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Refinery Operating System

ROS-019
Edition: 2015, Revision: 00/2015

SAFETY GUIDELINES FOR EXCAVATION

Kochi Refinery

This ROS outlines safety guidelines to be followed in BPCL Kochi Refinery for excavation / trenching
activities to prevent accidents / incidents endangering people and property.

This ROS or any part of this publication shall be reproduced, published or transmitted, in any form or
by any means, only with the prior written permission of BPCL-KR.
Refinery Operating System No: ROS-019

Edition 2015
Safety Guidelines for Excavation
Kochi Refinery Rev 00/2015

DOCUMENT RELEASE NOTE


Document Details
Document Name : Safety Guidelines for Excavation
Document No : ROS-019
Edition : 2015
Revision : 00/2015
Issue : Sept-2015
________

Reviewed by

HOD – Fire & Safety HOD – E & C HOD-Maintenance

Functional Head - Operations Functional Head - Projects

Reviewed in : Refinery Council

RC Meeting Record Note : 105


No………….... 01-08-2015
dated…………………....

Approved By

Head of Kochi Refinery

Digitally controlled document and hence sign is not requird for pdf version of ROS. Signed Mastercopy is available with Custodian

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Refinery Operating System No: ROS-019

Edition 2015
Safety Guidelines for Excavation
Kochi Refinery Rev 00/2015

AMENDMENT SHEET

All amendments in the ROS shall be documented in the following table. The details of the
amendment shall be elaborated in a separate document (Amendment Document) and shall be
available with custodian.

Section Amendment Amendment


Tracking ID Reason
No From To Document No

ROS-019/15-01 All Revised in total ROS019/AD-01

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Refinery Operating System No: ROS-019

Edition 2015
Safety Guidelines for Excavation
Rev 00/2015
Kochi Refinery

Table of Contents

Section No Title Page No

Document Release Note .................................................................................................... 2

Amendment Sheet ............................................................................................................ 3

Table of Contents .............................................................................................................. 4

Preface ....................................................................................................................... 6

1 INTRODUCTION ............................................................................................... 8

1.1 Purpose .................................................................................................................... 8

1.2 Scope ........................................................................................................................ 8

1.3 Coverage .................................................................................................................. 8

1.4 Limitations ............................................................................................................... 8

1.5 Exclusions ................................................................................................................. 9

1.6 Deviations ................................................................................................................ 9

2 Definitions & Abbreviations ............................................................................. 9

2.1 Defintions ................................................................................................................. 9

2.2 Abbreviations ......................................................................................................... 10

3 Requirements ................................................................................................ 11

3.1 Hazard Identification and Risk Assessment ........................................................... 11

3.2 Underground Services and Overhead Power Line ................................................. 12

3.3 Excavation Collapse................................................................................................ 13

3.4 Materials Falling into Excavations.......................................................................... 14

3.5 People and Vehicles Falling into Excavations ........................................................ 14

3.6 People Struck by Machinery .................................................................................. 16

3.7 Stability of Nearby Structures ................................................................................ 16

3.8 Accumulation of Gases and Vapours ..................................................................... 16

4 Roles and Responsibility ................................................................................ 17

4.1 Engineer in Charge ................................................................................................. 17

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Refinery Operating System No: ROS-019

Edition 2015
Safety Guidelines for Excavation
Rev 00/2015
Kochi Refinery

5 Approval ....................................................................................................... 17

5.1 Review of ROS ........................................................................................................ 17

5.2 Approval of ROS ..................................................................................................... 17

6 Monitoring and control.................................................................................. 18

7 Records ......................................................................................................... 18

8 References .................................................................................................... 18

9 Appendix....................................................................................................... 18

9.1 Appendix ROS-19/A9.1: Checklist for Excavation .................................................. 19

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Refinery Operating System No: ROS-019

Edition 2015
Safety Guidelines for Excavation
Rev 00/2015
Kochi Refinery

PREFACE

Director (Refinery) of erstwhile Cochin Refineries Limited (CRL) appointed a committee in 1994 for
devising a procedure of standard operations. The committee formulated a system named Refinery
Operating System (ROS). A set of ROS was formulated and released by the committee. Over years,
the ROS was evolved to a well-documented Refinery Operating System (ROS), which outlines the
Management System Procedure for various business processes in the refinery. There were 90
approved ROS and 12 ROS under formulation before the current edition. Prior to 2015 edition,
Project (Technical) department, which was earlier known as Corporate Planning, before
organizational re-structuring in 2006, was the custodian of the ROS.

