Safety Manual M-001-R3

TCE Consulting Engineers Limited
SECTION: TITLE
TCE.M7-GN-SF-M-001
SAFETY MANUAL Sheet (i) of (i)
GENERAL GUIDELINES FOR ENSURING SAFE
WORKING PRACTICES
VOLUME-I
REV. NO R0 R1 R2 ISSUE
INITIALS SIGN INITIALS SIGN INITIALS SIGN INITIALS SIGN
PPD.BY NSA Sd/- NSA Sd/- SS
CKD.BY GR Sd/- PBT Sd/- PGG R2
APP.BY PSS Sd/- RRK Sd/- PBT
DATE 01.02.1994 20.06.2001 20.10.2008

TCE Consulting Engineers Limited SECTION: WRITE UP
TCE.M7-GN-SF-M-001
SAFETY MANUAL SHEET 1 OF 52
CONTENTS
Section. No. Title Page No
1. Vision, Mission and Values 3
2. Safety, Health and Environment Policy 4
3. Introduction 5
4. Goals and Objective 7
5. Definitions 8
6. Safety Philosophy and Principles 10
7. Organization and Safety Culture 14
8. Hazard Identification and Risk Assessment 18
9. Accident, Incident and Near-miss / Dangerous 20

Occurrences
10. Causes of Accidents 26
11. Safety Inspection Observations and Audit 30
12. Training 38
13. First-Aid 40
14. Appendix 48
15 Cross-Reference 49
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REVISION STATUS SHEET
REV. NO. DATE DESCRIPTION
R0 01-02-1994 GENERAL GUIDELINES FOR

ENSURING SAFE WORKING
PRACTICES AT PROJECT
SITES.
R1 20-06-2001 GENERAL UPDATE IN VIEW

OF TECHNOLOGICAL UPDATE
OVER THE YEARS.
R2 20-10-2008 GENERAL UPDATE IN VIEW

OF TECHNOLOGICAL UPDATE
OVER THE YEARS.
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1. VISION, MISSION & VALUES
Vision
To be an internationally respected engineering consultant offering
comprehensive solutions.
Mission
Provide Technically Excellent and Innovative solutions, for
Adding Value for all Stakeholders, And Operate Globally, as
Professional Consulting Engineers.
Values
Customer satisfaction and Loyalty.
Employee Dignity and Self Respect.
Technical Excellence with Professional Ethics.
Organizational and Individual Growth.
Responsibility to Society.
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2. SAFETY, HEALTH AND ENVIRONMENT

POLICY
The management of TCE Consulting Engineers Limited (TCE) is committed

to consistently support Safety, Health and Environment systems.
Towards this end, TCE will ensure that –
o All its activities are carried out in a manner that provides reasonably
practical safe and healthy environment for its employees and
customers.
o Employees are trained to execute their work in a safe and

environmentally responsible manner.
o Safety, Health and Environment care is exercised in its design and

construction services.
o Safety, Health and Environment performance is continually improved.
TCE will implement this policy in compliance with Safety, Health and
Environmental standards and codes of practice of its customers and in
accordance with applicable national laws and regulations.
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3. INTRODUCTION
In the various chapters of this Manual an attempt has been made to concisely
define and describe the various aspects of Safety, including identification and
prevention of hazards related to construction work places / sites.
Safety of men and material is of vital importance for unhindered execution of

activities at site and timely completion of the project. Everyone associated with
the work, regardless of his / her position or status, has the responsibility of his /
her own safety and safety of people working with / for or around him / her.
Accidents and injury cause pain, misery, loss of earning and hardship not only to
the injured person, but also to his / her family. No one, therefore, wants to get
injured; instead wants to return home in the same condition in which he / she
came each day. This is, however, possible only if everyone followed the safety
requirements all the time.
While it is the responsibility of Management (Owner / Contractor) to provide

safe working conditions at work place / site, it is the duty of all associated with
the work to earnestly follow the safety rules, norms, standards and procedures,
and not to indulge in any unsafe act or practice, and be cause for creation of
unsafe conditions.
Site / Work place Safety Management should ensure wide coverage / awareness
and effective implementation of these to achieve the goal and objective. This shall
include establishment of effective channel of communication at site / work place,
training, observation & audit, motivation and counselling.
As work execution at site is generally carried out by Contractors, due care shall be
exercised for their proper selection, duly considering their past performance /
safety record, Safety Policy, resources with regard to trained man-power , safety
appliances, their understanding and appreciation of Client’s requirements,
inclusion of safety clause in the contract and effective contract management.
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SAFETY PYRAMID
1
Fatality
Indicators
Lagging
30 LTI
(DC)
300 medical treatments

(LWC)
3000 Near Miss or first aid cases

Indicators
30,000 Hazards and Risks Hazards

* Unsafe Act
Leading
* Unsafe Conditions
Gaps in Thinking
Near Misses / First-aid Cases = 10 % of Unsafe Acts + Unsafe Conditions
LWC / Minor Injuries = 10 % of Near Misses / First-aid cases
Disabling Causes (DC) / Major Injuries = 10 % of LWC / Minor Injuries
Fatality Cases = 3 % of DC / Major Injuries
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4. GOALS AND OBJECTIVE
To create a Safe and Healthy Environment by reducing, minimizing and

eliminating risks at work places / sites, and to demonstrate Management (TCE)
commitment with high standard of performance by adopting / practicing the
stipulations made in this Manual.
The objective of Safety Management is to reduce the Unsafe Acts to such a level
where probability of injury is eliminated; a step beyond would be Incident – free
Work place / site.
Safety is no accident. Following are the desired targets at work place / site:-
¾ NO Fatality
¾ NO Lost time Accidents
¾ NO Medical Cases
¾ NO Fires
¾ NO Spills
¾ NO Personal Injury
¾ NO Environment Incidents
¾ NO Loss to property
¾ NO Near misses / hits
Tracking Safety Performance against the above targets will serve as a yard stick
to measure whether safety today is better than last week. Persistence would yield
safety following week bettering the previous week.
The ultimate goal is “Incident free work”.
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5. DEFINITIONS
Accident:
It is an undesired event or incident that results in harm to people and / or
environment and damage to property or loss to process.
Incident:
It is an event that gives rise to an accident or had the potential to lead to an accident
or adverse community reaction. It is a symptom that something is wrong.
Near Miss / Near Hit:

It is an undesired event which under slightly different circumstances could have
resulted in harm to people and / or environment and damage to property or loss to
process.
Hazard:
Anything which has the potential to cause harm.
Risk:
The likelihood of harm being realized. (Lack of risk perception is responsible or
accidents. Perceiving risk is Safety Attitude and Safety Norms are followed then)
Injury:
It is always a result of some accident
Severity Rating:
Rating assigned to an unsafe situation (condition or act).
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Severity Index:
Weighted Average of Violations ratings observed during an Audit, that represents the
prevalent safety situation of a work place / site, area or sub-area.
Safety: Means:
No injuries; No accidents; No place for unplanned activity; All activities well
defined; Everyone knows his job well; Everyone takes pride in doing his job well;
and Work excellence.
Management:
Any one in administrative / executive capacity having powers to sanction leave, fills
appraisals / grants promotion to his subordinates, and sanctions budgets is considered
to be in management position or a part of management.
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6. SAFETY PHILOSOPHY AND PRINCIPLES
¾ Working safely shall be a Condition of Employment / Engagement.
¾ Training Employees to Work Safely shall be essential.
¾ All injuries can be prevented and preventing personal injury is a good

business.
¾ Management is responsible for preventing injuries.
¾ Employees’ involvement is essential.
¾ Every job shall be assessed for risk and due control action exercised.
¾ Causes of Unsafe Behaviour-BBS can be identified
¾ Regular management observation is a must.
¾ To read and understand all Safety Standards made available, incorporate

them in Safe Working Procedure (SWP) and manage site safety through
these.
¾ Safety should be managed – set practical achievable goals and plan to

achieve them.
¾ Safety is Line Management responsibility.
¾ Concern and Care for the Employees.
¾ Ensure hazard free and clean work environment.
¾ Safety System shall fit and reflect the culture of the Organization.
Remember:
“You get the level of safety that you demonstrate you want”
“Make safety a way of life”
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Behavioural Based Safety (BBS):
A new concept of behaviour based safety culture is emerging. According to this

even with varieties of safety system, procedures, knowledge and equipment in
place, injuries continue to happen, especially where human element is involved.
It has been felt that this is primarily due to unsafe behaviour and habits, and
consequent unsafe acts causing accidents and injuries. Cost of attending to the
injuries and absenteeism on this account will keep mounting more and more in
years to come. Apart from moral and statutory obligations, attention, therefore,
needs to be focused on behavioural safety.
Behavioural based safety system (BBSS) takes a look at the behaviours we all
demonstrate and practice, and how these habits and attitudes put us at risk.
Behaviour of personnel can be altered surely but slowly by organized, concerted
and conscious effort from all management personnel.
BBSS develops observations and analytical techniques, as well as

communication and relationship with fellow colleagues and workforce. The
process, basically involving and driving employees, constitutes the following
steps -
• Observe each other and give feedback on significant practices.

• Look for safe behaviour focusing on –
• Body Position, eyes on work, eyes on path, lifting practices and
holding practices.
• Work condition, selection and use of tools, labelling / tags, well
prepared work permit, work area free from tripping / slipping hazards,
signs / barricading, lighting, ventilation and fall protection.
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• Clothing, PPE condition, use of eye / face protection, helmet, respirator,

hazardous gas / underground services detection, N2 blanketing,
earthing, influence of drug / intoxicants / stimulants.
Prepare a list of Safe behaviours with employees’ direct involvement and clear
acceptance without overriding the existing rules, regulations and law of the
land, and make the list available with every employee.
Let each employee carry out observation on one employee for 5 minutes
informing the employee that his/her behaviour is being observed. The Observer
may express his/her concern on Unsafe behaviour, but will note down only the
safe behaviour on the sheet without mentioning the name of observed employee.
The observation shall be objective – following a particular rule, using a

particular PPE, and similar, and shall not be subjective like – well dressed, good
house-keeping, etc.
Supervisors / Managers also shall make similar observations during their turn,
noting down at least 3 - 4 safe behaviours exhibited by employees.
• Analyze observations
• Plan and Implement improvements.
• Set team goals
• Provide feedback to team on progress towards goal, and
• Encourage / Appreciate / Recognize individuals and commemorate team
Achievement.
In this model (BBSS) Safety Observations are Safety Index
Advantages of behavioural safety are –

• Promotes employees involvement,
• Reduces reliance on enforcement,
• Improves culture and moral,
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• Proactive rather than Reactive,

• Effective injury reduction, and
• Effective performance improvement.
Communication plays a vital role in disseminating information. Management

shall ensure that the Safety requirements, rules, regulations and policies are
clear, well defined and widely communicated through electronic media, PA
system, site and review meetings, bulletin boards, news letters / magazines,
hand outs, banners, posters, booklets, circulars, models, exhibitions, plays / acts
and safety campaigns. A “communication sub-committee” could be instituted
and its help taken in achieving this objective.
Another important aspect in achieving safety goals and objective is discipline.

Management shall be fair and firm, and discipline for safety violations must be
seen as consistently applied to everyone regardless of position and appropriate
to the degree of violation. All individuals shall be bound to follow all safety
rules as notified from time to time, and shall use safety equipment and
appliances when necessary. Breach of this shall be treated as misconduct and
shall be liable for punishment.
The following rules are considered Cardinal or Life saving rules, and shall be
strictly complied with and non-adherence/compliance shall not be condoned.
This is in view of very high order of present safety needs and to keep human life
above all.
• Starting the job With proper work permit or clearance,

• Not to be under influence of alcohol or illegal drugs at work,
• Compliance to the rules of confined space,
• Fulfilment of essential conditions for safe gas cutting and welding,
• No tempering of locks/protections in the positive isolation, and
.
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7. ORGANIZATION AND SAFETY CULTURE

A good Organization ensures –
¾ Maximum involvement / participation of and driven by employees and

management
¾ Analysis and Judgment at all appropriate levels
¾ Information flowing up as well as down- Two Way Communication
¾ All branches and levels working together
Employees / Workers involvement could be secured by letting them –
¾ Identify their safety training needs,

¾ Participate actively and interact with positive frame of mind,
¾ Follow safety rules and procedures,
¾ Maintain equipment and work place in order, and
¾ Avoid indifference to safety.
Safety is driven by the employees. A “Safety Committee” at each of the

location / site should be formed with wide representation from the employees.
To ensure safe working environment at work places, Employees are encouraged

to:
• Plan and carry out inspections of their areas,
• Identify issues and generate report on their observations.
The Safety Committee shall:

• Review such reports,
• Initiate corrective & preventive action,
• Set safety targets, monitor performance, measure improvements, and
Commemorate achievements.
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Management involvement would mean –
¾ Ensuring up to date safe procedure in place for each and every job.
¾ Inviting suggestions on/for Safety.
¾ Monitoring and checking the Unsafe Conditions.
¾ Obtaining feedback and conducting safety reviews regularly.
¾ Encouraging employees to bring out Safety Concerns / Issues without
Fear and giving due consideration.
¾ Each level of Management needs to feel and accept responsibility for
the behaviour of those who report to them, and control the events.
Management drive would require –
¾ Having clear, appropriate and relevant rules and regulations in place.

¾ Providing training at appropriate levels and ensuring resource for it.
¾ Selecting right design, men, material and equipment for the job.
¾ Enforcing implementation and measuring safety performance.
¾ Reward the performers and track the non-performers.
¾ Ensuring uniformity in discipline and reward.
The Leader must set example and expect this from his managers and
supervisors. The Leadership shall also define and communicate the need and
benefits of changes, and ensure –
¾ Strategic action planning

¾ Well defined management / Supervision activities.
¾ Employees’ participation, and
¾ Assessment, Review, Feed-back and Learning
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A good Process ensures –
¾ Safety focused meetings, including Tool-box talks and Mass meetings, with
employees.
¾ One to One talk with employees to get their feelings about Safety and
adequacy of facilities provided.
¾ Counselling and motivational means.
¾ Adequacy of banners, posters, notice boards, safety corners and exhibitions.
¾ Encouragement and celebrations
All Employees / Work- force expect –
¾ A safe work place

¾ To be accident free
¾ A good team and a good leader,
And a Proactive Organization must ensure this by creating a safety culture

having zero injuries as a result of effective enforcement of systems, procedures
and process.
The benefits of Safe Work Culture are:-
¾ Requirements consistently communicated,

¾ Responsibilities understood and accepted,
¾ Management and Employees’ relationship cordiality, and
¾ Behaviour driven safety results.
Common Organizational Impediments –
¾ Safety can be hired

