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Procedure for Hand and Portable

Power Tools

Doc. No. :S-HA-05-2010-018-E

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Contract KPPC/HA-05/2010

Procedure for Hand and Portable Power Tools




Submitted to owner for approval





Procedure for Hand and Portable

Power Tools

Doc. No. :S-HA-05-2010-018-E

Job No. :
Rev. A

Heavy Aromatics Project

(Off-Shore Portion)
Contract KPPC/HA-05/2010

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Procedure for Hand and Portable

Power Tools

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Revision Summary Sheet



Description of Amendment

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Procedure for Hand and Portable

Power Tools

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1. Purpose
2. Scope
3. Reference
4. Abbreviations and Definitions
5. Responsibilities
6. Requirements
7. Attachments

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Procedure for Hand and Portable

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To make the employees aware of the hazards involved in using different type of hand and
power tools and safe ways of using them.


These guidelines are to be followed by all the employees involved in Projects.


HYUNDAI Safety Manual.


Abbreviations & Definition

Hand tools are those tools for which the hand provides the motive force, e.g., pick axes,
shovels, axes, crowbars, wrenches, saws, chisels, hammers, screwdrivers, etc. Accidents
arising from the use of hand tools are frequently caused by human error.
Inferior materials can easily produce mushroom heads on cold chisels and fragmentation of
hammers, axes, and hacksaws. Poor quality tools increase the risk of accidents and also
reduce the efficiency of work.
Power tools, however, allow many jobs to be carried out more efficiently and with greater
speed and accuracy. The correct use of power tools can only be achieved by the proper
training of workmen, by proper maintenance, and by adequate site supervision. Many
accidents have occurred because unskilled and untrained labor has been allowed to operate
portable power tools in an incorrect manner.
Injuries such as burns, bruises, cuts, strains, eye injuries, electrical shock, fire, explosion of
Vapour / gases, falling tools and other objects may occur while using hand and portable power
tools due to the following:

Use of damaged hand tools or tool getting dislodged from handle

Wrenches with cracked or worn jaws

Screw drivers with broken tips, or stripped handles

Hammers with chipped, mushroomed heads

Broken, split or loose handle of the tool

Mushroomed head on chisels.

Selection of wrong size or poor quality

Wrong type of tool for particular job or area

Using an adjustable spanner instead of right size of ring spanner.

Using a screwdriver as a chisel

Procedure for Hand and Portable

Power Tools

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Using a portable power tool as a fixed tool

Hazard of flying particles or pieces from damaged tool

Damaged insulation or improper joints / connections

Missing or damaged or loosely fitted guards

Failure to use PPE or use of improper PPE (personal protective equipment)

Unskilled employees handling or repairing power tools.

Tripping hazards due to blocking of way by wire, air hoses, or tool itself.

Sparks generated by the use of tools.

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Employees To know the hazards, to know how to use each hand/power tool, to select proper
tool for the assigned job and use it safely.
Store keeper/Tool room attendant- To issue and receive the hand tools. To remove/repair
damaged tools.
Supervisor To ensure employees are provided with good tools and being used safely.


Training craftsmen on correct use of tools
Craftsman will be trained in the correct use of each type of hand or portable power tool.
Engineer in charge shall ensure that his men are well trained on the use of hand or portable
power tools.
Storing of tools

Tools shall be stored in a safe and orderly manner. Storekeeper shall ensure that only
good tools are issued and defective tools are segregated for repair or disposal.

Storekeeper shall record the condition of the tool while issuing as well as receiving. He
shall be capable of identifying defective tools from good tools.

Tools should be kept clean and protected from corrosion or damage. Moving and
adjustable parts should be lubricated.

Carrying tools

User should carry their tools to and from the work site in a toolbox or other appropriate tool
holder pouch. In this way, the user is protected as well as the tools.

User should never carry chisels, screwdrivers, and pointed tools with edges or point up
either in their pocket or by hand. They should carry such tools with points and cutting
edges away from their bodies.

User should never carry tools in any way that might interfere with the free use of both
hands when climbing a ladder or other structure. They should use a strong bag, pouch, or

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Power Tools

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similar container to hoist tools from the ground to the job. They should not throw the tools
up. Tool should be returned in the same manner and not brought down by hand, carried in
pocket or dropped on the ground.
Using tools

User shall accept only good condition tools. User should check tools before use and from
time to time. User should be able to distinguish between good & damaged tools.

