STANDARD OPERATING PROCEDURE (SOP)

SOP NO. CP/SOP/MECH/STRL/01 Effective 20/10/22 REV. 02

TS SOP FABRICATION,ERECTION & REPAIR OF
Date
SECTION
No.
MECHANICAL MAINTENANCE
DESCRIPTION STRUCTURE
NINL DEPARTMENT COKE PLANT PAGE Page 1 of 27

Ste p Activity Associated Process Steps [HOW] Responsibility Condition of Remarks/

No. (WHAT) Requirements (WHO) Tools/Tackles Reference
Hazards/ required,
Impacts OK

Risk and mitigation associated with Sheeting

activity
Sl. Hazard Mitigation
No
1 Movement of heavy vehicles 1. All workmen will be made alert preferably about the hazard from sudden arrival of heavy vehicles.
carrying materials 2. Trained flagmen equipped with whistle and flags will be deployed to warn and remove workmen to a
safe distance.

2 Fall of materials, spatters
From welding, gas cutting where
erection of structural materials/
equipment’s are lifted and other
agencies are working in same area
at different levels.
1. Proper access should be provided for going on required location.
2. Nobody will be allowed to work just below the structural job .
3. Entire area will be barricaded properly by safety ribbon by working agency to protected
unauthorized entry.
4. Use spatter arrester during cutting and welding at height.
5. Work permit must be followed strictly at job.

3 Falling of material during lifting &
fixing.
1. Any lifting activity will be carried out by ground only not from height.
2. Material will be tied properly on ground. Proper communication between workers should be there for
lifting of material.
3. Survey should be carried out before lifting of material to avoid fouling with any structure.
4. Area to be barricaded during lifting & Fixing.

Prepared by: Checked by Approved by:

Name and Designation: R.J. Singh (OCST) Name and Designation: K. Ravishankar, Sr. Mngr.(Mech) Name and Designation :B.S. Raju, AGM(Mech.)

Signature with Date : Signature and Date: Signature with Date :

 STANDARD OPERATING PROCEDURE (SOP)
SOP NO. CP/SOP/MECH/STRL/01 Effective Date 20/10/22 REV. No. 02
TS SOP
DESCRIPTION
FABRICATION,ERECTION & REPAIR OF
STRUCTURE
SECTION MECHANICAL MAINTENANCE

NINL DEPARTMENT COKE PLANT PAGE Page 2 of 27

Ste Activity Associated Process Steps [HOW] Responsibility Condition of Remarks/

p (WHAT) Requirements (WHO) Tools/Tackles Reference
No. Hazards/ Impacts required,
OK

4 Electrocution 1. Do not hold any electrical tools from wire.

5 1. Clean the area of work.
2. Pathway marking
3. stacking of material
4. Scrap bin marking with
nomenclature.
5. Scrap removed from working
area.
6. Disposed unwanted material
from site before site closing.
Prepared by:
Name and Designation: R.J. Singh (OCST)
2. Only industrial plug should be use.
3. Do not use any damaged cable if any joint needed only male-female plug should be use for joint.
4. All electrical tools should be connected through ELCB only.
5. Electrical wire should be protected from sharp edges.
6. Hard insulated cable should be use only.
7. Do not lay electrical cable on ground.
8. Body earth checked for the screw gun, it should be working properly.
9. Do not hold any electrical tools from wire.
10. Only industrial plug should be use.
11. Do not use any damaged cable if any joint needed only male-female plug should be use for joint.
1. Use of hand gloves, goggles & sin guard to avoid any injury.
2. Pathway should be marked with providing caution/display board.
3. Working area to be clean & stack the material properly before starting the work.
4. Temporary Scrap bin will be provided for daily stocking of scrap material & removed it before site closing.
5. All material & scraps to be removed after completion of job.
6. Working area to be clean on daily basis.
Checked by Approved by:
Name and Designation: K. Ravishankar, Sr. Mngr.(Mech) Name and Designation :B.S. Raju, AGM(Mech.)

Signature with Date : Signature and Date: Signature with Date :

 STANDARD OPERATING PROCEDURE (SOP)
SOP NO. CP/SOP/MECH/STRL/01 Effective 20/10/22 REV. 02
TS SOP FABRICATION, ERECTION & REPAIR OF
Date
SECTION
No.
MECHANICAL MAINTENANCE
DESCRIPTION STRUCTURE
NINL DEPARTMENT COKE PLANT PAGE Page 3 of 27
Ste p Activity Associated Process Steps [HOW] Responsibility Condition of Remar
No. (WHAT) Requirements (WHO) Tools/Tackles ks/
Hazards/ Impacts required, Refere
OK nce
y Shoe
List Of PPE’s

Safety Florescent
Safety Goggles Jacket
Safety Shoes Safety Ear Plug Positive
Dust Mask
Helmet Handgloves Co Detector isolation
Lock
During Pre X X X X X

Start-
upJob
activity.
During On Job X
List Of PPE’s

Any Other
PPE
[Please
Full Body Gas Welding Eye Mention]
Welding Eye Shield Shin Guard
Hardness Glass
Fire Protection Jacket

During Pre Start- X X X X

up
Job activity.
During On Job

Prepared by: Checked by Approved by:

Name and Designation: R.J. Singh (OCST) Name and Designation: K. Ravishankar, Sr. Mngr.(Mech) Name and Designation :B.S. Raju, AGM(Mech.)

Signature with Date : Signature and Date: Signature with Date :

 STANDARD OPERATING PROCEDURE (SOP)
SOP NO. CP/SOP/MECH/STRL/01 Effective 20/10/22 REV. 02
TS SOP FABRICATION, ERECTION & REPAIR OF
Date
SECTION
No.
MECHANICAL MAINTENANCE
DESCRIPTION STRUCTURE
NINL DEPARTMENT COKE PLANT PAGE Page 4 of 27

Ste Activity Associated Process Steps [HOW] Responsibility Condition of Remarks/

p (WHAT) Requirements (WHO) Tools/Tackles Reference
No. Hazards/ Impacts required,
OK

1 General Guide Unawareness of Safety Induction training at Plot-2 & specialized training by Safety Executive All mobile SS/Gen-25
Lines (Before safety rule job & Ergonomics dept. will be ensured for all workers & supervisors department equipment & (Work permit
Starting job) hazards, poor work before starting the job. Daily tools kit meeting/tool box talk/ safety TSK-Line PPE like Safety system)
knowledge and not induction will be given to workmen before to start of the job. It Manager Helmet, Safety
using safety must be ensured that workmen have clearly understood the job /Contractor shoe, safety
appliance may related hazards & its preventive measures half hour safety timings supervisor goggles. Full
cause of will strictly be followed before starting and after completion of work body harness
injury/accident for good housekeeping and safe condition of site. safety belt,
hand glove
Incident/ Accident Hazards will be identified/Permit to work must be assessed before nose mask etc. SS/Engg-05
due to start of work to start work. All proximity hazards along with corresponding (Welding & Gas
without doing precautions will be made known to workmen & other concerned Cutting)
Hazards persons.
identification & Risk
Assessment.

Job without work Working clearance/Permit to work must be taken duly signed by SS/Gen-25
permit & SWP not concerned persons before to start of job. SWP will be amended at (Work permit
amended to new the site for job unwritten on procedures & need to be performed. system)
job appeared during
work execution.
SS/Gen-12-
Unawareness of All staff and workmen will be made aware about all road safety Road Safety
road safety norms. norms.

Prepared by: Checked by Approved by:

Name and Designation: R.J. Singh (OCST) Name and Designation: K. Ravishankar, Sr. Mngr.(Mech) Name and Designation :B.S. Raju, AGM(Mech.)

