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Contents OHSPM/02

_______________________________________________________________ _______________________________________

Rev – 03 Page 1 of 1 28 Feb.’2008

1

B. CONTENTS

Chapter Title No. of

Pages

Current Rev. &

Date

A Cover Page & Authorisation 01 02 / 10.12.2007

B Contents 01 02 / 10.12.2007

C Abbreviations 02 02 / 10.12.2007

D Corporate Policy 02 01 / 02.12.2004

E Leadership and Commitment 01 00 / 10.06.2007

F Duties and Responsibilities 07 00 / 10.12.2007

01 OH&S Objectives and Targets 02 00 / 10.12.2007

02 OH&S Requirements – Implementation by ALL 13 02 / 30.01.2007

03 Reporting about Opening / Closing of the site 01 02 / 10.06.2007

04 Safety Officer/ Engineer 03 02 / 10.06.2007

05 Safety Committee Meeting 02 02 / 10.12.2007

06 Incident Reporting and Investigation 13 02 / 30.10.2007

07 Monthly HSE Statistics Reporting 08 02 / 10.10.2007

08 Positive Reporting on Safety Performance 01 01 / 02.12.2004

09 Onsite Emergency Preparedness Plan 05 02 / 10.12.2007

10 Pre-qualification for selection and performance of contractors 02 02 / 10.06.2007

11 Screening & Induction of Workmen 01 02 / 10.12.2007

12 Safety of visitors to L&T construction sites 02 01 / 02.12.2004

13 Hazard Identification & Risk Assessment 17 02 / 10.10.2007

14 Safety Tool Box Meetings / Talks 01 01 / 02.12.2004

15 Work Permit System 05 02 / 10.12.2007

16 Inspection of lifting appliances, gears and related vessels 03 02 / 10.06.2007

17 Inspection of plant and machinery and equipment including vehicles 01 01 / 02.12.200418 Display of Safety Performance Board 01 01 / 02.12.2004

19 HSE Audits And Inspections 03 02 / 10.11.2007

20 Training, Awareness and Competence 01 01 / 02.12.2004

21 Reporting of Safety Performance 01 02 / 10.06.2007

22 Noise Control 01 01 / 02.12.2004

23 Leakage / Spillage of Hydrocarbons and Chemicals 01 01 / 02.12.2004

24 Offshore Safety 03 01 / 02.12.2004

25 Provision of Accident Prevention Tools (APTs) and Safety related items 02 02 / 10.06.2007

26 Scaffolding 26 Under construction

27 Penalty system for contractors 02 00 / 10.06.2007

28 Radiography 06 00 / 10.06.2007

29 Electrical Safety 06 00 / 30.08.2007

30 Motivational Scheme 03 00 / 10.10.2007

31 Safety Scoring 01 00 / 10.10.2007

32 Safety during Pre -commissioning and Commissioning 13 00 / 25.02.2008

33 Displaying NFPA-704 Diamond & Requirements Of API- 650 Section 8 On

Storage Tanks Containing Hazardous Materials

15 00 / 28.02.2008

34 OH&S Records 04 02 / 25.02.2008



Abbreviations OHSPM/02

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Rev – 02 Page 1 of 2 10 Dec.’ 2007

C. ABBREVIATIONS

AERB - Atomic Energy Regulatory Board

AGM - Assistant General Manager

APT - Accident Prevention Tools

BARC - Bhabha Atomic Research Center

BIS - Bureau of Indian Standards

BOCW - Building and Other Construction Workers

BUH - Business Unit Head

BVQI - Bureau Veritas Quality International

CB - Circuit Breaker

CG - Center of GravityCI - Chief Inspector

CO - Central Office

CO2 - Carbon Dioxide

CHSECE - Contractor HSE Capability Evaluation

DB - Distribution Board

dBA - Decibel

DG - Director General

DGM - Deputy General Manager

DI - Dangerous Incident/OccurrenceDNV - Det Norske VeritasDP - Dye Penetration

ELCB - Earth Leakage Circuit Breaker

FPS - Field Production Superintendent

FR - Frequency Rate

H2S - Hydrogen Sulphide

HSE - Health, Safety and Environment

IC - Internal Combustion

L&T - Larsen & Toubro Limited

LPA - Loss Prevention Association of India

LRQA - Lloyd’s Register Quality Assurance

LT - Lost Time

LWC - Lost Workday Case

mA - milli Ampere

mR - milli Roentgens

MFF - Modular Fabrication Facility

MI - Minor Injury

MOM - Minutes of Meeting



Corporate Policy OHSPM/02

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Rev – 01 Page 1 of 2 02 Dec. 2004

D. CORPORATE POLICY



Corporate Policy OHSPM/02

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Rev – 01 Page 2 of 2 02 Dec. 2004



Leadership and Commitment OHSPM/02

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Rev – 00 Page 1 of 1 10 Jun. 2007

E. LEADERSHIP AND COMMITMENT

q Leadership Visibility; -Company leaders provide strong and visible leadership throughout L&T, and amongst their contractors, to

promote a culture of shared commitment to OH&S by:-

• Providing strong, visible leadership through being a good role model for all staff and contractors• Actively participating in site OH&S visits

• Attending OH&S Committee meetings and forums• Reviewing OH&S Performance of L&T – E&C

• Reviewing findings from high potential incidents and near misses

• Showing visible, timely and involved response to significant incidents, or any other deviation from

normal business

• Approving HSE Cases and/or Plans• Implementing the OHS&E-MS, and obtaining external system certification (e.g. OHSAS 18001, ISO

14001), by making the necessary resources available, and monitoring progress against specific

milestones within the Business Plan• Communicating OH&S expectations to staff and contractors, through the Corporate Policy, Zero Incident

Credo.

• Discussing and reviewing with employees, suppliers and contractors progress against set OHS&E targets• Demonstrating active personal participation in OH&S activities such as training, reward and recognition

schemes - “Safe Employee of the Month”, Safety Month/ Week Celebration, contractor workshops,

audits, and conferences.

q Proactive Target SettingThe leaders illustrate their commitment to proactive target setting by:-

• Engaging with their respective leadership teams, employees & contractors to determine relevant OH&S

“result” and “activity” objectives, targets & indicators inline with “Zero Incident Credo”• Ensuring that their staff have OH&S performance deliverables expressed in their annual tasks and targets

• Setting minimum expectation levels (e.g. enforcing standards, encouraging open reporting anddiscussion)

q Informed Involvement and Commitment“L&T-ites shall endeavour to create a safe working environment by following the policies and procedures

of Health, Safety and Environment, as applicable. L&T-ites shall strive to keep ones own place and surrounding work place clean and hygienic." as spelt

out in item (viii) of "L&T Code of Conduct " prepared by Corporate Governance Department at L&THouse

The leaders demonstrate informed involvement with OH&S issues by:-• Reviewing progress in the development and content of their OH&S Cases, and the continuous

improvements at project sites

• Making the appropriate resources (e.g. finance, technology, skills, training and expertise) available tomeet HSE targets

• Undertaking relevant HSE training

• Being fully aware of the high priority areas for improvement identified in the OHS&E Management

System, particularly in relation to legal compliance and stakeholder issues

• Being personally involved in the improvement efforts arising from the formal senior management‘review’ of the OHS&E Manage



Duties and Responsibilities OHSPM/02

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Rev – 00 Page 1 of 7 10 Dec.’ 2007

F. DUTIES AND RESPONSIBILITIES

1. Project Manager/ Project Head:

§ Formulates and owns of the HSE System, demonstrate commitment and allocate responsibility for

effective HSE management system.

§ Set up standards for Loss control in compliance to applicable laws & regulations.

§ Allocate resources for proactive HSE management such as Safety Budgets.

§ Ensure evaluation of Contractor Safety Capability before finalizing work order.

§ Review and act upon HSE performances, set up implement continual improvement plan.

§ Integrate HSE management during project tendering, construction and commissioning activities

such that all risks are identified and effectively managed at the planning stage.

§ To develop competency and awareness through effective training, motivation & promotional

program.

§ Empower personnel to stop activities/ unsafe conditions with imminent dangers of Accident.

2. HSE Capability Centre:

§ Develop operating procedures for effective HSE Management System.9

§ Establish, implement, maintain and review HSE objectives and programs including responsibility,

authority, means & time frame at all relevant functions and levels.

§ Identify, provide and evaluate effectiveness of training for implementation of HSE Management

System at all relevant functions and levels.

§ Conduct regular site inspections to monitor and measure HSE performance, incident investigation,

non conformity, status of corrective action & Preventive actions.

§ Review overall HSE Performance and suggest management for continual improvement.

3. Management Systems Cell:

§ Coordinate with HSE Capability centre in developing HSE management system procedures.

§ Train and educate all relevant functions and levels on HSE Management System

§ Conduct management reviews at relevant levels as per Corporate Manual to ensure improvement of

effectiveness of HSE Management System.

§ Conduct internal audits to as per corporate manual to objectively evaluate whether OH&S

processes and procedures

- confirms to planned arrangements to the requirements of the corporate manual & thisOH&S manual.

- is effectively implemented and maintained.- is effective in meeting corporate policy and OH&S objectives and Targets.

§ Coordinate with external agency/certification bodies and conduct External Audits.

4. Resident Construction Manager (RCM):

§ Demonstrate commitment and allocate responsibility for effective implementation Company HSE

management system at the Project site.

§ Review the Site HSE performances, establish HSE Objectives and implement SMART (specific,

measurable, achievable, realistic & target oriented) plans for continual HSE improvement at site.




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Rev – 00 Page 2 of 7 10 Dec.’ 2007

§ Evaluate risk for all activities & integrate HSE requirements for effectively managing the risk while

planning for the activity.

§ Regularly hold meeting with the site engineers/ supervisor to discuss the site HSE issues and chair

the site HSE committee meeting once a month.

§ Conduct planned HSE site visits & audits including the evaluation of the contractor HSE

performance.

§ Participate in the investigation of high potential incidents/Accidents.

§ Ensure availability of adequate HSE resources (shoes, helmets, Safety belts Harness, fire

Extinguishers, First aid boxes etc).

§ Provide & maintain safe working conditions inline with company HSE procedures, client’s HSE

requirements and HSE best practices.

§ Ensure proper training for site personnel, apprise them of the job hazards and required HSE

precautions before putting them on to the job.

§ Coordinate with clients, contractor(s)/sub agencies and ensure compliance of site HSE

requirements.

§ Provide & maintain First Aid facility, Fire fighting facility etc. establish mutual aid agreements and

develop emergency preparedness at site.

§ To encourage HSE suggestions, promotions and motivational program.

5. Discipline Manager/ Site Engineers/ Supervisors (L&T & Contractors) :

§ Demonstrate commitment and effectively implement the HSE management system requirements at

site in line with the allocated responsibility.



§ Participate in the site HSE Committees, site HSE meeting, site visits, inspections, and audits and

ensure all sites HSE issues are addressed at the earliest.

§ Ensure the implementation of the following HSE Procedure as minimum to prevent

accidents/minimizing the risk:

§ Risk assessment & prevention.

§ Permit to Work System

§ Use of PPE & Safety Equipment at site

§ Excavation

§ Working at height ( using Ladder, Scaffolds, Safety Nets etc)

§ Use of Electricity

§ Welding and Gas cutting safety

§ Entry into confined space

§ Material Handling (Crane Operation, using Lifting accessories etc)

§ Structural Erections

§ Radiography Safety

§ Shot Blasting & Paintings Safety etc.




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Rev – 00 Page 3 of 7 10 Dec.’ 2007

§ Report accidents and near misses, conduct investigation and implement recommendations at

site.

§ Ensure all company & Contractor personnel working under him are trained on safe working

procedures.

§ Conduct HSE Toolbox talks daily in the Morning at site.

§ Use only tested /third party certified lifting equipment, tools and tackles.

§ Maintain good housekeeping in their respective area of control.

§ Legal and other requirements.

§ Seek HSE advises and Coordinate with site HSE Officer in effectively implementing the L&T

HSE Management system & Project HSE Plan.

6. L&T Site HSE Officer:

§ Develop and assist site management in implementing company HSE Management System and

project specific HSE Plan.

§ To act as an advisory capacity for all levels of management at site.

§ Provide assistance in solving HSE related problems and making recommendations for to effectively

implement HSE requirements at site.

§ Review the site HSE performances against the set HSE Objectives and SMART plans and advise

the RCM / Site HSE committee on the areas of improvement.

§ In consultation with RCM and Committee members, prepare HIRA and Legal registers applicable

to the site and also to be reviewed and updated periodically.

§ Assist in investigation of near misses/ accidents, identify root causes and recommend corrective

action to the site management.

§ Assist site management in formulating, revising and updating the HSE procedures for critical

activities/ high-risk activities.

§ Exercise authority to stop work when need arises.

§ To advice site management on legal requirements affecting HSE and coordinates with local

authority, clients and contractors/agencies on issues regarding HSE.

§ Motivate, promote & propagate HSE through orientation, training, leaflets, memos, posters, notices,

etc as per Motivational Program set at the beginning of the project.

§ Assist Site Engineers/ supervisors in conducting HSE toolbox meetings at site.

§ Advise maintenance of such records as are necessary with regards to accidents, dangerous

occurrence and occupational diseases.

§ Advice site Engineers/ supervisors on the HSE areas requiring immediate attention especially for

housekeeping.

§ To arrange/ participate in periodic HSE inspection/ audits of work areas.

§ Review the records of accidents, analyze trends and advice site management to prevent recurrences.

§ Advice purchasing & Quality of PPE conforming to ISI standard.

§ Identify critical equipment and tools and ensure they have a valid statutory test certificates before

usage at site.




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Rev – 00 Page 4 of 7 10 Dec.’ 2007

§ Advise site management on the requirements of First Aider, First Aid Facility, Fire fighting facility,

identify mutual aids and develop emergency preparedness at site.

§ In the event of an emergency, coordinate with client and implement emergency evacuation plan as

agreed.

Contractors & Subcontractors:

7. Contractors’ Site Project Manager

§ Liasing with L&T’s project management personnel to ensure provision of a safe and healthy work

environment during the Project.

§ Demonstrate commitment and effectively implement the OH&S management system requirements

at site in line with the allocated responsibility.

§ Submit HSE Plan to L&T – RCM prior to start the activities and its successful implementation at

site.

§

Overseeing the successful implementation of the Safety, Health and Environment (HSE) Planduring the project execution.

§ Ensure all site personnel are provided with appropriate Personal Protective equipment (Safety Shoe,

Helmet, hand gloves etc.) and it is used by all. (note: penalties are applicable for not using PPE at

site)

§ Ensure daily HSE Tool Box meeting for all personnel conducted at site.

§ Participate in the safety committee meetings, site visits, inspections, audits and ensure all site HSE

issues are addressed at the earliest.

§ Nominate at least one person dedicated to supervise the HSE activities for his team ( Note: above

250 worker one qualified & experienced HSE officer is needed )

§ Supervising and monitoring all his direct and contract employees to ensure constant compliance

with the Safety, Health and Environment Management Plan and other local legislated regulations.

§ Any deviation from the Safety, Health and Environment (HSE) Plan shall be corrected immediately

and where necessary, affected work shall ceased until the affected work or situation is considered

safe.

§ Ensure that all accidents and near misses are reported , conduct investigation and implement

recommendations at site.

§ Authorised to immediately stop any work that is potentially unsafe and jeopardising the life of

others.

§ Ensure all company & contractor personnel working under him are trained on safe working

procedures.

§ Ensure only tested /third party certified lifting equipment, tools and tackles are used at site.

8. Contractor’s / subcontractor's HSE Supervisor:

§ Patrol the work site periodically to verify that the work is carried out under safe conditions, with no

violations of HSE requirements.

§ Assist to evaluate risk for all activities & integrate HSE requirements for effectively managing the

risk while planning for the activity.




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§ Advise promptly the construction supervisors and workers of the corrective action when any unsafe

conditions or violations are observed.

§ Check each work procedure from the HSE point of view and advise the construction supervisors

before commencement of work and/or while working.

§ HSE supervisor shall closely work with L&T HSE Officer and ensure that no contradictory work

methods are practiced during construction.

§ Submit accident report to L&T - RCM.

§ Maintain the published HSE literature, HSE regulations, codes and other communications. Advise

management of compliance and conditions requiring attention.

§ Check on the use of all types of personnel protective equipment effectiveness and suggest

improvements.

§ Compliance to all the safety inspection/ audits findings and report to be submitted to L&T HSE

Officer.

§ Maintain Daily HSE observation log book at site

§ Conduct Tool Box talks along with Site Engineers/ supervisors.

§ Support L&T HSE Officer for HSE activities such as Training Program, Motivational & Promotion

activities.

9. Subcontractor’s Site Engineer/ Supervisor:

§ Be familiar with those parts of L&T, E&C Division's HSE Program applicable to the work on

which subordinate workers are engaged.

§ Incorporate HSE procedures in routine tasks and see that they are obeyed.



§ Understand the hazards and legal requirements related to the job and comply it.

§ Conduct toolbox talks prior to daily work starts and convey the hazards involved in the job.

§ Eliminate unsafe acts and unsafe conditions at construction site.

§ Ensure all workmen undergo a HSE orientation program at project site before they are engaged in

site work.

§ Ensure that new employees are properly instructed in precaution to be taken before they are

allowed to start work.

§ Take work permit before starting the job.

§ Report accidents, unsafe conditions and defects in equipment to immediate superiors.

§ Set a personal example.

§ Be responsible for all HSE activities, including fire prevention during the construction period.

§ Participate in the safety committee meetings, site visits, inspections, audits and ensure all site HSE

issues are addressed at the earliest.

§ Motivate the workers to follow HSE rules and regulations at site.

§ Use only tested /third party certified lifting equipment, tools and tackles.




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Rev – 00 Page 6 of 7 10 Dec.’ 2007

10. HSE Committee Members:

§ Arrange/ participate in periodic HSE inspection/ audits of work areas and follow up recommended

correction status.

§ Participate in the investigation of high potential accident, identify system failure (root causes of

accident) and ensure implementation of the recommended action items.

§ Organizing HSE weeks, HSE competitions to promote & motivate HSE awareness among the site

personnel.

§ Review the Site HSE performances, establish HSE Objectives and implement SMART plans for

continual HSE improvement at site.

§ Recommend measures for improving welfare amenities in the construction sites and other

miscellaneous aspects of HSE;

11. Commissioning Team Leader (L&T)

§ To inform all the commissioning activities planned at site to L&T HSE Engineer.

§ To participate in HIRA and Legal Register review at site level.

§ Support HSE Engineer for conducting training program on commissioning activities to be

performed at site.

§ Participate in HSE Committee Meeting at site.

§ Person responsible for overall commissioning, regardless of his designation, will be designated as

Commissioning Team Leader to ensure safety during commissioning.

§ The commissioning team leader will be responsible to ensure safety of the commissioning team and

the facility being commissioned.

§ The commissioning team leader will ensure that:

– The HSE manual for commissioning is accessible to the commissioning team. – The personnel protective equipment necessary for the safe execution of job is inspected and is

in order.

– The commissioning team members are briefed on the availability and use of PPE.

– The commissioning team members are briefed on process hazards and that they are following

the safe method of working.

§ Co-ordinate with the project safety department including the client.

§ Obtain copies of the safety manual and other safety related documents from the client. This is more

so in case of project site is within or near to an operating plant.

§

Ensure availability of medical help and facility for the treatment in case of:

– Exposure to hazardous chemical.

– Physical Injury

– Asphyxiation

§ The team leader will, before the start of commissioning, ensure that the safety audit (Check) of the

plant is completed and the checklist neutralized (corrective action completed).

§ The team leader will ensure that the commissioning team members are aware of overall plot plan

and familiar with the emergency escape routes.

§ The team leader will ensure that a mock emergency drill is conducted and emergency procedures

followed.




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Rev – 00 Page 7 of 7 10 Dec.’ 2007

§ The leader will ensure before undertaking the commissioning that he has all emergency phone

numbers with him.

§ The team leader will ensure that he has the copy of the "On-site Emergency Management Plan

“and is conversant with its requirements.

12. All Employees (L&T, Contractors and Subcontractors):

§ Comply with L&T's HSE rules and regulations, work practices and procedures to protect himself

and his colleagues from any injury;

§ Report all unsafe acts and conditions to his superior immediately;

§ Report all accident and NEAR MISSES to his superior immediately;

§ Use the personal protective equipment appropriate to the type of activity.

§ Practice “No Smoking” within the Project site and abide strictly company “drug & Alcohol” policy.

§ Ensure good housekeeping in the area of the activity.

§ Abstain from abuse/ misuse/ horseplay at site.

§ Attain orientation training, tool box meeting and respect the HSE signs.

13. Marketing Capability Centre (L&T)

§ Forwarded HSE related queries arise from client to HSE Capability centre.

§ Review the response received from capability centre prior to send it to the client.

14. Estimation and Proposal Capability Centre (L&T)

§ Demand for safety related expenses from HSE capability centre at the beginning of the project for

smooth functioning of HSE related activities during execution phase of the project.

15. Procurement Capability Centre (L&T)

§ Incorporate HSE related instruction in the Purchase Order related to the items to be bought.

§ Respond to queries arise from site HSE officer from stie.

16. Engineering Design Centre

§ Fire / safety package developed by Design Engineering Centre for HSE comments, before sending

to Clients for approval.

§ Invite HSE Capability centre to participate in specific HSE studies i.e. HAZOP / EIA, etc.



Chapter - 01 OHSPM/02

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Rev – 00 Page 2 of 2 10 Dec .’2007

(vii) Site shall send positive reporting (OHS – 08) to HSE Capability Centre afterquantifying the achievement in terms of system improvement.

(viii) Corporate objectives shall be reviewed bimonthly in the HSE Meet.

5.0 Guidance for setting up Objectives–

5.1 Guidance for setting up Corporate HSE Objectives–Sample objective are given below

Sr. N Objectives & Targe Methods Time Frame Responsibility§ Deployment of adequate resources

for height work such as separate

scaffolding contractor, sound tube &

cup lock scaffold material, ladders,

Safety net, Life Line, fall Arrestor

At the beginning of the

project and also when t

demand

PM/ RCM

§ Implementation of Scaffolding proced

(OHS – 26)

During the project tenur All Employee

§ 100% training will be imparted to

improve skill and competence for

working at height job

o Present work force

o New comers

o Within 4 months

o During Induction

SSO

§ 100% Medical Check-up prior to deplthe workers on the height work

During the project tenur RCM/ SSO/ MedicOfficer

§ Proactive Monitoring system as per O

– 19 procedure like Safety round/walk

identify the height hazard

As per the Monthly Saf

Calendar

RCM/ Discipline

Incharge / SSO

1 Fall From height :

Reduce Accidents to

Zero level.

§ Implementation of Motivation scheme

per OHS-31 procedure

As mentioned in the O

31 procedure

RCM/ Discipline

Incharge / SSO

5.2 Guidance for setting up Site Specific Objectives–It is formulated based on 5.1 :Sample objective are given below as an example.

Sr. Objectives & Targe Methods Time Frame Responsibility

§ Procurement of tube & cup lock scaffoldmaterial, ladders, Safety net, Life Line,

fall Arrestor of adequate numbers (can be

quantified)

1 month Store Incharge

§ 100% use of above materials From 2nd

month

onward

All concerned

Incharge

§ 100% training will be imparted to improve

skill and competence for working at height

job

o Present work force – e.g If present

workforce is 600 nos., batch of 40

person per batch , 4 training programm

/month

o New comers, 100% training on work at

height during induction training

o Every week

for next 4

months

o Regular

SSO

§ 100% Medical Check-up before issuing

gate pass

During the

project tenure

Time Office

§ 4 inspection / month on work at height

§ Review compliance in committee meeting

o 4 inspection /

month

o Monthly

RCM/ Discipline

Incharge / SSO

1 Fall From height :Reduce Accidents to

Zero level.

§ “Best Contractor for working at height”

award

Bimonthly RCM/ Discipline

Incharge / SSO

6.0 Records – Zero Incident CredoForms Reference

Site OH&S Objectives and target OHS – 01AMonitoring of OH&S Objective & Target Report OHS – 01




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Rev – 02 Page 1 of 13 30 Jan.’2007

CHAPTER – 02

OH&S REQUIREMENTS – IMPLEMENTATION BY ALL

1.0 Purpose(i) To ensure that the OH&S requirements are implemented & monitored by all

personnel including subcontractors & visitors at project sites.

(ii) To prevent accidents and harmful effects on the health of workers in constructionactivities at site.

2.0 SAFE PRACTICES AT WORK PLACE

Before start of any activity at work site, ensure that appropriate Work Permit

system of Client / PMC / Authority is followed. In the absence of a Clint

specified work permit L&T own permit to work system will be the guideline.

(i) MEANS OF ACCESS AND EGRESS

Adequate and safe means of access to and egress from all workplaces shall be

provided and it shall be maintained.

(ii) HOUSEKEEPING

i) All employees shall ensure:a. Proper storage of materials and equipment;

b. that work areas are kept free from waste and debris generated during the

course of work.

ii) Removal of loose materials, which are not required for use to be ensured.iii) Workplaces and passageways, that are slippery owing to oil, grease or

other causes shall be cleaned up or strewn with sand, sawdust, etc.iv) Sufficient scrap bins and rubbish bins shall be provided at construction

sites and rubbish / scrap must be disposed off into the correct bins.

(iii) PRECAUTIONS - AGAINST THE FALL OF MATERIALS & PERSONS AND

COLLAPSE OF STRUCTURES

i) Everybody entering the work site shall wear Safety Helmet.ii) Provide fencing, lookout men or barriers to protect person against fall of

materials, tools or equipment being raised or lowered.iii) Guys, stays or supports shall be used to prevent the collapse of structuresor parts of structures that are being erected, maintained, repaired,

dismantled or demolished.iv) All openings through which workers are likely to fall shall be kept

effectively covered or barricaded and displayed prominently as & whenrequired.

v) Guardrails shall be provided to protect workers from falling from elevated

workplaces.vi) Construction sites located in built-up areas and alongside vehicular /

pedestrian traffic routes shall be fenced and caution board displayed to

prevent the entry of unauthorised persons.




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Rev – 02 Page 2 of 13 30 Jan.’2007

(iv) FIRE PREVENTION AND FIRE FIGHTING

i) All necessary measures should be taken to:

a. Avoid the risk of fire; b. Control quickly and efficiently any outbreak of fire;c. Quick and safe evacuation of persons;

d. Inform unit/client fire station control room, where construction work isin progress & operating plant area.

ii) Combustible materials such us packing materials, sawdust, greasy oilywaste and scrap wood or plastics shall be kept in metal containers in a safe

place.- until trial disposal at a pre.desisnated place outside the site

iii) Provide appropriate type and sufficient number of fire extinguishingequipment at easily accessible locations.

iv) Workers should be trained in the action to be taken in the event of various

types of fire, including the route of means of escape.v) At sites having combustible material, suitable visual signs should be

provided to indicate clearly the direction of escape in case of fire.vi) Means of escape should be kept clear at all times.

(v) LIGHTING

i) Where natural lighting is not adequate, working light fittings or portablehand-lamps should be provided at workplace on the construction site

ii) Artificial lighting should not produce glare or disturbing shadows.iii) Lamps should be protected by guards against accidental breakage.

iv) The cables of portable electrical lighting equipment should be of adequatesize and characteristics for the power requirements and of adequatemechanical strength to withstand severe conditions in construction

operations.v) Illumination level should be in accordance with Indian standard IS:6665

(vi) PLANT, MACHINERY, EQUIPMENT AND HAND TOOLS

Hand Tools

i) Use right tools for the job.

ii) Shall be provided with adequate guard, shields or other protective devices.iii) When not in use and while being carried or transported, sharp tools should

be kept in sheaths, shields, chests or other suitable containers.

ii) Only insulated or non-conducting tools should be used on or near liveelectrical installations.

iii) Only non-sparking tools shall be used near or in the presence of flammableLiquids / vapours or explosive dusts or vapours.

iv) Heads of hammers and other sharp tools shall be dressed or ground to a

suitable radius on the edge as they begin to mushroom or crack.

Pneumatic Tools

i) Operating triggers on portable pneumatic tools should be:

a. So placed as to minimise the risk of accidental starting of the machine.




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Rev – 02 Page 3 of 13 30 Jan.’2007

b. So arranged as to close the air inlet valve automatically when the

pressure of the operator's hand is removed.ii) Hose and hose connections for compressed air supply to portable pneumatic

tools should be:

a. Designed for the pressure and service for which they are intended; b. Fastened securely on the pipe outlet and equipped with the safety chain

as appropriate.iii) Pneumatic shock tools should be equipped with safety clips or retainers to

prevent dies and tools from being accidentally expelled from the barrel.

iv) Pneumatic tools should be disconnected from power and the pressure inhose lines released before any adjustment or repair is made.

Electrical Tools

i) All electrical tools should be earthed, unless they are ‘all insulated’ or

‘double insulated’ tools which do not require earthing.

ii) Tools should be switched off when not in use and positively isolated beforeany adjustment, cleaning or maintenance is done.

iii) Qualified Certified person only should repair electrical hand tools.

Engines

i) IC engines should not be run in confined spaces unless adequate exhaustventilation is provided.

ii) When IC engines are being re-fuelled:

a. The engine should be shut off. b. Care should be taken to avoid spilling fuel.

c. No person should smoke or have a naked light in the vicinity.d. A fire extinguisher should be kept readily available.e. Secondary fuel reservoir should be placed outside the engine room.

3.0 CONSTRUCTION ACTIVITIES

The salient safe practices to be followed during the implementation of various common

construction activities are given below:

(i) EXCAVATION

i) All excavation work should be planned and the method of excavation andthe type of support work required shall be decided considering thefollowing:

a. The stability of the ground; b. The excavation shall not affect adjoining buildings, structures or

roadways;c. Gas, water, electrical and other public utilities shall be shut off or

disconnected, if necessary;

d. Presence of underground pipes, cable conductors, etc.;e. The position of culvert/bridges, temporary roads and soil heaps shall be

determined.ii) Client or L&T’s work permit shall be taken for excavation of more than

1.5m.




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Rev – 02 Page 4 of 13 30 Jan.’2007

iii) Sides of excavations should be monitored regularly.

iv) Safe angle of repose should be given while excavating trenches exceeding1.5m depth. Except for hard rock or soft rock, provide proper shoring andstrutting to prevent cave- in or slides.

v) Excavated earth shall not be placed within one meter of the edge of thetrench or depth of trench whichever is greater.

vi) Don’t allow vehicles to operate too close to excavated area. No load, plantor equipment shall be placed or moved near the edge of any excavationwhere it is likely to cause its collapse and thereby endanger any person

unless provision of shoring or piling are taken to prevent the sides fromcollapsing.

vii) Barrication shall be provided to prevent vehicles being driven into theexcavation. Heavy vehicles should not be allowed near the excavationunless the support work has been specially designed to permit it.

viii) Barricade excavations beyond 1.5m depths. Provide entries / exits for such

excavation.ix) Make sure that underground utilities like cables, sewers are not accidentally

damaged.x) In case of mechanised excavation, precaution shall be taken not to allow

anybody to come within one meter of extreme reach of the mechanicalshovel. Experienced operator shall operate the mechanised excavator.

When not in operation the machine shall be kept on firm levelled groundwith mechanical shovel resting on ground. Wheel or belt shall be suitably

jammed to prevent any accidental movement of the machine.

xi) In case of blasting, certified blaster shall be deployed.

(ii) SCAFFOLDING, PLATFORMS & LADDERS

IS: 4014-1967 “Code of practice for steel tubular scaffolding” shall be the basis forscaffold erection.

i) Scaffold shall be erected, altered, dismantled or inspected only under thesupervision of experienced person as per scaffold checklist (OHSC – 19D).

ii) Loose bricks, drainpipes, chimney-pots or other unsuitable material shall

not be used for the construction or support of any part of a scaffold.iii) Entry to scaffolding should be restricted.iv) Use of barrels, boxes, loose bricks etc., for supporting platform shall not be

permitted.

v) Grease, mud, gravel, mortar etc., falling on platform or scaffolds shall beremoved immediately to avoid slippage.

vi) Workers shall not be allowed to work on scaffolds during storm or highwind.

vii) While using boatswain’s chair, workers shall be safeguarded by an extrarope having a point of attachment independent of the anchorage

arrangements of the scaffold.viii) Bamboo scaffold shall not be used at site.

(iii) STRUCTURAL WORK, LAYING OF REINFORCEMENT CONCRETING

Erection and dismantling of steel and prefabricated structures & Equipment




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Rev – 02 Page 5 of 13 30 Jan.’2007

i) Structural steel or prefabricated parts should be stored and handled in such

a manner that they shall not fall or overturnii) Racks are to be set on firm ground.iii) Structural steel or prefabricated parts should be lifted, by methods or

appliances that prevent them from spinning accidentally.iv) While structural steel or prefabricated parts are being erected, the workers

shall be provided with appliances for guiding them as they are being liftedand set down, so as to avoid crushing of hands and to facilitate theoperations. Use of such appliances should be ensured.

v) A raised structural steel or prefabricated part shall be secured againstexternal agencies such as wind and passing loads before its release from the

lifting appliance.vi) When adverse weather conditions such as high-speed wind or reduced

visibility entail risks of accidents the work should be carried on with

particular care, or if necessary, interrupted.

vii) Structural steel parts that are to be erected at a great height should as far as practicable be assembled on the ground.

viii) When structural steel or prefabricated parts are being erected, a sufficientlyextended area underneath the workplace should be barricaded or guarded

and no one shall be allowed to work underneath.ix) Ensure that workers use PPE like Safety Helmet, Safety Hand gloves,

Safety Shoes etc.

Reinforcement

i) All protruding reinforcing steel, onto and into which employees could fall,shall be guarded to eliminate the hazard of piercing.

ii) Ensure that workers use PPE like safety helmet, safety shoes, gloves etc

iii) DO NOT stand on cantilever rods.iv) While transporting material by trucks/trailers, the rods protruding outside

should be tied and tagged with red flags/lights.

Concreting

i) Barricade the concreting area while pouring at height/depths.

ii) Keep vibrator hoses, pumping accessories in good condition.iii) 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.iv) Safety cages & guards around moving motors/parts etc should be provided

in concreting mixers.v) Use PPEs like gloves, PVC / Rubber Shoes / Gumboot etc. while handling

concrete and wear respirators for handling with cement. Use Safety shoes,while climbing on structure/ scaffold or at higher elevation.

vi) Earthing of electrical mixers, vibrators, etc. should be done and verified.

vii) Cleaning of rotating drums of concrete mixers shall be done from outside.Positive Isolation / and tagout devices shall be ensured prior to entry.

viii) 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.




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Rev – 02 Page 6 of 13 30 Jan.’2007

ix) Ensure adequate lighting arrangements for carrying out concrete work

during night.

(iv) ROAD WORK

i) Site shall be barricaded and provided with warning signs including night warninglamps at appropriate locations for traffic diversion.

ii) Experienced drivers with valid driving license shall drive road rollers, bitumen

sprayers and pavement finishers and all vehicle on site.iii) Workers handling hot bitumen sprayers or spreading bitumen aggregate mix or

mixing bitumen with aggregate shall be provided with PVC hand gloves and rubbergumboot up to knee joints.

iv) If bitumen accidentally falls on ground, sprinkle sand immediately to cover it and to

prevent anybody stepping on it. It shall then be removed with the help of spade.v) For cement concrete roads, besides site barricading and installation of warning

signs for traffic diversion, safe practices mentioned in the section on 'Concreting'

shall also be applicable.vi) Use PPE such as Safety Goggle, Apron, Safety Shoes at site.

(v) CUTTING / WELDING

i) Before starting any hot job in the vicinity of flammable material or in the refinery,

Hot-work permit to be obtained from the appropriate authority / client / PMC.ii) Fire extinguisher of suitable type shall be made available in the work area.iii) Use flash back arresters to prevent flashback on outlet of pressure regulator. This

device is fitted at the outlet of acetylene and oxygen cylinders and at the Torch end.iv) Gas cylinders shall be properly secured in upright position.

v) Acetylene cylinder shall be turned and kept in such a way that the valve outlet points away from oxygen cylinder.vi) Acetylene cylinder key for opening valve shall be kept on valve stem while cylinder

is in use so that the acetylene cylinder could be quickly turned off in case ofemergency.

vii) When not in use, valves of all cylinders shall be kept closed.viii) No gas cylinders shall be allowed to fall over or dropped or be subjected to violent

shocks.

ix) All types of cylinders, whether full or empty, shall be stored under shed.x) Forced opening of any cylinder valve should not be attempted.

xi) Lighted gas torch shall never be left unattended.

xii) Store acetylene and oxygen cylinders separately.xiii) Store full and empty cylinders separately.

xiv) Avoid cylinders coming into contact with heat.xv) Cylinders that are heavy or difficult to carry by hand, use additional man power to

lift and carry or preferably use a purpose built trolley but never drag or roll on theground.

xvi) Do not use matches to light torches, use a friction lighter.

xvii) Move out any leaking cylinder to safe location immediately.xviii) Always use Red- hose for acetylene and other fuel gases and Blue/ Black for

oxygen and ensure that both are in equal length.xix) Ensure that hoses are of sound material suited to the type of gas or vapour carried,

free from defects like burns, cuts and cracks and properly clamped.




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Rev – 02 Page 7 of 13 30 Jan.’2007

xx) Protect hoses from flying sparks, hot slag, and other hot objects.

xxi) Lubricants shall not be used on Oxy-fuel gas equipment.xxii) During cutting/welding, use proper type goggles/face shields.xxiii) All covers and panels shall be kept in place when operating an electric arc welding

machine.xxiv) An energised electrode shall not be left unattended.

xxv) The power source shall be turned off at the end of job.

(vi) WORKING IN CONFINED SPACES

i) Entry inside the confined space and carrying out any job shall be done only after

issuance of valid Confined Space / Hot work Entry permit in line with therequirement of Client or L&T’s work permit.

ii) Barricade the confined spaces during hoisting, radiography, blasting, pressure

testing etc.iii) In jobs inside hydrocarbon processing areas, use 24V lamp fittings only, for

illumination.iv) Check the oxygen level inside the vessel. It should be minimum 19.5% and

Maximum 23%.v) Check the confined space for presence of flammable gases, toxic, corrosive fumes

etc. using a suitable detector.

vi) Everyone entering the confined space shall wear safety helmet, safety shoes andsafety belt .and appropriate respirator protection life line the confined space.

vii) The cutting torches shall also be kept outside the vessel immediately after thecutting.

viii) The gas cylinders used for cutting/welding shall also be kept outside.

ix) All cables, hoses, welding equipment etc. shall be removed from confined space atthe end of each workday, even if the work is to be resumed in the same space the

next day.x) Communication shall always be maintained between the worker and the attendant.xi) Oily rags, waste and clothes or other substances liable to spontaneous ignition

should be removed prior to start of work and also regularly while work in process(vii) HYDRO-TESTING

i) Provide relief valves of adequate size before testing.

ii) Keep the vents open before opening any valve for filling/draining of liquid used for

hydro testing. The filling/draining should not exceed the designed pressure.iii) Provide separate gauges of suitable range for pressurising pump and the equipment

to be tested for monitoring of pressures. Any other

(viii) WORKING AT HEIGHTS

i) While working at a height of more than 2 meters, permit should be issued beforecommencement of the job and approved full body harness shall be used.

ii) Worker should be medically fit to work at height more than 2 meters since he

should be free from vertigo, Epilepsy or Fits, General Giddiness and height relateddiseases.

iii) Worker should be well trained on usage of full body harness including its properusage at the time of ascending/descending.




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Rev – 02 Page 8 of 13 30 Jan.’2007

iv) All tools should be carried in tool kits to avoid their accidental fall.

v) Provide lifeline wherever required.vi) Additional safety measures like providing Fall Arrestor type Safety belt, Safety net

shall be arranged depending upon site conditions, job requirements.

vii) DO NOT throw or drop material/equipment / tools from height.

1.0 Roof Work

i) Work on roofs should not be carried on in adverse weather conditions.ii) Crawling boards, walkways and roof ladders should be securely fastened to

a firm structure.iii) On a large roof where work has to be carried out at or near the edge, a

simple barrier consisting of crossed scaffold tubes supporting a tubing

guardrail may be provided.iv) 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.

2.0 Work on tall chimneys

i) For the erection and repair of tall chimneys, scaffolding shall be provided.A safety net shall be maintained below the scaffold.

ii) The area surrounding the chimney should be enclosed by means of barrication.

iii) 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 notintended for the purpose.

c. Haul heavy materials or equipment up and down by hand to or from theworkplace on the chimney;

d. Work alone;e. Climb a chimney that is not provided with securely anchored ladders or

rungs;

f. Work on chimneys in use unless the necessary precautions to avoiddanger from smoke and gases have been taken.

iv) Work on independent chimneys should not be carried on in high winds, icy

conditions, fog or during storms.

(ix) HANDLING AND LIFTING EQUIPMENT:

i) Safe lifting capacity of all lifting & handling equipment, tools and shackles shall beverified periodically and certificates obtained from competent authorities before its

use.ii) The safe working load shall be marked on all lifting tools and tackles.iii) Every lifting appliance should:

a. Be suitable for the operations and not be capable of accidentaldisconnection;

b. Be inspected, approved by P&M and subsequently tested as perstatutory requirement.




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Rev – 02 Page 9 of 13 30 Jan.’2007

iv) Check the load to be lifted and accordingly decide the crane capacity, boom length

and angle of erection.v) While loading, unloading and stacking of pipes, proper wedges shall be placed to

prevent rolling down of the pipes.

vi) Only trained operators and riggers should carry out the job. While the crane ismoving or lifting the load, the trained rigger should be present for keeping a vigil

against hitting any other object.vii) Hook and load being lifted shall remain in full visibility of crane operators, while

lifting, to the extent possible.

viii) Don't allow booms or other parts of crane to come within 3 meters reach ofoverhead electrical cables.

ix) No structural alterations or repairs, which may affect the safety of the appliance,should be made to any part of a lifting appliance, without the permission andsupervision of the authorised person.

1.0 Hoistsi) Hoist shafts should be enclosed with rigid panels or other adequate fencing.

ii) The guides of hoist platforms should offer sufficient resistance to bendingand in the case of jamming by a safety catch, to buckling.

iii) If workers have to enter the cage or go on the platform at landings thereshould be a locking arrangement preventing the cage or platform frommoving.

iv) Counterweights should run in guides.

2.0 Derricks

i) Derricks should be erected on a firm base capable of taking the combinedweight of the crane structure and maximum rated load.ii) Electrically operated derricks should be effectively earthed from the sole

plate or framework.

3.0 Guy derricks

i) The restraint of the guy ropes should be ensured by fitting stirrups oranchor plates in concrete foundations.

ii) Equally spaced guys should support the mast of guy derricks. Competent

person & site condition will decide the number of guys.iii) The spread of the guys of a guy derrick crane from the mast should not be

more than 450 from the horizontal.iv) When a derrick is not in use, the boom should be anchored to prevent it

from swinging.

4.0 Gin poles

i) Gin poles should:

a. Be adequately guyed and anchored: b. Be vertical or raked slightly towards the load:

ii) Gin poles should be fastened at their feet to prevent displacement inoperation.




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Rev – 02 Page 10 of 13 30 Jan.’2007

iii) 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 underload.

5.0 Tower cranes

i) Where tower cranes have cabs at high level, persons, capable and trained to

work at heights, should only be employed as crane operators.ii) Care should be taken in the assessment of wind loads both during

operations and out of service..iii) 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 fromthe cab so that one driver may alert the other of impending danger.

iv) The manufacturers' instructions on the methods and sequence of erection

and dismantling should be followed.v) 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 thehorizontal. For longer periods or at times when adverse weather conditions

are expected, out of service procedures should be followed i.e. the main jibshould be slewed to the side of the tower away from the wind, put into freeslew and the crane immobilised.

vi) 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.

6.0 Lifting ropes

i) Only ropes with a known safe working capacity should be used as lifting

ropes.ii) Lifting ropes should be installed, maintained and inspected at regular

interval.iii) Repaired steel ropes shall not be used on hoists.

(x) VEHICLE MOVEMENT

i) Driver with proper, valid driving license shall only be allowed to drive the vehicle.ii) Park vehicles only at designated places. Don't block roads to create hindrance for

other vehicles.iii) DO NOT overload the vehicle.iv) Obey speed limits and traffic rules laid down by L&T/ Client.

v) Drive carefully during adverse weather and road conditions.vi) While reversing the vehicles, reverse horn / help of another worker should be

ensured at all times.vii) An unattended vehicle should have the engine switched off.viii) Barriers/fixed stops should be provided for excavation/openings to prevent fall of

vehicle.ix) Load should be properly secured.

x) The body of the tipper lorry should always be lowered before driving the vehic leoff.




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Rev – 02 Page 11 of 13 30 Jan.’2007

xi) Signs/signals/caution boards etc. should be provided on routes.

(xi) ELECTRICAL

i) Only persons having valid licenses shall be allowed to work on Electrical

Installations.ii) No person should be allowed to work on live circuit. If it is unavoidable, special

care and authorisation need to be taken.

iii) Treat all circuits is 'LIVE' unless ensured otherwise.iv) Electrical “Tag Out” procedure 'MUST' be followed for carrying out maintenance

jobs.v) Make sure that electrical switchboards, portable tools, equipment (like grinding

machine etc.) DO NOT get wet during their usage. If it happens, switch off the

main supply, make the tools dry and then only use them.vi) Dead man switch shall be provided for all portable grinders. The purpose is that

once the pressure on the knob operating the portable grinder is released, the

grinding wheel shall stop immediately.vii) DO NOT work, when wet, on electrical system.

viii) DO NOT overload the electrical system.ix) Use only fuses of correct rating.

x) All temporary connections, hand & power tools must be provided with 30mAsensitivity rating ELCB & regular inspection should be done.

xi) Use insulated industrial metal 3pin plug tops & socket.

xii) Provide rain protection hood/guard on DB (Distribution Board) for environmental protection.

xiii) All power supply cables should be laid properly and neatly so that they do not causehindrance to persons working and no physical damage also takes place to the cablesduring various construction activities.

xiv) Check installations of steel plates / pipes to protect underground cables at crossings.xv) DO NOT lay unarmored cable directly on ground, wall, roof or trees. Proper sleeves

should be provided at road crossings.xvi) DO NOT connect any earthing wire to the pipelines/structures.xvii) Ensure that temporary cables are free from cuts, damaged ins ulation, kinks or

improperly insulated or naked joints.xviii) Protect electrical wires/equipment from water and naked flames.xix) Illuminate suitably all the work areas.

xx) DO NOT use water for fighting electrical fires.

xxi) All parts of electrical installations should be so constructed, installed andmaintained as to prevent danger of electric shock, fire and external explosion.

xxii) A notice displaying following should be exhibited at suitable places:a. Prohibiting unauthorised persons from entering electrical equipment rooms;

b. Containing directions as to procedures in case of fire, rescue of persons incontact with live conductors and the restoration of persons suffering from

electric shock:xxiii) No other cables/pipes to be laid in trench used for electrical cables.xxiv) Utmost care should be taken while excavating Earth from cable trench to avoid

damage or any accident.xxv) Electricians should be provided with approved and tested tools and personal

protective equipment such as rubber gloves, mats etc.




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Rev – 02 Page 12 of 13 30 Jan.’2007

(xii) RADIOGRAPHY

i) Permit should be obtained for radiography from Area in-charge.ii) Entry into the restricted area by unauthorised persons should be strictly prohibited

during exposure.iii) All personnel working with radiography sources should wear appropriate protective

equipment and film badges issued by BARC or equivalent approved agencies, if

any.iv) Protection facilities such as radiation hazard placards and means to cordon off shall

be available at each site.v) The people working around the work area should be informed well in advance.vi) The operator should be aware of the dose record and send the records for periodic

medical examination.vii) The package containing radiography cameras and sources should never be carried

by public transport like bus, train etc.

viii) Radiography sources and cameras, when not in use, should be stored inside a source pit with lock and key arrangement as approved by BARC or equivalent approved

agencies, if any. The storage room should preferably be located in an isolated areaof minimum occupancy and radiation level outside the storage room should not

exceed 0.25 mR/hr as per client or BARC Regulations.ix) The survey meter and dosimeter used at site should be calibrated and its certificate

should be available at site.

x) Daily logbook shall be maintained for using radiography source stored in the pitroom.

xi) In case of an accident, action should be taken in line with BARC or equivalentapproved agencies’ Safety Rules.

xii) All radiography jobs shall be carried out as per BARC (AERB) (or equivalent

approved agencies, if any) Safety Regulations.

(xiii) SHOT BLASTING / SPRAY PAINTING

i) Valid test certificates should be available for air receiver by competent person.ii) Pressure release valve should be mounted on hopper.iii) Air Compressor used for / shot blasting / painting should have guard and positioned

away from the work place.iv) The hoses used for compressed air should be of proper quality, and health of the

same to be ensured through regular check / test.

v) The operator of / shot blasting / painting should wear suitable PPEs including mask.vi) Adequate measures to be taken to suppress dust / spray particle.

(xiv) WORK ABOVE WATER

i) Where work is done over or in close proximity to water for preventing workers

from falling into water by providinga. Fencing, safety nets and safety harnesses;

b. Lifebuoys, life jackets and / or manned boats

c. Rescuer of workers in danger of drowning;d. Safe and sufficient transport;

e. Protection against such hazards as reptiles and other animals.




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Rev – 02 Page 13 of 13 30 Jan.’2007

ii) Gangways, pontoons, bridges, footbridges and other walkways or work places over

water should:a. Be sufficiently wide to allow safe movement of workers;

b. Have level surfaces free from tripping hazards;

c. Be adequately illuminated when natural light is insufficient;d. Prevent dislodgement by rising water or high winds;

e. All deck, openings should be fenced.iii) Nobody should work alone on or above water.

(xv) DEMOLITION

i.) Preparation of Method Statement and Risk Assessment of all demolition activities.

ii.) Identify number of fire watch, Fire fighting equipments, Gas Monitors, etc required

for the job.

iii.) Ensure all utility services such as electrical lines, chemical and water pipelines, air

pipelines, telephone connection etc. are disconnected.iv.) Demolition activities shall be supervised by competent person.

v.) Remove fragile materials.

vi.) Cordon off area.

vii.) Restricat entry to unauthorised person.

viii.) Use Respiratory protection in dusty condition and Ear Protection from noise.

ix.) Work from correctly erected scaffold platforms or towers and hydraulic or crane-

handled work baskets.

x.) When cutting steel, secure gas cylinder, use flashback arresters, store spare cylinder

in compounds; take care with hoses and provide a means of putting out fires.

xi.) Special precautions to be taken for asbestos from pipe lagging and biological

hazards from Toilet, Septic Tanks.

