29 HIRA Annexure H

Nature of the Job: Dismantling and erection of ammonia tank
Name of the Contractor: Projects & Development India limited

Name of the Safety Engineer: Mr. Tarik Vahora
GENERAL – MECHANICAL
STEPS/ METHODS POTENTIAL HAZARD RISK RATING
(MAIN ACTIVITIES) (What can cause WITH
harm?) EXISTING
RISK
Sr. SUB
RISK
CONTROL
No. ACTIVITIES
C L R
 Physical hazard
while handling
material.
 Working at height.
 Struck by moving
vehicle.
 Unskilled Labor
Mobilization of  Unconditioned
Personnel, vehicles, / damaged Equipment
1 Equipments &  Vehicle accident 5 3 15 A
Delivery of material
to job site.
Date: 02/12/2020 Project No: PC-00187
Job Location: GNFC -1003A Project Bharuch Site
Contract Project manager: Mr.
CONTROL MEASURES/ MITIGATIONS RISK RATING RESPONSIBILI TY

(What can be done to prevent it from WITH ADDITIO
going wrong?) CONTRO GNF PDI LST
MEASURES C L K
PPEs TO BE
RISK
USED
C L R
 Compliance on PTW requirements to be  Basic PPEs S P
ensured. (Safety helmet, =S =PE
 Trained and competent person to be Safety Glass, UP RFO
monitored. Leather gloves, ER RM
Safety Shoe) VIS ER
 Conduct TBT to all craftsmen involved in IO
the work activities.  Full body
harness N
 Compliance with GNFC safety
requirements to be ensured.  Respirator
 Only competent and licensed drivers to  Dust
deliver material at site. coverall
3 1 3 C S
 Driver to be made aware of
requirements and deliver to designated
area only.
 Ensure all personnel are properly trained
and competent with appropriate PPE.
 Ensure the equipment/trailer
Scaffold Erection Lifting of  Hit man or material

and Dismantling Scaffold
2 materials 5 5 25 A
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
 Ensure all personnel have undergone  Basic PPEs

Site Safety Induction. 3 1 3 C  Fall S S P
 Ensure all personnel are trained arrestors
using Tower
crane /
Manually
Manual shifting
of Scaffold
Materials
 Personnel injury 5 4 20 A
and competent for rigging and tower  Full body
crane operation. harness with
 Ensure tower crane operator having 100% tie up of
valid 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 trained for  Basic PPEs

manual lifting activity.  Fall
 Tool Box Talks to be conducted before arrestors
starting the activity. 3 1 3 C  Full body
S S P
 Deploy the workers according to the harness
weight of the materials. with 100%
Erection of  Material Fall from

Scaffolds. height
5 5 25 A
 Ensure proper access for workers to shift tie up of
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  Basic PPEs

at height training.  Fall
 Ensure all the tools and tackles tied with arrestors
rope to avoid fall of materials  Full body
 Ensure no movement of workers harness with
underneath the working area. 100% tie up of
 Ensure proper barriers in the working lanyard
area.
 Deploy sufficient workers to position the
brackets.
 Ensure proper platform to position the 3 1 3 C S S P
bracket.
 Ensure proper mid railing, top railing and
toe guard provided.
complete.
 Man fall from height 5 5 25 A
Tie Rod  Fall of materials A

fastening
5 5 25
 Provide adequate warning signs for
awareness.
 Ensure all persons undergone with work  Basic PPEs
at height training.  Fall
 Tool Box Talks to be conducted before arrestors
starting the activity.  Full body
 Ensure worker should medically fit for harness with
work at height. 100% tie up of
 Ensure scaffolding inspected and lanyard
provided with green tag.  FBH with
 Ensure proper platform to position the shock absorber
bracket.
 Ensure proper anchorage point provided
for the work men to hook. 3 3 9 B S S P
 Ensure proper mid railing, top railing and
toe guard provided.
complete.
awareness.
 Ensure Scaffold was properly positioned. C  Basic PPEs

 Ensure tie rod was properly inserted into  Fall
the core wall. 3 1 3 arrestors S S P
 Ensure tie rod was fastened  Full body
harness
Platform hand
rails Erection/
Dismantlin g
 Fall of materials 5 5 25 A
Removal of  Working at height A

Scaffold
 Slip and falling 5 4 20
properly before going for the next bracket. with 100%
 Ensure all tools and tackles are tied with tie up of
the harness to material fall. lanyard
 Ensure all Scaffolds are fastened
properly before going for the platform
erection.
complete.
awareness.
 Ensure metal planks tied on the Scaffolds  Basic PPEs

with the binding wire.  Fall
 Ensure proper hand rails provide for the arrestors
brackets.  Full body
 Ensure proper anchorage point provided harness with
for the workmen to hook the harness. 100% tie up of
3 1 3 C lanyard
S S P
complete.
 Scaffold must be made according to the B  Basic PPEs

work to be 3 2 6  Fall S S P
done. arrestors
of tools
 Falling objects
 Handling heavy
objects
 Exposure to
chemicals
 Personnel injury
Blinding & De  Flammable gas
3
blinding
4 2 8 B
 Toxic gas
Dismantling & Movement of  Vehicle accident

Erection of base Vehicle
plate, angular plate,
4 bottom plate, shell 5 5 25 A
plate and
 Full body harness to be used.  Full body
 Isolate/cordon off working area to harness with
restrict unauthorized personnel entry. 100% tie up of
lanyard
 Scaffold to be done be proper scaffold
and inspected/certified by authority
personnel.
 Tie the tool with nylon thread.
 Compliance with PTW requirements  Hard Hat,

shall be ensured.  Leather
 Ensure the use of rated blinds. gloves,
 Tools use must be appropriate for the  Safety glasses,
job. Use proper lifting practices  Safety shoes,
 Ensure no blind is left unattended.  Coverall.
 Consider pinch points 3 1 3 C S/ P S P
 Compliance with requirements of GNFC
blinding & de blinding standard and
procedure shall be
ensured.
 All the plates and structure materials

shall be shifted to tank pad area by the
help of trailer.
 All the material shifted by trailer secured 2 2 6 B  Basic PPEs S S P
properly and 10 K.M/H speed shall be
follow
 Competent trailer operator shell
roof structure
material
 Hit by objects.
Lifting work by
 Vehicle accident.
using
Hydra/Cran e  Failure of lifting
4 5 20 A
toppling tools & Tackle.
 Trip / fall hazard
 Fall of plates during

lifting
4 5 20 A
is allowed for trailer driving.
 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 should be fit for the
laying activity.
 Ground conditions should be assessed
prior to setting up the crane / hydra for
lifting the material.
 No tandem lifts should be carried out
and no hydras should be used to transport 3 3 9 B  Basic PPEs S S P
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 trailer.
 Enough support should be provided to 3 3 9 B  Basic PPEs S S P
all Sides of trailers.
 Plate clamps should be used to
 Failure of lifting 5 4 20 A
tools.
5 3 15
 Hit by object A
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.
 All lifting tools should be inspected prior
to use. 3 3 9 B  Basic PPEs S S P
 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 3 3 9

high wind conditions.
 Load should be controlled by guide
B  Basic PPEs S S P
ropes & should not be
Loading and
Unloading of steel  Hit to men or
5
plates using Hydra/ materials
5 5 25 A
Crane
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.
 No plates should be lifted with forklifts.
 Ensure trained and competent personnel
operating tower crane to lift the Bucket  Hard Hat,
 Tool Box Talks to be conducted before  Leather
start of the activity. gloves,
3 1 3 C  Safety glasses,
S S P
 Ensure the LG and machines have legal
documents Like TPI.  Safety shoes,
 Ensure before starting the work physical  Coverall.
inspection should be done for the crane
and Sand Bucket using the check list
Offloading &  Fall of Materials

movement of
steel plates,  Fall of steel plates.
Structure
material
5 5 25 A
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  Hard Hat,

unloading of Steel plates materials  Leather
 Ensure web slings are free from damage. gloves,
 Ensure while slinging rigger must worn  Safety glasses,
with safety Harness.  Safety shoes,
 Use Proper communication device for 3 1 3 C  Coverall. S S P
safe signal propose.
 Provide proper tag line to avoid
oscillation.
 Hit by objects.
 Failure of lifting
tools & Tackle.
 Trip / fall hazard
Lifting work by
using
Hydra/Cran e
5 5 25 A
toppling.
 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  Hard Hat,

to pull the loads.  Leather
 Ground conditions should be assessed gloves,
prior to setting up the crane / hydra for  Safety glasses,
 Safety shoes,
 Coverall.
wind speed is more than 9.8m/min.
 Flagman should be assigned to guide the
traffic.
 Drivers should follow the traffic rules
while driving inside the project areas. 2 1 2 C S S P
 No lifting activity should be carried out
during night shift if
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.
Using Chain
block, Come
along, slings,
shackles
 Defective or
damaged chain block, 4 3 12 A
Come along, slings,
shackles, wire rope
 Failure of load
 Unauthorized use of
forklift.
Forklift  Unauthorized
Operations movement of forklift. 3 3 9 B
 Speeding with
forklift.
 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,  Hard Hat,

come along sling, and shackles) must be  Leather
inspected & certified gloves,
 Determine load & always stay within the  Safety glasses,
SWL of the lifting/pulling equipment.
 Safety shoes,
 Never use live pipelines and fragile
 Coverall.
structures to hang chain pulley for lifting a
load. AVOID sharp contact, Avoid shock 2 2 4 C S S P
loads.
 Avoid pinch point. NEVER leave a
suspended load unattended
 Only use Forklift trucks that are  Hard Hat,

inspected, certified and roadworthy.  Leather
 Only allow certified and experienced gloves,
forklift operators to operate forklifts.  Safety glasses
 Forklifts should be accompanied during 2 2 4 C  Safety shoes
S S P
travel and operations.
 Coverall
 Unsafe loading of
forklift.
 Inexperienced and
un-licensed operator.
 No flagman during
operations and travel.
 Roll over
 Personnel hit by
Forklift
Fabrication of plate  Hot work

and structure  Careless handling of
material. lighted cutting torch,
Welding, cutting & hot particles may
grinding (Hot Work) Exposure to cause burns.
6 if heat and hot  Using cutting torch 5 3 15 A
material too close to
combustible
 Forklifts should never be operated at  Reflective
speeds in excess of the required maximum vests to be worn
speed (should be at walking pace). by the flagman
 Operator must wear a seat-belt.
 Only materials and equipment to be
loaded and moved.
 Forklifts are NOT ALLOWED TO
TRANSPORT OR LIFT PASSENGERS.
 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.
 Plasma cutting should be carried out in  Hard Hat,

an isolated area.  Rubber gloves,
 Enough drinking water should be made  Safety glasses,
available in the fabrication yard.
 Safety shoes,
 Proper breaks should give to the
2 2 4 C  Coverall S S P
employees engaged in the plasma cutting.
 protective
 Flask back arrestor at both sides shall be
clothing,
used for gas cutting set.
required materials / personnel.
 Gas leaking from
hoses / valves or flash
back arrester
 Gas cutting set shall be up right position  gauntlets,
and secured by chain.  face shield
 Wear protective clothing, gauntlets, face  welding glass/
shield and welding glass along with other shield
regular PPEs.
 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 oxygen
reverse flow in to fuel
 Electrocution 5 4 20 A
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  Hard Hat,

machine should be done through proper  Rubber gloves,
rated ELCBs and ELCBs should be
 Safety glasses,
inspected and recorded on periodic basis
as per project requirements.  Safety shoes,
 Proper earth should be provided to all  Coverall.
required parts of the plasma cutting
machine.
 No employee other than electrician
should carry out the maintenance of the
1 3 3 C S S P
electrical systems of the machine.
 No substandard joints of cables are
accepted.
 Operator & electrician should
 Burn & cut injuries,

personal injuries
5 4 20 A
 Fire 5 3 15 A
Rolling and bending Lifting work by  Hit by objects.

of plates and angles using
Hydra/Cran e
toppling  Failure of lifting
tools & Tackle.
7  Trip / fall hazard 5 5 20 A
inspect the machine every day before
starting the job.
 Employees should be provided with  Basic PPEs
proper hand gloves and clothing.  Proper hand
 After cutting plates, scrap should be gloves and
disposed properly. 2 2 4 C clothing S S P
 Proper handling of scrap material.
 Obtain hot work permit.  Hard Hat,

 All combustible material should be  Rubber gloves,
removed under the cutting area.  Safety glasses,
 Metal plates should be placed under the  Safety shoes,
bed & area under the bed of machine
1 3 3 C  Coverall.
should be closed with metal sheets to
avoid.
 Proper fire extinguisher shall be
provided for all hot work.
 Inspected hydra / cranes should be  Hard Hat,

engaged in plate rolling.  Leather
 Alternative arrangement using power gloves,
operated chain blocks should be made.  Safety glasses,
 Hydra / cranes used in rolling of plates, 2 3 6 B  Safety shoes, S S P
proper coordination should be
 Coverall.
maintained.
 Proper coordination should be
 Crush injuries 5 4 20 A
 Injuries due to sharp 5 4 20 A

edges
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 guarded.
 Proper fencing should be maintained
around the machine. 2 2 4 C S S P
 After rolling, rolled plates should be
stored properly and should be locked
against rolling from
stored place.
 Leather hand gloves should be used to  Basic PPEs

handle plate. (Safety helmet,
 Employees should be provided with full Safety Glass,
body protective clothing. Leather gloves,
Safety Shoe)
 Guide lines should be used to control the
load. 1 3 3 C  Full body S S P
 Area of lifting / shifting should be
barricaded.
 Proper coordination between
 Electrocution 5 4 20 A
Hot work
8 (welding, cutting  Electrocution 5 5 25 A
,grinding)
crew to avoid communication gap. protective
clothing
 Rolling machine should be placed at  Basic PPEs
proper location.  Full body
 No one other than electrician should be harness
allowed to do the electrical maintenance  Respirator
work for the machine.
 Dust
 Machine should be inspected on daily 1 1 1 C coverall S S P
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 should be
allowed to do the electrical maintenance
work for the machine.
 Proper earth should be provided to the
machine.  Basic PPEs
3 3 9 B S S P
 Power supply of the machine should be  Rubber Gloves
provided through proper rated ELCBs or
GFCIs.
 Machine should be protected from rain
and other bad weather
 Fire 5 4 20 A
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 be
made with proper plugs, sockets,
connectors.
 No loose connections are allowed.
2 4 8 B  Basic PPEs S S P
 Cables with damage insulation should be
taken out of use.
 Welder should inspect the
 Burn injuries 5 4 20 A
 Damage to gas 5 5 25 A
cylinder & hoses
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 in
proper manner.
 Welding rod buds should be disposed at  Basic PPEs
a designated location only.  Leather apron
 Welder / employees engaged in over
3 3 9 B S S P
 Leather
head hot works should be provided with Coveralls
leather apron &
leather sleeves.
 Hoses should be laid in proper manner.  Basic PPEs

 Hoses should be protected from sharp  Repertory
edges. mask
 Hoses should be checked for 2 4 8 B S S P
damages on daily basis and if it is cracked,
cut it should be
 Fall of person from 5 5 25 A

height
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 starting the work.
 Proper scaffolding platform should be
provided to the employees working at  Basic PPEs
height.  Fall
 Fall arrestors, full body harness should 3 3 9 B arrestors S S P
be provided & its use should be ensured.  Full body
 100% tie off should be explained and harness
practiced.
 Scaffolding should be designed &
erected properly; no
Cutting of steel  Crush Injury

9 using bar cutting  Hit the men due to 5 4 20 A
machine temper.
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.
 Ensure all personnel have undergone  Hard Hat,

Site Safety Induction.  Leather
 Ensure PTW Issued by the PMC before gloves,
starting the work.  Safety glasses,
 Deploy trained worker for to cut the  Safety shoes,
steels
 Coverall.
start of the activity.
 Ensure the machine is inspected by EHS
dept before entering to site and color
coded. 3 1 3 C S S P
 Ensure safety guard provided for the
rotating parts of machine.
 Pedal guard/Hand lever protection
against accidental activation.
 Ensure cover guard protection for
cutting part of machine.
 Place re bar in position and
Roof plate and

compressor ring  Crane / hydra
10
dismantling & toppling
5 5 25 A
erection
 Fall of person 4 5 20 A
cover before activating the foot
pedal/Hand lever.
 Rods should be hold tightly while
cutting.
 Provide proper PPEs for the 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.
 Ground conditions should be assessed
prior to setting up the crane / hydra for  Basic PPEs
 Fall
 No tandem lifts should be carried out 3 3 9 B arrestors S S P
and no hydras should be used to transport
the material.  Full body
harness
wind speed is more than 9.8m/min.
 Only trained employees should 3 3 9 B  Basic PPEs S S P

from height
 Fall of plates during

lifting, demounting &
after installation
4 5 20 A
Installation of  Fall of lifted material

hydraulic jacks and due to failure of jacks
lifting of tank
11 5 5 20 A
be engaged in working at height.  Fall
 Employees should be medically fit for arrestors
working at height.  Full body
 Working at Height” permit should be harness
 Proper scaffolding platform should be
provided to the 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.  Basic PPEs

 All the plate shall be properly weld to  Fall
avoided any fall arrestors
 Remove all unwanted materials from  Full body
height 2 4 8 B harness S S P
 After erection the job engineer shall be
check and ensure there
is no any lapse.
 All jacks should be inspected for  Basic PPEs

damages before taking it into use.  Fall
 All hydraulic hoses should be laid arrestors
properly & should be prevented from 4 3 12 A  Full body
S S P
damages. harness
 Pinch point injuries

& crush injuries
4 5 20 A
 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 engaged in
the lifting of shell.
 No employees should allow passing 3 2 6 B  Basic PPEs S S P
under the shell while it is
being lifted.
 Hydraulic oil spillage 4 5 20 A
 Fall of person on
same level due to slip
& trip hazards
5 4 20 A
Lifting of roof
12 structure by  Fall of lifted material 5 5 25 A
hydraulic jack due to failure of jacks
 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 available &
employees should be trained to use the  Basic PPEs
same. 2 2 4 C  Spill kit S S P
 Drip trays should be used while refilling  PVC Suit
the oil.
 Spilled oil must be cleaned off
immediately.
 Proper housekeeping needs to be

maintained all the time.
 Hoses, cables should be laid properly.
 Proper access should be maintained to 3 1 3 C  Basic PPEs S S P
enter the tank
after installation of shell plates.
 All jacks should be inspected for  Basic PPEs

damages before taking it into use.  Fall
 All hydraulic hoses should be laid arrestors
properly & should be prevented from 4 3 12 A  Full body S S P
damages. harness
 Hydraulic jacks and its
 Hydraulic oil spillage 4 5 20 A

