5 Distribution, Administration & Display
For hot work / vessel entry / excavation & height permits original to be given to receiver, 1 st copy to HSSE Coordinator / dept. and 2 nd copy retained by issuer (Permit Approving Authority). All these permit shall be displayed at site.
For cold work permits the original to receiver and the copy to be retained .
At the end of the day or when permitted work is completed (which ever is earlier), the original copy of the permit issued to applicant in charge of work is to be returned to Permit Approving Authority. Safety Plan
A schedule of regular inspections / audits not only improves specific process unit conditions, but also supports a consistent approach to health and safety issues throughout the project site. The safety audit has two purposes. First, it serves as a tool for management to ensure that covered operations are in compliance with the safety as well as other environmental regulations. In addition, the audit allows management to perform a "real-time" check on the safety of its operations. A safety audit should also include a written report with recommendations, and a management response. Actions taken should be to address and correct deficiencies identified in the report.
8.1 Internal Safety Inspections
The HSSE Committee shall ensure that a minimum of one HSSE Committee Inspection per month is carried out. A written report will be completed during inspections.
These inspections will consist of, but not be limited to the following: a) A thorough physical inspection of the premises with particular attention paid to; housekeeping, chemical storage, machine guarding, work station layout, lighting, preventive maintenance, and equipment and tools. b) Observation of jobs, with particular attention being paid to: Personal Protective Equipment, safe job procedures, and discussing any noted deficiencies with employees involved.
Whenever possible, any dangerous or hazardous situations or deficiencies will be corrected at the time of inspection. Whenever this is not possible, written recommendations will be submitted as audit report.
An inspection checklist may be prepared for specific locations to facilitate internal audits in structured way.
HSSE-Coordinator should carryout daily routine inspection of the site to correct any dangerous / hazardous situation.
8.2 External Safety Inspections / Audits
External Safety audits / inspections should carried out of the site on random basis preferably quarterly by IOTL HO. Necessary reports shall be made for corrective actions and records.
External audits may also be carried out by clients on their sole desertion. Other audits may also be arranged from external agencies as per requirement. Compliance of all external audits reports shall be documented. Safety Plan
There are four main steps in Job Safety Analysis. First, the job to be analyzed must be selected. This selection is base upon the severity of potential losses, the frequency at which the task is performed and the probability of loss when the task is performed. The job safety is then broken down in to a sequence of steps. Potential hazards are identified at each step. Method to control or eliminate each hazards are then developed and implemented.
Some factors that will influence priority for the selection of jobs for Job Safety Analysis include; a) The frequency and severity of accident and incidents that have occurred. b) Introduction of new tasks, processes or operations c) Change to existing tasks, process or operations d) The frequency at which the task is performed e) The severity of potential losses. f) The probability of potential losses
Selection of jobs for initial job safety analysis will be done jointly by the HSSE Committee. The diversity of our operations and the many clients location at which we work dictates that it is probably impossible to analyze every job. It is the companys intention to analyze as many jobs as possible beginning with those that could result in severe potential losses.
All JSAs will be reviewed yearly by the HSSE Committee
The job safety analysis may be used as a basis for safe work procedures. It identifies tools and personal protective equipment requirements for specific tasks. It provides information on physical demands associated with the work activity. Supervisors will use the JSAs as a documented standard during Job Training, during investigation of accidents and incidents, safety inspections and auditing of safe task performance. In terms of accident prevention it is therefore a pro active tool.
It is the responsibility of the Project Manager to ensure that JSAs are completed as required, and that all job safety analyses are revised / updated whenever there is a change in the process / task / operation.
Copies of all JSAs will be forwarded to HO for records and review.
Copies of all JSAs will be kept in a convenient location available to all concerned.
Training must meet the needs of a project site in addition to complying with all National / Local requirements; specific training needs may include safe working procedures, fire fighting, evacuation, implementation of health and safety for construction work, workplace emergencies and first aid procedures.
