INDEX

Secti- Subject Page

on no.
1. Safety Policy of Company
2. Purpose and Scope
3. Fundamentals of Safety
G. GENERAL INSTRUCTIONS
FOR SAFETY
G 1. Responsibilities of Supervisors
G 2. Responsibilities of Individuals
G 3. Personal Conduct
G 4. Personal Caution and Self
Awareness
G 5. Physical Fitness
G 6. Reporting Hazardous
Conditions or Practices
G 7. Accident Reports, Records and
Investigations
G 8. House keeping
G 9. Storing and Piling Material
G 10. Lifting, Carrying and Hoisting
G 11. Ladders
G 12. Hand Tools
G 13. Metal Scaffolds & Towers
G 14. Suspended Scaffolds
G 15. Fall Arresting Equipment
G 16. Metal Working
G 17. Grinding Operations
G 18 Welding & Cutting
G 19 Safeguarding the Public
G 20. Use of Personal Protective
Equipment (PPE)
G 21. Cleaning of Parts
G 22 Preventing Fires & Explosions
G 23 Fire Fighting
Secti- Subject Page
on no.

G 24. Work on Tunnels, Penstocks,

Valves,Dams and Ductlines.
G 25. Work on Transmission lines
during inclement weather
conditions:
G 26 Safety Guidelines for Thermal
Units
Page 1 of 146
G 27 Office Work

E ELECTRICAL OPERATIONS
E 1. General Safety Precautions
E 2. Authorisation for doing work
E 3. Protective Equipment

E 4. Working on electrical lines

E 5 Working on Dead Lines and
Equipment. Grounding of lines
and equipment
E 6 Work on Double/four circuit
overhead lines with one
circuit/one side live
E 7. Inspection of equipment on
live lines
E 8. Line work on poles and towers
E 9. Tree trimming
E 10. Right of way clearing and
trimming
E 11. Patrolling lines
E 12. Switching Operations
E 13. Receiving Stations and Sub
stations
E 14. Pumped Storage Units
E 15. GIS Switchgear and SF6 Circuit
breakers

Secti- Subject Page

on no.

E 16. Storage Batteries

E 17. Transformers
E 18. Generators
E 19. Work on generator windings
E 20 Static Capacitors
E 21 Lightning Arresters
E 22 Underground systems

E 23. Ring Main Units (RMU)

E 24. Air Blast Circuit Breakers
E 25. SCADA
E 26. Communication system
equipment/FOP/Microwave/PL
CC/Broadband

Page 2 of 146
E 27. Testing of Electrical Equipment

28 Work Permit System

ST SAFETY TAGGING SYSTEM

ST 1. Fundamental Tagging Rule
ST 2. Requirements of Tagging
System
ST 3. Desirable Characteristics of
Tagging System
ST 4. Tags
ST 4A. Responsibilities involved
under the Tagging System
ST 5. Release Order
ST 6. Caution Order
ST 7. Operating Permit
ST 8. Construction Order
ST 9. Release Tagging Rules and
Tags : Procedure for
Equipment and
Lines
Subject Page
no.
10. Rules Pertaining to use of
Operating Permit (Green Tag)
12. Safety Tagging (illustrative)
Case 1 Outage of 220/132/110
KV Interconnecting
Buses
Case 2 Outage of
Interconnecting Tie
lines
Case 3 Outage of Thermal
Units
Case 4 Outage of
equipment/Auxiliary
System at Thermal
Power Stations

Case 5. Outage of Hydro

Generating Units
Case 6. Outage of a
Distribution Feeder fed
from a Receiving
Station

Case 7 Outage of an overhead

33/22/11 KV
Page 3 of 146
 Distribution Feeder
Case 8 Megger or High
Potential test on a
feeder cable:Use of a
Release order and
Operating Permit
Case 9 Protective Relay
testing
Case 10 Clearing of protection
schemes only after
equipment are taken in
load service

ST 12 Discussion on usage of
safety tags in day to
day operations

W Work Permit System

C CONSTRUCTION
C 1 Scaffolds
C 2 Rigging and Hoisting
C 3 Welding, Burning &
Cutting(General)
C 4 Handling & Storing Compressed
Gases
C 5 Explosives: Storage &
Transportation
C 6 Handling & Use of Explosives
C 7 Excavations
C 8 Concreting & Cementing
T TRANSPORTATION
T 1 General Precautions
T 2 Driving
T 3 Parking
T 4 Operation of Trucks & Trailars
T 5 Procedure in Traffic Accidents
F First Aid

F1 Principles of First Aid

F2 Restoration of Breathing by
artificial respiration
F3 External Cardiac Massage
F4 Cardio Pulmonary Resuscitation
F5 External bleeding
Page 4 of 146
F6 Burns
F7 Shock
F8 General rules for Treating an
Unconscious case
F9 General rules for Treatment of
Fractures
F10 Treatment for Chemical Burns
F11 Foreign body in the Eye
F12 Snake bite
F13 Heat Exhaustion
F14 Heat Stroke

Page 5 of 146
 SAFETY POLICY OF COMPANY

The safety policy of the company includes

the following objectives:

i. To integrate safety practices completely

with production maintenance and all related
operation requirements.

ii. To provide safe working conditions, proper

and adequate tools, equipment and
protective devices.

iii. To see that employees are at all times kept

familiar with the general and special
practices for the safe conduct of their work.

iv. To see that those safety measures and

recommendations that apply are in all cases
carried out by the employees.

2. PURPOSE AND SCOPE

This Safety Manual is for the guidance of

employees in prevention of accidents to
themselves, the public and the damage of the
company property. Accidents can be practically
eliminated with forethought, carefulness and
planned protection on the part of supervisor and
workmen. This manual also outlines First-Aid
methods as applicable to work processes,
environment and practices. These are to be used
at the time of accidents before medical aid
becomes available.

The safety instructions are divided into six

parts:

1) General (applicable to all situations)

2) Electrical Operations
3) Safety Tagging and Work Permit System
4) Construction
5) Transportation
6) First Aid

OMISSION OF ANY SAFE PRACTICE

HEREIN DOES NOT REDUCE INDIVIDUAL
RESPONSIBILITY FOR ALERTNESS AND GOOD
JUDGEMENT IN THE PERFORMANCE FOR
WORK.

Page 6 of 146
3. FUNDAMENTALS OF SAFETY

(1) Prevention of accidents requires the

wholehearted co-operation of all members
of the organisation. A capable, mentally
alert employee will avoid accidents.

(2) An unsafe person is a liability to the

company. Such person is danger to self,
fellow workers, the public and to the general
environment.

(3) Accidents Do Not “Just Happen” –

Accidents are the result of unsafe acts or
unsafe conditions or a combination of both.

(4) Unsafe Acts, which cause majority of

accidents, include the following :-

(a) Operating without Authority or

Warning such as closing switches,
operating valves without authority
and proper line up, operating hoists
and cranes without warning, failure
to block or guard equipment against
unexpected movement, failure to
place caution boards or signal
persons where needed.

(b) Operating or Working Unsafely

such as driving too fast, throwing
material or tools to another worker,
jumping from vehicles or platforms,
or unnecessary haste.

(c) Making Safety Devices

Inoperative such as using oversize
fuses, blocking safety valves,
defeating or bypassing interlocks.

(d) Using Unsafe Equipment or Using

Equipment Improperly such as
using dull cutting tools or mushroom-
head chisels, pipe extensions on
wrenches not designed for them,
using excess leverage instead of
hand force where required, wrong
tool for the job, using hands instead
of hand tools. Tools without proper
insulation or defective tools.

(e) Unsafe Loading, Placing or Mixing

such as overloading cranes and
winches, carrying too heavy a load,

Page 7 of 146
 leaving objects where they are likely
to fall, improper packing, combining
chemicals to form a dangerous
mixture.

(f) Acquiring unsafe position or

Posture such as walking under
suspended loads or too close to
openings, lifting while in awkward
position, riding on running boards or
other unsafe places on vehicles.

(g) Working on Dangerous

Equipment such as cleaning, oiling
or adjusting moving machinery and
working on live electrical equipment
that could conveniently be de-
energised.

(h) Distracting, Teasing, Startling

such as practical joking, horse play,
quarrelling or annoying.

(i) Failure to Use Personal Protective

Equipment (PPE) or Safe Clothing
such as failure to use rubber gloves
on energised equipment, and failure
to use goggles, helmet, safety
shoes, gas mask, respirator or
gloves when necessary and wearing
loose sleeves, neckties or jewellery
near moving machinery,

(j) Use of rings in fingers, carrying

metallic pen, wristwatch, coins, keys
in the pocket while working inside
any panel, open tank, exposed
equipment, etc.

(k) Use of jhoola while working at

height.

(5) Unsafe conditions that may result in

accident include the following: -

(a) Unguarded Equipment such as

unshielded moving parts of
machines, saws, compressor belts,
etc., un-barricaded floor opening and
excavations, and high voltage
circuits which are un-isolated, live,
unguarded and without caution
notice plates.

Page 8 of 146
 (b) Defective Material or Equipment
such as mushroomed chisels, split
handles, poorly constructed
scaffolding, damaged tools,
electrical hand tools without proper
insulation.

(c) Improper Illumination such as

insufficient light or unsuitable
location of lamps producing glare or
objectionable shadows.

(d) Unsafe Design and Construction.

Structures like platforms,
scaffoldings should have large
safety factors and their construction
and design in general should
incorporate safety features. All
anticipated hazards should be
pointed out to workers.

G. GENERAL INSTRUCTIONS FOR SAFETY

G-1 RESPONSIBILITIES OF SUPERVISORS

Divisional Heads Departmental heads, Line

Engineers and other Supervisors have the definite
responsibility of ensuring the following: -

(a) Safe working conditions.

(b) Necessary protective equipment and its

use.

(c) Properly maintained tools and equipment.

(d) Properly planned work performed in a safe

manner.

(e) Application of the general and special safety

instructions by their workmen.

(f) Assignment of employees to jobs which

they are capable of doing safely.

(g) Immediate steps to correct any violation of

safety rules observed or reported to them.

Supervisors will be held responsible for seeing that

work under them is done in a safe manner. Each
Supervisor shall make certain that his men
understand the following: -

Page 9 of 146
(a) Work to be done
(b) Hazards that may be encountered
(c) Proper procedure for doing the work safely.

Frequent periodic inspections of

construction, operation and maintenance
equipment, materials, work areas, conditions
and methods should be made by supervisors as
a part of their routine duty. Such inspections
are essential to prevent fires and accidents.

G-2 RESPONSIBILITIES OF INDIVIDUALS

(1) Your definite responsibility is to act so as to

provide

(a) Safety to yourself

(b) Safety to your fellow employees
(c) Protection to the public
(d) Protection to the company property.
(e) Protection to the general
environment.

(2) Every employee is expected to study the

Safety Manual, familiarise with its contents
and apply them. Ignorance of Rules and
Regulations will result in accidents to self
and co-workers.

(3) Whenever in doubt regarding any rules and

regulations, employees should consult their
Engineer or Supervisor.

(4) Before attempting any work under

conditions that is considered to be unsafe,
employees are required to call these
conditions to the attention of the person-in-
charge of work and seek his/her advice.

(5) It will be the duty of every employee to

report promptly to his/her Engineer or
Supervisor any dangerous or improper
condition of company apparatus or
equipment, which comes to his/her notice.

G-3 PERSONAL CONDUCT

(1) Use of intoxicating liquor and drugs while on

job is strictly prohibited. No employee shall
report for work while under the influence of
liquor, and no Engineer or other Supervisor
and Security on duty shall knowingly permit
a person to go to work while under the
influence of liquor/drugs.

Page 10 of 146
(2) Practical joking and horseplay or gossiping
while on the job is strictly prohibited.

(3) No employee shall distract the attention of

another worker from his job unless he thinks
that the worker is doing something, which is
dangerous or risky either to self or
equipment.

(4) Any employee who endangers own or

others’ safety and lives by violating the
foregoing requirements of personal conduct
shall render liable to disciplinary action.

(5) Security on duty should not allow any

person under the effect of liquor/drugs to
enter the company premises.

G-4 PERSONAL CAUTION AND SELF

AWARENESS

It is in workman’s own interest to exercise

utmost personal caution as indicated below so as
to prevent accidents and injury.

(1) Every employee should consider the result

of each act and no chances should be taken
that will endanger either workman’s own or
other employees’ lives.

(2) Always Be Careful (ABC); the work-man

should place himself in a safe position while
working to avoid falling, stumbling, slipping
or moving backwards against live parts.

(3) The workman should satisfy regarding the

safe working conditions before starting the
work. The care exercised by others should
be checked.

G-5 PHYSICAL FITNESS

(1) Before and during employment, every

employee will be given a physical
examination and must be certified by the
company’s Medical Officer as being
physically qualified for the work he/she will
be expected to do.

(2) Any employee who is unable to perform

duties due to illness or other disability shall
promptly report the condition to immediate
supervisor.

Page 11 of 146
(3) After absence from work due to illness or
injury, an employee may be required to
pass a physical examination to determine
fitness for duty.

G-6 REPORTING HAZARDOUS CONDITIONS

OR PRACTICES.

(1) All hazardous conditions should be reported

to the Supervisor and engineer on duty.

(2) Hazardous conditions should be eliminated

as soon as they are discovered. Where a
hazard cannot be removed, taking
reasonable and proper precautions can
prevent accidents.

G-7 ACCIDENT REPORTS, RECORDS AND

INVESTIGATION

(1) Accident records are essential to the

prevention of accidents. They show the
type of accidents most frequently
encountered where they occur and their
relatives severity. A study of these records
will emphasise common hazards, and
prompt a better understanding of the
causes of accidents and most effective
methods of preventing them.

(2) All accidents which result in injury or not or

however small the accident may be shall be
promptly reported to Engineer or Supervisor
and operation Engineer on duty. Many near
misses / near accidents, which are not
reported, recur with serious injuries.

(3) All accidents to the public involving

company personnel, equipment or property
shall be reported promptly.

(4) Accidents should be investigated to

determine the cause and what steps are
needed to prevent a recurrence. It shall be
the responsibility of the person-in-charge of
the job to get a complete, detailed story of
the accident as soon as possible after it
occurs.

(5) Accidents, whether they result in personal

injury or not, shall be promptly investigated
by the Divisional Head.

Page 12 of 146
Definitions :

Accident :

Accident is any event, which has or could have

caused injury. Such an event may also involve
damage to machinery / property.

Work Injury :

Work injury is an injury arising from the event

during the course of employment.

Reportable Accident :

Reportable Accident is an accident which causes

bodily injury as prevents or will probably prevent
the injured person from working for a period of 48
hours immediately following the accident

Handling of Accidents / Injuries :

Role of TATA Power Supervisor

After notifying the Medical Officer /

Retainer / Specialist, the TATA Power
Supervisor must ensure the removal of the
injured to Occupational Health Centre /
Dispensary / external hospital either using
the ambulance / vehicle or with the help of
co-workers of the injured employee. He
should send a note regarding the injury
immediately to Medical Officer / Retainer /
Specialist.

In case of damage to facilities, he must

immediately get suitable steps taken as per
requirement. If, in doubt, he must await
Dept. Manager / Divisional Head's advice.

Role of Medical Officer / Retainer /

Specialist

The Medical Officer / Retainer / Specialist

must immediately reach the Occupational
Health Centre / Dispensary / Hospital on
receipt of the information. He shall then
decide on the course of treatment and need
for hospitalisation and inform administrative
needs. After initial handling of the injured,
he should inform Divisional Head, the status
of the injured. In case of hospitalisation, the
Medical Officer / Retainer / Specialist should

Page 13 of 146
liaison with the hospital and advise by way
of remarks on internal report form. The
second copy of the internal report form
should be sent to Safety Officer / Steward
and the third retained in Occupational
Health Centre / Dispensary / Office for the
records.

Role of Safety Officer / Safety Steward

The Safety Officer / Safety Steward /

Supervisor nominated by Station Head must
rush to the scene of accident, establish first
information on how the accident occurred
and provide any assistance that may be
necessary. Subsequently, he should
proceed to the Occupational Health Centre /
Medical Dispensary / Hospital and interview
the injured with the consent of Medical
Officer / Retainer / Specialist.

Role of Department Head

He should immediately visit the scene of

accident and enable his supervisor to take
effective steps. He should keep Station /
Divisional Head informed of the
developments.

Role of Station / Divisional Head

He should render all administrative

assistance sought by Medical Officer /
Retainer / Specialist. These could include
providing vehicles for transporting Injured /
Relatives (if need be), to the hospital.
Administrative Officer will co-ordinate with
Division, if any outside assistance is to be
sought.

Role of Visitors

No visitors or onlookers are permitted near

the scene of accident. Co-workers of the
injured can visit the Occupational Health
Centre / Dispensary / Hospital only within
specified visiting hours with prior permission
of Medical Officer / Retainer / Specialist.

Role of Injured

The injured person should report the

accident immediately to his supervisor / to
the Department Head (in the absence of
supervisor). He is expected to co-operate

Page 14 of 146
 with Medical Officer / Retainer / Specialist in
treatment, hospitalisation, discharge and re-
instatement. The advice of Medical Officer /
Retainer / Specialist is binding on all
concerned personnel.

Statutory Reporting

Under the provisions of Factories Act, 1948,

and Maharashtra Factories Rules 1963,
framed within the Act, there are certain
statutory information that needs to be sent
to the various Government authorities in
case of reportable accident or dangerous
occurrence as defined by the Act.

As per Factories Act, following locations are

Factories

Thermal – Trombay

Hydro – Bhira, Bhivpuri, Khopoli.

Transmision and Distribution – Andhra Workshop,

Mahalaxmi.

Statutory reporting to the Directorate of Industrial

Safety and Health (Factory Inspection Office) is
applicable to accidents occurring at above
locations.

Briefly, the notices have to be sent as prescribed

under –
- Section 88 "Notice of Certain accidents"
and
- Section 88-A "Notice of Certain Dangerous
Occurrences" of the Act,
- “Form 24” for accidents as prescribed in
Rule 115 of the Factories Rules.
- “Form 24-A” for dangerous occurrences.

Form 24 / 24-A is to be sent to the Deputy Director

of Industrial Safety and Health (Formerly known as
Factory Inspector).

It is also necessary to maintain a "Register of

Accidents and Dangerous Occurrences" in Form 30
as prescribed in Rule 123.

Safety Officer / Steward, in consultation with

Station / Divisional Head, will take care of above
statutory communication.

Task Force members are covered under

Employee’s State Insurance (ESI) Act.

Page 15 of 146
ESI scheme is applicable to Mumbai region
(including Kalyan and Ambernath) and Lonavla.

Bhira, Bhivpuri and Khopoli are not covered under

ESI scheme.

Form no. 16, as per ESI Act, is to be sent to the

Administrative Medical Officer, Employees’ State
Insurance (ESI) Scheme, Mumbai.

In case of fatal accident, information shall be sent

by the factory manager by telephone, special
messenger or telegram within 24 hours of
occurrence to:

a. Factory Inspector (Directorate of Industrial

Safety and Health).
b. Administrative Medical Officer, Employees’
State Insurance Scheme, Mumbai.
c. District Magistrate or Sub-Divisional
Magistrate.
d. Officer-in-charge of the nearest Police Station.

G-8 HOUSEKEEPING

Workmen are frequently injured by tripping,

stumbling, stepping on, or bumping into
tools, material and other objects left lying
around, or by carelessly placed objects
falling from above.

To ensure good housekeeping following

precautions should be observed: -

(a) Walkways, aisles, stairways, fire

escapes and all other passageways
shall be kept clear of all
obstructions.

(b) Tools and materials should not be

placed where they may cause
tripping or stumbling hazards or
where they may fall and strike
anyone below.

(c) Puddles of oil and water create a

slipping hazard and should be
cleaned up promptly.

(d) Nails in boards, such as those

removed from scaffolds, forms and
packing boxes, constitute a hazard
and should be removed. The boards

Page 16 of 146
 should be carefully stacked or
stored.

(e) Dirty and oily waste rags should be

deposited in approved containers
and disposed off as soon as
practicable to avoid fire hazard.

(f) Broken light bulbs, glass metal and

scrap and other sharp objects
should be dumped in places or
containers provided specially for
them.

(g) Discarded fluorescent and other gas

filled tubes shall be disposed off
safely.

G-9 STORING AND PILING MATERIAL

(1) Material stored in quantity should be

arranged so that the weight is evenly
distributed and not top heavy.

(2) All stacks and piles should be protected

against overturning or other movement.

(3) Sand, gravel, lime, cement and other heavy

material require supports of unusual
strength and shall not be stored in buildings
unless the supports are designed for
additional weight.

(4) Barrels, drums and kegs should be stored

on end or securely blocked to prevent
rolling.

G-10 LIFTING, CARRYING AND HOISTING

(1) Most lifting accidents are due to improper

lifting methods rather than to lifting too
heavy loads. When manually lifting heavy
objects, person should keep his back close
to vertical and the lifting done with leg and
arm thigh muscles rather than with back
muscles.

(2) Bulky loads should be carried in such a way

as to permit unobstructed view ahead.

(3) Pipes, conduits, reinforcing rods and other

conducting materials should not be carried
on / above shoulders near exposed live
electrical equipment or conductors in
switchyards.

Page 17 of 146
(4) Rope tackle and slings, wherever required,
should be checked to ascertain that they
have sufficient strength to perform the work
in hand.

(5) Chain hoists will not be used until their

condition is known to be satisfactory. Care
should be taken to avoid overstraining
hoisting equipment. Chains should be
inspected before use and at intervals during
extended operations to avoid failure of worn
or weakened links, hooks or other parts.

(6) No one shall stand or pass under any

suspended load being handled by a crane,
derrick or other hoisting equipment.

(7) Safe loads that can be lifted with various

sizes of Nylon Manila and Sisal ropes under
different hitches are given in the attached
chart. The values given are valid for
undamaged ropes and when the loads are
lifted without jerk.