User shall not use damaged tools. Wooden handle of the tool shall be free of splinters,
cracks and splits. Handle shall be firmly fixed to the tool head.

User shall select tools of correct size or capacity, type, shape and material. Only good
quality tools shall be procured.

User shall wear Proper PPE (ex. Earmuff for jackhammer, goggles for grinding). He shall
not hold the tools with slippery (oily or greasy) hands.

User or helper shall not position any part of their body on the path of tool's accidental

Appropriate work permit shall be obtained in work permit areas.

When working on small objects they must be clamped securely or a vice should be used to
avoid hand injury.

Tools shall be prevented from falling from elevated place such as scaffolds, stepladder, or
overhead piping. Leaving tools overhead is especially hazardous where there is vibration
or where people are moving.

Tools should not be kept unattended after use and they shall be kept in toolbox or
designated place.

Tools should be used only for their intended purposes. (Ex. Never use pliers as wrench or
screwdriver as a chisel.) Tools should not be modified.

Screw drivers & pliers

Screwdrivers should not be used as chisels, punchers, wedges or pinch bars.

Screwdrivers with broken handles, bent blade or dull or twisted tip may cause it to slip and
cause an injury. Such tools shall be redressed or discarded.

Craftsmen shall use approved insulated screwdrivers, spanners and pliers, etc when
working on or around live electrical equipment and batteries.

Cutting pliers should be used only for soft material and never on hard metals or as nail

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Power Tools

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User should select hammers for their intended use and use them only for those purposes.

User should always strike hammer blow squarely with hammer striking face parallel with
the surface being struck.

When striking other tools, face of the hammers should be larger than the strike face of the
tools (approximately 1 cm).

User shall not use a hammer to strike another hammer.

User shall not use a hard surface hammer to strike another harder surface.

User shall not use a hammer with loose or damaged handle. Wooden handle shall not be
replaced by a metal handle as it will not absorb impact.

Discard hammer if it shows dents, cracks, chips, mushrooms or excessive wear.

Redressing is not recommended.

Wrenches (spanners)

User should position himself in a way that he will not lose balance and fall.

User should pull the wrench towards himself.

Extension pipes should not be used on the wrenches as it can exceed design torque.

Hammer shall be used only on wrenches designed for hammering. Hammer-wrench shall
be held in place by a rope and not by hand.

Ring and box wrenches should be used wherever possible and use of open or adjustable
spanner should be limited for light loads only.

Pipe wrenches should not be used as spanners.

Chisels & punches

Chisel should be large enough for the job and should be driven with a hammer of sufficient

Chisel should be held by a tong when hammered on by another person.

Mushroomed chisels and cracked or broken chisel handles should be replaced.

When sharpening a chisel original shape and angle must be maintained.

Chisel with rubber guard shall be used for concrete or hard surface chipping.

Punch should be straight and of suitable weight for the work.

Punch should be started with light tap and held securely.

When knocking out rivets and pins, work must begin with starting punch and end with a pin

Spanners and Wrenches

Only spanners and adjustable wrenches of the right size should be used. When possible, use

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Power Tools

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box-end rather than adjustable wrenches. The jaw should first be checked for any sign of
opening out or splitting. Spanner and wrench lengths are graded to provide sufficient leverage on
the nuts for which they are designed. Improvised extension to these tools is an unsafe practice
and may cause the bolt thread to trip or cause shearing of the bolt. On no account should a
hammer strike ordinary wrenches when tightening nuts. For heavy work of this nature, a properly
designed slugging wrench should be used.
Spanners and wrenches shall not be used as hammers.
Pipe Wrenches
Pipe wrenches must be large enough for the job, the jaw teeth must be kept clean and sharp, and
the knurl, pin, and spring should be kept free from damage. Pipe wrenches should never be
struck with a hammer, nor should they be used as a hammer.
Pliers should only be used when there are no other tools for the job. They are meant only for
gripping around objects and should not be used as a wrench.
Care should be taken when cutting soft metal with pliers to ensure the scrap portion does not fly
off and cause injury. If wire is cut under tension, then long handled pliers should be used. Where
pliers are used for electrical work, they must be fitted with insulated handles. All pliers should be
kept free from dirt and grit, and the movable parts should be lightly lubricated.
Jacks should be marked with rated capacity and must be heavy enough and strong enough to
raise and maintain the load. They should be placed on a firm and solid support, and the load
should be positioned on the center line of the jack.
Once a load has been raised, it must be shored or blocked. The jack should never be relied
upon to hold the raised load in position by itself. Extreme care should be taken when working
under or near a raised load.
The correct type of blade should be selected to suit the material to be cut. The blade should
be set in a hacksaw frame so that the teeth are pointing in the forward direction, and sufficient
tension should be applied to ensure the blade is maintained rigid.
Many kinds of woodworking handsaws are available, and care should be taken to select the
correct saw. All handsaws shall be regularly examined to ensure that the saw teeth are properly

