Occupational Health and Safety Measures in Bharat Heavy Electricals Limited

- An Introduction

Established in 1950s. ISO-9001:2000 version quality management certified. Certified with ISO 14001 for environmental management systems & OHSAS- 18001 certification for occupational health & safety management systems. Core Sectors of BHEL with wide network of 14 manufacturing divisions: Power Generation Transmission and Distribution Industries Transportation Renewable Energy, Oil and Gas

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International Operations. Health, Safety and Environment Management Summer Training Branch- BHEL (HERP), Varanasi: Established in 1984 Manufacturer of Operation and Maintenance spares HERP is now the spares hub for all types of Mill spares, Turbine spares and Turbine Tools and Tackles HERP has contributed a lot in refurbishing of various units of NTPC In 2009- 2010,the turnover growth is Rs. 24,000 lacs

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Job Profile
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OHSAS 18001 Regular Observation of the workplace
Machine Shop Fabrication Shop Babbiting Shop Canteen and Central Stores Area DG and Air Compressor Area First Aid Facilities Compressed Gas Cylinders Area

Making reports on the basis of observation


Accident Statistics
Largest cause of accidents at work  37% Manual Handling  19% Slips, Trips and Falls  12% Other Causes  20% Struck by an Object  7% Falling from Height  5% Machinery

ACCIDENTS ARE CAUSED BY:  Unsafe Acts Unsafe Conditions

OHSAS- 18001-An Introduction

OHSAS 18001 is an Occupation Health and Safety Assessment Standard for health and safety management systems To control its OH&S risks and improve its performance Protects the safety and health of people engaged in work or employment Covers OH&S management system



OHSAS 18001 was created via a concerted effort from a number of bodies

Certification of OHSAS:

Registration to OHSAS 18001

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The OHSAS specification is applicable to any organisation that wishes to: eliminate or minimize risk Implement, maintain and continually improve an OH&S management system Assure itself of its conformance with its stated OH&S policy Seek certification/registration



Improve efficiency and consequently reduce accident Increase control and reduction of hazards Demonstrate commitment to the protection of staff, property and plant and legal compliance Improve safety culture of organisation Increase organisation’s reputation for safety and occupational health

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Code of Practice for an Organisation:
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General Safety Requirements Training & Risk Assessment Working on or in the vicinity of HTHW systems and protection against noise Protection against fire & Hazardous Substances and Materials Accident Treatment/Accident Reporting/First Aid Facilities Working at Heights Personal Protective Equipment


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General Requirements OH& S Policy Hazard identification, risk assessment and determining controls Resources, roles, responsibility, accountability and authority Competence, training and awareness Communication and participation Documentation Operational control


OHSAS 18001 in BHEL
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Certified with OHSAS 18001 in 2002 Det Norske Veritas (DNV) has awarded conforming to OHSAS 18001, BHEL’s Power Sector-Northern Region (PS-NR)

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Occupational Health & Safety Policy in BHEL:
Compliance with applicable Legislation and Regulations Setting objectives and targets Appropriate structured training Formulation and maintenance of OH&S Management programmes Periodic review Communication of OH&S Policy



OHS Achievements:
Creation of fully trained and equipped model extension teams Creation of mobile multi-disciplinary occupational health and hygiene teams Large number of public and private sector enterprises have registered their requests for assistance Prominence as a training Centre THE OHS TIDE

 Creation of complete Model Centre
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Legal Aspects related to health and safety in BHEL:
  To identify and access the legal OH& S requirements, BHEL has its legal
aspects which is approved by:
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Factories Act, 1948 Water (Prevention and Control of Pollution) Act, 1974 Hazardous (Wastes Management and Handling) Rules, 1989 Indian Electricity Act, 1910 Noise Pollution (Regulation and Control) Act, 2000

Global legal aspects requiring health and safety measures:
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Health and Safety at Work Act etc. (UK) Occupational Safety and Health Act (US)