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  Basic PPEs

fittings & should sustain the required  Spill kit
pressure.
2 1 2 C  PVC Suit S S P
 Spill kit should be made available &
employees should be trained to use the
same.
ND Testing – DP  Exposure to
chemicals
13 Test, Radiography, 5 5 25 A
Vacuum Test  Exposure to the
radiation
 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.
 Ensure radiography permit is obtained
 Proper communication to be done to all
personnel working inside
 Barricade and clear off all personnel in
the affected area.  Basic PPEs
 Ensure the standby man people at all the  Eye
entry point to be effected area. 2 3 6 B protection
S S P
 Confirm sign board is place at all entry  Proper Mask
point.
 Locate the flash light at prominent place.
 Preferable time for the
 Fire, burn injuries 5 3 15 A
 Hazards associated 5 4 20 A
with radiography
radiography is break times and shift
change/over time.
 No dye, chemicals should be sprayed on
the hot surfaces / open flames.
 Cans of dye, chemicals used for DP
testing should be disposed at designated 1 3 3 C  Basic PPEs S S P
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 working
adjacent to the work area.
 Competent radiography technician shall
be engaged for radiography work.
 Basic PPEs
 All safety material like safety sign board,
dosimeter, survey meter, and warning 3 3 9 B  Eye S S P
light shall be provided. protection
 BARC Authorized radiography agency  Proper Mask
shall be engaged for
radiography work.
 Fall of person due to

bad lighting and 5 3 15 A
housekeeping
 Fall of person from A

height
Nozzle
14 5 5 25
installation
 Fall of material from 5 4 20 A

height
 Separate PIT room shall be provided for
handling and store
the source.
 Proper lighting arrangements should be
made to work inside the tank.
 Hoses, cables should be laid properly
and maintained the same
 Daily housekeeping should be practiced
at the end of the day. 2 2 4 C  Basic PPEs S S P
 Proper working platform if RT works at
height.
 Only trained employees should be B  Basic PPEs

engaged in working at height.  Fall
 Employees should be medically fit for 3 2 6 arrestors S S P
working at height.  Full body
harness
 Material should not be stacked on the  Basic PPEs
scaffolding or any other place at height.  Fall
 Platforms should be constructed in such arrestors
a manner that there should not be any  Full body
gaps in the platform, proper toe guard harness
should be provided to the platforms of the 3 3 9 B S S P
scaffolding.
 Structure components should
Painting work at
15 tank outer shell  Fall of person from 5 5 25 A
(work at height) height
 Injuries due to slip, A

trip & fall
4 5 20
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.
 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
 Basic PPEs
 FBH shall be provided for height work.
 Fall
 If ladders are used, it should be secured 3 3 9 B arrestors S S P
prior to start working on it.
 Full body
 Proper life lines should be installed and harness
used while working
at height
 Hoses cables should be laid in proper B  Basic PPEs

manner.  Fall
 Paint box should be removed from the 2 3 6 arrestors S S P
scaffolding platform on  Full body
daily basis. harness
 Exposure to paint 5 5 25 A
fumes
 Fire, explosion 4 5 20 A
 Platform should be maintained uniform
& steps should be avoided.
made at each
platform level of the scaffolding.
 Sufficient ventilation should be  Basic PPEs

maintained at the place of paining.  Canister masks
 Canister masks should be provided & its
 No hot work should be carried out in the 3 3 9 B S S P
nearby confined
spaces without gas testing.
 Paint should be stored away from the

heat or sparks.
heat or sparks.
 All electrical connections should be
provided with proper earth connections
and no lose connections are allowed as it
may lead to fire. 3 3 9 B  Basic PPEs S S P
 Empty paint drums should be disposed
properly & it should be disposed at
specified location.
 Fire extinguishers should be
Blasting and  Injuries due to high

16
painting work pressure grits
5 5 25 A
 Injuries due to 5 4 20 A
made available at site and
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.
 To control the grits area around the
blasting should be isolated with GI sheets /
Tarpaulin.
 Blaster should wear the required  Basic PPEs
protective clothing.
B  Full body S S P
 Full body protective clothing is must for 3 2 6
protective
blaster. clothing
 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.
 All hoses should be laid properly 2 2 4 C  Basic PPEs S S P

uncontrolled high
pressure hoses
and should be prevented from damages.  Full body
 All hoses should be connected to protective
compressors with proper connectors / clothing
coupling and hose clamps.  Body armor
 Whiplash arrestors should be provided  Shin
to all extension joints of the hoses. guards
 No vehicles should be moved on hoses.  Arm
 Hoses should not be subjected to protection
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.
 Noise exposure 5 4 20 A
 Exposure to paint 5 4 20 A
fumes
 Fire, explosion A
5 4 20
 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
 Blasting activity should be carried out by  Basic PPEs
scheduling it during particular intervals. 2 2 4 C  Ear S S P
 Compressors should be provided with Plug/Ear Muff
covers to reduce the noise and should be
checked on
regular basis.
 Sufficient ventilation should be  Basic PPEs

maintained at the place of paining.  Canister masks
 Canister masks should be provided & its
 Cartridges of the canister masks should 2 3 6 B S S P
be replaced after 12
days.
 Painting area should be declared as no B  Basic PPEs

smoking zone.
 Hot work should be carried out at least 5 2 3 6 S S P
meter away from the painting area.
 Environmental
pollution due to paint
drums disposal &
 grit disposal 5 4 20 A
 Pressurized system
 Bursting of hoses.
 Personal injury
Torque
17
/tensioning
4 3 12 A
heat or sparks.
 Empty pain drums should be disposed
properly & it should be disposed at
specified location.
 Fire extinguishers should be made
available at site and employees should be
trained to
use the same.
 As grits & empty paint drums are  Basic PPEs

considered as hazardous waste, it should  Shield for
be disposed at designated location. blasting shed
 Ensure proper shield for blasting shed to 2 3 6 B S S P
avoid dust flying to environment.
 Use calibrated gauge in the pump.

Ensure proper supervision at all times
 Use calculated value of pump pressure
in case of bolt tensioning.
 Release pressure in hose before
disconnection.
 Barricade area at ground level to 2 2 4 C  Basic PPEs S S P
prevent unauthorized entry.
 Tommy bar should be tied with rope to
prevent falling.
 Slip/trip/fall
 Pinch hazards
Hydro Testing/
General  Over pressurization
18 pneumatic test if requireme nts  Personnel injury due
4 5 20 A
required.
to hose rupture.
 Unauthorized entry
 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
 Ensure TBT meeting before start of
work.
 Inspect to all equipments before use at
site.
 Barricade the work area.
 Display related safety sign / caution
boards.
 Use leather gloves 2 3 6 B  Basic PPEs S/ P S P
 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.
 Ensure all hoses are arranged in
Filling of water  Area may be

into Tank slippery and chance
to fall
/slip
4 5 20 A
Use of pressure  Pump hose may

pump burst and cause injury
4 2 8 B
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 using
water hose or mechanized pump.
 Ensure controlling of spillage / flooding.
 Ensure the area is free from
2 2 4 C  Basic PPEs S S P
obstructions.
 Inspection the pressure lifting pump

before use.
 Ensure hoses used are free from crack/
damage.
 Use pressure hose as per design
/ calculation.
 Ensure trained and experienced person
operates the pressure pump.
 Calibration certificate of pressure gauge
2 1 2 C  Basic PPEs S S P
to be verified.
 Pressurizing to be stopped if fluctuation
in gauge is not observed, maybe due to
defect
or choke.
 Pressure buildup
may cause failure of
flange / plate blind
joints and rupture of
hose.
 Welding joints may
crack/ burst and water
may release with high
pressure.
 Chance of Physical
injury
Increasing of
pressure level 5 4 20 A
inside Tank
Pressure  Pipe may burst or

holding in loop blind joint may crack
3 2 6 B
 The flanges / joints shall be visually
checked before starting of Hydro testing.
 Suspend all works nearby the testing
area.
 Area shall be cordoned off to restrict
entry of other persons.
 Blind should be welded perfectly at the
end of pipe spool. Avoid use of rusted /
corroded plates as blind.
 Ensure welding of blind is inspected by
competent person before pressure test.
 Ensure pressure is increased gradually. 3 2 6 B  Basic PPEs S S P
 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.
 Ensure only hydro testing crew should
enter the barricaded zone. 2 1 2 C  Basic PPEs S S P
 Pressurized lines / piping spools to be
inspected / monitored
Releasing of
pressure  Slip /trip/ fall
/ Dewatering of hazards
4 5 20 A
pipe
 Blast of tank
 Hand injury
 Failure in identifying
blind(s) may leads to
process hindrance
Pressure testing &
19
Box up
5 4 20 A
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.
 Dewatering should be done safely.
 Workers should maintain a safe distance
from the vent point while releasing
pressure. 2 2 6 B S S P
 Basic PPEs
 Water should be drained slowly by water
hose to nearby drains or water collection
tanks
avoiding flooding of the area.
 Proper arrangements should be done

prior to do pressure testing of the tank.
 If required, permits should be taken
before starting the pressure test the same
should be communicated to the other
contractors working in the vicinity of the
tank being pressure tested well in 1 2 2 C  Basic PPEs S/ P S P
advance.
 All equipments used for
 Injuries due to
busting of pressure 4 5 20 A
lines
5 3 15 A
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 for the tanks
during testing.
 All hoses, pipes, fittings should be 3 3 9 B  Basic PPEs S S P
visually inspected for defects
before installation & prior to start the
testing.
 Identified drains & vents should 2 2 4 C  Basic PPEs S S P

 Sudden release of
pressure
 Entrapment of 3 5 15 A
person
Confined Space  Sharp surfaces

Entry for cleaning  Possible hydro-
and repair activities carbon vapors
(if required) present.
 Insufficient Oxygen
20 Levels. 5 4 20 A
 Insufficient light.
 Slippery surfaces.
be provided to release the 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 be ensured that
the tank is completely vacant.
 Company safety officer shall give final 2 4 8 B  Basic PPEs S S P
box up clearance after sign
in procedure.
 Obtain a valid Permit to Work as well as  Hard hat,

a Confined Space Permit Issued at the site  safety glasses,
 Ensure PTW is in place and ensure check  Dust
for Gases and shall ensure that Oxygen mask,
20.8% & LEL
 coverall,
- 0% which need to be monitored 3 2 6 B  Rubber gum
S S P
continuously.
 All crew members working in confined boots,
space shall be trained  Leather
because of the viscous
material inside
 High temperatures
inside the confined
space
Vacuum out sludge  Hand injuries while

using vacuum truck setting- up and
and disposed making connections
designated area.  Possible injuries as
21 result of tripping over 4 2 8 B
and competent to work in confined space gloves,
 Ensure standby man remains at  Safety shoes
entrance with constant communication  Full body
with the crew. harness with
 Post signage and barricades CONFINED double lanyard
SPACE ENTRY – DO NOT ENTER. and shock
 Erect sufficient lighting. absorber (when
working at
 Ensure adequate ventilation and heights
airflow.
 Ensure constant air monitoring.
 Do gas testing for explosive or
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.
 Ensure that hand protection and all  Basic PPEs

other PPE, as required are worn.  Safety
 Ensure all hoses are arranged in such a Goggles,
way that it does not pose any unnecessary  Respirator
tripping hazards. 2 1 2 C  Dust coverall,
S S/ P P
 Qualified Gas Tester
 Leather
gloves,
hoses.
 Flammable,
Radioactive and
health
 Failure to follow
procedure
 Hose failure
 Static electricity
generation may be a
source of ignition
 Inhalation of Toxic
Fumes
 Inhalation of
Hazardous Substance
 Possibility of fire
 Ensure no one is standing close to the
Equipment man way.
 To follow GNFC procedure
 Ensure to assess the vacuum truck
approach roads & its set up area in
coordination with GNFC 's competent
representative and ensure that, it is clear
from all obstacles before obtaining PTW
 Depute only qualified and trained
vacuum truck drivers and ensure to wear
appropriate PPE.
 Ensure all hoses are inspected, tested
and certified prior to its use.
 Barricade the area and post “DO 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 that are hazardous to
health
 Poor visibility A
4 4 16
 Slipping and Tripping

hazard 4 3 12 A
22 Working at night
 Lack of supervision A
4 3 12
 Unavailability of first
aid facilities. 4 4 16 A
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 C  Safety helmet,

 Ensure adequate illumination 3 1 3  Safety S S P
 Hoses cables should be laid in proper Goggles,
manner.  Respirator
 Paint box should be removed from the 3 1 3 C  Dust coverall, S S P
scaffolding platform on daily basis.  Leather
 Platform should be maintained uniform C gloves,
& steps should be avoided. 3 1 3 S S P
made at each
3 1 3 C S S P
 Drowsiness (feeling 4 3 12
sleepy)
A
 Fatigue 4 3 12 A
 Lack of amenities. 4 3 12 A
 Possible slipping and

falling of personnel
23 Housekeeping 4 3 12 A
platform level of the scaffolding. 2 1 2
 Ensure use of personal protective
equipments-Shoe- Helmet-Gloves. C S S P
 Break needs to be taken at regular
intervals.
 Full or alternative supervision
throughout the work. 3 1 3 C S S P
 Emergency vehicles with driver should
be there through the work time.
 Effective supervision will be made by
nominating designated decision making
person as in charge for night shift.
 Drinking water, snacks and other
amenities will be available. 2 1 2 C S S P
 Ensure frequent cleaning of work station  Safety helmet,

from obstructing, unwanted material /  Safety
objects and slippery floor. Goggles,
 Any spillage should be cleaned up  Respirator
immediately and stored into approved
 Dust coverall,
container.
 Make sure that hoses used are arrange
2 1 2 C  Leather S S/ P P
in such a way that it will not pose a gloves,
tripping hazard
during the housekeeping job.
CIVIL WORK
STEPS/ METHODS POTENTIAL HAZARD RISK RATING
(MAIN ACTIVITIES) (What can cause WITH
harm?) EXISTING
RISK
Sr. SUB
RISK
CONTROL
No. ACTIVITIES
C L R
Layout of pilling  Fall on the same
area and line level due to tripping
marking with chalk because of uneven
powder ground.
 Dust entering eyes
and nose due to loose
soil & gusty winds
1  Skin irritation and 5 4 20 A
trip hazards.
Loading &  Inadvertent A

unloading of movement / roll of
2 materials from materials from the 4 4 16
truck for pilling stack while loading /
work
CONTROL MEASURES/ MITIGATIONS RISK RATING RESPONSIBILI TY

(What can be done to prevent it from WITH ADDITIO
going wrong?) CONTRO GNF PDI LST
MEASURES C L K
PPEs TO BE
RISK
USED
C L
 Be cautious while walking on uneven  Safety helmet,
ground surface.  Safety Goggles,
 Wear safety shoes for protection.  Respirator
 Removal of thorny plants, debris and  Dust coverall,
other material if any before marking.
 gloves,
 Plan marking when the wind is low and
wear safety glasses and dust mask 3 1 3 C S S P
 Check the stack condition for any C  Safety helmet,

disturbance that may cause movement.  Safety Goggles,
 Do not step over the load that may 2 1 2  Respirator S S P
cause imbalance; instead
unloading
 Overloading
vehicle / axle load
exceeding rated
capacity
Erection Leveling of  Damage could result B

/Assembly of Rig ground to the existing
3 materials on 3 3 9
use tailor made platforms, where required  Dust coverall,
 Always load / unload from top layers in  gloves,
the stack; 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.
C  Safety helmet,
 Safety Goggles,
 Before leveling clear the area. 2 1 2  Respirator S S P
ground, if any.
Assembly of A-  Crane used for

Frame erection could be
including toppled during
placing of roller assembly.
tubes, main sill,
 Fall might result
positioning of
during height works.
winch up to
First stage of A-  Hit may result due
Frame. to breaking of wire
ropes / slings.
 Traffic problem
 Poor access
4 5 20 A
Lifting of  May hit the A

Derrick Post assembled part of A- 5 4 20
and Frame.
 Dust coverall,
 gloves,
 Ensure SWL, Lifting radius etc. of the  Safety helmet,

erection crane.  Safety Goggles,
 Provide experienced rigger for signaling.  Respirator
 Provide licensed operator.  Dust coverall,
 Area shall be barricaded.  gloves,
 Double lanyard Full body harness with
shock absorber with fall arrester, where
necessary, shall be used while work at
height.
 Tag Line shall be used to control
movement of lifted loads.
 Ensure TPI for all lifting tools and tackles 2 2 4 C S S P
including Rig assembly.
 Ensure life line for Tie off the harness, if
required.
 Traffic control by signalman with flag.
 Access ways and unloading zone
identified
 Ensure SWL, Lifting radius etc. of the B  Safety helmet,

erection crane. 3 3 9  Safety S S P
 Provide experienced foreman
assembly of  May hit the persons
second , third , involved.
fourth and fifth
 Fall of persons might
stage of A-
Frame result during height
works.
 3. Hit may result due
to breaking of wire
ropes / slings.
Area clearance
and identificati
on of buried
cables, utilities
and chemicals
etc.
4 Driving of piles  Damage to 4 5 20 A
underground utilities
Placement of  Hand injury might A

piling shoe on happen.
the pile 4 3 12
location  Pile shoe could slip
and fall.
for signaling. Goggles,
 Provide licensed operator.  Dust coverall,
 Area shall be barricaded.  gloves,
 Double lanyard Full body harness with  Double lanyard
shock absorber with fall arrester, where Full body
necessary, shall be used while work at harness with
height. shock absorber
 Tag Line shall be used to control with fall arrester
movement of lifted loads.
 Ensure TPI for all lifting tools and tackles
including Rig assembly.
 Valid permit should be obtained on daily  Basic PPEs

basis, which can provide information  Safety Goggles,
about the existence of underground
utilities, if any.  Respirator
 Dust coverall,
 If required, cable detectors would be
used to detect underground cables.  Leather gloves,
 A signal man shall be assigned to
2 2 4 C S S P
monitor the excavation.
 TBT shall be conducted on daily basis.
 All workers should use hand gloves/ C  Basic PPEs

safety shoes.  coverall,
 2.TBT shall be held with crew 2 2 4  Leather gloves, S S P
Placing the concrete  Collision with piling

5
mixer near to the rig
rig 4 3 12 A
 Hit to person
Vertical, Lateral and

Pull out test
Shifting of rebar,
farm and scaffolding
materials for
6  Struck by rebar, slip, 4 4 16 B
pile head trip, fall to same level
preparation
Lifting, shifting and  Load or hydra may

Placing of load collapse due to
(concrete block and overloading
beams) with the  Load collapsed due
help of hydra to failure of lifting
tools
7
 Load or hydra may
5 5 25 A
be collapsed due
to uneven floor
 Reverse horn of miller shall be in  Basic PPEs
working condition  Safety Goggles,
 Signal man shall be provided  Dust coverall,
 Ensure area is clear from obstacles for 2 2 4 C  Leather gloves, S S P
movements.
 Provide valid licensed driver
 Keep clear access and hand gloves shall  Basic PPEs

be in use.  Safety Goggles,
 Provide steps for excavation or provide  Dust coverall,
ladder for assess.
 Leather gloves,
2 2 4 C S S P
 Load shall be lifted as per the load chart  Basic PPEs

 Licensed and experienced operator shall  Safety Goggles,
be allowed to operate the hydra  Respirator
 Proper training shall be provided to the  Dust coverall,
hydra operator and helper
 Leather gloves,
 Certified and inspected lifting tools shall 3 3 9 B S S P
be allowed to lift the load Ground area
shall be
surface Strike with
moving or
stationary object
Cutting of steel  Crush Injury

using bar cutting  Hit the men due to
machine temper.
8 5 4 20 A
properly leveled.
 Tagline shall be provided to control the
load
 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.