Signature with Date : Signature and Date: Signature with Date :

 STANDARD OPERATING PROCEDURE (SOP)

SOP NO. CP/SOP/MECH/STRL/01 Effective 20/10/22 REV. 02

TS SOP FABRICATION,ERECTION & REPAIR OF
Date
SECTION
No.
MECHANICAL MAINTENANCE
DESCRIPTION STRUCTURE
NINL DEPARTMENT COKE PLANT PAGE Page 5 of 27

Ste Activity Associated Process Steps [HOW] Responsibility Condition of Remarks/

p (WHAT) Requirements (WHO) Tools/Tackles Reference
No. Hazards/ Impacts required,
OK

Wandering of All working persons will remain within the work area for which they
persons beyond have been given work permit. SS/Gen-25
work area or (Work permit
permitted area system)
Use of sub-standard All kinds of Standard safety appliances as per related hazards will Executive All mobile SS/Engg.-07
PPE’s be provided to workman like safety shoes, safety helmet, hand department equipment & (PPE’s)
gloves, safety goggles, Face shield and full body harness with TSK-Line PPE like Safety SS/Gen-2
double lanyards for working at height etc. All Manager Helmet, Safety (Loose
Engineers/Supervisors and workmen will be ensured aware about /Contractor shoe, safety Clothing).
job related and applicable safety standards before starting the job. supervisor goggles. Full SS/Gen04 (Foot
All hazards/precaution will be briefed to workmen before to body harness Protection)
starting the job. All workmen & safety belt, SS/Gen-05 (Hand
Supervisor must have valid safety induction training cards and gate hand glove Protection) SS/Gen-
passes. nose mask etc. 03 (Injury
Energy sources not Concerned person will keep adequate nos. of positive isolation ‘ Classification)
isolated before start Blue’ lock & slings and use wherever energy sources are to be
work or doing isolated based on standard procedure. Nos of rubber mats. Valid SS/Gen-26
maintenance e.g. fire Extinguishers will be kept in all D.Bs, ELCB, Double earthing (Positive
Electrical, Hydraulic will be used in D.B/Welding Machines. Isolation)
etc.
Doing work during No work will be carried out during rain or heavy wind in open area.
rain and heavy
wind in open area.
Electrical shock due D.B. Room, Welding M/c Room will be made proper and safe as per
to water in D.B TSK standard. It will be checked and ensured that no rain water
Room/ Welding M/c should enter into D.B. Room or Welding M/c booth.
Room

Prepared by: Checked by Approved by:

Name and Designation: R.J. Singh (OCST) Name and Designation: K. Ravishankar, Sr. Mngr.(Mech) Name and Designation :B.S. Raju, AGM(Mech.)
 STANDARD OPERATING PROCEDURE (SOP)
Signature with Date : Signature and Date: Signature with Date :

SOP NO. CP/SOP/MECH/STRL/01 Effective 20/10/22 REV. 02

TS SOP FABRICATION,ERECTION & REPAIR OF
Date
SECTION
No.
MECHANICAL MAINTENANCE
DESCRIPTION STRUCTURE
NINL DEPARTMENT COKE PLANT PAGE Page 6 of 27

Ste Activity Associated Process Steps [HOW] Responsibility Condition of Remarks/

p (WHAT) Requirements (WHO) Tools/Tackles Reference
No. Hazards/ Impacts required,
OK

Injury due to work Adequate illumination (more than 75 Lux) will be ensured during
in poor illuminated night work. Standard scaffold will be made and used if required.
area. Fall from
scaffold.
Fall of person due Medically fit & height trained persons will only be allowed to work Executive All mobile SS/Engg-03
to not wearing or at height. Full body harness will be used for work above 2 meters department equipment & (Working at
anchoring full body height with standard life line. TSK-Line PPE like Safety height.
harness. Manager Helmet, Safety
Job without  No job shall be executed in absence of Supervisor /Safety /Contractor shoe, safety
Supervisor & poor Supervisor. Housekeeping will be done on daily basis and supervisor goggles. Full
housekeeping. materials will be kept safely and in order. Disposal of scrap to body harness
the designated place. safety belt,
Injury & Fire First Aid box valid with medicine and Fire extinguishers will be kept hand glove
aggravated due to ready at all prominent places at site. nose mask etc. SS/Gen-25
lack of First Aid (Work permit
materials and fire system)
extinguishers near
to site.

Accident in absence Red lamp, Foreman with whistle, safety steward, display/caution
of caution board. boards etc. will be provided as per requirement at site.

Accident while Materials related to job must be kept at site systematically * as per
handling materials TPM check list)
kept.
Unsystematically

Prepared by: Checked by Approved by:

 STANDARD OPERATING PROCEDURE (SOP)
Name and Designation: R.J. Singh (OCST) Name and Designation: K. Ravishankar, Sr. Mngr.(Mech) Name and Designation :B.S. Raju, AGM(Mech.)

Signature with Date : Signature and Date: Signature with Date :

SOP NO. CP/SOP/MECH/STRL/01 Effective 20/10/22 REV. 01

TS SOP FABRICATION, ERECTION & REPAIR OF
Date
SECTION
No.
MECHANICAL MAINTENANCE
DESCRIPTION STRUCTURE
NINL DEPARTMENT COKE PLANT PAGE Page 7 of 26

Ste Activity Associated Process Steps [HOW] Responsibility Condition of Remarks/

p (WHAT) Requirements (WHO) Tools/Tackles Reference
No. Hazards/ Impacts required,
OK

2 Identification North, East, West, Executive All mobile

First of all go to the working site and identified the six
of SIX- South- Unwanted department equipment &
directional hazards.
Directions structure or material, TSK-Line PPE like Safety
Hazard at site. moving or rotatory Manager Helmet, Safety
Fill up the back side of the work permit form no- HMC-
equipment, splashing, /Contractor shoe, safety
PRO/GEN/4003 and its mitigation measured has been taken.
dust, electrical supervisor goggles. Full
equipment, falling of body harness
The concern department /contractor supervisor Explain the
material, sharp age safety belt,
identified hazard and its counter measure to his co-workers.
structure, barricading, hand glove
stability of adjutants nose mask etc.
structure or building.
Presence of excessive
hot and cold,
chemically hazards,
radioactive material.
Top – falling of
unwanted material,
stability of roof or
structure, splashing.
Bottom-Stability, slip
and trip, Unwanted
and non-specified
item to whom person
may stand.

