Welcome to Safety Induction

EHS & OHSAS POLICY

Our vision, mission and safety beliefs
Vision Kirloskar Brothers Limited shall be the first five pump companies in the world by the year 2015 and become the preferred choice of customers as well as employees. Mission Kirloskar Brothers Limited shall be known globally as a reliable, innovative and cost effective solution provider in hydraulic machines and systems and in water business. Our Safety beliefs ‡ We value your life, Accidents are avoidable ‡ Working safely is a condition of employment

EHS GOALS Our Goal ± ³Zero Incident´ The following Safety targets have been established and are applicable to all associated with KBL. ± Zero Fatalities. ± Zero Lost Time Injuries (LTI) .

‡ To ensure full compliance with the Health. ‡ Prevent accident and harmful effects on the health of workers.OBJECTIVE ‡ To minimize or eliminate the safety hazards and risk ‡ To create safe. environment friendly and healthy atmosphere at the site. ‡ Provide safety practice guidelines for appropriate measures of planning control and enforcement. ‡ Ensure appropriate safety norms in place. Safety and Environment Policy and regulations set out by statutes as applicable .

.Purpose of Induction ‡ To tell you the site rules and requirements for project sites and factories so that you can work safely. ‡ Explain the safe systems of work we will use to accomplish a injury free worksite. ‡ Explain our expectation an how we can meet our expectation.

value. ‡ Believing an incident & injury-free workplace is injurypossible. ‡ Moving safety & health from being a priority to a personal core value.Our challenges « ‡ Maintaining safe behaviour under time and cost constraints. .

. ± Not endanger yourself or your workmates ± Ask for guidance and help when you do not understand.Your responsibilities « ± Ensure your own safety at work. ± Don¶t do anything that may be unsafe for other people. ± Comply with the Site rules and safety instructions. ± Only do jobs that you are trained and competent to do.

± When suffering from illness or injury ± Not misuse or damage safety equipment. ± Report accidents. ± Participate in discussion of the HIRA / JSA.Your responsibilities « Cont¶d ± Not attend work if you are affected by alcohol or drugs. hazards or unsafe acts to your supervisor. .

. Pre-task meetings ± Job Safety Analysis. Safety Alert.Safety communication « ‡ ‡ ‡ ‡ ‡ ‡ Toolbox meetings / Safety induction. Safety signs and notice boards. Safety awareness pictures. Site safety Committee meeting. PreBehavioural observations.

CONTENTS ‡ ‡ ‡ ‡ ‡ ‡ ‡ ‡ ‡ ‡ ‡ ‡ Site Rules & Regulations Responsibilities Safe Work Method Statement PPE requirements Common Causes of Accidents Working at Height Vehicle Safety Tool Box Meeting Permit To Work System Proper Barricades Scaffoldings Gas Cylinder Safety .

CONTENTS Chemical Safety Awareness Electrical Safety Noise House Keeping Accidents & Near Miss Incidents ‡ Emergency Response ‡ ‡ ‡ ‡ ‡ .

SITE RULES & REGULATIONS The following are NOT allowed: Alcohol / Drug Camera Fighting Smoking Use Of Mobile Phone While Driving .

‡Specified personal protective equipment must be worn according to the work requirement at site and factory ‡No dangerous work practices.SITE RULES & REGULATIONS ‡All employees will abide by the safety rules and regulations outlined in Safety manual. . ‡All injuries. ‡Smoking is prohibited inside the project sites. unsafe acts and unsafe conditions must be reported to your supervisor immediately. ‡In case of an Emergency please follow instructions given by security and authorized persons. ‡No interfering or tampering with safety devices and equipment. near misses. offices and factory except in smoking zones identified.

The Factories Act. 72.Legal Requirements Building and Other construction workers ( Conditions of service and Regulation of employment) Act 1996 and Rules 1998 Rules 56. 71. 70. &73 : Certain equipments used in the construction work is to be tested & examined by competent person at specified intervals & certificates in that respect be obtained.1948 and Factories Rules Environmental Protection Act .

Emergency Preparedness. 3. or prevent hazards or accidents through hazard analysis and Risk Assessment 4. Define basic activities or steps which must be followed to complete a task 2.Safe Work Method Statement 4 Basic Parts 1. minimize. Identify hazards or potential accidents associated with each step Develop approaches that will eliminate. Training and Development .

damage to property or damage to the environment. .ACCIDENT An undesired event that results in harm to people.

COMMON CAUSES OF ACCIDENT  Taking shortcuts  Did not follow safety procedures  Did not use the required PPE  Did not perform equipment lockout prior to maintenance works  Slipped on wet floor or chemical spill surface  Tripped over uneven floor or obstructed objects  Unfamiliar with the operations of equipment / machinery  Horse Play  Over Confidence .

1% 2% 4% 5% 6% 3% 8% 52 % 19% .

