ALJ-HSEM-01

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Issue # 01

HSE MANUAL
In compliance with 14001:2015 & OHSAS 18001:2007

00/01 01Jul 2017 Issued for execution Ali Hadi Bassim A. Ali Jazeel
Mohammad Jassim

Rev/Issue. Date Description Prepared Checked Approved

ALJAZEEL Company For General

Contracting Ltd
Doc. No.
ALJ-HSEM-01

Copyright
The copyright of this manual, together with all confidential information contained herein is the sole
property of AL JAZEEL COMPANY for General Contracting Ltd.

It may be copied in full or in parts only by the Management / personnel and only for the purpose of
Company related activities. Disclosure of any information contained within this manual to any person (s)
outside the employee of company without written permission of the General Manager or the Projects
Manager is strictly prohibited.

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DISTRIBUTION LIST
DISTRIBUTION COPY # COPY HOLDER SIGN DATE

1. General Manager 01Jul 2017

2. Projects Manager 01Jul 2017

3. QA/QC Manager 01Jul 2017

4. HSE Manager 01Jul 2017

5. Technical Manager 01Jul 2017

REVISION SHEET

Page # Rev. # Date Reason for Approval Signature

Change

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LIST OF CONTENTS
1. OBJECTIVE
2. SCOPE
3. RESPONSIBILITIES
4. REFERENCES
5. ABBREVIATION / DEFINITION
6. PURPOSE
7. AL JAZEEL COMPANY GENERAL HSE RULES
8. PERSONNEL PROTECTIVE EQUIPMENT
9. FIRST AID FACILITIES
10. FIRE PROTECTION & PREVENTION
11. REPORTING PROCEDURES
12. HOUSE KEEPING
13. MAINTENANCE & EQUIPMENT INSPECTION
14. ELECTRICAL & INSTRUMENT WORK
15. HAND & POWER TOOLS
16. LADDERS
17. WELDING AND BURNING OPERATIONS
18. WELDING
19. VENTILATION & PROTECTION
20. HAZARDOUS SUBSTANCES
21. PAINTS & COATING
22. WORKING ABOVE GROUND LEVEL
23. SMOKING REGULATIONS
24. HSE TRAINING
25. WARNING SIGNS
26. WASTE MANAGEMENT
27. NOISE
28. ABRASIVE WHEELS
29. LOCKOUT/ BLOCKOUT
30. THE TEN COMMANDMENTS OF GOOD SAFETY HABITS
31. SEVEN COMMON ACCIDENT CAUSES
32. JOURNEY MANAGEMENT

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1. OBJECTIVE

The objective of these Safe Work Practices is to provide necessary information for healthy,
safe and environment-friendly execution of jobs mentioned in scope of work during the
project life cycle.

2. SCOPE

These Safe Work Practices are applicable to all active sites of the Al Jazeel Company as
well as its sites (as per applicability). All employees, vendors, suppliers as well as
customers are liable to comply with AL JAZEEL COMPANY’ Safe Work Practices at their
sites (while affiliated with the company) as well as at client’s site. As far as it is in
compliance with client HSE requirements.

3. RESPONSIBILITIES

3.1. HSE Manager, I/C HSE & Site Supervisor have the overall responsibility for
implementation of the HSE Operational Controls.

3.2. All matters concerning the HSE Operational Controls are channeled through HSE staff &
Supervisory staff for the enforcement of these controls at all worker level.

3.3. The execution of these controls are the responsibility of site management also.

3.4. All supervisory personnel are responsible for conforming that the men under their control
follow all the corresponding HSE Operational Controls.

3.5. Dedicated HSE personnel and Members of Management Review Committee would be
posted at site to audit that HSE Operational Controls are being executed in its true shape.

3.6. Regular HSE Audit of the site are taken by the HSE Manager. Project Manager is
responsible for the rectification of deficiencies.

3.7. Disciplinary Action on HSE Regulations Violation

a) In case of 1st HSE violation observed against any person, verbal warning would be
given by the relevant supervisor while informing Project Manager. This would be
followed by a good counseling session to avoid any HSE violation in future.
b) But if the same person found involved in 2nd HSE violation then written warning would
be issued by Project Manager followed by a counseling session as well.
c) On 3rd HSE violation, the individual will be suspended from work for a week without
pay.
d) On 4th HSE violation observed against the individual who was suspended for a week
on 3rd violation, this violator will be demobilized from the Site.

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4. REFERENCES

All Standard Operating Procedures (SOP’s) established under the framework of ALJ’s
HSE Management System are the reference and guiding documents for HSE Operational
Controls.

5. ABBRIVIATION / DEFINITIONS

HSE Health, Safety and Environment

PPE Personnel Protective Equipment

6. PURPOSE

The purpose of this manual is to ensure healthy, safe and environment-friendly working
condition at work site.
The HSE and well-being of all personnel working on any project site is of prime
importance to Al Jazeel Company. The Company is committed and convinced to maintain
and improve strict (HSE) Operational Controls to avoid any human distress and financial
loss. ALJ’s site HSE Philosophy is based on the following principles:

6.1. A job is well done only if it is done safely.

6.2. All accidents and injuries are preventable.

6.3. Every one associated with a job is responsible for preventing human injuries and financial
loss. Basic aspect of every one's job is to:

6.4. Eliminate or mitigate hazards.

6.5. Train subordinates for safe work practices.

6.6. Develop HSE consciousness and culture.

6.7. All exposures which result in injuries or loss can be safeguarded.

6.8. Every one can be trained to work safely.

6.9. Excellence is achieved through proactive rather than reactive action.

6.10. It is a good practice from efficiency and economy view point.

6.11. HSE is an important dimension of our organization and site performance like quality,
schedule and cost control.

7. AL JAZEEL COMPANY’S GENERAL HSE RULES

7.1 All new workers shall go through initial HSE Orientation session before starting any job.
Understand HSE POLICY and strictly follow HSE rules.