Prepared by: Checked by Approved by:

Name and Designation: R.J. Singh (OCST) Name and Designation: K. Ravishankar, Sr. Mngr.(Mech) Name and Designation :B.S. Raju, AGM(Mech.)
 STANDARD OPERATING PROCEDURE (SOP)
Signature with Date : Signature and Date: Signature with Date :

SOP NO. CP/SOP/MECH/STRL/01 Effective 20/10/22 REV. 02

TS SOP FABRICATION, ERECTION & REPAIR OF
Date
SECTION
No.
MECHANICAL MAINTENANCE
DESCRIPTION STRUCTURE
NINL DEPARTMENT COKE PLANT PAGE Page 8 of 27

Ste Activity Associated Process Steps [HOW] Responsibility Condition of Remarks/

p (WHAT) Requirements (WHO) Tools/Tackles Reference
No. Hazards/ Impacts required,
OK

3 Pre-requisites Job hazards, work Training of SOP to all working person. Executive All mobile SS/Gen-25
before work knowledge, not use of Working labor must know the use of safety appliances. department equipment & (Work permit
permit. safety appliances may Following minimum things are important while taking the TSK-Line PPE like Safety system)
cause of injury, clearance: Manager Helmet, Safety
accident and damage People will never wear loose clothes. /Contractor shoe, safety SS/Engg.-07
of property Cotton garments to be used. supervisor goggles. Full (PPE’s)
Unawareness of safety Good condition TSL standard PPE to be used properly. body harness
rules. People know about the emergency preparedness. safety belt, SS/Gen-2
People know about the rescue operation during emergency. hand glove (Loose
Before starting the job joint visit to site by the department nose mask etc. Clothing).
personal along with the Contractor’s supervisor to make a safe
plan to execute the job safely & ground reality to be shown. SS/Gen04 (Foot
Protection)
Clearance Authorization to start  Take power clearance if necessary. Power cutting
taking & job safely. SS/Gen-05 (Hand
(HMC/PRO/GEN/4001) with positive isolation.
starting of Protection)
 Take permit to work in Form. WORK PERMIT FORM
job.
(HMC/PRO/GEN/4003).
SS/Gen-03 (Injury
 Working at height more than 3 MTR. Follow safety stander
Classification)
SS/ENGG-03/A and FALL PROTECTION
SS/Engg-03
Electrical hazard, (Working at
Work area  Unnecessary material to be removed from site. height
Serious injury, fatality
clearance and  The working area should be completely barricaded with
of the person and
barricading No Entry Display board. SS/Gen-26
damage to the
 No additional person is allowed to working site whose (Positive
property.
name is not registered in work permit form. Isolation)
 STANDARD OPERATING PROCEDURE (SOP)
Prepared by: Checked by Approved by:
Name and Designation: R.J. Singh (OCST) Name and Designation: K. Ravishankar, Sr. Mngr.(Mech) Name and Designation :B.S. Raju, AGM(Mech.)

Signature with Date : Signature and Date: Signature with Date :

SOP NO. CP/SOP/MECH/CDCP/01 Effective 20/10/22 REV. 02

TS SOP DISMANTLING AND ERECTION OF
Date
SECTION
No.
MECHANICAL MAINTENANCE
DESCRIPTION STRUCTURE
NINL DEPARTMENT COKE PLANT PAGE Page 9 of 27

Ste Activity Associated Process Steps [HOW] Responsibility Condition of Remarks/

p (WHAT) Requirements (WHO) Tools/Tackles Reference
No. Hazards/ Impacts required,
OK

4 Transportation Accident due to Driver must use seat belt while driving. Executive All mobile SS/Gen-13
of welding m/c unsafe driving, wrong department equipment & (Barricading)
by 4 wheeler place parking, bad Follow road safety rules. TSK-Line PPE like Safety
store to the site.
condition of road, bad Manager Helmet, Safety
condition of tempo, Follow no entry/safety timing. /Contractor shoe, safety SS/Gen-12
unawareness of Only skilled & experienced driver to be deployed. supervisor goggles. Full (Road Safety)
driver re-road safety body harness
of TSL. safety belt,
Loading & Injury to person due During loading proper hand gloves & lifting rope to be used. hand glove SS/Gen-25
Unloading of to slippage of m/c Only tested lifting tools to be used & checked for physical nose mask etc. (Work permit
welding m/c at during manual damage before use. system)
site & manually
loading. Sufficient man power to be provided during manually loading.
shifted at
workplace SS/Gen-29
Injury to person due Placement of vehicle at correct location & fixing of scotch block (Transportation
to slippage of m/c at both side of the wheel. safety)
during manual During unloading proper hand gloves and lifting ropes to be
unloading. used.
Sufficient man power to be provided. SS/Gen-30
Welding m/c to be kept under shade, dry & plain area. Traveling by
road.
 STANDARD OPERATING PROCEDURE (SOP)
Connection of Electrical shock Injury Competent/authorized and licensed electrician will only be
welding m/c during cable laying & permitted to work on electrical lines. Proper electrical connection
with existing termination will be provided to machine. Tapping of power sources, earthing
power DB for m/c will be ensured. Positive isolation will be done for power
sources. Correct rated switches, Functional ELCB, Rubber mats,
DCP type Fire Extinguisher, Fire buckets filled with dry sand
SS/ELECT-
etc, will be ensured available at place.
01,05
Prepared by: Checked by Approved by:
Name and Designation: R.J. Singh (OCST) Name and Designation: K. Ravishankar, Sr. Mngr.(Mech) Name and Designation :B.S. Raju, AGM(Mech.)

Signature with Date : Signature and Date: Signature with Date :

SOP NO. CP/SOP/MECH/STRL/01 Effective 20/10/22 REV. 02

TS SOP FABRICATION, ERECTION & REPAIR OF
Date
SECTION
No.
MECHANICAL MAINTENANCE
DESCRIPTION STRUCTURE
NINL DEPARTMENT COKE PLANT PAGE Page 10 of 27
Ste Activity Associated Process Steps [HOW] Responsibility Condition of Remarks/
p (WHAT) Requirements (WHO) Tools/Tackles Reference
No. Hazards/ Impacts required,
OK

5 Transportation Accident due to Driver must use seat belt while driving. Executive All mobile SS/Gen-13
of cylinder unsafe driving wrong department equipment & (Barricading)
Cutting hose by place parking bad Follow road safety rules. TSK-Line PPE like Safety
4wheeler from
condition of road bad Manager Helmet, Safety SS/Gen-12
store to the
condition of tempo , Follow no entry/safety timing. /Contractor shoe, safety (Road Safety)
site
unawareness of Only skilled & experienced driver to be deployed. supervisor goggles. Full
driver re:- road safety body harness SS/Gen-25
of TSL. safety belt, (Work permit
hand glove system)
Unloading of Injury to person due During loading proper hand gloves & lifting rope to be used.
cylinder and
nose mask etc.
to slippage of cylinder Only tested lifting tools to be used & checked for physical SS/Gen-29
hose at site & during manual damage before use.
manually shifted (Transportation
loading. Sufficient man power to be provided during manually loading. safety)
at workplace.
Injury to person due During unloading proper hand gloves and lifting rope to be
to slippage of cylinder used. SS/Gen-30
during manual Proper & good condition trolley to be used during unloading of (Traveling by
loading. cylinders. road)
All cylinders to place at open space area.
Make sure all cylinder properly place on trolley in vertical SS/ENGG- 02
position & fixed with chain (for oxygen Cylinder). (Gas cylinder
Proper cage to be provided for LPG cylinder. handling)
 STANDARD OPERATING PROCEDURE (SOP)
Standard hose, tested regulator with double gauge & good
Fixing of -Leakage of hose. condition cutting torch to be used.
regulators & -No standard Ensure the uses of three pipes cutting torches with flashback
hose with
regulator, hose, arrester.
cylinders.
cutting torch Clamping of hose by proper jubilee clamps. LPG Cylinders
should be covered with wet gunny bags.
Validated fire extinguisher to be provided near to the cylinder.

Prepared by: Checked by Approved by:

Name and Designation: R.J. Singh (OCST) Name and Designation: K. Ravishankar, Sr. Mngr.(Mech) Name and Designation :B.S. Raju, AGM(Mech.)