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set so as to avoid binding in the timber, which can cause the blade to buckle. The teeth should
be kept sharp, clean, and lightly oiled. When the saw is not in use, the blade should be protected
by a slotted piece of timber or sheath.
Two-man should be operated by pulling only. The cut should be kept straight to avoid the blade
buckling. The cut should be wedged open to prevent the timber from pinching the blade.
Power tools
All the portable power tools will be of 220 volts and are manufactured of sound materials and free
from defects. 220 V power tools shall not be used in side confined spaces viz., Tanks, vessels,
towers, columns, boilers etc., All portable power tools with dead mans switch shall only be used.
Repair and Storage

All portable power tools shall be stored in clean, dry conditions.

All tools shall be returned to the storekeeper at the completion of each individual job.
Power tools must not be left lying around the job site where they could be damaged.

Rotating tools should be switched off and held until rotation has completely stopped before
they are set down.

Tools must be disconnected before changing bits, blades, cutters, or wheels.

Compressed air, explosive cartridge, or electricity can supply power for tools.

All portable power tools must be equipped with properly functioning "dead man" switches.

A schedule of systematic inspection and maintenance for all power tool will be provided.

Pneumatic tools

An air compressor shall always be under the supervision of a competent person. It should
always be situated in such a place so as to have adequate ventilation.

Compressors shall not be permitted to operate in confined spaces without the provision of
adequate exhaust ventilation.

All compressed air hoses shall be of the correct size to fit the tool being used. Any joint in
the hoses shall be made with a proper coupler and secured by safety wire. The hose
length shall be kept as short as possible and placed so as not to be subjected to damage.

Pneumatic tools require clean air to operate efficiently. In every line feeding power tool,
there shall be an adequate filter and lubricator.

During operation all air tools should be held firmly to prevent them spinning and jumping.

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Power Tools

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This pressure should be maintained during the stopping process to prevent injury to the
operator's feet and hands.
Individual power tools
Jack Hammer and Concrete Breakers
The tool bit retaining spring shall always be securely in position to prevent the bit from dropping
out. The bit must be kept sharp.
Ear protection shall be required when working with this type of equipment.
Rock Drill
It is extremely important that the operator maintains a firm grip with both hands and stands in a
balanced position. Any other method of using the tool can cause serious bodily injury.
Grinding Machine

This tool is probably the most misused of all the power tools. Care should always be taken
to ensure that the grinding wheel is free from defect before mounting. Any defect may
cause the wheel to disintegrate as it gains momentum.

Only persons who have been instructed in the proper selection and fitting of grinding
wheels should be allowed to install wheels on tools.

The proper size and type of wheel should be fitted to the tool so that the maximum
permissible running speed of the spindle does not exceed the maximum periphery speed
displayed on the grinding wheel. No grinding machine shall be used unless the maximum
speed is clearly marked on the case. All wheels shall be fitted with adequate guards..

Floor stand and bench mounted abrasive wheels, used for external grinding shall be
provided with safety guards (protection hoods). The maximum angular exposure of the
grinding wheel periphery and sides shall be not more than 90 degrees, except that when
work requires contact with the wheel below the horizontal plane of the spindle, the angular
exposure shall not exceed 125 degrees. In either case, the exposure shall begin not more
than 65 degrees above the horizontal plane of the spindle. Safety guards shall be strong
enough to withstand the effect of a bursting wheel.