Site Safety Induction.  Safety Goggles,
 Ensure PTW Issued by the PMC before  Respirator
starting the work.
3 1 3 C  Dust coverall, S S P
 Deploy trained worker for to cut the
 Leather gloves,
steels
Bending of steel  Crush Injury

using bar bending  Hit the men due to
machine temper.
9 5 4 20 A
coded.
 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.
completed.

starting the work.
3 1 3 C  Dust coverall, S S P
 Leather gloves,
steels
Binding of
steels using
binding wire
 Pinching hazard 4 4 16 A
coded.
 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.
completed.

starting the work. 3 1 3 C S S P
 Dust coverall,
 Leather
steels
 Tool Box Talks to be conducted
Shifting Of
fixed rods to  Fall of materials on
working area men/hit the men
4 4 16 A
manually
Electrical
10
Operation  Electrocution 5 4 20 A
before start of the activity. gloves,
 Use proper gloves to avoid pinching of
wires.
 Ensure workers are free from heat
stress.
completed.

starting the work.
 Dust coverall,
 Leather gloves,
steels
start of the activity. 3 1 3 C S S P
 Ensure access free from obstruction.
 Ensure no unwanted men movement in
the shifting area.
 Ensure proper positioning of fixed rods
 Ensure Competent Person Must work  Basic PPEs

with electrical machine Like motors  Safety Goggles,
 Ensure cables free from damaged.  Respirator
 Ensure Safety devices Like ELCB/RCCB 3 2 6 B  Dust coverall, S S P
Connected with the
 Leather /
Reinforcement  Fall of materials and

11
Work men
5 5 25 A
circuit. rubber
 Ensure isolation of power source while gloves,
maintenance works.
 Ensure proper body earthen should be
provided to the 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 working in  Basic PPEs

height.  Safety Goggles,
 Ensure workmen undergone with height  Respirator
work training.
 Dust coverall,
 Ensure Scaffold is inspected daily before
3 1 3 C  Leather gloves, S S P
starting the work.
 Safety harness
 Ensure proper working platform
provided for the workmen.
 Ensure all tools and tackles Tied with
rope avoid falling.
 Mechanical failure.
 Lack of supervision.
 Striking against
objects.
 Improper
barrication.
 Unguarded rotating
parts.
 Spillage of concrete.
12 Concreting.  Skin rashes. 4 4 16 A
 Electrocution A
13 Vibrator  Health hazard 5 5 25
 Skin diseases
 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  Basic PPEs

vehicle/concrete pump.  Safety Goggles,
 Ensure the equipment should have  Respirator
proper documents.
 Dust coverall,
 Continuous supervision to be provided.
 Gumboots
 Proper barrication has to be done for the
 Rubber gloves
entire area.
 No Unauthorized entry during the
activity.
 Guards to be provided for rotating parts 3 1 3 C S S P
 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.
 Ensure Competent Person Must work B  Basic PPEs

with electrical machine 3 2 6  Safety Goggles, S S P
Like vibrator
 Collapse of wheel
barrow with person
over speeding
 Over turning of
rider.
 Inhalation of cement
Dust, Eye and skin
irritation by direct
contact with cement.
 Electric Shock due to
water spillage.
 Air pollution
 Entanglement
 Ensure cables free from damage  Respirator
 Ensure Safety devices Like ELCB/RCCB  Dust coverall,
Connected with the circuit.  Leather gloves,
 Ensure isolation of power source while
maintenance works.
 Ensure proper body earthen should be
provided to the electrical machines.
 Ensure cables are over headed.
 Ensure there is no damage in electrical
panel Boards.
 Ensure Proper PPEs provided for the
Electrical Technician and operator
 Ensure Adequate supervision 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
14 Curing.  Slips and trips 4 3 12 A

 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.
 Use proper access and good 3 1 3 C  Basic PPEs S S P

housekeeping.  Safety
 Burn injury.
 Breathing problem
due to inhalation of
smoke.
 Chance of fire.
 Explosion.
 Personal injury.
 May cause severe
 Injuries or prove
fatal.
Bitumen  Property Damage.
15
Heating
5 5 25 A
 Proper PPE’s like gumboot and rubber Goggles,
gloves to be used while curing.  Respirator
 No Electrical wires to be in place while  Dust coverall,
curing.  Gumboots
 Rubber gloves
 Heating activity shall be always carried  Basic PPEs

out by trained and experienced person.  Safety Goggles,
 Workmen shall be work with necessary  Respirator
PPEs at site.
 Face shield
 Provide nose mask to the workmen.
 Leather gloves
 For eyes protection goggle to be
 Protective
provided.
cloth
 Flash back arrestor shall be ensured.
 Before starting of job burner & hose to
be checked.
 Gas leakage to be checked with soap
solution. 3 4 12 B S S P
 Keep LPG/metal cutting cylinder free
from spark/ heat.
 Use fire blanket for covering of cylinder.
 Fire extinguisher/fire hose shall be
placed nearby hot workplace.
 Small fires can

become big ones and
may spread to the
Surrounding areas.
 Cause burn injuries
and may prove fatal
Fire prevention and

16
protection.
5 4 20 A
4 5 20
 Fire A
 Stacking of LPG shall be placed
separately in up right direction.
 In case a fire breaks out, press fire alarm  Basic PPEs
system and shout "Fire, Fire"  Safety Goggles,
 Keep buckets full of sand / fire  Respirator
extinguishing equipment near hazardous
 Face shield
locations
 Leather gloves
 Train people for using specific type of
fire fighting equipment’s under different  FRC
classes of fire Cloths
 Keep fire doors/shutters, passages and
exit doors unobstructed.
 Maintain good housekeeping and first-
aid boxes
 Don't obstruct assess to Fire
3 3 9 B S S P
extinguishers.
 Do not use elevators for evacuation
during fire.
 Maintain lightening arrestors for
elevated structures
 Stop all electrical motors with internal
combustion.
 Ensure usage of correct fire extinguisher 3 4 12  Basic PPEs

meant for the specified fire.  Face shield
 Do not attempt to extinguish Oil
B S S P
 Leather
 Bitumen liquid may

chance to fall
hand/feet
/lower body part.
 Burn injury.
Applying bitumen to
17
surface.
5 5 25 A
 Men/ material may

fall down through cut
out opening.
 Slip, trip & fall
 Physical injury
Restriction of  Person may get
18 unauthorized entry injure. 5 5 25 A
near work area.  May prove fatal.
and electric fires with water. gloves
 Use sand bucket/CO2/DCO/sand or  FRC
earth. Cloths
 Ensure proper PPEs to work (helmet,  Basic PPEs

shoes, goggles, leather hand gloves,  Safety Goggles,
protective cloth etc.)
 Respirator
 Activity shall be always carried out by
 Face shield
trained and experienced person.
3 3 9 B  Leather gloves S S P
 Working under supervision.
 Protective
 Awareness/ training program to be
cloth
conducted.
 Work area shall be barricaded to restrict  Basic PPEs

entry.  Safety Goggles,
 Openings shall be covered if work is  Respirator
preceded in the higher elevation.
 Face shield
 Access shall be kept clean.
 Leather gloves
 No loose materials shall be stacked near
4 3 12 B  Protective S S P
the edge of the openings.
cloth
 When people are working close to the
cut out openings wearing
of full body harness.
RISK MATRIX
Rating 5 = Almost certain 5 10
Rating 4 = Very likely 4 8
Rating 3 = Possible 3 6
Rating 2 = Unlikely 2 4
C = CONSEQUENCES 
Rating 1 = Very unlikely 1 2
* Rating 1 = Negligible Rating 2 = Slight
First aid injury or Minor injury or illness

illness
L = LIKELIHOOD / SEVERITY 
Risk Risk Level Action
A = 1 to 5 Low Risk May be acceptable but review task to see if risk can be redu
B = 6 to 10 Medium Risk Task should only be undertaken with appropriate managem

consultation with specialist personnel.
C = 12 to 25 High Risk Task must not proceed. It should be redefined or further co
place to reduce risk.
K MATRIX
15 20 25
12 16 20
9 12 15
6 8 10
3 4 5
Rating 3 = Moderate Rating 4 = High Rating 5 = Very High
'3 day' injury or illness Major injury or illness Fatality, disabling injury,
etc.
L = LIKELIHOOD / SEVERITY 
Action
able but review task to see if risk can be reduced further.
ly be undertaken with appropriate management authorization after

th specialist personnel.
proceed. It should be redefined or further control measure put in
e risk.
Prepared By: SAFETY ENGINEER/PDIL
Checked By: RCM/PM/PDIL
Approved By: GNFC
Other
INTRODUCTION
Emergency planning is an integral part of the overall loss control programme and is essential for our o
important for effective management of an accident to minimize the losses to the people and property,
facility. The important aspect in emergency management is to prevent by technical and organizational
unintentional escape of hazardous materials out of the facility and minimize accidents and losses.
demonstrates the organizational commitment to the safety of employees and increases our organ
awareness.
An emergency in the factory has potential to cause serious injuries or loss of live or extensive damage
environment and serious disruption both inside and / or outside the works. In such cases someti
are required to call for help in handling the situation. The causative factors like plant / equipment fail
earthquake, sabotage etc. will normally manifest in various forms viz. Fire, Explosion, Toxic and Stru
In spite of best design and layout of plant, safe operating procedures and various preventive measur
disaster cannot be totally ruled out. During this event timely and organized action must be taken to co
minimize the damage or loss to the factory, human beings and environment hence, the need of a pro
Emergency Plan (EPRP)”. Such plan gives the guidelines for employees, contractors, transporters
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 Facto
new provisions sec 41A, 41B, 41C, 41D, 41E, 41G & 41H covering all hazardous process industries.
Sec 41B (4) every occupier shall with the approval of the Chief Inspector of Factories draw
Emergency Plan and detailed disaster control measures for his factory and make known to the w
and to the general public living in the vicinity of the factory the safety measures required to be taken i
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 a
emergency and it may lead to disaster, which
may cause heavy damage to plant, property and harm to person and create adverse affects on produc
like Bhopal gas tragedy, Chernobyl nuclear disaster etc. have occurred at many places in the world
life and property. Emergency situation arises all on a sudden and creates havoc and damage to
production and environment. Therefore such situations and risks should be thought in advance an
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 mana
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
improves local, district, state and national capacity to respond to disasters and public health emer
actions with vulnerable communities in health promotion, disease prevention and disaster risk re
As per our Indian regulations we have regulatory provisions that On-site Emergency Management Pl
prepared by industrial units and Off-site Emergency Management Plan (Off SEMP) by District Co
An occupier will prepare and keep an up-to date on-site emergency plan containing details of Manuf
Import of Hazardous Chemicals (MS&IHC) Rules 1989 and detailing how major accidents will be
which the industrial activity is carried on and that plan will include the name of the person who is resp
site and the names of those who are authorized to take action in accordance with the plan in case of an
occupier will ensure that the emergency plan prepared takes into account any modification mad
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
ON SITE EMERGENCY PLAN
ing is an integral part of the overall loss control programme and is essential for our organization. The same is
ective management of an accident to minimize the losses to the people and property, both in and around the
ortant aspect in emergency management is to prevent by technical and organizational measures, the
ape of hazardous materials out of the facility and minimize accidents and losses. Emergency planning
organizational commitment to the safety of employees and increases our organization’s safety
the factory has potential to cause serious injuries or loss of live or extensive damage to the property and / or
serious disruption both inside and / or outside the works. In such cases sometimes outside agencies
ll for help in handling the situation. The causative factors like plant / equipment failure, human error,
age etc. will normally manifest in various forms viz. Fire, Explosion, Toxic and Structure collapse etc.
esign and layout of plant, safe operating procedures and various preventive measures the possibility of a
e totally ruled out. During this event timely and organized action must be taken to control the situation and to
mage or loss to the factory, human beings and environment hence, the need of a proper “On–Site
(EPRP)”. Such plan gives the guidelines for employees, contractors, transporters and Visitors etc. The
efines the responsibilities but also inform about prompt rescue / evacuation
erations and some more.
DUCTION OF EMERGENCY PLANNING IS REQUIRED?
of Bhopal gas disaster, the Factories Act has been amended and a
Chapter IVA – provision relating to hazardous processes has been added to the Factories Act with addition of
ec 41A, 41B, 41C, 41D, 41E, 41G & 41H covering all hazardous process industries. Under the provision of
ery occupier shall with the approval of the Chief Inspector of Factories draw up an On-site
n and detailed disaster control measures for his factory and make known to the workers employed therein
l public living in the vicinity of the factory the safety measures required to be taken in the event of an
lace. This is the statutory provision laid
or preparation of On-site Emergency Plan to control disaster in the factories. Major accidents may cause
may lead to disaster, which
damage to plant, property and harm to person and create adverse affects on production. Many disasters
tragedy, Chernobyl nuclear disaster etc. have occurred at many places in the world causing heavy loss of
. Emergency situation arises all on a sudden and creates havoc and damage to person, property,
nvironment. Therefore such situations and risks should be thought in advance and it should be planned
ackle them immediately and control them within the shortest time.
ive of On-site emergency management plan (On-SEMP) is in emergency management planning is to

one knows:
hazards and risk in the plant
w to do in the event of an emergency; and
or potential and unexpected incidents at the workplace.
rgencies to plan for include fire, explosion, toxic releases, injuries and rescues in the hazardous events. Plan
istrict, state and national capacity to respond to disasters and public health emergencies, scaling up the
nerable communities in health promotion, disease prevention and disaster risk reduction.
regulations we have regulatory provisions that On-site Emergency Management Plan (On-SEMP) will be
ustrial units and Off-site Emergency Management Plan (Off SEMP) by District Collector.
prepare and keep an up-to date on-site emergency plan containing details of Manufacture, Storage and
dous Chemicals (MS&IHC) Rules 1989 and detailing how major accidents will be dealt with on the site on
ial activity is carried on and that plan will include the name of the person who is responsible for safety on the
s of those who are authorized to take action in accordance with the plan in case of an emergency. The
sure that the emergency plan prepared takes into account any modification made in the industrial activity
rson on the site who is affected by the plan is informed of its relevant provisions.
prepare the emergency plan required –

a new industrial activity, before that activity is commenced;
f an existing industrial activity within 90 days of commencing into operation of these rules.
On-site emergency can be due to the following causes
Man-made Cause Natural Cause Extraneous
Fire Flood Riots / Civil
disorder
Explosion/ Leakage Earthquake Terrorisms
Failure of critical control system Cyclone Sabotage
Design deficiency Outbreak of Bomb Threat
Disease
Unsafe Acts Extensive Rains War/Hit by 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
environment within or outside the factory. Sometimes emergency results into uncontrollable situ
towards the disaster. Such an unexpected severe situation may be too great for the normal wor
the plant. In any industry emergency can arise at any moment and this depends on the type of Structur
Machines / Plant, Nearby Industries etc.
A major emergency can be defined as an accident/ incident that have potential to cause serious injur
may cause extensive damage of property, serious disruption both in production and working o
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 t
involving only the persons working in the factory and the property inside the factory it is called as On
OFF-SITE EMERGENCY: If the accident is such that it affects inside the factory are
age or destruction to life or property or
ults into uncontrollable situations which leads
great for the normal workforce in the area within
nds on the type of Structure, Raw Materials,
ial to cause serious injuries or loss of life. It

roduction and working of factory and may
mergency.
, its effects is confined to the factory premises,

he factory it is called as On-site Emergency.
factory are
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
No
Electrical Panels, Flammable oil
storage tanks, Compressors, coolants,
paints, etc.
1 Fire / Explosion
Spillage of flammable / Hydraulic oil, Furnace Oil, Coolant etc.

Hazardous Oils &
2
coolant etc
Electrical panels, Power Distribution

Board, DG Set, Overhead Crane,
Voltage stabilizer, Electric
3 Electric Shock Transformer & Machine Operated by
electricity, etc.
Accidents – Factory (Major) Fall from height & Falling

4 of Heavy Materials, Dies, Bins or other
Heavy object.
Accident due to
5 Accidents-Transport transportation of man & material
6 Personal confinement Toilets, offices, Basement
Natural calamities
7 such as storm, earthquakes, Nature
etc.
8 Structure collapse Office building, & Any Wall or part Of
Factory building.
9 Riots, Arson, Sabotaging Anti Social elements.
premises, it is called as Off-site
fied in one or more of the
Effect
Small fires complete

equipment loss, complete Area
burn out, Air pollution, Soil
pollution, Dangers to Human
beings.
Fire, Burns, Soil pollution,

Injury by slippage
Burns, suffocation, Death.

Toxic chemical ingestion into
blood stream
Fracture
Death or Injury to Body
Suffocation
Structural collapse, Death
Serious injury, Major

Fracture, Death
Serious injury, major Fracture,
Death.
10 Toxic gas leakage Fire Hazard, Suffocation
11 TANK DYKE Fire Fire Hazard
12 Electric fire Fire Hazard
13 Office fire Fire Hazard
14 Person on flames Fire Hazard
15 Food/Water Poisoning Health Hazard
16 Bomb hoax Bomb threat

17 Burn-Minor Health Hazard
18 Electric shock casualties Health Hazard
19 Non Functioning of STP and Spillage of untreated water on ground

ETP
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-ordina
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.
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, t
gas/liquid release into the area from storage vessels or piping network, or a bomb threat. The appr
eliminate or reduce the risk of injury or harm that may occur during an evacuation by underta
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
Chemicals (MS and IHC) Rule 1989 and Chemical Accidents (Emergency Planning, Preparedness
(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
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 a
control the Emergency. He / She will wear a Red & White Helmet to confirm his identity. The General
controller. Site controller will ensure that all members of his/her team have been informed to collect
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 T
maintain a Log book of all the activities. He/she will keep in touch with the external communicat
ensure that information is sent to outside emergency services (Police and Fire Brigade). He/she w
 Attend to telephone
 Keep in touch with incident controller
 Communicate with Assembly Points
 Meet outside emergency services
 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
incident to overcome the Emergency. Shift Manager will act as Incident Controller. His responsibiliti
 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 Emer
 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 w
Assembly Point.
SAFETY OFFICER
 Will assist the Incident Controller with his special knowledge on the safety
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 t
 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
 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 Emerg
their area. Designated persons will carry out the actions detailed in the Individual Plant Emergency Pr
leader will hold a Roll call. Personnel not at their normal work place must go to the emergency
Personnel will remain at these points and await instructions from the Site Controller.
Essential Works and Team Leaders: During emergency the plants immediately affected o
determined by the Works Main Controller, need to be shut down for safety. In the area immediat
possible to isolate equipment from which flammable or toxic material is leaking. This work must be
by plant supervisors and essential operators.
Workers/ staffs need to be nominated to carry out the following essential works at the time of emerge
 Extra first aid personnel to deal with casualties.
 Emergency engineering works, provision of extra or replacement of light, isolation of equipm
electrical lines etc.
 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
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
e.g. ambulance, fire tenders etc.
For these essential jobs designated teams should be made available. The responsibilities
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
report to the emergency assembly point on this site. Personnel Manager will guide them in case
evacuation from the factory is taken.
VISITORS
Infrequent visitors are registered on each visit. They will be given a Visitors pass which includes an em
statement. The responsibility for visitors in emergency situation rests with the person being visited.
RESPONSIBILITIES OUTSIDE GENERAL SHIFT HOURS SHIFT SUPERV
He/she will act as Site controller for the time being. As soon as becomes aware of the emergency and
proceed to the scene. He will assess the scale of the incident and direct operations within the affected
He/she will contact and inform the Site Controller and Incident Controller immediately. Till t
continue to perform their duties.
He/she will contact the departmental head to act as incident controller and guide
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 resp
instructed.
INFRASTRUCTURE:
FIRE FIGHTING FACILITIES:
The plant will have adequate fire fighting aids including fire hydrants close to the required locations.
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 administe
treatment. A number of employees are trained for first aid use.
EMERGENCY CONTROL CENTRE is the point from which the Site Controller directs the movem
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 p
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
where in case of emergency personnel evacuated from the affected areas are to be assembled. The pl
workers and visitors should assemble in assembly point in case of emergency and the time of
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. Simp
operated siren – break open type, fire alarm etc. Automatic alarm may be needed for highly haza
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 e
be audible to a distance of 5 KM radius. The emergency siren should be used only in case of em
ESCAPE ROUTE: The escape route from each and every plant should be clearly marked. The
shortest route to reach out of the plant area to open area, which leads to assembly point. This route
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
the workers have to shut down the plant and move to the assembly point. The plant shut down procedu
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 offi
the details of personnel arriving at the assembly point. These should be checked with the atten
workers, contract workers present in the site on the day of emergency. The accident control should be
arrangement should be made for searching missing person in the emergency affected area. The
contact number of next to kin should be maintained in the time office so that during emergency rel
due to emergency may be informed accordingly.
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
controller about the cessation of emergency. The main controller can declare all clear by instructin
sound “All Clear Sirens”.
MUTUAL AID SYSTEM: Mutual aid scheme should be introduced among industries so that in cas
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 even
for improvement of the exercise. Exercises on On-site Emergency Planning should be monitored
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 an
time.
The onsite emergency plan so prepared shall be documented in a printed form in sufficient cop
for knowledge, study and easy follow up. The emergency plan shall be rehearsed and practiced at
test efficiency of personnel, equipments co-ordinate efforts and to increase confidence and exper
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.
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
updated information as necessary and ask for necessary help.
 SDO
 Police
 Fire Brigade
 District Hospital
 GPCB
 Factory Inspector
 Local Media
 District Magistrate
Serious injury, Death
Poisoning, Death
Explosion, Death, fear

