KAEFER PUNJ LLOYD LTD.

JAMNAGAR EXPORT REFINERY PROJECT

RIL, JAMNAGAR

SITE SAFETY PLAN

FCCU

Sl. No. NAME DESIGNATION SIGNATURE DATE

Prepared By Moncy Abraham Safety Officer

Checked By S.H. Koregaonkar DGM

Reviewed and
Approved By
 KAEFER PUNJ LLOYD LTD, SAFETY PLAN

INDEX

1. Introduction
2. HSE Commitment
3. Safety Responsibility & Structure
4. Safety Training
5. Working at Height
6. Scaffolding
7. Confined Space Entry
8. Safe use of Electricity
9. Safe Blasting
10. Safety in Welding, Cutting and Grinding
11. Safe Materials handling
12. Personal Protective Equipment
13. Pressure Testing & Lockout Tag-out Process
14. Casting, Gunning & Vibro-casting
15. First aid box

INTRODUCTION

It is our intension and our higher management that adoption of best practices of Health,
Housing and Environment Safety is a most important & valuable part of Efficient and
Effective management to construct and build up various Refractory & Insulation Projects
and Painting and Coating works in India and aboard.
KAEFER is a group of companies to execute and construct of various Refractory &
Insulation Projects and Painting and Coating works like in Refinery & Petrochemicals, Oil
Resource, Glass & Cement & ferrites in various countries of the world. In India KAEFER is
well set up as a joint venture company with Punj Lloyd group as KAEFER Punj Lloyd Ltd.

Our main HSE motto is to carry on & lead our projects with Zero Accident Policy by build
up a strong Safety Management for Implement the safety routines, control the accidents
to avoid loss of properties and betterment of employee-employer relationship and create
of productive image in the corporate market.

Safety Responsibility and Structure

For the success of our Safety Plan and to maintain our Zero Accident Policy it is essential
to have a Safety Organ-gram and a laid down responsibilities for the personal of our
different level in our FCCU Project.

FCCU-Organization Structure.
 CORPORATE-SAFETY DIRECTOR

MANAGER- COORDINATION

HOD-SAFETY CONSTRUCTION MANAGER REAL-SAFETY

LEAD-ENGINEER SUB-CONTRACTOR
SAFETY-OFFICER

FIELD-ENGINEER

SAFETY TRAINING

Safety Training is a very important part of our Safety Plan & Safety Program.
Management is giving too much concentration and attention on relevant trainings for safe
execution and completion of the Refractory & Insulation Projects of JERP. Training
includes necessary job related safety procedures, statutory requirements, implementation
& motivation of save practices and latest development and application on construction
safety. Thus it is important to impart training and practices to all personals who are
working in the construction field like JERP.

Objective

Objective of this method is to identify training requirement, establish training modules

and imparting relevant safety training to personals of all level engaged in Construction to
avoid accidents to prevent loss of life and wealth by ensuring our jobs with Accident and
Incident Free Policy & Zero Accident Policy.

Scope
The procedure is focused on requirements of Safety Trainings for all construction
employees engaged in JERP jobs on regular basis to ensure that the all safety skills are
updated.

Training need analysis

The induction and refresher training requirement has been worked out for different
groups by training and development department. Different training schedules for personals
of different level are tabled below.

TABLE-1 Entrant to JERP Site

Module No Program Title Target Group Duration Remarks

,Days(8 Hrs)
CST 10 Basic Safety All Entrants to 1/4 Mandatory Basis
Rules JERP site Safety Training
CST11 Safe Driving All vehicles 2 Mandatory
drivers, Training &
Equipment Validation
Operator

WORKING AT HEIGHT

World wide accident statistics shows that more than 40% of accident happens during work
at height. Falls are the leading cause of deaths in construction industry. Most fatalities
occur when employees fall from open-sided floors and through floor openings. Falls from as
little as 4-6 feet can cause serious lost-time accidents and sometimes death. Open sided
floors and platforms 6 feet or more in height must be guarded.

What will my personal fall arrest system do to protect me?

A personal fall arrest system places the employee into a body harness that is fastened to
a secure anchorage so that he cannot fall. Body belts are not acceptable as personal fall
arrest systems .A few key requirements:

 There should be no free fall from more than 6 feet.

 There should be prompt rescue after a fall.

 PFAS’s must be inspected prior to each use.

 PFAS’s must not be used until they have been inspected by a competent person.

What type of fall protection will I need?

In most cases, a guardrail system, a safety net system, or a personal fall system must be
used.Insome cases fences, barricades, covers, equipment guards or a controlled access
zone may be used. Employees must be protected not just from falling off a surface, but
from falling through holes and from having objects fall on them from above.

How do guard rail systems protect me from falling?

Guardrail systems provide a barrier to protect the employee from falling:

 Top edge of the guardrail must be 39-45 inches above the walking/working level.

 There must also be protection from falling between between the top rail and the
walking/working protection. There are specific requirement for their installation.