Page 18 of 146
Specifications of Manila, Polypropylene and Nylon
Ropes as per IS-1084, IS-5175 and IS-4572

Manila Ropes

Circum- Diameter Breaking Strength (Kg.) Weight

ference in MM (Per coil of
in MM 220 Mtrs)
Grade Grade Commer
2 3 -cial
25 8 483 419 210 12
32 10 635 559 280 15
38 12 955 838 419 23
44 14 1285 1118 561 31
51 16 1805 1576 788 42
57 18 2135 1880 940 49
64 20 2845 2215 1108 81
70 22 3405 2972 1136 73
76 24 4085 3558 1750 88
83 26 4725 4140 2070 103
89 28 5325 4725 2363 118
95 30 6055 5385 2693 138
102 32 8860 6071 3051 155
114 36 8635 7570 3786 197
127 40 10415 9703 4850 244
140 44 12700 11024 5500 298
152 48 14735 12955 6478 352
165 52 17275 15088 7500 414
178 56 19815 17425 8713 479
190 60 22805 19813 9908 549
203 64 25700 22800 11300 639
216 88 28500 24700 12350 707
229 72 32700 27600 13800 792
241 76 35000 30000 15000 881
254 80 38700 32600 16300 988
279 88 46800 39200 20500 1177

Page 19 of 146
Polypropylene Ropes

Circum- Diameter Breaking Weight

ference in MM strength (Per coil
in MM (Kg.) of 220
Mtrs)
4 214 1.63
6 602 3.67
25 8 1060 6.6
32 10 1560 10
38 12 2210 14.5
44 14 3050 20
51 16 3770 25.5
57 18 4810 32.5
64 20 5800 40
70 22 6960 48.5
76 24 8130 57
83 26 9410 67.6
89 28 10700 78
95 30 12220 89
102 32 13500 101
114 36 16930 129
127 40 20510 158
140 44 24640 194
152 48 28610 229
165 52 33110 268
178 56 37850 312
190 60 43280 359
203 64 48980 407
216 88 -- --
229 72 61500 515
241 76 -- --
254 80 75640 638
279 88 90760 772

Page 20 of 146
Nylon Ropes

Circum- Diameter Breaking Weight

ference in MM strength (Per coil
in MM (Kg.) of 220
Mtrs.)
4 320 2.3
6 750 4.95
25 8 1345 8.8
32 10 2088 13.6
38 12 2995 19.6
44 14 4095 26.8
51 16 5300 35
57 18 6695 44
64 20 8300 54
70 22 10000 66
76 24 12000 78
83 26 13950 92.4
89 28 15800 107
95 30 17755 122.1
102 32 20000 139
114 36 24900 176
127 40 30000 218
140 44 35800 264
152 48 42000 312
165 52
178 56
190 60
203 64
216 88
229 72
241 76
254 80
279 88

Page 21 of 146
(8) Some of the dependable rope knots and hitches
are shown in the attached sketches indicating their
special purpose and advantages.

(9) In switchyards No material should be

lifted/carried above shoulder level.

Page 22 of 146
Page 23 of 146
G-11 LADDERS

(1) All ladders shall be inspected at regular intervals

and maintained properly.

(2) When a ladder has fallen or been struck, it should

be carefully inspected for possible damage before
use.

(3) Split, broken or otherwise defective ladders should

be destroyed or cut to smaller lengths.

(4) A ladder shall never be placed on slanting, oily,

slippery or on vibrating footings, unless the ladder
is held by another person or securely fastened to
prevent it from slipping or twisting.

(5) The base of a ladder should not be placed more

than 1/4th the length of the ladder from a wall or
supporting surface.

(6) The overlap of sections for extension ladders

should be sufficient to prevent collapse of
extensions.

(7) Ladders placed near doors or in passageways

should be protected against being struck by doors
or traffic.

(8) While going up or down a ladder, always face the

ladder and use both hands for climbing.

(9) All ladders for outdoor use should be given a

suitable coating such as clear varnish or linseed oil.
Metallic paint shall not be used on wood ladders.

(10) Portable metal ladders shall not be used unless

specifically authorised.

(11) The use of ladders for other than their intended use
and the use of defective ladders is prohibited.

(12) The most likely type of accident to occur at a power

plant that could result in severe injuries is a fall.

(13) When you select a portable ladder, choose the

proper type and size and inspect it for defects.
Whenever possible, make sure the top of the
Page 24 of 146
 straight or extension ladder will be long enough to
extend at least three feet above the step-off level.

(14) Never climb an extension or straight ladder that is

not adequately tied off unless someone is holding
the ladder to prevent it from moving.

(15) Straight ladders and extension ladders, except for

job made ladders, are not to be used unless they
have safety feet. Job-made ladders should only be
used for a specific purpose intended. If possible,
they should also be provided with slip resistant feet.

(16) Be sure the horizontal distance from the foot of a

straight or extension ladder to the base of the
vertical support it rests against is equal to one-
fourth the working length of the ladder.

(17) Do not work higher than the second step from the
top of a stepladder or the third rung from the top of
a straight ladder.

(18) If it is necessary to place a ladder in the swing of

travel of a doorway, barricade the door and post
warning signs or post a watchman.

(19) Use a ladder-climbing safety device when it is

provided.

(20) Do not use stepladders as straight ladders.

(21) Straight or extension ladders are to be provided

with safety feet and must be tied off or held when in
use.

(22) Face the ladder and use both hands when

ascending or descending ladders.

(23) Carry tools up and down a ladder in a tool holder or

raise them with a hand line or hoist.

(24) Clean mud or grease from shoes before climbing

ladders. Ladder steps should also be kept cleaned
of oil and grease.

(25) Only one person at a time is permitted to work from

a ladder.

Page 25 of 146
(26) Metal ladders are not to be used in locations where
they may come in contact with electrical conductors
except for special jobs performed in switchyard that
must be approved by the supervisor prior to
beginning the job.

(27) Do not use general-purpose metal ladders for

electrical work.

(28) Do not use boxes, chairs, barrels etc., as a base for

a ladder.

(29) Ladders are to be inspected before each use and

defective ladders are to be tagged for the defect.

(30) Do not use a fixed ladder from which there is a fall

potential of over 6 meters unless it is equipped with
an approved cage or a ladder safety climbing
device.

(31) Do not use a fixed ladder that is greater than 10

meters in length unless the ladder is provided with
a cage, offsets, and rest platforms at least every 10
meter or is equipped with a ladder safety climbing
device.

(32) Fixed ladders must have at least 17-18 cms

clearance from the centreline of the grab bars to
the nearest permanent object behind the grab bars.

(33) While climbing the ladder the foot should be at right

angles to the step of the ladder.

Page 26 of 146
Page 27 of 146
G-12 HAND TOOLS

(1) Many accidents result from improper use of tools

and use of defective tools and equipment.
Employees should use only those tools and
equipment, which are in good condition and should
use only for the purpose for which they were
designed. Where proper and safe tools are not
available for the work at hand, the employee shall
report the fact to the Supervisor.

(2) Tools, which develop defects while in use, should

be removed from service, tagged and not used
again until placed in good condition.

(3) Impact tools such as chisels, drill, hammers and

wedges with mushroomed heads should not be
used until they have been reconditioned.
Page 28 of 146
(4) Hammers, axes, shovels and similar tools should
not be used if handles are loose, cracked or
splintered.

(5) Defective wrenches such as open-end and

adjustable wrenches with spread jaws, or pipe
wrenches with dull teeth, should not be used, as
they are likely to slip.

(6) Pipe or other extensions should not be used on a

wrench handle to increase the leverage unless the
wrench is specifically designed for such an
extension.

(7) Portable electric tools with metal body should be

equipped with 3-wire cord having the ground wire
permanently connected to the tool frame and
means for grounding the other end.

(8) Use of multimeter should be done for checking of

presence of electric supply/voltage instead of
tester.

G-13 METAL SCAFFOLDS AND TOWERS

(1) Ensure that metal scaffolds and towers are erected

in accordance with the manufacturer’s
specifications and that the recommended load
limits are not exceeded.

(2) Position metal scaffolds so that they will not come

in contact with energised electrical conductors.

(3) Plumb and level all scaffolds and towers. Use

rolling scaffolds only on firm, level and clean
surfaces.

(4) Securely fasten all braces used in metal scaffolds.

(5) Cleat or secure scaffolds planking at both ends to

prevent movement.

(6) Use a positive wheel-locking device to prevent all

rolling scaffolds from accidentally moving while the
scaffold is in use.

(7) Move all rolling scaffolds by applying force to the

base only.
Page 29 of 146
(8) Riding on rolling scaffolds while they are being
moved is prohibited. Remove or secure all tools,
materials, and equipment on the deck before
moving the scaffold.

(9) Do not allow the height of the work platform of free

standing scaffold towers to exceed four times the
smallest base dimension.

(10) Work only from scaffolds that have been approved

and display a current signed scaffold permit.

(11) Use an approved means of access to and from all

elevated work areas, i.e. ladders, stairs, or
approved personnel hoists.

G-14 SUSPENDED SCAFFOLDS

(1) Before getting on a suspended scaffold, attach a

lanyard from your full-body harness to an
independent lifeline secured to a firm anchorage
above. The anchorage for the lifeline or lanyard
must withstand at least a 5,000-pound load.

(2) Ensure that wire or fibre rope used to support

scaffolds is capable of supporting at least six times
the intended load.

G-15 FALL ARRESTING EQUIPMENT

(1) The use of full-body harnesses and lanyards, either

tied off to a life line or to an anchorage, is required
under the following circumstances:

a. When the scaffold permit requires their use.

b. When required by your supervisor.
c. When working from any suspended scaffold when
the fall potential exceeds four feet.
d. When working from any work surface that is not
protected by guardrails and all potential exceeds
four feet.
e. When working from an aerial lift bucket. (Tie off to
bucket or boom.)

(2) Lifelines and lanyards are to be tied off to

anchorage capable of supporting at least 5,000
pounds. All tie-offs shall made as high as possible
above waist height level.
Page 30 of 146
(3) Lanyards shall have as little slack as possible and
limit any fall to six feet or less with a harness.

(4) Lifelines, harnesses, and lanyards are to be

removed from service and destroyed if they have
been used to arrest a fall.

(5) Metal rules, metal tape lines, or tape lines

containing wires shall not be used around electric
conductors or equipment.

(6) All tools carried on trucks should be inspected each

month and defective tools repaired or replaced.

G-16 METAL WORKING:

GENERAL

(1) Operating machinery without authorisation by

supervision is prohibited.

(2) The floor area around machines is to be maintained

clear and free from grease, oil, scrap and trash.

(3) Keep machinery free of tools, rags and scrap.

(4) Know the operating capabilities of the machines

used and never exceed those limits.

(5) Before tripping shears, make certain that everyone

is in the clear.

(6) Keep fingers out of the area of cutting edges and

other exposed moving parts.

(7) Use a brush or other suitable means to remove

chips, dust, or other material from machines.

(8) Where the work must be held in position, it must be

securely bolted or clamped to the table or held in a
vice or jig. Do not try to hold it by hand.

(9) Shut off the power before setting up work on

equipment, such as shears, lathes, drill presses
etc.

(10) After using the chuck key, immediately remove it

from the chuck of a lathe or drill press.
Page 31 of 146
(11) Calipering or gauging is not to be attempted while
the lathe or milling machine is in operation unless
the device is designed for such use.

G-17 GRINDING OPERATIONS:

GENERAL

(1) Do not use a bench or floor stand grinder when any

of the following conditions exist:

a) Guard(s) are not installed.

b) Grinder not securely anchored.

c) Work rest exceeds 1/8 inch distance from

the wheel.

d) Adjustable tongue exceeds ¼ inch distance

from the wheel.

e) Excess wear is evident on the grinding

wheel.

f) Wheel is chipped, cracked, out of round, or

otherwise defective.

(2) Do not use potable grinders without guards.

(3) Before mounting a grinding wheel on a grinder,

check the operating speed marked on the grinder
and the rated safe speed of the grinder wheel.
Grinding wheels are not to be mounted on grinders
that operate in excess of the rated safe speed of
the grinding wheel.

(4) Adjusting the work rest or tongue guard while the

grinding wheel is in motion is prohibited.

(5) Inspect grinding wheel and discs on portable

grinders before use for any cracks, damage, or
wheels out of round or balance. Where any defect
is evident, the wheel or disc must be removed from
service immediately.

(6) Check the grinding wheel mounting flanges for

equal sizes and correct diameters. Flanges are to
Page 32 of 146
 be at least one-fourth diameter of the wheel
diameter.

(7) Do not stand directly in front of any grinder when

first starting it up.

(8) Allow the wheel to develop its full speed before

beginning work.

(9) Never force the stock into the wheel of a fixed

grinder or a portable grinder into the work to the
point where the motor slows noticeably or the work
becomes excessively hot.

(10) Ensure that the wheel is properly dressed at all

times.

(11) Do not grind on the side of the wheel unless the

wheel is specifically designed for this purpose.

(12) Store grinding wheels in a safe place designated

for that purpose.

(13) Machines must be shut off when unattended.

G-18 WELDING AND CUTTING :

A. GENERAL:

1. Only authorised employees are to perform welding and

cutting operations. Prior to starting a job, check with
your supervisor to see if a cutting and welding permit is
required.

2. Do not perform welding, cutting, or hot work on used

drums, barrels, tanks, containers, or inside confined
spaces prior to venting and testing the atmosphere.
Purge, inert, and clean, as necessary, to ensure that
the work can be done safely.

3. Inspect all welding and cutting equipment before use.

Remove defective equipment from service and tag it.

4. Protect or remove combustible material from any

welding and cutting area.

5. A fire watch must be maintained for at least 30 minutes

after completing cutting or welding in coal handling
areas.
Page 33 of 146
6. Use non-combustible material to cover openings when
cutting or welding over grated flooring.

7. Suspend welding cables and hoses overhead or

arrange them so they will not cause a hazard.

8. When welding or cutting, shirt collars must be fastened

and sleeves rolled down and fastened. Wear trousers
without cuffs, along with footwear designed for
industrial work exposures.

9. Approved eye protection must be worn in conjunction

with industrial safety glasses when performing welding
and cutting operations.

B. ELECTRIC ARC WELDING AND CUTTING:

1. Ground the non-current carrying metal parts of

electrically driven welding machines.

2. Neither terminal of the welding generator is to be

bonded / grounded to the frame of the welding
machine.

3. Do not use pipelines, which are pressurised or

contain flammable gases / liquid, or conduits
carrying electrical conductors for a welding ground
return circuit.

4. Welders are not to handle the electrode holders

from two different machines at the same time.

5. Do not coil or loop welding cable around parts of

your body while it is energised.

6. Electrode holders must not be dipped in liquids to

cool them.

7. Wearing rings, metal wristbands or other jewellery

while welding is prohibited.

8. Special precautions must be taken when welding

on wet or damp surfaces. See your supervisor for
protective requirements.

9. Do not use welding leads that have a splice within

10 feet of the electrode holder.

Page 34 of 146
C. GAS WELDING & CUTTING:

1. Keep compressed gas cylinders beyond the range

of sparks, hot slag, or flame. Keep two buckets of
water or a running water hose at the job site.
2. Close the torch valves and shut off the gas supply
whenever work is suspended. Bleed the torch
before disconnecting gauges.

3. Remove the torch and hose from confined spaces

whenever work is suspended during lunch breaks
and at the end of the shift. When torch and hose
removal is no practical, the cylinder valves must be
closed, the regulators backed off, and the torch
turned off to prevent any gas flow.

4. Use only appropriate tools to ignite torches. Do not

use open flames or matches.

5. Do not take compressed gas cylinders into

confined spaces.

6. Both the oxygen and fuel gas lines must be

equipped with flash back preventers (reverse flow
check valves / non-return valves) at their
connections to the torch.

7. A fire watch must be maintained for at least 30

minutes after completing cutting or welding
operations in the coal handling area.

D. PRESSURISED SYSTEMS AND CYLINDERS:

GENERAL:

1. Inspect pressurised equipment and systems for

damage before they are placed in service and after
major repairs or modifications.

2. Do not pressurise a non-pressure-rated vessel with

plant air, a compressed gas cylinder, or other
sources. Use liquid at atmospheric pressure to test
for leaks.

3. Atmospheric tanks, low-pressure tanks, and

pressure vessels are designed and manufactured
in accordance with acceptable standards and
therefore may not be pressurised above the
designed pressure of the vessel.
Page 35 of 146
E. COMPRESSED GAS CYLINDERS:

1. All compressed gas cylinders are to be labelled as

to their contents. Do not use cylinders if a label
does not identify their contents. Colour code for gas
cylinders is to be followed.

2. Store cylinders in well-ventilated locations.

3. Smoking within 15 meters of designated flammable

gas or oxygen storage facilities is not allowed.

4. Protect cylinders from extreme temperature,

physical damage and electric current.

5. Close cylinder valves and place valve caps on the

cylinders when they are in storage, in transit, or not
connected for use.

6. Secure all compressed gas cylinders to a fixed

structure or in portable racks or hand trucks.

7. Compressed gas cylinders transported by crane,

hoist, or derrick shall be transported in hoist racks,
cradles, nets, or skip pans, and never by silings,
chains or magnets.

8. Always store oxygen, acetylene and other fuel gas

cylinders in an upright position. Keep acetylene
cylinders upright at all times, except for short
periods of time. I.e. if necessary, during
transportation to a job.

9. Have a valve wrench or wheel ready to operate

when a cylinder is in use.

10. Leaking cylinders must be moved, using

appropriate precautions, to an isolated location out
of doors.

11. Using oxygen as a substitute for compressed air is

not allowed. Compressed gases of any kind are
not to be used as a substitute for compressed air
unless used in a system designed for such use.

12. Keep oil or grease away from oxygen cylinders and

fittings.

Page 36 of 146
F. COMPRESSED AIR:

1. Wear approved eye and face protection when using

compressed air for cleaning. Ensure that all
persons are adequately protected from flying chips
and particles. Do not direct compressed air toward
any part of your body or toward anyone else.

2. Do not use air pressure in excess of 30 psi (when

dead-ended) for cleaning operations.

Note 1 The down stream pressure of air at the discharge

end of a nozzle, cleaning lance, or opening of a
pipe shall remain at a pressure below 30 psi for all
operating conditions. This requirement is
necessary in order to prevent a backpressure build-
up if the nozzle is obstructed or dead-ended.

Note 2 To modify an air lance to meet the above

requirement, drill a series of small holes in the pipe
or lance directly behind the nozzle to relieve the
pressure in case the nozzles is obstructed. There
is no intent to restrict the diameter of the nozzle
orifice or the volume (CFM) flowing from it.

3. Using compressed air to pressurise or force the

contents out of a drum or a non-pressure-rated
vessel is prohibited.

G. EXCAVATIONS:

GENERAL:

1. Before starting any excavation, determine if there

are any underground utilities in the area that could
be damaged.

2. Excavations of one meter deep or more, unless in

solid rock, must be shored, sheeted and braced, or
sloped to such an angle that the soil is at rest
(angle of repose) as determined by a competent
person.

3. Use ladders, steps, or ramps as a means of

entrance and egress in excavations more than one
meter deep. Ladders must extend at least one
meter above the top landing for mounting and
dismounting.

Page 37 of 146
4. No more than 8 meters of lateral travel in an
excavation 4 feet deep or more is allowed without
an adequate means of egress.

5. Vibrations from machinery and equipment shall be

considered when determining the angle at which
the soil will be at rest.

6. Store and retain all excavated materials at least

half meter or more away from the edge of the
excavation. Keep equipment at least half meter
away from the edge of the excavation.

7. A competent person must make daily inspection of

excavations. If evidence of possible cave-ins or
slides is apparent, all work in the excavation is to
cease until the necessary precautions have been
taken to safeguard the employees.

8. Warning devices such as signs, lights, and

adequate barricades must be installed around
unattended excavations.

H. ABRASIVE BLASTING:

GENERAL:

1. Employees transferring abrasive blasting materials

or working near where any material may be flying
must wear approved goggles and respiratory
protection. The area of blasting should be
enclosed to avoid nuisance.

2 Use adequate ventilation in enclosed areas.

3. Unauthorised personnel are not to enter an

abrasive blasting area.

I. LABORATORIES :

GENERAL:

1. Know the exact locations and operation of

emergency showers, eye wash fountains, fire
extinguishers, etc.

2. Should acids or caustics come in contact with eyes

or skin, flush with large amounts of water for a
minimum of 15 minutes. DO NOT RUB YOUR
Page 38 of 146
 EYES. Seek medical attention immediately after
flushing eyes or skin.

3. Do not use broken, chipped, scarred, or badly

scratched laboratory glassware.

4. Use only substances from properly labelled

containers.

5. Ensure that incompatible chemicals are properly

separated in storage, such as oxidisers separated
from flammables.

6. Do not transport acids or caustics outside the

laboratory in exposed glassware. The glassware is
to be carried in sealed, padded containers.

7. Oxygen and fuel gas cylinders shall not be stored

in the laboratory.

8. All compressed gas cylinders must be properly

secured to prevent tipping.

9. Never use temporary tubing (i.e. Tygon, PVC., etc.)

for the piping of oxygen or fuel gas.

10. Ventilation in laboratory hoods must be verified as

adequate by flow measurement on an annual
basis.

J. COAL HANDLING :

GENERAL :

1. Smoking is not permitted anywhere in the coal

handling system, conveyors, bunkers etc.

2. Employees shall not step on a conveyer nor

attempt to repair the equipment unless proper
clearance has been obtained.

3. Do not ride on conveyors or cross over or under

operating conveyors except where designated
passageways are provided.

4. Before maintenance may begin on a conveyor,

proper release on respective system must be
obtained. Any adjustments made while it is running
must be under supervisory control.
Page 39 of 146
5. Safe access to conveyors shall be maintained to
permit safe inspection, lubrication, repair, and
maintenance operations.

6. Before entering a coalbunker or silo, the air within

the space shall be tested for oxygen content,
flammable and toxic gases, and vapours.

7. When cleaning down coal in a bunker, employees

should use a lance with a non-sparking tip and
should work from a position above the lodged coal.

8. Employees shall not work inside pulverised fuel

equipment until it has been thoroughly purged or
the coal dust has been wet down with water.

9. Employees shall not place hands on moving

conveyors, rollers, or pulleys.

K. ASH HANDLING:

GENERAL:

1. Persons who enter or clean areas contaminated

with ash shall wear all necessary personal
protective clothing and equipment.

2. If an employee becomes dizzy or drowsy while

working around ash-handling equipment, or in other
gaseous areas, he/she should immediately go to an
area of fresh air and notify someone of his/her
condition and location.

3. When inserting or using a rod in a furnace, the

operator shall keep the rod away from his /her body
so that he/she will not be struck if falling ash or slag
causes the rod to kick upward. A pipe shall never
be used for de-slagging operation unless the pipe
is sealed or connected to an air or water supply.

4. All rods in the vicinity of the area in which they are

used shall be treated as being hot.

Page 40 of 146
G-19 SAFEGUARDING THE PUBLIC

(1) Every effort should be made to protect the public at

all time where company’s work is in progress by the
use of signs, barricades or personal warning.

(2) When working on customer’s premises or public

property, every effort should be made to avoid
hazards to persons or unnecessary property
damage.

(3) When work is conducted along public streets or

highways, pedestrian and vehicular traffic shall be
warned by signs and flags by day and red lights or
flares by night. Whenever necessary, signalmen
should be provided.