Burn injury
Injury, Death
Land Contamination
handle the emergency are directed and co-ordinate.
rgency control are –
tory.
nufacturing records.
ter.
ne number etc.
es of industry, due to fire in a process area, tank form area, toxic
sels or piping network, or a bomb threat. The approach of the plan is to
hat may occur during an evacuation by undertaking following steps:-
ous situations;
tory provisions as per the Manufacture, Storage & Import of Hazardous

l Accidents (Emergency Planning, Preparedness and Response) [CA
regulations;
emergency;
arrying hazardous products;
is:
major accident
elevant components
ils about the site
dangerous substances.
of key personnel
ency control room
ardous chemicals at plant site:
tities and toxicological data)
if any, which could occur.
hazardous chemicals.
angers to the plant.
e effects of Accident
used during normal operation
and effect if any, of fire and explosion outside.
R ROLE FOR ONSITE EMERGENCY
bsolute control of the Factory and determines the action necessary to

White Helmet to confirm his identity. The General Manager will be the site
s of his/her team have been informed to collect at Emergency Control
Control Centre to take charge.
ive necessary instructions to Emergency Control Team. He / She will

ll keep in touch with the external communication Team. He/she will
ncy services (Police and Fire Brigade). He/she will depute people to,
side.
to the scene of emergency and supervises the actions taken at the

er will act as Incident Controller. His responsibilities will be
nt.
Officer. On hearing alarm He will proceed to Emergency Control Centre.

er and Deputy Incident Controller
phone and other communications fail
Centre
positioned in the office near gate.

s in consultation with Site Controller.
nd arrange for alternative transport if required

, contractor’s personnel, and visitors at the Gate which will act as
knowledge on the safety

azardous chemicals,
nt accident scenarios
matters to assist in the control activities
and any other immediate information needed for the people nearby
m outside
ntrol Centre or at Assembly Point

medical assistance during emergency
d.
mediately contact Site Controller

ller/Security Officer will ring Fire brigade, Police etc
ations.
emergency should proceed to/contact the Emergency Assembly Point in

ons detailed in the Individual Plant Emergency Procedure. The Roll Call
eir normal work place must go to the emergency assembly point.
uctions from the Site Controller.
ng emergency the plants immediately affected or likely to be affected, as
be shut down for safety. In the area immediately affected, it may be
le or toxic material is leaking. This work must be immediately carried out
e following essential works at the time of emergency-
extra or replacement of light, isolation of equipment, temporary by pass

f risk.
stem fails.
k force of suitable trained people for the following works-
ival of evacuated people.
d details of casualties.
on with security to direct emergency vehicle containing the gate
ould be made available. The responsibilities of the team and the

s are-
Emergency Procedures before commencing work on this site. They will

. Personnel Manager will guide them in case a major decision like
will be given a Visitors pass which includes an emergency action

cy situation rests with the person being visited.
AL SHIFT HOURS SHIFT SUPERVISOR
As soon as becomes aware of the emergency and its location, he will
incident and direct operations within the affected areas.
oller and Incident Controller immediately. Till their arrival he will
head to act as incident controller and guide

he damage.
t if necessary. Other staff with designated responsibilities will act as
ding fire hydrants close to the required locations. There will be Portable
e installed in specific places.
larm and also for ALL CLEAR signal.
ons including at the Assembly point for administering preliminary
rst aid use.
from which the Site Controller directs the movements of Personnel and
phone numbers. Below

ers
ncy Assembly Points.
called showing addresses and telephone numbers.
ups of employees.
ng.
ions.
ery).
nternal telephone and paging system, where people can wait in a
s from the Emergency Controller.
determined as assembly point
om the affected areas are to be assembled. The plant workers, contract
y point in case of emergency and the time office clerk should take
uring emergency.
ll depend on the size of the works area. Simple fire bell, hand
. Automatic alarm may be needed for highly hazardous nature of plant.
s a key component to control an emergency.
ded in the plant-
y should be different from the normal siren. The emergency siren should
emergency siren should be used only in case of emergency.
and every plant should be clearly marked. The escape route is the
area, which leads to assembly point. This route should be indicated
cy Plan.
vacuated from the emergency site. As soon as the emergency siren rings
o the assembly point. The plant shut down procedure in case of emergency
person should be nominated for the purpose.
king in the plant should be counted. Time office person should collect
point. These should be checked with the attendances of regular
day of emergency. The accident control should be informed and
ng person in the emergency affected area. The employees’ address,
ed in the time office so that during emergency relatives of those affected
n to the media and other agency.
y the Work Incident Controller will communicate to the works main
e main controller can declare all clear by instructing the time office to
uld be introduced among industries so that in case of emergency

extended.
y the Chief Executive of the industries concerned.

e requisition of materials from other industries.
ment that can be spared.
n during an emergency.
erience gained.
conducted once in 6 months and sequence of events should be recorded
ite Emergency Planning should be monitored by Factory Inspectorate
an is reviewed every year.
ties should be provided in any factory to tackle any emergency at any
documented in a printed form in sufficient copies to give all concerned

gency plan shall be rehearsed and practiced at regular intervals to
ate efforts and to increase confidence and experience to operate such
als.
of Key Personnel
es.
er.
er.
by Site Controller. The following persons and offices may be given

sary help.
Table: Important Telephone Numbers
NAME DESIGNATION CONTACT NO
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 emerge
called.
 Police help required during emergency for evacuation of the people, traffic control security
available.
 Medical help required: seriously injured personnel may be referred to the local Hospital / Nursing
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
effectiveness and adequacy of the equipments and to gain experience and confidence to impleme
finalized disaster plan
shall be given to all concerned for implementation and rehearsal for preparedness.
ne Numbers
EXT.NO (INT)
ies:
e fighting facilities but during emergency, fire brigade may be
f the people, traffic control security arrangements etc. will be
eferred to the local Hospital / Nursing Home / ESI Hospital
ensure its efficiency,

ators various service organizations evaluate the
xperience and confidence to implement the plan. The
l for preparedness.
EMERGENCY RESPONSE DIAGRAM
Message to
Site Controller
Proceeds to the Emergency

Control Centre and takes
Emergency
Decides the level of the

emergencydiscussing with Incident
Controller
Undertake a continuous review of the possible developments
and take decision accordingly
Incident Controller will rush to the

Personnel Communication incident site and takes
Manager Officer all site related
Works as Liaison
officer
Organizes all
requirements of
Emergency
Guides with
knowledge of
safety aspects
in the factory
Fire
Fighting
Deputy Incident controller will act as
assistant to Incident controller
Deals withpolice, media

andoutside enquiries
Informs
Medical
Officer
Plant officers take up duties

Involving their own units
E DIAGRAM
Safety Security
Officer Officer
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 am
Ammonia is also used in the manufacture of commercial explosives (e.g., TNT, nitroglyce
In the textile industry, ammonia is used in the manufacture of synthetic fibers (e.g., nylon an
neutralizes acidic by-products of petroleum refining, and in the rubber industry it prevents the coagula
transportation from plantation to factory. Ammonia is used in various metallurgical processes, includi
sheets to harden their surfaces. Because ammonia can be decomposed easily to yield hydrogen
portable source of atomic hydrogen for welding. In addition, ammonia can absorb substantial am
its surroundings (i.e., one gram of ammonia absorbs 327 calories of heat), which makes it useful as a c
and air-conditioning equipment. Ammonia used commercially is often called anhydrous ammonia. Ho
solution of anhydrous ammonia (NH3) and water.
PHYSICAL & CHEMICAL PROPERTIES / DEFINITION OF CHEMICAL GROU
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
Inhalation: May be harmful if inhaled. Material is extremely destructive to the 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
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
 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
Neoprene gloves are recommended.
 NOTE: Consult with your preferred glove manufacturer to ensure that the gloves you plan on usin
Ammonia.
EYE PROTECTION: Wear chemical splash goggles or a face shield to protect from splash hazards a
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 an
handling the product.
ENGINEERING CONTROLS: Handle using a chemical fume hood with good ventilation and electr
and equipment.
FIRST AID PROCEDURES
If inhaled…Move to fresh air and give oxygen. If the person is not breathing, give artificial respiratio
mouth contact.
In case of skin contact…Remove all contaminated clothing. Immediately (within seconds) flush a
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 hospita
If swallowed…DO NOT INDUCE VOMITING. Never give anything by mouth to an unconscious p
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 sa
 Ensure you are wearing the following minimum PPE: tightly fitting safety goggles and fac
resistant lab coat, full length pants, close-toe rubber or leather shoes, gloves constructed with nitrile
 Lab emergency contact information must be readily posted. Easy access to a cellular phone o
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 ve
personnel to safe areas. Do not attempt clean-up without minimum PPE. Beware of vapors
form explosive concentrations. Vapors can accumulate in low areas.
ENVIRONMENTAL PRECAUTIONS: Prevent further leakage or spillage – if safe to do so. Do n
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 coll
protected vacuum cleaner or by wet-brushing and place in container for disposal according to regulati
 Immediately assess amount spilled, follow posted Emergency Response Guide procedu
materials incidents.
 If a chemical exposure has occurred, a fellow worker shall call Emergency number and E
 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 materi
 Label and tag as hazardous waste and submit a pick-up request to EH&S using EHS As
DECONTAMINATION / WASTE DISPOSAL PROCEDURE

LABEL WASTE: Attach a completed Hazardous Waste tag to all waste containers as soon as the firs
to the container.
STORE WASTE
 Store hazardous waste in closed containers, in secondary containment and in a designated storage
 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 pr
laboratory personnel specific to the hazards involved in working with this substance, work area dec
emergency procedures.
 The Principal Investigator must provide his/her laboratory personnel with a copy of SOP and a co
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, neces
extended to the Authority.
*******
STANDARD OPERATING PROCEDURE (EHS
PROJECT
(NH3)
lied directly to the soil or in the form of ammonium salts.

mmercial explosives (e.g., TNT, nitroglycerin, and nitrocellulose).
ufacture of synthetic fibers (e.g., nylon and rayon). It also
in the rubber industry it prevents the coagulation of raw latex during
ed in various metallurgical processes, including the nitriding of alloy
an be decomposed easily to yield hydrogen, it is a convenient
ddition, ammonia can absorb substantial amounts of heat from
calories of heat), which makes it useful as a coolant in refrigeration
cially is often called anhydrous ammonia. Household ammonia is a
DEFINITION OF CHEMICAL GROUP
destructive to the tissue of the
s skin burns.
PPE)
cle respirator with type N100 (US) respirator cartridges.
ng circumstances:
dministrative controls have been exhausted).
ed or when there is a possibility that PEL will be exceeded.
ospheric contaminant (in the absence of PEL)

ess
per glove removal technique to avoid any skin contact. Nitride or
urer to ensure that the gloves you plan on using are compatible with
a face shield to protect from splash hazards and chemical vapors.
s, and clothing. Wash hands before breaks and immediately after
al fume hood with good ventilation and electrically grounded lines
erson is not breathing, give artificial respiration. Avoid mouth to
lothing. Immediately (within seconds) flush affected area for
Use nearest emergency

ue eye rinse during transport to the hospital.
r give anything by mouth to an unconscious person.
IREMENTS
ns.
pproved / certified emergency eyewash and safety shower.

PPE: tightly fitting safety goggles and face shield, flame
leather shoes, gloves constructed with nitrile or neoprene.
ily posted. Easy access to a cellular phone or land line is readily
vapors, mist or gas. Ensure adequate ventilation. Evacuate

hout minimum PPE. Beware of vapors accumulating to
in low areas.
r leakage or spillage – if safe to do so. Do not allow product to
oided.
NT AND CLEAN-UP: Consider
it is available. Contain spillage and the collect with an electrically
n container for disposal according to regulations.
posted Emergency Response Guide procedures for hazardous
worker shall call Emergency number and EH&S department.

ve PPE if not already being worn.
pill to prevent spread of the chemical.
contain the spill. Bag the collected material.
mit a pick-up request to EH&S using EHS Assistant.
L PROCEDURE
e tag to all waste containers as soon as the first drop of waste is added
dary containment and in a designated storage location.

s.
ting and disposing of it.
n 90 days.
equest system.
Principal Investigator or designee must provide to his/her

in working with this substance, work area decontamination, and
ratory personnel with a copy of SOP and a copy of the MSDS
will be educated on the emergency in a

al and District Authorities. However, necessary information can be
e Authority.
***
G PROCEDURE (EHS)
ECT
PROJECT MANAGEMENT CONSULTANCY SERVICES F
REPLACEMENT OF SINGLE WALL AMMONIA STORAGE TANK B
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

REV REV DATE EFF.DATE PURPOSE
Al
CONTENT
CY SERVICES FOR
ORAGE TANK BY DOUBLE
AT
ARUCH
RS & CHEMICALS
A
TANT
A LIMITED
PURA, VADODARA
TAV KMS SNY

PREPD REVWD APPD
All rights reserved
CLAUSE
1 .0
2 .0
3 .0
3.1
3.1 .1
3.1 .2
3.1 .3
3.1 .4
3.1 .5
3.1 .6
3.1 .7
3.1 .8
3.1 .9
3.1 .10
3.1 .11
3.1 .12
3.1 .13
3.1 .14
3.2
3.3
3 .3 .1
3 .3 .2
3 .3 .3
3 .3 .4
3 .3 .5
3 .3 .6
3 .3 .7
3. 3 .8
3.3 .9
3.3.2010
3.3.2011
3.3.2012
3.3.2013
3.3.2014
3.3.2015
3.3.2016
3.3.2017
3.3.2018
3.3.2019
TITLE PAGE
NO.
Scope 6
References 6
Requirement of Health, Safety and Environment (HSE) 7
Management System to be complied by Bidders
Management Responsibility 7
HSE Policy & Objective 7
Management System 7
Indemnification 7
Deployment & Qualification of Safety Personnel 7
Implementation, Inspection & Monitoring 10
Behavior Based Safety 12
Awareness & Motivation 14
Fire prevention & First-Aid 14
Documentation 15
Audit 15
Meetings 16
Intoxicating drinks & drugs and smoking 17
Penalty 18
Accident/Incident investigation 21
House Keeping 22
HSE Measures 23
Construction Hazards 23
Accessibility 25
Personal Protective Equipments (PPEs) 26
Working at height 27
Scaffoldings & Barricading 29
Electrical installations 30
Welding/Gas cutting 34
Ergonomics and tools & tackles 35
Occupational Health 36
Hazardous substances 37
Slips, trips & falls 38
Radiation exposure 38
Explosives/Blasting operations 39
Demolition/Dismantling 39
Road Safety 40
Welfare measures 41
Environment Protection 42
Rules & Regulations 42
Weather Protection 43
3.3.2020
3.3.2021
3.3.2022
3.3.2023
3.3.2024
3.3.2025
3.3.2026
3 .4
3 .5
3 .6
3 .7
3 .8
3 .9
4 .0
4 .1
4 .2
4 .3
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
ABREVATIONS
AERB : Atomic Energy Regulatory Board
ANSI : American National Standards Institute BARC : Bhabha Atomic Resea
BS : British Standard
PDIL : Projects & development India Limited ELCB : Earth Leakage Circuit
EPC : Engineering, Procurement and Construction
EPCC : Engineering, Procurement, Construction and Commissioning ESI :
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 :
SCC : Special Conditions of Contract
SLI : Safe Load Indicator
TBM : Tool Box Talks/Meeting
1.0 SCOPE
This specification establishes the Health, Safety and Environment (HSE) management
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
effective HSE system for construction activities and the contractor is expected to fulfill HSE requ
specification as a minimum. It is expected that contractor shall implement best HSE practi
mentioned in this specification.
Requirements stipulated in this specification shall supplement the requirements of HSE Managem
Act(s)/legislations, General Conditions of Contract (GCC), Special Conditions of Contract (S
(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 M
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 c
organization to ensure health, safety and environment aspects in their line of operations. HSE
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 a
fulfill them, including but not limited to what are specified under clause 1.0 and 2.0 abov
shall obtain the approval of its site specific HSE Plan from PDIL /Owner prior to commenceme
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
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
Supervisor / Safety Steward shall substitute deployment of Safety Officer / Safety Engineer wha
relevant statute of BOCW Act i.e. deployment of safety officer /Safety Engineer is com
site. The Safety supervisors, Safety stewards etc. would facilitate the HSE tasks at grass
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 preferabl
Certificate (of Class XII with Physics & Chemistry etc.) and trained in fire-fighting as well
safety/occupational health related subjects, with minimum two year of practical experience
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 posses
in Science (with Physics & Chemistry) or a diploma in Engineering or Technology with min
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
construction work in supervisory capacity for a period of not less than two years, or pos
diploma in any branch of Engineering or Technology with practical experience of building or
in supervisory capacity for a period of not less than five years.
 Recognized degree or diploma in Industrial safety with one paper in Construction
 Preferably have adequate knowledge of the language spoken by majority of the workers at the
 Person possessing Graduation Degree in Science with Physics & Chemistry and degree or
Safety (from any Indian institutes recognized by AICTE or State Council of Tech. Educatio
with practical experience of working in a building, plant or other construction works (as Safety O
Indian Factories Act, 1958) for a period of not less than five years, may be considered as S
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
experience (in HSE discipline), may be designated as HSE In-Charge. Duties & responsibil
be commensurate with that of relevant statute and primarily to coordinate with top management
contractors. In case the statutory requirements i.e. State or Central Acts and / or Rules as
Building and Other Construction Workers’ Regulation of Employment and Conditions of S
State Rules (wherever notified), the Factories Act, 1948 or Rules (wherever notified), etc.
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
shall be started at any of the project sites until above safety personnel & concerned Site
are physically deployed at site. The Contractor shall submit a HSE organogram clearly
of responsibility and reporting system and elaborate the responsibilities of safety personnel
The Contractor shall verify & authenticate credentials of such safety personnel and furnish
Curriculum Vitae of the safety personnel as above for PDIL/Owner’s approval, at least 1 mon
mobilization. The Contractor, whenever required, shall arrange submission of origin
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 re
deploying competent safety officer at site. Adequate planning and deployment of safety personne
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 monitorin
and compliance of all laws & statutory requirements. The Contractor shall also ensure that th
are clearly understood & implemented conscientiously by their site personnel at all levels at site.
 The Contractor shall ensure physical presence of their field engineers/sup
continuation of their contract works /site activities including all material transportation acti
absence of experienced field engineers / supervisors of Contractor at critical work spot dur
may invite severe penalization as per the discretion
of EIC, including halting / stoppage of work.
 Contractor shall furnish their annual Inspection Plan, with regard to project issues /subj
performers to PDIL /Owner.
 The Contractor shall regularly review inspection report internally and implement al
for improving the status continuously.
 The Contractor shall ensure important safety checks right from beginning of works at every w
this effect “Daily Safety Check List” shall be prepared by field engineer & duly checked by
conformance.
 The Contractor shall carry out inspection to identify various unsafe conditions of work sites/
as well as unsafe acts on the part of workmen/supervisor /engineer while carrying out dif
works.
 Adequate records for all inspections shall be maintained by the Contractor and the same
PDIL /Owner, whenever sought.
 The Contractor shall not carry-out work by engaging single worker anywhere without any sup
day or night.
 To demonstrate involvement/commitment of site management of Contractor, at least one Sa
a month shall be carried out by Contractor’s head of site (along with his area manager/field en
shall be furnished to PDIL/Owner “Safety walk through report” followed by compliance for unsa
 As a general practice lifting tools/tackles, machinery, accessories etc. shall be inspected, test
competent people (approved by concerned State authorities) before being used at site and als
(e.g. during replacement, extension, modification, elongation / reduction of machine / p
relevant statutes. Hydra, cranes, lifting machinery, mobile equipments / machinery / vehicl
inspected regularly by only competent / experienced personnel at site and requisite records
shall be maintained by every contractor.
Contractor shall also maintain records of maintenance of all other site
machinery (e.g. generators, rectifiers, compressors, cutters, etc.) & portable tools /equipments
related works (e.g. drills, abrasive wheels, punches, chisels, spanners, etc.). The Contractor sha
arbitrarily fabricated ‘derricks’ at project site for lifting / lowering of construction material
 Site facilities /temporary installations, e.g. batching plant, cement go down, DG-room, t
panels/distribution boards, shot-blasting booth, fabrication yards, etc. and site welfare fac
colonies, canteen/pantry, rest-shelters, motorcycle/bicycle-shed, site washing facilities, First-aid
etc. should be periodically inspected by Contractor (preferably utilizing HR /Admin person
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
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 fo
risk behaviors Intervene with workers to give positive reinforcement when safe behaviors’ a
 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.
 Change behaviors to be observed or change activators or change consequences as app