**********




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Rev – 02 Page 1 of 3 10 Jun’ 2007

CHAPTER – 04

SAFETY OFFICER / ENGINEER

1.0 Purpose

(i) This procedure stipulates appointment, qualifications and functions of SafetyOfficer (SO) / Safety Engineer (SE) at the L & T construction sites.

(ii) Appointment of SO/SE is one of the many efforts, towards creating safe work

environment at L & T sites.

2.0 Definitions – Safety officerSafety Engineer

3.0 Procedure

(i) At least One Safety Officer will be appointed by the Project Manager / Head Safetyto supervise safety at the site under any one of the following conditions:a. The site has/is likely to have up to 1000 workers at any time during the

construction.

b. Construction at the site is expected to last at least for a period of six months periods.

c. Value of the contract between L & T and the client is more than Rs. 5 crores(This value will be revised upward taking inflation into account).

(ii) If, according to the above conditions, no Safety Officer / Safety Engineer is

appointed, his duties and responsibilities will be assumed by Site Resident

Construction Manager/Coordinator (RCM ).

(iii) Appointment of more than one Safety Officer / Safety Engineer is laid down in thescale below.a Up to 2000 building workers - Two Safety Officers

b. Up to 5000 building workers - Three Safety Officersc. Up to 10000 building workers - Four Safety Officers

d. For every additional 5000 building workers or part thereof - One SafetyOfficer.

(iv) The appointment of a Safety Officer SHOULD NOT WAIT until 1000 workmen are

at the site. He should be at the site from the day one (i.e. when the very firstconstruction activity starts at the site). This will allow him to study the site

conditions, situation, contractors & contracts, nature of activities, number of people, clients requirements, etc. and be prepared to monitor safety aspects, well inadvance .

(i) Safety Officer / Safety Engineer will functionally report to the Head Safety.(ii) The concerned project Manager shall also provide minimum facilities like provision

desk, chair, a small cupboard & desktop PC along with e mail facility to SafetyOfficer for quick & easy communication with central at powai and to perform hisduties effectively.

(iii) Safety Officer should also be provided a communication device which can be usedeffectively during emergency

(vi) Safety Officer / Safety Engineer will be appointed to perform only work related to

safety at the site and will not be assigned any other work, whatsoever, at any time




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Rev – 02 Page 2 of 3 10 Jun’ 2007

while he works as Safety Officer / Safety Engineer at the site. The duties of a Safety

Officer / Safety Engineer shall be to advise and assist the site RCM in thefulfillment of his obligations, statutory or otherwise concerning prevention of

personal injuries and maintaining a safe working environment. These duties shall

include the following, namely:-a. To advise the building workers in planning and organising measures necessary

for effective control of personal injuries. b. To advise on safety aspects in a building or other construction work and to carry

out detailed safety studies of selected activities.

c. To check and evaluate the effectiveness of action taken or proposed to be takento prevent personal injuries.

d. To advice purchasing and ensuring quality of PPE confirming to requiredstandards such as BIS etc.

e. Ensure that workmen use appropriate PPE as required by the activities / work

they perform.

f. Insist with contractors to make available at the site all protective equipmentsand safe working conditions before work for the day begins. Do not allow thework to start, wherever the necessary protective equipment are notavailable/used and report to the concerned contractor to provide them

immediately to restart the workg. Inspect continuously all construction activities (actions) by workmen and

conditions (equipment, area, etc) from safety point of view and stop unsafeconditions and acts to prevent accidents.

h. Stop work immediately, if unsafe condition/ action is observed and report it to

the contractor Supervisor/Engineer/Manager and also to L&T –RCM/RCC/RCE to correct it immediately so that work/ activity restarts as soon

as the corrective action is taken.i. Ensure that all accidents, Near-misses are reported as per Chapter-06 of this

OHS manual.

j. To investigate all fatal and Lost Workday Cases.k. To investigate the cases of occupational diseases contracted and reportable

dangerous occurrences and the maintenance of such records.l. To promote the working of Safety Committees and to act as an advisor to such

committees. Ensure that Safety Committee Meetings are conducted every

month, actions are taken as per the discussions / MoM’s and MoM’s are sent tothe persons as mentioned in Chapter-05.

m. To organize, in association with concerned Departments, campaigns,competitions, contests and other activities which will develop and maintain theinterest of building workers in establishing and maintaining safe conditions of

work and procedures.n. Conduct / Facilitate Safety Tool Box Talks (TBT’s) on subjects related to site

activities, to contractor workmen/supervisors as mentioned in the chapter no-14.o. Instruct/train contractor, supervisor and workmen before work/activity is started,

to use protective equipment, method/procedure to carry out the work safely and

to caution them about the potential hazard/s in their work. p. Co-ordinate with the clients’ requirements of procedures for safety and certify

area / equipment, etc. for safe working, after thorough checking as necessary

and as required by client.




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Rev – 02 Page 3 of 3 10 Jun’ 2007

q. Co-ordinate with Safety Dept about all safety matters at the site and facilitate

enforcement of CORPORATE POLICY requirements.

4.0 Qualifications & experience of Safety Officer

(i) Minimum Degree / Diploma in EngineeringQualification: OR Degree Science (Physics + Chemistry) and

Diploma in Safety from a recognised institute.

(ii) Minimum For Engineering / Science Degree Holders - Experience: Two years as Safety Officer in building or other construction

work in a supervisory capacity.

For Diploma Holders -Five years as Safety Officer / Safety Engineer in Building or

other construction work in a supervisory capacity. In bothcases, conversant with training in safety, demonstrate use of

safety appliances, statutory requirements, knowledge of locallanguage, Incident investigation.

5.0 Administration (i) Safety Department will identify and select SSO/E.

(ii) RCM / RCC shall also inform in advance and in writing to Head Safety aboutabsence of SSO from the site on account of leave and other reasons.

(iii) SSO/E may be provided at important sites from a pool of Safety Officers / Safety

Engineers in HSE Capability Centre, if available. PM may request Head Safety forSSO/E at least one month before the site is opened with any such requirement.

6.0 Records - None




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Rev – 02 Page 1 of 2 10 Dec’ 2007

CHAPTER – 05

SAFETY COMMITTEE MEETING

1.0 Purpose

(i) Regular and frequent meetings to discuss the status of implementation of safety andhealth programme at the site and to make recommendations to management.

(ii) Discussion of accident and illness reports in order to make recommendations for prevention.

(iii) Evaluating improvements made and discussing / reviewing client requirements.(iv) Examination of suggestions made by workers, particularly by safety representatives.(v) Planning and taking part in educational and training programs and information

sessions.(vi) To comply the statutory requirements. (See section 38 of The Building and other

Construction workers (Regulation of employment and condition of service) Act1996, and Central Rules, 1998).

2.0 Definition - None

3.0 Procedure

Formation of Safety Committee, membership, objectives, meetings, minutes and follow upaction.(a) Formation of Safety Committee - Each site will have one Safety Committee.This

Safety Committee will consist of/be represented by site – in – charge of all

contractors / sub – contractors and headed by the L&T Site Manager (RCM). Thiscommittee will have periodic meetings headed by L&T Site Manager (RCM).

(ii) Meeting Frequencya. Meetings of the Safety Committee shall be held at least once in a month,

b. Dates of the next meeting shall be informed to all members in the precedingmeeting, so that the members can make themselves available for the next

meeting. This is important so that the members can plan their schedule so as to be available to attend the meeting.

c. Special Safety Committee Meetings shall be held, as required, to discuss

serious accidents, potentially accident – prone activities and such matters.

4.0 Administration

(i) A circular including agenda of safety meetings shall be prepared by theSSO/RCM/RCC at the site and communicate to all participants preferably, at least

two days in advance.The agenda of the meeting as given below shall be but notlimited to

Ø Recent Incident/Nearmiss

Ø Findings of latest Audit ReportØ HSE Violation

Ø New Recruits and their Induction/OrientationØ Legal Requirements




_______________________________________________________________________________________________

Rev – 02 Page 2 of 2 10 Dec’ 2007

Agenda shall include review of MoM of the previous month, acceptance by all

participants (to be recorded) and record of actual completion dates of actionitems.

5.0 Records

Form Reference

Safety Committee Meeting Report OHS-05




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Rev – 02 Page 1 of 13 30 Oct.’ 2007

CHAPTER – 06

INCIDENT REPORTING AND INVESTIGATION

1.0 Purpose(i) Objective of this procedure is to ensure that HSE Capability Centre is notified of

all incidents as soon as possible.

(ii) This procedure will also provide a systematic method for reporting andinvestigating an accident at a construction site and identify corrective action steps

to prevent recurrence.(iii) This procedure also outlines the method of communicating with HSE Capability

Centre.

2.0 Definitions

1. Accident - undesired event-giving rise to death, ill health, injury, damage or other

loss. (Defined as per OHSAS 18001)

2. Incident - event that gave rise to an accident or had the potential to lead to an

accident

Work Related I ncidents

Work relationship is presumed for incidents resulting from events or exposures in

or related to the work environment.

• If an event or exposure in the work environment either caused or contributed tothe resulting condition.

• A pre-existing condition is considered work related if an event or exposure in thework environment results in injury, illness, property damage or environmental

harm and would not have occurred but for an event or exposure related to thework environment.

Cases that occur while the employee / subcontractor employee is travelling are

considered work related if the employee / subcontractor employee is engaged in

work activities

3. Fatality : The death of an employee / subcontractor employee engaged in a work-

related activity, which results from an event or exposure in the work environment.The death may not actually take place at the work place.

4. Lost Workday Cases (LWC)

A Lost Workday Case is a medical case that involves

• Fatalities

• Recordable Incident Cases due to personal injury

• Cases where an employee/subcontractor employee is away from next scheduledshift resulting from a recordable incident and Restricted Work Activity Cases.




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Rev – 02 Page 2 of 13 30 Oct.’ 2007

If an employee is unable to work on a schedule shift because of a work relatedinjury or illness, the case is a Lost Workday Case (LWC). Presence at the sitedoes not constitute work.

The shift on which the injury or illness occurred and the shift on which the

employee returns to work are not counted in the total days lost. Vacation days,

holidays and days of rest that were scheduled before occurrence of the injury are

also not counted. Days away from work include only full scheduled workdays.

5. Lost Work-Days (LWD) : Case where the employee/sub contractor employee is

away from work after the day of work related injury or illness. Count the number of

calendar days lost (excluding holidays, vacation and weekends) where work is not

performed. The day of incident is not counted as a lost work day. Stop count if

employee/subcontractor employee leaves company.(Days after incident until days

returned to work).In case of fatality, count 6000 man days lost for the calculation of

Severity Rate.

6. I ncident F requency Rate: In frequency rate is the number of Lost Workday Cases

occurring among a given number of full-time workers (usually 100 full-time

workers) over a given period of time (usually one year). Frequency Rate for lost

workday Cases can be calculated as follows:

Frequency Rate of LWC =

(No. of LWC x 200,000/ Total hrs worked during same period)

7. Recordable Incidents: Work-related incidents causing injury or illness to personnel

that leads to medical treatment or lost time, including incidents causing property

damage and/or damage to the environment .

Total recordable/reportable incidents (TRI) is the sum of all work - related

• Fatalities

• Lost work day cases/ Days away from work cases

• Restricted work day cases

• Loss of consciousness,

• Transfer to another job,• Medical treatment only cases (other than first aid)

• Termination

• Illness.

8. Restr icted Work Day Cases (RWC): A Restricted Workday Case (RWC) is any

work related injury or illness that prevents the employee from either doing one or

more parts of his or her regularly scheduled duties or working a complete shift on

any subsequently scheduled shift.




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Rev – 02 Page 3 of 13 30 Oct.’ 2007

If an employee misses part of a subsequently scheduled shift because of

hospitalisation for treatment or observation, then the injury is an RWC only if the

employee is unable to perform all normal job assignments. The shift on which

injury occurred is not counted as a restricted workday.

In other words, if employees are unable to do the job they were doing when they

were injured or made ill, they are restricted until they can return to that job. The

restriction refers to limits of activity or time that can be spent doing the job (i.e the

employee can do part of the job all of the day or all of the job part of the day).

Following cases are generally considered RWC:

1) Temporary transfer: -

• While an injured employee may be assigned work other than his or her

normal duties, the temporary duties must be meaningful and pre-established, and the injured employee must be qualified to perform them

• If the employee is injured while working at a temporary assignment and

transferred back to his/ her normal job assignment , which he or she can

perform without limitation, then no days of restricted work activity are

counted.

2) Precautionary transfer: -

• While an injured employee is transferred to another job because ofsuspected Illness, such as dermatitis, the time on other job does not need

to the recorded as the days of restricted activity (DRA) while the case in being diagnosed. However, if the diagnosis reveals an illness thatrequired continuation of the transfer, all days should be recorded as

DRA. If the transfer is for the purpose of keeping an injury free ofcontamination, the DRA should be recorded. If the transfer is becausethe wounds, bandages, etc significantly reduce the ability to work, DRA

should also be recorded.

• The case is considered restricted only if the employee develops an

illness associated with exposure and if the employee is transferred toanother job or area as a precautionary measure because of exceeding

norms resulting from exposures.

Examples include the following:♦ an employee develops a skin rash and is removed from work area.

The rash is subsequently determined to have been caused by foodeaten at home. Therefore, the illness is not work-related.

♦ on the other hand, if the rash is determined to have been caused byexposure to chemicals in work area, then the days from the transfer

to the regular assignment are counted as restricted.

9. Medical Treatment Only Cases ( MTOC) : All Medical Treatment Cases (MTC)

which neither result in restricted workday nor lost workday are termed as a Medical

Treatment Only Cases (MTOC). Such cases will require one or more visits to a




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Rev – 02 Page 4 of 13 30 Oct.’ 2007

medical professional, but will not disable or restrict the employee from carrying out

his normal duties. Also, Medical treatment does not includes: visits to a physician

or other licensed health care professional solely for observation or counseling ; the

conduct of diagnostic procedures, such as X-rays and blood tests, including the

administration of prescription medications used solely for diagnostic purposes (e.geye drops to dilate pupils) or first aid. Medical treatment includes:

• Treatment of Infection

• Application of Antiseptics during second or subsequent visit to medical

personnel

• Treatment of Second or Third degree burn(s)

• Application of Sutures (stitches)

• Any use of Oxygen

• Removal of foreign bodies embedded in eye

• Removal of foreign bodies from wound; if procedure is complicated because

of depth of embedment, size or location.

• Any physical therapy / chiropractic treatment

• all no-prescription drugs at prescription strength and any dose of a

prescription drug.

• Use of hot or cold soaking therapy during second or subsequent visit to

medical personnel

• Use of hot or cold compress (es) during second or subsequent visit to

medical personnel

• Use of HEAT THERAPY during second or subsequent visit to medical

personnel

• Use of whirlpool bath therapy during second or subsequent visit to medical

personnel

• Positive X-Ray Diagnosis (Fracture, broken bones, etc)

• Cutting away dead skin (surgical debridement)

• Admission to a hospital or equivalent medical facility for treatment

10. Loss of Consciousness : If an employee loses consciousness as the result of awork-related injury, the case must be recorded no matter what type of treatment was

provided. The rationale behind this recording requirement is that loss of

consciousness is generally associated with the more serious injuries.

11. Transfer to another job: Injuries requiring transfer of the employee to another job

are also considered serious enough to be recordable, regardless of the type of

treatment provided. Transfers are seldom the sole criterion for recordability. This is

because injury cases are almost always recordable on other grounds, primarily

medical treatment or restriction of work or motion.




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Rev – 02 Page 5 of 13 30 Oct.’ 2007

12. First aid injury/ Case - A First Aid Case (FAC) is one-time treatment and

subsequent observation of minor cuts, scratches, burns, splinters, and other similar

injuries, which do not ordinarily require medical care. A case can be classified as

first aid if it is administered by a physician or other registered professional personnel. Administration of a single dose of a prescription medication on a first visit

for a minor injury is also considered first aid. Multiple use of non-prescription

medication, cold packs, heat treatments, and multiple antiseptic applications does not

affect the classification.

The following are generally considered first aid treatment:

• Administering tetanus immunizations (other immunizations, such as Hepatitis Bvaccine are considered medical treatment);

• Cleaning, flushing or soaking wounds on the surface of the skin;

• Using wound coverings such as bandages, Band-AidsTM, gauze pads, etc.; or

using butterfly bandages or Steri-StripsTM (other wound closing devices such assutures, staples, etc., are considered medical treatment);

• Using hot or cold therapy;

• Using any non-rigid means of support, such as elastic bandages, wraps, non-

rigid back belts, etc. (devices with rigid stays or other systems designed toimmobilize parts of the body are considered medical treatment);

• Using temporary immobilization devices while transporting an incident victim

(e.g. splints, slings,neck collars, back boards, etc.);

• Drilling of a fingernail, or toenail to relieve pressure, or draining fluid from a

blister;

• Using eye patches;• Removing foreign bodies from the eye using only irrigatio n or a cotton swab;

• Removing splinters or foreign material from areas other than the eye by

irrigation, tweezers, cotton swabs or other simple means;

• Using finger guards;

• Using massages (physical therapy treatment is considered medical treatment for

record keeping purposes); or

• Negative X-ray diagnosis

• Application of ointments to abrasions to prevent drying or cracking.

• Administrating Drinking fluids for relief of heat stress.

13. Dangerous Occur rences

a) Collapse or failure of lifting appliances, hoist, conveyors etc. b) Collapse or subsidence of soil, any wall, floor, gallery etc.

c) Collapse of transmission towers, pipeline, bridges etc.d) Explosion of receiver, vessel etc.e) Fire and explosion

f) Spillage or leakage of hazardous substancesg) Collapse, capsizing, toppling or collision of transport equipment

h) Leakage or release of harmful toxic gases at the construction sitei) Failure of loose gear, or building and other construction work machinery,

transport equipment etc.




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Rev – 02 Page 6 of 13 30 Oct.’ 2007

14. I ll ness (Occupational ) . A physiological harm or loss of capacity produced by

systemic infection; continued or repeated stress or strain; exposure to toxins,

poisons, fumes, etc.; or other continued and repeated exposures to conditions of the

work environment over a period of time. For practical purposes, an occupationalillness/disease is any reported condition, which does not meet the definition of

injury (traumatic).

Some conditions may be classified as either an injury or an illness (but not both),depending upon the nature of the event that produced condition. Example.

I) Loss of hearing resulting from an explosion (an instantaneous event) is classified asan injury; the same condition arising from exposure to industrial noise over a period

of time would be classified as an illness.II Similarly, irritation of throat from exposure of chlorine gas fumes could be

classified as either an injury or an illness. If the exposure was instantaneous andoccurred when a cylinder of gas ruptured, the case would be considered aninjury. The case would be an illness if the employee was exposed to the agent over

a period of time, such as working in an area where chlorine fumes from a bleaching process were present.

15. I nju ry (Traumatic) . A wound or other condition of the body caused by external

force including stress or strain. The injury is identifiable as to time and place of

occurrence and member or function of the body affected, and is caused by a specific

event or incident or series of events or incidents within a single day or work shift.

16. Near M iss: An incident where no ill health, injury, damage, or other loss occurs is

also referred to as a “Near-Miss”. The term “Incident” also includes “Near-

M isses” . (Defined as per OHSAS 18001) . Examples are

• Non relieving of a relief valve at set pressure;

• Relieving of relief valve before set pressure;

• Non-working of emergency appliance (eg. Non-working of fire fighting

facilities)

• Non working of shutdown / trip systems;

• Violation of Safety regulation (eg. Working without valid work permit,

working without proper PPE, working with improper tools, etc)• Free falling of objects from height;

• Bursting/ disconnection of pressure hoses.




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Rev – 02 Page 7 of 13 30 Oct.’ 2007

Figure A: Classification of Incidents

INCIDENT

Event that gave rise to an accident or had the potential to lead to an accident.

PERSONAL

ACCIDENT

DANGEROUS

OCCURENCE

FIRE

(Minor)

NEAR MISS

Resulting in

personal injury/

illness

Resulting in

property damage

Resulting into

personnel injury /

property damage.

Does not result, but has

potential for injury/

property damage

Work related

injury/ illness

Non - Work related

injury/ illness

Illness Medical

Treatment Cases

Fatal

Cases

Medical

Treatment Only

Restricted work

Day cases

Lost Work day

cases

During off

duty hours

While carrying out

non work related

activity

First Aid

Cases

Note: 1.) F ir e involving personal i nj ur y/ il lness to be treated as “Personal Accident” also.

2.) Dangerous Occurr ence involvin g personal i nj ur y/ i ll ness to be treated as “Personal Accident” also.




_________________ ______________________________________________________________________________

Rev – 02 Page 8 of 13 30 Oct.’ 2007

3.0 Procedure

(i) The procedure deals with reporting of incidents involving people, machinery, buildings, structure, surroundings, environment (air, water, land), dangerous

occurrence and Near-Miss Incidents and First Aid occurrence which could haveresulted in an accident and / or dangerous situation.

Responsibility of reporting – RCM/RE

Reporting - As per distribution given in the forms.Method of reporting - e-mail / by fax / courier

(Preceded by verbal report within 4 hours in case ofmajor mishap / fatal accident to BUH/ President (O)& Member of the Board / Head – HSE.

Report Forms - There are four basic forms:(a) Incident Report Form

- This is for reporting Fatal, Lost Work Day Cases, Restricted Work

day Case, Transfer of Job, Medical Treatment only Case, Fires &other dangerous occurrence. (High Potential incidents)

- To be filled by the Supervisor / Engineer of L&T/ Contractor and sentto his Site-in-charge with copies to L&T - RCM and others as shown

in the form, immediately within 24 hours.- If there is any fatality, an oral report must be sent to Head - HSE,

within 4 hours and following information must be provided

• The facility name;

• The location of the accident;

• The time of accident;

• The no. of fatalities or hospitalized employees and their names;

• The name of contact person and his Telephone number and;

• Brief description of the accident.

(b) Incident Investigation Form

- It is for communicating the findings of the investigation of theIncident / Dangerous Occurrences already reported in (a).

- It has to be filled in by the SSO / person investigating or nominated by L&T - RCM and copies to be sent as shown in the form, within 72hours.

- When indicated by the severity of the incident, steps to secure the

incident site must be initiated immediately to ensure the investigating party can reconstruct the events leading to the incident.- Individual interviews should be conducted with each person at the

time of the incident.

• The witnesses should be interviewed promptly, separately and privately.

• The interviewer should explain the purpose of the investigation to eachindividual.

• The interviewer should ask the witness to give their account of theevents that occurred.

• The interviewer should avoid questions that give a “Yes” or “No”

answer.




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Rev – 02 Page 9 of 13 30 Oct.’ 2007

• After the interview, the interviewer should document any concernsidentified.

• The investigation team must focus on getting accurate and completeinformation i.e. Immediate Causes (Actions and conditions) – as given

below-

Immediate Causes - Actions

§ Unsafe handling of material

§ Failure to use PPE properly

§ Removing / defective safety devices

§ Lack of communication

§ Use machine without guard

§ Use of Defective equipment

§ Failure to secure

§ Use of hands instead of aids

§ Improper dress

§ Running above the rated speed

§ Lack of attention/ concentration§ Work permit violation

§ Failure to warn

§ Operating equipment without authority§ Abuse or misuse

§ Using equipment improperly

§ Other (Pl. specify)…..

Immediate Causes - Conditions

§ Inadequate Housekeeping

§ Static Electricity

§ Faulty Cable / Improper Insulation

§ Inadequate Illumination

§ Inadequate Ventilation§ Inadequate/defective tools eqpt or materials/ substances Power Tools

§ Fall of Hot Spark/Spatter

§ Leakage of Gas Cylinder

§ Excessive Noise

§ Radiation exposure

§ Weather

§ Inadequate or improper PPE

§ Inadequate guards or barriers

§ Congestion/ restricted action/ poor access

§ Fire and explosion hazard

§ High or low temperature exposures

§ Lack of Knowledge

§ Poor supervision§ Other (Pl. specify)…..

• The investigation should be directed at determining the basic and Rootcause. Following are some of the basic causes and root causes which

can lead to the unsafe act or condition.

Basic Causes:§ Failure to react to an unusual situation. (New procedure, equipment, process, and

material).

§ No instruction provided or available.

§ Failure to correct existing situation.

§ Instruction/training inadequate or not understood.




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Rev – 02 Page 10 of 13 30 Oct.’ 2007

§ Supervision failed to tell why, or failed to listen.

§ Duties and tasks not clear.

§ Pressure of immediate tasks.

§ Responsibility not clear or understood.

§ Too many decision makers giving instructions.

§ Authority inadequate to manage the situation.

§ Decision exceeds the authority.§ Instructions failed to produce desired results.

§ Subordinates failed to use initiative.

§ Morals, tension and stress causing situations.

§ Honest error, wrong action taken.

§ Lack of co-ordination / teamwork.

§ Poor co-ordination.

§ Faulty inspection and maintenance.

§ Staff shortages high turnover/absenteeism.

§ Personality type i.e. impulsive, excitable, lazy etc.

§ Poor work habits, taking shortcuts, careless with tools.

§ Work assignment unsuited for the particular individual.

§ Inadequate delegation or development of subordinates.

§ Health and impairment of the individual.§ other influence.

Root Causes:§ Procedures: inadequate quality of existing procedures regarding application,

availability and understanding caused by,

ü Inadequate team that developed the procedure.

ü Inadequate feedback about the procedure.

ü Personnel not informed about procedures.

ü Lack of tasks procedurals.

§ Conflicting targets: can be caused by,

ü Conflict between production and safe working practices.ü Conflict between financial priorities and safe working practices.

ü Conflict between social and domestic priorities on safe working practices.

ü Conflict between individual priorities and safe working practices.

§ Communications: difficulties caused by,

ü Language problems, cultural barriers.

ü Lack of clear lines of communication.

ü Inadequate feedback (i.e. tool-box talks).

ü No standardization of information formats.

ü Lines of communication overloaded.

§ Hardware: quality, availability of tools caused by,

ü Inadequate specification of equipment

ü Wrong components purchased / used.

ü Defective equipment.

ü Age of equipment compared to life expectancy.

§ Design: inadequate design criteria of plant and equipment caused by,

ü Design not fully understood to operate safely.

ü Poor specifications leading to substandard material.

ü Specification not compiled with.




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Rev – 02 Page 11 of 13 30 Oct.’ 2007

§ Environmental conditions: a situation that may influence the individual

or the work place caused by,

ü Poor moral - This can be caused by a number of situation i.e. unfair

enforcement of rules, weak discipline, change of rules etc.

ü Physical deterioration, caused by long working hours/undue pressures.

ü Emergency or unusual situation with staff unable to cope or respond.

ü Information not correctly supplied.ü Poor co-ordination between departments causing interface problems.

ü Homesickness etc.

§ Training: shortcomings in skill and knowledge caused by,

ü Ineffective pre -employment selection.

ü Prior education not compatible with job requirements.

ü No structured planning of training programmes.

ü No assessment of training effectiveness.

ü Ineffective training.

ü Training not appropriate for the personnel it’s aimed at.

§ Organization: shortcomings in the structure of the organization leading toinadequate operation of the company, caused by,

ü Too much bureaucracy and rigidity.

ü Unclear accountability, responsibility.

ü Inadequate definitions of objectives and co-ordination of tasks.

ü Frequent reorganization of departments.

§ Maintenance: Inadequate management of maintenance and repairs

caused by,

ü Inadequate planning, controlling, execution and recording of programmes.

ü Shortage of maintenance personnel.

ü Financial or time constraints.

§ Defenses : Inadequate protection of employees and the environment

against hazardous situations caused by:

ü Lack of standardization (lay out and displays).ü Ergonomics consideration, human limitations i.e. size and strength of individual.

ü Inadequate communication between design and the user, allowing

substandard conditions to remain unchecked.

ü Poor discipline and enforcement.

• The investigation will identify corrective actions; both immediate

recovery actions and long term follow – up actions to prevent theincident from recurring.

(c) Near-Miss/ Dangerous Occurrence Form- It is for reporting Near-Miss incident/ Dangerous Occurrence.

- Incident, which does not come under above category i.e., Lost WorkDay Case, Restricted Work Day Case, Transfer of job, Medicaltreatment only case, Fire, First Aid should be sent as shown in the

form within 24 hours after an accident or Incident takes place.- To be filled by the Supervisor / Engineer of L&T / Contractor.




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Rev – 02 Page 12 of 13 30 Oct.’ 2007

Figure B: Flow chart of Incident Procedure

DANGEROUS,

NEARMISS

SUPERVISOR/

ENGINEER/

SSO(PREPARE ,SIGN &

FORWARD DANGEROUS /

NEARMISS REPORT TO

RCM (SIGN & FORWARD

REPORT TO)

FIRST AID

HSE CAPABILITY CENTRE, POWAI

RECORDABLE,

FIRE

RCM(SIGN &FORWARD

ACCIDENT REPORT TO)

INVESTIGATIONPERSON

(PREPARE ACCIDENT INVESTIGATION &

FORWARD TO )

CONTRACTOR/

SITE INCHARGE(SIGN &FORWARD

REPORT TO)

RCM (SIGN & FORWARD

REPORT TO)

INCIDENT

SSO(COPY)

SSO(COPY)

RCM(FORMATION OF

INVESTIGATION TEAM)

FIRST AIDER (MAINTAIN LOGBOOK

AND FORWARD DATATO SSO EVERY MONTH)

WITH IN 24 HRS

SUPERVISOR/ENGINEER

(PREPARE ,SIGN & FORWARD

ACCIDENT REPORT TO)

WITH IN 72 HRS




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Rev – 02 Page 13 of 13 30 Oct.’ 2007

4.0 Administration(i) The reports in photocopy or in typed form should be prepared and submitted to

HSE Capability Centre within stipulated time frame as mentioned in the form.(ii) In case of Lost Work Day Case, the RCM (or Client’s Project Manager) will have

to send separate reports to the authorities as per the Section 39, Rule 210 ofBuilding and other Construction workers (Regulation of employment & conditionsof service) Act, 1996, besides these internal reports.

(iii) Employees responsibility:Inform immediately to SSO/E or concerned supervisor for work related illness and

injuries (i.e. on the same day).

5.0 Records

Form Reference

1. Incident Report OHS-06 A

2. Incident Investigation OHS-06 B

3. Near-Miss Incident Report OHS-06 C




_______________________________________________________________________________________________

Rev – 02 Page 1 of 8 10 October 2007

CHAPTER - 07

MONTHLY HSE STATISTICS REPORTING

1.0 Purpose

(i) This procedure provides guidelines on the method and form to report Monthly HSEPerformance of L&T – E&C sites/ offices to the management.

(ii) Based on these reports, the management can initiate necessary actions to augment

corrective efforts as required, at the E&C sites/ offices.

2.0 Definitions

1. Accident - undesired event-giving rise to death, ill health, injury, damage or other

loss. (Defined as per OHSAS 18001)2. Incident - event that gave rise to an accident or had the potential to lead to an

accident

Work Related I ncidents

Work relationship is presumed for incidents resulting from events or exposures in

or related to the work environment.

• If an event or exposure in the work environment either caused or contributed to

the resulting condition.

• A pre-existing condition is considered work related if an event or exposure inthe work environment results in injury, illness, property damage or

environmental harm and would not have occurred but for an event or exposurerelated to the work environment.

Cases that occur while the employee / subcontractor employee is travelling are

considered work related if the employee / subcontractor employee is engaged in

work activities

3. Fatality : The death of an employee / subcontractor employee engaged in a work-

related activity, which results from an event or exposure in the work environment.

The death may not actually take place at the work place.

4. Lost Workday Cases (LWC)

A Lost Workday Case is a medical case that involves

• Fatalities

• Recordable Incident Cases due to personal injury

• Cases where an employee/subcontractor employee is away from next scheduledshift resulting from a recordable incident and Restricted Work Activity Cases.

If an employee is unable to work on a schedule shift because of a work relatedinjury or illness, the case is a Lost Workday Case (LWC). Presence at the site does

not constitute work.




_______________________________________________________________________________________________


The shift on which the injury or illness occurred and the shift on which the

employee returns to work are not counted in the total days lost. Vacation days,

holidays and days of rest that were scheduled before occurrence of the injury are

also not counted. Days away from work include only full scheduled workdays.

5. Lost Work-Days (LWD) : Case where the employee/sub contractor employee is

away from work after the day of work related injury or illness. Count the number of

calendar days lost (excluding holidays, vacation and weekends) where work is not

performed. The day of incident is not counted as a lost work day. Stop count if

employee/subcontractor employee leaves company.(Days after incident until days

returned to work).In case of fatality, count 6000 man days lost for the calculation of

Incidence Rate.

6. I ncident F requency Rate: In frequency rate is the number of Lost Workday Cases

occurring among a given number of full-time workers (usually 100 full-time

workers) over a given period of time (usually one year). Frequency Rate for lost

workday Cases can be calculated as follows:

Frequency Rate of LWC =

(No. of LWC x 200,000/ Total hrs worked during same period)

7. Recordable Incidents : Work-related incidents causing injury or illness to

personnel that leads to medical treatment or lost time, including incidents causing

property damage and/or damage to the environment.

Total recordable/reportable incidents (TRI) is the sum of all work - related

• Fatalities

• Lost work day cases/ Days away from work cases

• Restricted work day cases

• Loss of consciousness,

• Transfer to another job,

• Medical treatment only cases (other than first aid)

• Termination

• Illness.

8. Restr icted Work Day Cases (RWC) : A Restricted Workday Case (RWC) is any

work related injury or illness that prevents the employee from either doing one or

more parts of his or her regularly scheduled duties or working a complete shift on

any subsequently scheduled shift.

If an employee misses part of a subsequently scheduled shift because of

hospitalisation for treatment or observation, then the injury is an RWC only if the




_______________________________________________________________________________________________


employee is unable to perform all normal job assignments. The shift on which

injury occurred is not counted as a restricted workday.

In other words, if employees are unable to do the job they were doing when they

were injured or made ill, they are restricted until they can return to that job. The

restriction refers to limits of activity or time that can be spent doing the job (i.e the

employee can do part of the job all of the day or all of the job part of the day).

Following cases are generally considered RWC:

1) Temporary transfer: -

• While an injured employee may be assigned work other than his or her

normal duties, the temporary duties must be meaningful and pre-established,

and the injured employee must be qualified to perform them• If the employee is injured while working at a temporary assignment and

transferred back to his/ her normal job assignment , which he or she can

perform without limitation, then no days of restricted work activity are

counted.

2) Precautionary transfer: -

• While an injured employee is transferred to another job because of

suspected Illness, such as dermatitis, the time on other job does not need tothe recorded as the days of restricted activity (DRA) while the case in beingdiagnosed. However, if the diagnosis reveals an illness that required

continuation of the transfer, all days should be recorded as DRA. If thetransfer is for the purpose of keeping an injury free of contamination, the

DRA should be recorded. If the transfer is because the wounds, bandages,etc significantly reduce the ability to work, DRA should also be recorded.

• The case is considered restricted only if the employee develops an illness

associated with exposure and if the employee is transferred to another job orarea as a precautionary measure because of exceeding norms resulting from

exposures.Examples include the following:

♦ an employee develops a skin rash and is removed from work area. The

rash is subsequently determined to have been caused by food eaten athome. Therefore, the illness is not work-related.

♦ on the other hand, if the rash is determined to have been caused byexposure to chemicals in work area, then the days from the transfer to

the regular assignment are counted as restricted.

9. Medical Treatment Only Cases ( M TOC) : All Medical Treatment Case (MTC)

which neither result in restricted workday nor lost workday are termed as a Medical

Treatment Only Cases (MTOC). Such cases will require one or more visits to a

medical professional, but will not disable or restrict the employee from carrying out

his normal duties. Also, Medical treatment does not includes: visits to a physician




_______________________________________________________________________________________________


or other licensed health care professional solely for observation or counseling ; the

conduct of diagnostic procedures, such as X-rays and blood tests, including the

administration of prescription medications used solely for diagnostic purposes (e.g

eye drops to dilate pupils) or first aid. Medical treatment includes:

• Treatment of Infection

• Application of Antiseptics during second or subsequent visit to medical

personnel

• Treatment of Second or Third degree burn(s)

• Application of Sutures (stitches)

• Any use of Oxygen

• Removal of foreign bodies embedded in eye

• Removal of foreign bodies from wound; if procedure is complicated because of

depth of embedment , size or location.• Any physical therapy / chiropractic treatment

• all no-prescription drugs at prescription strength and any dose of a prescription

drug.

• Use of hot or cold soaking therapy during second or subsequent visit to

medical personnel

• Use of hot or cold compress(es) during second or subsequent visit to medical

personnel

• Use of hear therapy during second or subsequent visit to medical personnel

• Use of whirlpool bath therapy during second or subsequent visit to medical

personnel

• Positive X-Ray Diagnosis (Fracture, broken bones, etc)

• Cutting way dead skin (surgical debridement)

• Admission to a hospital or equivalent medical facility for treatment

10. Loss of Consciousness : If an employee loses consciousness as the result of a

work-related injury, the case must be recorded no matter what type of treatment was

provided. The rationale behind this recording requirement is that loss of

consciousness is generally associated with the more serious injuries.

11. Transfer to another job: Injuries requiring transfer of the employee to another job

are also considered serious enough to be recordable, regardless of the type of

treatment provided. Transfers are seldom the sole criterion for recordability. This is

because injury cases are almost always recordable on other grounds, primarily

medical treatment or restriction of work or motion.




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12. First aid injury/ Case - A First Aid Case (FAC) is one-time treatment and

subsequent observation of minor cuts, scratches, burns, splinters, and other similar

injuries, which do not ordinarily require medical care. A case can be classified as

first aid if it is administered by a physician or other registered professional

personnel. Administration of a single dose of a prescription medication on a first visit

for a minor injury is also considered first aid. Multiple use of non-prescription

medication, cold packs, heat treatments, and multiple antiseptic applications does not

affect the classification.

The following are generally considered first aid treatment:

• Administering tetanus immunizations (other immunizations, such as Hepatitis B

vaccine are considered medical treatment);

• Cleaning, flushing or soaking wounds on the surface of the skin;

• Using wound coverings such as bandages, Band-AidsTM, gauze pads, etc.; or using

butterfly bandages or Steri-StripsTM

(other wound closing devices such as sutures,staples, etc., are considered medical treatment);

• Using hot or cold therapy;

• Using any non-rigid means of support, such as elastic bandages, wraps, non-rigid back belts, etc. (devices with rigid stays or other systems designed to immobilize

parts of the body are considered medical treatment);

• Using temporary immobilization devices while transporting an incident victim (e.g.

splints, slings, neck collars, back boards, etc.);

• Drilling of a fingernail, or toenail to relieve pressure, or draining fluid from a

blister;

• Using eye patches;

• Removing foreign bodies from the eye using only irrigation or a cotton swab;

• Removing splinters or foreign material from areas other than the eye by irrigation,

tweezers, cotton swabs or other simple means;

• Using finger guards;

• Using massages (physical therapy treatment is considered medical treatment for

record keeping purposes); or

• Negative X-ray diagnosis

• Application of ointments to abrasions to prevent drying or cracking.

• Administrating Drinking fluids for relief of heat stress.

13. Dangerous Occur rences

a) Collapse or failure of lifting appliances, hoist, conveyors etc.

b) Collapse or subsidence of soil, any wall, floor, gallery etc.c) Collapse of transmission towers, pipeline, bridges etc.d) Explosion of receiver, vessel etc.

e) Fire and explosionf) Spillage or leakage of hazardous substances

g) Collapse, capsizing, toppling or collision of transport equipmenth) Leakage or release of harmful toxic gases at the construction sitei) Failure of lifting appliance, loose gear, hoist or building and other construction

work machinery, transport equipment etc.




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14. I ll ness (Occupational ) . A physiological harm or loss of capacity produced by

systemic infection; continued or repeated stress or strain; exposure to toxins,

poisons, fumes, etc.; or other continued and repeated exposures to conditions of the

work environment over a period of time. For practical purposes, an occupational

illness/disease is any reported condition which does not meet the definition of

injury (traumatic).

Some conditions may be classified as either an injury or an illness (but not both),

depending upon the nature of the event that produced condition. Ex.

I) Loss of hearing resulting from an explosion (an instantaneous event) is

classified as an injury; the same condition arising from exposure to industrialnoise over a period of time would be classified as an illness.

II) Similarly, irritation of throat from exposure of chlorine gas fumes could be

classified as either an injury or an illness. If the exposure was instantaneous andoccurred when a cylinder of gas ruptured, the case would be considered an

injury. The case would be an illness if the employee was exposed to the agentover a period of time, such as working in an area where chlorine fumes from a

bleaching process were present.

15. I nju ry (Traumatic) . A wound or other condition of the body caused by external

force including stress or strain. The injury is identifiable as to time and place of

occurrence and member or function of the body affected, and is caused by a specific

event or incident or series of events or incidents within a single day or work shift.

16. Near M iss: An incident where no ill health, injury, damage, or other loss occurs is

also referred to as a “Near-Miss”. The term “Incident” also includes “Near-

M isses” . (defined as per OHSAS 18001) . Examples are

• Non relieving of a relief valve at set pressure;

• Relieving of relief valve before set pressure;

• Non working of emergency appliance (eg. Non-working of fire fighting facilities)

• Non working of shutdown / trip systems;

• Violation of Safety regulation (eg. Working without valid work permit, working

without proper PPE, working with improper tools, etc)• Free falling of objects from height;

• Bursting/ disconnection of pressure hoses.




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Figure A: Classification of Incidents

INCIDENT

Undesired event resulting in or having potential to result in personal injury/ illness or property damage

PERSONAL

ACCIDENT

DANGEROUS

OCCURENCE

FIRE NEAR MISS

Resulting in

personal injury/

illness

Resulting in

property damage

Involves Minor fire

due to Welding,

Gas Cutting, etc

Does not result, but has

potential for injury/

property damage

Work related

injury/ illness

Non - Work related

injury/ illness

Illness MedicalTreatment Cases

FatalCases

Medical

Treatment Only

Restricted work

Day cases

Lost Work day

cases

During offduty hours

While carrying outnon work related

activity

Note: 1.) Fire involving personal injury/ illness to be treated as “Personal Accident” also.

2.) Dangerous Occurrence involving personal injury/ illness to be treated as “Personal Accident” also.

First AidCases




_______________________________________________________________________________________________


3.0 Procedure

i. SSO/E shall enter/ record the data on Incidents, Employee – Hours, Training,Inspections/ Audits, Tool Box Talks, Infringements etc as per the standard format

(OHS – 07) given by HSE Capability Centre.ii. SSO/E and RCM/RCC shall sign this report. If RCM/RCC is not present, his

representative will have to sign and forward to HSE Capability Centre by 5th of

subsequent month.iii. Monthly HSE Statistics Report is processed and analysed by HSE Capability Centre

and performance is evaluated for further action.

4.0 Administration

i. SSO/E shall prepare report and send it to RCM signature

ii. After RCM signature, SSO/E shall send the report to HSE Capability Centre.iii. If SSO/E is not present, RCM will be responsible to send the report to HSE

Capability Centre.iv. If there is nothing to report in a particular month then “Nothing to report” or “NIL”

will be entered/ recorded in “Month under report ” and the same cumulative data as

that of previous month shall be entered/ recorded.

5.0 Records

Form Reference

Monthly HSE Statistics Report OHS-07




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Rev – 01 Page 1 of 1 02 Dec. 2004

CHAPTER – 08

POSITIVE REPORTING ON SAFETY

1.0 Purpose

(i) To give feedback on various activities being carried out for Safety Promotion toimprove and comply with OH&S requirements.

2.0 Definitions – None

3.0 Procedure

(i) Reporting positive aspects of safety to the HSE Capability Centre at Powai, inwriting such as;

Compliance to chapters in the OHSP Manual.Provision and use of APTs to / by L&T and Contractors at site.

Regular On-site training of workmen, mock fire drills etc.First Aid and Fire Fighting Training of site personnelAny additional safety provision at site

Any aspect of safety promotion at site such as Safety Slogans/Essay/QuizCompetition, Safety Poster display / safety exhibition etc.

Recognition and Rewards for good safety performance.Compliance with statutory requirementsInteraction with the client/contractor on safety matters like safety meeting.

Achieve milestones such as accident-free 1,000,000 man-hours.

Before reporting, RCM should ensure the following requirements are met:(a) Compliance / provision being reported must be of permanent / regular nature,

i.e. they must continue at the site until the site is closed / end of the project.

(b) Compliance / provision must be seen as having definite and positive effects on preventing mishaps and personal injuries at the site.

4.0 Administration

(i) Whenever a positive action is taken at the site, RCM will send its details toHSE Capability Center in the form attached to this chapter.

(ii) Report may be sent at any time, as and when the positive safety action iscompleted.(iii) SE from HSE Capability Centre will ascertain the actual provision of the

measure/s reported by RCM, during periodic site visits.(iv) HSE Capability Centre will record the actions and use it for co-relation of

such actions with the Safety Performance of the site.

5.0 Records

Form Reference

Positive Report OHS-08




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Rev – 02 Page 1 of 5 10 Dec. 2007

CHAPTER - 09

ON SITE EMERGENCY PREPAREDNESS PLAN

1.0 Purpose

(i) To localise the emergency and if possible, eliminate it.

(ii) To recognize that accidents are possible, assessing the consequence of suchaccidents and deciding on the emergency procedures both on site and off site thatneed to be implemented in the event of an emergency.

(iii) To minimise the effects of the accident on people and property.Elimination will require prompt action by operators & emergency staff using for

example fire-fighting equipment, emergency shut off valves and opening of watersprays.Minimising the effects may include rescue, First Aid, evacuation, rehabilitation and

giving information promptly to people living nearby.(iv) This chapter outlines a Model Emergency Plan, however actual plan shall be

prepared as per the site conditions and client’s requirements. The EmergencyResponse Plan for Construction Site shall be in line with the client’s EmergencyResponse Plan.

2.0 Definitions:

(i) Emergency : A major emergency in a work site is one, which has the potential tocause serious injury or loss of life. It may cause extensive damage to property and

serious disruption both inside and outside the site premises. It would normallyrequire the assistance of outside emergency services to handle it effectively.

Although the emergency may be caused by a number of different factors, e.g. plantfailure, human error, and earthquake, vehicle crash or sabotage, it will normallymanifest itself in three basic forms: Fire, Explosion or Toxic Release.

(ii) Emergency control centers: The Emergency Control Center is the place fromwhere the operations to handle the emergency are directed and co-ordinated. It will

be attended by the Site Main Controller, key personnel and the senior officers of thefire and police services.

2.0 Procedure

On-site emergency planni ng:

(i) Formulation of the plan and of emergency services:

a. The on-site emergency plan must be related to the final assessment and it isthe responsibility of the site management to formulate it. The plan must

therefore be specific to the site. On very simple sites, the emergency plan mayconsist merely of putting key personnel on stand-by and calling in theemergency services. On large multi-location sites, the plan may well be a

substantial document including the following elements:i. Assessment of the size and nature of the events foreseen and the

probability of their occurrence.ii. Formulation of the plan and liaison with outside, including the

emergency services;




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Rev – 02 Page 2 of 5 10 Dec. 2007

iii. Procedures:

- Raising the alarm;- Communications both within and outside the works;

iv. Appointment of key personnel and their duties and responsibilities:

- Site Incident Controller;- Site Main Controller;

- Emergency control center- Action on site;- Action off site.

The plan should set out the way in which designated people at the site of theincident can initiate supplementary actions both inside and outside the works at an

appropriate time. An essential element of the plan must be the provision forattempting to make safe the affected unit for example by shutting it down. On acomplex site, the plan should contain the full sequence of key personnel to be called

in from other sections or from off site.

(ii) Alarm and communication mechanism:Communication is a crucial factor in handling an emergency. There should be areliable system for informing the emergency services as soon as the alarm is raisedon site. The details of the communication arrangements should be agreed locally.

(iii) Appointment of personnel and definition of duties:

Effective emergency plans require that, in the event of an accident, nominatedindividuals be given specific responsibilities, often separate from their day-to-day

activities. The following are the key personnel and their general duties.a. Site controller (RCM/RE):

i. RCM/RE remains in the Emergency Control Center till the emergency iscalled off .

ii. RCM/RE communicates and co-ordinates among various team leaders.

iii. RCM/RE is the final authority on all matters related with management ofemergency such as fire fighting, rescue operations, calling outside agencies

for assistance, evacuation, transport, liaison, public relations etc.iv. RCM/RE will perform all duties required to be done regarding mechanical,

electrical and other assistance as required during the emergency.

v. RCM/RE will co-ordinate and monitor all rescue operations.vi. RCM/RE will maintain liaison with all government agencies regarding the

emergency.

vii. RCM/RE will take all steps required for welfare such as providing tea,

snacks in the canteen.viii. He will also be responsible for arranging for the head count at the identified

Assembly Point. b. Responsibilities of unit in-charge (Engineer at site):

i. Report to the site controller and site co-ordinator about the status of theemergency.

ii. Unit In-charge will regulate the entry and exit of personnel required forcontrolling the fire/emergency.

iii. Unit In-charge will arrange PPE required for emergency.

iv. Unit In-charge will call the local fire brigade, police in case of necessity inconsultation with the Site Controller / Site co-ordinator.