¾ Priority of business over safety
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¾ Responsibility / Accountability not clearly defined and demonstrated

Proactively
¾ Tolerance of Unsafe Behaviour.
¾ Enforcement of rules :– Different standards practiced
An organization should strive for Interdependent Safety Culture which is both

employees and management driven with their full involvement and has –
¾ Teams building, team commitment, team goal and team owning Safety
¾ To Help others to conform to Safety.
¾ Value for each other
¾ Organizational pride is derived, and
¾ Working unsafely is considered disgraceful.
¾ Continual learning and improvement.
This culture will lead to achieving zero injuries by choice and not by chance.
What needs is a System of Planning, Implementation, Check / Audit,

Review, Learning and Continual Improvement.
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8. HAZARD IDENTIFICATION & RISK ASSESSMENT
Anything with potential to cause harm is Hazard, and the

likelihood of harm being realized is Risk.
Many a times people tend to ignore or fail to identify / assess hazards in the
background of their past experience, mindset, complacency or belief.
A few common examples of which are given below:
I know my job / trade.

This never happens.
I can get away with it if I did it once a while.
We will do it this way just one time only.
You are exaggerating the situation.
We have been doing it since last so many years and never had any
problem.
Risk perception reduces with time if there are no accidents / injuries.

Also, at times significant items are ignored and trivial concentrated upon.
Lack of / reduction in risk perception is responsible for accidents resulting
into severe injuries.
Risk perception is Safety Attitude and Safety norms are followed only
then. Education / information, however, play an important role. Risk
perception attitude has to be developed and maintained in the management
as well as employees.
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The following steps could be adopted for Hazard Identification –
¾ Involve employees and safety representatives to identify items / events /

work activities which may pose hazard – hazards may include what?
¾ Determine who, what might be harmed and how?

- Employees / work-force
- Visitors
- Property
- Environment
¾ Evaluate the risk and decide whether existing controls/measures are

adequate or do they require strengthening?
- Safe Work Procedures (SWP) and Standards
- Tools, appliances and equipment
- Trained crew
¾ Record the findings
¾ Review the assessment and revise following as control measures.

- New procedures
- New machine
- New materials
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9. ACCIDENT, INCIDENT AND NEAR-MISS /

DANGEROUS OCCURRENCES
Despite Proper Safety System, accidents at work places / sites do take place. The
workplaces / sites, therefore, shall be in preparedness all the time to promptly and
properly handle such eventualities. It is expected that all team members exercise
vigilant and ensure strict adherence to all safety norms by TCE staff as well as by
the contractor’s staff. Despite all the vigilance and measures, if an accident /
mishap takes place, please ensure that it should be immediately reported to
VP(CN) or his designated officer as well as to the respective Project Manager
/ Project Co-ordinator by telephone and followed by e-mail. Please ensure
that detail investigation is made and action plan to avoid such incident has to
be submitted within 72 hours of the accident.
The Emergency Plans preferably must include the following:-
¾ Contact telephone numbers exhibited at prominent places.

¾ Identified emergency Assembly Point and route
¾ A Vehicle / Ambulance with driver available at all the times.
¾ Written down procedure with specified responsibilities and identified
owners, known to individuals.
¾ Siren / hooter system for immediate and effective communication for
rushing help, and evacuation.
The below mentioned practice could be followed for reporting the accidents:
Accidents Not Involving Injury to Personnel
In case of any accident which does not involve injury to any personnel, the
in- charge of the area in which the accident has taken place shall prepare a brief
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report clearly mentioning the date, time, place, equipment involved, agency
involved, details of accident including damages caused, approximate extent of
loss, etc. The report shall be followed by a detailed report with identified
probable reasons / causes for the accident. These reports shall be routed through
proper channels to the concerned authorities for necessary information / action.
Accidents Involving Injury to Personnel
Whenever any accident involves injury (minor or serious but without fatality
potential) to any person, the in- charge of area in which the accident has taken
place shall prepare a report as above, also indicating the nature of injury caused to
the person, and route the report through proper channel to the concerned
authority, and, as the need may be, to the concerned Government Authority /
Statutory Bodies as required in consultation with the customers.
The in-charge of first aid and the medical officer must enter their diagnosis and
the nature of injury along with the treatment administered and advice for going
back to duty / rest / hospitalization.
The injured person shall not be permitted to resume duties unless and until fitness
certificate is issued to him by the attending medical officer.
The compensation payable, if any, shall be worked out, by the concerned agency
based on the nature of accident, causes of accident, nature of injury and applicable
Government Regulations.
Accident involving serious injury likely to be fatal
Whenever any accident involves serious injury to any personnel which could
result in fatality, the in-charge of area in which the accident has taken place
should prepare a detailed report as above. Also the report shall indicate the
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nature of injury caused to the person and route the report through proper channel
to the concerned authority, including to the concerned Government Statutory
Bodies as required in consultation with the customers.
The in-charge of first aid and the medical officer must enter their diagnosis and
nature of injury along with the treatment administered and the need for rest /
hospitalization / certification of death (in respect of fatal accident). In the event
of fatal accident certification of death has to be along with post-mortem report
from the concerned Government Medical Authorities.
The injured person shall not be permitted to resume duties unless and until fitness
certificate is issued to him by attending medical officer.
The compensation payable, if any, shall be worked out by the concerned agency
based on the nature of accident, cause of the accident, nature of injury and
applicable Government Regulations.
Fatal Accident
Whenever any fatal accident takes place the in-charge of the area in which the
accident has taken place shall prepare a detailed report and also immediately
arrange to intimate to the concerned Government Bodies, such as local police, in
the form of First Information Report (FIR) or as called for by applicable
Government Regulations as required in consultation with the customers.
In the event of fatal accident, certification of death has to be along with post-
mortem report from the concerned Government Medical Authorities.
The compensation payable shall be worked out, by the concerned agency based
on the nature of accident, cause of the accident, nature of injury and applicable
Government Regulations.In case the accident has caused loss / damage to
property along with injury, the report prepared by the in-charge must include such
details also.
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While rushing help to the victim, attending to him/her, his/her hospitalization,

compensation to him/her, corrective measures and restoring work at site / work
place will acquire priority; necessary action for preventing recurrence must also
be taken. For this the site / workplace management shall constitute an inquiry
committee to investigate the case and submit report highlighting the root cause of
the accident and measures required to be taken for preventing recurrence.
Investigation must also be carried out for Incidents and Near Misses. Each case is
the result of some Unsafe Behaviour which needs to be corrected. The Unsafe
behaviour has to be spelt out and the injury report along with it shared with all by
proper communication through the departmental or steering committee, and
action taken to eliminate the cause. Each case must bring out some learning to
enter the system for preventing recurrence.
In case of incidents / accidents the issues to be addressed are as follows:-
Immediate Action
Appropriate immediate action shall be taken by the personnel on the spot, e.g. –
first aid, fire fighting, containing spills, evacuation, isolation of energy sources,
etc. This shall also apply to situations where accident has not taken place; the
immediate action shall be aimed at mitigating the risk to personnel. The Line
Manager shall have the power to barricade and suspend work in the area where
incident has occurred till the site is declared safe for working and / or
investigations have been completed.
Reporting
The area in-charge shall raise an incident /accident report in appropriate form
available, if any. Serious accidents should immediately be reported to the Owner /
Client.
The following accidents are statutorily required to be reported to the specific