Floor and bench-mounted grinders shall be provided with work rests which are rigidly
supported and readily adjustable. Such work rests shall be kept at a distance not to
exceed one-eighth inch from the surface of the wheel.

Cup type wheels used for external grinding shall be protected by either a revolving cup
guard or a band type guard .All other portable abrasive wheels used for external grinding
shall be provided with safety guards (protection hoods) meeting the requirements of this
paragraph, except as follows:

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When the work location makes it impossible, a wheel equipped with safety flanges shall
be used.

When wheels, 50mm or less in diameter, which are securely mounted, on the

end of a

steel mandrel, are used.

Portable abrasive wheels used for internal grinding shall be provided with safety flanges
(protection flanges) except as follows.

If the wheels are entirely within the work being ground while in use.

When wheels, 50mm or less in diameter, which are securely mounted, on the end of
a steel mandrel, are used.

Safety guards are required and they shall be so mounted as to maintain proper alignment
with the wheel, and the guard and its fastenings shall be of sufficient strength to retain
fragments of the wheel in case of accidental breakage. The maximum angular exposure of
the grinding wheel periphery and sides shall not exceed 180 degrees.

when safety flanges are required, they shall be used only with wheels designed to fit the
flanges. Only safety flanges, of a type and design and properly assembled so as to ensure
that the pieces of the wheel will be retained in case of accidental breakage, shall be

All abrasive wheels shall be closely inspected and ring-tested before mounting to
ensure that they are free from cracks or defects.

Grinding wheels shall fit freely on the spindle and shall not be forced on. The spindle nut
shall be tightened only enough to hold the wheel in place.

All employees using abrasive wheels shall be protected by eye protection equipment.

Electrically Operated Tools


All electrically operated tools shall be rated and used at a voltage not exceeding 220V. For
working inside the confined spaces viz., Tanks, vessels, Drums etc., pneumatically operated
tools shall be used. Where required, permission shall be obtained from the Client safety dept
for using electrically operated tools inside the metal enclosures.

Before any electrical tool is used, a careful check shall be made by the supervisor to ensure
that the supply voltage is within the range marked on the information plate on the tool.

All electrical circuits shall be protected by Ground Fault Interrupters (GFI).

All hand tools shall be properly grounded or be of the double insulated type.
All tools shall be used with the trailing lead as short as possible. Each lead shall be fitted with
a grounded plug to fit the socket outlet on the distribution board.

Where it is necessary to make electrical splices, these shall be made with proper connector
blocks or by plug and socket connectors. Taped joints shall not be permitted.

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Maintenance and Storage

The contractor shall establish a proper monthly inspection and maintenance routine of all
electrical tools. A competent electrician shall carry out the inspection. Maintenance of all tools
shall be performed at least once in every working week.

All tools shall be stored in a clean, dry place and a record of issue and the storekeeper shall
maintain receipt.

Personal Protective Equipment

The contractor shall ensure that all operators are provided with eye, head, and ear protection. If
there is any likelihood of harmful dust being emitted, dust respirators should be used.
Monthly inspections
A competent employee will inspect all tools monthly and required colour code will be adopted.
The record all inspections will be made available to the Client upon request.
The store keeper shall check the tools for good condition before issue and the user shall
inspect the tools before use. Defects if any found, the tools shall be removed from the service
and sent for rectification / repair.
All hand operated power tools will be color coded with the monthly inspection color coding.
Electrical / power tools will be color coded with tie raps or electrical tape 200 millimeter from
the electrical plug on the cord and a color coded inspection tag affixed with the following
information: - Company name, inspectors name and signature, inspection date and
equipment/tool/serial number. The records are available in the format SHR/EHS/004 Series.

Attachment A :

Safety Training out line on Hand and Portable power tools

Procedure for Hand and Portable

Power Tools

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Attachment A :

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Safety Training out line on Hand and Portable Power Tools

The following subjects shall be discussed while conducting the Safety Training
on Hand and Portable Power Tools.

Discuss the purpose of Safety Training on Hand and Portable Power Tools.

Discuss the General Safety precautions to be taken while using Hand and Portable Power

Discuss about Hand Tools misuse.

Discuss Hazards of Power Tools.

Discuss important General Safety Guidelines for Power Tools.

Discuss about Power Tools Accessories and Attachments.

Discuss about Pneumatic tools and carring for the compressed air system.