In 2014, General Manager (Operations) constituted a task force for a thorough revision of ROS in
terms of the purpose, relevance, scope and work flow in the current business context vide office
note KDD/03/09 dated 28-02-2014.

The task force reviewed entire ROS and concluded that entire structure and contents required a
major revision. In order to incorporate standardization, the task force decided to formulate the first
ROS, which outlines procedure for formulating a ROS. Hence the first ROS in the series was revised in
full incorporating document structure, numbering philosophy and new approval procedure.

Excavation is one of the dangerous construction activities. Various types of excavations are
necessitated within the refinery facilities related to maintenance, additions as well as major projects.
The excavations vary from minor road cuttings to major site grading jobs such as major projects like
IREP.

The earlier version of ROS 63 (Rev 2) was guidelines for excavations. On review the task force
reviewed the entire ROS and renamed as ROS-019 as Guidelines for Safety Guidelines for Excavation.

Hence the ROS-019 is revised with wider understanding and explicit guidelines for preventing
accidents / incident related with the excavation activity thereby preventing damage to personnel,
structures and equipments. The 13 point checklist of the earlier version of ROS 63 is retained in this
edition.

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Refinery Operating System No: ROS-019

Edition 2015
Safety Guidelines for Excavation
Rev 00/2015
Kochi Refinery

Task Force for ROS Edition-2015

The Task Force was constituted by Mr. Soman C. K., General Manager (Operations) in 2014 for
revision of the existing Refinery Operating System.

Task Force

Sl. No. Name Designation

1. Muralidharan V. Manager (E & C)

2. Naizu A. V. Manager (F & S)

3. Roopesh M. Manager (Inspection)

4. Saji Babu Manager (Manufacturing)

In addition to the above, several experts from various departments contributed in the preparation,
review and finalisation of this document.

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Refinery Operating System No: ROS-019

Edition 2015
Safety Guidelines for Excavation
Rev 00/2015
Kochi Refinery

1 INTRODUCTION

Work associated with excavation is one of the most hazardous construction activities.
Accidents are caused mainly by land slide of the side walls of the excavation, toppling of
machinery into the trench or people getting struck by the bucket of the excavator and hazards
associated with underground power / instrument / communication cables.

To ensure safety of persons involved and to prevent accidents in the excavation works, they
have to be properly planned, managed, supervised and executed. The persons involved in all
stages should be aware of the hazards involved and procedures should be in place to control
risks associated with works involving excavation.

1.1 PURPOSE

The purpose of this Refinery Operating System (ROS) is to provide guidelines for carrying out
excavation works in BPCL Kochi Refinery so as to safe guard the persons carrying out them, to
avoid process interruption and to ensure structural integrity of the nearby facilities.

1.2 SCOPE

This ROS details guidelines with regard to hazard identification, risk assessment and
precautions to be taken with respect to the hazards identified such as underground services,
excavation collapse, falling of people, materials and vehicle into the excavations, accumulation
of water and gases etc. The scope also includes the guideline to ensure integrity of structures
close to excavations.

1.3 COVERAGE

ROS is applicable to the following facilities under KR and facilities under its administrative
control such as

1. Kochi Refinery

2. Pipeline corridor

3. STF

4. SWSS Aluva

1.4 LIMITATIONS

This ROS covers excavations in land only. The procedures / practices described in the ROS are
not intended to supplant other practices / procedure that have proven satisfactory, nor is the
ROS intended to discourage innovation and originality in the best practices in the refinery.