 The protective barrier must be strong to support a falling employee. Wood, chain
and wire rope may be used for top rails and mid rails

How do safety net systems protect?

Safety net systems catch the employee if he/she does fail. The safety nets:

 Must be strong enough to support the falling employee.

 Must be have sufficiently small mesh openings so that the employee can not fall
through the net.

 Must be close enough to the surface of the walking/working surface so that the fail
into the safety net will not still injure the employee (never more than 30 feet below
the walking/working level).

 Must be close enough to the edge of the working surface (the outer edge of the
net between 8-13 feet from the edge of the walking/working surface) so that the
falling employee will not slip past the net.

Where should I expect fall protection to be provided?

  When an employee is on walking/working surface that has an unprotected edge.

 When an employee is constructing a leading edge.

 When an employee may fall through a hole in the working/walking surface.

 When an employee is working on the face of formwork or reinforcing steel.

 When employees are on ramps, runways and other walkways.

 When employees are working at the end of an excavation, well, pit or shaft.

 When employees are working above dangerous equipment (even employees working
less than six feet over dangerous equipment must be protected).

 When an employee is performing overhand bricklaying and related work.

 When an employee is performing roofing work.

 When an employee is engaging in pre cast concrete erection (with certain

exceptions)

 When an employee is engaged in residential construction (with certain exception).

Risk Assessment sheet of Work at height

Sl.
Subject Hazard Risk Control Measures to be Implemented
No.

1 Working at Person May  Provide guard rails/barricade at

Heights can fall sustain the work place.
down severe
 Use PPE like full body harness
injuries
with two life line, helmet,
or fatal
safety shoes etc.

 Obtain work permit before

starting the work at height
above 2 mtrs.

 Fall arrested system like safety

 nets, must be installed.

 Provide proper working place

( min. 0.6 X 0.6 m)

 Tie/weld working platform with

fixed support.

 Check periodically oil, brakes,

gears, horn and tire pressure of
all moving machineries.

Failure of  Check quality, size and condition

load Can cause of chain pulley blocks, slings, U-
Handling &
lifting accident clamps, D-shackles, wire rope
2. lifting
and & prove etc.
equipment
moving fatal.
equipment  1 allow crane to move only on
hard firm and level ground.

 Allow lifting sling as short as

possible.

 Hose end connection shall be

Hose Dust/ checked for proper fixing.
detachme Foreign
 Air connection shall be
Material nt particle
identified and same shall be
3 cleaning with Misidenti inhalation
used for cleaning the body.
air. fication / /injury
wrong while  Ensure the use of dusk mask
condition blowing and eye protections. Avoid
horseplay.

SCAFFOLDINGS
This procedure provides guideline for safe scaffolding erection and dismantling work.

Scaffolding type and selection

Selecting a scaffolding system

The safe and efficient use of scaffolding depends first of all, on choosing the right
system of the job. If the scaffold’s basic characteristics are unsuited to the task or if
the necessary components are not available, proper erection and used are compromised.

Selection of scaffolding and released components requires an understanding of site

conditions and the work to be undertaken. The employer must be consider the following:

Basic considerations:

o The weight of workers, tools, materials and equipments to be carried by the

scaffold systems (safe work load)

o Site condition (interior, exterior, backfill, concrete floors, type and condition of
walls, access of the equipment, variations of the elevation, anchorage points etc.)

o Height to which scaffold may be erected (overhead power lines, tie-backs).

o Type of work that will be done from the scaffold (masonry work, sandblasting,
painting, metal sliding, Refractory installation, suspended selling installation).

o Duration of the work.

o Weather conditions, including wind and etc.

o Requirements for pedestrian traffic through and under the scaffold area.

o Means of access to the scaffold.

o Configuration of the building or structure being worked on

o Special erection or dismantling circumstances.

o Hoarding

BASIC TYPES OF SCAFFOLDS

Standard Tabular Frame Scaffold

This is most frequently used scaffolding system in construction. It is made of steel tubing
or aluminum and is manufactured in various configurations and spans.

The average of this type of scaffold is its portability and relative case of assembly. Its
main disadvantage of the fact that, because it is made up of component parts, all the parts
may not be at the site or someone decides that they are not all required.

It is essential with steel frame scaffolds that all components and parts are installed
properly, especially all connections and bracing components, base plates, work platforms
and tie-backs.

The spans in frame scaffolds normally range from 1.5 meters (5 ft) to 5 meters (10 ft).
These span lengths are varied using different lengths of bracing. Most manufacturers
have braces which will provide spans between 1.5 meters (5 ft) and 3 meters (10 ft) in
length. However, some manufacturers have special braces both sorter and longer than this
range.

Walk through (Masonry) frame scaffold

The standard walk-through frame scaffold is a variation of the standard tabular frame
type. It is designed to accommodate pedestrian traffic at the ground or steel level and is
frequently used by the masonry trade to provide greater height per tier and easier
movement and distribution of materials on platforms.