_______________________________________________________________________________________________

Rev – 02 Page 3 of 5 10 Dec. 2007

v. Unit In-charge will be responsible for arranging transport facilities for

evacuation of personnel to medical center (Hospital) or to a safer place.vi. Unit In-charge will collect and disseminate information as required to all

concerned.

vii. Unit In-charge will keep detailed report of the incident and the progress ofoperations to control emergency.

viii. In case of power failure/telephone service disruption, Unit In-charge willarrange for messenger for the purpose of communication.

ix. Unit In-charge will work in consultation with the Site Controller.

c. Site co-ordinator (SSO/E):

i. SSO/E will co-ordinate the activities of the entire team.ii. SSO/E will evaluate the safety and health hazards.iii. SSO/E will co-ordinate the transport services, arrange for temporary

shelter in consultation with the Unit-In charge.

d. Rescue / Evacuation team:i. This team will directly attempt to control the emergency under the

instructions from Unit-In charge / Site co-ordinator.ii. The team leader will be the Erection / Construction Supervisor or

Engineer and will be assisted by various Engineers for controlling theemergency.

iii. This team will ensure that the emergency does not escalate but iscontrolled and / or extinguished on the spot of occurrence.

iv. The team leader will ensure that he/ her and his/ her team members

wear the necessary PPE while searching for the missing personnel.v. The leader will mobilize his / her team and establish contact with the

Site Contractor regarding manpower accounting and start thesearching operation if required.

vi. One pre-identified person who is trained in fire fighting will cordon

off the emergency area to restrict the exposure of persons.vii. Rescue team should arrange to send out all tankers, lorries and

flammable material to a safer place.viii. Person trained in First Aid will provide assistance to injured persons.

e. Apart from these personnel other site personnel will have key roles to play in

the implementation of the Emergency Plan. These will include Senior Managersof site not directly involved in the emergency, First Aiders, Time Office and

Administrative staff to liaise with the media. All need to be aware at theemergency pre-planning stage of the precise nature of their roles.(iv) Emergency Control Center: Emergency Control Center should contain the

following (as applicable):a. An adequate number of external telephones; if possible, one should accept

incoming calls only, in order to avoid jammed switchboards during anemergency;

b. An adequate number of internal telephone / connections; At least one Mobile /

Cell Phone / walkie- talkiec. A list of key personnel, with addresses, telephone numbers, Mobile / Cellular

Phone numbers etc.

d. Radio equipment – with FM Radio channel




_______________________________________________________________________________________________

Rev – 02 Page 4 of 5 10 Dec. 2007

e. A plan of the works, to show:

i. Areas where there are large inventories of hazardous materials;ii. Sources and location of safety equipment;iii. The fire fighting system and additional sources of water;

iv. Site entrances and roadways, including up-to-date information on roadworks;

v. Assembly points;vi. The location of the works in relation to the surrounding community;vii. Lorry parks and rail sidings; (additional works plans should be available to

show affected areas, etc., during an emergency;)f. Notepads, pens and pencils;

g. A nominal roll of employees;(v) The Emergency Control Center should be located in an area of minimum risk. For

large sites, or where toxic releases might be anticipated, consideration should be

given to setting up two control centers to ensure, as far as possible, that one will

always be available for use.vii) Rehearsing emergency procedures: - Once the emergency plan is finalised,

it should be made known to all personnel so that each one knows his or her role inthe event of an emergency.

Do’s and Dont’s

Do’s1. Give attention to all instructions.

2. Report to your Team Leader and carry out your assignment / role.

3. Take out the visitors / contract labours outside the emergency zone to designated

location.

4. Only qualified First Aiders shall render First Aid wherever possible and wait for the

Doctor.

Dont’s1. Do not panic.

2. Do not communicate with any external agency unless instructed by the Site

Controller.

3. Do not spread unauthorized or exaggerated information to others.

4. Do not approach the emergency site as a spectator.

5. Do not engage the communications aids and other means so as to make the same

available for handling emergency.

6. Do not disturb the leader assigned with specific work for handling emergency.

Procedure for Mock Drill

a) Inform all the employees about Mock Drill and signal to all.

b) Fix date and location of emergency for Mock Drill.

c) Mock Drill should be monitored by an observer who is not involved in the exercise.

d) Raise the siren for emergency.

e) Site Controller, Unit-Incharge, Co-ordinator and Team Leaders shall follow their




_______________________________________________________________________________________________

Rev – 02 Page 5 of 5 10 Dec. 2007

stipulated duties/responsibilities.

f) Some pre-identified persons should cordon off the emergency area.

g) All clear signal should be raised after half an hour.

Frequency of Mock drill

a) Frequency of the mock drill shall be minimum but not limited to once in a 6

months

Scenarios for Mock Drill

a) Following scenarios can be covered while carrying out mock drill at site

Ø Evacuation/Rescue of Trapped person

Ø Release of Toxic Gases

Ø Major Spillage of chemicals

Ø Major Fire and explosion

Ø Bomb Threat

Ø Natural calamities

Ø Major Incident

On site Emergency Plan (OEP) Appraisal and updating

Mock Drill will be conducted and monitored. After each drill the plan will be thoroughlyreviewed to take account of omission or shortcomings and updated response time for eachaction will be noted and studied for any improvement.

Procedure on noticing an emergency

Inform the nearest Unit-In charge. Get back to your normal workstation if safe, or else

report to the Emergency Control Center.

3.0 Records - None




_______________________________________________________________________________________________

Rev – 02 Page 2 of 2 10 Jun.’2007

5.0 Records

Form Reference

CHSECE Form OHS – 10




_______________________________________________________________________________________________

Rev – 02 Page 1of 1 10 Dec 2007

CHAPTER – 11

SCREENING & INDUCTION OF WORKMEN

1.0 Purpose

(i) To assess the suitability of a particular workman for a specified job for which he is

due to be engaged.(ii) To inculcate general HSE awareness; educate him/her on common hazards and

appropriate precautionary measures.

2.0 Definition –(i) Visitor : Who will be on site for less than one day and who will be accompanied by

site personnel all times when on site (i.e except when in the offices) . (ii) Workmen: - Any person engaged in construction (Source: ILO, Safety and Health

in Construction)

3.0 Procedure

(i) The sub-contractor escorts the concerned new workman to Time Office withrelevant details relating to his Name, Age, Sex, Address, Father’s name, skillcategory entered into the standard format.

(ii) SSO/E in consultation with Site Engineer examines the suitability of the workmanfor site job and gives HSE Induction to him then signs the ‘HSE Induction Report’.

(iii) The topics involved in full HSE Induction shall include but not limited to

followingi. L&T corporate Policy as well as Client’s HSE Policy

ii. Project HSE policies and Objectives (ZERO INCIDENT CREDO)iii. Site HSE rules and regulations especially permit requirementsiv. Common construction HSE hazards and Precautions

v. General health Issues e.g smoking and substance abuse/ prohibitionvi. Reporting incidents, including near-misses

vii. Reporting hazardsviii. First aid and Emmergency procedures

ix. Health Risks of the region and the personal hygiene measures to be adopted

x. Any relevant environmental and social issues and legal requirementsxi. Housekeeping and the control and Management of construction waste

(iv) Visitors shall be imparted HSE induction that shall include minimum i. L&T corporate Policy as well as Client’s HSE Policy

ii. Project HSE policies and Objectives

iii. Site HSE rules and regulations especially permit requirementsiv. First aid and Emmergency procedures

(v) The further induction program shall be focused on commissioning activities andhazards, to be attended by everyone who is expected to work in commissioningareas of the project site.

4.0 Administration

(i) Time Office personnel, in co-ordination with SSO/ SE shall carry out the screeningof all the workmen.

5.0 Records

Forms Reference

HSE Induction Report OHS – 11




_______________________________________________________________________________________________

Rev – 01 Page 1 of 2 02 Dec. 2004

CHAPTER - 12

SAFETY OF VISITORS TO L&T CONSTRUCTION SITES

1.0 Purpose

(i) To make all visitors aware of the basic/minimum safety rules, before they enter thesite, and specific/working safety rules while they work on / go around the site.

2.0 Definitions

(i) Visitor : Who will be on site for less than one day and who will be accompanied

by site personnel all times when on site (i.e except when in the offices) .

3.0 Procedure

This chapter sets out safety guidelines and working procedures, which are considered asthe minimum standard applying to all `visitors’ entering at the site.

Term `visitors’ includes all persons who are not regularly employed by (registered/on theroll of) L&T or its contractors/sub-contractors, i.e. `visitors’ include all persons who enter

sites for discussion and/or for carrying out work/activity on behalf of suppliers/vendors ofL&T or its contractor/sub-contractors.

4.0 AdministrationIt is responsibility of RCM /RCE to ensure that the following steps are taken whenever he

permits a visitor into his construction site.

(i) RCM / RCE shall permit only authorised persons of companies / vendors / suppliersto enter the L&T construction site.

(ii) Visitors shall be advised by Concerned Person to read “Safety Guidelines for L&TConstruction Site Visitors”, given in Annexure-I which is available with him.

(iii) RCM / RCE shall ensure from visitors that they have read L&T’s safety guidelines

before they do any kind of work in the `construction area’.(iv) If the site is within the client’s premises and the entry pass is issued by the client’s

security staff, then RCM / RCE shall ensure that visitors, who are not familiar withthe site conditions and safety rules, shall be received at the entrance of the L&T siteand escorted to the site.

(v) RCM / RCE shall ensure clearly a ‘safe route’ to his office from the entrance of thesite. While walking on the `safe route’, visitors shall not be required to wear

protective equipment such as helmet, etc. However, if these are required, then RCM/ RCE shall ensure that these are issued at the entrance of the site.

(vi) Visitors permitted for discussion/meeting on the site, shall be restricted to stay

inside the site office. If however, they are required to go around in the `construction

area’, they shall be issued appropriate PPE by RCM / RCE, depending on the natureof hazards present in that area.They shall always be accompanied by a member of the RCM ’s staff at the site,while they are inside the construction area.

(vii) Visitors representing vendors/suppliers and L&T officers, who are required to carryout work such as installation, inspection, testing, commissioning or any kind of

supervision which may also require their independent presence in the constructionarea, shall be made aware of the site safety rules by RCM / RCE / SSO.These visitors shall be issued all necessary PPEs or shall be advised to bring their

own PPE’s and wear them before they enter the construction area and start working.

5.0 Records - None




_______________________________________________________________________________________________

Rev – 01 Page 2 of 2 02 Dec. 2004

Annexure -1

Safety Guidelines for L&T Construction Site Visitors

The following rules are the minimum standards applicable to all visitors to this site and are

supplemental to statutory laws & regulations. If any doubt, please check with L&T - Resident

Construction Manager or his staff.

1. Visitors shall enter into and work on this site at their own risk and shall have own adequateinsurance cover.

2. Visitors shall follow advice of RCM with respect to more detailed Safety Precaution for

the work which he is going to carry out at site.

3. Smoking is allowed only at designated places.

4. Possession of illegal drugs and paraphernalia, intoxicating beverages, fire arms chemicals/

solvents and weapons are prohibited. These may be searched / frisked by L&T and visitorsfound possessing these shall be immediately removed from the site.

5. Horseplay can be dangerous and is prohibited.

6. Littering and spillage of any kind is forbidden for maintaining good housekeeping.

7. Entry of chemicals / solvents, gas cylinders, photographic equipment, tools / gadgets /

instruments require prior written permission from RCM .

8. Wearing of Personal Protective Equipment (PPE) is necessary wherever required/directed

by L&T.

9. Visitors shall read and follow L&T’s `OHSP Manual’, if he is required to carry outinstallation, inspection, testing, commissioning or any kind of supervisory work on thissite.

10. Visitors shall make available to RCM, Material/Equipment Safety Data Sheets for

Materials/Equipment permitted to be carried by them and shall be trained to use themsuitably.

11. Visitors shall immediately report to RCM, accidents/injuries, unsafe conditions/near-misses and use of L&T’s fire fighting equipment.




_______________________________________________________________________________________________


CHAPTER - 13

HAZARD IDENTIFICATION & RISK ASSESSMENT

1. Purpose

1.1. To identify all OH&S hazards associated with both routine and non-routineactivities of project sites.

1.2. To introduce risk management terminology in order to assist L&T E&C in the

development toward a common and consistent approach to risk management.1.3. To introduce common risk terminology as a basis for sharing of principles, training

methods, ideas and resources throughout L&T E&C and the sub contractors,

vendors etc1.4. To highlight some of the techniques used to arrive at the quantitative assessments.

1.5. To set the basis for risk acceptance criteria and to set specific and consistenttolerability criteria for quantitative assessment of risk levels which are applicablethroughout the E&C division.

1.6. The principles of risk management as outlined in this Guideline are meant forreference and use by all L&T E&C Division’s Managers Engineers and

Supervisors. The guideline should assist management in making critical HSEdecisions as well as assist line supervision and foremen in the day to daymanagement of site HSE risks.

2. Definition

2.1. Accident – See ‘incident’.2.2. ALARP- means to reduce a risk to a level which is ‘as low as reasonably

practicable’ and involves balancing reduction in risk against the time, trouble,

difficulty and cost of achieving it. This level represents the point, objectivelyassessed, at which the time, trouble, difficulty and cost of further reduction

measures become unreasonably disproportionate to the additional risk reductionobtained.

2.3. Consequence (or severity) is the loss that can be inflicted if the hazard eventoccurs.

2.4. Frequency is the number of occurrences of an event per unit time.

2.5. Hazard – Source or situation with a potential for harm in terms of human injury orill health, damage to property, damage to the workplace or environment, or a

combination of these.2.6. Hazard Management is the systematic process of:

q Identifying potential hazardous events and their potential consequences(hazard analysis)

q Evaluating the risk potential of the hazardous event occurring (risk analysis)

q Managing the risk at an ALARP risk level, which may be achieved byreducing the probability of a hazardous event occurring or mitigating its

potential consequences

q Reviewing the hazards and risks on a periodic basis.2.7. Incident is an event or chain of events which has caused or could have caused

injury, illness, and/or damage (loss) to assets, the environment, company reputationor third parties.

2.8. Individual Risk – Individual risk ‘IR’ is defined as the combined fatal risks to a

‘named individual’. IR would include such factors as:




_______________________________________________________________________________________________


q Total Risk , the sum of contributions from all hazards exposed toq Occupancy, the proportion of time exposed to work hazards

q Vulnerability, the probability that exposure to the hazard will result in fatality2.9. Public - anybody not directly employed by L&T or Group Companies or

contractors (including sub-contractors) working for L&T and/or Group Companies.

2.10. Risk is the product of the measure of the likelihood of occurrence of an undesiredevent and the potential adverse consequences which this event may have upon:

q People - injury or harm to physical or psychological healthq Assets (or revenue) - damage to property (assets) or loss of productionq Environment - water, air, soil, animals, plants and social

q Reputation - employees and third partiesq Risk = Frequency x Consequences

2.11. Worker - anybody who is directly employed by L&T, the L&T Group Companiesor contractors (including sub- contractors) working for L&T E&C Division.

3. Abbreviations

ARA - Activity Risk AssessmentALARP - As Low As Reasonably Practicable

L&T - Larsen & Toubro LimitedFAC - First Aid CaseFMEA - Failure Mode and Effect Analysis

HAZAN - Hazard Analysis (review/study)HAZOP - Hazard and Operability (review/study)

HSE - Health, Safety and EnvironmentHSEIA - Health Safety and Environment Impact AssessmentLWC - Lost Workday Case

MTC - Medical Treatment CasePHSER - Project Health, Safety and Environmental Reviews

P&ID - Process & Instrumentation DiagramPLL - Potential Loss of LifeRWC - Restricted Work Case

RCM - Resident Construction Manager

4. RISK MANAGEMENT PROCESS FOR WORK

There are, in general, three types of work activity:q Work activities that have had a Risk Assessment previously completed and recorded in

proceduresq Work activities that are new or have not been risk assessed, andq Work activities that can be covered by individual’s competence, skills and training.

The following sections describe, for each of these types of activities, the steps that must betaken in order to ensure the integrity of the risk assessment process.

4.1. Activity Risk Assessment (ARA).

Whenever work has to be undertaken by L&T it is necessary to make a suitable andsufficient assessment of the risks to the health and safety of employees and others, for the

purpose of identifying the necessary control measures. Practically this involves four basic

steps, which are to:q Identify the possible hazards associated with the work activity;




_______________________________________________________________________________________________


q Assess the consequences of the hazardous event(s) and the likelihood of theirhappening, i.e. evaluating the risks arising from them;

q Introduce control measures (precautions) to prevent or reduce the consequences and/orthe likelihood that they will happen to a level ‘As Low As Reasonably Practicable’ (ALARP);

q Specify recovery measures for reinstatement in case the controls fail.

The process of identifying the hazards, evaluating risks and applying controls andspecifying any recovery measures will be referred to as ‘Activity Risk Assessment’(ARA). This is shown diagrammatica lly in Fig. 1 below.

IDENTIFY

What are the hazards?

What could go wrong?•List Hazards

ASSESS

What could happen?

How serious will it be?

How likely is it?

• Escalation

• Risk (Consequence x Probability)

CONTROL

Is there a better way?

How to prevent it?

•Eliminate

•Prevent

•Reduce risk to ALARP

RECOVER What if it happens?

How to recover?

•Emergency Response

•Limit consequences

•Reinstate to safe

Figure 1 – The Activity Risk Assessment (ARA) Process

In practice, these steps are not always distinct and many decisions about the overall process will be taken as part of the Activity Risk Assessment. Completing the four steps ofthe ARA will produce risk reduction measures that, both prevent incidents, by reducing the

probability of occurrence, and mitigate chronic and acute effects by reducing theconsequences4.1.1. Assessing the Risks:

Assessing risk involves considering how likely it is that each hazard could cause harm, by

considering the threats which may lead to the release of the hazard, what the consequencescould be, and, in some cases, the potential for the event to escalate.

The extent of any risk assessment will depend on the nature of the risks, the complexityassociated with the activity, and on whether the risks are well understood. The ARA in the

workplace can be as basic as deciding how to go about doing a task safely for simpleroutine jobs.In house Risk Assessment Matrix (RAM), which is based on the hazards identified during

audits, inspections, reviews, accident/incident investigations, as a tool to help categorisethe extent of a risk, based on its consequences and the probability of the potential

consequence occurring is in use (see Appendix A).




_______________________________________________________________________________________________


4.1.2. Controlling the Risks:

Controlling risk involves eliminating the hazard wherever possible, or applying measuresto prevent the hazardous event and/ or the harm from happening.

In all cases, the extent of any risk assessment and the controls arising from it should be proportionate to the risks. The higher the risk, the greater the degree of control required

and the more senior the management level required to approve the activity.Figure 2 below illustrates that, as the risk increases, the necessary level of control for theactivity can be achieved by adding controls or by strengthening existing ones.

- Degr ee of Cont r ol versus I ni ti al Ri sk

All jobs rely on the competence and skills of the individuals involved in doing the job. Forlow risk activities, this may provide sufficient control so no documented risk assessment

and no additional controls may be needed.As the risk increases, a documented risk assessment is required and the competency andskills may need to be strengthened and/ or a procedure implemented.

At higher levels of risk, Permit to Work Controls will be required. Ultimately, for thehigher level of risk senior management’s authority will be necessary to authorise/regulate

and to control such activity.

4.1.3. Performing an ARA for previously assessed activities

Most activities that are undertaken are not new, they are routine, or common tasks thathave previously been risk assessed and/or are covered by existing procedures. They have

probably been developed through established good practice and with due consideration for

the hazards that may be present.Such activities do not need a new risk assessment each time they are carried out, but dorequire that the assessment is subject to periodic review, primarily to identify if anything

has changed that would affect the outcome of the assessment.Some questions, which should be asked, are, for example:

q Have the persons doing the activi ty changed and are any new persons competent?

q Have new hazards been i ntr oduced?

q Ar e new tools being used or new procedures intr oduced?

Assessment

Ri skAssessment Management

Authori t

Ri skAwar eness

Degr eesof

Contro

LOW MEDIUM

aut hor i t y arerequi red as t he r i sk

i ncreases

HIGH

Ri skAssessment Permit to Work

Initial Ri sk




_______________________________________________________________________________________________


If new controls are identified then the ARA should be updated and the date of the reviewshould be recorded.

4.1.4. Performing a New Activity Risk Assessment

This section describes the steps required to perform a risk assessment for an activity, or

combination of concurrent activities, that have not been previously assessed. This processshould also be used if a previously assessed routine or common task has been reviewedand the risk assessment found to be not appropriate for the particular job.

When a new risk assessment is performed, all hazards and threats should be identified andthe risk assessed such that controls can be identified to reduce the risk to ALARP. If therisk cannot be reduced to ALARP, the activity should be redefined or not undertaken

Fi gure 3 - Act i vi ty Ri sk Assessment Pr ocess

IDENTIFY AND FORM ARA TEAM

IDENTIFY HAZARDS

INDENTIFY INITIAL RISK

IDENTIFY CONTROLS & RECOVERY

MEASURES

REVIEW RESIDUAL RISK

DOCUMENT AND RECORD

Stage 1

Stage 2

Stage 3

Stage 4

Stage 5

St age 6

Does the Team agree that

Controls are adequateand Residual Risk

ALARP?

YES

PERFORM NEW ARA Any task not previously performed or assessed or

reassessment o a task

NO




_______________________________________________________________________________________________


Figure 3 above sets out the main stages of this ARA process. These stages are described in moredetail in the remainder of this section.

Stage 1: I denti fy and form the ARA Team.The ARA is normally conducted within the Department responsible for doing the activity and

should include personnel who are:q Responsible for the task;

q Competent to conduct an ARA;q Have sufficient knowledge, expertise and competence in the activity to be performed to have

an understanding of the hazards it presents;

q Knowledgeable about the location, and the hazards that are present;q Will be involved in carrying out the task.

Where appropriate, the team should visit the worksite. The activity can be broken down into anumber of smaller activities where it is considered necessary.

Stage 2 : I denti fy the Hazards and Ef fects .

Each task is to be studied to identify the hazards, hazardous events and potential incidents whetherthey arise from the actions/inactions of people or from the conditions surrounding the activity.The assessment should identify who or what might be harmed and the findings recorded.

Stage 3. : I dentif ying Risk r atings for I ni tial Ri sks.

Risk rating is a means whereby the risks associated with a particular hazard or hazardous activitycan be expressed as a value and compared with acceptable limits.

The initial risk rating should be assessed on the situation that prevails before any controls areimplemented for each hazard. The Risk Assessment Matrix (see Appendix C) should be used to

calculate risk ratings.

Stage 4.: I denti fy Control and Recovery M easures.

Taking each hazard in turn, the ARA team should develop ways to either, eliminate the hazard or

provide appropriate control and recovery measures to mitigate them.In practice, a mixture of different controls often produces effective control, e.g. engineeringcontrols, personal protective equipment and procedures.

Stage 5 : Review Residual Risks.

The residual risk is any risk that remains after all the control measures are applied. The RiskAssessment Matrix (RAM)should again be used and the results entered in the ARA Worksheet.The residual risk should be ALARP.

Stage 6 Document and Record.

The ARA should be recorded using the ARA Worksheet. A copy of the ARA Worksheet isincluded in the Appendices (see Appendix B). An annotated version of the ARA is also providedin Appendix C, which provides guidance on its completion.The ARA Worksheet can be used to:

• Communicate the outcome and actions to those responsible for implementing the controlmeasures and performing the activity;

• Ensure the information is available to others who may have to perform the activity.




_______________________________________________________________________________________________


4.1.5. Activities covered by Individuals Competence

It is recognized that some low risk activities are adequately covered by the competence and skills

of the individual. Therefore, where a formal risk assessment would not produce any significantfindings it is not necessary to formally record the risk assessment.

4.1.6. Responsibility for ARA process

The Resident Construction Managers are responsible in their respective areas for the ARA process described above. In addition, for certain activities, they are personally responsible for

approving the ARA for activities where there is a higher level of initial risk, such as, for example:

• Hot tapping on live hydrocarbon process streams and or as per client’s requirement

• Confined space entry in oxygen deficient or toxic atmospheres

• Heavy lifting operations above 50 MT

5. PROCEDURE

5.1. Hazard Identification shall be conducted through careful examination of the actual job task. It shall identify all possible hazards encountered in performing the task.

5.2. The identification of hazards and subsequent Risk Assessment for all generalconstruction activities are spelt out in Annexure-1. This task was carried out by

involving all concerned individuals who are aware of the work process and aremost familiar with the actual and potential hazards.

5.3. At the time of a new site opening this process will be reviewed and updated (if

necessary). All concerned will be involved and HSE Capability Centre shall co-ordinate this activity.

5.4. Any job / task change or any process changes which may impact health or safetyissues must be reviewed by Safety Engineer, Safety Co-ordinator, or his designated

substitute.5.5. Should an injury/accident occur while performing a job task, it shall be reported as

per chapter no. OHS-06 and the Risk Assessment shall be reviewed and modified to

reflect any additional safety precautions and/or PPE required for performing jobsafely.

5.6. The result of Risk Assessment process will conclude whether the risk is Acceptable

or Unacceptable.5.7. It is to be noted that any activity, which leads to fatality or serious injuries are

considered as non- tolerable.5.8. The identification of all OH & S hazards and Risk Assessment of all routine and

non-routine activities are reviewed and updated as and when necessary by the HSE

Capability Centre at Central Office. The report will indicate the control measuresrequired to be implemented.

5.9. Also Hazard Identification and Risk Assessment process will be repeated as andwhen any new activity take place, before they are put in practice.




_______________________________________________________________________________________________


Annexure-1

Sr.

No.

Activity / Hazard Risk

Assessment

Result

Control Measures Acceptable /

Unacceptable

(After

Application of

Control

Measures)

01 Material handling (Crane

operations)

• Fall of Object

• Striking against any object

• Fall of person

• Exposure to or contact with

energised circuit

• Exposure to high noise

level

• Collapse of

structure/building etc

• Overturning

Unacceptable 1) Operation and Maintenance

Procedures for Cranes and other

material handling equipment to

be followed.

2) Trained person to be engaged

on the job.

3) Personal Protective Equipment

such as Safety Shoes and

helmets etc. to be used.

4) Good Housekeeping to be

followed.

5) Safe disposal of such material.

6) Carry out Inspection of all

lifting tools and tackles by

competent person.

Acceptable

02 Working at heights (Working

on scaffolding, beams at high

elevations etc.)

• Fall of Object

• Fall from height

• Struck by or strike against

any object


energised circuit

Unacceptable 1) Follow Work permit system

2) Procedure for safe working at

height including scaffolding,

formwork etc.


on the job.

4) Personal Protective Equipment

such as Helmets and Safety

Harness are to be used.

Acceptable

03 Excavation work


energised circuit


any object

• Collapse of walls/Cave in

• Exposure to oxygen

depleted area


level

• Step on Object

• Fire

• Exposure to dust

Unacceptable 1) Follow work permit system.

2) Procedure for checking

fumes/toxic substances/earthing

3) Sloping or shoring

4) Barricading Indicators

5) Safety against live underground

cables/pipes

6) Training of personnel

Acceptable

04 Electrical Work


energised circuit

• Fall of objects



any object

Unacceptable 1) Follow Procedures/Work permit

system.

2) Safety measures such as fuse

trips, relays, and insulation of

cables, ELCB, maintenance and

checking of electrical

equipment prior to use.

3) Training of personnel.

4) Use of Personal Protective

Equipment

Acceptable




_______________________________________________________________________________________________


Sr.

No.


Assessment

Result


Unacceptable

(After

Application

of Control

Measures)05 Non-Destructive Test

(Radiography)

• Exposure to X-rays and

Gamma rays


• Strike against or struck by any

object

Unacceptable 1) Engaging trained & authorised

personnel.

2) Follow work permit

system/safety procedures for

radiography work at site.

3) Safe handling procedure for

storage & transport of the

radioactive source

4) Cordoning work area

5) Awareness training

Acceptable

06 Handling of chemicals and other

toxic substances (Boiler blowout,

chemical cleaning, Pickling, passivation etc.)• Exposure to or contact with

Chemicals

• Fire


object

• Fall of container during handling

Unacceptable 1) Procedure for safe handling and

storage of chemicals.

2) Follow Instructions on Storageand Handling given in Material

Safety Data Sheets.

3) Use Personal Protective

Equipment.

4) Awareness training program.

Acceptable

07. Handling and storage of Industrial

gas cylinders• Fall of object during handling

cylinder

• Strike against any object

• Exposure to or contact withenergised circuit

• Exposure to or contact with heat

(Atmospheric or Environment)

• Fire and Explosion

Unacceptable 1) Safe working procedures

2) Mechanical / Manual handling


on the job.

Acceptable

08 Hot Work

(Welding &Cutting)


• Fall of person

• Exposure to or contact withenergised circuit

• Exposure to or contact with hotsubstance or object

Unacceptable 1) Follow work permit system

2) Provide adequate ventilation.

3) Use Hand Gloves, Welding

goggles welders nose mask,

face shield etc.

4) Use of good quality/safe

welding consumables which do

not emit toxic fumes

5) Follow Safe handling and

storage procedures for gas

cylinders

6) Training of personnel

Acceptable

09. Insulation work

• Fall of object during handling


object


energised circuit


• Fire

• Exposure to dust inhalation.

Unacceptable 1) Follow permit to work system


Equipment to prevent injuries.

Acceptable




_______________________________________________________________________________________________


Sr.

No.


Assessment

Result


Unacceptable

(After

Application of

Control

Measures)10. Hazards from plant &

equipment during assembly,

commissioning, modification,

repair and dismantling• Strike against or struck by any

object

• Fall of person



• Exposure to or contact withChemicals/gas/dust

Unacceptable 1) Follow L&T and/or

vender’s/licenser’s procedure

for assembly maintenance/

commissioning/ repairs etc.

2) Use of appropriate PPE

Acceptable

11. Hydraulic testing• Rupture of gaskets/vessels/

pipes etc


• Fall of person

• Caught in between any part of

machinery

Unacceptable 1) Follow Safety procedures.

2) Follow work permit system.

3) Use of PPE like handgloves,

Safety goggles, face shield,

Safety helmets etc.

Acceptable

12. Machinery Related Hazards

• Caught in between anymoving/stationary parts

• Strike against or struck by anyobject

• Noise

Unacceptable 1) Follow work permit system.

2) Safety devices/safety

interlocks in moving

machinery.3) Personal Protective

Equipment.

4) Maintenance of Machinery.

Acceptable

13. Painting/Shot blasting• Exposure to dust

• Noise

• Exposure to chemicals


• Fire

• Exposure to or contact withelectrical current

Acceptable 1) Follow works permit system.

2) Use appropriate Personal

Protective Equipment.

3) Follow Safe operating

procedure

Acceptable

14. Confined space working

(Breathlessness, gases)• Exposure to oxygen depleted

area


electrical current

• Exposure to chemicals

• Exposure to explosive gases.


2) Safe working procedures.3) Use of appropriate PPE such as

Self Contained Breathing

Apparatus, Airline Breathing

Apparatus.

4) Training of Personnel

5) Gas Testing prior to entry

6) Ensure effective ventilation

Acceptable

15. Vibration related hazards (e.g.

Concreting with electrical

vibrators)• Vibration Induced white

finger

• Noise

Acceptable 1) Vibration dampening

mechanisms

2) Alternate methods of working

Acceptable




_______________________________________________________________________________________________


Sr.

No.


Assessment

Result


Unacceptable

(After

Application of

Control

Measures)16. Use of non-potable water and

eating in unhygienic conditions

• Poisoning

Acceptable 1) Provision of potable water and

allocation of safe and clean

place to eat in the site.

Acceptable

17. Moving Vehicles & travel by

road

• Collision

Unacceptable 1) Procedures for traffic

regulation and control.

2) Training of personnel.

3) Procedure for vehicle

inspection

Acceptable

18. Hazards from stray substances

such as nails, packing materials,

corroded rods etc.

• Step on object• Strike against or struck by

any object

Acceptable 1) Good Housekeeping.

2) Safe disposal procedure of

such material.

Acceptable

19. Noise Acceptable 1) Use of remote areas.

2) Isolation of Noise source


Equipment e.g. earmuffs.

Acceptable

20. Use of Compressed air for

various processes

• Exposure to high pressure

air


2) Follow safety procedures.

Acceptable

21. Tripping Hazards

• Struck by or strike againstany object

• Step on object

Acceptable 1. Follow Good Housekeeping.

2. Safe disposal of such material

Acceptable

22. Blasting

• Explosion


Unacceptable 1. Follow safe storage &

handling procedure of blasting

materials.

2. Competent person to

supervise.

3. Follow precautionary

measures.

Acceptable

23. Emergency preparedness

• Earthquake

• Floods

• Cyclones

• Fire, Explosion

• Toxic release

Unacceptable 1. Adequate procedures to

eliminate/mitigate related

hazards due to these natural,

man-made calamities.

Acceptable

24.Snake Bite

• Poisoning by venom

• Collapse of victim

• Infection through blood

Unacceptable 1. Keeping the area clear of tall

grasses.

2. Spraying chemicals to prevent

Snakes.

3. Anti-venom shall be kept in

First Aid box.

Acceptable

25. Dog Bite

• Infected by Rabbies

• Cut Wounds

Unacceptable 1. Keeping the site clear of Stray

Dogs.

2. Training the First Aid

personnel.

Acceptable




_______________________________________________________________________________________________


Sr.

No.


Assessment

Result


Unacceptable

(After

Application of

Control

Measures)

26. Piling• Fall of packing wood

while handling.

• Hit by

• Moving/Rotating parts

• Electrocution

Unacceptable 1. Only experienced riggershall be engaged for work.

2. Proper work area shall be

prepared with handrails.

3. Horse play shall be avoided

4. Proper signaling to be

practiced.

5. Wire ropes shall be

inspected.

6. Power cables should be

connected to ELCB.

7. Proper lighting arrangements

to be given during night

Operations.

Acceptable

27. Loose Soil Around Foundations

• Fall of person

• Sliding of earth in the

excavation

• Foot getting immersed in

the soil.

Unacceptable 1. Visual inspection of the soil

for cracks .

2. Barrication of the area.

3. Providing proper walk over

for crossing the area.

Acceptable

28. Pre-commissioning

• Strike against or struck by

any object

• Fall of person


• Fall of object duringhandling


Chemical/ Gas/

Dust.

Unacceptable 1. Follow L&T and/ or

vendor’s / licenser’s

procedure for

assembly/maintenance / Pre-

commissioning/Repairs etc

2. First Aid Fire Fighting

Equipment like Fire

Extinguishers to be kept in

critical locations such as near

flammable material handling

pipe lines and their gate

valves.

3. Effective use of appropriate

PPE.

Acceptable

29. Storage of materials in stores

• Fall of person/objects

• Strike against or struck by

an object.

• Exposure or contact withsolvents/ chemicals

Acceptable 1. Follow good housekeeping

in the storage area.

2. Stacking height of materials

in the store to be maintained

at 1.5M. Any stack height

greater than 1.5M shall be

properly secured.

3. Proper labeling of chemicals

to be carried out.

4. Appropriate PPE to be used

while handling chemicals.

Acceptable

30. Use of Solvents/Thinners

• Poisoning

• Absorption by skin causing

skin cancer in case of

Carcinogens like Benzene.

• Fire hazard

• Health hazard (vapour)

Unacceptable 1. Effective use of appropriate

PPE.

2. Keeping solvents away from

Hot Work area.

3. Using canisters to prevent

vapours from entering into

human system.

Acceptable




_______________________________________________________________________________________________


Sr.

No.


Assessment

Result


Unacceptable

(After

Application of

Control

Measures)

31. Spread of Malaria• Infection of blood

• Person becomes weak

• Death if proper, timely

medical care is not

provided.

Unacceptable 1. Stagnation of sewage waternot to be allowed in the site.

2. Spraying of chemicals to

keep away mosquitoes and to

kill it’s larvae.

3. Ensuring proper medical care

for the infected victim.

4. Medical Awareness

regarding Malaria to

workmen.

5. Providing Mosquito curtains

in living quarters.

Acceptable

32. Workmen sleeping below

truck/besides pipes• Struck by materials

• Fall of person/material

• Pressed between objects.

Unacceptable 1. Awareness through Pep talks

and Tool Box Meetings2. Visual inspection of work

place to prevent workmen

from sleeping in such work

area.

3. Checking underneath the

vehicle before starting it by

the driver.

Acceptable

33. Domestic and Industrial Waste

Disposal

• Spread of Diseases

• Pollution of water

resources

• Unhygienic conditions at

site

• Low morale in the work

place

Unacceptable 1. Industrial and domestic

wastes shall be disposed off

in well-defined places away

from site.

2. Water sources for drinking

purpose to be covered orisolated to prevent being

polluted by waste.

3. Periodical cleaning of

workplace and the proper

disposal of waste to be

carried out.

Acceptable

34. Stress at work place

• Head ache

• Low morale

• Psychological problems

Acceptable 1. Identifying proper rest

periods for workmen.

2. Congenial atmosphere for

work to be provided.

3. Well defined working hours

Acceptable

35. Portable Hand Tools• Pressed in between

• Cut by grinding wheels

• Electrocution

Unacceptable 1. Proper guards to be providedfor portable machines like

grinding machines.

2. Experienced personnel

should operate the machine.

3. Proper Earthing shall be

provided for portable

machines.

4. Power shall be withdrawn

through ELCB.

Acceptable

36. Admixtures, Accelerators,

retardant usage in concrete

• Damage to exposed skin

Acceptable 1. Effective usage of

appropriate PPE like Hand

gloves and Gum boots to be

done.

Acceptable




_________________________________________________________________________________________________________________________________________________


APPENDIX A

Risk Assessment Matrix

POTENTIAL CONSEQUENCES PROBABILITY

RATING Harm toPeople

Losses or Damage toProperty

Effect onEnvironment

Impact onReputation

Has

occurred inworldwide

Industriesbut not inL&T

Has

occurred inanother L&T

groupcompany

Has

occurredin L&T

Occurs

severaltimes per

year inL&T

D

Occurs

several timesper year in the

same locationor operation

E

1Slight Injuryor HealthEffects

Slight DamageCost < USD 5,000

SlightEffect

SlightImpact

2Minor Injury

or HealthEffects

Minor Damage

Cost < USD 50,000 And > USD 5,000

Minor

Effect

Minor

Impact

3Major Injuryor Health

Effects

Local DamageCost < USD 200,000

And > USD 50,000

LocalisedEffect

Considerable Impact

4

SingleFatality orPermanent

TotalDisability

Major DamageCost < USD 500,000

And > USD 200,000

MajorEffect

MajorImpact

5

MultipleFatalities or

PermanentTotalDisabilities

Extensive DamageCost < USD

10,00,000 and >USD 500,000

MassiveEffect

CatostrophicImpact

A C

LowRisk

Medium Risk

B

ALARP

High Risk




_______________________________________________________________________________________________


LOW

MEDIUM

6. How to Use Risk Assessment Matrix (RAM)

1. Assess the POTENTIAL CONSEQUENCES of the hazard for the each of the four

catagories (People, Property, Environment and Reputation) 2. Assess the PROBABILITY of these POTENTIAL CONSEQUENCES occuring for

each of these four catagories (People, Property, Environment and Reputation)

3. Classify the risk on the matrix for each of the four catagories (People, Property,

Environment and Reputation) from the intersection of chosen row (POTENTIAL

CONSEQUENCES) with the chosen coloumn (PROBABILITY)

4. In order to document the risk classification first record the PROBABILITY (A-E) then

the POTENTIAL CONSEQUENCES (1-5) and finally the category to which the

classification applies (People = P; Asset =A; Environment = E; Reputation =R ) for

example C3P.

5. Based on the risk classification identify and implement appropriate remedial actions for

each of the four categories (People, Property, Environment and Reputation) as

indicated below

Risk = Manage for continuous Improvement

Risk = Demonstrate that the risk is at a level that is ASLOW AS REASONABLY PRACTICABLE (ALARP )

Risk = Take action to reduce risk to a leve l that is AS LOW

AS REASONABLY PRACTICABLE (ALARP)

7. Records:

Form Reference

Activity Risk Assessment Worksheet OHS - 13

HIGH




___________________________________________________________________________________________________________________________________________________

Rev – 02 Page 16 of17 10 October 2007

Appendix B

Ref. No: ACTIVITY RISK ASSESSMENT WORKSHEETDate:

Work Activity: Location: Assessment Team Approved by:

Position:

TASK HAZARDINITIAL

RISK

CONTROLS RESIDUAL RISK

StepNo:

Descriptionof Task

Step

Hazard Description & Effect Who orWhat

might beHarmed?

C o n s e q u e n c e

P r o b a b i l i t y

R i s k

R a t i n g

Controls Measures and/or RecoveryMeasures



R i s k

R a t i n g

ResidualRisk

Level

Low

Med ium

High




___________________________________________________________________________________________________________________________________________________

Rev – 02 Page 17 of17 10 October 2007

Appendix C

Ref. No: ACTIVITY RISK ASSESSMENT WORKSHEETDate:

Work Activity: Location: Assessment Team Approved by:

Position:

TASK HAZARDINITIAL

RISK

CONTROLS RESIDUAL RISK

StepNo:

Descriptionof Task

Step

Hazard Description & Effect Who orWhat

might beHarmed?



R i s k

R a t i n g

Controls Measures and/or RecoveryMeasures



R i s k

R a t i n g

ResidualRisk

Level

Low

Med ium

High

i nt o i ndi vi dual t asks and

r ecor d i n st ep sequence

Descri be al l hazardsi dent i f i ed and thei reff ect s for each t ask.

Addi ti onal

hazar ds may be causedby i nteract i on wi th ot herwork

Li st what mi ght beaff ected, i . e. People;Asset s; Envi ronment ;Re ut at i on

From* RAM, i denti fyt he potent i alconsequence wi t houtcont rols in pl ace foreach hazard

From* RAM, i dent i fy

the probabi l i t y, wi thoutcont rols in pl ace, f oreach hazar d

Cl assi fy r i sk rati ngf rom * RAM for

each hazar d

Descri be fully all controls applicable for eachhazard, e.g. if PPE is used as a control, it must be specifically descr i bed.

If a control can only be verified bydocumentation then it must be available.

All controls must be valid in that they reduceconsequence, probability or both.

From * RAM, i denti fy

the potent i alconsequence wi t hcontr ols i n pl ace foreach hazard

From*RAM, i dent i fy

the probabi l i t y, wi thcont rols in pl ace, f oreach hazard

Cl assi fy ri skrati ng fr om *RAM

f or each hazard

* Fr omtheRAM, recordt he overal l band f or t heresi dual ri sk, i . e. Low.Med iumor High




_______________________________________________________________________________________________

Rev – 02 Page 1 of 1 10 Dec 2007

CHAPTER – 14

SAFETY TOOL - BOX TALK (TBT)

1.0 Purpose

(i) To create OH&S awareness amongst personnel engaged in construction, andenhance knowledge about hazards and the methods for elimination / minimisationin construction activities. This awareness is essential to take adequate precaution,

make use of required PPE and safety devices, and protect themselves and othersfrom the outcome of the anticipated risks.

2.0 Definitions

Tool Box Talks: - It is a talk imparted by a site engineer/ supervisor to theirworkforce, every day in the morning or before activities start as well as in location where

construction activity likely to start, about the hazards and precautionary measures shalltaken to perform the task given to them in a safe manner.

3.0 Procedure

This chapter deals with the various aspects of conducting Safety TBT at sites.Steps to be taken by RCM to implement this are as follows:(i) RCM shall ensure that -

a. SSO/E along with Site Engineer/Supervisor conducts TBT’s every day in themorning, before activities in the areas start as well as in location whereconstruction activity is likely to start.

b. Each TBT shall be for duration of about 10-15 minutes and shall be directlyaddressed to workmen in a language they understand.

(ii) SSO/E shall maintain records as per Annexure – OHS – 14 or suitable form at sitefollowed by sub-contractors / client.

(iii) SSO/E shall ensure that the concerned Supervisors or Engineer/s of workmen

attending the TBT’s are present when TBT’s are conducted.(iv) In order to make TBT’s more effective and meaningful, SSO/ Site Engineer shall

get to know the nature of activities on which he plans to conduct TBT, on the previous day, so that he can tailor TBTs to suit the exact site conditions andhazards.

(v) SSO/E / Site Engineer will refer “Tool Box Talks” guidelines handbook foreffectively imparting TBTs at site.

4.0 Administration

(i) SE from HSE Capability Centre shall check up-to-date records of TBTs conducted by SSO / Site Engineer / Supervisor at the site and communicate his observations in

the visit report.(ii) SE shall also interact with SSO/E, during the site visit, on additional TBTs, which

need to be included in the safety guidelines.

5.0 Records –

Forms Reference

Safety Tool Box Talks OHS –14




_______________________________________________________________________________________________

Rev – 02 Page 1 of 5 10 Dec 2007

CHAPTER – 15

WORK PERMIT SYSTEM

1.0 Purpose (i) Work Permit Systems are designed and intended to specify adequate safety

measures in advance against identified hazards and stipulate implementation of the

said safety measures by the permittee to ensure safe execution of work in thedesignated workplace.

(ii) The commitment to follow safety instructions, in writing, is obtained through‘Permit System’, which has to commence from the day the first constructionactivity starts at site until the last activity. ‘Permit System’ is followed in case of

those activities where there are higher potential risks and hazards. These generallyare:

- Radiography work- Cold work- Hot work

- Entry into Confined Space- Working on Electrical Lines / Equipment

- Height Work

The corresponding model formats are:

- Radiography work permit for NDT (OHSR) - Cold work permit (OHSC)

- Hot work permit (OHSH)

- Permit for entry into confined space (OHSCS) - Permit for working on electrical lines/ equipment (OHSE)

- Permit for Height Work (OHSHW)

2.0 Definitions - None

3.0 Procedure

(i) This chapter lays down steps to be taken by RCM / RCE before and during theabove mentioned activities at construction site.

There are five different ‘Permit’ forms, each deals with various activities mentionedin Annexure-1. Each form has certain standard instructions and space for writing

special instructions by RCM / RCE, related to the activity and site situation. Theseinstructions have to be clearly understood by the workers, Manager/ Engineer/Supervisor and ensured that they are followed by the persons actually carrying out

the concerned activity. The forms, therefore, require signatures of concernedresponsible persons, implying their commitment to the instructions. The forms alsorequire communication regarding completion of the ‘permitted’ activities. After a

form is returned stating completion of an activity, the same can not be carried outagain unless the permit is renewed. The permit can be renewed for maximum 7

days only or SSO/E guidelines.(ii) In cases where client prescribes “Work Permit System”, that system shall be

followed.




_______________________________________________________________________________________________

Rev – 02 Page 2 of 5 10 Dec 2007

4.0 Administration

RCM shall ensure that this procedure is followed as outlined below:

(i) RCM shall inform all contractors about the permit system and advise them inwriting (by letters and notices) that permits are required to carry out the above

mentioned five activities.(ii) Contractors shall be advised to apply for permits for the concerned activity at least 2hours before it starts (4 hours, in case of radiography).

(iii) RCM shall issue the requisite permit form noting down special instructions, if any,to the contractor’s supervisor, who will sign on the form as the ‘Initiator’.

(iv) To carry out any of the above mentioned activities, contractor supervisor/ L&Tfield engineer has to fill up the requisite permit.

(v) After the site and persons are ready as per the instructions on the form, L&T Site

Engineer / Supervisor shall inspect the work-site , persons and mark the check points as per the requisite form and if instructions/ check points are fully

complied, the contractor’s supervisor, RCM , L&T Engineer and SSO/E shall sign

the form to permit the activity for the period and date mentioned on the form.(vi) During the progress of the activity/ work permitted, the contractor’s and RCM ’s

designated Engineer/ Supervisor shall ensure that there are no deviations from theinstructions. RCM , SSO/E or any Supervisor and Engineer can stop work and

cancel the permit immediately by stating the reason and signing the permit, if theyfind any deviations during the progress of work. The same activity can be carriedout again by obtaining a fresh permit from SSO/Site Engineer.

(vii) When the activity / work is completed or the period / date stipulated on the form haslapsed, RCM shall ensure that the contractor’ s supervisor returns the form (duly

signed) to RCM who shall file it chronologically for future reference.(viii) Permit shall only be renewed if the work - site conditions, activity and persons

involved are same.(ix) Fresh permit shall be issued if the activity has to be continued after completion of

the period, if the work-site is different, on a new day or if the work-site conditions

change.(x) Contractors’ Supervisors shall be advised by RCM to keep one copy of the permit

with them as long as activity/work is in progress and it may be demanded by any

L&T person as a proof for authorisation of the work in progress.(xi) HSE Capability Centre will send softcopy of each form to all new and on going

sites, before the effective date of this Procedure. However same can be obtainedfrom intranet or from this manual.

(xii) RCM shall ensure that under no normal circumstances, the said five activities /

work shall be carried out by contractors without a valid permit.(xiii) RCM shall inform HSE Capability Centre, if there is a need for an additional

‘permit’ for activities which are not covered in this ‘Permit System’ and which inthe opinion of RCM , require a permit.

(xiv) SE/Auditors from Powai will inspect/audit this aspect when they visit the site.




_______________________________________________________________________________________________

Rev – 02 Page 3 of 5 10 Dec 2007

FLOW CHART FOR WORK PERMIT PROCEDURE

PERMIT CLOSED

Initiator collects permit

format from RCM

Fill up the check points and discuss with the concerned L&T Engineer

“ Contractor Supervisor - Initiator”

seeks approval of concerned L&T Engineerfor the job he intends to carry out

Carries out preparation as per the check points and the instruction of the

L&T Engineer

L&T Engineer verifies the

preparation

Found

OK?Initiator rectifies

the condition

Initiator & L&T Engineer

signs the permit

Site Safety Officer fills the details of other works permit issued during

the shift and rechecks the whole preparation under safe practices , signs

and briefs all concerned of the hazards

RCM approves and sign

the permit

Initiator starts the job

On completion of the job, make sure that

everything is safe and sign the permit

L&T Engineer, SSO and RCM signs the

permit, record and file the permit

Yes

No




_______________________________________________________________________________________________

Rev – 02 Page 4 of 5 10 Dec 2007

5.0 Records

Forms Reference

Radiography work permit for NDT (OHSR) OHS – 15 A

Cold work permit (OHSC) OHS – 15 BHot work permit (OHSH) OHS – 15 CPermit for entry into confined space (OHSCS) OHS – 15 D

Permit for working on electrical lines/equipment (OHSE) OHS – 15 EPermit for Height Work (OHSHW) OHS – 15 F




_______________________________________________________________________________________________

Rev – 02 Page 5 of 5 10 Dec 2007

Annexure – 1

Table for ready reference:

Activity/ Applicable Permit

Type of work OHSR OHSC OHSH OHSCS OHSE OHSHW

Radiography/ N. D. T. √

Working at height √

Working in pit/ vessel √

Shot blasting √

Welding/ gas cutting √

Drilling/ grinding√

Operating diesel engine √

Working on electrical

equipment

√ √

Operating pneumatic

tools

√

Hydraulic/ Pneumatic

testing

√

Manual sand removal √

Tightening/opening of

flanges during

commissioning

√

Spray painting √

Manual painting √

Working on lifting tools/

tackles including cranes √

Excavation (below 1.5m) √

Trenches/ Narrowexcavation

For Manual Excavation

(Depth > Width),

Width < 15ft / 4.6m

√

√

Note:

* Some times more than one permit is required. e.g. While doing grinding work/gas-

cutting/welding in confined space requires ‘Hot Work Permit’ as well as ‘Permit for Entryinto Confined Space’.




_______________________________________________________________________________________________

Rev – 02 Page 1 of 3 10 June 2007

CHAPTER - 16

INSPECTION OF LIFTINGAPPLIANCES, GEARS AND RELATED VESSELS

1.0 Purpose(i) To ensure safe operation use of lifting appliances, gear and pressure vessels.(ii) To comply with statutory requirements under the law of the land.

(iii) To establish unique identification System of each & every lifting tools & tackles being used at site. This identification system shall ensure proper maintenance of the

items & their periodic inspection & load testing.

2.0 Definitions

(i) Competent Person: - A person or an institution recognised as such by the chiefinspector for the purpose of carrying out tests, examinations and inspections

required to be done. (Source: The Factory Act 1948).(ii) Lifting Appliance: - means a crane, hoist, derrick, winch, gin pole, shear legs, jack,

pulley block or other equipment used for lifting materials, objects or building

worker. (Source: The Building and Other Construction Workers (Regulation of Employment and Conditions of Service) Central Rules, 1998).

