1.0 2.0 3.0 1d 12 13 21 2.2 2.3 24 25 2.6 27 28 29 2.10 3.1 3.2 3.3 3.4 3.5 3.6 37 3.8 3.9 3.10 3.11 3.12 3.13 3.14 CONTENTS S#FETY UNIT GENERAL SAFETY RULES AND REGULATIONS IS Vou ws For Employees For Contractor & Contractor's Labourers For Visitors SAFETY PROCEDURES Work Permit System. Safety Tags & Locks Confined Space Entry Permit Hot Work Permit Line Breaking Permit/Vessel Opening Permit Permission to Start Work in Plant Electrical Isolation Permit Temporary Electrical Supply Permission to Work on Electrical Distribution System Tankfarm Entry Permit OPERATIONS & MAINTENANCE SAFETY Operational System Safeguards : Mechanical System. Safeguards Sampling, Draining & Venting Use of Common Utilities & Temporary Hose Connection Line & Equipment Identification Furnace & Flare Operation Hydro-jetting Procedure for Isolation of Safety Valves Procedure for Preparation of Equipment Checks before taking Equipment in Line Leakage/Spillage Checking Dechoking Operation of Pipelines & its Cleaning Procedure for Checking Trip System Identification of Openings/Trench Covers4.0 3.15. Drum Filling & Handling 3.16 Working with Cryogenic Fluids 3.12," Loading & Unloading of Chemicals 3.18 Tankfarm Safety 3.19 Radioactive Sources 3.20. Checkiig of Guards 3.21 Work involving Rotating Equipments 3.22 Working on or near Moving/Running Machines 3.23 Handtools and Portable Power Driven Tools 3.24 Working with Gas Cylinders 3.25 Welding and Gas Cutting 3.26 Blinding & Blanking 3.27 Online Repairs & Clamping 3.28 Specific Hot Works & Safety Precautions Manual Material Handling Procedures Mechanical Material Handling Equipments Procedure for Safety Valve Testing Safety in Machine Shop Insulation on Pipelines/Vessels Shutdown Reminders . 3.35 Eye Wash-Showers & Fire Sprinklers Checking 3.36 Safety Appliances & Fire Fighting Equipments Checking ELECTRICAL SAFETY 4.1 Hazards of Electricity 4.2. Electrical Area Classification 4.3 Protection against Static Electricity 4.4 Lightning Protection 4.5 Overhead Transmission Lines 4.6 Switchyard 4.7 Substations & Panels 4.8 — Transformers 4.9 Generators (Diesel Engine) 4.10 Batteries & Battery Room 18 19 80 89 93. ” 98 104 108 113 17 126 127 130 133 142 154 155 159 160 161 161 164 168 170 176 179 186 188 189 194 197 1995.0 60 70 8.0 4.11 4.12 413 4.14 AAS 4.16 5. 52 53 54 55 5.6 57 58 59 6.1 6.2 63 64 65 6.6 TW 12 — 1A 8.1 8.2 83 Electrical Cables Low Voltage Distribution System/Installations Power Driven Tools Safe use of Megger & Test Lamp Temporary Electrical Power Supply Earthing of Electrical System SAFETY RELATED TO CIVIL JOBS Design Criteria for Civil Structures Working at Height Working on Roofs Water Proofing using Hot Bitumen Excavation Work Pai Sand Blasting ing of Structures/Buildings Demolition of Structures/Buildings Accumulation of Water in Drain Channel & its Cleaning SAFETY IN SPECIFIC AREAS Chlorination at Cooling Towers Safety in Warehouse Safety in Laboratory Construction Safety Safety on Road & Rail at GSFC Safety Checks before Monsoon SAFE WORK ENVIRONMENT Ventilation & Heat Control Lighting & Colour Noise & Vibration Control Good Housekeeping CHEMICAL SAFETY GUIDE Hazardous Chemicals DOT Classification TREM Card 202 207 210 215 217 218 226 221 233 238 240 241 242 242 243 246 250 255 269 274 284 306 313 316 319 3519.0 10.0 11.0 12.0 84 85 86 87 88 o1 92 93 94 9.5 9.6 o7 98 99 9.10 91 9.12 10.1 10.2 10.3 Wd 1.2 12.1 12.2 12.3 12.4 12.5 HAZCHEM Panel GSFC Chemical Safety Guide Material Safety Data Sheet (MSDS) Hazardous Properties of the Chemicals List of Chemicals used in GSFC FIRE PROTECTION SYSTEMS AT GSFC Fundamentals of Fire Portable Fire Extinguishers Fire Alarm System Fire Detection System Hydrocarbon