29 HIRA Annexure H

ANNEXURE – R
HAZARD IDENTIFICATION & RISK ASSESMENT (HIRA)
Nature of the Job: Dismantling and erection of ammonia tank Date: 02/12/2020 Project No: PC-00187
Name of the Contractor: Projects & Development India limited Job Location: GNFC -1003A Project Bharuch Site
Name of the Safety Engineer: Mr. Tarik Vahora Contract Project manager: Mr.
GENERAL – MECHANICAL
RISK RISK RESPONSIBILI
RATING RATING TY
STEPS/ POTENTIAL CONTROL MEASURES/
WITH WITH
Sr. METHODS SUB HAZARD MITIGATIONS PPEs TO G P L
EXISTING ADDITIO N
RISK
RISK
No. (MAIN ACTIVITIES (What can cause (What can be done to prevent it BE D S
RISK CONTRO L
ACTIVITIES) harm?) from going wrong?) USED N I T
CONTROL MEASURES
L K
C L R C L R F
C
 Compliance on PTW
requirements to be
ensured.  Basic
 Physical hazard PPEs S
 Trained and competent P
while handling (Safety =
person to be monitored. =
material. helmet, S
Mobilization of  Conduct TBT to all craftsmen P
 Working Safety U
involved in the work E
Personnel, at height. Glass, P
activities. R
vehicles,  Struck by
 Compliance with GNFC
Leather E F
1 Equipments & moving 5 3 15 A safety requirements to be 3 1 3 C gloves, R S
O
Delivery of vehicle. Safety V
ensured. R
material to job  Unskilled Labor Shoe) I
 Only competent and M
site.  Unconditioned  Full S
licensed drivers to deliver E
/ damaged body I
material at site. R
Equipment harness O
 Driver to be made aware of
 Vehicle  Respirator N
requirements and deliver to
acciden designated area only.  Dust
t  Ensure all personnel are coverall
NOTE: All the activities may have impact on the running plants in surroundings of the tank location hence, extra care should be taken while execution of work.
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ANNEXURE – R
properly trained and
competent with appropriate
PPE.
 Ensure the equipment/trailer
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have updated and valid

statutory documents like
Registration, Road Tax, Road
permit, fitness certificate, valid
license (HMV/Earth movers),
Insurance, PUC, 3rd party
certificate if applicable etc
 TBT to be conducted
before start of the activity.
 Ensure prior checks to be
done on equipment/driver
 Client’s site induction
requirements Discuss likely
hazards to be found on site
with CLIENT
 Receive site map from Client
indicating the following:
1. Access roads to the site
2.Contact details for Site
in- charge
3. Lay down area for equipment
 Operators. Provide flag man
during vehicle movement inside
plant. Obey Site Safety Rules for
speed
Scaffold Lifting of  Ensure all personnel have  Basic PPEs
 Hit man
2 Erection and Scaffold
or
5 5 25 A undergone Site Safety Induction. 3 1 3 C  Fall S S P
Dismantling materials  Ensure all personnel are trained arrestors
material
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ANNEXURE – R
using and competent for rigging and  Full body

Tower tower crane operation. harness
crane /  Ensure tower crane with 100%
Manually operator having valid tie up of
license. lanyard
 Tool Box Talks to be
conducted before starting the
activity
 Ensure tag line provided to
avoid oscillation.
 Ensure tower crane inspected
and certified by the third party
inspector.
 Ensure no man movement
underneath the lifting area.
 Ensure proper signal man
provided for the tower
crane operator.
 Ensure proper stacking of
materials after de-slinging
 Proper supervision until the task
complete.
 Provide proper PPEs for the
workers.
 Ensure all personnel are  Basic PPEs
Manual trained for manual lifting  Fall
shifting of  Personnel activity. arrestors
Scaffold injury
5 4 20 A  Tool Box Talks to be
3 1 3 C  Full body
S S P
Materials conducted before starting the harness
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activity. with 100%
 Deploy the workers according
to the weight of the materials.
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 Ensure proper access for tie up of

workers to shift the materials. lanyard
 Ensure there is no wet floor,
obstructions of materials while
shifting activity.
complete.
 Provide proper PPES for
the workers.
 Ensure all persons
undergone with work at
height training.
 Ensure all the tools and tackles
tied with rope to avoid fall of
materials
 Ensure no movement of  Basic PPEs
workers underneath the  Fall
working area. arrestors
Erection of  Material Fall  Ensure proper barriers in  Full body
Scaffolds. from height
5 5 25 A 3 1 3 C harness
S S P
the working area.
 Deploy sufficient workers to with 100%
position the brackets. tie up of
 Ensure proper platform to lanyard
position the bracket.
 Ensure proper mid railing, top
railing and toe guard
provided.
complete.
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ANNEXURE – R
workers.
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 Provide adequate warning signs

for awareness.
 Ensure all persons
undergone with work at
height training.
conducted before starting the
activity.  Basic PPEs
 Ensure worker should medically  Fall
fit for work at height. arrestors
 Ensure scaffolding inspected  Full body
and provided with green tag. harness
 Man fall from
height
5 5 25 A  Ensure proper platform to 3 3 9 B with 100% S S P
position the bracket. tie up of
 Ensure proper anchorage point lanyard
provided for the work men to  FBH
hook. with
 Ensure proper mid railing, top shock
railing and toe guard absorber
provided.
complete.
workers.
for awareness.
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ANNEXURE – R
 Ensure Scaffold was  Basic PPEs
properly positioned.  Fall
Tie Rod  Fall of
fastening materials
5 5 25 A  Ensure tie rod was properly 3 1 3 C arrestors S S P
inserted into the core wall.  Full body
 Ensure tie rod was fastened harness
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ANNEXURE – R
properly before going for the with 100%

next bracket. tie up of
 Ensure all tools and tackles are lanyard
tied with the harness to material
fall.
 Ensure all Scaffolds are fastened
properly before going for the
platform erection.
complete.
workers.
for awareness.
 Ensure metal planks tied on
the Scaffolds with the binding
 Basic PPEs
wire.
 Fall
Platform  Ensure proper hand rails provide
arrestors
hand rails for the brackets.
 Fall of  Full body
Erection/
materials
5 5 25 A  Ensure proper anchorage point 3 1 3 C harness
S S P
Dismantlin provided for the workmen to
with 100%
g hook the harness.
tie up of
lanyard
complete.
workers.
 Working at  Scaffold must be made  Basic PPEs
Removal of
Scaffold
height 5 4 20 A according to the work to 3 2 6 B  Fall S S P
 Slip and falling be arrestors
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ANNEXURE – R
done.
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of tools  Full body harness to be used.  Full body

 Isolate/cordon off working area harness
to restrict unauthorized with 100%
personnel entry. tie up of
 Scaffold to be done be proper lanyard
scaffold and
inspected/certified by
authority personnel.
 Tie the tool with nylon thread.
 Compliance with PTW
requirements shall be
 Falling objects ensured.
 Hard Hat,
 Handling heavy  Ensure the use of rated blinds.
 Leather
objects  Tools use must be
gloves,
 Exposure to appropriate for the job. Use
Blinding & De  Safety S/
3
blinding
chemicals 4 2 8 B proper lifting practices 3 1 3 C glasses, P
S P
 Personnel  Ensure no blind is left
 Safety
injury unattended.
shoes,
 Flammable gas  Consider pinch points
 Coverall.
 Toxic gas  Compliance with requirements
of GNFC blinding & de blinding
standard and procedure shall
be
ensured.
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ANNEXURE – R
Dismantling &  All the plates and structure
materials shall be shifted to tank
Erection of
pad area by the help of trailer.
base plate, Movement  Vehicle
4
angular plate, of Vehicle accident
5 5 25 A  All the material shifted by trailer 2 2 6 B  Basic PPEs S S P
secured properly and 10 K.M/H
bottom plate, speed shall be follow
shell plate and  Competent trailer operator shell
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ANNEXURE – R
roof structure is allowed for trailer driving.

material  Proper equipment should be
used to lift and shift the
material.
 T.P.I certified hydra / crane
should be used to pull the
loads.
 All cranes / hydras used in the
lifting / shifting the material
 Hit by objects. should be fit for the laying
Lifting  Vehicle activity.
work by accident.  Ground conditions should be
using  Failure of lifting 4 5 20 A assessed prior to setting up the 3 3 9 B  Basic PPEs S S P
Hydra/Cran tools & Tackle. crane / hydra for lifting the
e toppling  Trip / fall material.
hazard  No tandem lifts should be
carried out and no hydras
should be used to transport the
material.
 No lifting activity should be
carried out if wind speed is more
than 9.8m/min.
 Plates should be unlashed only
after inspection and confirmed
that it will not slip from the
 Fall of plates
during lifting
4 5 20 A trailer. 3 3 9 B  Basic PPEs S S P
 Enough support should be
provided to all Sides of
trailers.
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ANNEXURE – R
 Plate clamps should be used to
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ANNEXURE – R
lift plates.
 One plate should be lifted at
a time.
 No plates should be lifted with
forklifts.
 Plates should not be pushed
or pulled from the trailer.
 Area of lifting radius / material
movement should be
barricaded
 Proper lifting tools should
be selected and used.
 Lifting tools should not be
subjected to tensions and should
not be used to pull the loads.
 Damaged lifting tools should not
be used.
 Failure of lifting
tools.
5 4 20 A  All lifting tools should be 3 3 9 B  Basic PPEs S S P
inspected prior to use.
 All lifting tools should be
protected from sharp edges.
 All lifting tools should have TPIs
& should be colour coded
according to the project colour
code.
 No lifting should be carried out
during high wind conditions.
 Hit by object 5 3 15 A  Load should be controlled
3 3 9 B  Basic PPEs S S P
by guide ropes & should not
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ANNEXURE – R
be
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HAZARD IDENTIFICATION & RISK ASSESMENT
handled directly.
 Area of plate handling should
be kept barricaded to restrict
the entry of unwanted
personnel.
 Proper sign boards should
be displayed.
 No one should be allowed to
work under the suspended
load.
 Ensure all personnel have
undergone Site Safety Induction.
 Ensure PTW Issued by the PMC
before starting the work.
 Plate clamps should be used to
lift plates. One plate should lift
at a time.  Hard Hat,
 No plates should be lifted with  Leather
Loading and
forklifts. gloves,
Unloading of  Hit to men
 Ensure trained and competent  Safety
5 steel plates or materials 5 5 25 A personnel operating tower crane
3 1 3 C glasses,
S S P
using Hydra/ to lift the Bucket  Safety
Crane  Tool Box Talks to be shoes,
conducted before start of the  Coverall.
activity.
 Ensure the LG and machines
have legal documents Like
TPI.
 Ensure before starting the
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ANNEXURE –
work physical inspection
should be done for the crane
and Sand Bucket using the
check list
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ANNEXURE –
9.Provide proper tag line to

avoid oscillation.
 Deploy trained signal man for
proper lifting
 Ensure Sign boards should be
provided.
 Ensure hooks in the Sand
Bucket should be properly
inspected before lifting
 Ensure No man movement in
the lifting area
 Ensure Proper supervision
until the task complete.
 Ensure no person should work
underneath the Suspended
load.
 Barricade the Lifting area before
starting the work.
 Deploy trained riggers for
loading and unloading of Steel
 Hard Hat,
Offloading plates materials
 Leather
&  Fall of  Ensure web slings are free from
gloves,
movement Materials damage.
 Safety
of steel  Fall of 5 5 25 A  Ensure while slinging rigger must 3 1 3 C glasses,
S S P
plates, steel worn with safety Harness.
 Safety
Structure plates.  Use Proper communication
shoes,
material device for safe signal
 Coverall.
propose.
 Provide proper tag line to avoid
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ANNEXURE –
oscillation.
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ANNEXURE –
 5.While loading the teeth of the

VR hook should be inserted fully
in the
 Avoid overloading.
 Ensure Center of gravity should
be stable while loading and
unloading.
 Ensure proper supervision until
the task complete.
 8. Provide proper PPEs for
the work men who work in
the
activity.
 Inspected hydra / crane
should be used to pull the
loads.
 Ground conditions should be
assessed prior to setting up the  Hard Hat,
 Hit by objects.
crane / hydra for lifting the  Leather
Lifting  Vehicle material. gloves,
work by accident.
 No lifting activity should be  Safety
using  Failure of lifting 5 5 25 A carried out if wind speed is more
2 1 2 C glasses,
S S P
Hydra/Cran tools & Tackle.
than 9.8m/min.  Safety
e toppling.  Trip / fall
 Flagman should be assigned to shoes,
hazard guide the traffic.  Coverall.
 Drivers should follow the traffic
rules while driving inside the
project areas.
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ANNEXURE –
carried out during night shift
if
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sufficient illumination is not

provided.
 All lifting tools should be
inspected before taking in to
use for damages.
 All lifting tools should have TPI
certificates.
 Lifting tools should not subject
to tensions and should not be
used to pull any material.
 Employees should use crow bars
while handling the material.
 Leather hand gloves should
be used while handling the
material.
 Proper coordination is to be
maintained between the
crew while handling the
material.
 Outriggers to be fully extended
on stable/solid & even ground,
using wood sole plates (if
applicable).
 Stop crane lifting in rainy, foggy
weather or during dust storm.
Monitor wind factor, If wind
velocity exceeds established
maximum speed limit, stop all
lifting operations.
Page 24 of
ANNEXURE –
 Signal to the crane operator

should be given by rigger only
and not by any unauthorized
person.
 Required number of riggers
should be provided.
 All lifting equipments (chain
blocks, come along sling, and
shackles) must be inspected &
certified  Hard Hat,
Using
 Defective or  Determine load & always stay  Leather
Chain
damaged chain within the SWL of the gloves,
block, lifting/pulling equipment.
block, Come  Safety
Come
along, slings,
4 3 12 A  Never use live pipelines and
2 2 4 C glasses,
S S P
along,
shackles, wire fragile structures to hang  Safety
slings,
rope chain pulley for lifting a load. shoes,
shackles
AVOID sharp contact, Avoid  Coverall.
shock loads.
 Avoid pinch point. NEVER leave
a suspended load unattended
 Failure of load  Only use Forklift trucks that are  Hard Hat,
 Unauthorized inspected, certified and  Leather
use of forklift. roadworthy. gloves,
Forklift  Unauthorized  Only allow certified and  Safety
Operations movement of
3 3 9 B experienced forklift operators to
2 2 4 C glasses
S S P
forklift. operate forklifts.  Safety
 Speeding with  Forklifts should be accompanied shoes
forklift. during travel and operations.  Coverall
Page 25 of
ANNEXURE –
 Unsafe loading  Forklifts should never be  Reflective

of forklift. operated at speeds in excess vests to
 Inexperienced of the required maximum be worn
and un-licensed speed (should be at walking by the
operator. pace). flagman
 No flagman  Operator must wear a seat-belt.
during  Only materials and equipment
operations and to be loaded and moved.
travel.  Forklifts are NOT ALLOWED TO
 Roll over TRANSPORT OR LIFT
 Personnel hit PASSENGERS.
by Forklift  Ensure fitness of equipment.
 Secure the load and
maintain load integrity.
 All hydraulic systems should
be tested before use.
 Forklift Operations must
conform to all relevant GNFC
safety procedures.
Fabrication of  Hot work  Plasma cutting should be carried  Hard Hat,
plate and  Careless out in an isolated area.  Rubber
structure handling of  Enough drinking water should be gloves,
Exposure lighted cutting made available in the fabrication  Safety
material.
to heat torch, hot yard. glasses,
6 and hot particles may
5 3 15 A  Proper breaks should give to the
2 2 4 C  Safety
S S P
Welding, material cause burns. employees engaged in the shoes,
cutting &  Using cutting plasma cutting.  Coverall
grinding (Hot torch too  Flask back arrestor at both  protective
Work) if close to sides shall be used for gas clothing,
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combustible cutting set.
Page 27 of
ANNEXURE –
required materials /  Gas cutting set shall be up right  gauntlets,

personnel. position and secured by chain.  face shield
 Gas leaking  Wear protective clothing,  welding
from hoses / gauntlets, face shield and glass/
valves or welding glass along with other shield
flash back regular PPEs.
arrester  Ensure to have proper
fire blanket and
barrication.
 Keep suitable fire extinguisher
nearby with a fire watch.
 Keep hoses clear of sharp edges
& abrasives.
 Do not allow hot metal
or spatter to fall on
hoses.
 Clamp the work piece,
don’t hold it by hand.
 Work in safe location and
maintain safe distance of at least
5 feet distance between two
personnel.
 Ensure cutting torch is fitted
with spring loaded non return
valve to prevent backflow.
 Ensure to have flash back
arresters to protect
cylinders from flashbacks.
 On return valves to prevent
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ANNEXURE –
oxygen reverse flow in to
fuel
Page 29 of
ANNEXURE –
line & vice versa.

 Turn off cylinder valves
when not in use.
 Handle cylinders carefully and
always keep them in an upright
position and fasten them to
prevent them from falling.
 Drainage manhole near the
location must be cover by
fire blanket.
 Fire watcher must be at site
while work is in progress.
 All connections of the plasma
cutting machine should be done
through proper rated ELCBs and
ELCBs should be inspected and
recorded on periodic basis as  Hard Hat,
per project requirements.  Rubber
 Proper earth should be provided gloves,
to all required parts of the  Safety
 Electrocution 5 4 20 A plasma cutting machine.
1 3 3 C glasses,
S S P
 No employee other than  Safety
electrician should carry out shoes,
the maintenance of the  Coverall.
electrical systems of the
machine.
 No substandard joints of
cables are accepted.
 Operator & electrician should
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ANNEXURE –
inspect the machine every day

before starting the job.
 Employees should be provided
with proper hand gloves and  Basic PPEs
 Burn &
clothing.  Proper
cut
injuries,
5 4 20 A  After cutting plates, scrap should 2 2 4 C hand S S P
be disposed properly. gloves and
personal
 Proper handling of scrap clothing
injuries
material.
 Obtain hot work permit.
 All combustible material should  Hard Hat,
be removed under the cutting  Rubber
area. gloves,
 Metal plates should be placed  Safety
 Fire 5 3 15 A under the bed & area under the
1 3 3 C glasses,
bed of machine should be  Safety
closed with metal sheets to shoes,
avoid.  Coverall.
 Proper fire extinguisher shall be
provided for all hot work.
 Inspected hydra / cranes
 Hard Hat,
 Hit by objects. should be engaged in plate
 Leather
Lifting  Vehicle rolling.
Rolling and gloves,
work by accident.  Alternative arrangement using
bending of  Safety
7
plates and
using  Failure of lifting 5 5 20 A power operated chain blocks 2 3 6 B glasses,
S S P
Hydra/Cran tools & Tackle. should be made.
angles  Safety
e toppling  Trip / fall  Hydra / cranes used in rolling of
shoes,
hazard plates, proper coordination
 Coverall.
should be maintained.
Page 31 of
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 Proper coordination should be
Page 32 of
ANNEXURE –
maintained between hydra/

crane operators & rolling
machine operator.
 Hydras /crane should not be left
unattended while it is being
used to control the load which
is
placed in bending machine.
 Only trained operators
should be engaged in the
bending / rolling operation.
 All rotating parts of the
bending machine should be
 Crush injuries 5 4 20 A guarded. 2 2 4 C S S P
 Proper fencing should be
maintained around the
machine.
 After rolling, rolled plates
should be stored properly and
should be locked against rolling
from
stored place.
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ANNEXURE –
 Leather hand gloves should  Basic PPEs
be used to handle plate. (Safety
 Employees should be provided helmet,
with full body protective Safety
 Injuries due clothing. Glass,
to sharp
5 4 20 A  Guide lines should be used
1 3 3 C Leather
S S P
edges to control the load. gloves,
 Area of lifting / shifting Safety
should be barricaded. Shoe)
 Proper coordination between  Full body
Page 34 of
ANNEXURE –
crew to avoid communication protective

gap. clothing
 Rolling machine should be
placed at proper location.
 Basic PPEs
 No one other than electrician
 Full body
should be allowed to do the
harness
electrical maintenance work for
 Electrocution 5 4 20 A the machine.
1 1 1 C  Respirator S S P
 Machine should be inspected  Dust
coverall
on daily basis and thoroughly on
periodic basis for identifying any
damages.
 Welding machine should be
placed at proper location.
 Electrical cables of machines
should be protected from
the damages.
 No one other than electrician
Hot work should be allowed to do the
electrical maintenance work for  Basic PPEs
(welding,
8
cutting
 Electrocution 5 5 25 A the machine. 3 3 9 B  Rubber S S P
Gloves
,grinding)  Proper earth should be provided
to the machine.
 Power supply of the machine
should be provided through
proper rated ELCBs or GFCIs.
 Machine should be protected
from rain and other bad
weather
Page 35 of
ANNEXURE –
conditions.
 Machine should be inspected on
daily basis and thoroughly on
periodic basis for identifying any
damages.
 Cables should be protected from
the damages due to its exposure
to sharp edges.
 Cables should be protected from
hot surfaces.
 Plugs of welding machine should
not be inserted / removed from
the sockets while socket is live.
 Naked electrical cable should
not be allowed.
 All combustible material should
be removed from the area.
 Buds of the welding rods
should be collected and
disposed at proper location.
 All electrical connections should
 Fire 5 4 20 A be made with proper plugs, 2 4 8 B  Basic PPEs S S P
sockets, connectors.
 No loose connections
are allowed.
 Cables with damage insulation
should be taken out of use.
 Welder should inspect the
Page 36 of
ANNEXURE –
cables every day for identifying

damages.
 Electrical supply of welding
machine should be switched
off
 Fire extinguishers should be
made available at site and
employees should be trained
to
use the same.
 Employees engaged in the hot
works should be provided with
proper PPEs & its use should
be ensured.
 Welding flux should be disposed  Basic PPEs
in proper manner.  Leather
 Burn injuries 5 4 20 A  Welding rod buds should 3 3 9 B apron S S P
be disposed at a designated  Leather
location only. Coveralls
 Welder / employees engaged
in over head hot works should
be provided with leather apron
&
leather sleeves.
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ANNEXURE –
 Hoses should be laid in proper
manner.
 Damage to  Hoses should be protected  Basic PPEs
gas cylinder & 5 5 25 A from sharp edges. 2 4 8 B  Repertory S S P
hoses  Hoses should be checked for mask
damages on daily basis and if
it is cracked, cut it should be
Page 38 of
ANNEXURE –
replaced.
 Cylinder should be stored away
from the work area in the
proper trolley.
 Soap solution should be kept
available to identify gas leaks
from hoses and connections
of gas cylinders.
 Cylinder should not be rolled &
should be kept upright even if
it is empty.
 Only trained employees should
be engaged in working at
height.
 Employees should be medically
fit for working at height.
 Working at Height” permit
should be taken prior to  Basic PPEs
starting the work.  Fall
 Fall of person
from height
5 5 25 A  Proper scaffolding platform 3 3 9 B arrestors S S P
should be provided to the  Full body
employees working at height. harness
 Fall arrestors, full body
harness should be provided &
its use should be ensured.
 100% tie off should be explained
and practiced.
 Scaffolding should be
designed & erected properly;
Page 39 of
ANNEXURE –
no
Page 40 of
ANNEXURE –
alteration should be done by

authorized personnel while
working on it.
 Platforms should be constructed
in such a manner that there
should not be any gaps in the
platform, proper toe guard
should be provided to the
platforms of the scaffolding.
undergone Site Safety Induction.
 Ensure PTW Issued by the
PMC before starting the work.
 Deploy trained worker for to
cut the steels
 Hard Hat,
 Leather
conducted before start of the
Cutting of steel  Crush Injury gloves,
activity.
using bar  Hit the men  Safety
9
cutting due to temper.
5 4 20 A  Ensure the machine is 3 1 3 C glasses,
S S P
inspected by EHS dept before
machine entering to site and color  Safety
coded. shoes,
 Ensure safety guard provided  Coverall.
for the rotating parts of
machine.
 Pedal guard/Hand lever
protection against
accidental activation.
 Ensure cover guard protection
Page 41 of
ANNEXURE –
for cutting part of machine.
 Place re bar in position and
Page 42 of
ANNEXURE –
cover before activating the foot

pedal/Hand lever.
 Rods should be hold tightly
while cutting.
work men who work in the
activity.
 Adequate supervision until the
task completed.
 Obtain work permit.
 Lifting shall be carried out as per
procedure.
 All cranes / hydras used in the
lifting / shifting the material
should be fit for the laying
activity.
Roof plate  Basic PPEs
 Ground conditions should be
and  Fall
 Crane / hydra assessed prior to setting up the
10 compressor
toppling
5 5 25 A crane / hydra for lifting the
3 3 9 B arrestors S S P
ring  Full body
material.
dismantling & harness
 No tandem lifts should be
erection carried out and no hydras
should be used to transport the
material.
carried out if wind speed is more
than 9.8m/min.
 Fall of person 4 5 20 A  Only trained employees should 3 3 9 B  Basic PPEs S S P
Page 43 of
ANNEXURE –
from height be engaged in working at height.  Fall