(iii) Lifting Gear:- means ropes, chains, hooks, slings and other accessories of a “Lifting

Appliance”. (Source: The Building and Other Construction Workers (Regulation of Employment and Conditions of Service) Central Rules, 1998).

(iv) Pressure Vessel: - means a vessel having pressure more than atmospheric pressure. (Source: The Factory Act 1948).

3.0 Procedure:

(i) All lifting appliances, lifting gears and air vessels attached to air compressorsshould have valid test certificates, copies of which to be submitted to SSO / RCM.

(ii) All cranes, chain pulley blocks, wire ropes, chain slings, Dee/Bow shackles, plate

clamps etc. will be inspected and certified by the “competent person” defined underthe law of the land. The valid test certificate of the all tackles and machines shall be

available with RCM or his designated nominee.(iii) Any defect observed in cranes shall be reported to RCM / SSO. Such defective

cranes shall not be used unless repaired and Re-certified by Competent person.

(iv) Any defect observed in lifting tools and tackles shall be reported to RCM / SSO.Such defective tools and tackles shall be rejected. Those lifting tackles shall be cut

in pieces and scrapped.




_______________________________________________________________________________________________

Rev – 02 Page 2 of 3 10 June 2007

(v) Identification of Lifting Tools & Tackles:

(a) Each item shall be identified by a unique identification number as below.

X X X X X

Serial No. 0 to 99

Identification of Item (Sling, D-Shackle, Chain Pulley block)

Identification: Contractors Code.

Example: 1W10

1: Contractor Name: L&T

W: Item D-Shackle

10: Serial no of item.

(a) The identification number shall be either punched on to it or tagged with suitable metal

tags.(b) Inspection & load test details shall be recorded for each item with respect to its

identification number (OHS-16/Jun07).

(c) The inspection & load test record shall have correlation with its items.

(d) The periodicity of inspection & load testing shall be as below:

Sl.

No.Method Periodicity Performing authority Remarks

1Physical

inspection

Every 3 months

& before every use

Responsible person

(P&M Dept.)

2 Load test Once in a YEARCompetent Person

(Third Party)

(e) During inspection & load test, if any item found not conforming to the specified

requirements, the item shall be marked by RED paint & shall be discarded.




_______________________________________________________________________________________________

Rev – 02 Page 3 of 3 10 June 2007

Appendix:

1. Identification of contractors shall be recorded as below:

Sl.No. Name of Contractor IdentificationCode Remarks

1

2

2. Identification of items shall be recorded as below:

Sl.

No.Item

Identification

CodeRemarks

1 D-Shackles W

2 Wire Rope Slings X

3 Chain Pulley Blocks Y4 Rope pulley Z

4.0 Administration(i) Concern contractors will arrange “Competent Person” for inspection / examination /

tests of their lifting appliances, gears and pressure vessels.

(ii) SSO/E will maintain copies of all the records of test certificates, examinationrecords of Lifting Tools, appliances and Pressure Vessels.

(iii) RCM will allot identification code to respective contractors.

5.0 Records –

Periodic Physical Inspection Record - OHS-16




________________________________________________________________________________________

Rev – 01 Page 1 of 1 02 Dec. 2004

CHAPTER - 17

INSPECTION OF PLANT & MACHINERY AND

EQUIPMENT INCLUDING VEHICLES

1.0 Purpose

(i) To ascertain effective functioning / provision of safety features of Plant &Machinery, equipment including vehicles.

2.0 Definition –(i) Plant or Equipment: includes any plant, equipment gear, machinery apparatus or

appliance, or any part thereof. (Source: The Building and Other ConstructionWorkers (Regulation of Employment and Conditions of Service) Central Rules,

1998).

3.0 Procedure(i) SSO/E periodically selects (at least once in a thirty days) Plant & machinery,Equipment and / or Vehicles for inspection in batches / area wise.

(ii) SSO/E informs the concerned contractor RCM of his inspection schedule verbally.(iii) SSO/E requests for involvement of the concerned L&T Supervisor/Engineer and /or

contractor person in the inspection exercise.

(iv) SSO/E carries the Plant & Machinery/ Equipment / Vehicle inspection checklist forhis general guidance.

(v) SSO/E highlights unsafe condition to the concerned contractor personaccompanying him on the spot for corrective action.

(vi) SSO/E records his findings in the Plant & Machinery/ Equipment / Vehicle Safety

Inspection report form and forwards the same to the concerned contractor RCMwith a copy to the L&T site in-charge / RCM.

1. Records

Forms / Guidelines Reference

Checklist for inspecting cranes OHSC – 17 A

Crane/Vehicle/ Earth moving equipment OHSC – 17 B

Inspection report

Checklist for inspecting vehicles & OHSC – 17 CEarth moving equipment




_______________________________________________________________________________________________

Rev – 01 Page 1 of 1 02nd

Dec.’ 2004

CHAPTER – 18

DISPLAY OF SAFETY PERFORMANCE

1.0 Purpose(i) To communicate Safety Performance to all persons working at L&T sites.(ii) The objective of this Chapter is to require all construction sites to display

information about the safety performance of their individual sites.

2.0 Definitions

(i) Lost Work Day Case (LWC)(ii) Minor Injury (MI)

(iii) Dangerous Incident/Occurrence (DI)

3.0 Procedure1.1. This procedure deals with the preparation, installation and updating of the Display-

Board giving up-do-date, correct and accurate information about safety performanceof the construction site, where the board is installed. The detailed information

pertaining to the board is as given in Annexure-1 or the contents may be as per

client guidelines.1.2. Location of the Board shall be such that it is visible to all persons working at the

site while they move around the site.1.3. Languages of safety information on the Board:

- English or Hindi

- Local language

4.0 Administration

(i) Within 15 days from the effective date of this Procedure RCM will get the Display

Board/s ready and have them installed at any of the suggested locations mentionedin 3.0 (ii) above.

(ii) Responsibility of operating/updating the Board shall be that of the SSO/E. IfSSO/E is not present at the site, then RCM or his designated person shall beresponsible for updating of the contents of the Board.

(iii) SSO/RCM shall update the information on the Board regularly.(iv) SE from HSE Capability Centre shall include, in his inspection, working of this

Procedure, during his site inspection/audit and check that the information matcheswith the one provided through Incident Reports sent to HSE Capability Centre bythe site RCM as per Procedure described under OHS-06.

5.0 Records- None

Please refer chapter –

06, Sub-clause 2.0




_______________________________________________________________________________________________

Rev – 02 Page 1 of 3 10th

Nov.’ 2007

CHAPTER – 19

HSE AUDIT AND INSPECTION

1.0 Purpose

HSE Audit:(i) To objectively evaluate whether HSE processes and procedures.

- conforms to planned arrangements to the requirements of the Corporate Manual

and this OH&S manual.- is effectively implemented and maintained.

- is effective in meeting Corporate Policy and OH&S objectives.

HSE Inspection:

(i) To ensure that the site complies with all the statutory requirements, codes andnorms and the OH&S Procedure s stipulated in this Manual.

(i) To identify Unsafe Conditions (UC) and / or Unsafe Acts (UA) which may lead toaccidents during the activities being undertaken during the execution of the job andalso to identify, suggest suitable remedial action/measures.

2.0 Definitions

(i) HSE Audit: A systematic, independent and documented process for obtaining “audit

evidence” and evaluating it objectively to determine the extent to which “auditcriteria” are fulfilled. (OHSAS 18001:2007)

(ii) HSE Inspection is a routine, scheduled inspection of a unit or Department which

may be carried out by personnel within the unit, possibly accompanied by someonefrom outside. The inspection would check maintenance standards, employeeinvolvement, working practices, and that work is carried out in accordance with

procedure etc., rather than the wide-reaching or in-depth approach taken in Audits

or Surveys.

3.0 Procedure

(I) HSE Audit

(i) HSE Audit shall be planned & carried out by MSC (Management System Cell) withscope, frequency and methods as per Corporate Manual.

(ii) The audit team shall be decided by Chief MSC & MR as per Annexure 1 of theCorporate Manual.

(iii) Audit Non conformities shall be reported by Management Systems Cell.

(iii) All non-conformities shall be attended within the agreed time frame between RCMand Auditor / Audit team.

(iv) Compliance Report on non-conformities along with evidence shall be sent to MSC.(v) Non-conformities Compliance Report on non-conformities shall be reviewed and

verified by MSC and closed by MR. Closing report shall be sent to RCM.




_______________________________________________________________________________________________


Nov.’ 2007

(II) HSE Inspection:

(A) By HSE Engineers of HSE Capability Centre: -(i) The HSE inspection shall be carried out by HSE Engineer from HSE Capability

Centre.

(ii) The frequency of the inspection shall be at least once in 6 months.(iii) The team will examine all HSE related activities performed at sites, like

quantifiable objectives and program, HIRA, legal compliance, inspections, HSEcommittee meetings, training, incident reporting and investigation, HSE

promotional activities, record keeping, etc.

(iv) Inspection observations shall be reported by HSE capability centre as per theInspection report format / template OHS – 19B.

(v) All observations shall be attended within the agreed time frame between RCM andinspection team and action taken along with evidence shall be communicated toHSE Capability Centre.

(vi) Inspection Compliance Report shall be reviewed and verified by HSE CapabilityCentre and closing report shall be sent to RCM with copy to BUH.

(B) By HSE Committee Member(s): -

(i) Site HSE committee members will carryout regular, scheduled, periodic HSE

Inspections.(ii) The frequency of such inspection shall be at least once in a month.

(iii) HSE Committee Members decide on the time and date to carryout such inspectionsas required preferably along with the RCM / Engineers / Supervisors.

(iv) HSE Committee Members conduct physical inspection of the workplaces using the

General HSE Inspection Checklist (OHSC – 19 B) & house keeping Inspection

Checklist (OHSC – 19 C) and also look for any other unspecified hazards.(v) Identifies all conformities and non- conformities in respect of physical conditions

and practices and specifies them with positive / negative remark on the checklist asthe case may be.

(vi) SSO/E shall consolidate and record all the observation in the OHS – 19B format.(vii) Circulates copy (duly signed by Chairman, Secretary and members of HSE

Committee) of the Site HSE Inspection Report (OHS – 19B) to RCM and theconcerned persons for initiating and completing necessary corrective actions.

(viii) Reviews and follows up implementation of the suggested HSE measures and

records his findings on the Site HSE Inspection Report Form (OHS-19B.)

(C) Site Safety Officer(i) Site Safety Officer along with the concerned site engineer/ In charges shall conduct

the regular HSE inspection of the critical on going activities at site like Height

Work, Scaffolding Safety, Electrical Safety, Fire Extinguishers Safety, ErectionSafety & Power Tool Safety, Radiography work.

(ii) Frequency shall be at least once in a month.(ix) Identifies all conformities and non- conformities in respect of physical conditions

and practices and specifies them with positive / negative remark on the checklist as

the case may be.(x) Circulates copy (duly signed by SSO/E) of the HSE Inspection Report to RCM and

the concerned responsible person for taking necessary corrective action.




_______________________________________________________________________________________________


Nov.’ 2007

(iii) Reviews and follows up implementation of the suggested HSE measures and

records his findings on the Site HSE Inspection Report Form-OHS-19B (iv) Also, whenever SSO finds any unsafe act/ unsafe condition at site, he will report

those observations to concerned person / supervisor / Engineer. (v) SSO will also maintain a daily log book / daily observation register to record the

findings on daily basis. This register will be reviewed and signed by RCM.

4.0 Records

Forms ReferenceHSE Inspection Checklist OHS – 19 ASite HSE Inspection Report OHS – 19 B

5.0 Checklists / Guidelines

Height Work Checklist OHSC – 19 AGeneral HSE Inspection Checklist OHSC – 19 B

Housekeeping Checklist OHSC – 19 CScaffolding Inspection checklist OHSC – 19 D

Electrical Safety Inspection Checklist OHSC – 19 EErection Safety Inspection Checklist OHSC – 19 FFire Extinguishers Inspection Checklist OHSC – 19 G

Power Tool Inspection Checklist OHSC – 19 HCrane Inspection Checklist OHSC – 19 I

Lifting Tools / Tackles Inspection Checklist OHSC – 19 JVehicle Inspection Checklist OHSC – 19 KHand tools Inspection Checklist OHSC – 19 L




_______________________________________________________________________________________________


Dec.’ 2004

CHAPTER - 20

TRAINING, AWARENESS AND COMPETENCE

1.0 Purpose

(i) To provide appropriate training to all employees including contract employees ofL&T to ensure effective implementation of OH&S requirements.

(ii) Applicability: -

a. Managers / Engineers of Contractors & Sub-contractors.

b. Supervisors / Site In-charge

c. Store keeper

d. General Administration staff.

2.0 Definition - None

3.0 Procedure

(i) The requisite training shall be imparted by the SSO/E / qualified SE from HSECapability Centre / MSC (Management Sys tems Cell) or by experts from outsideinstitutes/agencies.

(ii) Based on the requirements/needs, some of the personnel may be deputed to attendseminars/workshops conducted by professional organizations such as LPA, NSC,

NICMAR, LRQA, DNV, BVQI etc.

(iii) The training shall generally comprise of the following:a. General awareness and employees Roles and Responsibilities in achieving

conformance with the Corporate Policy, Objectives and targets.a. Relevant Occupational Health and Safety Rules & regulations.

b. Actual potential Hazards and Risks of their activities on Occupational Healthand Safety and methods for reducing the related risks.

c. Benefits to individuals and the society of improved Occupational Health and

Safety performance.d. Environment, Health and Safety Emergency preparedness and their response

requirement.e. Potential consequences of deviations from laid down OH&S Procedures.

(iv) General awareness training shall be imparted to the contractors’ workers and their

record will be maintained.(v) The content and provision of training shall take into account differing levels of:

a. Responsibility b. Literacyc. Magnitude of Risk




_______________________________________________________________________________________________


Dec.’ 2004

4.0 Administration

(i) RCM shall facilitate the smooth and effective conduct of site safety training and

arrange all necessary resources such as conference room facility, TV, VCP, DVDPlayer, Computer, Projector etc.

(ii) Training records shall be maintained by the HSE Capability Centre.

5.0 Records

Forms Reference

Attendance sheet OHS – 20 A

Feedback OHS – 20 B




_______________________________________________________________________________________________


June’ 2007

CHAPTER – 21

REPORTING OF HSE PERFORMANCE

1.0 Purpose(i) Chapter No. OHS-06 lays down the requirements on reporting of Incidents and

Dangerous occurrences to the respective BUHs at Powai / Baroda and to HSECapability Centre that advises the RCM / PM concerned about steps to be taken to

prevent incidents. Besides, HSE Capability Centre also analyses the IncidentReports and compiles incident data for the sites.

(ii) This data is useful in assessing and judging the trends of incidents and

enhancing/maintaining safe ty efforts of Business Units.(iii) This Procedure sets out the method and frequency of Incident reporting to BUHs

and President (Operations) and Member of the Board of Directors, from HSECapability Centre


3.0 Procedure(i) HSE Capability Centre will compile / analyse Incident Reports received from the

sites.

(ii) HSE Capability Centre will report the Incident data to the concerned Business UnitHead and President (Operations) in the format attached to this procedure.

(iii) This report will be sent on or before 16th of every month.

2.0 Administration

(i) HSE Capability Centre will prepare and send report to all BUHs and President

(Operations) and Member of the Board of Directors.

3.0 Records

Forms Reference

HSE Performance OHS – 21




________ _______________________________________________________________________________________


Dec.’ 2004

CHAPTER – 22

NOISE CONTROL

1.0 Purpose(i) To control Occupational Hazard due to noise generated at site.

2.0 Definition –

Noise – Unwanted Sound.

3.0 Procedure

(i) Identify, measure and record noise at various site locations.

(ii) Minimise noise exposure of personnel by Engineering and Administrative controls

or by providing PPEs.(iii) Noise level for continuous 8hrs. exposure shall not exceed 90dBA. For every rise in

5 dBA thereon, the exposure time of employees shall be reduced by half the valueof exposure hours.

(iv) Exposure in excess of 115 dBA is NOT permitted.

1.0 Administration

(i) SSO/E shall monitor the implementation of above procedure and maintain records atsite.

5.0 Records -

Forms Reference

Noise Measurement OHS – 22




_______________________________________________________________________________________________


Dec.’ 2004

CHAPTER - 23

LEAKAGE / SPILLAGE OF HYDROCARBONS AND CHEMICALS

1.0 Purpose (i) To avoid leakage and spillage of hydrocarbons and chemicals.

1.0 Definition – None

2.0 Procedure(i) Material Safety Data Sheet (MSDS) of all hazardous chemicals stored, handled at

site should be available.(ii) Supply of hazardous chemicals should be preferably in standard packing.

(iii) The container of chemical should have proper sticker/Label. All chemicals should be stored in the specific area / pre- identified location in stores at the time of receiptaccording to compatibility.

(iv) Full stock of hazardous chemicals should be stored in notified storage area onseparate racks as per the norms specified in MSDS according to compatibility.

(v) Appropriate lifting tackles are to be used while handling the drums/container.(vi) Stock of oils and lubricants or any other hazardous chemicals should comply with

the local legal rules.

(vii) Leakage / spillage of Oils/chemicals is to be collected in identified trays.(viii) All workmen handling chemicals shall wear appropriate PPEs, i.e. PVC Hand

gloves, Face shield, Safety shoes.(ix) Storage of hazardous chemicals should be monitored and safe methods / procedure

followed to mitigate the spillage of chemicals, hydrocarbons.

3.0 Administration(i) In-charge of main stores and In-charge of sub stores will ensure the implementation

of the above programme and taking necessary corrective and preventive actionsrequired from time to time.

4.0 Records

Forms ReferenceIncident Report OHS – 06A

Incident Investigation OHS – 06B Near-Miss Incident Report OHS – 06C




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Dec.’ 2004

CHAPTER – 24

OFFSHORE SAFETY

1.0 Purpose(i) To ensure and minimise the risk of hazards to the employees during Offshore

construction activities.


3.0 Procedure

(A) General Offshore Safety Guidelines

i) On arrival at offshore location, all persons should be briefed about the safety rulesto be followed at offshore location, evacuation procedure etc. All personnelshould wear Coverall (Dangri), Helmet, Shoes and Life Jackets for personnel

protection.In case of emergency, workers should follow instruction of FPS (Field Production

Superintendent).ii) There could be instances where instructions may be given to abandon the offshore

installation and evacuate the persons to safe location.

iii) Offshore personnel must receive training for using life saving appliances and also inPersonal Survival Techniques.

iv) Radio and other communication aids facilities should be such as to maintain contactwith base at all times, continuously.

(B) Drilling Rigs

i) Seabed condition at every location should be ensured for safety of rig.ii) During toeing of rig, the rig deck should be clear of load, toeing lines should be in

good condition and tensions in various toeing lines should be constantlymonitored.

iii) Few steps during toeing are:1. Operation should be completed preferably in daylight.

2. Crane booms should be secured to their rest position.3. All hatches and watertight doors should be closed.4. Number of personnel on board should be restricted.

5. Evacuate in case of emergency.

(C) Drillingi) In view of likelihood of the presence of CO and H2S gas release from well,

effective ventilation should be provided where drilling is in progress.

ii) Safety alarm shall be checked in advance in view of failure of ventilation system.iii) Suitable sensors for H2S, CO and Methane presence should be used for time to time

and suitable colour code should be given.iv) Working areas of the Crane should be well illuminated (Refer IS-6665: 1972, Code

of practice for industrial lighting) during night to avoid accident.

v) Clear space should be available for despatch and receipt of load and, in particular, basket transfer of passengers. Persons engaged in loading/unloading of materials

should be protected from falling into the sea.

vi) Signal light should be fitted at the top of the jib.




_______________________________________________________________________________________________


Dec.’ 2004

vii) Crane hook should be fitted with safety latches.

viii) Experienced person should be engaged in operation of specific equipment likewinches, cranes etc.

ix) At least three cable turns shall always be there on the winch drum.x) Crane operation should be completely stopped during helicopter landing/taking off

and over the areas where diving operation is undertaken.

xi) Except for helicopter landing deck, all decks, platforms, bridges, ladders shouldhave rigid and fixed guardrails at least 1m high and should have one

intermediate rail midway between the handrail and 100 mm toe board.xii) Wooden ladders shall not be used at offshore locations.xiii) Flow sensor in the flow line should be ensured for safe working to avoid blow out.

xiv) In case, H2S gas concentration in air > 10 ppm (0.001%), a person should not beexposed for more than 8 hrs.

xv) Portable H2S gas detector should be continuously used.

(D) Production Platforms

i) Sub surface safety valve (SSSV)) below the wellhead should be actuated duringuncontrolled well flow and they should be regularly checked.

ii) Surface safety valve or SDV should be checked for no gas leakage. It should not bein ‘Mechanical override’ or bypassed from panel.

iii) High-pressure gas lift lines blow down system should be O. K.

iv) Railings and Gratings etc. in and around work area should be O. K. and inspected toavoid slippage of man into sea.

v) Emergency shut down (ESD) system is initiated when an abnormal condition isdetected. ESD should be checked once in six months.

vi) Platform should be manned round the clock.

vii) All detectors should be calibrated as per recommendation of the manufacturer.

viii) No system, which affects/likely to affect the system of platform, should be bypassed.

ix) In H2S field platforms, due care shall be taken as per recommendations.

(E) Fire Prevention and Controli) Smoking should be restricted and “NO SMOKING” area should be identified.

ii) Fire and smoke detectors i.e. ultraviolet heat thermal and smoke detector should befunction tested once in three months.

iii) Lightweight breathing system should be used.

iv) The fire control plan at offshore should reveal control station, fire alarms and firedetectors, deluge valves and sprinkler, fire extinguishing appliances, fireman outfit

and ventilation system.

(F) Life Saving Appliances

i) Lifeboats with a speed of 6 knots and carrying capacity up to 50 persons shall beused.

ii) Number of lifeboats on one installation should have a capacity to accommodatetwice the number of persons onboard the installation.

iii) Launching appliances and lifeboat equipment should be checked every week.

iv) Boat landing areas should be adequately illuminated.v) Life raft has no power and they rely on drift.

vi) Life jacket lifts the wearer after entering water.

vii) Life buoys are used to rescue persons if any person accidentally falls in the sea.




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Dec.’ 2004

viii) All life saving appliances shall be inspected by competent authority once in a year.

ix) Every lifeboat shall be inspected once a week.x) Every lifeboat and life raft should be serviced once a year by a competent authority.

(G) Safety Precautions during Helicopter Transportationi) Before travelling in helicopter, all passengers shall be briefed on safety rules /

emergency procedure in case helicopter is to ditch into the sea.ii) Helipad should have a non-skid surface. Nylon rope net should be stretched on the

deck.iii) Proper drainage should be available on helideck.iv) No obstruction on the helideck itself and within 3m of its perimeter. Closest super

structure above the helideck should have red obstruction light.v) While landing fire crew of two persons should be standby adjacent to helideck.

vi) Helideck should be properly illuminated for night landing.vii) During switching off helicopter, persons should not be allowed to go out towards

helicopter.

4.0 Administration - None

5.0 Records - None




___________________________________________________________________________________________

Rev – 02 Page 1 of 4 10th June 2007

CHAPTER – 25

PROVISION OF ACCIDENT PREVENTION TOOLS (APTs)

& SAFETY RELATED ITEMS AT SITES

1.0 Purpose

(i) The objective of this chapter is to make the RCM aware of the minimum and

absolutely necessary APTs and other safety related items required at his site.

(ii) RCM has to ensure / provide / arrange required APTs at the sites.


3.0 Procedure

(i) The chapter deals with a list of standard APTs and safety related items, which shall

be made available at a construction site by L&T and/or Contractor as per Annexure-1 before the activities begin and these must be continued throughout the entireduration of the site. The quantity shall depend on the site requirements.

(ii) All items listed in Annexure-1 are important and essential for the management ofsafety at construction sites and RCM/ RCE shall ensure that there is no exception

whatsoever in ensuring that these items are readily available at the site.

4.0 Administration

(i) Items under L&T Responsibilitya. Project Execution/Procurement Managers of L&T are responsible to ensure

that appropriate PPEs are ordered in time and dispatched to the new and

existing sites. b. Project Execution/Procurement Managers should check/request RCM to check

the availability of items of L&T responsibility and immediately order/send theunavailable items to the site, whether new or existing.

c. SSO/E will check and suggest quantity of APTs and other safety gadgetsrequired for the project based on identified risk in the format mentioned in

Annexure 1

d. SE of HSE Capability Centre will check availability & condition of the L&Tand Contractor items, when he visits a site and record his observations in the

Inspection/Audit Report.e. Items Under Contractor Responsibility

(i) RCM shall ensure that the Contractors have brought the items requiredfor specific activity/ies in adequate nos. and stocked them in their

Stores when they mobilise the site.

(ii) RCM shall ensure that the Contractors issues the items necessary forrelated activities to their employees for use.

(iii) If L&T provides any item to a Contractor, the Contractor shall be

charged 1.5 times thereof from Contractors as penalty. Alternatively,

the Contractor should be asked to return the loaned items in clean &

good condition. The same shall be included in contract document withthe subcontractor.




___________________________________________________________________________________________


BUHs shall view seriously any lapse in provision of the safety items either

by L&T or Contractors.

5.0 Records – None




___________________________________________________________________________________________


Annexure-1

LIST OF SAFETY RELATED ITEMS FOR L&T SITES

Item

No.

Name Qty.

1 First Aid Boxes

2

(a)(b)

(c)

(d)

(e)

Portable Fire Extinguishers

Portable Fire Extinguisher, Water Type (Gas Cartridge) – Specification(BIS-940:2003)

Specification for portable fire extinguishers, dry powder (cartridge type)

(BIS-2171:1999)

Specification for Fire Extinguisher, Carbon Dioxide Type (Portable and

Trolley Mounted)

(BIS-2878:1986)Portable Fire Extinguishers Water Type (Stored Pressure) – Specification

(BIS-6234:2003)

Specification for portable fire extinguisher dry powder type (constant

pressure)

(BIS-13849:1993)

3 Emergency Lights

4 Safety Nets (BIS-11057:1984)

5 Foot Protection(a) Safety Shoes (BIS-11226:1985)

(b) Gum Boots (Rubber/PVC)

6 Full-body Harness

7 Fire Blankets (fire retardant cloth)

8 Welder’s -(a) Safety Helmets (BIS-8520:1977)

(b) Face Shields (BIS-1179:1967)

(c) Safety Goggles (BIS-5983:1980)

(d) Hand Gloves

9 Safety Goggles

10 Hand Gloves -

(a) Rubber (BIS-4770: 1991)(b) Cotton/Leather (BIS-6994: 1973)

11 Respiratory Masks(a) Canister type (BIS-8523:1977)

(b) Filter type for Particulate matter (BIS-9473:1980)

12 Eye Wash Cups

13 Ear Plugs/ Muffs (BIS-9167: 1979)

14 Safety Helmets (BIS-2925:1984)

15 Safety/Warning Signs

16 Audiometer,

Explosive meter,




___________________________________________________________________________________________


Oxygen monitor,

ELCB test meter,

Tool Box talks booklet

Booklet on “Rules for Contractors”




___________________________________________________________________________________________

Rev – 02 Page 1 of 10 25th Feb 2008

CHAPTER – 26

SCAFFOLDING

1.0 Purposei) The purpose of this document is to specify the requirements on erection of scaffolds

and their safe use and to establish a standard for erecting, dismantling and other related

activities associated with a scaffold to facilitate safe work at heights.

ii) To provide information and guidance to facilitate compliance with the legal and

statutory requirements such as The Building and Other Construction Workers

(Regulation of Employment and Conditions of Service) Central Rules, 1998, TheFactories Act, 1948, Indian Standards, OISD 192 and other international standards on

the subject of different aspects of scaffolding i.e., their storage, maintenance,

inspection, erection, dismantling and use.

2.0 Definitions:-

Scaffolding:-A temporary structure consisting of standards, putlogs, ledgers and fittings of metal, on

which persons work, providing support for the plant and materials used in building,

construction, maintenance, repair and demolition work.

Terminology:-Base Plate – It is a plate used for distributing the load from an upright or standard.

Sole plate (Sill) – A timber or other member of adequate size and suitable quality used todistribute the load from the base plate to the ground.

Castor – A swiveling wheel attached to the lower end of a tubular column for the purpose

of moving and supporting scaffolding.

Standard – A vertical member used on the construction of scaffold for transmitting the

load to the foundation.

Bay - The space between the center lines of two adjacent standards along the face of thescaffold.

Brace – A tube incorporated diagonally in scaffolding for stability.

Coupler - A fitting by which a grip is applied to the external surfaces of two tubes forholding them together.

Joint pin – It is an internal fitting for jointing two tubes end to end.

Ledger – A tube spanning horizontally and tying a scaffold longitudinally, that may act asa support for putlogs or transoms.




___________________________________________________________________________________________


Standard or Upright – A tube used as a vertical support or column in the construction of a

scaffold and transmitting a load to the ground or a base plate.

Transom – A tube spanning across ledgers to tie a scaffold transversely and which mayalso support a working platform.

Putlog – A tube or other member spanning from a ledger to the wall of a building and

which may have a specially formed end for the purpose of fixing into the brickwork.

Guard rail/ handrail – A member incorporated in the structure at all points and open

edges where a person working may fall. Its purpose is to prevent fall of person from openedges.

Trestle – A self-supporting stand made out of rolled steel sections or steel tubular sections

and incorporating one or more horizontal beams on which a working platform may be laid.

3.0 Resources:-

Sl

no

Materials Specifications Care of materials Criteria for

rejection

1 Steel tube Heavy class welded orseamless tubes of 40 mm

nominal bore ,IS: 1161-

1968 “Specification for

Steel Tubes for Structural

Purposes” (2nd revision)

Varnishing, painting,metallization and hot-dip

galvanization shall be

followed to avoid corrosion

of tubes. Straightening

should be carried out undercompetent supervision with

minimum of straining.

If anydeformation in

the tube in the

form of bending,

they shall be cut

out.

2. For other

scaffoldconsisting

of tubes

and unitframes

IS: 1161- 1968

“Specification for SteelTubes for Structural

Purposes” (2nd revision)

and IS: 2750-1964“Specification for Steel

Scaffoldings”.

Varnishing, painting,

metallization and hot-dipgalvanization shall be

followed to avoid corrosion

of tubes.

Deformation in

tubes or framesshall be discarded

and will not be

used at site.

3 Steel

fittings

Made of Steels of schedule

–II of IS: 1570-1961”Schedules forWrought Steels for General

Engineering Purposes” andIS: 2750-1964

“Specification for Steel

Scaffoldings”.

All moving parts shall be

in sound and welllubricated to ensure easyand positive movement.

Heat shall not be appliedunder any circumstances.

Any fittings with

worn out threadsshall not be usedand discarded

from worksite.

4 Base plate Steel plate 6mm x 150 mmx 150 mm

Shall be prevented fromcorrosion by varnishing

and painting.

Any deformationin shape shall be

discarded.




___________________________________________________________________________________________


An illustration of a standard scaffold with access ladder




___________________________________________________________________________________________


4.0 Procedure

Erection/addition/alteration of metal scaffold:

1. HIRA (Hazard identification and Risk Assessment) shall be carried out prior to all such

activities and shall be implemented during such activities.

2. Metal scaffolds shall be erected, added to, or altered by trained workmen under the

immediate supervision of a responsible, authorised person.

3. Work should be started from the bottom level to the top level and from the interior partto the exterior part.

4. During the erection of scaffolds, warning signs, safety cordons and other safetymeasures shall be provided to ensure safety for the traffic.

5. The standards of the scaffolds should be plumb.

6. Working platform:- Every working platform from which a person is liable to fall more

than 2.0 meters shall be closely boarded, planked or plated.

Sl

No

Components Purpose Size and specification

• Where the platform is used as

a footing only and not for thedeposit of any material

• At least 700 mm

wide

• Where the platform is used forthe deposit of material

• At least 900 mmwide

1 Working

platform

• Where the platform is used for

the support of any higher platform

• At least 1100 mm

wide

2 Boards and

planks

For forming part of a platform or used

as a toe board.

Minimum 32 mm

thick,200 mm widthIf the thickness is 50 mm

then width has to be

minimum 150 mm

3 Guard rails Every side of a working platform orworking place where a person is liable

to fall, there guard rail of adequatestrength should be provided from the

working platform.

At least 900 mm andmaximum 1200 mm.

4 Toe boards Provided on the working platform to prevent any fall of person, material

and tools.

Minimum of 150 mmheight from the working

platform




___________________________________________________________________________________________


§ Every working platform shall be closely planked, boarded or plated.

§ Every board or plank forming part of a working platform shall be of sound

construction, adequate strength and free from patent defects. Also, the board should besound and free from cracks and other defects affecting its strength.

§ Toe-boards shall be suitably fixed to all working platforms. They should be placed

inside the standards.

§ Space between platform and wall of a building or structure should be as small as

practicable. Guard-rails should be provided if there is a risk of falling from height.

7. Working platforms should be cleared of debris like concrete waste.

8. Working platforms should not be overloaded and the load should be evenly distributed.

9. No shock loading on the platforms should be allowed.

10. The scaffold should be effectively braced to ensure stability of the whole structure.

11. The bracings should extend from the base to the top of the scaffold.

12. If electrical equipment such as power hand tools or electric installation including

lighting is to be used on the scaffold, they should be of proper design and installation to

prevent electrical hazard.

13. Where a scaffold is erected adjacent to a road or pathway, overlay or safety nets must

be erected to envelop the scaffold for the protection of person or vehicular traffic

against falling objects.

14. When a scaffolder or workman has to work in a place where it is impracticable to erect

a safe working platform or to provide safe access and egress, the use of safety nets andsafety harness attached to a secure anchorage point or an independent lifeline

throughout the work is required. Scaffolding members should not be used for anchorage

purpose.

15.Particular attention should be drawn in the manual handling of heavy metal scaffoldingcomponents.

16.Scaffolding members should not be used as supports for lifting appliances unless the

scaffold has been designed for such purpose.

17.Double lanyard full body safety harness shall be used by the workmen engaged in the

erection work.




___________________________________________________________________________________________


18.Scaffolds shall be protected against accidental collision with the traffic. A clear height

of 2.5 m shall be maintained over pedestrian traffic areas.

19.Access to fire alarms, cable tunnels ,hydrants ,etc, shall remain free at all time

20.Support and stability of scaffolds:-

a) Every scaffold shall be securely supported or suspended and shall be sufficiently and

properly braced to ensure stability.

b) Any tower scaffold which may be moved on wheels or skids shall be

• Constructed with due regard to stability .Adequate weight may be provided at the base

if necessary to provide stability.

• Used only on a firm and even surface and it should not be so sloping that risk ofinstability remains.

• Adequately secured to prevent movement when any person is working upon it

• Moved only by the application of a force at or near the base without overturning.

c) Loose bricks, drain pipes, or any other unsuitable materials should not be used for the

construction or support of scaffolds.

d) No part of a building shall be used as a support for part of a scaffold unless it is of soundmaterials and stable.

e) Overhanging of projecting roofs, gutters shall not be used as such supports unless they have been specially designed as walkways and are of adequate strength.

Dismantling of metal scaffolds

1. HIRA (Hazard identification and Risk Assessment) shall be carried out for dismantlingactivity and shall be followed during such activities.

2. The dismantling work shall be done by trained workmen under the immediate

supervision of a responsible and authorised person.

3. Sufficient time should be allowed for the dismant ling work to be conducted safely.

4. The scaffold to be dismantled should be checked for its strength and stability

beforehand.

5. No components, which endanger the stability of the remaining structure, should be

removed. Unless necessary precautions have been taken, all the ties and bracingsshould remain secured in position.




___________________________________________________________________________________________


6. If dismantling has reached the stage at which a critical member has to be removed, for

example, a tie or a brace, the stability of the structure should be assured by fixing a

similar or otherwise adequate member in place lower down before the member to be

taken out is removed.

7. All the stacked materials and debris placed on the scaffold should be removed.

8. Dismantling sequence should be planned and that sequence of dismantling sections of

the scaffold should be logical and determined with due consideration of the scaffolders'

safety. Dismantling work should be carried out according to the plan. Because changes

may have been made in a scaffold structure during its working life, it is not sa fe toassume that dismantling can be carried out in the reverse order to the erection. The

scaffold, especially its tying and bracing, should be inspected prior to dismantling.

Also, the procedure of dismantling should be orderly and planned and should proceed

generally from the top in horizontal sections.

9. If the scaffold is defective, it should be made good before dismantling commences.

10. Scaffolds should not be dismantled in vertical sections from one end towards the other

unless special consideration is given to ties and bracings.

11. The scaffold to be dismantled should be fenced off at the ground level/public area to

prevent persons entering the work area and warning notices should be posted up in thevicinity.

12. Steps shall be taken to ensure that scaffold ing materials are not thrown, tipped, or shotdown from a height where they are liable to cause injury to any person on or near the

construction site; and where practicable, properly lowered in a safe manner by means ofa lifting appliance or lifting gear. Scaffolding materials should include the tubes, the

scaffold boards or planks, the metal couplers for scaffolding purposes, etc.

13. All materials should be lowered to the ground and not stored on the scaffold. In the case

where the pavement is not to be obstructed and scaffolding materials have to be storedon the lowest lift awaiting collection, this lift should be stiffened and fully braced, by

using the materials recovered from the upper lifts.

14. Every scaffolder involved in the dismantling work at height should wear double lanyardfull body safety harness attaching to suitable and sufficient anchorage and suitable

fixings, for example, the provision of an independent lifeline that extends from an

independent anchorage point to which a lanyard of a safety belt is attached using a fallarresting device.

15. Scaffold members should not be used for anchorage purpose. Whenever practicable,

safety nets for fall protection of scaffolders should be used.




___________________________________________________________________________________________


16. All the trades on the site should co-ordinate and collaborate closely with the contractor

engaged in scaffold dismantling work regarding the safety precautions necessary during

various stages of the work.

17. Scaffold materials, tools and other objects and materials (including waste materials)shall not be thrown, tipped from a height where they are liable to cause injury.

18. During dismantling of scaffolds, warning signs, safety cordons and other safety

measures shall be provided to ensure safety for the traffic.

Access during erecting or dismantling

1. Safe access to and egress from the place of work should be provided for the scaffolders.

Cross-braces on tubular welded frame scaffolds shall not be used as means of access or

egress.

2. Hook-on or attachable type of ladder shall be installed as soon as scaffold erection has

progressed to a point which permits safe installation and use.

3. While erecting or dismantling tubular welded frame scaffolds, end frames with

horizontal members that are parallel, level and are not more than 55cm apart vertically,these may be used as climbing devices for access. They shall be erected in such a

manner that creates a usable ladder which provides good hand hold and foot space.

Inspection of scaffolds:-

No scaffolding shall be used unless:

1. It has been inspected by an experienced and authorized person before use

2. It has been inspected by an experienced and authorized person within the immediate preceding seven days

3. It has been inspected by an experienced and authorized person when the scaffolding is

affected by weather conditions and the stability has been affected.4. A report of the results of such inspections certifying that the scaffold is suitable for use

signed by the person who has inspected and entered into a register to be kept atworksite.

Electrical wiring:-

The setting of a scaffold near unprotected current carrying wires or equipment, or insulatedwires and equipment shall be started only when the lines have been disconnected.

The wiring shall be either disconnected by skilled persons or protected against accidental

contact by maintaining safe distance. After the erection of scaffold the wires may be made

to carry the current only when sufficient safety measures have been adopted to avoidaccidental contact.




___________________________________________________________________________________________


Clearances:-

Scaffold operations adjacent to overhead power lines are prohibited unless one of thefollowing conditions is satisfied:

1. The power line has been de-energized, relocated, or protective coverings installed to

prevent accidental contact with the lines. If the power line has been de-energized, positive

means (lockout/tag out) shall be used to prevent the lines from being energized until the

line has been relocated or protected.

2. Scaffolds shall not be erected, used, dismantled, altered, or moved such that they or any

conductive material handled on them (i.e., scaffold tubes) might come closer to energized

power lines than as follows:

Clearances between Scaffolds and Power Lines

5.0 Administration

I. During erecting and dismantling of a scaffold, red tag shall be prominently displayed bythe authorised person.

II. Inspection shall be carried out prior to usage of any newly erected scaffold and theinspection checklist shall be filled by the authorised person. Records of such inspections




___________________________________________________________________________________________

Rev – 02 Page 10 of 10 25th Feb 2008

shall be maintained at site in OHSC – 19D & OHS – 26 (Scaffold Register) and a copy of

the same shall be submitted to SSO. The scaffold register shall be maintained for each

location where scaffolds have been erected and entries made at regular scheduled weekly

intervals until it is dismantled completely.

III. The scaffold shall be inspected every week by the authorised person all such records shall

be maintained at site.

IV. After inspection confirms that the scaffold is suitable for use, green tag shall be

displayed.

6.0 Records

Form Reference

Checklist for steel scaffolding OHSC – 19D

Scaffold Register OHS – 26

References, sources of information and for further reading:-

1. The Building and Other Cons truction Workers (Regulation of Employment and Conditions of Service)Central Rules,1998,

2. The Factories Act ,1948,

3. IS: 4014 : Part 1 : 1967 Code of practice for steel tubular scaffolding Definitions and materials, and Part 2 :

1967 Code of Practice for Steel Tubular Scaffolding Safety Regulations for Scaffolding4. IS: 2750: “Specification for Steel Scaffolding”

5. IS: 3696 Part 1: 1987 Safety code of scaffolds and ladders: Scaffolds and Part 2: 1991 Scaffolds and Ladders- Code of Safety - : Ladders

6. OISD - GDN - 192 Safety practices during construction

7. Safety ,Health and Welfare on construction sites – A training manual ,ILO Geneva

8. OSHA Construction Safety Regulations – 1926.4519. OSHA -U.S.A. Publication - A Guide to Scaffold Use in the Construction Industry - Reference Material for

Scaffold Construction , maintenance and use10. ANSI A10.8 , Scaffolding - Safety Requirements

11. Accident Prevention Manual for Business and industry, Engineering and Technology ,10th

edition published

by National Safety Council, USA12. Scaffold Safety Handbook, Saudi Aramco

13. Code of Practice for Metal Scaffolding Safety published by Occupational Safety and Health Branch Labour

Department, Government of Hong Kong ,First Edition June 2001

14. Publications of Scaffolding, Shoring & Forming Institute, Inc.I. ANSI/SSFI SC100-5/05 Standards for testing and rating scaffold assemblies and components

II. SSFI Technical bulletin on scaffolding sectionIII. SSFI Technical bulletin on shoring section

IV. Guide to Safety Procedures for Vertical Concrete FormworkV. SSFI RP102 Compression Testing of Welded Frame Scaffolds and Shoring Equipment

VI. SSFI RP103 Tube and Coupler TestsVII. Code of Safe practices for Frame scaffolds, system scaffolds, tube and clamp scaffolds & rolling

scaffoldsVIII. Independent post shore system safety rules

IX. Fly ing deck form safety rules

X. Code of safe practice for suspended scaffolds

15. “Health and Safety in Construction” Guidance issued by the Health and Safety Executive ,UK




_____________________________________________________________________________________________ __


June’ 2007

CHAPTER – 27

PENALTY SYSTEM FOR CONTRACTORS

1.0 Purpose(i) To ensure and minimise the unsafe acts / unsafe conditions and compliance with

the required Safety norms during construction activities by all employees.(ii) To discipline the defaulters.

2.0 DefinitionObserver – Employee from L&T Construction Team / Client / Contractor Staff.

3.0 Procedure

I. Project Manager, RCM, Safety Officer/ In-charge are authorised to issueinfringement report to the concerned person/ contractor.

II. HSE Violation: - The penalty system is divided into two categories, Minor and

Major. (L&T Safety Department shall decide whether an infringement is minor ormajor for violations which, are not listed below)

(a) Minor HSE Violation: -i) Not wearing Personal Protective Equipment (PPE) at work site;ii) Minor traffic violation (wrong parking, over speeding)

i) Blocking of emergency equipment or exits;ii) Using unapproved scaffolding.

iii) Not obeying HSE Instructionsiv) Ignoring Safety Signage.(b) Major HSE Violation: -

i) Smoking in the non-smoking area, carrying matches or lighter;

i) Working without valid work permit;ii) Not wearing proper breathing apparatus if instructed;iii) Not providing shoring for the excavations;iv) Not providing fire extinguisher for hot work;

v) Repeat minor violations more than twice;vi) Found guilty of negligent driving resulting in or likely to result in a vehicle

accident;vii) Entering closed area or classified area without permit;viii) Not complying with written instruction on the work permit.

III. Table of Penalty Stages: -

Violation First Second ThirdMinor Written Caution

NoticePenalty of Rs.5000/ -

Penalty of Rs.10000/- *

Major Penalty of Rs.

10000/-

Penalty of Rs.

20000/-*

Penalty of Rs.

30000/-*

* L&T reserves the right to impose more severe penalty, i.e suspend/ terminatethe employee, his supervisor or the Site Manager of the contractor.




_____________________________________________________________________________________________ __


June’ 2007

4.0 Administration –

a) After observing any unsafe acts/ unsafe conditions, observer shall report it to theL&T Safety Engineers/ Officers and give all the details such as Name of the

employee, Contractor Name, Details of Infringement, Time, Place, etc. b) L&T Safety Engineer/ Officer shall fill up the “Infringement Form (OHS – 27)”

and prepare covering letter which shall be signed by PM/ RCM/ Site Incharge.

c) L&T – Safety Engineer shall send those copies to site Account section forrecovery, along with PM/ site in-charge.

5.0 Records

Forms Reference

Infringement Report OHS – 27




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June 2007

7

Chapter – 28

Radiography

1. Purpose:

1. To ensure that the requirements spelt out under the Radiation Protection Rules 2004 issued

by Department of Atomic Energy, Government Of India are fully complied.2. To ensure that requirements spelt out under the AERB safety codes and AERB safety guides

are complied with completely.3. To ensure the safety of personnel engaged in carrying out radiographic work.

4. To ensure that likelihood of exposure to radiography source by personnel not connected withradiography operation is eliminated.

2. Definitions:Collimator:

A device used for restricting the useful radiation beam to a specific direction and size.Competent Authority:

Any officer or authority appointed by The Central Government by notification under RadiationProtection Rules, 1971.Curie:

A unit of radioactivity. It was originally defined as - the quantity of radon in radioactiveequilibrium with 1 gm of radium. The curie is now broadly defined as the radioactivity of anymaterial, which is disintegrating at a rate of 3.7 X 1010 atoms/sec. The disintegration rate of

Radon is approximately 3.7 X 1010 atoms sec. / curie.Panoramic Exposure:

An exposure in which radiation is allowed to be emitted in all directions.Radioactivity:The phenomenon exhibited by certain materials in which spontaneous emission of nuclear

radiation occurs. Gamma radiation is the electromagnetic radiation emitted in such nucleartransformations.

Radiographer:A radiation worker who performs industrial radiography operations employing radiation sourcesand who possesses a valid certificate duly recognized or issued by the competent authority for

this specific purpose and who further meets the qualifications specified for a radiographer in para. 13 of schedule GSR 735, 30 Jan. 1980, entitled "The Industrial Radiography (Radiation

Surveillance) Procedures" published in the Gazette of India.Radiography Camera:

An exposure device or equipment containing a gamma source employed for industrial

radiography operations.Radiological Safety Officer (RSO):

A person who possesses valid RSO's certificate duly recognized or issued by the competentauthority for this specific purpose and who further meets the qualifications specified for RSO in

para. 13(i) of the schedule GSR735, 30 Jan. 1980, entitled "The Industrial Radiography

(Radiation Surveillance) Procedures" published in the Gazette of India.Roentgen:

A unit of exposure dose of ionizing radiation. It is that amount of gamma or X-rays required to produce ions carrying 1 electrostatic unit of electrical charge in 1 cubic centimeter of dry airunder standard conditions.

Source Strength:

Amount of activity in curie.




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June 2007

7

3. Procedure:

I) Storage of Radioactive Cameras & Source:

1. The radiography cameras / sources when not in use shall always be stored in a separate pit

under lock and key.2. A storage facility for Radiography equipment / source should have approval of the

competent authority - (Any officer or authority appointed, approved or recognized byGovernment for the purpose of the Rules promulgated under the Atomic Energy Act,

1962).3. The proper storage of source inside the camera shall be verified after every operation with a

radiation survey meter both at the time of keeping them inside the storage room and while

taking them out of the storage room for use at site. The reading of the meter shall berecorded in order to check the leakage of radiation from the camera.

4. The source storage shall be conspicuously posted with appropriate warning signs alongwith radiation symbol as given below.

5. The operator of the radiographic equipment shall maintain a logbook to record the details

of day-to-day use of the equipment. Please refer the OHS – 28B

II) Permissible Leakage Level of Camera:

Measurement distance Average mR/hr Maximum mR/hr

5 cm from source position 20 100

1 m from source position 2 10

(Source: Radiographer’s Handbook of Industrial Radiographic Inspection & Co. based

BARC – Bhabha Atomic Research Centre, Regulations)

III) Safe Work Practices:1. Radiography cameras shall be operated only by certified radiographers.

2. As far as possible, field radiography shall be carried out at night time when there is littleoccupancy or no occupancy around.




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June 2007

7

3. Field radiography may be permitted on a restricted scale when there is little or nooccupancy. If field radiography is carried out at the same location repeatedly, it is advisable

to provide either a wire fencing around or a temporary enclosure.4. An appropriate area around the radiation source shall be cordoned off during field

radiography so that the radiation levels outside the area do not exceed the reference

radiation levels for the public. (Please refer “Cordoning off distance chart” on page no. 07).5. The radiation levels along the cordon shall be monitored by a suitable and calibrated

radiation survey meter, so as to confirm that the cordon distance is indeed adequate.6. Radiation warning symbols shall be conspicuously posted along the cordon. Placards

displaying the appropriate legend in English and local language shall be posted at thecordon. The placard and the radiation symbol shall be readable from a distance of 6 to 7meters under normal illumination.

7. When the radiography work is carried out at night-time, the radiography site up to the boundary of cordon on all sides shall be adequately illuminated throughout the duration of

radiography work.8. Red warning lights shall be available at the site very near the cordoned area throughout the

exposure.9. While using x-ray machine, full length of cable connecting the x-ray machine and control

console shall be used.

10. Suitable supporting and fastening devices shall be used for hoisting and positioningradiography cameras / x-ray machines in order to avoid mishaps such as accidental fall.

11. The radiography equipment shall always be operated by positioning oneself behind the

cameras / x-ray machine, making use of the shielding provided by the body of theequipment.