Sensors Fire Water System Sprinklers & MV Spray System Fixed Foam Installations Deluge Water Foam System Steam Blanketing Halon System CO, System SAFETY APPLIANCES AND INSTRUMENTS Selection & use of Personal Protective Appliances Types of PPA Safety Instruments ACCIDENT/INCIDENT REPORTING, INVESTIGATION AND RECORDKEEPING AT GSFC Accident/Incident Reporting Procedures Accident Investigation & Recordkeeping FIRST AID MEASURES Gas Poisoning or Asphyxiation Burns Electric Shock Cuts or Bruises Head Injury 352 353 354 356 358 362 365 371 375 380 385 389 393 395 397 397 398 401 407 408 420 424 426 431 437 438 441 444 44413.0 14.0 15.0 14.1 142 143 144 14s 146 147 148 EMERGENCY ACTION PLAN Objectives Risk & Environment Impact Assessment Emergency Organisation Communication Systems Action on Site Off Site Emergency Plan ‘Training, Rehearsal & Records Supporting Informations through Annexures Groupwise Emergency Action Plan STATUTORY REGULATIONS Factories Act, 1948 Manufacture, Storage & Import of Hazardous Chemicals Rules, 1989 Petroleum Act, 1934 & Rules, 1976 Gas Cylinders Rules, 1981 Static & Mobile Pressure Vessels (Unfired) Rules, 1981 Indian Electricity Act, 1910 & Rules, 1956 Poison Act, 1919 & Rules, 1984 Civil Aviation Regulations FORMS / CHECKLISTS IN PRACTICE F/73/001 F/73/002 F/73/003, F/73/004 F/73/005 F/73/006 ¥/73/007 F/73/008 F/73/009 F/73/010 F/73/011 F/T3/101 Safety Checklist (Plants) Checklist for Ammonia Plant Tankfarm (Naphtha Tanks) Checklist for Caprolactam-1 Plant Tankfarm Safety Checklist for Benzene Tankfarm (Unit-1980)-CEP Safety Checklist for Anone Tankfarm (Unit-1100}-CEP Safety Checklist for Intermediate Tankfarm (Unit-1150)-CEP Inspection Report of Safety Appliances Environment Gas Monitoring Noise Level Measurement Inspection Report of Eyewash & Showers Checklist for Lifts Form No.1 Application for Permission to Construct/Extend Building 449 449 431 484 456 456 456 456 458 463 an 479 485 492 496 504 50s 510 su 512 313 514 516 518. 520 522 523 524 925 526— 13. 14. 15. 16. 17. 18, 19, 20. 21. 22, 23. 24 2s 26. 27. 28. 29. F/73/102 F/73/103 F/73/104, F/73/108 F/73/106 F/73/107 F/73/108 F/73/201 F/73/202 F/73/203 F/73/204 F/73/208 F/73/206 F/73/207 F/73/208 F/73/209 F/73/210 FV73/211 Form No.7 White Wash/Colour Wash Register Form No.9 for Examination of Hoists & Lifts Form No.10 for Examination of Lifting Tools & Tackles Form No.11 for Examination of Pressure Vessels Form No.2I Notice of Accident or Dangerous Occurrence Form No.29 Register of Accidents & Dangerous Occurrences Work Accident Report Confined Space Entry Permit Hot Work Permit Line Breaking/Vessel Opening Permit Permission to Start the Work in Plant Electrical Isolation Permit Electrical Lock Out Permit for PG & Acid Plants ‘Temporary Electrical Supply “Permit to Work’ on Electric Di jon System Tankfarm Entry Permit (Benzene & Naphtha Tanks) Danger Tag Gas Tester’s Report 527 528 529 530 532 533 534 535 537 539 S41 543 544 345 S47 548 349 55010 hon - 6 prepee Ss oe e B 2.3, 2.3, Raraae PNPRNHN v fe 24.11 2.4.1.2 2.4.2 243 24.3.1 2.4.3.2 2.4.3.2.1 2.4.3.2.2 SAFETY PROCEDURES SAFETY WORK PERMIT SYSTEM ‘Types of Permit Permit Issuing & Receiving Authorities Minimum Contents of a Permit Salient Benefits of Work Permit System SAFETY TAGS & LOCKS CONFINED SPACE ENTRY PERMIT Definition of ‘Confined Space’ Hazards Involved Injuries Associated with Hazards Statutory Requirement Area/Equipment Covered Issue of Permit Permit Issuing Authority Preparation before Issue of Entry Permit Sample Analysis Approval of Permit Renewal, Resampling & Validity Check before taking the Vessel / Equipment in Line Permit Receiving Authority Basic Requirements to be Adhered to by the Permittee Other Specific Precautions Communicating the Overall Picture HOT WORK PERMIT List of Jobs involving Sparks / Flames Plant Area Areas not covered under Plant Area Statutory Requirements Salient Features of the Permit Hot Work Permit Format Categories of Hot Jobs Non-Hazardous Hazardous GSFC Safety Manuat Page 13 13 13 4 14 14 14 16 16 16 16 7 7 18. 