Professional Documents
Culture Documents
ROS-019
Edition: 2015, Revision: 00/2015
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
Reviewed by
Approved By
Digitally controlled document and hence sign is not requird for pdf version of ROS. Signed Mastercopy is available with Custodian
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.
Edition 2015
Safety Guidelines for Excavation
Rev 00/2015
Kochi Refinery
Table of Contents
Preface ....................................................................................................................... 6
1 INTRODUCTION ............................................................................................... 8
3 Requirements ................................................................................................ 11
Edition 2015
Safety Guidelines for Excavation
Rev 00/2015
Kochi Refinery
5 Approval ....................................................................................................... 17
7 Records ......................................................................................................... 18
8 References .................................................................................................... 18
9 Appendix....................................................................................................... 18
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.
Edition 2015
Safety Guidelines for Excavation
Rev 00/2015
Kochi Refinery
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
In addition to the above, several experts from various departments contributed in the preparation,
review and finalisation of this document.
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.
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
3. Tunnelling
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.
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.
Edition 2015
Safety Guidelines for Excavation
Rev 00/2015
Kochi Refinery
May : Optional
Shall : Mandatory
Should : Recommended
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
GOVT : Government
Edition 2015
Safety Guidelines for Excavation
Rev 00/2015
Kochi Refinery
KR : Kochi Refinery
RC : Refinery Council
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.
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.
f. struck by machinery
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.
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
Edition 2015
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.
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.
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).
Edition 2015
Safety Guidelines for Excavation
Rev 00/2015
Kochi Refinery
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.
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.
4. In rock cut excavations where the rock is friable, netting should be used.
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.
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.
Edition 2015
Safety Guidelines for Excavation
Rev 00/2015
Kochi Refinery
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.
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.
Edition 2015
Safety Guidelines for Excavation
Rev 00/2015
Kochi Refinery
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.
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.
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.
Edition 2015
Safety Guidelines for Excavation
Rev 00/2015
Kochi Refinery
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.
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:
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.
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.
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.
Edition 2015
Safety Guidelines for Excavation
Rev 00/2015
Kochi Refinery
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
8 REFERENCES
1. Excavation work: Code of Practice, Safe work Australia
9 APPENDIX
Edition 2015
Safety Guidelines for Excavation
Rev 00/2015
Kochi Refinery
Edition 2015
Safety Guidelines for Excavation
Rev 00/2015
Kochi Refinery
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?
.........................End of Document.........................