(4) Barriers shall be placed around all open manholes,

exposed open ditches and excavations.

G-20 USE OF PERSONAL PROTECTIVE EQUIPMENT

(PPE)

Personal Protective Equipment (PPE)

Protection for PPE to be PPE protecting from ------- PPE to be used during ------ / in
used -------
Body Cotton Uniform Exposure to Steam, Hot Oils, Constant use in designated places.
Chemicals, Alkalis.
Rubber Apron Splashes of Acids, Alkalis, Sampling, transferring, Filling,
Solvents. Drumming.
Head Helmet Falling objects and materials Constant use in designated places.
Eyes Safety goggles Flying objects, Splashes, Breaking of flanges, Chipping
Sprays concrete / metals, Gas Cutting,
Uncoupling of hoses, De-
pressurising, Venting, Sucking,
Sampling.
Welding Ultraviolet rays from welding Arc welding, Gas welding.
Goggles arc
Face 1. Face-shield Chemical Splashes Grinding, Furnace burner lighting,
Chemical handling, Metal shaving.
2. Blue Face- Hot rays, Ultraviolet rays, Arc welding, Gas welding.
shield Grinding sparks
Hands 1. Electrical Electric shock Working on high voltage electrical
Shock proof equipment / lines.
Gloves
Page 41 of 146
 2. Leather Abrasion Pulling ropes / chains, Using tools
Gloves like spanners, Operating hard
valves, Welding.
3. Asbestos Hot burns Handling hot materials, Tightening
Gloves steam leak.
4. PVC Acids, Alkalis, Chemical handling
Gloves
5. Rubber Oils, Aromatic solvents, Chemical handling
Gloves Alcohols.
Foot 1. Safety Falling object, Striking against Constant use in designated areas
Shoes object
2. Gum Muddy Land, Water, Chemical Use under specific condition
Boots Spill,
Respiratory 1. Canister Toxic Gas, Vapours, Use for specific jobs.
System Mask
2. Self Toxic gas leaks, Smoke, Use for specific conditions.
Contained Emergencies.
Breathing
Apparatus
Set
3. Dust Air containing dust / solid Coal / Fly Ash handling, Grit
Mask particles blasting.

Ears Ear Plugs / Noise Constant use in designated areas

Ear Muffs
Falls Safety Harness Fall from height 1. Working above 4 metres for
Belt erecting scaffolding.
2 Transmission line jobs.
3. Jobs at elevated locations
where adequate protection
against falling is not
available.
4. Working on elevated platforms
above 4 met. without hand
railing.
5. Working on Cooling
Tower tops where wood
is likely to cave in.
6. Entry in confined spaces,
Inspecting vessels.

Job / Operation Additional PPE

Welding Welding Screen, Chrome Leather Gloves.
Gas cutting, chipping Safety Goggles, Chrome Leather Gloves.
Manual hoist / tackle chain running Leather Gloves.
Shifting weights, equipment Leather Gloves.
Bench / pedestal grinding Safety Goggles / Face-shield.
Pneumatic tools Ear Plugs, Leather Gloves, Face-shield.
Power saw cutting Face-shield / Safety Goggles, Leather Gloves.
Tightening glands, Dismantling of equipment Safety Goggles / Face-shield.
Breaking flanges on pipelines / equipment Safety Goggles / Face-shield.

Page 42 of 146
Sweeping, Mopping up saw dust Dust Mask, Safety Goggles.
Concrete chipping, cold metal chipping Safety Goggles.
Painting Safety Goggles, Safety Harness Belt for the job
to be done at heights.
Acid / Caustic handling, filling toxic chemicals Rubber Apron.
Spading / de-spading, Connecting / disconnecting Safety Goggles / Face-shield.
hoses
Erecting scaffolding Safety Harness Belt, Leather Gloves.
Working on scaffolding Safety Harness Belt, Gloves (as per job).
HdPE pipe welding Safety Goggles, Leather Gloves.
Chlorine tonner connection / disconnection Canister mask
Lead Acid Battery maintenance jobs Safety Goggles / Face-shield.
Drawing samples Safety Goggles / Face-shield.
Transferring chemicals Safety Goggles / Face-shield.
Emptying / filling carboys / drums Safety Goggles / Face-shield.
Opening draining / de-pressurising valves Safety Goggles / Face-shield.
De-choking lines Safety Goggles / Face-shield.
Air blowing operations Safety Goggles / Face-shield.
Steaming operations Safety Goggles / Face-shield.

G-21 CLEANING OF PARTS

With flammable solvents

(1) Adequate ventilation must be available to

avoid fire, explosion and health hazards.

(2) Avoid breathing solvent vapours.

(3) Keep open flames and sparks away from

flammable liquids and their vapours.

(4) Metal nozzle of a hose for spraying

flammable solvents shall be grounded.

With compressed air

(5) Goggles shall be used when blowing out

dust with compressed air.

G-22 PREVENTING FIRES AND EXPLOSIONS

(1) Waste paper, rags and other combustible material

should not be allowed to accumulate.

Page 43 of 146
(2) Flammable liquids shall be kept in approved safety
cans and identified by proper labels.

(3) Varnish, paints, lacquers and thinners are highly

flammable and should be stored away from all-
open flames or possible sources of ignition.
Matches and open flames should not be used
where varnish, paint or lacquer is being applied
with a spray gun.

(4) Open flames and smoking are prohibited in all

areas where flammable liquids or gases are stored
or being used. Such areas shall be posted with
appropriate warning signs.

(5) All employees should be familiar with the location

and proper use of fire extinguishers in their work
area.

(6) No employee should smoke or use matches or

open flames on customer’s premises

G-23 FIRE FIGHTING:

ELECTRICAL FIRES

Any fire started by electrical equipment must be a

class A, B, C or D fire. Normal procedure is to cut
off the supply of electricity and use an extinguishing
method appropriate to burning material.

Special agents which are non-conductors of

electricity and non-damaging to equipment should
be used in case of any doubt about positive
isolation of electric supply.

FIRE- ITS ANATOMY & CLASSIFICATION

Nature of Fire

Fire is as old as human civilisation. Fire of

controlled nature has been part and parcel of day
to day life. As the proverb goes “FIRE IS A GOOD
SERVANT BUT BAD MASTER”, fire plays only
constructive role in generating electricity.

Page 44 of 146
 What is Fire

Fire is an exothermic chemical reaction resulting

from combination fuel, heat and oxygen.

CLASSIFICATION OF FIRES and

EXTINGUISHING MEDIA FOR PARTICULAR
CLASS

CLASSIFICATION OF FIRES

Fires are classified on the basis of type of fuel

involved.

Method of extinguishment & type of extinguishing media

depends upon
the class of fire.

As per Indian Standards : IS : 2190 - 1979, fires are

classified as follows :

Class Type of fuel / material Method of Extinguishing

of involved extinguishment Media to be
Fire used
A Ordinary Solid Cooling fuel below Water
Combustibles its ignition point.
e.g. Wood, Paper,
Grass, Plastics
B Flammable Liquids, Blanketing fuel Protein Foam
Liquefiable solids surface in the bulk AFFF,
e.g. Fuel Oil, LSHS, fire. Alcohol
Diesel, Gasoline Resistant
(Petrol), Paints, Foam
Petrochemicals. Flame Suppression CO2, D.C.P.,
in the spillage fire. Halon
C Flammable Gases Starvation by the No medium is
e.g. Acetylene, control of fuel required
Hydrogen, supply.
LPG, Associated Gas, Inhibition of the CO2, D.C.P.,
Natural Gas burning fuel at fast Halon
rate with an inert
gas.
D Combustible Metals Inhibition of the Special
e.g. Magnesium, chain reactions of D.C.P.
Aluminium, Zinc, combustion
Sodium, Potassium, process
etc.

II. Smothering :

In very simple word it can be understand as cutting

of O2 (air) supply.
Page 45 of 146
 This method can be accomplished by covering a
burning surface with blanket, sand, DCP, foam, etc.

III. Cooling :

If heat generated during combustion can be

dissipated at footer rate than generation by some
means, the combustion can not sustained by
proper cooling, the heat lost will be more than the
production and fire will die down.

IV. Chain Inhibition :

Fire Triangle
Fuel O2
Oxygen
Heat
Fuel Heat

Basic need of fire is these three elements in proper

proportion without which fire can not involve.

With removing any of the side of fire triangle, we

can extinguish fire. Depending upon these three
parts of fire triangle, there are three extinguishing
methods.

V. Chemical chain inhibition combustion consists of

repaid chain reactions involving hydrogen atom and
other active species and free oxygen atom. By
applying proper chemicals, these chain reactions
can be arrested e.g. D.C.P.

FIRE PREVENTION

Fire safety has four legs as shown below :

1. Fire Protection : Elimination of contribution

2. Fire Prevention : Elimination of causes
3. Quality control
4. Preventive maintenance

The best way of fire safety is to eliminate the cause

of fire i.e. fire prevention.

I) Good Housekeeping
II) No smoking (or separate preparation of smoking
zone)
Page 46 of 146
III) Use of fire resistant paint
IV) Electrical safety
V) Fire check doors
VI) Compartmentalisation
VII) Separate storage of Hazardous chemicals
VIII) Naked Flame safety
IX) Use of earth leakage and current balance relays
and thermostat, fireproof chokes.

Do’s and Don’ts for Prevention of Electrical Fire

1) Ensure that current ratings of wires, cables and

accessories are equal to or higher than maximum
possible loads.

2) Ensure that all electrical wires and cables are

protected by fuses.

3) Use of MCBs or cartridge fuses instead of wire

fuses.

4) Ensure switch boards, terminal boards, joints etc.

are not fixed close to combustible material.

Use only those electrical equipment, cables/wires

and accessories which comply with relevant I.S.

NOTE: All portable fire extinguishers should be wall

mounted (1000 mm above ground/floor level).

G-24 WORK ON TUNNELS, PENSTOCKS, VALVES,

DAMS AND DUCT LINES

(1) Isolate the tunnel, pipeline, aqua-duct or associated

turbine from all sources of water.

Open the switches or fuses controlling supply to

motors for operating all valves, intake, gates etc.
Lock all hand operating mechanism.

Work or inspection parties shall consist of not less

than two persons.

(2) Use Safety shoes always. Use Gum boots when

inside Duct-line

Confirm that Caution order or Release is taken.

Page 47 of 146
 Carry out head counting before starting and after
closing the days work.

Be cautious about ups and downs, slippery

conditions during monsoon etc.

Use Helmet and Safety belt while working on

heights.

(3) Read the Operating Instructions or consult the

supervisor before touching the equipment or
opening or closing valves.

Confirm that no one is in the path of waterfall while

opening the scour valves.

(4) For grass removals on Dams use Rope ladder,

Safety belts and helmets.

(5) All earth moving equipment movement in the tunnel

should be slow while de-mucking in the tunnel.

Wear safety helmet and safety shoes inside

tunnels.

The cable used for providing light should not have

any joint in between.

Carry a whistle for giving out warning of dangerous

situations when inside the tunnel.

Keep first aid box ready inside the tunnel.

(6) Ensure sufficient ventilation and light while working

inside penstocks.

Ropes and trolleys should be tested before use

inside the penstocks.

Carry out head count before entering and after

coming out of penstocks.

(7) While lowering or lifting of stop log gates, take the

help of Divers who are fully equipped with all the
diving accessories. Confirm still water condition is
maintained before entering into water.

While lowering and lifting of the stoplogs in

approach channels and dams, the weather
Page 48 of 146
 condition usually remains windy. Approach the job
with utmost care and maintain clear & proper
communication during this operation.

Physical fitness is a must for work inside the

penstocks and tunnels.

Use 24 Volts hand lamps for lighting inside.

G-25 WORK ON TRANSMISSION LINES DURING

INCLEMENT WEATHER CONDITIONS:

Fasten to the tower before starting any work and

wear safety belts.

Do not work on overhead lines during thunder

storms or lightning

G-26 SAFETY GUIDELINES FOR THERMAL

UNITS

1. Common Guide Lines for Various Thermal Station

Systems
2. General Safety Guide Lines for High Pressure Air
System
3. General Safety Guide Lines for Control Fluid System
4. General Safety Guide Lines for Fuel Oil LSHS
system

5. General Safety Guide Lines for High Pressure and

Temperature Feed Water / Steam System
6. General Safety Guide Lines for Pumps in Thermal
Station
7. General Safety Guide Lines for High Speed Rotary
Equipment
8. General Safety Guide Lines for Hydrogen Gas
System
9. General Safety Guide Lines for Various valves in
Thermal Station
10. General Safety Guide Lines for Handling Fuel Gas
System
11. General Safety Guide Lines for Lube Oil System
12. General Safety Guide lines for handling chlorine
leaks.

G-26-1
Page 49 of 146
1. Common Guide Lines for Various Systems
in Thermal Stations

1. Persons handling the system should use safety apparel

such as safety shoes, helmet, safety goggles, hand
gloves, earplugs etc.
2. Ensure all fire-fighting equipment is in working
condition.
3. Ensure adequate lighting in area of operation and its
vicinity.
4. Communication source i.e., phone or page-party,
should be available near the area of operation or in
the vicinity. VHF sets can be used as an
alternative.
5. Spanners of proper size should be available for
operation.
6. Persons doing the operation should have complete
knowledge of the system.
7. Before draining the system its isolation is to be re-
confirmed from parameters such as pressure, flow,
temperature etc.
8. After confirming the isolation, system should be
drained in controlled manner. Drain valve should be
opened such that there should not be heavy
steaming which would affect other systems.
9. In case of leakage in the system, utmost care to be
taken if it is a superheated steam as it is not visible.
The only indication is from the noise and visual
inspection.
10. Leaky system should be isolated at its earliest. If
immediate isolation is not possible then the area
should be cordoned off and should be properly
tagged and it should be attended at the earliest.

G-26-2

2. General Safety Guide Lines for High

Pressure Air Systems
1. Follow all Common Guide Lines of safety.
2. Before charging the system close all drains.
3. During initial charging the rate of pressure rise should
be minimum, so that air leakage in the system can
be traced out.
4. For releasing the system, after confirming isolation,
system should be depressurised in controlled
manner. Drains should be opened such that there
Page 50 of 146
 should not be any hindrance to other working
equipment.
5. In case of any leakage in the system, utmost care to be
taken as air is not visible. The only indication is
from noise.
6. No direct contact to be made with the rotating/moving
part of the compressor.
7. There should not be any loose or hanging clothes worn
by the person inspecting the compressor.
8. The compressor should not run with any abnormal
noise.
9. Monitor oil pressure and temperature to ensure that
they are within the range recommended by
manufacturer.
10. Check bearing metal temperature for confirming normal
operation as specified by the manufacturer.
11. Record vibration measurements on all bearings while
the compressor is rotating / running.

G-26-3

3. General Safety Guide Lines for

Control Fluid Systems
1. Follow all Common Guide Lines of safety.
2. Store control fluid in dry places only.
3. Do not use pure copper any where in the control fluid
system due to catalytic effect in the decomposition
of the phosphoric ester
4. Do not use Butyl rubber 11R is not compatible with
control fluid. Silicon rubber since it severely
impairs the air release capability of control fluid.
5. Biological decomposition of control fluid is difficult;
control fluid is heavier than water and affects it
adversely and therefore it should not be passed
into the sewage system.
6. Avoid inhaling control fluid spray clouds or
decomposition products.
7. Do not eat, smoke or drink when working with control
fluid or parts in contact with control fluid.
8. Keep control fluid away from foodstuffs
9. Keep control fluid away from skin, eyes and clothes.
10. After handling control fluid, wash hands immediately
11. If control fluid gets into eyes, sponge carefully and
rinse with large quantities of water. Obtain medical
attention if irritation persists.

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12. If skin contact occurs, flush areas with water and wash
with soap. Obtain medical attention if irritation
persists.
13. If control fluid is swallowed, give large amounts of salty
water to cause vomiting. If unsuccessful, tickle
back of patient's throat with finger. Obtain medical
attention if stomach discomfort persists.
14. All moisture should be eliminated from control fluid
system otherwise; the control fluid forms acid
components when in contact with water.
15. Chlorine presence in control fluid clauses erosion-
corrosion at the edges of control components.
Therefore all traces of solvents containing chlorine
should be removed.
16. Before charging of control fluid system, confirm that all
drains are closed.
17. In case of control fluid leakage it should be absorbed
by using saw dust or oil binding granules and
should be removed quickly.
18. For disposal control fluid may be mixed with saw dust
and burned in incinerating plant or mixed in small
quantities of used oil for burning.
19. In case of any major control fluid leakage, FIRE
PROTECTION should be activated to give a
complete shutdown to the control fluid system.

G-26-4

4. General Safety Guide Lines for Fuel

Oil LSHS systems
1. Follow all Common Guide Lines as Per Chapter 1.
2. Vents and drains of the system should be diverted to
the proper drains / sumps after checking sufficient
space availability. If not then alternative
arrangement should be made.
3. Open vents or drains (during charging or draining
operation) in controlled manner to avoid any
overflowing.
4. Confirm safe tank filling heights and reference heights
before filling the tanks.
5. Do not charge the steam to the tank heating coils until
the coils are fully submerged in the oil. The
condensate from the coils should be monitored for
oil content.
6. For first charging pumping rate should be maintained to
minimum so that line can be thoroughly checked for

Page 52 of 146
 any leaks. Subsequently the rate can be
increased.
7. Maintain oil tank temperature well below its flash point.
8. Rate of pumping should be within the maximum line
carrying capacity.
9. Start the pump always with re-circulation valve full
open. throttle re-circulation valve after confirming
flow & no oil leak.
10. All heat tracing circuits should be ON so that no part of
the LSHS line becomes cold. This is to avoid
solidification of the LSHS within the line.
11. While draining the LSHS tank care should be taken to
monitor the tank temperature.
12. Transfer oil to other tanks as fast as possible to avoid
wastage when a tank leak occurs.

G-26-5

5. General Safety Guide Lines for High

Pressure and Temperature Feed Water /
Steam Systems
1. Follow all Common Guide Lines as Per Chapter 1
2. During charging operation, drains (which are kept
open for warming up of the line) should be throttled so
as to avoid heavy steaming in the area. Also it will
help in closing the valve after the operation.
3. Take systems in service after thorough warming up so
as to avoid hammering of the line.
4. Before draining the system confirm isolation from
parameters such as pressure, flow, temperature etc.
5. In case of leakage in the system, utmost care to be
taken if it is superheated steam as it is not visible. The
only indication is from the noise.

G-26-6

6. General Safety Guide Lines for Pumps in

Thermal Stations
1. Follow all Common Guide Lines as Per Chapter 1

2. Safety precautions to be taken before starting and

isolating pump
Page 53 of 146
 Take following precautions before starting pump.

 All releases are cleared and area is

cleaned/ cleared by all working parties (No
oil drum, cotton waste, spanner etc are lying
in the vicinity).
 Protocol has been filled/ signed by the
respective departments.
 All fire-fighting equipment is in working
condition.
 Page party, Telephones and other modes of
communication are available near the
equipment to be started.
 Nearby emergency exit door in operable
condition.
 Persons should be technically qualified and
authorised to do the operations.
 Safety apparels should be worn by the
person starting/ inspecting the pump.

 Pre Starting Guidelines

 Check Pump and Prime mover alignment in

uncoupled condition
 Check suction / discharge piping to ensure
no strain coming on the pump
 Check direction of rotation of prime mover
 Check all piping connections
 Ensure all instruments are calibrated
 Tighten Foundation bolts and re-check
alignment.
 Couple the pump to the prime mover.
 Ensure replacement of lubricants/
lubricating oil (after flushing as necessary).
 Fix coupling guard.
 Check suction strainer for correct size.
 Prime the pump gradually.
 Attend leaks from joints/fittings (after the
pump attaining suction pressure).
 After completing all the above checks and
the pump housing attaining temperature
close to that of the fluid, the pump shall be
rotated to ensure free rotation.
 Ensure that the discharge valve is fully
closed and suction is fully opened.

Page 54 of 146
  Post Start Checks - The following shall
be checked/observed:
 Check all instruments, observe readings at
regular intervals and compare the
performance of equipment with
manufacturer’s data.
 Check vibration readings for any
abnormality and take necessary corrective
actions.
 Check temperature rise and pay attention to
any abnormal sound from bearings.

3. Safety precautions to be taken for isolating the

pump.

 Pump should be in stopped condition.

 Prime mover of pump is in de-energised condition.
 Prime mover breaker of pump is in off /racked out
condition. (Pump auto standby is off while its
breaker is being racked out).
 cool down the pump as per manufacturer
recommendations. (If required).
 Isolate pump from suction and discharge sides by
using right size of spanners if suction and
discharge valves are manually operated.
 Place releases tags at all the isolating points and
respective breakers. Place release tags only after
breaker is made off / valve is in closed condition).
 Hand over the equipment to the working party.

G-26-7

7. General Safety Guide Lines for High

Speed Rotary Equipment
1. Follow all Common Guide Lines of safety.
2. Carry out Overhaul/preventive maintenance as per
the schedule given by the manufacturer.
3. Carry out steam blowing of piping and flushing of
lubricating oil system for removal of foreign
materials as per requirement.
4. Provide proper foundation as per the specifications.
5. Fix couplings and coupling guards properly.
6. Fix all instruments for alarms and trip and ensure they
are functional.
7. Concerned departments should sign protocol before
the equipment is lined up and taken in service.
Page 55 of 146
8. Maintain proper housekeeping around the equipment
so that there is no hindrance for operation and
monitoring the equipment.
9. All safety devices and protections should be available.
10. Local/remote stopping of the equipment should be
available, wherever applicable.
11. All motor protection relays should be available for
alarms and trip service for motor driven equipment.
12. All commissioning / decommissioning checks should
be completed and the required procedures should
be followed.
13. All simulations should be removed and protections
that were bypassed (eg: for uncoupled run of the
motor) should be normalised before taking the
equipment in normal service.
14. Ensure proper line up, normal lug. oil levels, correct
lubrication oil, cooling water line up before taking
equipment in service.
15. For steam turbines ensure that the steam quality
(temperature, purity etc.) is matching the specified
values before admitting steam to the turbine.
16. For steam turbine driven equipment, ensure that over-
speed tests and other tests such as testing of
safety devices and steam valves is carried out at
regular and specified intervals.
17. When the equipment is in service it should be
continuously monitored for any abnormality.
Special attention is required to be paid to critical
parameters such as vibrations, bearing
temperatures, speed of the equipment, casing and
shaft expansions etc. Equipment should trip
automatically on protection or it should be manually
taken out of service if any of the parameters reach
values, beyond which operation of the equipment is
detrimental to the safety of the
personnel/equipment.
18. Maintain history of operation & maintenance and of
tests and trials.
19. The operation/maintenance personnel should wear
safety apparels (including earplugs when working
in the high noise level zone in the vicinity of the
equipment).
20. Only authorised persons should be allowed to operate
and carry out maintenance jobs on the equipment.
21. No direct contact should be made with the rotating
parts of the equipment.
22. Direction of rotation of the prime mover should be
checked (by carrying out motor uncoupled run)
wherever possible.
Page 56 of 146
23. Communication and fire fighting equipment should
always be available in the vicinity of the equipment.
24. Carrying of matches, lighters and smoking should be
prohibited in the vicinity of the Turbo-Generator. No
hot work should be allowed in the vicinity of the
Turbo-Generator.
25. All electrical and mechanical protections should be
available for the Turbo-Generator. As Generator is
filled with Hydrogen, special safety precautions
need to be taken in this regard.
26. Emergency stopping/tripping should be available for
all high-speed rotary equipment.
27. Whenever the equipment is to be given for
maintenance it should be de-energised and
properly isolated from all sources and should be
properly tagged.