Signature with Date : Signature and Date: Signature with Date :

\
SOP NO. CP/SOP/MECH/STRL/01 Effective 20/10/22 REV. 02
TS SOP FABRICATION, ERECTION & REPAIR OF
Date
SECTION
No.
MECHANICAL MAINTENANCE
DESCRIPTION STRUCTURE
NINL DEPARTMENT COKE PLANT PAGE Page 11 of 27
Ste Activity Associated Process Steps [HOW] Responsibility Condition of Remarks/
p (WHAT) Requirements (WHO) Tools/Tackles Reference
No. Hazards/ Impacts required,
OK

Loading/Unloading/Shifting of Structural Steel At work Place:

6 Placing of Hit due to other projected Projection of longer materials will be avoided at rear side and Executive All mobile SS/Engg.07
Trailer material at site. not to be projected sidewise beyond body of vehicle department equipment & (PPEs)
TSK-Line PPE like Safety
Physical injury due to Trained/ skilled Foreman/Sarong/Signalman with whistle will be Manager Helmet, Safety SS/Gen-02
untrained operator, non- deployed to control the movement of crane. Trained /Contractor shoe, safety (Road Safety)
availability of signalman. operator/flagman will be engaged during placing of Trailer. supervisor goggles. Full
body harness SS/Gen-9
Movement of Overloading, over- taking, No overloading, overtaking, high speed, wrong side parking will be safety belt, (Transportatio n
trailer with high speed and wrong side allowed. Materials shall be tightened properly with the body of hand glove safety)
material. driving & parking vehicle avoid toppling hazards. nose mask etc.

Use of defective truck, Damage truck/trailer/dumper will not be used for shifting of SS/Engg-06
Hydra Crane etc. Unfit & materials. Only experienced and valid license holder (Rigging
inexperienced operator drivers/operators will be deployed. equipment)
engaged. (Sling & Wire
ropes)

Improper approach for Sling will be checked physically before use with valid test certificate
crane movement and lifted load should not exceed the SWP of used
 STANDARD OPERATING PROCEDURE (SOP)
sling & Hydra Crane.
Loading & Swing hazards Before removing turn buckle/chain make sure site support is
Unloading of provided on the trailer bed so that material should not slip from
material by Snapping of sling during trailer.
crane/Hydra loading & unloading of
(F15) materials Crane/F15 will be placed on levelled surface. Crane/F15 will be
Un positioned straight & not of twisted angle while lifting materials.
Materials will be lifted slowly and not by sudden jerk or thrust.
fitness of crane Materials will be kept nearer to ground while lifting to avoid C.G. to
go off.
Toppling hazard

Prepared by: Checked by Approved by:

Name and Designation: R.J. Singh (OCST) Name and Designation: K. Ravishankar, Sr. Mngr.(Mech) Name and Designation :B.S. Raju, AGM(Mech.)

Signature with Date : Signature and Date: Signature with Date :

SOP NO. CP/SOP/MECH/STRL/01 Effective 20/10/22 REV. 02
TS SOP FABRICATION, ERECTION & REPAIR OF
Date
SECTION
No.
MECHANICAL MAINTENANCE
DESCRIPTION STRUCTURE
NINL DEPARTMENT COKE PLANT PAGE Page 12 of 27

Ste Activity Associated Process Steps [HOW] Responsibility Condition of Remarks/

p (WHAT) Requirements (WHO) Tools/Tackles Reference
No. Hazards/ Impacts required,
OK

7 Gas Cutting Fire hazards & burn All flammable materials removed from Gas cutting area. Valve Executive All mobile
Of Structural by gas cutting protection caps shall be in place and secured gas cutter will use department equipment & SS/Gen-25
Steel flame, heated safety helmet, safety goggles, hand gloves, full sleeve, cotton TSK-Line PPE like Safety (Work permit
Materials For surfaces, molten dress, leg guard etc. gas cutting, hose pipe, regulator, cutting torch Manager Helmet, Safety system)
Fabrication and material etc. will be checked before use, cotton dress will be used by welders/ /Contractor shoe, safety
Erection. Gas leakage from gas cutters, waster will be kept ready at site. Ceramic cloth will be supervisor goggles. Full
regulator used to arrest spatters falling from height. Soap solution provided body harness
ground level barricaded during gas cutting at height. safety belt,
Damage of eye from Gas cutter will always use dark cutting glass/face shield and nose hand glove
ultra violet rays, mask while doing gas cutting job.
SS/Engg-05
nose mask etc.
toxic furnace and (welding/gas
flying particles cutting)
released from
cutting point.
 STANDARD OPERATING PROCEDURE (SOP)
Bursting of hose Hose pipe to be checked. Physically before connecting. Hose should
pipe & fire with not be kinked tested to avoid bursting of pipe. SS/Engg-02
excessive line
pressure due to
(cyl. Handling)
damaged or faulty
regulator.
Cylinders kept in Compressed gas cylinders shall be secured in upright position at all
horizontal position. times except, if necessary, for short periods of time while handling.
Oxygen & Fuel gas Oxygen cylinders, in storage shall be separated from fuel gas
cylinder kept cylinders by min. Distance of 3 M “NO SMOKING” board will be SS/ENGG.-07
together displayed at cylinder storage yard. Max. 05 Nos. LPG Cylinder to be (PPE’s)
kept at one place.

Prepared by: Checked by Approved by:

Name and Designation: R.J. Singh (OCST) Name and Designation: K. Ravishankar, Sr. Mngr.(Mech) Name and Designation :B.S. Raju, AGM(Mech.)

Signature with Date : Signature and Date: Signature with Date :

SOP NO. CP/SOP/MECH/STRL/01 Effective 20/10/22 REV. 02

TS SOP FABRICATION, ERECTION & REPAIR OF
Date
SECTION
No.
MECHANICAL MAINTENANCE
DESCRIPTION STRUCTURE
NINL DEPARTMENT COKE PLANT PAGE Page 13 of 27

Ste Activity Associated Process Steps [HOW] Responsibility Condition of Remarks/

p (WHAT) Requirements (WHO) Tools/Tackles Reference
No. Hazards/ Impacts required,
OK

Cylinder kept near Cylinders shall be kept at safe distance from actual welding or
cutting/welding cutting operation so that sparks, hot slag, or flame will not reach
area. them.
Cylinder kept Cylinders shall be placed where they cannot become a part of an Executive All mobile
adjacent to power electrical circuit, Electrodes shall not be struck. department equipment &
cables. TSK-Line PPE like Safety SS/Gen-25
Cylinders used as Cylinders, whether full or empty, shall not be used as rollers or Manager Helmet, Safety (Work permit
supports or as supports. /Contractor shoe, safety
system)
rollers. supervisor goggles. Full
Cylinder valve Before a regulator is connected to a cylinder valve, the valve shall body harness
opened fully at be opened slightly and closed immediately. safety belt,
once.
 STANDARD OPERATING PROCEDURE (SOP)
Cutting hose kept Passage ways, ladders and stairs will be kept free from all
on passage obstructions.
Torch lighted with Torches shall be lighted by friction lighters or other approved
the help of match devices and not by matches or from hot work.
stick.
Flash back arrestor Flash back arrester shall be fitted with the torch and at cylinder’s
not used end.
Defective regulator Oxygen and fuel gas pressure regulators, including their related hand glove
used gauges, shall be in proper working order while in use nose mask etc.
Eye injuries due to Cutting glass, goggles, leg guard, Aprons & sleeve guard will be SS/Engg-05
flying spatters or used by gas cutters together with other mandatory PPE’s. Permit to (welding/gas
light, Burn injuries work in form No.-EHSMSM/work (446/4007) will be taken before cutting)
due to hot melted starting of gas cutting.
slag pcs.

Prepared by: Checked by Approved by:

Name and Designation: R.J. Singh (OCST) Name and Designation: K. Ravishankar, Sr. Mngr.(Mech) Name and Designation :B.S. Raju, AGM(Mech.)