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7.2. Practice Personal Protective Equipments (PPE’s) during all engineering
and/or other hot jobs on need basis and/or as instructed.

7.3. Avoid hurrying. Before starting any job, thoroughly understand it and get permission from
area Incharges.

7.4. Understand HSE boards/signage installed at sites and follow the messages and
instructions displayed.

7.5. In case of Fire or Emergency Alarm, do not be panical or do not panic and follow
company Emergency Response Plan.

7.6. Beware of Emergency Assembly Points and Escape (EXIT) routes.

7.7. Locate site First-Aid station and immediately get first aid in case of any injury.

7.8. Report promptly all accidents to your supervisor, Emergency Action Committee and HSE
personnel. Never hide facts.

7.9. Keep your nearby colleague and Incharge well informed if there is need to work all alone.

7.10. Never work in darkness or dim light.

7.11. Scraps, waste materials and garbage must be dumped in prescribed drums.

7.12. Do not forget! Good Housekeeping prevents accidents. Always clean your area after
completing the job.

7.13. Do not remove Barrications! Rather ensure its presence at vulnerable places.

7.14. Never monkey with electric cables and appliances. Never insert direct cables into
sockets, rather use proper plugs.

7.15. Work at heights is strictly prohibited without safety harness. Ensure presence of strong
side railings and toe boards at platforms.

7.16. Don't carry any tools or material while climbing up or down ladders. Use pouches or
ropes for this purpose.

7.17. Do not smoke or produce naked flame beyond 5 feet.

7.18. Keep all workways and aisles clear and clean at work sites.

7.19. Park vehicles at parking areas ONLY. Never travel at standing or over hanging position
in any vehicle nor without a seat belt. Never park vehicles nearby working sites except
loading and unloading vehicles

7.20. Keep your vehicles DEAD SLOW in construction site area. Follow SPEED LIMIT
specified therein. Driving is not allowed without valid license.

8. PERSONNEL PROTECTIVE EQUIPMENT

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8.1. All the PPEs being used at project site, establishments is comply with the standards set
by ANSI, BSI and EN.

8.2. Relevant Supervisors shall be responsible for the selection of proper PPE’s.

8.3. Selection of PPEs shall be based on its protective properties related to specific hazards
and / or conditions of the environment in which PPEs will be used.

8.4. All PPE’s shall be inspected to ensure that copies of the appropriate certificates of ANSI,
BSI and EN are attached.

8.5. It shall be the responsibility of all workers to properly inspect, clean, store & maintain all
PPEs in good working conditions. Whenever problems or defects are discovered in any of
the issued PPEs the worker must immediate inform their supervisor. The defective PPEs
are returned & new one should be issued to the worker immediately.

8.6. The work force training on PPEs shall include the following essential elements;

 Information about the related hazards

 How to safely use the PPEs
 How to put on the PPEs & take them off
 How to inspect the PPEs
 How to properly dispose off the used PPEs
 Information regarding thermal hazards created by wearing PPEs & how they can be
avoided
8.7. HSE Manager Site HSE I/C and HSE Supervisor reviews all aspects whenever needed &
at least annually to ensure its effectiveness.

8.8. Modifications in PPEs may be required through changes in scope of work, addition of new
chemicals, equipment modifications or revision of federal regulations / standards. When
changes are necessary all affected work force will be notified & re-trained.

8.9. Goggles shall be used to prevent Eye contact with cement crush and particulars. Use of
Face Shield shall also be an advantage in preventing face contact.

8.10. Safety Gloves are used while working to prevent skin contact.

9. FIRST AID FACILITIES

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9.1. An adequate First-Aid supply comprising of all necessary items as
prescribed by law for immediate treatment to injuries (under first-aid case) will be
available at the site.

9.2. Company provides training on First-Aid provision to departmental representatives for

covering all routine and emergency treatments.

9.3. A record will be kept at the field to maintain current information on the number of first-aid
cases and consumption of first-aid items.

9.4. First-Aid supply will be provided as per prescribed scale for a separate cabinet with First
Aid Kit shall be provided for every group consisting of not more than twenty (20)
workmen.

9.5. Emergency eye wash capability shall be available in the near proximity to operations
presenting a potential splash exposure.

9.6. In addition to which a stand-by vehicle will serve as an Ambulance or an emergency

vehicle.

9.7. ALJ keeps in continuous touch with nearest dispensaries, medical facilities and/or
hospitals (whichever will be nearest) to respond against recordable cases.

10. FIRE PROTECTION AND PREVENTION

10.1 Firefighting equipment are made available to maintain an adequate Fire Prevention
Standard.
10.2 Fire extinguishers (for fire class A, B & C) (appropriate to nature of the process, product
and/or material in use) will be installed in all site areas in easy access locations.
10.3 Water Hydrants, with an adequate water supply, shall be readily accessible so as to
provide water protection for site.
10.4 All Fire Extinguishing elements so installed will be inspected before installation and will
be periodically inspected, replaced and maintained.
10.5 Clearly visible NO-SMOKING and FIRE-WARNING signs will be posted throughout the
site area as applicalbe.
10.6 All flammable liquid and gases will be adequately segregated from the office areas in
order to minimize hazardous conditions.
10.7 Fire fighting instructions will be distributed and displayed in both written form and in the
form of fire drills on the use of the firefighting equipment available.
10.8 All flammable liquids is stored and transported in specifically designed containers and
containers shall be clearly marked as "INFLAMMABLE".
10.9 Other precautionary measures for emergency preparedness such as Smoke (Gas)
Detectors and Fire Alarms will also be installed at site.
10.10 In case of emergency it shall be ensured that:
 All work is stopped at once.
 All equipment is shut down.