G 26-8

8. General Safety Guide Lines for

Hydrogen Gas Systems
1. Follow all Common Guide Lines as Per Chapter 1.
2. Operation personnel should be well acquainted with
hydrogen handling system, as hydrogen gas is highly
explosive. Check gas purity cylinder wise before use.
3. Detailed operation procedure and checklist of the
hydrogen filling and purging should be followed.
4. Proper instrumentation should be available in
hydrogen gas system.
5. Purity of gas should be continuously monitored.
6. Adequate ventilation should be available for gas
escape in case of leakage.
7. Gas leak detection system should be available.
8. Fire fighting equipment should be available nearby.
9. No welding should be permitted without proper
approved permit.

G 26-9
9. General Safety Guide Lines for
Various valves in Thermal Stations
1. Follow all Common Guide Lines of safety.
2. Check mode of operation of valve i.e. motor operated,
pneumatically operated, hydraulically operated
manually operated etc.
Page 57 of 146
3. Check the position of valve i.e. close/open/in between
and confirm with remote and local feed back/ check
back. If the positions are not matching inform
respective maintenance department.
4. After or during the operation of any valve if any
abnormality like gland leak etc. is observed then
restore the original position of valve or keep the
valve in position where the abnormal behaviour is
minimised and inform respective maintenance
department.
5. Check the housing of the area in the vicinity of valve
to be operated, if not proper then inform respective
maintenance department or Main Control Room.
6. Check the type of valve i.e. isolating, control etc.
7. Confirm valve is easy to operate.
8. Gate valves are always to be operated in full open or
full close condition.
9. Avoid frequent operation of high-pressure valves as
for as possible to avoid any gland leak.
10. For Motor Operated Valve
 Confirm from working party or Main Control Room
whether valve operation is to be done electrically or
manually.
 For electrical operation check the direction of operation
by giving an impulse command if possible and if
direction is ok then operate it fully.
 If manual operation is to be done then first confirm that
motor breaker is off and then valve can be
operated in the similar way as that of manual valve
as given below for manual valves.
11. For Pneumatically Operated Valves
 Check instrument air supply isolating valve is open and
thus air is available for valve operation.
 Reset pneumatic air lock, if any and check the direction
of valve by giving small command from remote or
local and then valve can be further operated from
remote or local as per requirement.
 If valve operation is not possible pneumatically then it
can be done manually in the same as given for
manual operating valves by isolating its instrument
air supply.
12. For Hydraulically Operated Valves
 Check hydraulic circuit is properly lined up and enough
hydraulic pressure is available for valve operation.
 Check for any leakage during or after the operation of
valve in hydraulic circuit.
13. For Manually Operated Valves

Page 58 of 146
 Arrange right size of spanner as per size and location
of valve and also arrange hand gloves and other
safety accessories as per specific requirement of
the valve to be operated.
 Fix the spanner in such a way so that enough space is
available for spanner movement and also confirm
that spanner grip is proper and there is no slipping
or sliding of spanner. This can be confirmed by
applying smaller force initially. Change the spanner
if required.
 Gradually start operating the valve (close/open as per
requirement).

G 26-10

10. General Safety Guide Lines for

Handling Fuel Gas Systems
1. Follow all Common Guide Lines of safety.
2. Gas line filters, separators and line vents and drains
should diverted to vent stack or at higher elevation.
3. Smoking, welding or cutting job should not be carried
out in vicinity of gas pipeline, without chemist’s
confirmation that explosive test is nil. Also fire cell
personnel should be present at site with necessary
fire fighting equipment.
4. If welding or cutting job is required to be done in the
vicinity of gas pipeline, gas line should be covered
with asbestos sheet or other non-inflammable
material.
If welding or cutting job is to be done on gas line, it
must be properly purged with Nitrogen.
5. Inflammable material like wooden plates, plastic
sheets, cotton waste and sawdust should not be
stored near gas pipeline.
6. Healthiness of gas leak detection system should be
checked periodically.
7. ‘No Smoking, welding or cutting’ sign board and
‘Emergency telephone number of fire department
and control room’ should be displayed in vicinity of
gas pipeline.
8. Do not allow diesel engine without silencer to run in
the vicinity of gas pipeline before confirming that
explosivity is nil.

G 26-11

Page 59 of 146
11. General Safety Guide Lines for Lub.
Oil Systems
1. Follow all Common Guide Lines of safety.
2. Do not store inflammable material like wooden plates,
plastic sheets, cotton waste and sawdust near
lubrication oil system.
3. Check healthiness of fire fighting system for lub. oil
system periodically.
4. ‘No Smoking, welding or cutting’ sign board and
‘Emergency telephone number of fire department
and control room’ should be displayed in vicinity of
lubrication oil system.
5. Leakage or spillage of oil should be cleaned and
attended immediately.
6. Leaked oil should be prevented from coming in contact
with any high temperature system or electrical
equipment.
7. Sudden rise of oil temperature or any drop in
lubricating oil tank level should be checked
immediately.

G 26-12

12. General safety guidelines for

handling chlorine leaks.

Chlorine is a toxic gas. It is of dense greenish yellow

colour and pungent odour. It is 2.45 times heavier than
air. It is a strong oxidising agent and is soluble in water.
In case of gas leak, the presence of gas can be marked
with liquid ammonia (NH4OH) with which it will form a
thick white mist.

The persons trained in handling chlorine gas leakage

should only attend such operation by using SCBA (self-
contained Breathing Apparatus sets) and equipment
from chlorine emergency kit.

GENERAL INSTRUCTIONS -

At following events checks should be carried out for chlorine gas

leakage with ammonia solution.
1. After unloading the chlorine gas cylinder.
2. Before removing cylinder bonnet cap.
3. Before opening cylinder valve cap nut.
4. While opening cylinder valve after connecting cylinder on
header.

Page 60 of 146
5. Before disconnecting cylinder from header after cylinder is
empty.

IN CASE OF CHLORINE GAS LEAKAGE –

1. Alert persons working in the vicinity of Chlorination plant.

2. Sound Emergency alarm.
3. Try to close chlorine cylinder valve only after wearing air
mask/air canister.
4. Take out the person affected by Chlorine gas to open air.
5. Request for medical attention.
6. Always ensure all chlorine gas leak detectors are available
and their supply is on.
 follow the proper operation procedures while connecting /
disconnecting the cylinders.
 after closing the cylinder valve, ensure proper flushing of
chlorine in the pipeline before disconnecting the cylinder.
 do not pour water on liquid chlorine.
 windsock should be in proper condition.
 in the event of a chlorine gas leak, try to remain away from
the wind direction.
 do not allow any gas welding without
explosivity test.
 Provide chlorine scrubber system where applicable.

G-27 OFFICE WORK

(1) Lifting and carrying

(i) Serious strains often result from improper

handling of boxes and bundles of office
supplies, ledgers, portable filling cases and
office machines. Lifting should be done with
the back erect by using the more powerful
leg muscles.

(ii) Large boxes or bundles of supplies should

be moved by a hand truck, or unpacked and
delivered in smaller parcels.

(iii) Bulky objects should not be carried in such

a way as to obstruct the view ahead or
interfere with free use of handrails on
stairways.

(2) Slipping, Tripping and Falling

(i) Water, oil or other liquid spilled on floors

presents a dangerous slipping hazard and
should be cleaned up at once.
Page 61 of 146
 (ii) Where floor surface is treated, it should be
done with a slip-resistant preparation.
Waxing of floors should be avoided.

(iii) Loose objects such as matches and pencils

should not be left on stairs or floors as they
may cause slipping and bad falls.

(iv) Extension cords should not be strung

across aisles or walk ways where people
may trip or fall over them.

(v) Open desk or file drawers and desk slides

constitute a serious hazard as persons may
strike or fall over them.

(vi) Avoid standing on boxes,chairs or other

makeshift supports to reach objects
overhead. Use a safe ladder.

(vii) Open doors slowly to avoid striking anyone

on the other side.

(viii) Avoid running in aisles and corridors. Use

the handrail when going up or down
stairways.

(ix) In walking, particularly at blind corners,

always keep to the right.

(3) Office Equipment

(i) Serious injury may be caused by filing

cabinets that are not properly balanced or
anchored. Opening of overloaded upper
drawers, particularly more than one at a
time, may tip over the cabinet.

(ii) All exposed moving parts of power-driven

office machines should be covered with
suitable guards. Operators should be
instructed in the safe use of these
machines.

(iii) While using power-operated office

machines, avoid touching any grounded
metal object such as a radiator or water
pipe since short circuits sometimes develop
Page 62 of 146
 in such machines. Apparent defects in the
cords should be reported and promptly
repaired. Power Operated machine should
be disconnected each evening or before the
office is closed.

(4) Sharp or pointed Objects

(i) Do not use pins to fasten papers together.

Use paper clips or stapling machine.

(ii) Do not carry pointed objects such as

uncapped fountain pens and pencils with
the point exposed in the pockets, attached
to the clothing or through congested aisles
or working areas. This warning includes
knives and scissors also.

(iii) Paper cuts on fingers, hands or lips

frequently occur when handling paper or
sealing envelopes. Gummed strips of
envelopes should be moistened with
suitable device and not with the tongue.
Avoid opening envelopes with fingers and
sliding hands along edges of paper.

(iv) Do not use safety-razor blades for cutting

paper, sharpening pencils or other cutting
operations unless secured in a holder into
which the blade may be drawn out of sight
when not in use.

(v) Do not keep razor blades or other sharp

instruments loose in desk drawers/ pockets.

(vi) Broken glass or other sharp objects should

never be placed in wastebaskets but safely
wrapped, plainly marked and left beside the
wastebasket for removal.

(vii) Keep fingers of your free hand away from

cutting edge of paper cutters. The cutting
knife should never be left raised while
unsupported and should always be closed
when not in use.

(viii) Each employee should know nearest first-

aid kit and its proper use. Every injury, no

Page 63 of 146
 matter how trivial it may seem, should
receive prompt first-aid treatment.

(5) Personal computers – The wiring for the PCs

should be neatly arranged and tied properly so as
not to have overheating at the backside of
computer and prevent fall due to tripping over them
or pulling.

(6) Press Pins for velvet notice boards should not be

allowed to fall on floor as they may be stepped on
by any person.

(7) Glass top kept on the tables should be fixed with

proper locking corners so that it will not fall due to
sliding.

(8) Ensure no object is left behind on tabletop before

lifting the glass.

(9) While opening drawers of the tables it should be

pulled out slowly as the latch for the drawer may
not be properly engaged and the drawer may fall
down on feet.

(10) Discard old and scrap stationary papers, card

board boxes etc immediately as they are potential
fire hazards and presents possibility of termite
growth.

G-28 ELEVATORS:

1) Before operating the lift for going down or up

ensure proper working of the telephone in the lift.

2) Train all personnel about emergency lifting of the

elevator cabin manually and opening of the door at
proper floor level for rescuing of persons inside.

3) Wherever traffic through lifts is heavy, the stand by

arrangement of staircase must always be made
obstruction free for use particularly during major
maintenance work at the station.

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E ELECTRICAL OPERATIONS

E-1 GENERAL SAFETY PRECAUTIONS

(1) ALL VOLTAGES SHALL BE CONSIDERED

DANGEROUS EVEN THOUGH VOLTAGE MAY
NOT BE HIGH ENOUGH TO PRODUCE SERIOUS
SHOCK.

Page 65 of 146
(2) ALL ELECTRICAL CIRCUITS ARE TO BE
TREATED AS LIVE AND NO WORK
(MAINTENANCE, REPAIRS, CLEANING) IS TO
BE CARRIED OUT ON ANY PART OF
ELECTRICAL APPARATUS OR CIRCUIT UNLESS
SUCH PARTS ARE

(a) Dead

(b) Isolated and all practicable steps taken to

lock off from live conductors.

(c) Efficiently connected to earth at all points of

disconnection of supply to such apparatus,
or between such points and points of work.

(d) Released for work by issue of release or

other tags.

(e) Checked for de-energisation.

E-2 AUTHORISATION FOR DOING WORK

(1) Maintenance, repair and construction work on

electric circuit or apparatus shall not be done until
after making sure that working conditions are safe
and obtaining proper authorisation for doing the
work.

(2) “Proper authorisation” means notification by the

person in charge that a particular job is to be done
and also the approval by the person or persons
responsible for the equipment to be worked on.

(3) No person shall begin work on any circuit or

equipment until clear and complete instructions are
issued by the supervisor to do so.

E-3 PROTECTIVE EQUIPMENT -

USE AND CARE OF RUBBER PROTECTIVE

EQUIPMENT

(1) Rubber goods such as gloves, mats etc. may be

used for protection on electrical circuits.

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(2) All rubber goods shall be of high-grade material,
bearing ISI mark and carefully inspected, stored
and cared for.

(3) When not in use rubber should be shielded from

sunlight, heat, ozone and oil.

(4) Rubber will age or oxidise quickly at points of

distortion. Rubber gloves should not be worn
wrong-side out. Blankets should be rolled rather
than folded.

(5) Rubber gloves shall not be continued in use more

than specified number of days without an approved
electrical test.

(6) Rubber gloves shall be worn during the following

operations or conditions.

(a) Working on 220 to 5000 volts circuits and

also on lower voltage circuits where safety
requires gloves because of presence of
moisture, grounds and other conditions.

(b) Working on street lighting circuits.

(c) Stringing wire near live 220 to 5000 volts

circuits.

(d) Raising or lowering poles near 220 to 5000

volts circuits.

(e) Connecting, disconnecting or replacing

energised fuses with tongs and switch
sticks.

(f) Working on circuits within reaching distance

of 220 to 5000 volts circuits.

(g) Operating GODs or disconnects by handles.

E-4 WORKING ON ELECTRICAL LINES:

(1) Work close to energised H.T. equipment shall be

carried out only with explicit permission from the
Head of the Department and under his/her direct
supervision with adequate safety precaution.
Whenever practicable de-energise the HT
equipment for facilitating work in the vicinity.
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(2) When working near live lines or apparatus, each
person should plan moves and take extreme care
in moving from one position to another.

(3) Where impractical to erect barriers between

personnel at work and live parts within reach of
their hands and objects being handled, continuous
watch shall be kept by the Supervisor or someone
specifically designated for that purpose.

(4) When a truck-winch line or derrick is used near live

parts, all workmen except the driver should stay
away from the truck. Driver should see that the
truck is clear from live lines before leaving and
entering the truck.

(5) Whenever it is required to inspect an energised

equipment or work close to it, the following
minimum safe clearances must be maintained.

Voltage Range V Minimum Safe Distance mm

750 – 3,500 307
3,501 – 10,000 614
10,001 – 50,000 921
50,001 – 100,000 1535
100,001 – 250,000 3070

All inspection or work must be carried out without

approaching live parts nearer than the above safe
distances. All parts of an insulator like arcing
horns, grading rings etc. shall be treated as fully
live when the conductor is live.

(6) Outdoor work in the proximity of live H.T.

equipment shall be discontinued if signs of adverse
weather conditions like high humidity, thunder,
lightning or rainfall are encountered.

(7) Take a caution order when carrying out inspection

or work adjacent to an energised equipment or line,
so that such an equipment is not auto re-closed or
charged by the operating party subsequent to
tripping without obtaining clearance from the
working party.

E-5 WORKING ON DEAD LINES AND EQUIPMENT;

GROUNDING OF LINES AND EQUIPMENT

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(1) Before starting any work on dead lines or
equipment where there is a possibility of their
becoming energised from any source, such line or
equipment should be short circuited and grounded
between the locations of work and all possible
sources of energisation.

(2) Conductors to be grounded should be checked for

potential by an approved method before the ground
is installed.

(3) Temporary grounding cables shall be flexible

standard copper not less than No. 1/0 SWG (0.1
sq. inch) and shall be equipped with approved
clamps at each end.

(4) Grounding cables should be inspected before each

use.

(5) When grounding lines or equipment, the connection

to the ground shall be made first and that to the
circuit or equipment last. In removing grounds, first
remove the connection to the circuit or apparatus.

(6) Ground shall be placed on all phases even if work

is to be carried out on one phase only.

(7) For work on lines, grounds shall be placed at

nearest tower on each side of the point of work but
in no case should be more than six spans apart.
As an additional safety measure, line should also
be grounded on the tower where the work is to be
carried out.

(8) When work is to be carried out on lines of all

insulated construction and grounding point is not
provided at the point of work, temporary grounds
shall be connected at point of work to an efficient
portable earth stake driven into the ground. The
line shall also be grounded at the nearest line
grounding point on either side of the point of work.

(9) Where two or more crews are working

independently on the same line or equipment, each
crew shall properly protect themselves placing their
own temporary grounds.

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(10) Conductors used for temporary grounding shall be
kept clear of the working area and the workmen
should be warned not to handled those conductors
without adequate safety precautions while they are
connected to H.T. equipment or lines.

(11) The use of chains and defective grounding devices

is prohibited.

E-6 WORK ON DOUBLE/FOUR CIRCUIT OVERHEAD

LINES WITH ONE CIRCUIT/ONE SIDE LIVE

(1) To distinguish dead circuits from live ones, green

flags will be fitted on the towers on the side of the
dead circuit in case of double/four circuit towers.
Flags of any other colour shall not be used for
indicating a dead circuit.

(2) Flags will be removed only after work is finished

and temporary grounds have been removed.

(3) Procedure to be followed for working on Multi-

Circuit towers.

(a) Work planned on multi-circuit towers should be

discussed with line staff before commencement of
work for methodology and safety aspects.

(b) Walkie-talkie sets or Mobile phones shall be

available with ground as well as tower crew for
effective communication between them. While
carrying out the work, ensure proper
communication between staff at ground level and
on the tower.

(c) While carrying out any work on ‘Bottom Circuit” of

multi-circuit towers, obtain ‘Caution Order’ for the
‘Top Circuit’ (working in the vicinity of the top
circuit) and Release Order for the Bottom circuit.

(d) While carrying out any work on ‘Top Circuit’ of

multi-circuit towers, ‘Release Order’ for both the
‘Top and Bottom Circuits’ shall be obtained and
both the circuits shall be effectively grounded on
either sides of working place with flexible line
grounds before commencing the work.

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(e) All line crew shall ensure use of ‘Fall Safe
equipment’. Utmost care shall be taken by the first
person climbing the multi- circuit tower by carrying
rope with him as he shall not have advantage of
‘Fall Safe equipment’.

(f) Line crew shall use ‘Full Body Harness’ while

carrying out any work on multi-circuit towers and
anchor themselves firmly as soon as they reach the
required height of work.

(g) Line crew shall be instructed to climb slowly with a

steady speed and should rest for couple of minutes
at rest platform wherever provided.

(h) After completing the work, working party shall

ensure removal of flexible grounds and also ensure
that all men and material are away from the line.
Subsequently necessary Release/Caution Order
can be cleared.

(i) The Engineer, who is holding the release/caution

order, shall remain available till completion of work
at work site of the multi- circuit tower with vehicle
wherever possible.

E-7 INSPECTION OF EQUIPMENT ON LIVE LINES

(1) Inspection will be carried out from within the body

of tower.

(2) No tool shall be taken up the tower.

(3) No person shall climb above the anti-climbing

device unless under observation by another at
ground level.

E-8 LINE WORK ON POLES AND TOWERS

(1) Before climbing any elevated structure, every

employee shall first assure that the structure is
strong enough to sustain his/her weight safely.

(2) If poles or cross arms are apparently unsafe

because of decay or unbalanced tensions of wires
on them, they shall be properly braced or guyed.

Page 71 of 146
(3) Linemen shall wear their safety harness while
working on the poles and towers.

(4) Wire hooks shall not be attached to linemen’s belts

or safety straps.

(5) Safety straps should not be placed above the top

cross arm when he is at the top of the pole.

(6) No tools above 0.3 meter in length shall be taken

up the tower when both the lines are alive.

(7) All light equipment and tools to be used aloft should

be raised and lowered by means of hand-line and
canvas bucket or other suitable container. Men on
the ground should stay clear of overhead work to
prevent being stuck by falling objects.

(8) Tools and materials should not be thrown from the

ground to a lineman working aloft nor should
lineman throw tools and materials from above to
the ground.

(9) No person shall work in such a manner that his

arms or any tools extend beyond the body of tower
when working on the live side.

(10) Broken insulators or other sharp-edged material

shall not be left in vacant lots, along the right of
way or in the location where the hazard of cutting
feet could be caused for people or animals.

(11) When stringing wires across streets and highways,

avoid interfering with traffic or causing injury to
workmen or pedestrians. Danger signs should be
erected on both sides of the work location and
where conditions warrant, flagmen should be
stationed.

(12) Hand lines, materials, tools or equipment must not

be scattered round streets, sidewalks, highways,
etc. but must be kept in a neat, orderly manner,
where they will not be liable to cause accident.

(13) A lineman working on live wires should, wherever

possible, work from below the wires.
Page 72 of 146
(14) In handling wires on a pole, they should be raised
or lowered with a dry hand line and extreme care
exercised to prevent them from coming in contact
with a live line or equipment.

E-9 TREE TRIMMING

(1) The public shall be protected against hazards of

tree trimming along public streets and highways by
placing danger signs and signals.

(2) Before climbing a tree, the trimmer should look it

over carefully to decide how best to climb it, the
best locations from which to work, and the ground
area where bush and limbs may be safely dropped.

(3) Before climbing, the limbs should be carefully

inspected to make sure that they will hold the
trimmer’s weight. Dead or decayed limbs are not
safe to support any weight.

(4) Axes shall not be used aloft; always use saws or

bill hooks.