Signature with Date : Signature and Date: Signature with Date :

SOP NO. CP/SOP/MECH/STRL/01 Effective 20/10/22 REV. 02

TS SOP FABRICATION, ERECTION & REPAIR OF
Date
SECTION
No.
MECHANICAL MAINTENANCE
DESCRIPTION STRUCTURE
NINL DEPARTMENT COKE PLANT PAGE Page 14 of 27

Ste Activity Associated Process Steps [HOW] Responsibility Condition of Remarks/

p (WHAT) Requirements (WHO) Tools/Tackles Reference
No. Hazards/ Impacts required,
OK

Damage & Bursting Cylinders shall not to be moved by lifting and rolling them. On their
of gas cylinder due bottom edges. They shall not be intentionally dropped, struck or SS/ENGG.-07
to rolling them by permitted to strike each other violently. Cylinder should always be (PPE’s)
side striking again rolled down from deck of vehicle to same levelled platform or on
object or dropping thick coir mattresses. Only Trolley should be used for
them on hard handling/shifting the cylinder from one location to another.
surface.
 STANDARD OPERATING PROCEDURE (SOP)

Prepared by: Checked by Approved by:

Name and Designation: R.J. Singh (OCST) Name and Designation: K. Ravishankar, Sr. Mngr.(Mech) Name and Designation :B.S. Raju, AGM(Mech.)

Signature with Date : Signature and Date: Signature with Date :

SOP NO. CP/SOP/MECH/STRL/01 Effective 20/10/22 REV. 02

TS SOP FABRICATION, ERECTION & REPAIR OF
Date
SECTION
No.
MECHANICAL MAINTENANCE
DESCRIPTION STRUCTURE
NINL DEPARTMENT COKE PLANT PAGE Page 15 of 27

Ste Activity Associated Process Steps [HOW] Responsibility Condition of Remarks/

p (WHAT) Requirements (WHO) Tools/Tackles Reference
No. Hazards/ Impacts required,
OK

8 Welding Job Of Injury due to not Welder will use shock proof hand gloves, 18” long leather Executive All mobile
Structural Steel using PPE’s. hand gloves, rubber shoes, face shield attached with department equipment &
For fabrication helmet, other than mandatory PPE’s proper approach will TSK-Line PPE like Safety
& Erection be made. Welders & Gas cutter will use cotton dress, safety Manager Helmet, Safety
goggles will also be used with welding screen helmet. shoe, safety
 STANDARD OPERATING PROCEDURE (SOP)
Electrical shock/ Suitable socket joint will be used for extension of welding /Contractor goggles. Full
Electrocution. cable etc. Rubber mats will be provided in all D.B and supervisor body harness
Improper approach Welding m/c. All electrical connections with Elec. DB & safety belt,
for welding activities. welding m/c etc. will be checked carefully with adequate hand glove
earthing before use, and direct earthing to be provided in nose mask etc. SS/Gen-25
job, Adequate earthing is must with all electrical (Work permit
equipment. system)
Elect. shock due to Welding machine will be kept in dry place and under shed
wet soil or water to protect it from water. SS/Engg-05
accumulated- area of (welding/gas
welding m/c and job cutting)
location.
Elect. shock due to Proper insulated and standard welding holder as specified
use of substandard by Tata Steel will be used. SS/Engg-07
welding holder (PPE’s)
Elect. shock due to Power connection to the welding machine will always be
ELCB not provided or taken from main switch with proper power cable. ELCB will SS/ELECT-01
not functioning. be provided to W/M 30 mA ELCB will be uses.
Elect. shock due to Individual welding machine switch will be provided MRC
one switch used for flues will only be used for welding machines.
many nos. of welding
machines.
Elec. Shock due to Good quality welding cable will be used & the same will not
use of damaged be allowed to pass through the good conductive substances.
welding cables

Prepared by: Checked by Approved by:

Name and Designation: R.J. Singh (OCST) Name and Designation: K. Ravishankar, Sr. Mngr.(Mech) Name and Designation :B.S. Raju, AGM(Mech.)

Signature with Date : Signature and Date: Signature with Date :

SOP NO. CP/SOP/MECH/STRL/01 Effective 20/10/22 REV. 02
TS SOP FABRICATION, ERECTION & REPAIR OF
Date
SECTION
No.
MECHANICAL MAINTENANCE
DESCRIPTION STRUCTURE
NINL DEPARTMENT COKE PLANT PAGE Page 16 of 27

Ste Activity Associated Process Steps [HOW] Responsibility Condition of Remarks/

p (WHAT) Requirements (WHO) Tools/Tackles Reference
No. Hazards/ Impacts required,
OK
 STANDARD OPERATING PROCEDURE (SOP)
9 Grinding Job Eye injury Grinder will use face shield, 18 inch long leather hand Executive All mobile
of Structural gloves or sleeve guard, leather apron, Ear plug together department equipment &
Steel for with other required PPE’s will be used. Grinding m/c to be TSK-Line PPE like Safety
Fabrication & kept on a start while not in use & Elect. Plug to be Manager Helmet, Safety
Erection removed. /Contractor shoe, safety
supervisor goggles. Full
Physical injury due to Expiry date of grinding wheel will be checked before body harness
SS/Gen-06
Breakage of grinding starting grinding job. Proper PPE’s will be used. Only skin fit safety belt,
wheel. hand gloves to be used. hand glove
nose mask etc. SS/Engg-07
Elect. Shock Three pin plug / socket will be used. Electrical connection
will provided as per Tata Steel standard. Proper earthing of SS/ELECT.-01
220V/Grinding machine will be ensured. Grinding m/c
should be connected with ELCB.

Fire Hazard. Fire extinguisher, sand/water buckets to be kept at working

area.
10 Assembly Physical injuries to Use all relevant PPE’s with skin fit hand gloves.
/Fit-up of workmen during fit- Healthy and proper tools should be used.
Structural up, Alignment & Proper & safe approach for work should be provided.
Steel Bolting job. Area should be barricaded & defined for the specific job so
Materials that no unknown persons could enter in the job area.
If assembly bed is height(equal or more than 2 mtrs)then
Full body harness with proper horizontal lifeline (with
12mm WRS)should be used for working at height.
Standard scaffolding should be used for the job.
Workplace orderliness should be checked & maintained on
regular basis.
Standard, Physically tested & with valid calibration

Prepared by: Checked by Approved by:

Name and Designation: R.J. Singh (OCST) Name and Designation: K. Ravishankar, Sr. Mngr.(Mech) Name and Designation :B.S. Raju, AGM(Mech.)

Signature with Date : Signature and Date: Signature with Date :

SOP NO. CP/SOP/MECH/STRL/01 Effective 20/10/22 REV. 02

TS SOP FABRICATION, ERECTION & REPAIR OF
Date
SECTION
No.
MECHANICAL MAINTENANCE
DESCRIPTION STRUCTURE
NINL DEPARTMENT COKE PLANT PAGE Page 17 of 27

Ste Activity Associated Process Steps [HOW] Responsibility Condition of Remarks/

p (WHAT) Requirements (WHO) Tools/Tackles Reference
No. Hazards/ Impacts required,
OK
 STANDARD OPERATING PROCEDURE (SOP)
11 Working at Improper approach, Proper approach provided for going upto height. An Executive All mobile
height Fall of person due to anchorage will be ensured capable of supporting a department equipment &
inadequate strength minimum dead weight of 2268 kilograms for every person TSK-Line PPE like Safety
of anchorage attached to it. An anchorage is often a beam, girder, Manager Helmet, Safety
column or floor. A personal fall arrest system will be used /Contractor shoe, safety
and followed consisting of an anchorage, connectors, a supervisor goggles. Full
body harness and double lanyards. body harness
Fall of person due to During erection of material at height safety belt and fall safety belt,
use of substandard arrestor will be checked before use. And anchoring position hand glove
safety belts or also will be checked. nose mask etc.
substandard fall
arrestor
Untrained person at All riggers/persons liable to work at height will be medically
examined and made fit by authorized Doctors and will
SS/ENGG.-
height work having no
height test certificate. complete height training /test organized at Plot 2. They will 03,07,08
keep a copy of the certificate with them.
Fall of person due to A horizontal lifeline may serve as a mobile fixture point for
use of substandard the attachment of lanyards lifeline. A lifeline must be wire
lifeline. rope of at-least ½ inch and O3 Nos. u-clamps to be
provided on each horizontal lifeline.