 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 ap
/Owner.
 The HSE committee of contractor shall observe individual’s behavior for safe practices adap
/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.
 Regular awareness programs and fabrication shop / work site meetings at least on mo
arranged on HSE activities to cover hazards/risks involved in various operations during con
 Contractor to motivate & encourage the workmen & supervisory staff by issuing / awar
gifts/ mementos/ monetary incentives / certificates, etc.
 Contractor shall assess & recognize the behavioral change of its site engineers / su
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
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
sand & water and adequate number of appropriate portable fire extinguishers (Refer Appendix
satisfaction of PDIL /Owner.
 The Contractor shall deploy trained supervisory personnel / field engineers to cater to any em
 In case the number of workers exceeds 500, the Contractor shall position an Ambulance / ve
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
supervisory personnel & engineers. The Contractor shall maintain adequate record of such f
site.
3 .1.9 Documentation
The Contractor shall evolve a comprehensive, planned and documented system
covering the following as a minimum for implementation and monitoring of the HSE requi
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 o
thereof. The Contractor shall get similar HSE requirements implemented at his sub-contrac
However, compliance of HSE requirements shall be the responsibility of the Contractor. A
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 cover
minimum:
 Internal HSE audits regularly at least on quarterly basis by engaging internal qualified auditor
/Construction personnel having 5 years experience in construction safety and Lead Auditor C
certification).
 External HSE audits regularly at least on every six months by engaging qualified exte
safety officers/Construction personnel having 10 years experience in construction safety and Le
Course :OSHA 18001 certification). All HSE shortfalls/non-conformances on HSE matters
brought out during review /audit shall be resolved forthwith (generally within a
week) by Contractor & compliance report shall be submitted to PDIL /Owner. In addition to
contractor, the contractor’s work shall be subjected to HSE audit by PDIL /Owner at a
during the pendency of contract. The Contractor shall take all actions required to comply with
Audit Report and issue regular Compliance Reports for the same to Owner /PDIL till all the
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 Cons
Resident Engineer / Project Manager / Site- in-Charge) in Safety Committee/ HSE Committee
PDIL/Owner usually on monthly basis or as and when called for. In case Contractor’s top
site is not in a position to attend such meeting, he shall inform PDIL/Owner in writing befor
such meeting indicating reasons of his absence and nominate his representative – failu
very stringent penalization against the specific Contractor, as deemed fit in Contract. T
compliance of any observations during the meeting shall be always time bound. The Contra
PDIL/Owner to achieve the targets set by them on HSE management during the project implemen
 In addition, the Contractor shall also arrange internal HSE meetings chaired by his top most e
weekly basis and maintain records. Such internal HSE meetings shall essentially be attended
supervisors (& not by safety personnel only) of the Contractor and its associates. Records
meetings shall be maintained by
the Contractor for review by PDIL/Owner or for any HSE Audits.
 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) sha
intoxication during working hours and shall abide by any law relating to consumption & posse
drinks or drugs in force.
 The Contractor shall not allow any workman to commence any work at any locations of pro
influenced / effected with the intake of alcohol, drugs or any other intoxicating items being consu
work or working day.
 Awareness about local laws on this issue shall form part of the Induction Training and
discipline.
 The Contractor shall ensure that all personnel working for him comply with “No-Smok
the Owner as notified from time to time. Cigarettes, lighters, auto ignition tools or applia
intoxicating drugs, dry tobacco powder, etc. shall not be allowed inside the project / plant
complex.
 Smoking shall be permitted only inside smoking booths exclusively

designated & authorized by the Owner /PDIL.
Communication 43
Confined Space Entry 44
Heavy Lifts 44
Key performance indicators 45
Unsuitable Land Conditions 46
Under Water Inspection 47
Excavation 47
Tool Box talks 48
Training & Induction Program 49
Additional safety requirements for working Inside a running plant. 51
Self Assessment and Enhancement 53

HSE Promotion 53
LOTO for isolation of energy source 53
Details of HSE Management System by Contractor 54
On Award of Contract 54
During Job Execution 55
During short listing of the sub-contractors 57
APPENDICES
Standards/Codes on HSE Appendix-A
Details of First AID Box Appendix-B
Types of Fire Extinguishers & their Appln. Appendix-C
Indicative List of statutory Acts & Rules Appendix-D
Training subjects / topics Appendix-E
List of HSE procedures Appendix-F
REVATIONS
ERB : Atomic Energy Regulatory Board
NSI : American National Standards Institute BARC : Bhabha Atomic Research Centre
S : British Standard
DIL : Projects & development India Limited ELCB : Earth Leakage Circuit Breaker
PC : Engineering, Procurement and Construction
PCC : Engineering, Procurement, Construction and Commissioning ESI : Employee State
surance
CC : General Conditions of Contract GM : General Manager
TAW : Gas Tungsten Arc Welding HOD : Head of Department
SE : Health, Safety & Environment
V : High Voltage
: Indian Standard
: Indian Electricity
A : Job Safety Analysis
OTO : Lock Out & Tag Out
PG : Liquefied Petroleum Gas
STK : Lump Sum Turn Key
V : Medium Voltage
E : Personal Protective Equipment
CM : Resident Construction Manager or Site-in-Charge, as applicable ROW : Right of Way
CC : Special Conditions of Contract
LI : Safe Load Indicator
BM : Tool Box Talks/Meeting
COPE
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
Requirements of HSE Management system to be complied by Bidders

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
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
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
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.
 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
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.
 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.
 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
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
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.
 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.
 Smoking shall be permitted only inside smoking booths exclusively

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3 .1.13 Penalty
The Contractor shall adhere consistently to all provisions of HSE requirements. In case of non c
repeated failure in implementation of any of the HSE provisions, PDIL /Owner may impose stopp
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 the contract value for Item Rate,
0 .5 % (Zero decimal five percent) of the contract value for LSTK, EPC, EPCC This penalty shal
other penalties specified elsewhere in the contract. The decision of imposing stop-work-ins
imposition of penalty shall rest with PDIL /Owner. The same shall be binding on
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
No.
For not using personal protective equipment (Helmet, Shoes,
1 Goggles, Gloves, Full body harness, Face shield, Boiler suit, etc.)
2 Working without Work Permit / Clearance

3 Execution of work without deployment of requisite field engineer /
supervisor at work spot.
4 Unsafe electrical practices (not installing ELCB, using poor joints of
cables, using naked wire without top plug into socket, laying wire /
cables on the roads, electrical jobs by incompetent person, etc.)
5 Working at height without full body harness, using

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 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 ends.
8 No fencing /barricading of excavated
areas/trenches.
Not providing shoring /strutting /proper slope and
9 not keeping the excavated earth at least 1.5 M away from excavated
area.
Non display of scaffold tags, caution boards, list of hospitals,
10 emergency services available at work
locations.
Traffic rules violations like over speeding of vehicles, rash driving,
talking on mobile phones during vehicle driving, wrong parking, not
11 using
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 whenever called by PDIL / Owner & failure to
12 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
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 Program, Site HSE Training and HSE
14 audit at predefined frequencies (as approved in HSE Plan).
Failure to submit the monthly HSE report by 5th of

15 subsequent month to Project’s Engineer-in-Charge / Owner
Liquor/alcohol/ drugs/ Intoxicating drinks etc. carrying or

consumption inside port premises.
16
17 Failure to report & follow up accident (including

Near Miss) reporting system within specific
timeframe.
18 Degradation of environment (not confining toxic 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 allowing them to work in noise polluted
19 areas, made 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 site, unsafe rigging practices, non-availability of
20 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 & external), close-

21 out of identified shortfalls of
Observations of Safety Aspects(OSA),etc
22 Carrying out sand blasting instead of grit / shot
blasting
23 Failure to deploy adequately qualified and competent Safety Officer
Utilization of hydra/ back-hoe loader for material

24 shifting or any other unauthorized /unsafe lifting works
Any incident / accident at project site has been caused because of

willful negligence or gross violation of safety measures / provisions
on the part of the Contractor or any of its sub-agencies (Fatal
25 ,Major Accidents)
26 Poor Housekeeping
27 Any violation not covered above
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
various HSE requirements. Safety lapses /defects of project construction site shall be attribu
job supervisor /engineer of the Contractor, (who remains directly responsible for safely executing
repeated HSE violations, concerned job supervisor /engineer shall be reprimanded or appro
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 w
his first HSE violation. A written warning shall be issued on second violation & Fine will
training shall be arranged / provided by the Contractor to enhance HSE awareness/skill including
mistakes/ flaws. Any further violation of HSE stipulations by the erring individuals sh
forthright debar from the specific construction site and fine will be 10 times higher. A record of
worker / employee shall be maintained by the Contractor, like by punching their cards / Ga
displaying their names at the Project entry gate. Warnings, penalizations, appreciations etc. shall
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
writing within 24 hours as applicable, by Contractor. Thereafter, a Supplementary Accident /
Report shall be submitted to PDIL / Owner within 72 hours. Near Miss incidents, Danger
shall also be reported within 24 hours. The accident/ incident shall be investigated by a
senior Site personnel (involving Site-in- Charge or at least by his deputy) for establishing
recommending corrective & preventive actions. Findings shall be documented and suitable ac
recurrences shall be
communicated to PDIL / Owner. Owner/ PDIL shall have the liberty to
independently investigate such occurrences and the Contractor shall extend all necessary help an
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 ensu
 All surplus earth and debris are removed /disposed off from the working areas to designated l
 Unused /surplus cables, steel items and steel scrap lying scattered at different places wi
are removed to identify locations.
 All wooden scrap, empty wooden cable drums and other combustible packing materials, shall
place to identified locations.
 Roads shall be kept clear and materials like pipes, steel, sand, boulders, concrete, chips
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
movement.
 Utmost care shall be taken to ensure over all cleanliness and proper upkeep of the working ar
 Trucks carrying sand, earth and pulverized materials etc. shall be covered while moving
/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 b
 At least two exits for any unit area shall be assured at all times – same arrangement
pits /trench excavation /elevated work platforms /confined spaces etc.
 Welding cables and the power cable must be segregated and properly stored and used .The sa
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 bas
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 & Environme
of work he is going to undertake and enlist mitigation measures. Contractor shall carry out J
(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
 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
 Erection of pipes (full length or fabricated) at height more than 2.0 Mts. height with Crane
 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 c
 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).
 Pneumatic Tests
 Card board blasting
 Chemical cleaning and take feedback from PDIL /Owner. The necessary HSE measures de
place, prior to start of an activity & also shall be maintained during the course of works, by th
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
including provisions of suitable and sufficient scaffolding at various stages during all operation
safety of his workmen and PDIL /Owner.
 The Contractor shall implement use of all measures including use of “life line”, “fall arresters
arresters” , “safety nets” etc. during the course of using all safe accesses & exits, so that in no cas
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 proced
/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 l
safety helmets preferably with head &
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 EN
goggles, gloves, ear muffs, respiratory protective devices, etc. All these gadgets shall conf
Specifications /CE or other applicable international standards. The Contractor shall implement a
inspecting physical conditions of the PPEs being issued /used by the workmen of their own &
the damaged / unserviceable PPEs shall be replaced forthwith.
 Owner /PDIL may issue a comprehensive color scheme for helmets to be used by vario
Contractor shall follow the scheme issued by the Owner /PDIL and shall choose any colour other
or blue (for PDIL) All HSE personnel shall preferably wear dark green band on their helmet so
approach them for guidance during emergencies. HSE personnel shall preferably wear
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 protectiv
Such protective clothing should conform relevant IS Specification.
 For off-shore jobs/contracts, contractor shall provide PPEs (new) of all types to PDIL & Ow
(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 (co
IS mark /CE standard) by their staff, workmen & visitors including their subcontractors a
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)
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 t
also undertake to ensure compliance to the conditions of the permit during the currency of
adherence of personal protective equipments. Contractor’s Safety Officer shall verify com
items of permit document after implementation of action is completed by Contractor’s e
engineers at work site. Job Safety Analysis (JSA) for specific works at height duly commented b
be kept attached with particular Permit for Work (PFW) at site for ready reference & fol
shall be initially issued for one single shift or expected duration of normal work and exten
duration, if required. PDIL /Owner can devise block-permit system at any specific area, in consul
specific HSE Committee to specify the time-period of validity of such PFW or
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
Area Coordinators may verify and counter sign this permit (as an evidence of verification
of the job.
 All personnel shall be medically examined & certified by registered doctor, confirming
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,
Engineers may exercise their authority to cancel such permit and stop the work till satisfa
/rectification is arranged made. Contractors are expected to maintain a register for issuance of pe
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 h
are to be used while climbing
/descending tall structures or vessels /columns etc. These arresters should lock automaticall
line, restricting free fall of the user. The device is to be provided with a double security opening s
attachment or release of the user at any point of rope. In order to avoid shock, the system shoul
keeping the person in vertical position in case of a fall.
 The Contractor shall ensure that Full body harnesses conforming EN361 and having authoriz
by all personnel while working at height. The lanyards and life lines should have enough
take the load of the worker in case of a fall. One end of the lanyard shall be firmly tied with the
other end with life line. The harness should be capable of keeping the workman vertical in cas
him to rescue himself.
 The Contractor shall provide Roof Top Walk Ladders for carrying out activities on sloping ro
chances of slippages and falls.
 The Contractor shall ensure that a proper Safety Net System is used wherever the haza
present. The safety net, preferably a knotted one with mesh ropes conforming to IS 5175 /ISO 11
rope & tie cord of minimum 12mm dia. The Safety Net shall be located not more than 6.0 meters
surface extending on either side up to sufficient margin to arrest fall of persons working at differe
 In case of accidental fall of person on such Safety Net, the bottom most portion of Sa
any structure, object or ground.
 The Contractor shall ensure positive isolation while working at different levels like in the pipe
working platforms with toe boards & hand rails shall be sufficiently strong & shall have sufficien
workmen and tools & tackles including the equipments required for executing the job. Such wor
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 fr
solid construction except such short period work that can be safely done using ladders or certified
person) man-basket. When a ladder is used, an extra workman shall always be engaged for
 The Contractor shall ensure that the scaffolds used during construction activities shall b
the designed load. Main Contractor shall always furnish duly approved construction-design d
SWL (from competent designers) free of charge, before they are being installed /construct
/PDIL reserves the right to ask the
Contractor to submit certification and or design calculations from his Head
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
GREEN tag (duly signed by competent Scaffolding Inspector) on each scaffold found s
(duly signed by competent Scaffolding Inspector) on each scaffold found unsafe. Scaffolds
shall be permitted to be used and Scaffolds with RED ones shall immediately be made inacce
found continuing on scaffolds with RED tag shall be considered unauthorized work by Contracto
penalization from PDIL/Owner. For every 120- 125 m/m area / volume or 2/3 its parts there of m
be provided.
 The Contractor shall ensure positive barricading (indicative as well as protective)
radiography, heavy lift, high pressure hydrostatic & pneumatic testing and other such areas. Suffi
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
following codes/standards, in addition to the requirements of Statutory Authorities and IE/a
rules &
regulations:
- OISD STD 173: Fire prevention & protection system for electrical installations
- SP 30 (BIS) : National Electric Code
 All electrical installations shall be approved by the concerned statutory authorities.
 All temporary electrical installations/facilities shall be regularly checked by the licensed/com
the Contractor and appropriate records shall be maintained. Inspection of temporary electri
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 &
(duly approved by PDIL/Owner) shall be pasted on the front face of DBs (distribution boards) /JB
every site.
 Ensure that electrical systems and equipment including tools & tackles used during construc
properly selected, installed, used and maintained as per provisions of the latest revision
Electrical / applicable international regulations.
 Shall deploy qualified & licensed electricians for proper & safe installation and for regular
construction power distribution system /points including their earthing. A copy of the lic
submitted to PDIL
/Owner for records. Availability of at least one competent (ITI qualified) / licensed electric
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 rai
shed shall be elevated from the existing ground level to avoid water logging inside the shed. Inst
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
equipment/switchboard. Adequate clearances and operational space shall be provided around the
extinguishers and insulating mats shall be provided in all power distribution centers.
 Temporary electrical equipment shall not be employed in hazardous area without obtain
 Proper housekeeping shall be done around the electrical installations.
 All temporary installations shall be tested before energizing, to ensure proper earthing, bondin
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 a
point. The operating height of the main switch shall not exceed 1.5 M. The main switch sha
point of supply by means of armored cable.
 The outgoing feeders shall be double or triple pole switches with fuses/ MCBs. Loads
shall be balanced as far as possible and load on neutral should not exceed 20% of load in the phas
 The installation shall be adequately protected against overload, short circuit and earth leakag
protective devices. Fuses wherever used shall be HRC type. Use of re-wired fuses shall be strictly
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
 All single phase sockets shall be minimum 3 pin type only. All unused sockets shall be provid
 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.
 Only metallic distribution boxes with double earthing shall be used at site. No wooden boxes
 All power cables shall be terminated with compression type cable glands. Tinned copper lugs
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
cables shall be laid over a sand layer and covered with sand, brick & soil for ensuring m
Cables shall not be laid in waterlogged area as far as practicable. Cable route markers sha
every 25 M of buried trench route. When laid above ground, cables shall be properly cleared o
poles of at least 2.1 M high. Minimum head clearance of 6 meters shall be provided at road cross
road crossings for cables shall be avoided to the extent feasible. In any case no underground
allowed to cross the roads without pipe sleeve.
 An independent earthing facility should preferably be established within the temporary
All appliances and equipment shall be adequately earthed. In case of armored cables, the ar
the earthing system.
 All cable joints shall be done with proper jointing kit. No taped /temporary joints shal
 All cables and wire rope used for earth connections shall be terminated through tinned
 In case of local earthing, earth electrodes shall be buried near the supply point and ea
shall be connected to local earth plate for further distribution to various appliances. Al
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.
 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 ins
cylinders as well as at the torch end of the gas hose, while in use. All cylinders shall be mou
provided with a closing key. Empty & filled-up gas cylinders shall be stored separately with TAG
direct sun or rain. Minimum 2 nos. of Portable DCP type fire extinguishers (10 kg) shall be main
stores. Stacking & storing of compressed gas cylinders shall be arranged away from DG set
Panels /Elec. boards, etc
 The burner and the hose placed downstream of pressure reducer shall be equipped with
/Non Return Valve device.
 The hoses for acetylene and oxygen cylinders must be of different colours. Their conne
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 concurren
 All welding machines shall have effective earthing at least at distinctly isolated two points. In
good housekeeping, and to reduce fire hazard, live electrode bits shall be contained safely and sh
on the ground.
 The hoses of Acetylene and Oxygen shall be kept free from entanglement & away from comm
and preferably be hanged overhead in such a manner which can avoid contact with cranes, hydra
construction machinery.
 Hot spatters shall be contained /restricted appropriately (by making use of effective fir
and their flying-off as well as chance of contact with near-by flammable materials shall be st
 The Contractor shall arrange adequate systems & practices for accumulation
/collection of metal & other scraps and remnant electrodes and their safe disposal at regula
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, exp
health.
 All lifting tools, tackles, equipment, accessories including cranes shall be tested periodi
/competent authority for their condition and load carrying capacity. Valid test & fitness ce
applicable authority shall be submitted to Owner /PDIL for their review /acceptance before
equipment, accessories and cranes are used.
 The contractor shall not be allowed to use defective equipment or tools not adhering to safety
 Contractor shall arrange non-sparking tools for project construction works in operating plant
areas.
 Wherever required the Contractor shall make use of Elevated Work Platforms (EWP) or Aeri
(mobile or stationary) to avoid ergonomically risks and workmen shall be debarred to board such
the course of their shifting /transportation.
 Contractor shall ensure installation of Safe Load Indicator (SLI) on all cranes (while in use)
overloading risk. SLI shall have capability to continuously monitor and display the load o
automatically
compare it with the rated crane capacity at the operating condition of the
crane. The system shall also provide visual and audible warnings at set capacity levels to a
of violations.
 The contractor shall be responsible for safe operations of different equipments mo
him at the workplace like transport vehicles, engines, cranes, mobile ladders, scaffoldings, wo
 The Contractor shall arrange periodical training for the operators of hydra,
crane, excavator, mobile machinery, etc. at site by utilizing services from renowned manuf
3 .3.9 Occupational Health