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 All men are evacuated to a safe place, a roll call is taken and every man
is accounted for.
 No one is permitted to return to work until notification has been received from
operations or from the company representative that it is safe to do so.
10.11 A representative in OFF HOURS is made available at site so that he may be contacted
in OFF HOURS in case of HSE emergency.
10.12 Emergency situation at site always reported telephonically or dialing Emergency Contact
Numbers available.
10.13 Customer representative is immediately informed about the emergency situation (e.g.
serious personal injury, fire, critical damage of equipment etc.)
10.14 While transmitting a message by telephone, it is ensured that the detailed information
regarding the nature and seriousness of the emergency, exact location etc., are
conveyed. Name and identity of the reporting person is also be identified.
10.15 All workers brought to site would be trained about the different types of site alarms for
start and end of emergency along with their role statement and assembly points during
mandatory HSE orientation.

11. REPORTING PROCEDURES

11.1 Incident/ Accident Reporting
11.1.1. As soon as an incident occurs, the any worker will immediately inform immediate
supervisor, HSE team and/or Project Manager.
11.1.2. If an incident results into an injury or causes damage to the company/Customers
assets, HSE Manager would classify the type of injury and estimate the extent of
damage. (Accident Report & HSE/ Final Accident Report)
11.1.3. If the injury is more than a first aid case, or cost of damage is huge, HSE Supervisor
will initiate the near miss / incident reporting (Near Miss / Incident Report) and will
bring it in the notice of Projects Manager / GM.
11.1.4. For a serious incident or any lost time injury/fatality case, the Project Manager shall
send a fax within 24 hrs to GM by filling Initial Incident / Accident Report. He may also
inform the GM through telephone.
11.1.5. HSE Manager will draft HSE Flyer, highlighting the immediate cause of the
incident/accident, gets it reviewed from GM and display it at different locations on the
site and dispatch its copies to concerned supervisors within 24 hrs. of the happening of
incident.
11.1.6. HSE Manager will brief Projects Manager and GM about lost time injury/ fatality cases,
serious incidents, first aid cases and near misses.
11.1.7. A complete report will be prepared by HSE Manager within 72 hours of the incident.
Final Accident Report & Accident Investigation Report)
11.1.8. After completion of the incident report, its copies will be dispatched to GM and
Customer. One copy will be maintained in record with Project Manager.

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11.1.9. In the weekly/monthly progress meetings at site, Project Manager / HSE
manager will brief the attendees about the incidents.
11.1.10. HSE Supervisor ensures maintenance of Injury Record Sheet, First Aid Record
Sheet and Near Miss Record sheet by supervisor staff for analysis purpose.

11.2 Incident/ Accident Investigation

11.2.1. As soon as a serious incident occurs, the relevant supervisor and HSE Person will
rush to that specific location and would gather information about the initial facts, which
contributed to the incident.
11.2.2. Relevant Supervisor will take immediate corrective actions, by involving the HSE
Manager if required.
11.2.3. HSE Manager would further investigate the incident by getting statements from the
people involved and eyewitnesses.
Root cause investigation or incident investigation committee to be formed comprising
of the concerned Supervisor and Project Manager will visit the site immediately but
not later than the following day and the investigation should start as soon as possible
as:

 Quality of evidence may rapidly deteriorate with time.

 Delayed investigation is usually not as conclusive as those performed immediately.

 Prompt investigation is a good demonstration of Management concern on safety.

 To identify the causes of accidents so that action can be taken to prevent

recurrence.

 To establish the facts surrounding the accident so that the direct and indirect cost
can be established. It may help to motivate for prevention of accident.

 For use in relation to potential Insurance Claims or litigation.

 To meet the relevant statutory requirements on injury and accident reporting.

11.3. INVESTIGATION APPROACH

The following approach is to be used by the Investigation Team at the scene of the
incident as soon as possible after the incident:

At the initial stage the team will gather and record all the facts, which may be of
interest in determining causes. They should avoid reaching conclusions too early; it is
a trap to be avoided.

Checklists may be useful but limitations should also be understood.

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The team shall evaluate:

 Probable frequency of recurrence.

 Whether the act of negligence causing the accident was recognised and tolerated or was
not recognised at all until the time of accident.

 Evaluation for conditions of supervision, inspection and audit.

11.3.1. Based upon the basic root causes, relevant supervisor would prepare
recommendations / corrective actions, with the co-ordination of Project Manager, with
fixed responsibilities & target dates and put best efforts for closeout within the targets
dates agreed upon.
11.3.2. A follow up for recommendations/corrective actions are carried out by Project
Manager / HSE Manager from time to time. He will inform GM and Director, for non-
compliance.
11.3.3. Supervisory staff and worker cadre would be accountable for the HSE management in
their specific areas for eliminating the causes of accident in a preventive manner.

11.3 Incident/ Accident Analysis

11.4.1. In order to identify the underlying causes of an incident or accident root cause
analysis (RCA) will be performed by HSE Manager based on the information gathered
from incident reports & investigation and compiled in the form of a report.
11.4.2. After analysis and identification of problem, HSE Manager will inform PM & GM
through a memo attached supported with the analysis report which will be used for the
risk control and record purposes.
11.4.3. RCA report will be shared among the Projects Manager & GM by HSE Manager and
discussed with top management in the management review meeting for supporting
the decision making process:

12. HOUSE KEEPING

12.1 The layout of material Storage Areas, site/workshop Offices, Parking Areas etc., is
planned so as to afford safe access about site for pedestrians, vehicles and equipment.