12. The radiography work shall be carried out only under the supervision & guidance of theradiography-in-charge.

13. After termination of each exposure, it shall be verified by means of a radiation survey

meter in proper working condition that the source has indeed to its safe position inside thecamera.

14. Prior to on-site transport of the camera with source from one place to another in a roadvehicle, it shall be ensured that the source pencil is securely locked in camera. This willavoid any accidental opening of the shutter and falling from the camera.

15. In case of unusual occurrences like, damage to the cameras during transport, non-receipt ofconsignment in reasonable time, Inform to Division of Radiological Protection, BARC

(Bhabha Atomic Research Centre), Mumbai, (office phone no. – 5512601, telex – 011-71017 BARC IN, telegram – DRP (Division of Radiological Protection), BARC, Chembur,Mumbai.

16. Maintenance and servicing of radiographic equipment shall not be attempted withoutconsulting the Radiographic Safety Officer.

17. In case of radiation emergency, follow on-site emergency plan. Inform to Division ofRadiological Protection, BARC (Bhabha Atomic Research Centre), Mumbai, (office phoneno. – 5512601, telex – 011-71017 BARC IN, telegram – DRP (Division of Radiological

Protection), BARC, Chembur, Mumbai - 400085 immediately.18. Before starting or after finishing radiography operation, paging / announcement shall be

made on public address system so as to make employees aware about radiographyoperation.

IV) Radiography Workmen Safety:

1 Site Safety Officer (SSO) should ensure effective implementation of Radiography procedure.




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June 2007

7

2 When the work is in progress, the radiography workmen shall wear film badges and pocketdosimeters allotted to them and shall undergo medical check up (after every six months) as

per the regulation of BARC (Bhabha Atomic Research Atomic Centre) and records shall bemaintained.

3 Radiography work permit shall be strictly followed before starting radiography operation.

4 Job specimens or test objects and film cassettes shall never be held by hand during exposures.5 All radiographic exposures shall be given only by duly approved operators and they shall be

in immediate attendance when the radiographic equipment is in use.6 The source shall never be handled by bare hand. It shall be operated with manipulators only.

7 When the source is exposed, it is advisable:§ To stand behind buildings, steel or other shielding materials.§ To stand away from the source of radiation.

§ To limit the exposure time for a particular operator / day.8 The maximum length of the cable, provided between radiographic equipment and the control

unit / panel, should be made use of and the operator should always position the control unit / panel and himself behind temporary barrier / huge objects.

9 Radiographs shall be taken with a collimated beam exposure technique, in which the beamwill be directed towards the object only and the rest of the portion will be protected fromradiation by the camera. But it shall be seen that operator stands behind the camera only and

any part of the body does not come in the direct vicinity of radiation.10 It is advisable to use panoramic exposures (source outside the camera technique) only when

the source is of lesser strength (for example say less than 8 curie). When it is necessary to use

higher strength of source for radiography higher weldment, remote operated cameras (telefluxcameras) shall be ideal.

11 The operators should be aware of their dose records and reports of medical examination (afterevery six months).

12 In case of change of radiographer by contractor, certificate of radiographer shall be submitted

to QA/QC In-charge and Site Safety Officer.13 Maximum Permissible Dose Limit shall be as follows –

(Source: Radiographer’s Handbook of Industrial Radiographic Inspection & Co. based BARC –

Bhabha Atomic Research Centre, Regulations).

14. Suitable radiation monitors should be used to measure radiation levels -

Cumulative dose for an occupational worker can be (N-18) Rems, where N is the age of the

radiography workmen. On an average it shall not exceed 100 milli Rems per week, 1 ¼ Rems

per calendar quarter and 5 Rems per year. 250 to 400 RADs are sufficient to make it fatal in

Organ

Dose Limit for adult

radiography workmen

(rems/year)

Dose limit for public

(rems/year)

Bone marrow, Eye lens 5 0.5

Skin, Bones & Thyroid 30 3

Hands, forearms, feet and ankles 75 7.5

Other organs 15 1.5




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June 2007

7

50% of the cases within 30 days. With 50 to 100 RADs, the skin will turn reddish and a littlehigher dose will make the hair fall.

V) Cordoning off distance: Cordon off distances for open field radiography (Panoramic

Exposure) Iridium-192

Work Load

5

Hrs/week

10

Hrs/week

15

Hrs/week

20

Hrs/week

25

Hrs/week

Source

strength

Nature of

Human

occupancy

Cordon off distance (m)

Full 37 52 66 74 93

Partial 18 26 33 36 475 Curie

Occasional 10 13 17 18 24

Full 47 65 80 94 122



Full 53 74 90 100 126



* [Source – AERB Guide no. SG / IN-2]

4. Control measures:

The contractor shall submit following documents to QA / QC In-charge and Site Safety Officer–

1. Source Authorisation certificate.2. Source Storage approval certificate.

3. Source strength calibration certificate.4. Calibration certificate of Radiation survey meter.

5. Periodic inspection reports of Radiographic equipment.

Transportation of radioactive source shall be done in conformity with AERB guidelines. The

records of radioactive source transportation (IN/OUT details) shall be maintained by Security.

5. Site Safety Officer:1. Site Safety Officer shall ensure the radiation levels within limit (which will be measured by

Radiographer with the help of radiation survey meter) by shielding around the exposure

device.2. Authorisation of concerned contractors shall be checked, who enters site with radioactive

source.




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June 2007

7

3. Authoriasation of storage of source on site shall be checked as per AERB guidelines.4. Authorisation and validity certificate of radiographers who are performing radiography and

maintain copy of records shall be checked.5. Educate non-radiation employees (working in the radiography area) on Do’s & Don’ts

during radiography.

6. References:

1. Radiation Protection Rules – 20042. AERB Publications –

Safety code no. SC/TR-1 (Transport of Radioactive material)Safety guide no. SG/IN-1 (Enclosed radiography installations)

Safety guide no. SG/IN-2 (open field industrial radiography)Safety guide no. SG/IN-3 (Handling of radiation emergencies in industrial radiography)

3. Radiographer’s Handbook of Industrial Radiographic Inspection & Co. based BARC –

Bhabha Atomic Research Centre, Regulations

7. Records:

Forms ReferenceRadiography Inspection Checklist OHS – 28 ARadiography Equipment Usage Logbook OHS – 28 B




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Aug.’ 2007

CHAPTER – 29

ELECTRICAL SAFETY AT SITE

1. PURPOSE(i) To establish System of installation of temporary electrical setup and regular inspection

and maintenance at site. This system shall ensure proper planning of electrical setup,maintenance & their periodic testing and inspection.

(ii) The purpose of this program is to provide guidance for all employees to ensure that safeelectrical work practices are followed at sites.

2. DEFINITIONS

LOW VOLTAGE (LV) : - Low voltage means a voltage which does not exceed 250 volts 50cycle under normal conditions, subject to the percentage variation allowed under the IndianElectricity Rules, 1956 (As per Rule 2(1)(av) & Rule 54 of Indian Electricity Rules,1956)

MEDIUM VOLTAGE (LV) : - Medium voltage means a voltage which does not exceed 650

volts 50 cycle under normal conditions, subject to the percentage variation allowed under theIndian Electricity Rules, 1956 (As per Rule 2(1)(av) & Rule 54 of Indian Electricity

Rules,1956)

HIGH VOLTAGE (HV) : - High voltage means a voltage which does not exceed 33000 volts

under normal conditions, subject to the percentage variation allowed under the IndianElectricity Rules, 1956 (As per Rule 2(1)(av) & Rule 54 of Indian Electricity Rules,1956)

EXTRA HIGH VOLTAGE (EHV) : - Extra High voltage means a voltage which is higher

than 33000 volts under normal conditions, subject to the percentage variation allowed underthe Indian Electricity Rules, 1956 (As per Rule 2(1)(av) & Rule 54 of Indian Electricity

Rules,1956)

DEAD: - At or about zero potential and disconnected from any LIVE system.

LIVE: - Electrically charged.

EARTH, EARTHED or EARTHING: - Connecting to the general mass of earth in such a

manner as will ensure at all times that the body being earthed discharges immediately anyelectrical energy stored in it and further more is maintained at a safe potential with respect to

the general mass of the earth.

ISOLATED: -Disconnected from live apparatus and conductors by an open disconnector or by

an adequate physical gap.

LOCK OUT: - A device that utilizes a positive means such as a keyed lock to hold energyisolating device in a safe position to prevent the energization of a machine, equipment and/orsystem.




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Aug.’ 2007

TAG OUT: - The placement of a system Operations Tag on an energy isolating device, in

accordance with this procedure, ensuring that the energy isolating device and the equipment being controlled cannot be operated until the tag out device is removed.

EARTH LEAKAGE CIRCUIT BREAKER (ELCB): - An earth leakage circuit breaker(ELCB) is a device with two earth terminals to directly detect currents leaking to earth from an

installation and disconnect the power.

COMPETENT PERSON: - A person who has sufficient technical knowledge or experienceto avoid danger and has been appointed by the L&T to complete the procedure of electricalisolation/de-isolation certificates and electrical PERMITS-TO-WORK.

3. PROCEDURE: -

i) Follow Electric Work Permit System (OHS – 15 E) while working on electricalequipment.

ii) Communicate electric hazards to all concerned workmen through Toolbox Meetings

and maintain records.iii) Specific HIRA shall be made in consideration to the site conditions, climatic changes,

nature of activities performed before installation and shall be reviewed at least oncein a month and/or whenever new activity other than the identified above are initiated.

iv) Hazards identified in HIRA shall be eliminated before installation set-up.

v) Any unauthorized person shall not attempt repair of electrical apparatus, rectifyfaults, or perform any switching operation other than the normal function of the user,

i.e., Circuit breaker energized/de-energized.vi) Any abnormality shall be reported to the P&M staff/ electrical personnel on

duty.

vii) Placing or hanging cloth or other material on electrical equipment shall be forbidden.

viii) Electrical switches or the access to them shall not be blocked by any material.ix) Electrical rooms and space under sub-station shall not be used as a storage area.x) Precaution / Notice signs shall be displayed before starting the repair works /

Isolation work.

xi) Use of non-intrinsically safe pagers/mobile phones and similar devices shall not be permitted inside hazardous areas.

xii) Work on live electrical equipment is not allowed. However, if unavoidable, special precautions and protections shall be observed (Ex: Electrical gloves).

xiii) All electrical equipment operating above 250V shall have separate and distinct

connections to earth grid.xiv) 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 withwater due to water logging.

xv) Do not work wet on electrical system.

xvi) Do not overload the electrical system.xvii) Use only proper rated HRC fuses.

xviii) Industrial type extension boards and plug sockets are only to be used.xix) All power supply cables should be laid properly and neatly so that they do not cause

hindrance to persons working.

xx) Maintain safe overhead distance of HT cables as per Indian Electricity Rules andrelevant acts.

xxi) All switch boards should be of MS structures only and incoming source should be

marked.




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Aug.’ 2007

xxii) Fire extinguishers (DCP/CO2/Sand buckets) should be kept near temporary switch

boards being used for construction purposes. Do not use water for fighting electricalfires.

xxiii) At beginning of every shift, the person using the electrical equipment should make acareful external examination of the equipments.

xxiv) Rubber mat shall be placed in front of all electrical panels.

xxv) Discuss the outstanding/repeated issues/observations in committee meetings.

xxvi) SWITCH GEAR

• In the event of indoor switchgears, adequate level of illumination and ventilation

should be maintained.

• All the indoor switchgear rooms should be kept clean and tidy. Unwanted and

unnecessary accumulation of materials should be avoided.

• No explosive / inflammable substances should be stored within the enclosedcompartment.

• Smoke detectors should be installed at all indoor units and should be checked on

regular basis. Sufficient portable type of fire extinguishers should be installed.• All the switchgear panels should have a firm enclosure. Any cut outs or opening

should be properly sealed and prevent entry of dust or vermins within the panels

which are potential sources of electrical short circuit.

xxvii) ELECTRICAL ISOLATION

• Electrical isolation should-be carried out before starting work on or near

electrical equipment to avoid electric shock and other hazards. The extent ofisolation required will depend on the nature of work. Requirement of isolation andextent of isolation shall be jointly decided by the issuing authority (L&T –

Electrical Engineer) and executing authority (Contractor Competent Electrical

Person)., [see Electrical Isolation Certificate]• When multiple crafts are involved the multi-lock system shall be followed.

• Wherever the possibility of electrical shock or injury is expected due to

inadvertent starting, locking of power circuit at substation is mandatory. Lockingthe control circuit at local switch shall not be considered as adequate.

• When an electrical circuit/equipment is fed from two different sources of power

supply, both the sources of power to be switched off and tagged/locked to avoid back feeding.

xxviii) MULTI-LOCK SYSTEM : - Multi- lock system (lockout) is used to prevent injury

by accidental energizing of equipment, while it is attended by different crafts.• The executing authority and issuing authority will jointly decide therequirement.

• The issuing authority issues the work permit to competent electrical person toisolate the electrical equipment from substation.

• The competent electrical person and the Executing Authorities install their locksin the multi-lock pad as per color-coding. They shall test de-energizing by

pressing the local switch.

• Color coding of pad-locks:

– Electrical Maintenance/ Department - Brass yellow – Mechanical Maintenance/ Department - Black die

– Others - Grey




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Aug.’ 2007

• Each lock shall be numbered and the key shall be same number.

• After locking, the person who installs the lock is the responsible custodian of the

key. The locks shall be removed by individual craft after completion of their jobs.

• If the custodian of the key has to leave the site, responsibility should be

transferred by renewal of Electrical Isolation Certificate.

• If only Electrical Maintenance Department is involved they shall use single lock.

xxix) TAG-OUT : - Use of 'Danger - Do not Operate" tag with isolation by local switchshall be limited to minor electrical jobs carried out by Electrical Department, such as

relamping and minor A/C maintenance work. Remote isolation shall be done onlythrough multi- lock system.

xxx) PORTABLE LAMPS AND EQUIPMENT: - All the portable equipment shall bechecked regularly as per the form OHS – 19. Following are some of the portable

equipment used at site.a. Flash Light (Torch): All battery-operated flashlights (torch) shall be intrinsically

safe or Explosion proof types.

b. Portable Hand Lamp: The supply voltage to portable hand lamp on a trailing lead

shall not exceed 24 volts. Only explosion proof type shall be used in hazardous area,such as inside vessels and tanks.

c. Flood Lights: Explosion proof floodlights may be used up to 250 volts with screenedcables properly grounded and protected by ELCB/GFCI in the hazardous areas.

(ELCB -Earth Leakage Circuit Breaker, GFCI - Ground Fault Circuit Interrupter)excluding confined spaces like vessels, tanks etc. However, such use can be permittedonly after obtaining approval of Site Safety Department. All fittings and

accessories shall be conforming to the area classification. These shall beinstalled on a rigid support and cables shall be rooted and protected to avoid

mechanical damage.

d. Portable Instrument: Portable instruments used by different crafts in hazardous

area shall be intrinsically safe or explosion proof types. Ordinary types may beallowed in exceptional cases under hot work permit conditions with special approval

from Site Safety Department. All cables of portable equipment shall be screenedcables, which are properly grounded.

e. Hand Tools: Electrical hand tools up to 250 volts may be used with ELCB /GFCI

excluding confined spaces. However, such use can be permitted after obtaining dueapproval from Site Safety Department. All hand tools shall be of insulated type

xxxi) ELECTRICAL INSTALLATION : -

a. Generator

• Generator shall be installed safely as per manufacturer/supplier instruction.

• Generator shall be earthed, by bonding the neutral to the frame and connectingthe frame to earth.

• Sensitive earth fault protection may be necessary if earthing conditions aredifficult.

• A suitable fire extinguisher (DCP type) shall be kept near by the generator.




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Aug.’ 2007

• Only a trained person shall be permitted to operate the generator.

• Start up & shut down procedure shall be followed as per manufacturer

instruction.

• Provide appropriate PPE to Operator like Ear Muff/ Ear Plug, Safety Hand

gloves etc.

b. Movable Plant

• Plant such as lifts and hoists relocated occasionally during the work should besupplied by armored cable.

• Plant which is moved frequently (eg, a cement mixer) should be connected tothe supply by a flexible cable with protective braided abrasion-resistant heat.

xxxii) STATIC ELECTRICITY: - Static electricity hazard can be reduced by minimisingthe accumulation of charges and draining (earthing) accumulated charges as below.

• Bonding and earthing between source and receiver of the product handlingsystem (pipe lines, distribution system, spray painting and sand blasting).

• Minimizing use of non-conductive materials. Where hoses, containers andconveyors made of non-conductive materials have to be used special anti-static

material shall be selected (anti-static rubber belt, steel braided hoses).

• Use of anti-static PPE (safety shoe, coveralls, and disposable coveralls).

• Bonding of pneumatic tools and air removers/blower.

• Control of flow rate of static-prone materials.

• Use of anti-static additive (in Jet fuels).

• Avoiding splash filling in Tanks.

4. Administration: -

i) RCM/RCE shall ensure that this procedure is followed at site.ii) RCM/RCE shall inform all contractors about the electrical permit system, that permit isrequired to carry out all critical electrical jobs.

iii) To carry out any of the critical activities related to electrical, contractor supervisor/L&T field engineer has to fill up the requisite permit.

iv) Permit shall only be renewed if the work - site conditions, activity and persons involvedare same.

v) Fresh permit shall be issued if the activity has to be continued after completion of the

period, if the work-site is different, on a new day or if the work-site conditions change.vi) HIRA shall be prepared in assistance with P&M/Electrical In-charge.

vii) Regular inspection of all the work area shall be done jointly by safety personnel &

P&M/ Electrical personnel.viii) Safety Person records all the observations in the electrical inspection checklist and the

for the particular area and the consolidated report of observations from all the areasshall be prepared in the Electrical inspection report and given to P&M/Electrical in-

charge with a copy to site in-charge.ix) SSO/E will maintain all the records of electrical inspection.x) RCM will arrange “Competent Person” for inspection / examination / tests as and when

required.

5. Records




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Aug.’ 2007

Forms Reference

Permit for working on electrical lines/equipment OHS – 15 EElectrical Safety Checklist OHSC – 19 EElectrical Isolation Certificate OHS - 29




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Oct. 2007

7

CHAPTER – 30

MOTIVATIONAL SCHEME

1.0 Purpose:

(i) To be effective, a programme for maintaining interest in safety must be based onneeds. To develop suitable activities and promotional materials the needs and

emotions of supervisors and employees should be taken into account. The followingare the basic emotions and needs:

§ Pride in safe workmanship, in good records, both individual and group.§ Recognition, desire for approval by others in the group and family or praise

from supervisors

§ Participation desire to be one among the group, to get into action.§ Competition desire to outshine others.

§ Fear of painful injury, death, loss of income, family hardship, groupdisappointment or ridicule, supervisory criticism

(ii) The purpose of this procedure is to serve as a formal means to motivate siteemployees in order to implement the OH&S Management System and comply with

all the relevant legal requirements through safety promotional measures such as

§ Involvement in the safety programme

§ Actively participating in safety committee meetings

2.0 Definitions -

(i) Award – a prize / appreciation letter that is given.

(ii) Incentive – something that serves as a stimulus to action by appealing to selfinterest

3.0 Procedure:

(i). SELECTION OF SAFE EMPLOYEE OF THE MONTH:a. Every month one contractor employee will be selected from among the

contractor working with L&T – E&C for “Safe Employee of the Month”

b. L&T – SSO in consultation with concerned Discipline In-charge (likeElectrical, Mechanical and Civil) will identify the best performing employees

trade wise (like Rigger, Fitter, Helper, Welder, Grinder, Mason, Scaffolder,Gas Cutter, Fitter, Driver, Crane Operator, Electrician, etc) by 25th of everymonth.

c. Identified employees will be selected as per the evaluation sheet- OHS30B/Oct ’07.

d. SSO will bring those evaluation sheets to RCM and RCM will finalise the Number of employees to be awarded and type of awards to be given based onthe guidelines given as below.

e. Within First of week next month , Award function will be organised at site.f. RCM will inform the concerned client personnel, Project Manager/ SBU Head

to invite them for the function.g. Necessary arrangements for the award function like Gifts, Certificates,

Snacks, Photography, etc will be organised under the guidance / with the

support of RCM.




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Oct. 2007

7

h. SSO will publish photographs in site HSE Bulletin Board and also share itwith HSE Capability Centre, Powai.

(ii).SELECTION OF BEST CONTRACTOR:

a. Once in two months one contractor will be selected at project site

b. Process of identification, selection and awards will be done along with the process of identifying the “Safe Employee of the Month”.

c. Identified contractor will be selected as per criteria given in the evaluationsheet- OHS 30A/Oct ’07.

d. SSO will evaluate the contractor based on the feedback received fromconcerned site employees including concerned L&T Incharge.

(iii). NEAR MISS REPORTING:a. This award will be given to any person who is working at L&T Project sites

and who is reporting maximum number of near misses that have occurred atL&T Project sites.

b. The Selection will be based on following Criteria:I) Number of Near Miss ReportedII) Criticality of Incident

III) Clarity of Reportc. Employees will submit filled up near miss report to site safety person.d. Process of identification, selection and awards will be done along with the

process of identifying the “Safe Employee of the Month”.

(iv). SAFETY COMPETITION:a. All the project sites will organise following Safety Competitions during Safety

Month (i.e. January), Safety Week (4th – 10th March) or World Environment

Day (WED) (5th June). b. SSO will inform about the programme to all the site employees 20 days in

advance (i.e. 10th of the Month) and get their nomination for followingcompetitionsi. Safety Poster

ii. Safety Sloganiii. Safety Poem

c. Participants will submit their entries by 25th of month.d. On 27th of the month, Site Safety Department will display those articles /

posters/ Poem at suitable location at site for the exhibition till 30th of the

Month.e. Viewers will cast their votes for the best posters, slogan and poem.

f. Highest vote receiver for each of the category will be selected as the winner.g. Process of identification, selection and awards will be done along with the

process of identifying the “Safe Employee of the Month”.

h. Award function date for the above programme can be scheduled in following period

Sr. No.

Details Award Function can bescheduled

1 Safety Month Last Week of January

2 Safety Week Last Day i.e. 10th of March

3 World Environment Day 5th

of June




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Oct. 2007

7

(v). BEST HOUSEKEEPING:-

a. Once in two months Best Housekeeping Award will be given to a contractor. b. SSO/ RCM / Safety Committee will decide best contractor based on the

inspection of following areas as per criteria given in the evaluation sheet-

OHS 30C/Oct ’07.i. Housekeeping in store area

ii. Gas Cylinder storageiii. Work Place

c. Process of identification, selection and awards will be done along with the process of identifying the “Safe Employee of the Month”.

(vi). HAZARD IDENTIFICATION:a. This award will be given to any person who is working at L&T Project sites

and who is reporting maximum number of hazards at L&T Project sites. b. The Selection will be based on following Criteria:

I) Number of Hazards (Unsafe Acts/ Conditions Reported)II) Criticality of HazardIII) Clarity of Report

c. Process of identification, selection and awards will be done along with the process of identifying the “Safe Employee of the Month”.

GENERAL GUIDELINES FOR SAFETY AWARDS

Sr.No.

Motivation Scheme Frequency No. of Employeesto be Awarded (%

of Total

Employeesworking at site)

Type of Award

1 Safe Employee of

the Month

3-4% of the

employees presentduring the period

2 HazardIdentification

Monthly

30% of the TotalParticipants

Certificate+

Gift (Valuearound Rs. 750)

3 Best Contractor

4 Housekeeping Bimonthly

One Award forEach Disciplinarycontractor like

Civil, Mechanical,Electrical

Trophy (Valuearound Rs. 750)

+Certificate

5 Near Miss Reporting Quarterly 30% of the Total

Participants

Certificate+

Cash (Rs.500-1000/-)

6 Safety Competition 4th March or SafetyMonth – January or

World Environment Day

30% of the TotalParticipants

Cash / Gift(Value around

Rs. 750)

(Note: This is just a guidelines but the final decision will be with site RCM/ PM)

4.0 Administration:




___________________________________________________________________________________________


Oct. 2007

7

(i) SSO shall prepare Site Specific Motivational Program as per OHS – 30 D in

consultation with RCM, Discipline Incharge within the first month after opening of the

site.

(ii) Site Specific Motivational Program shall be monitored and reviewed quarterly by SSO

and RCM.(iii) RCM, Discipline Incharge and SSO shall be responsible to implement the Site Specific

Motivational Program at project site as per the above procedure.

(iv) It is the responsibility of SSO to send details of motivational activities carried out at

site to HSE-Capability Centre on monthly basis.

5.0 Records:

Forms Records

Selection for Best Contractor - OHS 30A

Selection for Safe Employee of the Month - OHS 30BSelection for Best Housekeeping - OHS 30C

Site Specific Motivational Program - OHS 30D




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Oct.’ 2007

CHAPTER – 31

SAFETY SCORING

1.0 Purpose

(i) To serve as a means to evaluate and rate the Safety Performance of L&T projectsites using a quantitative technique i.e. Safety Scoring.

2.0 Definitions - Nil

3.0 Procedure

(i) The site Safety Performance evaluation shall be carried out once in a quarter by

HSE Capability Centre.(ii) Evaluation shall be carried out by a team consisting of SSO, RCM or his

representative and HSE Personnel/ representative from HSE Capability Centre as

per enclosed OHS-31 checklist.(iii) Scoring shall be carried out by the above team.

(iv) HSE Capability centre shall prepare and present consolidated Report on thefindings to the Site Management, MSC, SBU Head within 2 days.

(v) Information on Sites having “Very Good” or “Excellent” Result, as per the below

mentioned scoring , shall be communicated to all other ongoing project sites acrossall SBUs.

(vi) Site scoring 71% or above will be eligible to receive a “Certificate of Appreciation”from the Top Management.

(vii) HSE Capability Centre will communicate achievement of project sites across E&CDivision through L&T – E&C intranet web site.

4.0 Records

Forms Records

Scoring Criteria & Strategy - OHS 31

Sr. No. Marks obtained Result

1 60 - 70% Good

2 71 - 80% Very Good

3 81% and above Excellent




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Rev – 00 Page 1 of 13 25 Feb.’2008

CHAPTER – 32

SAFETY DURING PRE-COMMISSIONING AND COMMISSIONING

1.0 Purpose:

The purpose of this document is to provide instructions for site-co-ordination activities for smooth

& safe pre-commissioning & commissioning of the plants, under the scope of Larsen & Toubro.

2.0 Definitions:

(i). Plant: An assembly of all systems / units including general installation of auxiliaries that arenecessary for start up & operation to manufacture the desired product(s)

(ii). Start- up: Start up of a plant is reckoned as those activities that are performed for the

operation of the plant in order to manufacture the required product as per processspecifications. This usually refers to initial operation of the plant.

(iii). Unit: An assembly of system which together form a distinct operating section & is a part ofthe plant.

(iv). Mechanical completion: The plant / unit /system is considered mechanically complete whenall the construction work is completed in accordance with the drawings, specifications, codes& regulations, all equipments & machines are erected & aligned, all instruments installed &

pipelines are hooked up, all testing & inspection activities are completed. All machines arefirmly grouted, All rotating equipments are dynamically aligned, All permanent gasketsinstalled, Initial charge of lubricants is filled, All electrical fittings & connections are

installed & tested, All instruments installed calibrated & loop checking completed, No-loadrun of all electrical prime-movers completed, Statutory calibration of all storage tanks is

complete, All painting & thermal insulation work completed, All paving grading & approachroads are completed, Final clean up is done, All temporary construction facilities areremoved, All statutory approvals required are obtained.

(v). Pre-Commissioning: Pre-commissioning activities are operational activities performed inorder to make the plant / unit / system ready for commissioning. These activities include, but

not limited to the following,

§ Inspection of tanks/vessels/columns etc for cleanliness & any other construction debris.

§ Isolation / removal of inline components / instruments for flushing operation & re-install them on the

completion of these operations.

§ Flushing & cleaning of pipes / vessels / equipments by air blowing / water flushing / steam blowing / oil

flushing / degreasing.

§ Cleaning & flushing of sewer systems & blow down systems.

§ Chemical cleaning for pipes / vessels etc as required as per the procedure given by specialist agency.

§ Passivation of lines / vessels / equipments as required.

§ Testing of safety valves & other safety devices

§ Testing of heat exchangers for leaks

§ Testing of plant communication system

§ Checking out interlock systems & emergency shut down systems

§ Installation of temporary blinds / spools to enable isolation of systems during pre-commissioning stage.

§ Refractory drying for furnaces

§ Removal of temporary blinds just prior to commissioning

§ Loading of catalyst, molecular sieve, packing etc

§ Water run / dry run for process system to check the functioning of controlling systems

§

Leak test of vessels / piping /equipments§ Drying of columns / reactors /equipment with dry air / nitrogen as required




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Rev – 00 Page 2 of 13 25 Feb.’2008

§ De-airing of the systems by nitrogen purging / steaming as required

(vi). Commissioning: Commissioning activities are those, which are required to be performed onthe plant to manufacture the required product as per process specifications. Commissioning

activities are operational activities performed after pre-commissioning that are directlyassociated with the manufacture of desired end / intermediate product. These activities will

extend up-to a period when the plant / unit is producing the desired product.(vii). Performance Test: A detailed program of test run to take the measurements which are

necessary for the verification of capacity, quality & consumption guarantees whenever these

are listed in the contract agreement. Performance test is carried out for a specified period bythe commissioning team in accordance with the provisions of the contract.

Responsibility of HSE capability centre:The responsibility of the HSE capability center is to develop safety consciousness amongst the

commissioning team. The department will function in an advisory capacity. ensuring thefollowing.

1) The commissioning team members have access to and are familiar with the HSE manual forcommissioning

2) The commissioning team is familiar with the process hazards and the hazards of chemicals being used / handled during commissioning. The safety department will assist SBU’S for the procurement of desired personnel protective equipments

3) The HSE capability center will co-ordinate with the safety department of client / owner on thesafety related issues in consultation with the commissioning team leader.

Responsibilities of representative from the HSE capability center:

1) Identifying the requirement of safety equipment and personnel protective Equipment (PPE),

ensuring its availability at site, and enforcing use of the PPE as per the job requirement.2) Ensure functioning of the fire and safety equipments installed.

3) Ensure functioning of fire alarm system and gas detector system before entry of Hydrocarbonsinto the unit.

4) Check availability of proper emergency lighting and wind sack.

5) Ensure availability of display boards at site, detailing the safety precautions, the importanttelephone numbers, the escape route in case of any emergency like fire or emission of toxic

gases etc. 6) Enforcement of safety procedures in dealing with hazardous jobs like hot work, entry in

confined space, vessels etc.

7) Ensure availability of first aid kit. In consultation with the commissioning team Leader, will

co-ordinate for the medical assistance for the commissioning team.8) Monitoring the environment as and when necessary for toxicity level and noise level. The

HSE department of the client can be asked for assistance in this regard.9) Formulation of proper evacuation plan in co-ordination with client safety department.

10) Organize regular safety meetings with client safety department and the commissioning teammembers.

11) Carryout emergency mock drill in co-ordination with the client's fire fighting / safety /operation department.

12) Organize training of the commissioning team with respect to use of fire fighting equipment

and first aid measures.13) Will carry out the safety audit before start of commissioning activities.




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Rev – 00 Page 3 of 13 25 Feb.’2008

Responsibility of the commissioning team leader

1) Person responsible for overall commissioning, regardless of his designation, will be designatedas Commissioning Team Leader to ensure safety during commissioning.

2) The commissioning team leader will be responsible to ensure safety of the commissioning

team and the facility being commissioned.3) The commissioning team leader will ensure that:

• The HSE manual for commissioning is accessible to the commissioning team.

• The commissioning team members are briefed on the availability and use of PPE.

• The commissioning team members are briefed on process hazards and that they arefollowing the safe method of working.

4) Co-ordinate with the project safety department including the client.5) Obtain copies of the safety manual and other safety related documents from the client. This

is more so in case of project site is within or near to an operating plant.

6) Ensure availability of medical help and facility for the treatment in case of:

• Exposure to hazardous chemical.

• Physical Injury

• Asphyxiation7) The team leader will, before the start of commissioning, ensure that the safety audit (Check) of

the plant is completed and the checklist neutralized (corrective action completed).

8) The team leader will ensure that the commissioning team members are aware of overall plot plan and familiar with the emergency escape routes.

9) The team leader will ensure that a mock emergency drill is conducted and emergency

procedures followed.10) The leader will ensure before undertaking the commissioning that he has all emergency phone

numbers with him.11) The team leader will ensure that he has the copy of the "On-site Emergency

Management Plan “and is conversant with its requirements.

Responsibility of the commissioning team members:

1. They have read and familiarized themselves with the HSE commissioning procedure.2. They have read the HSE protocol of the operations manual.3. They have read and have access to the material safety data sheet of the hazardous chemicals

being handled.4. They are aware and conversant with the process hazard of the plant being commissioned.

5. They have the list of PPE’S and familiar with the use of these equipments.6. They have read and understood the safety procedure of the operating plant.7. They are familiar with the plant layout and knowledge of the escape routes.

8. They are using the right PPE.9. They are familiar with the exposure symptoms of the hazardous chemicals being handled.

10. They have access to the emergency telephone numbers.11. They are physically fit and mentally alert during the work.

3.0 Procedure:

A) Safety during Pre-commissioning:

(i). Pre-commissioning HSE plan shall be formulated with details of PPE to be used by HSE

Engineer. Any special PPE requirements for pre-commissioning needs to be indicated. Local

statutory rules and HSE norms shall be understood while firming up HSE Plan for the project. Implementation of HSE plan and availability of PPE shall be the responsibility of HSE




_______________________________________________________________________________________________

Rev – 00 Page 4 of 13 25 Feb.’2008

Engineer however procurement of the same to be taken up by HSE Engineer with Procurement Manager .

(ii). HSE Plan shall be communicated to the pre-commissioning team by HSE Engineer through

“HSE Induction Program.”(iii). “Ten Safety Commandments for Commissioning” issued by HSE Engineer during

Induction Program shall be strictly adhered. (Refer Annexure 01)

(iv). HSE shall be managed on area basis.(v). Following construction activities shall be completed during pre-commissioning phase

§ Civil Work:

a) All the underground systems like OWS, CBD, SWS (Storm Water System) shall be hookedup with the outside system prior to start the pre-commissioning activities like Hydro test.

b) Fire Proofing of structure (OISD 164): Fire proofing shall be completed to vessels, pipingand structures as per the drawing.(if applicable).

§ Mechanical Work:a) Piping: - There are mainly three kinds of piping system exist in any process plant whichare as follows:

I) Utility Line: (Air, Water, Nitrogen & Steam)

§ Utility system shall be commissioned on priority so that the utilities like Service Water,Cooling Water, Boiler Feed Water, DM water, Plant Air, Nitrogen, Instrument Air, Steam

,etc will be available for carrying out pre-commissioning activities of other processsystems.

§ Water Flushing: The initial flushing shall be carried out prior to pressure testing. All thelines which are to be air blown followed by water flushing shall be checked by siteengineer at the beginning and during operation as per the enclosed Safety checklist ( OHSC

32E) for safe operation of the job.

§ Pneumatic Flushing: In cases where water is not desirable in the piping system (e.g.instrument/utility air), flushing by pressurized air shall be carried out. When pressurized air

is used, the minimum velocity shall be 35m/s. Safety check shall be carried out as perOHSC 32D by site engineer at the beginning of the job.

§ Pressure Test: After flushing operation, lines shall be pressure tested ( either pneumatic or

hydro test) based on the design criteria. Concerned site engineer shall carry out Safetychecks as per enclosed checklist (OHSC -32D) prior to start and during the operation.Annexure -01 can be referred for further information.

§ Control Valves operation shall be tested with instrument air. There is no need of leak test. II) Process Line:(e.g Naptha, Benzene, Paraxylene)

§ Water Flushing/ Air blowing/ Card Board Blasting: The initial flushing shall be carried out prior to pressure testing. All the process lines which are to be air blown followed by waterflushing shall be checked at the beginning and during operation as per the enclosed Safety

checklist ( OHSC 32D/ 32E) for safe operation of the job.

§ Pressure Test: After flushing operation, lines shall be pressure tested ( either pneumatic orhydro test) based on the design criteria. Concerned site engineer shall carry out Safety

checks as per enclosed checklist (OHSC -32D) prior to start and during the operation.Annexure -01 can be referred for further information.

§ Nitrogen Filling: Lines which are to be filled up with Nitrogen shall be carried out with

proper precautions like: – Follow the Work Permit System – Barricade the area

– Signboard to be displayed




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Rev – 00 Page 5 of 13 25 Feb.’2008

§ Steam Blowing Operation: Lines which are to be steam flush shall be checked as per theenclose Safety Checklist (OHSC 32B) by concerned site engineer prior to start as well asduring the operation.

§ Chemical Cleaning Operation: Lines which are to be chemically cleaned shall be checkedas per the enclose Safety Checklist (OHSC 32A) by concerned site engineer prior to start aswell as during the operation. Lines to be chemical cleaned shall be identified on the P&ID's

and line index. A procedure shall describe in detail the steps for chemical cleaning. It shallinclude

– Degreasing. – Chemical cleaning/ descaling. – Neutralization.

– Passivation – Water flushing.

– DryingFor equipment such as turbines, generators, pumps and compressors, the piping to becleaned shall have all sensitive items that can be damaged by the cleaning medium

removed or blanked off. Generally, the following items shall not be chemically cleaned (items shall be identified on chemical cleaning are)

– All instrument tubing downstream the first piping block valve. – Piping systems with copper alloy materials. – Flexible hoses.

– Pumps. – All bolted/screwed valves and instruments.

Removed or blanked off items shall be cleaned separately prior to reinstallation. Thesystems to be cleaned shall have high and low point vents and drains installed. "Deadlegs" shall be avoided. Cleaning shall be carried out after pressure testing unless

otherwise specified. If more than 3 months to start up of commissioning activities,

system shall be preserved with nitrogen. Overpressure shall be 0.5 bars.§ Unplugging of lines: A plug in a line is adhering to the inner surface of the pipe. These

plugs develop from some mechanical failure and also from polymerization / or salting /congealing. Tracing or Jacketing in a line is great help in melting out of a plug. But when

line is opened, the heat applied can cause pressure to build up and hot or corrosive materialto spray out on to anything in its path. The following are the rules to be followed whenperforming such a job:

1. The job of clearing a line should be preplanned.2. The procedure outlined shall be to first try to clear the line by applying a solvent directly in

to the closed line. Normally this is done with steam or water applied to permanentconnection of hose and shall be drained from lowest draining point.

3. The most effective means of cleaning in this manner is to pressurize this line & then drain,repeating this process frequently. This cyclic process helps to clear the clog. It also drainsthe solution from the area of the plug facilitating unplugging.

4. Heat should be applied to the outside of the line if it is possible, this can be in the form ofsteam tracing or steam applied safely from the open hose.

5. If the plug does not respond to the above cleaning procedure, probably it will be necessary

to dismantle the line.6. The line must be depressurized.

7. All tracing and jacketing should be shut off and the line allowed to cool.8. Use PPE such as Protective suit, Face shield over the helmet and glasses (if a full cover one

piece suit is available the same should be used), PVC suit and gloves when parting a line.

9. If the cleaning can be carried out by attaching valves and hoses and in a closed manner thesame should be attempted.




_______________________________________________________________________________________________

Rev – 00 Page 6 of 13 25 Feb.’2008

10. For de-choking of column and in case of partial choking of heat exchanger tubes: In process like ACN, suction/discharge lines 2" caustic connections are provided which arenormally kept blinded. In case choking problem is experienced, a particular type of

operation is isolated / by-passed as per the procedures laid down, then the column drained /flushed out to toxic sewer. Caustic connection can be made by hose connecting a loop

circulation and established for a period of time till choking is removed. Than the contents

can be drained out in to proper sewer and flushing with water carried out. This is normallyused in case of polymerized material or fouling material which are responsible for plugging

of process equipments. Before doing this, de-contamination of system, lines shall be donewith proper chemical solution.

11. Heat Exchangers tube cleaning : In case of fouling / choking of the tubes of heatexchangers, following is procedure for caustic cleaning:

§ Isolate the fouled/choked exchanger.

§ Depressurize drain and flush the exchanger.

§ Dismantle the exchanger tube bundles using PPE’S

§ Carefully put the exchanger tube bundle in caustic cleaning tank and start heating the

caustic by stream coils to 80° - 90°c. Keep the exchanger bundles soaked for overnight preferable 24 hours.

§ Remove the exchanger carefully after caustic has cooled down. Use all safety precautionsas far as handling non alkalis is concerned.

§ Flush heat exchanger tubes bundles with large quantities of water, till the entire caustic iswashed out.

III) Fire Fighting System

§ After mechanical completion of fire fighting pipeline system, safety check shall be carriedout prior to start water flushing operation as per the enclosed sheet (OHSC – 32E) byconcerned site engineer.

§ Safety Checks shall be carried out as per enclosed sheet (OHSC – 32D) beforecommencing Hydro test followed by water flushing operation.

§ Installation of hose boxes and portable fire extinguishers shall be completed as per the

design layout before commissioning activities started.

b) Static Equipment (like Tank, Vessel, Reactor, etc)

I) Cleaning:

§ Tank Cleaning: Following are the steps to perform for tank cleaning operation

a) Drain/pump out the contents b) Fill the tank with water & drain.

c) Flush with steam if containing solvents or hydrocarbon liquids.d) Flush with inert gas if containing fire hazardous gases.e) Flush with air after purging with inert gas before entry.f) Remove all sludge, deposits inside the tanks.

g) Positive isolation of incoming and outgoing pipelines to tank should be done.When closed piping systems are parted for replacing valves, servicing pump replacing

sections of lines etc this is called "Opening Lines. The following rules must be followedwhile performing such work:1. Familiarize with the piping system to be worked on.

2. Check all valves are properly positioned. All drain valves should be opened.3. Pump shall be electrically isolated.

4. Although the previous steps have been taken, the job should be performed as thoughthe line is full and under pressure.




_______________________________________________________________________________________________

Rev – 00 Page 7 of 13 25 Feb.’2008

– A sloping line may have a plug, a valve and another plug. Open the valve to drainthe line, but it could still be full between the plugs.

– A horizontal line may have sag or dip in it. Open the line up and blow it out, but

there could still be acid or other material where the line is sagging, if that section ofthe line is taken out and tilted, the material will run out.

– If a line is plugged, it may be from corrosion, which can produce gas under pressure.

5. The area around the possible spray release of material should be roped off.6. Use PPE such as Protective suit, Face shield, PVC gloves, etc.

7. Since opening a flange is the most common procedure used to open a line, the procedure to follow is:

– If the flange is horizontal, you want any sprays to be away from you. If it is verticala spray should be downward,

– These are the edges of the flanges that should be opened first.

– Keep the bolts near, you tight, and slowly open the ones away from you. A quarterof a turn at a time is not too little.

– If the flange stays tight, start a wedge between the flange on the side where the bolts were loosened.

– When you are sure the flange is open and that any drip is over, remove the rest ofthe bolts and nuts.

8. Lines taken out or brought to the shop can also be hazardous. Further handling or

dismantling in the shop could release material. The only fitting or section of line that issafe is one that has been blowout, washed out and looked through and tested.

9. After a section of line has been removed the remaining open flanges should be blinded.

II) Catalyst Loading : After completing the cleaning operation and vessel is ready forcatalyst operation, safety checks shall be carried out by concerned site engineer also

with HSE Engineer as per the enclosed checklist (OHSC – 32C) before and duringoperation.

c) Rotary Equipment (like Fire Water Pump, Motor, Compressor)

Motor: All the motors shall be tested under no load condition for its smooth

functioning prior to that following checks shall be carried out

§ Double Earthing

§ Secured with foundation.

§ Flame proof motor/ Non-flame proof

§ Authorized and trained person is on the job.

§ Marking on the switches for “ON” & “OFF”, Emergency Shutdown.

§ Communication system is in place

§ Barricading of area with sign board.

§ Covered with guard

Pump: Following checks shall be performed prior to commission the pump

§ Double Earthing

§ Coupling Guard is in place

§ Marking for direction of rotation

§ Free movement of the shaft

§ Oil cup provided

§ Calibrated pressure gauge at discharge end

§ NRV at the suction

§ On-off valve / control valve at both the end (Suction & Discharge)




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Rev – 00 Page 8 of 13 25 Feb.’2008

§ Provision of Earthing jumpers at pump & pipeline joints

§ No leakage from mechanical seal.

Compressor: Following checks shall be performed prior to commission thecompressor

§ Double Earthing

§ No external damage due to transportation

§ Lubrication system

§ Lube lines/ lube flow to all lubrication points

§ Lube filter elements are in good health

§ Instrument location/mounting as per good engineering practice

§ Level base plates and soles and grout all bearing surfaces

§ All control loops are tested

§ All instruments are calibrated

§ Coupling Guard is in place

§ Marking for direction of rotation

§ Free movement of the shaft

§ Safety valve provision

§ Electrical & Instrumentation Work:

a) Fire Alarm System: Smoke detectors, Gas detectors, Heat detectors, Flame detectors,Manual call points (Flame proof/ Non- flame proof), shall be installed andcommissioned as per the statutory requirements (TAC, NFPA)

b) Sub-Station Charging: To start the pre-commissioning activities for charging the sub-station panels following safety checks shall be carried out by the concerned site

engineer. § Valid Work Permit

§ Fencing of transformers

§ Permanent Signboards in place

§ Earthing to the equipment

§ Fire Extinguishers (CO2) and Fire Buckets of required number

§ Rubber mat for panel work

§ Illumination level in the work place

§ Trained and Authorized person on the job

§ Communication System in place

B) Safety during Commissioning:

(i). During commissioning all necessary supervision, operators, ancillary staff and operationalassistance if necessary by vendor representatives and subcontractor shall be planed and

arranged and the same shall be notified to the client in the commissioning manual. Allchemical lubricants, spares and consumables requirements are envisaged well in advance sothat it shall be made available for use during commissioning.

(ii). Pre Start up Safety Audit / review to be carried out before the plant goes into commissioningstage and all critical points should be liquidated before feed cut-in. The pre-startup Safety

Review checklist is a support tool to be specifically developed for a particular project andshall act as a support tool during review. The Pre-startup Safety reveiew shall be conducted bya review team which will include as a minimum the following participants




_______________________________________________________________________________________________

Rev – 00 Page 9 of 13 25 Feb.’2008

§ HSE Representative

§ Process Manager/Engineer

§ System Engineer/ System Supervisor

§ Representative of owner

§ Representative of PMC

§

Representative of Licensor – on the basis of contractual agreement§ Any external agency (e.g third party inspection) if required by owner.The review shall

check various aspsects of the plant. Typical List of Aspects for Safety Audits are as

follows:1. Fire Protection System

2. Fire/Gas detection System

3. Flare & Relief System

4. Plant and site layout

5. Dyke and drainage and sewer system

6. Buildings and structures

7. Noise contours

8. Safety showers and eye wash fountains

9. Protection devices on machinery and individual

10. Asphyxia or toxicity in closed environments

11. Safety Signs

12. Hazardous area classification conformity

13. Emergency Shutdown System

14. Process Safety Devices,

15. Process Safety Information and operating pro cedure

16. Operator Safety Training

17. Emergency Planning and response

18. Critical tests and checks

19. Safe Work Practices

20. Maintenance training and mechanical integrity

21. Emergency exists availability

22. Availability of PPE at site

(iii). HSE Meeting shall be conducted atleast once in a fifteen days to discuss HSE issues,compliance , measures to ensure complete compliance, safety training schedule.

(iv). Clear demarcation and signposts shall be made to ensure and demarcate the live areas ofcommissioning and the construction areas.

(v). It shall be ensured that no longer construction work can be carried out in the commissioning

area without a work permit.(vi). It shall be ensured that all relevant statutory certificates are obtained and properly maintained

(e.g IBR, OISD,LPA, etc) before start of the commissioning activities.(vii). HIRA shall be performed for commissioning . The results of the HIRA shall be incorporated

into the work execution plans, method statements and further reflected in the Permit to Work,where applicable.

(viii).In addition to the assessments mentioned above, Task/ job assessments shall be performed by

the project team for all “non routine” operation which present potential hazardous operations.For these tasks/ jobs, the project team shall develop method statements describing in detail thesteps and functions of the tasks/job. These method statements shall be used to communicate to

the workforce performing the task about the HSE hazards and control measures to beimplemented prior to the commencement of work.

(ix). Modules for Tool Box Talks shall be prepared by HSE Engineer in consultation withCommissioning team leader during the planning phase. Specific precautions, regardinghandling of any hazardous material or undertaking any high – risk activity, have to be brought

to notice and a plan for safe operation for further communication to the actual execution teamto understand the mitigation measures.




_______________________________________________________________________________________________

Rev – 00 Page 10 of 13 25 Feb.’2008

(x). Commissioning team shall be acquainted with the emergency procedures prevailing in the premises of the owner. A detail of the procedures shall be made available and communicated properly to all the personnel under direct or indirect purview of the commissioning team and

emergency drills shall be carried out periodically.(xi). Disposal of wastes: The waste material during commissioning may contain flammable, toxic

and hazardous chemicals it is recommended that the waste is disposed in consultation with the

environmental control department of the plant. Handling precautions are as follows:a) Solid Waste: Solid flakes, pellets or powder should be collected separately in

appropriate inert containers. Intermixing of waste should not be done. The waste is to belabeled, sealed and handed over to the environmental department for proper disposal.

b) Liquid: Waste samples etc., should be kept in a separate container specially made forthe purpose, duly labeled and handed over to the environmental department for disposalwhen disposing liquid waste into the OWS it is to be diluted effectively to avoid shock

loading to the effluent treatment plant. Disposal of liquid waste into the OWS done afterconsultation and with the knowledge of the plants environmental central department

c) Gases: Waste samples contained in SS bombs or rubber bladders should be dischargedout door in a manner to effectively dilute the contents. There should not be a source of

ignition when disposing flammable gases. Toxic gases should be disposed extremelycarefully avoiding possibility of exposure.

(xii). Before taking gas, following system shall be ready1. Fire Fighting System & Fire Alarm System2. Utility System3. Instrumentation4. Lighting5. Fire Proofing of structure , cables6. Insulation Work for piping, equipment

4.0 Administration:

(i). All the safety checks as mentioned below shall be carried out prior to start the activities byconcerned site engineer and record shall be submitted to site HSE Engineer except Catalystloading where both shall perform the check.

(ii). Commissioning Leader / Manage shall ensure that all the points mentioned in the checklistshall be complied prior to start the operation.

(iii). For special activities, necessary safety procedure shall be drawn out by HSE Engineer alongwith commissioning team.