Fall of person due to Standard lanyard should be 1-inch sharps. Adjustable upto
long and open 8’. They should also have shock absorbing capacity and
lanyards. self- locking snap hooks.

Falling asleep, poor Fatigue or workmen who have worked throughout the day
lighting/illumination at shall not be allowed to work in night. Arrangement will be
approaches. made and ensured for adequate illumination at all
approaches and other workplaces.
\
Prepared by: Checked by Approved by:
Name and Designation: R.J. Singh (OCST) Name and Designation: K. Ravishankar, Sr. Mngr.(Mech) Name and Designation :B.S. Raju, AGM(Mech.)

Signature with Date : Signature and Date: Signature with Date :

SOP NO. CP/SOP/MECH/STRL/01 Effective 20/10/22 REV. 02

TS SOP FABRICATION, ERECTION & REPAIR OF
Date
SECTION
No.
MECHANICAL MAINTENANCE
DESCRIPTION STRUCTURE
NINL DEPARTMENT COKE PLANT PAGE Page 18 of 27

Ste Activity Associated Process Steps [HOW] Responsibility Condition of Remarks/

p (WHAT) Requirements (WHO) Tools/Tackles Reference
No. Hazards/ Impacts required,
OK
 STANDARD OPERATING PROCEDURE (SOP)
Work started without Work will be planned in advance and accordingly permit to Executive All mobile
taking work permit, work and SWP will be taken and made. It will be ensured department equipment &
without making that all workmen have understood all activities to be carried TSK-Line PPE like Safety
standard operating out along with their associated hazards and corresponding Manager Helmet, Safety
procedure and without precautions /Contractor shoe, safety
tool box talk to supervisor goggles. Full
workmen. body harness
safety belt,
Fall of materials No job will be allowed to different levels at a time. No hand glove
person will be allowed to move or work under overhead nose mask etc.
work.

Accident in lack of Close monitoring & strict supervision will be ensured SS/ENGG.-
supervision continuously at site. 03,07,08

Injury due to height Ground area will be barricaded before working at height.
work area not
barricaded.

Fall of person due to Standard ladder with handrail will be positioned for
use of sub-standard ascending and descending purpose.
ladder.

Slip and fall of ladder Ladder with hook & base plate will be placed at 75 degree
due to incorrect whenever required for work purpose.
positioning of ladder

Prepared by: Checked by Approved by:

Name and Designation: R.J. Singh (OCST) Name and Designation: K. Ravishankar, Sr. Mngr.(Mech) Name and Designation :B.S. Raju, AGM(Mech.)

Signature with Date : Signature and Date: Signature with Date :

SOP NO. CP/SOP/MECH/STRL/01 Effective 20/10/22 REV. 02

TS SOP FABRICATION, ERECTION & REPAIR OF
Date
SECTION
No.
MECHANICAL MAINTENANCE
DESCRIPTION STRUCTURE
NINL DEPARTMENT COKE PLANT PAGE Page 19 of 27

Ste Activity Associated Process Steps [HOW] Responsibility Condition of Remarks/

p (WHAT) Requirements (WHO) Tools/Tackles Reference
No. Hazards/ Impacts required,
OK
 STANDARD OPERATING PROCEDURE (SOP)
Fall of person due to All workmen above 2 meters height, will use full body Executive All mobile
not using safety belt harness and anchored both lanyards of 1.8 mtr. length department equipment &
each separately with rigid member. TSK-Line PPE like Safety
Manager Helmet, Safety
Breaking or sagging of Steel wire rope of ½ inch ( 2 Nos.)will be used with 3 nos. /Contractor shoe, safety
Wire rope due to load, U-clamps at both end as horizontal life line. supervisor goggles. Full
used as horizontal life body harness
line. safety belt,
hand glove
Fall of materials No loose material will be kept at the platform. nose mask etc.

Fall due to sub- Handrail, toe board as per TSL standard will be provided on
standard working working platform.
platform.
SS/ENGG.-
Elect, shock due to Care shall be taken to see that no un-insulated electric wire 03,07,08
live un-insulated exists within 3 M of the working platform gangways, runs
elect, cable existing etc of the scaffold.
within 3 M range
from working
platform, gangways,
runs and scaffolds.
Elect, shock due to Special care shall be taken that bars, rods, pipes or any
carrying long steel kind of conducting materials of length greater than 3 M, do
materials at vicinity of not touch the electric wires while carrying it in high vicinity
have electric wires. of electric area.

Prepared by: Checked by Approved by:

Name and Designation: R.J. Singh (OCST) Name and Designation: K. Ravishankar, Sr. Mngr.(Mech) Name and Designation :B.S. Raju, AGM(Mech.)

Signature with Date : Signature and Date: Signature with Date :

SOP NO. CP/SOP/MECH/STRL/01 Effective 20/10/22 REV. 02

TS SOP FABRICATION, ERECTION & REPAIR OF
Date
SECTION
No.
MECHANICAL MAINTENANCE
DESCRIPTION STRUCTURE
NINL DEPARTMENT COKE PLANT PAGE Page 20 of 27

Ste Activity Associated Process Steps [HOW] Responsibility Condition of Remarks/

p (WHAT) Requirements (WHO) Tools/Tackles Reference
No. Hazards/ Impacts required,
OK
 STANDARD OPERATING PROCEDURE (SOP)
12 Working at Failure of MEWP Standard & Physically tested with Valid TPI certificate Executive All mobile
Height With MEWP should be used for the job. department equipment &
MEWP (Mobile Swing of MEWP TSK-Line PPE like Safety
Elevating Regular routine inspection should be done by competent Manager Helmet, Safety
Working Toppling/Overturning person. /Contractor shoe, safety
Platform) of MEWP supervisor goggles. Full
Area should be be stable at firm & levelled surface as well body harness
as barricaded with Safety Cones and Tape properly. safety belt,
hand glove
Overload should be avoided as per Manufacturer’s nose mask etc.
instruction.

All the workmen should work with MEWP having valid

Height Pass and wearing full body harness. SS/ENGG.-03

MEWP should be operated by only trained & experienced

Operator.

Cradle should not move independently while persons

standing as well as cradle should lower down or rested on
the ground while not in use.

MEWP should parked only designated place with proper

barricading.

No work should be done with MEWP during Heavy wind,

Rain etc.

Nobody should stand on the guardrail of Cradle.

Prepared by: Checked by Approved by:

Name and Designation: R.J. Singh (OCST) Name and Designation: K. Ravishankar, Sr. Mngr.(Mech) Name and Designation :B.S. Raju, AGM(Mech.)