9.1 New Employee Orientation
As well, inexperienced workers are generally involved in more accidents than veteran workers. Although experience increases safety awareness, early education in health and safety and job skills can improve the safety record for new workers right from the start.
A brief safety induction module for workers, supervisors and engineers shall include but not limited to; a) Companys HSSE Policy b) Safe working procedures c) When and how to use personal protective equipment d) Emergency procedures e) Electrical safety f) Hazards in jobs g) Incident & accident reporting procedure h) Reporting of substandard conditions, unsafe conditions and unsafe acts. i) Health & Hygiene j) Housekeeping
Additional to the above Supervisors and Engineers shall be also trained in. a) Risk analysis (JSA) b) Work permit system in detail
9.2 Periodical Safety Training
Periodical Safety Training will be conducted for engineers, supervisors, Trade men and worker on construction site safety. The training will contain but not be limited to; Site planning and layout, Excavation, Scaffolding, Ladders, Height work, Site erection, Demolition, Confined space, Material Movement, Welding and Cutting, Electrical equipment, Hand Tools, P.P.E. etc.
Operations always imply potential health hazards. As it is not possible to treat every possible danger by appropriate design measures suitable PPE must be used to prevent injuries.
10.1 Minimum Requirement
Every person entering the Restricted Area of a Project site shall be in possession of minimum PPE. For Indian Oiltanking operational personnel requiring PPE this equipment will be provided. For visitors helmets and shoes are to be provided as a lend out. It is every contractor's own responsibility to ensure that his personnel is in possession of the necessary PPE.
In every case all PPE used must be conform to local standards or EN (European Norm) or ANSI (American National Standard Institute). All PPE to be worn shall be approved by the HSSE Coordinator.
Head Protection
Safety helmets shall be worn at all times during the stay inside the Restricted Area of a Project site.
The use of labels is discouraged, as the adhesives may affect the helmet's material. Safety helmets made of plastic shall be replaced every three years. Any helmet damaged or exposed to heavy impact whether damage is apparent or not shall be replaced immediately.
Foot Protection
Safety footwear shall be worn at all times in the Restricted Area of a Project site. It must be worn at least when operational, maintenance, construction, demolition or inspection work is being carried out.
Shoes should be of better construction and must be antistatic if the work is being done in close proximity of process areas.
Body protection
Body protection shall be worn to prevent injuries caused by absorption of hazardous chemicals, severe cuts or lacerations, severe abrasions, punctures and harmful temperature extremes.
Cotton clothing or clothing made from other antistatic materials (e.g. Nomex) are preferred over other type of work clothings.
No nylon or purely synthetic fiber cloths should be worn in proximity of process areas.
Work clothes for operators shall be clean and properly fastened with cuffs secured to prevent loose clothing becoming caught in moving or rotating machinery. Loose clothing must not be worn.
Clothes contaminated with oil, chemicals or toxic substances may be a fire hazard or lead to skin disease or other illnesses and shall be laundered.
Hand Protection
Gloves made from cotton or fabric blends shall be worn to improve grip when handling slippery objects. They also insulate hands from mild heat or cold. While executing tasks that could cause injuries from sparks or scraping against rough surfaces, leather gloves shall be worn. It is recommended to use gloves with a combination of both materials.
10.2 Additional requirement
The HSSE Coordinator shall ensure that a formal assessment has been conducted for all activities to ascertain the need for further Personal Protective Equipment for the employees. An assessment of physical hazards and of the hazardous materials being handled shall be made and shall draw up schedule of the PPE required for each operation. Sufficient PPE shall be available in the sizes necessary to enable at least one change of outer clothing and two changes of underclothing if necessary. There shall also be sufficient PPE for immediate rescue operations. The activities of the sub- contractors regarding the selection and use of PPE shall be monitored by the HSSE Coordinator.
Head Protection
Additional requirement in head protection may be welding helmets as well as special helmets for working under high voltage lines.