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Refinery Operating System No: ROS-019

Edition 2015
Safety Guidelines for Excavation
Rev 00/2015
Kochi Refinery

Users of the ROS are reminded that no ROS is a substitute for the judgment of a responsible,
qualified person.

1.5 EXCLUSIONS

The following works are excluded from the scope of this ROS

1. Underwater excavations are not covered

2. Manual / mechanical piling activities

3. Tunnelling

4. Horizontal Directional Drilling

1.6 DEVIATIONS

The procedures / practices described in the ROS are intended for standardization of the
processes involved and hence the same shall be strictly adhered to. However, deviation, if
any, arises due to unavoidable circumstance(s), shall be approved by Head of Kochi Refinery.
The deviation note in the prescribed format specified in ROS-001 Appendix ‘ROS-001/A9.4:
Format for Approval of Deviation in ROS’ shall be initiated by the HOD of the department
proposing the deviation through the Functional Head.

2 DEFINITIONS & ABBREVIATIONS

This section lists all definitions and abbreviations used for the purpose of this ROS.

2.1 DEFINTIONS
Adjacent Structures Stability : This refers to the stability of the foundation(s) of adjacent
structures whose location may create surcharges, changes
in soil conditions or other disruptions that have the
potential to extend into the failure zone of the excavation
or trench.

Angle of repose : It is the steepest angle of descent or dip relative to the


horizontal plane to which a material can be piled without
slumping

Battering : Battering means forming face or side or wall of an


excavation to an angle, usually less than the natural angle
of repose to prevent earth slippage.

Corporation : Bharat Petroleum Corporation Limited.

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Refinery Operating System No: ROS-019

Edition 2015
Safety Guidelines for Excavation
Rev 00/2015
Kochi Refinery

Excavation : An excavation is any man-made cut, cavity, trench, or


depression in an earth surface that is formed by earth
removal.

Functional Head : Head of Functional Area such as General Manager, Deputy


General Manager (In charge).

Functional Area : Operations, Technical, Finance, Human Resources, Projects


etc.

KR & ME : BPCL Kochi Refinery Intralink

May : Optional

Refinery : Kochi Refinery premises and its connected facilities.

Shall : Mandatory

Shoring : Shoring is an assembly of structural members designed to


prevent earth or material from falling, sliding or rolling into
an excavation.

Should : Recommended

Trench : Trench means an excavation that is deeper than its width


measured at the bottom. In general, the depth of a trench
is greater than its width, and the width (measured at the
bottom) is not greater than 15 ft (4.6 m). If a form or other
structure installed or constructed in an excavation reduces
the distance between the form and the side of the
excavation to 15 ft (4.6 m) or less (measured at the bottom
of the excavation), the excavation is also considered to be a
trench.

Zone of influence : Zone of influence means the volume of soil around the
excavation affected by any external load (for example
vehicles, plant, excavated material).

2.2 ABBREVIATIONS
BPCL : Bharat Petroleum Corporation Limited

COT : Cochin Oil Terminal

GOVT : Government

HOD : Head of the Department

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Refinery Operating System No: ROS-019

Edition 2015
Safety Guidelines for Excavation
Rev 00/2015
Kochi Refinery

KR : Kochi Refinery

MHSSEC : Management Health Safety Security Environment


Committee

RC : Refinery Council

ROS : Refinery Operating System

SBU : Strategic Business Unit

SPM : Single Point Mooring

STB : South Tanker Berth

STF : Shore Tank Farm

SWSS : Standalone Water Supply Scheme

3 REQUIREMENTS

Hazards in excavation, their identification and risk assessment and management of risks are
covered in this section. Requirements for carrying out these steps to be followed in works
involving the excavation are specified.

3.1 HAZARD IDENTIFICATION AND RISK ASSESSMENT

1. A hazard identification and risk assessment shall be carried out in relation to activities
undertaken by persons at a place of excavation work and that a safe system of work be
prepared and implemented to protect employees and persons engaged or affected by the
activities taking place at that place of work.