 Employees should be medically arrestors
fit for working at height.  Full body
 Working at Height” permit harness
should be taken prior to
starting the work.
 Proper scaffolding platform
employees working at height.
 Full body harness shall be
used for height work
 Proper life line or anchoring
point shall be provided
 Barricaded the effecting radius.
 Barricaded the effecting radius.
 All the plate shall be properly
 Fall of plates  Basic PPEs
weld to avoided any fall
during lifting,  Fall
 Remove all unwanted materials
demounting & 4 5 20 A from height
after  Full body
 After erection the job engineer
installation harness
shall be check and ensure there
is no any lapse.
 All jacks should be inspected for
 Basic PPEs
Installation of damages before taking it into
 Fall of lifted  Fall
hydraulic jacks use.
11
and lifting of
material due 5 5 20 A  All hydraulic hoses should
4 3 12 A arrestors S S P
to failure of  Full body
tank be laid properly & should be
jacks harness
prevented from damages.
Page 44 of
ANNEXURE –
 Hydraulic jacks and its

accessories selected should
be more the 1.5 times of the
load which is being lifted.
 Approximately 20 hydraulic jacks
each capacity of 12 ton shall be
use to lift the tank step by step.
 Before start lifting of tank, it
must be ensured that all shell
plates are welded properly and
are safe for lifting.
 Tank shell to be lift Maximum
2.6 meter height
 After reaching the required
height of lifting of each level,
lifted shell should be properly
supported to prevent its fall
from height.
 Jacks should be placed at
appropriate locations of the
tank to avoid fall of shell due to
bending of shell plates.
 Proper coordination should be
maintained between the crew
 Pinch point
engaged in the lifting of shell.
injuries & crush 4 5 20 A  No employees should allow
injuries
passing under the shell while it is
being lifted.
Page 45 of
ANNEXURE –
 All area around the tank should

be kept barricaded while shell is
being lifted & proper warning
signs should be provided.
 Hoses used for jacks should
have proper fittings & should
sustain the required pressure.
 Spill kit should be made
 Basic PPEs
 Hydraulic oil available & employees should be
spillage
4 5 20 A trained to use the same.
2 2 4 C  Spill kit S S P
 PVC Suit
 Drip trays should be used while
refilling the oil.
 Spilled oil must be cleaned off
immediately.
 Proper housekeeping needs to
be maintained all the time.
 Fall of person
 Hoses, cables should be laid
on same
level due to
5 4 20 A properly. 3 1 3 C  Basic PPEs S S P
 Proper access should be
slip & trip
maintained to enter the
hazards
tank
after installation of shell plates.
 All jacks should be inspected for
damages before taking it into  Basic PPEs
Lifting of roof  Fall of lifted use.  Fall
12 structure by material due 5 5 25 A  All hydraulic hoses should 4 3 12 A arrestors S S P
hydraulic jack to failure of be laid properly & should be  Full body
jacks prevented from damages. harness
 Hydraulic jacks and its
Page 46 of
ANNEXURE –
accessories selected should be

more the 1.5 times of the load
which is being lifted.
 Approximately 20 hydraulic jacks
each capacity of 12 ton shall be
use to lift the roof structure step
by step.
 Maintain minimum 30 mm
distance from shell to truss
during lifting.
 Packing plates used between
ram of the jack and structure
being lifted should be welded to
prevent fall of structure due to
its slipping.
 Maximum 2.3 meter shall be lift
by the help of jack.
 Lifting should be carried out
gradually & no lifting should be
done more than 2.3meter
height
of the jack to avoid the
toppling of jacks.
 Hoses used for jacks should
have proper fittings & should
 Basic PPEs
 Hydraulic oil sustain the required pressure.
spillage
4 5 20 A  Spill kit should be made
2 1 2 C  Spill kit S S P
 PVC Suit
available & employees should be
trained to use the same.
Page 47 of
ANNEXURE –
 Spilled oil must be cleaned off

immediately.
 Proper masks should be
provided to crew engaged in
the DP test.
 MSDS of chemicals used in the
DP test should be available and
it should be explained to the
employees engaged in the DP
test.
 Eye protection should be used
to prevent eye injuries.
 Exposure to  Basic PPEs

ND Testing –  Ensure radiography permit is
chemicals obtained  Eye
DP Test,
13
Radiography,
5 5 25 A  Proper communication to be 2 3 6 B protection S S P
 Exposure to done to all personnel working  Proper
Vacuum Test the radiation Mask
inside
 Barricade and clear off all
personnel in the affected area.
 Ensure the standby man
people at all the entry point to
be effected area.
 Confirm sign board is place at all
entry point.
 Locate the flash light at
prominent place.
 Preferable time for the
Page 48 of
ANNEXURE –
radiography is break times and

shift change/over time.
 No dye, chemicals should be
sprayed on the hot surfaces
 Fire, burn / open flames.
injuries 5 3 15 A  Cans of dye, chemicals used for 1 3 3 C  Basic PPEs S S P
DP testing should be disposed at
designated locations & should
not be exposed to heat.
 Follow the safety requirements
for the radiography &
radiography permits to carry
out the radiography.
 Radiography should be pre
planned and information
about the same should be
passed to other contractors  Basic PPEs
 Hazards
working adjacent to the work  Eye
associated with
radiography
5 4 20 A area. 3 3 9 B protection S S P
 Competent radiography  Proper
technician shall be engaged for Mask
radiography work.
 All safety material like safety
sign board, dosimeter, survey
meter, and warning light shall be
provided.
 BARC Authorized radiography
agency shall be engaged for
radiography work.
Page 49 of
ANNEXURE –
 Separate PIT room shall be

provided for handling and
store
the source.
 Proper lighting arrangements
should be made to work
inside the tank.
 Fall of person  Hoses, cables should be laid
due to bad properly and maintained
lighting and
5 3 15 A the same
2 2 4 C  Basic PPEs S S P
housekeeping  Daily housekeeping should be
practiced at the end of the
day.
 Proper working platform if RT
works at height.
 Basic PPEs
 Fall
Nozzle  Fall of person be engaged in working at
14
installation from height
5 5 25 A height.
 Full body
harness
Page 50 of
ANNEXURE –
 Material should not be stacked
on the scaffolding or any other
place at height.
 Basic PPEs
 Platforms should be constructed
 Fall
 Fall of in such a manner that there
material from
5 4 20 A should not be any gaps in the
 Full body
height platform, proper toe guard
harness
platforms of the scaffolding.
 Structure components should
Page 51 of
ANNEXURE –
not be left suspended with the

lifting tools. It should be tack
welded to its position.
 Only qualified tack welders
should be allowed to do the
tack welds.
 Material should not be stacked
on high Elevations.
be engaged in working at
height.
 Working at Height” permit  Basic PPEs
Painting work
should be taken prior to  Fall
at tank outer  Fall of person
15
shell (work at from height
5 5 25 A starting the work. 3 3 9 B arrestors S S P
 FBH shall be provided for height  Full body
height) work. harness
 If ladders are used, it should be
secured prior to start working
on it.
 Proper life lines should be
installed and used while working
at height
 Hoses cables should be laid in  Basic PPEs
 Injuries due proper manner.  Fall
to slip, trip & 4 5 20 A  Paint box should be removed 2 3 6 B arrestors S S P
fall from the scaffolding platform on  Full body
daily basis. harness
Page 52 of
ANNEXURE –
 Platform should be maintained

uniform & steps should be
avoided.
should be made at each
platform level of the scaffolding.
 Sufficient ventilation should be
maintained at the place of
paining.
 Canister masks should be  Basic PPEs
 Exposure to
paint fumes
5 5 25 A provided & its use should 3 3 9 B  Canister S S P
be ensured. masks
 No hot work should be carried
out in the nearby confined
spaces without gas testing.
 Paint should be stored
away from the heat or
sparks.
sparks.
 Fire, explosion
4 5 20 A  All electrical connections should 3 3 9 B  Basic PPEs S S P
be provided with proper earth
connections and no lose
connections are allowed as it
may lead to fire.
 Empty paint drums should be
disposed properly & it should
be disposed at specified
Page 53 of
ANNEXURE –
location.
Page 54 of
ANNEXURE –

employees should be trained to
use the same.
 Area of blasting should be
isolated and proper warning
signs should be placed around
it.
 All pressure hoses should be
inspected on daily basis before
stating the job.
 Whiplash arrestors should be
used to control the accidental
movement of hoses if unlocked
from couplings.  Basic PPEs
 Injuries due  To control the grits area
Blasting and  Full body
16
painting work
to high 5 5 25 A around the blasting should be 3 2 6 B protective
S S P
pressure grits isolated with GI sheets / clothing
Tarpaulin.
 Blaster should wear the required
protective clothing.
 Full body protective clothing is
must for blaster.
 Moisture separator should be
installed on the air line
supplying air to hood of the
blaster as moisture can restrict
the vision of blaster.
 Only approved blaster should
be engaged in the job.
Page 55 of
ANNEXURE –
 Injuries due to 5 4 20 A  All hoses should be laid properly 2 2 4 C  Basic PPEs S S P
Page 56 of
ANNEXURE –
uncontrolled and should be prevented from  Full body

high pressure damages. protective
hoses  All hoses should be connected clothing
to compressors with proper  Body
connectors / coupling and hose armor
clamps.  Shin
 Whiplash arrestors should be guards
provided to all extension joints  Arm
of the hoses. protection
 No vehicles should be moved on
hoses.
 Hoses should not be
subjected to excessive
pressure than its design
pressure.
 Proper rated hoses should
be used.
 All hoses should be inspected
regularly to identify the
damages.
 Only skilled and trained
personnel body armor, shin
guards, arm protection allowed
for work.
 Use special type of PPE (i.e. body
armor, shin guards, arm
protection) for ultra pressure.
 Use only inspected hoses and
accessories.
Page 57 of
ANNEXURE –
 Automatic grit blasting machine

should be used to minimize the
hazards of open air grit blasting.
 All employees engaged in the
blasting should be provided with
ear plugs & its use should be  Basic PPEs
ensured.  Ear
 Noise exposure 5 4 20 A  Blasting activity should be
2 2 4 C Plug/Ear
S S P
carried out by scheduling it Muff
during particular intervals.
 Compressors should be
provided with covers to reduce
the noise and should be
checked on
regular basis.
 Sufficient ventilation should be
maintained at the place of
paining.
 Canister masks should be  Basic PPEs
 Exposure to
paint fumes
5 4 20 A provided & its use should
2 3 6
 Canister S S P
be ensured. B masks
 Cartridges of the canister masks
should be replaced after 12
days.
 Painting area should be declared
as no smoking zone.
 Fire, explosion 5 4 20 A  Hot work should be carried out 2 3 6 B  Basic PPEs S S P
at least 5 meter away from the
painting area.
Page 58 of
ANNEXURE –

sparks.
 Empty pain drums should be
disposed properly & it should
be disposed at specified
location.
employees should be trained
to
use the same.
 As grits & empty paint drums are
 Environmental considered as hazardous waste,
 Basic PPEs
pollution due it should be disposed at
 Shield for
to paint 5 4 20 A designated location. 2 3 6 B blasting
S S P
drums  Ensure proper shield for blasting
disposal & shed
shed to avoid dust flying to
 grit disposal environment.
Page 59 of
ANNEXURE –
 Use calibrated gauge in the
pump. Ensure proper
supervision at all times
 Use calculated value of pump
 Pressurized
pressure in case of bolt
system
Torque tensioning.
17
/tensioning
 Bursting of 4 3 12 A  Release pressure in hose before
hoses.
disconnection.
 Personal injury
 Barricade area at ground level to
prevent unauthorized entry.
 Tommy bar should be tied with
rope to prevent falling.
Page 60 of
ANNEXURE –
 Secure the hoses with whiplash

arrestor, and remove the
defective hoses from location.
 Valid work permit shall be
obtained from GNFC before start
of work.
 All employees/ workers should
wear necessary PPES.
 Ensure proper
housekeeping around the
area
 Slip/trip/fall  Ensure TBT meeting before start
 Pinch hazards of work.
 Over  Inspect to all equipments
Hydro Testing/ before use at site.
General pressurization
pneumatic test  Barricade the work area. S/
18
if required.
requireme  Personnel 4 5 20 A 2 3 6 B  Basic PPEs
P
S P
nts injury due to  Display related safety sign /
hose rupture. caution boards.
 Unauthorized  Use leather gloves
entry  Use calibrated and certified
pressure gauges only.
 Use certified and pressure
tested hoses for hydro
test.
 Ensure the hose connected
properly with whip check and
safety pin fixed.
 Inform all adjacent groups prior
to starting pressure testing.
Page 61 of
ANNEXURE –
 Ensure all hoses are arranged in
Page 62 of
ANNEXURE –
such a way that it does not pose

any unnecessary tripping
hazards.
 Area must be barricaded
with red & white striped
 Fill the water in safe manner.
 Water filling should be done by
 Area may be using water hose or mechanized
Filling of
slippery and pump.
water into
chance to fall
4 5 20 A  Ensure controlling of spillage /
Tank
/slip flooding.
 Ensure the area is free
from obstructions.
 Inspection the pressure lifting
pump before use.
 Ensure hoses used are free
from crack/ damage.
 Use pressure hose as per design
/ calculation.
Use of  Pump hose  Ensure trained and
pressure may burst 4 2 8 B experienced person operates 2 1 2 C  Basic PPEs S S P
pump and cause the pressure pump.
injury  Calibration certificate of
pressure gauge to be
verified.
 Pressurizing to be stopped if
fluctuation in gauge is not
observed, maybe due to
defect
Page 63 of
ANNEXURE –
or choke.
Page 64 of
ANNEXURE –
 The flanges / joints shall be

visually checked before starting
of Hydro testing.
 Pressure  Suspend all works nearby the
buildup may testing area.
cause failure of  Area shall be cordoned off to
flange / plate restrict entry of other
blind joints persons.
and rupture of  Blind should be welded perfectly
Increasing
hose. at the end of pipe spool. Avoid
of pressure
level inside
 Welding joints 5 4 20 A use of rusted / corroded plates 3 2 6 B  Basic PPEs S S P
may crack/ as blind.
Tank
burst and  Ensure welding of blind is
water may inspected by competent person
release with before pressure test.
high pressure.  Ensure pressure is increased
 Chance of gradually.
Physical injury  Ensure pressure inside pipe does
not exceed the design pressure.
 Ensure skilled experienced
workers are involved for hydro
testing activities.
 Ensure area is barricaded until
releasing of water pressure.
Pressure  Pipe may burst  Ensure only hydro testing
holding in or blind joint 3 2 6 B crew should enter the 2 1 2 C  Basic PPEs S S P
loop may crack barricaded zone.
 Pressurized lines / piping spools
to be inspected / monitored
Page 65 of
ANNEXURE –
during testing period.

 Display safety signage / caution
boards.
 Restrict others to not to
enter into pressure testing
zone.
 Ensure TBT for the crew.
 Don’t vent the water openly or
in pressure mode at
workplace.
Releasing  Dewatering should be done
of pressure safely.
 Slip /trip/ fall
/
hazards
4 5 20 A  Workers should maintain a safe 2 2 6 B  Basic PPEs S S P
Dewatering distance from the vent point
of pipe while releasing pressure.
 Water should be drained slowly
by water hose to nearby drains
or water collection tanks
avoiding flooding of the area.
Page 66 of
ANNEXURE –
 Proper arrangements should be
done prior to do pressure
 Blast of tank
testing of the tank.
 Hand injury
 If required, permits should be
Pressure  Failure in
taken before starting the
identifying S/
19 testing & Box
blind(s) may
5 4 20 A pressure test the same should 1 2 2 C  Basic PPEs
P
S P
up be communicated to the other
leads to
contractors working in the
process
vicinity of the tank being
hindrance
pressure tested well in advance.
 All equipments used for
Page 67 of
ANNEXURE –
pressure testing should be

calibrated & should be inspected
prior to use at site at the time of
testing.
 Continues monitoring is
essential & test area should
not be left unattended.
 The manifold should be fitted
with proper drains, vents,
calibrated pressure gauge &
calibrated PSV to avoid the
blasting of tanks.
 Obtain appropriate permit
to work.
 Use right and correct size of
tools & equipments for the
job.
 Wear hand gloves and other
required PPEs.
 Supervise the de-blinding crew
closely.
 Proper rated hoses, pipes, fitting
should be used for supply lines
 Injuries due for the tanks during testing.
to busting of 4 5 20 A  All hoses, pipes, fittings should 3 3 9 B  Basic PPEs S S P
pressure lines be visually inspected for
defects
before installation & prior
to start the testing.
Page 68 of
ANNEXURE –
5 3 15 A  Identified drains & vents should 2 2 4 C  Basic PPEs S S P
Page 69 of
ANNEXURE –
 Sudden release be provided to release the

of pressure pressure of tank in case of
emergency.
 Arrangements for safe release of
medium used for testing should
be made & proper barication
with required signs should be
provided to the same.
 Area barricading shall be
ensured .
 Before box up all unwanted
materials shall be removed.
 Before box up, it should
 Entrapment of be ensured that the tank is
person
3 5 15 A completely vacant.
 Company safety officer shall give
final box up clearance after sign
in procedure.
 Sharp surfaces  Obtain a valid Permit to Work as  Hard hat,
 Possible hydro- well as a Confined Space Permit  safety
carbon vapors Issued at the site glasses,
Confined Space
present.  Ensure PTW is in place and  Dust
Entry for
 Insufficient ensure check for Gases and shall mask,
20 cleaning and Oxygen Levels.
5 4 20 A ensure that Oxygen 20.8% & LEL
3 2 6 B  coverall,
S S P
repair activities  Insufficient - 0% which need to be  Rubber
(if required) light. monitored continuously. gum
 Slippery  All crew members working in boots,
surfaces. confined space shall be  Leather
trained
Page 70 of
ANNEXURE –
because of the and competent to work in gloves,

viscous confined space  Safety
material inside  Ensure standby man remains at shoes
 High entrance with constant  Full body
temperatures communication with the crew. harness
inside the  Post signage and barricades with
confined space CONFINED SPACE ENTRY – double
DO NOT ENTER. lanyard
 Erect sufficient lighting. and shock
 Ensure adequate ventilation and absorber
airflow. (when
 Ensure constant air monitoring. working at
 Do gas testing for explosive or heights
flammable atmospheres due to
hidden hydro-carbon vapors.
 Ensure that an ENTRY
LOGSHEET is completed by all
ENTRANTS and controlled by
the STANDBY MAN.
 Constant supervision is vital.
 Hand injuries  Ensure that hand protection and  Basic PPEs
Vacuum out while setting- all other PPE, as required are  Safety
sludge using up and worn. Goggles,
vacuum truck making  Ensure all hoses are arranged in  Respirator S/
21
and disposed connections
4 2 8 B such a way that it does not
2 1 2 C  Dust
S
P
P
designated  Possible pose any unnecessary tripping coverall,
area. injuries as hazards.  Leather
result of  Qualified Gas Tester gloves,
tripping over
Page 71 of
ANNEXURE –
hoses.  Ensure no one is standing close

 Flammable, to the Equipment man way.
Radioactive  To follow GNFC procedure
and health  Ensure to assess the vacuum
 Failure to truck approach roads & its set
follow up area in coordination with
procedure GNFC 's competent
 Hose failure representative and ensure
 Static that, it is clear from all
electricity obstacles before obtaining
generation may PTW
be a source of  Depute only qualified and
ignition trained vacuum truck drivers
 Inhalation of and ensure to wear
Toxic Fumes appropriate PPE.
 Inhalation of  Ensure all hoses are inspected,
Hazardous tested and certified prior to its
Substance use.
 Possibility of  Barricade the area and post “DO
fire NOT ENTER” sign board.
 The vacuum truck and hose
must be grounded
properly.
 Ensure earth continuity test
from hose suction point to
vehicle earthing clamp is carried
out prior to work commencing.
 If the material to be suck is in
liquid form it may release fumes
Page 72 of
ANNEXURE –
that are hazardous to health
Page 73 of
ANNEXURE –
depending on the type of

material.
 If the material to be suck is in
solid form it may generate dust
like particles that will be absorb
by the body through inhalation.
 Provide and used the
appropriate PPE as
recommended by
MSDS.
 Ensure portable fire
extinguishers fully charged,
sealed with inspection tags are
suitably placed,
 Ensure that vacuum truck is not
left unattended whilst engine is
running.
 Ensure night work permit
 Poor visibility 4 4 16 A  Ensure adequate illumination 3 1 3 C S S P
 Safety
 Hoses cables should be laid in
helmet,
 Slipping and proper manner.
4 3 12 A 3 1 3 C  Safety S S P
Tripping hazard  Paint box should be removed
Goggles,
Working at from the scaffolding platform on
22  Respirator
night  Lack of daily basis.
 Dust
supervision
4 3 12 A  Platform should be maintained 3 1 3 C S S P
coverall,
uniform & steps should be
 Unavailability  Leather
avoided.
of first aid 4 4 16 A 3 1 3 C gloves, S S P
facilities. should be made at each
Page 74 of
ANNEXURE –
platform level of the scaffolding.