authorities, depending upon the jurisdiction.
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Death, injury requiring hospitalisation, treatment needed due to chemical

exposure, major spills, emissions or serious environmental impact, medical
treatment needed within 48 hours of exposure to a substance, electric shock,
spinal injury, loss of body function, collapse of an excavation / building /
structure, implosion, explosion, fire, spillage of any dangerous goods, over-
turning / failure / collapse of a plant, release / fall of a substance from a height,
inrush of water / mud / gas, interruption in main ventilation system or any other
event specifically prescribed by legislation.
The report shall include type of accident (collapse, explosion, spill, gas leak,
electric shock, etc.), injury / illness to a person that results in his / her unfitness
for attending duty for a continuous period of more than 48 hours, nature / extent
of plant and machinery damage, potential damage due to exposure. Records of
such reports / notification shall be kept for a period of at least 5 years.
Investigation
All incidents evaluated based on their severity shall be investigated by an

individual or a committee, constituted by Management to inquire into the root
cause of the accident, and for corrective and preventive action to stop any
recurrence. The investigation shall analyse the following:-
• Whether there was SHE Management system failure?

• Was there a Safe Work Procedure for the activity?
• Was the procedure adequate–simple, easy to use, comprehensive,
practical, workable, and effective, etc.?
• Was the procedure properly implemented and followed?
• Was the crew trained to carry out the work?
• Was the Supervision adequate and of appropriate quality?
• Was proper resources and tools, tackles, etc provided for the job?
• What was the position of men and materials?
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A Corrective Action Note, detailing the scope and impact of the corrective action,
shall be raised. The potential cost of the accident shall be worked out as a part of
the investigation and shall form a part of the report. The scope of investigation
may also include identification of the person / agency responsible and the
consequence management arising thereupon. The record shall be kept with the
document controller or as specified by the legislation.
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10. CAUSES OF ACCIDENT
Standard Acts
¾ Operating without Authority

¾ Non-use of PPE / clothing or use of defective / damaged PPE
¾ Violation of Procedure
¾ Violation of standards / norms
¾ Use of defective or improper tools / tackles / equipment
¾ Working under influence of drug / alcohol / intoxicant
¾ Absent minded / unmindful / talking on cell phone while walking
driving, entering toilets, operation of machineries or climbing down
stairs.
¾ Faulty signalling
¾ Failure to warn or Failure to acknowledge warn
¾ Horseplay / Over- confidence / Complacency / Behavioural
¾ Lack of knowledge
¾ Issuance of incorrect / in-appropriate instructions
Mitigate by Observations and Feedback loops
No loose or thin garment, full pant, full sleeve shirt tucked in and buttoned
at the cuff, cotton dress except for those worn during special operations,
reflective high visibility jacket, overall, helmet, shoes, goggles, gloves, shin
guard, full body harness, gum boots, welder’s helmet, ear plugs, nose mask /
breather, nail-less shoes, and any other gadget required for specific work
irrespective of the gender/position of person.
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Standard Conditions
¾ Poor house-keeping / congestion

¾ Poor lighting / ventilation / working conditions
¾ Weather conditions (extreme heat, dust, storm, cold, dew, snow, heavy
rain, etc)
¾ Lack of training
¾ Defective equipment
¾ Hazardous / noisy atmosphere
¾ Improper storage of chemicals/ explosives
¾ Inadequate fire prevention / fire fighting devices
¾ Improper/ inadequate signs and signals
¾ Lack of control
¾ Inadequate supervision / leadership
Mitigate by Risk Assessment, Prevention & Control, Inspection and

Audits.
Personal Factors
¾ Lack of knowledge
¾ Physical / psychological stress
¾ Physical / mental inability
¾ Lack of motivation
Job Factors
¾ Inadequate Work Standards

¾ Inadequate Engineering / detailing
¾ Inadequate equipment / tools / materials
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¾ Abuse / misuse
¾ Wear / tear and inadequate maintenance
¾ Absence of / inadequate supervision
Mitigate personal and job factors by Training, Accountability,

Communication, Planning & Evaluation, Rules & Procedures, and Incident
Investigations
Most of the Injuries / accidents are caused by unsafe acts and behaviours,
and not merely due to unsafe conditions and equipment.
75% Injuries are only due to Unsafe Acts (u/a)

20% Injuries are due to a combination of Unsafe Acts and Unsafe
Conditions.
5% Injuries only are due to Unsafe Conditions (u/c)
Amongst the injuries caused due to unsafe acts, the major contributors are:
30% Incorrect / Improper Body Posture / Position

28% Faulty Tools/ Equipment
15% Non-use of PPE
12% Procedure Violation , and
15% Reaction of People / Action of Others / Orderliness
(%ages may vary depending upon site conditions and organization)
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Cost of Accident
Visible or Direct Cost
¾ Medical cost
¾ Compensation
¾ Property damage Insured Cost ( Tip of the Iceberg )
¾ Product loss
Hidden or Indirect Cost
¾ Production loss
¾ Loss of sales / deliverables Uninsured Cost ( the Iceberg )
¾ Dent on Company’s image
¾ Loss of Goodwill / confidence
¾ Cost of investigation / Management’s time
¾ Legal expenses, Fines / Penalties
¾ Loss of referrals / business
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11. SAFETY INSPECTION OBERVATION AND AUDIT
Safety Inspection
A routine, scheduled inspection of an Unit or Department which may be carried

out by personnel within the Unit, possibly accompanied by some one from
external. The inspection would check maintenance standards, employees’
involvement, working practices, and that work is carried out in accordance with
procedures etc., rather than wide-reaching or in-depth approach taken in audit.
Safety Observations
Safety observation during execution of work at sites / Work places is a “Process”

in which the assigned Safety Personnel visit the work areas to observe
implementation of Safety system in the work being performed. Ideally all work
centres / sub centres shall be visited and at least 80% of the engaged workmen
observed during a minimum of 2 hours duration. The safety observer notices the
safe as well as Unsafe Acts, Conditions and work practices. He / She
communicate with employees about his / her observations and safety aspects of
the job. While he / she gives complements to the employees for the good work,
their attention is drawn towards the Unsafe work, discusses the risk / hazard
involved and severity potential, decides upon urgency of corrective action / work
stoppage depending upon the severity, and also takes employees’ commitment to
work safely.
A differentiation has to be made between Safety Observations and Inspection

Observations, and the Observer must be unambiguously knowledgeable about it
so that his/her actions are guided accordingly. Or else the very purpose would
get defeated.
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During the Safety Observations people are observed, everyone is covered,

observations are positive as well as negative, and the interactive discussion is
followed by report generation and corrective / remedial action. This in contrast to
the Inspection Observations where things are observed, the observations are only
negative, only experts are talked to; the dialogue is passive and followed by
report generation and corrective action.
Field Observation is another ‘term’ often used. Field observations are primarily
for compliance, are on acts and conditions, involve only supervisors with passive
dialogue, provide 80+ % coverage, followed by report. Safety observations are
on people for preventive measures; involve everyone on 1 to 1 interactive
training, generation of report and subsequent follow up.
The benefits of Safety Observations (field observations included) and feedback

arising thereupon are:-
¾ Prevent injury and property loss.