There is a tendency to overload this type of scaffold, or not provide the proper width or
amount of work platform support. Consideration must also be given to pedestrian safety.
All employers shall ensure pedestrians are protected from falling debris and materials.

Rolling Scaffolds

Scaffolds which need to be moved frequently are often equipped with castors or wheels.
The most important consideration with these scaffolds is that both horizontal and vertical
bracing must be used with the standard tubular frame systems.Also, outrigger supports
may have to be provided to ensure the stability of the scaffold.

Rolling scaffolds must be erected so that the height-to-base width ratio is no grater than
3 to1.This limits platform height with standard outrigger stabilizers and single towers to
approximately 9.5 meters.(30ft)[this assumes outrigger stabilizers are 3 meters (10 ft
across)].
Castors on rolling scaffolds must be equipped with braking devices. The type of castor
used should not only include a braking device but must also be selected based upon the
loads under which it will be operating.Additionally, the ground surface upon which the
castor will be used must be free of defects such as potholes and other obstructive debris,
which may cause the scaffold to topple when it is being moved.

SCAFFOLD FOUNDATION NAD SUPPORT

Scaffolds must be created on surfaces which can adequately support all loads applied by
the scaffold. To support scaffolds, backfilled soils. Must be well compacted and leveled.
Mud and soft soil should be replaced with compacted gravel or crushed stone.
Embankments that appear unstable or susceptible to erosion must be contained.

Where mudsills must be placed on slopping ground, leveling the area should be done by
excavating, rather than backfilling. Backfilled material, unless properly compacted and
leveled, does not have the same capacity to support a load as undisturbed soil.

For sloped surface, it may be necessary to use half –frames to accommodate the grade
change. For these situations the bracing is usually provided by using tube-and clamp
components.

Scaffolds erected on any type of soil or gravel, etc.must are supported on a mudsill. The
mudsill must be a minimum of 50 mm X 250mm (2’’X10”) S-P-F plank and must be
continuous under at least two consecutive end-frames or supports.For frame scaffolds;
there must be proper base plates with adjustable screw jacks under each post support,
when the frames are supported on smooth concrete surface. A proper base plate is
required under all circumstances. The base plate should rest centrally on the mudsill and
the sill should project at least 600 mm (2 ft) beyond the scaffold foot ends or where
individual sills butt together. Mudsill should be placed along the length of the flames, in
preference to the width, for better overall support.

The use of blocking or packing such as bricks, short prices of lumber or scrap material
each under scaffold base plates or mudsills is prohibited. Vibration can cause blocking to
move or shift, and leave a scaffold leg unsupported. Under such conditions, the scaffold
can topple when heavy loads are applied. Take particular care when erecting scaffolds on
frozen ground. Thawing is an important consideration where tarps or other covers will be
placed around a scaffold and the enclosed area is to be heated.
SCAFFOLD ERECTION AND BRACING

Fittings and Accessories

It is absolutely essential to install all the parts, fittings and accessories required for
scaffold, so that it is erected to accordance with manufacturer’s instructions. If parts are
not available at the site, make sure that they are obtained as soon as possible. Do not
attempt to erect a scaffold with only a partial supply of base plates, braces, connectors
etc. Ensure that all the components are in good condition and examine them to see that
they are not damaged. All fittings must be positive and securely connected.

Base Plates and Screw Jacks

Base plate must be used on all non-mobile scaffolding of a size and capacity as specified by
the manufacturer. Combination base plates with screw jacks must not be over-extended. A
good rule of thumb is to use the 2:1 ratio, the outside length of exposed screw can only be
a maximum of twice the inside screw and 8 inches of inside length. Consult the
manufacturer for complete design information on the particular screw jacks.

Bracing

Bracing helps keep the scaffold frame plumb and square in both vertical and horizontal
planes. Once frames have been fitted with adjustable base plates, the braces must be
attached for each tower span. The braces should slide into the place easily. If force is
required, either the braces are bent or damaged or the frames are out of plumb or square.
Braces should be secured at each end and the self locking devices are moving freely and
have fallen into place. Rust or slight damage can prevent some of those devices from
working properly, so it essential to maintain the compounds in proper working condition.

Bracing in the vertical plane is a must on both sides of every frame. Bracing in the
horizontal plane should be provided at the joint of every third tier of frames. Horizontal
bracing should coincide with the point at which scaffold is tied to the building or structure
being worked on. Although it is sometime omitted, horizontal bracing is necessary to
maintain scaffold stability and full load-carrying capacity. The use of horizontal bracing on
the first tier helps to squire up the scaffold before nailing base plates to mudsills.

Bracing must be adequately secured in place. Otherwise, scaffold movement can dislodge
the brace, reducing the stability of the scaffold. These devices must operate freely for
ease of erection and dismantling. Trying to release a jammed or rusted drop hook when
dismantling a scaffold has resulted in falls.