 Drowsiness  Ensure use of personal
(feeling sleepy)
4 3 12 A protective equipments-Shoe-
2 1 2 C S S P
Helmet-Gloves.
 Break needs to be taken at
 Fatigue 4 3 12 A regular intervals. 3 1 3 C S S P
 Full or alternative supervision
throughout the work.
 Emergency vehicles with driver
should be there through the
work time.
 Lack of  Effective supervision will be
amenities.
4 3 12 A made by nominating 2 1 2 C S S P
designated decision making
person as in charge for night
shift.
 Drinking water, snacks and
other amenities will be
available.
Page 75 of
ANNEXURE –
 Ensure frequent cleaning of
work station from obstructing,  Safety
unwanted material / objects helmet,
and slippery floor.  Safety
 Possible
 Any spillage should be cleaned Goggles,
slipping and S/
23 Housekeeping falling of
4 3 12 A up immediately and stored 2 1 2 C  Respirator S
P
P
into approved container.  Dust
personnel
 Make sure that hoses used are coverall,
arrange in such a way that it  Leather
will not pose a tripping hazard gloves,
during the housekeeping job.
Page 76 of
ANNEXURE –
CIVIL WORK
RISK RISK RESPONSIBILI
RATING RATING TY
STEPS/ POTENTIAL CONTROL MEASURES/
WITH WITH
Sr. METHODS SUB HAZARD MITIGATIONS PPEs TO G P L
EXISTING ADDITIO N
RISK
RISK
No. (MAIN ACTIVITIES (What can cause (What can be done to prevent it BE D S
RISK CONTRO L
ACTIVITIES) harm?) from going wrong?) USED N I T
CONTROL MEASURES
L K
C L R C L F
R
C
 Fall on the
same level due
 Be cautious while walking
to tripping  Safety
on uneven ground surface.
because of helmet
Layout of  Wear safety shoes
uneven ,
for protection.
pilling area ground.  Safety
 Removal of thorny plants,
1 and line  Dust entering 5 4 20 A debris and other material if any
3 1 3 C Goggles S S P
marking with eyes and ,
before marking.
chalk powder nose due to  Respirator
 Plan marking when the wind is
loose soil &  Dust
low and wear safety glasses
gusty winds coverall
and dust mask
 Skin ,
irritation and  gloves,
trip hazards.
Loading &  Inadvertent  Check the stack condition for  Safety
unloading of movement / any disturbance that may helmet
2 materials from roll of 4 4 16 A cause movement. 2 1 2 C , S S P
truck for pilling materials from  Do not step over the load  Safety
Page 77 of
ANNEXURE –
work the stack while that may cause imbalance; Goggles
loading / instead ,
 Respirator
Page 78 of
ANNEXURE –
unloading use tailor made platforms,  Dust

 Overloading where required coverall,
vehicle / axle  Always load / unload from  gloves,
load exceeding top layers in the stack;
rated capacity Remove / place layer by layer
progressively.
 Move to a safe distance before
signaling the operator to lift the
load.
 Use guide ropes to control the
load from swinging while lifting
mechanically; do not be close
to the lifted load.
 Restrict movement of
personnel in the vicinity; do not
allow unauthorized personnel
in the work area.
 Never over load than the
rated capacity of the vehicle.
 Axle load shall be within those
prescribed by the
manufacturers and in
conformance to road
specifications.
 Safety
Erection  Damage could
helmet,
/Assembly of Leveling of result to the  Before leveling clear the area.
3 ground existing
3 3 9 B 2 1 2 C  Safety S S P
Rig Goggles,
materials on
 Respirator
Page 79 of
ANNEXURE –
ground, if any.  Dust

coverall,
 gloves,
 Ensure SWL, Lifting radius etc. of

the erection crane.
 Provide experienced rigger
 Crane used for for signaling.
Assembly erection could  Provide licensed operator.
of A- be toppled  Area shall be barricaded.
Frame during  Double lanyard Full body  Safety
including assembly. harness with shock absorber helmet,
placing of  Fall might with fall arrester, where  Safety
roller result during necessary, shall be used Goggles,
tubes, height works. 4 5 20 A while work at height. 2 2 4 C  Respirator S S P
main sill,  Hit may result  Tag Line shall be used to  Dust
positioning due to control movement of lifted coverall,
of winch breaking of loads.  gloves,
up to First wire ropes /  Ensure TPI for all lifting tools and
stage of A- slings. tackles including Rig assembly.
Frame.  Traffic problem  Ensure life line for Tie off
 Poor access the harness, if required.
 Traffic control by signalman with
flag.
 Access ways and unloading
zone identified
Lifting of  May hit the  Ensure SWL, Lifting radius etc. of  Safety
Derrick assembled part 5 4 20 A the erection crane. 3 3 9 B helmet, S S P
Post and of A- Frame.  Provide experienced foreman  Safety
Page 80 of
ANNEXURE –
assembly  May hit for signaling. Goggles,

of second , the  Provide licensed operator.  Dust
third , persons  Area shall be barricaded. coverall,
fourth and involved.  Double lanyard Full body  gloves,
fifth stage  Fall of persons harness with shock absorber  Double
of A- might result with fall arrester, where lanyard
Frame during height necessary, shall be used Full body
works. while work at height. harness
 3. Hit may  Tag Line shall be used to with shock
result due control movement of lifted absorber
to breaking loads. with fall
of wire  Ensure TPI for all lifting tools and arrester
ropes / tackles including Rig assembly.
slings.
Area  Valid permit should be obtained
clearance on daily basis, which can provide
 Basic PPEs
and information about the existence
 Safety
identificati of underground utilities, if any.
 Damage to Goggles,
on of  If required, cable
underground  Respirator
4 Driving of piles buried 4 5 20 A detectors would be used 2 2 4 C  Dust
S S P
cables, utilities to detect underground
cables. coverall,
utilities
 A signal man shall be assigned to  Leather
and
monitor the excavation. gloves,
chemicals
etc.  TBT shall be conducted on daily
basis.
Page 81 of
ANNEXURE –
Placement
 Hand injury  Basic PPEs
of piling  All workers should use hand
might happen.  coverall,
shoe on
 Pile shoe could
4 3 12 A gloves/ safety shoes. 2 2 4 C  Leather
S S P
the pile  2.TBT shall be held with crew
slip and fall. gloves,
location
Page 82 of
ANNEXURE –
 Basic PPEs
 Reverse horn of miller shall be in
 Safety
working condition
Placing the  Collision with Goggles,
 Signal man shall be provided
5 concrete mixer piling rig 4 3 12 A  Ensure area is clear from
2 2 4 C  Dust S S P
near to the rig  Hit to person coverall,
obstacles for movements.
 Leather
 Provide valid licensed driver
gloves,
Vertical, Lateral
and Pull out  Basic PPEs
test  Keep clear access and  Safety
Shifting of  Struck by Goggles,
hand gloves shall be in use.
rebar, slip, trip,
6 rebar, farm and 4 4 16 B  Provide steps for excavation or 2 2 4 C  Dust S S P
fall to same coverall,
scaffolding provide ladder for assess.
level  Leather
materials for
pile head gloves,
preparation
 Load or  Load shall be lifted as per the
hydra may load chart
Lifting, shifting  Basic PPEs
collapse due  Licensed and experienced
and Placing of  Safety
to operator shall be allowed to
Goggles,
load (concrete overloading operate the hydra
 Respirator
7 block and  Load collapsed 5 5 25 A  Proper training shall be provided 3 3 9 B  Dust
S S P
beams) with due to failure to the hydra operator and
helper coverall,
the help of of lifting tools
 Certified and inspected lifting  Leather
hydra  Load or
tools shall be allowed to lift the gloves,
hydra may be
collapsed due load Ground area shall be
to uneven floor
Page 83 of
ANNEXURE –
surface Strike properly leveled.

with moving or  Tagline shall be provided to
stationary control the load
object  Bank man shall be provided with
hydra
 Horns and lights shall be in
proper working condition.
 Workplace shall be cordon off
prior to start of pile testing
operating
 Maintain a safe distance while
placing the bearing supports
and jacks.
 Ensure falling of objects is not
in line with your body posture.
 Only certified hydraulic jack
(SCP112) 300MT Capacity shall
be used for testing purpose
 Place the concrete cube safely
to protect from falling.
 Ensure all personnel have  Basic PPEs
undergone Site Safety  Safety
Cutting of steel  Crush Injury Induction. Goggles,
using bar  Hit the men  Ensure PTW Issued by the  Respirator
8
cutting due to temper. 5 4 20 A PMC before starting the work.
3 1 3 C  Dust
S S P
machine  Deploy trained worker for to coverall,
cut the steels  Leather
 Tool Box Talks to be gloves,
Page 84 of
ANNEXURE –
activity.
Page 85 of
ANNEXURE –
 Ensure the machine is

entering to site and color
coded.
 Ensure safety guard provided
machine.
 Pedal guard/Hand lever
protection against accidental
activation.
 Ensure cover guard
protection for cutting part of
machine.
 Place re bar in position and
cover before activating the foot
pedal/Hand lever.
 Rods should be hold
tightly while cutting.
activity.
task completed.
Bending of  Crush Injury Induction. Goggles,
steel using bar  Hit the men  Ensure PTW Issued by the  Respirator
9
bending due to temper. 5 4 20 A PMC before starting the work.
3 1 3 C  Dust
S S P
machine  Deploy trained worker for to coverall,
Page 86 of
ANNEXURE –
 Tool Box Talks to be gloves,
activity.
Page 87 of
ANNEXURE –
 Ensure the machine is

entering to site and color
coded.
 Ensure safety guard provided
machine.
 Ensure the second stopper
for protection against struck
by swing arm in case of
failure of first stopper.
 Ensure pinching will happen by
using multiple rods.
 While operating the machine
stand front to the machine to
hold the rod to avoid hit.
 Ensure emergency switch is in
working condition.
activity.
task completed.
Binding of Induction. Goggles,
steels using  Pinching hazard
binding
4 4 16 A  Ensure PTW Issued by the 3 1 3 C  Respirator S S P
PMC before starting the work.  Dust
wire
 Deploy trained worker for to coverall,
Page 88 of
ANNEXURE –
 Tool Box Talks to be conducted
Page 89 of
ANNEXURE –
before start of the activity. gloves,

 Use proper gloves to avoid
pinching of wires.
 Ensure workers are free
from heat stress.
task completed.
undergone Site Safety
Induction.
 Ensure PTW Issued by the  Basic PPEs
PMC before starting the work.  Safety
Shifting Of  Fall of  Deploy trained worker for to Goggles,
fixed rods materials on cut the steels  Respirator
to working men/hit the 4 4 16 A  Tool Box Talks to be
3 1 3 C  Dust
S S P
area men conducted before start of the coverall,
manually
activity.  Leather
 Ensure access free gloves,
from obstruction.
 Ensure no unwanted men
movement in the shifting
area.
 Ensure proper positioning
of fixed rods
 Ensure Competent Person  Basic PPEs
Must work with electrical  Safety
machine Like motors Goggles,
Electrical  Electrocution
10
Operation
5 4 20 A  Ensure cables free 3 2 6 B  Respirator S S P
from damaged.  Dust
Page 90 of
ANNEXURE –
 Ensure Safety devices Like coverall,
ELCB/RCCB Connected with  Leather /
the
Page 91 of
ANNEXURE –
circuit. rubber
 Ensure isolation of power gloves,
source while maintenance
works.
 Ensure proper body earthen
electrical machines.
 Ensure cables are over headed.
 Ensure there is no damage in
electrical panel Boards.
 Ensure working area should
be barricaded.
 Ensure LOTO is following while
electrical maintenance.
 Ensure Proper PPEs provided
for the Electrical Technician and
operator
 Ensure adequate supervision
until the task complete.
 Ensure trained workmen  Basic PPEs
working in height.  Safety
 Ensure workmen Goggles,
 Fall of undergone with height  Respirator
Reinforcement materials and work training.  Dust
11.
Work
5 5 25 A  Ensure Scaffold is inspected
3 1 3 C coverall,
S S P
men
daily before starting the  Leather
work. gloves,
 Ensure proper working platform  Safety
provided for the workmen. harness
Page 92 of
ANNEXURE –
 Ensure all tools and tackles Tied
with rope avoid falling.
Page 93 of
ANNEXURE –
 Ensure Reinforced materials

erected and proper support
should be given.
 Ensure workers worn
proper PPEs like Safety
harness.
 Ensure Proper supervision until
the task complete.
 Prior checks to be done
for vehicle/concrete
 Mechanical pump.
failure.  Ensure the equipment
 Lack of should have proper
 Basic PPEs
supervision. documents.
 Safety
 Striking against  Continuous supervision to
Goggles,
objects. be provided.
 Respirator
 Improper  Proper barrication has to be
12 Concreting.
barrication.
4 4 16 A done for the entire area. 3 1 3 C  Dust S S P
coverall,
 Unguarded  No Unauthorized entry during
the activity.  Gumboots
rotating parts.
 Guards to be provided for  Rubber
 Spillage of gloves
concrete. rotating parts
 Skin rashes.  Concrete to be removed and
after completion of the
work.
 Proper access/platform to be
provided.
 PPE like rubber hand gloves
goggles should be wearied.
Page 94 of
ANNEXURE –
 Electrocution  Ensure Competent Person  Basic PPEs
13 Vibrator  Health hazard 5 5 25 A Must work with electrical 3 2 6 B  Safety S S P
 Skin diseases machine Goggles,
Like vibrator
Page 95 of
ANNEXURE –
 Collapse of  Ensure cables free from damage  Respirator

wheel barrow  Ensure Safety devices Like  Dust
with person ELCB/RCCB Connected with coverall,
over the circuit.  Leather
speeding  Ensure isolation of power gloves,
 Over turning source while maintenance
of rider. works.
 Inhalation of  Ensure proper body earthen
cement Dust, should be provided to the
Eye and skin electrical machines.
irritation by  Ensure cables are over headed.
direct contact  Ensure there is no damage in
with cement. electrical panel Boards.
 Electric Shock  Ensure Proper PPEs provided
due to water for the Electrical Technician and
spillage. operator
 Air pollution  Ensure Adequate supervision
 Entanglement until the task complete
 Ensure person who working
with vibrator machine must
need time interval (Rest).
 Ensure person is medically fit to
operate the vibrator.
 Ensure worker provided with
required PPEs
 Ensure Adequate supervision
until the task complete
 Ensure LEL level zero by using
Multi Gas Detector
Page 96 of
ANNEXURE –
 Ensure Edge protection/proper

support/working platform
 Use proper PPEs, follow up
daily tool box talk & work
permit system.
 Availability of Machine guard
 Arrangement of portable fire
fighting facilities nearby
workplace
 Ensure uses of PPEs like
safety goggles, gumboots,
rubber gloves and helmets.
 Ensure availability of Trained /
experienced vibrator operator.
 Ensure proper maintenance
of vibrators.
 Ensure adequate support to
make for vibrator machine when
in use.
 Ensure the connection should
be drawn through 30mA rated
capacity of ELCB/RCCB
 Valid license holder electrician
should check the electrical
system becomes healthy before
start of work.
 Slips and trips  Use proper access and  Basic PPEs
14 Curing. 4 3 12 A good housekeeping.
3 1 3 C  Safety
S S P
Page 97 of
ANNEXURE –
 Proper PPE’s like gumboot and Goggles,

rubber gloves to be used while  Respirator
curing.  Dust
 No Electrical wires to be in coverall,
place while curing.  Gumboots
 Rubber
gloves
 Heating activity shall be always
carried out by trained and
experienced person.
 Burn injury.  Workmen shall be work with
 Breathing necessary PPEs at site.
problem due  Provide nose mask to
 Basic PPEs
to inhalation of the workmen.
 Safety
smoke.  For eyes protection goggle to
Goggles,
 Chance of fire. be provided.
 Respirator
 Explosion.  Flash back arrestor shall
Bitumen  Face
15
Heating  Personal injury. 5 5 25 A be ensured. 3 4 12 B shield
S S P
 May cause  Before starting of job burner &
hose to be checked.  Leather
severe gloves
 Injuries or  Gas leakage to be checked
 Protective
prove fatal. with soap solution.
cloth
 Property  Keep LPG/metal cutting
Damage. cylinder free from spark/ heat.
 Use fire blanket for covering of
cylinder.
 Fire extinguisher/fire hose shall
be placed nearby hot
workplace.
Page 98 of
ANNEXURE –
 Stacking of LPG shall be placed

separately in up right
direction.
 In case a fire breaks out, press
fire alarm system and shout
"Fire, Fire"
 Keep buckets full of sand / fire
extinguishing equipment near
hazardous locations
 Small fires can  Train people for using specific  Basic PPEs
become big type of fire fighting equipment’s  Safety
ones and may under different classes of fire Goggles,
spread to the  Keep fire doors/shutters,  Respirator
Fire prevention passages and exit doors
Surrounding  Face
16 and protection. 5 4 20 A unobstructed. 3 3 9 B shield
S S P
areas.
 Cause burn  Maintain good housekeeping  Leather
injuries and and first-aid boxes gloves
may prove  Don't obstruct assess to Fire  FRC
fatal extinguishers. Cloths
 Do not use elevators
for evacuation during
fire.
 Maintain lightening arrestors for
elevated structures
 Stop all electrical motors with
internal combustion.
Page 99 of
ANNEXURE –
 Ensure usage of correct fire  Basic PPEs
 Fire extinguisher meant for the  Face
4 5 20 A specified fire.
3 4 12 B shield
S S P
 Do not attempt to extinguish Oil  Leather
Page 100 of
ANNEXURE –
and electric fires with water. gloves

 Use sand bucket/CO2/DCO/sand  FRC
or earth. Cloths
 Ensure proper PPEs to work  Basic PPEs
(helmet, shoes, goggles, leather  Safety
 Bitumen liquid hand gloves, protective cloth Goggles,
may chance to etc.)  Respirator
Applying fall hand/feet  Activity shall be always carried  Face
17 bitumen to /lower body 5 5 25 A out by trained and experienced
3 3 9 B shield
S S P
surface. part. person.  Leather
 Burn injury.  Working under supervision. gloves
 Awareness/ training program to  Protective
be conducted. cloth
 Work area shall be barricaded to
 Men/ material restrict entry.  Basic PPEs
may fall down
 Openings shall be covered if  Safety
through cut Goggles,
work is preceded in the
Restriction of out opening.
higher elevation.  Respirator
 Slip, trip & fall
unauthorized  Access shall be kept clean.  Face
18
entry near
 Physical injury 5 5 25 A  No loose materials shall be
4 3 12 B shield
S S P
 Person may stacked near the edge of  Leather
work area. get injure.
the openings. gloves
 May prove  When people are working close  Protective
fatal. to the cut out openings wearing cloth
of full body harness.
Page 101 of
ANNEXURE –
RISK MATRIX
Rating 5 = Almost certain 5 10 15 20 25
Rating 4 = Very likely 4 8 12 16 20
C = CONSEQUENCES 
Rating 3 = Possible 3 6 9 12 15
Rating 2 = Unlikely 2 4 6 8 10
Rating 1 = Very unlikely 1 2 3 4 5
* Rating 1 = Negligible Rating 2 = Slight Rating 3 = Moderate Rating 4 = High Rating 5 = Very High
First aid injury or Minor injury or '3 day' injury Major injury or Fatality, disabling
illness illness or illness illness injury, etc.
L = LIKELIHOOD / SEVERITY 
Risk Risk Level Action

May be acceptable but review task to see if risk can be reduced
A = 1 to 5 Low Risk
further.
Task should only be undertaken with appropriate management
B = 6 to 10 Medium Risk
authorization after consultation with specialist personnel.
Task must not proceed. It should be redefined or further control
C = 12 to 25 High Risk
measure put in place to reduce risk.
Page 102 of
ANNEXURE –
Prepared By: SAFETY ENGINEER/PDIL
Checked By: RCM/PM/PDIL
Approved By: GNFC
Other
Page 103 of
ANNEXURE – R
ON SITE EMERGENCY PLAN

INTRODUCTION
Emergency planning is an integral part of the overall loss control programme and is essential
for our organization. The same is important for effective management of an accident to
minimize the losses to the people and property, both in and around the facility. The important
aspect in emergency management is to prevent by technical and organizational measures, the
unintentional escape of hazardous materials out of the facility and minimize accidents and
losses. Emergency planning demonstrates the organizational commitment to the safety of
employees and increases our organization’s safety awareness.
An emergency in the factory has potential to cause serious injuries or loss of live or extensive
damage to the property and / or environment and serious disruption both inside and / or
outside the works. In such cases sometimes outside agencies are required to call for help in
handling the situation. The causative factors like plant / equipment failure, human error,
earthquake, sabotage etc. will normally manifest in various forms viz. Fire, Explosion, Toxic
and Structure collapse etc.
In spite of best design and layout of plant, safe operating procedures and various preventive
measures the possibility of a disaster cannot be totally ruled out. During this event timely and
organized action must be taken to control the situation and to minimize the damage or loss to
the factory, human beings and environment hence, the need of a proper “On–Site Emergency
Plan (EPRP)”. Such plan gives the guidelines for employees, contractors, transporters and
Visitors etc. The EPRP not only defines the responsibilities but also inform about prompt
rescue / evacuation
/co-ordination operations and some more.
WHY INTRODUCTION OF EMERGENCY PLANNING IS REQUIRED?

After the incident of Bhopal gas disaster, the Factories Act has been amended and a new
chapter i.e. Chapter IVA – provision relating to hazardous processes has been added to the
Factories Act with addition of new provisions sec 41A, 41B, 41C, 41D, 41E, 41G & 41H
covering all hazardous process industries. Under the provision of Sec 41B (4) every occupier
shall with the approval of the Chief Inspector of Factories draw up an On-site Emergency
Plan and detailed disaster control measures for his factory and make known to the workers
employed therein and to the general public living in the vicinity of the factory the safety
measures required to be taken in the event of an accident taking place. This is the statutory
provision laid down in the act for preparation of On-site Emergency Plan to control disaster
in the factories. Major accidents may cause emergency and it may lead to disaster, which
ANNEXURE – R
may cause heavy damage to plant, property and harm to person and create adverse affects on
production. Many disasters like Bhopal gas tragedy, Chernobyl nuclear disaster etc. have
occurred at many places in the world causing heavy loss of life and property. Emergency
situation arises all on a sudden and creates havoc and damage to person, property, production
and environment. Therefore such situations and risks should be thought in advance and it
should be planned before hand to tackle them immediately and control them within the
shortest time.
OBJECTIVE
The main objective of On-site emergency management plan (On-SEMP) is in emergency
management planning is to ensure that everyone knows:
 What are the hazards and risk in the plant

 What and how to do in the event of an emergency; and
 Preparations for potential and unexpected incidents at the workplace.
The types of emergencies to plan for include fire, explosion, toxic releases, injuries and
rescues in the hazardous events. Plan improves local, district, state and national capacity to
respond to disasters and public health emergencies, scaling up the actions with vulnerable
communities in health promotion, disease prevention and disaster risk reduction.
As per our Indian regulations we have regulatory provisions that On-site Emergency
Management Plan (On-SEMP) will be prepared by industrial units and Off-site Emergency
Management Plan (Off SEMP) by District Collector.
An occupier will prepare and keep an up-to date on-site emergency plan containing details of
Manufacture, Storage and Import of Hazardous Chemicals (MS&IHC) Rules 1989 and
detailing how major accidents will be dealt with on the site on which the industrial activity is
carried on and that plan will include the name of the person who is responsible for safety on
the site and the names of those who are authorized to take action in accordance with the
plan in case of an emergency. The occupier will ensure that the emergency plan prepared
takes into account any modification made in the industrial activity and that every person on
the site who is affected by the plan is informed of its relevant provisions.
The occupier will prepare the emergency plan required –

 In the case of a new industrial activity, before that activity is commenced;
 (In the case of an existing industrial activity within 90 days of commencing into
operation of these rules.
ANNEXURE – R
On-site emergency can be due to the following causes
Man-made Cause Natural Cause Extraneous

Riots / Civil
Fire Flood
disorder
Explosion/ Leakage Earthquake Terrorisms
Failure of critical control system Cyclone Sabotage
Outbreak of
Design deficiency Bomb Threat
Disease
War/Hit by
Unsafe Acts Extensive Rains
missiles
In-adequate maintenance Tsunami Abduction
Food poisoning / Water
Poisoning
WHAT IS EMERGENCY?
An emergency is a situation, which may lead to or cause a large-scale damage or destruction

to life or property or environment within or outside the factory. Sometimes emergency
results into uncontrollable situations which leads towards the disaster. Such an unexpected
severe situation may be too great for the normal workforce in the area within the plant. In any
industry emergency can arise at any moment and this depends on the type of Structure, Raw
Materials, Machines / Plant, Nearby Industries etc.
A major emergency can be defined as an accident/ incident that have potential to cause
serious injuries or loss of life. It may cause extensive damage of property, serious disruption
both in production and working of factory and may adversely affect the environment. The
following factors may cause major emergency.
(i) Plant failure.