 The contractor shall identify all operations that can adversely affect the health of its workers a
mitigation measures.
 For surface cleaning operations, sand blasting shall not be permitted even if not explicitly stat
contract.
 To eliminate radiation hazard, Tungsten electrodes used for Gas Tungsten Arc Welding
Thorium.
 Appropriate respiratory protective devices (hood with respiratory devices) shall be used
inhalation of air borne contaminants like silica, asbestos, gases, fumes, etc.
 Workmen shall be made aware of correct methods for lifting, carrying, pushing & pulli
Wherever possible, manual handling shall be replaced by mechanical lifting equipments.
 For jobs like drilling /demolishing /dismantling where noise pollution exceeds the specified li
muffs shall be provided to the workers.
 To avoid work related upper limb disorders (WRULD) and backaches, Display Screen Equip
stations shall be carefully designed & used with proper sitting postures. Power driven hand-h
maintained
in good working condition to minimize their vibrating effects and personnel
using these tools shall be taught how to operate them safely & how to maintain good bloo
 The Contractor shall arrange health check up (by registered medical practitioner)
the time of induction. Health check may have to be repeated if the nature of duty assign
necessitating health check or doubt arises about his wellness. PDIL/Owner reserves the righ
submit medical test reports. Regular health check-ups are mandatory for the workers assigne
Radiography, Blasting, Painting, Heavy Lift and Height (>2m) jobs. All the health check-u
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, duri
project span.
 Regular distribution of standard quality soap / sanitizer to all employees of the company for H
 Provided Medical facilities to employees & their dependent family members including H
companies authorized reputed hospitals. An in- house dispensary facility is available with part
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 s
materials shall be stored in appropriate containers preferably with lids having spillage catchment
stored in a good ventilated area. These containers shall be labeled with the name of the material
hazards associated with its use and necessary precautions to be taken. Respective MSDS (Materia
shall be made available at site & may be
referred whenever problem arises.
 Where contact or exposure of hazardous materials are likely to exceed the specified lim
harmful effects, appropriate personal protective equipments such as gloves, goggles
chemical resistant clothing, respirator, etc. shall be used.
 The work place shall be checked prior to start of activities to identify the location, ty
any asbestos materials which could be disturbed during the work. In case asbestos materia
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
the workplace to help minimize the risk of slips, trips & falls. The contractor shall take posit
keeping the work area tidy, storing waste in suitable containers & harmful items separately, keep
stairways, entrances & exits especially emergency ones clear, cleaning up spillages immed
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, in
or similar other physical agents shall be provided with adequate shielding or protection comm
exposure involved.
 For Open Field Radiography works, requirements of Bhabha Atomic Research Cen
Energy Regulatory Board (AERB) shall be
followed.
 The Contractor shall implement an effective system of control (as described in the AERB regulations) at site for
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) w
The Contractor shall obtain license from Chief Controller of Explosives (CCOE) for collection
of explosives as well as for carrying out blasting operations.
 The Contractor shall prepare exclusive method statement (in cognizance with statutory requir
unfired explosives, if any, at project site before carrying out actual task. Nowhere blasting shall b
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
working practices.
 The contractor shall disconnect service lines (power, gas supply, water, etc.)/ make alternate
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
shall depute an experienced engineer for supervision and shall make adequate arrange
& First-Aid during the execution of these activities.
 The Contractor shall arrange approved Job Safety Analysis (JSA) /Method Statement fo
demolition /dismantling task and corresponding action plan commensurate with hazards /risks
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 s
 The Contractor shall also ensure a separate pedestrian route for safety of the workers and com
& regulations, including maintaining speed limit of 20 kmph or indicated by owner for all types o
machinery. The maximum allowable speed shall be adhered to.
 The vehicles shall be fitted with reverse warning alarms & flashing lights /fog- lights and usa
ensured.
 In case of an alert or emergency, the Contractor must arrange clearance of all the routes, roa
Contractor shall deploy sufficient number of traffic controllers at project site routes /roads
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
colony to & from project sites.
 Hydras shall only be allowed for handling the materials at fabrication /storage yards and in no
transport the materials over project / plant roads.
 The Contractor shall not deploy any such mobile machinery / equipments,
Signalman. Such machinery /equipments shall have effective limit-switches, reverse-alarm, a
lights etc. and shall be maintained in good working order.
 The Contractor shall not carry-out maintenance of vehicles /mobile machinery occupying spa
roads and shall always arrange close supervision for such works.
 For pipeline jobs, the contractor shall submit a comprehensive plan covering transportation,
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 year
 Adequately ventilated /illuminated rooms at labour camps & its hygienic up- keeping. Reaso
at site and in labour camps at appropriate location depending upon site conditions. Contra
“industrial” variety of LPG cylinder & satisfactory illumination at the canteens. Necessary
efficient disposal of wastes from canteens & urinals /toilets shall also be made and regu
made to maintain the ambience satisfactorily hygienic & shall also comply with all applic
requirements. Adequately lighted & ventilated Rest rooms at site (separate for male workers an
Urinals, Toilets, washing facilities, adequate lighting at site and labour camps, comme
Laws /Legislation.
 Providing water, milk, Lemon water, glucose etc. to employees working at
heat treatment & Dusty areas.
 Provided purified drinking water to all employees of company.
 Providing of Personal Protective equipment as per requirement of employees according to their respectiv
 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 detrimen
Where required, Contractor shall ensure that only the environment friendly materials are sele
recycling of waste materials, such as metals, plastics, glass, paper, oil & solvents. The wa
minimized, reused or recovered shall be stored and disposed of safely. In no way, toxic spills
percolate into the ground. The contractor shall not use the empty areas for dumping the waste
strive to conserve energy and water wherever feasible.
The contractor shall ensure dust free environment at workplace by sprinkling water on the
intervals. The air quality parameters for dust, poisonous gases, toxic releases, harmful radiatio
by the contractor on daily basis and whenever need arises.
The contractor shall not be allowed to discharge chemicals, oil, silt, sewage, sullage and o
directly into the controlled waters like surface drains, streams, rivers, ponds. A discharge plan
methods of treating the waste before discharging shall be submitted to PDIL /Owner for a
For pipeline jobs, top soil shall be stacked separately while making ROW through fields. This fer
back on top after backfilling. For offshore construction barges, arrangements shall be made fo
human,
food & other wastes and applicable laws in this regard shall be followed.
3 .3.18 Rules & Regulations

All persons deployed at site shall be knowledgeable of and comply with the environmenta
regulations relating to the hazardous materials, substances and wastes. Contractor shall
otherwise discharge or disposes off any such materials without the express authorization of PDIL
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, so
poisonous gases, dust, etc. by ensuring proper usage of PPEs like Sun glasses, Sun screen loti
masks, etc. and rearranging /planning the construction activities to suit the weather co
arrangement (without creating inconvenience to project facilities & permanent installations) fo
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 communica
incident can be reported immediately and assistance sought by them. All health & safety
communicated in a simple & clear language easily understood by the local workforce. For
typical subjects that should be communicated
are: -
Inside the company (Top to down)

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
into confined space, must be medically examined & certified by registered doctor, confirm
fitness for working in confined space’. All necessary precautions mentioned therein shall be adh
shall be positioned outside a confined space for extending help during an emergency. All
air quality parameters shall be checked before entering a confined space. It shall be ensure
equipment which has to be opened is pressure-
free by checking that blinds are in place, vents are open and volume is drained.
Inside confined space works, only electrical facilities /installations of 24V shall be permitted. Co
usage of safe & suitable arrangement of oxygen supply for individual workmen (during th
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 pri
which cannot be erected with a crane of approx. 100 Ton capacities due to constraints of i
of foundation height, approach & weight. Contractor shall generate the format for “Permit
erection” Prior to actual lifting activities; contractor shall check the validity of the crane inspe
statutory / competent authority. This requirement shall also apply to all rigging equipments utilize
 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 ever
with the help of a registered medical practitioner & record shall be maintained Adequate safety m
barricading, usage of appropriate PPEs, permit to work, etc. shall be taken during all heavy or cri
 For lifting any material (irrespective of shape, size or volume), at any height, it is always ad
Plan of Erection (POE) taking into consideration hazards & risks associated therein – this c
their own experiences of various natures & side-by-side establish a practical method for risk
contractor shall prepare POE & shall document the same, when risks are identified as “medium”
and the same shall be approved by its competent /qualified engineer.
3 .3.23 Key Performance Indicators

The contractor shall measure an activity in both leading & trailing indicators for statistical and
measurement. The activities pertaining to key performance indicators are covered in Month
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 :-
- 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, m
Contractor shall make right assessment and take all necessary action for developing work area
suitable for crane operations or other vehicular movement before carrying out any project related
Contractor shall take all necessary actions to make the surroundings of its site establishments
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 & in
be certified seaworthy by a recognized classification society. It shall be equipped with all
like life jackets, adequate fire protection arrangements and shall posses’ communication facilitie
wireless, walkie-talkie. All divers used for seabed surveys, underwater inspections shall have
license, suitable life saving kit. Number of hours of work by divers shall be limited as pe
/Owner shall have the right to inspect the boat and scrutinize
documents in this regard.
3 .3.26 Excavation
The Contractor shall obtain permission from competent authorities prior to excavation wher
Contractor shall locate the position of buried utilities (water line, cable route, etc.) by referrin
drawing / in consultation with PDIL /Owner. The Contractor shall start digging manually
position of buried utilities & thereafter use mechanical means. The Contractor shall keep soil h
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 pr
bench as decided by PDIL /Owner.
The Contractor shall arrange “battering” or “benching” wherever required for preventing co
excavations.
The Contractor shall identify & arrange de-watering pump or well-point system to prevent earth c
rain /influx of underground water.
The Contractor shall arrange protective fencing / barricading with warning signal around excavat
along with minimum 2 (two) entries, exits / escape ladders.
The Contractor must avoid “underpinning” /under-cutting to prevent collapse of chunk of e
The Contractor shall use “stoppers” to prevent over-run of vehicle wheels at the edge of excavate
The Contractor shall arrange strengthening of “shoring” & “strutting” proactively to avoid collap
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 cond
supervisor of the workers The
Contractor shall conduct TBT before start of every morning or evening shift or night shift
the workers on specific hazards and their appropriate dos & don’ts. The Contractor shall prov
site workmen and their foremen to avert fatigue & thereby endangering their lives
during the course of site works.
provisions of HSE requirements. In case of non compliances and also for
he HSE provisions, PDIL /Owner may impose stoppage of work without any
mpose a suitable penalty.
faulted Contractor shall be up to a cumulative limit of 2 .0 % (Two percent)
ract value for LSTK, EPC, EPCC This penalty shall be in addition to all
ract. The decision of imposing stop-work-instruction and
IL /Owner. The same shall be binding on the Contractor.
Contractor eligible to
Contractor on different types of HSE
Penalty Amount
Rs 500/- per day/ Item / Person.
Rs 20,000/- per occasion.

Rs. 5,000/- per violation per day
Rs 5,000/- per item per day.
Rs. 5,000/- per case per day.
Rs 500/- per item per day.
Rs. 3,000/- per occasion.

Rs. 3,000/- per occasion
Rs.5,000/- per occasion
Rs.1,000/- per occasion per day
Rs. 2,000/- per occasion per day
Rs5,000/- per meeting
Rs 5,000/- per month
Rs.10,000/- per occasion.

and Rs. 1,000/- per day of further
delay.
Rs 1,000 & warning letter on 1st
offence,
Rs 2,500 & termination of worker on 2nd
offence.
Rs10,000/- per occasion
Rs 5,000/- per occasion per worker

Rs. 50,000/- per day
Rs. 10,000/- per day per Officer
Rs 25,000/- per occasion
Rs 10,00,000/- per occasion (1st Instant)

Rs 15,00,000/- per occasion (2nd Instant)
Termination of present Contract (3rd
instant)
Rs. 5,000/- per occasion per day
To be decided by PDIL/Owner.
d engineers/supervisors fully aware of the fact

orkmen for their behavior and compliance of
defects of project construction site shall be attributable to the concerned
ho remains directly responsible for safely executing field works). For
pervisor /engineer shall be reprimanded or appropriate action, as deemed
L & Owner) by the concerned Contractor.
h fine and verbal warning shall be given to the worker/employee during
shall be issued on second violation & Fine will be double and specific
ontractor to enhance HSE awareness/skill including feedback on the
f HSE stipulations by the erring individuals shall call for his
on site and fine will be 10 times higher. A record of warnings for each
the Contractor, like by punching their cards / Gate passes or by
e. Warnings, penalizations, appreciations etc. shall be discussed in HSE
ractor.
n
PDIL / Owner at least telephonically by Contractor immediately and in
Contractor. Thereafter, a Supplementary Accident / Incident investigation
r within 72 hours. Near Miss incidents, Dangerous accidents / incident
he accident/ incident shall be investigated by a team of Contractor’s
arge or at least by his deputy) for establishing root-cause and
s. Findings shall be documented and suitable actions taken to avoid
L shall have the liberty to
nd the Contractor shall extend all necessary help and cooperation in this
side world.
gree of housekeeping is maintained and shall ensure the followings:
disposed off from the working areas to designated locations.
steel scrap lying scattered at different places within the working areas
ums and other combustible packing materials, shall be removed from work
s like pipes, steel, sand, boulders, concrete, chips and bricks etc shall not
ment of men & machineries.
materials shall be stacked properly for erection.
ed.
and trailers etc shall be allowed on roads, which may obstruct the traffic
all cleanliness and proper upkeep of the working areas.

zed materials etc. shall be covered while moving within the plant area
surface wet.
phere in plant area and on roads is
, etc. by keeping the top surface wet for ease in breathing.
all be assured at all times – same arrangement is preferable for digging
ms /confined spaces etc.
be segregated and properly stored and used .The same shall be laid away
rom obstruction.
o be firmed up and implemented on regular basis for maintaining high
of all Occupational Health, Safety & Environmental hazards in the type

ist mitigation measures. Contractor shall carry out Job Safety Analysis
al jobs like.
r cold (incl. colour washing, painting, insulation etc.) & hot works.
pth > 2.0 mts.)

Plant.
ultiple pour) for columns, parapets & roofs.
ne.
oof-trusses /pipes at height more than 2.0 Mts. with or without crane.
ted) at height more than 2.0 Mts. height with Crane of 100T capacity.
nical pulling.
ndem Lifting).
lifting equipments (hydra, crane etc.).
n deep narrow trenches– manually or mechanically.
uction of crane-boom on roads or in yards.
t using 100T crane or of higher capacity
umns and water-flushing.
d)
ircuits
rations
2.0 Mts.)
(+2.0 Mts.)
llic sheet over roof /structures.
vessels at heights (+2.0 Mts) with & without using cranes.
and functional tests at yards / work- sites.
coupling) & Compressors.
ace.
ignments into project areas.
ls
by Gas-burners).
rom PDIL /Owner. The necessary HSE measures devised shall be put in to
all be maintained during the course of works, by the Contractor. Copies of
work sites by the
g out checks /verification.
of access(in sufficient numbers) & efficient exit to any working place

ent scaffolding at various stages during all operations of the work for the
measures including use of “life line”, “fall arresters”, “retractable fall

e of using all safe accesses & exits, so that in no case any individual remains
plex shall be strictly regulated. Any

hall undergo identification check, as per the procedures in force
erned by specific system /regulation,
(PPEs)
taff, workers and visitors including
ecords to be kept) & wear appropriate PPEs like nape strap type
of industrial HDPE), safety shoes
body harness (CE marked and conforming to EN361), protective
ective devices, etc. All these gadgets shall conform to applicable IS
tional standards. The Contractor shall implement a regular regime of
being issued /used by the workmen of their own & also its sub-agencies and
placed forthwith.
ve color scheme for helmets to be used by various agencies. The
the Owner /PDIL and shall choose any colour other than white (for Owner)
eferably wear dark green band on their helmet so that workmen can
ncies. HSE personnel shall preferably wear such dresses with
uring night, when light falls on them.
ve face shield and helmets, gauntlet and protective clothing is mandatory.
vant IS Specification.
all provide PPEs (new) of all types to PDIL & Owner's personnel, at his
life jacket at all time.
is given under Appendix-A.
age of following safety equipments/ accessories (conforming to applicable
men & visitors including their subcontractors all through the span of
mmissioning:-
gloves, Safety Shoes, etc)
ess than 8.0 mm)
ngths)
pe) – 6 kg capacity
with eyelets)
king (PFW) at height after verifying and certifying the checkpoints. He shall
onditions of the permit during the currency of the permit including
ts. Contractor’s Safety Officer shall verify compliance status of the
ntation of action is completed by Contractor’s execution / field
SA) for specific works at height duly commented by PDIL /Owner, shall
Work (PFW) at site for ready reference & follow-up. Such PFW
t or expected duration of normal work and extended further for balance
block-permit system at any specific area, in consultation with project
eriod of validity of such PFW or
areas where specific clearance
t. is not required. PDIL /Owner’s field Engineers /Safety Officers /
sign this permit (as an evidence of verification) during the execution
ned & certified by registered doctor, confirming their ‘medical fitness for
all be done once in six months.
ing sufficient precautions as given in the permit, PDIL /Owner
cancel such permit and stop the work till satisfactory compliance
re expected to maintain a register for issuance of permit and extensions
its for verification during audits etc.
st) and ensure use of Fall Arrester Systems by his workers. Fall arresters
mns etc. These arresters should lock automatically against the anchorage
e is to be provided with a double security opening system to ensure safe
of rope. In order to avoid shock, the system should be capable of
se of a fall.
harnesses conforming EN361 and having authorized CE marking is used
The lanyards and life lines should have enough tensile strength to
ne end of the lanyard shall be firmly tied with the harnesses and the
d be capable of keeping the workman vertical in case of a fall, enabling
alk Ladders for carrying out activities on sloping roofs in order to reduce the
per Safety Net System is used wherever the hazard of fall from height is
ne with mesh ropes conforming to IS 5175 /ISO 1140 shall have a border
afety Net shall be located not more than 6.0 meters below the working
nt margin to arrest fall of persons working at different heights.
such Safety Net, the bottom most portion of Safety Net should not touch
ion while working at different levels like in the pipe rack areas. The
ls shall be sufficiently strong & shall have sufficient space to hold the
uipments required for executing the job. Such working platforms shall
ple
workmen for all works that cannot be safely done from the ground or from
ork that can be safely done using ladders or certified (by 3rd party competent
d, an extra workman shall always be engaged for holding the ladder.
affolds used during construction activities shall be strong enough to take
ays furnish duly approved construction-design details of scaffold &
charge, before they are being installed /constructed at site. Owner
esign calculations from his Head

g load carrying capacity of the scaffoldings.
petent Scaffolding Inspector of the Contractor. He shall paste a
Scaffolding Inspector) on each scaffold found safe and a RED tag
pector) on each scaffold found unsafe. Scaffolds with GREEN tag only
th RED ones shall immediately be made inaccessible. Work being
hall be considered unauthorized work by Contractor and may invite
0- 125 m/m area / volume or 2/3 its parts there of minimum one TAG shall
barricading (indicative as well as protective) of the excavated,

atic & pneumatic testing and other such areas. Sufficient warning signs shall
ffolding shall be constructed using
shall be carried out as per the provisions of latest revision of

he requirements of Statutory Authorities and IE/applicable international
n & protection system for electrical installations