12.2 Material is required to be stored only in designated areas until it is required for use.

12.3 Small Tools, Fittings, etc., are kept in racks, at suitable location in the warehouse. Timber
with protruding nails are removed from site to avoid injury. Drum containers will be
provided in the office Lay down area for trash and debris, and are clearly marked. These
containers will be emptied daily.

12.4 Loose and surplus material does not stored within operational areas.
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12.5 Special attention is given to any trash or debris that could constitute a fire
hazard.

12.6 No trash, garbage and/or municipal waste will be burnt.

12.7 No trash, garbage and/or municipal waste will be land-filled.

13. MAINTENANCE AND EQUIPMENT INSPECTION

13.1 Prior to the commencement of any work, all equipment will undergo a thorough inspection
to satisfy established HSE standards.

13.2 Equipment Inspection requirements are met at all times prior to the mobilization of
equipment to the job site.

13.3 It will be the responsibility of the immediate Supervisor to implement and enforce
maintenance procedures for all the company's equipment.

13.4 Periodic maintenance inspections will be made at least once every fifteen days for all
vehicles and machinery.

13.5 At the end of a work day, every piece of equipment is properly parked in accordance with
established HSE procedures.

13.6 A record keeping system will be established for all inspections and/or maintenance checks
made on all the equipment.

13.7 For maintenance and equipment inspection at customer sites, technical procedures will be
followed with enforcement of all Safe Work Practices for Electricity, Testing, PPE’s, High
Pressure Area etc.

14. ELECTRICAL & INSTRUMENT WORK

14.1 Existing Installations

14.1.1. No one is allowed to interfere with or work on, or work in the immediate vicinity of, any
existing electrical installations or equipment without a valid permit to work. This
applies to both temporary and permanent electrical installations and equipment.
14.1.2. Where it would be required to work in the vicinity of electrical equipment all necessary
precautions to avoid accidental contact with live conductors, etc. would be taken.
14.1.3. Installation, modification or work in the immediate vicinity of any electrical equipment
is carried out under full time supervision by a competent qualified electrician.

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14.1.4. Only persons under full time supervision by a competent qualified
electrician is permitted inside substations, unless with written permission from the
Customer’s Representative.

14.2 New Installations

14.2.1. The electrical supply to powered hand tools shall not exceed 24 volts. Where this is
not possible, due to the type of tool being used, the approval of the Customer’s
Representative must be sought. But these electrical supplies must be protected by
ELCBs (Earth Leak Circuit Breakers)
14.2.2. Electrical lighting for use in confined spaces shall not exceed 24 volts. Powered hand
tools used in confined spaces shall, be air operated. Where this is not possible, all
such tools shall be equipped with a deadman’s switch.
14.2.3. All works on electrical equipment will be in accordance with Customer’s
Representative Lock Out/Tag Out procedure.
14.2.4. The temporary electrical network installed for job would be protected by ELCBs (Earth
Leak Circuit Breakers) to avoid any accidental contact.
14.2.5. All E&I equipment in stores, should be safe guarded from fire by placing suitable fire
extinguishers.
14.2.6. All panels will be kept lock in order to avoid theft of small components present in the
panels.
14.2.7. Proper rigging is be ensured during lifting activity.
14.2.8. Winch is operated by an experienced person and not by a helper or some untrained
person.
14.2.9. Suitable fire extinguishers are provided in electrical/instrument panel rooms.
Preferably CO2.
14.2.10. Panel rooms are kept lock and entry should be prohibited for unauthorized persons.
14.2.11. Excavation permit may be introduced while excavation of trenches
14.2.12. For excavation in rocky area while using jack hammer ear protection is provided.
14.2.13. Unfilled excavated trenches must be provided with warning lights during night.
14.2.14. Persons are provided hand protection (gloves) while working manually.
14.2.15. Chemical resistance gloves must be used while using chemical.
14.2.16. Fire extinguisher are provided while working near oil areas and smoking should not be
allowed in vicinity of oil filling activities.
14.2.17. A work permit system are established prior to testing/checking/energizing of electrical
equipment to avoid any incident.

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14.2.18. It will be preferable that inspection/testing of electrical/instrument
equipment should be carried out through checklist.
14.2.19. Heat and smoke detecting system must be functional in sub-stations/G.rooms.
14.2.20. Hazard warning signs should be placed on all live electrical panels.
14.2.21. “DO NOT TOUCH” tags should be placed on all switches in order to refrain persons
touching/pressing etc.

15. HAND AND POWER TOOLS

15.1 Correct type, size and weight of tool is used for each job.

15.2 Properly insulated and non-conductive tools are used for electrical work.

15.3 Screw drivers - A screw driver are the correct size of tip to fit the slot of the screw. Screw
drivers are not be hammered or twisted with pliers or wrenches. Screw drivers shall not be
carried in the pockets.

15.4 Hammers - Right kind of hammer shall be selected for the job. Eye protection shall be
worn when hammering.

15.5 Chisels - Cutting edges shall be kept sharp. Chisels heads that have mushroomed shall
be repaired. Eye protection shall be worn when using a cold chisel.

15.6 Picks and shovels shall be maintained in a serviceable condition. Shovel blades shall not
be allowed to become blunt, turned, split, or jagged, Pick head points shall be kept sharp
and heat-treated so that the metal wears down in use and does not splinter or chip off.
Shafts of picks and shovels shall be kept free from cracks and splinters.

15.7 Spanners and wrenches - Right type and size shall be used. Extension on spanners and
wrenches shall not be used unless the wrenches are designed for such use. A pipe wrench
shall not be used as a hammer. A wrench (except slugging wrenches) shall not be
hammered to tighten a bolt.

15.8 Pliers shall not be used as wrenches. It will be ensured that scrap does not fly off and
cause injury when cutting metal with pliers. Only long handled pliers shall be used to cut
wire under tension. Pliers with insulated handles shall be used for electrical work.