(ii) Human error.
(iii) Vehicle crash.
(iv) Sabotage.
(v) Earthquake.
(vi) Natural Calamities.
ON-SITE EMERGENCY: If an accident/ incident takes place in a factory, its effects is

confined to the factory premises, involving only the persons working in the factory and the
property inside the factory it is called as On-site Emergency.
OFF-SITE EMERGENCY: If the accident is such that it affects inside the factory are
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uncontrollable and it may spread outside the factory premises, it is called as Off-site
Emergency.
NATURE OF EMERGENCY
The emergency has been identified and can be specified in one or more of the
followings with source and effect:
Sr.
Emergency Source Effect
No
Small fires complete
Electrical Panels, Flammable equipment loss,
oil storage tanks, Compressors, complete Area burn
1 Fire / Explosion
coolants, paints, etc. out, Air pollution, Soil
pollution, Dangers to
Human beings.
Spillage of
Fire, Burns, Soil
flammable / Hydraulic oil, Furnace Oil,
2 pollution,
Hazardous Oils & Coolant etc.
Injury by slippage
coolant etc
Electrical panels, Power
Distribution Board, DG Set, Burns, suffocation,
Overhead Crane, Voltage Death. Toxic chemical
3 Electric Shock
stabilizer, Electric ingestion into blood
Transformer & Machine stream
Operated by electricity, etc.
Fall from height & Falling
Accidents – Factory
4 of Heavy Materials, Dies, Fracture
(Major)
Bins or other Heavy object.
Accident due to
Death or Injury to
5 Accidents-Transport transportation of man &
Body
material
Personal
6 Toilets, offices, Basement Suffocation
confinement
Natural calamities
Structural collapse,
7 such as storm, Nature
Death
earthquakes, etc.
Office building, & Any Wall Serious injury, Major
8 Structure collapse
or part Of Factory building. Fracture, Death
Riots, Arson, Serious injury, major
9 Anti Social elements.
Sabotaging Fracture, Death.
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10 Toxic gas leakage Fire Hazard, Suffocation Serious injury, Death

11 TANK DYKE Fire Fire Hazard Serious injury, Death
12 Electric fire Fire Hazard Serious injury, Death
13 Office fire Fire Hazard Serious injury, Death
14 Person on flames Fire Hazard Serious injury, Death
Food/Water
15 Health Hazard Poisoning, Death
Poisoning
16 Bomb hoax Bomb threat Explosion, Death, fear
17 Burn-Minor Health Hazard Burn injury
Electric shock
18 Health Hazard Injury, Death
casualties
Non Functioning of Spillage of untreated water
19 STP and ETP on ground Land Contamination
EMERGENCY ACTION PLAN:

The Action Plan should consist
 Designated Emergency Control Centre/Room.
 Key Personnel.
EMERGENCY CONTROL CENTRE:

This is the main center from where the operations to handle the emergency are directed
and co-ordinate.
Maximum facilities to be made available in the emergency control are –
i. Internal and external communication.

ii. Computer and other essential records.
iii. Daily attendance of workmen employed in factory.
iv. Storage of hazardous material records and manufacturing records.
v. Pollution records.
vi. Walky-talky.
vii. Plan of the plant showing-
a. Storage area of hazardous materials.
b. Storage of safety equipments.
c. Fire fighting system and additional source of water.
d. Site entrance, roadway and emergency exist.
e. Assembly points.
f. Truck parking area.
g. Surrounding location.
viii. Note Book, Pad and Pencil.
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ix. List of Key Personnel with addresses, telephone number etc.
KEY ELEMENTS OF THE ON-SEMP

Emergencies can happen at any time in any types of industry, due to fire in a process area,
tank form area, toxic gas/liquid release into the area from storage vessels or piping network,
or a bomb threat. The approach of the plan is to eliminate or reduce the risk of injury or harm
that may occur during an evacuation by undertaking following steps:-
a) Classification and identifying potentially hazardous situations;

b) Assessment of the risks;
c) Implementation and compliance of the regulatory provisions as per the Manufacture,
Storage & Import of Hazardous Chemicals (MS and IHC) Rule 1989 and Chemical
Accidents (Emergency Planning, Preparedness and Response) [CA (EPPR)] Rules
1996 schedule;
d) Consequences of defaults or non-compliance of regulations;
e) Statutory requirements;
f) Pre-emergency planning;
g) Emergency mitigation measures;
h) Emergency preparedness measures;
i) Emergency response procedures and measures;
j) Emergency organization and responsibilities;
k) Infrastructure requirements;
l) Procedures for declaration of on-site and off-site emergency;
m) Resources for controlling emergency;
n) Demographic information;
o) Medical facilities;
p) Evacuation;
q) Public relations and information to public;
r) Reporting of the incident;
s) Emergency recovery procedures;
t) Emergency plans for tank trucks and pipelines carrying hazardous
products;
PRE- EMERGENCY PREPAREDNESS
This may have following components:
a) Information on the preliminary hazard analysis:

b) Type of accident
c) System elements or events that can lead to a major accident
d) Hazards
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e) Safety relevant components

f) Details about the site
g) Location of dangerous substances.
h) Seat of key personnel
i) Emergency control room
j) Description of hazardous chemicals at plant site:
k) Chemicals (Quantities and toxicological data)
l) Transformation if any, which could occur.
m) Purity of hazardous chemicals.
n) Likely dangers to the plant.
o) Enumerate effects of Accident
p) Stress and strain caused during normal operation
q) Fire and explosion inside the plant and effect if any, of fire and explosion
outside.
THE KEY PERSONNEL & THEIR ROLE FOR ONSITE EMERGENCY
1. Works main site controller.

2. Works incident controller.
a. Communication Officer.
b. Security and Fire Officer.
c. Telephone Operators.
d. Medical Officer.
e. Personnel/Administrative Officer.
f. Essential work team leaders.
SITE CONTROLLER is the person who assumes absolute control of the Factory and
determines the action necessary to control the Emergency. He / She will wear a Red &
White Helmet to confirm his identity. The General Manager will be the site controller.
Site controller will ensure that all members of his/her team have been informed to collect
at Emergency Control centre. He / She will then proceed to Emergency Control Centre to
take charge.
After firsthand assessment of situation he/she will give necessary instructions to

Emergency Control Team. He / She will maintain a Log book of all the activities. He/she
will keep in touch with the external communication Team. He/she will ensure that
information is sent to outside emergency services (Police and Fire Brigade). He/she will
depute people to,
 Attend to telephone
 Keep in touch with incident controller
 Communicate with Assembly Points
 Meet outside emergency services
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 Ensure proper flow of traffic and security

 Meet media/ other people coming at site from outside.
 Arrange for Medical Aid
INCIDENT CONTROLLER is the person who goes to the scene of emergency and
supervises the actions taken at the incident to overcome the Emergency. Shift Manager
will act as Incident Controller. His responsibilities will be
 Direct all efforts to contain and control the incident.
 Keep non-essential persons away from the site.
 Guide outside emergency services at the site.
 Arrange to remove any casualties at the site.
 Keep in touch with Emergency Controller.
SECURITY IN-CHARGE WILL

 Actuate the Emergency Siren, if not done already.
 Send one guard to start the fire pump.
 Attend to incoming telephone.
 Await instructions from the Emergency Controller
COMMUNICATION OFFICER
Public Relations Officer will act as Communication Officer. On hearing alarm He will
proceed to Emergency Control Centre.
 Maintains communication with Incident Controller and Deputy Incident
Controller
 Recruits suitable staff to act as messengers if telephone and other
communications fail
 Organizes all requirement of Emergency Control Centre
 Arranges Food, Transport, Nursing Home etc
PERSONNEL MANAGER
 He/she will work as Liaison officer. He should be positioned in the office near
gate.
 Will deal with police, media and outside enquiries in consultation with Site
Controller.
 Will keep in touch with Union
 Will arrange for refreshments if required
 Will control traffic movement inside the factory and arrange for alternative
transport if required
 Will keep a record of attendance of workers, staff, contractor’s personnel, and
visitors at the Gate which will act as Assembly Point.
SAFETY OFFICER
 Will assist the Incident Controller with his special knowledge on the safety
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aspects in the factory. He will help to identify the hazardous chemicals, hazard
zones and zone of probable impact in different accident scenarios
 Will select people with special training in safety matters to assist in the
control activities
FIRE & SECURITY OFFICER

 His/her main task is fire fighting and control
 Announce through PAS about the incident zone and any other immediate
information needed for the people nearby
 Maintains liaison with the Fire Brigade team from outside
MEDICAL OFFICER
 Will immediately open a First Aid Centre at Control Centre or at Assembly Point
 Will take up the full responsibility of providing medical assistance during
emergency
 Will arrange for outside medical help if required.
TELEPHONE OPERATOR
 On hearing the emergency alarm, he/she will immediately contact Site
Controller
 On the advice of Site controller/Incident Controller/Security Officer will ring Fire
brigade, Police etc
 Keep telephone board free for urgent communications.
GENERAL EMPLOYEES
Who have not been specified a duty in case of emergency should proceed to/contact the
Emergency Assembly Point in their area. Designated persons will carry out the actions
detailed in the Individual Plant Emergency Procedure. The Roll Call leader will hold a
Roll call. Personnel not at their normal work place must go to the emergency assembly
point. Personnel will remain at these points and await instructions from the Site
Controller.
Essential Works and Team Leaders: During emergency the plants immediately
affected or likely to be affected, as determined by the Works Main Controller, need to be shut
down for safety. In the area immediately affected, it may be possible to isolate equipment
from which flammable or toxic material is leaking. This work must be immediately carried
out by plant supervisors and essential operators.
Workers/ staffs need to be nominated to carry out the following essential works at the
time of emergency-
 Extra first aid personnel to deal with casualties.
 Emergency engineering works, provision of extra or replacement of light, isolation of
equipment, temporary by pass electrical lines etc.
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 Moving tankers or other vehicles from area of risk.

 To carry out tests on ambient air quality.
 To act as runner in case of communication system fails.
 The Works Main Controller will require a task force of suitable trained people for
the following works-
i. Manning of assembly points to record the arrival of evacuated people.
ii. Assistance of casualty arrival areas to record details of casualties.
iii. Manning the factory entrance in liaison with security to direct emergency
vehicle containing the gate e.g. ambulance, fire tenders etc.
For these essential jobs designated teams should be made available. The responsibilities of
the team and the leader should be given. The essential work teams are-
1. Task Force and repair team.
2. Fire fighting team.
3. Communication team.
4. Security Team.
5. Transport Team.
6. First aid and medical team.
7. Safety team.
CONTRACTOR’S EMPLOYEES
Contractor's employees will be instructed in the Emergency Procedures before
commencing work on this site. They will report to the emergency assembly point on this
site. Personnel Manager will guide them in case a major decision like evacuation from
the factory is taken.
VISITORS
Infrequent visitors are registered on each visit. They will be given a Visitors pass which
includes an emergency action statement. The responsibility for visitors in emergency
situation rests with the person being visited.
RESPONSIBILITIES OUTSIDE GENERAL SHIFT HOURS SHIFT

SUPERVISOR
He/she will act as Site controller for the time being. As soon as becomes aware of the
emergency and its location, he will proceed to the scene. He will assess the scale of the
incident and direct operations within the affected areas.
He/she will contact and inform the Site Controller and Incident Controller immediately.
Till their arrival he will continue to perform their duties.
He/she will contact the departmental head to act as incident controller and guide
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Safety Officer and Security Officers for containing the damage.
He/she will call the Medical Officer to the plant if necessary. Other staff with designated
responsibilities will act as instructed.
INFRASTRUCTURE:
FIRE FIGHTING FACILITIES:
The plant will have adequate fire fighting aids including fire hydrants close to the
required locations. There will be Portable Fire Extinguishers of different types and sizes
are installed in specific places.
The factory siren will be used for raising the alarm and also for ALL CLEAR signal.
FIRST AID BOXES are provided in specific locations including at the Assembly point
for administering preliminary treatment. A number of employees are trained for first aid
use.
EMERGENCY CONTROL CENTRE is the point from which the Site Controller
directs the movements of Personnel and Equipment during an Emergency.
Contents of Emergency Control Centre:

 External telephone line and a list of relevant telephone numbers. Below
Table 1 provides a list of relevant telephone numbers
 Internal telephone and telephone list of Emergency Assembly Points.
 List of Emergency Control Team, who must be called showing addresses and
telephone numbers.
 Emergency Controller's Red & White Helmet.
 A list of all persons (by title) responsible for groups of employees.
 Logs and Emergency Controller's checklist.
 Emergency lighting.
 Copy of the emergency plan.
 List of persons trained in First Aid & Fire Fighting.
 List of safety cabinets and their contents & locations.
 Battery operated torches.
 Detailed site plan.
 First aid equipment including stretchers (in surgery).
ASSEMBLY POINT is a place containing an internal telephone and paging system,

where people can wait in a group during emergency to receive instructions from the
Emergency Controller.
A safe place far away from the plant should be pre determined as assembly point
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where in case of emergency personnel evacuated from the affected areas are to be assembled.
The plant workers, contract workers and visitors should assemble in assembly point in case of
emergency and the time office clerk should take their attendance so as to assess the missing
person during emergency.
ALARM SYSTEM: Alarm system varies and will depend on the size of the works area.
Simple fire bell, hand operated siren – break open type, fire alarm etc. Automatic alarm may
be needed for highly hazardous nature of plant.
COMMUNICATION SYSTEM: Communication is a key component to control an

emergency.
The following communication system may be provided in the plant-

 Walky Talky.
 Telephone (internal & external).
 Cell phone.
 Intercom/paging.
 Runners (verbal or written messages).
SIREN FOR EMERGENCY: Siren for emergency should be different from the normal
siren. The emergency siren should be audible to a distance of 5 KM radius. The emergency
siren should be used only in case of emergency.
ESCAPE ROUTE: The escape route from each and every plant should be clearly marked.
The escape route is the shortest route to reach out of the plant area to open area, which leads
to assembly point. This route should be indicated on the layout plan attached to the On-
site Emergency Plan.
EVACUATION: All non-essential staff should be evacuated from the emergency site. As
soon as the emergency siren rings the workers have to shut down the plant and move to the
assembly point. The plant shut down procedure in case of emergency should be prepared and
kept ready and responsible person should be nominated for the purpose.
PERSONNEL COUNTING: All personnel working in the plant should be counted. Time
office person should collect the details of personnel arriving at the assembly point. These
should be checked with the attendances of regular workers, contract workers present in the
site on the day of emergency. The accident control should be informed and arrangement
should be made for searching missing person in the emergency affected area. The employees’
address, contact number of next to kin should be maintained in the time office so that during
emergency relatives of those affected due to emergency may be informed accordingly.
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Information in respect of emergency should be given to the media and other agency.
ALL CLEAR SIGNAL: After control of emergency the Work Incident Controller will
communicate to the works main controller about the cessation of emergency. The main
controller can declare all clear by instructing the time office to sound “All Clear Sirens”.
MUTUAL AID SYSTEM: Mutual aid scheme should be introduced among industries so that
in case of emergency necessary help from mutual aid partner may be extended.
Essential elements of this scheme are –
 Mutual aid must be a written document signed by the Chief Executive of the
industries concerned.
 Specify key personnel who are authorized to give requisition of materials from other
industries.
 Specify the available quantity of material/equipment that can be spared.
 Mode of requisition during emergency.
 Mode of payment/ replacement of material given during an emergency.
 May be updated from time to time based on experience gained.
MOCK DRILLS on emergency planning should be conducted once in 6 months and
sequence of events should be recorded for improvement of the exercise. Exercises on On-site
Emergency Planning should be monitored by Factory Inspectorate and the high officials of
the organization and the plan is reviewed every year.
EMERGENCY FACILITIES: The following facilities should be provided in any factory to

tackle any emergency at any time.
The onsite emergency plan so prepared shall be documented in a printed form in sufficient
copies to give all concerned for knowledge, study and easy follow up. The emergency plan
shall be rehearsed and practiced at regular intervals to test efficiency of personnel,
equipments co-ordinate efforts and to increase confidence and experience to operate such
plan
 On-site emergency plan should contain -
1. Site plan and topographic plan.
2. Plan showing the fire fighting facilities.
3. Plan showing hazardous material storage area.
4. Material safety data sheets for hazardous chemicals.
5. Facilities available in main control center.
6. List of emergency equipment.
7. List of Safety Equipment.
ANNEXURE – R
8. Names and address & contact telephone number of Key Personnel

9. List of important telephone numbers and addresses.
i. Nearest hospitals and ambulance service center.
ii. Nearest fire station.
iii. Govt. Officials.
iv. Transport provider.
 Fire protection and fire fighting facilities.
 Emergency lighting and standby power.
 Emergency equipment and rescue equipment –
i. Breathing apparatus with compressed air cylinder.
ii. Fire proximity suit.
iii. Resuscitator.
iv. Water gel Blanket.
v. Low temperature suit.
vi. First aid kit.
vii. Stretchers.
viii. Torches.
ix. Ladders.
 Safety Equipment –
i. Respirators.
ii. Gum boots.
iii. Safety helmets.
iv. Asbestos Rubber hand gloves.
v. Goggles and face shield.
vi. Toxic gas measuring instruments.
vii. Explosive meter.
viii. Oxygen measuring instruments.
ix. Toxic gas measuring instrument.
x. Wind direction indicator.
EXTERNAL COMMUNICATION will be done by Site Controller. The following
persons and offices may be given updated information as necessary and ask for
necessary help.
 SDO
 Police
 Fire Brigade
 District Hospital
 GPCB
 Factory Inspector
 Local Media
 District Magistrate
ANNEXURE – R
Table: Important Telephone Numbers

NAME DESIGNATION CONTACT NO EXT.NO (INT)
Security Officer
Fire Officer
Safety Officer
Plant Manager
Operation Manager
ERT Manager
Police Officer
Medical Officer
OFF-SITE EMERGENCY PLAN

Type of emergency facilities/ actions required from outside bodies:
 Fire fighting facilities required: Factory will have its own fire fighting facilities but
during emergency, fire brigade may be called.
 Police help required during emergency for evacuation of the people, traffic control
security arrangements etc. will be available.
 Medical help required: seriously injured personnel may be referred to the local
Hospital / Nursing Home / ESI Hospital depending upon the gravity and type of
injuries.
CONCLUSION:
To carry out mock exercises and rehearsal of the off site plan to ensure its efficiency, test and
response, interaction and co-ordination of operators various service organizations evaluate
the effectiveness and adequacy of the equipments and to gain experience and confidence to
implement the plan. The finalized disaster plan shall be given to all concerned for
implementation and rehearsal for preparedness.
ANNEXURE – R
EMERGENCY RESPONSE DIAGRAM
Message to Proceeds to the

Emergency
Emergency
Site
Decides the level of the

emergencydiscussing
with Incident Controller
Personn
el
Undertake a continuous review of the possible
developments and take decision accordingly
Works as Organizes
Liaison all
officer requirements
Incident Controller will
Communicati Safet Securi
on rush to the incident site y ty
and takes all site related Offic
Guides with Fire

Deputy Incident knowledge of Fighti
controller will act as safety
assistant to Incident aspects in the
Deals controller
withpolice, Plant officers take up duties Involving their own units
media Infor
ms
Medic
ANNEXURE – R
AMMONIA (NH3)
PURPOSE
The major use of ammonia is as a fertilizer. It can be applied directly to the soil or in the form
of ammonium salts. Ammonia is also used in the manufacture of commercial explosives
(e.g., TNT, nitroglycerin, and nitrocellulose). In the textile industry, ammonia is used in the
manufacture of synthetic fibers (e.g., nylon and rayon). It also neutralizes acidic by-products
of petroleum refining, and in the rubber industry it prevents the coagulation of raw latex
during transportation from plantation to factory. Ammonia is used in various metallurgical
processes, including the nitriding of alloy sheets to harden their surfaces. Because ammonia
can be decomposed easily to yield hydrogen, it is a convenient portable source of atomic
hydrogen for welding. In addition, ammonia can absorb substantial amounts of heat from its
surroundings (i.e., one gram of ammonia absorbs 327 calories of heat), which makes it useful
as a coolant in refrigeration and air-conditioning equipment. Ammonia used commercially is
often called anhydrous ammonia. Household ammonia is a solution of anhydrous ammonia
(NH3) and water.
PHYSICAL & CHEMICAL PROPERTIES / DEFINITION OF CHEMICAL

GROUP
CAS: 7664-41-7
Class: Toxic, Compressed gas, Corrosive
Molecular Formula: NH3
Form (physical state): gas
Color: Colorless
Boiling Point: -33 °C
POTENTIAL HAZARDS / TOXICITY

Potential Health Effects
Target Organs: Lungs, Central nervous system, Liver, Kidney
May be harmful if inhaled. Material is extremely destructive to the
Inhalation:
tissue of the mucous membranes and upper respiratory tract.
Skin: May be harmful if absorbed through skin. Causes skin burns.
Eyes: Causes eye burns.
Ingestion: May be harmful if swallowed.
PERSONAL PROTECTIVE EQUIPMENT (PPE)

RESPIRATORY PROTECTION: Use a full-face particle respirator with type N100
(US) respirator cartridges.
ANNEXURE – R
Respirators should be used only under any of the following circumstances:

 As a last line of defense (i.e., after engineering and administrative
controls have been exhausted).
 When Permissible Exposure Limit (PEL) has exceeded or when there is a
possibility that PEL will be exceeded.
 Regulations require the use of a respirator.
 An employer requires the use of a respirator.
 There is potential for harmful exposure due to an atmospheric
contaminant (in the absence of PEL)
 As PPE in the event of a chemical spill clean-up process
HAND PROTECTION: Gloves must be worn. Use proper glove removal technique to avoid
any skin contact. Nitride or Neoprene gloves are recommended.
 NOTE: Consult with your preferred glove manufacturer to ensure that the
gloves you plan on using are compatible with Ammonia.
EYE PROTECTION: Wear chemical splash goggles or a face shield to protect from
splash hazards and chemical vapors.
SKIN & BODY PROTECTION:

 Flame resistant lab coat
 Full-length pants
 Closed-toe rubber or leather shoes
HYGIENE MEASURES: Avoid contact with skin, eyes, and clothing. Wash hands
before breaks and immediately after handling the product.
ENGINEERING CONTROLS: Handle using a chemical fume hood with good

ventilation and electrically grounded lines and equipment.
FIRST AID PROCEDURES

If inhaled…Move to fresh air and give oxygen. If the person is not breathing, give
artificial respiration. Avoid mouth to mouth contact.
In case of skin contact…Remove all contaminated clothing. Immediately

(within seconds) flush affected area for FIFTEEN (15) minutes.
In case of eye contact…Remove any contact lenses. Use nearest emergency

eyewash immediately for at least 15 minutes. Continue eye rinse during transport to the
hospital.
ANNEXURE – R
If swallowed…DO NOT INDUCE VOMITING. Never give anything by mouth to an

unconscious person.
SPECIAL STORAGE & HANDLING REQUIREMENTS

STORAGE
 Ensure the container is tightly closed at all times.
 Keep in a dry, cool, and well-ventilated area.
 Keep away from incompatible materials and conditions.
 Keep cool and protect from sunlight.
HANDLING
 The lab where the material is being handled has an approved / certified
emergency eyewash and safety shower.
 Ensure you are wearing the following minimum PPE: tightly fitting safety
goggles and face shield, flame resistant lab coat, full length pants, close-toe
rubber or leather shoes, gloves constructed with nitrile or neoprene.
 Lab emergency contact information must be readily posted. Easy access to a
cellular phone or land line is readily available.
 Avoid inhalation and contact with skin and eyes.
 Avoid inhalation of vapor or mist.
 Avoid formation of dust.
SPILL AND ACCIDENT PROCEDURE

PERSONAL PRECAUTIONS: Avoid breathing vapors, mist or gas. Ensure adequate
ventilation. Evacuate personnel to safe areas. Do not attempt clean-up without minimum PPE.
Beware of vapors accumulating to form explosive concentrations. Vapors can accumulate in
low areas.
ENVIRONMENTAL PRECAUTIONS: Prevent further leakage or spillage – if safe to do
so. Do not allow product to enter drains. Discharge into environment must be avoided.
METHODS AND MATERIALS FOR CONTAINMENT AND CLEAN-UP: Consider
material compatibility prior to clean-up. Verify spill kit is available. Contain spillage and the
collect with an electrically protected vacuum cleaner or by wet-brushing and place in
container for disposal according to regulations.
 Immediately assess amount spilled, follow posted Emergency Response Guide
procedures for hazardous materials incidents.
 If a chemical exposure has occurred, a fellow worker shall call Emergency
number and EH&S department.
ANNEXURE – R
 Don compatible gloves and other protective PPE if not already being worn.
 Secure / restrict access to the area of the spill to prevent spread of the
chemical.
 Use the available spill kit to stop and contain the spill. Bag the
collected material.
 Label and tag as hazardous waste and submit a pick-up request to EH&S
using EHS Assistant.
DECONTAMINATION / WASTE DISPOSAL PROCEDURE

LABEL WASTE: Attach a completed Hazardous Waste tag to all waste containers as soon
as the first drop of waste is added to the container.
STORE WASTE
 Store hazardous waste in closed containers, in secondary containment and in
a designated storage location.
 Double-bag dry waste using sealable transparent bags.
 Waste must be under the control of the person generating and
disposing of it.
DISPOSE OF WASTE
 Dispose of regularly generated chemical waste within 90 days.
 Use EHS Assistant online hazardous waste pick-up request system.
 Contact EH&S Department with questions.
DOCUMENTATION OF TRAINING
 Prior to conducting any work with this material, Principal Investigator or designee
must provide to his/her laboratory personnel specific to the hazards involved in
working with this substance, work area decontamination, and emergency
procedures.
 The Principal Investigator must provide his/her laboratory personnel with a copy of
SOP and a copy of the MSDS provided by the manufacturer.
EDUCATION OF PUBLIC / WORKER

People working within the influence zone will be educated on the emergency in a suitable
manner. This can be achieved only through the Local and District Authorities. However,
necessary information can be extended to the Authority.
*******
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STANDARD OPERATING PROCEDURE (EHS)
PROJECT
PROJECT MANAGEMENT CONSULTANCY

SERVICES FOR
REPLACEMENT OF SINGLE WALL AMMONIA
STORAGE TANK BY DOUBLE WALL STORAGE
TANK AT
GNFC AMMONIA PLANT, BHARUCH
OWNER
GUJARAT NARMADA VALLEY FERTILIZERS & CHEMICALS

BHARUCH - GUJARAT, INDIA
ENGINEERING CONSULTANT
PROJECTS & DEVELOPMENT INDIA LIMITED

(A Govt. of India Undertaking)
SAMTA, SUBHANPURA, VADODARA
0 17.12.2020 17.12.2020 FOR IMPLEMENTATION TAV KMS SNY