PERSONAL PROTECTIVE EQUIPMENT (PPE) ‡ SAFETY HELMET ‡ EYE PROTECTION ‡ COVERALLS ‡ SAFETY FOOTWEAR WEAR HEAD PROTECTION WEAR EYE PROTECTION WEAR HEARING PROTECTION .

General Protection Medical Protection Chemical Protection Welding Protection Riggers hand protection . General Purpose. Welder.Hand Protection Wear correct gloves for job. Chemical. When. Know Which. Rigger. Where.

Eye Protection .

HEARING PROTECTION EAR MUFFS EAR PLUGS .

RESPIRATORY PROTECTION Dust only NOT Vapours Gases! Dust and Vapours only NOT Gases! Dust. Vapours and Gases! B/A Trained Personnel use only!! .

Fall Protection When working at heights.8 meters . always wear Fall Protection ‡ ‡ ‡ ‡ Full Body Harness Lanyard (regular or retractable) Shock Absorber Locking Snap Hooks (no single action) ‡ Lifeline (as needed) needed) ‡ Fall arrester ‡ Anchoring point Must be worn when working at heights of over 1.

Remember Please use ISI marked good quality PPE always .

‡ Shankar Video .

Falling Objects ‡ ‡ ‡ ‡ ‡ ‡ ‡ ‡ ‡ ‡ ‡ Dropped during installation or removal. Use of lanyards on hand tools . Securing of loose items . Inadequate edge protection . Lack of barricading and signage . Inadequately secured or supported . Lifting loose items in approved material baskets . Control measures Pre start checks and workplace inspections Positioning materials away from edges . Improper lay-out materials . Inadequate fall protection . .

Indicator. parking light must be in operating conditon.VEHICLE SAFETY REQUIREMENTS ‡ ‡ ‡ ‡ ‡ ‡ ‡ Have a valid Driving License. including passengers Use Banks man /Signal Man when reversing (Heavy Equip. Seat Belts. Reverse horn. . Ensure vehicle is inspected before entering site.) Never tailgate Follow the Road Signs and Speed Limits.

.TOOLBOX MEETING TO BE DONE BEFORE THE START OF EVERY DAY.

Manual handling « Any lift which is heavy or could cause physical strain ± use a mechanical lifting device or share the load. Bend Knees & Keep Back Straight .

Use Your Head and Save Your Back! ‡STAND close to the load ‡Bend your knees not your back! ‡Let your legs do the lifting Get Help with heavy or awkward loads! Use the right tools! .

Electrical Permit (LOTO) .Confined Space Entry ‡ . BEFORE ANY Non routine activity or a high Risk Activity!!! ‡ .PERMIT-TO-WORK SYSTEM A Work Permit is required «.Height Work Permit ‡ .Hot Work Permit ‡ .Excavation Permit ‡ ..Radiography Permit ‡ .

Work Permit Movie .

SCAFFOLDING ‡ Green Tag = Inspected &Approved ‡ Red Tag = Not Inspected / Not Approved. .

.GUARDRAILS Top Rail Mid Rail Toe board ‡ All openings and Cutouts to be closed. ‡ All edges are to be protected with Hand Railings.

and shoring the excavation.. and mobile equipment.EXCAVATION SAFETY ‡ The greatest risk in an excavation is a cave-in. . toxic fumes. falls. shielding. ‡ Other excavation hazards include water accumulation. cave‡ Employees can be protected through sloping. oxygen deficiency. ‡ A competent person is responsible to inspect the excavation. ‡ All Excavation Work must be BARRICADED all Around.

GAS CYLINDERS SAFETY Compressed gas cylinders must be: ‡ stored upright ‡ secured ‡ Segregated ‡ Proper ventilation ‡ Under sun shade ‡ Labeled content/full/empty ‡ Fire fighting provisions ‡ Gas Cylinders must be fitted withy Flash Back Arrestors. .

‡ All cables must be in proper condition.Welding ‡ All Welding Machines must be properly earthed. ‡ Do not use damaged cable. .

Lifting Tools & Tackles ‡ All lifting equipment. . tools and tackles must be tested and certified by a competent authority once in 12 months ‡ It should be physically fit for use ‡ Safe Working Load for all Equipment / tools must be displayed.

Machine Guarding 8 out of 10 workplace fatalities and 1 in 4 workplace injuries involve mechanical equipment. ‡contact or entanglement with machinery ‡trapping between machine and material or a fixed structure ‡contact with material in motion ‡being struck by material ejected from a machine ‡release of potential energy .

FIRE SAFETY ‡ Three components ‡ Need all three components plus chain reaction to start a fire ‡ Fire extinguishers remove one or more of the components or Inhibit chain reaction .

the fire could re-ignite ‡ Always notify supervisor of extinguisher use so it can be replaced or recharged and the fire investigated. ‡ Fire fighting video .Fire Extinguisher Use ‡ ‡ ‡ ‡ ‡ ‡ Select correct extinguisher for class of fire Pull the locking pin Aim at base of fire Squeeze and hold the discharge lever Sweep from side to side CAUTION ± check the extinguisher is working before attempting to extinguish a fire. then monitor the area.