A brace which does not easily drop onto pins is an indicator that something is wrong. The
brace can be bent and must be discarded. Often, however, it means the scaffold is twisted
and out of plumb. Braces should not be forced or hammered onto the pin. The condition
causing this difficulty must be corrected so that the brace slides onto the pin easily.
Adjusting screw jacks slightly will often solve this problem. However, make sure that the
scaffold is not adjusted out of plumb to make a brace fit.

Coupling Devices

Every scaffold manufacturer provides coupling devices to join scaffold frames together in
the vertical plane. The devices are sometimes omitted, with the belief that the bearing
weight of the scaffold and its load will keep the frame above firmly resting on the frame
below. This will probably hold true until the scaffold moves or sways. Then the joint may
pull apart causing a scaffold collapse. Therefore, coupling devices must always be used and
installed properly on every leg of the scaffold on every leg of the scaffold at every joint
as assembly proceeds.

Wheels or Castors

If wheel or castors are used, they must be securely attached to the scaffold and equipped
with braces. Failure to properly attach wheels or castors to the frame has been the cause
of many accidents involving rolling scaffolds. Ensure that the ground is level and free of
potholes and other obstructions. Wheels or castors must have brakes which are well
maintained and easily applied.

Platform erection

All parts of fittings must be in place and ensure before platform component are placed on
a scaffold tier. When proceeding with the next tire, worker should lift platform sections
or planks from the previous tier leaving either one platform section or two planks. While
this requires more material, it speeds up erection because workers have platforms to
stand on when erecting or dismantling the platform above.
Hoisting Materials

Where scaffolds will be more than three frames high, a suitable mechanical device will
make the hoisting of material easier during erection. While materials can be pulled up by
rope, it is easier to rig a pulley system to the scaffold so that hoisting can be done by
workers on the ground. This is much safer and eliminates the risk or workers falling from
the scaffold platform as they pull materials up by rope. Ensure that you don’t lift material
in excess of the load capacity of the hoist system or scaffold connection.

Dismantling

The dismantling of a scaffold proceeds in reverse order to its erection. Each tier should
be completely dismantled and the material lowered to the ground before dismantling of
the next tier begins. If platform sections or planks have been left at each level during
erection, it is best to lower additional platform materials from above to the working deck
being dismantled. Extra platform material can be lowered to the ground. Using this
procedure, workers will be operating most of the time from a fully decked in platform. In
addition to this, workers should be equipped with a safety harness and lifeline for
sacrament to a suitable anchoring system, since guardrails will not always be in place as
dismantling proceeds.

Removing jammed or rushed scaffold components can be very hazardous operation. When
scaffolds have been in the same location for a long time, pins and other components may
rust, braces become bent and materials such as mortar or paint often build up scaffold
parts. All of those can prevent components from separating easily. Tugging and pulling on
stuck components can cause loss of balance leading to a fall. Worker should wear a safety
harness and lanyard tied off to a secure anchor before attempting to lessen stuck or
jammed parts. Do not hammer or pry apart the scaffold components. This may cause
damage to the components and/or affect the structural integrity of the scaffold
members.

SACFFOLD ACCESS

Fall Protection
In most cases, a proper system of fall protection can be instituted for workers erecting
and dismantling scaffolding. Often the scaffold is being erected on the side of building or
structure. In this case, a lifeline can be secured to a suitable anchor on the building and a
fall arrestor (rope grab) attachment to a full body harness will protect the worker
erecting the scaffolding.

Ladders

Whether built into scaffold frames, attached as a separate component or portable,

ladders are an important means of access to scaffold platforms. Falls connected with
climbing up and down scaffolds would be substantially reduced if adequate and properly
erected ladders were always used.

There are four primary means of ladder access to a scaffold:

1) Climbing frames

2) Portable ladders

3) Stand-off vertical ladders

4) Scaffold stairway systems

CONFINED SPACE ENTRY

General Requirements

All employees required to enter confined or enclosed space must be instructed in:

 Nature of the hazards.

 Necessary precaution to be taken.

 Use of protective and emergency equipment.

Construction Industry Standard

All employees required to enter into confined or enclosed spaces shall be instructed as to
the nature of the hazards involved, the necessary particulars to be taken , and in the use
of protective and the emergency equipment required. The employee shall comply with any
specific regulations that apply to work in dangerous or potentially dangerous areas.
How to identify Confined Spaces

 Limited openings for entry and exit.

 Unfavorable Natural Ventilation

 Not designed for continuous worker Occupancy.

Permit required spaces

 Contains or has a potential to contain a hazardous atmosphere.

 Contains a material that has the potential for engulfing an entrant.

 Has an internal configuration such that an entrant could be trapped or asphyxiated

by inwardly converging walls or by a floor which slopes downward and tapers to a
smaller cross-section.

 Contains any other recognized serious safety or health hazards.

Typical Confined Spaces

1. Boilers & Furnaces

2. Pipelines

3. Pits

4. Process Vessel

5. Silo & Storage Tanks

6. Sewer & Manholes

7. Trenches & Excavations

Hazards of Confined Spaces

Atmospheric

 Physical configuration

 Mechanical
  Electrical

 Thermal

 Noise

 Vibration

 Engulfment or Entrapment

Controlling Confined Space Hazards

Each confined space has different hazards. Hazards can also change with time and usage.