REV REV DATE EFF.DATE PURPOSE PREPD REVWD APPD
All rights reserved
ANNEXURE – R
CONTENT
PAGE
CLAUSE TITLE
NO.
1 .0 Scope 6
2 .0 References 6
Requirement of Health, Safety and Environment (HSE)
3 .0 7
Management System to be complied by Bidders
3.1 Management Responsibility 7
3.1 .1 HSE Policy & Objective 7
3.1 .2 Management System 7
3.1 .3 Indemnification 7
3.1 .4 Deployment & Qualification of Safety Personnel 7
3.1 .5 Implementation, Inspection & Monitoring 10
3.1 .6 Behavior Based Safety 12
3.1 .7 Awareness & Motivation 14
3.1 .8 Fire prevention & First-Aid 14
3.1 .9 Documentation 15
3.1 .10 Audit 15
3.1 .11 Meetings 16
3.1 .12 Intoxicating drinks & drugs and smoking 17
3.1 .13 Penalty 18
3.1 .14 Accident/Incident investigation 21
3.2 House Keeping 22
3.3 HSE Measures 23
3 .3 .1 Construction Hazards 23
3 .3 .2 Accessibility 25
3 .3 .3 Personal Protective Equipments (PPEs) 26
3 .3 .4 Working at height 27
3 .3 .5 Scaffoldings & Barricading 29
3 .3 .6 Electrical installations 30
3 .3 .7 Welding/Gas cutting 34
3. 3 .8 Ergonomics and tools & tackles 35
3.3 .9 Occupational Health 36
3.3.10 Hazardous substances 37
3.3.11 Slips, trips & falls 38
3.3.12 Radiation exposure 38
3.3.13 Explosives/Blasting operations 39
3.3.14 Demolition/Dismantling 39
3.3.15 Road Safety 40
3.3.16 Welfare measures 41
3.3.17 Environment Protection 42
3.3.18 Rules & Regulations 42
3.3.19 Weather Protection 43
TITLE: REPLACEMENT OF SINGLE WALL AMMONIA PC-00187-PVPM-
HSE-001 0
STORAGE TANK BY DOUBLE WALL STORAGE TANK
IN GNFC AMMONIA PLANT AT BHARUCH-GUJARAT DOCUMENT NO REV
DOCUMENT NAME: ENVIRONMENT HEALTH &
SAFETY PLAN SHEET 3 OF 63
3.3.20 Communication 43
3.3.21 Confined Space Entry 44
3.3.22 Heavy Lifts 44
3.3.23 Key performance indicators 45
3.3.24 Unsuitable Land Conditions 46
3.3.25 Under Water Inspection 47
3.3.26 Excavation 47
3 .4 Tool Box talks 48
3 .5 Training & Induction Program 49
Additional safety requirements for working Inside a running
3 .6 51
plant.
3 .7 Self Assessment and Enhancement 53
3 .8 HSE Promotion 53
3 .9 LOTO for isolation of energy source 53
4 .0 Details of HSE Management System by Contractor 54
4 .1 On Award of Contract 54
4 .2 During Job Execution 55
4 .3 During short listing of the sub-contractors 57
APPENDICES
1. Standards/Codes on HSE Appendix-A
2. Details of First AID Box Appendix-B
3. Types of Fire Extinguishers & their Appln. Appendix-C
4. Indicative List of statutory Acts & Rules Appendix-D
5. Training subjects / topics Appendix-E
6. List of HSE procedures Appendix-F

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ABREVATIONS
AERB : Atomic Energy Regulatory Board ANSI
: American National Standards Institute
BARC : Bhabha Atomic Research Centre
BS : British Standard
PDIL : Projects & development India Limited
ELCB : Earth Leakage Circuit Breaker
EPC : Engineering, Procurement and Construction
EPCC : Engineering, Procurement, Construction and Commissioning ESI
: Employee State Insurance
GCC : General Conditions of Contract
GM : General Manager
GTAW : Gas Tungsten Arc Welding
HOD : Head of Department
HSE : Health, Safety & Environment
HV : High Voltage
IS : Indian Standard
IE : Indian Electricity
JSA : Job Safety Analysis
LOTO : Lock Out & Tag Out
LPG : Liquefied Petroleum Gas
LSTK : Lump Sum Turn Key
MV : Medium Voltage
PPE : Personal Protective Equipment
RCM : Resident Construction Manager or Site-in-Charge, as applicable ROW
: Right of Way
SCC : Special Conditions of Contract
SLI : Safe Load Indicator
TBM : Tool Box Talks/Meeting
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1.0 SCOPE
This specification establishes the Health, Safety and Environment (HSE) management
requirement to be complied by Contractors/Vendors including their sub-contractors/sub
vendors during work.
This specification is not intended to replace the necessary professional judgment needed
to design & implement an effective HSE system for construction activities and the
contractor is expected to fulfill HSE requirements in this specification as a minimum. It
is expected that contractor shall implement best HSE practices beyond whatever are
mentioned in this specification.
Requirements stipulated in this specification shall supplement the requirements of HSE
Management given in relevant Act(s)/legislations, General Conditions of Contract
(GCC), Special Conditions of Contract (SCC) and Job (Technical) Specifications. Where
different documents stipulate different requirements, the most stringent shall apply.
REFERENCES
The document should be read in conjunction with following:
- General Conditions of Contract (GCC)

- Special Conditions of Contract (SCC)
- Building and other construction workers Act,
- Indian Factories Act
- Job (Technical) specifications
- Relevant International / National Codes
- Relevant State & National Statutory requirements.
- Operating Manuals Recommendation of Manufacturer of various
construction Machineries
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3.0 Requirements of HSE Management system to be complied by Bidders
3. 1 Management Responsibility
3 .1.1 HSE Policy & Objectives
The Contractor should have a documented HSE policy duly & objectives to demonstrate
commitment of their organization to ensure health, safety and environment aspects in
their line of operations. HSE Policy of the contractor shall be made available to Owner /
PDIL at the place of execution of specific contract works, as a valid document.
3 .1.2 Management System
The HSE management system of the Contractor shall cover the HSE requirements and
commitments to fulfill them, including but not limited to what are specified under clause
1.0 and 2.0 above. The Contractor shall obtain the approval of its site specific HSE Plan
from PDIL /Owner prior to commencement of any site works. Corporate as well as Site
management of the Contractor shall ensure compliance of their HSE Plan at work sites in
its entirety & in true spirit.
3 .1.3 Indemnification
Contractor shall indemnify & hold harmless, Owner /PDIL & their representatives, free
from any and all liabilities arising out of non-fulfillment of HSE requirements or its
consequences.
3 .1.4 Deployment & qualifications of Safety personnel
The Contractor shall designate/deploy various categories of HSE personnel at site as

indicated below in sufficient number. In no case, deployment of safety
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Supervisor / Safety Steward shall substitute deployment of Safety Officer / Safety

Engineer what is indicated in relevant statute of BOCW Act i.e. deployment of safety
officer /Safety Engineer is compulsory at project site. The Safety supervisors, Safety
stewards etc. would facilitate the HSE tasks at grass root level for construction sites
and shall assist Safety Officer / Engineers.
A) Safety Steward
For every 250 workmen, one safety steward shall be deployed. As a minimum, he shall
preferably possess School leaving Certificate (of Class XII with Physics & Chemistry
etc.) and trained in fire-fighting as well as in safety/occupational health related subjects,
with minimum two year of practical experience in construction work environment and
preferably have adequate knowledge of the language spoken by majority of the workers
at the construction site.
B) Safety Supervisor
For every 500 workmen, one safety Supervisor shall be deployed. As a minimum, he
shall possess a recognized Degree in Science (with Physics & Chemistry) or a diploma
in Engineering or Technology with minimum Two years of practical experience in
construction work environment and should possess requisite skills to deal with
construction safety & fire related day-to-day issues.
C) Safety Officer / Safety Engineer
One for every 1000 workers or part thereof shall be deployed. Safety officer/ Engineer
Should Possess following Qualification & Experience:
 Recognized degree in any branch of Engineering or Technology or

Architecture with practical experience of working in a building or other
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construction work in supervisory capacity for a period of not less than two years, or
possessing recognized diploma in any branch of Engineering or Technology with
practical experience of building or other construction work in supervisory capacity for
a period of not less than five years.
 Recognized degree or diploma in Industrial safety with one paper in Construction
Safety.
 Preferably have adequate knowledge of the language spoken by majority of the
workers at the construction site.
 Person possessing Graduation Degree in Science with Physics & Chemistry and
degree or diploma in Industrial Safety (from any Indian institutes recognized by
AICTE or State Council of Tech. Education of any Indian State) with practical
experience of working in a building, plant or other construction works (as Safety
Officer, in line with Indian Factories Act, 1958) for a period of not less than five
years, may be considered as Safety Officer, in case Owner/Client of the project agrees
for /approves the same.
D) HSE In-Charge
In case there is more than one Safety Officer at any project construction site, one of them,
who is senior most by experience (in HSE discipline), may be designated as HSE In-
Charge. Duties & responsibilities of such person shall be commensurate with that of
relevant statute and primarily to coordinate with top management of Client and
contractors. In case the statutory requirements i.e. State or Central Acts and / or Rules as
applicable like the Building and Other Construction Workers’ Regulation of Employment
and Conditions of Service- Act,1996 or State Rules (wherever notified), the Factories
Act, 1948 or Rules (wherever notified), etc. are more stringent than above clarifications,
the same shall be followed.
Contractors shall ensure physical availability of safety personnel at the place of specific
work location, where Hot Work Permit is required / granted. No work
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shall be started at any of the project sites until above safety personnel & concerned Site
Engineer of Contractor are physically deployed at site. The Contractor shall submit a
HSE organogram clearly indicating the lines of responsibility and reporting system and
elaborate the responsibilities of safety personnel in their HSE Plan.
The Contractor shall verify & authenticate credentials of such safety personnel and
furnish Bio-Data/ Resume/ Curriculum Vitae of the safety personnel as above for
PDIL/Owner’s approval, at least 1 month before the mobilization. The Contractor,
whenever required, shall arrange submission of original testimonials/certificates of their
Safety personnel, to PDIL /Owner (for verification
/scrutiny, etc.) Imposition / Realization of penalty shall not absolve the Contractor from
his/her responsibility of deploying competent safety officer at site. Adequate planning
and deployment of safety personnel shall be ensured by the Contractor so that field
activities do not get affected because of non-deployment of competent & qualified safety
people in appropriate numbers.
3 .1.5 Implementation, Inspection / Monitoring
 The Contractor shall be fully responsible for planning, reporting, implementing and
monitoring all HSE requirements and compliance of all laws & statutory
requirements. The Contractor shall also ensure that the HSE requirements are
clearly understood & implemented conscientiously by their site personnel at all levels
at site.
 The Contractor shall ensure physical presence of their field engineers/supervisors,
during the continuation of their contract works /site activities including all material
transportation activities. Physical absence of experienced field engineers / supervisors
of Contractor at critical work spot during the course of work may invite severe
penalization as per the discretion of EIC, including halting / stoppage of work.
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 Contractor shall furnish their annual Inspection Plan, with regard to project issues
/subjects, frequency and performers to PDIL /Owner.
 The Contractor shall regularly review inspection report internally and implement all
practical steps / actions for improving the status continuously.
 The Contractor shall ensure important safety checks right from beginning of works at
every work site locations and to this effect “Daily Safety Check List” shall be
prepared by field engineer & duly checked by safety personnel for conformance.
 The Contractor shall carry out inspection to identify various unsafe conditions of
work sites/machinery/equipments as well as unsafe acts on the part of
workmen/supervisor /engineer while carrying out different project related works.
 Adequate records for all inspections shall be maintained by the Contractor and the
same shall be furnished to PDIL /Owner, whenever sought.
 The Contractor shall not carry-out work by engaging single worker anywhere without
any supervisor anytime during day or night.
 To demonstrate involvement/commitment of site management of Contractor, at least
one Safety Walk through in a month shall be carried out by Contractor’s head of site
(along with his area manager/field engineers) and a report shall be furnished to
PDIL/Owner “Safety walk through report” followed by compliance for unsatisfactory
remarks.
 As a general practice lifting tools/tackles, machinery, accessories etc. shall be
inspected, tested and examined by competent people (approved by concerned State
authorities) before being used at site and also at periodical interval (e.g. during
replacement, extension, modification, elongation / reduction of machine / parts, etc.)
as per relevant statutes. Hydra, cranes, lifting machinery, mobile equipments /
machinery / vehicles, etc. shall be inspected regularly by only competent /
experienced personnel at site and requisite records for such inspections shall be
maintained by every contractor. Contractor shall also maintain records of
maintenance of all other site
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machinery (e.g. generators, rectifiers, compressors, cutters, etc.) & portable tools
/equipments being used at project related works (e.g. drills, abrasive wheels, punches,
chisels, spanners, etc.). The Contractor shall not make use of arbitrarily fabricated
‘derricks’ at project site for lifting / lowering of construction materials.
 Site facilities /temporary installations, e.g. batching plant, cement go down, DG-
room, temporary electrical panels/distribution boards, shot-blasting booth, fabrication
yards, etc. and site welfare facilities, like labour colonies, canteen/pantry, rest-
shelters, motorcycle/bicycle-shed, site washing facilities, First-aid centers,
urinals/toilets, etc. should be periodically inspected by Contractor (preferably
utilizing HR /Admin personnel to inspect site welfare facilities) and records to be
maintained.
3 .1.6 Behavior Based Safety
 The contractor shall develop a system to implement Behavior-Based Safety (BBS)

through which work groups can identify, measure and change the behaviors’ of
employees and workers.
 The BBS process shall include the following:
 Identify the behaviors’ critical to obtaining required safety performance.
 Communicate the behaviors’ and how they are performed correctly to all
observe the work force and record safe/at risk behaviors Intervene with
workers to give positive reinforcement when safe behaviors’ are observed.
 Provide coaching/ corrections when at risk behaviors’ are observed.
 Collect and record observation data.
 Summarize and analyze observation data
 Communicate observation data and analysis results to all employees.
 Provide recognition or celebrate when safe behavior improvements occur.
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 Change behaviors to be observed or change activators or change

consequences as appropriate.
 Communicate any changes to workforce.
 Contractor through its own HSE committee shall implement the above process.
The necessary procedures and reporting formats shall be developed by the contractor for
approval by PDIL /Owner.
 The HSE committee of contractor shall observe individual’s behavior for safe
practices adapted for utilization /execution of work for following as a minimum:-
- PPE
- Tools & equipment
- Hazard Identification & control
- House keeping
- Confined space entry
- Hot works
- Excavation
- Loading & unloading
- Work at height
- Stacking & storage
- Ergonomics
- Procedures
3 .1.7 Awareness and Motivation
 The Contractor shall promote and develop awareness on Health, Safety and
Environment protection among all personnel working for the Contractor.
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 Regular awareness programs and fabrication shop / work site meetings at least on
monthly basis shall be arranged on HSE activities to cover hazards/risks involved in
various operations during construction.
 Contractor to motivate & encourage the workmen & supervisory staff by issuing /
awarding them with tokens/ gifts/ mementos/ monetary incentives / certificates, etc.
 Contractor shall assess & recognize the behavioral change of its site engineers /
supervisors periodically and constantly motivate / encourage them to implement HSE
practices at project works.
3 .1.8 Fire prevention & First-Aid
 The Contractor shall arrange suitable First-aid measures such as First Aid Box
(Refer Appendix-B for details), trained personnel/nurse (male) to administer First
Aid, stand-by Ambulance vehicle.
 The Contractor shall arrange installation of fire protection measures such as adequate
number of steel buckets with sand & water and adequate number of appropriate
portable fire extinguishers (Refer Appendix-C for details) to the satisfaction of PDIL
/Owner.
 The Contractor shall deploy trained supervisory personnel / field engineers to cater to
any emergency situation.
 In case the number of workers exceeds 500, the Contractor shall position an
Ambulance / vehicle and nurse on round the clock basis very close to the worksite.
 The Contractor shall arrange FIRE DRILL at each site at least once in three months,
involving site workmen and site supervisory personnel & engineers. The Contractor
shall maintain adequate record of such fire drills at project site.
3 .1.9 Documentation
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The Contractor shall evolve a comprehensive, planned and documented system covering
the following as a minimum for implementation and monitoring of the HSE requirements
and the same shall be submitted for approval by Owner/PDIL.
- HSE Organogram
- Site specific HSE Plan
- Safety Procedures, forms and Checklist.
- Inspections and Test Plan
- Risk Assessment & Job Safety Analysis for critical works.
The monitoring for implementation shall be done by regular inspections and compliance
of the observations thereof. The Contractor shall get similar HSE requirements
implemented at his sub-contractors work site /office. However, compliance of HSE
requirements shall be the responsibility of the Contractor. Any review/approval by PDIL
/Owner shall not absolve contractor of his responsibility /liability in relation to fulfilling
all HSE requirements.
3 .1.10 Audit
The Contractor shall submit an Audit Plan to PDIL/Owner indicating the type of audits
and covering following as minimum:
 Internal HSE audits regularly at least on quarterly basis by engaging internal qualified
auditors (viz safety officers /Construction personnel having 5 years experience in
construction safety and Lead Auditor Course :OSHA 18001 certification).
 External HSE audits regularly at least on every six months by engaging qualified
external auditors (viz safety officers/Construction personnel having 10 years
experience in construction safety and Lead Auditor Course :OSHA 18001
certification). All HSE shortfalls/non-conformances on HSE matters brought out
during review /audit shall be resolved forthwith (generally within a
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week) by Contractor & compliance report shall be submitted to PDIL /Owner. In

addition to above audits by contractor, the contractor’s work shall be subjected to
HSE audit by PDIL /Owner at any point of time during the pendency of contract. The
Contractor shall take all actions required to comply with the findings of the Audit
Report and issue regular Compliance Reports for the same to Owner /PDIL till all
the findings of the Audit Report are fully complied. Failure to carry-out HSE Audits
& its compliance (internal & external) by Contractor, shall invite penalization.
3 .1.11 Meetings
 The Contractor shall ensure participation of his top most executive at site (viz.
Resident Construction Manager / Resident Engineer / Project Manager / Site- in-
Charge) in Safety Committee/ HSE Committee meetings arranged by PDIL/Owner
usually on monthly basis or as and when called for. In case Contractor’s top most
executive at site is not in a position to attend such meeting, he shall inform
PDIL/Owner in writing before the commencement of such meeting indicating reasons
of his absence and nominate his representative – failure to do so may invite very
stringent penalization against the specific Contractor, as deemed fit in Contract. The
obligation of compliance of any observations during the meeting shall be always time
bound. The Contractor shall always assist PDIL/Owner to achieve the targets set by
them on HSE management during the project implementation.
 In addition, the Contractor shall also arrange internal HSE meetings chaired by his
top most executive at site on weekly basis and maintain records. Such internal HSE
meetings shall essentially be attended by field engineers / supervisors (& not by
safety personnel only) of the Contractor and its associates. Records of such internal
HSE meetings shall be maintained by the Contractor for review by PDIL/Owner or
for any HSE Audits.
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 Agenda of internal HSE meeting should broadly cover: -

a. Confirmation of record notes / minutes of previous meeting
b. Discussion on outstanding subjects of previous points / subjects, if any
c. Incidents / Accidents (of all types) at project site, if any
d. Current topics related to site activities / subjects of discussion
e. House keeping
f. Behavioral Safety
g. Information / views / deliberations of members / site sub Contractors
h. Report from Owner / Client
i. Status of Safety awareness, Induction programs & Training programs
j. The time frame for such HSE meeting shall be religiously maintained by one
and all.
3 .1.12 Intoxicating drinks & drugs and Smoking
 The Contractor shall ensure that his staff members & workers (permanent as well
casual) shall not be in a state of intoxication during working hours and shall abide by
any law relating to consumption & possession of intoxicating drinks or drugs in force.
 The Contractor shall not allow any workman to commence any work at any locations
of project activity who is/are influenced / effected with the intake of alcohol, drugs or
any other intoxicating items being consumed prior to start of work or working day.
 Awareness about local laws on this issue shall form part of the Induction Training and
compulsory work-site discipline.
 The Contractor shall ensure that all personnel working for him comply with “No-
Smoking” requirements of the Owner as notified from time to time. Cigarettes,
lighters, auto ignition tools or appliances as well as intoxicating drugs, dry tobacco
powder, etc. shall not be allowed inside the project / plant complex.
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 Smoking shall be permitted only inside smoking booths exclusively

designated & authorized by the Owner /PDIL.
3 .1.13 Penalty
The Contractor shall adhere consistently to all provisions of HSE requirements. In case
of non compliances and also for repeated failure in implementation of any of the HSE
provisions, PDIL /Owner may impose stoppage of work without any cost & time
implication to the Owner and/or impose a suitable penalty.
The amount of penalty to be levied against defaulted Contractor shall be up to a
cumulative limit of 2 .0 % (Two percent) of the contract value for Item Rate,
0 .5 % (Zero decimal five percent) of the contract value for LSTK, EPC, EPCC This
penalty shall be in addition to all other penalties specified elsewhere in the contract. The
decision of imposing stop-work-instruction and imposition of penalty shall rest with
PDIL /Owner. The same shall be binding on the Contractor. Imposition of penalty does
not make the Contractor eligible to continue the work in unsafe manner.
The amount of penalty applicable for the Contractor on different types of HSE violations
is specified below:
Sr.
Violation of HSE norms Penalty Amount
No.
For not using personal protective equipment
Rs 500/- per day/ Item /
1 (Helmet, Shoes, Goggles, Gloves, Full body
Person.
harness, Face shield, Boiler suit, etc.)
2 Working without Work Permit / Clearance Rs 20,000/- per occasion.
Execution of work without deployment of requisite Rs. 5,000/- per violation per
3
field engineer / supervisor at work spot. day
Unsafe electrical practices (not installing ELCB, using
poor joints of cables, using naked wire without top plug
4 Rs 5,000/- per item per day.
into socket, laying wire / cables on the roads, electrical
jobs by incompetent person, etc.)
5 Working at height without full body harness, using Rs. 5,000/- per case per day.
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non-standard/ rejected scaffolding and not

arranging fall protection arrangement as required, like
handrails, life-lines, safety nets etc.
Unsafe handling of compressed gas cylinders (No
6 trolley, jubilee clips double gauge regulator, and not Rs 500/- per item per day.
keeping cylinders vertical during storage/handling).
Use of domestic LPG for cutting purpose / not using
7 flash back arresters on both the hoses/tubes on both Rs. 3,000/- per occasion.
ends.
No fencing /barricading of excavated
8 Rs. 3,000/- per occasion
areas/trenches.
Not providing shoring /strutting /proper slope and
9 not keeping the excavated earth at least 1.5 M Rs.5,000/- per occasion
away from excavated area.
Non display of scaffold tags, caution boards, list of
Rs.1,000/- per occasion per
10 hospitals, emergency services available at work
day
locations.
Traffic rules violations like over speeding of
vehicles, rash driving, talking on mobile phones
Rs. 2,000/- per occasion per
11 during vehicle driving, wrong parking, not using
day
seatbelts, vehicles not fitted with reverse horn / warning
alarms / flicker lamps during foggy weather.
Absence of Contractor’s RCM/SIC or his nominated
representative (prior approval must be taken for each
meeting for nomination) from site HSE meetings
12 Rs5,000/- per meeting
whenever called by PDIL / Owner & failure to nominate
his immediate deputy (in the site
organogram) for such HSE meetings.
Failure to maintain HSE records by Contractor
13 Safety personnel, in line with approved HSE Rs 5,000/- per month
Plan/Procedures/Contract specifications.
Failure to conduct daily site safety inspection (by
Contractor’s safety engineers/safety officers), internal
HSE meeting, internal HSE Awareness / Motivation
14 Rs.10,000/- per occasion.
Program, Site HSE Training and HSE
audit at predefined frequencies (as approved in HSE
Plan).
Failure to submit the monthly HSE report by 5th of Rs. 10,000/- per occasion
15 subsequent month to Project’s Engineer-in-Charge / and Rs. 1,000/- per day of
Owner further delay.
Rs 1,000 & warning letter on
Liquor/alcohol/ drugs/ Intoxicating drinks etc. 1st offence,
16
carrying or consumption inside port premises. Rs 2,500 & termination of
worker on 2nd offence.
17 Failure to report & follow up accident (including Rs. 25,000/- per occasion
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Near Miss) reporting system within specific

timeframe.
Degradation of environment (not confining toxic
18 Rs10,000/- per occasion
spills, spilling oil /lubricants onto ground)
Not medically examining the workers before allowing
them to work at height / to work in confined space / to
work in shot-blasting / to work for painting / to work in
bitumen or asphalt works, not providing ear muffs while Rs 5,000/- per occasion per
19
allowing them to work in noise polluted areas, made worker
them to work in air
polluted areas without respiratory protective
devices, etc.
Violation of any other safety condition as per job HSE
plan / work permit and HSE conditions of contract (e.g.
using crowbar on cable trenches, improper welding
booth, not keeping fire extinguisher ready at hot work
20 Rs. 5,000/- per occasion
site, unsafe rigging practices, non-availability of First-
Aid box at site, not using hood with respiratory devices
by blaster for
shot//grit blasting, etc.)
Failure to carry-out Safety audit in time (internal &
21 external), close-out of identified shortfalls of Rs. 20,000/- per occasion
Observations of Safety Aspects(OSA),etc
Carrying out sand blasting instead of grit / shot
22 Rs. 50,000/- per day
blasting
Failure to deploy adequately qualified and Rs. 10,000/- per day per
23
competent Safety Officer Officer
Utilization of hydra/ back-hoe loader for material
24 shifting or any other unauthorized /unsafe lifting works Rs 25,000/- per occasion
Rs 10,00,000/- per occasion (1st