Health and Safety Measures in BHEL
The major activities of the HR in this field are to check health and safety of human resources in the each and every field but especially in:
Areas/ Shops Machine Shop Hazards Health and Safety Measures lubricating Oil slip, chips- •Soaking of oil with saw dust oil flow on the floor, break •Collection & Sweeping regularly of slings, spread of coolant •Trained workmen •Saw dust and buckets are used •Protective sheet on one side •Use of PPE, welding shields •Visual inspection of the wire •Trained workmen •Proper tightness of grinding disc

Fabrication Shop: Grinding spark, flying dust, Grinding, Welding, glare, welding fumes, and Cutting Heat/hot surfaces, loose wiring


Babbiting Shop

Spread of shots, NH3 fumes •Collection of shots inhalation, oil tank blast, •Use of PPEs break of wire slope sling •General Cleaning •No accumulation of water •Trained operator for hydra

Canteen and Central Store Canteen- Unhygienic Area condition, flies, mouse etc. Central store- brake failure, sling breakage

DG and Air Compressor Huge noise, pipeline leakage, •Fire extinguisher explosion •Use of Ear Muffs •Regular checking Compressed Gas Cylinders Pipeline leakage, explosion air receiver No other inflammable material Fire extinguisher Switch off the knob of cylinder


First Aid Facilities:
Each First Aid box has to be under the charge of a separate person trained for first aid. The following contents are to be maintained in a First Aid Boxes where more than 50 persons are employed:
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24 small-sterilised dressings 12 medium sized sterilised dressings 20 large size sterilised dressings 12 large size sterilised burn dressings 12 packets sterilised cotton wool One Snake Bite Lancet One pair of Scissors 12 roller bandages 4 inches wide Savlon, betadine lotion Wooden scale









Extremely Highly flammable flammable

Very toxic Toxic



Danger to


UniSA 10 February 2007


Analysis Work
The analysis work is based on following parts:  Concentration of chemicals contaminants in Babbiting Process:
Location During Pouring Pollutants Studied Copper, lead, antimony, chloride Respirable Dust Exposure details Permissible Range 0.015, 0.1158, 0.2, 0.15, 0.0122, 2 0.0122, 0.346 resp. resp. 4.02 mg/ cu.m 3.0 mg./ cu.m

During shot blasting process

Illumination Level
Illumination Level Obtained Day night 670 208 Required illumination 300 300

Location Near Heavy duty QC inspection

385 77

Ambient and personal Noise Exposure Levels
Measured Exposure levels 8 hrs. in db (A) 104.4 80.7 Permissible limit

Location Fabrication Area During Grinding process Near shearing machine

85 db (A)

In Babbiting section During shot blasting process 99.8 Near horizontal boring machine 83.4 Near heavy duty 89

85 db (A)


Findings and Suggestions
In Machine Shop: Findings- At the time of:

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Horizontal boring Vertical boring Radial drilling of machine Material handling by crane

SuggestionsProper collection system for oil cutting  Protective sheet should be use one side  In Fabrication Shop: Findings- At the time of:  Gas cutting by pug machine  Grinding& using hand tools


Welding process  Shearing process Suggestions Workforce should ensure tighten of disc and wheels regularly  Employees should properly use the personal protective equipments In Babbiting shop: Findings- At the time of:  Shot blasting process  Melting of babbit metal process  Pouring of babbit metal Suggestions: Mask should be provided at the time of processing Use strictly the compliance of PPEs


In canteen Area: Findings The bulbs, tube lights, CFLs, are not covered properly  General cleaning Suggestions Provisions of hot water at the time of cleaning oily utensils  Ensure proper personal hygeine of canteen staff  Provision of sand bucket at the place of gas tank



BHEL is increasingly concerned about achieving and demonstrating sound Occupational Health and Safety performance Improve efficiency and consequently reduce accident OHSAS 18001 enables an organisation to have control over operations There is a full commitment of each and every employee towards the applicability of occupational and health safety measures in the company Some new employees and apprenticeship trainees are not aware about the OHSAS 18001 certification and the use of PPEs It encourage more effective internal and external communication and improve the organisation’s safety culture.

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REMEMBER……………… ……….. No job is so important and No service is so urgent – that we cannot take time to perform UniSA our work safely.


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