1. Post signs to warn of the dangers.

2. Use barriers to prevent uncontrolled access.

3. Develop and use a written space entry program.

4. Conduct air monitoring and tests to identify and evaluate hazards.

Define acceptable entry conditions.

5. Monitor entry conditions.

6. Laminate or control the space’s atmospheric hazards before entry.

7. Lockout all initial hazards prior to entry.

Entrant Responsibilities

To assure that the space has been adequately ventilated, isolated, equipped, or otherwise
made safe for entry.

To immediately exit a space, without question, upon ward of the attachment, no matter what
the reason.

To follow all safety rules and procedures those apply to the job.

To be familiar with the work to be performed and the procedures those apply to the job.
To use the appropriate PPE whenever necessary.

Supervisor Responsibilities

To assure adequate protection is provided to the entrains by verifying adequate lockout/tag

out and that all hazards are securely isolated.

To support the attendant’s authority in controlling access to a confined space.

To verify that all personnel have exited prior to closing the space.

To assure that all personnel are involved are aware of the hazards associated with the space.

To assure that rescue services are available prior to entry.

Entry point hazards

 Small openings make entry and rescue difficult.

 Sharp edges can tear protective clothing or air lines.

 Temporary ladders and vent gear can make even large openings difficult to transit.

 Vertical entry points are fall hazards.

Ventilation Needed

Deadly gases can be trapped inside.

Rotting organic materials create hazardous gases.

Pipe leaks, welding, system material can create hazardous atmosphere.

Rust consumes the oxygen you need.

Atmospheric Hazards

 Oxygen Deficient Atmosphere

  Oxygen Enriched Atmosphere

 Flammable Atmosphere

 Toxic Atmosphere

 Corrosive Atmosphere

 Asphyxiating atmosphere

Oxygen Deficiency

19.5%- is the minimum acceptable oxygen level for work with an air supplied respirator.

10-12%-Lips blue Mental Confusion

8-10%-Fainting & Nausea

6-8%-Cause Death

Asphyxiating Atmosphere

Reduction of oxygen in a confined space may be the result of either consumption or

displacement.

Consumption of oxygen taken place during

- Combustion of flammable substances.

- Bacterial action, as in the fermentation process.

- Chemical reactions as in the formation of rust.

Oxygen Enriched

Oxygen level above 21%

 • Causes flammable and combustible materials to burn violently when ignited, such as:
Hair, clothing, oil socked materials.

• Never use pure oxygen to ventilate.

• Never store or place compressed gas tanks into a confined space.

ELECTRICAL SAFETY

 Electricity is a good servant but a bad master.

 Electricity can cause damage to living human being and to property or both.

 Voltage is the force between two charged particles.

 Current is the flow of electrons from higher potential to the lower.

 There is an inherent characteristic of current that it heats the media through

which it paces.

 The general health of the safety is more prior than the use of unsafe electrical
arrangement.

Preventive Measures

 Ensure proper connection of the lines.

 Ensure proper earthing of the equipment.

 Avoid contact with live lines.

 Use low voltage (24 volts or 110 V/230 V with proper earthing and ELCB).

 Ensure current fuse link.

 Don’t overload circuit.

 Never experiment.

 Use insulated tools and Work with Electrical Work Permit.

 HUMAN BODY RESISTANCE
Dry Skin 10000 to 60000 ohms
Wet Skin 1000 ohms
Hand to foot 400 to 600 ohms
Ear to Ear 100 ohms

How to avoid hazards?

 Look for overhead power lines and buried power line indicators. Post warning signs.

 Contact utilities for buried power line location.

 Stay at least 10 feet away from overhead power lines.

 Unless you know otherwise, assume that overhead lines are energized.

 De-energize and ground lines when working near them. Other protective measures
include guarding or insulating the lines.

 Use non-conductive wood or fiberglass ladders when working near power lines.

How to avoid Hazards?

 Use of ground-fault circuit interrupted ELCB on all 230-volt, single-phase, 5 to 30

ampere receptacles.

 Follow manufacturer’s recommended testing procedure to ensure GFCL is working

correctly.

 Use double-insulated tools and equipment, distinctively marked.

Electrical injures

There are four type of electrical injuries

Direct

 Electrocution or death due to electrical shock

 Electrical Shock

 Burns
Indirect

 Falls

Electrical shock

An electrical shock is received when electrical current passes through the body.

You will get an electrical shock if a part of your body completes an electrical circuit by

 Touching a leave wire and an electrical ground.

 Touching a live wire and anchor wire at a different voltage.

SAFE GRIT BLASTING

Blasting is one of the essential activities in major construction projects. Major serious
accident happen due to improper transportation, storage and handling of explosives and
pressurization of a system beyond its limited bearable capacity. So it is very vital part of
site safety management system.