Any incident / accident at project site has been caused
Instant)
because of willful negligence or gross violation of safety
Rs 15,00,000/- per occasion
25 measures / provisions on the part of the Contractor or
(2nd Instant)
any of its sub-agencies (Fatal
Termination of present
,Major Accidents) Contract (3rd instant)
Rs. 5,000/- per occasion per
26 Poor Housekeeping
day
To be decided by
27 Any violation not covered above
PDIL/Owner.
The Contractor shall make his field engineers/supervisors fully aware of the fact that
they keep track with the site workmen for their behavior and compliance of
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various HSE requirements. Safety lapses /defects of project construction site shall be
attributable to the concerned job supervisor /engineer of the Contractor, (who remains
directly responsible for safely executing field works). For repeated HSE violations,
concerned job supervisor /engineer shall be reprimanded or appropriate action, as deemed
fit, shall be initiated (with information to PDIL & Owner) by the concerned Contractor.
Contractor shall initiate levy of mentioned cash fine and verbal warning shall be given to
the worker/employee during his first HSE violation. A written warning shall be issued on
second violation & Fine will be double and specific training shall be arranged / provided
by the Contractor to enhance HSE awareness/skill including feedback on the mistakes/
flaws. Any further violation of HSE stipulations by the erring individuals shall call for his
forthright debar from the specific construction site and fine will be 10 times higher. A
record of warnings for each worker / employee shall be maintained by the Contractor,
like by punching their cards / Gate passes or by displaying their names at the Project
entry gate. Warnings, penalizations, appreciations etc. shall be discussed in HSE
Committee meetings by site Head of the Contractor.
3 .1.14 Accident / Incident investigation
All accidents / incidents shall be informed to PDIL / Owner at least telephonically by

Contractor immediately and in writing within 24 hours as applicable, by Contractor.
Thereafter, a Supplementary Accident / Incident investigation Report shall be submitted
to PDIL / Owner within 72 hours. Near Miss incidents, Dangerous accidents / incident
shall also be reported within 24 hours. The accident/ incident shall be investigated by a
team of Contractor’s senior Site personnel (involving Site-in- Charge or at least by his
deputy) for establishing root-cause and recommending corrective & preventive actions.
Findings shall be documented and suitable actions taken to avoid recurrences shall be
communicated to PDIL / Owner. Owner/ PDIL shall have the liberty to
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independently investigate such occurrences and the Contractor shall extend all necessary
help and cooperation in this regard. PDIL/Owner shall have the right to share the
content of this report with the outside world.
3. 2 House Keeping
The Contractor shall ensure that a high degree of housekeeping is maintained and shall
ensure the followings:
 All surplus earth and debris are removed /disposed off from the working areas to
designated locations.
 Unused /surplus cables, steel items and steel scrap lying scattered at different places
within the working areas are removed to identify locations.
 All wooden scrap, empty wooden cable drums and other combustible packing
materials, shall be removed from work place to identified locations.
 Roads shall be kept clear and materials like pipes, steel, sand, boulders, concrete,
chips and bricks etc shall not be allowed on the roads to obstruct free movement of
men & machineries.
 Fabricated steel structural, pipes & piping materials shall be stacked properly for
erection.
 Water logging on roads shall not be allowed.
 No parking of trucks /trolleys, cranes and trailers etc shall be allowed on roads, which
may obstruct the traffic movement.
 Utmost care shall be taken to ensure over all cleanliness and proper upkeep of the
working areas.
 Trucks carrying sand, earth and pulverized materials etc. shall be covered while
moving within the plant area /these materials shall be transported with top surface
wet.
 The contractor shall ensure that the atmosphere in plant area and on roads is free from
particulate matter like dust, sand, etc. by keeping the top surface wet for ease in
breathing.
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 At least two exits for any unit area shall be assured at all times – same arrangement is
preferable for digging pits /trench excavation /elevated work platforms /confined
spaces etc.
 Welding cables and the power cable must be segregated and properly stored and
used .The same shall be laid away from the area of movement and shall be free from
obstruction.
 Schedule for upkeep /cleaning of site to be firmed up and implemented on regular
basis for maintaining high standard of housekeeping and maintain records for the
same.
3. 3 HSE Measures
3 .3.1 Construction Hazards
The Contractor shall ensure identification of all Occupational Health, Safety &
Environmental hazards in the type of work he is going to undertake and enlist mitigation
measures. Contractor shall carry out Job Safety Analysis (JSA) /Risk Analysis
specifically for high risk jobs /critical jobs like.
 Working at height (+2.0 Mts height) for cold (incl. colour washing, painting,
insulation etc.) & hot works.
 Work in confined space,
 Deep excavations & trench cutting (depth > 2.0 mts.)
 Operation & Maintenance of Batching Plant.
 Shuttering / concreting (in single or multiple pour) for columns, parapets &
roofs.
 Erection & maintenance of Tower Crane.
 Erection of structural steel members /roof-trusses /pipes at height more than
2.0 Mts. with or without crane.
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 Erection of pipes (full length or fabricated) at height more than 2.0 Mts.
height with Crane of 100T capacity.
 All lifts using 100T Crane plus mechanical pulling.
 All lifts using two cranes in unison (Tandem Lifting).
 Any lift exceeding 80% capacity of the lifting equipments (hydra, crane etc.).
 Lying of pipes (isolated or fabricated) in deep narrow trenches– manually or
mechanically.
 Maintenance of crane /extension or reduction of crane-boom on roads or in
yards.
 Erection of any item at >2.0 Mts. height using 100T crane or of higher
capacity
 Hydrostatic test of pipes, vessels & columns and water-flushing.
 Radiography jobs (in-plant & open field)
 Work in Live Electrical installations / circuits
 Handling of explosives & Blasting operations
 Demolishing / dismantling activities
 Welding / gas cutting jobs at height (+2.0 Mts.)
 Lifting / placing roof-girders at height (+2.0 Mts.)
 Lifting & laying of metallic / non-metallic sheet over roof /structures.
 Lifting of pipes, gratings, equipments/vessels at heights (+2.0 Mts) with &
without using cranes.
 Calibration of equipment, instruments and functional tests at yards / work- sites.
 Operability test of Pump, Motors (after coupling) & Compressors.
 Cold or Hot works inside Confined Space.
 Transportation & shifting of ODC consignments into project areas.
 Working in “charged /live” elect. Panels
 Stress Relieving works (Electrically or by Gas-burners).
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 Pneumatic Tests
 Card board blasting
 Chemical cleaning and take feedback from PDIL /Owner. The necessary HSE
measures devised shall be put in to place, prior to start of an activity & also shall
be maintained during the course of works, by the Contractor. Copies of such JSAs
shall be kept available at work sites by the Contractor to enable all concerned
carrying out checks /verification.
Accessibility
 The Contractor shall provide safe means of access(in sufficient numbers) & efficient
exit to any working place including provisions of suitable and sufficient scaffolding
at various stages during all operations of the work for the safety of his workmen and
PDIL /Owner.
 The Contractor shall implement use of all measures including use of “life line”, “fall
arresters”, “retractable fall arresters” , “safety nets” etc. during the course of using all
safe accesses & exits, so that in no case any individual remains at risk of slip & fall
during their travel.
 The access to operating plant /project complex shall be strictly regulated. Any person
or vehicle entering such complex shall undergo identification check, as per the
procedures in force /requirement of PDIL /Owner.
Accessibility to ‘confined space’ shall be governed by specific system /regulation, as

established at project site.
Personal Protective Equipments (PPEs)
 The Contractor shall ensure that all their staff, workers and visitors including their
subcontractors have been issued (records to be kept) & wear appropriate PPEs like
nape strap type safety helmets preferably with head &
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sweat band with ¾” cotton chin strap (made of industrial HDPE), safety shoes with
steel toe cap and antiskid sole, full body harness (CE marked and conforming to
EN361), protective goggles, gloves, ear muffs, respiratory protective devices, etc. All
these gadgets shall conform to applicable IS Specifications /CE or other applicable
international standards. The Contractor shall implement a regular regime of
inspecting physical conditions of the PPEs being issued /used by the workmen of
their own & also its sub-agencies and the damaged / unserviceable PPEs shall be
replaced forthwith.
 Owner /PDIL may issue a comprehensive color scheme for helmets to be used
by various agencies. The Contractor shall follow the scheme issued by the Owner
/PDIL and shall choose any colour other than white (for Owner) or blue (for PDIL)
All HSE personnel shall preferably wear dark green band on their helmet so that
workmen can approach them for guidance during emergencies. HSE personnel shall
preferably wear such dresses with fluorescent stripes, which are noticeable during
night, when light falls on them.
 For shot blasting, the usage of protective face shield and helmets, gauntlet and
protective clothing is mandatory. Such protective clothing should conform relevant IS
Specification.
 For off-shore jobs/contracts, contractor shall provide PPEs (new) of all types to PDIL
& Owner's personnel, at his (contractor's) cost. All personnel shall wear life jacket at
all time.
 An indicative list of HSE standards/codes is given under Appendix-A.
 Contractor shall ensure procurement & usage of following safety equipments/
accessories (conforming to applicable IS mark /CE standard) by their staff, workmen
& visitors including their subcontractors all through the span of project
construction /pre-commissioning /Commissioning:-
a. PPEs (Helmet, Ear-muff, Face shield, Hand gloves, Safety Shoes, etc)
b. Barricading tape / warning signs
c. Rechargeable Safety torch (flame-proof)
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d. Safety nets (with tie-chords)

e. Fall arresters
f. Portable ladders (varying lengths)
g. Life-lines (steel wire-rope, dia not less than 8.0 mm)
h. Full body harness (double lanyard)
i. Lanyard
j. Karabiner
k. Retractable fall arresters (various lengths)
l. Portable fire extinguishers (DCP type) – 6 kg capacity
m. Portable Multi Gas detector
n. Sound level meter
o. Digital Lux meter
p. Fire hoses & flow nozzles
q. Fire blankets / Fire retardant cloth (with eyelets)
Working at height
 The Contractor shall issue permit for working (PFW) at height after verifying and
certifying the checkpoints. He shall also undertake to ensure compliance to the
conditions of the permit during the currency of the permit including adherence of
personal protective equipments. Contractor’s Safety Officer shall verify compliance
status of the items of permit document after implementation of action is completed by
Contractor’s execution / field engineers at work site. Job Safety Analysis (JSA) for
specific works at height duly commented by PDIL /Owner, shall be kept attached
with particular Permit for Work (PFW) at site for ready reference & follow-up.
Such PFW shall be initially issued for one single shift or expected duration of
normal work and extended further for balance duration, if required. PDIL /Owner can
devise block-permit system at any specific area, in consultation with project specific
HSE Committee to specify the time-period of validity of such PFW or
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its renewal. This permit shall be applicable in areas where specific clearance from
Owner’s operation Dept. / Safety Dept. is not required. PDIL /Owner’s field
Engineers /Safety Officers / Area Coordinators may verify and counter sign this
permit (as an evidence of verification) during the execution of the job.
 All personnel shall be medically examined & certified by registered doctor,
confirming their ‘medical fitness for working at height. The fitness examination shall
be done once in six months.
 In case work is undertaken without taking sufficient precautions as given in the
permit, PDIL /Owner Engineers may exercise their authority to cancel such
permit and stop the work till satisfactory compliance /rectification is arranged made.
Contractors are expected to maintain a register for issuance of permit and extensions
thereof including preserving the used permits for verification during audits etc.
 The Contractor shall arrange (at his cost) and ensure use of Fall Arrester Systems by
his workers. Fall arresters are to be used while climbing
/descending tall structures or vessels /columns etc. These arresters should lock
automatically against the anchorage line, restricting free fall of the user. The device is
to be provided with a double security opening system to ensure safe attachment or
release of the user at any point of rope. In order to avoid shock, the system should be
capable of keeping the person in vertical position in case of a fall.
 The Contractor shall ensure that Full body harnesses conforming EN361 and having
authorized CE marking is used by all personnel while working at height. The
lanyards and life lines should have enough tensile strength to take the load of the
worker in case of a fall. One end of the lanyard shall be firmly tied with the harnesses
and the other end with life line. The harness should be capable of keeping the
workman vertical in case of a fall, enabling him to rescue himself.
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 The Contractor shall provide Roof Top Walk Ladders for carrying out activities on
sloping roofs in order to reduce the chances of slippages and falls.
 The Contractor shall ensure that a proper Safety Net System is used wherever the
hazard of fall from height is present. The safety net, preferably a knotted one with
mesh ropes conforming to IS 5175 /ISO 1140 shall have a border rope & tie cord of
minimum 12mm dia. The Safety Net shall be located not more than 6.0 meters below
the working surface extending on either side up to sufficient margin to arrest fall of
persons working at different heights.
 In case of accidental fall of person on such Safety Net, the bottom most portion of
Safety Net should not touch any structure, object or ground.
 The Contractor shall ensure positive isolation while working at different levels like in
the pipe rack areas. The working platforms with toe boards & hand rails shall be
sufficiently strong & shall have sufficient space to hold the workmen and tools &
tackles including the equipments required for executing the job. Such working
platforms shall have mid-rails and top-rails, to enable people work safely in sitting
posture.
Scaffoldings & Barricading
 Suitable scaffoldings shall be provided to workmen for all works that cannot be
safely done from the ground or from solid construction except such short period work
that can be safely done using ladders or certified (by 3rd party competent person)
man-basket. When a ladder is used, an extra workman shall always be engaged for
holding the ladder.
 The Contractor shall ensure that the scaffolds used during construction activities shall
be strong enough to take the designed load. Main Contractor shall always furnish duly
approved construction-design details of scaffold & SWL (from competent designers)
free of charge, before they are being installed /constructed at site. Owner /PDIL
reserves the right to ask the Contractor to submit certification and or design
calculations from his Head
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office /Design /Engineering expert regarding load carrying capacity of the

scaffoldings.
 All scaffolds shall be inspected by a competent Scaffolding Inspector of the
Contractor. He shall paste a GREEN tag (duly signed by competent Scaffolding
Inspector) on each scaffold found safe and a RED tag (duly signed by competent
Scaffolding Inspector) on each scaffold found unsafe. Scaffolds with GREEN tag
only shall be permitted to be used and Scaffolds with RED ones shall immediately be
made inaccessible. Work being found continuing on scaffolds with RED tag shall be
considered unauthorized work by Contractor and may invite penalization from
PDIL/Owner. For every 120- 125 m/m area / volume or 2/3 its parts there of
minimum one TAG shall be provided.
 The Contractor shall ensure positive barricading (indicative as well as protective) of
the excavated, radiography, heavy lift, high pressure hydrostatic & pneumatic testing
and other such areas. Sufficient warning signs shall be displayed along the
barricading areas. Scaffolding shall be constructed using foot seals or base plates
only.
3 .3.6 Electrical installations
 All electrical installations/connections shall be carried out as per the provisions of

latest revision of following codes/standards, in addition to the requirements of
Statutory Authorities and IE/applicable international rules & regulations:
- OISD STD 173: Fire prevention & protection system for electrical
installations
- SP 30 (BIS) : National Electric Code
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 All electrical installations shall be approved by the concerned statutory authorities.

 All temporary electrical installations/facilities shall be regularly checked by the
licensed/competent electricians of the Contractor and appropriate records shall be
maintained. Inspection of temporary electrical booth/installation at project
construction site”. Such inspection records are to be made available to PDIL /Owner,
whenever asked for.
3 .3 .6 .1 The Contractor shall meet the following requirements:

 Shall make Single Line Diagram (SLD) for providing connection to each equipments
& machinery and the same (duly approved by PDIL/Owner) shall be pasted on the
front face of DBs (distribution boards) /JBs (Junction boxes) at every site.
 Ensure that electrical systems and equipment including tools & tackles used during
construction phase are properly selected, installed, used and maintained as per
provisions of the latest revision of the Indian Electrical / applicable international
regulations.
 Shall deploy qualified & licensed electricians for proper & safe installation and for
regular inspection of construction power distribution system /points including their
earthing. A copy of the license shall be submitted to PDIL
/Owner for records. Availability of at least one competent (ITI qualified) / licensed
electrician (by State Elec. authorities) shall be ensured at site round the clock to
attend to the normal /emergency jobs.
 All switchboards /welding machines shall be kept in well-ventilated & covered
shed /with rain shed protection. The shed shall be elevated from the existing ground
level to avoid water logging inside the shed. Installation of electrical switch board
must be done taking care of the prevention of shock and safety of machine.
 No flammable materials shall be used for constructing the shed. Also flammable
materials shall not be stored in and around electrical
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equipment/switchboard. Adequate clearances and operational space shall be provided

around the equipment. Fire extinguishers and insulating mats shall be provided in all
power distribution centers.
 Temporary electrical equipment shall not be employed in hazardous area without
obtaining safety permit.
 Proper housekeeping shall be done around the electrical installations.
 All temporary installations shall be tested before energizing, to ensure proper
earthing, bonding, suitability of protection system, adequacy of feeders
/cables etc.
3.3.6.2 The following features shall also be ensured for all electrical
installations during construction phase by the contractor:
 Each installation shall have a main switch with a protective device, installed in an
enclosure adjacent to the metering point. The operating height of the main switch
shall not exceed 1.5 M. The main switch shall be connected to the point of supply by
means of armored cable.
 The outgoing feeders shall be double or triple pole switches with fuses/ MCBs.
Loads in a three phase circuit shall be balanced as far as possible and load on neutral
should not exceed 20% of load in the phase.
 The installation shall be adequately protected against overload, short circuit and earth
leakage by the use of suitable protective devices. Fuses wherever used shall be HRC
type. Use of re-wired fuses shall be strictly prohibited. The earth leakage device shall
have an operating current not exceeding 30 mA.
 All connections to the hand tools / welding receptacles shall be taken through proper
switches, sockets and plugs.
 All single phase sockets shall be minimum 3 pin type only. All unused sockets shall
be provided with socket caps.
 Only 3 core (P+N+E) overall sheathed flexible cables with minimum conductor size
of 1.5 mm copper shall be used for all single phase hand tools.
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 Only metallic distribution boxes with double earthing shall be used at site. No
wooden boxes shall be used.
 All power cables shall be terminated with compression type cable glands.
Tinned copper lugs shall be used for multi-strand wires / cables.
 Cables shall be free from any insulation damage.
 Minimum depth of cable trench shall be 750 mm for MV & control cables and 900
mm for HV cables. These cables shall be laid over a sand layer and covered with
sand, brick & soil for ensuring mechanical protection. Cables shall not be laid in
waterlogged area as far as practicable. Cable route markers shall be provided at every
25 M of buried trench route. When laid above ground, cables shall be properly cleared
or supported on rigid poles of at least 2.1 M high. Minimum head clearance of 6
meters shall be provided at road crossings. Underground road crossings for cables
shall be avoided to the extent feasible. In any case no underground power cable shall
be allowed to cross the roads without pipe sleeve.
 An independent earthing facility should preferably be established within the
temporary installation premises. All appliances and equipment shall be adequately
earthed. In case of armored cables, the armor shall be bonded to the earthing system.
 All cable joints shall be done with proper jointing kit. No taped /temporary joints
shall be used.
 All cables and wire rope used for earth connections shall be terminated through
tinned copper lugs.
 In case of local earthing, earth electrodes shall be buried near the supply point and
earth continuity wire shall be connected to local earth plate for further distribution to
various appliances. All insulated wires for earth connection shall have insulation of
green colour.
 Separate core shall be provided for neutral. Earth /Structures shall not be used as a
neutral in any case.
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 ON / OFF position of all switches shall be clearly designated /painted for easy
isolation in emergency.
3 .3.7 Welding / Gas cutting
 Contractor shall ensure that flash back arrestors conforming to BS: 6158 or equivalent
are installed on all gas cylinders as well as at the torch end of the gas hose, while in
use. All cylinders shall be mounted on trolleys and provided with a closing key.
Empty & filled-up gas cylinders shall be stored separately with TAG, protecting them
from direct sun or rain. Minimum 2 nos. of Portable DCP type fire extinguishers (10
kg) shall be maintained at the gas cylinder stores. Stacking & storing of compressed
gas cylinders shall be arranged away from DG set, hot works, Elect. Panels /Elec.
boards, etc
 The burner and the hose placed downstream of pressure reducer shall be equipped
with Flash Back Arrester /Non Return Valve device.
 The hoses for acetylene and oxygen cylinders must be of different colours. Their
connections to cylinders and burners shall be made with a safety collar.
 At end of work, the cylinders in use shall be closed and hoses depressurized.
 Cutting of metals using gases, other than oxygen & acetylene, shall require written
concurrence from Owner.
 All welding machines shall have effective earthing at least at distinctly isolated two
points. In order to help maintain good housekeeping, and to reduce fire hazard, live
electrode bits shall be contained safely and shall not be thrown directly on the ground.
 The hoses of Acetylene and Oxygen shall be kept free from entanglement & away
from common pathways /walkways and preferably be hanged overhead in such a
manner which can avoid contact with cranes, hydra or other mobile construction
machinery.
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 Hot spatters shall be contained /restricted appropriately (by making use of effective
fire retardant cloth/fabric) and their flying-off as well as chance of contact with near-
by flammable materials shall be stopped.
 The Contractor shall arrange adequate systems & practices for accumulation
/collection of metal & other scraps and remnant electrodes and their safe disposal at
regular interval so as to maintain the fabrication and other areas satisfactorily clean &
tidy.
 All gas cylinders must have a cylinder cap on at all times when not in use.
3 .3.8 Ergonomics and tools & tackles
 The Contractor shall assign to his workmen, tasks commensurate with their
qualification, experience and state of health.
 All lifting tools, tackles, equipment, accessories including cranes shall be tested
periodically by statutory /competent authority for their condition and load carrying
capacity. Valid test & fitness certificates from the applicable authority shall be
submitted to Owner /PDIL for their review /acceptance before the lifting tools,
tackles, equipment, accessories and cranes are used.
 The contractor shall not be allowed to use defective equipment or tools not adhering
to safety norms.
 Contractor shall arrange non-sparking tools for project construction works in
operating plant areas /hydrocarbon prone areas.
 Wherever required the Contractor shall make use of Elevated Work Platforms (EWP)
or Aerial Work Platforms (mobile or stationary) to avoid ergonomically risks and
workmen shall be debarred to board such elevated platform during the course of their
shifting /transportation.
 Contractor shall ensure installation of Safe Load Indicator (SLI) on all cranes (while
in use) to minimize overloading risk. SLI shall have capability to continuously
monitor and display the load on the hook, and automatically compare it with the
rated crane capacity at the operating condition of the
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crane. The system shall also provide visual and audible warnings at set capacity levels
to alert the operator in case of violations.
 The contractor shall be responsible for safe operations of different equipments
mobilized and used by him at the workplace like transport vehicles, engines, cranes,
mobile ladders, scaffoldings, work tools, etc.
 The Contractor shall arrange periodical training for the operators of hydra, crane,
excavator, mobile machinery, etc. at site by utilizing services from renowned
manufacturers.
3 .3.9 Occupational Health
 The contractor shall identify all operations that can adversely affect the health of its
workers and issue & implement mitigation measures.
 For surface cleaning operations, sand blasting shall not be permitted even if not
explicitly stated elsewhere in the contract.
 To eliminate radiation hazard, Tungsten electrodes used for Gas Tungsten Arc
Welding shall not contain Thorium.
 Appropriate respiratory protective devices (hood with respiratory devices) shall be
used to protect workmen from inhalation of air borne contaminants like silica,
asbestos, gases, fumes, etc.
 Workmen shall be made aware of correct methods for lifting, carrying, pushing &
pulling of heavy loads. Wherever possible, manual handling shall be replaced by
mechanical lifting equipments.
 For jobs like drilling /demolishing /dismantling where noise pollution exceeds the
specified limit of 85 decibels, ear muffs shall be provided to the workers.
 To avoid work related upper limb disorders (WRULD) and backaches, Display
Screen Equipments' workplace stations shall be carefully designed & used with
proper sitting postures. Power driven hand-held tools shall be maintained in good
working condition to minimize their vibrating effects and personnel
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using these tools shall be taught how to operate them safely & how to maintain good
blood circulation in hands.
 The Contractor shall arrange health check up (by registered medical practitioner) for
all the workers at the time of induction. Health check may have to be repeated if the
nature of duty assigned to him is changed necessitating health check or doubt arises
about his wellness. PDIL/Owner reserves the right to ask the contractor to submit
medical test reports. Regular health check-ups are mandatory for the workers
assigned with Welding, Radiography, Blasting, Painting, Heavy Lift and Height
(>2m) jobs. All the health check-ups shall be conducted by registered Medical
practitioner and records are to be maintained by the Contractor.
 The Contractor shall ensure vaccination of all the workers including their families,
during the course of entire project span.
 Regular distribution of standard quality soap / sanitizer to all employees of the
company for Hygienic up keeping.
 Provided Medical facilities to employees & their dependent family members
including Hospitalization at companies authorized reputed hospitals. An in- house
dispensary facility is available with part time doctor and trained staff to take care of
emergency services of employee’s health.
3 .3.10 Hazardous substances
 Hazardous, inflammable and/or toxic materials such as solvent coating, thinners, anti
termite solutions, water proofing materials shall be stored in appropriate containers
preferably with lids having spillage catchment trays and shall be stored in a good
ventilated area. These containers shall be labeled with the name of the materials
highlighting the hazards associated with its use and necessary precautions to be
taken. Respective MSDS (Material Safety Data Sheet) shall be made available at site
& may be referred whenever problem arises.
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 Where contact or exposure of hazardous materials are likely to exceed the specified
limit or otherwise have harmful effects, appropriate personal protective equipments
such as gloves, goggles / face-shields, aprons, chemical resistant clothing, respirator,
etc. shall be used.
 The work place shall be checked prior to start of activities to identify the location,
type and condition of any asbestos materials which could be disturbed during the
work. In case asbestos material is detected, usage of appropriate PPEs by all
personnel shall be ensured and the matter shall be reported immediately to PDIL
/Owner.
3 .3.11 Slips, trips & falls
The contractor shall establish a regular cleaning and basic housekeeping program that
covers all aspects of the workplace to help minimize the risk of slips, trips & falls. The
contractor shall take positive measures like keeping the work area tidy, storing waste in
suitable containers & harmful items separately, keeping passages, stairways, entrances &
exits especially emergency ones clear, cleaning up spillages immediately and replacing
damaged carpet / floor tiles, mats & rugs at once to avoid slips, trips & falls.
3 .3.12 Radiation exposure
 All personnel exposed to physical agents such as ionizing & non-ionizing radiation,
including ultraviolet rays or similar other physical agents shall be provided with
adequate shielding or protection commensurate with the type of exposure involved.
 For Open Field Radiography works, requirements of Bhabha Atomic Research
Centre (BARC) /Atomic Energy Regulatory Board (AERB) shall be followed.
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 The Contractor shall implement an effective system of control (as described in the
AERB regulations) at site for handling radiography-sources & for avoiding its misuse
& theft.
 The contractor shall generate the “Permit for radiation work” before start of work.
 In case the radiography work has to be carried out at day time, suitable methodology
to be used so that other works, people are not affected.
3 .3.13 Explosives / blasting operations
 Blasting operations shall be carried out as per latest Explosive Rules (Indian /
International) with prior permission. The Contractor shall obtain license from Chief
Controller of Explosives (CCOE) for collection, transportation, storage of
explosives as well as for carrying out blasting operations.
 The Contractor shall prepare exclusive method statement (in cognizance with
statutory requirements) for diffusing unfired explosives, if any, at project site before
carrying out actual task. Nowhere blasting shall be carried out by the Contractor or its
agency without the involvement of competent supervisor and licensed blaster / shot
blaster.
3 .3.14 Demolition /Dismantling
 The contractor shall adhere to safe demolishing/ dismantling practices at all stages of
work to guard against unsafe working practices.
 The contractor shall disconnect service lines (power, gas supply, water, etc.)/ make
alternate arrangements prior to start of work and restore them, if required as directed
by PDIL /Owner at no extra cost.
 Before carrying out any demolition/ dismantling work, the contractor shall take prior
approval of PDIL /Owner. For revamp jobs in operating plants where
location of underground utilities is not known with certainty, the contractor