2. The common hazards associated with excavation works are


a. contact with underground services like electric cable, pipelines etc.

b. contact with overhead pipelines and power transmission lines

c. collapse of the excavation's sides (cave-in) and land slides

d. materials falling onto people working in the excavation

e. people and vehicles falling into the excavation

f. struck by machinery

g. collapse of nearby structures

h. ingress / egress to / from the excavation

i. presence of fumes gases etc. and lack of oxygen.

j. ground water, flooding

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Refinery Operating System No: ROS-019

Edition 2015
Safety Guidelines for Excavation
Rev 00/2015
Kochi Refinery

k. accidents to public

3. The job shall be planned considering the hazards identified and the risk posed by the
activities. The job shall be carried out only using valid work permits (Earth work permit,
cold / hot work permit as the case may be) issued as per ROS-016.

3.2 UNDERGROUND SERVICES AND OVERHEAD POWER LINE

If the presence of underground services like cables, sewers, hydrocarbon pipelines etc. or
overhead lines cannot be identified or diverted, then the following steps should be taken to
avoid contact.

1. Look around for obvious signs of underground services, e.g. valve covers, patching of the
road surface, cable markers etc.

2. Use locators, if available, to trace for any services and mark the ground accordingly.

3. Mechanical excavations, using earth movers, shall be started only after excavating up to
1.2m by manual methods. If the area to be excavated is free of any underground lines or
cables, excavation using mechanical devices can be started directly.

4. Manual excavations shall be carried out using equipment having wooden / non
conductive handles.

5. Pointed tools shall not be used to probe for underground gas and electrical services.

6. If possible, blunt shovels should be used to expose the facility. Adequate caution should
be taken especially, if new and sharp spade shovels are used.

7. Trees, utility poles, rocks, or similar objects near the edge of an excavation must be
removed or secured to prevent workers getting injured.

8. Survey the area for overhead obstructions such as power transmission lines, pipeline,
structures etc.

Figure 1: Bunting to Protect Equipment from Coming into Contact with Overhead Electricity Line

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Safety Guidelines for Excavation
Rev 00/2015
Kochi Refinery

9. Works that are in close proximity to overhead lines should be conducted as per advice of
Electrical Safety Officer. Goal posts and bunting if required should be erected (Figure 1).

10. No electric power driven pumps or machinery shall be kept inside the excavation
whenever not in use.

3.3 EXCAVATION COLLAPSE

1. Excavation deeper than 1.2m shall be protected from dislodgement of the sides of the
excavation. This protection could be in the form of shoring and strutting (support for the
excavation), battering (sloping excavation) or other suitable means. Notwithstanding this,
all excavations and the area in the vicinity of an excavation must be safe (when people
have access to them) and without risk to health as far as reasonably practicable.

2. All or a combination of the following steps shall be taken to prevent a person becoming
engulfed or injured in an excavation due to its collapse.

a. Battering: Battering is where the wall of an excavation is sloped back to a


predetermined angle to ensure stability (Figure 2). Battering prevents ground
collapse by cutting the excavated face back to a safe slope.

Figure 2: Battering Figure 3: Benching

b. A safe angle of repose shall be maintained for excavation exceeding 1.5 m depth up
to 3.0m. Based on soil conditions, a slope of 450 (45 degree) should be provided.

c. Benching: Except hard rock area, suitable bench of 0.5 m width at every 1.5 m depth
of excavation in all soils shall be provided (Figure 3).

d. Shoring and Strutting: Alternatively, proper shoring and strutting, which match the
depth of excavation shall be ensured to prevent cave-in. (Figure 4).

Figure 4: Shoring and strutting

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Safety Guidelines for Excavation
Rev 00/2015
Kochi Refinery

3. No vehicle or machinery shall be allowed near an edge of an excavation, which is likely to


cause collapse.

4. Excavated earth should be placed at least 1m away from the edge of the trench or to a
distance equal to the depth of trench whichever is greater.

5. A ladder shall be provided for easy ingress to / from egress for excavations more than
1.2m deep. The ladder shall extend minimum 1m above ground level.