During Grit Blasting Following Safety Hazards happens

 Improper transportation of blasting materials.

 Storage and handling of explosives.

 Pressurization of a system beyond its limited bearable capacity.

Another problem arises during blasting

1) Noise Pollution

2) Sound Pollution

3) Physical Injury During Blasting

SAFETY IN WELDING, GAS-CUTTING AND GRINDING

Welding, gas cutting and grinding are the most common and important operation in the
construction field. The associated hazards during those operations are electrical shock,
fire and explosions, burns exposure to UV radiations and toxic fumes and gases. Before
starting arc welding welder should be aware and concuss about its detrimentally things.
The high temperature and hot metal can cause sever burns.

Welding

In addition of electrical arc it itself provides an additional safety hazards. When welding
is executed with the help of electrical arc then the flux which is created fly in all
direction. They present a personal burn hazard plus a fire hazard if they fall in
inflammable materials. The welding operation needs to protect himself, by means of a
helmet and other protective devices from harmful rays of the arc and flaying sparks. The
fitter glass in the welding helmet will remove 99% of the harmful rays if the proper shade
lens is used. Other dangers associated with electrical welding are:

1. Electrical Shock

2. Harmful fumes

3. Electrical Shock

4. Burns

5. Radiant energy

6. Confined space welding

 Only trained people to work in confined spaces.

 Check adequate ventilation or breathing apparatus.

 Check tank, drum, or pipe has been purged and is safe to work on.

 Gas cylinder not permitted inside confined space.

 Check hoses for leakage.

 Turn off gas supply and remove hoses at break times.

Gas Welding/Cutting

Equipment check:
  Ensure that the tip of the torch is free from dirt metal

 Check the cylinder and its valve or leakage and move out any leaking cylinder
immediately.

 Check the regulator and torches that they are inspected by MTT and having
inspection tag on the same.

 Check for leaks around regulators, hoses/fittings & nozzle with soap solution.
Faulty equipment should be changed immediately.

 Check the entire hose length if it is cracked or worn out cut the length of hose and
replace the hose.

 Check the flash back arrester used for the purpose if it is approved
make/specification only.

Equipment set-up.

 Use trolley for movement of Oxygen & acetylene cylinder set chains them to
prevent its fall.

 Unwound only require length of hose from the trolley to avoid tripping hazard.

 Before attaching regulator to the cylinder, it is necessary to crack open the valve
so as to blow out foreign particles from the valve sate.

 Never use grease or oil on any regulator, valve or other assembly lines especially
acetylene or oxygen line.

 Select the proper welding/cutting torches and nozzles of approved brand only.

 Keep fire extinguisher or water buckets readily available at work place during work.
Keep all flammable materials clear of the work area at least by 8 mtrs.

Grinding Operations

Handling and storage of Grinding Wheels

  Grinding wheels should be kept vertically during storage instead of keeping or
stacking horizontally.

 Grinding wheel should be stored in dry place.

 Grinding wheel should be away from heat/fire.

 Grinding wheel should be segregated size wise to avoid wrong selection of the
wheel.

 After expiry date, grinding wheel must be condemned, broken into pieces.

SAFE MATERIAL HANDELING

 Material handling is significant not with the value of the product only cost of the
product.

 Material value handling accounts for 36% of production cost.

 About 20% to 80% of total labor cost goes into labor used in handling and
rehandling the material.

 About 2/3 of manufacturing cycle time spent on material handling.

 About 50 to 100 tons of materials is handled and re-handled for every 1 tons of
finished products.
 Material Handling

Manual Handling Mechanical Handling

Lifting Equipment Transport Equipment

Lifts & Hoists Lifting Industrial Trucks Conveyor

Manual Handing

Hazards in Manual Handling

Strains, Sprains, fractures and bruises and bruises are the common injuries arising due to
unsafe manual handling. Back injury is a common problem arising out of improper manual
handing. Method of safe manual handling is as under:

- Correct positioning of feet

- Bent knees and Straight back

- Firm grip

- Keep the load close to the body

- Chin in

- Use of feet muscle and body weight to lift the load.

The maximum weight to be lifted by

- Adult male is 50kg.

- Adult female is 30Kg.

In case of more load more than one person can lift with proper arrangement but above
limits should not be exceeded.

Use hand gloves and safety shoes while manual lifting.

Mechanical Material Handling

It involves use of various equipments such as chain pulley blocks, winches, different type
of cranes and other lifting machineries. It enhances the load lifting/shifting capacity
several times than of manual handling.

Selection of equipments

• Load to be lifted e.g. its weight, size and shape.

• SWL capacity of the equipment.

• Place where the load is to be shifted and to where? E.g. distance between two places,
elevation between two places.

• Space available for replacing the lifting equipment.

• Availability of equipment.

• Frequency of the lifting activity.

Inspection and testing of equipment and tools-tackles.

- Initial load test: it is responsibility of the manufacturer to carry out examination of

their respective workshop.