18 18, 19 19 20 20 20 20 2 22 22 22 23 23 23 24 24 25 26 26 %Safety Procedures 2.4.3.2.3 24.3.3 2.4.3.3.1 2.43.3.2 2.4.3.3.3, 243.34 Major Hazardous Permit Issuing Authority Plant Area Other than Plant Area ‘Transformer Yard & Electrical Substation Inter Plant Pipelines Permit Receiving Authority Activities related to Hot Works Preparation for the Job By Process Group By Maintenance Group Gas Tester’s Report Issue of Permit Understanding the Hazards involved & use of PPA Safe Execution of Maintenance Ac Checks before taking the Equipment Maintenance Group Operation Group LINE BREAKING / VESSEL of Joints Overall Picture tivities in Line after Maintenance OPENING PERMIT List of Jobs involving Breaking Preparation for the Job By Process Group By Maintenance Group Issue of Permit Issuing Authority Safety Instructions Receiving Authority Communicating the Overall Pitre Other related Instruction Use of Special Tools Use of PPA - The Minimu Requirement PERMISSION TO START WORK IN PLANT ‘Area / Jobs covered Civil Mechanical 26 26 26 26 27 2 27 27 27 a7 28 29 30 30 30 31 31 31 32 32 32 23 33 33 33 33 34 34 34 34 35 35 35 38 35 362 26.1.3 26.14 2615 262 262.1 262.11 26.212 26.213 262.14 26.2115 26.22 27 271 272 272.1 27.22 213 28 2811 282 29 2.10 GSFC Safety Many Electrical Instrument Any other Department Permit Operation & Basic Preparation Permit Operation ‘The Initiator ‘Work Authorisation Renewal & Validity Contractor's Supervisor General Instructions Basic Preparation for the Job ELETRICAL ISOLATION PERMIT Need & Associated Hazards Type of Permits Electrical Lockout Permit (For Phosphatic & Acid group of plants) Electrical Isolation Permit (For Plants other than PG & Acids) Use of Safety Tags & Locks TEMPORARY ELECTRICAL SUPPLY Operation of the Permit Minimum Requirement PERMISSION TO WORK ON ELECTRICAL DISTRIBUTION SYSTEM TANKFARM ENTRY PERMIT 41 C7)Safety Procedures y 2.0 2d 221 SAFETY PROCEDURES SAFETY WORK PERMIT SYSTEM Serious accidents, often resulting in fatalities have occurred and continue to occur repeatedly while performing certain type of jobs under certain conditions. Therefore, to control and prevent the repeatitive accident occurrence, some positive means of safe-guard & controlling measures are necessary. As a result, the work permit system drawned from the experiences of several industrial organisations & of our own, proved to be one of the most satisfactory methods for ensuring positive controls over hazardous operations performed in unfavourable coniditions. Moreover, the system helped to affect greater controls on execution of jobs, maintenance and repair works performed simultaneosly on the same equipment by different trades and sections under seperate supervisions. About Work Permit Work Permit” is essentially a document, that, categorically spells out the task, equipment involved, its location, personnel involved, time limitations, precautionary ‘measures to be taken together with likely hazards to be encountered, if any. Usefulness of Permit Work permits provide written information on the prevalent hazards connected with the job performance. It spells out the suitable remedial measures to be adopted to encounter the hazardous conditions that are prevailing or that can be encountered while performing the job. It also stipulates various conditions and limitations