Code
oved by the concerned statutory authorities.
ties shall be regularly checked by the licensed/competent electricians of
l be maintained. Inspection of temporary electrical booth/installation at
ords are to be made available to
following requirements:
) for providing connection to each equipments & machinery and the same
ed on the front face of DBs (distribution boards) /JBs (Junction boxes) at
ent including tools & tackles used during construction phase are
intained as per provisions of the latest revision of the Indian
ns.
ans for proper & safe installation and for regular inspection of
points including their earthing. A copy of the license shall be
t one competent (ITI qualified) / licensed electrician (by State Elec.

clock to attend to the normal /emergency jobs.
be kept in well-ventilated & covered shed /with rain shed protection. The
d level to avoid water logging inside the shed. Installation of electrical
prevention of shock and safety of machine.
for constructing the shed. Also
and around electrical
and operational space shall be provided around the equipment. Fire
vided in all power distribution centers.
ot be employed in hazardous area without obtaining safety permit.
d the electrical installations.
before energizing, to ensure proper earthing, bonding, suitability of
o be ensured for all electrical

e by the contractor:
with a protective device, installed in an enclosure adjacent to the metering

h shall not exceed 1.5 M. The main switch shall be connected to the
or triple pole switches with fuses/ MCBs. Loads in a three phase circuit
n neutral should not exceed 20% of load in the phase.
cted against overload, short circuit and earth leakage by the use of suitable
be HRC type. Use of re-wired fuses shall be strictly prohibited. The earth
t not exceeding 30 mA.
g receptacles shall be taken through proper switches, sockets and plugs.
m 3 pin type only. All unused sockets shall be provided with socket caps.
ed flexible cables with minimum
d for all single phase hand tools.
ble earthing shall be used at site. No wooden boxes shall be used.
compression type cable glands. Tinned copper lugs shall be used for multi-
amage.
50 mm for MV & control cables and 900 mm for HV cables. These
covered with sand, brick & soil for ensuring mechanical protection.
ea as far as practicable. Cable route markers shall be provided at
aid above ground, cables shall be properly cleared or supported on rigid
learance of 6 meters shall be provided at road crossings. Underground
to the extent feasible. In any case no underground power cable shall be
.
preferably be established within the temporary installation premises.
dequately earthed. In case of armored cables, the armor shall be bonded to
per jointing kit. No taped /temporary joints shall be used.

h connections shall be terminated through tinned copper lugs.
des shall be buried near the supply point and earth continuity wire
further distribution to various appliances. All insulated wires for
n colour.
utral. Earth /Structures shall not be
clearly designated /painted for easy

estors conforming to BS: 6158 or equivalent are installed on all gas
hose, while in use. All cylinders shall be mounted on trolleys and
up gas cylinders shall be stored separately with TAG, protecting them from
e DCP type fire extinguishers (10 kg) shall be maintained at the gas cylinder
gas cylinders shall be arranged away from DG set, hot works, Elect.
tream of pressure reducer shall be equipped with Flash Back Arrester
linders must be of different colours. Their connections to cylinders and
be closed and hoses depressurized.

oxygen & acetylene, shall require written concurrence from Owner.
earthing at least at distinctly isolated two points. In order to help maintain
live electrode bits shall be contained safely and shall not be thrown directly
be kept free from entanglement & away from common pathways /walkways
manner which can avoid contact with cranes, hydra or other mobile
ed appropriately (by making use of effective fire retardant cloth/fabric)
ontact with near-by flammable materials shall be stopped.
tems & practices for accumulation
mnant electrodes and their safe disposal at regular interval so as to
actorily clean & tidy.
on at all times when not in use.
en, tasks commensurate with their qualification, experience and state of
cessories including cranes shall be tested periodically by statutory

d load carrying capacity. Valid test & fitness certificates from the
Owner /PDIL for their review /acceptance before the lifting tools, tackles,
defective equipment or tools not adhering to safety norms.

s for project construction works in operating plant areas /hydrocarbon prone
ake use of Elevated Work Platforms (EWP) or Aerial Work Platforms

risks and workmen shall be debarred to board such elevated platform during
e Load Indicator (SLI) on all cranes (while in use) to minimize

to continuously monitor and display the load on the hook, and
t the operating condition of the

l and audible warnings at set capacity levels to alert the operator in case
for safe operations of different equipments mobilized and used by

s, engines, cranes, mobile ladders, scaffoldings, work tools, etc.
training for the operators of hydra,
site by utilizing services from renowned manufacturers.
that can adversely affect the health of its workers and issue & implement
ting shall not be permitted even if not explicitly stated elsewhere in the
electrodes used for Gas Tungsten Arc Welding shall not contain
es (hood with respiratory devices) shall be used to protect workmen from

a, asbestos, gases, fumes, etc.
ect methods for lifting, carrying, pushing & pulling of heavy loads.
replaced by mechanical lifting equipments.
ntling where noise pollution exceeds the specified limit of 85 decibels, ear
s (WRULD) and backaches, Display Screen Equipments' workplace

d with proper sitting postures. Power driven hand-held tools shall be
eir vibrating effects and personnel

operate them safely & how to maintain good blood circulation in hands.
check up (by registered medical practitioner) for all the workers at
ave to be repeated if the nature of duty assigned to him is changed
about his wellness. PDIL/Owner reserves the right to ask the contractor to
heck-ups are mandatory for the workers assigned with Welding,
t and Height (>2m) jobs. All the health check-ups shall be conducted
rds are to be maintained by the Contractor.
of all the workers including their families, during the course of entire
ap / sanitizer to all employees of the company for Hygienic up keeping.

s & their dependent family members including Hospitalization at
n in- house dispensary facility is available with part time doctor and trained
s health.
such as solvent coating, thinners, anti termite solutions, water proofing

preferably with lids having spillage catchment trays and shall be
shall be labeled with the name of the materials highlighting the
autions to be taken. Respective MSDS (Material Safety Data Sheet)
s materials are likely to exceed the specified limit or otherwise have
tective equipments such as gloves, goggles / face-shields, aprons,
all be used.
to start of activities to identify the location, type and condition of
urbed during the work. In case asbestos material is detected, usage of
ured and the matter shall be
cleaning and basic housekeeping program that covers all aspects of

f slips, trips & falls. The contractor shall take positive measures like
uitable containers & harmful items separately, keeping passages,
ergency ones clear, cleaning up spillages immediately and replacing
& falls.
ts such as ionizing & non-ionizing radiation, including ultraviolet rays

ovided with adequate shielding or protection commensurate with the type of
requirements of Bhabha Atomic Research Centre (BARC) /Atomic

ol (as described in the AERB regulations) at site for handling radiography-
voiding its misuse & theft.
Permit for radiation work” before start of work.
has to be carried out at day time, suitable
hat other works, people are not affected.
s
per latest Explosive Rules (Indian / International) with prior permission.
f Controller of Explosives (CCOE) for collection, transportation, storage
ng operations.
thod statement (in cognizance with statutory requirements) for diffusing
e carrying out actual task. Nowhere blasting shall be carried out by the
ent of competent supervisor and
shing/ dismantling practices at all stages of work to guard against unsafe
es (power, gas supply, water, etc.)/ make alternate arrangements prior to

as directed by PDIL /Owner at no extra cost.
ntling work, the contractor shall take
mp jobs in operating plants where
r supervision and shall make adequate arrangements for Firefighting
activities.
Job Safety Analysis (JSA) /Method Statement for the specific
ding action plan commensurate with hazards /risks associated therein. In no
mantling shall be carried out by the
/field engineer.
ly planned road transport safety management system.

e pedestrian route for safety of the workers and comply with all traffic rules
mit of 20 kmph or indicated by owner for all types of vehicles /mobile
all be adhered to.
arning alarms & flashing lights /fog- lights and usage of seat belts shall be
ractor must arrange clearance of all the routes, roads, access. The
of traffic controllers at project site routes /roads /accesses, to alert
as well as pedestrians.
d to carry workers within the plant area and also to & from the labour
the materials at fabrication /storage yards and in no case shall be allowed to

ds.
uch mobile machinery / equipments,
hall have effective limit-switches, reverse-alarm, and front & rear-end
working order.
nance of vehicles /mobile machinery occupying space on project /plant
vision for such works.
mit a comprehensive plan covering transportation, loading /unloading of
ent of vehicles on the ROW, etc.
oad signs, diversion boards, caution
nt of men and machinery.
ollowing facilities at work sites:

workers are having children below the age of 6 years.
at labour camps & its hygienic up- keeping. Reasonable canteen facilities
location depending upon site conditions. Contractor shall make use of
isfactory illumination at the canteens. Necessary arrangement for
s & urinals /toilets shall also be made and regular review shall be
ly hygienic & shall also comply with all applicable statutory
ted Rest rooms at site (separate for male workers and female workers).
ate lighting at site and labour camps, commensurate with applicable
lucose etc. to employees working at

ng water to all employees of company.
quirement of employees according to their respective working areas.
as been provided to all employees for safe
om their residence to workplace & back.
ilization methodology of materials that are detrimental to the environment.

only the environment friendly materials are selected and emphasize on
ls, plastics, glass, paper, oil & solvents. The waste that cannot be
ored and disposed of safely. In no way, toxic spills shall be allowed to
ll not use the empty areas for dumping the wastes. The contractor shall
ver feasible.
onment at workplace by sprinkling water on the ground at frequent
ust, poisonous gases, toxic releases, harmful radiations, etc. shall be checked
need arises.
charge chemicals, oil, silt, sewage, sullage and other waste materials
drains, streams, rivers, ponds. A discharge plan suggesting the
arging shall be submitted to PDIL /Owner for approval.
arately while making ROW through fields. This fertile soil shall be placed
nstruction barges, arrangements shall be made for safe disposal of
is regard shall be followed.

wledgeable of and comply with the environmental laws, rules &
ials, substances and wastes. Contractor shall not dump, release or
materials without the express authorization of PDIL/Owner. An indicative
is given
to protect workers from severe storms, rain, solar radiations,

oper usage of PPEs like Sun glasses, Sun screen lotions, respirators, dust
construction activities to suit the weather conditions. Effective
e to project facilities & permanent installations) for protecting workmen
e at site.
ll have access to effective means of communication so that any untoward

stance sought by them. All health & safety information shall be
ge easily understood by the local workforce. For information to all,
d
or HSE Management
safety defects
y provisions, if any
lls
rts)
it before entering a confined space. People, who are permitted to enter

amined & certified by registered doctor, confirming their ‘medical
cessary precautions mentioned therein shall be adhered to. An attendant
ce for extending help during an emergency. All appropriate PPEs and
ore entering a confined space. It shall be ensured that the piping of the
ure-
s are open and volume is drained.
acilities /installations of 24V shall be permitted. Contactor shall ensure
xygen supply for individual workmen (during the course of work in
less than 19.5% (v/v) there.
ging studies plan for PDIL/ Owner approval prior to lifting equipment
pprox. 100 Ton capacities due to constraints of its dimensions, location
Contractor shall generate the format for “Permit for heavy lift /critical
ontractor shall check the validity of the crane inspection certificate issued by
ent shall also apply to all rigging equipments utilized for the job.
nsible for all rigging activities.
s of all workmen who are engaged
tc. and such fitness checks shall be carried-out every six months interval
ner & record shall be maintained Adequate safety measures such as positive
t to work, etc. shall be taken during all heavy or critical lifts.
ape, size or volume), at any height, it is always advisable to prepare a
ideration hazards & risks associated therein – this can enable people to put
& side-by-side establish a practical method for risk-free erection /lifts. The
nt the same, when risks are identified as “medium” or “high”
ent /qualified engineer.
th leading & trailing indicators for statistical and performance
o key performance indicators are covered in Monthly HSE Report. The
ir record and strive for its continual improvement.
-out at site (for workmen & staff members)

out.
carried-out by site-head.
entified per contractor & closed-out in time.
ted (in-house / with contractors)
al & external) vis-à-vis non conformances raised
d at site for supervisors & workmen
ational program conducted by contractors
ons to workmen, job supervisors & field engineers.
quency rate, severity rate, LTA free man-hours, etc

ture, severity, types etc.)
spect to :-
nt
d necessary work permits

ound marshy areas, river crossings, mountains, monuments, etc. The
d take all necessary action for developing work areas to make them safe &
r movement before carrying out any project related activity /operation.
make the surroundings of its site establishments (site office, stores, lay-
er means used for transportation, surveying & investigation works shall

ssification society. It shall be equipped with all life saving devices
ngements and shall posses’ communication facilities like cellular phones,
seabed surveys, underwater inspections shall have required authorized
hours of work by divers shall be limited as per regulations. PDIL
and scrutinize
m competent authorities prior to excavation wherever required. The
utilities (water line, cable route, etc.) by referring to project /plant
er. The Contractor shall start digging manually to locate the exact
mechanical means. The Contractor shall keep soil heaps at least 1.5 M away
whichever is more).
ngle of repose” during excavation – shall also provide slope or suitable
r “benching” wherever required for preventing collapse of edge of
atering pump or well-point system to prevent earth collapse due to heavy
g / barricading with warning signal around excavated pits, trenches, etc.

cape ladders.
/under-cutting to prevent collapse of chunk of earth during excavation
t over-run of vehicle wheels at the edge of excavated pits /trenches.
f “shoring” & “strutting” proactively to avoid collapse of earth /edges due to
kers prior to start of work and shall

gested format is given below. The TBT is to be conducted by the immediate
of every morning or evening shift or night shift activities, for alerting
appropriate dos & don’ts. The Contractor shall provide sufficient rests to the
atigue & thereby endangering their lives
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 m
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 th
works and how to carry-out safely and the same should not be inter mixed with Tool Box Ta
this regard careful action should be made & maintained for imparting HSE
induction to every individual, irrespective of his task /designation /level of
employment, whereas, HSE Training should be imparted to specific person / group of people who
specific task more than once – for example, Riggers must be trained for working at heights,
trained for work in confined space, fitters/carpenters, mesons must be trained for work at heights,
 Contractor shall conduct Safety induction program on HSE for all his workers and maintain r
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 t
proceeding to site and make necessary arrangements to issue appropriate PPEs like Apron
goggles & safety shoes etc., to his visitors. The Contractor shall always maintain relevan
from visitor on providing him brief information on HSE actions.
 Contractor shall ensure that all his personnel possess appropriate training to carry out the as
training should be imparted in a language understood by them and should specifically be train
- 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
- 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
activities & their safe-guarding utilizing experienced persons /outside agency /faculty. A progr
(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 undergon
survival training including use of lifeboats, basket landing, use of radio communication etc. from
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, Liftin
Height, Electrical work and Radiography work from Owner.
 The contractor shall monitor record and compile list of his workers entering the operatio
day and ensure & record their return after completing the job.
 Contractor’s workers and staff members shall use designated entrances and proceed by desig
areas only assigned to them. The workers shall not be allowed to enter units' area, tanks
etc. without work authorization permit.
 Work activities shall be planned in such a way so as to minimize the disruption of oth
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 us
prior approval of the Owner.
 Specific training on working in a hydrocarbon plant shall be imparted to the work force and m
carried out for Rescue operations /First- Aid measures.
 Proper barricading /cordoning of the operational units /plants shall be done before start
activities. No unauthorized person shall be allowed to trespass. The height and overall design
structure shall be finalized in consultation with the Owner and shall be got approved from t
 Care shall be taken to prevent hitting underground facilities such as electrical cables, hydroca
execution of work.
 Barricading with water curtain shall be arranged in specific /critical areas where hydro
likely to be present such as near Horton spheres or tanks. Positioning of fire tenders (fro
ensured during execution of critical activities.
 Emergency evacuation plan shall be worked out and all workmen shall be apprised ab
Mock drill operations may also be conducted.
 Flammable gas test shall be conducted prior to any hot work using appropriate
Sewers, drains, vents or any other gas escaping points shall be covered with flame retardant ta
 Respiratory devices shall be kept handy while working in confined zones where there
inhalation of poisonous gases. Constant monitoring of presence of Gas /Hydrocarbon shall b
 Clearance shall be obtained from all parties before starting hot tapping,
patchwork on live lines and work on corroded tank roof. Positive isolation of
line/equipment by blinding for welding/cutting/grinding shall be done. Closing of valve will not b
for isolation.
 Welding spatters shall be contained properly and in no case shall be allowed to fall on the gro
Similar care shall be taken during cutting operations.
 The vehicles, cranes, engines, etc. shall be fitted with spark arresters on the exhaust pipe and
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
 Gas detectors should be installed in gas leakage prone areas as per requirement of Own
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 imp
systems.
3. 8 HSE Promotions
The contractor shall encourage his workforce to promote HSE efforts at workplace
workshops /seminars /training programs, celebrating HSE awareness weeks & National Safe
quizzes & essay competitions, distributing pamphlets, posters & material on HSE, providing ince
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
 Contractor shall follow the LOTO /Isolation procedure of owner for all energy source isolatio
purview by /of owner i.e. “Brown field” For the other entire energy source (not under purview of
“Green field” Contractor shall develop a system to ensure the isolation of equipments, pipelines,
from the energy source covering following as minimum:-
- Identification of all energy source viz electrical, mechanical, hydraulic, pneumatic, chem
gravitational, radiation and other forms of stored or kinetic energy.
- Establishing the energy isolation devices viz: manually operated electrical circuit breakers, dis
blind flanges, etc
- Lock Out and Tag out log book
- Installation of Lock Out devices for preventing the inadvertent release of stored energy and Ta
(“Danger”, “Do Not operate” or Do not Remove” tags) to indicate that testing, maintenance
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, pum
supervisors, etc.
Contractor shall ensure that all the sources are locked out and tagged properly before givin
job.
After the completion of job, contractor shall ensure all tools and tackles are removed and nobod
working area and signing on LOTO log book.
Only on confirmation of above the contractor will remove their lock and tag from the isolat
instructions for energizing the same. Only the person carrying out the task shall himself carry the
/Lock out.
4. 0 DETAILS OF HSE MANAGEMENT SYSTEM BY CONTRACTOR