(iv). HSE Engineer shall provide necessary training to all the site employees to communicate the

hazard involve in the pre-commissioning and commissioning activities.(v). In co-ordination with the commissioning leader & RCM, necessary PPEs essential for the

commissioning activities shall be procured by HSE Engineer from the reliable source.

5.0 Records:

Forms Reference1. Safety Check for chemical cleaning operation - OHSC-32A

2. Safety Check for Steam Blowing operation - OHSC-32B3. Safety Check for Catalyst Loading operation - OHSC-32C4. Safety Check for Hydro test operation /

Pneumatic test/Card board blasting - OHSC-32D5. Safety Check for Water Flushing operation - OHSC-32E

6.0 Annexure




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Rev – 00 Page 11 of 13 25 Feb.’2008

Ten Safety Commandments forCommissioning

1) Smoking is strictly prohibited in the operating

plant except in smoking booths2) To obtain necessary safety permit before start of

any repair maintenance work.

3) Safety Induction is Mandatory for all.

4) Operation of machine / equipment by authorized personnel only.5) Use of PPE to comply with.6) Use of only flameproof portable lamps (24Volts)

inside tanks / confined locations.7) Follow proper safety instructions according to

the chemical's material safety data sheet (MSDS)supplied by the manufacturer / supplier

8) Use of camera only on authoriza tion.

9) Keep plant area clean and free of junk10) Entry of automotive vehicles in the process area

is restricted.

1. Ten Safety Commandments for commissioning - Annexure 012. Pressure Test - Annexure 02

Annexure 01




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Rev – 00 Page 12 of 13 25 Feb.’2008

Annexure - 02PRESSURE TESTS: Following precaution shall be taken during pressure test (i.e Pneumatic/Hydro test)

1. General: The test pressure shall, unless otherwise specified, be in accordance with ASMEB31.3. Testing shall not take place with system temperatures 4°C ,during rain or fog unless

under suitable cover.

2. Test preparation:§ Pressure, temperature and time shall be recorded for all hydrostatic tests.

§ Calibrated Pressure gauges and recorders used to indicate and record test pressure shall be deadweight tested for accuracy according to a procedure, dependent of type of equipment.

§ Minimum of one gauge shall be positioned at the highest point and one gauge to be positioned atthe lowest point. If there is a deviation of more than 2% between gauges during test, the test shall be stopped and the equipment recalibrate.

§ All piping shall be adequately supported before the pressure test. Spring or other variable typesupports shall be blocked to prevent movement.

§ Unless otherwise noted, all valves are to be through body tested. First block valve for pressureinstruments shall be included in the test.

§ Piping containing check valves shall have the source of test pressure on the upstream side. If this isnot possible, the check valve disc shall be removed or jacked open.

§ Ball valves shall be pressure te sted in the half open position. Other valves shall be tested in thefully open position. Where the test pressure to be applied to the piping is greater than the maximumallowable test pressure for valves, the valves shall be blinded off on the side to be tested, orremoved and replaced by dummy spools.

§ Turbines, pumps, compressors and vessels shall be blinded off prior to pressure testing.

§ A list shall be prepared for sensitive equipment that shall be removed, blocked off or isolatedduring testing, such as relief valves, inline instruments, turbines, pumps, compressors and vessels.This list shall be a part of the test procedure

3. Test media:§ For hydrostatic testing the test medium shall in general be fresh water, except that other

suitable liquid may be used if, – The piping or inline equipment would be adversely affected by water – If the liquid is flammable, its flash point shall be at least 49°C and consideration shall

be given to the environment – The liquid is approved to be used

§ The chloride ion content of the water used for pressure testing stainless steel lines shall be

less than 200 ppm and the line shall be properly drained soon after testing. pH value of thewater shall be between 6.5 and 7.5. The preservation fluid shall be a water impellent andemulsifiable rust preventive lubricating oils that contain detergents and inhibitors that have

been specially formulated to prevent rust.

§ For pneumatic testing, the test media shall be oil free, dry air or any inert gas. The use ofair for testing shall be limited to a maximum pressure of 7bar.g. Above this pressure

nitrogen shall be used. The extent of pneumatic testing shall be approved. Forinstrument/utility air systems, where the introduction of water is undesirable, test media

shall be air or inert gas




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Rev – 00 Page 13 of 13 25 Feb.’2008

4. Hydrostatic testing: The test pressure shall be maintained for a sufficient length of time to permit visual examination to be made of all surfaces, welds and connections, but not less thanthirty minutes. One hour test duration shall apply for piping systems with pressure rating class

600# and above. Care shall be taken to ensure that over pressuring due to static Head does nottake place. The piping systems shall not show any sign of plastic deformation or leakage.

5. Pneumatic testing: The sequence of test pressuring installed systems shall be as follows,

– A pressure of 0.5 bars shall be introduced in the system and a leak test performed. The pressure shall gradually be increased to 50% of the specified test pressure and kept for

minimum 10 minutes to equalize strain – The pressure shall then be increased in steps of 10% of the specified test pressure, until the

specified test pressure is reached. At each step, the pressure shall be kept for 10 minutesminimum to equalize strain

– The specified test pressure shall be kept for one hour. The pressure shall than be reduced to

the design pressure before examining for leakage. The piping systems shall not show anysign of plastic deformation or leakage.

6. After completion of test: The tested systems shall be depressurized by opening thedepressurizing valve in the test rig. After depressurization, all vents and low point drain valves

shall be opened and the system shall be thoroughly drained in designated drain point (as agreedwith client) where the test medium is water. Where required, blowing by dry air or pressurizedair shock blowing to remove any trapped water to be performed. Systems with drying

requirement shall be dried out after hydro-testing with dry oil free air with a dew point of -10°C. Drying can be terminated when the dew point at the outlet is equal to the dew point atthe inlet. Other methods, such as vacuum drying or air shocking, may also be used if the same

dryness can be documented. If more than 3 months to commissioning, drying shall be followed by preservation with nitrogen to keep the pipe system completely dry and to avoid condense.

7. Verification of cleanliness: All systems shall be internal visual inspected for acceptablecleanliness by spot check.. If pipe configuration in critical parts of systems is too complicatedfor visual inspection, the PAS method or other suitable methods shall be used for verification

of cleanliness.




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Rev – 00 Page 1 of 15 28 Feb.’2008

CHAPTER – 33

DISPLAYING NFPA-704 DIAMOND & REQUIREMENTS OF API- 650 SECTION 8 ONSTORAGE TANKS CONTAINING HAZARDOUS MATERIALS

1. Introduction:

NFPA diamond is a standard system for the identification of the fire / health / reactivity hazards

of the material. It is proposed to display this identification mark on all the above ground

storage tanks within plant battery limits / tank farms containing hazardous liquids & gases.

This information has proved to be of immense help to fire- fighters & operating staff during

emergencies.

The diamond is divided into four equal quadrants with different background colors representing

hazard & its severity from 0 to 4. The left side quadrant with blue background color represents

health hazard with its severity number, top quadrant with red background represents fire hazard

with its severity number, the right side quadrant with yellow background represents reactivity

hazard with its severity number. The bottom quadrant is without any color & is generally kept

blank, unless the material has a special hazard. This special hazard is represented by pre-

defined hazard symbols, as shown in the hazard information guide.

The severity numbers (of stored material) is to be picked up from the label description list &

displayed in the respective quadrants of the diamond.

Also as per API-650, sec 8, the following information is required to be put on the tanks.

1. Nominal diameter

2. Nominal height

3. Nominal capacity4. Product name stored.

The relevant sketch showing dimensions & color scheme is a part of this procedure.

This shall be a value addition to the plants safety while handing over to the operating group of

the client.




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Rev – 00 Page 2 of 15 28 Feb.’2008




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Rev – 00 Page 3 of 15 28 Feb.’2008




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Rev – 00 Page 4 of 15 28 Feb.’2008

NFPA Label Description

NFPA Table A-B

Chemical Name CAS # H F R Special

ACETALDEHYDE 75070 2 4 2

ACETIC ACID, [GLACIAL] 64197 2 2 0

ACETIC ANHYDRIDE 108247 2 2 1

ACETONE 67641 1 3 0

ACETONE CYANOHYDRIN 75865 3 2 2

ACETONITRILE 75058 3 3 0

ACETOPHENONE 98862 1 2 0

ACETYL CHLORIDE 75365 3 3 2 No water

ACETYLENE 74862 1 4 3

ACETYLENE TETRABROMIDE 79276 3 1 0

ACETYL PEROXIDE SOLUTION,[<=25% PEROXIDE] 110225 1 2 4

ACROLEIN DIMER, [STABILIZED] 100732 1 2 1

ACROLEIN, [INHIBITED] 107028 3 3 3

ACRYLAMIDE 79061 3 2 2

ACRYLIC ACID 79107 3 2 2

ACRYLONITRILE 107131 4 3 2

ADIPIC ACID 124049 1 0

ADIPONITRILE 111693 4 2 1

ALKYL ALUMINUM HALIDES 3 4 3 No water

ALLYL ALCOHOL 107186 3 3 1

ALLYLAMINE 107119 3 3 1

ALLYL BROMIDE 106956 3 3 1

ALLYL CHLORIDE 107051 3 3 1

ALLYL CHLOROCARBONATE 2937500 3 3 1

ALUMINUM ALKYL CHLORIDE 3 4 3 No water

ALUMINUM CHLORIDE, [ANHYDROUS] 7446700 3 0 2 No water

ALUMINUM PHOSPHIDE 20859738 3 4 2 No water

ALUMINUM POWDER, [METALLIC] 7429905 0 1 1

ALUMINUM TRIETHYL 97938 3 4 3 No water

AMMONIA, [ANHYDROUS] 7664417 3 1 0

AMMONIUM BICHROMATE 7789095 2 1 1 Oxidizer

AMMONIUM FLUORIDE 12125018 3 0 0

AMMONIUM NITRATE, [NO ORGANIC COATING] 6484522 1 0 3 Oxidizer

AMMONIUM NITRATE, [ORGANIC COATING] 6484522 1 0 3 Oxidizer

AMMONIUM PERCHLORATE, [OXIDIZER] 7790989 1 0 4 Oxidizer

AMMONIUM PERMANGANAT E 13446101 1 0 3 Oxidizer

AMYL ACETATE 628637 1 3 0 AMYL ALCOHOL 71410 1 3 0

N-SEC-AMYL ALCOHOL 0 2 0




_______________________________________________________________________________________________

Rev – 00 Page 5 of 15 28 Feb.’2008

TERT-AMYL ALCOHOL 75854 1 3 0

AMYLAMINE 110587 2 3 0

AMYL MERCAPTAN 110667 2 3 0

AMYL NITRATE 1002160 2 2 0 Oxidizer

ANILINE 62533 3 2 0

ANTIMONY PENTACHLORIDE 7647189 3 0 1

ANTIMONY PENTAFLUORIDE 7783702 3 0 1

ANTIMONY SULFIDE, [SOLID] 12627520 2 1 1

ARSENIC PENTOXIDE, [SOLID] 1303282 2 0 0

ARSENIC TRICHLORIDE, [LIQUID] 7784341 3 0 0

ARSENIC TRIOXIDE, [SOLID] 1327533 2 0 0

ARSENIC TRISULFIDE 1303339 2 0 0

ARSINE 7784421 4 4 2

ASPHALT 8052424 0 1 0

BARIUM CHLORATE 13477004 2 0 1 Oxidizer BENZALDEHYDE 100527 2 2 0

BENZENE 71432 2 3 0

BENZOTRICHLORIDE 98077 3 3 1

BENZOYL CHLORIDE 98884 3 2 2 No Water

BENZYL CHLORIDE 100447 2 2 1

BERYLLIUM, [POWDER] 7440417 3 1 0

BIS(CHLOROMETHYL) ETHER 542881 3 3 1

BORON TRIBROMIDE 10294334 4 0 2 No water

BORON TRIFLUORIDE 7637072 4 0 1

BROMINE 7726956 3 0 0 Oxidizer

BROMINE PENTAFLUORIDE 7789302 4 0 3 No Water; Oxidizer

BROMINE TRIFLUORIDE 7787715 4 0 3 No Water; Oxidizer

BROMOPENTANE 29756385 1 3 0

BROMOPROPYNE 106967 4 3 4

1,3-BUTADIENE, [INHIBITED] 106990 2 4 2

BUTANE 106978 1 4 0

BUTENE 25167673 1 4 0

BUTYL ACETATE 123864 1 3 0

BUTYL ACRYLATE 141322 2 2 2

BUTYL ALCOHOL 35296721 1 3 0

N-BUTYL ALCOHOL 71363 1 3 0

SEC-BUTYL ALCOHOL 78922 1 3 0

TERT-BUTYL ALCOHOL 75650 1 3 0

BUTYLAMINE 109739 3 3 0

1,2-BUTYLENE OXIDE 106887 2 3 2

BUTYL ETHER 142961 2 3 1

TERT-BUTYL HYDROPEROXIDE 75912 1 4 4 Oxidizer

BUTYL LITHIUM 109728 3 4 2 No water TERT-BUTYL PEROXYACETATE, [<= 76% IN SOLUTION] 107711 2 3 4 Oxidizer

TERT-BUTYL PEROXYACETATE 107711 2 3 4 Oxidizer




_______________________________________________________________________________________________

Rev – 00 Page 6 of 15 28 Feb.’2008

TERT-BUTYL PEROXYBENZOATE, [TECHNICALLY PURE] 614459 1 3 4 Oxidizer

TERT-BUTYL PEROXYPIVALATE, [<= 77% IN SOLUTION] 927071 0 3 4 Oxidizer

N-BUTYL PHTHALATE 84742 0 1 0

BUTYRALDEHYDE 123728 2 3 2

BUTYRIC ACID 107926 3 2 0

NFPA Table C-DChemical Name CAS # H F R Special

CALCIUM CARBIDE 75207 1 3 2 No Water

CALCIUM CHLORATE 10137743 1 0 1 Oxidizer

CALCIUM CYANIDE, [SOLID] 592018 3 0 1

CALCIUM HYPOCHLORITE MIXTURE, [DRY, WITH >39%

AVAILABLE CHLORINE] 7778543 1 0 2 Oxidizer

CALCIUM, METAL 7440702 1 1 2 No water

CALCIUM, METAL, [CRYSTALLINE] 7440702 1 1 2 No water

CALCIUM OXIDE 1305788 1 0 1

CARBON DISULFIDE 75150 2 4 0

CARBON MONOXIDE 630080 3 4 0

CARBON TETRACHLORIDE 56235 3 0 0

CHLORINATED PHENOLS/CHLOROPHENOLS 3 2 0

CHLORINE 7782505 3 0 0 Oxidizer

CHLORINE TRIFLUORIDE 7790912 4 0 3

No water;

Oxidizer

CHLOROACETIC ACID, [SOLID] 79118 3 1 0 CHLOROACETONITRILE 107142 3 2 0

CHLOROACETYL CHLORIDE 79049 3 0 1

CHLOROBENZENE 108907 2 3 0

CHLOROETHANOL 107073 4 2 0

CHLOROFORM 67663 2 0 0

CHLOROMETHYL METHYL ETHER, [ANHYDROUS] 107302 3 3 2

CHLOROPENTANE, [FLAMMABLE LIQUID] 29656631 1 3 0

CHLOROPHENOLS, [LIQUID] 25167800 3 2 0

CHLOROPHENOLS, [SOLID] 106489 3 1 0

CHLOROPICRIN, [LIQUID] 76062 4 0 3

CHLOROSILANE, [CORROSIVE LABEL] 13465786 3 3 2 No water

CHLOROSILANE, [EMITS FLAMMABLE GAS WHEN WET,

CORROSIVE LABELS] 13465786 3 3 2 No water

CHLOROSILANE, [FLAMMABLE, CORROSIVE LABELS] 13465786 3 3 2 No water

CHLOROSULFONIC ACID 7790945 3 0 2

No Water,

Oxidizer

CHROMIC ACID, [SOLID]

7738945/111

15745 3 0 1 Oxidizer

CHROMIC CHLORIDE 10025737 3 0 0

CHROMIUM OXYCHLORIDE 14977618 3 0 2 No Water

COLLODION 9004700 2 3 3




_______________________________________________________________________________________________

Rev – 00 Page 7 of 15 28 Feb.’2008

CRESOL 1319773 3 2 0

M-CRESOL 108394 3 2 0

O-CRESOL 95487 3 2 0

P-CRESOL 106445 3 2 0

CROTONALDEHYDE 4170303 3 3 2

CUMENE, [FLAMMABLE LIQUID] 98828 2 3 1

CUMENE HYDROPEROXIDE 80159 1 2 4 Oxidizer

CYANOACETIC ACID 372098 3 1 0

CYANOGEN BROMIDE 506683 3 0 1

CYANOGEN GAS 460195 4 4 2

CYCLOHEXANE 110827 1 3 0

CYCLOHEXANOL 108930 1 2 0

CYCLOHEXANONE 108941 1 2 0

CYCLOHEXYLAMINE 108918 2 3 0

CYCLOPENTANE 287923 1 3 0 CYCLOPROPANE 75194 1 4 0

DECABORANE 17702419 3 2 1

DECANE 124185 0 2 0

DECYL ALCOHOL 112301 0 2 0

DIAMYLAMINE 2050922 3 2 0

DIBORANE 19287457 3 4 3 No Water

DIBUTYLAMINE 111922 3 2 0

DI-TERT-BUTYL PEROXIDE, [TECHNICALLY PURE] 110054 3 2 4 Oxidizer

DICHLOROACETYL CHLORIDE 79367 3 2 2 No water

DICHLOROANILINE 27134276 3 1 0

O-DICHLOROBENZENE, [LIQUID] 95501 2 2 0

DICHLOROETHYLENE 25323302 2 3 2

1,2-DICHLOROETHYLENE 540590 2 3 2

1,2-DICHLOROETHYLENE 156605 2 3 2

DICHLOROETHYL ETHER 111444 3 2 1

DICHLOROMETHANE 75092 2 1 0

1,2-DICHLOROPROPANE 78875 2 3 0

DICHLOROPROPENE 26952238 3 3 0

1,3-DICHLOROPROPENE 542756 3 3 0

DICHLOROSILANE 4109960 3 4 2 No water

DIETHANOLAMINE 111422 1 1 0

DIETHYL ALUMINUM CHLORIDE 96106 3 4 3 No water

DIETHYLAMINE 109897 3 3 0

DIETHYLCARBINOL 584021 1 2 0

DIETHYLENE GLYCOL 111466 1 1 0

DIETHYLENETRIAMINE 111400 3 1 0

DIETHYL PHTHALATE 84662 0 1 0

DIETHYL SULFATE 64675 3 1 1 DIETHYLZINC 557200 1 4 3 No water

DIISOPROPYLAMINE 108189 3 3 0




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Rev – 00 Page 8 of 15 28 Feb.’2008

DIISOPROPYL ETHER 108203 2 3 1

DIKETENE 674828 3 2 2

DIMETHYLAMINE, [ANHYDROUS] 124403 3 4 0

DIMETHYLAMINE, [AQUEOUS SOLUTION] 124403 3 4 0

DIMETHYLHYDRAZINE, [UNSYMMETRICAL] 57147 3 3 1

DIMETHYL SULFATE 77781 4 2 0

DIMETHYL SULFIDE 75183 2 4 0

2,4-DINITROANILINE 97029 3 1 3

O-DINITROBENZENE 528290 3 1 4

DINITROCHLOROBENZENE

97007/25567

673 3 1 4

DINITROTOLUENE, [LIQUID] 25321146 3 1 3

DINITROTOLUENE, [SOLID] 25321146 3 1 3

DI-N-OCTYL PHTHALATE 117840 0 1 0

1,4-DIOXANE 123911 2 3 1

DIPROPYLENE GLYCOL 25265718 0 1 0

DIVINYL BENEZENE, [COMBUSTIBLE LIQUID LABEL] 2 2 2

DIVINYL BENZENE, [FLAMMABLE LIQUID LABEL] 108576 2 2 2

DIVINYL ETHER 109933 2 3 2

NFPA Table E-L

Chemical Name CAS # H F R Special

EPICHLOROHYDRIN 106898 3 3 2

ETHYL ACETATE 141786 1 3 0

ETHYL ACRYLATE, [INHIBITED] 140885 2 3 2

ETHYL ALCOHOL 64175 0 3 0

ETHYLAMINE SOLUTION 75047 3 4 0

N-ETHYLANILINE 103695 3 2 0

ETHYLBENZENE 100414 2 3 0

ETHYLBUTANOL 97950 2 3 1

ETHYL BUTYL ACETATE 123660 1 2 0

ETHYL CHLORIDE 75003 2 4 0

ETHYL CHLOROFORMATE 541413 3 3 1 ETHYLENE 74851 1 4 2

ETHYLENE CYANOHYDRIN 109784 2 1 2

ETHYLENEDIAMINE 107153 3 3 0

ETHYLENE DIBROMIDE 106934 3 0 0

ETHYLENE DICHLORIDE 107062 2 3 0

ETHYLENE GLYCOL 107211 1 1 0

ETHYLENEIMINE, [INHIBITED] 151564 3 3 3

ETHYLENE OXIDE 75218 2 4 3

ETHYL ETHER 60297 2 4 1

2-ETHYLHEXYL ACRYLATE 103117 2 2 2

ETHYL METHYL ETHER 540670 2 4 1




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Rev – 00 Page 9 of 15 28 Feb.’2008

ETHYL NITRITE 109955 2 4 4

FLUOBORIC ACID 16872110 3 0 0

FLUORINE 7782414 4 0 4

No Water;

Oxidizer

FLUORINE, [CRYOGENIC LIQUID] 7782414 4 0 4

No Water;

Oxidizer

FORMALDEHYDE SOLUTION, [FLASH POINT <= 141 DEG F.; IN

CONTAINERS <= 110 GALLONS] 50000 3 2 0

FORMIC ACID 64186 3 2 0

FUEL OIL, [COMBUSTIBLE LIQUID LABEL] 0 2 0

FUEL OIL, [DIESEL] 0 2 0

FUEL OIL, [NO. 1] 0 2 0

FUEL OIL, [NO. 2] 0 2 0

FUEL OIL, [NO. 4] 0 2 0

FUEL OIL, [NO. 5] 0 2 0

FUEL OIL, [NO. 6] 0 2 0 FURFURAL 98011 2 2 0

GALLIUM TRICHLORIDE 13450903 3 0 1

GASOLINE 8006619 1 3 0

GERMANE 7782652 4 4 3

GLYCERINE, [CRUDE, CONCENTRATED] 56815 1 1 0

HEPTANE 142825 1 3 0

HEXANE 110543 1 3 0

HEXANOL 111273 1 2 0

HYDRAZINE, [ANHYDROUS] 302012 3 3 3

HYDROBROMIC ACID, [> 49% STRENGTH] 10035106 3 0 0

HYDROCYANIC ACID, [LIQUEFIED] 74908 4 4 2

HYDROFLUORIC ACID SOLUTION 7664393 4 0 1

HYDROGEN 1333740 0 4 0

HYDROGEN BROMIDE 10035106 3 0 0

HYDROGEN CHLORIDE, [ANHYDROUS] 7647010 3 0 0

HYDROGEN CHLORIDE, [REFRIGERATED LIQUID] 7647010 3 0 0

HYDROGEN CYANIDE, [ABSORBED] 74908 4 4 2

HYDROGEN FLUORIDE 7664393 4 0 1

HYDROGEN PEROXIDE SOLUTION, [> 52% PEROXIDE] 7722841 2 0 3 Oxidizer

HYDROGEN PEROXIDE SOLUTION, [40% TO 52% PEROXIDE] 7722841 2 0 1 Oxidizer

HYDROGEN, [REFRIGERATED LIQUID] 1333740 3 4 0

HYDROGEN SULFIDE 7783064 3 4 0

HYDROXYLAMINE 7803498 2 0 3

ISOAMYL ALCOHOL 123513 1 2 0

ISO-BUTYL ACETATE 110190 1 3 0

ISOBUTYRALDEHYDE 78842 2 3 2

ISOPHORONE 78591 2 2 0

ISOPRENE 78795 2 4 2

ISOPROPANOL 67630 1 3 0




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Rev – 00 Page 10 of 15 28 Feb.’2008

ISOPROPYLAMINE 75310 3 4 0

ISOPROPYL FORMATE 625558 2 3 0

ISOPROPYL PERCARBONATE, [STABILIZED] 105646 0 4 4 Oxidizer

ISOPROPYL PERCARBONATE, [UNSTABILIZED] 105646 0 4 4 Oxidizer

KEROSENE 8008206 0 2 0

LEAD ARSENATE 3687318 2 0 0

LEAD ARSENATE, [SOLID]

7645252/

7784409/

10102484

2 0 0

LIQUEFIED NATURAL GAS 3 4 1

LITHIUM ALUMINUM HYDRIDE 16853853 3 2 2 No water

LITHIUM HYDRIDE 7580678 3 2 2 No Water

LITHIUM METAL 7439932 3 2 2 No water

NFPA Table M-OChemical Name CAS # H F R Special

MAGNESIUM ALLOY, [WITH > 50% MAGNESIUM, PELLETS,

TURNINGS] 0 1 1

No

water

MAGNESIUM ALLOY, [WITH > 50% MAGNESIUM, POWDER] 0 1 1

No

water

MAGNESIUM GRANULES COATED, [PARTICLE SIZE >= 149

MICRONS] 7439954 0 1 1

No

water

MAGNESIUM, METAL, (POWDERED, PELLETS, TURNINGS, OR

RIBBON) 7439954 0 1 1

No

water

MALEIC ANHYDRIDE 108316 3 1 1 MERCURIC CYANIDE, [SOLID] 592041 3 0 0

MESITYL OXIDE 141797 3 3 1

METHACRYLIC ACID 79414 3 2 2

METHANOL 67561 1 3 0

METHYL ACETATE 79209 1 3 0

METHYL ACRYLATE, [INHIBITED] 96333 2 3 2

METHYLAMINE, [ANHYDROUS] 74895 3 4 0

METHYLAMINE, [AQUEOUS SOLUTION] 74895 3 4 0

METHYL BROMIDE AND > 2% CHLOROPICRIN MIXTURE,

[LIQUID] 8004099 3 1 0

METHYL BROMIDE, LIQUID, [WITH < 2% CHLOROPICRIN] 74839 3 1 0

METHYL CHLORIDE 74873 2 4 0

METHYLCYCLOPENTANE 96377 2 3 0

METHYL DICHLOROSILANE 75547 3 3 2

No

water

METHYL ETHER 115106 2 4 1

METHYL ETHYL KETONE 78933 1 3 0

METHYL ETHYL PYRIDINE 104905 2 2 0

METHYL FORMATE 107313 2 4 0

METHYL HYDRAZINE 60344 3 3 2

METHYL ISOBUTYL KETONE 108101 2 3 0




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Rev – 00 Page 11 of 15 28 Feb.’2008

METHYL ISOCYANATE 624839 4 3 2

METHYL METHACRYLATE MONOMER, [INHIBITED] 80626 2 3 2

METHYL METHACRYLATE MONOMER, [UNINHIBITED] 80626 2 3 2

METHYL ORTHOSILICATE 681845 3 3 1

METHYLTRICHLOROSILANE 75796 3 3 2

No

water METHYL VINYL KETONE, [INHIBITED] 78944 3 3 2

MONOETHANOLAMINE 141435 2 2 0

MORPHOLINE 110918 2 3 0

MORPHOLINE, AQUEOUS MIXTURE, [CORROSIVE LABEL] 110918 2 3 0

MORPHOLINE, AQUEOUS MIXTURE, [FLAMMABLE LIQUID

LABEL] 110918 2 3 0

NAPHTHALENE 91203 2 2 0

NAPHTHALENE, [MOLTEN] 91203 2 2 0

NATURAL GA S, [COMPRESSED] 0 4 0

NATURAL GAS, [REFRIGERATED LIQUID] 3 4 1

NICKEL CARBONYL 13463393 4 3 3

NICKEL CATALYST, [DRY] 7440020 2 3 3

NITRIC ACID, [<=40%] 7697372 3 0 0

NITRIC ACID, [> 40%] 7697372 3 0 0 Oxidizer

NITRIC ACID, [FUMING] 7697372 3 0 1 Oxidizer

NITRIC OXIDE 10102439 3 0 0 Oxidizer

P-NITROANILINE, [SOLID] 100016 3 1 2

NITROBENZENE, [LIQUID] 98953 3 2 1

NITROCELLULOSE, [COLLOIDED, GRANULAR OR FLAKE, WETWITH >= 20% ALCOHOL OR SOLVENT, OR BLOCK, WET WITH

>= 25% ALCOHOL] 2 3 0

NITROCELLULOSE, [COLLOIDED, GRANULAR OR FLAKE, WET

WITH >= 20% WATER] 2 3 0

NITROCELLULOSE, [WET WITH >= 30% ALCOHOL OR

SOLVENT] 9004700 2 3 2

NITROCELLULOSE, [WET WITH >= 20% WATER] 9004700 1 2 2

NITROCHLOROBENZENE 121733/100005 3 1 0

O-NITROCHLOROBENZENE, [LIQUID] 88733 3 1 0

NITROETHANE 79243 1 3 3

NITROGEN 7727379 3 0 0

NITROGEN DIOXIDE, [LIQUID] 10102440 3 0 0 Oxidizer

NITROGEN, [REFRIGERATED LIQUID] 7727379 3 0 0

NITROGEN TETROXIDE, [LIQUID] 10544726 3 0 0 Oxidizer

NITROGEN TRIOXIDE 10544737/12033497 3 0 0 Oxidizer

NITROMETHANE 75525 1 3 4

4-NITROPHENOL 100027 3 1 2

NITROPROPANE 25322014 1 3 2

2-NITROPROPANE 79469 1 3 2

NITROTOLUENE 1321126 3 1 1

P-NITROTOLUENE 99990 3 1 1




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Rev – 00 Page 12 of 15 28 Feb.’2008

OCTANE 111659 0 3 0

OCTANOL 111875 1 2 0

OIL, [MINERAL] 0 1 0

OILS, EDIBLE: COCONUT 0 1 0

OILS, EDIBLE: COTTONSEED 0 1 0

OILS, EDIBLE: LARD 0 1 0

OILS, EDIBLE: PALM 0 1 0

OILS, EDIBLE: PEANUT 0 1 0

OILS, EDIBLE: SOYA BEAN 0 1 0

OILS, EDIBLE: TUCUM 0 1 0

OILS, EDIBLE: VEGETABLE 0 1 0

OILS, MISCELLANEOUS: LINSEED 0 1 0

OIL, [TRANSFORMER] 0 1 0

OLEIC ACID 112801 0 1 0

OLEUM 8014957 3 0 2 Nowater

OXALIC ACID 144627 2 1 0

OXYGEN, [COMPRESSED] 7782447 3 0 0 Oxidizer

OXYGEN, [REFRIGERATED LIQUID] 7782447 3 0 0 Oxidizer

NFPA Table P-SChemical Name CAS # H F R Special

PARAFORMALDEHYDE 30525894 2 1 0

PARALDEHYDE 123637 2 3 1

PENTABORANE 19624227 4 4 2

PENTACHLOROPHENOL 87865 3 0 0

PENTANE 109660 1 4 0

PERACETIC ACID 79210 3 2 4 Oxidizer

PERCHLORIC ACID, [> 50% BUT <= 72% STRENGTH] 7601903 3 0 3 Oxidizer

PHENOL, [LIQUID] 108952 3 2 0

PHENOL, [MOLTEN] 108952 3 2 0

PHENOL, [SOLID] 108952 3 2 0

PHENYLMERCURIC ACETATE 62384 3 1 0

PHENYLMERCURIC ACETATE, [LIQUID] 62384 3 2 0

PHOSGENE 75445 4 0 1

PHOSPHINE 7803512 3 4 2

PHOSPHORIC ACID 7664382 3 0 0

PHOSPHORUS, [AMORPHOUS, RED] 7723140 1 1 1

PHOSPHORUS OXYCHLORIDE 10025873 3 0 2 No water

PHOSPHORUS PENTACHLORIDE, [SOLID] 10026138 3 0 2 No water

PHOSPHORUS PENTASULFIDE 1314803 2 1 2 No water

PHOSPHORUS TRIBROMIDE 7789608 3 0 2 No water

PHOSPHORUS TRICHLORIDE 7719122 3 0 2 No water PHOSPHORUS, [WHITE, MOLTEN] 7723140 3 4 2




_______________________________________________________________________________________________

Rev – 00 Page 13 of 15 28 Feb.’2008

PHTHALIC ANHYDRIDE 85449 2 1 0

PICRIC ACID, [WET, WITH >= 10% WATER] 88891 3 4 4

POLYCHLORINATED BIPHENYLS various 2 1 0

POTASSIUM CHLORATE 3811049 1 0 1 Oxidizer

POTASSIUM CYANIDE, [SOLID] 151508 3 0 0

POTASSIUM CYANIDE SOLUTION 151508 3 0 0

POTASSIUM DICHLORO-S-TRIAZINETRIONE, [DRY, WITH >

39% AVAILABLE CHLORINE] 2244215 3 0 2 Oxidizer

POTASSIUM HYDROXIDE, [DRY SOLID, FLAKE, BEAD, OR

GRANULAR] 1310583 3 0 1

POTASSIUM HYDROXIDE, [LIQUID] 1310583 3 0 1

POTASSIUM, [METAL] 7440097 3 3 2 No water

POTASSIUM PERCHLORATE 7778747 1 0 1 Oxidizer

POTASSIUM PEROXIDE 17014710 3 0 1 Oxidizer

POTASSIUM SULFIDE

1312738/12136491

/12136504/37488758 3 1 0

PROPANE 74986 1 4 0

PROPARGYL ALCOHOL 107197 3 3 3

PROPIONALDEHYDE 123386 2 3 2

PROPIONIC ACID 79094 2 2 0

PROPIONIC ACID, [SOLUTION] 79094 2 2 0

PROPIONIC ANHYDRIDE 123626 2 2 1

PROPYL ACETATE 109604 1 3 0

N-PROPYLAMINE 107108 3 3 0

PROPYLENE 115071 1 4 1

PROPYLENE GLYCOL 57556 0 1 0

PROPYLENE OXIDE 75569 4 2 2

PROPYL NITRATE 627134 2 3 3 Oxidizer

PROPYL TRICHLOROSILANE 141571 3 3 1

PYRIDINE 110861 2 3 0

PYROXYLIN PLASTIC, RODS, SHEETS, ROLLS, OR TUBES 2 3 2

SILANE 7803625 2 4 3

SILANE, (4-AMINOBUTYL)DIETHOXYMETHYL- 3037727 3 2 1

SILICON CHLORIDE 10026047 3 0 2 No water

SILICON TETRAFLUORIDE 7783611 3 0 2 No water

SODIUM CHLORATE 7775099 1 0 1 Oxidizer

SODIUM CHLORITE 7758192 1 1 1 Oxidizer

SODIUM CYANIDE, [SOLID] 143339 3 0 0

SODIUM CYANIDE SOLUTION 143339 3 0 0

SODIUM DICHLORO-S-TRIAZINETRIONE, [DRY, CONTAINING

> 39% AVAILABLE CHLORINE] 2893789 0 3 2

No

Water;

Oxidizer

SODIUM FLUORIDE, [SOLID] 7681494 2 0 0

SODIUM HYDRIDE 7646697 3 3 2 No water

SODIUM HYDROGEN SULFITE, [SOLID] 7631905 3 1 2




_______________________________________________________________________________________________

Rev – 00 Page 14 of 15 28 Feb.’2008

SODIUM HYDROXIDE, [DRY SOLID, FLAKE, BEAD] 1310732 3 0 1

SODIUM HYDROXIDE, [LIQUID] 1310732 3 0 1

SODIUM, [METAL] 7440235 3 3 2 No water

SODIUM PERCHLORATE 7601890 2 0 1 Oxidizer

SODIUM PEROXIDE 1313606 3 0 1 Oxidizer

SODIUM POTASSIUM ALLOY, [LIQUID] 11135812 3 3 2 No water

SODIUM POTASSIUM ALLOY, [SOLID] 11135812 3 3 2 No water

SODIUM SULFIDE, [ANHYDROUS] 1313822 3 1 1

SODIUM SULFIDE, [HYDRATED, WITH >= 30% WATER] 1313822 3 1 1

SODIUM SUPEROXIDE 12034127 3 0 1 Oxidizer

STIBINE 7803523 4 4 2

STYRENE MONOMER, [INHIBITED] 100425 2 3 2

SULFUR CHLORIDE (MONO) 10025679 2 1 1

SULFUR DIOXIDE 7446095 3 0 0

SULFURIC ACID 7664939 3 0 2 No water SULFURIC ACID, [SPENT] 7664939 3 0 2 No water

SULFUR, [MOLTEN] 7704349 2 1 0

SULFUR MONOCHLORIDE 12771083 2 1 1

SULFUR, [SOLID] 7704349 1 1 0

SULFURYL CHLORIDE 7791255 3 0 1

NFPA Table T-ZChemical Name CAS # H F R Special

TALLOW 0 1 0

TETRACHLOROETHYLENE 127184 2 0 0

TETRAETHYL LEAD, [LIQUID] 78002 3 3 3

TETRAFLUOROETHYLENE, [INHIBITED] 116143 2 4 3

TETRAHYDROFURAN 109999 2 3 1

TETRAHYDRONAPHTHALENE 119642 1 2 0

TETRAMETHYLLEAD 75741 3 3 3

THIONYL CHLORIDE 7719097 3 0 2 No water

TIN TETRACHLORIDE, [ANHYDROUS] 7646788 3 0 1

TIN TETRACHLORIDE, [HYDRATED] 10026069 3 0 1

TITANIUM TETRACHLORIDE 7550450 3 0 2 No Water

TOLUENE 108883 2 3 0

TOLUENE-2,4-DIISOCYANATE 584849 3 1 2

O-TOLUIDINE 95534 3 2 0

TRIBUTYLAMINE 102829 3 2 0

1,1,1-TRICHLOROETHANE 71556 2 1 0

1,1,2-TRICHLOROETHANE 79005 3 1 0

TRICHLOROETHYLENE 79016 2 2 0

TRICHLOROETHYLSILANE 115219 3 3 2 No Water MONO-(TRICHLORO) TETRA-(MONOPOTASSIUM DICHLORO)-

PENTA-S-TRIAZINETRIONE, [DRY, WITH > 39% AVAILABLE 3 0 2

No Water;

Oxidizer




_______________________________________________________________________________________________

Rev – 00 Page 15 of 15 28 Feb.’2008

CHLORINE]

TRICHLOROSILANE 10025782 3 4 2 No water

TRICHLORO-S-TRIAZINETRIONE, [DRY, CONTAINING > 39%

AVAILABLE CHLORINE] 87901 3 0 2 Oxidizer

TRIETHANOLAMINE 102716 2 1 1

TRIETHYLAMINE 121448 2 3 0 TRIETHYLENE GLYCOL 112276 1 1 0

TRIISOBUTYL ALUMINUM 100992 3 4 3 No water

TRIMETHOXY SILANE 2487903 3 3 2

TRIMETHYLAMINE, [ANHYDROUS] 75503 3 4 0

TRIMETHYLAMINE, AQUEOUS SOLUTION 75503 3 4 0

TRIPROPYLALUMINUM 102670 3 4 3 No water

TURPENTINE 8006642/9005907 1 3 0

VANADIUM TETRACHLORIDE 7632511 3 0 2 No water

VINYL ACETATE 108054 2 3 2

VINYL CHLORIDE 75014 2 4 2

VINYLIDENE CHLORIDE, [INHIBITED] 75354 2 4 2

VINYL TOLUENE 25013154 2 2 2

WAXES: PARAFFIN 0 1 0

XYLENE 1330207 2 3 0

M-XYLENE 108383 2 3 0

O-XYLENE 95476 2 3 0

P-XYLENE 106423 2 3 0

XYLIDINE 1300738 3 1 0

2,6-XYLIDINE 87627 3 1 0

ZINC CHLORATE 10361952 1 0 1 Oxidizer

ZINC PHOSPHIDE 1314847 3 3 1

ZINC PHOSPHIDE, [CONC. > 10%] 1314847 3 3 1

ZIRCONIUM TETRACHLORIDE, [SOLID] 10026116 3 0 2 No Water




_______________________________________________________________________________________________________________________________________________


Feb. 2008

8

CHAPTER –34

OH&S RECORDS

1.0 Purpose

(i) List of OH&S Records to be maintained by HSE Capability Centre/ Site.


2.0 Procedure – None

3.0 Administration – None

4.0 Records –

Doc. No. Title Cross Ref./

Chapter No.

Maintained

By

Retention Period

(Min.)

Remarks

OHS – 01 A Site OH&S Objectives and targets 01

OHS – 01 B Monitoring of OH&S Objectives and

targets report

01 Project SiteTill the closing of

the site.

OHS – 03 A Site Opening Report 03

OHS – 03 B Site Closing Report 03

OHS – 05 Safety Committee Meeting Report 05OHS – 06 A Incident Report 06

OHS – 06 B Incident Investigation 06

OHS – 06 C Near-Miss Incident Report 06

OHS – 06 D Analysis of First Aid Cases 06

Safety – CO 3 yrs. Aftercompletion of the

project

Also a copy to be

maintained by the

site till closing of

the project site.




_______________________________________________________________________________________________________________________________________________


Feb. 2008

8


Chapter No.

Maintained

By

Retention

Period (Min.)

Remarks

OHS – 07 Monthly Safety Statistics Report 07

OHS – 08 Positive Report 08

OHS – 10 CHSECE Form 10

OHS – 11 Proforma for Screening of Workman 11 Project SiteTill the closing of

the site.

OHS – 14 Safety Tool Box Talks 14

OHS – 15 A Radiography work permit for NDT

(OHSR)

15

OHS – 15 B Hot work permit (OHSH) 15

OHS – 15 C Cold work permit (OHSC) 15

OHS – 15 D Permit for entry into confined space

(OHSCS)

15

OHS – 15 E Permit for working on electrical lines

/equipment (OHSE)

15

OHS – 15 F Permit for working on

Height(OHSHW)

15

OHS – 16 Periodic Physical Inspection Record 16

OHSC – 17 A Checklist for inspecting cranes 17OHSC – 17 B Crane / Vehicle / Earth Moving

equipment inspection report

17

OHSC – 17 C Checklist for inspecting vehicles &

earth moving equipment

17

Project SiteTill the closing of

the site.




_______________________________________________________________________________________________________________________________________________


Feb. 2008

8


Chapter No.

Maintained

By

Retention Period

(Min.)

Remarks

OHS – 19 A Safety Audit Checklist 19

OHS – 19 B Site Safety Inspection Report

19Safety – CO

3 yrs. After

completion of the

project

Also a copy to be

maintained by the


the project site.

OHSC – 19 A Checklist for working at height 19

OHSC – 19 B General Safety Inspection Checklist 19


the site.

OHSC – 19 C Checklist for Housekeeping 19

OHSC – 19 D Checklist for Scaffoldings 19

OHSC – 19 E Electrical Safety Checklist 19

OHSC – 19 F Erection Safety Checklist 19

OHSC – 19 G Maintenance checklist for fire

extinguishers

19

OHSC – 19 H Power tools inspection Checklist 19

OHSC – 19 I Crane operation daily Checklist 19


the site.

OHS – 20 A Attendance Sheet 20

OHS – 20 B Feed Back Form 20Safety – CO

3 yrs. After

completion of the

project

Also a copy to be

maintained by the


the project site.

OHS – 21 Safety Performance Report 21 Safety – CO6 yrs. From the

date of report




_______________________________________________________________________________________________________________________________________________


Feb. 2008

8


Chapter No.

Maintained

By

Retention Period

(Min.)

Remarks

OHS – 22 Noise Measurement 22 Project SiteTill the closing of

the site.

OHS - 26 Scaffold Register 26 Project SiteTill the closing of

the site.

OHS – 27 Infringement Report 27 Project SiteTill the closing of

the site.

OHS – 28A Radiography Inspection Checklist 28 Project SiteTill the closing of

the site.

OHS – 28BRadiography Equipment Usage

Logbook28 Project Site

Till the closing of

the site.

OHS – 29 Electrical Isolation Certificate 29 Project SiteTill the closing of

the site.

OHS – 30 A Selection criteria for best contractor

OHS – 30 BSelection criteria for safe employee of

the month

OHS – 30 CSelection criteria for best

housekeeping

OHS – 30 D Site specific motivational program

30 Project SiteTill the closing of

the site.

OHS – 31 Safety Scoring 31 Safety – CO

3 yrs. After

completion of the

project

Also a copy to be

maintained by the


the project site.




_______________________________________________________________________________________________________________________________________________


Feb. 2008

8


Chapter No.

Maintained

By

Retention Period

(Min.)

Remarks

OHSC – 32 A Checklist for Chemical Cleaning 32Project Site Till the closing of

the site.

OHSC – 32 B Checklist for Steam blowing 32Project Site Till the closing of

the site.

OHSC – 32 C Checklist for Catalyst loading 32 Project SiteTill the closing of

the site.

OHSC – 32 DChecklist for Hydrotest/ Pneumatic

test/ Card board blasting32

Project Site Till the closing ofthe site.

OHSC – 32 E Checklist for Water Flushing 32Project Site Till the closing of

the site.



OHS– 01A/ Dec ’07

LARSEN & TOUBRO LIMITED

HSE CAPABILITY CENTRE(PROJECT NAME)

REV.: DATE:

SITE OH&S OBJECTIVES AND TARGESTS

Sr.

No.

Objectives &

Targets

Methods Time Frame Responsibility

§ § § § §

§

Date: __________________Signature of RCM



OHS– 01B/ Dec ’07


HSE CAPABILITY CENTRE(PROJECT NAME)

MONITORING OF OH&S OBJECTIVES & TARGETS REPORT

Sr.No.

Month(mm/yy)

Set Objectivesand Targets

AchievementStatus

Remarks Name &Signature of

RCM



OHS– 03A/ Jun.’07

LARSEN & TOUBRO LIMITEDHSE CAPABILITY CENTRE

To: Head (Safety Department)

(A) SITE OPENING REPORT : (Attach separate sheet if required)

1. Name of site/ project

2. Name of Client

2. Project job no. & Debit code no.

3. Location

4. Complete address

Telephone, V-sat (hotline)

Fax nos.

e - mail address

5. Name of Resident Construction Manager /

Resident Engineer

6. Names of Site Engineers

7. Name of Site Safety Officer

8. (A) Names of Main contractors

Nature/ type of their activities

(B) Names of Package contractors

Nature/ type of their activities

9. Estimated no. of employee-hours

10. Duration of construction activities

11. OH&S Manual Available at site /

required at site 12. Corporate Policy Available at site /

required at site

13. Whether commissioning is in L&T’s scope of

responsibilities or whether L&T will

provide commissioning assistance only to

the client ?

14. When will ownership of the plant/ facility be

transferred to the client?

(a) After mechanical completion.

(b) After commissioning &Test-run.

15. Date of opening of construction site

16. Any other relevant information

Date: __________ Signature: ________________________________

Name : ________________________________(Project Execution Manager/ Resident Construction Manager)

Copies to :

: All SBU Heads

: Project Execution Manager - Powai/ Baroda

: Champion of concerned SBU



OHS – 03B/ Jun.’07


To: Head (Safety Department)

Name of the Project site/ Location:

(B) SITE CLOSING REPORT :

1. Date of Site Opening : _________________

2. Date of Mechanical Completion : _________________

3. Date of Commissioning : _________________

4. Date of Site Closing : _________________

3. Cumulative employee-hours worked : _________________(Since Opening of the site)

4.Retained / Handed over To

(SD / SBU)

(i) Corporate Policy Board(ii) OH&S Manual

Date: __________ Signature : _____________________

Name : _____________________(Project Manager/ Resident Construction Manager)

Copies to:

: All SBU Heads

: Project Manager – Powai / Baroda



OHS – 05/ Dec.’04

Larsen & Toubro Limited. Site : _______________________

HSE CAPABILITY CENTRE Date of Issue : ___________Sheet ____of ____

Minutes of Safety Committee/ Council Meeting

held on _______, at the sitefor the month of __________ Year _______

Present

SR.

NO.

NAME COMPANY SIGNATURE



OHS – 05/ Dec.’04

Larsen & Toubro Limited. Site :___________________

HSE CAPABILITY CENTRE Date of Issue : ___________Sheet ____of ____

Minutes of Safety Committee / Council Meetingheld on _____________________, at the site

Sr.

No.

Particulars of the minutes

(Including recommendation)

Action

By

Target

Datefor

action

Actual

Comple-tion

Date of

action

1Review of previous MoM held on ______

The next safety committee meeting will be held on

______________________________ ____________________________ Name & Signature of SSO/E ( Name & Signature of RCM/RCE)

Date : Date :

Copy Distribution: 1. Site Notice Board Note : 2. All committee memb er

1. Report should be legible, properly typed. 3. SD

4. Project Manager



OHS - 06A/ Oct.’07


INCIDENT REPORT HSE CAPABILITY CENTRE

(OHS-06-R2-AR NO.__________) To be submitted immediately after the Incident (Within 24 hours)

Project Name. Exact location of Incident Date & Time ofIncident

SBU Work Related

Yes¨ No ¨

Incident that has occurred ( Tick as applicable )

¨ Personal Incident ¨ Fire / Explosion ¨ Mechanical

¨ Collapse of Structure ¨ Spillage of dangerous fluids ¨ Others ( Specify ) :

Event ( Tick as applicable )¨ Injury ¨ Property damage ¨ Material loss¨ Environment pollution ¨ Others ( Specify ) :

Name of Injured Designation & Token no. Age : ____

Sex : ____

Name of Contractor ( with whom he /

she is working ) :

Brief Description of Incident :

Specify the injury, extent of damage/ loss

¨ Bruises / Abrasion ¨ Burn (Scald)¨ Contusion Cut / Laceration¨ Eye injury¨ Electric shock ¨ Fracture¨ Foreign body ̈ Head injury

¨ Puncture ¨ Sprain¨ No Injury ¨ Dislocation¨ Asphyxia ¨ Amputation¨ Crush injury

¨ Others (Pl Specify Injury)

Location of Injury¨ Head cranium region ¨ Shoulder

(Skull brain ,scalp)

¨ Eye ¨ Elbow¨ Ear ¨ Fore arm¨ Mouth ¨ Wrist

¨ Nose ¨ Hand¨ Face, Head, ¨ Fingers

multiple locations¨ Neck ¨ Hip

¨ Back ¨ Chest¨ Thigh(Upper leg) ¨ Knee¨ Abdomen ¨ Ankle¨ Foot (except toes alone)¨ Toes

¨ Leg (lower leg)

¨ Pelvis¨ Other (Pl.specify)…

Object causing injury¨ G.I Sheet ¨ Hot Spatters¨ Wooden plank ¨ Welding slag

¨ Gasket ¨ Nail¨ Compressed air ¨ structural Material¨ Pipe ¨ Reinforcement rod

¨ Shuttering plate ¨ Steel plate¨ Working platform ¨ Scaffolding¨ Hand tools ¨ Grinding wheel¨ Electric equipment¨ Chain pulley block

¨ Wire sling ¨ Crane¨ Gas cylinder ¨ Vehicle¨ Cutting machine ¨ Lift / Elevator¨ Earth moving eqpt ¨ Ladder

¨ Radiation

¨ Fumes/ Gases¨ Other (Pl.specify)…

Whether there was any unsafecondition

Yes¨ No ¨ Whether any unsafe act by injured person Yes¨

No ¨

Whether medical aid was given Yes¨ No ¨

Whether person was hospitalised Yes¨ No ¨

Has report been given to authoritiesIf Yes, to whom ( Specify ) :

Yes¨ No ¨

What immediate actions have been taken to prevent such incidents :

Name of two witnesses and signatures

1. Name : 2. Name :

Date : ( Signature ) : Date : ( Signature ) :

____________________________________

Name of supervisor of L & T / Contractor

Date : ( Signature ) :

L & T RCM’s remarks

Date : ( Signature ) :Note : 1. Please attach sketches or a separate sheet if

space for any column is not adequate.