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shall depute an experienced engineer for supervision and shall make adequate
arrangements for Firefighting & First-Aid during the execution of these activities.
 The Contractor shall arrange approved Job Safety Analysis (JSA) /Method Statement
for the specific demolition /dismantling task and corresponding action plan
commensurate with hazards /risks associated therein. In no case any activity related to
demolition /dismantling shall be carried out by the Contractor without engaging own
supervision /field engineer.
3 .3.15 Road Safety
 The Contractor shall ensure adequately planned road transport safety management
system.
 The Contractor shall also ensure a separate pedestrian route for safety of the workers
and comply with all traffic rules & regulations, including maintaining speed limit of
20 kmph or indicated by owner for all types of vehicles /mobile machinery. The
maximum allowable speed shall be adhered to.
 The vehicles shall be fitted with reverse warning alarms & flashing lights /fog- lights
and usage of seat belts shall be ensured.
 In case of an alert or emergency, the Contractor must arrange clearance of all the
routes, roads, access. The Contractor shall deploy sufficient number of traffic
controllers at project site routes /roads /accesses, to alert reversing movement of
vehicles & machinery as well as pedestrians.
 Dumpers, Tippers, etc. shall not be allowed to carry workers within the plant area and
also to & from the labour colony to & from project sites.
 Hydras shall only be allowed for handling the materials at fabrication /storage yards
and in no case shall be allowed to transport the materials over project / plant roads.
 The Contractor shall not deploy any such mobile machinery / equipments,
which do not have competent operator and/or experienced banks-man /

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Signalman. Such machinery /equipments shall have effective limit-switches, reverse-

alarm, and front & rear-end lights etc. and shall be maintained in good working
order.
 The Contractor shall not carry-out maintenance of vehicles /mobile machinery
occupying space on project /plant roads and shall always arrange close supervision
for such works.
 For pipeline jobs, the contractor shall submit a comprehensive plan covering
transportation, loading /unloading of pipes, movement of side booms, movement of
vehicles on the ROW, etc.
 Contractor’s shall arrange /install visible road signs, diversion boards, caution boards,
etc on project roads for safe movement of men and machinery.
3 .3.16 Welfare measures
Contractor shall, at the minimum, ensure the following facilities at work sites:
 A crèche at site where 10 or more female workers are having children below the age
of 6 years.
 Adequately ventilated /illuminated rooms at labour camps & its hygienic up- keeping.
Reasonable canteen facilities at site and in labour camps at appropriate location
depending upon site conditions. Contractor shall make use of “industrial” variety of
LPG cylinder & satisfactory illumination at the canteens. Necessary arrangement for
efficient disposal of wastes from canteens & urinals /toilets shall also be made and
regular review shall be made to maintain the ambience satisfactorily hygienic & shall
also comply with all applicable statutory requirements. Adequately lighted &
ventilated Rest rooms at site (separate for male workers and female workers). Urinals,
Toilets, washing facilities, adequate lighting at site and labour camps, commensurate
with applicable Laws /Legislation.
 Providing water, milk, Lemon water, glucose etc. to employees working at heat
treatment & Dusty areas.
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 Provided purified drinking water to all employees of company.

 Providing of Personal Protective equipment as per requirement of employees
according to their respective working areas.
 Companies Transportation has been provided to all employees for safe
transportation of employees from their residence to workplace & back.
3 .3.17 Environment Protection
Contractor shall ensure proper storage and utilization methodology of materials that are
detrimental to the environment. Where required, Contractor shall ensure that only the
environment friendly materials are selected and emphasize on recycling of waste
materials, such as metals, plastics, glass, paper, oil & solvents. The waste that cannot be
minimized, reused or recovered shall be stored and disposed of safely. In no way, toxic
spills shall be allowed to percolate into the ground. The contractor shall not use the empty
areas for dumping the wastes. The contractor shall strive to conserve energy and water
wherever feasible.
The contractor shall ensure dust free environment at workplace by sprinkling water on the
ground at frequent intervals. The air quality parameters for dust, poisonous gases, toxic
releases, harmful radiations, etc. shall be checked by the contractor on daily basis and
whenever need arises.
The contractor shall not be allowed to discharge chemicals, oil, silt, sewage, sullage and
other waste materials directly into the controlled waters like surface drains, streams,
rivers, ponds. A discharge plan suggesting the methods of treating the waste before
discharging shall be submitted to PDIL /Owner for approval.
For pipeline jobs, top soil shall be stacked separately while making ROW through fields.
This fertile soil shall be placed back on top after backfilling. For offshore construction
barges, arrangements shall be made for safe disposal of human, food & other wastes and
applicable laws in this regard shall be followed.
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3 .3.18 Rules & Regulations
All persons deployed at site shall be knowledgeable of and comply with the
environmental laws, rules & regulations relating to the hazardous materials, substances
and wastes. Contractor shall not dump, release or otherwise discharge or disposes off any
such materials without the express authorization of PDIL/Owner. An indicative list of
Statutory Acts & Rules relating to HSE is given under Appendix-D.
3 .3.1 9 Weather Protection
Contractor shall take appropriate measures to protect workers from severe storms, rain,
solar radiations, poisonous gases, dust, etc. by ensuring proper usage of PPEs like Sun
glasses, Sun screen lotions, respirators, dust masks, etc. and rearranging /planning the
construction activities to suit the weather conditions. Effective arrangement (without
creating inconvenience to project facilities & permanent installations) for protecting
workmen from hailstorm, drizzle in the form of temporary shelter shall be made at site.
3 .3.20 Communication
All persons deployed at the work site shall have access to effective means of
communication so that any untoward incident can be reported immediately and assistance
sought by them. All health & safety information shall be communicated in a simple &
clear language easily understood by the local workforce. For information to all, typical
subjects that should be communicated are: -
Inside the company (Top to down)

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a. Quality Policy
b. HSE Policy contents
c. Environment Policy
d. HSE Objectives
e. Safety Cardinal Rules
f. HSE Target – reached or missed
g. Praises & Warnings to personnel for HSE Management
h. Safety Walk Through Reports and safety defects
i. HSE Audit results
j. Revised Statutory Health & Safety provisions, if any
k. H & S publicity
l. Suggestions
Inside the Company (Bottom to up)

a. Complaints
b. Compliances on safety defects / shortfalls
c. Suggestions
d. Proposals for changes & improvements
e. HSE Reports (including near-miss reports)
3 .3.21 Confined Space Entry
The contractor shall generate a work permit before entering a confined space. People,
who are permitted to enter into confined space, must be medically examined & certified
by registered doctor, confirming their ‘medical fitness for working in confined space’. All
necessary precautions mentioned therein shall be adhered to. An attendant shall be
positioned outside a confined space for extending help during an emergency. All
appropriate PPEs and air quality parameters shall be checked before entering a confined
space. It shall be ensured that the piping of the equipment which has to be opened is
pressure- free by checking that blinds are in place, vents are open and volume is
drained.
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Inside confined space works, only electrical facilities /installations of 24V shall be
permitted. Contactor shall ensure usage of safe & suitable arrangement of oxygen supply
for individual workmen (during the course of work in confined space), if oxygen
concentration is found to be less than 19.5% (v/v) there.
3.3.22 Heavy Lifts
 The contractor shall submit detailed rigging studies plan for PDIL/ Owner approval
prior to lifting equipment which cannot be erected with a crane of approx. 100 Ton
capacities due to constraints of its dimensions, location of foundation height,
approach & weight. Contractor shall generate the format for “Permit for heavy lift
/critical erection” Prior to actual lifting activities; contractor shall check the validity
of the crane inspection certificate issued by statutory / competent authority. This
requirement shall also apply to all rigging equipments utilized for the job.
 The contractor shall, at all times, be responsible for all rigging activities.
 The Contractor shall ensure medical fitness of all workmen who are engaged
/involved in erection of equipments, vessels etc. and such fitness checks shall be
carried-out every six months interval with the help of a registered medical practitioner
& record shall be maintained Adequate safety measures such as positive barricading,
usage of appropriate PPEs, permit to work, etc. shall be taken during all heavy or
critical lifts.
 For lifting any material (irrespective of shape, size or volume), at any height, it is
always advisable to prepare a Plan of Erection (POE) taking into consideration
hazards & risks associated therein – this can enable people to put their own
experiences of various natures & side-by-side establish a practical method for risk-
free erection /lifts. The contractor shall prepare POE & shall document the same,
when risks are identified as “medium” or “high” and the same shall be approved by its
competent /qualified engineer.
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3 .3.23 Key Performance Indicators
The contractor shall measure an activity in both leading & trailing indicators for
statistical and performance measurement. The activities pertaining to key performance
indicators are covered in Monthly HSE Report. The contractor shall try to achieve a
statistically fair record and strive for its continual improvement.
Leading Indicators viz:-
- Number of Safety Inductions carried-out at site (for workmen & staff

members)
- Number of HSE inspections carried out.
- Number of “Safety Walk Through” carried-out by site-head.
- Number of HSE shortfalls / lapses identified per contractor & closed-out in
time.
- Number of Safety Meetings conducted (in-house / with contractors)
- Number of HSE Audits made (internal & external) vis-à-vis non
conformances raised
- Number of HSE Trainings conducted at site for supervisors & workmen
- Number of HSE Awareness / Motivational program conducted by
contractors
- Study of Near miss case reported
- Encouragements /Awards /Recognitions to workmen, job supervisors & field
engineers.
- Suggestions for improvement
Trailing Indicators viz:-
- Calculation of HSE statistics viz frequency rate, severity rate, LTA free man-
hours, etc
- Analysis of incidents / accidents (nature, severity, types etc.)
- Study of Incident / Accident with respect to :-
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- Variety
- Period of the year / project span
- Timings of the incident / accident
- Age profile of victims
- Body parts involved
- Penalty levied for causing incident / accident
3 .3.24 Unsuitable Land Conditions
Contractor shall take appropriate measures and necessary work permits

/clearances if work is to be done in or around marshy areas, river crossings, mountains,
monuments, etc. The Contractor shall make right assessment and take all necessary action
for developing work areas to make them safe & suitable for crane operations or other
vehicular movement before carrying out any project related activity /operation.
Contractor shall take all necessary actions to make the surroundings of its site
establishments (site office, stores, lay-down area etc.) work-worthy safe and secure.
3 .3.25 Under Water Inspection
Contractor shall ensure that boats and other means used for transportation, surveying &
investigation works shall be certified seaworthy by a recognized classification society. It
shall be equipped with all life saving devices like life jackets, adequate fire protection
arrangements and shall posses’ communication facilities like cellular phones, wireless,
walkie-talkie. All divers used for seabed surveys, underwater inspections shall have
required authorized license, suitable life saving kit. Number of hours of work by divers
shall be limited as per regulations. PDIL /Owner shall have the right to inspect the boat
and scrutinize documents in this regard.
3 .3.26 Excavation
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The Contractor shall obtain permission from competent authorities prior to excavation
wherever required. The Contractor shall locate the position of buried utilities (water line,
cable route, etc.) by referring to project /plant drawing / in consultation with PDIL
/Owner. The Contractor shall start digging manually to locate the exact position of buried
utilities & thereafter use mechanical means. The Contractor shall keep soil heaps at least
1.5 M away from edge or a distance equal to depth of pit (whichever is more).
The Contractor shall maintain sufficient “angle of repose” during excavation – shall also
provide slope or suitable bench as decided by PDIL /Owner.
The Contractor shall arrange “battering” or “benching” wherever required for preventing
collapse of edge of excavations.
The Contractor shall identify & arrange de-watering pump or well-point system to
prevent earth collapse due to heavy rain /influx of underground water.
The Contractor shall arrange protective fencing / barricading with warning signal around
excavated pits, trenches, etc. along with minimum 2 (two) entries, exits / escape ladders.
The Contractor must avoid “underpinning” /under-cutting to prevent collapse of chunk of
earth during excavation
The Contractor shall use “stoppers” to prevent over-run of vehicle wheels at the edge of
excavated pits /trenches.
The Contractor shall arrange strengthening of “shoring” & “strutting” proactively to
avoid collapse of earth /edges due to vehicular movement in close proximity of excavated
areas /pits /trenches, etc.
3. 4 Tool Box Talks (TBT)
Contractor shall conduct daily TBT with workers prior to start of work and shall maintain
proper record of the meeting. A suggested format is given below. The TBT is to be
conducted by the immediate supervisor of the workers The
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Contractor shall conduct TBT before start of every morning or evening shift or night shift
activities, for alerting the workers on specific hazards and their appropriate dos & don’ts.
The Contractor shall provide sufficient rests to the site workmen and their foremen to
avert fatigue & thereby endangering their lives during the course of site works.
The topics during TBT shall include.
- Hazards related to work assigned on that day and precautions to be taken.

- Any forthcoming HSE hazards /events /instruction /orders, etc.
The above record can be kept in local language, which workers can read. These records
shall be made available to PDIL /Owner whenever demanded.
TOOL BOX TALK RECORD
Date & Time
Work Location
Subject (Nature of work)
Presenter
Hazards involved
Precautions to be taken
Worker's Name Signature Section
Remarks, in any
3. 5 Training & Induction Program
 Initial induction of workers into Construction oriented activities and appraising them
about the methodology of works and how to carry-out safely and the same should not
be inter mixed with Tool Box Talks or HSE Training. In this regard careful action
should be made & maintained for imparting HSE induction to every individual,
irrespective of his task /designation /level of
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employment, whereas, HSE Training should be imparted to specific person / group of

people who are to carry-out that specific task more than once – for example, Riggers
must be trained for working at heights, welders must be trained for work in confined
space, fitters/carpenters, mesons must be trained for work at heights, etc.
 Contractor shall conduct Safety induction program on HSE for all his workers and
maintain records. The Gate Pass shall be issued only to those workers who
successfully qualify the Safety induction program.
 The Contractor shall brief the visitors about the HSE precautions which are required
to be taken before their proceeding to site and make necessary arrangements to issue
appropriate PPEs like Aprons, hard hats, ear-plugs, goggles & safety shoes etc., to his
visitors. The Contractor shall always maintain relevant acknowledgement from visitor
on providing him brief information on HSE actions.
 Contractor shall ensure that all his personnel possess appropriate training to carry out
the assigned job safely. The training should be imparted in a language understood by
them and should specifically be trained about
- Potential hazards to which they may be exposed at their workplace
- Measures available for prevention and elimination of these hazards The
topics during training shall cover, at the minimum: -
- Why safety should be considered during work - explanation

- Education about hazards and precautions required
- Employees’ duties & responsibilities
- Emergency and evacuation plan
- HSE requirements during project activities
- Fire fighting and First-Aid
- Use of PPEs
- Occupational health issues – dos & don’ts
- Local laws on intoxicating drinks, drugs, smoking in force
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- Common environmental subjects – lighting, ventilation, vibration, smoke

/fumes etc.
 Records of the training shall be kept and submitted to PDIL /Owner.
 The Contractor shall make regular program for conducting Safety Training on various
topics related to various activities & their safe-guarding utilizing experienced persons
/outside agency /faculty. A program for Safety Training (indicative list as per
Appendix –E) shall be furnished by the Contractor in its HSE Plan.
 For offshore and jetty jobs, contractor shall ensure that all personnel deployed have
undergone a structured sea survival training including use of lifeboats, basket landing,
use of radio communication etc. from an agency acceptable to Owner /PDIL.
ADDITIONAL SAFETY REQUIREMENTS FOR WORKING INSIDE A

RUNNING PLANT
As a minimum, the contractor shall ensure adherence to following safety requirements

while working in or in the close vicinity of an operating plant:
 Contractor shall obtain permits for hot work, Cold work, Excavation, Confined Space,
Lifting activities, Work at Height, Electrical work and Radiography work from
Owner.
 The contractor shall monitor record and compile list of his workers entering the
operational plant /unit each day and ensure & record their return after completing the
job.
 Contractor’s workers and staff members shall use designated entrances and proceed
by designated routes to work areas only assigned to them. The workers shall not be
allowed to enter units' area, tanks area, pump rooms, etc. without work authorization
permit.
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 Work activities shall be planned in such a way so as to minimize the disruption of

other activities being carried out in an operational plant/unit and activities of other
contractors.
 The contractor shall submit a list of all chemicals /toxic substances that are intended
to be used at site and shall take prior approval of the Owner.
 Specific training on working in a hydrocarbon plant shall be imparted to the work
force and mock drills shall be carried out for Rescue operations /First- Aid measures.
 Proper barricading /cordoning of the operational units /plants shall be done before
starting the construction activities. No unauthorized person shall be allowed to
trespass. The height and overall design of the barricading structure shall be finalized
in consultation with the Owner and shall be got approved from the Owner.
 Care shall be taken to prevent hitting underground facilities such as electrical cables,
hydrocarbon piping during execution of work.
 Barricading with water curtain shall be arranged in specific /critical areas where
hydrocarbon vapors are likely to be present such as near Horton spheres or tanks.
Positioning of fire tenders (from owner) shall also be ensured during execution of
critical activities.
 Emergency evacuation plan shall be worked out and all workmen shall be apprised
about evacuation routes. Mock drill operations may also be conducted.
 Flammable gas test shall be conducted prior to any hot work using appropriate
measuring instruments. Sewers, drains, vents or any other gas escaping points shall be
covered with flame retardant tarpaulin.
 Respiratory devices shall be kept handy while working in confined zones where there
is a danger of inhalation of poisonous gases. Constant monitoring of presence of Gas
/Hydrocarbon shall be done.
 Clearance shall be obtained from all parties before starting hot tapping, patchwork on
live lines and work on corroded tank roof. Positive isolation of
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line/equipment by blinding for welding/cutting/grinding shall be done. Closing of

valve will not be considered sufficient for isolation.
 Welding spatters shall be contained properly and in no case shall be allowed to fall on
the ground containing oil. Similar care shall be taken during cutting operations.
 The vehicles, cranes, engines, etc. shall be fitted with spark arresters on the exhaust
pipe and got it approved from Safety Department of the Owner.
 Plant air should not be used to clean any part of the body or clothing or use to blow
off dirt on the floor.
 Gas detectors should be installed in gas leakage prone areas as per requirement of
Owner's plant operation personnel.
 Experienced full time safety personnel shall be exclusively deployed to monitor
safety aspects in running plants.
Self Assessment and Enhancement
The contractor shall develop a method of check & balance through self assessment &
enhancement techniques and shall explore the opportunities for continual improvement in
the HSE systems.
3. 8 HSE Promotions
The contractor shall encourage his workforce to promote HSE efforts at workplace by
way of organizing workshops /seminars /training programs, celebrating HSE awareness
weeks & National Safety Day, conducting quizzes & essay competitions, distributing
pamphlets, posters & material on HSE, providing incentives for maintaining good HSE
practices and granting incentives /bonus for completing the job without any lost time
accident.
3. 9 Lock Out and Tag out (LOTO) for isolation of energy source
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 Contractor shall follow the LOTO /Isolation procedure of owner for all energy
source isolations and installed/under purview by /of owner i.e. “Brown field” For
the other entire energy source (not under purview of client/owner) i.e. “Green field”
Contractor shall develop a system to ensure the isolation of equipments, pipelines,
Vessel, electrical panels from the energy source covering following as minimum:-
- Identification of all energy source viz electrical, mechanical, hydraulic,
pneumatic, chemical, thermal, gravitational, radiation and other forms of stored or
kinetic energy.
- Establishing the energy isolation devices viz: manually operated electrical circuit
breakers, disconnection switches, blind flanges, etc
- Lock Out and Tag out log book
- Installation of Lock Out devices for preventing the inadvertent release of stored
energy and Tag Out devices (“Danger”, “Do Not operate” or Do not Remove”
tags) to indicate that testing, maintenance or servicing is underway and the device
cannot be operated until the tag out device is removed.
- Permit for isolation and de-isolation of energy source.
- Availability of competent persons like experienced operators at substations, pump
house, units, etc, supervisors, etc.
Contractor shall ensure that all the sources are locked out and tagged properly before
giving clearance to start the job.
After the completion of job, contractor shall ensure all tools and tackles are removed
and nobody is present in the working area and signing on LOTO log book.
Only on confirmation of above the contractor will remove their lock and tag from the
isolation points and give instructions for energizing the same. Only the person
carrying out the task shall himself carry the key for the lock in
/Lock out.
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4. 0 DETAILS OF HSE MANAGEMENT SYSTEM BY
CONTRACTOR On Award of Contract
The Contractor shall submit a comprehensive Health, Safety and Environment Plan
or program for approval by PDIL /Owner prior to start of work. The Contractor shall
participate in the pre-start meeting with PDIL
/Owner to finalize HSE Plans which shall including the following:
- HSE policy & Objectives
- Job procedure to be followed by the Contractor for construction activities
including handling of equipments, scaffolding, electric installations, etc.
describing the risks involved, actions to be taken and methodology for
monitoring each activity.
- PDIL /Owner review/audit requirement.
- Organization structure along with responsibility and authority, on HSE
activities.
- Administrative & disciplinary steps involving implementation of HSE
requirements.
- Emergency evacuation plan / procedures for site and labour camps
- Job Safety Analysis for high risk jobs.
- Procedures for reporting & investigation of accidents and near misses.
- HSE Inspection.
- HSE Training programs at project site.
- HSE Awareness programs, at project site.
- Reference to Rules, Regulations and statutory requirements.
- HSE documentation viz reporting, analysis & record keeping.
During Job Execution