¾ Reinforce positive safety behaviour.
¾ Raise safety awareness and reduces complacency about hazards.
¾ Establish Safety standards.
¾ Test understanding of safety standards.
¾ Test compliance with standards.
¾ Identify weakness in safety standards.
¾ Identify and correct unsafe situations / fix some hazard immediately
¾ Tips sharing between experienced and new people.
¾ Motivate people to use safe practice consistently.
Safety Observations could be categorised under the following (generally

classified as six steps):-
¾ Reaction of people,
¾ Position of people,
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¾ Clothing and Personal protective equipment,

¾ Tools and Equipment,
¾ Procedures and Orderliness, and
¾ Ergonomics (repetitive motions)
When a personnel working unsafely is observed, the Safety Observer shall draw
the employee’s attention. He / She shall primarily comment on the employee’s
safe work, and then discuss the Unsafe Act, its possible consequences and safer
way to do the job. He / She shall get the employee’s agreement / commitment to
work safely in future. The observer shall also discuss other safety related issues,
and then at the end express gratitude to the employee.
While discussing the Unsafe Act, the Safety Observer must express his concern,
and focus on effect and not the act. All queries shall be framed to sound like
exploring and learning, and definitely not like teaching.
Observation matrix
¾ First line supervision to observe employees of their own area 3 – 5

times per week.
¾ Team to observe each other in their own area 3 – 5 times per week, and
Cross observation with other teams as required / requested.
¾ Mid-management to observe the first line supervision, team members
and employees of entire area 1- 4 times per month.
Top management to
(a) Observe team members and employees of segments 1 - 4 times per

month, and
(b) Mid-management of entire operation once per quarter.
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Observation information, reports and feedbacks can be utilized for assessing the
personnel and the work they do, detecting developing problems (follow up and
action), visualizing trends and reinforce positives.
Safety Audit
Safety audit is a technique to systematically appraise the effectiveness of a safety

program under execution. This helps to improve and upgrade the existing safety
program.
Safety audit is a methodology to critically evaluate safety program and

performance in terms of accident frequency, severity rates, identification and
control of hazards and assessment of financial losses on account of bad
performance. Safety audit also helps to evaluate the overall quality and character
of the safety program and its effectiveness.
Safety audit is meant to bring to light lacunae and lapses in the safety practices
being followed so that ways and means can be found to initiate corrective
measures to achieve better performance, efficiently and economy.
Types of Safety Audit
Safety audit can be internal or external based on whether it is carried out by a

team of persons within the organization or by a team of experts from an outside
safety / consulting organization hired for carrying out the audit.
Internal and External Safety audits have their own merits / demerits. In case of
internal safety audit, information as necessary could be had due to close
association with colleagues but there could be a tendency to protect person(s)
responsible for deficiencies. In case of external audit, collecting the information
is more difficult but the analysis is likely to be more objective and remedies
suggested more realistic since the auditors are expected to be neutral.
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Safety audit can also be categorised as basic audit, self audit and professional
audit. Basic audit means ensuring that all basic elements of the safety program
are implemented including analysis of qualitative, quantitative, setup, procedures
and controls, hazard identification education, training and maintenance of
relevant records. Self audit involves analysis of elements such as leadership and
administration, training, inspection procedures, inventory and job analysis of
critical jobs, investigations of accidents / incidents, emergency preparedness,
rules and regulations, group safety meetings and communication, community
education and demonstration.
Professional analysis is essentially external audit by a professional consultancy

organization. Professional audit involves analysis of various critical elements of
safety program at micro level, such as health of safety program, health hazard
control, personnel protection equipment, program evaluation system, purchase
and engineering control, general promotion of safety awareness including
training, display of audio / video cassettes etc., selection and placement of
personnel to implement the safety program etc. Professional audit involves
review of basic and self audits, safety programs, preparation of a questionnaire
for the audit to be filled in by the industrial unit for which the professional safety
audit is conducted, identification of vulnerable areas on the basis of the
completed questionnaire, verification of information and clarifications obtained
etc, analysis of information collected, arriving at loss indices, submission of
report along with recommendations.
Safety audit, both basic and self, need to be conducted by in-house safety
personnel on regular basis in order to assess the site situation, to facilitate taking
corrective action / remedial measures to ensure safe working conditions, to
exhibit management care and concern about them, and to keep their morale high.
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Measurement of Safety Performance
Safety performance of site is measured to improve processes and procedures

being practiced at site. Following two methods have been adopted.
I. DuPont Method
The Site should be audited on daily basis, maintaining an element of surprise, to

assess the unsafe conditions and unsafe acts – the prime factors responsible for
causing accidents / incidents / near misses. The audit observations could be
categorized, as explained above under the heading - observations, and assigned
severity rating on 1 to 5 scales on the following pattern depending upon the
severity -1 being minor and 5 posing fatality potential (Alternatively it could be
Safety index from 1-5 with sites/ work places with Safety Index as one being
Most Unsafe and 5 being Most Safe).
Severity Rating 1: Untidy area, minor issues.

Severity Rating 2: Restricted access, littered scrap / trash, and disorderliness.
Severity Rating 3: Violations of Rules and Procedures – potential injury.
Severity Rating 4: Unsafe conditions – serious injury potential – take prompt
action
Severity Rating 5: Immediate serious injury potential – stop activity
immediately and correct
A Severity Index (SI) of 2.2 or lower shall be targeted to ensure safe working.
Maximum of the week’s SI should be reported on weekly basis for review.
Depending upon the size, the site may be divided into zones, and responsibility
assigned to a senior person for each zone. In case of higher than 2.5 SI found
during the audit, all activities of the site/zone should be stopped and corrective
action taken before restarting the work.
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Severity Index (SI) = Sum of violations X Their respective severity rating
Total no. of violations observed during the audit

The audit process shall also provide coverage to ‘compliance to safety
standards’, ‘good citizens(clothing & PPE compliance and no act
violation)’,‘quality of safe work procedures’, and ‘awareness of safety standards
and rules’; aim / target 98 – 100 % for compliance to safety standards and good
citizens, and 4.9 – 5 for the rest on 1 to 5 scale.
A simple guide for site work execution could be –

• 100 % compliance to safety standards.
• 100 % good citizens
• Severity index ≤ 2.2
• No incidents
As described earlier, the objective of safety observations and audit is to improve
the safety performance. Some of the parameters against which this could be
measured are as follows –
- Lost work days
- Total injury rates
- Reduction in cost of equipment damage, insurance premium, and
compensation
- Attendance at safety meetings
- Completion of training
- Increase in strength of knowledgeable and skilled employees
- Increase in employees involvement and cooperation
- Reassured full work force with high morale
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II. Site Safety Index
Quantitative Rating Method