2. Report should be legible, properly typed.3. The purpose of accident report is to find out the

causes, not to fix blame on somebody.

Copy distribution : 1. Site Safety Officer / Engineer2. Head HSE

3. BUH Powai or Baroda4. Project Manager Baroda / Powai



OHS – 06B/ Oct.’07


INCIDENT INVESTIGATION HSE CAPABILITY CENTRE

(OHS-06-R2-AI NO.__________) Investigation of the Incidents reported in OHS-06-R2-AR bypersons nominated by L&T RCM ( within 72 hours )

Name & designation of investigating person Project name Exact location of Incident

Name of Injured Designation & Token no. Age : _____

Sex : _____

Date & Time of Incident

State whether it is Personal Injury / Propertydamage

(Specify value in Rs. )

Type of Incident (Whether LWC,RWC,MTOC, Transfer of job, Removal from job,

Loss of consciousness, illness , fire (Minor))

Name of Contractor

Incident details (OHS-06-R2-Incident Report (AR) No. ______) (Please attach sketches or a separate sheet if required.)

What was Injured doing at the time of Incident :Immediate Causes – Actions (To identify Immediate causes – Action, refer guidelines given in the procedure)

Immediate Causes – Conditions (To identify Immediate causes – Condition, refer guidelines given in the procedure)

Basic Causes (To identify Basic causes, refer guidelines given in the procedure)

Root Causes (To identify Root causes, refer guidelines given in the procedure)

Was he under the influence of alcohol / drug Yes ̈ No ¨

The Injured person working

Since : ______ Month, _______Year

Date & Time the person resumed

work after Incident

Specify the failure / deviation

from Safety norms :

What actions could be taken to prevent such Incidents in future :

SSO / Investigating Person

____________________________Name

Date : (Signature)

Contractor / L&T Site in-charge

_____________________________Name

Date : (Signature)

Resident Construction Manager

__________________________Name

Date : (Signature)

Note : 1. Report should be legible, properly typed.

2. The purpose of investigation report is to find out thecauses, not to fix blame on somebody.

Copy distribution : 1. Site Safety Officer / Engineer2. Head HSE

3. BUH Powai or Baroda4. Project Manager Baroda / Powai



OHS – 06C/ Oct.’07


DANGEROUS OCCURRENCE/ HSE CAPABILITY CENTRE

NEAR-MISS INCIDENT REPORT(OHS-06C-R2-NO.__________)

Project Name Exact location of Dangerous Occurrence/ Near Miss

Date & Time of DangerousOccurrence / Near Miss

SBU

Probable Incident that could have occurred ( Tick as applicable )

¨ Personal Incident ¨ Fire / Explosion ¨ Mechanical

¨ Collapse of Structure ¨ Spillage / Release of Hydrocarbon ¨ Others ( Specify ) :

Brief description of Dangerous Occurrence / Near Miss :

Name of Contractor Brief description of Unsafe Act / Conditions which caused the dangerousoccurrence / Near Miss

Name of the reporter

________________________________________Name

Date : ( Signature )

L&T Safety Officer’s remarks

Date : ( Signature )

Note : 1. Please attach sketches or a separate sheet ifspace for any column is not adequate.

2.The purpose of near miss /accident report is to findout the causes, not to fix blame on somebody

Copy distribution :1. Head HSE ,Powai




ANALYSIS OF FIRST-AID CASES

NAME OF THE SITE: MONTH:

Sl. NO GROUPING OF CASES BASED ONCAUSATIVES

NUMBER OF CASES

1 Fall from height

2 Slip & fall on level

3 Fall into depth

4 Fall of materials

5 Pressed between objects

6 Hit by objects

7 Breaking of Grinding wheel

8 Contact with moving Grinding wheel

9 Contact with moving parts of the machinery

10 Soil subsidence

11 Struck against object

12 Road accident (Vehicle / Equipment)

13 Electric Shock

14 Electric Burn

15 Contact with hot objects16 Burn injury due to Fire

17 Chemical burns

18 Foreign body in Eye

19 Welding Flash in eye

20 Gas poisoning

21 Asphyxia (suffocation)

22 Defective tools / wrong tools

23 Others

Total

________________________SSO/Site Safety Co-ordinator

OHS – 06D/ Oct.’07



Larsen & Toubro Limited OHS – 07/ Oct.’07 HSE Capability Centre

MONTHLY HSE STATISTICS REPORT

For (Month – Yr) Site Opening Date:Name of Project/ SBU’s Date Of Last LWC

Details L&T(A)

Package Contractor(B)

Total(A+B)

No. of EmployeesEmployee Hrs including OTCumulative Employee HrsEmployee hrs since last LWC

Description This Month Cumulative Total

§ No. of First Aid Cases (FAC)

§ No. of Recordable Cases1) No. of Lost Workday Cases (LWC)

2) No. of Restricted Work Day Cases (RWC)3) No. of Medical Treat. Only Cases

4) No. of Transfer of job cases5) No. of Removal from Job cases6) No. of Loss of consciousness7) No. of Illness§ No. of Days lost due to LWC§ No. of Near-Miss Incidents§ No. of Dangerous Occurrences§ No. of Fire IncidentsNo. of Safety Committee MeetingsNo. of Tool Box Meetings/ Attendees

No. of Safety TrainingsNo. of Safety Audits / InspectionsNo. of Infringement Notifications

Details of Safety Violations / Infringement Notices:

Date Name and Emp.Designation

Company Brief description of Violation Action Taken

Safety Man of the Month:

Name : Designation: Company: Emp. No.:

_______________________ ______________________________Name & Signature of SSO Name & Signature of RCM

Date: Date:

Note : 1. Standard 6000 days lost is taken for any fatal accidents2. LWC report is to be sent within 24 hours of occurrence3. Attach Separate sheet if necessary

Copy distribution :1. Site Safety Officer/ RCM2. Head HSE Capability Centre3. BUH Powai or Baroda

4. Project Manager Baroda / Powai



OHS – 08/ Dec.’04

Positive Safety Measure/Action

Name of Site :

Ref. : OHS Manual, Chapter - 08

Date :

To: Head Safety DepartmentL&T.

From :

We are pleased to report the following positive safety measure/s at our site:

Sr. No.

Date of action/implementation

Description Whether one-time orContinuous/regular(Frequency)?

We shall ensure that this measure/practice will continue until the site is closed.

_____________________ __________________________________

Site Safety Officer Resident Construction Manager / Engineer Name: Name:



Page 1 of 5

FOR L&T USE ONLY

VENDOR CODE No.

TO BE UPDATED INJANUARY EVERY YEAR

SECTION A – BASIC DETAILS

COMPANY NAME ADDRESS FOR COMMUNICATION

MAIN CONTACT NAME / DESIGNATION TELEPHONE NUMBER FAX NUMBER

PERSONNEL RESPONSIBLE FOR HSE AT SITE

TYPE OF COMPANY / INDUSTRY / FIRM (TICK AS APPROPRIATE)

PUBLIC PRIVATE GOVERNMENT PARTNERSHIP PROPRIETRY CONTRACTORS

OTHERS (SPECIFY) SECTION B – EVALUATION REQUIREMENTS

SERVICE PROFILE (TICK AS APPROPRIATE)

CIVIL MECH.ERECTION PIPING ELECTRICAL INSTRUMENTATION

INSULATION PAINTING STRUCTURAL OTHERS (SPECIFY)

SCOPE OF APPROVALTHE SCOPE OF APPROVAL DETERMINES THE NATURE OF YOUR SERVICES YOU INTEND TO PROVIDE TO L&T

CONTRACTOR HSE CAPABILITY EVALUATIONTo enable us to assess & evaluate you capabilities in HSE please complete & return to:

LARSEN & TOUBRO LIMITED TELEPHONE: +91-22-6705 4152HSE Capabil ity Centre

Saki Vihar Road, P.O.Box 8901, Powai, Mumbai 400 072, India

OHS – 10 / Oct.’07



Page 2 of 5

SECTION C – POLICY & ORGANISATION

1. Health Safety & Environment Policya) Does your Company have specific policy statements(s) at senior and operational levels reflecting management’s

commitment to Health Safety & Environment ? Please attach copy.Ans.:

2. Management Responsibilitya) Who has overall responsibility for Health, Safety and/or Environmental protection matters in your organisation? (Pleaseprovide name, title and organisation chart organogram);Ans.:

3. Communicationa) How the Health, Safety and Environmental Protection policies are communicated to your employees and how are youremployees advised of changes to these policies?Ans.:

4. Management Commitmenta) Does senior management of your company demonstrate their commitment to Health, Safety and Environmental matters by

making site visits and conducting inspections? If YES, please state frequency of such visits. Describe the last visit andindicate for what purpose this was carried out, please state if visit was audited/recorded If NO, please describe the processby which management commitment to Health, Safety and Environmental management is demonstrated to your employees.Ans.:

SECTION D-CERTIFICATION1. Is your HSE Management System certified by external, independent agency like LRQA, TUV, BVQA to comply with the

requirements of OHSAS: 18001, ISO: 14001 etc, If yes, Please attach copies of certificate.

Ans.:

SECTION E – HSE PERFORMANCE

1. Provide the following details (for last three years) (incl: your sub-contractors)

Incident No. No. of job-sites No. of employee-hours Compensation paid /Involved worked Loss (Rs.)

a. Recordable Cases _____ _____________ ________________ _________________

b. Lost Workday Cases _____ _____________ ________________ _________________

c. Fire Incidents _____ _____________ ________________ _________________

d. Explosions _____ _____________ ________________ _________________

e. Other dangerousoccurrences (describe) _____ _____________ ________________ _________________

f. Fatal accidents _____ _____________ ________________ _________________

g. Accident Frequency rate ________________ Accident Severity rate _________________

2. Performance Achievement Awardsa) Has your company received awards for HSE performance achievement? If yes , please provide details.Ans.:

OHS – 10 / Oct.’07



Page 3 of 5

OHS 10/ Oct.’07SECTION F – HSE PRACTICES AND PROCEDURES

1. Do your company have HSE Manual? Yes / No

2. Does the HSE Manual includes work practices and procedures for the following

(i). Hazard Identification and Risk Assessment Methodology Yes ¨ NO ¨

(ii). Unsafe condition Reporting Yes ¨ NO ¨

(iii). Safety Inspection and Audit Yes ¨ NO ¨

(iv). Safety Committee Meeting Yes ¨ NO ¨

(v). Work Permit System Yes ¨ NO ¨

(vi). Scaffolding Yes ¨ NO ¨

(vii). House Keeping Yes ¨ NO ¨

(viii). Welding, Gas Cutting and Grinding Yes ¨ NO ¨

(ix). Fall Protection Yes ¨ NO ¨

(x). Crane Operation and Rigging Yes ¨ NO ¨

(xi). Vehicle Safety Yes ¨ NO ¨

(xii). Confined Space Entry Yes ¨ NO ¨

(xiii). Incident Investigation and Reporting Yes ¨ NO ¨

(xiv). Safety Promotional Scheme Yes ¨ NO ¨

(xv). Pre-employment and periodic Medical Check-up Yes ¨ NO ¨

(xvi). Handling of Compressed Gas Cylinders Yes ¨ NO ¨

(xvii). Electrical Safety Yes ¨ NO ¨

(xviii). Fire Protection and Prevention Yes ¨ NO ¨

(xix). Drug and Alcohol Program Yes ¨ NO ¨

(xx). Personal Protective Equipment Yes ¨ NO ¨

(xxi). Emergency Response Yes ¨ NO ¨

(xxii). Solid , Liquid Waste Disposal Yes ¨ NO ¨

(xxiii). First Aid Yes ¨ NO ¨

(xxiv). Pre-commissioning Yes ¨ NO ¨

(xxv). Commissioning Yes ¨ NO ¨

ECTION G – HSE TRAINING / ORIENTATION

1. Do your company provide HSE Orientation training to the following :

(i). New Employees Yes ¨ NO ¨

(ii). Field Supervisors/ Engineers Yes ¨ NO ¨

2. Do your company provide Specific skilled based HSE training to the following :

(i). Drivers (including crane operator) Yes ¨ NO ¨

(ii). Welders Yes ¨ NO ¨

(iii). Riggers Yes ¨ NO ¨

(iv). Electricians Yes ¨ NO ¨

(v). Scaffolders Yes ¨ NO ¨

SECTION H – LEGISLATION1. Describe the process in place to identify the legislation applicable to the scope of this work and the steps taken to

discharge the duties imposed by the applicable legislationAns.:

2. Is your company / company official involved in any litigation due to accident / fire etc. at project sites in the last threeyears? Is there any court case pending against your company / company official? Provide details.

Ans.:

3. Is there a practice of conducting Daily Safety Tool Box Talks?Ans.:



Page 4 of 5

SECTION I – YOUR PROPOSAL FOR THE SPECIFIC JOB-SITE FOR WHICH YOU ARE BIDDING TO L&T

1. Provide details of insurance, legal arrangement etc. being considered for this project.Ans.:

2. Does your company indemnify L&T and its personnel against any legal action due to accident, fire, dangerous occurrence atproject site & its surroundings? Provide details.

Ans.:

SECTION J – INFORMATION SUBMITTALProvide copies of the following documents (if available) . Check the box for the documents that are being provided.¨ HSE Policy and Procedure

¨ HSE Organogram of your company

¨ HSE Motivational Program

¨ Incident / Accident Investigation Procedure

¨ HSE Orientation Training Program

¨ Material and equipment HSE inspection form

¨ Substance Abuse Program (Drug and Alcohol)

¨ Hazard Identification and Risk Assessment Procedure¨ Hazard Communication Program

¨ Work Area HSE Audit / Inspection program and forms

¨ Safety Committee Meeting Procedure

¨ Waste Management Program

¨ Office and Worksite Emergency Response Procedure (Sample Copy)

¨ Work Permit Procedure

¨ Radiography Safety Procedure

¨ Scaffold Procedure

¨ Tool Box Talks Procedure

¨ Hot Work Procedure

¨ Legal register (Sample Copy)

¨ Fire Prevention and Protection Procedure

¨ Confined Space Entry Procedure

¨ Surface preparation and Painting Procedure

¨ Safety During Insulation work

¨ Awards / certificates received

¨ Copy of OHSAS: 18001, ISO: 14001 certification

¨ Pre-commissioning Safety Program

¨ Commissioning Safety Program

List other documentation provided that is not listed above

Date ________________ Signature of authorised Person

with company seal

Place ________________ Name :

Position :

OHS – 10 / Oct.’07



Page 5 of 5

SECTION J EVALUATION & RECOMMENDATION FOR L & T USE ONLY

HSE ENGINEERING’S / PROJECT MANAGER’S COMMENT & REMARKS

_____________________________________________________________________________________________________

_____________________________________________________________________________________________________

_____________________________________________________________________________________________________

________________

_____________________________________________________________________________________________________

_____________________________________________________________________________________________________

_____________________________________________________________________________________________________

________________

RECOMMENDATION: ¨ RECOMMENDED ¨ NOT RECOMMENDED

DATE OF EVALUATION:

______________________

SIGNATURE OF SE / PM

____________________

DATE: NAME OF SE/PM

APPROVER’S COMMENTS:

_____________________________________________________________________________________________________

_____________________________________________________________________________________________________

_____________________________________________________________________________________________________

_____________________________________________________________________________________________________

________________

SCOPE OF APPROVAL:

_____________________________________________________________________________________________________

_____________________________________________________________________________________________________

_____________________________________________________________________________________________________

_____________________________________________________________________________________________________

________________

CONCLUSION: ¨ APPROVED ¨ NOT APPROVED

______________________

SIGNATURE OF APPROVER

____________________

DATE: NAME OF APPROVER

THIS APPROVAL IS VALID FROM___________________TO__________________(MAXIMUM UP TO ONE YEAR FROM THE

DATE OF )

* REVIEW BY HEAD HSE CAPABILITY CENTRE

OHS – 10 / Oct.’07




SAFETY INDUCTION REPORT

Name of Contractor: _______________________

TOPICS to be covered

Sr. No.

Name of Workman Trade Date of InductionThumb Impression /

Signature of WorkmanSignature of SE

OHS – 11/ Dec.’07

q L&T carporate Policy as well as Client’s HSE Policy

q Project HSE policies and Objectives

q Site HSE rules and regulations especially permit requirements

q Common cons truction HSE hazards and Precautions

q General health Issues e.g smoking and substance abuse

q Reporting incidents, including nearmisses

q Reporting hazards

q First aid and Emmergency procedures

q Health Risks of the region and the personal hygiene measures to be

adopted

q Any relevent environmental and social issues and legal requirements

q Houskeeping and the control and Management of construction waste



OHS – 14/Dec.’04


HSE CAPABILITY CENTRE

PEPTALK / TOOL BOX TALKS REPORT FORM

Identify / Name of the site :

Job Number :

Name of the Site In-charge :

Name of the Safety Co-ordinator :

Name of the Sub-contractors / dept. :

Number of workmen present :

Date & Time :

Topic discussed :

Response of Workmen :

Any significant problem identified :

Remarks of Site Engineer & SSO/E :

________________ ________________

Signature of SSO/E Site Engineer



LARSEN & TOUBRO LIMITED OHS – 15A/ Dec.’07


RADIOGRAPHY WORK PERMIT(OHSR)General Information

Valid from ________________AM/PM Date________________to_______________AM/PM Date_________________Location of work :________________________________________________________________________________Source strength: ___________________________________ Curie: ____________________________________

Equipment to be use (Specify Valid Certificate No if any). : -________________________________________________ _______________________________________________________________________________________________

Name of Persons involved in Radiography work1. 3.

2. 4.

Name of Contractor : Name of Incharge:

Name of Radiography agency : Name of Incharge of Radiography agency:

The following items must be checked before issuing the permit

Item Y N N/A Item Y N N/A

1

2

3

4

5

All the persons at the siteinformed/ removed from the area

Area around the source ofradiation cordoned off with rope/

chordsRadiation warning symbol/ boardsdisplayed around radiographywork/ on ropes & chords

Radiographer worn radiationbadges during testingRadiography camera and carrying

box having radiation symbol

¨

¨

¨

¨

¨

¨

¨

¨

¨

¨

¨

¨

¨

¨

¨

6

7

Radiographer has valid certificate fromRadiation Protection Service Division,

BARCRadiation survey meter is in working

condition

¨

¨

¨

¨

¨

¨

Additional permit required and / or attached:- No¨ Yes ¨ ( If yes specify:- )

Daily visual Inspection

Time / PeriodTo be signed only after completing

the job

Date ofWork

From ToRemarks Signature ofSite

Engineer

Signature

ofRCM/RE/Section

Incharge

Signature of Site

Engineer

Signature ofRCM/RE/Section

Incharge

Specia l Instruct io ns : 1. This permit must be available at the work site at all times.

2. Location & description of work must be clearly indicated by the permittee.3. Terms applicable must be clearly indicated by the permittee.

4. All precautions given in permit must be strictly adhered to by the permittee.5. The permit shall be submitted 4 hours before carrying out radiography to Safety Department/Section incharge (RE), L&T for his

authorisation.6. This permit shall be renewed each day only after checking all the compliance jointly by L & T & the contractor.

7. Permit renewal – for not more than 7 times including the issue date.8. Permit shall be returned to issuer after completing the job.

Additional Precautions required / Remarks, If any :

TO BE SIGNED JOINTLY BY L&T AND THE CONTRACTOR AFTER CHECKING FOR THE COMPLIANCE

All the points mentioned in the above checklist have been checked & found OK

____________________________________ ___________________ _ _________________ ________________________

(Contractor’s Site Incharge) (L&T Engineer) (L&T-SSO/E) (RCM/RE/ Section Incharge)TO BE SIGNED JOINTLY BY L & T AND CONTRACTOR AFTER THE WORK IS OVER.

Permit is hereby returned after completing the job & ensuring safe removal of men & material.

__________________________________ ___________________ __________________ ________________________

(Contractor’s Site Incharge) (L&T Engineer) (L&T-SSO/E) (RCM/RE/ Section Incharge)

Permit No.: -



OHS – 15B/ Dec.’07 HSE CAPABILITY CENTRE

HOT WORK PERMIT (OHSH)General Information

Valid from ________________AM/PM Date________________to_______________AM/PM Date_________________Nature of work :________________________________________________________________________________

Area : __________________________________Exact Location of work :____________________________________

Equipment to be use (Specify Valid Certificate No if any): ________________________________________________ ______________________________________________________________________________________________




1

2

3

4

56

7

8

9

10

Equipment / work area inspected

Surrounding area checked /cleaned up;oil/rags/ grass etc.,removed

Equipment blinded / disconnected/ closed isolated / wedged open.Equipment completely drained /

depressurised.Equipment properly steam purged.Equipment water flushed

Gas / Oxygen deficiency test done( Oxygen level -19.6% - 23%)Precautionary tags/boards

providedFire water hose/ portableextinguisher/ nozzle provided

Shield against spark provided

¨ ¨

¨

¨

¨ ¨ ¨

¨

¨

¨

¨ ¨

¨

¨

¨ ¨ ¨

¨

¨

¨

¨ ¨

¨

¨

¨ ¨ ¨

¨

¨

¨

11

12

13

1415

16

17

1819

20

Proper ventilation and Lighting

provided.Sewers, manholes,etc., and hotsurfaces nearby covered /sealed/

isolatedConsidered hazards from other routine/non-routine operations & concerned

persons alerted.Proper means of exit provided

All persons provided with proper PPE

Equipment electrically isolated /Grounded and taggedSuitable scaffolding provided

Area cordoned offFlash back arrester provded to gascutting set

All the drain inlets(if any) been closed

¨

¨

¨

¨ ¨

¨

¨ ¨ ¨

¨

¨

¨

¨

¨ ¨

¨

¨ ¨ ¨

¨

¨

¨

¨

¨ ¨

¨

¨ ¨ ¨

¨


Testing Record

Time / Period Meter ReadingTo be signed only after completing

the jobDate of

WorkFrom To

Lower ExplosiveLimit %

Upper ExplosiveLimit %

Signature ofSite

Engineer

Signature

ofRCM/RE/

SectionIncharge

Signature of SiteEngineer

Signatureof RCM/RE/

SectionIncharge

Specia l Instruct io ns : 1. This permit must be available at the work site at all times.

2. Location & description of work must be clearly indicated by the permittee.3. Terms applicable must be clearly indicated by the permittee.4. All precautions given in permit must be strictly adhered to by the permittee.5. This permit shall be renewed each day only after checking all the compliance jointly by L & T & the contractor.6. Permit renewal – for not more than 7 times including the issue date.

7. Permit shall be returned to issuer after completing the job.




____________________________________ ___________________ _ _________________ _____________________ ___

(Contractor’s Site Incharge) (L&T Engineer) (L&T-SSO/E) (RCM / RE/Section Incharge)

TO BE SIGNED JOINTLY BY L & T AND CONTRACTOR AFTER THE WORK IS OVER.Permit is hereby returned after completing the job & ensuring safe removal of men & material.

__________________________________ ___________________ __________________ ________________________

(Contractor’s Site Incharge) (L&T Engineer) (L&T- SSO/E) (RCM / RE/Section Incharge)

Permit No.: -



OHS – 15C/ Dec.’07 HSE CAPABILITY CENTRE

COLD WORK PERMIT(OHSC)General Information

Valid from ________________AM/PM Date________________to_______________AM/PM Date_________________Nature of work :________________________________________________________________________________

Area : __________________________________Exact Location of work :____________________________________

Equipment to be use (Specify Valid Certificate No if any): ________________________________________________ ______________________________________________________________________________________________


The following items must be checked before issuing the permitItem

Y N N/AItem

Y N N/A

1

2

3

4

5

6

78

9

10

Equipment/work area inspected

Surrounding area checked / cleanedup;oil/rags etc., removedEquipment blinded / disconnected /closed isolated / wedged open.

Equipment completely drained /depressurised.

Provide adequate material with which toshore the sides of excavationsGas / Oxygen deficiency test done( Oxygen level -19.6% - 23%)

Precautionary tags/boards providedConfirm the locations of the Fire

hydrant mains/ Electrical cable/ Servicelines/ Drainage system / water mains,

etc.Provide adequate ladder for getting in

and out of the excavationsUsed the method of work for putting inshoring which protects the shorer

¨

¨

¨

¨

¨

¨

¨ ¨

¨

¨

¨

¨

¨

¨

¨

¨

¨ ¨

¨

¨

¨

¨

¨

¨

¨

¨

¨ ¨

¨

¨

11

12

13

14

1516

17

1819

20

21

Proper ventilation and Lighting provided.

Sewers, manholes,etc., and hot surfacesnearby covered /sealed/ isolatedConsidered hazards from other routine/ non-routine operations & concerned persons

alerted.Made sure that there are no bldg. whose

stability is affected by excavations All persons provided with proper PPEEquipment electrically isolated / Groundedand tagged

Sides of excavations are sufficiently shored/are sloped back to 45

0

Area cordoned offEnsured that there is no spoil or eqpt. close

to the edge of the excavations.Made arrangement necessary to prevent

vehicles driving into the excavations. Are workers briefed about the hazards?

¨

¨

¨

¨

¨ ¨

¨

¨

¨

¨

¨

¨

¨

¨

¨

¨ ¨

¨

¨

¨

¨

¨

¨

¨

¨

¨

¨ ¨

¨

¨

¨

¨

¨


Daily Visual Inspection

Time / PeriodTo be signed only after

completing the jobDate of

Work From To Remarks

Signature of

Site Engineer

Signature ofRCM/RE/

SectionIncharge

Signature ofSite Engineer

Signature of

RCM/RE/Section

Incharge

Specia l Instruct io ns :

1. This permit must be available at the work site at all times.2. Location & description of work must be clearly indicated by the permittee.3. Terms applicable must be clearly indicated by the permittee.

4. All precautions given in permit must be strictly adhered to by the permittee.5. This permit shall be renewed each day only after checking all the compliance jointly by L & T & the contractor.6. Permit renewal – for not more than 7 times including the issue date.





_ ___________________________________ ___________________ ___________________ ________________________


TO BE SIGNED JOINTLY BY L & T AND CONTRACTOR AFTER THE WORK IS OVER.Permit is hereby returned after completing the job & ensuring safe removal of men & material.

__________________ _____________ ___________ ____________(Contractor’s Site Incharge) (L&T Engineer) (L&T- SSO/E) (RCM / RE/Section Incharge)

Permit No.: -



LARSEN & TOUBRO LIMITED OHS – 15D/ Dec.’07 HSE CAPABILITY CENTRE

CONFINED SPACE ENTRY PERMIT(OHSCS)General Information

Valid from ________________AM/PM Date________________to_______________AM/PM Date_________________

Nature of work :________________________________________________________________________________ Area : __________________________________Exact Location of work :____________________________________Equipment to be use (Specify Valid Certificate No if any): ________________________________________________

______________________________________________________________________________________________


The following items must be checked before issuing the permitItem

Y N N/AItem

Y N N/A

12

3

4

5

67

89

Equipment/work area inspectedSurrounding area checked / cleaned

up;oil/rags/grass etc., removedEquipment blinded / disconnected /closed isolated / wedged open.

Equipment completely drained /depressurised.Equipment properly steam purged.

Equipment water flushed.Gas / Oxygen deficiency test done

( Oxygen level -19.6% - 23%)Equipment properly taggedMaximum No. of personAllowed: ___________

¨ ¨

¨

¨

¨ ¨ ¨

¨

¨ ¨

¨

¨

¨ ¨ ¨

¨

¨ ¨

¨

¨

¨ ¨ ¨

¨

10

11

12

13

14

151617

Proper ventilation and 24vLighting / handlamp provided.

Stand by personnel provided for vesselentry.Considered hazards from other routine

/ non-routine operations & concernedpersons alerted.Proper means of exit provided.

All persons provided with proper PPE& APT (i.e. life line)

Proper portable ladder providedSuitable scaffolding providedMeans of exit available

¨

¨

¨

¨ ¨

¨ ¨ ¨

¨

¨

¨

¨ ¨

¨ ¨ ¨

¨

¨

¨

¨ ¨

¨ ¨ ¨


Testing Record

Time / Period Meter ReadingTo be signed only after completing

the jobDate ofWork

From ToFlammability

%

O2

Content %

Toxic Gases

PPM

Signature of

SiteEngineer

Signature of

RCM/RE/Section

InchargeSignature of Site

Engineer

Signature ofRCM/RE/

SectionIncharge

Specia l Instru ct ion s : 1. This permit must be available at the work site at all times.

2. Location & description of work must be clearly indicated by the permittee.3. Terms applicable must be clearly indicated by the permittee.4. All precautions given in permit must be strictly adhered to by the permittee.

5. This permit shall be renewed each day only after checking all the compliance jointly by L & T & the contractor.6. Permit renewal – for not more than 7 times including the issue date.





____________________________________ ___________________ __________________ ________________________


TO BE SIGNED JOINTLY BY L & T AND CONTRACTOR AFTER THE WORK IS OVER.


__________________________________ ___________________ __________________ ________________________


Permit No.: -



LARSEN & TOUBRO LIMITED OHS – 15E /Dec.’07


GENERAL ELECTRICAL PERMIT(OHSE)General Information

Valid from ________________AM/PM Date________________to_______________AM/PM Date_________________

Nature of work :________________________________________________________________________________ Area : __________________________________Exact Location of work :____________________________________Equipment to be use (Specify Valid Certificate No if any): ________________________________________________

______________________________________________________________________________________________




1*2

3

45

6

78

9

10*11

12

13

Equipment locked outCaution notice provided near the place ofworkSurrounding area checked / cleaned

up;oil/rags/grass etc., removedIsolator / Breaker switched off (fully)Fuses removed / Breaker withdrawn

Aux. Supply (Diesel generator) switchedoff.

Transformer isolated from both ends.Equipment earthed / earthing truck

inserted / earthing rod put. All person provided with proper PPE.

Adequate lighting providedBarrier established to prevent inadequate

entry.Verify circuits de-energized and capacitor

shortedIsolation tag in Place (Tag No.:_______)

¨ ¨

¨

¨ ¨

¨

¨ ¨

¨ ¨ ¨

¨

¨

¨ ¨

¨

¨ ¨

¨

¨ ¨

¨ ¨ ¨

¨

¨

¨ ¨

¨

¨ ¨

¨

¨ ¨

¨ ¨ ¨

¨

¨

*14

1516

17

18

19

20

21

22

Workers insulated from ground byinsulating material/ Hylem sheetcovering any adjacent metal /energized circuits.

Person certified and trainedMetal hand tools used are electricallyinsulated

All metal and loose clothing removedfrom person doing the work.

Hydraulic / air / Gas / Steam / acidvalves closed.

Appropriated fire-fighting eqpt.Provided.

Temporary connection required? If so,Load________ Amp

Test meter is calibrated and checkedagainst known energized source

before checking circuit All residual electrical energy was

discharged fully

¨

¨

¨

¨

¨

¨

¨

¨

¨

¨

¨

¨

¨

¨

¨

¨

¨

¨

¨

¨

¨

¨

¨

¨

¨

¨

¨


Daily Clearance

Time / Period To be signed only after completing the job

Date of

Work From To

RemarksSignature of

site engineer

Signature ofRCM/RE/

SectionIncharge

Signature of site

engineer

Signature ofRCM/RE/

SectionIncharge

Special Instruct ions :

1. This permit must be available in three copies two for initiator and one for issuer.

2. Location & description of work must be clearly indicated by the permittee.3. Terms applicable must be clearly indicated by the permittee.

4. All precautions given in permit must be strictly adhered to by the permittee.

5. This permit shall be renewed each day only after checking all the compliance jointly by L & T & the contractor.6. Permit renewal – for not more than 7 times including the issue date.7. Permit form shall be returned to issuer after completing the job.

8. (*) used only for energized equipment.9. Use proper PPE while working with energized equipment / Non energized equipment




__________________ __________ _________ ____________(Contractor’s Site Incharge) (L&T Engineer) (L&T- SSO/E) (RCM / RE/Section Incharge)

TO BE SIGNED JOINTLY BY L & T AND CONTRACTOR AFTER THE WORK IS OVER.


______________________ _________ _________ _____________(Contractor’s Site Incharge) (L&T Engineer) (L&T- SSO/E) (RCM / RE/Section Incharge)

Permit No.: -




HEIGHT WORK PERMIT (OHSHW)

General Information

Valid from ________________AM/PM Date________________to_______________AM/PM Date___________________Nature of work :__________________________________________________________________________________

Area : __________________________________Exact Location of work :______________________________________

Equipment to be use (Specify Valid Certificate No if any): __________________________________________________ ________________________________________________________________________________________________ ___________




1. Work method explained to the workers 10. Platforms free from oil / grease

2. Adequate illumination ensured 11. Use of safety harness, safety helmet

3. Work area inspected prior to start the

work

12. Anchoring points provided at all places of

work

4. Area below the work place barricaded,especially below hot work

13. Common lifeline provided wherever linearmovement at height is required

5. Workers provided with bags / box tocarry bolts, nuts and hand tools.

14. Safety nets are in use wherever required

6. Work at more than one elevation at the

same segment is restricted.

15. Proper fall arrest system is deployed at

critical work places?7. Platform was provided with handrail,mid rail and toe guard?

16. Crawler boards / safety system for workon fragile roof are used

8. Are ladders properly secured to preventslipping, sliding or falling?

9. Metal ladders not used around

electrical hazards?

Additional permit required and / or attached : Yes No (If yes specify:- )

Daily clearance

Time / PeriodTo be Signed only after

completing the jobDate ofwork From To

Remarks Signature ofSite Engineer

Signature ofRCM/RE/

Section

Incharge

Signature ofSite Engineer Signature of

RCM/RE/Section

Incharge

Special Instructions:

1. This permit must be at the work site at all times.2. Location & description of work must be clearly indicated by the permittee.3. Terms applicable must be clearly indicated by the permittee.4. All precautions given in the permit must be strictly adhered to by the permittee.

5. This permit shall be renewed each day only after checking all compliance jointly by L&T & the contractor.6. Permit renewal – for not more than 7 times including the issuing date.7. Permit shall be returned to the issuer after completing the job.

Additional Precautions required / remarks, if any:



---------------- ----------------------------- ------------------------- --------------------

(Contractor’s site in charge) (L&T Engineer) ( L&T – SSO /E) (RCM / RE/Section Incharge)TO BE SIGNED JOINTLY BY L& T AND CONTRACTOR AFTER THE WORK IS OVER

Permit is hereby returned after completing the job & ensuring safe removal of men & material

________________ _________________ _________________ ______________

(Contractor’s site in charge) (L&T Engineer) ( L&T – SSO /E) (RCM / RE/Section Incharge)

Permit No:-

– – ec.



OHS – 16 / Jun’07



Periodic Physical Inspection Record

Name of Site : -

Job No.: -

Inspected By : -

Date : -

Sl.No

Item IdentificationNumber

SWL Observation Condition Remarks

(P & M Engineer)



OHSC – 17 A/ Dec.’04



CRANE INSPECTION CHECKLIST

Name of Site : -

Job No.: -Inspected By : -Date : -

Sr.No.

Description Observation Measures

1 Valid driving license

2 Hook and Hook latch

3 Over hoist limit switch

4 Boom limit switch5 Boom angle indicator

6 Boom limit cut off switch

7 Condition of boom

8 Condition of ropes

9 Number of load lines

10 Size and condition of the slings

11 Stability of crane

12 Soil condition

13 Swing break and lock

14 Propel break and lock15 Hoist break and lock

16 Boom break and lock

17 Main clutch

18 Leakage in hydraulic cylinders

19 Out riggers fully extendable

20 Tyre pressure

21 Condition of battery and lamps

22 Guards of moving and rotating parts

23 Load chart provided

24 Number and position of pedant

ropes25 Reverse horn

26 Load test details

27 Operators fitness

28 Pollution Under Control Certificate

29 Fire Extinguisher of appropria tetype

30 Training to the operator



OHSC – 17 B/ Dec.’04



CRANE / VEHICLE / EARTH MOVING EQUIPMENT INSPECTION REPORT

Name of Site : -


Sr.No.

Identification /Registration Number

Make/ Model Unsafe Conditions /Deficiencies observed

Action By Close OutDate

Remarks

___________________________ __________________________ __

( SSO ) ( P & M Engineer / Site Engineer )



OHSC – 17 C/ Dec.’04



VEHICLES & EARTH MOVING EQUIPMENT INSPECTION REPORT

Name of Site : -


Sr.

No.

Description Observation Measures

1 Valid Driving license

2 Engine Condition

3 Clutch and Break condition4 Hydraulic System

5 Horn / Reverse Horn / Lights

6 Indicators / Wiper Blades

7 Operator / Driver fitness

8 Tyre Pressure

9 Condition of battery and Lamps

10 Operating levers / stirring

11 Doors / Guard / Cover

12 Gauges & Warning devices

13 Fire extinguisher provided

14 Breathing cap on fuel tank

15 Pollution Under Control (PUC)test certificate

16 Training to the driver/ operator

17 Any other point



Page 1 of 3


SAFETY INSPECTION CHECKLIST

SITE : INSPECTOR:

DATE : REFERENCE : L&T OHS MANUAL

SR.

NO.

REQUIREMENT TO THE COMPLIANCE ACTIVITY

COMPLIANCE

YES / NO

REMARKS

1. Is the Company Corporate Policy displayed at

site office and conference room?

2. Is full time site safety officer deputed at site?

3. Is SSO approved by Safety Department?

4. Are OHS Manual available at site?

5. Does the site have safety committee?

6. Are sub-contractors included in safety

committee?

7. Is safety committee meeting held monthly?

8. Are unsafe acts / conditions, accident causes and

recommendations discussed in meeting?

9. Are action by and target date columns included in

minutes of meeting?

10. Are minutes of meeting circulated among

members and copy sent to SD?11. Is accident reporting and investigation procedure

followed at site?

12. Are near miss accidents reported and

investigated?

13. Is safety inspection logbook maintained by SSO?

14. Is safety inspection signed by RCM?

15. Is SSO conducting toolbox talks at site?

16. Are records maintained?

17. Is site-opening report sent to SCD, Powai?

18. Is safety day / week celebrated at site?

19. Are safety posters displayed at site?

20. Are adequate numbers of first aid boxes availableat site?

i) Site office

ii) One box for every 300 M radius

21. Is ambulance available at site?

22. Is clinic available at site?

23. Is house keeping in order?

24. Are walkways clear from obstruction?

25. Is material stacked properly?

26. Are sufficient dustbins provided?

27. Is work permit system followed at site?

28. Whether all safety precautions taken, which are

mentioned in work permit?

OHS – 19A/ Nov.’07



Page 2 of 3

SR.

NO.


COMPLIANCE

YES / NO

REMARKS

29. Are Personal Protective Equipment (PPE)

provided for employees?30. Are employees using PPE?

31. Are safety belts used for working at height above

2 M?

32. Are safety belts anchored to fixed point?

33. Are ear muffs / plugs provided, where noise level

is more than 85 dB?

34. Is safe access / platform provided for working at

height?

35. Are adequate scaffolding provided for working at

height?

36. Is scaffolding checked / inspected before use?

37. Are sufficient fire extinguishers provided at site?

i) Near site office

ii) Near stores

iii) Near hot work

38. Are fire extinguishers properly serviced and

validity date marked on it?

39. Are employees trained for operating fire

extinguishers?

40. Whether all lifting equipment / tackles are

marked with their S.W.L.?

41. Are inspection / test certificates of competent

person (s) available at site?

42. Are adequate lifting tackles provided at site?

43. Are trained operators engaged for operating theequipment?

44. Are lifting equipment / tackles maintained in

good working conditions and record maintained?

45. Whether proper storage is provided for gas

cylinders?

46. Whether valve protection caps are provided for

gas cylinders?

47. Whether flash back arresters provided for oxy -

acetylene gas cutting set?

48. Whether trolley provided for gas cutting set?

49. Whether proper clamps provided for hose

connection?

50. Are pressure vessels tested / certified by

competent person?

51. Are ELCB's provided for electrical installations?

52. Are emergency nos. displayed at site?

53. Is emergency vehicle available at site?

54. Are guards of machinery’s in position?

55. Is work place properly illuminated?

56. Are adequate ladders provided at site?

57. Is monthly accident statistics report copy sent to

SCD, Powai?

58. Are accident prevention tools & safety-related

items available at site as per Chapter-04 ofOH&S Manual?

OHS – 19A/ Nov.’07



Page 3 of 3

SR.

NO.


COMPLIANCE

YES / NO

REMARKS

59. Is safety performance board displayed at site?

60. Is positive reporting on safety report sent to SCD,Powai?

61. Are excavations safe for work?

62. Are excavation barricaded?

63. Is proper slope or shoring provided for

excavation?

64. Whether hand tools are in good working

condition?

65. Are damaged tools discarded?

66. Whether portable electrical tools are in good

working condition?

67. Is earthing provided for portable electrical tools?

68. Are guards provided for portable grindingmachines?

69. Whether AERB rules followed for radiography?

Signature of Inspector : - ________________

OHS – 19A/ Nov.’07



OHS – 19B/ Nov.’07



SITE SAFETY INSPECTION REPORT

Name of the site: -Area / Location of the site inspected: -

To, RCM Date: - Team Members: - Members Absent: -

Sr. No. Unsafe Conditions / Unsafe acts observed Action Required Action By &

Target DateClose out

dateRemarks

SSO/E (Signature) Date Members Present (Signature)



OHSC – 19A / Nov.’07


SAFETY AT WORKING AT HEIGHT CHECK-LIST

Name of Job site: - Date: -

Guide Word “Yes”

SI.No.

Description ObservationYes/No

Remarks

1. All the workers have been explained the safe work method2. An established communication system have been established and explained

to the workers.3. Adequate illumination has been ensured

4. Work area inspected prior to start the work

5. Area below the work place barricaded, especially below hot work

6. Workers provided with bags/box to carry bolts, nuts and hand tools.7. Arrangement for fastening hand tools made.

8. All work platforms ensured to be of adequate strength and ergonomicallysuitable

9. Fabricated makeshift arrangements are checked for quality and type ofmaterial welding, anchoring etc.

10. Work at more than one elevation at the same segment is restricted.

ACCESS / EGRESS

1. Walkways provided with handrail, mid-rail & toe board

2. All checkered plates, gratings properly welded/ bolted

3. Ladders inspected and are maintained in good condition

4. Ladders are properly spliced5. Ladders are properly secured to prevent slipping, slid ing or falling

6. Ladder is extended 1m above top landing

7. Built up ladders are constructed of sound materials

8. Rungs and cleats are not over 1ft (12”) on center

9. Rubber stoppers are provided for Metal ladders used around electricalinstallations.

10. Proper maintenance and storage

11. Ladders are placed at right slop

12. Ladders, staircases welded / bolted properly.

13. No obstruction in the stairs14. All landings are provided with handrails, knee rails, toe boards etc.

15. Whether ramp is provided with proper slope

16. Proper hand rail/ guards are provided in ramps.

HOUSEKEEPING 1. Walk ways, aisles & all overhead workplaces are cleared of loose material

2. Combustible, Flammable materials are cleared

3. All deshuttering material are removed after deshuttering is done4. Platforms and walkways are free from oil/grease or other slippery material

5. Collected scrap is brought down or lowered down and not dropped fromheight

PPE AND SAFETY DEVICES

1 Use of safety helmets, safety harness are ensured for all workers

2. Anchoring points provided at all places of work

3. Common life line provided where ever linear movement at height isrequired

4. Safety nets are in use wherever required5. Proper fall arrest system is deployed at critical work places

6. Crawler boards are used / Safety system is practiced for work on fragile

roof are used

Checked By:

Signature: Date:



Page 1 of 4

OHSC – 19B / Nov.’07


GENERAL HSE INSPECTION CHECKLIST

Name of Site : Area Inspected :

Inspected By : Date :Guide Word “Yes”

Sl.

No.

Activities Observation

(Y/N)

Measures

A PILING WORK

1 Condition of tripod and its stability

2 Condition of wire ropes, D shackles, Bulldog Grips etc. is acceptable

3 Loose earth, slush etc. are removed

4 Entry in register, details of periodical checking & maintenance of piling

rigs and pulley blocks are in place.

5 Guards for rotating parts of machines are in place

6 PPE such as Ear Muff, Ear plugs, etc are being used at site7 Area is barricaded and sign boards are displayed

B EXCAVATION

1 Obtained permission from competent authorities ,prior to excavation

2 Verified underground electrical cable/ pipelines prior to excavation

3 Kept soil heaps 1.5m/ depth of pit (whichever is more) away from the edge

of excavated pit

4 Ensured no undercutting

Provided Barricade / Fencing/ Displaying of danger sign, warning sign by

way of red flag /tape/ light etc.

5 Provided dewatering facilities

6 Provided two proper means of access / egress.

7 Provided escape ladders

8 Stability of nearby structure is found ok.

9 Avoided traffic movement, piling work in the vicinity.

10 Safety signboards are displayed.

C DEMOLITION

1 Surrounding area is barricaded.

2 Warning sign Red Flag/Tape/ Light etc. is displayed

3 Demolition from top in a planned manner

4 Disconnected electrical cable connection/ water/ steam /gas line etc.

5 Debris is being removed immediately to a safe place

6 Emergency Transport available

7 Fire extinguishers kept nearby for emergency.

8 Safety signboards are displayed.

D BLASTING

1 Blasting record incorporating number of holes made/type of explosive

used / firing pattern & sequence with date and time of blast

2 Handling of explosives by licensed blaster

3 Intensity of the charge calculated before use

4 Before drilling presence of unfired explosives checked

5 Blasting is carried out only during lean hours say lunch/night hours

6 Standard warning signal / all clear signal before and after firing is ensured



Page 2 of 4

Sl.

No.


(Y/N)

Measures

7 Competent persons equipped with red flags are posted at possible

approaches to stop traffic and by trespassers.

E GROUND SURFACES

1 Ground level , no soft spot

2 Footing timber level adequately supported

3 No Unauthorised entry.

F SCAFFOLDS

1 Base plate level

2 Spindle jack vertical

3 Standard plumb (vertical tubes) , no damage

4 Ledgers level (horizontal tubes), no damage

5 Diagonal bracing, check secure and non missing

6 Lock pin in place and secure

7 Support from permanent structure.

8 Scaffolding tags provided, signed by responsible person ?(Red –Unsafe,

Green Safe)9 Work platforms are provided with handrail, midrail and toeboard.

G LADDERS

1 Check placed on level ground

2 Position at an angle of 1:4

3 Adequately secured

4 No damage

5 Ladder extended 1m above stepping off point

6 Uniform and proper spacing of rung.

H WORKING PLATFORM

1 Should not be less than 700 mm wide2 Guard rails adequate check

i) Top rail at least 900 mm height

ii) Toe board at least 150mm height

iii) Mid rail

3 Boards free of defects check

i) No gaps

ii) Adequate supports

iii) No risk of trips

iv) Properly secured / tied

I PP E

1 Helmet and footwear worn

2 Safety harnesses as required and secured above shoulder level

3 Use full body harness while working at height

4 Safety Goggles during welding /gas cutting /Grinding etc.

5 Condition / Maintenance of safety appliances

6 Use of body guards, gloves etc.

J STRUCTURAL FABRICATION & ERECTION

1 All electrically operated equipment has proper earthing and connected

through ELCB.

2 Safety guards for drilling & grinding machine are in position

3 Use of Scotch block / wedge on wheels of trailors during unloading of

material.

4 End stoppers fixed and maintained for rail mounted gantry cranes and limitswitches are in operating condition.

5 Checking lifting tool & tackles before use

6 Precaution during slinging on sharp edges




Page 3 of 4

Sl.

No.


(Y/N)

Measures

7 Signaling to crane operators by one person at a time

8 Withdrawal of persons beneath suspended load

9 Cordoning on all sides displaying Red Flags / Tape/ Light and warning

signs

10 Load to be lifted is properly ascertained to identify centre of gravity etc.

11 Clear passages of men, posts, material etc. and easy access for cranes to

move with suspended loads12 Proper tag line is used for guiding lifting loads

13 Proper sequence of erection is followed.

14 Guy ropes are used and secured during and after erection of heavy lift.

15 Wire ropes are maintained and its safe working load inscribed

16 Adequate illumination provided

K GAS CUTTING AND WELDING

1 Separate Storing of gas cylinder like DA, Oxygen full & empty etc.

2 Proper handling of gas cylinder

3 Condition of regulator, hose, torch etc. is good

4 Welding generators / transformers condition and its proper earthing5 Condition of welding cable and joints

6 Electrode holder

7 Area free from combustible material

8 Area Cordon when Welding /Gas cutting is in progress at height.

9 Provision of fire extinguishers

10 Smouldering fires are religiously extinguished after day's job.

11 Stacking of cylinders not near live wires, battery charging rooms / oil

rooms

L MEANS OF ACCESS

1 Staircase and railing is provided

2 Safe access to and fro m means of access

M ELECTRICAL WORKS

1 Earthing is provided to electrically operated equipment

2 Shed /Canopy/ cover is provided to distribution board and sub-distribution

board.

3 Insulation of cables and joints are in good condition

4 Cable laying above 7ft from ground level

5 Fire extinguishers is provided in main distribution board room.

6 Periodical checking of portable tools is being done.

7 Use of ELCBs

8 Men working don't switch on board and other related warning boards, tags

9 Use of proper plug and sockets

10 Job safety analysis for shutdown jobs and its proper action

11 Followed Permit to work

O HOUSEKEEPING

1 Material is properly stacked and stored

2 Working /moving area clean

3 Access/Main Approach /Passages free form obstacles

4 Cordoning /covering of pit, vat, machine foundation etc.

5 Unwanted materials like excavated earth debris etc. are removed.

P FIRE PREVENTION /PROTECTION

1 Combustible material away from source of heat /fire

2 Fire extinguishers are provided and maintained properly




Page 4 of 4

Sl.