Contractor shall implement approved HSE management program including but not
limited to as brought out under para 3.0. Contractor shall also ensure:
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 To arrange workmen compensation insurance, registration under ESI Act, third party
liability insurance, registration under BOCW Act, etc, as applicable.
 To arrange all HSE permits before start of activities (as applicable), like permits for
hot work, working at height, confined space, Radiation Work Permit, Demolishing /
Dismantling Work Permit, Permit for erection/modification & dismantling of
scaffolding, Permit for heavy lift/critical erection, Permit for energy Isolation & De-
isolation”, storage of chemical / explosive materials & its use and implement all
precautions mentioned therein. In this regard, requirements of Oil industry Safety
Directorate Standard No.:- 105 "Work Permit Systems” shall be complied with while
working in existing Oil, Gas or Chemical processing plants. List of the persons
involved shall be maintained as annexure to the work permit issued for a particular
activity.
 To submit, timely, the completed checklist on HSE activities, Monthly HSE report
(use of web based package (www.pdil.co.in/conthse) is compulsory wherever the
facility is available else a hard copy is to be submitted), accident/ incident reports,
investigation reports etc. as per PDIL/Owner requirements. Compliance of
instructions on HSE shall be done by contractor and informed urgently to PDIL
/Owner.
 Provide posters, banners for safe working to promote safety consciousness.
 That his top most executive at site attends all the Safety Committee /HSE meetings
arranged by PDIL /Owner and carries out safety walk through regularly. Only in case
of his absence from site that a second senior most person shall be nominated by him,
in advance, and communicated to PDIL/Owner for performing the tasks.
 Appraise PDIL /Owner on HSE activities at site regularly.
 Display at site office and at prominent locations HSE Policy, caution boards, list of
hospitals, emergency services available, safety signs like Men at work, Speed Limits,
Hazardous Area, various do’s & don’ts, etc.
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 Identify access, analyze & mitigate the construction hazards & incorporate relevant
control measures before actually executing site works. (HIRAC = Hazard
Identification, Risk Analysis and Control).
 Arrange testing, examination, inspection of own as well as borrowed construction
equipments / machinery (stationary & mobile) before being used at site and also at
periodical interval, through own resources and also by 3 rd party competent agencies
(as deemed fit in statutes). Records of such test, examination etc. shall be maintained
& shall be submitted to PDIL /Owner as & when asked for.
 Carryout audits /inspection (internal & external) at his works as well as sub contractor
works as per approved HSE plan /procedure /program & submit the compliance
reports of identified shortfalls for PDIL /Owner review.
 Arranging HSE training for site workmen (of his own & sub contractors) through
internal or external faculty at periodical intervals.
 Assistance & cooperate during HSE audits by PDIL /Owner or any other 3 rd party
and submit compliance report. Generate & submit of HSE records
/report as per this specification.
 Carry-out all dismantling activities safely, with prior approval of PDIL/Owner
representative.
 The Contractor shall ensure that “Hot works” and painting works do not continue at
the same place /location at project site for which chance or probability of “fire”
incident exists.
During Short Listing of the Sub-Contractors
The contractor shall review the HSE management system of the sub-contractors in line
with the requirements given in this specification. The contractor shall be held responsible
for the shortcomings observed in the HSE management system of the sub-contractor(s)
during execution of the job.
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APPENDIX-A
A. IS CODES ON HSE
- SP: 53 Safety code for the use, Care and protection of hand operated tools.
- IS: 838 Code of practice for safety & health requirements in electric and gas
welding and cutting operations
- IS: 1179 Eye & Face precautions during welding, equipment etc.
- IS: 1860 Safety requirements for use, care and protection of abrasive
grinding wheels.
- IS: 1989 (Pt -II)Leather safety boots and shoes
- IS: 2925 Industrial Safety Helmets
- IS: 3016 Code of practice for fire safety precautions in welding & cutting
operation.
- IS: 3043 Code of practice for earthing
- IS: 3764 Code of safety for excavation work
- IS: 3786 Methods for computation of frequency and severity rates for
industrial injuries and classification of industrial accidents
- IS: 3696 Safety Code of scaffolds and ladders
- IS: 4083 Recommendations on stacking and storage of construction
materials and components at site
- IS: 4770 Rubber gloves for electrical purposes
- IS: 5121 Safety code for piling and other deep foundations
- IS: 5216 (Pt-I) Recommendations on Safety procedures and practices in
electrical works
- IS: 5557 Industrial and Safety rubber lined boots
- IS: 5983 Eye protectors
- IS: 6519 Selection, care and repair of Safety footwear
- IS: 6994 (Pt-I) Industrial Safety Gloves (Leather & Cotton Gloves)
- IS: 7293 Safety Code for working with construction Machinery
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- IS: 8519 Guide for selection of industrial safety equipment for body
protection
- IS: 9167 Ear protectors
- IS: 11006 Flash back arrestor (Flame arrestor)
- IS: 11016 General and safety requirements for machine tools and their
operation
- IS: 11057 Specification for Industrial safety nets
- IS: 11226 Leather safety footwear having direct molded rubber sole
- IS: 11972 Code of practice for safety precaution to be taken when
entering a sewerage system
- IS: 13367 Code of practice-safe use of cranes
- IS: 13416 Recommendations for preventive measures against hazards at
working place
B. INTERNATIONAL STANDARDS ON HSE
- Safety Glasses : ANSI Z 87.1, ANSI ZZ 87.1, AS 1337, BS 2092, BS

1542, BS 679, DIN 4646/ 58311
- Safety Shoes : ANSI Z 41.1, AS 2210, EN 345
- Hand Gloves : BS 1651
- Ear Muffs : BS 6344, ANSI S 31.9
- Hard Hat : ANSI Z 89.1/89.2, AS 1808 , BS 5240, DIN 4840
- Goggles : ANSI Z 87.1
- Face Shield : ANSI Z 89.1
- Breathing Apparatus : BS 4667, NIOSH Welding & Cutting : ANSI Z 49.1
- Safe handling of compressed: P-1 (Compressed Gas Association Gases in
cylinders 1235 Jefferson Davis Highway, Arlington VA 22202 - USA)
- Full body harness : EN-361, ANSI Z 359.1
- Lanyard : EN-354
- Karabiner : EN-362 and EN-12275
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APPENDIX-B
DETAILS OF FIRST AID BOX

Sr. No. DESCRIPTION QUANTITY
1 Small size Roller Bandages, 1 Inch Wide (Finger Dressing small) 6 Pcs.
2 Medium size Roller Bandages, 2 Inches Wide (Hand & Foot Dressing) 6 Pcs.
3 Large size Roller Bandages, 4 Inches Wide (Body Dressing Large) 6 Pcs.
4 Large size Burn Dressing (Burn Dressing Large) 4 Pkts.
5 Cotton Wool (20 gms packing) 4 Pkts.
6 Antiseptic Solution Dettol (100 ml.) or Savlon 1 Bottle
7 Mercurochrome Solution (100 ml.) 2% in water 1 Bottle
8 Ammonia Solution (20 ml.) 1 Bottle
9 Pair of Scissors 1 Piece
10 Adhesive Plaster (1.25 cm X 5 m) 1 Spool
11 Eye pads in Separate Sealed Pkt. 4 pcs.
12 Tourniquet 1 No.
13 Safety Pins 1 Dozen
14 Tinc. Iodine/ Betadin (100 ml.) 1 Bottle
15 Polythene Wash cup for washing eyes 1 No.
16 Potassium Permanganate (20 gms.) 1 Pkt.
17 Tinc. Benzoine (100 ml.) 1 Bottle
18 Triangular Bandages 2 Nos.
19 Band Aid Dressing 5 Pcs.
20 Iodex/Moov (25 gms.) 1 Bottle
21 Tongue Depressor 1 No.
22 Boric Acid Powder (20 gms.) 2 Pkt.
23 Sodium Bicarbonate (20 gms.) 1 Pkt.
24 Dressing Powder (Nebasulf) (10 gms.) 1 Bottle
25 Medicinal Glass 1 No.
26 Duster 1 No.
27 Booklet (English & Local Language) 1 No. each
28 Soap 1 No.
29 Toothache Solution 1 No.
30 Vicks (22 gms.) 1 Bottle
31 Forceps 1 No.
32 Note Book 1 No.
33 Splints 4 Nos.
34 Life Saving/Emergency/Over-the counter Drugs As decided at site
Note: The medicines prescribed above are only indicative. Equivalent medicines can also be
used. A prescription, in this regard, shall be required from a qualified Physician.
HSE-001 0
APPENDIX-C
TYPE OF FIRES VIS-À-VIS FIRE EXTINGUISHERS
Fire Multi
Extinguisher Water Foam CO2 Dry Powder purpose
(ABC)
Fire
Originated from paper, D D Can control Can control D

clothes, wood minor surface minor surface
fires fires
Inflammable liquids like

alcohol, diesel, petrol, edible X D D D D
oils, bitumen
Originated from gases like

LPG,CNG, H2 X X D D D
Electrical fires X X D D D
LEGEND:
D: CAN BE USED
X: NOT TO BE USED
Note: Fire extinguishing equipment must be checked at least once a year and after every use by
an authorized person. The equipment must have an inspection label on which the next
inspection date is given. Type of extinguisher shall clearly be marked on it.
HSE-001 0
APPENDIX-D
LIST OF STATUTORY ACTS & RULES RELATING TO HSE
- The Indian Explosives Act and Rules

- The Motor Vehicle Act and Central Motor Vehicle Rules
- The Factories Act and concerned Factory Rules
- The Petroleum Act and Petroleum Rules
- The Workmen Compensation Act
- The Gas Cylinder Rules and the Static & Mobile Pressure Vessels Rules
- The Indian Electricity Act and Rules
- The Indian Boiler Act and Regulations
- The Water (Prevention & Control & Pollution) Act
- The Water (Prevention & Control of Pollution) Cess Act
- The Air (Prevention & Control of Pollution) Act
- The Atomic Energy Act
- The Radiation Protection Rules
- The Indian Fisheries Act
- The Indian Forest Act
- The Wild Life (Protection) Act
- The Environment (Protection) Act and Rules
- The Hazardous Wastes (Management & Handling) Rules
- The Manufacturing, Storage & import of Hazardous Chemicals Rules
- The Public Liability Act
- The Building and Other Construction Workers (Regulation of Employment And
Condition of service) Act
- Other statutory acts Like EPF, ESIS, and Minimum Wage Act.
HSE-001 0
APPENDIX-E
TRAINING SUBJECTS / TOPICS (For contractors’ personnel)
1. The Law & Safety – Statutory Requirement / Applicable statutes / Duties of

employer / employee
2. Policy & Administration – Why HSE? / Duties & Responsibilities of Safety
Personnel at project site / Effect of incentive on accident prevention
3. HSE & Supervision – Duties of Supervisor / HSE integrated supervision / who
should be held responsible for site accidents?
4. Safety Budget /Cost of Accidents – Direct costs /Indirect costs
5. Hazard Identification /Type of hazards /HIRAC
6. Behavioral Safety & Motivation
7. Housekeeping – Storage /Stacking /Handling of materials /Hydra handling
8. Occupational Health in Construction sector
9. Personal Protective Equipments – Respiratory & Non- respiratory
10. Electricity & Safety – ELCB /Fuse /Powered tools /Project illumination
11. Handling of Compressed Gas – Transportation /Storage /FBAs /Fire
prevention
12. Machine Safety – Machine guarding /Maintenance
13. Transportation – Hazards & risks in transp. of materials /ODC consignments
14. Cranes & Other Lifting machinery – Legal requirements vis-à-vis essential safety
requirements.
15. Communication – HSE Induction /TBTs /Safety Committee /Safety meeting /
Safety propaganda /Publicity.
16. Excavation – Risks & Dangers /Safety measures
17. Working at Heights – Use of ladder /Work on roofs /Scaffolds /Double
harness lanyards /Lifeline /Fall arrester /Safety Nets /Floor openings
18. Hazards in Welding & important safety precautions
19. Gas Cutting – Hazards & safety measures
20. Fire prevention & fire protection
HSE-001 0
APPENDIX-F
LIST OF PROCEDURES (MINIMUM) TO BE FORMING PART OF HSE PLAN:-
A. HSE Management Procedures:
 HSE Risk Management (including JSA/HIRA)

 HSE Legal Compliance and Other Requirements
 HSE Objectives & Performance
 HSE Training and Competence (including Induction)
 HSE Motivation & Award Scheme
 HSE Audits
 HSE Meetings
 HSE Sub Contractor Management
 HSE Emergency Management
 HSE Incidents Reporting and Management
 HSE Reports
 HSE Management System Review
 HSE Change Management
 HSE procedure for Behavior based Safety
 First Aid & Management
 Roles, Responsibility, accountabilities and Authorities
B. Job procedures /Safe Operating procedures
 Setting Up Site & Signage’s

 Handling of Electrical Appliances
 Working at Height
 Confined Space Entry
 Permit to Work (including hot works)
 Housekeeping
 Lifting Operations
 Transportation of materials including Manual Handling
 Compressed Air Tools and Units
 Earthmoving Operations & excavation
 Scaffolding
 Fire Prevention/Protection
 Hazardous Substance handling & Storage
 Radiation Hazard
 Personal Protective Equipment
********
Date:
PROJECTS & DEVELOPMENT Project No.: PC-00187
INDIA LIMITED SHEET 1 OF 20
SAFETY TALK TOPICS
SR. NO. SAFETY TALK TOPICS SR. NO. SAFETY TALK TOPICS
1 Accident/Incident Prevention 21 Importance of Checklist
2 Ammonia (NH3) Safety 22 Incident reporting
3 Are we Safe or just Lucky? 23 Industrial Radiography Safety
4 Attitude and Behavior 24 Job Safety Analysis (JSA)
5 Back Safety 25 Knowledge of LSC rules
6 Barricade and Signage 26 Ladder Safety
7 Blinding Safety 27 Look out for Your Co-Workers
8 Breathing Apparatus 28 Machine guarding safety
9 Carbon Monoxide Poisoning 29 Manual Material Handling
10 Chemical / Toxic Handling 30 Material Safety Data Sheet - MSDS
11 Chain and Sling Safety Tips 31 Modification of Tools or Equipments

Near Misses are Lucky Escapes -
12 Chemical Safety 32
Report them
13 Compressed Gas Cylinders 33 Over Confidence can kill you
14 Confined Space Entry 34 Personal behavior
15 Crane Operation 35 Personal Hygiene
16 De-blinding Safety 36 Personal Protective Equipment (PPE)

Donning and doffing of safety
17 37 Pinch Points
harnesses
18 Dust mask & Cartridge filter mask 38 Preventing Strains and Sprains
19 Electrical Safety 39 Eye and Face Protection
20 Emergency Response & Evacuation 40 Fall Protection & Prevention
41 Falling Objects 66 Prohibited Items Inside Plant
Page 1 of
Date:
42 Fatigue 67 Respiratory Protection
44 Fire Prevention and Extinguishing 68 Responsibilities of Fire Watch
45 Fire Safety 69 Responsibilities of Permit Receiver
45 Foot and Leg Protection 70 Responsibilities of Standby Man
46 Forklift Safety 71 Risk Assessment
47 General Safety 72 Safe Handling of Flammable Liquids
48 Grounding of Equipments 73 Safe Storage of Flammable Liquids
49 Hand and Finger Protection 74 Safety is everyone's responsibility
50 Hand tools & Power Tools 75 Scaffold Safety
51 Hazard Recognition 76 Short cuts
52 Hearing Safety 77 Site Safety Rules & Regulation
53 Heat Stress 78 Sleeping at site
54 High Pressure Water Jetting 79 Slip, trip and fall hazards
55 Home Made Tools 80 Smoking safety
56 Horseplay 81 Static Electricity
57 Hot Bolting Safety 82 Take safety ownership of your job
58 Hot work safety 83 The Cost of the Accident
59 Housekeeping is safe keeping 84 Traffic Safety
60 Hurry Up can Hurt!!!! 85 Unsafe acts & conditions
61 Hydro test Safety 86 Vacuum Truck Safety
62 If you are not sure! ASK! 87 What you do not know, can hurt you!
63 Responsibilities of Rigger 88 Why safety audit
64 Excavation Safety 89 Work Permit System
65 Construction site survey for visitors 90 Working at Height
Page 2 of
Date:
CLASSIFICATION OF LIFTING APPLIANCES

LIFTING APPLIANCES
Lifting tools Lifting tackles
LIFTING TOOLS AND TACKLES

cranes D-shackles
Hoists Wire ropes
 Lifting tool: Lifting tool is device which is used to lift load such as
Chain pulley blocks Chains
 Jib
Crab crane Clamps etc
 Winch
 Teagle
 Gin wheel
 Jacks
 Cranes etc
 Chain block
 Mono rail
 Lifting tackle: Lifting tackle is device which is used to facilitates for lifting load such as
 Chain sling
 Swivel
 Ropes
 D- shackles
 Hooks
 Clamps
 Eye bolts etc
Date:
INSPECTION OF LIFTING TOOLS & TACKLES

TPI – Third party Inspection
 Third Party Inspection of any product is the Inspection & Testing carried out by Any
Person or Agency who is not Manufacturer or User of that particular product or service.
 Third Agency is always technically strong enough and competent to execute the
checking and testing of all Technical Aspects of the equipment or service.
 In case of Lifting Equipment & Lifting Tools & Tackles, Govt. Approved / Authorized
Competent Person carry out Inspection and testing of the products and certify to use
them.
 State wise competent persons are authorized by State Govt. to carry out Inspection &
testing of various products.
Why TPI? –
 Carrying out TPI of Lifting Equipment and Lifting Tools & Tackles is Statutory Norm /
Requirement as prescribed in Factories Act.
 Safety Level of the Equipment is enhanced, as competent person shall note down the
loop holes during the inspection & testing and recommend or suggest corrective
measures.
 Equipment Manufacturer shall issue Mfr. Test Certificate by Self Attested way and
define products’ attributes.
 However, as per the Law: Obtain ‘Form-10’ (In Gujarat it is ‘Form-10’) Certificate issued
by TPI (Competent Person) from the date of installation or from the date when
product is First Taken for Use.
Procedure:
Procedure of Inspection & Testing is carried out strictly as per checklist developed individually.
Competent Persons also offer their service as per the scope of work:
1). Thorough Inspection & Testing:

 Complete Technical Parameters are checked thoroughly. i.e. Brakes, Limit Switches,
Wire Rope, Hook Blocks and other safety parameters.
 Operational Parameters are checked and measured.
 Load Testing at Proof Load and Over-Load.
2). Load Testing:

Date:
 First all operating parameters are checked and then, Load Testing at Proof Load and
Over-Load is carried out.
‘Form-10’ Certificate as per govt. Format is issued on successful Inspection & Testing of the
products.
Note: Form-10 Certificate is issued by Competent Person as per State Govt. Format in Gujarat
State. However, state wise this Form No. is different.
Interval for Inspection & testing:

As directed in the Section-29 of Factories Act, these Tests are carried out annually and Register
should be maintained for every product to keep record regarding Health of the Products.
SECTION – 29 OF FACTORIES ACT - LIFTING TOOLS AND TACKLES

1. In any factory the following provisions shall be complied with in respect of every lifting
machine (other than a hoist and lift) and every chain, rope and lifting tackle for the purpose
of raising or lowering persons, goods or materials :-
 All parts, including the working gear, whether fixed or movable, of every lifting
machine and every chain, rope or lifting tackle shall be –
 Of good construction, sound material and adequate strength and free
from defects;
 Properly maintained; and
 Thoroughly examined by a competent person at least once in every period of
twelve months, or at such intervals as the Chief Inspector may specify in
writing, and a register shall be kept containing the prescribed particulars of
every such examination;
 No lifting machine and no chain, rope or lifting tackle shall, except for the purpose of
test, be loaded beyond the safe working load which shall be plainly marked thereon
together with an identification mark and duly entered in the prescribed register; and
where this is not practicable, a table showing the safe working loads of every kind
and size of lifting machine or chain, rope or lifting tackle in use shall be displayed in
prominent position on the premises;
 While any person is employed or working on or near the wheel track of a traveling
crane in any place where he would be liable to be struck by the crane, effective
measures shall be taken to ensure that the crane does not approach within 63[six
meters] of that place.
Date:
2. The State Government may make rules in respect of any lifting machine or any chain,
rope or lifting tackle used in factories -
 Prescribing further requirements to be complied with in addition to those set out

in this section;
 Providing for exemption from compliance with all or any of the requirements of
this section, where in its opinion, such compliance is unnecessary or impracticable.
3. For the purposes of this section a lifting machine or a chain, rope or lifting tackle shall be
deemed to have been thoroughly examined if a visual examination supplemented, if
necessary, by other means and by the dismantling of parts of the gear, has been carried
out as carefully as the conditions permit in order to arrive at a reliable conclusion as to the
safety of the parts examined.
Explanation:
In this section, -
 "lifting machine" means a crane, crab, winch, teagle, pulley block, gin wheel,
transporter or runway;
 64(b) "lifting tackle" means any chain sling, rope sling, hook, shackle, swivel,
coupling, socket, clamp, tray or similar appliance, whether fixed or movable, used
in connection with the raising or lowering of persons, or loads by use of lifting
machines.
********

29 HIRA Annexure H

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29 HIRA Annexure H

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ANNEXURE – R

HAZARD IDENTIFICATION & RISK ASSESMENT (HIRA)

have updated and valid

using and competent for rigging and  Full body

 Ensure proper access for tie up of

 Provide adequate warning signs

properly before going for the with 100%

of tools  Full body harness to be used.  Full body

roof structure is allowed for trailer driving.

9.Provide proper tag line to

 5.While loading the teeth of the

sufficient illumination is not

 Signal to the crane operator

 Unsafe loading  Forklifts should never be  Reflective

required materials /  Gas cutting set shall be up right  gauntlets,

line & vice versa.

inspect the machine every day

maintained between hydra/

crew to avoid communication protective

cables every day for identifying

alteration should be done by

cover before activating the foot

from height be engaged in working at height.  Fall

 Hydraulic jacks and its

 All area around the tank should

accessories selected should be

 Spilled oil must be cleaned off

 Exposure to  Basic PPEs

radiography is break times and

 Separate PIT room shall be

not be left suspended with the

 Platform should be maintained

made available at site and

uncontrolled and should be prevented from  Full body

 Automatic grit blasting machine

 Paint should be stored

 Secure the hoses with whiplash

such a way that it does not pose

 The flanges / joints shall be

during testing period.

pressure testing should be

 Sudden release be provided to release the

because of the and competent to work in gloves,

hoses.  Ensure no one is standing close

depending on the type of

platform level of the scaffolding.

unloading use tailor made platforms,  Dust

ground, if any.  Dust

 Ensure SWL, Lifting radius etc. of

assembly  May hit for signaling. Goggles,

surface Strike properly leveled.

 Ensure the machine is

 Ensure the machine is

before start of the activity. gloves,

 Ensure Reinforced materials

 Collapse of  Ensure cables free from damage  Respirator

 Ensure Edge protection/proper

 Proper PPE’s like gumboot and Goggles,

 Stacking of LPG shall be placed

and electric fires with water. gloves

Risk Risk Level Action

Prepared By: SAFETY ENGINEER/PDIL

Checked By: RCM/PM/PDIL