- Operational Test: Load test of mobile cranes shall be ensured P & M at the arrival to
site. After approved load test, the hired crane should be deployed.

- Related Load Test: in case of any repair or alteration of cranes, it should be

examined by a competent person for rated load before putting them for use.
 - Periodic Inspection: It is the responsibility of P & M Department to ensure periodic
inspection for all cranes.

- Periodic Examination: All cranes, suspended Personnel Platform, chain pulley blocks
and all lifting tools and tackles should be thoroughly examined by a component person
at least one in twelve months and a record of such testing is to be maintained in
form no 10.

Risk Assessment Sheet of material handling

Sl. Sub Hazards And

Control Measures to be implemented
No. Activities Risks
Correct working procedures are to be followed
in store/ site during manual material handling.
Use suitable approach like ladder, mobile
Injury due to
platform etc. while taking material from
fall of person
shelves at top or from higher elevation.
Always use safety belt while managing
material above 3 mtr. Height.
Keep the floors always clean.
Injury due to
All floor openings/holes should be
Lifting & slip edge.
protected/hard barricaded.
1 Shifting of
Place the material in arrange manner on
Materials
Injury due to shelf/platform.
fall of material Check the condition of shelf Gratings, on
which materials are placed on regular basis.
Back Injury due Maintain suitable posture, while handling the
to bad postures. material.
Maintain proper house keeping in the store
Injury due to area.
trip. Ensure walkway is clear before moving the
material.

PERSONAL PROTECTIVE EQUIPMENTS

To work in the construction field and in any other industries everyone should maintain
their specified PPE for their personal safety. In general Safety Helmet and Safety shoes
are belongs in the common PPE. But some cases depending on the job specification some
other specified PPE have to use at site Like Safety Belt, Nose Mask, Safety Goggles and
Hand Gloves. So everyone must aware about their personal protection by wearing their
useful PPE.

Mandatory PPE

Safety shoes and helmet are mandatory PPE for purpose of the project. All employees
must aware safety shoes and helmet in all project areas. No one will be permitted to enter
in the site with out Safety Shoes & Safety Helmet.

Our PPE’s shall be provided and used as per the following PPE selection matrixes.

PPE Selection Matrix

Type of Protection
Activity
Head Foot Hand Eye Ear Body Respiratory

Mandatory PPE’s
H SS CG* SG* EP* - -
for Site
Gas
H SS LG WG - BS
Welding/Cutting SAMH/SCBA(Confined
Electric Arc Space)
HMWS SS LG HMWS - BS,LA
Welding
Rigging H SS CG SG - - -
Working at height H SS - - - FBH -
Grinding/Chipping H SS CG SG/FS EP BS -
Type of Protection
Activity
Head Foot Hand Eye Ear Body Respiratory

Working at
H SS - - EP/EM - -
height, noise area
Handling of
Refractory H SS RG SG - - DM
Casting
Gunning of
Refractory H SS RG/CG SG EP BS FS/DM
Materials
Vibro-Casting H SS RG/CG SG EP BS DM
Blasting H SS CG SG EP BS FS/DM
PPEs must be issued and available at site

1. Safety Helmet = H

2. Face shield = FS

3. Chemical Splash Goggles = CSG

4. Helmet Mounted Welder’s Shield = HMWS

5. Safety Shoes = SS

6. Full Body Harness = FBH

7. Safety Goggles = SG

8. Dusk Musk = DM

9. Supplied Air Musk/Hood = SAMH

10. Earmuffs/plugs = EM/EP

11. Cotton Gloves = CG

12. Leather Gloves = LG

13. Rubber Gloves = RG

14. Self Contained Breathing Apparatus = SCBA

15. Welding Goggles = WG

16. Boiler Suit = BS

Personal Protection General Guideline

Personal Protective Equipments for various parts of the body can be divided in to the six
broad groups.

1. Head protection

2. Foot protection
 3. Eye protection

4. Hand protection

5. Hearing Protection

6. Fall Protection

7. Clothing

PRESSURE TESTING AND LOG-OUT & TAG-OUT PROCESS

Pressure Testing

The pressure testing of all the pressure equipments should be monitored for using in the
construction fields. The hazards of high pressure system arise from failure caused by
hoppers, pulsation and vibration and over-pressure. Unless until proper safety are being
taken tanks & hoses may rupture and causes serious injuries. That’s why the pressure
testing of the pressure equipments must be done before using in the site.

Lockout-secured by physical means such that reenergizing the system requires the use of
special equipment routinely available only to person who applied the control. A warning
containing appropriate information shall be displayed at the points of control. The most
common device used for security it’s the padlock.

Tag out- post of warning at the points of control providing information as to why the
energy sources have been isolated, blocked or dissipated, the date, and the person
responsible for the work to be accomplished. In addition access to the control points must
be limited to persons who are trained to understood and observe the posted warning.