No.


(Y/N)

Measures

3 No smoking board/caution board displayed at suitable location

4 Combustible & non combustible materials at suitable location

Q ROAD SAFETY

1 Driving by authorised person

2 Material load on truck, dumper are secured properly

3 Followed Speed Limit4 No horse play on job

5 Reverse horn provided to all the vehicles

6 No unauthorized road block

7 Persons are being transported by Jeep or bus and not by Dumper .

8 Location of Overhead lines identified and precautions taken.

9 Vehicles are inspected periodically and records are maintained.

R MISCELLANEOUS

1 First Aid box with proper medicine is provided and maintained.

2 Validity date of medicine

3 Proper Illumination is provided at work place during dark time4 Provided sufficient Safety board and safety promotional materials

i) Posters

ii) Stickers

5 Followed Accident report form

6 Reporting system with regional office

7 Provided drinking water and sanitation at site

8 Provided emergency vehicle.

Checked By:

Signature: Date:




OHSC – 19C / Nov.’07


HSE CAPABILITY CENTREHOUSEKEEPING CHECKLIST

Guide word “Yes” Date : -

Sr.No.

Contents Yes /No

Remarks

A Structural Fabrication / Erection Site.

1 Walkways, passages kept clear of material.2 Area and roads kept clear for maneuvering of cranes and material handling eqpt.3 Scrap, cut-pieces, welding electrode stubs, hand-tools kept tidy in work area and

disposed suitably.4 Scrap bins available at site.

5 Welding cables, power cables routed properly to avoid run over by vehicle ortripping hazards and obstruction to personnel movement.

6 Compressed gas hoses routed properly in the site.

7 Compressed gas cylinders,hoses kept away from hot work & grinding work.8 At least 1meter on both sides of gantry rails are kept clear of material.

9 Floor kept clear of water, oil spillage / accumulation.

B Civil Work Area1 All approach, aisle, ingress / egress to / from site, excavated pits, ramps, walkwayskept clear of material debris tools etc.

2 Scaffolding material, (H- beam, H-D tower frames, bracing, clamps) shuttering boards acrosspans etc. are stacked properly at site.

3 Stacking of breaks, hollow blocks are done in safe manner.4 Nails removed from wooden planks / timber and not protruding out.

5 Saw dust, wood chips & scrap wood cleared from carpentry shop & disposedsuitably.

6 Debris from demolition and excavated earth cleared from site and accesses.

C Electrical Installation & Booths1 Approach to DB, panels, and switches kept clear.

2 Fire extinguisher installed at an easy accessible location.3 Welding cables and power cables are routed separately.

4 Routing of cables are done properly to avoid obstruction & tripping hazards5 Floor of electrical booths kept dry

6 Rubber mats are in place at electrical panels.

D Stores 1 Walkways, entry and exits kept clear.

2 Materials placed on rack are safely accessible.3 Compressed gas cylinders are segregated as full or empty and type of gas.

4 Vertically stored cylinders are secured/ chained to avoid toppling and horizontalonce guarded against rolling down.

5 Flammables storage areas are isolated from store, office and work areas.6 Cement bags are stacked in proper gradient safely.7 Corrosion material are stored away from other material & kept on collection trays to

safeguard against accidental leakage.

8 Storing of lifting tools & tackles and PPE are in dry & clean space.9 Easy accessibility installed fire extinguishers ensured in store.

E General1 Separate scrap yard is allocated for the site.

2 Approaches to workstations, office, time offices, stores, P&M are well laid &demarcated.

3 Site roads are kept clear of stacked material for free & safe vehicular movement

4 Heavy material stacking are taken care of to prevent slips, collapse and rolling.

Signature of SSO/E: ___________



Page 1 of 2

OHSC – 19D / Nov.’07



CHECKLIST FOR SCAFFOLDING

Name of Site : Inspected By :

Sub-Contractors Name : Location :

Date :Guide Word “Yes”

Sl.

No.

Points Observation

(Y/N)

Measures

1 Sufficient and suitable scaffolds provided at site for height work

2 Scaffold being erected under the direction of a competent person

3 Deployed trained and experienced workmen for constructing / dismantling /

shifting scaffolding works

4 People working on scaffold are medically fit

5 Scaffold platforms are designed/constructed with a safety factor of minimum 4

6 Provided a safe means of access (e.g Ladder) to the working platform

7 Ladders are properly secured with the scaffold structure.8 Scaffold structures are having a solid base avoiding pavements & manhole

covers etc

9 The scaffolding structure is free from excavation pit/proper distance is

maintained

10 Verticality and horizontal position of the structure is properly maintained

11 Guard rails provided between 0.9 Mtrs and 1.2Mtrs high.

12 Toe-boards are placed and having height atleast 150mm.

13 Metallic planks used for working platforms are free from cracks, damages.

14 All planks have been properly secured to the scaffold structure with binding

wire to prevent blowing off in the event of high winds.

15 Gap between two planks are not more than 25mm.

16 All braces, clamps are secured, all sections pinned or appropriately secured.

17 Scaffolds are inspected once in a week and also after prolonged interruption in

the work

18 Provided Scaffold Tag - “Green – Safe for Use” , “Red – Do not Use ”

19 Employees are aware of the importance of load distribution on a given working

platform.

20 Overhanging of the working platform is restricted to less than 50mm/four times

the thickness of the board

21 For suspend scaffold, lifeline is anchored to an overhead structure and not to the

scaffold.

22 Is the width of a working platform properly maintained according to usage, viz.

a. Minimum 700mm for footing only and not for deposit of materials

b. Minimum 900mm for footing and deposit of materials

c. Minimum 1100mm when used for heavier loads or to support higher

platforms

23 All the materials stored on the platforms are properly secured.

24 Openings in working platform are safely covered/fenced

25 Scaffold meets electrical safety clearance distance.(Ref Procedure)

26 Wheels / castors are locked and can not be unlocked accidentally

27 Mobile scaffolds are used on a firm and level surface

28 Scaffold have a height and width ratio of at least 4:1

Inspected By:

Signature: Date:



OHSC – 19E /Nov.’07


ELECTRICAL SAFETY INSPECTION CHECKLIST

Guide Word : Yes Date: - Sr.No

Contents Y/N

Remarks

A Cable1 Cables are free from damage /defects

2 All cables used at site are checked for insulation resistance before putting them into use

3 Main Cables

(i) All underground Cables are laid through cable trench

(ii) All overhead Cables routed through a firm structure /pole and they are at a safe

distance from the working levels

4 Cables are routed properly above the ground? (if necessary in cable trays)

5 No overlapping of welding & electrical cables

6 Improper joining of cables-wires are avoided at site

7 Used proper rating cables at site

8 No cables are trailing in water/solvents.

B DBs(Distribution Boards)/ SDBs(Sub-Distribution Boards)

1 Earth conductor is continued up to DB / SDB

2 DBs & extension boards are protected from rain / water

3 Over loading of DBs / SDBs is avoided

4 Provided correct / proper fuses & CB’s (Circuit Breakers) at main boards & sub-

boards.

5 Energized wiring in junction boxes, CB panels & similar places are covered all times.

6 DANGER symbols are displayed on the panel boards

7 Proper rubber mats are provided

8 Fire Extinguishers (D.C.P. / CO2) are provided.

9 People are trained to operate the fire extinguishers

10 Electric Shock Treatment Chart is displayed near work places

11 People are trained to administer the first aid facility available

C ELCB1 All the electrical connections are routed through ELCB

2 ELCB sensitivity is maintained at 30 mA

3 ELCB numbered & tested periodically & test results recorded in a logbook

countersigned by competent person

D Grounding

1 Natural earthing is ensured at the source of power (main DB at Generator or

Transformer)?

2 The continuity & tightness of earth conductor are checked and records maintained at site

3 Mentioned the gauge of earth conductor used at site.

4 Mentioned the value of Earth Resistance.

E Electrically Operated Machines / Accessories

1 The plug top provided everywhere

2 The sockets & plug tops are of Industrial type

3 The sockets provided with covers

4 All metal parts of electrical equipment & light fittings / accessories are grounded

5 Provided shed / cover for welding machines

6 Halogen lamps are fixed at proper places

7 Portable power tools are maintained in a good working condition and inspected

regularly.

8 Power tools are of double insulated type

F Persons working

1 Users of portable electrical equipment are competent/ trained.

2 Electricians are having valid license to work on electrical installations

3 LOTO (Lock Out Tag Out) system is being followed

3 People are using PPE, while working with electrical equipments/ system/ installation?

Name of SSO/ E: ___________ Signature : ______________ Date: _____________



OHSC – 19F / Nov.’07


ERECTION SAFETY CHECK-LIST

Name of Site : Inspected By :

Sub-Contractors Name : Date :

Material to be lifted : Approx. Weight :


Sl.

No.

Points Observation

(Y/N)

Measures

1 Erection plan is prepared and approved from the concerned party.

(for critical lifting more than 50 ton)

2 Test certificate for cranes, and other lifting tools and tackles are

available and valid.

3 Determined position of CG

4 Suitable sling /'D' shackle is selected and available

5 Bull dog grips are being provided in correct manner for wire ropes /

slings

6 Required number of 'U' clamps are fastened

7 The signal man are provided with whistle/ suitable communication

device

8 There is only one signal man identified for guiding lifting operation.

9 He is equipped with a distinct self-luminescence jacket to facilitate

easy identification.

10 All the workmen at higher elevation are wearing safety harness withtheir life line hooked

11 Precaution have been taken , for obstructions as well as tag line

12 (If suspension involved) The condition of the suspension method is

checked

13 Lifting Hook is Inspected by (D.P) Dye Penitent test

14 Standby lifting tools & tackles is arranged (if required)

15 Safety net is provided (if required)

16 Arranged adequate illumination

17 Guy rope is available

18 Protected against sharp edge19 Area clearance taken care of

20 People working near by area have been informed about the hazards

and precautionary measures through TBT

21 All the riggers are trained and experienced

22 Loose materials have been removed from the platform such as pipes,

channels, paint drum , gas cylinders , etc

23 All the openings are covered with gratings and are properly tied.

24 Sides are barricaded with temporary or permanent guardrails.

Inspected by :

Signature: Date:



OHSC-19G/Nov.07

Maintenance Checks Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec

Checks shel l of Ext inguisher for: Extinguisher No.

Extinguisher Type

- mechanical damage/denting Capacity

Check Nozzle for: Particulars of Repairs and

-clogging with dirt Remarks, if any

-deformity/damage/crack Monthly Repairs Done By: Remarks

-wear/tear of its threads Jan

Check cap for Feb

-wear/ tear of threads Mar

-blocking of vent holes Apr

- Wear/tear of lugs May

-smooth functioning of plunger rod Jun

-deformity/wear of lugs locking device Jul

Check inner cage for: Aug

Sep

Check washer for: Oct

-damage (cut,crack,or wear) Nov

Check Hose Assy. / Horn For: Dec

- Cut, crack or wear * Recharging due on Recharing done on

- Coupling or swivel joint 1

Check locking device for: 2

- bend , corrossion or binding 3

Check gas cart r idge for * Hydraulic Test due on Hydraulic Test done on

-damage seal disc * Performance Test due on Performance Test done on

-damaged threads 1

2Check CO2 Ext inguisher for 3

Check Dry Powder for

- caking or contamination

- improper fill level

Year :



-its weight (Loss of wt. should not exceed

more than 10% of wt.)

MAINTENANCE CHECK FOR FIRE EXTINGUISHERS

CARBON DIOXIDE / DRY POWDER TYPE

- Corrosion on inner or outer surface

- Wear /tear of threads

-deformity, corrossion, or clogging

Area/ Location/ floor

Other information / Remarks

Note: 1. Check that each part is thoroughly cleaned up and reassembled before remounting.

2. Inspection Tag shall be available on the neck of extinguisher.

3. Extingusiher is mounted at an accessible location at a comfortable level/height.

-Corrosion

-corrosion

-its weight (Loss of wt. should not exceed

more than 10% of wt.)



OHSC – 19H/ Nov.’07


POWER TOOLS INSPECTION CHECKLIST

Name of Inspector: Date of Inspection:Guideword: “YES”

POINTS TO BE CHECKED

Sr.

No.

Equipment No./

Model No. CorrectVoltage(Prescribed

by Manu al)

ProperlyGrounded ProperlyGuarded GoodCableCondition

CorrectDisc/Revs

DoubleInsulated Auto shutoff(Working)

PPEused byOperator

SkilledOperator Remarks

Inspector

Signature



OHSC – 19I / Nov.’07


CRANE OPERATION DAILY CHECKLIST

CRANE OPERATION DAILY CHECKLIST FOR THE MONTH ______YEAR _____

Name of Site:___________________Operator's Name:______________ Licence No.__________

Crane No.___________________ Model#__________________ Type: _______________________

Date of Inspection: __________________________Date of expiry: _________________by competent person

Description Date Item NumberThe following applicable items shall b e checked daily,

other items may apply.

1 2 3 4 5 6 7 8 Operators

Remark

Sign

1

2

3

4

5

6

7

8

9

10

11

1213

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

1.) Test run unit, observe operation for malfunctions

-Safety, Emergency stop

-Pendant, Joystick

-Correct direction of motions-Brakes of all motions

2.) Check for deterioration or leakage in lines, tanks, valves

drain pumps and other parts of air or hydraulic systems

3.) Examine load hooks for wear, Cracks, or Damage

-Saddle wear (10%) Max

-Twist (10%) Max

-Throat opening (15%) Max4.) Check Hoist Rope, or Chain

-End connections

Chain-excessive wear, Twist distorted links, stretchRope- crushing, kninking, broken wires

-Latch

5.) Check load attachments

-Capacity ratings, End connections

Chain- excessive wear, Twist, Distorted links, Stretch

Slings- crushing, Kninking, Broken wires tears

6.) Check for excessive wear, Cracks or components

-Hok block, Sheaves, Hook

7.) Check all running ropes and chains for correct reeving

- Proper spooling

8.) Check upper limit with no load 31

Code: A= Acceptable D=Defective, Report at Once

Signature of P & M Incharge :

Signature of Site Safety Officer :

Signature of RCM :



OHS – 20A / Dec.’04


ATTENDANCE SHEET

PROGRAMME:

PLACE: DATE:

FACULTY :

DURATION:

Sr.

No.

Participant’s Name Designat ion Company’s

Name

Signature

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20



OHS – 20B / Dec.’04


FEED-BACK FORM

PROGRAMME : ……………………………………………………….……… DATE/ s: ………………………………

PLACE : …………………………………….……………………………………………………………………………….

NAME : .………………………………………………………..(Optional), DESIGNATION :……………..……………

ORGANISATION : ………………………………….……………………………………………………………………….

( I ) What according to you is the objective of the programme ?

………………………………………………………………………………………………………….…………………………………………………………………………………………………………. ………………………………………………………………………………………………………….

( II ) Please answer each of the following by ticking the appropriate answer.

( a ) Did the programme achieve its objective ?

0 % 20% 40% 60% 80% 100%

( b ) Considering the objectives, the level of subject treatment was :

too elementary too advanced about right

( c ) The subjects were :

not relevant at all relevant partly relevant

( d ) The programme duration was :

too short too long about right

( e ) Effectiveness of the audio-visual aids (such as video films and slides) :

0 % 20% 40% 60% 80% 100%

( III ) General Comments……………………………………………………………………………………………………………………

……………………………………………………………………………………………………………………

…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………

( IV ) What action will you take after attending this programme ?

………………………………………………………………………………………………………………………………………………………………………………………………………………………………...………

…………………………………………………………………………………………………………….………

( V ) Bearing in mind the general objectives of the programme, how would you rate this

programme ?

Unsatisfactory Good Very good Excellent



To:HSE Performance Report

During the month of __________HSE performance of various ongoing construction sites of E&C Division, including MFF was as under.

Chemical

plantsUnit System Petrochem Refinery OGSP MFF NPBU E&C Power Cement

A This Month

This Month

Year till date

This Month

Year till date

This Month

Year till date

This Month

Year tilll date

This Month

Year tilll date

This Month

Year till date

This Month

Year till date

This Month

Year till date

This Month

Year tilll date

Lost Workday Case Frequency Rate = No.of LWC x 200,000

No. of Employee-hours worked

This Month

Year till date

Lowest

Worst

LWDSR = No.of Lost Work Day x 200000No. of Employee-hours worked

This Month

Year till date

Lowest

Worst

M

A. K. Ahuja

Fire incidentsJ

IDangerous Occurrence

CC: JMA - VP (TSS)CC: KV - President (O)

No. of Lost Workday Case

(LWC)

B

C Employee hourscompleted without LWC

G

E No. of Recordable Case

Annexure: HSE Promotional activities carried out during this month.

L

Lost Work Days Severity

rate (LWDSR)

Year Till Date

No.of work places/sites - SBU wise

OHS-21/Oct.'07

Power & MineralOverall

Division

No. of First Aid Cases



Total number of

employees including

contractors

Date:

Up Stream

Total employee hours

worked

D

Business GroupSr.

No.Mid & Down Stream

K

Lost Workday Case

Frequency Rate

Year Till Date

Lost Work days due to

LWC

HNear Miss

F



OHS – 22/Dec.’04



NOISE MEASUREMENT

Name of the Project Site:

Date of Noise Measurement:

Serial Number of the Equipment used:

Sr. No. Location Time Noise Level in dB(A) Remarks

_______________________ ________________

Name & Signature of Person Signature of SSO/E

carrying out Noise Measurement



OHS - 26 / Feb.’08


SCAFFOLD REGISTER

Name of the work : Location:

Name of the agency carrying out the work :

Date :

Purpose for erecting scaffold :

Height : Length :

Working platforms :

§ Width of platform :

§ Any gap in the platform between planks:

§ No of employees likely to engaged on the platform :

§ Quantity of material liked to be loaded on the platform :

Comments :

Inspection record:

Date: Name of the authorized person Signature Remarks



OHS – 27/ Jun 07



INFRINGEMENT REPORT

Date :

From:

To:

Ref No.:

Given below are violation details of Safety Regulations/ Site Safety Instructions committed by an employee/

contractor working at ______________________________project.

Name: Emp. No.:

Occupation: Company:

Location: Vehicle No.:

Date: Time:

Supervisor Name/ Job Title: Tele:

Details of Infringement:

Immediate action taken:

Previous Violations:

This violation is : Minor (First / Second/ Third) Major(First/ Second/ Third)

Action recommended : Written Warning Peanlty Rs.___________

Suspension Dismissal

Other______________________________________________________

Please advise action taken as a per the penalties for safety violations on or before_______________

____________________________________

(Safety Officer/ Engineer)



OHS – 28A’Jun07

Larsen & Toubro Limited

Radiography Inspection Checklist

Name of Site: Inspected by:Sub contractor’s name: Date:

Sr.

No.Observations

Compliance status

Yes / No / Not applicableCorrective Measures

1All radiation-measuring instruments are calibrated prior to first useor after repairs.

2All radiation instruments are stored in dust free, dry and airconditioned rooms.

3Instruments are not kept in a high radiation area or contaminated

area.

4Whether instruments are not contaminated during their use and

switched off immediately after use.5 Ensure removal of batteries of instruments when not in use.

6The calibration certificates and instructions or operating manuals ofradiation instruments are available in storage room.

7Logbook containing periodic checks & inspections of instrumentsis available.

8All defective equipments are repaired and recalibration records are

maintained.

9Monitoring badges and dosimeters are stored in a radiation free place.

10The personnel monitoring film is regularly sent to DRP (Divisionof Radiological Protection) for evaluation. Records are available or

not.

11

As per AERB safety guide, following radiation monitoringinstruments and safe handling accessories are available –1. Radiation monitor with 3m extension probe

2. Radiation monitor3. Pocket radiation alarm

4. Pocket dosimeter

5. TLD (Thermo-luminescent Dosimeter) Badge

6. Remote handling tongue7. Lead pot of different sizes

8. Lead shots in cloth, bags / lead wool9. Lead sheets 1.6 mm thi ck

10. Forceps

11. Polythene bags

12. Hand gloves and shoes

13. Respirators and protective clothing14. Radiation warning labels with ”Skull and

Bone” marks

15. First Aid Box

16. Emergency van

17. Flash lamp or warning lamp (Red)

18. Spare batteries19. Spare bulbs

12The radiography instruments / source transport records are

available with security department.



OHS – 28B’Jun07

Larsen & Toubro Limited

Radiography Equipment Usage logbbook

Name of Site: Inspected by:Sub contractor’s name: Date:

Duration of use SignatureSr.

No.

Date on which

Camera taken out

from storage From To

Camera

model /

serial no.

Name of

Radiographer

Location

of useRadiographer Supervisor

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

1617

18

19

20

21

22

23

24

25

2627

28

29

30

31



OHS – 29 / Aug. 07


ELECTRICAL ISOLATION CERTIFICATE

Work Permit No.: …………………………………

Location: …………………………….Isolation Certificate Applied For By: ………………………………………..

Department/Section: …………………………………………….

1 Permission is given to a Competent/Authorized Electrical Person to isolate the aboveequipment

Signed ………………………… Date ………………………….

Name …………………………..

(Electrical Engineer, L&T)

2 The Equipment is isolated from: ………………………

Fuses removed and place at: ……………………….

Signed …………………………….. Time………………………….. Date……………………………

Contractor Competent Electrical Person

3 De-Isolation Applied For By:

Signed…………………………. Date…………………………

Contractor Competent Electrical Person

4 I Confirm That The De-Isolation Requested Has Been Completed And Caution Notices

Removed.

Signed……………………………………… Date………………………………….

*Competent/Authorised Electrical Person



OHS No.: 30A/ Oct.’07



SELECTION CRITERIA FOR BEST CONTRACTOR

Name of the Project: Name of Contractor:

Sr.

No.

Criteria Max.

Marks

Marks

Received

Remarks

1 Management Commitment – System,

Procedures

10

2 HSE Performance Record 10

3 Legal Compliance 10

4 Non-repetition of non-conformity 10

5 Safety Awareness Activities 10

6 Housekeeping 10

7 Employees discipline 10

8 Implementation of corrective action

within target date and time

10

12 Participation in Site Safety Activities 05

9 Visible Safety 05

10 PPE Compliance 05

11 Safety Infringement/ Violation 05

Total Score 100

Name of Evaluator : Signature of Evaluator:



OHS No.: 30B/ Oct.’07


SELECTION CRITERIA FOR SAFE EMPLOYEE OF THE MONTH

Name of the Project: Name of Employee:

Company Name: Designation:

(For the Month of ____________________)

Sr.

No.

Criteria Max.

Marks

Marks

Received

Remarks

1 Following Safe Work Practices 10

2 Attitude towards safety 10

3 Involvement in Accident/

Incident

10

4 Safety Infringement/ Violation 10

5 Attendance in Tool Box Talks 10

6 Knowledge about Work Permit 10

7 Identifying Unsafe Conditions 10

8 Site Preparation and

Housekeeping

10

9 Use of Proper Tools and their

maintenance

10

10 Use of PPE 10

Total Score 100




OHS No.: 30C/ Oct.’07


SELECTION CRITERIA FOR BEST HOUSEKEEPING

Name of the Project: Name of Contractor :

Area Inspected: Date of Inspection:

Sr.

No.

Criteria Max.

Marks

Marks

Received

Remarks

1. Proper means of access and egress is

available to all places of work

10

2. Project work areas are clean and free

of excess trash, debris

10

3. Walkways , passageways and Exits

are clear

10

4. Project materials have been stored

safely and at appropriate places andclear aisles for travel are maintained.

10

5. Electrical cords, hoses, welding leadsetc, are placed so as to prevent trip

hazards

10

6. Separate Trash cans (with uniqueidentification labels) for collecting

metallic scrap, non-metallic, glass,welding rod stubs, cotton waster, oily

waste, combustible waste, hazardouswaste are provided at work areas

10

7. Rebar protection is present

(Horizontality and vertically)

10

8. All Gas Cylinders is stored properly. 10

9. Storing of lifting tools & tackles and

PPE are in dry and clean space

10

10. Scrap metal is free of protruding

nails or other puncture hazards

5

11. Barricades installed and maintained 5

Total Score 100




OHS No.: 30D/ Oct.’07

SITE SPECIFIC MOTIVATIONAL PROGRAM

Name of Project :Date : Rev.: 0

Action Period (Monthly Basis)

* Phase - I Phase - II Phase - III

Sr.

No

Motivation

Techniques

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

Action by

SafetyEmployee of

the Month

(To be conducted once in a month)RCM / SSO /Field Incharge

1

#(Trade based

IncludingSupervisor)

2 Safety

Competition

(Once in a year in the month of January or National Safety Day / World Environment Day) RCM / SSO /

Field Incharge

Slogan

Poster

Poem

3 Near Miss

Reporting Award

(To be conducted quarterly)

RCM/ SSO

4 Best House

keeping Award (To be conducted once in two months)

RCM/ SSO/

Committee

Member



SITE SPECIFIC MOTIVATIONAL PROGRAM

Name of Project :Date : Rev.: 0

Action Period (Monthly Basis)

* Phase - I Phase - II Phase - III

Sr.No

MotivationTechniques

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

Action by

5 HazardIdentification

Award

(To be conducted once in a month) RCM/ SSO/Field Incharge

6 Safe

Contractor Award

(To be conducted once in two months)RCM / SSO /

Field Incharge

##(RollingTrophy)

Note: * - Phase would be different for different project based on the project work.

# - Trade based will include welder, Gas Cutter, Grinder, Fitter, Rigger, Helper, Crane Operator, Electrician, Driver, Mechanics, Supervisor

It will be decided based on the prescribed criteria in this procedure.

## - Selection of Best Safe Contractor will be again based on criteria prescribed in the procedure.



Template for Safety Scoring OHS - 31

Page 1 of 17

SCORING CRITERIA & STRATEGY

I. Safety Leadership & Administration / Demonstrationof Management Commitment to Safety

Maximum Marksobtained

Improvementreqd. /

Deficiencies

observed

Imminent hazard(If any)

1. RCM participates in Safety meetings? 5.02. RCM participates in Management Walk-rounds? 5.0

3. RCM support for Safety promotion activities? 5.04. Willingness to STOP work in case of Imminent dangerdelegated?

5.0

5. Employee empowerment to STOP work? 5.06. Daily log book/register filled by Site Engineers and

Supervisors and reviewed by RCM?5.0

7. Meeting at the end of the day regarding daily activitiesand their safety implications?

5.0

8. Site safety / HSE plan is up-to- date? 5.0

9. Organisation of HSE programmes 5.010. Training documentation on file includes orientation 5.011. Inspection documented with corrective actions taken 5.0

12. Bilingual Corporate Policy is displayed on site. 5.013. Safety Performance Board is displayed on site and is

updated.5.0

14. Observation data is collected and trends recorded /tracked.

5.0

15. Observation data is posted in common areas 5.016. Is HIRA carried out for all critical activities on site, and

reviewed, updated at monthly intervals?5.0

Section I Total 80.0Section I Score:




Page 2 of 17

II. Housekeeping at Contractor Yard and site

1. Proper means of access and egress is available to allplaces of work

5.0

2. Project work areas are clean and free of excess trash,debris

5.0

3. Walkways , passageways and Exits clear 5.0

4. Project materials have been stored safely and atappropriate places and clear aisles for travel are

maintained.

5.0

5. Electrical cords, hoses, welding leads etc, are placed soas to prevent trip hazards

5.0

6. Scrap metal is free of protruding nails or other puncturehazards

5.0

7. Trash cans / waste bins are provided for work areas 5.08. Barricades installed and maintained 5.0

9. Rebar protection is present (Horizontality and vertically) 5.010. Potable water samples analysed to conform compliance

with IS: 10500, records maintained and available in workareas.

5.0

11. Method for preventing, handling spills and leaks are

established.

5.0

Section II Total 55.0Section II Score

III. Machine Guarding

1. Moving parts of all machines are guarded properly 5.02. Guards that are once provided are maintained properly 5.0

Section III Total 10.0

Section III Score




Page 3 of 17

IV Enforcement (Compliance with Legal / other

requirements)

1 Legal register is prepared and necessary compliancesare made as per the requirements.

5.0

2 Documented on file 5.0

3 Supervisors know HSE responsibilities and place a high

priority on ES&H

5.0

4 Employees observed in maintaining PPE compliance on

site and records maintained.

5.0

5 Supervisor initiates corrective action of pending pointsrelated to HSE and records maintained.

5.0

6 Reference materials e.g. relevant Indian Standards,OISD Standards and Codes of Practice available at site

5.0

Section IV Total: 30.0Section IV Score

V Safety Orientation , Education & Training

1 All employees , visitors are exposed to Safety Induction

Training and records maintained

5.0

2 Working groups at site are exposed to Daily Safety Tool-Box Talks and records maintained

5.0

3 Specialized Safety training programmes on specificsubjects / topics / hazards are conducted at

scheduled/periodic intervals and records maintained

5.0

4 Practical demonstrations on

• Use of portable fire extinguishers;• Administering First Aid training to selected group• Emergency Mock Drills are conducted once in a

quarter.are conducted and records maintained

5.0

5 Specific Safety training on hazards of pre-commissioning 5.0




Page 4 of 17

and commissioning has been conducted and recordsmaintained

Section V Total 25.0

Section V Score

VI Health and welfare of workers and staff

1 Pre-employment medical examination is conducted for allpersons seeking employment and records are

maintained

5.0

2 Periodical medical examinations (once in a year) are

conducted at scheduled , pre-determined intervals asrequired by law

5.0

3 Adequate drinking water facility of appropriate quality[ WHO norms / IS 10500 : 1991] is available/ provided toall workmen

5.0

4. Adequate and clearly earmarked space which is clean isprovided for employees to have their lunch

5.0

5. Adequate space is provided for employees to park theirbi-cycles, scooters etc.

5.0

6. Adequate number of Toilets and washing facilities (asrequired by law) is provided /available.

5.0

7. Adequate number of Rest Rooms (as required by law)

are provided

5.0

8. Noise at workplace does not exceed 90 dBA. 5.0

9. Dust at project site is kept under control 5.0 Section VI Total 45.0Section VI Score

VII Work Permit system

1 A Permit-to-work system [either Client specified or L&T’Sown ] is meticulously followed for carrying out a ll criticalactivities and records maintained.

5.0




Page 5 of 17

2 Work permits are authorised properly (as prescribed inthe system documentation)

5.0

3 Work Permits are re-validated at scheduled/ prescribedintervals

5.0

4 Separate records of all closed Work Permits areavailable for Inspection.

5.0

Section VII Total 20.0

Section VII Score

VIII Transportation of employees1 Condition of roads facilitates/enables safe road travel 5.0 2. “Speed Limits” are clearly, legibly and conspicuously

displayed.

5.0

3. Speed breakers are provided where necessary. 5.0

4. Vehicles are road-worthy , maintained in good conditionand inspected regularly and records are maintained

5.0

5. There are no sharp turns on the route to the site location 5.0

6. PUC certificate is available for vehicles. 5.0 7. Vehicles are not overloaded, over-crowded; no standing

employees are allowed inside the vehicles.5.0

8. Drivers are medically fit and in a condition fit enough todrive without endangering the lives/limbs of employees /others.

5.0

9. The prescribed speed limits are not exceeded 5.0

10. Vehicles used for hazardous operations / processes areregularly inspected.

5.0

11. Use of mobile phone is strictly prohibited by vehicledriver while driving / working in hydrocarbon area.

5.0

12. LMV / HMV driving license is available with the driver. 5.0

13. Vehicle driver is not working beyond 12 hours a day andlog is maintained for the same.

5.0

14. Spark arrestor is fixed / attached in the vehicle exhaust 5.0




Page 6 of 17

before moving to hydrocarbon handling area.Section VIII Total 70.0

Section VIII Score

IX Hand tools

1 Tool kit provided is non-sparking for hydrocarbonhandling area

5.0

2 Drills – doubled Insulated? 5.0 3 Records of maintenance and inspection schedule of tool

kit maintained?5.0

Section IX Total 15.0

Section IX Score

X Electrical Installations/ System

1 Layout and condition of electrical system / installation ismeeting the requirements of the National Electrical Codeand / or IS: 732.

5.0

2 Cables are in good condition and are routed throughproper cable trays.

5.0

3 Cables are NOT trailing in water 5.0 4 Electrical Panels are equipped with canopy for rain

protection.5.0

5 Bare cables/wires are not inserted in panels 5.0 6 Adequate means of earthing as per IS 3043 or

equivalent is provided

5.0

7 “Caution Notice Board “/ “Danger – 440 Volts supply”Symbol is displayed.

5.0

8 “Electric Shock Treatment Chart” is displayed 5.0

9 Rubber mats are provided in front of all electrical panels 5.0

10 Adequate number of fire extinguishers [CO2 or DCPtype) is/are available to handle fires involving electricity.

5.0

11 ELCB test records are maintained 5.0




Page 7 of 17

12 Glands are provided to electrical panel 5.0

13 Proper access to panel is available. 5.0

14 Electrical work permit system is followed while workingon live electrical system, HT and LT cables.

5.0

Section X Total 70.0Section X Score

XI Fall Protection

1 Body harness worn properly 5.0

2 Lanyards are adequately secured to suitable anchoragepoint

5.0

3 Edge protection (Top rail, mid rail, toe board) is provided

to prevent from falling.

5.0

4 Static lines, tag lines installed and capable of supporting2268 kgs of force per person

5.0

5 Fall protection equipment is used only for fall protection 5.0

6 Fall protection maintained and has current inspection

documented

5.0

7 Fall protection training conducted / documented 5.0

8 Safety net is provided while working at height. 5.0 Section XI Total 40.0Section XI Score

XII Excavations

1 Sloped and / or shore provided. 5.0

2 Access and egress is provided every 7.62 Meters(Round figure preferably).

5.0

3 Daily documented inspection conducted by competentperson

5.0

4 Permits being used on-site for all excavations 5.0

5 Sign boards / barricading tape provided around 5.0




Page 8 of 17

excavation.6 Red light is provided at workplace during night working. 5.0

7 Area to be excavated checked for flammable gas traceswith gas monitoring devices during the course of workand records maintained.

5.0

8 Area to be excavated checked for underground pipelinesand live electrical cables.

5.0

9 No material observed near the edge of excavation area. 5.0

10 Excavated area is dewatered with pumping devices in

case of rains, floods, etc.

5.0

11 Vehicle movement is restricted near the excavation work. 5.0 Section XII Total 55.0

Section XII Score

XIII Scaffolds (while work ing abov e 1.80 meters ) andLadders

1 Toe board, mid rail and top rail are provided. 5.0

2 Daily inspection by competent person & recordsavailable.

5.0

3 Proper access and egress provided (ladder, gates, tie offpoints)

5.0

4 Scaffolding is inspected and tagged as per requirements 5.0

5 Proper ladder for the job performed / property secured 5.0

6 Ladder are inspected quarterly / documented 5.0

7 Proper angle of ladder in ratio of 4:1 is maintained. 5.0 8 Ladder railing is provided at height of 0.9 meters. 5.0

9 Scaffolding is erected on level ground and base platesare provided to scaffolding.

5.0

10 Scaffolding under erection is surrounded by Barricading

tape.

5.0

Section XIII Total 50.0

Section XIII Score:




Page 9 of 17

XIV Hoisting, lifting equipment and lifting tackles

1 Chain slings, wire rope slings, D-shackles, Bowshackles, turn buckle, web slings, chain pulley blocks,lifting hooks are in condition with current inspection andrecords available.

5.0

2 Softeners used as required 5.0

3 All rigging inspected / documented (certified bycompetent person)

5.0

4 Proper rigging techniques used as per erection plan. 5.0 5 Certificate of testing of hoists, lifting equipments and

lifting tackles is available.5.0

6 Safe Working Load (SWL) is mentioned on hoists, liftingequipments and lifting tackles.

5.0

7 Lifting tools and tackles are properly stored under shed. 5.0

8 Proper color coding is done to hoists, lifting equipments

and lifting tackles.

5.0

Section XIV Total 40.0Section XIV Score

XV Vehicles / Mobile Equipment / Cranes

1 Lights, brakes, horns, and reverse alarms are in workingcondition.

5.0

2 Seat belts provided and used in all equipment andvehicles

5.0

3 Seat belts provided and used with rollover protection 5.0

4 Inspection, preventive maintenance schedule of vehiclesis available and followed and records maintained.

5.0

5 Licenses or certification as required for forklift, crane and 5.0




Page 10 of 17

man lift operation6 Certificate of testing of cranes is available. 5.0

7 Safe Working Load (SWL) is mentioned on cranes. 5.0

8 PUC certificate for vehicles, mobile equipments and

cranes is available.

5.0

Section XV Total 40.0

Section XV Score:

XVI Power Tools and Equipment

1 Electrical cords-condition and current inspection (Colorcoded) & records available.

5.0

2 Tools are properly stored, maintained & records

available.

5.0

3 Pneumatic / hydraulic hose connections properly secured 5.0

4 Proper tools used for the job performed 5.0

5 Proper adjustment on work rest and wheels properly onbench grinders

5.0

Section XVI Total 25.0

Section XVI Score

XVII Fire Prevention & Protection Methods

1 Flammables and combustibles stored in metalliccontainers.

5.0

2 Containers labeled indicating content and hazards 5.0 3 Fire extinguishers are strategically located, inspection &

testing schedule of fire extinguishers is followed andrecords available. Fire extinguishers are taggedaccordingly.

5.0

4 Flash back arrestors installed at gauge and torch end ofcutting sets

5.0

5 Compressed gas cylinders properly maintained, 5.0




Page 11 of 17

protective caps in a place on stored cylinder storedcylinders properly secured to prevent tipping.

6 Compressed gas cylinder properly transported in asecure and vertical position

5.0

7 Containment or hot work and welding screens areavailable as required.

5.0

8 Regulator gauges properly attached and maintained. 5.0

9 Flammable gas cylinder storage license is available. 5.0

10 Fire hydrant system, emergency communication system

is functional. The records of inspection and testing aremaintained.

5.0

Section XVII Total 50.0Section XVII Score:

XVIII HIRA / JHA / Safety Task Analysis & Risk Reduction

1 Hazard Identification & Risk Analysis (HIRA) is being

carried out for all activities and records are maintained.

5.0

2 Applicable permit posted (excavations, confined space,hot work) on job site.

5.0

3 Pre-task safety reviews are completed by supervisor. 5.0

4 Procedure compliance: hazard assessment, confined

space lead, asbestos

5.0

5 Permit to work system in place for operating plants,

during startup operation.

5.0

6 HIRA, Job Hazard Analysis (JHA) programmes are inplace

5.0

7 JHA required for work which may pose a risk topersonnel is done.

5.0

8 Employees are trained to identify hazards, risks duringthe course of work & are working according to HIRA /JHA / RA procedures.

5.0




Page 12 of 17

Section XVIII Total 40.0

Section XVIII Score:

XIX Cutting and Welding

1. Prescribed Permit-to-work system is followed 5.0

2 PPE requirements are followed as explained in training. 5.0

3 Welding Leads and torch hoses are clear of aisle waysand walkways

5.0

4. Screens are used in work areas to protect others. 5.0 5. Extinguishers are available at cutting and welding

workstation5.0

6 Flash back arrestors are used at gauge end and torchend of gas cutting torch.

5.0

7 It is ensured that fire exits are free from any obstructionsbefore starting cutting and welding operation.

5.0

Section XIX Total 35.0Section XIX Score

XX Steel Erection (pipe Racks (See related SafeWorking Procedures)

1 Steel erection plan is available. 5.0

2 Site is following the approved plan. 5.0

3 Plan is part of training and orientation 5.0

4 Evidence of the steel erection plan is evident in fieldoperations

5.0

5 Signal man is available during steel erection activity. 5.0

6 Barricading tape and sign boards are displayed in andaround steel erection activity area.

5.0

7 It is ensured that guide rope is being used during thesteel erection activity.

5.0

Section XX Total 35.0




Page 13 of 17

Section XX Score

XXI Personal Protective Equipment Compliance

1 Hard hats / Safety Helmets worn and maintained asrequired

5.0

2 Hearing protection is worn as required 5.0

3 Face shield or goggles or e ye protection required andworn in a proper manner

5.0

4 Proper foot protection worn for job performed (i.e. Steeltoes, metatarsal covers)

5.0

5 Proper footwear, respirators, gloves, chemical resistantgarments are available and worn as required

5.0

6 All PPE’s used at site are as per ISI, CE, Euro Norm orequivalent certified/marked equipment.

5.0

7 Sufficient no. of PPE along with spare PPE aremaintained in the stock and records of the same aremaintained

5.0

Section XXI Total: 35.0

Section XXI Score

XXII Storage, Handling and use of gas cylinders

1 All gas cylinders are stored in upright (vertical) position,in a fenced, well-ventilated, covered storage area

5.0

2 Full and Empty gas cylinders are clearly identified andstored separately. 5.0

3 Oxygen and Fuel gas (Acetylene) cylinders are storedseparately

5.0

4 Gas cylinders are transported only in purpose-built

trolleys

5.0

5 Gas cylinders are not dropped, rolled and/or otherwiseimproperly handled.

5.0




Page 14 of 17

Section XXII Total 25.0

Section XXII Score:

XXIII Other General Parameters

1 Adequacy of Illumination at site. 5.0

2 Periodic “Noise Level” sampling conducted. 5.0

3 Adequacy of Ventilation at site. 5.0

4 Manual material handling practices appropriateness. 5.0 5 Availability of MSDS – Material Safety Data Sheets of all

hazardous chemicals, other substances handled at the

project site.

5.0

6 Availability / Provision of adequate number of SignBoards and Safety Messages/Posters at appropriatelocations

5.0

Section XXIII Total 30.0Section XXIII Score:




Page 15 of 17

XXIV Specific Instructions

1 Specific safety instructions / practices for carrying outfollowing operations –ConcretingPilingBar bendingCarpentry works/shutteringForm works

Batching Plant OperationsPipeline layingUnderground worksElectrical & Instrumentation works Abrasive Blasting [Shot/Grit Blasting]PaintingInsulation and CladdingErection of heavy equipment

40.0

2 Per-commissioning & Commissioning• No load trial runs

• Hydro-testing• Pneumatic tests• Card-board blasting• Special equipment commissioning e.g.

Pumps, Compressors, Distillation Columns, re-boilers, Boilers, fired Heaters, Heat exchangersetc.

5.0

Section XIV Total 45.0Section XIV Score:

XXV Medical Facilities

1 Facilities are of adequate size, have finished interiors,

covered floors, toilets, hot and cold running water, and

5.0




Page 16 of 17

air conditioning and adequate lighting.2 A minimum of two radio communication is provided to

call upon for help.5.0

3 A trained and property qualified medical attendant is onduty.

5.0

4 Medical equipment is a maintained in good sanitaryworking condit ion and suitable for the size of the

workforce and function of the site as per Law.

5.0

5 Medicines and medical supplies are sufficiently stocked

and within expiration project.

5.0

6 Physical fitness records & health records of employeesare organized, updated and secured.

5.0

7 Special Antidotes (e.g. Anti-snake venom, Rabies) areavailable in the occupational health center for handling

medical emergencies.

5.0

Section XXV Total : 35.0

Section XXV ScoreTotal Points: 1000

Preliminary Score:




Page 17 of 17

IH deduction

Score Adjustment

( Imminent Hazards-Deduc t 10% Of Assessed

Score Per Item ) :

Total Point Deducted from Assessed Score

The final score is obtained by: Subtracting imminenthazard deduction points from awarded points anddividing by total possible points

Points Awarded – imminent Hazards Deduction/points possible

FINAL SCORE:

RESULT:

Sr. No. Marks obtained Result

1 60 - 70% Good

2 71 - 80% Very Good

3 81% and above Excellent



OHSC – 32A / Feb.’08


HSE CAPABILITY CENTRESAFETY CHECK FOR CHEMICAL CLEANING OPERATION


Job Location: -


SI.

No.

Description Observation

Yes/No

Remarks

1. Valid Work Permit is available at site and followed meticulously

2. Portion of Pipelines to be chemically cleaned is positively isolated from the

loop.

3. Incoming/ Outgoing or Inlet / Outlet valves to pipes / equipment are closed

and tagged “DO NOT OPERATE”

4. Pumps are electrically isolated & fuses removed and tags put5. Pipelines/ equipments are depressurized6. No residual holdup is present in the line/ equipment

7. Procedure for Chemical Cleaning is prepared.

8. Safety shower eyebath fountain is available / provided/ commissioned.

Alternatively, arrangement s for showering with water, flushing eyes withwater is available at site.

9. PPE’s like Hand gloves, apron, face shield, goggles, helmet, safety shoes are provided and used.

10. Area is barricaded before starting chemical cleaning of pipelines/equipment11. “Work In Progress” Board is displayed at work area.

12. Employees are informed about activity & its hazards through Training and

Tool Box Talks13. No leakage in the pump seals

14. Spark arrestor is provided on the exhaust outlet (for diesel operated engines)

15. MSDS is available at job location16. Fire Extinguisher is kept near the job location

17. After neutralizing, drain and arrangements for disposing off the cleaningagent has been identified (as per the client’s instructions.)

18. All temporary electrical installation is away from drain point.

19. Proper access/ platform provided for connecting hose with the pipelines/equipment (especially for points which are at higher elevation)

20. The integrity of the system components is checked and tightness is ensured

Name of Site Supervisor:

Signature:Date:



OHSC – 32B / Feb.’08


HSE CAPABILITY CENTRESAFETY CHECK FOR STEAM BLOWING OPERATION


Job Location: -


SI.No.


Remarks


2. Specialized & trained Team is deployed for steam blowing operation.

3. All the pipelines are insulated .

4. If Insulation is not provided, Safety Caution Board is provided.

5. PPE’s like Hand gloves, apron, face shield , goggles, helmet,, ear plug/ earmuff are provided to operation team and are being used.

6. All Employees (including employee working near by area) are informed

about activity & its hazards through Training and Tool Box Talks

7. All Vent areas are cordoned off

8. No Combustible materials (especially cable wires, gas hoses) are lyingaround the charged line which are not insulated at the time of steam blowing

9. Communication facilities like Walkie – Talkie is available to all concernedstaff

10. Procedure for Steam Blowing is prepared.11. Contingency Plan is prepared and informed to all employees.

12. Proper access/ platform provided wherever required.

13. All the spring pipe supports are unlocked.14. Proper illumination is provided during working hours.15. All drains along with steam trap are bypassed/ removed.

16. F- keys are available to operate the valve.

17. Display board such as “Do not face Opening Side of the Valve”, “Are you

authorized to open the valve?” on the operating valve.(e.g Vent Valve, DrainValve) are displayed suitably.

18. Area is barricaded before starting steam blowing of pipelines

19. Work In Progress Board is displayed at work area.

Name of Site Supervisor:

Signature:

Date:



OHSC – 32C / Feb.’08


HSE CAPABILITY CENTRESAFETY CHECK FOR CATALYST LOADING OPERATION


Job Location: - Equipment Number:

Guide Word “Yes” Catalyst Name:

SI.No.


Remarks


2. Safe Work Procedure including connection of the loading sock to a “loadinghard pipe” fitted directly to the loading hopper is followed.


4. Experienced catalyst team employed on the project.5. Equipment is under normal (21% Oxygen) atmosphere.6. Communication System like Walki – Talki , Life Line are available in place

7. Flexible loading sock is not more than its recommended length (as percatalyst loading procedure)

8. A dedicated Safety Person is assigned to this job.

9. Procedure for Catalyst Loading is prepared

10. MSDS is available

11. Catalyst flow is always strictly regulated while loading.

12. Valid Test Certificate for the Crane is available at site & displayed on thecrane.

13. PPE’s like handgloves, apron, goggles, helmet, dust masks are provided to

operation team and are being used.14. All concerned Employees are informed about activity & its hazards through

Training and Tool Box Talks.

15. Confined space attendant is available outside the equipment.16. Rescue /retrieval procedure is prepared and practical training given to all

staff.

17. Proper illumination (24 Volt hand lamp) arrangement is done for vessel

entry.

18. Work In Progress Board is displayed at work area.

19. Displayed board such as “Do not Enter into the Vessel”, “Entry to only

Authorized Person” , “ Catalyst Loading in Progress” on the vessel/equipment.

20. Area is barricaded before starting the operation.

21. First Aid Box is available at site office.

Name of Site Safety Officer Name of Site Supervisor:

Signature: Signature:Date: Date:



OHSC – 32D / Feb.’08


HSE CAPABILITY CENTRESAFETY CHECK FOR HYDROTEST OPERATION / PNEUMATIC TEST/

CARD BOARD BLASTING OPERATION


Job Location: - Equipment Number/ Pipeline:


SI.No.

Description ObservationYes/No/N.A

Remarks


2. Procedure for Hydro Test is prepared (including De -pressurizing & Draining)

3. Area is barricaded before starting the operation.


5. Equipment/ Line is identified.6. Trained and experienced gang is deployed on the job.

7. The equipment/line is adequately supported for test in the vertical or horizontal

position

8. The applicable inspection records have been checked to assure all necessary

nondestructive examinations and inspections have been performed

9. All test hoses and fittings are rated for the primary test pressure

10. Employees are informed about§ Not to tighten the flange bolts while line is under pressure§ Not to face flange joints while line is under pressure.

11. There are minimum of two gauges on each circuit within 1 – ½ to 3 times the

primary test pressure ranges, all of which have been calibrated & valid calibration

certificate is available.

12. All test connections, caps and blanks have been checked for the proper pressurerating

13. Use of Gasket as per design specification(Pl. mention design specification in

remark)

14. Communication System like Walkie – Talkie is available (if required)

15. There is a safety relief valve on each circuit set at 5% above the primary test

pressure which has been calibrated specifically for this job

16. Provisions have been made to add a high poin t vents(s) to relieve trapped gaswhile filling and to open prior to draining the circuit

17. PPE’s like handgloves, apron, goggles, face shield, helmet, are provided tooperation team and are being used.

18. All concerned Employees are informed about activity and its hazards through

Training and Tool Box Talks.

19. Displayed board such as“Hydro Test is going on” , “Pneumatic Test is in progress”,“Do not Touch Me” “Card Board Blasting is in progress” on the equipment.

20. After testing, drain and dispose of the water has been identified (as per the client’sinstructions.)

21. All temporary electrical installation is away from drain point.

22. For Air Compressor checked :§ Free from Leakage§ Exhaust fitted with spark arrestor§ Valid test certificate for air receiver

22. First Aid Box is available at site office.

Name of Site Supervisor:Signature:

Date:



OHSC – 32E /Feb.’08


HSE CAPABILITY CENTRESAFETY CHECK FOR WATER FLUSHING OPERATION


annexure manual

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