(5) Avoid dropping tools from a loft to the ground. All

tools should be raised and lowered by hand lines in
such a way as to avoid touching hot conductors.

(6) Parts of trees in contact with live wires should be

handled as live wires.

(7) Before cutting down a tree, all limbs should be cut

off for a sufficient height to avoid striking electric
lines. Where there is danger that the tree may
strike and damage property, block and tackle
should be used to control the direction of fall.

(8) Felling operation, once started, should be finished

before the crew leaves for the night or for lunch
hour.

E-10 RIGHT-OF-WAY CLEARING AND TRIMMING

(1) A number of hazards to be guarded against for

these jobs are

(a) When walking through slush, use ankle high

canvas boosts to prevent injury to feet from
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 broken insulators, thorny undergrowth,
shells, etc.

(b) Take extreme care while handling axes,

brushing hooks and other sharp cutting
tolls.

(c) Trees should be carefully felled to prevent

their falling on transmission lines or
adjacent buildings.

(d) Be careful of grass or forest fires and avoid

starting a fire.

E-11 PATROLLING LINES

(1) Emergency line patrol, trouble shooting on

transmission lines and similar work should always
be done with the greatest caution. Patrolmen
should be particularly alert at night to avoid walking
into fallen wires or metal fences, which may be
energised by fallen conductors.

(2) Be careful with lighted cigarettes and matches that

may cause a fire along transmission rights-of-way.
Break matches and crush cigarette stubs into earth
on discarding.

(3) Patrolmen should be alert of poisonous snakes and

stumbling hazards.

E-12 SWITCHING OPERATIONS

(1) A record of switching operations will be entered in

station logs.

(2) All switches and disconnects should have lettering

or sign boards to indicate the circuit they control.

(3) When releasing electric circuits, breakers or

equipment for work on them, the associated
breaker and disconnecting switches shall be
opened in the following order.

(a) The circuit breaker will be opened first.

(b) Then the disconnecting switches will be

opened, but before operating the
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 disconnects it shall be made sure that the
breaker is open.

(4) After opening disconnects and air break switches,

checks carefully to see that all blades are in full
open position.

(5) If the circuit is controlled by an automatic re-closing

breaker, the re-closing mechanism shall be made
inoperative.

(6) Disconnects shall be closed in firm positive

manner, using sufficient force to make full contact
of blades.

(7) Before removing fuses, switches should be

opened, if provided. Removing fuses from an
inductive circuit carrying current without opening
the switch is hazardous.

(8) Removal of fuses from circuits, where no switches

are provided should be done with approved fuse-
pullers.

(9) Interlock system should not be made inoperative

unless authorised by the Station In-charge.

E-13 RECEIVING STATIONS/SUB-STATIONS:

(1) Danger signs should be placed on all enclosures of

high-voltage equipment and wherever necessary to
warn persons of the presence of high-voltage
equipment.

(2) Gates in switchyard fences and doors to bus

compartments and other enclosures containing live
equipment or other hazards should be kept locked
at all times except when people are working inside.

(3) When carrying ladders, pipes, conduits, reinforcing

rods and other long material into stations,
switchyards, bus compartment rooms and other
places, where there is danger of touching live parts,
the material should be held by two men, one at
each end, and carried in the hands and not on the
shoulders.

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(4) When working in the vicinity of fuses, circuit
breakers or buses use every precaution to avoid
injury from arcing.

(5) Before doing any work on rotating equipment it

should be shut down and properly disconnected
from power source, except when necessary to
change commutator brushes, clean with
compressed air or add oil.

(6) Care should be taken to prevent clothing, wiping

cloths, waste dusters, oil cans or tools from
catching in the moving parts of machinery.

(7) When using compressed air on live electrical

machinery, an insulating hose and nozzle should
be used. Dust-proof goggles should always be
used when cleaning with compressed air.
Compressed air should never be used for cleaning
or dusting clothes or any part of body.

(8) If personnel are working on H.T. (voltages above

600 V) equipment the area safeguarded for work
shall be cordoned off by tying red buntings of 9” to
12” width all round and danger boards shall be
fixed within the safeguard area at various locations
with the inscription facing the safe working area to
warn personnel not to cross over to the area with
live equipment during the progress of work.

(9) The metal bodies of portable equipment or hand

tools shall never be grounded by connecting them
to the main station ground to which the neutrals of
H.T. equipment are connected. Separate ground
should be provided for such equipment.

E-14 PUMPED STORAGE UNITS

1. Operation of pumped storage units, although fully

automatic through PLC, may need manual
interface.

2. Manual operation is also possible for checking

each step in PLC sequence.
3. While in manual mode or local auto mode machine
need not be kept in hot standby mode for more
than half a minute due to high vibration problem in
penstock.

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 4. Before draining of draft tube and penstock of
pumped storage units, it is necessary to have
maximum number of drainage and de-watering
pumps in working condition since these drains are
located below ground level.

E-15 GIS SWITCHGEAR AND SF6 CIRCUIT

BREAKERS

SF6 gas, commonly used in GIS Switch gears &

SF6 breakers, is considered to be an inert gas
inhalation of very high gas content can cause
headache, giddiness, unconsciousness and
suffocation due to lack of oxygen. Degraded
products may cause irritation at high temperatures.
The gas is approximately five times heavier than
air, colourless and odourless. Presence of SF6
gas, while being filled in the tank, is difficult to
identify.

The following precautions are normally observed.

i) Have good ventilation at work place.

ii) Substitute air for the gas before entering the tank.
iii) Donot touch the decomposed by-products.
iv) Use rubber hand gloves.
v) Clean the by-products with a vacuum cleaner.

E-16 STORAGE BATTERIES

(1) When making electrolyte for storage batteries

always pour acid into water. The reverse method
(i.e. pouring acid in water) may cause an explosion.
Suitable goggles or face shields should always be
worn when making electrolyte.

(2) Smoking and use of matches or other open flames

are not permitted in battery rooms or while
inspecting, filling testing or handling batteries.
Vents in covers of battery should be clear.

E-17 TRANSFORMERS

(1) Before starting work on any transformer, ensure

both electrical and physical isolation. Take care to

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 prevent any possibility of transformer being made
live through synchronising or voltmeter plug.

(2) Before commencing any work on a transformer, the

transformer winding should be discharged to
ground. In case the transformer is isolated from
the supply by a single point of disconnection e.g.
fuse disconnects or disconnects only, the
transformer shall be safeguarded by shorting the
phase terminals together and connecting them to
ground before commencing any work.

(3) Whenever transformers are replaced the new

transformer should be checked carefully for
voltage, polarity and phase rotation before taking
into service.

E-18 INSTRUMENT TRANSFORMERS.

(1) The cases of all instrument transformers should be

grounded.

(2) Current transformer secondary should never be

open circuited when current is flowing in the
primary.

(3) The secondary circuit of current transformers

should be connected to ground at all times when
the transformer is in service.

(4) Potential transformer secondary should never be

shorted.

(5) The low voltage winding of potential transformers

should always have one side permanently and
effectively grounded.

E-19 GENERATORS

1) Generators in the system have different

specifications and accessories as per the station
conditions.

2) When work is to be carried out on a generator, the

generator must be at standstill and disconnected
from the grid and isolated properly. Similarly
before working on connected PT / CT circuits,
proper isolation on primary and secondary side
must be insured.
Page 78 of 146
 3) For working on generator auxiliaries, separate
release orders as per station equipment list are
issued.

4) The generators should be released as per station

operating procedures. Whenever particular
isolations are required such as draining of inlet
bends, stopping of auxiliary pumps, making
emergency stop activated & keeping the machine
control on local etc. These should be done in
consultation with working party.

5) Before working on slip rings for cleaning or brush

replacement, rotor earth fault protection needs to
be made inoperative.

6) Before bypassing any protection, proper

authorisation from station in-charge is to be
obtained and informed at the time of normalising.

7) Make CO2 protection inoperative before opening

the generator door.

G-20 WORK ON GENERATOR WINDINGS

(1) The generator shall be at rest.

(2) The field circuit will be opened and isolated.

(3) The valve or valves controlling the supply to the

turbine shall be locked in closed position.

(4) Before commencing any work on a generator with

an ungrounded neutral, the windings shall be
discharged to ground.

E-21 STATIC CAPACITORS

(1) Every capacitor shall be treated as hot until proved

otherwise. Capacitors store energy and are not
Page 79 of 146
 necessarily dead when disconnected from the
power source. Once charged, a capacitor may
retain this charge for several hours after it has been
disconnected.

(2) Before starting work on capacitor banks, open all

cut-outs or disconnecting devices to the capacitors.
Wait for a least five minutes for the internal resistor
to reduce the voltage. Next using a hot stick, short
circuit and ground all terminals of the capacitor.
The short-circuiting grounding jumpers should be
left attached while work is being done on the
capacitor.

(3) To place the capacitor banks in service, first

remove the jumpers with hot sticks, then close the
cut-outs.

(4) The capacitor container acts as one terminal and

as it is insulated from earth through bus support. It
is live unless the bank is isolated and safeguarded.

E-22 LIGHTNING ARRESTERS

No work shall be done on a lightning arrester

unless it is disconnected from the live circuit
discharged and grounded at both the line and
ground terminals.

E-23 UNDERGROUND SYSTEMS

(1) When manhole cover is removed, properly

constructed railings and warning signs must guard
the hole. Warning flags by day and red lights by
night should be placed at all open manholes,
excavations and on tool carts located on public
right-of-way or where exposed to traffic of any kind.
The warnings should be placed in such a manner
as to be visible from a distance and give persons or
vehicles ample time to avoid the obstructions.

(2) If the Supervisor considers that manhole working

conditions warrant additional precautions, a person
should remain within easy calling distance of
occupant to render assistance in case of
emergency and also to warn traffic of existing
danger.

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(3) Before any one enters a manhole, ascertain that
the air is safe enough. If harmful gases are
present, they should be expelled and frequent
checks made during work progress to determine
the condition of the air.

About 10% of carbon-di-oxide will extinguish most

flames. Before entering the manhole, it should be
kept open at least 10 minutes even if air is
expected to be safe. Look out for the smell of
Hydrogen sulphide gas. Tie a rope round the
worker entering the manhole.

(4) Never step on live cables even though they are

enclosed in lead sheath. Tools and materials
should not be allowed to rest against the sheath of
live cables.

(5) Open flames and smoking should be avoided in

manholes.

(6) Solder and compound pot should be kept where

they will not spill into the manhole if the pot is
upset.

(7) Before any work is started on a cable in a manhole,

the cable should be checked by the Engineer for
duct number, location identifying tag and by other
approved methods to make sure that work is
started on the appropriate cable only.

(8) After completing cable work in a manhole, the

cable should be properly tagged and identified for
exact location by a sketch, and this information be
kept in cable identification cards.

(9) A person in a manhole shall carry out no work,

where space is restricted, unless someone else is
present nearby.

E-24 RING MAIN UNITS (RMU):

1. All earth switches in a Ring Main Unit can be

closed only after opening respective line switch
disconnector.

2. Cable back charge indicators are provided to draw

attention to avoid accidentally grounding a charged

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 cable. Also cable back charge indicator voltage is
used for checking phasing of both incomers safely.

3. SF6 gas indicator shows safe operating pressure.

4. The sheet metal cover of incomer cable

compartment and fuse compartment can be
removed only after the respective earth switch is
closed, and vice versa i.e. ground switch cannot be
opened unless the covers are in place and locked.

E-25 AIR BLAST CIRCUIT BREAKERS

High voltage air blast circuit breakers close back

automatically when the air pressure drops to a pre-
set value. The breaker should be isolated
whenever the equipment connected to this breaker
or the breaker itself is given out for maintenance.
The isolation should be effected without time delay
after the breaker is opened out.

E-26 SCADA

1. SCADA systems are used for monitoring and

control of switchyard equipment at Generating and
Receiving Stations. They also provide a user
interface for the purpose of monitoring and
controlling Generating Units.
Every SCADA System has the following essential
components.

 Master Computers along-with peripherals

 Front End Processors
 RTU along-with Input/output modules

2. All the above components are located in the

Control Rooms, Switchyards or in Turbine /
Generator rooms. General safety precautions as
outlined in safety manual should be followed while
working on this equipment.

3. As the system uses electronic circuits, it is

essential that proper safety strap is wrapped on the
hand (with other end connected to ground) of the
personnel while working on these circuits.

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4. The Master Computers and Front End Processors
use an auxiliary supply of 230 V AC.

5. The peripherals of the Master Computer, RTU and

the input/output modules use an auxiliary supply of
48 Volts DC. This voltage is also used for contact
wetting purpose for digital inputs. The
transducers/energy meters use an auxiliary supply
of 48/110/220 Volts DC.

6. Positive terminal of Station DC Voltage(230/110 /48

Volts) is routed through the contacts of output
relays connected to Digital Output Cards of SCADA
for Trip and close commands.

7. CT inputs (1 Amp or 5 Amp) and PT inputs (415 /

110 Volts) are wired to the transducers/energy
meters for the purpose of providing analogue
parameters on SCADA.

8 It is essential that proper drawings of the panels,

circuits and Interconnecting cable schedule to
identify source and destinations of the cables are
available with the personnel before starting any
work. A written step by step procedure for the job to
be done on SCADA equipment, approved by the
concerned authorities, should also be available with
the working personnel.

9 The safety tagging rules are applicable for any

work on SCADA equipment. Maintenance
Engineer of the Division/Station will request for
appropriate safety tag and obtain it from the
concerned authority before actual work is started.

10 The personnel carrying out the work will inform the

Maintenance Engineer of the division at least two
days in advance providing following details:
 The name/ number of the equipment
 Time duration of work
 Specific jobs to be performed

(a) Maintenance Engineer in turn will request the

operating authority to issue the appropriate safety
tag.

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(b) Personnel carrying out the task will record above
details in SCADA register kept in the Control
Room.

(c) If the task involves testing of control outputs, relevant

control output links will be dropped prior to the
testing.

(d) Record the results of the tests carried out, if any.

Confirm in presence of maintenance engineer that
the system is functioning normal.

(e) Make the relevant output links through after confirming

that there are no pending commands and there are
no “Command Fail” messages in the alarm list
indicating that an unwarranted Command was
issued.

E-27 COMMUNICATION

1. All the communication equipment are located in the

Carrier room, Relay room or in Control room.
General safety precautions of this safety manual
should be followed while working on this
equipment.

2. As the system uses electronic circuits, it is

essential that proper safety strap is wrapped on the
hand (with other end connected to ground) of the
personnel while working on these circuits.

3. The 48 V battery chargers for the above equipment

use an auxiliary supply of 230 V AC.

4. The peripherals of the Fibre Optics system,

Microwave system and PLCC and Broad Band
system use an auxiliary supply of 48 V DC. This
voltage is also used for contact wetting purpose for
digital inputs. The 4 Wire E and M circuits use an
auxiliary supply of 12/24/48 Volts and the
protection coupler modules use an auxiliary supply
of 110/220 Volts DC.

5. CT and PT inputs and switchyard conditions are

wired for the purpose of providing analogue and
digital parameters on SCADA and SMS RTU.
These parameters are in turn wired with the data
module of FOP/MW/PLCC/Broad Band system.

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6 It is essential that proper drawings of the panels,
circuits and Interconnecting cable schedule to
identify source and destinations of the cables are
available with the personnel before starting any
work. A written step by step procedure for the job to
be done on communication equipment, approved
by the concerned authorities, should also be
available with the working personnel.

7 The safety tagging rules are applicable for any

work on communication equipment. Maintenance
Engineer of the Division/Station will request for
appropriate safety tag and obtain it from the
concerned authority before actual work is started.

8. The personnel carrying out the work will inform the

maintenance engineer of the division at least two
days in advance providing following details:
 The name/ number of the equipment
 Time duration of work
 Specific jobs to be performed

(a) Maintenance engineer in turn will request the

operating authority to issue the appropriate safety
tag.

(b) Personnel carrying out the task will record above

details in communication register kept in the
Control Room.

(c) If the task involves testing of control outputs,

relevant control output links will be dropped prior to
the testing.

(d) Record the results of the tests carried out, if any.

Confirm in presence of maintenance engineer that
the system is functioning normal.

(e) Make the relevant output links through after

confirming that there are no pending commands
and there are no “Command Fail” messages in the
alarm list indicating that an unwarranted Command
was issued.

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9 Working on transmission tower joint boxes may
require outage of 220/110/33/22 KV line. The
working parties will co-ordinate the outage
requirements with the concerned departments
after providing details of work.

10 No person should go near any equipment or

inspect or do any kind of check or test without
taking proper permission from the operating
authority however small the work may be.

W Work Permit System :

1. All activities such as working at heights

fragile roof tops, confined spaces or any
other work in operational area that involves
generation of hot work, open flame, spark
etc. are considered as critical & safety
officers clearance will be sought.

2. Format for work permit will have a specific

checklist to indicate various criticalities
against each work.

3. These formats may vary from division to

division according to the nature and scope
of work without diluting the safety
precautions to be taken for each type of
work.

ST-1 FUNDAMENTAL SAFETY TAGGING RULE

All lines and equipment must be considered

energised unless tags are placed to designate
other conditions.

ST-2 REQUIREMENTS OF SAFETY TAGGING

SYSTEM

(1) The Safety Tagging System is intended to meet

three principal requirements of safety.

(a) Protect personnel at work under all

conditions.

(b) Protect equipment from damage.

(c) Designate abnormal conditions.

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ST-3 DESIRABLE CHARACTERISTICS OF TAGGING
SYSTEM

(1) The tagging system should apply with equal force

to both electrical and mechanical equipment, broad
enough to cover every condition that can arise and
applicable throughout the entire organisation.

(2) The system should be easily understood and

reasonably simple in application. A system that is
too elaborate becomes burdensome and
encourages unsafe short cuts. Simplicity, however,
should not be obtained at the expense of safety.

(3) It should be workable from viewpoints of both the

issuing authority and workmen.

(4) Maximum protection will be obtained by the use of

more than one type of tag, each of which has a
single purpose. The name of each tag should
indicate its general use. Each tag should be of
different colour.

(5) In order to obtain uniformity in safety and tagging

practices, each station should incorporate in its
station rules, the step by step operations to
safeguard every station equipment for maintenance
work and should list the locations where tags are to
be located. In case of abnormal switching
operations or conditions of work regarding special
tagging system, a scheme will be prepared in
advance in consultation with Load Despatch
Department/Division head.

(6) To ensure correct functioning of the tagging

system, the placement and removal of tags will be
the sole responsibility of the operating organisation
in charge. Similarly, tags issued to a working party
should be handled by the person concerned only.
Any person delegating the authority to handle the
tags to an unauthorised person as well as the
unauthorised person himself would be liable for
disciplinary action.

ST-4 TAGS

(1) The tags designed to meet requirement outlined in

Section ST-3 are as follows :

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 RELEASE : Pink tag, with
ORDER blue printing.
:
RELEASE RELEASE : Red tag, with
TAGS PERMIT black printing

RELEASE : Thin yellow

PERMIT paper with
Black printing.

CAUTION : White tag with

ORDER red printing

OPERATING ; Green tag with

PERMIT black printing

CONSTRUC- : Blue tag with

TION ORDER black printing

The first three tags listed function as one tag and

the last being used for construction or
reconstruction leaves only three types of tags for
system operation purpose.

(2) The tags are of shipping tag style, about seven by

15 Cms. Each tag has a string for attaching it to
equipment. The tags shall never be attached to

Energise equipment or to locations where they can

get energised. Similarly a tag should not be placed
close to an energised equipment in crowded
locations, such that the person removing or placing
the tag is required to approach the energised
equipment closer than the safe distances. Special
arrangements may be made so that they can be
placed and removed safely.

(3) Transparent plastic envelopes will protect tags that

are to be placed outdoors during wet weather.

(4) Space is provided on each tag for recording a tag

number, the station name, date, time, line or
equipment covered, person to whom issued,
person placing, person ordering and reason for
placing. A brief summary of the rules covering its
use is printed on the back of each tag. All tags
must be completely filled out before being placed.

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(5) Placement and removal of the tags must be done
by authorised personnel of operating organisation
in-charge. Persons on probation or under training
apprentices, trainees, shift mazdoors, etc. are not
authorised to place, remove or fill up safety tags.

ST-4 RESPONSIBILITIES INVOLVED UNDER THE

TAGGING SYSTEM

Three parties are generally required for the correct

functioning of the tagging system. The names of these
parties appear on the tags and they are as follows:

i) The party authorising operations and the

commencement of outage, whose name
appears under “Ordered by”

(ii) The party carrying out the actual operations

and placing the tags, whose name appears
under “Placed by”

(iii) The party who would be taking over the

equipment for work or tests etc., whose
name appears under “Issued to”

The functions and responsibilities of these parties

are defined below:

(i) The Authorising Party:

Party authorising operations and the outage

will be the party under whose charge or
jurisdiction the equipment concerned is
placed e.g. the party may be the Load
Despatcher, Station In-charge, Divisional In-
charge,In-charge-Transmission/Distribution,
or their qualified representatives. The
names of the authorising parties should
always appear in the Station Rules or
operating instructions. This party will be
responsible for the following functions:

(a) Pre-planning of the outage.

He/she will ensure that due to the outage

there shall be no interruption in supply or
process or lowering of standard of service
or security of power supply. If any of these
factors are involved, he/she will obtain prior
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 concurrence of the consumers or parties
concerned. He/she will also inform all
concerned parties of the outage soon after it
is arranged preferably one or two days in
advance.

(b) Planning of operations.

He/she will check if operating instructions

for the outage are available to the operating
organisation. If not, he/she will issue such
instructions in advance of the outage.

(c) Checking the Working Party

He/she will check that the party taking over

the equipment is included in the tagging list.
If not, and if in his opinion the working party
is capable of undertaking the work, he/she
will arrange with the concurrence of the
Station In-charge to have the party’s name
included in the tagging list before handing
over the equipment to him/her.

He/she will also check that the working

party is familiar with all operations that are
to be carried out for isolating and
safeguarding the equipment.

(d) Issuing of the Release Permit

He/she will normally hand over the

equipment to the working party. Before
handing over, he/she will call the party
taking over the equipment in person or on
phone and advise him/her of the isolation
and safeguarding of the equipment that is
carried out. He/She will ask the working
party to confirm that he/she is satisfied with
the safety precautions taken on the
equipment and inform the working party of
the conditions under which the outage has
been sanctioned viz. Duration, time to clear
in emergency, etc. He/she would appraise
him/her of abnormal conditions, if any, that
may exist on the equipment being handed
over.