Electrical Isolation

Before doing the any job which is electrically connected that is to be electrically isolated
with lock-out and tag-out procedure. Client electrical engineer has certified and
accomplished the isolation process. After complication of the job electrical engineer will
restore the power and remove the respective tags and sign the part of the section.

Tag out
The purpose of tag out procedure is two fold. Tagout provides a prominent visual
inspection of a lockout or of any potential problem or hazards associated with equipment.
Tagout of locked energy isolating devices is required as part of the lockout procedure.
Tagout also provides a written, permanent record of lockouts and other circumstances
where lockout is not required.

Issue of Tags: Facility Owner or Facility Owner Designated is the only person authorized
to issue tags. Each tag issued shall have a unique serial number on it in 2 places. A log shall
be maintained for each tag distributed.

Placement of tags: The Reliance Tag with serial number is the only approved tag for the
tagout procedure.

Sequence: all of the following information must be filled legibly on the tag.

 The apparatus protected, listing the name and / or location of the apparatus
being tagged out.

 The signature of the person placing the tag, together with the current time, date,
and the cause for tag out.

 The top portion of the tag will be tagged onto the control points which have to be
kept inoperative.

 The middle portion of the tag should be removed immediately after filling out the
required information and affixing the tag. This portion will remain with electrical
engineer /person who carry out electrical isolation.

Removal of tags: Removal of the tag shall be done as per following steps.

 After completion of job, execution engineer shall surrender the middle portion of
the tag to electrical engineer along the request for restoration of electrical
energy.

 After receiving middle portion of tag and request for restoration, electrical
engineer energizes the equipment and removes the tag.
CASTING, GUNNING AND VIBRO-CASTING

Casting, Gunning and Vibro-Casing are the procedures for application of the Refractory
monolithic materials. During application of those materials some safety precaution must
have to take to complete the work in safe way. Some safety hazards appear during those
activities. So every one have to aware about the safe way for installation of those
applications.

Casting

Casting is one of the procedures for application of Refractory castable by the help
formwork and template. Casting is accomplished in two ways

1. Pour Casting.

2. Hand Casting.

Pour Casting

Pour casting is one of the easier ways for application of the Refractory materials in the
vertical shell wall of the anchor welded surface.

The following safety precaution have to be taken during this work

 Proper connection to the Refractory Pan Mixture and lights in the confined space.

 PPE-The common PPE for hand casting are Safety Shoe, safety Helmet, Hand
gloves & Nose mask. Another PPE like Dust Mask, Safety Belt will be provided as
per site requirements.

 During installation and ramming of the refractory castable the applicator must be
aware about physical injuries.

Hand Casting

The general method of hand casting is also the easier way for application of the
Refractory Material on horizontal flat upper face by the help of short bolts.

The safety precautions for hand casting are same as Pour Casting.

Vibro-Casting
The Vibro-casting of the Refractory Material is the installation of the dense catables or
monolithic in the vertical shell or inclined shell to the ground by the help of the vibrators
(Electrical or Pneumatic) those will be well fixed outer to the shell. The casting material
will be poured from the upper openings. Here the material will flow towards the ground
level with the help of vibration. The following safety precaution must have to be taken
during Vibro-casting.

 Proper electrical connection has to be checked to all the machineries like Pan
mixture machine, water cooling machines, lights etc. The safety people have to
ensure that the entire electrical are well connected. There is no possibility of
electrical hazards.

 The steel formwork has to be well set and fixed in such way there will be no
possibility of distortion of the formwork and fixing support of the vibrators. That’s
why all safety guards have to be taken at vibro-casting.

 Proper handlings of the materials have to be accomplished to avoid physical injuries.

Gunning

Gunning is also a procedure for application of Refractory Materials using gunning machine
arrangements which are be operated by compressed air. At the time of gunning, gunning
materials and mixing water are respectively thrown through separate hoses with the help
of compressed hopper and twin water tank respectively. Before feeding the materials the
gunning material and water come in contact in the nozzle and a slide mixing happen of the
material with water (as per requirement of water) then the feeding is happened on the
shell. This operation is vital for application of the Refractory. So the concern people must
aware for that type of safety hazards. For doing this type job, following safety precaution
must have to be taken.

The following safety precautions have to taken for doing Gunning operations.

 Proper arrangement and electrical connection to the machineries. Electrical hazards

have to be prevented by using proper electrical safety implementation. Like-
manufacturer test certificate, certification and approval of the machineries, safe
electrical connection & proper handling of the machineries.
  Before gunning all the pressure equipments like hoppers, twin water tank, hoses etc
have to pressure check by using pressure gauge.

 During Gunning inside a confined space, there is a possibility to create too much
dust inside the space that causes breathing problem, and create darkness lowering
illumination of the light. So, Gunning personal must have to use the Dusk Mask at
the time of Gunning and proper light arrangements have to be done inside the
Confined Space.

 During Gunning there should be very good communication between Gunman and the
Hopper-man.

FIRST AID BOX

In any construction site there should be one first aid box for some small injures at the
site. Anyhow the contractor workers have to aware for avoiding those small injures.