on the part of persons actually required to perform the job. It indicates the various types of personal protective equipment to be used at different stages of work. It serves as a predetermined checklist for various safety precautions to be taken. It also serves as a media of information to all concerned in advance. It provides a written record of the operation including the personnel who are involved in authorising and carrying out the operation. The permit system which necessiates carrying out various tests and safeguards, create a sense of security from accidents In a nut-shell, the work permit system offers one of the best methods to meet all the various conditions required for making a hazardous operation safe and easy to perform. Types of Permit Depending on the type of industry and the hazardous operations carried out, various types of permits have been developed to suit the need of an individual industry. We in GSFC have the following permits in use. Sr.No. Name of Permit Colour of the Permit i Permission to start the work Light Blue z Hot Work Permit Red 3. Line breaking / Vessel Opening Permit Yellow1 Sloe v 21.2 243 2.1.4 22 GSFC 4. Confined Space Entry Permit Green 5. Electrical Isolation Permit White 6. Electrical Lockout Permit (for PG) White 7. Permission to Start Work on Electrical White Distribution System 8. Temporary Electric Supply Connection Yellow Card 9. Tankfarm Entry Permit White Permit Issuing & Receiving Authorities Permits are issued by Officers having proprietory responsibility of areas & equipments It is generally issued on the name of Officer who is to carry out the required op under the known conditions Minimum Contents of a Permit A permit contains written information & instructions pertaining to hazards that are to be avoided in a particular operation, It indicates that all hazards have been considered in advance and foreseeable appropriate precautionary measures have been taken, People responsible to execute a job defined in the permit are to review them from the point of compliance. 4m other words, a permit is a writen consent of the issuer that guarantees proper and safe conditions where personnel can work safely by complying with the instructions on the permit. Similarly, it also indicates that people executing the job have reviewed the permit and accept responsibility of adhering to the instructions & limitations stipulated Thus a permit finally becomes a document of consent by both parties ie. the issuer and the receiverijob executor. Salient Benefits of Work Permit System Safety work permit procedures is an administrative control pertaining to procedures & methods by which men, materials & machineries are involved to meet the specific requirement for maintaining safe working conditions during repair, maintenance & inspection work in chemical factories. It is an integral part of comprehensive accident & fire prevention programme. Permit system helps the industry and the people concerned to convert a known hazardous work situation into a safe work environment, The success of the system is greatly dependable upon the understanding & strict compliance by all concerned. Most of accidents, injuries, deaths, fires, explosions and disasters can be prevented by adopting and enforcing a safety permit procedure in toto. SAFETY TAGS & LOCKS In a continuous process industryit is often necessary to isolate equipment for the purpose of carrying out repairs, maintenance and testing. This is generally done by closing valve or isolating electrical circuits of equipments etc. Thus the deviation have to be made from the normal circuits of operation, It will be safe procedure to “Tag” or “Label” valves and switches