Foot Protection
Additional foot protection for electrical hazards (people working with HV equipment may be required. Other requirements may be due to corrosive or other hazardous material requiring suitable protection.
Requirement of disposable gloves for first aid treatment, use of rubber / nitrile gloves while dealing with corrosive chemicals, asbestos gloves while working with high temperature equipment etc.
Body protection
Additionally for working with corrosive chemicals where there is a chance of material spilling on to body, full protection of body by wearing full body chemical suits may be necessary. At the same time proximity suits may be required for working in close proximity of high heat radiating atmosphere and fire fighting. Flash fire proof suits come handy when work is to be done in such area where a flash fire may be anticipated in extraordinary situations.
Eye and Face protection
Safety goggles must be worn while performing construction activities like Grinding, Gas cutting, Sand blasting etc. Other face protection requirements includes welding (welding face shield), Splash of chemicals (full face shield) and spray protection ( safety glasses)
It must be understood that ordinary glasses do not provide protection against special hazards.
Hearing Protection
Regular exposure of employees to noise, particularly in the workplace, can result in damage to hearing. In order to safeguard the hearing of employees engaged in operations that involve exposure to noise. In high noise area where noise exceeds 85 dBA (for 8 hrs shift), suitable hearing protection by virtue of using either ear plugs or ear muffs as per requirement.
Respiratory Protection
Areas having either heavy dust or chemical vapours may require use of suitable respiratory protection. For need of the same work zone monitoring may be considered for identification of areas requiring such protection. Dust mask for dust protection and cartridge type filter mask to be used for specific chemical vapors as per suitability.
Continuous air line or Self Contained Breathing Apparatus may be required while performing work in oxygen deficient or toxic atmosphere. The normal filter type masks shall never be used for such applications.
Personal Protective Equipment is not suitable unless it; a) is appropriate for risks involved ar\d conditions at the place of exposure. b) takes account of ergonomic requirements and the state of health of the person who wears it. c) is capable of fitting the wearer correctly. d) is effective to prevent or adequately control risks involved without increasing the overall risk.
Where more than one item of PPE is; used, it must be compatible with other items used at the same time. This has to be checked by the HSSE Coordinator.
The HSSE Coordinator shall provide adequate information, instruction and training to enable users of PPE to know: a) the risks which personal protective~ equipment will avoid or minimise. b) the purpose for which and manner in which personal protective equipment is to be used. c) any action which the employee might take to ensure that personal protective equipment remains effective and in good condition.
10.4 Storage and maintenance
For IOTL employees, HSSE Coordinator shall be responsible for storage and issuance of PPEs.
The sufficient inventories of PPEs shall be maintained and records kept and updated regularly.
There shall also be sufficient PPEs for immediate rescue operation as well as for emergency use.
Responsibilities of maintenance of the PPEs and at the same time getting it replaced when these are not suitable for further use rests with the individual issued with such PPEs.
HSSE Coordinator shall approve the quality of the PPEs being used.
Preferably a display of available PPEs may be made in showcase to enhance the awareness and usage of the same.
Alert the persons nearby by shouting fire! fire! fire!
If there is a fire alarm system, activate fire alarm or inform any nearby person to do so. Or arrange to inform the control room / project in-charge / HSSE Coordinator / Other emergency response teams by available means (phone / messenger / walky talky / PA System etc.)
Confirm the location, type & magnitude of fire / emergency.
Try to extinguish the fire with available means (fire extinguishers, fire hoses etc.) from upwind direction, if the same can be done without endangering yourself.
Guide the emergency response personnel with the information.
Dont venture in to rumour spreading or unauthorized statements to outside agencies.
11.2 When fire alarm sounds
Generally emergency sirens / fire alarms are continuously sounding warbling sirens (on off on off )
Essential personnel
Persons, whose services may be required during emergency, shall report directly to the project incharge or the person incharge of response operations.
Non essential personnel
Stop work immediately.