15.9 Jacks shall be positioned under the center of the load and placed on a solid support.
Jacks shall be operated slowly. It shall be ensured that no one gets under items being
picked up.

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15.10 Hacksaws - Correct type of blade shall be selected to suit the material to
be cut. The blade should be set in a hacksaw frame so that the teeth are pointing in the
forward direction and sufficient tension shall be applied to ensure the blade is maintained
rigid.

15.11 Power Tools - All portable power tools shall be stored in clean dry conditions. Power
tools shall not be left lying around the job site where they may be damaged.

Rotating tools shall be switched off and held until rotation has completely stopped
before they are set down. Tools shall be disconnected before changing bits, blades,
cutters, or wheels.
All portable power tools shall be equipped with properly functioning "deadman
switches".

15.12 Grinding Machine - Care are always be taken to ensure that the grinding wheel is free
from defect before mounting.

The proper size and type of wheel is fitted to the tool so that the maximum permissible
periphery speed of the wheel does not exceed the maximum speed displayed on the
machine. No grinding machine is used unless the maximum speed is clearly marked on
the case. All wheels shall be fitted with adequate guards.

15.13 Know the tool you are using, its application, limitations and potential hazards.

15.14 Select the proper tool for the job.

15.15 Don't tackle a big job with an undersized tool - make-shift tools can cause accidents.

15.16 Ground all tools unless double insulated. A double insulated tool usually has a plastic or
non-conductive outside housing and 'double insulated' embossed into the case or
stamped on the manufacturer's label.

15.17 If the tool is equipped with a three-prong plug, it should be plugged into a three-hole
receptacle or extension cord. Never break off the ground prong, it's there for your
protection.

15.18 Always remove adjusting keys and wrenches before turning on the tool. It's a good
practice to make adjustments only when the tool is unplugged.

15.19 Keep your work area free of clutter and debris. These can become tripping hazards.

15.20 Tool guards are designed to make tools safer. Never remove or wedge a guard out of
the way.

15.21 Sites are change constantly. Be alert to potential hazards in your work area.

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15.22 Avoid accidental start-up. Make sure the switch is OFF before plugging in
the cord or when the power has been interrupted.

15.23 Make sure saw blades, drill bits, router cutters, etc., are sharp, clean and regularly
maintained. Use only recommended accessories and follow the manufacturer's
instructions.

15.24 Do not force the tool. Each tool can do a better job at its designed speed. Do not over-
reach. Keep proper footing and balance at all times.

15.25 Dress properly. Avoid loose clothing that could catch in moving parts.

15.26 Secure your work. Use clamps or a vise to hold your work whenever practical.

15.27 Never use a tool with a frayed or damaged cord.

15.28 Do not attempt any field repairs. Return broken tools for proper repair.

15.29 After use return the tool to its original carrying case and store in a dry, secure location.

16. LADDERS

16.1 Ladders shall be in good condition and free from defects i.e, broken rungs, split stiles.

16.2 Ladders shall not be painted to hide defects.

16.3 Ladders shall :

 Be securely fastened at the top and footed by another individual whilst such
fastening is taken place.

 Be positioned on firm stable ground.

 Extend at least 1 meter (5 rungs) above the working platform

 Be at an angle of 300 mm (1foot) horizontal for every 1.2m (4 feet) vertical

17. WELDING AND BURNING OPERATIONS

Welding and burning operations have a high potential for personnel injuries and fires. When
doing either, precautions will be taken as follows:

17.1 Before starting to burn or weld, the work area shall be inspected to insure that sparks or
molten metal will not fall on combustible materials.

17.2 No welding or burning shall be done in a hazardous area without obtaining written
authorization from the responsible authority.

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17.3 It will be made sure that suitable fire extinguishing equipment is available in
the work area.

17.4 Suitable eye protection with suitable lenses shall be worn.

17.5 Burning or welding equipment shall be maintained in safe operating conditions.

17.6 All welding leads and burning hoses shall be kept off walkways and stairways.

17.7 No welding or burning shall be carried out on barrels, tanks, piping or other systems
which may have contained either combustible or unknown products without first obtaining
approval from responsible authority.

18. WELDING

a) Approved eye protection shall be worn by those who are exposed to flying objects from
chipping slag or other weld-cleaning activity.

b) When arc-welding is carried out near other workmen, they shall be protected from the
arc rays by noncombustible screens or they shall wear adequate eye protection.

c) The frames of all welding machines shall be grounded.

19. VENTILATION AND PROTECTION

Welding, burning and heating performed in confined, spaces would require ventilation to
reduce the concentration of smoke and fumes to acceptable levels. If adequate ventilation
cannot be provided employees will be provided with and required to use air-supplied
breathing apparatus.

19.1 Welding machine other than rotary type shall be provided with a transformer having the
secondary winding isolated from primary winding.

19.2 Connection to the power supply shall be made by means of a board mounted switch with
suitable fuse.

19.3 Metal frames of welding machines shall be effectively earthed.

19.4 When welding is discontinued, machines shall be isolated by opening both the switch on
the machine and the one on the power supply line.

19.5 How welding fires start - Fires from welding operations are started by sparks, hot slag,
and flame from the torch. Sparks often drop or are carried long distances by the wind.
Slag falls on surfaces or materials below. And a welding torch flame can ignite many

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substances within a radius of several feet. Be familiar with the standard
safety rules for welding so you can spot and report any problems.

19.6 The welders' responsibility - When a welding operation moves into a work area, it's
primarily the welders' duty to guard against fire. This means making sure there's no
flammable material within range of the flame. Wood, paper or other combustibles should
be removed. The welders also are responsible to see that no sparks or slag fall on
combustible materials. Keep extinguishing materials, such as water or sand, on hand if
you must weld near combustibles. You may even find it necessary to assign a worker with
a fire extinguisher to stand by and put out sparks.