6. Water accumulation in the trench shall be pumped / bailed out. Necessary precautions
should be taken to prevent entry of surface water in trenches.

3.4 MATERIALS FALLING INTO EXCAVATIONS

1. Spoil or other materials shall not be stored close to the sides of excavations. The spoil
may fall into the excavation and the extra loading will make the sides more prone to
collapse.

2. The edges of the excavation shall be protected against falling materials. Provide toe
boards where necessary.

3. Hard hat shall be worn when working in excavations.

4. In rock cut excavations where the rock is friable, netting should be used.

3.5 PEOPLE AND VEHICLES FALLING INTO EXCAVATIONS

1. Adequate steps shall be taken to prevent people falling into excavations. Provide
substantial barriers, for example guard rails and toe boards. Barricade of 1m height shall
be provided for excavations beyond 1.2m depth. Provide two entries / exists for such
excavation.

2. Mechanical plant, vehicles, storage of materials (including excavated material) or any


other heavy loads should not be located in the ‘zone of influence’ of an excavation.

3. In case of excavation provided with shoring and strutting, the mechanical plant, vehicles,
storage of materials etc. shall be kept away from the edge of excavations as shown in
Figure 5.

4. In all other cases vehicles shall not be allowed to operate too close to excavated area. At
least 2m distance from edge of excavation shall be maintained while operating the
vehicles.

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Safety Guidelines for Excavation
Rev 00/2015
Kochi Refinery

Figure 5: Excavated material and loads near


excavations
Top: an excavation with shoring that has been
designed to carry vehicle and material loads.
Bottom: an excavation with shoring that has been
designed only to carry the load of the excavated
faces and the related zone of influence.

5. If vehicles have to tip materials into excavations, use stop blocks to prevent them from
over-running (Figure 6). The sides of the excavation shall be provided extra support to
prevent collapse.

6. Powered mobile plant / excavators shall not operate near the edge of an excavation
unless the ground support system is installed. Physical barriers, such as wheel stoppers,
shall be considered for restricting movement near an excavation.

Figure 6: Preventing plant operation near excavations

7. Never have a person in an excavation while machinery is working over it. The extra
surcharge from the weight of the machine may induce a collapse.

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Safety Guidelines for Excavation
Rev 00/2015
Kochi Refinery

3.6 PEOPLE STRUCK BY MACHINERY


1. Workers should be away from moving machinery such as excavators. The workers should
work outside the reach of the excavator bucket. Safe systems of work shall be used to
prevent people getting struck if this is not possible.

2. The machinery operators shall be competent and possess necessary license to operate
the type of equipment.

3. Attachments for excavators fitted via quick hitch mechanisms must be effectively
secured.

4. All moving machinery shall be fitted with reverse horns that operate automatically while
reversing.

3.7 STABILITY OF NEARBY STRUCTURES

1. Excavations shall not affect the foundations of nearby structures or footings of scaffolds.
Walls may have very shallow foundations that can be undermined by even small
trenches.

2. In case the location of the excavation is close to other structures, the engineer in charge
of the work involving excavation shall consult the Section Head of Civil section of E&C
Department and obtain foundation details of nearby structures and measures to be
adopted for ensuring their stability before starting digging.

3.8 ACCUMULATION OF GASES AND VAPOURS

1. Internal Combustion engine driven equipment such as generators or compressors shall


not be placed in or near the edge of an excavation unless the exhaust gases can be
ducted away to a safe area or the area can be adequately ventilated.

2. The activity inside an excavated area shall not introduce toxic, flammable or other
asphyxiant gases within, which can endanger workers.

3. Gas cylinders shall not be kept inside the excavation unattended, to avoid accidental
leakage and possible gas accumulation.