CHEMICAL SAFETY AWARENESS ‡ All chemical containers must be labeled with the identity of the material and hazard warning ‡ Material Safety Data Sheets (MSDS) must be available and readily accessible in the workplace. .

ELECTRICAL SAFETY .

ELECTRICAL SAFETY Electrical Hazards ‡ Inadequate wiring ‡ Exposed electrical parts ‡ Wires with bad insulation ‡ Ungrounded electrical systems and tools ‡ Overloaded circuits ‡ Damaged power tools and equipment ‡ Using the wrong PPE and tools ‡ Overhead powerlines ‡ All hazards are made worse in wet conditions Protective Measures ‡ Proper grounding ‡ Using ELCB¶s ‡ Using fuses and circuit breakers ‡ Guarding live parts ‡ Proper use of flexible cords ‡ Training Electrical Video .

HOUSEKEEPING .

HOUSEKEEPING ‡ Keep the floors dry at all times. ‡ Keep tools clean and store them at designated areas. ‡ Ensure no tripping hazards are created by equipment, hoses, cabling, etc.

Housekeeping Video

ENVIRONMENT

Keep The Environment Safe and Clean.

Identify the aspects Reduce the impacts

WASTE MANAGEMENT ‡ All waste materials must be segregated. ‡ All Hazardous waste must be stored in a designated Hazardous waste area. ‡ All waste movement shall be recorded. ‡ NO disposal of Chemical into drains/sewer.

Accident Triangles For every there were and 1 29 Major Injury Minor Injuries Incidents For every there were and and 1 10 30 600 600 Bird Serious Injury Minor Injuries damage only Incidents 300 300 Heinrich For every 1 Fatal / serious The reporting of near misses is a vital part of safety within our company 3 50 80 400 400 Lost time First aid damage Incidents Tye / Pearson .

Safety and Environmental practice based on a condition or a incident with potential for more serious consequences. [Near Miss ± An Opportunity to improve Health. Reporting of errors is Near Miss Reporting. Near Miss occurs due to error.] .Near Miss Reporting Near Miss is Incident without consequences.

‡ Employee Awareness is Increased. ‡ Corrective Action reduces the hazard level. .Advantages of Near Miss Reporting ‡ Corrective Action taken eliminates the hazard. ‡ Corrective action manages recurrence. ‡ Standard Operating Procedures are changed to account of hazard. ‡ Corrective actions alerts people of hazard.

g. . Sudden leakage from Hose pipe. grinding work without face shield) Person working without fall protection arrangement Open cables in water Fall of tools.What can be Reported as a Near Miss Accident ‡ ‡ ‡ ‡ ‡ ‡ ‡ ‡ Fall of material from height without injury Slip. Trip and Fall incidents Over speeding of vehicle Person working without required PPEs (e.

‡ Exposed electrical fitting. ‡ Work underway in wrong method. No access for work Can not work without removing the guards Material/ job lifted above head height unnecessarily. ‡ Pathway/ walkway blocked by stack of material.What can be Reported as a Near Miss Accident ‡ ‡ ‡ ‡ ‡ Working without valid work permit Material protruding in walkway or working place. .

‡Within 24 Hours ± Site accident report in the format ‡Site Investigation by Project manager & Safety Officer ± within24 hours ‡Detailed Investigation by HO Team .Accident Reporting and investigation For Fatal/major accident (hospitalisation) ‡Immediate reporting by Telephone to HO.

EMERGENCY PREPAREDNESS ‡ You Must know the location of fire EXITS & ASSEMBLY POINTS ‡ Do not obstruct fire Exits. fire fighting equipment & evacuation routes!!! .

without putting your life in danger! ‡ Proceed to Assembly Point Area.EMERGENCY PREPAREDNESS On Hearing The Siren. You Should«« Should«« ‡ Stop work immediately ‡ Switch off and isolate/depressurize supply to any equipment in use. . if possible.

ASK someone!! ‡ Report Injuries/Incidents/Illnesses ‡ Report safety issues to the safety committee . Housekeeping.Good Safety Practices ‡ Inspect work area daily ‡ Be an observer .stay alert ‡ Housekeeping. Housekeeping ‡ Use your best safety device ± THINK ‡ If you¶re not sure .

Immediately Report them UNSAFE ACTS ± Immediately Stop Them .WATCH OUT FOR: UNSAFE CONDITIONS .

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‡ To achieve our goal of an incident-free and injury-free workplace requires the belief that we can do it. ‡ Do you BELIEVE we can achieve it ? ‡ Can you COMMIT to achieving it ? .

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