Switch off all electrical equipment and welding machines.
Proceed immediately to assembly area.
Wait for further instructions from authorized personnel.
Main causes of fire during projects may be summerised as; a) Careless gas cutting / welding b) Smoking c) Throwing lighted matches d) Uncontrolled rubbish burning e) Incorrect storage and careless use of flammable liquids and compressed gases f) Electrical sparks (loose cabling, wet electrical equipment etc.) g) Electrostatic discharges
Main preventive / protective measures should be taken are a) Nobody shall be allowed to misuse or horse play with the emergency equipment. b) Demonstration on the usage of fire extinguishers shall be arranged. c) Fencing of loading areas like flammable stores, paint oil storage and other combustible material storage with no smoking or naked flames sign. Also such areas to be kept free of dry grass / vegetation. d) Fire extinguishers shall be conspicuously located and the personnel should be trained in the use of the same. e) All hot work shall be routed through permits and thoroughly inspected and supervised. f) All electrical equipment shall be of sufficient rating and the junction boxes, fuse units properly closed and located at sufficient height free from dry grass / vegetation in close vicinity. Cable running either underground or at sufficient heights.
12. HSSE for Sub-contractors
12.1 General guidelines
No Sub-contractor is allowed to begin a job for IOTL until they have provided proofs of compliance to statutory requirements which shall include but not be limited to the following. (PF, Labour License, Insurance, WC policy)
Before a Contractor begins work, the Project Manager or his designate, will meet with the Contractor, or his representative and explain the applicable Company Safety Policy and Procedures.
Ensure the contractor has an Employee designated to be responsible for HSSE
As a minimum standard, all Sub-contractors employees must wear shoes and hard hats while at our job site. Other PPEs at discretion of management may also be required.
Sub-contractors must report all injuries occurring to their employees while on our job sites to our Project Manger or his designate. We will keep a record of such injuries.
All our employees working in areas where work is being performed by Sub- contractors will be advised of their presence. Our employees should also be cautioned of any hazards that may exist because of Sub-contractors work.
Sub-contractor staff must be present for, and participate in IOTL pre construction safety meetings and subsequent safety meetings and trainings as and when called for.
Sub-contractors shall provide a list of any chemical / toxic substance they plan to bring onto our job site. Only after the MSDS have been reviewed by our HSSE committee, will permission be given to proceed with their use. All empty containers and / or left over substances will be removed by the Sub- contractor.
The Sub-contractor will become familiar with IOTL job site first aid facilities.
The Sub-contractor will become familiar with IOTL Emergency / Fire Protection Equipment at our jobsite.
The Sub-Contractor or his representative will sign an acknowledgement (form no. FM/HSSE/006) of these procedures. The form will be kept on file by IOTL
Failure to meet any of the above conditions may result in being removed from the job site and possible loss of work site contract.
13. Rescue / First Aid / Medical Treatment
It is known that the quicker the first aid treatment is given, the less impact the injury will have on the patient. For more serious injuries, the purpose of first aid is to maintain the injured in a stable condition until professional help arrives.
13.1 Equipment
First Aid Boxes
First aid boxes and first aid equipment must comply with local legal requirements. It should be located at strategic points e.g. control rooms, office buildings, guard rooms
The first aid box should be regularly checked by the HSSE Coordinator for completeness and for replacement of out-of-date materials.
A booklet shall also be kept in the first aid box detailing basic first aid techniques.
A list of qualified first aiders and nearby hospitals should also be pasted / stuck on the wall / kept near first aid box.
Eye wash and emergency showers
Emergency showers shall be provided in all areas where acids or other corrosive substances are handled. Similar precautions against overheating or freezing, as above, should be observed. Emergency showers should be tested weekly and always before any work involving the handling of acids or corrosive liquids. Defects shall be reported immediately to the HSSE Coordinator.