19.7 Flammable liquids - Welders should not begin working in any area where there are
flammable liquids before checking with the supervisor. If you have to weld or touch any
tank or drum that has contained flammable liquids or gas, don't start your work until an
approved test shows that there's no danger of vapors present. Don't take anyone's word
that the tank or drum was tested previously. Insist on a test just before starting your work.

19.8 Combustibles - Where floors are combustible, welders must place fire resistant material
beneath the work area, so that hot slag cannot contact the floor. Wood floors should be
swept clean before welding over them, and should be covered with metal or some other
material that won't burn. In some cases, it is advisable to wet the floor down. But
remember that this adds a shock hazard, which must be guarded against if you are arc
welding. Be sure there are no cracks into which sparks or slag may fall, and never allow
this hot material to fall into concealed spaces between walls and floors.

19.9 You may have to protect openings, such as open doorways, with a non-combustible
curtain. Be sure this curtain reaches to the floor, so that the hot slag can't roll under it. Ask
yourself also if wind can carry sparks or slag over the side and down onto storage areas
or adjacent property.

19.10 Welding equipment - Welders must keep cylinders a safe distance from where they are
working, which means that hoses must be completely uncoiled. You should keep the
tanks and hoses behind you, never in front where flame, heat, or slag will strike them.
Hoses must be protected to keep trucks from running over them, and people from walking
into them or dragging things across them. Cylinders must be properly secured when in
use and the caps in place during transportation.

19.11 Ventilation - Good ventilation is a must for all welding operations. Many of these
operations produce fumes that are harmful in heavy concentrations, and good ventilation
is the only method of protecting yourself against this hazard. Screens around your work
must be placed so as not to prevent good air circulation. Sometimes special ventilating

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equipment is necessary. If you have any doubt about the adequacy of
ventilation on a job, ask the supervisor for his opinion. Don't weld in a small room or tank
or other closed place without first making sure the ventilation is good.

19.12 When welders leave their equipment or stop work, they must shut off the oxygen and
acetylene at the cylinders, so that no gas can enter either hose. And, of course, the rule
for everyone except the welders is: "Hands Off All Welding Gear."

19.13 Eye protection - Eye protection is necessary on all welding jobs, and full face protection
is needed on many jobs. The type of protection you've been told to wear on your
operations has been proven necessary by experience.

19.14 Face and eye protection are needed in many operations performed by welders besides
actual cutting and welding. That's why, for instance, electric welders need goggles as well
as the regular helmet. Any welder may have to do a good deal of chipping. And this work,
usually done with the helmet raised, can throw particles of metal into your eyes.

19.15 Basically, however, eye protection is designed to protect you against sparks, slag, molten
metal, and flash burns caused by radiation from the welding equipment. If you follow the
rules for wearing face and eye protection you won't have any face and eye injuries from
cutting or welding work.

19.16 Everyone's responsibility - Remember that preventing welding fires is everyone's

responsibility, whether doing the actual welding or not.

20. HAZARDOUS SUBSTANCES

20.1 Hazardous substances include any flammable liquid or any substance likely to give rise to
toxic, corrosive, irritant or risk to property or persons.

20.2 No hazardous substance shall be brought onto site without the approval of the Customer’s
Representative or Project Manager.

20.3 A copy of the material hazard Data Sheet for the substance must be given to the
Customer’s Representative before its arrival on site.

20.4 Storage facilities for hazardous substances must be approved by the Customer’s
Representative or Project Manager.

20.5 Substances shall :

 Be kept to a minimum
 Be securely locked or fenced off
 Have appropriate warning notices affixed to the storage facility

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 Have “no smoking” notices affixed to the storage facility where flammable
substances are stored.
 Have fire fighting extinguishers (appropriate to the substance) and other emergency
equipment, including spill equipment located nearby the containment area.

20.6 Substances shall be held in secure appropriate containers with the substance clearly
identified on the exterior of the container.

20.7 All containers holding hazardous substances shall have their lids replaced as soon as they
are not in use. Only small quantities should be removed from the approved store at any
one time.

20.8 Empty containers shall be removed as soon as possible and arrangements made for their
safe disposal in accordance with relevant legislative requirements.

20.9 Hazardous substance shall not be discharged onto the ground or into water drains where
they can cause pollution or an explosion.

20.10 All hazardous substances disposed of shall be kept separate from normal waste.

21. PAINTS AND COATING

21.1 Appropriate personal protective gear like overalls, working gloves, safety hats, goggles,
respirators etc., shall be used when working on surface painting and or handling the
paint/coating materials.

21.2 The paint shall be mixed in an adequately ventilated area.

21.3 Solvents and paints shall not be applied to surfaces warmer than summer ambient
temperature.

21.4 Smoking or use of open flames shall be permitted only in designated safe areas.

21.5 Paints, solvents or coating materials shall be saved from exposures to extreme heat such
as the direct sun light in summer.

21.6 Prior to flame cleaning of surface, make sure that no flammable material exists in the
vicinity of work.

21.7 Protective hoods shall be used while carrying out sand blasting in open/enclosed space.

22. WORKING ABOVE GROUND LEVEL

22.1 Only adequately trained & experienced personnel shall be allowed to work on height.

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22.2 In order to minimize exposure to risk, the minimum practical number of
personnel shall be assigned to job.

22.3 Operations above ground level are carried out in such a way that non-involved personnel,
in the vicinity of the activity, are not at risk.

22.4 Suitable HSE equipment to prevent falling are provided to persons working at places from
which they are liable to fall.