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 In case the working party is close to the
operating party, then the ordering party may
authorise the operating party to hand over
the equipment, e.g. Load Despatcher may
authorise the control room engineer on duty
to hand over a turbo-generator to a working
party. In such a case the operating party
should follow the above-mentioned
procedure of handing over.

(e) Cancellation of an outage.

The ordering party is empowered to cancel

the outage at any time either before its
commencement or during the outage
period, if system or station conditions so
require. In the event of such cancellation,
the working party will be asked to clear the
equipment within the period prescribed for
clearing the equipment in emergency. It will
therefore be necessary for the ordering
party to be vigilant and watch carefully the
progress of work on the equipment in
relation to the system or station operating
condition.

(f) Obtaining Clear

When the working party gives clear, the

ordering party will check that the switching
conditions of the equipment are normal for
taking equipment back in service. If any
abnormal conditions still exist, he/she will
issue the necessary caution order indicating
the restrictions and ensure that adequate
tagging is carried out by the operating party.

(ii) The Operating Party

The operating party is normally the control room

engineer on duty of the operations. The operating
party will be responsible for the following :

(a) Cross check the outage.

To study the conditions under which the

outage is authorised by the ordering party
and ensure that the system or station
operation is not affected by the outage. The
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 operating party will keep a vigilant watch on
the system or station conditions prior to and
during the course of the outage and in case
the outage is likely to affect the system or
the station he will advise the ordering or
authorising party of the same without delay.

(b) Planning of Operations.

The operating party will ensure that clear

operating and switching instructions are
available for the planned outage. If not,
he/she will request the ordering party to
issue them in advance.

The operating party will carry out all

operations as per operating instructions
issued and the tagging as per Station rules.
He/She will bring to the attention of the
ordering party if any amendment is required
in the operating instructions and the Station
rules due to changed operating conditions.

(c) Verifying the Working party.

The operating party will ensure that the

equipment is never handed over to any
party not included in the tagging list.

He/She will appraise the working party of all

the switching operations carried out to
isolate and safeguard the equipment and
obtain confirmation from him/her that the
safety precautions taken are adequate and
satisfactory.

He/She will study the scope of the work to

be carried out by the working party, and if
required he/she may ask the working party
to carry out additional safety precautions
like cordoning off the working area, placing
danger boards, additional grounds etc.

(d) Cancellation of Outages.

In case of severe system or station

emergency during which no delay is
permissible in cancelling the outage, the
operating party may cancel the outage and
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 advise the ordering party as soon as
possible thereafter of the cancellation under
emergency conditions.

(e) Obtaining Clear.

When the working party gives clear, the

operating party will check that the electrical
and mechanical condition of the equipment
under his/her charge is normal i.e. as it was
at the time of handing over and that all
grounds and safeguards placed by the
working party are removed. He/She will
also find out from the working party if any
abnormal operating conditions exist and if
so he/she will prepare suitable caution
orders for them under instructions from the
ordering party.

If everything is clear, the operating party will

take the equipment into service as per
station rules and operating instructions,
grounds and safeguards placed by the
working party are cleared. He/she will also
find out from the working party if any
abnormal operating conditions exist and if
so he/she will prepare suitable caution
orders for them under instructions from the
ordering party.

If everything is clear, the operating party will

take the equipment into service as per
station rules and operating instructions,
after obtaining authorisation from the
ordering party.

(iii) The Working Party :

The working party will be a person whose name is

included in the tagging list of the station or division
concerned and who is familiar with all operations
that are to be carried out for isolating and
safeguarding the equipment.

The working party will have the following

responsibilities:

(a) Preplanning of the Outage and Operations.

Page 93 of 146
 The working party will fully familiarise with
the operations that are planned in
connection with the outage. He/she will be
responsible for checking that the isolation
and safeguarding that is proposed to be
carried out would be adequate and
sufficient for the work planned. If any
special safeguarding or tagging is required
he/she should advise it to the operating
party.

(b) Taking Over the equipment.

Before taking over the equipment, the

working party will visually inspect all
points of isolation, safeguarding and
tagging of the equipment. If the working
party is away from the operating party and
is taking over the equipment on telephone,
he/she should ask the operating party of all
details of isolation, safeguarding and
tagging to satisfy himself/herself of the
safety precautions taken and should also
obtain a third party confirmation of the
same. If he/she finds that the operations
carried out do not provide adequate safety,
he/she should ask the operating party to
carry out further isolation and tagging as per
his/her requirements.

He/she will be fully responsible for ensuring

that safe conditions of working exist for all
personnel working under him/her & will take
all necessary precautions like placing
grounds at the location of work, placing
danger boards at necessary locations and
cordoning off safe area etc.

Before taking over he/she will carefully note

the conditions under which the outage is
arranged and will work within those
restrictions. He/she will advise the crew
working under him/her of the exact location,
nature and scope of the work and the safety
precautions to be taken. The crew should
not be authorised to work unless this
briefing is adequately carried out at the
location of work.

Page 94 of 146
 (c) Giving Clear.

On completion of the work and before

clearing the equipment, he/she will restore
the equipment to the same operating
condition electrically and mechanically in
which he/she had taken it over, by removing
grounds placed, reconnecting jumpers that
may have been removed etc.

If any abnormal conditions exist on the

equipment, the operating party will be
advised and will have the necessary caution
order issued. He/she should advise the
crew working under him to clear away from
the work location prior to giving clear to the
operating party.

The above mechanics of the safety tagging

provides that each phase of the outage is
double checked viz. Preplanning, switching
operations, safety measures, clearing etc.
Thus if one party omits a particular detail of
an outage, it is detected and corrected by
the other party.

ST-5 RELEASE ORDER

(1) PURPOSE

This tag is used to protect personnel at work on de-

energised lines or equipment. The word ‘’release’’
was adopted from the thought “a line or equipment
is released from service”. The line or equipment
covered by this tag is said to be released from
service and the persons working under it are said
to have obtained a Release.

(2) ISSUING OF RELEASE

THE RELEASE SHALL NEVER BE IN FORCE ON

ANY ENERGISED LINE OR EQUIPMENT. LINES
OR EQUIPMENT UPON WHICH RELEASE TAGS
ALONE ARE ISSUED SHALL NEVER BE
ENERGISED OR OPERATED BY ANY PERSON
UNTIL ALL PERSONS HOLDING RELEASES
HAVE REPORTED CLEAR.
Page 95 of 146
 Note: The word ALONE signifies that the
equipment under release should not be
energised by internal or external source of
energy. However, it can be energised
under operating permit issued along with
the release order to one party only for trial
operations.

The word energised as used in tagging system

refers to any electrical or mechanical force
including steam, air, water, fluids, gas that might be
dangerous to persons coming into contact with it. It
is not permissible to energise the equipment
released under “Release Order” tag from any
source of power whether normal or external like
mechanical or electrical charging.

Whenever the meggering of an electrical

equipment does not require the removal of all
safety precautions taken under the “Release Order”
and when the equipment being meggered is not
likely to build up dangerous electric charge, megger
tests upto a voltage of 1000 volts are permitted
under the “Release Order”, without the need for an
“Operating Permit”.

A “Release“ on any equipment shall not be issued

until (I) a visible isolation has been provided to
each possible source of energy, (ii) all such
isolations have been properly checked and tagged
regardless of their position during normal operation
(iii) it is safeguarded and (iv) all safety precautions
are taken.

(3) REPORTING CLEAR

A Release Order is issued to protect personnel at

work. The supervisor to whom the Release is
issued, when not working or proceeding away from
the scene of work, must clear his personnel and
report the same even though the work is not
completed and the equipment is not available for
service. This is to forbid the men from working
without supervision or authority during the absence
of their supervisor. When an equipment is handed
over to the working party for the work, it is to be
treated as a continuous one and no reporting of

Page 96 of 146
 clear for temporary short stopping of work is
necessary.

No equipment that has been cleared should be

energised unless all release notices are collected
and cross checked against the entries on the
“Release Order or Orders”.

The working party while giving clear for a released

equipment shall restore it to the same conditions as
it was when the equipment was handed over for
work. Any difference in conditions should be
brought to the attention of the operating party at the
time of giving clear and should request for
necessary Caution Order.

(4) MULTIPLE RELEASES

A Release is issued to only one person who is

responsible for the safety of all personnel working
under him/her on the job until he/she reports clear.
If a second person wants to work on the same
equipment and cannot work under the first person,
he/she must obtain an entirely separate Release in
his/her own name.

No person may delegate any other person to

obtain a Release for him/her or report clear for
him/her. A Release is non-transferable. If the
holder of a Release desires to leave the work and
have it continued by another person, he/she must
have a new Release issued to him/her. If the
working party is not available and equipment is to
be cleared in emergency, the divisional
head/department in charge is authorised to give
clear on behalf of working party after thorough
checking.

Multiple releases shall not be issued for an

equipment whenever the equipment is released
to one working party along with an operating
permit.

When multiple releases are issued on an

equipment it will be the responsibility of the
Supervisor of working party to ensure that the work
of one party does not interfere with or endanger the
crew of the other party.

Page 97 of 146
 Whenever multiple outages at a station are planned
it will be the duty of the operating party and the
working parties concerned to plan and arrange the
timing of the operations in such a manner that the
operating party can carry out the sequence of the
switching operations for the outages without undue
interruptions.

RELEASE NOTICE

(1) PURPOSE AND FILLING OF TAG

Switching operations for release of an equipment

usually require placing several tags. If Release
Orders only were issued, the amount of writing
required would become burdensome and placing of
these tags cumbersome. To eliminate these
difficulties, an auxiliary miniature tag known as
Release Notice is used at all points except the
master control of equipment in a station. The tag
requires only the recording of the number of
Release, the name of line or equipment and the
person to whom the release is issued with the
dateline. When an outage is required at short
notice for a short duration, the Release Notice tags
need bear only the Release number and date.

(2) CROSS-CHECK

Space is provided on the back of the ‘Release

Order’ in which the operating party indicates each
point to which a ‘Release Notice’ is attached. The
number of Release Notices entered on the Release
Order must tally with the number of Release
Notices removed before the equipment is returned
to service.

(3) WEATHERPROOF ENVELOPES.

Miniature Release notice tags are inserted in fully

covered plastic envelopes to make them water
proof for outdoor use and removable. The same
weatherproof Release Notice tag can be used with
different miniature tags for different outages.

Miniature Release Notice tags alone can be used in

crowded locations like control boards, test links or
terminal boxes where the shipping size Release
Page 98 of 146
 Notice tags prove too large and unwieldy and have
the same significance as the full sized release
notice tag.

(4) “MEN AT WORK” NOTICE

At consumer substations, where tagging system as

laid down in this manual cannot be fully
implemented and where operations are carried out
by consumer operators only, Notices 18” x 12” in
size with the following inscriptions shall be used
instead of the “Release Notice” Tags.

TATA POWER

RELEASE NOTICE
MEN AT WORK
DO NOT CLOSE
THIS SWITCH

The board will be pink in colour with black lettering.

“Men at Work” and “Caution” Notices are printed on

either side of the same board. Working party
should ensure that the correct side of the tag is
displayed on the operating handle of the switch.

RELEASE PERMIT

(1) PURPOSE

When a release is issued on equipment at attended

stations, a replica in the form of a Release Permit is
issued to the person obtaining the Release. It is
desirable for the person receiving the Release
Permit to accompany the operating party
performing the switching operations and check
each operation or check the switchings done and
tags placed before taking over the equipment.

The Release Permit must be signed and turned

over to the operation personnel when reporting
clear with appropriate remarks.

(2) FILLING OF PERMIT

The front of the ‘Release Permit’ tag is a duplicate

of the front of the Release Order tag and is printed
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 on a thin paper with a gummed edge by which it is
attached to the Release Order Tag. The two Tags
can be filled out at the same time with carbon
paper.

ST-6 CAUTION ORDER

(1) PURPOSE

Caution Order tag is used to indicate abnormal

conditions such as failure, hazards, relay
inoperative, equipment not in service, temporary
changes in operating rules etc. This tag can be
placed on either energised or de-energised
equipment. This Caution Order tag may be issued
either to a person or placed on equipment to
designate a particular operating condition.

(2) DESIGNATING EQUIPMENT FAILURE/DEFECT.

Equipment failures/defects are designated by

placing Caution Order tags on control switches,
valves etc. until the equipment is taken out for
inspection and repairs.

(3) DESIGNATING HAZARDS, CAUTIONING

AGAINST OPERATION OF SWITCHES,
DISCONNECTS, VALVES AND PUMPS (WHICH
PROHIBITS THE OPERATION OF EQUIPMENT)

EXAMPLE (WHEREVER APPLICABLE)

At the Generating and Receiving stations, where

the operating personnel has to leave the control
room and go to the switchyard to open or close
disconnects after opening or before closing circuit
breaker, a blank Caution Order tag is placed on
switchboard control of the breaker. This way, the
tag not only protects the operating party from
operation of the breaker by another person but also
directs the attention to the proper control switch
upon his/her return.

(4) ISSUING TO A PERSON

The Caution Order may be issued to a person

when he/she is working near energised lines or
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 equipment and might accidentally contact or foul
the equipment.

While getting a caution order issued, the working

party should indicate to the operating party the
possible hazards by way of nature of caution and
by way of nature of work.

For transmission lines with auto-re-closing facility,

when a Caution Order of this nature is issued, the
re-closing gear is made inoperative.

It should be clearly understood that A CAUTION

ORDER ISSUED TO A PERSON NEITHER
AUTHORISES HIM/HER TO OPERATE THE
EQUIPMENT NOR DOES IT PROTECT HIM/HER
FROM OPERATION OR ENERGISING OF THE
EQUIPMENT EXCEPT WHEN AN AUTOMATIC
TRIP OUT OCCURS.

(5) “Caution Notices” at Consumer Substations.

At consumer Substations, where tagging system as

laid down in this manual is not in force and where
operations are carried out by consumer operators,
“Caution” Notice boards 18 x 12 cms in size with
the following inscription are to be used in place of
“Caution Order” tags :

TATA POWER

CAUTION NOTICE
DO NOT CLOSE
THIS SWITCH

The notice board will be with white background and

red lettering.

These caution notices will be placed on the

operating handles of disconnects or switches which
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 are open under normal and abnormal operating
conditions to remind consumer operators that the
switches are to be operated only under instructions
from Tata Control room operation engineers.

ST-7 OPERATING PERMIT

(1) PURPOSE

One of the fundamental requirements of operation

is that no equipment be operated by any person
other than the operating personnel authorised to do
so. The operating personnel or any other person is
prohibited from operating any equipment upon
which persons are working. Both the Release
Order and Caution Order forbid this.

Under certain conditions such as relay testing and

checking breaker operations etc, the equipment
needs to be operated. This tag authorises such an
operation.

An operating permit is also issued to carry out hot

line work, meggering above 1 kV, hi-pot-test,
current injection or any other test, which is likely to
inject or induce high voltage and dangerous electric
charge, relay testing, trial tripping of live equipment,
machine slip ring grinding, valve operation, trial run
of machine and its adjustments after maintenance,
operation of valves / gates, test charging of
equipment when requested by working party,
changing machine brushes in running condition etc.

(2) ISSUING RULE

The Operating Permit may be placed on either

energised or de-energised equipment. If used on
de-energised equipment, it can be placed either
alone or with a Release Order. When used in
conjunction with a Release Order, the Operating
Permit may authorise operations, which would
energise the equipment or a line from a source of
power which is normal or external for trials only.

Equipment to which an Operating Permit is

attached may be operated only by or under
personal direction of the person to whom it is
issued. But this person is restricted by the rules
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 that no person except the operation personnel may
operate the equipment from a switchboard.

Only one operating permit will be issued at a

time for an equipment. If an equipment is
released to more than one person under
separate Release Orders, Operating Permit
cannot be issued.

When used in conjunction with a ‘Release order’,

the operating permit authorises trial operations of
certain equipment, especially in thermal plants,
where the equipment is energised from a source of
power which is normal or external.

ST-8 CONSTRUCTION ORDER

(1) PURPOSE

During construction work, there are times when

work is being performed on new or removed
equipment that is in the vicinity of equipment in
operation. Although normal operating rules cannot
be applied to such work, it is necessary to
designate the equipment under construction in
order to prevent accidental work on the wrong
equipment. The tag used for this purpose, known
as the Construction Order, is not really an
operating tag but is intended for use by the
construction organisation that may not be familiar
with the operating safety rules. A Construction
Order will not be issued unless the equipment
involved is isolated from all possible sources of
power by an opening other than normal isolating
equipment viz. removing jumpers etc. Also all
control and protection circuits are isolated and
links dropped. This means, for example, that when
the final leads are to be connected to a circuit
breaker or set of disconnects to a bus, the
Construction Order will no longer be valid and a
Release Order must be obtained for any further
work. The placing of a Construction Order
removes the equipment from normal jurisdiction of
operating organisation and permits the construction
personnel to work on, move, operate, or energise
the equipment at will with the restriction that they
may not energise it from the existing system or
operate it from a switchboard in service which is
likely to lead to undesirable trippings.
Page 103 of 146
 Operating Permit during Construction Work :

When an equipment is under construction order,

there are occasions when hipoting is required. In
such cases an operating permit shall be issued for
the high potential testing activity to the same party
to whom construction order is issued. The hipot
activity is permitted only if it does not adversly
affect other equipment/task in the proximity. Only
one such operating permit for a particular hipot can
be issued at a time.

ST-9 RELEASE TAGS: TAGGING RULES AND

PROCEDURE FOR EQUIPMENT AND LINES.

(1) As a general rule, all equipment which affect overall

power supply reliability in case of Mumbai licensed
area are within jurisdiction of the Load Despatch
Department.
(2) The Divisions are equipped with lists of equipment
conforming to the above operational philosophy.

(3) No work shall be done on lines or equipment where

release is required for safe conduct of the work
until release has been applied for and lines and
equipment released in accordance with Rules and
Procedure outlined.

(4) During emergencies, the equipment may be taken

out by the concerned operating party. Once the
equipment is out under emergency and isolated,
tags should be prepared and placed before
handing over the equipment to the Maintenance
Engineer for repairs, inspection etc.

(5) The personnel in tagging list should be thoroughly

familiar with the tagging system and plant layout.

(6) It is the duty of the Authorising Party to interpret

and rigidly enforce rules to keep an accurate record
of all orders, checks and circumstances of all work
carried on under the rules and to assist employees
and others to interpret and comply with the rules.

(7) It is the duty of the operation personnel to assist

authorising party in rigidly enforcing rules and to
keep an accurate record of all orders, checks and
circumstances of work carried out.

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(8) All circuits and equipment shall be considered ‘live’
until released by the proper authority.

The Authorising Party shall require the following

information of the outage:

(i) Equipment to be released.

(ii) Nature of work.
(iii) Time and date of commencement of
outage.
(iv) Duration of outage.
(v) Names of the person taking over the
equipment.
(vi) Time to clear the equipment in emergency.
(vii) Any special safety precautions necessary.

(9) The Authorising party shall investigate conditions

and have those consumers notified whose service
will be interfered with and also arrange, wherever
possible, alternative feeds to consumers affected.
If in his/her judgement the time and date asked for
are suitable, Release will be arranged as required.
Otherwise, considering the system operating
conditions, alternative time and date will be
advised. As soon as the outage programme is
decided, all the parties concerned will be informed
by a Telephone/E-mail message at least one day in
advance. The Telepnone/E-mail message will
contain the relevant details when an outage is
arranged at short notice, the information to all the
concerned parties will be conveyed on phone.

(10) All instructions and messages relating to the

operation and switching given over the telephone
shall be repeated in full to the sender to ensure that
the message has been accurately understood.

(11) In order to obtain uniformity in safety and tagging

procedures, each station will incorporate in its
Station Rules, the step by step operation to
safeguard every station equipment to maintenance
work and the tagging scheme to be followed. In
abnormal switching operations requiring special
tagging, a scheme will be prepared in advance in
consultation with the authorising party.

(12) To ensure correct functioning of the tagging

system, the placement and removal of tags will

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 remain sole responsibility of the Operation in
charge/representatives. Tags issued to a working
party should be handled only by the person for
whom it is issued. If any person from the Operating
party or from the tagging list for whom equipment is
tagged, is observed delegating such authority to
others he/she will be liable for disciplinary action.
Any unauthorised person, who is observed
handling, tampering or making entries on safety
tags, will render himself/herself liable for
disciplinary action. In emergency, if an exception
has been made, the Local Authorising party should
be advised without delay.

(13) At the scheduled time, the station operating party

will carry out the necessary switching operations in
proper sequence to de-energise the line or
equipment as per operating instructions.

(14) After opening out the circuit breaker and before

operating any disconnects, the operator shall
attach a blank Caution Order tag to breaker
switchboard control switch. The operator will then
proceed to circuit breaker and after making visually
sure that it is open, will open the disconnects to
isolate the equipment and place Release Notices
on each of the disconnects (including Transfer Bus
disconnects, if any) and other sources of energising
the line or equipment and check by approved
methods that the equipment or line is de-energised.

(15) If the apparatus or line is de-energised, the

operator will proceed to ground the apparatus. If a
grounding disconnect is provided he shall close the
disconnect and attach a Release Notice to its
operating lever. If no grounding disconnect is
provided, the operator shall request working party
to ground the equipment by means of an approved
3-wire grounding device. The connection to the
ground will be made first and that to the line or
equipment last. All the three phases will be
grounded.

The use of chains and defective grounding devices

is prohibited.

(16) Returning to the control room, the operator will

remove the Caution Order and attach a Release
Order to the control switch. He will then report to
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 the authorising party in detail all the operations that
he performed and the tags he placed.

(17) After receiving reports from all the operators about

having placed “Release Order Number’’ the
authorising party will call the person for whom the
equipment is tagged for and hand over the line or
equipment to him/her.

(18) In case work is to be carried within an attended

station, a ‘Release Permit’; will be issued to the
person for whom the equipment or line is tagged.

(19) Before starting work, the person for whom the line
or equipment is tagged shall check in the presence
of another person whether the line or equipment is
de-energised and effectively grounded by one or
more of the following methods:

(a) Electrically for electrical apparatus such as

glow detectors, neon testers voltage
indicating devices etc.
(b) Visually such as open disconnects, grounds
closed and locked whenever applicable,
main valves head on the drained out
penstocks etc.
(c) By Inspection of Release Order and
Release Notice tags.
(d) By checking with operator directly. Further,
the person in charge of work will be
cautious regarding any close clearances,
hazards or unusual conditions known or
suspected to exist. The working party, if
necessary, may provide own additional
temporary grounds on the line or
equipment, which is released. On placing
temporary grounds, care should be taken to
make the ground connections first and then
the connections to the line or equipment
afterwards.