On Award of Contract
The Contractor shall submit a comprehensive Health, Safety and Environment
approval by PDIL /Owner prior to start of work. The Contractor shall participate in the pr
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 handlin
scaffolding, electric installations, etc. describing the risks involved, actions to be taken an
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 b
3.0. Contractor shall also ensure:
 To arrange workmen compensation insurance, registration under ESI Act, third party liability insurance, re
 Identify access, analyze & mitigate the construction hazards & incorporate relevant con
actually executing site works. (HIRAC = Hazard Identification, Risk Analysis and Control).
 Arrange testing, examination, inspection of own as well as borrowed construction
(stationary & mobile) before being used at site and also at periodical interval, through own resour
party competent agencies (as deemed fit in statutes). Records of such test, examination etc. shall
submitted to PDIL /Owner as & when asked for.
 Carryout audits /inspection (internal & external) at his works as well as sub contractor wor
HSE plan /procedure /program & submit the compliance reports of identified shortfalls for PD
 Arranging HSE training for site workmen (of his own & sub contractors) through inter
periodical intervals.
 Assistance & cooperate during HSE audits by PDIL /Owner or any other 3 rd party and subm
Generate & submit of HSE records
/report as per this specification.
 Carry-out all dismantling activities safely, with prior approval of PDIL/Owner representativ
 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
During Short Listing of the Sub-Contractors

The contractor shall review the HSE management system of the sub-contractors in line with the r
specification. The contractor shall be held responsible for the shortcomings observed in the HSE
of the sub-contractor(s) during execution of the job.
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 an
- 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
industrial accidents
- IS: 3696 Safety Code of scaffolds and ladders
- IS: 4083 Recommendations on stacking and storage of construction materials and comp
- 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
- 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 s
- 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, DI
- 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 123
Highway, Arlington VA 22202 - USA)
- Full body harness : EN-361, ANSI Z 359.1
- Lanyard : EN-354
- Karabiner : EN-362 and EN-12275
AP
en.
These records shall be made available to
ppraising them about the methodology of

ixed with Tool Box Talks or HSE Training. In
g HSE
n / group of people who are to carry-out that
working at heights, welders must be
ned for work at heights, etc.
workers and maintain records. The Gate Pass
nduction program.
h are required to be taken before their
iate PPEs like Aprons, hard hats, ear-plugs,
ways maintain relevant acknowledgement
ng to carry out the assigned job safely. The

ld specifically be trained about
moke
ning on various topics related to various

gency /faculty. A program for Safety Training
its HSE Plan.
eployed have undergone a structured sea
ommunication etc. from an agency acceptable
G INSIDE A
t:
Confined Space, Lifting activities, Work at
s entering the operational plant /unit each
and proceed by designated routes to work

ter units' area, tanks area, pump rooms,
e the disruption of other activities being
at are intended to be used at site and shall take
to the work force and mock drills shall be
l be done before starting the construction

ght and overall design of the barricading
e got approved from the Owner.
ctrical cables, hydrocarbon piping during
cal areas where hydrocarbon vapors are

g of fire tenders (from owner) shall also be
shall be apprised about evacuation routes.
rk using appropriate measuring instruments.

with flame retardant tarpaulin.
ed zones where there is a danger of
s /Hydrocarbon shall be done.
pping,
of
sing of valve will not be considered sufficient
owed to fall on the ground containing oil.
n the exhaust pipe and got it approved from
r use to blow off dirt on the floor.

per requirement of Owner's plant operation
yed to
ough self
ities for continual improvement in the HSE
efforts at workplace by way of organizing

weeks & National Safety Day, conducting
on HSE, providing incentives for maintaining
energy source isolations and installed/under
(not under purview of client/owner) i.e.
equipments, pipelines, Vessel, electrical panels
aulic, pneumatic, chemical, thermal,
cal circuit breakers, disconnection switches,
of stored energy and Tag Out devices

testing, maintenance or servicing is
is removed.
s at substations, pump house, units, etc,
d properly before giving clearance to start the
re removed and nobody is present in the
and tag from the isolation points and give

shall himself carry the key for the lock in
ty and Environment Plan or program for
all participate in the pre-start meeting with
ties including handling of equipments,

actions to be taken and methodology for
E activities.
E requirements.
s.
g but not limited to as brought out under para

party liability insurance, registration under BOCW Act, etc, as applicable. To arrange all HSE permits before start of activities (as applicable),
corporate relevant control measures before
nalysis and Control).
borrowed construction equipments / machinery
val, through own resources and also by 3 rd
examination etc. shall be maintained & shall be
as sub contractor works as per approved

tified shortfalls for PDIL /Owner review.
ntractors) through internal or external faculty at
er 3 rd party and submit compliance report.
L/Owner representative.
s do not
or probability of “fire” incident exists.
actors in line with the requirements given in this

gs observed in the HSE management system
ated
ric and gas welding and cutting operations

.
sive grinding wheels.
& cutting operation.
s for industrial injuries and classification of
on materials and components at site
ices in electrical works
es)
ody protection
their operation
ole
n entering a sewerage system
zards at working place
, BS 1542, BS 679, DIN 4646/ 58311
NSI Z 49.1
Gases in cylinders 1235 Jefferson Davis
APPENDIX-B
DETAILS OF FIRST AID BOX
Sr. No. DESCRIPTION
1 Small size Roller Bandages, 1 Inch Wide (Finger Dressing small)
2 Medium size Roller Bandages, 2 Inches Wide (Hand & Foot Dressing)
3 Large size Roller Bandages, 4 Inches Wide (Body Dressing Large)
4 Large size Burn Dressing (Burn Dressing Large)
5 Cotton Wool (20 gms packing)
6 Antiseptic Solution Dettol (100 ml.) or Savlon
7 Mercurochrome Solution (100 ml.) 2% in water
8 Ammonia Solution (20 ml.)
9 Pair of Scissors
10 Adhesive Plaster (1.25 cm X 5 m)
11 Eye pads in Separate Sealed Pkt.
12 Tourniquet
13 Safety Pins
14 Tinc. Iodine/ Betadin (100 ml.)
15 Polythene Wash cup for washing eyes
16 Potassium Permanganate (20 gms.)
17 Tinc. Benzoine (100 ml.)
18 Triangular Bandages
19 Band Aid Dressing
20 Iodex/Moov (25 gms.)
21 Tongue Depressor
22 Boric Acid Powder (20 gms.)
23 Sodium Bicarbonate (20 gms.)
24 Dressing Powder (Nebasulf) (10 gms.)
25 Medicinal Glass
26 Duster
27 Booklet (English & Local Language)
28 Soap
29 Toothache Solution
30 Vicks (22 gms.)
31 Forceps
32 Note Book
33 Splints
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.
AP
QUANTITY
6 Pcs.
6 Pcs.
6 Pcs.
4 Pkts.
4 Pkts.
1 Bottle
1 Bottle
1 Bottle
1 Piece
1 Spool
4 pcs.
1 No.
1 Dozen
1 Bottle
1 No.
1 Pkt.
1 Bottle
2 Nos.
5 Pcs.
1 Bottle
1 No.
2 Pkt.
1 Pkt.
1 Bottle
1 No.
1 No.
1 No. each
1 No.
1 No.
1 Bottle
1 No.
1 No.
4 Nos.
can
sician.
APPENDIX-C
TYPE OF FIRES VIS-À-VIS FIRE EXTINGUISHERS
Fire Extinguisher Water Foam CO2
Fire
Originated from paper, clothes, wood D D Can control

minor surface fires
Inflammable liquids like alcohol,

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

H2
X X D
Electrical fires X X 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
The equipment must have an inspection label on which the next inspection date is given. Type of exti
be marked on it.
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 se
- Other statutory acts Like EPF, ESIS, and Minimum Wage Act.
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 proje
incentive on accident prevention
3. HSE & Supervision – Duties of Supervisor / HSE integrated supervision / who should be held
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 requiremen
15. Communication – HSE Induction /TBTs /Safety Committee /Safety meeting / Safety propaga
16. Excavation – Risks & Dangers /Safety measures
17. Working at Heights – Use of ladder /Work on roofs /Scaffolds /Double harness lanyards /Life
/Safety Nets /Floor openings
18. Hazards in Welding & important safety precautions
19. Gas Cutting – Hazards & safety measures
20. Fire prevention & fire protection
APPENDIX-F LIST OF PROCEDURES (MINIMUM) TO BE FORMING PART OF HSE PL
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
********
RE EXTINGUISHERS
Dry Powder Multi
purpose
(ABC)
Can control D
minor surface
fires
D D
D D
D D
ast once a year and after every use by an authorized person.

ext inspection date is given. Type of extinguisher shall clearly
RELATING TO HSE
es
ure Vessels Rules
ct
es
hemicals Rules
tion of Employment And Condition of service) Act

age Act.
ble statutes / Duties of
sponsibilities of Safety Personnel at project site / Effect of
egrated supervision / who should be held responsible for site
rect costs
rials /Hydra handling
n- respiratory
roject illumination
/Storage /FBAs /Fire prevention
als /ODC consignments

ents vis-à-vis essential safety requirements.
mmittee /Safety meeting / Safety propaganda /Publicity.
Scaffolds /Double harness lanyards /Lifeline /Fall arrester

TO BE FORMING PART OF HSE PLAN:-
Procedures:
cluding JSA/HIRA)
Other Requirements
Performance
e (including Induction)
ward Scheme
ts
ngs
Management
Management
and Management
rts
stem Review
nagement
vior based Safety
agement
bilities and Authorities
erating procedures
Signage’s
al Appliances
Height
e Entry
ing hot works)
ing
ations
uding Manual Handling
ols and Units
s & excavation
ng
rotection
ndling & Storage
azard
Equipment
**
SAFETY TALK TOPICS
SR. NO. SAFETY TALK TOPICS SR. NO.
1 Accident/Incident Prevention 21
2 Ammonia (NH3) Safety 22
3 Are we Safe or just Lucky? 23
4 Attitude and Behavior 24
5 Back Safety 25
6 Barricade and Signage 26
7 Blinding Safety 27
8 Breathing Apparatus 28
9 Carbon Monoxide Poisoning 29
10 Chemical / Toxic Handling 30
11 Chain and Sling Safety Tips 31
12 Chemical Safety 32
13 Compressed Gas Cylinders 33
14 Confined Space Entry 34
15 Crane Operation 35
16 De-blinding Safety 36
17 Donning and doffing of safety harnesses 37
18 Dust mask & Cartridge filter mask 38
19 Electrical Safety 39
20 Emergency Response & Evacuation 40
41 Falling Objects 66
ETY TALK TOPICS
SAFETY TALK TOPICS
Importance of Checklist
Incident reporting
Industrial Radiography Safety
Job Safety Analysis (JSA)
Knowledge of LSC rules
Ladder Safety
Look out for Your Co-Workers
Machine guarding safety
Manual Material Handling
Material Safety Data Sheet - MSDS
Modification of Tools or Equipments
Near Misses are Lucky Escapes - Report them
Over Confidence can kill you
Personal behavior
Personal Hygiene
Personal Protective Equipment (PPE)
Pinch Points
Preventing Strains and Sprains
Eye and Face Protection
Fall Protection & Prevention
Prohibited Items Inside Plant

42 Fatigue 67
44 Fire Prevention and Extinguishing 68
45 Fire Safety 69
45 Foot and Leg Protection 70
46 Forklift Safety 71
47 General Safety 72
48 Grounding of Equipments 73
49 Hand and Finger Protection 74
50 Hand tools & Power Tools 75
51 Hazard Recognition 76
52 Hearing Safety 77
53 Heat Stress 78
54 High Pressure Water Jetting 79
55 Home Made Tools 80
56 Horseplay 81
57 Hot Bolting Safety 82
58 Hot work safety 83
59 Housekeeping is safe keeping 84
60 Hurry Up can Hurt!!!! 85
61 Hydro test Safety 86
62 If you are not sure! ASK! 87
63 Responsibilities of Rigger 88
64 Excavation Safety 89
65 Construction site survey for visitors 90

Respiratory Protection
Responsibilities of Fire Watch
Responsibilities of Permit Receiver
Responsibilities of Standby Man
Risk Assessment
Safe Handling of Flammable Liquids
Safe Storage of Flammable Liquids
Safety is everyone's responsibility
Scaffold Safety
Short cuts
Site Safety Rules & Regulation
Sleeping at site
Slip, trip and fall hazards
Smoking safety
Static Electricity
Take safety ownership of your job
The Cost of the Accident
Traffic Safety
Unsafe acts & conditions
Vacuum Truck Safety
What you do not know, can hurt you!
Why safety audit
Work Permit System
Working at Height
CLASSIFICATION OF LIFTING APPLIANCES
LIFTING APPLIANCES
Lifting tools Lifting tackles
cranes Hoists D-shackles Wire ropes Chains

Chain pulley blocks Jib crane Clamps etc
LIFTING TOOLS AND TACKLES

 Lifting tool: Lifting tool is device which is used to lift load such as
 Crab
 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
INSPECTION OF LIFTING TOOLS & TACKLES

TPI – Third party Inspection
 Third Party Inspection of any product is the Inspection & Testing carried out by Any Person o
Manufacturer or User of that particular product or service.
 Third Agency is always technically strong enough and competent to execute the checking a
Technical Aspects of the equipment or service.
 In case of Lifting Equipment & Lifting Tools & Tackles, Govt. Approved / Authorized Compete
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 / Require
Factories Act.
 Safety Level of the Equipment is enhanced, as competent person shall note down the loop hole
inspection & testing and recommend or suggest corrective measures.
 Equipment Manufacturer shall issue Mfr. Test Certificate by Self Attested way and define prod
 However, as per the Law: Obtain ‘Form-10’ (In Gujarat it is ‘Form-10’) Certificate issued by TPI (Com
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. Compete
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, Hoo
safety parameters.
 Operational Parameters are checked and measured.
 Load Testing at Proof Load and Over-Load.
2). Load Testing:

 First all operating parameters are checked and then, Load Testing at Proof Load and Over-Load is
‘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. Ho
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 (oth
and every chain, rope and lifting tackle for the purpose of raising or lowering persons, goods or materia
 All parts, including the working gear, whether fixed or movable, of every lifting machine and every c
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 s
Chief Inspector may specify in writing, and a register shall be kept containing the prescribed particulars
examination;
 No lifting machine and no chain, rope or lifting tackle shall, except for the purpose of test, be
safe working load which shall be plainly marked thereon together with an identification mark an
prescribed register; and where this is not practicable, a table showing the safe working loads of
lifting machine or chain, rope or lifting tackle in use shall be displayed in prominent position on
 While any person is employed or working on or near the wheel track of a traveling crane in
would be liable to be struck by the crane, effective measures shall be taken to ensure tha
approach within 63[six meters] of that place.
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 secti
 Providing for exemption from compliance with all or any of the requirements of this section,
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
examined if a visual examination supplemented, if necessary, by other means and by the dismantling of
been carried out as carefully as the conditions permit in order to arrive at a reliable conclusion as to the
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
appliance, whether fixed or movable, used in connection with the raising or lowering of persons, or load
machines.
********
IFTING APPLIANCES
ackles
es Wire ropes Chains

Clamps etc
ad such as
acilitates for lifting load such as

on & Testing carried out by Any Person or Agency who is not
and competent to execute the checking and testing of all
es, Govt. Approved / Authorized Competent Person carry out

hem.
ovt. to carry out Inspection &
ls & Tackles is Statutory Norm / Requirement as prescribed in
tent person shall note down the loop holes during the
ve measures.
cate by Self Attested way and define products’ attributes.
is ‘Form-10’) Certificate issued by TPI (Competent Person) from
st Taken for Use.
er checklist developed individually. Competent Persons also offer
. i.e. Brakes, Limit Switches, Wire Rope, Hook Blocks and other
Load Testing at Proof Load and Over-Load is carried out.
sful Inspection & Testing of the
per State Govt. Format in Gujarat State. However, state wise this
e carried out annually and Register
rding Health of the Products.
AND TACKLES
with in respect of every lifting machine (other than a hoist and lift)
ising or lowering persons, goods or materials :-
ovable, of every lifting machine and every chain, rope or lifting
ngth and free from defects;
ce in every period of twelve months, or at such intervals as the

e kept containing the prescribed particulars of every such
ackle shall, except for the purpose of test, be loaded beyond the
reon together with an identification mark and duly entered in the
e, a table showing the safe working loads of every kind and size of
shall be displayed in prominent position on the premises;
near the wheel track of a traveling crane in any place where he
tive measures shall be taken to ensure that the crane does not
lifting machine or any chain, rope
with in addition to those set out in this section;

ll or any of the requirements of this section, where in its opinion,
ain, rope or lifting tackle shall be deemed to have been thoroughly
y, by other means and by the dismantling of parts of the gear, has
er to arrive at a reliable conclusion as to the safety of the parts
ley block, gin wheel, transporter or runway;

ook, shackle, swivel, coupling, socket, clamp, tray or similar
th the raising or lowering of persons, or loads by use of lifting
****

29 HIRA Annexure H

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29 HIRA Annexure H

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Nature of the Job: Dismantling and erection of ammonia tank

Name of the Contractor: Projects & Development India limited

CONTROL MEASURES/ MITIGATIONS RISK RATING RESPONSIBILI TY

Scaffold Erection Lifting of  Hit man or material

 Ensure all personnel have undergone  Basic PPEs

 Ensure all personnel are trained for  Basic PPEs

Erection of  Material Fall from

 Ensure all persons undergone with work  Basic PPEs

 Man fall from height 5 5 25 A

Tie Rod  Fall of materials A

 Ensure Scaffold was properly positioned. C  Basic PPEs

Removal of  Working at height A

 Ensure metal planks tied on the Scaffolds  Basic PPEs

 Scaffold must be made according to the B  Basic PPEs

Dismantling & Movement of  Vehicle accident

 Compliance with PTW requirements  Hard Hat,

 All the plates and structure materials

 Fall of plates during

 T.P.I certified hydra / crane should be

 Plates should be unlashed only after

 Proper lifting tools should be selected

 No lifting should be carried out during 3 3 9

 Ensure all personnel have undergone

Offloading &  Fall of Materials

 Deploy trained riggers for loading and  Hard Hat,

 Inspected hydra / crane should be used  Hard Hat,

 All lifting equipments (chain blocks,  Hard Hat,

 Only use Forklift trucks that are  Hard Hat,

Fabrication of plate  Hot work

 Plasma cutting should be carried out in  Hard Hat,

 All connections of the plasma cutting  Hard Hat,

 Burn & cut injuries,

Rolling and bending Lifting work by  Hit by objects.

 Obtain hot work permit.  Hard Hat,

 Inspected hydra / cranes should be  Hard Hat,

 Injuries due to sharp 5 4 20 A

 Only trained operators should be

 Leather hand gloves should be used to  Basic PPEs

 Welding machine should be placed at

 All combustible material should be

 Employees engaged in the hot works

 Hoses should be laid in proper manner.  Basic PPEs

 Fall of person from 5 5 25 A

 Only trained employees should be

Cutting of steel  Crush Injury

 Ensure all personnel have undergone  Hard Hat,

Roof plate and

 Obtain work permit.

 Only trained employees should 3 3 9 B  Basic PPEs S S P

 Fall of plates during

Installation of  Fall of lifted material

 Barricaded the effecting radius.  Basic PPEs

 All jacks should be inspected for  Basic PPEs

 Pinch point injuries

 Proper coordination should be

 Hydraulic oil spillage 4 5 20 A

 Proper housekeeping needs to be

 All jacks should be inspected for  Basic PPEs

 Hydraulic oil spillage 4 5 20 A

 Hoses used for jacks should have proper  Basic PPEs

 Fire, burn injuries 5 3 15 A

 Follow the safety requirements for the

 Fall of person due to

 Fall of person from A