22.5 Means of access to elevated areas are approved type, of sound construction, suitable for
the purpose and shall be used in safe manner.

22.6 All the access shall be kept clear of any loose articles e.g. tools, equipment, scaffold
boards etc.

22.7 Personnel shall not be permitted to climb whilst carrying tools or equipment, the only
exception being tools carried in a waist belt designed specifically for the purpose.

23. SMOKING REGULATIONS

Smoking is normally prohibited in operational areas other than in locations authorized and
designated as smoking areas by the employer/Customer.

Strict compliance to this effect shall be adhered. Refer to (Fire Prevention Checklist).

24. HSE TRAINING

24.1 HSE Orientation for Newly Appointed Staff from Outside

24.1.1. After recruitment Project Manager will send the new employees to HSE Manager for
orientation.
24.1.2. HSE orientation is arranged at a suitable place with best communication system
available to improve the effectiveness.
24.1.3. HSE Manager will perform the HSE orientation based upon following principles:
 Company organization and HSE Policy.
 General HSE Rules and Regulation including the use of PPE, incident reporting,
first aid facility, emergency preparedness (alarm system, escape route, assembly
point), HSE inspection and housekeeping.
 Health & Safety hazards specific to the site activities.
 Environmental Management Company wide.
24.1.4. Project Manager will keep the record in form of orientation record form.

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24.2 Specific Orientation (on the job) for Newly Appointed, Promoted or Transferred
Staff and Staff Facing Change

First line supervisors will conduct a specific on job orientation for new comers, which
will include:

 Introduction to the nature of job.

 Explanation about the work environment, particular location and specific job
hazards.

24.3 Tool Box Talk for Existing Staff & Staff Facing Change

24.3.1. HSE Manager will coordinate with the respective Leads of execution to conduct a
daily session of Tool Box Talk in the job related areas or as required by the customer.
24.3.2. The subject for Tool Box Talk would be the specific hazards and remedial measures
of particular site incorporated with feedback from immediate supervisors and HSE
personnel at the site.
24.3.3. Area Leads / his representative will deliver the Tool Box Talk.
24.3.4. A record of Tool Box Talk will be maintained by HSE Manager on the specified form.

24.4 Management Training Program for Newly Appointed & Existing Management Staff

24.4.1. This program effectively covers the professional level of know-how for management
employees and first line supervisors.
24.4.2. The mentioned training program will be conducted twice during the life cycle of project
so that all management employees go through it.
24.4.3. This program will be conducted by representative from HSE department at
projects/establishments sites on as and when required basis.
24.4.4. The duration of this course will be one day.
24.4.5. HSE personnel will maintain a record for the participants of this course.
24.4.6. Management Training Program module will be reviewed annually.

24.5 Training Effectiveness Monitoring

 The effectiveness of training will be monitored by pointing out the areas and the
level to which the candidate has improved his/her on job skills and knowledge.

 At the same time any deficiency in the training module will also be mentioned by the
individual and the relevant Manager / Supervisor.

25. WARNING SIGNS

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25.1 HSE condition signs shall be used for highlighting all emergency exit passage ways, fire
doors, first aid post, eye wash stations & emergency muster point.

25.2 Mandatory signs are displayed at various locations for enforcing the use of personal
protective equipment & clothing.

25.3 Electrical equipment, openings, overhead working, noisy areas, fire hazards & other
hazards shall be indicated by erecting & displaying warning signs.

25.4 Prohibitation signs are displayed for restricting access or entry, no smoking areas, no
parking & any other unauthorized acts.

25.5 Clearly visible fire signs are provided at locations where fire equipment has been sited e.g.
fire extinguishers, fire posts etc

26. WASTE MANAGEMENT

26.1 Used welding bars, Commercial value timber & other scrap shall be separated & stored in
segregated areas before its removal.

26.2 Aqueous waste will be connected to sewage treatment plants through closed drains.

26.3 Domestic solid waste from the camps & accommodation will be stored in predetermined
collection points prior to their removal & disposal.

26.4 Oil & other lubricants are collected in drums and disposed off as per customer instructions.

26.5 Batteries shall be drained and flushed before disposal and the residual acid diluted and
neutralized shall be discharged into the sewage plant.

26.6 Near first-aid stations, sharps containers will be provided (for cotton, blood-soaked
bandages etc.) and also clearly identified bagging for infectious or contaminated
dressings, these will be removed & incinerated.

26.7 Water being used for Bowzer/Gas Container showering will be Re-Used for the same
and/other purpose(s).

27. NOISE

27.1 For noise levels 85 db (A) and over signs will be provided, mandatory hearing protection
will be used and an analysis of the noise emissions be carried out.

27.2 The maximum noise levels to which anyone may be exposed to are 75 dB(A) continuous &
85 db(A) impulse or short duration. This includes personnel wearing hearing protection.

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27.3 In the instances where personnel are exposed to high levels of noise
screening will be required to assess if any impairment has occurred.

28. ABRASIVE WHEELS

28.1 Every abrasive wheel are mounted between suitable flanges, which would be not less than
one third the diameter of the wheel.

28.2 Guards are securely attached to the body of the machine.

28.3 Machines in which abrasive wheels are used will be provided with efficient devices for
starting and cutting off power.

28.4 Persons carrying out dry grinding operators, or turning or dressing an abrasive wheel, shall
wear suitable eye protection, or be protected by suitable transparent screens.

28.5 Before mounting this shall be ensured that speed of the spindle does not exceed the max
permissible speed marked on the wheel.