0 1 2 3 4 5
Housekeeping Materials are Materials are Awareness Awareness is Awareness good, Clearly identified
scattered, No scattered, No is not good, clear clearly location for material
clear area, clear area, available, identification, identification, storages, description of
haphazard, haphazard, not clearly barricaded, barricaded, no materials to be stored
personnel are personnel are identified., few material signages is displayed, personnel
not aware, not aware passage not not stacked , are ensuring 100% 0f
repeated clear. no personnel material are stacked in
finding. wrongly its place. Stacking of
approaching material is as per
the movement standard. All the
employees are aware
of where to keep what,
walking passage is
clearly marked, no
hindrance.
Permit To No permit to Permit to Permit to Permit to work Permit to work PTW in place, signed,
Work work work and work written valid. written valid. displayed, understood,
personnel JSA written- written Tool box talk Tool box talk not being followed, Closed.
working not signed, valid. Tool not done. Not done. Signed
Not box talk not displayed. Displayed not
understood done. closed.
by
supervisor.
PPE No JSA, NO JSA written, JSA cover JSA cover all JSA cover all JSA cover all activity,
Adherence DETAILS of Not covering all activity, activity, activity, Hazards Hazards are
activity. all activity Hazards are Hazards are are Identified adequately identified,
being done, Identified Identified adequately recommendations
Hazard inadequate adequately identified, adequate, good
findings are identified, recommendations awareness.
not adequate recommendati adequate,
ons Awareness need
inadequate, improvement
Awareness
poor.
Unsafe More than 10 More than 8 More than 6 More than 4 More than 2 No unsafe condition
Condition/Uns finding finding finding finding during finding during
afe Act during the during the during the the walk the walk
walk walk walk
Supervision No Supervisor Supervisor Supervisor Supervisor Supervisor present at
supervisor identified but present at present at present at work, work, observing,
identified and not present . work, work, observing, conduct tool box
present. observing observing, conduct tool box signature and aware of
details- due conduct tool signature and process. Coaches and
to too many box talk, Lack aware of process. mentors the team
activities. of awareness No documents
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12. TRAINING AND COMPETANCY

The site management must ensure that no one is deployed without proper training,
irrespective of his / her position. In order to familiarize with the general
requirements of safety, all employees shall go through safety orientation /
induction training, and possess valid safety card as a testimony of it all the time.
This is an important formality before issuing entry pass to the employees for
working in their workplace / site. Work related training for specific requirement
also need to be organized. Some suggested areas of such training are mentioned
below:
Majority of accidents are due to materials falling from height, working at height,
faulty platform / scaffold and hand rails, non-use of lifeline / lanyard / full body
harness, faulty access / ladder, traffic rule violation, unguarded machinery, and fire
due to gas cutting / welding spatters. As some of these may pose serious injury /
fatality potential, training in these areas should be arranged on priority basis.
Suggested Training Areas
• First aid
• Fire fighting / prevention
• Full body harness and specific PPE / clothing
• Road safety
• Track line safety
• Crane operator
• Storage and handling of compressed gases and hazardous materials
• Working in gaseous/ hazardous/ confined areas
• Positive isolation
• Hoisting / Lifting / rigging
• Access ladder and fall arrestors
• Scaffold, platform and hand railing
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• Barricading
• Working in electrical rooms
• Gas cutting, welding and grinding
• Working at height, and fall protection
• Pressure vessels and pressure testing
• Roof sheeting work
• Disposal of wastes and toxic materials
• Temporary electrical wiring and installations
• Use of portable electrically operated tools
• Hydra Operation
• Heavy Vehicle Drivers Training
• SA 8000
Site management shall from time to time assess the training needs of the personnel
working at sites and arrange for imparting such training. The “Steering
Committee” or the communication sub-committee can play an important role in
this. A record of trained persons in safety shall be available at site. It should also
be made obligatory on part of the senior persons to ensure that their subordinates
have received requisite safety training.
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13. FIRST AID
First aid is the immediate medical aid made available at the work site itself to an
injured or seriously ill person before regular expert medical facility could be
provided. This is essential to ensure preservation of life, promotion of recovery
and prevent injury or illness from worsening till medical aid from an authorized
specialist doctor is obtained.
It is to be ensured that all the erection agencies have adequate first aid facilities
at the work site itself for use of their employees at all times.
Bare minimum first aid kit as advised by the registered medical practitioner
should be available.
At least one first aid attendant / trained nurse should be always available at the
work site with every erection contractor having manpower exceeding 50.
A transport vehicle should be available for any emergency at all times at the
work site.
Telephone numbers and addresses of Doctors, Hospitals and first aid attendants
should always be available (preferably displayed at suitable prominent
location) to ensure prompt communication / availing expert medical aid.
A brief procedure for first aid treatment at site is given below.
Mental shock
This is a condition of severe depression of vital functions either due to severe
injury or narrow escape. This is a condition of collapse of patient wherein if
proper control is not ensured immediately, it could end up in death.
Symptoms:
Cold moist skin, nausea, pallor and giddiness, skin colour pale/ white ashen
grey or slightly blue, breathing shallow and rapid, pulse rate rapid but weak; the
patient would be thirsty and with clouded consciousness.
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Treatment
Lay the patient on his back in 'head low' position; attend to injuries, if any. If
the patient vomits, turn his head to one side. Wrap the patient in blanket to
provide warmth. If the patient is in a condition to swallow, give weak tea or
coffee. The patient should be reassured. The patient should not be
unnecessarily moved about but shifted to hospital at the earliest opportune
moment.
Electric shock
Switch off the source of supply if easily accessible, if not, pull the victim using
aids such as dry rope, dry walking stick, rubber gloves, folded newspaper, dry
garment or any dry non-conducting ( insulation ) material. The rescuer should
preferably be standing on insulation material like wooden board, wooden
planks, rubber mats or with rubber soled shoes or newspapers. In no case the
rescuer should use bare hands to pull the victim which could be fatal to the
rescuer himself.
Unless the patient is breathing normally which is most unlikely in case of a
severe shock, give the patient artificial respiration and continue the same till the
doctor is available to take further care.
Check the carotid pulse of the patient; give external heart massage if necessary.
Lay the patient on back, clear the mouth and throat of obstructions if any, keep
the head low so as to ensure nostrils pointing directly upwards and by pushing
the jaw to open air passages.
Repeat the process till the patient's pulse, breathing improves or the summoned
doctor arrives for taking further care.
Burns or scalds
In case of serious burn or scald, a doctor and an ambulance must be summoned
at once.
The patient should be immediately wound in a blanket and rolled to extinguish
fire caught by the clothes etc. Immediately on extinguishing the fire, pour /
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spray cold water on the affected part of the body. Apply ice or 'burnol'. Cover
the burnt area with clean or prepared sterilized burn dressing. Bandage the
affected area firmly except when blisters are present. Immobilize the affected
part. Treat the patient for mental shock if required; attend to the patient till the
doctor is available.
External bleeding.
Lay the patient in a comfortable horizontal position. Elevate the bleeding
portion. Every effort should be made to stop bleeding by direct pressure or by
applying a pad or sterilized dressing after cleaning the wound using antiseptics
such as 'dettol' or 'savalon' and then applying tincture iodine or tincture
benzoinco. The wound should be firmly bandaged. If direct pressure does not
stop bleeding, use indirect pressure by applying pressure on the relevant
pressure point or by using constrictive pad. Arterial bleeding, if encountered,
may be controlled by applying mild pressure on the artery between the wound
and the heart.
Summon for the doctor or ambulance and shift the patient to the hospital.
Fractures
Where a fracture is suspected, the limb must be immobilized. Do not attempt to
move the patient until the injured part is immobilized by a trained person. The
patient should be shifted to hospital only by competent ambulance staff.
Minor wounds
All minor wounds, cuts, scratches should be attended to immediately to avoid
risk of infection. The wound should be cleaned using 'dettol' / 'savalon' and
then applied with tincture iodine, tincture benzoinco or 'Neosporin' powder as
per individual case. Cover the wound using a sterilised dressing or adhesive
plaster based on the location of the wound. In case of injury becoming painful
or if it gets inflamed, patient should be immediately rushed to the hospital to
avail proper medical attention.
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Eye injuries
In case the patient complains of foreign body in the eye, he should be advised
not to rub the eye but casually and gradually blink the eye lid under water.
Even after repeating the cleansing operation with water, if the complaint persists,
then the first aid attendant / nurse should blow air by mouth in the affected eye to
remove the trapped foreign material. If the complaint still persists, eye drops
such as ‘locula’ may be used and the patient sent to the hospital for adequate
medical aid but in no case shall the patient be allowed to rub the eyes or any
attempt made to remove the foreign body using external means since this could
result in permanent damage to the eye, retina etc.
Snake bite
The treatment should be prompt. Call for the doctor and ambulance, but start the
first aid immediately by arresting the blood circulation in the snake bitten limb
by using constrictive bandage for 15 minutes and release for 1 minute
repeatedly till the doctor arrives to ensure that the poison does not spread. If
possible suck the spot of bite but only after constructive bandage is applied and
the wound is cleaned and washed using solution of potassium permanganate in
order to remove venom which may have dried on the skin, and spit out
immediately; repeat this till the patient feels relieved. Make a deep cut with a
sharp knife or razor blade at the bitten spot in order to bleed out the venom -
mixed blood. Keep the patient warm by covering with a blanket. Patient should
be absolutely still and no movement is permitted. If the patient is in a condition
to swallow, give him strong coffee or tea. If it is noticed that breathing is
reduced or has stopped, give artificial respiration using 'mouth to mouth'
method.
Chemical burns
In case the patient complains of burns due to acid, thoroughly flood the affected
part with water which would result in diluting the acid as well provide cooling
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effect. Bathe the affected part freely with alkaline solution prepared by mixing
one teaspoonful of baking soda i.e. sodium bi-carbonate dissolved in a glass of
water. Ensure that alkaline solution is not concentrated. Remove acid
contaminated clothing by cutting with scissors. Send the patient to hospital for
further treatment.
If the patient complains of burns due to alkali, thoroughly flood the affected part
with water to effectively dilute the alkali and to give cooling effect. If the alkali
is in powder form, it should be brushed off from the skin before flooding the
affected part with water to ensure that alkaline solution does not form. Bathe
the affected part of the body with a very weak solution of acid to neutralize the
alkali. Such a weak acid solution can be prepared by thoroughly mixing equal
quantities of lime juice or vinegar with water. Remove alkali contaminated
clothes by cutting with scissors. Send the patient to hospital for further
treatment.
Unconsciousness
If a patient is noticed to fall unconscious, immediately ensure supply of fresh
air by removing harmful gases present if any or by shifting the affected person
to airy space. Open the windows / doors / ventilators and keep the crowd away.
Keep the breathing passage clear by removing false teeth if any, taking the
tongue away from the back of the throat of the patient. If breathing has reduced
or stopped, give immediate artificial respiration. If the breathing is noisy on
account of blood, vomit, saliva etc. in the throat, keep the patient in 'three
quarter prone' position. Wrap the patient in a blanket after loosening the tight
clothing. Preferably shift the patient to an airy and safe shelter on a stretcher
and attend to him either till doctor arrives or till patient could be carried to
hospital for further treatment. The doctor / ambulance should be called for
immediately. If the patient is not unconscious, he may have symptoms like
giddiness, confusion and inability to walk straight if affected by gas /
fumes but not entirely overcome by it.
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Heat stroke
Heat stroke could affect a person due to hot, still, humid atmosphere and
inadequate consumption of drinking water. It is a serious state of the patient
which could result even due to excessive alcohol consumption and constipation.
If affected by heat stroke, the patient is mentally excited, restless, vomits and
has muscular cramps along with high fever - usually above 104 Degree F.
Under such circumstances, immediately summon doctor / ambulance. Strip
the patient naked and wrap him up completely in cold water soaked bed sheet.
Put on the fan and if not available use paper fan vigorously till temperature
comes down to 102 Degree F at which cooling process should be stopped to
avoid Pneumonia. After the temperature is brought down to 102 Degree F,
patient should be dried and covered using light blanket. Water can be
administered orally to eliminate poisons. Call a doctor.
Heat exhaustion
Remove the patient to cooler conditions in the fresh air. Lay the patient down
and loosen his clothing particularly around the neck to bring him to a
comfortable position, dash cold water on the head and neck to stimulate. Put on
the fan for vigorous cooling effect. If severe shock is noticed, use stimulants.
Crush syndromes
Early diagnosis is of utmost importance to prevent kidney failure. If the victim
is crushed for more than an hour by heavy weight such as fallen masonry or
machinery, he may show little signs of injury except redness and swelling of the
injured part, bruising, blistering, numbness or tingling may also be noticed.
After rescue, in a short while, injured part swells and becomes hard due to
outpouring of plasma into injured tissues. Due to the loss of fluid, blood
pressure drops rapidly and the patient may go in a deep shock and kidney failure
can occur.
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The patient should be laid down in such a way as to keep his head lower than
the legs. If the patient is in a state of consciousness, administer oral fluid
immediately to make up for fluid loss.
The patient should be carefully shifted to hospital at the earliest using preferably
ambulance / stretcher etc. Call for doctor for proper medical aid.
Serious injury / fatal accident