(20) GIVING CLEAR

Before giving clear, the person in charge of work

shall make certain that all personnel are clear from
the work site, that equipment is in good condition,
that all temporary grounds placed by them have
been removed and all tools used on the job
accounted for. In removing temporary grounds,
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 care should be taken to remove the connection to
the line or equipment first and remove the ground
connection last. At the time of giving clear he will
specify his Release Number, name of line or
equipment and his own name.

In case a Release Permit has been issued to the

person in charge of work, the reverse side of the
permit will be filled and returned to the operating
party. If there is any difference in condition it should
be brought to the attention of the operating party at
the time of giving clear and necessary ‘caution
order’ issued.

(21) On receiving clearance, the authority as specified

in the operating instructions, will have the grounds
removed and ask the station to remove Release
Number for which the clearance is received After
removing the Release Notices, the Release Order
will be removed from the main control point.

(22) If there is more than one Release Notice attached

to any control point, only that Release Notice will
be removed which corresponds to the Release
Number and person from whom clearance has
been received.

(23) After removing the Release Order, the Operator

shall enter thereupon the name of the person who
removed the tag and the authority that ordered it to
be removed alongwith date and time.

(24) After all Release Orders attached to the main

control point have been removed, the equipment
will be taken into service as specified in the
operating instructions.

ST-10 RULES PERTAINING TO THE USE OF

OPERATING PERMIT (GREEN TAG)

(1) Whenever any person wants to carry out tests on

any equipment, like meggering, hipot test, current
injection test, or any other test which is likely to
inject or induce high voltage and dangerous electric
charge, relay testing or trial tripping of energised or
de-energised equipment like circuit breakers, valve
operations, trial run of machine and its
adjustments, operation of valves/gates etc he/she
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 shall apply for an operating Permit for the
equipment to the authorising party under whose
control the equipment may be situated.

(2) The person requiring to carry out the tests shall

furnish the following information when making an
application :

(a) Name of the equipment

(b) Exact nature of tests proposed to be carried
out
(c) Whether equipment is required to be de-
coupled,made dead and grounded before
carrying out the tests
(d) Time at which tests are proposed to be
carried out and duration.

(3) Authorisng party shall investigate conditions, and if,

in his/her judgement, such tests may be carried
out, permission will be granted.

(4) If the apparatus is required to be made dead and

grounded while carrying out the tests, it will be
necessary to obtain Release Order also in addition
to the Operating Permit.

(5) When the Operating Permit alone is issued to the

person, the equipment shall be considered live
equipment & no work except testing/trial operation
shall be done or allowed to be done on the
equipment.
(6) The person to whom the Operating Permit is issued
shall be responsible for safety of the personnel
working under him/her.

(7) Equipment, issued under an Operating Permit, is

under orders of the person for whom it is tagged
and may be energised or de-energised as per
his/her directives only.

An operating Permit shall never be issued to a

party if a release for the same equipment is already
issued to another party or vice versa.

(8) After the testing is completed, the person to whom

Operating Permit has been issued shall report clear
to the operating party. The tags will be removed
then and the equipment returned to normal service.
If the equipment is de-energised grounded and
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 covered by a Release Order, grounds will be
removed and necessary switching operations
carried out to take the equipment in service as per
operating instructions.

ST-11 SAFETY TAGGING: (ILLUSTRATIVE)

Case 1:

OUTAGE OF 220/132/110 KV INTERCONNECTING

BUSES:

There are instances in the system wherein electrical

equipment controlled by two or more control rooms are
connected to a common bus. Proper co-ordination and
utmost care are called for when the outages are planned &
executed on these buses. Approved step by step operating
instructions must be available in the associated control
rooms for carrying out all switching operations
sequentially.

Case 2:

OUTAGE OF INTERCONNECTING TIE LINES:

There are 220/110 KV interconnections with

MSEB/BSES in service in Mumbai area. A system of
issuing cross permit numbers is prevalent for the safe
conduct of these outages.

Case 3: Outages of thermal units

a. For Mechanical Works.

1. The outage of Thermal units will be arranged in

consultation with the authorising party/parties.
2. The machine will be taken out of service as per
written down procedure. Boiler may be remain on
HP / LP bypass (wherever applicable) or fire may
be killed as per the requirement of the outage jobs.
Machine will be on turning gear.
3. A Release order on the Unit will be issued to
Manager (Operation) on duty.
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4. Release notices will be placed at the following
locations :
 Generator breaker and isolators.
 Unit Auxiliary Transformer breakers racked out
and tagged.
 On Unit Control Board.
5. Operation personnel in unit control room will
arrange to issue releases for various associated
outage jobs after confirming isolations.
6. When work on various outage jobs gets completed,
the working party will return Release permit duly
signed. Unit control room engineers will check for
any abnormal remarks and arrange to remove all
Release notices from various locations.
7. Manger (Operation) on duty will give clear the
Release order on the Unit.
8. Normal unit start-up procedure will be followed to
take the unit back in service.

b. For Work on Generator.

1. Release order on the unit will be issued to

Manager (Operation) on duty.
2. Generator shall be at standstill condition.
3. The field circuit will be opened and isolated.
4. The generator winding is disconnected at the
generator terminals.
5. The unit control room engineers will arrange to
issue releases to various associated outage jobs
after confirming isolations.
6. The generator winding shall be discharged to
ground before commencing any work on the
generator.
7. Generator hydrogen will be purged by CO2 and
further purged by Instrument air. Generator shell
will be depressurised.
8. Generator seal oil system will be taken out of
service.
9. Main turbine lub. oil system will be taken out of
service.
10. Exciter rotor / stator connection will be
disconnected and dismantled.
11. Generator primary water system may be kept in
service.
12. When work on various outage jobs gets
completed, the working party will return Release
permit duly signed. Unit control room engineers

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 will check for any abnormal remarks and arrange to
remove all Release notices from various locations.
13 The unit control room engineers will ensure that the
protocol is duly filled and signed by all working
parties. The system will then be charged in
concurrence with the re-commissioning group. If no
abnormalities are found and all tests / trials / re-
commissioning checks carried are out, the system
will be taken back in service.
14 Manger (Operation) on duty will clear the Release
order on the Unit.
15 Normal unit start-up procedure will be followed to
take the unit back in service.

NOTE – Normally, for all the generator/UAT/GT side jobs,

the machine should be standstill i.e. off the turning gear.
However, when machine is on turning gear, some of the
jobs can be carried out under caution tags with proper
precautions taken such as grounding at proper location (s),
use of specified standard safety gloves and insulated
tools. Working party is responsible for taking safety
precautions while carrying out above jobs. The
authority concerned should thoroughly look into all safety
aspects before allowing personnel on the job. Following
are some of the jobs that may be carried out when the
machine is on turning gear with safety precautions
mentioned above: -
1. Cold line washing of GT bushings, coolers, gantry
insulators, isolators of GT breakers, CVTs & LAs.
2. CVT of GT replacement.
3. Attending to GT oil leaks.
4. GT /UAT oil topping up.
5. Investigations of GT / UAT primary protection tripping.
6. Generator Transformer HT clamp tightness checking.
7. GT breaker CT replacement.
8. GT breaker replacement.
9. GT unit replacement.
10. GT breaker gantry insulator replacement.
11. Work on GT isolators.
12. Generator jumper disconnection work before long
duration outage jobs.

c. For long duration outages

The outage of the thermal unit will be arranged in

consultation with the authorising party/parties. The
long duration outage will be generally for Main Turbine
overhaul / Generator overhaul / Boiler re-certification.

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1. The machine will be taken out of service as per
written down procedure. Boiler fire will be killed.
The Machine will be on turning gear to bring down
Main Turbine metal temperatures less than 100C.
Machine will be taken off turning gear thereafter.
2. A Release order on the Unit to Manager
(Operation) on duty will be issued.
3. Generator leads will be disconnected at the
terminals and exciter leads will be disconnected
from main exciter. Control and protection circuit
will be isolated and links will be dropped.
4. Once the release is issued to various working
parties, Lub oil, Seal oil and Hydrogen systems will
be taken out of service. Various other systems will
also be shut down and isolated as per requirement.
Release order and Release notices will be placed
at proper locations and then released equipment
will be handed over to working parties.
5. When work on various systems gets completed, the
working party will return Release permit duly
signed. Unit control room engineers will check for
any abnormal remarks and will arrange to remove
all Release notices from various locations.
6. The unit control room engineers will ensure that the
protocol is duly filled and signed by all working
parties. The system will then be charged in
concurrence with the re-commissioning group. If
no abnormalities are found and all tests / trials / re-
commissioning checks are carried out, the system
will be taken back in service.
7. Manger (Operation) on duty will clear the Release
order on the Unit.
8. Normal unit start-up procedure will be followed to
take the unit back in service.

Case-4 OUTAGE OF EQUIPMENT/AUXILIARY

SYSTEM AT THERMAL POWER
STATIONS

(1) When any equipment/auxiliary system is to be

released for maintenance, the impact on generation
on the unit and chances of a trip out need to be
assessed.

(2) The plant conditions should be brought to a level

suitable for taking the equipment/system out of
service causing minimum disturbance on the unit
system.

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(3) The equipment concerned should be first isolated
from the electrical side, if it is electrical power
operated.

(4) Subsequent isolations on steam/water/gas/air /

hydraulic, lubricating oil or fuel, should be carried
out as per station rules and as per requirements of
the working party.

(5) While isolating the equipment system, the following

should be considered.

(a) Possible effect on other associated

equipment.
(b) Changes it may cause in plant operating
conditions.
(c) Urgency of the nature of job and adverse
effects if the equipment is left out of service.

(6) Safety Tagging: Depending on the nature of

maintenance work, the tagging should be done for
all necessary switches and valves as per the
procedure described in the Safety Manual.

Case 5: Outage of Hydro generating units:

For annual overhaul:

1 The outage is arranged in consultation with the

authorising party/parties.
2 ‘On load draining’ of penstock is carried out as per
specified draining rate normally before disconnecting
the unit from the grid. In some cases the unit is first cut
out, shut down and then the penstock is drained.
3 Isolate the generator by opening its main bus side
isolator. (or rack out generator LT breaker) and shut
down the turbine on hydraulic side.
4 Control room engineer on duty will obtain a release
order for annual overhaul of the generator unit from the
authorising party, place proper safety tags as per
station operating instructions and hand over the
Turbine Generator unit to working party(s).

1. On receiving clear from the working party/parties,

check that all the releases on the unit are cleared.
2. Fill up the penstock as per station operation
procedure and synchronise the unit.

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3. A heat run test under operating permit is carried out
when stator winding resistance is found low
(especially during rainy/winter seasons.)

Note: For the outage of a pumped storage unit,

the outage procedure is similar to outage of any hydro unit.

In addition, spherical valve and draft tube will have to be
drained as per operating instructions and filled up before
taking the generator in service.

Case 6:

Outage of hydro units for longer duration:

1. The outage may be required for stator rewinding

and turbine major overhaul.

2. The penstock of the unit will be drained as stated

above.

3. The generator will be placed under a Release

Order for disconnecting the generator leads from
the circuit breaker and the field leads from the
generator field switch. Also control and protection
circuits are isolated or links dropped.

4. After item 3 are completed and release permit is

duly returned, the operating party obtains
construction order for further works on the
generator

5. When the construction work is over and the

generator leads and field leads are required to be
reconnected, the Construction Order is cleared and
a Release is obtained for reconnection of generator
leads.

6. Commissioning test are carried out under an

operating permit before clearing the set for service.

Case-7 OUTAGE OF A DISTRIBUTION FEEDER

FED FROM A RECEIVING STATION

(a) Outage of a Distribution feeder will be

arranged through the Distribution Division.

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 (b) Outage will be given as per the station
operating instructions for distribution
feeders/system.

Case-8 OUTAGE OF AN OVERHEAD 33/22/11KV

DISTRIBUTION FEEDER

The concerned stations prepare detailed outage

procedures. These procedures will be strictly
followed.

Case-9 MEGGER OR HIGH POTENTIAL TEST ON

A FEEDER CABLE: USE OF “RELEASE
ORDER” AND “OPERATING PERMIT”

(a) The work connected with the testing of a

cable can be divided into three parts:

(i) Isolating and safeguarding the cable

and connecting up testing
equipment.

(ii) Energising the cable from the testing

set for testing.

(iii) Discharging the static charge from

the cable and disconnecting the
testing equipment after the tests are
over.

The work stages (I) and (iii) will be

carried out under a ‘Release Order’
and the work of stage (ii) shall be
carried out under an ‘Operating
Permit’. The procedure will be
followed as per operating
instructions provided in station
operating instructions.

Case-10 PROTECTIVE RELAY TESTING :

“Caution Order” is necessary for keeping the inoperative.

In addition an “Operating Permit” is necessary, if tests are
to be carried out on the relay. “Release Order” is taken for
disconnected and shifting the relay. Operating permit is
taken for carrying out trial trippings of circuit breakers
through relays.
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Case-11 CLEARING OF PROTECTION SCHEMES
ONLY AFTER EQUIPMENT ARE TAKEN
IN LOAD SERVICE :

Working party should mention on the “Release Permit”,

while giving clear for the equipment that the specific
protection scheme has to be taken into service only after
the equipment has been taken in service and the tests /
checks on the protection equipment are completed.
However no primary protection will remain inoperative
while taking back any equipment in service. A “Caution
Order” will be issued stating the reason as above. The
“Caution Order” will be cleared only after all protection
schemes are tested and cleared.

ST-12 DISCUSSION ON USAGES OF SAFETY TAGS IN

DAY TO DAY OPERATIONS

(1) Use of “Release Order” and “Operating

Permit”:

After particular maintenance job is completed, the

working party may wish to check the performance
by operating the equipment for few times and make
some adjustments, if necessary (e.g. decoupled
trial run of pump-motor unit). An Operating Permit
can therefore, be issued to the working party along
with the existing Release Order provided that all
other Release orders are cleared except the one in
the name of the working party, who is also the
operating party.

(2) Use of “Construction Order” and “Caution

Order”:

Electric supply and compressed air supply of the

station may be provided to the equipment under
construction without adversely affecting the station
working condition.
Equipment being erected by construction party
under “Construction Order” may required to be
pressurised, charged or trial operations and
adjustments carried out before the final jumpers are
connected. E.g. the air pipeline with isolating valve
is installed and is ready for pressurising the new Air
Blast Circuit Breaker from the Station compressed
Air System. A Caution Order was placed on this
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 isolating valve since the time the station
compressed air supply was connected to this
breaker under construction. The construction party
will request the station/department for compressed
air supply requirement for trial operations of the
breaker. The concerned head will arrange to
monitor the air supply & pressure during the trial
operations of the breaker and then request the
operation department to issue a Caution Order to
construction party with instructions, that the station
air supply will not be allowed to drop below a
certain pressure during the trial operation of the
breaker. This will be then co-ordinated with
engineer on duty. The Operation Engineer will then
open air valve for the breaker under direction of
Construction Supervisor to pressurise the breaker.

The Construction Supervisor will take precautions

while operating the breaker that the station
compressed airs supply pressure is maintained at
the required safe value.

(3) Work on Bus Fault Relay/ Current Injection

Tests – Use of “Caution Order and Operating
Permit”

Caution order is necessary for keeping it on the bus

fault relay as it is made inoperative for Testing
work. In addition an Operating Permit is also
issued to the working party, if the tests are to be
carried out on the relay. Instead of Operating
Permit, a Release Order may be required to be
issued if the relay is to be disconnected for shifting
etc. The Operating Permit or Release Order will
depend upon the nature of the work.

(4) Equipment in Service – Use of Caution Order :

A Caution order is issued to the control room

engineer on duty when certain jobs are done on an
equipment so that he does not commission the
equipment, if it trips out unless clearance is
obtained from the concerned working party. A
caution order is also issued to the working party so
that he works at a safe distance from the
line/bus/equipment.

(5) Hot Line Changing of an Insulator – Use of a

Caution Order & Operating Permit :
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 Under Caution Order, the control room engineer on
duty will make the auto-reclosure of the line
inoperative. He is prohibited from charging the
line/equipment in case it trips out unless clearance
is obtained from the concerned working party.
Operating Permit is issued to the working party for
changing the insulators etc. under hot line
conditions with hot line tools.

(6) Starting a hydro unit after Routine Maintenance

or Overhaul – Use of Operating Permit &
Release Order” :

If the unit has to be started for trial operations,

adjustments etc. the Release Order should be
cleared since the penstocks, turbines are
hydraulically energised. Operating Permit should
be issued for starting the set for trial purposes,
adjustments, observation, etc.

(7) Still Water condition in Headworks – Use of

Caution Order, Operating Permit and Release
Order :

Under Caution Order, the control room engineer on

duty will maintain still water condition by cutting out
sets/exciters etc. or locking the sets at no loads.
An Operating Permit should be issued to the
working party for lowering or lifting the stop logs,
gates, etc. Release order should be issued to the
working party for working in still water condition.

(8) Cleaning of Slip rings/Replacement of Exciter

brushes, Grinding of slip rings of a Generator –
Use of Caution Order :

Under the caution order, protections such as rotor

earth fault will be made inoperative for cleaning slip
rings, replacement of exciter brushes or slip ring
grinding.

CONSTRUCTION:

C-1 SCAFFOLDS

(1) Scaffolds shall be built of sound material, securely

fastened, and be capable of supporting four times
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 the combined weight of men and materials which
may be placed on them.

(2) Wood planks used in scaffolds should be not less

than ten (10) inches wide and two (2) inches thick,
and shall not extend beyond the outer supports
more than twelve (12) inches nor less than six (6)
inches and the planks should be securely fastened
down. Wooden planks without any nails projecting
should be used; similarly planks or ballies with
cracks should not be used for scaffolding purpose.

(3) Guard rails and toe boards shall be installed on all

scaffolds that are ten (10) feet or more in height,
and on all scaffolds immediately adjacent to
excavations, deep-water, machinery, or other
sources of danger.

C-2 RIGGING AND HOISTING:

(1) Man in charge of working party shall be responsible

for the safe loading and use of ropes, chains,
cables, slings, jacks, skids and other hoisting and
rigging apparatus. In no case shall such equipment
be used until the supervisor has determined that it
is free from defects and safe for use.

(2) Before operating crane, derrick or other hoisting

equipment, the operator should sound warning and
accept only one person’s signal to start raising,
lowering or swinging load. However, the operator
shall stop immediately upon signal from anyone.

(3) Never place yourselves near cables under tension,

and under no condition within the angle formed by
ropes or cables. When anyone is in this or other
dangerous position, the hoist operator shall never
place tension on a rope or cable.

(4) Employees shall familiarise, themselves with the

proper use of knots, ties, and hitches, and safe
methods of hooking and slinging required in their
work.

(5) Particular care must be exercised to see that

cables, chains and other hoisting equipment are
not unduly stressed by improper use. All ropes,
cables chains etc. shall be discarded when they
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 have worn or deteriorated to the point where their
safe use may be questionable in the judgement of
the supervisor.

(6) Chains shall not be spliced or joined by make shift

means such as open links, bolts, or wire. New links
shall be inserted by some competent person, or the
chain returned to the manufacturer for repairs.

(7) Wire ropes or cables should not be allowed to kink

as this weakens them.

(8) When applying U-bolt clips to cables, a sufficient

number should be used.

(9) Hooks, rings, clevises and other fittings used on

chains or cables shall exceed the carrying capacity
of the chain or cable.

(10) Fibre rope shall be properly cared for to retain its

strength and lasting quality. Following precautions
will preserve the strength and life of rope.

a. Where a rope sling passes over sharp

edges, pads should be used to protect the
fibres against cutting and undue stress.

b. Do not drag rope on the ground

unnecessarily as dirt chafes the fibres.

c. Do not use too small a sheave.

d. Do not use sheaves with rough surfaces or

broken edges.

e. Do not let rope slip on winch drum or lie idle

on moving drum.

f. Do not place kinked rope under stress.

g. Do not allow rope to unravel. Finish the

ends.

h. Do not tie the knots where splices should be

used.

i. Do not allow ropes to become oil-soaked

nor exposed to acid or corrosive
substances.
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 j. Do not allow rope to remain dirty or gritty.
Wash and dry.

k. Do not allow rope to remain exposed to

weather any more than necessary.
Carefully dry rope when it becomes wet.

L. Do not use excessive heat when drying

rope.

C-3 WELDING, BURNING, CUTTING (GENERAL):

(1) The primary hazards encountered during welding

are-Electric shock, burns, radiant energy, toxic
metal fumes, fires and explosions.

(2) Avoid burns from electric arcs, gas-welding flames,

hot slag, or touching welded parts before cooling by
the following precautions.

a. Gauntlet gloves should be worn while

welding or cutting. Outer clothes should be
free from oil and grease.

b. Suitable goggles or welding helmets shall

be worn for protection while welding.
Barriers should be erected to protect other
persons from rays or electric arcs or welding
flames. Goggles should be worn by the
helper also. Ultraviolet, infrared and
excessively bright visible-light rays are
injurious to eyes.

c. Clean goggles should be worn while

chipping the slag.

d. Adequate ventilation shall be provided while

welding in confined spaces or while brazing,
cutting or welding zinc, brass, bronze,
galvanised or lead-coated material.
Poisonous fumes may be generated during
the welding process by metallic oxides,
coatings on the material being cut or
welded, or by the electrode or flux rod.

e. Never use a cutting or welding torch where

there is danger of starting a fire. Move
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 work, if practicable, to a location where
possibility of starting a fire is not likely.
Danger of fire always exists when welding
near flammable material or explosive gases.
Where flammable material cannot be
removed from exposure to sparks; it should
be protected by a barrier of sheet metal or
other suitable material and a fire
extinguisher kept handy.

f. When welding or cutting in elevated

positions, precautions should be taken to
prevent sparks or hot metal falling on to
people or flammable material. Asbestos
cloth can be used.

g. No welding or cutting should be attempted

in dusty or gaseous areas where there is
danger of causing explosion.

h. Before welding or cutting a pipe, tank or

container that has held flammable material,
drain it thoroughly out and fill the container
with water, or thoroughly wash the container
with a caustic solution, and spray sufficient
carbon-tetrachloride into the container to fill
it with non-explosive vapour.

(3) Avoid personal contact with the electrode or other

live parts of electric welding equipment. Alternating
currents are dangerous even at low voltage.

(4) When changing, electrodes keep them insulated

from ground or other nearby metal objects.

(5) Extreme caution should be exercised to prevent

accidental contact of electrode with ground. When
passing the electrode through doors, or close
clearance, and when the welder is not in use, the
main switch should be off. Welding ground should
be close to the job.

(6) In acetylene burning and welding, never allow oil or

grease to come in contact with any cylinder,
regulator, or connection of gas-welding equipment.
Oil or grease in the presence of oxygen may cause
a violent explosion.