Eye baths can stand alone or are incorporated as part of an emergency shower. Due to the high ambient temperatures experienced in some locations, water feed lines to eye baths that are exposed to direct sunlight should be insulated
SCBA & Resuscitation Equipment
Consideration must be given for resuscitation equipment and SCBA to be provided at the Project site. For chemical and gas Project sites such equipment will normally be required.
Stretchers
Depending upon the size of the Project site, at least one stretcher should be provided and stored in a prominent place for the movement of any casualty. Injured persons should not be moved unless they continue to be in danger of further injury or the movement is approved by a qualified medical person.
Water gel blankets
Water gel blanket should also be kept for rescue / first aid from burn injuries.
Emergency tool kit
An emergency tool kit detailing various sizes etc. of tools and rescue equipment may also be considered for project sites.
There shall be a continuous program of first aid training given by qualified persons or recognised institutions. Such training should ensure that there is adequate first aid proficiency available! locally to work stations at all times.
Records should be kept of training given and the development of proficiency. Training by some recognized authorities does permit certificates to be issued.
Internal training on first aid to worker by the qualified first aiders shall be undertaken with normal training programs.
13.3 Outside Medical Support
In case of an emergency that involves injured personnel, outside medical support will be required . Contact with relevant medical authorities has to be established and they have to be invited to participate in regular emergency drills in order to get familiarized with the Project site and the particular hazards.
Name & Telephone numbers of these installations (outside medical services) must be prominently displayed at least in the control room, first aid boxes and the office building. Normally, these numbers shall be included in the Emergency Contact List.
During commissioning a facility, a significant number of issues should be reviewed to make a reasonably sound evaluation of the facility. Checklists for every conceivable safety and environmental aspect are a handy tool to carryout a safe commissioning activity.
A new facility should be identified for every potential hazard and such hazards should be eliminated. With the conscientious application of checklists, a safety professional can be reasonably assumed to have made an honest, professional appraisal to ensure the highest possible level of safety implementation. Following are a set of commonly used checklists for new facilities.
14.1 Planning
S Item Y N Remarks 1 Flow diagrams and layout drawings available and reviewed
2 Operation Manual Developed reviewed and all significant activities are covered with Standard Operating Procedures and Work Instructions.
3 Safety Procedures are available and reviewed
4 MSDS (Material Safety Data Sheets) are available for all products / Chemicals
5 On-site emergency plan is available for the facility and known by commissioning personnel.
14.2 Tank Farms
S Item Y N Remarks 1 Tanks are provided with equipment for guarding against excessive vacuum or pressure and the equipment is tested.
2 Tanks are properly earthed and floating roof tanks are provided with bonding wire with tank shell
S Item Y N Remarks 1 Facilities for storing flammable material are provided with Flameproof electrical fittings with proper ventilation
2 All flanges, tapings and connections are leak proof for all flammable liquid handling line / equipment.
3 Only metal drums are used for dispensing flammable liquids and are properly grounded.
4 All lines carrying flammable substances are protected for collision / hitting from traffic, mobile equipment.
5 No Smoking or Naked Lights signs are posted at strategic locations.
6 Cylinders are provided with a dedicated storage facility with segregation between incompatible gases.
7 Appropriate Portable Fire Exitinguishers are placed at strategic locations.
14.6 Miscellaneous
S Item Y N Remarks 1 All rotating machinery (including drive belts) are properly guarded to avoid any physical contact
2 All Hazardous substance containers are properly identified and marked with hazard associated
3 All safety and critical interlocks are tested and functioning properly.
4 All product pipelines are hydrotested at recommended pressure.
It is known that most accidents/incidents occur during commissioning, shut-down and recommissioning. It is therefore necessary that extra care is exercised during these operations and that the HSSE standards and procedures are strictly adhered to. Particular attention needs to be paid to vents, drains, earthing, bonding and whether work permits are in force.
Commissioning and recommissioning shall only be undertaken during daylight and with an adequate number of trained staff. Wherever practicable pre-testing of the equipment should be considered.