In case of serious injury / fatal accident, reporting of accident should be
immediate
Recordable Injuries
One which results in 1 or more days away from work.
Lost Workday Case (LWC)

Injury that prevents an employee from reporting to work on subsequent
scheduled shift.
LWC Rate = No. of LWCs x 1,000,000 / Total Exposure Hours
Restricted Workday Case (RWC)

Injury / illness that prevents an employee from performing his / her regularly
scheduled job on subsequent scheduled shift.
First Aid Case (FAC)

Injury that involving one-time treatment which does not necessarily require a
medical professional. Hospitalisation for observation where no medical
treatment is rendered is normally considered FAC unless the employee misses
whole of his / her next scheduled job shift.
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Medical Treatment Case (MTC)

Injury / illness that requires treatment by a registered medical practitioner. Loss
of consciousness due to injury or work exposure is always an MTC.
Total Recordable Rate = (No. of LWCs + RWCs + MTCs) x 1,000,000 / Total

Exposure Hours
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APPENDIX-1
ABBREVIATIONS:
SWP- Safe Working Procedure
BBSS- Behavioural based safety system
LWC- Lost Work-days Cases
DC- Disabling Cases
LTI- Lost Time Injury
PPE- Personal Protective Equipment
U /A, U/C- Unsafe Acts, Unsafe Conditions
FIR- First Information Report
SHE- Safety, Health and Environment.
SI- Severity Index
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CROSS REFERENCES
This document makes reference to the following Standard Documents of Construction
Office.
Document No. Document Title
TCE.M7-EL-ER-G-001 Guideline for Erection of Transformer at Site
TCE.M7-ME-ER-G-002 Guideline for Erection of Turbine Generator &

Condenser
TCE.M7-ME-ER-G-003 Guidelines for Erection of Rotary Equipment
TCE.M7-CV-CS-G-004 Guide for Concrete Mix Design
TCE.M7-CV-CS-G-006 Guide for Construction of RCC Chimney using Slip form