4. Oxygen / flammable / toxic gas presence shall always be checked before starting jobs
inside the excavation.

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Refinery Operating System No: ROS-019

Edition 2015
Safety Guidelines for Excavation
Rev 00/2015
Kochi Refinery

4 ROLES AND RESPONSIBILITIES

This section outlines only the major roles and responsibilities of various stakeholders related
to ROS-019. The roles and responsibilities are detailed in the requirement given in Section of
3.0 of this document. The stakeholders shall comply with these requirements.

4.1 ENGINEER IN CHARGE

1. Before carrying out excavation, the engineer in charge of the job shall prepare a check list
in the format given as Appendix ROS-19/A9.1. The filled in checklist shall form a part of
the hot / cold work permit taken for the job.

2. Excavation permit shall be obtained as per the Work Permit System ROS-016.

3. Site of excavation shall be thoroughly inspected by the Engineer in Charge as per the
below given schedule:

a. Daily, prior to starting of work

b. After every blasting operation

c. After an unexpected fall of ground

d. After substantial damage to supports

e. After rain.

5 APPROVAL

This ROS undergoes a review and approval process in line with the process specified in Section
5.0 of ROS-001.

5.1 REVIEW OF ROS


1. HODs of F&S, E&C and Maintenance and Functional Heads of Operations and Projects are
reviewing authorities of this ROS.

2. The reviewing authorities shall ensure that requirements of ROS are relevant with respect
to context of the business and are in line with current environment.

3. Reviewing authority shall sign on the Document Release Note of this ROS.

5.2 APPROVAL OF ROS

Refinery Council (RC) is the approving authority for the approval of this ROS. Head of KR is the
signatory on behalf of the RC and shall sign on the Document Release Note of this ROS.

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Safety Guidelines for Excavation
Rev 00/2015
Kochi Refinery

6 MONITORING AND CONTROL

Fire & Safety department shall conduct random site inspections and verify records thereof as
per this ROS and ensure the compliance. Any discrepancy noticed shall be reported along with
corrective action.

7 RECORDS

1. Duly filled excavation checklist.

2. Excavation permit obtained from the department.

8 REFERENCES
1. Excavation work: Code of Practice, Safe work Australia

2. OHSA technical manual

3. OISD105- Work Permit System

4. Previous revision of ROS63 Safety guidelines for excavation in refinery premises

9 APPENDIX

1. Appendix ROS-019/A9.1- Checklist for Excavation

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Safety Guidelines for Excavation
Rev 00/2015
Kochi Refinery

9.1 APPENDIX ROS-19/A9.1: CHECKLIST FOR EXCAVATION

Name of the Job:……………………………………………………………. Area / Location:...............................

Sl. Check Point Checked If No, what other Remarks


No. (√) remedial steps taken?
Yes No
1 Is the ground stable for
excavation?
2 Are the adjoining buildings,
structures or roadways
unaffected by the excavation?
3 Have gas, water, electrical and
other public utilities shut off or
disconnected?
4 Is the area to be evacuated free
of underground pipes, cables,
conductors etc.
5 Is it possible to maintain a safe
repose angle of 450 for the
excavation?
6 Is it possible to provide suitable
bench of 0.5 m wide at every
1.5 m depth of excavation?
If the above points 5 & 6
7 cannot be met, has proper
shoring and strutting to
prevent cave-in or slides be
provided?
Has exit route in case of
8 emergency decided and
marked at site? Does facilities
like ladder etc., has been kept
ready to enable workers to
come out quickly?
Has steps taken to place the
9 excavated earth at least one
meter away from the trench?
10 Has steps taken to prevent
vehicular movement or locating
the plant or equipment close to
1.5m from the edge of the
trench?
Has necessary precautions
11 taken to comply with the
conditions in work permit

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Safety Guidelines for Excavation
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system in KR regarding
underground utility lines
taken?
Has steps taken to prevent
12 entry of surface water into the
trenches?
Does the site has facilities for
pumping out water, if any
accumulating in the trench?
Has steps taken to prevent
13 superimposed load like new
construction coming near the
excavation site within a
distance equal to depth of
excavation?

----------------------- ----------------------- ----------------------- -----------------------------


Signature Name Designation Department

.........................End of Document.........................

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