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(7) Never use matches to light a blowpipe. Use a
friction lighter, stationary pilot flame or other
suitable source of ignition.

(8) LPG cylinders should not be used for gas cutting

jobs. Acetylene cylinder should be used.

C-4 HANDLING AND STORING COMPRESSED

GASES:

(1) Cylinders containing acetylene, oxygen, chlorine,

hydrogen, nitrogen, carbon-dioxide, etc. should be
stored upright in approved safe places where they
cannot be knocked over, and well separated from
radiators, furnaces and combustible material.

(2) Oxygen cylinders should be isolated from acetylene

cylinders, and full cylinders separated from empty
ones.

(3) Gas cylinders should be protected from direct rays

of the sun.

(4) Empty cylinders should be plainly marked EMPTY,

and the valves closed.

(5) Gases like carbon dioxide, chlorine have a

tendency to settle down when released in air. They
also diffuse very slowly. Therefore when working in
manholes and basements, care must be taken to
see that an accidental leak will not lead to
suffocation. In such locations the gas cylinders
should be placed away from the manhole openings
or entrances to basements.

C-5 EXPLOSIVES: STORAGE & TRANSPORTATION

(1) Detonators for exploding dynamite are of two kinds.

Those ignited by fuse are known as blasting caps,
those fired by electric current are known as electric
blasting caps.

(2) Only persons who are qualified by training and

experience shall be permitted to handle, use or
transport explosives.

(3) Dynamite and caps shall be stored in separate

magazines, containers and marked. While
transporting, Dynamite and caps shall be placed in
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 separate locked containers. Such containers will
be kept as far apart as possible but not less than 3
ft.

(4) All surplus explosives shall be returned to

magazines as soon as possible following
completion of a job.

(5) The area within 28 feet of a magazine shall be kept

free of flammable debris, and magazine floors shall
be kept clean.

(6) Smoking and open flames are prohibited within 50

feet of any magazine or explosive.

(7) Trucks carrying explosives must not be left parked

in congested areas, or subject to major repairs.

C-6 HANDLING AND USE OF EXPLOSIVES

(1) Smoking and open flames are strictly prohibited

within 50 feet of explosives.

(2) Explosives, either in containers or otherwise, shall

not be thrown from trucks, slid along floors or
handled roughly in any manner.

(3) Do not expose explosives to direct rays of the sun

for a long time.

(4) Do not leave dynamite and caps unguarded.

(5) During approach and progress of a lightning storm,

and all personnel shall seek a place of safety.

(6) Do not leave explosives should be destroyed by

methods recommended by the manufacturer. They
should not be thrown into streams or bodies of
water, nor buried in the ground.

C-7 EXCAVATIONS

(1) Proper and adequate timber shoring and bracings

shall be provided to prevent sliding or slipping of
loose or unstable earth, rock or other material or
caving in of excavation.

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(2) Under cutting of banks of trenches and other
excavations shall be avoided.

(3) Excavated material shall be dumped away from the

edge of the excavated trench to avoid the slipping
of the excavated material in to the trench.

(4) Excavations shall be properly fenced to protect

men and animals from falling in.

(5) Warning signals shall be placed near the

excavation to warn the approaching traffic and
men. At night, red danger light shall be displayed
at a conspicuous place near the excavation.

C-8 CONCRETING AND CEMENTING

(1) All form raising and form stripping operations shall

be conducted under proper supervision. If working
at a height, the workers should use lifelines or
safety belts.

(2) Workers handling cement or concrete shall protect

themselves by wearing goggles, hard hats, and
rubber boots and rubber gloves as required.

(3) Proper guards and covers shall be provided on

mixer gears, chains and rollers.

(4) While grouting or gunniting the nozzle, men shall

be provided with suitable respirators.

(5) All pipes or hoses used to convey grout shall be of

sufficient strength to withstand the maximum
pressure likely to be reached during the operation.

(6) While gunniting the workers shall be protected

against rebound material.

TRANSPORTATION

T-1 GENERAL PRECAUTIONS

(1) Equipment should be kept in good operating

condition, and driven in a safe manner so as to
prevent injury to you and others and save damage
or loss of valuable equipment. Driving of a
company car or truck is a responsibility, not a
privilege.
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(2) No employee shall operate a company car or truck
upon a public thoroughfare unless he has the
proper license in his possession.

(3) Every driver of company car or truck shall be

thoroughly familiar and comply with the State and
City traffic laws covering the territory where he
operates.

(4) Before operating a company vehicle each driver

should make sure that it is in proper operating
condition. Observe especially the following
precautions :

a. Test brakes, clutch, horn and lights.

b. See that tyres are in good condition and
properly inflated.
c. Check emergency equipment such as first-
aid kit jacks and tools. Any equipment
found missing or defective should be
reported immediately.

(5) Every driver shall report any vehicle’s defect

detected.

(6) Before filling the petrol tank, the motor should

always be shut off. The hose nozzle should be
kept in contact with the tank to avoid static sparks.

(7) While filling the petrol tank, smoking or using an

open flame near the vehicle should be avoided.

(8) Driver and co-passengers in vehicle should wear

seat belts while driving / travelling in vehicle.

T-2 DRIVING

(1) Most traffic accident can be prevented by faithful

observance of three things.

a. Control Speeds.
Speeding is dangerous. A few minutes
saved at the cost of an accident is no
bargain.

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 b. Avoid Distractions.
Give your undivided attention to the job of
driving. Keep your eyes on the road.
c. Drive Defensively.
Don’t insist on your right of way. Try to
anticipate the intention of other drivers and
pedestrians. Their failure to observe traffic
regulations does not justify your running into
them.

(1) Company vehicles shall be operated within the

legal speed limit at all times and at lower speeds
where conditions like bad road, poor visibility and
weather conditions warrant it.

(2) Keep a safe distance from vehicle in front.

(3) Do not attempt to pass another vehicle going in the

same direction unless you can plainly see far
enough ahead to be sure you can pass safely.
Proper horn signal should be given before passing.

(4) Do not drive to the right of road centre when

approaching the crest of a hill, an intersection,
railroad crossing, or curve where full view of the
roadway ahead is obstructed.

T-3 PARKING

(1) Park on the proper side of the street close to the

curb, or of the highway so as not to interfere with
traffic.

(2) When parking along a highway at night parking

lights shall be left on. If any work is to be done,
flares shall be set opposite ends to warn other
drivers.

(3) When parking on a grade, place vehicle in gear, set

hand brake, turn wheels to curb, or otherwise block
the car so it cannot accidentally roll.

(4) To change a tyre or make other necessary repairs

along the highway, pull off to the side of the road as
far as possible.

(5) Before leaving a parked vehicle, always remove the

ignition key to prevent theft or unauthorised starting
of car.
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(6) Leave or enter parked vehicles on the curbside
wherever possible. Use extreme care if doors are
open on roadside to see that no other vehicles are
near.

(7) Before starting a parked vehicle, observe front and

rear to make sure that persons and objects are out
of the way.

T-4 OPERATION OF TRUCKS AND TRAILERS

(1) Before starting a truck, the man in-charge of party

should carefully inspect the loading of materials
and see that wherever necessary the material is
secured safely and that all men are safely aboard.

(2) Loading of vehicles should not exceed their rated

capacity, and objects should not be permitted to
extend beyond the sides unless the necessary
permit has been obtained from the Authorities.

(3) The passengers carried in trucks should not

exceed the legally permitted number.

T-5 PROCEDURE IN TRAFFIC ACCIDENTS

(1) Do not become involved in an argument as to who

was responsible for an accident, but endeavour to
get all the facts in the case. Remember that
accidents that may appear trivial often result in
claim for personal injury or property damage.

(2) Do not lose your temper; try to be courteous and

helpful.

(3) Following instructions should be observed in the

order given, if possible, when you are involved in a
traffic accident :

a. STOP- Pull over to the curb or out of traffic,

if possible. Never leave the scene of an
accident without stopping to identify yourself
and render such assistance as possible.

b. Assist injured persons in so far as you are

able, giving immediate attention to severe
bleeding. Do not move seriously injured
persons unless necessary for their
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 protection against further injury. Send for
doctor and ambulance, if necessary.

c. When requested give your name, address,

company affiliation and show driver’s
license to the other party.

d. Secure name, address and license number

of the other driver, car license number, and
names and address of car owner and
Insurance Company.

e. Record names and address of witness.

f. Unless some policeman is present at the

scene of the accident, notify police having
jurisdiction in the territory.

g. Sketch the location showing position of

vehicles or pedestrians involved, and any
special conditions such as obstructions,
parked cars, skid marks. Show date, time
of day, weather and road conditions and
any other information which you may
consider useful.

h. Notify your supervisor, and also submit

written report with all useful information
which you possess.

F. FIRST AID

The principles of First-aid are based on the

principles of practical medicine and surgery, a
knowledge of which, in case of accident, injury, or
sudden illness, enables a trained person to give such
assistance as will preserve life, shorten the recovery
period of recovery and give relief from pain.

First aid is limited to the assistance rendered at the

time of the emergency with such material as may be
available.

F-1 PRINCIPLES OF FIRST AID:

(1) Death is not to be assumed; it is better to render First

aid to a cadaver than allow a living person to die from
absence of First aid.

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(2) If the breathing and / or the heart beats have stopped,
try to restore the same by giving Artificial Respiration
and, if required, Cardiac Massage. (Cardio-Pulmonary-
Resuscitation.)
(3) Stop any bleeding.
(4) Treat the patient of circulatory shock by lowering the
head and raising the legs.
(5) Keep crowds away as fresh air is essential.
(6) Keep the patient warm.
(7) In case of fracture, apply a splint to immobilise the part.
(8) In case of burns wash the affected area with copious
amounts of water till pain subsides or for half an hour.
(9) Do not try to force feed fluids to a semi- conscious or
unconscious person. Arrange for prompt Medical help
and evacuation of the person to a Medical facility.

F-2 RESTORATION OF BREATHING BY ARTIFICIAL

RESPIRATION.

(1) If normal breathing stops due to any reason, and the

same is not restored within 3 minutes, then permanent
brain damage can occur, and if the delay is more than
5 minutes, it could result in death.
(2) To check whether the person is breathing or not, place
the palm of the hand in front of the nostrils to feel the
warm air coming out of the nose. One can also look at
the chest and abdomen for heaving movements that
take place when a person breathes. Absence of warm
air from the nose and heaving movement of the chest
and abdomen indicate cessation of breathing.
(3) Begin the process of Artificial Respiration without
delay. There are 2 important methods of artificial
respiration: Mouth to mouth method and Holger –
Nielson’s method.
(4) Mouth to mouth method:
a) Position of Casualty:
1) Keep the casualty on his back and tilt his
head backwards and support the neck.

2) Check the mouth for any foreign body and

mop up the secretions with cloth. Do not
remove artificial dentures.

3) If necessary, roll the injured on his side

and slap him between the shoulder blades.
Sometimes this alone may resume the
breathing.

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(5) Holger – Nielson method (Back pressure – arm lift
method)
a) Position of Casualty :
1) Remove pointed objects from chest and
pants pockets & loosen the belt.
2) Place distance foot on the nearer foot
and turn the casualty face and chest
downwards.
2) Give a sharp tap between the shoulder
blades, place casualty’s hands one over
the other with head slightly turned to one
side. Above points are prerequisites of
back pressure – Arm lift method (Holger-
Nielson method) & Schafer’s method.

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b) Position of the operator:
1) Place one knee with the inner side in line
with the casualty’s cheek six to twelve
inches from the top of his head.
2) Place the other foot with the heel in line with
the casualty’s elbow.
3) Place the hands on the casualty’s back with
the lower part of the shoulder blades, the
thumbs along side the spine, and the
fingers pointing to casualty’s feet.
c) Movements of the Operator:
1) Movement 1: While counting “One-Two”
gently rock forward until your arms are
vertical to casualty’s body (Operator should
not bend his elbow) see fig.1. This
compression is to be effected by the weight
of operator’s body.

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2) Movement 2: With count “three” catch the
casualty’s elbows as in Fig. 2.

3) Movement 3: While counting ‘four and

five” gently rock backwards, pulling and
elbows until there is little tension on
them, as in fig.3. This allows entry of
fresh air into the casualty’s lungs by
expanding his chest.

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F-4 EXTERNAL CARDIAC MASSAGE.
a) Lay the injured person on his back on a firm
surface and kneel at his side.
b) Place the heel of one hand on the lower half of the
injured person’s sternum (breastbone).
c) Place your other hand on top of the first hand and
exert downward pressure till breastbone dips by 1
½ inches.
d) Then quickly release the pressure (fig.7.)
e) Repeat this cycle 60 times per minute.

F-4 CARDIO-PULMONARY RESUSCITATION.

If both respiration & circulation have stopped then-
1) First give 5 to 6 quick breath by mouth to
mouth method and check carotid pulse. If

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 pulse is felt, continue mouth to mouth
respiration only.
2) If carotid pulse is not felt after 5 to 6 mouth
to mouth breaths, compress chest 15
times as described in external cardiac
massage and then give 2 quick mouth to
mouth breaths. Continue this rhythm of 15
compressions followed by 2 quick mouth
breaths till medical help is available. If any
assistance is available, one person should
give one quick mouth breath while other
gives 5 chest compressions immediately
after it. Maintain this 1 to 5 rhythm till
medical assistance is available.(fig.7)

Page 136 of 146

Page 137 of 146
F-5 EXTERNAL BLEEDING
Place the casualty in comfortable (horizontal)
position. Elevate the bleeding part, except in the cabs of
fractured limb.
Expose the wound but do not disturb the blood clots if they
have formed.
Apply direct pressure with thumb or palm and give firm pad
and bandage.
If direct pressure does not stop bleeding, then use indirect
pressure by 1) pressure on relevant pressure point 2)
constrictive bandage.

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1) Pressure points:
a) neck pressure point: (fig. 8.) place the thumb in the
hollow between the lower part of voice box and sterno
mastoid muscle, on the injured side and compress the
artery below the levels of wound.

b) Arm pressure point- compress the artery against

the arm bone (as shown in fig. 9.)

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c) Thigh pressure point- with knee flexed,
press directly downward in the centre of the groin
with both the thumbs as shown in fig. 10.

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2) Indirect pressure by constrictive bandage:
(Tourniquet) in severely bleeding injury where it is
necessary to maintain indirect pressure for a long time,
use constrictive bandage as shown in fig 11.

a) After every 15 minutes it should be loosened for a

minute or two & retighten.
b) It should only be tied between elbow and shoulder
or between hip and knee.
c) Constrictive bandages should never be covered by
other bandage or applied under splints.
d) Time of application of constrictive bandage should
be carefully noted and conveyed to Doctor.
e) It should be tight enough to stop the bleeding.
2) Bleeding from the nose: sit the casualty in a chair with
his head slightly thrown forward.
Pinch the soft part of nose (do not plug the nose).
Warn the casualty not to blow the nose.
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3) Bleeding from mouth cavity: give ice to suck.
Compress the bleeding part with cotton plug.

F-6 BURNS
(1) General Rule for the Treatment of Burns:
(a) Apply running water over the burnt area till pain
stops or for 30 minutes.
(b) Avoid frequent handling of the part affected by burn.
(c) Cover the burnt area with clean or prepared sterile
dressing (Burn dressing).
(d) If sterile dressing is not available, use a freshly
washed & sun-dried cloth to wrap the area.
(e) Immobilise the affected part.
(f) Treat circulatory shock.

F-7 SHOCK
Shock is a condition of severe depression of
vital functions. In this condition patient has cold moist skin,
nausea pallor and giddiness. This circulatory shock is
different from electric shock. Every electric shock need not
lead to circulatory shock.

1) Treatment of circulatory shock:

a) Lay the casualty on his back in head low position.
b) If casualty vomits, turn the head to one side.
c) Wrap him in a blanket.
d) If casualty is able to swallow, give him weak tea or
coffee.
e)Reassure the casualty &send for medical help.
e) Do not apply heat or friction to limbs

2) Electric shock:
Act at once- delay may be fatal, send for doctor
immediately but never wait for him.
Switch off the current. If this is not possible, remove the
casualty from the contact with the current by help of a dry
rope, a walking stick, rubber gloves, folded newspaper or a
dry garment. While doing so, rescuer should stand on
insulating material like wooden board, piles of newspapers
or rubber soled shoes.
Unless casualty is breathing normally, give artificial
respiration and continue till doctor declares death of
casualty. Give artificial respiration by 1) mouth to mouth
method or 2) Holger-Nielson method or described
elsewhere.
Also check the carotid pulse and give external heart
massage as described under ‘external cardiac massage’

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If pulse is not felt & normal breathing has also stopped
give card- pulmonary resuscitation as described under
cardio- pulmonary resuscitation.
Treat casualty for circulatory shock as stated under
circulatory shock
Treat the burns if any, as stated under
‘general rules for the treatment of
burns .see f-6
Every electric shock case should be kept under medical
observation for at least 24 hours. Because casualty’s
condition is liable to worsen when effects have seemed to
be mild.

3) Electrical injuries: alternating current is more dangerous

than direct current as the muscles are thrown into spasm
causing casualty to remain in contact with the current. A/c
current 50 cycles 15 to 20 milli. Amps prevent victim from
releasing grasp. More than 20 milli. Amps may cause
breathing difficulty.
Moisture is a powerful conductor of electricity and when
present, will facilitate the passage of the current. If the skin
at the point of contact of earth is wet, even lower voltages
may be dangerous. More important than the current is the
path it takes through the body in finding its way to earth.
Thus a very strong current passing to earth through the
lower limb might be less dangerous than a much weaker
current crossing the chest as unfortunately it is likely to do
if it enters through the hand or arm. In these cases there
may be immediate fatal paralysis of the heart or more
commonly a sudden stoppage of breathing from paralysis
of the muscles of respiration. If the nerves controlling the
heart and circulation escape, the heart may continue to
function even though the breathing has stopped. It is for
this reason that in electrical injuries the face is blue rather
than white and that artificial respiration may have to be
carried on for a very long-time. As long as the heart beats,
life may be saved.

F-8 GENERAL RULES FOR TREATING AN

UNCONSCIOUS CASE

1) Ensure supply of air to the casualty by:

a) Removing harmful gases if any or by shifting
the casualty to suitable place.
b) Opening the doors and windows and keeping
the crowds away.
c) Keeping passage of breathing clear by
removing false teeth and taking the tongue

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 away from the back of the throat of the
casualty.
2) If breathing has stopped give artificial respiration by
Holger – Nielson Method or mouth to mouth method as
described elsewhere.
3) If breathing is noisy, on account of blood, vomit or
saliva etc. in the throat, keep the casualty in 3/4th prone
position as shown in fig.12.

4) Wrap the casualty in a blanket after loosening the tight

clothing.
5) Do not leave the casualty until he has been placed in
charge of a responsible person
6) Do not attempt to give food or fluids while casualty is
unconcious.
7) Remove him to a shelter on a stretcher.

F-9 GENERAL RULES FOR TREATMENT OF

FRACTURES.
1) Do not attempt to move the casualty until a trained
person immobilises the injured part.
2) Steady and support the injured parts if necessary, with
rolls of blankets or sandbags
3) Treat the physical shock.
4) Treat external bleeding if any.

F-10 TREATMENT FOR CHEMICAL BURNS

1) Acid burns:
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 a) Thoroughly flood the part with water.
b) bathe the part freely with an alkaline solution
prepared as follows :- one teaspoonful of baking
soda (bicarbonate of soda) dissolved in a glass of
water
c) Remove acid contaminated clothing by cutting it
with scissors.

2) Alkali burns:
a) Thoroughly flood the part with water
b) If alkali is in powder form, brush it off from the skin
before flooding the part with water.
c) Bathe the part freely with weak acid solution
prepared as follows: equal quantities of lime juice or
vinegar and water mixed together.
d) Remove alkali contaminated clothing by cutting it
with scissors

3) When an alkali goes in the eye:

Casualty should be asked to blink the eyelid under
water or alternatively flush the eye with copious amount
of water. Do not use acid or alkali for washing the eye.
Soft pad of cotton wool should be kept over the eye and
bandage should be applied lightly.

F-11 FOREIGN BODY IN THE EYE

Prevent the casualty from rubbing the eye. Advise the

casualty to blink the eye under water (eyewash).

F-12 SNAKE BITE

Treatment for snakebite should always be prompt.

1) arrange for medical help immediately
2) In the meanwhile, arrest circulation in the snake
bitten limb by using constrictive bandage between
shoulder and elbow or between hip and knee joint
(as the case may be) till the pulse is not felt beyond
the constrictive bandage. Constrictive bandage
should be kept in a position for 20 minutes, then
released for 1 minute or until skin becomes pink and
again tightened. Repeat the procedure till the arrival
of the doctor.
3) Immediately after the constriction is applied, wash
the wound with a solution of potassium
permanganate, in order to remove any venom that
may have dried on the skin.
4) Make a deep cut with a sharp knife or razor blade at
the bitten site in order to bleed the bitten site.
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 5) Assure the patient and keep him warm by means of
blanket.
6) Patient should be absolutely still
7) If he is able to swallow, give him strong tea or
coffee.
8) If breathing stops, give artificial respiration by mouth
to mouth or Holger-Nielson Method.

F-13 HEAT EXHAUSTION

Heat exhaustion occurs among the workers in stuffy

atmosphere or in overheated, poorly ventilated room.
There may be feeling of giddiness or fainting, skin is
always cold and moist. Prevention by wearing loose
clothing, drinking large quantities of water is possible.
1) Active first-aid treatment of heat exhaustion;
a) Remove patient to cooler conditions in the fresh air.
b) Lay him down and loosen all clothing around the neck
c) Dash cold water around the neck to stimulate.
d) Fan him vigorously.
e) If severe shock is present, use stimulants.

F-14 HEAT STROKE

Heat stroke proper is an entirely different reaction in the

human body, to the same conditions which favour heat
exhaustion. It is serious and often fatal condition. Hot,
still humid atmosphere and inadequate drinking of water
favours development of heat stroke. Alcohol
consumption and constipation also favour its onset.

Casualty shows mental excitement, restlessness,

vomiting, muscular cramps and high temperature in the
range of 104F or above. If temperature reaches 106F
patient may become unconscious.

1) treatment for heat stroke:

a) Send for doctor.
b) Commence active treatment before temperature
reaches 104F.
c) Strip the patient naked and wrap him up completely
in cold-water soaked bed sheet.
d) Fan vigorously and when the temperature of body
comes down to 102 F, cooling process should be
stopped.
e) Later on, patient should be dried and covered with
light blanket.
f) Water can be given to drink to eliminate poisons

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