Signature with Date : Signature and Date: Signature with Date :

SOP NO. CP/SOP/MECH/STRL/01 Effective 20/10/22 REV. 02

TS SOP FABRICATION, ERECTION & REPAIR OF
Date
SECTION
No.
MECHANICAL MAINTENANCE
DESCRIPTION STRUCTURE
NINL DEPARTMENT COKE PLANT PAGE Page 21 of 27

Ste Activity Associated Process Steps [HOW] Responsibility Condition of Remarks/

p (WHAT) Requirements (WHO) Tools/Tackles Reference
No. Hazards/ Impacts required,
OK
 STANDARD OPERATING PROCEDURE (SOP)
13 ERECTION OF Unawareness of job Proper erection scheme will be made in consultation with Executive All mobile
HEAVY STRL. knowledge may cause dept. before starting major erection work, Proper & department equipment &
STEEL BY of injury/accident. adequate capacity crane/slings/ropes/pulley/winch etc will TSK-Line PPE like Safety
CRANES. be insured. Signalman with adequate experience will be Manager Helmet, Safety SS/Engg-03
provided Erection sequence will be decided and materials /Contractor shoe, safety
will be kept accordingly. supervisor goggles. Full
body harness
Shearing of Proper & adequate capacity crane/ safety belt,
SS/Engg-06
sling/rope/pulley slings/ropes/pulley/winch etc. will be insured. All tools & hand glove
tackles/ winch will be ensured to have test certificate, nose mask etc.
Physical injury. certified by competent authority. Physical checking of tools- SS/Engg-07
tackles will be done before starting the job. Equal length
slings of adequate capacity shall be provided for lifting the
load. Sling will be placed at center of materials to keep the SS/Engg-08
materials horizontal and guy rope will be provided for
control of free movement of the materials. No materials will
be allowed to stand under suspended load/. Proper padding
of sling will be done so that no sharp edge can damage the
sling. SS/Engg-11
Movement of crane Foreman with whistle on either side of the erection area will
be deputed for controlling of the cane. All workmen will be SS/Engg-13
given instruction to take proper attention about crane
movement. Guide rope will be used for proper monitoring
of structure to prevent swinging of the same while lifting by
crane.
injury while making Proper PPE’s will be used. Adequate size of packing will be
leveling. provided on ground for keeping materials.

Prepared by: Checked by Approved by:

Name and Designation: R.J. Singh (OCST) Name and Designation: K. Ravishankar, Sr. Mngr.(Mech) Name and Designation :B.S. Raju, AGM(Mech.)

Signature with Date : Signature and Date: Signature with Date :

SOP NO. CP/SOP/MECH/STRL/01 Effective 20/10/22 REV. 02

TS SOP FABRICATION, ERECTION & REPAIR OF
Date
SECTION
No.
MECHANICAL MAINTENANCE
DESCRIPTION STRUCTURE
NINL DEPARTMENT COKE PLANT PAGE Page 22 of 27

Ste Activity Associated Process Steps [HOW] Responsibility Condition of Remarks/

p (WHAT) Requirements (WHO) Tools/Tackles Reference
required,
 STANDARD OPERATING PROCEDURE (SOP)
No. Hazards/ Impacts OK

Wrong placing of sling Marking will be done for correct positioning of sling to take Executive All mobile
equal load. Only one person with sufficient experience will department equipment &
be allowed to do proper signaling. Equal length of sling will TSK-Line PPE like Safety
only be used. Manager Helmet, Safety
/Contractor shoe, safety SS/Engg-03
Damage due to hitting Proper attention will be taken during erection work. supervisor goggles. Full
to existing structures/ Scheme of crane for erection must be submitted before body harness
pipe lines by crane erection. Trained foreman with whistle must be deployed in safety belt,
and materials. the job for signalling. hand glove SS/Engg-06
nose mask etc.
Fall of person and Both lanyards of full body harness will be anchored
materials from height. separately with rigid member while working at height. SS/Engg-07
Lanyards will never be tied up sharp adage member.
Only height trained & medically fit persons will be allowed
to work at height. SS/Engg-08
Proper scaffold/proper approach will be provided. Working
area will be barricaded.
Height job will not be continued after sunset/ during
rain/during excess sun temperature.
Loads ready for lifting shall be tightened properly with SS/Engg-11
slings and D-shekels.
Balancing rope must be used to balance the lifting load.
Entire area will be barricaded properly be indicative tape. SS/Engg-13
Required flagman will be deployed with whistle and flag to
restrict & protect unauthorized entry.
Fall arrestor. OK scaffold, wire rope sling(1/2” dia) as
lifeline must be used for height job.

Prepared by: Checked by Approved by:

Name and Designation: R.J. Singh (OCST) Name and Designation: K. Ravishankar, Sr. Mngr.(Mech) Name and Designation :B.S. Raju, AGM(Mech.)

Signature with Date : Signature and Date: Signature with Date :

SOP NO. CP/SOP/MECH/STRL/01 Effective 20/10/22 REV. 02

TS SOP FABRICATION, ERECTION & REPAIR OF
Date
SECTION
No.
MECHANICAL MAINTENANCE
DESCRIPTION STRUCTURE
NINL DEPARTMENT COKE PLANT PAGE Page 23 of 27

Ste Activity Associated Process Steps [HOW] Responsibility Condition of Remarks/

p (WHAT) Requirements (WHO) Tools/Tackles Reference
 STANDARD OPERATING PROCEDURE (SOP)
No. Hazards/ Impacts required,
OK

Sudden entry of un- Trained Foreman & supervisor shall be deployed at erection Executive All mobile
authorized person area to minimize this hazard. Cordoning around erection department equipment &
inside the erection area is must by indicative barricades. Unauthorized persons TSK-Line PPE like Safety
Area to be removed from the area. Manager Helmet, Safety
Whistle must be provided to the Foreman for strong /Contractor shoe, safety SS/Engg-03
signalling. supervisor goggles. Full
body harness
Toppling of used Condition of used crane shall be OK in all respect having safety belt,
crane due to lifting of valid test certification. Lifted load will not cross, its SWL hand glove SS/Engg-06
excess load and its position of crane shall be on compacted and firmly levelled nose mask etc.
position on ground. Adequate plates should be provided for
uncompleted and positioning/Marching of crane. SS/Engg-07
undulated ground.
Swung hazard of Nobody will be allowed inside the swing area of crane and a
SS/Engg-08
machine. trained flagman will be deployed to warm the person to be
at safe place.
Use of damaged lifting OK lifting rope & proper locking arrangement will be
rope and other tools & provided at the time of lifting of DGI sheet. SS/Engg-11
tackles.
Snapping of slings Sling & D-shackles must be checked carefully before use SS/Engg-13
and D-shackles. with valid test certificate and lifted load will not exceed the
SWL of the both.

Inadequate path & Adequate path & approach shall be provided

approach upto the
working place.

Prepared by: Checked by Approved by:

Name and Designation: R.J. Singh (OCST) Name and Designation: K. Ravishankar, Sr. Mngr.(Mech) Name and Designation :B.S. Raju, AGM(Mech.)

Signature with Date : Signature and Date: Signature with Date :

SOP NO. CP/SOP/MECH/STRL/01 Effective 20/10/22 REV. 02

TS SOP FABRICATION, ERECTION & REPAIR OF
Date
SECTION
No.
MECHANICAL MAINTENANCE
DESCRIPTION STRUCTURE
NINL DEPARTMENT COKE PLANT PAGE Page 24 of 27

Ste Activity Associated Process Steps [HOW] Responsibility Condition of Remarks/

p (WHAT) Requirements (WHO) Tools/Tackles Reference
 STANDARD OPERATING PROCEDURE (SOP)
No. Hazards/ Impacts required,
OK

14 Erection of Failure of CPB Only physically tested, approved brand as per TSL standard Executive All mobile
Strl. Steel by and with valid TPIC CPB should be used for the job. department equipment &
CPB/Rope Use of damaged Rope Daily Routine inspection of CPB, rope pulley should be TSK-Line PPE like Safety
Pulley/ pulley done. Manager Helmet, Safety
Manually /Contractor shoe, safety
Breakage of sling and Materials should be lifted as per SWL. goggles. Full
supervisor
Chain link of CPB. body harness
safety belt, SS/Engg.-
Physical injuries to Lifting scheme should be prepared and approved prior to hand glove
workmen start erection work. 03, 07
nose mask etc.