29. LOCKOUT/BLOCKOUT

"Lockout" and "Blockout" are methods of keeping equipment from being set in motion and
endangering workers.
To Lockout equipment the disconnect switch is put in the safe or off position and a lock is
attached so that the equipment cannot be energized. A written warning or tag is also
attached with the following information:
1. Reason for placing tag.
2. Name of person placing tag.
3. How that person can be contacted.
4. Date of tag placed.
To Blockout equipment blocks are placed under raised equipment so that parts that may
fall are braced. Blinds are placed in pipes so that substances cannot pass through.
Locks, tags, blocks and blinds do not de-energize equipment. Attach them only after the
machinery has been isolated from its energy sources.

30. THE TEN COMMANDMENTS OF GOOD SAFETY HABITS

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30.1 Set Your Own Standards. Don't be influenced by others around you who are negative. If
you fail to wear safety glasses because others don't, remember the blindness you may
suffer will be yours alone to live with.

30.2 Operate Equipment Only if Qualified. Your supervisor may not realize you have never
done the job before. You have the responsibility to let your supervisor know, so the
necessary training can be provided.

30.3 Respect Machinery. If you put something in a machine's way, it will crush it, pinch it or
cut it. Make sure all guards are in place. Never hurry beyond your ability to think and act
safely. Remember to de-energize the power first before placing your hands in a point of
operation.

30.4 Use Your Own Initiative for Safety Protection. You are in the best position to see
problems when they arise. Ask for the personal protective equipment or additional
guidance you need.

30.5 Ask Questions. If you are uncertain, ask. Do not accept answers that contain, "I think, I
assume, I guess." Be sure.

30.6 Use Care and Caution When Lifting. Most muscle and spinal injuries are from
overstrain. Know your limits. Do not attempt to exceed them. The few minutes it takes to
get help will prevent weeks of being off work and in pain.

30.7 Practice Good Housekeeping. Disorganized work areas are the breeding grounds for
accidents. You may not be the only victim. Don't be a cause.

30.8 Wear Proper and Sensible Work Clothes. Wear sturdy and appropriate footwear.
These should enclose the foot fully. Avoid 1oose clothing, dangling jewelry, and be sure
that long hair is tied back and cannot become entangled in the machinery.

30.9 Practice Good Personal Cleanliness. Avoid touching eyes, face, and mouth with gloves
or hands that are dirty. Wash well and use barrier creams when necessary. Most
industrial rashes are the result of poor hygiene practices.

30.10 Be a Positive Part of the Safety Team. Willingly accept and follow safety rules.
Encourage others to do so. Your attitude can play a major role in the prevention of
accidents and injuries.

31. SEVEN COMMON ACCIDENT CAUSES

31.1 Taking Shortcuts: Every day we make decisions we hope will make the job faster and
more efficient. But do time savers ever risk your own safety, or that of other crew
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members? Short cuts that reduce your safety on the job are not shortcuts,
but an increased chance for injury.

31.2 Being Over Confident: Confidence is a good thing. Overconfidence is too much of a
good thing. "It'll never happen to me" is an attitude that can lead to improper procedures,
tools, or methods in your work. Any of these can lead to an injury.

31.3 Starting a Task with Incomplete Instructions: To do the job safely and right the first
time you need complete information. Have you ever seen a worker sent to do a job,
having been given only a part of the job's instructions? Don't be shy about asking for
explanations about work procedures and safety precautions. It isn't dumb to ask
questions; it's dumb not to.

31.4 Poor Housekeeping: When clients, managers or safety professionals walk through your
work site, housekeeping is an accurate indicator of everyone's attitude about quality,
production and safety. Poor housekeeping creates hazards of all types. A well
maintained area sets a standard for others to follow. Good housekeeping involves both
pride and safety.

31.5 Ignoring Safety Procedures: Purposely failing to observe safety procedures can
endanger you and your co-workers. You are being paid to follow the company safety
policies-not to make your own rules. Being "casual" about safety can lead to a casualty!

31.6 Mental Distractions from Work: Having a bad day at home and worrying about it at
work is a hazardous combination. Dropping your 'mental' guard can pull your focus away
from safe work procedures. You can also be distracted when you're busy working and a
friend comes by to talk while you are trying to work. Don't become a statistic because
you took your eyes off the machine "just for a minute."

31.7 Failure to Pre-Plan the Work: There is a lot of talk today about Job Hazard Analysis.
JHA's are an effective way to figure out the smartest ways to work safely and effectively.
Being hasty in starting a task, or not thinking through the process can put you in harms
way. Instead, Plan Your Work and then Work Your Plan!

"It is better to be careful 100 times than to get killed once." (Mark Twain)

32. JOURNEY MANAGEMENT

32.1 Complete checking and inspection of vehicles for tire pressure, indicators, back alarm,
horns and rest of the systems before starting movement toward destination.

32.2 Only competent and authorized drivers should be allowed to drive the carrier vehicles.

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32.3 Day time travelling is to preferred.

32.4 Drivers and concerned staff should avoid interaction with unknowns on the way to project
site.

32.5 Every one among the staff should have ID Cards, contact information for emergencies and
vehicle documents accordingly.

32.6 Load should be properly distributed and secured before starting the movement.

32.7 Use of seat belt will be necessary.

32.8 Speed limit is to be observed strictly at the roads and within the plant as well.

32.9 Heavy vehicles like Cranes etc. should be mobilized with required HSE signs on the carrier
vehicle.

32.10 Over loading of the vehicles must be avoided to eliminate the chances of horrible
consequences.

32.11 Equipment mobilization plan is to be implemented accordingly.

32.12 Proper rest is to be provided to vehicle driving staff.

32.13 First aid box & fire extinguisher must be present in every vehicle.

32.14 During the transportation of chemicals, fuel and explosives special precautionary
measures must be observed to eliminate the possibility spark and fire.

32.15 Avoid traveling in the congested area.

32.16 During the long journey rest point will be identified before starting the activity and
constant communication will be maintained with the project site.

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