Technique
TCE.M7-CV-CS-G-007 Guide for Construction of Liquid Retention Structure
TCE.M7-CV-CS-G-009 Guide for Repairs to Concrete
TCE.M7-CV-CS-G-010 Guidelines for Non-Destructive Testing of Concrete
TCE.M7-ME-ER-G-013 Guidelines for Erection of Electrostatic Precipitator
TCE.M7-ME-ER-G-014 Guidelines for Application of Thermal Insulation
TCE.M7-ME-ER-G-015 Guidelines for Fabrication & Erection of Steel Stack
TCE.M7-ME-ER-G-016 Guidelines for Static Equipment Erection
TCE.M7-EL-ER-G-017 Guidelines for Erection of Control & Relay Panel
TCE.M7-ME-ER-G-018 Guideline for Fabrication and Erection of Piping
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TCE.M7-EL-ER-G-020 Guidelines for Construction Power Supply
TCE.M7-EL-ER-G-021 Guidelines for Erection of Gas Insulated Switchgear
TCE.M7-EL-ER-G-022 Guidelines for Erection of Transmission Line
TCE.M7-GN-PM-G-023 Guidelines for Handing Over Procedure
TCE.M7-EL-ER-G-024 Guidelines for Erection of H. V. Indoor Substation
Guidelines for Erection of Air Conditioning,

TCE.M7-ME-ER-G-025
Refrigeration and Ventilation
TCE.M7-ME-ER-G-026 Guidelines for Erection of D. G. Set
TCE.M7-ME-ER-G-027 Guidelines for Hot Tapping
TCE.M7-ME-ER-G-028 Guidelines for Erection of Storage Tanks
TCE.M7-EL-ER-G-029 Guidelines for Erection of Outdoor Switchyard
TCE.M7-EL-ER-G-030 Guidelines for Installation of Earthling & Lightening

Protection System
TCE.M7-ME-ER-G-031 Guidelines for Fabrication & Erection of Spheres
TCE.M7-ME-ER-G-032 Guidelines for Erection of Horizontal Pumps
TCE.M7.ME-ER-G-034 Guidelines for Erection of Steam Generator
TCE.M7-ME-ER-G-035 Guidelines for Handling, Heating and Heat Tracing of

Fuel Oil System
TCE.M7-ME-ER-G-036 Guidelines for Erection of Fly Ash Extraction / Disposal
System
TCE.M7-EL-ER-G-039 Guidelines for DC System Installation
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TCE.M7-ME-ER-G-043 Guidelines for Erection of Air Pre-Heater
TCE.M7-ME-ER-G-044 Guidelines for Erection of HP Piping
TCE.M7-ME-ER-G-046 Guidelines for Erection of Boiler Feed Pump & Deaerator
TCE.M7-ME-ER-G-047 Guidelines for Silent Steam Blowing
TCE.M7-ME-ER-G-048 Guidelines for Coating and Wrapping of Underground

piping
TCE.M7-ME-ER-G-051 Guidelines for Erection of Waste Water Treatment Plant
TCE.M7-ME-ER-G-052 Guidelines for Erection of Floating Low Speed Aerator
Procedure for Supervision of Concrete Structures

TCE.M7-CV-CS-P-001 Construction
TCE.M7-CV-CS-P-002 Procedure for Supervision of Piling Work
TCE.M7-CV-CS-P-003 Procedure for Supervision of Earthwork
Procedure for Supervision of Fabrication and Erection of

TCE.M7-CV-ER-P-004 Structural Steel
TCE.M7-CV-CS-P-005 Procedure for Supervision of Ductile Iron Pipeline

Installation
TCE.M7-CV-CS-P-006 Procedure for Supervision of Survey
TCE.M7-CV-CS-P-007 Procedure for Supervision of Road Work
TCE.M7-GN-QA-P-010 Responsibility Profile for Field Engineers
ISSUE
R2
TCE.M7-GN-SF-M-001
Procedure for Site Fabricated Large Diameter Mild Steel

TCE.M7-ME-ER-P-012
Pipe
Quality Control Procedure - Civil Construction (

TCE.M7-CV-QA-P-015
TCE.M7-CV-QA-F-001 to 093 )
Quality Control Procedure - Instrumentation & Control

TCE.M7-IC-QA-P-016
Construction ( TCE.M7-IC-QA-F-001 to 021 )
Quality Control Procedure - Electrical Construction (

TCE.M7-EL-QA-P-017
TCE.M7-EL-QA-F-001 to 018 )
ISSUE
R2

Safety Manual M-001-R3

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Safety Manual M-001-R3

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TCE Consulting Engineers Limited

GENERAL GUIDELINES FOR ENSURING SAFE

INITIALS SIGN INITIALS SIGN INITIALS SIGN INITIALS SIGN

PPD.BY NSA Sd/- NSA Sd/- SS

CKD.BY GR Sd/- PBT Sd/- PGG R2

APP.BY PSS Sd/- RRK Sd/- PBT

DATE 01.02.1994 20.06.2001 20.10.2008

Section. No. Title Page No

1. Vision, Mission and Values 3

2. Safety, Health and Environment Policy 4

4. Goals and Objective 7

6. Safety Philosophy and Principles 10

7. Organization and Safety Culture 14

8. Hazard Identification and Risk Assessment 18

9. Accident, Incident and Near-miss / Dangerous 20

10. Causes of Accidents 26

11. Safety Inspection Observations and Audit 30

REVISION STATUS SHEET

REV. NO. DATE DESCRIPTION

R0 01-02-1994 GENERAL GUIDELINES FOR

R1 20-06-2001 GENERAL UPDATE IN VIEW

R2 20-10-2008 GENERAL UPDATE IN VIEW

1. VISION, MISSION & VALUES

To be an internationally respected engineering consultant offering

Provide Technically Excellent and Innovative solutions, for

Adding Value for all Stakeholders, And Operate Globally, as

Professional Consulting Engineers.

Customer satisfaction and Loyalty.

Employee Dignity and Self Respect.

Technical Excellence with Professional Ethics.

Organizational and Individual Growth.

2. SAFETY, HEALTH AND ENVIRONMENT

The management of TCE Consulting Engineers Limited (TCE) is committed

Towards this end, TCE will ensure that –

o Employees are trained to execute their work in a safe and

o Safety, Health and Environment care is exercised in its design and

o Safety, Health and Environment performance is continually improved.

Safety of men and material is of vital importance for unhindered execution of

While it is the responsibility of Management (Owner / Contractor) to provide

300 medical treatments

3000 Near Miss or first aid cases

30,000 Hazards and Risks Hazards

Near Misses / First-aid Cases = 10 % of Unsafe Acts + Unsafe Conditions

LWC / Minor Injuries = 10 % of Near Misses / First-aid cases

Disabling Causes (DC) / Major Injuries = 10 % of LWC / Minor Injuries

Fatality Cases = 3 % of DC / Major Injuries

4. GOALS AND OBJECTIVE

To create a Safe and Healthy Environment by reducing, minimizing and

The ultimate goal is “Incident free work”.

Near Miss / Near Hit:

6. SAFETY PHILOSOPHY AND PRINCIPLES

¾ Working safely shall be a Condition of Employment / Engagement.

¾ Training Employees to Work Safely shall be essential.

¾ All injuries can be prevented and preventing personal injury is a good

¾ Management is responsible for preventing injuries.

¾ Employees’ involvement is essential.

¾ Causes of Unsafe Behaviour-BBS can be identified

¾ Regular management observation is a must.

¾ To read and understand all Safety Standards made available, incorporate

¾ Safety should be managed – set practical achievable goals and plan to

¾ Safety is Line Management responsibility.

¾ Concern and Care for the Employees.

¾ Ensure hazard free and clean work environment.

I know my job / trade.