Erection/Lifting area should be barricaded from

surroundings.

Only Trained and experienced Riggers, Foreman/Sarong

should be deployed for the job.
15 Alignment of Hands/Leg/body may Hand gloves, safety helmet and other PPE’s will be used at Executive All mobile
Erected be injured during site. Guy rope will be provided for free movement of department equipment &
materials materials handling. materials. TSK-Line PPE like Safety
(Strl. Steel) Fall of person Both Lanyard of full body harness will be anchored Manager Helmet, Safety
Fall of materials from separately with rigid member while working at height. /Contractor shoe, safety SS/ENGG.-
height Lanyard will never be tied up sharp edge member. Only supervisor goggles. Full 03,07,08
height trained person will be allowed to work at height. body harness
Proper scaffold/Proper approach will be provided. Working safety belt,
area will be barricaded. No loose material will be kept at hand glove
height Working area will be barricaded by safety tape. nose mask etc.

Prepared by: Checked by Approved by:

Name and Designation: R.J. Singh (OCST) Name and Designation: K. Ravishankar, Sr. Mngr.(Mech) Name and Designation :B.S. Raju, AGM(Mech.)

Signature with Date : Signature and Date: Signature with Date :

SOP NO. CP/SOP/MECH/STRL/01 Effective 20/10/22 REV. 02

TS SOP FABRICATION, ERECTION & REPAIR OF
Date
SECTION
No.
MECHANICAL MAINTENANCE
DESCRIPTION STRUCTURE
NINL DEPARTMENT COKE PLANT PAGE Page 25 of 27
 STANDARD OPERATING PROCEDURE (SOP)
Ste Activity Associated Process Steps [HOW] Responsibility Condition of Remarks/
p (WHAT) Requirements (WHO) Tools/Tackles Reference
No. Hazards/ Impacts required,
OK

16 Removing Fall & slip of men and Proper scaffolding will be provided for doing the job as per Executive All mobile
scaffolding materials. TSL standard. department equipment &
& all temporary TSK-Line PPE like Safety
supporting Physical injuries due Proper “PPE”S provided. Manager Helmet, Safety
structure.
to improper handling /Contractor shoe, safety
& fall. Use proper full body harness & be careful. supervisor goggles. Full
body harness
Use all relevant PPE’s & proper handling with care. safety belt,
hand glove
17 Housekeeping. Hindrance of Working area shall be kept clean & tidy. nose mask etc.
approach.
SS/ENGG-07
-Obstruction of object. Separate bins to be provided for scraps.
SS/ENGG-11
SS/ENGG-13
Approach to the work location will kept clear.

Scraps will be kept on the barricade area & will be disposed

periodically.

18 Removed and Injury of people while Use hand gloves

disposed removing damaged Don’t clean in bare hand.
Damaged / liner plate. Keep damaged plate in proper way.
Parts / Finger injury during If pathway goes below the working area, then barricade the
Channel / cleaning whole area or anybody should present below working area for
Grating area/removed liner awaking to others.
area. Use dust mask & safety goggles.
Dusty environment. Disposed the wastage to the proper demarcated area.
Fire hazard.

Prepared by: Checked by Approved by:

Name and Designation: R.J. Singh (OCST) Name and Designation: K. Ravishankar, Sr. Mngr.(Mech) Name and Designation :B.S. Raju, AGM(Mech.)

Signature with Date : Signature and Date: Signature with Date :

SOP NO. CP/SOP/MECH/STRL/01 Effective 20/10/22 REV. 02

TS SOP FABRICATION, ERECTION & REPAIR OF
Date
SECTION
No.
MECHANICAL MAINTENANCE
DESCRIPTION STRUCTURE
NINL DEPARTMENT COKE PLANT PAGE Page 26 of 27
 STANDARD OPERATING PROCEDURE (SOP)
Ste Activity Associated Process Steps [HOW] Responsibility Condition of Remarks/
p (WHAT) Requirements (WHO) Tools/Tackles Reference
No. Hazards/ Impacts required,
OK

19 Dismantling. Falling of material Hold the material in proper way and by proper means being Executive All mobile
Flying of dust dismantled to avoid falling. department equipment &
Flying gas cutting Barricade the area. TSK-Line PPE like Safety
spatter Use proper scaffolding if required. Manager Helmet, Safety
Falling hot material. Confined space if any take the confined space work permit. /Contractor shoe, safety
dust generate Position of the working person to be safe and stable by supervisor goggles. Full
Dust pollution keeping the safe distance from the dismantling material body harness SS/GEN-36
Noise pollution. and structure. safety belt,
Contamination of soil The person should have the sufficient skill and knowledge hand glove
and water about the job and keeping his body parts safely. nose mask, CO
Scrap generation Detector etc.
20 Gaseous SAFETY: Gas Effects. a. Contractor supervisor must carry Co gas
Area detector.
b. In case CO raises beyond 50 ppm all working
personal must be removed from working site
c. All safety precaution must be taken while SS/Gen-10
working at the gaseous area.
d. All required PPE's to be used.
22 Hot Coke Coke falling on Nobody should pass in front of open door.
bucket person. All Nearby working person should wear FR jackets.
movement. Ensure no one standing Underneath lifting Coke bucket
directly in front. SS/GEN-25
During coal cake breakage, never stand in front of oven.

Prepared by: Checked by Approved by:

Name and Designation: R.J. Singh (OCST) Name and Designation: K. Ravishankar, Sr. Mngr.(Mech) Name and Designation :B.S. Raju, AGM(Mech.)

Signature with Date : Signature and Date: Signature with Date :

SOP NO. CP/SOP/MECH/STRL/01 Effective 20/10/22 REV. 01

TS SOP FABRICATION, ERECTION & REPAIR OF
Date
SECTION
No.
MECHANICAL MAINTENANCE
DESCRIPTION STRUCTURE
NINL DEPARTMENT COKE PLANT PAGE Page 27 of 27
 STANDARD OPERATING PROCEDURE (SOP)
23 Emergency Fire/Gas Keep DCP/CO2 extinguisher, dry sand filled buckets and Executive All mobile
preparedness water filled bucket should be kept at job site. department equipment &
Display board with emergency phone No and name. TSK-Line PPE like Safety
Emergency exits with proper marking. Manager Helmet, Safety
Ensure & earmark proper climb down facility from working /Contractor shoe, safety SS/GEN-25
platforms / scaffoldings for emergency. supervisor goggles. Full
Keep water supply source ready if found necessary. body harness
Open pathway for emergency vehicle movement. safety belt,
hand glove nose
mask etc.
24 Return work Unawareness of job Remove all persons and scrap etc. made the area clean
permit Completion. from site before returning the clearance.
Sleepers Work permit to be returned using standard format to
authorized person.
If power getting is required, after removing the positive
isolation lock, raise the power clearance form.

Prepared by: Checked by Approved by:

Name and Designation: R.J. Singh (OCST) Name and Designation: K. Ravishankar, Sr. Mngr.(Mech) Name and Designation :B.S. Raju, AGM(Mech.)

Signature with Date : Signature and Date: Signature with Date :